EZ Zone COMMERCIAL BUILDING ZONE CONTROLS

Transcription

1 (596) EZ Zone COMMERCIAL BUILDING ZONE CONTROLS SINGLE PACKAGE AIR CONDITIONERS, HEAT PUMPS & SPLIT-SYSTEM AIR CONDITIONERS INTRODUCTION Using constant volume unitary equipment to heat and cool small-to-medium sized commercial buildings has become an accepted practice. On many of these systems, each unit is controlled by a single thermostat that is usually located in the area requiring the most heating or cooling. Although this arrangement works fine in large spaces without any partitions, the modern buildings of today are designed for maximum flexibility in occupancy and much of their space is divided into small offices. This trend has created the need for a system that can provide year round comfort in each zone regardless of the usage today or in the future. The York EZ Zone system answers this need. By incorporating micro processor technology into the control system, a low cost unitary heating/cooling unit can be used on multi-zone applications. The York system permits a constant volume unit to be controlled by multiple thermostats or zone sensors. These sensors not only modulate the zone dampers for the proper air flow to each zone, they also control the operation of the air conditioning unit by communicating the cooling and heating requirements of each zone to a master controller. Variable air volume and variable air temperature work in unison to comfort condition each zone to the personal desires of the occupant without over-heating or over- cooling the building. A layout of a typical York EZ Zone system is shown in Figure 1. Although a rooftop unit is shown, other models can be used without any special factory or field modifications. Economizer operation will be controlled by the unit - not by the EZ Zone system. To understand the York system, let s begin with the distribution of supply air. The amount of air being delivered to each zone is regulated by the position of the zone damper installed in the branch duct. This position is determined by the difference between the zone setpoint and the actual zone temperature. A zone damper will open as the temperature difference increases and will close as the temperature difference decreases. Note, however, that a damper will close to its minimum position when: the zone requires cooling and the supply air is warm. (or) the zone requires heating and the supply air is cool. A by-pass damper is installed between the supply and the return air side of the unit, and it modulates to maintain a constant static pressure in the supply duct. This arrangement also provides full air flow through the unit which is necessary for the satisfactory operation of the constant volume unit. Each zone damper is controlled by a zone controller, a micro processor with the ability to send and receive data, compare data, and give commands. It receives data from the zone sensor and the master controller, compares the data, and positions the damper accordingly. It also communicates zone data back to the master controller. The master controller receives data from all the zone sensors and the supply air sensor. From this data, it decides the unit s mode of operation and the steps of capacity required to maintain the desired conditions in each zone. In addition, it receives data from a static pressure sensor and uses it to position the bypass damper. The master controller is the center of the York EZ Zone system because it constantly communicates with all the devices in the system. From the keypad and the LC display (LCD) on the face of the master controller, all functions including setpoints and time schedules can be adjusted. The LCD supplies a read-out of all the pertinent data for each zone and the master controller upon command from the keypad. The system is easy to program to meet the desires of each occupant.

2 SYSTEM FEATURES VERSATILE - The York system may be applied to any single package or split system air conditioner with up to two stages of heating and cooling. York single package heat pumps from 3 and 20 tons can also be used. ECONOMICAL COMFORT - The York system makes it possible to use less costly unitary products to provide individual comfort to a multiple number of zones. SINGLE-POINT CONTROL - The York system is controlled from a single location regardless of the number of zones. Microprocessor technology applied to the control system makes it possible to communicate with all zones so each may be configured, monitored, and diagnosed at the master control location. EASY PROGRAMMING - An on-board LC display supplies a read-out of the pertinent data for each zone and the unit. Any function displayed can be easily reconfigured using the on-board keypad. SIMPLIFIED INSTALLATION - The York system is powered by 24 volts. Only low cost, low voltage wiring connects point to point. The communication loop is designed for daisy-chain wiring. RELIABLE - The York system uses only solid state components which contain no moving parts and are noted for continuous reliability. UNOBTRUSIVE ZONE SENSOR - The unique patented zone sensor is flush mounted to the wall either horizontally or vertically and may be painted to match the decor of the room. TIME CLOCK day calendar including eleven holidays. FIG. 1 - TYPICAL ZONE CONTROL SYSTEM Introduction... 1 Product Information... 2 PRODUCT INFORMATION Zone and Bypass Dampers... 3 Zone and Master Controllers... 3 Zone, Supply Air Temperature and Static Pressure Sensors... 4 Fan Terminal Controller... 4 APPLICATION PROCEDURE Determine How Space is Zoned... 7 Design the Air Distribution System... 7 Select the Zone and Bypass Dampers... 7 CONTROL SEQUENCE Initialization...11 Communications...11 Occupied Mode Unoccupied Mode Override Schedule Setpoints and Defaults Configure System Failure Modes and Self Diagnostics TABLE OF CONTENTS Other Functions Keypad LC Display Screens INSTALLATION Zone, Bypass and Balancing Dampers Master Controller Zone Controller Zone and Supply Air Temperature Sensors Static Pressure Sensor Fan Terminal Controller WIRING PROCEDURE General Transformer Sizing Power Wire Sizing Master Controller Zone Controller Communications Loop Modem Linc Central Modem Connections Setting the Address Switch MONITORING AND PROGRAMMING Monitoring Procedure Programming Procedure Unitary Products Group

3 PRODUCT INFORMATION Zone Damper - Model 2MD0470**24 One or more is required per zone to regulate the flow of conditioned air to the zone. All zone dampers are round and consist of a 20 gauge galvanized sheet metal casing, a single gasketed damper assembly and a mounting bracket on which the damper actuator and control box less controls are mounted. Refer to Table 1 and Figure 2 for performance and physical data. The casing is designed to accept nominally sized round sheet metal or flexible ducting. Each end contains a formed stiffener ring for added rigidity. The zone controller is an electronic control board consisting of solid state components including a micro processor. The solid state components make the unit very reliable and long lasting. The micro processor is programmed to operate in concert with the Master Controller. Sixteen (16) zone controllers can be networked together to share data with the Master Controller. An on-board DIP switch must be programmed for addressing each zone. All low voltage 24V electrical connections are made on a screw-type deplugable terminal block. This makes field wiring easy and field replacement, if necessary, very simple. The board snaps easily into a snap track in the damper control box. It does not have to be installed until the other trades have completed their work TG1Y The board contains an auxiliary control system accessed through a jack plug that makes it possible to control a fan terminal unit with auxiliary heat using a Fan Terminal Controller. The damper assembly is a single blade-type damper that is elliptical in shape to provide positive shut-off when in the closed position. The periphery is gasketed with a soft neoprene material that is sandwiched between two 20 gauge sheet metal plates. This construction prevents the gasket from becoming unglued by the air stream. The soft material presses tightly against the casing to provide a positive seal when the damper is closed. The double thickness of metal provides a rigid blade that does not vibrate, or sing, with changes in air velocity. The round bearing pins are securely clamped to the damper blade and rotate in bronze bushings that never require lubrication. A 24 VAC electronic damper actuator is factory installed on the mounting plate to the right of the control box. It has a pigtail with a phone-jack to make the field connection to the zone controller easy and foolproof. The zone controller is shipped separately to prevent it from being damaged while the zone damper is being installed. An adequate length of snap-track is factory installed in the control box to simplify the installation of the zone controller. Fiberglas insulation is installed between the mounting bracket and casing to make insulating the ductwork and casing simpler. Bypass Damper - Model 2MD0470**24 (Same as zone damper described above.) One or more is required per system to regulate the static pressure of the supply air by relieving the excess air to the return side of the unit when the zone dampers demand less than normal air quantities. This action also provides a nearly constant volume of air through the unit. Zone Controller - Model 2CF Normally, one zone controller is required for each zone damper. On some installations, however, it may be possible to slave a second zone damper to the first damper/controller. In such cases, only one zone controller is required. Up to two additional actuators may be slaved to the primary actuator/zone controller. Master Controller - Model 2CF One Master Controller is required per system. As the name implies, it has overall control of the operation of the system. The Master Controller is a highly sophisticated electronic control device, the heart of which is a micro processor. It has the ability to monitor sixteen (16) individual zones and control the operation of the equipment to satisfy the heating and/or cooling requirements of each one. It does this by receiving data from each of the zones, deciding the proper mode of operation, and turning on one or two stages of cooling or heating as required. It also receives supply air temperature input and provides this information to each zone so the zone damper controller can properly modulate the damper to maintain the highest degree of comfort in the zone. One other function is to monitor supply air pressure and regulate the bypass damper to maintain the predetermined supply air pressure which best supplies air to the zones. This also controls daily and holiday operating schedules. The Master Controller is shipped mounted in an enclosure. On the cover of the enclosure are installed a Keypad, LC Display and LED Indicator Lights. They are connected to the control board by a ribbon cable and socket so that the cover may be easily removed to fully access the master control for wiring or service. The keypad and display provides a means for the operator to change setpoints, reconfigure the system and reset the time clock and schedule. Other system parameters such as time delays, control temperature differentials and default values are pre-programmed at the factory. Minimum OFF and ON cycles are built into the controller for both heating and cooling operation. (4 minutes off; 4 minutes on.) Unitary Products Group 3

4 The Master Controller, like all other components in the system, operates on 24 volts. All the interconnecting wiring required in the field can be inexpensive, low voltage wiring. To further minimize installed cost, wiring may be daisy-chained from component to component. Each zone damper does NOT have to be wired back to the master controller. Connections at the Master Controller are made with quick connecting type terminal blocks. A bag of miscellaneous wiring accessories is provided with the controller to make wiring tasks easier and to prevent problems due to incorrect or intermittent wiring connections. Zone Sensor - Model 2TS One zone sensor is required per zone. It senses zone temperature and provides this information to the zone controller that controls the damper regulating the air flow to a zone. The patented sensor may be mounted vertically or horizontally as there are no moving parts. The temperature is sensed by a thermistor attached to a sensing plate. The manner in which the precise temperature is sensed is unique. This makes it possible to flush mount the sensor in the wall with less protrusion than an ordinary light switch. Screw terminals on the back of the sensor provide for quick wiring connections. Master Interface Board For connecting groups of controllers to the main communications trunk via the Modem Linc Central, one master Interface Board per master controller is required. The master controller may be ordered with this board already installed, or an upgrade kit may be ordered separately. Modem For remote dial-in monitoring and/or control of any system, one modem is required at the project site as well as the remote station. Static Pressure Sensor - Model 2PS One kit is required per system to measure and convert static pressure into an electrical signal to the Master Controller. The kit contains a transducer, sensor tap, gasket, bracket and short length of plastic tubing. The transducer is a small compact light weight device with an integral mounting bracket for installation on the supply air ductwork. Zone Sensor (Adjustable) - Model 2TS This is an optional zone sensor with added features. The setpoint adjustment is a slide that makes it possible to manually raise or lower the zone temperature set point ± 2 F. The override button will interrupt the night set-back (unoccupied) sequence for a 2 hour time period after the button has been pushed. Otherwise, the sensor functions the same as the basic sensor as outlined above. Pushing the button twice will not provide 4 hours override; only 2 hours from the last push. Pushing the button for 10 seconds cancels the override mode. Supply Air Temperature Sensor - Model 2TS One is required per system. It should be mounted in the supply air duct upstream of the bypass damper as close to the unit discharge as possible. The probe extends into the air stream to sense the temperature. The sensor is an accurate thermistor potted in a 1/4" OD metal probe 5-1/2" long. The probe is mounted on a bracket (including a gasket) for installation on the ductwork with 2 sheet metal screws. Conduit or an electrical box may be attached to the probe using the 1/2" MPT connection on the end of the probe. Modem Linc Central with Software - 2MC The sensor tap mounts on the bracket and is inserted into the ductwork to sense the static pressure. The 1/8" ID plastic tubing is included to connect the sensor tap to the transducer. Fan Terminal Controller - Model 2CF Whenever a fan terminal unit or auxillary heat is used to control a zone, the unit will require both a Zone Controller and a Fan Terminal Controller. The Fan Terminal Controller is a printed circuit board that contains pilot duty relays to operate the fan and the heating device in the fan terminal unit. It plugs into a phone jack receptacle on the Zone Controller. For information regarding the performance and selection of fan terminal units, refer to the Variable Air Volume Manual issued by the Applied Systems Division of York International Corporation. If a zone has supplemental baseboard heat, the zone damper will require a fan terminal controller in addition to the zone controller. There is enough space in the control box of the zone damper to mount both the zone controller and the fan terminal controller. For optional monitoring and/or controlling with the EZ Zone System, one Modem Linc Central per site may be used to coordinate peer-to-peer communications between up to 20 master controllers. The device may be connected directly or remotely by phone modem to an IBM compatible personal computer. Software is included on a double sided 3.5 " diskette with each Modem Linc Central. Bypass Interface -2PJ One I/F is required for each Bypass Damper installed to provide the connection from the actuator pigtail to the Master Controller. 4 Unitary Products Group

