Zonex Systems DigiTract 4 Installation

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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

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

Leaving Air Sensor

ZONE 4

Zone Damper

Zone Thermostat

Bypass Damper

Damper

Transformer

The Leaving Air Sensor (LAT) is part of the staging and capacity con-

11, for further information.

ZONE 3

ZONE 2

ZONE 1

LAT

DIGITRACT 4

System Controller

Fused 24V Transformer

leaving air temperature and time.

zone damper blow-by. See pages 17 to 22 for further information.

Transformer section, page 23.

Digitract 4 COMPONENT SELECTION GUIDE

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

OFF

LAT

}

R C

UNIT TERMINALS

AIRFLOW

R C

W R Y G C

ZONE 1 THERMOSTAT

LAT. Locate the leaving air sensor in the supply air stream, as far from the coil/heat exchanger as possible

before the bypass takeoff. Do not locate the LAT downstream of the bypass takeoff. Refer to "CAPACITY

Zonex DigiTract GE

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

STAT 3

135

125

115

LO HI

145

155

TIME

DPR 1 DPR 2 DPR 3 DPR 4

STAT 4

W R Y G CW R Y G C

ZONE 4 THERMOSTAT

CONTROLLER-LAT INSTALLATION” on page 12 for further information.

DAMPER

1 1 2 2 3 3 4 4

TR1 TR2

24V AC Transformer

to Power Dampers

TRANSFORMER” on page 23.

WIRING – HEAT PUMP DTHP4A

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

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

O/B

OAS

O/B

+ –

–

S TAT 2

O/B FF

FAN

W 2

O/B R Y G CO/B R Y G C

S TAT 3

DTHP4A

40 50

25 41

LOBP

STAT 4

O/B R Y G C

120

115 125

DPR 1

DPR 2

DPR 3

DPR 4

5 25

TIME

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.

Install one 24V AC transformer, sized and fused for the total number of zone dampers. See “DAMPER TRANSFORMER” on page 23.

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.

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

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.

135

Zonex DigiTract GE

OFF

LAT

}

UNIT TERMINALS

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

JP1

PWR

JP2

DTGE4A

STAT 3

W R Y G CW R Y G C

ZONE 3 THERMOSTAT

125

115

155

TIME

STAT 4

DPR 1 DPR 2 DPR 3 DPR 4

DAMPER

145

1 1 2 2 3 3 4 4

TR1 TR2

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), indoor blower and energizes the reversing valve (O made to R) if the reversing valve selection jumper is in the O position. This is indicated by the corresponding Y, G and O/B (if jumper in O position) LEDs illuminating. Also, the dampers for the zones not calling for cool are 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, 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 compressor(s), indoor blower and energizes the reversing valve if the reversing valve selection jumper is in the B position. This is indicated by the corresponding Y, G and O/B (if jumper in B position) LEDs illuminating. Also, the dampers for the zones not calling for heat are closed and the dampers for the zones calling for heat are left open. This is indicated by the DPR LEDs. If the DPR LED is on the damper terminal strip and damper terminal board, the corresponding damper is closed. After running in heat mode for 8 minutes, the System Controller will energize the auxiliary heat if the coil leaving air temperature drops below 90° and will de-energize when the coil leaving air temperature rises above 100°. The W2 LED is on when the auxiliary heat is energized. 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 a purge mode.

Changeover – While the system is operating in one mode, if 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 has been reached or all current calls are satisfied. The System controller will then go into a 4-minute purge, then change over to the opposite 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 open position 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.

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.

Auxiliary heat – 8 minutes after the System Controller has run in heat mode, if the coil leaving air temperature is below 90°, the auxiliary heat is energized and the W2 LED illuminates. When the coil leaving air temperature rises above 100°, the auxiliary heat is de-energized and the W2 LED cycles off.

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 and the G LED is on. This provides ventilation to all zones.

Emergency heat – Emergency Mode is selected from STAT1 position only. To make an emergency heat call, STAT1 must be in the emergency heat mode and make a heat call. When STAT1 places the call for heat, all thermostats will then be able to place a call for emergency heat independently. Compressors will be locked out of operation until STAT1 places a cool or heat call. When a call for emergency heat is placed the blower and electric strip heat will energize. Zones that are not calling for heat will close their dampers; those that are calling will remain open.

Fossil Fuel Operation – The DTHP4A provides a selectable integrated Fossil Fuel operation. Applying this controller to Fossil Fuel systems eliminates the need for a “Fossil Fuel Kit,” additional capacity control, auxiliary relays and complicated control wiring. The controller offers balance point control when the optional FOAS outdoor air sensor is used. This enables the heat pump compressor to be locked out and the Furnace to be energized on a call for heat, when the outdoor temperature is below the BP setpoint on the DTHP4A controller. When the FOAS is not used, the controller will stage up to the furnace based on time and temperature.

By placing the controller jumper in the FF position the controller is configured for Fossil Fuel operation. When there is no Outside Air Sensor applied, a call for heat from any zone energizes Y1 compressor output and G blower output (“B” mode energizes rev valve also). With the factory POT settings: LO 45° and HI 120°, the controller will stage up from Y1 to Y2 after four minutes, if the supply air temperature is below 95°. After 8 minutes run time if the supply air temperature is 90° or below, W2 LED will illuminate energizing the furnace; Y1 and Y2 will drop out leaving the fan circuit energized. When the controller energizes W2 for the furnace, the capacity control automatically implements a fixed cutout temperature of approximately 135°. When this temperature is exceeded, W2 drops out and the system goes into a 4-minute purge cycle to reduce supply air temperature.

