Belimo ZIP Economizer™ Installation and Operation Manual Discover the advantages www.belimo.us Fast Route to Reliable Energy Savings j li il , Table of Contents Installation and Wiring Instructions 5 ECON-ZIP-BASE 8 ECON-ZIP-EM 10 ECON-ZIP-COM 11 ECON-ZIP-10K 12 ECON-ZIP-TH Setup and Configuration 14 Quick Setup 16 Demand Control Ventilation Setup (DCV & 2-Speed Fan Setup) 18 Multiple Actuator Configuration Main Sequence Documentation 19 Menu Flow / Overview 20 Monitor Live Conditions 21 Settings 22 Present Devices 23 Alarm 24 Manual Mode 25 Service & Commissioning 28 Menu Structure Table 33 Method of Operation 38Alarms 39 Fault Detection & Diagnostics 42Troubleshooting 46 10K Sensor Table 47BACnet Object Descriptions 53 Protocol Implementation Conformance Statement (PICS) j li il , 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, indoor fan- 2 speed control or remote diagnostic alarm notification, power exhaust fan, remote override for damper positioning, and preoccupancy 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 diagnostic alarm indication with future capabilities such as data trending and building automation integration. Required for BACnet MS/TP communication. ECON-ZIP-10K ZIP Economizer Temperature Sensor The ECON-ZIP-10K allows for reliable air temperature 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. 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 discrete 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 enthalpy changeover strategy. Note: When using the ECON-ZIP-TH it is not necessary to use a separate temperature sensor ECON-ZIP-10K for outdoor air (OAT), return air (RAT). 22DC-51 Carbon Dioxide (CO2)Sensor The 22DC-51 Carbon Dioxide (CO) air quality sensor may be incorporated to further increase energy savings and occupant comfort through Demand Control Ventilation (DCV). By directly measuring CO concentration levels in the served space the outside air damper position will modulate to accommodate for changes in space occupancy (CO). ECON-ZIP-EM required for Demand Control Ventilation functionality. j li il , Installation and Operation Manual ZIP PacksModel#Description Components (# included in kit) ECON-ZIP-SDTF Single Dry Bulb with DCV Capability, 2-Speed Fan, Exhaust Fan, and TF Spring Return Actuator (22 in-lb, 7.5 tons**) ECON-ZIP-Base ECON-ZIP-EM ECON-ZIP-10K (2) TFB24-SR ECON-ZIP-TF1 ECON-ZIP-DDTF Differential Dry Bulb with DCV Capability, 2-Speed Fan, Exhaust Fan, and TF Spring Return Actuator (22 in-lb, 7.5 tons**) ECON-ZIP-BASE ECON-ZIP-EM ECON-ZIP-10K (3) TFB24-SR ECON-ZIP-TF1 ECON-ZIP-SETF Single Enthalpy with DCV Capability, 2-Speed Fan, Exhaust Fan, and TF Spring Return Actuator (22 in-lb, 7.5 tons**) ECON-ZIP-BASE ECON-ZIP-EM ECON-ZIP-10K ECON-ZIP-TH TFB24-SR ECON-ZIP-TF1 ECON-ZIP-DETF Differential Enthalpy with DCV Capability, 2-Speed Fan, Exhaust Fan, and TF Spring Return Actuator (22 in-lb, 7.5 tons**) ECON-ZIP-BASE ECON-ZIP-EM ECON-ZIP-TH (2) ECON-ZIP-10K TFB24-24-SR ECON-ZIP-LF1 ECON-ZIP-SELF Single Enthalpy with DCV Capability, 2-Speed Fan, Exhaust Fan, and LF Spring Return Actuator (35 in-lb, 12 tons**) 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-lb, 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-lb, 12 tons**) ECON-ZIP-BASE ECON-ZIP-EM ECON-ZIP-10K (3) LF24-SR US ECON-ZIP-LF1 ECON-ZIP-DELF Differential Enthalpy with DCV Capability, 2-Speed Fan, Exhaust Fan, and LF Spring Return Actuator (35 in-lb, 12 tons**) ECON-ZIP-BASE ECON-ZIP-EM ECON-ZIP-TH (2) ECON-ZIP-10K LF24-SR US ECON-ZIP-LF1 Retrofit Kits ECON-ZIP-ACT Actuator Shaft Adapter allows easy retrofit from Honeywell black box motors (M7XXX) to Belimo spring return actuator using existing linkage and crank arm assembly. Shaft M4x8 Screws (4) Locking Nuts (4) ECON-ZIP-LF1 Bracket with hole patterns to mount the LF Series actuator, horizontal or vertical position in existing Honeywell black box motor footprint. ECON-ZIP-ACT ZG-112 Screws ECON-ZIP-TF1 Bracket with hole patterns to mount the TF Series actuator, horizontal or vertical position in existing Honeywell black box motor footprint. ECON-ZIP-ACT ZG-113 Spacers and Screws **Recommended max RTU tonnage. j li il , Input/Output Specifications TypeNameDescriptionElectrical Specification InputSupply HotAC 24 V, ± 20%, 50/60Hz InputG/ OCC Fan Signal (occupied)On/Off, AC 24 V, ± 20%, 50/60Hz InputSupply CommonCommon InputY1Cooling requirement Stage 1 On/Off, AC 24 V, ± 20%, 50/60Hz InputY2Cooling requirement Stage 2 On/Off, AC 24 V, ± 20%, 50/60Hz InputW1/ O/B Heating requirement Stage 1 On/Off, AC 24 V, ± 20%, 50/60Hz InputSAT ±Supply Air Temperature Sensor Type: 10K NTC (Type II thermistor) InputOAT ±Outdoor Air TemperatureType: 10K NTC (Type II thermistor) InputOAH ±Outdoor Air HumidityDC 0...10 V Auto Detection: Sensor present if voltage 0.5...10 V InputRAT ±Return Air TemperatureType: 10K NTC (Type II thermistor) InputRAH ±Return Air HumidityDC 0...10 V Auto Detection: Sensor present if voltage 0.5...10V OutputCC1Compressor 1 RTU Stage 1 Mechanical Cooling Circuitry 100'000 cycles @ inrush current of 3A, normal current 1.5A Impedance for Auto detection @ 24 V: <60O @ 60Hz <80O @ 50Hz OutputCC2Compressor 2 RTU Stage 2 Mechanical Cooling Circuitry 100'000 cycles @ inrush current of 3A, normal current 1.5A Impedance for Auto detection @ 24 V: <60O @ 60Hz <80O @ 50Hz OutputAct 1Actuator supply commonCommon OutputAct 2Actuator supply hotAC 24 V, 50/60Hz OutputAct 3Actuator control outputDC 2...10 V InputAct 5Actuator feedback signal DC 2...10 V Installation You can mount the ZIP Economizer in any orientation; it is recommended that you mount it in a position that will allow full utilization of the LCD and key pad and proper clearance for installation, servicing, 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 ¼” female insulated spade connectors to prevent corrosion. Technical Data Power supplyAC 24 V ± 20%, 50/60 Hz; Class 2 power source Power consumption rating* 4 VA base control (ECON-ZIP-BASE) 5.5 VA base control with Energy Module (ECON-ZIP-BASE + ECON-ZIP-EM) 5 VA base control with Communication Module (ECON-ZIP-BASE + ECON-ZIP-COM) 6.5 VA base with Energy Module and Communication Module. (ECON-ZIP-BASE + ECON-ZIP-EM + ECON-ZIP-COM) Rated impulse voltage330 V Connectors¼” male spade connectors EnvironmentalRoHS, conformally coated Software class Control pollution degree Temperature input signalNTC 10k Ω, Type II Humidity5 to 95% RH non-condensing Humidity input signalDC 0...10 V; corresponds to 0...100% HousingNEMA 1 Housing materialUL94-5VA Ambient temperature range-40...+158°F [-40...+70°C] Storage temperature range-40...+176°F [-40...+80°C] Display2x16 character LCD; LED backlight; transflective Display op. range**-22...+176°F [-30...+80°C] Agency listingcULus acc. to UL873, CAN/CSA C22.2, No. 24-93 Energy code compliantASHRAE 90.1, CA Title 24, NECB Dimensions(Inches [mm]) 7.12 [181] 2.42 [61.6] 0.18 [4.6] 6.04 [153.4] 5.5 [140] 6.63 [168.5] 2 [50.8] 0.16 [4.1] G/ OCC W1 O/B ECON-ZIP-BASE ZIP Economizer™ Base Module * The power consumption is for the control only and does not include connected loads such as actuator, compressors, fans, and sensors. For transfomer sizing, the power consumption of these attached components must be included. ** At low temperature the display has decreased response time. Below -22°F [-30°C] it will not function. j li il , ECON-ZIP-BASE ZIP Economizer™ Base Module Wiring Diagrams Single Dry Bulb Single Enthalpy R C G OCC W1 O/B Y1 Y2 ACT1ACT2 ACT3 ACT5 R C R C