Carrier ZONEKIT4ZCAR User Manual

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Installation and Start-Up Instructions

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

PAGE

Safety Consideration......................................................................1

Installation Considerations..........................................................1-2

Introduction ....................................................................................2

Installation.................................................................................2-18

Check Equipment and Jobsite..................................................2

Wiring........................................................................................2

Shielded Cable.....................................................................2

Install Comfort Zone Center ....................................................3

Install Zone Dampers............................................................3-5

Round Metal Duct Work.....................................................4

Rectangular Metal Duct Work............................................4

Round Flexible Duct Work..............................................4-5

Rectangular Fibrous Glass Duct Work...............................5

Install Barometric Bypass Dampers.........................................5

Install Duct Temperature Sensor ..........................................5-6

Install Dx Coil Sensor..............................................................6

Install Four Zone Controller.....................................................6

Install Remote Room Sensor or Smart Sensors ......................6

Comfort Zone System Wiring Diagram...................................7

Sequence Of Operation.............................................................6-12

Temperature Setpoints.........................................................6

Heating and Cooling Comfort Setpoints.....................6 & 8

Sequence of Events For a Normal Heating

or Cooling Cycle............................................................8

Selection of a Reference Zone In The System ..................8

Pre-positioning Dampers And Starting

The System Fan................................................................8-9

Controlling The Zone Dampers..........................................9

Operating The Heating And Cooling Equipment...............9

Control Strategy For Heating/Cooling Stages...............9-10

Configuration Options For Equipment Operation............10

Relay Pack To HVAC Equipment Connections ..............10

Starting The HVAC Equipment ..................................10-11

Stage Control During Equipment Operation...............11-12

Configuring Four Zone Controller....................................12-13

Programmable Options Settings ..................................12-13

Programmable Options Toggles........................................13

Wiring Diagram Reference Tables.........................................13

Start Up..............................................................................13-14

Programming Schedules....................................................14-16

System Switches...........................................................14-15

Controller Display .............................................................15

Zone Selector Dial .......................................................15-16

Accessories ........................................................................16-17

Troubleshooting ......................................................................17

Care And Maintenance ................................................................17

Toggle Summary Table................................................................18

Operating Problem Table.............................................................19

Storage Failure Error Table.........................................................20

ZONEKIT4ZCAR

Comfort Zone

COOL HEAT

Fig. 1−Comfort Zone System

Hardware Failure Error Table......................................................21

Wiring Diagrams.....................................................................22-31

Configuration Table .....................................................................32

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 a non-condensing area with ambients between 32°F and 120°F.

2:45

A93208

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

Book 1144 Tab 3a 5a 2a 5a

PC 101 Catalog No. 809-568 Printed in U.S.A. Form ZONEKIT4-1SI Pg 1 7-95 Replaces: 920415-3SI

2. Use vibration isolators (flex connectors) on zone dampers and duct work 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 Comfort Zone System (50 va minimum, class 2, 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 oversized.

7. Duct work must be designed based off the sum of peaks plus 25 percent oversize. It is imperative duct work is not undersized.

INTRODUCTION

This installation guide pertains to revision 1.6 or greater. The Comfort Zone System allows air conditioning and heating equipment to control temperatures in up to 4 distinct spaces or Zones within a building. Each zone has independent temperature settings. The comfort temperature settings can change automatically through the use of schedules. This allows Comfort Zone to change temperature settings in zones to reflect occupancy or usage. For example, you can condition the bedrooms in a home from 5:00 PM through 7:00 AM or the kitchen from 3:00 PM through 6:00 PM. The Comfort Zone System uses motorized air volume control dampers (also called zone dampers) to regulate flow of conditioned air into zones. In this manner Comfort Zone can selectively heat or cool certain portions of a building depending upon space temperature requirements.

INSTALLATION

Step 1—Check Equipment and Jobsite

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

Step 2—Wiring

Shielding For A Single Comfort Zone System

1. Fig. 16 Shows a Comfort Zone System with all possible options. The shield from all devices should be tied together at I/O board and terminated at shield ground at lower right hand corner of board. Be sure shielding does not touch any other wiring on board.

NOTE: Do not connect shield wire at device end. Cut end and tape up to avoid shorting.

Shielding For Multiple Comfort Zone Systems

1. If more than 1 Comfort Zone System resides on 1 job, they may be tied together for communication purposes. If no communication is required, then Comfort Zone System should be wired separate and shielded as previously stated.

2. When 2 to 4 systems are on 1 job and require communication, they should be daisy chained together through 3-wire communication bus at COM BUS HAM terminal.The shielding should only be grounded at 1 point on end of communication bus as shown in Fig. 2.

SHIELD DRAIN WIRE

Comfort Zone I/O

NOTES:

1. Use butt splices, or solder, for shield connections. Then tape up shield. 

2. Do not connect the shield drain wire at the end of Communication Bus. Cut and tape up to avoid shorting.

Comfort Zone I/O

SHIELD DRAIN WIRE

Comfort Zone I/O

NOTE 2NOTE 1

A93251

Fig. 2—Daisy-Chained Comfort Zone Systems

To prevent personal injury or possible equipment damage disconnect power supply before routing wire.

All wiring must comply with local and state codes. NOTE: A remote room sensor requires a 2-wire cable, however,

it is recommended that a 5-wire cable be installed to allow for a possible smart sensor upgrade. Connect white wire to terminal labeled B- if a 5-wire cable is used. Connect red wire to R+. Shielded cable is recommended to reduce noise interference.

NOTE: Use No. 22 AWG color-coded, insulated (35°C min) wire. If thermostats are to be located more than 100 ft from Comfort Zone Center as measured along control voltage wires, use 18 AWG colored-coded wires to avoid excessive voltage drop.

All wiring is run back to Comfort Zone Center. Keep wires a minimum of 12 in. from any AC voltage. Do not tie-wrap wires together. When wiring to COM BUS, a 3-wire cable must be separate from the 5-wire cable. The thermostats should be located approximately 5 ft above floor and must be located within 200 ft of Comfort Zone Center.

SHIELDED CABLE General

1. All wiring should be shielded (except damper wiring) with 18 or 22 gage. The 3-wire, 5-wire, and Remote Sensor wire must be in separate jacketed cable.

2. All system wiring must be within 1 building. Never connect devices between 2 or more buildings.

3. If more than 4 systems are used on 1 job, multiple device buses must be used. Each device bus must be separated by an ISOSAT-01. A typical arrangement is shown in Fig. 3.

Communication Bus Guidelines for Maximum Number of Devices

1. The maximum number of Comfort Zone Systems allowed on 1 device bus is 4.

2. Four Zone Controllers must be addressed 4 addresses apart, example 4, 8, 12, 16 for a device bus with 4 Comfort Zone Systems.

3. Home Access Module (optional) will scan a maximum of 4 Comfort Zone Systems.

4. Multiple device buses can be tied together for communication via ISOSAT-01. An ISOSAT-02 is required for remote or direct communications via personal computer or modem. (See Fig. 4.)

5. Comfort Zone Systems may reside on a bus with VVT system devices. They may receive or broadcast time to these devices accordingly by toggling T5 enable broadcast on or off.

NOTE: If multiple 4-zone controllers are on 1 bus, only 1 can broadcast time. Turn all others off (T5).

NOTE 2

PORT #1 PORT #2

ISOSAT-01

NOTE 2

PORT #1 PORT #2

ISOSAT-01

Comfort Zone I/O

ISOSAT BUS

PORT #1 PORT #2

SHIELD DRAIN WIRE (TYP) PORT #1 PORT #2

PORT #1 PORT #2

ISOSAT-01

DEVICE BUS (TYP)

ISOSAT-01

BUILDING GROUND

Fig. 3—Typical Communications Network

Comfort Zone I/O

SHIELD DRAIN WIRE (TYP)

NOTES:

1.Use butt splices, or solder, for shield connections. Then tape up shield. 

2.Do not connect the shield drain wire at the end of Communication Bus. Cut and tape up to avoid shorting.

Comfort Zone I/O

NOTE 2NOTE 1

A93249

Table 1—Wiring Requirements

FROM

COMFORT ZONE

CENTER TO

Four Zone Controller

Remote Room Sen-

sors

NO.

OF WIRES

GAGE

3‡ 18/22 200/100 5‡ 18/22 200/100

2‡ 18/22 200/100

Remote Duct Sensors 2‡ 18/22 200/100

Dx Coil Sensor 2‡ 18/22 200/100

Home Access

Module

3‡ 18/22 1000/100

ISOSAT* 3‡ 18/22 1000/100

Transformer† 21875

* When using ISOSATS in interfacing multiple buses together, the length of

wiring between ISOSATS cannot exceed 4000 ft with 18 gage. † 24 vac, 50-75 va ‡ Shielded cable recommended to reduce noise interference.

Step 3—Install Comfort Zone Center NOTE: The Comfort Zone System is approved for indoor use

only and should never be installed with any of its components exposed to the elements. The enclosure must be installed with center cover to help prevent damage from other sources. Do not mount Comfort Zone Center where it will be accessible to children. Do not locate 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 Comfort Zone in an area with a temperature range between 32°F and 120° F.

Install Comfort Zone Center in either a vertical or horizontal position. Locate in an area that is easily accessible in case servicing should be required.

NOTE: Four vent plugs and 2 bushings have been supplied. Snap bushings in the 1-in. diameter holes that are to be used for wiring and place plugs in remaining holes.

MAX.

LENGTH

(FT)

Comfort Zone I/O

ISOSAT BUS

PORT #1 PORT #2

SHIELD DRAIN WIRE (TYP) PORT #1 PORT #2

PORT #1 PORT #2

BUILDING GROUND

ISOSAT-01

DEVICE BUS (TYP)

ISOSAT-01

TO PERSONAL COMPUTER OR MODEM

ISOSAT-02

Fig. 4—Communication Network With

Comfort Zone I/O

SHIELD DRAIN WIRE (TYP)

NOTES:

1.Use butt splices, or solder, for shield connections. Then tape up shield. 

2.Do not connect the shield drain wire at the end of Communication Bus. Cut and tape up to avoid shorting.

Comfort Zone I/O

NOTE 2NOTE 1

A93250

An ISOSAT-02

To prevent possible damage to Comfort Zone Center, do not mount on plenum, duct work, or flush against furnace.

1. Separate Comfort Zone Center cover. (See Fig. 5)

2. Mount back plate of center cover to wall using screws and wall anchors provided.

3. Level back plate and tighten screws.

Step 4—Install Zone Dampers IMPORTANT: If conditions exist for possible condensing, motor

must be positioned for adequate draining. (See Fig. 6.) NOTE: If a multi-damper enabler is used to link dampers

together, 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 that actuator is visible for inspection and

accessible in the event it would ever need to be serviced. The black mark on the end of damper shaft represents the position of damper blade.

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.

COMFORT ZONE CENTER  BACK PLATE

INTERCHANGEABLE HOLE PLUGS AND BUSHINGS

MOUNTING

HUB

AIRFLOW

POSITION INDICATOR

COMFORT ZONE CENTER COVER

Fig. 5—Comfort Zone Center

Comfort Zone

Center

DAMPER MOUNTING

BRACKET

A93247

ACTUATOR

HOUSING

QUICK BLADE

RELEASE

BUTTON

(RED)

FIELD

INSTALLED

POWER WIRING

Fig. 7—Damper 24-vac Connections

SUPPLY

Fig. 8—Round Metal Duct Work

CLS



FLEX

CONNECTOR

COM

OPN

ZONE DAMPER

ANGULAR ROTATION STOPS

MOUNTING BRACKET

A95096

A95129

1

/ ″ STEEL STRAP

ACTUATOR

Fig. 6—Damper Motor Positioning

A95128

Before insulating the duct work, check for proper damper operation. Apply the 24vac between COM and OPN to open the damper and COM and CLS to close the damper. (See Fig. 7.) The damper will modulate counter-clockwise to open and clockwise to close.

