Sys. 2000 Manual 8-03
Design & Installation for
Zonex Systems
System 2000
2-20 Zone Auto Changeover
System 1000
2-7 Zone Manual Changeover
Part #101ASIM
Rev. September 2003
TABLE OF CONTENTS
System 2000
System Operation.................................................................................................................................................................1
Components.........................................................................................................................................................................1
Component Selection Guide .................................................................................................................................................2
System 2000 System Controllers...........................................................................................................................................3
Gas/Electric (101ASSB).............................................................................................................................................3-5
Heat Pump (101AACBHP) .........................................................................................................................................5-7
Startup.................................................................................................................................................................................8
System 1000
System Operation.................................................................................................................................................................9
Components.........................................................................................................................................................................9
Component Selection Guide ...............................................................................................................................................10
System 1000 Switching Centers
Gas/Electric (SYGE)..............................................................................................................................................11, 12
Heat Pump (SYHPA) ..............................................................................................................................................12-14
Startup...............................................................................................................................................................................15
Zone Thermostats ...........................................................................................................................................................16, 17
Remote Sensors .................................................................................................................................................................17
Zone Dampers .......................................................................................................................................................................18
Round Zone Dampers..................................................................................................................................................18, 19
Rectangular Zone Dampers..........................................................................................................................................20, 21
Sizing Zone Dampers .........................................................................................................................................................22
Wiring Zone Dampers........................................................................................................................................................22
Damper Installation Notes..................................................................................................................................................22
Paralleling Zone Dampers..................................................................................................................................................23
Bypass Dampers ....................................................................................................................................................................23
Barometric ..................................................................................................................................................................23, 24
Electronic ....................................................................................................................................................................25, 26
Bypass Position Indicators ..........................................................................................................................................26
Paralleling Bypass Dampers........................................................................................................................................26
Bypass Damper Static Pressure Controller .......................................................................................................................27
Capacity Controllers .............................................................................................................................................................28
101CAPGE....................................................................................................................................................................29, 30
TRLAT ..........................................................................................................................................................................31, 32
TRFPC................................................................................................................................................................................32
SYCAP ..........................................................................................................................................................................33, 34
101ALAS ............................................................................................................................................................................35
CAPL-2.........................................................................................................................................................................36, 37
CAPL-4.........................................................................................................................................................................38, 39
Capacity Controllers Installation.........................................................................................................................................40
Capacity Controllers, Setpoints, Calibration........................................................................................................................41
Important Diagrams
Five Wire Link....................................................................................................................................................................41
Transformer/Fuse Sizing ....................................................................................................................................................42
Application Schematics ................................................................................................................................................42, 43
SYSTEM 2000
The System 2000 is a light commercial/residential zone control system.
It enables a single HVAC unit to be controlled by up to twenty zone (room)
thermostats. System 2000 is a vote based, auto changeover system. The
system operates on a first call, first served majority wins on changeover
strategy. To provide economical, effective and simplified remote control
and monitoring capability of one or more System 2000 zone control sys-
tems, the ZonexCommander may be used to manage up to 80 thermostat
schedules. The ZonexCommander is a Window’s based thermal management system, which can integrate gas/electric and heat pump zone systems to include stand alone HVAC systems. For modulating communicating control, use the ZonexCommander (Plus).
CONCEPTUAL
DRAWING ONLY
Refer to System 2000
Controller Section for
Wiring Information
SYSTEM OPERATION
The System Controller communicates with the Zone Dampers and Zone
Thermostats via a patented Five-Wire Link. The Five-Wire Link is daisy
chained from damper to damper using standard five-conductor
thermostat wire. The System Controller polls every zone every 120 seconds and registers the number of thermostats calling for heating and
cooling. The System Controller then runs the HVAC/Heat Pump unit in the
mode with the most calls. If the majority changes, the System Controller
will automatically change over to the new mode of operation.
System 2000
Zonex Systems Supplied Components
System Controllers ..............................................................Pages 3- 7
Zone Thermostats ...............................................................Pages 16-17
Zone Dampers ....................................................................Pages 18-23
Bypass Dampers .................................................................Pages 23-27
Capacity Controllers............................................................Pages 28-41
The Zone Dampers are open for the zones calling and closed for the
zones not calling for the operating mode. When the HVAC/Heat Pump unit
is not running, all Zone Dampers are open to provide ventilation if the
indoor blower fan is running continuously.
System 2000
Field Supplied Components
Thermostat Wire........................................................................Page 41
24V Transformers and Fuse .......................................................Page 42
While the unit is running, the Capacity Controller monitors the leaving air
temperature from the unit and will cycle the HVAC/Heat Pump unit off
and on to maintain the air temperature within a preset range to eliminate
coil freeze-up and premature heat exchanger failure.
1
SYSTEM 2000 COMPONENT SELECTION GUIDE
Auto Changeover for 2 to 20 Zones
START
GAS ELECTRIC
System Controller
(101ASSB)
HEAT PUMP ❶
System Controller
2 Stage Heat/Cool with Auxiliary Heat
(101AACBHP)
Capacity Controller
Single Stage(TRLAT) or (101CAPGE)
2-Stage (CAPL-2)
3- or 4-Stage (CAPL-4)
Capacity Controller
101ALAS (Included with Controller)
Optional
Outdoor T-Stat
(field supplied)
ZONE THERMOSTATS
Communicating
(DIGICOM)
Digital
(101DIGI)
COMMAND CENTER
(101CEC Communication Package,
one per 20 thermostats)
Programmable
(101PROG)
Auxiliary Heat
for reheat/baseboard
(101DIGITS)
ZONE DAMPERS
5 TONS AND UNDER
OVER 5 TONS
Low Pressure Dampers
Round (101ARZD size) up to .5” SP
Rectangular (101EC W x H) up to .5” SP
Medium Pressure Dampers
Round (101AMPD size) up to 1.75” SP
Rectangular (101MRTD W x H) up to 1” SP ❷
Heavy Duty Rectangular (101CD W x H) to 1.75” SP
12 X (Number of Dampers) = VA for the
24V System Transformer (Field Supplied)
6 X (Number of Dampers) =VA for the
24V System Transformer (Field Supplied)
BYPASS DAMPERS
OVER 5 TONS
5 TONS AND UNDER
Electronic Bypass Damper
Round (STMPD size)
Rectangular (STCD W x H)
Barometric Bypass Damper
Round (101ABBD size)
Rectangular RBB W x H
Static Pressure Controller (101ASPC)
24V, 40VA Independent Transformer
for bypass (Field Supplied)
COMPLETE SYSTEM
❶ Some Heat Pumps utilize Gas/Electric thermostats, typically units over 7.5 tons.
For this application, use the Gas/Electric parts selection and field modify the capacity
control heat cutoff setpoint to 118° F.
2
❷ Use heavy duty rectangular dampers on systems of 7.5 tons or larger
SYSTEM 2000 CONTROLLERS
Dimensions 7” x 7” x 2.5”
Gas Electric System Controller
(101ASSB)
Heat Pump System Controller
with LAS Sensor
(101AACBHP)
SYSTEM 2000 CONTROLLERS – GAS/ELECTRIC 101ASSB
HEAT CALLS – If the majority of calls are for heat, the System Controller
will turn on the heat. If the fan switch is set for auto, the bonnet control
or a delay relay will start the fan. When all heating calls are satisfied or
the majority changes to cooling, the gas valve will turn off.
OVERVIEW
The 101ASSB is a Gas/Electric System Controller that will control up to
20 zones for the System 2000 zoning system. The System Controller
selects the mode of operation based on a majority calls basis. It is
used in conjunction with a Capacity Controller. The Capacity Controller
controls the HVAC system staging. Capacity Controllers are available for
one, two, three and four stage systems. Refer to Capacity Controller
section (pg. 28) for further information.
CHANGEOVER – If the system is running in one mode and the majority
of calls changes to the other mode, a timer will start. The System Controller will give the current operating mode another 4 minutes to try and
satisfy the zone(s). It will then go into a 4-minute purge cycle before
switching modes.
The 101ASSB is a vote based, auto changeover System Controller. It polls
each zone every 120 seconds, registering heat or cool calls. Majority
wins, and the Controller operates the HVAC system in that mode until all
calls are satisfied or it detects a majority of offsetting calls.
PURGE MODE – When a heat or cool call is satisfied or before changing modes, the System Controller will go into a 4-minute purge cycle.
The compressor or gas valve will turn off and the indoor blower will continue to run. The dampers of any zone thermostat not satisfied in the
previous mode will remain open. This allows the supply air to adjust
to room temperature before changeover or ventilation while providing a
time delay to prevent short cycling.
The System Controller should be located in an accessible, conditioned
space. The Controller does not sense temperature; it simply receives data
from the zone thermostats. The Controller communicates to the zone
dampers and thermostats through a five-wire link. These five wires are
daisy chained to each zone damper. This simple patented wiring process
eliminates home run wiring.
VENTILATION – When no zones are calling, all zone dampers open after
the purge mode. This permits ventilation in all zones if the blower fan is
on continuously.
OPERATION
When heating or cooling calls are sent to the System Controller, the
controller will treat these calls as votes.
COOL CALLS – If the majority of calls are for cooling, the System
Controller will turn on the compressor and fan. The air conditioner will
continue to operate until all cooling calls are satisfied or the majority
changes to heating.
3
SYSTEM 2000 CONTROLLERS – GAS/ELECTRIC 101ASSB
COMPONENTS
The 101ASSB System Controller consists of the following:
A. TB1 (Terminal Block 1): Wires to daisy chain, transformer
and time clock.
TC1, TC2 – Time clock switch terminals. Used for Select-Temp
system only.
S – Nite call. Used for Select-Temp system only.
Y – Cool call.
W – Heat Call.
Rd – Damper close signal.
B – 24V AC common. Same terminal as TR2.
G – 24V AC hot. Same terminal as TR1 when PWR switch ON.
TR2 – 24V AC common.
TR1 – 24V AC hot.
B. Jumpers J1 and J2:
J1 – Not used.
J2 – Not used for System 2000. Used for Select-Temp system
only.
C. Microcontroller: Responsible for zone communication, activation
and control of outputs based upon zone demand and leaving air
temperature. Occasionally software upgrades may become available. If so, the 101ASSB software can be field upgraded by changing this microcontroller.
D. Off board fuse: One amp. Protects Y and W terminals of TB1.
E. Status lights: Refer to status light section for details.
F. TB2 (Terminal Block 2): Wires to Capacity Controller and
HVAC unit.
R – HVAC unit 24V AC power
W1 – Heat enable
Y1 – Cool enable
G – Indoor blower fan enable
G. FAN switch:
AUTO – Turns on indoor blower fan when unit is running in cool
mode.
ON – Indoor blower fan runs continuously.
H. COOL and HEAT mode switches:
AUTO – Accepts calls from thermostats.
OFF – Ignores calls.
I. Power switch. When on, applies 24V AC power to G of TB1.
J. On board fuse. One amp. Protects 101ASSB board only.
TC2 TC1 S Y W Rd B G TR2 TR1
A
1
101ASSB
D
E
SET BACK
F
TB2
R
W1
Y1
G
H
G
PWR
C
I
DELAY
HEAT
COOL
DAMPER
UNIT
J1
J2
B
ON
HEAT COOL
J
TB1
OFF
FAN
1
AUTO
OFF
AUTO
OFF
ON
STATUS LIGHTS
DELAY
HEAT*
COOL*
DAMPER
UNIT
On when HVAC unit energized. Flashing when in purge/delay mode.
On in heat mode.
On in cool mode.
When on, dampers of zones not calling for present mode are closed.
On when HVAC unit energized.
Delay
Heat*
0
0
1
1
FLASH
FLASH
1
0
1
0
1
0
Status Lights
Cool*
Damper
0
1
0
1
0
1
0
0
1
1
1
1
Mode
Function
Unit
0
0
1
1
0
0
Heat, no calls
Cool, no calls
Heat call
Cool call
Purge heat
Purge cool
HVAC unit off. All dampers open.
HVAC unit off. All dampers open.
Heat energized. Heat calling zone dampers open.
AC energized. Cool calling zone dampers open.
Blower fan on, HVAC unit off. Heat calling zone dampers open.
Blower fan on, HVAC unit off. Cool calling zone dampers open.
*MODE LIGHTS TOGGLE BETWEEN HEAT AND COOL EVERY 120 SECONDS. THIS INDICATES THE SYSTEM CONTROLLER IS POLLING FOR HEAT OR COOL CALLS.
4
SYSTEM 2000 CONTROLLERS - GAS/ELECTRIC 101ASSB
WIRING
ZONE
THERMOSTAT
1
W Y R C
4
DAMPER MOTORS
Close Open
ZONE
DAMPER
2
5
6
W2 W Y R C
TB2
TB1
RC MC RO
DAMPER RELAY
BOARD (P/N 101ARLY)
W2 W Y G Rd B
sizing.
UP TO 20
3
4
C terminal for hard wired electronic
thermostats only.
5
Open motor not utilized on low pressure
(spring open) dampers.
ZONES
Fused
24V AC
2
Damper
Transformer
TC2 TC1 S Y
TB1
W Rd B
6 If using more than one damper per
G TR2 TR1
thermostat, refer to Slaving Zone
Dampers section, page 23 and 44.
101ASSB
System Controller
7
TB2
R
W1
24V damper transformer. Requires in-line
fuse. See table on page 42 for sizing transformer and fuse.
3 Refer to page 41 for Five Wire Link wire
DAISY CHAIN
7
If the heater does not turn on the
blower fan, a blower fan relay must be
installed. See page 43.
Do not remove factory installed jumper
between TC1 and TC2. TC1 and TC2 are
used for Select-Temp Zoning System only.
Y1 G
8 When using the 101ASSB controller in a
1
heat pump application which utilizes G/E
terminals, a fan relay must be installed,
see page 43.
TO CAPACITY CONTROLLER
AND HVAC UNIT (PG 28)
SYSTEM 2000 CONTROLLERS – HEAT PUMP 101AACBHP
Overview
*The reversing valve is energized depending on the O/B
jumper setting.
The 101AACBHP Heat Pump Controller greatly simplifies coordination of
single stage or two stage Heat Pumps with dampered zone systems. The
Controller communicates to the zone dampers through a five wire link.
These five wires are daisy chained to each zone damper. This simple
patented wiring process eliminates home run wiring. The 101AACBHP
has a built-in capacity control system which uses an LAS (included with
the Controller) for capacity control. Refer to the section on Capacity
Control LAS for more information.
Second stage operation is based on the leaving air temperature of the unit.
The LAS reports the discharge temperature to the Controller. Three
minutes after initiating cooling, the Controller checks the LAS. If the
discharge temperature is above 52 degrees, the second stage is turned
on. Three minutes after initiating heating, the Controller checks the
LAS. If the discharge temperature is below 114 degrees, the second
stage is turned on.
Operation
The Heat Pump Controller is also set up to operate electric strip heat in
the Heat Pump. The Controller monitors the air temperature leaving the
Heat Pump coil. When there is a call for heat and the air leaving the coil
is not above 85 degrees, the electric strip will turn on after an eight minute
delay. This operation can be modified, if desired by an outdoor thermostat.
The Controller operates the Heat Pump using signals from each zone
thermostat in the system. When heating or cooling calls are sent to the
controller, it treats these calls as votes. If the majority of calls are for
cooling, the Controller will operate in the cool mode. The Heat Pump
will continue to operate in the cool mode until the majority of calls shift
to heating or all cooling calls are satisfied. If the majority of calls are for
heating, the Controller will operate in the heat mode. The Heat Pump
will continue to operate in the heat mode until the majority of calls shift
to cooling or all heating calls are satisfied.
The Heat Pump Controller simplifies system wiring. The Controller
terminals connect directly to the Heat Pump terminal strip. (Heat Pump
thermostats are not used for this system). Relays, timers and other
miscellaneous controls are not required.
5
SYSTEM 2000 CONTROLLERS – HEAT PUMP 101AACBHP
Cool, Damper and Pump LEDs will illuminate. The first stage cool will
energize on Y1 and O/B with the Rev Valve LED flashing for 8 minutes.
After 8 minutes from Y1, if the supply air temperature is 60° or higher,
Y2 second stage of cooling will energize. The Rev Valve LED will change
from flashing to steady ON. (Cool “B” mode for Rev Valve LED will change
from flashing to OFF after Y2 energizes.)
OPERATION (Continued)
The 101AACBHP Zonex Systems SYSTEM 2000 Heat Pump controller
has a series of lights which indicate different operations. These are
labeled “Heat,” “Cool,” “Damper,” “Pump,” “Rev. Valve,” “Y1 Cool”, “Y2
Cool,” “Y1 Heat” and “Y2 Heat.” The “Heat” and “Cool” lights
indicate, when illuminated, the present mode of operation. These lights
will momentarily toggle to the other mode every 120 seconds when
polling. Polling is when the controller checks to see how many heat and
cool calls are being made. If there are no calls, the “Heat” or “Cool”
light will be on based on the last operating mode. The “Damper” light
indicates that a thermostat is calling and that power is being supplied to
the damper motors. The “Pump” light indicates that the first stage pump
is operating. The “Rev. Valve” light indicates that the reversing valve is
activated, or when it flashes, that a time delay is active. The “Y1” and
“Y2” Cool and Heat lights are part of the Capacity control function
included on the Heat Pump Controller. The Y2 Heat or Cool LED, when
illuminated, indicates the Y2 compressor has cycled OFF, because the
capacity control setpoint has been exceeded. When Y1 and Y2 heat or
Cool LEDs are both illuminated, the controller will initiate a 4-minute
temperature cut out, with both stages cycling off.
AUTO CHANGEOVER – If an existing mode is overridden by an opposite
majority, the existing call will remain in operation for 4 minutes, and
then the controller will go into a 2 minute purge with the existing
dampers staying open. After the purge cycle has timed out, the system
blower cycles OFF (when in the auto mode). The controller goes into a
2 to 4 minute delay, switching to the opposite mode, with the dampers
making the opposite call opening. Y1 and Y2 are not energized during
this delay. After this final delay times out, the controller energizes Y1 in
the opposite mode.
If all zones satisfy, the “Pump” and “Damper” lights will go out. The
“Heat” or “Cool” lights will be on based on the last mode of operation.
If your system includes auxiliary heat, it will be activated by the “W”
terminal on the SYSTEM 2000’s Heat Pump Controller. Auxiliary heat
will be activated when the following conditions are met. The “Heat” and
“Damper” lights are on indicating a heat call; the “Pump” light is on
and the “Rev. Valve” light is not flashing, indicating that first and second
stage are activated; four minutes after the “Rev. Valve” light stops
flashing the auxiliary heat will be activated if the leaving air temperature
is below the Electric Heat setpoint (factory set at 85 degrees). The time
delay before bringing on the auxiliary heat gives the second stage time
to raise the leaving air temperature over 85 degrees. Even if the system
is single stage, the controller will still delay the electric heat until after
the second stage time delay is satisfied.
