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ZIP Economizer

Installation and Operation Manual

PART OFFERING

ECON-ZIP-BASE

ZIP Economizer Base Unit

The ZIP Economizer™ is a modular designed, plug and play economizer control solution. The ZIP
offers an extended temperature transflective LCD display, with on board help, providing information
every step of the way. Through its superior fault detection and diagnostics (FDD), it troubleshoots
faults, initiates alarms, and reconfigures for best operation. Up to 10 alarms are stored as historic
alarms and with operating hours, makes troubleshooting and maintenance easier. Base unit
designed to provide most common economizer functions; two stages of mechanical cooling,
integrated cooling, four change over strategies for free cooling, indoor fan speed and ventilation
damper position feedback.

ECON-ZIP-EM

ZIP Economizer
Energy Module

The ZIP Economizer™ Energy Module provides additional I/Os to offer higher control functionalities
that will save even more energy. The Energy Module is needed for demand control ventilation, (DCV)
indoor fan- 2 speed control, power exhaust fan, remote override for damper positioning, and pre-
occupancy purge. The auto-detection and plug and play capability offers quick set up.

ECON-ZIP-COM

ZIP Economizer
Communication Module

The ZIP Economizer™ Communication Module provides remote alarm indication with future
capabilities such as data trending and building automation integration.

ECON-ZIP-10K

ZIP Economizer
Temperature Sensor

The ECON-ZIP-10K allows for reliable temperature air readings. The sensor may be used for outdoor
air (OAT), return air (RAT), or supply air (SAT) temperature measurements and control, with no
configuration required. A minimum of one SAT and one OAT sensor is required for the ZIP
Economizer to function. An RAT sensor can be added for differential temperature change over
strategy. For best control results, sensors should be placed in the air stream. With the T-Bracket
mounting is universal and can be inserted through the ductwork, fan housing or surface mounted.

ECON-ZIP-TH

ZIP Economizer Temperature
and Humidity Sensor

The ECON-ZIP-TH Sensor may be used to measure temperature and humidity in the outdoor or
return air stream. The temperature and humidity output is via 2 analog channels that can be
independently measured with a multimeter. One sensor is used in the outdoor air intake for single
enthalpy changeover strategy. An additional sensor can be added in the return air stream for
differential changeover strategy. When using the ECON-ZIP-TH it is not necessary to use a separate
temperature sensor ECON-ZIP-10K for OAT or RAT.

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Содержание ECON-ZIP-10K

Страница 1: ... Manual Belimo ZIP Economizer Technical Specifications Installation and Wiring Menu Sequence Setup and Configuration Service and Commissioning Sequence of Operation Alarms Troubleshooting 71578 00001_B Software version 1 10 000 ...

Страница 2: ...lay capability offers quick set up ECON ZIP COM ZIP Economizer Communication Module The ZIP Economizer Communication Module provides remote alarm indication with future capabilities such as data trending and building automation integration ECON ZIP 10K ZIP Economizer Temperature Sensor The ECON ZIP 10K allows for reliable temperature air readings The sensor may be used for outdoor air OAT return a...

Страница 3: ...ECON ZIP BASE ECON ZIP EM ECON ZIP TH ECON ZIP 10K LF24 SR US ECON ZIP LF1 ECON ZIP SDLF Single Dry Bulb with DCV Capability 2 Speed Fan Exhaust Fan and LF Spring Return Actuator 35 in lbs 12 tons ECON ZIP BASE ECON ZIP EM ECON ZIP 10K 2 LF24 SR US ECON ZIP LF1 ECON ZIP DDLF Differential Dry Bulb with DCV Capability 2 Speed Fan Exhaust Fan and LF Spring Return Actuator 35 in lbs 12 tons ECON ZIP B...

Страница 4: ...GURATION Quick Setup 13 Demand Control Ventilation Setup DCV 2 Speed Fan Setup 15 Multiple Actuator Configuration 17 MENU SEQUENCE DOCUMENTATION Menu Flow Overview 18 Monitor Live Conditions 19 Settings 20 Present Devices 21 Alarm 22 Manual Mode 23 Service Commissioning 24 Menu Structure Table 27 SEQUENCE OF OPERATION 32 ALARMS 37 FAULT DETECTION DIAGNOSTICS 38 TROUBLESHOOTING 41 10K SENSOR TABLE ...

