Aprilaire Zoned Comfort Control 6202 User manual

Owner’s
Manual

Preface
Thank you for purchasing a new Aprilaire®Zone Control
System. We sincerely appreciate your business and are
pleased to add your name to our growing list of customers.
With this purchase, you have invested in the highest quality
equipment currently available.
Please be assured that in addition to product quality, we
are committed to product performance and complete
customer satisfaction. It should be of equal significance to
you that we have a network of dealers throughout North
America that sell, install, and service our products to help
back up our commitment to quality and performance.
Overview
The Aprilaire Zone Control System has been designed
to increase comfort in your home and reduce energy costs.
It’s able to do this because it solves the problem caused by
various areas of the home gaining and losing heat at
different rates. Unlike conventional heating and air
conditioning systems, Zone Control knows, at any given
time, which areas (zones) of your home require conditioned
air. With this information, the Zone Control automatically
directs the air to the zones that require it. Because of this, it
will not only increase the comfort level throughout your
home, it will also allow your equipment to work more
efficiently, thus reducing your energy costs.
The components that make up the Aprilaire Zone
Control System are the following: a Control Panel and air
control dampers, as shown in the illustration on the following
page. The Control Panel is located on an inside wall near
your heating and air conditioning equipment. The dampers
are located inside your air ducts in such a way that each
zone can be independently controlled.Thermostats, placed
in each zone, are directly connected to the Control Panel.
©Research Products Corporation 2000

Model Types
Models 6202 & 6203
These two models were designed to work with your single-
stage heat/cool equipment (for example a furnace and an
air conditioner). The 6202 is for two zones while the 6203 is
for three.
Models 6302 & 6303
These two models were designed to work with your heat
pump. Each of these models can handle three stages of heat
and two stages of cool. The 6302 is for two zones while the
6303 is for three.
Basic Operation
Your Aprilaire Zone Control System will allow you to increase
your comfort by directing conditioned air to separate areas
(zones) based on each zone’s thermostat setting.
To operate this system, just set or program each zone’s
thermostat to your desired comfort set points.When there is a
heating or cooling call from any zone, the appropriate heating
or cooling equipment will be turned on. The dampers to zones
not requiring heating or cooling will close and the conditioned
air will be directed to the calling zone (s) until the thermostat
is satisfied.
If one zone is calling for heat, while another zone is calling for
cooling during the minimum off time between cycles, the heat
call will be satisfied first. After the heat call is satisfied, the
cooling call will be satisfied. The heating and cooling
equipment will not operate at the same time.
Your zone control system is designed to direct conditioned air
only to the rooms served by that zone’s thermostat. However,
due to the open design of today’s homes, it may not be
possible to maintain drastic temperature differences between
zones. Closing interior doors is a good way to reduce the air
exchange between zones and increase the temperature
difference between them.
The following sections describe how to make Heating,
Cooling, and Emergency Heat calls.

Heating Operation (All Models)
To start heating:
1. Set your thermostat to the Heat mode. Depending on the
thermostat, this is accomplished by either manually
moving a switch to the Heat position or digitally selecting
Heat mode with a push button. Consult your thermostat
Owner’s Manual for details.
2. Adjust the thermostat set point to a temperature higher
than the displayed room temperature so that a Heat call is
initiated. Again, consult your thermostat Owner’s Manual
for details on how to do this properly.
When you have correctly initiated a Heat call, the Aprilaire
Zone Control Panel will start your heating equipment. If the
furnace does not come on right away it may be due to the
minimum-off time delay. Four minutes must elapse after the
last furnace cycle before it can come on again. This built in
feature ensures that the furnace does not cycle too
frequently, which can reduce the life of your furnace.
Cooling Operation (All Models)
1. To start cooling: Set your thermostat to the Cool mode.
Depending on the thermostat, this is accomplished by
either manually moving a switch to the Cool position or
digitally selecting Cool mode with a push button. Consult
your thermostat Owner’s Manual for details.
2.Adjust the thermostat set point to a temperature lower than
the displayed room temperature so that a Cool call is
initiated. Again, consult your thermostat Owner’s Manual
for details on how to do this properly.
When you have correctly initiated a Cooling call, the Aprilaire
Zone Control Panel will start your cooling equipment. If your
air conditioning does not come on right away it may be due to
the minimum-off time delay. Four minutes must elapse after
the last air conditioner cycle before it can come on again.This
built-in feature ensures that the air conditioner does not cycle
too frequently, which can reduce the life of your equipment.
Emergency Heat Operation
(Models 6302 & 6303 only)
Only your Zone 1 thermostat can put the system into the
Emergency Heat mode. Most likely the main living area in
your home is your Zone 1. The Zone 1 thermostat can

