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ZONE PERFECT TWO-ZONE

Bryant ZONE PERFECT TWO-ZONE Installation Instructions Manual

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Page 1
installation instructions
ZONE PERFECT™ TWO-ZONE
NOTE: Read the entire instruction manual before starting the installation.
This symbol → indicates a change since the last issue.
TABLE OF CONTENTS
Safety Considerations.....................................................................1
Installation Considerations.............................................................1
Introduction ....................................................................................1
Installation...................................................................................1-4
Sequence Of Operation...............................................................4-7
Thermostat Wiring......................................................................6-8
Care And Maintenance ..................................................................8
Troubleshooting ........................................................................9-11
Wiring Diagrams.....................................................................12-16
Wiring Diagram Notes.................................................................16
SAFETY CONSIDERATIONS
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 require­ments.
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 CAU­TION. These words are used with the safety-alert symbol. DAN­GER 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
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1. Install in non-condensing area with ambients between 32°F and 150°F.
2. Use vibration isolators (flex connectors) on zone dampers and ductwork to minimize noise.
3. Place dampers away from areas that may be noise sensitive.
4. TXV is required in air conditioning and heat pump appli­cations.
5. Use separate isolated transformer to supply power to Zone Perfect Two-Zone Center. (40va minimum, class 2, trans­former, field supplied)
PAGE
ZONEKIT
Cancels: II ZONEKIT-0-2 II ZONEKIT-0-6
6-97
®
T'stat
Y2 Y1
R W1 W2
C
G
Y2
HP
→
Fig. 1—Zone Perfect Two-Zone System
(Shown Without Cover)
6. Load calculations must be performed to determine equip­ment size. Equipment selection is matched to block load. It is imperative equipment is not over sized.
7. Ductwork must be designed based off the sum of peak plus
.
25 percent oversize. It is imperative ductwork is not under sized.
The Zone Perfect Two-Zone System allows the air conditioning and heating equipment to control temperatures in 2 distinct spaces or zones within a building. Each zone has independent temperature settings controlled by a thermostat.
NOTE: Thermostats are purchased separately. The comfort temperature settings can change automatically
through the use of schedules if programmable thermostats are selected. This allows Zone Perfect Two-Zone to change the temperature settings in zones to reflect occupancy or usage. The Zone Perfect Two-Zone System uses motorized air volume control dampers (also called zone dampers) to regulate the flow of conditioned air into the zones.
I. CHECK EQUIPMENT AND JOBSITE A. Inspect Equipment
RC-RH
Equpimt
Jumper
Z
Fnc
Emergency
HP
24 VAC
RC
Equipment Term.
C1
o
Op
n
G
Heat
e
C
1
On
WARNING!
Z
C1
Off
o
under this label
Op
n e
C
2
Rev
B
O
Y2
Y1
W1
DTO
Y1
Sensors
HP
Fnc
Fnc Ht
Off
w/oF
On
w/F
R
W1W2 C
Duct
INTRODUCTION
INSTALLATION
Y1
HOT parts
W1
W2
3
Y2
W2
G
RH
A97291
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II. WIRING
WARNING: To prevent personal injury or possible
equipment damage, disconnect the power supply before routing wire.
All wiring must comply with local, state, and national codes. NOTE: Use No. 18 AWG color-coded, insulated (35°C min)
wire. If thermostats are to be located more than 100 ft from the Zone Perfect Two-Zone Center as measured along the control voltage wires, use 16 AWG colored-coded wires to avoid exces­sive voltage drop. All wiring is run back to the Zone Perfect Two-Zone Center.
III. INSTALL ZONE PERFECT TWO-ZONE
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NOTE: Zone Perfect Two-Zone is approved for indoor use only and should never be installed with any of its components exposed to the elements. Do not mount Zone Perfect Two-Zone Center where it will be accessible to children. Do not locate the center in areas of the home that are noise sensitive since relays are energized and de-energized during operation and may be an annoyance. Install Zone Perfect Two-Zone in an area with a temperature range between 32°F and 150°F.
Install Zone Perfect Two-Zone center in a vertical position. Locate in an area that is easily accessible in case servicing should be required.
CAUTION: To prevent possible damage to the Zone Perfect Two-Zone Center, do not mount on plenum, ductwork, or flush against furnace.
IV. INSTALL ZONE DAMPERS IMPORTANT: If conditions exist for possible condensing, the
motor must be positioned for adequate draining. (See Fig. 2.) NOTE: If a multi-damper enabler is used to link dampers
together, then add 5va per damper to the transformer power supply rating. Reference multi-damper enabler Installation Instructions.
Zone dampers may be installed in any direction. Install dampers so the actuator is visible for inspection and
accessible in the event it would ever need service. The black mark on the end of the damper shaft represents the position of the damper blade.
Before insulating the ductwork, check for proper damper opera­tion. Apply 24vac between COM and OPN to open the damper and COM and CLS to close the damper. (See Fig. 3.) The damper will modulate counter-clockwise to open and clockwise to close.
MOUNTING
HUB
ACTUATOR
HOUSING
QUICK BLADE
RELEASE
BUTTON
(RED)
FIELD
INSTALLED
POWER WIRING
Fig. 3—Damper 24-vac Connections
AIRFLOW
AIRFLOW
90
45
0
CLS
COM
OPN
POSITION INDICATOR
ANGULAR ROTATION STOPS
MOUNTING BRACKET
A95096
If in an emergency it becomes necessary to force a damper open manually, press in red quick blade release button with 1 hand and turn mounting hub to reposition the damper shaft. Release button to hold damper shaft in the new position.
To avoid noise and vibration, do not hard mount dampers to any solid structure such as joists.
A. Round Metal Ductwork IMPORTANT: If application exists with all metal ductwork
without insulation, flex connectors should be used on each end of the zone dampers to avoid noise and vibration.
1. Crimp end of branch duct.
2. Slip end of flex connector over zone damper and use self-tapping sheet metal screw to secure. (See Fig. 4.)
DAMPER MOUNTING
ACTUATOR
Fig. 2—Damper Motor Positioning
BRACKET
A95128
NOTE: Insulate damper using 1-1/2 in. insulation (check local codes). In areas where excessive condensing may occur, carefully insulate over the actuator assembly. Make sure insulation does not interfere with operation of actuator.
—2—
SUPPLY
FLEX
CONNECTOR
ZONE DAMPER
Fig. 4—Round Metal Ductwork
A95129
3. Properly seal joint using duct tape, mastic, or other ap­proved method. Do not allow mastic to come in contact with actuator.
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check your local codes.) (See Fig. 5.)
B. Rectangular Metal Ductwork
1. Make connections using S-lock and drives. (See Fig. 6.)
2. Properly seal joint using duct tape, mastic, or other ap­proved method. Do not allow mastic to come in contact with actuator.
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1
/ ″ STEEL STRAP
2
FLEXIBLE
DUCT
ZONE
DAMPER
Fig. 5—Insulated Round Metal Ductwork
S-LOCK
SUPPLY AIR DUCT
DRIVE
Fig. 6—Rectangular Metal Ductwork
3. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check your local codes.) (See Fig. 7.)
1
2
1 / " TO 2"
INSULATION
A95130
ZONE DAMPER
A92478
Fig 8—Round Flexible Ductwork
A95132
1
2
/ ″ STEEL STRAP
A95133
Fig. 9—Insulated Round Flexible Ductwork
D. Rectangular Fibrous Glass Ductwork
1. Insert 1 end of zone damper into 1 end of fibrous glass ductwork approximately 2 to 3 in. (See Fig. 10.)
FIBROUS GLASS DUCTWORK
FIELD SUPPLIED SCREWS
ZONE DAMPER
A95131
Fig. 7—Insulated Rectangular Metal Ductwork
ported according to local codes or SMACNA standards. NOTE: There should be a minimum of 4 ft between the zone
C. Round Flexible Ductwork
1. Slip 1 end of flexible ductwork over 1 end of zone damper. (See Fig. 8.)
2. Secure the flexible duct to zone damper using SMACNA or other approved method.
3. Properly seal joint using duct tape, mastic, or other ap­proved method. Do not allow mastic to come in contact with actuator.
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check your local codes.) (See Fig. 9.)
2″ TO 3″
A92480
Fig. 10—Rectangular Fibrous Glass Ductwork
2. Screw field-supplied screws and tabs into zone damper.
3. Properly seal joint using duct tape, mastic, or other ap­proved method. Do not allow mastic to come in contact with actuators
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check your local codes.) (See Fig. 11.)
1
2
1 / ″ TO 2″ INSULATION
A95134
Fig. 11—Insulated Rectangular Fibrous Glass Ductwork V. INSTALL BAROMETRIC BYPASS DAMPER
NOTE: The barometric bypass damper is a critical part of the
Zone Perfect Two-Zone System for control of minimum airflow and noise reduction. It is recommended that the bypass be installed.
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The bypass should be installed according to local codes and SMACNA standards. Be sure the bypass is properly supported.
For proper installation, refer to the Installation Instructions pack­aged with the barometric bypass.
CAUTION: Failure to properly install the bypass damper can cause permanent damage to the HVAC equipment. For single-speed furnace applications, the bypass air must never exceed 25 percent.
VI. INSTALL LEAVING AIR TEMPERATURE DUCT SEN-
→
SOR
Locate duct temperature sensor in main supply trunk after heating and cooling coil and before the bypass damper and before the first branch. The duct sensor must be radiant shielded to prevent heat from affecting the correct air temperature.
1. Drill 1/4-in. hole at location in supply trunk where sensor will be installed.
2. Insert sensor in hole and use as template to mark 2 mounting holes.
3. Drill two 1/16-in. holes to accept No. 6 screws through pre-drilled holes in duct temperature sensor back plate.
4. Use 2 No. 6 sheet metal screws to mount duct temperature sensor to unit.
5. Connect sensor to 2-conductor wire using provided wire nuts. (See Fig. 12 for connection to equipment controller.)
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VII. INSTALL HEAT PUMP (HP) TEMPERATURE SEN­SOR
The HP temperature sensor is required in all heat pump/fan coil installations. It is not used in dual fuel (heat pump/furnace installation.) It measures the indoor coil temperature. The sensor is to be installed downstream of the indoor coil, but before the electric heaters. It can be installed through the wall of the fan coil or may be located entirely inside the fan coil near the blower inlet. Anchor firmly in place with cable ties so that it cannot interfere with the blower wheel. To activate the HP temperature sensor, remove factory supplied resistor from HP terminal block and replace with sensor leads. When activated, the HP temperature sensor has built in LAT set points of 50°F and 45°F in the cooling mode, and 105°F and 110°F in the heating mode. This is non-adjustable. (See Fig. 12 for connection to Zone Perfect Two-Zone center.)
