ZCV6 Installation Manual

RCS
HVAC Zone Control Systems
Model ZCV6
6 Zone
HVAC Zone Control Unit
With RS232/RS485
Serial Communications
INSTALLATION AND OPERATION MANUAL
DCN: 141-01068-01
2/06/06
*** IMPORTANT NOTICE ***
DO NOT USE THIS PRODUCT FOR BUILDING FREEZE PROTECTION! YOU ARE ADVISED TO
INSTALL A MECHANICAL FREEZE PROTECTION DEVICE ON YOUR SYSTEM FOR THIS PURPOSE.
DCN 141-01068 -01 2/06/06
2
OPERATION
The ZCV6 HVAC Zone Control Unit allows a single HVAC mechanical system to be divided into six fully
independent zones. Zone control is accomplished with individual “thermostats” or temperature sensors in
each zone and motorized zone dampers to control the flow of air to each zone.
Each zone “thermostat” is a RCS Wall Display Unit (WDU). The Wall Display Unit looks like a traditional
thermostat and is the wall mounted user interface for each zone of the ZCV6 controller. It provides visual
display of temperature, setpoints and modes, the control pushbuttons, and the zone temperature sensor.
The WDU’s connects to the Zone Control Unit by a 4 wire cable, which can be existing thermostat wires in
retrofit applications or Category 5/6 wiring in new construction.
The Zone Control Unit connects to the HVAC system at the standard thermostat connections. Electrically,
it functions just like a regular thermostat to the HVAC system, provides the thermostatic control of each
zone and sends the appropriate heating and cooling outputs to the HVAC mechanical system.
Wall Display Units. The ZCV6 supports RCS Model TS40 and TS16 Wall Display Units. You must
have at least one TS40 WDU on the ZCV6 for setup. (RCSLink2 type Wall Display Units)
Standard or Heat Pump HVAC Systems. The ZCV6 is compatible with either standard Gas/Electric or
Heat Pump HVAC systems. System type is selectable. The ZCV6 is 100% Heat Pump compatible with
changeover valve operation that can be selected for either changeover with cooling or changeover with
heating (O or B type).
Multi-Stage HVAC Compatibility. The ZCV6 series HVAC outputs supports 2 stages of heating and 2
stages of cooling for Standard systems, and 3 stages of heating and 2 stages of cooling for Heat Pump
systems.
Stage one comes on at 1 deg from setpoint, stage two comes on at 3 deg from setpoint and stage 3
heating for heat pump systems comes on at 5 degrees from setpoint. Stage 1 and 2 operation will stay on
until setpoint is reached. For Heat Pump systems, the stage 3 auxiliary or heat strip heating will go off at 3
degrees from setpoint. These stage deltas can be adjusted.
Fully Independent Zones. Each zone is fully independent and can be set to any setpoint or mode.
Mixed modes are allowable among the zones, that is, one zone may be set to heating while another may
be set to cooling. The system is fully automatic and has auto changeover capability. Heating calls are give
priority over cooling calls. The Zone Control Unit monitors the setpoint and modes of all zones and
determines what Heating calls will be satisfied first and when all heating calls are satisfied, the system
mode will switch to cooling to satisfy all cooling calls.
Fail Safe Zone Damper Operation. The ZCV6 uses normally open dampers for fail safe operation. In the
event that zonal control is lost, all dampers are open so that heating or cooling to all zones is possible until
zone control can be restored. During normal operation, when a zone calls for cooling, all other zones not
calling will be closed. At the end of the call, all dampers will return to open. This “all zones normally open
mode” also allows for system wide ventilation.
Fresh Air Venting. A vent damper relay output is provided for fresh air venting operation.
Remote Communications. The ZCV6 can be jumper selected for RS232 or RS485 serial
communications (only one at a time). It can send and receive data and commands by serial
communications to allow remote control of the system. Commands including requesting status of zone
temperature, setpoint, heating/cooling mode and fan mode as well as setting any zone setpoint or mode.
Individual and global zone commands are allowed. Refer to the RCS RS232/485 protocol manual.
Each Zone is assigned a network address. RCS Automation Control Units, such as the CommStar
Models CS30/308/48, can support up to 32 HVAC zones.
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Outside Temperature Operation
The ZCV6 can use and display outside temperature information from a sensor attached to the ZCV6
Outside Temp Sensor Input or from outside temperature data received from the network. In either case,
the outside temperature will be displayed on all zone WDU’s. A TS16 WDU can view the outside
temperature by pressing the up/down arrows simultaneously. A TS40 WDU will show the outside
temperature at the top center of the screen when outside sensor data is available.
Outside Temp Sensor Attached to the ZCV6. When a outside temp sensor is attached to the ZCV6, it
is “enrolled” as an active sensor when the unit powers up and initializes. Changes in outside temperature
are sent to the wall display units for local display and also reported on the network.
Reporting Outside Temperature on the Network. When an Outside Temp Sensor is attached to the
ZCV6 Outside Temp Sensor Input, the outside temperature will be reported on the network in response to
the Request Status message R=1. The outside temperature shows up as “OA=xx” in the status message
data string.
Displaying Network Outside Temp Data. If a local outside temp sensor is not connected to the ZCV6,
outside temperature data can be received from the network and the ZCV6 will treat it just like a local
sensor is installed. If a local outside temp sensor has been installed on the ZCV6 it will inhibit
network outside temp data from being accepted. This is true even if a outside sensor was enrolled
and then disconnected but has not been un-enrolled by resetting the ZCV6.
Note that network supplied outside temp data will NOT be reported in Request Status R=1 message
response (no “OA=” data will appear).
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4
HVAC CONTROL OPERATION AND SETUP
STANDARD HVAC SYSTEMS
Heat and Cool Mode Operation. In the HEAT mode, the heating system will be turned on when the
room temperature falls one deg below the Heating Setpoint and will turn off when the temperature
reaches the setpoint. This is referred to as the heating delta setting and is factory default set to 1 degree.
In the COOL mode, the cooling system will be turned on when the room temperature rises one degree
above the Cooling Setpoint and will turn off when the temperature reaches the setpoint. This cooling
delta setting is also factory default set to 1 degree.
These factory default settings can be changed from the “Installer Settings” menu on the TS40 Wall
Display Unit. These variables are in the “Delta T Settings” menu item.
Heat/Cool Delta. The system requires a minimum separation between heating and cooling setpoints.
This is factory default set to 4 degrees. Any attempt to change a heating or cooling setpoint that results in
less than the 4 degrees separation will result in “setpoint push”. Changing a heating setpoint will push the
cooling setpoint to maintain the 4 degrees separation and, likewise, changing the cooling setpoint will push
the heating setpoint as needed to maintain the delta. The Heat/Cool delta can also be changed in the
“Installer Settings” menu on the TS40 in the Delta T Settings selection “H/C Delta”.
Auto Mode Operation. In the AUTO mode, the system will automatically switch between heating or
cooling modes as needed to maintain the heat/cooling setpoints.
STANDARD HVAC SYSTEM STAGING
For Standard HVAC system types, the ZCV6 has two stages of heating (W1 and W2) and two stages of
cooling outputs (Y1 and Y2). The second stage heating or cooling will come on when the room
temperature is 3 degrees from setpoint and will turn off when the temperature reaches the setpoint.
The Second Stage Deltas are factory default set to 3 degrees but can be changed from the “Installer
Settings” menu on the TS40 Wall Display Unit. These variables are in the “Delta T Settings” menu item.
HVAC SYSTEM TYPE SELECTION
HVAC systems are generally “Standard” type, which are gas or electric heating systems coupled with
compressor cooling or “Heat Pump” type which use reversible compressors for both heating and cooling.
The ZCV6 works with either HVAC system type. The HVAC system type is set by dipswitch SW1, switch
position S1 on the ZCV6 controller board.
The ZCV6 Control Unit is factory default set to Standard HVAC system type (SW1-S1 OFF)
HVAC SYSTEM FAN MODE SELECTION
Standard HVAC systems using GAS heating DO NOT require fan control outputs from thermostats when
in the heating mode because the furnace automatically turns on the system fan when the system heats
up.
