ez zone · the york international corporation’s ez zone controls system was first introduced in...

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EZ ZoneEZ ZoneEZ ZoneEZ ZoneEZ Zone

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8500 NW River Park Drive • Parkville , MO 64152PH: (816) 505-1100 • FX: (816) 505-1101 • E-mail: [email protected] our website at www.wattmaster.comForm: 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 ContentsIntroduction ........................................................................................................................................ 4EZ Zone Upgrade Overview .............................................................................................................. 5Component Descriptions .................................................................................................................... 6Upgrade Package Selection ................................................................................................................ 7Example #1 - EZ Zone Stand Alone To AZ Basic ..................................................................... 8 & 9Example #2 - EZ Zone Stand Alone To AZ Plus................................................................... 10 & 11Example #3 - Networked EZ Zone To AZ Plus ..................................................................... 12 & 13Optional Controllers And Accessories ................................................................................... 14 & 15EZ Zone Wiring ................................................................................................................................ 16Auto-Zone Basic Wiring .................................................................................................................. 17Auto-Zone Plus Wiring .................................................................................................................... 18Auto-Zone Plus Address Switches ................................................................................................... 19HVAC Staging Connections ............................................................................................................. 20Sensor Connections .......................................................................................................................... 21Bypass Damper Connections ........................................................................................................... 22Honeywell Economizer Actuators ................................................................................................... 23System Manager Installation ........................................................................................................... 24CommLink II Installation ................................................................................................................ 25Modem Linc Central EPROM Replacement ................................................................................ 26Master Interface EPROM Replacement ........................................................................................ 27Zone Controller EPROM Replacement.......................................................................................... 28EPROM Installation Procedures..................................................................................................... 29Ribbon Cable Installation ................................................................................................................ 30Upgrade Parts List Summary .......................................................................................................... 31Additional Information .................................................................................................................... 32

Table of FiguresFigure 1: Existing EZ Zone Master Controller Wiring ................................................................ 16Figure 2: New Auto-Zone Basic Controller Wiring ...................................................................... 17Figure 3: Existing Auto-Zone Plus Controller Wiring .................................................................. 18Figure 4: New Auto-Zone Plus Address Switch Setting ................................................................ 19Figure 5: Existing EZ Zone HVAC Wiring .................................................................................... 20Figure 6: New Auto-Zone HVAC Wiring ....................................................................................... 20Figure 7: Existing EZ Zone Master Controller Sensor Wiring .................................................... 21Figure 8: New AZ Zone Manager Sensor Wiring.......................................................................... 21Figure 9: Existing EZ Zone Bypass Damper Wiring .................................................................... 22Figure 10: New Auto-Zone Bypass Damper Wiring...................................................................... 22Figure 11: Honeywell Economizer Actuators Wiring Information.............................................. 23Figure 12: System Manager Wiring ................................................................................................ 24Figure 13: CommLink II Wiring ..................................................................................................... 25Figure 14: EZ Zone Modem Linc Central EPROM Location ...................................................... 26Figure 15: EZ Zone Master Interface Board EPROM Location ................................................. 27Figure 16: EZ Zone Zone Controller EPROM Location .............................................................. 28Figure 17: EPROM Removal & Installation .................................................................................. 29Figure 18: 3 Connector Ribbon Cable Installation ....................................................................... 30

EZ Zone/Auto-Zone

4 Upgrade

The York International Corporation’s EZ Zone ControlsSystem was first introduced in the early nineties. TheEZ Zone Controls System was designed for York, byWattMaster Controls, as a simple zone control systemfor York’s line of commercial unitary roof top and splitsystem HVAC units. Since its original design and in-troduction, the York EZ Zone Control System haschanged very little.

Introduction

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The Auto-Zone Controls System was created from theoriginal EZ Zone Control System concept by redesign-ing, enhancing and expanding the original systems ca-pabilities under the new Auto-Zone Controls Systemname.

WattMaster’s Auto-Zone Control Systems have contin-ued in the York EZ Zone tradition of keeping the con-trols simple to install and use while enhancing the sys-tem to make it more applicable and in line with the needsof the current marketplace. In addition to offering anexcellent control system for zoning applications, theAuto-Zone Control System has been expanded to al-low control of multiple single zone constant volumeunits and other devices such as lighting, exhaust fans,and unit heaters.

Upgrading your EZ Zone system to the Auto-Zone Con-trols system allows you and your customer to take ad-vantage of the many improvements that have been madein the Auto-Zone Controls system without having toreplace all the EZ Zone system components that areinstalled on your job.

This guide is intended to provide you with simpleinstructions on upgrading an existing EZ Zone systemto an Auto-Zone Control System.

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EZ Zone/Auto-Zone

Upgrade 5

The basic steps required to upgrade your EZZone system to an Auto-Zone system are:

Determine what EZ Zone componentsare currently installed on the system.

Replace the existing EZ-Zone MasterController board with an Auto-ZoneZone Manager controller board

Replace the existing EZ ZoneEPROM’s in each Zone Controllerwith a new Auto-Zone EPROM.

Install return air and outside airtemperature sensors

EZ Zone to Auto-Zone upgrade allows you toretain:

All existing wiring

Master Controller enclosure withkeypad and display

Existing supply air and static pressuresensors

Existing bypass damper

All Zone Dampers

* All Zone Controllers

Room sensors

* Modem Link Central

* All Master Interface Boards

All Fan Terminal Controllers

EZ Zone Upgrade Overview

After upgrading your system from EZ Zone toAuto-Zone, you will be able to take advantageof many new enhancements including:

Damper actuators can be programmedfor direct or reverse operation

Full modulating economizer controlcapability including optional wetbulbeconomizer control

Outside air temperature sensor provideslockout function for both heating andcooling. When converted to Auto-ZonePlus system only one outside air sensoris required for the entire system

Contact closure input for dirty filterstatus

Global and individual zone overridemodes

Zones can be set for voting ornonvoting status

Room sensor slide can be programmed ± 0° F to ± 5° F adjustmentfrom setpoint

Staging delays, minimum off times,and changeover intervals areprogrammable

Sensor offset calibration to correctsensor errors due to poor location

ZoneView enhanced graphical computerfront end software available whenCommLink and a PC are used

System Manager operator interfaceallows all controllers to be accessed fromone central location

* These controllers can be retained but they will re-quire an EPROM chip upgrade to be compatiblewith the Auto-Zone System.

EZ Zone/Auto-Zone

6 Upgrade

Component Descriptions

The general architecture of the EZ Zone and the Auto-Zone Systems are very similar making the upgrade pro-cess relatively easy.

There are some changes in the component descriptionsbetween the EZ Zone system and the Auto-Zone sys-tem. It is important to understand these differencesbefore you begin the upgrade process.

Many of these components look similar, however, insome cases they do not function in an identical fashion.Having the wrong component installed can cause im-proper system operation.

The chart below depicts the difference in descriptionsfor the various comparable system components in theEZ Zone and Auto-Zone Systems.

Master Controller Zone Manager

Fan TerminalController

Master Interface BoardMiniLink

CommunicationsInterface

Modem Linc Central CommLink II

Zone Controller Zone Controller

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Board

Must Be Replaced Improved Hardware & Software

Replacement Not Required

EPROM Replacement Required



Same As Existing Fan Terminal Controller

Improved Software

Improved Software

Improved Software

EZ Zone/Auto-Zone

Upgrade 7

Upgrade Package Selection

There are basically 3 possible EZ Zone to Auto-Zoneupgrade scenarios you may encounter. We have out-lined these below to assist you in deciding which op-tion is best for your application.

