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Carrier ZONEKIT4ZCAR manual

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Table of contents for the manual

  • Page 1

    ZONEKIT4ZCAR Comfort Zone Installation and Start-Up Instructions NOTE: Read the entire instruction manual before starting the installation. TABLE OF CONTENTS PAGE Safety Consideration ......................................................................1 Installation Considerations..........................................................1-2 Intro[...]

  • Page 2

    2. Use vibration isolators (flex connectors) on zone dampers and duct work to minimize noise. 3. Place dampers away from areas that may be noise sensitive. 4. TXV is required in air conditioning and heat pump applica- tions. 5. Use separate isolated transformer to supply power to Comfort Zone System (50 va minimum, class 2, field supplied). 6. Load[...]

  • Page 3

    Table 1—Wiring Requirements FROM COMFORT ZONE CENTER TO NO. OF WIRES GAGE MAX. LENGTH (FT) Four Zone Controller 3‡ 18/22 200/100 5‡ 18/22 200/100 Remote Room Sen- sors 2‡ 18/22 200/100 Remote Duct Sensors 2‡ 18/22 200/100 Dx Coil Sensor 2‡ 18/22 200/100 Home Access Module 3‡ 18/22 1000/100 ISOSAT* 3‡ 18/22 1000/100 Transformer† 21[...]

  • Page 4

    Before insulating the duct work, check for proper damper opera- tion. Apply the 24vac between COM and OPN to open the damper and COM and CLS to close the damper. (See Fig. 7.) The damper will modulate counter-clockwise to open and clockwise to close. If in an emergency it becomes necessary to force a damper open, manually press in the red quick bla[...]

  • Page 5

    2. Secure flexible duct to zone damper using SMACNA or other approved method. 3. Properly seal joint using duct tape, mastic, or other approved method. Do not allow mastic to come in contact with actuator. 4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check your local codes.) NOTE: All zone dampers and duct work must be properly supporte[...]

  • Page 6

    5. Insert 2-conductor wiring through 1 of pre-drilled holes in side of back plate. 6. Connect sensor to 2-wire conductor using provided wire nuts. (See Fig. 16 for connection to Comfort Zone Center.) Step 7—Install Dx Coil Sensor The Dx coil temperature sensor is recommended for use in heat pump with fan coil applications only. The sensor should [...]

  • Page 7

    Fig. 16—Comfort Zone System Wiring Diagram A94311  Zone Dampers Dx Coil Sensor (optional) Outside Air Sensor (optional) Duct Sensor Zone 2* Zone 3* Zone 4* Zone 1 4-Zone Controller Remote Room Sensors 72 68 2:45 24 VAC Transformer (Field Supplied) 50 VAC req. for basic 4 damper system. Please see Page 1, Electrica[...]

  • Page 8

    Changing the base temperatures will change the Comfort Temperature Setpoints used in the system schedules. Always set the Base Temperatures prior to programming the system schedules. Comfort Zone also uses a minimum temperature and a maximum temperature for comfort setpoints. The minimum and maximum temperatures are the same for all 4 zones. The Ma[...]

  • Page 9

    If Fan Switch on 4 zone controller is set to ON instead of Auto, then system fan will run continuously. Any time Comfort Zone is operating fan, it will be in active control of system. NOTE: If Auto Fan Off For Heating option (rotary switch position T-9) is ON, and Fan Switch on the 4 zone controller is ON, Comfort Zone will operate fan full time. O[...]

  • Page 10

    heater. The electric strip heat is much more expensive to operate when comparing cost per unit of heat. Because auxiliary stages of heating tend to be more expensive to operate, Comfort Zone attempts to keep number of stages at a minimum. CONFIGURATION OPTIONS FOR EQUIPMENT OPERATION Comfort Zone has several configurable options which allow it to c[...]

  • Page 11

    NOTE: Comfort Zone uses a 3-minute timer to delay start of second-stage (heating or cooling). This timer is started whenever first-stage heating or cooling is energized. This delay cannot be overridden or disabled. STAGE CONTROL DURING EQUIPMENT OPERATION As shown earlier, Comfort Zone has 6 configurable options which help govern equipment operatio[...]

