Bryant ZONE PERFECT TWO-ZONE User manual

NOTE: Read the entire instruction manual before starting the
installation.
This symbol →indicates a change since the last issue.
TABLE OF CONTENTS
PAGE
Safety Considerations.....................................................................1
Installation Considerations.............................................................1
Introduction ....................................................................................1
Installation...................................................................................1-4
Sequence Of Operation...............................................................4-7
Thermostat Wiring......................................................................6-8
Care And Maintenance ..................................................................8
Troubleshooting ........................................................................9-11
Wiring Diagrams.....................................................................12-16
Wiring Diagram Notes.................................................................16
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a qualified
installer, service agency, or your distributor or branch for infor-
mation or assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this prod-
uct. Refer to the individual instructions packaged with the kits or
accessories when installing.
Follow all safety codes and wear safety glasses. Have fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult local
and state building codes and Sheet Metal and Air Conditioning
National Association (SMACNA) for special installation require-
ments.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on the unit or in instructions and
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, or CAU-
TION. These words are used with the safety-alert symbol. DAN-
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage.
INSTALLATION CONSIDERATIONS
1. Install in non-condensing area with ambients between 32°F
and 150°F.
2. Use vibration isolators (flex connectors) on zone dampers
and ductwork to minimize noise.
3. Place dampers away from areas that may be noise sensitive.
4. TXV is required in air conditioning and heat pump appli-
cations.
5. Use separate isolated transformer to supply power to Zone
Perfect Two-Zone Center. (40va minimum, class 2, trans-
former, field supplied)
6. Load calculations must be performed to determine equip-
ment size. Equipment selection is matched to block load. It
is imperative equipment is not over sized.
7. Ductwork must be designed based off the sum of peak plus
25 percent oversize. It is imperative ductwork is not under
sized.
INTRODUCTION
The Zone Perfect Two-Zone System allows the air conditioning
and heating equipment to control temperatures in 2 distinct spaces
or zones within a building. Each zone has independent temperature
settings controlled by a thermostat.
NOTE: Thermostats are purchased separately.
The comfort temperature settings can change automatically
through the use of schedules if programmable thermostats are
selected. This allows Zone Perfect Two-Zone to change the
temperature settings in zones to reflect occupancy or usage. The
Zone Perfect Two-Zone System uses motorized air volume control
dampers (also called zone dampers) to regulate the flow of
conditioned air into the zones.
INSTALLATION
I. CHECK EQUIPMENT AND JOBSITE
A. Inspect Equipment
File claim with shipping company, prior to installation, if shipment
is damaged or incomplete.
Fig. 1—Zone Perfect Two-Zone System
(Shown Without Cover)
A97291
3
WARNING!
Rev
HOT parts
under this label
Y1
W1 W2
W1W2 GRH
RC BOY2Y1
Equipment Term.
Sensors
HP Duct
C1
Z
o
n
e
1
Z
o
n
e
2
Op
C
C1
Op
C
Emergency
Heat
RC-RH
Jumper
Y2
G
On
Off
24 VAC
RW1W2 C
GY2 Y1
Y2
Y1
R
W1
W2
C
Equpimt
DTO Fnc Ht
w/oF
w/F
On
Off
HP
Fnc
T'stat
Fnc
HP
®
installation instructions
ZONE PERFECT™
TWO-ZONE
Cancels: II ZONEKIT-0-2 II ZONEKIT-0-6
6-97
ZONEKIT
—1—
→
→

II. WIRING
WARNING: To prevent personal injury or possible
equipment damage, disconnect the power supply before
routing wire.
All wiring must comply with local, state, and national codes.
NOTE: Use No. 18 AWG color-coded, insulated (35°C min)
wire. If thermostats are to be located more than 100 ft from the
Zone Perfect Two-Zone Center as measured along the control
voltage wires, use 16 AWG colored-coded wires to avoid exces-
sive voltage drop. All wiring is run back to the Zone Perfect
Two-Zone Center.
III. INSTALL ZONE PERFECT TWO-ZONE
NOTE: Zone Perfect Two-Zone is approved for indoor use only
and should never be installed with any of its components exposed
to the elements. Do not mount Zone Perfect Two-Zone Center
where it will be accessible to children. Do not locate the center in
areas of the home that are noise sensitive since relays are energized
and de-energized during operation and may be an annoyance.
Install Zone Perfect Two-Zone in an area with a temperature range
between 32°F and 150°F.
Install Zone Perfect Two-Zone center in a vertical position. Locate
in an area that is easily accessible in case servicing should be
required.
CAUTION: To prevent possible damage to the Zone
Perfect Two-Zone Center, do not mount on plenum,
ductwork, or flush against furnace.
IV. INSTALL ZONE DAMPERS
IMPORTANT: If conditions exist for possible condensing, the
motor must be positioned for adequate draining. (See Fig. 2.)
NOTE: If a multi-damper enabler is used to link dampers
together, then add 5va per damper to the transformer power supply
rating. Reference multi-damper enabler Installation Instructions.
Zone dampers may be installed in any direction.
Install dampers so the actuator is visible for inspection and
accessible in the event it would ever need service. The black mark
on the end of the damper shaft represents the position of the
damper blade.
NOTE: Insulate damper using 1-1/2 in. insulation (check local
codes). In areas where excessive condensing may occur, carefully
insulate over the actuator assembly. Make sure insulation does not
interfere with operation of actuator.
Before insulating the ductwork, check for proper damper opera-
tion. Apply 24vac between COM and OPN to open the damper and
COM and CLS to close the damper. (See Fig. 3.) 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 red quick blade release button with 1 hand and
turn mounting hub to reposition the damper shaft. Release button
to hold damper shaft in the new position.
To avoid noise and vibration, do not hard mount dampers to any
solid structure such as joists.
A. Round Metal Ductwork
IMPORTANT: If application exists with all metal ductwork
without insulation, flex connectors should be used on each end of
the zone dampers to avoid noise and vibration.
1. Crimp end of branch duct.
2. Slip end of flex connector over zone damper and use
self-tapping sheet metal screw to secure. (See Fig. 4.)
3. Properly seal joint using duct tape, mastic, or other ap-
proved 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.) (See Fig. 5.)
NOTE: All zone dampers and ductwork must be properly sup-
ported according to local codes or SMACNA standards.
B. Rectangular Metal Ductwork
1. Make connections using S-lock and drives. (See Fig. 6.)
2. Properly seal joint using duct tape, mastic, or other ap-
proved method. Do not allow mastic to come in contact
with actuator.
Fig. 2—Damper Motor Positioning A95128
DAMPER MOUNTING
BRACKET
ACTUATOR
Fig. 3—Damper 24-vac Connections A95096
90
45
0
CLS COM OPN
ACTUATOR
HOUSING
MOUNTING
BRACKET
QUICK BLADE
RELEASE
BUTTON
(RED)
FIELD
INSTALLED
POWER WIRING
ANGULAR
ROTATION
STOPS
POSITION
INDICATOR
MOUNTING
HUB
AIRFLOW
AIRFLOW
Fig. 4—Round Metal Ductwork A95129
SUPPLY FLEX
CONNECTOR ZONE DAMPER
—2—
→

3. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check
your local codes.) (See Fig. 7.)
NOTE: All zone dampers and ductwork must be properly sup-
ported according to local codes or SMACNA standards.
NOTE: There should be a minimum of 4 ft between the zone
damper and the first branch duct if more than 1 branch duct is
downstream of the zone damper.
C. Round Flexible Ductwork
1. Slip 1 end of flexible ductwork over 1 end of zone damper.
(See Fig. 8.)
2. Secure the flexible duct to zone damper using SMACNA or
other approved method.
3. Properly seal joint using duct tape, mastic, or other ap-
proved 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.) (See Fig. 9.)
NOTE: All zone dampers and ductwork must be properly sup-
ported according to local codes or SMACNA standards.
D. Rectangular Fibrous Glass Ductwork
1. Insert 1 end of zone damper into 1 end of fibrous glass
ductwork approximately 2 to 3 in. (See Fig. 10.)
2. Screw field-supplied screws and tabs into zone damper.
3. Properly seal joint using duct tape, mastic, or other ap-
proved method. Do not allow mastic to come in contact
with actuators
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check
your local codes.) (See Fig. 11.)
V. INSTALL BAROMETRIC BYPASS DAMPER
NOTE: The barometric bypass damper is a critical part of the
Zone Perfect Two-Zone System for control of minimum airflow
and noise reduction. It is recommended that the bypass be
installed.
Fig. 5—Insulated Round Metal Ductwork A95130
/ ″STEEL STRAP
1 2
Fig. 6—Rectangular Metal Ductwork A92478
DRIVE ZONE
DAMPER
S-LOCK
SUPPLY
AIR DUCT
Fig. 7—Insulated Rectangular Metal Ductwork
A95131
1 / " TO 2"
INSULATION
12
Fig 8—Round Flexible Ductwork A95132
FLEXIBLE
DUCT ZONE
DAMPER
Fig. 9—Insulated Round Flexible Ductwork A95133
/ ″STEEL STRAP
12
Fig. 10—Rectangular Fibrous Glass Ductwork
A92480
ZONE
DAMPER
2″TO 3″
FIBROUS
GLASS
DUCTWORK FIELD
SUPPLIED
SCREWS
Fig. 11—Insulated Rectangular Fibrous Glass Ductwork
A95134
1 / ″TO 2″
INSULATION
12
—3—