generally be identified by the presence of an additional mode
category of Emergency Heat. A call for Emergency Heat will
use a source of heating apart from your Heat Pump. To
operate Emergency Heat you must do the following:
1.Set your thermostat to Emergency Heat. Depending on the
thermostat, this is accomplished by either manually moving
a switch to the Emergency Heat position or digitally
selecting Emergency Heat mode with a push button.
Consult your thermostat Owner’s Manual for details.
2.Adjust the thermostat set point to a temperature higher than
the displayed room temperature so that a Heat call is
initiated. Again, consult your thermostat Owner’s Manual
for details on how to do this properly.
Once Zone 1 has successfully made an Emergency Heat call,
the control panel will remain in the Emergency Heat mode
until the Zone 1 thermostat calls for standard Heat Pump
Operation or it makes a Cooling call. While your Control Panel
is in the Emergency Heat mode, Zones 2 and/or 3 can not call
for cooling.
Note: Emergency Heat is generally much more expensive
to operate than the Heat Pump. Use only when necessary.
Your equipment may not include Emergency Heat.
Damper Operation (All Models)
When the Aprilaire Zone Control Panel receives a call and
turns on the appropriate equipment, it also automatically
closes the dampers that serve the non-calling zones and
opens those in the calling zones. When all calls are satisfied,
the Control Panel initiates a 1 minute purge cycle during which
time the dampers maintain their last position. After this purge
all dampers open.
Fan Operation for Models 6302 and 6303
The Model 6302 and 6303 Aprilaire Control Panels allow you
to control fan operation through your Zone 1 (usually main
living area) thermostat. Fan operation has no effect on
damper operation.
Fan Operation for Model 6202 and 6203
The Model 6202 and 6203 Aprilaire Control Panels allow you
to control fan operation from any zone. Dampers in zones not
calling for fan will close. If continous fan operation is desired in all
zones, the fan must be turned on at the thermostat in each zone.

Turning the System Off (All Models)
In order to shut off the system and prevent the Aprilaire
Control Panel from turning on your equipment, you need to
set ALL of your thermostats to the OFF mode. Depending on
your thermostats, this is done manually with a slide switch on
your thermostat’s sub-base or with a digital push button.Consult
the Owner’s Manual for your particular thermostat.
If leaving the home for a long period of time, set the Zone 1
thermostat to the Heat mode and adjust the set point to a
temperature that will prevent freezing in all areas of the home.
It is not recommended to turn off all thermostats for extended
periods in climates where freezing temperatures may occur.
System Pressure Relief
With a Zone Control System, some form of pressure relief
must be designed into the system to assure proper operation
and reduce the possibility of noise due to airflow. The method
of pressure relief that has been designed into your system
could include use of a bypass damper or the Zone Control
strategy of controlled pressure relief. With the Zone Control
strategy, a predetermined amount of air is allowed to pass
through a closed damper. The amount of air that is passed by
each damper (the bypass) is not enough to cause a noticeable
temperature change in a non-calling zone, but is enough to
relieve the higher system pressures.
So, if you feel small amounts of air entering into a non-
calling zone, what you are feeling is the bypass air.
Remember, this bypass is normal and provides pressure
relief for the system without causing a noticeable change
in temperature within that zone.
Maintenance
Once your Aprilaire Zone Control System is properly installed,
there is no maintenance required.