G/OCCW1/O/B Y1 Y2 CC1 CC2 OAT+ OAT- OAH+ OAH- SAT+ SAT- RAT+ RAT- RAH+ RAH- -SR 1 -Common 2 + Hot 3 Y Input, 2 to 10V 5 U Output, 2 to 10V ACT 1 ACT 2 ACT 3 ACT 5 R C Y1 Y2 ECON-ZIP-10K Supply Air Temp SAT + SAT - OAT + OAT - CC1 CC2 OCC W1 RTU Stage 1 Mechanical Cooling Circuitry RTU Stage 2 Mechanical Cooling Circuitry ECON-ZIP-10K Outside Air Temp THERMOSTATRTU TERMINAL ECON-ZIP-BASE 57 52 51 53 56 59 R C G OCC W1 O/B Y1 Y2 ACT1ACT2 ACT3 ACT5 R C R C G/OCCW1/O/B Y1 Y2 CC1 CC2 OAT+ OAT- OAH+ OAH- SAT+ SAT- RAT+ RAT- RAH+ RAH- -SR 1 -Common 2 + Hot 3 Y Input, 2 to 10V 5 U Output, 2 to 10V ACT 1 ACT 2 ACT 3 ACT 5 R C Y1 Y2 ECON-ZIP-10K Supply Air Temp SAT + SAT - CC1 CC2 OCC W1 RTU Stage 1 Mechanical Cooling Circuitry RTU Stage 2 Mechanical Cooling Circuitry ECON-ZIP-TH Outside Air Enthalpy T (+) T (-) 24 V (R) RH (+) RH (-) OAT + OAT - OAH + OAH - R ECON-ZIP-BASE THERMOSTATRTU TERMINAL 57 50 52 51 53 56 59 When the thermostat is not equipped with occupancy control, "Fan On" output "G" shall be wired to the ECON-ZIP-BASE. 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 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 ECON-ZIP-BASE.56 Actuators can be mounted in parallel with the ACT3 output from the ZIP Economizer. The ACT5 feedback input should be wired to the Outside Air damper actuator feedback wire. 57 Iso relay may be required with certain RTU manufacturers.59 Power source should be the same as ECON-ZIP-BASE.50 When the thermostat is not equipped with occupancy control, "Fan On" output "G" shall be wired to 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 valve position, O/B must be wired to W1 on ECON-ZIP-BASE. 52 Actuators can be mounted in parallel with the ACT3 output from the ZIP Economizer. The ACT5 feedback input should be wired to the Outside Air damper actuator feedback wire.57 Thermostat with two (2) stages of cooling required. Thermostats with mercury switches are not compatible with the ZIP Economizer. 58 Iso relay may be required with certain RTU manufacturers.59 j li il , Differential Enthalpy R C G/ OCC W1/ O/B Y1 Y2 ACT1ACT2 ACT3 ACT5 R C R C G/OCCW1/O/B Y1 Y2 CC1 CC2 OAT+ OAT- OAH+ OAH- SAT+ SAT- RAT+ RAT- RAH+ RAH- -SR 1 -Common 2 + Hot 3 Y Input, 2 to 10V 5 U Output, 2 to 10V ACT 1 ACT 2 ACT 3 ACT 5 R C Y1 Y2 ECON-ZIP-10K Supply Air Temp SAT + SAT - OAT + OAT - CC1 CC2 G/ OCC W1/ O/B RTU Stage 1 Mechanical Cooling Circuitry RTU Stage 2 Mechanical Cooling Circuitry ECON-ZIP-TH Outside Air Enthalpy ECON-ZIP-TH Return Air Enthalpy RAT+ T (+) T (-) 24 V (R) RH (+) RH (-) RAT- RAH+ RAH- R T (+) T (-) 24 V (R) RH (+) RH (-) OAH + OAH - R ECON-ZIP-BASE THERMOSTATRTU TERMINAL 57 50 52 51 53 50 56 58 59 Differential Dry Bulb R C G/ OCC W1/ O/B Y1 Y2 ACT1ACT2 ACT3 ACT5 R C R C G/OCCW1/O/B Y1 Y2 CC1 CC2 OAT+ OAT- OAH+ OAH- SAT+ SAT- RAT+ RAT- RAH+ RAH- -SR 1 -Common 2 + Hot 3 Y Input, 2 to 10V 5 U Output, 2 to 10V ACT 1 ACT 2 ACT 3 ACT 5 R C Y1 Y2 ECON-ZIP-10K Supply Air Temp SAT + SAT - OAT + OAT - THERMOSTATRTU TERMINAL CC1 CC2 G/ OCC W1/ O/B RTU Stage 1 Mechanical Cooling Circuitry RTU Stage 2 Mechanical Cooling Circuitry ECON-ZIP-10K Outside Air Temp ECON-ZIP-10K Return Air Temp RAT+ ECON-ZIP-BASE 57 52 51 53 56 RAT- 58 59 Power source should be the same as ECON-ZIP-BASE.50 When the thermostat is not equipped with occupancy control, "Fan On" output "G" shall be wired to 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 valve position, O/B must be wired to W1 on ECON-ZIP-BASE. 52 Actuators can be mounted in parallel with the ACT3 output from the ZIP Economizer. The ACT5 feedback input should be wired to the Outside Air damper actuator feedback wire.57 Thermostat with two (2) stages of cooling required. Thermostats with mercury switches are not compatible with the ZIP Economizer. 