Carrier COMFORT ZONE ZONEKIT4ZCAR Installation And Start-Up Instructions Manual
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Carrier COMFORT ZONE ZONEKIT4ZCAR Installation And Start-Up Instructions Manual

Carrier COMFORT ZONE ZONEKIT4ZCAR Installation And Start-Up Instructions Manual

Carrier air conditioner user manual
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Installation and Start-Up Instructions
NOTE: Read the entire instruction manual before starting the
installation.

TABLE OF CONTENTS

PAGE
Safety Consideration ......................................................................1
Installation Considerations..........................................................1-2
Introduction ....................................................................................2
Installation.................................................................................2-18
Check Equipment and Jobsite ..................................................2
Wiring........................................................................................2
Shielded Cable.....................................................................2
Install Comfort Zone Center ....................................................3
Install Zone Dampers ............................................................3-5
Round Metal Duct Work.....................................................4
Rectangular Metal Duct Work ............................................4
Round Flexible Duct Work..............................................4-5
Rectangular Fibrous Glass Duct Work...............................5
Install Barometric Bypass Dampers.........................................5
Install Duct Temperature Sensor ..........................................5-6
Install Dx Coil Sensor ..............................................................6
Install Four Zone Controller.....................................................6
Comfort Zone System Wiring Diagram...................................7
Sequence Of Operation.............................................................6-12
Temperature Setpoints.........................................................6
Heating and Cooling Comfort Setpoints.....................6 & 8
or Cooling Cycle ............................................................8
The System Fan................................................................8-9
Controlling The Zone Dampers ..........................................9
Starting The HVAC Equipment ..................................10-11
Configuring Four Zone Controller....................................12-13
Programmable Options Settings ..................................12-13
Programmable Options Toggles........................................13
Wiring Diagram Reference Tables.........................................13
Start Up..............................................................................13-14
Programming Schedules ....................................................14-16
System Switches...........................................................14-15
Controller Display .............................................................15
Zone Selector Dial .......................................................15-16
Accessories ........................................................................16-17
Troubleshooting ......................................................................17
Care And Maintenance ................................................................17
Toggle Summary Table................................................................18
Operating Problem Table.............................................................19
Storage Failure Error Table .........................................................20
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 1 4 4
PC 101
Tab 3a 5a 2a 5a
Catalog No. 809-568
Printed in U.S.A.
ZONEKIT4ZCAR
Comfort Zone
Fig. 1 Comfort Zone System
Hardware Failure Error Table......................................................21
Wiring Diagrams.....................................................................22-31
Configuration Table .....................................................................32
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a qualified
installer, service agency or your distributor or branch for informa-
tion or assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this prod-
uct. Refer to the individual instructions packaged with the kits or
accessories when installing.
Follow all safety codes and wear safety glasses. Have fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult local
and state building codes and Sheet Metal and Air Conditioning
National Association (SMACNA) for special installation require-
ments.
Recognize safety information. This is the safety-alert symbol
When you see this symbol on the unit or in instructions and
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, or CAU-
TION. These words are used with the safety-alert symbol. DAN-
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage.

INSTALLATION CONSIDERATIONS

1. Install in a non-condensing area with ambients between 32°F
and 120°F.
Form ZONEKIT4-1SI
Pg 1
72
2:45
HEAT
68
A93208
7-95
Replaces: 920415-3SI
.

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Summary of Contents for Carrier COMFORT ZONE ZONEKIT4ZCAR

  • Page 1: Table Of Contents

    Installation and Start-Up Instructions NOTE: Read the entire instruction manual before starting the installation. TABLE OF CONTENTS PAGE Safety Consideration ...1 Installation Considerations...1-2 Introduction ...2 Installation...2-18 Check Equipment and Jobsite ...2 Wiring...2 Shielded Cable...2 Install Comfort Zone Center ...3 Install Zone Dampers ...3-5 Round Metal Duct Work...4 Rectangular Metal Duct Work ...4 Round Flexible Duct Work...4-5...

  • Page 2: Introduction

    2. Use vibration isolators (flex connectors) on zone dampers and duct work to minimize noise. 3. Place dampers away from areas that may be noise sensitive. 4. TXV is required in air conditioning and heat pump applica- tions. 5. Use separate isolated transformer to supply power to Comfort Zone System (50 va minimum, class 2, field supplied).

  • Page 3: Install Comfort Zone Center

    NOTE 2 PORT #1 ISOSAT-01 PORT #2 Comfort Comfort Zone Zone ISOSAT BUS NOTE 1 SHIELD DRAIN WIRE (TYP) PORT #1 ISOSAT-01 PORT #2 DEVICE BUS (TYP) SHIELD DRAIN WIRE (TYP) PORT #1 ISOSAT-01 PORT #2 NOTES: 1.Use butt splices, or solder, for shield connections.

  • Page 4: Round Metal Duct Work

    COMFORT ZONE CENTER BACK PLATE o r t n t e COMFORT ZONE CENTER COVER Fig. 5—Comfort Zone Center DAMPER ACTUATOR Fig. 6—Damper Motor Positioning Before insulating the duct work, check for proper damper opera- tion. Apply the 24vac between COM and OPN to open the damper and COM and CLS to close the damper.

