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Summary of Contents for Zonex System 2000
- Page 1 Design & Installation for Zonex Systems System 2000 2-20 Zone Auto Changeover System 1000 2-7 Zone Manual Changeover Part #101ASIM Rev. September 2003...
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Page 2: Table Of Contents
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... -
Page 3: System 2000
HVAC systems. For modulating communi- strategy. To provide economical, effective and simplified remote control cating control, use the ZonexCommander (Plus). and monitoring capability of one or more System 2000 zone control sys- CONCEPTUAL DRAWING ONLY... - Page 4 SYSTEM 2000 COMPONENT SELECTION GUIDE Auto Changeover for 2 to 20 Zones START HEAT PUMP GAS ELECTRIC System Controller System Controller 2 Stage Heat/Cool with Auxiliary Heat (101ASSB) (101AACBHP) Capacity Controller Capacity Controller 101ALAS (Included with Controller) Single Stage(TRLAT) or (101CAPGE)
- Page 5 The 101ASSB is a Gas/Electric System Controller that will control up to or a delay relay will start the fan. When all heating calls are satisfied or 20 zones for the System 2000 zoning system. The System Controller the majority changes to cooling, the gas valve will turn off.
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Page 6: Components
S Y W Rd B G TR2 TR1 J1 – Not used. J2 – Not used for System 2000. Used for Select-Temp system only. Microcontroller: Responsible for zone communication, activation and control of outputs based upon zone demand and leaving air temperature. - Page 7 TO CAPACITY CONTROLLER see page 43. 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.
- Page 8 If your system includes auxiliary heat, it will be activated by the “W” temperature cut out, with both stages cycling off. terminal on the SYSTEM 2000’s Heat Pump Controller. Auxiliary heat will be activated when the following conditions are met. The “Heat” and When power is first turned on, if there are no calls for cooling or “Damper”...
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Page 9: Heat Pump (101Aacbhp)
SYSTEM 2000 CONTROLLERS – HEAT PUMP 101AACBHP OPERATION SUMMARY TABLE (EFFECTIVE HPC V1.04 8/02) CALL (HEAT/COOL): 2ND STAGE AUX. HEAT POWER UP, NO CALLS: 1ST STAGE DELAY IN MINUTES STATUS LIGHTS: STATUS LIGHTS: DAMPER DAMPER NOTE 1 FLASH NOTE 1 REV. -
Page 10: Startup
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 If you are not using Zonex Systems supplied zone thermostats, thermostats are now in the “OFF” position. -
Page 11: System 1000
SYSTEM 1000 System 1000 Zone Control enables a single HVAC unit to be controlled by is manually selected. For auto changeover capability select Zonex up to seven zone (room) thermostats. System 1000 is a manual Systems System 2000. changeover system. This means that the mode of operation (heat/cool) - Page 12 SYSTEM 1000 – COMPONENT SELECTION GUIDE Manual Changeover for 2 to 7 Zones START HEAT PUMP GAS ELECTRIC Switching Center Switching Center (SYHPA) (SYGE) 2 Stage Heat/1 Stage Cool ZONE THERMOSTATS ZONE THERMOSTATS Digital Programmable (101DIGI) (101PROG) Digital Programmable (101DIGI) (101PROG) CAPACITY CONTROLLERS DIGITAL CAPACITY CONTROLLER...
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Page 13: Components
SYSTEM 1000 SWITCHING CENTERS – GAS/ELECTRIC SYGE OVERVIEW OPERATION The SYGE Switching Center is a manual changeover, Gas/Electric System The user manually selects the mode (heat/cool) at the Switching Center. Controller. It can control up to 7 zone thermostats. Its function is to look Heat mode –... - Page 14 SYSTEM 1000 SWITCHING CENTERS – GAS/ELECTRIC SYGE WIRING NOTES: SIMPLIFIED SCHEMATIC, SYGE 24V damper transformer. Requires in line fuse. See table on page 42 for sizing transformers and fuse. COOL HEAT HEAT COOL Refer to page 41 for five wire link wire sizing. LOGIC POWER BOARD...
- Page 15 SYSTEM 1000 SWITCHING CENTERS – HEAT PUMP SYHPA The Mode, Power, Fan and Emergency Heat control switches are located (RD made to GD) which tells the dampers of all zones not calling to close at the Switching Center. The Switching Center should be placed in and energizes Y, and G (Y and G made to R).
- Page 16 SYSTEM 1000 SWITCHING CENTERS - HEAT PUMP SYHPA 7. Reversing Valve Selection Jumper – Configures Switching Cen- ter 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 WD YD BD GD B and center pin to energize in heat mode.