When power is first turned on, if there are no calls for cooling or
heating, the “Heat” light will be the only light illuminated, with the
exception of the “Rev. Valve” light. It will also be on if jumper J1 is
removed (“B” operation). When there is a cooling or heating call, the
“Damper” and “Heat” or “Cool” lights will turn on.
When the “Rev. Valve” light is not indicating a time delay by flashing, it
will stay illuminated only when the reversing valve is operated.
HEAT – Reversing valve “O” Mode – When the controller receives
an initial or consecutive call for Heat, the Rev Valve LED will flash; the
Heat, Damper and Pump LEDs will illuminate. The first stage heat will
energize on Y1, and the Rev Valve LED will continue to flash for at least
4 minutes. After 4 minutes from Y1, if the supply temperature is 95° or
less, Y2 will energize and the Rev Valve LED will go OFF (Heat “B” mode
will change the flashing Rev Valve LED to ON when Y2 energizes). The
auxiliary heat will energize 4 minutes after Y2 and when the supply air
temperature is 85° or less.
The reversing valve is controlled by the “O/BL” terminal. This terminal
should be connected to the Heat Pumps terminal strip according to the
unit manufacturers recommendations. Jumper J1 on the SYSTEM 2000
Heat Pump board needs to be adjusted to operate with the different
manufacturers designs. The Heat Pump board is shipped from our
factory ready to operate a heat pump unit which requires the “O” wire
to energize the reversing valve in cooling. If the reversing valve needs to
be activated for the “BL” terminal, jumper J1 needs to be removed from
the Controller board. Refer to the Heat Pump Controller drawing on the
previous page for the location of jumper “J1”. Remove the jumper from
the board to activate the reversing valve using the “BL” terminal.
COOL – Reversing Valve “O” Mode – When the controller receives
an initial or consecutive call for Cool, the Rev Valve LED will flash; the
Warning: For heat pumps using standard gas/electric thermostats, do not use the 101AACBHP System Controller. Instead, use the
101ASSB System Controller and the CAPL-2 Capacity Controller.
6
SYSTEM 2000 CONTROLLERS – HEAT PUMP 101AACBHP
OPERATION SUMMARY TABLE (EFFECTIVE HPC V1.04 8/02)
CALL (HEAT/COOL):
POWER UP, NO CALLS:
STATUS LIGHTS:
DAMPER
REV. VALVE
HEAT*
COOL*
PUMP
TB2:
Y1
Y2
G
W
O/BL
STATUS LIGHTS:
DAMPER
REV. VALVE
HEAT
COOL
PUMP
TB2:
Y1
Y2
G
W
O/BL
OFF
NOTE 1
ON
OFF
OFF
OFF
OFF
OFF
OFF
NOTE 1
STATUS LIGHTS:
DAMPER
REV. VALVE
HEAT*
COOL*
PUMP
TB2:
Y1
Y2
G
W
O/BL
AUX. HEAT
0
ON
FLASH
ON FOR HEAT
ON FOR COOL
ON
DELAY IN MINUTES
4*
ON
NOTE 1
ON FOR HEAT
ON FOR COOL
ON
8
ON
NOTE 1
ON FOR HEAT
ON FOR COOL
ON
ON
OFF
ON
OFF
NOTE 1
ON
ON
ON
OFF
NOTE 1
ON
ON
ON
NOTE 2
NOTE 1
O
4
1ST STAGE
DELAY IN MINUTES
8
10
12
ON
ON
FLASH
ON FOR HEAT
ON FOR COOL
OFF
ON
FLASH
ON FOR HEAT
ON FOR COOL
ON
ON
NOTE 1
ON FOR HEAT
ON FOR COOL
ON
ON
NOTE 1
ON FOR HEAT
ON FOR COOL
ON
OFF
OFF
OFF
OFF
NOTE 1
ON
OFF
ON
OFF
NOTE 1
ON
ON
ON
OFF
NOTE 1
ON
ON
ON
NOTE 2
NOTE 1
CONTINUE
PREVIOUS
MODE
OPERATION
MODE CHANGE:
2ND STAGE
1ST STAGE
2ND STAGE
AUX. HEAT
*NOTE:
Cool: Y2 delay on
make 8 min.
Heat: Y2 delay on
make 4 min.
NOTE 1: On if: a) In cool mode and reversing valve set for “O” operation (J1 jumper installed).
b) In heat mode and reversing valve is set for “BL” operation (J1 jumper removed).
NOTE 2: On when in heat mode and supply air temperature below Electric Heat setpoint.Heat, Cool, and Fan switches
in AUTO position. Capacity Controller lights off. Delay times are approximate.
*Momentarily toggles to opposite mode every 120 seconds.
WIRING
NOTES:
1
2
Zone
Thermostat
Refer to page 41 for 5 wire link wire sizing.
W
24V damper transformer. Requires in-line fuse. See table on page 42 for sizing
transformer and fuse.
Y
R
C
Motors
Close Open
Zone
Damper
7
3 C terminal for hardwired electronic thermostats only.
4 J1 Reversing Valve Selection Jumper. Leave jumper in place to
energize reversing valve in cool mode, “O” mode. Remove
jumper to energize in heat mode, “B” mode. J2 is not used for
System 2000.
(PG 35)
Y
R
C
RC
MC RO
W
Y
G
Rd
B
Relay Board
(101ARLY)
-
TR2 TR1
OFF
COOL
OFF
AUTO
OFF
TB2
5 ELECTRIC HEAT
PUMP #2
PUMP #1
REV VALVE
FAN
7
R
W
Y2
Y1
O/BL
G
R
TO
HEAT
PUMP
W
Y2
Y1
O/
BL
G
FAN
AUTO
HEAT ADJ
TP3
NOTE:
If the Heat Pump system does not have rev. valve
inputs, use the 101ASSB (Gas/Electric Controller).
ON
PWR
G
HEAT
J1
J2
COOL ADJ
TP2
B
Rd
101AACBHP
HEAT PUMP
CONTROLLER
4
ELECTRIC
HEAT ADJ
TP1
2
W
PUMP
-
DAMPER
+
NC
TC1 TC2 S Y
COOL
TB1 TEMP
6
HEAT
GND
+
UP TO
1
20
ZONES
REV.
VALVE
If using more than one damper per thermo8 stat, refer to Slaving Zone Dampers section,
pages 23 and 44.
W
W2
Y1
HEAT
Y2
Y1
COOL
Y2
Open motor not utilized on low pressure
7 (spring open) dampers.
GROUND
W2
TB1
DUCT
MOUNTED
LEAVING AIR
SENSOR
(101ALAS)
5 If the heat pump does not include an outdoor thermostat, it is
recommended that the “W” wire to the unit is run thru an
optional outdoor thermostat with a manual override switch.
6 Do not remove the jumper wire from TC1 and
TC2. Used for Select-Temp Zoning System only.
TB2
ON
FUSED 24 VOLT
TRANSFORMER
SYSTEM 2000 SYSTEM STARTUP
Make sure the correct size fuse is installed in-line with the transformer
powering the Controller.
5.
After cooling calls are tested, turn the cooling switch to “OFF” and
set the heating switch to “AUTO”. Set the first zone to call for heat.
If the call is received by the Controller, “Damper” and “Heat” lights
will turn on. Test each thermostat to be sure that each properly
communicates with the Controller for the heating sequence.
6.
After all zones have been checked, turn the ON/OFF switch at the
System Controller to OFF.
7.
Before wiring the System Controller to your A/C unit or furnace,
check the relays with a volt meter (set on 200 Ohms). Be certain no continuity exists on the A/C unit terminal connections at the
System Controller. Check between each terminal to the “R” terminal. There should be no continuity between the terminals. (If you
do show continuity, your System Control board should be replaced.)
8.
If no continuity exists from the test detailed above, connect the
terminal to the A/C unit and the System Controller. Be certain all
thermostats are now in the “OFF” position.
9.
Turn the power switch to “ON” and the “HEAT” and “COOL” switches should be set to “AUTO”. Initiate a call for cooling from only one
stat. After a time delay, both compressor and fan should be running.
Turn off the cooling and initiate a heating call, (you may experience
up to a 4 minute time delay). The heat should come on and after a
short time delay the fan will be operated by the internal controls of
the unit. On the Heat Pump controller, eight minutes on the initial start of CAPL-2 after stage one starts, the LAS or capacity control will control second stage operation.
For both Gas/Electric and Heat Pump Controllers
1. These system tests are to be done with all wiring to the air conditioning unit disconnected.
A. Be sure that the power switch to the Controller is in the “OFF”
position. For Gas/Electric remove “R,” “W1,” “Y1” and “G” wires
from Terminal Strip 2 labeled (TB2).
B. Be sure that the power switch to the Controller is in the “OFF”
position. For Heat Pumps remove “R,” “W,” “Y2,” “Y1,” “O/BL”
and “G” wires from Terminal Strip 2 labeled (TB2).
2.
Check wiring of the 5 wire link to the dampers. All connections
must be made color to color.
3.
If you are not using Zonex Systems supplied zone thermostats,
check each one to make sure it is an auto changeover type stat.
Turn all thermostats to the OFF position. Check the Controller
“HEAT” and “COOL” switches to be sure that both are in the “OFF”
position. The “FAN” switch should be in the “AUTO” position. Observe
the fuse on the Controller Board and transformer. Turn the power
switch to “ON.” If the fuse blows, there is a wiring problem. If the
fuse does not blow, turn the “HEAT” switch to “AUTO” and “COOL”
switch to “AUTO.” If the fuse blows at any of these steps, find and
repair the short in the wiring.
4.
If the system is operating normally, the Heat light should be on for
the 101ASSB, and 101AACB-HP. Set the “HEAT” switch to “OFF”.
Check the first zone by turning it on and setting it to call for cooling. If the call is received by the Controller, the “Damper” and
“Cool” lights will turn on. If the lights come on, turn off the first
stat and the “Damper” light should turn off. Test each stat this way
to be sure that each one is capable of communicating with the
Controller, and able to start and stop the air conditioner.
10. After completing the system check and startup procedure, set the
system up for normal operation.
NOTE: “Heat” and “Cool” Led indicators will toggle every two minutes to check opposite mode callers, regardless of heat and cool
switch positions.
8
SYSTEM 1000
System 1000 Zone Control enables a single HVAC unit to be controlled by
up to seven zone (room) thermostats. System 1000 is a manual
changeover system. This means that the mode of operation (heat/cool)
is manually selected. For auto changeover capability select Zonex
Systems System 2000.
CONCEPTUAL DRAWING ONLY
Refer to System 1000 Switching
Center Section for Wiring
Information.
4.25"
2.5"
1"
System 1000
Switching Center
SYSTEM OPERATION
System 1000
Zonex Systems Supplied Components
The user manually selects the mode (heat/cool) at the Switching Center.
If any zone thermostat calls for the mode selected, the green call light
turns on at the Switching Center, the HVAC/heat pump unit turns on, and
all non-calling zone dampers close.
Switching Centers................................................................Pages 11-14
Zone Thermostats ...............................................................Pages 16-17
Zone Dampers ....................................................................Pages 18-23
Bypass Dampers .................................................................Pages 23-27
Capacity Controllers............................................................Pages 28-41
Once all zones are satisfied, the green call light turns off, the HVAC/heat
pump unit shuts off and all dampers open. If the Switching Center
fan switch is ON, the fan will continue to run to allow ventilation in
all zones.
System 1000
Field Supplied Components
The Capacity Controller independently monitors the supply air temperature
to prevent coil freeze up or overheating.
Thermostat Wire........................................................................Page 41
24V Transformer(s) and Fuse....................................................Page 42
The Bypass damper will independently bypass any supply air not needed
back to the return duct.
9
SYSTEM 1000 – COMPONENT SELECTION GUIDE
Manual Changeover for 2 to 7 Zones
START
HEAT PUMP ❶
Switching Center
(SYHPA)
2 Stage Heat/1 Stage Cool
GAS ELECTRIC
Switching Center
(SYGE)
ZONE THERMOSTATS
ZONE THERMOSTATS
Digital
(101DIGI)
Programmable
(101PROG)
Digital
(101DIGI)
CAPACITY CONTROLLERS
1 Stage
(TRLAT)
or
Digital Version
(101CAPGE)
Programmable
(101PROG)
DIGITAL CAPACITY CONTROLLER
(SYCAP)
2 Stage
(CAPL-2)
Optional Outdoor
T-Stat (field supplied)
ZONE DAMPERS
5 TONS AND UNDER
OVER 5 TONS
Low Pressure Dampers
Round (101ARZD size) up to .5” SP
Rectangular (101EC W x H) up to .5” SP
Medium Pressure Dampers
Round (101AMPD size) up to 1.75” SP
Rectangular (101MRTD W x H) up to 1” SP ❷
Heavy Duty Rectangular (101CD W x H) to 1.75” SP
12 X (Number of Dampers) = VA for the
24V System Transformer (Field Supplied)
6 X (Number of Dampers) =VA for the
24V System Transformer (Field Supplied)
BYPASS DAMPERS
OVER 5 TONS
5 TONS AND UNDER
Electronic Bypass Damper
Round (STMPD size)
Rectangular (STCD W x H)
Barometric Bypass Damper
Round (101ABBD size)
Rectangular RBB W x H
Static Pressure Controller (101ASPC)
24V, 40VA Independent Transformer
for bypass (Field Supplied)
COMPLETE SYSTEM
❶ Some Heat Pumps utilize Gas/Electric thermostats. For this type of Heat Pump,
use the Gas/Electric parts selection and field modify the capacity control heat cutoff
setpoint to 118° F.
10
❷ Use heavy duty rectangular dampers on systems of 7.5 tons or larger
SYSTEM 1000 SWITCHING CENTERS – GAS/ELECTRIC SYGE
OVERVIEW
OPERATION
The SYGE Switching Center is a manual changeover, Gas/Electric System
Controller. It can control up to 7 zone thermostats. Its function is to look
for calls from the zone thermostats for the mode (heat/cool) selected. If a
call is received, it sends a signal to close the dampers of all zones not
calling and sends a signal to the HVAC unit to energize heating or cooling.
The user manually selects the mode (heat/cool) at the Switching Center.
Heat mode – If any zone thermostat calls for heat, electrical current
flows in WD. The Switching Center senses this current, turns on the green
Call light, energizes RD (RD made to GD) which tells the dampers of all
zones not calling to close and energizes W (W made to R) which tells the
HVAC unit to turn on heat.
Cool mode – If any zone thermostat calls for cool, electrical current
flows in YD. The Switching Center senses this current, turns on the green
Call light, energizes RD (RD made to GD) which tells the dampers of all
zones not calling to close, and energizes Y and G (Y and G made to R)
which tells the HVAC unit to turn on cooling and the indoor blower fan.
No calls – When no thermostats are calling, the green Call light is off,
RD is not energized so all dampers are open, and W, Y are not energized
so the HVAC unit is off. If the FAN switch is ON, then G is energized (G
made to R), and the indoor blower fan will run. This allows ventilation
in all zones.
The Mode, Power and Fan control switches are located at the Switching
Center. The Switching Center should be placed in a location that provides
easy access to these switches.
The Switching Center is used in conjunction with a Capacity Controller.
The Capacity Controller protects the evaporator coil from freezing and the
heat exchanger from overheating. The Capacity Controller also controls
staging for multistage HVAC systems. Refer to the Capacity Controller
section (pg. 28) for more information.
COMPONENTS
5.
1. 5 Wire Link Terminals – Daisy chain wires to zone dampers.
YD – Cool call input signal. Current flows in this terminal when Mode
switch at COOL, Power switch ON and thermostat calling for cool.
6.
WD – Heat call input signal. Current flows in this terminal when
Mode switch at HEAT and thermostat calling for heat.
BD – 24V return. Same as TR2.
GD – 24V hot. Same as TR1.
RD – Unit on output signal. Energized (RD made to GD) when
Switching Center acknowledges thermostat call. See 7.
7.
2. Transformer Terminals – 24V AC transformer terminals. This
transformer powers the dampers, thermostats and Switching Center.
It does not power the HVAC unit. That power comes from terminal
R; see 3.
3. HVAC Unit Terminals – Connect to HVAC unit via Capacity Controller. See Capacity Controller section for wiring
information.
W – Heat enable. Energized (W made to R) when SwitchHEAT
ing Center acknowledges a heat call. See 7.
Y – Cool enable. Energized (Y made to R) when SwitchCOOL
ing Center acknowledges a cool call. See 7.
ON
R – HVAC unit 24V power.
G – Fan enable. Energized when FAN switch is at ON posiOFF
tion or when FAN switch is at AUTO position and Switching Center acknowledges a cool call. See 7.
AUTO
4. Mode Switch – Selects mode (heat/cool) to run system. FAN
Switching Center will only respond to thermostats calling
ON
for mode selected.
11
Power Switch – When OFF the Switching Center will not respond to
thermostat calls. Power remains to all dampers and thermostats.
The indoor blower fan will run if fan switch is on.
Fan Switch – Controls the indoor blower fan (G).
AUTO – Indoor blower fan turns on when air conditioner is on.
Note: In heat mode, furnace controls indoor blower fan.
ON – Indoor blower fan continuously on as long as Power switch
is ON.
Call Light – On when Switching Center responds to a calling
thermostat.
1
2
3
YD WD BD GD RD TR1 TR2
4
5
6
WYRG
SYSTEM 1000
GAS/ELECTRIC
SWITCHING CENTER
(SYGE)
GREEN CALL
LIGHT
7
SYSTEM 1000 SWITCHING CENTERS – GAS/ELECTRIC SYGE
WIRING
NOTES:
1
2
3
SIMPLIFIED SCHEMATIC, SYGE
24V damper transformer. Requires in line fuse. See table on page
42 for sizing transformers and fuse.
YD
W
COOL
HEAT
COOL
Y
Refer to page 41 for five wire link wire sizing.
WD
BD
GD
K1
LOGIC
BOARD
C terminal for hard wired electronic thermostats only.
R
4
Open motor not utilized on low pressure (spring open) dampers.
5
If using more than one damper per thermostat, refer to Paralleling
Zone Dampers section, pages 23 and 44.
K1
ON
G
FAN
AUTO
RD
HEAT
POWER
GREEN
CALL LIGHT
160
OHMS
K1
TR1
LOGIC
BOARD
TR2
SWITCHING CENTER
SYSTEM 1000 SWITCHING CENTERS – HEAT PUMP SYHPA
SIMPLIFIED SCHEMATIC, SYHPA
WD
3P3T
YD
GD
BD
RD
SWITCHING
OFF
HEAT
SWITCH
COOL
K1
(SYHPA)
LOGIC
BOARD
160
OHMS
TR
1
TR2
F
U
S
E
K1
COOL
OFF
E.M.
