Modine Manufacturing Varsity ZCF 1000 Installation And Service Manual Download Page 6

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AIR14-501.2

START-UP PROCEDURE

IMPORTANT

1.  Start-up and adjustment procedures should be performed 

by a qualified service agency.

2.  No water-flow can cause a freeze condition resulting in 

damage to the coil.

3.  Never leave the unit filled with water in a building without 

heat unless antifreeze has been added.

START-UP PROCEDURE

See start-up sheet examples - Figures 9.1 and 10.1. 

 

Pre-Start Checks

  1.   Check that the supply voltage matches the unit supply 

voltage listed on the Unit Serial Plate. Verify that all wiring is 

secure and properly protected. Trace circuits to insure that 

the unit has been wired according to the wiring diagram.

  2.    Check that the unit has no visible damage and that all the 

components are secure.

  3.    Check that all field electrical and mechanical work has been 

performed according to all applicable Federal, State, and 

Local codes.

  4.    Check the supply voltage to the unit is /- 5% of the 

voltage on the unit serial plate.

  5.   Check that the system has been correctly flushed.

  6.   Check for any water leaks.

  7.    The unit and interconnecting piping have been evacuated 

correctly and the condensing unit service valves are open 

(DX Cooling units only).

  8.    Check that the plug is installed for the condensate 

connection that is not being used.

 10.   Check that the motor is secure and the shaft and blower set 

screws are tight. Rotate the blower shaft by hand.

 11.   Check that the filters have been properly installed.

Unit Start-Up Procedure

Note: 

For models with DX Cooling, see the installation and 

maintenance manual provided with the condensing unit for start-

up information. 

 

  1.   (DX Cooling models only) Ensure that the condensing unit 

start-up procedure has been carried out, as detailed in the 

condensing unit installation and maintenance manual.

  2.   (DX Cooling models only) The compressor should be 

isolated by removing the connection at the Y1 terminal 

on the indoor unit. Main power can now be applied to the 

indoor and outdoor units. A system electrical check can now 

be carried out.

  3.  Switch the 3-speed switch to position 1, 2 or 3.

  4.  Switch the disconnect switch to the “ON” position.

  5.   Confirm that the blower motor is rotating in the correct 

direction and blowing air out of the supply air grill.

  6.   (Units with Chilled Water, Hot Water and Steam coils only) 

Ensure all valves are open to the unit.

  7.   (Units with Chilled Water and Hot Water only) Check water 

flow rates and pressure drops and compare to design.

  8.   Check that the dampers are not obstructed and move 

through their full range of motion.

  9.   During the unit operation, measure and record all the 

information that is required to complete the Start-Up Sheets 

that are supplied with the unit. Copy the information onto the 

Start-Up Sheets (Figures 9.1 and 10.1) in this manual for 

your records.

 10.  (DX Cooling models only) Shut unit down and disconnect 

the main power. The compressor signal Y1 (disconnected 

from the indoor unit in step 2) can now be re-connected and 

main power applied to the system.

Note: 

(DX Cooling models only) The 24V power for the indoor 

unit control circuit is supplied from a unit factory-installed 

transformer. When the indoor and outdoor units are supplied 

from separate main supplies, care must be taken to ensure that 

the outdoor unit is isolated whenever the indoor unit power is 

removed. Failure to do so may result in freeze ups and other 

damage to the unit.

Summary of Contents for Varsity ZCF 1000

Page 1: ...nded for a qualified installation and service agency A qualified installation and service agency must perform all installation and service of these appliances 2 ZCV and ZCF units with DX evaporator coils contain the refrigerant R 410A Review the R 410A Material Safety Data Sheet MSDS for hazards and first aid measures 3 Refrigerant charging should only be carried out by an EPA certified air condit...

Page 2: ...n 3 Handling 3 Preparation 3 Drainage 3 Electrical 3 Installation 3 Piping Installation 4 Piping Insulation 5 Wiring 5 Terminal Strip Connections 5 Start Up Procedure 6 Pre Start Checks 6 Unit Start Up Procedure 6 Typical Sequence of Operation 7 8 Start Up Sheet Example 9 10 Dimensions 11 12 Technical Data 13 Component Layout 14 Maintenance 15 Troubleshooting 16 17 Replacement Parts Model Nomencla...

Page 3: ...ould be sealed with waterproof sealant Drainage Units with cooling coils have a condensate drain pan connection and 3 4 ID condensate line The condensate drain pan connection is field changeable and can be mounted on either the left or right side of the unit To change the connection location remove the condensate line from the elbow Remove the elbow from the drain pan and remove the plug from the ...

Page 4: ...1 Condensing unit is typically factory charged for a 15 foot lineset For additional lineset lengths please refer to manufacturer s charging chart See the installation and maintenance manual provided with the condensing unit for installation evacuation and system charge information 1 Chilled water and hot water coils are supplied from the factory with unions Field installed piping can be mounted to...

Page 5: ...xtra cable must be left outside the panel to allow the panel to open fully Failure to follow these instructions may cause damage to the wiring and or the unit Terminal Strip Connections The terminal strip connections are designed to clamp down on the wires To properly connect the wires to the terminal strip 1 Push a small flat head screwdriver into the square hole on the terminal Press firmly unti...

