Vortex ZC24L Originalbetriebsanleitung
Owner’s Manual &
Installation Instructions
Zone Comfort
hot water air handler
and zoned distribution system
with iStat6 electronic controller for 2 to 4 zones
Vortex Source Systems
4 Cowansview Rd.
Cambridge, Ontario
N1R 7L2
Phone: 888-781-81 1
Fax: 888-670-2 44
info@vortexsource.com
www.vortexsource.com
Page 2 ZC-KI6-VSS1707
Table of Contents
CHECKLIST FOR THE INSTALLER .................................................................................................................. 3
TYPICAL PLUMBING CONNECTIONS ............................................................................................................. 4
ELECTRICAL WIRING DIAGRAM – 4 ZONE COMPLETE................................................................................. 5
ELECTRICAL WIRING DIAGRAM – 4 ZONE BASE ........................................................................................... 7
EQUIPMENT SPECIFICATIONS AND SIZING TABLES ................................................................................ 8
INTRODUCTION ....................................................................................................................................................
HOW IT WORKS.....................................................................................................................................................
Zone One ................................................................................................................................................................. 9
Off ......................................................................................................................................................................... 10
Heating .................................................................................................................................................................. 10
Cooling.................................................................................................................................................................. 10
Continuous Fan ..................................................................................................................................................... 10
Features ................................................................................................................................................................. 10
Evaporator Coil Freeze Protection........................................................................................................................ 10
PRODUCT DESCRIPTION .................................................................................................................................. 10
Cabinet .................................................................................................................................................................. 11
Heating coils ......................................................................................................................................................... 11
Fan and Motor ....................................................................................................................................................... 11
Circulating pu p .................................................................................................................................................. 11
Check Valve .......................................................................................................................................................... 11
EQUIPMENT SIZING AND SELECTION ......................................................................................................... 12
Procedure .............................................................................................................................................................. 12
Heat Loss / Heat Gain ........................................................................................................................................... 12
Air Handler Selection ........................................................................................................................................... 12
Define Zones ......................................................................................................................................................... 12
INSTALLATION ................................................................................................................................................... 13
Air Handler Mounting .......................................................................................................................................... 13
Ductwork .............................................................................................................................................................. 13
Risk of Freezing .................................................................................................................................................... 14
ELECTRICAL ........................................................................................................................................................ 14
Ther ostat ............................................................................................................................................................ 14
Heat Anticipator Setting ....................................................................................................................................... 15
Dehu idistat ......................................................................................................................................................... 15
START-UP PROCEDURE .................................................................................................................................... 16
SERVICE AND MAINTENANCE........................................................................................................................ 16
Filter ...................................................................................................................................................................... 16
Duct cleaning ........................................................................................................................................................ 16
Coils ...................................................................................................................................................................... 16
Air conditioning coil ............................................................................................................................................. 16
Fan and otor ....................................................................................................................................................... 16
Pu p ..................................................................................................................................................................... 17
TROUBLESHOOTING ......................................................................................................................................... 17
Page 3 ZC-KI6-VSS1707
CHECKLIST FOR THE INSTALLER
A Qu ck Check L st
Are the water connections to the water heater oriented in a way to avoid
trapping air in the heating circuit? (see diagram on next page)
Is the purge valve installed on the return water line from the air handler
upstream from the isolation valve?
Is the air handler hung and isolated to avoid transmitting vibration through
framing and duct work?
Are the isolation valves full-port? Restrictive valves will limit performance.
Is outdoor cooling unit contactor wired according to the wiring diagram?
Are Thermostat connections correct, including cooling and continuous run
connections? Do they operate their intended zone?
Have the packing materials been removed from the blower?
Is there an installation manual and controls user manual for the home owner ?
Is the unit accessible? Are there clearances for service and component
replacement?
Is the return duct/drop acoustically lined ? (recommend lining at least 6 ft. of
the return duct/drop)
Is the filter cover in place? Is a clean filter in place?
Has the electronic controller been properly configured as per instructions in the
controls user manual?
Page 4 ZC-KI6-VSS1707
TYPICAL PLUMBING CONNECTIONS
Page 8 ZC-KI6_VSS1709
EQUIPMENT SPECIFICATIONS AND SIZING TABLES
REFER TO Small-D des gn Gu de for add t onal duct s z ng opt ons.
TABLE 1 - A r Handler Select on Table
Model ZC24L
ZCT24L
ZC30L
ZCT30L
ZC36L
ZCT36L
ZC42L
ZCT42L
ZC48L
ZCT48L
ZC60L
ZCT60L ZC100
Min. 4” Branches per Zone 6 8 9 11 12 1 1
Min. 14”x8” Return Air Grilles 7 8 8 9 10 11
Heating Capacity
1
(Btu/h)@130ºF 0,000 8,000 6 ,000 6 ,000 69,000 73,000 91,000
Heating Capacity
1
(Btu/h)@140ºF 4,000 63,000 70,000 70,000 7 ,000 80,000 106,000
Heating Capacity
1
(Btu/h)@160ºF 66,000 80,000 90,000 90,000 97,000 103,000 13 ,000
Heating Capacity
1
(Btu/h)@180ºF 81,000 99,000 110,000 110,000
117,000 12 ,000 164,000
Air flow rate at full heating
(cfm) 1000 1200 1400 1400 1600 1800 2000
Max. Ext. Static Pressure (“wc)
1.3 0.6 1.1 1.1 1.2 0.7 0.8
USGPM Heating 6 6 6 6 6 6 10
Cooling Capacity 2,3 (Tons) 2.0 2. 3.0 3. 4.0 .0 .0
Blower Motor Full Load
(Amps) . . 7.7 7.7 9.6 9.6 9.6
Circulator Full Load (Amps) 0.8 0.8 0.8 0.8 0.8 0.8 1.4
Cabinet Width (in.) 22 22 22 22 22 22 22
Cabinet Depth (in.) 2 2 2 2 2 2 2
Cabinet Height (in.)
(Regular ZC) 44 44 44 44 44 44 6
Cabinet Height (in.)
(Tall ZCT) 6 6 6 6 6 6 N/A
Supply Air ( per Zone) 8”Φ 8”Φ 8”Φ 10”Φ 10”Φ 10”Φ 10”Φ
Return air (in.) 18x23 18x23 18x23 18x23 18x23 18x23 18x23
Supply and Return Water
Connections (in.) 3/4 3/4 3/4 3/4 3/4 3/4 1
Weight-air handler only
(pounds) 1 0 1 0 1 170 17 17 200
1. capacity based on 70ºF return air, high speed and 12. feet length per branch at 4”
diameter. Two 3” branches = one 4”, two 4” = one 6”. Do not exceed grille rating. Higher
static pressure/reduced heating capacity available at lower airflow.
2. Regular ZC requires external cooling coil (extra) in the return air duct.
3. Tall ZCT can use cooling A-coil supplied by others. Cabinet opening is 20W x 24D x 21H.
Page 9 ZC-KI6-VSS1709
INTRODUCTION
The Zone Comfort system is a heating
and cooling system that enhances
comfort and improves efficiency by giving
more control over the distribution of
conditioned air. Homeowners enjoy
many benefits such as healthy indoor air,
comfortable basements and cool
summer evenings. Multiple thermostats
provide the means to zone the home by
section or level in order to gain more
control. This will virtually eliminate over
or under conditioned spaces as is
common in a lot of homes today.
The Zone Comfort system is designed
for use in hydronic (boiler) systems or
combination space and water heating
systems (Combo Systems). Combo
heating systems use the home’s water
heater to provide both the space heating
and domestic hot water, eliminating the
need for a furnace. The equipment can
be configured for heating only, heating
and cooling or cooling only applications.
Contact Vortex for Zone Comfort
systems to be connected to a heat pump.
The Zone Comfort duct system can be
much smaller than conventional ducting
making it ideal for retrofit applications or
where a conventional duct system would
result in unsightly bulkheads and wasted
space.
When used as the warm air distributor of
a boiler heating system the Zone
Comfort air system can provide
warmer more comfortable air
temperature than a gas furnace with less
noise and much smaller duct
requirements. This is ideal for large
custom homes where a premium heating
product is required that is quiet,
comfortable and out of sight.
Controls usage and settings are covered
in a separate document.
HOW IT WORKS
The key to the Zone Comfort system is
the level of comfort and efficiency
provided by the unique control system.
Zone dampers in the air handler operate
to increase or decrease the capacity in
each zone of the house as needed.
Heating and cooling air flow for each
zone can be set by the installer to
customize every installation.
Cooling mode uses a fixed or automatic
strategy to maximize homeowner
comfort. In auto mode, blower speed is
carefully controlled to optimize
dehumidification. When cooling demand
is low (determined based on the number
of zones calling or on the measured
supply air temperature) the blower runs a
little slower. The air has more residence
time in the evaporator coil. This results
in removing more moisture from the air,
thus maintaining the humidity in an
optimum range.
Zone One
The primary or master or zone one tells
the air handler whether it is heating
season or cooling season or if
continuous air circulation is desired. Any
zone can be zone one but it is typically
Page 10 ZC-KI6_VSS1709
the main area of the building (living
area).
Additional zones act as slaves to the
primary zone. The pr mary zone must
call for heat ng or cool ng at least
once (a short, 5 second call s
adequate) at the beg nn ng of the
season to tell the Zone Comfort a r
handler that t s n heat ng mode or
cool ng mode. The sw tch on the
pr mary thermostat s not enough!
Until this happens, a call on zone two,
three or four is ignored.
Off
All zone dampers are open if there is no
call for heating or cooling or power is off.
Heating
When a thermostat calls for heating, the
internal pump starts and the boiler is
activated (if connected to TT). The zone
damper for any zone not requiring heat
closes. The fan will gradually ramp up to
the programmed speed for the given
zone.
Cooling
When a thermostat calls for cooling, the
outdoor air conditioning (AC) condenser
is activated. The zone damper for any
zone not requiring cooling closes. Fan
speed can be controlled based on
number of zones calling and their
programmed cooling loads, or on
measured supply air temperature. Two-
stage a r cond t oners are strongly
recommended as a means of
mprov ng eff c ency, lower ng fan
speed for s ngle zone calls and more
closely match ng AC output to the
home’s cool ng requ rements.
Continuous Fan
When the thermostat fan switch for the
primary zone is set to continuous fan, the
fan will run at the set speed for all zones.
When there is a call for heating or
cooling, the normal heating or cooling
speed will over-ride the continuous fan
setting. Zones not requiring heating or
cooling will close. Once the thermostat is
satisfied, continuous fan speed will
resume.
Features
Vortex air handlers offer many unique
features that set them apart from the
competition:
Soft Start is a feature that starts the fan
slowly and quietly rather than a large
“thump” common in some furnaces and
air handlers.
Evaporator Coil Freeze Protection
If the evaporator coil air temperature
drops outside of the expected operating
range this indicates a potential
evaporator coil freeze condition. Coil
freezing can lead to slugging (liquid
refrigerant going back to the compressor)
which will damage the compressor. All
Zone Comforts come equipped with a
sensor and controller which will respond
by shutting off the outdoor cooling unit to
allow the system to warm up. Note that
this freeze condition is not normal and
may indicate blocked ducts, dirty filter or
an over-sized cooling unit.
PRODUCT DESCRIPTION
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