Zone Comfort Install manual
Contents
1. setae 13 Risk Of 14 2555 5 EAE 14 TEA Sa 14 5 15 DEM HISA 5 15 START UP PROCEDURE sssisscsscsscccssccesssencssvssescsescoavesovesesseesseuccoscbesensevese sesvooncssenssoseessebasesonseseseessoasedesssvseeesssoesves 16 SERVICE AND MAIN TENA NC Eivicsssssscsscesondsssscccsesosssccssssescstbnsstessessectssonssevecsssonsssesesssobesbeatsdebesdoosesseses sbesesesesses 16 16 Duct cleaning 16 a WA AI SA ANA KA Pe ner Re BA NA Ser 16 Saeed 17 ee 172. 17 TROUBLESHOOTING sosnevsoncsoutecepacesoosevensesdonsesesesdsesecssuuderobessssecsonsecsdensesesssseeeess 17 2 2 6 20141025 CHECKLIST FOR THE INSTALLER A Quick Check List Are the water connections to the water heater oriented in a way to avoid trapping air in the heating circuit see diagram on next page Is the purge valve installed on the return water line from the air handler upstream from the isolation valve Is the air handler hung and isolated to avoid transmitting vibration through framing and duct work Are the isolation valves full port Restrictive valves will limit performance Is outdoor cooling unit contactor wired according to the wiring diagram Are Thermostat connections correct including cooling and continuous run connections Do they operate their intended zone Have the packing materials been removed from the blower and the pump Is there an installation manual and controls user manual for the home owner Is the unit accessible Are there clearances for service and component replacement Is the return duct drop acoustically lined at least 6 ft of the return duct drop must be lined Is the filter cover in place Is aclean filter in place Is the supplied filter rack installed a E i BO A e UW Has the electronic controller been properly configured as per instru
3. WAA 10 aoa ale ba teed es aed ao 10 10 CON BUSU AN 10 10 Evaporator Coil Freeze Pi Aa kukua 10 PRODUCT DESGRIPTION ssa AAA EA 11 MUA MSA AKA BA WAA Renata ns 11 11 11 Circulating pump Hn Stents ae leet el 11 11 EQUIPMENT SIZING AND SELECT ION oscccssssssccsonsssesssssosssssenssenscssassssseassosessssessonassscessnnsshsasenensessenseseasssesesses 12 KWA TEMA 12 Heat kosi Heat Gani AUIWA og BEE 12 Aim Handler S elec temic 12 ZONES leh ASS oI SA ea oleh ERI LE ERIE 12 INS FAL DATION svctevecsccosceedesnevsoncceutecegucesoseetesecseessesesesvenscecsuusorebesessnedeseedeeesusessssuseess 13 Ait Handler Mounting E EEEE WA 13 DIU CE WOT
4. blue oronge of ZL COOL kich _ white GROUKD SCREW serene 1 TRANSFORMER 247 irod JUMPER ZAVEC red 2 21 yellow RELAY 21_ 6 2 6 20141027 ELECTRICAL WIRING DIAGRAM 4 Zone base ZI HEART Z1 C00L G_Fan 22_CALL Z3_CALL Z4_CALL AIR_COND 5 18 VAC 5 SUPPLY youths 2 Contact Vortex for wiring diagrams for Zone Comfort systems with more than 4 zones Page 7 2 6 20141027 EQUIPMENT SPECIFICATIONS AND SIZING TABLES REFER TO Small D design Guide for additional duct sizing options TABLE 1 Air Handler Selection Table 2624 2630 ZC48 ZC60 Model ZCT24 ee ae ZCT48 2 100 ZCT30 ZCT60 Minimum Branches per Zone 10 12 14 20 23 Heating Capacity Btu h 130 F 56 000 61 000 61 000 71 000 91 000 Heating Capacity Btu h 140 F 60 000 66 000 66 000 77 000 106 000 Heating Capacity Btu h 160 F 77 000 85 000 85 000 100 000 135 000 Heating Capacity Btu h 180 F 95 000 104 000 104 000 122 000 164 000 1200 1400 1400 1800 1800 USGPM Heating 4 8 4 8 4 8 4 8 7 0 Cooling Capacity 23 Tons 2 5 3 0 3 5 5 0 5 0 Blower Motor Full Load 55 77 77 96 96 Amps Circulator Full Load Amps 0 8 0 8 0 8 0 8 1 4 Cabi
5. ZC KI6_20141027 EQUIPMENT SIZING AND SELECTION Procedure 1 Conduct a complete heat loss heat gain calculation 2 Determine inlet water temperature 3 Select Air Handler 4 Determine three zones within the space 5 Select outlets per room 6 Determine Duct Layout Heat Loss Heat Gain Room by room calculations need to be completed using HRAI ASHRAE or another approved sizing methods Air Handler Selection The selected air handler must be sized according to the following rules a Heating capacity must be between 100 and 140 of the heat loss 110 to 140 for combo systems 130 F water temp b Cooling capacity must be between 75 100 of the heat gain Note that slightly under sizing the cooling equipment improves efficiency and provides better humidity control Page 12 When using a boiler system select a boiler with an output that meets or exceeds the heat loss of the space being heated If the boiler is serving additional loads size the boiler to meet the total combined load For combo heating systems use an approved sizing method such as the Unified Combo Guidelines published by HRAI Define Zones The space served by the air handler should be divided up into zones Three is tyical Each of these zones is to be served by a single main duct by the air handler Zones can represent areas such as the basement main floor and second floor In some applications it may be desirable
