iO HVAC Controls ZP3-HPS-ESP User manual

ZP3-HPS-ESP Installation and Operation Instructions
3 Heat / 2 Cool Heat Pump or Dual Fuel
Auto Changeover - First Call Priority - Time Share
with Integrated ESP Static Pressure Module
OVERVIEW:
The ZP3-HPS-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 three 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 SPS LED will come on with the non-calling
zone LEDs until the static pressure reaches
setpoint and then the LEDs will turn off. 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. 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. The
heat pump reversing valve only changes position
when the mode of operation changes.
HIGH AND LOW LIMIT PROTECTION:
The 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 and 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 non-calling
ventilation zones as required.
POWER REQUIREMENTS:
The panel is powered by a single 24VAC, 40VA
transformer. Never use the equipment
1
3 AMP
3 AMP
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302HP
1 2

ZP3-HPS-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
PURGE
SWITCH
24 VOLT POWER LED
AUXILIARY OR EHEAT LED
1ST STAGE COMPRESSOR LED
2ND STAGE COMPRESSOR LED
FAN LED
LIMIT LED
ZONE 1 DAMPER LED
ZONE 2 DAMPER LED
ZONE 3 DAMPER LED
REVERSING VALVE LED
O/B REVERSING
VALVE SWITCH
CONVENTIONAL HEAT PUMP
OR FOSSIL FUEL SWITCH
3 AMP
3 AMP
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302HP
ZONE 2
THERMOSTAT
ZONE 2 DAMPER
ZONE 3
THERMOSTAT
ZONE 3 DAMPER
HVAC UNIT
TERMINALS
DISCHARGE
TEMPERATURE
SENSOR
OUTDOOR SENSOR
(USED FOR HIGH &
LOW BALANCE POINT
CONTROL
STATIC PRESSURE SENSOR LED
STATIC PRESSURE
SENSOR TERMINALS
LOW BP LED
LOW BP SETPOINT DIAL
SPEED UP
BUTTON
HIGH LIMIT
ADJUSTMENT
SWITCHES
HIGH BP LED
HIGH BP SETPOINT DIAL
ESP ZONE BYPASS
SELECTOR
PINS
1 2

302HP
ZP3-HPS-ESP TERMINAL DESIGNATIONS
3
TRANSFORMER
24VAC POWER
C (24V COMMON)
R (24V HOT)
W (AUXILIARY HEAT)
Y1 (1ST STAGE COMPRESSOR)
Y2 (2ND STAGE COMPRESSOR)
G (FAN)
O/B (REVERSING VALVE)
POWER CLOSE
COMMON
POWER OPEN
C (24V COMMON)
R (24V HOT)
W (AUXILIARY HEAT)
Y1 (1ST STAGE COMPRESSOR)
Y2 (2ND STAGE COMPRESSOR)
G (FAN)
O/B (REVERSING VALVE)
POWER CLOSE
COMMON
POWER OPEN
C (24V COMMON)
R (24V HOT)
W (AUXILIARY HEAT)
Y1 (1ST STAGE COMPRESSOR)
Y2 (2ND STAGE COMPRESSOR)
G (FAN)
O/B (REVERSING VALVE)
POWER CLOSE
COMMON
POWER OPEN
R (24V HOT)
W (AUXILIARY HEAT)
Y1 (1ST STAGE COMPRESSOR
Y2 (2ND STAGE COMPRESSOR
G (FAN)
O/B (REVERSING VALVE
WIRE TO ESP-400-PS
PRESSURE SENSOR
WIRE TO ZPA-DST
DISCHARGE TEMPERATURE
SENSOR
WIRE TO OPTIONAL
ZPA-OTS OUTDOOR
TEMPERATURE SENSOR
FOR BALANCE POINT
CONTROL

ZP3-HPS-ESP LED STATUS DEFINITIONS
4
ON (24V POWER TO PANEL)
ON (AUXILIARY HEAT RELAY ENERGIZED)
ON (1ST STAGE COMPRESSOR RELAY ENERGIZED)
ON (2ND STAGE COMPRESSOR RELAY ENERGIZED)
ON (FAN RELAY ENERGIZED)
ON (REVERSING VALVE RELAY ENERGIZED)
ON (STATIC PRESSURE ABOVE SETPOINT)
ON (ZONE DAMPER OPEN)
ON (ZONE DAMPER OPEN)
ON (ZONE DAMPER OPEN)
ON (DISCHARGE AIR SENSOR DETECTED)
BLINKING (DISCHARGE AIR TEMPERATURE
ABOVE OR BELOW LIMIT SETTINGS)
ON (OUTDOOR TEMPERATURE
ABOVE HIGH BALANCE POINT
SETTING)
ON (OUTDOOR TEMPERATURE
BELOW LOW BALANCE POINT
SETTING)
SELECTOR SWITCHES
CON/FOSSIL
OFF = CONVENTIONAL HEAT PUMP
ON = FOSSIL FUEL SYSTEM
O/B
OFF = ‘O’ REVERSING VALVE (ENERGIZES IN COOLING)
ON = ‘B’ REVERSING VALVE (ENERGIZES IN HEATING)
PURGE
OFF = NO FAN PURGE
ON = 1 MINUTE FAN PURGE AFTER CALL DROPS OUT
BALANCE POINT DIALS
(USED WITH OPTIONAL Z-300-OTS OUTDOOR SENSOR)
When a ZPA-OTS outdoor sensor is wired
to the OT terminals on the panel, both
High and Low balance points settings can
be adjusted using the calibrated balance
point dials. High BP is adjustable from 45°
F to 65° F. Low BP is adjustable from 0° F
to 40° F. High and Low balance point
control can be used for both conventional
heat pumps and fossil fuel systems. If the
outdoor temperature goes above the High
BP setting, the system will not stage
auxiliary heat. If the outdoor temperature
falls below the Low BP setting, only the
auxiliary heat source will be used. High
BP can be overridden by placing any zone
thermostat in the emergency heat mode.
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
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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.