SEQUENCE OF OPERATION
• Make sure all zone dampers are fully open.
• Energize HVAC equipment fan.
• Energize heating or cooling equipment. The equipment may be a compressor, furnace, strip heater, etc.
• Set zone damper to the open or closed position based upon
individual zone demand.
• Turn off heating or cooling equipment when all zones are satisfied.
This is the basic sequence of operation for the Zone Perfect Two-Zone System. The actual control of the dampers, HVAC equipment, and system fan will change with the configuration of the system. Depending upon the configuration, Zone Perfect Two-Zone can control heat pumps, furnaces, and dual fuel applications, (dual fuel will require a third party relay interface).
II. SELECTION OF A SYSTEM MODE
The first step in any heating or cooling cycle requires Zone Perfect Two-Zone to receive an input from any thermostat located in a zone. Zone Perfect Two-Zone will then prepare to operate the heating or cooling equipment as requested by the thermostat. (See Fig. 12.)
III. PRE-POSITIONING DAMPERS AND STARTING SYSTEM FAN
The other reason for opening the dampers is to provide unrestricted ductwork to other equipment which is not directly controlled by Zone Perfect Two-Zone. One example may be a Heat Recovery Ventilator. If Zone Perfect Two-Zone is not actively controlling the HVAC system, then it must not impose any control influences (such as closed zone dampers) on the system and prevent proper operation of other devices.
Only the zone 1 thermostat controls continuous fan operation. When the zone 1 thermostat has the fan selector switch in the AUTO position, the fan will operate only when the heating and cooling equipment is operating. When the zone 1 thermostat has the fan selector switch in the ON position, the fan will operate continuously. Zone 2 will not control this.
IV. HVAC EQUIPMENT CONNECTIONS
The Zone Perfect Two-Zone relay outputs are shown in Table 1. The Y1 and Y2 contacts are used for the compressor contactor only. Zone Perfect Two-Zone operates the heat pump by energiz­ing the compressor contactor and controlling the reversing valve through the O relay output. The W1 and W2 contacts are always used for heat sources. These are heating only units such as furnaces, strip heaters, etc. The relay outputs for Zone Perfect Two-Zone are shown in Table 1.
TABLE 1—AVAILABLE HEATING AND COOLING STAGES VERSUS SYSTEM TYPE
TYPE OF HVAC
EQUIPMENT USED
Single-Stage Heat
Pump
2-Stage Heat Pump Y1 Y2 Energized Y1/W1 W2 De-energized
Cooling Only, any
Heater Type
COOLING STAGE 1 COOLING STAGE 2
Y1 — Energized Y1/W1 W2 De-energized
Y1 Y2 — W1 W2 —
REVERSING VALVE
O
HEAT STAGE 1 HEAT STAGE 2
REVERSING VALVE
O
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V. DUCT TEMPERATURE OPTIMIZER (DTO)
→
FOR MONITORING LEAVING AIR TEMPERATURE
As Zone Perfect Two-Zone System operates through a heating or cooling cycle, the zone demands will change. This changes the actual load that is applied to the HVAC equipment. If the zone airflow decreases, the cooling equipment will tend to lower supply-air temperatures which could tend to exceed the LAT trip limits. Conversely, the heating equipment will tend to raise supply-air temperatures which could exceed high trip limits. In cooling, when the LAT reaches the non-adjustable low tempera­ture trip limit (50°F) the LAT algorithm begins operating, closed dampers are initially opened 3 positions, then 1 position every 20 sec there after until full open. Zone Perfect Two-Zone will not shut down second-stage cooling (if used); however, if temperature continues to drop to 45°F, the zoning system will turn off both stages of cooling. If the temperature improves, the system will stay in the duct temperature optimizer mode until the LAT reaches 55°F or higher. At 55°F the LAT algorithm will reset and return dampers to their original position. In the heating mode, Zone Perfect Two-Zone will perform the same duct temperature opti­mization. The trip limits will be determined by the jumper setting. (See Fig. 12.) This will continue until the LAT problem is corrected.
The duct temperature optimizer works by controlling how cold or hot the air inside the supply-air duct gets by monitoring the temperature of the air inside the supply-air system.
Whenever Zone Perfect Two-Zone is providing heating or cooling, the zone within the home that is asking for conditioned air will always have its damper fully open. The other zone in the system may or may not have an open damper depending upon its particular needs. If the ductwork is too small (or the air conditioner/heater is too large), then the zone requiring condi­tioned air may not be able to take enough air to allow your equipment to operate properly. Zone Perfect Two-Zone will detect this, and open up the closed damper allowing the equipment to continue to operate.
CAUTION: The duct temperature optimizer may be disabled on the control center. A 10k resistor can be installed in place of the duct sensor at the terminal block. By disabling the duct temperature optimizer, the LAT safety algorithm is removed from the system.
If you encounter a situation where 1 zone seems to have poor ductwork, then the Zone Perfect Two-Zone system is capable of reverting back to a fully open, constant-volume system. If this condition persists, it should always be looked upon as an indication of a HVAC problem, not a Zone Perfect Two-Zone problem.
VI. ELECTRONIC THERMOSTAT CONNECTION WITH ZONE PERFECT TWO-ZONE CONTROL
Bryant electronic non-programmable and programmable thermo­stats can be connected to the Zone Perfect Two-Zone. See pre-sale literature for thermostat part numbers.
