Carrier 2-STAGE 58TMA Instruction Manual

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ZONEKIT4ZCAR
Comfort Zone
Installation and Start-Up Instructions
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
Safety Consideration ......................................................................1
Installation Considerations..........................................................1-2
Introduction ....................................................................................2
Installation.................................................................................2-18
Check Equipment and Jobsite ..................................................2
Wiring........................................................................................2
Shielded Cable.....................................................................2
Install Comfort Zone Center ....................................................3
Install Zone Dampers ............................................................3-5
Round Metal Duct Work.....................................................4
Rectangular Metal Duct Work............................................4
Round Flexible Duct Work..............................................4-5
Rectangular Fibrous Glass Duct Work...............................5
Install Barometric Bypass Dampers.........................................5
Install Duct Temperature Sensor ..........................................5-6
Install Dx Coil Sensor ..............................................................6
Install Four Zone Controller.....................................................6
Install Remote Room Sensor or Smart Sensors ......................6
Comfort Zone System Wiring Diagram...................................7
Sequence Of Operation.............................................................6-12
Temperature Setpoints.........................................................6
Heating and Cooling Comfort Setpoints.....................6 & 8
Sequence of Events For a Normal Heating
or Cooling Cycle............................................................8
Selection of a Reference Zone In The System ..................8
Pre-positioning Dampers And Starting
The System Fan................................................................8-9
Controlling The Zone Dampers ..........................................9
Operating The Heating And Cooling Equipment...............9
Control Strategy For Heating/Cooling Stages...............9-10
Configuration Options For Equipment Operation............10
Relay Pack To HVAC Equipment Connections ..............10
Starting The HVAC Equipment ..................................10-11
Stage Control During Equipment Operation...............11-12
Configuring Four Zone Controller....................................12-13
Programmable Options Settings ..................................12-13
Programmable Options Toggles........................................13
Wiring Diagram Reference Tables.........................................13
Start Up..............................................................................13-14
Programming Schedules....................................................14-16
System Switches...........................................................14-15
Controller Display .............................................................15
Zone Selector Dial .......................................................15-16
Accessories ........................................................................16-17
Troubleshooting ......................................................................17
Care And Maintenance ................................................................17
Toggle Summary Table................................................................18
Operating Problem Table.............................................................19
Storage Failure Error Table.........................................................20
Hardware Failure Error Table......................................................21
Wiring Diagrams.....................................................................22-31
Configuration Table .....................................................................32
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a qualified
installer, service agency or your distributor or branch for informa-
tion or assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this prod-
uct. Refer to the individual instructions packaged with the kits or
accessories when installing.
Follow all safety codes and wear safety glasses. Have fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult local
and state building codes and Sheet Metal and Air Conditioning
National Association (SMACNA) for special installation require-
ments.
Recognize safety information. This is the safety-alert symbol
.
When you see this symbol on the unit or in instructions and
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, or CAU-
TION. These words are used with the safety-alert symbol. DAN-
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage.
INSTALLATION CONSIDERATIONS
1. Install in a non-condensing area with ambients between 32°F
and 120°F.
Fig. 1Comfort Zone System
A93208
72
68
2:45
COOL HEAT
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1144
Tab 3a 5a 2a 5a
PC 101 Catalog No. 809-568 Printed in U.S.A. Form ZONEKIT4-1SI Pg 1 7-95 Replaces: 920415-3SI
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1 2 ... 32

Summary of Contents

Page 1 - Comfort Zone

ZONEKIT4ZCARComfort ZoneInstallation and Start-Up InstructionsNOTE: Read the entire instruction manual before starting theinstallation.TABLE OF CONTEN

Page 2

heater. The electric strip heat is much more expensive to operatewhen comparing cost per unit of heat. Because auxiliary stages ofheating tend to be m

Page 3 - An ISOSAT-02

NOTE: Comfort Zone uses a 3-minute timer to delay start ofsecond-stage (heating or cooling). This timer is started wheneverfirst-stage heating or cool

Page 4 - Comfort Zone

then temperature at which first stage will be shut down will beoffset 5°F above limit value (110°F to 114°F). If limit temperatureis between 110°F and

Page 5

If a value of 105 to 110 is selected (second-stage heating isturned off at this value) then the first-stage high temperaturetrip limit is the programm

Page 6

7. Write down on a piece of paper AND GIVE TO THEOWNER a list showing what rooms are controlled by whatdampers, and their corresponding zone numbers.

