Robertshaw SlimZone Premier, SZP-3, SZEX, DSL-520P Installation And Operation Manual

ZONE CONTROL SYSTEM

INSTALLATION AND OPERATION MANUAL

SlimZone Premier i

TABLE OF CONTENTS

1. INTRODUCTION.............................................................................................................................1

1.1 IMPORTANT NOTE....................................................................................................................................1

1.2 FEATURES.................................................................................................................................................1

1.3 SAFETY INSTRUCTIONS ..........................................................................................................................2

2. APPLICATION AND DESIGN CONSIDERATIONS ........................................................................2

3. COMPONENT REQUIREMENTS...................................................................................................3

3.1 BASIC SYSTEM ........................................................................................................................3

3.2 EXPANDER MODULE...............................................................................................................3

3.3 ENVIRONMENTAL MODULE....................................................................................................4

3.4 SIZING TRANSFORMERS........................................................................................................4

3.5 SIZING DAMPERS ....................................................................................................................4

3.6 TYPICAL SYSTEM DIAGRAM...................................................................................................4

4. SYSTEM INSTALLATION................................................................................................................6

4.1 SLIMZONE PREMIER CONTROL MODULE (SZP) ..................................................................................6

4.1.1 REMOVAL AND INSTALLATION OF THE DOOR .........................................................................6

4.1.2 INSTALLATION OF THE BACKPLATE..........................................................................................6

4.2 THERMOSTAT INSTALLATION: DSL-520P...............................................................................................7

4.3 DAMPERS ..................................................................................................................................................7

4.4 WIRING INFORMATION..........................................................................................................................10

4.5 CURRENT LIMITED OUTPUT TERMINALS ...........................................................................................10

4.6 SLIMZONE ENVIRONMENTAL MODULE (SZEM)..................................................................................11

5. SYSTEM OPTIONS AND OPERATION........................................................................................12

5.1 INTERACTION BETWEEN MODULES ...................................................................................................12

5.1.1 SZP CONTROL MODULE............................................................................................................12

5.1.2 DSL-520P ZONE THERMOSTAT.................................................................................................13

5.1.3 SZEM ENVIRONMENTAL MODULE ...........................................................................................14

5.2 SYSTEM PROGRAMMING......................................................................................................................14

5.2.1 PROGRAMMING FEATURES .....................................................................................................14

5.2.2 SCHEDULES................................................................................................................................14

5.2.3 FACTORY DEFAULTS.................................................................................................................15

5.3 USER OPTIONS......................................................................................................................................15

5.4 HVAC OPTIONS.......................................................................................................................................15

5.5 CONTROL METHODS.............................................................................................................................16

5.5.1 TIMESHARE.................................................................................................................................16

5.5.2 DIFFERENTIAL............................................................................................................................16

5.6 SEQUENCE OF OPERATION .................................................................................................................17

5.6.1 TIMESHARE MODE........................................................................................................... ..........17

5.6.2 DIFFERENTIAL MODE ................................................................................................................18

5.7 USER INTERFACE..................................................................................................................................18

5.7.1 LCD SYMBOL DESCRIPTION .....................................................................................................18

5.8 FLOW DIAGRAM .....................................................................................................................................19

ii SlimZone Premier

6. START UP AND TEST...................................................................................................................22

TROUBLESHOOTING GUIDE...............................................................................................................26

GLOSSARY ............................................................................................................................................27

APPENDIX A: LIST OF FIGURES........................................................................................................28

APPENDIX B: LIST OF TABLES ..........................................................................................................28

ZONE SCHEDULE.................................................................................................................................29

ZONE DIAGRAM....................................................................................................................................30

WARRANTY ...........................................................................................................................................31

SlimZone Premier 1

1. INTRODUCTION

The SlimZone Premier (SZP) is a commercial/residential HVAC (Heating/Ventilation/Air
Conditioning) zone control system which allows control of up to nineteen (19) zones with a
single HVAC system. Each zone is controlled by its own zone thermostat and motorized
damper. The control module monitors the zone thermostats, sets the HVAC system in the
appropriate mode of operation, and energizes the number of stages of heating or cooling
accordingly.

The basic system consists of the main SlimZone Premier control module (SZP-3) which may
control up to three (3) zones. The modular nature of this system allows the expansion of the
number of controlled zones by simply adding SlimZone Expander modules (SZEX) which add
two (2) zones to the system per module. Up to eight (8) expander modules may be connected
to the control module, allowing a total of nineteen (19) zones.

Only DSL-520P communicating zone thermostats may be used with the SlimZone Premier
Control module. Each zone to be controlled requires a zone thermostat.

The user interface to the SlimZone Premier consists of a four (4) button keypad and a four (4)
line by twenty (20) character LCD display, through which all system information may be viewed
or modified.

1.1 IMPORTANT NOTE

IT IS IMPORT ANT THAT YOU READ AND UNDERSTAND THIS MANUAL SUPPLIED WITH
THE SLIMZONE PREMIER, AS WELL AS THE HVAC EQUIPMENT MANUFACTURER’S
INFORMATION, BEFORE BEGINNING INSTALLATION OF THE SYSTEM.

1.2 FEATURES

• Ultra slim styled cabinet (8-7/8" (22.5cm)W x 9-1/2" (24cm)H x 1-3/4" (4.5cm)D)

•Two (2) modes of operation: timesharing or differential

• Four (4) lines by twenty (20) characters backlit LCD display

• User friendly interface which allows access to features such as:

- panel setup

- system programming (temperatures, schedules, 2 or 4 events per day)

- 12 or 24 hour clock

- temperature display in °F or °C

- equipment test

• LED (light emitting diode) status indicators on all system functions

• Solid state control module with current limited relay outputs

• Controls heat pumps, cooling units and gas, oil or electric furnace units

• Number of controlled zones expandable to nineteen (19) in increments of two (2) zones by
ordering the SlimZone Expander module (SZEX)

• Controls up to four (4) stages of heating and three (3) stages of cooling in heat/cool mode

• Controls up to three (3) stages of heating and three (3) stages of cooling in heat pump mode

•Two (2) speed fan output

• Forty-five (45) second fan purge into last zone(s) calling

• Constant or automatic fan during occupied cycle

•Two (2) or three (3) wire damper capability

• Perimeter heat control from zone thermostats

•High/Low limit downstaging

• High/Low balance control

2 SlimZone Premier

• Minimum on/off times (short cycle protection)

• Occupied/unoccupied cycle capability

• Manual or automatic changeover

• Smoke detector input

•All low voltage wiring

• No batteries required

1.3 SAFETY INSTRUCTIONS

• Sudden equipment operation may cause serious injury from moving parts. Leave power
disconnected until installation is complete.

• Sharp edges may cause damage to wires. Use care during the installation.

• Installation must be done in accordance with all applicable codes and regulations.

•Installer should touch a grounded metal object before handling any of the modules in the
SlimZone Premier control system, to avoid potential loss of internal computer programs due to
static discharge.

2. APPLICATION AND DESIGN CONSIDERATIONS

A. Only DSL-520P communicating zone thermostats may be used.
B. Air conditioning control systems require that the air handling equipment be properly sized for

the application; otherwise, satisfactory temperature control may not be realized.

C. It is recommended that system installations be limited to thirty (30) tons of equipment capacity.

Enerstat dampers are designed to work only with low pressure systems (1.0" WC or less).

D. Oversizing of HVAC equipment is not recommended. In most cases it is better to slightly

undersize than oversize.

E. Extra consideration should be given in applications that require lar ge amounts of cooling in cold

weather, such as buildings with a center or core area.

F. At least two (2) stages of cooling and/or compressor unloading are highly desirable.
G. Hot gas bypass should be considered on some commercial systems.
H. If the HVAC unit is supplied with an economizer, it is recommended that the economizer

package be equipped with a relief air damper.

I. The pressure drop across typical dampers is negligible and normally is not a factor when sizing

or calculating branch duct CFM.

J. Balancing dampers should be installed ahead of all motorized zone dampers.

K. Zone dampers should be installed ten (10) feet back from discharge grille when possible.

L. Flex or lined duct is recommended on the last five (5) feet.

M. A bypass damper must be installed on all systems of three (3) zones or more.

N. The thermostats and motorized dampers may be located up to 300 feet (90m) from the control

module, using nonshielded 3 (dampers) and 4 (thermostat) conductor 18 - 24AWG copper
wires.

