IntelliZ one2 Installation Manual Inte
Contents
1. Legend Low voltage wiring Zone ID Codes Zone 2 Zone 3 yee mee Config or gy 77 T Shoot IntelliZone2 lt Z21K Kit Relay Board Damper Nee es ee oe ee Transformer 1 5o r7 Series Heat Pump gt i i A F2 Relay Sd Aurora ABC Board Fuse ae Damper Power Blue 240V AID Tool i R A ee Components A BlackWhite 18 Red 208V C A fone Ns Yellow i A 5A Fuse RE de Black Com A axe N e on a 75VAkitmounted urora ermos inpul P10 A H will blow the ABC Zone 6 Dmpr i inheatpump We ea De a e e I fuse not this fuse Open f PN ZTK240 Harness Supplied with Hino A EA IntelliZone2 then Close wire nut to stat wire Fe At one 5 Dmpr E 0 3 5 R 2 Open Com SensorStat sji Ace e O BO Zone 5 code shown P8 Om one 4 Dmpr Zone ID must be set for each Zone 2 6 ID cannot be OR Open confirmed on Zone SensorStat See Zone ID Codes Oc Com 2 Os Close P7 r a ae one 3 Dmpr 3 Wire Damp R open O 3 Open De Com 2 1 Com g2. ajajuj Njaj a ju N Med Factory speed settings are in Bold 6 14 12 High Med High Med 1x10 1 2 Med Low Low High Med High Med 1x10 1 High 2245 2230 2092 2073 11x10 1 Med Low Low High Air flow values are with dry coil and standard filter For wet coil performance first calculate the face velocity of the air coil Face Velocity fom Airflow cfm Face Area sq ft Then for velocities of 200 fpm reduce the static capability by 0 03 in wg 300 fpm by 0 08 in wg 400 fpm by 0 12in wg and 500 fpm by 0 16 in wg Med High 2472 2454 Med High 2271 Med 1x10 1 2133 Med Low Y1 2008 1985 Low 1 G 1806 1784 Highest setting is for auxiliary heat W and lowest setting is for constant blower G The Y1 and Y2 settings must be between the G and W settings 21 INTELLIZONE2 INSTALLATION MANUAL Blower Data cont 5 Series Single Speed with Variable Speed ECM Blower Speed Settings with IntelliZone2 Blower Level Percentages 6 7 8 9 850 000 1100 1200 1300 1400 1500 G L 55 70 85 H 100 1100 1300 1500 1600 1800 1950 2100 L_55 70 H_85 100 900 050 1150 1250 1350 1450 1550 G L 55 70 85 H_100 1000 1200 1400 1600 1700 1850 2000 L_55 70 H 85 100 900 050 1150 1250 1350 1450 1550 G L 55 70 85 H 100 1000 200 1400 1600 1700 1850
3. 7 y y y N N N z aia Y Figure 2 Foam Taping Zone Damper Cross emboss for duct stiffness may cause excessive air bypass Foam Tape top and bottom Foam Seal Figure 3 Mounting Damper Attach duct damper to joist within 6 on both sides Mounting Screws T 4 places Figure 4 Checking Damper Blade for Obstructions BELO e 45 nb SNm 24VACIDC Rotate by hand CCW Closed Manual release INTELLIZONE2 INSTALLATION MANUAL Damper Installation cont Insulating Rectangular Dampers in Metal Ductwork Insulate ductwork as shown in Figure 5 All metal must be covered Care must be taken not to obstruct the shaft from rotating when insulating Do not insulate the zone damper actuator Installing Rectangular Dampers in Ductboard 1 Cut out dimensions A and B by using a ductboard knife NOTE Dimensions A and B are listed in the Dimensional Examples table 2 A ductboard spacer should be installed on the end of the damper frame as shown in Figure 7 to prevent excessive air bypass For example A one inch thick 8 in x 20 in ductboard and a 8 in x 20 in zone damper would have a one inch gap at the end of the frame once it is installed without a ductboard spacer Use the piece cut out for installation 3 Foam insulation tape should be used on the top and bottom o
4. x XX el Alarm Heating Cooling Fan Status On No Faults Communications Error No Damper Power Flashing Code 1 Code 2 Code 3 Code 4 Code 5 ZONE LED Codes off Damper Closed On Damper Open Flashing Damper Moving Other LED Codes HeatOn Heating Mode Cool On Cooling Mode FanOn Fan Only Mode 1Z2 MasterStat Errors displayed on Master Stat Humidity Temp Sensor Open 122 Sensor Errors displayed on Master Stat IZ2 Panel Errors on Master Stat No Damper Power Zone Sensor Control Failure Humidity Temp Sensor Shorted Zone Sensor Temperature Reading Difference Low Voltage Below 19 VAC Outdoor Temp Sensor Error Humidity Reading too Low Humidity Reading too High Humidity Sensor Failure Remote Room Sensor Error Primary Temp Sensor Open Primary Temp Sensor Shorted emp Reading Too Low emp Reading Too High AXB Control no Communications Low Voltage under 19 VAC Low Voltage under 16 VAC ntelliZone2 Panel no Communications Zone 2 Sensor no Communications Zone 3 Sensor no Communications Zone 4 Sensor no Communications Zone 5 Sensor no Communications Zone 6 Sensor no Communications NOTES 1 Where equals the number of the zone 2 Example Z3 4 Zone 3 Sensor Control Error Primary Temp Sensor Shorted Low Voltage Below 16 VAC Primary Temp Sensor Open OAT Sensor Shorted
5. Single and Dual Staging Normal This as shipped mode will upstage the blower and compressor normally Quicker This mode will upstage the blower compressor and auxiliary electric heat more expediently than norma mode for increased comfort Faster When heating this mode will upstage the blower and auxiliary electric heat slightly faster than quicker mode Cooling operation same as quicker mode Faster with Time EH This mode allows for a timed element in compressor and electric heat upstaging in 45 and 70 zones for situations in which normal staging is inadequate when heating This staging position should be reserved for the most demanding and aggressive situations If the heat pump is already operating in the first stage activate second stage after a 15 minute continuous H3 zone call from a 45 or 70 zone until the zone call is reduced to a H2 Airflow will be increased to speed tap 3 or INTELLIZONE2 INSTALLATION MANUAL IntelliZone2 Configuration cont 4 during this period If the heat pump is already operating in second stage activate third stage after a 15 minute continuous H3 zone call from a 45 or 70 zone until the zone call is reduced to a H2 Airflow will be increased to EH selection during this period Cooling operation remains the same as quicker mode Variable Speed Staging Normal This as shipped mode will upstage the blower and variable soeed compressor
6. Secondary Temp Sensor Shorted OAT Senser Open Secondary Temp Sensor Open NOTE Example ZP 4 Zone Panel 26 OAT Sensor Shorted Temp 2 above 99 degF NOTE E Codes diplayed on the IntelliZone2 Temp 2 below 40 degF MasterStat originate from the heat pump Low Voltage below 19VAC i e E11 Freeze Detection Sensor Error Low Voltage below 16VAC 2 Tsuo2 P1 Optional Outdoor 2 Temp Sensor LAS 0AT Use the Z2TK Harness kit to temporarily connect the IntelliZone2 MasterStat directly to the IntelliZone2 Relay Panel for ease of setup or troubleshooting IntelliZone2 Relay Panel F2 Relay Board Fuse Smarter from the Ground Up Manufactured by WaterFurnace International Inc 9000 Conservation Way Fort Wayne IN 46809 www waterfurnace com Product IntelliZone2 Type Comfort Zoning System Size Six Zone Capability Document Installation Manual SA _ GEO o IN 2012 WaterFurnace International Inc 9000 Conservation Way Fort Wayne IN 46809 9794 WaterFurnace has a policy of continual product research and development and reserves the right to change design and specifications without notice IM1578EW 07 12