If in an emergency it becomes necessary to force a damper open, manually press in the red quick blade release button with one hand and turn the mounting hub to reposition the damper shaft. Release the button to hold the 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 DUCT WORK IMPORTANT: If application exists with all metal duct work

without insulation, flex connectors must be used on each end of zone dampers to avoid noise and vibration.

1. Crimp end of branch duct.

2. Slip end of zone damper over end of duct work. Use self-tapping sheet metal screw to secure. (See Fig. 8.)

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.)

Fig. 9—Insulated Round Metal Duct Work

NOTE: All zone dampers and duct work must be properly

supported according to local codes or SMACNA standards. RECTANGULAR METAL DUCT WORK

1. Make connections using S-lock and drives. (See Fig. 10.)

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.)

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

NOTE: There should be a minimum of 4 ft between zone damper and first branch duct if more than 1 branch duct is downstream of zone damper.

ROUND FLEXIBLE DUCT WORK

1. Slip 1 end of flexible duct work over 1 end of zone damper. (See Fig. 12.)

A95130

S-LOCK

/ ″ STEEL STRAP

SUPPLY AIR DUCT

DRIVE

Fig. 10—Rectangular Metal Duct Work

1 / " TO 2"

INSULATION

ZONE DAMPER

A92478

A95131

Fig. 11—Insulated Rectangular Metal Duct Work

FLEXIBLE

DUCT

Fig 12—Round Flexible Duct Work

ZONE

DAMPER

A95132

A95133

Fig. 13—Insulated Round Flexible Duct Work

FIBROUS GLASS DUCTWORK

2″ TO 3″

FIELD SUPPLIED SCREWS

ZONE DAMPER

A92480

Fig. 14—Rectangular Fibrous Glass Duct Work

1 / ″ TO 2″ INSULATION

A95134

Fig. 15—Insulated Rectangular Fibrous Glass Duct

Work

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

Comfort 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 bypass is properly supported.

For proper installation, refer to Installation Instructions packaged with barometric bypass.

2. Secure 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.)

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

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. 14.)

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 actuator.

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

Failure to properly install bypass damper can cause permanent damage to the HVAC equipment. For single speed furnace applications bypass air must never exceed 25 percent.

Step 6—Install Duct Temperature Sensor

Locate duct temperature sensor in main supply trunk after heating and cooling coil and before bypass damper and first branch. The duct temperature sensor must be radiant shielded to prevent heat from affecting correct air temperature.

1. Drill a 7/8-in. hole at location in unit where sensor will be installed.

2. Remove cover and insert sensor probe through 7/8-in. hole.

3. Drill two 1/16-in. holes to accept No. 6 screws through pre-drilled holes in duct temperature sensor back plate.

4. Use two No. 6 sheet metal screws included with sensor to mount duct temperature sensor back plate to unit.

5. Insert 2-conductor wiring through 1 of pre-drilled holes in side of back plate.

6. Connect sensor to 2-wire conductor using provided wire nuts. (See Fig. 16 for connection to Comfort Zone Center.)

Step 7—Install Dx Coil Sensor

The Dx coil temperature sensor is recommended for use in heat pump with fan coil applications only. The sensor should be installed between Dx coil and electric heaters. It measures Dx coil temperature and adds extra protection for high/low temperature limits. The range is from 30°F to 180°F. The Dx coil sensor interfaces to Comfort Zone Center on terminal TB-1. (See Fig. 16.) To activate Dx coil temperature sensor turn T-27 on. When activated, the Dx coil sensor has built-in LAT setpoints of 50°F and 45°F in the cooling mode, and 105°F and 110°F in the heating mode. This is non-adjustable.

Step 8—Install Four Zone Controller

The Four Zone Controller is the zone 1 thermostat. It is recommended to locate this in the zone occupied as the living room or family room for maximum comfort.

DO NOT locate controller where supply air can blow directly on it. Avoid locating controller where heat from any lamps, appliances, or direct sunlight will affect temperature sensor on controller. Do not locate on an outside wall or next to a return air grill.

1. Separate base plate from main body of controller.

2. Pull 3-wire cable for communication bus and 5-wire cable for controller through 3/4-in. round hole on base plate. Three-wire cable and 5-wire cable must be separate jacketed wiring. Do not use one 8-wire cable. (See Fig. 17.)

NOTE: Insulate or seal field wiring feed through hole to reduce draft.

3. Mount base plate using provided screws, starting screw in round hole first then second screw in slotted hole. On drywall it is recommended to use provided plastic wall anchors.

NOTE: If mounting controller using an electrical box, mount base plate using pair of horizontal holes.

4. Level base plate and tighten screw in slotted hole first, then the screw in round hole.

5. Connect the 3 wires for communication bus and the 5 wires for controller to base plate terminal screws. (See Fig. 16.) Ensure that there are no excess or bare wires exposed.

6. Plug base plate connector into back of main body and ensure it is secure into connector located on back of 4 zone controller’s main body. Ensure connectors and main body are secure.

7. Align main body with base plate and snap into place.

Step 9—Install Remote Room Sensors or Smart Sensors (Optional)

Comfort Zone may have up to 4 zones. The 4 zone controller controls zone 1. Remote room sensors or smart sensors control the other 3 zones. If using a smart sensor, a smart sensor power pack must be used. The remote sensors should be located 5 ft above the floor and must be less than 200 ft away from Comfort Zone Center.

DO NOT locate sensors where supply air can blow directly on them. Avoid locating sensors where heat from any lamps, appliances, or direct sunlight will affect temperature sensor on room sensors. Do not locate on an outside wall or next to a return air grill.

1. Separate the 2 parts of sensor and mount back plate with provided flat-head screw.

2. Pull a 2-wire conductor through hole on right-hand side.

3. Connect black or white wire to terminal labeled B- and connect red wire to terminal labeled R+.

4. Align sensor case with base plate then press firmly until cover snaps into place.

Step 10—Sequence of Operation

TEMPERATURE SETPOINTS The Comfort Zone System uses 2 temperature setpoints. The

setpoints are displayed in the left-hand window on the 4 zone controller. (See Fig. 18.)

In display window, cooling setpoint is shown on upper left and heating setpoint is shown on lower right.

The temperature setpoints for any of the 4 zones can be displayed by the 4 zone controller. When the 4 zone controller rotary switch points to zone 1, setpoints for zone 1 at the 4 zone controller are displayed. Selecting zone 2, zone 3, or zone 4 will display setpoints for each of these zones which use either remote room sensors or smart sensors. The system is not required to have all 4 zones installed.

HEATING AND COOLING COMFORT SETPOINTS If space temperature is between heating and cooling setpoints for

the zone, then the zone is said to be "satisfied" with respect to temperatures. When a zone is "satisfied" no heating or cooling equipment will turn on to condition the space. For example, if cooling setpoint is 76°F and heating setpoint is 72°F, then a space temperature of 73°F is assumed to be satisfactory and no heating or cooling of zone is required.

If space temperature in a zone falls below heating setpoint, then that zone needs to have heat added to zone which will raise space temperature back to heating setpoint. For example, if heating setpoint is 72°F and space temperature is 70°F, then space temperature must be raised 2 degrees in order for zone to be satisfied. In this case, temperature "heating demand" for zone is 2°F. (72°F minus 70°F.)

Otherwise, if space temperature in a zone rises above cooling setpoint, then that zone needs to have heat removed from zone which will lower space temperature back to cooling setpoint. For example, if cooling setpoint is 76°F and space temperature is 77°F, space temperature must be lowered 1° in order for zone to be satisfied. In this case, "cooling demand" for zone is 1°F. (77°F minus 76°F.)

Comfort Zone allows owner or installer to set ranges for comfort setpoints along with maximum and minimum temperatures which can be used by system.

Comfort Zone allows both heating and cooling comfort setpoints to operate in a 14° span. The heating and cooling temperature "spans" can be set to allow for a selected range of operation. Rotary switch position 9 sets base temperatures for both heating and cooling spans.

When switch is set to 9, both heating and cooling base temperatures are displayed and each can be modified by using up/down setpoint buttons. The base temperatures are the same for all 4

zones.

If cooling base temperature is set to 68°F, then cooling comfort range will be 68°F to 82°F. If heating base temperature is set to 54°F, then heating comfort range will be 54°F to 68°F.

Zone Dampers

ZN4

BYPASS

CL OP COM CL OP COM CL OP COM CL OP COM CL OP COM

COMFORT ZONE I/O

COMM

BUS HAM

ZN3 ZN2 ZN1

COMM BUS

CONTROLLER



RWRWRWRWRWR

OAT

LAT

ZT4

ZT3

ZT2

PWR. 24VAC

SHIELD

GROUND

24 VAC Transformer (Field Supplied) 50 VAC req. for basic 4 damper system. Please see Page 1, Electrical Rating for details.

#16 AWG to Grounded to Water Pipe or Solid Electrical Ground

PWR

CHR06

RELAY

CHR06

Y B

SYSTEM CONTROLLER

Zone 2*

Zone 3*

Power

To

HVAC

System

FAN (G)

RV COOL (0)

RV HEAT (B)

HEAT 2 (W2)

OR

4-Zone Controller

COOL 2 (Y2)

HEAT 1 (W1)

COOL 1 (Y1)

UNIT 24 VAC (R)

CHR-06

2:45

Dx Coil Sensor

(optional)

Outside Air

(optional)

Custom Cable

CALLOUT TO PHONE COMM BUSPOWER PHONE LINE

Home Access Module

(optional)

Sensor

Duct

Sensor

Remote Room

Sensors

* It is recommended that a 5 wire cable be used to install Remote Room Sensors to allow for future upgrade to Smart Sensors.

Fig. 16—Comfort Zone System Wiring Diagram

Zone 4*

Zone 1

Communication Bus

B Y G W RB Y G W RB Y G W R

Smart Sensor Power Pack

(optional)

Smart Sensor

(optional)

A94311

5 WIRE CONDUCTOR

(INTERFACE BOARD)

3 WIRE CONDUCTOR

(COMM BUS)

COMM BUS

FIELD WIRING

(FEED THRU)



I/O BOARD

Fig. 17—Wiring Four Zone Controller

GRN

RED

WHT

RED

YEL

BLU

GRN

WHT

GREEN

RED

WHITE

RED

YELLOW

BLUE

GREEN

WHITE

A93231

Changing the base temperatures will change the Comfort Temperature Setpoints used in the system schedules. Always set the Base Temperatures prior to programming the system schedules.

Comfort Zone also uses a minimum temperature and a maximum temperature for comfort setpoints. The minimum and maximum

temperatures are the same for all 4 zones.

The Maximum Temperature is only used for cooling. It is set by selecting Rotary Switch Position S-2. The Maximum Temperature setting is used when a temperature above the 14° span is selected. If Cooling Base Temperature is set to 68°F and cooling setpoint is 82°F, any attempt to raise cooling setpoint will select Maximum Temperature.

The Minimum Temperature is only used for heating. It is set by selecting Rotary Switch Position S-3. The Minimum Temperature setting is used when a temperature below the 14 ° span is selected. If Heating Base Temperature is set to 54°F, any attempt to lower heating setpoint below 54°F will select Minimum Temperature.

Both Maximum and Minimum Temperatures are intended for use with schedules or setpoints which are extreme compared to normal building temperatures.

Comfort Zone also has one additional set of temperature settings. These are Vacation Setpoints. The Vacation Setpoints are heating and cooling setpoints to be used in all 4 zones whenever 4 zone controller rotary switch is turned to "Vacation." The Vacation option is used to place entire building in setback during long unoccupied periods without danger of freezing or extreme heat/humidity.

SEQUENCE OF EVENTS FOR A NORMAL HEATING OR COOLING CYCLE

Given Comfort Setpoints and space temperature for zones within system, Comfort Zone will determine if active heating or cooling is required. If so, Comfort Zone will perform the following:

1. Select a reference zone.

2. Make sure all zone dampers are fully open.

3. Energize HVAC equipment fan.

4. Energize heating or cooling equipment. The equipment may be a compressor, furnace, strip heater, etc.

5. Set the zone damper positions based upon zone demand.

6. Energize additional stages of heating or cooling if demand warrants.

7. Continue to adjust zone dampers as conditions within zones change.

8. Turn off heating or cooling equipment when all zones are within 0.5°F of desired comfort setpoint.

9. Open all zone dampers when equipment is turned off.

This is the basic Sequence of Operation for the Comfort Zone system. The actual control of dampers, HVAC equipment, and system fan will change with configuration of system. Depending upon configuration, Comfort Zone can control heat pumps, furnaces, and dual fuel applications.

SELECTION OF A REFERENCE ZONE IN THE SYSTEM The first step in any heating or cooling cycle requires Comfort

Zone to evaluate zones, determine if heating or cooling is needed, and select a Reference Zone.

The Comfort Zone system actively looks at Comfort Setpoints and space temperature in all zones. If any zone in system has a demand of 1.5°F or more, then Comfort Zone will prepare to operate heating or cooling equipment to reduce demand.

First, Comfort Zone will select a reference zone in the system. The reference zone will be zone with greatest demand. The zone damper serving reference zone will be forced fully open and will remain fully open as long as that zone is used as reference.

As long as any zone in system has a demand greater than or equal to 1.5°F, then Reference Zone will be selected by zone with greatest demand. Once all zones have a demand less than 1.5 Reference Zone selection will not change until demand in that zone is below 0.5°F. At this point Comfort Zone will re-select Reference Zone and position that particular zone damper fully open.

The objective of Reference Zone is to ensure that zone with greatest demand is receiving as much conditioned air as system will allow. It also gives Comfort Zone system a point of reference in observing response of zones to equipment operation.

PRE-POSITIONING DAMPERS AND STARTING THE SYSTEM FAN

In order to minimize noise and enhance system operation, Comfort Zone maintains all zone dampers full open prior to starting system fan or heating or cooling equipment. The intent is to provide HVAC equipment with unrestricted duct work and reduce pressure surges. Comfort Zone also fully opens dampers whenever a heating or cooling cycle is completed and system fan is shutting down. If Fan Switch on 4 zone controller is set to Auto, then all zone dampers will remain fully open until next heating or cooling cycle.

The other reason for opening dampers is to provide unrestricted duct work to other equipment which is not directly controlled by Comfort Zone. One example may be Heat Recovery Ventilator. If Comfort Zone is not actively controlling HVAC system, then it must not impose any control influences (i.e., closed zone dampers) on system and prevent proper operation of other devices.

For Fan operation, switch settings on 4 zone controller and system configuration can change actual operation.

If Auto Fan Off For Heating option (Rotary switch position number T-9) is ON, then Comfort Zone will only energize fan for cooling cycles. This option is intended for furnaces which will control their own fan internally.

If Fan Switch on 4 zone controller is set to ON instead of Auto, then system fan will run continuously. Any time Comfort Zone is operating fan, it will be in active control of system.

NOTE: If Auto Fan Off For Heating option (rotary switch position T-9) is ON, and Fan Switch on the 4 zone controller is ON, Comfort Zone will operate fan full time.

Operating fan continuously will place Comfort Zone in a Float Mode any time no active heating or cooling is taking place. During Float Mode, Comfort Zone will position zone dampers based upon demand in each zone. Comfort Zone will check air temperature in duct work and allow air into zones if it will help zones reduce their individual demands. For example, if temperature of air in duct work is 65°F, cooling comfort setpoint for a zone is 72°F, and space temperature is 73°F, then Comfort Zone will open damper servicing that zone and allow cooler air into space.

Ventilation Mode is only in effect when temperature of supply air is between 65°F and 80°F. Ventilation Mode establishes minimum position of zone dampers and is intended to help air movement throughout zones and reduce chance of having areas which are stagnant or have high humidities with respect to rest of system. The changes to dampers are detailed in the next section "Controlling the Zone Dampers."

CONTROLLING THE ZONE DAMPERS The zone dampers have a total of 16 possible positions or

increments which are numbered 0 (zero) through 15. Position number 0 is fully closed and position number 15 is fully open. While damper servicing reference zone remains fully open, all other zone dampers are positioned by selecting a position equal to demand of space in tenths of a degree. (See Table 2.)

Table 2—Zone Damper Positions

Damper Position Versus Zone Demand

DAMPER

POSITION

Fully Closed

10.1 0.06 2 0.2 0.11 3 0.3 0.17 4 0.4 0.22 5 0.5 0.28 6 0.6 0.33 7 0.7 0.39 8 0.8 0.44

9 0.9 0.50 10 1.0 0.55 11 1.1 0.61 12 1.2 0.67 13 1.3 0.72 14 1.4 0.78 15

Fully Opened

For example, a zone which has a 1.0°F demand will have damper set to position number 10 while a zone which has a demand of

0.5°F will have damper set to position number 5. A demand of 0 (zero) will fully close zone damper. Any zone which has a demand greater than 1.5°F will remain fully open.

Notice that positions are based upon tenths of a degree Fahrenheit. If Comfort Zone has Celsius Temperature Display option (rotary position T-2) turned on, the damper control is still based upon Fahrenheit scale.

DEMAND °F DEMAND °C

1.5 0.83

The damper positions in table are also used during a Float Mode. A zone with a demand of 0.5°F will be set to position number 5.

The actual control of zone dampers by Comfort Zone system can be modified using 3 configurable options. These are Maximum Damper Position, Minimum Damper Position, and Ventilation Mode.

These options apply to all zone dampers simultaneously. Any dampers servicing Zone 1 cannot be configured differently than those servicing Zone 2. The options are as follows:

1. The Maximum Damper Position (rotary position number

S-4) sets maximum open damper position for all 4 zones. The allowable range for this option is damper positions number 8 through number 15 (fully open). The factory default is 15. The only time zone dampers will exceed this position is if system fan is off or zone dampers are being calibrated.

2. The Minimum Damper Position (rotary position number

S-5) sets minimum open damper position for all 4 zones. The allowable range for this option is damper positions number 0 through number 7. The factory default is number 0 (fully closed). If Ventilation Mode (rotary position T-25) is turned OFF, then minimum damper position will be an absolute minimum regardless of operating mode. If Ventilation Mode is turned ON, then minimum damper position will be minimum position during a Ventilation Mode only and dampers will be allowed to fully close at any other time.

3. Ventilation Mode (rotary position T-25). If Ventilation Mode

is turned ON, then any time air inside supply air duct work is between 65°F and 80°F, system will be in a "Ventilation Mode". During a Ventilation Mode all zone dampers will have a minimum position which is set by Minimum Damper Position (rotary position S-5). The zone dampers are not allowed to fully close as long as supply air temperature remains within the 65°F-80°F range. If supply air temperature falls outside the 65°F-80°F range, then zone dampers may fully close.

NOTE: If Ventilation Mode option (rotary position T-25) is turned ON, and Minimum Damper Position (rotary position S-5) is set to position 0, there is no difference between Float Mode and Ventilation Mode. In other words, Ventilation Mode option has no effect on system.

OPERATING THE HEATING AND COOLING EQUIPMENT Before any heating or cooling equipment is started, Comfort Zone

must first choose between heating or cooling. For most of the year there is little question as to the need for heat or cooling. But for portions of the year, particularly during mid-season, a building may have simultaneous needs for both heating and cooling.

The first step in selecting heating or cooling is the determination of a Reference Zone. If there is a single zone which has greatest demand, then it will become the Reference Zone and Comfort Zone will start equipment based upon needs of that zone. If 2 zones have same "greatest demand" but in different modes (1 needs heating and the other needs cooling), then Comfort Zone will select mode which has greatest number of zones which require same mode.

CONTROL STRATEGY FOR HEATING / COOLING STAGES The Comfort Zone system will attempt to minimize use of

additional stages of heating or cooling equipment. In an ideal case, building conditioning needs can be supplied by first stage cooling or first stage heating alone.

For most heat pump applications, there may be only 2 or 3 stages of heat depending upon type of emergency heater present. For a heat pump, secondary heat source will generally be an electric strip

Table 3—Heating System Option Vs. Type of Heater Used

HEATER TYPE USED

IN SYSTEM

Single-Stage Heat Pump On Off 0

Two-Stage Heat Pump On On 0

Heat Pump/Furnace Dual

Two-Stage Heat Pump,

* Refer to 2-speed heat pump Installation and Start-Up Instructions for details regarding 2-speed heat pump operation. It is recommended that heat pump control board controls operation of this equipment and not Comfort Zone.

Fuel

Furnace Dual Fuel*

Furnace Heat Only Off Off 0

Strip Heater Only Off Off 0

HEAT PUMP

SYSTEM TOGGLE:

T-6

On Off 10 to 60

On On 0°F Off

TWO STAGE HEAT PUMP

TOGGLE: T-26

DUAL FUEL

SYSTEM SWITCH:

S-7

F (off) Off

F Off

F (off) On or Off

F (off) Off

FAN ON

FOR COOLING ONLY

TOGGLE:

T-9

Table 4—Available Heating and Cooling Stages Vs. System Type

TYPE OF HVAC

EQUIPMENT USED

Cooling Only, any Heater Type Y1 Y2 W1 W2 -- --

Single-Stage Heat Pump Y1 -- Y1 W1 W2 --

Two-Stage Heat Pump Y1 Y2 Y1 Y2 W1 W2

For cooling applications, the second stage of an air conditioner is not necessarily more expensive to operate than first stage. But additional cooling can drive down the efficiency of a 2-speed air conditioner and longer use of first stage alone tends to deliver better humidity control in moist climates. Again, because of these advantages, Comfort Zone will attempt to minimize use of second stage cooling. This is not as great of a concern for a heating application, because the majority of small air conditioning systems sold today (5 tons and below) are single-stage cooling only.

COOLING STAGE 1 COOLING STAGE 2 HEAT STAGE 1 HEAT STAGE 2 HEAT STAGE 3 HEAT STAGE 4

heater. The electric strip heat is much more expensive to operate when comparing cost per unit of heat. Because auxiliary stages of heating tend to be more expensive to operate, Comfort Zone attempts to keep number of stages at a minimum.

CONFIGURATION OPTIONS FOR EQUIPMENT OPERATION

Comfort Zone has several configurable options which allow it to control different types of HVAC equipment and change the manner in which the equipment is controlled. This first group must be set given the type of HVAC equipment installed. These include:

1. Heat Pump Operation (Rotary Position T-6).

2. Two-Stage Heat Pump (Rotary Position T-26).

3. Dual Fuel trip temperature (Rotary Position S-7).

4. Auto Fan Off For Heat (Rotary Position T-9).

The second group modifies the way the HVAC equipment is controlled. These include:

1. Comfort Trend Staging (Rotary Position T-8).

2. System Mode Reselect (Rotary Position T-22).

3. High/Low Temperature Limits Enabled (Rotary Position T-10).

4. High Temperature Trip Limit (Rotary Position S-6).

5. Dx Sensor (Rotary Position T-27).

6. Smart Start (Heat Pump Strip Heat Economy Feature)

The first options which must be set are based upon the type heater or heaters used. These are shown in Table 3. The only option which appears to impact cooling operation is Two-Stage Heat Pump which implies the availability of 2 stages of cooling. In reality there are no changes to cooling control scheme.

