HVAC Controls ZP4-ESP-FAV User manual

FORCED AIR ZONING SYSTEM
INSTALLATION GUIDE
ZP4-ESP-FAV
Indianapolis, IN 46237

TABLE OF CONTENTSTABLE OF CONTENTS
Overview ............................................................................................................................................................. 3
Sequence of Operation ........................................................................................................................................ 3
Design and Installation Guidelines ....................................................................................................................... 3
ZP4-ESP-FAV Panel Layout ................................................................................................................................4
System Wiring .................................................................................................................................................. 5-9
Warning! .................................................................................................................................................. 5
Caution! ................................................................................................................................................... 5
Mounting the Panel .................................................................................................................................. 5
System Power ......................................................................................................................................... 5
HVAC System .......................................................................................................................................... 5
DH Terminals............................................................................................................................................6
Night Stat (Optional) .................................................................................................................................6
Sensors .................................................................................................................................................. 7
Discharge Air Sensor ................................................................................................................... 7
Outdoor Temperature Sensor (Optional) ...................................................................................... 7
Return Air Sensor......................................................................................................................... 7
SPS Terminals ......................................................................................................................................... 8
How ESP Works ...................................................................................................................................... 8
Using a conventional electronic bypass damper .......................................................................................9
CO2 Sensor............................................................................................................................................. 9
FAD fresh air damper ............................................................................................................................. 10
Zone Dampers........................................................................................................................................10
Panel Setup .................................................................................................................................................. 11-14
Switch Configurations............................................................................................................................. 11
System Configuration .............................................................................................................................11
GDM (Graphic Display Module) ..............................................................................................................12
Discharge Air Sensor ............................................................................................................................. 12
Return Air Sensor ...................................................................................................................................12
Outdoor Temperature Sensor .................................................................................................................12
Setting High Limit ................................................................................................................................... 12
Setting Low Limit ................................................................................................................................... 12
Setting High Balance Point .................................................................................................................... 13
Setting Low Balance Point ..................................................................................................................... 13
Upstage Timer Option ............................................................................................................................13
Selecting ESP Zones ..............................................................................................................................13
Selecting Conventional Bypass Damper ................................................................................................13
Ventilation Timer ....................................................................................................................................14
Ventilation Timer Quick Reference Chart ................................................................................................14
Formula For Setting Ventilation Timer .....................................................................................................14
Ventilation Timer Hi Limit ........................................................................................................................15
Ventilation Timer Lo Limit.......................................................................................................................15
Overcool DH Timer .................................................................................................................................15
Panel LED Definitions and Functions ........................................................................................................... 15
Speed Up Mode .................................................................................................................................................16
Optional Night Stat Setup and Scheduling .................................................................................... 16-18
Overview ................................................................................................................................................16
How It Works ..........................................................................................................................................17
Recommended Setup ............................................................................................................................17
System Switch Settings ..........................................................................................................................17
Installer Setup Menu Changes ...............................................................................................................17
Setting The Clock And Day Of Week .......................................................................................................17
Daylight Saving Time ..............................................................................................................................17
Programming Events .............................................................................................................................18
Typical 7-Day Schedule ..........................................................................................................................18
2