  • Page 12

    then temperature at which first stage will be shut down will be offset 5°F above limit value (110°F to 114°F). If limit temperature is between 110°F and 155°F, then temperature at which first stage will shut down will be offset 20°F above limit value (130°F to 175°F). For Cooling modes the temperature is fixed at 50°F (10°C) for starting [...]

  • Page 13

    If a value of 105 to 110 is selected (second-stage heating is turned off at this value) then the first-stage high temperature trip limit is the programmed value plus 5°F (first-stage is turned off). If a value of 111 to 155 is selected (second-stage heating is turned off) then the first-stage high temperature trip limit is the programmed value plu[...]

  • Page 14

    7. Write down on a piece of paper AND GIVE TO THE OWNER a list showing what rooms are controlled by what dampers, and their corresponding zone numbers. Keep list for your future use. 8. Instruct owner to turn cool switch OFF in the fall, and turn it ON in the spring. 9. Make sure emergency heat switch is in the OFF position. If a gas furnace is use[...]

  • Page 15

    Cool Switch OFF —Cooling will not come on. AUTO —Cooling will come on when any zone is more than 1.5°F above desired cool setpoint. Fan Switch ON —Fan will stay on continuously (recommended). AUTO —Fan will come on only when heating or cooling is required. Emergency Heat Switch (Heat Pump Systems only) OFF —Electric strip heat will not c[...]

  • Page 16

    Press ADVANCE TIME/DAY button until desired start time is displayed. 6. Adjust setpoints. Adjust setpoints using up and down buttons until desired temperatures for the selected time period appear in display. These setpoints will be used during the time period currently displayed in clock window. 7. Complete time period programming. Repeat 4 through[...]

  • Page 17

    OUTSIDE AIR TEMPERATURE SENSOR The Outside Air Temperature Sensor must be used whenever an Outside Air Damper is installed. An Outside Air Temperature Sensor must also be used for dual fuel applications. Step 16—Troubleshooting This section contains information to assist you in troubleshooting problems and errors associated with the Comfort Zone [...]

  • Page 18

    Table 11—Toggle Summary TOGGLE SETTING ON OFF DEFAULT (T1)-Timeguard Override Timeguard delay is 30 sec, overrides 5-minute delay be- tween de-energizing and re-energizing HVAC stages. This option automatically returns to OFF after 30 sec timeout. If equipment has been shut down due to a leaving air tem- perature trip, the timeguard override has [...]

  • Page 19

    Table 12—Operating Problems SYMPTOM POSSIBLE CAUSE No Display Thermostat is not receiving power. 1. Verify that comfort zone center is receiving 24 vac. (50 va minimum required with 4 motorized dampers, 5 va for each additional motorized damper.) 2. Check that the thermostat is receiving a steady 10 VDC across the red and white wires at the syste[...]

  • Page 20

    Table 13—Storage Failure Errors Error Display (Dial Position T4) must be turned on. SF ERROR CODE DESCRIPTION SOLUTION 01 Temperature Programming Error Reprogram the scheduled temperatures. 02 Time Period Programming Error Reprogram the scheduled time periods. 03 Zone 1 Temperature Calibration Out of Range 1. Turn selection dial to position 2. 2.[...]

  • Page 21

    Table 14—Hardware Failure Errors Error Display (Dial Position T4) must be turned on. HF ERROR CODE DESCRIPTION SOLUTION 40 Zone 1 Temperature Sensor Bad sensor, shorted or open. 1. Check wiring and sensor. 2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F. 41 Zone 2 Temperature Sensor Bad sensor, shorted or open. 1. [...]

  • Page 22

    UNIT 24 VAC (R) C Y STANDARD SINGLE SPEED AIR CONDITIONER Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR FAN COIL COMFORT ZONE SYSTEM Y W2 W3 R C G O L E A A93227 UNIT 24 VAC (R) STANDARD SINGLE SPEED AIR CONDITIONER Yellow Red Blue White Brown Green Oran[...]

