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selected zone is unoccupied. It will normally supply no condition-
ing to an OUT zone. If zone temperature exceeds 85°F or goes
below 60°F, conditioning will be supplied to maintain the zone
within these limits.

The system will also use OUT zones to relieve the equipment
under overload conditions. If the total demand from all zones is
such that airflow is insufficient (or bypassing is excessive) this
condition will be sensed by the LAT or HPT temperature sensors.
When these temperatures begin to approach their limits, Zone
Perfect Plus will first begin to open dampers in the OUT zones to
relieve overload condition. The system will also monitor tempera-
tures in the OUT zone and never allow them to become cooler than
the coolest zone (in cooling) or warmer than the warmest zone (in
heating). This prevents over conditioning of OUT zones while still
using them to relieve an overload condition.

Zones can be set to OUT at any time or OUT can be programmed
like any other temperature. The home or business owner can then
program OUT for times that the zone is not likely to be occupied.
When OUT is selected, both heating and cooling set points are
replaced by "--."

D.

Sequence Of Events For Normal Heating Or Cooling

Cycle

Given comfort set points and space temperature for zones within
system, Zone Perfect Plus will determine if active heating or
cooling is required. If so, Zone Perfect Plus will perform the
following:

1. Fully open 1 or more dampers and position others so that all

zones will be conditioned back to their set points at the
same time.

2. Turn on equipment.

3. While equipment is on, continually make small adjustments

in damper positions so that all zones converge on their set
points at the same time.

4. Turn off equipment when all zones reach their set points.

5. Leave dampers at their final positions while equipment is

off.

6. If equipment does not run for 2 hours, it will fully open all

dampers.

This is the basic sequence of operation for the Zone Perfect Plus
system. The actual control of dampers, HVAC equipment, and
system fan will change with the configuration of system. Depend-
ing upon configuration, Zone Perfect Plus can control heat pumps,
furnaces, and dual fuel applications.

E.

Control Strategy for Heating / Cooling Stages

The Zone Perfect Plus system will attempt to minimize use of
additional stages of heating or cooling equipment.

Zone Perfect Plus controls multi-stage equipment in response to
the level of demand and the number of zones with demand. In
general, it tries to satisfy demand with a minimum number of
stages. In heat pump systems, where auxiliary heat is usually
expensive, a small extra demand is required to bring on auxiliary
heat. This acts to prevent the unnecessary use of auxiliary heat. In
addition, when an outdoor sensor is attached, the system can be set
to lock out auxiliary heat for outdoor temperatures above an
installer selectable value. This will be covered under System
Configuration.

SYSTEM CONFIGURATION

Zone Perfect Plus must be configured to match the type of
equipment connected to it. In addition, there are several choices of
configuration based on how the user wants the system to operate.
Configuration is done in 2 parts. One is the setting of 8 DIP
switches on the Equipment Controller. The second is a group of 11
software selections made via User Interface. Follow the sequence
below for easy setup.

Configuration of the Equipment Controller is done first with the
power off. Then power is applied and the User Interface is
configured with power on.

NOTE:

A DIP switch module is oriented with switch 1 at the

bottom and switch 8 at the top. Refer to Fig. 12 for switch
orientation and labels.

I.

EQUIPMENT CONTROLLER CONFIGURATION

Located near bottom of Equipment Controller circuit board, there
is an 8 section DIP switch. The use of each switch is described
below. Using a pen or pencil, set each switch to its proper state.
ON is to the left and is the factory setting. OFF is to the right. Fig.
12 is a pictorial drawing of this selector switch.

Switch 1—Selects AC or HP.
ON—Selects AC.
OFF—Selects HP.
Switch 2—Selects single- or 2-speed compressor.
ON—Selects single speed.
OFF—Selects 2 speed.
Switch 3—Selects 3-stage electric heat. Equipment must include
FK fan coil with single-speed heat pump and selected heater with
2:1 ratio element size.
ON—Normal 1- or 2-stage electric heat.
OFF—Special 3-stage electric heat.
Switch 4—Selects Smart Recovery in both heating and cooling.
The system starts adjusting temperature 1-1/2-hours earlier than
selected recovery time so it will arrive at new temperature at
selected time.
ON—Smart recovery.
OFF—Normal recovery.
Switch 5—Zone system address selection. When 2 zoning systems
are connected together, the second system should be set to OFF.
ON—Normal single system.
OFF—Address selection for second zoning system.
Switch 6—Select installer test mode to assist in checking out the
system. See Starting System.
ON—Selects normal operation.
OFF—Selects installer test mode.
Switch 7—Disables cooling when outdoor temperature is below
55°F. Requires outdoor air temperature sensor.
ON—Cooling enabled at all temperatures.
OFF—Low temperature cooling disabled.
Switch 8—Dual fuel selection for systems with heat pump and
furnace.
ON—Selects normal system.
OFF—Selects dual fuel system.

