iO HVAC Controls ZP2-HC-ESP User manual

ZP2-HC-ESP Installation and Operation Instructions
1 Heat / 1 Cool - Auto Changeover
First Call Priority - Time Share
with Integrated ESP Static Pressure Module
OVERVIEW:
The ZP2-HC-ESP is a residential/light commercial
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.
SEQUENCE OF OPERATION:
The panel allows a single HVAC unit to have up
to two separate zones. Each zone is controlled
by its own thermostat. When a zone thermostat
calls for heating or cooling, the zone not calling
will have its dampers powered closed, and the
zone calling will have its 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 the non-calling zone
damper to start to open to a point where the
static pressure setpoint is maintained. The SPS
LED will come on with the non-calling zone LED
until the static pressure reaches setpoint. The
small amount of air allowed to bleed into non-
calling zone eliminates air noise and assures
proper airflow through the HVAC system. This
also prevents coil freeze up and high
temperature issues. When all calls are
satisfied, all zone dampers will go to the full open
position provided none of the thermostats are
calling for ventilation mode. If opposite calls take
place, the first zone to call receives priority. When
the first call is satisfied, the system will
changeover and take care of the opposite call. If
zones being served (heating or cooling) have not
been satisfied within 20 minutes while an opposite
call is taking place, the system will changeover.
When the zone is satisfied or 20 minutes has
elapsed, the system will again changeover if an
opposite call exists. This is referred to as Auto-
Changeover - First Call Priority - Time Share. In
the event of a tie, cooling will receive priority.
HIGH AND LOW LIMIT PROTECTION:
A ZPA-DTS Discharge Temperature Sensor
should be mounted on the discharge air plenum of
the HVAC unit and wired to the DA terminals on
the panel. The sensor is used for both high
(adjustable) and low (fixed) limit protection. The
high limit setting can be adjusted using the two
slide switches located on the panel. (See switch
location and settings on page 2) Low limit is fixed
at 45° F. When the discharge air temperature rises
above the high limit setting or falls below the low
limit setting, the panel will cycle the equipment off
while the fan continues to run. The LIMIT LED
blinks when high or low limit is reached. In cooling
mode, a 3 minute time delay is activated to
prevent short cycling of the equipment.
VENTILATION MODE:
Zone ventilation is established by the individual
zone thermostat fan setting. When no calls are
taking place, any thermostat set in the fan AUTO
mode will not receive ventilation air and its zone
damper will be closed. Any zone thermostat set in
the fan ON mode will receive ventilation air and its
zone damper will be opened. Heating or cooling
calls take priority over ventilation mode. The ESP
function will continue to maintain the system static
pressure by modulating open the non-calling
ventilation zone as required.
POWER REQUIREMENTS:
The panel is powered by a single 24VAC, 40VA
transformer. Never use the equipment
transformer.
1
SPEED UP
3=1SEC MIN
.
.
.
ON
OFF
3 AMP
3 AMP
1 2
.
.
.
ON
OFF

ZP2-HC-ESP Panel Layout
2
3 AMP FUSE PROTECTS
PRINTED CIRCUIT BOARD
3 AMP FUSE PROTECTS
THE RELAY CONTACTS
ZONE 1
THERMOSTAT
ZONE 1 DAMPER
24 VOLTS
24 VOLT POWER LED
1ST STAGE HEATING LED
1ST STAGE COMPRESSOR LED
FAN LED
LIMIT LED (ON WHEN DAS IS
DETECTED. BLINKS WHEN TEMP
EXCEEDS HIGH OR LOW LIMIT)
ZONE 1 DAMPER LED
ZONE 2 DAMPER LED
ZONE 2
THERMOSTAT
ZONE 2 DAMPER
HVAC UNIT
TERMINALS
DISCHARGE
AIR SENSOR
STATIC PRESSURE SENSOR LED
(ON WHEN STATIC PRESSURE IS
ABOVE SETPOINT)
STATIC PRESSURE
SENSOR TERMINALS
SPEED UP
BUTTON
HIGH LIMIT
ADJUSTMENT
SWITCHES
ESP ZONE BYPASS
SELECTOR
PINS
SPEED UP
3=1SEC MIN
.
.
.
ON
OFF
3 AMP
3 AMP
1 2
.
.
.
ON
OFF

