Control Manual for Zone Comfort
Contents
1. cooling mode If the snowflake is not displayed cooling calls on zones 2 3 and 4 are ignored A brief cooling call from zone 1 is required to switch the controller to cooling mode If in doubt turn the cooling on all Thermostat calls The status screen default will show any calls detected from any thermostat including continuous fan ON Table 1 Using the outer keys the user can scrol through the screens to see individual thermostat calls and fan speed Table 3 Rev_20150715 Page Bal 12 Gy Vortexses Controls User Manual ZCxx KI6 If a thermostat is calling but not detected by the contral 1 Check the thermostat and its connections 2 Check thermostat wiring at the thermostat and air handier 3 Check the 8gang relay indicator lights W1 Y1 and G1 are connected directly trom the thermostat terminal strip W2 Y2 W3 Ya W4 and Y4 are filtered through the 24vac relay lft allowing only heating calls during heating mode and only cooling calls during cooling mode The 8gang relay converts 24vac thermostat signals to digital signals for input to the iStat controller Ifthe lights are on but the controler does not respond the problem is tha wiring to the control or the control has failed Blower motor never fully stops even with no demand signal Ensure the thermostats have been wired according to the Zone Comfort Installation Instructions Ensure the blower motor speed control board has a jumper inst2. Rate valus 5 ERZ IMP eec Seting Freeze alarn setpoint 2 FRZ DY ett min Seting Freeze Delay 1 wait ime acivae Weaze aarm 3 Freeze Delay 2 Wal Eme Ta Talore operato SEFT FRZ DLY2 sete min Setting ree alarm 2 ro S938 REV D Dispiay Program name and revaon number 308 Moas ae Seting Maanus address 136 7 ae On sees variable or Gay Ory and nar SAREE Rev_20150715 Page 12 of 12
3. may exceed 100 Note that a single zone calling wil receive at least H_MIN Multiple zones calling will not exceed H_MAX Z1_CL Z2_C Z3_CL Z4_CL Cooling loads for each zone as a percentage of manimim cooling alow based on air conditioner capacity AC CAP Default for each is 50 The total for all zones may exceed 100 Note that a single zone caling wil ecaive atleast the calculatod minimum of MINTON 270 cim default x AC CAP for single stage AC condensers and MIN TON AC2_ADJ 270 20 cim Gofault x AC_CAP for 2 stage AC condensers Muiiple zones caling wil not xcood MAX TON 420 cim defaut x AC CAP D8_MAX D10_MAX Set the maximum airflow in cfm for 8 inch and 10 inch dampers respectively D8_MAX is used by ZC24 ZC30 and ZC36 D10_MAX is used by the larger models They should not be adjusted unless there are operational issues that cannot be fixed with the other settings Consult the factory Cooling Control Mode There are two modes of operation available for controlling cooling airflow fixed and auto Descriptions for each mode are found below C_SPD Cooling speed control mode options are fixed and auto Controls are in fixed mode by default Note that in either mode the cooling airflow wil always be maintained between MIN_TON 270 minimum default and MAX_TON 420 cfm per ton maximum default of air conditioner capacity AC_CAP In fixed mode the cooling airflow will operate s
4. open position The controler provides a delay on damper Closing in order to prevent this from occurring If this is an issue increase the delay sotting DMP_DLY in admin mode default delay is 20 seconds Also check that the folowing Values are correct in the program ZC_MODL AC_CAP H_MIN MIN_TON D8_MAX D10_MAX and all zone settings Z1_HL Z1_CL etc Too much airflow to a single zone causing noise This can occur due to undersized ductwork or improper setup ofthe air handler zone heating cooling loads The problem may be fixed by reducing the amount of airtiow designated to the problem zane See above section on zane heating cooling loads to adjust the airflow used for each zone Note that H_MIN MIN_TON and AC_CAP will override zone settings Installing a 2 stage air conditioner will reduce the minimum cooling airflow for single zones Alarm message TST ERR There is a simultaneous call for heating and cooling on zone one indicating an error with thermostat wiring or setup Ensure that all the zone thermostats are wired as per the Zone Comfort Installation Instructions and are configured for 1 heat 1 cool systems Note that when zone one has set the system in heating mode cooling calis on all other zones are ignored Likewise whan zone one has set the system in cooling mode heating calis on all other zones are ignored Not enough humidity removal in cooling mode The Zone Comfort air handler controls humidity du
