The ZC 107 Zone Control System was designed to provide the perfect comfort control within the home. At the same time it was designed to make an airconditioning system work more efficiently and thereby help significantly save on energy costs. The ZC 107 Zone Control System knows exactly what the cooling requirement is in each room at any given time and automatically adjusts the operation of the airconditioning system to provide the necessary amount of comfort conditions to a particular area. SYSTEM CONFIGURATION The system enables connecting up to 7 dampers with damper control devices to one ducted airconditioning system. The damper and it s motor (C315) is located inside the flexible ducts. The ZC 107 Zone Control Master Control should be positioned within the roof space near the airhandler and for convenience sake near the access door to the ceiling void. The operation Panel (C 206) should be located in a central position within the home for easy access and operational control. SYSTEM COMPONENTS AND FEATURES Encased in a Fireproof ABS Plastic Casing Nominal Voltage 230 V 50Hz Protection against line voltage drops Has outputs for two compressors Compatible with a 3 speed Evaporator Fan Works with Heat Pump Systems Two temperature sensors to protect against freezing and high head pressure in both the indoor evaporator and the outdoor condenser 5 minute anti short cycle delay to protect the two compressors While cooling the evaporator fan runs continuously (fan on) While heating the evaporator fan runs only in parallel to the compressor operation (fan auto) Pilot lamp to indicate line voltage 8 Pilot lamps indicating connection of damper to the control box (ZC 107) (at each damper input on the controller) Operates up to 7 dampers and one bypass damper unit Voltage disconnection relay for power supply to the power supply box (C 315)
OPERATION LOGIC OF THE ZC 107 ZONE CONTROL SYSTEM The core of the system is the ZC 107 Master Control Box, which automatically identifies the number of dampers connected to it and the opening position of each damper. The controller will check and test to verify whether or not a damper is connected to each input. This operation is automatic and no manual action is required. During operation the controller calculates the airconditioning load. According to the accumulation of the total openings of the dampers, the airconditioning system operation is adjusted to the required level of airconditioning comfort that is required at any specific time. Furthermore, the system controller controls Evaporator Fan Speeds Two compressors (serving as first and second stage) Heat Pumps which operate in heating mode through a reversing valve Condenser Fan The controller includes two temperature sensors, which should be positioned inside the indoor evaporator to protect against the freezing of the coil and against high head pressure within the compressors. These sensors should be mounted on the evaporator coil two-thirds up measuring from the bottom of the coil. All elements within the indoor evaporator and the outdoor condenser are controlled by the ZC 107 Master Zone Control Board. The ZC 107 controls the compressors, evaporator fan speeds, condenser fan and the by-pass according to the percentage of the damper opening. (not according to the temperature) DAMPER CONTROL The dampers are controlled by any one of the following : 128DD Standard Thermostat 650DD Flush Mount Thermostat or RC 11 Wireless Thermostat. Either of these thermostats will control the damper. It is possible to use any configuration of these thermostats in any one system. The connection between each damper and the main controller will be via RJ11 cable connectors. The percentage of the openings are calculated as the opening angle, (which controls the airflow within the duct) and not the mechanical angle of the damper. Both the damper and temperature control in each room will be taken care by either one of these thermostats. The only information that is sent to the main controller is the angle of each damper within each area. The main controller will turn off the power to either of the thermostats if necessary. POTENTIOMETER On each damper motor, a potentiometer is connected to the shaft and it indicates the position of the damper. Because of this the ZC 107 Master Control Board will know each damper opening percentage and it will therefore be able to avoid a high-pressure situation by reducing the airflow at each damper point if necessary. It is possible to have a system configuration of less than 7 dampers. The main controller automatically tests to see how many dampers are connected to it. Based on that initialization check, the controller will divide the full capacity between the number of dampers connected to it.
So in the case of 5 dampers, the full capacity will be (5/5) divided between 5 dampers and so on. Each damper input has a LED connected to it. If the processor detects that no damper has been connected then that LED light will switch on giving a clear indication that no damper has been connected. This will provide the installer with a clear diagnostic feature as to which dampers are not connected to the system. REDUCING AND CONTROLLING THE AIRFLOW The ZC 107 Master Control will receive a maximum of 7 damper potentiometers. The by-pass damper will not use a potentiometer. When the damper start to close, the main controller will also start to reduce the evaporators indoor fan speed, remove the second stage compressor (if available) and start opening the by-pass damper accordingly. The ZC 107 will allow two rooms to have bigger size dampers, twice the size of a standard damper. The two rooms will be defined by using two dip switches on the ZC 107 main board. In the case that twice the size damper will be used, then the calculation of the dampers opening will be based on 8 damper or 9 damper units [8/8] or [9/9]. The openings of dampers are measured in airflow and not in the angle of the opening. DEFROST The defrost logic (deice) will operate according to the temperatures at the two deice sensors. On Cooling Mode the fan will run continuously On Heating Mode the fan will run (Auto) per demand (Only when the compressor runs) The reversing valve will be energized on Heating Mode 5 Minute Anti Short cycle timer will apply to both compressors A jumper wire will determine if the controller works as a HEAT PUMP or FAN COIL. If it is a HEAT PUMP system, then all operation of the compressor and reversing valve are controlled. If it is a standard FAN COIL, then the compressor relay will be used for heating and the reversing relay will be used for cooling. In the FAN COIL option, there will be no requirement for the 5-minute anti short cycle timer. OPERATING PANEL The main operating panel is a wallpad that should ideally be mounted in a suitable accessible area. This main operating panel is called C206 and is able to instruct the system to HEAT / COOL or to provide FAN only. The entire system is switched on or off from this operating panel. The C206 is also able to provide various programming and timing features. FAN ONLY It is possible to select the FAN ONLY option at the C206 operation panel. In this mode the indoor fan will operate according to the percentage of the damper openings. Fan speed and by-pass damper will operate as per the logic set in the master controller. CHILLED WATER FAN COILS This system can also be used with chilled water fan coils.
