York ZD Series Installation Manual
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York ZD Series Installation Manual

60 hertz, 3 - 5 ton, r-410a,
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R-410A
ZD SERIES
3 - 5 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Field Power and Control Wiring . . . . . . . . . . . . . . . . . . . . 15
Typical Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15
16
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Jade Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 34
Simplicity SE Economizer Sequences . . . . . . . . . . . . . . . . . . . 36
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 ZD-03 Thru -05 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . 6
2 ZD-03 Thru -05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZD-03 Thru -05 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8
4 ZD-03 Thru -05 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 10
5 ZD-03 Thru -05 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 ZD-03 Thru -05 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 29
9 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31
10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32
13 Simplicity SE Economizer Board Details . . . . . . . . . . . . . . . . 38
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42
15 ZD Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 45
16 ZD Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 47
1 ZD-03 thru -05 Component Location . . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 ZD-03 Thru -05 Cooling Only/Gas Heat Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZD-03 Thru -05 Disconnect Location . . . . . . . . . . . . . . . . . . 10
9 ZD-03 Thru -05 Unit Side Duct Openings . . . . . . . . . . . . . . . 11
10 ZD-03 Thru -05 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13
14 Typical Simplicity SE Control Wiring . . . . . . . . . . . . . . . . . . 16

TABLE OF CONTENTS

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 50
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 52
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 52
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 53
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 55
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fan On And Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Unit Control Board Navigation Examples: . . . . . . . . . . . . . . . . 68
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
LIST OF TABLES
17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 48
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 48
20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 53
24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 55
25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 55
26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 58
27 ZD-03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
28 ZD-04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
29 ZD-05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 62
30 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 67
31 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 67
32 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
LIST OF FIGURES
15 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
16 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
17 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 34
18 Economizer LCD and Keypad Layout. . . . . . . . . . . . . . . . . . 34
19 Single Enthalpy Curve And Boundaries . . . . . . . . . . . . . . . . 35
20 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 38
21 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
22 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43
23 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 49
24 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
25 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 56
26 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 56
27 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 57
28 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 57
29 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
30 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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Summary of Contents for York ZD Series

  • Page 1: Table Of Contents

    R-410A ZD SERIES 3 - 5 Ton 60 Hertz TABLE OF CONTENTS General ..........2 Auto .

  • Page 2: General

    5188236-BIM-A-0316 General ® Model ZD units are either single package cooling units equipped with optional factory installed electric heaters, or single This product must be installed in strict compliance with package gas-fired central heating furnaces with cooling unit. the installation instructions and any applicable local, Both are designed for outdoor installation on a rooftop or slab.
  • Page 3 5188236-BIM-A-0316 Due to system pressure, moving parts, and electrical Reference components, installation and servicing of air conditioning Additional information is available in the following reference equipment can be hazardous. Only qualified, trained service forms: personnel should install, repair, or service this equipment. Untrained personnel can perform basic maintenance functions •...
  • Page 4 5188236-BIM-A-0316 Product Nomenclature 3-5 Ton Brand Model Number Nomenclature Z D -03 C A 2 A 1 Product Generation Product Category 1 = First Generation Z = A/C, Single Pkg., R-410A Cabinet Options A = Std Cabinet Product Identifier B = HDF(HingedFLTR/Tooless DR) E = SSD (SST Drain Pan) D = Pkg AC Mid Eff F = SSD, HFD...

  • Page 5: Installation

    5188236-BIM-A-0316 Installation Limitations These units must be installed in accordance with the following: Installation Safety Information In U.S.A.: Read these instructions before continuing this appliance National Electrical Code, ANSI/NFPA No. 70 - Latest installation. This is an outdoor combination heating and cooling Edition unit.

  • Page 6: Thru -05 Unit Limitations

    5188236-BIM-A-0316 Power Ventor Motor With 20 Gauge Aluminized Post Purge Cycle Steel Tubular Heat Exchanger High Efficiency HACR Compressor Breaker Economizer Hood Highly Efficient Enhanced Copper Tube/Enhanced Aluminum Fin Knockout Micro-Channel For Side Aluminum Power Entry Tube/Aluminum Fin Condenser Slide-In Economizer Smoke Detector...

