York W)036 THRU 060 Specifications download pdf

R-410A

ZF SERIES

3 - 5 Ton

60 Hertz

542300-YIM-A-1009

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Economizer And Power Exhaust Set Point Adjustments . 33

Checking Supply Air CFM. . . . . . . . . . . . . . . . . . . . . . . . . 41

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cooling Sequence Of Operation. . . . . . . . . . . . . . . . . . . . 42

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 43

Electric Heating Sequence Of Operations . . . . . . . . . . . . 44

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 44

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 45

Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 45

Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Resets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Heat Anticipator Setpoints. . . . . . . . . . . . . . . . . . . . . . . . . 46

Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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

Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fan On And Off Delays. . . . . . . . . . . . . . . . . . . . . . . . . . . 58

LIST OF TABLES

1 ZF036-060 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 6

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

3 ZF036-060 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8

4 ZF036-060 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 10

5 ZF036-060 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

8 ZF036-060 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 28

9 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 30

10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . 30

11 Gas Pipe Sizing - CapacIty of Pipe . . . . . . . . . . . . . . . . . 31

12 Altitude/Temperature Correction Factors . . . . . . . . . . . . 35

13 ZF Blower Performance Side Duct . . . . . . . . . . . . . . . . . 38

14 ZF Blower Performance Bottom Duct . . . . . . . . . . . . . . . 39

15 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . 40

16 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . 41

17 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 41

18 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 42

19 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . 44

20 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 45

21 Single Stage Gas Heat Limit Control Setting . . . . . . . . . 46

22 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . 46

23 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 46

24 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . 49

25 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 58

26 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . 58

LIST OF FIGURES

1 ZF036-060 Component Location . . . . . . . . . . . . . . . . . . . 6

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

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

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

5 ZF036-060 Cooling Only/Electric Heat Front View 

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

6 ZF036-060 Cooling Only/Gas Heat Front View 

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

7 ZF036-060 Fixed Outdoor Air Motorized 

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

8 ZF036-060 Disconnect Location . . . . . . . . . . . . . . . . . . 10

9 ZF036-060 Unit Side Duct Openings . . . . . . . . . . . . . . . 11

10 ZF036-060 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 31

15 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 31

16 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . 33

17 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . 34

18 Honeywell Economizer Control W7212 . . . . . . . . . . . . . 34

19 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

20 Altitude/Temperature Correction Factors . . . . . . . . . . . . 35

21 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . 41

22 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

23 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . 48

24 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . 48

25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . 48

26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . 48

27 ZF036 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . 52

28 ZF048 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . 52

29 ZF060 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . 53

30 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1 2 3 4 5 6 ... 57 58

Summary of Contents

Page 1 - ZF SERIES

R-410AZF SERIES 3 - 5 Ton60 Hertz 542300-YIM-A-1009TABLE OF CONTENTSGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 2

542300-YIM-A-100910 Johnson Controls Unitary ProductsFigure 7: ZF036-060 Fixed Outdoor Air Motorized Damper Rain Hood Physical DimensionsFigure 8: ZF0

Page 3

542300-YIM-A-1009Johnson Controls Unitary Products 11Figure 9: ZF036-060 Unit Side Duct OpeningsFigure 10: ZF036-060 Roof CurbTable 5: ZF036-060 Utili

Page 4 - Product Nomenclature

542300-YIM-A-100912 Johnson Controls Unitary ProductsDuctworkDuctwork should be designed and sized according to the methods in Manual D of the Air Con

Page 5 - Installation

542300-YIM-A-1009Johnson Controls Unitary Products 13Figure 12: Compressor Restraining BracketFiltersOne or two-inch filters can be supplied with each

Page 6

542300-YIM-A-100914 Johnson Controls Unitary ProductsConvenience OutletIf a factory option convenience outlet is installed, the weatherproof outlet co

Page 7 - Rigging And Handling

542300-YIM-A-1009Johnson Controls Unitary Products 15Figure 13: Typical Field Power and Control WiringREFER TO THE ELECTRICAL DATATABLES TO SIZE THE D

Page 8

542300-YIM-A-100916 Johnson Controls Unitary ProductsTable 7: Electrical DataZF036-060 - Without Powered Convenience Outlet (Belt Drive) Size(Tons)Vol

Page 9

542300-YIM-A-1009Johnson Controls Unitary Products 17060(5.0)208-1-60 26.2 150.0 41.0 2.3 7.6 0.0None - - - 42.7 60E05 4.0 1 19.2 42.7 60E07 5.6 1 26.

Page 10 - 542300-YIM-A-1009

542300-YIM-A-100918 Johnson Controls Unitary ProductsZF036-060 Without Powered Convenience Outlet (Belt Drive High Static) Size(Tons)VoltCompressors(e

Page 11

542300-YIM-A-1009Johnson Controls Unitary Products 19060(5.0)208-3-60 17.6 120.0 27.5 2.3 8.2 0.0None - - - 32.5 40E05 4.0 1 11.1 32.5 40E07 5.6 1 15.

