Zonex Systems DigiTract 4-2 User Manual

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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

SYSTEM CONTROLLER – HEAT PUMP DTHP4-2

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), indoor blower and energizes the reversing valve (O/B 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 88 degrees and will deenergize when the coil leaving air temperature rises above 97 degrees. 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.

Purge mode – When all calls are satisfied or before changing modes, the System Controller will go into a 3-minute purge cycle. During this mode the compressor and indoor blower will deenergize. This is indicated by the Y and G LEDs cycling off. If the reversing valve is energized, it will deenergize. This is indicated by the O/B LED turning off. The damper of the last calling zone will remain open and all other dampers will be closed. This provides a 3-minute time delay to prevent equipment 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.

Auxiliary heat – 8 minutes after the System Controller has run in heat mode, if the coil leaving air temperature is below 88 degrees, the auxiliary heat is energized and the W2 LED illuminates. When the coil leaving air temperature rises above 97 degrees, the auxiliary heat is deenergized 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 heat mode is controlled by STAT1 only. To make an emergency heat call, STAT1 must be in Emergency Heat mode and making a heat call. When the System Controller receives an emergency heat call from STAT 1, it will lock-out the compressors and energize the auxiliary heat strips and fan unless the system is already running in heat or cool mode. If the system is running, the unit’s auxiliary heat will be energized based on leaving air temperature. Zones not calling for heat will close their dampers. When all zone temperatures are satisfied, the System Controller removes the auxiliary heat call and monitors all zones for the next call.

Changeover – While the system is operating in one mode, if the

SYSTEM CONTROLLER – HEAT PUMP DTHP4-2

STATUS LEDs

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 DTHP4-2 Controller. W2 Auxiliary heat LED, red. On when the auxiliary heat is energized. PWR Power LED, orange. On when DTHP4-2 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. OFF OFF OFF ON OFF ON 0 Vent Blower on, compressor(s) off, all zone dampers open. OFF OFF OFF ON 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 ON ON C 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. OFF OFF OFF ON ON ON 0 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.

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

COMPONENTS DTHP4-2

Y1 Y2

O/B

R E

L C

DIGITRACT 4-2 HP TWO STAGE 210806

R72

R10 R9

PWR

Y1 G W2

STAT 2

O/B R Y G C

STAT 1

O/BR Y G CEL

Vx.x

DPR1 DPR2 DPR3 DPR4

Y2O/B

STAT 3

O/B R Y G C

JPR1

STAT 4

O/B R Y G C

1 1

2 2 3

3 4

4 TR1 TR2

SYSTEM CONTROLLER – HEAT PUMP DTHP4-2

COMPONENTS (Continued)

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

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

temperature.

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 4-2 and

thermostats.

E: Emergency Heat. Separate output (E made to R) to cycle additional

stages (if applicable) when in the emergency heat mode. L: Compressor Fail Flag. Connected to L of STAT1 terminal. See B. C: Heat pump unit 24V power return.

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

thermostats. L: Compressor Fail Flag. On STAT1 only. Connected to L of Heat

Pump Unit terminal (see A). If the heat pump compressor fails,

the heat pump will energize L (R made to L) which will turn on

an indicator light on thermostat 1. This feature is not available

on all heat pumps and/or thermostats. E: Auxiliary/Emergency Heat. On STAT 1 only. Connected to E

terminal on STAT 1. When thermostat 1 is in the emergency

heat mode and making a heat call, Y is locked out and W is

energized as the first stage of heat. The W2 and E outputs from

the controller will be energized simultaneously.

NOTE: When the controller receives a STAT 1 E input from the

thermostat W terminal when in the normal heat mode, it is

ignored. The W2 output of the controller is cycled according to

leaving air temperature. 0/B: Mode control. For O thermostats, thermostat is in cool mode

when energized (O/B made to R) and in heat mode when not

energized. The reverse is true for B thermostats. R: Heat pump unit 24V power. See A. Y: Compressor. When energized (Y made to R), requests that the

DGHP4-2 energize the heat pump compressor. G: Blower. When energized (G made to R), requests that the

DTHP4-2 energize the indoor blower fan. C: Heat pump 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 Lights – Light on when corresponding zone

damper is closed.