5 * DAMPER MODEL DIMENSIONS (INCHES) D L W X Y NOM. SIZE (IN.) WEIGHT (LBS.) 2MD / /8 3-15/ MD / /8 4-15/ MD / /8 5-15/ MD / /8 6-15/ MD / /8 7-15/ MD / /8 8-15/ (4).150" DIA. MOUNTING HOLES ON BACK PANEL C C C NOTE: Two (2) dual 7/8" or 1-1/8" knockouts are provided on the top & bottom panels of the control box, 2-1/4" from the edges. These knockouts will accommodate 1/2" or 3/4" electrical fittings. *If connecting to a Kreuter or Neptronics actuator refer to Alternate Actuator Connections, pg. 32. SEE NOTE MASTER CONTROLLER LC DISPLAY WINDOW KEYPAD " STATUS LIGHTS NOTE:Two (2) dual 7/8" or 1-1/8" knockouts are provided on the top, bottom and back panels of the control box, 1-1/2" from the edges. (location on back panel is near the bottom) C These knockouts will accommodate 1/2" or 3/4" electrical fittings FIG. 2 - DIMENSIONS (DAMPER & CONTROLS) Unitary Products Group 5

6 TABLE 1 - ZONE DAMPER PERFORMANCE RECOMMENDED APPLICATION VELOCITY 1 FPM P.D. 2 IWG CFM BY DUCT SIZE 6" 8" 10" 12" 14" 16" ZONE DAMPER BYPASS DAMPER FOR NOISE CONTROL, SELECT VELOCITY EQUIVALENT TO THAT USED FOR DUCT DESIGN. 2. P.D. IS THE PRESSURE DROP ACROSS THE ZONE DAMPER WITH THE DAMPER WIDE OPEN. 3. BYPASS DAMPER SHOULD BE SIZED FOR 60% OF THE DESIGN AIR QUANTITY. IF SELECTION FALLS BETWEEN TWO SIZES, SELECT THE LARGER DAMPER. TWO OR MORE BYPASS DAMPERS CAN BE SLAVED TO MEET A HIGHER BYPASS CFM. AS AN ALTERNATIVE TO SLAVING, ROUND OR SQUARE DAMPERS CAN BE FABRICATED IN THE FIELD AND CONTROLLED BY A 24-VOLT DAMPER ACTUATOR. THIS ACTUATOR (PART NO ) CAN BE ORDERED THROUGH SERVICE PARTS AND WILL ACCEPT ANY 1/2" ROUND SHAFT. NOTE: FOR OPTIMUM PERFORMANCE AND NOISE CONTROL, DO NOT EXCEED A SUPPLY AIR STATIC PRESSURE OF 1 IWG. TABLE 2 - ELECTRICAL DATA POWER CONSUMPTION DEVICE VOLTAGE* POWER ZONE DAMPER VA BYPASS DAMPER VA ZONE CONTROLLER VA MASTER CONTROLLER VA MASTER CONTROLLER w/interface VA FAN TERMINAL CONTROLLER VA * MAXIMUM SIZE OF EACH TRANSFORMER NOT TO EXCEED 75VA. THE TRANSFORMERS SHALL BE UL RECOGNIZED CLASS 2 DESIGN. THE TRANSFORMER SECONDARY SHALL BE 22.5V AC TO 27.O V AC UNDER FULL LOAD CONDITIONS. WIRING SIZING WIRE SIZE, AWG (COPPER ONLY) VA LOAD MAX. LENGTH TO DEVICE, FT COMMUNICATIONS LOOP WIRING WIRE SIZE, AWG* MAX LENGTH OF LOOP, FEET * SHIELDED CABLE (BELDEN #82760 OR EQUIVALENT). CALL FOR YOUR NEAREST BELDEN SUPPLIER. THIS CABLE IS PLENUM-RATED WITHOUT CONDUIT AND INCLUDES: A TWISTED-PAIR OF INSULATED 18-GAUGE STRANDED COPPER CONDUCTORS A 20-GAUGE STRANDED COPPER DRAIN WIRE AN ALUMINUM-POLYESTER SHIELD 6 Unitary Products Group

7 APPLICATION PROCEDURE TG1Y Several logical steps are required to make a satisfactory installation of a York EZ Zone system. STEP 1 - Determine how the space should be zoned. Guidelines: If the space requires more than sixteen (16) zones, two units will be required and zoned accordingly. In such cases, best results can be attained if the individual zones being served by a unit are about equal in time of day demand. For instance, a single unit applied to zones with North and South exposures will perform better than one applied with East and West zones. Even when there are less than 16 zones, it may be advisable to use two units if there are extremely wide variations in either the heating or cooling requirements of the zones. A load analysis by zones will often reveal such irregularities. Interior zones and zones such as computer or office equipment rooms with unique cooling/heating demands can best be served by a dedicated constant volume system. The bypass air should be ducted: To prevent the ceiling plenum from being pressurized during economizer operation. Cool air dropping through return air grilles could cause a discomfort problem in zones not requiring any cooling. To minimize the operating cost of the system. Heating and cooling the air in a ceiling plenum when the unit switches its mode of operation will reduce system efficiency. The ductwork will also shorten the time the system will take to satisfy the loads in the zones. STEP 2 - Calculate the cooling and heating requirements. The load calculations should be made two ways - 1) the peak load for each zone, and 2) the instantaneous load for the building. The former is required to design the ductwork and to select the zone dampers. The latter is required to select the unit. The York Smart Systems Commercial Load Calculation QHVAC computer program may be used for calculating the above requirements. Wide diversities in demand may cause the instantaneous load of the building to be less than the peak demand of all the zones. To provide a satisfactory installation at the lowest first cost, the unit should be selected to meet the instantaneous load. STEP 3 - Design the Air Distribution System. a. Supply Air Static Pressure - For optimum performance and noise control, do not exceed 1 IWG. b. Duct Design - No special precautions are necessary when designing the ductwork applicable with the York EZ Zone system. Since the supply air pressure should not exceed 1 IWG, the static regain method of duct design is not desirable. The more feasible methods are equal friction or constant velocity. Regardless of what method is used, the parameters should be the same as those normally used for low pressure duct design. The following nominal values are suggested if no others have been established: Equal Friction Method: Supply = 0.1 IWG per 100 ft. Return = 0.08 IWG per 100 ft. Maximum Velocity Method: Main duct = 1500 fpm Branch duct = 1000 fpm. The York Smart Systems Duct Sizing Computer program is an excellent aid to duct design and analysis. It has all three versions of design procedure available. c. Zone Diffuser - Many installations may be made using state of the art ceiling or sidewall diffusers. For these devices, air throw and drop are critical for acceptable comfort levels. On the York system, a good quality diffuser with excellent throw and minimum drop characteristics is preferred. Bear in mind that as the zone dampers close, the performance of the diffuser will be less than at design conditions, and poor quality diffusers could literally dump air into the zone without any diffusion whatsoever. Of course, low air quantities come at a time when the heat losses or gains are also less which tends to partially offset the need for full diffusion. On some installations, it may be advantageous to consider other means of distributing air in the zone - especially for the heating season. Downdrafts along the perimeter walls tend to produce very uncomfortable conditions for the occupants. A proper solution to the downdraft problem depends on the severity of the condition. To determine what this may be, an analysis of the heat loss per linear foot of wall is essential. The calculation of the heat loss for the worst case is as follows: Wall loss Height (ft.) x U x T = H (wall) (+) Glass loss Height (ft.) x U x T = H (glass) (+) Infiltration loss CFM x 1.08 x T = H (infiltration) Total Loss = H T BTUH/linear foot If the H T < 250 BTUH/linear foot, there is no downdraft and special consideration is not absolutely necessary. If the H T is BTUH/linear foot, the downdraft can be counteracted by using slot diffusers next to the outside wall and directed inward. Since they work best with constant air volume, replacing the zone damper with a series flow fan terminal unit is sometimes considered as an alternative to the zone dampers. If the H T > 400 BTUH/linear foot, the downdraft is serious and can be overcome with a vertical high induction slot diffuser and a series flow fan terminal unit. NOTE: For information on slot diffusers and fan terminal units in various sizes and configurations, consult the York Variable Air Volume manual that is issued by the Applied Systems Division of York International Corporation. STEP 4 - Select the Zone Dampers and the Bypass Damper. Although the zone dampers are a part of the air distribution system, they are treated as a separate step in the process. To select the zone damper, refer to the Performance Data in Table 1. Select the desired velocity through the damper, and trace horizontally across the table until the design CFM is satisfied. Then read the size at the top of the column. If it s the same as or smaller than the equivalent diameter of the branch duct, then it should be sized according to the branch duct. If it is larger than the branch duct, a transition would be required to adapt the larger damper to the smaller duct. The same would be true if the branch duct has a rectangular configuration. Unitary Products Group 7

8 The bypass damper is also part of the ductwork. The selection process is the same, except higher velocities may be used because noise is not usually critical at the unit. The CFM requirement must be calculated and should be at least 60% of the design air quantity. If the unit is a 10 ton rooftop with a nominal design air quantity of 4000 CFM, the bypass damper should be selected for at least 2400 CFM. The following example demonstrates the procedures. Example: Figure 3 represents the executive offices of a mechanical contractor. a. Determine how the space should be zoned. This step is almost insignificant in this example. The only area that lends itself to this type of application is the private offices. All other space is public area, and a constant volume unit would be acceptable. b. Calculate the cooling and heating requirements. The York Smart Systems Commercial Load Calculation QHVAC program was used to obtain these requirements. Table 3 is a copy of the Air System Zone Summary, and Table 4 is a copy of the Air System Total Load Summary generated by this program. The Total Load Summary indicates the heating requirement is 30,880 BTUH and the cooling requirement is 4.46 TONS. The ideal unit for this application would be a York year round unit model D_CG060N082. The right hand column of the Air System Zone Summary shows the CFM requirements. Their values will be used in the duct design. c. Design the Air Distribution System. The York Smart Systems Duct Sizing program was used to design the ductwork. The equal friction method was used. The CFM per zone is shown on the Air System Zone Summary printout mentioned above in Table 3. Table 5 is a printout of the Ductsize Output Data, and Figure 4 is a layout of the installation using all round ducts. Figure 4 shows the three trunk ducts (AB, BC, and BD). They are labeled #1, 2, and 3 respectively on Table 5. There are 7 zones starting with #1 on the right of Figure 4 and moving sequentially to the left. The branch duct size for each zone shows on the printout. A good quality 4-way ceiling diffuser with adjustable louvers was selected for each zone. Where necessary, two were used. Using the data provided by the report entitled Detailed Project Zone Load Calculations of the York Smart Systems Commercial Load Calculations (not shown), the BTUH/linear foot of wall and glass was determined to be less than 250 BTUH. d. Select the Zone Dampers and the By-pass Damper. The CFM per zone appears either on the Ductsize Output Data printout or the Air System Zone Summary printout mentioned above. Using the CFM s listed and a maximum velocity of 1000 FPM, the zone dampers may be selected from the Performance in Table 1 as follows: The largest zone (office #6) requires 506 CFM. Enter the Damper Performance Table 1 at 1000 FPM, and trace horizontally to the CFM rating that most closely meets the requirements. In this case, a 10" damper will deliver 530 CFM. However, from the ductsize output data, a 12" branch duct is recommended. To eliminate a transition, the 12" damper would be the ideal selection. In a like manner, the other zone dampers for the balance of the system would be selected. The minimum size of the bypass damper for this application would be based on 60% of the design CFM which totals 1460 (See Air System Zone Summary) or 876 CFM. Using the same Performance Table but a velocity of 2250 FPM, the bypass damper should be the 10" size. FIG. 3 - OFFICE BUILDING LAYOUT 8 Unitary Products Group