7. Y1 call in the above chart will result in one half of the zone demand in this case 1 2 of 50 for a 25 system demand A common complaint is insufficient cooling when only one zone is calling for cooling The IntelliZone2 will not initiate a Y2 output to the unit until it senses a 51 total system demand This is when the IntelliZone2 is set for normal upstaging If the IntelliZone2 is set for quicker upstaging it drops to 41 By this example it will require a Y2 call from one zone 50 and a Y1 call from the second zone 25 This will give us a total system demand of 50 25 75 System demand for three and four zone systems are computed in the same manner Heating demand is determined in the same manner but we now have a third stage instead of two for cooling The IntelliZone2 assigns values as follows Y1 40 Y2 80 Y3 100 We know from the previous example that the IntelliZone2 will initiate a Y2 output to the compressor when it is set to normal upstaging and 51 of total demand is needed It will issue a W call to the unit when there is a 90 total demand It is a common assumption that if you have a house with two zones equally divided each zone should be set at an INTELLIZONE2 INSTALLATION MANUAL IntelliZone2 Configuration cont equal amount usually 70 As can be seen in the above chart it will take a Y3 call from one zone as well as a Y2 call from t
8. Figure 1 IntelliZone2 Relay Panel Mounting lt 9 25 in gt en ED DN 0 Mounting Slots E amp Hinge Side 8 3 6 00 in lt gt 7 75 in 2 P B Y Al 0 Depth 2 00 in Deep with cover S Y lt 10 35 in gt NOTE Use longer screws not provided to penetrate through drywall into stud INTELLIZONE2 INSTALLATION MANUAL Damper Installation Installing Rectangular Dampers in Metal Ductwork 1 Cut out dimensions A and B as shown in Figure 2 by using sheet metal snips NOTE Dimensions A and B are listed in the Dimensional Examples table Use foam insulation tape on the top and bottom of the zone damper to prevent excessive air bypass Also check the cross emboss for excessive air bypass see Figure 2 Slide the zone damper into the ductwork making sure no obstructions will interfere with damper blade operation Use the screws provided to mount the damper flange to the ductwork Four to six mounting holes are provided as shown in Figure 3 Use drive cleats or regular duct mounting brackets to attach ductwork to joist within six inches on both sides of the damper see Figure 3 Check damper blade operation for obstructions by holding the manual release button and rotating the damper shaft CW Open and CCW Closed 3 Wire only as shown in Figure 4 Dimensional Examples ZDR1024 ZDRO812 m
9. LOG Logger TST Comm Thermostat IZ2 Intellizone2 AWL Aurora Weblink Config Aurora System Dev Comm Ver ABC Y X XX AXBY X XX Add Device Remove Device lt Back Option VA lt Back Option VA Enter Enter m 14 As always a Y in the communication column shows that communication is OK This will initiate communication between the IntelliZone2 system and the Aurora AXB ABC Software Versions Software versions of the IntelliZone2 MasterStat can be found in the startup screen or in the AID Tool Aurora Config screen Software can be uploaded to the MasterStat via the USB port on the thermostat Consult your local WaterFurnace representative or tech service for details Wiring and Configuring the ZoneStats SensorStats The Zone Sensors should be wired with the MasterStat on Zone 1 using standard 4 wire thermostat cable if issues with EMI shielded cable should be used and grounded at the terminal on one end The other zones should be added sequentially on the relay board until complete The dip switch on the back of each ZoneStat or SensorStat should be selected for the appropriate zone number for instance Zone 2 stat should be selected using the DIP switch on the back for off off off ZoneStats SensorStats PCB SensorStat IntelliZone2 Relay Board On w A A o eje a REO OR S O
10. minimum of 18 gauge thermostat wire for connections Yellow S R e 5A Fuse Figure 17 IntelliZone2 to 5 or 7 Series Control Wiring IntelliZone2 Relay Board I _ 5 0r7 Series Heat Pump _ e 1 EE A a Aurora Sh i A 1 RR w AID Tool ABC N 6 Bs A i 1 a gt Aurora AXB E l Harness supplied with IntelliZone2 then wire nut to stat wire n INTELLIZONE2 INSTALLATION MANUAL Thermostat Installation Locating the Thermostats The thermostats must be located in the room or zone that each controls Locate a thermostat about five feet above the floor Do not locate a thermostat where it may be exposed to direct sunlight drafts or direct supply air Do not place a thermostat on an outside wall Follow the same guidelines that apply with standard thermostat installation If two or more rooms are on a single zone locate the thermostat in a hallway or area where it can sense the return air from all rooms Figure 18 Four Zone Thermostat Location E Zone 1 Main Living E Zone 2 Bedrooms Zone 3 Master Suite Not Zone 4 Basement Shown BN intelliZone2 Thermostat 12 Master Bedroom INTELLIZONE2 INSTALLATION MANUAL Thermostat Installation cont Mounting and Wiring the Thermostats Figure 19 Wiring t
11. open and IntelliZone2 MasterStat temperature control and can be useful during initial construction of the home or during service etc Also in Central Zone mode each damper can be individually cycled off on to verify operation during Installation or service It should be noted that the MasterStat Z2TK troubleshooting harness can be useful here by allowing the temporary connection of the MasterStat directly at the IntelliZone2 relay board for ease of configuration or servicing Aux Heat Lockout Allows the configuration to lockout electric heat above a selected outdoor temperature The outdoor sensor OAT must be installed on the IntelliZone2 Relay Board NOTE LAS OAT on IntelliZone2 relay board INTELLIZONE2 INSTALLATION MANUAL IntelliZone2 Configuration cont Offsets Temperature Offsets Allows the calibration of Indoor outdoor and remote temperature readings Humidity Offset Allows the calibration of humidity readings Humidity Allows the configuration of humidify dehumidify both or none Temperature Sensors Allows the configuration of the remote sensor to be remote only average of remote and internal or no remote sensor Allows the configuration of the outdoor sensor to be zone panel MasterStat or no outdoor sensor Accessories Allows the configuration of the Air Filter Change Cumulative run time or calendar time Humidifier Change Cumulative run time or calendar time UV Lamp Change Cu
12. 2 2 0 Y c i O 1 S o N Be B j Zone 5 code shown Zone ID must be set for each Zone 2 6 ID cannot be confirmed on Zone SensorStat See Zone ID Codes ZoneStat 2 On BO DA 9 ha al 3 o RE OR Ig M M O 2 elc AIN gt _ O vo Oy NBA B Zone 4 code shown Zone ID must be set for each Zone 2 6 ID can be confirmed on ZoneStat by pressing cancel button for 5 sec ID shown on display See Zone ID Codes Zone ID Codes Zone 2 Zone 3 On O O O NOTES 1 Zone ID must be set for each Zone 2 6 ID can be confirmed on ZoneStat by pressing cancel button for 5 sec ID shown on display 2 Small screw driver can be used to set ID thru protective plastic skin 3 MasterStat always Zone 1 Zone ID not necessary INTELLIZONE2 INSTALLATION MANUAL IntelliZone2 Configuration cont Once added to the Aurora system the setup and configuration mode should be entered at the MasterStat by holding a finger over the IntelliZone2 logo for 5 sec The Configuration and Setup mode will appear automatically HUMIDITY 47 MODE STANDBY FAN OFF Single speed equipment Is limited to a maximum of 2 zones Dual Capacity equipment is limited to a maximum of 4 zones Variable speed equipment can have up to the maximum of 6 zones NOTE If the number of zones selected Is less than 6 the remaining zones will be disab
13. 2000 L_55 70 H_85 100 300 1500 1750 1950 2100 2300 L 55 70 85 H_100 1500 1950 2100 70 85 H_ 100 Blower level percentages are shown with factory recommended blower speed settings 6 8 12 Factory settings are at recommended G L H Aux speed settings L H settings MUST be located within boldface CFM range Aux is factory setting for auxiliary heat and must be equal to or above the H setting as well as at least the minimum required for the auxiliary heat package G may be located anywhere within the airflow table CFM is controlled within 5 up to the maximum ESP Max ESP includes allowance for wet coil and standard filter 5 Series Dual Capacity with Variable Speed ECM Blower Speed Settings with IntelliZone2 Blower Level Percentages 6 7 8 9 500 600 800 900 1000 1100 G 70 85 H 100 850 000 1200 1300 1400 1500 L_55 70 H_ 85 100 1100 1300 1600 1800 1875 1925 55 70 H 85 100 900 050 1250 1350 1450 1550 L 55 70 85 H 100 1600 1700 1850 L_55 70 H 85 100 1750 1950 2100 70 85 H 100 1750 1950 2100 L 55 70 85 H 100 Blower level percentages are shown with factory recommended blower speed settings 6 8 12 Factory settings are at recommended G L H Aux speed settings L H settings MUST be located within boldface CFM range Aux is factory setting for auxiliary heat and must be equal to or above the H setting as well as at least the min
14. 3 Blwr Spd Stage Low 222 5 15 Comp 3 Blwr Spd Stage Low 19 6 15 Comp gt Blwr Spd Stage High 99 7 15 Comp y Blwr Spd Stage High 190 8 15 NOTES 1 Continuous Blower activated by G only call from IntelliZone2 selection can be anywhere 2 Aux Heat Airflow activated by Aux or Emergency heat call selection must be greater than high and allow proper airflow for the installed electric heat heat pump model Airflow Selection Variable Speed Airflow from the IntelliZone2 is communicated to the Aurora via a blower Level These blower levels are 25 40 55 70 85 and 100 The Aurora will dictate actual airflow based upon these percentages Below is a graphic showing how the IntelliZone2 would signal for a 25 100 blower level percent and the resulting airflow based upon the ABC setpoints of speed 3 for low and speed 8 for high in the example AID Tool setting Notice that a Blower level of 85 would result in a blower speed of 7 with these settings All airflows are rounded to the nearest 1 12 blower speeds Continuous blower and aux heat blower speeds are set Independently of the compressor blower speeds Heating Airflow Selection Variable Speed Speed Selected in AID Tool Cont Low Hi Blwr_ Comp Comp From IZ2 Air Level Low Selection Comp Speeds 1 amp 2 Zn Comp Speeds o 3 amp 4 49 Comp Speeds 0 586 23 Comp Speeds O 788 TOR Comp Speeds
15. 8 for high in the example AID Tool setting Notice that a blower level of 85 would result in a blower speed of 7 with these settings All airflows are rounded to the nearest 1 12 blower speeds Continuous blower and aux heat blower speeds are set Independently of the compressor blower speeds Heating Airflow Selection Single or Dual Capacity Selected in AID Tool Blower Cont Low High Aux Speed Blower 9 Heat 1 2 3 4 5 NOTES 1 Continuous Blower activated by G only call from Intel selection can be anywhere 2 Aux Heat Airflow activated by Aux or Emergency heat call selection must be greater than high and allow proper airflow for the installed electric heat heat pump model From IZ2 Air Level 55 70 85 100 Comp Stage Low Comp Stage Low Comp Stage High Comp Stage High iZone2 In cooling a similar procedure occurs with the exception that when dehumidification reduces airflow it is a reduction as shown below Therefore in dehumidification mode if blower speed 5 is selected the resulting airflow will be blower speed 5 less 15 If cooling airflow is configured to be 15 less than heating airflow then there is no difference between cooling and dehumidification cooling airflow Cooling Airflow Selection Single or Dual Capacity Selected in AID Tool From 1Z2 Actual Cont Low High Air Level Blwr Spd Speed Blwr 9 Comp
16. 9 amp 10 oon Comp Speeds 11812 High O Selection 109 Continued on the next page INTELLIZONE2 INSTALLATION MANUAL Blower Data cont In cooling a similar procedure occurs with the exception that compressor speed is limited to a maximum of speed 9 However compressor speed 10 12 is available for a short period of time and the resulting airflow during the SuperBoost mode is shown below Another exception is when dehumidification reduces airflow it is a reduction as shown below Therefore in dehumidification mode if blower speed 3 is selected the resulting airflow will be blower speed 3 less 15 Cooling Airflow Selection Variable Speed Selected in AID Tool From IZ2 Actual AID Reported Air Level Blower Speed Blower Speed Cont Blower Low Comp Hi Comp Aux Heat ed ae Low Selection 25 Blower Spd 3 15 ee 40 Blower Spd 4 15 eee 55 Blower Spd 5 15 a 70 Blower Spd 6 15 Pee Cooling Max 85 Blower Spd 7 15 A SuperBoost Only 100 Blower Spd 8 15 NOTE Denotes default cooling airflow setting of 15 less than heating mode airflow Dual or Single Capacity Heating Unit Call Blower Level Call Norm 55 or 70 Blower Level Call Dehumid 85 or 100 Aux Blower Aux Blower G Only cont Blower Cooling Unit Call Blower Level Call Norm 55 or 70 85 or 100 Blowe
17. Intelli Zone Comfort Zoning System Six Zone Capability Installation Information Damper Installation Thermostat Installation IntelliZone2 Electrical Startup Procedures ae z ACA Wiring Schematic RY CQAATEERD Smarter from the Ground Up IM1578EW 07 12 IntelliZone2 Installation Manual INTELLIZONE2 INSTALLATION MANUAL Table of Contents General Installation Information 0 asana 5 Damper Installation E A el ci Aries AA E Same A Rathod noes 6 Recea WRI Gist teenth A heat AA nt a it ia E 9 Thermostatinstallati iii AT A es Gath ew haat Seay 12 IntelliZone2 ConfiguFationws i 4 dar o salt eek od Gb ded eed ha aed Sack Raed 4 14 IntelliZone2 cfm Design 23 System Startup and Checkout eeaeee eee een eee eee eens 23 WHIFING SCHEMALICS riot a a thee Aes wRiatend a a ia AA 25 IntelliZone2 Fault CodeS viii a Ec ae ha DLS 26 INTELLIZONE2 INSTALLATION MANUAL IntelliZone 2 T A A Toa a2 A oo ee The IntelliZone2 Components IntelliZone2 Relay Board The IntelliZone2 relay board provides basic relay logic for the damper operation and serves as a common connection point for all IntelliZone2 IntelliZone2 thermostats and the heat pump IntelliZone2 MasterStat The IntelliZone2 MasterStat is the master control for the system and has all of the programming for operation It is a 4 3 in communicating color touch screen device that also functions as a zone thermostat fo
