Specifications

ManualsBrandsYork ManualsAir ConditionerZF300

R-410A

ZF SERIES

3 - 6 Ton

60 Hertz

570568-YIM-A-0310

TABLE OF CONTENTS

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

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Economizer And Power Exhaust Set Point

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Checking Supply Air CFM. . . . . . . . . . . . . . . . . . . . . . . . . 50

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 51

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 52

Electric Heating Sequence Of Operations . . . . . . . . . . . . 53

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 53

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 54

Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 54

Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Resets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Heat Anticipator Setpoints. . . . . . . . . . . . . . . . . . . . . . . . . 55

Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Start-up (Gas Heat). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Checking Gas Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Fan On And Off Delays. . . . . . . . . . . . . . . . . . . . . . . . . . . 67

LIST OF TABLES

1 ZF036-072 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 6

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

3 ZF036-072 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8

4 ZF036-072 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 10

5 ZF036-072 Utilities Entry. . . . . . . . . . . . . . . . . . . . . . . . . 11

6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 ZF036-072 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 34

9 Electric Heat Minimum Supply Air. . . . . . . . . . . . . . . . . . 38

10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . 38

11 Gas Pipe Sizing - CapacIty of Pipe . . . . . . . . . . . . . . . . . 39

12 Altitude/Temperature Correction Factors . . . . . . . . . . . . 43

13 ZF Blower Performance Side Duct . . . . . . . . . . . . . . . . . 46

14 ZF Blower Performance Bottom Duct . . . . . . . . . . . . . . . 48

15 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . 49

16 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . 50

17 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 50

18 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 51

19 Electric Heat Limit Setting. . . . . . . . . . . . . . . . . . . . . . . . 53

20 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 54

21 Single Stage Gas Heat Limit Control Setting . . . . . . . . . 55

22 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . 55

23 Gas Heat Anticipator Setpoints. . . . . . . . . . . . . . . . . . . . 56

24 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . 58

25 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 67

26 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . 67

LIST OF FIGURES

1 ZF036-072 Component Location . . . . . . . . . . . . . . . . . . . 6

2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 ZF036-072 Cooling Only/Electric Heat Front View

Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 ZF036-072 Cooling Only/Gas Heat Front View

Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 ZF036-072 Fixed Outdoor Air Motorized Damper

Rain Hood Physical Dimensions . . . . . . . . . . . . . . . . . . 10

8 ZF036-072 Disconnect Location . . . . . . . . . . . . . . . . . . 10

9 ZF036-072 Unit Side Duct Openings . . . . . . . . . . . . . . . 11

10 ZF036-072 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 11

11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . 13

13 Typical Field Power and Control Wiring . . . . . . . . . . . . . 15

14 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 39

15 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 39

16 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . 41

17 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . 42

18 Honeywell Economizer Control W7212 . . . . . . . . . . . . . 42

19 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

20 Altitude/Temperature Correction Factors . . . . . . . . . . . . 43

21 Pressure Drop Across Coil. . . . . . . . . . . . . . . . . . . . . . . 50

22 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

23 Typical Single Stage Gas Valves. . . . . . . . . . . . . . . . . . 57

24 Typical 2 Stage Gas Valves. . . . . . . . . . . . . . . . . . . . . . 57

25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . 57

26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . 57

27 ZF036 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . 61

28 ZF048 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . 61

29 ZF060 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . 62

30 ZF072 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . 62

31 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Summary of content (67 pages)

