Aprilaire 6404 Setup guide

Safety & Installation Instructions

Model 6404

Zoned Comfort Control System

SAFETY INSTRUCTIONS

WARNING

1. 120 Volts may cause serious

injury from electrical shock.

Sudden operation may cause

serious injury from moving parts.

Leave power disconnected until

installation is complete.

2. Sharp edges may cause serious

injury from cuts. Use care when

making duct openings and

handling ductwork.

3. The Aprilaire Zoned Comfort

Control System is designed for

indoor use only. Do not expose

any component of the zone

control system to moisture. Do

not mount any Aprilaire Zone

Control equipment where it may

be accessible to children.

CAUTION

1. Turn off the system power before removing or installing any wires into the

terminals of any component on the system. Wiring with a live circuit can

lead to electrical shorts that can damage components.

2. Installation must be done in accordance with all applicable codes.

3. Installer should touch a grounded metal object before handling the

Aprilaire control panel to avoid potential loss of internal computer

programs due to static discharge.

4. A Zoned Comfort Control system may not control temperature properly

unless the heating and cooling system is properly sized and balanced.

5. Insufficient air flow or excessive temperatures through the heating and

cooling system could result in equipment damage. Refer to the

manufacturer’s recommendations for minimum safe airflow and

temperature requirements.

6. Excessive pressure across a bypass evaporative type humidifier may

cause high air velocity in the humidifier, resulting in water being blown

into the ductwork. Refer to Design Guide (form 5001) for humidifier

installation considerations.

7. Install an outdoor thermostat to prevent non-seasonal equipment starts

if using auto changeover thermostats.

8. Do not mount the control panel on any part of the heating/cooling

equipment or ductwork.

9. Do not install control panel where temperatures exceed 158°F (70°C)

or are below 32°F (0°C).

10. Improper system installation could cause water damage from frozen

pipes. Check system operation after installation.

Read this Installation Manual before beginning installation of the Aprilaire Zoned Comfort Control System.

For questions call Research Products Corporation at (800) 334-6011.

TABLE OF CONTENTS

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

CONTROL PANEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . .3

CONTROL PANEL INSTALLATION . . . . . . . . . . . . . . . . . . . .4

Run Wire for System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Mount the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

SET CONTROL PANEL FOR APPLICATION . . . . . . . . . . . . .6

WIRE THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Select and Wire the Transformer to the Control Panel . . . . .8

Select and Wire Thermostats . . . . . . . . . . . . . . . . . . . . . . . . .9

Wire the HVAC Equipment to the Control Panel . . . . . . . . .10

Wire Zone Dampers to the Control Panel . . . . . . . . . . . . . . .12

Wire an 8052 Plenum Temperature Sensor (included) . . . . .12

Wire an Aprilaire Humidifier Control or Electronic

Air Cleaner to the Control Panel – OPTIONAL . . . . . . . . . . .13

Wire Expansion Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . .15

(1) DAMPERS

a. Separate 24 VAC power input for 2 or 3-wire

dampers.

b. Damper LEDs light when the NO contact is closed.

c. Damper output terminals for 2 or 3-wire dampers.

(2) CONTROL PANEL POWER

a. 24 VAC power input serves the main 6404 panel, up

to four expansion panels and thermostats.

b. The POWER LED light blinks approximately

once per second with power applied.

(3) HUMIDIFIER

a. Dry contact relay that closes during heat calls,

allowing for control of a humidifier.

b. HUM LED lights when the relay is closed.

(4) ELECTRONIC AIR CLEANER

a. Dry contact relay that closes during heating, cooling

and fan calls.

b. EAC LED lights when relay is closed.

(5) EQUIPMENT LEDS

a. LEDs visible through the cover that indicate when the

system is Heating, Cooling or operating the Fan.

b. LEDs adjacent to Equipment output terminals that

allow technician to determine which equipment

outputs are currently energized.

(6) CONFIGURATION SETTINGS

Dip switch settings to configure HVAC outputs,

set plenum sensor temperature limits and control

equipment stage timing.

(7) TIME DELAY OVERRIDE

Time Delay Override button accelerates timing

(6 seconds = 1 minute) for quicker testing of control

panel. The POWER LED blinks approximately twice per

second when the TDO button is pressed.

(8) PLENUM SENSOR

Plenum temperature sensor (8052) inputs.

(9) THERMOSTATS

Thermostat inputs.

(10) ZONE/VAC SELECTOR SWITCH

When on, zone panel responds only to the Zone 1 thermostat and damper terminals do not energize.

