York ZF076 User Manual Download

Page: 1 / 71

R-410A

ZF SERIES

3 - 6.3 Ton
50 Hertz

5725848-XIM-A-0319

TABLE OF CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation safety information . . . . . . . . . . . . . . . . . . . . . . . 7

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Typical cool/heat control wiring (Smart Equipment™ ZF036-

076) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power and control wiring. . . . . . . . . . . . . . . . . . . . . . . . . . 11

Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Optional gas heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

L.P. units, tanks, and piping . . . . . . . . . . . . . . . . . . . . . . . 14

Vent and combustion air hoods. . . . . . . . . . . . . . . . . . . . . 15

RRS economizer interface overview . . . . . . . . . . . . . . . . . 16

Smart Equipment™ economizer sequences. . . . . . . . . . . 16

Dry bulb changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Single enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . 17

Dual enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . 17

Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Free cooling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Jade Economizer interface overview . . . . . . . . . . . . . . . . 22

ZF036-076 unit weights. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Supply air blowers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Checking supply airflow rate . . . . . . . . . . . . . . . . . . . . . . . 35

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cooling sequence of operation . . . . . . . . . . . . . . . . . . . . . 37

Electric heating sequence of operations . . . . . . . . . . . . . . 39

Safety controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . . . 40

Gas heating sequence of operation . . . . . . . . . . . . . . . . . 40

Gas heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . . 40

Flash codes or error messages. . . . . . . . . . . . . . . . . . . . . 41

Heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . . . 41

Start-up (cooling). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Prestart checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Post start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Shutting down the unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Start up (gas heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Pre-start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Post start checklist (gas) . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Manifold gas pressure adjustment . . . . . . . . . . . . . . . . . . 43

Pilot checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Burner instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Burner air shutter adjustment . . . . . . . . . . . . . . . . . . . . . . 43

Checking gas input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Adjustment of temperature rise . . . . . . . . . . . . . . . . . . . . . 44

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Cooling troubleshooting guide. . . . . . . . . . . . . . . . . . . . . . 45

Gas heat troubleshooting guide . . . . . . . . . . . . . . . . . . . . 46

Flash code troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 47

Symptomatic troubleshooting . . . . . . . . . . . . . . . . . . . . . . 49

Unit flash codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fan on and off delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Navigation components for the Smart Equipment™ control

board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Typical wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Simplicity® Lite control board . . . . . . . . . . . . . . . . . . . . . . 58

Smart Equipment™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

LIST OF TABLES

1 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 Electric heater supply air limitations . . . . . . . . . . . . . . . . 13

3 Gas heat application data . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Gas pipe sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Smart Equipment™ Economizer Board details . . . . . . . 19

6 Single enthalpy and dual enthalpy high limit curves. . . . 24

7 ZF036-076 imperial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8 ZF036-076 metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9 ZF036-076 unit accessory weights . . . . . . . . . . . . . . . . . 25

10 ZF036-076 physical data. . . . . . . . . . . . . . . . . . . . . . . . . 26

11 Electrical data ZF036-076 . . . . . . . . . . . . . . . . . . . . . . . . 28

12 Electric heat correction factors . . . . . . . . . . . . . . . . . . . . 28

13 Voltage limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

14 Utilities entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

15 Minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

16 Supply air blower performance (3 and 4 ton direct drive) -

side duct applications . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

17 Supply air blower performance (5 ton belt drive) - side duct

application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

18 Supply air blower performance (6.3 ton belt drive) - side duct

application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

19 Belt drive motor and drive data . . . . . . . . . . . . . . . . . . . . 35

20 Static resistances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

21 Limit control setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

22 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . 40

23 Limit control setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

24 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . 41

25 Gas rate - cubic feet per hour . . . . . . . . . . . . . . . . . . . . . 44

26 Simplicity Lite unit control board flash codes . . . . . . . . . 51

27 Ignition control board flash codes . . . . . . . . . . . . . . . . . . 51

28 Smart Equipment™ UCB details . . . . . . . . . . . . . . . . . . 52

29 Cable for FC buses and SA buses in order of preference 57

Summary of Contents for ZF076

Page 1: ...Burner air shutter adjustment 43 Checking gas input 43 Adjustment of temperature rise 44 Troubleshooting 45 Cooling troubleshooting guide 45 Gas heat troubleshooting guide 46 Flash code troubleshooti...

Page 2: ...od 30 18 Unit dimensions rear view 31 19 Disconnect blower access location 31 20 Belt adjustment 36 21 Pressure drop across coil 37 22 Gas valve piping 40 23 Proper flame adjustment 43 24 Typical valv...

