iO HVAC Controls ZP6-ESP-PRO User manual

UNIVERSAL 2-POSITION
FORCED AIR ZONING SYSTEM
Installation Guide
ZP6-ESP-PRO
Indianapolis, IN 46237

TABLE OF CONTENTS
Overview .................................................................................................................... 2
Sequence of Operation ............................................................................................... 2
Design and Installation Guidelines .............................................................................. 2
ZP6-ESP-PRO Panel Layout .............................................................................................3
System Wiring .......................................................................................................... 4-8
Warning! ........................................................................................................... 4
Caution! ............................................................................................................ 4
System Power .................................................................................................... 4
HVAC System .................................................................................................... 4
Heat/Cool ............................................................................................... 4
Heat Pump .............................................................................................. 4
DS/BK Option .......................................................................................... 5
HUM Option ........................................................................................... 5
DHUM Option ......................................................................................... 5
Sensors .......................................................................................................... 5-6
Discharge Air Sensor .............................................................................. 5
Return Air Sensor .................................................................................... 6
Outdoor Air Sensor ................................................................................. 6
Night Stat Option .............................................................................................. 6
Fault Terminals .................................................................................................. 7
Zone Thermostats ........................................................................................... 7-8
Heat/Cool ............................................................................................ 7
Heat Pump ........................................................................................... 7-8
Zone Dampers .......................................................................................... 8
SPS Terminals.............................................................................................9
How ESP Works................................................................................9
Adding 3-Zone Expansion Panels................................................................................ 10
Panel Setup ......................................................................................................... 11-12
Switch Congurations ...................................................................................... 11
System Conguration ............................................................................ 11
Capacity Control .................................................................................. 12
DS/BK Control ..................................................................................... 12
Graphic Display Module ........................................................... 12
Setting High Limit ........................................................................ 12
Setting Low Limit ......................................................................... 13
Setting High Balance Point .......................................................... 13
Setting Low Balance Point ........................................................... 14
Upstage Timer Option ................................................................. 14
Selecting ESP Zones .......................................................................15
Panel LED Denitions and Functions ........................................................... 16-17
Panel Time Delays ..................................................................................................... 17
Optional Night Stat Setup and Scheduling ............................................................ 18-19
Overview ...................................................................................................... 18
How It Works ................................................................................................... 18
Recommended Setup ....................................................................................... 18
System Switch Settings ..................................................................................... 18
Installer Setup Menu Changes ......................................................................... 18
Setting the Clock and Day of Week .................................................................. 19
Daylight Saving Time ....................................................................................... 19
Programming Events ................................................................................... 19-20
Typical 7-Day Schedule .................................................................................. 20
Notes ........................................................................................................................ 21
1

OVERVIEW
The ZP6-ESP-PRO is a residential and light commercial forced air zone control systems that allows
a single HVAC unit to have up to 6 separate zones. The system can be expanded to as many as 12
zones by adding 3-zone expansion panels. The panel can be used with single stage or multi-stage
heat/cool equipment as well as heat pump and duel fuel systems having up to 4 stages of heating
and 2 stages of cooling. Simple slide switch congurations allow for a wide range of system setup
and control options best suited for each zoning application. The ZP6-ESP-PRO 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. 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 and selection of designated ESP zones.
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. The heating or cooling
equipment will be brought on at the same time. When all zones are satised, the heating or
cooling equipment turns off. Zone dampers then reposition based on ventilation mode selection.
The system can be set up to operate in either Cooling Priority or Majority Wins mode of
operation.
COOLING PRIORITY:
When zones call for heating and cooling at the same time, cooling will receive priority and the
system will operate in the cooling mode until all cooling calls are satised and then automatically
change over to satisfy heating calls.
MAJORITY WINS:
If more zones call for heating than cooling, the system will be in the heating mode. If more zones
call for cooling than heating, the system will be in the cooling mode. If the number of heating and
cooling calls are equal, cooling wins.
DESIGN AND INSTALLATION GUIDLINES
2
[ ] 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
identication.
[ ] 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 and thermostats.
[ ] Never use the equipment transformer regardless of its VA rating.
[ ] When using forced air zoning with a variable speed HVAC system, high speed fan should be set
at 400 CFM per ton of cooling.

ZP6-ESP-PRO PANEL LAYOUT
3
SELECT UP DOWN
3 AMP3 AMP
3 AMP 3 AMP
3 AMP
602ZP-ESP
24 VOLT POWER
ZONE 1 DAMPER
ZONE 2 DAMPER
ZONE 3 DAMPER
ZONE 4 DAMPER
ZONE 5 DAMPER
ZONE 6 DAMPER
OPTIONAL NIGHT STAT
STATIC PRESSURE SENSOR
DISCHARGE AIR SENSOR
RETURN AIR SENSOR
OUTDOOR SENSOR
EQUIPMENT FAULT INPUT
HVAC EQUIPMENT
ZONE 1 THERMOSTAT
ZONE 2 THERMOSTAT
ZONE 3 THERMOSTAT
ZONE 4 THERMOSTAT
ZONE 5 THERMOSTAT
ZONE 6 THERMOSTAT
EXPANSION BOARD CONNECTOR 3 AMP FUSES
PROTECT RELAY
CONTACTS
3 AMP FUSE
PROTECTS CIRCUIT
BOARD
SYSTEM
SETUP
SWITCHES
TIME DELAY
SPEED UP
BUTTON
SYSTEM
STATUS
LEDs
HVAC
SYSTEM
LEDs
ZONE
DAMPER
POSITION
LEDs
(ON WHEN
OPEN)
OCCUPIED
LED
GRAPHIC
PROGRAMMING
DISPLAY MODULE
Rev 1
PC2
C1
PO3
PC2
C1
PO3
PC2
C1
PO3
PC2
C1
PO3
PC2
C1
PO3
PC2
C1
PO3