18. ctuator Zone 1 Dampers Power to 2 122 Dampers Zone 2 Dampers Power to 1122 Dampers Zone 3 Dampers Power to 2 122 Dampers Zone 4 Dampers Power to 3 122 Dampers Zone 5 Dampers Power to 2 122 Dampers Zone 6 Dampers Power to 3 122 Dampers Total VA Draw 39 0 VA Figure 15 Mounting and Wiring Transformer to Control Box 5 Series shown WARNING All wiring must comply with local and state codes Disconnect the power supply before beginning to wire to prevent electrical shock or equipment damage Mount the transformer onto the side of the unit s control box on the 5 Series and on the back of the control box on the 7 Series by inserting and tightening screws provided into the pre punched holes Thread all transformer wires through the hole with bushing and follow the wiring schematic for connecting the transformer primary and secondary leads as shown in Figure 15 5 Series and Figure 16 7 Series For 208 volt operation the red and blue transformer wires must be switched Use wire nuts only for connections to thermostat wire ol A op 5 IntelliZone2 E an OD Relay Board alala Za Ee saat W a E F1Damper amperP
19. dual zones four with dual capacity and two with single speed equipment can be chosen 2 Calculate loads using software or other recognized methodology 3 Use software to determine the equipment size and performance based on the total heating and cooling demands of the building not the sum of the individual zone demands 4 Find the peak heating and cooling demands and the peak cfm required for each of the zones 5 Determine zone design air flow and zone size settings using IntelliZone2 Calculator software 6 Lay out and size the supply air ductwork and dampers Care should be taken to avoid under sizing either the supply air systems return air systems or diffusers 7 Decide where to locate the thermostats 8 Install the unit and the IntelliZone2 Comfort Zoning system IntelliZone2 Control Panel Locate the IntelliZone2 panel in an indoor area that has enough space for service personnel to perform maintenance or repair Provide sufficient room to make electrical connection s The IntelliZone2 is not approved for outdoor installation and therefore must be installed inside the structure being conditioned Do not locate the control panel in areas where ambient conditions are not maintained within 45 F to 95 F and are greater than 75 relative humidity The IntelliZone2 control panel should be mounted on or as close to the unit as possible by using the sheet metal screws provided See Figure 1 for mounting hole locations
20. ed Low Low High Med High Med Med Low Low High Med High Med 9x7 1 2 Med Low Low Factory speed settings are in Bold 6 14 12 Air flow values are with dry coil and standard filter For wet coil performance first calculate the face velocity of the air coil Face Velocity fom Airflow cfm Face Area sq ft Then for velocities of 200 fpm reduce the static capability by 0 03 in wg 300 fpm by 0 08 in wg 400 fpm by 0 12in wg and 500 fpm by 0 16 in wg Highest setting is for auxiliary heat W and lowest setting is for constant blower G The Y1 and Y2 settings must be between the G and W settings The gray wire is not factory wired to the motor and is tied to the wire harness This wire can be field connected and can be used with 3ht 2cl thermostats or IntelliZone2 to deliver the required air flow for the Y2 signal I NPR OTP 1 WBS OTP 1h JB Ont W BR pth GS BS OTP fh WB fu 5 Series Dual Capacity with 5 Speed ECM T stat Blower Airflow cfm at External Static Pressure in wg Cnct Size Med High Med Med Low Y1 Low G 1 2 IN W Aju
21. f the zone damper to prevent excessive air bypass as shown in Figure 7 4 Slide the zone damper into the ductboard making sure no obstructions will interfere with damper blade operation 5 Tape the damper face flange to the ductboard using foil tape making sure the damper is secure and air tight as shown in Figure 8 6 Support the full length of the ductboard underside within six inches and on both sides of the damper as shown in Figure 8 7 Check the damper blade operation for obstructions by holding the manual release button and rotating the damper shaft CCW and CW see Figure 4 Figure 5 Insulating Rectangular Metal Ductwork Duct wrap insulation Do not insulate zone damper actuator Figure 7 Taping Zone Damper with Foam Tape Foam tape top and bottom Insulate between actuator and damper Duct board spacer _ Keep spacer clear of end bushing Figure 8 Taping Damper Flange to Ductboard Foil tape damper face to ductboard Support the full length of ductboard underside within 6 of damper INTELLIZONE2 INSTALLATION MANUAL Damper Installation cont Insulating Rectangular Ductboard Metal Sleeve Care must be taken not to obstruct the shaft from rotating when insulating Do not insulate the zone damper actuator Installing Circular Dampers in Round Metal Duct 1 Crimp the end of the duct that is the supply air to dam
22. ge cooling is energized Y1 Y2 and O LEDs Check the fan speed LEDs and compare to the Blower Speed tables 6 Adjust the thermostats until the temperature displayed is 5 higher than the actual temperature on all thermostats 7 The call for cooling should be canceled after a delay Set all of the zone thermostats to the heating mode 9 Increase the heating set point to 2 above the actual zone temperature on all thermostats After a delay the unit should start up in the first stage heating mode H1 Check the fan speed LEDs and compare to the Blower Speed tables 11 Increase the heating set points two more degrees and check to see that the fan speed increases and second stage heating is energized H2 Check the fan speed LEDs and compare to the Blower Speed table Increase the heating set point to 4 above the actual zone temperatures Be sure the auxiliary heat is energized and the fan speed increases Y1 Y2 and W Check the fan speed LEDs and compare to the Blower Speed tables Set system to maintain desired comfort level Instruct the owner operator of correct thermostat and system operation Fill out and forward all warranty registration papers to WaterFurnace go 10 12 13 14 15 NOTE Unit check out can be accomplished by going to the Test Mode screen at the MasterStat and selecting Central Zone The system will be controlled only by the MasterStat Any time superheat and subcooling i
23. he Thermostat to the IntelliZone2 Position the thermostat subbase against the wall so that MasterStat it is level and the thermostat wires protrude through the e IntelliZone2 middle of the subbase Mark the position of the subbase a s29 Relay Board mounting holes and drill holes with a 3 16 inch bit zo SLB Pe Install supplied anchors and secure base to the wall Use 8 Y ge 23 4 conductor 18 or 20 AWG thermostat wire unless issues och g with EMI are anticipated In that situation use 24 AWG MasterStat is B E shielded twisted pair cable grounded to C terminal on always Zone 1 the relay board end Strip the wires back 1 4 inch longer strip lengths may cause shorts and insert the thermostat SensorStat IntelliZone2 wires into the IntelliZone2 connector as shown in Figure Relay Board 19 Tighten the screws to ensure tight connections The On nA QA 2 thermostat has the same type connectors requiring the 5 O 3 wo z a ae N same wiring Caulk the hole in the wall where the wires O 1 Siz Al OB 2 enter the thermostat Zone 5 code shown NOTE See the instructions enclosed in the thermostat for Zone ID must be set for each Zone 2 6 ID cannot be g y confirmed on Zone SensorStat See Zone ID Codes detailed installation and operation information ZoneStat On 3s Ah DA E 93 SR OR S O42 2e Qc 91 B B Zone 4 code show
24. he ground loop Dehumidification Active Active dehumidification will only activate during cooling operation when cooling demand from the IntelliZone2 MasterStat is compressor speed 4 or lower and the humidity setpoint of the MasterStat is at least 5 below the actual relative humidity The green status LED will flash code 2 when active The compressor will ramp up and airflow will begin at a low level Airflow is then reduced periodically until air coil temperature setpoint is reached If coil temperature continues to drop the airflow is increased until air coil setpoint is maintained After 20 minutes of operation in the Active Dehumidification mode normal cooling operation will resume for 5 minutes This cycle continues until the dehumidification setpoint is reached or IntelliZone2 MasterStat cooling demand requires greater than compressor speed 4 normal cooling takes over In IntelliZone2 systems the main zone will remain open during active dehumidification INTELLIZONE2 INSTALLATION MANUAL Blower Data Airflow Selection Single or Dual Capacity Airflow from the Intellizone2 is communicated to the Aurora via a Blower Level These blower levels are 55 70 85 and 100 The Aurora will dictate actual airflow based upon these percentages Below is a graphic showing how the IntelliZone2 would signal for a 55 100 blower level percent and the resulting airflow based upon the ABC setpoints of speed 5 for med and speed
25. he second zone to obtain auxiliary heat This is a simple example but three and four zone systems are calculated in the same manner Blower speeds are also assigned upon the percentage of system demand and a complete understanding of this process is not necessary for day to day decisions As a serviceman the temptation arises in some instances to influence the logic of the board by jumping Y1 and Y2 While this will create a quicker response the ductwork of that zone must be capable of handling the cfm delivered by the unit i e if a Y2 signal is given to the unit can the ductwork handle the total cfm of the unit When setting up a new system remember that if you have unused zones they must be set to zero If they are not the setting that they have will be included in the total demand preventing the other zones from operating correctly as there will be no inputs on those zones The IntelliZone2 allows the selection of either comfort or economy mode in each individual zone to provide maximum savings in areas that allow it such as workshops and basements while maintaining perfect comfort in the zones where accurate temperature is most desired such as bedrooms and baths oix IntelliZone2 Version 1 0 0 Customer lohn Q Public GeoSystem Modet ND049 Job ray Job Number of Zones 4 Y Date Nom CFM 1500 Zone Priority Comfort Mode A single zone call Y1 for conditioning will engage the c
26. ify that damper rotation direction is correct The 3 wire damper rotation direction is reversible with switch on front cover Figure 13 Damper Actuator Wiring 3 Wire Damper Indicated rotation direction is valid for switch position 0 45 indb 5Nm 2avacDe ose Damper Switch Reverse Rotation Z gt CCW Red Minimum 18 gauge wire Note 1 Each zone must have dampers that match by manufacturer and type COM Gray CCW Yellow Each IntelliZone System must have dampers that match Minimum either 2 wire or 3 wire 18 gauge wire Damper Actuator Wiring Notes Figure 14 Actuator Wiring 1 Minimum of 18 gauge thermostat wire is recommended 2 Use wire nuts to connect the thermostat wire to the actuator wire solid wire to stranded wire as shown in Figure 14 3 The actuator wiring should be secured using a wire tie to prevent the wires from being separated see Figure 14 Wire Nuts Strain Relief INTELLIZONE2 INSTALLATION MANUAL Electrical Wiring cont Transformer Sizing Providing adequate transformer power VA to supply the system is an important requirement Each 3 wire damper requires 3 0 VA at nominal voltage Each 2 wire damper requires 7 0 VA at nominal voltage The standard transformer available is a 75VA with circuit breaker Part ZTK240 Transformer VA Calculation 3 wire a
27. imum required for the auxiliary heat package G may be located anywhere within the airflow table CFM is controlled within 5 up to the maximum ESP Max ESP includes allowance for wet coil and standard filter 7 Series Variable Speed with Variable Speed ECM 7 Series Blower Speed Settings with IntelliZone2 Blower Level Percentages Speed 3 Speed 4 Speed5 Speed6 Speed7 Speed8 Speed9 Speed 10 Speed 11 Speed 12 1440 H_ 100 1410 036 w 1hp lO 1650 948 H_ 100 2010 060 H_100 VS Compressor Speed Blower level percentages are shown with factory recommended blower speed settings 6 7 12 VS Compressor speed is given for the factory default cfm settings When the cfm default settings are changed it will change the relationship to the compressor speed that is shown in the table In cooling mode compressor speeds 10 12 are only available when SuperBoost mode is selected at the thermostat optional 1 HP ECM Factory speed settings are at recommended G L H and Aux positions G may be located anywhere within the airflow table L setting should be located within the boldface CFM range H setting MUST be located within the shaded CFM range Aux setting MUST be equal to or greater than the minimum allowable CFM for the auxiliary heater kit see auxiliary heat ratings table CFM is controlled within 5 up to the maximum ESP Max ESP includes all
28. joist within six inches on both sides of the damper as shown in Figure 12 Insulating Damper Actuators Insulate the damper as shown in Figure 12 All metal must be covered to prevent condensation When insulating care must be taken not to obstruct the shaft from rotating Do not insulate the zone damper actuator Figure 9 Taping Round Duct to Circular Damper Three screws sealed with duct tape or mastic Manual release button l Ae gt Air Flow gt Figure 10 Supporting and Insulating Circular Damper Support with wide steel strap Do not insulate damper actuator 1 1 2 or 2 if in unconditioned space Figure 11 Attaching Flexible Duct to Damper Flexible duct Slide duct 2 3 past damper end rib Clamp with duct strap Install screw no farther than 1 from either end of damper Figure 12 Supporting and Insulating Circular Damper Support with wide steel strap 1 1 2 or 2 if in unconditioned space Do not insulate damper actuator INTELLIZONE2 INSTALLATION MANUAL Electrical Wiring Wiring Damper Actuators All wiring must comply with local and state codes Disconnect the power supply before beginning to wire to prevent electrical shock or equipment damage All wiring should be run back to the control panel Keep wires a minimum of 12 inches from any high voltage lines Follow the damper wiring schematic as shown in Figure 13 Ver