ZP2-HC-ESP TERMINAL DESIGNATIONS
3
TRANSFORMER
24VAC POWER
ZONE 1
THERMOSTAT
C (24V COMMON)
R (24V HOT)
W (1ST STAGE HEAT)
Y1 (1ST STAGE COMPRESSOR)
G (FAN)
POWER CLOSE
COMMON
POWER OPEN
ZONE 1
DAMPER
R (24V HOT)
W (1ST STAGE HEAT)
Y1 (1ST STAGE COMPRESSOR)
G (FAN)
HVAC UNIT
WIRE TO ZPA-SPS
PRESSURE SENSOR
WIRE TO ZPA-DTS
DISCHARGE TEMPERATURE
SENSOR
ZONE 2
THERMOSTAT
C (24V COMMON)
R (24V HOT)
W (1ST STAGE HEAT)
Y1 (1ST STAGE COMPRESSOR)
G (FAN)
POWER CLOSE
COMMON
POWER OPEN
ZONE 2
DAMPER

ZP2-HC-ESP LED STATUS DEFINITIONS
4
SPEED UP BUTTON
The Speed Up button can be used
to put the internal panel time
delays in speed up mode. When
the button is pushed, the Speed
Up LED will blink. Pushing the
bottom again will reset the time
delays and the LED will turn off or
will automatically reset in 10
minutes.
Speed Up
LED
.
.
.
ESP ZONE BYPASS
SELECTOR PINS
Each zone has an ESP Zone Bypass selector pin. The
panel comes from the factory with all zones set to ON.
By placing a zones selector pin in the OFF position, this
will prevent air from bleeding into the zone when it is
not calling even if the static pressure goes above the
setpoint. This is sometimes useful for basement zones
or zones with small CFM requirements providing other
non-calling zones have the CFM capacity to allow
enough air to bleed without causing air noise without
over heating and cooling.
ADJUSTABLE
HIGH LIMIT
24 VOLT POWER LED
1ST STAGE HEATING LED
1ST STAGE COMPRESSOR LED
FAN LED
LIMIT LED
ZONE 1 DAMPER LED
ZONE 2 DAMPER LED
STATIC PRESSURE SENSOR LED
High Limit adjustment switches are located on the
panel. The switches can be set to provide limit
protection below the safety limit on the furnace.
1 2

INSTALLING AND WIRING THE ZP2-HC-ESP
MOUNTING THE ENCLOSURE:
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.
NOTE:
The panel utilizes home run wiring. Tag each
zone thermostat cable and its associated zone
damper cable to minimize wiring errors.
WIRING ZONE THERMOSTATS:
Use conventional 18-8 thermostat wire. After
removing the outer jacket, strip approximately
1/8” insulation off of each wire. Land each wire to
its designated screw terminal.
WIRING ZONE DAMPERS:
Use conventional 18-3 thermostat wire. After
removing the outer jacket, strip approximately
1/8” insulation off of each wire. Land each wire to
its designated screw terminal.
WIRING TO THE HVAC EQUIPMENT:
Use conventional 18-6 thermostat wire. After
removing the outer jacket, strip approximately
1/8” insulation off of each wire. Land each wire
into its designated screw terminal on the HVAC
UNIT terminals.
Note: Do not wire the equipment common to
the HVAC UNIT terminals on the panel.
INSTALLING AND WIRING THE ZPA-DTS
DISCHARGE TEMPERATURE SENSOR:
Drill a 15/32” hole in the middle of the main
discharge air plenum approximately 18” to 30”
from the heat pump electric strip heater or the
furnace heat exchanger in a fossil fuel
application. Slide the discharge air probe into the
hole and use two self-tapping sheet metal screws
to secure the base to the plenum. Use
conventional 18-2 thermostat wire and wire nuts
to attach the sensor leads. Replace the cover with
the wire nut connections inside. Strip 1/8”
insulation off of each wire at the other end and
land the wires to the screw terminals marked DA
on the panel.
INSTALLING AND WIRING THE ZPA-SPS
STATIC PRESSURE SENSOR:
The ZPA-SPS pressure 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 ( ) highP1+
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 3-1/8” x 1/4” O.D. Install and
mount the probe with the arrow in the direction of
airflow. The ZPA-SPS is factory set for 0.35” W.C.
but is fully adjustable from 0.08” to 1.20” 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 the 2 and 3 terminal on the
pressure sensor. Repeat the process on the other
end and land the wires to the screw terminals on
the panel marked SPS 2 and 3.
5
32
FACTORY SET
0.35” W.G.AT
WIRE TO
SPS 2 & 3
STATIC PRESSURE
SETPOINT DIAL
5

