Professional Documents
Culture Documents
WeatherMaker Two-Zone
Installation and Start-Up Instructions
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
Safety Considerations.....................................................................1
Installation Considerations.............................................................1
Introduction ....................................................................................1
Installation...................................................................................1-4
Sequence Of Operation...............................................................4-8
Thermostat Wiring.................................................................7-8
Troubleshooting ...................................................................9-11
Wiring Diagrams.....................................................................11-19
Care And Maintenance ................................................................20
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 information or assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this product. 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 requirements.
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 word DANGER, WARNING, or CAUTION. These words are used with the safety-alert symbol. DANGER 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 non-condensing area with ambients between 32F
and 120F.
2. Use vibration isolators (flex connectors) on zone dampers and
ductwork to minimize noise.
3. Place dampers away from areas that may be noise sensitive.
4. TXV is required in air conditioning and heat pump applications.
5. Use separate isolated transformer to supply power to WeatherMaker Two-Zone Center. (40va minimum, class 2, transformer, field supplied)
COMFORT ZONING
Y2 T'stat Equpimt
RC-RH
Jumper
Y1
HP
Fnc
R
Fnc
HP Emergency
W1
Heat
W2 DTO Fnc Ht
On
C
Off w/oF
Off
On w/F
G Y2 Y1 R W1 W2
C
Sensors
DX
Duct
24 VAC
Z C1
o
n Op
e
1 C
Z C1
o
n Op
e
2 C
SYSTEM
G Y1 Y2
WARNING!
HOT parts
under this label
Rev
W1 W2
RC B O Y2 Y1 W1 W2 G
RH
Equipment Term.
A95243
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 1 4 4
PC 101
Catalog No. 809-573
Printed in U.S.A.
Form ZONEKIT-2SI
Pg 1
8-95
Replaces: ZONEKIT-1SI
Tab 3a 5a 2a 5a
Step 2Wiring
insulate over the actuator assembly. Make sure insulation does not
interfere with operation of actuator.
Before insulating the ductwork, check for proper damper operation. Apply 24vac between COM and OPN to open the damper and
COM and CLS to close the damper. (See Fig. 3.) The damper will
modulate counter-clockwise to open and clockwise to close.
MOUNTING
HUB
AIRFLOW
AIRFLOW
All wiring must comply with local, state, and national codes.
POSITION
INDICATOR
45
ACTUATOR
HOUSING
CLS
COM
OPN
QUICK BLADE
RELEASE
BUTTON
(RED)
MOUNTING
BRACKET
FIELD
INSTALLED
POWER WIRING
A95096
ANGULAR
ROTATION
STOPS
MOUNTING
BRACKET
SUPPLY
FLEX
CONNECTOR
ZONE DAMPER
A95129
ACTUATOR
A95128
/ 2 STEEL STRAP
FLEXIBLE
DUCT
A95130
ZONE
DAMPER
A95132
S-LOCK
1/ 2
STEEL STRAP
SUPPLY
AIR DUCT
DRIVE
ZONE
DAMPER
A95133
A92478
FIBROUS
GLASS
DUCTWORK
FIELD
SUPPLIED
SCREWS
ZONE
DAMPER
2 TO 3
A92480
A95131
NOTE: All zone dampers and ductwork must be properly supported according to local codes or SMACNA standards.
NOTE: There should be a minimum of 4 ft between the zone
damper and the first branch duct if more than 1 branch duct is
downstream of the zone damper.
ROUND FLEXIBLE DUCTWORK
1 1/ 2 TO 2
INSULATION
A95134
Energized
Y1/W1
W2
De-energized
Pump
2-Stage Heat Pump
Y1
Y2
Energized
Y1/W1
W2
De-energized
Cooling Only, any
Y1
Y2
W1
W2
Heater Type
Carrier electronic non-programmable and programmable thermostats can be connected to the WeatherMaker Two-Zone. See
pre-sale literature for thermostat part numbers.
NOTE: The zone control board is only capable of 2-stage heat
and 2-stage cool operation. Fig. 13 and 14 will reflect these
applications only. Review and understand the following items
before installing.
THERMOSTAT SETUP
1. Thermostat will not operate unless both R and C are connected
to zone module input.
2. If selected thermostat is a heat pump (HP) or 2-speed (2S)
model, convert thermostat to air conditioning operation. This
will assure that Y signals are generated for cooling, and W
signals are generated for heating from thermostat to zone
module input. The thermostat O/W2 output will now be the
second-stage heat call. If installation is a heat pump system,
the zone control board will provide proper output signal to
heat pump.
3. Select Zoning option on thermostat. This will disable the
Timeguard and 4-cycle per hr (cph) protection built into
thermostat. Let zone control board perform the Timeguard and
cycle protection. Refer to thermostat Installation Instruction
under Zoning for more detail.
Whenever WeatherMaker Two-Zone is providing heating or cooling, the zone within the home that is asking for the conditioned air
will always have its damper fully open. The other zone in the
system may or may not have an open damper depending upon its
particular needs. If the ductwork is too small (or the air
conditioner/heater is too large), then the zone requiring the
conditioned air may not be able to take enough air to allow your
equipment to operate properly. WeatherMaker Two-Zone will
detect this, and open up the closed damper allowing the equipment
to continue to operate.
Thermostat
Zone 2
Y2
Y1
R
W1
W2
C
2
L
CL
Zone
1
OP
Damper
C
CL
Zone
2
OP
Damper
C
1
Duct
G
Y1 W1 C DX
Y2 R W2
Thermostat
Zone 1
Rc
B
Sensors
Y1 W2 Rh 24v
Y2 W1 G
Equipment
24 VAC
Power
A95122
ZONE 1
I/O CENTER CONNECTIONS
G
Y2 Y1
Y2 Y1
W1 W2
W1 W2
ZONE 2
I/O CENTER CONNECTIONS
Y2 Y1
*
C
Y2 Y1
THERMOSTAT/SUBBASE
CONNECTIONS
W1 W2
W1 W2
*
C
THERMOSTAT/SUBBASE
CONNECTIONS
A93494
A93495
NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL AC
TWO-ZONE BOARD
THERMOSTAT
INPUT
NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL HP
R
24 VAC COMM
HEAT STAGE 1
W/W1
W1
Y1
COOL STAGE 1
Y/Y2
Y1
FAN
24 VAC HOT
24 VAC COMM
HEAT STAGE 1
W/W1
COOL STAGE 1
Y/Y2
24 VAC HOT
FAN
W1
Y2
SINGLE-STAGE HEAT,
SINGLE-STAGE COOL
SEE NOTES 1 AND 3
HEAT STAGE 2
O/W2
N/A
Y1
N/A
N/A
OUTDOOR
SENSOR
CONNECTION
24 VAC COMM
HEAT STAGE 1
W/W1
W1
COOL STAGE 2
Y/Y2
Y2
HEAT STAGE 2
O/W2
W2
COOL STAGE 1
Y1
Y1
N/A
TROUBLE
OUTDOOR
SENSOR
CONNECTION
S1
S2
S1
W2
TWO-STAGE HEAT,
SINGLE-STAGE COOL
SEE NOTES 1, 2, AND 3
S2
TWO-ZONE BOARD
THERMOSTAT
INPUT
24 VAC HOT
FAN
Y2
W2
NON-PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL 2S
TWO-ZONE BOARD
THERMOSTAT
INPUT
TWO-STAGE HEAT,
TWO-STAGE COOL
SEE NOTES 1, 2, AND 3
A95213
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL AC
24 VAC HOT
FAN
TWO-ZONE BOARD
THERMOSTAT
INPUT
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL HP
24 VAC HOT
FAN
HEAT STAGE 1
COOL STAGE 1
Y/Y2
Y1
COOL STAGE 1
Y/Y2
N/A
O/W2
W2
HEAT STAGE 2
O/W2
N/A
Y1/W2
Y2
N/A
Y1/W2
24 VAC COMM
W1
Y1
W2
N/A
N/A
N/A
N/A
SINGLE-STAGE HEAT,
SINGLE-STAGE COOL
S2
OUTDOOR
SENSOR
CONNECTION
PROGRAMMABLE
ELECTRONIC
THERMOSTAT
MODEL 2S
COOL STAGE 1
FAN
S1
S2
Y2
C
TWO-STAGE HEAT,
SINGLE-STAGE COOL
SEE NOTES 1, 2, AND 3
TWO-ZONE BOARD
THERMOSTAT
INPUT
Y1/W2
Y1
HEAT STAGE 1
W/W1
W1
COOL STAGE 2
Y/Y2
Y2
HEAT STAGE 2
O/W2
W2
24 VAC HOT
24 VAC COMM
N/A
TROUBLE
OUTDOOR
SENSOR
CONNECTION
HEAT STAGE 1
S1
W/W1
24 VAC COMM
OUTDOOR
SENSOR
CONNECTION
W/W1
W1
TWO-ZONE BOARD
THERMOSTAT
INPUT
S1
S2
TWO-STAGE HEAT,
TWO-STAGE COOL
SEE NOTES 1, 2, AND 3
A95214
Step 7TROUBLESHOOTING
1
Tstat
NORMAL HEAT
PUMP SETTING
Equipmt
EQUIPMENT
SHUTOFF
TEMPERATURE
155F
155F
175F
147F
147F
164F
138F
138F
153F
130F
130F
143F
122F
122F
132F
113F
113F
121F
105F
105F
110F
W/O FANWhen demand for heating exists, fan is controlled by gas/electric furnace.