Page 3: ...parts and electrical components installation and servicing of air conditioning equipment can be hazardous Only qualified trained ser vice personnel should install repair maintain or service this equi...

Page 4: ...es refrigerant containers and recovery systems must be designed to handle R 410A If you are unsure consult the equipment manufacturer Failure to use R 410A compatible servicing equipment may result in...

Page 5: ...mbustible material 4 For use with natural gas convertible to LP with kit This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state...

Page 6: ...d Filters Merv 8 4 Coil Guard CG STD Filter 5 2 Pleated Filter CG A Std Cabinet B HDF HingedFLTR Tooless DR E SSD SST Drain Pan F SSD HFD A No Economizer C Economizer w o Barometric RLF F Econ BAS Rdy...

Page 7: ...al Code CSA C22 1 2 Installation Codes CSA B149 1 3 Local plumbing and waste water codes and 4 Other applicable local codes Refer to unit application data found in this document After installation gas...

Page 8: ...air in accordance with section 5 3 of Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 Latest Edition in U S A or Sections 7 2 7 3 or 7 4 of Gas Installation Codes CSA B149...

Page 9: ...f the evaporator coil and must be kept clean or replaced with same size and type Dirty filters will reduce the capacity of the unit and will result in frosted coils or safety shutdown Minimum filter a...

Page 10: ...2 Y1 W2 W1 X R THERMOSTAT TERMINALS CONTROL TERMINAL BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 1 4 3 1 2 4 Second stage ot required on single stage he g units Jumper is required if there is n...

Page 11: ...tolerances which must be maintained at the compressor terminals during starting and running OCC C RC G Y2 Y1 W2 W1 X R THERMOSTAT TERMINALS CONTROL TERMINAL BLOCK TERMINALS ON A LIMITED NUMBER OF THER...

Page 12: ...led heaters are wired for single point power supply Power supply need only be brought into the single point terminal block and thermostat wiring to the low voltage terminal strip located in the upper...

Page 13: ...3 50 M3 S 0 47 0 57 0 57 0 61 CFM 1100 1200 1200 1300 4 380 415 3 50 M3 S 0 61 0 61 0 61 0 61 CFM 1300 1300 1300 1300 5 380 415 3 50 M3 S 0 75 0 75 0 75 0 75 0 75 CFM 1600 1600 1600 1600 1600 6 3 380...

Page 14: ...uitable for the purpose NEVER USE A FLAME 6 The furnace and its individual manual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at te...

Page 15: ...od slips in under the top of the access panel opening when installing Refer to Vent and Combustion Air Hood Figure 7 The vent hood is installed by inserting the top flange of the hood into the slotted...

Page 16: ...EDs at the center left of the RRS Economizer Controller indicate POWER green Lit whenever 24 volts AC power is present to the RRS Economizer Controller C and R pins FAULT red Lit then flashes during t...

Page 17: ...t available Free cooling operation When the control determines that the outside air is suitable the first stage of cooling will always be free cooling Thermostat In free cooling with a thermostat inpu...

Page 18: ...No inputs are present for non modulating power exhaust Outputs a 2 10 VDC from ECON on Economizer Expansion module b 24 vac from EX FAN to energize exhaust fan on Economizer Expansion module Operation...

Page 19: ...istor MAT parameter reports input status F C 3 65 VDC reading MAT to COM with open circuit Read only use in current control revision IN1 MAT LEDs at left on upper edge of economizer board POWER POWER...

Page 20: ...power exhaust actuator and economizer actuator Connects through circuit trace to 24V IN pin HOT ECON 2 10 VDC output for the Economizer actuator Econ parameter reports output status 0 100 Used to posi...

Page 21: ...negative for the indoor air quality sensor Connects through circuit trace to 24V IN pin COM R 24V 24 VAC hot supplied for the outdoor air quality sensor Connects through circuit trace to 24V IN pin HO...

Page 22: ...pad layout Keypad The four navigation buttons illustrated in Fig 8 are used to scroll through the menus and menu items select menu items and to change parameter and configuration settings Using the ke...

Page 23: ...E Economizer Module accessory instruction P N 1150208 UAI A 0514 included in this instruction packet for additional menu information Economizer setup and configuration Before being placed into service...

Page 24: ...ry the economizer sets the economizing mode to YES economizing is available When conditions are above the selected boundary the conditions are not good to economize and the mode is set to NO Fig 9 sho...

