Honeywell TotalZone TZ-4 Operation manual

PRODUCT DATA
68-0259-1
® U.S. Registered Trademark
Copyright © 2002 Honeywell • All Rights Reserved
TZ-4 TotalZone® Zone Control Panel
APPLICATION
The TZ-4 TotalZone Zone Control Panel controls single-stage,
multi-stage, conventional or heat pump heat/cool equipment.
It controls 2, 3 or 4 zones, and is expandable up to 32 zones
with optional TotalZone® Add-A-Zone™ Four Zone Control
Panel.
FEATURES
• Up to three stages heat and two stages cooling can be
controlled by thermostat, built-in timer, or based on
the percentage of zones calling.
• Controls single-stage, multi-stage, conventional, heat
pump or dual-fuel equipment.
• Controls up to four zones and can be expanded up to
32 zones with Add-A-Zone Control Panels.
• Uses Honeywell four-wire, single-stage, multi-stage, or
select heat pump thermostats.
• Zone-A-Lone central setback feature.
• Purge timer protects equipment between calls for heat
or cool with choice of panel or HVAC equipment
controlled fan.
• System and zone damper LEDs indicate system and
damper status.
• Individual zone fan control.
• Discharge Air Temperature Sensor for capacity control
with adjustable high and low limits.
• Thermal circuit breaker protects panel and transformer
from damage if miswired.
For Internet access:
www.honeywellzoning.com
For technical support, call 1-800-828-8367.
To download Zoning literature: http://hbctechlit.honeywell.com
Contents
Application......................................................................... 1
Features ............................................................................ 1
Specifications .................................................................... 2
Installation ......................................................................... 4
Startup and Checkout........................................................ 12
Operation........................................................................... 12
Troubleshooting................................................................. 17

TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 2
SPECIFICATIONS
Input Ratings:
Voltage: 20-30 Vac, 50/60 Hz.
Power: 13 VA, nominal.
Output Ratings:
1.5A run, 200,000 cycles (30 Vac). 3.5 inrush.
1.5A run, 100,000 cycles (30 Vac) 7.5A inrush.
Humidity Ratings:
5 to 90 percent RH, non-condensing.
Temperature Ratings:
Shipping: -20° to 120°F.
Operating: -40° to 150°F.
Dimensions: 10-3/4 in. H x 12-3/4 in. W x 1-7/8 in. D.
See Fig. 1.
Mounting: Mounts with four 1 in. no. 8 screws (provided)
through holes in cabinet back. Wall anchors are provided.
Wiring: 18-gauge wire for all equipment and system
connections.
Wiring Connections:
Thermostat: R, C, W1/E, W2, W3/AUX, Y1, Y2, G, L, O/B
Dampers: M6 (Closed); M4 (Open); M1 (Common).
Discharge Air Temperature Sensor (C7735A1000); DATS,
DATS.
Zone-A-Lone: OC, OC.
Outdoor Temperature: OT, OT.
Transformer 1: R (hot), C (common).
Transformer 2: T1 (hot), T2 (common).
Equipment: Rc-Rh, W1/E, W2, W3/AUX Y1, Y2, G, O/B.
Thermostats (See Table 1):
Most conventional four-wire (R,W,Y,G) thermostats can be
used to control conventional, heat pump, or multi-stage
equipment.
Manual or automatic changeover switching thermostats can
be used.
Multi-stage or select heat pump thermostats can also be
used.
Fig. 1. TZ-4 dimensions in in. (mm).
M20516
10-3/4
(273)
12-3/4
(273)
1-7/8
(47)