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
INSTALLING AND WIRING THE ZP3-HPS-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 ( ) high P1+
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 ZP3-HPS-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.
WIRING THE ZPA-OTS OUTDOOR SENSOR
FOR HIGH AND LOW BALANCE POINT
CONTROL:
The balance point feature can be used for both
conventional or fossil fuel applications allowing
up to 2 stages of cooling and 3 stages of heating.
For fossil fuel systems having a 2 stage furnace,
‘W1’ and ‘W2’ are jumpered at the furnace. This
method utilizes the internal furnace upstage
timer to bring on second stage fossil fuel. The
ZPA-OTS Outdoor Sensor can be used for both
high and low balance point control by adjusting
the onboard balance point dials on the panel.
High BP is adjustable from 45° F to 65° F. Low BP
is adjustable from 0° F to 40° F. If the outdoor
temperature goes above the High BP setting, the
system will not stage auxiliary heat. If the outdoor
temperature falls below the Low BP setting, only
the auxiliary heat source will be used. High BP
can be overridden by placing any zone
thermostat in the emergency heat mode.
Mount the sensor inside the heat pump cabinet
to avoid direct sunlight, freezing rain or snow.
The sensor requires separate 18-2 thermostat
wire. Connect the sensor leads using wire nuts.
Land the other end to the SENSOR screw
terminals marked OT on the panel.
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 for the specific
application.
3. Apply 24 Volt power to the panel.
4. Place all zone thermostats in the OFF mode with
Auto fan.
5. With no calls taking place, the following panel
LEDs should be lit:
24V
LIMIT
ZD1
ZD2
ZD3
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 non-
calling zone LEDs until non-calling zone dampers
modulate 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 and zone 3. The only change
in LED status will be ZD2 LED will light for zone 2
and ZD3 LED will light for zone 3.
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. Once the
cooling cycle is energized, the following panel
LEDs should be lit:
24V
Y1
G
O/B (If reversing valve = O cooling)
LIMIT
ZD1
6

TEST, CHECK AND STARTUP:
10. Repeat the same step for zone 2 and zone
3. LED status should be the same with the
exception that ZD2 light for the zone 2
thermostat cooling test and ZD3 LED will light
for the zone 3 thermostat test.
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.
ZP3-HPS-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
Purge ON = 1 minute
Thermostats:
Single or multi-stage heat pump
Programmable or non-programmable
Auto or manual changeover
Sensors:
iO-ZP3-DAS Discharge Air Sensor
NTC Type 3, 10K @ 77° F, +/- 3% @ 77° FΩ
iO-ZP3-OT Outdoor Sensor
NTC Type 3, 10K @ 77° F, +/- 3% @ 77° FΩ
FIELD WIRING TERMINALS:
Zone Thermostats:
C 24Vac (Common)
R 24Vac (Hot)
W Auxiliary or Emergency Heat
Y1 First Stage Compressor
Y2 Second Stage Compressor
G Fan
O/B Reversing Valve
HVAC Equipment:
R 24Vac Equipment Hot
W Auxiliary or Emergency Heat
Y1 First Stage Compressor
Y2 Second Stage Compressor
G Fan
O/B Reversing Valve
High / Low Limit
DA Land to ZPA-DTS
DA Land to ZPA-DTS
Outdoor Temperature Sensor
OT Land to ZPA-OTS
OT Land to ZPA-OTS
Panel Power:
C 24Vac (Common)
R 24Vac (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-06-1279-060221
Indianapolis, IN 46237
www.iohvaccontrols.com
For Technical Support Call Toll Free: 866-225-5032

Indianapolis, IN 46237
www.iohvaccontrols.com
For Technical Support Call Toll Free: 866-225-5032
SPECIAL ADDENDUM
USING ESP ZONING PANELS WITH GAS FURNACES
HAVING DIRECT SPARK IGNITION (DSI)
DSI functions by creating a rapid series of high-voltage electric
sparks, which means DSI controls generate electromagnetic
interference (EMI) during their trial for ignition. This electronic noise
can sometimes interfere with ESP zoning panels as well as other
nearby electronic components and even with the ignition control itself.
When using an ESP zoning panel with a gas furnace having DSI, we
recommend that the panel be mounted at least ten feet away from the
furnace to reduce any effects of EMI that can cause sporadic cycling
of the relay outputs.