Arzel AirBoss User manual

1
Arzel® Zoning Technology, Inc.
INSTALLATION INSTRUCTIONS
Models with 2, 3, 4, 6 and 8 Zones
Comfort, Reliability and Easy Installation
U. S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.
Rev. 5/1/01
Arzel Zoning Technology, Inc.
4801 Commerce Parkway
Cleveland, Ohio 44128
Toll Free 800-611-8312
[phone]
Fax [phone]

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For just a few dollars a month
You can extend your warranty for 10 years
Please ask your installing contractor for details.
This offer expires 180 days from the purchase date of your Arzel Zoning Equipment.
Purchaser Name:_______________________________________
Date of Purchase:______________________________________
Date Installed:________________________________________
Model#:____________________ Serial#:___________________
Address:_____________________________________________
____________________________________________________
NOTES:
Warranty Brought to you by:
Arzel®Zoning Technology, Inc.
Rev. 5/01/01
© copyright 2004 by Arzel Zoning Technology, Inc.
YourArzel Zoning System comes with a 5 year
parts and labor warranty at no additional cost.
You may choose to purchase extended
protection for up to 10 years.

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TABLE OF CONTENTS
3 ZoningGlossary
4 When Installing This Product . . .
4 General System Operation
4 Locating and Mounting the Control Panel
4 24-Volt Power Supply and Grounding
5 Thermostats
5 Equipment Set-Up (Furnace/Heat Pump)
6 HVACOutput
6 ZoneSolenoids
7 Staging with Single-Stage or Two-Stage Thermostats
7 Second-Stage Heating and Cooling Delay and Timer Settings
7 Heat Pump Control Operation: Emergency Heat Operation
8 Heat Pump with Fossil Fuel Back-Up Heat (Dual Fuel Systems)
8 Three Way Priority System: Heating - Cooling -Automatic
8 Call Waiting
9 Energy Conservation Cycle (ECC)
9 ECC Bypass
9 Compressor Lockout TDO 1 (Stage 1) and TDO 2 (Stage 2)
9 Fan-On-Heat Operation
10 Master Zone Control (MZC)
10 LAT Limit Controls for Heating and Cooling
11 Sensor Verification Test
11 Smart Slave Zone (SSZ )/Slave Thermostats
12 Air Pump Operation
12 Manual Pump Switch (MPS )
13 Damper Installation Procedures (Round)
14 Damper Installation Procedures (Square and Rectangular)
15 Air Tube Connection
15 IdentifyingtheZones
15 Damper Position Indicator
16 Bypass Damper Installation, Adjustment and Checkout
17 System Checkout
Rev.5/01/01
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.
Page No. Topic

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Arzel Series - AirBoss™Zoning System
Zoning Glossary
Air Pump: The Arzel®Zoning System uses
self-contained, low-pressure micro pumps to open
and close dampers. They provide noiseless, long-life
and economical service. P. 12
Automatic Bypass Control: Pressure-switch
operated bypass control is available. (Must be
ordered separately.) P. 16
Compressor Lockout “ Timed Off Delay”: When the
compressor is turned off, it cannot restart for 4
minutes. This feature allows the refrigerant pressure
to balance before restarting. P. 9
Damper Positioning Delay: On a call for Heat, the
damper closure will delay for 1 minute to allow the air
handler to start before any dampers are positioned.
This provides for a SofStart™.
Damper Position Indicator: External indicator of the
damper position. Makes troubleshooting and system
check-out easy. P. 15
Emergency Heat: A changeover switch (manual or
remote) is located on the PC board for heat pump
operation only. P. 7
Energy Conservation Cycle (ECC™): Dampers remain
open for 2 minutes, in the last zone that called for
heating or cooling, to take advantage of additional
energy savings from residual heating and cooling in
the HVAC system. P. 9
EzySlide™ Damper Installation: Round and
rectangular dampers are available from 4” to 40”.
P. 13
Fan-On-Heat: In the “ON” position, the fan starts
immediately with any call for heating at the HVAC
Output terminals. P. 9
Fossil Fuel Back-up Switch: Switches customize the
system operation for a Fossil Fuel backup furnace
when used with a heat pump. This eliminates the
need for a fossil fuel kit. P. 8
Heat Pump: All AirBoss™ systems are fully heat
pump compatible. P. 7, 8
LeavingAir Temperature Control (LAT): Easily set
with rotary switches; range is 40°F to 56°F for cooling,
and 110°F to 180°F for heating. LAT sensor kit with
15-ft. cable is included. P. 10,11
Manual Pump Switch (MPS™): Opens all dampers
during emergency or test operations by switching
“MPS” to “ON” and “PWR” switch to “OFF”. P. 12
Master Zone Control (MZC™): Can be set-up either by
a programmable thermostat, manual switch or a time
clock. It gives control of the entire HVAC system to the
Zone 1 thermostat. Use for occupied/unoccupied
set-back, or set-up programs. P. 10
Self-Testing LAT Circuit: LATcontrol will indicate, with
LED flashes, when the sensor is shorted or open. P. 10
Sensor Verification: Easy conversion of LAT (DC
Voltage) reading to monitor temperatures in the supply
duct. P. 11
Smart Slave Zones (SSZ™): A Smart Slave Zone
thermostat controls dampers only. It does not control
the HVAC equipment, and only opens its dampers when
the conditioned air in the ducts matches its
requirements. Any number of thermostats
(programmable/ non-programmable or autochangeover)
can be used. P. 11
Thermostat Selection: Any standard thermostat,
programmable/non-programmable or auto-changeover
over can be used. Heat pump thermostats are required
on all zones for heat pump installation. P. 5
ThreeWay Priority™System: Provides a selection of
“Heating”, “Cooling” or “Automatic” Priority Systems. In
Automatic mode, the first call establishes priority.
Heating and Cooling calls always override fan-only
operation. Under any priority, an opposing call, after
waiting 20 minutes, will take control of the system
and serve its zone for up to 20 minutes. All zone
thermostats have equal, full-function heating, cooling,
and fan capability. P. 8
Transformer: A single 24 Volt AC Transformer (40 or
100 VA) is included to power all Arzel equipment,
dampers and thermostats. P. 4
Two-Stage: Heating and/or cooling is available from all
zones with either 2-stage or single-stage thermostats.
Second-stage time delay can be adjusted from 2 to 30
minutes if a single-stage thermo stat is used.
Second-stage (both heating and cooling) is delayed by
30 seconds to prevent starting both stages
simultaneously. P. 7
Rev. 5/01/01
© copyright 2004 by Arzel Zoning Technology, Inc.
U.U.S. and Foreign Patents & patents pending.