HEAT
OFF
AUTO
HEAT
O
FAN
K1
ON
COOL
COMP. FAIL
(YELLOW)
OFF
Y
G
R
E.M. HT LIGHT
(RED)
ON
HEAT
B
O/B
CENTER
POWER
LOGIC
BOARD
GREEN
CALL LIGHT
OVERVIEW
The SYHPA Switching Center is a manual changeover, single stage cool,
two stage heat, heat pump System Controller. It can control up to 7 zone
thermostats. Its function is to look for calls from the zone thermostats for
the mode (heat/cool) selected. If a call is received, it sends a signal to close
the dampers of all zones not calling and sends a signal to the heat pump
unit to energize heating or cooling.
W2
E
L
C
The Switching Center is used in conjunction with a SYCAP Capacity
Controller. The SYCAP cycles the heat pump on and off to maintain the
leaving air temperature within a set range. Refer to the SYCAP in the
Capacity Controller section (pg. 33) for more information.
12
SYSTEM 1000 SWITCHING CENTERS – HEAT PUMP SYHPA
(RD made to GD) which tells the dampers of all zones not calling to close
and energizes Y, and G (Y and G made to R). G turns on the indoor blower fan. Y controls the heat pump compressor. Y is further controlled by
the SYCAP Capacity Controller which makes and breaks Y to maintain a
minimum leaving air temperature. See SYCAP under Capacity Controller
section for further information. The reversing valve is energized (O made
to R) if the Reversing Valve jumper is set to O.
The Mode, Power, Fan and Emergency Heat control switches are located
at the Switching Center. The Switching Center should be placed in
a location that provides easy access to these switches.
NOTE: If your heat pump is controlled by a gas/electric thermostat, use
an SYGE Switching Center. See SYGE Switching Center section, pg. 3.
OPERATION
No calls – When no thermostats are calling, the green Call light is off,
The user manually selects the mode (heat/cool) at the Switching Center.
Heat mode – With the Mode switch set to HEAT, Fan switch set to AUTO,
EM HT switch set to OFF and Power switch set to ON, if any zone thermostat calls for heat, electrical current flows in WD. The Switching Center senses this current, turns on the green Call light, energizes RD (RD
made to GD) which tells the dampers of all zones not calling to close
and energizes Y, W2 and G (Y, W2 and G made to R). G turns on the
indoor blower fan. Y controls the heat pump compressor and W2 controls
auxiliary heat. Y and W2 are further controlled by the SYCAP Capacity Controller which makes and breaks Y and W2 to maintain a minimum and
maximum leaving air temperature. See SYCAP under Capacity Controller
section for further information. The reversing valve is energized (B made
to R) if the reversing valve jumper is set to B.
RD is not energized so all dampers are open, and W2, Y are not energized
so the HVAC unit is off. If the FAN switch is ON then G is energized (G made
to R) and the indoor blower fan will run. This allows ventilation in all
zones.
Emergency Heat – With the Mode switch set to HEAT, Fan switch set
to AUTO, EM HT switch set to ON and Power switch set to ON, if any zone
thermostat calls for heat, electrical current flows in WD. The Switching
Center senses this current, turns on the green Call light and red Emergency Heat light, energizes RD (RD made to GD) which tells the dampers
of all zones not calling to close and energizes E (E made to R). What E is
wired to depends on the make of your heat pump. Refer to the SYHPA
wiring diagram for further information.
Cool mode – With the Mode switch set to COOL, Fan switch set to AUTO,
EM HT switch set to OFF and Power switch set to ON, if any zone
thermostat calls for cool, electrical current flows in YD. The Switching
Center senses this current, turns on the green Call light, energizes RD
Note: Do not leave the Emergency Heat switch set to ON when the Mode
switch is set to COOL. Doing so will energize E (turning on emergency
heat) when a thermostat makes a cool call.
COMPONENTS
R – Heat Pump unit 24V power.
E – Emergency Heat enable. Energized (E made to R) when
Switching Center acknowledges a heat call and Emergency Heat
switch is ON. See 6 and 9.
W2 – Auxiliary Heat enable. Energized (W2 made to R) when
Switching Center acknowledges a heat call and Emergency Heat
switch is OFF. Sends signal to SYCAP.
L – Compressor fail flag input terminal. If feature is provided by Heat
Pump, when L is energized (L made to R), red light DL3 is illuminated to signal compressor is not working.
C – Heat Pump unit 24V power return.
4. Mode Switch – Selects mode (HEAT/OFF/COOL) to run system.
Switching Center will only respond to thermostats calling for mode
selected.
5. Fan Switch – Controls the indoor blower fan (G) when the Emergency Heat switch is OFF.
AUTO – Indoor blower fan turns on when Heat Pump is on.
ON – Indoor blower fan is continuously on as long as Power
switch is ON.
6. Emergency Heat – Disables compressor (Y) and blower fan (G)
and energizes E (E made to R). This tells the Heat Pump to
turn on auxiliary heat. Should only be used when Mode switch is in
HEAT. If used when mode switch is in COOL, auxiliary heat will turn
on when there is a cool call.
1. 5 Wire Link Terminals – Daisy chain wires to zone dampers.
WD – Heat call input signal. Current flows in this terminal when
Mode switch is at HEAT and thermostat is calling for heat.
YD – Cool call input signal. Current flows in this terminal when Mode
switch is at COOL, Power switch is ON and thermostat is calling for
cool.
BD – 24V return. Same as TR2.
GD – 24V hot. Same as TR1.
RD – Unit on output signal. Energized (RD made to GD)
when Switching Center acknowledges thermostat call. See 9.
2. Transformer Terminals – 24V AC transformer terminals. This
transformer powers the dampers, thermostats and Switching Center.
It does not power the HVAC unit. That power comes from terminal
R; see 3.
3. Heat Pump Unit Terminals – Connect to Heat Pump unit via SYCAP
Capacity Controller.
O/B – Reversing Valve terminal. Energized (O/B made to R) in heat
mode when O/B jumper is at B. Energized in cool mode when O/B
jumper is at O.
Y – Compressor enable. Energized (Y made to R) when Switching
Center acknowledges a heat or cool call and Emergency Heat Switch
OFF.
G – Fan enable. Energized when FAN switch is at ON position or
when FAN switch is at AUTO position, Emergency Heat Switch is OFF
and Switching Center acknowledges a heat or cool call.
13
SYSTEM 1000 SWITCHING CENTERS - HEAT PUMP SYHPA
7. Reversing Valve Selection Jumper – Configures Switching Center to energize reversing valve in cool mode or heat mode. Place on
O and center pin to energize reversing valve in cool mode. Place on
B and center pin to energize in heat mode.
8. Fuse – 1/10 amp. Protects WD and YD terminals.
9. Status Lights –
DL1 – Call light, green. On when Switching Center responds to a
calling thermostat.
DL2 – Compressor fail, yellow. On when L terminal is energized
(L made to R). Indicates heat pump compressor is not functioning.
DL3 – Emergency Heat, red. On when E terminal is energized (E
made to R). Indicates emergency heat is on.
10. Power Switch – When OFF the Switching Center will not respond to
thermostat calls. The indoor blower fan will run if Fan switch is ON.
Power remains to all dampers and thermostats.
1
HEAT
4
3
OFF
COOL
O
DL2 DL3
7
SYHPA
9
DL1
8
OFF
EM. HT.
ON
6
2
O/B Y G R E W2 L C
B
AUTO
FAN
ON
5
TR2 TR1
WD YD BD GD RD
OFF ON
10
WIRING
6
7
TB2
DAMPER RELAY BOARD
ZONE
THERMOSTAT
Daisy chain up to six additional zones
(101ARLY)
4
3
FUSED 24V
DAMPER
TRANSFORMER
W D Y D BD G D RD
TB1
SYHPA
SWITCHING CENTER
If the heat pump does not include an
outdoor thermostat, it is recommended
that the “W2” wire to the heat pump
unit is run thru an optional outdoor
thermostat with a manual override
switch.
O/B Y
If using more than one damper per
thermostat, refer to paralleling zone
dampers, pages 23 and 44.
G
R
E W2 L
TR1 TR2
5
Refer to page 41 for Five Wire Link wire
sizing.
2
R Y W W2
4
24V damper transformer. Requires
in-line fuse. See table on page 42 for
sizing transformer and fuse.
1 OPEN
MOTOR
CLOSE
MOTOR
C R Y W
3
C terminal for hardwired electronic
thermostats only.
ZONE DAMPER 6
RO MC RC C
2
Open motor not utilized on low pressure
(spring open) dampers.
W2 W Y G Rd B
1
C
Y1Y1 W2 W2
O/B Y G
If the heat pump does not have an
emergency heat terminal, connect “E”
of Switching Center to auxiliary heat
terminal of heat pump. If the heat
pump does not turn on the indoor
blower fan in emergency heat mode,
add blower fan relay as shown below.
R
SYCAP
CAPACITY
CONTROL
(PG 33)
5
E W2 L C
HEAT PUMP TERMINALS
R C
7
EMERGENCY HEAT BLOWER FAN RELAY
If the heat pump does not energize
the indoor blower fan when
emergency heat is energized, add
relay K1 as shown. Relay K1 is a
24VAC SPDT relay.
SYHPA
SWITCHING CENTER
G
R
E
C
K1
K1
K1
G
14
R
E
C
HEAT PUMP TERMINALS
SYSTEM 1000 STARTUP
When all wiring is completed to the dampers and the gas electric/heat
pump unit, the following tests should be made:
✓ Disconnect the R wire from the Switching Center.
✓ Check to be sure that there is 24 volt power between
terminals TR1 & TR2.
✓ Set all thermostat switches to the OFF position.
✓ Set the Switching Center in the HEAT mode.
✓ Set the Switching Center ON/OFF switch to ON.
HEAT PUMP (SYHPA) with the SYCAP
Check that the fuse on the SYHPA has not blown. If it has, check for
shorts on the WD and/or YD wires on the five wire link and replace the
1/10 amp fuse.
Turn the POWER switch on the SYHPA and SYCAP OFF: Check all
thermostats to be sure that they are off. Reconnect the R wire at the SYHPA.
Check to be sure that the O/B jumper on the SYHPA is in the correct
position for the heat pump. Turn the POWER switch on the SYHPA to ON.
The green call light should be off at the Switching Center. If it is on, there
is a thermostat calling or the WD wire is shorted.
✓ Check all of the thermostats, if they are off, remove the WD wire
from the Switching Center. The green light should go off. If it
does, find the short in the five wire link before re-connecting it. If
the green light does not turn on, test each thermostat, one at a
time. Turn on one thermostat, set it to call for heating, and the
green light on the Switching Center should turn on. When you set
this same thermostat for no heat, the green light at the Switching
Center should turn off. Test each thermostat in this manner to
be sure all thermostats are properly wired.
Now, set the Switching Center in the COOL mode.
If the green light turns on with all thermostats off, there is a short in the
YD wire. Correct the problem before proceeding.
To test the COOL mode, set the HEAT/COOL switch on the SYHPA to the
COOL position. Set only one thermostat to call for cooling. The green
call light on the SYHPA should turn on and the compressor will run. The
indoor fan will start with the compressor. If the compressor or fan do
not start, check the wiring between the SYHPA and the Heat Pump.
To test the HEAT mode, turn the POWER switch on the SYHPA to OFF.
Turn all thermostats off. Set the MODE switch on the SYHPA to HEAT and
then turn the POWER switch ON. Set one thermostat to call for heat. The
green call light will turn on at the SYHPA and the compressor will turn on
in the heat mode. The fan will turn on with the compressor. If the
fan or compressor does not turn on, check the wiring.
When yellow DL2 is lit, there is a heat pump compressor failure (if “L”
terminal has been wired).
Repeat the test of each thermostat in the cool mode. When a thermostat
is calling, the green call light will turn on. Turning this thermostat off will
turn off the green call light at the Switching Center.
When the “EM HT” switch is set to ON, the SYHPA will never power the
“Y” or “G” terminal and will power the “E” terminal during a call. While
the “EM HT” switch is set to ON, the red light labeled DL3 will turn on if
there is a call. To test the Auxiliary/Electric heat, see the unit manufacturers wiring diagrams and instructions.
GAS/ELECTRIC SYGE
Turn the ON/OFF switch off and reconnect the R wire. Be sure that all
thermostats are off. Turn the ON/OFF switch ON. Decide if you want to
test the heating or cooling system and set the HEAT/COOL switch to the
desired position.
SYCAP and Auxiliary/Electric Heat
To test the Auxiliary/Electric heat, turn the SYCAP switch ON. If the display begins to toggle between “E” and “157”, the factory installed temperature sensor or its wiring to terminals ± is open. If the display toggles
between “E” and “32”, the temperature sensor is shorted. Check connections + and – and the wire holding the sensor in the plenum for shorts.
If you have set the switch to COOL, set one thermostat to call for cooling.
The green light will turn on and the cooling system compressor and
indoor fan will turn on. If it does not, check wiring between the Switching Center and the unit.
During normal startup the supply air temperature should be displayed.
Unless modified at this time, the SYCAP will operate at factory cut-out
setpoints of 118 degrees F. for heat and 48 degrees F. for cooling. To
modify these cut-out setpoints see “Determine the existing cut-out setpoints on a CAP” in the Capacity Control section of this manual.
If you have set the switch to HEAT, set one thermostat to call for heat. The
green light will turn on and the furnace should start. The fan will start
when the time delay or bonnet control turns it on. If the system does not
turn on, check the wiring between the Switching Center and the furnace.
To test the Auxiliary/Electric heat disconnect the Y wire at the SYCAP or
SYHPA. Set one stat to call for heat. If the supply air temperature is below
the electric heat cut-in setpoint, and after a four minute time delay, DL2
and the Auxiliary/Electric heat will turn on.
The Switching Center controls the furnace and air conditioner with relay
contacts. The Switching Centers R,Y,W&G terminals operate exactly like
a four wire thermostat. Trouble shooting the heating and air conditioning equipment should be handled as though the Switching Center is a
four wire thermostat.
After testing the SYCAP, replace the Y wire for proper heat pump operation.
Note: At temperatures below 38°F and above 125°F (heat pumps), the
display will toggle between “E” and the supply duct temperature. This is
normal operation and provisions have been made to allow the heating and
cooling to operate.
15
ZONE THERMOSTATS
Each zone requires a zone thermostat. This thermostat can be digital,
mechanical, or programmable. All three types are available. Zonex Systems thermostats have been specifically designed to work with Zonex
Systems Zone Control systems. Attempting to use another manufacturer’s
thermostat may create compatibility problems and cause nuisance calls.
For trouble free installation, use only Zonex Systems supplied thermostats.
1. Determine the existing Setpoints:
>
A. To determine the existing Heat
Setpoint, press and hold the
top button marked
until
the letter “H” appears and
then release. The current heat
setpoint will be displayed
following the letter “H” (If
the button is held down too
long the Heat Setpoint will
begin to increase). Approximately two seconds after the
button is released the current
room temperature will be
redisplayed.
Digital Thermostats
Zonex Systems makes two Digital Thermostats for the System 1000/2000:
101DIGI – a single stage thermostat that can be used whenever auxiliary zoned heating is not required.
101DIGITS – a single stage cool, two stage heat thermostat. It should
be used when auxiliary zoned heating is needed.
101DIGI: This is a digital, dual setpoint, single stage zone thermostat,
accurate to within one degree. The 101DIGI is auto changeover, is non
power robbing, and is designed with a non-volatile memory to retain all
programmed setpoints. The stat is operated by two push buttons to review
and modify heat and cool setpoints. To avoid unauthorized setpoint modifications, the 101DIGI has locking setpoint capability. There is also a zone
On/Off switch. Under the cover there is a green and red light. When the
green light is on the stat is calling for cooling. When the red light is on the
stat is calling for heat. Following any call, the stat is designed with a twominute minimum run time to prevent short cycling. It can be used with any
of the System 1000/2000 Controllers. This thermostat can be ordered with
a remote sensor (101DIGIRS). The 101DIGI Dimensions are: 2-7/8”W
x 4-1/2”H x 1”D, the color is off white. Requires four thermostat wires for
installation.
>
B. To determine the existing Cool
Setpoint press and hold the lower button marked until the
letter “C” appears and then
release. The current Cool
Setpoint will be displayed
following the letter “C” (If the
button is held down too long
the Cool Setpoint will begin to
decrease). Approximately
two seconds after the button is
released the current room
temperature will be redisplayed.
101DIGITS This is an auto
101DIGI
changeover, electronic zone thermoRequires
stat with auxiliary heat output. This
4 Wires
dual setpoint thermostat has a large
101 DIGITS
digital readout which displays curRequires
rent room temperature. Under the
5 Wires
cover there are two red lights and
one green light. When the green
light is on, the thermostat is calling
for cooling. When the red light labeled “D-1” is on, the the stat is calling for first stage heat. When the the red light labeled “HT2” is on, the
stat is calling for second stage heat. This zone thermostat is designed for
zones that require supplemental heat. This thermostat can be ordered
with a remote sensor by adding RS to its part number. 101DIGITS dimensions are 2 7/8” W x 4 1/2” H x 1” D. Installation requires five
wires.
2. Modifying the Setpoints:
>
A. To change the Heat Setpoint,
press and hold the top button
until the Heat Setpoint is displayed. Continue to press this
button (the up button ) to
increase the Heat Setpoint or
press and hold the bottom
button to reduce the Heat
Setpoint to your desired
comfort level in this room.
>
B. To change the Cool Setpoint,
press and hold the lower button
until the Cool Setpoint is
displayed. Continue to hold this button to lower the Cooling
Setpoint or press the top button to raise the Cool Setpoint
to your desired comfort level in this room.
>
>
101DIGI Thermostat Operation
Each digital thermostat has an “ON” / “OFF” switch located at the bottom.
Typically, this thermostat should always be in the “ON” position. When
the room is unoccupied, use this switch to take the zone out of your system by sliding it to the left to turn it off. When the room is occupied slide
the switch to the right to turn it on. Assign the Heating and Cooling Setpoints desired by using the following instructions:
Set up all of the zone thermostats in this way to provide room
by room comfort control.
16
ZONE THERMOSTATS
101PROG: Features a battery powered,
7-day programmable, auto changeover
control for single stage heating and cooling
applications. Thermostat can be programmed
for up to four periods per day, and offers
three operating modes: Manual, Automatic
and Vacation. Blower operation is manual
selectable for auto, on, or programmed for
fossil fuel or electric heat, fan cycling. The
oversized LCD display clearly shows the
time, day of the week, space temperature,
101PROG
and selected operating mode. The 101PROG
also provides for mode control through an optional telephone controller.
Dimensions are 3.75”W x 5”H x 1”D. Color: White.
3. Locking the Set points:
To avoid unauthorized setpoint
modifications, the 101DIGI has
locking setpoint capability. After
the heat and cool setpoints have
been selected, use the jumper
located under the cover near
the middle of the board labeled
LCK to lock the setpoints. Slide
the jumper over both terminals
as shown in the diagram above.