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Page 17: Heat Pump (Syhpa)
SYSTEM 1000 STARTUP When all wiring is completed to the dampers and the gas electric/heat HEAT PUMP (SYHPA) with the SYCAP pump unit, the following tests should be made: Check that the fuse on the SYHPA has not blown. If it has, check for Disconnect the R wire from the Switching Center. -
Page 18: Zone Thermostats
ZONE THERMOSTATS Each zone requires a zone thermostat. This thermostat can be digital, 1. Determine the existing Set- mechanical, or programmable. All three types are available. Zonex Sys- points: A. To determine the existing Heat tems thermostats have been specifically designed to work with Zonex Systems Zone Control systems. -
Page 19: Remote Sensors
Power robbing type thermostats are not compatible. All types of battery power from either the zone system or HVAC unit transformer, with the operated thermostats may be used with any System 2000 control system. addition of a two conductor, twisted pair cable for communications. -
Page 20: Zone Dampers
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. - Page 21 ZONE DAMPERS ROUND LOW & MEDIUM PRESSURE DAMPER SIZES ROUND LOW PRESSURE DAMPER SIZE DIAMETER (D) LENGTH (L) WIDTH (W) PART # 6" 6" 10" 9" 101ARZD06 7" 7" 10" 10" 101ARZD07 8" 8" 10" 11" 101ARZD08 9" 9" 11" 12"...
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Page 22: Rectangular Zone Dampers
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”... - Page 23 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” 5" Part Number 101EC W x H 2-1/2" Sizes available from 8” x 8” up to 24”...
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Page 24: Sizing Zone Dampers
Select damper size by using a duct sizing table or calculator. For new systems or retrofit jobs: c) Select a Zonex Systems damper to fit the duct size selected for that a) Determine CFM from heat gain or loss calculations. - Page 25 DAMPER #1 RELAY BOARD FIVE WIRE LINK SYSTEM CONTROLLER TO THERMOSTAT DAMPER #3 DAMPER #2 No connection RELAY BOARD RELAY BOARD (- - - -) For power open/closed damper applications only.
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Page 26: Bypass Dampers
BYPASS DAMPERS – BAROMETRIC INSTALLATION BAROMETRIC BYPASS SETUP a) Turn off all thermostats. The round barometric bypass damper can be installed in any position. b) Turn on Switching Center/Controller and set fan switch to “ON” This damper is factory set for horizontal installation and can be field position. -
Page 27: Electronic
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. -
Page 28: Bypass Position Indicators
BYPASS DAMPERS – ELECTRONIC RECTANGULAR BYPASS SELECTION TABLE WIDTH IN INCHES 833 1000 1167 1333 1500 1667 1833 2000 2333 2667 3000 3333 3667 4000 833 1042 1250 1458 1667 1875 2083 2292 2500 2917 3333 3750 4167 4583 5000 1000 1250 1500 1750 2000 2250 2500 2750... -
Page 29: Bypass Damper Static Pressure Controller
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 STATIC PRESSURE CONTROLLER DESCRIPTION blower fan turns off. -
Page 30: Capacity Controllers
Left unchecked, the A/C temperature within set parameters. Zonex Systems offers six unique capac- coil could freeze up causing compressor slugging or the furnace could ity controllers to meet all your application needs: TRLAT, 101CAPGE, CAPL- overheat causing premature heat exchanger failure. -
Page 31: Capge
DL1 is lit and the relay contacts between Y1 Y1 and W1 W1 break, de-energizing the The Zonex Systems 101CAPGE capacity controller protects both the air compressor or furnace. Four minutes after the leaving air temperature conditioner and furnace. -
Page 32: 101Capge
CAPACITY CONTROLLERS – 101CAPGE HVAC/System Controller Interface Terminals Power Switch – Y1 controls – When off, the display is off, the 101CAPGE is the A/C compressor and W1 controls the furnace. W1 controls the disabled and the relay contacts are closed. The HVAC unit can run at first stage furnace and W2 controls second stage. -
Page 33: Trlat
CAPACITY CONTROLLERS – TRLAT OVERVIEW COMPONENTS The Zonex Systems TRLAT is a single stage Gas/Electric or Heat Pump A. Status Lights: Capacity Controller. However, the heat pump feature is not compatible DELAY (red): On when compressor or furnace is disabled. -
Page 34: Trlat
Using the table to right, set the switch positions to System 1000 Switching Center (SYGE) correspond to the cutoff temperatures desired. For heat pumps, the System 2000 Controller (101ASSB) heat cutoff point is 118 degrees and unchangeable. Cool... - Page 35 CAPACITY CONTROLLERS - SYCAP OVERVIEW HEAT CUT-OUT – If the SYHPA is making a heat call and the leaving air temperature rises above the Heat Cut-out setpoint, the connection between The SYCAP is a single stage cool, two stage heat Heat Pump Capacity Y2 Y2 breaks, red light DL1 turns on, and the Heat Pump compressor is Controller.
