York ZWTA3 Instructions Manual Download Page 1

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R-410A

ZW SERIES W/SMART EQUIPMENT™

3 - 5 Ton
60 Hertz

5803642-TIM-B-0620

TABLE OF CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 17

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 29

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 29

Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 44

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 44

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 44

Electric Heating Sequence Of Operations . . . . . . . . . . . . 45

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 46

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 47

Ignition Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 47

Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Control Board Navigation Components. . . . . . . . . . . . . . . . . 51

Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

LIST OF TABLES

1 ZWTA3 thru TA5 Unit Limitations . . . . . . . . . . . . . . . . . . . 7

2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZWTA3 thru TA5 Unit Accessory Weights . . . . . . . . . . . . 8

4 ZWTA3 thru TA5 Unit Physical Dimensions . . . . . . . . . . 11

5 ZWTA3 thru TA5 Unit Clearances . . . . . . . . . . . . . . . . . 11

6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7 Left/End Duct Dimensions. . . . . . . . . . . . . . . . . . . . . . . . 14

8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

10 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 25

12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . 26

13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 27

14 Smart Equipment™ Economizer Board Details . . . . . . . 31

15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

16 Altitude/Temperature Correction Factors . . . . . . . . . . . . 35

17 Airflow Performance - Side Duct Application . . . . . . . . . 38

18 Airflow Performance - Bottom Duct Application . . . . . . . 39

19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . 40

21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 40

22 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . 42

23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 43

24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . 46

25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 46

26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 48

27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 50

28 Gas Heat Stages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . 52

30 Cable for FC Buses and SA Buses in Order of Preference . 58

31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . 58

LIST OF FIGURES

1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 TempMaster Component Location (ZWTA3 Shown) . . . . 6

5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8

7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8 ZWTA3 thru TA4 Physical Dimensions . . . . . . . . . . . . . . 9

9 ZWTA5 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . 10

10 ZWTA3 thru TA5 Unit Bottom Duct Openings . . . . . . . . 12

11 ZWTA3 thru TA5 Unit Electrical Entry . . . . . . . . . . . . . . 13

12 ZWTA3 thru TA5 Unit Side Duct Openings . . . . . . . . . . 13

13 ZWTA3 thru TA5 Unit Left/End Duct Opening . . . . . . . . 14

14 ZWTA3 thru TA5 Roof Curb. . . . . . . . . . . . . . . . . . . . . . 14

15 ZWTA3 thru TA5 Transition Roof Curb . . . . . . . . . . . . . 15

16 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . 15

17 Return Downflow Plenum With Panel . . . . . . . . . . . . . . 16

18 Discharge Panel In Place. . . . . . . . . . . . . . . . . . . . . . . . 16

19 Save Side Panels For Economizer Hood Tops . . . . . . . 16

20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . 18

22 Typical Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 19

23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 26

24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 26

25 SE-ECO1001-1 Economizer Controller . . . . . . . . . . . . . 31

26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

27 Altitude/Temperature Correction Factors . . . . . . . . . . . . 36

28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

29 Typical Flame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

30 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . 51

31 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Summary of Contents for ZWTA3

Page 1: ...15 Supply Air Limitations 34 16 Altitude Temperature Correction Factors 35 17 Airflow Performance Side Duct Application 38 18 Airflow Performance Bottom Duct Application 39 19 RPM Selection 40 20 Indo...

Page 2: ...st edition Wear safety glasses and work gloves Use quenching cloth and have a fire extinguisher available during brazing operations Improper installation may create a condition where the operation of...

Page 3: ...directly on combustible flooring or in the U S on wood flooring or Class A Class B or Class C roof covering materials 4 For use with natural gas convertible to LP with kit This product must be instal...

Page 4: ...Conv Outlet Options Filter Options 1 2 Throwaway Filters 2 2 Pleated Filters Merv 8 3 2 Cleanable Filters 4 4 Pleated Filters Merv 13 A None C BACnet MSTP Modbus N2 COM Card E Verasys Single Zone G Ve...