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1. Read these instructions carefully.Failure to
followthem coulddamage theArzel®Zoning
System and/or cause a hazardous condition.
2. Disconnect the power supply to the HVAC
system and the Zoning System before making
anywiring connectionsto preventthe dangerof
electricalshock orequipmentdamage.
3. The Arzel System is designed for indoor use
only.
4. Youmust touchagrounded metalobjectbefore
handlingthe ControlPanel toavoidpotential
loss of internal programs due to electrostatic
discharge.
5. Installin ambienttemperature between40oF
and95oF ina non-condensingarea.
6. Besure theHVACmanufacturer’s operating
specifications are compatible with the Arzel
ZoningSystem.
WHEN INSTALLING THIS PRODUCT...
CONTROL PANEL DANGER!
7. Check all sysem operations after installation is
complete.
8. All wiring must comply with applicable electrical
codes,ordinances andregulations.
9. Useproperly groundedtools,safety glassesand
gloves,when drillingor cuttingsheet-metal
ducts, fiberglass or any hard objects.
10.The damper bladegently wipesthe insideofthe
ductwork.Insert asleeveinside anyfiber- glass,
orabraidable ductwork, sothe bladedoes not
abradethematerials intothe air.
11. Leave these instructions with the installed
system for future use.
12.There arebothAC andDC Terminals onthe
circuit board. Do not intermingle wires.
13. All LAT limit controls are to be used as
secondary controls only. The LATcontrol
settingmust bebelow/above yourprimary
factoryprotection level.
GENERAL SYSTEM OPERATION:
Acall from any zone thermostat will call on the HVAC equipment, position the solenoid air valve and open
the dampers for its zone. Both micro pumps are energized to automatically position the dampers, either
openorclosed, asrequired. The vacuum pumpopens thedampers, and thepressure pumpclosesthe
dampers. When the thermostat is satisfied, a 3-minute Energy Conservation Cycle™ (ECC) is initiated
and the dampers are held in place for 2 minutes. This will deliver the residual conditioned air to the last
zone(s) served. In the third minute, the micro pump continues to operate to open all the zone dampers for
a SofStart™ on the next cycle. See ECC Bypass (Fig. 9d) if you wish to eliminate the third minute of the
ECC cycle.
LOCATING AND MOUNTING THE CONTROL PANEL:
Locatethe controlpanel ona wallarea nearthe HVAC air-handlingequipment (furnace,fan, coil,etc.)
5-feetabove the floor. Do notmountthe controlpanelon ductwork orHVACequipment. Panelsshould be
installedin non-condensingareas atan ambienttemperature rangebetween 40oF to150oF.
24-VOLT POWER SUPPLY AND GROUNDING:
One 24-VoltAC transformer (provided with the system) powers all zone thermostats, and theArzel
ControlPanel.The HVACsystemtransformerprovides powerfor theheatingand air-conditioning
equipment outputs only. Do not mix HVAC andArzel transformer outputs.Apositive ground terminal is
providedfor groundingconnection. (Fig. 5a)
Rev. 5/01/01
© copyright 2004 by Arzel Zoning Technology, Inc.
U.S and Foreign Patents & patents pending.