(11) E-HEAT SELECTOR SWITCH

Use to put panel in Emergency Heat mode if controlling a heat pump with standard heat/cool thermostats. 3

SPECIFICATIONS

CONTROL PANEL LAYOUT

ELECTRICAL ENVIRONMENTAL

Operating Temperature 32°F (0°C) to 158°F (70°C)

Operating Humidity up to 90% non-condensing

Shipping Temperature -40°F (-40°C) to 180°F (82°C)

Plenum Temperature

Sensor RPC Model 8052

Input Voltage 20-30 VAC

Power Requirement for control

panels and thermostats only 40 VA

Damper Voltage 18-30 VAC

Power Requirement for dampers 10 VA per damper

Max. Current through EAC/HUM terminals 1 amp @ 24 VAC

Max. Current through equipment 1 amp each or

control terminals 3 amp total @ 24 VAC

Fuse Size 3 amp

FIGURE 1 – Control Panel Layout

CONTROL PANEL INSTALLATION

CAUTION

Installer must touch a grounded metal object before handling the Aprilaire control panel to avoid potential loss of

programs due to static discharge.

RUN WIRE FOR SYSTEM

Single-Stage Two-Stage Boiler w/AC Radiant 1st Stage Heat, Single-Stage Two-Stage

System Type Furnace & A/C Furnace & A/C (2-xformer) Furnace 2nd Stage Heat & A/C Heat Pump Heat Pump

Wires 465 5 57

TABLE 1 – WIRES REQUIRED BETWEEN HVAC EQUIPMENT AND CONTROL PANEL

Aprilaire Thermostat

Model Number Number of Wires

8570 5 - 8

8363 4

8365 6

8366 6

8344 4

8346 6

8348 6

TABLE 2 – WIRES REQUIRED BETWEEN THERMOSTATS

AND CONTROL PANEL WIRE TYPE

Standard 18-24 gauge stranded or solid thermostat wire

can be used for all wire runs.

IMPORTANT

Avoid running thermostat and sensor wire alongside

line voltage and high current carrying conductors

(motors). This will prevent potential interference and

ensure proper operation of the Zoned Comfort

Control system.

FIGURE 2

MOUNT THE CONTROL PANEL

NOTE: Mount in location where the temperature will not exceed 158°F and will not drop below freezing (32°F). Do not

mount on foundation walls, or on the HVAC equipment or ductwork. These locations can cause the enclosure to become

cooler than the surrounding air, which can cause moisture to condense on the enclosure.

1. Press in the latch on the left side of the enclosure and pull open the cover.

2. Use #8 screws (field supplied) to mount the base.

SET CONTROL PANEL FOR APPLICATION

There are six setup switches that must be set to meet your particular zoning application.

➤ZONE 1/ANY ZONE determines how the control panel will

control the mode of operation. In the ZONE 1 configuration,

Zone 1 sets the mode of operation through the use of the O

and B thermostat inputs. When the Zone 1 O terminal is

energized, the system is in the cool mode and only cool and

fan calls will be satisfied. When the Zone 1 B terminal is

energized, the system is in heat mode and only heat and

fan calls will be satisfied. If neither the Zone 1 O nor B

terminal is energized, the system will not respond to cool or

heat calls, but fan operation is unaffected. This

configuration offers restricted control and is likely to be

used in commercial applications where control from Zone 1

is desired (i.e. restaurants, churches, etc.). In the ANY

ZONE configuration, the control panel responds to each

individual thermostat equally. This allows thermostats to

call for heating or cooling as required. If opposite calls

(heating and cooling) occur at the same time, the zone

panel will alternate between the heating and cooling call in

20 minute intervals. This offers control flexibility and is

likely to be used in most residential applications and office

or retail type commercial applications where the heating

and cooling needs of the zones are completely independent.

TALK WITH THE CUSTOMER TO DETERMINE WHICH

CONTROL CONFIGURATION SHOULD BE USED. Refer to the

sequence of operation sections on the following pages for

additional details.

➤HEAT PUMP or HEAT/COOL refers to the type of heating

and cooling system. If a heat pump is to be used, set the

switch to the ON position. If different equipment is used for

heating and cooling (i.e. furnace and air conditioner, or boiler

and air conditioner), set the switch to the OFF position.

➤ELECTRIC/GAS refers to the heat source. If electric heat is

to be used, set the switch to the ON position. This will turn

on the fan (G output terminal) with a heat call (W1 output

terminal). If the switch is left in the OFF position, it is

assumed that the heating equipment will control the fan.

For Dual Fuel Heat Pump systems, leave this switch in the

GAS position.

➤NO PURGE / PURGE determines whether the zone control

panel or the equipment will control the compressor fan

purge. If the NO PURGE/PURGE switch is set to PURGE, the

G terminal will remain energized for a one minute purge

delay following the completion of a compressor call. If set

for NO PURGE, the G terminal will de-energize immediately

following the completion of a compressor call. The NO

PURGE setting is designed for use with systems where the

equipment has a built in fan purge.

➤CL-45/40: If using a plenum temperature sensor, this switch

controls the temperature at which the cooling equipment

will cut out to prevent freezing the indoor coil. For a low

limit temperature of 45°F, move the switch to the ON

position (45). For a low limit temperature of 40°F, leave the

switch in the OFF position (CL-40).

➤HT-140/170: If using a plenum temperature sensor, this

switch controls the temperature at which the heating

equipment will cut out to prevent overheating. For a high

limit temperature of 140°F, move the switch to the ON

position (140). For a high limit temperature of 170°F, leave

the switch in the OFF position (HT-170).

HEAT/COOL

OFFON

ANY ZONE

GAS

FAN PURGE

ZONE 1

HEAT PUMP

ELECTRIC

NO PURGE

OFFON

CL:40

HT:170

140 PLENUM SENSOR

SET THE STAGE TIME

SET AUXILIARY HEAT STAGE UP TIME (HEAT PUMP SYSTEMS ONLY)

➤# ZONES TO STAGE If staging

thermostats are not installed with the

system, second stage (does not apply to

auxiliary heat on heat pump applications)

operation can be initiated when more

than one zone is calling for conditioning.

Four selections are available: one, two,

three and four zones. Set to one,

thermostat inputs or timed length of call

control staging, for all other settings only

the specified number of calling zones

can trigger staging.

➤STAGE MINUTES If staging

thermostats are not installed and the #

Zones to Stage is set to 1, staging can

be controlled by the amount of time that

any one zone must be calling for

conditioning before initiating a second

stage (does not apply to auxiliary heat on

heat pump applications). Four selections

are available: 0, 10, 60 and 120 minutes.

Set to zero, thermostat inputs or “# of

Zones to Stage” control staging.

OFFON

#ZONES TO

STAGE

OFFON

STAGE

MINUTES

For systems with two-stage equipment (for heat pump applications, this does not include Auxiliary Heat), you have three options

for controlling the second stage. The control panel will stage up the equipment outputs based on the number of zones calling for

conditioning (# Zones to Stage), the time length of a call (Stage Minutes), or by staging thermostats.

For thermostat control of auxiliary heat, set all AUX. MINUTES

switches to the OFF position and refer to the sequence of

operations sections on the following pages for details. For timed

control, set the AUX. MINUTES switches to the amount of time the first and second stage

(where applicable) compressors are allowed to try and satisfy a call for heating before auxiliary

heat will be activated. There are four selections available: 0, 10, 60 and 120 minutes. Set to

zero, auxiliary heat will be controlled by the thermostat.

AUX. MINUTES

# ZONES

TO STAGE

(Staging by

thermostat

input or time)

OFFON

STAGE

MINUTES

(Staging not

time controlled)

120

OFFON

AUX.

MINUTES

(Aux. heat not

time controlled)

120

OFFON

➤THERMOSTAT CONTROL The 2S terminal

available at each zone thermostat input can be

used to control staging by the thermostat. For

single-stage equipment or to control staging

through thermostat input only (2S), set the

“# ZONES TO STAGE” and “STAGE MINUTES”

dip switches to the OFF position.

• For two-stage heat pump systems, the 2nd

stage compressor thermostat output (usually

denoted Y2) is wired to the 2S terminal.

• For two-stage heat, one-stage cool

systems (not heat pump systems), the 2nd

stage heat thermostat output (usually denoted

W2) is wired to the 2S terminal.

• For two-stage cool, one-stage heat

systems, the 2nd stage cool thermostat

output (usually denoted Y2) is wired to the

2S terminal.

• For systems with two stages of heat and

two stages of cooling, wire both the Y2

and W2 thermostat output terminals to the

2S terminal.

The control panel will stage up immediately

(following the minimum on-time for first stage)

when the 2S terminal in any calling zone has

been activated. Set the “# ZONES TO STAGE”

and “STAGE MINUTES” dip switches to the

OFF position when controlling staging by the

thermostats.

IMPORTANT

Thermostat control of auxiliary heat is only available

when heat pump thermostats are used in all zones.

SELECT AND WIRE THE TRANSFORMER TO THE CONTROL PANEL

WIRE THE SYSTEM

WARNING

120-volts may cause serious injury from electrical shock. Sudden operation may cause serious injury from moving parts.

Leave power disconnected until installation is complete.

1. Two separate 24-volt transformers may be required for the system. The HVAC Equipment transformer cannot be used for power.

Transformer #1 is used to power the control panels and thermostats. Transformer #2 is used to power the zone dampers.

Optionally, a single transformer may be used to power both the zone board and dampers provided it has a sufficient VA rating.

This can be accomplished by using a jumper wire to connect the R Terminal on the Control Power to the R Terminal on the

Damper Power and a jumper wire to connect the C Terminal on the Control Power to the C Terminal on the Damper Power.

