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To
Auto-Zone
Upgrade
Guide
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INC |
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CONTROLS |
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WATTMASTER |
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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
+
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YORK |
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MODEFRI |
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COOL |
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03:48PM |
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Meridian08 OCCUPIEDALARMS |
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+ |
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.
The Auto-Zone Controls System was created from the 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.
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.
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Plus |
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-Zone |
WED |
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Auto 03:38PM |
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OCCUPIEDALARMS |
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09/20/00 |
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NO |
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MANAGER |
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4 |
Upgrade |
EZ Zone/Auto-Zone
EZ Zone Upgrade Overview
The basic steps required to upgrade your EZ Zone system to an Auto-Zone system are:
zDetermine what EZ Zone components are currently installed on the system.
zReplace the existing EZ-Zone Master Controller board with an Auto-Zone Zone Manager controller board
zReplace the existing EZ Zone EPROM’s in each Zone Controller with a new Auto-Zone EPROM.
zInstall return air and outside air temperature sensors
EZ Zone to Auto-Zone upgrade allows you to retain:
zAll existing wiring
zMaster Controller enclosure with keypad and display
zExisting supply air and static pressure sensors
zExisting bypass damper
zAll Zone Dampers
z* All Zone Controllers
zRoom sensors
z* Modem Link Central
z* All Master Interface Boards
zAll Fan Terminal Controllers
*These controllers can be retained but they will require an EPROM chip upgrade to be compatible with the Auto-Zone System.
After upgrading your system from EZ Zone to Auto-Zone, you will be able to take advantage of many new enhancements including:
zDamper actuators can be programmed for direct or reverse operation
zFull modulating economizer control capability including optional wetbulb economizer control
zOutside 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
zContact closure input for dirty filter status
zGlobal and individual zone override modes
zZones can be set for voting or nonvoting status
zRoom sensor slide can be programmed
±0° F to ± 5° F adjustment
from setpoint
zStaging delays, minimum off times, and changeover intervals are programmable
zSensor offset calibration to correct sensor errors due to poor location
zZoneView enhanced graphical computer front end software available when CommLink and a PC are used
zSystem Manager operator interface 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.
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.
EZ Zone Components
Master Controller
Must Be Replaced
Fan Terminal
Controller
Replacement Not Required
Master Interface Board
EPROM Replacement Required
Modem Linc Central
EPROM Replacement Required
Zone Controller
EPROM Replacement Required
Zone Manager
Improved Hardware & Software
Relay Expansion
Board
Same As Existing Fan Terminal Controller
MiniLink
Communications
Interface
Improved Software
CommLink II
Improved Software
Zone Controller
Improved Software
Auto-Zone Components
6 |
Upgrade |
EZ Zone/Auto-Zone
Upgrade Package Selection
There are basically 3 possible EZ Zone to Auto-Zone |
Please see the Auto-Zone upgrade selection chart be- |
upgrade scenarios you may encounter. We have out- |
low to help determine which example best fits your |
lined these below to assist you in deciding which op- |
needs. |
tion 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
•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 #1
On
Pages 8 & 9
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/Auto-Zone
EZ Zone Stand Alone to AZ Basic
Existing System
To HVAC Unit
Control Panel
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FAN |
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COOL |
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COOL |
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T 1 |
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YORK03:48PM |
MM |
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HEA |
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HEA |
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EN |
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BYP |
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MODEFRI |
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CLO |
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TION |
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COOL |
BYP |
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-08 |
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UNICA |
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OCCUPIEDALARMS |
ARM |
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ZONE |
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EZ |
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A = |
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ZONE |
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Supply
Air Temp
Sensor
Master
Controller
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HVAC |
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ALARMS |
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Zone Air Dampers |
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Bypass Air |
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Damper |
Up to 16 Zone Air Dampers Allowed |
#1 |
#16 |
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Pressure |
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Upgraded System
Telephone Line
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Remote Link)
Sychronous |
Data |
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6
3
Remote Link
(Optional)
CommLink II
Single Loop
(Optional)
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OMM |
LINK II |
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OD |
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ME |
W
C
L I
To HVAC Unit
Control Panel
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COO |
L 1 |
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COO |
L 2 |
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Computer
(Optional - By Others)
Supply
Air Temp
Sensor
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HEAT |
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YORKE C3:OE4D8P |
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Air Temp |
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BYP MUNICA |
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Zone Manager |
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SS OPE |
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MODFRI |
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TIO |
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E-Z0-8Z-OO9NC6CAU0LPAIRMS |
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COARM M |
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ONES |
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LL Z |
UNIT/C |
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CH ZO |
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Bypass Air |
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Damper |
Up to 16 Zone Air Dampers Allowed |
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#16 |
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Pressure |
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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/Auto-Zone
EZ Zone Stand Alone to AZ Plus
Existing System
To HVAC Unit |
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Control Panel |
Master |
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Controller |
Supply |
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Air Temp |
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Sensor |
YORK |
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MODEFRI |
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COOL |
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ZONE |
03:48PM |
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EZ08-OCCUPIEDALARMS |
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96 |
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04- |
NO |
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A |
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Bypass Air |
Zone Air Dampers |
Damper |
Up to 16 Zone Air Dampers Allowed |
Master
Controller
To HVAC Unit
Control Panel
YORK |
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MODEFRI |
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COOL |
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ZONE |
03:48PM |
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EZ08-OCCUPIEDALARMS |
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#16 |
Supply |
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Air Temp |
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Sensor |
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Static |
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Pressure |
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Bypass Air |
Zone Air Dampers |
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Damper |
Up to 16 Zone Air Dampers Allowed |
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#16 |
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Pressure |
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Upgraded System
Telephone Line
(Required For Remote Link)
To Other Zone Managers
(Up to 30 Allowed On System)
Sychronous |
Data |
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Link |
Remote Link
*
7
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4 |
2 |
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8 |
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0 |
#
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6
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To HVAC Unit |
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Control Panel |
Network Loop |
Supply
Air Temp
Sensor
(Optional) |
Computer |
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COMM L
INK II
W
C
(Optional - By Others)
Network Loop
YORK03:48PM |
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MODEFRI |
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COOL |
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Return
Air Temp
Sensor
Bypass Air |
Zone Air Dampers |
Damper |
Up to 16 Zone Air Dampers Allowed |
L I |
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#16 |
CommLink II |
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Zone Manager |
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Zone Manager |
YORK03:48PM |
Return |
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Air Temp |
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NO |
COOL |
MODEFRI |
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Pressure |
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Air Temp |
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A |
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Sensor |
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D |
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8 |
# |
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Zone Air Dampers |
Manager |
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Damper |
Up to 16 Zone Air Dampers Allowed |
(Optional If Computer Front End Used) |
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#1 |
#16 |
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(Optional - Up to 13 On Each Loop)) |
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For Entire |
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MANA |
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-Zone Plu |
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7 |
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Local Loop |
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Pressure |
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Sensor |
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Upgrade |
11 |
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