PAGE 1
R-410A ZF SERIES 3 - 6 Ton 60 Hertz TABLE OF CONTENTS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation Safety Information. . . . . . . . . . . . . . . . . . . . . . . 5 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2
570568-YIM-A-0310 General YORK® Model ZF units are either single package cooling units equipped with optional factory installed electric heaters, or single package gas-fired central heating furnaces with cooling unit. Both are designed for outdoor installation on a rooftop or slab. The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested.
PAGE 3
570568-YIM-A-0310 Due to system pressure, moving parts, and electrical components, installation and servicing of air conditioning equipment can be hazardous. Only qualified, trained service personnel should install, repair, or service this equipment. Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. Observe all precautions in the literature, labels, and tags accompanying the equipment whenever working on air conditioning equipment.
PAGE 4
570568-YIM-A-0310 Product Nomenclature Z F 048 N04 A 2 A AA 1 0 1 2 4 A Product Category Product Style Z = A/C, Single Pkg., R-410A X = HP, Single Pkg., R-410A A = Style A Configuration Options (not required for all units) These four digits will not be assigned until a quote is requested, or an order placed. Product Identifier SS Drain Pan 1 F = 13.0 SEER, A/C = 11.2 EER,2 A/C = 11.0 EER,3 CLG/GAS R = 13.0 SEER Reheat P = 13.
PAGE 5
70568-YIM-A-0310 Installation Limitations Installation Safety Information These units must be installed in accordance with the following: Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling unit. The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference. 1. Refer to the unit rating plate for the approved type of gas for this product. 2.
PAGE 6
570568-YIM-A-0310 HACR breaker Belt drive or Direct drive blower Electric heat accessory location 20 Gauge aluminized steel tubular heat exchanger Power ventor motor with post purge cycle High efficiency compressor Economizer hood Micro-Channel Aluminum Tube/ Aluminum Fin Condenser Slide-in economizer Smoke detector Full perimeter baserails with forklift slots and lifting holes Knockout for side gas supply entry 3/4" PVC female condensate drain GFCI convenience outlet Simplicity ® control board
PAGE 7
570568-YIM-A-0310 Location codes. Refer to Table 4 for clearances required for combustible construction, servicing, and proper unit operation. Use the following guidelines to select a suitable location for these units: 1. Unit is designed for outdoor installation only. 2. Condenser coils must have an unlimited supply of air. Where a choice of location is possible, position the unit on either north or east side of building. 3. Suitable for mounting on roof curb. 4.
PAGE 8
570568-YIM-A-0310 C D B A A B Front D C E Front F Figure 2: Unit 4 Point Load Weight Figure 3: Unit 6 Point Load Weight Y X FRONT LEFT Figure 4: Center of Gravity Table 2: Weights and Dimensions Weight (lbs.) Center of Gravity Size (Tons) Shipping Operating X Y 036 475 470 33 18.25 (3.0) 048 544 539 31.5 18.5 (4.0) 060 572 567 37 15 (5.0) 072 645 640 37 15 (6.0) Table 3: 4 Point Load Location (lbs.) A B C D A 6 Point Load Location (lbs.
PAGE 9
570568-YIM-A-0310 Figure 5: ZF036-072 Cooling Only/Electric Heat Front View Physical Dimensions Figure 6: ZF036-072 Cooling Only/Gas Heat Front View Physical Dimensions Johnson Controls Unitary Products 9
PAGE 10
570568-YIM-A-0310 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 Dimension “A” Fixed Outdoor 12 Air Damper Motorized Damper 4-3/8 Detail “B” 16-1/2 Figure 7: ZF036-072 Fixed Outdoor Air Motorized Damper Rain Hood Physical Dimensions Table 4: ZF036-072 Unit Clearances Location Front Rear Left Side (Filter Access) Right Side (Cond.
PAGE 11