Standard HVAC systems using ELECTRIC heat strips for heating DO require fan control outputs from
thermostats during heating calls.
The fan mode selection is set by dipswitch SW1, switch position S2 on the ZCV6 controller board.
The ZCV6 Control Unit is factory default set to “GAS” system type fan mode. (SW1-S2 OFF)
If you have a Standard HVAC system with ELECTRIC heating, the fan mode must be set to “ELEC” mode
which is dipswitch SW1 position S2 ON.
Be sure to check your HVAC system’s requirements.
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HEAT PUMP HVAC SYSTEMS
HEAT PUMP SYSTEM OPERATION
Heat Pump HVAC Systems use the system’s compressor for both heating and cooling. The system
reverses the compressor operation to change heating/cooling mode. In addition, Heat Pump HVAC
systems may have Auxiliary Heat (heat strips) stages.
Heating and Cooling Mode Operation. Heat Pump HVAC systems work the same as Standard systems
for Stage 1 and Stage 2 heating and cooling operation. Delta T settings are the same and change be
changed the same way as Standard systems.
Heat/Cool delta and Auto mode operation is also the same as Standard systems.
HEAT PUMP SYSTEM STAGING
The ZCV6 has 3 stages of heating and 2 stages of cooling for Heat Pump HVAC systems. Stage one and
stage two heating are Y1 and Y2 outputs. Stage 3 heating is auxiliary heat and is the W1 output. Stage
one and stage two cooling are also the Y1 and Y2 outputs, with heating/cooling mode determined by the
reversing valve (also call the changeover valve) O output. ()
The third stage of heating will be turned on when the current temperature falls 5 deg below the current
setpoint and will turn off at 3 degrees below the setpoint. The Delta T settings can be changed from the
“Installer Settings” menu on the TS40 Wall Display Unit. These variables are in the “Delta T Settings”
menu item.
HVAC SYSTEM TYPE SELECTION
The HVAC system type is set by dipswitch SW1, switch position S1, on the ZCV6 controller board.
To set the ZCV6 for Heat Pump HVAC system type, set the dipswitch SW1-S1 to HP (SW1-S1 ON).
CHANGEOVER VALVE OPERATION SELECTION. Heat Pump systems change from heating to cooling
mode by reversing the direction of refrigerant flow in the system. This “changeover” is controlled by the
reversing valve or changeover output (a shared output marked W2/O) from the Control Unit.
Most Heat Pump HVAC systems are designed to work normally in the heating mode and require a change
over output for cooling. Dipswitch SW1 is used to
The ZCV6 is factory default set for Changeover with cooling (SW1-S2 OFF)
Set CO SEL switch SW1-2 to CO/CL (default) for this type system. Check your HVAC system
requirements for correct settings. If your system requires change over with heating, set SW1-2 to CO/HT.
The changeover relay will stay on until the MOT expires before dropping out. If another call commences
before the MOT timeout, it will avoid unnecessary cycling of the changeover valve.
Minimum Run Time (MRT)
The ZCV6 control unit has a Minimum Run Time after the start of any heat or cool call. This 6 minutes
minimum run time assures even heating and cooling cycles. Minimum Run Time will keep the system on,
even if you change the setpoint to a temperature that would satisfy the call, until it expires. Changing the
Mode to OFF will cancel the MRT and the system will turn off immediately.
Minimum Off Time (MOT)
The ZCV6 control unit has a Minimum Off Time after any heat or cool call. This 6 minutes delay prevents
rapid heating/cooling cycles and also provides “short cycle protection” for compressor calls. This delay
may be noticeable when you change a zone setpoint and it does not respond immediately due to another
call have been recently completed and the MOT delay timer is still active.
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NETWORK OPERATION
The ZCV6 HVAC controller has the option for either RS-232 or RS-485 serial communications. The serial
port allows remote commands generated by other systems to be received by the ZCV6. These remote
commands can change the individual zone setpoint, temperature and modes or may request current
status of a zone temperature, setpoint and mode. Remote commands received by the ZCV6 to change a
zone setpoint or mode are sent to the zone WDU to update its display. Whenever new commands are
received, the WDU will switch its display to show the updated information for three seconds and then
return to the current temp display.