  • Page 5: Rectangular Fibrous Glass Duct Work

    S-LOCK SUPPLY AIR DUCT DRIVE Fig. 10—Rectangular Metal Duct Work 1 / " TO 2" INSULATION Fig. 11—Insulated Rectangular Metal Duct Work FLEXIBLE DUCT Fig 12—Round Flexible Duct Work 2. Secure flexible duct to zone damper using SMACNA or other approved method.

  • Page 6: Install Dx Coil Sensor

    5. Insert 2-conductor wiring through 1 of pre-drilled holes in side of back plate. 6. Connect sensor to 2-wire conductor using provided wire nuts. (See Fig. 16 for connection to Comfort Zone Center.) Step 7—Install Dx Coil Sensor The Dx coil temperature sensor is recommended for use in heat pump with fan coil applications only.

  • Page 7: Comfort Zone System Wiring Diagram

    Zone Dampers BYPASS ZN4 CL OP COM CL OP COM CL OP COM CL OP COM CL OP COM COMFORT ZONE I/O COMM COMM BUS BUS HAM CONTROLLER R W R W R W R W R W R W W R G OAT LAT ZT4 ZT3 ZT2 Dx Coil...

  • Page 8: Sequence Of Events For A Normal Heating Or Cooling Cycle

    5 WIRE CONDUCTOR (INTERFACE BOARD) 3 WIRE CONDUCTOR (COMM BUS) COMM BUS FIELD WIRING (FEED THRU) I/O BOARD Fig. 17—Wiring Four Zone Controller Changing the base temperatures will change the Comfort Temperature Setpoints used in the system schedules. Always set the Base Temperatures prior to programming the system schedules.

  • Page 9: Controlling The Zone Dampers

    If Fan Switch on 4 zone controller is set to ON instead of Auto, then system fan will run continuously. Any time Comfort Zone is operating fan, it will be in active control of system. NOTE: If Auto Fan Off For Heating option (rotary switch position T-9) is ON, and Fan Switch on the 4 zone controller is ON, Comfort Zone will operate fan full time.

  • Page 10: Configuration Options For Equipment Operation

    Two-Stage Heat Pump For cooling applications, the second stage of an air conditioner is not necessarily more expensive to operate than first stage. But additional cooling can drive down the efficiency of a 2-speed air conditioner and longer use of first stage alone tends to deliver better humidity control in moist climates. Again, because of these advantages, Comfort Zone will attempt to minimize use of second stage cooling.

  • Page 11: Stage Control During Equipment Operation

    Table 5—HVAC Equipment Stages Vs. Zone Demand HEATING & COOLING DEMAND °F EQUIPMENT STAGES First-Stage Cooling Second-Stage Cooling First-Stage Heating Second-Stage Heating Third-Stage Heating Fourth-Stage Heating NOTE: Comfort Zone uses a 3-minute timer to delay start of second-stage (heating or cooling). This timer is started whenever first-stage heating or cooling is energized.

  • Page 12: Configuring Four Zone Controller

    Refer to Table 6 for settings and their definitions. 1. Zone Controller Bus Address (S-1) This setting establishes the identity of the 4 zone controller on the Carrier communication bus. NOTE: Remote room sensors do not require addressing. If using optional Smart Sensors, they must be addressed as follows: Table 6—Programmable Options-Settings...

  • Page 13: Programmable Options Toggles

    3. Check location of 4 zone controller and remote room sensors to make sure that they are not near heat producing devices such as lamps, sunlight, and appliances. Table 7—Wiring Diagram Reference For Fig. 19 and 20 FAN COIL WITH AIR CONDITIONER INDOOR UNIT (FIG. 19) FA4A OUTDOOR UNIT FB4A...

  • Page 14: Programming Schedules

    7. Write down on a piece of paper AND GIVE TO THE OWNER a list showing what rooms are controlled by what dampers, and their corresponding zone numbers. Keep list for your future use. 8. Instruct owner to turn cool switch OFF in the fall, and turn it ON in the spring.

  • Page 15: Controller Display

    Cool Switch OFF—Cooling will not come on. AUTO—Cooling will come on when any zone is more than 1.5°F above desired cool setpoint. Fan Switch ON—Fan will stay on continuously (recommended). AUTO—Fan will come on only when heating or cooling is required.

  • Page 16: Accessories

    Press ADVANCE TIME/DAY button until desired start time is displayed. 6. Adjust setpoints. Adjust setpoints using up and down buttons until desired temperatures for the selected time period appear in display. These setpoints will be used during the time period currently displayed in clock window.

  • Page 17: Outside Air Temperature Sensor

    OUTSIDE AIR TEMPERATURE SENSOR The Outside Air Temperature Sensor must be used whenever an Outside Air Damper is installed. An Outside Air Temperature Sensor must also be used for dual fuel applications. Step 16—Troubleshooting This section contains information to assist you in troubleshooting problems and errors associated with the Comfort Zone System.