Comfort Zone assumes that there are always 2 stages of cooling present. These are connected to the Comfort Zone Relay Pack on the Y1 and Y2 contacts.

RELAY PACK TO HVAC EQUIPMENT CONNECTIONS Given system configuration, Comfort Zone can determine number

of heating stages that it will actually control and which relay outputs will be used to control each stage of heat. Comfort Zone can control up to 4 stages of heat depending upon system configuration.

For cooling only applications with any type of heater, Comfort Zone will only control 2 stages of heat. If system uses a heat pump, then Comfort Zone will control 3 stages of heat. The additional stage is heat pump compressor contact. The auxiliary heat is still 2 stages. If system uses a 2 stage heat pump, then Comfort Zone will control 4 stages of heat, 2 stages for heat pump and 2 stages for auxiliary heat.

The Comfort Zone Relay Pack outputs are shown in Table 4. The Y1 and Y2 contacts are used for compressor contacts only. Comfort Zone operates heat pumps by energizing compressor contacts and controlling reversing valve through Reversing Valve (RV) 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 Comfort Zone 1.4 are shown in Table 4.

Under no circumstances may the W1 and Y1 contacts on the relay pack be jumpered together. This is a common practice for many heat pump installations but will cause improper operation of the Comfort Zone (1.4 or greater) system.

STARTING THE HVAC EQUIPMENT Once Comfort Zone selects a mode, controller will use configu-

ration options to modify control of HVAC equipment. The controller first selects number of stages of heating and cooling that may be applied to building load. The "available" stages are determined by Reference Zone temperature demand and are shown in Table 5.

Using Table 5, if Reference Zone has a 2.3°F demand, then Comfort Zone may use 2 stages of cooling or 2 stages of heating. The HVAC equipment may not have 3 stages of heat or even 2 stages of cooling. The table is only used to determine what equipment Comfort Zone is allowed to turn on at any given time during a heating or cooling cycle. Actual operation of stages depends on other variables as well.

Normally Comfort Zone will start equipment operation when it has a demand of 1.5°F or greater. In some cases, Comfort Zone will be facing a demand greater than 1.5°F when a mode is starting. This can occur when user changes setpoints in a zone or if a schedule change has reset the Comfort Setpoints.

Table 5—HVAC Equipment Stages

Vs. Zone Demand

HEATING & COOLING EQUIPMENT STAGES

First-Stage Cooling 1.5 0.83

Second-Stage Cooling 2.0 1.11

First-Stage Heating 1.5 0.83

Second-Stage Heating 2.0 1.11

Third-Stage Heating 2.5 1.39

Fourth-Stage Heating 3.0 1.67

NOTE: Comfort Zone uses a 3-minute timer to delay start of

second-stage (heating or cooling). This timer is started whenever first-stage heating or cooling is energized. This delay cannot be overridden or disabled.

STAGE CONTROL DURING EQUIPMENT OPERATION As shown earlier, Comfort Zone has 6 configurable options which

help govern equipment operation. They are:

1. Comfort Trend Staging (Rotary Position T-8).

2. System Mode Reselect (Rotary Position T-22).

3. High/Low Temperature Limits Enabled (Rotary Position T-10).

4. High Temperature Trip Limit (Rotary Position S-6).

5. Dx Sensor (Rotary Position T-27).

6. Smart Start (Heat Pump Strip Heat Economy Feature)

Comfort Trend Staging and High/Low Temperature Limits control the use of extra stages of heating and cooling. Both can be turned off by the installer but the use of these options is highly recommended.

Comfort Trend Staging is used by Comfort Zone as an aid to decide if second-stage (heating or cooling) is needed. The system must have at least 1 zone with a demand equal to or greater than

2.0

F to allow use of second stage. Comfort Trend looks at temperature inside zone and watches trend over time. If zone demand is being lowered by first-stage operation, second stage is not energized. Stage 1 would remain ON and Stage 2 would remain OFF as long as temperature and trend continued to improve.

Comfort Trend Staging uses a 6-minute timer and a record of the Reference Zone demand to control second stage. When Comfort Trend Staging starts, demand in Reference Zone is recorded and temperature in zone is continuously monitored. If demand in Reference Zone is reduced (temperature is approaching comfort setpoints), then 6-minute timer is restarted and new demand is recorded. If 6-minute timer expires and demand is the same or has grown greater, Comfort Zone will start second stage.

Comfort Trend works for all stages of heating and cooling operation.

Comfort Trend staging will be used if rotary Position T-8 is turned ON. If T-8 is turned OFF, then second stage will be energized whenever Reference Zone demand meets or exceeds 2.0°F and after 3-minute delay.

System Mode Reselect allows Comfort Zone to switch between heating and cooling even if current system demand has not been satisfied. For example, if Comfort Zone is providing heat, System Mode Reselect allows Comfort Zone to look at any cooling needs which may also exist in the building. If cooling demand exceeds heating demand for 20 minutes, Comfort Zone will stop providing

DEMAND °F DEMAND °C

heat and switch into a cooling mode. Once cooling demand is satisfied (or System Mode Reselect dictates a switch), Comfort Zone will revert to a heating mode in order to try and satisfy that demand.

The need for System Mode Reselect usually indicates some type of system problem. Common use of System Mode Reselect may be caused by poor or improper duct work, open windows or doors, HVAC equipment failure, improper equipment sizing, etc. The need for System Mode Reselect usually occurs in larger installations where zone use or occupancy may vary widely. For residential application, the need for System Mode Reselect is normally not frequent unless the building has unusual architectural features or problems with HVAC system.

High/Low Temperature Limits is an option that allows Comfort Zone to control equipment stages and position dampers based upon temperature of supply air leaving HVAC equipment. As the Comfort Zone system operates through a heating or cooling cycle, zone demands and damper positions will change. This changes actual tonnage or BTUH that is applied to HVAC equipment. The tonnage generated by HVAC equipment must equal tonnage placed into zones. If zone’s airflow decreases, cooling equipment will tend to drive down supply air temperatures. Conversely, heating equipment will tend to drive up supply air temperatures.

With High/Low Temperature Limits turned ON, Comfort Zone will detect this condition and take corrective action. The first step taken by Comfort Zone will be to start turning off extra stages of equipment. this will continue until either the Leaving Air Temperature problem is corrected or system is operating on first-stage heating or cooling only.

If system is operating on first-stage heating or cooling, Comfort Zone will begin to gradually open zone dampers. This can continue until system has become a fully-open constant-volume system if needed. The objective is to provide required heating or cooling as best as possible prior to shutting off equipment. In practice the control tends to match equipment capacity to zone demands and will seldom revert back to a fully-open system.

The Leaving Air Temperature control can also indicate problem zones within a system which are not receiving sufficient airflow. If 1 area (or zone) within a building has difficulty becoming satisfied then there may be a sizing problem or an obstruction in duct work supplying that zone.

To use the Leaving Air Temperature Control, 3 options must be setup properly. They are:

1. High/Low Temperature Limits Enabled (Rotary Position T-10).

2. High Temperature Trip Limit (Rotary Position S-6).

3. Dx Coil Sensor For Leaving Air Temperature Checking (Rotary Position T-27).

First, High/Low Temperature Limits Enabled must be turned ON. This is the ON-OFF switch for the control option. The temperature used for this control is measured by Remote Duct Sensor and (optionally) the Dx Coil Sensor.

The High Temperature Trip Limit (Rotary Position S-6) is supply air temperature for heating that the Leaving Air Temperature control uses to detect a problem during heating modes only. The Comfort Zone thermostat will display a number between 05 and 55°F. The actual temperature is 100°F greater, such that the actual range is 105°F to 155°F. Comfort Zone cannot display the 100’s digit.

Selecting the Offset Temperature picks the temperature when Comfort Zone will start taking action to correct the Leaving Air Temperature. If limit temperature is between 105°F and 109°F,

then temperature at which first stage will be shut down will be offset 5°F above limit value (110°F to 114°F). If limit temperature is between 110°F and 155°F, then temperature at which first stage will shut down will be offset 20°F above limit value (130°F to 175°F). For Cooling modes the temperature is fixed at 50°F (10°C) for starting the control and 45°F (7.2°C) for turning off first-stage cooling.

The heating value must be set given the type of heater used in the system. This is for the final heat source. So a heat pump with strip heat would use a temperature appropriate for strip heaters. A furnace application may have a setting in the 130°F to 155°F range. Strip heaters may fall into a 115°F to 130°F range. Heat pump only systems may use 105°F to 115°F. Check equipment manufacturer recommendations and verify setting is in accordance with UL, NFPA, or any applicable Local or State Building Codes. If there is any question about what may be an appropriate temperature setting, use conservative (low) temperatures.

Dx Coil Sensor For Leaving Air Temperature (Rotary Position T-27) allows Comfort Zone to use a Dx Coil Sensor in addition to Remote Duct Sensor for Leaving Air Temperature Checking. The Dx Coil Sensor is used in heat pumps with fan coil applications and will be located after the Dx coil and before any strip heaters. This sensor is only active during heat pump operation. The temperature setting for this sensor is fixed at 105°F for initiating the control option and 110°F for shutting down first stage.

Heat Pump-Strip Heat Economy Feature (Smart Start). This is an automatic control within Comfort Zone and not a selectable option. The Smart Start feature is used whenever primary source of heat is a heat pump. As such, the Heat Pump toggle (Rotary Position T-6) must be turned ON. Smart Start is designed to help minimize use of strip heat or emergency heat whenever a large heating demand occurs due to a scheduled setpoint change. Smart Start looks at scheduled comfort setpoints for the next hour. If scheduled setpoints will make system provide heat, Smart Start will start heat pump an hour early. Smart Start will operate until zone demand is brought within 0.5°F (0.28°C) of the next hour’s heat setpoint or setpoints change due to the schedule (the hour expires).

Smart Start assumes auxiliary heat is more expensive to operate when compared to heat pump and it assumes that heat pump is a relatively "slow" source of heat. Smart Start allows a zone to recover from a setback or unoccupied period and use the most economic source of heat in doing so. The idea of using a setback or unoccupied schedule is to save money in operating costs. There is little incentive to use schedules if zone is heated with most expensive source of heat available.

Step 11—Configuring Four Zone Controller

PROGRAMMABLE OPTIONS-SETTINGS Turn zone selector dial to position S. (See Fig. 18.) The controller

display shows setting number and its value. The upper 2 digits show the setting’s number and the lower 2 digits

show the value of setting. Press the COOL up or down setpoint buttons to change setting

number and the HEAT up or down setpoint buttons to change value. Refer to Table 6 for settings and their definitions.

1. Zone Controller Bus Address (S-1) This setting establishes the identity of the 4 zone controller on

the Carrier communication bus.

NOTE: Remote room sensors do not require addressing.

If using optional Smart Sensors, they must be addressed as follows:

Table 6—Programmable Options-Settings

SETTING

NO.

S-1 4 Zone Controller Bus Address 4-64 4 S-2 Maximum Cooling Setpoint 80-95 85 S-3 Minimum Heating Setpoint 34-64 65 S-4 Maximum Damper Position 8-15 15 S-5 Ventilation/Minimum Damper Position 0-7 0 S-6 High Temperature Trip Limit 105-155 105 S-7 Dual Fuel Setpoint 0 or 10-60 0

ZONE 1 Address of 4 zone controller ZONE 2 Address must be 1 less than zone 1 ZONE 3 Address must be 2 less than zone 1 ZONE 4 Address must be 3 less than zone 1

To set address of a Smart Sensor, rotary switch position 1 on Smart Sensor must be selected first.

