ZONEMASTER MAXIPOINT V2 User manual

MAXIPOINT V2
DAMPER CONTROL SYSTEM
Installation Manual
www.zonemaster.com.au
www.polyaire.com.au
©2009 Polyaire Pty Ltd

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 1
1) Application 2
2) Features 2
3) Components 3
4) Configuration 4
5) Pre-Installation 6
6) Component Installation 7
7) Recommended Commissioning Procedure 10
7.1 Initiating and Exiting Setting Process 10
7.2 Setting Parameters 10
1) Touchpad Address 10
2) Number of Groups in the System 11
3) Supply Air Safety High & Low Limits 11
4) Spill/Bypass Mode 12
5) Turbo Group 14
7.3 Grouping Zones 15
7.4 Balancing Zones 16
7.5 Naming Groups 17
7.6 Enabling/Disabling Service Reminder 18
7.7 Enabling/Disabling Temperature Display 19
7.8 Programming On/Off Mode 20
1) Set Clock and Day 20
2) Adjust Program Time 21
3) Select Program for a Group 22
7.9 Testing Damper On/Off 22
7.10 Wiring Diagram for MaxiPoint V2 23
TABLE OF CONTENTS
Liability
Please read the instructions before installing this Zonemaster Zoning Control System.
Polyaire Pty Ltd does not accept any responsibility for loss or damage that may occur
as a result of the incorrect installation of this Zoning Control System.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 2
1) Application
The Zonemaster MaxiPoint V 2 control system is a fully featured and
 engineeredsystemthatisdesignedtomanagetheairowfromtheA/C
 Unitprovidingabalancedandmanagedairowtoalloutlets.Itiswell
suited to all ducted reverse cycle, ducted heating and evaporative air
conditioning systems in light commercial, residential and apartment
applications.
2) Features
 • Supportsupto16individual zones (Zone 1, 2…9, A, B…G), 16 groups
(Group 1, 2…9, A, B…G) with maximum of 4 zones in a group.
 • Dampers are connected directly to the main control module or its
extension module.
 • Wallmountedtouchpad(s)withupto4touchpadsavailablein
a system.
 • Manualandtimeprogrammablegroupon/offcontrol.
 • LCDonthetouchpadsforgroupstatusandparameterdisplay.
 • Personalisedgrouplabelling.
 • 5-1-1programmableon/offtimeprograms.
 • Remotezonebalancing---eachzone’sopeningpositioncanbe
  programmedforbalancingpurposeviatouchpadfrom0-100%.
 • Oneselectableturbogroup.
 • Autospill/bypass(dedicatedbypasszoneport)---thedesignated
zone dampers are forced open when all zones are turned off.
 • Safetysystem---Opensalldampersifthesupplyairtemperature
reaches low or high limit.
 • All zones automatically resume their original on/off state once power
up after power outage.
 • Halfyearly (182 days) and Two yearly (728 days) service alerts remind
customers to call technician for cleaning and air conditioning system
service respectively.
• 24volts for easy and safe installation and maintenance.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 3
3) Components
3.1 Wall Controller (Touchpad)
Users can input control commands from
the wall controller to turn a group on or off.
It is used to input all the program parameters.
The LCD on the wall controller displays clock,
zone status and temperature.
3.2 Main Control Module and its
Extension Module
Main control module (8 zones with bypass
port) and its optional extension module
(extra 8 zones) control the position of
motorized damper of each zone.
3.3 Motorized Damper (Bright Green)
Motorized damper drives the blade of the
damper to turn on/off the air supply.
3.4 Cables
Cables with left latch or central latch
plugs connect the main control module, its
extension module, touchpads and motorized
damper together.
3.5 Supply Air Sensor
Supply air sensor measures the temperature
of the supply air for safety purposes.
3.6 Power Supply
24VAC transformers provide power to the
main control module and extension module.
3.7 Rechargable Battery
The backup battery is used to store the time
when there is a power surge. It is recommended
to install the battery after power is on. Otherwise
the system may not be initialised properly due
to the low voltage of the new battery.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 4
4) Conguration
MaxiPoint V2 is a star architecture system for communications between
the main control module, extension module, 8 or 16 zone dampers and
 upto4touchpads.Figure1and2showtwodifferentcongurations
covering 8 & 16 zones. Figure 3 shows the linking of the main module to
the extension module and the touchpads.