2. Install Transformer #1 (see Diagram 1). The 24-volt side

of Transformer #1 is wired to the “Control Power”

terminals on the control panel.

3. Size Transformer #2

• Add up all the zone dampers that are in the system.

• Subtract the number of dampers in the zone with the

least number of dampers.

• This is the most number of dampers that could be

energized at one time. Multiply this number by 10

to determine the Transformer #2 size.

Example: If you have a 4-zone system, and there

are two dampers per zone, then the total number of

dampers that could be energized at one time is

8 - 2 = 6 dampers.

6 x 10 = 60 VA

4. Install Transformer #2 (see Diagram 1). The load side

(24-volt side) of Transformer #2 is wired to the

DAMPER POWER terminals of the control panel.

5. If multiple transformers are required for damper power,

refer to Diagram 8.

Component Component VA Required Refer to Wiring Schematic

Main Control Panel (6404), up to 4 Expansion Panels (6402)

and up to 12 Thermostats 40 VA* Diagram 1

Zone Damper 10 VA each Diagram 8 (page 12)

DIAGRAM 1

*24V thermostats (i.e. 8570) require a 75 VA transformer when using 12 thermostats.

SELECT AND WIRE THERMOSTATS

How the ZONE 1/ANY ZONE switch, HEAT PUMP/ HEAT/COOL switch and AUX. MINUTES switches are set will determine the

thermostat requirements for each zone. Use the following table to determine which thermostat is required.

THERMOSTAT TERMINAL DEFINITIONS

(refer to thermostat manufacturer’s literature

for matching terminals)

THERMOSTAT REQUIREMENTS

ZONE 1 OTHER ZONES

THERMOSTAT THERMOSTAT

TYPE TERMINALS RECOMMENDED TYPE TERMINALS RECOMMENDED

(See Note) THERMOSTATS (See Note) THERMOSTATS

HEAT/COOL R, W, Y, G Aprilaire®8570, HEAT/COOL R, W, Y, G Aprilaire®8570,

8344, 8348, 8344, 8348,

8363, 8366 8363, 8366

HEAT/COOL R, W, Y, G, O, B Aprilaire®8570 HEAT/ COOL R, W, Y, G Aprilaire®8570,

(See Note) 8344, 8348,

8363, 8366

HEAT/COOL R, W, Y, G Aprilaire®8570, HEAT/COOL R, W, Y, G Aprilaire®8570,

8344, 8348, 8344, 8348,

8363, 8366 8363, 8366

HEAT/COOL R, W, Y, G, O, B Aprilaire®8570 HEAT/COOL R, W, Y, G Aprilaire®8570,

(See Note) 8344, 8348,

8363, 8366

HEAT PUMP R, W1, Y1, G, O Aprilaire®8570 HEAT PUMP R, W1, Y1, G, O Aprilaire®8570,

(See Note) 8346, 8365 (See Note) 8346, 8365

CONTROL PANEL

DIP SWITCH

POSITIONS

HEAT/COOL

OFFON

ANY ZONE

ZONE 1

HEAT PUMP

HEAT/COOL

OFFON

ANY ZONE

ZONE 1

HEAT PUMP

HEAT/COOL

OFFON

ANY ZONE

ZONE 1

HEAT PUMP

AUX. MIN.

HEAT/COOL

OFFON

ANY ZONE

ZONE 1

HEAT PUMP

AUX. MIN.

HEAT/COOL

OFFON

ANY ZONE

ZONE 1

HEAT PUMP

AUX. MIN.

R= 24V-hot

C= 24V-common

W / W1 = 1st-stage heat or 1st-stage auxiliary heat

W2 = 2nd-stage heat

Y / Y1 = 1st-stage cool or 1st-stage compressor

Y2 = 2nd-stage cool or compressor

B= Reversing valve – heating

O= Reversing valve – cooling

G= Fan

CONTROL PANEL TERMINAL DEFINITIONS

R= 24V-hot

C= 24V-common

W= 1st-stage heat or auxiliary heat

Y= 1st-stage cool or compressor

B= Reversing valve – heating

O= Reversing valve – cooling

G= Fan

2S = 2nd-stage heat, cool or compressor

NOTE: A common terminal (labeled “C”) is provided at the control panel thermostat terminal strip for use with 24-volt thermostats.

The B terminal listed in the required terminals is not a 24V-com terminal (Trane/ American Standard or GE thermostat users).

WIRE THE HVAC EQUIPMENT TO THE CONTROL PANEL

1. Disconnect power to the HVAC system.

2. Run wire between the HVAC equipment and the control panel.

3. Set the HVAC equipment configuration switches to match your application (see “Set Control Panel for Application” on page 6).