NOTE: The zone control board is only capable of 2-stage heat and 2-stage cool operation. Fig. 13 and 14 will reflect these applications only. Review and understand the following items before installing.
A. Thermostat Setup
1. Thermostat will not operate unless both R and C are connected to zone module input.
2. If selected thermostat is a heat pump (HP) or 2-speed (2S) model, convert thermostat to air conditioning operation. This will assure that Y signals are generated for cooling, and W signals are generated for heating from thermostat to zone module input. The thermostat O/W2 output will now be the second-stage heat call. If installation is a heat pump system, the zone control board will provide proper output signal to heat pump.
3. Select "Zoning" option on thermostat. This will disable the Timeguard and 4-cycle per hr (cph) protection built into thermostat. Let zone control board perform the Timeguard and cycle protection. Refer to thermostat Installation In­struction under Zoning for more detail.
4. The zone 1 thermostat is the only thermostat that can control continuous fan operation with zoning. Connect G between zone 1 thermostat and zone 1 input on zone control module.
5. Follow all safety and installation considerations outlined in the thermostat Installation Instructions.
B. Zone Control Board Setup
1. Configure zone control board jumper for Tstat (thermostat) Fnc option only. Do not use Tstat HP option. When Tstat Fnc is selected this will setup control inputs to recognize Y1 and Y2 for first- and second-stage cooling, W1 and W2 for first- and second-stage heating.
2. Configure zone control board for either Equipmt (equip­ment), HP or Fnc. When a heat pump system is used, Equipmt HP mode should be selected. The zone control board will provide the proper output signal to the heat pump. When a gas/electric furnace is used, Equipmt Fnc mode should be selected for proper output signal.
3. Configure zone control board for either Fnc Ht, w/f (with fan), or w/of (without fan). With Fan mode should be selected when a heat pump is installed and fan is needed to come on immediately with demand. Without Fan mode should be selected when fan is controlled by gas/electric furnace.
4. Configure zone control board for either DTO On or Off. When DTO On is selected (Factory default) and if a LAT trip occurs, closed dampers will begin opening to try and keep equipment running by maintaining proper air tempera­tures. However, if LAT temperatures exceed their limits, equipment will start staging down. When DTO Off is selected, equipment will stage down. Closed dampers will not open on initial trip, however if LAT temperatures exceed their limits, control will lock out and damper will open.
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NOTE: An HP temperature sensor must be used with a heat pump application using electric strip heat. This is necessary in case the DTO is set to the Off position.
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Page 6
Thermostat Zone 2
Y2 Y1 R W W2 C
1
1
G
D
4
Y1
W1
Y2
R
Thermostat Zone 1
W2
B
C
G
2
3
Duct
HP
Sensors
H
L
Rc
I
O
B
Y
Equipment
J
K
M
N
Y1
W2
W1
Rh
G
2
C
3
24
24 VAC Power
E
v
A
F
CL OP C
CL OP C
Zone
1 
Damper
Zone
2 
Damper
A97293
I/O CENTER CONNECTIONS
GGY2Y2Y1Y1RRW1W1W2W2C
ZONE 1
††
*
C
THERMOSTAT/SUBBASE
CONNECTIONS
ONLY HOOKUP "C" WHEN SUPPLIED BY THERMOSTAT
*
†
HOOKUP WHEN USING APPLICABLE TWO-STAGE THERMOSTATS WITH TWO-STAGE EQUIPMENT
→ Fig. 12—Zone Perfect Two-Zone Circuit Board with Standard Thermostat Wiring
I/O CENTER CONNECTIONS
Y2Y2Y1Y1RRW1W1W2W2C
ZONE 2
††
*
C
THERMOSTAT/SUBBASE
CONNECTIONS
ONLY HOOKUP "C" WHEN SUPPLIED BY THERMOSTAT
*
†
HOOKUP WHEN USING APPLICABLE TWO-STAGE THERMOSTATS WITH TWO-STAGE EQUIPMENT
A93494 A93495
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NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL AC
TWO-ZONE BOARD THERMOSTAT INPUT
NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL HP
TWO-ZONE BOARD THERMOSTAT INPUT
R24 VAC HOT 24 VAC COMM HEAT STAGE 1 COOL STAGE 1 FAN
SINGLE-STAGE HEAT,
SINGLE-STAGE COOL
SEE NOTES 1 AND 3
NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL 2S
C
W
/W1
Y
/Y2
G
R C
W1
Y1
*
G
W2
Y2
TWO-ZONE BOARD THERMOSTAT INPUT
24 VAC COMM HEAT STAGE 1 COOL STAGE 1 FAN
HEAT STAGE 2 N/A N/A N/A
OUTDOOR SENSOR CONNECTION
R24 VAC HOT C
W
/W1
Y
/Y2 G
O
/W2
Y1
B
L S1 S2
R C
W1
Y1
G
*
Y2
W2
TWO-STAGE HEAT, SINGLE-STAGE COOL  SEE NOTES 1, 2, AND 3
R C
W1
Y2
*
G
W2
Y1
TWO-STAGE HEAT, TWO-STAGE COOL  SEE NOTES 1, 2, AND 3
WIRING DIAGRAM NOTES:
* Hook up G on zone 1 thermostat only.
1. Cut R19 jumper on thermostat.
2. Disable timeguard and cycle protection in thermostat by setting
3. it to ZONE mode. Refer to thermostat Installation Instructions for details on how to do this.