E. Reversing Valve Selection Jumper – Configures Digitract 4-2 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. Board Number – This number indicates the circuit board number

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

G. Microcontroller – Responsible for activation and control of the

unit and dampers 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. Power Switch – When OFF, power from the heat pump transformer

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

I. Heat Pump Status LEDs – Indicates what the DTHP4-2 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.

J. Leaving Air Sensor Potentiometer – Turn to calibrate the leaving

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

STAGING AND CAPACITY CONTROL

Y2 W1 G W2

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 4-2 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.

COOLING OPERATION – DTGE4-2 AND DTHP4-2

Y1 Cool Operation – Upon a cool call, the controller will energize Y1

and operate with a minimum run time of 4 minutes, regardless of the leaving air temperature. At the completion of the minimum run time, if the leaving air temperature drops below 45°F., Y is deenergized; the Y LED is off and the PWR LED will flash. G will remain energized, upon which the leaving air temperature is rechecked after 4 minutes. If the leaving air temperature has recovered to 45°F. or greater, Y will be reenergized and the PWR LED will stop flashing. If the reversing

valve jumper is in the O position, the O/B output will be energized simultaneously with Y, indicated by the O/B LED.

Y2 Cool Operation – After 8 minutes of continuous Y1 run time, the leaving air temperature, LAT is checked. If the LAT is above 60°F., Y2 will be energized and the Y2 LED will illuminate. Y2 will cycle off when the LAT drops below 50°F., or when all cool calls are satisfied.

HEAT OPERATION – GAS/ELECTRIC DTGE4-2

W1 Heat Operation – Upon a heat call, the controller will energize W1

if the leaving air temperature is less than 145°F. W1 will deenergize if the LAT exceeds 145°F. The W1 LED will then cycle off and the PWR LED will begin to flash indicating a capacity control cutout. After a 4-minute recycle timer has completed, W1 will energize if the LAT is below 145°F.

W2 Heat Operations – After W1 has operated continuously for 4 minutes and the LAT is 120°F or less, W2 will energize. W2 will remain energized until the LAT rises above 135°F or if all heat calls become satisfied. The W2 LED will then cycle off.

HEAT OPERATION – HEAT PUMP DTHP4-2

Y1 Heat Operation – Upon a heat call, the controller will energize Y1

and operate with a minimum run time of 4 minutes, regardless of the leaving air temperature. At the completion of the minimum run time, if the leaving air temperature rises above 120°F, Y1 is deenergized; the Y LED is off and the PWR LED will flash. G will remain energized, upon which the leaving air temperature is rechecked after 4 minutes. If the leaving air temperature has recovered to 120°F. or lower Y1 will recycle and the PWR LED will stop flashing. If the reversing valve jumper is in the O position, the O/B output will be energized simultaneously with Y, indicated by the O/B LED.

Y2 Heat Operation – After 4 minutes of continuous Y1 run time, the leaving air temperature, LAT is checked. If the LAT is below 95°F., Y2 will be energized and the Y2 LED will illuminate. Y2 will cycle off when the LAT rises above 105°F., or when all heat calls are satisfied.

Auxiliary Heat – After 8 minutes of continuous Y1 operation the leaving air temperature, LAT is checked. If the LAT is below 88°F., W2 will be energized and the W2 LED will illuminate. W2 will cycle off when the LAT rises above 97°F., or when all heat calls are satisfied.

CAPACITY CONTROLLER – CALIBRATION

The Capacity Controller comes factory calibrated. However, if field calibration is ever necessary, perform the following:

1. Use a digital, DC voltmeter with 3 digits to the right of the decimal accuracy.

2. On the System Controller, place - probe of voltmeter to C terminal and + probe to left side of second resistor from top (R10) as shown in adjacent diagram.

3. Measured voltage should read 2.718 VDC. If the voltage is incorrect, slowly adjust potentiometer R72 until 2.718 VDC is obtained.

Voltmeter

2.718

–

4. The LAS is now calibrated.

CAPACITY CONTROLLER – LAS INSTALLATION

A. Cut or drill a hole in selected location large enough to fit sensor through. B. Select location to install the LAS. For gas/electric HVAC systems, sensor must be in leaving air duct, preferably as

far from the coil/heat exchanger as possible but not past the bypass tap. For heat pumps, locate LAS downstream from indoor coil but before auxiliary heat strips.