This will lock the setpoints in
place. To modify the setpoints,
the jumper must be to moved to
the adjustable position.
ZONE THERMOSTATS – COMPATIBILITY
DIGICOM
The 101ASSB gas/electric and 101AACBHP heat pump controllers are
compatible with most thermostats, offering a wide thermostat selection
to the installing contractor. NOTE: the 101AACBHP pump controller
utilizes gas/electric thermostats. When using other than Zonex
Systems thermostats, please refer to the following guidelines:
DIGICOM: The DIGICOM auto
changeover, communicating
thermostat is used exclusively in ZonexCommander thermal management
systems. Using a computer and the ZonexCommander software, all thermostats in the system can be programmed and viewed. The DIGICOM
may be applied in stand alone unit control, from 1 to 80 split or packaged systems. When used with a modem, all ZonexCommander software
functions can be controlled remotely. The DIGICOM requires 24V AC
power from either the zone system or HVAC unit transformer, with the
addition of a two conductor, twisted pair cable for communications.
Dimensions: 2-7/8” W x 4-1/2” H x 1” D.
Electronic Thermostats: Digital thermostats requiring 24V AC power
must be “Hard wired” with a separate R and C or common terminal.
Power robbing type thermostats are not compatible. All types of battery
operated thermostats may be used with any System 2000 control system.
Mechanical Thermostats: When using a mechanical thermostat,
ensure the cooling compensator (anticipator) is removed, and the
heating anticipator is shorted or set to its lowest setting.
Please contact Factory Technical Support for additional thermostat
compatibility information.
ZONE THERMOSTATS – REMOTE SENSORS
The Zonex Systems digital thermostats can be ordered with a remote sensor. Remote sensors are useful if you would like to place the thermostat
and sensor in different locations. Simply add “RS” at the end of the part
number to order with a remote sensor; i.e.: “101DIGIRS”.
Wiring: The remote sensor must be wired with a minimum 18 ga., two
conductor shielded cable, with a maximum length of 200 feet. The wires
have no polarity. Use field supplied wire nuts to connect the sensor. Flare
back and tape off the cable shield closest to the sensor. Connect the
shield at the thermostat to the “R” terminal.
REMOTE SENSOR BOARD
TYPICAL
ZONE
THERMOSTAT
R
Temperature
Sensing
Thermistor
Wire Nut
Wire Nut
Shield to the "R" terminal
17
REMOTE SENSOR
COVER
4.5" x 2.75"
ZONE DAMPERS
Zonex Systems zone dampers are used in cooling/heating systems to
provide room by room zone control. The damper is provided with a
factory mounted relay board and zone actuator. Each zone damper is
controlled by a zone thermostat. More than one damper can be
controlled by one zone thermostat; see Slaving Dampers. Use the table
below to determine which zone dampers to use.
MAXIMUM
DIFFERENTIAL ROUND
DAMPER
PRESSURE
SYSTEM SIZE
5 TONS OR UNDER
UNDER 7.5 TONS
7.5 TONS OF LARGER
RECTANGULAR
DAMPER
LOW PRESSURE
LOW PRESSURE
1"
MEDIUM PRESSURE
MEDIUM PRESSURE
1.75"
MEDIUM PRESSURE
HEAVY DUTY
0.5"
Maximum Differential Pressure refers to the maximum static pressure drop in inches of water column between the
input (upstream) of the zone damper and the output (downstream) when the damper is closed.
ROUND ZONE DAMPERS
There are two styles of round zone dampers, low pressure or medium
pressure. For systems 5 tons or under with a maximum differential static
pressure of 0.5”, use low pressure dampers. Otherwise use medium
pressure for up to 1.75” differential pressure on any system over 5 tons.
ROUND LOW PRESSURE ZONE DAMPERS
Zonex Systems round low pressure zone dampers can be used for systems
up to 5 tons with a maximum differential static pressure of 0.5”. These are
two position, spring open, power close dampers for very simple operation.
Round damper sizes 9 inches and under are manufactured from 24
gauge galvanized steel. Sizes 10”, 12”, 14” and 16” are made from 20 - 22
gauge steel. All sizes are designed with rolled-in stiffening beads for superior rigidity. The damper pipe is furnished with one crimped end and one
straight end for easy installation. A hat section supports a synchronous 24V
AC 60Hz 12VA motor and terminal board. The motor is designed for continuous full stall operation. Special winding and heavy duty gearing provide for
long motor life and easy spring open operation. A cross pin on the motor
shaft provides positive direct drive to the damper blade shaft without a coupling or set screws, allowing for a quick and easy motor change if required.
Motor drive time from full open to full close is 30 seconds. Since this is a
spring open damper, in the event of power failure, the damper fails to the full
open position.
LOW PRESSURE (101ARZD)
ROUND MEDIUM PRESSURE ZONE DAMPERS
Zonex Systems round medium pressure zone dampers are recommended for systems over 5 tons or with a maximum differential static pressure
up to 1.75”. This power open / power close damper is manufactured from
20-22 gauge galvanized steel with rolled-in stiffening beads for superior rigidity. Mechanical minimum and maximum set stops are provided and easily
adjustable. The damper pipe is furnished with one crimped end and one
straight end for easy installation. A hat section supports a 35 lb./in. 24V, 6 VA
power open, power closed actuator with a damper relay board interface. The
actuator is designed for full stall operation, with a magnetic clutch to protect the
internal gearing. The actuator is direct coupled to the damper shaft, which provides positive operation and offers replacement ease if required. Drive time from
full open to full closed is 60 seconds.
18
MEDIUM PRESSURE (101AMPD)
ZONE DAMPERS
ROUND LOW & MEDIUM PRESSURE DAMPER SIZES
ROUND LOW PRESSURE DAMPER
PART #
101ARZD06
101ARZD07
101ARZD08
101ARZD09
101ARZD10
101ARZD12
101ARZD14
101ARZD16
SIZE DIAMETER (D)
6"
7"
8"
9"
10"
12"
14"
16"
LENGTH (L) WIDTH (W)
W
9"
10"
11"
12"
13"
15"
17"
18 1/2"
10"
10"
10"
11"
12"
14"
16"
18"
6"
7"
8"
9"
10"
12"
14"
16"
D
ROUND MEDIUM PRESSURE DAMPER
PART #
101AMPD06
101AMPD08
101AMPD10
101AMPD12
101AMPD14
101AMPD16
101AMPD18
SIZE DIAMETER (D) LENGTH (L) WIDTH (W)
6"
8"
10"
12"
14"
16"
18"
6"
8"
10"
12"
14"
16"
18"
L
9"
11"
13"
15"
17"
19"
21"
10"
10"
12"
14"
16"
18"
23 1/2"
TYPICAL ROUND CAPACITIES*
Duct
Diameter
Nominal
CFM
Duct Velocity Damper
FPM
∆P " WC
6"
110
540
.014
7"
160
600
.014
8"
250
700
.015
9"
320
725
.015
10"
410
750
.015
12"
660
850
.022
14"
1000
925
.035
16"
1450
1070
.036
18"
2000
1100
.036
* These air quantities were derived from a duct sizing chart .1” friction loss per 100’ of duct. All CFMs listed are approximate. For accurate selection
use duct sizing table or device.
19
ZONE DAMPERS
RECTANGULAR ZONE DAMPERS
The rectangular zone dampers come in either low pressure, medium pressure, or heavy duty. For systems 5 tons or under use low pressure.
For systems under 10 tons use medium pressure dampers. For systems 10 tons or over use heavy duty dampers. Motor drive time open and close
is 90 seconds, except for the low pressure damper which springs open.
RECTANGULAR LOW PRESSURE ZONE DAMPERS
(101EC W x H)
Zonex Systems rectangular low pressure dampers can be used for systems
up to 5 tons with a maximum differential static pressure of 0.5”. These are
two position, spring open, power close dampers. They are constructed
from heavy duty galvanized steel. The damper is a single blade type that
slips into a 2-1/2” wide cutout in the existing duct and attaches with
screws via a duct mounting plate. The duct mounting plate is 5” wide. The
drive assembly supports a synchronous 24V AC 60Hz 12VA motor and terminal board. The motor is designed for continuous full stall operation. Special winding and heavy duty gearing provide for long motor life and easy
spring open operation. A cross pin on the motor shaft provides positive
direct drive to the damper shaft without a coupling or set screws. Motor
drive time from full open to full close is 30 seconds. Since this is a
spring open damper, in the event of power failure the damper fails to the
full open position.
LOW PRESSURE (101EC W x H) RECTANGULAR DAMPER
RECTANGULAR MEDIUM PRESSURE ZONE DAMPERS (101MRTD W x H)
Zonex Systems rectangular medium pressure dampers are recommended for systems under 7.5 tons with a maximum differential static
pressure of 1”. These are power open, power close dampers. They are constructed from heavy duty aluminum and stainless steel. The damper is an
opposed blade type that slips into a 3-1/4” wide cutout in the existing duct and attaches with screws via a duct mounting plate. The duct mounting
plate is 5” wide. The damper supports a 35 lb./in. 24V, 6 VA power open, power closed actuator with a damper relay board interface. The actuator is designed
for full stall operation, with a magnetic clutch to protect the internal gearing. The actuator is direct coupled to the damper shaft, which provides positive
operation and offers replacement ease if required.
RECTANGULAR HEAVY DUTY ZONE DAMPERS
(101CD W x H)
Zonex Systems rectangular heavy duty dampers are recommended for
systems 7.5 tons or larger with a maximum differential static pressure of
1.75”. These are power open, power close dampers made of 20 gauge
“snap-lock” steel frame with S and Drive duct connections. Allow a 16”
gap in the duct for the damper. Formed steel blade stops incorporate a
gasket for quiet operation and improved structural rigidity. Rectangular
dampers under 10” in height incorporate a single blade design. Dampers
10” or over use opposed blade design. A full stall motor, drawing 6 VA and
a relay board control the damper position.
MEDIUM PRESSURE (101MRTD) AND
HEAVY DUTY (101CD) RECTANGULAR DAMPERS
20
ZONE DAMPERS
LOW AND MEDIUM PRESSURE RECTANGULAR DAMPER DIMENSIONS
Part Number 101MRTD W x H
Sizes available from 8” x 6” up
to 24” x 20”
W
Part Number 101EC W x H
Sizes available from 8” x 8” up
to 24” x 12”
5"
2-1/2"
H
HEAVY DUTY RECTANGULAR DAMPER DIMENSIONS
Part Number 101CD W x H
Sizes available from 8” x 8” up to 48” x 48”
4"
48" MAXIMUM WIDTH
A
MOTOR
B
16
WIDTH HEIGHT DEPTH
A
B
16"
Rectangular dampers should operate at 1500 FPM.
E.G. A 24" x 12" damper = 2 square feet.
2 square feet X 1500FPM = 3000 CFM.
RECTANGULAR DAMPER CAPACITIES*
Dampers listed below are standard sizes. For larger sizes and capacities, contact the factory.
HEIGHT IN INCHES
WIDTH IN INCHES
8
10
12
14
16
18
20
22
24
6
200
250
310
390
440
500
570
630
700
8
280
390
490
590
680
770
900
960
1090
10
390
510
650
800
950
1100
1220
1400
1500
12
490
650
850
1000
1200
1400
1600
1850
2000
14
1000
1250
1500
1750
2000
2250
2500
16
1200
1500
1800
2100
2450
2300
3000
18
1400
1750
2100
2500
2850
3080
3600
4000
20
Motors on low and medium pressure dampers will be mounted on the Height (H) side. Bottom mount motors will be located on the Width (W) side.
*These air quantities were derived from a duct sizing chart .1” friction loss per 100’ of duct. All CFMs listed are approximate. For accurate selection use duct
sizing table or device.
21
ZONE DAMPERS
SIZING ZONE DAMPERS
If the ductwork already exists, simply size the damper to fit the ductwork.
For new systems or retrofit jobs:
b) Select damper size by using a duct sizing table or calculator.
c) Select a Zonex Systems damper to fit the duct size selected for that
zone.
a) Determine CFM from heat gain or loss calculations.
WIRING ZONE DAMPERS
*OPEN MOTOR NOT UTILIZED
ON LOW PRESSURE
(SPRING OPEN) DAMPERS.
C R Y W W2
W2 W Y G Rd B
CLOSE MOTOR
RO MC RC
OPEN MOTOR*
Electronic stat
if applicable
TB1
TB2
TO
THERMOSTAT
FIVE WIRE LINK TO
SYSTEM CONTROLLER
For heavy-duty rectangular dampers:
CW = RC (Run Closed)
COM = MC (Motor Common)
CCW = RO (Run Open)
For heavy-duty round dampers:
CCW = RC (Run Closed)
COM = MC (Motor Common)
CW = RO (Run Open)
DAMPER INSTALLATION NOTES
1. Do not exceed 700 FPM in a register/diffuser branch duct.
2. If a damper is installed within 3 feet of register/diffuser, install sound
attenuating flex duct between damper and outlet.
tion and pipe. Therefore, insulation should be applied to the round
pipe and be butted against the hat section, (do not insulate the
motor or relay board). Both motor and the relay board generate
enough heat so no condensation will develop on the hat section.
3. Zone dampers should be preceded by 2’-4’ of straight pipe where
possible.
5. Remember to allow a 16” gap in the duct for Heavy Duty rectangular
dampers.
4. In attic installations and high humidity areas, the Zonex Systems
damper should be insulated along with the ductwork. The hat section on the damper is delivered with insulation between the hat sec-
6. Low and Medium pressure rectangular dampers slide into a 3-1/4”
wide cutout in the side of the preexisting ductwork.
22
ZONE DAMPERS
PARALLELING ZONE DAMPERS
If a thermostat needs to control more than three dampers and/or the
maximum number of zone dampers is exceeded, use the wiring diagram
shown on page 44)
TB1
W2 W Y G Rd B
*
*
*
*
*
TB2
DAMPER #3
RELAY BOARD
*
*
*
*
*
*
TB1
DAMPER #2
RELAY BOARD
RO MC RC C R Y W W2
TB2
*
*
*
*
*
*
RO MC RC C R Y W W2
RO MC RC C R Y W W2
*
*
*
*
*
W2 W Y G Rd B
Use the following diagram if the thermostat will control no more than
three dampers and the maximum number of zone dampers is not exceeded (ten dampers for System 1000, twenty dampers for System 2000).
DAMPER #1
RELAY BOARD
TB2
W2 W Y G Rd B
Each zone thermostat can control more than one zone damper.
FIVE WIRE LINK
TO
SYSTEM
CONTROLLER
TB1
C R Y W
TO THERMOSTAT
* No connection
(- - - -) For power open/closed damper applications only.
BYPASS DAMPERS
Bypass dampers are used to provide constant air delivery through the air
handling unit. This is done by bypassing excess air from the supply duct
back to the return duct. As a zone is satisfied, its zone damper closes.
When this happens, the bypass damper opens just enough to bypass the
excess air. This will control static pressure and noise at the diffusers.
Zonex Systems offers two types of bypass dampers, Barometric and Electronic. Each is available in round or rectangular configuration. Barometric bypass dampers are limited to systems of 5 tons. Electronic
dampers can be used on any size system. For systems 5 tons or smaller,
the barometric bypass can be used. For systems over 5 tons, we recommend the electronic bypass.
BYPASS DAMPERS – BAROMETRIC
The barometric bypass damper is for systems 5 tons or under. It utilizes
a weighted damper blade to maintain constant duct pressure. This allows
for easy installation without the need for electrical power or wiring. The
round barometric damper can be installed in any position. It is an efficient solution for small system fan capacity control.
SIZING: When only the smallest zone is
calling, the maximum amount of excess
supply air will flow through the bypass
damper. To determine the proper size bypass
damper to use, do the following steps:
bypass damper with the CFM rating equal to or greater than the value calculated in Step 1. For rectangular barometric dampers, use a ductulator to convert from round to rectangular.
If bypassing more than 1600 CFM, use electronic bypass damper.
Example: You have a 4 ton system. Your smallest zone will use 500
CFM. The total CFM is 1600 CFM (400 * 4). Your bypass CFM is 1100
(1600 - 500). From the table, you determine that a 12" bypass damper
is needed.
BAROMETRIC BYPASS
SELECTION TABLE
Diameter
9”
10”
12”
14”
16”
CFM
650
800
1200
1600
2000
Do not use the barometric bypass in any system over 5 tons.
For systems over 5 tons, or to bypass more than 1600 CFM, use the
electronic bypass.
Step 1: Calculate bypass air volume as follows.
A) Calculate total air volume at 400 CFM
per ton.
B) Calculate air volume of smallest zone in
CFM.
C) Calculate bypass air volume by subtracting the smallest zone air
volume from the total.
(A - B = C)
BAROMETRIC BYPASS
DAMPER
AIRFLOW
3
1
2
Step 2: Select damper from sizing table.
Once you have calculated the bypass air volume from Step 1, use the
BAROMETRIC BYPASS SELECTION TABLE. From the table, select the
RECTANGULAR & ROUND
BAROMETRIC BYPASS
23
4
1. Damper Shaft
2. Lock Nut
3. Lever Arm
4. Counter Weight
BYPASS DAMPERS – BAROMETRIC
INSTALLATION
BAROMETRIC BYPASS SETUP
a) Turn off all thermostats.
b) Turn on Switching Center/Controller and set fan switch to “ON”
position. Allow fan to run for 5 minutes to equalize pressure.
Then make sure all dampers are open by checking for air flow
out of each damper.
c) By moving counter weight up or down the lever arm, adjust it
so that the damper just wants to start opening.
d) If the damper cannot be held closed with the counter weight all
the way at the bottom of the lever arm, then hold the damper
shaft, loosen the lever arm from the damper shaft, and rotate
the lever arm further to the right and retighten. Repeat Step C.
e) The barometric bypass damper is now calibrated.
The round barometric bypass damper can be installed in any position.
This damper is factory set for horizontal installation and can be field
modified for vertical installation. Do not run speed screws into damper
housing. Screws may interfere with damper travel. Make sure counter
weight is not obstructed in any way.
a) Install the bypass damper between the supply and return
plenums of the unit. It must be the first tap off the supply plenum.
b) Be sure the air flows through the damper in the proper direction as indicated by the arrow on the damper. Airflow is always
from supply to return plenum. Be certain the damper shaft
is horizontal.
c) Loosen counter weight with allen wrench.
d) Loosen lever arm from damper shaft and allow to hang straight
down.
e) Fully close damper by grabbing damper shaft on side attached
to lever arm and turning clockwise until it stops.
f) While holding the damper fully closed, rotate the lever arm a
little to the right (facing the damper) and then screw in to
tighten to the damper shaft. Then tighten lock nut.
g) Be sure the damper is being held closed by the counter weight.
Proceed to set up.