Eight motorised dampers can be connected to the main control module.
In addition, there is a dedicated bypass port where a damper is used to
return the supply air directly to the return air duct. (See Spill/Bypass Mode
on Page 12 )
Extension Module
An extension module can be plugged into the main control module to
expand the number of zones to 16, as shown in Figure 2. A separate 24
VAC power supply is required for the power supply to the 8 extra zones.
The cabling of the MaxiPoint V2 is straightforward. A cable with central
latched plugs connects a motorised damper to the relevant output port
clearly marked on the main control or extension module.
Figure 1: MaxiPoint V2 Main Control Module with
2 Touchpads and 8 dampers

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 5
Main module and extension module can be located in different positions
and connected via a cable with left latched plugs on both ends as shown
inFigure3.Touchpadisconnectedtothe‘T’portonmainmoduleusinga
cable with left latched plugs.
Up to 4 touchpads can be joined in a system. The 4 touchpads are
connected to each other with a double left latched adaptor.
Figure 2: MaxiPoint V2 with Extension Module and 8 Zone Ports
Figure 3: MaxiPoint V2 with Main Control Module
and Extension Module, 4 Touchpads and 16 zone
ports (Dampers not shown)

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 6
5) Pre-Installation
Good planning leads to a successful zone system installation. Before
physical installation and commissioning a zoning system, please complete
the following listed tasks:
5.1 Decide how many zones (dampers) are to be controlled in the system.
5.2 Assign lower order zones (1, 2, 3…) to dampers close to return air
grille which will automatically open when spilling required. However
avoid using lower order zones for bedrooms as this may cause
discomfort if auto spilling occurs during sleep time.
5.3 Groupzonesaccordingtocustomer’srequirements.Eachgroup
initially has one zone but can have up to a maximum of 4 zones
(Example: There could be 1 or more zones going into a common area
  suchasKitchen/DiningorFamily/Diningroom).Workoutthetotal
group number (Maximum total group number in a system is 16).
5.4 Decide which group will have the Turbo function. Record the above
mentioned information to table 1 and 2 on page 8 in the Operation
manual and to the table on the sticker of the Main Control Module.
NOTE: It is important to test all cables before installation.
Testing all cables to be used before the start of the installation will
save considerable diagnostic time if the fully installed system is
subsequently found to have a problem. Cable testing is quick and
easy with a Zonemaster Cable tester available from Polyaire
Cable Tester
(Item Number: 657089)

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 7
6) Component Installation
6.1 Mount the main control module and/or
extension module (if using more than
8 zones) by screwing the box(es) to a
roof frame or Polyaire Diffusion Fitting
(PDF).
6.2 Remove thetwo-sidecoversonthe
main control module so that all the
LEDs and sockets for zone dampers
are exposed.
6.3 If extension module is used connect
main module to extension module at
  the‘E’portsonbothmoduleswitha1
metre left latched cable (provided).
6.4 Usepre-testedcabletoconnect‘Z1’
port on the main control module to the
motorised damper of the 1st zone.
6.5 Repeat step 6.4 to connect other zone
dampers, including bypass damper
  (‘B’port)ifinstalled,totheirrelevant
zone ports on the main control module
and extension module.
6.6 Mount the supply air sensor in the
supply air duct between the fan coil
  andtherstdamperandpushthe
plug of supply air temperature sensor
into the socket on the main control
module (Optional).

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 8
6.7 Connect Touchpad(s) to the main
 moduleat‘T’portonthemain
module. If multi touchpads used,
use the provided left latched cables
 and‘1in2out’femaletofemale
adaptor to join all touchpads.
 (Seeinstructionsbelowontmentof
touchpad to wall)
6.8 Connect the 24VAC transformer to
screw terminals on the main control
module. If extension module is used,
connect another 24 VAC transformer
to the screw terminals of the extension
module.
6.9 If both transformers (main module
and extension module) share the same
power switch, switch the power on.
(IMPORTANT NOTE) If NOT, switch
on the power to extension module
 rst.Thenturnonthepowertomain
 module.Otherwise, the extension
module will NOT be initialised properly.