Please see the Auto-Zone upgrade selection chart be-low to help determine which example best fits yourneeds.

Upgrade A Simple EZ Zone Stand AloneSystem(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 MasterControllers

• No Central Display Or Computer Interface Is Desired

See Example #1On

Pages 8 & 9

See Example #2On

Pages 10 & 11

See Example #3On

Pages 12 & 13

Upgrade A Simple EZ Zone Stand AloneSystem(s) To The Auto-Zone Plus System• Two Or More Existing Master Controllers On The Job.

• No Communications Cable Between Existing MasterControllers

• The Customer Wants To Connect The MasterControllers So That They Are Part Of A NetworkedSystem And/Or Install Constant Volume UnitControllers Or Other Controller Boards On TheirSystem

Upgrade A Networked EZ Zone System ToThe 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 VolumeUnit Controllers Or Other Controller Boards To TheirSystem

EZ Zone/Auto-Zone

8 Upgrade

Example #1:Your project has a single EZ Zone Master Panel andit’s associated Zone Controllers. This is a typical EZZone system. The upgrade will essentially convert thisto an Auto-Zone Basic System. Please see the requiredupgrade components to be ordered in the list below.

To upgrade your existing EZ Zone System to the Auto-Zone Basic System the following procedure will be re-quired.

Warning: All removal and installation proceduresmust be done with the power to the controllersturned off. Failure to do so can cause severe dam-age to the controller boards.

1) All power and input/output wiring will need to bedisconnected from the board. Remove the enclosurecover and disconnect the keypad & display cable byunplugging the cable connector at the board connec-tion.

2) The new Return Air Sensor should be installed inthe return air stream in a location upstream of the pointthat the bypass duct connects to the return duct.

3) Install the new Outdoor Air Sensor in a location onthe exterior of the building that provides shade and pro-

tection from the weather. See the mounting instructionsincluded with the sensor for detailed mounting instruc-tions.

4) Remove the existing EZ Zone Master ControllerBoard from the EZ Zone enclosure. This will requirethe removal of 4 screws securing the board to the en-closure base.

5) Install the new Zone Manager board onto the exist-ing enclosure base. The new board installation requires6 plastic standoffs be inserted between the back of thenew board and the existing standoffs. Secure the boardto 4 of the threaded standoffs (one in each corner of theboard) with the mounting screws provided.

6) Connect the input, output and power wiring per theAuto-Zone Basic wiring diagram (See Figure 2 on page17). Connect the keypad display connector of the exist-ing EZ Zone enclosure cover to the new Auto-Zone ZoneManager board and secure the existing enclosure coverto the enclosure base with the existing screws.

7) Remove and replace each EPROM on all the exist-ing EZ-Zone Zone Controllers. See Figures 16 & 17 onpages 28 & 29 for detailed EPROM Replacement in-formation.

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)

Note: When ordering be sure to specify Fahrenheit or Celsius operation for your system

For optional components list and information see pages 14 & 15 of this manual.

EZ Zone/Auto-Zone

Upgrade 9

EZ Zone Stand Alone to AZ Basic

Zone Air DampersUp to 16 Zone Air Dampers Allowed

SupplyAir TempSensor

To HVAC UnitControl Panel

MasterController

Bypass AirDamper

StaticPressureSensor

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ReturnAir TempSensor

OutsideAir TempSensor

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Upgraded System

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EZ Zone/Auto-Zone

10 Upgrade

Example #2:Your project has multiple EZ Zone Master Panels andtheir associated Zone Controllers. This upgrade willconvert this to an Auto-Zone Plus System.

To upgrade your existing EZ Zone System to the Auto-Zone Plus System the following procedures will berequired.


1) All power and input/output wiring will need to bedisconnected from the existing Master Controller board.Disconnect the keypad & display cable from the boardby unplugging its connector from the board and the dis-play on the existing enclosure cover.


3) Install the new Outdoor Air Sensor in a location onthe exterior of the building that provides shade andprotection from the weather. Only one OA sensor isrequired for the entire system. See the mounting instruc-tions included with the sensor for detailed mountinginstructions.

4) Connect the CommLink to the network communica-

tions loop and wire in 24VAC power (See Figure 13 onpage 25).

5) Remove the existing EZ Zone Master ControllerBoard from the EZ Zone enclosure. This will requirethe removal of 4 screws securing the board to the en-closure base.

6) Install the new Zone Manager board onto the exist-ing enclosure base. The MiniLink should then bemounted to the Zone Manager board using the stand-offs and screws included with the MiniLink. The newZone Manager board installation requires 6 plasticstandoffs be inserted between the back of the new boardand the existing standoffs. Secure the board to 4 of thethreaded standoffs (one in each corner of the board)with the screws that were included with the new ZoneManager board.

7) Connect the input, output and power wiring per theAuto-Zone Plus wiring diagram (See Figure 3 on page18). Connect the new 3 Connector Ribbon Cable key-pad display connector to the existing EZ Zone enclo-sure cover and to the new Auto-Zone Zone Managerboard (See Figure 18 on page 30). Secure the existingenclosure cover to the enclosure base with the existingscrews.


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)



EZ Zone/Auto-Zone

Upgrade 11

EZ Zone Stand Alone to AZ Plus

Zone Air Dampers

Zone Air Dampers

Up to 16 Zone Air Dampers Allowed






MasterController

MasterController

Bypass AirDamper

Bypass AirDamper



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Zone Air Dampers

Zone Air Dampers





To Other Zone Managers(Up to 30 Allowed On System)


Network Loop

Network Loop

Local Loop

Zone Manager

Zone Manager


Bypass AirDamper

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Only One OASensor IsRequiredFor EntireSystem

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SystemManager

(Optional If Computer Front End Used)

Other Controllers(Optional - Up to 13 On Each Loop))

Upgraded System

Existing System

EZ Zone/Auto-Zone

12 Upgrade

Example #3:Your project has a Networked EZ Zone System that youwant to convert to the Auto-Zone Plus system. Pleasesee the required upgrade components list below for thenecessary parts to be ordered.

To upgrade your existing Networked EZ Zone Systemto the Auto-Zone Plus System the following procedureswill be required.


1) All power and input/output wiring will need to bedisconnected from the existing Master Controller board.Disconnect the keypad & display cable from the boardby unplugging its connector from the board.


3) Install the new Outdoor Air Sensor in a location onthe exterior of the building that provides shade andprotection from the weather. Only one OA sensor isrequired for the entire system. See the mounting instruc-tions included with the sensor for detailed mountinginstructions.

4) Take the cover off of the Modem Link Central, re-move the old EPROM and replace with the newCommLink EPROM. See Figures 14 & 17 on pages 25

& 27 for detailed EPROM installation instructions.

5) Remove the existing EZ Zone Master ControllerBoard from the EZ Zone enclosure. This will requirethe removal of 4 screws securing the board to the en-closure base. Remove the existing Master InterfaceBoard from the old Master Controller board. Removethe old EPROM from the Master Interface board andinstall the new MiniLink upgrade EPROM to the Mas-ter Interface board. See Figures 15 & 17 on pages 26 &27 for detailed EPROM installation instructions.

6) Install the upgraded Master Interface board to thenew Zone Manager board using the existing mountinghardware. Install the new Zone Manager board onto theexisting enclosure base. The new Zone Manager boardinstallation requires 6 plastic standoffs be inserted be-tween the back of the new board and the existing stand-offs. Secure the board to 4 of the threaded standoffs(one in each corner of the board) with the screws thatwere included with the new Zone Manager board.