9 TABLE 3 - AIR SYSTEM ZONE SUMMARY TG1Y TABLE 4 - AIR SYSTEM TOTAL LOAD SUMMARY Unitary Products Group 9

10 FIG. 4 - OFFICE BUILDING W/DUCT LAYOUT TABLE 5 - DUCT SIZE OUTPUT DATA 10 Unitary Products Group

11 CONTROL SEQUENCE INITIALIZATION 1. TIME DELAY On system power-on, all LED s on the Master Controller will light to assure that they are operational. There will be an initialization delay for 12 seconds followed by a start-up delay for 50 seconds. During the start-up delay, the LC display will show the countdown and the status LED s will blink off, one by one, every few seconds TG1Y The Master Controller will start sending current data to the zones. As soon as valid data is received from the zones, the system starts to operate per the appropriate sequence. The entire initialization and calibration period takes approximately 10 minutes. 5. START-UP When the initialization and calibration period is over, the system will power up in the Auto Mode in either the Occupied or Unoccupied Period. The main system screen will appear. NOTE: The system will automatically perform self calibration at 4 a.m. everyday. The Master Controller awaits a null reading of approximately.5 volts at the static pressure sensor. This reading is subtracted from subsequent static readings to provide an accurate baseline. A null reading below.18 volts or above.65 volts results in a static null sensor alarm. During this period, no other action will take place. Actuators, heating, fan and cooling will stay locked off. The LC display will show the current number of zones, date and time. This will allow the user to check that the system is properly configured. If any of this information is wrong, the user should correct the program information as soon as the main operating screen appears. When the Zone Controller receives power, its SCAN LED lights for 1 second and then turns off. After five seconds, it will blink the address of the controller. (Example: 7 blinks for the seventh zone, etc.) Following this, the SCAN LED extinguishes for 5 seconds and then blinks once each second during its 20-second power-on time delay. On the 20th blink, it remains ON through the Zone Damper calibration routine. 2. DAMPER SELF-CHECK Following the start-up delay at the Zone Controller, the Zone Damper actuator will provide a self-check by first driving closed and then open. It will hold at the open position until information is received from the Master Controller. During the self-check period, a calibration flag will be sent from the Zone to the Master Controller to prevent a zone from being polled until that zone is ready for operation. Programming screens and data screens for each zone will indicate which zones are in a calibration mode. Following the start-up delay at the Master Controller, the Bypass Damper will calibrate by first driving open and then driving closed. Indication of this process will appear on the Bypass Damper Calibration Screen. When the calibration is finished, the Bypass Damper will move to the 25% open position until the system starts. The calibration check takes about 4 minutes. 3. GAS DELAY COUNTER - If gas is selected for type of heat, a 10 minute delay counter will be initiated for purging of the system and allowing a fan and limit switch to shut the fan off. 4. OTHER CHECKS The Master Controller rewrites the passcode (9675) to make sure that it is still valid. The Zone Controller checks to see if an Expansion Card for Auxiliary Heat has been added. The Master and Zone Controllers set the communications parameters. Default setpoints will appear when the unit is started for the first time and will be used until new setpoints have been programmed into the system. Variables and communication blocks are set to zero, and constants for the thermistor temperature conversions are established. The Zone Controller will operate according to its current setpoints. The Master Controller screen will display the latest setpoints. The SCAN LED blinks about once every 10 seconds. If any faults occur, it blinks out a diagnostic alarm message as outlined in FAILURE MODES & SELF DIAG- NOSTICS section on page 15. If power-on occurs in the Occupied Mode, the fan energizes and the Occupied Sequence begins. If the system powers on in the Unoccupied Period, the fan will not energize unless there is a zone calling for heating or cooling. COMMUNICATIONS 1. GENERAL Once communications is established, the Communication LED on the Master Controller gives two short bursts of light every 4 seconds. This indicates that a single zone has been polled. If a system had 6 zones, the time to poll the entire system would be about 24 seconds. The REC LED on the Zone Controller flashes continuously. The SCAN LED on the Zone Controller blinks once every 10 seconds unless a diagnostic fault is detected. 2. MASTER CONTROLLER TO ZONE CONTROLLER - CONTINUOUS The following data is transferred at the rate of 4 seconds per zone: a. Supply Air Temperature b. Schedule (Occupied - Unoccupied) c. Main Fan - On/Off d. Force Mode 3. ZONE CONTROLLER TO MASTER CONTROLLER - CONTINUOUS The following data is transferred at the rate of 4 seconds per zone: a. Zone (Room) Temperature b. Damper Position c. Current Cooling Setpoint d. Current Heating Setpoint e. Client Setpoint Adjustment f. Calibration Flag g. Status Information: Aux. Heat Attached and On/Off Bad Zone Sensor Zone Override Button Damper Failure 4. MASTER CONTROLLER TO ZONE CONTROLLER - ZONE SETPOINTS The following setpoints will be transferred when entered/updated at the Master Controller: a. Minimum Damper Position Set b. Maximum Damper Position Set c. Cooling Setpoint (unoccupied) d. Heating Setpoint (unoccupied) e. Day Cooling Setpoint (occupied) f. Day Heating Setpoint (occupied) g. Vent Position Set Unitary Products Group 11

12 OCCUPIED MODE 1. MASTER CONTROLLER - GENERAL During the Occupied Period, the supply fan operates continuously. A main screen will show the time, date, current mode and any alarm indications. LED s will denote HVAC status-on indications for the fan, stages of heat, stages of cooling and bypass damper driving open or closed. Alarms will be generated if any Zone Damper or the Bypass Damper fails its calibration check, a zone is missing, or any sensor (zone, static pressure or supply air temperature) is reading outside of its normal limits. Maverick zones (discussed later) also generate an alarm. If an alarm appears on the main screen, the alarm LED will also light. For additional alarm information, see FAILURE MODES & SELF DIAG- NOSTICS section on page 15. At least once every four seconds, the Master Controller polls a different Zone Controller. The total system polling time equals the number of zones times 4 seconds. Information will appear on two zone reporting screens selected from the keypad by the A or B keys. If a zone is not communicating, a Missing Zone or Zone Calibrating message (if valid) will appear. Otherwise, zone temperatures, damper position, setpoints and other information is displayed. Status information about the HVAC unit can be seen by pressing the C key on the keypad. Any alarm messages are viewed by pressing the D key. 2. MASTER CONTROLLER - STATIC PRESSURE CONTROL The Bypass Damper modulates to maintain a given static pressure. If the actual static pressure exceeds the static pressure setpoint by.05 inches W.C., the bypass damper opens to relieve the pressure. If the actual static pressure is less than the static pressure setpoint by.05 inches W.C., the bypass damper closes to regain the pressure. If the actual static pressure is within ±.05 inches W.C. from the static pressure setpoint, the bypass damper remains at its current position. 3. MASTER CONTROLLER - SELECTING HEATING/COOL- ING A vote for cooling demand is recognized if the temperature of one zone is more than 1 degree above the occupied cooling setpoint. The demand value of this vote is the difference between the actual space temperature and the zone occupied cooling setpoint. A vote for heating demand is recognized if one zone temperature is more than 1 degree below the occupied heating setpoint. The demand value of this vote is the difference between the actual space temperature and the zone occupied heating setpoint. The demand value for heating and cooling of all the zones is summed and compared. The system will go into the mode with the greatest demand value. If the cooling demand is greater than the heating demand, the system will go into the COOLING MODE. Likewise, if the heating demand is greater than the cooling demand, the system will go into the HEAT- ING MODE. Note, however, that minimum ON and OFF times must be satisfied. If all zone temperatures are less than 1/2 degree from their cooling or heating setpoints, the second stage of cooling and heating will be locked out. When all of the zones have reached or are between their heating and cooling setpoints, the heating and cooling demand value = 0. The system fan continues to operate but no heating nor cooling stages are energized. Neither heating nor cooling will be energized again until at least one zone exceeds its heating or cooling setpoint by more than 1 degree and the minimum OFF times have been satisfied. 4. MASTER CONTROLLER - PRIORITY MODES If an individual zone has a cooling demand greater than 4 degrees, it is established as a cooling priority. The system overrides the heating mode regardless of its demand value and goes into the cooling mode. If an individual zone has a heating demand greater than 4 degrees, it is established as a heating priority. The system overrides the cooling mode regardless of its demand value, unless it has already established a cooling priority. When both a cooling and a heating priority exist, the cooling priority is satisfied first. If the cooling priority is not satisfied after 15 minutes, the system switches to satisfy the heating priority. The unit will switch between heating and cooling priorities every 15 minutes as long as both priority conditions exist. Cooling and Heating priorities cancel when the zone space temperature falls back to within 2 degrees of its heating or cooling setpoint. 5. MASTER CONTROLLER - VOTES NOT COUNTED a. Mavericks: When a zone goes into a priority cooling or heating mode and is still a priority after 60 minutes has expired, the system will consider it to be a Maverick zone. Any zone that goes Maverick causes an alarm message to be displayed and will be ignored as a voting zone. However, the Zone Controller will continue to control its local space temperature. If over 75% of the zones are Maverick, the Master Controller will reset all Maverick timers for another 60 minute trial period. b. Others: A zone will not be included in the voting procedure if the zone is missing" or the zone reports a bad sensor, zone recalibrating mode, or zone damper failure. 6. HVAC SYSTEM STAGING - COOLING MODE The following occurs when there is a call for cooling: a. If stage 1 has been off for a minimum of 4 minutes and the supply air temperature is above 58 F, stage 1 will energize and run for a minimum of 4 minutes. b. If the supply air temperature drops below 58 F with stage 1 running, stage 2 will not start. c. If the supply air temperature stays above 58 F with stage 1 running but all zone temperatures are within 1/2 degree of their cooling setpoint, stage 2 will not start. d. If only stage 1 is running and the supply air temperature drops below 50 F, it will cut off provided it has satisfied its 4 minute minimum run time. e. If stage 1 has been running for at least 4 minutes, the temperature in at least one zone is more than 1/2 degree above its cooling setpoint, and the supply air temperature has not dropped below 58 F, stage 2 energizes and will run for a minimum of 4 minutes. f. If the supply air temperature drops below 50 F and stage 2 has been on for at least 4 minutes, it will turn off. It will not restart until the supply air temperature rises above 58 F, the temperature in at least one zone is more than 1/2 degree above its cooling setpoint, and it has completed an off-cycle delay of 4 minutes. g. If the supply air temperature drops below 50 F and remains there after stage 2 cuts off, stage 1 cuts off 4 minutes later. h. If all zones are within 1/2 degree of their cooling setpoint, stage 2 is disabled provided it has satisfied its 4 minute run-time period. Stage 2 can not restart until one zone rises more than 1/2 degree above its setpoint, the 4 minute off-time period has been satisfied, and the supply air temperature is above 58 F. i. If the supply air temperature falls below 45 F, both stages of cooling are immediately disabled regardless of run-time. Neither stage re-energizes until the supply air temperature rises above 58 F and they satisfy their 4 minute off-time period. While the system is in the cooling mode, zones requiring cooling will modulate between their minimum and maximum position setpoints as determined by the zone cooling demand. Satisfied zones and zones requiring heat will maintain their minimum position setpoint. If a zone has a fan terminal box with supplemental heat, the heater will be energized at this time. 12 Unitary Products Group