When using the optional FOAS Outdoor Air Sensor, the Balance Point “BP” POT should be checked and adjusted as required; factory setting is 33°. On call for heat, if the OA temp is above the BP setting, Y1 will be energized on the Heat Pump. When the OA is below the BP, call for heat will energize W2 gas furnace directly.

SYSTEM CONTROLLER – HEAT PUMP DTHP4A

OPERATION

STATUS LED LEGEND

COMPONENTS DTHP4A

SYSTEM CONTROLLER – HEAT PUMP DTHP4A

O/B Reversing valve LED, yellow. On when the reversing valve is energized. Y1 Compressor LED, yellow. On when the first compressor stage is energized. Y2 Compressor LED, yellow. On when the second compressor stage is energized. G Indoor blower LED, green. On when the indoor blower is energized by the DTHP4A Controller. W2 Auxiliary heat LED, red. On when the auxiliary heat is energized. PWR Power LED, orange. On when DTHP4A is powered. Flashing during capacity control cutout. DPR Damper status LED, red. One per damper. On when damper is closed.

STATUS LEDs

O/B Y1 Y2 G W2 PWR DPR MODE FUNCTION

OFF OFF OFF OFF OFF OFF OFF Off Power off.

OFF OFF OFF OFF OFF ON OFF On Power on, blower off, all zones satisfied.

ON/OFF OFF OFF ON OFF ON 0 Vent Blower on, compressor(s) off, all zone dampers open.

ON/OFF OFF OFF OFF OFF ON 1 Purge Blower off, compressor(s) off. Dampers with LED on are closed.

A ON OFF ON OFF ON 1 Y1 Cool 1st stage cool, blower on. Dampers with LED on are closed.

A ON ON ON OFF ON 1 Y2 Cool 2nd stage cool, blower on. Dampers with LED on are closed.

B ON OFF ON OFF ON 1 Y1 Heat 1st stage heat, blower on. Dampers with LED on are closed.

B ON ON ON C ON 1 Y2 Heat 2nd stage heat, blower on. Dampers with LED on are closed.

ON/OFF OFF OFF ON ON ON 1 Em. Heat Auxiliary and emergency heat on.

OFF OFF OFF ON OFF FL 1 Cap Cut out Blower on, all compressors off. Dampers with LED on are closed.

ON/OFF ON ON ON ON ON 1 Em. Heat If below 90°, stages up to Y1, Y2 and W2

ON/OFF OFF OFF ON ON ON 1 Em. Heat Fossil fuel mode, stages up to W2 only

FL = Flashing A = On when reversing valve jumper is in O position B = On when reversing valve jumper is in B position C = On when auxiliary heat is energized 1 = One or more damper LEDs on 0 = All damper LEDs are off

leaving air temperature.

±: OAS Optional Outside Air Sensor for use in Fossil Fuel /

Dual Fuel applications

W2: Auxiliary Heat. When energized (W2 made to R), turns on the

heat pump auxiliary heat.

G: Blower. When energized (G made to R), turns on the

indoor blower.

Y1: Compressor. When energized (Y1 made to R), turns on the heat

pump first stage compressor.

Y2: Compressor. When energized, (Y2 made to R), turns on the

heat pump second stage compressor.

O/B: Reversing Valve. When energized (O/B made to R), engages

the heat pump reversing valve. R: Heat pump unit 24V power. Powers Digitract 4 and thermostats. C: Heat pump unit 24V common.

B. Thermostat Terminals – Connects up to four zone heat pump

thermostats. E: Emergency Heat. On STAT 1 only. Connected to E terminal on

STAT 1.

0/B: Reversing valve signal. “O” energizes reversing valve in the Cool

mode. “B” energizes reversing valve in the Heat mode.

R: Heat pump unit 24V power. See A. Y: Compressor. G: Blower. C: Heat pump 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 Lights – Light on when corresponding zone

damper is closed.

E. Reversing Valve Selection Jumper – Configures Digitract 4 to

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

F. Microcontroller – Responsible for activation and control of the

unit and dampers based upon thermostat input.

G. Power Switch – When OFF, power from the heat pump transformer

is disconnected from the Digitract 4 and thermostats. When ON, power from the heat pump transformer is supplied to the Digitract 4 and the zone thermostats.

H. Heat Pump Status LEDs – Indicates what the DTHP4A is

energizing on the heat pump. O/B: Reversing valve, yellow. On when the reversing valve is

energized.

Y1: Compressor, yellow. On when the first stage compressor is

energized.

Y2: Compressor, yellow. On when the second stage compressor is

energized. G: Blower, green. On when the indoor blower is energized. W2: Auxiliary heat, red. On when the auxiliary 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 9, for further information.

I. FF fossil fuel jumper – Place jumper in FF position to use fossil

fuel features.

J. Adjustable potentiometer for balance point (BP), LO limit, HI limit

and changeover time.

SYSTEM CONTROLLER – HEAT PUMP DTHP4A

COMPONENTS

A. Heat Pump Unit/LAT Terminals – Connects to Heat Pump and

Leaving Air Sensor (LAT). ± LAT terminals. The LAT monitors the heat pump coil

The HVAC system is sized to handle the load of the entire home or building. Because of this, when all the zones are not calling, the load to the HVAC system can diminish below its designed capacity. Left unchecked, the HVAC unit could freeze up or overheat. To compensate for this, the Digitract 4 is furnished with a built in Capacity Controller.