The bypass should be installed according to local codes and
SMACNA standards. Be sure the bypass is properly supported.
For proper installation, refer to the Installation Instructions pack-
aged with the barometric bypass.
CAUTION: Failure to properly install the bypass
damper can cause permanent damage to the HVAC
equipment. For single-speed furnace applications, the
bypass air must never exceed 25 percent.
VI. INSTALL LEAVING AIR TEMPERATURE DUCT SEN-
SOR
Locate duct temperature sensor in main supply trunk after heating
and cooling coil and before the bypass damper and before the first
branch. The duct sensor must be radiant shielded to prevent heat
from affecting the correct air temperature.
1. Drill 1/4-in. hole at location in supply trunk where sensor
will be installed.
2. Insert sensor in hole and use as template to mark 2
mounting holes.
3. Drill two 1/16-in. holes to accept No. 6 screws through
pre-drilled holes in duct temperature sensor back plate.
4. Use 2 No. 6 sheet metal screws to mount duct temperature
sensor to unit.
5. Connect sensor to 2-conductor wire using provided wire
nuts. (See Fig. 12 for connection to equipment controller.)
VII. INSTALL HEAT PUMP (HP) TEMPERATURE SEN-
SOR
The HP temperature sensor is required in all heat pump/fan coil
installations. It is not used in dual fuel (heat pump/furnace
installation.) It measures the indoor coil temperature. The sensor is
to be installed downstream of the indoor coil, but before the
electric heaters. It can be installed through the wall of the fan coil
or may be located entirely inside the fan coil near the blower inlet.
Anchor firmly in place with cable ties so that it cannot interfere
with the blower wheel. To activate the HP temperature sensor,
remove factory supplied resistor from HP terminal block and
replace with sensor leads. When activated, the HP temperature
sensor has built in LAT set points of 50°F and 45°F in the cooling
mode, and 105°F and 110°F in the heating mode. This is
non-adjustable. (See Fig. 12 for connection to Zone Perfect
Two-Zone center.)
SEQUENCE OF OPERATION
I. SEQUENCE OF EVENTS FOR A NORMAL HEATING
OR COOLING CYCLE
The thermostats will determine if active heating or cooling is
required. If so, the Zone Perfect Two-Zone system will perform
the following:
• Make sure all zone dampers are fully open.
• Energize HVAC equipment fan.
• Energize heating or cooling equipment. The equipment may be
a compressor, furnace, strip heater, etc.
• Set zone damper to the open or closed position based upon
individual zone demand.
• Energize additional stages of heating or cooling if the thermostat
demand warrants.
• Turn off heating or cooling equipment when all zones are
satisfied.
• Open all zone dampers when equipment is turned off (after 90
sec delay).
This is the basic sequence of operation for the Zone Perfect
Two-Zone System. The actual control of the dampers, HVAC
equipment, and system fan will change with the configuration of
the system. Depending upon the configuration, Zone Perfect
Two-Zone can control heat pumps, furnaces, and dual fuel
applications, (dual fuel will require a third party relay interface).
II. SELECTION OF A SYSTEM MODE
The first step in any heating or cooling cycle requires Zone Perfect
Two-Zone to receive an input from any thermostat located in a
zone. Zone Perfect Two-Zone will then prepare to operate the
heating or cooling equipment as requested by the thermostat. (See
Fig. 12.)
III. PRE-POSITIONING DAMPERS AND STARTING
SYSTEM FAN
In order to minimize noise and enhance system operation, Zone
Perfect Two-Zone maintains fully open zone dampers prior to
starting the system fan or the heating/cooling equipment. The
intent is to provide the HVAC equipment with unrestricted
ductwork and to reduce pressure surges. Zone Perfect Two-Zone
also fully opens the dampers whenever a heating or cooling cycle
is completed (this is done after a 90 sec delay). All zone dampers
will remain fully open until the next heating or cooling cycle.
The other reason for opening the dampers is to provide unrestricted
ductwork to other equipment which is not directly controlled by
Zone Perfect Two-Zone. One example may be a Heat Recovery
Ventilator. If Zone Perfect Two-Zone is not actively controlling
the HVAC system, then it must not impose any control influences
(such as closed zone dampers) on the system and prevent proper
operation of other devices.
Only the zone 1 thermostat controls continuous fan operation.
When the zone 1 thermostat has the fan selector switch in the
AUTO position, the fan will operate only when the heating and
cooling equipment is operating. When the zone 1 thermostat has
the fan selector switch in the ON position, the fan will operate
continuously. Zone 2 will not control this.
IV. HVAC EQUIPMENT CONNECTIONS
The Zone Perfect Two-Zone relay outputs are shown in Table 1.
The Y1 and Y2 contacts are used for the compressor contactor
only. Zone Perfect Two-Zone operates the heat pump by energiz-
ing the compressor contactor and controlling the reversing valve
through the O relay output. The W1 and W2 contacts are always
used for heat sources. These are heating only units such as
furnaces, strip heaters, etc. The relay outputs for Zone Perfect
Two-Zone are shown in Table 1.
In automatic changeover, the zoning system works on a first come
first serve basis. If 1 zone is calling for heating and the other for
cooling, the zone which sent its demand to the I/O center first will
operate the equipment in that mode until that zone is satisfied.
TABLE 1—AVAILABLE HEATING AND COOLING STAGES VERSUS SYSTEM TYPE
TYPE OF HVAC
EQUIPMENT USED COOLING STAGE 1 COOLING STAGE 2 REVERSING VALVE OHEAT STAGE 1 HEAT STAGE 2 REVERSING VALVE O
Single-Stage Heat
Pump Y1 — Energized Y1/W1 W2 De-energized
2-Stage Heat Pump Y1 Y2 Energized Y1/W1 W2 De-energized
Cooling Only, any
Heater Type Y1 Y2 — W1 W2 —
—4—
→
→

V. DUCT TEMPERATURE OPTIMIZER (DTO)
FOR MONITORING LEAVING AIR TEMPERATURE
As Zone Perfect Two-Zone System operates through a heating or
cooling cycle, the zone demands will change. This changes the
actual load that is applied to the HVAC equipment. If the zone
airflow decreases, the cooling equipment will tend to lower
supply-air temperatures which could tend to exceed the LAT trip
limits. Conversely, the heating equipment will tend to raise
supply-air temperatures which could exceed high trip limits. In
cooling, when the LAT reaches the non-adjustable low tempera-
ture trip limit (50°F) the LAT algorithm begins operating, closed
dampers are initially opened 3 positions, then 1 position every 20
sec there after until full open. Zone Perfect Two-Zone will not shut
down second-stage cooling (if used); however, if temperature
continues to drop to 45°F, the zoning system will turn off both
stages of cooling. If the temperature improves, the system will stay
in the duct temperature optimizer mode until the LAT reaches
55°F or higher. At 55°F the LAT algorithm will reset and return
dampers to their original position. In the heating mode, Zone
Perfect Two-Zone will perform the same duct temperature opti-
mization. The trip limits will be determined by the jumper setting.
(See Fig. 12.) This will continue until the LAT problem is
corrected.
This control helps Zone Perfect Two-Zone System cope with
installations where the air conditioning system may suffer from
poor ductwork, improperly sized heating or cooling equipment,
and/or improper settings of the barometric bypass damper. This
control is especially useful in retrofit applications where the size
and routing of the ductwork may not be entirely known or
satisfactory.
The duct temperature optimizer works by controlling how cold or
hot the air inside the supply-air duct gets by monitoring the
temperature of the air inside the supply-air system.
Whenever Zone Perfect Two-Zone is providing heating or cooling,
the zone within the home that is asking for conditioned air will
always have its damper fully open. The other zone in the system
may or may not have an open damper depending upon its
particular needs. If the ductwork is too small (or the air
conditioner/heater is too large), then the zone requiring condi-
tioned air may not be able to take enough air to allow your
equipment to operate properly. Zone Perfect Two-Zone will detect
this, and open up the closed damper allowing the equipment to
continue to operate.
CAUTION: The duct temperature optimizer may be
disabled on the control center. A 10k resistor can be
installed in place of the duct sensor at the terminal block.
By disabling the duct temperature optimizer, the LAT
safety algorithm is removed from the system.
It is highly recommended that you use this control option. The
heating LAT is adjustable for the duct sensor. In this Installation
Instruction, you will find the section showing an adjustment for the
heating LAT. (See Fig. 12.) It is very important that this tempera-
ture is properly set. For gas or oil furnaces, the temperature limit
will be in the higher temperature range. For heat pumps the
temperature setting should always be in the lower temperature
range.
If you encounter a situation where 1 zone seems to have poor
ductwork, then the Zone Perfect Two-Zone system is capable of
reverting back to a fully open, constant-volume system. If this
condition persists, it should always be looked upon as an indication
of a HVAC problem, not a Zone Perfect Two-Zone problem.
VI. ELECTRONIC THERMOSTAT CONNECTION WITH
ZONE PERFECT TWO-ZONE CONTROL
Bryant electronic non-programmable and programmable thermo-
stats can be connected to the Zone Perfect Two-Zone. See pre-sale
literature for thermostat part numbers.
NOTE: The zone control board is only capable of 2-stage heat
and 2-stage cool operation. Fig. 13 and 14 will reflect these
applications only. Review and understand the following items
before installing.
A. Thermostat Setup
1. Thermostat will not operate unless both R and C are
connected to zone module input.
2. If selected thermostat is a heat pump (HP) or 2-speed (2S)
model, convert thermostat to air conditioning operation.
This will assure that Y signals are generated for cooling,
and W signals are generated for heating from thermostat to
zone module input. The thermostat O/W2 output will now
be the second-stage heat call. If installation is a heat pump
system, the zone control board will provide proper output
signal to heat pump.
3. Select "Zoning" option on thermostat. This will disable the
Timeguard and 4-cycle per hr (cph) protection built into
thermostat. Let zone control board perform the Timeguard
and cycle protection. Refer to thermostat Installation In-
struction under Zoning for more detail.
4. The zone 1 thermostat is the only thermostat that can
control continuous fan operation with zoning. Connect G
between zone 1 thermostat and zone 1 input on zone control
module.
5. Follow all safety and installation considerations outlined in
the thermostat Installation Instructions.
B. Zone Control Board Setup
1. Configure zone control board jumper for Tstat (thermostat)
Fnc option only. Do not use Tstat HP option. When Tstat
Fnc is selected this will setup control inputs to recognize Y1
and Y2 for first- and second-stage cooling, W1 and W2 for
first- and second-stage heating.
2. Configure zone control board for either Equipmt (equip-
ment), HP or Fnc. When a heat pump system is used,
Equipmt HP mode should be selected. The zone control
board will provide the proper output signal to the heat
pump. When a gas/electric furnace is used, Equipmt Fnc
mode should be selected for proper output signal.
3. Configure zone control board for either Fnc Ht, w/f (with
fan), or w/of (without fan). With Fan mode should be
selected when a heat pump is installed and fan is needed to
come on immediately with demand. Without Fan mode
should be selected when fan is controlled by gas/electric
furnace.
4. Configure zone control board for either DTO On or Off.
When DTO On is selected (Factory default) and if a LAT
trip occurs, closed dampers will begin opening to try and
keep equipment running by maintaining proper air tempera-
tures. However, if LAT temperatures exceed their limits,
equipment will start staging down. When DTO Off is
selected, equipment will stage down. Closed dampers will
not open on initial trip, however if LAT temperatures
exceed their limits, control will lock out and damper will
open.
NOTE: An HP temperature sensor must be used with a heat pump
application using electric strip heat. This is necessary in case the
DTO is set to the Off position.
—5—
→
→

→Fig. 12—Zone Perfect Two-Zone Circuit Board with Standard Thermostat Wiring
A97293
3
Thermostat
Zone 2
Y2
Y1
R
W1
W2
C
G
Thermostat
Zone 1
Y2Y1RW1
W2C
Sensors
HP Duct
Equipment
RcBOY2Y1
W1
W2GRh
24 VAC
Power
24v
CL
OP
C
Zone
1 
Damper
Zone
2 
Damper
CL
OP
C
G
B
D
4
F
A
E
C
K
J
I
H
LMN
2
3
1
ZONE 1
I/O CENTER CONNECTIONS
G
G
Y2
Y2
Y1
Y1
R
R
W1
W1
W2
W2
C
C
††
THERMOSTAT/SUBBASE
CONNECTIONS
† ONLY HOOKUP "C" WHEN SUPPLIED BY THERMOSTAT
HOOKUP WHEN USING APPLICABLE TWO-STAGE
THERMOSTATS WITH TWO-STAGE EQUIPMENT
*
*
ZONE 2
I/O CENTER CONNECTIONS
Y2
Y2
Y1
Y1
R
R
W1
W1
W2
W2
C
C
††
THERMOSTAT/SUBBASE
CONNECTIONS
† ONLY HOOKUP "C" WHEN SUPPLIED BY THERMOSTAT
HOOKUP WHEN USING APPLICABLE TWO-STAGE
THERMOSTATS WITH TWO-STAGE EQUIPMENT
*
*
A93494 A93495
—6—

TIMEGUARD
The Zone Perfect Two-Zone provides equipment protection with
an internal 5-minute timeguard delay. This delay is present upon
initial power up. There is also a 5-minute timeguard delay for all
cooling (Y1) and heat pump modes. The time guard can be cleared
by using the comprotec override feature. Second-stage (Y2) and
(W2) will have a 5-minute delay between stages and also can be
cleared using the comprotec override feature.
→Fig. 13—Electronic Non-Programmable Thermostat Wiring Diagrams A97294
W/W1
C
Y/Y2
R24 VAC HOT
TWO-ZONE BOARD
THERMOSTAT
INPUT
24 VAC COMM
HEAT STAGE 1
COOL STAGE 2
FAN
HEAT STAGE 2
COOL STAGE 1
N/A
TROUBLE
OUTDOOR
SENSOR
CONNECTION
TWO-STAGE HEAT,
TWO-STAGE COOL
SEE NOTES 1, 2, AND 3
G
O/W2
Y1
C
R
W1
Y2
G
W2
Y1
B
L
S1
S2
W/W1
C
Y/Y2
R24 VAC HOT
NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL AC
NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL HP
TWO-ZONE BOARD
THERMOSTAT
INPUT
24 VAC COMM
HEAT STAGE 1
COOL STAGE 1
FAN
SINGLE-STAGE HEAT,
SINGLE-STAGE COOL

SEE NOTES 1 AND 3
G
C
R
W1
Y1
G
W2
Y2
NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL 2S
*
*
W/W1
C
Y/Y2
R24 VAC HOT
TWO-ZONE BOARD
THERMOSTAT
INPUT
24 VAC COMM
HEAT STAGE 1
COOL STAGE 1
FAN
HEAT STAGE 2
N/A
N/A
N/A
OUTDOOR
SENSOR
CONNECTION
TWO-STAGE HEAT,
SINGLE-STAGE COOL
SEE NOTES 1, 2, AND 3
G
O/W2
Y1
C
R
W1
Y1
G
Y2
W2
B
L
S1
S2
*
WIRING DIAGRAM NOTES:
* Hook up G on zone 1 thermostat only.
Cut R19 jumper on thermostat.
Disable timeguard and cycle protection in thermostat by setting
it to ZONE mode. Refer to thermostat Installation Instructions for
details on how to do this.
1.
2.
3.
—7—

MAXIMUM CYCLE RATE
The Zone Perfect Two-Zone will allow a maximum of 4 equip-
ment cycles per hr or 1 every 15 minutes when a heating or cooling
mode is activated. When a demand exists, and internal timer will
start counting down 15, 14, 13...0 minutes. Once the timer expires
the control will allow a new mode to restart the equipment. The
internal time, as well as the cooling 5-minute timeguard can be
cleared by using the comprotec override feature.
CARE AND MAINTENANCE
For continuing optimum performance and to minimize possible
equipment failure, it is essential that periodic maintenance be
performed on this equipment. Consult your servicing contractor for
the proper frequency of maintenance. Frequency may vary depend-
ing upon geographic areas.
→Fig. 14—Electronic Programmable Thermostat Wiring Diagrams A97295
W/W1
Y1/W2
G
R
Y/Y2
COOL STAGE 1
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL 2S
TWO-ZONE BOARD
THERMOSTAT
INPUT
FAN
HEAT STAGE 1
COOL STAGE 2
HEAT STAGE 2
24 VAC HOT
24 VAC COMM
N/A
TROUBLE
OUTDOOR
SENSOR
CONNECTION
TWO-STAGE HEAT,
TWO-STAGE COOL
SEE NOTES 1, 2, AND 3
O/W2
B
C
G
Y1
W1
Y2
R
C
L
S1
S2
W2
*
W/W1
G
Y/Y2
O/W2
Y1/W2
R24 VAC HOT
TWO-ZONE BOARD
THERMOSTAT
INPUT
FAN
HEAT STAGE 1
COOL STAGE 1
HEAT STAGE 2
N/A
24 VAC COMM
N/A
N/A
OUTDOOR
SENSOR
CONNECTION
TWO-STAGE HEAT,
SINGLE-STAGE COOL
SEE NOTES 1, 2, AND 3
B
C
G
R
W1
Y1
W2
Y2
C
L
S1
S2
*
W/W1
G
Y/Y2
O/W2
Y1/W2
R24 VAC HOT
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL AC
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL HP
TWO-ZONE BOARD
THERMOSTAT
INPUT
FAN
HEAT STAGE 1
COOL STAGE 1
N/A
N/A
24 VAC COMM
N/A
N/A
OUTDOOR
SENSOR
CONNECTION
SINGLE-STAGE HEAT,
SINGLE-STAGE COOL
SEE NOTES 1 AND 3
B
C
G
R
W1
Y1
W2
Y2
C
L
S1
S2
*
WIRING DIAGRAM NOTES:
* Hook up G on zone 1 thermostat only.
Set thermostat dip switch A to ON. 
Set thermostat dip switch C to ON. This will disable 
timeguard and cycle protection in thermostat by setting
it to ZONE mode. Refer to thermostat Installation Instructions 
for details on how to do this.
1.
2.
3.
—8—

TROUBLESHOOTING
This section contains information to assist you in troubleshooting
problems and errors associated with the Zone Perfect Two-Zone
system. See Table 2.
I. SYSTEM DIAGRAM, JUMPERS, AND SWITCHES
NOTE: For correct control board operation, it must have either a
sensor attached or a 10k resistor in place at the duct and HP inputs.
1Fnc—Gas/electric thermostat is installed in
each zone.
Must be in this position to function prop-
erly.
HP—DO NOT USE.
Tstat
2Fnc—Air conditioning equipment installed
is a cooling only unit.
HP—Air conditioning equipment installed
is a heat pump.
Equipmt
3W/O FAN—When demand for heating ex-
ists, fan is controlled by gas/electric fur-
nace.
W/FAN—When demand for heating exists,
fan comes on immediately (heat pump
only).
Fnc Ht
4DTO Off—When supply-air temperatures
approach a trip limit, HVAC equipment
will turn off. Dampers do not open until
equipment is locked out by control.
DTO On—When supply-air temperatures
approach a trip limit, closed dampers open
to maintain proper air temperatures.
DTO
ADamper Fuse—Protects damper from electrical dam-
age (3 Amp).
BHigh Heating Temperature Trip Limit Setting —
When DTO is On, temperature is sensed by duct
temperature sensor. When the duct temperature
reaches this temperature setting, the duct temperature
optimizer is enabled.
If the LAT is exceeded then heating will turn off.
NOTE: HP temperature sensor is recommended for
all heat pump applications.
155°F
NORMAL HEAT
PUMP SETTING
NORMAL GAS/
ELECTRICAL
SETTING
147°F
138°F
130°F
122°F
113°F
105°F
155°F
147°F
138°F
130°F
122°F
113°F
105°F
175°F
164°F
153°F
143°F
132°F
121°F
110°F
EQUIPMENT
SHUTOFF
TEMPERATURE
CEmergency Heat Switch—This switch should remain
in the OFF position for both furnace and heat pump
operation. It should be switched to the ON position
only upon heat pump compressor failure to provide
emergency heat.
ON OFF
DComprotec Override—Momentarily short
pins together for temporary equipment time
delay override.
EJ6 jumper—Connects Rc and Rh inter-
nally.
FEmergency heat LED—Will turn on when
emergency heat is on.
GRed LED—Used for diagnostic errors.
HGreen LED—Flashes once every second
for normal operation, alternates with red
LED for diagnostic errors.
—9—
→

IRed LED—Displays ON when fan is energized.
JRed LED—Displays ON when first-stage cooling is
energized.
KRed LED—Displays ON when second-stage cooling is
energized.
LRed LED—Displays ON when reversing valve is ener-
gized.
MRed LED—Displays ON when first-stage heat is
energized.
NRed LED—Displays ON when second-stage heat
is energized.
OJ2 (Not Shown)—Cut for 50 hz operation. Lo-
cated under plastic housing approximately 1 in.
above comprotec override.
→TABLE 2—TROUBLESHOOTING
LED CODES ERROR DESCRIPTION ACTION REQUIRED
Green flashes 1 time every sec and no
other LEDs are flashing. Normal operation. None.
Green flashes 1 time and Red flashes 1
time Duct temperature sensor. First-stage heat limit exceeded; heat will be locked out.
Wait until duct temperature cools below
exceeded temperature trip. (Heat leaving
air temperature trip limits set at LAT limits
POT on central control circuit board; range
is 110° to 175°F.)
Green flashes 1 time and Red flashes 2
times Duct temperature sensor. Second-stage heat limit exceeded. Wait until duct temperature cools below
exceeded temperature trip. Range is 105°
to 155°F.
Green flashes 1 time and Red flashes 3
times Duct temperature sensor. First-stage cool limit exceeded; cool will be locked out. Wait until duct temperature raises above exceeded temperature trip (45°F).
Green flashes 1 time and Red flashes 4
times Duct temperature sensor. Second-stage cool limit exceeded. Wait until duct temperature raises above exceeded temperature trip (50°F).
Green flashes 1 time and Red flashes 5
times HP temperature sensor. First-stage heat limit exceeded; heat will be locked out. Wait until HP temperature cools below ex- ceeded temperature trip. Fixed at 110°F.
Green flashes 2 times and Red flashes 1
time HP temperature sensor error. Second- stage heat limit exceeded. Wait until HP temperature cools below ex- ceeded temperature trip. Fixed at 105°F.
Green flashes 2 times and Red flashes 2
times HP temperature sensor. First-stage cool limit exceeded; cool will be locked out. Wait until duct temperature raises above exceeded temperature trip (45°F).
Green flashes 2 times and Red flashes 3
times HP temperature sensor. Second-stage cool limit exceeded. Wait until duct temperature raises above exceeded temperature trip (50°F).
Green flashes 2 times and Red flashes 4
times 1. Duct temperature sensor. 2. Temperature sensor is shorted.
1. Verify that duct temperature sensor or
10k ohm resistor is attached to control cen-
ter at duct temperature connectors.
2. Replace duct temperature sensor.
Green flashes 2 times and Red flashes 5
times 1. Duct temperature sensor. 2. Temperature sensor is open.
1. Verify that duct temperature sensor or
10k ohm resistor is attached to control cen-
ter at duct temperature connectors.
2. Replace duct temperature sensor.
Green flashes 3 times and Red flashes 1
time 1. HP temperature sensor. 2. Temperature sensor is shorted.
1. Verify that HP temperature sensor or
10k ohm resistor is attached to control cen-
ter at HP temperature connectors.
2. Replace HP temperature sensor.
Green flashes 3 times and Red flashes 2
times 1. HP temperature sensor. 2. Temperature sensor is open.
1. Verify that HP temperature sensor or
10k ohm resistor is attached to control cen-
ter at HP temperature connectors.
2. Replace HP temperature sensor.
Green flashes 3 times and Red flashes 3
times Damper fuse blown.
1. Check for short circuits on damper wire
connections at the dampers and control
center.
2. Replace damper fuse.
3. Check damper operation, may need to
be replaced.
Green flashes 3 times and Red flashes 4
times Fatal control center circuit board failure. Replace control center.
—10—

Table 3 shows a temperature/ohm/voltage relationship to help aid in troubleshooting the Zone Perfect Two-Zone System. This table will evaluate
both the Duct/HP temperature sensor operation. Use a digital multimeter to perform the following:
To verify a sensor is good, disconnect both leads from the I/O board and measure the resistance through the sensor. Match ohm reading to table
and compare temperature reading on table to ambient temperature surrounding sensor (Accuracy should be ±5-10 percent). Example: if 10.92k
ohms are measured, this equals approximately 73°F.
To verify if I/O board is normal, reattach sensor to I/O board, set meter to 5vdc, and measure voltage across terminal connections. Match voltage
reading to temperature reading in chart. The ambient temperature surrounding sensor should be ±5-10 percent. Example: 2.61vdc is approximately
73°F.
→TABLE 3—TEMPERATURE/OHM/VOLTAGE RELATIONSHIP
TEMP °F OHMS VOLTS TEMP °F OHMS VOLTS TEMP °F OHMS VOLTS TEMP °F OHMS VOLTS
30 34,367 3.873 73 10,921 2.610 117 4042 1.439 160 1693 0.724
32 32,654 3.828 75 10,449 2.555 118 3889 1.400 162 1637 0.703
34 31,030 3.781 77 10,000 2.500 120 3743 1.362 163 1582 0.683
36 29,498 3.734 79 9571 2.445 122 3603 1.324 165 1530 0.663
37 28,052 3.686 81 9164 2.391 124 3469 1.288 167 1480 0.645
39 26,686 3.637 82 8776 2.337 126 3340 1.252 169 1431 0.626
41 25,396 3.587 84 8407 2.284 127 3217 1.217 171 1385 0.608
43 24,171 3.537 86 8056 2.231 129 3099 1.183 172 1340 0.591
45 23,013 3.485 88 7720 2.178 131 2986 1.150 174 1297 0.574
46 21,918 3.433 90 7401 2.127 133 2878 1.117 176 1255 0.558
48 20,883 3.381 91 7096 2.075 135 2774 1.086 178 1215 0.542
50 19,903 3.328 93 6806 2.025 136 2675 1.055 180 1177 0.527
52 18,972 3.274 95 6530 1.975 138 2579 1.025 181 1140 0.512
54 18,090 3.220 97 6266 1.926 140 2488 0.996 183 1104 0.497
55 17,255 3.165 99 6014 1.878 142 2400 0.968 185 1010 0.483
57 16,464 3.111 100 5774 1.830 144 2315 0.940 187 1037 0.470
59 15,714 3.056 102 5546 1.784 145 2235 0.913 189 1005 0.457
61 15,000 3.000 104 5327 1.738 147 2157 0.887 190 974 0.444
63 14,323 2.944 106 5117 1.692 149 2083 0.862 ———
64 13,681 2.889 108 4918 1.648 151 2011 0.837 ———
66 13,071 2.833 109 4727 1.605 153 1943 0.813 ———
68 12,493 2.777 111 4544 1.562 154 1876 0.790 ———
70 11,942 2.721 113 4370 1.521 156 1813 0.767 ———
72 11,418 2.666 115 4203 1.480 158 1752 0.745 ———
WIRING DIAGRAMS
→TABLE 4—WIRING DIAGRAM REFERENCE
OUTDOOR
UNIT SINGLE-SPEED AIR CONDITIONER TWO-SPEED AIR CONDITIONER SINGLE-SPEED HEAT PUMP TWO-SPEED HEAT PUMP
Single-Stage Furnace Fig. 15 Fig. 19 Fig. 23 Fig. 27
Two-Stage Furnace Fig. 16 Fig. 20 Fig. 24 Fig. 28
Typical Fan Coil Fig. 17 Fig. 21 Fig. 25 Fig. 29
FK4C Fan Coil Fig. 18 Fig. 22 Fig. 26 Fig. 30
—11—
→

→Fig. 17—Typical Fan Coil
With Single-Speed Air Conditioner
A97298
SINGLE-SPEED
AIR CONDITIONER
TYPICAL
FAN COIL
C
Y
G
W2
W3
C
R
Y/Y2
O
L
E
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
See notes 1 and 3
*
*
**
*
Y1
**
→Fig. 15—Single-Stage Furnace
With Single-Speed Air Conditioner
A97296
SINGLE-SPEED
AIR CONDITIONER
SINGLE-STAGE
FURNACE
Y
C
W
R
G
Y
C
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
→Fig. 18—FK4C Fan Coil
With Single-Speed Air Conditioner
A97299
SINGLE-SPEED
AIR CONDITIONER
FK4C
FAN COIL
C
Y
G
W2
Y/Y2
C
R
Y1
O
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
W1
DH J1 JUMPER
REMOVE J2 JUMPER
FOR HEAT STAGING AND
CONNECT W2 TO W2
See note 1
→Fig. 16—Two-Stage or Variable-Speed Furnace
With Single-Speed Air Conditioner
A97297
SINGLE-SPEED
AIR CONDITIONER
2-STAGE OR 
VARIABLE-SPEED
FURNACE
C
W2
W/W1
Y/Y2
R
G
C
Y
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
—12—

→Fig. 21—Typical Fan Coil
With 2-Speed Air Conditioner
A97302
2-SPEED
AIR CONDITIONER
TYPICAL
FAN COIL
R
G
R
C
W2
Y/Y2
E
W3
L
O
Y1
C
Y2
Y1
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
See notes 1, 2, and 3
*
*
*
*
*
→Fig. 19—Single-Stage Furnace
With 2-Speed Air Conditioner
A97300
2-SPEED
AIR CONDITIONER
SINGLE-STAGE
FURNACE
R
W
R
G
C
YY2
C
Y1
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
See note 2
→Fig. 22—FK4C Fan Coil
With 2-Speed Air Conditioner
A97303
RH
G
W2
W1
Y1
Y2
O
B
RC
2-SPEED
AIR CONDITIONER
FK4C
FAN COIL
TWO-ZONE SYSTEM
R
G
R
C
W1
W2
Y1
Y/Y2
O
C
Y1
L
Y2
See note 1
DH
J1 JUMPER
REMOVE J2 JUMPER
FOR HEAT STAGING AND
CONNECT W2 TO W2
→Fig. 20—Two-Stage or Variable-Speed Furnace
With 2-Speed Air Conditioner
A97301
2-SPEED
AIR CONDITIONER
2-STAGE OR
VARIABLE-SPEED
FURNACE
C
W2
W/W1
Y/Y2
R
G
C
Y2
R
Y1
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
See notes 2 and 3
Y
*
—13—

→Fig. 23—Single-Stage Furnace With Single-Speed Heat Pump A97304
SINGLE-STAGE
FURNACE
TWO-ZONE SYSTEM
INTERFACE
CONTROL
R
GF
RF
WF
R
GT
E
HP
O
HP
OT
Y
HP
C
W2
Y
O
RH
G
W2
W1
Y1
Y2
O
B
RC
G
R
W
C
SINGLE-SPEED
HEAT PUMP
YT
ET
C
Y
21
3
OUTDOOR
THERMOSTAT
(KHAOT0301FST)
See notes 4, 5, 6, and 7
(KHAIC0101AAA)
→Fig. 24—Two-Stage or Variable-Speed Furnace With Single-Speed Heat Pump A97305
2-STAGE OR 
VARIABLE-SPEED
FURNACE
TWO-ZONE SYSTEM
INTERFACE
CONTROL
R
GF
RF
WF
R
GT
E
HP
O
HP
OT
Y
HP
C
W2
Y
O
RH
G
W2
W1
Y1
Y2
O
B
RC
G
R
W/W1
C
SINGLE-SPEED
HEAT PUMP
YT
ET
C

Y/Y2
21
3
OUTDOOR
THERMOSTAT
(KHAOT0301FST)
See notes 4, 5, 6, 7, and 8
(KHAIC0101AAA)
W2
—14—

→Fig. 27—Single-Stage Furnace
With 2-Speed Heat Pump
A97308
2-SPEED
HEAT PUMP
SINGLE-STAGE
FURNACE
R
G
R
C
W
Y
C
Y2
W3
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
W2
Y1
O
See notes 2, 5, 6, 7, 9, 10, and 11
→Fig. 25—Typical Fan Coil With Single-Speed Heat Pump
A97306
SINGLE-SPEED
HEAT PUMP
TWO-ZONE SYSTEM
TYPICAL
FAN COIL
R
G
W2
W3
C
R
Y/Y2
O
L
E
Y1
C
W2
Y
O
RH
G
W2
W1
Y1
Y2
O
B
RC See notes 1 and 3
*
*
*
*
*
→Fig. 28—Two-Stage or Variable-Speed Furnace
With 2-Speed Heat Pump
A97309
2-SPEED
HEAT PUMP
2-STAGE OR
VARIABLE-SPEED
FURNACE
C
W2
W/W1
Y/Y2
R
G
C
Y2
R
Y1
RH
G
W2
W1
Y1
Y2
O
B
RC
TWO-ZONE SYSTEM
See notes 2, 3, 5, 6, 7, 8, 9, 10, and 11
Y1
*
*
W2
O
O
W3
→Fig. 26—FK4C Fan Coil
With Single-Speed Heat Pump
A97307
FK4C
FAN COIL
R
G
W1
W2
C
R
Y/Y2
O
Y1
DH
C
W2
Y
O
RH
G
W2
W1
Y1
Y2
O
B
RC
SINGLE-SPEED
HEAT PUMP
TWO-ZONE SYSTEM
See note 1
J1 JUMPER
J2 JUMPER
—15—

→Fig. 29—Typical Fan Coil With 2-Speed Heat Pump
A97310
RH
G
W2
W1
Y1
Y2
O
B
RC
2-SPEED
HEAT PUMP
TYPICAL
FAN COIL
C
G
W2
Y/Y2
R
C
W3
L
E
Y1
R
W2
O
W3
Y1
Y2
O
TWO-ZONE SYSTEM
See notes 1, 2, 3, 9, and 11
*
*
*
*
*
→Fig. 30—FK4C Fan Coil With 2-Speed Heat Pump
A97311
FK4C
FAN COIL
R
R
G
W1
C
DH
W2
Y1
Y/Y2
O
C
W2
Y1
Y2
RH
G
W2
W1
Y1
Y2
O
B
RC
2-SPEED
HEAT PUMP
TWO-ZONE SYSTEM
J1 JUMPER
J2 JUMPER
O
W3
See notes 1, 2, 9, and 11
→WIRING DIAGRAM NOTES
1. Refer to fan coil Installation Instructions for proper wiring.
2. Refer to outdoor unit Installation Instructions for latent kit requirements.
3. Terminals marked with * may not be present on equipment.
4. Interface control transformer must be in phase with furnace transformer to get high-speed fan during heat pump operation.
5. Heat pump MUST have a high-pressure switch for dual-fuel applications.
6. Two-Zone Control does not know that dual fuel is applied. Do not use thermostat AUTO CHANGEOVER mode with dual-fuel applications,
keep both thermostats in same mode (heating or cooling).
7. Configure Two-Zone Control board (jumpers) for:
(J1) T-stat = Fnc
(J3) Equipmt = HP
(J4) Fnc Ht = w/fan
(J5) LAT = Set LAT jumper high enough to allow furnace to come on during defrost and second-stage operation.
(J7) DTO = On
8. Furnace must control its own second-stage heat operation, via the furnace control algorithm.
9. Refer to outdoor equipment Installation Instructions for proper set up.
10. Select Furnace Interface option, Balance Point, and Defrost Time on 2-speed heat pump control board.
11. DO NOT select "ZONE" position on 2-speed heat pump control board. In heating mode, heat pump outdoor temperature sensor will control
the compressor low- and high-speed change.
© 1997 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231 —16— Printed in U.S.A. zkit06 Catalog No. 809-661