BAROMETRIC BYPASS STARTUP TEST
a) Have at least half of the zones call for either heating or cooling.
b) Check to be sure the calling zone dampers are open, (air is
flowing).
c) Verify the bypass damper is open. Note, the damper may not
fully open.
d) If the open zones are not noisy, the bypass damper is set.
HORIZONTAL APPLICATION
AIRFLOW
A/C UNIT
OR
FURNACE
RETURN
SHEET METAL
PIPE
BAROMETRIC
BYPASS
ROOF TOP INSTALLATION Down Discharge Application
SUPPLY
PLENUM
A/C UNIT
OR
FURNACE
AIRFLOW
ROOF LINE
BAROMETRIC
BYPASS
AIRFLOW
SUPPLY
PLENUM
RETURN
PLENUM
SHEET METAL
PIPE
VERTICAL APPLICATION
AIRFLOW
BAROMETRIC
BYPASS
OPEN RETURN PLENUM BYPASS APPLICATION
SUPPLY
PLENUM
A/C UNIT
OR
FURNACE
BYPASS DAMPER
RETURN
AIR
PLATFORM
RETURN AIR GRILLE
To prevent bypass air from
flowing out the return grill,
use a short open ended
return air plenum to
connect the bypass
damper to the unit.
RETURN AIR
GRILLE
24
AIR CONDITIONING
UNIT
SUPPLY
DUCT
BYPASS DAMPERS – ELECTRONIC
ELECTRONIC BYPASS DAMPERS
Bypass dampers are used to provide constant air delivery through the air handling unit. This
is done by bypassing excess air from the supply duct back to the return duct. As a zone
is satisfied its zone damper closes. When this happens, the bypass damper opens just enough
to bypass the excess air. This will control static pressure and noise at the diffusers.
The Electronic Bypass Damper can be used on any size system over. The damper can be
round or rectangular and multiple dampers can be slaved together. The Electronic Bypass
Damper consists of a medium pressure round or a heavy duty rectangular damper and
a static pressure sensor.
SIZING ELECTRONIC BYPASS DAMPERS
When only the smallest zone is calling, the maximum amount of excess supply air will flow
through the bypass damper.
CFM CALCULATION
To determine the proper size bypass damper:
A) Calculate total air volume at 400 CFM per Ton.
B) Calculate air volume of smallest zone in CFM .
C) Calculate bypass CFM by subtracting the smallest zone air volume from the total.
(A - B = C).
RECTANGULAR & ROUND BYPASS DAMPER
WITH THE STATIC PRESSURE CONTROL
ROUND DIMENSIONAL DATA
ROUND BYPASS DAMPER SELECTION
When you know the bypass CFM requirement as
determined in the “CFM calculation” section, use the
ROUND BYPASS SELECTION TABLE. From the table,
select the bypass damper with the CFM rating equal to
or greater than the value calculated in step C of CFM
Calculation.
ROUND BYPASS SELECTION TABLE
Diameter
6”
8”
10”
12”
14”
16”
CFM
320
560
900
1250
1700
2200
PART #
STMPD06
STMPD08
STMPD10
STMPD12
STMPD14
STMPD16
Example: We know the smallest zone air volume is
400 CFM and we have a four ton system. Thus the
air volume we need to bypass is (400 * 4) – 400
which equals 1200 CFM. Using the ROUND BYPASS SELECTION TABLE, we would select a 12 inch
bypass since it can handle up to 1250 CFM of air.
SIZE
6
8
10
12
14
16
D
6"
8"
10"
12"
14"
16"
L
10"
10"
12"
14"
16"
18"
W
9"
11"
13"
15"
17"
19"
L
D
W
Never exceed 16 inches for the round bypass damper. If you need to bypass more than 2200 CFM,
either use a rectangular bypass or slave multiple round bypass dampers.
RECTANGULAR BYPASS DAMPER SELECTION
When you know the bypass CFM requirement as determined in the
“CFM calculation” section, use the RECTANGULAR BYPASS SELECTION TABLE. From the table, select the bypass damper with the CFM
rating equal to or greater than the value calculated in step C of CFM
Calculation.
Example: We know the smallest zone air volume is 250 CFM and we
have a 7-1/2 ton system. Thus the air volume we need to bypass is
(400 X 7.5) -250) which equals 2750 CFM. Using the RECTANGULAR
BYPASS SELECTION TABLE, we see the smallest damper we can use
is a 12” x 22” or a 22” x 12”.
RECTANGULAR BYPASS DAMPERS
SELECT FROM 8 X 8 THRU 48 X 48
48" MAXIMUM WIDTH
W
4"
H
D
WIDTH HEIGHT DEPTH
W
H
16"
Part Number STCD W X H
25
Rectangular bypass dampers should operate at 1500 FPM*
E.G. A 24" x 12" damper = 2 square feet.
2 square feet X 1500FPM = 3000 CFM.
* FPM = Feet Per Minute
BYPASS DAMPERS – ELECTRONIC
RECTANGULAR BYPASS SELECTION TABLE
WIDTH IN INCHES
8
8
HEIGHT IN INCHES
10
667
10
12
14
16
18
20
22
24
28
32
36
40
44
48
833 1000
1167
1333
1500
1667
1833
8
2000
2333
2667
3000
3333
3667
4000
1250
1458
1667
1875
2083
10
2292
2500
2917
3333
3750
4167
4583
5000
12
1000
833 1042
1250
1500
1750
2000
2250
2500
12
2750
3000
3500
4000
4500
5000
5500
6000
14
1167
1458
1750
2042
2333
2625
2917
14
3208
3500
4083
4667
5250
5833
6417
7000
16
1333
1667
2000
2333
2667
3000
3333
16
3667
4000
4667
5333
6000
6667
7333
8000
18
1500
1875
2250
2625
3000
3375
3750
18
4125
4500
5250
6000
6750
7500
8250
9000
20
1667
2083
2500
2917
3333
3750
4167
20
4583
5000
5833
6667
7500
8333
9167
10000
22
1833
2292
2750
3208
3667
4125
4583
22
5042
5500
6417
7333
8250
9167
10083
11000
24
2000
2500
3000
3500
4000
4500
5000
24
5500
6000
7000
8000
9000
10000
11000
12000
28
2333
2917
3500
4083
4667
5250
5833
28
6417
7000
8167
9333
10500
11667
12833
14000
32
2667
3333
4000
4667
5333
6000
6667
32
7333
8000
9333
10667
12000
13333
14667
16000
36
3000
3750
4500
5250
6000
6750
7500
36
8250
9000
10500
12000
13500
15000
16500
18000
40
3333
4167
5000
5833
6667
7500
8333
40
9167
10000
11667
13333
15000
16667
18333
20000
44
3667
4583
5500
6417
7333
8250
9167
10083
44
11000
12833
14667
16500
18333
20167
22000
48
4000
5000
6000
7000
8000
9000
10000
11000
48
12000
14000
16000
18000
20000
22000
24000
Bypass air in CFM. Calculated at 1500 FPM.
Formula used: B = W X H / 144 X 1500, where B = Bypass air in CFM, W = damper width in inches, H= damper height in inches, 144 = 144 sq.
inches per sq. ft., 1500 = 1500 FPM.
BYPASS POSITION INDICATOR
ROUND AND RECTANGULAR
BYPASS DAMPER MOTORS
SHAFT END MARKING IS PARALLEL
WITH DAMPER BLADE. DAMPER TRAVEL
IS 60° ON ROUND BYPASS AND 90°
ON RECTANGULAR BYPASS
CCW
CW
Note: Clockwise to close
on rectangular bypass and
counterclockwise on
round bypass.
RC
N/C
MC
COM
RO
N/O
101ASPC
Static
Pressure Control
SLAVING BYPASS DAMPERS
Use only one Pressure Sensor when slaving two
or more Bypass Dampers together. Connect the
Pressure Sensor to one damper as described
above. Connect the slave dampers in parallel as
shown. Up to 4 dampers can be slaved to one
Sensor. The slaved dampers will self synchronize each time the dampers reach full open
or full close.
***
DAMPER
ACTUATOR RC RO MC
***
SLAVE
DAMPER
ACTUATOR
RC RO MC
TO NEXT SLAVE
BYPASS DAMPER
IF APPLICABLE
RC
RO
MC
To Static Pressure Controller As Shown On The Bypass Wiring Diagram On The Next Page.
26
BYPASS DAMPER – STATIC PRESSURE CONTROLLER
The Static Pressure Controller controls a standard medium pressure round damper (STMPD) or the heavy duty rectangular damper (STCD) by
maintaining constant static pressure in the duct downstream of the bypass takeoff. As the zone dampers close, the static pressure increases. When
this happens, the static pressure controller opens the bypass damper to bring the static pressure back to the setpoint.
Zonex Systems recommends de-energizing the bypass damper when the
blower fan turns off. If not installed as recommended, when the blower fan
turns off the bypass will fully close. Then when the blower fan turns back
on, there could be excessive air supplied to the calling zone, causing excessive air noise until the bypass is able to open sufficiently. An alternative wiring diagram is provided using an additional static pressure sensor
to deenergize the bypass damper.
STATIC PRESSURE CONTROLLER DESCRIPTION
A:
B:
C:
D:
Mounting tabs.
Supply air barb.
Reference air, “LOW”, barb.
Diaphragm must be
mounted vertically.
E: Pressure adjusting screw.
F: Normally closed, N/C, terminal.
G: Normally open, N/O, terminal.
H: Common, COM, terminal.
B
C
D
E
A
F
G
Alternative Wiring
H
STATIC PRESSURE CONTROLLER INSTALLATION
a. Select location for pressure sensor tube. Location should be in supply duct, downstream of bypass takeoff, upstream of any zone
dampers and perpendicular to the air flow.
b. Drill 5/16” hole at selected location for pressure sensor tube.
c. Mount Static Pressure Controller near the drilled hole with the
diaphragm of the sensor vertical. The controller must be mounted
on a stable, non vibrating surface.
d. Attach 5/16” pressure sensor tube, supplied, to the barb of the Static Pressure Controller located closest to the mounting tabs. The other barb, labeled “LOW”, is left open if the Controller is in the
conditioned building. If the Controller is located outside the building, another tube, not provided, must be connected between the
“LOW” barb and a location inside the building.
e. Remove the terminal cover and wire as shown in the wiring
diagram.
f. Reattach terminal cover. Installation is complete. Proceed to Static
Pressure Controller Setup.
AIRFLOW
C
O
I
L
b. Verify bypass damper is Closed.
Bypass dampers using a square
motor have a grey release lever on the bottom/side of the damper
(near motor) to manually open or close the damper.
c. At 101ASPC Static Pressure Controller, remove the NO wire from the
micro switch. Connect A/C voltmeter (or test light) to COM and NC
terminals of static pressure controller. Zero V ac (no light) should
be present, ensuring a connection is made between COM and NC. If
24V ac is present (light on), turn adjustment screw on 101ASPC Static Pressure Controller clockwise (CW) until connection is made and
0V ac (no light) is obtained. Do Not Overtighten Adjusting Screw.
d. Verify bypass damper is Closed. Slowly back out adjusting screw
(CCW) until 24V ac (light on) is present ensuring no connection
between COM and NC. STOP. Slowly turn adjusting screw in (CW)
until 0V ac (no light) is present. STOP. Bypass damper should be on
verge of opening but still closed with all zone dampers open and the
blower fan on high speed.
e. If the bypass damper sizing and duct design are correct, this
completes the bypass damper setup. Connect all wires and proceed to
Bypass Checkout.
AIR
CONDITIONER
1
STOPS
AIRFLOW
MOTOR
WINDOW
STATIC
PRESSURE
SENSOR
BYPASS DAMPER
BYPASS CHECKOUT FOR STATIC
PRESSURE CONTROLLER
Insert the tube into the side of the duct, approximately
1 3”. Make sure the tube is perpendicular to the air flow.
a. Make a cool call at the zone thermostat of the smallest (damper size) zone.
b. Verify all zone dampers are closed except for calling zone.
c. Verify noise at zone register is not excessive. Adjust static pressure
controller CCW to lower noise (airflow) or CW to increase airflow
until too noisy.
STATIC PRESSURE CONTROLLER SETUP
Note: 24V ac may be read on both terminals (RO & RC to MC) due to
voltage bleeding thru the motor windings. Disconnect the RO or RC wire
to determine which wire is energizing the motor.
a. Ensure all dampers are open and blower is running on high speed.
27
CAPACITY CONTROLLERS
An HVAC system is sized to handle the load of an entire home or building.
Because of this, when all the zones are not calling, the load to the HVAC
system can diminish below its designed capacity. Left unchecked, the A/C
coil could freeze up causing compressor slugging or the furnace could
overheat causing premature heat exchanger failure. To compensate for
this, a Capacity Controller is needed.
The basic function of the Capacity Controller is to monitor the leaving
air temperature and cycle the unit on and off to maintain a leaving air
temperature within set parameters. Zonex Systems offers six unique capacity controllers to meet all your application needs: TRLAT, 101CAPGE, CAPL2, CAPL-4, SYCAP and TRFPC.
CAPACITY CONTROLLER SELECTION
Select the Capacity Controller best suited for your application based on the following table and feature list.
P/N
101CAPGE
TRLAT
CAPL-2
CAPL-4
SYCAP
TRFPC
GE/HP
GE
GE
GE
GE
HP
GE
#
ECONO
CNTRL
STAGES
1 HT, 1 CL
NO
1 HT, 1 CL
NO
2 HT, 2 CL
YES
4 HT, 4 CL
YES
2 HT, 1 CL
NO
NO
1 CL
CUT-IN
SET-POINT
LEAVING
AIR
NO
NO
YES
YES
NO
NO
FULL RANGE
4 HT, 4 CL
FULL RANGE
FULL RANGE
FULL RANGE
FULL RANGE
YES
NO
YES
YES
YES
NO
COMPRESSOR
MIN. RUN
NO
NO
YES
YES
NO
NO
FAN
CONTROL
NO
YES
YES
YES
NO
NO
FEATURE LIST
GE/HP – Gas/Electric or Heat Pump. For Gas/Electric HVAC systems,
select GE. For heat pumps select HP unless heat pump uses GE thermostats
(no external reversing valve control), then select GE.
SETPOINT – Number of setpoints available for heat and cool.
LEAVING AIR DISPLAY – Digitally displays the leaving air temperature.
This is useful for troubleshooting and system monitoring.
# STAGES – Maximum number of HVAC system heat and cool stages.
COMPRESSOR MIN. RUN – Runs the compressors a minimum of
four minutes whenever they are energized. This ensures proper oil return
and increased compressor life.
ECONO CNTRL – This feature allows the economizer to operate as an
additional stage of cooling when outdoor air conditions are acceptable. May
be used with HVAC systems that utilize an economizer.
FAN CONTROL – Runs the indoor blower fan during capacity cut-out.
CUT-IN – This advanced feature separates the cut-in setpoint from the
This ensures the heat exchanger properly cools down and the AC coil
warms up during capacity cut-out. It also provides better zone temperature control by providing conditioned air during capacity cut-out
periods. This feature is not provided or necessary for heat pumps because
blower fan is continuously energized as long as there is a call. This feature is also not necessary if blower fan is run continuously.
cut-out setpoint. This permits better staging and leaving air temperature
control. Example: Without this feature, in cool mode with a cut-out
setpoint of 48 degrees, the compressor will turn off if the leaving air drops
below 48 and, after a time delay, turn back on when the air rises above
48. With this feature, if the cut-out is 48, the cut-in will be 58. If the air
drops below 48 the compressor will turn off. It will not turn on, however, until the air temperature rises above 58 and a time delay has elapsed.
This gives longer compressor running times and maintains a more comfortable leaving air temperature.
28
CAPACITY CONTROLLERS – 101CAPGE
is off and relay K1 is made, permitting the System Controller to energize
the compressor or furnace. The leaving air temperature is displayed on
the digital display during this time.
OVERVIEW
The 101CAPGE is a Gas/Electric Capacity Controller that digitally displays
leaving air temperature. It should be utilized for single stage
applications. For multistage HVAC systems, use either the CAPL-2 or CAPL4 Capacity Controller.
Out of Range – If the leaving air temperature drops below the cool
cutout setpoint or rises above the heat cutout setpoint, light DL1 is lit and
the relay contacts between Y1 Y1 and W1 W1 break, de-energizing the
compressor or furnace. Four minutes after the leaving air temperature
has returned within operating range light DL1 is turned off and the
relay contacts close, making Y1 Y1 and W1 W1 and energizing the furnace or compressor. The leaving air temperature is displayed on the
digital display during this time.
The Zonex Systems 101CAPGE capacity controller protects both the air
conditioner and furnace. It simply measures the leaving air temperature.
If the air gets too cold (drops below the cool cutout setpoint), it breaks
the “Y” connection, disengaging the compressor. If the air gets too warm
(rises above the heat cutout setpoint), it breaks the “W” connection, deenergizing the furnace. To prevent short cycling, the compressor or furnace cannot reenergize for at least four minutes after cutout. The heating and cooling cutout setpoints can be changed by the installer.
Enable Mode – On the digital display, “E” followed by the leaving air
temperature indicates that the 101CAPGE is in the Enable Mode. The
purpose of this mode is to ensure the furnace can turn on in a cold
building and the air conditioner can turn on in a hot building. Enable
Mode is entered if the leaving air temperature is below the cool cutout
setpoint or above the heat cutout setpoint for more than eight minutes.
The relay contacts are made during this mode, enabling the furnace or
air conditioner to run. After the leaving air temperature has returned
within operating range the 101CAPGE will return to normal operation,
displaying only the leaving air temperature.
The 101CAPGE has a three digit LED display and two push buttons.
Normally the leaving air temperature is displayed. When the push buttons are pressed the cut-out setpoints are displayed.
OPERATION
The 101CAPGE has three modes of operation: in range, out of range and
enable mode.
In Range – If the leaving air temperature is between the cool and heat
cutout setpoints and the 101CAPGE is not in cutout time delay, light DL1
COMPONENTS
The 101CAPGE consists of the following:
A. Digital Display – Three digit LED. Normally displays the leaving
air temperature of the HVAC unit. When “E” is displayed, it indicates
101CAPGE is in Enable mode; refer to OPERATION section. When
the UP/DN buttons are pressed, the cutout setpoints are displayed.
Refer to the Setpoint Calibration section for reading and adjusting the
setpoints.
961205-C
A
UP
K
J
DN
B CAPGE V3.4
B. Microcontroller – Activates and controls outputs based
upon leaving air temperature comparison with programmed setpoints. Occasionally software upgrades may become available. If
so, the 101CAPGE software can be field upgraded by changing this
microcontroller.
C
DL1
E
D
ON
I
OFF
R11
C. Cut-out Indicator Lights – DL1 light is on when relay K1 is
energized. See E.
D. Thermometer Calibrator – Calibrates the leaving air temperature thermometer. Turn clockwise to lower temperature. Turn counterclockwise to raise. Refer to CALIBRATION section for complete calibration information.
