Aprilaire 6504 Safety & Installation Instructions
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Aprilaire 6504 Safety & Installation Instructions

Aprilaire 6504 Safety & Installation Instructions

Intelligent zoned comfort control system
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Intelligent Zoned Comfort Control System
Safety & Installation Instructions
Model 6504

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Summary of Contents for Aprilaire 6504

  • Page 1 Intelligent Zoned Comfort Control System Safety & Installation Instructions Model 6504...

  • Page 2: Table Of Contents

    • Plenum Temperature Sensor (Aprilaire Model 8052) • 2-wire or 3-wire dampers • Model 56 Aprilaire Automatic Humidifier Control • Outdoor Temperature Sensor (Aprilaire Model 8052 – not INTEGRATES WITH: needed if installed with an AHC) • Aprilaire Automatic Humidifier Control (AHC) to enhance humidity control •...

  • Page 3: Warnings And Cautions

    Leave power disconnected until 3. Installer should touch a grounded metal object before handling the installation is complete. Aprilaire control panel to avoid potential loss of internal computer 2. Sharp edges may cause serious programs due to static discharge. injury from cuts. Use care when 4.

  • Page 4: Control Panel Layout

    CONTROL PANEL LAYOUT (See Figure 1) (1) 24 VAC power input serves FIGURE 1 thermostat and AHC connection. (2) POWER LED light blinks at once per second with power applied unless put in Test Mode when it blinks twice per second. (3) Four sets of thermostat inputs.

  • Page 5: Run Wire For The System

    IMPORTANT Avoid running thermostat, AHC and sensor wires along side line voltage wires to prevent electrical noise on the Intelligent Zoned Comfort Control system. FIGURE 2 Model 6504 Control Panel 4 wires (1000 ft. max.) Model 8570 Thermostat 2 or 3 wires...

  • Page 6: Mount The Control Panel

    MOUNT THE CONTROL PANEL (See Figure 3) • Do not mount directly on foundation walls or on the HVAC equipment or ductwork. These locations can cause moisture to condense on the control panel. • Mount indoors, in a location where the temperature will not exceed 140°F (60°C) or drop below 32°F (0°C). 1.

  • Page 7: Set The Control Configuration Switches/Jumper

    SET THE CONTROL CONFIGURATION SWITCHES/JUMPER (See Figure 4) EAC ON or EAC OFF – In the future, the Aprilaire Model 5000 will be capable of wiring directly to the 6504. Alternative wiring options do currently exist – contact the factory and request Diagram 30-293. Set the jumper to the top two pins if EAC control is desired.

  • Page 8: Wire The System

    10 VA 2. Size Transformer #1. • If an Aprilaire Automatic Humidifier control (AHC) will be part of the system, install a 50 VA transformer. • If an AHC will not be part of the system, install a 40 VA transformer.

  • Page 9: Install The Model 8570 Thermostats And Wire To The Control Panel

    – this will help to ensure a successful start up. 4. Set the 6504/AHC dip switch (see Figure 5) located on the thermostat circuit board to the 6504 position, and set the other...

  • Page 10: Wire The Hvac Equipment To The Control Panel

    WIRE THE HVAC EQUIPMENT TO THE CONTROL PANEL WARNING 120-volts may cause serious injury from electrical shock. Sudden operation may cause serious injury from moving parts. Turn off power to HVAC System and leave power disconnected until installation is complete. 1.
  • Page 11 DIAGRAM 5 – Boiler and A/C DIAGRAM 6 – Radiant Floor First-Stage Heat, Furnace 2nd-Stage Heat and A/C TERMINAL DEFINITIONS Y1 = 1st-stage cooling W1 = 1st-stage TERMINAL DEFINITIONS boiler heat Y1 = 1st-stage cooling G = Fan W1 = 1st-stage radiant floor heat W2 = 2nd-stage furnace heat G = Fan...

  • Page 12: Wire The Zone Dampers To The Control Panel

    Do not mount the sensor in direct line-of-sight of the heat exchanger, cooling coils or UV lights as this may cause the sensor to report false temperature readings. 1. Locate the Aprilaire Model 8052 sensor in the supply trunk, after the heat exchanger and cooling coils and before the zone dampers (see the shaded areas of Figure 6).

  • Page 13: Wire An Outdoor Sensor To The Control Panel - Optional

    Outdoor temperature is transmitted to all the connected thermostats to be shown on the display, is used for ventilation control and is used for balance point control on heat pump applications. 1. Mount the Aprilaire Model 8052 sensor (see Figure 7). FIGURE 7 •...

  • Page 14: Wire An Aprilaire Automatic Humidifier Control (Ahc) To The Control Panel - Optional

    3. Wire the AHC to the control panel – see Diagram 10. Use wire color as a means to ensure the terminals are connected correctly. 4. After completing the Model 6504 installation, you will need to verify proper operation of the AHC – see AHC installation instructions for details on how this is done.