13 7. HVAC SYSTEM STAGING-CHANGEOVER - When the system is switching from cooling to heating or from heating to cooling, there will be a 4 minute off-cycle between the switching. 8. HVAC SYSTEM STAGING - HEATING MODE The following occurs when there is a call for heating: a. If stage 1 has been off for a minimum of 4 minutes and the supply air temperature is below 105 F (gas)/90 F (electric), stage 1 will energize and run for a minimum of 4 minutes. b. If the supply air temperature rises above 105 F (gas)/90 F (electric) with stage 1 running, stage 2 will not start. c. If the supply air temperature drops below 105 F (gas)/90 F (electric) with stage 1 running but all zone temperatures are within 1/2 degree of their heating setpoint, stage 2 will not start. d. If only stage 1 is running and the supply air temperature rises above 130 F (gas)/105 F (electric), it will cut off provided it has satisfied its 4 minute run-time. e. If stage 1 has been running for at least 4 minutes, the temperature in at least one zone is more than 1/2 degree below its heating setpoint, and the supply air temperature has not risen above 105 F (gas)/90 F (electric), stage 2 energizes and will run for a minimum of 4 minutes. f. If the supply air temperature rises above 130 F (gas)/105 F (electric) and stage 2 has been on for at least 4 minutes, it will turn off. It will not restart until the supply air temperature drops below 105 F (gas)/90 F (electric), the temperature in at least one zone is more than 1/2 degree below its heating setpoint, and it has completed an off-cycle delay of 4 minutes TG1Y If the supply air temperature is more than 5 degrees above the zone temperature, the controller operates the damper actuator in the heating mode, moving the damper actuator between the minimum and maximum position setpoints. If the supply air temperature is within ±5 degrees of the zone temperature and the zone temperature is between the heating and cooling setpoints, the damper actuator is in the vent mode and moves to the vent position setpoint. It remains there until a heating or cooling condition is re-established. In the heating mode, the space temperature causes the zone damper to modulate to the minimum setpoint if the space temperature is at least 1/2 degree above the heating setpoint. Between 1/2 degree above the heating setpoint and 1-1/2 degrees below the heating setpoint, the damper modulates between the minimum and the maximum position setpoints. If the space temperature in the zone is more than 1-1/2 degrees below the heating setpoint, the zone damper remains at the maximum position setpoint. In the cooling mode, the space temperature causes the zone damper to modulate to the minimum setpoint if the space temperature is at least 1/2 degree below the cooling setpoint. Between 1/2 degree below the cooling setpoint and 1-1/2 degrees above the cooling setpoint, the damper modulates between the minimum and the maximum position setpoints. If the space temperature in the zone is at least 1-1/2 degrees above the cooling setpoint, the zone damper remains at the maximum position setpoint. 10. FAN TERMINAL CONTROLLER The following occurs when the Fan Terminal Controller is used: a. Relay #1 - When the zone is operating in the cooling mode, the zone temperature is more than 1/2 degree below its heating setpoint and the zone damper is at its minimum position, this relay will energize. g. If the supply air temperature rises above 130 F (gas)/105 F (electric) and stage 2 is already off, stage 1 cuts off 4 minutes later. h. If all zones are within 1/2 degree of their heating setpoint, stage 2 is disabled provided it has satisfied its 4 minute run-time period. Stage 2 can not restart until one zone drops more than 1/2 degree below its setpoint, the 4 minute off-time period has been satisfied, and the supply air temperature is below 105 F (gas)/90 F (electric). i. If the supply air temperature rises above 150 F (gas or electric), both stages of heating are immediately disabled regardless of run-time. Neither re-energizes until the supply air temperature has fallen below 105 F (gas)/90 F (electric) and they satisfy their 4 minute off-time period. While the system is in the heating mode, zones requiring heat will modulate between their minimum and maximum position setpoints as determined by the zone heating demand. Satisfied zones and zones requiring cooling will maintain their minimum position setpoint. If a fan terminal controller is used, the zone heat is locked out while the system is in the heating mode. 9. ZONE CONTROL - DAMPER ACTUATOR In the occupied mode, the Zone Controller determines one of three states of operation: vent mode, heating mode, or cooling mode. This determination is made based on the difference between the supply air temperature and the space temperature of the zone. If the supply air temperature is more than 5 degrees below the zone temperature, the controller operates the damper actuator in the cooling mode, moving the damper actuator between the minimum and maximum position setpoints. b. Relay #2 - This relay will energize if the space temperature in the zone drops more than 1-1/2 degrees below the heating setpoint. It de-energizes when the space temperature rises within 1 degree of the zone temperature setpoint. c. Relay #3 - If the space temperature in the zone drops more than 1/2 degree below the heating setpoint, this relay will energize regardless of the central fan operation. It de-energizes when the space temperature rises to 1/2 degree above the zone temperature setpoint. d. Relay #4 - When the fan in the air conditioning unit is operating, this relay will energize. e. If the system is in the heating mode, the Fan Terminal Controller will not energize Relay# SCHEDULE In the auto mode, the Master Controller allows for a seven-day schedule with one start time and one stop time event per day and holiday. If a value of 0" is entered into both the start and stop time fields, the schedule for that day will follow the Unoccupied mode of operation from 12 A.M. to 12 A.M. of the next day. If a value of 2359" is entered into both the start and stop time fields, the schedule for that day will follow the Occupied mode of operation from 12 A.M. to 12 A.M. of the next day. The start time schedule and the stop time schedule selected corresponds to the Occupied and Unoccupied periods. NOTE: Up to 11 holidays can be programmed to follow the start and stop times schedule entered above. Unitary Products Group 13

14 UNOCCUPIED MODE 1. MASTER CONTROLLER Communications is identical to the Occupied mode. The zones poll for the heating and cooling modes except that they now control to the unoccupied heating and cooling setpoints. The fan in the air conditioning unit remains off until a zone calls for heating or cooling. The bypass damper will be 25% open until the fan starts. When there is a call for heating or cooling in the Unoccupied Period, the fan first energizes for 2 minutes before either heating or cooling is activated. This gives the zones time to stabilize to the overall building temperatures. When a cooling or heating demand is satisfied, the fan runs for an additional 2 minutes before shutting down. 2. ZONE CONTROLLER As long as the fan is off at the Master Controller, the zone dampers remain in their maximum setpoint (open) position. The actuator follows the same pattern of operation as during the occupied period except that it now controls to the unoccupied period setpoints. 3. FAN TERMINAL CONTROLLER The Fan Terminal Controller energizes the series fan relay (relay #4) any time the fan in the air conditioning unit is energized. If the system is in the cooling mode and zone temperatures are below the unoccupied heating setpoint, the parallel fan relay and the auxiliary heat relays will energize at 1/2 degree and 1-1/2 degrees below the unoccupied heating setpoint, respectively. They will de-energize at setpoint and 1 degree below setpoint, respectively. The fan terminal controller (other than the series fan relay) will not operate if the system is in the heating mode. OVERRIDE SCHEDULE 1. AUTO MODE In this mode, the system changes from the Occupied to the Unoccupied schedule as set up in the SCHEDULE menu. The internal time clock triggers the unit between the two schedules. The only exception is that the zone can override the system from Unoccupied back into the Occupied periods in 2 hour increments (See ZONE OVER- RIDE below). The main screen displays the status of the system as either Occupied or Unoccupied. If power is lost to the system, the internal clock will keep track of schedule and time. When power is restored, the system will always reboot in the auto mode with the correct time, date and schedule. 2. OCCUPIED OVERRIDE In this mode, the system operates according to the Occupied Period schedule until it is reset to the auto or other override mode. The main screen will display Occupied Override. Cycling power to the Master Controller for this mode will also cause the unit to start in the Auto mode. 3. UNOCCUPIED OVERRIDE In this mode, the system continually operates according to the Unoccupied Period schedule until it is changed back to the auto or other override mode. The main screen will display Unoccupied Override. This mode can be overridden by the zone override button in 2 hour increments as described below. Cycling power to the Master Controller for this mode will also cause the unit to start in the Auto mode. 5. ZONE OVERRIDE With an adjustable thermostat, it is possible to override the Auto-Unoccupied setting or the Unoccupied Override setting by pushing the override button on the thermostat. The button is not effective in the Fan Only, Occupied Override or Auto-Occupied modes. The button must be depressed for at least 1 second and must be released within 5 seconds. Within 60 seconds, a 2 hour override is initiated. If the button is depressed any time during this 2 hour period, a new 2 hour cycle begins. Once initiated, the override period may be reset to the unoccupied period by depressing the button for at least 5 seconds. Pushing this button turns the entire system to the occupied mode and all zones operate according to their occupied setpoints. During the override period, the Main Screen displays Zone Override to indicate the current status of the system. If the override button is depressed for longer than 20 seconds, the Zone Controller will interpret this as a faulty zone sensor and will not initiate an override. It will display a Bad Sensor alarm instead. SETPOINTS AND DEFAULTS: SETPOINT LOW DEFAULT HIGH Occupied Clg. Temp Occupied Htg. Temp Min. Pos. Setpoint Max. Pos. Setpoint Vent Pos. Setpoint Unoccup. Clg. Temp Unoccup. Htg. Temp Static Pressure.1.5 2* No. Stages Cooling No. Stages Heating Address of First Zone Address of Last Zone Occup. Starting Hr Unocc. Stopping Hr User Passcode 9675 Gas/Electric Heat Electric Fahrenheit/Celsius Fahrenheit Time Clock Auto Time/Date No Default *For optimum performance and noise control, the supply air static pressure should not exceed 1 IWG. NOTES: 1. An attempt to enter a value beyond the limits of a setpoint field will be rejected, and the cursor will not step to the next entry. 2. Occupied heating cannot be set higher than occupied cooling. There must be a difference of at least 2 degrees between heating and cooling. 4. FAN ONLY In this mode, the Master Controller will energize the fan. Heating and cooling will be locked out! The unit will only reset from this mode by a manual change back to the auto or other override modes, or by cycling power to the Master Controller. In this mode, the zones move to their maximum position setpoint and remain there regardless of space temperature, zone temperature setpoint or pushing the zone override button. 3. Maximum position setpoint cannot be lower than minimum position setpoint, and vent position setpoint cannot be higher than maximum position setpoint. 4. A damper may be locked into position by setting the minimum position, vent position and the maximum position setpoints to the same value, anywhere from 0 to 100% open. 14 Unitary Products Group