Страница 5: ...g wiring and removal Take the overall dimensions of 6 63 168 5 x 7 12 181 x 2 50 8 and mount in the interior of the RTU in a convenient location that you can access Secure the ZIP utilizing 8 self tapping screws included A minumum of two tabs need to be secured one which is a top tab Ideally secure all four tabs Wire the electrical connection using female insulated spade connectors to prevent corr...

Страница 6: ...t Pump operation if conventional thermostat is used in conjunction with Defrost Board If Thermostat and RTU use O B control reversing valve position O B must be wired to W1 on ECON ZIP BASE Existing refrigeration safety devices may exist consult RTU wiring diagram 51 52 53 If RTU is not a Heat Pump using a conventional thermostat and it is desired to record heating operation hours connect W1 to EC...

Страница 7: ...o the ECON ZIP BASE Existing refrigeration safety devices may exist consult RTU wiring diagram 51 53 If RTU is not a Heat Pump using a conventional thermostat and it is desired to record heating operation hours connect W1 to ECON ZIP BASE 56 W1 must be wired for Heat Pump operation if conventional thermostat is used in conjunction with Defrost Board If Thermostat and RTU use O B control reversing ...

Страница 8: ... 40 F to 158 F 40 C to 70 C Storage temperature range 40 F to 176 F 40 C to 80 C Agency listing cULus acc to UL873 CAN CSA C22 2 No 24 93 The power consumption is for the control only and does not include connected loads such as actuator compressors fans and sensors For transformer sizing the power consumption of these attached components must be included Dimensions Inches mm Type Name Description...

Страница 9: ... VDC 4 0 to 10 VDC SGA24 SGF24 Common 1 2 Y Input 2 to 10 VDC 3 2 to 10 VDC 4 AUX1 CO2 AUX1 CO2 AUX2 AUX2 IF EF ECON ZIP EM 52 55 54 50 50 Power source should be the same as ECON ZIP BASE 50 Not supplied by Belimo Sold separately by Belimo 54 55 W1 must be wired for Heat Pump operation if conventional thermostat is used in conjunction with Defrost Board If Thermostat and RTU use O B control revers...

Страница 10: ...to 70 C Storage temperature range 40 F to 176 F 40 C to 80 C Agency listing cULus acc to UL873 CAN CSA C22 2 No 24 93 The power consumption is for the control only and does not include connected loads such as actuator compressors fans and sensors For transformer sizing the power consumption of these attached components must be included Wiring Diagram 24 VAC Alarm Light Pilot Relay 24 VAC ALM ALM E...

Страница 11: ...turn temperature If mounted outside the sensor must be placed within hood behind the outdoor air filter It needs to be protected from direct exposure to water snow rain and direct exposure to sunlight UV radiation Secure the sensor with 8 self tapping screws included in kit using a size 16 or 18 drill Wiring Diagram ZIP Economizer Terminal inputs SAT OAT RAT ECON ZIP 10K ECON ZIP 10K ZIP Economize...

Страница 12: ...in kit The electrical connection needs to be wired using appropriate insulated spade connectors female according to the wiring diagram Wiring Input Output Specifications Technical Data Type Name Description Electrical Specification ZIP Terminal Input 24V Supply Hot 24 VAC 20 50 60Hz Same Power Supply R Output T Temperature Type 10K NTC Type II thermistor OAT RAT Output RH Relative Humidity 0 10 VD...

Страница 13: ... pressing any key will drop the user down from Status to the next level so repeatedly pressing esc will toggle the display between Status and Monitor Live Conditions Note If status Setup incomplete is displayed the RTU cooling operation will be disabled and additional parameters must be set to achieve Setup complete Installation 1 Shut off power to RTU before beginning installation 2 Note orientat...

Страница 14: ... has built in commissioning processes found in Acceptance Test 1 Economizer Test Use Economizer Test to verify RTU Integrated Economizer operation Navigate to the Service and Commissioning menu press OK press the down arrow to access Acceptance Test Press OK again when Economizer Test appears Press OK again to confirm running test Follow prompts during test This test will open damper to 100 enable...