5. value is 3 C Lowering this value will decrease sensitivity of the freeze protection feature FRZ_DLY Amount of time in minutes to wait before acknowledging a freeze protection condition Default setting is 3 minutes Increasing this value will decrease Sensitivity of the freeze protection feature FRZ_DLY2 Amount of time in minutes to wait before bringing the A C compressor back on once the measured supply air temperature has retumed to a safe value Defaut setting is 2 minutes Troubleshooting Warning The homeowner can diagnose many issues from the main controller on the front of the air handler but any diagnostics or servicing inside the air handler blower compartment should only be performed by a qualified service person High voltages are present No Display If pushing one of the four front buttons does not refresh the display there may be no power to the air handier or the transformer has failed or the controller has failed No Heating Note the controller display icons tiame heating mode Ifthe flame icon is not displayed heating calls on zones 2 3 and 4 are ignored A brief heating call trom zone 1 is required to switch the controller to heating mode If in doubt turn the heat on all zones Test Mode pushing the button on the bottom underneath of the control will run the pump and fan for 20 seconds Damper position will not change No Cooling Note the controlar display icons snowflake
6. Gomt erer D Display Display status of system NO CALL Same sese o ron _ Suppy air temperate Feir air Temperature TAEAE OTST rate ssc p mon esis FAN PO 8 D caie Conved FAN CFM mia parcariage 0 100 FCI ORO D ingu Zone 1 1hermostat heating put EKI 1OOMAOn D Ingun Zone thermostat cooing inout Z2 CA oontOn 0 ineat Zone 2 vaid termosta cair Z CAL f i0OR On D meut Zone 3 vald thermostat cal Za caL ioonmon 0 inea Zone vald hermostat cal E FEAE REV D Desply Program name and ravison number aa fe D net dete vara efor lay only and TE TAT stable Rev_20150715 Page 11 of 12 SVvortexsr Controls User Manual ZCxx KI6 Table 4 Admin Mode Tet oez Sei Type Deserpion Data oneco a D Depay Depay sats oraya TO CALL Te ze woot sett Sering set ne Zone Comfort Model zoas Teri Capaciy of a condloner none ST FanT accap_ seen Seting avaiable chacar 1 SA TMP feere D non Supply ar temperate ATM esenc D inout Renum ai temp spay aniy not used n caica FAN PO emre D ale Conver FAN_ CFM into percentage 0 100 FAN PO remo Seting Continuous Fan alow as a percent ot maximam EJ HUN ate Seting Setpoint af minimum heating sfow as a percemage 25 HMA a Seting Setpoint af maximum heating aiow as a percentag
7. S Vortexsex Controls User Manual Zone Comfort hot water air handler and zoned distribution system with 4 zone iStat6 electronic controller Vortex Source Systems 45 Cowansview Ri Cambridge Ontario NIR TZ Phone 888 781 8151 Fax 888 670 2544 into vortexsource com www vortexsouree com GVortexver Controls User Manual ZCxx KI6 Table of Contents Controller Basics Controller Keypad USER MODE ADMIN MODE Initial Controls Setup Zone heating cooling loads Cooling Control Mode Two Stage Air Conditioning Cycle Timer Pump Exerciser Freeze Protection Troubleshooting Table 3 User Mode Tabie 4 Admin Mode Rav 20160715 Page Botte GVortexae Controls User Manual ZCxx KI6 This document describes proper setup and use ofthe electronic controller tor the Vortex Zone Comiort air handier with the itat6 controller Although the system wil function Whan leit at factory defaut settings itis recommended thatthe installer read through this short manual in order to ensure the system has been setup to match Te required heating and cooling loads and air conditioning equipment installed and to take advantage of the various features available This control is capable of upto four zones hough only two or three may be connected Settings far unconnected zones can be ignored Controller Basics The controller automaticaly adjusts blower motor speeds and engages relays for control of the system components Thro
8. ade tan ower sunning below 80 ade fan ower is running above 50 Rav 20160715 Page Satta GVortexses Controls User Manual ZCxx KI6 Controller Keypad By using the option and setting keys afferent parameters and thelr current settings may be displayed and modified Use the outer option keys to scroll through the available parameters and use the inner setting keys to modify the paramatar s current setting available By default the control will remain in user made in which a limited selection of parameters may be accessed By entering admin made additional parameters may be made available Please exercise caution while in admin mode as these settings are meant to be accessed by the experienced user or installing contractor A description of each of the modes is found below iStat6 User Interface USER MODE This is the basic display and operating mode in which only a limited selection of parameters may be displayed Refer to Table 3 for a description of each item displayed ADMIN MODE This is the advanced display and configuration mode Itis intended only tor the properly trained contractor To enter admin mode press any button to illuminate the display backlight then press and hold the two option outer buttons at the same time user will be displayed at first hold until admin is displayed You can now scroll through the display items by using the outer two
9. alled across the terminals labeled P The motor speed control board and the jumpers are shown below Note The green signal light of the EVO motor control flashes according to its speed output to the motor Ex 5 long 3 short blinks 53 Tip The fan can be tested from 0 100 by placing the primary thermostat in FAN ON with no other calls on any zone Then adjust GFAN_PC up and down within ADMIN mode Pump Does Not Run For any heating call the controller provides a 12vde output to ti Rev_20150715 Page 9 of 12 GVortexses Controls User Manual ZCxx KI6 pump relay The relay runs the pump 120vac and provides a 24vac signal to the 8gang relay board If the light is on at the 8 gang relay the wiring to the pump or the pump itself is the problem Air Conditioning Does Not Run For any cooling call the controller provides a 24vac signal directly to the Ytout connection to the A C condenser and also to the 8gang relay indicator ight Ifthe light is on the problem is not in the air handler If the ight is off the problem would be wiring or controller Second Stage Air Conditioning Does Not Run Chock settings in Table 4 For second stago the controller providas a 12vde output to the 2 stage relay The relay provides 24vac ta the terminal strip Y2out Dampers get stuck when changing position When a zone damper tries to change position under high airflow or static pressure it may become stuck in a half
10. e 100 EESE Seting Zone 1 heating speed percentage EJ FEA Seting Zone T cooing speed percentage 30 ZL Seting Zone 2 heating speed percentage 50 Bot ate ating Zone 2 cooing speed percentage EJ EECA Seting Zone 3 heating speed percentage EJ ae faa Seting Zone 3 cooing speed percentage 30 ZL a Seting Zone amp heating speed percentage 50 Zack aera Seting Zone 4 cooing speed percentage 30 ZH oonan 0 input Zone 1 inermostat heating input 2 c oomo 0 mou Zone thermostat cooing rout Z2 CAL oommOn o inout Zone 2 vald themostat cal Z3 CAL 00MtOn 0 iout Zone 3 vald thermostat call Za CAL ommon D mou Zone vald thermostat cal Taoing artem corr mode FED based on Text demand irom zones AUTO conrad based on osen sere Sering measured supply ar temperature FINED Ac Staz Oon Sating s he air conditioner 2 sag OFF AGE MIN serne Seting Wenimam aon fo activate 2nd stage casing m Text How many dampers must be open to activate 25 AC2 DMP sett Sening _ sage soning 2 dampr COOL SP anne Serina Cooing setpoint al supp ae Temperate it DMP BLY ae sec Seting Damper Delay 1a clase damper In seconds 20 cT mone oonan Seting Cycle Timer On or O Once per day pump exercice OFF P PROT arn saina Coina PID Proponaral vaiu 7 pont eso Sseting_ Cooling PID integral value 02 PO De eae Seting Cooing PID Deadband valus o5 PID_RAME ar ssec Seting Cooing PIO Ram
11. et this to match the maximum capacity of the Zone Comfort air handler i e ZC24 2 tons ZC48 4 tons Refer to the table above Caution An improper setting may resul in coil freeze excess noise or poor perfomance GFAN_PC the amount of airtlow used for a continuous fan call as a percentage of the maximum system airflow The default setting is 50 H_MIN minimum heating airtiow as a percentage of the maximum system alow Default is 20 H_MAX maximum heating airflow as a percentage of the maximum system aiflow Lower settings wil mean longer heating cycles and improved air distribution throughout the home Default setting is 100 Zone heating cooling loads With the Zone Comfort system the amount of heating and cooling airfiow supplied to each individual zone may be adjusted This may be desired on systems which have a large differance in actual heating amp cooling loads for each zone Since many basements have a much lower cooling load far example it may make sense to Rev_20150715 Page Saf 12 GVortexses Controls User Manual ZCxx KI6 decrease the basement zone s cooling airflow in order to increase cycle times and improve comfor Modify the variables below to adjust these allows Ideally zones should be of similar size or capacity Z1_HL 22 HL Z3_HL 24 HL Heating loads for each zone as a percentage of maximum heating airflow H_MAX Default for each is 50 The total for all zones
12. here are operational issues in cooling mode Consult the factory Two Stage Air Conditioning An output is available on the low voltage terminal strip for the control of a two stage air conditioner When a cooling call is present second stage wil be activated in fixed mode if the cooling demand exceeds AG2_MIN determined based on the current zone calls and their respective cooling loads Z1_CL Z2 CL Z3_CL and Z4_CL If in auto mode second stage will be activated if the number of current coaling calls dampers open equals or exceeds AC2_DMP AC2_ADJ Adjusts the air flow down when the first stage of a two stage AC system is active The default is 90 cfm ton which is approx a 1 3 reduction in airflow most 2 stage condensers reduce capacity by 1 3 during first stage This should not be adjusted unless there are operational issues in cooling mode Consult the factory AC2_MIN in fixed mode the cooling alow at which 2 stago is activated set by Gofaut to 80 Decreasing this value wil cause 2 stage to be activated sooner Teading to tul capacity and colder supply air temperatures AC2_DMP In auto mode the minimum number of dampers open at which 2 Staga is activated sot by defaut set to 2 dampers open any 2 zones caling Decreasing this value will cause 2 stage to be activated sooner leading to full cooling capacity and higher airflow Note that higher values increases run time in first stage which will imp
13. imilar to that used in heating made adjusting based on the zones currently calling for cooling and the corresponding oltings for zone cooling loads Z1_CL 22 CL 23 CL and 24 CL In auto mode the airflow will adjust to maintain the supply air temperature at the chosen cooling setpoint COOL SP This made can provide better control of indoor comfort helping to ensure adequate dehumidification is taking place Caution for proper operation the supply air temperature sensor must be installed downstream of the cooling coil and measuring well mixed cold air COOL SP The cooling setpoint temperature for auto cooling mode Default setting is 11 C 52 F Lower setpoint temperatures wil lead 10 lower airflow increased dehumidification and comfort but may decrease overall cooling capacity and efficiency PID_PROP PID_INT PID_DB PID_RAMP These settings affect the proportional Rev_20150715 Page 6 of 12 GVortexses Controls User Manual ZCxx KI6 integral deadband and ramp rate used for the P 1 D cooling speed control when in auto mode It is recommended that these settings only be changed by someone who has a firm understanding of P D control schemes and only if the response rate of the fan is unsatisfactory Contact Vortex if you believe there s an issue with these settings MIN_TON MAX_TON These settings affect the minimum and maximum airflow respectively They should not be adjusted unless t
14. option buttons and adjust certain values using the inner two setting buttons To retum the control to user mode simply wait a few minutes or press and hold bath option buttons Use Table 4 as a quick reference on the items available in this mode Detailed descriptions on important parameters are found below Rev_20150715 Page 401 12 Gg Votersas Controls User Manual ZCxx KI6 Initial Controls Setup When first powering up the Zone Comfort air handler during commissioning enter admin made on the controller and adjust the folowing settings to match the installed equipment ZC_MODL the model number af the Zone Comfort air handler Options are 2034 2030 236 2042 ZC48 ZC60 and ZC100 This is used to set maximum irlow per zone based on damper size and total maximum airflow based on fan and motor capacity This will be preset in the factory but should be verified by the installer Refer tothe table below Damper Max one zone Max Airflow Model Max Tonnage size airiow cim ctm 2024 2030 202 ain 840 1200 zc36 3 ain 840 1200 zea av 101 1440 1400 ZC48 2060 a 5 101 1440 1800 AC_CAP the capacity in tons of the air conditioning equipment This setting impacts the amount of airflow when the system is in cooling mode If a two stage air conditioner is installed use the nominal full capacity tonnage If air conditioning is not installed it is recommended to s
15. ring cooling through use of the auto cooling speed made set C_SPD to auto See the Cooling Control Made section above Supply or return air temperature SA_TMP or RA_TMP reads 50 C This indicates the supply air temperature sensor is not properly connected to the controller Ensure that the sensor is connected as per the wiring diagram found in the Zone Comfort Installation Instructions and that no wires have become loose Rev_20150715 Page 10 of 12 y Vortex Controls User Manual ZCxx KI6 RA_TMP is not used and can be ignored A failed supply air temperature sensor will put the system into freeze protection Freeze protection errors alarm message FROZEN This usually occurs when there is inadequate airtlow for a given air conditioner Ensure that the air fiter is not plugged and all ductwork is open Ensure the setting ZC_MODL matches tho air andlor model and AC _CAP has been selected to match the installed air conditioner capacity Ensure supply air temperature sensor is located after cooling coil and in the Supply air stream not touching the cooling col heat source plumbing etc Ensure the cooling setpoint temperature COOL_SP is not set too ow Decrease sensitivity of the freeze protection feature see Freeze Protection above Sot FRZ_TMP lower and or FRZ_DLY higher Table 3 User Mode default That Tine Sai Type Desaipion Dea Zone
16. rove etficiency and may reduce airflow noise Cycle Timer Pump Exerciser The Zone Comfort includes an optional cycle timer or pump exerciser feature which may need to be enabled depending on the hot water source and local regulations When enabled the cycle timer will run the heating circulating pump for 30 seconds every 24 hours CT_MODE Cycle timer mode Set to 1 to enable Oto disable Cycle timer is disabled by default Freeze Protection In order to prevent the heat exchanger coils from freezing during cooling the Zone Rev_20150715 Page 7 of 12 GVortexses Controls User Manual ZCxx KI6 Comfort includes a freeze protection feature If the measured supply air temperature drops below the freeze protection temperature FRZ_TMBP the signal to the air Conditioner contactor is interrupted In order to prevent short cycing ofthe compressor this feature includes two settable delay intervals FRZ_DLY sets the amount of time the supply air temperature has to remain below FAZ_TMP before the alarm is triggered and FRZ_DLY2 sets the amount of me until the compressor is allowed to come back on onice the supply air temperature has retumed to above FRZ_TMP Note This feature wil only tum off the AC compressor signal It will not proiect the home or air handler from freezing house temperatures or improper fresh air connections such as trom a heat recovery ventilator FRZ_TMP The freeze protection setpoint temperature Defaut
17. ugh its LCD display and keypad important system parameters may be configured and operating conditions may be monitored When the controller keypad has not bean pressed for a few minutes the backlight will turn off and the display may go blank Simply press any one of the buttons to wake up the controller By defaut the controller will display a short message describing the operating Status of the system Table 1 provides a list of the different possible status messages and their meaning There are also a number of small icons that may appear around the edges of the display according to the current operating status Table 2 gives an explanation of the diferent icons Table 1 status messag Message Meaning NO CALL Bratem e nat cran csaa HEATING Thera a curenti a call Tor heating COOLING finere is curentiy a cal for cooing anny Tere curenti a cal Tor continuous fan oniy and na heating ar cooing SST error simultaneous heating Sahay eae Tom zon TJ CHER WT TST ERR Snare healcoa most are used oo s i Suppl a Te Too ol eaze protec has BERT SaNa CONTERIS FROZEN i be suspended unl temperature raes and tme delays are alte easing hs Dunen on ths bantar ofthe contral wl operate the Tan and UNG TET TEST o seconds to very operation Aner 20 seconds i retums 1o normal EEEE Table 2 display icons Ton Meaning Fae Tam E Tn Peang mode nowlaka fystem iin cooing mode l
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