Page 25: ...LEFT FRONT Table 8 ZF036 076 metric Size Tons Model Weight kg Center of Gravity mm 4 point Load Location kg 6 point Load Location kg Shipping Operating X Y A B C D A B C D E F 036 3 0 ZF036 228 225 10...

Page 26: ...F 15 45 25 70 25 55 25 55 Gas Limit Setting F Direct Drive 240 210 Gas Limit Setting F Belt Drive 210 210 Gas piping connecting in 1 2 1 2 1 2 1 2 DIMENSIONS inches Length 82 1 4 82 1 4 82 1 4 82 1 4...

Page 27: ...VAP FAN DATA Quantity 1 1 Fan Size Inch 12 x 10 12 x 11 Type Centrifugal Centrifugal Motor Sheave 1VL44 IVM50 Blower Sheave AK54 AK56 Belt A35 A36 Motor HP each 1 1 2 1 1 2 RPM 1450 1450 Frame size 56...

Page 28: ...3 25 2EH04512046 12 2 2 18 5 29 4 30 415 3 50 7 8 51 5 12 1 1 3 4 24 NONE 15 3 20 2EH04510746 5 1 1 7 1 15 3 20 2EH04511046 7 5 1 10 4 19 2 20 2EH04511546 10 2 2 14 2 23 9 25 2EH04512046 14 6 2 20 3 3...

Page 29: ...as heat front view 829 325 8 1140 447 8 64 21 2 213 83 8 292 111 2 445 171 2 445 171 2 181 77 8 171 63 4 206 81 8 137 53 8 2089 821 4 165 61 2 178 7 111 43 8 165 61 2 819 321 4 819 32 1 4 mm inch 829...

Page 30: ...omizer rain hood Figure 17 Unit with fixed outdoor air motorized damper rain hood DETAIL A 699 271 2 699 271 2 41 15 8 260 101 4 1140 447 8 502 193 4 mm inch DETAIL B 454 177 8 184 71 4 699 271 2 485...

Page 31: ...th Belt Drive Option Control Box Access A B Wiring Entry See Detail B Mounting Bracket for Disconnect Switch Field Supplied Field Supplied Disconnect Switch Location Blower Motor Access Filter Access...

Page 32: ...25 LOW 0 67 645 0 63 620 0 58 595 0 53 575 CFM UNIT TONNAGE MOTOR SPEED AVAILABLE EXTERNAL STATIC PRESSURE IWG 0 20 0 30 0 40 0 50 0 60 CFM WATTS CFM WATTS CFM WATTS CFM WATTS CFM WATTS 31 HI 1699 825...

Page 33: ...25 1101 980 1130 1045 1158 1075 CFM UNIT TONNAGE AIR FLOW CFM AVAILABLE EXTERNAL STATIC PRESSURE IWG 0 20 0 30 0 40 0 50 0 60 0 70 0 80 RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM...

Page 34: ...75 1118 1150 1148 1250 1176 1360 CFM UNIT TONNAGE AIR FLOW CFM AVAILABLE EXTERNAL STATIC PRESSURE IWG 0 20 0 30 0 40 0 50 0 60 0 70 0 80 RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM...

Page 35: ...id bases and are inherently protected These motors can be selected to operate into their service factor because they are located in the moving air upstream of any heating device Table 20 Static resist...

Page 36: ...4 Knowing the pressure drop across a dry coil the actual volumetric flow rate through the unit can be determined from the curve in Pressure Drop vs Supply Air flow rate Figure 21 After readings have b...

Page 37: ...the fan off delay for cooling To be available a compressor must not be locked out due to a high or low pressure switch or freezestat trip Simplicity Lite Control or Evaporator Low Limit sensor detecti...

Page 38: ...ser fan If the call for cooling is still present at the conclusion of the ASCD the UCB will re energize the halted compressor Should a freezestat open three times within two hours of operation the UCB...

Page 39: ...and on any compressor reset or lock out Flash codes or error messages The UCB will initiate flash a code on the Simplicity Lite Control see Table 26 or sent error message to the LCD Smart Equipment Co...

Page 40: ...peration of the draft motor The UCB continues the operation of the indoor blower for a configurable amount of time after the call for heat is satisfied Two stage furnace only If a W1 only call for hea...

Page 41: ...of the main gas valve will shut off the flow of gas to both the pilot and main gas valves Centrifugal switch The centrifugal switch is mounted on the end of the draft motor and it is an integral part...

Page 42: ...installed Operating instructions Lighting the pilot and main burners 1 Turn off electric power to unit 2 Turn room thermostat to lowest setting 3 Turn gas valve knob to on position 4 Turn on electric...