Страница 15: ...t to ECON ZIP EM CO2 sensor input Operation Type of Output Ventilation Rate cfm Person Analog Output CO2 Control Range ppm Any 0 10V 0 2000 The ZIP Economizer logic will control the outside air damper position based on space CO2 dilution needs If the CO2 value is low the damper shall remain at DCV Min Pos when not in free cooling When the CO2 concentration rises above the CO2 PPM Set Pnt as the sp...

Страница 16: ...Vent Min Pos however equal the same measured airflow rate value b Low Sp DCV Min When a 2 Speed strategy is used to save energy an additional DCV Min Pos needs to be entered for low speed operation due to less available static pressure from the fan This position will be greater than DCV Min Pos however equal the same measured airflow rate value c Low Exh Fan Pos When a 2 speed stategy is used to s...

Страница 17: ...izer should be wired to the Outside Air Damper actuator feedback wire Wiring for the multiple actuator configuration is shown in the illustration below please ensure to follow all warnings and cautions listed in the actuator mounting instructions Any combination of TFB24 SR LF24 SR NFB24 SR and AFB24 SR can be mounted in this arrangement 1 Common 2 Hot 3 Y1 Input 5 U Output Feedback 1 Common 2 Hot...

Страница 18: ...his menu 3 Settings is the first menu displayed when the ZIP Economizer is first powered and has not been previously setup Example Free Cooling Dmp 40 OAT 70F esc Moves up through the menu on the same level Will increase values by one increment at a time When setting values holding key down will fast scroll Moves down through the menu on the same level Will decrease values by one increment at a ti...

Страница 19: ... kJ kg 6 Press esc button from any sub menu item 7 Returns to previous place in menu tree 8 Only displayed with enthalpy configurations Compressor 2 1 3 Start_xxxsec Stop_xxxsec on off off SAT ok off EcoPotential off checking SAT off DXLL off LCLO Run Time Comp 2 1 xxxxxxhrs 3 Only one value below 1st row is displayed on 2nd row at any one time 4 Only one of the below change over high limit strate...

Страница 20: ...all auto 3 not installed 3 installed 3 OAH Sensor Auto 3 not installed 3 installed 3 RAH Sensor auto 3 not installed 3 installed 3 DCV Min Pos 1 xxx DCV PPM Set Pnt 1 xxxxppm Low Sp Vent Min 1 xxx Low Sp DCV Min 1 xxx Exh Fan On Pos 1 xxx Low Exh Fan Pos 1 xxx Temp Unit F 3 C 3 Purge Enable On 3 Off 3 Remote Dmp Cntrl On 3 Off 3 SAT Y2 Limit On 3 Off 3 Purge Dmp Set 8 xxx High Limit Modification 1...

Страница 21: ... Com Module 3 Connected Not Connected OK esc 4 Sub menu 1 Only displayed if device is connected and functioning 2 Only displayed after setup has been completed else navigation jumps over this menu 3 Only one value below 1st row is displayed on 2nd row at any one time 4 Press esc button from any sub menu item 4 3 2 1 Status line Monitor Live Conditions Settings Present Devices Alarm esc esc esc esc...

Страница 22: ... alarm confirmation 3 esc esc esc esc OK OK OK OK 1 Only displayed If an alarm exists 2 Only displayed when historic alarms exist 3 Only displayed if there is any alarm to delete 4 Only displayed after setup has been completed else navigation jumps over this menu 5 Press esc button from any sub menu item 4 3 2 1 Status line Monitor Live Conditions Settings Present Devices Alarm esc esc esc esc Any...

Страница 23: ... esc 1 Only displayed if acceptance test or manual mode is active If not displayed navigation jumps over this entry Press OK to return to automatic 2 Only displayed after setup has been completed 3 Only one value below 1st row is displayed on 2nd row at any one time 4 Only displayed if manual mode is active a value is entered in Set Timeout Manual 5 Only displayed if device is connected and functi...

Страница 24: ...up to a 90 second delay till you are asked to confirm damper opening Damper opening Dmp xxx EF xxx Ready in 3 xxxsec Push ok if ExhF runs esc if no 5 Push ok if Dmp opened esc if no 6 OK Integrated Cool Dmp xxx CC1 xxx Comp start in 4 xxxsec Push ok if ExhF stops esc if no 5 Comp to stop in 3 xxxsec Damper closing Dmp xxx EF xxx Push ok if Dmp closed esc if no Min Pos Verify Dmp xxx Push ok if Dmp...

Страница 25: ...ny key esc Service and Commissioning 2 esc esc esc esc esc Return to Automatic 1 esc Any key 1 esc Damper Scaling Manual Mode Acceptance Test Up Down arrow past other tests Push ok to run Ventilation Test Push esc to run return to auto OK 1 Only displayed if acceptance test or manual mode is active If not present navigation jumps over this entry Must press OK to return to automatic 2 Only displaye...

Страница 26: ... is connected and functioning esc OK esc esc 4 3 2 1 Status line Acceptance Test Monitor Live Conditions Settings Present Devices Alarm esc esc esc esc Any key esc Service and Commissioning 2 esc esc esc esc esc Return to Automatic 1 esc Any key 1 esc Damper Scaling DCV Test Manual Mode Acceptance Test Damper scaling for better operation if obstruction is present rescale damper in commissioning me...

Страница 27: ...ol circuit IF to be automatically detected when wired If circuit is not automatically detected the functionality can be manually enabled by choosing available If there is a desire to disable functionality for any reason the operator can choose not available and the operation of the economizer will function as if the device is not installed or configured Compressor Qty3 Auto2 Auto 1 2 Allows for up...

Страница 28: ...os needs to be entered for low speed operation due to less available static pressure from the fan This position will be greater than Vent Min Pos however equal the same measured airflow rate value Low Sp DCV Min6 Low Sp DCV Min _ _ DCV Min Pos Low Sp Vent Min When a 2 Speed strategy is used to save energy an additional DCV Min Pos needs to be entered for low speed operation due to less available s...

Страница 29: ...rement When off 2nd stage is not limited and compressor delay is 10 seconds This function saves energy by having one stage of cooling satisfy space cooling requirements 1 Required setting for Economizer operation If the value is not set outputs of the economizer such as compressors will not operate regardless of thermostat call 2 Attached Devices will be automatically detected and the related func...

Страница 30: ... when there is a Y1 call in Mech Cooling or when there is a Y2 call in Integrated Cooling and the minimum off time has not elapsed Off DXLL Off EcoPotential Off LCLO Displayed when there is a Y1 call during Free Cooling or may be displayed when there is a Y2 call and not in Integrated Cooling Compressor 25 Off Displayed when there is no Y2 call and Mech Cooling available On Displayed when there is...

Страница 31: ...er individual needs Run Time DCV Hours Displays the time when energy is saved by resetting the damper position within range from Vent Min Pos ECOM DCV Min Pos DCVM Note in DCV Heating and mechanical cooling is possible Logged time can be reset through menu for seasonal maintenance equipment repairs or for other individual needs Run Time Integra Hours Displays the operating time when in Free Coolin...

Страница 32: ...eratures IF OAT falls below the low limit 50 F AND not in Heat Pump Mode THEN Compressor 1 and Compressor 2 will be disabled IF OAT rises 2 F above the low limit 52 F OR in Heat Pump Mode THEN Compressor 1 and Compressor 2 will be enabled Minimum On and Minimum Off Time This strategy prevents the compressors from short cycling IF any Compressor is energized THEN run it at least 180 seconds EXCEPT ...

Страница 33: ...Outdoor Enth is 2 5 btu lb less than Return Air Enth AND Outdoor Enth is 2 btu lb less than the reference differential enthalpy high limit DEHL 30 btu lb AND OAT is 2 F below the reference differential temperature high limit DTHL based on entered ZIP code THEN economizing will be enabled If Outdoor Air Enthalpy is 1 btu lb less than Return Air Enthalpy OR Outdoor Air Enthalpy is greater than refer...

Страница 34: ...indoor fan is on low speed the two minimum damper settings reference will change to Low SP Vent Min and Low SP DCV Min respectively Possible Co existing Modes of Operation3 Mechanical Cooling Heating Ventilation Outdoor air may or may not be suitable for free cooling Y1 is de energized Y2 is de energized W1 is de energized G input is energized indicating occupied state of operation Compressor 1 is...

Страница 35: ...gh or low speed See Indoor 2 Speed Fan sequence under Energy Module Option Functions1 Exhaust Fan is off1 Damper Pos output goes to value set in Purge Dmp Set Possible Co existing Modes of Operation3 Mechanical Cooling Heating Damper Override IF Remote Dmp Cntrl is turned on enabled in Settings menu AND G powered THEN Damper Pos will go to the value of the signal input 0 10 VDC at AUX2 Note If out...