The basic function of the Capacity Controller is to monitor the leaving air temperature and cycle the unit off when the air is out of operating range and, after a minimum four minute time delay, turn the unit back on when the air temperature has returned within operating range. Additionally, for heat pumps the Capacity Controller will turn on the heat pump auxiliary heat if the coil leaving air temperature is not hot enough in heat mode.

Upon a heat call, the controller will energize W1 LED if the leaving air temperature is less than High Limit Setpoint. This setpoint is determined by adjusting the potentiometer located in the upper right corner of the controller, HI. W1 will de-energize if LAT exceeds the HI setpoint, W1 LED will de-energize and the PWR LED will flash slowly indicating a stage 1 capacity cutout. If the LAT is below the High limit, W1 will energize, W1 LED will illuminate.

W2 Heat operations – After W1 has operated continuously for 4 minutes and LAT is less than High Limit minus 25°(if HI of 145° – 25°=120°), then W2 will energize indicated by the W2 LED. If LAT rises to High Limit minus 5°, then W2 will de-energize indicted by W2 LED off and PWR LED flashing quickly. If all heat calls are satisfied both W1 and W2 will de-energize and controller will go into a 4-minute purge cycle.

Y1 Heat Operation – Upon a call for heat, the controller will energize Y1 LED, if the LAT rises above the High Limit (potentiometer located on controller top right corner, marked HI), then Y1 LED will de-energize and PWR LED will flash indicating a stage 1 capacity cutout. After a 4-minute time delay the LAT will be checked; if LAT is less than HI cutout, then Y1 LED will reenergize and PWR LED will stop flashing. If the O/B jumper is in the B position, the O/B LED will illuminate with Y1.

Y2 Heat Operation – After 4 minutes of continuous Y1 operation, the leaving air temperature will be checked. If the LAT is less than High Limit (HI) minus 25° (HI of 120-25 = 95°), then Y2 will energize, indicated by the Y2 LED. Y2 will cycle off when LAT is HI minus 5° (120 – 5 = 115) or when all heat calls are satisfied.

Fossil Fuel Operation – For Fossil Fuel operation, FF jumper must be placed in the FF position.

• For greater efficiency and comfort, an Outdoor Air Sensor, Part # FOAS, should be used in the Fossil Fuel application. The FOAS is used to lock out compressor operation when outside air temperature has dropped below Balance Point setpoint, the temperature at which that heat pump is no longer efficient. When the outside temperature is less than Balance Point setpoint and there is a call for heat, Y1 and

Y2 will be locked out; and W2 will energize indicated by W2 LED illuminating. The HI limit will be reset automatically to 135° to provide HI limit protection for furnace. Calls for heat are recognized from all thermostats; dampers for zones calling for heat will open, indicated by DPR LEDs off, while zones not calling will close, indicated by illuminated DPR LEDs. The Balance Point setpoint is adjustable from 25° to 41° by moving Balance Point potentiometer to desired setpoint. Refer to page 9 for potentiometer location on DTHP4A.

• Applications without FOAS will stage on time and temperature. With the Fossil Fuel jumper in the FF position, after 8 minutes of continuous heat operation, if leaving air is less than 90°, then W2 will energize. Y1 and Y2 will de-energize indicated by LEDs off; W2 LED will illuminate and furnace will start. The HI limit will be reset automatically to 135° to protect furnace heat exchanger. DPR LED for calling zones will be off, while DPR LEDs for non-calling zones will illuminate. All thermostats are able to make calls for heat.

Auxiliary Heat (Electric Strip Heat) – After 8 minutes of continuous operation the leaving air temperature is checked. If LAT is below 90°, W2 will energize and W2 LED will illuminate. W2 will cycle off above 100°, or when all calls are satisfied.

Y1 Cool Operation – Upon a cool call, the controller will energize Y1 and G. If the leaving air temperature drops below the low limit setpoint, Y1 will be de-energized, the PWR led will flash indicating a stage 1 capacity cutout. After 4 minutes the leaving air temperature will be checked again; if the leaving air temperature has risen above the cutout set point, then Y1 will reenergize and PWR LED will stop flashing. If controller is for a Heat Pump, and the reversing valve is in the O position, the O/B output will be energized simultaneously with the Y1, indicated by the O/B LED.

After 8 minutes of continuous Y1 run time, LAT (leaving air temperature) will be checked. If LAT is greater than low limit (LO) plus 12° (LO of 45° + 12° = 57°), then Y2 will energize and Y2 LED will illuminate. Y2 will cycle off when LAT drops below 5° plus low limit (45°+ 5° = 50°). Y2 and G will de-energize when all calls are satisfied, and the controller will go into a 4-minute purge cycle.

CAPACITY CONTROL AND STAGING

COOLING OPERATION – DTGE4A AND DTHP4A

HEAT OPERATION – GAS/ELECTRIC DTGE4A

HEAT OPERATION – HEAT PUMP DTHP4A

Red

Black

1.Drill a 3/8” hole in the supply air, ahead of the bypass tap. A. GAS/Electric application – install sensor as far as possible from the FAU heat exchanger but still before the bypass tap. B. Heat Pump application – install the sensor after the indoor coil but before the electric strip heat assembly.

2.Secure the sensor-mounting base to the duct or AHU cabinet (HP) with the self-tapping screws provided.

3.Run the shielded sensor cable back to the controller location; trim off any excess cable.

OAS INSTALLATION FOR FOSSIL FUEL

OAS, outdoor air sensor (Optional for Fossil Fuel applications), Sensor Installation

1. Install the OAS outside of the building, away from direct sun exposure, and above the snow line.

2. Run the sensor cable to the Digitract controller location; trim off any excess cable.

NOTE: Use of OAS with fossil fuel

creates a more efficient system, providing greater comfort control. See page 11.

SHIELD

LAT AND OAS INSTALLATION

CAPACITY CONTROLLER – LAT INSTALLATION

Capacity control installation, LAT installation

4. The LAT requires no calibration.

3. The OAS does not require calibration.

4. Check the Balance Point (BP) POT on the controller. It is factory set at 33°.

Wiring Diagram for Fossil Fuel Applications

LAT

COIL

Furnace

Shield

Red

Black

R C

Shield

Red

Black

LAT

– +

OAS

– Y2

O/B

R E

DTHP4A

Controller

OAS (Outdoor Air Sensor)

Optional

R W Y1 O/B C

Outdoor Unit

Use the table below to determine which zone dampers to use.

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.

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

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

ROUND LOW PRESSURE ZONE DAMPERS (TR diam)

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

ROUND MEDIUM PRESSURE ZONE DAMPERS

(101AMPD series)

The Zonex Systems round medium pressure zone dampers are recommended for any size system above 5 ton, 2000 CFM, and are rated for a maximum of 1.75” SP. These dampers are constructed from 20-22 gauge galvanized steel, with an elliptical damper disc. The damper shell is manufactured with the supply end crimped and an air flow direction arrow. The damper is driven by a 24-volt power open / power close, direct coupled actuator rated at 2VA. The actuator assembly includes manual open and close stop adjustments and mechanical drive release. The actuator is designed for full stall operation in the open and close positions and requires no end switches.

MEDIUM PRESSURE (101AMPD diam)

LOW PRESSURE (TR diam)

ZONE DAMPERS

ROUND ZONE DAMPERS

SYSTEM SIZE

MAXIMUM

DIFFERENTIAL

PRESSURE

ROUND DAMPER

RECTANGULAR DAMPER

5 TONS OR UNDER

UNDER 7.5 TONS

7.5 TONS OF LARGER

0.5"

1.75"

LOW PRESSURE

MEDIUM PRESSURE

LOW PRESSURE

MEDIUM PRESSURE

HEAVY DUTY

ZONE DAMPERS

TYPICAL ROUND CAPACITIES*

* 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.

ROUND LOW & MEDIUM PRESSURE DAMPER SIZES

ROUND LOW PRESSURE DAMPER

PAR T #

TR06 TR07 TR08 TR09 TR10 TR12 TR14 TR16

ROUND MEDIUM PRESSURE DAMPER

PAR T #

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

SIZE DIAMETER (D) LENGTH (L)

6" 7" 8"

9" 10" 12" 14" 16"

SIZE DIAMETER (D) LENGTH (L)

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

6" 7" 8"

9" 10" 12" 14" 16"

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

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

10" 10" 12" 14" 16" 18" 20"

WIDTH (W)

9" 10" 11" 12" 13" 15" 17" 18 1/2"

WIDTH (W)

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

Duct

Diameter

10"

12"

14"

16"

Nominal

CFM

110

160

250

320

410

660

1000

1450

Duct Velocity

FPM

540

600

700

725

750

850

925

1070

18" 2000 1100 .036

Damper

P " WC

.014

.015

.022

.035

.036

ZONE DAMPERS

Rectangular zone dampers are available for the DigiTract 4 controllers in three (3) styles: TREC WxH for low pressure applications (5 tons or less) rated at .5” SP; 101MRTD WxH for medium pressure application up to 7.5 tons, rated at 1” SP; 101CD WxH for heavy duty applications over 7.5 tons, rated at 1.75” SP.

RECTANGULAR LOW PRESSURE ZONE DAMPERS (TREC W x H)

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

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

Zonex Systems rectangular medium pressure dampers are recommended for systems under 7.5 tons with a maximum differential static pressure of 1”. These are power open, power close dampers. They are constructed from heavy duty aluminum and stainless steel. The damper is an opposed blade type that slips into a 3-1/4” wide cutout in the existing duct and attaches with screws via a duct mounting plate. The duct mounting plate is 5” wide. Power consumption is 6VA. The motors are designed for continuous full stall operation. Special winding and heavy duty gearing provide for long motor life.

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

Zonex Systems rectangular heavy duty dampers are recommended for systems

7.5 tons or larger with a maximum differential static pressure of 1.75”. These are power open, power close dampers made of 20 gauge “snap-lock” steel frame with S and Drive duct connections. Allow a 16” gap in the duct for the damper. Formed steel blade stops incorporate a gasket for quiet operation and improved structural rigidity. Rectangular dampers under 10” in height incorporate a single blade design. Dampers 10” or over use opposed blade design. A full stall motor, drawing 2 VA and a relay board control the damper position.

MEDIUM PRESSURE (101MRTD W x H) AND

HEAVY DUTY (101CD W x H) RECTANGULAR DAMPERS

LOW PRESSURE (TREC W x H) RECTANGULAR DAMPER

RECTANGULAR ZONE DAMPERS

ZONE DAMPERS

LOW AND MEDIUM PRESSURE RECTANGULAR DAMPER DIMENSIONS

HEAVY DUTY RECTANGULAR DAMPER DIMENSIONS

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

use duct sizing table or device.

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

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

RECTANGULAR DAMPER CAPACITIES*

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

2-1/2"

MOTOR

WIDTH HEIGHT

B 16"

DEPTH

2-1/4"

48" MAXIMUM WIDTH

Rectangular heavy duty dampers should operate at 1500 FPM.

E.G. A 24" x 12" damper = 2 square feet.

2 square feet X 1500FPM = 3000 CFM.

8 1012 1416 18202224

200

280

390

490

HEIGHT IN INCHES

250

390

510

650

310

490

650

850

1000

1200

1400

WIDTH IN INCHES

390

590

800

1000

1250

1500

1750

440

680

950

1200

1500

1800

2100

500

770

1100

1400

1750

2100

2500

570

900

1220

1600

2000

2450

2850

630

960

1400

1850

2250

2300

3080

700

1090

1500

2000

2500

3000

3600

4000

The barometric bypass damper is for systems 5 tons or under. It utilizes a weighted damper blade to maintain constant duct pressure. This allows for easy installation without the need for electrical power or wiring. The round barometric damper can be installed in any position. The RBB rectangular damper must be installed with horizontal air flow only.

SIZING: When only the smallest zone is calling, the maximum

amount of excess supply air will flow through the bypass damper. To determine the proper size bypass damper to use, do the following steps:

Step 1: Calculate bypass air volume as follows. A) Calculate total air volume at 400 CFM

per ton.

B) Calculate air volume of smallest zone in

CFM.

C) Calculate bypass air volume by subtract-

ing the smallest zone air volume from the total.

(A - B = C)

Step 2: Select damper from sizing table. Once you have calculated the bypass air volume from Step 1, use the BAROMETRIC BYPASS SELECTION TABLE. From the table, select the

bypass damper with the CFM rating equal to or greater than the value calculated in Step 1. For rectangular barometric dampers, use a ductulator to convert from round to rectangular.

If bypassing more than 2000 CFM, use electronic bypass damper.

Example: You have a 4 ton system. Your smallest zone will use 500 CFM. The total CFM is 1600 CFM (400 * 4). Your bypass CFM is 1100 (1600 - 500). From the table, you determine that a 12” bypass damper is needed.

Do not use the barometric bypass in any system over 5 tons. For systems over 5 tons, or to bypass more than 2000 CFM, use the electronic bypass.

RECTANGULAR & ROUND

BAROMETRIC BYPASS

BYPASS DAMPERS

BYPASS DAMPERS – BAROMETRIC

Diameter CFM

9” 650 10” 800 12” 1200 14” 1600 16” 2000

ZONE DAMPERS

SIZING ZONE DAMPERS

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

a) Determine CFM from heat gain or loss calculations.

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

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

that zone.

DAMPER 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 ductwork. The hat section on the 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 terminal board or relay board). Both motor and the relay board generate enough heat so no condensation will develop on the hat section.

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

6. Low and medium pressure rectangular dampers slide into a 3” wide cutout in the ductwork.

7. Install TR round dampers to the motor in the 9 to 3 o’clock position. Do not install damper so the motor is in the 4 to 8 o’clock position.

BAROMETRIC BYPASS

SELECTION TABLE

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.

Zonex Systems offers two types of bypass dampers, Barometric and Electronic. Each is available in round or rectangular configuration.

Barometric bypass dampers are limited to systems of 5 tons. Electronic dampers can be used on any size system. For residential HVAC systems with variable speed blowers, the barometric or electric bypass dampers

can be used. NOTE: When using the electric bypass (STBP/STCDBP), see the Bypass Dampers - Electronic Section, Pages 19-22; or contact Technical Support.

BAROMETRIC BYPASS

DAMPER

AIRFLOW

1. Damper Shaft

2. Lock Nut

3. Lever Arm

4. Counter Weight

INSTALLATION

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

a) Install the bypass damper between the supply and return

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

b) Be sure the air flows through the damper in the proper direction

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

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

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

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

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

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

Proceed to setup.

BAROMETRIC BYPASS SETUP

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

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

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

so that the damper just wants to start opening.

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

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

e) The barometric bypass damper is now calibrated.

BAROMETRIC BYPASS STARTUP TEST

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

flowing).

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

fully open.

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

BYPASS DAMPERS – BAROMETRIC

AIRFLOW

SHEET METAL

PIPE

AIRFLOW

BAROMETRIC

BYPASS

HORIZONTAL APPLICATION

A/C UNIT

RETURN

VERTICAL APPLICATION

FURNACE

BAROMETRIC

BYPASS

SUPPLY

PLENUM

A/C UNIT

FURNACE

RETURN AIR GRILLE

RETURN

AIR

PLATFORM

SUPPLY

PLENUM

AIRFLOW

ROOFTOP INSTALLATION Down Discharge Application

SUPPLY

PLENUM

OPEN RETURN PLENUM BYPASS APPLICATION

To prevent bypass air from flowing out the return grill,

use a short open ended

return air plenum to connect the bypass

damper to the unit.

RETURN AIR

GRILLE

SHEET METAL

PIPE

BYPASS DAMPER

AIR CONDITIONING

UNIT

A/C UNIT

FURNACE

BAROMETRIC

BYPASS

AIRFLOW

RETURN PLENUM

SUPPLY

DUCT

ROOF LINE

Diameter

CFM

8”

560

10”

900

12”

1250

14”

1700

16”

2200

18”

2600

PART #

SIZE D L

STBP08

8”

10”

11”

STBP10

10”

12”

13”

STBP12

12”

14”

15”

STBP14

14”

16”

17”

STBP16

16”

18”

19”

STBP18

18”

20”

21”

ROUND BYPASS SELECTION TABLE

RECTANGULAR BYPASS DAMPERS

SELECT FROM 8 x 8 thru 48 x 48

4”

48” MAXIMUM WIDTH

BYPASS DAMPERS – ELECTRONIC

ELECTRONIC BYPASS DAMPERS

The Electronic Bypass Damper is used on any size system over 5 tons. The damper can be round (STBP) or rectangular (STCDBP) with integrated static pressure control; and multiple dampers can be slaved together.

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 STBP 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 STCDBP 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.

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.

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

DAMPER

ACTUATOR

To Static Pressure Controller As Shown On The Bypass Wiring Diagram On Page 22.

RC RO MC

***

SLAVE

DAMPER

ACTUATOR

RC RO MC

TO NEXT SLAVE BYPASS DAMPER IF APPLICABLE

RC RO MC

BYPASS DAMPERS with INTEGRATED PRESSURE CONTROL

Part # STBP or STCDBP

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 registers 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

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.)

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 1st supply takeoff. Mount pressure supporting block over ¼” hole, align hole in block with hole in duct. Use provided 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 Control.

Fig. 2

BYPASS DAMPER WITH INTEGRATED

BYPBYPASS DAMPERS with INTEGRATED PRESSURE CONTROLASS DAMPERS with INTEGRATED PRESSURE CONTROL

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.

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 the smallest zone.

2. Verify all zone dampers are closed except for 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.

DAMPER TRANSFORMER

The 24V transformer connected to TR1 and TR2 of the Digitract 4 System Controller powers the zone dampers. The power rating of the transformer must be sufficient to power the number of dampers used. Also, a properly rated in line fuse must be used on the secondary of the transformer. To determine the power rating of the transformer and

the amperage rating of the fuse, use the table below. If using a combination of spring open and power open dampers, size as if all dampers are spring open.

Note: The System Controller and thermostats are powered by the HVAC unit transformer via terminals R and C.

STARTUP TEST, GAS/ELECTRIC DTGE4A

1. If there is no heating system, go to step 12

2. At System Controller: a. Turn power switch to ON. Verify power LED is illuminated.

3. Turn off all thermostats except thermostat 1.

4. At zone 1 thermostat: a. Set power switch to ON, if applicable. b. Set to Heat mode. c. Set fan switch to AUTO mode. d. Set heat setpoint 4° above room temperature.

5. At System Controller: a. Verify W1 and PWR LEDs are ON. If not, cycle System Controller

power switch OFF and then ON and recheck.

b. If fan jumper is across middle and top pin, verify that G is

energized for fan operation in Heat mode.

c. Verify that DPR 1 LED is OFF and DPR 2 through DPR 4 are ON.

6. At furnace, verify that furnace is on and blower fan is running. If the G LED on System Controller is not on, the blower fan is controlled by the furnace and there will be a delay before it turns on.

7. At zone 1, verify that air is coming out of register.

verify that W2 LED energizes and, if 2nd stage heat is available, 2nd stage starts.

9. At next zone: a. Verify that no air is coming out of register.

b. At thermostat:

1. Set power switch to ON, if applicable.

2. Set to Heat mode.

3. Set fan switch to AUTO mode

4. Set heat setpoint 4° above room temperature.

c. Verify that air is now coming out of register.

10. At previous zone, turn off thermostat, and verify there is no airflow. Verify that DPR 2 is OFF and DPR 1, 3 and 4 are ON.

11. Repeat steps 9 and 10 for remaining zones.

12. Turn off all thermostats except zone 1.

13. At zone 1 thermostat: a. Set power to ON, if applicable. b. Set to Cool mode. c. Set fan switch to AUTO mode. d. Set cool setpoint 4° below room temperature.

14. At System Controller: a. Verify Y1, G and PWR LEDs are on. If not, cycle System Controller

power switch OFF and ON and recheck.

b. Verify that DPR 1 LED is OFF and DPR 2 through 4 are ON.

15. At HVAC unit, verify air conditioner and blower are running.

16. Verify that air is coming out of registers.

NUMBER TR SERIES TR SERIES TR SERIES TR SERIES MED. PRESSURE/HEAVY DUTYMED. PRESSURE/HEAVY DUTYMED. PRESSURE/HEAVY DUTYMED. PRESSURE/HEAVY DUTY

OF (SPRING OPEN) DAMPERS (SPRING OPEN) DAMPERS (SPRING OPEN) DAMPERS (SPRING OPEN) DAMPERS (POWER OPEN) DAMPERS (POWER OPEN) DAMPERS (POWER OPEN) DAMPERS (POWER OPEN) DAMPERS

DAMPERS XFMR PWR XFMR PWR FUSE SIZE FUSE SIZE

1 40 VA 1 AMP 40 VA 1 AMP

2 40 VA 2 AMP 40 VA 1 AMP

3 40 VA 2 AMP 40 VA 1 AMP

4 40 VA 3 AMP 40 VA 2 AMP

5 48 VA 3 AMP 40 VA 2 AMP

6 60 VA 4 AMP 40 VA 2 AMP

7 72 VA 5 AMP 40 VA 3 AMP

8 84 VA 5 AMP 42 VA 3 AMP

9 96 VA 6 AMP 48 VA 3 AMP

10 108 VA 6 AMP 54 VA 3 AMP

11 120 VA 7 AMP 60 VA 4 AMP

12 132 VA 7 AMP 66 VA 4 AMP

Notice:

All wiring must meet state and local codes.

TRANSFORMER/FUSE SIZING

XFMR PWR

FUSE SIZE

8. After 4 minutes of W1 run time, check LAT. If LAT is less that HI limit minus 25°, then W2 will energize. If LAT is greater than HI limit minus 25°, remove LAT from supply plenum and

17. After 8 minutes, check LAT. If LAT is above LO cutout plus

12°, verify that Y2 energizes. If LAT is less than LO cutout plus 12°, remove LAT from supply plenum and verify Y2 operation.

STARTUP TEST, GAS/ELECTRIC DTGE4A (Continued)

18. At next thermostat: a. Verify that air is not coming out of register. b. At thermostat:

1. Set power switch to ON, if applicable

2. Set to Cool mode.

3. Set fan to AUTO mode.

4. Set cool setpoint 4° below room temperature.

c. Verify that there is airflow from register.

19. At previous zone, turn off thermostat and verify that there is no airflow from register.

20. Repeat steps 18 and 19 for remaining zones.

Test complete.

1. Disconnect Y1, Y2, O/B, W2 and G wires between controller and air handler. This will allow controller to cycle all stages of heat and cool without energizing compressors, fans or heat strips.

2. Turn off all thermostats except zone 1.

3. At zone 1 thermostat: a. Set power switch to ON, if applicable. b. Set to Heat mode. c. Set fan to AUTO mode. d. Set heat setpoint 4° above room temperature.

4. At System Controller: a. Verify Y1, G and PWR LEDs are ON. If not, cycle System Controller

power switch OFF and then ON and recheck.

b. If jumper O/B is on B, verify O/B LED is ON. Otherwise, verify O/B

LED is OFF.

c. Verify DPR 1 LED is OFF, and DPR 2 through DPR 4 LEDs are ON.

5. At next zone thermostat: a. Set power switch to ON, if applicable. b. Set to Heat mode. c. Set fan switch to AUTO mode. d. Set Heat setpoint 4° above room temperature.

6. Repeat steps 4 and 5 for all remaining zones. As a zone calls for heat, the corresponding DPR LED for that zone will de-energize and the damper will open. As each zone is satisfied, the associated DPR LED will illuminate and the damper will close.

7. Verify a call for 2nd stage heat. Confirm that Y2 energizes after the

(leaving air temperature) is less than Y2 cut-in temperature (LO cutout setpoint minus 25°; if HI limit is 120°, subtract 25° and cut-in will be 95°). After a total of 8 minutes of continuous call for heat, verify that W2 LED has illuminated, calling for electric strip

then W2 will energize and auxiliary heat is on.

8. Turn off all thermostats except zone 1.

9. At zone 1 thermostat: a. Verify power switch is ON, if applicable. b. Set to Cool mode. c. Set fan to AUTO mode. d. Set cool setpoint 4° below room temperature.

10. At System Controller: a. Verify Y1, G and Power LEDs are on. If not, cycle System Controller

power switch OFF and ON and recheck.

b. If jumper O/B is in the O position, verify that O/B LED is ON. If

O/B is in the B position, verify O/B LED is OFF.

c. Verify DPR 1 LED is OFF and DPR LEDs 2 through 4 are ON.

11. At zone 2 thermostat: a. Set power switch to ON, if applicable. b. Set to Cool mode. c. Set fan switch to ON. d. Set cool setpoint 4° below room temperature.

12. Verify Y1, G and Power LEDs are ON. O/B LED is ON for O mode or

OFF for B mode. Verify damper LEDs for DPR 1 and 2 are OFF, and damper LEDs for 3 and 4 are ON.

13. Turn zone 1 thermostat OFF. Verify damper 1, 3 and 4 LEDs are ON.

Damper 2 LED is OFF.

14. Repeat steps 11 through 13 at zone thermostats. Verify damper LEDs

for 3 and 4 are OFF when calls from zones are made.

15. Verify call for 2nd stage cool. Confirm that after the heat pump has

been running in Y1 for 8 minutes that Y2 will then energize. As the

temp will be at ambient temperature, allowing the controller to stage up. With the heat pump outputs connected, after 8 minutes of continuous running, the Leaving Air Temperature must be a minimum of 12° above the LO cutout setting for Y2 to energize.

16. Turn off all thermostats.

17. Connect wires to System Controller terminals Y1, Y2, W2 and G.

18. Place call on zone 1 for Heat. Verify heat pump startup and airflow on zone 1 registers.

19. Place a call on zone 2 for Heat, and verify airflow. Switch off zone thermostat 1, and verify airflow.

20. Repeat for zones 3 and 4.

21. Turn off all thermostats.

22. Place a call on zone 1 for Cool. Verify cool startup and airflow on zone 1 registers.

23. Place a call on zone 2 for Cool, and verify airflow. Switch zone thermostat 1 to OFF, and verify airflow.

24. Repeat for zones 3 and 4.

Test complete.

STARTUP TEST, HEAT PUMP DTHP4A

heat pump has been running for 4 minutes. Y2 will energize if LAT

heat. After 8 minutes of continuous heat call, if LAT is less than 90°,

21. Reinstall LAT sensor, if removed for startup.

heat pump outputs have been disconnected for this test, the LAT

Digitract 4 TROUBLESHOOTING / SERVICE CHECKS

Malfunction Probable Cause Corrective Action

Will not initiate cooling cycle Controller in heat mode Delay prior to changeover

Controller in changeover from heat mode 4-minute purge cycle must complete

Thermostat has cooling anticipator (compensator) Remove anticipator Air flow too low over evaporator Isolate and correct air flow problem Bypass damper opening prematurely Adjust bypass damper closed w/ all zone dampers open

Will not initiate heat calls Controller in cool mode Delay prior to changeover

Controller in changeover from cool mode 3-minute purge cycle must terminate

Heating anticipator incorrectly set Set anticipator to lowest setting Bypass damper opening prematurely Adjust bypass damper closed w/ all zone dampers open

Zone dampers will not close Loss of 24V ac on TR1 And TR2 Repair power source

Transformer VA too low Replace w/ correct transformer

Dampers incorrectly wired Correct damper wiring

No output on damper terminal(s) Cycle power to controller. Verify thermostat inputs are correct.

If problem persists, replace controller

Zone damper remains closed Zone not calling while mode is active Initiate thermostat call

Triac shorted (Continuous 24V ac @ damper terminals) Replace controller W2 will not energize Discharge air temperature above 88° F. Normal operation (DTHP4A only) Relay contact failure (W2 LED on) Replace controller

Bypass damper opening prematurely Adjust bypass damper closed w/ all zone dampers open

Controller in cool mode Verify jumper JU1 position Blower runs continually Fan operation selected on any thermostat Verify fan switch on all thermostats

Fan relay contacts in controller seized Replace controller, check 24 V AC

All thermostats will not call Loss of 24V ac on R and C Repair power source

Cooling calls short cycle LAT shorted (0V dc on + and – w/ LAT installed) Replace LAT

Heating calls short cycle LAT open (5V dc on + and – w/ LAT installed) Replace LAT

LAT wiring shorted (0V dc on + and – w/ LAT installed) Repair LAT wiring Controller failure (0V dc on + and – w/ LAT removed) Replace controller

LAT electrical interference (Applicable to spark ignition) Install shielded cable to LAT, terminate shield on C terminal ONLY

LAT wiring open (5V dc on + and – w/ LAT installed) Repair LAT wiring

LAT SENSOR TEMPERATURE TO DC VOLTS / RESISTANCE CHART

The sensor DC voltage is read by placing the Black meter probe on any " ""C" terminal and the Red meter probe on the negative ( - ) sensor terminal.

DC DC DC DC DC DC DC DC DC

° F. Volts ° F. Volts ° F. Volts ° F. Volts ° F. Volts ° F. Volts ° F. Volts ° F. Volts ° F. Volts

32 1.341 47 1.711 62 2.105 77 2.500 92 2.879 107 3.226 122 3.531 137 3.793 152 4.013 33 1.365 48 1.737 63 2.131 78 2.526 93 2.904 108 3.247 123 3.550 138 3.809 153 4.026 34 1.389 49 1.762 64 2.158 79 2.552 94 2.928 109 3.269 124 3.569 139 3.825 154 4.039 35 1.413 50 1.788 65 2.184 80 2.578 95 2.952 110 3.290 125 3.587 140 3.840 155 4.052 36 1.437 51 1.814 66 2.210 81 2.603 96 2.975 111 3.311 126 3.605 141 3.856 156 4.064 37 1.461 52 1.841 67 2.237 82 2.629 97 2.999 112 3.332 127 3.623 142 3.871 157 4.076 38 1.486 53 1.873 68 2.263 83 2.655 98 3.022 113 3.353 128 3.641 143 3.886 158 4.089 39 1.510 54 1.893 69 2.289 84 2.680 99 3.046 114 3.374 129 3.659 144 3.901 159 4.101 40 1.535 55 1.919 70 2.316 85 2.705 100 3.070 115 3.394 130 3.676 145 3.915 160 4.113 41 1.560 56 1.946 71 2.343 86 2.730 101 3.092 116 3.414 131 3.694 146 3.930 42 1.585 57 1.972 72 2.370 87 2.756 102 3.114 117 3.434 132 3.711 147 3.944 43 1.610 58 1.999 73 2.396 88 2.781 103 3.137 118 3.454 133 3.728 148 3.958 44 1.635 59 2.025 74 2.421 89 2.806 104 3.159 119 3.474 134 3.744 149 3.972 45 1.661 60 2.052 75 2.447 90 2.830 105 3.222 120 3.493 135 3.761 150 3.986 46 1.686 61 2.078 76 2.474 91 2.855 106 3.204 121 3.512 136 3.777 151 3.999

Digitract 4

Comfort Control System

Hot Line: (800) 228-2966

5622 Engineer Drive

Huntington Beach, CA 92649

Factory: (714) 898-9963 • Fax: (714) 898-6802

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

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Rev. October 2013

Zonex Systems DigiTract 4 Installation

Specifications and Main Features

Frequently Asked Questions

User Manual