Auto-Zone Control Systems EZ-Zone User Manual
EZ ZoneEZ Zone
EZ Zone
EZ ZoneEZ Zone
+
FAN
COOL 1
COOL 2
HEAT1
HEAT2
BYPASSOPEN
MODE
FRI
M
+
+
COOL
YORK
03:48P
OCCUPIED
Meridian
ALARMS
4-08-96
NO
0
2
1
5
4
8
7
0
*
BYPASSCLOSE
COMMUNICATION
ALARM
A = ALL ZONES
B = EACH ZONE
A
C = HVACUNIT/CLEAR
3
B
D = ALARMS
6
C
# = STEP/ENTER
9
= DECIMAL
D
*
#
+
+
COOL
YORK
03:48PM
OCCUPIED
Meridian
ALARMS
NO
04-08-96
2
1
5
4
8
7
0
*
MODE
3
6
9
#
FRI
A
B
C
D
FAN
COOL 1
COOL 2
HEAT1
HEAT2
BYPASSOPEN
BYPASSCLOSE
COMMUNICATION
ALARM
A = ALL ZONES
B = EACH ZONE
C = HVACUNIT/CLEAR
D = ALARMS
# = STEP/ENTER
= DECIMAL
*
+
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AA
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A
uto-Zone
AA
uto-Zoneuto-Zone
Auto-Zone Plus
OCCUPIED
09/20/00 03:38PM WED
NO ALARMS
M
3
2
6
1
5
9
4
7
Dec.
*
C
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WATTMASTER CONTROLS INC.
n
e
GuideGuide
Guide
GuideGuide
8500 NW River Park Drive • Parkville , MO 64152
PH: (816) 505-1100 • FX: (816) 505-1101 • E-mail: mail@wattmaster.com
Visit our website at www.wattmaster.com
Form: WM-AEZ-UG-01C Copyright 2000 WattMaster Controls, Inc.
Auto-Zone & System Manager are registered trademarks of WattMaster Controls, Inc.
EZ Zone is a registered trademark of York International Corp.
WattMaster Controls assumes no responsibility for errors, or omissions.
This document is subject to change without notice. All rights reserved.
Table of Contents
Introduction ........................................................................................................................................ 4
EZ Zone Upgrade Overview .............................................................................................................. 5
Component Descriptions .................................................................................................................... 6
Upgrade Package Selection ................................................................................................................ 7
Example #1 - EZ Zone Stand Alone To AZ Basic ..................................................................... 8 & 9
Example #2 - EZ Zone Stand Alone To AZ Plus ................................................................... 10 & 11
Example #3 - Networked EZ Zone To AZ Plus ..................................................................... 12 & 13
Optional Controllers And Accessories................................................................................... 14 & 15
EZ Zone Wiring ................................................................................................................................ 16
Auto-Zone Basic Wiring .................................................................................................................. 17
Auto-Zone Plus Wiring .................................................................................................................... 18
Auto-Zone Plus Address Switches................................................................................................... 19
HVAC Staging Connections ............................................................................................................. 20
Sensor Connections .......................................................................................................................... 21
Bypass Damper Connections ........................................................................................................... 22
Honeywell Economizer Actuators ................................................................................................... 23
System Manager Installation ........................................................................................................... 24
CommLink II Installation ................................................................................................................ 25
Modem Linc Central EPROM Replacement ................................................................................ 26
Master Interface EPROM Replacement ........................................................................................ 27
Zone Controller EPROM Replacement.......................................................................................... 28
EPROM Installation Procedures..................................................................................................... 29
Ribbon Cable Installation ................................................................................................................ 30
Upgrade Parts List Summary .......................................................................................................... 31
