System 2000 GEN II A MODULATING SYSTEM Vote Based Auto Changeover VAV Installation and Applications Manual Part #GENIIMAN November 2013
GEN II QUICK START AND COMMISSIONING Follow these Quick steps for a successful job If you need additional information, please read the GEN II Manual 1. Install GEN II Controller in an easily accessible location for your customer. 2. Install an Independent 24 Volt 40 VA transformer, and connect to the TR1 and TR2 terminals on the GEN II controller. 3. Install the LAT sensor in the supply air, ahead of any bypass takeoffs. Wire sensor to the S S terminals on the GEN II controller. 4.
GEN II QUICK START AND COMMISSIONING The GEN II is equipped with a Digital Display (O) on the GEN II controller that constantly displays Leaving Air Temperature from the unit. At startup, this display also reports the number of thermostats communicating with the GEN II controller. The display and 3 buttons (N) beneath the display provide the installing contractor the ability to tailor the system to your specific application.
Table of Contents Page System Overview ....................................................................................................................................1 System Overview Diagram ..................................................................................................................1 General Sequence of Operation ............................................................................................................2 Gas Electric Operation ....................................
SYSTEM OVERVIEW The SYSTEM 2000 GEN II is a commercial modulating or 2-position zone control system controlling 2-17 independent zones per unit. The GEN II controller is designed for Auto Change- over, multistage Heat Pump (2C/3H) and Gas Electric (2C/2H) applications. For modulating applications, the GEN II system uses the Zonex ModStat, which controls the “ST” series, 3-wire, 24-volt, power open / power close round and rectangular dampers.
System 2000 GEN II offers the following additional control features: 1. 2. 3. 4. 5. 6.
GAS ELECTRIC OPERATION LEGEND TERMINAL FUNCTIONS / CONNECTIONS TX / RX – Data Transmit / Receive A EH Jumper (Set Up Fan Operation for Electric Heat) B O/B Jumper (Heat Pump Only – Reversing Valve Operation) C H/P Jumper (Jump for Heat Pump Operation) D Priority Jumper (Allows for Priority Vote Setup) E On / Off Switch F R C Power to ModStats (18 ga.
3. Install the leaving air sensor (LAT) in the supply air, ahead of the bypass take-off. Sensor wires are connected to the S S terminals on the controller (J). The LAT sensor leads may be extended using standard 18/2 thermostat wire. 4. The leaving air sensor (LAT) is calibrated to the controller at the factory. However, the calibration should be checked as part of the system setup procedures.
2. O/B and HP jumpers (B&C) should both be on one pin or removed, for GE operation. 3. PRIORITY jumper (D) should be on one pin. Note: If the Priority opposing zone strategy is to be used, this jumper position will be changed after the initial system start-up is completed. See Advanced Feature Configuration. 4. Set the power switch (E) to ON. 5. Set the NIGHT DAY switch (L) to the DAY position. 6. Set the fan jumper (M) to AUTO for intermittent operation or ON for constant ON operation in the Occupied mode.
2. To decrease the Y2 and W2 cut-in delay, press and hold the SET and DN buttons (N) simultaneously. When delay time appears in the display, release the buttons and immediately press the DN button and hold until the desired delay time is displayed, and release. To verify the change, press and hold the SET and DN buttons until the delay time is shown, and release. Configure 2nd Stage Cut-in For Time Delay and Thermostat Demand Only nd 1.
General Installation Instructions GEN II Controller 1. 2. 3. 4. 5. 6. Install the GEN II controller on an interior wall where the ambient temperature is between 32°120°F (0°- 48°C) non-condensing. This controller is to be installed in an accessible interior area; not in attics or above ceilings. The controller is to be powered by a dedicated 24vac 40va transformer. The transformer secondary is wired to TR1 TR2 on the controller (G). The secondary voltage to the controller must be 24 to 28vac.
To select Emergency Heat on any ModStat: 1. Press and hold the ModStat Menu button 2. When the mode display indicates Emg, release the Menu button; and immediately press and hold the Select button to set the mode. Heat Pump operation “B” reversing valve By placing the O/B jumper (B) on both pins, the GEN II controller is configured for “B” reversing valve operation.
3. RAISE – Press the DN button. After “C” is displayed, immediately release the DN button, and press the UP button. Hold until the desired temperature reading is displayed; then release. 4. Press the DN button to verify the new cool cut-out temperature. 2nd Stage Heat and Cool Cut-in Configuration The GEN II controller is set up at the factory to stage Y2 and W2 cut-in operation based on a 3minute time delay and supply air temperature.
