INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS Observer Zning Bard ZONE0101ZP6 These instructins must be read and understd cmpletely befre attempting installatin Safety Labeling and Signal Wrds DANGER, WARNING, CAUTION, and NOTE The signal wrds DANGER, WARNING, CAUTION, and NOTE are used t identify levels f hazard seriusness. The signal wrd DANGER is nly used n prduct labels t signify an immediate hazard. The signal wrds WARNING, CAUTION, and NOTE will be used n prduct labels and thrughut this manual and ther manual that may apply t the prduct. DANGER Immediate hazards which will result in severe persnal injury r death. WARNING Hazards r unsafe practices which culd result in severe persnal injury r death. CAUTION Hazards r unsafe practices which may result in minr persnal injury r prduct r prperty damage. NOTE Used t highlight suggestins which will result in enhanced installatin, reliability, r peratin. Signal Wrds in Manuals The signal wrd WARNING is used thrughut this manual in the fllwing manner:! WARNING The signal wrd CAUTION is used thrughut this manual in the fllwing manner:! CAUTION Signal Wrds n Prduct Labeling Signal wrds are used in cmbinatin with clrs and/r pictures r prduct labels.! WARNING PERSONAL INJURY, AND/OR PROPERTY DAMAGE HAZARD Failure t carefully read and fllw this warning culd result in equipment malfunctin, prperty damage, persnal injury and/r death. Installatin r repairs made by unqualified persns culd result in equipment malfunctin, prperty damage, persnal injury and/r death. The infrmatin cntained in this manual is intended fr use by a qualified service technician familiar with safety prcedures and equipped with prper tls and test instruments. Installatin must cnfrm with lcal building cdes and with the natinal Electrical Cde NFPA70 current editin r Canadian Electrical Cde part 1 CSA C..1. The Natinal Fuel Gas Cde (NFGC) NFPA 54/ANSI Z3.1, and in Canada refer t the current editins f the Natinal Standards f Canada CAN/CSA B149.1 and. Natural Gas and Prpane Installatin cdes.! WARNING ELECTRICAL SHOCK HAZARD Failure t fllw this warning culd result in persnal injury r death. Befre installing r servicing system, always turn ff main pwer t system and install lckut tag. There may be mre than ne discnnect switch.! CAUTION CUT HAZARD Failure t fllw this warning culd result in persnal injury. When remving access panels r perfrming maintenance functins inside yur unit, be aware f sharp sheet metal parts and screws. Althugh special care is taken t reduce sharp edges t a minimum, be extremely careful and wear apprpriate clthing, safety glasses, and glves when handling parts r reaching int the unit. 616 01 1301 00 3 10 14

NOTE: Read the entire instructin manual befre starting the installatin. SAFETY CONSIDERATIONS Imprper installatin, adjustment, alteratin, service maintenance, r use can cause explsin, fire, electrical shck, r ther cnditins which may cause death, persnal injury, r prperty damage. Cnsult a qualified installer, service agency, r yur distributr r branch fr infrmatin r assistance. The qualified installer r agency must use factry authrized kits r accessries when mdifying this prduct. Refer t the individual instructins packaged with the kits r accessries when installing. Fllw all safety cdes. Wear safety glasses, prtective clthing, and wrk glves. Have a fire extinguisher available. Read these instructins thrughly and fllw all warnings r cautins included in literature and attached t the unit. cnsult lcal building cdes, the current editins f the Natinal Fuel Gas Cde (NFGC) NFPA 54/ANSI Z3.1, and the Natinal Electrical Cde (NEC) NFPA 70. In Canada refer t the current editins f the Natinal Standards f Canada CAN/CSA B149.1 and. Natural Gas and Prpane Installatin cdes, and Canadian Electrical Cde CSA C.1 Recgnize safety infrmatin. This is the safety alert symbl. When yu see this symbl n the unit and in instructins r manuals, be