The above illustration shows a typical three zone Aprilaire Zone
Control system with the following Research Products
Corporation components added for the ultimate in indoor air
quality and comfort:
• Eliminates dry nose, dry throat, itchy skin.
• Reduces static electricity.
• Reduces heating costs because you feel warmer at lower
temperatures.
• Proper humidity helps repel upper respiratory problems
caused by excessively dry air. Ask your doctor.
• Protects your home and furnishings from damaging
dryness and shrinkage.
• Reaches 99% efficiency on particles five microns or larger.
• Provides allergy relief.
• Lifetime limited warranty.
• Filtering media lasts one to two years.
• Protects heating and cooling equipment.
• Absolutely silent operation.
• Requires no service calls.
• Uses no electricity.
• Produces no ozone.
• Provides a constant, controlled supply of fresh air to your
home year-round.
• Reduces unhealthy indoor air pollutants, such as radon,
formaldehyde, smoke, and odors.
• Handles up to a 3,600 sq. ft. home, and conserves energy
by efficiently retaining the energy value from indoor air.
• Helps produce a quiet, safe, secure, healthy indoor
environment.
• Saves energy and energy costs with pinpoint accuracy.
• Ultra-slim, attractive vertical design to enhance any decor.
• Provides ultimate comfort and reliability through state-of-
the-art engineering.
• Easy-to-set, easy-to-read controls.
For information on any of these products, please contact your
heating and air conditioning contractor or feel free to write or call us.
A
B
C
Zone 1
68˚F (20˚C)
Zone 2
70˚F (21˚C)
Zone 3
65˚F (18˚C)
A
B
C
D
D

LIMITED WARRANTY
Your Research Products Corporation Aprilaire®Zone Control
System is expressly warranted for two (2) years from date of
installation to be free from defects in material or workmanship.
Research Products Corporation’s exclusive obligation under
this warranty shall be to supply, without charge, a replacement for
any part of the zone control system which is found to be defective
within such two year period and which is returned not later than thirty
(30) days after said two year period by you to either your original
supplier or to Research Products Corporation, Madison, Wisconsin
53701, together with the model number, serial number, and
installation date of the unit.
THE WARRANTY SHALL NOT OBLIGATE RESEARCH
PRODUCTS CORPORATION FOR ANY LABOR COSTS AND
SHALL NOT APPLY TO DEFECTS IN WORKMANSHIP OR
MATERIALS FURNISHED BY YOUR INSTALLER AS
CONTRASTED TO DEFECTS IN THE ZONE CONTROL SYSTEM
ITSELF.
IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN
DURATION TO THE AFORESAID TWO YEAR PERIOD.
RESEARCH PRODUCTS CORPORATION’S LIABILITY FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES, OTHER THAN
DAMAGES FOR PERSONAL INJURIES, RESULTING FROM ANY
BREACH OF THE AFORESAID IMPLIED WARRANTIES OR THE
ABOVE LIMITED WARRANTY, IS EXPRESSLY EXCLUDED. THIS
LIMITED WARRANTY IS VOID IF THIS UNIT IS NOT INSTALLED
BY A QUALIFIED HEATING AND AIR CONDITIONING
CONTRACTOR. IF THE LIMITED WARRANTY IS VOID DUE TO
FAILURE TO USE A QUALIFIED CONTRACTOR, ALL
DISCLAIMERS OR IMPLIED WARRANTIES SHALL BE
EFFECTIVE UPON INSTALLATION.
Some states do not allow limitation on how long an implied
warranty lasts or the exclusion of limitation of incidental or
consequential damages, so the above exclusion or limitations may
not apply to you.
This warranty gives you specific legal rights and you may also
have other rights which vary from state to state.
®
P.O. BOX 1467 • MADISON, WI 53701-1467
Call 608/257-8801 • FAX [phone]
Products For Better Indoor Air Quality™
DP10005202 2.8.00