2. Maximum Cooling Setpoint (S-2) This is the highest temperature value to which cooling setpoint

can be adjusted. All zones will use same value. The maximum cooling setpoint can be programmed from 80°F to 95°F. This allows cooling setpoints to be programmed above normal range.

Example: Maximum cooling setpoint is programmed at 92° F. The temperature range for cooling setpoint is 70° F to 84°F. When the COOL setpoint up button is pressed to adjust cooling setpoint above 84°F, setpoint will jump to 92°F.

3. Minimum Heating Setpoint (S-3) This is the lowest temperature value to which heating setpoint

can be adjusted. All zones will use same value. The minimum heating setpoint can be programmed from 34°F to 64°F. This allows heating setpoints to be programmed below normal range.

Example: Minimum heating setpoint is programmed at 56° F. The temperature range for heating setpoint is 66° F to 80°F. When the HEAT setpoint down button is pressed to adjust heating setpoint below 66°F, setpoint will jump to 56°F.

4. Maximum Damper Position (S-4) This is the highest open position to which a damper will

change. Full open is designated as position 15. Maximum open damper position can be programmed between 8 (half open) and 15, in increments of 1. All zone dampers will use the same programmed maximum value.

5. Ventilation/Minimum Damper Position (S-5) When there is no demand for cooling or heating, this is the

minimum position that every zone damper will maintain as long as air temperature in duct work is between 65°F and 80°F. Full closed is designated as position 00. Minimum open damper position can be programmed between 7 (half-open) and 00, in increments of 1. All zone dampers will use the same programmed ventilation value.

6. High Temperature Trip Limit (S-6) The trip temperatures limits are duct temperatures used to turn

HVAC equipment off to prevent damage to equipment. Temperature values are measured by duct temperature sensors.

The low temperature trip limits are 50°F (turn off second-stage cooling) and 45°F (turn off first-stage cooling) and cannot be changed.

The second-stage high temperature trip limit can be programmed from 105°F to 155°F.

SETTING NAME VALUE

FACTORY DEFAULT

If a value of 105 to 110 is selected (second-stage heating is turned off at this value) then the first-stage high temperature trip limit is the programmed value plus 5°F (first-stage is turned off). If a value of 111 to 155 is selected (second-stage heating is turned off) then the first-stage high temperature trip limit is the programmed value plus 20°F (first stage is turned off).

Example 1:

High temperature trip limit selected is 105°F. (Shown as 05 in controller display.) Second-stage heat will turn off when duct temperature sensor measures a temperature greater than 105°F. First-stage heat will turn off when duct temperature sensor measures a temperature greater than 110°F. Example 2: High temperature trip limit selected is 140°F. (Shown as 40 in controller display.) Second-stage heat will turn off when duct temperature sensor measures a temperature greater than 140°F. First-stage heat will turn off when duct temperature sensor measures a temperature greater than 160°F.

7. Dual Fuel Setpoint (S-7) This option is used with a system that has a heat pump and

another heat source (possibly gas) that should not run at the same time as heat pump. When any heat pump is on, all auxiliary heat will be off, and vice versa.

NOTE: The auxiliary heat must always have greater heating ability than the heat pump at low outdoor temperatures for this option to have any value. NOTE: If Dual Fuel setpoint is set to 0, then this option is disabled. If Dual Fuel option is used, an outside air temperature sensor or refrigerated air sensor must be used.

When dual fuel setpoint variable is set to outdoor temperature (10°F to 60°F) that is the crossover point between running heat pump or using auxiliary heat as the preferred method of heating. The setpoint is used only when the first stage of heating is brought on. If outdoor temperature is above setpoint, heat pump (Y1) is energized. If outdoor temperature is below setpoint, auxiliary heat (W1) is used. If heat pump is started and outdoor temperature goes below setpoint, dual fuel option is not used for that heating cycle.

PROGRAMMABLE OPTIONS-TOGGLES Turn zone selector dial to position T. (See Fig. 18.) The controller

display shows setting number and its value. The upper left 2 digits show setting number while the right side

shows the value of ON or OFF. Press the COOL up or down setpoint buttons to change toggle

number and the HEAT up or down setpoint buttons to change status of toggle. (See Table 11.)

Step 12—Wiring Diagrams

Refer to Tables 7 and 8 for wiring diagram reference information.

Step 13—Start-Up

1. Verify that zone number for remote room sensors and corresponding zone damper wire connections are the same in the Comfort Zone Center.

2. Check that AC power wires (dampers and transformer) are kept away from DC wires (remote room sensors, 4 zone controller, communication bus) leading up to, and in the Comfort Zone Center.

3. Check location of 4 zone controller and remote room sensors to make sure that they are not near heat producing devices such as lamps, sunlight, and appliances.

Table 7—Wiring Diagram Reference

For Fig. 19 and 20

FAN COIL WITH AIR CONDITIONER

INDOOR UNIT (FIG. 19)

OUTDOOR UNIT

Single-Stage

Air Conditioner

Two-Speed

Air Conditioner

OUTDOOR UNIT

Single-Speed

Air Conditioner

Two-Speed

Air Conditioner

* KGATT0101VSP (Optional) Two-stage relay kit— may help to control over conditioning. † Latent capacity control—Required, field supplied. See 2-speed Installation Instructions.

FA4A FB4A FC4B

AA B

C† D E

FURNACE WITH AIR CONDITIONER

58VUA/VCA

A* B B B C C

DE* F† G† H HI†

FK4A FK4B

INDOOR UNIT (FIG. 20)

58PAP 58RAP 58GFA 58DFA 58EFA 58SXA 58DXA

58WAV

58ZAV 58PAV 58RAV 58SXC

58DXC

58EJA 58MXA 58MCA

58MVP

Table 8—Wiring Diagram Reference

For Fig. 21 and 22

FAN COIL WITH HEAT PUMP

INDOOR UNIT (FIG. 21)

OUTDOOR UNIT

Single-Stage

Heat Pump

Two-Speed

Heat Pump

OUTDOOR UNIT

Single-Speed

Heat Pump

Two-Speed

Heat Pump

* KGATT0101VSP (Optional) Two-stage relay kit—may help to control over conditioning. † Latent capacity control—Required, field supplied. See 2-speed Installation Instructions. ** Field-supplied isolation relay.

FA4A FB4A FC4B

AA B

C† D E

FURNACE WITH HEAT PUMP

58VUA/VCA

A** B* ** C C D D

E** F* ** G† H† I I

FK4A FK4B

INDOOR UNIT (FIG. 22)

58PAP 58RAP 58GFA 58DFA 58EFA 58SXA 58DXA

58WAV

58ZAV 58PAV 58RAV 58SXC

58DXC

58EJA 58MXA 58MCA

58MVP

4. Make sure that the 3 wire communication bus cable for the 4 zone controller is not run in same conduit, or use same cable jacket, as the 5 wire conductor of the 4 zone controller.

5. On a remote room sensor follow wire guide stamped on base by terminal screws in order to keep polarity and voltages correct. Otherwise sensor will not work properly.

6. Make sure duct temperature sensor is placed in supply air duct work, downstream of furnace and evaporator coil, and upstream of bypass damper.

58TUA 58TMA

7. Write down on a piece of paper AND GIVE TO THE OWNER a list showing what rooms are controlled by what

dampers, and their corresponding zone numbers. Keep list for your future use.

8. Instruct owner to turn cool switch OFF in the fall, and turn it ON in the spring.

9. Make sure emergency heat switch is in the OFF position. If a gas furnace is used this switch should never be turned on. It is for heat pumps only.

10. Be sure and set clock to correct time of day. You only need to do this when you first power up system, or after a power outage lasting longer than 8 hours.

11. Go to rotary switch setting 2 on the 4 zone controller. Check calibration of room sensor. Do same for zones 2, 3, and 4 (rotary switch 3-4-5). Sensors must be calibrated.

12. Instruct owner in operation of Comfort Zone System

13. Instruct owner to call 800 number supplied with Comfort Zone Center to receive free "How to use Comfort Zone" video tape.

14. For toggle settings for configuration see Programmable Toggles and Options and Table 9.

Step 14—Programming Schedules

The 4 zone controller is the program center for the Comfort Zone System. The 4 zone controller provides the ability to program system for unique demands of each zone at different times during the day and week. See Fig. 18 to become familiar with various parts of the 4 zone controller.

SYSTEM SWITCHES System switches select desired equipment operation. Heat Switch

OFF—Heat will not come on. AUTO—Heat will come on when any zone is more than 1.5°F

below desired heat setpoint.

INDICATES ZONE SETPOINTS, ZONE TEMPERATURES, 

AND PROGRAMMING INFORMATION AND 

ALLOWS SETPOINT ADJUSTMENT.

FOUR

CONTROLLER DISPLAY

ZONE

CONTROLLER

OPTIONS

T89

ZONE 1

ZONE 2

ZONE 3

ZONE 4

VACATION

SET TIME/TEMP SCHEDULES

HOLD TEMPERATURES

OFF AUTO AUTO OFF AUTO ON ONOFF

HEAT COOL FAN EMERGENCY HEAT

SELECT MIN/HR/DAY

ADVANCE TIME/DAY

INDICATES THE CURRENT TIME AND DAY 

AND THE START TIMES/WEEKLY PERIODS 

DURING PROGRAMMING.

SET TIME/TEMP SCHEDULES

HOLD TEMPERATURES

SELECT MIN/HR/DAY

ADVANCE TIME/DAY

PROGRAMMING ADJUSTMENT BUTTTONS

ALLOWS FOR PROGRAMMING WEEKLY PERIODS, START TIMES 

FOR EACH ZONE AND SETS THE CLOCK FOR DAY AND TIME.

CLOCK DISPLAY

OPTIONS

ZONE 1

ZONE 2

ZONE 3

ZONE 4

VACATION

ZONE SELECTOR DIAL

PROVIDES ACCESS TO INFORMATION AND PROGRAMMING 

FOR EACH ZONE AND SELECTION OF VACATION MODE. 

OPTION AREA IS FOR USE BY INSTALLATION/SERVICE.

Fig. 18—Four Zone Controller

OFF AUTO AUTO OFF AUTO ON ONOFF

HEAT COOL FAN EMERGENCY HEAT

SYSTEM SWITCHES

PROVIDES FOR SELECTION OF HEAT, COOL, 

FAN AND EMERGENCY HEAT OPERATION.

A93232

Cool Switch

OFF—Cooling will not come on. AUTO—Cooling will come on when any zone is more than 1.5°F

above desired cool setpoint. Fan Switch

ON—Fan will stay on continuously (recommended). AUTO—Fan will come on only when heating or cooling is

required. Emergency Heat Switch (Heat Pump Systems only) OFF—Electric strip heat will not come on unless there is a zone

more than 2°F below desired heat setpoint and comfort trend demand has been satisfied.

ON—When any zone requires heat, electric strip heat will turn on. The compressor will remain off.

CONTROLLER DISPLAY When set for normal operation, the 4 zone controller display shows

current zone temperature setpoints and allows adjustment of these setpoints using setpoint buttons. By pressing both heating or cooling setpoint buttons simultaneously, controller will lock in and display temperatures for that zone. To release, push both buttons simultaneously again. This will only work when T-20 is off.

ZONE SELECTOR DIAL To view setpoints for each zone, turn zone selector dial to zone

number you wish to view. The setpoints for selected zone will be displayed in controller

display. Program Schedules Each zone has 3 different weekly periods, (Weekdays, Saturday,

and Sunday) and up to 4 different possible combinations of heating and cooling setpoints that can be programmed to provide automatic climate control depending upon day of week and time of each day. Each zone can be programmed independently. (See Table 9.)

NOTE: All zones must be programmed.

Table 9—Example Weekly Schedule

WEEKDAYS SATURDAY SUNDAY

6AM 72/70 7 AM 72/68 8 AM 72/70 8AM 85/65 10 AM 85/65 10 AM 85/65 5PM 70/68 2 PM 70/68 7 PM 70/68

10 PM 85/65 11 PM 85/65 10 PM 85/65

WEEKLY PERIOD

Start Time Cooling Setpoint/Heating Setpoint

Vacation Mode Vacation mode displays current vacation temperature setpoints and

allows adjustment of these setpoints using setpoint buttons. These setpoints are used by all zones until selector dial is returned to 1 of the zone selection positions. At all times, the setpoints displayed will be the temperature range that the system will maintain.

This mode can also be used to maintain entire home at 1 constant temperature-typically when unoccupied.

NOTE: If Fan Switch is set to ON, fan will continue to run in vacation mode.

To enter vacation mode, turn selector dial to VACATION. The word "VACATION" will appear on controller display whenever system is in this mode. Set vacation mode setpoints.

Setting The Clock The clock display will normally show hour, minutes, AM or PM,

and day.

1. Set minutes. Press SELECT MIN/HR/DAY button once. Press ADVANCE TIME/DAY button to scroll to proper

minutes.

2. Set hour. Press SELECT MIN/HR/DAY button once again. Press ADVANCE TIME/DAY button to scroll to proper hour,

AM or PM.

3. Set day. Press SELECT MIN/HR/DAY button once again. Press ADVANCE TIME/DAY button to scroll to proper day.

4. Return to normal operation. Press SELECT MIN/HR/DAY button once again. The newly

programmed time will be displayed.

Programming Schedules

1. Enter Program Mode Press SET TIME/TEMP SCHEDULES button to enter pro-

gram mode. The program mode and current zone will be shown on controller display.

2. Select a zone. Turn rotary switch to the zone to be programmed.

3. Select a weekly period. The clock display will show MTWTHF. Pressing ADVANCE TIME/DAY button selects weekly pe-

riod to be programmed. Pressing button 1 time will change clock display to SA. A second press will change display to SU. A third press returns display to MTWTHF.

4. Program time periods. There are 4 start times that can be programmed in each weekly

period. Press SELECT MIN/HR/DAY button to program start times

for selected weekly period. Pressing SELECT MIN/DAY/HR button once shows first

program start time on clock display and setpoints, with the word PROGRAM for this start time on controller display.

Additional presses display start times 2, 3, 4, and then back to weekly period display.

NOTE: While in program mode, if a period of 4-1/2 minutes passes without a change to some value, the controller will return to normal operation.

5. Program start time

NOTE: Start times must be programmed in chronological order and must be in the same day. Any times before previous time period will be ignored. In the WRONG example below, periods 2 and 4 will be ignored.

RIGHT 6 AM - TIME PERIOD 1

8 AM - TIME PERIOD 2 5 PM - TIME PERIOD 3 9 PM - TIME PERIOD 4

WRONG 6 AM - TIME PERIOD 1

2 AM - TIME PERIOD 2 9 PM - TIME PERIOD 3 5 PM - TIME PERIOD 4

Press ADVANCE TIME/DAY button until desired start time is displayed.

6. Adjust setpoints. Adjust setpoints using up and down buttons until desired

temperatures for the selected time period appear in display. These setpoints will be used during the time period currently displayed in clock window.

7. Complete time period programming. Repeat 4 through 6 to program remaining weekly period start

times. Each weekly period can be programmed with 4 different time periods.

8. Complete weekly schedule. After completing start time programming, press SELECT

MIN/HR/DAY until MTWTHF reappears in clock display. Repeat steps 3 through 7 to program weekly periods. Once

finished, this will complete programming of 1 zone.

9. Program a different zone. To program a different zone, turn rotary switch to desired zone

to be programmed and repeat 2 through 8.

10. Exit program mode. Exit program mode by pressing SET TIME/TEMP SCHED-

ULES button.

Overriding Programming To override time programming, press any setpoint button. This

will also adjust setpoints for override period. Once setpoints are adjusted, they will not change until the next programmed time period for that zone.

If HOLD TEMPERATURES button is pressed, then current setpoints will not change with time, but remain at last values entered for as long as hold mode is active.

To release hold mode, press HOLD TEMPERATURE button a second time.

The controller display will show the word HOLD whenever hold mode is active.

Temperature Sensor Calibration NOTE: Temperature sensors are factory calibrated; however,

field calibration is recommended. The setpoint display shows actual temperature (Fahrenheit or

Celsius). The upper left-hand corner of display indicates the whole number

value. The lower right-hand corner indicated the tenths. Pressing either HEAT or COOL button raises or lowers displayed

temperature by 1/10 of a degree. If temperature readings are not stable within 0.5°F, refer to

troubleshooting section for details. Damper Service Mode The Damper Service Mode can be selected to check full operation

of each zone damper independently. The controller display shows zone number in the upper left digits, and damper position in the lower right digits. The left hand setpoint buttons will toggle the zone number (1-4) and 5.

NOTE: No. 5 not used for damper service mode, see below for details when setting motorized bypass damper pressure relief limit.

When this mode is selected, all 4 zone dampers are activated and opened to position 15. (See Table 2.) Fan will energize. Use right hand setpoint buttons to toggle down from position 15 to position

0. This feature can verify that each zone damper is operating

properly by manually opening and closing each zone. When rotary switch dial is moved onto another position, Damper Service Mode will be cleared and controller will resume normal operation.

Table 10—Temperature Sensor Calibrations

ZONE SELECTOR

DIAL

Position 1

Position 2

Position 3

Position 4

Position 5

Position 6

Position 7 Position 8 Dx Coil Sensor Position 9

Bypass Damper Pressure Relief Limit We do not encourage using a motorized bypass damper. Using a

barometric bypass damper is the preferred method to control operating pressures in supply duct.

The display shows zone number in the upper left digits, and the lower right digits show damper position. The left hand setpoint buttons will toggle the zone number (1-4) and also to 5 where collective damper position is programmed in for bypass. When it is toggled to position 5 and annunciator is toggled from OFF to ON with right hand buttons, controller totals all damper positions and stores them. While displaying 1-4, the damper for that zone can be directed to any position with right hand buttons. The collective damper position that is programmed at position 5 is the minimum total damper open position. The largest minimum open position is 60 (4 zones with 15 positions each). The number that is programmed in will be the minimum total damper open positions that bypass will try to maintain. The bypass damper positions are 1 for every 3 that the total needs. (Example: The maximum total is 60, but only 3 dampers are open. This is only 45, so bypass takes 60, subtracts 45, comes up with 15, and divides this number by 3. The result is 5, so bypass goes to position 5.)

Step 15—Accessories

Refer to individual Installation Instructions packaged with kits or accessories when installing.

HOME ACCESS MODULE The Home Access Module (HAM) is designed to detect Comfort

Zone System errors. The HAM can report when system is operating correctly, or when an error is detected. The HAM can automatically call an ACS dealer or the ACS National Response Center.

NOTE: The HAM must be programmed via Report Logger or PC Command Center Software prior to installation.

SMART SENSOR AND SMART SENSOR POWER PACK NOTE: These 2 accessories must be used together.

The Smart Sensor provides the ability to view and adjust setpoints in zone where sensor is located.

The Smart Sensor replaces a Remote Room Sensor and requires a single 5-wire conductor instead of a 2-wire conductor.

OUTSIDE AIR DAMPER The outside air damper allows fresh outside air into building.

SENSOR TO BE

CALIBRATED

Damper Service

Position

Zone 1 Temperature

Sensor

Zone 2 Temperature

Sensor

Zone 3 Temperature

Sensor

Zone 4 Temperature

Sensor

Duct Temperature

Sensor

Outside Air

Temperature Sensor

Base Temperature Set-

point Scale

OUTSIDE AIR TEMPERATURE SENSOR The Outside Air Temperature Sensor must be used whenever an

Outside Air Damper is installed. An Outside Air Temperature Sensor must also be used for dual fuel applications.

Step 16—Troubleshooting

This section contains information to assist you in troubleshooting problems and errors associated with the Comfort Zone System. The most common operating problems and different types of errors associated with the Comfort Zone System are: Operating Problems—No display, flashing display, and flashing HEAT or COOL annunciators. Comfort Zone controller selects a system mode but does not energize heating/cooling unit. Hardware Failure (HF) Errors—Occur when Comfort Zone controller detects a problem with 1 of its own components or an associated device. Storage Failure (SF) Errors—Occur when Comfort Zone controller detects and replaces faulty data contained within its memory with factory selected default values. Transparent Errors—Occur when Comfort Zone controller detects a system or zone operating problem.

When any zone cannot maintain room temperature within 5°F of desired setpoint for a period of 20 minutes, a comfort trend error is declared. This error is transparent and will not be shown on controller display. If a Home Access Module (HAM) is on the system, the ACS dealer or national ACS response center will receive a call identifying this error.

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 or User’s Manual for the proper frequency of maintenance. Frequency of maintenance may vary depending upon geographic area.

Leave system manual with homeowner. Explain system operation and maintenance procedures outlined in

User’s Manual.

Table 11—Toggle Summary

TOGGLE SETTING ON OFF DEFAULT

Timeguard delay is 30 sec, overrides 5-minute delay be-

(T1)-Timeguard Override

(T2)-Celsius Display Temperature and setpoints are displayed in Celsius degrees. (T3)-2400 Baud Rate Communication baud rate is 2400. Communications baud rate is 4800. ON (T4)-Error Code Display

(T5)-Enable Broadcast

(T6)-Heat Pump Operation

(T7)-Outside Air Temperature

(T8)-Comfort Trend Staging

(T9)-Auto Fan Off For Heat

(T10)-High/Low Temperature Limits

(T11)-Installer Switch Lockout

(T12)-Force Outside Air Ventilation

(T13)-Smart Sensor Attached For Zone 2

(T14)-Smart Sensor Attached For Zone 3

(T15)-Smart Sensor Attached For Zone 4

(T16)-Zone 2 Active Zone 2 is being used. Zone 2 is not being used. ON (T17)-Zone 3 Active Zone 3 is being used. Zone 3 is not being used. ON (T18)-Zone 4 Active Zone 4 is being used. Zone 4 is not being used. ON

(T19)-Economizer

(T20)-Enable Alternate Display

(T21)-Outside Air Damper Attached

(T22)-System Mode Reselect

(T23)-System Error Checking

(T24)-50 Hz Operation The system will be set to operate using 50 hz power source.

(T25)-Ventilation Mode

(T26)-Two Stage Heat Pump

(T27)-Dx Sensor for LAT Checking

(T28)-Cool Without Fan

* Pressing any setpoint button when a hardware error exists causes a reset if in a run position.

tween de-energizing and re-energizing HVAC stages. This option automatically returns to OFF after 30 sec timeout. If equipment has been shut down due to a leaving air temperature trip, the timeguard override has no effect.

Non-critical errors are displayed.*; when set to ON both SF/HF errors are displayed.

The system broadcasts the time on communication bus with every scan.

Heat Pump mode First-stage heat pump will energize Y1 to turn compressor on.

The system assumes that an outside air temperature sensor is attached and will broadcast outside air temperature on communication bus if enable broadcast is turned on.

The system will energize the second stage only if zone demand exceeds 2˚F and the zone temperature has not improved at least 0.1˚F for 6 minutes. The 6 minute timer is reset if the zone temperature trend is improving.

When the fan switch is set to AUTO, the system will not energize the fan during heat modes. This allows the equipment to control fan operation for proper heat exchanger warm-up.

The system will check leaving air temperature (measured by the duct sensor) for excessive heating and cooling limits. Cool limits are fixed at 50˚ F (second-stage cool deenergized) and 45˚ F (first-stage cool de-energized). Heating limits are programmable between 105˚/110˚ to 155˚/175˚F.