OVERVIEW
The ZP4-ESP-FAV is a residential and light commercial forced air zone control system that allows a
single HVAC unit to have up to 4 separate zones. The panel can be used with single stage or multi-
stage heat/cool equipment as well as heat pump and dual fuel systems having up to 3 stages of
heating and 2 stages of cooling. Simple slide switch configurations allow for a wide range of system
setup and control options best suited for each zoning application. The ZP4-ESP-FAV incorporates an
integrated ESP static pressure control logic designed to eliminate the need for a conventional bypass
damper when used with 3-wire zone dampers or can be used with a single motorized bypass damper
through installer selection. A Graphics Display Module (GDM) allows real time monitoring of
discharge air, return air and outside air temperature when used with appropriate sensors. The GDM is
also used to set high and low limits, high and low outdoor balance points, timed upstaging, high and
low limits for fresh air ventilation as well as fresh air ventilation timing and selection of designated
ESP zones or use of a single electronic bypass damper in place of the ESP function.
SEQUENCE OF OPERATION
Each zone is controlled by its own space thermostat and motorized zone damper. If any zone
thermostat calls for heating or cooling, the zones not calling will have their dampers powered closed
and the zones calling will have their dampers powered open. If the ESP feature is enabled, non-
calling zones will modulate open enough to maintain system static pressure. If conventional bypass is
selected, all non-calling zones will go to the closed position and the heating or cooling equipment will
be energized. When all zones are satisfied, the heating or cooling equipment will turn off. Zone
dampers will then reposition based on ventilation mode selection. The system uses First Call
Priority - Time Share mode of operation.
First Call Priority - Time Share:
The first zone that calls for heating or cooling establishes the equipment mode of operation. If an
opposite call takes place, it will be delayed until the first call is satisfied or after twenty minutes at
which time the equipment will change mode of operation.
DESIGN AND INSTALLATION GUIDLINES
[ ] Zone control begins with good HVAC design.
[ ] Proper load calculations used to determine duct and equipment sizing are essential in achieving
optimum performance.
[ ] Install zone thermostats in their respective zones.
[ ] System wires should be tagged to match the panel terminal designations and zone
identification.
[ ] Zone dampers should be installed at least 10’ back from discharge air grills whenever possible.
[ ] Zone dampers need to be located where they can be accessed for trouble shooting.
[ ] Flex or lined duct is recommended on the last 5’ of each branch run.
[ ] Thermostats and zone dampers can typically be located up to 300’ from the control panel when
18AWG copper thermostat wire is used.
[ ] Always use a separate 24VAC transformer rated at the proper VA to power the panel, zone
dampers, thermostats and other optional peripherals.
[ ] Never use the equipment transformer regardless of its VA rating.
[ ] When using forced air zoning with a variable speed HVAC system, the fan should be set
at 400 CFM per ton of cooling.
3

ZP4-ESP-FAV PANEL LAYOUT
SELECT UP DOWN
3 AMP3 AMP
3 AMP 3 AMP
ZP4-ESP-FAV
24 VOLT POWER
ZONE 1 DAMPER
ZONE 2 DAMPER
ZONE 3 DAMPER
ZONE 4 DAMPER
BYPASS DAMPER
OPTIONAL NIGHT STAT
STATIC PRESSURE SENSOR
DISCHARGE AIR SENSOR
RETURN AIR SENSOR
OUTDOOR SENSOR
CO2 SENSOR
HVAC EQUIPMENT
ZONE 1 THERMOSTAT
3 AMP FUSE
PROTECT RELAY
CONTACTS
3 AMP FUSE
PROTECTS CIRCUIT
BOARD
SYSTEM
SETUP
SWITCHES
TIME DELAY
SPEED UP
BUTTON
HVAC
SYSTEM
LEDs
ZONE
DAMPER
POSITION
LEDs
(ON WHEN
OPEN)
AUXILIARY LEDS
GRAPHIC
PROGRAMMING
DISPLAY MODULE
PC2
C1
PO3
PC2
C1
PO3
PC2
C1
PO3
PC2
C1
PO3
PC2
C1
PO3
C
R
Y1
Y2
W1-AUX
W2-O/B
G
ZONE STAT 1
ZONE 2 THERMOSTAT
C
R
Y1
Y2
W1-AUX
W2-O/B
G
ZONE STAT 2
C
R
Y1
Y2
W1-AUX
W2-O/B
G
ZONE STAT 1
ZONE 3 THERMOSTAT
C
R
Y1
Y2
W1-AUX
W2-O/B
G
ZONE STAT 3
ZONE 4 THERMOSTAT
C
R
Y1
Y2
W1-AUX
W2-O/B
G
ZONE STAT 4
DH
DH
1 2 3 4 5 6
DAS
DAS
RAS
RAS
OTS
OTS
BYPASS
C
R
CO2
CO2
C
P0
FAD
Y1
Y2
W1-AUX
W2-O/B
G
R
HVAC SYSTEM
POWER
ZD1
ZD2
ZD3
ZD4
OCCUPIED
DAS
OTS
SPS
BP
CO2
FAD
Y1
Y2
W1-AUX
W2-O/B
G
HP HC SYSTEM
FOSSIL CONV HEAT PUMP
B O REV VALVE
ELECT GAS FAN
1 MIN OFF PURGE
2 ZONES OFF CAP CTRL
DEHUMIDIFACTION
INPUT
POWER
LED
FRESH AIR DAMPER
4

SYSTEM WIRING
WARNING!
1. Turn power off to HVAC equipment and control panel during installation to prevent serious injury
from electrical shock and/or damage to the system.
2. Use extreme care when making duct openings and handling sheet metal to avoid injury.
3. Install all components in a manner that provides easy access for test, check, and startup.
CAUTION!
1. Installation of this system must be in compliance with all applicable codes.
2. HVAC system must be properly sized and balanced to assure optimum system performance.
3. All low voltage cable must be 18 gauge solid (not stranded) wire.
4. All wiring should be color coded and tagged for proper identification.
Mounting the Panel
Carefully remove the panel from the shipping carton. Remove the cover and any packing material.
Position the panel on a flat, non-condensating, vertical surface near the indoor unit that will facilitate
ease of wiring and service access. Use appropriate anchors and screws to secure the panel to the
surface.
System Power
1. Wire a 24VAC, 75VA transformer to the 24VAC ‘R’ and ‘C’ terminals on the ZP4-ESP-FAV panel.
HVAC System
2. Wire the HVAC equipment to the HVAC SYSTEM terminals on the ZP4-ESP-FAV panel.
Y1
Y2
W1-AUX
W2-O/B
G
R
Y1
Y2
W1
W2
G
R
C
CONVENTIONAL
HEATING & COOLING SYSTEM
ZP4-ESP-FAV
HVAC SYSTEM TERMINALS
Y1
Y2
W1-AUX
W2-O/B
G
R
Y1
Y2
W1
O/B
G
R
C
HEAT PUMP OR FOSSIL FUEL
HEAT / COOL SYSTEM
ZP4-ESP-FAV
HVAC SYSTEM TERMINALS
WARNING! NEVER USE THE EQUIPMENT TRANSFORMER
24V COMMON
NOT USEDNOT USED
24VAC 120/208/240/480 VAC
TR-75 TRANSFORMER
R
C
NOT USED
24VAC
5

SYSTEM WIRING
DH Terminals
The ZP4-ESP-FAV has a set of terminals marked DH that are a normally open dry contact input
designed for an optional dehumidistat. When the HVAC system is in the cooling mode and the
humidity is above the dedhumidistat setpoint, the cooling setpoint will be overridden and the
equipment will continue to run until either the dehumidistat setpoint is reached or the equipment is
shut off based on a selectable run time from 1 minute to 15 minutes in 1 minute increments.
Dehumidification is ignored during the heating mode.
DH
DH
DEHUMIDISTAT
INPUT
N.O. CONTACTS
Night Stat (Optional)
The NIGHT STAT terminals are designed to be used with a UT32-NS programmable thermostat for
occupied and unoccupied scheduling of the ZP4-ESP-FAV panel. This feature is suitable for
commercial applications and eliminates the need for programmable thermostats in each zone.
Remove the factory jumper across the R and NS terminals on the panel. Wire the 24V Common C
from the panel to the Common C on the thermostat. Wire the 24V Hot R on the panel to the Hot R on
the thermostat. Wire the NS terminal on the panel to the G terminal on the thermostat. The
thermostat can also be fitted with a remote sensor in applications where the Night Stat is located in
an equipment room or maintenance office. Refer to the Night Stat Setup and Scheduling section in
this Installation Guide.
UT32-NS
NIGHT STAT
C
R
NS
Optional
T-S1
Remote
Sensor
Terminals
S2
SC S1 O/B AUX AUX Y1 Y2 W1 G
R C
WIRE
ACCESS
HOLE
BATTERY
COMPARTMENT
MOUNTING HOLES
MOUNTING HOLES
W2 MOUNTING
HOLE
NIGHT STAT
6

SYSTEM WIRING
Outdoor Temperature Sensor (Optional)
The outdoor temperature sensor is used for High and Low Balance Point control in heat pump and
dual fuel applications but can also be used for High and Low outdoor temperature limits for fresh air
ventilation as well as outdoor temperature display. Mount the sensor inside the outdoor unit where it
will not be directly exposed to sunlight, water, snow or ice. Wire the sensor to the OTS terminals on
the panel.
S
E
N
S
O
R
ENCLOSURE
ZPA-OTS
DAS
DAS
RAS
RAS
OTS
OTS
SENSORS
The SENSOR terminals provide inputs for Discharge Air (DAS), Return Air (RAS) and Outdoor
Temperature (OTS) sensors. All sensors are NTC Type III thermistors rated at 10K Ohms @ 77° F.
Discharge Air Sensor
Mount the discharge air sensor in the main supply duct out of the line of sight of the heat exchanger
or cooling coil and upstream of any duct transitions or zone dampers. Wire the sensor to the DAS
terminals on the panel. The sensor is used for High and Low Limit protection as well as display of
discharge air temperature.
ZPA-DTS
DUCT
DAS
DAS
RAS
RAS
OTS
OTS
Return Air Sensor (Optional)
Mount the return air sensor in the main return duct. Wire the sensor to the RAS terminals on the
panel. The sensor is used to display return air temperature only.
ZPA-DTS
DUCT
DAS
DAS
RAS
RAS
OTS
OTS
7

SPS Terminals
The SPS terminals wire to the ZPA-SPS Static Pressure Sensor. The sensor should be installed on a
flat surface so that the diaphragm is in the vertical position. Use the 1/4” x 36” tubing provided and
connect one end to the (P1+) high pressure fitting on the sensor. The other end of the tubing should
be connected to the plastic sensing probe mounted in the main discharge air plenum prior to any
zone dampers or duct transitions. The sensing probe is 2-1/8” x 1/4” O.D. Install and mount the probe
with the arrow in the direction of airflow. The pressure sensor is factory set for 0.35” W.C. but is fully
adjustable from 0.08 to 1.2” W.C. The terminals are not polarity sensitive. Use 18-2 thermostat wire.
After removing the outer jacket, strip approximately 1/8” insulation off of each wire. Land the wires to
terminals 2 and 3 on the pressure sensor and repeat the process on the other end by landing the
wires to the SPS terminals 2 and 3 on the panel.
NOTE: The ESP function only works with 3-wire, power open / power close dampers.
32
FACTORY SET
AT 0.35” W.C.
STATIC PRESSURE
SETPOINT DIAL
ZPA-SPS
How ESP works when selected over conventional bypass
As zone dampers open and close, the ZPA-SPS Static Pressure Sensor continuously monitors the
system static pressure. If the static pressure goes above the static pressure setpoint, the sensor will
send a signal to the panel which will begin to open selected non-calling zone dampers until the static
pressure setpoint is maintained. The SPS LED will come on until the static pressure reaches setpoint
and then turns off. Selected non-calling ESP zone LEDs will blink when their dampers are in a
floating position. The small amount of air allowed to bleed into non-calling zones eliminates air noise
and ensures proper airflow through the HVAC system. This also prevents coil freeze up and high
temperature issues. When all zones are satisfied, all zone dampers will go to the full open position
provided no thermostat is calling for ventilation mode.
CONTROL MUST BE MOUNTED
IN VERTICAL POSITION
THE 1/4” TUBING SHOULD BE
CONNECTED TO P1+
HIGH PRESSURE FITTING ON THE
PRESSURE SENSOR
AIR HANDLER
TOP VIEW
RETURN
AIR
SUPPLY
AIR
INSTALL
SENSING
PROBE
WITH ARROW
IN DIRECTION
OF AIRFLOW
ZPA-SPS
SYSTEM WIRING
8

SYSTEM WIRING
PC2
C1
PO3
BYPASS
Using a conventional electronic bypass damper
A conventional electronic bypass damper can be used in place of the ESP feature. When selected,
the bypass damper wires to the BYPASS terminals on the panel which is then controlled by the ZPA-
SPS static pressure control.
CO2 Sensor
The ZP4-ESP-FAV panel has an input for a CO2 sensor having a normally open dry contact output.
When CO2 reaches a pre-selected setting on the sensor, the CO2 contacts will close causing a fresh
air damper to open and the system fan to run regardless of what mode the equipment is in. Once the
CO2 level falls below the sensor setting, the contact will open and the fresh air damper will close and
the fan will go intermittent with the equipment.
C
R
CO2
CO2
CO2-TH AC
AC
+
-
AC/DC
12-30V
T1
T2
Remote
Input
0-10V Coms Relay
Com
0-V
Com
0-V
CO2 RH
Temp
A B NO NC
Com
WIRING DIAGRAM FOR iO CO2-TH INDOOR CO2,
TEMPERATURE AND HUMIDITY MONITOR
9
FP18-MOTOR
24VAC/DC
2.5 VA 1.5W
1 Comm
2 Close
3 Open
0
1
1 2 3

Zone Dampers
The panel has dedicated terminals for each zone damper. Dampers have three-wire, floating point
actuators rated at 2.5VA.
NOTE: 3-wire dampers must be used with the ESP function that eliminates the need for a traditional
bypass damper.
PC2
C1
PO3
ZD1
C
P0
FAD
SYSTEM WIRING
FAD (Fresh Air Damper)
The ZP4-ESP-FAV has a fresh air damper terminal designed to be used with a 24VAC Power Open /
Spring Close, 2-wire damper. The fresh air damper can be used for both timed fresh air ventilation
and/or CO2 ventilation.
TYPICAL 2-WIRE
POWER OPEN / SPRING CLOSE
FRESH AIR DAMPER
10
FP18-MOTOR
24VAC/DC
2.5 VA 1.5W
1 Comm
2 Close
3 Open
0
1
1 2 3