  • Page 7: Location

    5188236-BIM-A-0316 codes. Refer to Table 4 for clearances required for combustible Location construction, servicing, and proper unit operation. Use the following guidelines to select a suitable location for these units: Unit is designed for outdoor installation only. Condenser coils must have an unlimited supply of air. Do not permit overhanging structures or shrubs to Where a choice of location is possible, position the unit on obstruct condenser air discharge outlet, combustion air...

  • Page 8: Thru -05

    5188236-BIM-A-0316 Front Front Figure 2: Unit 4 Point Load Weight Figure 3: Unit 6 Point Load Weight FRONT LEFT Figure 4: Center of Gravity Table 2: ZD-03 Thru -05 Center of Weight (lbs.) 4 point Load Location (lbs.) 6 point Load Location (lbs.) Size (Tons) Shipping...

  • Page 9: Thru -05 Cooling Only/Electric Heat Front View Physical Dimensions

    5188236-BIM-A-0316 Figure 5: ZD-03 Thru -05 Cooling Only/Electric Heat Front View Physical Dimensions Figure 6: ZD-03 Thru -05 Cooling Only/Gas Heat Front View Physical Dimensions Johnson Controls Unitary Products...

  • Page 10: Thru -05 Unit Clearances

    5188236-BIM-A-0316 27-1/2 1-5/8 27-1/2 19-3/4 19-1/2 44-7/8 Detail “A” 27-1/2 7-1/4 27-1/2 10-1/4 19-1/8 3-1/2 8-1/4 “A” 44-7/8 LH End View Rear View 4-3/8 Dimension “A” Fixed Outdoor Air Damper Detail “B” Motorized 16-1/2 Damper Figure 7: ZD-03 Thru -05 Fixed Outdoor Air Motorized Damper Rain Hood Physical Dimensions Table 4: ZD-03 Thru -05 Unit Clearances Location Clearance...

  • Page 11: Thru -05 Utilities Entry

    5188236-BIM-A-0316 Figure 9: ZD-03 Thru -05 Unit Side Duct Openings Table 5: ZD-03 Thru -05 Utilities Entry Hole Opening Size (Dia.) Used For Side 7/8” KO Control Wiring Bottom Side 2” KO Power Wiring Bottom 1-5/8” KO Gas Piping (Front) 1-1/2”...

  • Page 12: Ductwork

    5188236-BIM-A-0316 Ductwork Compressors Ductwork should be designed and sized according to the The scroll compressor used in this product is specifically methods in Manual D of the Air Conditioning Contractors of designed to operate with R-410A Refrigerant and cannot be America (ACCA) or as recommended by any other recognized interchanged.

  • Page 13: Filters

    A disconnect must be utilized for these units. Factory installed Figure 12: Compressor Restraining Bracket disconnects are available. If installing a disconnect (field ® supplied or York International supplied accessory), refer to Figure 8 for the recommended mounting location. Do not loosen compressor mounting bolts.

  • Page 14: Control Wire Sizes

    5188236-BIM-A-0316 When installing equipment in a facility with a 3 phase 208/230-3-60 and 380/415-3-50 units with factory high-leg delta power supply, care must be taken to installed Powered Convenience Outlet Option are wired ensure that the high-leg conductor is not attached to for 230v and 415v power supply respectively.

  • Page 15: Typical Field Power And Control Wiring

    5188236-BIM-A-0316 Typical Field Power and Control Wiring Typical Power Wiring REFER TO THE ELECTRICAL DATA TABLES TO SIZE THE DISCONNECT SWITCH, OVERCURRENT PROTEC- TION AND WIRING. Typical Cool/Heat Control Wiring (Simplicity Lite ZD-03 Thru -05) CONTROL TERMINAL THERMOSTAT BLOCK TERMINALS SD-24 Smoke Detector...