Rotary switch positions 1 through 7 and S on controller display will display dashes.

The outside air damper is forced to a minimum position of 2 when fan is on.

The system assumes a smart sensor is attached to zone 2. The 4 zone controller will read zone temperature and setpoints for zone 2 via the 3-wire communication bus at 1 address below controller.

The system assumes a smart sensor is attached to zone 3. The 4 zone controller will read zone temperature and setpoints for zone 3 via the 3-wire communication bus at 2 addresses below controller.

The system assumes a smart sensor is attached to zone 4. The 4 zone controller will read zone temperature and setpoints for zone 4 via the 3-wire communications bus at 3 addresses below controller.

The system will use outside air as first-stage cooling and mechanical cooling as second stage. When outside air temperature drops below 65˚ F, damper will modulate 10 percent open. Full open in cooling.

The controller display will alternate between setpoints and zone temperatures.

The system will operate fifth motorized damper as an outside air damper.

The system will re-evaluate demand while still in a mode. If simultaneous demand exists and demand for opposite mode exceeds demand for current mode for 20 minutes the system will change modes.

The system will report a transparent error when any zone cannot be maintained within 5˚ F for longer than 20 minutes.

When duct temperature is below 65˚F or above 80˚F damper will go fully closed, i.e., below minimum damper position in order to avoid over conditioning zone.

Y2 will be used to turn on second stage of a 2-stage compressor in a heat pump system.

Dx Sensor will be LAT checked in addition to Duct Temperature Sensor. (T-10 must also be on)

The fan will not be energized. The cooling equipment must provide a way to turn fan on.

Time delay is standard 5 minutes between de-energizing and re-energizing HVAC stages.

Temperature and setpoints are displayed in Fahrenheit degrees.

Only critical errors are displayed. ON The system does not broadcast time or

outside air temperatures on bus. No heat pump operation. Used for electric

heat or gas furnace. W1 will be energized for heat.

The outside air temperature sensor is not attached.

A 2˚F demand alone will energize the second stage after timeguard between stages has been satisfied.

The fan relay is energized during heating and cooling.

Operates the same as ’ON’ position, but dampers will not modulate open in a LAT trip.

All switch positions operate normally. OFF The outside air damper is set to the posi-

tion the system requests.

The system reads zone 2 temperature via the remote room sensor.

The system reads zone 3 temperature via the remote room sensor.

The system reads zone 4 temperature via the remote room sensor. OFF

The system will use only mechanical cooling.

The controller display will continuously show setpoints.

The system will operate fifth motorized damper as a motorized bypass damper.

The system will not change modes until current mode has been satisfied.

The system will not report error. OFF The system will be set to operate using

60 hz power source. Damper position will not go below mini-

mum damper position, which is set as S5, even when the duct temperature is too cold or too hot.

Second-stage operation will be canceled. OFF

Dx Sensor is ignored for LAT checking. OFF The fan relay is energized anytime there

is a cooling demand.

OFF

SYMPTOM POSSIBLE CAUSE

No Display

Blinking Temperature Display

Blinking HEAT or COOL Annunciator Cooling or Heating is Requested But

The HEAT or COOL Annunciator is not displayed

COOL or HEAT Annunciator is Lit But Cool or Heat is Not On

Damper Will Not Open or Close

System is Too Noisy

Unstable Temperature Readings

Room Sensors Fluctuating

Table 12—Operating Problems

Thermostat is not receiving power.

1. Verify that comfort zone center is receiving 24 vac. (50 va minimum required with 4 motorized dampers, 5 va for each additional motorized damper.)

2. Check that the thermostat is receiving a steady 10 VDC across the red and white wires at the system controller terminal block on the comfort zone, I/O board, and on the Red/White terminals on the base plate of the 4 zone controller.

Low voltage.

1. Verify that the comfort zone center is receiving 24 vac. (50 va minimum required with motorized dampers, 5 va for each additional motorized damper.)

2. Check that the thermostat is receiving a steady 10 VDC across the red and white wires at the system controller terminal block on the comfort zone, I/O board, and on the red/white terminals on the base of the 4 zone controller.

3. Check that the yellow or blue wires are connected properly and not broken at the system controller terminal block on the comfort zone I/O board and on the yellow/blue terminal on the base of the 4 zone controller.

4. Verify that the terminals are properly installed on the base plate of the controller.

5. Wiring connector block for smart sensor could be defective.

1. Check to see if high/low temperature trip limits have been exceeded.

2. Temperature sensor is improperly wired or defective.

1. Must have at least 1 zone with a demand greater than 1.5° F from setpoints.

2. Check system switches. They must be set to AUTO or ON to operate.

3. Have you waited for timeguard (5 minutes) to expire?

1. Check that the LEDs on the CHR06 relay pack are indicating the correct relay is closed. If not, check for a bad relay.

2. Measure voltage across common (red) and any de-energized relay. Voltage should be 24 vac.

3. Apply 24 vac directly across relay.

1. Verify that there are no obstructions binding the damper blade or shaft.

2. Check for 24 vac across common and either the open or close terminals.

3. Check stop switch. If defective, replace actuator.

4. Verify that motor is operating correctly.

5. Check damper fuse.

1. Make sure bypass damper is working properly.

2. Verify that duct work is properly sized.

1. Check for drafts.

2. Use shielded cable.

1. Make sure that the sensor wire is not run in parallel with any wires carrying AC voltage.

2. Disconnect all other sensors from the comfort zone I/O board and check to see if the sensor reading is still fluctuating.

3. Disconnect all other sensors from the comfort zone panel and check to see if the problem still exists.

4. Disconnect the 4 zone controller and re-wire it directly to the I/O board with a separate 5-conductor cable.

5. If all sensors are still fluctuating, replace the 4 zone controller.

6. If only 1 sensor is fluctuating, disconnect that sensor from the I/O board and re-wire it directly to the I/O board using a separate 2-conductor cable.

7. If the sensor still has the problem, replace the I/O board.

8. Verify if shielded or non-shielded cable is being used.

9. If shielded, follow through the remaining steps. If non-shielded, go to No. 6.

10. Verify that the shield is connected to the comfort zone panel and that the panel is properly

grounded to the chassis.

11. Remove the shield wire and check to see if the problem still exists.

12. Verify that the shield wire has been clipped off at the sensor end and is not touching any other

wires or any exposed metal.

13. Ensure that there is a solid electrical ground on the electric power box.

Table 13—Storage Failure Errors

Error Display (Dial Position T4) must be turned on.

SF ERROR CODE DESCRIPTION SOLUTION

01 Temperature Programming Error Reprogram the scheduled temperatures. 02 Time Period Programming Error Reprogram the scheduled time periods.

10 LAT Error

11 Device Address Error

12 Configuration Error

13 Configuration Error

14 Configuration Error

15 Configuration Error

16 Configuration Error Push HOLD button on/off.

17 Current Setpoints

18 Vacation Setpoints

21 Bypass Damper Total

22 Baud Rate

23 Dual Fuel Trip Temperature Error

24 Base Temperatures Error

Zone 1 Temperature Calibration Out of Range

Zone 2 Temperature Calibration Out of Range

Zone 3 Temperature Calibration Out of Range

Zone 4 Temperature Calibration Out of Range

Duct Temperature Calibration Out of Range

Outside Temperature Calibration Out of Range

Dx Coil Temperature Calibration Out of Range

Maximum/Minimum Temperature Setpoints

Maximum/Minimum Damper Ventilation

1. Turn selection dial to position 2.

2. Change temperature value.

3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.

1. Turn selection dial to position 3.

2. Change temperature value.

3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.

1. Turn selection dial to position 4.

2. Change temperature value.

3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.

1. Turn selection dial to position 5.

2. Change temperature value.

3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.

1. Turn selection dial to position 6.

2. Change temperature value.

3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.

1. Turn selection dial to position 7.

2. Change temperature value.

3. Return selection dial to any run mode position. Valid temperature range = 30°—120°F.

1. Turn selection dial to position 8.

2. Change temperature value.

3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.

1. Turn selection dial to position S.

2. Select variable number 6.

3. Enter a new value.

4. Return selection dial to any run mode position.

1. Turn selection dial to position S.

2. Verify correct address of the 4 zone controller is as shown in the Programming and Operation Section.

3. Verify smart sensor address(es) are as shown in the Programming and Operation Section.

1. Turn selection dial to position T2, T11, T12, T18, T20, T22, and T24.

2. Check and correct the configuration.

3. Return selection dial to any run mode position.

1. Turn selection dial to position T4, T5, T6, T13, and T17.

2. Check and correct the configuration.

3. Return selection dial to any run mode position.

1. Turn selection dial to position T7, T8, T9, T10, T19, T21, T23, and T25.

2. Check and correct the configuration.

3. Return selection dial to any run mode position.

1. Turn selection dial to position T26 and T27.

2. Check and correct the configuration.

3. Return selection dial to any run mode position.

1. Turn the error display T4 off.

2. Change any setpoint.

3. Turn the error display T4 on.

4. Return selection dial to any run mode position.

1. Turn the error display T4 off.

2. Turn the selection dial to Vacation.

3. Change any setpoint.

4. Turn the error display T4 on.

5. Return selection dial to any run mode position.

1. Turn selection dial to position S.

2. Change the maximum cooling setpoint (S2). Must be outside 14° range.

3. Change the minimum heating setpoint (S3). Must be outside 14° range.

4. Return selection dial to any run mode position.

1. Turn the selection dial to position S.

2. Change the maximum damper position (S4). Default = 15.

3. Change the vent damper position (S5). Default = 0.

4. Return selection dial to any run mode position.

1. Turn the selection dial to position 1.

2. Re-program bypass damper pressure relief limit according to instructions on Programming Section.

1. Turn selection dial to position T1.

2. Toggle the baud rate twice (T3).

3. Return selection dial to any run mode position.

1. Turn selection dial to position S7.

2. Change the value.

3. Return selection dial to any run mode position.

1. Turn selection dial to position 9.

2. Set base temperatures. Do not overlap with 14° maximum cooling/minimum heating set point

range.

3. Return selection dial to any run mode position.

Table 14—Hardware Failure Errors

Error Display (Dial Position T4) must be turned on.

HF ERROR CODE DESCRIPTION SOLUTION

40 Zone 1 Temperature Sensor

41 Zone 2 Temperature Sensor

42 Zone 3 Temperature Sensor

43 Zone 4 Temperature Sensor

44 Duct Temperature Sensor

45 Outside Air Temperature Sensor

46 Dx Coil Sensor

47 Bus Access Error

48 Zone 2 Smart Sensor

49 Zone 3 Smart Sensor

50 Zone 4 Smart Sensor

51 Clock Not Ready No correction possible. 52 Parker Custom Chip Not Ready No correction possible. Fatal error. 53 Non-Volatile RAM Not Ready No correction possible. Fatal error.

Bad sensor, shorted or open.

1. Check wiring and sensor.

2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F. Bad sensor, shorted or open.

1. Check wiring and sensor.

2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F. Bad sensor, shorted or open.

1. Check wiring and sensor.

2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F. Bad sensor, shorted or open.

1. Check wiring and sensor.

2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F. Bad sensor, shorted or open.

1. Check wiring and sensor.

2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F. Bad sensor, shorted or open.

1. Check wiring and sensor.

2. Replace failed sensor, if necessary. Valid temperature range = -30°—120°F. Bad sensor, shorted or open.

1. Check wiring and sensor.

2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F. Controller can not communicate on bus.

