IO HVAC Controls ZP3-HPS-ESP 3 Heat / 2 Cool Heat Pump or Dual Fuel Instruction Manual

IO HVAC Controls ZP3-HPS-ESP 3 Heat / 2 Cool Heat Pump or Dual Fuel

Instruction Manual

ZP3-HPS-ESP Installation and Operation Instructions3 Heat / 2 Cool Heat

Pump or Dual Fuel

Auto Changeover – First Call Priority – Time Sharewith 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 noncalling 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 noncalling 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

ZP3-HPS-ESP Panel Layout

ZP3-HPS-ESP TERMINAL DESIGNATIONS

ZP3-HPS-ESP TERMINAL DESIGNATIONS

ZP3-HPS-ESP LED STATUS DEFINITIONS

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

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 10minutes.

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

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.

MOUNTING THE ENCLOSURE:

Carefully remove the panel from the shipping carton. Remove the cover and any packing material. Locate the panel on a flat, noncondensating, 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 (P1+) high
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.

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 powerto 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.
6. 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 0/B (If reversing valve = 0 cooling) LIMIT ZD1

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.

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

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

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.

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References

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