alert t the ptential fr persnal injury. Understand these signal wrds: DANGER, WARNING, and CAUTION. These wrds are used with the safety alert symbl. DANGER identifies the mst serius hazards which will result in severe persnal injury r death. WARNING signifies hazards which culd result in persnal injury r death. CAUTION is used t identify unsafe practices which may result in minr persnal injury r prduct and prperty damage. NOTE is used t highlight suggestins which will result in enhanced installatin, reliability, r peratin. INSTALLATION CONSIDERATIONS Befre the actual installatin f a zning system can begin, decisins need t be made t determine the number and lcatin f znes and sensrs. This affects duct and damper selectins. This instructin cvers the physical installatin and start up f the Observer Zning Bard. Use this instructin t guide the actual installatin prcess after all the air side decisins have been made. e Zning Bard is capable f handling up t fur znes f peratin. When greater than fur znes are required, a secnd Zning Bard Mdule is needed fr znes 5 thrugh 8 (8 znes maximum). 1. Install the Observer Zne Cntrl (User Interface) and Remte Rm Sensrs in nn-cndensing areas with ambient temperatures between 3 F. and 10 F. Install Dampers and Observer Zning Bard in nn-cndensing areas with ambient temperatures between -4 F. t 158 F., (-0 t 70 C).. A TXV is required n the indr cil when used with all residential split system equipment. 3. Prper equipment selectin and duct sizing are imprtant in a zned system. 4. Either a barmetric bypass r a pwered damper used as a dump zne may be used with the Observer Zning System. Sizing f the bypass duct shuld be selected s that a maximum f X% is allwed t bypass int the return duct. Excessive bypass can cause equipment shrt cycling and reduce equipment life. INSTALLATION STEP 1 CHECK EQUIPMENT AND JOB SITE INSPECT EQUIPMENT File claim with shipping cmpany, prir t installatin, if shipment is damaged r incmplete. STEP COMPONENT LOCATION AND WIRING CONSIDER- ATIONS! WARNING ELECTRICAL SHOCK HAZARD Failure t fllw this warning culd result in persnal injury r death. Befre installing r servicing system, always turn ff main pwer t system and install lckut tag. There may be mre than ne discnnect switch. Discnnect supply pwer befre ruting wire. NOTE: All wiring must cmply with natinal, lcal, and state cdes. Lcating Observer Zning Bard NOTE: All wiring is run back t the Observer Zning Bard. All system wiring is run back t the Observer Zning Bard. Select a lcatin near the Observer furnace r fan cil where wiring frm the Observer wall cntrl, each Remte Rm Sensr r CTS Sensr, each damper actuatr, and the equipment itself can cme tgether easily. The Observer Zning Bard is apprved fr indr use nly and shuld never be installed with any f its cmpnents expsed t the elements. The Observer Zning Bard (and the zne dampers) may be installed in any area where the temperature remains between -4 F. t 158 F. (-0 C t 70 C), and where there is n cndensatin. The cver must be installed t prevent damage frm ther surces. D nt lcate where it will be accessible t children. It may be munted in either vertical r hrizntal psitin. Remember that wiring access is likely the mst imprtant cnsideratin.! CAUTION ELECTRICAL OPERATION HAZARD Failure t fllw this cautin may result in damage t the unit r imprper peratin. T prevent pssible damage t the Observer Zning Bard, d nt munt n plenum, duct wrk, r flush against furnace. LOCATING Observer Wall Cntrl The Observer Wall Cntrl is the cmmand center fr the Observer Zne System. It shuld be lcated where it is easily accessible and visible t the hme r business wner. It is the Zne 1 sensr and as such needs t be lcated t prperly measure the temperature in Zne 1. If it cannt be installed in the zne 1 space, a separate Remte Rm Sensr can be added fr Zne 1 by cnnecting it t the S1 and S terminals n the Observer CTS back plate. NOTE: The Observer Wall Cntrl als cntrls humidity functins. If the User Interface is nt used t cntrl Zne 1 temperature, it must still be lcated in a suitable area where humidity cntrl will nt be affected. LOCATING SENSORS Fr prper peratin, each sensr must accurately measure the temperature within its zne. Fr accurate temperature measurement, the fllwing guidelines shuld be fllwed: 616 01 1301 00