1. Check 3-wire bus between controller and comfort zone center.

2. Replace faulty controller/center boards, if necessary Cannot communicate with zone 2 smart sensor.

1. Turn toggle 13 off if there is no smart sensor attached to zone 2.

2. Check wiring between sensor and comfort center.

3. Verify correct address.

4. Must be addressed 1 less than 4 zone controller’s address. Cannot communicate with zone 3 smart sensor.

1. Turn toggle 14 off if there is no smart sensor attached to zone 3.

2. Check wiring between sensor and comfort center.

3. Verify correct address.

4. Must be addressed 2 less than 4 zone controller’s address. Cannot communicate with zone 4 smart sensor.

1. Turn toggle 15 off if there is no smart sensor attached to zone 4.

2. Check wiring between sensor and comfort center.

3. Verify correct address.

4. Must be addressed 3 less than 4 zone controller’s address.

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

FAN COILCOMFORT ZONE SYSTEM

R C

G O L E

STANDARD

SINGLE SPEED

AIR CONDITIONER

C Y

A93227

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

FAN COILCOMFORT ZONE SYSTEM

R C

Y/Y2

G O L

STANDARD

SINGLE SPEED

AIR CONDITIONER

A93296

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

FAN COILCOMFORT ZONE CENTER

R C

Y E

L O

2-SPEED

AIR CONDITIONER

(38TD)

R C

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

FAN COILCOMFORT ZONE CENTER

R C

2-SPEED

AIR CONDITIONER

(38TD)

R C

A94033

Latent Capacity Control (LCC)

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026)

Fig. 19—Typical Wiring Diagrams (Fan Coil with Air Conditioner)

A94032

FAN COILCOMFORT ZONE CENTER

2-SPEED

AIR CONDITIONER

(38TD)

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

R C

Y/Y2

C Y1 Y2

A94034

Fig. 19—Typical Wiring Diagrams (Fan Coil with Air Conditioner) Continued

COMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

STANDARD

SINGLE SPEED

AIR CONDITIONER

VARIABLE SPEED

FURNACE

R C

Y W G

(KGATT0101VSP)

RELAY

COIL

Black

Green

STANDARD

SINGLE SPEED

AIR CONDITIONER

FURNACECOMFORT ZONE CENTER

UNIT 24 VAC (R)

C Y

COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

R C

Y W G

A93220

NOTE: Put set-up Switch

No. 2 at the control board to the ON  position (up) when using Two Stage Relay Kit KGATT0101VSP Accessory (Optional)

CONTROL BOARD

(P5)

CONNECTION AT

A93219

STANDARD

SINGLE-SPEED

AIR CONDITIONER

FURNACECOMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

NOTE: Locking furnace into "low fire" may help prevent over conditioning

in the heating mode. This will allow the furnace to stage between low and high fire. Before using this feature read furnace Installation Instructions for two-stage operation. Connect "W2" from the Comfort Zone Center to "W2" on the furnace control board.

See Furnace Installation Instructions For Details Involving Set-Up Switch Configuration and Two-Stage Furnace Operation.

Red Yellow Blue White Brown Green Orange Black

C Y/Y2 W/W1

2-SPEED

AIR CONDITIONER

COMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1)

C Y

COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

VARIABLE SPEED

FURNACE

R Y

G C

(38TD)

A94036

A94035

Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner)

COMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

NOTE: Put set-up switch No. 2

at the control board to the ON position (up) when using Two Stage Relay Kit KGATT0101VSP Accessory (Optional).

Red Yellow Blue White Brown Green Orange Black

AIR CONDITIONER

VARIABLE SPEED

FURNACE

(KGATT0101VSP)

RELAY

COIL

Black

CONNECTION AT

CONTROL BOARD

AIR CONDITIONER

FURNACECOMFORT ZONE CENTER

2-SPEED

(38TD)

Green

(P5)

2-SPEED

(38TD)

A94037

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

Latent Capacity Control (LCC)

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026)

2-SPEED

AIR CONDITIONER

FURNACECOMFORT ZONE CENTER

R C

(38TD)

C G W Y

A94038

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

Latent Capacity Control (LCC)

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026)

R C

FURNACECOMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

C Y/Y2 W/W1

2-SPEED

AIR CONDITIONER

(38TD)

R C

G W

NOTE: Locking furnace into "low fire" may help prevent over conditioning

See Furnace Installation Instructions For Details Involving Set-Up Switch Configuration and Two-Stage Furnace Operation.

A94040

A94039

Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) Continued

2-SPEED

AIR CONDITIONER

(38TD)

FURNACECOMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

NOTE:

Locking furnace into "low fire" may help prevent over conditioning in the heating mode. This will allow the furnace to stage between low and high fire. Before using this feature read furnace Installation Instructions for twostage operation. Connect "W2" from the Comfort Zone Center to "W2" on the furnace control board.

See Furnace Installation Instructions For Details Involving Set-Up Switch Configuration and TwoStage Furnace Operation.

Red Yellow Blue White Brown Green Orange Black

R C

W/W1

Y/Y2

Latent Capacity Control (LCC)

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026)

R C

A93219

Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) Continued

STANDARD

SINGLE SPEED

HEAT PUMP

FAN COILCOMFORT ZONE CENTER

FAN COILCOMFORT ZONE SYSTEM

STANDARD

SINGLE SPEED

HEAT PUMP

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

R C

W2 W3

G O

R C

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

O L E

Red Yellow Blue White Brown Green Orange Black

R C

Y/Y2

G O

R C

A93242

A93243

2-SPEED

HEAT PUMP

(38YD)

FAN COILCOMFORT ZONE SYSTEM

R C

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

FAN COILCOMFORT ZONE SYSTEM

R C

G O

2-SPEED

HEAT PUMP

(38YD)

R C

Latent Capacity Control (LCC)

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026)

Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump)

A94043

A94042

2-SPEED

HEAT PUMP

(38YD)

FAN COILCOMFORT ZONE SYSTEM

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

R C

Y/Y2

G O

C Y1 Y2

A94044

Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump) Continued

COMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

SINGLE SPEED

VARIABLE SPEED

FURNACE

STANDARD HEAT PUMP

C O Y

COMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

(KGATT0101VSP)

SINGLE SPEED

VARIABLE SPEED

FURNACE

R Y

G C

STANDARD

HEAT PUMP

C O Y

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent.

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

RELAY

COIL

A93234

STANDARD

SINGLE SPEED

HEAT PUMP

NOTE: Put set-up Switch No. 2 at the control board to the ON  position (up) when using Two Stage Relay Kit KGATT0101VSP Accessory (Optional)

FURNACECOMFORT ZONE CENTER

R Y

C O

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Black

Green

CONNECTION AT 

CONTROL BOARD

(P5)

R1 = Relay, DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent.

Red Yellow Blue White Brown Green Orange Black

FURNACECOMFORT ZONE CENTER

Y/Y2 W/W1

G C

A93298

STANDARD

SINGLE-SPEED

HEAT PUMP

R Y

A93235

NOTE: Locking furnace into "low fire" may help prevent over conditioning

See Furnace Installation Instructions For Details Involving Set-Up Switch Configuration and Two-Stage Furnace Operation.

Fig. 22—Typical Wiring Diagram (Furnace with Heat Pump)

A94045

COMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

VARIABLE SPEED

FURNACE

R C

G W Y

2-SPEED

HEAT PUMP

(38YD)

R C

L O

COMFORT ZONE CENTER

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

(KGATT0101VSP)

RELAY

COIL

Black

Green

VARIABLE SPEED

FURNACE

C G W

2-SPEED

HEAT PUMP

(38YD)

R C

L O

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent.

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

(P5)

A94047

A94046

2-SPEED

HEAT PUMP

(38YD)

CONNECTION AT

CONTROL BOARD

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent.

NOTE: Put set-up Switch No. 2 at the control board to the ON  position (up) when using KGATT0101VSP Accessory (Optional)

FURNACECOMFORT ZONE CENTER

R C

C G W Y

Latent Capacity Control (LCC)

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026)

Fig. 22—Typical Wiring Diagrams (Furnace with Heat Pump) Continued

A94048

2-SPEED

HEAT PUMP

FURNACECOMFORT ZONE CENTER

(38YD)

FURNACECOMFORT ZONE CENTER

2-SPEED

HEAT PUMP

(38YD)

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

Latent Capacity Control (LCC)

R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) or Equivalent. H = Humidistat, opens on humidity rise (HL38MG026)

Fig. 22—Typical Wiring Diagrams (Furnace with Heat Pump) Continued

R C

C G W

W2 Y1

UNIT 24 VAC (R) COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O)

RV-HEAT (O)

Red Yellow Blue White Brown Green Orange Black

R C

Y/Y2

W/W1

R C

Y2 W3 W2

NOTE: 38YD – with dual fuel, use the 38YD “Furnace Interface” and

“Balance Point” feature on the heat pump control to operate dual fuel option. Configure the 4-Zone controller to act as if it were controlling a single speed heat pump. Turn (T-6) ON. Turn (T-9 & T-26) OFF. Set (S-7) to 0. (Let the 38YD perform the dual fuel optimization).

In addition, lock furnace into “low fire”. This may help prevent over conditioning during the back-up heat (furnace) mode. This will also allow the furnace to stage between low and high fire. Before using this feature read furnace Installation Instructions for two-stage operation. Connect “W2” from the Comfort Zone Center to “W2” on the furnace control board.

See Furnace Installation Instructions For Details Involving Set-Up Switch Configuration and Two-Stage Furnace Operation.

38YDA – with dual fuel, same as above, however in addition if (T-26) is turned “ON”, and stage 2 latch pot is set to zone position,

A94049

4 stages of heat are possible. See Heat Pump Installation Instructions For Details Involving

Two-Speed Configuration and Operation.

A94312

Comfort Zone Configuration Table

TOGGLE DESCRIPTION

T1 Timeguard Override OFF T2 Celsius Temperature Display OFF T3 2400 Baud Rate ON T4 Error Code Display ON T5 Enable Broadcast ON T6 Heat Pump Operation OFF T7 Outside Air Temp Sensor Attached OFF T8 Comfort Trend Setting ON

T9 Auto Fan Off For Heat OFF T10 High/Low Temperature Limits ON T11 Installer Switch Lockout OFF T12 Force Outside Air Ventilation OFF T13 Smart Sensor Attached For Zone 2 OFF T14 Smart Sensor Attached For Zone 3 OFF T15 Smart Sensor Attached For Zone 4 OFF T16 Zone 2 Active ON T17 Zone 3 Active ON T18 Zone 4 Active ON T19 Economizer OFF T20 Alternating Display OFF T21 Outside Air Damper Attached OFF T22 System Mode Reselect OFF T23 System Error Checking OFF T24 50 Hz Operation OFF T25 Ventilation Mode OFF T26 Two-Stage Heat Pump OFF T27 Dx Sensor For LAT Checking OFF T28 Cool Without Fan OFF

SETTING

S-1 4 Zone Controller Bus Address 04 S-2 Max Cooling Setpoint 85 S-3 Min Heating Setpoint 65 S-4 Max Damper Position 15 S-5 Ventilation Damper Position 00 S-6 High Temp Trip Limit 105 S-7 Dual Fuel Setpoint 00

ROTARY

09 Base Temp Setpoint Scale

08 Calibrate Dx Coil Sensor

07 Calibrate Outside Air Temp Sensor

06 Calibrate Duct Temperature Sensor

05 Calibrate Zone 4 Temp Sensor

04 Calibrate Zone 3 Temp Sensor

03 Calibrate Zone 2 Temp Sensor

02 Calibrate Zone 1 Temp Sensor

01 Damper Service Position

FACTORY DEFAULT

RECORD

JOB SETTING

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

Book 1144 Tab 3a 5a 2a 5a

PC 101 Catalog No. 809-568 Printed in U.S.A. Form ZONEKIT4-1SI Pg 32 7-95 Replaces: 920415-3SI

Carrier ZONEKIT4ZCAR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual