Zonex ZonexCommander, ZonexCommander Plus Installation Manual

Installation and Applications Manual

Part #ZCMAN

ZonexCommander

ZonexCommander

(Plus)

Network All Your HVAC Equipment

Centralized DDC Communications

for Stand-Alone HVAC and Zoned Systems

Rev. Oct 2014

1

Table of Contents Page

Commander System Overview.....................................................................................................................................................................................3

System Selection Criteria.............................................................................................................................................................................................3

ZONEXCOMMANDER

ZONEXCOMMANDER (PLUS)

Unit Relay Module (RMOD)

OPTIONAL COMPONENTS

ZONE DAMPERS

Component Descriptions.........................................................................................................................................................................................4-5

Concept Drawing................................................................................................................................................................................................6

Component Selection Guide................................................................................................................................................................................7

Sequence Of Operation.......................................................................................................................................................................................8

Installation Instructions......................................................................................................................................................................................9

DIGICOM / DIGIHP Thermostats ................................................................................................................................................................10-11

Command Center – ZonexCommander.............................................................................................................................................................12

Wiring Overview ..............................................................................................................................................................................................13

Concept Drawing .............................................................................................................................................................................................14

Component Selection Guide..............................................................................................................................................................................15

Wiring Overview ..............................................................................................................................................................................................16

Sequence Of Operation ...............................................................................................................................................................................17-18

Command Center – ZonexCommander (Plus) .................................................................................................................................................19

Installation Instructions....................................................................................................................................................................................20

ModStat Thermostat and Supplemental Heat Applications............................................................................................................................21-22

Sequence Of Operation.............................................................................................................................................................................23

RMOD Terminal Diagram ........................................................................................................................................................................24

Description / Installation..........................................................................................................................................................................25

Wiring Overview – RMOD ........................................................................................................................................................................26

RMOD To Unit Wiring Diagram.................................................................................................................................................................27

SENDCOM – Communicating Duct Temperature Sensor .............................................................................................................................28-29

Communicating Relay Module (RLYCOM).........................................................................................................................................................30

Round Dampers ...............................................................................................................................................................................................31

Rectangular Dampers..................................................................................................................................................................................32-33

D-Fuser ...........................................................................................................................................................................................................33

Sizing................................................................................................................................................................................................................34

Slaving..............................................................................................................................................................................................................34

Bypass Dampers .........................................................................................................................................................................................35-36

Static Pressure Controller. ...........................................................................................................................................................................37-38

System Start-Up – Commander Software Review ........................................................................................................................................39-48

Trend And Data Logging Operation ..............................................................................................................................................................49-50

Troubleshooting....................................................................................................................................................................................................51

Operating Schedule..............................................................................................................................................................................................52

2

COMMANDER SYSTEM OVERVIEW

SYSTEM SELECTION CRITERIA

Are you using zone dampers on this job?

NO, control your stand-alone equipment with a ZonexCommander.
YES, use a ModCom or a ZonexCommander (Plus).

Stand-Alone Unit Applications

ZONEXCOMMANDER

1. How many units are on this project?

2. Are units Gas Electric or Heat Pump?

3. Are there any generic loads to control (pumps, lights, or fans)?

4. Is a Network/Internet communication required?

5. Proceed to the ZonexCommander Component Selection Guide,
and insert the above answers to develop a bill of materials for your
control system composed of stand-alone RTUs or split systems.

1. How many zones are on each unit?

2. How many stand-alone units are in this application?

3. What size dampers are needed?

4. What size and how many bypass dampers are needed?

5. Are there any generic loads to control and schedule (pumps, fans or
lights)?

6. Is Network/Internet communication required?

7. Proceed to the ZonexCommander (Plus) Component Selection

This manual covers the design and installation for the ZonexCommander
systems. ZonexCommander is a communicating Windows-based DDC
system designed to remotely control 1 – 80 RTUs, split systems or zones.
The systems can control stand-alone HVAC equipment, zoned units with
fully modulating or two-position zone dampers and auxiliary equipment
such as exhaust fans, lighting or other generic loads scheduled via the
ZonexCommander software.

Zonex is designed to network one or multiple zoned units on one
two-wire twisted pair for remote communications over the Internet in
buildings too large for multiple programmable thermostats but too small
for a full blown energy management system.

1. ZonexCommander – Controls stand-alone HVAC equipment 1-80 units

constant volume and VAV systems.

following features to enhance control and management of the facility
remotely or on-site as follows:
– On-site or remote control of all HVAC equipment
– Remotely collect and view temperature data, RA/SA from any unit
– Monitor or change every thermostat remotely, individually or globally
– Schedule each thermostat for two occupied and two unoccupied

periods per day
– Remotely lock thermostats individually or globally
– Vacation scheduling for 20 events of up to 30 days in duration
– Provide scheduled occupied and unoccupied operation of generic

devices (pumps, lights, fans, and more)
– Print reports for thermostat setpoints, zone or room temperatures
– Trend logging capability

– Remote system control with simple Windows operating software

To select the proper Zonex system for your application please answer the following questions:

Two versions of the product are available:

2. ZonexCommander (Plus) – designed to centralize control of multiple

Communications with these systems are accomplished with a computer

connected directly to the system or over the Internet. A dedicated on-site
computer is not required to operate any ZonexCommander.

Systems utilize Zonex Windows-based software and provide the

– Alarming

ZONEXCOMMANDER (PLUS) – for Multiple Zoned and

Stand-Alone Units

Guide.

3

ZONEX COMPONENT DESCRIPTIONS

providing remote communication with all RTUs or splits in your
system. The ZonexCommander eliminates the need to continually set

building. ZonexCommander bridges the gap between ineffective
stand-alone thermostats and expensive and complex automation systems.

COMMAND CENTERS

The Command Center is a microprocessor based digital communicating
controller. Each Command Center supports up to 20 devices (thermostats

ZonexCommander
ZonexCommander (Plus)

The Command Centers communicate with the computer through the RS-232
link, and communications with thermostats or devices communicate
through the RS-485 link using a daisy chained two-wire twisted pair
(Belden 8740).

not affected by power interruptions.

The Command Centers are powered by dedicated 24vac 40va, field
supplied transformers. Each Command Center must have its own

Part #CETCIP

network device, for 20 communicating devices.

The ZonexCommander automates and networks 1-80 HVAC units,

and reset multiple programmable thermostats located throughout yourr

Please review integral components of the Zonex Systems below.

and RLYCOM relay modules).

A unique Command Center exists for each communicating Zonex System::

Each Command Center maintains Day, Date, Time and Year with battery
backup. All Occupied, Unoccupied and Vacation schedules, device name
tags and addresses are programmed into non-volatile memory, which is

transformer power supply.

ZONEXCOMMANDER COMMAND CENTER

CETCIP – ZonexCommander Communications Package with TCIP

COMCIP – Command center with TCIP – adds 20 additional com-

municating devices for larger systems.

ZONEXCOMMANDER (PLUS) COMMAND CENTER

ZPTCIP – ZonexCommander (Plus) Communications Package with

TCIP network device for internet communications, for 1-4 RMODs

with 20 communicating devices. Includes system operating software.

CZNXIP Command Center with TCIP – supports 4 additional

RMODs and another 20 additional communicating devices.

ZonexCommander (Plus) is designed to provide centralized control

for multiple zoned HVAC systems. Each Command Center supports up

to 20 devices (ModStat, MODS2, DIGICOM thermostats and

RLYCOMs). Each ZPTCIP Command Center controls up to four

RMOD controllers, each controlling one HV AC unit. CZNXIP Com-

mand Centers via TCIP device provide expansion capability to

support up to 16 HVAC units with 80 zones. The thermostats are allo-

cated to the RMOD controller through ZonexCommander (Plus)

software.

RMOD – UNIT RELAY MODULE

For use with ZonexCommander (Plus) systems only

Each Command Center can support 4 RMODs. Each Universal RMOD

controls a zoned GE or

HP unit with on-board

capacity control. The

RMOD communicates

with the Command

Center and thermostats

assigned to that RMOD.

Each thermostat can

send a heat or cool call

to the RMOD. The RMOD

polls the number of heat

or cool calls every

minute and energizes

the unit based on our

control algorithm of

first call first served, majority wins on changeover..

THERMOSTATS

The DIGICOM and DIGIHP thermostats are used to control stand-

alone Gas Electric (2H/2C) or Heat Pump (3H/2C) HVAC systems.

4

ZONEX COMPONENT DESCRIPTIONS

Commander software and have a manual two-hour override. When
the thermostats are “locked,” the setpoints can be adjusted locally by

The Heat / Cool setpoints and address assignments are stored in

non-volatile memory to insure recovery in the event of a power inter­ruption. Thermostats are powered with 24vac, and communication is
through the RS-485 twisted pair (Belden 8740) communication wire.

COMMUNICATION WIRE SPECIFICATION RS-485

The Commander System sends and receives data from the Command
Center to all communicating devices through a 2-conductor twisted pair
RS-485 link (Belden 8740). The communication wire has a maximum
run length of 4,000 L Ft. The communication link is a vital component
of any DDC system, and it must be installed correctly using the correct
wire for the specific application.

For standard applications the basic twisted pair (Belden 8740) wire is
used, which is daisy chained to each communicating device. For
installations with any potential for electrical interference such as caused

shielded twisted pair (Belden 8450) should be used to insure clean
communications.

OLAT - 5vdc OUTSIDE AIR SENSOR

The LAT Thermistor sensor assembly is provided with the Zonex­Commander and ZonexCommander (Plus) Command Centers to

provide the Outside Air Temperature which is displayed on the System
screen of the ZonexCommander/Commander (Plus) program.

COMPUTER SPECIFICATIONS
A dedicated on-site “control” computer is not required. All of the

ZonexCommander Family of control systems are accessed by Windows

OPTIONAL DEVICES

SENDCOM Sensor

The SENDCOM is a microprocessor
based communicating air duct

device is used to display Supply and

requires a SENDCOM to display
Return and Supply air temperature for
that particular system. This data is
transmitted to and displayed on the
Commander software.

The SENDCOM is designed for installation on the supply duct, with a
remote sensor for the return duct. The SENDCOM does not use a
dedicated address on the communication link; it piggybacks a
thermostat address and displays data when that thermostat number

temperature.

device equipped with two SPDT relays,
which are used for controlling fans,
pumps, blowers, lighting, etc. The

devices to be cycled ON and OFF
by programmed schedules in the
Commander software. Status is
displayed on the REVIEW screen for

dedicated address from 01 to 20. The load applied to the relay

mode and de-energize in the Unoccupied mode.

TCIP Network Device

The ModStat (modulating) and MODS2

(2-position) are zone thermostats, which

control zone dampers.

The Zonex thermostats are microprocessor

based, auto changeover, digital commu-

nicating thermostats. The thermostats

have a large, easy-to-read LCD display

with a distinctive grey backlight. The

display is designed to clearly indicate

space temperature from 57°to 92°, heat and cool

setpoints, system status, override and thermostat address.

The factory set Heat and Cool setpoints are 70° and 75°, and the factory

set address is 25. Thermostats can be electronically "locked" by the

no more than 2° above or below the locked setpoints.

based Laptop or Desktop computers using Windows 7, 8,XP or Vista

operating systems. Our systems can be easily accessed with a direct

connected computer or the optional TCIP device for Internet or

Ethernet access.

Communicating Supply and Return Air Temperature Sensors

temperature sensor. This optional

Return air on stand-alone HVAC
systems. Each stand-alone HVAC system

is selected by double clicking over that thermostat's current room

RLYCOM

The RLYCOM is a communicating

by large transformers, VFDs, ballasts and other electrical devices,

LAT – 5vdc TEMPERATURE SENSORS

LAT sensors are used on the RMOD and SENDCOM devices

for Return and Supply Air temperature sensing. The Supply

and Return sensors provide data to the RMOD and

CMod for proper system capacity control and HI/LO limiting. The
SENDCOM has a supply sensor, which is factory installed in the

enclosure for supply plenum installation; and the remote return
sensor is included for field installation on the return plenum.

ModCC /

RLYCOM enables these auxiliary

verification. Each RLYCOM uses a

contacts must not exceed one amp at 24vac. The RLYCOMis designed
to switch 24vac circuits only. The relays energize in the Occupied

The TCIP device provides communication with the Commander

System through the Internet or Ethernet Network using an assigned

IP address and Port Forwarding.

The Network device includes
the iServer with power supply,
installation software and the
Commander Network version

operating software.

5

ZonexCommander is a DDC system for automating and networking new and existing stand-alone HVAC systems and mechanical devices. Gas Electric
and Heat Pump HVAC units are controlled with communicating thermostats while mechanical devices are controlled with a relay device (RLYCOM).
Each of these devices can be scheduled through the simple Windows-based ZonexCommander software and communicate to the Command Center
via a daisy-chained 2-wire twisted pair communications link.

ZONEXCOMMANDER CONCEPT DRAWING

Twisted Pair Communications Wire (Belden #8740)

DIGICOM or DIGIHP Thermostat

Standard 18-ga. Thermostat Wiring to Unit

1

2

3

4

ZonexCommander Command Center (Part #CETCIP)

6

ZONEXCOMMANDER COMPONENT SELECTION GUIDE

SYSTEM

NUMBER OF THERMOSTATS

Up to 20

from above)

THERMOSTATS

Gas/Electric

Heat Pump

DIGICOM

(2H/2C)

DIGIHP
(3H/2C)

ZonexCommander

Remotely control 1-80 stand-alone rooftops or split systems

COMMUNICATING ACCESSORIES (Optional)

STAND-ALONE

EQUIPMENT

COMMAND CENTER

21 to 80

additional 20 Thermostats

Stand-Alone Equipment

SENDCOM

Duct Temperature Sensor

(1 per HVAC unit)

Communicating

Relay Device

RLYCOM

CETCIP Communications package

Includes: Command Center, software, TCIP Device, cables and LAT Sensor

(Use 1 – CETCIP

1 – CETCIP Communications Package

1 – COMCIP Command Center per

7

SYSTEM OVERVIEW

ZonexCommander is a DDC system for automating and networking new
and existing stand-alone HVAC systems and mechanical devices.

The ZonexCommander networks 1-20 RTUs, AHUs, Heat Pumps, or split
systems per Command Center with an expansion capability of up to 80 units.

Gas Electric and Heat Pump HVAC units are controlled with communicat­ing thermostats (DIGICOM / DIGIHP), while mechanical devices are
controlled with a relay device (RLYCOM). Each of these devices can be
scheduled through the simple Windows-based ZonexCommander
software and communicated to the Command Center via a daisy-chained
2-wire twisted pair communications link (Belden 8740).

The Command Center has available inputs for outside air temperature
display; and, with the addition of a SENDCOM sensor, each unit’s Return
Air and Supply Air temperature is remotely displayed on the Commander
software. This information may also be trend logged via the Zonex-
Commander Trending Program, included with your Commander software.

ZonexCommander allows you to instantly communicate and
remotely control every unit in your system.

OPERATION

The ZonexCommander Command Center polls all devices every minute
to register information on operation in the Command Center. DIGICOM
and DIGIHP thermostats place calls to HVAC units based on thermostat
setpoint.

Cool Call

The DIGICOM and DIGIHP thermostats will initiate a Y1 cool call when
the space temperature rises 1° above the Cool setpoint. The fan will also
be energized on “G.” On 2-stage systems, Y2 will be energized when the
space temperature rises 2° above the Cool setpoint. Y1 and Y2 will remain
energized until the active cool call is satisfied at setpoint.

When the DIGIHP thermostat is configured for “O” reversing valve on an
active cool call, “O” will energize on call for cool and will remain energized
until a heat call is made. When the DIGIHP is configured for “B” reversing
valve, there is no signal from the O/B terminal on an active cool call.

Heat Call

The DIGICOM and DIGIHP thermostats will initiate a 1st stage heat call
(W1 or Y1 & G) when the space temperature drops 1° below the Heat setpoint.
2nd stage heat is energized (W2 or Y2 & G) when the space temperature
drops 2° below the Heat setpoint. The DIGICOM thermostat does not
energize “G” for fan on a heat call unless the thermostat has been
configured for FAN ON in the Occupied mode.

On the DIGIHP thermostat, when the temperature drops 3° below the
heat setpoint, the auxiliary heat will be energized on W2 and G, along
with Y1 and Y2. When Emergency Heat is selected, Y1 and Y2 are
de-energized; and W2 and “G” are energized.

When the DIGIHP thermostat is configured for “O” reversing valve on an
active heat call, the O/B output will be de-energized. When the DIGIHP

is configured for “B” reversing valve on a call for heat, “B” will energize
the reversing valve and will remain energized until a call for cool is made.

Occupied/ Unoccupied

A schedule for Occupied and Unoccupied operation is made through the
ZonexCommander Windows-based software. This schedule will
communicate with thermostats to reset temperature setpoints of thermostats
for occupied and unoccupied time. Each thermostat can have its own
occupied and unoccupied schedule and thermostat setpoints. The Zonex-
Commander Windows-based software allows for seven-day programmability
with two occupied and two unoccupied time periods per day.

Thermostat Lock Feature

The DIGICOM / DIGIHP thermostats can be electronically locked
either individually or globally through the ZonexCommander program.
When a thermostat is in the Lock mode, the address number on the left
column of the Review screen on the Zonex software will be in red. The
thermostat will also display the Lock mode with a padlock symbol on the
upper left of the LCD display. When in the Lock mode, the thermostat can
be locally controlled providing heating or cooling changes ±2° from Heat
or Cool setpoint. The 2-hour override is operational in the Lock mode.

Schedule Override

The DIGICOM / DIGIHP thermostats provide a 2-hour override in the
Unoccupied mode. When the thermostat goes into the Unoccupied mode,
the backlight automatically goes off, and Unoccupied is displayed. When
the Select button on the thermostat is pressed in the Unoccupied mode,
the backlight energizes and the 2-hour override to Occupied begins. To
terminate the 2-hour override, press the Select button again, which
returns the thermostat to the Unoccupied mode.

schedule input on the Commander software. When the Command Center

Center sends an Unoccupied call, the RLYCOM de-energizes. Manual

SENDCOM
SENDCOMs work in conjunction with their assigned thermostats. To

review SENDCOM information, double click on an assigned thermostat’s
current room temperature. Supply and Return air temperatures will
appear on the REVIEW page for this SENDCOM, if a SENDCOM was
installed in this application.

ZONEXCOMMANDER SEQUENCE OF OPERATION

RLYCOM

The RLYCOM energizes and de-energizes two SPDT relays based on the

sends an Occupied call, the RLYCOM energizes. When the Command

changes are performed from the Toggle button on the RLYCOM. When
the red LED is illuminated, the RLYCOM is energized. Multiple
RLYCOMS may be utilized to control additional devices or loads.

8

3. When the installation calls for an on-site, direct connected computer,
the Command Center must be located within 10’ of the computer if the

4. Install a 24vac 40va dedicated transformer for each individual
Command Center, and wire to terminals “G” and “B.” (See Fig. 1)

6. A single air sensor (OLAT) is supplied to display the Outside Air

Temperature on the System screen of the Commander program. It

7. The twisted pair communication wire (Belden 8740) is to be daisy
chained to each communicating device, which is controlled by the
specific Command Center. When multiple Command Centers are used,
each Command Center is to have a dedicated communication loop.
The communication loop is polarity sensitive on RX and TX. Wire
nuts are never to be used on the communication wire. When
splicing wire, use screw type terminal strips or solder.

NOTE: for systems with potential electrical interference, such as
large transformers, VFDs, etc, shielded twisted pair (Belden 8450)
may be used for the communications loop.

ZONEXCOMMANDER INSTALLATION INSTRUCTIONS

Fig.1

CETCIP Command Center

1. Install the CETCIP Command Center on a wall or mounting board

in a dry interior space where the ambient temperatures will be between

32° and 125° non-condensing.

2. When installing multiple Command Centers, mount all boards
together on the same surface.
NOTE: 120vac outlets are required for the TCIP iServer device power
supplies.

USB cable is used. The TCIP device requires an Ethernet cable,

which is field provided.

should be installed where it will not be in direct sunlight. If the sensor

leads must be extended, simply use standard 18/2 thermostat wire,

and connect to the S S terminals on the Command Center.

NOTE: Power supply voltage on G and B should be 24 to 28vac.

5. For system TCIP configuration, you must provide a 120vac outlet for
the power supply.

9

DIGICOM / DIGIHP THERMOSTATS

DESCRIPTION

The Zonex Systems DIGICOM and DIGIHP are
microprocessor based, auto changeover, stand-

The DIGICOM and DIGIHP are very easy to configure through the
system program or to make manual adjustments using the buttons located
on the front cover.

These thermostats feature an onboard thermistor for precise tempera­ture measurement. In the event of power loss, the Heat and Cool set­points are stored in a non-volatile memory, without the need for bat­tery backup.

The space ambient temperature is continually displayed with large,

Programmed setpoints can be manually adjusted at the thermostat or
electronically locked through the system program to provide limited
manual setpoint adjustment. Two-hour override is provided for
after-hours temporary operation with a touch of a button.

INSTALLATION
Thermostat and terminal base

1. The thermostat is to be installed on an interior wall, away from drafts,
supply air currents and direct sunlight or any heat generating source.

2. To remove the thermostat cover, grasp the cover at the top and pull
straight off; do not pivot the cover from the base.

3. Install the thermostat terminal base to the wall using the provided
anchors and screws. The thermostat can also be mounted on a 2x4
electrical box using two #6-32” screws.

Wiring

The Zonex Systems DIGICOM and DIGIHP thermostats have been
specifically designed to make wall mounting and wire connections very
easy. The thermostat terminal base has two separate terminal blocks: the
left side terminal block is for the 24vac control circuits, and the right
side terminal block is for the RX TX communication circuits. There are
two sets of RX TX terminals on the base to make daisy chain wiring from
device to device straightforward and simple.

1. Use minimum 18-gauge AWG thermostat wire for the 24vac control
circuits. The load on these circuits must not exceed 1 amp. The voltage
range on R and C must not exceed 28vac.

2. Connect the communication wires to the RX TX terminals. There are
2 sets of RX TX terminals for “daisy chain” installation of this circuit.
The communication wire specification is twisted pair (Belden 8740)
or shielded twisted pair wire (Belden 8450).

NOTE: When using shielded twisted pair wire (Belden 8450), just
connect the shield conductors together, as there is no electrical
connection on the thermostat base terminals. The shield will be landed
on the Command Center on the G or TR2 terminal.

Fig. 1

DIGICOM

DIGIHP

Fig. 2

Fig. 3

Blower Fan Relay
For electrical heat applications, which require a fan output on a call for
heat. (See Fig 3.)

alone thermostats used to control stand-alone units

with no dampers in the system. The DIGICOM
the Gas Electric version and has two-stage heat /
cool outputs with selectable fan operation. The

DIGIHP

Heat Pump thermostats have two-stage

cool and three-stage heat outputs with selectable
fan. The DIGICOM and DIGIHP thermostats have a large, easy-to-read
LCD display with a distinctive gray backlight. The display backlight is

continuously illuminated in the Occupied mode and goes off in the Un-

occupied mode.

easy-to-read numbers. The DIGICOM temperature display range is
57°to 90°F., and the DIGIHP temperature display range is 57°to 90°F.
Fan mode, Heat or Cool setpoints and operation modes are all indicated

on the display.

is

RG

W1

H

R

10

V
A

G

C

C

U
N
I
T

2

5

1

SPDT, 24V

AC Relay

4

3

Configuration

1. Set the unique address for each thermostat from 01 to 20.

2. Press and hold the Menu button until you see the system mode

display on the lower right begin to scroll and change modes; then
press and hold the Heat/Cool button with the Menu button.

3. When the display shows “address” and the setpoint temperature

MANUAL ADJUSTMENTS
Heat and Cool Setpoint Display

Press the Heat/Cool button to display the Heat or Cool setpoint temperatures.

Temperature Setpoints
COOL Setpoint

1. Press the Heat/Cool button to display the

Cool setpoint on the upper right.

2. Press the UP or DN buttons to change the

Cool setpoint.

HEAT Setpoint

1. Press the Heat/Cool button to display the

Heat setpoint on the upper right.

2. Press the UP or DN buttons to change the

Heat setpoint temperature.

FAN Mode

To change the FAN operation to AUTO or ON, press the UP and DN
buttons together, once to toggle fan operation.

HVAC system mode

To select Heat, Cool, Auto, Emergency Heat (HP only) or OFF, press and

hold the Menu button; and when the desired mode is displayed, press
and hold the Select button; then release both to confirm mode.

Override

When the system is in the Unoccupied mode, the thermostat provides a
2-hour override for after-hours system operation. To select the 2-hour

override, press the Select button and note “Override” indicated on the
display, along with the backlight coming on. When additional override is

required, press the Select button again.

Calibration
When re-calibration is required, press and hold the Heat/Cool and

Select buttons simultaneously (the screen will flash). Then press the UP

button once to increase temperature 1°, or press the DN button once to
decrease the temperature 1°. If additional calibration is required, repeat
this step.

THERMOSTAT OPERATION
Display

The grey display backlight is constantly illuminated in the Occupied mode.
The display backlight goes off when in the Unoccupied mode. When in the
Unoccupied mode, if any button is pressed, the backlight will illuminate
for 5 seconds. If the thermostat is placed into the override mode, the
backlight will illuminate until the 2 hours times out. To terminate
override, press the Select button again.

COOL – DIGICOM / DIGIHP: The thermostat will make a Y1 cool call
when the space temperature rises 1° above the cool setpoint. Y2 will
energize when the space temperature rises 2° above the cool setpoint.
When the room temperature is less than 2°from setpoint, Y2 de-energizes.
Y1 de-energizes at setpoint. O or B is energized for the reversing valve
circuit, depending on configuration. The G circuit is energized for fan.

HEAT – DIGICOM: The thermostat will make a W1 heat call when the
space temperature is 1° below the heat setpoint. W2 will energize when
the space temperature is 2° below the heat setpoint. When the room
temperature rises to within 2° of the heat setpoint, W2 de-energizes.
W1 de-energizes at setpoint.

NOTE: The “G” fan circuit on the DIGICOM thermostat is not energized
in the Heat mode unless the fan is set for ON operation.

HEAT – DIGIHP: The thermostat will make a Y1 heat call when the space

space temperature is 2° below the heat setpoint. E (aux heat) will
energize when the space temperature is 3° below setpoint. When the
room temperature rises to within 2° of the heat setpoint, E (aux heat)
de-energizes. When the room temperature rises to within 1°, Y2
de-energizes. Y1 de-energizes at setpoint.