O. A maximum load of 2.5 Amps may be switched by the output terminals, which complies with

Class 2 wiring code.

P. System wires should be tagged to match the module terminal designations.

Q. The addition of equipment heating and cooling limits, as provided by the SlimZone

Environmental module (SZEM), is strongly recommended and will greatly help in preventing
temperature swings as well as constant heating/cooling changeover.

R. All zones served by a SlimZone control module should have the same basic load characteristics

(i.e., do not put 4 zones on an east exposure, and the 5th zone on a southwest exposure).

S. All references to typical dampers refer to Enerstat model dampers.

T. Zones 14-19 adher e to the same schedule and act as a single call for equipment. Although they

are separate physical zones they act as a single zone when communicating with the SZP
Control module. It is recommended that when considering the layout of your zone system,
zones 14-19 should be assigned to areas of low priority.

3. COMPONENT REQUIREMENTS

3.1 BASIC SYSTEM

The basic system consists of the main SlimZone Premier Control module (SZP-3: 3 zone
module) and its supporting components.

ITEM QUANTITY CONSIDERATIONS

SZP-3 control module one (1) contains three (3) zones
DSL-520P zone thermostat one (1) per zone use standard nonshielded 4

conductor 18-24AWG copper wire

Motorized zone dampers one (1) per zone (minimum) use standard nonshielded 3

conductor 18AWG copper wire

24VAC transformers one (1) for main module 75VA

zone dampers powered by refer to section 3.4 for sizing
separate transformer(s)

Table 3.1: SlimZone Premier Basic Components

3.2 EXPANDER MODULE

Each SlimZone Expander module (SZEX) consists of two (2) additional zones. For each
expander module added, the following items are required:

ITEM QUANTITY CONSIDERATIONS

SZEX expander module one (1) contains two (2) zones
DSL-520P zone thermostat one (1) per zone use standard nonshielded 4

conductor 18-24AWG copper wire

Motorized zone dampers one (1) per zone (minimum) use standard nonshielded 3

conductor 18AWG copper wire

24VAC transformers SZEX powered by SZP N/A

zone dampers powered refer to section 3.4 for sizing
by separate transformer(s)

Table 3.2: SlimZone Expander Module Components

Note: Expander module itself does not require a transformer as it is powered by the control

module.

SlimZone Premier 3

4 SlimZone Premier

3.3 ENVIRONMENTAL MODULE

ITEM QUANTITY CONSIDERATIONS

SZEM environmental module one (1) contains two (2) remote temperature

probes, and PVC tubing for static
pressure

use standard nonshielded 2
conductor 18-24 AWG copper wire
to connect to SZP

Motorized bypass damper one (1) - may require two (2) use standard nonshielded 3

in larger systems conductor 18AWG copper wire

24VAC transformer one (1) 20VA (300mA)

Table 3.3: SlimZone Environmental Module Components

3.4 SIZING TRANSFORMERS

To avoid unsatisfactory operation DO NOT power the SZP control module with the HVAC
equipment transformer. A dedicated field supplied 24VAC, 75VA transformer is recommended
to power the control module, which in turn may have up to nineteen (19) zones connected to
it. Zone dampers require separate transformers.

Zone dampers may be powered by individual zone transformers or by a single transformer. A
single transformer used to power more than one damper must have a sufficient power rating
(VA) to energize all dampers. To determine the total power requirements, add each damper’s
VA rating. Typical dampers require a maximum of 12VA each. This total must not exceed the
VA rating of the transformer.

3.5 SIZING DAMPERS

It is important that dampers be sized according to system ductwork specification (CFM) and
balanced in compliance to SMACNA, ACCA and ASHRAE guidelines in order for the control
system to properly control comfort in each zone. Typical dampers are nonmodulating and are
available in two (2) wire (powered closed, spring return to open), or three (3) wire (powered
closed, powered open) configuration. The pressure dr op across Enerstat dampers is negligible
and normally not a factor when sizing or calculating branch duct CFM. Typical dampers are
designed to work with low pressure systems (1.0" WC) or less.

3.6 TYPICAL SYSTEM DIAGRAM

Figure 3.1 illustrates a typical SlimZone Premier installation, including the optional
environmental module (SZEM) and its accessories.