Page 5: ...Bracket 2 Turn each bracket toward the ground and the protective plywood covering will drop to the ground 3 Remove the condenser coil external protective covering prior to operation 4 Remove the tooll...

Page 6: ...oling system down to 0 F when this product is applied in a comfort cooling application for people An economizer is typically included in this type of application When applying this product for process...

Page 7: ...the unit is near the place of installation Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails Spreader bars whose length exceeds the largest dimension acr...

Page 8: ...eight lbs Center of Gravity 4 Point Load Location lbs 6 Point Load Location lbs Shipping Operating X Y A B C D A B C D E F TA3 3 ZW 745 740 40 26 180 147 186 228 124 108 95 120 137 157 TA4 4 ZW 767 76...

Page 9: ...nson Controls Ducted Systems 9 Figure 8 ZWTA3 thru TA4 Physical Dimensions 25 31 59 00 15 51 29 75 59 LEFT 11 3 8 21 3 16 89 27 5 16 4 3 16 FRONT See detail A for gas inlet A See detail B for drain lo...

Page 10: ...Johnson Controls Ducted Systems Figure 9 ZWTA5 Physical Dimensions LEFT A 59 00 C D E F 4 19 27 31 89 00 21 19 11 38 15 38 59 00 15 38 29 69 15 25 FRONT SEE DETAIL B FOR DRAIN LOCATION SEE DETAIL A FO...

Page 11: ...3 16 15 3 16 6 3 16 42 CABINET 3 126 2 000 3 184 4 727 7 705 14 594 Gas Pipe Inlet Gas Exhaust Vent 5 3 8 1 FPT Table 5 ZWTA3 thru TA5 Unit Clearances Direction Distance in Direction Distance in Top1...

Page 12: ...Unit Bottom Duct Openings Bottom condensate drain Bottom gas supply entry FRONT RETURN AIR SUPPLY AIR RIGHT LEFT 20 1 8 19 1 8 17 1 8 6 13 16 6 13 16 32 11 16 14 1 2 16 3 8 18 1 16 25 9 16 12 5 16 27...

Page 13: ...with Cover Power Entry 2 1 2 Control Entry 7 8 Power Entry 2 1 2 Convenience Outlet Cover Convenience Outlet Power Entry 7 8 FRONT Dot Plugs 5 5 32 31 11 16 2 31 32 18 1 4 Return Air Supply Air A B C...

Page 14: ...ru TA5 Roof Curb 4 5 16 A C B Table 7 Left End Duct Dimensions Unit Model Number Dimension in A B C ZWTA3 30 357 13 365 22 516 ZWTA4 30 357 13 365 22 516 ZWTA5 30 357 13 365 22 516 8 or 14 50 1 2 30 2...

Page 15: ...ver the bottom of the unit For bottom duct application no duct cover changes are necessary For side duct application remove the side duct covers and install over the bottom duct openings The panels re...

Page 16: ...tall condensate drain line from the 1 inch NPT female connection on the unit to an open drain Figure 20 Condensate Drain Compressors The scroll compressor used in this product is specifically designed...

Page 17: ...lacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire A disconnect must be utilized for these units Factory installed disconnects are available...

Page 18: ...he unit nameplate Refer to Electrical Data Table 9 to size power wiring fuses and disconnect switch Power wiring is brought into the unit through the side of the unit or the basepan inside the curb Fi...

Page 19: ...OL 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 no Smoke Detector circuit Jumper is requir...

Page 20: ...1 35 40 E06 4 5 1 12 5 24 6 30 1 35 40 E08 6 8 1 18 9 30 1 37 35 40 E15 11 3 2 31 4 45 8 52 6 50 60 E20 15 2 41 6 58 5 65 4 60 70 230 13 8 83 1 22 2 1 5 2 5 5 None 24 6 30 1 35 40 E06 6 1 14 4 24 6 31...