24 VAC COMM HEAT STAGE 1 COOL STAGE 2 FAN
HEAT STAGE 2 COOL STAGE 1 N/A TROUBLE
OUTDOOR SENSOR CONNECTION
R24 VAC HOT C
W
/W1
Y
/Y2 G
O
/W2
Y1
B
L S1 S2
→ Fig. 13—Electronic Non-Programmable Thermostat Wiring Diagrams
TIMEGUARD
The Zone Perfect Two-Zone provides equipment protection with an internal 5-minute timeguard delay. This delay is present upon initial power up. There is also a 5-minute timeguard delay for all cooling (Y1) and heat pump modes. The time guard can be cleared by using the comprotec override feature. Second-stage (Y2) and (W2) will have a 5-minute delay between stages and also can be cleared using the comprotec override feature.
A97294
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Page 8
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL AC
TWO-ZONE BOARD THERMOSTAT INPUT
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL HP
TWO-ZONE BOARD THERMOSTAT INPUT
FAN HEAT STAGE 1 COOL STAGE 1 N/A N/A
24 VAC COMM N/A N/A
OUTDOOR SENSOR CONNECTION
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL 2S
R24 VAC HOT G
W
/W1
Y
/Y2
O
/W2
Y1
/W2
C B
L S1 S2
R G
*
W1
Y1
W2
Y2
C
SINGLE-STAGE HEAT, SINGLE-STAGE COOL  SEE NOTES 1 AND 3
TWO-ZONE BOARD THERMOSTAT INPUT
FAN HEAT STAGE 1 COOL STAGE 1 HEAT STAGE 2 N/A
24 VAC COMM N/A N/A
OUTDOOR SENSOR CONNECTION
R24 VAC HOT G
W
/W1
Y
/Y2
O
/W2
Y1
/W2
C
B
L S1 S2
R G
*
W1
Y1
W2
Y2
C
TWO-STAGE HEAT, SINGLE-STAGE COOL  SEE NOTES 1, 2, AND 3
COOL STAGE 1 FAN HEAT STAGE 1 COOL STAGE 2 HEAT STAGE 2 24 VAC HOT
24 VAC COMM N/A TROUBLE
OUTDOOR SENSOR CONNECTION
Y1
/W2
G
W
/W1
Y
/Y2
O
/W2 R
C B
L S1 S2
Y1
G
*
W1
Y2
W2
R
C
TWO-STAGE HEAT, TWO-STAGE COOL  SEE NOTES 1, 2, AND 3
WIRING DIAGRAM NOTES:
* Hook up G on zone 1 thermostat only.
1. Set thermostat dip switch A to ON. 
2. Set thermostat dip switch C to ON. This will disable 
3. timeguard and cycle protection in thermostat by setting it to ZONE mode. Refer to thermostat Installation Instructions  for details on how to do this.
→ Fig. 14—Electronic Programmable Thermostat Wiring Diagrams
MAXIMUM CYCLE RATE
The Zone Perfect Two-Zone will allow a maximum of 4 equip­ment cycles per hr or 1 every 15 minutes when a heating or cooling mode is activated. When a demand exists, and internal timer will start counting down 15, 14, 13...0 minutes. Once the timer expires the control will allow a new mode to restart the equipment. The internal time, as well as the cooling 5-minute timeguard can be cleared by using the comprotec override feature.
A97295
CARE AND MAINTENANCE
For continuing optimum performance and to minimize possible equipment failure, it is essential that periodic maintenance be performed on this equipment. Consult your servicing contractor for the proper frequency of maintenance. Frequency may vary depend­ing upon geographic areas.
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Page 9
TROUBLESHOOTING
This section contains information to assist you in troubleshooting problems and errors associated with the Zone Perfect Two-Zone system. See Table 2.
I. SYSTEM DIAGRAM, JUMPERS, AND SWITCHES
→
NOTE: For correct control board operation, it must have either a sensor attached or a 10k resistor in place at the duct and HP inputs.
High Heating Temperature Trip Limit Setting — When DTO is On, temperature is sensed by duct
B
temperature sensor. When the duct temperature reaches this temperature setting, the duct temperature optimizer is enabled. If the LAT is exceeded then heating will turn off.
NOTE: HP temperature sensor is recommended for all heat pump applications.
1
Tstat
2
Equipmt
3
Fnc Ht
Fnc—Gas/electric thermostat is installed in each zone. Must be in this position to function prop­erly.
HP—DO NOT USE.
Fnc—Air conditioning equipment installed is a cooling only unit.
HP—Air conditioning equipment installed is a heat pump.
W/O FAN—When demand for heating ex­ists, fan is controlled by gas/electric fur­nace.
W/FAN—When demand for heating exists, fan comes on immediately (heat pump only).
NORMAL HEAT
PUMP SETTING
155°F
147°F
138°F
130°F
122°F
113°F
105°F
Emergency Heat Switch—This switch should remain in the OFF position for both furnace and heat pump
C
operation. It should be switched to the ON position only upon heat pump compressor failure to provide emergency heat.
NORMAL GAS/
ELECTRICAL
SETTING
155°F
147°F
138°F
130°F
122°F
113°F
105°F
ON OFF
TEMPERATURE
EQUIPMENT
SHUTOFF
175°F
164°F
153°F
143°F
132°F
121°F
110°F
DTO
DTO Off—When supply-air temperatures
4
Damper Fuse—Protects damper from electrical dam-
A
age (3 Amp).
approach a trip limit, HVAC equipment will turn off. Dampers do not open until equipment is locked out by control.