Circular Red LED on the main module
(and extension module) should be on and
 thesystemwillstartinitialising&nish
in about 30 seconds after power on.
6.10 Install the battery as shown in the picture
on the main control module.
6.11 Replace the side covers back on the
main control and extension module
 oncenishedsettingandcommissioning.
NOTE: Record the grouped zones and
balancing details on the sticker off the
Main Control Module after commissioning
the system.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 9
Opening the case of the Touchpad for tment to wall
The plastic casing of the touchpad consists of two halves. The front cover
contains the PCB board along with the LCD screen and the buttons. The back
cover attaches to the wall. During the installation process the case will have
to be opened to mount the touchpad on the wall. In order to prevent the case
from being damaged, follow the steps below to carefully open the casing,
1) Use aatheadscrewdrivertopushthe
two notches at the bottom of the casing
inside and turn the screwdriver blade just
enough to open the cover as shown in the
  rightgure.
2) The bottom end opens up and the top end
still remains attached.
3) The top part is now removed by folding
back the front section of the body thus
releasing the clip from the notch of the
back cover.
4) Position the back cover on the wall (about
  1.5mhighfromtheoor)awayfromany
heat or cool source and mark the cable hole
and screw holes. Cut the hole for the cable/
retrieve the touchpad cable (from main
control module) out of the cable hole and
plug it into the touchpad. Mount the back
cover to the wall on the marked place.
5) Replace the front cover on the back cover.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 10
7) Recommended Commissioning Procedure
7.1 Initiating and Exiting Setting Process
NOTE: Wait till ‘Please Wait’ disappears
from LCD screen before initiating
a) Hold down both and buttons for
about 5 seconds until the LCD displays
   ‘Setting’menuontheLCDscreen.
b) At Setting mode, pressing button
at any time will return to the normal
operation mode.
7.2 Setting Parameters
1) Touchpad Address
One or multiple (up to 4) touchpads can be
installed in one MaxiPoint V 2 system. Each
  touchpadhasadefaultaddressof‘None’.
During commissioning, each touchpad
should be assigned a unique address for
them to communicate with the main control
module properly. Follow the steps below to
set Touchpad Address:
a) At the settingmode,select‘Parameter’by
pressing or button. Then press
   buttontoenter‘Parameter’screen
b) Use or button to select Touchpad
Add (highlighted).
c) Use or button to select a
touchpad address from 1 to 4.
NOTE: Each controller (touchpad) must have a unique address.
The same address for any other touchpad will cause communication
problems between the main control module and the touchpad.
If this happens, ‘CHECK ADDRESS’ will display at the bottom of LCD
screen and the ON/OFF function will be locked until the conicting
addresses are resolved.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 11
2) Number of Groups in the System
For the purpose of group status display and spill/bypass zone
calculation, the system needs to know the total number of groups to be
installed. Its factory default value is 8.
IMPORTANT: This input number must be equal to the total group
  numberusedinthesystemasplannedinPre-Installationprocess.If
  thisiswrong,thesystemmaynotworkproperly.
a) AttheSettingmode,select‘Parameter’
by using or button. Then press
  buttontoenterthe‘Parameter’screen.
b) Use arrows or button to scroll
down to Total Groups line.
c) Press the or button to change
the number to the total number of groups
in the system. The selectable number is
1 to 16.
3) Supply Air Safety High & Low Limits
For safety reasons, the system can monitor the supply air temperature. If
the temperature moves outside the set limits, all dampers in the system
are forced open. The factory default setting is that the safety control is
disabled. Setting this feature is optional.
a) At theSettingmodein‘Parameter’screen,
   pressorbuttontoselect‘H-limit’
   or‘L-limit’,andpressbuttonto
   enablethesafetycontrol.TheH-limit
   shows60°CasdefaultandL-limitshows
5°C as default.
b) Change theset-pointtorequiredvaluesby
pressing or button. The
adjustable range of the high limit is from
45 to 75°C and adjustable range of the
low limit is from 0 to 15°C.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 12
c) The safety limits can be disabled by
pressing button once when it is
enabled, if this function is not required.
For instance, supply air sensor has not
been installed or the supply air sensor is
faulty and the replacement sensor is not
available immediately but the system
needs to run.