  • Page 15: Wire An Eac, Erv Or Ventilation Damper To The Control Panel - Optional

    5. For ERV control – connect the Contact the factory and request diagram 30-293 to control other end of the wires to the an Aprilaire Model 5000 Electronic Air Cleaner. ERV/Vent terminals on the control panel (see Diagram 12). • Set the ERV/Vent switches as DIAGRAM 12 shown in Diagram 12.
  • Page 16 Control of a ventilation damper requires a 24-volt power source, which can be taken from the zone damper power input terminals. It also requires an AHC or an outdoor temperature sensor – see sequence of operation for details. 1. Install the Aprilaire Model 6506 DIAGRAM 13...

  • Page 17: Start Up And Test

    2 Zones 3 Zones 4 Zones • Verify that the 6504/AHC dip switch is set to 6504 on all thermostats. • Verify that the following dip switches are set correctly and are the same on the control panel and the thermostats: –...
  • Page 18 4. Power up the damper transformer. 5. Auto Test Auto Test allows you to turn on/off all of the outputs without having to go to the thermostats to make calls for heating, cooling or fan. Auto Test will turn on and off all of the outputs that have been configured to be available. If, for example, the EAC and ERV/Vent outputs are not turned on by their respective dip switch, or an AHC has not been installed, then these steps are skipped in the Auto Test sequence.
  • Page 19 FIGURE 8 – Control Panel Layout...
  • Page 20 TROUBLESHOOTING GUIDE SYMPTOM CAUSE Auto Test did not start No power – apply power to control panel. Auto Test is only available the first four minutes after power up – press the RESET button and try Auto Test again. EAC or ERV/Vent output Outputs not configured to be on –...
  • Page 21 8. Press the MENU button on the thermostat to access the Main Menu of the thermostat. Use the L and M buttons to scroll, and the Multi-Function buttons to select items or go back within a menu – see the thermostat Owners Manual for additional information on how to navigate within the thermostat menus.

  • Page 22: Sequence Of Operation

    AUTOMATIC CHANGEOVER The Model 6504 is a heat call priority system with automatic mode changeover after 20 minutes of operation. If two calls for opposing mode exist while the system is idle, the Heat call will be satisfied first. The heating equipment will not stop operating until all heat calls have been satisfied and the minimum-on time lapses or if the equipment has been on for 20 minutes while a cooling call exists.

  • Page 23: Heating Equipment Outputs - Configured For Heat/Cool Operation

    HEATING EQUIPMENT OUTPUTS – CONFIGURED FOR HEAT/COOL OPERATION There is a two minute minimum-on and minimum-off time for heating outputs. On first stage heat, the W1 and B terminals are energized. If the ELEC/GAS switch is set to the ELEC position, the G terminal is also energized.

  • Page 24: Heating Equipment Outputs - Configured For Heat Pump Operation

    HEATING EQUIPMENT OUTPUTS – CONFIGURED FOR HEAT PUMP OPERATION There is a four minute minimum-on and minimum-off time for compressor operation, and a two minute minimum-on and off time for fossil fuel auxiliary heat operation. There is no minimum-on or off time for electric auxiliary heat. On first stage heat, the Y1, B and G terminals are energized.

  • Page 25: Emergency Heat Equipment Outputs - Applies Only When Configured For Heat Pump Operation

    EMERGENCY HEAT EQUIPMENT OUTPUTS – APPLIES ONLY WHEN CONFIGURED FOR HEAT PUMP OPERATION There is a two minute minimum-on and off time for fossil fuel auxiliary heat operation. There is no minimum-on or off time for electric auxiliary heat. Should any zone call for emergency heat during a heat call, the compressor outputs will turn off (after the four minute minimum-on time for compressor), and all calls for heat will be satisfied with emergency heat output until there are no emergency heat calls.

  • Page 26: Eac Output

    EAC OUTPUT The EAC output will energize on a call for cooling, heating or continuous fan, unless the EAC ON/EAC OFF jumper has been set for EAC OFF, in which case the EAC output does not energize. There is a thirty second delay in the turning on and off of the EAC output with a heat call when the ELEC/GAS switch is in the GAS position.

  • Page 27: Ahc Operation

    The control panel does not control the Aprilaire Humidifier; this is left to the Automatic Humidifier Control. Setting the desired humidity level and sensing the actual humidity level is also performed at the AHC. The control panel does, however, send the AHC an enable signal whenever the heat or continuous fan is operating.
  • Page 28 B2203365 10006211 1015 E. WASHINGTON AVE. • MADISON, WI 53703 • PHONE: 800/334-6011 • FAX: 608/257-4357 • www.aprilaire.com...

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