C. Place sensor through hole made in duct and mount Capacity Controller to duct with screws. Use grommet or tape

to protect sensor wire from sharp edges.

D. The cable between the LAS sensor and the controller must be installed separately from all 24 volt control and

power wiring. Using the shielded cable provided, connect the LAS between the + and – terminals of the controller as shown. The shielded conductor is provided for installations with spark ignition or distances from controller to LAS beyond 10’. 18/2 thermostat wire may be used in most applications. Terminate the shield at the controller end only on the “C” terminal of the equipment terminal block. Important: The shield at the LAS end of the wire must not be grounded, or attached to any other terminal. The shield should be cut and taped off at the LAS end to prevent grounding.

R72

SHIELD

ZONE THERMOSTATS

Each zone requires a zone thermostat. The following lists the types of thermostats to use with each Digitract 4-2 system, information on Zonex

Systems thermostats and how to select a thermostat not manufactured by Zonex Systems.

ZONE THERMOSTATS – TYPES

Gas/Electric DTGE4-2 – Use 24V ac single stage gas/electric thermostats.

Zonex Systems offers three models: SADIGI, 101PROG and DIGICOM. If not using Zonex Systems thermostats, see Thermostat Compatibility section below.

Heat pump DTHP4-2 – Use 24V ac single stage heat, single stage cool heat pump thermostats. If emergency heat feature is preferred then the thermostat for Stat1 must have the emergency heat mode feature. If the heat pump has the compressor fail flag feature, STAT1 should also have a compressor fail light. See Thermostat Compatibility section below.

ZONEX SYSTEMS THERMOSTATS

Zonex Systems offers three thermostat models that can be used with the Gas/Electric Digitract 4-2 System Controller (DTGE4). These models are SADIGI, 101PROG and DIGICOM.

SADIGI: The SADIGI is a single stage gas/electric, hard wired (non-power robbing) thermostat. It can control one heat, one cool and blower fan. It can run in Heat, Cool, or Auto changeover mode. Setpoint range is from 55° to 86° Fahrenheit. The mode and setpoints are stored in nonvolatile memory so they will be remembered even if power is interrupted. It has a bright and easy to read digital display and is simple to operate. Up and down push buttons select the mode and setpoint(s). Under the cover of the thermostat there are two mode status lights: one red and one green. The red light is on when the thermostat is making a heat call. The green light is on when the thermostat is making a cool call. The dimensions are: 2 and G. Requires 5 conductor thermostat wire. Can be ordered with remote sensor; p/n SADIGIRS.

⁄8”W x 41⁄2”H x 1”D, the color is off white. Terminal designations are: R, C, Y, W

101PROG: Programmable, dual setpoint, single stage heat/cool, electronic, non power robbing, auto changeover, weekday/weekend (5,1,1) programmable, manual override capable. Thermostat includes a large LCD that displays time, day, program, setpoints and room temperature. Can program up to four different schedules per day. Battery backup memory. Dimensions are: 6”W x 3 five thermostat wires for installation. Color: White. Can be ordered with remote sensor; p/n 101PROGRS.

DIGICOM/DIGIHP: The DIGICOM and DIGIHP are auto changeover, communicating thermostats used exclusively in ZonexCommander thermal management systems. Using a computer and the ZonexCommander software, all thermostats in the system can be programmed and viewed. The DIGICOM/DIGIHP may be applied in stand alone unit control, from 1 to 20 split or packaged systems. When used with a modem, all ZonexCommander software functions can be controlled remotely. The DIGICOM/DIGIHP requires 24V AC power from either the zone system or HVAC unit transformer, with the addition of a two conductor, twisted pair cable for communications. Dimensions: 2-7/8” W x 4-1/2” H x 1” D.