II.

USER INTERFACE CONFIGURATION

The User Interface is configured via a group of selections made
through the keypad in a special configuration mode. Before the
equipment is operated, the system must be properly configured.
Make sure this step is not left out.
Before turning power on to the zoning system, disable the system
equipment itself by either turning off its main power or by
temporarily disconnecting its 24-vac power at the RC and RH
terminals of the Equipment Controller. This will allow the zoning
system only to operate. Go through the following steps with the
equipment power off.
By this time 8 DIP switches on the Equipment Controller should
be properly set.
Turn on power to the zoning system by applying power to its
24-vac transformer. When power is first applied to Zone Perfect
Plus the Equipment Controller immediately begins positioning all
dampers to fully open by running each damper motor in the open
direction for 15 sec. This is done in succession, 2 zones at a time,
starting with Zone 1. The time required will be 15 sec for each pair
of zones. Remember that the system automatically determines the
number of zones by detecting the presence of zone sensors.

—8—

Summary of Contents for ZONE PERFECT PLUS ZONEBB2KIT

Page 1: ... in minor personal injury or product and property damage INSTALLATION CONSIDERATIONS Before the actual installation of a zoning system can begin decisions need to be made to determine the number and location of zones and sensors This affects duct and damper selections For assistance with these decisions consult the Design Guide available from your distributor or branch This instruction covers the ...

Page 2: ...The User Interface also controls humidity functions If the User Interface is not used to control Zone 1 temperature it must still be located in a suitable area where humidity control will not be affected C Locating Sensors For proper operation each sensor must accurately measure the temperature within its zone Remember that zone sensors can be a combination of 3 different types as described in int...

Page 3: ...If duct work requires multiple dampers for a single zone up to 3 dampers may be wired in parallel A multi damper enabler is not needed For retrofit applications older type dampers with their original actuators may be used under the following conditions 1 A single damper may be connected directly to a Zone Perfect Plus output 2 If multiple dampers are needed for a single zone a multi damper enabler...

Page 4: ...k must be properly supported according to local codes or SMACNA standards D Rectangular Fibrous Glass Duct Work 1 Insert 1 end of zone damper into 1 end of fibrous glass duct work approximately 2 to 3 in See Fig 7 2 Screw field supplied screws and tabs into zone damper 3 Properly seal joint using duct tape mastic or other ap proved method Do not allow mastic to come in contact with actuator 4 Insu...

Page 5: ...ace with cable ties so that it cannot interfere with the blower wheel See Fig 9 10 or 11 for connection to Equipment Controller VIII FINAL WIRING Bring all Equipment Controller wires together at Equipment Controller Make all connections as indicated on Fig 9 for 2 zone installations Fig 10 for up to 4 zone installations or Fig 11 for up to 8 zone installations Figures 15 through 38 show the connec...

Page 6: ...ld be turned on It forces the furnace to adjust its airflow more frequently to accommodate the effects of damper movement See furnace instructions All 2 speed air conditioners and heat pumps need to be configured so that Y1 controls low speed and Y1 and Y2 together control high speed in both heating and cooling This is usually done by selecting the zoning position of the stage 2 latch pot See 2 sp...

Page 7: ... a zone rises above cooling set point then that zone needs to have heat removed from zone which will lower space temperature back to cooling set point For example if cooling set point is 76 F and space temperature is 77 F space temperature must be lowered 1 F in order for zone to be satisfied In this case cooling demand for zone is 1 F 77 minus 76 F C Out Feature A new feature called OUT can be se...

Page 8: ... the system to operate Configuration is done in 2 parts One is the setting of 8 DIP switches on the Equipment Controller The second is a group of 11 software selections made via User Interface Follow the sequence below for easy setup Configuration of the Equipment Controller is done first with the power off Then power is applied and the User Interface is configured with power on NOTE A DIP switch ...