Additional Information .................................................................................................................... 32
Table of Figures
Figure 1: Existing EZ Zone Master Controller Wiring ................................................................ 16
Figure 2: New Auto-Zone Basic Controller Wiring ...................................................................... 17
Figure 3: Existing Auto-Zone Plus Controller Wiring .................................................................. 18
Figure 4: New Auto-Zone Plus Address Switch Setting ................................................................ 19
Figure 5: Existing EZ Zone HVAC Wiring .................................................................................... 20
Figure 6: New Auto-Zone HVAC Wiring ....................................................................................... 20
Figure 7: Existing EZ Zone Master Controller Sensor Wiring .................................................... 21
Figure 8: New AZ Zone Manager Sensor Wiring.......................................................................... 21
Figure 9: Existing EZ Zone Bypass Damper Wiring .................................................................... 22
Figure 10: New Auto-Zone Bypass Damper Wiring...................................................................... 22
Figure 11: Honeywell Economizer Actuators Wiring Information.............................................. 23
Figure 12: System Manager Wiring................................................................................................24
Figure 13: CommLink II Wiring ..................................................................................................... 25
Figure 14: EZ Zone Modem Linc Central EPROM Location ...................................................... 26
Figure 15: EZ Zone Master Interface Board EPROM Location ................................................. 27
Figure 16: EZ Zone Zone Controller EPROM Location .............................................................. 28
Figure 17: EPROM Removal & Installation .................................................................................. 29
Figure 18: 3 Connector Ribbon Cable Installation ....................................................................... 30
EZ Zone/Auto-Zone
Introduction
+
YORK
OCCUPIED
Meridian COOL MODE
NO ALARMS
04-08-96 03:48PM FRI
1
4
7
*
The Auto-Zone Controls System was created from the
+
FAN
COOL 1
COOL 2
HEAT1
HEAT2
BYPASSOPEN
BYPASSCLOSE
COMMUNICATION
ALARM
A = ALL ZONES
B = EACH ZONE
A
C=HVACUNIT/CLEAR
3
B
D = ALARMS
2
6
C
# = STEP/ENTER
5
9
= DECIMAL
D
*
8
#
0
+
original EZ Zone Control System concept by redesigning, enhancing and expanding the original systems capabilities under the new Auto-Zone Controls System
name.
WattMaster’s Auto-Zone Control Systems have continued in the York EZ Zone tradition of keeping the controls simple to install and use while enhancing the system to make it more applicable and in line with the needs
of the current marketplace. In addition to offering an
excellent control system for zoning applications, the
Auto-Zone Control System has been expanded to allow control of multiple single zone constant volume
units and other devices such as lighting, exhaust fans,
and unit heaters.
+
The York International Corporation’s EZ Zone Controls
System was first introduced in the early nineties. The
EZ Zone Controls System was designed for York, by
WattMaster Controls, as a simple zone control system
for York’s line of commercial unitary roof top and split
system HVAC units. Since its original design and introduction, the York EZ Zone Control System has
changed very little.
Auto-Zone Plus
OCCUPIED
09/20/00 03:38PM WED
NO ALARMS
3
2
6
1
5
9
4
8
Minus
7
0
Dec.
*
Upgrading your EZ Zone system to the Auto-Zone Controls system allows you and your customer to take advantage of the many improvements that have been made
in the Auto-Zone Controls system without having to
replace all the EZ Zone system components that are
installed on your job.
This guide is intended to provide you with simple
instructions on upgrading an existing EZ Zone system
to an Auto-Zone Control System.
MANAGER
Alarm
Menu
Clear
SYSTEM
Esc
Enter
T
A
W
Communication
R
E
T
S
A
M
T
Override
O
C
.
C
IN
S
L
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N
4 Upgrade
EZ Zone Upgrade Overview
EZ Zone/Auto-Zone
The basic steps required to upgrade your EZ
Zone system to an Auto-Zone system are:
z Determine what EZ Zone components
are currently installed on the system.
z Replace the existing EZ-Zone Master
Controller board with an Auto-Zone
Zone Manager controller board
z Replace the existing EZ Zone
EPROM’s in each Zone Controller
with a new Auto-Zone EPROM.