Page 7

Cool SwitchOFF—Cooling will not come on.AUTO—Cooling will come on when any zone is more than 1.5°Fabove desired cool setpoint.Fan SwitchON—Fan will st

Page 8 - (INTERFACE BOARD)

Press ADVANCE TIME/DAY button until desired start timeis displayed.6. Adjust setpoints.Adjust setpoints using up and down buttons until desiredtempera

Page 9 - Table 2—Zone Damper Positions

OUTSIDE AIR TEMPERATURE SENSORThe Outside Air Temperature Sensor must be used whenever anOutside Air Damper is installed. An Outside Air TemperatureSe

Page 10

Table 11—Toggle SummaryTOGGLE SETTING ON OFF DEFAULT(T1)-Timeguard OverrideTimeguard delay is 30 sec, overrides 5-minute delay be-tween de-energizing

Page 11 - Vs. Zone Demand

Table 12—Operating ProblemsSYMPTOM POSSIBLE CAUSENo DisplayThermostat is not receiving power.1. Verify that comfort zone center is receiving 24 vac. (

Page 12

2. Use vibration isolators (flex connectors) on zone dampers andduct work to minimize noise.3. Place dampers away from areas that may be noise sensiti

Page 13 - For Fig. 21 and 22

Table 13—Storage Failure ErrorsError Display (Dial Position T4) must be turned on.SF ERROR CODE DESCRIPTION SOLUTION01 Temperature Programming Error R

Page 14 - Fig. 18—Four Zone Controller

Table 14—Hardware Failure ErrorsError Display (Dial Position T4) must be turned on.HF ERROR CODE DESCRIPTION SOLUTION40 Zone 1 Temperature SensorBad s

Page 15

UNIT 24 VAC (R)CYSTANDARDSINGLE SPEEDAIR CONDITIONERYellowRedBlueWhiteBrownGreenOrangeBlackCOOL 1 (Y1)COOL 2 (Y2)HEAT 1 (W1)HEAT 2 (W2)FAN (G)RV-COO

Page 16

Fig. 19—Typical Wiring Diagrams (Fan Coil with Air Conditioner) ContinuedA94034EUNIT 24 VAC (R)2-SPEEDAIR CONDITIONER(38TD)YellowRedBlueWhiteBrownGr

Page 17

UNIT 24 VAC (R)CYSTANDARDSINGLE SPEEDAIR CONDITIONERYellowRedBlueWhiteBrownGreenOrangeBlackCOOL 1 (Y1)COOL 2 (Y2)HEAT 1 (W1)HEAT 2 (W2)FAN (G)RV-COO

Page 18 - Table 11—Toggle Summary

UNIT 24 VAC (R)Y2RC2-SPEEDAIR CONDITIONER(38TD)YellowRedBlueWhiteBrownGreenOrangeBlackCOOL 1 (Y1)COOL 2 (Y2)HEAT 1 (W1)HEAT 2 (W2)FAN (G)RV-COOL (O)

Page 19 - Table 12—Operating Problems

Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) ContinuedLocking furnace into "low fire" may help prevent over conditioning i

Page 20

Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump)UNIT 24 VAC (R)STANDARDSINGLE SPEEDHEAT PUMPYellowRedBlueWhiteBrownGreenOrangeBlackCOOL 1 (

Page 21

Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump) ContinuedUNIT 24 VAC (R)2-SPEEDHEAT PUMP(38YD)YellowRedBlueWhiteBrownGreenOrangeBlackCOOL

Page 22

Fig. 22—Typical Wiring Diagram (Furnace with Heat Pump)UNIT 24 VAC (R)YW2STANDARDSINGLE SPEEDHEAT PUMPYellowRedBlueWhiteBrownGreenOrangeBlackCOOL 1

Page 23

Table 1—Wiring RequirementsFROMCOMFORT ZONECENTER TONO.OF WIRESGAGEMAX.LENGTH(FT)Four Zone Controller3‡ 18/22 200/1005‡ 18/22 200/100Remote Room Sen-s

Page 24

Fig. 22—Typical Wiring Diagrams (Furnace with Heat Pump) ContinuedUNIT 24 VAC (R)CRY2L2-SPEEDHEAT PUMP(38YD)YellowRedBlueWhiteBrownGreenOrangeBlackC

Page 25

Fig. 22—Typical Wiring Diagrams (Furnace with Heat Pump) ContinuedUNIT 24 VAC (R)CRY1O2-SPEEDHEAT PUMP(38YD)YellowRedBlueWhiteBrownGreenOrangeBlackC

Page 26

Comfort Zone Configuration TableTOGGLE DESCRIPTIONFACTORYDEFAULTRECORDJOB SETTINGT1 Timeguard Override OFFT2 Celsius Temperature Display OFFT3 2400 Ba

Page 27

Before insulating the duct work, check for proper damper opera-tion. Apply the 24vac between COM and OPN to open the damperand COM and CLS to close th

Page 28

2. Secure flexible duct to zone damper using SMACNA or otherapproved method.3. Properly seal joint using duct tape, mastic, or other approvedmethod. D

Page 29

5. Insert 2-conductor wiring through 1 of pre-drilled holes in sideof back plate.6. Connect sensor to 2-wire conductor using provided wire nuts.(See F

Page 30

Fig. 16—Comfort Zone System Wiring DiagramA94311Zone DampersDx CoilSensor(optional)Outside AirSensor(optional)DuctSensorZone 2*Zone 3*Zone 4*Zon

Page 31

Changing the base temperatures will change the ComfortTemperature Setpoints used in the system schedules. Alwaysset the Base Temperatures prior to pro

Page 32 - Tab 3a 5a 2a 5a

If Fan Switch on 4 zone controller is set to ON instead of Auto,then system fan will run continuously. Any time Comfort Zone isoperating fan, it will

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