Hvac ZP4-ESP User manual

Indianapolis, IN 46237

TABLE OF CONTENTS
Overview .............................................................................................................................................. 3
Sequence of Operation ......................................................................................................................... 3
Design and Installation Guidelines ........................................................................................................ 3
ZP4-ESP Panel Layout ..........................................................................................................................4
Installing and Wiring the ZP4-ESP Panel ............................................................................................ 5-9
Warning! .................................................................................................................................... 5
Caution! ..................................................................................................................................... 5
Mounting the Panel .................................................................................................................... 5
System Power ............................................................................................................................ 5
HVAC System ............................................................................................................................ 5
Sensors .................................................................................................................................... 6
Discharge Air Sensor ....................................................................................................... 6
Outdoor Temperature Sensor (Optional) .......................................................................... 6
SPS Terminals ................................................................................................................. 7
How ESP Works .............................................................................................................. 7
Zone Thermostats ...................................................................................................................... 8
Single Stage Heat Cool .................................................................................................... 8
Multi-Stage Heat Cool ..................................................................................................... 8
2 Heat / 1 Cool Heat Pump or Fossil Fuel .......................................................................... 8
3 Heat / 2 Cool Heat Pump or Fossil Fuel .......................................................................... 9
Zone Dampers ........................................................................................................................... 9
Panel Setup ................................................................................................................................... 10-11
Configuring Panel for Equipment Application ............................................................................ 10
Limit Adjustments ..................................................................................................................... 10
High Limit ...................................................................................................................... 10
Low Limit ....................................................................................................................... 10
Balance Point Adjustments ....................................................................................................... 11
High Balance Point ........................................................................................................ 11
Low Balance Point ......................................................................................................... 11
Panel LED Definitions and Functions .................................................................................................. 11
Panel Time Delay Chart ....................................................................................................................... 12
Test, Check and Startup ................................................................................................................. 12-14
ZP4-ESP Specifications ...................................................................................................................... 14

The ZP4-ESP is a 4 zone universal zone control panel that includes integrated ESP static pressure
control logic designed to eliminate the need for a conventional bypass damper when used with 3-wire
zone dampers. The panel is capable of handling up to 2 stages of conventional heating and cooling or
3 stages of heating and 2 stages of cooling for heat pump and fossil fuel applications.
SEQUENCE OF OPERATION
The panel allows a single HVAC unit to have up to four separate zones. Each zone is controlled by its
own thermostat. When a 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 opened. The
heating or cooling equipment will also be brought on.
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 panel will
send a signal to all selected non-calling zone dampers to start to open to a point where the static
pressure setpoint is maintained. The ESP LED will come on with the non-calling zone LEDs until the
static pressure reaches setpoint. The small amount of air allowed to bleed into non-calling zones
eliminates air noise and assures proper airflow through the HVAC system. This also prevents coil
freeze up and high temperature issues.
DESIGN AND INSTALLATION GUIDLINES
[ ] Zone control begins with good design. HVAC
[ ] 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
18 copper thermostat wire is used. AWG
[ ] Always use a separate 24 transformer rated at the proper to power the panel, zoneVAC VA
dampers and thermostats.
[ ] Never use the equipment transformer regardless of its rating.VA
[ ] When using forced air zoning with a variable speed system, high speed fan should be setHVAC
at 400 per ton of cooling.CFM

ZP PANEL LAYOUT4-ESP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19 20 21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
1. 3 AMP FUSE PROTECTS PRINTED CIRCUIT BOARD
2. 24 VOLT TRANSFORMER TERMINALS
3. ZONE 1 DAMPER TERMINALS
4. ZONE 2 DAMPER TERMINALS
5. ZONE 3 DAMPER TERMINALS
6. ZONE 4 DAMPER TERMINALS
7. DISCHARGE AIR SENSOR TERMINALS
8. OUTDOOR TEMPERATURE SENSOR TERMINALS
9. STATIC PRESSURE SENSOR TERMINALS
10. SPARE 3 AMP FUSES
11. HVAC EQUIPMENT TERMINALS
12. 3 AMP FUSE PROTECTS THE RELAY CONTACTS
13. PANEL POWER LED
14. ZONE 1 LED
15. ZONE 2 LED
16. ZONE 3 LED
17. ZONE 4 LED
18. ESP LED
19. HIGH LIMIT POTENTIOMETER
20. LOW LIMIT POTENTIOMETER
21. DISCHARGE AIR SENSOR LED
22. HIGH BALANCE POINT POTENTIOMETER
23. LOW BALANCE POINT POTENTIOMETER
24. OUTDOOR TEMPERATURE SENSOR LED
25. Y1 RELAYS LED
26. Y2 RELAY LED
27. W1/AUX LED
28. W2/OB LED
29. G LED
30. ZONE 1 BYPASS JUMPER
31. ZONE 2 BYPASS JUMPER
32. ZONE 3 BYPASS JUMPER
33. ZONE 4 BYPASS JUMPER
34. ZONE 1 THERMOSTAT TERMINALS
35. ZONE 2 THERMOSTAT TERMINALS
36. ZONE 3 THERMOSTAT TERMINALS
37. ZONE 4 THERMOSTAT TERMINALS
38. TIME DELAY SPEED UP LED
39. TIME DELAY SPEED UP BUTTON
40. SYSTEM CONFIGURATION SELECTOR SWITCHES
41. SYSTEM CONFIGURATION SWITCH DEFINITIONS
40
41