Page 6: ...p information 1 DX Cooling models only Ensure that the condensing unit start up procedure has been carried out as detailed in the condensing unit installation and maintenance manual 2 DX Cooling models only The compressor should be isolated by removing the connection at the Y1 terminal on the indoor unit Main power can now be applied to the indoor and outdoor units A system electrical check can no...

Page 7: ...ide air temperature is below 55 F Hot Water or Steam with Valve Control Units with a hot water or steam coil and non Carel controls desiring valve control shall use a spring return normally open modulating valve operated by a proportional signal 2 10VDC or a tri state 24VAC signal Units with Carel controls desiring valve control shall use a modulating control valve with a proportional signal When ...

Page 8: ... a call for heating The valve shall always open when the outside air temperature drops below 40 F This is to prevent the coil from freezing or nuisance tripping of the freeze stat The 2 position hot water valve shall be closed when the 2 position chilled water valve is open if equipped The valve is controlled by a 24VAC digital output The 2 position valve used on a 2 pipe changeover system shall o...

Page 9: ...9 AIR14 501 2 START UP SHEET EXAMPLE Figure 9 1 Start Up Sheet EXAMPLE Page 1 ...

Page 10: ...10 AIR14 501 2 START UP SHEET EXAMPLE Figure 10 1 Start Up Sheet EXAMPLE Page 2 ...

Page 11: ...11 AIR14 501 2 DIMENSIONS Figure 11 1 Front Discharge Unit Table 11 1 Unit Dimensions Model Size Dimensions inches W1 W2 750 62 36 1000 74 48 1250 86 60 1500 98 72 ...

Page 12: ...12 AIR14 501 2 DIMENSIONS Figure 12 1 Down Discharge Unit Table 12 1 Unit Dimensions Model Size Dimensions inches W1 W2 750 62 36 1000 74 48 1250 86 60 1500 98 72 ...

Page 13: ...6 0 88 3 Row gal 0 72 0 91 1 1 1 28 4 Row gal 0 92 1 17 1 42 1 66 CONNECTIONS Water Coils Inches Unions with 3 4 female solder joint Evaporator Coil Inches 3 4 OD Suction 1 2 OD Liquid Steam Coil Inches 1 NPT Condensate Line Inches 3 4 ID condensate line UNIT WEIGHT approximate Shipping Weight lbs 375 420 470 520 Operating Weight lbs 320 365 410 450 FILTER 1 Woven Fiberglass 70 75 Arrestance Quant...

Page 14: ...1 2 COMPONENT LAYOUT Figure 14 1 Exploded View PIPING TOP ACCESS PANELS BASE ASSEMBLY DAMPER ASSEMBLY CONTROL PANEL FILTER COIL ASSEMBLY BLOWER ASSEMBLY END PANELS BOTTOM ACCESS PANELS DISCHARGE AIR PANEL ASSEMBLY ...

Page 15: ...cessary Remove the filter support bracket and slide the filter s out of the track Replace with new filter s and reinstall the filter support bracket see Figure 14 1 Never run the unit without filters Every SIX 6 MONTHS Before the heating and cooling season 1 Check for correct fan operation no excessive noise or vibrations With the Disconnect Switch in the OFF position 2 Inspect all electrical circ...

Page 16: ...ections 5 Inspect connections beginning with compressor output from the microprocessor 6 Tripped circuit breakers 6 Reset the tripped circuit breaker s 7 Low temperature unit lockout 7 Consult microprocessor setpoints 8 DX Split Units Only Compressor faulty 8 Replace compressor 9 Condensate pan pump float switch tripped 9 Check condensate pan pump and piping for blockage C No Indoor Fan 1 Motor tr...

Page 17: ...er installation of wall sleeve and louver 1 Ensure splitter plate is in contact with the back of the louver blade and the unit to ensure no re circulation of exhaust air takes place 2 Dirty condenser coils 2 Clean condenser coil 3 System overcharged 3 Remove excess refrigerant 4 Noncondensables in system 4 Evacuate refrigerant circuit and recharge 5 Condenser fan speed is too slow cooling mode 5 N...

Page 18: ...m Outside Air R Bottom Return Air No Outside Air S Top Return Air No Outside Air 9 Discharge Air DA E Front Discharge with Duct Collar F Front Disch with Dbl Defl Grille G Down Disch with Dbl Defl Grille 10 Cooling Option CO 0 None 2 2 Row Chilled Water Hot Water 2 Pipe 3 3 Row Chilled Water Hot Water 2 Pipe 4 4 Row Chilled Water Hot Water 2 Pipe 5 Direct Expansion DX Cooling Only 11 Heating Optio...

Page 19: ...19 AIR14 501 2 SERIAL PLATE Figure 19 1 Serial Plate EXAMPLE ...

Page 20: ...UIPMENT MANUFACTURED BY BUYER BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER FOR GAS FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO TEN YEARS FROM DATE OF SHIPMENT FROM SELLER These warranties are issued only to the origin...

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