29. led Damper The Damper screen allows the selection of either 2 wire spring closed or 3 wire power open power closed type SELECT DAMPER TYPE It should be noted that the MasterStat Z2TK troubleshooting harness can be useful during setup by allowing the temporary connection of the MasterStat directly at the IntelliZone2 relay board for ease of configuration or servicing Use the Z2TK Harness kit to temporarily connect the IntelliZone2 MasterStat directly to the IntelliZone2 Relay Panel for ease of setup or troubleshooting IntelliZone2 Relay Panel F2 Relay gt Board Fuse Equipment and Number of Zones The first screen is Equipment and of Zones Here the total number of desired zones and the type of equipment is selected Equipment is automatically detected Press the up and down arrows until the desired number of zones appears The zones should always be installed sequentially starting with the MasterStat always in Zone 1 SELECT EQUIPMENT AND ZONES DETECTED MAX EQUIPMENT ZONES ZONES i v DUAL CAPACITY 4 15 Staging Staging allows custom selection of staging Single dual capacity selection is different than the variable speed selections The IntelliZone2 system allows four different staging options Once the compressor call has been initiated by a zone the compressor will be upstaged using one of four staging options in single or dual capacity equipment
30. mulative run time or calendar time Air Cleaner Change Cumulative run time or calendar time Dealer Information Allows the input of the dealer contact information Fault Status Shows the last 10 IntelliZone2 system Faults heat pump fault history is displayed at the heat pump on the AID Tool The faults can be cleared or refreshed from this screen Restore Defaults Restores the factory default settings Restart Thermostat Upgrade Software This allows a convenient way to restart the thermostat or upload the latest software using the USB port without killing power to the whole system USB Allows the import and export of data using the USB port Importation of Installer settings User Settings Program Dealer Details Exportation of Installer settings User Settings Program Dealer Details Data Logging Allows the USB thumb drive to record the data every 5 seconds Superboost Variable Speed Heat Pumps ONLY Superboost can be found under the main menu settings of the thermostat The Superboost option temporarily enables a larger cooling capacity range Normal cooling mode is limited to compressor speeds 1 9 and Superboost allows compressor speeds 10 12 if needed This screen will allow the homeowner to turn the Superboost option ON or OFF The Superboost option will be enabled by default for a 24 hour period of time then will automatically be disabled NOTE Continuous use of SuperBoost could result in overheating t
31. n Zone ID must be set for each Zone 2 6 ID can be confirmed on ZoneStat by pressing cancel button for 5 sec ID shown on display See Zone ID Codes Zone ID Codes Zone 2 Zone 3 Zone 4 Zone 5 On On On O O O O O O O O O NOTES 1 Zone ID must be set for each Zone 2 6 ID can be confirmed on ZoneStat by pressing cancel button for 5 sec ID shown on display 2 Small screw driver can be used to set ID thru protective plastic skin 3 MasterStat always Zone 1 Zone ID not necessary INTELLIZONE2 INSTALLATION MANUAL IntelliZone2 Configuration Aurora System and Communication Configuration of IntelliZone2 Aurora Communication Basics The Aurora Control functions around the concept of modularity and intercommunications between these boards The communication is a 4 wire ModBus protocol ModBus protocol is an open source protocol becoming more popular with equipment manufacturers for use in HVAC equipment The Aurora has one bus for the ABC AXB AWL VS Drive EEV and thermostats The AID Tool only plugs into the ABC AID Tool port RJ style connector and will not work at any other location The AXB has 3 other independent ports for differing protocols for IntelliZone2 ClimateTalk Components and Communicating ECM blower motors None of these ports comply with the ModBus protocol set up for the rest of the Aurora sy
32. n cycle thru all of the active zones to view the configuration Zone Percentage Selecting the zone percentage can also be calculated by using the IntelliZone2 Calculator software This percentage represents an approximation of the maximum heating or cooling load percentage of the zone and thus to a certain extent volume of airflow The IntelliZone2 allows O 25 45 and 70 selections Some general rules to follow in this selection procedure are as follows Pick the larger percentage for major living areas such as family rooms etc Pick the smaller percentage for minor living areas such as dens or bedrooms Pick a larger percentage if more branches are required than the load indicates due to large area per load i e unfinished insulated basement The IntelliZone2 software should be used to aid in the selection and calculation of design cfm The IntelliZone2 determines modes as a proportion of the total demand A simple example of this to begin with is a two zone system in the cooling mode If each zone is set at 70 we have the following scenario Zone 1 50 Zone 2 50 NOTE All Zone calculations are normalized using the following process We now must determine what percentage of the total load each zone represents To perform this operation add the two zones together 70 70 140 One zone would then be 70 140 or 50 The IntelliZone2 then reduces the total demand based upon thermostat demand A
33. normally Quicker This mode will upstage the blower compressor and auxiliary electric heat more expediently than normal mode for increased comfort Generally the compressor will be upstaged 1 extra speed more than normal Faster When heating this mode will upstage the blower and auxiliary electric heat slightly faster than quicker mode Generally the compressor will be upstaged 2 extra speeds more than normal Faster with Time EH This mode allows for a timed element in compressor and electric heat upstaging in 45 and 70 zones for situations in which normal staging is inadequate when heating This staging position should be reserved for the most demanding and aggressive situations If the heat pump is already operating in the first stage activate second stage after a 15 minute continuous H3 zone call from a 45 or 70 zone until the zone call is reduced to a H2 Airflow will be increased to speed tap 3 or 4 during this period If the heat pump is already operating in second stage activate third stage after a 15 minute continuous H3 zone call from a 45 or 70 zone until the zone call is reduced to a H2 Airflow will be increased to EH selection during this period Cooling operation remains the same as quicker mode Zone Configuration Zone configuration allows the selection of the zone size and the zone priority The zone can be selected by touching the upper right screen text noting the zone In this way you ca