6. Vortex Owner s Manual amp Installation Instructions Zone Comfort hot water air handler and zoned distribution system with iStat6 electronic controller for 2 to 4 zones Vortex Source Systems 45 Cowansview Rd Cambridge Ontario 712 Phone 888 781 8151 Fax 888 670 2544 info vortexsource com www vortexsource com Table of Contents CHECKLIST FOR THE INSTALLER 25 asetessvaseeddacssesteesonnes 3 TYPICAL PLUMBING CONNECTIONS wisvscsscsancsencsssctsssteceosscsssstcssnscsosses snsnsssencsoccesooenes 4 ELECTRICAL WIRING DIAGRAM 4 ZONE 2 5 ELECTRICAL WIRING DIAGRAM 4 ZONE 7 EQUIPMENT SPECIFICATIONS AND SIZING TABLES sseseseeeeeeeceeeeeeeeeeeeeeeneene 8 565 sets da snsudondsonseesasecevssccussessasssseescovsesossesssocts 9 5255 AAA 9 OME tacts AA 10 OMe
7. for good contact on coil headers Page 18 Cold water at hot faucet When heat source is a water heater the most probable cause is reverse flow through the heating loop from a stuck check valve repair or replace valve Fan runs for cooling but not heating Room thermostat may be connected improperly Refer to Electrical section or wiring schematic on air handler for proper installation Heating during Standby Mode Probable cause is thermal siphoning See check valve description for details repair or replace check valve Check elevation of air handler above water heater to see if motorized valve required for positive shut off 2 6 20141027 ZONE COMFORT 5 6 Air Handler Parts amp Accessory List Part No Description X 6 g q 8 g 8 NNNN N N NN NNNN UC18203 Hot Water Coil 20 18 S S S S UC18203ASS Coil assembly c w pump 18x20 S S S S UCA100 Hot Water Dual 18x20 GUPS15 58RU 5 5 5 5 GUPS26 99BFC Pump Grundfos c w check 008 8in motorized damper 5 5 010 10 motorized damper 5 5 XELH620 Wire Harness power 5 5 5 5 XELK710 EVO ECM motor speed control 5 5 5 5 XELK711 Motor speed cable 5 5 5 5 XELK715 8 Gang Relay Board 5 5 5 5 XELK721 10k Thermister 5 5 5 5 XELK725 Remote monitoring gateway XELK740 iStat6 Programmable control 5 5 5 5 XELRO12DC Relay 12vdc 5 5 5 5 XELRO24DPDT Relay 24VAC 5 5 5 5 XELT002 Transfo
8. caused by improper installation or operation accident abuse or alteration operation of device at temperatures or pressures outside of the rated capacities lime or scale deposits corrosive operating environment equipment moved from original installation location Replacements furnished under this warranty will be Vortex Source Systems product distribution points in the United States and Canada They will be invoiced at regular prices The account will be credited the full amount when the defective part is received by Vortex examined and approved as a valid warranty Warranty applies to the original purchaser but may be transferred to another owner provided the equipment is not moved from the original installation site This warranty does not apply to labour freight or any other cost associated with the service repair or operation of the product Vortex shall not be liable for any direct special incidental or consequential damages caused by the use misuse or inability to use this product Vortex is under no legal obligations to rectify including but not limited to lost profits downtime good will damages to or replacement of equipment and property Purchaser assumes all risk and liability of loss damage or injury to purchaser and purchaser s property and to others and their property arising out of the use misuse or inability to use this product Page 20 2 6 20141027
9. covered in a separate document capacity The air handler runs quietly at lower speeds for the majority of the time This cutting edge approach reduces fan energy requirements promotes better blending of the room air and less stratification within the living space Cooling mode uses a modulating strategy to maximize homeowner comfort Blower speed is carefully controlled to optimize dehumidification When cooling demand is low determined based on the number of zones calling or on the measured supply air temperature the blower runs a little 7 6 20141027 slower The air has more residence time in the evaporator coil This results in removing more moisture from the air thus maintaining the humidity in an optimum range Zone One The primary or master or zone one tells the air handler whether it is heating season or cooling season or if continuous air circulation is desired Any zone can be zone one but it is typically the main area of the building living area Additional zones act as slaves to the primary zone The primary zone must call for heating or cooling at least once at the beginning of the season to tell the Zone Comfort air handler that it is in heating mode or cooling mode The switch on the primary thermostat is not enough There must also be at least one call for heating or cooling a short 5 second call is adequate Until this happens a call on zone two or three is ignored Off All zone