⁄2”H x 13⁄4”D. Requires

ZONE THERMOSTATS – COMPATIBILITY

The DTGE4-2 gas/electric and DTHP4-2 heat pump controllers are compatible with most thermostats, offering a wide thermostat selection to the installing contractor. When using other than Zonex Systems thermostats, please refer to the following guidelines:

Electronic Thermostats: Digital thermostats requiring 24V AC power must be “Hard wired” with a separate R and C or common terminal. Power robbing type thermostats are not compatible. All types of battery operated thermostats may be used with any Digitract 4-2 control system.

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

SADIGI

Please contact Factory Technical Support for additional thermostat compatibility information.

DIGICOM/DIGIHP

SADIGI THERMOSTAT OPERATING INSTRUCTIONS

Lower heat setpoint

Pwr

Off/On

Fan

On/Auto

A C

Raise heat setpoint

Lower cool setpoint

Raise cool setpoint

View heat setpoint

View cool setpoint

SLIDE SWITCHES

There are two switches located on the bottom of the thermostat. The switch on the left controls the fan and the switch on the right powers the thermostat. Sliding the fan switch to the left turns the indoor blower fan on continuously. Sliding it to the right runs the fan only when the air conditioner is on. Slide the power switch to the right to turn on the thermostat and to the left to turn it off.

MODE

The SADIGI thermostat can operate in three different modes: Heat, Cool or Auto. In Heat mode, the SADIGI can only make heat calls and only the heat setpoint can be viewed or changed. In Cool mode, the SADIGI can only make cool calls and only the cool setpoint can be viewed or changed. In Auto mode, the SADIGI can make either heat or cool calls and both the heat and cool setpoints can be viewed.

View mode: To view the current mode, press the top and bottom buttons simultaneously. The present mode will be displayed by the letter H, C or A.

Change mode: To change the mode, continue simultaneously pressing both the top and bottom buttons until at the mode desired, then release both buttons.

When the SADIGI thermostat is in Auto or Heat mode, the thermostat will make a heat call when the room temperature drops two degrees below the heat setpoint and, after running a minimum of 2 minutes, turn off when the temperature has risen to the heat setpoint. When in Auto or Cool mode, the thermostat will make a cool call when the room temperature rises two degrees above the cool setpoint and, after running a minimum of 2 minutes, turn off when the temperature has dropped to the cool setpoint.

View/change heat setpoint: The heat setpoint can be viewed when in either Auto or Heat mode. To view the current heat setpoint in Auto mode, press the top button until “H” appears and then release. To view in Heat mode, press either the top or bottom button until “H” appears and then release. The heat setpoint is displayed after “H”. To change the setpoint, immediately after the setpoint is displayed press and hold either the top or bottom button until the setpoint is at the desired value and then release. Approximately two seconds after the button is released the current room temperature will be redisplayed.

SETPOINTS

View/change cool setpoint: The cool setpoint can be viewed when in either Auto or Cool mode.

To view the current cool setpoint in Auto mode, press the bottom button until “C” appears and then release. To view in Cool mode, press either the top or bottom button until “C” appears and then release. The cool setpoint is displayed after “C”. To change the setpoint, immediately after the setpoint is displayed press and hold either the top or bottom button until the setpoint is at the desired value and then release. Approximately two seconds after the button is released the current room temperature will be redisplayed.

SYSTEM SIZE

5 TONS OR UNDER

UNDER 7.5 TONS

7.5 TONS OF LARGER

MAXIMUM

DIFFERENTIAL

PRESSURE

0.5" 1"

1.75"

ROUND DAMPER

LOW PRESSURE MEDIUM PRESSURE MEDIUM PRESSURE

RECTANGULAR DAMPER

LOW PRESSURE MEDIUM PRESSURE HEAVY DUTY

ZONE DAMPERS

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

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

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

ROUND ZONE DAMPERS

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

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.

