Water Furnace IntelliZone Installation Manual
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Water Furnace IntelliZone Installation Manual

Comfort zoning system
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Table of Contents

Comfort Zoning System
Four Zone Capability
Installation Information
Damper Installation
Thermostat Installation
Electrical
Startup Procedures
Wiring Schematic
™
IM1958 03/09

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Summary of Contents for Water Furnace IntelliZone

  • Page 1 ™ Comfort Zoning System Four Zone Capability Installation Information Damper Installation Thermostat Installation Electrical Startup Procedures Wiring Schematic IM1958 03/09...
  • Page 2 Y1 to finish) or finish on second stage (Y2 runs to finish the call). The units are shipped from the factory with DIP switch SW3-2 OFF which will enable the unit to finish a call with normal downstaging. When using the Intellizone it is necessary to ensure that SW3-2 is in the OFF position so that downstaging will work properly.

  • Page 3: Table Of Contents

    INTELLIZONE INSTALLATION MANUAL Table of Contents General Installation Information Damper Installation Electrical Wiring Thermostat Installation 10-11 Blower Motor Wiring Harness Installation DIP Switch Setup 13-15 Blower Data 16-18 System Startup and Checkout 19-20 Wiring Schematic...

  • Page 4: General Installation Information

    Determine zone design air flow and zone size settings using IntelliZone Calculator software. Lay out and size the supply air ductwork and IntelliZone dampers. Care should be taken to avoid under sizing either the supply air systems, return air systems, or diffusers.
  • Page 5 General Installation Information (cont.) IntelliZone Control Panel Locate the IntelliZone panel in an indoor area that has enough space for service personnel to perform maintenance or repair. Provide sufficient room to make electrical connection(s). The IntelliZone is not approved for outdoor installation and, therefore, must be installed inside the structure being conditioned.

  • Page 6: Damper Installation

    INTELLIZONE INSTALLATION MANUAL Damper Installation Installing Rectangular Dampers in Metal Ductwork Cut out dimensions A and B as shown in Figure 2 below by Dimensional Examples using sheet metal snips. Damper Model Note: Dimensions A and B are listed in the table to the right.
  • Page 7 INTELLIZONE INSTALLATION MANUAL Damper Installation (cont.) Insulating Rectangular Dampers in Metal Ductwork Insulate ductwork as shown in Figure 5 below. All metal must be covered. Care must be taken not to obstruct the shaft from rotating when insulating. Do not insulate the zone damper actuator.
  • Page 8 INTELLIZONE INSTALLATION MANUAL Damper Installation (cont.) Insulating Rectangular Ductboard/Metal Sleeve Care must be taken not to obstruct the shaft from rotating when insulating. Do not insulate the zone damper actuator. Installing Circular Dampers in Round Metal Duct Crimp the end of the duct that is the supply air to damper. Insert into circular damper no more than 1.5 inches.

  • Page 9: Electrical Wiring

    INTELLIZONE INSTALLATION MANUAL Electrical Wiring Wiring Damper Actuators All wiring must comply with local and state codes. Disconnect the power supply before beginning to wire to prevent elec- trical shock or equipment damage. All wiring should be run back to the control panel. Keep wires a minimum of 12 inches from any high voltage lines.
  • Page 10 Providing adequate transformer power (VA) to supply the system is an important requirement. Each IntelliZone 3-wire damper requires 3.0 VA at nominal voltage. Each IntelliZone 2-wire damper requires 7.0 VA at nominal voltage. The stan- dard transformer available is a 75VA with circuit breaker (Part # ZTK240).
  • Page 11 INTELLIZONE INSTALLATION MANUAL Electrical Wiring (cont.) Figure 16: 24 Volt Transformer Wiring (Envision shown) Note: The IntelliZone control board must be grounded to the unit to operate properly. IntelliZone Control 18 gauge thermostat wire to IntelliZone Control Wiring IntelliZone to the Unit...