INSTALLING AND WIRING THE ZP4-ESP PANEL
WARNING!
1. Turn power off to equipment and control panel during installation to prevent serious injuryHVAC
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. system must be properly sized and balanced to assure optimum system performance. HVAC
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.
Locate 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 24 , transformer to the 24 ‘R’ and ‘C’ terminals on the 4-ESP panel.VAC 40VA VAC ZP
HVAC System
2. Wire the equipment to the terminals on the 4-ESP panel.HVAC HVAC SYSTEM ZP
DO NOT WIRE EQUIPMENT COMMON TO PANEL
24VAC 120/208/240/480 VAC
TRANSFORMER
Y1
Y2
W
O or B
G
R
C
Y1
Y2
W1
W2
G
R
C

Sensors
The S terminals provide inputs for Discharge Air Sensor ( S), and Outdoor Temperature SENSOR DA
Sensor ( S) and Static Pressure Sensor (SPS). The DAS and OTS sensors are Type OT NTC 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 S and DA
DAS terminals on the panel. The sensor is used for High and Low Limit protection.
ZPA-DTS
Outdoor Temperature Sensor (Optional)
The outdoor temperature sensor is used for High and Low Balance Point control in heat pump and
fossil fuel applications. 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 S and S terminals on the panel. OT OT
S
E
N
S
O
R
ENCLOSURE
ZPA-OTS

SPS Terminals
The SPS terminals 2 and 3 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 on thepanel.
NOTE: The ESP function only works with 3-wire, power open / power close dampers.
32
FACTORY SET
0.35” W.C.AT
STATIC PRESSURE
SETPOINT DIAL
ZPA-SPS
How ESP Works
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 will turn off. Any zone with the bypass jumper in the OFF position will not be allowed to
bleed air. The small amount of air allowed to bleed into selected 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
RETURN
AIR
SUPPLY
AIR
INSTALL
SENSING
PROBE
WITH ARROW
IN DIRECTION
OF AIRFLOW
ZPA-SPS

Zone Thermostats
The Panel has inputs for four zone thermostats. Each zone thermostat must be equipment
compatible.
C
R
Y1
Y2
G
W1/AUX
W2/OB
C
R
Y1
W1
G
C
R
Y1
Y2
G
W1/AUX
W2/OB
C
R
Y1
Y2
W1
W2
G
C
R
Y1
Y2
G
W1/AUX
W2/OB
C
R
Y1
W
O/B
G

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.
FP MOTOR18-
24 /VAC DC
2.5 1.5WVA
1 Comm
2 Close
3 Open
0
1
1 2 3
3-WIRE
DAMPER ACTUATOR
C
R
Y1
Y2
G
W1/AUX
W2/OB
C
R
Y1
Y2
W
O/B
G

PANEL SETUP
CONFIGURING PANEL FOR EQUIPMENT APPLICATION:
Once all wiring is completed, the panel can be configured for the specific equipment application.
The ZP4-ESP has a row of slide switches located on the printed circuit board along with a switch
selection chart.
SWITCH DEFINITIONS:
SW-1 Select type of HVAC equipment.
Right = Conventional Heat/Cool
Left = Heat Pump
SW-2 Selects type of heat pump system.
Right = Conventional heat pump
Left = Heat pump with fossil fuel furnace
SW-3 Selects heat pump reversing valve order.
Right = O (energizes in cooling)
Left = B (energizes in heating)
SW-4 Selects fan operation .
Right = Fan controlled by furnace
Left = Fan energized on call for heat
SW-5 Purge option
Right = No purge after call
Left = Purge after call is satisfied for 1
minute into last zone calling before all
dampers go open
SW-6 Capacity Control option
Right = No Capacity Control
Left = Only allow additional equipment
staging if 2 or more zones are calling and at
least one zone is calling for an additional
stage
LIMIT ADJUSTMENTS:
High Limit - The panel has a potentiometer marked HI LIM that is
adjustable from 100° to 180° F. When used with the ZPA-DTS duct
sensor, should the temperature rise above the high limit setting, the
panel will shut off the heating system. The fan will continue to run until
the temperature drops below the high limit setting. The high limit
setpoint should always be below the internal safety limit setting of the
heating system.
Low Limit - The panel has a potentiometer marked LO LIM that is
adjustable from 30° to 55° F. When used with the ZPA-DTS duct
sensor, should the temperature fall below the low limit setting, the
panel will shut off the compressor. The fan will continue to run until
the temperature rises above the low limit setting. A time delay will also
be initiated to prevent short cycling of the equipment.