  • Page 16: Typical Cool/Heat Control Wiring (Simplicity S E Zd-03 Thru -05)

    5188236-BIM-A-0316 Typical Cool/Heat Control Wiring (Simplicity S E ZD-03 Thru -05) CONTROL TERMINAL THERMOSTAT BLOCK TERMINALS SD-24 Smoke Detector 24 VAC Class 2 SD-24 Jumper Located on Harness TERMINALS ON A (If Smoke Detector Is Used) (If No Smoke Detector) LIMITED NUMBER OF THERMOSTATS SD-R...

  • Page 17: Electrical Data

    5188236-BIM-A-0316 Table 7: Electrical Data ZD-03 Thru -05 - Without Powered Convenience Outlet (Belt Drive) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) NONE...
  • Page 18 5188236-BIM-A-0316 ZD-03 Thru -05 - Without Powered Convenience Outlet (Belt Drive) (Continued) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) NONE 41.6 19.2 41.6...
  • Page 19 5188236-BIM-A-0316 ZD-03 Thru -05 - Without Powered Convenience Outlet (Belt Drive High Static) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) NONE 28.3 19.2...
  • Page 20 5188236-BIM-A-0316 ZD-03 Thru -05 - Without Powered Convenience Outlet (Belt Drive High Static) (Continued) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) NONE 31.2...
  • Page 21 5188236-BIM-A-0316 ZD-03 Thru -05 - Without Powered Convenience Outlet (Direct Drive) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) NONE 27.5 19.2 31.5 26.9...
  • Page 22 5188236-BIM-A-0316 ZD-03 Thru -05 - Without Powered Convenience Outlet (Direct Drive) (Continued) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) NONE 42.5 19.2 42.5...
  • Page 23 5188236-BIM-A-0316 ZD-03 Thru -05 - With Powered Convenience Outlet (Belt Drive) OD Fan Supply Max Fuse Compressors Size Motors Blower Conv Electric Heat Option Breaker Volt (each) (each) Motor Outlet (Tons) (Amps) Size (Amps) RLA LRA Model Stages Amps NONE 38.3 19.2 44.9...
  • Page 24 5188236-BIM-A-0316 ZD-03 Thru -05 - With Powered Convenience Outlet (Belt Drive) (Continued) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (Tons) (each) Motor Outlet (Amps) Size (Amps) RLA LRA Model Stages Amps NONE 51.6 19.2...
  • Page 25 5188236-BIM-A-0316 ZD-03 Thru -05 - With Powered Convenience Outlet (Belt Drive High Static) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (each) Motor Outlet (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) NONE 38.3...
  • Page 26 5188236-BIM-A-0316 ZD-03 Thru -05 - With Powered Convenience Outlet (Belt Drive High Static) (Continued) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (Tons) (each) Motor Outlet (Amps) Size (Amps) RLA LRA Model Stages Amps NONE...
  • Page 27 5188236-BIM-A-0316 ZD-03 Thru -05 - With Powered Convenience Outlet (Direct Drive) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (each) Motor Outlet (Tons) (Amps) Size (Amps) RLA LRA Model Stages Amps NONE 37.5 19.2 26.9...
  • Page 28 5188236-BIM-A-0316 ZD-03 Thru -05 - With Powered Convenience Outlet (Direct Drive) (Continued) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (each) Motor Outlet (Tons) (Amps) Size (Amps) RLA LRA Model Stages Amps NONE 52.5 19.2...