DTO On—When supply-air temperatures approach a trip limit, closed dampers open to maintain proper air temperatures.
Comprotec Override—Momentarily short pins together for temporary equipment time
D
delay override.
J6 jumper—Connects Rc and Rh inter-
E
nally.
Emergency heat LED—Will turn on when
F
emergency heat is on.
Red LED—Used for diagnostic errors.
G
Green LED—Flashes once every second
H
for normal operation, alternates with red LED for diagnostic errors.
—9—
Page 10
Red LED—Displays ON when fan is energized.
I
Red LED—Displays ON when first-stage heat is energized.
M
Red LED—Displays ON when first-stage cooling is energized.
J
Red LED—Displays ON when second-stage cooling is energized.
K
Red LED—Displays ON when reversing valve is ener-
L
gized.
LED CODES ERROR DESCRIPTION ACTION REQUIRED
Green flashes 1 time every sec and no other LEDs are flashing.
Green flashes 1 time and Red flashes 1 time
Green flashes 1 time and Red flashes 2 times
Green flashes 1 time and Red flashes 3 times
Green flashes 1 time and Red flashes 4 times
Green flashes 1 time and Red flashes 5 times
Green flashes 2 times and Red flashes 1 time
Green flashes 2 times and Red flashes 2 times
Green flashes 2 times and Red flashes 3 times
Green flashes 2 times and Red flashes 4 times
Green flashes 2 times and Red flashes 5 times
Green flashes 3 times and Red flashes 1 time
Green flashes 3 times and Red flashes 2 times
Green flashes 3 times and Red flashes 3 times
Green flashes 3 times and Red flashes 4 times
Red LED—Displays ON when second-stage heat is energized.
N
J2 (Not Shown)—Cut for 50 hz operation. Lo­cated under plastic housing approximately 1 in.
O
above comprotec override.
→ TABLE 2—TROUBLESHOOTING
Normal operation. None.
Wait until duct temperature cools below
Duct temperature sensor. First-stage heat limit exceeded; heat will be locked out.
Duct temperature sensor. Second-stage heat limit exceeded.
Duct temperature sensor. First-stage cool limit exceeded; cool will be locked out.
Duct temperature sensor. Second-stage cool limit exceeded.
HP temperature sensor. First-stage heat limit exceeded; heat will be locked out.
HP temperature sensor error. Second­stage heat limit exceeded.
HP temperature sensor. First-stage cool limit exceeded; cool will be locked out.
HP temperature sensor. Second-stage cool limit exceeded.
1. Duct temperature sensor.
2. Temperature sensor is shorted.
1. Duct temperature sensor.
2. Temperature sensor is open.
1. HP temperature sensor.
2. Temperature sensor is shorted.
1. HP temperature sensor.
2. Temperature sensor is open.
Damper fuse blown.
Fatal control center circuit board failure. Replace control center.
exceeded temperature trip. (Heat leaving air temperature trip limits set at LAT limits POT on central control circuit board; range is 110° to 175°F.)
Wait until duct temperature cools below exceeded temperature trip. Range is 105° to 155°F.
Wait until duct temperature raises above exceeded temperature trip (45°F).
Wait until duct temperature raises above exceeded temperature trip (50°F).
Wait until HP temperature cools below ex­ceeded temperature trip. Fixed at 110°F.
Wait until HP temperature cools below ex­ceeded temperature trip. Fixed at 105°F.
Wait until duct temperature raises above exceeded temperature trip (45°F).
Wait until duct temperature raises above exceeded temperature trip (50°F).
1. Verify that duct temperature sensor or 10k ohm resistor is attached to control cen­ter at duct temperature connectors.
2. Replace duct temperature sensor.
1. Verify that duct temperature sensor or 10k ohm resistor is attached to control cen­ter at duct temperature connectors.
2. Replace duct temperature sensor.
1. Verify that HP temperature sensor or 10k ohm resistor is attached to control cen­ter at HP temperature connectors.
2. Replace HP temperature sensor.
1. Verify that HP temperature sensor or 10k ohm resistor is attached to control cen­ter at HP temperature connectors.
2. Replace HP temperature sensor.
1. Check for short circuits on damper wire connections at the dampers and control center.
2. Replace damper fuse.
3. Check damper operation, may need to be replaced.
—10—
Page 11
Table 3 shows a temperature/ohm/voltage relationship to help aid in troubleshooting the Zone Perfect Two-Zone System. This table will evaluate
→
both the Duct/HP temperature sensor operation. Use a digital multimeter to perform the following: To verify a sensor is good, disconnect both leads from the I/O board and measure the resistance through the sensor. Match ohm reading to table and compare temperature reading on table to ambient temperature surrounding sensor (Accuracy should be ± 5-10 percent). Example: if 10.92k ohms are measured, this equals approximately 73°F. To verify if I/O board is normal, reattach sensor to I/O board, set meter to 5vdc, and measure voltage across terminal connections. Match voltage reading to temperature reading in chart. The ambient temperature surrounding sensor should be ± 5-10 percent. Example: 2.61vdc is approximately 73°F.