LOW PRESSURE (TR diam)

ROUND MEDIUM PRESSURE ZONE DAMPERS

(101AMPD diam)

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

MEDIUM PRESSURE (101AMPD diam)

ROUND LOW & MEDIUM PRESSURE DAMPER SIZES

ROUND LOW PRESSURE DAMPER

PART #

TR06 TR07 TR08 TR09 TR10 TR12 TR14 TR16

ROUND MEDIUM PRESSURE DAMPER

PART #

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

SIZE DIAMETER (D) LENGTH (L)

6" 7" 8"

9" 10" 12" 14" 16"

SIZE DIAMETER (D) LENGTH (L)

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

6" 7" 8"

9" 10" 12" 14" 16"

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

ZONE DAMPERS

WIDTH (W)

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

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

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

WIDTH (W)

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

TYPICAL ROUND CAPACITIES*

Duct

Diameter

6" 7"

8" 9"

10" 12" 14" 16"

18" 2000 1100 .036

Nominal

CFM

110 160

250 320

410

660 1000 1450

Duct Velocity

FPM

540 600

700 725

750 850 925

1070

Damper

P " WC

∆

.014 .014

.015 .015

.015 .022 .035 .036

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

ZONE DAMPERS

RECTANGULAR ZONE DAMPERS

The rectangular zone dampers are available in low, medium and heavy duty pressure ratings. For systems up to 5 tons or with .5” ESP blower capacity, use low pressure rated dampers. For systems up to 7.5 tons or with a 1.0” ESP blower capacity, use medium pressure rated dampers. For systems over 7.5 tons or up to 1.75” ESP blower capacity, use heavy duty rated dampers.

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.

LOW PRESSURE (TREC W x H) RECTANGULAR DAMPER

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

Zonex Systems rectangular medium pressure dampers are recommended for systems under 7.5 tons with a maximum differential static pressure of 1”. These are power open, power close dampers. They are constructed from heavy duty aluminum and stainless steel. The damper is an opposed blade type that slips into a 3-1/4” wide cutout in the existing duct and attaches with screws via a duct mounting plate. The duct mounting plate is 5” wide. 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 6 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 AND MEDIUM PRESSURE RECTANGULAR DAMPER DIMENSIONS

DEPTH

B 16"

WIDTH HEIGHT

MOTOR

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.

200 280 390 490

700 1090 1500 2000 2500 3000 3600 4000

630 960 1400 1850 2250 2300 3080

570 900 1220 1600 2000 2450 2850

500 770 1100 1400 1750 2100 2500

440 680 950 1200 1500 1800 2100

390 590 800 1000 1250 1500 1750

310 490 650 850 1000 1200 1400

250 390 510 650

8 10 12 14 16 18 20

81012 141618202224

HEIGHT IN INCHES

WIDTH IN INCHES

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

ZONE DAMPERS

2-1/4"

2-1/2"

HEAVY DUTY RECTANGULAR DAMPER DIMENSIONS

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

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

RECTANGULAR DAMPER CAPACITIES*

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.

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.

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

BYPASS DAMPERS

b) Select damper size by using a duct sizing table or calculator. c) Select a Zonex Systems damper to fit the duct size selected for

that zone.

and be butted against the hat section, (do not insulate the motor or relay board). Both motor and the relay board generate enough heat so no condensation will develop on the hat section.

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

6. Low and medium pressure rectangular dampers slide into a 3” 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.

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.

BYPASS DAMPERS – BAROMETRIC

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. It is an efficient solution for small system fan capacity control.

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 subtracting 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

BAROMETRIC BYPASS

SELECTION T ABLE

Diameter CFM

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

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 systems 5 tons or smaller, the barometric bypass can be used. For systems over 5 tons, we recommend the electronic bypass.

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.

BAROMETRIC BYPASS

DAMPER

AIRFLOW

RECTANGULAR & ROUND

BAROMETRIC BYPASS

1. Damper Shaft

2. Lock Nut

3. Lever Arm

4. Counter Weight

BYPASS DAMPERS – BAROMETRIC

INSTALLATION

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

a) Install the bypass damper between the supply and return

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

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

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

BYPASS DAMPERS – ELECTRONIC

ELECTRONIC BYPASS DAMPERS

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

The Electronic Bypass Damper can be used on any size system over 5 tons. The damper can be round or rectangular and multiple dampers can be slaved together. The Electronic Bypass Damper consists of a medium pressure round or a heavy duty rectangular damper and a static pressure sensor.

SIZING ELECTRONIC BYPASS DAMPERS

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

CFM CALCULATION

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

(A - B = C).