  • Page 29: Thru -05 Physical Data

    5188236-BIM-A-0316 Table 8: ZD-03 Thru -05 Physical Data ZD-03 Thru -05 Physical Data Models Component ZD-03 ZD-04 ZD-05 Nominal Tonnage ARI COOLING PERFORMANCE Gross Capacity @ AHRI A point (Btu) 36600 49100 59000 AHRI net capacity (Btu) 35500 47500 57000 12.0 12.0 11.8...
  • Page 30 5188236-BIM-A-0316 ZD-03 Thru -05 Physical Data (Continued) Models Component ZD-03 ZD-04 ZD-05 Nominal Tonnage CONDENSER FAN DATA Quantity of fans Fan diameter (Inch) Type Prop Prop Prop Drive type Direct Direct Direct Quantity of motors Motor HP each No. speeds 1090 1090 1100...

  • Page 31: Optional Electric Heat

    5188236-BIM-A-0316 These CSA approved heaters are located within the central Optional Electric Heat compartment of the unit with the heater elements extending in The factory or field installed heaters are wired for single point to the supply air chamber. power supply. Power supply need only be brought into the Fuses are supplied, where required, by the factory.

  • Page 32: Gas Pipe Sizing - Capacity Of Pipe

    5188236-BIM-A-0316 NOTE: Maximum capacity of pipe in cubic feet of gas per hour Gas Piping based upon a pressure drop of 0.3 inch W.C. and 0.6 Proper sizing of gas piping depends on the cubic feet per hour specific gravity gas. of gas flow required, specific gravity of the gas and the length of run.
  • Page 33 5188236-BIM-A-0316 The pressure drop in the lines between regulators and between the second stage regulator and the appliance. Pipe size required will depend on the length of the pipe run and the total load of all appliances. FIRE OR EXPLOSION HAZARD Complete information regarding tank sizing for vaporization, Failure to follow the safety warning exactly could result recommended regulator settings, and pipe sizing is available...

  • Page 34: Options/Accessories

    5188236-BIM-A-0316 Extreme care must be exercised in turning all set point, maximum and minimum damper positioning adjustment screws to prevent twisting them off. Minimum Position Adjustment • Check that the damper blades move smoothly without binding; carefully turn the Minimum Position Adjust screw (found on the damper control module) fully clockwise and Figure 17: Vent And Combustion Air Hood then set the thermostat indoor fan switch to the ON...

  • Page 35: Single Enthalpy Curve And Boundaries

    5188236-BIM-A-0316 • Press the  button (MenuUp/Exit) to return to the Keypad previous menu. The four navigation buttons illustrated in Fig. 28 are used to scroll through the menus and menu items, select menu items, Menu Structure and to change parameter and configuration settings. The Menus in display order are: Using the Keypad with Menus •...

  • Page 36: Simplicity Se Economizer Sequences

    5188236-BIM-A-0316 Table 12: Single Enthalpy and Dual Enthalpy High Limit Curves. Point P1 Point P2 Enthalpy Temp. Temp. Enthalpy Curve Dry-Bulb (°F) Dewpoint (°F) (btu/lb/da) Temp. °F Humidity %RH Temp. °F Humidity %RH 80.0 60.0 28.0 80.0 36.8 66.3 80.1 75.0 57.0 26.0...

  • Page 37: Free Cooling Operation

    5188236-BIM-A-0316 • Return and outside air dry bulb and return and outside air If the economizer output goes to minimum position and the SAT humidity = dual enthalpy is less than Economizer Setpoint -1°F, the control starts a 12- minute timer to de-energize a compressor output. •...

  • Page 38: Simplicity Se Economizer Board Details

    5188236-BIM-A-0316 Figure 20: SE-ECO1001-0 Economizer Controller Table 13: Simplicity SE Economizer Board Details Board Cover Description Function & Comments Label Label Directional orientation: viewed with the center text of the cover label upright ANALOG INPUTS Terminal at left on upper edge of economizer board 24 VAC common/0-10 VDC negative for Connects through circuit trace to 24V~ IN pin COM economizer actuator position feedback...
  • Page 39 5188236-BIM-A-0316 Table 13: Simplicity SE Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label EconCtrlr parameter reports UCB-to-economizer board SA BUS communication status. Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to C; at least 0.25 volts lower –...
  • Page 40 5188236-BIM-A-0316 Table 13: Simplicity SE Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label 24 VAC hot connection to power the economizer board. 24 VAC transformer HOT Connects through circuit traces to R/24V~ terminals and pins distributed on the economizer board. ANALOG INPUTS Terminal on lower edge of economizer board 24 VAC hot supplied for the outdoor air 24V~...
  • Page 41 5188236-BIM-A-0316 Table 13: Simplicity SE Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label 24 VAC common/0-5 VDC negative for the Connects through circuit trace to 24V~ IN pin COM building pressure sensor BINARY INPUTS at right on lower edge of economizer board Purge parameter reports input status (False with 0 VAC input- True with 24 VAC input).