Zone Thermostat - ModStat Installation Wiring All 24-volt and communication wiring connections are made to terminal blocks on the thermostat sub-base. The communication terminal block (RX TX/RX TX) is designed as a junction for two sets of 22 ga. solid copper, twisted pair communications cable. The cable should be daisy chained from thermostat to thermostat (use Belden 8740). 1.
Configuration Addressing Each thermostat must have a unique address from 1-17. 1. Press and hold the Menu button until you see the system mode display on the lower right begin to change modes; then press and hold the Heat/Cool button with the Menu button. 2. When the display shows “address,” release the Menu and Heat/Cool buttons, and press the UP or DN button until the correct address is displayed in the upper right of the display. 3.
Heat - If “Heat Setting” is displayed on the top right of the display, simply press the UP or DN button to change the heat set point. If “Cool Setting” is displayed and you want to change the Heat set point, press the Heat/Cool button twice to change from “Cool Setting” to “Heat Setting”. Then press the UP or DN button to change the set point. Cool - If “Cool Setting” is displayed on the top right of the display, simply press the UP or DN button to change the cool set point.
SUPPLEMENTAL HEAT APPLICATIONS MODSTAT SUBBASE ModStat Terminal Designations TX – Data transmit {twisted pair} RX – Data receive AUX – Reheat/AUX Heat Fan RO – Run Open, damper RC – Run Closed, damper {18 ga. stat wire} R – 24vac power input C-MC – 24vac power common NOTE: A larger transformer may be needed to power fan relay and/or heat strip relay.
DIGICOM / DIGIHP THERMOSTATS DESCRIPTION The Zonex Systems DIGICOM (2H, 2C) and DIGIHP (3H, 2C) are microprocessor based, auto changeover, stand-alone thermostats used to control stand alone units with no dampers in the system. The DIGICOM is the Gas Electric version and has two-stage heat / cool outputs with selectable fan operation. The DIGIHP Heat Pump thermostats have twostage cool and three-stage heat outputs with selectable fan.
Wiring (Continued) 1. Use minimum 18-gauge AWG thermostat wire for the 24vac control circuits. The load on these circuits must not exceed 1 amp. The voltage range on R and C must not exceed 28vac. Check Polarity before applying the transformer wire to R and C. Refer to the Polarity Check diagram on Page 17. 2. Connect the communication wires to the RX TX terminals. There are 2 sets of RX TX terminals for “daisy chain” installation of this circuit.
Configuration 1. Set the unique address for each thermostat from 01 to 20. 2. Press and hold the Menu button until you see the system mode display on the lower right begin to scroll and change modes; then press and hold the Heat/Cool button with the Menu button. 3. When the display shows “address” and the set point temperature changes to the address number, press the UP or DN button to raise or lower the number.
HEAT – DIGICOM: The thermostat will make a W1 heat call when the space temperature is 1 degree below the heat set point. W2 will energize when the space temperature is 2 degrees below the heat set point. When the room temperature rises to within 2 degrees of the heat set point, W2 de-energizes. W1 de-energizes at set point. NOTE: The “G” fan circuit on the DIGICOM thermostat is not energized in the Heat mode unless the fan is set for ON operation.
System Start and Test 1. Plug all thermostats into sub-bases. Turn GEN II power switch (E) to ON. 2. Choose any Thermostat and change its address from 25 to 1. (See ModStat installation instructions – Configuration – Addressing). 3. Turn GEN II power switch OFF and then ON. The Display should flash 01 and then show the leaving air temperature. This confirms your successful wiring and communication with that thermostat. 4. If 01 is displayed, change the next thermostat’s address from 25 to 2.
Advanced Feature Configuration - Gas Electric and Heat Pump Occupied / Unoccupied fan operation The factory setting for FAN operation is AUTO, with the FAN jumper (M) on the middle and lower pins. In this setting, the fan circuit on “G” is only energized on an active cool call in Gas/Electric mode or on an active heat call or cool call in Heat Pump mode. This applies to both Occupied and Unoccupied modes.
3. Press and hold the SET and UP buttons (N), and the LED display will scroll through the number of zones starting with 01. 4. When the display indicates the address (01 to 17) of the thermostat you want to add votes to, release both buttons and press the DN button. The display will scroll through 00, 01, 02. To add one additional vote, release the DN button when the display indicates 01 (this assigns a total of 2 votes).
Default Thermostat Set Point Programming Global default set points can be established from the GEN II controller. The following procedure will provide a 75°F (23°C) Cool and 70°F (21°C) Heat occupied set point along with Unoccupied 58°F (14°C) Heat and 85°F (29°C) Cool set point for every thermostat in the system. This handy feature minimizes visits to the thermostats. To establish these default set points: 1. EH jumper (A) - place the jumper over both pins. 2.