10. freezing All Zone Comforts with electronic controls include a temperature sensor that will detect a near freezing condition and will interrupt the outdoor air conditioner until it warms up Refer to Controls User Manual Attic and crawl spaces Air handlers may be located in areas subject to freezing conditions It is necessary to protect the hot water coil from freezing The optional Freeze protection kit Catalogue No can be used to cycle on the pump and blower when conditions get close to freezing The Freeze Protection Kit cannot protect piping that passes through unconditioned spaces robbing types require the addition of a resistor between the W amp C terminals and the Y amp C terminals This is usually covered in the thermostat instruction manual 1 000 ohm 5 watt resistor on each of the W and Y terminals will usually be enough to drain the current required to power the thermostat Some thermostats will need 250 ohm 10 watt resistors on each of the W and Y terminals Any zone with cooling will require a heat cool thermostat The Zone Comfort air handler is compatible with ZC KI6_20141027 all standard setback thermostats Setback thermostats can be used to achieve greater energy savings Two stage thermostats are not required with two stage air conditioning The Zone Comfort will determine when to bring on second stage cooling based on total building demand Heat Anticipator S
11. Provide at least R 12 of insulation above ZC KI6_20141027 ducts If cooling is required the branch and trunk lines must be insulated and sealed with a vapour barrier prior to applying house insulation Risk of Freezing Steps must be taken to prevent the hot water coil from freezing Coils that have failed due to freezing and damage caused by frozen coils are not covered under warranty HRV and Fresh air connections If a fresh air duct is required make connection to return air plenum at least 18 inches from filter Insulate all fresh air ducts Fresh air and HRV connections to ductwork can pose a risk of dumping cold air into ductwork during periods of stand by or continuous run Calculate mixed air stream temperatures and provide interlock controls to prevent freezing conditions ELECTRICAL Warning Make sure unit is properly grounded Locate air handler separate electric circuit All air handlers operate on 115VAC 1ph 60hz line voltage All control circuits are low voltage either 24VAC or 0 10VDC Thermostat The Zone Comfort air handlers are compatible with most thermostats Some electronic thermostats primarily power Page 14 Evaporator coils The Zone Comfort is designed to provide acceptable airflow for cooling even if only one zone is operating in cooling mode However a small single zone operating for a long time or abnormal conditions such as plugged filter can pose the risk of
12. alve on the return leg of the loop and open the drain to purge air Open the return leg isolation valve and then close the drain valve 4 Start the boiler or water heater according to the manufacturer s instructions Set the design water temperature and wait for the system to shut off You can check that the water heater is set properly during the warm up by running a small amount of water into a glass in a sink while the water heater is warming up Using a thermometer measure the SERVICE AND MAINTENANCE Filter The Vortex air handler is provided with a pleated filter media This filter should be inspected monthly and replaced as required Replacement filters are available from Vortex Duct cleaning If proper filter maintenance is adhered to duct cleaning will not be required for the life of the equipment Page 16 1 and yellow duct connection to thermostat 3 reverse the yellow and blue wires on the terminal block temperature of the water as soon as the water heater burner shuts off If the set point temperature is too low or is above 140F 60C reset the tank control run water until the burner starts again and repeat the measurement 5 Turn on the power to the air handler and set up the electronic controller as per instructions in the Controls User Manual This is important to ensure that the correct airflows are used for the equipment as installed 6 Set the room thermostat for heat to energize the
13. ctions in the controls user manual Page 3 ZC KI6 20141025 TYPICAL PLUMBING CONNECTIONS VALVE lt OPTIONAL gt _ HORIZONTAL CONNEC TION TANK TYPE WATER HEATER HANGLER TANKLESS WATER HEATER COMBINATION BOILER AIR HANDLER Page 4 ISOLATION AND PURGE ASSEMBLY FACE PIPING DOWN TO AVOID AIR ENTRAINMENT IN SPACE HEATING LOOP ZC KI6 20141025 ELECTRICAL WIRING DIAGRAM 4 Zone complete REV 20141009 Supply dereor F GROUND SCREW treerd E al b 24 TRARSFORNER 245741 Creo 3 JNPER SAYAC tredh 21 yalipa SUFFLY THERMISTER ETEN HEETE EN b ES AIR COMD st 5096 bloch I3 CALL bius ar FAN SPEED ororae PUMP RELAY valet ku 1 Mock 24 bror TLHEAT shite PND STAGE YANGA 1 hey 10C INPUT CABLE i 5 gt 3 J E iros A Reture AA 7 Sereor NOTOR US Vv 7 O wh Bock 9 z coL 2334 is SUPPLY ZC KI6 20141027 ELECTRICAL WIRING DIAGRAM 3 Zone complete REV 20141009 Supply Ar Sensor 757 DANPER TICOAMER blue BE GO ack FAN SPEED shite SUPPLY THERMISTER PUHP RELAY vilet END STAGE A C NI RETURN THERMISTER grey
14. dampers are open if there is no call for heating or cooling or power is off Heating The objective of the heating strategy is to run the blower only as high as required in order to provide good air circulation at a low noise level Because the blower speed can be programmed to adjust based on each zone s actual heating loads the fan will only run as high as necessary to satisfy the current calls When a thermostat calls for heating the internal pump starts and the boiler is activated if connected to TT The zone damper for any zone not requiring heat closes The fan will gradually ramp up to Page 10 the programmed speed for the given zone Cooling When a thermostat calls for cooling the outdoor air conditioning condenser is activated The zone damper for any zone not requiring cooling closes Fan speed can be controlled based on number of zones calling and their programmed cooling loads or on measured supply air temperature Two stage air conditioners are strongly recommended as a means of improving efficiency lowering fan speed for single zone calls and more closely matching AC output to the home s cooling requirements Continuous Fan When the thermostat fan switch for the primary zone is set to continuous fan the fan will run at the set speed for all zones When there is a call for heating or cooling the normal heating or cooling speed will over ride the continuous fan setting Zones not requiring heatin
15. elay LED The 8 gang relay provides a dry contact TT for a boiler If the PUMP LED is illuminated but the pump does not run the issue is the pump ZC KI6_20141027 e Seized due to lime build up clean or replace Air bound re purge e Valves closed in error Second Stage Air Conditioning Second stage air conditioning is activated by a 12vdc DPDT relay powered by the control Only one set of contacts is used to provide 24vac to the air conditioner second stage First stage is driven directly from the control Insufficient or no heat e Plugged air filter or coil Refer to Maintenance section for filter care and coil cleaning heating loop purge system e Inlet and outlet connections to air handler backwards reverse connections e Water heater supply tube dip tube is restricted or damaged check and or replace e Supply water temperature set too low or not calibrated properly check water temperature In the case of water heater If the temperature has been set low because of homeowner preference it may be necessary to install an anti scald valve to control the faucet temperature and raise the operating temperature of the water heater e Restrictions in heating loop remove restrictions check valve stuck isolation valves too restrictive left partially closed after purging or closed valve e Water heater supply temperature is unstable Check water heater setting and temperature sensors
16. etting For optimum comfort the anticipator setting should be set to provide approximately 4 cycles per hour Typical Heat Anticipator Setting 0 25 amps Note The wires from each thermostat should be labeled for future reference Label suggestions 1 2 3 4 or bsmt main upstairs If labels are not available use one two or three stripes of tape Thermostat wires should be connected to terminal strip inside the air handler Each zone has its own terminal for R W1 W2 and W3 represent heating for zone 1 2 3 4 Y1 Y2 Y4 represents cooling for zone 1 2 3 4 Only G from the primary thermostat should be connected to the air handler Thermostats with a C terminal should be connected Dehumidistat Dehumidistats are not necessary as dehumidification may be achieved through Zone Comfort s automatic control of cooling speed Refer to Controls User Manual for more details Zone Selection amp Set up Zone 1 Page 15 Any zone can be the primary zone or Zone One However it is strongly recommended that this be the main zone to be heated and cooled In a home this is typically the main living area This thermostat is the only one that is used to select continuous fan operation It also plays a critical role in telling the air handler whether to be in heating mode or cooling mode When initially started or during seasonal changeover from heating cooling this thermostat must call at least