  • Page 23

    Fig. 19—Typical Wiring Diagrams (Fan Coil with Air Conditioner) Continued A94034 E UNIT 24 VAC (R) 2-SPEED AIR CONDITIONER (38TD) Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR FAN COIL COMFORT ZONE CENTER C R Y2 L Y1 Y1 R C G L E W3 Y/ Y2 W2 23[...]

  • Page 24

    UNIT 24 VAC (R) C Y STANDARD SINGLE SPEED AIR CONDITIONER Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR VARIABLE SPEED FURNACE COMFORT ZONE CENTER Y W G R C RELAY COIL Green (P5) CONNECTION AT CONTROL BOARD Black 13 NOTE: Put set-up Switch No. 2[...]

  • Page 25

    UNIT 24 VAC (R) Y2 R C 2-SPEED AIR CONDITIONER (38TD) Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR VARIABLE SPEED FURNACE COMFORT ZONE CENTER W G C R Y Y1 L RELAY COIL Green (P5) CONNECTION AT CONTROL BOARD Black 13 E (KGATT0101VSP) NOTE: Put set-[...]

  • Page 26

    Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) Continued Locking furnace into "low fire" may help prevent over conditioning in the heating mode. This will allow the furnace to stage between low and high fire. Before using this feature read furnace Installation Instructions for two- stage operation. Connect "W2"[...]

  • Page 27

    Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump) UNIT 24 VAC (R) STANDARD SINGLE SPEED HEAT PUMP Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR FAN COIL COMFORT ZONE CENTER G C R Y W2 O R C L A E Y W2 O W3 A93242 UNIT 24 VAC (R) STANDARD SINGLE SP[...]

  • Page 28

    Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump) Continued UNIT 24 VAC (R) 2-SPEED HEAT PUMP (38YD) Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR FAN COIL COMFORT ZONE SYSTEM G C R Y1 W2 O W2 R C E E O Y2 L W3 Y/ Y2 L W3 Y1 A94044 28[...]

  • Page 29

    Fig. 22—Typical Wiring Diagram (Furnace with Heat Pump) UNIT 24 VAC (R) Y W2 STANDARD SINGLE SPEED HEAT PUMP Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR VARIABLE SPEED FURNACE COMFORT ZONE CENTER G A R C O R R1 R1 = Relay DPST, Pilot Duty, 24-v coil [...]

  • Page 30

    Fig. 22—Typical Wiring Diagrams (Furnace with Heat Pump) Continued UNIT 24 VAC (R) C R Y2 L 2-SPEED HEAT PUMP (38YD) Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR VARIABLE SPEED FURNACE COMFORT ZONE CENTER G Y1 R1 R R1 = Relay DPST, Pilot Duty, 24-v co[...]

  • Page 31

    Fig. 22—Typical Wiring Diagrams (Furnace with Heat Pump) Continued UNIT 24 VAC (R) C R Y1 O 2-SPEED HEAT PUMP (38YD) Yellow Red Blue White Brown Green Orange Black COOL 1 (Y1) COOL 2 (Y2) HEAT 1 (W1) HEAT 2 (W2) FAN (G) RV-COOL (O) RV-HEAT (O) OR FURNACE COMFORT ZONE CENTER G Y2 H R1 R R1 = Relay DPST, Pilot Duty, 24-v coil (HN61KK324) o[...]

  • Page 32

    Comfort Zone Configuration Table TOGGLE DESCRIPTION FACTORY DEFAULT RECORD JOB SETTING T1 Timeguard Override OFF T2 Celsius Temperature Display OFF T3 2400 Baud Rate ON T4 Error Code Display ON T5 Enable Broadcast ON T6 Heat Pump Operation OFF T7 Outside Air Temp Sensor Attached OFF T8 Comfort Trend Setting ON T9 Auto Fan Off For Heat OFF T10 High/[...]