7) Connect the input, output and power wiring per theAuto-Zone Plus wiring diagram (See Figure 3 on page18). Connect the existing 3 Connector Ribbon Cablekeypad display connector to the existing EZ Zone en-closure cover and to the new Auto-Zone Zone Managerboard (See Figure 18 on page 30). Secure the existingenclosure cover to the enclosure base with the existingscrews.


To Upgrade To The Auto-Zone Plus System Order the Following:(X) (OE751) EZ Zone to AZ Basic Upgrade Kit (One Required Per Existing Master Controller)

(Includes: Zone Manager Board w/ Mounting Screws, Plastic Standoff Kit for Zone Manager,Return Air Sensor, Upgrade Label, Installation Instructions)

(1) (OE755) Modem Link Central to CommLink II Upgrade Kit(Includes: ComLink EPROM Upgrade Chip, Upgrade Label)

(1) (OE754) Master Interface Board to MiniLink Upgrade Kit(Includes: MiniLink EPROM Upgrade Chip, Upgrade Label)

(1) OE250 Outside Air Sensor (Only One Required Per 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)



EZ Zone/Auto-Zone

Upgrade 13

Networked EZ Zone To AZ Plus

Zone Air Dampers

Zone Air Dampers





To Other Master Controllers(Up to 30 Allowed On System)


Network Loop

Network Loop

Local Loop


Bypass AirDamper

Bypass AirDamper



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COO

L1

COO

L2

HEAT1

HEAT2

BYPASSO

PEN

BYPASSCLO

SE

COM

MUNIC

ATION

ALARM

A=

ALLZO

NES

B=

EACHZO

NE

C=

HVACUNIT

/CLEAR

D=

ALARMS

#=

STEP/ENTER

* =DECIM

AL

+

+

+

+

Meridian

COOL

MODE

04-08-96

03:48PMFRI

OCCUPIED

NOALARMS

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

YO

RK

MasterController

MasterController

Zone Air Dampers

Zone Air Dampers





To OtherZone Managers(Up to 30 Allowed On System)


Network Loop

Network Loop

Local Loop


Bypass AirDamper

Bypass AirDamper



#1

#1

#16

#16

8

9

7

4

5

6

3

2

1

#

0*

Modem(Optional)

UpgradedModem Link Central

24VAC

24VAC

W

C

LI

ATTMASTER

ONTRO

S,NC

CO

MM

LINK

II

CO

MM

LINK

II

L

C

M

M

O

O

O

O

M

D

P

PE

Computer(Optional)

Telephone Line

FAN

COO

L1

COO

L2

HEAT1

HEAT2

BYPASSO

PEN

BYPASSCLO

SE

COM

MUNIC

ATION

ALARM

A=

ALLZO

NES

B=

EACHZO

NE

C=

HVACUNIT

/CLEAR

D=

ALARMS

#=

STEP/ENTER

* =DECIM

AL

+

+

+

+

Meridian

COOL

MODE

04-08-96

03:48PMFRI

OCCUPIED

NOALARMS

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

YO

RK

FAN

COO

L1

COO

L2

HEAT1

HEAT2

BYPASSO

PEN

BYPASSCLO

SE

COM

MUNIC

ATION

ALARM

A=

ALLZO

NES

B=

EACHZO

NE

C=

HVACUNIT

/CLEAR

D=

ALARMS

#=

STEP/ENTER

* =DECIM

AL

+

+

+

+

Meridian

COOL

MODE

04-08-96

03:48PMFRI

OCCUPIED

NOALARMS

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

YO

RK

ZoneManager

ZoneManager




Only One OASensor IsRequiredFor EntireSystem

1

4

2

5

3

6

9

8

07

Enter

Esc

*

Min

us

Menu

Cle

ar

Dec.

Ala

rm

Com

munic

ation

Overr

ide

MANAGER

SYSTEM

Auto-Z

onePlus

01/01/9

703:3

8PMW

ED

OCCUPIED

NOALARM

S

SystemManager

(Optional If Computer Front End Used)

Other Controllers(Optional - Up to 13 On Each Loop))

Upgraded System

Existing System

EZ Zone/Auto-Zone

14 Upgrade

Optional Controllers and Accessories

In addition to the standard Zone Manager and ZoneControllers, WattMaster offers many other controllersand accessories to enhance your new Auto-Zone Sys-tem. Optional Controllers that are available for use withthe Auto-Zone Plus system include the CV, CV-C, GPC,Optimal Start Scheduler, Lighting Panel Controller andWetbulb Module. These controllers are not availablefor use with the Auto-Zone Basic System. To utilizeany of the optional controllers you must upgrade yoursystem to the Auto-Zone Plus configuration. Accesso-

ries that are available for use with either the Auto-ZonePlus or Basic System include the CommLink II Com-munications Interface, Remote Link, Room Sensors,Round Zone Dampers and Rectangular Zone Dampers.WattMaster also offers Communication Cable that iscolor coded and labeled for the network communica-tions loop and local communications loop.

Following are brief descriptions of the optional con-trollers and accessories that are available.

CV Controller

The CV Controller provides control of single zone con-stant volume rooftop or split system HVAC equipment.CV controllers have four configurable relay outputs forheating/cooling staging, a 0-10VDC output for econo-mizer control, on board time clock for scheduling/nightsetback functions and built in alarming features.The CV Controller can be used with the Auto Zone

Plus System only. The CV can be programmed andmonitored from the either the System Manager or froma personal computer which has the ZoneView Com-puter front end software installed. Up to 13 CV con-trollers can be installed on each local communicationsloop of your Auto-Zone Plus system.

CV-C Controller

The CV-C Controller is a field configurable constantvolume unit controller that provides additional featureswhich are not available with the standard CV control-ler. CV-C controllers can be configured for applicationsrequiring CO2/IAQ economizer control, modulating HWand CW control valves and dehumidification. The CV-C relay outputs can be expanded via a plug-in expan-sion board for use in applications requiring additionalheating/cooling staging control.

The CV-C Controller can be used with the Auto-ZonePlus System only. The System Manager cannot be usedto program or monitor the CV-C controller. CV-C con-trollers require that a personal computer which has theZoneView computer front end software installed be usedfor all programming and monitoring. Up to 13 CV-Ccontrollers can be installed on each local communica-tions loop of your Auto-Zone Plus system.

GPC ControllerThe GPC (General Purpose Controller) is a very versa-tile controller that can be used for a variety of controlapplications that are outside the function of our stan-dard HVAC unit controllers. Each GPC controller has(5) Universal Inputs that can accept contact closures,thermistor temperature sensors, or 4-20mA/2-10VDCsignals. The controller has (5) digital outputs for on/offcontrol and (1) 0-10VDC analog output to modulate avalve or damper. These inputs and outputs can be con-figured in a variety of ways using And/Or logic func-tions, time schedules, setpoints, etc. to perform manydifferent tasks.

The GPC can be used for many applications including,but not limited to:

• Control of Unit Heaters• Control of Boilers• Control of Exhaust Fans• Monitoring of Temperature• Monitoring of Humidity• Monitoring of Status Contacts

The GPC Controller can be used with the Auto-ZonePlus System only. The System Manager cannot be usedto program or monitor the GPC controller. GPC con-trollers require that a personal computer which has theZoneView computer front end software installed be usedfor all programming and monitoring.