  • Page 42: Altitude/Temperature Correction Factors

    5188236-BIM-A-0316 CFM Static Pressure and Power-Altitude and Temperature Corrections Defl Force The information below should be used to assist in application of product when being applied at altitudes at or exceeding 1000 feet above sea level. The air flow rates listed in the standard blower performance tables are based on standard air at sea level.

  • Page 43: Altitude/Temperature Correction Factors

    5188236-BIM-A-0316 1.100 1.050 1.000 Sea Level 0.950 1000 ft 0.900 2000 ft 3000 ft 0.850 4000 ft 0.800 5000 ft 6000 ft 0.750 7000 ft 8000 ft 0.700 9000 ft 10000 ft 0.650 0.600 Air Temperature (ºF) Figure 22: Altitude/Temperature Correction Factors The examples below will assist in determining the airflow blower tables to select the blower speed and the BHP performance of the product at altitude.
  • Page 44 5188236-BIM-A-0316 Drive Selection Determine side or bottom supply air duct application. Determine desired airflow. Calculate or measure the amount of external static pressure. Using the operating point determined from steps 1, 2 & 3, locate this point on the appropriate supply air blower performance table. (Linear interpolation may be necessary.) Noting the RPM and BHP from step 4, locate the appropriate motor and/or drive on the RPM selection table.

  • Page 45: Zd Blower Performance Side Duct

    5188236-BIM-A-0316 Table 15: ZD Blower Performance Side Duct ZD-03 (3 Ton Belt Drive) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive Standard Drive Option High Static Drive Option...
  • Page 46 5188236-BIM-A-0316 ZD-03 Thru -05 (3-5 Ton Direct Drive) Side Duct AVAILABLE EXTERNAL STATIC PRESSURE - IWG UNIT MOTOR TONNAGE SPEED 5 (HI) 1574 1530 1488 1451 1411 1374 1331 1292 1249 4 (MED/HI) 1480 1433 1389 1347 1303 1257 1208 1153 1080 3 (MED)

  • Page 47: Zd Blower Performance Bottom Duct

    5188236-BIM-A-0316 Table 16: ZD Blower Performance Bottom Duct ZD-03 (3 Ton Belt Drive) Bottom Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive Standard Drive Option High Static Drive Option...

  • Page 48: Checking Supply Air Cfm

    5188236-BIM-A-0316 ZD-03 Thru -05 (3-5 Ton Direct Drive) Bottom Duct AVAILABLE EXTERNAL STATIC PRESSURE - IWG UNIT MOTOR TONNAGE SPEED 5 (HI) 1520 1478 1438 1401 1363 1327 1286 1248 1207 4 (MED/HI) 1430 1384 1342 1302 1259 1215 1168 1114 1044 3 (MED)

  • Page 49: Pressure Drop Across Coil

    5188236-BIM-A-0316 Note the following: Knowing the pressure drop across a dry coil, the actual CFM through the unit can be determined from the curve in The supply air CFM must be within the limitations shown in Pressure Drop vs. Supply Air CFM (Figure 23). the Unit Physical Data Table .

  • Page 50: Operation

    Once the thermostat has been satisfied, it will de-energize Y1. If the compressor has satisfied its minimum run time, the For the ZD series of units, the thermostat makes a circuit compressor and condenser fan de-energize. Otherwise, the between “R” and “Y1” for the first stage of cooling.

  • Page 51: Cooling Operation Errors

    5188236-BIM-A-0316 off delay for cooling, and the economizer damper goes to the the low-pressure limit switch for any openings. If the low-pressure closed position. If the unit is in continuous fan operation the switch opens for greater than 5 seconds, the UCB will de-energize economizer damper goes to the min.

  • Page 52: Electric Heating Sequence Of Operations

    5188236-BIM-A-0316 too soon after its previous run. Additionally, a minimum run time Low Ambient Cooling (Simplicity SE Control) is imposed any time a compressor is energized. To determine when to operate in low ambient mode, the UCB The ASCD is initiated on unit start-up and on any compressor has an Outdoor Air Temperature Sensor (OAT) with a low reset or lock-out.

  • Page 53: Gas Heating Sequence Of Operations

    5188236-BIM-A-0316 Safety Controls Electric Heat Anticipator Setpoints The UCB monitors the temperature limit switch of electric heat It is important that the anticipator setpoint be correct. Too high units. of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space.

  • Page 54: Gas Heat Operation Errors

    5188236-BIM-A-0316 over and the UCB will de-energize the blower for 45 seconds. Redundant valve Main valve However, the auxiliary limit is in series with the primary limit and it takes first control. If the excessive heat has been high enough to cause the auxiliary limit (AUX) to open, then the Gas main ICB will flash the primary limit code but the furnace will not retry ignition during the same call for heat.

  • Page 55: Flash Codes Or Error Messages

    5188236-BIM-A-0316 area the roll-out switch will open, the ICB will close both the Table 25: Gas Heat Anticipator Setpoints main and pilot gas valves and flash a code (Table 31). The ICB Gas Valve Anticipator Setpoints will not retry the ignition sequence during the same call for heat. Honeywell VR8204M 0.60 amp White-Rogers 36E36...

  • Page 56: Typical Single Stage Gas Valves

    5188236-BIM-A-0316 nor the operating pressure drop below 5.0" for natural gas Operating Instructions units. If gas pressure is outside these limits, contact the local gas utility for corrective action. This furnace is equipped with an intermittent pilot “ON” - “OFF” Control Pilot Adj.

  • Page 57: Checking Gas Input

    5188236-BIM-A-0316 Burner assembly bracket Heat Tube Adjustable Shutter Exchanger Burner Flame sensor bulb Burner Flame Pilot Tube (Blue Only) Gas Supply Pipe Figure 28: Typical Flame Appearance 1/8” gap between carry-over tube and flame sensor bulb Burners are now accessible for service. Reverse the above procedure to replace the assemblies.

  • Page 58: Troubleshooting

    5188236-BIM-A-0316 Troubleshooting Table 26: Gas Rate-Cubit Feet per Hour Size of Test Dial Seconds for One Rev. 1/2 cu. ft. 1 cu. ft. Troubleshooting of components may require opening the electrical control box with the power connected to the unit. Use extreme care when working with live circuits! Check the unit nameplate for the correct line voltage and set the voltmeter to the correct range before making any connections with line terminals.
  • Page 59 5188236-BIM-A-0316 If 24 volts is not present at the “FAN” terminal, check for 24 If 24 volts is present at the UCB Y1 terminal, the volts from the room thermostat. If 24 volts are not present compressor may be out due to an open high-pressure from the room thermostat, check for the following: switch, low-pressure switch, or freezestat.
  • Page 60 5188236-BIM-A-0316 For units with factory installed economizers, the UCB is time. This programming can be checked or changed by the programmed to lock out compressor operation when the local distributor. LAS set point is reached. 15. If none of the above correct the error, replace the UCB. For units without factory installed or with field installed economizers, the UCB allows compressor operation all the Johnson Controls Unitary Products...

  • Page 61: 3.0 Ton) Operating Pressures

    5188236-BIM-A-0316 Normal Operating Pressures Table 27: ZD-03 (3.0 Ton) Operating Pressures Air Flow Indoor Outdoor Suction Suction Liquid Liquid Delta T Entering Leaving Compressor Indoor Db/Wb DB/WB Pressure Temp. Pressure Temp. Evap Db Evap Db Amps 300 Cfm/Ton 80/62 300 Cfm/Ton 80/67 300 Cfm/Ton 80/72...

  • Page 62: 5.0 Ton) Operating Pressures

    5188236-BIM-A-0316 Table 29: ZD-05 (5.0 Ton) Operating Pressures Air Flow Indoor Outdoor Suction Suction Liquid Liquid Delta T Entering Leaving Compressor Indoor Db/Wb DB/WB Pressure Temp. Pressure Temp. Evap Db Evap Db Amps 300 Cfm/Ton 80/62 300 Cfm/Ton 80/67 300 Cfm/Ton 80/72 300 Cfm/Ton 75/63...
  • Page 63 5188236-BIM-A-0316 wired per the wiring diagram. If there is any indication the unit black on two stage models). If it is less than 177 volts, has been previously repaired, then the first priority is to verify then check and repair the power circuit to the draft that the furnace is wired per the wiring diagram.
  • Page 64 5188236-BIM-A-0316 the pilot cannot be adjusted to obtain a strong and stable is restricted and the flame will either roll out of the tube inlet flame in the flame sensor area, then remove the burner or heat will build to an abnormal level in the burner area. assembly and verify the pilot burner assembly is open This can usually be determined by observing burner flame internally and the holes in the burner are clean.
  • Page 65 5188236-BIM-A-0316 contactor is pulled in. Check for loose wiring between the indicated by the fault code. If not, then remove power to the contactor and the supply air blower motor. unit for more than 20 seconds. If upon restoring the power to the unit the draft motor does not start with a call for heat, If M2 is pulled in and voltage is supplied at M2, lightly touch then verify that terminal “L1”...

  • Page 66: Fan On And Off Delays

    5188236-BIM-A-0316 The pilot burner lights and the spark stops but the main burners Pressing the button two times within five seconds causes do not light. the control to flash its address. Pressing the button three times within five seconds forces Check electrical connections between the ignition control the control to reset its address to 1, which is the factory and the gas valve.

  • Page 67: Simplicity Se Control Board Navigation Components

    5188236-BIM-A-0316 Table 31: Ignition Control Board Flash Codes Table 30: Unit Control Board Flash Codes Flash Code Description Flash Code Description 7 Flashes Rollout Switch Open On Steady Control Failure - Replace Control 8 Flashes Flame Present With Gas Off Heart Beat Normal Operation 9 Flashes...

  • Page 68: Simplicity™ Se (Smart Equipment) Firmware Version 3. Basic Unit Control Board Navigation Examples

    5188236-BIM-A-0316 SIMPLICITY™ SE (SMART EQUIPMENT) FIRMWARE VERSION 3. BASIC UNIT CONTROL BOARD NAVIGATION EXAMPLES: The following document details the navigation and viewing of navigate the basic status menu and how to change basic the LCD display screen equipped as a standard item on the configuration settings.
  • Page 69 5188236-BIM-A-0316 When the "Cancel" button is pressed multiple times to exit each menu level and the screen returns to the first "Status, Alarms" dis- play the next demonstration can begin. In this demonstration the information below steps through the "Commissioning" menu. Step 2- Once commission Step 1- Beginning at the status/alarm screen toggle the joystick down three times.