→ TABLE 3—TEMPERATURE/OHM/VOLTAGE RELATIONSHIP
TEMP °F OHMS VOLTS TEMP °F OHMS VOLTS TEMP °F OHMS VOLTS TEMP °F OHMS VOLTS
30 34,367 3.873 73 10,921 2.610 117 4042 1.439 160 1693 0.724 32 32,654 3.828 75 10,449 2.555 118 3889 1.400 162 1637 0.703 34 31,030 3.781 77 10,000 2.500 120 3743 1.362 163 1582 0.683 36 29,498 3.734 79 9571 2.445 122 3603 1.324 165 1530 0.663 37 28,052 3.686 81 9164 2.391 124 3469 1.288 167 1480 0.645 39 26,686 3.637 82 8776 2.337 126 3340 1.252 169 1431 0.626 41 25,396 3.587 84 8407 2.284 127 3217 1.217 171 1385 0.608 43 24,171 3.537 86 8056 2.231 129 3099 1.183 172 1340 0.591 45 23,013 3.485 88 7720 2.178 131 2986 1.150 174 1297 0.574 46 21,918 3.433 90 7401 2.127 133 2878 1.117 176 1255 0.558
48 20,883 3.381 91 7096 2.075 135 2774 1.086 178 1215 0.542 50 19,903 3.328 93 6806 2.025 136 2675 1.055 180 1177 0.527 52 18,972 3.274 95 6530 1.975 138 2579 1.025 181 1140 0.512 54 18,090 3.220 97 6266 1.926 140 2488 0.996 183 1104 0.497 55 17,255 3.165 99 6014 1.878 142 2400 0.968 185 1010 0.483 57 16,464 3.111 100 5774 1.830 144 2315 0.940 187 1037 0.470 59 15,714 3.056 102 5546 1.784 145 2235 0.913 189 1005 0.457 61 15,000 3.000 104 5327 1.738 147 2157 0.887 190 974 0.444 63 14,323 2.944 106 5117 1.692 149 2083 0.862 — —— 64 13,681 2.889 108 4918 1.648 151 2011 0.837 — —— 66 13,071 2.833 109 4727 1.605 153 1943 0.813 — —— 68 12,493 2.777 111 4544 1.562 154 1876 0.790 — —— 70 11,942 2.721 113 4370 1.521 156 1813 0.767 — —— 72 11,418 2.666 115 4203 1.480 158 1752 0.745 — ——
WIRING DIAGRAMS
→ TABLE 4—WIRING DIAGRAM REFERENCE
OUTDOOR
UNIT
Single-Stage Furnace Fig. 15 Fig. 19 Fig. 23 Fig. 27
Two-Stage Furnace Fig. 16 Fig. 20 Fig. 24 Fig. 28
Typical Fan Coil Fig. 17 Fig. 21 Fig. 25 Fig. 29
FK4C Fan Coil Fig. 18 Fig. 22 Fig. 26 Fig. 30
SINGLE-SPEED
AIR CONDITIONER
TWO-SPEED
AIR CONDITIONER
SINGLE-SPEED
HEAT PUMP
TWO-SPEED HEAT PUMP
—11—
Page 12
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
→ Fig. 15—Single-Stage Furnace
With Single-Speed Air Conditioner
SINGLE-STAGE
FURNACE
R
AIR CONDITIONER
G W
Y
C
SINGLE-SPEED
Y
C
A97296
2-STAGE OR 
TWO-ZONE SYSTEM
RH
G
VARIABLE-SPEED
FURNACE
R G
SINGLE-SPEED
AIR CONDITIONER
W2
W2
W/W1
W1
Y1
Y/Y2
C
Y2
O
B
RC
→ Fig. 16—Two-Stage or Variable-Speed Furnace
With Single-Speed Air Conditioner
Y C
A97297
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
See notes 1 and 3
→ Fig. 17—Typical Fan Coil
With Single-Speed Air Conditioner
TYPICAL
FAN COIL
C R G
W2
W3
Y/Y2
O
L
E
Y1
SINGLE-SPEED
AIR CONDITIONER
C Y
* * ** * **
A97298
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
With Single-Speed Air Conditioner
FK4C
AIR CONDITIONER
FAN COIL
DH
R C G
W1 W2
Y/Y2
Y1
O
See note 1
→ Fig. 18—FK4C Fan Coil
SINGLE-SPEED
J1 JUMPER
C
Y
REMOVE J2 JUMPER
FOR HEAT STAGING AND
CONNECT W2 TO W2
A97299
—12—
Page 13
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
→ Fig. 19—Single-Stage Furnace
With 2-Speed Air Conditioner
SINGLE-STAGE
FURNACE
R G
W C Y
See note 2
2-SPEED
AIR CONDITIONER
R
C Y2 Y1
A97300
2-SPEED
AIR CONDITIONER
2-STAGE OR
TWO-ZONE SYSTEM
RH
G
VARIABLE-SPEED
FURNACE
R G
W2
W2
W/W1
W1
Y1
Y2
Y/Y2
C Y
*
Y2
Y1
O
B
See notes 2 and 3
RC
→ Fig. 20—Two-Stage or Variable-Speed Furnace
With 2-Speed Air Conditioner
R
C
A97301
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
→ Fig. 21—Typical Fan Coil
With 2-Speed Air Conditioner
TYPICAL
FAN COIL
R C
G
W2
Y/Y2
E
W3
L
O
Y1
See notes 1, 2, and 3
2-SPEED
AIR CONDITIONER
R
C
*
Y2
*
* * *
Y1
TWO-ZONE SYSTEM
A97302
RH
W2
W1
Y1
Y2
RC
2-SPEED
AIR CONDITIONER
FK4C
FAN COIL
DH
R
G
O
C
G W1 W2
Y1
Y/Y2
O
J1 JUMPER
R C
REMOVE J2 JUMPER
FOR HEAT STAGING AND