58 Iso relay may be required with certain RTU manufacturers.59 Power source should be the same as ECON-ZIP-BASE. 50 When the thermostat is not equipped with occupancy control, "Fan On" output "G" shall be wired to 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 valve position, O/B must be wired to W1 on ECON-ZIP-BASE. 52 Actuators can be mounted in parallel with the ACT3 output from the ZIP Economizer. The ACT5 feedback input should be wired to the Outside Air damper actuator feedback wire. 57 Thermostat with two (2) stages of cooling required. Thermostats with mercury switches are not compatible with the ZIP Economizer. 58 Iso relay may be required with certain RTU manufacturers. 59 ECON-ZIP-BASE ZIP Economizer™ Base Module Wiring Diagrams j li il , ECON-ZIP-EM ZIP Economizer™ Energy Module Technical Data Power supplyAC 24 V ± 20%, 50/60Hz, class 2 power source Power consumption rating*1.5 VA (ECON-ZIP-EM), 5.5 VA (ECON-ZIP-BASE + ECON-ZIP-EM) Connectors1/4" male spade connectors EnvironmentalRoHS, conformally coated Indoor fan speed selection100'000 cycles @ inrush current of 3A, normal current 1.5A Exhaust fan selection100'000 cycles @ inrush current of 3A, normal current 1.5A Supported CO2 sensorDC 0...10 V, sensor auto-detection, 0-2000 ppm Auxiliary input - purge contact on/off - AC 24 V, 50/60HZ - current load min 10 mA Auxiliary input - remote potentiometer DC 2...10 V Humidity5...95% RH non-condensing HousingNEMA 1 Housing materialUL94-5VA Ambient temperature range-40...+158°F [-40...+70°C] Storage temperature range-40...+176°F [-40...+80°C] Agency listingcULus 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]) I/O Specifications TypeNameDescriptionElectrical Specification InputCO2 +/- CO2 sensor input DC 0...10 V Sensor auto-detection OutputALM/IF Alarm relay or Indoor fan low speed relay 100’000 cycles @ inrush current of 3A, normal current 1.5A Impedance for Auto detection @24 V: <600 @ 60Hz <800 @ 50Hz OutputEF Exhaust fan enable 100'000 cycles @ inrush current of 3A, normal current 1.5A Impedance for Auto detection @ 24 V: <600 @ 60Hz <800 @ 50Hz InputAUX1 ± Auxiliary input Purge contact input On/Off, AC 24 V, 50/60 Hz Current load min. 10 mA InputAUX2 ± Auxiliary input Remote Potenti- ometer Input DC 2...10 V Product Features The ZIP Economizer™ Energy Module provides additional I/Os to offer higher control functionalities that will save energy and will meet new and future minimum code requirements. The Energy Module is needed for CO2 sensors, Indoor Fan, 2 Speed Fan, Exhaust Fan, Remote Potentiometer for Damper Positioning, as well as purge control. The auto-detection and plug and play capability offers quick set up. Application The ZIP Economizer™ Energy Module offers demand control ventilation for high occupancy areas. (A third party CO2 sensor required). Pre- occupancy purge input for VOC removal (requires thermostat with purge contact). Power exhaust for building pressure control (requires power exhaust fan) Remote damper override (requires remote potentiometer installed). 2 speed fan control (requires supply fan to be equipped with multi speed fan or VFD). j li il , ECON-ZIP-EM ZIP Economizer™ Energy Module Wiring Diagrams ECON-ZIP-EM CO 2 Sensor RemotePotentiometer AC 24 V Power 2...10 V Signal EFC LSF EFC Indoor Fan Low Speed Relay/ VFD Enable Power Exhaust Fan Relay 1 1 Power Source should besame asECON-ZIP-BASE PurgeContact Thermostat 24Vac 2 Not Supplied by Belimo 2 3Sold Separately by Belimo 3 4If the RTU has a 2speed fan (IF wired), then W1 on the ECON-ZIP-BASE needs to be wired as well, since the fan shall not run in part load when heating. 1 Common 2 + 3 + Y 4 + SGA24SGF24 AC 24 V Power 0...10 V Signal 1 Common 2 + 3 + Y 4 - CO 2 SensorNext >