RS-485 connections are a twisted pair multi-drop network that can have up to 254 devices connected to
one pair of wires. With use of a RCS Star Wiring Hub, wiring can also be “star” or “homerun” from each
connected device to the host system, such as RCS CommStar network control units.
Network Addressing. The RS485 address is set from the Wall Display Unit. Network address 0 is
reserved for the Host control unit and address 255 is reserved for global commands.
Each zone in the ZCV control unit is treated like a separate thermostat and has its own RS485 address.
When you set the address for the control unit, you are setting the base address for Zone 1. Each zone is
sequentially addressed from this number. Note that zone addresses are assigned to all zones on the zone
controller, even if they are not used.
For example: with the ZCV6 network address set to 1, each zone address is as follows:
Zone 1 = network address 1
Zone 2 = network address 2
Zone 3 = network address 3
Zone 4 = network address 4
Zone 5 = network address 5
Zone 6 = network address 6
WDU’s can be set to any address from 1 to 254, as a group.
Communications Parameters. The ZCV6 serial communications setup is 9600 baud, no parity, 8 data
bits, 1 stop bit and no flow control.
The RS485 port connects to the J9 screw terminal connector. The D+ and D- connections are required.
The ground connection is optional, but can improve long distance communications and may be needed
when the host and ZCV6 are powered from different power sources.
The RS232 port connects to PC style Com ports using the serial cable and DB9 adapter provided.
Communications Protocol
The ZCV6 Zone Controller uses the RCS serial communications protocol for HVAC control devices. It is
fully compatible with the RCS CommStar Automation Controllers, such as Models CS30/308 or CS48.
The communications protocol is an ASCII message protocol. Refer to the RCS RS-232/485
communications protocol document, PN: 150-00225, for detailed information on serial commands to
communicate with the ZCV6 HVAC control units.
Note that not all commands in the protocol document are applicable to or supported by the ZCV6. The
protocol document has an appendix that identifies specific ZCVx series commands.
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INSTALLATION
LOCATION AND MOUNTING
Install the Control Unit in a protected, convenient, INDOOR location near the HVAC system or in a service
accessible area such as an equipment closet or garage.
Mount the Control Unit in a vertical position on a wall or sturdy structural member. The unit may be
mounted on the HVAC system but care should be taken to avoid the hot burner section or high vibration
areas.
WIRING
Wiring To The Wall Display Units
Wire specification: 4 conductor, 18Ga thermostat wire, 22Ga twisted pair or Cat 3/5 wire (preferred)
The Control Unit connects to each zone’s Wall Display Unit or Sensor by four wires. In retrofit
applications, the existing thermostat wiring may be used, however, for best results and in new
construction, a Category 5 twisted pair cable is recommended.
ZCV CONTROL UNIT
WALL DISPLAY UNIT
ZONE 1 WDU
GND
GND
G
+12V
+12VDC +V
CLOCK
C
DATA
D
CLK
DATA
TWISTED PAIR WIRE RECOMMENDED
22GA Cat3/5
CAUTION! Do not mis-wire the Wall Display Units – damage may result. Check the wiring before
applying power to the Control Unit.
Wiring To The Outside Temp Sensor (if installed)
Wire specification: 2 conductor, 22Ga twisted pair or Cat 3/5 wire (preferred)
Blk
Model OS5
Outside Temp Sensor
Red
Sensor wiring is not polarized.
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8
S1
S1
OS Sensor
Wiring To The Zone Dampers
Wire specification: 2 conductor for RD or 3 conductor for RDM series dampers, standard 18/20GA
thermostat wire.
The ZCV6 HVAC Control Unit has zone damper output relays plus a fresh air vent damper output. These
SPDT relays are rated at 1 Amp, 24VAC. Zone outputs support either two wire (normally open, power
close/spring return) or three wire dampers (power open, power close).