INSTALLING AND WIRING THE ZP2-HC-ESP
WIRING THE TRANSFORMER:
Wire the separate 24 Volt transformer to the
24VAC POWER ‘R’ and ‘C’ terminals. Use
conventional 18-2 thermostat wire. After
removing the outer jacket, strip approximately
1/8” insulation off of each wire. Land each lead to
the 24VAC POWER screw terminals marked C
and R.
TEST, CHECK AND STARTUP:
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.
3. Apply 24 Volt power to the panel.
4. Place all zone thermostats in the OFF mode
withAuto fan.
5. With no calls taking place, the following panel
LEDs should be lit:
24V
LIMIT
ZD1
ZD2
6. Visually confirm that all zone dampers are in
the open position.
7. Place zone 1 thermostat in the continuous fan
ON mode and the system blower should come
on. The following panel LEDs should be lit:
24V
G
LIMIT
ZD1
Note: If system static pressure goes above
setpoint, the SPS LED will light along with the
selected non-calling zone LED until the non-
calling zone damper modulates to relieve the
static pressure then both LEDs will turn off.
8. Put zone 1 thermostat in Auto fan and repeat
the same steps for zone 2. The only change in
LED status will be ZD2 will light and ZD1 will turn
off.
9. 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 and that
the panel has a 3 minute short cycle time delay
before allowing the equipment to come on.
6
Once the cooling cycle is energized, the
following panel LEDs should be lit:
24V
Y
G
LIMIT
ZD1
10. Repeat the same step for zone 2. LED
status should be the same with the exception
that ZD2 LED will be lit and ZD1 LED will turn
off.
11. The same test can be done for a heating call
from each zone.
12. Once testing is confirmed, place zone
thermostats in their proper mode of operation.

ZP2-HC-ESP SPECIFICATIONS:
Enclosure:
Aluminum
Panel Dimensions:
Height: 8.0”
Width: 6.0”
Depth 2.25”
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:
3 minutes off between heating and cooling calls.
3 minutes off on high or low limit
20 minute time share
Thermostats:
Single Stage
Programmable or non-programmable
Auto or manual changeover
Sensors:
ZPA-DTS Discharge Temperature Sensor
NTC Type 3, 10K @ 77° F, +/- 3% @ 77° FΩ
FIELD WIRING TERMINALS:
Zone Thermostats:
C24Vac (Common)
R 24Vac (Hot)
W First Stage Heat
Y First Stage Compressor
G Fan
HVAC Equipment:
R 24Vac Equipment Hot
W First Stage Heat
Y1 First Stage Compressor
G Fan
High / Low Limit
DA Land to ZPA-DTS
DA Land to ZPA-DTS
Panel Power:
C 24Vac (Common)
R24Vac (Hot)
Damper Outputs
PC Power Close
C Common
PO Power Open
Pressure Sensor:
2 Land to ZPA-SPS
3 Land to ZPA-SPS
7
iO-06-1281-010818
HVAC Controls
Indianapolis, IN 46237
www.iohvaccontrols.com
For Technical Support Call Toll Free: 866-225-5032