Page 9: ... Display HPT temperature reading Option 20 Display LAT temperature reading Option 21 and up Display zone damper positions NOTE If END button is pressed or if no button is pressed for 180 sec Zone Perfect Plus will exit configuration mode and return to normal operation To re enter configuration mode FAN button must be pressed and held for 10 sec again While in configuration mode the large display s...

Page 10: ...ation mode OPTION 6 IGNORE LAT AND HPT TEMPERATURES CAUTION Leaving this selection ON can cause perma nent damage to HVAC equipment This option when ON tells the system to ignore the LAT and HPT temperature information It should only be used for troubleshoot ing and to allow temporary operation with a failed or missing sensor until the sensor can be replaced Factory default is OF off TO SELECT 1 E...

Page 11: ...30 35 40 45 50 55 and OF off 5 Press SET TIME TEMP button again to flash 10 on small display or press END to exit configuration mode OPTIONS 11 AUTO CHANGEOVER TIMER This option selects either a 10 or 30 minute time delay between heat and cool while in auto changeover mode System must have no demand in current mode for selected time 10 or 30 minutes before changeover between heating and cooling is...

Page 12: ...tep be sure to return installer setup switch Equipment Controller DIP switch No 6 to ON position This will enable normal operation When any output is turned on a red LED on the Equipment Controller board adjacent to the output s connection terminal is also turned on This can be used at any time to monitor the state of the Equipment Controller outputs even if the equipment is not yet connected or p...

Page 13: ...rovides humidity control by operating the cooling system when cooling is not required If the humidity rises above the dehumidification set point a special dehumidification routine is executed As long as zone temperatures are not more than 3 F below their cooling set points a dehumidify demand will turn on the cooling equipment but will limit its ON time to no more than 7 minutes at a time Finally ...

Page 14: ...ed for heat POWER ON CHECK When power is first applied to the system the large display indicates the equipment type selected by DIP switches as follows 1 AC 1 Speed Air Conditioner 2 HP 1 Speed Heat Pump 3 A2 2 Speed Air Conditioner 4 H2 2 Speed Heat Pump 5 AS 1 or 2 Speed Air Conditioner with 3 Stage Auxiliary Heat 6 HS 1 or 2 Speed Heat Pump with 3 Stage Auxiliary Heat 7 dF Dual Fuel with 1 Spee...

Page 15: ...o occupied When a zone is set to OUT desired temperature will be displayed as dashes when UP and DOWN buttons are pressed B Viewing Outdoor Temperature and Indoor Humidity 1 Pressing both UP and DOWN buttons simultaneously will display outdoor temperature if this feature is included and indoor humidity Outdoor temperature will be displayed first for 5 sec followed by humidity for 5 sec Smart Senso...

Page 16: ...gram Use the temperature UP and DOWN buttons to adjust the start times and to raise and lower set points When inside the program the blinking icon indicates that a setting may now be changed 1 Decide on a program schedule that you desire Table 2 is an example of what already exists in the User Interface as the Energy Star recommended setting table 2 To begin programming press PROGRAM button 3 Pres...

Page 17: ...OUT Function At the User Interface Pressing OUT button activates and deactivates OUT function for a single zone When OUT function is active OUT icon is displayed This function programs the zone as being unoccupied When OUT function is active the zone has no set points The zone temperature will be kept within the 60 85 F range and if necessary the zone will be used as a dump zone to relieve LAT pro...

Page 18: ... F to 140 F range See Table 4 to determine the temperature ohm relationship for a Remote Sensor Do not confuse dashes in the display for a zone that is set to OUT or ALL ZONE OTHER HELPFUL HINTS Read and understand System Startup and Checkout to review Installer Test Setup Mode and check the equipment operation This is a good place to start in evaluating any problems associated with the zoning sys...

Page 19: ... G Y2 Y1 DEF DHUM HUM HUMIDIFIER 24 VAC N A HEAT STAGE 1 FAN N A COOL STAGE 1 Fig 18 1 Stage Furnace with 2 Speed Heat Pump Dual Fuel A98092 TWO SPEED HEAT PUMP C O R W2 Y2 W3 C R Y1 W G Y O B RH SINGLE STAGE FURNACE EQUIPMENT CONTROLLER RC DEF DHUM HUM W2 W1 G Y2 Y1 N A N A N A HEAT STAGE 3 FAN DEFROST HUMIDIFY RVS COOLING 24 VAC HOT COOL HEAT STAGE 2 COOL HEAT STAGE 1 See notes 1 2 3 4 6 7 8 9 1...

Page 20: ...1 FAN N A COOL STAGE 1 See note 12 N A N A HUMIDIFY DEF DHUM HUM HUMIDIFIER 24 VAC Fig 22 2 Stage Furnace with 2 Speed Heat Pump Dual Fuel A98096 W W1 W2 Y Y2 TWO SPEED HEAT PUMP C O R W2 Y2 W3 C R Y1 G O B RH RC DEF W2 W1 G Y2 Y1 HEAT STAGE 4 HEAT STAGE 3 FAN COOL HEAT STAGE 2 COOL HEAT STAGE 1 See notes 1 2 3 4 6 7 8 9 10 11 and 12 TWO STAGE FURNACE EQUIPMENT CONTROLLER RVS COOLING DEFROST HUMID...

Page 21: ...HUMIDIFY HUMIDIFY DEF DHUM HUM HUMIDIFIER 24 VAC HUM DHUM PL9 10 O Y1 AFS BOARD Fig 26 Variable Speed Non Condensing Furnace with 2 Speed Heat Pump A98100 C C R Y2 W W1 G W2 Y Y2 O B RH RVS COOLING VSP FURNACE BOARD TWO SPEED HEAT PUMP EQUIPMENT CONTROLLER N A 24 VAC HOT RC W2 W1 G Y2 Y1 HEAT STAGE 3 HEAT STAGE 2 FAN COOL HEAT STAGE 2 COOL HEAT STAGE 1 See notes 1 2 3 4 6 7 8 9 10 11 12 15 and 16 ...

Page 22: ...otes 12 15 and 17 N A DEHUMIDIFY HUMIDIFY DEF DHUM HUM HUMIDIFIER 24 VAC HUM DH Fig 30 Variable Speed Condensing Furnace with 2 Speed Heat Pump A98104 C C R W2 W W1 G W2 Y Y2 O B RH RVS COOLING VSP SPEED FURNACE TWO SPEED HEAT PUMP EQUIPMENT CONTROLLER N A 24 VAC HOT RC W2 W1 G Y2 Y1 HEAT STAGE 4 HEAT STAGE 3 FAN COOL HEAT STAGE 2 COOL HEAT STAGE 1 See notes 1 2 3 4 6 7 8 9 10 11 12 15 and 17 DEFR...

Page 23: ...FAN COOL STAGE 1 N A N A HUMIDIFY DEF DHUM HUM HUMIDIFIER 24 VAC See note 13 Fig 34 Typical Fan Coil with 2 Speed Heat Pump A98108 C R W3 C R W3 W2 Y1 W2 G Y E O B RH RVS COOLING TYPICAL FAN COIL TWO SPEED HEAT PUMP 24 VAC HOT RC W2 W1 Y2 G Y1 HEAT STAGE 4 HEAT STAGE 3 FAN COOL HEAT STAGE 1 COOL HEAT STAGE 2 O Y2 EQUIPMENT CONTROLLER DEFROST N A N A HUMIDIFY DEF DHUM HUM HUMIDIFIER 24 VAC See note...

Page 24: ... N A N A DEHUMIDIFY HUMIDIFY DEF DHUM HUM HUMIDIFIER 24 VAC See notes 13 14 and 15 Fig 38 FK4C Fan Coil with 2 Speed Heat Pump A98112 C W2 O B RVS COOLING N A R1H FK4C EASY SELECT TERMINAL BOARD TWO SPEED HEAT PUMP REMOVE J1 JUMPER REMOVE J2 JUMPER FOR HEAT STAGING EQUIPMENT CONTROLLER 24 VAC HOT R1C W2 W1 G Y2 Y1 HEAT STAGE 4 HEAT STAGE 3 FAN HEAT COOL STAGE 2 HEAT COOL STAGE 1 O R Y2 Y1 C R DH W...

Page 25: ...per defrost operation 11 Configuration Option No 10 at User Interface must be activated to select dual fuel crossover temperature Configuration Option No 9 is optional in selecting an auxiliary heat lockout temperature 12 It is recommended to let the zoning system control furnace staging Refer to indoor unit Installation Instructions for proper setup 13 Refer to Fan Coil Installation Instructions ...

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Page 28: ...based formats and materials All include video and or slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training A94328 1998 ...

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