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Zonex GEN III VVT Series, Installation And Application Manual

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Zonex GEN III VVT Series Installation And Application Manual Download Page 11

Wire Unit to GEN III Controller

Using standard 18 ga. thermostat wire, connect GEN III unit outputs to HVAC unit. Standard HVAC

control terminal designations are used, R Y1 Y2 W1(O/B) W2 G, and energize HVAC unit.

1. Gas/Electric Wiring

Gas/Electric systems use the same terminal designations, R power (24 volt), Y1 Cooling first stage, Y2 

Cooling second stage, W1 Heating first stage, W2 Heating second stage and G Fan.  From the GEN III 

controller, wire each required terminal, R on GEN III to R on HVAC unit, Y1 on GEN III to Y1 on HVAC unit, 

Y2 on GEN III to  Y2 on HVAC unit (if used) the W1 on GEN III to W1 on HVAC unit, W2 on GEN III to W2 on 

HVAC unit (if used) and G on GEN III to G on HVAC unit.

2. HEAT PUMP Wiring— O/B operation

Heat Pump systems use the following terminal designations, R power (24 volt), Y1 Compressor first stage, 

Y2 Compressor second stage, O/B (W1) reversing valve, W2 Heating Auxiliary (3) stage, G Fan.  From the 

GEN III controller, wire each required terminal, R on GEN III to R on HVAC unit, Y1 on GEN III to Y1 on 

HVAC unit, Y2 on GEN III to Y2 on HVAC unit (if used), O/B (W1) on GEN III to O on HVAC unit, W2 on GEN 

III to W2 on HVAC unit (if used) and G on GEN III controller to G on HVAC unit.

Note:  1.  Many systems are single stage and will not use Y2 or W2 terminals for operations.  

                  Please confirm your system operation to ensure proper wiring.

            2.  For Heat Pump applications with Gas/Electric inputs, set system for gas operation and reset high limit to 115 degrees.

GEN III CONTROLLER

POWER SWITCH

ID / SYNC

24VAC IN

24VAC OUT

TO UNIT TERMINALS

RS485 COMMUNICATION LINK ( BELDEN 8740)

AUX SENSOR (AS)

LEAVING AIR SENSOR (LVAIR)

OUTSIDE AIR SENSOR (OA)

RETURN AIR SENSOR (RA)

INSTALLATION INSTRUCTIONS

GEN III

– VVT

INSTALLATION INSTRUCTIONS

STATUS LIGHTS

10

Summary of Contents for GEN III VVT Series

Page 1: ...GEN III VVT A M O D U L A T I N G S Y S T E M INSTALLATION AND APPLICATIONS MANUAL VOTE BASED AUTO CHANGEOVER VAV with WIRELESS PROGRAMMABLE THERMOSTATS 68 70 75 72 ...

Page 2: ......

Page 3: ...EM OPERATION Set Thermostat Display Modes Thermostat Operation End User Guide Zone Set Up Menu Monitor Thermostat Configuration Set Schedules Lock Thermostats Master Temperature Set System Diagnostic High Low Limit Second Stage Delay Override Hours Priority Vote Fan Mode Unit Type Sync Monitor Maverick Call System Air Balance Temp Format Clock Password Number Of Dampers LAT Calibration Morning Warm...

Page 4: ... functions digital leaving air temperature return air temperature and outside air temperature display fully adjustable capacity control with on board limit settings and optional staging strategies An integrated clock allows for setup and night setback scheduling globally or individually available for each wireless thermostat with selectable 2 to 8 hour override along with a unique feature to remot...

Page 5: ...ess Thermostat Part WSTAT 1 Thermostat per Damper Modulating Zone Dampers Part WST Damper Size Round Damper up to 1 75 S P WCD Damper Size Rectangular Dampers up to 1 75 S P Electronic Bypass Damper Part STBP Damper Size Round Bypass Dampers STCDBP Damper Size Rectangular Bypass Dampers 1 24 VAC 40VATransformer to Power Bypass Damper For assistance contact Zonex at 800 288 2966 or visit zonexprodu...

Page 6: ... After a 4 minute purge cycle Cooling is turned on until the cool call is satisfied or there is a majority vote for heat received by the GEN III controller If all calls have been satisfied after the 4 minute off delay dampers will modulate to approximately 40 open position for ventilation mode The system fan blower operation can be configured for ON or intermittent AUTO operation The controllers are ...