  • Page 12: Thermostat Installation

    INTELLIZONE INSTALLATION MANUAL Thermostat Installation Locating the Thermostats The thermostats must be located in the room or zone that each controls. Locate a thermostat about five feet above the floor. Do not locate a thermostat where it may be exposed to direct sunlight, drafts or direct supply air. Do not place a ther- mostat on an outside wall.

  • Page 13: Thermostat Installation

    1/4 inch (longer strip lengths may cause shorts) and insert the Control thermostat wires into the IntelliZone connector as shown in Figure 19 at right. Tighten the screws to ensure tight connections. The thermostat has the same type connectors, requiring the same wiring.

  • Page 14: Blower Motor Wiring Harness Installation

    Connect the new harness to the blower motor as shown in Figure 20, below. Strap the original harness to the new one so that it is free of shorting/obstructing the blower wheel. Thread the IntelliZone end of the harness through the zone cabinet and connect to the IntelliZone printed circuit board (See Page 22).

  • Page 15: Dip Switch Setup

    DIP Switch Setup IntelliZone Slide Switch Setup (SW1 Through SW4) A three-position DIP switch package located on each zone section of the IntelliZone control allows the following field selectable zone options. Zone setting DIP switches are located below each thermostat’s connections as shown in Figure 21 below.
  • Page 16 Selecting the zone percentage should be accomplished by using the Zone Calc Software. This percentage is an approxi- mation of the maximum heating and cooling load of the zone. The IntelliZone allows 0, 25, 45 and 70% selections. Below are some general rules to follow when selecting percentages: •...
  • Page 17 ECM2 fan motors have 12 different speeds. There are five airflow levels at which the ECM2 will operate depending on the current load level of the structure. If the IntelliZone is controlling a dual capacity unit, there are two levels each for both low and high capacity compressor operation.

  • Page 18: Blower Data

    INTELLIZONE INSTALLATION MANUAL Blower Data Premier and E Series Single-Speed Blower AIRFLOW DIP SWITCH SETTINGS MODEL 1000 1100 1150 1225 1300 E035, P034 0.50 — — — 1050 1150 1250 1325 1375 1475 E040, P040 0.50 — — 1050 1150...
  • Page 19 INTELLIZONE INSTALLATION MANUAL Blower Data (cont.) Envision Single Speed ECM AIR FLOW DIP SWITCH SETTINGS MODEL 1000 1100 1200 1300 1400 1500 0.50 1000 1100 1300 1500 1600 1800 0.75 w/1hp* 1050 1150 1250 1350 1450 1550 0.50 1000 1200...

  • Page 20: Blower Data

    INTELLIZONE INSTALLATION MANUAL Blower Data (cont.) Envision Air Handler ECM with Envision Split Single Speed AIR FLOW DIP SWITCH SETTINGS AIR HANDLER SPLIT MODEL MODEL 1000 1100 1200 1400 NAH036 0.50 1100 1300 1500 1700 1850 1950 2100 NAH042 0.75...

  • Page 21: System Startup And Checkout

    The blower and the “G” LED should cycle off. All dampers should start to close immediately. After approximately 90 seconds, all IntelliZone dampers should be com- pletely closed. Check the shaft position indicator on all damper actuators shown in Figure 25.

  • Page 22: System Startup And Checkout

    INTELLIZONE INSTALLATION MANUAL System Startup and Checkout (cont.) System Checkout Set all of the zone thermostats to the cooling mode. Reduce the cooling set point to 2° below the actual zone temperature on all thermostats. First stage cooling should energize after a delay. Output LEDs Y1 and O should be on.

  • Page 23: Wiring Schematic

    INTELLIZONE INSTALLATION MANUAL Wiring Schematic IntelliZone System 97P538B01 (SW3-2 must be in the OFF position on the main logic board when used with a zone control system) IntelliZone Auxiliary Transformer for zone dampers. To be mounted inside control box. (See Configuration Table below)
  • Page 24 Manufactured by WaterFurnace International, Inc. 9000 Conservation Way Fort Wayne, IN 46809 www.waterfurnace.com Product: IntelliZone Type: Comfort Zoning System I M 1 9 5 8 0 3 /0 9 Document: Installation Manual WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and reserves...

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