Aprilaire 6303 User Manual

ZONED COMFORT CONTROL SYSTEM

WARNING

1. 120 Volts may cause serious injury from
electrical shock. Sudden operation may cause
serious injury from moving parts. Leave power
disconnected until installation is complete.

2. Sharp edges may cause serious injury from

cuts. Use care when making duct openings and
handling ductwork.

3. The Aprilaire Zoned Comfort Control System is

designed for indoor use only. Do not expose
any component of the zone control system to
moisture. Do not mount any Aprilaire Zoned
Comfort Control equipment where it may be
accessible to children.

CAUTION

1. Installation must be done in accordance with
all applicable codes.

2. Installer should touch a grounded metal object
before handling the Aprilaire control panel to
avoid potential loss of internal computer
programs due to static discharge.

3. A zoned comfort control system may not
control temperature properly unless the
heating and cooling system is

properly sized

and balanced.

4. Insufficient air flow or excessive temperatures
through the heating and cooling system could
result in equipment damage. Refer to the
manufacturer’s recommendations for minimum
safe airflow and temperature requirements.

5. Excessive pressure across a bypass
evaporative type humidifier may cause high air
velocity in the humidifier, resulting in water
being blown into the ductwork. Refer to Design
Guide for humidifier installation instructions.

6. Install an outdoor thermostat to prevent non­seasonal equipment starts if using auto
changeover thermostats.

7. Do not mount the control panel on any part of
the heating/cooling equipment or ductwork.

8. Do not install control panel where
temperatures exceed 158°F (70°C).

Read this Installation Manual before beginning installation of the Aprilaire Zoned Comfort Control System.

For questions call Research Products Corporation at [phone].

SAFETY INSTRUCTIONS

CAUTION: Installer must touch a
grounded metal object before
handling the Aprilaire Zoned
Comfort Control panel to avoid
potential loss of programs due to
static discharge.

1. MOUNT THE CONTROL PANEL

Four holes are provided on the back of the
unit for mounting. (See Figure 1)

• Mount indoors using #8 or #10 screws (field
supplied).

• Mount in location where the temperature will

not exceed 158°F and will not drop below
freezing (32°F).

• Do not mount on foundation walls, or on the

HVAC equipment or ductwork. These
locations can cause the enclosure to become
cooler than the surrounding air, which can
cause moisture to condense on the
enclosure.

6303

INSTALLATION

MANUAL

INSTALLATION

FIGURE 1

MOUNTING HOLE

2 PLACES

E-H

ON

E-H

E

A

T

ON

OFF

ENCLOSURE BASE

CONTROL BOARD

MOUNTING HOLE

2 PLACES

“THROUGH-THE-WALL”

E

A

T

OFF

#8 SCREWS (Field Supplied)

WIRING HOLE,

2 PLACES

ENCLOSURE

COVER

2. MOUNT THE 8052 PLENUM TEMPERATURE SENSOR (provided)

IMPORTANT: Do not mount the sensor in direct line-of-sight of the heat exchanger,
cooling coils, or UV lights as they may cause the sensor to report false temperature
readings.

• Locate the sensor in the supply trunk, after the heat exchanger and cooling coils and
before the zone dampers (shaded areas). (See Figure 2)

• Mount the 8052 Sensor according to Installation Instructions provided with the sensor.

• Wire the 8052 Sensor to the Plenum Sensor terminals on the zoned comfort control panel

before power is applied to control panel.

• Measure the resistance across the Plenum Sensor terminals (before power is applied to

the panel) and confirm that it roughly corresponds to the ambient temperature values
listed in the table below.

• NOTE: In order for the control panel to recognize a sensor, it must be wired to the panel before power is applied.

3. PROVIDE CONTROL SYSTEM POWER

Install a transformer, separate from the transformer provided for the HVAC equipment, to provide power for the control panel, thermostats and
dampers. The size of the transformer depends on the greatest number of dampers that will be energized at any given time. If more than 6
dampers could be powered at one time, install dedicated damper transformers and a Model 8028 Damper Power Distribution Panel. Use the table
below to size the added transformer(s). Aprilaire Flexible Link Dampers require 12 VA per damper. Multiply the number of dampers by 12 and
select a transformer that meets or exceeds this value.
The table below illustrates.

4. SET UP THE CONTROL PANEL FOR THE APPLICATION

• Z1 HC/Z1 HP is set according to the type of thermostat installed in Zone 1. If a heat/cool thermostat is used in Zone 1, place the pin jumper
block on the left two pins (Z1 HC). While set as Z1 HC, emergency heat can only be controlled with the on board E-HEAT switch. If a heat pump
thermostat is used in Zone 1, place the pin jumper block on the right two pins (Z1 HP). Using a heat pump thermostat in Zone 1 allows for
emergency heat control from the Zone 1 thermostat.

• GAS/ELECTRIC refers to the auxiliary heat source. If gas (or propane or oil) heat is to be used, place the pin jumper block on the left two pins

(GAS). This will allow the auxiliary heating equipment to control the fan operation through the use of a plenum switch. If electric heat is to be
used, place the pin jumper block on the right two pins (ELECTRIC).

• PURGE/NO PURGE determines whether the zone control panel or the equipment will control the fan purge. If set to PURGE, pin jumper block on
left two pins, the G terminal and any energized damper terminals will remain energized for a one-minute purge delay following the completion
of a cool call, regular heat call or an electric auxiliary heat call. If set to NO PURGE, pin jumper block on right two pins, the G terminal will de­energize immediately and any energized damper will remain energized for 3.5 minutes following the completion of a call. The NO PURGE
setting is designed for use with systems where the equipment has a built-in fan purge.

• HT-160/120: If using a plenum temperature sensor, this jumper controls the temperature at which the heating equipment will cut out to prevent

overheating. Set the high limit temperature that is appropriate for the equipment being used. For a high limit temperature of 160°F, place the pin
jumper block on the left two pins (HT-160). For a high limit temperature of 120°F, place the pin jumper block to the right two pins (120).

• CL-45/40: If using a plenum temperature sensor, this jumper controls the temperature at which the cooling equipment will cut out to prevent
freezing the indoor coil. For a low limit temperature of 45°F, place the pin jumper block on the left two pins (CL-45). For a low limit temperature
of 40°F, place the pin jumper block to the right two pins (40).

5.WIRE THE SYSTEM

Use standard 18 or 20 gauge thermostat wire, color coded wherever possible to simplify troubleshooting. The wiring diagram and the
THERMOSTAT SELECTION guide below are to be used to guide you through wiring the system.

Highest Number of Powered Dampers

3 or Less

4
5
6

7 or More

VA Required

36 VA or less

48 VA
60 VA
72 VA

No. of Dampers* 12

Select Transformer

40 VA
50 VA
75 VA
75 VA

75 VA + 40 VA / 3 Dampers

Ambient Temperature (°F)

30
40
50
60
70
80
90

100

Resistance (kΩ)

7.8

7.2

6.6

6.0

5.4

4.8

4.2

3.6

ZONED COMFORT CONTROL:

MOUNT PLENUM SENSOR IN

SHADED AREA

ZONE DAMPERS

UPFLOW

FURNACE

FIGURE 2

90-690