Sensr shuld be munted: Apprximately 5 ft. (1.5m) frm flr. Clse t the center f its zne, preferably n an inside wall. a sectin f wall withut pipes r ductwrk. Sensr shuld NOT be munted: Clse t a windw, n an utside wall, r next t a dr leading t the utside. Where it will be expsed t direct light and heat frm a lamp, sun, fireplace, r ther temperature radiating bject which may cause a false reading. Clse t r in direct airflw frm supply registers. In areas with pr air circulatin, such as behind a dr r in an alcve. WIRING CONSIDERATIONS Ordinary thermstat wire is ideal when wiring the Observer Zning System (shielded cable is nt typically necessary). Use AWG r larger fr typical installatins. Lengths ver 100 ft. shuld use 0 AWG r larger wire. Zne sensrs require 4 cnductrs t be run. A CTS Zne Sensr may replace the Remte Rm Sensr with n wiring changes at a later date. The Observer Wall Cntrl requires 4 cnductrs, each damper actuatr requires either r 3 cnductrs. Cut ff r fld back and tape any unneeded wires. Plan the ruting f wiring early t avid pssible prblems later. Smetimes, it is a gd idea t run cnduit in hard t access lcatins, in case a new wire must be pulled at a later date. Remember, all wires cnverge at the Observer Zning Bard, s its lcatin is imprtant. NOTE: Wiring f the cmmunicatin bus nly requires a fur wire cnnectin; hwever, it is gd practice t run thermstat cable having mre than fur wires in the event f a damaged r brken wire during installatin. The fllwing clr cde is recmmended fr each ABCD bus cnnectin: DX+ Green = Data + DX- Yellw = Data - C White = 4 VAC (Cm) R Red = 4VAC (Ht) It is nt mandatry that the abve clr cde be used, but each bus cnnectin in the system MUST be wired cnsistently. STEP 3 INSTALL COMPONENTS INSTALL Observer Zning Bard The Observer Zning Bard is designed s that wires can enter it frm behind, abve, r belw. Plan wire ruting befre munting Damper Cntrl. 1. Open cver t access munting hles.. Munt back plate t wall using screws and wall anchrs prvided. 3. Level back plate and tighten screws. INSTALL Observer Wall Cntrl (see Observer Wall Cntrl Installatin Instructins fr details). NOTE: :Imprper wiring f the green cmmunicatin bus cnnectr will cause the Observer Zning System t perate imprperly and/r fail t cmmunicate. Check t make sure all wiring is crrect befre prceeding with installatin r turning n pwer. Fig. 1 Zning Bard and Remte Sensrs ZONING BOARD REMOTE ROOM SENSOR INSTALL Remte Rm Sensrs 1. Separate the sensr cver and munting back plate by squeezing the tp and bttm f the cver tgether firmly by grasping the raised tp and bttm ridges. This will release the cver. Munt t wall using prvided screws and anchrs.. Pull a 4-cnductr wire thrugh hle n right-hand side. 3. Recmmended cnnectin is: DX+ Green = Data + DX- Yellw = Data - C White = 4 VAC (Cm) R Red = 4VAC (Ht) Stranded r cmmn bell wire may be used. Lengths up t 100 ft. are acceptable. 4. Push any extra wire int wall and seal hle t prevent air leaks. Align sensr cver with base plate then press firmly until cver snaps int place. The Observer Wall Cntrl and Zne Sensrs shuld be wired t the apprpriate terminal cnnectrs n the Observer Zning Panel. 18- Gauge wire shuld be used. If the lw-vltage wiring must be run alngside line vltage wiring r near flurescent lighting r ther electrically nisy devices, shielded cable shuld be used and grunded at the cmmn terminal n 3 616 01 1301 00