17. fan and pump If a gurgling sound is present it should subside within one minute If noise is still present after one minute repeat step 3 to purge air as necessary 7 Check pipes for heating to make sure there is flow and feel the pump motor to see if it is running hot Coils Air conditioning and heating coils should not require cleaning if the filter maintenance schedule is adhered to lf a filter is damaged or collapses from plugging dust may foul the coils If this happens replace the filter and carefully vacuum the heating coil The fan may need to be removed to gain access to the face of the heating coil ZC KI6_20141027 Air conditioning coil At the start of each cooling season check the drain connection to the cooling coil to ensure it is free of debris If a plugged air conditioning coil is suspected call a service technician for testing and cleaning Fan and motor TROUBLESHOOTING Also refer to the controls troubleshooting guide Thermostat Call Error Thermostat calls are displayed on the 8 gang relay board ANY valid heating call will be illuminated as well as the pump LED Likewise ANY valid cooling call will illuminate as well as AIR COND LED If both 21 HEAT Z2 COOL are at the same time there is a thermostat error Check wiring and that the thermostat is set as a regular heat cool and not heat pump mode Calls on thermostats two three and four are ignored if the air handle
18. g or cooling will close Once the thermostat is satisfied continuous fan speed will resume Features Vortex air handlers offer many unique features that set them apart from the competition Soft Start is a feature that starts the fan slowly and quietly rather than a large thump common in some furnaces air handlers Evaporator Coil Freeze Protection If the evaporator coil air temperature drops outside of the expected operating range this indicates a potential evaporator coil freeze condition Coil freezing can lead to slugging liquid ZC KI6_20141027 refrigerant going back to the compressor which will damage the compressor All Zone Comforts come equipped with a sensor and controller which will respond by shutting off the outdoor cooling unit to PRODUCT DESCRIPTION Cabinet All cabinets have a tough durable low maintenance painted finish Cabinet dimensions are designed to provide maximum installation flexibility Refer to installation requirements for more details Heating coils All heating coils are potable water grade copper suitable for use in plumbing systems No lead solder is used in any component construction All coils and internal piping conform to ASTM 68 or ASTM B88 standards High density aluminum fins provide maximum heat transfer for small coil surface Fan and Motor All fans are wide body dynamically balanced for extra quiet operation Multi directional sleeve bearing m
19. home s water heater to provide both the space heating and domestic hot water eliminating the need for a furnace The equipment can be configured for heating only heating and cooling or cooling only applications HOW IT WORKS The key to the Zone Comfort system is the level of comfort and efficiency provided by the unique control system Zone dampers in the air handler operate to increase or decrease the capacity in each zone of the house as needed The controller employs the Quiet Comfort control strategy in order to have the capacity of the air handler meet the needs or load of the space as closely as possible This means that the blower does not run on high speed each time the room thermostat calls for heat rather the air handler dynamically adjusts its Page 9 Contact Vortex for Zone Comfort systems to be connected to a heat pump The Zone Comfort duct system can be much smaller than conventional ducting making it ideal for retrofit applications or where a conventional duct system would result in unsightly bulkheads and wasted space When used as the warm air distributor of a boiler heating system the Zone Comfort air system can provide warmer more comfortable air temperature than a gas furnace with less noise and much smaller duct requirements This is ideal for large custom homes where a premium heating product is required that is quiet comfortable and out of sight Controls usage and settings are