NOTE: If the limits are reached, ‘SAFETY
CONTROL’ will be displayed at the bottom
of the LCD screen (see gure on right) and
ON/OFF function of groups will be disabled
till supply air temperature moves back
within the limits or the H-limit and L-limit
protection is disabled (there is about one
minute delay after disabling the protection).
Check the air conditioning unit if ‘SAFETY
CONTROL’ displays at bottom of LCD screen.
4) Spill/Bypass Mode
Bypass and spill modes are safety features of the MaxiPoint V2 system
to prevent pressure from building up and causing duct damage. This
usually occurs if someone has turned off all the dampers while the A/C
unit is pumping air into the system leading to a pressure buildup (and
potential of puncture of the duct or joints splitting).
  Whenopened zones in the system are less than the bypass/spill
  set-pointwhichisapercentageofopenedzonesagainsttotalzones,
the designated spill dampers or Bypass damper will be automatically
forced open to prevent pressure from building up.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 13
Spill Mode
This is a program designed to automatically open several allocated
dampers if someone attempts to shut all dampers down thus
preventing pressure build up. Spill mode uses the zones with lower
addressesinthesystem.Whenallocatingaddressestozonesinspill
mode, it is strongly recommended to give lower addresses to those
zones that have higher spill privileges. These zones are normally
located closer to the return air grilles. The lower the address, the
higher the spill privilege the zone has.
Another point to remember is DO NOT use bedrooms as spill zones.
During sleep time if the air conditioner is on and spill zones are
automatically forced to open, the spill zones will be very cold or hot.
This may cause discomfort if bedrooms are used as spill zones.
Whenthespillset-pointisreached,themaincontrolmoduleinstructs
zone1toopenasspill.Iftherstspillzonecannotsatisfythespillair
control, zone 2 will be forced to open to spill excess air. This process
willcontinueuntilthespillairset-pointissatisedinthesystem.
Example:Inan8zonesystem,ifsetpointissetat30%thenitwill
have at least 3 (calculated value = 2.4) or more zones remaining open,
hence rounding up the number of zones to open in the system.
Bypass Mode
In Bypass mode there is an extra damper and a length of duct that
goes directly from the supply air duct back to the return air duct. The
main control module instructs the bypass damper to open and dump
excess air to the return air duct. The bypass damper should be care-
fully sized to be able to handle excess air while all zones are closed.
Thebypassdampershouldbeconnectedtothe‘B’portonthemain
control module.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 14
The factory default is set in spill mode and the
  set-pointis30%.Whenthesetpointisreached
  forspill,thescreenshows‘SPILLCONTROL’
and some of the lower order zones remain open
and will not respond to ON/OFF operation.
Similarly if bypass set point is reached the
  screendisplays‘BYPASSCONTROL’asshown
  intherightgure.
a) Atthesettingmodein‘Parameter’screen,
press or button to select
   ‘SafetySpill’.
b) Press button to select Spill or
Bypass mode.
c) Press or button to change
   thespill/bypassset-pointtorequired
   value.Theadjustablerangeisfrom0%
   to50%with10%increments.
IMPORTANT: DO NOT set spill/bypass set-point to 0% unless there is
  apermanentopenzoneusedasspillzone.Otherwise,therewillbe
no spill zone when all zones are closed and damage may be caused
  byhighpressurebuildupinsideductsifairconditionerisrunning.
5) Turbo Group
The Turbo function will give the selected group
  afull-openingwhilealltheothergroups
(dampers) opening positions are reduced by
  50%oftheirbalancedvalue.Thiswillbringa
large volume of extra air into the designated
area and cool or heat the area quicker. Typically
  thismaybeafamily-room,diningroomorhome
theatre (or in commercial application a meeting,
lunch or board room). (See Grouping Zones
section for how to group).

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 15
a) Goto‘Setting’menubyholdingand
buttons at the same time for 5 seconds.
b) Select‘Parameters’sub-menubypressing
button.
c) Go to‘TURBO’menubypressingor
button and highlight NONE (Default value
   is‘NONE’).
d) Select desired group by pressing or
button
e) Backto‘Setting’menubypressingbutton
f) Back to normal display by pressing button.
7.3 Grouping Zones
For ease of control operation, multiple zones can
be grouped together. The grouped zones are
treated as one group with its own name and
turned on or off together. Individual balanced
damper position is not affected by grouping,
which means zone balancing can be conducted
before or after grouping.