4. Use the diagram appropriate for your application to terminate the wires (refer to Diagrams 2 – 7).

WARNING

120-volts may cause serious injury from electrical shock. Sudden operation may cause serious injury from moving parts.

Turn off power to HVAC System and leave power disconnected until installation is complete.

DIAGRAM 2 – Single-Stage Furnace and A/C DIAGRAM 3 – Two-Stage Furnace and A/C

TERMINAL DEFINITIONS

Y1 = 1st-stage cooling

W1 = 1st-stage heating

G= Fan

TERMINAL DEFINITIONS

Y1 = 1st-stage cooling

Y2 = 2nd-stage cooling

W1 = 1st-stage heating

W2 = 2nd-stage heating

G= Fan

DIAGRAM 4 – Boiler and A/C DIAGRAM 5 – Radiant Floor First-Stage Heat,

Furnace 2nd-Stage Heat and A/C

DIAGRAM 6 – Singe-Stage Heat Pump DIAGRAM 7 – Two-Stage Heat Pump

TERMINAL DEFINITIONS

Y1 = 1st-stage cooling

W1 = 1st-stage

boiler heat

G= Fan

TERMINAL DEFINITIONS

Y1 = 1st-stage cooling

W1 = 1st-stage radiant

floor heat

W2 = 2nd-stage furnace heat

G= Fan

TERMINAL DEFINITIONS

Y1 = 1st-stage compressor

W1 = 2nd-stage heat & emer.

heat (auxiliary heat)

G= Fan

O= Reversing valve

(cooling)

TERMINAL DEFINITIONS

Y1 = 1st-stage compressor

Y2 = 2nd-stage compressor

W1 = 3rd-stage heat & emer.

heat (auxiliary heat)

W2 = Emergency heat

G= Fan

O= Reversing valve

(cooling)

WIRE ZONE DAMPERS TO THE CONTROL PANEL

1. Run 2-wire thermostat cable for spring return dampers (normally open or normally closed). Run 3-wire cable for power

open/power close dampers. Multiple dampers for the same zone can be paralleled together as shown.

2. Wire the dampers to the Zone Damper output terminals on the control panel:

NC – This terminal remains

energized when that zone

thermostat is calling for

heating/cooling/fan or

when no zone is calling.

This terminal is used to

power a damper open.

NO – This terminal

energizes in a non-calling

zone when another zone

thermostat makes a call

for heating/cooling/fan.

This terminal is used to

power a damper closed.

COM – This terminal

provides a common

connection for the NC

and NO terminals.

3. If multiple transformers will be required, wire them in parallel as shown. Before wiring the transformers together,

ensure that they are connected in phase by observing polarity marks or terminal orientation on each transformer.

WIRE AN 8052 PLENUM TEMPERATURE SENSOR (INCLUDED)

1. Locate the sensor in the supply trunk, downstream of the heat exchanger and cooling

coils and before the zone dampers (see the shaded areas of Figure 3).

2. Mount the sensor according to the installation instructions provided with the sensor.

3. Before wiring to the control panel, measure the resistance across the sensor.

The resistance corresponds (approximately) to the sensed temperature according

to the following table:

4. Wire the sensor to the control panel PLENUM SENSOR terminals. THIS MUST BE

DONE BEFORE POWER IS APPLIED TO THE CONTROL PANEL or the sensor will not be

recognized by the control panel.

IMPORTANT

Do not mount the sensor in direct line-of-sight of the heat exchanger, cooling coils or UV lights as this may cause the

sensor to report false temperature readings.

FIGURE 3 – Furnace Setup

Temperature (°F) 30 40 50 60 70 80 90 100

Resistance (kΩ)34.6 26.1 19.9 15.3 11.9 9.4 7.4 5.9 Locate

sensor

in shaded

area.

DIAGRAM 8

IMPORTANT: Check Phase of

transformers before wiring together

WIRE AN APRILAIRE HUMIDIFIER CONTROL OR ELECTRONIC AIR CLEANER TO THE CONTROL PANEL – OPTIONAL

The control panel closes a dry contact relay to complete a circuit between the HUM terminals on the control panel when the heat

is on, eliminating the need for a Model 50 relay or use of equipment humidifier terminals.

1. Install the Humidifier Control and its outdoor temperature sensor:

• Constant power must be applied to the Humidifier Control transformer. DO NOT power the transformer through furnace

accessory terminals.

2. Run a 2-wire cable from the Humidifier Control to the control panel.

3. Wire the Humidifier Control to the control panel – see Diagram 9. Use wire color as a means to ensure the terminals are

connected correctly.

• Connect one of the H terminals on the Humidifier Control to one of the HUM terminals on the 6404 control panel.

• Connect the remaining (open) HUM terminal on the 6404 control panel to the humidifier lead

(refer to Humidifier Control Installation Manual).

• Connect the remaining (open) humidifier lead back to the remaining (open) H terminal on the Humidifier Control.

4. After completing the Model 6404 installation, you will need to verify proper operation of the Humidifier Control – see

Humidifier Control installation instructions for further details.

TO 24-VOLT

ELECTRONIC AIR CLEANER

CONTROLLER

EAC

DIAGRAM 9

To control an electronic air cleaner (EAC), 24-volt control will be required. The EAC relay closes whenever the HVAC equipment is

operating (heating, cooling or continuous fan – see sequence of operation for details).

EAC INSTALLATION REQUIRES 24-VOLT CONTROL:

1. Mount the EAC in accordance with the installation instructions provided with the unit.

2. Run a 2-wire cable from the 24-volt control of the device to the control panel.

3. Connect the wires to the 24-volt control of the device.

4. Connect the other end of the wires to the EAC terminals on the control panel.

DIAGRAM 10

WIRE EXPANSION PANELS

1. Disconnect the Control Power and Damper Power on the

6404 control panel until installation is complete.

2. Mount the expansion panels using four #8 screws (field

supplied) in location where the temperature will not exceed

140°F and will not drop below freezing (32°F). Do not mount

on foundation walls, or on the HVAC equipment or

ductwork. These locations can cause the enclosure to

become cooler than the surrounding air, which can cause

moisture to condense on the enclosure.

3. Connect the R, C, A and B terminals labeled “EP_OUT” on

the 6404 panel to the R, C, A and B terminals labeled

“EP_IN” on the first 6402 expansion panel. To wire

additional 6402 expansion panels, connect the R, C, A and

B terminals labeled “EP_OUT” on the first expansion panel

to the R, C, A and B terminals labeled “EP_IN” on the next

expansion panel. See Diagram 10. Polarity is important. If

wired incorrectly control panel power and/or

communications will be affected. Use wire color as a

means to ensure the terminals are connected correctly.

4. Connect the Damper Power R and C terminals on the 6404

control panel to the Damper Power R and C terminals on

the first 6402 expansion panel. For additional 6402

expansion panels, damper power can be daisy chained as

shown in Diagram 10.

5. Wire dampers to 6402 expansion panel(s) as previously

described in the “Wire Dampers to Control Panel Section”.

6. Wire thermostats to 6402 expansion panel(s). Use the same

thermostats as were selected for zones 2-4 on the 6404

control panel. Refer to “Select and Wire Thermostats”

section for additional detail on terminal designations.

7. Address each 6402 expansion panel. Each expansion panel

must have its own unique address, 1 through 4, or

communications cannot be established between the 6404

panel and the expansion panel.

Up to four expansion panels, each with 2 zones, can be added to the Model 6404 control panel if additional zones are required.

To add Model 6402 expansion panels, follow these guidelines:

SEQUENCE OF OPERATION

The 6404 Control Panel is a heat call priority system with automatic mode changeover after 20 minutes of operation. If two calls

for opposing mode exist while the system is idle, the Heat call will be satisfied first. The heating equipment will not stop

operating until 1.) all heat calls have been satisfied, 2.) the minimum-on time lapses, 3.) the equipment has been on for 20

minutes and a cooling call exists or 4.) the call is interrupted by the plenum temperature sensor due to high limit settings. After

the heating equipment has stopped, calls for cooling can be satisfied. Similarly, once the cooling equipment comes on it will not

stop operating until 1.) all cool calls have been satisfied, 2.) the minimum-on time lapses, 3.) the equipment has been on for 20

minutes and a heat call exists or 4.) the call is interrupted by the plenum temperature sensor due to low limit settings.

Equipment operation is only interrupted if an Emergency Heat call exists. The sequence of operation is dependent on the position

of the ZONE 1/ANY ZONE switch and the HEAT PUMP or HEAT/COOL switch. A Time Delay Override (TDO) button is available on

the control panel to speed up the internal timer for system checkout. Note that immediately after the board is powered, there is a

four minute minimum off delay where only the fan output will respond.

Heat/Cool Changeover: When a call for heat/cool exists and an opposing call is made from another zone, a changeover time

limit of 20 minutes begins at the time that the opposing call is made. If the original call is not satisfied within that 20-minute

time period, the call will be interrupted, turning the equipment off and allowing for the normal fan purge cycle and minimum

equipment off time. The opposing call will then be answered. After 20 minutes, if the original call still exists, the opposing call

will be interrupted and the original call can once again be recognized.

High/Low Limit Temperature: The high/low limit temperature settings are designed to prevent the heat exchanger from

overheating or the cooling coil from freezing. An 8052 Sensor mounted in the supply duct senses the plenum air temperature and

interrupts the heating/cooling equipment (depending on the Heat and Cool temperatures set on the control panel) before

overheating/freezing occurs. When a heating/cooling call is interrupted by the high/low temperature limit, the zone control panel

turns the equipment off and energizes the G terminal (if not already energized). The Heating/Cooling LED on the control panel will

flash during a high/low limit temperature interrupt. Once the temperature drops/rises 10°F, the equipment is turned back on if the

call for conditioning still exists. The Heating/Cooling LED will then stop flashing.

Zone/Vac (Vacation) Selector: This switch allows the homeowner to switch

from normal operation (ZONE) to a VACATION mode. In VACATION mode (switch

in the ON position), Zone 1 becomes the only zone from which a call for heating

or cooling is recognized. Additionally, when in VACATION mode, damper outputs

do not change – they remain in the open position. The VACATION LED will

illuminate when the switch in in the VACATION position.

E-Heat Selector: This feature can only be used with heat pump systems. When the EMERGENCY HEAT switch is in the ON

position, any call for heat will be answered with auxiliary heat equipment outputs (W1 and W2). This feature enables the

homeowner to activate EMERGENCY HEAT mode when heat/cool thermostats are in stalled in all zones.

HEAT/COOL SYSTEM WHERE ANY ZONE SETS THE MODE

THERMOSTAT INPUT DEFINITIONS

All Zones: Heat = W, Cool = Y, Fan = G, 2nd Stage Heat or Cool = 2S

FAN OPERATION

A call for Fan from any zone will initiate the G equipment output terminal. The damper terminal at all zones not calling for

continuous fan will be energized.

HEATING OPERATION

When a zone makes a call for Heat, the W1 and B output terminals (and G terminal with the ELECTRIC/GAS switch in the ELECTRIC

position) will energize. The NO contact of the damper terminals for any zone not calling for Heat also energizes, while the NC

contact de-energizes. Following a 2-minute minimum on time, the W1 terminal de-energizes when (1) all zones stop calling for

Heat, (2) the call has exceeded the heat/cool changeover time limit while a cooling call exists or (3) the call is interrupted by the

high limit setting. The G terminal and any energized damper terminals remain energized for a one-minute purge delay if set to

PURGE. If set to NO PURGE, the G terminal de-energizes immediately and the dampers remain energized for a 3.5 minute purge.

When the W1 terminal is de-energized, a minimum off time delay of 4 minutes must elapse before it can be energized again.

Should any call for Heat not be satisfied in the time that is set on the STAGE dip switch bank, or should the 2S terminal of any

calling zone be energized, or the number of zones calling for conditioning matches or exceeds the # Zones to Stage setting, the W2

terminal will energize. If all the dip switches are OFF (zero stage time) the W2 terminal can only be energized if a 2S thermostat

terminal is energized. When the zone that initiated the W2 terminal is no longer calling, the W2 terminal will de-energize unless a

different zone has been calling for longer than the time set on the STAGE dip switch bank or unless another zone’s 2S terminal has

been energized. Following a 2 minute minimum on time (if set to GAS) or immediately (if set to ELECTRIC) the W2 terminal will

de-energize at the end of a heat call. Once de-energized, the W2 terminal has a 4 minute minimum off time if set to GAS or no

minimum off time if set to ELECTRIC. The B terminal remains energized until there is a Cool call.

COOLING OPERATION

When a zone makes a call for Cooling, the Y1, G and O terminals will energize. The NO contact of the damper terminals for any

zone not calling for Cooling also energizes, while the NC contact de-energizes. Following a 4-minute minimum on time, the Y1

terminal de-energizes when (1) all zones stop calling for Cooling, (2) the call has exceeded the heat/cool changeover time limit

while a heat call exists or (3) the call is interrupted by the low limit temperature setting. The G terminal and any energized

damper terminals remains energized for a one-minute purge delay if set to PURGE. If set to NO PURGE, the G terminal de-

energizes immediately and any energized damper terminals remain energized for a 3.5 minute purge delay. When the Y1 terminal

is de-energized, a minimum off time delay of 4 minutes must elapse before it can be energized again. Should any call for Cooling

not be satisfied in the time that is set on the STAGE dip switch bank, or should the 2S terminal of any calling zone be energized,

or should the number of zones calling for conditioning be greater or equal to the # Zones to Stage setting, the Y2 terminal will

energize. If all the dip switches are OFF (zero stage time) the Y2 terminal can only be energized if a 2S thermostat terminal is

energized. When the zone that initiated the Y2 terminal is no longer calling, the Y2 terminal will de-energize unless a different

zone has been calling for longer than the time set on the STAGE dip switch bank or unless another zone’s 2S terminal has been

energized. Once energized the Y2 terminal remains energized for a minimum on time of 4 minutes. Once de-energized, the Y2

terminal can not be energized again until a 4-minute minimum off time delay elapses. The O terminal remains energized until

there is a Heat call.

HEAT/COOL

OFFON

ANY ZONE

ZONE 1

HEAT PUMP

HEAT/COOL SYSTEM WHERE ZONE 1 SETS THE MODE

THERMOSTAT INPUT DEFINITIONS

All Zones: Heat Call = Zone 1 B + W, Cool Call = Zone 1 O + Y, Fan = G,

2nd Stage Heat or Cool = 2S

FAN OPERATION - same as previous

HEATING OPERATION - same as previous with the following exception:

The Zone 1 B terminal must be continuously energized for the control panel to recognize a call for heat from any zone.

When the Zone 1 B terminal is energized, cool calls will not be recognized.

COOLING OPERATION – same as above sequence with the following exception:

The Zone 1 O terminal must be continuously energized for the control panel to recognize a call for cooling from any zone.

When the Zone 1 O terminal is energized, heat calls will not be recognized.

HEAT PUMP SYSTEMS WHERE ANY ZONE SETS THE MODE

THERMOSTAT INPUT DEFINITIONS

Aux Time ≠0 (Heat /Cool thermostats in all zones): Heat = W, Cool = Y, Fan = G,

2nd Stage Heat or Cool = 2S, Emergency Heat = See “Emergency Heat Operation” below

Aux. Time = 0 (Heat Pump thermostats in all zones): Heat = Y, Cool = Y+O, Fan = G, 2nd Stage Heat or Cool = 2S,

Auxiliary Heat = Y+W, Emergency Heat = See “Emergency Heat Operation” below

FAN OPERATION

A call for Fan from any zone will initiate the G equipment output terminal. The damper terminal at all zones not calling for

continuous fan will be energized.

HEATING OPERATION

When a zone makes a call for Heat, the Y1, G and B output terminals will energize. The NO contact of the damper terminals for

any zone not calling for Heat also energizes, while the NC contact de-energizes. Following a 4-minute minimum on time, the Y1

terminal de-energizes when (1) all zones stop calling for Heat, (2) the call has exceeded the heat/cool changeover time limit while

a cooling call exists or (3) the call is interrupted by the high limit setting. The G terminal and any energized damper terminals

remain energized for a one-minute purge delay if set to PURGE. If set to NO PURGE, the G terminal de-energizes immediately and

the dampers remain open for a 3.5 minute purge. When the Y1 terminal is de-energized, a minimum off time delay of 4 minutes

must elapse before it can be energized again. Should any call for Heat not be satisfied in the time that is set on the STAGE dip

switch bank, or should the 2S terminal of any calling zone be energized, or should the number of zones calling for conditioning

match or exceed the # Zones to Stage setting, the Y2 terminal will energize. If all the dip switches are OFF (zero stage time) the

Y2 terminal can only be energized if a 2S thermostat terminal is energized. When the zone that initiated the Y2 terminal is no

longer calling, the Y2 terminal will de-energize unless a different zone has been calling for longer than the time set on the STAGE

dip switch bank or unless another zone’s 2S terminal has been energized. Once energized the Y2 terminal remains energized for a

minimum on time of 4 minutes. Once de-energized, the Y2 terminal can not be energized again until a 4-minute minimum off time

delay elapses. The B terminal remains energized until there is a Cool call.

HEAT/COOL

OFFON

ANY ZONE

ZONE 1

HEAT PUMP

HEAT/COOL

OFFON

ANY ZONE

ZONE 1

HEAT PUMP

AUXILIARY HEAT OPERATION

Auxiliary Heat can be controlled by time or by the thermostats.

Thermostat Control (Heat Pump thermostats in all zones): If the Y and W thermostat input terminals at any zone are

energized concurrently (assuming the heat pump is on in the Heat mode of operation), the W1 output terminal will energize

immediately. This is thermostat control.

Time Control (Heat/Cool thermostats in all zones): If it is desired to have the auxiliary heat come on after a specific amount

of time, set the appropriate AUX switch(es) to ON. Should any call for Heat not be satisfied in the time that is set on the STAGE

MINUTES plus the AUX MINUTES dip switch bank, the W1 equipment output terminal will energize.

Following a two minute minimum on time (if set to GAS) or immediately (if set to ELECTRIC), the W1 terminal immediately de-

energizes when both of the above two conditions no longer exist.

DUAL FUEL

Your system acts as a dual fuel system when the HEAT PUMP/HEAT COOL switch is set to the HEAT PUMP position and the

ELECTRIC/GAS switch is set to the GAS position. The dual fuel system is set up so that when the auxiliary heat comes on,

whether initiated by time or zone input, the compressor outputs (Y1 and Y2) will turn off before the W1 output is turned on. The

dual fuel mode effects auxiliary heat operation only.