Page 21: ...E06 4 5 1 12 5 24 6 30 1 35 40 E08 6 8 1 18 9 30 1 37 35 40 E15 11 3 2 31 4 45 8 52 6 50 60 E20 15 2 41 6 58 5 65 4 60 70 230 13 8 83 1 22 2 1 5 2 5 5 None 24 6 30 1 35 40 E06 6 1 14 4 24 6 31 4 35 40...

Page 22: ...5 1 12 5 34 6 41 5 45 50 E08 6 8 1 18 9 42 6 49 5 45 50 E15 11 3 2 31 4 58 3 65 1 60 70 E20 15 2 41 6 71 77 9 80 80 230 13 8 83 1 22 2 1 5 2 5 5 20 None 34 6 40 1 45 50 E06 6 1 14 4 37 43 9 45 50 E08...

Page 23: ...1 12 5 34 6 41 5 45 50 E08 6 8 1 18 9 42 6 49 5 45 50 E15 11 3 2 31 4 58 3 65 1 60 70 E20 15 2 41 6 71 77 9 80 80 230 13 8 83 1 22 2 1 5 2 5 5 20 None 34 6 40 1 45 50 E06 6 1 14 4 37 43 9 45 50 E08 9...

Page 24: ...AFUE Steady state efficiency 81 5 81 81 81 5 81 81 81 81 80 5 No burners 4 4 6 4 4 6 4 6 8 No stages 21 22 22 21 22 22 22 22 22 Temperature Rise Range F 20 50 F 25 65 F 50 80 F 20 50 F 25 65 F 40 70...

Page 25: ...M34 1VL44 1VL40 1VP56 Blower Sheave AK69 AK69 AK56 AK56 AK61 AK74 Belt A47 A47 A47 A47 A47 A51 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 2 RPM 1725 1725 1725 1725 1725 1725 Frame size 56 56 56 56 56...

Page 26: ...with locality The value should be checked with the local gas utility Figure 23 Side Entry Gas Piping Figure 24 Bottom Entry Gas Piping NOTE Maximum capacity of pipe in cubic feet of gas per hour base...

Page 27: ...odel numbers 1NP0454 or 1NP0455 All LP gas equipment must conform to the safety standards of the National Fire Protection Association Table 13 Gas Heat Minimum Supply Air Size Tons Model Heat Size Sup...

Page 28: ...ing to NFPA 72 requirements and cleaned at least once a year For specific troubleshooting and maintenance procedures please refer to the smoke detector s installation instructions which accompanies th...

Page 29: ...for free cooling The position of the damper is set proportionally between the Economizer Minimum Position and the Economizer Minimum Position Low Speed Fan set points in relationship to the VFD output...

Page 30: ...sor output be turned ON if the economizer output is less than 100 even if the differential between zone or return temperature and the current cooling setpoint is great enough to demand more than one s...

Page 31: ...nomizer actuator position feedback Connects through circuit trace to 24V IN pin HOT C COM Mixed Air Temperature sensor input from 10K 77 F Type III negative temperature coefficient thermistor MAT para...

Page 32: ...r Used to ramp the power exhaust fan VFD position the discharge damper actuator COM 24 VAC common 0 10 VDC negative for the power exhaust variable frequency drive discharge damper modulating power exh...

Page 33: ...sitive input from the Indoor Air Quality sensor IAQRange parameter sets the CO2 parts per million measured by the indoor air quality sensor when it outputs 10 VDC IAQ parameter reports input status 0...

Page 34: ...ion If the blower is rotating backwards the line voltage at the unit point of power connection is misphased See PHASING R 24V 24 VAC hot supplied for the building pressure sensor Connects through circ...

Page 35: ...or adjusting belt tension 1 Loosen six nuts top and bottom A 2 Adjust by turning B 3 Never loosen nuts C 4 Use belt tension checker to apply a perpendicular force to one belt at the midpoint of the sp...

Page 36: ...0 56 Example 2 A system located at 5 000 feet of elevation is to deliver 1 400 CFM at a static pressure of 1 5 Use the unit blower tables to select the blower speed and the BHP requirement Solution A...