15 CONFIGURE SYSTEM 1. HEATING/COOLING STAGES When configuring for cooling, a 0 entry will lock out cooling entirely, a 1 will sequence one stage of cooling and 2 will sequence two stages. When configuring for heating, a 0 entry will not be accepted (i.e. heat cannot be locked out entirely), a 1 will sequence one stage of heating and a 2 will sequence two stages. 2. LAST ZONE/FIRST ZONE These numbers should follow the addressing of the zones. The first zone will almost always be 1, and the last zone will correspond to the number of zones in the system. For diagnostic purposes, it will be possible to set the first zone higher than 1, but the last zone must always be equal to or greater than the first zone. The last zone cannot be set lower than the first zone. 3. TYPE OF HEAT By entering a 0 for electric heat, the supply air temperature limits will be reduced. By entering a 1 for gas heat, the supply air temperature limits will be increased. 4. CHANGE OF FAHRENHEIT TO CENTIGRADE Selecting 0 configures the LC Display to read out temperatures in Fahrenheit. Selecting 1 changes the readout to Celsius. Static pressure will read out in inches WC with either selection. FAILURE MODES & SELF DIAGNOSTICS 1. HVAC ALARMS a. Bad Duct Sensor: This alarm occurs if the Supply Air Temperature reads below 35 F or above 210 F. The Master Controller locks Heating and Cooling OFF and leaves the Fan in the ON mode. The zone dampers go to a maximum open position. b. Static Null Alarm: This alarm occurs if the static pressure sensor did not pass the null reading test at initialization with the fan off. The unit will continue to operate with the bypass damper at the 25% open position. c. Bad Static Sensor: Occurs if the main fan is running and the static pressure reading in the duct is below.05 or above 3 inches of static pressure. The unit will continue to operate with the bypass damper at the 25% open position. d. Bypass Damper Fail: If the bypass damper fails its selfcheck, this alarm occurs. 2. ZONE ALARMS In all zone alarms, the number of the zone will follow the alarm message to indicate which zone is experiencing the failure. a. Bad Zone Sensor: If the zone temperature reading is below 40 F or above 105 F, the zone temperature sensor is labeled as bad. The zone damper will move to the maximum position and the zone will not be counted in the voting sequence for heating/cooling at the Master Controller. A temporary push of the override button will not trigger this alarm. b. Zone Damper Fail: If the zone damper fails its self-check, the zone damper will still attempt to control. c. Maverick: When a zone is in a priority mode for over 60 minutes without moving back within 2 F of its setpoint, it is labeled a Maverick. The zone will continue to control but will not be counted in the voting sequence for heating/cooling at the Master Controller. d. Missing Zone: If a Zone loses communications for 5 minutes or more, it will drive its damper actuator to the maximum position setpoint and will not execute any other control sequences until communications is re-established. No data is displayed, and setpoints cannot be entered for a missing zone. The zone will not be included in any voting for heating or cooling by the Master Controller. 3. ZONE SCAN LED The zone SCAN LED will display diagnostic information by emitting one second pulses within a 10 second interval. This displays an operational/fault code as follows: a. 1 Pulse: System is running normally in non-override condition. b. 2 Pulses: System is running normally in override condition. c. 3 Pulses: System is experiencing zone sensor failure. d. 4 Pulses: System is experiencing zone damper failure. e. 5 Pulses: Unit has not communicated with Master Controller for over 5 minutes. f. SCAN LED locked full ON or full OFF: Zone Controller is not operating program correctly. OTHER FUNCTIONS SETPOINT ADJUSTMENT With an adjustable thermostat, the occupied and unoccupied heating and cooling setpoints may be raised or lowered by 2 degrees by moving the setpoint adjustment slide potentiometer toward the top (warmer) or bottom (cooler). KEYPAD LC DISPLAY SCREENS 1. USE OF KEYPAD In addition to the keys for numeric entries, the keypad allows four special screens to be called through the A, B, C and D keys. * The # serves as an enter, advance, or step key. The key serves as a decimal point and as an exit back to the main menu. The C key in the programming screens section also serves to clear a field entry if a mistake has been made and the # key has not been pushed. 2. INITIALIZATION SCREENS During the initialization startup, these screens display the present date, time and number of zones configured. If this information is incorrect, such as a first time start-up, these screens remind the user to program the Master Controller for the correct information. Calibration of the Bypass Damper may also be monitored from these screens. 3. MAIN SCREEN This screen shows the logo EZ Zone, the date, the time and the current mode of operation: Occupied, Unoccupied, Occupied Override, Unoccupied Override, Fan Only and Zone Override. If any alarms occur, the screen indicates the number of alarms that are active. 4. REPORTING SCREENS: a. Key A - This key scrolls the temperature of all the zones configured as well as their heating and cooling setpoints. The setpoint adjustment of the adjustable zone sensor is calculated in. If a zone is in its calibration mode or is missing, this is printed in the entry for that zone. b. Key B - This key shows complete status for any given zone including temperature and setpoints, damper position and setpoints, the number of degrees offset of the zone, and if any auxiliary heat is on. c. Key C - This key displays status of the HVAC unit including supply air temperature, static pressure and bypass damper position. d. Key D - This key reports the Alarm Status: No Alarms Bad Duct Sensor Static Null Alarm Bad Static Sensor Bypass Damper Fail Bad Zone Sensor (+ Zone #) Zone Damper Fail (+ Zone #) Maverick Zone (+ Zone #) Missing Zone (+ Zone #) 5. PROGRAMMING SCREENS: a. Programming Menu - Change Operation Configure System Override System b. Change Operation - Zone Setpoints HVAC Setpoints Next Menu c. Configure System - Stages Cooling Stages Heating Last Zone First Zone Electric/Gas Fahrenheit/Celsius d. Override System - Auto Occupied Unoccupied Fan Only TG1Y Schedule Time/date Holiday Previous menu Unitary Products Group 15

16 INSTALLATION Zone Dampers The zone dampers may be installed in any position as the direction of air flow does not effect the performance, and there is virtually no thrust on the damper actuator bearings. However, since they are not weatherproof, the dampers must always be installed indoors. The zone damper may be suspended from above by either a wire cradle or sheet metal strapping, or connected directly to a round collar on the main or branch sheet metal duct. If sheet metal screws are screwed through the casing, they should never be more than 6" from the ends to avoid restricting the damper movement. On some installations, it may be permissible to lay the zone dampers between the roof bar joists or T-bars of a suspended ceiling. Although sheet metal ducts may be used to connect the zone damper to the air diffuser, round flexible ducting will provide better sound attenuation. Use at least six feet of ductwork from the damper to the diffuser to reduce sound transmission into the space. On some applications where noise may be critical, adding diffusers will reduce the noise level in the space. A rule-ofthumb is that each additional diffuser will decrease the noise level in the zone approximately 3 decibels. The zone damper must be insulated when installed in a nonconditioned area. Two inches of Fiberglas or equivalent is recommended. The area between the damper casing and control mounting plate has been insulated at the factory for convenience. When the zone damper is used as a bypass damper, there is no zone controller required. The pigtail with phone-jack must be inserted into the bypass interface. The field wiring from the Master Controller should then be connected to the terminals inside the interface. Balancing Dampers (Field-Supplied) When programmed and operated properly, the zone dampers will admit only the amount of air necessary to satisfy the conditions in the space. Although the York system is self-balancing, the maximum position of the dampers on some installations may have to be reduced so that all zones will receive their design air quantity at full load. When the Master Controller is programmed for the override screens, choose the Fan Only mode. This will bring on the system fan, but lock out heating and cooling. The zone dampers will drive to their maximum position setpoints, and the bypass damper will modulate to control the static pressure in the supply air ductwork. At this time; (1.)Check the CFM thru the unit and adjust if necessary. (2.)Check the CFM to each zone. If the CFM to any zone is too high, reduce the maximum setpoint of that zone damper as described in the MONITORING AND PROGRAMMING section. When finished, be sure to return the Master Controller back to the Auto mode to allow heating and cooling to operate as before. The damper actuator is mounted in position and is connected directly to the damper jack shaft by a universal clamp assembly. The actuator is loosely held in position by a rotational stop pin mounted on the control mounting plate that engages a slot in the actuator body opposite the drive end. NEVER SCREW OR BOLT DOWN THE END OF THE ACTUATOR DIRECTLY TO THE PLATE. NEVER DRILL INTO THE ACTUATOR CASING. The loose mounting permits the actuator to self-align to the shaft. With the elliptical shaped damper, the travel of the drive from full open to full closed is 60 degrees and requires 80 seconds. If there is a power failure to the actuator, it will lock in its current position at the time of failure until power is restored. Attached to the actuator is a short length of wire with a phonejack. When the zone controller electronic board is installed in place, the jack must be plugged into a receptacle marked Actuator on the board in order to energize the actuator. To prevent damage to the actuator, it should never be installed in areas reaching ambient temperatures above 140 F. As far as service is concerned, the zone damper itself requires no attention. The bearings do not require lubrication. Likewise, the damper actuator does not require any maintenance. If it fails, it can be easily replaced by removing the rotational stop pin bracket, disconnecting the jack shaft by loosening the universal clamp, and sliding the actuator off the shaft. Bypass Damper A zone damper may also be used as a bypass damper. One or more may be required per system depending on the CFM to be bypassed (at least 60% of the total design CFM). When locating the bypass damper in the system, remember that it must always be installed indoors - out of the weather. Round duct is preferred although not mandatory. The connections to the system ductwork should be made as close to the unit as possible. It is possible to move the damper blade by depressing the clutch on the actuator. This disengages the motor and allows the damper blade to be manually rotated to a desired position. CAUTION: This should only be done with the actuator in the unpowered condition. Before disengaging the motor, be sure the damper actuator is unplugged from the Zone Controller, or that no power is applied to the Zone Controller. If two or more diffusers are served by the same zone damper, it will be necessary to install a balancing damper behind each diffuser. These balancing dampers should be adjusted with a full flow of air through the zone damper. This can be done by temporarily programming that particular zone for full open and reprogramming the zone when the balancing is complete. Master Controller The Master Controller may be installed in any convenient location. If outside the conditioned space, the surrounding temperature should never exceed a minimum of 40 F or a maximum of 122 F. For ease of operation, it should be located at a normal viewing level. To prevent damage, the cover on the enclosure which contains the LC display and Keypad should be removed prior to installation. It is only necessary to disconnect the ribbon cable from the socket, and the cover is free to be set aside. CAUTION: Do not remove or install cover unless electrical power is off. It is not necessary to remove the electronic control board to mount the enclosure. However, extreme caution must be exercised to avoid damage to the electronic board. The enclosure is designed for surface mount only and is held in position by screws in the 4 corners in the back of the enclosure. The screws should be obtained locally to suit the type of construction to which the control is mounted. 16 Unitary Products Group

17 NOTE: Care should be taken to avoid metal shavings from falling onto the circuit board during installation. All wiring to the Master Controller enters through knockouts in the bottom, top, or back of the enclosure and connects to marked terminal blocks with depluggable connections. To prevent the sharp edges of the knockouts from cutting the insulation on the wire, use the bushings that are supplied in the bag of parts shipped with the Master Controller. Pay particular attention to the sliding cage within the terminal block and be sure that the teeth of the cage close securely on the wires. It is all low voltage 24 volt wiring. The wiring must comply with national or local codes. Refer to the blueprint that is packaged with the Master Controller to aid in making the necessary wiring connections. The following electrical systems must be connected to the Master Controller: 1. Supply Voltage: 24 volt, 2-wire 2. Communication Loop: 24 volt, twisted pair w/drain wire (BELDEN #82760 OR EQUIVALENT) 3. A/C Unit Control Circuit: 24 volt, 4 or 6-wire (4-wire for 1-stage heating/cooling) (6-wire for 2-stage heating/cooling) 4. Supply Air Temperature Sensor: 24 volt, 2-wire 5. Supply Air Pressure Sensor: 24 volt, 3-wire 6. Bypass Damper Control: 24 volt, 4-wire After the enclosure and control have been mounted and wired, the cover may be replaced by reconnecting the ribbon cable and socket connection to the key pad and reinstalling the cover screws. Zone Controller Remove the control box cover. This will expose the factory installed snap track. Prior to snapping the zone controller electronic board in place, it should be oriented so the actuator cable does not cross over the board. The electronic board is placed over the snap track and pushed into position. The track will spread and then snap over the edges of the board to hold it tightly in place. When in place, the pigtail and phone-jack on the damper actuator should be plugged into the receptacle marked ACTUATOR on the board. The following additional wiring is required: 1. Supply Voltage: 24 volt, 2-wire 2. Communication Loop: 24 volt, twisted pair with drain wire ( #82760 OR EQUIVALENT) 3. Zone Sensor: 24 volt, 2-wire for standard sensor or 3-wire for optional sensor with override and adjustment. NUMBER OF ZONES: INSTALLED DATE: ZONE LOCATION HEAT TEMP COOL TEMP SENSOR AIR VALVE ZONE # ZONE # ZONE # ZONE # ZONE LOCATION HEAT TEMP COOL TEMP ZONE LOCATION ZONE # ZONE # NUMBER OF ZONES: INSTALLED DATE: ZONE LOCATION HEAT TEMP COOL TEMP ZONE # ZONE # ZONE # ZONE # ZONE LOCATION HEAT TEMP COOL TEMP FIG. 5 - TYPICAL ZONE IDENTITY LABELS Zone Sensor The zone sensor should be mounted on an inside wall approximately 5-1/2 feet above floor level. For best results, it should not be located on a sunlit wall or above heat producing devices such as lamps or office equipment. It is designed to be mounted flush with the wall and will not be influenced by small temperature differentials of the air in the stud space. Normally an electrical box is not required unless the code requires low voltage wiring to be encased. If a box is used, a standard 2" x 4" box is required. The basic zone sensor has a terminal block with two (2) terminals labeled TMP and GND to which wires are connected. The optional zone sensor (with temperature adjustment slide and override button) has three (3) terminals, the additional terminal being labeled AUX. For surface-mount applications, the zone sensor can be mounted on a field-supplied electrical box (Wiremold #2347/NM3 or equivalent) as shown below. MOUNTING PLATE ZONE # ZONE # ZONE LOCATION WALL BOX SENSOR AIR VALVE SENSOR CAUTION: Do NOT remove or install cover unless electrical power is OFF. Knockouts are provided on the control box for the field wiring. Install bushings in the knockouts before pulling the wire to prevent the insulation from being damaged by the metal edges of the enclosure. The terminal blocks will unplug from the board to make wiring easier. BE SURE TO OBSERVE POLARITY IN MAKING ALL CONNECTIONS. Carefully review all wiring diagrams in this manual and in the accompanying diagram supplied with the Master Controller. If local codes require that the wiring be encased in conduit, conduit fittings can be field installed in these knockouts. The Address Switch may now be programmed. Special adhesive-backed labels (see Figure 5), provided with the Master Controller, are used to identify the zones by their appropriate address at both the zone sensor and the zone controller. Refer to the WIRING SECTION for additional address information. When the wiring and addressing has been completed, the cover can be replaced. The zone can be marked with the correct address-zone number for future reference. Supply Air Temperature Sensor The supply air temperature sensor is mounted in the discharge air duct upstream of the bypass air connection. For a better response to changes in temperature, it should be located as close to the unit discharge as possible and in the middle of the duct on the widest dimension. To mount the sensor, use the template supplied and drill a 5/16" hole in the duct. Slip the gasket over the sensor probe so that it lies between the bracket and the ductwork. Attach the bracket to the ductwork using the sheet metal screws provided. Be sure the gasket is compressed to make an air tight seal. Unitary Products Group 17

18 On Fiberglas or non-metallic ducts, it may be necessary to field fabricate a metal plate to attach onto the ductwork for mounting the temperature sensor. A metal plate or fastener(s) will also have to be provided on the inside of the duct so that sheet metal screws will hold securely. Make sure that any opening in the duct will be positively sealed so that the temperature sensor only senses supply air. Attached to the probe are two 12" long wires. They may be connected to the field wiring with the crimp type splice connectors supplied in the bag of parts shipped with the sensor. There is a 1/2" MNPT connection at the end of the sensor to accommodate an electrical box when required. Static Pressure Sensor The sensor measures the static pressure in the supply air ductwork and controls the bypass damper accordingly through the Master Controller. Locate the sensor tap after at least the 2nd takeoff. If at all possible, the sensor tap should be the equivalent of two (2) duct diameters away from any connections or fittings that would influence duct pressure such as take offs, transitions, elbows, etc. A mounting template is provided to align the drill holes for the pressure tap. After drilling the holes for the tap and the mounting screws, mount the tap with the tube extending into the ductwork. Be sure the gasket is placed between the mounting bracket and the ductwork, and is compressed to form a tight seal. On Fiberglas or non-metallic ducts, it may be necessary to provide a metal plate per the same procedure as for the Supply Air Temperature Sensor described above. Since this Sensor Tap and the Pressure Transducer (described in the next paragraph) must be installed relatively close together, the metal plate should be big enough to accommodate both components. Make sure that any opening in the duct will be positively sealed to prevent false sensing. Locate the sensor within 6" of the pressure tap. It should be mounted so that the input tubes on the sensor are pointed downward to prevent the accumulation of moisture within the sensor. Mount the sensor on the ductwork using the two sheet metal screws provided. After installation, the sensor tap is connected to the inboard or HI side of the pressure sensor using the 1/8" plenum rated tubing furnished. Be sure the tubing is not kinked when the connection is made. The LO or outboard tube is left exposed to the atmosphere. The sensor has three 12" color coded wire leads extending from the base of the unit. These must be spliced for a wire run to the Master Control Panel. Use gauge wire and the crimp connectors supplied. Be sure to observe the correct color coding so that each sensor wire is correctly connected to the Master Controller (see Wiring Procedure section). Check local codes to determine if an electrical enclosure is required. Fan Terminal Controller The fan terminal controller is only required when a fan terminal unit or baseboard heat is installed. The fan terminal will require a zone controller which would be field mounted in the control compartment of the fan terminal unit. The fan terminal controller must be mounted adjacent to it, or within the limits of the pigtail connected to the control. The fan terminal is connected to the zone controller via a phonejack which plugs into the receptacle marked Expansion on the Zone Controller. The relays on the board are pilot duty and must be field wired to the fan control relay and the heating relay in the fan terminal control box. After the wiring is complete and prior to operating the system, the dip switch on the zone controller has to be set. The dip switch marked A must be set to the OFF position: WIRING PROCEDURE GENERAL After the location of the components has been determined, the wiring may begin. The only line voltage wiring required is the power supply to the transformer(s). All the other wiring is low voltage (24 volts). All wiring should conform to national or local codes. TRANSFORMER The EZ Zone control system can be powered from one or more transformers. A single transformer may be used on installations where the 24-volt wiring will never be heavier than 16-gauge. Our Zone Controller cannot accommodate more than two 16- gauge wires per terminal. Multiple transformers may be preferred on larger jobs: To reduce the installed cost. Multiple small transformers and shorter wiring runs may be cheaper than one large transformer. To provide some stand-by protection. If a transformer for one or more zone dampers fails, the other transformers can keep the remainder of system in operation. To minimize the voltage drop through the 24-volt wiring. CAUTION: Be sure the ground side of the 24 volts ( GND ) is always connected to the same side of the line. Never cross the hot side of the line ( 24 VAC ) with the GND. POLARITY MUST BE OBSERVED! TRANSFORMER SIZING To size the transformer, the power requirement must be determined. To do this, refer to the Power Consumption data in Table 2, summarize the power required for all components, and apply a safety factor of 1.2. Example #1: An installation consists of four zone dampers and one bypass damper. Find the transformer size required. Solution: Components VA x 1.2 Safety Factor (1) Master 15 VA and Bypass 4 VA = 19.0 VA x 1.2 = 22.8 VA (4) Zone 4.0 VA ea. = 16.0 VA x 1.2 = 19.2 VA } 51.8 VA (4) Zone 6.8 VA ea. = 27.2 VA x 1.2 = 32.6 VA Total 74.6 VA Although a 75 VA transformer could be used to power the total system, we d recommend two separate transformers to reduce the voltage drop through the 24-volt wiring. A 25 VA transformer for the Master Controller and Bypass Damper. A 60 VA transformer for the four Zone Dampers and Zone Controllers. Example #2: Assume individual transformers are going to be used for each zone in the example above! What are the requirements? Master Controller and Bypass Damper: 15 VA + 4 VA = 19 VA x 1.2 = 22.8 VA Each Zone Controller and Zone Damper: 6.8 VA + 4 VA = 10.8 VA x 1.2 = 13.0 VA each Select a 25VA transformer or higher for the Master Controller and a 15 VA transformer or higher for each of the zones. POWER WIRE SIZING Next, determine the wire size for connecting the components to the transformer. For satisfactory operation, the voltage drop in the line should not exceed 1.2 volts. To determine the wire size for the system, refer to the Wire Sizing data in Table 2. Example: In reference to Example #1 under TRANSFORMER SIZING procedure, assume that the maximum distance from the transformer to the farthest component is 50 feet! What wire size should be used? Refer to Wire Sizing data in Table 2. A power requirement of 51.8 VA is between 32 and 52 VA. At 52 VA, #16 gauge wire is satisfactory for 55 ft. Therefore, #16 gauge wire will be safe for 51.8 VA at 50 feet distance. 18 Unitary Products Group

19 After the wire size has been selected, it can be daisy-chained from component to component until all units are connected. CAUTION: WHEN CONNECTING THE WIRES TO THE 24V TERMINAL BLOCK ON THE COMPONENTS, IT IS IMPERATIVE THAT ALL CONNECTIONS ARE POLARIZED. INCORRECT POLARITY COULD DESTROY THE TRANSFORMER AND/OR THE ELECTRONICS TG1Y Up to two additional zone dampers may be slaved to the controlling zone damper as shown on the diagram in Figure 9. Remove the phone cord with phone jack from the slave zone damper and connect terminals CW, COM and CCW to the like terminals on the controlling zone damper. If the zone sensor with adjustment and override is used, an additional wire is connected from AUX terminal on the sensor to AUX1" terminal on the zone controller. The terminals on the controllers are clearly marked as 24VAC and GND. Typically, power wiring consists of red and white or black and white leads. Connect the white wire to ground ( GND ) and the other color for the hot ( 24VAC ) side of the controller. Keeping white as the ground lead will help avoid cross connecting the power wiring in the system. MASTER CONTROLLER All wiring required to connect the Master Controller to the system components is shown in Figure 6. All the interconnecting wiring, with the exception of the connections to the air conditioning unit and the transformer, may be 18 gauge if the total length does not exceed 2,000 feet. Since the Master Controller is used in lieu of a system thermostat, the wiring to the air conditioning unit should be sized in the normal manner. Connections for the Supply Air Temperature Sensor are made to terminals #1 and ground (G) of the Master Controller. Splice the sensor leads using the crimp type splice connectors supplied in the bag of parts shipped with the supply air sensor. Do not use wire nuts as these may lead to intermittent connections. The Static Pressure Sensor has three leads marked IN, GND and OUT. The IN or red wire should connect to the +5V terminal on the board. The GND or green wire should connect to the terminal marked GND. The OUT or black wire should connect to the center terminal marked SIG. Use the crimp type splice connectors supplied in the bag of parts shipped with the Static Pressure Sensor. Do not use wire nuts when making these spliced connections. When connecting the bypass damper, plug the phone cable pigtail from the acutuator into the bypass interface. Remove the cover from the bypass interface and connect 4 wires between the bypass interface and the Master Controller as follows: BYPASS INTERFACE MASTER MONTROLLER Black Input Terminal 6 White Ground Green Output Relay 7 Yellow Output Relay 6 Be sure that the output relays 6 & 7 are connected to the 24VAC power terminal. Up to three additional bypass dampers can be slaved to the controlling initial bypass damper. As shown on the diagram in Figure 7. Plug the phone cable pigtail from the actuator into the bypass interface and connect the white, green and yellow wires ( in parallel) to the like terminals on the controlling initial bypass. The communication loop wiring is special and is covered under the COMMUNICATIONS LOOP section of this wiring procedure. ZONE CONTROLLER All the wiring necessary to connect a Zone Controller into the system is shown in Figure 8. The same precautions mentioned above regarding the transformer connections apply. Communications loop wiring is covered under the COMMUNICATIONS LOOP section of this wiring procedure. The phone-jack from the damper motor plugs into the zone controller - requiring no field wiring. The zone sensor hookup is as follows: TMP on the sensor connects to TEMP on the zone controller, and GND on the sensor connects to GND on the zone controller. FAN TERMINAL CONTROLLER A typical wiring diagram for auxillary heat is shown in the figure below. Different wiring circuits may be used for the other applications as needed. The phone jack from the fan terminal controller plugs into the zone controller plug marked expansion. PARALLEL FAN SERIES FAN com HEAT 2 HEAT 1 24 VAC TYPICAL AUXILLARY HEATING CONTROL COMMUNICATIONS LOOP The communications loop does not have to be daisy-chained in sequential order (address by address) from one zone controller to the next. Refer to Figures 10A & 10B for typical wire routing and terminal connection detail. Be consistent in connecting the communications wire. Use the same wire throughout the installation. Twisted-pair wires are usually either black and white or red and white. The drain wire is usually a bare wire, and the foil shield is wrapped around the twisted pair and the drain wires. On each controller, connect the white wire to the terminal labeled T and the colored wire (red or black) to the terminal labeled R. The drain wire must be connected to the terminal labeled S. The actual foil shield need not be connected. Plan the wiring for no more than two communication connections per zone controller. On larger systems, locate the master controller at a central location to reduce the required wire size. Make all connections at the controller terminals. Use only complete lengths of wire from controller to controller, and avoid making splices between the controller runs. All communications connections must be tight and secure. Be sure that the wires do not touch each other at the terminals. This is especially true of the drain wire which typically is not insulated. Keep the wire loop as orderly as possible to assist in tracking down any loop problems during system start-up. To avoid future problems, use wire ties to secure the communications loop to the building structure rather than allowing it to simply lay on the ceiling tile or in areas where it may be pulled loose. Many installation and start-up problems can be minimized by simply laying out the route of the communications wire on a floor plan prior to running the loop. Unitary Products Group 19 H G

20 KEYPAD DISPLAY FURNISHED ON COVER OF MASTER CONTROLLER FIG. 6 - MASTER CONTROLLER WIRING FIG. 7 - MASTER CONTROLLER WIRING w/slave DAMPER 20 Unitary Products Group

21 TG1Y ZONE SENSOR TSO SHIELDED TWISTED PAIR WITH DRAIN WIRE CORD WITH PHONE JACK FURNISHED WITH ZONE DAMPER AND DAMPER MOTOR FIG. 8 - ZONE CONTROL WIRING w/zone SENSOR FIG. 9 - ZONE CONTROL WIRING w/adjustable ZONE SENSOR AND MULITPLE ZONE DAMPER MOTORS Unitary Products Group 21

22 ZONE CONTROLLERS ZONE CONTROLLERS ADDRESS 5 DETAIL A (typical) ADDRESS 5 ADDRESS 3 DETAIL A ADDRESS 3 ADDRESS 2 MASTER CONTROLLER ADDRESS 2 ADDRESS 6 ADDRESS 6 ADDRESS 4 ADDRESS 4 ADDRESS 1 ADDRESS 1 MASTER CONTROLLER FIG TYPICAL COMMUNICATIONS WIRING FIG. 10A - ALTERNATIVE COMMUNICATIONS 22 Unitary Products Group

23 MODEM LINC CENTRAL WIRING Wiring to the Modem Linc Central is accomplished by connecting a twisted pair with drain wire ( # or equivalent) from the connector labeled "485 Loop" to the "Network" connector on the Master Interface Board. Additional Master Controllers may be daisy-chained together following the same procedures as shown in Figure 11. MODEM CONNECTIONS Plug the 9-pin connector to the back of the 9-pin socket on the Model Linc Central TG1Y If the building has multiple units, the zones on unit 1 could be addressed 1 thru 7, and the zones on unit 2 could be addressed 8 thru 14. If the building drawings do not specify the zone by number, each zone should be assigned an identification number and recorded on the labels in the bag of parts shipped with the Master Controller. In addition to the master location label, additional labels are provided for the zone damper and each zone sensor. The address setting on the Zone Controller circuit board should correspond with the zone number placed on each label. The address of a particular Zone Controller is set using the block of 8 DIP switches. Next to the block, silk-screened on the controller board itself are the switch designations: 1,2,4,8,16,A,B,C. Disregard any numbers that may appear directly on address block when assigning zone addresses. Plug the 25-pin connector to the 25-pin socket on the back of the modem. Connect the phone line RJ11 jack into the modem. SETTING THE ADDRESS SWITCH Before the cover is replaced on the Zone Controller, the address switch must be set to the proper position. Each zone is to have a separate address, beginning with the first address and continuing through the total number of Zone Controllers included in the system. Do not skip any number or a missing zone alarm will appear on the screen. The address switches in the Master Controller are factory set in the OFF position and should NOT be changed. The system will not communicate if these switches are set in the ON position. A switch will ADD its value when its rocker is depressed toward the numbering on the circuit board in the direction as indicated by the arrow. A switch is OFF if the rocker is depressed away from the numbering and in the opposite direction shown by the arrow. DIP switches are sometimes known to fail to seat. When setting the switches, be certain that they were firmly turned to the ADD or OFF position as required. DIP switch addressing must be altered when the Controllers are powered off. If an address is changed when power is applied to the board, it will not be read until the board is powered off and then back on again. Address cards are supplied with each Zone Controller showing the complete addressing scheme for every address number from 1 thru 16. The black end of the switch indicates the end to be pushed down. MASTER INTERFACE BOARD MASTER INTERFACE BOARD FIG TYPICAL APPLICATION DIAGRAM Unitary Products Group 23

24 MONITORING AND PROGRAMMING INITIALIZATION SCREEN The Keypad/Display on the Master Controller cover is an electronic device that is used to monitor and / or program the EZ Zone system. Also included on the cover are status LED s that show the current system operating condition. MONITORING PROCEDURE 1. Keypad operation - The functions of the keys during the monitoring process are as follows:: APPEARS AFTER COUNTDOWN DELAY APPEARS AFTER COUNTDOWN DELAY A Used to access the current temperature status of all zones B Used to access the current status of individual zones BYPASS CALIBRATION SCREEN C Used to access the status of the HVAC unit * 0 # D Used to access the current alarm status Used to advance to the next screen The numbered keys are used to access the individual zones by using their respective assigned address identification number. No passcode is required to view Reporting Screens. The operator has free access to monitor the data. 2. Reporting Screens: a. Initialization Screen - When power is first applied to the Master Controller, an Initialization screen appears. For approximately 12 seconds, the system goes through several internal diagnostic checks. Next, a Start-up Delay screen appears. This screen displays a 50 second countdown. At the same time, the LED s extinguish one by one, every few seconds. The countdown screen also displays the current number of zones for which the total system has been configured as well as the time and date. If any of this information is incorrect, the Master Controller should be re-programmed for the correct system set-up. When the last LED extinguishes at the end of the 50-second countdown, a theird screen appears. This is the Bypass Calibration screen. It remains active for 2-3 minutes while the bypass damper goes through a self check routine. The Bypass Open and Bypass Closed LED s indicate the direction of the actuator. Following this, the Main Reporting Screen appears. b. Main Reporting Screen - In addition to displaying the EZ Zone logo, the main reporting screen shows the current date and time, the current mode of operation and whether or not any diagnostic alarms are present. Occupied Override Fan Only Unoccupied Override Zone Only The modes of operation include the automatic Occupied and Unoccupied periods as well as the following special override conditions: Explanations for each of these conditions appear later in the programming section. Bad Duct Sensor Bad Static Sensor Bypass Damper Failure Static Null The Alarm message appears only if alarms are active. The Master Controller monitors the following alarm conditions with respect to the HVAC operation: 24 Unitary Products Group

25 If the static sensor is defective or miswired, a static null alarm appears. If the fan starts and the static pressure is not within limits, a bad static sensor appears. The following four alarms are monitored for each of the zones: Bad Zone Sensor Maverick Zone Zone Damper Failure Missing Zone d. Individual Zones Status - To access a complete status report of an individual zone, press the B key. The following screen will immediately appear: INDIVIDUAL ZONE REPORTS PRESS B KEY ON KEYPAD TG1Y Explanations for each of these conditions appear later in the programming section. All alarm messages with the exception of the static null alarm will automatically clear once the problem is repaired. MAIN REPORTING SCREEN Enter the number of the zone to be monitored on the numerical keyboard. The display will automatically scroll through 3 more screens as follows: INDIVIDUAL ZONE DAMPER REPORTS CONTINUED REPORTS ADVANCE MAY ALSO READ ONLY IF ALARM "UNOCCUPIED" IS DETECTED "ZONE OVERRIDE" "OCCUPIED OVERRIDE" "UNOCCUPIED OVERRIDE" OR "FAN ONLY" c. Temperature Status Screen - To access the temperature status of all the zones, press the A key. The display will automatically scroll through as many screens as it takes to read the number of zones attached to the system. The actual zone temperature is displayed as well as the actual heating and cooling setpoints to which the zone is trying to control. If the zone has the adjustable room sensor, the setpoint adjustment will already be calculated into the displayed heating and cooling setpoint. Each screen displays for approximately 30 seconds. However, it is possible to move to the next screen by pressing the # key without having to wait for the screen to automatically advance. AUTO. ADV. INDIVIDUAL ZONE REPORTS - TEMP & STPTS CONTINUED REPORTS ADVANCE ZONE TEMP & STPT REPORTS PRESS "A" KEY ON KEYPAD INDIVIDUAL ZONE VENT REPORTS CONTINUED REPORTS ADVANCE AUTO. ADV. SCREENS AUTOMATICALLY ADVANCE FOR ALL ZONES ONLY IF OPTIONAL FAN TERMINAL TERMINAL IS ATTACHED TO THE ZONE CONTROLLER ALSO, NO REPORT IF AUX HEAT IS "OFF" As in the A key, these screens will move slowly but automatically. If you desire to get to another screen more quickly or back to the main screen, simply press the # key. Unitary Products Group 25

26 The B key will report not only the temperature and heating/cooling setpoints for each zone, but it will display the zone damper s minimum, maximum and vent position setpoints as well as the actual damper position. If the adjustable zone sensor is used, the amount of adjustment set by the sliding potentiometer is shown. This is any value from ± 2 F from the heating and cooling setpoints. If the non-adjustable zone sensor is used, this value will read zero. The diagram, shown in Figure 12, may be useful as a quick reference guide to summarize the sequences displayed on the foregoing reporting screens of the EZ Zone system. If a fan terminal controller is attached to the zone controller, an AUX HEAT ON message will appear any time the zone calls for additional heating. e. HVAC System Status - If the C key is pressed, the supply air temperature is displayed. Also shown are the duct static pressure and the current position of the bypass damper. The screen will automatically exit to the main screen or it can be advanced to the main screen with the # key. HVAC STATUS REPORT PRESS C KEY ON KEYPAD f. Alarm Status Report - Any alarm messages indicated at the main screen may be viewed by pressing the D key. Three different alarms for the HVAC system and four alarms for each zone may be displayed. In the case of zone alarms, the zone number to which the alarm applies is also shown. If their are no alarms for either the HVAC unit or the zones, the screen so indicates. Like the other screens, this screen will advance automatically or may be advanced using the # key. ALARM STATUS REPORT PRESS D KEY ON KEYPAD OR MAY ALSO REPORT: "BAD ZONE SENSOR" "BAD DUCT SENSOR" "ZONE DAMPER FAIL" "BAD STATIC SENSOR" "MAVERICK ZONE" "BYPASS DAMPER FAIL" "MISSING ZONE" "STATIC NULL" (ALSO IDENTIFIES ZONE SENDING ALARM) FIG. 12- TYPICAL REPORTING SCREENS DISPLAY 26 Unitary Products Group

27 PROGRAMMING PROCEDURE 1. Passcode - To program the system, enter code 9675" (the telephone dial equivalent to the name YORK ). It may be entered any time the Main Reporting Screen is being displayed. Merely begin entering the 4 digits and the following line will be added to the bottom line of the display: MAIN SCREEN ENTER ACCESS CODE FOR PROGRAMMING 2. Keypad Operation - The functions of the keys during the programming process are as follows: A B C TG1Y Note: Use of numerals is explained as required in the process. Used for correction and for clearing the screen before making a change * 0 # D If the access code is not valid, the display will appear briefly with the following message: MAIN SCREEN INCORRECT ACCESS CODE ENTERED Used to enter a decimal point when called for Used to advance to the next screen, from line to line or to close out an entry 3. Selection from Main Menu - There are 3 options available from the main menu. They pertain to the operation, configuration and override modes of both the zones and the system. Pressing either the 1, 2 or 3 key will activate the desired option. 4. Change Operation - Press the 1 key and the following sub-menu will appear... If the access code is valid, the display will appear briefly with the following message: SUB-MENU PROGRAMMING SCREEN PRESS A NUMBER TO "SELECT" - # SYMBOL TO "EXIT" MAIN SCREEN CORRECT ACCESS CODE ENTERED... and a selection has to be made from this sub-menu. After the passcode has been successfully entered and access is approved, the screen will automatically advance or you may press the # key. The main programming menu screen will appear. MAIN MENU PROGRAMMING SCREEN By pressing the 1 key, the following screen will appear: ZONE SETPOINT PROGRAMMING SCREEN PRESS 1 ON KEYPAD TO "ENTER" Unitary Products Group 27