CONNECT W2 TO W2
Y1 Y2
L
B
See note 1
A97303
→ Fig. 22—FK4C Fan Coil
With 2-Speed Air Conditioner
—13—
Page 14
TWO-ZONE SYSTEM
INTERFACE
CONTROL
(KHAIC0101AAA)
SINGLE-STAGE
FURNACE
SINGLE-SPEED
HEAT PUMP
RH
G
W2
W1
Y1
Y2
O
B
RC
R GT GF
RF
WF
E HP
O HP
OT
Y HP
YT
E
C
T
1
2
3
OUTDOOR
THERMOSTAT
(KHAOT0301FST)
C G
R
W
Y
See notes 4, 5, 6, and 7
→ Fig. 23—Single-Stage Furnace With Single-Speed Heat Pump
2-STAGE OR 
VARIABLE-SPEED
FURNACE
TWO-ZONE SYSTEM
INTERFACE
CONTROL
(KHAIC0101AAA)
R
W2
O
Y
C
A97304
SINGLE-SPEED
HEAT PUMP
RH
G
W2
W1
Y1
Y2
O
B
RC
R GT GF
RF
WF
E HP
O HP
OT
Y HP
YT
E
C
T
1
2
3
OUTDOOR
THERMOSTAT
(KHAOT0301FST)
W2
C G
R
W/W1
Y/Y2
R
W2
O
Y
C
See notes 4, 5, 6, 7, and 8
→ Fig. 24—Two-Stage or Variable-Speed Furnace With Single-Speed Heat Pump
A97305
—14—
Page 15
C R G
W2
W3
O
Y1
* * *
L
*
E
*
SINGLE-SPEED
HEAT PUMP
C R
W2
Y O
A97306
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
See notes 1 and 3
TYPICAL
FAN COIL
Y/Y2
→ Fig. 25—Typical Fan Coil With Single-Speed Heat Pump
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
See note 1
→ Fig. 26—FK4C Fan Coil
With Single-Speed Heat Pump
FK4C
FAN COIL
C
DH
R
G W1 W2
Y/Y2
O
Y1
SINGLE-SPEED
HEAT PUMP
C
J1 JUMPER
R
J2 JUMPER
W2
Y O
A97307
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
See notes 2, 5, 6, 7, 9, 10, and 11
→ Fig. 27—Single-Stage Furnace
SINGLE-STAGE
FURNACE
R C
G W Y
With 2-Speed Heat Pump
2-SPEED
HEAT PUMP
R C
W2
Y2 Y1
O
W3
A97308
2-SPEED
HEAT PUMP
2-STAGE OR
TWO-ZONE SYSTEM
RH
G
VARIABLE-SPEED
FURNACE
R G
W2
W2
W/W1
W1
Y1
Y2
O
Y/Y2
C
Y1
O
* *
B
RC
See notes 2, 3, 5, 6, 7, 8, 9, 10, and 11
→ Fig. 28—Two-Stage or Variable-Speed Furnace
With 2-Speed Heat Pump
R
W2
Y2
C
Y1
O
W3
A97309
—15—
Page 16
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
See notes 1, 2, 3, 9, and 11
TYPICAL
FAN COIL
R C
G
W2
*
Y/Y2
*
O
W3
*
L
*
E
*
Y1
2-SPEED
HEAT PUMP
R C
W2
Y2
O
W3
Y1
TWO-ZONE SYSTEM
RH
G
W2
W1
Y1
Y2
O
B
RC
See notes 1, 2, 9, and 11
FK4C
FAN COIL
C
DH
R
G W1 W2
Y1
Y/Y2
O
2-SPEED
HEAT PUMP
C
J1 JUMPER
R
J2 JUMPER
W2
Y1 Y2
O
W3
A97310
→ Fig. 29—Typical Fan Coil With 2-Speed Heat Pump
→ Fig. 30—FK4C Fan Coil With 2-Speed Heat Pump
A97311
→ WIRING DIAGRAM NOTES
1. Refer to fan coil Installation Instructions for proper wiring.
2. Refer to outdoor unit Installation Instructions for latent kit requirements.
3. Terminals marked with * may not be present on equipment.
4. Interface control transformer must be in phase with furnace transformer to get high-speed fan during heat pump operation.
5. Heat pump MUST have a high-pressure switch for dual-fuel applications.
6. Two-Zone Control does not know that dual fuel is applied. Do not use thermostat AUTO CHANGEOVER mode with dual-fuel applications, keep both thermostats in same mode (heating or cooling).
7. Configure Two-Zone Control board (jumpers) for: (J1) T-stat = Fnc (J3) Equipmt = HP (J4) Fnc Ht = w/fan (J5) LAT = Set LAT jumper high enough to allow furnace to come on during defrost and second-stage operation. (J7) DTO = On
8. Furnace must control its own second-stage heat operation, via the furnace control algorithm.
9. Refer to outdoor equipment Installation Instructions for proper set up.
10. Select Furnace Interface option, Balance Point, and Defrost Time on 2-speed heat pump control board.
11. DO NOT select "ZONE" position on 2-speed heat pump control board. In heating mode, heat pump outdoor temperature sensor will control the compressor low- and high-speed change.
© 1997 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231
—16—
Printed in U.S.A. zkit06 Catalog No. 809-661
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