z Install return air and outside air
temperature sensors
EZ Zone to Auto-Zone upgrade allows you to
retain:
z All existing wiring
z Master Controller enclosure with
keypad and display
z Existing supply air and static pressure
sensors
z Existing bypass damper
After upgrading your system from EZ Zone to
Auto-Zone, you will be able to take advantage
of many new enhancements including:
Damper actuators can be programmed
z
for direct or reverse operation
z Full modulating economizer control
capability including optional wetbulb
economizer control
z Outside air temperature sensor provides
lockout function for both heating and
cooling. When converted to Auto-Zone
Plus system only one outside air sensor
is required for the entire system
z Contact closure input for dirty filter
status
z Global and individual zone override
modes
z Zones can be set for voting or
nonvoting status
z Room sensor slide can be programmed
± 0° F to ± 5° F adjustment
from setpoint
z All Zone Dampers
z * All Zone Controllers
z Room sensors
z Staging delays, minimum off times,
and changeover intervals are
programmable
z Sensor offset calibration to correct
sensor errors due to poor location
z * Modem Link Central
z * All Master Interface Boards
z ZoneView enhanced graphical computer
front end software available when
CommLink and a PC are used
z All Fan Terminal Controllers
z System Manager operator interface
* These controllers can be retained but they will re-
quire an EPROM chip upgrade to be compatible
with the Auto-Zone System.
allows all controllers to be accessed from
one central location
Upgrade 5
EZ Zone/Auto-Zone
Component Descriptions
The general architecture of the EZ Zone and the AutoZone Systems are very similar making the upgrade process relatively easy.
There are some changes in the component descriptions
between the EZ Zone system and the Auto-Zone system. It is important to understand these differences
before you begin the upgrade process.
Master Controller Zone Manager
Must Be Replaced Improved Hardware & Software
Fan Terminal
Controller
Many of these components look similar, however, in
some cases they do not function in an identical fashion.
Having the wrong component installed can cause improper system operation.
The chart below depicts the difference in descriptions
for the various comparable system components in the
EZ Zone and Auto-Zone Systems.
Relay Expansion
Board
Replacement Not Required
Master Interface Board
EPROM Replacement Required
EZ Zone Components
Modem Linc Central CommLink II
EPROM Replacement Required
Zone Controller Zone Controller
EPROM Replacement Required
Same As Existing Fan Terminal Controller
MiniLink
Communications
Interface
Improved Software
Auto-Zone Components
Improved Software
Improved Software
6 Upgrade
Upgrade Package Selection
EZ Zone/Auto-Zone
There are basically 3 possible EZ Zone to Auto-Zone
upgrade scenarios you may encounter. We have outlined these below to assist you in deciding which option is best for your application.
Upgrade A Simple EZ Zone Stand Alone
System(s) To The Auto-Zone Basic System
•
Each Existing Master Controller Has It’s Own Display
And Keypad And Is Treated As A Separate System
•
No Communications Cable Between Existing Master
Controllers
•
No Central Display Or Computer Interface Is Desired
Upgrade A Simple EZ Zone Stand Alone
System(s) To The Auto-Zone Plus System
Please see the Auto-Zone upgrade selection chart below to help determine which example best fits your
needs.
See Example #1
On
Pages 8 & 9
•
Two Or More Existing Master Controllers On The Job.
•
No Communications Cable Between Existing Master
Controllers
•
The Customer Wants To Connect The Master
Controllers So That They Are Part Of A Networked
System And/Or Install Constant Volume Unit
Controllers Or Other Controller Boards On Their
System
Upgrade A Networked EZ Zone System To
The Auto-Zone Plus System
•
Two Or More Existing Master Controllers That Are
Networked Together With A Modem Linc Central
•
The Customer May Want To Add Constant Volume
Unit Controllers Or Other Controller Boards To Their
System
See Example #2
On
Pages 10 & 11
See Example #3
On
Pages 12 & 13
Upgrade 7
EZ Zone/Auto-Zone
Example #1:
Your project has a single EZ Zone Master Panel and
it’s associated Zone Controllers. This is a typical EZ
Zone system. The upgrade will essentially convert this
to an Auto-Zone Basic System. Please see the required
upgrade components to be ordered in the list below.