Fnc Ht
W/FANWhen demand for heating exists,
fan comes on immediately (heat pump
only).
DTO
OFF
I
J
K
L
Table 2Troubleshooting
LED CODES
Green flashes 1 time every sec and no
other LEDs are flashing.
ERROR DESCRIPTION
Normal operation.
None.
Green
times
Green
times
Green
times
Green
time
Green
times
Green
times
ACTION REQUIRED
1. Dx temperature sensor.
2. Temperature sensor is shorted.
1. Dx temperature sensor.
2. Temperature sensor is open.
10
Table 3 shows a temperature/ohm/voltage relationship to help aid in troubleshooting the WeatherMaker Two-Zone System. This table will
evaluate both the Duct/Dx Sensor operation. Use a digital multimeter to perform the following:
To verify a sensor is good, disconnect both leads from the I/O board and measure the resistance through the sensor. Match ohm reading to table
and compare temperature reading on table to ambient temperature surrounding sensor (Accuracy should be +/- 5-10 percent). Example: if
10.92k ohms are measured, this equals approximately 73F.
To verify if I/O board is normal, reattach sensor to I/O board, set meter to 5vdc, and measure voltage across terminal connections. Match voltage
reading to temperature reading in chart. The ambient temperature surrounding sensor should be +/- 5-10 percent. Example: 2.61vdc is
approximately 73F.
OHMS
34367
32654
31030
29498
28052
26686
25396
24171
23013
21918
20883
19903
18972
18090
17255
16464
15714
15000
14323
13681
13071
12493
11942
11418
VOLTS
3.873
3.828
3.781
3.734
3.686
3.637
3.587
3.537
3.485
3.433
3.381
3.328
3.274
3.220
3.165
3.111
3.056
3.000
2.944
2.889
2.833
2.777
2.721
2.666
TEMP F
73
75
77
79
81
82
84
86
88
90
91
93
95
97
99
100
102
104
106
108
109
111
113
115
OHMS
10921
10449
10000
9571
9164
8776
8407
8056
7720
7401
7096
6806
6530
6266
6014
5774
5546
5327
5117
4918
4727
4544
4370
4203
VOLTS
2.610
2.555
2.500
2.445
2.391
2.337
2.284
2.231
2.178
2.127
2.075
2.025
1.975
1.926
1.878
1.830
1.784
1.738
1.692
1.648
1.605
1.562
1.521
1.480
TEMP F
117
118
120
122
124
126
127
129
131
133
135
136
138
140
142
144
145
147
149
151
153
154
156
158
OHMS
4042
3889
3743
3603
3469
3340
3217
3099
2986
2878
2774
2675
2579
2488
2400
2315
2235
2157
2083
2011
1943
1876
1813
1752
VOLTS
1.439
1.400
1.362
1.324
1.288
1.252
1.217
1.183
1.150
1.117
1.086
1.055
1.025
0.996
0.968
0.940
0.913
0.887
0.862
0.837
0.813
0.790
0.767
0.745
TEMP F
160
162
163
165
167
169
171
172
174
176
178
180
181
183
185
187
189
190
OHMS
1693
1637
1582
1530
1480
1431
1385
1340
1297
1255
1215
1177
1140
1104
1010
1037
1005
974
VOLTS
0.724
0.703
0.683
0.663
0.645
0.626
0.608
0.591
0.574
0.558
0.542
0.527
0.512
0.497
0.483
0.470
0.457
0.444
Timeguard
11
OUTDOOR UNIT
Single-Stage
Air Conditioner
Two-Speed
Air Conditioner
(38TD)
FK4B
C*
FA4A
FB4A
FC4B