EZ Zone/Auto-Zone

Upgrade 15

Lighting Panel ControllerAdds building lighting control capability to the Auto-Zone System. The Lighting Panel Controller providesup to (7) Independent time schedules and light levelsfor control of up to (7) lighting circuits. The LightingPanel Controller relay outputs can be set for on/off re-lay or pulsed relay control depending on the lightingsystem control contactor requirements. Pushbutton over-ride is available for each lighting circuit by connectinga momentary pushbutton to the Lighting Panel Con-troller board.

The Lighting Panel Controller can be used with the AutoZone Plus System only. The System Manager cannotbe used to program or monitor the Lighting Panel Con-troller. Light Panel Controllers require that a personalcomputer which has the ZoneView computer front endsoftware installed be used for all programming andmonitoring.

Optimal Start SchedulerProvides expanded scheduling capabilities beyond thoseincorporated with the standard Auto-Zone controllers.The Optimal Start Scheduler provides for optimalStart/Stop and up to (7) independent schedules with 2Start/Stop events per day and (14) Start/Stop holidayevents per schedule.

The Optimal Start Scheduler can be used with the AutoZone Plus System only. The System Manager cannotbe used to program or monitor the Optimal Start Sched-uler Controller. This controller requires that a personalcomputer which has the ZoneView computer front endsoftware installed be used for all programming andmonitoring.

Wetbulb Module

Provides wetbulb temperature monitoring for controlof all economizer equipped units on the Auto-Zonesystem. The Wetbulb Module includes an Outside AirHumidity Sensor for measuring outside air relativehumidity and utilizes the installed Outdoor Air Sensoron the Auto-Zone System to calculate the wetbulbtemperature. This temperature is used by the economizercontrol portion of the unit controller to provide accurate

economizer operation. The Wetbulb Module can be usedwith the Auto-Zone Basic and Plus Zone Systems. TheWetbulb Module can be monitored and programmedfrom either the System Manager or from a personalcomputer which has the ZoneView computer front endsoftware installed.

AccessoriesWattMaster offers a complete line of accessories foryour Auto-Zone system. For part ordering informationand a complete list of accessories please see the Auto-Zone Product List Pricing manual and the Auto-Zone

Replacement Parts List Pricing Catalogs. Following isa brief list of some of the accessories that are offeredfor the Auto-Zone system.

• Remote Link - 14,400 baud modem forremote access to any Auto-Zone system

• CommLink II - Required to connect theAuto Zone Basic system to a personalcomputer

• Round Air Dampers - Air damper with aZone Controller and actuator mounted in acontrol enclosure. Available in pressuredependent and pressure independent models.Available in round duct sizes of 6”, 8”, 10”,12”, 14” and 16” diameter.

• Rectangular Air Dampers - Rectangular,aluminum frame opposed blade dampers.Available in rectangular duct sizes from 8” x8” to 24” x 36” in 2” increments of height andwidth

• Rectangular Air Damper Kit - ZoneController and actuator mounted in a controlenclosure for use with Rectangular AirDampers

• ZoneView Computer Front End SoftwareFree when ordered with an EZ Zone to Auto-Zone upgrade

EZ Zone/Auto-Zone

16 Upgrade

EZ Zone Wiring

The wiring diagram below depicts a typical existingEZ Zone Master Controller wiring. This diagram isshown for reference only. It’s intent is to show the dif-ference between the EZ Zone system wiring and the

Auto-Zone system wiring. All wiring should be con-nected per the specific Auto-Zone system wiring dia-grams on the following pages.

StaticPick-up


Supply AirTemp Sensor

Splice AsRequired

LO HI

HV

AC

Un

it

24VAC Only

R

G

Y1

Y2

W1

W2

LineVoltage

GND

24VAC

Actuator WiringInterface

Feedback (BK)

Close (GR)

Open (YL)

Gnd (WH)

Bypass Air DamperActuator

Re

d

Blk

Grn

RS-485Communication cableto Zone Controllers

Master Controller Board

75

90

60

45

Figure 1: Existing EZ Zone Master Controller Wiring

EZ Zone/Auto-Zone

Upgrade 17

Auto-Zone Basic Wiring

Zone Manager

Feedback (BK)

Close (GR)

Open (YL)

Gnd (WH)

Notes:

1.)24 VAC Must Be Connected SoThat All Ground Wires RemainCommon.

3.)All Communication Wiring To Be 18Ga. Minimum, 2 Conductor TwistedPair With Shield. Belden #82760 OrEquivalent.

4.)For Individual Component Wiring SeeSpecific Component Wiring Diagram.

5.)It Is Recommended That AllControllers Address Switches AreSet Before Installation.

2.)All Wiring To Be In Accordance WithLocal And National Electrical Codesand Specifications.

RS-485Communications To Zone

Controllers

Return Air Temp.Sensor

Supply Air Temp.Sensor

LineVoltage

HV

AC

Un

it

24VAC Only

Re

d

Blk

To Relief / Exhaust Fans

Grn

StaticPick-up


Splice AsRequired

LO HI

GND

24VAC

Belimo Actuator Wiring Shown.Consult Factory For Other

Models Of Economizer Actuators.Some Actuators Require IsolationTransformers In Order To PreventDamage To The Controller Board.

WARNING!

Use Extreme Care When WiringEconomizer Actuators

Never Connect Or DisconnectWiring With Power Applied!

Never Apply Power If TheGnd ( 1 Com ) Terminal On The

Actuator Is Not Connected.

See Note 1 &2

Outdoor Air Temp.Sensor

Aux3Forced

OccupiedMode

Aux1Economizer

Disable

Aux2FilterAlarm

Auxiliary Inputs( Dry Contacts )

R

G

Y1

Y2

W1

W2

Economizer Actuator

133 IN-LB

AF24-SR

1 COM

2 +

3 Y1

4 Y2

5 UBELIMO



C987

CABLE

R6

R5

HEAT 2 SW

1

W2

W1

Y2

HEAT2

HEAT1

COOL2

COOL1

FAN

HEAT 1

COOL 2

COOL 1

C 1992

1

1632

BNET

248

AD

D

COMM DRIVER

RS-485

75176

MADE IN U.S.A.

D1

7

D1

8

D1

9

D2

0

D2

1

D2

2

D2

3

D2

4

0* # D

R

SH

T

COMM

C1C2

+

P1

RIBBON

GN

D

06/11/95 03:48PM FRIAuto-Zone COOL MODE

G

Y1V6

V5

CLOSE

V4

V3

OPEN

GND

FDBK

FAN

CLOSE

OPEN

+

REC

+

GND

NE5090

4 5 6

KEYPAD

1 2 3

B

A

NO ALARM(S)OCCUPIED

LCD DISPLAY

&

++

24VAC

TB2

POWER

+

++

ADJUST

5.11V

PJ1

++PRESSU

RE

SEN

SO

RJA

CK

+5

V

SIG

BUSS

EXP

TB2

A2

G

OUTPUTS

ANALOG

A1

N.O.

CONTACTS

EXHAUST

AUX3

GND

GND

AUX2

AUX1

ANALOG

SAT

OAT

RAT

INPUTS

+12V

TB1

2

BYPASS

BYPASS

Local Loop

Address Switch Must Always Be SetTo Address 0 on Zone Manager Board

As Shown

Zone ManagerAddress Switch

These Switches Must BeIn The OFF PositionAs Shown

ADD

12

481632B

NET

AD

D

32

BNE

T

16 8 4 12

OF

F>

OF

F>

RockerDown

RockerDown

75

90

60

45

Figure 2: New Auto-Zone Basic Controller Wiring

Figure 2 below depicts the wiring schematic that shouldbe used for the Auto-Zone Basic System upgrade asdescribed in Example 1 on pages 8 and 9 of this manual.

Be sure to pay strict attention to all warnings and cau-tions listed on the schematic.

Warning:See Figure 11 in this manual forimportant wiring instructionsregarding HoneywellEconomizer Actuators

EZ Zone/Auto-Zone

18 Upgrade

Zone Manager

Notes:


3.)All Communication Wiring To Be 18Ga. Minimum, 2 Conductor TwistedPair With Shield. Belden #82760 OrEquivalent.

5.)For Individual Component Wiring SeeSpecific Component Wiring Diagram.

2.)All Wiring To Be In Accordance WithLocal And National Electrical Codesand Specifications.

RS-485Communications To ZoneControllers, CV ControllersAnd/Or System Manager



LineVoltage

HV

AC

Unit

24VAC Only

Red

Blk

To Relief / Exhaust Fans

Grn

StaticPick-up


Splice AsRequired

LO HI

GND

24VAC

Belimo Actuator Wiring ShownConsult Factory For Other

Models Of Economizer ActuatorsSome Actuators Require IsolationTransformers In Order To PreventDamage To The Controller Board.

WARNING!

Use Extreme Care When WiringEconomizer Actuators

Never Connect Or DisconnectWiring With Power Applied!

Never Apply Power If TheGnd ( 1 Com ) Terminal On The

Actuator Is Not Connected.

See Note 1 &2

+

+

++

+

++

+ +

HEAT2

HEAT1

COOL2

COOL1

FAN

R

2

8C

SW

1

16AB 24

AD

D

LOCALLOOP

Local Loop

T

SH

RTB3

COMM

T

SH

R

32

16

8

4

1

2

MINILINK

R9

R10

R8

I CEXP

PORT

PWR

V4

V3

CLOSE

OPEN

FDBK

REC

GND

GND

24VAC

AUX1

OPEN

K1

NETWORKLOOP

Network Loop RS-48519200 Baud

To Other ZoneManagers and/or

CommLink onSystem

SH

R

T

CLOSEK

2

NE5090

ANALOGOUTPUTS

A2

G

TB2

A1

N.O.

EXHAUSTCONTACTS

GND

GND

AUX3

AUX2

7824

D2

5

U1

4

VR

3

R4

0

ADJUST5.11V

C2

7

7812 C2

6V

R2

D1

D3

D4

D2

PJ1

PR

ES

SU

RE

SE

NS

OR

JA

CK

+5V

R7

OAT

RAT

+12V

SAT

ANALOGINPUTS

GN

D

SIG

T

R

SHIELD

T

R

SHIELD


(See Note 4)

Aux3Forced

OccupiedMode

Aux1Economizer

Disable

Aux2FilterAlarm

Auxiliary Inputs( Dry Contacts )

R

G

Y1

Y2

W1

W2

Economizer Actuator

133 IN-LB

AF24-SR

1 COM

2 +

3 Y1

4 Y2

5 UBELIMO



4.)Only One Outside Air Sensor IsRequired Per System. It May BeConnected To Any CV Controller OrZone Manager On The System. If AWetbulb Module Controller Is Used TheOA Sensor Must Be Connected To TheWetbulb Module.

75

90

60

45

Auto-Zone Plus Wiring

Figure 3: Existing Auto-Zone Plus Controller Wiring

Figure 3 below depicts the wiring schematic that shouldbe used for the Auto-Zone Plus System upgrade as de-scribed in Example 2 on pages 10 and 11 of this manual.This schematic is also used for wiring of Example 3 on

pages 12 & 13 of this manual. Be sure to pay strict at-tention to all warnings and cautions listed on the sche-matic.

Warning:See Figure 11 in this manual forimportant wiring instructionsregarding Honeywell economizeractuators

EZ Zone/Auto-Zone

Upgrade 19

1632

8421

Caution!The MiniLinks Must Have Address Switches Set Between 1And 30 (Up To 30 MiniLinks (Mounted on Zone Managers)Are Allowed Per Auto-Zone Plus System). The MiniLinksShould Be Addressed In Consecutive Order Starting WithAddress #1. Address #1 Must Be Present On The Loop ForThe System To Function.

Address Switch Shown IsSet For Address 1

Address Switch Must Always Be SetTo Address 17 on Zone Manager Board

As Shown

Address Switch Shown IsSet For Address 4

Zone ManagerAddress Switch

MiniLinkAddress Switch



Caution:The Power To The Zone Manager Must BeRemoved And Reconnected After Changing TheMiniLink Or Zone Manager Address Switch SettingsIn Order For Any Changes To Take Effect.

Caution:Disconnect All Communication Loop Wiring FromThe Zone Manger Before Removing Power.Reconnect Power And Then ReconnectCommunication Loop Wiring To Zone Manager.

ADD

ADD

ADD

12

481632B

NET

ADD

All Zone Managers On System Must BeAddressed As 17

Network Switch As ShownMust Be ON

The Address For Each MiniLinkMust Be Unique To The Other MiniLinksOn The Network Loop. Loop #1 MiniLink

Should Be Addressed As #1Loop #2 MiniLink Should Be Addressed

As #2 Etc..

ADD

AD

D

AD

D

32

32

32

B

B

NE

T

NE

T

16

16

16

8

88

4

4

4

1

1

1

2

2

2

OFF >

OF

F>

OF

F>

Rocker

Dow

n

RockerDown

RockerDown

HEAT2

HEAT1

COOL2

COOL1

FAN

R

LOCALLOOPT

SH

RTB3

COMM

T

SH

R

MINILINKV4

V3

CLOSE

OPEN

FDBK

GND

OPEN

K1

NETWORKLOOP

SH

R

T

CLOSE

K2

ANALOGOUTPUTS

A2

G

TB2

A1

Zone Manager Board(Under MiniLink Board)

MiniLink Address Switch Setting

Zone Manager Address Switch Setting

MiniLink Board(Mounted On Top Of Zone Manager Board)

Auto-Zone Plus Address Switches

Figure 4: New Auto-Zone Plus Address Switch Setting

The Auto-Zone Plus Zone Manager has two differentaddress switches. One is located on the main ZoneManager board and one is located on the MiniLink boardthat is located on the top of the Zone Manager board.The Zone Manager board address should always be setto address 17 on an Auto-Zone Plus system. The

MiniLink board should be addressed with a unique num-ber for each Zone Manager on the system. It is recom-mended that you start with address 1 and address eachZone Manager consecutively. See Figure 4 below fordetailed information.

EZ Zone/Auto-Zone

20 Upgrade

HVAC Staging Connections

Figure 6: New Auto-Zone HVAC Wiring

Figure5 below shows the EZ Zone Master Controllerwiring. Figure 6 below depicts the wiring schematicthat should be used for wiring of all Auto-Zone ZoneManagers boards. As can be seen below, the Auto-Zone

OUT1

OUT2

OUT3

OUT4

OUT5

FAN

COOL1

COOL2

HEAT1

HEAT2

24 VAC - R

Fan - G

Cool - Y1

Cool - Y2

Heat - W1

Heat - W2

HEAT2

HEAT1

COOL2

COOL1

FAN

R

Fan - GCool - Y1Cool - Y2Heat - W1Heat - W2

24 VAC -R

Figure 5: Existing EZ Zone HVAC Wiring

The EZ Zone Master Con-troller relay outputs consistof a series of five double poleterminal blocks. Wire jump-ers between terminal blocksare required to the commonof each relay.