To upgrade your existing EZ Zone System to the AutoZone Basic System the following procedure will be required.
Warning: All removal and installation procedures
must be done with the power to the controllers
turned off. Failure to do so can cause severe damage to the controller boards.
1) All power and input/output wiring will need to be
disconnected from the board. Remove the enclosure
cover and disconnect the keypad & display cable by
unplugging the cable connector at the board connection.
2) The new Return Air Sensor should be installed in
the return air stream in a location upstream of the point
that the bypass duct connects to the return duct.
3) Install the new Outdoor Air Sensor in a location on
the exterior of the building that provides shade and pro-
tection from the weather. See the mounting instructions
included with the sensor for detailed mounting instructions.
4) Remove the existing EZ Zone Master Controller
Board from the EZ Zone enclosure. This will require
the removal of 4 screws securing the board to the enclosure base.
5) Install the new Zone Manager board onto the existing enclosure base. The new board installation requires
6 plastic standoffs be inserted between the back of the
new board and the existing standoffs. Secure the board
to 4 of the threaded standoffs (one in each corner of the
board) with the mounting screws provided.
6) Connect the input, output and power wiring per the
Auto-Zone Basic wiring diagram (See Figure 2 on page
17). Connect the keypad display connector of the existing EZ Zone enclosure cover to the new Auto-Zone Zone
Manager board and secure the existing enclosure cover
to the enclosure base with the existing screws.
7) Remove and replace each EPROM on all the existing EZ-Zone Zone Controllers. See Figures 16 & 17 on
pages 28 & 29 for detailed EPROM Replacement information.
Note: When ordering be sure to specify Fahrenheit or Celsius operation for your system
To Upgrade To The AZ Basic System Order the Following:
(1) (OE751) EZ Zone to Auto-Zone Basic Upgrade Kit
(Includes: Zone Manager Board w/ Mounting Screws, Plastic Standoff Kit for Zone Manager,
Return Air Sensor, Upgrade Label, Installation Instructions.
(1) (OE250) Outside Air Sensor
(X) (OE752) EPROM (Replaces EZ Zone, Zone Controller EPROM) (One Required Per Controller)
For optional components list and information see pages 14 & 15 of this manual.
8 Upgrade
EZ Zone Stand Alone to AZ Basic
COMM
LINK
II
Existing System
To HVAC Unit
Master
Controller
Control Panel
+
YORK
EZ-ZONE COOL MODE
OCCUPIED
NO ALARMS
04-08-96 03:48PM FRI
2
1
5
4
8
7
0
*
+
+
FAN
1
COOL
2
OOL
C
®
HEAT1
2
EN
HEAT
OP
SE
BYPASS
TION
BYPASSCLO
UNICA
MM
CO
ARM
AL
ALLZONES
=
ZONE
A
EACH
=
B
UNIT/CLEAR
AC
=HV
A
C
ARMS
3
AL
=
B
D
6
C
#= STEP/ENTER
9
DECIMAL
=
D
*
#
+
Supply
Air Temp
Sensor
Bypass Air
Damper
Zone Air Dampers
Up to 16 Zone Air Dampers Allowed
#1
EZ Zone/Auto-Zone
#16
Static
Pressure
Sensor
Upgraded System
Telephone Line
(Required For
Remote Link)
1
2
4
3
5
7
6
S
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D
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in
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SIG
DET
RDY
SND
REC
PWR
C
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Remote Link
(Optional)
CommLink II
Single Loop
(Optional)
Outside
Air Temp
Sensor
LS
C
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Zone Manager
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To HVAC Unit
Control Panel
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Supply
+
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+
Air Temp
Sensor
Return
Air Temp
Sensor
Bypass Air
Damper
Zone Air Dampers
Up to 16 Zone Air Dampers Allowed
#1
#16
+
Static
Pressure
Sensor
Upgrade 9
EZ Zone/Auto-Zone
Example #2:
Your project has multiple EZ Zone Master Panels and
their associated Zone Controllers. This upgrade will
convert this to an Auto-Zone Plus System.