ne end). The dip switch n each OBSERVER Zne Sensr shuld be selected fr the apprpriate zne number; fr instance, Zne sensr shuld be selected using the DIP switch fr ff, ff, ff. Fig. Zning Remte Sensrs Zne ID must be set fr each Zne -6. ID cannt be cnfirmed n Zne SensrStat. See Zne ID Cdes. STEP 4 INSTALL ZONE S Prper selectin and sizing f dampers is very imprtant fr prper system peratin. Be sure t cnsult the Damper Prduct Data Digest fr assistance in making these selectins. Selectin and sizing infrmatin is nt prvided in this installatin instructin. Zne dampers are available in rund and rectangular and may be installed in any psitin. Install dampers s that actuatr is visible fr inspectin and accessible in the event it wuld need t be serviced. The black mark n the end f the damper shaft represents psitin f damper blade. T wire damper, lcate terminals labeled: OPN (pen); COM (cmmn); CLS (clsed; and wire apprpriately (see Fig. 1 fr Damper 4 VAC cnnectin). Zne ID Cdes Zne 3 1 Zne 3 3 1 Zne 4 3 1 Zne 5 3 1 Fig. 3 Damper 4 VAC Cnnectins Zne 6 3 1 3/16" GAP SET SCREW MOUNTING HUB SET SCREW MOUNTING HUB ACTUATOR HOUSING PLASTIC COVER QUICK BLADE RELEASE CLS COM OPN CLS COMOPN 3/16" GAP ANTI-ROTATION MOUNTING SCREW (CLS) CLOSED (COM) COMMON (OPN) OPEN If duct system requires multiple dampers fr a single zne, up t 3 dampers (maximum) may be wired in parallel. Fr all applicatins, including retrfit, it is recmmended t use nly current dampers with direct-drive style actuatrs. DO NOT use lder damper with crank-arm style actuatrs. If an actuatr is remved frm a damper fr any reasn, it must be prperly aligned when it is reinstalled. This can be dne by rtating the actuatr and the blade t their clsed psitins and then tightening the actuatr (set screw) t the shaft. This assures alignment at the clsed psitin. (Pressing the quick blade release buttn allws the actuatr t be manually turned). ANTI-ROTATION MOUNTING SCREW (5/16")! CAUTION ELECTRICAL OPERATION HAZARD Failure t fllw this cautin may result in damage t the unit r imprper peratin. Cndensatin can damage the actuatr. When dampers are lcated in an uncnditined space, cndensatin is likely t ccur in cling. T prevent cndensatin and lsses, all dampers and ductwrk in uncnditined space must be insulated r therwise prtected. 616 01 1301 00 4

Fr specific duct types, fllw instructins belw: NOTE: All zne dampers and ductwrk must be prperly supprted accrding t lcal cdes r SMACNA standards. ROUND METAL DUCTWORK 1. Crimp end f branch duct.. Slip end f zne damper ver end f ductwrk. Use selftapping sheet metal screw t secure. 3. Prperly seal jint using duct tape, mastic, r ther apprved methd. D nt allw mastic t cme in cntact with actuatr. 4. If dampers are applied in an uncnditined space, insulate damper using 1-1/ inch t inch insulatin (See Fig. 4). 4..If dampers are applied in an uncnditined space, insulate damper using 1-1/ inch t inch insulatin (See Fig. 8). Fig. 7 Rund Flexible Ductwrk FLEXIBLE DUCT ZONE Fig. 4 Insulated Rund Metal Ductwrk 1/ STEEL STRAP Fig. 8 Insulate Ductwrk 1/ STEEL STRAP RECTANGULAR DUCTWORK 1. Make cnnectins using S-lck and drives (See Fig.5).. Prperly seal jint using duct tape, mastic, r ther apprved methd. D nt allw mastic t cme in cntact with actuatr. 3. If dampers are applied in an uncnditined space, insulate damper using 1-1/ inch t inch insulatin (See Fig. 6). Fig. 5 Rectangular Ductwrk SUPPLY AIR DUCT S-LOCK DRIVE ZONE RECTANGULAR FIBROUS GLASS DUCTWORK 1. Insert ne end f zne damper int end f fibrus glass ductwrk apprximately t 3 inches (See Fig. 9).. Use field supplied screws t secure duct bard t zne damper. 3. Prperly seal jint using duct tape, mastic, r ther apprved methd. D nt allw mastic t cme in cntact with actuatr. 4. If dampers are applied in an uncnditined space, insulate damper using 1-1/ inch t inch insulatin (See Fig.10). Fig. 9 Rectangular Fibrus Glass Ductwrk FIBROUS GLASS DUCTWORK FIELD SUPPLIED SCREWS ZONE Fig. 6 Insulate Damper 1 1/ " TO " INSULATION TO 3 Fig. 10 Insulated Rectangular Fibrus Glass Ductwrk 1 1/ TO INSULATION ROUND FLEXIBLE DUCTWORK 1. Slip ne end f flexible ductwrk ver end f zne damper (See Fig. 7).. Secure flexible duct t zne damper using SMACNA r ther apprved methd. 