570568-YIM-A-0310 Figure 9: ZF036-072 Unit Side Duct Openings Table 5: Hole ZF036-072 Utilities Entry Opening Size (Dia.) 1 A 7/8” KO B 2” KO1 C D 1-5/8” KO 1-1/2” KO Used For Side Bottom Side Power Wiring Bottom Gas Piping (Front) Gas Piping (Bottom) Control Wiring2 1. Opening in the bottom to the unit can be located by the slice in the insulation. 2. Do not remove the 2” knockout ring.
PAGE 12
570568-YIM-A-0310 Ductwork Compressors Ductwork should be designed and sized according to the methods in Manual D of the Air Conditioning Contractors of America (ACCA) or as recommended by any other recognized authority such as ASHRAE or SMACNA. The scroll compressor used in this product is specifically designed to operate with R-410A Refrigerant and cannot be interchanged. A closed return duct system should be used. This will not preclude use of economizers or outdoor fresh air intake.
PAGE 13
570568-YIM-A-0310 Compressor Mounting bracket base 208/230-3-60 and 380/415-3-50 units control transformers are factory wired for 230v and 415v power supply respectively. Change tap on transformer for 2083-60 or 380-3-50 operation. See unit wiring diagram. Remove these screws (2) Mounting bracket top (remove) Wire tie (cut and remove) Figure 12: Compressor Restraining Bracket The internal wiring harnesses furnished with this unit are an integral part of the design certified unit.
PAGE 14
570568-YIM-A-0310 Convenience Outlet If a factory option convenience outlet is installed, the weatherproof outlet cover must be field installed. The cover shall be located behind the filter access panel. To install the cover, remove the convenience outlet shipping label located in the lower section of the control panel, and attach the cover to the unit using the (4) screws provided.
PAGE 15
570568-YIM-A-0310 TYPICAL POWER WIRING REFER TO THE ELECTRICAL DATA TABLES TO SIZE THE DISCONNECT SWITCH, OVERCURRENT PROTECTION AND WIRING. TYPICAL CONTROL WIRING COOLING ONLY (24 VOLT THERMOSTAT) THERMOSTAT TERMINALS 1 COOLING / HEATING (24 VOLT THERMOSTAT) THERMOSTAT 1 TERMINALS UNIT TERMINAL STRIP TB1 R RV 24 VOLT TRANSFORMER Y1 YC ADD JUMPER Y2 UNIT TERMINAL STRIP TB1 RC R Y Y1 24 VOLT TRANSFORMER Y2 G GF W C 1 RH W1 W2 24 VOLT THERMOSTAT 2TH07701024.
PAGE 16
570568-YIM-A-0310 Table 7: Electrical Data ZF036-060 - Without Powered Convenience Outlet (Belt Drive) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-1-60 14.7 74.0 23.0 2.3 7.6 0.0 230-1-60 14.7 74.0 23.0 2.3 7.6 0.0 208-3-60 9.1 68.0 14.2 2.3 5.2 0.0 230-3-60 9.1 68.0 14.2 2.3 5.2 0.0 460-3-60 4.5 34.0 7.0 1.3 2.6 0.0 575-3-60 3.8 28.0 6.0 1.3 2.0 0.0 208-1-60 20.5 115.0 32.0 2.3 7.
PAGE 17
570568-YIM-A-0310 ZF036-060 - Without Powered Convenience Outlet (Belt Drive) (Continued) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-1-60 26.2 150.0 41.0 2.3 7.6 0.0 230-1-60 26.2 150.0 41.0 2.3 7.6 0.0 208-3-60 17.6 120.0 27.5 2.3 5.2 0.0 230-3-60 17.6 120.0 27.5 2.3 5.2 0.0 460-3-60 8.3 70.0 13.0 1.3 2.6 0.0 575-3-60 7.4 53.0 11.5 1.3 2.0 0.0 060 (5.
PAGE 18
570568-YIM-A-0310 ZF072 - Without Powered Convenience Outlet (Belt Drive) Cooling With/Without Electric Heat Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 19.0 123.0 29.7 5.3 5.2 0.0 230-3-60 19.0 123.0 29.7 5.3 5.2 0.0 460-3-60 9.7 62.0 15.2 5.3 2.6 0.0 575-3-60 7.4 50.0 11.6 5.3 2.0 0.0 072 (6.
PAGE 19
570568-YIM-A-0310 ZF036-060 Without Powered Convenience Outlet (Belt Drive High Static) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-1-60 14.7 74.0 23.0 2.3 7.6 0.0 230-1-60 14.7 74.0 23.0 2.3 7.6 0.0 208-3-60 9.1 68.0 14.2 2.3 5.2 0.0 230-3-60 9.1 68.0 14.2 2.3 5.2 0.0 460-3-60 4.5 34.0 7.0 1.3 2.6 0.0 575-3-60 3.8 28.0 6.0 1.3 2.0 0.0 208-1-60 20.5 115.0 32.0 2.3 7.6 0.
PAGE 20
570568-YIM-A-0310 ZF036-060 Without Powered Convenience Outlet (Belt Drive High Static) (Continued) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 17.6 120.0 27.5 2.3 8.2 0.0 230-3-60 17.6 120.0 27.5 2.3 8.2 0.0 460-3-60 8.3 70.0 13.0 1.3 4.1 0.0 575-3-60 7.4 53.0 11.5 1.3 3.6 0.0 060 (5.
PAGE 21