To upgrade your existing EZ Zone System to the AutoZone Plus System the following procedures will be
required.
Warning: All removal and installation procedures
must be done with the power to the controllers
turned off. Failure to do so can cause severe damage to the controller boards.
1) All power and input/output wiring will need to be
disconnected from the existing Master Controller board.
Disconnect the keypad & display cable from the board
by unplugging its connector from the board and the display on the existing enclosure cover.
2) The new Return Air Sensor should be installed in
the return air stream in a location upstream of the point
that the bypass duct connects to the return duct.
3) Install the new Outdoor Air Sensor in a location on
the exterior of the building that provides shade and
protection from the weather. Only one OA sensor is
required for the entire system. See the mounting instructions included with the sensor for detailed mounting
instructions.
4) Connect the CommLink to the network communica-
tions loop and wire in 24VAC power (See Figure 13 on
page 25).
5) Remove the existing EZ Zone Master Controller
Board from the EZ Zone enclosure. This will require
the removal of 4 screws securing the board to the enclosure base.
6) Install the new Zone Manager board onto the existing enclosure base. The MiniLink should then be
mounted to the Zone Manager board using the standoffs and screws included with the MiniLink. The new
Zone Manager board installation requires 6 plastic
standoffs be inserted between the back of the new board
and the existing standoffs. Secure the board to 4 of the
threaded standoffs (one in each corner of the board)
with the screws that were included with the new Zone
Manager board.
7) Connect the input, output and power wiring per the
Auto-Zone Plus wiring diagram (See Figure 3 on page
18). Connect the new 3 Connector Ribbon Cable keypad display connector to the existing EZ Zone enclosure cover and to the new Auto-Zone Zone Manager
board (See Figure 18 on page 30). Secure the existing
enclosure cover to the enclosure base with the existing
screws.
8) Remove and replace each EPROM on all the existing EZ-Zone Zone Controllers. See Figures 16 & 17 on
pages 28 & 29 for detailed EPROM Replacement information.
Note: When ordering be sure to specify Fahrenheit or Celsius operation for your system
To Upgrade To The Auto-Zone Plus System Order the Following:
(X) (OE753) EZ Zone to Auto-Zone Plus Upgrade Kit (One Required Per Existing Master Controller)
(Includes: Zone Manager Board w/ Mounting Screws, Plastic Standoff Kit for Zone Manager,
MiniLink w/ Mounting Hardware, Return Air Sensor, 3 Way Display/Keypad Connector cable,
Upgrade Label, Installation Instructions).
(1) (OE361-04-CLMA) CommLink II Kit (Includes: Cables, Power Supply, Installation Instructions)
(1) (OE250) Outside Air Sensor (Only One Required For Entire System)
(X) (OE752) EPROM (Replaces EZ Zone, Zone Controller EPROM) (One Required Per Controller)
(1) (OE392-01-AZSYSM) System Manager (Not Required if Using Optional Computer)
For optional components list and information see pages 14 & 15 of this manual.
10 Upgrade
EZ Zone Stand Alone to AZ Plus
C
COMM
LINK
II
MANAGER
Existing System
To HVA
Unit
To HVAC Unit
Control Panel
+
+
YOR K
EZ-ZONE
OCCUPIED
NO
04-08-96
1
4
7
*
Controller
®
FRI
COOL MODE
03:48PM
ALARMS
A
3
B
2
6
C
5
9
D
8
#
0
Master
N
FA
1
L
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C
2
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1
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2
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A
#
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C
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D
=
*
Control Panel
Supply
+
N
R
A
+
Air Temp
Sensor
Bypass Air
Damper
Static
Pressure
Zone Air Dampers
Up to 16 Zone Air Dampers Allowed
#1
Sensor
+
+
#16
YOR K
EZ-ZONE
OCCUPIED
NO
04-08-96
1
4
7
*
Master
Controller
®
MODE
FRI
COOL
03:48PM
ALARMS
A
3
B
2
6
C
5
9
D
8
#
0
Supply
+
N
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2
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A
#
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C
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=
*
+
Air Temp
Sensor
Bypass Air
Damper
EZ Zone/Auto-Zone
Zone Air Dampers
Up to 16 Zone Air Dampers Allowed
#1
#16
Static
Pressure
Sensor
Upgraded System
Telephone Line
(Required For Remote Link)
To Other Zone Managers
1
2
4
3
5
7
6
S
y
c
h
r
o
n
o
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s
D
a
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a
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SIG
DET
RDY
SND
REC
PWR
CO
N
TR
O
L
S
Remote Link
(Optional)
8
9
*
0
#
Computer
(Optional - By Others)
Supply
Air Temp
Sensor
Return
Air Temp
Sensor
Network Loop
Zone Air Dampers
Up to 16 Zone Air Dampers Allowed
#1
C
O
M
M
L
I
N
K
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C
O
O
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P
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WCLI
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T
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A
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T
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R
O
N
T
R
O
S,N
C
CommLink II
Multiple Loop
To HVAC Unit
Control Panel
Zone Manager
Outside
Air Temp
Sensor
Only One OA
Sensor Is
Required
For Entire
System
+
+
YOR K
OCCUPIED
Meridian
ALARMS
NO
04-08-96
1
4
7
*
+
N
FA
1
L
O
O
C
2
L
O
O
C
1
T
A
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2
T
A
N
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P
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A
P
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B
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C
S
MODE
N
FRI
S
O
A
I
P
T
Y
A
B
IC
COOL
N
U
M
M
03:48PM
O
C
M
R
A
L
S
A
E
N
O
Z
L
L
E
A
N
=
O
R
Z
A
A
H
E
L
C
A
/C
E
IT
=
N
B
U
C
A
V
H
=
S
A
C
M
R
A
L
3
R
A
E
T
=
B
N
D
2
/E
P
E
6
T
S
=
L
C
A
#
5
M
I
C
9
E
D
=
D
*
8
#
0
Bypass Air
+
Damper
To HVAC Unit
Control Panel
Zone Manager
Pressure
Sensor
+
+
Static
YOR K
04-
#16
MODE
FRI
COOL
03:48PM
OCCUPIED
Meridian
ALARMS
08-96
NO
A
3
B
2
6
1
C
5
9
4
D
8
#
7
0
*
Local Loop
Static
Pressure
Sensor
(Up to 30 Allowed On System)
Network Loop
Supply
Air Temp
+
N
FA
1
L
O
O
C
2
L
O
O
C
1
T
A
E
H
2
T
A
N
E
E
H
P
O
S
S
E
A
P
S
Y
O
B
L
C
S
N
S
A
IO
P
T
Y
A
B
IC
N
U
M
M
O
C
M
R
A
L
S
A
E
N
O
Z
L
L
E
A
N
=
O
R
Z
A
A
H
E
L
C
A
/C
E
T
I
=
N
B
U
C
A
V
H
=
S
C
M
R
A
L
R
A
E
T
=
N
D
/E
P
E
T
S
=
L
A
#
IM
C
E
D
=
*
+
(Optional If Computer Front End Used)
Sensor
Return
Air Temp
Sensor
Bypass Air
Damper
System
Manager
s
lu
ED
P
SYSTEM
W
e
n
o
-Z
S
uto
A
RM
LA
OCCUPIED
01/01/9703:38PM
NOA
c
s
E
u
en
M
3
2
6
1
r
e
t
n
E
5
r
9
a
le
4
C
s
8
u
in
M
7
0
.
c
e
D
*
ER
ANAG
M
rm
a
Al
n
tio
a
ic
n
u
m
e
m
d
o
ri
C
er
v
O
Zone Air Dampers
Up to 16 Zone Air Dampers Allowed
#1
Other Controllers
(Optional - Up to 13 On Each Loop))
#16
Upgrade 11
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