DESCRIPTION OF OPERATION When the system is switched ON for the first time, the fan will run at high speed for 7 minutes to quickly overcome the internal heat load. After 7 minutes the system will return to automatic operation, and the controller will identify the total openings of the dampers. It will also calculate the airconditioning load requirement and adjust the airconditioning system to operate accordingly. Consequently, with the decrease in the cooling or heat load, the evaporator fan speed will decrease, one compressor will stop its operation and in parallel, the bypass damper will open to recycle the surplus air volume within the system. CALIBRATION AND PRECISION The system performs automatic calibration to each damper unit, thus reaching the maximum precision in opening and closing percentages of each damper separately. SWITCHING THE SYSTEM OFF When an OFF command is received from the operation panel (C 206), all dampers will fully open automatically and the by-pass will close. PRIMARY SETTING OF THE SYSTEM The controller ZC 107 is equipped with small dip switches, by which the operating mode of the system is determined. In ON Mode the following functions are activated : DIP SWITCH # 1 = defines that in channel no 1 the damper connected is a large damper sized 10 (250mm diameter) or sized 12 (300mm diameter) DIP SWITCH # 2 = determines in respect of the control system, if there are any air openings without dampers. In this mode, the evaporator fan will always operate at high speed, and the system will not discontinue it s operation as a result of closing the connected dampers but only by disconnection from the operating panel (C 206) DIP SWITCH # 3 = determines that the system is a fan coil DIP SWITCH # 4 = NOT IN USE Each damper input channel on the controller has a red pilot lamp indicating the connection of a damper to the controller. A green lighted pilot lamp indicates (a) that the damper has not been connected (b) the connection is faulty OR (c) that no damper is connected to this channel
INSTALLATION PROCEDURE Remove the cover of the ZC 107 The fuse that is supplied within the master controller is rated at 10 Amps Using the same four screws mount the box base to the evaporator body or preferably on to a secure mounting near the access door to the roof void On one side of the ZC 107 box bring in the 220 Volt line voltage and at the other side take out the low voltage connections to the dampers and the evaporator coil sensors For connection to the airconditioning system it is recommended that wiring of a minimum 0.75 thickness should be used Do not join cabling on site. Only use full-length cables that can be supplied at the time of order. The temperature sensors must be installed inside the condenser and evaporator coils. These sensors can be extended as required using screw terminals. On completion of the installation return the ZC 107 cover and cover the PCB CABLE COLOURS RJ11 WHITE goes from the ZC 107 Master Controller (right side) to the C206 Wallpad Operating panel as well as to the by-pass damper motor. RJ11 WHITE goes from the any of the thermostats (650DD)(128DD) or (RC11) to the appropriate power box (C315). RJ11 BLACK goes from the ZC 107 Master Controller to the appropriate damper motor. RJ11 RED goes from the ZC 107 Master Controller to the by-pass damper motor only. DO NOT PUT WHITE RJ11 CABLING INTO THE MASTER CONTROL BOX ZC 107 START UP PROCEDURE 1. Connect voltage to the ZC 107 Master Control Board. This will also enable the supply of power to the C 315 power supply boxes. The entire system will be switched on once the Operation Panel (C 206) has been switched ON. 2. Examine the independent and proper operation of each damper in each zone. To do this, activate the Operation Panel (C 206) in VENTILATION Mode only. In this mode only air circulation will be achieved within the system. The correct installation and operation of each damper is vital to the operation of the ZC 107. 3. Once the dampers have been examined in each zone and their operation is confirmed the Operation Panel (C 206) can be switched into cooling or heating mode. 4. Ensure that all indoor evaporator fan speeds are functioning, which can be examined by controlled closing of the dampers, by changing, one by one, the desired temperature. Check that the heat pump is activated in heating mode on the Operation Panel (C 206) Check that the cooling mode is activated in cooling mode on the Operation Panel (C 206) Check the functioning of the two compressors Check the condenser fan operation and the operation of the by-pass damper
BY-PASS DAMPER The by-pass damper must be sized according to the airhandling unit that is being used. The recommended guideline is 36 000 Btu should use a 8 (203mm) by-pass damper 48 000 Btu should use a 10 (254mm) by-pass damper 60 000 Btu should use a 12 (304mm) by-pass damper DUCT DESIGN When a zone control system is being designed, the sizing of ducting should be increased by one size, to allow for the increased pressurization as a result of the by-pass damper. SAFETY AND WARNING INSTRUCTIONS Before starting installation, ensure that ALL system components have been disconnected from the 220 Volt power line. During installation of the ZC 107 control box, the evaporator, the condenser, the power supply boxes must all remain disconnected from the power line until the entire system is ready to be switched on. Installation MUST BE carried out ONLY by certified technicians who are familiar with the procedures of installation regarding this system These systems are intended for installation inside of buildings only. Keep all the system components out of the reach of all unqualified people. If the airconditioning system is not properly designed, it will affect the accuracy of the zone control system considerably. Ensure, before installation that the airconditioning design is compliant with the area it is being designed to cool. The correct installation of the flexible ducts and dampers is vital to the performance of the entire system. A balanced airflow to all the diffuser points, when the dampers are all open must be assured. Do not install the control box in an environment where the temperature may rise to higher than 70 C