TZ-4 TOTALZONE® ZONE CONTROL PANEL
3 68-0259-1
aHeat pump thermostat with single Y first-stage terminals. See Heat Pump Thermostats section and Fig. 6.
bMulti-stage and heat pump thermostats are not required to control multi-stage and heat pump systems with TotalZone. They are
used only when second stage or emergency heat control from the zone thermostat is needed.
cThe Y594R1243 must be wired to the panel using the B terminal for changeover.
dCut thermostat second-stage variable heating anticipator wire (gray).
eCut thermostat first-stage fixed heating anticipator wire (bare) and second-stage variable heating anticipator wire (gray).
fCut thermostat second-stage cooling anticipator wire (lowest bare wire).
Recommended Dampers (See Table 2):
Ten ZD or ARD dampers maximum connected to each panel
and a maximum of five dampers per zone when using two
40 VA transformers.
Use SDCR and 40 VA transformer for additional dampers
required on one zone.
Dampers are connected to M1 Common, M4 Open, and M6
Closed (see Fig. 7-10 for hookups).
Accessories: For required accessories, see Table 3.
Table 1. Recommended Thermostats.
System Non-Programmable Programmable
Single Stage T87F1859/Q539A1014
T87F4010/Q539A4026
T8501D1046
T8400C1016
T8400C1040
T8400C1099
T8601D2027
T8600D2069
T8600D2028
T8601D2019
T8602D2018
T8602D2000
T8000C1002
T8000C1010
T8001C1019
PC8900/W8900A/C
Heat PumpbY594R1243a,c,d
Y594G1252a,e
T8411R1002
T8411R1028
T8611G2051
T8011R1006
T8011R1014
Multi-StagebY594D1347f
T8524D1015
T8624D2004
T8624D2012
Motor Terminal Damper Action
Common/M1 Common
Open/M4 Power Open
Closed/M6 Power Close
Table 2. Recommended Dampers.
Honeywell Damper Type Round Rectangular
Power-open/power-closed (for
systems > 2000 cfm)
MARD D643 using
ML6161
Motor
Actuator
Spring-open/power-closed (for
systems </= 2000 cfm)
ARD ZD

TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 4
INSTALLATION
Mounting
CAUTION
Equipment Damage Hazard.
Do not mount TZ-4 inside HVAC equipment
Mount only on wall or on cold air return.
Identifying DIP Switches
This panel has two banks of DIP switches, DIP switch 4 (S4)
and DIP switch 5 (S5), see Fig 15. Each bank has eight
individual switches that are identified by two numbers; the first
number is the bank number (4 or 5) and the second number
identifies the individual switch. For example, DIP 5-1 is bank
5, switch 1.
1. Mount the thermostats in each zone of the living space
using the installation instructions provided with each
thermostat.
2. Mount the dampers in the ductwork using the installa-
tion instructions provided with each damper.
3. Mount the TZ-4 zone panel near the HVAC equipment;
(on a wall or on the cold-air return). See Fig. 2.
4. Level the TZ-4 for appearance only.
Wiring
CAUTION
Voltage Hazard.
Can cause electrical shock or equipment damage.
Disconnect power before continuing installation.
Wiring must comply with applicable codes, ordinances, and
regulations.
1. Connect thermostats as shown in Fig. 3-6.
2. Connect dampers as shown in Fig. 7-10.
3. Connect C7735A Discharge Air Temperature Sensor
(not supplied) to the DATS terminals. The wires are not
polarized. See Fig. 13.
4. Connect Add-A-Zone panels (if used) to the AZ1 and
AZ2 terminals.
5. Connect the HVAC equipment to the EQUIP terminals
on the panel. See Fig. 15-21.
6. Connect a 40 VA, 24 volt transformer to R (hot) and C
(common). This must be a dedicated transformer and
each TAZ-4 board also requires a transformer. See Fig.
12.
7. The auxiliary 40 VA 24-volt transformer can be con-
nected to T1 and T2 if additional power for dampers is
required. This second transformer is not required; how-
ever, total power consumption of panel and damper is
limited to 40VA without it.
Fig. 2. TZ-4 mounting location.
Table 3. Required Accessories (Not Supplied).
Accessory Description Bypass Rating
(cfm)
40 VA
transformers
AT140D1046
(PMT-40)
—
Capacity
protector
C7735A1000 —
Outdoor
Temperature
Sensor
(Required for
dual-fuel
applications)
C7089B1000 —
Round static
pressure
regulator
damper
SPRD7
SPRD8
SPRD9
SPRD10
SPRD12
SPRD14
SPRD16
300
400
600
750
1200
1800
2400
Rectangular
static pressure
regulator
damper
SPRD12x8
SPRD12x10
SPRD12x12
SPRD20x8
SPRD20x10
SPRD20x12
1000
1200
1400
1600
2000
3000
M20517
WATER
HEATER
TZ-4
ELECTRONICAIRCLEANER
RETURN
AIR
TZ-4
OPTIONAL
LOCATION
FURNACE
OR BOILER
HIGH
EFFICIENCY
AIR CLEANER

TZ-4 TOTALZONE® ZONE CONTROL PANEL
5 68-0259-1
Wiring Diagrams (Fig. 3 and 4)
Conventional Thermostats
Conventional (RWYG) thermostats can be used to control
conventional, multi-stage, and heat pump equipment. If the
thermostat has a common terminal, it is wired to C on the
panel, see Fig. 3. A multi-stage thermostat is wired with the
second and third stage of heat to W2 and W3 on the panel
thermostat connections, and with the second stage of cooling
to Y2. Leave the zone O/B thermostat jumper on the TZ-4
disconnected. See Single and Multi-Stage Operation in the
Operation section for instructions on staging the TZ-4.
The PC8900 with the W8900A or W8900C can be used as a
zone thermostat. See Fig. 4 for hookup. This thermostat can
be used to control up to 2 heat and 2 cool stages of
conventional equipment. When used to control heat pump
equipment, the W8900A is recommended.
Connect a jumper on the W8900 from Rc to Rh as shown in
Fig. 4. Wire terminals R and C to a transformer. If the system
current draw is within specifications, the R and C on the
W8900 could alternately be connected to R and C on the
TZ-4. The PC8900/W8900 draws 5 VA.
Fig. 3. Typical single-stage thermostat wiring.
M20509B
G
C
R
Y
W
COMMON (C) TERMINAL IS USED ONLY BY THERMOSTATS
THAT REQUIRE A COMMON WIRE.
MULI-STAGE THERMOSTATS ARE WIRED SIMILARLY BUT WITH
Y2 AND W2 USED FOR SECOND STAGE COOL AND HEAT.
THIRD STAGE OF HEAT (W3) CAN BE WIRED TO W3/AUX.
LEAVE O/B JUMPER ON TZ-4 DISCONNECTED.
TZ-4 THERMOSTA
T
CONNECTORS
TYPICAL SINGLE STAGE
THERMOSTAT WIRING
1
2
3
1
3
2

TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 6
Fig. 4. PC8900 with W8900A,C Thermostat wiring.
Heat Pump Thermostats
Select a heat pump thermostat from Table 1. If the thermostat
selected has a separate Y1 and W1 wire, as shown in Fig. 5,
leave the zone O/B thermostat type jumper on the TZ-4
disconnected, and wire as shown in Fig. 5.
If the PC8900/W8900 /Thermostat is used in a heat pump
application, use the W8900A, not the W8900B, and wire as
shown in Fig. 4.
M20508
B
W8900A/C IS RECOMMEDED FOR CONVENTIONAL AND HEAT PUMP APPLICATIONS. THE W8900B CANNOT
SWITCH THE PANEL TO EMERGENCY HEAT.
LEAVE O/B JUMPER ON TZ-4 DISCONNECTED.
TZ-4 THERMOSTA
T
CONNECTORS
1
2
1
S1
S
T1
T
OUT
OUT
LED
G
Y2
Y1
W1
W2
1
2
3
4
GND
C
R
RH
RC
HUM
HUM
VNT
VNT
W8900A,C
PC8900
CO2
1234
2
24 VAC
120 VAC

TZ-4 TOTALZONE® ZONE CONTROL PANEL
7 68-0259-1
.
Fig. 5. Heat pump thermostat with separate Y1 and W1
terminals and multi-stage thermostat wiring.
If the thermostat selected from Table 1has a single Y terminal
for first stage heat and cool, wire as shown in Fig. 6. Wire
either O or B (not both) from the thermostat to the O/B
terminal on the panel. Locate the O/B thermostat jumper on
the TZ-4 near each zone thermostat wiring terminal. Connect
the jumper if O was used or leave disconnected if B was used.
Connect second stage, auxiliary heat to W2.
When using two- or three-stage heat pump thermostats with
single Y first-stage hookup, place a jumper from W2 to Y2 on
the TZ-4 thermostat connections. See Fig. 7.
See Single and Multi-Stage Operation in the Operation
section for instructions on staging the TZ-4.
ARD or ZD Dampers
Wire the ARD or ZD Damper to the panel as shown in Fig. 8.
Multiple dampers can be wired in parallel. Use these dampers
on systems up to 2000 cfm.
AOBD Dampers
Wire the AOBD dampers to the panel as shown in Fig. 9. Two
AOBD can be wired in tandem as shown in Fig. 10. More than
two AOBD dampers require the Slave Damper Control Relay
(SDCR).
Fig. 6. Heat pump thermostat with single Y thermostat
wiring.
M20506
B
G
C
R
Y
W1
L
W2
E
B
O
COMMON (C) TERMINAL IS USED ONLY BY THERMOSTATS
THAT REQUIRE A COMMON WIRE.
JUMP E TERMINAL TO W1 FOR EMERGENCY HEAT.
LEAVE O/B JUMPER ON TZ-4 DISCONNETED.
TZ-4 THERMOSTA
T
CONNECTORS
HEAT PUMP THERMOSTAT WITH
SEPARATE Y1 AND W1
THERMOSTAT WIRING
1
2
3
12
3
M20507
B
G
C
R
Y1
W1
L
W2
E
B
O
COMMON (C) TERMINAL IS USED ONLY BY THERMOSTATS
THAT REQUIRE A COMMON WIRE.
NORMALLY, CONNECT E ON THERMOSTAT TO W1 ON PANEL.
ALTERNATIVELY, INSTALL JUMPER FROM E TO Y1 ON
THERMOSTAT.
CONNECT O/B TERMOSTAT JUMPER ON TZ-4 PANEL IF
USING O FROM THERMOSTAT; DISCONNECT IF USING B.
TZ-4 THERMOSTA
T
CONNECTORS
HEAT PUMP THERMOSTAT WITH
SINGLE Y THERMOSTAT WIRING
1
2
3
1
3
2

TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 8
Fig. 7. Heat pump thermostat with 3-stage heat, 2-stage
cool single Y thermostat wiring.
Fig. 8. Wiring ARD or ZD damper to panel.
Fig. 9. Wiring AOBD damper to panel.
Fig. 10. Wiring two AOBD dampers in parallel.
MARD Dampers or Dampers Using an ML6161 Motor
Actuator
Wire the MARD Damper or ML6161 Actuator to the panel as
shown in Fig. 11. These are floating control actuators, but are
controlled as two-position devices on the TZ-4 panel. Multiple
dampers can be wired in parallel.
The ML6161 Motor causes the damper LED to illuminate
green constantly. WIre a relay as shown in Fig. 12 to restore
damper position indication.
Use the MARD or D643 with the ML6161 on systems above
2000 cfm..
Fig. 11. Wiring MARD Damper or ML6161 Actuator to
panel.
M20891
G
C
R
Y1
Y2
L
W3
E
B
O
COMMON (C) TERMINAL IS USED ONLY ON THERMOSTATS
THAT REQUIRE A COMMON WIRE.
ALTERNATIVELY, JUMPER E THERMOSTAT TERMINAL TO Y1 FO
R
EMERGENCY HEAT.
CONNECT O/B JUMPER ON TZ-4 WHEN USING O OR DISCONNEC
T
WHEN USING B FOR CHANGEOVER.
FIELD INSTALLED JUMPER FROM Y2 TO W2 ON PANEL
THERMOSTAT CONNECTIONS.
TZ-4
THERMOSTAT
CONNECTORS
HEAT PUMP THERMOSTAT WITH
SINGLE Y THERMOSTAT WIRING
1
2
3
4
14
3
2
M6
DAMPER
MOTOR TERMINALS
M4 M1
M1471
9
C
L
O
S
E
O
P
E
N
C
O
M
M
O
N
4
M6 M4 M1
5 6
123
Z
X
DAMPER MOTOR
F
IELD JUMPER
M1906
7
MOTOR TERMINALS
4
M6 M4 M1
5 6
123
DAMPER MOTORS M1906
8
MOTOR TERMINAL
S
4 5 6
123
Z
X
Z
X
FIELD JUMPER
M1 M4
M20136A
ZONE PANEL
CONNECTION
S
M
6
CW
COM
CCW
MARD

TZ-4 TOTALZONE® ZONE CONTROL PANEL
9 68-0259-1
Fig. 12. MARD or ML6161 Damper Motor Actuator using
R8222 Relay wiring.
Transformer
1. Wire the transformers to the panel as shown in Fig. 13.
One 40 VA, 24 Vac transformer controls up to five ARD
or ZD dampers.
2. Connect the transformer to terminals R and C.
3. Add the auxiliary transformer if six to ten ARD or ZD
dampers are used.
a. Wire auxiliary transformer to terminals T1 and T2.
b. It is important that these two transformers be wired
in phase. If they are wired out of phase, the internal
circuit breaker trips and the board de-powers. If this
occurs, remove power, correct the wiring and
restore power to the board.
IMPORTANT
If more than five dampers are required for one zone
or if more than ten dampers are used for the TZ-4,
use the Slave Damper Control Relay (SDCR).
Fig. 13. Wiring transformer(s) to panel.
Discharge Air and Outdoor Temperature Sensors
Wire the C7735A Discharge Air Temperature Sensor (DATS)
to the panel as shown in Fig. 14. The Purge LED (yellow)
flashes in all modes except purge if no DATS is connected to
the TZ-4 or if there is a problem with the DATS or the wiring.
For dual fuel applications, connect the C7089 Outdoor
Temperature Sensor as shown in Fig. 14.
Fig. 14. Wiring C7735A Discharge Air Temperature Sensor
(DATS) to panel.
Add-A-Zone Panel
Remove power from TZ-4 before connecting AZ-1 and AZ-2.
Wire the Add-A-Zone (TAZ-4) Panel to the TotalZone (TZ-4)
Panel as shown in Fig.15. Up to seven TAZ-4 Panels can be
wired to one TZ-4 panel to control up to 32 zones.
COM
CCW
CW
ML6161
R8222 RELAY
ZONE CONTROL PANEL
DAMPER TERMINALS
M2054
8
M6 M4 M1 ZONE
THERMOSTAT
TERMINAL
R
R
C
T1
T2
CR
C
R
24 VAC, 40 VA
Transformer
(Required if
more than
four dampers)
24 VAC, 40 VA
Transformer
DAMPER
XFRM
PANEL
XFRM
M20518
M20519
DATS
DATS
DATS
OT
OT
OT
Sensor

TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 10
Fig. 15. TotalZone Add-A-Zone wiring.
Conventional Equipment
Wire the heating and cooling equipment to the equipment
terminals on the TZ-4 Panel as shown in Fig. 16.
Conventional Equipment: Set DIP switch 5-1 to on.
Electric Furnaces: Set DIP switch 5-6 to off to energize the fan
with a call for heat.
Hydro-Air: Wire the zone valve or circulator relay to the Rh
and W1 equipment terminals. (If the circulator relay has
powered terminals, remove the Rh Rc jumper.) Set DIP switch
5-6 to off to energize the fan with a call for heat.
Oil Heat: Wire the oil primary T, T terminals to the Rh and W
equipment terminals. (If the oil primary has powered
terminals, remove the Rh Rc jumper.)
Multi-Stage: Wire the equipment as shown in Fig. 16 using the
W2 and W3 terminals for second and third stages of heat.
Wire Y2 for second stage of cooling.
See Single and Multi-Stage Operation in the Operation
section to configure DIP switches 4-1, 4-2, 4-3, and 4-4.
M20362
TotalZone Panel
TotalZone
Add-A-Zone Panel
AZ1
DIP-SWITCHES
AZ2
AZ1
AZ2
AZ1
AZ2 TO NEXT
ADD-A-ZON
E
PANEL
54321
O
N