  • Page 70: Simplicity Se Ucb Details

    5188236-BIM-A-0316 THERMOSTAT WIRED HERE SD-24 Figure 30: Unit Control Board Table 32: Simplicity SE UCB Details Description Function & Comments Terminal Directional orientation: viewed with silkscreen labels upright Limit, 24 VAC power and shutdown connections from unit wiring harness at left on upper edge of UCB Monitored 24 VAC input through heat section limit If voltage is absent, indicating the heat section is over- LIMIT...
  • Page 71 5188236-BIM-A-0316 Table 32: Simplicity SE UCB Details (Continued) Description Function & Comments Connects through circuit trace to the thermostat connection 24 VAC hot for switched inputs to the UCB strip R terminal, right FAN OVR pin, right HPS1 pin, right HPS2 pin, lower DFS pin and lower APS pin Terminal Thermostat connection strip on left edge of UCB 1st stage heating request, 24 VAC input switched...
  • Page 72 5188236-BIM-A-0316 Table 32: Simplicity SE UCB Details (Continued) Description Function & Comments Pin Temperature sensor connections at right on upper edge of UCB Input required for operation; 3.625 VDC reading SAT+ to SAT– Supply Air Temperature sensor input from 10KΩ with open circuit.
  • Page 73 5188236-BIM-A-0316 Table 32: Simplicity SE UCB Details (Continued) Description Function & Comments Output is active with indoor blower operation. For CV units: this output provides stepped IntelliSpeed control of the indoor 2-10 VDC (0-100%) output for the indoor blower blower VFD based on fan-only, cooling stage and heating stage Variable Frequency Drive outputs.
  • Page 74 5188236-BIM-A-0316 Table 32: Simplicity SE UCB Details (Continued) Description Function & Comments Input is only considered after 30 seconds of C1 output; 24 VAC hot return from refrigerant circuit 1 Low afterwards, input must be present to allow C1 output. Three LPS1 (left pin) Pressure Switch...
  • Page 75 5188236-BIM-A-0316 Table 32: Simplicity SE UCB Details (Continued) Description Function & Comments Button for display menu acknowledgment and ENTER navigation Button for display menu navigation and zeroing of CANCEL active compressor ASCD timer 4-way Joystick for display menu navigation Item USB connector at right of UCB Used for backup, restoration, &...

  • Page 76: Start-Up Sheet

    Technical Services Department available. Therefore, some variation in the startup procedure will 5005 York Drive exist depending upon the products capacity, control system, Norman, OK 73069 options and accessories installed.
  • Page 77 5188236-BIM-A-0316 1034349-UCL-C-0315 SAFETY WARNINGS The inspections and recording of data outlined in this procedure are required for start-up of Johnson Controls/UPG's packaged Lethal voltages are present during some start-up products. Industry recognized safety standards and practices checks. Extreme caution must be used at all times. must be observed at all times.
  • Page 78 5188236-BIM-A-0316 1034349-UCL-C-0315 REFERENCE General Inspection Completed See Notes Unit inspected for shipping, storage, or rigging damage Unit installed with proper clearances Unit installed within slope limitations Refrigeration system checked for gross leaks (presence of oil) Terminal screws and wiring connections checked for tightness Filters installed correctly and clean Economizer hoods installed in operating position Condensate drain trapped properly, refer to Installation Manual...
  • Page 79 5188236-BIM-A-0316 1034349-UCL-C-0315 Operating Measurements - Air Flow Fan operates with proper rotation ID Fans Exh. Fans Cond. Fans Pressure drop across dry evaporator coil (At maximum design CFM) External Static Pressure Return Static Pressure Supply Static Pressure Supply Air CFM Using Dry Coil Chart Final Adjusted Supply Air CFM 1.
  • Page 80 5188236-BIM-A-0316 1034349-UCL-C-0315 OPERATING MEASUREMENTS - COOLING Discharge Discharge Liquid Line Suction Suction Stage Subcooling Superheat Pressure Temp. Temp. Pressure Temp. First ° ° ° ° ° Second (if equipped) ° ° ° ° ° Third (if equipped) ° ° ° °...

  • Page 81: 5188236-Bim-A-0316

    _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ Subject to change without notice. Printed in U.S.A. 5188236-BIM-A-0316 Copyright © 2016 by Johnson Controls, Inc. All rights reserved. Supersedes: 1189508-BIM-C-0815 York International Corporation 5005 York Drive Norman, OK 73069...

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