Page 7: ...RE TUBE LOCATED AFTER THE BYPASS BEFORE THE FIRST SUPPLY TAKEOFF BYPASS DAMPER MOTOR BP DM SUPPLIED WITH ZONEX BYPASS DAMPER FACTORY PRE WIRED VISIT OUR ON LINE CATALOG AT ZONEXPRODUCTS COM FOR APPLICATIONS ASSISTANCE CALL 800 228 2966 RS485 COMMUNICATION LINK WIRELESS COMMUNICATION COMMUNICATES WITH WIRELESS DAMPER BOARD AND THERMOSTAT TWISTED PAIR WIRING BELDEN 8740 DAISY CHAIN DAMPER TO DAMPER ...

Page 8: ...ol and High and Low temperature limits to protect the compressor and heat exchanger Outside air and return air sensors are also provided The HVAC unit is staged based on leaving air temperature and time Auto change over operation is vote based predicated on a first call first served majority wins on changeover algorithm Additional control strategies are established on a Monitor Thermostat which init...

Page 9: ...ized Each damper control board must be synced with its respective thermostat Once the damper is energized and associated thermostat has its ID set press the ID button on the damper control board until blue light flashes continuously and then press the YES button on the wireless thermostat which will display SYNC SUCCESSFUL L RX TX IN communication link Belden 8740 daisy chained into damper board M ...

Page 10: ...falls greater than 2 degrees below HEAT set point AUX is energized and BASEBOARD heat is operating ON will be displayed When zone temperature rises to HEAT set point thermostat will release call for AUX operations REHEAT When wireless thermostat is configured for REHEAT operation when the zone temperature falls greater than 2 degrees below HEAT set point thermostat transmits REHEAT call to the comm...

Page 11: ...ations R power 24 volt Y1 Compressor first stage Y2 Compressor second stage O B W1 reversing valve W2 Heating Auxiliary 3 stage G Fan From the GEN III controller wire each required terminal R on GEN III to R on HVAC unit Y1 on GEN III to Y1 on HVAC unit Y2 on GEN III to Y2 on HVAC unit if used O B W1 on GEN III to O on HVAC unit W2 on GEN III to W2 on HVAC unit if used and G on GEN III controller t...

Page 12: ...o the RA terminals on the GEN III controller and place the sensor in the return duct after the bypass takeoff Note If extension of wire is needed 18 ga thermostat wires may be used GENIII VVT GEN III CONTROLLER POWER SWITCH ID SYNC 24VAC IN 24VAC OUT TO UNIT TERMINALS RS485 COMMUNICATION LINK BELDEN 8740 AUX SENSOR AS LEAVING AIR SENSOR LVAIR OUTSIDE AIR SENSOR OA RETURN AIR SENSOR RA I K STATUS L...

Page 13: ... communications wire using the RX and TX G terminals on GEN III controller and daisy chain to the first supply damper in the system and wire to RX TX terminals of the communication damper board Continue daisy chain to the next damper using RX TX terminals of communication damper board to the RX TX of the next damper control board repeating this process until all supply dampers are wired into the co...

Page 14: ...ptimal system operation Mounting the WirelessThermostat Once you have determined where you want to place the thermostat place the mounting plate in that spot and with a pencil mark where the drill holes will be Drill holes using a 1 8 drill bit Install screw anchors supplied with the thermostat Install the screws into the screw anchors half way and place the mounting plate over the screws Once the...

Page 15: ...bel 1 on the inside of the thermostat sub base All stats are SYNCED with its damper ID 001 to 020 maximum of 20 zone on one GEN III system Once System ID is set press EXIT to SAVE Sync Dampers and WirelessThermostats Each Damper will need to be ID d and Synced with its control thermostat Beginning with the first damper in the daisy chain closest to the GEN III controller place provided label 1 on t...

Page 16: ...e blue light flashing indicates communication between the GEN III controller and the communicating damper board While still in ZONE SETUP use the UP or DOWN to highlight and select item A SYNCHRONIZE DAMPER Go to the damper control board and press the SYNC button and hold until blue communications light flashes continuously and then press YES on thermostat to Synchronize When damper and stat are syn...

Page 17: ...et to 115 degrees F Once GEN III controller is mounted Monitor Thermostat is synced with GEN III controller and associated damper and zone stats are synced with their associated dampers system is ready to be commissioned and started up Prior to wiring control outputs to the HVAC unit turn on the GEN III controller and confirm all communicating damper boards are flashing blue lights this indicates th...

Page 18: ...the UP or DOWN button to select current minutes Once minutes are set press NEXT button and select AM or PM by using the UP or DOWN buttons then press NEXT to select the day of the week using the UP or DOWN buttons to select current day Once hour minutes AM PM and day of week are set press the exit button to save and return to System Configuration Menu Confirm High Low Limits Factory defaults for GAS...

Page 19: ...amper Operation From the MONITOR STAT access SYSTEM CONFIGURATION Menu and highlight MASTER TEMP SET menu option and press select TEMP SET ID will appear on display using the UP and DOWN buttons select STAT ID GLOBAL and press NEXT button When prompted with SELECT GLOBAL ID press YES SET OCCUPIED COOL using the UP or DOWN buttons select a temperature lower than building temperature and press EXIT ...

Page 20: ...r DOWN buttons select a temperature higher than building temperature and press EXIT to save and set all thermostats in heating mode Within 2 minutes a call for heating will be made from GEN III controller and confirm W1 light is on at the GEN III controller Go to each zone and confirm damper is open Once all dampers are confirmed open satisfy heating calls at each wireless stat At each zone stat lowe...

Page 21: ...nu To do this press MENU and AUTO buttons and scroll down to C SET AUXILIARY HEAT When SET AUXILIARY HEAT option is highlighted press select Three options are offered BASEBOARD BASEBOARD W1 or REHEAT If BASEBOARD is desired press select display will provide an option for heat dead band set up Auxiliary heat can be set up for 2 3 or 4 degrees use UP DOWN buttons to select desired temperature dead b...

Page 22: ...PER MOTOR AUX C AUX C AUX C DAMPER BOARD DAMPER BOARD DAMPER BOARD DAMPER Wire from AUX C terminals to the 24v coil on a field supplied SPDT relay Wire baseboard heat to the load side of the relay to the baseboard heater VAV DUCT REHEAT Wire one AUX terminal to the air proving switch from the air proving switch complete wiring to the terminal on the 24v coil relay Wire the C terminal to the 24v co...

Page 23: ...system The Monitor coordinates global or individual schedules for the system locks thermostats individually and provides minimal local adjustment establishes master temperature settings individually or globally for the system and provides diagnostic functions to streamline system troubleshooting Air balance shortcuts along with password protection are also enabled at the Monitor thermostat Sleep a...

Page 24: ...ure is set ON icon will appear below set point ON icon will flash until system is operating in HEAT mode Once system is in heating mode ON will remain constant Vent Mode When all calls for heating and cooling are satisfied damper controller will set the damper into VENT position and report to the thermostat VENT operations During this time if GEN III controller is configured for FAN ON recirculating ...

Page 25: ...corner of the communicating damper board This will energize a blue flashing light indicating Sync or pairing mode is active 2 Once damper light is blinking and in active Sync mode return to the thermostat and enter Zone Setup Menu Use the up and down buttons to scroll and highlight item A SYNC DAMPER Press Select confirm ID matches the ID you assigned earlier Push Yes to Sync SYCHRONIZE DAMPER YES N...

Page 26: ... G SET 7 DAY SCHEDULE In the Zone Setup Menu select item G set SET 7 DAY SCHEDULE and press Select Use the up and down buttons to select and hightlight ZONE SCHEDULE then use the UP and Down buttons to select hour and continue to press Next to set minutes AM PM etc for each day of the 7 day schedule Press exit to save this information and return to Zone Setup Menu Press exit again to return to nor...

Page 27: ...the system This user interface provides diagnostic functions to streamline system troubleshooting along with air balance shortcuts password protection and more functions are also enabled at the Monitor Thermostat The Monitor Thermostat performs all the functions of a zone thermostat along with its active System Configuration menu to access 20 unique functions to control and schedule the GEN III sys...

Page 28: ... Set the hour for daily operations using the Up and Down buttons for each of the following items Press Next button to set the minutes Press Next button to set AM or PM Press Next button to set Scheduled Off time SET SCHEDULE OFF Set the hour for daily operations using the Up and Down buttons for each of the following items Press Next button to set the minutes Press Next button to set AM or PM Sele...

Page 29: ... GLOBAL ID or use the UP DOWN buttons to independently select individual thermostats Then follow the instructions below to set OCCUPIED and UNOCCUPIED Heating and Cooling set points Individual temperatures on each thermostat or zone can also be reviewed Use the UP DOWN buttons to scroll and review current temperature status for each zone in the system MASTER TEMP SET GLOBAL TEMP SET INDIVIDUAL TEM...

Page 30: ...T BACK NEXT This function allows the user to review the current conditions for the GEN III System Number of Channels in the system How many zones are communicating Leaving Air Temperature Return Air Temperature Outside Air Temperature all from the Monitor Stat For system protection the GEN III has high and low limit protections built into the MONITOR STAT configurations Factory defaults for Gas Ele...

Page 31: ...lt is set to 1 or 1 vote per thermostat When needed a thermostat can be set for higher weight by changing the number and adding extra votes to the thermostat If needed thermostats may have up to two additional votes for a total weight to 3 votes Additionally if there is a desire for a thermostat to not be able to place a call for heat or cool a null vote may be configured by using a value of 0 in t...

Page 32: ...n on until zone is satisfied then run purge and return to majority operations EXIT ON OFF While in SYSTEM CONFIGURATION menu press Down and press SELECT on the 12 MAVERICK menu item instructions above Select On to enable Maverick or Off to disable If ON is selected press the up or Down buttons to select the period 15 30 minutes Press Exit to return to the System Configuration screen Press yes to sav...

Page 33: ...d then Exit button to place system back into normal operation GEN III may be configured for F or C operations From the configuration menu toggle the UP or DOWN button to highlight TEMP FORMAT When desired temperature format is displayed press the EXIT button and save data System clock and clock operation including all setup and setback functions are based on the system time clock Set the clock to yo...

Page 34: ...LAT is calibrated at the factory however in shipping and installation calibration may become skewed If calibration is needed use a thermometer to find reference temperature next to LAT in supply duct and follow the steps below to set an offset for LAT from Monitor Stat Press the up or Down button to ENABLE or DISABLE Press Exit button Press yes to save the settings 19 MORNING WARM UP EXIT MORNING W...

Page 35: ...Minutes 6 SECOND STAGE DELAY 2 hours 7 OVERRIDE HOURS 1 8 PRIORITY AUTO 9 FAN MODE Gas Electric 10 UNIT TYPE No action required 11 SYNC MASTER Disable 12 MAVERICK No action required 13 SYSTEM AIR BALANCE Fahrenheit 14 TEMP FORMAT No action required 15 CLOCK 000 16 PASSWORD 20 17 NUMBER OF DAMPERS No action required 18 LAT CALIBRATION Disable 19 MORNING WARM UP System ID 001 Energy Savings Mode 20 ...

Page 36: ...also available and when it detects a first body movement it will quickly blink the LED and read the slide pot Battery Installation 1 Remove wireless remote sensor cover plate 2 Install two AAA batteries provided with the wireless remote sensor Wireless Remote Sensor Wireless Occupancy Remote Sensor Procedure To Synchronize ID On Wireless Remote Sensor Use any a wireless LCD stat to sync up Hold dow...

Page 37: ... to initiate override Temperature Settings Use the Monitor stat to set and review the room temperature on any remote sensor Remote Sensor Operation for the end user The Wireless Remote Sensor provides local adjustment of 2 degrees from set point using the sensors slide pot The Remote Sensor temperature set points are set at the Monitor thermostat Changing temperature To change the temperature adju...

Page 38: ...onds GEN III zone dampers are used in cooling heating systems to provide room by room zone control The damper is provided with a factory mounted actuator and communicating damper board 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 Maximum Differential Pressure refers to the max...

Page 39: ...nnect the motor to the damper shaft allowing quick motor replacement if necessary Motor drive time from full open to full close is 90 seconds RectangularHeavyDutyZoneDampers WCD Zonex Systems rectangular heavy duty dampers are recommended for systems 7 5 tons or larger with a maximum differential static pressure of 1 75 The damper is equipped with a damper board designed to support and communicate...