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THERMOSTATS
Wires coming from the zone thermostats must be connected to the input terminals in the panel for their
respectivezones (Fig. 5b).Use anystandard thermostat:"Heat/Cool” and“Fan-Auto-On" sub-base
switching,Programmable/Non-programmableorAuto-changeover.“R” and“C”terminalsareavailablefor
all zones from the 24V AC circuit. Staging can be accomplished either with two-stage thermostats or
single-stage thermostats in combination with the built-in Arzel Delay Timer (ADT™). Be sure to set
heating anticipator to the shortest or lowest setting (if adjustable). Heating operation is indicated by red
LEDs (W1 and W2). Compressor operation is indicated by yellow LEDs (Y1 and Y2). Fan operation is
indicatedbygreen LEDs. Heatpump thermostats arerequired onall zones forheat pumpoperation.
Locate the thermostats for each zone in a central area within the zone on an inside wall, five
feet from an outside wall and five feet from the floor. Avoid areas near register outlets, lights
and other equipment that could cause a false reading.
EQUIPMENT TYPE SET UP ( FURNACE / HEAT PUMP )
The Arzel AirBoss™ System is factory set for furnace applications. Any time the board PWR switch
is turned ON, the system will automatically check itself and flash the appropriate LED to indicate the
type of equipment it is set up to handle. For Heat Pump use, you MUST turn the PWR switch OFF
and move the “Furnace/Heat Pump” switch to the “Heat Pump” position (Fig. 5c).Turn the PWR switch
back to ON and the panel will respond to Heat Pump demands.
(Fig. 5a )
Arzel Panel (Fig. 5b)
•Furnace mode: TDO-2 (DS18 LED) will flash once on power-up. (See p.9, Fig.9b)
• Heat Pump mode: TDO-1 (DS17 LED) will flash once on power-up. (See p.9, Fig. 9b)
( Arzel Panel )
( Fig. 5c )
Rev. 5/01/01
© copyright 2004 by Arzel Zoning Technology, Inc.
U.S. and Foreign Patents & patents pending.

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HVAC Output
TheAirBoss™controls the HVAC equipment through a set of six “dry contact” output relays. When a
thermostat calls for equipment operation, the AirBoss™closes the appropriate output relays, sending the
“R”signal fromthe HVACTransformerbackto theappropriate equipmentterminals.
There are LEDs directly below the HVAC output terminal strip. When the output relays close, the
coresponding LEDs are illuminated (Fig. 6a).
Bringthe Equipment transformerR andC tothecoresponding terminalson theHVACTerminal strip.
Zone Solenoids
Signal LED Indication Service Provided
W1, W2 Red first and second stage heat
Y1,Y2 Yellow first and second stage compressor
G Green fan
O Yellow reversing valve (energized in cooling)
B No LED reversing valve (energized in heating)
Fig 6a Fig. 6b
Damper positioning is controlled by a bank of 24VDC solenoids (one per zone) mounted along the top of
the box. When a zone is to be served, the solenoid is de-energized and a vacuum passes through the
valve, opening all the dampers in that zone. The zones not calling will energize their solenoids allowing
a pressure to pass through the valves, closing all the dampers in those zones. The zones that are open
forservice areidentifiedby agreen litLED belowthe “Zone Solenoid”terminal block(Fig. 6b).
REMEMBER:
VacuumOpens the Dampers
PressureClosesthe Dampers
The solenoids are 24VDC.
Do not connect thermostat or transformer wires to the solenoid terminals. Damage will occur.
Rev. 5/01/01
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

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SECOND-STAGE HEATING AND COOLING
DELAY AND TIMER SETTINGS
Second-stage heating and second-stage cooling delay can be activated by the ON or OFF switches
provided. You may select either or both. If you want to control the second-stage heat and/or cooling
with a single-stage thermostat, set the HTG-DELAY and/or CLG-DELAY slide switches to ON and set
the rotary Delay Timer for the desired delay time. The delay time will be the same for heating and
cooling. The timer is activated by a W1 or Y1 signal at the HVAC Output (Fig. 7a).
HEAT PUMPCONTROLOPERATION:
EMERGENCYHEAT OPERATION (HEATPUMPONLY)
AllArzelAirBoss™ system boards have emergency or backup heat capability. When the Emergency heat
mode is activated it will convert all “Y” signals to “W” signals, thus bypassing heat pump operation and
activating backup heat. Emergency heat mode can be initiated either with the “Emergency Heat” switch
on the panel, a remote (outdoor) thermostat or a call for “W1” in the Fossil Fuel mode. The
Emergency Heat Mode can also be initiated by using a 24V AC relay energized by a designated
thermostat’s “E” terminal. The relay Com-N/O contacts will provide closure to the Emergency Heat
Remotecircuit.
STAGING WITH SINGLE-STAGE OR
TWO-STAGE THERMOSTATS
Stagingcan be accomplishedwith eithersingle-stage ortwo-stage thermostats.
Single-stage thermostats: W1 and Y1 are controlled by the thermostat. W2 and Y2 are brought on
bythe ArzelHeating andCooling DelayTimer(see paragraphbelow).
Two-stage thermostats: W1, W2, Y1, and Y2 are all controlled by the thermostat. W2 and Y2 are
always delayed by 30 seconds to prevent both stages from coming on simultaneously.
(Fig. 7a)
(Fig. 7b)
Rev. 5/01/01
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.
Emergency heat mode is indicated by a red LED located to the right of the manual switch.

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HEAT PUMP WITH FOSSILFUELBACK-UPHEAT
(DUAL FUEL SYSTEMS)
Fossil Fuel Switch: The Arzel AirBoss™ Series lets you customize the system for fossil fuel backup
heat, without the need for a fossil fuel kit. When switched to “Fossil Fuel” and the system is operated
in emergency heat mode, theArzel board will add 50° F to the “HTG. LAT” set-point (up to a safety
maximumof 190°F). *NOTE* Arzel controls must be used as secondary controls only.
The control setting must be below your primary factory protection level.
Thisaccommodates thehigher temperaturesrequired forthe fossilfuel backupfurnace (Fig. 7b).
Fossil Fan Switch: Will break the “G” circuit, allowing the furnace to control the fan cycle when the
system is operated in emergency heat (Fossil Fuel) mode (Fig. 7b).
If you are not using a fossil fuel backup furnace, you must leave these switches in the Off position!
CALLWAITING:
In heating, cooling or automatic priority mode, an opposing call (i.e. a cooling call when in heating mode)
after waiting 20 mins. will be served as follows: The waiting call will shut down the existing service, go
through the Energy Conservation Cycle (ECC) and serve itself for up to 20 minutes. If after this 20 mins.
the earlier call is still there, the service will revert to the original call after completing an Energy
Conservation Cycle. This feature eliminates the problem of opposing service calls waiting too long to be
served. Rev. 5/12/04
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.
THREE WAY PRIORITY™ SYSTEM
PROVIDES A CHOICE OF HEATING, COOLING OR
AUTOMATIC PRIORITY ( FIG. 8A )
In Heating Priority: Heatingpriority allowsheating tohave priorityovercooling andcooling tohave
priority over constant fan operation. Any zone calling for heating will be served immediately. Any
zone calling for cooling will be served immediately if no other zone wants heating. Any zone can have
constant fan, if no other zone wants either heating or cooling. Heating operation is indicated by red
LEDs (W1 and W2).
In Cooling Priority: Coolingpriority allowscooling tohave priorityover heatingand heatingto have
priority over constant fan operation.Any zone calling for cooling will be served immediately. Any zone
calling for heating will be served immediately if no other zone wants cooling. Any zone can have
constant fan, if no other zone wants cooling or heating. Compressor operation is indicated by yellow
LEDs (Y1 and Y2).
In Automatic Priority: Auto priority will allow the first call (either heating or cooling) to establish the
priority sequence for this cycle. A heating or cooling call will always override fan-only operation. Any
zonecan have constantfan ifno other zonewants eitherheating orcooling.
In Fan ON Operation: Constant fan operation is available unless other zones call for heating or
cooling. Any thermostat in the Fan ON position will start the fan and open its zone dampers for air
circulation. All other zone dampers will be closed automatically. Fan operation is indicated by a green
LED(G).
( Fig. 8a )

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ECCBYPASS
Insome applications, wheresmaller zonestend tooverheat duringthe third (last)minute ofthe Energy
Conservation cycle, the ECC Bypass can be switched OFF, eliminating the third minute and leaving
dampers in the last call position (Fig. 9d).
COMPRESSOR LOCKOUT TDO 1 (STAGE 1) AND TDO 2
(STAGE 2)
All Arzel®circuit boards have a 4-minute compressor lockout timer (delay on break) on the compressor
circuit. When the compressor is turned off, it will stay locked out for 4 minutes. This allows the
refrigerant pressures to equalize. Time delay lockout is indicated by 2 yellow LEDs, TDO 1 (Stage 1)
and TDO 2 (Stage 2).
NOTE:Twomomentary-contactTime DelayOverride(TDO)switches,one foreachstage, areprovided
on the PC board (Fig. 9b) to speed the checkout of the HVAC system. Before using the TDO
switches you must disconnect the HVAC “R” wire to avoid short-cycling the compressor.
FAN-ON-HEAT OPERATION
Use the Fan-On-Heat switch if immediate fan operation is desired on a call for heating, such as with
electric furnaces, hot-water coils, steam coils, etc., (Fig. 9c). Fan operation is also indicated by a
green LED (G) at the zone calling and at the HVAC Output LED.
ENERGY CONSERVATION CYCLE (ECC™)
After every cycle completion, dampers will be held in place for two minutes and supply residual
conditioned air to the last zone served. After two minutes, the micro pumps continue to operate for
another minute to open all the zone dampers for a SofStart™ on the next cycle. The momentary Energy
ConservationOverride (ECO)switch (Fig. 9a) will overridethe cycleduringtestorset-upoperation.
Rev. 5/12/04
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.
Fig. 9a Fig. 9b
Fig. 9c Fig. 9d

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Duringnormal operationof zoningequipment, theamount ofair passingthrough theair conditioning coil
orover theheat exchangermaybe reducedto apoint thatundesirable airtemperatures maydevelop in
the duct system (too cold or too hot). The LeavingAir Temperature (LAT) system is used to cycle theAC
compressoror heatingsystem topreventevaporator coilfreeze-up oroverheatingof theheat exchanger.
Install the Sensor into the supply duct just around the corner from the Plenium and connect to the “LAT
Sensor” terminals (Fig. 10b). Connect the Green grounding lead to the ground terminal at the 24 VAC
terminals (Fig. 5a) along with the mechanical ground wire.Add no more than 25 ft. of wire to LAT Sensor.
NOTE: All LAT limit controls must be used as secondary controls only.
The LAT control setting must be above/below your primary factory protection level.
LAT SYSTEM SET-UP
Setbothrotaryswitches(Heating LATand Cooling LAT)tothe desiredheating andcooling limits(Fig.10a).
Heating LAT settings range from 100° F to 180° F and OFF.
Cooling LAT settings range from 40° F to 56° F and OFF.
If you do not wish to use either or both, place the unused rotary switch pointer to the Off position.
You must install the sensor or place both rotary switches to the Off position.
Self Test: TheArzel Panel automatically detects an open or shorted LAT sensor and locks out the
equipmentaccordingly.
· Both Red LED’S at Heating LATflashing indicates a shorted sensor wire or probe.
· Both Yellow LED’S at Cooling LAT flashing indicates an open sensor wire or probe.
High LAT: The temperature setting cycles the first-stage heating at set point temperature. Second-stage
heating is automatically cycled 10° lower than high temperature setting. Both stages will re-connect after
a15° temperaturedrop.
Low LAT: The temperature setting cycles the first-stage cooling at set point temperature. Second-stage
cool- ing is automatically cycled 5° higher than set point temperature. Y1 will reconnect after a 4-minute
time delay if the duct temperature is above set point. Y2 will reconnect after a 4-minute time delay, if the
duct temperature is 5° aboveset point.
NOTE: All LAT limit controls are to be used as secondary controls only.
The LAT control setting must be above/below your primary factory protection level. Rev. 5/01/01
MASTER ZONE CONTROL (MZC®)
Moving this switch to the ON position or closing a circuit across the “Set-Back” terminals, establishing
Zone1 asthe“Master Zone”and allowsautomatic (occupied/unoccupied) set-backor set-upcontrol. The
“Master Zone Control” mode operates as a single zone system: all zone dampers open and the
equipment is cycled based on Zone 1 thermostat settings. Master Zone operation may be initiated by
manual operation of the switch or it may be operated by a time clock or programmable thermostat with
dry contacts that close in the unoccupied mode (wired across the MZC Remote terminals). The switch
and the remote terminal are electrically parallel. You may use either one or both (Fig. 10b).
LAT™ (Leaving Air Temperature) Limit Controls for Heating and Cooling
(Fig. 10a) (Fig. 10b)
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

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Sensor Verification Test
Proceedas follows:
With LAT sensor connected to PC Board:
1. Insert test thermometer into duct as near to LAT sensor as possible.
2. Measure DC voltage across two LAT terminals.
3. Voltagereadingshould indicate thesame temperatureas testthermometer readingshown
on chart (Fig. 11a), plus or minus 3° F.
4. Ifvoltage readingis differentthanchart voltage,proceed tothe followingsensor check.
With LAT sensor disconnected from PC Board:
1. Measure resistance across sensor at 100k to 200k Ohm scale. Ohm reading should
indicate the same temperature as test thermometer chart below. (Fig. 11a)
2. If Ohm reading does not match chart (+ or - 10 %), replace the sensor.
3. If Ohm reading matches the chart, check for 5 volts DC at LAT terminals.
4. If voltage is not 5 Volt DC, replace PC Board.
LAT - TEMPERATURE / OHMS / DC VOLTAGE RELATIONSHIP CHART
SMART SLAVE ZONE (SSZ™) Thermostat
Anynumber ofSmartSlave Zonesmay beadded toall Arzelpanels. The SmartSlave Zonethermostat
does not control the HVAC equipment. It will only open its zone dampers if the air temperature in the
duct is compatible with the thermostat call. Smart Slave Zone operation is indicated by the LED on its
PC board. If the LED is lit, the damper is in the open position. Do not use a Heat Pump thermostat for
theSmart SlaveZones.
SMART SLAVE ZONE (SSZ™) WIRING AND TUBE CONNECTIONS (Fig.12a)
• SmartSlaveZone thermostatsdo notneeda heating-coolingsub-base tooperate but couldbe
used to lock out cooling calls in the heating season or heating calls in the cooling season.
• Connect “R”, “W” and “Y” thermostat wires to “R”, “W” and “Y” terminals on the Smart Slave
Zone PC board.
• ConnectSmart SlaveZone dampertubing totheSmart SlaveZone solenoidbulkhead fittingon
top of the panel.
• Do not use a heat pump thermostat for any Smart Slave Zone, in Heat Pump applications.
(Fig. 11a)
Temp Ohms (k) DC Volts Temp Ohms (k) DC Volts
40 26.1 3.82 76 10.2 2.85
42 24.7 3.77 80 9.3 2.72
44 23.4 3.72 90 7.3 2.42
46 22.1 3.69 100 5.8 2.14
48 20.9 3.63 110 4.7 1.88
50 19.9 3.57 120 3.8 1.63
52 18.8 3.52 130 3.0 1.41
54 17.9 3.46 140 2.5 1.22
56 16.9 3.40 150 2.0 1.05
58 16.1 3.35 160 1.7 0.90
61 14.5 3.28 170 1.4 0.77
70 11.8 2.98 180 1.2 0.66
Rev. 5/01/01
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

13
AIR PUMP OPERATION
Both pumps will start and position up to 50 dampers any time there is a call for heating, cooling or fan
operation. Both pumps will stop three minutes after the last thermostat is satisfied. Pumps will restart
for any call for heating, cooling or fan from any thermostat. Pump operation is indicated by a red LED
(Pump). Both pumps are delayed one minute on a call for heat (fossil fuel) to allow the blower to start
before any dampers close. Pumps are designed for continuous duty.
MANUAL PUMP SWITCH (MPS™):
The Manual Pump Switch (MPS) (Fig. 12b) is provided to test the damper system and to bypass the
zoning system in case of a board emergency. This switch will start the pumps manually and with the
“Power” switch in the OFF position, all the zone dampers will open. This will aid in troubleshooting by
allowing the operation of the HVAC system independent of theArzel panel, if you suspect a PC board
failure.
YOU CAN BYPASS THE ZONING SYSTEM BY FOLLOWING STEPS BELOW:
1. Turn theArzel PWR switch off. You must keep this switch in Off position to blockALL
zone thermostats from calling for service and placing all the zone dampers in the normally
open position.
2. Disconnect the wires from any one zone thermostat terminal and connect them to the
HVAC Output terminals.
3. Turn the MPS switch ON.
The HVAC equipment will now be controlled by the one thermostat connected to the Output terminals.
The pumps will run continuously, holdingALL the dampers open. Only the pump LED will be on. All
other LEDs will be off in this mode of operation.
Fig. 12b
Fig.12a Arzel Panel
Arzel Panel Rev. 5/01/01
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

14
Damper Installation Procedures
INSTALLING ROUND DAMPERS - EzySlide™ TYPE “R”
The EzySlide “R” damper is designed to be inserted from the bottom, top or side of round ducts without
cuttingoff orremoving sectionsof theduct. Anadhesive templateis providedwith eachdamper.
Removebacking paperand placetemplate onduct (Fig 13a) ,observingdirection ofairflow arrowon the
template. Cut out required triangle (Fig. 13b). Insert damper blade with blade facing the long side of
the triangle (Fig 13c). Rotate damper so that the flat side of the blade is positioned to face airflow
(not the side with the connecting rods) and fasten with four sheet-metal screws (Fig. 13d).
(Fig. 13c) (Fig. 13d)
(Fig. 13a ) ( Fig. 13b )
Rev. 5/12/04
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

15
INSTALLING SQUAREANDRECTANGULAR DAMPERS -
EzySlide™TYPE “S”
The EzySlide “S” damper is designed to be inserted in an existing or new rectangular duct from the
bottom, top, or side of the duct. Cut a slot 5 inches wide by any required length. The slot should be cut
to 3/4-inch from each duct corner (Fig 14a). This will avoid the need to cut into the “Pittsburgh Lock” in
the duct and leave sheet metal for the mounting plate screws. Slide the damper into the duct at an
angle to avoid cutting the gasket (Fig. 14b). Position the flat side of the blade to face airflow (not the
side with the connecting rods). Fasten with sheet-metal screws (Fig. 14c).
Fig.14a
Fig. 14b
Fig. 14c
Rev. 5/12/04
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

16
CONNECTINGAIRTUBESTODAMPERS
Each zone has one air line bulkhead fitting on the top of the Arzel® panel. Each air line provides
vacuum and pressure, as needed, to open and close the dampers. All additional dampers in each zone
must be connected with a “T“ fitting to its main zone air line. For example: Zone #1 air line must be
connected to all the dampers in Zone #1. A cap or plug must be placed on any unused zone fittings or
tubes. Tubing is available in eight colors to easily identify each zone.
IDENTIFYINGTHEZONES
Tubing isavailable ineightcolors foreasy tracingand identificationofdampers. To avoid zonemix-ups,
markall supply ductsclearlywithroom designationand properzone number.TheArzelDuct-Finder™
makes duct tracing easy.
DAMPERPOSITION INDICATOR
Observe themovements ofthe damper positionindicator (Fig. 15a). Yellow indicatorshows the position
of the damper. Note: Not to be used as a manual override.
Fig.15a
Damper OPEN Position Damper CLOSED Position
Rev. 5/12/04
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

17
BYPASS DAMPER INSTALLATIONandADJUSTMENT
Automatic pressure switch operated or barometric Bypass damper systems are installed to
relieve excess air pressure that is sometimes caused by zoning. Excess air pressure may
create high air velocity and air noise. Install a bypass duct directly between the supply air
trunk line and the return air trunk line. The bypass supply air takeoff must be installed before
any trunk line dampers. We recommend the bypass be connected to the return duct as far
away from the air handler as possible for optimum performance. This will allow for the supply
air to mix with the maximum amount of return air. One of the benefits of zoning is the ability to
increase the static pressure in a zone that is difficult to condition ( 2nd floor, long ranch homes,
etc.). Don’t waste needed energy by over-sizing or prematurely opening the Bypass damper.
Automatic Bypass Control, Adjustment and Checkout:
1. Connect the pressure switch NORM OPEN and COMMON terminals (Fig. 16a) to terminals A and B
on the Arzel board (Fig. 16b) with standard 18-2 wire. The pressure switch must be mounted in a
vertical position with the pressure tap at the bottom.
2. Start a fan call for the smallest zone only. Adjust the pressure switch to open the Bypass damper
when air noise at the registers approaches the level you determine would be objectionable to the
customer.Thisis usuallyfound whenonly thesmallest zoneis calling.Minimumpressurerequiredto
activate the Bypass damper is 0.05 in. WC.
3. Open the remaining zones and verify that the bypass closes with all zones calling.
Barometric Bypass:
1. Locate the bypass duct per recommendations above and adjust counter weight to bypass enough
air to eliminate unwanted air noise at registers with only the smallest zone open by itself.
2. Call for “Fan On” at the remaining zones and verify that the bypass closes with all zones open.
Dual Bypass:
When using two bypass ducts due to larger CFM needs, control one duct with the Automatic
Bypass Control, and the other with a Barometric Bypass Control. Set up the bypasses so that the
Barometric damper opens first, followed by the Automatic damper once the Barometric is fully open.
This set-up will provide multiple levels of bypass capacity to fit the needs of a zoning system with
varied bypass needs, i.e. 2 or more small zones.
Fig. 16a Fig. 16b
Rev. 5/12/04
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

18
SYSTEM CHECKOUT:
1. Set all thermostats to the “Off” position and all fan switches to the “Auto” position before starting
thecheckout procedure.
2. Turn power ON to theArzel panel and the HVAC equipment, the green LED next to the “Power”
switch will come on.
3. Turn Zone 1 thermostat to Fan “On”. The following LED’s will light: Zone 1– G, Zone 1 solenoid,
Pump & “G” @ HVAC Output.
4. Check air flow at all registers to verify that only zone 1 is open, and all others are closed.
5. Repeat the same procedure for the remaining zones.
HEATING CHECKOUT:
1. Set all thermostats to the “Off” position and all fan switches to “AUTO” before starting heating
system checkout.
2. Set Zone 1 thermostat to the HEAT position. Turn thermostat up so that the thermostat is
callingfor heat.
3. The following LEDs will come on: Zone 1– W1, Solenoid for calling zone, Pump & W1 @ output.
4. Check and set heating LAT and second-stage heating and cooling delay timer settings.
5. The pressure and vacuum pumps will automatically position all the dampers.
6. Check to see that the heating valve or relay is energized.
7. If heat pump is installed, check operation of emergency backup heating.
8. Turn the thermostat down until the thermostat is satisfied. The dampers and system will go
through its Energy Conservation Cycle (ECC) for 3 minutes. The LED lights will go out and the
pumps will stop. If you wish to save checkout time, you can push the Energy Conservation
Override (ECO) switch to skip this automatic cycle.
COOLING CHECKOUT:
1. Set thermostat for Zone 1 to the Cool position. Turn thermostat down so that the thermostat is
calling for cooling. The following LEDs will come on: Zone 1- Y1 and G, Solenoid, Pump, & Y1 &
G @ HVAC Output.
2. Check and set cooling LAT and heating and cooling second-stage delay timer settings.
3. The pressure and vacuum pumps will automatically position all the dampers.
4. Check to see that the compressor relay or contactor is energized. Rapid cycle Zone 1 to see
that the 4-minute lockout takes place. If you wish to save checkout time, you can push TDO 1
and TDO 2 to skip the delay.
5. Place Zone 1 thermostat in the “Off” position. The dampers and system will go through its
Energy Conservation Cycle™(ECC). If you wish to save checkout time, you can push the
EnergyConservation Override (ECO)switch toskip thisautomatic cycle.
6. Follow the above procedure for all other zones.
Rev. 5/01/01
U.S. and Foreign Patents & patents pending. © copyright 2004 by Arzel Zoning Technology, Inc.

19
TEARHERE
Type of Building:


Office


Single Family


Condo


Commercial


Other________________
I learned of the Arzel Zoning
System through:


Contractor


Serviceman


Salesperson


Consumer report


Friend


Building or home exposition


Magazine


TV


Store Demonstration


Newspaper


Internet


Other__________________
How many years have you been in
this building / house?


1 to 5


6 to 10


11 to 15


16 or more
Was the zoning system purchased:


By itself


With Furnace


With Air Conditioning
Would you recommend The Arzel
Zoning System to your friends?


Yes


No
Approx. Age of building
_______ Years
We appreciate your taking the
time to complete this card; the
information provided will help
us serve you better in the future.
How many rooms in this
building / house?


5 to 8


9 to 15


16 or more
What is your occupation?


Proffessional


Executive


Management


Physician / Dentist


Tradesman


Clerical / Service Worker


Sales Marketing


Military


Homemaker


Retired


Other__________________
$_________ Established yearly
heatingbill
$_________ Estimated yearly
coolingbill
__________ Total sq. ft. of
building / house
Type of building / house:


Single story


2 story


Bi level


Tri level


Room Addition


Finished basement


Other___________________
Why was zoning system
purchased?


To decrease heating costs


To decrease cooling costs


To correct a heating problem


To correct a cooling problem


To save energy costs
What is the Brand name of your
furnace?
______________________
What is the brand name of your A/C?
______________________
Type of System:


Gas


LP Gas


Oil


Heat Pump


Electric
Total household income:


Up to $34,999



$35,000 - $74,999


 $75,000 - $149,999


 $150,000 - $249,999


 $250,000 and over
Head of household age:


Under 30


31 - 40


41 - 50


51 - 64


65 and over
What infuenced your selection of the
Arzel Zoning System?


Uncomfortable Rooms


Energy Conservation


Easy to use


Guarantee


Simple Installation


Other_____________________
Which feature appealed the most?


Simplicity


Comparable price


Guarantee


Overall comfort
What other selections are installed in
this building / house?


Humidifiers


High efficiency Air Cleaners


Air Purifiers (U/V Lights)


Ozone generators


Home Automation
Comments?_________________________________________________
Features?___________________________________________________
Read! Owners Must Mail Registration Form within 30 days To Register Warranty
Arzel Zoning Technology, Inc.
DATE:___________________________TELEPHONE:_______/_______/______
NAME:___________________________________________________________
ADDRESS:________________________________________________________
CITY:________________________STATE:___________ZIP:________________
DATE OF INSTALLATION:_________________MODEL:___________________
PANEL#:___________________INSTALLED BY:_________________________
© copyright 2004 by Arzel Zoning Technology, Inc.

20
TEARHERE
FOLDHERE
We’d like to thank you for choosing Arzel.
AtArzel, we’recommittedtoquality,innovationandperformance.We
designproductsforcomfortandenergyconservation.Ourreputation
dependsontheability to betterunderstandyourcomfort needs. Sowe
cancontinueinthiseffort,please fill outthissurveycardand return itto
us.Comfort makes a house a home. Comfortalso makesa commercial
environmentmoreproductive.YourdecisiontoinstallanArzelZoning
Systemnotonly providesyouthe comfortyoudeserve butalsoenergy
savings.Please feel freeto letothers knowabout your experienceswith
Arzelorhave them contactus at ourwebsite(www.arzelzoning.com).
Pleasetape closed on this edgebefore mailing.