Two Wire Damper Wiring
Com
Open
Close
Three Wire Damper Wiring
Y
Com
Open
Close
Y
RD Series 2 Wire
Normally Open Dampers
1
2
3
RDM Series 3 Wire
Power Open/Close Dampers
ZONE DAMPERS
The ZCV6 requires Normally Open dampers. Without any heat/cool calls, all dampers are open. When
a zone calls for heat/cooling, the other zones NOT calling are closed.
This provides two important functions. First, if there is a zone output failure, the zone is still capable of
getting heating or cooling. Second, it allows for ALL zone ventilation during periods of no heating or
cooling (continuous fan mode).
RCS Round Motorized Dampers
xxRDNO series round motorized dampers. xx = damper size from 6 to 16 inches. These standard
dampers feature an extra rigid barrel with a self sealing blade that provides a 99% seal. They are
24VAC, 2 wire, 2 position, power close/spring return, normally open dampers. Current draw is 0.5 amps
each. Rated for continuous power in the closed position.
xxRDMNO series round motorized dampers. xx = damper size from 6 to 20 inches. These heavy duty
style dampers have the same extra ridge barrels of the RD series, coupled with a commercial heavy duty
3 wire damper motor. These wire as 24VAC common, power open and power close. Current draw is 0.1
amps max each. Rated for continuous power in the open and closed positions.
The xxRDMNO dampers are the preferred damper for use with the ZCV6 control unit.
POWER
The Control Unit requires 24VAC Power. Power is provided by an external transformer (not supplied).
You must calculate the size of the transformer VA rating for the maximum number of dampers powered at
one time. The worst case load is when only one zone calls and all others are powered close.
Each RD series damper draws 0.5 amps when closed. Each RDM series damper requires 0.1 amps and
is powered in both open and closed positions.
A 40VA transformer supplies 1.67 amps and supports three RD series dampers or 15 RDM series
dampers.
A 75 VA transformer supplies 3.125 amps and supports 6 RD series dampers.
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COMMUNICATIONS
Communications Setup and Wiring
RS232 Communications
When the RS232 communications mode is selected, the ZCV6 COM Port is a standard PC compatible
serial port.
RS232 COM Port Setup
The RS232 communications parameters are 9600 baud, no parity, 8 data bits, 1 stop bit (9600 N81). Set
Flow Control to None.
NOTE: RS232 communications still requires that a network address of 1 be assigned to the ZCV6
even though only one control unit can be attached via RS232. Individual zones must be addresses
1 to 6 for RS232 communications (default address).
Refer to the RCS Serial Protocol Manual for more information on serial communications and commands
for the ZCV6 control unit.
Selecting RS232 Communications Mode
Set jumpers JP1 and JP2 on the Communications PCB to RS232 Mode (jumpers to the left).
232
485
JP1
JP2
Connecting to RS232 PC Style Com Ports
A serial cable is provided with the ZCV6 for connection to the J10 RJ45 connector on the ZCV6 and to a
DB9 adapter that connects to a PC style com port.
PC System
ZCV6 HVAC
Control Unit
COM1
COM PORT
J10
RS232 Serial COM Port Cable
and DB9 adapter provided.
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10
RS485 Communications
When the RS485 communications mode is selected, the ZCV6 COM port is a 2 wire (D+ and D –) plus
ground, half-duplex network connection.
RS485 COM Port Setup
The RS485 communications parameters are 9600 baud, no parity, 8 data bits, 1 stop bit (9600 N81). Set
Flow Control to None.
RS485 Communications Mode Selection
Set jumpers JP1 and JP2 on the Communications PCB to RS485 Mode (jumpers to the right).
232
485
JP1
JP2
RS485 Wiring Methods
The ZCV6 control unit can be wired by three methods:
1. Direct connection to RS485 com ports
2. Multi-drop (daisy chained) to other thermostats/devices
3. Homerun wired to a Star Hub.
ZCV6 HVAC
Control Unit
Direct Connection
Host System
RS485 port
COM PORT
J9
Up to 4000 ft
12V
Gnd
D+
D-
Gnd
D+
DRS485 Wiring Note
Always wire + to + and – to –, regardless of the D+/ D- or A/B or TX/RX labels.
