Zonex System 2000, Design & Installation Manual

Page 1: ...Zonex Systems System 2000 2 20 Zone Auto Changeover System 1000 2 7 Zone Manual Changeover Design Installation for Part 101ASIM Rev September 2003...

Page 2: ...Round Zone Dampers 18 19 Rectangular Zone Dampers 20 21 Sizing Zone Dampers 22 Wiring Zone Dampers 22 Damper Installation Notes 22 Paralleling Zone Dampers 23 Bypass Dampers 23 Barometric 23 24 Electr...

Page 3: ...sed for the zones not calling for the operating mode When the HVAC Heat Pump unit is not running all Zone Dampers are open to provide ventilation if the indoor blower fan is running continuously While...

Page 4: ...ONS AND UNDER OVER 5 TONS Low Pressure Dampers Medium Pressure Dampers Round 101ARZD size up to 5 SP Round 101AMPD size up to 1 75 SP Rectangular 101EC W x H up to 5 SP Rectangular 101MRTD W x H up to...

Page 5: ...urn on the compressor and fan The air conditioner will continue to operate until all cooling calls are satisfied or the majority changes to heating HEAT CALLS If the majority of calls are for heat the...

Page 6: ...s running in cool mode ON Indoor blower fan runs continuously H COOL and HEAT mode switches AUTO Accepts calls from thermostats OFF Ignores calls I Power switch When on applies 24V AC power to G of TB...

Page 7: ...e information Operation The Controller operates the Heat Pump using signals from each zone thermostat in the system When heating or cooling calls are sent to the controller it treats these calls as vo...

Page 8: ...tes After 8 minutes from Y1 if the supply air temperature is 60 or higher Y2 second stage of cooling will energize The Rev Valve LED will change from flashing to steady ON Cool B mode for Rev Valve LE...

Page 9: ...zing 24V damper transformer Requires in line fuse See table on page 42 for sizing transformer and fuse C terminal for hardwired electronic thermostats only J1 Reversing Valve Selection Jumper Leave ju...

Page 10: ...g with the Controller and able to start and stop the air conditioner NOTE Heat and Cool Led indicators will toggle every two min utes to check opposite mode callers regardless of heat and cool switch...

Page 11: ...Bypass damper will independently bypass any supply air not needed back to the return duct System 1000 Zonex Systems Supplied Components Switching Centers Pages 11 14 Zone Thermostats Pages 16 17 Zone...

Page 12: ...RLAT or Digital Version 101CAPGE CAPACITY CONTROLLERS DIGITAL CAPACITY CONTROLLER SYCAP Switching Center SYHPA 2 Stage Heat 1 Stage Cool GAS ELECTRIC ZONE THERMOSTATS ZONE THERMOSTATS HEAT PUMP 5 TONS...

Page 13: ...G made to R and the indoor blower fan will run This allows ventilation in all zones 1 5 Wire Link Terminals Daisy chain wires to zone dampers YD Cool call input signal Current flows in this terminal w...

Page 14: ...link wire sizing C terminal for hard wired electronic thermostats only Open motor not utilized on low pressure spring open dampers If using more than one damper per thermostat refer to Paralleling Zon...

Page 15: ...h tells the dampers of all zones not calling to close and energizes E E made to R What E is wired to depends on the make of your heat pump Refer to the SYHPA wiring diagram for further information Not...

Page 16: ...P TERMINALS E G R Y O B W2 L C SYCAP CAPACITY CONTROL PG 33 Y1 Y1 W2 W2 C R 3 4 5 7 B 2 6 1 CLOSE MOTOR OPEN MOTOR ZONE DAMPER If the heat pump does not energize the indoor blower fan when emergency h...

Page 17: ...it has check for shorts on the WD and or YD wires on the five wire link and replace the 1 10 amp fuse Turn the POWER switch on the SYHPA and SYCAP OFF Check all thermostats to be sure that they are of...

Page 18: ...tage heat When the the red light labeled HT2 is on the stat is calling for second stage heat This zone thermostat is designed for zones that require supplemental heat This thermostat can be ordered wi...

Page 19: ...through an optional telephone controller Dimensions are 3 75 W x 5 H x 1 D Color White ZONE THERMOSTATS COMPATIBILITY The 101ASSB gas electric and 101AACBHP heat pump controllers are compatible with...

Page 20: ...The motor is designed for contin uous full stall operation Special winding and heavy duty gearing provide for long motor life and easy spring open operation A cross pin on the motor shaft provides pos...

Page 21: ...13 15 17 19 21 PART 101AMPD06 101AMPD08 101AMPD10 101AMPD12 101AMPD14 101AMPD16 101AMPD18 6 8 10 12 14 16 18 Nominal CFM Duct Diameter Duct Velocity FPM Damper P WC 10 12 14 16 6 8 7 9 410 660 1450 10...

Page 22: ...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 clos...

Page 23: ...WIDTH A Rectangular dampers should operate at 1500 FPM E G A 24 x 12 damper 2 square feet 2 square feet X 1500FPM 3000 CFM 4 200 280 390 490 700 1090 1500 2000 2500 3000 3600 4000 630 960 1400 1850 22...

Page 24: ...d along with the ductwork The hat sec tion on the damper is delivered with insulation between the hat sec tion and pipe Therefore insulation should be applied to the round pipe and be butted against t...

Page 25: ...ers 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 clo...

Page 26: ...inutes to equalize pressure Then make sure all dampers are open by checking for air flow out of each damper c By moving counter weight up or down the lever arm adjust it so that the damper just wants...

Page 27: ...w the smallest zone air volume is 400 CFM and we have a four ton system Thus the air volume we need to bypass is 400 4 400 which equals 1200 CFM Using the ROUND BYPASS SELECTION TABLE we would select...

Page 28: ...4667 16500 18333 20167 22000 48 12000 14000 16000 18000 20000 22000 24000 8 10 12 14 16 18 20 22 8 667 833 1000 1167 1333 1500 1667 1833 10 833 1042 1250 1458 1667 1875 2083 2292 12 1000 1250 1500 175...

Page 29: ...ypass damper is Closed Bypass dampers using a square motor have a grey release lever on the bottom side of the damper near motor to manually open or close the damper c At 101ASPC Static Pressure Contr...

Page 30: ...during capacity cut out This ensures the heat exchanger properly cools down and the AC coil warms up during capacity cut out It also provides better zone tem perature control by providing conditioned...

Page 31: ...isplay during this time Enable Mode On the digital display E followed by the leaving air temperature indicates that the 101CAPGE is in the Enable Mode The purpose of this mode is to ensure the furnace...

Page 32: ...ASSB Switching Center SYGE R G W Y 4 2 5 1 3 CAPACITY CONTROLLERS 101CAPGE G HVAC System Controller Interface Terminals Y1 controls the A C compressor and W1 controls the furnace W1 controls the first...

Page 33: ...starts the heater and returns indoor blower fan control to the heater or Switching Center Controller Cut out disable The cool cutout is disabled in heat mode The heat cutout is disabled in cool mode T...

Page 34: ...ir temperature drops below 47 degrees Fahrenheit and re energize when the temperature rises above 47 degrees This setpoint is non adjustable It has no control for preventing compressor short cycling I...

Page 35: ...is disabled Every four minutes after Y1 is broken the leaving air temperature is checked If the temperature rises above the cool cut out setpoint Y1 Y1 is made red light DL1 turns off and the compress...

Page 36: ...ts Calibration section Page 41 for reading and adjusting the setpoints K Board Number This number indicates the circuit board num ber and revision You may need to know this number if con ferring with...

Page 37: ...nd test point Rotate the correspond ing potentiometer until the meter reads the proper voltage according to Table 2 below WIRING The 101ALAS is installed as detailed in the Capacity Controllers Instal...

Page 38: ...s on it will run a minimum of four minutes This prevents short cycling and ensures sufficient compressor oil return When the heat call is removed all compressors are immediately turned off SEQUENCE OF...

Page 39: ...controller C Thermometer Calibrator Calibrates the leaving air temperature thermometer Turn clockwise to lower temperature Turn counterclock wise to raise Refer to CALIBRATION section for complete cal...

Page 40: ...mizer if available is enabled and outside air is supplied based on enthalpy COMPRESSOR STAGING ON If the leaving air is 58 or greater the next compressor will turn on within four minutes As long as th...

Page 41: ...icates economizer enabled Y1 On when first stage compressor energized Y2 On when second stage compressor energized Y3 On when third stage compressor energized Y4 On when fourth stage compressor energi...

Page 42: ...circuit board away from casing 3 Pull sensor out of casing 4 Reattach circuit board to casing with screws previously removed 6 Place sensor in hole made in duct and secure with tape wire tie or cable...

Page 43: ...TPOINTS CALIBRATION FIVE WIRE LINK 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 to ensure the wiring i...

Page 44: ...ng Center System Controller The power rating of the transformer must be sufficient to power the number of dampers used Also a properly rated in line fuse must be used on the secondary of the transform...

Page 45: ...Fan Mode AUTO ON is usually selected at the System Controller Switching Center If preferred the Fan Mode can be selected at one zone thermostat using this diagram The thermostat needs to have a fan s...

Page 46: ...E ON HEATER W Y R LINE VOLTAGE 24 V STAT B W Y G R d W Y R C RO MC RC TB2 TB1 DAMPER RELAY BOARD W 2 W 2 B W Y G R d W Y R C RO MC RC TB2 TB1 DAMPER RELAY BOARD W 2 W 2 C C C Terminal used for electro...

Page 47: ...00 turning Controller Power switch off will remove power from GD The Power switch will not remove power from GD on System 1000 2 BD B 24V return chassis ground Measure all Daisy Chain voltages in refe...

Page 48: ...9 Factory 714 898 9963 Fax 714 898 6802 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 a...