Zonex System 2000, System 1000 Design & Installation Manual

Design & Installation for

Zonex Systems

System 2000

2-20 Zone Auto Changeover

Part #101ASIM

Rev. September 2003

System 1000

2-7 Zone Manual Changeover

TABLE OF CONTENTS

System 2000

System Operation.................................................................................................................................................................1

Components.........................................................................................................................................................................1

Component Selection Guide .................................................................................................................................................2

System 2000 System Controllers...........................................................................................................................................3

Gas/Electric (101ASSB).............................................................................................................................................3-5

Heat Pump (101AACBHP) .........................................................................................................................................5-7

Startup.................................................................................................................................................................................8

System 1000

System Operation.................................................................................................................................................................9

Components.........................................................................................................................................................................9

Component Selection Guide ...............................................................................................................................................10

System 1000 Switching Centers

Gas/Electric (SYGE)..............................................................................................................................................11, 12

Heat Pump (SYHPA)..............................................................................................................................................12-14

Startup...............................................................................................................................................................................15

Zone Thermostats ...........................................................................................................................................................16, 17

Remote Sensors .................................................................................................................................................................17

Zone Dampers .......................................................................................................................................................................18

Round Zone Dampers..................................................................................................................................................18, 19

Rectangular Zone Dampers..........................................................................................................................................20, 21

Sizing Zone Dampers .........................................................................................................................................................22

Wiring Zone Dampers........................................................................................................................................................22

Damper Installation Notes..................................................................................................................................................22

Paralleling Zone Dampers..................................................................................................................................................23

Bypass Dampers ....................................................................................................................................................................23

Barometric ..................................................................................................................................................................23, 24

Electronic ....................................................................................................................................................................25, 26

Bypass Position Indicators ..........................................................................................................................................26

Paralleling Bypass Dampers........................................................................................................................................26

Bypass Damper Static Pressure Controller .......................................................................................................................27

Capacity Controllers .............................................................................................................................................................28

101CAPGE....................................................................................................................................................................29, 30

TRLAT..........................................................................................................................................................................31, 32

TRFPC................................................................................................................................................................................32

SYCAP ..........................................................................................................................................................................33, 34

101ALAS ............................................................................................................................................................................35

CAPL-2.........................................................................................................................................................................36, 37

CAPL-4.........................................................................................................................................................................38, 39

Capacity Controllers Installation.........................................................................................................................................40

Capacity Controllers, Setpoints, Calibration........................................................................................................................41

Important Diagrams

Five Wire Link....................................................................................................................................................................41

Transformer/Fuse Sizing ....................................................................................................................................................42

Application Schematics ................................................................................................................................................42, 43

SYSTEM 2000

The System 2000 is a light commercial/residential zone control system.
It enables a single HVAC unit to be controlled by up to twenty zone (room)
thermostats. System 2000 is a vote based, auto changeover system. The
system operates on a first call, first served majority wins on changeover
strategy. To provide economical, effective and simplified remote control
and monitoring capability of one or more System 2000 zone control sys-

tems, the ZonexCommander may be used to manage up to 80 thermostat
schedules. The ZonexCommander is a Window’s based thermal manage­ment system, which can integrate gas/electric and heat pump zone sys­tems to include stand alone HVAC systems. For modulating communi-

cating control, use the ZonexCommander (Plus).

System 2000

Zonex Systems Supplied Components

System Controllers ..............................................................Pages 3- 7

Zone Thermostats ...............................................................Pages 16-17

Zone Dampers ....................................................................Pages 18-23

Bypass Dampers .................................................................Pages 23-27

Capacity Controllers............................................................Pages 28-41

System 2000

Field Supplied Components

Thermostat Wire........................................................................Page 41

24V Transformers and Fuse.......................................................Page 42

CONCEPTUAL

DRAWING ONLY

Refer to System 2000

Controller Section for

Wiring Information

SYSTEM OPERATION

The System Controller communicates with the Zone Dampers and Zone
Thermostats via a patented Five-Wire Link. The Five-Wire Link is daisy
chained from damper to damper using standard five-conductor
thermostat wire. The System Controller polls every zone every 120 sec­onds and registers the number of thermostats calling for heating and
cooling. The System Controller then runs the HVAC/Heat Pump unit in the
mode with the most calls. If the majority changes, the System Controller
will automatically change over to the new mode of operation.

The Zone Dampers are open for the zones calling and closed for the
zones not calling for the operating mode. When the HVAC/Heat Pump unit
is not running, all Zone Dampers are open to provide ventilation if the
indoor blower fan is running continuously.

While the unit is running, the Capacity Controller monitors the leaving air
temperature from the unit and will cycle the HVAC/Heat Pump unit off
and on to maintain the air temperature within a preset range to eliminate
coil freeze-up and premature heat exchanger failure.

1

SYSTEM 2000 COMPONENT SELECTION GUIDE

Auto Changeover for 2 to 20 Zones

START

GAS ELECTRIC

System Controller

(101ASSB)

Capacity Controller

Single Stage(TRLAT) or (101CAPGE)

2-Stage (CAPL-2)

3- or 4-Stage (CAPL-4)

HEAT PUMP

System Controller

2 Stage Heat/Cool with Auxiliary Heat

(101AACBHP)

Capacity Controller

101ALAS (Included with Controller)

❶

ZONE THERMOSTATS

Communicating Digital Programmable Auxiliary Heat

(DIGICOM) (101DIGI) (101PROG) for reheat/baseboard

COMMAND CENTER

(101CEC Communication Package,

one per 20 thermostats)

5 TONS AND UNDER OVER 5 TONS

Low Pressure Dampers Medium Pressure Dampers

Round (101ARZD size) up to .5” SP Round (101AMPD size) up to 1.75” SP

Rectangular (101EC W x H) up to .5” SP Rectangular (101MRTD W x H) up to 1” SP

ZONE DAMPERS

Heavy Duty Rectangular (101CD W x H) to 1.75” SP

(101DIGITS)

Optional
Outdoor T-Stat
(field supplied)

❷

12 X (Number of Dampers) = VA for the 6 X (Number of Dampers) =VA for the

24V System Transformer (Field Supplied) 24V System Transformer (Field Supplied)

BYPASS DAMPERS

5 TONS AND UNDER

Barometric Bypass Damper

Round (101ABBD size)
Rectangular RBB W x H

COMPLETE SYSTEM

❶ Some Heat Pumps utilize Gas/Electric thermostats, typically units over 7.5 tons.
For this application, use the Gas/Electric parts selection and field modify the capacity
control heat cutoff setpoint to 118° F.

OVER 5 TONS

Electronic Bypass Damper

Round (STMPD size)

Rectangular (STCD W x H)

Static Pressure Controller (101ASPC)

24V, 40VA Independent Transformer

for bypass (Field Supplied)

❷ Use heavy duty rectangular dampers on systems of 7.5 tons or larger

2

SYSTEM 2000 CONTROLLERS

Dimensions 7” x 7” x 2.5”

Gas Electric System Controller

SYSTEM 2000 CONTROLLERS – GAS/ELECTRIC 101ASSB

OVERVIEW

The 101ASSB is a Gas/Electric System Controller that will control up to
20 zones for the System 2000 zoning system. The System Controller
selects the mode of operation based on a majority calls basis. It is
used in conjunction with a Capacity Controller. The Capacity Controller
controls the HVAC system staging. Capacity Controllers are available for
one, two, three and four stage systems. Refer to Capacity Controller
section (pg. 28) for further information.

The 101ASSB is a vote based, auto changeover System Controller. It polls
each zone every 120 seconds, registering heat or cool calls. Majority
wins, and the Controller operates the HVAC system in that mode until all
calls are satisfied or it detects a majority of offsetting calls.

The System Controller should be located in an accessible, conditioned
space. The Controller does not sense temperature; it simply receives data
from the zone thermostats. The Controller communicates to the zone
dampers and thermostats through a five-wire link. These five wires are
daisy chained to each zone damper. This simple patented wiring process
eliminates home run wiring.

OPERATION

When heating or cooling calls are sent to the System Controller, the
controller will treat these calls as votes.

Heat Pump System Controller

(101ASSB)

HEAT CALLS– If the majority of calls are for heat, the System Controller

will turn on the heat. If the fan switch is set for auto, the bonnet control
or a delay relay will start the fan. When all heating calls are satisfied or
the majority changes to cooling, the gas valve will turn off.

CHANGEOVER – If the system is running in one mode and the majority
of calls changes to the other mode, a timer will start. The System Con­troller will give the current operating mode another 4 minutes to try and
satisfy the zone(s). It will then go into a 4-minute purge cycle before
switching modes.

PURGE MODE – When a heat or cool call is satisfied or before chang­ing modes, the System Controller will go into a 4-minute purge cycle.
The compressor or gas valve will turn off and the indoor blower will con­tinue to run. The dampers of any zone thermostat not satisfied in the
previous mode will remain open. This allows the supply air to adjust
to room temperature before changeover or ventilation while providing a
time delay to prevent short cycling.

VENTILATION– When no zones are calling, all zone dampers open after
the purge mode. This permits ventilation in all zones if the blower fan is
on continuously.

with LAS Sensor

(101AACBHP)

COOL CALLS – If the majority of calls are for cooling, the System

Controller will turn on the compressor and fan. The air conditioner will
continue to operate until all cooling calls are satisfied or the majority
changes to heating.

3

RW1Y1G

TB2

ON

OFF

OFF

OFF

AUTO

ON

AUTO

TB1

TR2 TR1

1

TC2 TC11SYWRdBG

A

J

C

B

D

E

I

H

G

F

101ASSB

DELAY

HEAT

COOL

DAMPER

UNIT

J1

J2

SET BACK

FAN

HEAT

COOL

PWR

SYSTEM 2000 CONTROLLERS – GAS/ELECTRIC 101ASSB

COMPONENTS

The 101ASSB System Controller consists of the following:

A. TB1 (Terminal Block 1): Wires to daisy chain, transformer

and time clock.
TC1, TC2 – Time clock switch terminals. Used for Select-Temp
system only.
S – Nite call. Used for Select-Temp system only.
Y – Cool call.
W – Heat Call.
Rd – Damper close signal.
B – 24V AC common. Same terminal as TR2.
G – 24V AC hot. Same terminal as TR1 when PWR switch ON.
TR2 – 24V AC common.
TR1 – 24V AC hot.

B. Jumpers J1 and J2:

J1 – Not used.
J2 – Not used for System 2000. Used for Select-Temp system
only.

C. Microcontroller: Responsible for zone communication, activation

and control of outputs based upon zone demand and leaving air
temperature. Occasionally software upgrades may become avail­able. If so, the 101ASSB software can be field upgraded by chang­ing this microcontroller.

D. Off board fuse: One amp. Protects Y and W terminals of TB1.
E. Status lights: Refer to status light section for details.
F. TB2 (Terminal Block 2): Wires to Capacity Controller and

HVAC unit.
R – HVAC unit 24V AC power
W1 – Heat enable
Y1 – Cool enable
G – Indoor blower fan enable

G. FAN switch:

AUTO – Turns on indoor blower fan when unit is running in cool
mode.
ON – Indoor blower fan runs continuously.

H. COOL and HEAT mode switches:

AUTO – Accepts calls from thermostats.
OFF – Ignores calls.

I. Power switch. When on, applies 24V AC power to G of TB1.
J. On board fuse. One amp. Protects 101ASSB board only.

STATUS LIGHTS

DELAY On when HVAC unit energized. Flashing when in purge/delay mode.
HEAT* On in heat mode.
COOL* On in cool mode.
DAMPER When on, dampers of zones not calling for present mode are closed.
UNIT On when HVAC unit energized.

*MODE LIGHTS TOGGLE BETWEEN HEAT AND COOL EVERY 120 SECONDS. THIS INDICATES THE SYSTEM CONTROLLER IS POLLING FOR HEAT OR COOL CALLS.

Delay Heat* Cool* Damper Unit

01000Heat, no calls HVAC unit off. All dampers open.
00100Cool, no calls HVAC unit off. All dampers open.
11011Heat call Heat energized. Heat calling zone dampers open.

10111Cool call AC energized. Cool calling zone dampers open.
FLASH 1010Purge heat Blower fan on, HVAC unit off. Heat calling zone dampers open.
FLASH 0110Purge cool Blower fan on, HVAC unit off. Cool calling zone dampers open.

Status Lights Mode Function

4

SYSTEM 2000 CONTROLLERS - GAS/ELECTRIC 101ASSB

Fused
24V AC
Damper
Transformer

1

7

6

TR2

TR1

SY WRdB G

TB1

DAISY CHAIN
UP TO 20
ZONES

101ASSB

System Controller

TC2 TC

1

3

2

ZONE
DAMPER

WY G RdBW2

WY R C RCW2 MC RO

Open

Close

DAMPER MOTORS

TB2

TB1

WY R C

ZONE

THERMOSTAT

DAMPER RELAY
BOARD (P/N 101ARLY)

W1 Y1RG

TB2

TO CAPACITY CONTROLLER

AND HVAC UNIT (PG 28)

4

5

1

2

3

4

5

6

7

8

WIRING

If the heater does not turn on the
blower fan, a blower fan relay must be
installed. See page 43.

24V damper transformer. Requires in-line
fuse. See table on page 42 for sizing trans­former and fuse.

Refer to page 41 for Five Wire Link wire
sizing.

C terminal for hard wired electronic
thermostats only.

Open motor not utilized on low pressure
(spring open) dampers.

If using more than one damper per
thermostat, refer to Slaving Zone
Dampers section, page 23 and 44.

Do not remove factory installed jumper
between TC1 and TC2. TC1 and TC2 are
used for Select-Temp Zoning System only.

SYSTEM 2000 CONTROLLERS – HEAT PUMP 101AACBHP

The 101AACBHP Heat Pump Controller greatly simplifies coordination of
single stage or two stage Heat Pumps with dampered zone systems. The
Controller communicates to the zone dampers through a five wire link.
These five wires are daisy chained to each zone damper. This simple
patented wiring process eliminates home run wiring. The 101AACBHP

Overview

has a built-in capacity control system which uses an LAS (included with
the Controller) for capacity control. Refer to the section on Capacity
Control LAS for more information.

The Controller operates the Heat Pump using signals from each zone
thermostat in the system. When heating or cooling calls are sent to the

Operation

controller, it treats these calls as votes. If the majority of calls are for
cooling, the Controller will operate in the cool mode. The Heat Pump
will continue to operate in the cool mode until the majority of calls shift
to heating or all cooling calls are satisfied. If the majority of calls are for
heating, the Controller will operate in the heat mode. The Heat Pump
will continue to operate in the heat mode until the majority of calls shift
to cooling or all heating calls are satisfied.

When using the 101ASSB controller in a
heat pump application which utilizes G/E
terminals, a fan relay must be installed,
see page 43.

*The reversing valve is energized depending on the O/B
jumper setting.

Second stage operation is based on the leaving air temperature of the unit.
The LAS reports the discharge temperature to the Controller. Three
minutes after initiating cooling, the Controller checks the LAS. If the
discharge temperature is above 52 degrees, the second stage is turned
on. Three minutes after initiating heating, the Controller checks the
LAS. If the discharge temperature is below 114 degrees, the second
stage is turned on.

The Heat Pump Controller is also set up to operate electric strip heat in
the Heat Pump. The Controller monitors the air temperature leaving the
Heat Pump coil. When there is a call for heat and the air leaving the coil
is not above 85 degrees, the electric strip will turn on after an eight minute
delay. This operation can be modified, if desired by an outdoor thermostat.

The Heat Pump Controller simplifies system wiring. The Controller
terminals connect directly to the Heat Pump terminal strip. (Heat Pump
thermostats are not used for this system). Relays, timers and other
miscellaneous controls are not required.

5

SYSTEM 2000 CONTROLLERS – HEAT PUMP 101AACBHP

OPERATION (Continued)

The 101AACBHP Zonex Systems SYSTEM 2000 Heat Pump controller
has a series of lights which indicate different operations. These are
labeled “Heat,” “Cool,” “Damper,” “Pump,” “Rev. Valve,” “Y1 Cool”, “Y2
Cool,” “Y1 Heat” and “Y2 Heat.” The “Heat” and “Cool” lights
indicate, when illuminated, the present mode of operation. These lights
will momentarily toggle to the other mode every 120 seconds when
polling. Polling is when the controller checks to see how many heat and
cool calls are being made. If there are no calls, the “Heat” or “Cool”
light will be on based on the last operating mode. The “Damper” light
indicates that a thermostat is calling and that power is being supplied to
the damper motors. The “Pump” light indicates that the first stage pump
is operating. The “Rev. Valve” light indicates that the reversing valve is
activated, or when it flashes, that a time delay is active. The “Y1” and
“Y2” Cool and Heat lights are part of the Capacity control function
included on the Heat Pump Controller. The Y2 Heat or Cool LED, when
illuminated, indicates the Y2 compressor has cycled OFF, because the
capacity control setpoint has been exceeded. When Y1 and Y2 heat or
Cool LEDs are both illuminated, the controller will initiate a 4-minute
temperature cut out, with both stages cycling off.

When power is first turned on, if there are no calls for cooling or
heating, the “Heat” light will be the only light illuminated, with the
exception of the “Rev. Valve” light. It will also be on if jumper J1 is
removed (“B” operation). When there is a cooling or heating call, the
“Damper” and “Heat” or “Cool” lights will turn on.

When the “Rev. Valve” light is not indicating a time delay by flashing, it
will stay illuminated only when the reversing valve is operated.

HEAT – Reversing valve “O” Mode – When the controller receives
an initial or consecutive call for Heat, the Rev Valve LED will flash; the
Heat, Damper and Pump LEDs will illuminate. The first stage heat will
energize on Y1, and the Rev Valve LED will continue to flash for at least
4 minutes. After 4 minutes from Y1, if the supply temperature is 95° or
less, Y2 will energize and the Rev Valve LED will go OFF (Heat “B” mode
will change the flashing Rev Valve LED to ON when Y2 energizes). The
auxiliary heat will energize 4 minutes after Y2 and when the supply air
temperature is 85° or less.

COOL – Reversing Valve “O” Mode – When the controller receives
an initial or consecutive call for Cool, the Rev Valve LED will flash; the

Cool, Damper and Pump LEDs will illuminate. The first stage cool will
energize on Y1 and O/B with the Rev Valve LED flashing for 8 minutes.
After 8 minutes from Y1, if the supply air temperature is 60° or higher,
Y2 second stage of cooling will energize. The Rev Valve LED will change
from flashing to steady ON. (Cool “B” mode for Rev Valve LED will change
from flashing to OFF after Y2 energizes.)

AUTO CHANGEOVER – If an existing mode is overridden by an opposite
majority, the existing call will remain in operation for 4 minutes, and
then the controller will go into a 2 minute purge with the existing
dampers staying open. After the purge cycle has timed out, the system
blower cycles OFF (when in the auto mode). The controller goes into a
2 to 4 minute delay, switching to the opposite mode, with the dampers
making the opposite call opening. Y1 and Y2 are not energized during
this delay. After this final delay times out, the controller energizes Y1 in
the opposite mode.

If all zones satisfy, the “Pump” and “Damper” lights will go out. The
“Heat” or “Cool” lights will be on based on the last mode of operation.

If your system includes auxiliary heat, it will be activated by the “W”
terminal on the SYSTEM 2000’s Heat Pump Controller. Auxiliary heat
will be activated when the following conditions are met. The “Heat” and
“Damper” lights are on indicating a heat call; the “Pump” light is on
and the “Rev. Valve” light is not flashing, indicating that first and second
stage are activated; four minutes after the “Rev. Valve” light stops
flashing the auxiliary heat will be activated if the leaving air temperature
is below the Electric Heat setpoint (factory set at 85 degrees). The time
delay before bringing on the auxiliary heat gives the second stage time
to raise the leaving air temperature over 85 degrees. Even if the system
is single stage, the controller will still delay the electric heat until after
the second stage time delay is satisfied.

The reversing valve is controlled by the “O/BL” terminal. This terminal
should be connected to the Heat Pumps terminal strip according to the
unit manufacturers recommendations. Jumper J1 on the SYSTEM 2000
Heat Pump board needs to be adjusted to operate with the different
manufacturers designs. The Heat Pump board is shipped from our
factory ready to operate a heat pump unit which requires the “O” wire
to energize the reversing valve in cooling. If the reversing valve needs to
be activated for the “BL” terminal, jumper J1 needs to be removed from
the Controller board. Refer to the Heat Pump Controller drawing on the
previous page for the location of jumper “J1”. Remove the jumper from
the board to activate the reversing valve using the “BL” terminal.

Warning: For heat pumps using standard gas/electric thermostats, do not use the 101AACBHP System Controller. Instead, use the

101ASSB System Controller and the CAPL-2 Capacity Controller.

6

SYSTEM 2000 CONTROLLERS – HEAT PUMP 101AACBHP

POWER UP, NO CALLS:

CALL (HEAT/COOL):

1ST STAGE

2ND STAGE

AUX. HEAT

DELAY IN MINUTES

STATUS LIGHTS: STATUS LIGHTS:

0

4*

8

DAMPER

OFF DAMPER

ON

ON

ON

REV. VALVE

NOTE 1 REV. VALVE

FLASH

NOTE 1

NOTE 1

HEAT*

ON HEAT

ON FOR HEAT

ON FOR HEAT

ON FOR HEAT

COOL*

OFF COOL

ON FOR COOL

ON FOR COOL

ON FOR COOL

PUMP

OFF PUMP

ON

ON

ON
TB2: TB2:
Y1 OFF Y1

ON

ON

ON
Y2

OFF Y2

OFF

ON

ON
G

OFF G

ON

ON

ON
W

OFF W

OFF

OFF

NOTE 2

O/BL NOTE 1 O/BL

NOTE 1

NOTE 1

NOTE 1

MODE CHANGE: 1ST STAGE 2ND STAGE AUX. HEAT

STATUS LIGHTS:

O 4 8 10 12

DAMPER

ON ON ON ON ON

REV. VALVE

FLASH FLASH NOTE 1 NOTE 1

HEAT*

ON FOR HEAT ON FOR HEAT ON FOR HEAT ON FOR HEAT

COOL*

ON FOR COOL

ON FOR COOL

ON FOR COOL

ON FOR COOL

PUMP

OFF ON ON ON
TB2:
Y1

OFF ON ON ON
Y2

OFF OFF ON ON
G

OFF ON ON ON
W

OFF OFF OFF NOTE 2
O/BL

NOTE 1 NOTE 1 NOTE 1 NOTE 1

DELAY IN MINUTES

NOTE 1: On if: a) In cool mode and reversing valve set for “O” operation (J1 jumper installed).

b) In heat mode and reversing valve is set for “BL” operation (J1 jumper removed).

NOTE 2:

On when in heat mode and supply air temperature below Electric Heat setpoint.Heat, Cool, and Fan switches
in AUTO position. Capacity Controller lights off. Delay times are approximate.

*Momentarily toggles to opposite mode every 120 seconds.

CONTINUE

PREVIOUS

MODE

OPERATION

UP TO

20

ZONES

WYRC

BWY GRd

W Y R C RC MC RO

TB1

TB2

-

+

NC

W2

W2

FUSED 24 VOLT

TRANSFORMER

ELECTRIC HEAT

PUMP #2
PUMP #1

REV VALVE

FAN

Y1

G

Y2

W

R

O

BL

/

TO

HEAT

PUMP

101AACBHP
HEAT PUMP

CONTROLLER

REV.

VALVE

HEAT

COOL

DAMPER

PUMP

Y1

Y2

Y1

Y2

HEAT

COOL

J1

ON

PWR

OFF

COOLHEAT

OFF

AUTO

OFF

ON

AUTO

FAN

HEAT ADJ
TP3

COOL ADJ

TP2

ELECTRIC
HEAT ADJ
TP1

GROUND

GND

Y1

G

Y2

TB2 WR

O

BL

/

TC2

Y

W

BG

Rd TR1TR2STB1 TC1TEMP

-

+

J2

5

1

7

2

4

6

Zone

Thermostat

Zone

Damper

Relay Board

(101ARLY)

Motors

Close Open

DUCT

MOUNTED

LEAVING AIR

SENSOR

(101ALAS)

(PG 35)

1

2

3

4

5

6

7

8

OPERATION SUMMARY TABLE (EFFECTIVE HPC V1.04 8/02)

*NOTE:

Cool:Y2 delay on

make 8 min.
Heat:Y2 delay on

make 4 min.

NOTES:

Refer to page 41 for 5 wire link wire sizing.

24V damper transformer. Requires in-line fuse. See table on page 42 for sizing
transformer and fuse.

C terminal for hardwired electronic thermostats only.

J1 Reversing Valve Selection Jumper. Leave jumper in place to
energize reversing valve in cool mode, “O” mode. Remove
jumper to energize in heat mode, “B” mode. J2 is not used for
System 2000.

If the heat pump does not include an outdoor thermostat, it is
recommended that the “W” wire to the unit is run thru an
optional outdoor thermostat with a manual override switch.

Do not remove the jumper wire from TC1 and
TC2. Used for Select-Temp Zoning System only.

Open motor not utilized on low pressure
(spring open) dampers.

If using more than one damper per thermo­stat, refer to Slaving Zone Dampers section,
pages 23 and 44.

NOTE:

If the Heat Pump system does not have rev. valve
inputs, use the 101ASSB (Gas/Electric Controller).

WIRING

7

SYSTEM 2000 SYSTEM STARTUP

Make sure the correct size fuse is installed in-line with the transformer
powering the Controller.

For both Gas/Electric and Heat Pump Controllers

1. These system tests are to be done with all wiring to the air condi­tioning unit disconnected.

A. Be sure that the power switch to the Controller is in the “OFF”

position. For Gas/Electric remove “R,” “W1,” “Y1” and “G” wires
from Terminal Strip 2 labeled (TB2).

B. Be sure that the power switch to the Controller is in the “OFF”

position. For Heat Pumps remove “R,” “W,” “Y2,” “Y1,” “O/BL”
and “G” wires from Terminal Strip 2 labeled (TB2).

2. Check wiring of the 5 wire link to the dampers. All connections

must be made color to color.

3. If you are not using Zonex Systems supplied zone thermostats,

check each one to make sure it is an auto changeover type stat.
Turn all thermostats to the OFF position. Check the Controller
“HEAT” and “COOL” switches to be sure that both are in the “OFF”
position. The “FAN” switch should be in the “AUTO” position. Observe
the fuse on the Controller Board and transformer. Turn the power
switch to “ON.” If the fuse blows, there is a wiring problem. If the
fuse does not blow, turn the “HEAT” switch to “AUTO” and “COOL”
switch to “AUTO.” If the fuse blows at any of these steps, find and
repair the short in the wiring.

4. If the system is operating normally, the Heat light should be on for

the 101ASSB, and 101AACB-HP. Set the “HEAT” switch to “OFF”.
Check the first zone by turning it on and setting it to call for cool­ing. If the call is received by the Controller, the “Damper” and
“Cool” lights will turn on. If the lights come on, turn off the first
stat and the “Damper” light should turn off. Test each stat this way
to be sure that each one is capable of communicating with the
Controller, and able to start and stop the air conditioner.

NOTE: “Heat” and “Cool” Led indicators will toggle every two min­utes to check opposite mode callers, regardless of heat and cool
switch positions.

5. After cooling calls are tested, turn the cooling switch to “OFF” and
set the heating switch to “AUTO”. Set the first zone to call for heat.
If the call is received by the Controller, “Damper” and “Heat” lights
will turn on. Test each thermostat to be sure that each properly
communicates with the Controller for the heating sequence.

6. After all zones have been checked, turn the ON/OFF switch at the
System Controller to OFF.

7. Before wiring the System Controller to your A/C unit or furnace,
check the relays with a volt meter (set on 200 Ohms). Be cer­tain no continuity exists on the A/C unit terminal connections at the
System Controller. Check between each terminal to the “R” termi­nal. There should be no continuity between the terminals. (If you
do show continuity, your System Control board should be replaced.)

8. If no continuity exists from the test detailed above, connect the
terminal to the A/C unit and the System Controller. Be certain all
thermostats are now in the “OFF” position.

9. Turn the power switch to “ON” and the “HEAT” and “COOL” switch­es should be set to “AUTO”. Initiate a call for cooling from only one
stat. After a time delay, both compressor and fan should be running.
Turn off the cooling and initiate a heating call, (you may experience
up to a 4 minute time delay). The heat should come on and after a
short time delay the fan will be operated by the internal controls of
the unit. On the Heat Pump controller, eight minutes on the ini­tial start of CAPL-2 after stage one starts, the LAS or capacity con­trol will control second stage operation.

10. After completing the system check and startup procedure, set the
system up for normal operation.

8

SYSTEM 1000

System 1000 Zone Control enables a single HVAC unit to be controlled by
up to seven zone (room) thermostats. System 1000 is a manual
changeover system. This means that the mode of operation (heat/cool)

CONCEPTUAL DRAWING ONLY
Refer to System 1000 Switching
Center Section for Wiring
Information.

is manually selected. For auto changeover capability select Zonex
Systems System 2000.

4.25"

2.5"

1"

SYSTEM OPERATION

The user manually selects the mode (heat/cool) at the Switching Center.
If any zone thermostat calls for the mode selected, the green call light
turns on at the Switching Center, the HVAC/heat pump unit turns on, and
all non-calling zone dampers close.

Once all zones are satisfied, the green call light turns off, the HVAC/heat
pump unit shuts off and all dampers open. If the Switching Center
fan switch is ON, the fan will continue to run to allow ventilation in
all zones.

The Capacity Controller independently monitors the supply air temperature
to prevent coil freeze up or overheating.

The Bypass damper will independently bypass any supply air not needed
back to the return duct.

System 1000

Switching Center

System 1000

Zonex Systems Supplied Components

Switching Centers................................................................Pages 11-14

Zone Thermostats ...............................................................Pages 16-17

Zone Dampers ....................................................................Pages 18-23

Bypass Dampers .................................................................Pages 23-27

Capacity Controllers............................................................Pages 28-41

System 1000

Field Supplied Components

Thermostat Wire........................................................................Page 41

24V Transformer(s) and Fuse....................................................Page 42

9

SYSTEM 1000 – COMPONENT SELECTION GUIDE

Manual Changeover for 2 to 7 Zones

GAS ELECTRIC

Switching Center

(SYGE)

ZONE THERMOSTATS

Digital Programmable

(101DIGI) (101PROG)

CAPACITY CONTROLLERS

START

HEAT PUMP

Switching Center

(SYHPA)

2 Stage Heat/1 Stage Cool

ZONE THERMOSTATS

Digital Programmable

(101DIGI) (101PROG)

❶

1 Stage

(TRLAT)

or

Digital Version

(101CAPGE)

Round (101ARZD size) up to .5” SP

Rectangular (101EC W x H) up to .5” SP

12 X (Number of Dampers) = VA for the

24V System Transformer (Field Supplied)

2 Stage

(CAPL-2)

5 TONS AND UNDER

Low Pressure Dampers

5 TONS AND UNDER

Barometric Bypass Damper

Round (101ABBD size)
Rectangular RBB W x H

DIGITAL CAPACITY CONTROLLER

(SYCAP)

Optional Outdoor
T-Stat (field supplied)

ZONE DAMPERS

OVER 5 TONS

Medium Pressure Dampers

Round (101AMPD size) up to 1.75” SP

Rectangular (101MRTD W x H) up to 1” SP ❷

Heavy Duty Rectangular (101CD W x H) to 1.75” SP

6 X (Number of Dampers) =VA for the

24V System Transformer (Field Supplied)

BYPASS DAMPERS

OVER 5 TONS

Electronic Bypass Damper

Round (STMPD size)

Rectangular (STCD W x H)

Static Pressure Controller (101ASPC)

COMPLETE SYSTEM

❶ Some Heat Pumps utilize Gas/Electric thermostats. For this type of Heat Pump,
use the Gas/Electric parts selection and field modify the capacity control heat cutoff
setpoint to 118° F.

10

24V, 40VA Independent Transformer

for bypass (Field Supplied)

❷ Use heavy duty rectangular dampers on systems of 7.5 tons or larger

SYSTEM 1000 SWITCHING CENTERS – GAS/ELECTRIC SYGE

OVERVIEW

The SYGE Switching Center is a manual changeover, Gas/Electric System
Controller. It can control up to 7 zone thermostats. Its function is to look
for calls from the zone thermostats for the mode (heat/cool) selected. If a
call is received, it sends a signal to close the dampers of all zones not
calling and sends a signal to the HVAC unit to energize heating or cooling.

The Mode, Power and Fan control switches are located at the Switching
Center. The Switching Center should be placed in a location that provides
easy access to these switches.

The Switching Center is used in conjunction with a Capacity Controller.
The Capacity Controller protects the evaporator coil from freezing and the
heat exchanger from overheating. The Capacity Controller also controls
staging for multistage HVAC systems. Refer to the Capacity Controller
section (pg. 28) for more information.

COMPONENTS

1. 5 Wire Link Terminals – Daisy chain wires to zone dampers.

YD – Cool call input signal. Current flows in this terminal when Mode
switch at COOL, Power switch ON and thermostat calling for cool.
WD – Heat call input signal. Current flows in this terminal when
Mode switch at HEAT and thermostat calling for heat.
BD – 24V return. Same as TR2.
GD – 24V hot. Same as TR1.
RD – Unit on output signal. Energized (RD made to GD) when
Switching Center acknowledges thermostat call. See 7.

2. Transformer Terminals – 24V AC transformer terminals. This

transformer powers the dampers, thermostats and Switching Center.
It does not power the HVAC unit. That power comes from terminal
R; see 3.

3. HVAC Unit Terminals – Connect to HVAC unit via Capac-

ity Controller. See Capacity Controller section for wiring
information.
W – Heat enable. Energized (W made to R) when Switch­ing Center acknowledges a heat call. See 7.
Y – Cool enable. Energized (Y made to R) when Switch­ing Center acknowledges a cool call. See 7.
R – HVAC unit 24V power.
G – Fan enable. Energized when FAN switch is at ON posi­tion or when FAN switch is at AUTO position and Switch­ing Center acknowledges a cool call. See 7.

4. Mode Switch – Selects mode (heat/cool) to run system.

Switching Center will only respond to thermostats calling
for mode selected.

HEAT

COOL

AUTO

FAN

OPERATION

The user manually selects the mode (heat/cool) at the Switching Center.
Heat mode – If any zone thermostat calls for heat, electrical current
flows in WD. The Switching Center senses this current, turns on the green
Call light, energizes RD (RD made to GD) which tells the dampers of all
zones not calling to close and energizes W (W made to R) which tells the
HVAC unit to turn on heat.
Cool mode – If any zone thermostat calls for cool, electrical current
flows in YD. The Switching Center senses this current, turns on the green
Call light, energizes RD (RD made to GD) which tells the dampers of all
zones not calling to close, and energizes Y and G (Y and G made to R)
which tells the HVAC unit to turn on cooling and the indoor blower fan.
No calls – When no thermostats are calling, the green Call light is off,
RD is not energized so all dampers are open, and W, Y are not energized
so the HVAC unit is off. If the FAN switch is ON, then G is energized (G
made to R), and the indoor blower fan will run. This allows ventilation
in all zones.

5. Power Switch – When OFF the Switching Center will not respond to

thermostat calls. Power remains to all dampers and thermostats.
The indoor blower fan will run if fan switch is on.

6. Fan Switch – Controls the indoor blower fan (G).

AUTO – Indoor blower fan turns on when air conditioner is on.

Note: In heat mode, furnace controls indoor blower fan.

ON – Indoor blower fan continuously on as long as Power switch
is ON.

7. Call Light – On when Switching Center responds to a calling

thermostat.

1 2 3

ON

OFF

ON

YD WD BD GD RD TR1 TR2 W Y R G

4

SWITCHING CENTER

5

6

SYSTEM 1000

GAS/ELECTRIC

(SYGE)

GREEN CALL

LIGHT

7

11

YD

WD GDBDRD

LOGIC
BOARD

160
OHMS

COOLHEAT

SWITCHING

CENTER

(SYHPA)

GREEN
CALL LIGHT

OFF

K1

LOGIC
BOARD

TR

1
TR2

POWER

K1

F
U
S
E

3P3T

SWITCH

K1

COOL

HEAT

OFF

OFF

E.M.
HEAT

ON

FAN

ONAUTO

OB

COOLHEAT

OFF

O/B Y

G R W2 E L C

E.M. HT LIGHT

(RED)

COMP. FAIL

(YELLOW)

SYSTEM 1000 SWITCHING CENTERS – GAS/ELECTRIC SYGE

2

3

4

5

1

WIRING

NOTES:

24V damper transformer. Requires in line fuse. See table on page
42 for sizing transformers and fuse.

Refer to page 41 for five wire link wire sizing.

C terminal for hard wired electronic thermostats only.