20. ily accessible Install the air handler with the door firmly screwed in place to make sure the cabinet remains square Page 13 Provide at least 2 feet 0 75 metres of service clearance in front of the access panel of the air handler Zero clearance is acceptable on all other faces Ductwork Zone Comfort air handlers are suitable for conventional ductwork or small D systems Duct selection for each zone should be based upon ease of installing ductwork Final assignment of zones can be done by changing zone damper wires on the terminal strip in the top section of the air handler Duct connections at the air handler should be labeled for future reference eg bsmt main upstairs Supply trunks may be square or round SEAL all joints and seams with metal tape or sealing compound Locate outlets at least 6 inches from outside walls or window coverings One 25 ft length of flex duct will provide two 12 5ft branches Use only Class 1 flex duct or duct connector All vertical portions of branch connections such as to high wall grilles must be rigid duct Flexible duct may only be used in horizontal portions of the branch Return air plenum should be the same cross sectional area as the air handler return air opening In vertical installations a conventional return air drop and elbow is acceptable Ductwork installed in unheated spaces such as attics must be installed between the insulation and the heated space
21. net Width in 22 22 22 22 22 Cabinet Depth in 25 25 25 25 25 Cabinet Regular AA AA AA AA 65 Cabinet Height in Tall ZCT 65 65 65 65 N A Supply Air Zone Dampers 8 8 3 10 3 10 3 10 Return air in 18x23 18x23 18x23 18x23 18x23 Supply and Return Water 3 4 3 4 3 4 3 4 1 Connections Weight air handler only 150 155 170 175 200 pounds Notes 1 Heating capacity based on 70 F return air high speed and 12 5 feet length per branch at 3 diameter 2 Regular ZC requires horizontal slab cooling coil extra model HC2018TX410 for up to 3 tons 3 5 ton and above require horizontal slab coil by others 3 Tall ZCT can use cooling A coil supplied by others Cabinet opening is 20W x 24D x 21H Page 8 2 6 20141027 INTRODUCTION The Zone Comfort system is a heating and cooling system that enhances comfort and improves efficiency by giving more control over the distribution of conditioned air Homeowners enjoy many benefits such as healthy indoor air comfortable basements and cool summer evenings Multiple thermostats provide the means to zone the home by section or level in order to gain more control This will virtually eliminate over or under conditioned spaces as is common in a lot of homes today The Zone Comfort system is designed for use in hydronic boiler systems or combination space and water heating systems Combo Systems Combo heating systems use the
22. once before the air handler control will properly recognize a heating or cooling call from the other zones Other Zones 2 3 4 These zones are the same and any area to be heated and or cooled can be selected as zone 2 3 or 4 Duct Zone Connections to Air Handler The 6 8 10 round duct connections top of the air handler are labeled zone 1 2 3 and 4 colours yellow orange blue and violet correspond to the wire colours connecting them to the air handler control NOTE THESE ARE FACTORY DEFAULT ZONE SELECTIONS AND THE INSTALLATING CONTRACTOR CAN REASSIGN ANY DUCT CONNECTIONS ON TOP OF THE AIR HANDLER ZONE ONE TWO THREE OR FOUR To change duct connection assignments change the wires connected to the bottom of the terminal block The output is as follows thermostat 1 Yellow 2 Orange 3 Blue 4 Violet The factory default is for the same coloured wires connected to the dampers and labeled zones 1 2 3 and ZC KI6_20141027 4 The colour labels on top of the air handler correspond to the wire colours to the damper For example to reassign the blue duct connection to thermostat START UP PROCEDURE Do not start the air handler or water heater until ALL air has been purged 1 Fill the boiler loop or water heater with water but do not start it 2 Purge all air from the boiler heating or domestic water system 3 Purge all air from the space heating loop by closing the isolation v
23. otors allow mounting in any direction for maximum installation flexibility Circulating pump The circulating pump is matched for maximum performance Air handlers come with internally mounted pumps for ease of installation Air handlers can be Page 11 allow the system to warm up Note that this freeze condition is not normal and may indicate blocked ducts dirty filter or an over sized cooling unit special ordered with external field installed pumps when it is desirable to locate the circulator below the air handler such as in attic installations Check Valve Check valves serve two purposes e protect against back flow of water to avoid short circuiting around the water heater during domestic water use e protect against thermal siphoning Thermal siphoning is flow of water through the space heating circuit while the circulating pump is not operating due to hot water rising by natural convection During summer months this will cause overheating interfere with air conditioning and waste energy All Vortex air systems come supplied with spring loaded check valves The check valve may be integral with the pump These check valves have been tested and proven to resist thermal siphoning for installations where the air handler elevation does not exceed the distance above the water heater shown in the table below valve size Maximum elevation 1 2 12mm 25 feet 8 metres 3 4 20 50 feet 15 metres