Page 12 - Compressors

542300-YIM-A-10092 Johnson Controls Unitary ProductsGeneralYORK® Model ZF units are either single package cooling units equipped with optional factory

Page 13 - Power And Control Wiring

542300-YIM-A-100920 Johnson Controls Unitary ProductsZF036-060 Without Powered Convenience Outlet (Direct Drive) Size(Tons)VoltCompressors(each)OD Fan

Page 14 - 18 AWG 150 Feet

542300-YIM-A-1009Johnson Controls Unitary Products 21060(5.0)208-1-60 28.8 145.0 45.0 2.3 7.6 0.0None - - - 45.9 60E05 4.0 1 19.2 45.9 60E07 5.6 1 26.

Page 15 - TYPICAL POWER WIRING

542300-YIM-A-100922 Johnson Controls Unitary ProductsZF036-060 - With Powered Convenience Outlet (Belt Drive) Size(Tons)VoltCompressors(each)OD FanMot

Page 16 - Table 7: Electrical Data

542300-YIM-A-1009Johnson Controls Unitary Products 23060(5.0)208-1-60 26.2 150.0 41.0 2.3 7.6 10.0None - - - 52.7 70E05 4.0 1 19.2 52.7 70E07 5.6 1 26

Page 17

542300-YIM-A-100924 Johnson Controls Unitary ProductsZF036-060 With Powered Convenience Outlet (Belt Drive High Static) Size(Tons)VoltCompressors(each

Page 18

542300-YIM-A-1009Johnson Controls Unitary Products 25060(5.0)208-3-60 17.6 120.0 27.5 2.3 8.2 10.0None - - - 42.5 60E05 4.0 1 11.1 42.5 60E07 5.6 1 15

Page 19

542300-YIM-A-100926 Johnson Controls Unitary ProductsZF036-060 With Powered Convenience Outlet (Direct Drive) Size(Tons)VoltCompressors(each)OD FanMot

Page 20

542300-YIM-A-1009Johnson Controls Unitary Products 27060(5.0)208-1-60 26.2 150.0 41.0 2.3 7.6 10.0None - - - 52.7 70E05 4.0 1 19.2 52.7 70E07 5.6 1 26

Page 21

542300-YIM-A-100928 Johnson Controls Unitary ProductsTable 8: ZF036-060 Physical Data ComponentModelsZF036 ZF048 ZF060Nominal Tonnage 3.0 4.0 5.0ARI

Page 22

542300-YIM-A-1009Johnson Controls Unitary Products 29CONDENSER FAN DATAQuantity 1 1 1Fan diameter (Inch) 24 24 24Type Prop Prop PropDrive type Direct

Page 23

542300-YIM-A-1009Johnson Controls Unitary Products 3Due to system pressure, moving parts, and electrical components, installation and servicing of air

Page 24

542300-YIM-A-100930 Johnson Controls Unitary ProductsOptional Electric HeatThe factory or field installed heaters are wired for single point power sup

Page 25

542300-YIM-A-1009Johnson Controls Unitary Products 31Gas PipingProper sizing of gas piping depends on the cubic feet per hour of gas flow required, sp

Page 26

542300-YIM-A-100932 Johnson Controls Unitary ProductsLp Units, Tanks And PipingAll gas heat units are shipped from the factory equipped for natural ga

Page 27

542300-YIM-A-1009Johnson Controls Unitary Products 33Figure 16: Vent And Combustion Air HoodOptions/AccessoriesElectric HeatElectric heaters are avail

Page 28

542300-YIM-A-100934 Johnson Controls Unitary Productsthe actuator modulates from the minimum position to the full open position based on the highest c

Page 29

542300-YIM-A-1009Johnson Controls Unitary Products 35CFM Static Pressure and Power-Altitude and Temperature CorrectionsThe information below should be

Page 30 - Optional Electric Heat

542300-YIM-A-100936 Johnson Controls Unitary ProductsThe examples below will assist in determining the airflow performance of the product at altitude.