Page 43: ...unction properly Burner instructions To check or change burners pilot or orifices CLOSE MAIN MANUAL SHUT OFF VALVE AND SHUT OFF ALL ELECTRIC POWER TO THE UNIT 1 Remove the screws holding either end of...

Page 44: ...e readings of both the return air and the heated air in the ducts about six feet from the furnace where they will not be affected by radiant heat Increase the blower Volumetric Flow Rate to decrease t...

Page 45: ...terminal is connected to the G terminal of the UCB and for loose wiring 10 If the thermostat and UCB are properly wired replace the UCB On a call for cooling the supply air blower motor is operating b...

Page 46: ...1 ECON terminal 13 For units with economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT...

Page 47: ...e ICB LED If it now flashes the heartbeat then the fault was a bad connection between the harness connector and the ICB connector or a broken wire exists in the harness With the harness connected to t...

Page 48: ...manual reset type If either one opens then the ICB removes power to the gas valve and the UCB energizes the indoor blower until the primary limit automatically resets or the auxiliary limit is manuall...

Page 49: ...e the motor 6 If 24 volts is not present at M2 check that 24 volts is present at the supply air blower motor terminal on the UCB If 24 volts is present at the UCB terminal check for loose wiring betwe...

Page 50: ...es for obstruction and alignment Removal procedure is described in BURNER INSTRUCTIONS on page 43 Clean or replace burner orifices and burners as needed Unit flash codes Various flash codes are utiliz...

Page 51: ...Operation 1 Flash Not Applicable 2 Flashes Control waiting ASCD1 1 These flash codes do not represent alarms 3 Flashes HPS1 Compressor Lock out 5 Flashes LPS1 Compressor Lock out 7 Flashes FS1 Compres...

Page 52: ...the UCB microprocessor connects through circuit trace to the SD 24 terminal SD 24 24 VAC hot out for factory accessory smoke detector condensate overflow and or user shutdown relay switching in serie...

Page 53: ...t indicates 24 VAC is present at C and 24V terminals FAULT Red hard lockout networking error and firmware error indicator 1 2 second on off flashing indicates one or more alarm is currently active 1 1...

Page 54: ...reading EC2 to EC2 with open circuit Used in suction line temperature safety Pinned connections on right edge of UCB RAH Return Air Humidity input from 0 10 VDC 0 100 RH sensor Input required for rehe...

Page 55: ...ut for indoor blower contactor coil indoor blower VFD enable relay coil Output with heat cool operation G input or schedule demand C1 24 VAC hot output for compressor 1 If demand is present and permis...

Page 56: ...er of the board Positive of the 15 VDC reading to C circuit for powering an optional netstat and or Multi Touch gateway C Common for SA BUS power and communication circuits Also incorporated in the J8...

Page 57: ...indicates the UCB is supplying power to the communication sub board 1 When wiring unit and other devices using the SA Bus and FC Bus see Table 29 Table 28 Smart Equipment UCB details continued Descri...

Page 58: ...5848 XIM A 0319 58 Johnson Controls Ducted Systems Typical wiring diagrams Simplicity Lite control board Figure 28 Typical ZF036 048 with Simplicity Lite control with without electric heat wiring diag...

Page 59: ...5725848 XIM A 0319 Johnson Controls Ducted Systems 59 Figure 29 Typical ZF036 048 with Simplicity Lite control with gas heat wiring diagram...

Page 60: ...5725848 XIM A 0319 60 Johnson Controls Ducted Systems Figure 30 Typical ZF060 076 with Simplicity Lite control with without electric heat wiring diagram...

Page 61: ...5725848 XIM A 0319 Johnson Controls Ducted Systems 61 Figure 31 Typical ZF060 076 with Simplicity Lite control with gas heat wiring diagram...

Page 62: ...5725848 XIM A 0319 62 Johnson Controls Ducted Systems Smart Equipment Figure 32 Typical ZF036 048 with Smart Equipment control with without electric heat wiring diagram...

Page 63: ...5725848 XIM A 0319 Johnson Controls Ducted Systems 63 Figure 33 Typical ZF036 048 with Smart Equipment control with gas heat wiring diagram...

Page 64: ...5725848 XIM A 0319 64 Johnson Controls Ducted Systems Figure 34 Typical ZF060 076 with Smart Equipment control with without electric heat wiring diagram...

Page 65: ...5725848 XIM A 0319 Johnson Controls Ducted Systems 65 Figure 35 Typical ZF060 076 with Smart Equipment control with gas heat wiring diagram...

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