The Auto-Zone Zone Man-ager wiring has been simpli-fied. There is only one termi-nal block with connectionsclearly marked for ease of in-stallation. Jumpers are nolonger required since thecommons are tied togetherwithin the circuit board.

Zone Manager wiring is much simpler than the EZ ZoneMaster Controller wiring. Be sure to pay strict atten-tion to all warnings and cautions listed on the sche-matic.

EZ Zone/Auto-Zone

Upgrade 21

Sensor Connections

Figure 8: New AZ Zone Manager Sensor Wiring

ANALOGINPUTS

+V

+V12345678GG

PRESSURESENSOR

+5

V

SIG

GN

D

TB12

StaticPick-up


Splice AsRequired

LO HI

Red

Blk

Grn

Supply AirSensor

To BypassActuator Feedback

++

+ +

R9

R10

C4

C4

R8

AUX1

ANALOGOUTPUTS

A2

G

TB5

TB4

TB3

A1

N.O.CONTACTS

EXHAUST

GND

GND

AUX3

AUX2

D3

D4

D5

D6

D8

D2

PR

ES

SU

RE

SE

NS

OR

JA

CK

+5

V

R7 INPUTS

OAT

RAT

+12V

SAT

ANALOG

GN

D

SIG

TB

1

PJ1




StaticPick-up


Splice AsRequired

LO HI

Figure 7: Existing EZ Zone Master Controller Sensor Wiring

The EZ Zone Master Controller sensor connec-tions are located on the right side of the board.Only a supply air temperature sensor and thebypass actuator feedback are connected here.

The Auto-Zone Zone Manager includes termi-nals for connecting the following sensors:

• Supply Air Temperature• Return Air Temperature• Outside Air Temperature

The terminals are marked SAT, RAT, and OATfor ease of wiring. Auxiliary input terminalsAUX1, AUX2 and AUX3 are used for Econo-mizer Disable, Dirty Filter Alarm and ForcedOccupied Mode. Bypass damper feedback hasbeen relocated (see next page).

EZ Zone/Auto-Zone

22 Upgrade

Figure 10: New Auto-Zone Bypass Damper Wiring

ANALOGINPUTS

+V

+V12345678GG

PRESSURESENSOR

+5

V

SIG

GN

D

TB12

OUT6

OUT7

BYPASS

OPEN

BYPASSCLOSE

FeedbackGnd

OpenClose


24 VAC

V4

V3

REC

CLOSE

OPENK1

K2

NE

TW

OR

K

SH

R

T

NE5090

FDBK

GND

OPEN

CLOSE

Feedback (Bk)Ground (Wh)

Open (Yl)

Close (Gr)

Actuator InterfaceWiring

Figure 9: Existing EZ Zone Bypass Damper Wiring

The EZ Zone Master Con-troller has two double poleterminal blocks for the by-pass actuator connections.These terminal blocks mustbe tied together by an exter-nal jumper. In addition, thefeedback connection from theactuator must be terminatedon the other side of the con-troller .

The Auto-Zone Zone Man-ager wiring has been simpli-fied. There is only one termi-nal block with connectionsclearly marked for ease ofinstallation. The actuator“feedback” connection isnow terminated at the samelocation as all the connec-tions. Jumpers are no longerrequired since the commonsare tied together within thecircuit board.

Bypass Damper Connections

EZ Zone/Auto-Zone

Upgrade 23

Honeywell Economizer Actuators

TR

T1

P

P1

24VAC24VAC

Zone Manager

Wiring OE266-01 Actuator Interface Module Kit To Zone Manager (Basic & Plus Systems)

Installing MS000204 Interface Module To Honeywell M7415 Or 7405 Actuator

Q769C1007 Interface Module(WM # MS002004)

Warning:

!

An Isolation TransformerMust Be Used For Connection ToActuator Or Serious Damage WillResult

+

TR1

T

-

A1

G

TB2

A2

G

OUTPUTSANALOG

A1

N.O.CONTACTS

EXHAUST

AUX3

GND

GND

AUX2

AUX1

ANALOG

SAT

OAT

RAT

INPUTS+12V

Honeywell Series M7415Or M7405 Actuator

24VA

C

24VA

C

T1 T1

TR TR

T T

P

P1

TR1

TR1

SEN

SO

R

SEN

SO

R

MINPO

SN

M7415A1014

025-26250

M7415A1014

025-26250

24 VAC - Isolation Transformer(WM # WP000019)

Honeywell M7415 ActuatorWithout Interface Module

Honeywell M7415 Actuator WithQ769C1007 (WM # MS000204)Interface Module Installed

Place Interface Module OnTerminals P1 and P

Figure 11: Honeywell Economizer Actuators Wiring Information

When the HVAC units that are being upgraded tothe Auto-Zone system are equipped with either theHoneywell M7415 or M7405 economizer actua-tors, an interface module and a isolation transformerare required in order to connect and use the econo-mizer outputs on the Auto-Zone system. The inter-face module converts the Honeywell actuator from0-5VDC operation to 0-10VDC operation. An iso-lation transformer is also required for this installa-tion to prevent voltage feedback to the control sys-tem. The OE266-01 Actuator Interface Module kit

is available from WattMaster. This kit includes boththe MS000204 Interface Module and a 24VAC Iso-lation Transformer.

Warning: Both the interface module and a 24VACisolation transformer must be installed as shownbelow when connecting to the Honeywell M7415or M7405 actuator. Failure to install these com-ponents as shown can result in serious damage tothe Auto-Zone controller board.

EZ Zone/Auto-Zone

24 Upgrade

To MiniLink Local Loop Terminals (Recommended)Or Local Loop Terminals Of Any Device On

Local Loop

To Next DeviceOn Local Loop

(If Desired - Not Required)

YS101716 REV. 1

SYSTEM MANAGER POWER SUPPLY

SHLD

COMMUNICATIONS

RS-485

R

T

GND

24VAC

POWER

WATTMASTER CONTROLS INC.

Override

Communication

Alarm

987

CLEAR0DEC. MINUS

ENTER

NO ALARM(S)

03/11/98 03:38PM WED

Auto-Zone v.X.XX

2

54

1

6

3

OCCUPIED

MENU ESC

Line Voltage

See Note 1

See Note 3

24VAC

Required VA For TransformerSystem Manager = 25VA Max.

The Ideal Recommended Location For The System Manager Is As TheFirst Device On The Local Loop, (Connect To MiniLink Local Loop Terminals)Although The System Manager May Be Connected To Any Local Loop AtAny Point On The Local Loop.The System Manager Will Not Operate Correctly If Attached To The Network Loop.

DO NOT CONNECT TO THE NETWORK LOOP.

The Ideal Recommended Location For The System Manager Is As TheFirst Device On The Local Loop, (Connect To MiniLink Local Loop Terminals)Although The System Manager May Be Connected To Any Local Loop AtAny Point On The Local Loop.The System Manager Will Not Operate Correctly If Attached To The Network Loop.

DO NOT CONNECT TO THE NETWORK LOOP.

System Manager

Notes:


3.) All Communication Wiring To Be2 Conductor Twisted Pair WithShield. Use Belden #82760 OrEquivalent.

2.)All Wiring To Be In AccordanceWith Local And National ElectricalCodes And Specifications.

Figure 12: System Manager Wiring

System Manager Installation

EZ Zone/Auto-Zone

Upgrade 25

Commlink II Communications Interface

(Jumper Set For Multiple Loop)

Caution: Use The “Molded Cable” ToConnect To The Computer (DCE) Connector.This Cable Is Only To Be Used To ConnectFrom The CommLink (DTE) Connection ToThe Modem (When Used).