Page 31

542300-YIM-A-1009Johnson Controls Unitary Products 37Drive Selection1. Determine side or bottom supply air duct application.2. Determine desired airfl

Page 32

542300-YIM-A-100938 Johnson Controls Unitary ProductsTable 13: ZF Blower Performance Side DuctZF036 (3 Ton Belt Drive) Side DuctAir Flow(CFM)Available

Page 33 - Adjustments

542300-YIM-A-1009Johnson Controls Unitary Products 39Table 14: ZF Blower Performance Bottom DuctZF036 - 060 (3-5 Ton Direct Drive) Side DuctUNITTONNAG

Page 34 - Span Length

542300-YIM-A-10094 Johnson Controls Unitary ProductsProduct NomenclatureZ F 048 N04 A 2 A AA 1 0 1 2 4 AZ = A/C, Single Pkg., R-410AProduct CategoryAi

Page 35 - Correction Factor

542300-YIM-A-100940 Johnson Controls Unitary Products* Field Option Sheave.ZF060 (5 Ton Belt Drive) Bottom DuctAir Flow(CFM)Available External Static

Page 36

542300-YIM-A-1009Johnson Controls Unitary Products 41Checking Supply Air CFMThe RPM of the supply air blower will depend on the required CFM, the unit

Page 37 - Table X: RPM Selection

542300-YIM-A-100942 Johnson Controls Unitary ProductsOperationCooling Sequence Of OperationFor the ZF series of units, the thermostat makes a circuit

Page 38

542300-YIM-A-1009Johnson Controls Unitary Products 43Economizer With Dual Enthalpy SensorsThe operation with the dual enthalpy sensors is identical to

Page 39

542300-YIM-A-100944 Johnson Controls Unitary ProductsCompressor ProtectionIn addition to the external pressure switches, the compressor also has inher

Page 40

542300-YIM-A-1009Johnson Controls Unitary Products 45Electric Heat Anticipator SetpointsIt is important that the anticipator setpoint be correct. Too

Page 41 - Checking Supply Air CFM

542300-YIM-A-100946 Johnson Controls Unitary Productsover and the UCB will de-energize the blower for 45 seconds. However, the auxiliary limit is in s

Page 42 - Operation

542300-YIM-A-1009Johnson Controls Unitary Products 47Start-up (Cooling)Prestart Check ListAfter installation has been completed:1. Check the electrica

Page 43

542300-YIM-A-100948 Johnson Controls Unitary ProductsFigure 23: Typical Single Stage Gas ValvesFigure 24: Typical 2 Stage Gas ValvesManifold Gas Press

Page 44

542300-YIM-A-1009Johnson Controls Unitary Products 49Burners are now accessible for service.Reverse the above procedure to replace the assemblies. Mak

Page 45 - Gas Heat Operation Errors

542300-YIM-A-1009Johnson Controls Unitary Products 5InstallationInstallation Safety InformationRead these instructions before continuing this applianc

Page 46 - Heat Anticipator Setpoints

542300-YIM-A-100950 Johnson Controls Unitary ProductsAdjustment Of Temperature RiseThe temperature rise (or temperature difference between the return

Page 47 - Start-up (Gas Heat)

542300-YIM-A-1009Johnson Controls Unitary Products 51the compressor contactor, M1, and that the contactor is pulled in. Check for loose wiring between

Page 48

542300-YIM-A-100952 Johnson Controls Unitary ProductsNormal Operating PressuresFigure 27: ZF036 (3.0 Ton) Operating PressuresFigure 28: ZF048 (4.0 Ton

Page 49 - Checking Gas Input

542300-YIM-A-1009Johnson Controls Unitary Products 53Figure 29: ZF060 (5.0 Ton) Operating PressuresGas Heat Troubleshooting GuideBefore beginning symp

Page 50 - Troubleshooting

542300-YIM-A-100954 Johnson Controls Unitary ProductsFlash Code TroubleshootingPower to the unit should be interrupted during the troubleshooting of i

Page 51

542300-YIM-A-1009Johnson Controls Unitary Products 55not clean, then clean, reinstall and adjust pilot per the start up procedures.2. If the flame is

Page 52 - 3 Ton Charging Chart

542300-YIM-A-100956 Johnson Controls Unitary Productsshort delay (the room thermostat fan switch is in “AUTO” position).1. Place the thermostat fan sw

Page 53 - 5 Ton Charging Chart

542300-YIM-A-1009Johnson Controls Unitary Products 572. Check the supply pressure as described in “POST START CHECK LIST” on page 47. Make adjustments

Page 54

Page 55

542300-YIM-A-10096 Johnson Controls Unitary ProductsFigure 1: ZF036-060 Component Location3/4" PVC female condensate drainKnockout forside power

Page 56

542300-YIM-A-1009Johnson Controls Unitary Products 7LocationUse the following guidelines to select a suitable location for these units:1. Unit is desi

Page 57

542300-YIM-A-10098 Johnson Controls Unitary ProductsFigure 2: Unit 4 Point Load Weight Figure 3: Unit 6 Point Load WeightFigure 4: Center of GravityAD

Page 58 - Fan On And Off Delays

542300-YIM-A-1009Johnson Controls Unitary Products 9Figure 5: ZF036-060 Cooling Only/Electric Heat Front View Physical DimensionsFigure 6: ZF036-060 C