ZONE DAMPERS Zonex Systems zone dampers are used in cooling/heating systems to provide room by room zone control. The damper is provided with a factory mounted actuator. Each zone damper is controlled by a zone thermostat. More than one damper can be controlled by one zone thermostat. Use this table to determine which zone dampers to use. DAMPER MODEL STMPD Round Med. Pressure STMRTD Rect. Med. Pressure STCD Rect. Heavy Duty D-FUSER MAXIMUM DIFFERENTIAL PRESSURE 1.75” 1” 1.75” 0.
RECTANGULAR ZONE DAMPERS The rectangular zone dampers are available in either medium pressure or heavy duty. For systems under 7.5 tons, use medium pressure dampers. For systems 7.5 tons or over, use heavy duty dampers. Motor drive time open and close is 90 seconds. RECTANGULAR MEDIUM PRESSURE ZONE DAMPERS (STMRTD) Zonex Systems rectangular medium pressure dampers are recommended for systems under 7.5 tons with a maximum differential static pressure of 1”.
RECTANGULAR DAMPER SELECTION Rectangular Damper Capacities* WIDTH IN INCHES HEIGHT IN INCHES 8 10 12 14 16 18 20 22 24 26 28 30 32 8 10 12 14 16 18 20 22 24 26 28 30 32 300 400 500 610 710 820 925 1050 1175 1250 1400 1500 1600 400 540 680 825 975 1125 1300 1400 1590 1750 1975 2100 2175 500 680 850 1000 1200 1400 1600 1850 2000 2300 2550 2700 2850 610 825 1000 1250 1500 1750 2000 2250 2500 2900 3150 3425 3625 710 975 1200 1500 1800 2100 2450 2700 3000 3600 3950 4200 4425 820 1125 1400 17
SIZING ZONE DAMPERS If the ductwork already exists, simply size the damper to fit the ductwork. For new systems or retrofit jobs: A. Determine CFM from heat gain or loss calculations. B. Select damper size using either the round capacities chart, the rectangular capacities chart or by using a duct sizing table or calculator. C. Select a Zonex Systems damper to fit the duct size selected for that zone. Make sure your zone dampers match the type specified in the table showing Maximum Differential Pressure.
BYPASS DAMPERS – ELECTRONIC ELECTRONIC BYPASS DAMPERS Bypass dampers are used to provide constant air delivery through the air handling unit. This is done by bypassing excess air from the supply duct back to the return duct. As a zone is satisfied, its zone damper closes. When this happens, the bypass damper opens just enough to bypass the excess air. This will control static pressure and noise at the diffusers. The Electronic Bypass Damper is used on any size system over 5 tons.
HEIGHT IN INCHES RECTANGULAR BYPASS SELECTION TABLE 8 10 12 14 16 18 20 22 24 28 32 36 40 44 48 8 667 833 1000 1167 1333 1500 1667 1833 2000 2333 2667 3000 3333 3667 4000 10 833 1042 1250 1458 1667 1875 2083 2292 2500 2917 3333 3750 4167 4583 5000 12 1000 1250 1500 1750 2000 2250 2500 2750 3000 3500 4000 4500 5000 5500 6000 14 1167 1458 1750 2042 2333 2625 2917 3208 3500 4083 4667 5250 5833 6417 7000 16 1333 1667 2000 2333 2667 3000 3333 3667 4000 4667 5333 6000 6667 7333 8000 18 1500 1875 2250 2625
BYPASS DAMPER with INTEGRATED PRESSURE CONTROL (Part # STBP or STCDBP) Bypass Damper with Integrated Pressure Control is used to control bypass operations. The bypass damper modulates to maintain static pressure as zone dampers open and close. The bypass system reduces air noise from the supply registers caused by excessive air velocity.
4. Static Pressure Option: The Integrated Pressure Control Board can be field configured for specified static pressure using a multi meter and the static pressure – voltage chart. (Exhibit A). This chart shows voltage (DC) to inches of W.C. (static pressure) relationship. Use a multi meter set on VDC and place the leads on the “C” terminal and “TP1” (test point one) next to the potentiometer. The Voltage reading translates to inches of W.C. BYPASS CHECKOUT FOR STATIC PRESSURE CONTROLLER 1. 2. 3.
ONLINE Step-by-Step Installation Instructions and Commissioning www.zonexcontrols.com/gen.
System 2000 GEN II Hot Line: (800) 228-2966 5622 Engineer Drive Huntington Beach, CA 92649 Factory: (714) 898-9963 Fax: (714) 898-6802 Visit our Web Site http://www.zonexsystems.com Quick Quote Web Site: www.zonexproducts.com The easy way to Get Quotes Fast PATENTED PRODUCT Zonex Systems reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