Do Not

Caution:Disconnect All Communication Loop WiringFrom The CommLink Before Removing PowerFrom The CommLink. Reconnect Power And ThenReconnect Communication Loop Wiring.

Use 25 Pin Or 9 Pin Connector AsRequired By Available Serial (COM) PortOn Computer.

Caution: Use The “25 Pin Or 9 Pin Cable” ToConnect To The Modem (DTE) Connector.. ThisCable Is Only To Be Used To Connect From TheCommLink (DCE) Connection To The Computer

Serial Port (COM) Connection.

Do Not

(When Used) Note:Place Jumper BetweenPins 1 & 2 for MultipleLoop Applications &Between Pins 2 & 3 forSingle Loop Applications

COMM DRIVER CHIP( U1 )PIN 1

MULTI

SINGLE

12

3

CommLink Jumper Switch Settings

Notes:

R

SH

T

R

SH

T

R

SH

T

R

SH

T

All Communication LoopWiring Is Straight Through

Connect To First ZoneManager On Network Loop

Network LoopRS-485

19200 Baud(See Note 3).

Line Voltage

See Note 1

24VAC

Required VA For TransformerCommLink = 14VA Max.

CommLink Is Supplied With 110/24VAC Power Supply.If Desired A Transformer (By Others)

May Be Wired To The CommLink Instead

Molded Modem Cable.Part #HZ000098

Supplied With CommLink

(DTE)MODEMMODEM

485 LOOP485 LOOP

COMPUTER(DCE)

GT R

G2

V4

DN

POWER

4 Piece ComputerCable Kit.Part # HZ000112Supplied WithCommLink

Connect To Modem .Modem Is Part # OE419-02

Only

9P

inF

em

ale

9 PinFemale

25 PinFemale

9P

inF

em

ale

120/24 VacTransformer

Part # PX000015

25 PinMale

Part #CLMA19A1

Connect Supplied RJ12 Modular Phone CableTo Supplied 9 Pin Or 25 Pin Connector As ReqdBy Your Computer Com Port Connection


2.)All Wiring To Be In AccordanceWith Local And National ElectricalCodes And Specifications.

3.)All Communication Wiring To Be2 Conductor Twisted Pair WithShield. Use Belden #82760 OrEquivalent.

Figure 13: CommLink II Wiring

CommLink II Installation

Note:For Auto-Zone Basic System (See Example 1 page 8& 9) jumper must be set for single loop operation asshown above.For Auto-Zone Plus System (See Example 2 page 10& 11) jumper must be set for multiple loop operationas shown above.

EZ Zone/Auto-Zone

26 Upgrade

EPROM LocationSee Figure 17 ForRemoval AndInstallation Instructions

Figure 14: EZ Zone Modem Linc Central EPROM Location

Modem Linc Central EPROM Replacement

The EZ Zone Modem Linc Cen-tral EPROM chip must be re-placed with the Auto-ZoneCommLink upgrade EPROMchip part #OE754. ThisEPROM chip is factory pro-grammed with the new Auto-Zone to EZ Zone software. Thischip must be replaced or theModem Linc Central will notfunction with the Auto-Zonesystem.

CAUTION:Power must be removed from theModem Linc Central during re-moval of the old EPROM chipand installation of the newEPROM chip. It is also impera-tive that the old EPROM chip isremoved gently to avoid damageto the circuit board. Installationof the new EPROM chip mustalso be done with care to preventdamage to the pins on the newchip. See Figure 17 for detailedchip removal and installation in-formation.

Notch

EZ Zone/Auto-Zone

Upgrade 27

LO

OP

NE

TW

OR

K

T

SH

R

24VAC

GND

T

SH

R

32

16

8

4

1

2

1

2

3

4

7

5

6

8

OFF>

Ro

cke

rD

ow

n


Figure 15: EZ Zone Master Interface Board EPROM Location

The EZ Zone Master InterfaceBoard EPROM chip must be re-placed with the Auto-ZoneMiniLink upgrade EPROM chippart # OE755. This EPROMchip is factory programmed withthe new Auto-Zone to EZ Zonesoftware. This chip must be re-placed or the Master InterfaceBoard will not function with theAuto-Zone system.

CAUTION:Power must be removed from theMaster Interface Board duringremoval of the old EPROM chipand installation of the newEPROM chip. It is also impera-tive that the old EPROM chip isremoved gently to avoid damageto the circuit board. Installationof the new EPROM chip mustalso be done with care to preventdamage to the pins on the newchip. See Figure 17 for detailedchip removal and installation in-formation.

Master Interface EPROM Replacement

Notch

EZ Zone/Auto-Zone

28 Upgrade

Figure 16: EZ Zone Zone Controller EPROM Location

Zone Controller EPROM Replacement

CX

6

SW

1

U10

75176

EX

PA

N

SIO

N

Q3

Q2

D3

VR

17824

GND

24VAC

M

7824C

T

MC340

64A9936

R17

R16

U7

C7

R15

PO

WE

RR

21

RE

V.2

YS

101

562

MDL

F1

250D4

R26

LD3

L1

SCAN REC

R12

C6

R11

TOKEN

NET

LD

2

32

R14

R13

R100

LD

1

C5

D1

K1

V2

24VDC

CONTACT:

UL / CSA 5A250VAC

K2

D2

AC

TU

A

TO

R

24VDC

CONTACT:

UL / CSA 5A250VAC

R10

R9

PJ2

V1

C4

74H

C573N

B31920P

S

TC

U3

2K

2V

9936

MS

6264L-7

0P

C

EPROM

VR

EF

AD

J

R23

C10

PC

B80C

552-5

-16W

P

500650=

1/3

DF

D9940S

M

PH

ILIP

S

EW

DO

G

CO

MM

D7

CX10

R25

R28

T'STA

T U11

C15

R20

C11

R24

8

16

2

4

ADDRE

SS ADD

1 U6

93C

46

U5

R19

PH

ILIP

S

U9CX9

R32

D5

C14

P.U.

R22

C13

LM

C662

R27

D5

RAM

C9

C8

80C55

2

CX

5P

J1

C3

R8

R7

R5

R6

R4

C2

C1

X1 74H

C259

B31920P

S

U2

R1

R2

R3

CX2

Q1

16L8

32K

R34FLOW

U8

1

RN1

CX8 U4

R18 CX4

8KRAM

U3

CX3

U1

CX1

The EZ Zone Zone ControllerEPROM chip must be replacedwith the Auto-Zone ZoneContoller upgrade EPROM chippart # OE752. This EPROMchip is factory programmed withthe new Auto-Zone to EZ Zonesoftware. This chip must be re-placed or the zone controller willnot function with the Auto-Zonesystem.

CAUTION:Power must be removed from theZone Controller board during re-moval of the old EPROM chipand installation of the newEPROM chip. It is also impera-tive that the old EPROM chip isremoved gently to avoid damageto the circuit board. Installationof the new EPROM chip mustalso be done with care to preventdamage to the pins on the newchip. See the next page for de-tailed chip removal and instal-lation information.


Notch

EZ Zone/Auto-Zone

Upgrade 29

EPROM Installation Procedures

Small FlatheadScrewdriver

Chip

Chip

Printed CircuitBoard



Chip

WARNING!

Direction Of Pull

Notch

Dot

Pin1

Be sure the chip you have selected to replace is asocketed chip. Not all driver chips on the boardsare field replaceable. Only socketed chips may beremoved and replaced in the field. All other chipsthat are not socketed will require sending the boardto the WattMaster factory for repair.