Multi-drop Wiring
Host System
RS485 port
12V
Gnd
D+
DRS485
RS485
Gnd
D+
DDCN 141-01068 -01 2/06/06
Gnd
D+
D11
RS485
Gnd
D+
D-
100 ohm end of line
termination resistor
recommended on
last device
Termination Resistor
On multi-drop network wiring, the last device on the network is typically installed with an “end of line”
termination resistor. This may not be needed for short networks, but if your line length exceeds 1000 feet,
you may benefit from this termination to keep network reflections to a minimum.
The ZCV6 can be jumper to provide a 100 ohm end of line termination resistor.
Jumper JP3 on the communications PCB to enable this resistor.
Star Hub Wiring
Star networks are home run wiring and may be used with the RCS CommStar CS308 Automation
Controller, or added to other controllers with the Model 8AH485 RS485 Star wiring hub. Star wiring is
simple and easy to install and trouble shoot.
CommStar Model CS308
or Model 8AH485
8 Channel Star RS485 Hub
ZCVx
Control Unit
RS485 Port
RS485 Port
RS485 Port
RS485 Port
RS485 Port
RS485 Port
RS485 Port
RS485 Port
RS485 Port
ZCVx
Control Unit
RS485 Port
ZCVx
Control Unit
RS485 Port
ZCVx
Control Unit
RS485 Port
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HVAC SYSTEM WIRING
Electrically, the ZCV6 Control Unit looks like a standard thermostat to your HVAC system. All connections
to the HVAC systems are made at the normal thermostat connection on the HVAC unit.
Refer to the following HVAC wiring information for the type of HVAC system, Standard or Heat Pump, that
the ZCV6 control unit is being connected to. Refer to your HVAC system’s documentation for specific
information on its thermostat connections.
Standard Gas/Electric HVAC System Wiring
JP1: RH and RC Jumper
This commons both RH and RC for normal single transformer HVAC systems.
Cut JP1 jumper for separate RH and RC transformer systems.
ZCV6 Control Unit
HVAC System Output
STANDARD HVAC SYSTEM
JP1
HVAC SYSTEM
RH 24VAC
THERMOSTAT CONNECTION
Optional separate RH
RC 24VAC
RED
W1 HEAT
WHITE
W2/O
Y1 COMP
R 24VAC RETURN
W1 Heat Stage 1
W2 Heat Stage 2
YELLOW
Y1 Compressor Stage 1
Y2 COMP
G1 FAN
C 24VAC COMMON
Y2 Compressor Stage 2
GREEN
G Fan
Heat Pump HVAC System Wiring
JP1: RH and RC Jumper
Do NOT cut for Heat Pump Systems
ZCV6 Control Unit
JP1
HEAT PUMP HVAC SYSTEM
HVAC SYSTEM
THERMOSTAT CONNECTION
RH 24VAC
C 24VAC COMMON
RC 24VAC
RED
W1 HEAT
WHITE
W2/O
ORANGE
Y1 COMP
YELLOW
Y2 COMP
G1 FAN
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R 24VAC RETURN
W1 Heat Stage 1
O/B Changeover Valve
Y1 Compressor Stage 1
Y2 Compressor Stage 2
GREEN
13
G Fan
SYSTEM CHECKOUT
It is strongly recommended that you hook-up and run a simple bench test before installing this controller.
Not only will this save you time in system checkout but will also familiarize you with the ZCV6 operation.
QUICK TEST
NOTE: Before power up, set the dipswitch on the controller PCB, SW1, to ALL OFF.
1. Connect a Wall Display Unit to ZONE 1 input on the Control Unit with a short 4 wire cable.
2. Connect the 24VAC transformer to the Control Unit.
3. Plug the transformer into a 110v outlet and apply power to the Control Unit.
4. Verify Power Status LED is flashing.
5. Verify the WDU display comes on and shows the current temperature.
a. If no display or a “CF” display is shown on the WDU, double check your wiring.
b. Do not proceed until the current temperature is displayed on the WDU and communications
between it and the Control Unit is OK. Any problems will result in a “CF” (Communications Failure) display
on the WDU.
