Carrier ZONEKIT2ZCAR User Manual

COMFORT ZONING SYSTEM

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3

WARNING!

Rev

HOT parts

under this label

Y1

W1

W2

W1

W2

G

RH

RC

B

O

Y2

Y1

Equipment Term.

Sensors

HP

Duct

C1

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2

Op
C
C1
Op
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Emergency

Heat

RC-RH
Jumper

Y2

G

On
Off

24 VAC

R

W1W2 C

G

Y2

Y1

Y2
Y1

R
W1
W2

C

Equpimt

DTO

Fnc Ht
w/oF
w/F

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Off

HP

Fnc

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Installation and Start-Up Instructions

NOTE: Read the entire instruction manual before starting the

installation.
This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

PAGE

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

ZONEKIT2ZCAR

WeatherMaker® Two-Zone

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,
or use can cause fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a qualified
installer, service agency, or your distributor or branch for infor­mation or assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this prod­uct. Refer to the individual instructions packaged with the kits or
accessories when installing.

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

1. Install in non-condensing area with ambients between 32°F

→

and 150°F.

→

Fig. 1—WeatherMaker Two-Zone System

(Shown Without Cover)

5. Use separate isolated transformer to supply power to Weath­erMaker Two-Zone Center. (40va minimum, class 2, trans­former, field supplied)

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 WeatherMaker 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 WeatherMaker Two-Zone to change the
temperature settings in zones to reflect occupancy or usage. The
WeatherMaker Two-Zone System uses motorized air volume
control dampers (also called zone dampers) to regulate the flow of
conditioned air into the zones.

INTRODUCTION

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.

Book 1144
Tab 3a 5a 2a 5a

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 101 Catalog No. 809-500 Printed in U.S.A. Form ZONEKIT-8SI Pg 1 6-97 Replaces: ZONEKIT-2SI

Step 1—Check Equipment and Jobsite

INSPECT EQUIPMENT — File claim with shipping company,
prior to installation, if shipment is damaged or incomplete.

INSTALLATION

A97292

Step 2—Wiring

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
WeatherMaker 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 WeatherMaker
Two-Zone Center.

Step 3—Install WeatherMaker Two-Zone
NOTE: WeatherMaker Two-Zone is approved for indoor use

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only and should never be installed with any of its components
exposed to the elements. Do not mount WeatherMaker 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 WeatherMaker Two-Zone in an area with a
temperature range between 32°F and 150°F.

Install WeatherMaker Two-Zone center in a vertical position.
Locate in an area that is easily accessible in case servicing should
be required.

To prevent possible damage to the WeatherMaker Two-Zone
Center, do not mount on plenum, ductwork, or flush against
furnace.

Step 4—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.

DAMPER MOUNTING

BRACKET

insulate over the actuator assembly. Make sure insulation does not
interfere with operation of actuator.

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.

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 self­tapping sheet metal screw to secure. (See Fig. 4.)

ACTUATOR

Fig. 2—Damper Motor Positioning

A95128

NOTE: Insulate damper using 1-1/2 in. insulation (check local
codes). In areas where excessive condensing may occur, carefully

SUPPLY

FLEX

CONNECTOR

ZONE DAMPER

Fig. 4—Round Metal Ductwork

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.)

NOTE: All zone dampers and ductwork must be properly sup­ported according to local codes or SMACNA standards.

RECTANGULAR METAL DUCTWORK

1. Make connections using S-lock and drives. (See Fig. 6.)

2

A95129

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

A95130

ZONE
DAMPER

A92478

2. Properly seal joint using duct tape, mastic, or other approved
method. Do not allow mastic to come in contact with actuator.

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

Fig 8—Round Flexible Ductwork

A95132

4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check
your local codes.) (See Fig. 9.)

NOTE: All zone dampers and ductwork must be properly sup­ported according to local codes or SMACNA standards.

1

2

/ ″ STEEL STRAP

A95133

Fig. 9—Insulated Round Flexible Ductwork

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

NOTE: All zone dampers and ductwork must be properly sup-

ported according to local codes or SMACNA standards.
NOTE: There should be a minimum of 4 ft between the zone

damper and the first branch duct if more than 1 branch duct is
downstream of the zone damper.

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.

2″ TO 3″

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

Fig. 11—Insulated Rectangular Fibrous Glass

Ductwork

3

A92480

A95134

Step 5—Install Barometric Bypass Damper
NOTE: The barometric bypass damper is a critical part of the

WeatherMaker Two-Zone System for control of minimum airflow
and noise reduction. It is recommended that the bypass be
installed.

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.

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.

Step 6—Install Leaving Air Temperature Duct Sensor

→

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.)

→

Step 7—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 WeatherMaker
Two-Zone center.)

SEQUENCE OF OPERATION
Step 1—Sequence of Events for a Normal Heating or
Cooling Cycle

The thermostats will determine if active heating or cooling is
required. If so, the WeatherMaker Two-Zone System will perform
the following:

• 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.

• Energize additional stages of heating or cooling if the thermostat
demand warrants.

• Turn off heating or cooling equipment when all zones are
satisfied.

• Open all zone dampers when equipment is turned off (after 90
sec delay).

This is the basic sequence of operation for the WeatherMaker
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, WeatherMaker
Two-Zone can control heat pumps, furnaces, and dual fuel
applications, (dual fuel will require a third party relay interface).

Step 2—Selection of a System Mode

The first step in any heating or cooling cycle requires Weather­Maker Two-Zone to receive an input from any thermostat located
in a zone. WeatherMaker Two-Zone will then prepare to operate
the heating or cooling equipment as requested by the thermostat.
(See Fig. 12.)

Step 3—Pre-Positioning Dampers and Starting
System Fan

In order to minimize noise and enhance system operation, Weath­erMaker Two-Zone maintains fully open zone dampers prior to
starting the system fan or the heating/cooling equipment. The
intent is to provide the HVAC equipment with unrestricted
ductwork and to reduce pressure surges. WeatherMaker Two-Zone
also fully opens the dampers whenever a heating or cooling cycle
is completed (this is done after a 90 sec delay). All zone dampers
will remain fully open until the next heating or cooling cycle.

The other reason for opening the dampers is to provide unrestricted
ductwork to other equipment which is not directly controlled by
WeatherMaker Two-Zone. One example may be a Heat Recovery
Ventilator. If WeatherMaker 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.

Step 4— HVAC Equipment Connections

The WeatherMaker Two-Zone relay outputs are shown in Table 1.
The Y1 and Y2 contacts are used for the compressor contactor
only. WeatherMaker 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 WeatherMaker
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

4

In automatic changeover, the zoning system works on a first come
first serve basis. If 1 zone is calling for heating and the other for
cooling, the zone which sent its demand to the I/O center first will
operate the equipment in that mode until that zone is satisfied.

Step 5—Duct Temperature Optimizer (DTO)

→

For Monitoring Leaving Air Temperature

As the WeatherMaker Two-Zone System operates through a
heating or cooling cycle, the zone demands will change. This
changes 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 the
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. WeatherMaker 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, Weather­Maker 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.

This control helps WeatherMaker Two-Zone System cope with
installations where the air conditioning system may suffer from
poor ductwork, improperly sized heating or cooling equipment,
and/or improper settings of the barometric bypass damper. This
control is especially useful in retrofit applications where the size
and routing of the ductwork may not be entirely known or
satisfactory.

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 WeatherMaker 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. WeatherMaker Two-Zone will
detect this, and open up the closed damper allowing the equipment
to continue to operate.

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.

It is highly recommended that you use this control option. The
heating LAT is adjustable for the duct sensor. In this Installation
Instruction, you will find the section showing an adjustment for the
heating LAT. (See Fig. 12.) It is very important that this tempera­ture is properly set. For gas or oil furnaces, the temperature limit
will be in the higher temperature range. For heat pumps the
temperature setting should always be in the lower temperature
range.

If you encounter a situation where 1 zone seems to have poor
ductwork, then the WeatherMaker 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 WeatherMaker Two-Zone problem.

Step 6—Electronic Thermostat Connection with
WeatherMaker Two-Zone Control

Carrier electronic non-programmable and programmable thermo­stats can be connected to the WeatherMaker 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.

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.

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 first­and 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 inial trip,
however if LAT temperatures exceed their limits, control will
lockout and damper will open.

5