ROUND BYPASS DAMPER SELECTION

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

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

ROUND BYPASS SELECTION TABLE

Diameter CFM

6” 320

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

RECTANGULAR & ROUND BYPASS DAMPER

WITH THE STATIC PRESSURE CONTROL

ROUND DIMENSIONAL DATA

PART # STMPD06 STMPD08 STMPD10 STMPD12 STMPD14 STMPD16

SIZE

8 10 12 14

10"

12" 14"

16"

18"

W 9" 11" 13"

15" 17" 19"

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

RECTANGULAR BYPASS DAMPER SELECTION

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

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

RECTANGULAR BYPASS DAMPERS

SELECT FROM 8 X 8 THRU 48 X 48

WIDTH HEIGHT

Part Number STCD W X H

DEPTH

H 16"W

48" MAXIMUM WIDTH

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

* FPM = Feet Per Minute

24 28 32 36 40 44 48

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

8 10 12 14 16 18 20 22

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

WIDTH IN INCHES

HEIGHT IN INCHES

BYPASS DAMPERS – ELECTRONIC

RECTANGULAR BYPASS SELECTION TABLE

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

BYPASS POSITION INDICATOR

SLAVING BYPASS DAMPERS

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

ACTUATOR

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

ROUND AND RECTANGULAR

BYPASS DAMPER MOTORS

SHAFT END MARKING IS PARALLEL

WITH DAMPER BLADE. DAMPER TRAVEL

IS 60° ON ROUND BYPASS AND 90°

ON RECTANGULAR BYPASS

CCW

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

DAMPER

RC RO MC

***

RC MC

RC MC RO

101ASPC

Static

Pressure

Control

See Page 22

SLAVE

DAMPER

ACTUATOR

RC RO MC

TO NEXT SLAVE BYPASS DAMPER IF APPLICABLE

RC RO MC

BYPASS DAMPER – STATIC PRESSURE CONTROLLER

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

STATIC PRESSURE CONTROLLER DESCRIPTION

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

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

F G H

STATIC PRESSURE CONTROLLER INSTALLATION

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

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

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

diaphragm of the sensor vertical. The controller must be mounted

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

Static Pressure Controller located closest to the mounting tabs.

The other barb, labeled “LOW”, is left open if the Controller

is in the conditioned building. If the Controller is located outside

the building, another tube, not provided, must be connected

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

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

Pressure Controller Setup.

AIR

CONDITIONER

AIRFLOW

Insert the tube into the side of the duct, approximately

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

MOTOR

WINDOW

STOPS

AIRFLOW

STATIC

PRESSURE

SENSOR

BYPASS DAMPER

STATIC PRESSURE CONTROLLER SETUP

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

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

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

The DigiTract controller should have the green blower LED on all of the red damper LEDs off.

and

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

Alternative Wiring

b) Verify bypass damper is Closed

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

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

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

(no light) should

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

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

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

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

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

BYPASS CHECKOUT FOR STATIC PRESSURE CONTROLLER

a) Make a cool call at the zone thermostat of the smallest (damper size)

zone. b) Verify all zone dampers are closed except for calling zone. c) Verify noise at zone register is not excessive. Adjust static pressure

controller CCW to lower noise (airflow) or CW to increase airflow

until too noisy.

DAMPER TRANSFORMER

The 24V transformer connected to TR1 and TR2 of the Digitract 4-2 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

TRANSFORMER/FUSE SIZING

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

9 108 VA 6 AMP 54 VA 3 AMP 10 120 VA 6 AMP 60 VA 3 AMP 11 132 VA 7 AMP 66 VA 4 AMP 12 144 VA 7 AMP 72 VA 4 AMP

Notice:

XFMR PWR

All wiring must meet state and local codes.

FUSE SIZE

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 DTGE4-2

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

2. At System Controller: a. Disconnect LAS sensor at + - terminals and place jumper wire

between + - terminals.

b. Turn power switch ON.

3. Turn off all thermostats except zone 1.

4. At zone 1 thermostat: a. Set power switch on. b. Set to Heat mode. c. Set Fan switch to Auto mode. d. Set heat setpoint several degrees above room temperature.

5. At System Controller: a. Verify W and PWR lights are on. If not, cycle System Controller

power switch OFF and then ON and recheck. b. If jumper JU1 is on B, verify G light is on. c. Verify DPR 1 light is off and DPR 2 through DPR 4 lights are on.

6. At HVAC unit, verify furnace is on and blower fan is running. If the G light 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 air is coming out of the register/diffuser.

8. At next zone:

a. Verify air is not coming out of register/diffuser.

b. At thermostat:

b-1 Set power switch on. b-2 Set to Heat mode. b-3 Set Fan switch to Auto mode. b-4 Set heat setpoint several degrees above room

temperature.

c. Verify air is now coming out the register/diffuser.

9. At previous zone, turn thermostat off and verify air stops coming out of the register/diffuser.

10. Repeat steps 8 and 9 for all remaining zones.

11. If no cooling system, reconnect LAS to the + - terminals of the System Controller and test is complete.

12. Disconnect all wires from the + - terminals of the System Controller.

13. Turn off all thermostats except zone 1.

14. At zone 1 thermostat: a. Set power switch on. b. Set to Cool mode. c. Set Fan switch to Auto mode. d. Set cool setpoint several degrees below room temperature.

STARTUP TEST, GAS/ELECTRIC DTGE4 (Continued)

15. At System Controller: a. Verify Y, G and PWR lights are on. If not cycle System Controller

power switch OFF and then ON and recheck.

b. Verify DPR 1 light is off and DPR 2 through DPR 4 lights are on.

16. At HVAC unit, verify air conditioner is on and blower fan is running.

17. Verify air is being delivered to zone 1 and not to any of the other zones.

18. At zone 1, verify air is coming out of the register/diffuser.

19. At next zone: a. Verify air is not coming out of the register/diffuser. b. At thermostat:

b-1 Set power switch on.

STARTUP TEST, HEAT PUMP DTHP4 & DTHP4-2

1. At System Controller:

a. Disconnect LAS sensor at + - terminals and place jumper

wire between + - terminals.

b. Turn power switch ON.

2. Turn off all thermostats except zone 1.

3. At zone 1 thermostat:

a. Set power switch on. b. Set to Heat mode. c. Set Fan switch to Auto mode. d. Set heat setpoint several degrees above room temperature.

4. At System Controller:

a. Verify Y, G and PWR lights 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 light is on. Otherwise, verify

O/B light is off.

c. Verify DPR 1 light is off and DPR 2 through DPR 4 lights are on.

5. Verify heat pump is running in heat mode and the blower fan is

running.

6. At zone 1, verify air is coming out of the register/diffuser.

7. At next zone:

a. Verify air is not coming out of register/diffuser. b. At thermostat:

b-1 Set power switch on. b-2 Set to Heat mode. b-3 Set Fan switch to Auto mode. b-4 Set heat setpoint several degrees above room

temperature.

c. Verify air is now coming out of the register/diffuser.

8. At previous zone, turn thermostat off and verify air stops coming out

of the register/diffuser.

9. Repeat steps 7 and 8 for all remaining zones.

10. If the heat pump has auxiliary heat, after the heat pump has been

running at least 4 minutes, verify W2 LED is on at System Controller and the auxiliary heat is on, if LAT is below 88°F.

b-2 Set to Cool mode. b-3 Set Fan switch to Auto mode. b-4 Set cool setpoint several degrees below room

temperature.

c. Verify air is now coming out of the register/diffuser.

20.At previous zone, turn thermostat off and verify that air stops coming out of the register/diffuser.

21. Repeat steps 19 and 20 for all remaining zones.

22. At System Controller reconnect LAS to + - terminals.

Test complete.

11. Disconnect jumper wire between the + - terminals of the System Controller.

12. Turn off all thermostats except zone 1.

13. At zone 1 thermostat: a. Set power switch on. b. Set to Cool mode. c. Set Fan switch to Auto mode. d. Set cool setpoint several degrees below room temperature.

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

power switch OFF and then ON and recheck.

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

O/B light is off.

c. Verify DPR 1 light is off and DPR 2 through DPR 4 lights are on.

15. Verify heat pump is running in cool mode and the blower fan is running.

16. Verify air is being delivered to zone 1 and not to any of the other zones.

17. At zone 1, verify air is coming out of the register/diffuser.

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

b-1 Set power switch on. b-2 Set to Cool mode. b-3 Set Fan switch to Auto mode. b-4 Set cool setpoint several degrees below room

temperature.

c. Verify air is now coming out of the register/diffuser.

19. At previous zone, turn thermostat off and verify air stops coming out of the register/diffuser.

20. Repeat steps 18 and 19 for all remaining zones.

21. At System Controller reconnect LAS to + - terminals.

Test complete.

DIGITRACT 4-2 TROUBLESHOOTING / SERVICE CHECKS

Malfunction Probable Cause Corrective Action

All thermostats will not call Loss of 24V ac on R and C Repair power source Will not initiate cooling cycle Controller in heat mode 15 minute delay prior to changeover

Controller in changeover from heat mode 3 minute purge cycle must complete LAS polarity incorrect Red lead to + terminal, white to – terminal

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

LAS wiring shorted (0V dc on + and – w/ LAS installed) Repair LAS wiring Controller failure (0V dc on + and – w/ LAS removed) Replace controller 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 LAS out of calibration Recalibrate LAS

Will not initiate heat calls Controller in cool mode 15 minute delay prior to changeover

Controller in changeover from cool mode 3 minute purge cycle must terminate LAS polarity incorrect Red lead to + terminal, white to – terminal LAS electrical interference (Applicable to spark ignition) Install shielded cable to LAS, terminate shield on C terminal ONLY

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

LAS wiring open (5V dc on + and – w/ LAS installed) Repair LAS wiring Heating anticipator incorrectly set Set anticipator to lowest setting Bypass damper opening prematurely Adjust bypass damper closed w/ all zone dampers open LAS out of calibration Recalibrate LAS

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.

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 (DTHP4-2 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

If problem persists, replace controller

DIGITRACT 4-2 LAS VOLTAGE – TEMPERATURE CONVERSION CHART

Using a digital volt-ohm meter, place the red lead on the + terminal and the black lead on the - terminal of the equipment terminal strip. Set the voltmeter to the 20VDC scale, and convert the measured voltage to its corresponding temperature.

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

40 2.775 56 2.864 72 2.953 88 3.042 41 2.781 57 2.870 73 2.959 89 3.048 42 2.787 58 2.875 74 2.964 90 3.053 43 2.792 59 2.881 75 2.970 91 3.059 44 2.798 60 2.887 76 2.975 92 3.064 45 2.803 61 2.892 77 2.981 93 3.070 46 2.809 62 2.898 78 2.987 94 3.075 47 2.814 63 2.903 79 2.992 95 3.081 48 2.820 64 2.909 80 2.998 96 3.087 49 2.825 65 2.914 81 3.003 97 3.092 50 2.831 66 2.920 82 3.009 98 3.098 51 2.837 67 2.925 83 3.014 99 3.103 52 2.842 68 2.931 84 3.020 100 3.109 53 2.848 69 2.937 85 3.025 101 3.114 54 2.853 70 2.942 86 3.031 102 3.120 55 2.859 71 2.948 87 3.037 103 3.125

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

104 3.131 119 3.214 134 3.298 149 3.387 105 3.137 120 3.220 135 3.303 150 3.392 106 3.142 121 3.225 136 3.309 151 3.398 107 3.148 122 3.231 137 3.314 152 3.403 108 3.153 123 3.237 138 3.320 153 3.409 109 3.159 124 3.424 139 3.325 154 3.409 110 3.164 125 3.248 140 3.331 155 3.414 111 3.170 126 3.253 141 3.337 156 3.420 112 3.175 127 3.259 142 3.342 157 3.425 113 3.181 128 3.264 143 3.348 158 3.431 114 3.187 129 3.270 144 3.353 159 3.437 115 3.192 130 3.275 145 3.359 160 3.442 116 3.198 131 3.281 146 3.364 117 3.203 132 3.287 147 3.375 118 3.209 133 3.292 148 3.381

Hot Line: (800) 228-2966

DigiTract 4-2

Comfort Control System

5622 Engineer Drive

Huntington Beach, CA 92649

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

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

E-mail us at calecon@hvaccomfort.com

Zoning

Part #DT4MAN

Rev. April 2003

Zonex Systems DigiTract 4-2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual