TempMaster ZV Series - User Manual

R-410A
ZV SERIES W/SMART EQUIPMENT™
6.5 - 12.5 Ton
60 Hertz
5567613-TIM-B-1218
Table of contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 44
Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Reheat mode sequence of operation . . . . . . . . . . . . . . . . . . . 62
Electric heating sequence of operations . . . . . . . . . . . . . . . . . 64
Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 64
Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 64
Ignition control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 65
Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Navigation components for the Smart Equipment™ control board . . 69
Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 70
Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
List of tables
1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 ZVT06 through T12 unit limitations . . . . . . . . . . . . . . . . . . . . . 8
3 ZVT06 through T12 standard unit weights and dimensions . 11
4 ZVT06 through T12 unit weights with the Magna Dry option 11
5 ZVT06 through T12 unit accessory weights . . . . . . . . . . . . . 11
6 ZVT06 through T12 unit physical dimensions . . . . . . . . . . . . 13
7 ZVT06 through T12 unit clearances . . . . . . . . . . . . . . . . . . . 14
8 ZVT06 through T08 side duct dimensions. . . . . . . . . . . . . . . 17
9 ZVT10 through T12 side duct dimensions. . . . . . . . . . . . . . . 17
10 Left/end duct dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
13 Physical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
14 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 35
15 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 36
16 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 36
17 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 49
19 Airflow performance - side duct application . . . . . . . . . . . . . . 51
20 Airflow performance - bottom duct application . . . . . . . . . . . 54
21 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
22 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 56
23 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 56
24 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 58
25 3 stage dehumidification sequence in normal and alternate
mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
26 Electric heat limit setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
27 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 64
28 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . 66
29 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 68
30 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
31 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 68
32 Cable for FC buses and SA buses in order of preference . . 76
33 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 76
34 ZVT06 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 77
35 ZVT06 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 77
36 ZVT07 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 78
37 ZVT07 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 78
38 ZVT08 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 79
39 ZVT08 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 79
40 ZVT10 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 80
41 ZVT10 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 80
42 ZVT12 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 81
43 ZVT12 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 81
List of figures
1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Barometric relief hood - shipping location . . . . . . . . . . . . . . . 5
3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 ZV component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 4 point and 6 point load weight for W units. . . . . . . . . . . . . . 10
6 4 point and 6 point load weight for V units . . . . . . . . . . . . . . 10
7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZVT06 through T08 physical dimensions . . . . . . . . . . . . . . . 12
9 ZVT10 through T12 physical dimensions . . . . . . . . . . . . . . . 13
10 ZVT06 through T12 unit bottom duct openings . . . . . . . . . . 15
11 ZVT06 through T12 unit electrical entry . . . . . . . . . . . . . . . . 16
12 ZVT06 through T12 unit left/end duct opening . . . . . . . . . . . 18
13 ZVT06 through T12 roof curb . . . . . . . . . . . . . . . . . . . . . . . . 18
14 ZVT06 through T12 transition roof curb . . . . . . . . . . . . . . . . 19
15 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 20
16 Return downflow plenum with panel . . . . . . . . . . . . . . . . . . . 20
17 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
18 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 21
19 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
20 Field wiring disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
21 Typical control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
22 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
23 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
24 Simplified VFD wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
25 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 44
26 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
27 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 49
28 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
29 Cooling operation piping schematic - circuit no. 1 . . . . . . . . 63
30 Reheat operation piping schematic - circuit no. 1 . . . . . . . . 63
31 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
32 Typical two stage gas valve . . . . . . . . . . . . . . . . . . . . . . . . . 69
33 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Summary

General

Safety considerations

Understand signal words (DANGER, WARNING, CAUTION) for potential hazards.

Inspection

Nomenclature

Installation

Installation safety information

Read instructions before installation, ensure consumer receives them.

Preceding installation

Steps to take before the main installation process.

Limitations

Location

Rigging and handling

Clearances

ZVT06 through T08 unit side duct openings

ZVT10 through T12 unit side duct openings

Ductwork

Duct covers

Units are shipped with side duct openings covered; no changes for bottom duct.

Side panels

Panels cover areas for economizer/damper; use as tops for economizer rain hoods.

Compressors

Condensate drain

Side condensate drain can be re-oriented; plumbing must conform to local codes.

Filters

Power and control wiring

Power wiring detail

Thermostat wiring

Typical control wiring detail

Color-coded wires connect thermostat to unit.

ZVT06 through T12 high static indoor blower - without powered convenience outlet

ZVT06 through T12 standard indoor blower - with powered convenience outlet

ZVT06 through T12 high static indoor blower - with powered convenience outlet

Optional electric heat

Optional gas heat

Gas piping

Proper sizing of gas piping depends on gas flow, gravity, and run length.

Gas connection

LP units, tanks and piping

Vent and combustion air

Smoke detectors

Motorized outdoor damper

Economizer

Power exhaust

Manual bypass

Economizer sequences

Economizer minimum position sequences

Six minimum position sequences available.

Minimum position

Economizer positions to setpoint unless another function commands it.

VAV economizer minimum position reset

Controls damper position based on VFD speed settings.

Low ambient minimum position

Air monitoring station reset

Demand ventilation

Free cooling changeover options

Auto

Control determines free cooling type based on available sensors.

Dual enthalpy

Control determines free cooling type based on sensors and reliable data.

Single enthalpy

Control determines free cooling type based on sensors and reliable data.

CV option A thermostat sequence

Cooling stages set to one for single compressor unit

Cooling stages set to two for a two compressor unit

Cooling stages set to four for a four compressor unit

CV option B thermostat sequence

CV option A occupied

CV option B occupied

CV option A and option B unoccupied

VAV unit sensor option A

VAV unit sensor option B

Economizer loading

Power exhaust

Smart Equipment economizer board

Smart Equipment economizer board - analog inputs

Tables describe analog inputs and their functions.

Smart Equipment economizer board - analog inputs (Continued)

Smart Equipment economizer board - LED details

Smart Equipment economizer board - SA bus details

Smart Equipment economizer board - analog outputs

Smart Equipment economizer board - binary outputs

Smart Equipment economizer board - 24 V~ IN connections

Smart Equipment economizer board - binary inputs

Indoor air quality

IAQ regulated by indoor sensor input; connects to economizer board.

Phasing

Blower rotation

Adjusting the belt tension

CFM static pressure and power-altitude and temperature corrections

Drive selection

Airflow performance

ZVT06 (6.5 Ton) side duct

Airflow performance table.

ZVT07 (7.5 Ton) side duct

Airflow performance table.

ZVT08 (8.5 Ton) side duct

ZVT10 (10 Ton) side duct

ZVT12 (12.5 Ton) side duct

ZVT06 (6.5 Ton) bottom duct

ZVT07 (7.5 Ton) bottom duct

ZVT08 (8.5 Ton) bottom duct

ZVT10 (10 Ton) bottom duct

ZVT12 (12.5 Ton) bottom duct

Air balance

Checking air quantity

Method one

Steps for checking air quantity using manometer.

Method two

Steps for checking air quantity using holes in ducts.

Supply air drive adjustment

Example

Example calculation for required DD.

Additional static resistance - ZVT06 through T12

Operation

Cooling operation

Describes Y1, Y2, Y3 calls and their impact on components.

Free cooling operation with economizer

Operation when outside air is suitable for free cooling.

Economizer with single enthalpy sensor

Operation with single enthalpy sensor.

Economizer with dual enthalpy sensors

Operation with dual enthalpy sensors.

Economizer with power exhaust

Operation with economizer and power exhaust.

Motorized outdoor air dampers

Operation of motorized outdoor air dampers.

Cooling Operation Errors

High-pressure limit switch

What happens when high-pressure limit switch opens.

Low-pressure limit switch

What happens when low-pressure limit switch opens.

Evaporator low limit

Protects against low evaporator temperatures.

Low ambient cooling

Safety controls

Compressor protection

Inherent protection for compressors against abnormal temperature rise.

Reheat mode sequence of operation

Normal occupied operation mode

Operation based on return humidity and cooling demand.

Normal cooling mode

Unit operation during first, second, and third stage cooling.

Normal reheat mode

Unit operates with reheat coil and condenser coil.

Alternate mode

Operation based on return humidity and cooling/dehumidification demand.

Optional aux mode

Electric heating sequence of operations

Two-stage heating

Operation for first and second stage heat calls.

Electric heat operation errors

Errors related to temperature limit and safety controls.

Reset

Electric heat anticipator setpoints

Gas heating sequence of operations

First stage of heating

Ignition sequence for first stage heat.

Second stage of heating

Retry operation

Gas heating operation errors

Lockout

One-hour lockout occurs after three retries or five recycles.

Temperature limit

Monitors high temperature limit for gas heat units.

Flame sense

Gas valve

Safety controls

Limit switch

Shuts down heater if high temp condition occurs.

Auxiliary limit switch

Pressure switch

Roll-out switch

Internal microprocessor failure

Flash codes

Resets

Gas heat anticipator setpoints

Cooling start-up

Pre-start checklist

Checks before starting the cooling system.

Operating the unit

Steps to operate the unit after pre-start checks.

Post-start checklist

Checks after the unit has started.

Gas heat start-up

Pre-start checklist

Checks before starting the gas heating system.

Lighting the main burners

Post-start checklist

Shutting down the unit

Checking gas heat input

Determining the rate of gas flow (second stage)

Measures gas consumption for second stage heat.

Determining the rate of gas flow (first stage)

Measures gas consumption for first stage heat.

Calculating the cubic feet of gas consumed per hour

Adjusting the manifold gas pressure

Adjusting the temperature rise

Measures temperature difference between return and heated air.

Inspecting and servicing burners and orifices

Navigation components for the Smart Equipment control board

Smart Equipment unit control board

Smart Equipment UCB - thermostat connection strip

Describes thermostat connections and their functions.

Smart Equipment UCB - limit, 24 VAC power, and shutdown connections

Smart Equipment UCB - space temperature sensor connections

Smart Equipment UCB - temperature sensor connections

Smart Equipment UCB - temperature sensor connections (Continued)

Smart Equipment UCB - pinned connections

Smart Equipment UCB - USB connector

Smart Equipment UCB - 24 V terminal

Smart Equipment UCB - refrigerant circuit safety switch and indoor blower overload connections

Smart Equipment UCB - refrigerant circuit safety switch and indoor blower overload connections (Continued)

Smart Equipment UCB - SA BUS¹ connections

Smart Equipment UCB - user interface

Smart Equipment UCB - LEDs

Smart Equipment UCB - optional communication sub-board

Start-up sheet

START-UP CHECKLIST

Checklist for initial equipment setup and data recording.

WARRANTY STATEMENT

Details warranty coverage and claim procedures.

EQUIPMENT STARTUP

Instructions on using LCD or MAP Gateway for startup.

SAFETY WARNINGS

DESIGN APPLICATION INFORMATION

REFERENCE

Operating Measurements - Air Flow

ELECTRICAL DATA

Records nameplate and measured electrical data.

OPERATING MEASUREMENTS - COOLING

REFRIGERANT SAFETIES

Checks for proper refrigerant safety operation.

OPERATING MEASUREMENTS - GAS HEATING

Prove Smoke Detector Operation

Verification of smoke detector functionality.

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

FINAL - INSPECTION

Final checks on setpoints, options, panels, and backup file.

OBSERVED PRODUCT DEFICIENCIES & CONCERNS:

TempMaster ZV Series Specifications

General

Refrigerant	R410A
Type	Split System
Power Supply	220-240V, 50Hz
Noise Level (Outdoor)	50 dB
Weight (Outdoor Unit)	35 kg