34. ompressor and allow a minimal set point variation thus providing ultimate comfort Economy Mode A single zone call Y1 for conditioning will be ignored by the IntelliZone2 until either a Y2 call is initiated from the same zone or another zone calls for conditioning Y1 This allows a slightly greater set point variation than in comfort mode This setting prevents less important zones from energizing the compressor 17 unless it is really needed thus saving money As a bonus in this mode upon a Y1 call the IntelliZone2 may try to precondition the zone with return air from other zones already satisfied and in some cases can preclude the need for energizing the compressor Variable Speed Fan Staging Variable Speed Fan Staging allows the ability to expand the blower levels Options are Normal and Expanded There are three airflow speeds assigned to a compressor speed and the airflow level is determined by the fan demand total zone Normal is the recommended airflow levels Selecting Expanded will increase the highest airflow level by one level and decrease the lowest airflow level by one level from Normal Not available for single speed or dual capacity models FANSTAGING 11 57AM Wed 1 4 Test Mode In Test mode Central Zone mode can be selected In Central mode all dampers are opened and thermostat readings are taken ONLY from the Zone 1 MasterStat This will approximate operation without a zone system all dampers
35. owance for wet coil and standard filter 22 INTELLIZONE2 INSTALLATION MANUAL IntelliZone2 CFM Design CFM Percentage NSO36 850 5 5 5 5 5 NDO72 2000 1100 NVO36 1500 300 2 NVO48 1800 450 2 NVO60 2100 450 20 O O O O O O 40 40 40 40 o o o System Startup and Checkout It should be noted that the MasterStat Z2TK Damper and Continuous Blower Checkout troubleshooting harness can be useful during startup by allowing the temporary connection of the MasterStat directly at the IntelliZone2 relay board for ease of configuration or servicing 1 Push the Fan button to the ON position on all thermostats alternate method shown in the note below 2 All dampers should start to open immediately 3 The blower should come on continuous fan speed and Before powering the unit check the following should illuminate the G LED only all other fan speed Fuses breakers and wire size are correct LEDs should be off Low voltage wiring has been completed 4 After approximately 90 seconds all IntelliZone2 MasterStat has been configured correctly dampers should be completely opened Check the Thermostats are wired and DIP switches are set for shaft position indicator on all damper actuators as proper zone shown in Figure 25 Blower speed has been set on the AID Tool 5 Push the Fan button to the OFF position on A
36. ower TH ZE O Fuse c CH il N a QU a Secondary R Yellow co a a La Leads 5A Fuse ao co pn E o 5 Eal O o ol o aie oo Bates de Le y q Gea Tre E SN o I Bd y mom E E E ES Primary Leads ooo 10 INTELLIZONE2 INSTALLATION MANUAL Electrical Wiring cont Figure 16 Mounting and Wiring Transformer to Control Box 7 Series shown Zone Transformer IntelliZone2 mounted on backside Secondary Relay Board of control box Leads ie Damper Power F1 Damper Black White c Fuse ojo o VILA prt Wiring IntelliZone2 to the Unit WARNING All wiring must comply with local DM and state codes Disconnect the power supply before beginning to wire to prevent electrical shock or equipment damage Follow the wiring schematic in Figure 17 for unit control connections Strip the wires back 1 4 inch longer strip lengths may cause shorts and insert the thermostat wires into the unit s connector as shown in Figure 17 Tighten the screws to ensure tight connections Use a
37. per Insert into circular damper no more than 1 5 inches 2 Fasten the duct to the damper with three screws Screws installed more than one inch from either end may obstruct damper blade rotation 3 Seal completely around the duct with metal duct tape or mastic to prevent air leakage as shown in Figure 10 4 Check the damper blade operation for obstructions by holding the manual release button and rotating damper shaft CCW and CW 3 wire only See Figure 4 5 Support the duct to joist within six inches of the damper as shown in Figure 9 Insulating Circular Dampers in Round Metal Duct Insulate ductwork as shown in Figure 10 All metal must be covered to prevent condensation Care must be taken not to obstruct the shaft from rotating when insulating Do not insulate the zone damper actuator Installing Circular Dampers in Flexible Duct 1 Slide flexible duct two to three inches over the damper pipe past the damper rib as shown in Figure 11 2 Fasten duct to damper with a nylon duct strap screwing the strap to the pipe to prevent the duct from slipping off Screws installed more than one inch from either end may obstruct damper rotation 3 Seal completely around the duct with metal duct tape or mastic to prevent any air leakage 4 Check the damper blade operation for obstructions by holding the manual release button and rotating damper shaft CW Open and CCW Closed 3 wire only See Figure 4 5 Support the damper to
38. r Level Call Dehumid 55 or 70 less 15 cfm 85 or 100 less 15 cfm Variable Speed Capacity Blower Level Call Normal Staging Shown 25 or 40 Heating Unit Call H1 or H2 Blower Level Call Dehumid H3 or H4 25 or 40 or 55 H5 or H6 40 or 55 or 70 H7 or H8 55 or 70 or 85 H9 or H10 70 or 85 or 100 H11 or H12 85 or 100 H9 H12 W Aux Blower W Aux Blower C2 G G Only cont Blower G Only cont Blower 20 G G Only cont Blower Cooling Unit Call C1 or C2 Blower Level Call norm 25 or 40 Blower Level Call Dehumid Norm less 15 cfm C3 or C4 25 or 40 or 55 Norm less 15 cfm C5 or C6 40 or 55 or 70 Norm less 15 cfm C7 or C8 55 or 70 or 85 Norm less 15 cfm C9 or C10 70 or 85 or 100 85 or 100 Norm less 15 cfm Norm less 15 cfm C11 or C12 G G Only cont Blower G Only cont Blower NOTE C10 C12 are only available in SuperBoost mode INTELLIZONE2 INSTALLATION MANUAL Blower Data cont 5 Series Single Speed with 5 Speed ECM Motor Motor Ea Airflow cfm at External Static Pressure in wg Tap Cnct Size o oos o1o 0 15 0 20 0 25 0 30 0 35 0 40 0 45 0 50 0 60 W 980 960 Y1 High Med High Med Med Low Low High Med High Med Med Low Low High Med High Med Med Low Low High Med High Med Med Low Low High Med High Med M
39. r Zone 1 Optional remote sensor capability is also available IntelliZone2 ZoneStat The IntelliZone2 ZoneStat is a zone thermostat option for any of Zones 2 through 6 It has full setback capability and communicates to the IntelliZone2 system IntelliZone2 SensorStat The IntelliZone2 SensorStat is a zone thermostat option for any of Zones 2 through 6 It has full setback capability through the MasterStat interface only and communicates to the IntelliZone2 system INTELLIZONE2 INSTALLATION MANUAL General Installation Information Safety Considerations Installing and servicing heating and air conditioning equipment can be hazardous due to system electrical components Only trained and qualified service personnel should install repair or service heating and air conditioning equipment When working on equipment observe precautions in the literature tags and labels attached to the unit and other safety precautions that may apply Follow all safety codes Wear safety glasses and work gloves maintenance operations on the system turn off main power switches to the indoor unit Turn off accessory heater power switch if applicable Electrical shock could cause serious personal injury 1 WARNING Before performing service or Delivery Information When the equipment is received all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received Examine the conten
