Zonex Systems DigiTract 4-2 User Manual

Installation Guide

DigiTract 4-2

Two Stage Heat/Cool

Comfort Control System

Part #DT4MAN

Rev. April 2003

Zoning Systems

That’s all we do.

TABLE OF CONTENTS...................................................................................................................................................................Page

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

SYSTEM DESCRIPTION...........................................................................................................................................................................................1

COMPONENT SELECTION GUIDE..........................................................................................................................................................................2

WIRING

Gas/Electric DTGE4-2.........................................................................................................................................................................................3

Heat Pump DTHP4-2..........................................................................................................................................................................................4

Zone Dampers....................................................................................................................................................................................................5

SYSTEM CONTROLLERS

Gas/Electric DTGE4-2

Operation...........................................................................................................................................................................................6

Status Lights .......................................................................................................................................................................................6

Components.......................................................................................................................................................................................7

Heat Pump DTHP4-2

Operation...........................................................................................................................................................................................8

Status Lights .......................................................................................................................................................................................9

Components.....................................................................................................................................................................................10

CAPACITY CONTROLLERS.....................................................................................................................................................................................11

Gas/Electric DTGE4-2.......................................................................................................................................................................11

Heat Pump DTHP4-2........................................................................................................................................................................11

Calibration .......................................................................................................................................................................................11

LAS Installation ................................................................................................................................................................................11

ZONE THERMOSTATS

Types ........................................................................................................................................................................................................12

Zonex Systems Gas/Electric Models..................................................................................................................................................................12

Digital (SADIGI)...............................................................................................................................................................................12

Digital (SADIGI) Operation..............................................................................................................................................................13

Programmable (101PROG)..............................................................................................................................................................12

Communicating (DIGICOM/DIGIHP)................................................................................................................................................12

Compatibility ....................................................................................................................................................................................................12

ZONE DAMPERS

Round ...................................................................................................................................................................................................14-15

Rectangular.................................................................................................................................................................................................16-17

Installation Notes..............................................................................................................................................................................................18

BYPASS DAMPERS

Barometric..................................................................................................................................................................................................18-19

Electronic ...................................................................................................................................................................................................20-21

Static Pressure Controller.................................................................................................................................................................22

DAMPER TRANSFORMER .....................................................................................................................................................................................23

SYSTEM STARTUP

Troubleshooting / Service Checks.....................................................................................................................................................................25

LAS Voltage – Temperature Conversion Chart..................................................................................................................................................25

Fused 24V Transformer

DIGITRACT 4-2

System Controller

ZONE 4

ZONE 3

ZONE 2

ZONE 1

LAS

INTRODUCTION

System Controller

Leaving Air Sensor

Zone Damper

Zone Thermostat

Bypass Damper Damper

Transformer

The Zonex Systems Digitract 4-2 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. To provide economical, effective and simplified remote control and monitoring capability of one or more Digitract 4-2 zone control systems, the ZonexCommander may be used to manage up to 80 thermostat schedules. The ZonexCommander is a Windows®based thermal management system, which can integrate gas/electric and heat pump zone systems to include stand alone HVAC systems.

SYSTEM DESCRIPTION

The DigiTract 4-2 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 4-2 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.

The Leaving Air Sensor (LAS) is part of the staging and capacity control feature of the System Controller. It is a sensor placed in the leaving air of the HVAC system. The LAS monitors the leaving 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 information is also used to control the auxiliary heat to maintain a minimum supply air temperature of 88 degrees. See Capacity Controller section, page 11, for further information.

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 14 to 18 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 4-2 System. The System Controller will cycle staging and auxiliary strip heat based on leaving air temperature. See pages12 to 13 for further information.

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 zone damper blow-by. See pages 18 to 22 for further information.

Damper Transformer. Wired to TR1 and TR2 on the System Controller. Powers the zone dampers only. Requires an in-line fuse. See Damper Transformer section, page 23.

Digitract 4-2 COMPONENT SELECTION GUIDE

START

SYSTEM CONTROLLER

(DTGE4-2)

2-Stage Heat/Cool

CAPACITY CONTROLLER

System Controller includes Capacity Control

and Leaving Air Sensor

GAS/ELECTRIC THERMOSTATS

DIGITAL

(SADIGI)

5 TONS AND UNDER

(Up to 0.5” S.P.)

Round (TR diam)

Rectangular (TREC W x H)

GAS/ELECTRIC

PROGRAMMABLE

(101PROG)

COMMUNICATING

(DIGICOM)

ZONE DAMPERS

(Up to 1” S.P.)

Rectangular

(101MRTD W x H)

HEAT PUMP

SYSTEM CONTROLLER

(DTHP4-2)

3-Stage Heat/2-Stage Cool

CAPACITY CONTROLLER

System Controller includes Capacity Control

and Leaving Air Sensor

HEAT PUMP THERMOSTATS

(One per zone. Field Supplied.

See Thermostat Compatibility section, pg. 12)

COMMUNICATING

(DIGIHP)

COMMAND CENTER

(101CEC Communication Package,

one per 20 thermostats)

OVER 5 TONS

(Up to 1.75” S.P.)

Round (101AMPD diam)

Rectangular (101CD W x H)

5 TONS AND UNDER

BAROMETRIC BYPASS

Round (101ABBD diam)

Rectangular (RBB W x H)

BYPASS DAMPERS

OVER 5 TONS

ELECTRONIC BYPASS

Round (STMPD diam)

Rectangular (STCD W x H)

STATIC PRESSURE CONTROLLER

(101ASPC)

BYPASS TRANSFORMER

(FIELD SUPPLIED. 24VAC, 40VA)

DAMPER TRANSFORMER

(Field supplied. Requires in line fuse.

See Transformer/Fuse Sizing Table, pg. 23)

COMPLETE SYSTEM

Y1 G W1

PWR

DPR1 DPR2 DPR3 DPR4

R C

2 3 3 4

4 TR1 TR2

DIGITRACT 4-2 GE TWO STAGE 220108

JPR1

Vx.x

R72

R8 R10 R9 R5

Y2 W1

G W2 Y1

ZONE 1 THERMOSTAT

ZONE 3 THERMOSTAT

STAT 1

W R Y G C

STAT 2

W R Y G C

STAT 3

W R Y G C

STAT 4

W R Y G C

AIR FLOW

BYPASS

TAP

BYPASS RETURN

WIRING – GAS/ELECTRIC DTGE4-2

DigiTract 4-2 Gas/Electric 2-Stage Heat/Cool

HVAC unit and LAS terminals. Do not connect Y2 or W2 for single stage heat/cool systems.

Use minimum 18 gauge for all wiring. All wiring must meet state and local codes.

Zone damper terminals. Refer to “Wiring – Zone Dampers” section, pg. 5.

1. LAS. 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 LAS downstream of the bypass takeoff. Ensure wire polarity is correct. Refer to "CAPACITY CONTROLLER- LAS INSTALLATION" on P. 11 for further information. NOTE: Shielded conductor provided for installations with spark ignition or distances from controller to LAS beyond 10’. 18/2 thermostat wire may be used in most applications.

2. Connect W2 and Y2 of the DTGE4-2 only if there are two heat and/or two cool stages.

3. Connect C from the controller to the thermostat 24V AC common terminal if hard wired. Not required with use of battery operated thermostats. Refer to "THERMOSTATS- COMPATIBILITY" on P. 12 for further information.

4. Zone damper terminals. Refer to "WIRING- ZONE DAMPERS" on P. 5.

5. Install one 24V AC transformer, sized and fused for the total number of zone dampers. See "DAMPER

TRANSFORMER" on P. 23.

6. Fan cycling jumper: A – FAU fan control; B – electric heat, fan on with heat call

Y1 G W2

PWR

DPR1 DPR2 DPR3 DPR4

R E L C

O/B

2 3 3 4

4 TR1 TR2

DIGITRACT 4-2 HP TWO STAGE 210806

JPR1

Vx.x

R72

O/B

STAT 4

O/B

STAT 3

O/B

STAT 2

STAT 1

O/B

RYGC

O/B

R10

R9 R5

O/B

R E

AIR FLOW

O/B

RYG CW L

ZONE 1

THERMOSTAT

O/B R Y G C

ZONE 3

THERMOSTAT

BYPASS

TAP

BYPASS RETURN

WIRING – HEAT PUMP DTHP4-2

DigiTract 4-2 HP 3-Stage Heat/2-Stage Cool

LAS. Locate the leaving air sensor between the refrigerant coil and the electric heat coil(s) or other auxiliary

heat source. Verify that the polarity is correct. Refer to “CAPACITY CONTROLLER – LAS INSTALLATION” page 11, for further information.

Connect W2 from the controller to the unit’s electric heat stage terminal designation. It is recommended to

install an outdoor thermostat in series with any electric heat stages.

Connect C from the controller to the thermostat 24V AC common terminal if hardwired. Refer to “ZONE

THERMOSTATS – COMPATIBILITY” page 12, for further information.

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

TRANSFORMER” on page 23.

Emergency heat terminal, E. Use only if emergency heat source is different from auxiliary heat W2. If used,

do not jumper to W2.

Reversing valve jumper: B – energize for heat; O – energize for cool

NOTE: Some combination thermostats do not have an E terminal. Connect W2 of the thermostat to the E terminal of STAT 1 terminal block.

WIRING – ZONE DAMPERS

FUSED 24VAC XFMR. Transformer and fuse must be sized for

total

number of zone dampers. See Transformer/Fuse Sizing Table on page 23.

SERIES

DAMPER

M M

2 3 3 4

4 TR1 TR2

DIGITRACT 4-2 SYSTEM CONTROLLER

TO TWO MORE TR SERIES DAMPERS IF APPLICABLE

DMPR1DMPR

M M M M

DMPR

M M

DMPR

M M

2 3 3 4

4 TR1 TR2

TO ADDITIONAL TR SERIES DAMPERS IF APPLICABLE

FUSED 24VAC XFMR. Transformer and fuse must be sized for

total number of zone dampers. See Transformer/Fuse Sizing Table on page 23.

DIGITRACT 4-2 SYSTEM CONTROLLER

24VAC

relay

2 3 3 4

4 TR1 TR2

DIGITRACT 4-2 SYSTEM CONTROLLER

N/C - No connection

- Factory wired motor 101 series dampers include:

101AMPD, 101MRTD & 101CD

DAMPER RELAY BOARD

RC MCRCWWY RO

TB2

TB1

N/C N/CN/C

N/C N/C N/CN/CN/C

***

101 SERIES DAMPER

TO ADDITIONAL 101 SERIES DAMPERS IF APPLICABLE

FUSED 24VAC XFMR. Transformer and fuse must be sized for

total number of zone dampers. See Transformer/Fuse Sizing Table on page 23.

GRdBWWY

B must wire to bottom terminal and Rd must wire to top terminal. Do not reverse.

{

G must wire to TR2. Do not wire to TR1.

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: If wiring two or three TR series dampers to a zone, wire per

Method 3: If using 101 series dampers with a DTGE4 controller, wire

per method 3. Notice: 101 series dampers are required for all systems over 5 tons. Refer to Parts Selection Table, page 14.

method 1. Method 2: If wiring more than three TR series dampers to a zone, use method 2. This method requires a 24V ac, SPNO relay.

Method 1: Wiring Up to Three TR Series Dampers to a Zone

Method 2: Wiring More than Three TR Series Dampers to a Zone

Method 3: Wiring 101 Series Medium/Heavy Duty Dampers to a Zone

SYSTEM CONTROLLERS

The DigiTract 4-2 System Controller is the heart of the Digitract 4-2 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 zone damper(s) of the zones not calling for the operating mode. The mode of operation is determined by the first call received. If thermostats are calling for opposite modes, every 15 minutes it will change over to the other mode as long as there

SYSTEM CONTROLLER – GAS/ELECTRIC DTGE4-2

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 Fan Control Jumper is in the B position, the indoor blower will energize with 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 the DPR LED is on the damper terminal strip and damper terminal board, the corresponding damper is 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 a purge mode.

are opposing calls. The built in Capacity Controller maintains the supply air temperature within an operating range to prevent freeze ups and overheating. For heat pumps, the DTHP4 System Controller will also control the auxiliary heat to maintain an 88 degrees minimum coil leaving air temperature.

The DigiTract 4-2 is available in two models, Gas/Electric 2-Stage Heat/Cool and Heat Pump 3-Stage Heat/2-Stage Cool.

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 for 15 minutes or until all current calls are satisfied. Then the System Controller will go into a purge mode for 3 minutes, then change over to the new mode.

Purge mode – When all calls are satisfied or before changing

modes, the System Controller will go into a three minute purge cycle. During this mode, the compressor or heat will turn off and the indoor blower fan will continue to run. This is indicated by the W and Y LEDs off and the G LED on. The damper(s) of the last calling zones will remain open and all other damper(s) will be closed. This allows the supply air to adjust to room temperature before changeover or ventilation while providing a time delay to prevent short cycling. The DPR LEDs indicate which dampers are open and which are closed. If the DPR LED is on, the damper is closed. If the DPR LED is off, the damper is open.

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.

STATUS LEDS

Y1 Y2 G W1 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. OFF OFF ON ON OFF ON 0 Vent Blower on, compressor(s) off, all zone dampers open. OFF OFF ON OFF OFF ON 1 Purge Blower on, compressor(s) off. Dampers with LED on are closed.

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

ON ON ON OFF OFF ON 1 Y2 cool 2nd stage cool, blower on. Dampers with LED on are closed. OFF OFF A / B ON OFF ON 1 W1 heat 1st stage heat, blower on. Dampers with LED on are closed. OFF ON A/ B ON ON ON 1 W2 heat 2nd stage heat, blower on. Dampers with LED on are closed. OFF OFF ON OFF OFF FL 1 Cap cut out Blower on, all compressors off. Dampers with LED on are closed.

FL = Flashing A = On when JMPR1 is in Aposition B = OFF when JMPR1 is in B position 1 = One or more damper LED’s on 0 = All damper LED’s are off

SYSTEM CONTROLLER – GAS/ELECTRIC DTGE4-2

COMPONENTS

A. HVAC Unit/LAS Terminals – Connects to HVAC unit and

Leaving Air Sensor (LAS). ±: LAS terminals. The LAS monitors the leaving air

temperature.

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 4-2 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 4-2 to run in heat mode. R: HVAC unit 24V power. Y: Cool call. When energized (Y made to R),

requests the Digitract 4-2 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 power return.

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. May need to know this number if conferring with technical support.

F. Heat Mode Fan Control Selection Jumper – In the A position,

the blower is energized by the furnace when heat is energized (gas furnaces). In the B position, the blower is energized by the DTGE4-2 when heat is energized (electric furnaces).

Y2 W1

Y1 R C

DIGITRACT 4-2 GE TWO STAGE 220108

E F

R72

R10 R9 R5

W R Y G C

PWR

STAT 2

Y1 G W1

STAT 1

W R Y G C

ZONE 1 THERMOSTAT

Vx.x

DPR1 DPR2 DPR3 DPR4

STAT 3

W R Y G C

W R Y G CW R Y G C

ZONE 3 THERMOSTAT

JPR1

STAT 4

W R Y G C

G. Microcontroller – Responsible for activation and control of the

unit based upon thermostat input. Occasionally software upgrades may become available. If so, the Digitract 4-2 software can be field upgraded by changing this microcontroller.

H. HVAC System Status LEDs – Indicates what the DTGE4-2 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. Leaving Air Sensor Potentiometer – Turn to calibrate the

leaving air sensor if required. See Calibration in Capacity Controller section.

J. Power Switch – When OFF, power from the HVAC unit transformer is

disconnected from the Digitract 4-2 and thermostats. When ON, power from the HVAC unit transformer is supplied to the Digitract 4-2 and the zone thermostats.

TR1 TR2

1 1

2 2 3 3 4 4

+ 19 hidden pages

Zonex Systems DigiTract 4-2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual