York Sunline ZE Series Installation Manual
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York Sunline ZE Series Installation Manual

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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
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
13 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 41
14 ZE Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 44
15 ZE Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 46
16 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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

TABLE OF CONTENTS

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 51
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 51
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 52
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 53
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 56
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
LIST OF TABLES
17 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 47
18 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 47
19 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 48
20 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
21 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 52
23 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 53
24 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 54
25 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 56
26 ZE036 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 59
27 ZE048 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 59
28 ZE060 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
30 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 64
31 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 65
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 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
21 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42
22 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 48
23 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
24 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 55
25 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 55
26 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 55
27 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 55
28 Simplicity Lite Control Board . . . . . . . . . . . . . . . . . . . . . . . . 64
29 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 65
5188235-YIM-E-0518

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Summary of Contents for York Sunline ZE Series

  • Page 1: Table Of Contents

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

  • Page 2: General

    5188235-YIM-E-0518 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 Renewal Parts accompanying the equipment whenever working on air conditioning equipment. Be sure to follow all other applicable ® Contact your local York parts distribution center for authorized safety precautions and codes including ANSI Z223.1 or CSA- replacement parts. B149.1- latest edition.
  • Page 4 5188235-YIM-E-0518 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...

  • Page 5: Installation

    5188235-YIM-E-0518 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

    5188235-YIM-E-0518 Power Ventor Motor With 20 Gauge Aluminized Post Purge Cycle Steel Tubular Heat Exchanger High Efficiency Compressor HACR 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

    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

    5188235-YIM-E-0518 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: ZE036-060 Center of Weight (lbs.) 4 point Load Location (lbs.) 6 point Load Location (lbs.) Size (Tons) Shipping...

  • Page 9: Ze036-060 Cooling Only/Electric Heat Front View Physical

    5188235-YIM-E-0518 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 Ducted Systems...

  • Page 10: Ze036-060 Unit Clearances

    5188235-YIM-E-0518 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: ZE036-060 Fixed Outdoor Air Motorized Damper Rain Hood Physical Dimensions Table 4: ZE036-060 Unit Clearances Location Clearance...

  • Page 11: Ze036-060 Utilities Entry

    5188235-YIM-E-0518 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-E-0518 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

    5188235-YIM-E-0518 Voltage tolerances which must be maintained at the Compressor compressor terminals during starting and running conditions are Mounting bracket indicated on the unit Rating Plate and Table 1. base 208/230-3-60 and 380/415-3-50 units control Remove these transformers are factory wired for 230v and 415v power screws (2) supply respectively.

  • Page 14: Control Wire Sizes

    5188235-YIM-E-0518 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-E-0518 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 Detector Jumper TERMINALS ON A...

  • Page 16: Typical Cool/Heat Control Wiring

    5188235-YIM-E-0518 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 SD-R 24V Output Second stage...

  • Page 17: Electrical Data

    5188235-YIM-E-0518 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 19.2...
  • Page 18 5188235-YIM-E-0518 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 26.9 208-1-60 24.4 144.2...
  • Page 19 5188235-YIM-E-0518 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 32.4 26.9...
  • Page 20 5188235-YIM-E-0518 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 11.1 31.2...
  • Page 21 5188235-YIM-E-0518 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 41.2 208-1-60 15.4...
  • Page 22 5188235-YIM-E-0518 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 26.9 43.2...
  • Page 23 5188235-YIM-E-0518 ZE036-060 - With Powered Convenience Outlet (Belt Drive) 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 19.2 44.9 26.9 54.5...
  • Page 24 5188235-YIM-E-0518 ZE036-060 - With Powered Convenience Outlet (Belt Drive) (Continued) OD Fan Supply Max Fuse Compressors Size Motors Blower Conv Electric Heat Option Breaker Volt (each) (Tons) (each) Motor Outlet (Amps) Size (Amps) RLA LRA Model Stages Amps NONE 51.6 19.2 51.6 26.9...
  • Page 25 5188235-YIM-E-0518 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 (Amps) RLA LRA Model Stages Amps NONE 38.3 19.2 44.9...
  • Page 26 5188235-YIM-E-0518 ZE036-060 - With Powered Convenience Outlet (Belt Drive High Static) (Continued) OD Fan Supply Max Fuse Compressors Size Motors Blower Conv Electric Heat Option Breaker Volt (each) (Tons) (each) Motor Outlet (Amps) Size (Amps) RLA LRA Model Stages Amps NONE 41.2 11.1...
  • Page 27 5188235-YIM-E-0518 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 53.7 208-1-60 15.4...
  • Page 28 5188235-YIM-E-0518 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 (Tons) (each) Motor Outlet (Amps) Size (Amps) RLA LRA Model Stages Amps NONE 52.5 19.2 52.5 26.9...

  • Page 29: Ze036-060 Physical Data

    5188235-YIM-E-0518 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 14.0 14.0...
  • Page 30 5188235-YIM-E-0518 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 1100 4000 4000...

  • Page 31: Optional Electric Heat

    5188235-YIM-E-0518 Optional Electric Heat These CSA approved heaters are located within the central 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-E-0518 Gas Piping NOTE: Maximum capacity of pipe in cubic feet of gas per hour 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-E-0518 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

    5188235-YIM-E-0518 • 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-E-0518 • 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-E-0518 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-E-0518 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-E-0518 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-E-0518 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.
  • Page 40 5188235-YIM-E-0518 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: Altitude/Temperature Correction Factors

    5188235-YIM-E-0518 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 42: Altitude/Temperature Correction Factors

    5188235-YIM-E-0518 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 21: 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 43 5188235-YIM-E-0518 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 44: Ze Blower Performance Side Duct

    5188235-YIM-E-0518 Table 14: 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 Field Supplied Drive Standard Drive Option High Static Drive Option...
  • Page 45 5188235-YIM-E-0518 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 1153 1080 3 (MED)

  • Page 46: Ze Blower Performance Bottom Duct

    5188235-YIM-E-0518 Table 15: 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 Field Supplied Drive Standard Drive Option High Static Drive Option...

  • Page 47: Belt Drive Rpm Selection

    5188235-YIM-E-0518 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 1114 1044 3 (MED)

  • Page 48: Checking Supply Air Cfm

    5188235-YIM-E-0518 Checking Supply Air CFM drop across a wet coil under field conditions would be 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 49: Operation

    5188235-YIM-E-0518 Operation Equipment™) of the outdoor air is below the setpoint of the enthalpy or dry bulb controller (previously determined), “Y1” Cooling Sequence Of Operation energizes the economizer. The dampers will modulate to maintain a constant supply air temperature as monitored by the ZE units have either a Simplicity Lite or a Smart Equipment™...
  • Page 50 5188235-YIM-E-0518 Table 29) or sent error message to the LCD Smart Low ambient mode always begins with compressor operation. Equipment™ Control. Compressor minimum run time may extend the minutes of compressor operation. The defrost cycle will begin immediately Low-Pressure Limit Switch following the elapse of the minimum run time.

  • Page 51: Electric Heating Sequence Of Operations

    5188235-YIM-E-0518 Compressor Protection This limit is monitored regardless of unit operation status, i.e. the limit is monitored at all times. In addition to the external pressure switches, the compressor also has inherent (internal) protection. If there is an abnormal If the temperature limit opens three times within one hour, it will temperature rise in a compressor, the protector will open to shut lock-on the indoor blower motor and a flash a code on the down the compressor.

  • Page 52: Gas Heating Sequence Of Operations

    5188235-YIM-E-0518 Reset Redundant valve Main valve Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature.This resets any flash codes. Gas main Electric Heat Anticipator Setpoints To main burner Gas Valve It is important that the anticipator setpoint be correct. Too high To pilot burner of a setting will result in longer heat cycles and a greater Figure 23: Gas Valve Piping...

  • Page 53: Flash Codes Or Error Messages

    5188235-YIM-E-0518 over and the UCB will de-energize the blower for 45 seconds. area the roll-out switch will open, the ICB will close both the However, the auxiliary limit is in series with the primary limit main and pilot gas valves and flash a code (Table 30). The ICB and it takes first control.

  • Page 54: Start-Up (Cooling)

    5188235-YIM-E-0518 Make sure that the vent and combustion air hoods have Table 24: Gas Heat Anticipator Setpoints been properly installed. Gas Valve Anticipator Setpoints Honeywell VR8204M 0.60 amp Operating Instructions White-Rogers 36E36 0.54 amp Start-up (Cooling) Prestart Check List This furnace is equipped with an intermittent pilot and automatic re-ignition system.

  • Page 55: Typical Single Stage Gas Valves

    5188235-YIM-E-0518 Burner assembly bracket “ON” - “OFF” Control Pilot Adj. (Under Screw) Flame sensor bulb High Fire Adj. (Under Screw) Honeywell VR8204M “ON” - “OFF” Control 1/8” gap between carry-over tube and flame sensor bulb Figure 24: Typical Single Stage Gas Valves Carry-over tube Regulator Adj.

  • Page 56: Checking Gas Input

    5188235-YIM-E-0518 Checking Gas Input Adjustment Of Temperature Rise The temperature rise (or temperature difference between the Natural Gas return air and the heated air from the furnace) must lie within the range shown on the rating plate and the data in the Gas Turn off all other gas appliances connected to the gas meter.
  • Page 57 5188235-YIM-E-0518 contactor is pulled in. Check for loose wiring between the If M1 is not pulled in, check for 24 volts at the M1 coil. If 24 contactor and the supply air blower motor. volts are present and M1 is not pulled in, replace the contactor.
  • Page 58 5188235-YIM-E-0518 13. For units with economizers: If 24 volts is present at the Y1 14. The UCB can be programmed to lock out compressor “OUT” terminal, check for 24 volts at the Y1 “ECON” operation during free cooling and in low ambient terminal.

  • Page 59: Ze036 (3.0 Ton) Operating Pressures

    5188235-YIM-E-0518 Normal Operating Pressures Table 26: 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 80/67 300 Cfm/Ton 80/72...

  • Page 60: Ze060 (5.0 Ton) Operating Pressures

    5188235-YIM-E-0518 Table 28: 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 61 5188235-YIM-E-0518 indicated. All troubleshooting procedures assume the unit is (white and red on single stage models and white and 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 62 5188235-YIM-E-0518 above the minimum inlet pressure stated on unit data label, Cracked heat exchanger tube(s). If a heat exchanger tube or then adjust the pilot pressure per the start up procedures. If tubes is cracked, then the flow through the heat exchanger 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...
  • Page 63 5188235-YIM-E-0518 supplied to the contacts of the M2 contactor, and that the indicated by the fault code. If not, then remove power to the contactor is pulled in. Check for loose wiring between the unit for more than 20 seconds. If upon restoring the power contactor and the supply air blower motor.

  • Page 64: Simplicity Lite Unit Control Board Flash Codes

    5188235-YIM-E-0518 The pilot burner lights and the spark stops but the main burners do not light. Test Reset Check electrical connections between the ignition control Last Error Control Board Comm Setup Button Button and the gas valve. If intact, check for 24 volts across Button terminals “MV”...

  • Page 65: Smart Equipment™ Control Board Navigation Components

    5188235-YIM-E-0518 Smart Equipment™ Control Board Mobile Access Portal (MAP) Gateway (Portable). 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 66 5188235-YIM-E-0518 Table 31: Smart Equipment™ UCB Details (Continued) Description Function & Comments Connects through circuit trace to thermostat connection strip SD-24. A wiring harness jumper plug connecting SD 24 to SD R 24 VAC hot out for factory accessory smoke is in place if factory accessories for unit shutdown are not used - SD 24 detector, condensate overflow and/or user...
  • Page 67 5188235-YIM-E-0518 Table 31: Smart Equipment™ UCB Details (Continued) Description Function & Comments Terminal Space temperature sensor connections at center on upper edge of UCB Positive of VDC circuit (3.625 VDC reading to COM with open Space Temperature sensor input from 10KΩ @ circuit), effective if “Thermo- stat-only Control”...
  • Page 68 5188235-YIM-E-0518 Table 31: Smart Equipment™ UCB Details (Continued) Description Function & Comments When this optional input is enabled: the air proving switch must close within 30 seconds of initiation of indoor blower operation and not open for greater than 10 seconds during in- door blower APS (upper pin) 24 VAC hot return from Air Proving Switch operation to allow heat/cool operation and prevent an “APS...
  • Page 69 5188235-YIM-E-0518 Table 31: Smart Equipment™ UCB Details (Continued) Description Function & Comments Pin Refrigerant circuit safety switch and indoor blower overload connections at center on lower edge of UCB HPS1 24 VAC hot out for refrigerant circuit 1 High Connects through circuit trace to the R terminal (right pin) Pressure Switch Input is only considered if C1 output is needed;...
  • Page 70 5188235-YIM-E-0518 Table 31: Smart Equipment™ UCB Details (Continued) Description Function & Comments Also incorporated in the J8 6-pin phone jack connector at the left-center of the board. Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to C; at least 0.25 volts Communication for SA BUS devices higher than –) SA BUS communication circuit to optional economizer board, 4-stage board, fault detection &...

  • Page 71: Cable For Fc Buses And Sa Buses In Order Of Preference

    5188235-YIM-E-0518 Table 32: Cable for FC Buses and SA Buses in Order of Preference Non-Plenum Applications Plenum Applications Bus and Cable Type Part Number O.D. Part Number O.D. Anixter: Anixter: CBL-22/3-FC-PLN CBL-22/3-FC-PVC 0.138 in. 0.140 in. FC Bus: 22 AWG Stranded, 3-Wire Twisted Shielded Cable Belden: B6501FE Belden®: B5501FE Anixter:...

  • Page 72: Start-Up Sheet

    5188235-YIM-E-0518 Start-Up Sheet Johnson Controls Ducted Systems...
  • Page 73 5188235-YIM-E-0518 Johnson Controls Ducted Systems...
  • Page 74 5188235-YIM-E-0518 Johnson Controls Ducted Systems...
  • Page 75 5188235-YIM-E-0518 Johnson Controls Ducted Systems...
  • Page 76 5188235-YIM-E-0518 Johnson Controls Ducted Systems...
  • Page 77 Subject to change without notice. Printed in U.S.A. 5188235-YIM-E-0518 Copyright © 2018 by Johnson Controls, Inc. All rights reserved. Supersedes: 5188235-YIM-D-0917 York International Corporation 5005 York Drive Norman, OK 73069...

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