Open motor not utilized on low pressure (spring open) dampers.

If using more than one damper per thermostat, refer to Paralleling
Zone Dampers section, pages 23 and 44.

SYSTEM 1000 SWITCHING CENTERS – HEAT PUMP SYHPA

SIMPLIFIED SCHEMATIC, SYHPA

SIMPLIFIED SCHEMATIC, SYGE

W

COOL

Y

R

G

HEAT

K1

ON

FAN

AUTO

LOGIC

BOARD

GREEN

CALL LIGHT

COOL

K1

WDYD GDBD RD

HEAT

POWER

160

OHMS

LOGIC

BOARD

SWITCHING CENTER

K1

OVERVIEW

The SYHPA Switching Center is a manual changeover, single stage cool,
two stage heat, heat pump System Controller. It can control up to 7 zone
thermostats. Its function is to look for calls from the zone thermostats for
the mode (heat/cool) selected. If a call is received, it sends a signal to close
the dampers of all zones not calling and sends a signal to the heat pump
unit to energize heating or cooling.

The Switching Center is used in conjunction with a SYCAP Capacity
Controller. The SYCAP cycles the heat pump on and off to maintain the
leaving air temperature within a set range. Refer to the SYCAP in the
Capacity Controller section (pg. 33) for more information.

12

TR1

TR2

SYSTEM 1000 SWITCHING CENTERS – HEAT PUMP SYHPA

The Mode, Power, Fan and Emergency Heat control switches are located
at the Switching Center. The Switching Center should be placed in
a location that provides easy access to these switches.

NOTE: If your heat pump is controlled by a gas/electric thermostat, use

an SYGE Switching Center. See SYGE Switching Center section, pg. 3.

OPERATION

The user manually selects the mode (heat/cool) at the Switching Center.

Heat mode – With the Mode switch set to HEAT, Fan switch set to AUTO,

EM HT switch set to OFF and Power switch set to ON, if any zone ther­mostat calls for heat, electrical current flows in WD. The Switching Cen­ter senses this current, turns on the green Call light, energizes RD (RD
made to GD) which tells the dampers of all zones not calling to close
and energizes Y, W2 and G (Y, W2 and G made to R). G turns on the
indoor blower fan. Y controls the heat pump compressor and W2 controls
auxiliary heat. Y and W2 are further controlled by the SYCAP Capacity Con­troller which makes and breaks Y and W2 to maintain a minimum and
maximum leaving air temperature. See SYCAP under Capacity Controller
section for further information. The reversing valve is energized (B made
to R) if the reversing valve jumper is set to B.

Cool mode – With the Mode switch set to COOL, Fan switch set to AUTO,

EM HT switch set to OFF and Power switch set to ON, if any zone
thermostat calls for cool, electrical current flows in YD. The Switching
Center senses this current, turns on the green Call light, energizes RD

(RD made to GD) which tells the dampers of all zones not calling to close
and energizes Y, and G (Y and G made to R). G turns on the indoor blow­er fan. Y controls the heat pump compressor. Y is further controlled by
the SYCAP Capacity Controller which makes and breaks Y to maintain a
minimum leaving air temperature. See SYCAP under Capacity Controller
section for further information. The reversing valve is energized (O made
to R) if the Reversing Valve jumper is set to O.

No calls – When no thermostats are calling, the green Call light is off,

RD is not energized so all dampers are open, and W2, Y are not energized
so the HVAC unit is off. If the FAN switch is ON then G is energized (G made
to R) and the indoor blower fan will run. This allows ventilation in all
zones.

Emergency Heat – With the Mode switch set to HEAT, Fan switch set

to AUTO, EM HT switch set to ON and Power switch set to ON, if any zone
thermostat calls for heat, electrical current flows in WD. The Switching
Center senses this current, turns on the green Call light and red Emer­gency Heat light, energizes RD (RD made to GD) which tells the dampers
of all zones not calling to close and energizes E (E made to R). What E is
wired to depends on the make of your heat pump. Refer to the SYHPA
wiring diagram for further information.

Note: Do not leave the Emergency Heat switch set to ON when the Mode
switch is set to COOL. Doing so will energize E (turning on emergency
heat) when a thermostat makes a cool call.

COMPONENTS

1. 5 Wire Link Terminals – Daisy chain wires to zone dampers.

WD – Heat call input signal. Current flows in this terminal when
Mode switch is at HEAT and thermostat is calling for heat.
YD – Cool call input signal. Current flows in this terminal when Mode
switch is at COOL, Power switch is ON and thermostat is calling for
cool.
BD – 24V return. Same as TR2.
GD – 24V hot. Same as TR1.
RD – Unit on output signal. Energized (RD made to GD)
when Switching Center acknowledges thermostat call. See 9.

2. Transformer Terminals – 24V AC transformer terminals. This

transformer powers the dampers, thermostats and Switching Center.
It does not power the HVAC unit. That power comes from terminal
R; see 3.

3. Heat Pump Unit Terminals – Connect to Heat Pump unit via SYCAP

Capacity Controller.
O/B – Reversing Valve terminal. Energized (O/B made to R) in heat
mode when O/B jumper is at B. Energized in cool mode when O/B
jumper is at O.
Y – Compressor enable. Energized (Y made to R) when Switching
Center acknowledges a heat or cool call and Emergency Heat Switch
OFF.
G – Fan enable. Energized when FAN switch is at ON position or
when FAN switch is at AUTO position, Emergency Heat Switch is OFF
and Switching Center acknowledges a heat or cool call.

R – Heat Pump unit 24V power.
E – Emergency Heat enable. Energized (E made to R) when
Switching Center acknowledges a heat call and Emergency Heat
switch is ON. See 6 and 9.
W2 – Auxiliary Heat enable. Energized (W2 made to R) when
Switching Center acknowledges a heat call and Emergency Heat
switch is OFF. Sends signal to SYCAP.
L – Compressor fail flag input terminal. If feature is provided by Heat
Pump, when L is energized (L made to R), red light DL3 is illuminat­ed to signal compressor is not working.
C – Heat Pump unit 24V power return.

4. Mode Switch – Selects mode (HEAT/OFF/COOL) to run system.

Switching Center will only respond to thermostats calling for mode
selected.

5. Fan Switch – Controls the indoor blower fan (G) when the Emer-

gency Heat switch is OFF.
AUTO – Indoor blower fan turns on when Heat Pump is on.
ON – Indoor blower fan is continuously on as long as Power
switch is ON.

6. Emergency Heat – Disables compressor (Y) and blower fan (G)

and energizes E (E made to R). This tells the Heat Pump to
turn on auxiliary heat. Should only be used when Mode switch is in
HEAT. If used when mode switch is in COOL, auxiliary heat will turn
on when there is a cool call.

13

SYSTEM 1000 SWITCHING CENTERS - HEAT PUMP SYHPA

1

2

3

4

5

6

7

Daisy chain up to six additional zones

ZONE

THERMOSTAT

RYW

WYG Rd

W

Y

R

C

RO MC RC

TB2

C

W2

W2

TB1

DAMPER RELAY BOARD

(101ARLY)

FUSED 24V

DAMPER

TRANSFORMER

SYHPA

SWITCHING CENTER

RDBD GDWD YD

TR1 TR2

EGRYO/B W2LC

HEAT PUMP TERMINALS

EGRY

O/B

W2 LC

SYCAP

CAPACITY

CONTROL

(PG 33)

Y1Y1 W2W2 CR

3

4

5

7

B

2

6

1

CLOSE

MOTOR

OPEN

MOTOR

ZONE DAMPER

AUTO

FAN

ON

HEAT

OFF

COOL

OFF

ON

EM.

HT.

RDBD GDWD YD

O/B Y G R E W2 L C

OFF ON

DL2

DL3

DL1

O B

4

5

6

7

1

2

3

8

9

10

SYHPA

TR2 TR1

7. Reversing Valve Selection Jumper – Configures Switching Cen-

ter to energize reversing valve in cool mode or heat mode. Place on
O and center pin to energize reversing valve in cool mode. Place on
B and center pin to energize in heat mode.

8. Fuse – 1/10 amp. Protects WD and YD terminals.

9. Status Lights –

DL1 – Call light, green. On when Switching Center responds to a
calling thermostat.
DL2 – Compressor fail, yellow. On when L terminal is energized
(L made to R). Indicates heat pump compressor is not functioning.
DL3 – Emergency Heat, red. On when E terminal is energized (E
made to R). Indicates emergency heat is on.

10. Power Switch – When OFF the Switching Center will not respond to

thermostat calls. The indoor blower fan will run if Fan switch is ON.
Power remains to all dampers and thermostats.

WIRING

Open motor not utilized on low pressure
(spring open) dampers.

C terminal for hardwired electronic
thermostats only.

24V damper transformer. Requires
in-line fuse. See table on page 42 for
sizing transformer and fuse.

Refer to page 41 for Five Wire Link wire
sizing.

If the heat pump does not include an
outdoor thermostat, it is recommended
that the “W2” wire to the heat pump
unit is run thru an optional outdoor
thermostat with a manual override
switch.

If using more than one damper per
thermostat, refer to paralleling zone
dampers, pages 23 and 44.

If the heat pump does not have an
emergency heat terminal, connect “E”
of Switching Center to auxiliary heat
terminal of heat pump. If the heat
pump does not turn on the indoor
blower fan in emergency heat mode,
add blower fan relay as shown below.

EMERGENCY HEAT BLOWER FAN RELAY

If the heat pump does not energize
the indoor blower fan when
emergency heat is energized, add
relay K1 as shown. Relay K1 is a
24VAC SPDT relay.

14

SYHPA

SWITCHING CENTER

GR E C

K1

K1

GR E C

HEAT PUMP TERMINALS

K1

SYSTEM 1000 STARTUP

When all wiring is completed to the dampers and the gas electric/heat
pump unit, the following tests should be made:

✓ Disconnect the R wire from the Switching Center.
✓ Check to be sure that there is 24 volt power between

terminals TR1 & TR2.

✓ Set all thermostat switches to the OFF position.
✓ Set the Switching Center in the HEAT mode.
✓ Set the Switching Center ON/OFF switch to ON.

The green call light should be off at the Switching Center. If it is on, there
is a thermostat calling or the WD wire is shorted.

✓ Check all of the thermostats, if they are off, remove the WD wire

from the Switching Center. The green light should go off. If it
does, find the short in the five wire link before re-connecting it. If
the green light does not turn on, test each thermostat, one at a
time. Turn on one thermostat, set it to call for heating, and the
green light on the Switching Center should turn on. When you set
this same thermostat for no heat, the green light at the Switching
Center should turn off. Test each thermostat in this manner to

be sure all thermostats are properly wired.
Now, set the Switching Center in the COOL mode.
If the green light turns on with all thermostats off, there is a short in the
YD wire. Correct the problem before proceeding.

Repeat the test of each thermostat in the cool mode. When a thermostat
is calling, the green call light will turn on. Turning this thermostat off will
turn off the green call light at the Switching Center.

GAS/ELECTRIC SYGE

Turn the ON/OFF switch off and reconnect the R wire. Be sure that all
thermostats are off. Turn the ON/OFF switch ON. Decide if you want to
test the heating or cooling system and set the HEAT/COOL switch to the
desired position.

If you have set the switch to COOL, set one thermostat to call for cooling.
The green light will turn on and the cooling system compressor and
indoor fan will turn on. If it does not, check wiring between the Switch­ing Center and the unit.

If you have set the switch to HEAT, set one thermostat to call for heat. The
green light will turn on and the furnace should start. The fan will start
when the time delay or bonnet control turns it on. If the system does not
turn on, check the wiring between the Switching Center and the furnace.

The Switching Center controls the furnace and air conditioner with relay
contacts. The Switching Centers R,Y,W&G terminals operate exactly like
a four wire thermostat. Trouble shooting the heating and air condition­ing equipment should be handled as though the Switching Center is a
four wire thermostat.

HEAT PUMP (SYHPA) with the SYCAP

Check that the fuse on the SYHPA has not blown. If it has, check for
shorts on the WD and/or YD wires on the five wire link and replace the
1/10 amp fuse.

Turn the POWER switch on the SYHPA and SYCAP OFF: Check all
thermostats to be sure that they are off. Reconnect the R wire at the SYHPA.
Check to be sure that the O/B jumper on the SYHPA is in the correct
position for the heat pump. Turn the POWER switch on the SYHPA to ON.

To test the COOL mode, set the HEAT/COOL switch on the SYHPA to the
COOL position. Set only one thermostat to call for cooling. The green
call light on the SYHPA should turn on and the compressor will run. The
indoor fan will start with the compressor. If the compressor or fan do
not start, check the wiring between the SYHPA and the Heat Pump.

To test the HEAT mode, turn the POWER switch on the SYHPA to OFF.
Turn all thermostats off. Set the MODE switch on the SYHPA to HEAT and
then turn the POWER switch ON. Set one thermostat to call for heat. The
green call light will turn on at the SYHPA and the compressor will turn on
in the heat mode. The fan will turn on with the compressor. If the
fan or compressor does not turn on, check the wiring.

When yellow DL2 is lit, there is a heat pump compressor failure (if “L”
terminal has been wired).

When the “EM HT” switch is set to ON, the SYHPA will never power the
“Y” or “G” terminal and will power the “E” terminal during a call. While
the “EM HT” switch is set to ON, the red light labeled DL3 will turn on if
there is a call. To test the Auxiliary/Electric heat, see the unit manufac­turers wiring diagrams and instructions.

SYCAP and Auxiliary/Electric Heat

To test the Auxiliary/Electric heat, turn the SYCAP switch ON. If the dis­play begins to toggle between “E” and “157”, the factory installed tem­perature sensor or its wiring to terminals ± is open. If the display toggles
between “E” and “32”, the temperature sensor is shorted. Check con­nections + and – and the wire holding the sensor in the plenum for shorts.

During normal startup the supply air temperature should be displayed.
Unless modified at this time, the SYCAP will operate at factory cut-out
setpoints of 118 degrees F. for heat and 48 degrees F. for cooling. To
modify these cut-out setpoints see “Determine the existing cut-out set­points on a CAP” in the Capacity Control section of this manual.

To test the Auxiliary/Electric heat disconnect the Y wire at the SYCAP or
SYHPA. Set one stat to call for heat. If the supply air temperature is below
the electric heat cut-in setpoint, and after a four minute time delay, DL2
and the Auxiliary/Electric heat will turn on.

After testing the SYCAP, replace the Y wire for proper heat pump operation.

Note: At temperatures below 38°F and above 125°F (heat pumps), the

display will toggle between “E” and the supply duct temperature. This is
normal operation and provisions have been made to allow the heating and
cooling to operate.

15

ZONE THERMOSTATS

Each zone requires a zone thermostat. This thermostat can be digital,
mechanical, or programmable. All three types are available. Zonex Sys­tems thermostats have been specifically designed to work with Zonex
Systems Zone Control systems. Attempting to use another manufacturer’s
thermostat may create compatibility problems and cause nuisance calls.
For trouble free installation, use only Zonex Systems supplied thermostats.

Digital Thermostats

Zonex Systems makes two Digital Thermostats for the System 1000/2000:
101DIGI – a single stage thermostat that can be used whenever auxil-

iary zoned heating is not required.

101DIGITS – a single stage cool, two stage heat thermostat. It should

be used when auxiliary zoned heating is needed.

101DIGI: This is a digital, dual setpoint, single stage zone thermostat,
accurate to within one degree. The 101DIGI is auto changeover, is non
power robbing, and is designed with a non-volatile memory to retain all
programmed setpoints. The stat is operated by two push buttons to review
and modify heat and cool setpoints. To avoid unauthorized setpoint mod­ifications, the 101DIGI has locking setpoint capability. There is also a zone
On/Off switch. Under the cover there is a green and red light. When the
green light is on the stat is calling for cooling. When the red light is on the
stat is calling for heat. Following any call, the stat is designed with a two­minute minimum run time to prevent short cycling. It can be used with any
of the System 1000/2000 Controllers. This thermostat can be ordered with
a remote sensor (101DIGIRS). The 101DIGI Dimensions are:
x 4-1/2”H x 1”D, the color is off white
installation.

101DIGITS This is an auto
changeover, electronic zone thermo­stat with auxiliary heat output. This
dual setpoint thermostat has a large
digital readout which displays cur­rent room temperature. Under the
cover there are two red lights and
one green light. When the green
light is on, the thermostat is calling
for cooling. When the red light labeled “D-1” is on, the the stat is call­ing for first stage heat. When the the red light labeled “HT2” is on, the
stat is calling for second stage heat. This zone thermostat is designed for
zones that require supplemental heat. This thermostat can be ordered
with a remote sensor by adding RS to its part number. 101DIGITS dimen­sions are 2 7/8” W x 4 1/2” H x 1” D. Installation requires five
wires.

101DIGI Thermostat Operation

Each digital thermostat has an “ON” / “OFF” switch located at the bottom.
Typically, this thermostat should always be in the “ON” position. When
the room is unoccupied, use this switch to take the zone out of your sys­tem by sliding it to the left to turn it off. When the room is occupied slide
the switch to the right to turn it on. Assign the Heating and Cooling Set­points desired by using the following instructions:

. Requires four thermostat wires for

2-7/8”W

101DIGI
Requires
4 Wires

101 DIGITS
Requires
5 Wires

1. Determine the existing Set­points:

A. To determine the existing Heat

Setpoint, press and hold the
top button marked until

>

the letter “H” appears and
then release. The current heat
setpoint will be displayed
following the letter “H” (If
the button is held down too
long the Heat Setpoint will
begin to increase). Approxi­mately two seconds after the
button is released the current
room temperature will be
redisplayed.

B. To determine the existing Cool

Setpoint press and hold the low­er button marked until the

>

letter “C” appears and then
release. The current Cool
Setpoint will be displayed
following the letter “C” (If the
button is held down too long
the Cool Setpoint will begin to
decrease). Approximately
two seconds after the button is
released the current room
temperature will be redisplayed.

2. Modifying the Setpoints:

A. To change the Heat Setpoint,

press and hold the top button
until the Heat Setpoint is dis­played. Continue to press this
button (the up button ) to

>

increase the Heat Setpoint or
press and hold the bottom

>

button to reduce the Heat
Setpoint to your desired
comfort level in this room.

B. To change the Cool Setpoint,

press and hold the lower button until the Cool Setpoint is

>

displayed. Continue to hold this button to lower the Cooling
Setpoint or press the top button to raise the Cool Setpoint

>

to your desired comfort level in this room.

Set up all of the zone thermostats in this way to provide room
by room comfort control.

16

ZONE THERMOSTATS

REMOTE SENSOR BOARD

Temperature

Sensing

Thermistor

REMOTE SENSOR

COVER

TYPICAL

ZONE

THERMOSTAT

Wire Nut

Wire Nut

R

Shield to the "R" terminal

4.5" x 2.75"

3. Locking the Set points:

To avoid unauthorized setpoint
modifications, the 101DIGI has
locking setpoint capability. After
the heat and cool setpoints have
been selected, use the jumper
located under the cover near
the middle of the board labeled
LCK to lock the setpoints. Slide
the jumper over both terminals
as shown in the diagram above.
This will lock the setpoints in
place. To modify the setpoints,
the jumper must be to moved to
the adjustable position.

DIGICOM

DIGICOM: The DIGICOM auto

changeover, communicating
thermostat is used exclusively in ZonexCommander thermal management
systems. Using a computer and the ZonexCommander software, all ther­mostats in the system can be programmed and viewed. The DIGICOM
may be applied in stand alone unit control, from 1 to 80 split or pack­aged systems. When used with a modem, all ZonexCommander software
functions can be controlled remotely. The DIGICOM requires 24V AC
power from either the zone system or HVAC unit transformer, with the
addition of a two conductor, twisted pair cable for communications.
Dimensions: 2-7/8” W x 4-1/2” H x 1” D.

101PROG: Features a battery powered,
7-day programmable, auto changeover
control for single stage heating and cooling
applications. Thermostat can be programmed
for up to four periods per day, and offers
three operating modes: Manual, Automatic
and Vacation. Blower operation is manual
selectable for auto, on, or programmed for
fossil fuel or electric heat, fan cycling. The
oversized LCD display clearly shows the
time, day of the week, space temperature,
and selected operating mode. The 101PROG
also provides for mode control through an optional telephone controller.
Dimensions are 3.75”W x 5”H x 1”D. Color: White.

101PROG

ZONE THERMOSTATS – COMPATIBILITY

The 101ASSB gas/electric and 101AACBHP heat pump controllers are
compatible with most thermostats, offering a wide thermostat selection
to the installing contractor. NOTE: the 101AACBHP pump controller
utilizes gas/electric thermostats. When using other than Zonex
Systems thermostats, please refer to the following guidelines:

Electronic Thermostats: Digital thermostats requiring 24V AC power
must be “Hard wired” with a separate R and C or common terminal.
Power robbing type thermostats are not compatible. All types of battery
operated thermostats may be used with any System 2000 control system.

Mechanical Thermostats: When using a mechanical thermostat,
ensure the cooling compensator (anticipator) is removed, and the
heating anticipator is shorted or set to its lowest setting.

ZONE THERMOSTATS – REMOTE SENSORS

The Zonex Systems digital thermostats can be ordered with a remote sen­sor. Remote sensors are useful if you would like to place the thermostat
and sensor in different locations. Simply add “RS” at the end of the part
number to order with a remote sensor; i.e.: “101DIGIRS”.

Please contact Factory Technical Support for additional thermostat
compatibility information.

Wiring: The remote sensor must be wired with a minimum 18 ga., two
conductor shielded cable, with a maximum length of 200 feet. The wires
have no polarity. Use field supplied wire nuts to connect the sensor. Flare
back and tape off the cable shield closest to the sensor. Connect the
shield at the thermostat to the “R” terminal.

17

SYSTEM SIZE

5 TONS OR UNDER

UNDER 7.5 TONS

7.5 TONS OF LARGER

MAXIMUM

DIFFERENTIAL

PRESSURE

0.5"
1"

1.75"

ROUND
DAMPER

LOW PRESSURE
MEDIUM PRESSURE
MEDIUM PRESSURE

RECTANGULAR
DAMPER

LOW PRESSURE
MEDIUM PRESSURE
HEAVY DUTY

ZONE DAMPERS

Zonex Systems zone dampers are used in cooling/heating systems to
provide room by room zone control. The damper is provided with a
factory mounted relay board and zone actuator. Each zone damper is

Maximum Differential Pressure refers to the maximum static pressure drop in inches of water column between the
input (upstream) of the zone damper and the output (downstream) when the damper is closed.

ROUND ZONE DAMPERS

There are two styles of round zone dampers, low pressure or medium
pressure. For systems 5 tons or under with a maximum differential static

ROUND LOW PRESSURE ZONE DAMPERS

Zonex Systems round low pressure zone dampers can be used for systems
up to 5 tons with a maximum differential static pressure of 0.5”. These are
two position, spring open, power close dampers for very simple operation.
Round damper sizes 9 inches and under are manufactured from 24
gauge galvanized steel. Sizes 10”, 12”, 14” and 16” are made from 20 - 22
gauge steel. All sizes are designed with rolled-in stiffening beads for superi­or rigidity. The damper pipe is furnished with one crimped end and one
straight end for easy installation. A hat section supports a synchronous 24V
AC 60Hz 12VA motor and terminal board. The motor is designed for contin­uous full stall operation. Special winding and heavy duty gearing provide for
long motor life and easy spring open operation. A cross pin on the motor
shaft provides positive direct drive to the damper blade shaft without a cou­pling or set screws, allowing for a quick and easy motor change if required.
Motor drive time from full open to full close is 30 seconds. Since this is a
spring open damper, in the event of power failure, the damper fails to the full
open position.

controlled by a zone thermostat. More than one damper can be
controlled by one zone thermostat; see Slaving Dampers. Use the table
below to determine which zone dampers to use.

pressure of 0.5”, use low pressure dampers. Otherwise use medium
pressure for up to 1.75” differential pressure on any system over 5 tons.

LOW PRESSURE (101ARZD)

ROUND MEDIUM PRESSURE ZONE DAMPERS

Zonex Systems round medium pressure zone dampers are recommend­ed for systems over 5 tons or with a maximum differential static pressure
up to 1.75”. This power open / power close damper is manufactured from
20-22 gauge galvanized steel with rolled-in stiffening beads for superior rigid­ity. Mechanical minimum and maximum set stops are provided and easily
adjustable. The damper pipe is furnished with one crimped end and one
straight end for easy installation. A hat section supports a 35 lb./in. 24V, 6 VA
power open, power closed actuator with a damper relay board interface. The
actuator is designed for full stall operation, with a magnetic clutch to protect the
internal gearing. The actuator is direct coupled to the damper shaft, which pro­vides positive operation and offers replacement ease if required. Drive time from
full open to full closed is 60 seconds.

18

MEDIUM PRESSURE (101AMPD)

ZONE DAMPERS

ROUND LOW & MEDIUM PRESSURE DAMPER SIZES

ROUND LOW PRESSURE DAMPER

PART #

101ARZD06
101ARZD07
101ARZD08
101ARZD09
101ARZD10
101ARZD12
101ARZD14
101ARZD16

ROUND MEDIUM PRESSURE DAMPER

PART #

101AMPD06
101AMPD08
101AMPD10
101AMPD12
101AMPD14
101AMPD16
101AMPD18

SIZE DIAMETER (D) LENGTH (L)

6"
7"
8"

9"
10"
12"
14"
16"

SIZE DIAMETER (D) LENGTH (L)

6"

8"
10"
12"
14"
16"
18"

6"
7"
8"

9"
10"
12"
14"
16"

6"

8"
10"
12"
14"
16"
18"

10"
10"
10"
11"
12"
14"
16"
18"

10"
10"
12"
14"
16"
18"

23 1/2"

WIDTH (W)

9"
10"
11"
12"
13"
15"
17"

18 1/2"

WIDTH (W)

9"
11"
13"
15"
17"
19"
21"

W

D

L

TYPICAL ROUND CAPACITIES*

Duct

Diameter

6"
7"

8"
9"

10"
12"
14"
16"

18" 2000 1100 .036

Nominal

CFM

110
160

250
320

410

660
1000
1450

Duct Velocity

FPM

540
600

700
725

750
850
925

1070

Damper

P " WC

∆

.014
.014

.015
.015

.015
.022
.035
.036

* These air quantities were derived from a duct sizing chart .1” friction loss per 100’ of duct. All CFMs listed are approximate. For accurate selection
use duct sizing table or device.

19

ZONE DAMPERS

RECTANGULAR ZONE DAMPERS

The rectangular zone dampers come in either low pressure, medium pressure, or heavy duty. For systems 5 tons or under use low pressure.
For systems under 10 tons use medium pressure dampers. For systems 10 tons or over use heavy duty dampers. Motor drive time open and close
is 90 seconds, except for the low pressure damper which springs open.

RECTANGULAR LOW PRESSURE ZONE DAMPERS
(101EC W x H)

Zonex Systems rectangular low pressure dampers can be used for systems
up to 5 tons with a maximum differential static pressure of 0.5”. These are
two position, spring open, power close dampers. They are constructed
from heavy duty galvanized steel. The damper is a single blade type that
slips into a 2-1/2” wide cutout in the existing duct and attaches with
screws via a duct mounting plate. The duct mounting plate is 5” wide. The
drive assembly supports a synchronous 24V AC 60Hz 12VA motor and ter­minal board. The motor is designed for continuous full stall operation. Spe­cial winding and heavy duty gearing provide for long motor life and easy
spring open operation. A cross pin on the motor shaft provides positive
direct drive to the damper shaft without a coupling or set screws. Motor
drive time from full open to full close is 30 seconds. Since this is a
spring open damper, in the event of power failure the damper fails to the
full open position.

LOW PRESSURE (101EC W x H) RECTANGULAR DAMPER

RECTANGULAR MEDIUM PRESSURE ZONE DAMPERS (101MRTD W x H)

Zonex Systems rectangular medium pressure dampers are recommended for systems under 7.5 tons with a maximum differential static
pressure of 1”. These are power open, power close dampers. They are constructed from heavy duty aluminum and stainless steel. The damper is an
opposed blade type that slips into a 3-1/4” wide cutout in the existing duct and attaches with screws via a duct mounting plate. The duct mounting
plate is 5” wide. The damper supports a 35 lb./in. 24V, 6 VA power open, power closed actuator with a damper relay board interface. The actuator is designed
for full stall operation, with a magnetic clutch to protect the internal gearing. The actuator is direct coupled to the damper shaft, which provides positive
operation and offers replacement ease if required.

RECTANGULAR HEAVY DUTY ZONE DAMPERS
(101CD W x H)

Zonex Systems rectangular heavy duty dampers are recommended for
systems 7.5 tons or larger with a maximum differential static pressure of

1.75”. These are power open, power close dampers made of 20 gauge
“snap-lock” steel frame with S and Drive duct connections. Allow a 16”
gap in the duct for the damper. Formed steel blade stops incorporate a
gasket for quiet operation and improved structural rigidity. Rectangular
dampers under 10” in height incorporate a single blade design. Dampers
10” or over use opposed blade design. A full stall motor, drawing 6 VA and
a relay board control the damper position.

MEDIUM PRESSURE (101MRTD) AND

HEAVY DUTY (101CD) RECTANGULAR DAMPERS

20

LOW AND MEDIUM PRESSURE RECTANGULAR DAMPER DIMENSIONS

DEPTH

B 16"

A

WIDTH HEIGHT

16

B

MOTOR

48" MAXIMUM WIDTH

A

Rectangular dampers should operate at 1500 FPM.
E.G. A 24" x 12" damper = 2 square feet.
2 square feet X 1500FPM = 3000 CFM.

4"

200
280
390
490

700
1090
1500
2000
2500
3000
3600
4000

630
960
1400
1850
2250
2300
3080

570
900
1220
1600
2000
2450
2850

500
770
1100
1400
1750
2100
2500

440
680
950
1200
1500
1800
2100

390
590
800
1000
1250
1500
1750

310
490
650
850
1000
1200
1400

250
390
510
650

6

8
10
12
14
16
18
20

81012 1416 18202224

HEIGHT IN INCHES

WIDTH IN INCHES

Part Number 101MRTD W x H
Sizes available from 8” x 6” up
to 24” x 20”

ZONE DAMPERS

W

Part Number 101EC W x H
Sizes available from 8” x 8” up
to 24” x 12”

2-1/2"

HEAVY DUTY RECTANGULAR DAMPER DIMENSIONS

Part Number 101CD W x H
Sizes available from 8” x 8” up to 48” x 48”

Dampers listed below are standard sizes. For larger sizes and capacities, contact the factory.

5"

RECTANGULAR DAMPER CAPACITIES*

H

Motors on low and medium pressure dampers will be mounted on the Height (H) side. Bottom mount motors will be located on the Width (W) side.
*These air quantities were derived from a duct sizing chart .1” friction loss per 100’ of duct. All CFMs listed are approximate. For accurate selection use duct

sizing table or device.

21

ZONE DAMPERS

FIVE WIRE LINK TO

SYSTEM CONTROLLER

TO

THERMOSTAT

TB2

WY

RC

RO
MC

RC

W2

BWYG
R

d

TB1

W2

Electronic stat

if applicable

OPEN MOTOR*

CLOSE MOTOR

*OPEN MOTOR NOT UTILIZED
ON LOW PRESSURE
(SPRING OPEN) DAMPERS.

SIZING ZONE DAMPERS

If the ductwork already exists, simply size the damper to fit the ductwork.
For new systems or retrofit jobs:

a) Determine CFM from heat gain or loss calculations.

WIRING ZONE DAMPERS

b) Select damper size by using a duct sizing table or calculator.

c) Select a Zonex Systems damper to fit the duct size selected for that

zone.

For heavy-duty rectangular dampers:
CW = RC (Run Closed)
COM = MC (Motor Common)
CCW = RO (Run Open)

1. Do not exceed 700 FPM in a register/diffuser branch duct.

2. If a damper is installed within 3 feet of register/diffuser, install sound
attenuating flex duct between damper and outlet.

3. Zone dampers should be preceded by 2’-4’ of straight pipe where
possible.

4. In attic installations and high humidity areas, the Zonex Systems
damper should be insulated along with the ductwork. The hat sec­tion on the damper is delivered with insulation between the hat sec-

DAMPER INSTALLATION NOTES

For heavy-duty round dampers:
CCW = RC (Run Closed)
COM = MC (Motor Common)
CW = RO (Run Open)

tion and pipe. Therefore, insulation should be applied to the round
pipe and be butted against the hat section, (do not insulate the
motor or relay board). Both motor and the relay board generate
enough heat so no condensation will develop on the hat section.

5. Remember to allow a 16” gap in the duct for Heavy Duty rectangular
dampers.

6. Low and Medium pressure rectangular dampers slide into a 3-1/4”
wide cutout in the side of the preexisting ductwork.

22

TO THERMOSTAT

*

No connection

(- - - -) For power open/closed damper applications only.

FIVE WIRE LINK

TO

SYSTEM

CONTROLLER

DAMPER #2

RELAY BOARD

YRC

W

YRC

RO MC RC W

Rd B

WY

G

TB1TB2

W2

W2

DAMPER #1

RELAY BOARD

YRC

RO MC RC W

Rd B

W

YG

TB1TB2

W2

W2

*
*

*

*

*

*
*

*

*

*

*

YRC

RO MC RC W

Rd BW

Y

G

TB1TB2

W2

W2

*
*

*

*

*

*
*

*

*

*

*

DAMPER #3

RELAY BOARD

BYPASS DAMPERS – BAROMETRIC

INSTALLATION

The round barometric bypass damper can be installed in any position.
This damper is factory set for horizontal installation and can be field
modified for vertical installation. Do not run speed screws into damper
housing. Screws may interfere with damper travel. Make sure counter
weight is not obstructed in any way.

a) Install the bypass damper between the supply and return

plenums of the unit. It must be the first tap off the supply plenum.

b) Be sure the air flows through the damper in the proper direc-

tion as indicated by the arrow on the damper. Airflow is always
from supply to return plenum. Be certain the damper shaft

is horizontal.
c) Loosen counter weight with allen wrench.
d) Loosen lever arm from damper shaft and allow to hang straight

down.
e) Fully close damper by grabbing damper shaft on side attached

to lever arm and turning clockwise until it stops.
f) While holding the damper fully closed, rotate the lever arm a

little to the right (facing the damper) and then screw in to

tighten to the damper shaft. Then tighten lock nut.
g) Be sure the damper is being held closed by the counter weight.

Proceed to set up.

BAROMETRIC BYPASS SETUP

a) Turn off all thermostats.
b) Turn on Switching Center/Controller and set fan switch to “ON”

position. Allow fan to run for 5 minutes to equalize pressure.
Then make sure all dampers are open by checking for air flow
out of each damper.

c) By moving counter weight up or down the lever arm, adjust it

so that the damper just wants to start opening.

d) If the damper cannot be held closed with the counter weight all

the way at the bottom of the lever arm, then hold the damper
shaft, loosen the lever arm from the damper shaft, and rotate
the lever arm further to the right and retighten. Repeat Step C.

e) The barometric bypass damper is now calibrated.

BAROMETRIC BYPASS STARTUP TEST

a) Have at least half of the zones call for either heating or cooling.
b) Check to be sure the calling zone dampers are open, (air is

flowing).

c) Verify the bypass damper is open. Note, the damper may not

fully open.

d) If the open zones are not noisy, the bypass damper is set.

AIRFLOW

SHEET METAL

PIPE

AIRFLOW

BAROMETRIC

BYPASS

HORIZONTAL APPLICATION

A/C UNIT

RETURN

VERTICAL APPLICATION

SUPPLY

PLENUM

A/C UNIT

FURNACE

RETURN AIR GRILLE

OR

FURNACE

BAROMETRIC

BYPASS

OR

RETURN

AIR

PLATFORM

SUPPLY

PLENUM

AIRFLOW

ROOF TOP INSTALLATION Down Discharge Application

A/C UNIT

FURNACE

BAROMETRIC

SUPPLY

PLENUM

OPEN RETURN PLENUM BYPASS APPLICATION

To prevent bypass air from

flowing out the return grill,

use a short open ended

return air plenum to
connect the bypass

damper to the unit.

RETURN AIR

GRILLE

SHEET METAL

BYPASS DAMPER

AIRFLOW

PIPE

AIR CONDITIONING

UNIT

OR

BYPASS

ROOF LINE

RETURN
PLENUM

SUPPLY

DUCT

24

BYPASS DAMPERS – ELECTRONIC

ELECTRONIC BYPASS DAMPERS

Bypass dampers are used to provide constant air delivery through the air handling unit. This
is done by bypassing excess air from the supply duct back to the return duct. As a zone
is satisfied its zone damper closes. When this happens, the bypass damper opens just enough
to bypass the excess air. This will control static pressure and noise at the diffusers.

The Electronic Bypass Damper can be used on any size system over. The damper can be
round or rectangular and multiple dampers can be slaved together. The Electronic Bypass
Damper consists of a medium pressure round or a heavy duty rectangular damper and
a static pressure sensor.

SIZING ELECTRONIC BYPASS DAMPERS

When only the smallest zone is calling, the maximum amount of excess supply air will flow
through the bypass damper.

CFM CALCULATION

To determine the proper size bypass damper:
A) Calculate total air volume at 400 CFM per Ton.
B) Calculate air volume of smallest zone in CFM .
C) Calculate bypass CFM by subtracting the smallest zone air volume from the total.

(A - B = C).

ROUND BYPASS DAMPER SELECTION

When you know the bypass CFM requirement as
determined in the “CFM calculation” section, use the
ROUND BYPASS SELECTION TABLE. From the table,
select the bypass damper with the CFM rating equal to
or greater than the value calculated in step C of CFM
Calculation.

Example: We know the smallest zone air volume is
400 CFM and we have a four ton system. Thus the
air volume we need to bypass is (400 * 4) – 400
which equals 1200 CFM. Using the ROUND BYPASS SELECTION TABLE, we would select a 12 inch
bypass since it can handle up to 1250 CFM of air.

ROUND BYPASS SELECTION TABLE

Diameter CFM

6” 320

8” 560
10” 900
12” 1250
14” 1700
16” 2200

RECTANGULAR & ROUND BYPASS DAMPER

WITH THE STATIC PRESSURE CONTROL

ROUND DIMENSIONAL DATA

PART #
STMPD06
STMPD08
STMPD10
STMPD12
STMPD14
STMPD16

SIZE

6

8
10
12
14

16

D

L

6"

10"

8"

10"

10"

12"
14"

12"
14"

16"

16"

18"

L

D

W

W
9"
11"
13"

15"
17"
19"

Never exceed 16 inches for the round bypass damper. If you need to bypass more than 2200 CFM,
either use a rectangular bypass or slave multiple round bypass dampers.

RECTANGULAR BYPASS DAMPER SELECTION

When you know the bypass CFM requirement as determined in the
“CFM calculation” section, use the RECTANGULAR BYPASS SELEC­TION TABLE. From the table, select the bypass damper with the CFM
rating equal to or greater than the value calculated in step C of CFM
Calculation.

Example: We know the smallest zone air volume is 250 CFM and we
have a 7-1/2 ton system. Thus the air volume we need to bypass is
(400 X 7.5) -250) which equals 2750 CFM. Using the RECTANGULAR
BYPASS SELECTION TABLE, we see the smallest damper we can use
is a 12” x 22” or a 22” x 12”.

RECTANGULAR BYPASS DAMPERS

SELECT FROM 8 X 8 THRU 48 X 48

H

D

WIDTH HEIGHT

Part Number STCD W X H

DEPTH

H 16"W

25

48" MAXIMUM WIDTH

Rectangular bypass dampers should operate at 1500 FPM*
E.G. A 24" x 12" damper = 2 square feet.
2 square feet X 1500FPM = 3000 CFM.

* FPM = Feet Per Minute

W

4"

24 28 32 36 40 44 48

8 2000 2333 2667 3000 3333 3667 4000
10 2500 2917 3333 3750 4167 4583 5000
12 3000 3500 4000 4500 5000 5500 6000
14 3500 4083 4667 5250 5833 6417 7000
16 4000 4667 5333 6000 6667 7333 8000
18 4500 5250 6000 6750 7500 8250 9000
20 5000 5833 6667 7500 8333 9167 10000
22 5500 6417 7333 8250 9167 10083 11000
24 6000 7000 8000 9000 10000 11000 12000
28 7000 8167 9333 10500 11667 12833 14000
32 8000 9333 10667 12000 13333 14667 16000
36 9000 10500 12000 13500 15000 16500 18000
40 10000 11667 13333 15000 16667 18333 20000
44 11000 12833 14667 16500 18333 20167 22000
48 12000 14000 16000 18000 20000 22000 24000

8 10 12 14 16 18 20 22

8 667 833 1000 1167 1333 1500 1667 1833
10 833 1042 1250 1458 1667 1875 2083 2292
12 1000 1250 1500 1750 2000 2250 2500 2750
14 1167 1458 1750 2042 2333 2625 2917 3208
16 1333 1667 2000 2333 2667 3000 3333 3667
18 1500 1875 2250 2625 3000 3375 3750 4125
20 1667 2083 2500 2917 3333 3750 4167 4583
22 1833 2292 2750 3208 3667 4125 4583 5042
24 2000 2500 3000 3500 4000 4500 5000 5500
28 2333 2917 3500 4083 4667 5250 5833 6417
32 2667 3333 4000 4667 5333 6000 6667 7333
36 3000 3750 4500 5250 6000 6750 7500 8250
40 3333 4167 5000 5833 6667 7500 8333 9167
44 3667 4583 5500 6417 7333 8250 9167 10083
48 4000 5000 6000 7000 8000 9000 10000 11000

WIDTH IN INCHES

HEIGHT IN INCHES

BYPASS DAMPERS – ELECTRONIC

RECTANGULAR BYPASS SELECTION TABLE

Bypass air in CFM. Calculated at 1500 FPM.
Formula used: B = W X H / 144 X 1500, where B = Bypass air in CFM, W = damper width in inches, H= damper height in inches, 144 = 144 sq.
inches per sq. ft., 1500 = 1500 FPM.

BYPASS POSITION INDICATOR

SLAVING BYPASS DAMPERS

Use only one Pressure Sensor when slaving two
or more Bypass Dampers together. Connect the
Pressure Sensor to one damper as described
above. Connect the slave dampers in parallel as
shown. Up to 4 dampers can be slaved to one
Sensor. The slaved dampers will self syn­chronize each time the dampers reach full open
or full close.

DAMPER

ACTUATOR

To Static Pressure Controller As Shown On The Bypass Wiring Diagram On The Next Page.

ROUND AND RECTANGULAR

BYPASS DAMPER MOTORS

SHAFT END MARKING IS PARALLEL

WITH DAMPER BLADE. DAMPER TRAVEL

IS 60° ON ROUND BYPASS AND 90°

ON RECTANGULAR BYPASS

CW

CCW

Note: Clockwise to close
on rectangular bypass and
counterclockwise on
round bypass.

RC RO MC

**

***

RC
MC

RO

N/C
COM
N/O

101ASPC

Static

Pressure Control

SLAVE

DAMPER

ACTUATOR

*

RC RO MC

26

TO NEXT SLAVE
BYPASS DAMPER
IF APPLICABLE

RC
RO
MC

BYPASS DAMPER – STATIC PRESSURE CONTROLLER

The Static Pressure Controller controls a standard medium pressure round damper (STMPD) or the heavy duty rectangular damper (STCD) by
maintaining constant static pressure in the duct downstream of the bypass takeoff. As the zone dampers close, the static pressure increases. When
this happens, the static pressure controller opens the bypass damper to bring the static pressure back to the setpoint.

STATIC PRESSURE CONTROLLER DESCRIPTION

A: Mounting tabs.
B: Supply air barb.
C: Reference air, “LOW”, barb.
D: Diaphragm must be

mounted vertically.
E: Pressure adjusting screw.
F: Normally closed, N/C, terminal.
G: Normally open, N/O, terminal.
H: Common, COM, terminal.

BC

D

E

A

F

G

H

STATIC PRESSURE CONTROLLER INSTALLATION

a. Select location for pressure sensor tube. Location should be in sup-

ply duct, downstream of bypass takeoff, upstream of any zone

dampers and perpendicular to the air flow.
b. Drill 5/16” hole at selected location for pressure sensor tube.
c. Mount Static Pressure Controller near the drilled hole with the

diaphragm of the sensor vertical. The controller must be mounted

on a stable, non vibrating surface.
d. Attach 5/16” pressure sensor tube, supplied, to the barb of the Sta-

tic Pressure Controller located closest to the mounting tabs. The oth-

er barb, labeled “LOW”, is left open if the Controller is in the

conditioned building. If the Controller is located outside the build-

ing, another tube, not provided, must be connected between the

“LOW” barb and a location inside the building.
e. Remove the terminal cover and wire as shown in the wiring

diagram.
f. Reattach terminal cover. Installation is complete. Proceed to Static

Pressure Controller Setup.

AIR

C

CONDITIONER

O

AIRFLOW

Insert the tube into the side of the duct, approximately

1

3”. Make sure the tube is perpendicular to the air flow.

I

L

MOTOR

WINDOW

STOPS

AIRFLOW

STATIC

PRESSURE

SENSOR

BYPASS DAMPER

1

STATIC PRESSURE CONTROLLER SETUP

Note: 24V ac may be read on both terminals (RO & RC to MC) due to

voltage bleeding thru the motor windings. Disconnect the RO or RC wire
to determine which wire is energizing the motor.

a. Ensure all dampers are open and blower is running on high speed.

Zonex Systems recommends de-energizing the bypass damper when the
blower fan turns off. If not installed as recommended, when the blower fan
turns off the bypass will fully close. Then when the blower fan turns back
on, there could be excessive air supplied to the calling zone, causing exces­sive air noise until the bypass is able to open sufficiently. An alterna­tive wiring diagram is provided using an additional static pressure sensor
to deenergize the bypass damper.

Alternative Wiring

b. Verify bypass damper is Closed

.
Bypass dampers using a square
motor have a grey release lever on the bottom/side of the damper
(near motor) to manually open or close the damper.

c. At 101ASPC Static Pressure Controller, remove the NO wire from the

micro switch. Connect A/C voltmeter (or test light) to COM and NC
terminals of static pressure controller. Zero V ac

(no light) should

be present, ensuring a connection is made between COM and NC. If
24V ac is present (light on), turn adjustment screw on 101ASPC Sta­tic Pressure Controller clockwise (CW) until connection is made and
0V ac (no light) is obtained. Do Not Overtighten Adjusting Screw.

d. Verify bypass damper is Closed. Slowly back out adjusting screw

(CCW) until 24V ac (light on) is present ensuring no connection
between COM and NC. STOP. Slowly turn adjusting screw in (CW)
until 0V ac (no light) is present. STOP. Bypass damper should be on
verge of opening but still closed with all zone dampers open and the
blower fan on high speed.

e. If the bypass damper sizing and duct design are correct, this

completes the bypass damper setup. Connect all wires and proceed to
Bypass Checkout.

BYPASS CHECKOUT FOR STATIC
PRESSURE CONTROLLER

a. Make a cool call at the zone thermostat of the smallest (damper size) zone.
b. Verify all zone dampers are closed except for calling zone.
c. Verify noise at zone register is not excessive. Adjust static pressure

controller CCW to lower noise (airflow) or CW to increase airflow
until too noisy.

27

P/N GE/HP

#

STAGES

ECONO

CNTRL

CUT-IN SET-POINT LEAVING

AIR

COMPRESSOR

MIN. RUN

FAN

CONTROL

101CAPGE

GE 1 HT, 1 CL NO NO FULL RANGE

YES

NO NO

TRLAT

GE 1 HT, 1 CL NO NO

4 HT, 4 CL

NO NO YES

CAPL-2

GE 2 HT, 2 CL YES YES FULL RANGE YES YES YES

CAPL-4

GE 4 HT, 4 CL YES YES FULL RANGE YES YES YES

SYCAP

HP 2 HT, 1 CL NO NO FULL RANGE YES NO NO

TRFPC

GE

1 CL

NO NO FULL RANGE NO NO NO

CAPACITY CONTROLLERS

An HVAC system is sized to handle the load of an entire home or building.
Because of this, when all the zones are not calling, the load to the HVAC
system can diminish below its designed capacity. Left unchecked, the A/C
coil could freeze up causing compressor slugging or the furnace could
overheat causing premature heat exchanger failure. To compensate for
this, a Capacity Controller is needed.

The basic function of the Capacity Controller is to monitor the leaving
air temperature and cycle the unit on and off to maintain a leaving air
temperature within set parameters. Zonex Systems offers six unique capac­ity controllers to meet all your application needs: TRLAT, 101CAPGE, CAPL­2, CAPL-4, SYCAP and TRFPC.

CAPACITY CONTROLLER SELECTION

Select the Capacity Controller best suited for your application based on the following table and feature list.

GE/HP – Gas/Electric or Heat Pump. For Gas/Electric HVAC systems,

select GE. For heat pumps select HP unless heat pump uses GE thermostats
(no external reversing valve control), then select GE.

# STAGES – Maximum number of HVAC system heat and cool stages.

ECONO CNTRL – This feature allows the economizer to operate as an

additional stage of cooling when outdoor air conditions are acceptable. May
be used with HVAC systems that utilize an economizer.

CUT-IN – This advanced feature separates the cut-in setpoint from the

cut-out setpoint. This permits better staging and leaving air temperature
control. Example: Without this feature, in cool mode with a cut-out
setpoint of 48 degrees, the compressor will turn off if the leaving air drops
below 48 and, after a time delay, turn back on when the air rises above

48. With this feature, if the cut-out is 48, the cut-in will be 58. If the air
drops below 48 the compressor will turn off. It will not turn on, howev­er, until the air temperature rises above 58 and a time delay has elapsed.
This gives longer compressor running times and maintains a more com­fortable leaving air temperature.

FEATURE LIST

SETPOINT – Number of setpoints available for heat and cool.

LEAVING AIR DISPLAY– Digitally displays the leaving air temperature.

This is useful for troubleshooting and system monitoring.

COMPRESSOR MIN. RUN – Runs the compressors a minimum of

four minutes whenever they are energized. This ensures proper oil return
and increased compressor life.

FAN CONTROL – Runs the indoor blower fan during capacity cut-out.

This ensures the heat exchanger properly cools down and the AC coil
warms up during capacity cut-out. It also provides better zone tem­perature control by providing conditioned air during capacity cut-out
periods. This feature is not provided or necessary for heat pumps because
blower fan is continuously energized as long as there is a call. This fea­ture is also not necessary if blower fan is run continuously.

28

CAPACITY CONTROLLERS – 101CAPGE

OVERVIEW

The 101CAPGE is a Gas/Electric Capacity Controller that digitally displays
leaving air temperature. It should be utilized for single stage
applications. For multistage HVAC systems, use either the CAPL-2 or CAPL­4 Capacity Controller.

The Zonex Systems 101CAPGE capacity controller protects both the air
conditioner and furnace. It simply measures the leaving air temperature.
If the air gets too cold (drops below the cool cutout setpoint), it breaks
the “Y” connection, disengaging the compressor. If the air gets too warm
(rises above the heat cutout setpoint), it breaks the “W” connection, de­energizing the furnace. To prevent short cycling, the compressor or fur­nace cannot reenergize for at least four minutes after cutout. The heat­ing and cooling cutout setpoints can be changed by the installer.

The 101CAPGE has a three digit LED display and two push buttons.
Normally the leaving air temperature is displayed. When the push but­tons are pressed the cut-out setpoints are displayed.

OPERATION

The 101CAPGE has three modes of operation: in range, out of range and
enable mode.

In Range – If the leaving air temperature is between the cool and heat
cutout setpoints and the 101CAPGE is not in cutout time delay, light DL1

is off and relay K1 is made, permitting the System Controller to energize
the compressor or furnace. The leaving air temperature is displayed on
the digital display during this time.

Out of Range – If the leaving air temperature drops below the cool
cutout setpoint or rises above the heat cutout setpoint, light DL1 is lit and
the relay contacts between Y1 Y1 and W1 W1 break, de-energizing the
compressor or furnace. Four minutes after the leaving air temperature
has returned within operating range light DL1 is turned off and the
relay contacts close, making Y1 Y1 and W1 W1 and energizing the fur­nace or compressor. The leaving air temperature is displayed on the
digital display during this time.

Enable Mode – On the digital display, “E” followed by the leaving air
temperature indicates that the 101CAPGE is in the Enable Mode. The
purpose of this mode is to ensure the furnace can turn on in a cold
building and the air conditioner can turn on in a hot building. Enable
Mode is entered if the leaving air temperature is below the cool cutout
setpoint or above the heat cutout setpoint for more than eight minutes.
The relay contacts are made during this mode, enabling the furnace or
air conditioner to run. After the leaving air temperature has returned
within operating range the 101CAPGE will return to normal operation,
displaying only the leaving air temperature.

COMPONENTS

The 101CAPGE consists of the following:

Digital Display – Three digit LED. Normally displays the leaving

A.

air temperature of the HVAC unit. When “E” is displayed, it indicates
101CAPGE is in Enable mode; refer to OPERATION section. When
the UP/DN buttons are pressed, the cutout setpoints are displayed.
Refer to the Setpoint Calibration section for reading and adjusting the
setpoints.

B. Microcontroller – Activates and controls outputs based

upon leaving air temperature comparison with programmed set­points. Occasionally software upgrades may become available. If
so, the 101CAPGE software can be field upgraded by changing this
microcontroller.

Cut-out Indicator Lights – DL1 light is on when relay K1 is

C.

energized. See E.

D. Thermometer Calibrator – Calibrates the leaving air tempera-

ture thermometer. Turn clockwise to lower temperature. Turn coun­terclockwise to raise. Refer to CALIBRATION section for com­plete calibration information.

E. Relays K1 and K2 – DPDT, NC relays. When K1 is energized, it

breaks contact between Y1 Y1 and W1 W1 terminals.

G

961205-C

K

C

DL1

E

UP

J

DN

ON

I

OFF

TR1 TR2

H

A

CAPGE V3.4

B

D

R11

+-

F

Leaving Air Sensor (LAS) Terminals – Leaving air tempera-

F.

Y1 Y1 W1W1

ture sensor is connected to the 101CAPGE here. Red to + and white
to –. The sensor monitors the leaving air of the HVAC system. If pre­ferred, the 101CAPGE can be mounted up to 500 feet from the sen­sor. See INSTALLATION section for further information.

29

System Controller (101ASSB)

Switching Center (SYGE)

101CAPGE

K1aK1b

H
V
A
C

U
N

I

T

Y

W

C

G

R

R G WY

Y1Y1

W1W1

TR1TR2

Without Fan Relay

With Fan Relay

K1aK1b

H
V
A
C

U
N

I

T

Y1Y1W1W1TR1TR2

SPDT, 24V

AC Relay

Y

W

C

G

R

101CAPGE

System Controller (101ASSB)

Switching Center (SYGE)

R G WY

4

2

5

1

3

CAPACITY CONTROLLERS – 101CAPGE

G. HVAC/System Controller Interface Terminals– Y1 controls

the A/C compressor and W1 controls the furnace. W1 controls the
first stage furnace and W2 controls second stage. One Y and W connect
to the System Controller, the other Y and W connect to the HVAC unit.
It does not matter which W/Y connects to the System Controller and
which connects to the HVAC unit. See WIRING section for detailed
wiring instructions.

Power Source Terminals – Connect to 24V AC power source.

H.

Recommend using either the HVAC unit transformer or the System
Controller transformer. 101CAPGE uses less than 2 VA of power. See
WIRING section for detailed wiring instructions.

101CAPGE WIRING

The 101CAPGE is installed as detailed in the Capacity Controllers
installation section, Page 40. The following wiring diagrams show how
to wire the 101CAPGE to the System Controller and the HVAC unit.
Terminals TR1 and TR2 of the 101CAPGE can be wired either to R and C
of the HVAC Unit or to TR1 and TR2 of the System Controller.

There are two ways of wiring the 101CAPGE: without a fan relay and with
a fan relay.

I.

Power Switch – When off, the display is off, the 101CAPGE is

disabled and the relay contacts are closed. The HVAC unit can run at
this time but will not have capacity control protection. When the
switch is on, the display is on and the 101CAPGE is operational.

J. Setpoint Adjustment – Use the UP/DN buttons to view and change

the cut-out setpoints. Refer to the Setpoints, Calibration section (Page

41) for reading and adjusting the setpoints.

Board Number – This number indicates the circuit board number

K.

and revision. You may need to know this number if conferring with
technical support.

Use the “Without Fan Relay” drawing if the indoor blower fan will be
running continuously or the furnace keeps the indoor blower fan on for
at least three minutes after the heat call is removed (W de-energized).

Use the “With Fan Relay” drawing if the indoor blower fan will not be
running continuously and the furnace does not keep the indoor blower fan
on for at least three minutes after the heat call is removed (W de-energized).
The relay is a SPDT, 24V AC.

30

CAPACITY CONTROLLERS – TRLAT

GE

O

HP
B

CONTROLLER UNIT

+ -

ONOFF

SW1
SW2
SW3
SW4

WYRO/B G C W YRO/B G C

D
E
L
A
Y

P
W
R

B

A

G

E

F

C

D

OVERVIEW

The Zonex Systems TRLAT is a single stage Gas/Electric or Heat Pump
Capacity Controller. However, the heat pump feature is not compatible
with the Zonex Systems System 1000/2000 Zoning Systems so we will
only address the Gas/Electric features. If you have a heat pump that uses
heat pump controls refer to the SYCAP for System 1000 and LAS for
System 2000.

The TRLAT Capacity Controller protects both the air conditioner and
furnace. It simply measures the leaving air temperature. If the air gets
too cold (drops below the cool cutout setpoint), it breaks the “Y”
connection, disengaging the compressor, If the air gets too warm (rises
above the heat cut-out setpoint), it breaks the “W” connection, de-energizing
the furnace. To prevent short cycling, the compressor or furnace cannot
reenergize for at least four minutes after cut-out. The heating and
cooling cut-out setpoints can be changed by the installer.

OPERATION

Cool mode: If the leaving air temperature drops below the TRLAT

cooling setpoint (field settable to 41, 44, 47 or 50 degrees Fahrenheit),
the Y (Controller) breaks from Y (Unit) and makes to G. This turns off
the compressor and keeps the indoor blower fan running to warm up
the evaporator. Four minutes after the leaving air temperature rises above
the cooling setpoint, Y (Controller) makes to Y (Unit) and breaks to G.
This restarts the compressor and returns indoor blower fan control to
the Switching Center/Controller.

COMPONENTS

A. Status Lights:

DELAY (red): On when compressor or furnace is disabled.
PWR (yellow): On when TRLAT is powered.

B. Jumpers:

GE/HP: For gas/electric systems, place jumper on GE and center
pin. For heat pumps, place jumper on HP and center pin.(Digitract
Systems only)
O/B: For heat pumps, if reversing valve is energized in cool mode,
place jumper on O and center pin. If reversing valve is energized in
heat mode, place jumper on B and center pin.

C. Unit terminal block: Connects to HVAC unit. O/B – Reversing

Valve; R – 24V AC hot; G – Blower fan; C – 24V AC rtn; W – heat; Y –
compressor. See WIRING section for detailed wiring instructions.

D. Controller terminal block: Connects to System Controller. Terminal

designations same as for Unit terminal block. See WIRING section for
detailed wiring instructions.

E. Leaving Air Sensor (LAS) Terminals: Leaving air temperature sensor

is connected to the TRLAT here. Red to + and white to –. The sensor
monitors the leaving air of the HVAC system. If preferred, the TRLAT
can be mounted up to 500 feet from the sensor. See INSTALLATION
section for further information.

Heat mode: If the leaving air temperature rises above the TRLAT heating
setpoint (field settable to 125, 140, 150 or 160 degrees Fahrenheit), the
W (Controller) breaks from W (Unit) and makes to G. This turns off the
heater and keeps the indoor blower fan running to cool down the heater.
Four minutes after the leaving air temperature drops below the heating
setpoint, W (Controller) makes to W (Unit) and breaks to G. This restarts
the heater and returns indoor blower fan control to the heater or
Switching Center/Controller.

Cut-out disable: The cool cutout is disabled in heat mode. The heat
cutout is disabled in cool mode. This permits the heat to turn on in a cold
building and the air conditioner to turn on in a hot building. For heat
pumps, this also prevents the compressor from cycling off when the heat
pump is in defrost mode. The O/B (Controller) input tells the TRLAT
which mode of operation (heat or cool) is active.

NOTE: For GE systems, a jumper wire (factory installed) must be
connected between O/B (Controller) and W (Controller).

F. Jumper wire: Factory installed. Must be connected between O/B

(Controller) and W (Controller) for GE systems and removed for heat
pumps.

G. Setpoint Select: Sets the heat and cool cutoff setpoints. See SETPOINT

SETUP, TRLAT section.

31

CAPACITY CONTROLLERS – TRLAT

SETPOINT SETUP, TRLAT

A four pole dip switch is used to designate the desired heat and cool
cutoff setpoints. Using the table to right, set the switch positions to
correspond to the cutoff temperatures desired. For heat pumps, the
heat cutoff point is 118 degrees and unchangeable.

Cool

SW1 SW2
On On 50 Deg F
On Off 47 Deg F
Off On 44 Deg F
Off Off 41 Deg F

SW3 SW4
On On 125 Deg F
On Off 140 Deg F
Off On 150 Deg F
Off Off 160 Deg F

Cut-out

Heat

Cut-out

TRLAT WIRING

System 1000 Switching Center (SYGE)

System 2000 Controller (101ASSB)

RG WY

1

O/B R G

C W

TRLAT

O/B R G C

R G

HVAC UNIT

The TRLAT is installed as detailed in the Capacity Controllers
Installation section, page 40. Wire as shown above.

WARNING

1

Jumper wire (factory installed) must be connected for GE
applications between W (Controller) and O/B (Controller). If not,
the TRLAT will not shut off the heater when the heat setpoint is
exceeded.

W

C W

CONTROLLER

Y

UNIT

Y

Y

CAPACITY CONTROLLERS – TRFPC

OVERVIEW

The TRFPC is an inexpensive no frills single stage air conditioning only
Capacity Controller. It will simply interrupt power to the air conditioning
compressor when the supply air temperature drops below 47 degrees
Fahrenheit and re-energize when the temperature rises above 47 degrees.
This setpoint is non-adjustable. It has no control for preventing compressor
short cycling. If your air conditioner does not have a non-recycle timer,
we highly recommend adding one when using this Capacity Controller to
prevent short cycling.

OPERATION

The TRFPC will interrupt power to the air conditioning compressor when
the supply air temperature drops below 47 degrees Fahrenheit and
re-energize when the temperature rises above 47 degrees. This setpoint
is non-adjustable. The TRFPC is powered by the “Y” terminal. Thus, the
TRFPC will operate only when there is a call for cooling (24V at “Y”). A
green status light is provided. When on, the compressor can run (relay
closed). When off, the “Y” circuit is broken, disengaging the compressor.

WIRING

The TRFPC is installed as
detailed in the Capacity

System Controller (101ASSB)

Switching Center (SYGE)

R G WY

Controllers installation
section, page 40. The fol­lowing wiring diagrams
show how to wire the
TRFPC to the System
Controller and the HVAC

R

H
V

G

A
C

C

U

W

N
I

Y

T

unit. Terminal C of the
TRFPC must be wired to

C

YOUTYIN

the HVAC unit’s trans­former common.

TRFPC

Note: A non recycle timer on the air conditioner is strongly recommended

to prevent short cycling.

32

CAPACITY CONTROLLERS - SYCAP

OVERVIEW

The SYCAP is a single stage cool, two stage heat Heat Pump Capacity
Controller. It works in conjunction with the System 1000 SYHPA
Switching Center only. Its function is to control the heat pump coil
leaving air temperature within a set operating range.

When the heat pump is running, the SYCAP keeps the heat pump coil leaving
air temperature within operating range by turning the heat pump
compressor off for a minimum of four minutes if the air temperature gets
too cold in cool mode or too hot in heat mode. The SYCAP will also turn
on the heat pump auxiliary heat if the coil leaving air temperature is not
hot enough in heat mode. The compressor is kept off for a minimum of
four minutes to prevent short cycling.

OPERATION

The SYCAP has two relays (K1 and K2) and two corresponding status
lights (DL1- red and DL2- green). Relay K1 is a normally closed relay.
When energized, it breaks the connection between Y1 Y1 which disables
the heat pump compressor. Relay K2 is a normally open relay. When
energized, it makes the connection between W2 W2 which enables the
heat pump auxiliary heat.

There are three adjustable setpoints on the SYCAP: Heat Cut-out, Cool
Cut-out, and Auxiliary Heat Cut-in. The Heat Cut-out Setpoint is the
maximum allowable leaving air temperature in heat mode. If the air
temperature rises above this setpoint in heat mode, the compressor is
disabled for a minimum of four minutes. The Cool Cut-out setpoint is the
minimum allowable leaving air temperature in cool mode. If the air
temperature drops below this setpoint in cool mode, the compressor is
disabled for a minimum of four minutes. The Auxiliary Heat Cut-in
temperature is the minimum allowable leaving air temperature in heat
mode. Four minutes after the heat pump compressor has been turned
on, if the coil air temperature cannot rise above this setpoint, the auxiliary
heat is enabled. The auxiliary heat is disabled when the air temperature
rises nine degrees above the Auxiliary Heat Cut-in setpoint.

The SYCAP knows which mode of operation it is in by monitoring the W2
signal from the SYHPA Switching Center. If W2 is energized, it knows the
SYHPA is making a heat call.

The following is a detailed operation description of each mode.

IN RANGE, HEAT MODE – If the SYHPA Switching Center is making

a heat call and the leaving air temperature is below the Heat Cut-out
setpoint and above the Auxiliary Heat Cut-in, relays K1 and K2 are
de-energized, red light DL1 is off and green light DL2 is off. The leaving
air temperature is displayed on the digital display.

COOL CUT-OUT – If the SYHPA is making a cool call and the leaving

air temperature drops below the Cool-Cut-out setpoint, the connection
between Y1 Y1 breaks, red light DL1 turns on, and the Heat Pump
compressor is disabled. Every four minutes after Y1 is broken, the
leaving air temperature is checked. If the temperature rises above the
cool cut-out setpoint, Y1 Y1 is made, red light DL1 turns off and the
compressor is re-enabled.

HEAT CUT-OUT – If the SYHPA is making a heat call and the leaving air

temperature rises above the Heat Cut-out setpoint, the connection between
Y2 Y2 breaks, red light DL1 turns on, and the Heat Pump compressor is
disabled. Every four minutes after Y2 is broken, the leaving air temperature
is checked. If the temperature drops below the heat cut-out setpoint, Y2
Y2 is made, red light DL2 turns off and the compressor is re-enabled.

AUXILIARY HEAT CONTROL – Four minutes after the SYHPA initiates

a heat call, the leaving air temperature is continuously checked. If the air
temperature does not rise above the Auxiliary Heat Cut-in setpoint, green
light DL2 turns on, the connection between W2 W2 is made, and the Heat
Pump Auxiliary heat is enabled. When the leaving air temperature rises
nine degrees above the auxiliary heat cut-in setpoint, green light DL2
turns off, W2 W2 is broken, and the auxiliary heat is disabled.

SYCAP Components

The SYCAP consist of the following:

A. Digital Display – Three digit LED. Normally displays the coil

leaving air temperature of the heat pump. When “E” displayed,
indicates SYCAP is in Enable mode; refer to OPERATION section. When
the UP/DN buttons are pressed, the cutout setpoints are displayed.
Refer to the Setpoint Calibration section for reading and adjusting
the setpoints.

B. Microcontroller – Brains of the SYCAP and where the program

resides. Occasionally, software upgrades may become available. If so,
the SYCAP software can be field upgraded by changing this micro­controller.

C. Status Lights – Red light DL1 is on when relay K1 is energized.

Green light DL2 is on when relay K2 is energized. See E.

D. Thermometer Calibrator – Calibrates the leaving air temperature

thermometer. Turn clockwise to lower temperature. Turn counter­clockwise to raise. Refer to CALIBRATION section for complete
calibration information.

E. Relays K1 and K2 – SPST relays. Relay K1 is a normally closed

relay. When energized, it breaks contact between Y1 Y1. Relay K2 is
a normally open relay. When energized, makes contact between W2
W2 terminals.

F. Leaving Air Sensor (LAS) Terminals – Leaving air temperature

sensor is connected to the SYCAP here. Red to + and white to –. The
sensor monitors the coil leaving air of the heat pump. If preferred,
the SYCAP can be mounted up to 500 feet from the sensor. See
INSTALLATION section for further information.

G. Heat Pump/Switching Center Interface Terminals – Y1

controls the heat pump compressor. W2 controls the heat pump
auxiliary heat. One Y1 and W2 connect to the Switching Center, the
other Y1 and W2 connect to the heat pump. It does not matter which
W2/Y1 connects to the Switching Center and which connects to the
heat pump. See WIRING section for detailed wiring instructions.

33

CAPACITY CONTROLLERS - SYCAP

UP

DN

RC+-

DL1

K1

A

K

J

B

D

I

H

G

F

DL2

C

Y1 Y1 W2W2

K2

E

90107C

ON

OFF

H. Heat Pump Power Terminals – Connect to heat pump 24V AC

power source. R is 24 V hot. C is 24 V rtn. Cannot be connected to
any other power source. SYCAP uses less than 2 VA of power. See
WIRING section for detailed wiring instructions.

I. Power Switch – When off, the display is off, the SYCAP is disabled

and K1 relay contacts are made. The heat pump compressor can run
at this time but will not have capacity control protection. The
auxiliary heat cannot run. When the switch is on, the display is on
and the SYCAP is operational.

J. Setpoint Adjustment – Use the UP/DN buttons to view and

change the cut-out setpoints. Refer to the Setpoints, Calibration
section (Page 41) for reading and adjusting the setpoints.

K. Board Number – This number indicates the circuit board num-

ber and revision. You may need to know this number if con­ferring with technical support.

WIRING

The SYCAP is installed as detailed in the Capacity Controllers Installation
section, page 40. Wire as diagrammed below. The W2 terminal from the
SYHPA Switching Center must be wired to the SYCAP Capacity Controller
even if the Heat Pump does not have auxiliary heat. The SYCAP determines
the mode of operation based on this signal.

Terminals R and C of the SYCAP must be wired to terminals R (24V hot)
and C (24V rtn) of the Heat Pump system transformer.

34

Switching Center (SYHPA)

RGW2YO/B E L C

O/B

H

Y

E
A

G

T

R

P

E

U

M

W2

P

L

C

CR

SYCAP

W2W2

Y1Y1

K1K2

CAPACITY CONTROLLERS - 101ALAS

Deg. F. DC Volts Deg. F. DC Volts Deg. F. DC Volts

40 2.775 70 2.942 100 3.109
41 2.781 71 2.948 101 3.114
42 2.787 72 2.953 102 3.120
43 2.792 73 2.959 103 3.125
44 2.798 74 2.964 104 3.131
45 2.803 75 2.970 105 3.137
46 2.809 76 2.975 106 3.142
47 2.814 77 2.981 107 3.148
48 2.820 78 2.987 108 3.153
49 2.825 79 2.992 109 3.159
50 2.831 80 2.998 110 3.164
51 2.837 81 3.003 111 3.170
52 2.842 82 3.009 112 3.175
53 2.848 83 3.014 113 3.181
54 2.853 84 3.020 114 3.187
55 2.859 85 3.025 115 3.192
56 2.864 86 3.031 116 3.198
57 2.870 87 3.037 117 3.203
58 2.875 88 3.042 118 3.209
59 2.881 89 3.048 119 3.214
60 2.887 90 3.053 120 3.220
61 2.892 91 3.059 121 3.225
62 2.898 92 3.064 122 3.231
63 2.903 93 3.070 123 3.237
64 2.909 94 3.075 124 3.242
65 2.914 95 3.081 125 3.248
66 2.920 96 3.087 126 3.253
67 2.925 97 3.092 127 3.259
68 2.931 98 3.098 128 3.264
69 2.937 99 3.103 129 3.270

Deg. F. DC Volts

130 3.275
131 3.281
132 3.287
133 3.292
134 3.298
135 3.303
136 3.309
137 3.314
138 3.320
139 3.325
140 3.331
141 3.337

OVERVIEW

The 101ALAS works with the System 2000 Heat Pump System Controller
(101AACBHP). The 101ALAS provides leaving air temperature readings
to the System Controller, which allows it to make capacity control decisions.

OPERATION

The 101ACBHP System Controller has four status lights that represent
capacity control. The heat Y1 and Y2 red lights indicate heating opera­tion and the cool Y1 and Y2 green lights indicate cooling operation. Heat­ing or cooling will be initiated depending on the position of the revers­ing valve. When one of the lights turns on, the leaving air temperature in
the duct, sensed by the LAS, has exceeded one of the capacity control set­points. The light will indicate which stage will be turned off. The sec­ond stage factory default cut-in temperature for heating is 95 degrees, and
for cooling 60 degrees. If the setpoint is exceeded, a stage light will illu­minate, the stage will be shut down, and a four-minute time delay will
begin. After the four minute delay, if the leaving air temperature has recov­ered to an acceptable temperature, the stage which was shut down will
restart. If the temperature has not recovered, the time delay will contin­ue. If both first and second stage setpoints are exceeded by the leaving
air, then a four-minute time delay per stage will go into effect.

MODIFYING SETPOINT ADJUSTMENT

The Heat Pump Controller is designed so that it is possible to modify the
cut-in setpoints for cooling, heating (and electric heat on the Heat Pump
Controller). If necessary, locate the potentiometer associated with its test
point on the diagram above. “GND” is the common ground test point, TP2

is the cool test point and TP3 is the heat test point. (TP1 is the electric
heat test point on the Heat Pump Controller). Clip the leads of a digital
volt meter, set to 20 volts DC, between the potentiometer test point that
needs to be modified and the ground test point. Rotate the correspond­ing potentiometer until the meter reads the proper voltage according
to Table 2 below.

101ALAS

+

GROUND

ELECTRIC
HEAT ADJ
TP1

COOL ADJ
TP2

HEAT ADJ
TP3

1

GND

TB2 WRO

TB1

Y1

+

Y2

HEAT

–

–

J1

Y1

COOL

TC2 Y W B GRd TR1TR2S

TC1TEMP

J2

Y2

Y2

101AACBHP
HEAT PUMP

CONTROLLER

REV.

VALVE

Y1

/

BL

ON

PWR
OFF

OFF

COOLHEAT

AUTO

OFF

AUTO

G

FAN

ON

WIRING

The 101ALAS is installed as detailed in the Capacity Controllers

1

Installation Section, page 40. The + or – terminals of the LAS are
wired to the + or – terminal of the 101AACBHP using two
conductor 18 gauge thermostat wire.

LAS VOLTAGE CONVERSION CHARTS

TABLE 1: CAPACITY CONTROL

STAGE CUT-IN TEMPERATURES*

Cooling

Second Stage 60 GND & TP2 2.887

Heating

Second Stage 95 GND & TP3 3.081
Electric Heat 85 GND & TP1 3.025
Discharge Duct

Temperature –– LAS + & – per table #2

*The Y2 cut-out temperature is 10° fixed below the cut-in temperature

in cooling, and 10° above in heating.
The Y1 cut-out temperature is 15° fixed below the cut-in temperature in
cooling, and 25° above in heating.

TABLE 2: TEMPERATURE TO VOLTAGE
CONVERSION CHART

35

CAPACITY CONTROLLERS – CAPL-2

YINY1Y2G

I
N

WIN W1W2 R C

24V PWR

24V RTN

HEAT 1

HEAT 2

ECONOMIZER

COMP 1

COMP 2

FAN

Y

G

W

R

LAS

SENSOR

+

-

CAPL-2

HVAC UNIT

+ –

SYGE Switching Center

101ASSB System Controller

G
O

U
T

*Lennox L Series Units may require a direct connection from YIN to the Economizer.

*

OVERVIEW

The Zonex Systems CAPL-2 is a combination staging and capacity control
device for use with gas/electric units and heat pumps that use standard
gas/electric thermostats. It can stage an economizer, two stages of cooling
and up to two compressors and two stages of heat. The CAPL-2 monitors
the leaving air temperature and stages the cooling or heating to maintain
the leaving air temperature within a fixed range. Controlling the staging
based on the leaving air temperature ensures the supply always matches
the load. This is essential with a zoning system since the load varies sub­stantially as the number of zones calling varies.

Cool Mode – When there is a cool call, if the leaving air is above the cool
cut-in temperature, the CAPL-2 turns on the next stage compressor after
a time delay. If the air gets too cold, it turns off the last stage compressor
after that compressor has run a minimum of four minutes. As long as
there is a cool call, when a compressor turns off it will stay off for a
minimum of four minutes if the jumper is on ECON and when a compres­sor turns on it will run a minimum of four minutes. This prevents
short cycling and ensures sufficient compressor oil return. When the
cool call is removed, all compressors are immediately turned off.

Heat Mode (Gas/Electric) – If the leaving air is below the heat cut­in temperature, it turns on the next heat stage after a time delay. If the air
gets too warm, it turns off the last heat stage after a time delay. When the
heat call is removed, all heat stages turn off immediately.

Heat Mode (Heat Pump) – When there is a heat call, if the leaving air
is below the heat cut in temperature, the CAPL-2 turns on the next stage
heat after a time delay. If the air gets too warm, it turns off the last stage
heat after that stage has run a minimum of four minutes. As long as there
is a heat call, when a heat stage turns off, it will stay off for a minimum of
four minutes and when a heat stage turns on it will run a minimum of four
minutes. This prevents short cycling and ensures sufficient compressor
oil return. When the heat call is removed, all compressors are immediately
turned off.

SEQUENCE OF OPERATION

The following sequence of operation assumes the cool cut-out setpoint is
48 degrees Fahrenheit and the heat setpoint is 150 degrees for
gas/electric units and 118 degrees for heat pump units. For any other
cut-out settings, add or subtract the difference to the values stated.
Example: If your actual cool cut-out is 50 degrees, add 2 degrees to each
temperature value stated under the Cooling Call section. All temperatures
are in degrees Fahrenheit.

COOLING CALL (cool setpoint 48): As long as there is a cooling call

(YIN energized), the following will occur.

ECONOMIZER:

• As long as there is a cooling call the economizer, if available, is enabled
and outside air is supplied based on enthalpy. The Economizer
selection jumper must be on ECON if there is an economizer. If no
economizer, place jumper on ECOFF.

COMPRESSOR STAGING ON:

• If the leaving air is 58 degrees or greater and no compressors are

running, compressor one will turn on within six minutes. If compressor
one is running, compressor two will turn on within eight minutes.

COMPRESSOR STAGING OFF:

• If the leaving air is between 48 and 52 degrees and
compressor two is running, compressor two will shut off after
running a minimum of four minutes. Compressor one will shut off
after it has been on a minimum of four minutes and compressor two
has been off a minimum of six minutes.

• If the leaving air is 48 degrees or less, then all compressors will turn

off after the last compressor running has run for at least four minutes.

NO STAGING:

• If the

HEATING CALL (Gas/Electric)

Heat setpoint may be field modified to compensate for local temperatures

leaving air is equal to or greater than 52 and less than

58 degrees, then no compressor staging will occur.

(The factory heat setpoint is 150.

WIRING – CAPL-2

36

CAPACITY CONTROLLERS – CAPL-2

and field conditions. For example, in milder climates setting may be as low
as 110 to 115 degrees. In more severe climates up to 150 degrees.) As long
as there is a heating call (WIN energized), the following will occur.

HEAT STAGING ON:

• If the leaving air is 130 degrees or less and heat one is off, heat

one will turn on within four minutes. If heat one is on, heat two will
turn on within ten minutes.

HEAT STAGING OFF:

• If the leaving air is between 145 and 150 degrees and heat two

is running, heat two will turn off. Heat one will turn off after 150
Degree setpoint is exceeded

• If the leaving air is 150 degrees or greater then all heat stages

will turn off and the indoor blower fan is energized until heat one
turns back on or until the heat call is satisfied.

NO STAGING: If the leaving air is greater than 130 and less than

or equal to 145 degrees, then no heat staging will occur.

COMPONENTS

The CAPL-2 consists of the following:

A. Digital Display – Three digit LED. Normally displays the leaving air
temperature of the HVAC unit. When the UP/DN buttons are pressed, the
cut-out setpoints are displayed. Refer to the Setpoint Calibration
section for reading and adjusting the setpoints.

B. Microcontroller – Activates and controls outputs based upon leaving
air temperature comparison with programmed setpoint. Occasionally soft­ware upgrades may become available. If so, the CAPL-2 software can be
field upgraded by changing this microcontroller.

C. Thermometer Calibrator – Calibrates the leaving air temperature
thermometer. Turn clockwise to lower temperature. Turn counterclock­wise to raise. Refer to CALIBRATION section for complete calibration infor­mation.

D. Economizer Selection Jumper:

ECON – Place here if you have an economizer.
ECOFF – Place here if no economizer.

E. Leaving Air Sensor (LAS) Terminals – Leaving air temperature
sensor is connected to the CAPL-2 here. Red to + and white to –. The
sensor monitors the leaving air of the HVAC system. If preferred, the
CAPL-2 can be mounted up to 500 feet from the sensor. See Installation
section for further information.

F. HVAC/System Controller Interface Terminals – Y IN – Cool call
input, Economizer output; Y1 – Compressor 1; Y2 – Compressor 2;
G – Indoor blower fan; W IN – Heat call input; W1 – Heat 1; W2 – Heat

2. See Wiring section for detailed wiring instructions.
G. HVAC Power Terminals – Connect to HVAC system 24V AC power

source. R is 24 V hot. C is 24 V rtn. Cannot be connected to any other
power source. CAPL-2 uses less than 2 VA of power. See Wiring section
for detailed wiring instructions.

HEATING CALL (Heat Pump) (heat setpoint 118). As long as there

is a heating call (WIN energized), the following will occur:

HEAT STAGING ON:

• If the leaving air is 98 degrees or less and heat one is off, heat

one will turn on within four minutes. If heat one is on, heat two will
turn on within eight minutes.

HEAT STAGING OFF:

• If the leaving air is between 113 and 118 degrees and heat two

is on, heat two will shut off after running a minimum of four min­utes. Heat one will turn off after it has been on a minimum of four min­utes and heat two has been off a minimum of six minutes.

• If the leaving air is 118 degrees or greater then all heat stages will

turn off after the last heat stage running has run for at least four min­utes.

NO STAGING:

• If the leaving air is greater than 98 and less than or equal to
113 degrees, then no heat staging will occur.

H. Status Lights – ECONO – On during cool call. Indicates economiz-

er enabled; Y1 – On when first stage compressor energized; Y2 – On
when second stage compressor energized; Y3 – On when third
stage compressor energized; Y4 – On when fourth stage compressor
energized; FAN – On when indoor blower fan energized by System Con­troller or CAPL-2 (G energized); W1 – On when first stage furnace
energized; W2 – On when second stage furnace energized; W3 – On
when third stage furnace energized; W4 – On when fourth stage furnace
energized.

I. Power Switch – When off, the display is off, the CAPL-2 is disabled and
the relay contacts are closed. The HVAC unit can run at this time but will
not have staging control or capacity control protection. When the switch
is on, the display is on, and the CAPL-2 is operational.

J. Board Number – This number indicates the circuit board number and
revision. May need to know this number if conferring with technical
support.

K. Heat Pump/Gas Electric selection jumper – Place at GE position
for gas/electric units.

ECON

E
C
O
N
O

Y1 Y2

UP

L

DN

HP

GE

D

H

F
A
N

W1 W2

GOUT

F

Place at HP position for
heat pump units that use
gas/electric thermostats.

L. Setpoint Adjust­ment – Use the UP/DN

buttons to view and
change the cutout set­points. Refer to the Set­points, Calibration sec­tion (Page 41) for read­ing and adjusting the set-

s.

point

37

A

B

R4

ECOFF

C

E

Y IN Y1 Y2 GINRCWIN W1 W2

-

+

J

K

990616B

ON

OFF

I

G

CAPACITY CONTROLLERS – CAPL-4

OVERVIEW

The Zonex Systems CAPL-4 is a combination staging and capacity control
device in one. It can stage an economizer and up to four compres­sors and up to four stages of heat. The CAPL-4 monitors the leaving air
temperature and stages the cooling or heating to maintain the leaving air
temperature within a fixed range. Controlling the staging based on the
leaving air temperature ensures the supply will always match the load.
This is essential with a zoning system, since the load varies sub­stantially as the number of zones calling varies.

Cool mode – When there is a cool call, if the leaving air is above the
cool cut-in temperature, the CAPL-4 turns on the next stage compressor
after a time delay. If the air gets too cold, it turns off the last stage
compressor after that compressor has run a minimum of four minutes.
As long as there is a cool call, when a compressor turns off it will stay off
for a minimum of four minutes and when a compressor turns on it will
run a minimum of four minutes. This prevents short cycling and
ensures sufficient compressor oil return. When the cool call is
removed, all compressors are immediately turned off.

Heat mode – If the leaving air is below the heat cut-in temperature, it
turns on the next heat stage after a time delay. If the air gets too warm,
it turns off the last heat stage after a time delay. When the heat call is
removed, all heat stages turn off immediately.

OPERATION

The following sequence of operation assumes the cool cut-out setpoint is
48 and the heat is 150 degrees Fahrenheit. For any other cut-out settings,
add or subtract the difference to the values stated. Example: If your actu­al cool cut-out is 50 degrees, add 2 degrees to each temperature val­ue stated under the Cooling Call section. All temperatures are in degrees
Fahrenheit.

NO STAGING:

If the leaving air is equal to or greater than 52 and less than 58°
then no compressor staging will occur.

HEATING CALL (heat setpoint 150). As long as there is a heating call
(WIN energized), the following will occur.

HEAT STAGING ON:

If the leaving air is 130° or less, the next heat stage will turn on
within four minutes. As long as the air temperature remains within this
range the next higher heat stage will turn on every four minutes.

HEAT STAGING OFF:

If the leaving air is between 145 and 150° the highest heat stage on
will shut off within four minutes. As long as the air temperature remains
within this range the next highest heat will stage off every four minutes.

If the leaving air is 150° or greater then all heat stages will turn off.

COMPONENTS

The CAPL-4 consist of the following:

A. Digital Display – Three digit LED. Normally displays the leaving air
temperature of the HVAC unit. When the UP/DN buttons are pressed, the
cut-out setpoints are displayed. Refer to the Setpoint Calibration section
for reading and adjusting the setpoints.

B. Microcontroller – Activates and controls outputs based upon leav­ing air temperature comparison with programmed setpoints. Occasion­ally software upgrades may become available. If so, the CAPL-4 software
can be field upgraded by changing this microcontroller.

COOLING CALL (cool setpoint 48): As long as there is a cooling call
(YIN energized), the following will occur.

ECONOMIZER:

As long as there is a cooling call the economizer, if available, is enabled
and outside air is supplied based on enthalpy.

COMPRESSOR STAGING ON:

If the leaving air is 58° or greater, the next compressor will turn
on within four minutes. As long as the air temperature remains within
this range the next higher compressor will stage on every four minutes.

COMPRESSOR STAGING OFF:

If the leaving air is between 48 and 52°, the highest compressor
stage on will shut off within four minutes. As long as the air temperature
remains within this range the next highest running compressor will stage
off every four minutes.

If the leaving air is 48° or less then all compressors will turn off after
the last compressor running has run for at least four minutes.

38

A

C

+

D

R4

-

B

E
C
O
N
O

Y1 Y2 Y3 Y4 G

Y1 IN Y1 Y2

Y3

Y4

UP

J

DN

G

W1 IN

990407A

SW1

G

W1 W2W3 W4

W3

W1W2

W4

I

ON

H

RC

F

E

CAPACITY CONTROLLERS - CAPL-4

C. Thermometer Calibrator – Calibrates the leaving air temperature

thermometer. Turn clockwise to lower temperature. Turn counter­clockwise to raise. Refer to CALIBRATION section for complete calibra­tion information.

D. Leaving Air Sensor (LAS) Terminals – Leaving air temperature
sensor is connected to the CAPL-4 here. Red to + and white to –. The
sensor monitors the leaving air of the HVAC system. If preferred, the CAPL­4 can be mounted up to 500 feet from the sensor. See INSTALLATION
section for further information.

E. HVAC/System Controller Interface Terminals – Y IN – Cool call
input, Economizer output; Y1 – Compressor 1; Y2 – Compressor 2; Y3
– Compressor 3; Y4 – Compressor 4; G – Indoor blower fan; W IN – Heat
call input; W1 – Heat 1; W2 – Heat 2; W3 – Heat 3; W4 – Heat 4. See
WIRING section for detailed wiring instructions.

F. HVAC power terminals – Connect to HVAC system 24V AC power
source. R is 24 V hot. C is 24 V rtn. Cannot be connected to any other
power source. CAPL-4 uses less than 2 VA of power. See WIRING section
for detailed wiring instructions.

WIRING – CAPL-4

G. Status Lights – ECONO – On during cool call. Indicates economizer

enabled; Y1 – On when first stage compressor energized; Y2 – On when
second stage compressor energized; Y3 – On when third stage
compressor energized; Y4 – On when fourth stage compressor energized;
FAN – On when indoor blower fan energized by System Controller or
CAPL-4 (G energized); W1 – On when first stage furnace energized;
W2 – On when second stage furnace energized; W3 – On when third stage
furnace energized; W4 – On when fourth stage furnace energized.

H. Power Switch – When off, the display is off, the CAPL-4 is disabled
and the relay contacts are closed. The HVAC unit can run at this time but
will not have staging control or capacity control protection. When the
switch is on, the display is on and the CAPL-4 is operational.

I. Board Number – This number indicates the circuit board number and
revision. May need to know this number if conferring with technical support.

J. Setpoint Adjustment – Use the UP/DN buttons to view and change
the cut-out setpoints. Refer to the Setpoint, Calibration section (Page 41)
for reading and adjusting the setpoints.

24V RTN

24V PWR

HEAT 4
HEAT 3
HEAT 2
HEAT 1

FAN

HVAC UNIT

COMP 4
COMP 3
COMP 2
COMP 1

ECONOMIZER

LAS

SENSOR

+ –

-

+

G

W

Y

R

101ASSB System Controller

Y1 IN Y1 Y2 Y3 Y4 G W1 IN W1 W2W3W4 R C

CAPL-4

39

C
A
P
A
C

I
T
Y

Sensor

Protect sensor wire from
sharp edges by using
grommet or tape.

C

O

N
T
R

O

L
L
E
R

CAPACITY CONTROLLERS – INSTALLATION

A. Select location to place sensor. For gas/electric HVAC systems, sen-

sor must be in leaving air duct, preferably as far from the coil/heat
exchanger as possible but not past the bypass tap. For heat pumps,
sensor must be placed between coil and auxiliary heat. If heat
pump does not have auxiliary heat, place sensor as specified for
gas/electric system. See Figure 1.

B. Cut or drill a hole in selected location large enough to fit sensor

through.

C. For 101CAPGE, TRLAT, SYCAP, CAPL-2 and CAPL-4, determine if

Capacity Controller will be mounted integral with sensor or remote
from sensor. Mounting sensor remotely enables you to place the
Capacity Controller in a location easily visible and serviceable.

D. For the 101ALAS, TRFPC, or if mounting any other model with the

sensor integral with Capacity Controller, place sensor through hole made
in duct and mount Capacity Controller to duct with screws. Use grommet
or tape to protect sensor wire from sharp edges. See Figure 2.

GAS/ELECTRIC

C

O

I

AIRFLOW

BYPASS
RETURN

L

Figure 1. Sensor Location

HEAT PUMP

E. If mounting sensor remotely, refer to Figure 3 and do the following:

1. On Capacity Controller, loosen + and – terminal screws and
disconnect sensor.

2. Remove circuit board screws and pull circuit board away from
casing.

3. Pull sensor out of casing.

4. Reattach circuit board to casing with screws previously removed.

6. Place sensor in hole made in duct and secure with tape, wire tie
or cable clamp. Use grommet or tape to protect sensor wire from
sharp edges.

7. Select location for Capacity Controller and mount with screws.

8. Wire sensor to Capacity Controller, red to + and white to –. If less
than 200 feet, use separate 18 gauge, two conductor wire. If over
200 feet, use separate two conductor shielded wire and connect
shield to TR2 or C terminal of Capacity Controller.

Place sensor in supply duct,
as far from coil/heat exchanger
as possible but not past
Bypass tap.

BYPASS

TAP

C

O

AIRFLOW

BYPASS
RETURN

L

Place sensor in heat
pump between coil and
auxiliary heat

Figure 2. Capacity Controller Mounted with Sensor

H

A

E

I

U
X

A
T

+ -

White to –
Red to +

BYPASS

TAP

Circuit board screws (qty. 3)

If using shielded wire, connect
shield to TR2 or C

Secure sensor with tape,
cable clamp or wire tie

White
Red

Protect sensor wire from
sharp edges by using
grommet or tape.

Figure 3. Capacity Controller with Remote Sensor

40

CAPACITY CONTROLLERS – SETPOINTS, CALIBRATION

WIRE LENGTH

NUMBER OF

ZONE

DAMPERS

50' 100' 150' 200'
1 18 GA 18 GA 18 GA 18 GA
2 18 GA 18 GA 18 GA 18 GA
3 18 GA 18 GA 18 GA 18 GA
4 18 GA 18 GA 18 GA 18 GA
5 18 GA 18 GA 18 GA 18 GA
6 18 GA 18 GA 18 GA 16 GA
7 18 GA 18 GA 18 GA 16 GA
8 18 GA 18 GA 16 GA 16 GA
9 18 GA 18 GA 16 GA 14 GA

10 18 GA 18 GA 16 GA 14 GA
11 18 GA 16 GA 16 GA 14 GA
12 18 GA 16 GA 14 GA 14 GA
13 18 GA 16 GA 14 GA 12 GA
14 18 GA 16 GA 14 GA 12 GA
15 18 GA 16 GA 14 GA 12 GA
16 18 GA 14 GA 14 GA 12 GA
17 18 GA 14 GA 12 GA 12 GA
18 18 GA 14 GA 12 GA 12 GA
19 18 GA 14 GA 12 GA 12 GA
20 18 GA 14 GA 12 GA 12 GA

The following applies to the

101CAPGE,
CAPL-2,
CAPL-4 and
SYCAP Setpoints:

There are two cut-out setpoints, one for heat and one for cool. The
digital display normally displays the leaving air temperature of the
HVAC/heat pump unit. By pressing the UP and DN buttons, the setpoints
can be viewed and changed.

Cool Setpoint – To read the cool cut-out setpoint, press the DN button
until “C” appears and then release. The number that follows is the cool
cut-out setpoint. After a couple of seconds the leaving air temperature will
be redisplayed. To change the setpoint, press the bottom or down button
until the “C” is displayed, then immediately after the setpoint is displayed
press and hold the UP/DN button till setpoint is at the desired value.

Zonex Systems’s patented Five Wire Link is one of the most important ele­ments of the System 1000/2000 zoning system. Extra care should be made
to ensure the wiring is done correctly. The color code must be strictly fol­lowed. Ensure the stripped wire leads are not touching each other at the ter­minal blocks. If putting two wires into one terminal block, use the same
gauge wire for both and ensure they are seated properly.

You must ensure the wire is sized properly to match the power needs of
the number of dampers installed. The more dampers used, the greater the
current draw and the greater the voltage loss on the Five Wire Link. If too
much voltage is lost on the Five Wire Link, there will not be enough
voltage at the zone dampers to properly operate them. To ensure the
correct wire size, use the following table. Select the row matching the
number of zone dampers you have. Move across horizontally to the
column that matches the distance from the System Controller to the
farthest damper. Use the wire size specified at the row/column
intersection.

To reduce wire size, you can run more than one Five Wire Link Daisy Chain.
Example: If you have 10 dampers, and the maximum distance is 200 feet,
you would need 12 GA wire. If instead, you used two Five Wire Links with
5 dampers on each, you would now only need 18 GA wire for each daisy
chain. Multiple daisy chains are wired color to color at the System
Controller.

NOTE: Never use less than 18 GA wire on the 5 Wire Link.

Heat Setpoint – To read the heat cut-out setpoint, press the UP button

until “H” appears and then release. The number that follows is the heat
cut-out setpoint. After a couple of seconds the leaving air temperature
will be redisplayed. To change the setpoint, press the top or up button
until the “H” is displayed, then immediately after the setpoint is displayed
press and hold the UP/DN button till setpoint is at the desired value.

Auxiliary Heat Setpoint – For the SYCAP only, to read the auxiliary
heat setpoint, press the UP and DN buttons simultaneously until “E”
appears and then release. The number that follows is the auxiliary heat
setpoint. After a couple of seconds the leaving air temperature will be
redisplayed. To change the setpoint, immediately after the setpoint is displayed
press and hold the UP/DN button till the setpoint is at the desired value.

CALIBRATION

The digital display normally displays the leaving air temperature of the
internal thermometer. This thermometer is factory calibrated. If calibration
is ever required, turn the Thermometer Calibrator clockwise to lower the
temperature. Turn counterclockwise to raise.

FIVE WIRE LINK

41

WIRING THE ZONE DAMPER

For Duct Supplemental Heat
Applications

K1 = RELAY DPDT

W
Y

R
C

RC

K1

DAMPER

MOTOR

B

K1 A

MC
RO

TO FIVE

WIRE

LINK

SAIL OR PRESSURE

SWITCH

MAKE AND BREAK

ELECTRIC HEAT

CIRCUIT

NOTE: CONTACT "K1 A" IS ONLY REQUIRED FOR DUCT

HEATER APPLICATIONS TO FORCE DAMPER TO THE
OPEN POSITION

Rd

G

Y

W

THERMOSTAT

1 STAGE COOL 2 STAGE HEAT

R

YW

1 W2 C

K1 B

TO

A/C UNIT

OR FURNACE

G

R

Time
Clock
Switch

RG

SWITCHING CENTER

OR

SYSTEM CONTROLLER

W

RC

C

Y

T-STAT

TRANSFORMER / FUSE SIZING

Transformer/fuse sizing:The 24V transformer

connected to TR1 and TR2 of the Switching
Center/System Controller powers the zone
dampers, zone thermostats and Switching
Center/System Controller. The power rating of
the transformer must be sufficient to power
the number of dampers used. Also, a properly
rated in line fuse must be used on the secondary
of the transformer. To determine the power
rating of the transformer and the amperage
rating of the fuse, use the table above.

Note: If using both spring open and power open
dampers, size as if all dampers are spring open.

NUMBER LOW PRESSURE MED. PRESSURE/HEAVY DUTY

OF (SPRING OPEN) DAMPERS (POWER OPEN) DAMPERS

DAMPERS XFMR PWR FUSE SIZE XFMR PWR FUSE SIZE

1 12 V A 1 AMP 6 V A 1 AMP
2 24 V A 2 AMP 12 VA 1 AMP
3 36 V A 2 AMP 18 VA 1 AMP
4 48 V A 3 AMP 24 VA 2 AMP
5 60 V A 3 AMP 30 VA 2 AMP
6 72 V A 4 AMP 36 VA 2 AMP
7 84 V A 5 AMP 42 VA 3 AMP
8 96 V A 5 AMP 48 VA 3 AMP

9 108 V A 6 AMP 54 VA 3 AMP
10 120 VA 6 AMP 60 V A 3 AMP
11 132 VA 7 AMP 66 V A 4 AMP
12 144 VA 7 AMP 72 V A 4 AMP
13 156 VA 8 AMP 78 V A 4 AMP
14 168 VA 9 AMP 84 V A 5 AMP
15 180 VA 9 AMP 90 V A 5 AMP
16 192 VA 10 AMP 96 VA 5 AMP
17 204 VA 10 AMP 102 VA 5 AMP
18 216 VA 11 AMP 108 VA 6 AMP
19 228 VA 11 AMP 114 VA 6 AMP
20 240 VA 12 AMP 120 VA 6 AMP

APPLICATION SCHEMATICS

TYPICAL SETBACK/SETUP WIRING FOR ALL
SWITCHING CENTERS AND SYSTEM CONTROLLERS

For continuous fan operation in the occupied mode and intermittent
operation during unoccupied periods, leave the System Controller/
Switching Center fan switch in the “ON” position.

Time Clock Switch:

Closed – Occupied
Open – Unoccupied

42

TB1

TR2TR1 B W Y GRD

FUSED 24 VOLT

TRANSFORMER

TO
ADDITIONAL
ZONES

SYSTEM

CONTROLLER

YW1 W2

TO BASE BOARD
CONTACTOR

**

*

DAMPER

RELAY

BOARD

NOTE:

FACTORY WIRED.

WYR CR

C MC RO

W2

BWYGR

dW2

R

C

THERMOSTAT
1 STAGE COOL
2 STAGE HEAT

(101DIGITS)

CENTRAL & AUXILIARY

BASE BOARD HEAT WIRING

H
V
A
C

U
N

I

T

SPDT, 24V

AC Relay

C

G

R

System Controller (101ASSB)

Switching Center (SYGE)

RG

W

4

2

5

1

3

APPLICATION SCHEMATICS

BLOWER FAN RELAY

If the heater does not turn on the indoor blower fan when heat is on, you
must add a blower fan relay as shown below. The relay will energize the
fan signal “G” when the heat signal “W” is energized.

*

The Blower Fan Mode (AUTO/ON) is usually selected at
the System Controller/Switching Center. If preferred, the
Fan Mode can be selected at one zone thermostat using
this diagram. The thermostat needs to have a fan switch.

ECONOMIZER INTERFACE FOR SWITCHING CENTERS AND SYSTEM CONTROLLERS
NOT UTILIZING THE CAPL-2 OR CAPL-4.

ECONOMIZER

ENTHALPY

CONTROL

COMPRESSOR

101ASSB

& SYGE

Y

Y
Y

101CAPGE OR
TRLAT ONLY

W

ZONE FAN CONTROL

C

R

WY
W

2

TB2

WY G

R

Auto

On

ZONE THERMOSTAT

(SADIGI)

(101PROG)

Note: Leave the fan switch in the "AUTO" position at the Switching Center or System Controller.

101AACB-HP

ENTHALPY

CONTROL

ECONOMIZER

Y1

COMPRESSOR

#1

Y2

COMPRESSOR

#2

RELAY

SWITCHING CENTER

G

SYSTEM CONTROLLER

ECONOMIZER

BW

d

R

DAMPER

G

RELAY

Y

BOARD

W2

TB1

OR

ENTHALPY

CONTROL

AC UNIT

43

G

R

SYHPA

Y

SYCAP

Y
Y

COMPRESSOR

SLAVING MULTIPLE DAMPERS

YRCRO MC RC W2

Rd B

WY

GW2

W

W

NC
NC
NC
NC

NC

NC
NC
NC
NC
NC

NC

NC

TO THERMOSTAT:
Wires used vary per application

FIVE

WIRE LINK TO

SWITCHING

CENTER

or

CONTROLLER

DAMPER #1

TB1

TB2

DAMPER #2

TB1TB2

DAMPER #3

TB1

TB2

SPDT
RELAY

24 Volt

Transformer

DAMPER

MOTOR

#1

Size Transformer

12VA Per Spring Return Damper

and 6VA Per Power Open /

Power Close Damper

To

Additional

Dampers

NC

No connection

(- - - -) For power open / power close dampers only

YRC

RO MC RC

W2

Rd B

WY

GW2

W

W

YRCWW2

YRCRO MC RC W2

Rd B

WYGW2

W

W

Damper Relay

Board

Damper Relay

Board

Damper Relay

Board

NC
NC
NC
NC

NC

NC
NC

NC
NC
NC

NC

NC

For Controller Transformer. (Transformer
connected to TR1 and TR2 of the Central
Controller) add 6VA for each relay used.

1

1

LINE

VOLTAGE

24 V

R

HEATING/COOLING AUTO CHANGE OVER WITH DUCT STAT

Mechanical

Room Stat

Duct Stat set at

65 degrees

R

WY

Y

W

HEATING/COOLING AUTO CHANGE OVER WITH

RELAY

PARALLEL THE RELAY WITH GAS

VALVE W WIRE ON HEATER

W

Y

R

LINE

VOLTAGE

24 V.

STAT

B

W

Y

G Rd

W

YRC

RO
MC
RC

TB2

TB1

DAMPER

RELAY

BOARD

W2

W2 B

W

Y

G Rd

W

YRC

RO

MC

RC

TB2

TB1

DAMPER

RELAY

BOARD

W2

W2

C

C

*

*

* "C" Terminal used for electronic thermostats

COOLING ONLY DAMPER

Y

R

STAT

LINE

VOLTAGE

24 V.

B

WY

G Rd

WYRCRO MC RC

TB2 TB1

DAMPER

RELAY

BOARD

W2

W2

C

*

W

Each zone thermostat can control more than one damper. To determine when to use this application drawing, refer to Slaving Zone Dampers section
on page 23.

PROPER BYPASS INSTALLATION WITH ECONOMIZER

When sizing a bypass damper, compute the
system total air volume at 400 CFM/Ton and
subtract the CFM of the smallest zone. The
balance of the air can be bypassed at any one
time. Refer to the Round and Rectangular
damper CFM Charts. Choose the bypass
closest to your CFM to bypass.

1. Outside Air Intake

2. Mixing Damper for Outside Air &
Return Air

3. Pressure Relief of Outside Air
from Building

4. Barometric Damper to Prevent
Return Air Pressurization

5. Modulating Bypass Damper

WIRING A STAND ALONE DAMPER

When no system controller is used, use Zonex Systems’s Digital, Auto
Changeover Stand Alone Modulating Thermostat (SAMOD) in con­junction with an ST Series round or rectangular damper.

Listed below are some non-modulating solutions to stand alone
applications if it is not possible to use a SAMOD.

44

SYSTEM 1000/2000 TERMINAL DESCRIPTIONS

Daisy Chain, 5 or 6 Wire Link:

1. GD/G Hot wire, 24V. Hot when Switching Center/Controller
TR1 is hot. For System 2000, turning Controller Power
switch off will remove power from GD. The Power switch
will not remove power from GD on System 1000.

2. BD/B 24V return (chassis ground). Measure all Daisy Chain
voltages in reference to this terminal.

3. RD Hot when the Switching Center/Controller recognizes a
thermostat call. Damper light on Switching Center/ Con­troller is on when RD is hot.

4. YD/Y Cool call, hot when cool call recognized by Switching
Center/Controller. For System 1000: 5V to 16V (1 to 7
zones calling). For System 2000: 212 mv to 3.64V
(1 to 20 zones calling). There should never be 24V on
this terminal when the System 1000 Switching Center
green light is on and the mode switch is at “Cool” or
when the System 2000 Controller’s “Damper” and
“Cool” lights are on. If there is, you have a short to either
RD or GD.

5. WD/W Heat call, hot when heat call recognized by Switching
Center/Controller. Voltages the same as for YD. There
should never be 24V on this terminal when the System
1000 Switching Center green light is on and the mode
switch is at “Heat” or when the System 2000 Controller’s
“Damper” and “heat” lights ar on. If there is, you have
a short to either RD or GD.

6. W2 Second stage heat call. 24V when second stage of zone
thermostat is calling. Only used with System 1000 SYHPA.

Damper Relay Board:

1. TB2:
a. MC

b. RC Run Closed. 24V when damper motor closing.

c. RO Run Open. 24V when damper motor opening.

d. R 24V hot. Same as GD.

e. C 24V return. Same as BD.

f. W Thermostat heat call. See below how to determine

g. Y Thermostat cool call. See below how to determine

h. W2 Second stage thermostat heat call. Same as W2 on

2. TB1: Daisy Chain. See Daisy Chain, 5 or 6 Wire Link above.

Motor common. Return for 24V damper motor(s).
Motor voltages measured in reference to this termi­nal.

if a zone is calling.

if a zone is calling.

Daisy Chain.

SYSTEM 1000/2000 TROUBLE SHOOTING

To determine if a zone is calling:

On Damper Relay board, measure voltage from W to W and Y to Y
(TB1 to TB2). If the voltage is at least 8 volts for System 1000 or 20
volts for System 2000, that zone is calling. If voltage is between W
and W, zone is calling for heat. If between Y and Y, zone is calling
for cool. To take this reading, RD must also be powered which
means the Switching Center/Controller has recognized the call
(Damper light on). Note: Do not test for a call by measuring the
voltage from Y to C or W to C on TB2. The system utilizes pull up
resistors which can give you false readings.

If Controller/Switching Center transformer fuse is blowing:

1. Check for short on five wire link between RD and B or between
G and B.

2. Check for short on thermostats between R and C.

If Controller circuit board fuse is blowing (System 2000 only):

Make sure that the voltage between TR1 and TR2 is not less than 24
V or more than 30 V. If voltage is okay, replace Controller. If volt­age is not within range, be sure you have the correct transformer and
that the primary voltage is adequate. If primary voltage is okay and
transformer is correct size, replace transformer.

If Controller off circuit board fuse is blowing (System 2000 only):

You have a short on the five wire link between either Y and G, W and
G, Y and Rd, or W and Rd.

If System 1000 SYHPA Switching Center circuit board fuse is
blowing:

You have a short on the five wire link between either YD and GD, WD
and GD, YD and RD or WD and RD.

45

Zonex Systems

System 2000

2-20 Zone Auto Changeover

System 1000

2-7 Zone Manual Changeover

Hot Line: [phone]

5622 Engineer Drive

Huntington Beach, CA 92649

Factory: [phone] • Fax: [phone]

Visit our Web Site http://www.hvaccomfort.com

E-mail us at [e-mail]

PATENTED PRODUCT
Zonex Systems reserves the right to discontinue, or change at any time,
specifications or designs without notice and without incurring obligations.
Copyright 2003 by Zonex Systems, Inc.

Zoning

Part #101ASIM

Rev. September 2003