+ -
Y1 Y1 W1 W1
F
G
TR1 TR2
H
F. Leaving Air Sensor (LAS) Terminals – Leaving air temperature sensor is connected to the 101CAPGE here. Red to + and white
to –. The sensor monitors the leaving air of the HVAC system. If preferred, the 101CAPGE can be mounted up to 500 feet from the sensor. See INSTALLATION section for further information.
E. Relays K1 and K2 – DPDT, NC relays. When K1 is energized, it
breaks contact between Y1 Y1 and W1 W1 terminals.
29
CAPACITY CONTROLLERS – 101CAPGE
G. HVAC/System Controller Interface Terminals – Y1 controls
the A/C compressor and W1 controls the furnace. W1 controls the
first stage furnace and W2 controls second stage. One Y and W connect
to the System Controller, the other Y and W connect to the HVAC unit.
It does not matter which W/Y connects to the System Controller and
which connects to the HVAC unit. See WIRING section for detailed
wiring instructions.
I. Power Switch – When off, the display is off, the 101CAPGE is
disabled and the relay contacts are closed. The HVAC unit can run at
this time but will not have capacity control protection. When the
switch is on, the display is on and the 101CAPGE is operational.
J. Setpoint Adjustment – Use the UP/DN buttons to view and change
the cut-out setpoints. Refer to the Setpoints, Calibration section (Page
41) for reading and adjusting the setpoints.
H. Power Source Terminals – Connect to 24V AC power source.
Recommend using either the HVAC unit transformer or the System
Controller transformer. 101CAPGE uses less than 2 VA of power. See
WIRING section for detailed wiring instructions.
K. Board Number – This number indicates the circuit board number
and revision. You may need to know this number if conferring with
technical support.
101CAPGE WIRING
The 101CAPGE is installed as detailed in the Capacity Controllers
installation section, Page 40. The following wiring diagrams show how
to wire the 101CAPGE to the System Controller and the HVAC unit.
Terminals TR1 and TR2 of the 101CAPGE can be wired either to R and C
of the HVAC Unit or to TR1 and TR2 of the System Controller.
Use the “Without Fan Relay” drawing if the indoor blower fan will be
running continuously or the furnace keeps the indoor blower fan on for
at least three minutes after the heat call is removed (W de-energized).
Use the “With Fan Relay” drawing if the indoor blower fan will not be
running continuously and the furnace does not keep the indoor blower fan
on for at least three minutes after the heat call is removed (W de-energized).
The relay is a SPDT, 24V AC.
There are two ways of wiring the 101CAPGE: without a fan relay and with
a fan relay.
Without Fan Relay
With Fan Relay
System Controller (101ASSB)
Switching Center (SYGE)
Y
H
V
A
C
G
C
U
N
I
T
W
Y
TR2 TR1
K1b
W
Y
R
G
C
W
Y
SPDT, 24V
AC Relay
W1 W1 Y1 Y1
101CAPGE
G
4
R
R
3
U
N
I
T
W
2
H
V
A
C
G
1 5
R
System Controller (101ASSB)
Switching Center (SYGE)
TR2 TR1
K1a
W1 W1 Y1 Y1
K1b
101CAPGE
30
K1a
CAPACITY CONTROLLERS – TRLAT
OVERVIEW
COMPONENTS
The Zonex Systems TRLAT is a single stage Gas/Electric or Heat Pump
Capacity Controller. However, the heat pump feature is not compatible
with the Zonex Systems System 1000/2000 Zoning Systems so we will
only address the Gas/Electric features. If you have a heat pump that uses
heat pump controls refer to the SYCAP for System 1000 and LAS for
System 2000.
A. Status Lights:
DELAY (red): On when compressor or furnace is disabled.
PWR (yellow): On when TRLAT is powered.
B. Jumpers:
GE/HP: For gas/electric systems, place jumper on GE and center
pin. For heat pumps, place jumper on HP and center pin.(Digitract
Systems only)
O/B: For heat pumps, if reversing valve is energized in cool mode,
place jumper on O and center pin. If reversing valve is energized in
heat mode, place jumper on B and center pin.
The TRLAT Capacity Controller protects both the air conditioner and
furnace. It simply measures the leaving air temperature. If the air gets
too cold (drops below the cool cutout setpoint), it breaks the “Y”
connection, disengaging the compressor, If the air gets too warm (rises
above the heat cut-out setpoint), it breaks the “W” connection, de-energizing
the furnace. To prevent short cycling, the compressor or furnace cannot
reenergize for at least four minutes after cut-out. The heating and
cooling cut-out setpoints can be changed by the installer.
C. Unit terminal block: Connects to HVAC unit. O/B – Reversing
Valve; R – 24V AC hot; G – Blower fan; C – 24V AC rtn; W – heat; Y –
compressor. See WIRING section for detailed wiring instructions.
OPERATION
D. Controller terminal block: Connects to System Controller. Terminal
designations same as for Unit terminal block. See WIRING section for
detailed wiring instructions.
Cool mode: If the leaving air temperature drops below the TRLAT
cooling setpoint (field settable to 41, 44, 47 or 50 degrees Fahrenheit),
the Y (Controller) breaks from Y (Unit) and makes to G. This turns off
the compressor and keeps the indoor blower fan running to warm up
the evaporator. Four minutes after the leaving air temperature rises above
the cooling setpoint, Y (Controller) makes to Y (Unit) and breaks to G.
This restarts the compressor and returns indoor blower fan control to
the Switching Center/Controller.
E. Leaving Air Sensor (LAS) Terminals: Leaving air temperature sensor
is connected to the TRLAT here. Red to + and white to –. The sensor
monitors the leaving air of the HVAC system. If preferred, the TRLAT
can be mounted up to 500 feet from the sensor. See INSTALLATION
section for further information.
F. Jumper wire: Factory installed. Must be connected between O/B
(Controller) and W (Controller) for GE systems and removed for heat
pumps.
Heat mode: If the leaving air temperature rises above the TRLAT heating
setpoint (field settable to 125, 140, 150 or 160 degrees Fahrenheit), the
W (Controller) breaks from W (Unit) and makes to G. This turns off the
heater and keeps the indoor blower fan running to cool down the heater.
Four minutes after the leaving air temperature drops below the heating
setpoint, W (Controller) makes to W (Unit) and breaks to G. This restarts
the heater and returns indoor blower fan control to the heater or
Switching Center/Controller.
G. Setpoint Select: Sets the heat and cool cutoff setpoints. See SETPOINT
SETUP, TRLAT section.
Cut-out disable: The cool cutout is disabled in heat mode. The heat
cutout is disabled in cool mode. This permits the heat to turn on in a cold
building and the air conditioner to turn on in a hot building. For heat
pumps, this also prevents the compressor from cycling off when the heat
pump is in defrost mode. The O/B (Controller) input tells the TRLAT
which mode of operation (heat or cool) is active.
D
E
L
A
Y
G
OFF
ON
SW1
SW2
SW3
SW4
NOTE: For GE systems, a jumper wire (factory installed) must be
connected between O/B (Controller) and W (Controller).
A
E
D
+ -
O/B R
G
C
W
HP
O
B
C
CONTROLLER
F
31
GE
P
W
R
Y
O/B R
B
UNIT
G
C
W
Y
CAPACITY CONTROLLERS – TRLAT
TRLAT WIRING
SETPOINT SETUP, TRLAT
A four pole dip switch is used to designate the desired heat and cool
cutoff setpoints. Using the table to right, set the switch positions to
correspond to the cutoff temperatures desired. For heat pumps, the
heat cutoff point is 118 degrees and unchangeable.
System 1000 Switching Center (SYGE)
System 2000 Controller (101ASSB)
R G
SW1 SW2
On
50 Deg F
On
Off
47 Deg F
Off
On
44 Deg F
Off
Off
41 Deg F
SW3 SW4
Y
1
Cool
Cut-out
On
W
O/B R
G
C
W
Y
CONTROLLER
O/B R
G
C
W
Y
UNIT
R
G
C
W Y
TRLAT
Heat
Cut-out
On
On
125 Deg F
On
Off
140 Deg F
Off
On
150 Deg F
Off
Off
160 Deg F
HVAC UNIT
The TRLAT is installed as detailed in the Capacity Controllers
Installation section, page 40. Wire as shown above.
1
WARNING
Jumper wire (factory installed) must be connected for GE
applications between W (Controller) and O/B (Controller). If not,
the TRLAT will not shut off the heater when the heat setpoint is
exceeded.
CAPACITY CONTROLLERS – TRFPC
OVERVIEW
WIRING
The TRFPC is an inexpensive no frills single stage air conditioning only
Capacity Controller. It will simply interrupt power to the air conditioning
compressor when the supply air temperature drops below 47 degrees
Fahrenheit and re-energize when the temperature rises above 47 degrees.
This setpoint is non-adjustable. It has no control for preventing compressor
short cycling. If your air conditioner does not have a non-recycle timer,
we highly recommend adding one when using this Capacity Controller to
prevent short cycling.
The TRFPC is installed as
detailed in the Capacity
Controllers installation
section, page 40. The following wiring diagrams
show how to wire the
TRFPC to the System
Controller and the HVAC
unit. Terminal C of the
TRFPC must be wired to
the HVAC unit’s transformer common.
OPERATION
The TRFPC will interrupt power to the air conditioning compressor when
the supply air temperature drops below 47 degrees Fahrenheit and
re-energize when the temperature rises above 47 degrees. This setpoint
is non-adjustable. The TRFPC is powered by the “Y” terminal. Thus, the
TRFPC will operate only when there is a call for cooling (24V at “Y”). A
green status light is provided. When on, the compressor can run (relay
closed). When off, the “Y” circuit is broken, disengaging the compressor.
System Controller (101ASSB)
Switching Center (SYGE)
R
H
V
A
C
U
N
I
T
G
W
Y
R
G
C
W
Y
C YIN YOUT
TRFPC
Note: A non recycle timer on the air conditioner is strongly recommended
to prevent short cycling.
32
CAPACITY CONTROLLERS - SYCAP
OVERVIEW
HEAT CUT-OUT – If the SYHPA is making a heat call and the leaving air
The SYCAP is a single stage cool, two stage heat Heat Pump Capacity
Controller. It works in conjunction with the System 1000 SYHPA
Switching Center only. Its function is to control the heat pump coil
leaving air temperature within a set operating range.
temperature rises above the Heat Cut-out setpoint, the connection between
Y2 Y2 breaks, red light DL1 turns on, and the Heat Pump compressor is
disabled. Every four minutes after Y2 is broken, the leaving air temperature
is checked. If the temperature drops below the heat cut-out setpoint, Y2
Y2 is made, red light DL2 turns off and the compressor is re-enabled.
When the heat pump is running, the SYCAP keeps the heat pump coil leaving
air temperature within operating range by turning the heat pump
compressor off for a minimum of four minutes if the air temperature gets
too cold in cool mode or too hot in heat mode. The SYCAP will also turn
on the heat pump auxiliary heat if the coil leaving air temperature is not
hot enough in heat mode. The compressor is kept off for a minimum of
four minutes to prevent short cycling.
AUXILIARY HEAT CONTROL – Four minutes after the SYHPA initiates
a heat call, the leaving air temperature is continuously checked. If the air
temperature does not rise above the Auxiliary Heat Cut-in setpoint, green
light DL2 turns on, the connection between W2 W2 is made, and the Heat
Pump Auxiliary heat is enabled. When the leaving air temperature rises
nine degrees above the auxiliary heat cut-in setpoint, green light DL2
turns off, W2 W2 is broken, and the auxiliary heat is disabled.
OPERATION
The SYCAP has two relays (K1 and K2) and two corresponding status
lights (DL1- red and DL2- green). Relay K1 is a normally closed relay.
When energized, it breaks the connection between Y1 Y1 which disables
the heat pump compressor. Relay K2 is a normally open relay. When
energized, it makes the connection between W2 W2 which enables the
heat pump auxiliary heat.
SYCAP Components
The SYCAP consist of the following:
A. Digital Display – Three digit LED. Normally displays the coil
leaving air temperature of the heat pump. When “E” displayed,
indicates SYCAP is in Enable mode; refer to OPERATION section. When
the UP/DN buttons are pressed, the cutout setpoints are displayed.
Refer to the Setpoint Calibration section for reading and adjusting
the setpoints.
There are three adjustable setpoints on the SYCAP: Heat Cut-out, Cool
Cut-out, and Auxiliary Heat Cut-in. The Heat Cut-out Setpoint is the
maximum allowable leaving air temperature in heat mode. If the air
temperature rises above this setpoint in heat mode, the compressor is
disabled for a minimum of four minutes. The Cool Cut-out setpoint is the
minimum allowable leaving air temperature in cool mode. If the air
temperature drops below this setpoint in cool mode, the compressor is
disabled for a minimum of four minutes. The Auxiliary Heat Cut-in
temperature is the minimum allowable leaving air temperature in heat
mode. Four minutes after the heat pump compressor has been turned
on, if the coil air temperature cannot rise above this setpoint, the auxiliary
heat is enabled. The auxiliary heat is disabled when the air temperature
rises nine degrees above the Auxiliary Heat Cut-in setpoint.
B. Microcontroller – Brains of the SYCAP and where the program
resides. Occasionally, software upgrades may become available. If so,
the SYCAP software can be field upgraded by changing this microcontroller.
C. Status Lights – Red light DL1 is on when relay K1 is energized.
Green light DL2 is on when relay K2 is energized. See E.
D. Thermometer Calibrator – Calibrates the leaving air temperature
thermometer. Turn clockwise to lower temperature. Turn counterclockwise to raise. Refer to CALIBRATION section for complete
calibration information.
The SYCAP knows which mode of operation it is in by monitoring the W2
signal from the SYHPA Switching Center. If W2 is energized, it knows the
SYHPA is making a heat call.
E. Relays K1 and K2 – SPST relays. Relay K1 is a normally closed
relay. When energized, it breaks contact between Y1 Y1. Relay K2 is
a normally open relay. When energized, makes contact between W2
W2 terminals.
The following is a detailed operation description of each mode.
IN RANGE, HEAT MODE – If the SYHPA Switching Center is making
a heat call and the leaving air temperature is below the Heat Cut-out
setpoint and above the Auxiliary Heat Cut-in, relays K1 and K2 are
de-energized, red light DL1 is off and green light DL2 is off. The leaving
air temperature is displayed on the digital display.
F. Leaving Air Sensor (LAS) Terminals – Leaving air temperature
sensor is connected to the SYCAP here. Red to + and white to –. The
sensor monitors the coil leaving air of the heat pump. If preferred,
the SYCAP can be mounted up to 500 feet from the sensor. See
INSTALLATION section for further information.
COOL CUT-OUT – If the SYHPA is making a cool call and the leaving
air temperature drops below the Cool-Cut-out setpoint, the connection
between Y1 Y1 breaks, red light DL1 turns on, and the Heat Pump
compressor is disabled. Every four minutes after Y1 is broken, the
leaving air temperature is checked. If the temperature rises above the
cool cut-out setpoint, Y1 Y1 is made, red light DL1 turns off and the
compressor is re-enabled.
G. Heat Pump/Switching Center Interface Terminals – Y1
controls the heat pump compressor. W2 controls the heat pump
auxiliary heat. One Y1 and W2 connect to the Switching Center, the
other Y1 and W2 connect to the heat pump. It does not matter which
W2/Y1 connects to the Switching Center and which connects to the
heat pump. See WIRING section for detailed wiring instructions.
33
CAPACITY CONTROLLERS - SYCAP
H. Heat Pump Power Terminals – Connect to heat pump 24V AC
J. Setpoint Adjustment – Use the UP/DN buttons to view and
power source. R is 24 V hot. C is 24 V rtn. Cannot be connected to
any other power source. SYCAP uses less than 2 VA of power. See
WIRING section for detailed wiring instructions.
change the cut-out setpoints. Refer to the Setpoints, Calibration
section (Page 41) for reading and adjusting the setpoints.
K. Board Number – This number indicates the circuit board numI. Power Switch – When off, the display is off, the SYCAP is disabled
ber and revision. You may need to know this number if conferring with technical support.
90107C
and K1 relay contacts are made. The heat pump compressor can run
at this time but will not have capacity control protection. The
auxiliary heat cannot run. When the switch is on, the display is on
and the SYCAP is operational.
A
UP
K
J
DN
B
C
D
E
K1
+
-
ON
DL2
I
K2
Y1 Y1 W2 W2
R
G
F
OFF
DL1
C
H
WIRING
The SYCAP is installed as detailed in the Capacity Controllers Installation
section, page 40. Wire as diagrammed below. The W2 terminal from the
SYHPA Switching Center must be wired to the SYCAP Capacity Controller
even if the Heat Pump does not have auxiliary heat. The SYCAP determines
the mode of operation based on this signal.
Switching Center (SYHPA)
O/B Y G R E W2 L
Terminals R and C of the SYCAP must be wired to terminals R (24V hot)
and C (24V rtn) of the Heat Pump system transformer.
C
O/B
H
E
A
T
P
U
M
P
Y
G
R
E
W2
L
C
C
R
W2 W2 Y1 Y1
SYCAP
K2
34
K1
CAPACITY CONTROLLERS - 101ALAS
is the cool test point and TP3 is the heat test point. (TP1 is the electric
heat test point on the Heat Pump Controller). Clip the leads of a digital
volt meter, set to 20 volts DC, between the potentiometer test point that
needs to be modified and the ground test point. Rotate the corresponding potentiometer until the meter reads the proper voltage according
to Table 2 below.
101ALAS
+ –
GROUND
TB1 TEMP TC1 TC2 S Y W Rd B G TR2 TR1
–
+
Y1
COOL
Y2
Y1
HEAT
Y2
COOL ADJ
TP2
OFF
101AACBHP
HEAT PUMP
CONTROLLER
J1
J2
ELECTRIC
HEAT ADJ
TP1
ON
PWR
GND
1
OFF
COOL
OPERATION
The 101ACBHP System Controller has four status lights that represent
capacity control. The heat Y1 and Y2 red lights indicate heating operation and the cool Y1 and Y2 green lights indicate cooling operation. Heating or cooling will be initiated depending on the position of the reversing valve. When one of the lights turns on, the leaving air temperature in
the duct, sensed by the LAS, has exceeded one of the capacity control setpoints. The light will indicate which stage will be turned off. The second stage factory default cut-in temperature for heating is 95 degrees, and
for cooling 60 degrees. If the setpoint is exceeded, a stage light will illuminate, the stage will be shut down, and a four-minute time delay will
begin. After the four minute delay, if the leaving air temperature has recovered to an acceptable temperature, the stage which was shut down will
restart. If the temperature has not recovered, the time delay will continue. If both first and second stage setpoints are exceeded by the leaving
air, then a four-minute time delay per stage will go into effect.
AUTO
HEAT
The 101ALAS works with the System 2000 Heat Pump System Controller
(101AACBHP). The 101ALAS provides leaving air temperature readings
to the System Controller, which allows it to make capacity control decisions.