Page 40: ... 500 600 700 800 900 0 019 0 03 0 045 0 056 0 041 0 093 140 170 207 247 280 315 Neck Vel P CFM Throw 50 PM 5 6 7 8 9 10 10 400 500 600 700 800 900 0 029 0 045 0 066 0 09 0 12 0 146 218 273 330 382 438 497 Neck Vel P CFM Throw 50 FPM 6 8 9 10 11 12 24 2 12 COLLAR PLACE ON SIDE PLACE ON TOP 12 AT NECK VELOCITIES UP TO 700 FPM NC LESS THAN 30 RECTANGULAR DAMPER SELECTION RectangularDamperCapacities T...

Page 41: ...GEN III damper control board The first damper must be a WST round or WCD rectangular damper slave dampers will be STMPD round or STCD rectangular dampers without damper control boards To wire two or three dampers for a zone use the following wiring diagram Remember to size the power transformer for the total number of zone dampers in the system 2VA per damper When slaving more than three zone dampe...

Page 42: ...he bypass damper is to be sized for the total system CFM 1500 FPM System CFM should be calculated at 400 CFM per ton Example A 5 ton system is rated at 2000 CFM 5x400 2000 When calculated at 1500 FPM the bypass damper should be 16 Never undersize the bypass damper Round Bypass Damper Selection The Zonex Systems STBP damper is used for round bypass applications When you know the bypass CFM requirem...

Page 43: ...33 6000 6667 7333 8000 9333 10667 12000 13333 14667 16000 36 3000 3750 4500 5250 6000 6750 7500 8250 9000 10500 12000 13500 15000 16500 18000 40 3333 4167 5000 5833 6667 7500 8333 9167 10000 11667 13333 15000 16667 18333 20000 44 3667 4583 5500 6417 7333 8250 9167 10083 11000 12833 14667 16500 18333 20167 22000 48 4000 5000 6000 7000 8000 9000 10000 11000 12000 14000 16000 18000 20000 22000 24000 ...

Page 44: ... dedicated 24vac 40VA transformer Do not install the bypass damper outside Locate the Integrated Pressure Control IPC and air tube on the bypass damper Drill hole into the side of the supply duct 2 after the bypass and before the 1st supply take off Mount pressure supporting block over hole align hole in block with hole in duct Use provided sheet metal screws Install air tube into supply air duct ...

Page 45: ...t for calling zone Verify noise at zone registers is not excessive Adjust the Integrated Pressure Control LEFT to lower noise airflow or RIGHT to increase airflow until too noisy 1 2 3 Note 1 To open all dampers it may be necessary to remove Y outputs to unit on the zone control board and to make full cool calls on all thermostats This will modulate dampers fully open and lock out compressor On Zone...

Page 46: ...ween thermostat and communicating damper board Set Cooling set point lower than room temperature ON icon flashing Waiting for changeover ON icon solid cool call is active Confirm Cool Call Y1 at GEN III controller Y1 light should be energized Check HVAC unit 1 2 3 Cool set points incorrect Set Heating set point higher than room temperature ON icon flashing Waiting for changeover ON icon solid heat ca...

Page 47: ...tage will remain off 1 2 Place a call for Heat at any thermostat Check the number of thermostats calling for heat versus calls for cooling Check System Diagnostic on any thermostat to review discharge air Wait 4 minutes for Heat call to recover 1 2 3 4 Check staging time delay from any thermostat in System Configuration menu If not second stage will remain off until time has expired If so second st...

Page 48: ...amper actuator If power is present replace actuator Check 24 volt power to damper control board R and C terminals If 24 volt power is present replace damper control board 1 DAMPER DOES NOT OPEN OR CLOSE DAMPER OPENS WHEN BASEBOARD HEAT IS CALLING No call for heat or thermostat is not set up for Baseboard heat 1 2 AUXILIARY HEAT REHEAT BASEBOARD Confirm there is no call for heating on GEN III contro...

Page 49: ...48 ...

Page 50: ... still allows for temperature adjustment of 2 degrees and override operations O Using the System Diagnostic function have you confirmed the following items below MENU ITEM 3 O a Number of dampers in the System O b All dampers are communicating with MONITOR STAT O c Have you confirmed Leaving Air SA Return Air RA and Outside Air OA temperatures are displayed Note An NC in these fields indicates No Com...

Page 51: ......

Page 52: ...VVT 5622 Engineer Drive Huntington Beach CA 92649 714 898 9963 714 898 6802 www zonexproducts com FACTORY FAX Quick Quote Online 800 228 2966 HOTLINE The easy way to Get Quotes Fast Part GENIIIMAN January 2017 ...

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