  • Page 18: Toggle Summary Table

    TOGGLE SETTING Timeguard delay is 30 sec, overrides 5-minute delay be- tween de-energizing and re-energizing HVAC stages. This (T1)-Timeguard Override option automatically returns to OFF after 30 sec timeout. If equipment has been shut down due to a leaving air tem- perature trip, the timeguard override has no effect.

  • Page 19: Operating Problem Table

    SYMPTOM Thermostat is not receiving power. 1. Verify that comfort zone center is receiving 24 vac. (50 va minimum required with 4 motorized No Display 2. Check that the thermostat is receiving a steady 10 VDC across the red and white wires at the Low voltage.

  • Page 20: Error Codes

    Error Display (Dial Position T4) must be turned on. SF ERROR CODE DESCRIPTION Temperature Programming Error Time Period Programming Error Zone 1 Temperature Calibration Out of Range Zone 2 Temperature Calibration Out of Range Zone 3 Temperature Calibration Out of Range Zone 4 Temperature Calibration Out of Range Duct Temperature Calibration Out of...

  • Page 21: Hardware Failure Error Table

    Error Display (Dial Position T4) must be turned on. HF ERROR CODE DESCRIPTION Zone 1 Temperature Sensor Zone 2 Temperature Sensor Zone 3 Temperature Sensor Zone 4 Temperature Sensor Duct Temperature Sensor Outside Air Temperature Sensor Dx Coil Sensor Bus Access Error Zone 2 Smart Sensor Zone 3 Smart Sensor Zone 4 Smart Sensor...

  • Page 22: Wiring Diagrams

    Latent Capacity Control (LCC) R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026) Fig. 19—Typical Wiring Diagrams (Fan Coil with Air Conditioner) STANDARD SINGLE SPEED AIR CONDITIONER COMFORT ZONE SYSTEM...
  • Page 23 COOL 1 (Y1) Blue COOL 2 (Y2) White HEAT 1 (W1) Brown HEAT 2 (W2) Green FAN (G) Orange RV-COOL (O) Black RV-HEAT (O) Fig. 19—Typical Wiring Diagrams (Fan Coil with Air Conditioner) Continued 2-SPEED AIR CONDITIONER (38TD) FAN COIL Y/Y2 A94034...
  • Page 24 Instructions for two-stage operation. Connect "W2" from the Comfort Zone Center to "W2" on the furnace control board. See Furnace Installation Instructions For Details Involving Set-Up Switch Configuration and Two-Stage Furnace Operation. Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) STANDARD SINGLE SPEED AIR CONDITIONER...
  • Page 25 Latent Capacity Control (LCC) R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026) Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) Continued 2-SPEED AIR CONDITIONER (38TD) COMFORT ZONE CENTER UNIT 24 VAC (R)
  • Page 26 "W2" on the furnace control board. See Furnace Installation Instructions For Details Involving Set-Up Switch Configuration and Two- Stage Furnace Operation. Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) Continued 2-SPEED AIR CONDITIONER (38TD) FURNACE W/W1 Y/Y2 Latent Capacity Control (LCC) R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent.
  • Page 27 COMFORT ZONE CENTER FAN COIL UNIT 24 VAC (R) Yellow COOL 1 (Y1) Blue COOL 2 (Y2) White HEAT 1 (W1) Brown HEAT 2 (W2) Green FAN (G) Orange RV-COOL (O) Black RV-HEAT (O) COMFORT ZONE SYSTEM FAN COIL UNIT 24 VAC (R) Yellow COOL 1 (Y1) Blue...
  • Page 28 COMFORT ZONE SYSTEM UNIT 24 VAC (R) Yellow COOL 1 (Y1) Blue COOL 2 (Y2) White HEAT 1 (W1) Brown HEAT 2 (W2) Green FAN (G) Orange RV-COOL (O) Black RV-HEAT (O) Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump) Continued 2-SPEED HEAT PUMP (38YD)
  • Page 29 COMFORT ZONE CENTER VARIABLE SPEED FURNACE UNIT 24 VAC (R) Yellow COOL 1 (Y1) Blue COOL 2 (Y2) White HEAT 1 (W1) Brown HEAT 2 (W2) Green FAN (G) Orange RV-COOL (O) Black RV-HEAT (O) R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent.
  • Page 30 COMFORT ZONE CENTER VARIABLE SPEED FURNACE UNIT 24 VAC (R) Yellow COOL 1 (Y1) Blue COOL 2 (Y2) White HEAT 1 (W1) Brown HEAT 2 (W2) Green FAN (G) Orange RV-COOL (O) Black RV-HEAT (O) R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent.

  • Page 31: Wiring Diagrams

    COMFORT ZONE CENTER FURNACE UNIT 24 VAC (R) Yellow COOL 1 (Y1) Blue COOL 2 (Y2) White HEAT 1 (W1) Brown HEAT 2 (W2) Green FAN (G) Orange RV-COOL (O) Black RV-HEAT (O) Latent Capacity Control (LCC) R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent.

  • Page 32: Cool

    Calibrate Zone 1 Temp Sensor Damper Service Position Copyright 1995 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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