6. Press the Fan button on the WDU. The Control Unit Fan LED and relay should turn on. Also all
damper LED’s should turn on except Zone 1.
7. Press the Fan button again. The Fan LED and all relays should turn off.
8. Press the Mode button until the WDU is showing “H” for Heat Mode.
9. Press the Setpoint Up button until the setpoint is above the current temperature. The Heat LED and
relay should come on.
10. Press the Mode button until the WDU is showing “O” for OFF. The Heat LED and relay will turn OFF.
11. Press the Mode button until the WDU is showing “C” for Cool Mode.
12. Press the Setpoint Down button until the setpoint is below the current temperature. The Cool and Fan
LEDs and relays should turn on.
13. Press the mode button until the WDU is showing “O” for OFF Mode.
14. All LEDs and relays should turn off.
15. When you have successfully completed all these tests, you have verified that the Control Unit and the
WDU are working and communicating correctly.
RS-232 QUICK TEST with a PC
1. With the Control Unit and WDU connected as above, proceed with connecting the ZCV6’s com port to
a PC serial port (COM1). Set the ZCV6 com port to RS232 mode by setting the jumpers on JP1 and
JP2 to the right.
3. Set the ZCV6 base address to 1
4. Start the Hyperterm terminal emulator program in Windows/Accessories/Communications/Hyper
Terminal.
5. Set Hyperterm communications parameters for COM1 to 9600 baud, no parity, 8 data bits, 1 stop bit
and NO flow control.
6. Set CAPS lock on (Commands are case sensitive).
7. Send the Request for Status command R=1. Type “A=1 R=1” followed by the carriage return (cr).
8. ZCV6 should respond with the R=1 status response showing temp, setpoint, mode and fan for zone 1
(A=00 O=1 Z=1 T=(current temp) SP=70 M=0 F=0)
9. Set zone 1 Mode to Heat. Type “A=1 M=H (or 1) cr”.
10. Zone 1 WDU should change to show the new mode is “H”.
11. Set zone 1 setpoint to 78 degrees. Type “A=1 SP=78 cr”
12. Zone 1 WDU should change to show a setpoint update of “78”.
13. If the WDU responds properly to these commands, proceed with installation.
It is recommended that you install the ZCV6 and then rerun these quick tests BEFORE you connect the
Control Unit to the HVAC system. You will be confident that the ZCV6 is working correctly before you
attempt to interface the HVAC system.
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HVAC SYSTEM QUICK TEST
In the event that you have difficulty with the ZCV6 controlling the HVAC system, you can perform the
following quick test to confirm that the HVAC system is working correctly.
The ZCV6 Control Unit connects to the HVAC system at the normal thermostat connections on the
HVAC unit. Standard thermostat control of the HVAC systems consist of contact closures in the
thermostat. You can verify that your HVAC system is working correctly by duplicating these contact
closures by shorting across the proper terminals on the HVAC systems thermostat connection. Refer to
the following HVAC system example.
HVAC SYSTEM EXAMPLE
This is a simplified diagram of an HVAC System and
Thermostat. The Thermostat operates like switches to
control the HVAC Fan, Heat, and Cool functions.
HVAC SYSTEM
STANDARD GAS/AC
FURNACE AND BLOWER UNIT
THERMOSTAT
C 24VAC COMMON
24VAC
R 24VAC HOT
G FAN
FAN
HEAT
W HEAT
COMP
Y COMP
FAN
RELAY
GAS
VALVE
For Standard HVAC systems:
Go to the HVAC system’s thermostat connection terminals.
Verify FAN operation by shorting across the R to G (Fan) terminals.
• HVAC system fan should come on. (Caution: Delays may be
part of normal start up cycle, check manual)
• If not check HVAC system power and fuses.
• If power is OK, HVAC system is NOT working correctly.
COMP
RELAY
OUTDOOR
CONDENSING
UNIT
Verify HEAT operation by shorting across R to W (Heat) terminals (A Fan call is not necessary for gas furnaces).