28 Enter the number of the respective zone setpoints you wish to change. For example, press the 12 and the # keys, and the following screen will appear: SUB-MENU PROGRAMMING SCREEN PRESS A NUMBER TO "SELECT" - # SYMBOL TO "EXIT" ZONE SETPOINT PROGRAMMING SCREEN ENTER DESIRED ZONE NUMBER If you wish to change the HVAC system s setpoints, press the 2 and # keys. When the following screen appears, you can change the system static pressure, unoccupied cool temperature and unoccupied heat temperature. The procedure for acknowledging or changing the setpoints is the same as described above with the cursor under the first digit of the zone number. The cursor, a small black line _, will be located under the first digit of the cooling setpoint, indicating that you can change the value. If you wish to make a change, enter the new setpoint. If you make a mistake, press C and enter the correct setpoint. If the new setpoint is correct, press the # key. HVAC SETPOINTS PROGRAMMING SCREEN PRESS 2 ON KEYPAD For each setpoint, there are high and low limits. Refer to SETPOINTS AND DEFAULTS section on page 14 for a listing of maximum, minimum and default values. The cooling setpoint must always be 2 F above the heating setpoint, or the entered value will automatically reset the heating setpoint 2 F lower. If you do not wish to change the cooling setpoint, you just press the # key without entering a new setpoint. After the # key has been pressed, the cursor will move under the first digit of the heating setpoint. Just as above, you can change the setpoint or leave it as is. The accepted range is between 50 and 80 F. However, the heating setpoint must always be at least 2 F below the cooling setpoint. Once the new setpoints have been entered or the old setpoints acknowledged by pressing the # key, the following screen will appear: When changing the Static pressure setpoint, the key is used to enter a decimal point. The unoccupied heating setpoint must be set at least 2 degrees below the unoccupied cooling setpoint. After the setpoints are entered or acknowledged, the screen returns to the sub-menu. SUB-MENU PROGRAMMING SCREEN PRESS A NUMBER TO "SELECT" - # SYMBOL TO "EXIT" ZONE DAMPER PROGRAMMING SCREEN PRESS # ON KEYPAD TO "STEP" To change time, date, scheduling, or holidays, press 3 key, and the following screen appears. SUBMENU PROGRAMMING SCREEN PRESS A NUMBER ON KEYPAD TO "SELECT" The procedure to change the minimum and maximum damper position is the same as above with the cursor under the first digit of the zone number. The acceptable range for the setpoints is anywhere between 0-100% open. The minimum position can be less than or equal to the maximum position, but cannot be greater than the maximum position. For vent applications, the minimum setpoint is at least 10% for minimum ventilation. The vent position setpoint applies when the zone controller goes into the recirculation or Vent Mode. The position can be equal to or between the minimum and maximum position setpoints. It cannot be larger than the maximum setpoint or smaller than the minimum setpoint. Although 50% is normal, a higher setpoint will provide more ventilation when the unit is neither heating nor cooling. If you wish to change the occupied/unoccupied schedule, press the 1 and # keys, and the following screen will appear: SETTING SCHEDULE PROGRAMMING SCREEN PRESS 3 ON KEYPAD Once the new damper positions have been entered or the old ones acknowledged by pressing the # key, then the sub-menu screen will re-appear. CONTINUE FOR EACH DAY OF THE WEEK 28 Unitary Products Group

29 Both START and STOP are in military time. The procedure for acknowledging or changing these times is the same as described above with the cursor under the first digit of the start time. If you want the system to remain in the unoccupied mode for the entire day (from midnight of the previous day to midnight of the next day), enter 0 in both the Start Time and the Stop Time fields. If you want the system to remain in the occupied mode for the entire day, enter 2359 in both the Start Time and the Stop Time fields. After the START/STOP times have been entered for Sunday, the screen for Monday appears: CONTINUING SCHEDULE PROGRAMMING MONDAY- PRESS # TO "STEP" TG1Y After changing or acknowledging the day and time, the following screen allows you to enter the month, day of the month and year. SETTING TIME/DATE PROGRAMMING SCREEN PRESS # TO "STEP" After the month, day of the month and year have been changed or acknowledged, the display will return to the sub-menu. SUBMENU PROGRAMMING SCREEN PRESS A NUMBER ON KEYPAD TO "SELECT" The screens for Tuesday, Wednesday, Thursday, Friday and Saturday all appear sequentially. When all the START/STOP times have been entered or acknowledged, the sub-menu screen reappears. SUBMENU PROGRAMMING SCREEN PRESS A NUMBER ON KEYPAD TO "SELECT" If you wish to change the holidays, press the 3 key, and the following screen appears: SUBMENU PROGRAMMING SCREEN If you wish to change the current time and date, press the 2 key and the following screen will appear: SETTING TIME/DATE PROGRAMMING SCREEN PRESS 2 ON KEYPAD For each holiday, enter a four digit number consisting of the month (from 1 to 12) and the day of the month (from 1 to 31). The holiday # will advance from 1 to 11 as each holiday is entered. After Holiday 11 is entered, the sub-menu screen appears. The day and time can be changed or acknowledged in the same manner as described above with the cursor under the digit for DAY. Day 1 is Sunday, Day 2 is Monday, Day 3 is Tuesday, Day 4 is Wednesday, Day 5 is Thursday, Day 6 is Friday, and Day 7 is Saturday. Time is military. SUBMENU PROGRAMMING SCREEN PRESS A NUMBER ON KEYPAD TO "SELECT" Unitary Products Group 29

30 To return to the Previous Menu, press the 4 key. SUB-MENU PROGRAMMING SCREEN PRESS A NUMBER TO "SELECT" - # SYMBOL TO "EXIT" After changing or acknowledging the stages of cooling and heating and the zone addresses, the screen will scroll to the following: CONFIGURE SYSTEM PROGRAMMING SCREEN PRESS "#" TO "STEP" If you wish to return to the main menu screen, press the # key and the main menu will appear as follows: MAIN MENU PROGRAMMING SCREEN The type of heat must be entered by pressing either the 0 key for Electric Heat and Heat Pump or the 1 key for Gas Heat. If desiring to display temperature in Fahrenheit, enter a 0. Entering a 1 will cause the display to read out in Celsius. Press the # key, and the main menu will reappear. MAIN MENU PROGRAMMING SCREEN If you wish to change or examine the systems configuration, press the 2 key and the following screen will appear: CONFIGURE SYSTEM PROGRAMMING SCREEN If you want to manually override the system, press the 3 key and the following screen will appear: SYSTEM OVERRIDE PROGRAMMING SCREEN PRESS #3 ON KEYPAD PRESS #2 ON KEYPAD The mode of operation may be changed by pressing the appropriate number and the # key. This system is set up for a unit that is 2 stage heat/2 stage cool. You can change the number of stages of cooling or heating or acknowledge the current number of stages as described above with the cursor under the digit for cooling stages. For the number of cooling stages, you may enter a 0, 1 or 2. Entering a 0 locks out the cooling entirely, a 1 is for 1-stage of cooling, and a 2 is for 2 stages of cooling. For the heating field, only a 1 or a 2 may be entered. For proper operation of the EZ Zone system, the last and the first zones must be addressed correctly. The system ASSUMES and DEMANDS that all the zones on any given heating/cooling unit be addressed in sequence. In the example system, the screen implies that zones 9, 10, 11, 12, 13, 14, 15, and 16 are all ducted to the same heating/cooling unit. Zone 13 can NOT be connected to another heating/cooling unit. 0 = Auto operation means the system will function according to the programmed TIME CLOCK schedule. 1 = Occupied operation means the system will operate continuously in the occupied mode, regardless of the TIME CLOCK schedule. 2 = Unoccupied operation means the system will be operating continuously in the unoccupied mode, regardless of the TIME CLOCK schedule. Note, however, that pressing the override button on the adjustable zone sensor will switch system operation to the occupied mode for 2 hours. 3 = Fan Only operation means only the fan will run. Heating and cooling will be locked out. The latter mode can be used when mechanically balancing the system to deliver the proper CFM to each zone at full load CFM. It may also be used to ventilate the conditioned space. After changing or acknowledging the mode, the main menu will reappear. 30 Unitary Products Group

31 MAIN MENU PROGRAMMING SCREEN MAIN REPORTING SCREEN To exit from the main menu back to the main reporting screen, press the # key. The main display screen will reappear as follows: MAY ALSO READ ONLY IF ALARM "UNOCCUPIED" IS DETECTED "ZONE OVERRIDE" "OCCUPIED OVERRIDE" "UNOCCUPIED OVERRIDE" OR "FAN ONLY" The diagram, shown in Figure 13 may be useful as a quick reference guide to summarize the sequences displayed on the foregoing programming screens of the EZ Zone system. The passcode must be re-entered to return to the programming screens. MAIN SCREEN EZ ZONE 01/05/90 17:21 FRI OCCUPIED CODE XXXX DISPLAYS WHEN CODE IS ENTERED PRESS "1" KEY ENTER ZONE # "C" TO CLEAR "*" FOR DECIMAL "#" TO STEP ZONE SETPOINTS ZONE NUMBER 12 COOL SETPOINT 75.3 HEAT SETPOINT 70.1 ZONE DAMPER % POS ENTER ACCESS CODE PRESS "1" TO ENTER PRESS "#" TO EXIT ZONE NUMBER 12 MAX % POSITION 90 MIN % POSITION 10 VENT % POSITION 50 MAIN MENU PROGRAMMING SCREEN 1 CHANGE OPERATION 2 CONFIGURE SYSTEM 3 OVERRIDE SYSTEM PRESS # TO EXIT SUB-MENU PROGRAMMING SCREEN 1 ZONE SETPOINTS 2 HVAC SETPOINTS 3 SCHEDULE 4 TIME/DATE PRESS "2" KEY "C" TO CLEAR "*" FOR DECIMAL "#" TO STEP HVAC SETPOINTS HVAC SETPOINTS STATIC PRESS.4 UNOCC COOL 85 UNOCC HEAT 60 PRESS "2" KEY "C" TO CLEAR ENTER NEW NUMBER "#" TO STEP CONFIGURE SYSTEM COOLING STAGES 2 HEATING STAGES 2 LAST ZONE ADDR 03 FIRST ZONE ADDR 01 PRESS "3" KEY "C" TO CLEAR "#" TO STEP SCHEDULE SCHEDULE SUNDAY START = 0530 STOP = 1930 REPEATS FOR EACH DAY OF THE WEEK PRESS "3" KEY ENTER CHOICE OVERRIDE SYSTEM OVERRIDE TIME CLOCK 0=AUTO 1=OCCUPIED 2=UNOCC 3=FAN ONLY ENTER MODE ENTER TYPE OF HEAT 0=ELECTRIC 1=GAS ENTER TYPE OF TEMP 0=DEG F 1=DEG C PRESS "4" KEY "C" TO CLEAR "#" TO STEP TIME / DATE TIME/DATE DAY (SUN=1) 1 TIME 1107 TIME/DATE MONTH ( 1-12) 11 DATE ( 1-31) 07 YEAR (00-99) 90 NOTES: THE "#" KEY IS USED TO STEP FROM SCREEN TO SCREEN AND FROM LINE TO LINE. IT IS THE "ENTER" KEY. THE "C" KEY IS USED FOR CORRECTION AND FOR CLEARING THE SCREEN BEFORE MAKING CHANGES. THE "*" KEY IS USED TO ENTER A DECIMAL POINT WHEN CALLED FOR. IT IS ALSO USED TO EXIT THE PROGRAMMING SEQUENCE AND RETURN TO THE MAIN SCREEN. FIG TYPICAL PROGRAMMING SCREENS DISPLAY Unitary Products Group 31

32 FIG Alternate Actuator Connections P.O. Box 1592, York, Pennsylvania USA Subject to change without notice. Printed in U.S.A Copyright by York International Corporation All Rights Reserved. Codes: EBY, EGY TG1Y Supersedes: TG1Y(494)