BALANCE POINT ADJUSTMENTS:
When used with a heat pump or dual fuel system and fitted with a
ZPA-OTS outdoor sensor, the panel can provide both high and low
balance point control.
High Balance Point - The panel has a potentiometer marked HI BAL
PT that is adjustable from 20° to 60° F. If the outdoor temperature
rises above the high balance point setting, the panel will prevent
auxiliary heat from coming on.
Note: If a zone thermostat is set in the emergency heat mode, the
panel will override the high balance point setting regardless of the
outdoor temperature and the system will function in emergency heat
until the thermostat is taken out of the emergency heat mode.
Low Balance Point - The panel has a potentiometer marked LO BAL
PT that is adjustable from 0° - 40° F. If the outdoor temperature falls
below the low balance point setting, the panel will lock out
mechanical heating and change over to the auxiliary heat source.
ZONE BYPASS
Each zone has a Zone Bypass jumper that can be used to remove
the ESP function for that zone. This can be useful in applications
where one zone out of three or four zones may represent a very small
percentage of the total system CFM.
PANEL LED DEFINITIONS AND FUNCTIONS
LED COLOR DEFINITION FUNCTION
PWR
ESP
ZD1
ZD2
ZD3
ZD4
DAS
OTS
SPD
UP
Y1
Y2
W1/AUX
W2/OB
G
Red
Red
Green
Green
Green
Green
Red
Red
Red
Red
Red
Red
Red
Red
Power
Static Pressure
Control
Zone Damper 1
Zone Damper 2
Zone Damper 3
Zone Damper 4
Discharge Air
Sensor
Outdoor Temp
Sensor
Speed Up Mode
1st Stage
Compressor
2nd Stage
Compressor
1st Stage Heat
or Aux Heat
2nd Stage Heat-
Reversing Valve
Fan
ON - 24VAC to panel
OFF - No 24VAC to C and R terminals or 3 AMP POWER fuse is blown
ON - When system static pressure is above static pressure control setpoint
OFF - When system static pressure is below static pressure control setpoint
ON - Damper driving open or in the open position
OFF - Damper in the closed position
BLINKING - Damper in floating position to relieve static pressure as part of
ESP function
ON - Confirms discharge air sensor is wired to panel
OFF - No discharge air sensor wired to panel or wiring problem
BLINKING - Panel out on High or Low Limit
ON - Confirms outdoor temperature sensor is wired to panel
OFF - No outdoor temperature sensor wired to panel or wiring problem
BLINKING - Panel out on High or Low Balance Point
OFF - Panel time delays in standard operating mode
BLINKING - Panel time delays in speed up mode
ON - Panel calling for 1st stage compressor
OFF - No call for 1st stage compressor
ON - Panel calling for 2nd stage compressor
OFF - No call for 2nd stage compressor
ON - Panel calling for 1st stage or auxiliary heat
OFF - No call for 1st stage or auxiliary heat
ON - Panel calling for 2nd stage heat or reversing valve is energized
OFF - No call for 2nd stage heat or reversing valve is de-energized
ON - Fan relay energized
OFF - Fan relay de-energized

PANEL TIME DELAY CHART
TIME DELAY NORMAL MODE SPEED UP MODE
Minimum Time 3 Minutes 9 SecondsOFF
Changeover 5 Minutes 15 Seconds
Time Share 20 Minutes 60 Seconds
Purge 1 Minute 3 Seconds
TEST, CHECK AND START-UP
1. Verify that all component wires have been connected to the proper terminals and are secure.
2. Make sure that the selector switches on the panel are in their proper position for the specific
equipment application.
3. Temporarily disconnect the R wire from the panel to the HVAC system.
4. Apply 24 Volt power to the panel.
5. Place all zone thermostats in the OFF mode with Auto Fan.
6. With no calls taking place, the following panel LEDs should be lit:
PWR
ZD1
ZD2
ZD3
ZD4
DAS (If Discharge Air Sensor is wired to panel)
OTS (If Outdoor Temperature Sensor is wired to panel)
7. Visually confirm that all zone dampers are in the open-position.
8. Place zone 1 thermostat in the continuous fan ON mode. The following LEDs should be lit:
PWR
ZD1
DAS (If Discharge Air Sensor is wired to panel)
OTS (If Outdoor Temperature Sensor is wired to panel)
G
9. Put zone 1 thermostat in Auto Fan and repeat the same steps for each zone thermostat in the
system. The only change in LED status will be the ZD2 LED will light for zone 2, ZD3 LED will light for
zone 3 and ZD4 will light for zone 4.
10. Once the ventilation test is completed, and the zone thermostat fan modes are set to Auto, place
zone 1 thermostat in the cooling mode and adjust the setpoint above the space temperature until it
calls for cooling. Keep in mind that the zone thermostat may have a time delay.
NOTE: The panel also has built-in time delays that can be put in speed up mode
by pressing the SPD UP button on the panel. The SPD UP LED will start blinking
confirming the time delays in the panel are in speed up mode.
3 seconds = 1minute in speed up mode. Pushing the SPD Up button manually
turns speed up on and off. If left on, speed up mode will automatically drop out
in 10 minutes.

11. Once the cooling cycle is energized, the following panel LEDs should be lit:
PWR
ZD1
DAS (If Discharge Air Sensor is wired to panel)
OTS (If Outdoor Temperature Sensor is wired to panel)
Y1
Y2 (If two stage system and setpoint is low enough to energize second stage)
G
NOTE: If the panel has been configured for heat pump or fossil fuel, and the reversing valve is set to
‘O’ for cooling, the W2/OB LED would come on indicating that the reversing valve output is energized.
12. Leave zone 1 thermostat in the cooling mode and place zone 2 thermostat in the cooling mode.
Once the thermostat calls for cooling ZD2 LED will come on.
13. Repeat this step for each zone thermostat in the system and confirm that its zone LED comes on.
14. Turn each zone thermostat off until the panel no longer displays any cooling calls.
15. Place zone 1 thermostat in the heating mode and adjust the setpoint above the space
temperature to force a heating call.
16. Once the heating cycle is energized, the following panel LEDs should be lit based on the following
equipment configurations:
Conventional Heat/Cool
PWR
ZD
DAS (If Discharge Air Sensor is wired to panel)
OTS (If Outdoor Temperature Sensor is wired to panel)
W1
W2 (If two stage system and setpoint is high enough to energize second stage)
G (If fan selector switch is set for electric)
Conventional Heat Pump or Fossil Fuel
PWR
ZD1
DAS (If Discharge Air Sensor is wired to panel)
OTS (If Outdoor Temperature Sensor is wired to panel)
Y1
Y2 (If two stages of compressor and setpoint is high enough to energize second stage)
W1/AUX (If setpoint is high enough to energize auxiliary heat)
G
NOTE: If the panel has been configured for heat pump or fossil fuel, and the reversing valve is set to
‘B’ for heating, the W2/OB LED would come on indicating that the reversing valve output is energized.
In fossil fuel configuration, if the thermostat calls for auxiliary heat, all compressors will be dropped
out.
17. Repeat this step for each zone thermostat in the system and confirm that its zone LED comes on.
18. Turn each zone thermostat off until the panel no longer displays any heating calls.
19. Turn off 24 volts to the panel and reconnect the R wire from the panel to the HVAC system.
20. Reapply 24 volts to the panel.
21. Place zone one thermostat in the continuous fan ON mode.
22. and G LED should light and the system fan should come on. ZD1
23. If the system static pressure rises above the ESP static pressure sensor setting, the ESP LED will
come on and the non-calling zone LEDs will come on confirming that they are opening.

Indianapolis, IN 46237
www.iohvaccontrols.com
For Technical Support Call Toll Free: 866-225-5032
ZP4-ESP SPECIFICATIONS:
Enclosure:
Aluminum
Panel Dimensions:
Height: 8.75”
Width: 7.0”
Depth 1.5”
PC Board Mounting:
Individual Snap Track mounted to enclosure base
Operating Temperature Rating:
-40° F to 150° F
Operating Humidity:
5% to 90% RH non-condensing
Wiring:
18-gauge wire for all equipment and component
connections.
Time Delays:
5 minutes off between heating and cooling calls.
3 minutes off on high or low limit
20 minute time share
Purge ON = 1 minute
Thermostats:
Single or multi-stage
Programmable or non-programmable
Auto or manual changeover
Sensors:
ZPA-DTS Discharge Temperature Sensor
NTC Type 3, 10K @ 77° F, +/- 3% @ 77° FΩ
ZPA-OTS Outdoor Temperature Sensor
NTC Type 3, 10K @ 77° F, +/- 3% @ 77° FΩ
24. When the system static pressure falls below the ESP static pressure sensor setting, the ESP LED
will go out but the non-calling zone LEDs will blink confirming they are in a floating position.
25. After confirming the ESP function is working, place the zone one thermostat in the Auto fan mode.
26. The system fan should shut off and all zone LEDs will light confirming that the zone dampers are
now in the full open position.
27. Place the zone thermostats in their normal operating mode and adjust setpoints and scheduling
accordingly.
iO-06-1338-090320