Figure 3.1: Typical System Diagram

SlimZone Premier 5

AND ACCESSORIES.

OPTIONAL ACCESSORIES.

6 SlimZone Premier

4. SYSTEM INSTALLATION

4.1 SLIMZONE PREMIER CONTROL MODULE (SZP)

4.1.1 REMOVAL AND INSTALLATION OF THE DOOR

Installer should touch a grounded metal object before handling the control panel to avoid
potential loss of programming due to static discharge.

NOTE:

The door is hinged on the left

side.

Open the door by gently pulling on the bottom right corner, applying finger pressure only. The
door may be removed once opened by applying a slight backward pressure. Replace the door
by hooking around the tabs on the left side of the backplate and snapping back into place.

4.1.2 INSTALLATION OF THE BACKPLATE

The control module can be mounted on any interior surface. Use the mounting holes on the
backplate of the main unit and the two (2) mounting holes on the expander modules (if so
equipped) to secure using the supplied #8 screws (Figure 4.1). Mount the control module in a
location that provides easy access for service. Do not mount the control module on any part
of the HVAC equipment or where moisture may be present. There are several round holes and
knock-outs for through-the-wall or surface wiring.

CAUTION: Use proper care when removing upper or lower end cap knock-outs. Apply a
sharp rap with the butt end of a screwdriver to remove. Do not use sharp instruments to
remove the knock-outs as internal damage may occur.

SZP-3 SHOWN WITH ONE

EXPANDER MODULE (SZEX)

Figure 4.1: Mounting Holes

4.2 THERMOSTAT INSTALLATION: DSL-520P
LOCATION

The most important consideration in installing your DSL-520P Communicating Zone thermostat
is where to locate the unit. The location can radically affect the operation of the thermostat.
To ensure proper operation, the thermostat should be mounted on an inside wall in a frequently
occupied area of the zone. In addition, its position must be at least 18 inches (46cm) from any
outside wall, and approximately 5 feet (1.5m) above the floor in a location with freely circulating
air of an average temperature. The control module has four (4) terminals at each zone terminal
strip for connecting the thermostat.

CAUTION: Ensure that the following polarity is respected (refer to Figure 4.2):

DSL-520P.......SZP

1 ..................... 1

2 ..................... 2

3 ..................... 3

4 ..................... 4

Refer to the manual provided with the DSL-520P thermostat for detailed instructions.

4.3 DAMPERS

Typical dampers are designed to work with low pressure systems (1.0" WC or less). Balancing
dampers should be installed ahead of all zone dampers. Zone dampers should be installed
10ft. (3m) back from discharge grille. A flex or lined duct is recommended for the last 5ft.
(1.5m). Enerstat dampers are nonmodulating dampers. Two (2) wire dampers are powered
closed and spring return open. Three (3) wire dampers are power ed closed and power ed open.
For applications requiring minimum air ventilation, an adjustment screw is available to set the
damper to a specified minimum open position. Enerstat dampers are shipped from the factory
with the minimum position adjustment screw in the fully closed position; allow for a 3% to 5%
leakage with damper closed. The control module has five (5) terminals at each zone terminal
strip for damper connections which are as follows (refer to Figure 4.2):

24L: 24VAC transformer, 24N: 24VAC transformer common
PC: power damper closed 24N: common
PO: power damper opened

Power to the dampers is provided by the 24L and 24N terminals at each zone terminal strip.
Refer to section 3.4 for information on sizing transformers.

High ambient temperatures that may be encountered (in an attic for instance), will have an
impact on the current capabilities of the panel and the number of zone dampers that can be
connected to the panel. The SZP is powered by a single 75VA transformer. This transformer is
used to power the panel and thermostats. The ambient temperature will have an impact on the
polyfuse current limiting protection. The maximum number of dampers that can be connected
per zone using Enerstat dampers are:

At 25°C (77°F) At 40°C (104°F)
5 E Series dampers 4 E Series dampers
4 E2 Series dampers 3 E2 Series dampers
5 E3 Series dampers 4 E3 Series dampers

If additional dampers are required you must use a relay to energize these additional
dampers from an independent source.

SlimZone Premier 7

8 SlimZone Premier

Figure 4.2: SZP Wiring Diagram