Zonex Systems DigiTract 4 Installation
DigiTract 4
Two Stage Heat/Cool
Comfort Control System
Installation Guide
Part #DT4MAN
Zoning Systems
That’s all we do.
Rev. October 2013
TABLE OF CONTENTS...................................................................................................................................................................Page
INTRODUCTION.......................................................................................................................................................................................................1
SYSTEM DESCRIPTION...........................................................................................................................................................................................1
COMPONENT SELECTION GUIDE ..........................................................................................................................................................................2
WIRING
Gas/Electric DTGE4A ..........................................................................................................................................................................................3
Heat Pump DTHP4A ...........................................................................................................................................................................................4
Zone Dampers....................................................................................................................................................................................................5
SYSTEM CONTROLLERS
Gas/Electric DTGE4A
Operation...........................................................................................................................................................................................6
Status Lights .......................................................................................................................................................................................6
Components.......................................................................................................................................................................................7
Heat Pump DTHP4A
Operation...........................................................................................................................................................................................8
Status Lights .......................................................................................................................................................................................9
Components..................................................................................................................................................................................9-10
Fossil Fuel Application .....................................................................................................................................................................11
CAPACITY CONTROLLERS
Gas/Electric DTGE4A........................................................................................................................................................................11
Heat Pump DTHP4A.........................................................................................................................................................................11
Capacity Control and Staging............................................................................................................................................................11
ZONE DAMPERS
Round.........................................................................................................................................................................................................13-14
Rectangular.................................................................................................................................................................................................15-16
Installation Notes..............................................................................................................................................................................................17
BYPASS DAMPERS
Barometric..................................................................................................................................................................................................17-18
Electronic ...................................................................................................................................................................................................19-20
SYSTEM STARTUP
LAT and OAS Installation ..................................................................................................................................................................12
Bypass Damper with Integrated Pressure Control.........................................................................................................................................21-22
DAMPER TRANSFORMER .....................................................................................................................................................................................23
Gas/Electric DTGE4A...................................................................................................................................................................................23-24
Heat Pump DTHP4A .........................................................................................................................................................................................24
Troubleshooting / Service Checks.....................................................................................................................................................................25
LAT Voltage – Temperature Conversion Chart..................................................................................................................................................25
The Digitract 4 zoning system enables up to four room thermostats to control a single HVAC system. This permits superior building temperature control
over a standard single thermostat. Any generic thermostat may be used on this control system. When using digital thermostats, they must have “C”
terminal for common or be battery powered. Both Programmable and Non-Programmable thermostats can be used. This system is designed to be
installed and serviced by qualified licensed professionals.
INTRODUCTION
SYSTEM DESCRIPTION
The Digitract 4 zoning system consists of a 2-stage System Controller
with built-in Capacity Control (leaving air sensor), Zone Dampers, Zone
Thermostats, Bypass Damper and Damper Transformer.
The System Controller is the heart of the Digitract 4 zoning system. It
monitors the leaving air temperature, zone thermostats and controls the
HVAC System and zone dampers. See pages 6 to 10 for further information.
trol feature of the System Controller. It is a sensor placed in the supply
air of the HVAC system. The sensor monitors the supply air temperature of the HVAC system and sends this information to the System
Controller. The System Controller uses this information to stage and temporarily cycle the HVAC system off if the leaving air gets too hot in heat
mode or too cold in cool mode. For heat pumps, this input is also
used to control the auxiliary heat. See Capacity Controller section, page
Balance Point is used for fossil fuel applications when an FOAS is
applied. The balance point feature will lock out compressor and enable
gas furnace when outside air temperature drops below BP (balance
point) setting.
The Zone Dampers are air valves placed in the forced air duct work
for each zone. They are controlled by the System Controller. While the
HVAC system is running, the zone dampers for any zone thermostats not
calling will close and zone dampers for the zones calling will remain
open. Conditioned air is only directed to the zones needing it. See pages
13 to 17 for further information.
The Zone Thermostats monitor the room temperature of each zone
and compare it to the heat and cool setpoints stored in them. If the room
temperature drops below the heat setpoint, the zone thermostat makes
a heat call telling the System Controller that zone needs heating. If the
room temperature rises above the cool setpoint, that thermostat makes
a cool call telling the System Controller that zone needs cooling.
Two-stage thermostats are not required with the Digitract 4 System. The
System Controller will cycle staging and auxiliary strip heat based on
The Bypass Damper is a pressure relief valve placed between the
supply and return ducts of the forced air duct work. As zone dampers
start closing, the bypass damper will open and divert some of the supply
air to the return. This prevents a pressure buildup in the supply duct
which can cause fan cavitation, excessive air velocities, and excessive
Damper Transformer. Wired to TR1 and TR2 on the System Controller.
Powers the zone dampers only. Requires an in-line fuse. See Damper
*The Digitract 4 was designed for both residential and
commercial applications of 4 or less zones. The full
spectrum of supply dampers can be applied, from low
pressure; medium pressure; and heavy duty; round and
rectangular.
System Controller
1
Leaving Air Sensor
2
ZONE 4
73
Zone Damper
3
Zone Thermostat
4
Bypass Damper
5
Damper
6
Transformer
The Leaving Air Sensor (LAT) is part of the staging and capacity con-
11, for further information.
ZONE 3
ZONE 2
ZONE 1
2
LAT
5
3
73
4
1
73
73
DIGITRACT 4
System Controller
6
Fused 24V Transformer
leaving air temperature and time.
zone damper blow-by. See pages 17 to 22 for further information.
Transformer section, page 23.
1
Digitract 4 COMPONENT SELECTION GUIDE
2
WIRING – GAS/ELECTRIC DTGE4A
Use minimum 18 gauge for all wiring.
All wiring must meet state and local codes.
Zone damper terminals. Refer to “Wiring – Zone Dampers” section, page 5.
Connect W2 and Y2 of the DTGE4A only if there are two heat and/or two cool stages.
Most thermostats are compatible with the DigiTract 4.
Zone damper terminals. Refer to “WIRING – ZONE DAMPERS” on page 5.
Install one 24V AC transformer, sized and fused for the total number of zone dampers. See “DAMPER
Fan cycling jumper: Bottom position = FAU fan control; Upper position = energized fan on heat call (JPI not used)
Adjustable potentiometers:
• HI – To establish HI cutout for furnace protection and staging temperatures – must be field adjusted to 120°
for HP applications.
• LO – To establish LO cutout, to protect freezing of coil, to set up staging for compressors
• TIME – To establish changeover time when opposite calls will be recognized by controller
Digitract 4 Gas/Electric 2-Stage Heat/Cool
HVAC unit and LAT terminals. Do not connect Y2 or W2 for single stage heat/cool systems.
BYPASS
DAMPER
LAT
SENSOR
1
ON
OFF
S
LAT
}
S
Y2
W1
G
W2
Y1
R
C
UNIT TERMINALS
AIRFLOW
2
Y2
W1
G
W2
Y1
R
C
W R Y G C
3
ZONE 1
THERMOSTAT
LAT. Locate the leaving air sensor in the supply air stream, as far from the coil/heat exchanger as possible
1
before the bypass takeoff. Do not locate the LAT downstream of the bypass takeoff. Refer to "CAPACITY
Zonex DigiTract GE
6
JP1
R11
Y1 G W1 Y2 W2
STAT 1 STAT 2
W R Y G C W R Y G C W R Y G C
W R Y G C
ZONE 2
THERMOSTAT
JP2
PWR
DTGE4A
W R Y G C
ZONE 3
THERMOSTAT
40
STAT 3
7
135
45
125
50
115
LO HI
15
10
145
25
155
5
TIME
3
DPR 1
DPR 2
DPR 3
DPR 4
STAT 4
W R Y G CW R Y G C
ZONE 4
THERMOSTAT
20
CONTROLLER-LAT INSTALLATION” on page 12 for further information.
DAMPER
1
1
2
2
3
3
4
4
TR1
TR2
4
24V AC Transformer
to Power Dampers
5
2
3
4
5
TRANSFORMER” on page 23.
6
7
3
WIRING – HEAT PUMP DTHP4A
1
2
3
4
5
6
7
8
Digitract 4 HP 3-Stage Heat/2-Stage Cool
Connect W2 from the controller to the unit’s electric heat stage terminal designation. It is recommended to install an outdoor thermostat
for non-fossil fuel applications.
Most heat pump thermostats are compatible; 1C/2H.
NOTE: Some combination thermostats do not have an E terminal. Connect W2 of the thermostat to the E terminal of STAT 1 terminal block.
Zone damper terminals. Refer to “WIRING – ZONE DAMPERS” on page 5.
Reversing valve jumper:
Fossil fuel jumper:
Fan jumper:
FOAS – Outdoor Air Sensor used to sense Balance Point temperature for auto-changeover, fossil fuel application only. Use FOAS only; not
HP outdoor thermostat.
Adjustable potentiometers:
• BP – To establish temperature that locks out heat pump and energizes fossil fuel furnace
• HI – To establish HI cutout for furnace protection and staging temperatures
• LO – To establish LO cutout, to protect freezing of coil, to set up staging for compressors
• TIME – To establish changeover time when opposite calls will be recognized by controller
B-Mode –
energize for heat
O Mode –
energize for cool
Fossil Fuel Application
Not Used
Normal HP Operation
ON
Zonex DigiTract HP
OFF
LAT
}
Y 1 G O/B Y 2
STAT 1
E O/B R Y G C
BYPASS
DAMPER
AIRFLOW
LAT
SENSOR
Y2
O/B
G
W2
Y1
R
C
OAS
OAS
O/B
W2
+
–
+
–
Y2
G
Y1
R
C
S TAT 2
O/B FF
FAN
W 2
O/B R Y G CO/B R Y G C
S TAT 3
DTHP4A
33
45
40 50
25 41
LOBP
STAT 4
O/B R Y G C
120
115 125
HI
DPR 1
DPR 2
DPR 3
DPR 4
5 25
TIME
15
1
1
2
2
3
3
4
4
TR1
TR2
E O/B R Y G C
ZONE 1
THERMOSTAT
O/B R Y G C
ZONE 2
THERMOSTAT
O/B R Y G C
ZONE 3
THERMOSTAT
O/B R Y G C
ZONE 4
THERMOSTAT
24V AC Transformer
to Power Dampers
LAT. Locate the leaving air sensor between the refrigerant coil and the electric heat coil(s) or other auxiliary heat source. Refer to
“CAPACITY CONTROLLER – LAT INSTALLATION” page 12, for further information.
2
3
4
Install one 24V AC transformer, sized and fused for the total number of zone dampers. See “DAMPER TRANSFORMER” on page 23.
5
6
7
8
4
WIRING – ZONE DAMPERS
There are three methods of wiring the zone dampers. If necessary, you
can mix wiring methods on different zones to suit your application.
Method 1: When wiring one to three TR/TREC series dampers to
a zone.
Method 2: When wiring more than three TR/TREC series dampers to a
zone, use a 24V ac, SPNO relay.
Method 3: When using 101AMPD or 101CD series dampers with a
DigiTract controller. Note: 101 series medium pressure dampers are
required for all systems over 5 tons. Refer to Parts Selection Table,
page 13.