Once you have determined that thechip needing replacement is indeed a socketed chipplease proceed in the following manner.

Remove the communications loop connector andthen the 24VAC power connector on the controllerbefore attempting to change any components.

will occur if components are removed orinstalled with power applied.

If you are unsure how to safely remove the chip orabout the correct pin placement, please consult thefactory before proceeding.

Use extreme care to avoid inserting the screwdriveror I.C. Puller under the socket. You must insert the tipof the screwdriver or ends of the I.C. Puller betweenthe body of the chip and the chip socket.

Each chip be installed with Pin 1 in the correctlocation. Installing the chip “backwards” will in mostcases destroy the device when power is reapplied.

Pin 1 can be located by looking for the notch in the endof the chip. Pin 1 on "some" chips is identified with a dot.

Be certain that pins are lined up in the socketbefore pressing the chip in. Failure to properly lineup the pins will result in damage to the chip.This is a common error -

Only after confirming that the chip has been correctlyinstalled with Pin 1 in the proper position and that thepins are lined up and none are bent or out of the socket,should communication or power wiring be reconnectedto the board. Tp prevent possible damage alwaysreconnect the power wiring first and then thecommunication wiring.

If you try toremove a chip that is not socketed it will destroythe circuit board.

DAMAGE

Damage to the board caused by failure to correctlyremove or install the chip is not covered by theWattMaster warranty.

MUST

ALL

VERY BE CAREFUL.

Using I.C. Puller To Remove Socketed Chip

Using Screwdriver To Remove Socketed Chip

End View Of Socketed Chip AssemblyTop View Of Socketed Chip Assembly

I.C. Puller

Chip Socket

Chip Socket

Chip Socket

Gently Rock Chip Side To Side And ThenLift Straight Up To Remove Chip FromChip Socket.

Gently Lift The Chip On One End And Rock ChipBack And Forth With Screwdriver As Shown.Repeat This Process On The Other End Of Chip.Alternate This Process On Both Ends Of Chip UntilThe Chip Is Free From The Chip Socket.

Pin 1

Dot

Socket

PrintedCircuitBoard

Typical RS-485 CommunicationsDriver Chip Detail

Figure 17: EPROM Removal And Installation

EZ Zone/Auto-Zone

30 Upgrade

Minilink Board

Zone Manager Board

Keypad And DisplayCircuit Board

3- Connector Ribbon CableTo KeyPad & Display BoardSee Connection Detail Below

Cable Connection Detail

+

+

++

+

++

+ +

HEAT2

HEAT1

COOL2

COOL1

FAN

R

2

8C

SW

1

16AB 24

AD

D

LOCALLOOPT

SH

RTB3

COMM

T

SH

R

32

16

8

4

1

2

MINILINK

R9

R10

R8

I CEXP

PORT

PWR

V4

V3

CLOSE

OPEN

FDBK

REC

GND

GND

24VAC

AUX1

OPEN

K1

NETWORKLOOP

SH

R

T

CLOSE

K2

NE5090

ANALOGOUTPUTS

A2

G

TB2

A1

N.O.

EXHAUSTCONTACTS

GND

GND

AUX3

AUX2

7824

D25

U14

VR

3

R40

ADJUST5.11V

C27

7812 C26

VR

2

D1

D3

D4

D2

PJ1

PR

ES

SU

RE

SE

NS

OR

JA

CK

+5V

R7

OAT

RAT

+12V

SAT

ANALOGINPUTS

GN

D

SIG

Use 3-Connector Ribbon Cable When ConnectingAuto-Zone Plus Zone Manager BoardTo EZ Zone Keypad & Display Board

USE CARE TO ROUTE THE RIBBON CABLE SO THAT IT IS NOT CRIMPED AND SOIT IS CLEAR OF ENCLOSURE COVER SCREWS WHEN INSTALLED

CAUTION!

Figure 18: 3 Connector Ribbon Cable Installation

Note:The 3 Connector Ribbon Cable Is Only RequiredWhen Connecting A System As Shown InExample #2 On Pages 10 & 11 Of This Guide.

Ribbon Cable Installation

EZ Zone/Auto-Zone

Upgrade 31

Upgrade Parts List Summary

All the standard and components that are required oravailable for the Auto-Zone to EZ Zone upgrades aresummarized below. See the upgrade examples on pages8 through 13 of this manual for the parts lists that arerequired for your specific application. For other Auto-

Zone products such as CV Unit Controllers, LightingPanel Controllers etc., please see pages 14 & 15 or con-sult the factory to see if these are available for yourspecific application.

Part No Description

OE392-01-ZSYSM System Manager (Used on Plus Systems)Includes: System Manager Only.

OE751 EZ Zone To Auto-Zone Basic Upgrade KitIncludes: Zone Manager Board w/ Mounting Screws, Plastic Standoff Kit forZone Manager, Return Air Sensor, Upgrade Label, Installation Instructions.

OE753 EZ Zone To Auto-Zone Plus Upgrade KitIncludes: Zone Manager Board w/ Mounting Screws, Plastic Standoff Kit forZone Manager, MiniLink w/ Mounting Hardware, Return Air Sensor, 3 WayDisplay/Keypad Connector cable, Upgrade Label, Installation Instructions.

OE231 Duct Temperature Sensor(10kohm with 12” Probe, used for Return or Supply Air Sensor)Includes: Duct Temperature Sensor, 2 Wire with 12” Long Probe.

OE250 Outside Air Temperature Sensor (10kohm)Includes: Temperature Sensor Mounted in Weatherproof Handy Box.

OE419-03 Remote Data Link (Modem- External -14,400 Baud )Includes: Modem and 120/9 VAC Power Supply.

OE361-04 CommLink II (Used on Basic & Plus Systems )Includes: CommLink II, Power Supply & Cables for Connection to Computer andRemote Link are Included.

OE752 Replacement EPROM ChipContains Auto-Zone software to replace EZ Zone software in Zone ControllerIncludes: EPROM Chip

OE755 Modem Linc Central To CommLink II Upgrade KitIncludes: ComLink II EPROM Upgrade Chip, Upgrade Label

OE754 Master Interface Board To MiniLink Upgrade KitIncludes: MiniLink EPROM Upgrade Chip, Upgrade Label

EC101600-3 Blank Enclosure CoverUsed to replace EZ Zone Master Controller Cover when Keypad & Display arenot Desired. Includes: Metal Enclosure Cover Only

SP500 ZoneView AZ SoftwareWindows Based Software for Accessing System using a PCIncludes: 3.5” Floppy Installation Diskettes and Operations Manual.

EZ Zone/Auto-Zone

32 Upgrade

For further technical information regarding the Auto-Zone products please refer to the appropriate Installa-tion, Operation and Maintenance manual included with

Additional Information

your upgrade package. Additional technical assistanceis available by contacting the WattMaster technical sup-port group at the numbers listed below.

WattMaster Controls Inc.Phone: (816) 505-1100Fax: (816) 505-1101E-mail: [email protected]

Thank you for choosing WattMaster Controls!

EZ Zone/Auto-Zone

Upgrade 33

Notes:

Form: WM-EZA-UG-01C Printed in the USA October 2000All rights reserved Copyright 2000WattMaster Controls Inc. • 8500 NW River Park Drive • Parkville MO • 64152Phone (816) 505-1100 E-mail: [email protected] Fax (816) 505-1101

ez zone · the york international corporation’s ez zone controls system was first introduced in...

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