Страница 36: ...his menu is available after Setup has been completed This complies with the California Title 24 Mechanical Testing and has four tests To prevent RTU safety lockout and possible equipment damage ensure the RTU indoor fan is running Economizer Test NA7 5 4 This is an automatic functional and verification test that moves the damper 100 open 100 closed and minimum position and switches on CC1 and EF1 ...

Страница 37: ...py 11 RAH Sensor out of range operation by OAH enthalpy 12 RAH Sensor not detected operation by OAH enthalpy 13 RAH Sensor detected but OAH Sensor not detected 14 RAH Sensor detected but RAT Sensor not detected 15 SAT Sensor out of range economizing is disabled 16 SAT Sensor not detected economizing is disabled 17 Y2 present without Y1 single stage 18 SAT drop for CC1 insufficent cooling system pr...

Страница 38: ...alled not deleted Supply power missing Sensor electronics open Wire harness broken A B Sensor previously installed is not detected or sensor has not been installed Differential Enthalpy Economizing functioning by differential temperature with return air humidity limit A RAT sensor out of range Sensor is returning a value that is out of the predetermined range Differential Temperature Economizing f...

Страница 39: ...ordance change over configuration If Y1 follows Y2 2nd stage integrated or mechanical cooling will be enabled Miswired or reverse wired thermostat Miswired ZIP Economizer Thermostat failure Wire harness broken N A SAT drop for CC1 or CC2 insufficient SAT sensor determined that temperature downstream of evaporator did not drop by at least 5 F after 4 min of CC1 or CC2 being energized Informational ...

Страница 40: ...ge to wire increasing resistance Wire harness broken Only 1 compressor in unit wiring inadvertently terminated at CC2 not deleted N A 2 Speed fan not detected Control circuit connected to IF is not detected Logic reconfigured to high speed fan operation only although maintains settings in memory Low speed fan control circuit failure Wire harness broken Damage to wire increasing resistance Wire har...

Страница 41: ...as been detected and will prompt setup Until setup is complete the ZIP Economizer will function as if the devices are not there Proceed to Settings menu and look for menu items that have a blank value press OK and enter value Once all values have been paramatized the ZIP Economizer will function as intended There is No Free Cooling Display shows OAT sensor out of range economizing is disabled Sens...

Страница 42: ... Installed If Auto change it to Installed and see if Alarm disappears or a value OAH value is displayed in Monitor Live Conditions menu Also can try to Delete alarm and see if sensor is again auto detected OAH Sensor Display shows RAH sensor detected but OAH sensor not detected Sensor previously detected is not present Previously configured for differential enthalpy now economizing will be based o...

Страница 43: ...ed inspect SAT sensor in location where are is not mixed perform temperature traverse Indoor fan is inoperable check relay belt motor bearings Condenser fan is inoperable check relay motor head pressure control Compressor is faulty internal damage check amperage pressures Contactor energizes but compressor is out on internal external overload High voltage problem to compressor check wiring phases ...

Страница 44: ...e through the coil and compare to min requirements in technical document Inability to auto detect If the two potential problems above have been verified then there may be a problem with auto detecting In Settings menu under Devices 1 verify the set value is Auto or Installed If set on Auto try setting value to Installed Once Installed the alarm will clear the user must verify the fan does enable a...

Страница 45: ...16 11 14925 63 17 22 14180 65 18 33 13478 67 19 44 12814 69 20 56 12182 71 21 67 11590 73 22 78 11030 75 23 89 10501 77 25 00 10000 79 26 11 9526 81 27 22 9078 83 28 33 8653 85 29 44 8251 87 30 56 7866 89 31 67 7505 91 32 78 7163 93 33 89 6838 95 35 00 6530 97 36 11 6238 99 37 22 5960 101 38 33 5697 103 39 44 5447 105 40 56 5207 107 41 67 4981 109 42 78 4766 111 43 89 4561 F C Ohms 113 45 00 4367 ...

Страница 46: ...www ZIPeconomizer com Belimo Americas USA Latin America and the Caribbean www belimo us Canada www belimo ca Brazil www belimo com br Belimo Worldwide www belimo com ...

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