Grouping can be carried out as follows:
a) At setting mode, press or button
   toselect‘Grouping’,andpressbutton
to bring up Grouping screen.
b) Press or button to highlight the
group to which the zones are to be added
to or subtracted from.
c) Press or button to add or minus
zones to the group.
d) Repeat Step b) and c) todeneallgroups.
e) Press button once to exit back to
setting menu.
NOTE: The maximum number of zones in a
group is 4. The factory default for grouping
is that each group has one zone.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 16
7.4 Balancing Zones
BalancingfeatureofMaxiPointV2offerstheexibilityofbalancing
  theamountofairowtoeachzoneelectronically.Itworksinthesame
  wayasamanualdamperdoestobalancetheairowforeachzone
without using an extra damper. Once the opening position of the
damper is set, the damper will only open to this position. The default
  settingforeachdamperis100%openingposition.Thebalancing
settings can be conducted on the touchpad as follows:
a) At setting mode, press or button
   toselect‘Balance’,andpressbutton
to enter the sub menu of the balancing
screen.
b) Press or button to select the zone
to be balanced.
c) Press button when the zone to be
balanced is highlighted to initiate
balancing. Then the numbers in the
highlighted section starts blinking and the
zone damper initiates to closed position.
d) Press or button to increase or
decrease the percentage of opening
positions for the zone.
e) Once the percentage has been set for the
respective zone wait for about 15 seconds
   tillwords‘PLEASEWAIT’atthebottom
disappears. Then press button
   againtoconrmthechange.
f) Follow step b) to e) to adjust the settings
for the other zones.
NOTE: The balancing menu will display all the 16
zones irrespective of the number of zones actually
present in the system. The balancing percentages of
the inactive zones remain locked. Also, once the zone
is balanced with a percentage opening, it is treated as a complete zone
when calculating spilling setpoint. If lower order zones are balanced
with small opening percentage, it is highly recommended to set a higher
spill set-point to ensure there is enough opening for spilling.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 17
7.5 Naming Groups
Thenameofagroupissetas‘Group-addr’indefaultsetting.For
  example,group1iscalled‘Group-1’onitsfactorydefault.Thenames
can be customised as follows:
a) At setting mode, press or button
   toselectthe‘Naming’,andpressthe
button to enter the sub menu of the
   namingscreen.(‘GP1’meansgroup1
   and‘Group-1’isitscurrentname)
b) Press or button to select the
group to be named.
c) Press or button to select one
of the preset group names for the group.
d) If user wants to make some changes to the
preset name selected, press button
to initialize the change, and then press
and button to select the character to
be changed.
e) Then use or button to change
the character as prefered. There are 26
letters, 10 numbers and a space to choose
from through this process.
f) Press button to exit the change
process.
g) Press or button to select the next
group and follow steps c) to f) to customize
the names for other groups.
h) Press button once to exit back to
Setting menu.

ZONEMASTER MAXIPOINT V2 DAMPER CONTROL SYSTEM - Installation Manual 18
7.6 Enabling/Disabling Service Reminder
Thereisabuilt-inservicereminderinthe
MaxiPoint V 2 system for half yearly and two
yearly to automatically display an alert to tell
customers that the air conditioning system is
due for service. Installers can also use this
feature to leave their details such as their
names and contact numbers.
The service reminder (if enabled) will display
  ‘CLEANINGDUE’or‘ACSERVICEDUE’and
  installer’snameandcontactnumberonLCD
screen for 5 consecutive days if it has been
enabled for 6 months (182 days) or 2 years
(728 days) respectively since the air
conditioning system being commissioned
  orservicedasshownintherightgure.It
is disabled by default but can be enabled
as follows:
a) In‘Setting’menu,selectServiceby
highlighting it and follow by pressing
to bring up next screen.
b) In‘Service’menu, Name line is highlighted
and installers name can be input by using
or buttons to select letters or
numbers, or buttons to move to
the next letter. The maximum allowable
characters are 10. It can be left blank if the
installer wants to be unnamed.
c) Moveto‘No’lineusingor
buttons and input phone or mobile
number by using or to select
numbers and or buttons to
move to next digit. The maximum
allowable characters are 12.