40. s being checked the zone system must be in the central zone mode 24 Blower Speed Tables Single or Dual Capacity Heating Blower Level Call Blower Level Call Unit Call Norm Dehumid H1 55 or 70 N A H2 W N A A A 2 85 or 100 Aux Blower G G Only Cont Blower N Blower Level Call Norm 55 or 70 85 or 100 G Only Cont Blower Unit Call cl G Variable Speed Capacity Unit Call Normal Staging Shown Dehumid H1 or H2 25 H3 or H4 40 H5 or H6 55 H7 or H8 70 H9 or H10 85 H11 or H12 100 H9 H12 W Aux Blower N A G G Only Cont Blower N A Unit Call Norm Dehumid C1 or C2 25 less 15 cfm C3 or C4 40 less 15 cfm C5 or C6 55 less 15 cfm C7 or C8 70 less 15 cfm C9 or C10 85 85 less 15 cfm C11 or C12 100 100 less 15 cfm G G Only Cont Blower G Only Cont Blower Blower Level Call Dehumid 55 or 70 less 15 cfm 85 or 100 less 15 cfm G Only Cont Blower 70 IntelliZone2 Configuration Once added to the Aurora control system the setup and configuration mode should be entered at the MasterStat by holding a finger on the IntelliZone2 logo for 5 seconds The Configuration and Setup mode will appear automatically INTELLIZONE2 INSTALLATION MANUAL Wiring Schematic IntelliZone2 System For Temporary
41. stem The ModBus communication is accomplished within the cabinet using shielded and ground cabling This shield is most important in 7 Series applications where the VS Drive component by its very nature emits electro magnetic interference and can interfere with ModBus communications Round ferrite donuts can be observed at various locations to aid in cleaning the communication lines Each line is comprised of an R 24VAC C common and a and communication line At times the R and C lines may not be connected or needed The terminals marked and should not be switched although damage may not occur to the boards communication is not possible The communication voltage and current are small therefore 24 awg wire is adequate for these communication lines and a shield is not required but recommended in high EMI environments An extra expansion connector is available for connecting the AWL and other devices onto the main ABC ModBus A small LED is located next to each of the communication ports to aid in evaluating active communication at that specific port This is true for each board The blinking indicates transmission or receiving communication activity Configuring the Aurora for the IntelliZone2 Adding the IntelliZone2 to the Aurora system can be accomplished using the AID Tool via the Config Aurora screen and scrolling to IntelliZone2 selecting and adding Add Device
42. t gt B Close 2 Close SE Drive Open P6 i one 2 Dmpr Drive Close Open Com 2 Close 2 P5 A d one 1 Dmpr 2 Wire Dampi le Open A Com 1 Com F n Bota on Oa SEQ SEX SEL com MasterS tat is E Heating Cooling fan Status Spring Open always Zone 1 Jl AA P1 TSU02 Zone 2 Zone 4 Zone 6 LAS Outdoor A Yet Jeol Ye Asensi Optional Outdoor Temp Sensor Yel Light emitting diode Green A Screw Terminal Stri 1 p P y Internal junction On On On On O Wire nut O O O O O O O O Relay Contacts N O N C NOTES 1 Zone ID must be set for each Zone 2 6 ID can be confirmed on ZoneStat by pressing cancel button for 5 sec ID shown on display 2 Small screw driver can be used to set ID thru protective plastic skin 3 MasterStat always Zone 1 Zone ID not necessary 4 18 12 NOTE This drawing is for visual reference for wiring and configuring a zone Do not skip zones as shown here Zones MUST be wired in numerical sequence 25 INTELLIZONE2 INSTALLATION MANUAL IntelliZone2 Fault Codes The following are IntelliZone2 fault codes that can appear on the IntelliZone2 relay board LEDs and MasterStat All Aurora control errors will be displayed on the MasterStat as Exx xx equals error number style and fault information can be found in AID Tool and Aurora Control literature
43. ts for shipping damage removing them from the cartons if necessary If any damage is noted the carrier should make the proper notation on the delivery receipt acknowledging the damage General rules to follow when installing a zone system CAUTION When installing the IntelliZone2 in AS a structure with fossil fuel oil gas propane appliances it is important that both supply and return dampers are used in each zone to avoid potential back drafting of fossil fueled appliances Up to six zones on variable speed up to four zones with dual capacity units two with single speed units All dampers should be located as close to the main trunk as possible to limit the amount of pressurized trunk line and thus limit air leakage No less than three branch runs in a zone to prevent a single branch obstruction curtains or clothes etc from affecting unit airflow Insulate and seal around rectangular dampers to prevent leakage All dampers must be wired with 18 gauge wire NOTE Crimp connections should never be used on solid conductor wire Ensure that the transformer can handle the power requirements of the system No more than three dampers per zone Ductboard mounted dampers should be supported within six inches of the damper due to the weight and stress on the ductboard Installation and Design Steps 1 Decide which areas of a home or office will comprise each of the individual zones A maximum of six indivi
44. urora control is configured for IntelliZone2 all thermostats 6 The blower and the G LED should cycle off Figure 25 Checking the Shaft Position Indicator 7 All dampers should start to close immediately After approximately 90 seconas all dampers should be completely closed Check the shaft position indicator Damper Open 7 Damper Closed on all damper actuators shown in Figure 25 CCW CW Rotate by hand NOTES To cycle dampers open and closed access the PAN Test Mode Screen in the Installer Setup mode on the O IntelliZone2 MasterStat Once here each damper can be cycled individually by pushing the specific zone damper button to check for proper operation Central Zone mode can also be used to open all dampers Manual Release Button Shaft End Position Indicator 23 INTELLIZONE2 INSTALLATION MANUAL System Startup and Checkout cont In the following procedure check for proper calls on the Status Screen ZONE STATUS esc System Checkout 1 Set all of the zone thermostats to the cooling mode 2 Reduce the cooling set point to 2 below the actual zone temperature on all thermostats 3 First stage cooling should energize after a delay 4 Besure the compressor and blower are activated Check the fan speed LEDs and compare to the Blower Speed tables 5 Decrease the cooling set point two more degrees and check to see that the fan speed increases and second sta
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