24. r system through zone one has not switched over to the same season For example if zone one is in heating mode any cooling call on zones 2 3 or 4 are ignored and Z2 CALL Z3_CALL and Z4 CALL will not illuminate If the air handler does not run when zones two three or four are calling activate the primary zone briefly 5 seconds to set the air handler in heating or cooling Page 17 Check fan for dust once a year If dirty vacuum to remove dust Keeping the fan blades clean will reduce noise and improve the capacity and efficiency of the heating system Pump The circulating pump is water lubricated and should require no regular maintenance A cycle timer is available to exercise the pump even during prolonged periods of no heat to avoid seizing from long idle periods mode Note that some thermostats have a delay typically five minutes before they will start the air handler in cooling the first time Relay failure 24 DPDT relay acts as a latching relay for zones 2 and 3 to prevent incorrect thermostat calls from reaching the control A second relay may be present for zones 4 and 5 Wrong Zones Operating Change the damper wires on the terminal block Refer to the labels on the thermostat wires and colour code at the damper connections Pump does not run The pump is activated by a 12vdc DPDT relay powered by the control One side runs the pump 120vac and the other side is 24vac to the 8 gang r
25. rmer 24VAC 40 VA 5 5 5 5 XELDO02 Door interlock switch 5 5 5 5 Blower motor 1 3 HP 5 4 EC Blower motor 1 2 5 5 XECMO6E EC Blower motor 3 4 HP 5 XBLF108 Blower 10x8 DD 5 5 5 XBLF128T Blower 12x8T DD 5 6 Valve Assembly 34 full port sweat ball valves plus drain S Standard A Alternate O Option Contact Vortex for blower control assemblies or cabinet parts Page 19 ZC KI6_20141027 Product Warranty This product is warranted by Vortex Source Systems to be free from defects in materials and workmanship that affect product performance under normal use and maintenance within the applicable periods specified below Replacements furnished will carry only the un expired portion of the original warranty Two Year Parts Vortex Source Systems will provide replacement parts for ANY part that fail within two years of purchase subject to the terms below Five Year Parts Vortex Source systems will provide replacement parts for any heating coils cooling coils cabinetry and piping that fail within five years of purchase subject to the terms below Terms Reasonable proof of original purchase date must be provided in order to establish the effective date of the warranty failing which the effective date will be based on the date of manufacture plus thirty days The warranty does not cover failure or damages
26. to divide the area in to east facing west facing and basement zones depending on solar gain Zoning based on usage is also acceptable office living and sleeping areas for example 7 6 20141027 INSTALLATION The installer must adhere strictly to all local and national code requirements pertaining to the installation of this equipment Detailed instructions are shipped with all accessory items and should be followed closely Air Handler Mounting The Zone Control air handler can be installed in any direction Some precautions must be observed for some of the possible mounting positions For installations where the access door faces up or down select an air handler with an external pump to avoid the pump being mounted with its shaft vertical The pump shaft must be mounted horizontally to avoid premature failure The air handler can be hung by securing straps through any of the existing screw holes in the cabinet When the existing screw is too short for securing a mounting strap a longer screw can be used provided care is taken not to damage any internal components When fastening straps using screws other than those supplied with the cabinet special care should be taken in the vicinity of the coil to avoid tube puncture The cabinet is designed so that the return air can be located on either side of the cabinet through the bottom of the cabinet or from the back Position the filter rack so that the filter is read
Download Pdf Manuals
Related Search