REV.
VALVE
OVERVIEW
OFF
AUTO
FAN
HEAT ADJ
TP3
TB2
R
W
Y2
Y1
O/BL G
ON
WIRING
MODIFYING SETPOINT ADJUSTMENT
The Heat Pump Controller is designed so that it is possible to modify the
cut-in setpoints for cooling, heating (and electric heat on the Heat Pump
Controller). If necessary, locate the potentiometer associated with its test
point on the diagram above. “GND” is the common ground test point, TP2
The 101ALAS is installed as detailed in the Capacity Controllers
Installation Section, page 40. The + or – terminals of the LAS are
wired to the + or – terminal of the 101AACBHP using two
conductor 18 gauge thermostat wire.
1
LAS VOLTAGE CONVERSION CHARTS
TABLE 2: TEMPERATURE TO VOLTAGE
CONVERSION CHART
TABLE 1: CAPACITY CONTROL
STAGE CUT-IN TEMPERATURES*
Cooling
Second Stage
60
GND & TP2
Heating
Second Stage
95
GND & TP3
Electric Heat
85
GND & TP1
Discharge Duct
Temperature
––
LAS + & –
2.887
3.081
3.025
per table #2
*The Y2 cut-out temperature is 10° fixed below the cut-in temperature
in cooling, and 10° above in heating.
The Y1 cut-out temperature is 15° fixed below the cut-in temperature in
cooling, and 25° above in heating.
35
Deg. F.
DC Volts
Deg. F.
DC Volts
Deg. F.
DC Volts
Deg. F.
DC Volts
40
2.775
70
2.942
100
3.109
130
3.275
41
2.781
71
2.948
101
3.114
131
3.281
42
2.787
72
2.953
102
3.120
132
3.287
43
2.792
73
2.959
103
3.125
133
3.292
44
2.798
74
2.964
104
3.131
134
3.298
45
2.803
75
2.970
105
3.137
135
3.303
46
2.809
76
2.975
106
3.142
136
3.309
47
2.814
77
2.981
107
3.148
137
3.314
48
2.820
78
2.987
108
3.153
138
3.320
49
2.825
79
2.992
109
3.159
139
3.325
50
2.831
80
2.998
110
3.164
140
3.331
51
2.837
81
3.003
111
3.170
141
3.337
52
2.842
82
3.009
112
3.175
53
2.848
83
3.014
113
3.181
54
2.853
84
3.020
114
3.187
55
2.859
85
3.025
115
3.192
56
2.864
86
3.031
116
3.198
57
2.870
87
3.037
117
3.203
58
2.875
88
3.042
118
3.209
59
2.881
89
3.048
119
3.214
60
2.887
90
3.053
120
3.220
61
2.892
91
3.059
121
3.225
62
2.898
92
3.064
122
3.231
63
2.903
93
3.070
123
3.237
64
2.909
94
3.075
124
3.242
65
2.914
95
3.081
125
3.248
66
2.920
96
3.087
126
3.253
67
2.925
97
3.092
127
3.259
68
2.931
98
3.098
128
3.264
69
2.937
99
3.103
129
3.270
CAPACITY CONTROLLERS – CAPL-2
OVERVIEW
SEQUENCE OF OPERATION
The Zonex Systems CAPL-2 is a combination staging and capacity control
device for use with gas/electric units and heat pumps that use standard
gas/electric thermostats. It can stage an economizer, two stages of cooling
and up to two compressors and two stages of heat. The CAPL-2 monitors
the leaving air temperature and stages the cooling or heating to maintain
the leaving air temperature within a fixed range. Controlling the staging
based on the leaving air temperature ensures the supply always matches
the load. This is essential with a zoning system since the load varies substantially as the number of zones calling varies.
The following sequence of operation assumes the cool cut-out setpoint is
48 degrees Fahrenheit and the heat setpoint is 150 degrees for
gas/electric units and 118 degrees for heat pump units. For any other
cut-out settings, add or subtract the difference to the values stated.
Example: If your actual cool cut-out is 50 degrees, add 2 degrees to each
temperature value stated under the Cooling Call section. All temperatures
are in degrees Fahrenheit.
COOLING CALL (cool setpoint 48): As long as there is a cooling call
(YIN energized), the following will occur.
Cool Mode – When there is a cool call, if the leaving air is above the cool
cut-in temperature, the CAPL-2 turns on the next stage compressor after
a time delay. If the air gets too cold, it turns off the last stage compressor
after that compressor has run a minimum of four minutes. As long as
there is a cool call, when a compressor turns off it will stay off for a
minimum of four minutes if the jumper is on ECON and when a compressor turns on it will run a minimum of four minutes. This prevents
short cycling and ensures sufficient compressor oil return. When the
cool call is removed, all compressors are immediately turned off.
ECONOMIZER:
• As long as there is a cooling call the economizer, if available, is enabled
and outside air is supplied based on enthalpy. The Economizer
selection jumper must be on ECON if there is an economizer. If no
economizer, place jumper on ECOFF.
COMPRESSOR STAGING ON:
• If the leaving air is 58 degrees or greater and no compressors are
running, compressor one will turn on within six minutes. If compressor
one is running, compressor two will turn on within eight minutes.
Heat Mode (Gas/Electric) – If the leaving air is below the heat cutin temperature, it turns on the next heat stage after a time delay. If the air
gets too warm, it turns off the last heat stage after a time delay. When the
heat call is removed, all heat stages turn off immediately.
COMPRESSOR STAGING OFF:
• If the leaving air is between 48 and 52 degrees and
compressor two is running, compressor two will shut off after
running a minimum of four minutes. Compressor one will shut off
after it has been on a minimum of four minutes and compressor two
has been off a minimum of six minutes.
Heat Mode (Heat Pump) – When there is a heat call, if the leaving air
is below the heat cut in temperature, the CAPL-2 turns on the next stage
heat after a time delay. If the air gets too warm, it turns off the last stage
heat after that stage has run a minimum of four minutes. As long as there
is a heat call, when a heat stage turns off, it will stay off for a minimum of
four minutes and when a heat stage turns on it will run a minimum of four
minutes. This prevents short cycling and ensures sufficient compressor
oil return. When the heat call is removed, all compressors are immediately
turned off.
• If the leaving air is 48 degrees or less, then all compressors will turn
off after the last compressor running has run for at least four minutes.
NO STAGING:
• If the leaving air is equal to or greater than 52 and less than
58 degrees, then no compressor staging will occur.
HEATING CALL (Gas/Electric) (The factory heat setpoint is 150.
Heat setpoint may be field modified to compensate for local temperatures
G
+ –
W
Y
24V RTN
HVAC UNIT
24V PWR
R
HEAT 2
HEAT 1
FAN
COMP 2
COMP 1
ECONOMIZER
*
+
-
YIN Y1 Y2 G G
I O
N U
T
WIN W1W2
R C
CAPL-2
*Lennox L Series Units may require a direct connection from YIN to the Economizer.
36
SYGE Switching Center
101ASSB System Controller
WIRING – CAPL-2
LAS
SENSOR
CAPACITY CONTROLLERS – CAPL-2
and field conditions. For example, in milder climates setting may be as low
as 110 to 115 degrees. In more severe climates up to 150 degrees.) As long
as there is a heating call (WIN energized), the following will occur.
HEATING CALL (Heat Pump) (heat setpoint 118). As long as there
HEAT STAGING ON:
• If the leaving air is 98 degrees or less and heat one is off, heat
one will turn on within four minutes. If heat one is on, heat two will
turn on within eight minutes.
is a heating call (WIN energized), the following will occur:
HEAT STAGING ON:
• If the leaving air is 130 degrees or less and heat one is off, heat
one will turn on within four minutes. If heat one is on, heat two will
turn on within ten minutes.
HEAT STAGING OFF:
• If the leaving air is between 113 and 118 degrees and heat two
is on, heat two will shut off after running a minimum of four minutes. Heat one will turn off after it has been on a minimum of four minutes and heat two has been off a minimum of six minutes.
HEAT STAGING OFF:
• If the leaving air is between 145 and 150 degrees and heat two
is running, heat two will turn off. Heat one will turn off after 150
Degree setpoint is exceeded
•
• If the leaving air is 118 degrees or greater then all heat stages will
turn off after the last heat stage running has run for at least four minutes.
If the leaving air is 150 degrees or greater then all heat stages
will turn off and the indoor blower fan is energized until heat one
turns back on or until the heat call is satisfied.
NO STAGING:
NO STAGING: If the leaving air is greater than 130 and less than
• If the leaving air is greater than 98 and less than or equal to
113 degrees, then no heat staging will occur.
or equal to 145 degrees, then no heat staging will occur.
COMPONENTS
The CAPL-2 consists of the following:
H. Status Lights – ECONO – On during cool call. Indicates economizer enabled; Y1 – On when first stage compressor energized; Y2 – On
when second stage compressor energized; Y3 – On when third
stage compressor energized; Y4 – On when fourth stage compressor
energized; FAN – On when indoor blower fan energized by System Controller or CAPL-2 (G energized); W1 – On when first stage furnace
energized; W2 – On when second stage furnace energized; W3 – On
when third stage furnace energized; W4 – On when fourth stage furnace
energized.
A. Digital Display – Three digit LED. Normally displays the leaving air
temperature of the HVAC unit. When the UP/DN buttons are pressed, the
cut-out setpoints are displayed. Refer to the Setpoint Calibration
section for reading and adjusting the setpoints.
B. Microcontroller – Activates and controls outputs based upon leaving
air temperature comparison with programmed setpoint. Occasionally software upgrades may become available. If so, the CAPL-2 software can be
field upgraded by changing this microcontroller.
I. Power Switch – When off, the display is off, the CAPL-2 is disabled and
the relay contacts are closed. The HVAC unit can run at this time but will
not have staging control or capacity control protection. When the switch
is on, the display is on, and the CAPL-2 is operational.
C. Thermometer Calibrator – Calibrates the leaving air temperature
thermometer. Turn clockwise to lower temperature. Turn counterclockwise to raise. Refer to CALIBRATION section for complete calibration information.
J. Board Number – This number indicates the circuit board number and
revision. May need to know this number if conferring with technical
support.
D. Economizer Selection Jumper:
ECON – Place here if you have an economizer.
ECOFF – Place here if no economizer.
K. Heat Pump/Gas Electric selection jumper – Place at GE position
for gas/electric units.
UP
Place at HP position for
heat pump units that use
A
L
gas/electric thermostats.
DN
F. HVAC/System Controller Interface Terminals – Y IN – Cool call
input, Economizer output; Y1 – Compressor 1; Y2 – Compressor 2;
G – Indoor blower fan; W IN – Heat call input; W1 – Heat 1; W2 – Heat
2. See Wiring section for detailed wiring instructions.
G. HVAC Power Terminals – Connect to HVAC system 24V AC power
source. R is 24 V hot. C is 24 V rtn. Cannot be connected to any other
power source. CAPL-2 uses less than 2 VA of power. See Wiring section
for detailed wiring instructions.
K
GE
C
E
+ -
ECON
ECOFF
D
H
ON
OFF
E
C
O
F
N
A
O Y1 Y2 N
I
W1 W2
Y IN Y1 Y2 GIN GOUT WIN W1 W2
R C
G
F
37
J
HP
B
990616B
L. Setpoint Adjustment – Use the UP/DN
buttons to view and
change the cutout setpoints. Refer to the Setpoints, Calibration section (Page 41) for reading and adjusting the setpoints.
R4
E. Leaving Air Sensor (LAS) Terminals – Leaving air temperature
sensor is connected to the CAPL-2 here. Red to + and white to –. The
sensor monitors the leaving air of the HVAC system. If preferred, the
CAPL-2 can be mounted up to 500 feet from the sensor. See Installation
section for further information.
CAPACITY CONTROLLERS – CAPL-4
OVERVIEW
NO STAGING:
If the leaving air is equal to or greater than 52 and less than 58°
then no compressor staging will occur.
The Zonex Systems CAPL-4 is a combination staging and capacity control
device in one. It can stage an economizer and up to four compressors and up to four stages of heat. The CAPL-4 monitors the leaving air
temperature and stages the cooling or heating to maintain the leaving air
temperature within a fixed range. Controlling the staging based on the
leaving air temperature ensures the supply will always match the load.
This is essential with a zoning system, since the load varies substantially as the number of zones calling varies.
HEATING CALL (heat setpoint 150). As long as there is a heating call
(WIN energized), the following will occur.
HEAT STAGING ON:
If the leaving air is 130° or less, the next heat stage will turn on
within four minutes. As long as the air temperature remains within this
range the next higher heat stage will turn on every four minutes.
Cool mode – When there is a cool call, if the leaving air is above the
cool cut-in temperature, the CAPL-4 turns on the next stage compressor
after a time delay. If the air gets too cold, it turns off the last stage
compressor after that compressor has run a minimum of four minutes.
As long as there is a cool call, when a compressor turns off it will stay off
for a minimum of four minutes and when a compressor turns on it will
run a minimum of four minutes. This prevents short cycling and
ensures sufficient compressor oil return. When the cool call is
removed, all compressors are immediately turned off.
HEAT STAGING OFF:
If the leaving air is between 145 and 150° the highest heat stage on
will shut off within four minutes. As long as the air temperature remains
within this range the next highest heat will stage off every four minutes.
If the leaving air is 150° or greater then all heat stages will turn off.
COMPONENTS
Heat mode – If the leaving air is below the heat cut-in temperature, it
turns on the next heat stage after a time delay. If the air gets too warm,
it turns off the last heat stage after a time delay. When the heat call is
removed, all heat stages turn off immediately.
The CAPL-4 consist of the following:
A. Digital Display – Three digit LED. Normally displays the leaving air
temperature of the HVAC unit. When the UP/DN buttons are pressed, the
cut-out setpoints are displayed. Refer to the Setpoint Calibration section
for reading and adjusting the setpoints.
OPERATION
The following sequence of operation assumes the cool cut-out setpoint is
48 and the heat is 150 degrees Fahrenheit. For any other cut-out settings,
add or subtract the difference to the values stated. Example: If your actual cool cut-out is 50 degrees, add 2 degrees to each temperature value stated under the Cooling Call section. All temperatures are in degrees
Fahrenheit.
B. Microcontroller – Activates and controls outputs based upon leaving air temperature comparison with programmed setpoints. Occasionally software upgrades may become available. If so, the CAPL-4 software
can be field upgraded by changing this microcontroller.
COOLING CALL (cool setpoint 48): As long as there is a cooling call
(YIN energized), the following will occur.
UP
A
ECONOMIZER:
As long as there is a cooling call the economizer, if available, is enabled
and outside air is supplied based on enthalpy.
990407A
J
I
SW1
ON
DN
B
COMPRESSOR STAGING ON:
If the leaving air is 58° or greater, the next compressor will turn
on within four minutes. As long as the air temperature remains within
this range the next higher compressor will stage on every four minutes.
R4
C
COMPRESSOR STAGING OFF:
If the leaving air is between 48 and 52°, the highest compressor
stage on will shut off within four minutes. As long as the air temperature
remains within this range the next highest running compressor will stage
off every four minutes.
+
-
E
C
O
N
O
G
Y1 Y2 Y3 Y4 G
W1 W2 W3 W4
Y1 IN Y1 Y2 Y3 Y4 G
W1 IN W1 W2 W3 W4
D
38
R C
F
E
If the leaving air is 48° or less then all compressors will turn off after
the last compressor running has run for at least four minutes.
H
CAPACITY CONTROLLERS - CAPL-4
G. Status Lights – ECONO – On during cool call. Indicates economizer
enabled; Y1 – On when first stage compressor energized; Y2 – On when
second stage compressor energized; Y3 – On when third stage
compressor energized; Y4 – On when fourth stage compressor energized;
FAN – On when indoor blower fan energized by System Controller or
CAPL-4 (G energized); W1 – On when first stage furnace energized;
W2 – On when second stage furnace energized; W3 – On when third stage
furnace energized; W4 – On when fourth stage furnace energized.
C. Thermometer Calibrator – Calibrates the leaving air temperature
thermometer. Turn clockwise to lower temperature. Turn counterclockwise to raise. Refer to CALIBRATION section for complete calibration information.
D. Leaving Air Sensor (LAS) Terminals – Leaving air temperature
sensor is connected to the CAPL-4 here. Red to + and white to –. The
sensor monitors the leaving air of the HVAC system. If preferred, the CAPL4 can be mounted up to 500 feet from the sensor. See INSTALLATION
section for further information.
H. Power Switch – When off, the display is off, the CAPL-4 is disabled
and the relay contacts are closed. The HVAC unit can run at this time but
will not have staging control or capacity control protection. When the
switch is on, the display is on and the CAPL-4 is operational.
E. HVAC/System Controller Interface Terminals – Y IN – Cool call
input, Economizer output; Y1 – Compressor 1; Y2 – Compressor 2; Y3
– Compressor 3; Y4 – Compressor 4; G – Indoor blower fan; W IN – Heat
call input; W1 – Heat 1; W2 – Heat 2; W3 – Heat 3; W4 – Heat 4. See
WIRING section for detailed wiring instructions.
I. Board Number – This number indicates the circuit board number and
revision. May need to know this number if conferring with technical support.
F. HVAC power terminals – Connect to HVAC system 24V AC power
source. R is 24 V hot. C is 24 V rtn. Cannot be connected to any other
power source. CAPL-4 uses less than 2 VA of power. See WIRING section
for detailed wiring instructions.
J. Setpoint Adjustment – Use the UP/DN buttons to view and change
the cut-out setpoints. Refer to the Setpoint, Calibration section (Page 41)
for reading and adjusting the setpoints.
LAS
SENSOR
G
+ –
W
Y
24V RTN
HVAC UNIT
24V PWR
R
HEAT 4
HEAT 3
HEAT 2
HEAT 1
FAN
COMP 4
COMP 3
COMP 2
COMP 1
ECONOMIZER
+
-
Y1 IN Y1 Y2 Y3 Y4 G
CAPL-4
39
W1 IN W1 W2W3 W4
R C
101ASSB System Controller
WIRING – CAPL-4
CAPACITY CONTROLLERS – INSTALLATION
A. Select location to place sensor. For gas/electric HVAC systems, sensor must be in leaving air duct, preferably as far from the coil/heat
exchanger as possible but not past the bypass tap. For heat pumps,
sensor must be placed between coil and auxiliary heat. If heat
pump does not have auxiliary heat, place sensor as specified for
gas/electric system. See Figure 1.
E. If mounting sensor remotely, refer to Figure 3 and do the following:
1. On Capacity Controller, loosen + and – terminal screws and
disconnect sensor.
2. Remove circuit board screws and pull circuit board away from
casing.
3. Pull sensor out of casing.
4. Reattach circuit board to casing with screws previously removed.
6. Place sensor in hole made in duct and secure with tape, wire tie
or cable clamp. Use grommet or tape to protect sensor wire from
sharp edges.