• Heating operation should start. (Caution: Delays may be part of normal start up cycle, check manual)
• If not, check wiring, check 24VAC power is on R terminal. (measured across R to C).
• If power is OK, HVAC system is NOT working correctly.
Verify COOL operation by shorting across R to Y (Compressor) and R to G (Fan) terminals.
• Cooling operation should start. (Caution: Short Cycle Protection 5 minute delays are normal
between calls and may delay start)
• If not, check wiring, check 24VAC power is on R terminal (measured across R to C)
• If power is OK, HVAC system is NOT working correctly.
For Heat Pump systems:
Follow the above test to check the FAN operation. If FAN works OK, then power is verified also.
Short across R to Y and R to G. You should get either Heat (normal) or Cool operation depending on the
whether your system is changeover with cool (normal) or heat.
Short across R to Y, R to G and R to O/B(Changeover terminal) to get opposite heat or cool operation
from step 2. If any of these checks fail, the HVAC system is not working correctly.
DCN 141-01068 -01 2/06/06
15
ZCV6
Zone 1
WDU
75
Zone 2
WDU
75
Zone 3
WDU
75
Zone 4
WDU
75
Zone 5
WDU
75
Zone 6
WDU
75
Outside
Temp Sensor
Model OS5
6 ZONE HVAC CONTROL UNIT
+
C
D
Wiring Diagram
Fuse F1
+
C
D
RC/RH Jumper
Cut for separate
Heating and Cooling
Transformers
+
C
D
_
+
C
D
G
V
C
D
GND
Zone 1
12V
CLK Wall Display Unit
DATA
G
V
C
D
GND
Zone 2
12V
CLK Wall Display Unit
DATA
G
V
C
D
GND
Zone 3
12V
CLK Wall Display Unit
DATA
G GND
V 12V
C CLK
D DATA
_
+
C
D
_
+
C
D
GND
Zone 5
12V
CLK Wall Display Unit
DATA
G
V
C
D
GND
Zone 6
12V
CLK Wall Display Unit
DATA
Red
Black
HVAC
Sensor
G
V
C/SL
D/SC
Com Port
Network
Connection
DCN 141-01068 -01 2/06/06
GND
D+
D-
Gnd
Data +
Data -
16
STD S1
RH
RC
W1
W2/O
Y1
Y2
G1
Thermostat Connection
C
R
W1
W2
Y1
Y2
G
Red
White
Yellow
Green
HVAC System
Standard or
Heat Pump
24C Com
24V Ret
Heat 1
Heat 2
Comp1
Comp2
Fan
Set DIPSW1 to
Correct System Type
Fan Control
G1
G2
G3
G4
G5
G6
G7
Note: W2 = O (Changeover) when
Heat Pump System Type Selected
Fan Control not used
Vent Damper
Red
Green
White
Com
CL
OP
1 24V Com
2 Close
3 Open
Vent Damper
RDM Series
or 2030DD
Zone Dampers
Zone 1 Com
CL
Damper
OP
HP
Zone 2
Damper
ON
S1
S2 OFF
STD GAS
HP
CO/C
Size for Max
damper load
JP1
S2
OFF
Transformer
24VAC
24R
24C
HVAC System
DIPSW1
G
V
C/SO
D/SC
24VAC
Power
Zone 4
Wall Display Unit
G
V
C
D
Outside
Sensor
3A
S2 ON
ELECT
CO/H
Com
CL
OP
Zone 4 Com
CL
Damper
OP
Zone 4 Com
CL
Damper
OP
Zone 5 Com
CL
Damper
OP
Zone 6 Com
CL
Damper
OP
Yel
Yel
Red
Zone 1
RD Series
Yel
Yel
Zone 2
RD Series
White
Yel
Yel
Red
Zone Dampers
Zone 3
RD Series
Yel
Yel
White
Yel
Yel
Red
Green
White
Normally Open
RD Series 2 Wire
or RDM Series 3 Wire
Zone 4
RD Series
Zone 5
RD Series
Zone 6
RDM Series