3. Prperly seal jint using duct tape, mastic, r ther apprved methd. D nt allw mastic t cme in cntact with actuatr. STEP 5 FINAL WIRING Bring all damper and sensr wires tgether at the Observer Zning Bard. Make all system wiring cnnectins as indicated in Fig. 11. The tw DX+DX R C bus cnnectins n the Observer Zning Bard are in parallel with each ther. Use either terminal blck t cnnect the Zning User Interface, Rm Remte Sensr(s), variable-speed indr unit and -speed cmmunicating utdr 5 616 01 1301 00

unit (if applied). If mre than fur znes are required (up t 8 znes maximum), see Step 6 and Fig. 10 fr Additinal Zning Bard Bard Setup fr Znes 5-8. LEAVING AIR TEMPERATURE SENSOR The LAS input n the Observer Zning Bard is used t prtect the equipment frm very high r very lw leaving air temperatures. The equipment will be cycled ff if the temperature is less than 180 F r mre than 45 F. The equipment will cycle back n when the temperature is abve 45 F and belw 180 F and after 15 minutes have passed. The heating and cling LAS limits are adjustable. See the Observer cntrl installatin instructins fr mre infrmatin. LED INDICATORS Under nrmal peratin, the Yellw and Green LEDs will be n cntinuusly (slid). If the Observer Damper Cntrl des nt receive cmmunicatins with the User Interface, the Green LED will nt be n. If there are faults present, the Yellw LED indicatr will blink a single digit status cde. It will blink at a fast rate, pause, then repeat. FUSE A 5-amp autmtive type fuse is used t prtect the Observer Zning Bard frm ver current n the damper drive utputs. If this fuse fails, damper wiring shuld be inspected fr shrts. Als, n mre than five damper mtrs shuld be cnnected t a single damper utput. Fuse shuld always be replaced with an identical 5 amp autmtive fuse. STEP 7 Transfrmer Requirements The Observer Zning System requires its wn 75VA transfrmer t pwer the dampers. Use f the transfrmer prvided in the furnace r fan cil is NOT recmmended. STEP 8 System Start Up Fllw the system start-up prcess utlined in the Observer Zne Cntrl Installatin Instructins fr details. initial pwer up, the Observer Wall Cntrl will display the fllwing screen. Fig. 11 Pwer Up Display Select the prper ptin fr the Observer Wall Cntrl. The main cntrl shuld be selected as Thermstat. If the Observer wall cntrl is t be used as a zne sensr, select the secnd ptin, Zne Sensr. If the Observer Wall Cntrl is already installed in an applicatin, the zning panel, sensrs, and dampers may be added at a later date. The Observer Wall Cntrl must have sftware versin 3.0 installed fr it t cmmunicate with the zning panel and sensrs. NOTE: If the number f znes selected Is less than 6, the remaining znes will be disabled. After selecting Thermstat n the Observer Wall Cntrl, it will search fr cmmunicating indr equipment. If a cmmunicating unit is fund, it will prceed t search fr a cmmunicating utdr unit, then the zning panel and remte sensrs. Fig. 1 Searching fr Cmmunicating Equipment The Damper screen allws the selectin f either wire (spring pen/spring clsed) r 3 wire (pwer pen/pwer clsed) type. If a pwer pen/spring clsed-type damper is t be used, cnnect the damper wires t the Open and Cmmn terminals n the Observer Zning Bard. If a pwer clsed/spring pen-type damper is t be used, cnnect the damper wires t the Clse and Cmmn terminals n the Observer Zning Bard. 616 01 1301 00 6

Fig. 13 System Wiring *** *** Designed fr use with cmmunicating equipment, Zning can be used with Nn-Cmmunicating equipment by using a NAXA00101DB. PLEASE REFER t TSTAT0101SC set up instructins fr mre detailed infrmatin regarding prper daughterbard set up use. 7 616 01 1301 00

616 01 1301 00 Cpyright 014 Internatinal Cmfrt Prducts Lewisburg, TN 37091 USA 8