5
The DigiTract Controller is the heart of the DigiTract zoning system. It
is an auto changeover, home run system with a built in staging and
capacity controller. The function of the system controller is to receive
calls from the zone thermostats, operate the HVAC system in either heat
or cool mode and close the damper(s)of zones not calling for the operating mode. The mode of operation is determined by the first call
received. If the thermostats are calling for opposite modes, a
changeover sequence will start. Based on the Time Setpoint setting, a
changeover will occur after time delay. Changeover will continue as long
as there are opposing calls. The built in Capacity Controller maintains
the supply air temperature within an operation range to prevent freeze
ups and overheating. For Heat Pumps, the DTHP4A System Controller
will also control the auxiliary heat.
The Digitract 4 controller is not to be subjected to temperatures below
33°F or above 160°F. The controllers must not be installed in atmospheres that could create condensation or corrosion. Warranty is voided
on controllers that fail due to moisture or corrosion evidenced on the
circuit board. The operating voltage range on the Digitract 4 controllers
is 24 vac to 28 vac.
The DigiTract 4 is available in two models, Gas Electric 2-Stage
Heat/Cool and Heat Pump 3 stage Heat/2 Stage Cool with integrated fossil
fuel control.
NOTE: For Heat Pump systems using gas electric inputs (no “O” or “B”
reversing valve circuits) use the DTGE4A controller.
SYSTEM CONTROLLERS
SYSTEM CONTROLLER – GAS/ELECTRIC DTGE4A
OPERATION
The System Controller will initially run in the mode requested by the first
calling zone thermostat.
Cool mode – When running in the cool mode, the System Controller
energizes the compressor(s) and indoor blower. This is indicated by the
corresponding Y and G LEDs illuminating. Dampers for the zones not
calling for cool are powered closed and the dampers for the zones calling
for cool are left open. This is indicated by the DPR LEDs. If the DPR LED
is illuminated on the damper terminal strip and damper terminal board, the
corresponding damper is closed. The system will continue to run in the
cool mode until all calls are satisfied or changeover occurs. When all calls
are satisfied or prior to changeover, the system will go into a purge mode.
Heat mode – When running in the heat mode, the System Controller
energizes the heat stage (s), indicated by the W LEDs illuminating. If the
a call for heat, indicated by the G LED illuminating. Dampers for the
zones not calling for heat are powered closed and the dampers for the
zones calling for heat are left open. This is indicated by the DPR LEDs.
If a DPR LED is on, the corresponding damper to the LED is being
powered closed. The system will continue to run in the heat mode until
all calls are satisfied or changeover occurs. When all calls are satisfied
or prior to changeover, the system will go into purge mode.
Changeover – While the system is operating in one mode, and the
System Controller receives a call for the opposite mode, the System
Controller will continue to run in the current mode until the changeover
TIME limit has been reached, or all current calls have been satisfied.
Then the System Controller will go into a purge mode for 4 minutes,
then change over to the new mode
Purge mode – Purge mode is initiated after the last calling zone is
satisfied, or when the controller goes into a forced changeover. All HVAC
output LEDs on the controller go off during this cycle. When the last calling
zone thermostat satisfies, the Digitract controller goes into a four-minute
purge cycle. During this time delay all controller outputs to the HVAC
system and dampers are terminated. All dampers go to a full openp osition
and the HVAC system fan delay control runs the blower for a time. This
time delay with no control outputs allows the supply duct to return to
ambient temperature before the next call is initiated.
When the controller goes into a force mode changeover, and the initial call
drops out to the purge cycle, the HVAC outputs are terminated, and the initial zone damper remains open for a 4-minute delay with the other dampers
closing. The HVAC system fan control allows the blower to run for a time,
and the initial calling zone supply duct returns to ambient temperature.
Ventilation– When no zones are calling, all zone dampers are open.
During this time, if any thermostat has the fan switch ON then the indoor
blower is energized (G made to R) and the G LED is on. This provides
ventilation to all zones.
Fan Control Jumper is in the JP2 position, the blower will energize with
6
W1: First stage heat. When energized (W1 made to R),
energizes first-stage heat.
W2: Second stage heat. When energized (W2 made to R),
energizes second-stage heat.
G: Blower. When energized (G made to R),
energizes the indoor blower.
Y1: First stage cool. When energized (Y1 made to R),
energizes first stage cooling.
Y2: Second stage cool. When energized (Y2 made to R),
energizes second stage cooling.
R: HVAC unit 24V power. Powers the Digitract 4 board
and zone thermostats.
C: HVAC unit 24V power return.
B. Thermostat Terminals – Connects up to four zone
thermostats.
W: Heat call. When energized (W made to R),
requests the Digitract 4 to run in heat mode.
R: HVAC unit 24V power.
Y: Cool call. When energized (Y made to R),
requests the Digitract 4 to run in cool mode.
G: Blower Fan- When energized (G made to R), requests the
DigiTract 4 to turn on the indoor blower fan.
C: HVAC unit 24V common.
C. Damper Terminals – Connects dampers for up to four zones and
damper power supply.
TR1/TR2: 24V AC transformer terminals. This transformer powers
only the zone dampers.
1 1: Zone damper 1.
When energized, powers zone damper 1 closed.
2 2: Zone damper 2.
When energized, powers zone damper 2 closed.
3 3: Zone damper 3.
When energized, powers zone damper 3 closed.
4 4: Zone damper 4.
When energized, powers zone damper 4 closed.
D. Damper Status LEDs – On when corresponding zone damper is
being powered closed.
E. Board Number – This number indicates the circuit board number
and revision. You must know this number if conferring with technical support.
F. Special Function Jumpers
JP1 – Not used.
place the jumper over the top and middle jumper pins. Controller is shipped
with the jumper on the middle and lower pin for furnace fan control.
G. Microcontroller – Responsible for activation and control of the
unit based upon thermostat input.
H. HVAC System Status LEDs – Indicates what the DTGE4A is
energizing on the HVAC system.
Y1: Compressor, yellow. On when the first-stage cool is energized.
Y2: Compressor, yellow. On when the second-stage cool is energized.
G: Blower, green. On when the indoor blower is energized.
W1: Heat, red. On when first stage heat is energized.
W2: Heat, red. On when second stage heat is energized.
PWR: Power, orange. On when power at R and C and the Power
Switch is on. Flashing when in Capacity Control cut out mode.
See Status Lights section, page 6, for further information.
I. Power Switch – When OFF, power from the HVAC unit transformer is
disconnected from the Digitract 4 and thermostats. When ON, power
from the HVAC unit transformer is supplied to the Digitract 4 and the
zone thermostats.
J. Adjustable Potentiometers – For HIGH limit, LO limit and TIME
changeover. Use these potentiometers to adjust limits for a customized
job. From factory the settings are 145° high, 45° low and 15-minute
changeover.
SYSTEM CONTROLLER – GAS/ELECTRIC DTGE4A
COMPONENTS
A. HVAC Unit/LAT Terminals – Connects to HVAC unit
and Leaving Air Sensor (LAT).
S S: LAT terminals. The LAT monitors the leaving
air temperature.
J
15
135
Zonex DigiTract GE
ON
OFF
S
A
LAT
}
S
UNIT TERMINALS
Y2
W1
G
W2
Y1
R
C
STAT 1 STAT 2
W R Y G C
ZONE 1
THERMOSTAT
JP2 – Electric Heat – To energize the system blower on a call for heat,
R11
Y1 G W1 Y2 W2
W R Y G C W R Y G C W R Y G C
B
JP1
PWR
JP2
DTGE4A
H
F
45
E
50
40
LO
G
STAT 3
W R Y G CW R Y G C
ZONE 3
THERMOSTAT
125
115
HI
155
5
TIME
D
STAT 4
25
DPR 1
DPR 2
DPR 3
DPR 4
DAMPER
20
10
145
1
1
2
2
3
3
4
4
TR1
TR2
C
7
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