iO HVAC Controls ZP2-HC-ESP Residential/Light Commercial Zone Control Panel Instruction Manual

ZP2-HC-ESP Residential/Light Commercial Zone Control Panel

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Product Specifications

• Model: ZP2-HC-ESP

• Function: Heat / Cool with Auto Changeover

• Features: Time Share, Integrated ESP Static Pressure
  Module

• Power Requirement: 24 Volts, 3 AMP

Product Usage Instructions

Panel Layout

The ZP2-HC-ESP panel layout includes various components such as
thermostats, dampers, LEDs for different statuses, speed up button,
and zone bypass selector pins.

High Limit Adjustment

The panel features high limit adjustment switches to provide
limit protection below the safety limit on the furnace.

Speed Up Button

Pressing the Speed Up button activates speed up mode for
internal panel time delays. The Speed Up LED blinks when in this
mode and can be reset by pushing the button again or automatically
resets after 10 minutes.

ESP Zone Bypass Selector Pins

Each zone has a ZONE ESP Bypass selector pin that can be set to
ON or OFF. Setting it to OFF prevents air from bleeding into the
zone when it is not calling, even if static pressure exceeds the
setpoint.

Installing and Wiring

To install and wire the ZP2-HC-ESP:

• Mount the enclosure on a flat, vertical surface near the indoor
  unit for easy access.

• Secure the panel using appropriate anchors and screws.

• Wire the connections to the screw terminals marked DA on the
  panel.

• Use home run wiring and tag each zone thermostat cable with its
  associated zone damper cable to minimize wiring errors.

Frequently Asked Questions (FAQ)

Q: What is the purpose of the Speed Up button?

A: The Speed Up button activates speed up mode for internal
panel time delays, indicated by the blinking Speed Up LED. It can
be reset by pressing the button again or automatically resets after
10 minutes.

Q: How do I adjust the high limit on the ZP2-HC-ESP panel?

A: The high limit adjustment switches are located on the panel.
These switches can be set to provide limit protection below the
safety limit on the furnace.

Q: What are the ESP Zone Bypass Selector Pins for?

A: Each zone has a ZONE ESP Bypass selector pin that can be set
to ON or OFF. Setting it to OFF prevents air from bleeding into the
zone when it is not calling, even if static pressure exceeds the
setpoint.

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ZP2-HC-ESP Installation and Operation Instructions
1 Heat / 1 Cool – Auto Changeover First Call Priority – Time Share
with Integrated ESP Static Pressure Module

SPS

3 AMP

SPEED UP

ZONE ESP

3 SEC = 1 MIN
O…N
OFF 1 2
PC2 C1 PO3
O…N
OFF

ZONE ESP

PC2 C1 PO3

SPS

Rev 1.2

3 AMP

OVERVIEW: The ZP2-HC-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 two separate zones. Each zone is controlled by its own thermostat. When a zone thermostat calls for heating or cooling, the zone not calling will have its dampers powered closed, and the zone calling will have its 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 the non-calling zone damper 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 LED until the static pressure reaches setpoint. The small amount of air allowed to bleed into noncalling zone 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 AutoChangeover – First Call Priority – Time Share. In the event of a tie, cooling will receive priority. HIGH AND LOW LIMIT PROTECTION: A 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. In cooling mode, 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 the non-calling ventilation zone as required. POWER REQUIREMENTS: The panel is powered by a single 24VAC, 40VA transformer. Never use the equipment transformer.

1

ZP2-HC-ESP Panel Layout

3 AMP FUSE PROTECTS PRINTED CIRCUIT BOARD

3 AMP

24 VOLTS
ZONE 1 THERMOSTAT ZONE 1 DAMPER
ZONE 2 THERMOSTAT ZONE 2 DAMPER

O…N
OFF
PC2 C1 PO3
O…N
OFF
PC2 C1 PO3

ZONE ESP

ZONE ESP

SPEED UP BUTTON
SPEED UP 3 SEC = 1 MIN
1 2

SPS

SPS

24 VOLT POWER LED 1ST STAGE HEATING LED 1ST STAGE COMPRESSOR LED FAN LED LIMIT LED (ON WHEN DAS IS DETECTED. BLINKS WHEN TEMP EXCEEDS HIGH OR LOW LIMIT) STATIC PRESSURE SENSOR LED (ON WHEN STATIC PRESSURE IS ABOVE SETPOINT) ZONE 1 DAMPER LED ZONE 2 DAMPER LED
HIGH LIMIT ADJUSTMENT
SWITCHES
HVAC UNIT TERMINALS
STATIC PRESSURE SENSOR TERMINALS DISCHARGE AIR SENSOR

Rev 1.2
ESP ZONE BYPASS SELECTOR PINS

3 AMP

3 AMP FUSE PROTECTS THE RELAY CONTACTS

2

ZONE 1 THERMOSTAT

ZONE 1 DAMPER

ZP2-HC-ESP TERMINAL DESIGNATIONS

TRANSFORMER 24VAC POWER

C (24V COMMON)

R (24V HOT)

W (1ST STAGE HEAT)

Y1 (1ST STAGE COMPRESSOR)

G (FAN)

POWER CLOSE

PC2

COMMON

C1

POWER OPEN

PO3

C (24V COMMON)

R (24V HOT)

W (1ST STAGE HEAT)

Y1 (1ST STAGE COMPRESSOR)

G (FAN)

POWER CLOSE

PC2

COMMON

C1

POWER OPEN

PO3

Rev 1.2

R (24V HOT) W (1ST STAGE HEAT) Y1 (1ST STAGE COMPRESSOR) G (FAN)
WIRE TO ZPA-SPS PRESSURE SENSOR
WIRE TO ZPA-DTS DISCHARGE TEMPERATURE
SENSOR

ZONE 2 THERMOSTAT

ZONE 2 DAMPER

3

ZP2-HC-ESP LED STATUS DEFINITIONS
24 VOLT POWER LED 1ST STAGE HEATING LED 1ST STAGE COMPRESSOR LED FAN LED LIMIT LED STATIC PRESSURE SENSOR LED ZONE 1 DAMPER LED ZONE 2 DAMPER LED

SPS ZONE ESP

1 2

ADJUSTABLE

HIGH LIMIT

High Limit adjustment switches are located on the panel. The switches can be set to provide limit protection below the safety limit on the furnace.

SPEED UP BUTTON

Speed Up LED

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.

ESP ZONE BYPASS SELECTOR PINS

Each zone has a ZONE ESP 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.

4

INSTALLING AND WIRING THE ZP2-HC-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, 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.

land the wires to the screw terminals marked DA on the panel.

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.

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 0.4″ 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.

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

STATIC PRESSURE SETPOINT DIAL

FACTORY SET AT 0.4″ W.G.

3

2

WIRE TO SPS 2 & 3

RETURN AIR

AIR HANDLER
TOP VIEW

ZPA-SPS

CONTROL MUST BE MOUNTED IN VERTICAL POSITION
THE 1/4″ TUBING SHOULD BE CONNECTED TO P1+
HIGH PRESSURE FITTING ON THE PRESSURE SENSOR

SUPPLY AIR

INSTALL SENSING PROBE WITH ARROW IN DIRECTION OF AIRFLOW

5

INSTALLING AND WIRING THE ZP2-HC-ESP

WIRING THE TRANSFORMER: Wire the separate 24 Volt transformer to the 24VAC POWER R’ andC’ 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.
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. 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 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 selected non-calling zone LED until the noncalling zone damper modulates 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. The only change in LED status will be ZD2 will light and ZD1 will turn off. 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 Y G LIMIT ZD1 10. Repeat the same step for zone 2. LED status should be the same with the exception that ZD2 LED will be lit and ZD1 LED will turn off. 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.

6

ZP2-HC-ESP SPECIFICATIONS:
Enclosure:
Plastic
Panel Dimensions:
Height: 9.5″ Width: 6.75″ Depth 2.25″
PC Board Mounting:
Individual snap 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
Thermostats:
Single Stage Programmable or non-programmable Auto or manual changeover
Sensors:
ZPA-DTS Discharge Temperature Sensor NTC Type 3, 10K @ 77° F, +/- 3% @ 77° F

FIELD WIRING TERMINALS:
Zone Thermostats:
C 24Vac (Common) R 24Vac (Hot) W First Stage Heat Y First Stage Compressor G Fan
HVAC System:
R 24Vac Equipment Hot W First Stage Heat Y1 First Stage Compressor G Fan
High / Low Limit Sensor
DA Land to ZPA-DTS DA Land to ZPA-DTS
Panel Power:
C 24Vac (Common) R 24Vac (Hot)
Damper Outputs
PC 2 Power Close C1 Common PO3 Power Open
SPS Pressure Sensor:
2 Land to ZPA-SPS 3 Land to ZPA-SPS

Indianapolis, IN 46237

www.iohvaccontrols.com For Technical Support Call Toll Free: 866-225-5032
iO-06-1281-031224
7

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.

Indianapolis, IN 46237

www.iohvaccontrols.com For Technical Support Call Toll Free: 866-225-5032

SPECIAL ADDENDUM Using iO ESP Zoning with A2L Refrigerant Systems
New HVAC equipment using A2L refrigerants (R-32, R-454B, etc.) may incorporate a Refrigerant Leak Detection System (RDS) as an added safety measure. iO HVAC Controls ESP series zone panels can accept a signal from the RDS in order to drive open all dampers when a leak is detected.
To connect the panel to the RDS, wire the output of the RDS to the SPS terminals on the zone panel. This can be done concurrently with the ZPA-SPS pressure sensor, letting you still use ESP pressure control with an RDS. If the SPS LED on the panel is constantly lit for over one minute, the RDS has likely detected a leak and the dampers should be opened. See wiring diagrams below:

RDS interface with ESP pressure control
ESP SERIES ZONE PANEL
S P S

RDS interface only (using bypass for pressure control)

ZPA-SPS
NORMALLY OPEN RDS CONTACTS

ESP SERIES ZONE PANEL
S P S

NORMALLY OPEN RDS CONTACTS

NOTE: All zones must be set to ESP ON via jumper or LCD display

ESP series zone panels require a normally open contact closure input to open dampers. For an RDS that outputs a different signal, reference the wiring diagrams below:
TRANSFORMER

NO

COIL

S

24V

P

RY-1-HB

RDS OUTPUT

S

SIGNAL

COM

COIL

24V

120V

NC

COIL

S

P

RY-1-HB

S

COM

COIL

NORMALLY CLOSED RDS CONTACTS

www.iohvaccontrols.com For Technical Support Call Toll Free: 866-225-5032
iO-06-1410-090324

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