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 identication.
iO-ZP6-ESP-PRO PANEL WIRING
System Power
1. Wire a 24VAC, 75VA transformer to the 24VAC ‘R’ and ‘C’ terminals on the ZP6-ESP-PRO panel.
HVAC System
2. Wire the HVAC equipment to the HVAC SYSTEM terminals on the ZP6-ESP-PRO panel.
DO NOT WIRE EQUIPMENT COMMON TO PANEL
24VAC 120/208/240/480 VAC
TR-75 TRANSFORMER
R
C
NOT USED
24VAC
Y1
Y2
O/B
G
DS/BK
W1
W2
HUM
HUM
DHUM
DHUM
RH
RC
Y1
Y2
G
W1
W2
R
C
CONVENTIONAL
HEAT / COOL SYSTEM
Y1
Y2
O/B
G
DS/BK
W1
W2
HUM
HUM
DHUM
DHUM
RH
RC
Y1
Y2
O/B
G
W1
W2
R
C
HEAT PUMP SYSTEM
4

SYSTEM WIRING
DS/BK Terminals
The HVAC SYSTEM terminals have a DS/BK output. The DS/BK terminal is used with a variable-
speed fan. Connect the HVAC equipment DS, BK, ODD, or DHUM terminal to the DS/BK terminal
on the ZP6-ESP-PRO panel. Based on the DS/BK selector switch settings, this terminal will be de-
energized when the number of zones calling are less than or equal to the switch selection. This
will reduce the blower speed on most variable speed blowers.
HUM Terminals
The HVAC SYSTEM terminals have a set of normally open dry contact HUM terminals. These
terminals can be used with a thermostat wired to Zone 1 that has a humidication output
designed to control a powered or non-powered humidier. Refer to the specic thermostat manual
for humidication control.
DHUM Terminals
The HVAC SYSTEM terminals have a set of normally open dry contact DHUM terminals. These
terminals can be used with a thermostat wired to Zone 1 that has an output for a dehumidier or
ventilator. Refer to the specic thermostat manual for dehumidication control.
Y1
Y2
O/B
G
DS/BK
W1
W2
HUM
HUM
DHUM
DHUM
RH
RC
DS/BK Terminal
Humidication Terminals
Dehumidication Terminals
Sensors
The SENSOR terminals provide inputs for Discharge Air (DA), Return Air (RA) and Outdoor
Temperature (OT) 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 DA and DA terminals on the panel. The sensor is used for High and Low Limit protection as
well as display of discharge air temperature.
DA
DA
RA
RA
OT
OT
ZPA-DTS
DUCT
5

SYSTEM WIRING
Return Air Sensor (Optional)
Mount the return air sensor in the main return duct. Wire the sensor to the RA and RA terminals
on the panel. The sensor is used to display return air temperature only.
DA
DA
RA
RA
OT
OT
ZPA-DTS
DUCT
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 outdoor temperature display only. 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 OT and OT terminals on the panel.
DA
DA
RA
RA
OT
OT
S
E
N
S
O
R
ENCLOSURE
Night Stat (Optional)
The NIGHT STAT terminals are designed to be used with a single programmable thermostat for
occupied and unoccupied scheduling of the ZP6-ESP-PRO 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. Refer
to the Night Stat Setup and Scheduling section in this Installation Guide.
C
R
NS
Optional
T-S1
Remote
Sensor
Terminals
UT32-NS
NIGHT STAT
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
6
ZPA-OTS

SYSTEM WIRING
Fault Terminal
The Fault Terminals are designed to send a 24 volt signal to each zone thermostat that has a fault
input. This is an important feature on a heat pump system that can provide a visual alert to the
user at the zone thermostat of a mechanical failure. If the equipment has a fault terminal, wire
the equipment common and the fault terminal to the C and L on the panel.
L
C
HVAC TERMINALS
L
C
Zone Thermostats
The Panel has inputs for six zone thermostats. Only Zone 1 has inputs for humidication and
dehumdication control. Wire each zone thermostat as illustrated.
Note: For heat pump applications, zone thermostats should be congured for heat pumps with
electric backup regardless of if heat pump system is conventional or dual fuel.
C
R
Y1
Y2
W1
W2
G
O/B
L
ZONE THERMOSTAT TERMINALS
SINGLE STAGE HEAT COOL
C
R
Y1
W1
G
ZONE THERMOSTAT
C
R
Y1
Y2
W1
W2
G
O/B
L
ZONE THERMOSTAT TERMINALS
MULTI-STAGE HEAT COOL
ZONE THERMOSTAT
C
R
Y1
Y2
W1
W2
G
C
R
Y1
Y2
W1
W2
G
O/B
L
ZONE THERMOSTAT TERMINALS
2 HEAT / 1 COOL HEAT PUMP OR DUAL FUEL
ZONE THERMOSTAT
C
R
Y1
W1
G
O/B
LIf thermostat has fault input
7