Table of Contents
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R-410A
ZE 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
Typical Cool/Heat Control Wiring (Smart Equipment™ ZE036-
060) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
RRS Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 34
Smart Equipment™ Economizer Sequences. . . . . . . . . . . . . . 35
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 ZE036-060 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 ZE036-060 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZE036-060 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 8
4 ZE036-060 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 ZE036-060 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 ZE036-060 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31
10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32
12 Smart Equipment™ Economizer Board Details . . . . . . . . . . 37
13 Single Enthalpy and Dual Enthalpy High Limit Curves. . . . . . 42
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43
15 ZE Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 46
16 ZE Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 48
17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1 ZE036-060 Component Location . . . . . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZE036-060 Disconnect Location . . . . . . . . . . . . . . . . . . . . . 10
9 ZE036-060 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 11
10 ZE036-060 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13
14 Typical Smart Equipment™ Control Wiring . . . . . . . . . . . . . 16
TABLE OF CONTENTS
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Jade Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 40
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 51
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 53
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 53
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 54
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 56
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Board Navigation Examples: . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
LIST OF TABLES
18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 49
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 49
20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 54
23 Single Stage Gas Heat Limit Control Setting . . . . . . . . . . . . 55
24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 55
25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 56
26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 58
27 ZE036 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
28 ZE048 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
29 ZE060 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 62
30 Simplicity Lite Unit Control Board Flash Codes . . . . . . . . . . 66
31 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 66
32 Smart Equipment™ 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 RRS Economizer LCD and Keypad Layout. . . . . . . . . . . . . 34
19 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 37
20 Jade Economizer LCD and Keypad Layout. . . . . . . . . . . . . 40
21 Single Enthalpy Curve And Boundaries . . . . . . . . . . . . . . . . 41
22 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
23 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 44
24 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 50
25 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
26 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 57
27 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 57
28 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 57
29 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 58
30 Simplicity Lite Control Board . . . . . . . . . . . . . . . . . . . . . . . . 66
31 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 70
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Related Manuals for York ZE036
Summary of Contents for York ZE036
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Page 1: Table Of Contents
2 ZE036-060 ........ -
Page 2: General
5188235-YIM-B-1016 General ® YORK Model ZE 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 Untrained personnel can perform basic maintenance functions • Technical Guide - ZE036-060, 5190086 of cleaning coils and filters and replacing filters. • General Installation - ZE036-060, 5188235 Observe all precautions in the literature, labels, and tags...
- Page 4 5188235-YIM-B-1016 Product Nomenclature ® 3-5 Ton York Model Number Nomenclature Z E 036 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...
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Page 5: Installation
5188235-YIM-B-1016 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: Ze036-060 Unit Limitations
Convenience Outlet Or Smart Equipment™ Control Board Knockout Belt Drive Or For Side Direct Drive Control Entry Blower Figure 1: ZE036-060 Component Location Table 1: ZE036-060 Unit Limitations Unit Limitations Size Unit Voltage Applied Voltage Outdoor DB Temp (Tons) Max (°F) -
Page 7: Location
If a unit is to be installed on a roof curb other than a ® York roof curb, gasketing must be applied to all Excessive exposure of this furnace to contaminated surfaces that come in contact with the unit underside. -
Page 8: Ze036-060
6 point Load Location (lbs.) Size (Tons) Shipping Operating 34.5 18.25 18.5 37.5 18.2 Table 3: ZE036-060 Unit Accessory Weights Weight (lbs.) Unit Accessory Shipping Operating Economizer Power Exhaust Electric Heat Gas Heat 1. Weight given is for the maximum heater size available (30KW). -
Page 9: Ze036-060 Cooling Only/Electric Heat Front View Physical
5188235-YIM-B-1016 Figure 5: ZE036-060 Cooling Only/Electric Heat Front View Physical Dimensions Figure 6: ZE036-060 Cooling Only/Gas Heat Front View Physical Dimensions Johnson Controls Unitary Products... -
Page 10: Ze036-060 Unit Clearances
Dimension “A” Fixed Outdoor Air Damper Detail “B” Motorized 16-1/2 Damper Figure 7: ZE036-060 Fixed Outdoor Air Motorized Damper Rain Hood Physical Dimensions Table 4: ZE036-060 Unit Clearances Location Clearance Filter Access 24” (Cooling/Electric Heat) Front 32” (Gas Heat) Blower Motor Access 12”... -
Page 11: Ze036-060 Utilities Entry
5188235-YIM-B-1016 Figure 9: ZE036-060 Unit Side Duct Openings Table 5: ZE036-060 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” KO Gas Piping (Bottom) 1. -
Page 12: Ductwork
5188235-YIM-B-1016 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
5188235-YIM-B-1016 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
5188235-YIM-B-1016 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 ZE036-060) CONTROL TERMINAL THERMOSTAT BLOCK TERMINALS SD-24 Smoke... -
Page 16: Typical Cool/Heat Control Wiring
5188235-YIM-B-1016 Typical Cool/Heat Control Wiring (Smart Equipment™ ZE036-060) 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... -
Page 17: Electrical Data
5188235-YIM-B-1016 Table 7: Electrical Data ZE036-060 - 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 28.3... - Page 18 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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 41.2...
- Page 27 5188235-YIM-B-1016 ZE036-060 - 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 5188235-YIM-B-1016 ZE036-060 - 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...
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Page 29: Ze036-060 Physical Data
5188235-YIM-B-1016 Table 8: ZE036-060 Physical Data ZE036-060 Physical Data Models Component ZE036 ZE048 ZE060 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 SEER 14.0... - Page 30 5188235-YIM-B-1016 ZE036-060 Physical Data (Continued) Models Component ZE036 ZE048 ZE060 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...
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Page 31: Optional Electric Heat
5188235-YIM-B-1016 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
5188235-YIM-B-1016 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 5188235-YIM-B-1016 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...
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Page 34: Options/Accessories
5188235-YIM-B-1016 • Keypad and menu navigation • Settings and parameter changes • Menu structure and selection User Interface The user interface consists of an LCD display and a 4-button keypad on the front of the economizer module. Figure 17: Vent And Combustion Air Hood An adhesive backed label is provided over the outside of the combustion air inlet opening to prevent moisture from entering the unit, which could cause damage to... -
Page 35: Smart Equipment™ Economizer Sequences
5188235-YIM-B-1016 • Lit whenever 24 volts AC power is present to the RRS Free Cooling Economizer Controller C and R pins Four types of free cooling options are available: dry bulb • FAULT (red) changeover, single enthalpy, dual enthalpy changeover, and •... -
Page 36: Power Exhaust
5188235-YIM-B-1016 In free cooling, with a thermostat input to Y1, the dampers If at any time the economizer output goes above the minimum modulate to control the supply air temperature to the position the timer stops and resets when the economizer output Economizer Setpoint +/- 1°F (default 55°F). -
Page 37: Smart Equipment™ Economizer Board Details
5188235-YIM-B-1016 Figure 19: SE-ECO1001-0 Economizer Controller Table 12: Smart Equipment™ 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 38 5188235-YIM-B-1016 Table 12: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label SA BUS Pin connections at left on upper edge of economizer board EconCtrlr parameter reports UCB-to-economizer board SA bus communication status. Negative of the SA BUS communication Common for SA BUS power and circuit to the UCB.
- Page 39 5188235-YIM-B-1016 Table 12: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label 24V~ IN Pin connections at right on upper edge of economizer board 24 VAC common connection to power the economizer board. 24 VAC transformer Common referenced to Connects through circuit traces to C/COM terminals and pins cabinet ground distributed on the economizer board.
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Page 40: Jade Economizer Interface Overview
5188235-YIM-B-1016 Table 12: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label 24 VAC hot supplied for the building pressure 24V~ Connects through circuit trace to 24V~ IN pin HOT sensor BldgPres parameter reports input status (-.250-.250”/w/-.062- BLDG 0-5 VDC positive input from the Building .062kPa). -
Page 41: Single Enthalpy Curve And Boundaries
5188235-YIM-B-1016 • Press the button to move to the previous menu. • STATUS • Press the button to move to the next menu. • SETPOINTS • SYSTEM SETUP • Press the button (Enter) to display the first item in the currently displayed menu. -
Page 42: Single Enthalpy And Dual Enthalpy High Limit Curves
5188235-YIM-B-1016 Table 13: 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 43: Altitude/Temperature Correction Factors
5188235-YIM-B-1016 When installing equipment in a facility with a 3 phase Procedure for adjusting belt tension: high-leg delta power supply, care must be taken to 1. Loosen six nuts (top and bottom) A. ensure that the high-leg conductor is not attached to 2. -
Page 44: Altitude/Temperature Correction Factors
5188235-YIM-B-1016 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 23: 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 45 5188235-YIM-B-1016 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.
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Page 46: Ze Blower Performance Side Duct
5188235-YIM-B-1016 Table 15: ZE Blower Performance Side Duct ZE036 (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... - Page 47 5188235-YIM-B-1016 ZE036 - 060 (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...
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Page 48: Ze Blower Performance Bottom Duct
5188235-YIM-B-1016 Table 16: ZE Blower Performance Bottom Duct ZE036 (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... -
Page 49: Belt Drive Rpm Selection
5188235-YIM-B-1016 ZE036 - 060 (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... -
Page 50: Checking Supply Air Cfm
5188235-YIM-B-1016 drop across a wet coil under field conditions would be Checking Supply Air CFM inaccurate. To assure a dry coil, the compressors should The RPM of the supply air blower will depend on the required be deactivated while the test is being run. CFM, the unit accessories or options and the static resistances Knowing the pressure drop across a dry coil, the actual of both the supply and the return air duct systems. -
Page 51: Operation
5188235-YIM-B-1016 Operation Economizer With Single Enthalpy Sensor (Simplicity Lite) or Economizer With Dry Bulb Sensor (Smart Equipment™) Cooling Sequence Of Operation When the room thermostat calls for cooling, the low voltage control circuit from “R” to “G” and “Y1” is completed. The UCB ZE units have either a Simplicity Lite or a Smart Equipment™... - Page 52 5188235-YIM-B-1016 High-Pressure Limit Switch Low Ambient Cooling (Simplicity Lite Control) During cooling operation, if a high-pressure limit switch opens, To determine when to operate in low ambient mode, the UCB the UCB will de-energize the compressor, initiate the ASCD has a pair of terminals connected to a temperature-activated (Anti-short cycle delay), and stop the condenser fan.
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Page 53: Electric Heating Sequence Of Operations
5188235-YIM-B-1016 A high-pressure switch to protect against excessive energized. After completing the specified fan on delay for discharge pressures due to a blocked condenser coil or a heating, the UCB will energize the blower motor. condenser motor failure, (opens at 625 ± 25 psig). If the second stage of heat is required, heater sequencer (2S) (12, 20, 30 kW 230 volt) or contactor (3M) (20, 30 kW A low-pressure switch to protect against loss of refrigerant... -
Page 54: Gas Heating Sequence Of Operations
5188235-YIM-B-1016 The ICB checks the state of the flame sense circuit, the roll out Table 21: Electric Heat Limit Setting switch, the centrifugal switch and the primary / auxiliary Temperature Limit Open Temperature temperature limit switch circuit. If they are in the expected state, Voltage Switch °F... -
Page 55: Single Stage Gas Heat Limit Control Setting
5188235-YIM-B-1016 state, then the ICB immediately closes the pilot and main gas Centrifugal Switch valves. The ICB will determine the device that is signaling a The centrifugal switch is mounted on the end of the draft motor fault and flash a code for that device. A primary limit trip, and it is an integral part of the motor assembly. -
Page 56: Flash Codes Or Error Messages
5188235-YIM-B-1016 Flash Codes or Error Messages Post Start Check List Verify proper system pressures. The UCB will initiate a flash code associated with errors within the system. Refer to flash a code on the Simplicity Lite Control Measure the temperature drop across the evaporator coil. (See Table 31) or sent error message to the LCD Smart Measure the system Amperage draw across all legs of 3 Equipment™... -
Page 57: Typical Single Stage Gas Valves
5188235-YIM-B-1016 Adjust as follows: Remove the adjustment screw cap(s) on the regulator. To decrease the gas pressure, turn the adjusting screw counterclockwise. FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result To increase the gas pressure, turn the adjusting screw in serious injury, death or property damage. -
Page 58: Checking Gas Input
5188235-YIM-B-1016 Table 26: Gas Rate-Cubit Feet per Hour Heat Tube Adjustable Shutter Exchanger Burner Seconds for Size of Test Dial One Rev. 1/2 cu. ft. 1 cu. ft. Burner Flame Pilot Tube (Blue Only) Gas Supply Pipe Figure 29: Typical Flame Appearance Burners are now accessible for service. - Page 59 5188235-YIM-B-1016 10. If the thermostat and UCB are properly wired, replace the UCB. On a call for cooling, the supply air blower motor is operating Label all wires prior to disconnection when servicing but the compressor is not (the room thermostat fan switch is in controls.
- Page 60 5188235-YIM-B-1016 out, cancel any call for cooling. This will reset any 13. For units with economizers: If 24 volts is present at the Y1 compressor lock outs. “OUT” terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring NOTE: While the above step will reset any lockouts, the from the Y1 “OUT”...
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Page 61: Ze036 (3.0 Ton) Operating Pressures
5188235-YIM-B-1016 Normal Operating Pressures Table 27: ZE036 (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... -
Page 62: Ze060 (5.0 Ton) Operating Pressures
5188235-YIM-B-1016 Table 29: ZE060 (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 5188235-YIM-B-1016 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 5188235-YIM-B-1016 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 5188235-YIM-B-1016 contactor is pulled in. Check for loose wiring between the to the unit the draft motor does not start with a call for heat, contactor and the supply air blower motor. then verify that terminal “L1” of the ICB has a minimum of 120 volts to ground on 230 and 460 volt models or a If M2 is pulled in and voltage is supplied at M2, lightly touch minimum of 18 volts to ground on 575 volt models.
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Page 66: Simplicity Lite Unit Control Board Flash Codes
5188235-YIM-B-1016 Check electrical connections between the ignition control and the gas valve. If intact, check for 24 volts across terminals “MV” and “GROUND” terminals. If no voltage Test Reset Last Error Control Board Comm Setup detected, replace ignition control. If voltage is present, Button Button Button... -
Page 67: Smart Equipment™ Control Board Navigation Components
5188235-YIM-B-1016 Mobile Access Portal (MAP) Gateway (Portable). Smart Equipment™ Control Board Navigation Components • Source 1 P/N S1-JC-MAP1810-OP • MAP Gateway Quick Start Guide P/N 24-10737-16 The following components are needed to access the control • MAP Gateway Instruction P/N 24-10737-8 points in the Smart Equipment™... -
Page 68: Smart Equipment™ Firmware Version 3.1 Basic Unit Control Board Navigation Examples
5188235-YIM-B-1016 SMART EQUIPMENT™ FIRMWARE VERSION 3.1 BASIC UNIT CONTROL BOARD NAVIGATION EXAMPLES: The following document details the navigation and viewing of the LCD display screen equipped as a standard item on the Smart Equipment™ control installed within various commercial UPG packaged and split system equipment. The following information provides a step-by-step demonstration on how to navigate the basic status menu and how to change basic configuration settings. - Page 69 5188235-YIM-B-1016 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.
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Page 70: Smart Equipment™ Ucb Details
5188235-YIM-B-1016 THERMOSTAT WIRED HERE SD-24 Figure 31: Smart Equipment™ Unit Control Board Table 32: Smart Equipment™ 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 5188235-YIM-B-1016 Table 32: Smart Equipment™ UCB Details (Continued) Description Function & Comments Terminal Thermostat connection strip on left edge of UCB 1st stage heating request, 24 VAC input switched Not effective for cooling-only units from R 2nd stage heating request, 24 VAC input switched Not effective for cooling-only units or units with single-stage from R heat sections...
- Page 72 5188235-YIM-B-1016 Table 32: Smart Equipment™ UCB Details (Continued) Description Function & Comments Input required for operation; 3.625 VDC reading RAT+ to RAT– Return Air Temperature sensor input from 10KΩ with open circuit. Used in return air enthalpy calculation. RAT+ @ 77°F, Type III negative temperature coefficient Substitutes for space temperature if no other space thermistor temperature input is present.
- Page 73 5188235-YIM-B-1016 Table 32: Smart Equipment™ UCB Details (Continued) Description Function & Comments Terminal at lower right corner of UCB 24 VAC hot for H1, H2, CN-FAN, AUX HGR, FAN Output relay circuitry is isolated from other UCB components 24V FOR OUTPUTS C1 and and the 24 VAC hot source may be from a second transformer C2 output relay contact switching...
- Page 74 5188235-YIM-B-1016 Table 32: Smart Equipment™ UCB Details (Continued) Description Function & Comments Not effective for one stage compressor UCBs. Input is only considered if C2 output is needed; input must be present to 24 VAC hot return from refrigerant circuit 2 High allow C1 output.
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Page 75: Cable For Fc Buses And Sa Buses In Order Of Preference
5188235-YIM-B-1016 Table 32: Smart Equipment™ UCB Details (Continued) Description Function & Comments Factory wired SA Bus connector Optional communication sub-board at center of UCB Terminal FC BUS connections on left edge of the communication board Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts FC (“Field Connected”) BUS BACnet MSTP reading to COM;... -
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 5188235-YIM-B-1016 1034349-UCL-D-0516 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 5188235-YIM-B-1016 1034349-UCL-D-0516 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 5188235-YIM-B-1016 1034349-UCL-D-0516 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 5188235-YIM-B-1016 1034349-UCL-D-0516 OPERATING MEASUREMENTS - COOLING Discharge Discharge Liquid Line Suction Suction Stage Subcooling Superheat Pressure Temp. Temp. Pressure Temp. First ° ° ° ° ° Second (if equipped) ° ° ° ° ° Third (if equipped) ° ° ° °...
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Page 81: 5188235-Yim-B-1016
________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ Subject to change without notice. Printed in U.S.A. 5188235-YIM-B-1016 Copyright © 2016 by Johnson Controls, Inc. All rights reserved. Supersedes: 5188235-YIM-A-0316 York International Corporation 5005 York Drive Norman, OK 73069...
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