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Page 36: Sycap
CAPACITY CONTROLLERS - SYCAP H. Heat Pump Power Terminals – J. Setpoint Adjustment – Connect to heat pump 24V AC Use the UP/DN buttons to view and power source. R is 24 V hot. C is 24 V rtn. Cannot be connected to change the cut-out setpoints. -
Page 37: 101Alas
TP3 is the heat test point. (TP1 is the electric heat test point on the Heat Pump Controller). Clip the leads of a digital The 101ALAS works with the System 2000 Heat Pump System Controller volt meter, set to 20 volts DC, between the potentiometer test point that (101AACBHP). - Page 38 CAPACITY CONTROLLERS – CAPL-2 OVERVIEW SEQUENCE OF OPERATION The Zonex Systems CAPL-2 is a combination staging and capacity control The following sequence of operation assumes the cool cut-out setpoint is device for use with gas/electric units and heat pumps that use standard 48 degrees Fahrenheit and the heat setpoint is 150 degrees for gas/electric thermostats.
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Page 39: Capl-2
CAPACITY CONTROLLERS – CAPL-2 and field conditions. For example, in milder climates setting may be as low HEATING CALL (Heat Pump) (heat setpoint 118). As long as there as 110 to 115 degrees. In more severe climates up to 150 degrees.) As long is a heating call (WIN energized), the following will occur: as there is a heating call (WIN energized), the following will occur. -
Page 40: Capl-4
NO STAGING: If the leaving air is equal to or greater than 52 and less than 58° The Zonex Systems CAPL-4 is a combination staging and capacity control then no compressor staging will occur. device in one. It can stage an economizer and up to four compres- sors and up to four stages of heat. -
Page 41: Capl-4
CAPACITY CONTROLLERS - CAPL-4 C. Thermometer Calibrator – Calibrates the leaving air temperature G. Status Lights – ECONO – On during cool call. Indicates economizer thermometer. Turn clockwise to lower temperature. Turn counter- enabled; Y1 – On when first stage compressor energized; Y2 – On when clockwise to raise. -
Page 42: Capacity Controllers Installation
CAPACITY CONTROLLERS – INSTALLATION A. Select location to place sensor. For gas/electric HVAC systems, sen- E. If mounting sensor remotely, refer to Figure 3 and do the following: sor must be in leaving air duct, preferably as far from the coil/heat 1. -
Page 43: Capacity Controllers, Setpoints, Calibration
Turn counterclockwise to raise. FIVE WIRE LINK WIRE LENGTH Zonex Systems’s patented Five Wire Link is one of the most important ele- ments of the System 1000/2000 zoning system. Extra care should be made NUMBER OF to ensure the wiring is done correctly. The color code must be strictly fol- ZONE lowed. -
Page 44: Transformer/Fuse Sizing
TRANSFORMER / FUSE SIZING Transformer/fuse sizing: The 24V transformer NUMBER LOW PRESSURE MED. PRESSURE/HEAVY DUTY connected to TR1 and TR2 of the Switching (SPRING OPEN) DAMPERS (POWER OPEN) DAMPERS Center/System Controller powers the zone DAMPERS XFMR PWR FUSE SIZE XFMR PWR FUSE SIZE dampers, zone thermostats and Switching 12 VA... -
Page 45: Application Schematics
APPLICATION SCHEMATICS BLOWER FAN RELAY CENTRAL & AUXILIARY If the heater does not turn on the indoor blower fan when heat is on, you BASE BOARD HEAT WIRING must add a blower fan relay as shown below. The relay will energize the THERMOSTAT 1 STAGE COOL fan signal “G”... - Page 46 CFM to bypass. Return Air Pressurization 5. Modulating Bypass Damper WIRING A STAND ALONE DAMPER When no system controller is used, use Zonex Systems’s Digital, Auto HEATING/COOLING AUTO CHANGE OVER WITH DUCT STAT Changeover Stand Alone Modulating Thermostat (SAMOD) in con- LINE junction with an ST Series round or rectangular damper.
- Page 47 V or more than 30 V. If voltage is okay, replace Controller. If volt- volts for System 2000, that zone is calling. If voltage is between W age is not within range, be sure you have the correct transformer and and W, zone is calling for heat.
- Page 48 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. Part #101ASIM Copyright 2003 by Zonex Systems, Inc.
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