Emergency Heat – DIGIHP: When Emergency heat is selected on the
DIGIHP thermostat, on a call for heat, there is an output signal on “E”

for backup heat and “G” for the fan. The compressor circuits “Y1” and
“Y2” are locked out during heat calls until Auto, Heat or Cool mode is
selected. The thermostat display will indicate when Emergency Heat has
been selected.

DIGICOM – FAN operation for electric heat applications: A pilot relay
may be required to energize the fan for heat operation on electric heat
applications. This relay is a 24vac coil – SPST and is field supplied. The coil
is energized from W1 and C from the DIGICOM

thermostat terminal base.

DIGICOM / DIGIHP THERMOSTATS

changes to the address number, release Heat/Cool and Menu buttons

and press the UP or DN button to raise or lower the number.

Reversing Valve Mode

DIGIHP (O&B) is factory set at "O" and can be field configured for "B"

reversing valve operation. For "B" mode reversing valve (reversing valve

energized in the heat mode), press and hold the Heat/Cool and Select

buttons; then press and release the Menu button once. Release the Heat/

Cool and Select buttons. The ° symbol next to the set point display

should disappear. Repeat steps above to go back to "O."

temperature is 1° below the heat setpoint. Y2 will energize when the

11

COMMAND CENTER – ZONEXCOMMANDER

LEGEND

1

DATE AND TIME BACKUP BATTERY

SENSOR CALIBRATION:

2

R12 OUTSIDE AIR (OA)

POWER LED INDICATOR

3

MAIN CONTROL CHIP ZONEXCOMMANDER

4

5

COMMUNICATION RS-485 TWISTED PAIR (POLARITY SENSITIVE)
(BELDEN 8740)

6

USB COMPUTER

OUTDOOR AIR SENSOR TERMINAL

7

TERMINALS G AND B, 24VAC 40VA INPUT

8

9

ON/OFF SWITCH

12

ZONEXCOMMANDER WIRING OVERVIEW

ROOFTOP UNITS: UP TO 20 PER COMMAND CENTER

13

ZONEXCOMMANDER (PLUS) CONCEPT DRAWING *

The ZonexCommander (Plus), ZPTCIP, is a DDC system for automating multiple zoned HVAC systems, stand-alone HVAC units and mechanical

devices. The universal RMOD controls both Gas Electric and Heat Pump units with onboard capacity control. The modulating/two-position

thermostats (ModStat and MODS2) are used to communicate calls for heat and cool, as well as modulate dampers based on zone demand.

The ZonexCommander (Plus) system can be applied to existing HVAC systems or new installations providing central control of HVAC operations

using Windows-based ZonexCommander (Plus) software.

* Concept Drawing Only. See Wiring Schematic on Page 16

14

ZONEXCOMMANDER (PLUS) COMPONENT SELECTION GUIDE

15

ZONEXCOMMANDER (PLUS) INSTALLATION WIRING DIAGRAM

NOTE: Each Command Center supports up to 4 RMODs and a maximum of 20 communicating devices. When the application requires more than

Fig. 2

Fig. 1

ELECTRIC HEAT FAN CYCLING
AUXILIARY BLOWER FAN RELAY

When W1 is energized from the DIGICOM, ModCC or RMOD, the fan
circuit (G) is not energized. For applications requiring the blower to be cycled

The W1 output signal is connected to the heating device input terminal and the
coil of the fan relay. This is required for electric heat and gas furnaces with no
fan control. (See Fig. 2)

4 RMODs or more than 20 communicating devices, additional Command Center(s) will be required. There must be separate communications circuit
(twisted pair Belden 8740) for each Command Center (channel). (See Fig. 1)

All RX communication wires must be connected to the RX terminals.

All TX communication wires must be connected to the TX terminals.
The RX and TX wires should never intersect.

on a W1 heat output, a field supplied, 24-volt coil SPDT relay must be used.

16

H

R
V
A

G
C

C
U
N
I
T

BLOWER FAN RELAY

RG

W1

2

5

1

SPDT, 24V

AC Relay

4

3

ZONEXCOMMANDER (PLUS) SEQUENCE OF OPERATION

SYSTEM OVERVIEW

for communication and control with the zoning and stand-alone

provides interface between the communicating system and a Windows-

modulating zones totaling 20 system devices. Twenty thermostats are
available to be allocated to the 1-4 RMODs associated with each
Command Center. Communication is accomplished through a
two-conductor twisted pair RS-485 link (Belden 8740), which is daisy
chained between all system communicating components.

OPERATION

The ZonexCommander (Plus) Command Center polls every minute.
When the Command Center polls, it goes to each ModStat to gather
information on whether it is making a cool call, heat call or no call. Based
on this information the Command Center then sends calls for cool, heat
or no call to RMOD and ModStats.

ModStat/MODS2
Cool Call

If room is one or more degrees above setpoint, a call for cool will be
made to the Command Center. If a majority of thermostats assigned to
the same RMOD is calling for cooling, the Command Center will
communicate to RMOD to make a call for cool. Command Center will
also send a mode call to all thermostats assigned to this RMOD for cool.
This tells ModStat what the system mode is so that damper control may
be made. If the room is calling for cooling and the RMOD is in the cool
mode, the ModStat will modulate the dampers calling and closed to sat­isfy room demand. If the room temperature is two or more degrees above
setpoint, the damper will be between 100% and 0% open, based on room
load desire. If using a MODS2 with a two-position damper, the damper
will be open. When call is satisfied, the damper will close.

Heat Call
ModStats will place a call for heat if room temperature is two or more degrees

below setpoint. When the Command Center polls, if there is a majority call
for heat from ModStats that are assigned to the same RMOD and the
system is not in cooling mode, then the Command Center will communicate
a call for heat to the RMOD and a heat call will be initiated. If there is a
current call for cooling and a majority heat call has been received, a
changeover sequence will begin. After two minutes the cool call will end,

a two-minute purge will start, and at the end of the purge a heat call will
be made. The Command Center will communicate a heat mode call to the

is two degrees or more below room temperature, ModStat will modulate
the damper to 100% open. If the room temperature is within two degrees
of setpoint, the ModStat will control the damper from 100% open to 0%
open based on deviation of setpoint. If using a MODS2

in the heat mode,

the damper will be open.

Auxiliary Heat

the AUX heat output will energize initiating auxiliary heat.

RMOD

When heating or cooling calls are sent to the RMOD Relay Module by the
thermostat, the RMOD will treat these calls as votes to determine mode of

Cool Mode

If the majority of calls are for cooling, the RMOD will energize Y1 and G
for 1st stage cooling. After four minutes, the RMOD will check the
leaving air temperature. If the leaving air temperature is 10° above cutout

compressor safety.

Heat Mode

If the majority of calls are for heating, the RMOD will energize W1 for 1st
stage heating. After four minutes, the RMOD will check the leaving air
temperature. If the leaving air temperature is 15° below high limit cutout
(145° - 15° = 130°F), then W2 will energize. W2 will stage off at 5°
below temperature cutout (145° - 5° = 140°F), and W1 will stage off on
high temperature at 145°F.

Changeover

If the system is running in one mode and the majority of calls change to
the other mode, a timer will start. The RMOD will give the current
operating mode another four minutes to try to satisfy the zone(s). It will
then go into the purge cycle before switching modes to the majority.

The ZPTCIP is the primary Command Center, which provides a source

thermostats, along with various communicating devices. The ZPTCIP

based PC computer over the Internet. Included with the ZPTCIP are a
TCIP driver, Operating Software, Cables, and Sensor.

The ZPTCIP Command Center manages 1 to 4 HVAC systems with

The CZNXIP controller is the ZPTCIP Command Center without software

to expand communication for an additional 20 devices per each
CZNXIP Command Center. When using additional CZNXIP Com-

mand Centers, an additional TCIP device and an individual IP

address must be used for interface communications.

RMOD, and ModStats will control dampers. If the room temperature

If the space temperature drops 2°F below the Heat setpoint temperature,

operation. Adjustable factory limits are 45°F cool and 145°F heat.

(45° + 10° = 55°F), then Y2 will energize. Y2 will stage off 4° above
cutout (45° + 4° = 49°F) and Y1 will stage off on low temperature at
45°F. A four-minute off delay between operations is provided for

17

ZONEXCOMMANDER (PLUS) SEQUENCE OF OPERATION

Purge Mode

When a heat or cool call is satisfied or before changing modes, the
RMOD will go into a three-minute purge cycle. The call for heat or cool
will be removed, and the dampers will remain in their last position to
allow time for air to adjust to room temperature before going into
ventilation mode or changeover.

Fan Operation

Fan operation in the ZonexCommander (Plus) is controlled by the RMOD.
The fan jumper on RMOD allows for the option of fan continuous in
Occupied and intermittent in Unoccupied. Fan intermittent can be selected in
both Occupied and Unoccupied modes. Place fan jumper in desired position.

Ventilation

When no zone is calling for heat or cool, the dampers will open 50%. This
permits ventilation in all zones if the blower fan is on continuously.

COMMUNICATION FAILURE

If the RMOD cannot communicate with any of the thermostats, it will
control the HVAC unit based on return air temperature. The RMOD will
try to maintain 70°F heat and 75°F cool return air.

TEMPERATURE LIMITS AND STAGING

The RMOD monitors the leaving air temperature for staging and Hi /Low

145° F. Staging is based on the limit settings.

Gas Electric & Heat Pump

Example:

Gas Electric
Heating W2 cut-in temperature is high limit minus 15° F (145° – 15° =

130° F). The W2 cut-out is cut-in plus 10° F (130° + 10° = 140° F).
Example:
Adjustable high limit = 145°
W2 Cut-in = 130° F (high limit minus fifteen)
W2 Cut-out = 140° F (cut-in plus ten)
W1 cut out = 145°

Heat Pump
Heating – When the RMOD is configured for HP operation, the high

cut-out is automatically set to 121°.

• W2 energizes when the SA temperature is 88° or less after 4 minutes
of run time. W2 de-energizes when the SA temperature rises to 100°.

• Y2 energizes when the SA temperature is below 100° after 2 minutes
of run time and de-energizes above 115°.

• Y1 cuts out for 4 minutes when the SA temperature is above 120°.

TEMPERATURE LIMIT ADJUSTMENT

Low Limit –

1. Push DN button until display shows C.

2. Current setpoint will be displayed.

3. Push UP or DN button until desired setpoint is displayed.

4. Release button.

1. Push UP button until display shows H.

2. Current setpoint will be displayed.

3. Push UP or DN button until desired setpoint is displayed.

4. Release button.

operation. A shorted sensor or wiring will display low temperature, and

RLYCOM

The RLYCOM energizes and de-energizes the two SPDT relays based on

the schedule input on the Commander software. When the Command

Center sends an Occupied call, the RLYCOM energizes. When the

Command Center sends an Unoccupied call, the RLYCOM de-energizes.

When the red LED is illuminated, the RLYCOM is energized.

Supply and Return Air Temperature Display

System supply and return air temperatures can be read from each RMOD

and the REVIEW screen of the ZonexCommander (Plus) program. On the
REVIEW screen simply double-click on the Current

Room Temperature of

address 1, 2, 3, 4. The address number is displayed on the left hand

column. The Read

Sensors Screen will appear with the supply and return

temperatures for the specific RMOD.

Address: 1 = RMOD 92

2 = RMOD 93
3 = RMOD 94
4 = RMOD 95

SENDCOM sensor.

SENDCOM

On the ZonexCommander (Plus) system, the supply and return

temperatures from the stand-alone DIGICOM and DIGIHP thermostats
are provided by the SENDCOM. One SENDCOM is installed for each
stand-alone system. When assigning addresses for the stand-alone
thermostats and SENDCOMs, you must start at #75 through #90
(5 through 20). The first 4 address numbers on the program are for

SENDCOMs associated with the 4 RMODs only. Pay particular attention
to this issue. Each RMOD has a SENDCOM associated with it. If 4

RMODs are utilized with 1 Command Center, the information from those
SENDCOMs will be retrieved on the Zonex software from thermostat

locations 1, 2, 3, or 4.

limit. The adjustable factory low limit is 45° F and the high limit is

Cooling Y2 cut-in temperature is low limit plus 10°F (45°+ 10°= 55°F).
The Y2 cut-out is cut-in minus 8°F (55° – 8° = 47°F).

Adjustable low limit = 45°F
Y2 Cut-in = 55°F (low limit plus ten)
Y2 Cut-out = 47°F (cut-in minus eight)

High Limit –

NOTE: The RA and SA air sensors (P# LAT) must be installed for unit

an open sensor or wiring will display high temperature.

Manual changes are performed from the Toggle button on the RLYCOM.

To obtain this information from stand-alone equipment, include a

18

COMMAND CENTER – ZONEXCOMMANDER (PLUS)

LEGEND

DATE AND TIME BACKUP

1

SENSOR CALIBRATION:

2

3

4

5

6

7

8

9

R12 OUTSIDE AIR

POWER LED I NDICATOR

MAIN CONTROL CHIP ZONEX COMMANDER (PLUS)

COMMUNICATION RS-485 TWISTED PAIR
(POLARITY SENSITIVE) (BELDEN 8740)

USB COMPUTER

SENSOR TERMINAL
OA (OUTSIDE AIR) ONLY

TERMINALS G AND B, 24VAC 40VA INPUT

ON/OFF SWITCH

BATTERY

19

3. If the installation calls for an on-site computer to be directly

4. Install a 24vac 40va dedicated transformer for each individual

Command Center, and wire to terminals “G” and “B.” Power supply
voltage on G and B should be 24 to 28vac.

6. The only sensor connected to the Command Center is the Outside Air

Sensor (OA), which is Part # OLAT. The Outside Air Sensor is not
polarity sensitive.

The outside air temperature is displayed on the SYSTEM screen in the

7. The twisted pair communication wire (Belden 8740) is to be daisy
chained to each communicating device, which is controlled by the

each Command Center is to have a dedicated communication loop.

The communication loop is polarity sensitive on RX and TX. Wire

nuts are never to be used on the communication wire. When

making connections, use screw type terminal strips or solder.

NOTE: for systems with potential electrical interference, such as

large transformers, VFDs, etc, use shielded twisted pair (Belden

8450) for the communications loop.

ZONEXCOMMANDER (PLUS) INSTALLATION INSTRUCTIONS

Fig. 1

ZPTCIP/CZNXIP Command Centers

1. Install the Command Center on a wall or mounting board in a
dry interior space where the temperatures will be between 32-125°

non-condensing.

2. When additional Command Centers are used, mount all together
on the same wall or mounting board.

connected to the Command Center, the computer must be located
within 10 feet of the Command Center.

5. For system TCIP configuration, you must provide a 120vac outlet
for the power supply.

ZONEXCOMMANDER (ZPTCIP / CZNXIP)

Commander program.

specific Command Center. When multiple Command Centers are used,

20

DESCRIPTION

The LCD ModStat is available for the ZonexCommander

The unique grey display backlight is constantly illuminated in the Occupied
mode. The display backlight will go out in the Unoccupied mode. If any
button is pressed while the thermostat is in the Unoccupied mode, the
backlight will illuminate for 5 seconds. The backlight will also be
illuminated when the thermostat is in the 2-hour override mode.

INSTALLATION
Thermostat and terminal base

1. The thermostat is to be installed on an interior wall, away from drafts,
supply air currents and direct sunlight or any heat generating source.

2. To remove the thermostat cover, grasp the cover at the top and pull
straight off; do not pivot the cover from the base.

3. Install the thermostat terminal base to the wall using the provided
anchors and screws. The thermostat can also be mounted on a 2x4
electrical box using two #6-32” screws.

WIRING

The Zonex Systems ModStat and MODS2 thermostats have been specifically
designed to make wall mounting and wire connections very easy. The
thermostat terminal base has two separate terminal blocks: the left side
terminal block is for the 24vac control circuits, and the right side terminal
block is for the RX TX communication circuits. There are two sets of RX
TX terminals on the base to make daisy chain wiring from device to device
straightforward and simple.

1. Use minimum 18-gauge AWG thermostat wire for the 24vac control
circuits. The load on the auxiliary heat circuit must not exceed 1 amp
at 24vac. The voltage range on R and C must not exceed 28vac.

2. Connect the communication wires to the RX TX terminals. There are
2 sets of RX TX terminals for “daisy chain” installation of this circuit.
The communication wire specification is: twisted pair (Belden 8740)
or shielded twisted pair wire (Belden 8450). Refer to manual (ZCMAN).
NOTE: When using shielded twisted pair wire (Belden 8450), just
connect the shield conductors together, as there is no electrical
connection on the thermostat base terminals. The shield will be landed
on the Command Center on the G or TR2 terminal.

3. On the ModStat, connect the damper control wires from MC, RC and RO to
the actuator terminals. For MODS2, connect MC and RC to the damper motor.

4. Auxiliary Heat – The ModStat and MODS2 provide a 24vac signal

gized when the space temperature is 2° below the heat setpoint. The
signal is de-energized at setpoint temperature.

CONFIGURATION
Addressing (1-20). Each thermostat must have a unique address from 1 to 20.

1. Press and hold the Menu button until you see the system mode display

on the lower right begin to scroll and change modes; then press and
hold the Heat/Cool button with the Menu button.

2. When the display shows “address,” release the Menu and Heat/Cool
buttons; and press the UP or DN button until the correct address is
displayed in the upper right of the display.

3. After setting the address, the thermostat will automatically go back to
normal operation; and the setpoint temperature will replace the
address number just programmed.

Manual Operation - Adjusting Setpoints

The Heat or Cool setpoints can be displayed by pressing the Heat/Cool
button; the setpoint will be displayed on the upper right of the display.

Heat – If “Heat Setting” is displayed on the top right of the display,
simply press the UP or DN button to change the heat setpoint. If “Cool
Setting” is displayed and you want to change the Heat setpoint, press and
hold the Heat/Cool button twice to change from “Cool Setting” to “Heat
Setting.” Then press the UP or DN button to change the setpoint.

Cool – If “Cool Setting” is displayed on the top right of the display, simply
press the UP

or DN button to change the cool setpoint. If “Heat Setting”

is displayed and you want to change the Cool setpoint, press and hold the
Heat/Cool button twice to change from “Heat Setting” to “Cool Setting.”
Then press the UP or DN button to change the setpoint.

Changing Mode

The thermostats are auto changeover, but specific modes may be selected.
Auto mode is the default.

Heat only – Press and hold the Menu button, and note the mode display
begin to change. Press the Select button when Heat is displayed.

Cool only – Press and hold the Menu button, and note the mode display
begin to change. Press the Select button when Cool is displayed.

System Off – Press and hold the Menu button, and note the mode
display begin to change. Press the Select button when Off is displayed.

Auto mode – Press and release the Menu button.

Override

When the thermostat displays “Unoccupied” (top of display), a 2-hour
temporary override may be initiated by pressing the Override/Select button.
When additional override time is required, press the Override/Select
button again.

Display Temperature Calibration

Thermostats are calibrated at the factory and should require no further
adjustment. However, the display space temperature may be field cali­brated by the following procedure:

1. Press and hold the Heat/Cool and Select buttons together; then press

2. To lower the temperature display, press the DN button once, after
pressing the Heat/Cool and Select buttons. This makes a 1°change.

ModStat / MODS2 THERMOSTATS

(Plus) DDC control system. It is also utilized

with the System 2000 GEN II product. The ModStat

version drives medium pressure, power open / power

close dampers for modulating applications. The

MODS2 version drives low pressure, power close /
spring open dampers for 2-position systems, which are
2000 CFM or less.

output on the "AUX” terminal for Auxiliary Heat. This signal is ener-

5. Reheat - The ModStat can be field configured for Reheat applications,

including Fan Powered VAV boxes. The terminal base provides a
24 volt output on terminal “AUX” for the heat elements and the fan relay
circuit (if applicable).

NOTE: An Air Proving Switch must be wired into the “AUX” output to
protect the electric heating devices.

and release the UP button to increase the display temperature by 1°.

21

ModStat / MODS2 THERMOSTATS

ModStat Terminal Designations:
TX – Data transmit
RX – Data receive

RO – Run Open, damper
RC – Run Closed, damper
R – 24vac power input
C-MC – 24vac power common

MODSTAT

GENERAL OPERATION
Ventilation – No active Heat or Cool calls

With no active calls, the ModStat or MODS2 will open the damper for
blower ventilation.

Cool Call – The ModStat and MODS2 will send a signal for demand
cooling when the space temperature exceeds the cool setpoint temperature
by 1°. The thermostat will end the active call when the space temperature
meets the cool setpoint.

Heat Call – The ModStat and MODS2 will send a signal for demand
heating when the space temperature drops 1° below the heat setpoint
temperature. If the temperature drops 2° below the heat setpoint tem-

will end the active call when the space temperature meets the heat setpoint.

When configured for Reheat, if the space temperature drops 1° below

modulate the damper open. The heat call will terminate when the space

system goes into the ventilation mode, the damper will then modulate
open.

Reheat - The ModStat can be field configured for Reheat operation
by pressing the Heat/Cool and Select buttons together, and then press
the Menu button and release all three buttons. The Heat/Cool set­point display will show the ° symbol to verify Reheat configuration.

SUPPLEMENTAL HEAT APPLICATIONS

perature, the “AUX” output will energize for auxiliary heat. The thermostat

the heat setpoint, the ModStat will energize the “AUX” output and

temperature reaches the heat setpoint temperature. The “AUX”
output will de-energize, and the damper will modulate closed. If the

Note 1: Sail switch or pressure switch

should be used to prove fan operation.

NOTE: A larger transformer may be needed to power fan relay and/or heat strip relay.

22

SUBBASE

AUX – Reheat/AUX Heat Fan

OPERATION

When heating or cooling calls are sent to the RMOD Relay Module by the
thermostat, the RMOD will treat these calls as votes to determine mode

When configured for Heat Pump operation, the cut-out is automatically

COOL CALLS

If the majority of calls are for cooling, the RMOD will energize Y1 and G
for 1st stage cooling. After 4 minutes, the RMOD will check the leaving

provided for compressor safety.

HEAT CALLS

If the majority of calls are for heating, the RMOD will energize W1 for 1st
stage heating. The RMOD will bring on additional stages in 3-minute
increments. See Gas Electric and Heat Pump staging.

CHANGEOVER

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

PURGE MODE

When a heat or cool call is satisfied, or before changing modes, the
RMOD will go into a 3-minute purge cycle. The call for heat or cool will
be removed, and the dampers close.

VENTILATION MODES

The RMOD can be field configured for FAN Constant in the Occupied
mode or FAN Automatic. When all zones are satisfied, dampers will
modulate to 50% open.

EMERGENCY HEAT

Selected by the on-board switch or remote switch.

COMMUNICATION FAILURE

If the RMOD loses communications, it will then control the HVAC unit
based on the return air temperature. The RMOD will maintain 70°F heat
and 75° F cool as measured by the MIX Air sensor in the return air.

TEMPERATURE LIMITS AND STAGING

The RMOD monitors the leaving air temperature for staging and Hi /Low

145° F. Staging is based on the limit settings.

Gas Electric & Heat Pump

Example:

Gas Electric
Heating W2 cut-in temperature is high limit minus 15° F (145° - 15°

= 130° F). The W2 cut-out is cut-in plus 10° F (130° + 10° = 140° F).
Example:
Adjustable high limit = 145° F
W2 Cut-in = 130° F (high limit minus fifteen)
W2 Cut-out = 140° F (cut-in plus ten)
W1 cut out = 145°

Heat Pump
Heating – When the RMOD is configured for HP operation, the high

cut-out is automatically set to 121°.

• W2 energizes when the SA temperature is 88° or less after 4 minutes
of run time. W2 de-energizes when the SA temperature rises to 100°.

• Y2 energizes when the SA temperature is below 100° after 2 minutes
of run time and de-energizes above 115°.

• Y1 cuts out for 4 minutes when the SA temperature is above 120°.

TEMPERATURE LIMIT ADJUSTMENT

The high and low cut-out temperatures are field adjustable.

HVAC unit operation.

RMOD SEQUENCE OF OPERATION

of operation. Adjustable factory limits are 45°F cool and 145°F heat.

set for 121° heat.

air temperature. If the leaving air temperature is above 55° F, then Y2 will
energize. Y2 will stage off at 47° F and Y1 will stage off on low temperature
at 45° F. Four-minute minimum run and four-minute off delays are

limit. The adjustable factory low limit is 45° F and the high limit is

Cooling Y2 cut-in temperature is low limit plus 10°F (45°+ 10°= 55°F).
The Y2 cut-out is cut-in minus 8° F (55° – 8° = 47° F).

Adjustable low limit = 45° F
Y2 Cut-in = 55° F (low limit plus ten)
Y2 Cut-out = 47° F (cut-in minus eight)

NOTE: The RA and LV AIR sensors (P# LAT) must be installed for

23

RMOD TERMINAL DIAGRAM

TERMINAL DESIGNATIONS

TX – Data transmit
RX – Data receive

RA – Return air sensor

Gas/Electric
G – Fan output
W2 – Stage 2 heat output
W1 – Stage 1 heat output
Y2 – Stage 2 cool output
Y1 – Stage 1 cool output
R – 24vac from HVAC unit transformer

Heat Pump
G – Fan output
W2 – Aux heat output
O/B – Reversing valve signal
Y2 – Stage 2 compressor
Y1 – Stage 1 compressor
R – 24vac from HVAC unit transformer

R – 24vac power input
C – 24vac power common

LV AIR – Supply Air sensor input

R45 – RA calibration
R52 – LV AIR calibration

LEGEND

LEAVING AIR TEMPERATURE DISPLAY, TO DISPLAY RETURN TEMP,

1

HOLD BOTH HEAT/COOL BUTTONS

2

SENSOR CALIBRATION:

R52 SUPPLY AIR TEMP
R45 RETURN AIR TEMP

3

HEAT (UP) / COOL (DN) / ADDRESS BUTTON

MAIN CONTROL CHIP

4

2-PIN SELECTABLE HEAT PUMP/GAS ELECTRIC (JUMPED FOR HEAT PUMP)

5

O/B MODE SELECT (JUMPED “O” OUTPUT IN COOLING)

6

STATUS LEDs - PWR1, Y1, Y2, W1 and O/B, W2, G

FAN JUMPER:

7

CENTER AND TOP = ON
CENTER AND BOTTOM = AUTO FAN

8

EMERGENCY HEAT SWITCH, USED IN HP MODE ONLY

9

TO HVAC UNIT TERMINALS

10

ON/OFF SWITCH

11

SENSOR TERMINALS RA AND LV AIR MUST BE INSTALLED.

24

DESCRIPTION

The Zonex Systems RMOD is a microprocessor based digital communi­cating HVAC Relay Module for the ZonexCommander (Plus) system. The
RMOD controls Gas/Electric 2-stage heat and cool, as well as Heat Pump,
2-stage cool and 3-stage heat, based on supply air temperature. The
RMOD provides high and low limits to protect HVAC system components.

Each RMOD can communicate with up to 20 thermostats. There can
be up to 4 RMOD controllers per Command Center; however, each
Command Center controls up to 20 thermostats. The total number of
thermostats cannot exceed 20 on each Command Center.

The RMOD and corresponding ModStats must be configured into the
ZonexCommander (Plus) system before the RMODs will communicate.
See Installation Guide.

INSTALLATION

RMOD circuit board

The RMOD can be installed with the Command Center or in the HVAC unit
it is controlling. It must be protected from the elements in an area
where the temperature range is from 25° to 125° non-condensing. DO
NOT install the Command Centers or RMODs in close proximity to large
transformers, VFDs, or any device that produces electrical energy fields.

1. Install the RMOD where it can be properly accessed.

3. The RMOD is shipped from the factory to operate in the Gas Electric

mode. For Heat Pump operation, place the HP jumper tab over
both pins.

4. For Heat Pump “O” reversing valve operation the O/B jumper tab is
on one pin. For reversing valve “B” operation, place the jumper tab
over both pins.

intermittent fan. For Constant FAN in the Occupied mode, place the
jumper tab over the middle and upper pins (ON).

of the bypass

take-off.

bypass take-off (Gas Electric), or between the indoor coil and strip
heat elements (Heat Pump AHU).

Addressing & Calibration

button until the correct address appears, and release.

2. Energize the FAN only and check RMOD display calibration.

adjust calibration.

4. Return air temperature is displayed when the UP and DN buttons are

holding down these buttons.

Wiring

8740).

any other ac voltage wiring; it must be run completely separate. Use

switch to the EM terminals on the RMOD.

The RMOD is ready to be configured in the ZonexCommander (Plus)
program.
See Installation Guide.

RMOD UNIT DESCRIPTION / INSTALLATION

HVAC UNIT CONTROLLER

2. The RMOD is powered by the Command Center transformer
by daisy chaining the 24vac from Command Center to the RMOD.
You will need to properly size the transformer to the total number

of dampers on the system.

3. When the sensor leads are too short, you may extend the wire
with 18 AWG thermostat wire.

1. Set the address for the RMOD (92, 93, 94 or 95) by switching the
RMOD to ON from S1, and press the ADR button. To change the
address from 92, continue to hold the ADR button; and press the UP

3. Constant display indicates supply air temperature. Rotate R52 to

pressed simultaneously. Rotate R45 to adjust the calibration, while

1. Connect the twisted pair communication wires to RX and TX (Belden

NOTE: The twisted pair communication wire cannot be installed with

shielded twisted pair (Belden 8450) if there is any potential

for electrical interference.

2. Connect the Return Air sensor to the RA terminal screw block.

3. Connect the Supply Air sensor to the LV Air terminal screw block.

5. Set the FAN jumper tab (JPR1) on the center and lower pin (AUTO) for

Sensors – Supply and Return (LAT)

1. Install the RA sensor (LAT) in the return duct, ahead

2. Install the LV AIR sensor (LAT) in the supply duct ahead of the

4. Connect the RMOD outputs to the HVAC system.

5. If Emergency Heat is to be controlled by a remote switch, wire a SPST

25

RMOD WIRING OVERVIEW

All RX communication wires must be connected to the RX terminals.

All TX communication wires must be connected to the TX terminals.

The RX and TX wires should never intersect.

26

RMOD (RELAY MODULE) TO UNIT WIRING DIAGRAM

• Minimum 18 AWG thermostat wire.

• Y2 & W2 terminals are not used for gas/electric single stage units.

• SA (supply air sensor) controls low and high temperature limits and heat/cool staging.

• RA (return air sensor) controls unit operation in communication failure mode.

• Keep sensor wires and power wires separate.

NOTE: Shorted wiring or sensors cause a low temperature reading. Open wiring or sensors cause a high temperature reading.

• Use 18 AWG. for RA & LV.

• Part# LAT for all sensors.

27

SENDCOM DESCRIPTION

DESCRIPTION

The Zonex Systems SENDCOM is a microprocessor based, communicating air duct temperature sensor. The SENDCOM is used to display the
discharge air and return air temperature of a single HVAC unit. The temperatures are displayed within the ZonexCommander software on the
REVIEW page. Double Click on Current Room Temp where a SENDCOM is attached to display duct temperatures.

SENDCOM Communicating Duct Temperature Sensor – Part # SENDCOM

SENDCOM

1. The SENDCOM communicates both supply and return temperatures,

and is mounted directly to the supply trunk or plenum of the HVAC unit.

2. The SENDCOM must be mounted in a dry, protected atmosphere not

subject to the elements.

3. Locate the position of the SENDCOM enclosure with the attached
supply air sensor, on to the supply duct or plenum.

4. Drill a 1/4” hole for the sensor and attach the SENDCOM assembly
so that the sensor fits through the 1/4” hole.

5. Attach the SENDCOM assembly to the duct or plenum with the sheet
metal screws provided.

6. Locate the position in the return duct or plenum for the return
sensor and drill a 1/4” hole.

sheet metal screws, and extend the sensor wire to the SENDCOM

8. Connect the shield conductor of the return air sensor lead wire to –
on the RA terminal block.

9. Connect 24 volts using 18 AWG wire minimum, to the “R” and “C”
terminals of the SENDCOM. Power can be taken from the HVAC unit

10. Connect the communication wire to RX and TX. The communication
wire must be separate from any 24-volt or higher wiring.

NOTE: After setting the address switches, cycle power to the

SENDCOM to set the address.

TERMINAL FUNCTIONS

7. Install the sensor assembly labeled LAT SENSOR with the provided

RA terminal block.

control transformer.

11. Each SENDCOM must be addressed to the corresponding stand

alone thermostat. Determine the thermostat address to which

the SENDCOM is applied and add 70 to that address. Press and hold
the ADR button, and then press the UP or DN button to raise or

lower the displayed address number (see Page 29).

28

12. Set the individual SENDCOM address to correlate to the thermostat

for that HVAC unit.

EXAMPLE: If the DIGICOM or DIGIHP thermostat has an address of 01,
to address the SENDCOM, add 70 to the address number of thethermostat.
This makes the SENDCOM address 71. If the address on the DIGICOM
or DIGIHP is 02; add 70 to make the SENDCOM address 72, etc.
Applications with ZonexCommander (Plus) will not use SENDCOMs
to see supply and return air temperatures. These are reported from the
RMODs and will be seen on address 1, 2, 3, and 4 current room
temperatures. On ZonexCommander (Plus) systems a SENDCOM
cannot be addressed for thermostats 1, 2, 3, or 4, so start addressing any
stand alone equipment in a ZonexCommander (Plus) system at 75.

13. The SENDCOM is calibrated at the factory but can be field calibrated

tiometer for return air.

SENDCOM DESCRIPTION

171
272
373
474
575
676
777
878

979
10 8 0
11 8 1
12 8 2
13 8 3
14 8 4
15 8 5
16 8 6
17 8 7
18 8 8
19 8 9
20 9 0

ADDRESSING

Determine the thermostat address to which the SENDCOM will be

by adjusting the R2 potentiometer for Supply Air or the R10 poten-

THERMOSTAT

ADDRESS SENDCOM

TENS ONES

applied, and add a value of 70.

29

RLYCOM DESCRIPTION

DESCRIPTION

The Zonex Systems RLYCOM is a communicating relay module, which
provides programmed on and off schedules for auxiliary devices such as
blowers, fans, lighting, etc. As with the communicating thermostats, the
Commander Schedule program provides up to 4 Occupied/Unoccupied
events per day for each RLYCOM, including vacation days. The control
status of the RLYCOM is displayed on the REVIEW screen of the
Commander program.

The RLYCOM consists of 2 SPDT relays for controlling auxiliary devices
such as lighting, blowers, etc. The relay contacts are designed for 24vac
circuits only, with a maximum one amp load. Power for the RLYCOM is
provided by a separate 24vac 40va transformer.

The RLYCOM requires a unique address from 01 to 20 (except Zonex
Commander (Plus) 05-20). Communication is through the RS-485
twisted pair wire.

OPERATION

When the RLYCOM is in the Occupied mode, the on-board relays are
energized. In the Unoccupied mode, the relays are de-energized. The
mode status is displayed on the REVIEW screen of the Commander
program and on the RLYCOM circuit board. On the Commander

is displayed with a RED “0” in the Unoccupied Heat column. Unoccupied
mode is displayed with a BLUE “0” in the Cool Unoccupied column. The
mode is displayed on the RLYCOM circuit board with the red PWR LED.
When the LED is illuminated, the device is in the Occupied Mode. When
the LED is OFF, the RLYCOM is in the Unoccupied mode. The mode can

The SPDT relays are dry contacts for maximum 2 amp 24-volt circuits only.

RLYCOM Communicating Relay Module – Part# RLYCOM

The RLYCOM address is selected by simultaneously pressing the

ADDR button and either the UP or DN button to raise or lower the

address.

program the RLYCOM is displayed with a row of 0’s. Occupied mode

be changed manually at the RLYCOM by pressing the Toggle button. The
mode can also be changed from the Commander program from the

SYSTEM tab.

30

Zonex Systems zone dampers are used in
cooling/heating systems to provide room by
room zone control. The damper is provided

zone damper is controlled by a zone thermostat.
More than one damper can be controlled by
one zone thermostat. Use this table to determine
which zone dampers to use.

ROUND MEDIUM PRESSURE ZONE DAMPERS

Zonex Systems round medium pressure zone dampers are recommended for systems
with a maximum differential static pressure up to 1.75”. This modulating 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 is elliptical, which allows the
airflow to be tracked linearly. The damper pipe is furnished with one crimped end and
one straight end for easy installation. Do not install damper in an inverted position.

ROUND MEDIUM PRESSURE DAMPER
PART NUMBERS AND SIZES

TYPICAL ROUND CAPACITIES

These air quantities were derived from a duct sizing chart 0.1” friction loss per
100’ of duct. All CFMs listed are approximate. For accurate selection use duct sizing
table or device.

MEDIUM PRESSURE (STMPD)

MODSTAT

ZONE DAMPERS

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.

DAMPER TO
MODSTAT WIRING

with a factory mounted actuator. Each

STMPD ROUND MEDIUM PRESSURE 1.75” ANY SIZE 18”

STMRTD RECT. – MED. PRESSURE

DAMPER MODEL

STCD RECT. – HEAVY DUTY 1.75” ANY SIZE 48”W x 48”H

D-FUSER 0.1” ANY SIZE 10”

A hat section supports a reversing, 24vac, 60Hz, 2 VA motor. A magnetic clutch
allows for continuous power to the motor and longer motor life. Motor drive time from

full open to full close is 90 seconds.

MAXIMUM

DIFFERENTIAL

PRESSURE

1” 7.5 TONS 24”W x 20”H

MAXIMUM

SYSTEM SIZE

MAXIMUM

DUCT SIZE

ROUND DIMENSIONAL DATA

PAR T #

L

D

W

STMPD06
STMPD08
STMPD10
STMPD12
STMPD14

STMPD16

STMPD18

SIZE

6

8
10
12
14

16

18

D

6"

8"
10"
12"
14"
16"

18" 20" 21"

L

10"
10"
12"
14"

16"
18"

W

11"
13"
15"
17"
19"

9"

Duct

Diameter

10”
12”
14”
16”

6”
8”

Nominal

CFM

110
250
410

660
1000
1450

Duct Velocity

FPM

540
700
750
850
925

1070

18” 2000 1100 .036

Damper

ΔP

WC

"

.014
.015
.015
.022
.035
.036

31

MEDIUM PRESSURE RECTANGULAR DIMENSIONAL DATA

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

HEAVY DUTY RECTANGULAR DIMENSIONAL DATA

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

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 “snap­lock” steel frame with S &
Drive duct connections.
Allow a 16 inch 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

RECTANGULAR ZONE DAMPERS

The rectangular zone dampers come in either medium pressure or heavy
duty. For systems under 7.5 tons use medium pressure dampers. For
systems 7.5 tons or over use heavy duty dampers. Motor drive time open
and close is 90 seconds.

RECTANGULAR MEDIUM PRESSURE
ZONE DAMPERS

Zonex Systems rectangular medium pressure dampers are recommended
for systems under 7.5 tons with a maximum differential static pressure of 1”.

MEDIUM PRESSURE (STMRTD) AND
HEAVY DUTY (STCD) RECTANGULAR
DAMPERS

ZONE DAMPERS

RECTANGULAR HEAVY DUTY ZONE DAMPERS

These are fully modulating 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 inch wide cutout in the
existing duct and attaches with screws via a duct mounting plate. The duct

mounting plate is 5 inches wide. A hat section supports a reversing
24vac, 60 Hz, 2 VA motor. A magnetic clutch allows for continuous

power to the motor and longer motor life. Two set screws connect the motor

to the damper shaft, allowing quick motor replacement, if necessary.

Motor drive time from full open to full close is 90 seconds.

blade design. A full stall motor, drawing 2 VA, drives the motor from
full open to full close in 90 seconds.

2-1/4”

W

2-1/2"

MOTOR

B

16

WIDTH HEIGHT

A

5"

H

48” MAXIMUM WIDTH

DEPTH

B 16”

2.5”

A

32

6” Neck Vel 400 500 600 700 800 900

ΔP 0.011 0.016 0.023 0.035 0.04 0.055

CFM 80 98 120 135 157 176

Throw 50 FPM 4’ 4’ 5’ 6’ 6’ 7’

8” Neck 400 500 600 700 800 900

ΔP 0.019 0.03 0.045 0.056 0.041 0.093

CFM 140 170 207 247 280 315

Throw 50 FPM 5’ 6’ 7’ 8’ 9’ 10’

10” Neck Vel 400 500 600 700 800 900

ΔP 0.029 0.045 0.066 0.09 0.12 0.146

CFM 218 273 330 382 438 497

Throw 50 FPM 6’ 8’ 9’ 10’ 11’ 12’

D-FUSER ZONE DAMPER

Zonex Systems D-Fuser is a combination zone damper and diffuser. It
mounts in a standard 2’ x 2’ T-bar ceiling opening, providing for simple
installation and easy maintenance access. The D-Fuser is a cone shaped
fluidic nozzle with a platen that modulates up and down to control air

and throw remain constant. This keeps the air hugging the ceiling
which maximizes room air mixing and minimizes the “waterfall” effect.

ZONE DAMPERS

RECTANGULAR DAMPER CAPACITIES*

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

*

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.

AT NECK VELOCITIES UP TO 700 FPM

NC LESS THAN 30

flow. As the platen moves up, the air volume is reduced but the air velocity

The D-Fuser is a fully modulating power open, power close damper

using a 24vac 60Hz 2 VA motor. Motor drive time from full open to

full close is 90 seconds. The D-Fuser connects to round duct either on

the side or top. Collars are available for 6", 7", 8", 9" and 10" duct.

COLLAR:

12”

12”

2”

24”

PLACE ON SIDE
OR TOP

33

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.
b) Select damper size using either the round capacities chart, the

rectangular capacities chart or by using a duct sizing table or
calculator.

c) Select a Zonex Systems damper to fit the duct size selectedfor

that zone.
Make sure your zone dampers match the type specified in the table
showing Maximum Differential Pressure.

INSTALLATION NOTES

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 duct work. The hat section
on the round damper is delivered with insulation between the hat
section and pipe. Therefore, insulation should be applied to the
round pipe and be butted against the hat section, (do not insulate the
motor). The motor generates enough heat so that no condensation
will develop on it.

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

6. Medium pressure rectangular dampers slide into a 3

1

⁄4-inch wide

cutout in the side of the preexisting ductwork.

NOTE: Dampers should not be installed with motor upside down in
the 6:00 position.

Up to three dampers can be directly controlled by one thermostat.
To wire two to three zone dampers to one thermostat, use the
following diagram shown. Remember to size the damper power

SLAVING MORE THAN
THREE ZONE DAMPERS

Use the following diagram when a thermostat will be
controlling more than three zone dampers. Use an

power the slaved dampers.

ZONE DAMPERS

SLAVING UP TO THREE ZONE DAMPERS

transformer for the total number of zone dampers. Each actuator

draws 2 VA.

7. Minimum open and close positioning is field adjustable on the

actuator. The damper is shipped from the factory to close 100%.

ZONE DAMPER

RC

ZONE DAMPER

MC R O

RCMC R O

ZONE DAMPER

MC R O

RC

additional 24V transformer sized at 2VA per damper to

34

MC R O RC

MODSTAT

SIZE TRANSFORMER AT

2VA PER DAMPER

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 is used on any size system over 5 tons. 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

The bypass damper is to be sized for the total system
CFM @1500 FPM. System CFM should be calculated at
400 CFM per ton.
Example: A 5-ton system is rated at 2000 CFM
(5x400 = 2000). When calculated at 1500 FPM, the
bypass damper should be 16”. Never undersize the
bypass damper.

ROUND BYPASS
DAMPER SELECTION

The Zonex Systems STMPD damper is used for round
bypass applications. When you know the bypass CFM
requirements, use the ROUND BYPASS SELECTION
TABLE to confirm the round damper size.
NOTE: multiple round dampers can be slaved from one
static pressure control to provide the correct capacity.
One large rectangular bypass damper may be used
instead of multiple round dampers. See below.

RECTANGULAR BYPASS
DAMPER SELECTION

The Zonex Systems STCD WxH damper is used for
rectangular bypass applications. These dampers are
also sized for the total system CFM rated at 1500
FPM. Multiple dampers can be slaved from a single
static pressure control.

RECTANGULAR & ROUND BYPASS DAMPER

WITH THE STATIC PRESSURE CONTROL

BYPASS DAMPERS – ELECTRONIC

Diameter CFM

8” 560
10” 900
12” 1250
14” 1700
16” 2200
18” 2600

ROUND BYPASS SELECTION TABLE

PART # SIZE D L W
STMPD08 8 8" 10" 11"
STMPD10 10 10" 12" 13"
STMPD12 12 12" 14" 15"
STMPD14 14 14" 16" 17"
STMPD16 16 16" 18" 19"
STMPD18 18 18" 20" 21"

L

D

W

RECTANGULAR BYPASS DAMPERS

SELECT FROM 8 X 8 THRU 48 X 48

H

D

WIDTH HEIGHT

35

H 16”

W

PART # STCD W x H

48" MAXIMUM WIDTH

W

DEPTH

4"

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.

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

ROUND AND RECTANGULAR

BYPASS DAMPER MOTORS

DAMPER

ACTUATOR

**

***

RC RO MC

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

36

SLAVE

DAMPER

ACTUATOR

*

RC RO MC

TO NEXT SLAVE
BYPASS DAMPER
IF APPLICABLE

RC
RO
MC

BYPASS DAMPER WITH INTEGRATED PRESSURE CONTROL

Bypass Damper with Integrated Pressure Control is used to control bypass operations. The bypass damper modulates to maintain
static pressure as zone dampers open and close. The bypass system reduces air noise from the supply registers caused by
excessive air velocity. If the system is configured for intermittent fan mode and the system satisfies, there will be a 3 -minute delay
to allow for system purge, after which the bypass damper will open to 25%, preventing noisy rush of air through supply regist ers
when fan starts up on a call for heat or cool. If the system is configured for fan continuous operation, the STBP (Round) or

STCDBP (Rectangular) Electronic Bypass will monitor static pressure continuously, providing constant control of system static.

INTEGRATED PRESSURE CONTROL
DESCRIPTION

A. Supply air tube
B. 24vac R and C

C. Damper Terminal RO, RC, MC
D. LED lights

E. Adjustable Potentiometer
F. TP1 Test Point

2. Bypass damper and controller are powered by a
dedicated 24vac 40VA transformer.

3. Do not install the bypass damper outside.

4. Locate the Integrated Pressure Control (IPC) and air
tube on the bypass damper.

5. Drill ¼” hole into the side of the supply duct 2’ after
the bypass and before the 1
pressure supporting block over ¼” hole, align hole in
block with hole in duct. Use provide d sheet metal
screws.

6. Install air tube into supply air duct by slipping supplied
plastic tubing into holes in support block and duct.
Slip tube 3” into the duct. Pickup tubing fits snugly
into provided hole.

7. Connect pressure tube from static air pickup to
Integrated Pressure Controller (port closest to you).

st

supply take-off. Mount

Fig. 1

BYPASS DAMPER INSTALLATION

1. Verify the bypass damper is sized properly to the
system and not undersized. (Bypass damper sizing is
recommended for 100% of system CFM.)

Fig. 2

BYPASS DAMPER WITH INTEGRATED
BYPASS CONTROL SETUP

1. Run all supply dampers to the full open position and
have blower motor running at 100% fan speed. (See
Note #1)

2. Manually close the bypass damper by pressing in the
release lever on the motor side of the actuator. With
the release lever pressed, rotate the damper actuator
collar to close the damper and release the lever to lock
the damper closed.

37

BYPASS DAMPER WITH INTEGRATED PRESSURE CONTROL

3. Quick Set Option: Turn the potentiometer on the
damper control board to the full left position and
slowly rotate RIGHT, until the “RC” RED LED turns
on. Now rotate LEFT just slightly, until RC LED
turns off. The IPC is ready for operation.

“RC” RED LED means damper closing.

“RO” GREEN LED means damper opening.

4. Static Pressure Option: The Integrated Pressure
Control Board can be field configured for specified
static pressure using a multi meter and the static

pressure – voltage chart. (Exhibit A). This chart shows
voltage (DC) to inches of W.C. (static pressure)
relationship. Use a multi meter set on VDC and place
the leads on the “C” terminal and “TP1” (test point
one) next to the potentiometer. The Voltage reading
translates to inches of W.C.

BYPASS CHECKOUT FOR STATIC

PRESSURE CONTROLLER

1. Make cool call at the zone thermostat of smallest zone.

2. Verify all zone dampers are closed except calling zone.

3. Verify noise at zone registers is not excessive. Adjust
the Integrated Pressure Control LEFT to lower noise
(airflow) or RIGHT to increase airflow until too noisy.

BYPASS DAMPER WIRING DIAGRAM
WITH INTEGRATED BYPASS CONTROL

Note #1: To open all dampers, it may be necessary to

remove Y outputs to unit on the zone control board and to
make full cool calls on all thermostats. This will modulate
dampers fully open and lock out compressor.

On Zonex Systems
balance modes for simplified bypass setup.

GEN II

and

ModCom II

, use air

38

6. Please answer the questions as the Installation Wizard is loading.

7. When the Wizard has completed the loading process, confirm the
Zonex icon is located on the Desktop:
NOTE: A second icon with our trending or Zonex
charts icon will also reside on your desktop.

ZonexCommander and ZonexCommander (Plus)

1. Connect USB cable to computer and USB plug on Command Center.

2. Start with Commander program closed, and switch on the Command
Center with on/off switch. Verify Command Center is on by the power
LED. “Found new hardware” wizard should appear on computer screen.

3. Insert the Driver CD into the CD drive on computer, and follow the
installation wizard prompts to install.
A. Can Windows connect to Windows Update to search for software?

Select “YES, this time only”

B. “This Wizard helps you install software for: ZonexCommander.

What do you want the wizard to do?” Select: “Install the software

automatically”

C. When the message “ZonexCommander has not passed Windows

logo testing…” Click “Continue Anyway”

D. When the wizard has finished installing the software for the

ZonexCommander, Zonex Commander (Plus), the message
“Completing the Found New Hardware Wizard” will appear.

4. Remove the Driver CD from computer.

with COM1, 2, 3 or 4.

it to an open COM1, 2, 3 or 4.

plug on the Command Center.

Center.

Common Ground Phasing procedure. See below.

SYSTEM START-UP PROCEDURE

Installing System Software

1. Place Systems Software Master CD in the CD drive.

2. Click on My Computer.

3. Click on the CD or DVD RW drive; i.e., “D” or “E.”

4. Double click on the Commander..exe file.

5. Click on OK to start the Installation Wizard.

USB Driver Installation for Windows XP and Vista

5. Proceed to Assigning COM Port Instructions (below).

USB Driver Installation for Windows 7777 and 8

1. With the ZonexCommander (Plus) Command Center in the OFF

position, connect the USB cable to the Commander board and USB

port on the computer. Turn on the Command Center. The message,

“New Hardware Found” will appear., followed by “Device Driver

software was not successfully installed.”

2. Click on the

Hardware and Sounds. Locate and click on Device Manager.

Select Other Devices

and note the COM Port assigned. Right click on ZonexCom-

mander,

3. Insert the USB Driver CD into the computer drive, and note which

drive is being used.

Start

menu and select

, and locate the ZonexCommander listing

and then click on

Control Panel

Properties.

. Then select

4. Under the

select “Browse My Computer for Driver Software.”

5. Select the Drive which has the CD installed; and click on

warning may appear; click on

6. After installation, a message will appear, stating “Windows has

successfully updated driver . ”

7. Remove the Driver CD from computer..

8. Proceed to Assigning COM Port Instructions (below).

Assigning COM Port Instructions for Windows 777, 8, XP and Vista

1. From the computer desktop, right click on MY COMPUTER.

2. Select PROPERTIES.

3. Select Hardware on System Properties page.

4. Select Device Manager.

5. On Device Manager page, find COM & LPT ports and expand by
clicking on the + next to COM & LPT.

6. ZonexCommander or ZonexCommander (Plus)

7. If the COM assignment is higher than 4, you must manually change

8. Reboot computer.

9. Once computer has restarted, select the ZonexCommander or

ZonexCommander (Plus) icon on display; and click on Connect Now.

10. Select COM1, 2, 3 or 4 from connection settings window.

11. When Connection Successful window appears, click OK.

Continue with system setup and configuration steps in Zonex­Commander Installation manual.

General Tab for properties, click on

“Install the software anyway.

Update Drivers;;;

Next.

”

should be listed

Connecting to the System

Direct Connect - Computer connected directly to a single Command

Center.

NOTE: It is recommended to first set up and configure a new system

with a direct connected computer (laptop or desktop), and verify oper-

ation.

Setup

Zonex Commander/Commander (Plus) (CETCIP / ZPTCIP)

1. With the Command Center switched OFF and the Commander

program closed, connect the 6’ USB cable to computer and USB

2. Switch the Command Center ON, and then bring up the Commander
system program on the computer.

3. Remove the insulating tag from the backup battery on the Command

4. With all components wired, addressed and powered up, perform the

A

39

Program Screens

The Zonex software provides 6 tabbed screens for System status and configuration. If you are installing ZonexCommander (Plus) to control multiple
zoned units, your software is equipped with 7 tabs:

Welcome Tab Use to connect to the system.
Review Tab Display total number of thermostats and devices, along with current space and heat/cool setpoint temperatures.
Schedule Tab Assign Occupied and Unoccupied events for each thermostat and RLYCOM in the system.
Set Temp Tab Enter Occupied and Unoccupied, Heat and Cool temperatures remotely for selected thermostats.
System Tab To access or set the Day, Date, and Time – display Outside air on all systems, Mixed air (return) and Leaving air (supply)

temperature warning alert and temperature trending.

Vacation Tab Assign up to 20 vacation/holiday events for each thermostat and RLYCOM.
Zoned Units Tab Used only with ZonexCommander (Plus), allocates thermostats to their respective units when multiple units are included in the system.

SYSTEM START-UP PROCEDURE

COMMON GROUND PHASING PROCEDURES

1. With the ModStats powered up, set voltmeter to the AC scale.

2. Separate the thermostat circuit board and cover from the terminal
base.

3. Place one meter probe on the RX terminal and the other probe on the
R terminal - note the voltage reading.

4. Keeping one probe on RX, place the other meter probe on terminal C
and note the voltage reading.

5. The lowest voltage reading must be on the RX to C terminals.

6. If the low voltage reading is measured on RX to R, reverse the R and
C wires on the thermostat terminal base.

7. If erratic voltages are read, contact Technical Support.

temperatures on SYSTEMS TAB – Number of thermostats and devices (RLYCOM) – Override for Occupied / Unoccupied
modes – Enter names or tags for thermostats and other devices – Thermostat lock feature –

40

Accessing the Systems

WELCOME Screen – Fig. 1

Double click on the Zonex icon to open the program’s WELCOME screen

(see Fig. 1)

Setting a Password (Optional)

If a password is required, it may be entered now or at a later time. If you
do not require a password and do not need to add or modify a device,
proceed to Connecting to the Zonex System section below.

1. Click on the Password Maintenance button on the lower right side

of the WELCOME screen. (see Fig. 2)

2. Enter your new password. The password must not exceed 30 characters
and spaces.
NOTE: the password only affects the computer on which it is entered.

3. Re-enter your password in the Verify box.

4. Click on OK to store the password.
NOTE: Your password should be retained elsewhere. If it is lost, the
program will have to be re-installed and all information re-entered.

Adding, Modifying or Deleting Records

To add or change a project name, phone number or IP address:

1. Add a record:

a. Click on the Connect Now button from the WELCOME screen.
b. Verify that the Connection Settings window appears (see Fig. 3).

c. Click on Commander Job and Installation Contacts button.
d. Verify that the Contacts window appears (see Fig. 4).

e. Click on Records.
f. Click on ADD (see Fig. 5); and enter new project name, phone

number for the dedicated phone line to this job or IP address
and port number, if applicable. Multiple facilities may be
accessed from this software.

g. Click on File; then click on Save.
h. Click on Exit to return to the WELCOME Tab.

SYSTEM START-UP PROCEDURE

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

41

2. Modify an existing record:

a. Click on the Connect Now button from the WELCOME screen.
b. Verify that the Connection Settings window appears.
c. Click on Commander Job and Installation Contacts button.
d. Verify that the Contacts window appears (see Fig. 4).
e. Use the Scroll buttons (<< or >>) at the bottom right of the

Contacts screen to locate the record to be modified.

f. Click inside the field to be changed, and revise data.
g. Click on File; then click on Save.
h. Click on Exit to return to the WELCOME Tab.

3. Delete a record:

a. Click on the Connect Now button from the WELCOME screen.
b. Verify that the Connection Settings window appears.
c. Click on Commander Job and Installation Contacts button.
d. Verify that the Contacts window appears (see Fig. 4).
e. Use the Scroll buttons (<< or >>) at the bottom right of the

Contacts screen to locate the record to be deleted.

f. Click on Records.
g. Click on Delete.
h. Click on File; then click on Save.
i. Click on Exit to return to the WELCOME Tab.

Connecting to the Zonex System

1. Click on the Connect Now button from the WELCOME screen

(see Fig. 6).

2. Verify that the Connection Settings window appears (see Fig. 7).

4. Click on the Connect button (see arrow in Fig. 7). The screen then

displays: Please wait while system is loading (see Fig. 8).
The connection should complete within 30 seconds and is verified
when the Connection Successful window appears.

5. Click on OK in the Connection Successful window (see Fig. 9).

SYSTEM START-UP PROCEDURE

Fig. 8

Fig. 6

Fig. 7

Fig. 9

For International systems equipped with Celsius thermostats, you may
now select a Celsius temperature display by clicking the box labeled
"Click here for Celsius." If you are not using Celsius thermostats, please
ignore this step. Each time you enter the program, this step must be ini­tiated to display Celsius Temperatures.

3. Click on the appropriate COM port or TCP/IP network connection.

42

System Setup and Configuration

SYSTEM Screen – Fig. 10

Stats

2. Select the total number of system devices (up to 20 thermostats and

RLYCOMs on the Command Center communication buss).

3. The program is equipped with a System Alarm Deviation function,

establish out of range temperature criteria from 3-10°. Whenever a
thermostat exceeds the selected deviation from its heating or cooling
setpoints, the current temperature will be highlighted in Yellow on
the REVIEW Screen. If this feature is not required, select 00 to
disable the alert; otherwise, select the temperature deviation.

4. Click on Send Settings to place this information into memory.

Date/Time

will appear on the upper right of the screen.

2. Click on the right or left arrownext to the month and year to select

the current month or click on today’s date.

3. Click on current day to highlight in gray.

4. Click on the Select Hour and Select Minute down arrow buttons

to select time.

5. Click on the AM or PM radio button.

6. Click on Send Settings to place this information into memory.

7. Verify setting by clicking on the Clock Setting button on the top left

of the screen.

SYSTEM START-UP PROCEDURE

Fig. 10

1. Click on the SYSTEMS Tab, and click on the radio button next to

Stats (see Fig. 11).

1. Click on the Date/Time radio button (see Fig. 12), and a calendar

Fig. 12

Fig. 11

or System warning alert (see Fig. 11), which allows the user to

43

SYSTEM START-UP PROCEDURE

Stat Name

Do not exceed 20 characters and spaces on each entry.

2. Click on Send Settings after typing each address to place it into

memory. Confirm that entries have been saved by clicking on the
REVIEW Tab; then return to the SYSTEMS Tab to continue labeling the
thermostats.

Occupied Mode

2. Select Global, and click on Send Settings. This is to ensure all

devices are in the Occupied mode for the start-up. Settings can be
changed to Unoccupied Mode after initial setup.

Lock/Unlock Thermostats

2. Select the thermostat from the drop down menu, or click on Global to

lock or unlock all thermostats, or select an individual address to lock.

3. Click on Send Settings to place this information into memory.

4. Confirm your lock/unlock request by returning to the REVIEW Tab.
If the thermostat number you selected is Red, it is locked; if it is
Black, it is unlocked. If necessary, repeat the sequence above to
change to desired setting.

Reviewing System Data

1. Click on the REVIEW Tab at the top of the screen to verify thermostat,

2. Verify that the number of thermostats and devices (upper left of
screen) is correct.

3. Occupied and Unoccupied temperature setpoints and space
temperatures should be displayed in each address row.

NOTE: If any thermostat shows “0” across the row, there is no com­munication with that thermostat. See the Troubleshooting section.

1. Click on the Stat Name radio button (see Fig. 13), and enter 1. Click on the Lock/Unlock radio button to lock or unlock thermostats
individual thermostat names, RLYCOM, or SENDCOM designations. remotely (see Fig. 15).

Fig. 13

1. Click on the Occupied Mode radio button (see Fig. 14).

Fig. 15

Fig. 14

SYSTEM Screen – Fig. 16

RLYCOM and SENDCOM communications (see Fig. 16).

Fig. 16

44

SYSTEM START-UP PROCEDURE

4. RLYCOM devices, if utilized, control generic loads and will be displayed
with a Red “0” when energized and a Blue“O” when off.

a. A Red “0” should appear in the Unoccupied Heat column, which

indicates the RLYCOM is energized. (During setup, all devices
were set to Occupied mode.)

c. If all of the RLYCOM “0’s” are Black, the device is not commu-

nicating. See the Troubleshooting section.

5. To test the RLYCOM operation and communications, switch to the
Unoccupied mode and verify the result, as follows:

a. Note the address number of the RLYCOM to be tested.

b. Click on the SYSTEM Tab, and click on the Unoccupied mode

radio button.

c. When the address window appears, select the address assigned to

the RLYCOM being tested.

d. Click on Send Settings.

e. Return to the REVIEW Tab, and verify the RLYCOM has changed

to a Blue “0” in the Unoccupied column. The power light on the
RLYCOM should be off.

f. After testing, you may wish to adjust the mode back to the

original setting.

6. SENDCOM communications are used to display RA/SA temperatures
from stand-alone units.

a. Place the cursor directly over a Current Room Temperature

thermostat number with a SENDCOM attached; and double click

b. The Read Sensors window will appear, displaying Discharge

and Return Air temperatures. If a single “0” is displayed for both
sensors, or if the temperature appears to be incorrect, see the
Troubleshooting section.

7. For multiple Command Centers repeat the above steps in this section
for each Command Center.

Additional Information Displayed on the
REVIEW Screen

1. Click on the thermostat number to confirm that the thermostat is in

This feature is not available with a RLYCOM. Its status is indicated
by a Red “0” for either ON or HOT (Occupied) and a Blue “0”
(for OFF or de-energized.).

2. Click on a thermostat name to display Schedules after they have been

3. Click on the Legend button for an explanation of activities displayed

b. A Blue “0” in the Unoccupied Cool column indicates the

RLYCOM is either off or de-energized.

the Occupied or Unoccupied mode (see Fig. 18).

Fig. 18

entered (see Fig. 19).

on it (see Fig. 17).

Fig. 17

Fig. 19

on the REVIEW Screen (see Fig. 20).

Fig. 20

45

SYSTEM START-UP PROCEDURE

4. The REVIEW Screen is dynamic and automatically updates every three

minutes. To initiate an immediate update, click on the Refresh
Thermostat button.

5. To print a copy of the REVIEW Screen, which displays all
current temperature data, as well as a date and time stamp, click
on the Print button.

Thermostat Management

Everything the on-site user can perform at the thermostat can be
performed remotely on the SET TEMP screen. The SET TEMP screen
displays a thermostat feature, which allows the Heat and Cool setpoints
to be changed on individual or all (global) thermostats, for either
Occupied or Unoccupied modes.

1. Click on the SET TEMP Tab.

2. To change temperature setpoints on all thermostats, click on the

3. To change an individual thermostat, click on the Individual radio
button.

NOTE: When the Individual radio button is selected, a window will
appear with a down arrow button:

a. Click on the down arrow button to display thermostat address

numbers and names, and click on an address.

b.After selecting the desired address, the current Occupied and

Unoccupied temperature setpoints for that thermostat will be

4. After the Individual or Global radio button has been selected,

click on either the Occupied or Unoccupied mode radio button.

5. Click on either the Heat or Cool radio button.

6. To change the temperature, click on the Up or Down buttons on

the thermostat until the desired temperature is displayed.

7. Click on the Send to Thermostat button to place information

into memory.

8. After adjusting setpoints, click on the REVIEW TAB to confirm entries
have been saved. If a change did not occur, repeat the sequence above.

Scheduling the System

The ZonexCommander software provides up to four scheduled events
each day, for each thermostat. To assign Occupied and Unoccupied schedules:

1. Click on the SCHEDULE Tab.

2. Under Select Thermostat at the top left of the screen, click on the

down arrow button; and select a thermostat from the drop down menu.

SET TEMP Screen – Fig. 21

Fig. 21

Global radio button (see Fig. 22); or,

displayed (see Fig. 23).

Fig. 23

SCHEDULE Screen – Fig. 24

Fig. 22

Fig. 24

46

SYSTEM START-UP PROCEDURE

3. Event times can be entered separately for each day or for the entire

week. Click on the All Week radio button. This allows a complete
schedule to be assigned to one thermostat for every day of the week.
(If, after the week’s schedule has been set, you would like to change
one day, see No. 6 below for instructions.)

4. To enter the time schedules on the selected thermostat or RLYCOM
address, use the down arrow buttons in each Hour, Minute and
AM or PM field to make your selections.

You must make an entry into each time event. If there is no difference
in time between the Occupied and Unoccupied modes, select NC
(“No Change”) in the appropriate fields.

EXAMPLE: Thermostat 01 will be in the Occupied mode
from 6:30 AM until 5:00 PM –

a. Under Day Occupied select 6 in the hour field, 30 in the minute

field, and then AM.

b. Under Day Unoccupied select NC in the hour field (this denotes

“No Change”).

c. Under Night Occupied select NC in the hour field (this denotes

“No Change”).

d. Under Night Unoccupied select 5 in the hour field, 00 in the

minute field, and then PM.

e. Click on Set Schedule to program the schedule into memory.

f. Repeat this process for each thermostat and RLYCOM address.

5. To copy the same schedule to another thermostat or RLYCOM:

a. Click on the Copy Schedule to Thermostat radio button, and

select the destination thermostat address.

b. Click on Set Schedule to copy the schedule to the destination

thermostat.

6. Thermostats and RLYCOMs can have individual schedules for
every day of the week. To assign a schedule for one day:

a. Select the thermostat or RLYCOM address from the pull down

menu under Select Thermostat.

b. Click on the radio button next to the day of the week to be

scheduled. Schedule each day individually. After each day’s
schedule is entered, click on the Set Schedule button.

7. The schedules can be printed from the SCHEDULE screen:

a. Click on either the Individual or Global radio button below

the Print button. The Global selection will print the schedules
for all thermostats and RLYCOMs, and the Individual selection
will print a copy of the SCHEDULE screen displayed.

b. Click on Print

. It is recommended that this information be printed

following the start-up of the system.

8. The Individual schedules can also be viewed on the REVIEW screen:

a. Click on the REVIEW Tab.

Vacation Scheduling

The vacation schedule provides 20 separate Unoccupied events for up to
30 days. This feature is designed to maximize your energy savings by
placing the thermostat(s) into a 24-hr Unoccupied mode for 1 to 30 days.

To set an event:

1. Click on the VACATION Tab at the top of the screen, and verify all

thermostat and RLYCOM addresses are listed under the column,

2. To enter an Unoccupied day event, click on the down arrow

button in the field showing the event numbers [“Select 1-20”]. Begin
by selecting 1 for the first event.

3. Select the Month, Day, and Duration of the event by using the
down arrow buttons in the appropriate fields.

4. Click on Set Vacation Schedule.

5. Verify that the event Month, Day and Duration appear in the list on
the left side of the screen.

6. Repeat steps 1 – 4 to set each vacation date, using the next available
event number.

VACATION Screen – Fig. 25

Fig. 25

Thermostats below on Vacation Schedule (see Fig. 26).

b. Click on the thermostat name (see Fig. 19).

Fig. 26

47

To clear an event:

1. Click on the down arrow button in the event number [“Select 1-20”]

field, and select the event number.

2. Click on the down arrow button in the Month field.

3. Click on Clear.

4. Click on Set Vacation Schedule.

To override an event, if you have signage or other units
that will operate during a vacation period:

1. In the Thermostats below on Vacation Schedule column, click

on each thermostat address that you wish to override. Notice that,
when you click on an address, it moves to the Override Vacation

2. Click on Confirm Override.

To print the Vacation event schedule:

1. Click on the Print button.

Allocating Thermostats to Specific Units for use
with ZonexCommander (Plus) only

The ZONED UNITS screen is only applicable to ZonexCommander (Plus)
software. It is used to configure, allocate and display thermostats assigned
to their specific RMOD controllers. Each Command Center can support
up to four RMODs. The RMODs are designated as Units #92 – #95.

1. Click on the ZONED UNITS Tab.

2. Verify that all thermostat/device address numbers appear in the

3. Select the RMOD #92 radio button, and highlight the thermostat
address numbers to be assigned to that RMOD (one or more addresses
may be highlighted).
NOTE: When DIGICOM, DIGIHP thermostats or RLYCOM devices
are part of the installation, they must be addressed above #05 (5).

4. Click on Add.

5. It is important to confirm that the correct thermostats are assigned to

6. Repeat steps 1-5 to allocate thermostats to each RMOD.

7. If an address has been assigned in error, simply highlight the address
number and click on the Remove button. This returns the thermostat
to the Add/Remove column. Reassign the address to the appropriate unit.

8. After all addresses have been assigned to the corresponding RMOD,
click on the Set Zoned Units button on the lower left of the screen.

9. Repeat these procedures for each RMOD #93, #94 and #95 when

10. When the hourglass returns to the arrow cursor on the ZONED UNITS

screen, close the ZonexCommander (Plus) program on the computer;
and recycle power on the Command Center and RMOD(s).

11. Bring up the ZonexCommander (Plus) program again, and direct-

connect to the system.

12. Go the the REVIEW screen, and verify all termostats are indicating

temperatures.

SYSTEM START-UP PROCEDURE

Schedule column (see Fig. 27).

Fig. 27

Add/Remove left column (see Fig. 28).

that RMOD (see Fig. 29).

Fig. 29

applicable (see Fig. 30).

ZONED UNITS Screen – Fig. 28

Fig. 28

Fig. 30

48

13. Double left click on the Current Room Temperature of thermostat

confirms communication with the RMOD.

14. Double left click on the Current Room Temperature on thermostat

15. Click on the ZONED UNITS screen, and verify any DIGICOM,
DIGIHP and RLYCOM addresses remaining in the Add/Remove
column.

on the Print Units button.

17. RMOD configuration is complete

Activating Trend Logging Data

Trending Thermostat Data

Historical data must be developed in order to trend thermostat
information.

1. Click on the SYSTEM Tab.

2. Underneath Use Log File, in the lower right corner of the SYSTEM
screen, click on the New radio button to open a new trend log.

3. Click on the Logging button.

4. If you have SENDCOM Sensors in your system:

a. Click on the box labeled Enable RA/SA Sensors (SENDCOM)

Logging. This will open another box, which lists all thermostats

b. Click on thermostats with SENDCOM Sensors to move them to

the right column for inclusion in the trending data.

5. The program must be named and then saved onto your C drive

C:\Program Files\ Zonex Systems.

6. After the logging commences, you may minimize the Zonex program

in order to use other computer functions; but do not turn off the
computer or trending program during data collection. This
will cause the logging function to cease. Typically, 2-3 days of
logging information polled at 20-minute intervals provides you with
sufficient data to establish a trend.

Displaying Trending Data

Trending data is displayed in a separate Zonex program called Zonex

Software. A Zonex Trends icon should reside on your Desktop.

1. Click on the Zonex Trends icon.

2. Click on the Select Log file, and retrieve the saved data file. (Using

our example above, we would select C:\Program Files\Zonex
Systems; then click on Log Zones).

TREND AND DATA LOGGING OPERATION

#1, to bring up RMOD 92 Supply and Return temperatures. This

#2 for RMOD 93, #3 for RMOD 94 and #4 for RMOD 95.

16. To print the ModStat to RMOD listings for future reference, click

System Requirements: Windows 7,8, XP or Vista are required

to trend log. Not compatible with Windows 95 or 98.

SYSTEMS Screen – Fig. 31

in your system (see Fig. 32).

(see Fig. 33). For example, we saved a file named Log Zones in

Fig. 33

Fig. 31

Trends (see Fig. 34). This program was initially loaded with the Zonex

Fig. 34

Fig. 32

49

TREND AND DATA LOGGING OPERATION

3. When the file is retrieved, use the drop down box to select your

4. The data logging program logs data on every thermostat in your

system every 20 minutes. Use the pull down box to select the
thermostat you want to analyze.

Enter the From/To date and time range you want to review.

6. You also have the option of viewing the saved data every 20 minutes
or hourly; select one option.

7. Click on the Continue button. The trending program will provide

you with a Trend Analysis Chart reflecting the temperatures of the
desired thermostat vs. the heating and cooling setpoints during the
trending period.

8. The chart displays temperatures from 40-100º in 2º increments on the

9. Different presentations may be prepared by selecting options

listed in the Chart Type drop down box. The initial chart is
displayed as a 2d line.

10. A correlation exists between the number of data points and the rows
of data displayed. Reducing the number of rows allows you to zoom
in on the data.

11. To print the Trending Chart, click on the Print button; or save it in
your computer as a bitmap (.bmp), which can be e-mailed easily.

12. To generate additional data for other thermostats in the system,
click on the X button located at the top of the page to return to
Page 1 of the Trending program. Then select another thermostat you
wish to analyze by using the drop down arrow, and the data will be
retrieved quickly.

13. After the data is collected, if you would like to trend Return and
Supply air from each unit:

a. If you are using SENDCOM sensors in your system, click on the

Discharge/Return Air Temps button on the graphing page
associated with that thermostat.

b.If you are using a ModCom System, the system’s RA/SA will be

shown as the last entry in the pull down thermostat box. To display,
click on the Discharge/Return Air Temps button on the
graphing page. If you are using SENDCOM sensors with
stand-alone equipment, that information will follow its
thermostat number.

14. Temperature points on the trend lines can be highlighted by double
clicking on any of the lines (additional data points will appear). By
clicking inside each small box, the temperature at that data point
will be displayed at the bottom of the graph with its value at that
point. Data points will be displayed for any SENDCOM assigned to
that specific thermostat number.

installation name, thermostat number, and date and time range;

then click the Continue button (see Fig. 35). Multiple buildings

can be accessed via the trending program, and files can be saved

under various names.

Fig. 35

5. A calendar resides in the trending software package (see Fig. 36).

Y axis, and dates and times are displayed on the X axis (see Fig. 37).

Fig. 37

Fig. 36

50

TROUBLESHOOTING COMMON PROBLEMS

ZonexCommander Will Not Connect

Direct Connect

1. System will not connect; error message, “

operation. Please try again.”

A. Verify ZonexCommander Command Center is

energized.

B. Verify that the USB cable is installed between the

ZonexCommander Controller and the computer.

C. Verify the correct COM port is assigned to the

computer

D. Close all running programs except the Zonex-

Commander. Uninstall USB Driver; reinstall

following USB Installation procedures on Page 39 9
of Installation and Applications Manual.

2. System will not connect; error message, “

port number. Please try again.”

A. Verify the correct COM port is assigned on the

computer.

B. Change COM port assignment in Computer

Device Manager to port 1-4.

Error on

Invalid

Network Connection

1. System won’t connect on the network,

Timed Out.”

A. Verify the network cable is installed to the Network

ISERVER Device.

B. Check cable from the ISERVER to the Zonex-

Commander Controller.

C. Verify the ISERVER Network device is powered

and energized.
D. Check the IP Address being used to connect.
E. Check the configuration of the ISERVER and

verify the baud rate of 4800.

“System

Communicating Devices Not Responding

ModStat, DIGICOM and DIGIHP

1. When trying to read the thermostats, the REVIEW

screen shows “0” for temperature.
A. Verify device is powered up.
B. Verify device has the correct address.
C. Verify communication wire is in correct polarity on

terminals RX & TX.

D. Verify communication wire is properly connected

from ModStat/DIGICOM/DIGIHP thermostats
to Command Center with no disconnected or
broken connections. Wire nuts are not to be used.

E. Check polarity of R & C to the thermostats

(Common Ground Phasing).

SENDCOM

1. SENDCOM reporting “0” on Read Sensors window.
A. Verify device is powered up.

B. Verify device has the correct address. For

corresponding thermostat address, add 70.

C. Verify communication wire is in correct polarity on

terminals RX & TX.

D. Verify communication wire is properly connected

from the SENDCOM(s) to the communication
link with no disconnected or broken connections.

Wire nuts are not to be used.
E. Verify C/F jumper position.
F. Verify the R & C polarity (Common Ground

Phasing).

RLYCOM

1. RLYCOM indicates all black zeroes (“0”) on REVIEW
screen and does not switch from computer schedule.

A. Verify device is powered up.

B. Verify device has the correct address (01 to 20).
C. Verify communication wire is in correct polarity on

terminals RX & TX.

D. Verify communication wire is properly connected

from the RLYCOM(s) to the communication link,
with no disconnected or broken connections. Wire
nuts are not to be used.

E. Check polarity of R & C (Common Ground

Phasing).

Programming and System Setup Problems

1. Thermostat names disappear after entering.

A. When entering thermostat names or ID, do not

exceed 20 characters, including spaces.

B. After entering each name or ID, click on Send

Settings button.

2. Cannot manually change address or set points on the
thermostats.

A. Thermostat is electronically locked.
B. Thermostat can only be unlocked from the

computer on the SYSTEM screen.

3. Thermostat display is blank.

A. Verify thermostat 24 volt power, verify 24-28vac

measured from “R” to “C” on circuit board.

4. System goes into Unoccupied during the day.

A. Go to the SYSTEM screen and verify that the Day,

Date and Time are correct.

B. Verify Occupied and Unoccupied times are correct

from the SCHEDULE screen.

C. Verify Vacation schedule entries.

51

OPERATING SCHEDULE

For additional questions on programming and technical support, please call Zonex Systems at [phone], M-F 6:30 AM-5:00 PM PST.

DAY OCC DAY UNOCC NIGHT OCC NIGHT UNOCC

DAY ADR NAME H C H C H C H C

MON
TUES
WED

THUR

FRI

SAT

SUN

MON
TUES
WED

THUR

FRI

SAT

SUN

MON
TUES
WED

THUR

FRI

SAT

SUN

MON
TUES
WED

THUR

FRI

SAT

SUN

MON
TUES
WED

THUR

FRI

SAT

SUN

MON
TUES
WED

THUR

FRI

SAT

SUN

MON
TUES
WED

THUR

FRI

SAT

SUN

52

Hot Line: [phone]

www.zonexcontrols.com

The easy way to Get Quotes Fast

5622 Engineer Drive

Huntington Beach, CA 92649

Factory: [phone] • Fax: [phone]

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

Part #ZCMAN

ZonexCommander

(Plus)

Network All Your HVAC Equipment

Centralized DDC Communications

for Stand-Alone HVAC and Zoned Systems

Designed to centralize

control of multiple

constant volume VAV

systems

ZonexCommander

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

Copyright 2014 by Zonex Systems.

52

Rev. Oct 2014