570568-YIM-A-0310 ZF072 - Without Powered Convenience Outlet (Belt Drive High Static) Cooling With/Without Electric Heat Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 19.0 123.0 29.7 5.3 10.9 0.0 230-3-60 19.0 123.0 29.7 5.3 10.9 0.0 460-3-60 9.7 62.0 15.2 5.3 5.3 0.0 575-3-60 7.4 50.0 11.6 5.3 4.1 0.0 072 (6.
PAGE 22
570568-YIM-A-0310 ZF036-060 Without Powered Convenience Outlet (Direct Drive) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-1-60 16.6 88.0 26.0 2.3 6.0 0.0 230-1-60 16.6 88.0 26.0 2.3 6.0 0.0 208-3-60 12.8 95.0 20.0 2.3 6.0 0.0 230-3-60 12.8 95.0 20.0 2.3 6.0 0.0 208-1-60 21.1 113.0 33.0 2.3 7.6 0.0 230-1-60 21.1 113.0 33.0 2.3 7.6 0.0 208-3-60 16.0 120.0 25.0 2.3 7.6 0.0 230-3-60 16.
PAGE 23
570568-YIM-A-0310 ZF036-060 Without Powered Convenience Outlet (Direct Drive) (Continued) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-1-60 28.8 145.0 45.0 2.3 7.6 0.0 230-1-60 28.8 145.0 45.0 2.3 7.6 0.0 208-3-60 17.6 123.0 27.5 2.3 7.6 0.0 230-3-60 17.6 123.0 27.5 2.3 7.6 0.0 060 (5.
PAGE 24
570568-YIM-A-0310 ZF072 - Without Powered Convenience Outlet (Direct Drive) Cooling With/Without Electric Heat Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 19.0 123.0 29.7 5.3 7.6 0.0 230-3-60 19.0 123.0 29.7 5.3 7.6 0.0 072 (6.0) Electric Heat Option MCA1 (Amps) Model kW Stages Amps None E05 E07 E10 E15 E20 E30 None E05 E07 E10 E15 E20 E30 4.0 5.6 8.0 11.9 15.9 22.2 5.3 7.5 10.6 15.9 21.2 29.
PAGE 25
570568-YIM-A-0310 ZF036-060 - With Powered Convenience Outlet (Belt Drive) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) FLA Supply Blower Motor FLA Pwr Conv Outlet FLA 208-1-60 14.7 74.0 23.0 2.3 7.6 10.0 230-1-60 14.7 74.0 23.0 2.3 7.6 10.0 208-3-60 9.1 68.0 14.2 2.3 5.2 10.0 230-3-60 9.1 68.0 14.2 2.3 5.2 10.0 460-3-60 4.5 34.0 7.0 1.3 2.6 5.0 575-3-60 3.8 28.0 6.0 1.3 2.0 4.0 208-1-60 20.5 115.0 32.0 2.3 7.6 10.0 230-1-60 20.5 115.
PAGE 26
570568-YIM-A-0310 ZF036-060 - With Powered Convenience Outlet (Belt Drive) (Continued) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) FLA Supply Blower Motor FLA Pwr Conv Outlet FLA 208-1-60 26.2 150.0 41.0 2.3 7.6 10.0 230-1-60 26.2 150.0 41.0 2.3 7.6 10.0 208-3-60 17.6 120.0 27.5 2.3 5.2 10.0 230-3-60 17.6 120.0 27.5 2.3 5.2 10.0 460-3-60 8.3 70.0 13.0 1.3 2.6 5.0 575-3-60 7.4 53.0 11.5 1.3 2.0 4.0 060 (5.
PAGE 27
570568-YIM-A-0310 ZF072 - With Powered Convenience Outlet (Belt Drive) Cooling With/Without Electric Heat Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 19.0 123.0 29.7 5.3 5.2 10.0 230-3-60 19.0 123.0 29.7 5.3 5.2 10.0 460-3-60 9.7 62.0 15.2 5.3 2.6 5.0 575-3-60 7.4 50.0 11.6 5.3 2.0 4.0 072 (6.
PAGE 28
570568-YIM-A-0310 ZF036-060 With Powered Convenience Outlet (Belt Drive High Static) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) FLA Supply Blower Motor FLA Pwr Conv Outlet FLA 208-1-60 14.7 74.0 23.0 2.3 7.6 10.0 230-1-60 14.7 74.0 23.0 2.3 7.6 10.0 208-3-60 9.1 68.0 14.2 2.3 5.2 10.0 230-3-60 9.1 68.0 14.2 2.3 5.2 10.0 460-3-60 4.5 34.0 7.0 1.3 2.6 5.0 575-3-60 3.8 28.0 6.0 1.3 2.0 4.0 208-1-60 20.5 115.0 32.0 2.3 7.6 10.
PAGE 29
570568-YIM-A-0310 ZF036-060 With Powered Convenience Outlet (Belt Drive High Static) (Continued) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) FLA Supply Blower Motor FLA Pwr Conv Outlet FLA 208-3-60 17.6 120.0 27.5 2.3 8.2 10.0 230-3-60 17.6 120.0 27.5 2.3 8.2 10.0 460-3-60 8.3 70.0 13.0 1.3 4.1 5.0 575-3-60 7.4 53.0 11.5 1.3 3.6 4.0 060 (5.
PAGE 30
570568-YIM-A-0310 ZF072 - With Powered Convenience Outlet (Belt Drive High Static) Cooling With/Without Electric Heat Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 19.0 123.0 29.7 5.3 10.9 10.0 230-3-60 19.0 123.0 29.7 5.3 10.9 10.0 460-3-60 9.7 62.0 15.2 5.3 5.3 5.0 575-3-60 7.4 50.0 11.6 5.3 4.1 4.0 072 (6.
PAGE 31
570568-YIM-A-0310 ZF036-060 With Powered Convenience Outlet (Direct Drive) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) FLA Supply Blower Motor FLA Pwr Conv Outlet FLA 208-1-60 14.7 74.0 23.0 2.3 6.0 10.0 230-1-60 14.7 74.0 23.0 2.3 6.0 10.0 208-3-60 9.1 68.0 14.2 2.3 6.0 10.0 230-3-60 9.1 68.0 14.2 2.3 6.0 10.0 208-1-60 20.5 115.0 32.0 2.3 7.6 10.0 230-1-60 20.5 115.0 32.0 2.3 7.6 10.0 208-3-60 16.0 120.0 25.0 2.3 7.6 10.0 230-3-60 16.
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570568-YIM-A-0310 ZF036-060 With Powered Convenience Outlet (Direct Drive) (Continued) Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) FLA Supply Blower Motor FLA Pwr Conv Outlet FLA 208-1-60 26.2 150.0 41.0 2.3 7.6 10.0 230-1-60 26.2 150.0 41.0 2.3 7.6 10.0 208-3-60 17.6 120.0 27.5 2.3 7.6 10.0 230-3-60 17.6 120.0 27.5 2.3 7.6 10.0 060 (5.
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570568-YIM-A-0310 ZF072 - With Powered Convenience Outlet (Direct Drive) Cooling With/Without Electric Heat Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 19.0 123.0 29.7 5.3 7.6 10.0 230-3-60 19.0 123.0 29.7 5.3 7.6 10.0 072 (6.0) Electric Heat Option MCA1 (Amps) Model kW Stages Amps None E05 E07 E10 E15 E20 E30 None E05 E07 E10 E15 E20 E30 4.0 5.6 8.0 11.9 15.9 22.2 5.3 7.5 10.6 15.9 21.2 29.
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570568-YIM-A-0310 Table 8: ZF036-072 Physical Data ZF036-060 Physical Data Models Component ZF036 ZF048 ZF060 3.0 4.0 5.0 Gross Capacity @ ARI A point (Btu) 38500 50500 59500 ARI net capacity (Btu) 57000 Nominal Tonnage ARI COOLING PERFORMANCE 36000 47500 EER 11.0 11.0 10.8 SEER 13.0 13.0 13.0 IPLV Nominal CFM - - - 1200 1600 1750 System power (KW) Refrigerant type 3.27 4.32 5.
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570568-YIM-A-0310 ZF036-060 Physical Data (Continued) Models Component Nominal Tonnage ZF036 ZF048 ZF060 3.0 4.0 5.0 1 1 1 CONDENSER FAN DATA Quantity Fan diameter (Inch) 24 24 24 Prop Prop Prop Direct Drive Direct Drive Direct Drive 1 1 1 1/2 1/2 1/2 Type Drive type Quantity of motors Motor HP each No.
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570568-YIM-A-0310 ZF072 Physical Data Models Component ZF072 Nominal Tonnage 6.0 ARI COOLING PERFORMANCE Gross Capacity @ ARI A point (Btu) 70360 ARI net capacity (Btu) 68000 11.21 / 11.02 EER IEER 11.3 Nominal CFM 2000 System power (KW) 6.07 Refrigerant type R-410A Refrigerant charge (lb-oz) System 1 6-4 ARI HEATING PERFORMANCE Heating model N08 N10 D06 Heat input (K Btu) 100 125 75 125 Heat output (K Btu) 80 100 60.8 100.6 AFUE % D10 80.5 80.
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570568-YIM-A-0310 ZF072 Physical Data (Continued) Models Component ZF072 Nominal Tonnage 6.0 CONDENSER FAN DATA Quantity 1 Fan diameter (Inch) 24 Type Prop Drive type Direct Drive No.
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570568-YIM-A-0310 Optional Electric Heat These CSA approved heaters are located within the central compartment of the unit with the heater elements extending in to the supply air chamber. The factory or field installed heaters are wired for single point power supply. Power supply need only be brought into the single point terminal block, and thermostat wiring to the low voltage terminal strip located in the upper portion of the unit control box.
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570568-YIM-A-0310 Gas Piping Proper sizing of gas piping depends on the cubic feet per hour of gas flow required, specific gravity of the gas and the length of run. “National Fuel Gas Code” Z223.1 (in U.S.A.) or the current Gas Installation Codes CSA-B149.1 (in Canada) should be followed in all cases unless superseded by local codes or gas utility requirements. Refer to the Pipe Sizing Table 11. The heating value of the gas may differ with locality. The value should be checked with the local gas utility.
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570568-YIM-A-0310 3. FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
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570568-YIM-A-0310 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 Figure 16: 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 electrical components. Allow this closure label to remain in place until the combustion air hood is to be installed.
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570568-YIM-A-0310 the actuator modulates from the minimum position to the full open position based on the highest call from either the mixed air sensor input or the AQ voltage input. • Optional CO2 Space Sensor Kit Part # 2AQ04700324 • Optional CO2 Sensor Kit Part # 2AQ04700424 Replace the economizer access panel. CONTROL CURVE CONTROL POINT APPROX.
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570568-YIM-A-0310 CFM Static Pressure and Power-Altitude and Temperature Corrections Procedure for adjusting belt tension: 1. Loosen six nuts (top and bottom) A. 2. Adjust by turning (B). 3. Never loosen nuts (C). 4. Use belt tension checker to apply a perpendicular force to one belt at the midpoint of the span as shown. Deflection distance of 4mm (5/32”) is obtained. To determine the deflection distance from normal position, use a straight edge from sheave to sheave as reference line.
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570568-YIM-A-0310 The examples below will assist in determining the airflow performance of the product at altitude. blower tables to select the blower speed and the BHP requirement. Example 1: What are the corrected CFM, static pressure, and BHP at an elevation of 5,000 ft. if the blower performance data is 1,400 CFM, 0.6 IWC and 0.67 BHP? Solution: As in the example above, no temperature information is given so 70°F is assumed. Solution: At an elevation of 5,000 ft.
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570568-YIM-A-0310 Drive Selection 1. Determine side or bottom supply air duct application. 2. Determine desired airflow. 3. Calculate or measure the amount of external static pressure. 4. 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.) 5. Noting the RPM and BHP from step 4, locate the appropriate motor and/or drive on the RPM selection table. 6.
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570568-YIM-A-0310 Table 13: ZF Blower Performance Side Duct ZF036 (3 Ton Belt Drive) Side Duct Air Flow (CFM) 800 1000 1200 1400 1600 1. 2. 3. 4. Available External Static Pressure - IWG1 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive 634 0.34 735 0.39 659 0.39 760 0.45 685 0.47 786 0.52 716 0.57 816 0.62 752 0.69 852 0.75 828 853 879 909 945 0.45 0.51 0.58 0.68 0.81 Standard Drive Option 914 0.52 995 0.
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570568-YIM-A-0310 ZF072 (6 Ton Belt Drive) - Side Duct Air Flow (CFM) 1600 1800 2000 2200 2400 2600 2800 3000 Available External Static Pressure - IWG1 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive 811 0.64 895 0.71 857 0.80 940 0.87 907 1.00 990 1.07 960 1.24 1043 1.31 1015 1.51 1099 1.59 1074 1.83 1157 1.90 1135 2.18 1218 2.25 1198 2.56 1281 2.
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570568-YIM-A-0310 Table 14: ZF Blower Performance Bottom Duct ZF036 (3 Ton Belt Drive) Bottom Duct Air Flow (CFM) 800 1000 1200 1400 1600 Available External Static Pressure - IWG1 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive 613 0.35 724 0.40 640 0.40 751 0.46 669 0.48 779 0.53 702 0.57 812 0.63 741 0.70 852 0.75 826 853 881 914 954 0.46 0.52 0.59 0.69 0.81 Standard Drive Option 920 0.53 1007 0.60 947 0.
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570568-YIM-A-0310 ZF072 (6 Ton Belt Drive) Bottom Duct Air Flow (CFM) 1600 1800 2000 2200 2400 2600 2800 3000 Available External Static Pressure - IWG1 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive 807 0.65 897 0.72 856 0.80 947 0.87 910 0.99 1001 1.06 968 1.23 1059 1.30 1029 1.50 1119 1.57 1093 1.81 1183 1.88 1159 2.15 1250 2.22 1228 2.52 1318 2.59 984 1034 1088 1146 1206 1270 1337 1405 0.79 0.95 1.14 1.37 1.
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570568-YIM-A-0310 Table 16: Indoor Blower Specifications (Belt Drive) Motor Size (Tons) HP RPM Eff. SF 036 (3.0) 048 (4.0) 060 (5.0) 072 (6.0) 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 1-1/2 3 1725 1725 1725 1725 1725 1725 1725 1725 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.15 1.15 1.15 1.15 1.15 1.15 1.15 1.15 Motor Sheave Blower Sheave Datum Dia. Datum Dia. Bore (in.) Model Bore (in.) Model Frame (in.) (in.) 56 2.8 - 3.8 7/8 1VL44 6.0 1 AK64 56 4.0 - 5.0 7/8 1VP56 6.2 1 AK66 56 2.8 - 3.8 7/8 1VL44 5.
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570568-YIM-A-0310 Table 18: Additional Static Resistance Size (Tons) CFM Cooling Only1 Economizer2 3 036 (3.0) 048 (4.0) 060 (5.0) 072 (6.0) 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0.23 0.26 0.29 0.32 0.07 0.08 0.09 0.11 0.13 0.15 0.17 0.20 0.23 0.26 0.30 Electric Heat kW2 7 - 15 20 - 30 0.04 0.06 0.05 0.07 0.06 0.08 0.07 0.09 0.08 0.11 0.10 0.13 0.12 0.15 0.14 0.17 0.16 0.20 0.19 0.23 0.22 0.26 1.
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570568-YIM-A-0310 Economizer With Dual Enthalpy Sensors The operation with the dual enthalpy sensors is identical to the single sensor except that a second enthalpy sensor is mounted in the return air. This return air sensor allows the economizer to choose between outdoor air and return air, whichever has the lowest enthalpy value, to provide maximum operating efficiency.
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570568-YIM-A-0310 Compressor Protection In addition to the external pressure switches, the compressor also has inherent (internal) protection. If there is an abnormal temperature rise in a compressor, the protector will open to shut down the compressor. The UCB incorporates features to minimize compressor wear and damage. An Anti-Short Cycle Delay (ASCD) is utilized to prevent operation of a compressor too soon after its previous run.
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570568-YIM-A-0310 Electric Heat Anticipator Setpoints Redundant valve It is important that the anticipator setpoint be correct. Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space. Reducing the value below the correct setpoint will give shorter “ON” cycles and may result in the lowering of the temperature within the conditioned space. Refer to Table 20 for the required electric heat anticipator setting.
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570568-YIM-A-0310 over and the UCB will de-energize the blower for 45 seconds. 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 ICB will flash the primary limit code but the furnace will not retry ignition during the same call for heat.
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570568-YIM-A-0310 Table 23: Gas Heat Anticipator Setpoints Gas Valve Honeywell VR8204M White-Rogers 36E36 Anticipator Setpoints 0.60 amp 0.54 amp 2. Make sure that the vent and combustion air hoods have been properly installed. Operating Instructions Start-up (Cooling) Prestart Check List This furnace is equipped with an intermittent pilot and automatic re-ignition system. DO NOT attempt to manually light the pilot. After installation has been completed: 1.
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0568-YIM-A-0310 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 23: Typical Single Stage Gas Valves Carry-over tube Regulator Adj. “HI” (Under Screw) Regulator Adj. “LO” (Under Screw) Figure 25: Proper Flame Adjustment Pilot Checkout “ON” - “OFF” Control The pilot flame should envelope the end of the flame sensor.
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570568-YIM-A-0310 Burners are now accessible for service. Reverse the above procedure to replace the assemblies. Make sure that burners are level and seat at the rear of the heat exchanger. Burner Air Shutter Adjustment Adjust burner shutters so no yellow flame is observed in the heat exchanger tubes. Checking Gas Input Natural Gas 1. Turn off all other gas appliances connected to the gas meter. 2.
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570568-YIM-A-0310 2. If the blower motor runs with the fan switch in the ON position but will not run after the compressor has energized when the fan switch is in the AUTO position, check the room thermostat for contact between R and G in the AUTO position during calls for cooling. 3. If the supply air blower motor does not energize when the fan switch is set to ON, check that line voltage is being supplied to the contacts of the M2, contactor, and that the contactor is pulled in.
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570568-YIM-A-0310 the compressor contactor, M1, and that the contactor is pulled in. Check for loose wiring between the contactor and the compressor. 3. If M1 is pulled in and voltage is supplied at M1, lightly touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls for cooling and wait for the internal overload to reset. Test again when cool. 4. If M1 is not pulled in, check for 24 volts at the M1 coil.
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570568-YIM-A-0310 Normal Operating Pressures 3 Ton Charging Chart Outdoor Temp (ºF) 115º Discharge Pressure (psi) 460.0 105º 410.0 95º 360.0 85º 310.0 75º 260.0 65º 210.0 100 105 110 115 120 125 130 135 140 145 150 155 160 165 Suction Pressure (psi) 1. Make sure that condenser fan is running when charging. 2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, The charging chart may no longer apply.
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570568-YIM-A-0310 5 Ton Charging Chart Outdoor Temp (ºF) Discharge Pressure (psi) 530 115° 480 105° 430 95° 380 85° 330 75° 280 65° 230 105 110 115 120 125 130 135 140 145 150 155 160 Suction Pressure (psi) 1. Make sure that condenser fan is running when charging. 2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, Whe charging chart may no longer apply. Figure 29: ZF060 (5.
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570568-YIM-A-0310 Gas Heat Troubleshooting Guide 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. When not necessary, shut off all electric power to the unit prior to any of the following maintenance procedures so as to prevent personal injury.
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570568-YIM-A-0310 2. (white and red on single stage models and white and black on two stage models). If it is less than 177 volts, then check and repair the power circuit to the draft motor. If the voltage is greater than 176 volts and the draft motor is not turning, then disconnect power and draft motor power leads. Measure the resistance of the draft motor windings. If an open circuit exists in the motor, then replace the draft motor.
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570568-YIM-A-0310 4. Cracked heat exchanger tube(s). If a heat exchanger tube or tubes is cracked, then the flow through the heat exchanger is restricted and the flame will either roll out of the tube inlet or heat will build to an abnormal level in the burner area. This can usually be determined by observing burner flame with and without indoor blower operation. If the flame changes when the blower is running compared to when it is not, then visually inspect the heat exchanger tubes.
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570568-YIM-A-0310 3. The draft motor is a 230 volt draft motor on all models regardless of unit supply voltage. If the ICB is flashing a code other than the heartbeat, then troubleshoot the device indicated by the fault code. If not, then remove power to the unit for more than 20 seconds.
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Fan On And Off Delays The fan ON and OFF delays can be field adjusted by pressing a combination of buttons on the UCB. • Gas Heat Option #1 - Press the LAST ERROR and TEST RESET buttons simultaneously and then release. The control flashes three times as it writes a 30 second delay ON and a 90 second delay OFF to the program. • Gas Heat Option #2 - Press the COMM SETUP and TEST RESET buttons simultaneously and then release.