Page 37: ...HP exceeds the maximum continuous BHP rating of the 1 5 HP motor The 2 HP motor is required 6 1230 RPM is within the range of the 2 HP drives 7 Using the 2 HP motor and drive 5 turns open will achieve...

Page 38: ...0 956 0 80 1015 0 90 1072 0 99 1130 1 08 1189 1 16 1500 650 0 35 720 0 44 786 0 54 849 0 64 911 0 74 970 0 84 1028 0 93 1086 1 03 1144 1 12 1202 1 20 1600 664 0 39 734 0 49 800 0 58 863 0 68 924 0 78...

Page 39: ...2 1039 0 92 1099 1 01 1160 1 09 1223 1 16 1500 675 0 37 744 0 46 810 0 56 872 0 66 933 0 77 993 0 87 1053 0 96 1113 1 05 1174 1 14 1237 1 20 1600 690 0 42 759 0 51 825 0 61 887 0 72 948 0 82 1008 0 92...

Page 40: ...12 hrs run time is recommended Table 19 RPM Selection Size Tons Model HP Max BHP Motor Sheave Blower Sheave 6 Turns Open 5 Turns Open 4 Turns Open 3 Turns Open 2 Turns Open 1 Turn Open Fully Closed T...

Page 41: ...motor sheave is open 5 Select the correct blower performance table for the unit from Tables 17 and 18 Tables are presented for side and down flow configuration 6 Determine the unit Measured CFM from...

Page 42: ...can result in substantial changes in static pressure and BHP BHP and AMP draw of the blower motor will increase by the cube of the blower speed Static pressure will increase by the square of the blowe...

Page 43: ...2 0 03 0 01 0 01 0 01 0 02 0 02 0 02 1200 0 04 0 00 0 04 0 01 0 01 0 01 0 02 0 02 0 02 1300 0 03 0 01 0 05 0 01 0 01 0 01 0 03 0 03 0 03 1400 0 03 0 03 0 07 0 02 0 02 0 02 0 03 0 03 0 03 1500 0 03 0 0...

Page 44: ...ontroller previously determined Y1 energizes the economizer The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor If the outdoor air enthalpy...

Page 45: ...with compressor operation Compressor minimum run time may extend the minutes of compressor operation The off cycle will begin immediately following the elapse of the minimum run time When operating i...

Page 46: ...erature condition caused by inadequate supply air flow occurs thus shutting down the heater and energizing the blower Reset Remove the call for heating by lowering the thermostat setting lower than th...

Page 47: ...hree ignition attempts the furnace is locked out for one hour The furnace is monitored during this one hour period for unsafe conditions Recycle Operation When a flame is lost after the flame stabiliz...

Page 48: ...e switch closes or W1 is lost Roll out Switch ROS The roll out switch is wired in series with the pressure switch As such the ICB cannot distinguish the roll out switch operation from that of the pres...

Page 49: ...time should the standby gas pressure exceed 10 5 in or the operating pressure drop below 4 5 in for natural gas units If gas pressure is outside these limits contact the local gas utility or propane s...

Page 50: ...This gas furnace has two heat stages Therefore the gas valve has two adjustment screws located under a plastic protective cover The second stage 100 input adjustment screw is adjacent to the HI marki...

Page 51: ...or replacement NOTE Reverse the above procedure to replace the assemblies Make sure that burners are level and seat at the rear of the gas orifice Figure 29 Typical Flame Figure 30 Typical Two Stage...

Page 52: ...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 series Connec...

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: ...C 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 re...

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: ...ication circuit Earth ground reference of the cable to prevent interference on the FC bus BACnet MSTP communication circuit Item Selector in red housing at left on top edge of the communication board...

Page 58: ...air Cable2 2 We recommend 26 AWG solid 6 wire 3 twisted pairs cable as the best fit for fabricating modular cables with the modular jack housing assembly Be sure the cable you use fits the modular jac...

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