7. Select location for Capacity Controller and mount with screws.
8. Wire sensor to Capacity Controller, red to + and white to –. If less
than 200 feet, use separate 18 gauge, two conductor wire. If over
200 feet, use separate two conductor shielded wire and connect
shield to TR2 or C terminal of Capacity Controller.
B. Cut or drill a hole in selected location large enough to fit sensor
through.
C. For 101CAPGE, TRLAT, SYCAP, CAPL-2 and CAPL-4, determine if
Capacity Controller will be mounted integral with sensor or remote
from sensor. Mounting sensor remotely enables you to place the
Capacity Controller in a location easily visible and serviceable.
D. For the 101ALAS, TRFPC, or if mounting any other model with the
sensor integral with Capacity Controller, place sensor through hole made
in duct and mount Capacity Controller to duct with screws. Use grommet
or tape to protect sensor wire from sharp edges. See Figure 2.
GAS/ELECTRIC
C
O
I
L
AIRFLOW
Place sensor in supply duct,
as far from coil/heat exchanger
as possible but not past
Bypass tap.
BYPASS
RETURN
BYPASS
TAP
Figure 1. Sensor Location
HEAT PUMP
C
O
I
L
AIRFLOW
BYPASS
RETURN
H
A E
U A
X
T
Place sensor in heat
pump between coil and
auxiliary heat
BYPASS
TAP
Circuit board screws (qty. 3)
C
A
P
A
C
I
T
Y
C
O
N
T
R
O
L
L
E
R
If using shielded wire, connect
shield to TR2 or C
Sensor
+
-
Secure sensor with tape,
cable clamp or wire tie
White
White to –
Red to +
Protect sensor wire from
sharp edges by using
grommet or tape.
Red
Protect sensor wire from
sharp edges by using
grommet or tape.
Figure 3. Capacity Controller with Remote Sensor
Figure 2. Capacity Controller Mounted with Sensor
40
CAPACITY CONTROLLERS – SETPOINTS, CALIBRATION
Heat Setpoint – To read the heat cut-out setpoint, press the UP button
until “H” appears and then release. The number that follows is the heat
cut-out setpoint. After a couple of seconds the leaving air temperature
will be redisplayed. To change the setpoint, press the top or up button
until the “H” is displayed, then immediately after the setpoint is displayed
press and hold the UP/DN button till setpoint is at the desired value.
The following applies to the
101CAPGE,
CAPL-2,
CAPL-4 and
SYCAP Setpoints:
Auxiliary Heat Setpoint – For the SYCAP only, to read the auxiliary
heat setpoint, press the UP and DN buttons simultaneously until “E”
appears and then release. The number that follows is the auxiliary heat
setpoint. After a couple of seconds the leaving air temperature will be
redisplayed. To change the setpoint, immediately after the setpoint is displayed
press and hold the UP/DN button till the setpoint is at the desired value.
There are two cut-out setpoints, one for heat and one for cool. The
digital display normally displays the leaving air temperature of the
HVAC/heat pump unit. By pressing the UP and DN buttons, the setpoints
can be viewed and changed.
Cool Setpoint – To read the cool cut-out setpoint, press the DN button
until “C” appears and then release. The number that follows is the cool
cut-out setpoint. After a couple of seconds the leaving air temperature will
be redisplayed. To change the setpoint, press the bottom or down button
until the “C” is displayed, then immediately after the setpoint is displayed
press and hold the UP/DN button till setpoint is at the desired value.
CALIBRATION
The digital display normally displays the leaving air temperature of the
internal thermometer. This thermometer is factory calibrated. If calibration
is ever required, turn the Thermometer Calibrator clockwise to lower the
temperature. Turn counterclockwise to raise.
FIVE WIRE LINK
Zonex Systems’s patented Five Wire Link is one of the most important elements of the System 1000/2000 zoning system. Extra care should be made
to ensure the wiring is done correctly. The color code must be strictly followed. Ensure the stripped wire leads are not touching each other at the terminal blocks. If putting two wires into one terminal block, use the same
gauge wire for both and ensure they are seated properly.
You must ensure the wire is sized properly to match the power needs of
the number of dampers installed. The more dampers used, the greater the
current draw and the greater the voltage loss on the Five Wire Link. If too
much voltage is lost on the Five Wire Link, there will not be enough
voltage at the zone dampers to properly operate them. To ensure the
correct wire size, use the following table. Select the row matching the
number of zone dampers you have. Move across horizontally to the
column that matches the distance from the System Controller to the
farthest damper. Use the wire size specified at the row/column
intersection.
To reduce wire size, you can run more than one Five Wire Link Daisy Chain.
Example: If you have 10 dampers, and the maximum distance is 200 feet,
you would need 12 GA wire. If instead, you used two Five Wire Links with
5 dampers on each, you would now only need 18 GA wire for each daisy
chain. Multiple daisy chains are wired color to color at the System
Controller.
NOTE: Never use less than 18 GA wire on the 5 Wire Link.
41
WIRE LENGTH
NUMBER OF
ZONE
DAMPERS
50'
100'
150'
200'
1
18 GA
18 GA
18 GA
18 GA
2
18 GA
18 GA
18 GA
18 GA
3
18 GA
18 GA
18 GA
18 GA
4
18 GA
18 GA
18 GA
18 GA
5
18 GA
18 GA
18 GA
18 GA
6
18 GA
18 GA
18 GA
16 GA
7
18 GA
18 GA
18 GA
16 GA
8
18 GA
18 GA
16 GA
16 GA
9
18 GA
18 GA
16 GA
14 GA
10
18 GA
18 GA
16 GA
14 GA
11
18 GA
16 GA
16 GA
14 GA
12
18 GA
16 GA
14 GA
14 GA
13
18 GA
16 GA
14 GA
12 GA
14
18 GA
16 GA
14 GA
12 GA
15
18 GA
16 GA
14 GA
12 GA
16
18 GA
14 GA
14 GA
12 GA
17
18 GA
14 GA
12 GA
12 GA
18
18 GA
14 GA
12 GA
12 GA
19
18 GA
14 GA
12 GA
12 GA
20
18 GA
14 GA
12 GA
12 GA
TRANSFORMER / FUSE SIZING
Transformer/fuse sizing: The 24V transformer
connected to TR1 and TR2 of the Switching
Center/System Controller powers the zone
dampers, zone thermostats and Switching
Center/System Controller. The power rating of
the transformer must be sufficient to power
the number of dampers used. Also, a properly
rated in line fuse must be used on the secondary
of the transformer. To determine the power
rating of the transformer and the amperage
rating of the fuse, use the table above.
NUMBER
OF
DAMPERS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Note: If using both spring open and power open
dampers, size as if all dampers are spring open.
LOW PRESSURE
(SPRING OPEN) DAMPERS
XFMR PWR FUSE SIZE
12 VA
1 AMP
24 VA
2 AMP
36 VA
2 AMP
48 VA
3 AMP
60 VA
3 AMP
72 VA
4 AMP
84 VA
5 AMP
96 VA
5 AMP
108 VA
6 AMP
120 VA
6 AMP
132 VA
7 AMP
144 VA
7 AMP
156 VA
8 AMP
168 VA
9 AMP
180 VA
9 AMP
192 VA
10 AMP
204 VA
10 AMP
216 VA
11 AMP
228 VA
11 AMP
240 VA
12 AMP
MED. PRESSURE/HEAVY DUTY
(POWER OPEN) DAMPERS
XFMR PWR
FUSE SIZE
6 VA
1 AMP
12 VA
1 AMP
18 VA
1 AMP
24 VA
2 AMP
30 VA
2 AMP
36 VA
2 AMP
42 VA
3 AMP
48 VA
3 AMP
54 VA
3 AMP
60 VA
3 AMP
66 VA
4 AMP
72 VA
4 AMP
78 VA
4 AMP
84 VA
5 AMP
90 VA
5 AMP
96 VA
5 AMP
102 VA
5 AMP
108 VA
6 AMP
114 VA
6 AMP
120 VA
6 AMP
APPLICATION SCHEMATICS
WIRING THE ZONE DAMPER
For Duct Supplemental Heat
Applications
TYPICAL SETBACK/SETUP WIRING FOR ALL
SWITCHING CENTERS AND SYSTEM CONTROLLERS
For continuous fan operation in the occupied mode and intermittent
operation during unoccupied periods, leave the System Controller/
Switching Center fan switch in the “ON” position.
THERMOSTAT
1 STAGE COOL 2 STAGE HEAT
TO FIVE
WIRE
LINK
SWITCHING CENTER
OR
SYSTEM CONTROLLER
R
Time Clock Switch:
Closed – Occupied
Open – Unoccupied
R
TO
A/C UNIT
G
OR FURNACE
C
W
W
Y
Y
G
R
K1 A
G
B
W
Y
R
T-STAT
W1
W2
C
K1
C
Rd
Time
Clock
Switch
Y
R
RC
DAMPER
MOTOR
MC
RO
K1 B
C
SAIL OR PRESSURE
SWITCH
MAKE AND BREAK
ELECTRIC HEAT
CIRCUIT
K1 = RELAY DPDT
NOTE: CONTACT "K1 A" IS ONLY REQUIRED FOR DUCT
HEATER APPLICATIONS TO FORCE DAMPER TO THE
OPEN POSITION
42
APPLICATION SCHEMATICS
BLOWER FAN RELAY
CENTRAL & AUXILIARY
BASE BOARD HEAT WIRING
If the heater does not turn on the indoor blower fan when heat is on, you
must add a blower fan relay as shown below. The relay will energize the
fan signal “G” when the heat signal “W” is energized.
THERMOSTAT
1 STAGE COOL
2 STAGE HEAT
(101DIGITS)
R
C
Y W1
W2
TO BASE BOARD
CONTACTOR
Y
R
C
RC
W
Y
G
Rd
B
M C RO
R
TO
ADDITIONAL
ZONES
FUSED 24 VOLT
TRANSFORMER
H
V
A
C
G
W
R
G
C
U
N
I
T
TR1 TR2 B
TB1
RD W
Y
4
W
W2
3
W2
System Controller (101ASSB)
Switching Center (SYGE)
*
2
DAMPER
RELAY
BOARD
*
1 5
*
G
SYSTEM
CONTROLLER
SPDT, 24V
AC Relay
* NOTE:
FACTORY WIRED.
W
R
Y
W2 W Y G Rd B
The Blower Fan Mode (AUTO/ON) is usually selected at
the System Controller/Switching Center. If preferred, the
Fan Mode can be selected at one zone thermostat using
this diagram. The thermostat needs to have a fan switch.
C R Y W W2
ZONE FAN CONTROL
TB2
TB1
DAMPER
RELAY
BOARD
G
G
AC UNIT
Auto
RELAY
R
On
ZONE THERMOSTAT
(SADIGI)
(101PROG)
G SWITCHING CENTER
OR
SYSTEM CONTROLLER
Note: Leave the fan switch in the "AUTO" position at the Switching Center or System Controller.
ECONOMIZER INTERFACE FOR SWITCHING CENTERS AND SYSTEM CONTROLLERS
NOT UTILIZING THE CAPL-2 OR CAPL-4.
101ASSB
& SYGE
Y
SYHPA
Y
101AACB-HP
W
Y1
ENTHALPY
CONTROL
Y2
ENTHALPY
CONTROL
ECONOMIZER
Y
Y 101CAPGE OR
TRLAT ONLY
ENTHALPY
CONTROL
ECONOMIZER
Y SYCAP
Y
ECONOMIZER
COMPRESSOR
#1
COMPRESSOR
43
COMPRESSOR
#2
COMPRESSOR
SLAVING MULTIPLE DAMPERS
Each zone thermostat can control more than one damper. To determine when to use this application drawing, refer to Slaving Zone Dampers section
on page 23.
For Controller Transformer. (Transformer
connected to TR1 and TR2 of the Central
Controller) add 6VA for each relay used.
24 Volt
Transformer
DAMPER
MOTOR
#1
NC No connection
(- - - -) For power open / power close dampers only
Size Transformer
To
12VA Per Spring Return Damper
Additional
and 6VA Per Power Open /
Power Close Damper
Dampers
TB2
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
TB1
TB2
DAMPER #3
W2 W W Y G Rd B
W2 W W Y G Rd B
NC
NC
NC
NC
NC
RO MC RC C R Y W W2
NC
Damper Relay
Board
Damper Relay
Board
RO MC RC C R Y W W2
NC
NC
NC
NC
RO MC RC C R Y W W2
Damper Relay
Board
1
SPDT
RELAY
W2 W W Y G Rd B
1
TB2
TB1
NC
FIVE
WIRE LINK TO
SWITCHING
CENTER
or
CONTROLLER
DAMPER #1
NC
NC
C R Y W W2
TO THERMOSTAT:
Wires used vary per application
TB1
DAMPER #2
PROPER BYPASS INSTALLATION WITH ECONOMIZER
When sizing a bypass damper, compute the
system total air volume at 400 CFM/Ton and
subtract the CFM of the smallest zone. The
balance of the air can be bypassed at any one
time. Refer to the Round and Rectangular
damper CFM Charts. Choose the bypass
closest to your CFM to bypass.
1. Outside Air Intake
2. Mixing Damper for Outside Air &
Return Air
3. Pressure Relief of Outside Air
from Building
4. Barometric Damper to Prevent
Return Air Pressurization
5. Modulating Bypass Damper
WIRING A STAND ALONE DAMPER
When no system controller is used, use Zonex Systems’s Digital, Auto
Changeover Stand Alone Modulating Thermostat (SAMOD) in conjunction with an ST Series round or rectangular damper.
HEATING/COOLING AUTO CHANGE OVER WITH DUCT STAT
B
TB2
R
C
W
R
C
Duct Stat set at
65 degrees
STAT
TB1
Y
W
W
Y
R
Mechanical
Room Stat
B
W2W Y G Rd
B
W2 W Y G Rd
LINE
VOLTAGE
C R Y W W2
TB2
LINE
VOLTAGE
24 V
HEATING/COOLING AUTO CHANGE OVER WITH RELAY
*
Y
TB1
RO MC RC
C R Y W W2
DAMPER
RELAY
BOARD
24 V.
W2 W Y G Rd
DAMPER
RELAY
BOARD
COOLING ONLY DAMPER
RO MC RC
*
C R Y W W2
Listed below are some non-modulating solutions to stand alone
applications if it is not possible to use a SAMOD.
RO MC RC
*
DAMPER
RELAY
BOARD
TB2
TB1
PARALLEL THE RELAY WITH GAS
VALVE W WIRE ON HEATER
* "C" Terminal used for electronic thermostats
44
24 V.
LINE
VOLTAGE
R
Y
W
STAT
C
SYSTEM 1000/2000 TERMINAL DESCRIPTIONS
Damper Relay Board:
Daisy Chain, 5 or 6 Wire Link:
1.
2.
3.
4.
5.
6.
GD/G
Hot wire, 24V. Hot when Switching Center/Controller
TR1 is hot. For System 2000, turning Controller Power
switch off will remove power from GD. The Power switch
will not remove power from GD on System 1000.
BD/B 24V return (chassis ground). Measure all Daisy Chain
voltages in reference to this terminal.
RD
Hot when the Switching Center/Controller recognizes a
thermostat call. Damper light on Switching Center/ Controller is on when RD is hot.
YD/Y Cool call, hot when cool call recognized by Switching
Center/Controller. For System 1000: 5V to 16V (1 to 7
zones calling). For System 2000: 212 mv to 3.64V
(1 to 20 zones calling). There should never be 24V on
this terminal when the System 1000 Switching Center
green light is on and the mode switch is at “Cool” or
when the System 2000 Controller’s “Damper” and
“Cool” lights are on. If there is, you have a short to either
RD or GD.
WD/W Heat call, hot when heat call recognized by Switching
Center/Controller. Voltages the same as for YD. There
should never be 24V on this terminal when the System
1000 Switching Center green light is on and the mode
switch is at “Heat” or when the System 2000 Controller’s
“Damper” and “heat” lights ar on. If there is, you have
a short to either RD or GD.
W2
Second stage heat call. 24V when second stage of zone
thermostat is calling. Only used with System 1000 SYHPA.
1. TB2:
a.
MC
b.
c.
d.
e.
f.
RC
RO
R
C
W
g.
Y
h.
W2
2. TB1:
Motor common. Return for 24V damper motor(s).
Motor voltages measured in reference to this terminal.
Run Closed. 24V when damper motor closing.
Run Open. 24V when damper motor opening.
24V hot. Same as GD.
24V return. Same as BD.
Thermostat heat call. See below how to determine
if a zone is calling.
Thermostat cool call. See below how to determine
if a zone is calling.
Second stage thermostat heat call. Same as W2 on
Daisy Chain.
Daisy Chain. See Daisy Chain, 5 or 6 Wire Link above.
SYSTEM 1000/2000 TROUBLE SHOOTING
To determine if a zone is calling:
On Damper Relay board, measure voltage from W to W and Y to Y
(TB1 to TB2). If the voltage is at least 8 volts for System 1000 or 20
volts for System 2000, that zone is calling. If voltage is between W
and W, zone is calling for heat. If between Y and Y, zone is calling
for cool. To take this reading, RD must also be powered which
means the Switching Center/Controller has recognized the call
(Damper light on). Note: Do not test for a call by measuring the
voltage from Y to C or W to C on TB2. The system utilizes pull up
resistors which can give you false readings.
If Controller circuit board fuse is blowing (System 2000 only):
Make sure that the voltage between TR1 and TR2 is not less than 24
V or more than 30 V. If voltage is okay, replace Controller. If voltage is not within range, be sure you have the correct transformer and
that the primary voltage is adequate. If primary voltage is okay and
transformer is correct size, replace transformer.
If Controller/Switching Center transformer fuse is blowing:
1. Check for short on five wire link between RD and B or between
G and B.
2. Check for short on thermostats between R and C.
If System 1000 SYHPA Switching Center circuit board fuse is
blowing:
You have a short on the five wire link between either YD and GD, WD
and GD, YD and RD or WD and RD.
If Controller off circuit board fuse is blowing (System 2000 only):
You have a short on the five wire link between either Y and G, W and
G, Y and Rd, or W and Rd.
45
Zonex Systems
System 2000
2-20 Zone Auto Changeover
System 1000
2-7 Zone Manual Changeover
Hot Line: (800) 228-2966
5622 Engineer Drive
Huntington Beach, CA 92649
Factory: (714) 898-9963 • Fax: (714) 898-6802
Visit our Web Site http://www.hvaccomfort.com
E-mail us at calecon@hvaccomfort.com
PATENTED PRODUCT
Zonex Systems reserves the right to discontinue, or change at any time,
specifications or designs without notice and without incurring obligations.
Copyright 2003 by Zonex Systems, Inc.
Zoning
Part #101ASIM
Rev. September 2003
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