FK4A
FK4B
C*
OUTDOOR UNIT
Single-Speed
Air Conditioner
Two-Speed
Air Conditioner
(38TD)
58SXB
A* B
C D*
E F*
58MXA
58MCA
58MVP
58TUA
58TMA
12
STANDARD
SINGLE-SPEED
AIR CONDITIONER
TWO-ZONE SYSTEM
STANDARD
SINGLE-SPEED
AIR CONDITIONER
TWO-ZONE SYSTEM
RH
RH
FAN COIL
FAN COIL
G
C
W2
W2
C
W1
W1
Y1
W2
Y1
W2
Y2
W3
Y2
Y/Y2
Y1
O
O
RC
RC
W3
E
B
A93496
A93497
2-SPEED
AIR CONDITIONER
2-SPEED
AIR CONDITIONER
TWO-ZONE SYSTEM
RH
TWO-ZONE SYSTEM
FAN COIL
G
R
W2
W1
Y1
W2
FAN COIL
RH
G
W2
W2
W1
Y2
Y1
Y2
Y1
Y2
W3
W3
RC
Y1
Y2
RC
D
H
R1
A93499
13
2-SPEED
AIR CONDITIONER
TWO-ZONE SYSTEM
FAN COIL
RH
G
W2
W2
W1
Y1
Y1
Y1
Y/Y2
Y2
Y2
W3
B
RC
E
A93500
14
STANDARD
SINGLE-SPEED
HEAT PUMP
TWO-ZONE SYSTEM
STANDARD
SINGLE-SPEED
HEAT PUMP
TWO-ZONE SYSTEM
RH
RH
FAN COIL
FAN COIL
G
C
W2
W2
R
W1
W1
Y1
W2
Y2
W3
W2
Y1
Y1
Y2
W2
W2
Y/Y2
O
O
RC
RC
W3
E
A
A95123
A95124
2-SPEED
HEAT PUMP
FAN COIL
2-SPEED
HEAT PUMP
TWO-ZONE SYSTEM
RH
TWO-ZONE SYSTEM
FAN COIL
G
R
W2
RH
W2
W2
W2
Y2
W1
W1
Y1
W2
W2
Y1
Y1
Y2
W3
W3
Y2
E
W3
W3
RC
RC
Y2
Y1
R1
A95126
A95125
C
Fig. 16Wiring Diagrams (Fan Coil With Heat Pump)
15
2-SPEED
HEAT PUMP
FAN COIL
TWO-ZONE SYSTEM
RH
W2
W2
W2
Y1
Y1
Y1
Y/Y2
Y2
Y2
W3
W3
W1
O
B
RC
A95127
16
TWO-ZONE SYSTEM
STANDARD
SINGLE-SPEED
AIR CONDITIONER
TWO-ZONE SYSTEM
STANDARD
SINGLE-SPEED
AIR CONDITIONER
RH
G
RH
VARIABLE-SPEED
FURNACE
FURNACE
G
R
W2
W2
W1
Y1
Y1
Y2
W1
Y2
B
(KGATT0101VSP)
RC
RC
RELAY
COIL
1
Black
re
en
A93502
A93501
(P5)
CONNECTION AT
CONTROL BOARD
2-SPEED
AIR CONDITIONER
RH
2-SPEED
AIR CONDITIONER
R
G
VARIABLE-SPEED
FURNACE
TWO-ZONE SYSTEM
VARIABLE-SPEED
FURNACE
TWO-ZONE SYSTEM
W2
RH
W1
Y1
W2
W1
Y1
Y1
Y2
Y1
Y2
O
B
Y2
RC
RC
Y2
(KGATT0101VSP)
RELAY
COIL
1
TO
FURNACE
BLOWER
MOTOR
Black
re
en
ACCESSORY
INTERFACE KIT
(P5)
CONNECTION AT
CONTROL BOARD
ACCESSORY
INTERFACE KIT
KSAIF01012SP
(Required)
TO
FURNACE
BLOWER
MOTOR
A93503
KSAIF01012SP
(Required)
A93504
2-SPEED
AIR CONDITIONER
2-SPEED
AIR CONDITIONER
VARIABLE-SPEED
FURNACE
TWO-ZONE SYSTEM
RH
RH
VARIABLE-SPEED
FURNACE
TWO-ZONE SYSTEM
W2
W2
C
W1
W1
Y2
Y1
Y2
Y2
Y1
Y1
Y1
L
Y2
RC
RC
A93506
(KGATT0101VSP)
A93505
RELAY
COIL
Black
re
en
(P5)
CONNECTION AT
CONTROL BOARD
F
2-SPEED
AIR CONDITIONER
TWO-ZONE SYSTEM
RH
2-SPEED
AIR CONDITIONER
TWO-ZONE SYSTEM
RH
FURNACE
FURNACE
G
R
W2
W1
W1
Y1
Y1
Y1
W2
Y2
Y2
Y1
RC
RC
Y2
Y2
R1
A93508
R1
A93507
2-SPEED
AIR CONDITIONER
STANDARD
SINGLE-SPEED
AIR CONDITIONER
TWO-ZONE SYSTEM
TWO-ZONE SYSTEM
FURNACE
FURNACE
RH
RH
W2
W2
W2
W2
W/W1
W/W1
W1
Y1
Y/Y2
W1
Y/Y2
Y2
Y1
Y2
Y2
RC
RC
Y1
L
A93509
J
Fig. 17Wiring Diagrams (Furnace With Air Conditioner) Continued
CARE AND MAINTENANCE
For continuing optimum performance and to minimize possible
equipment failure, it is essential that periodic maintenance be
performed on this equipment. Consult your servicing contractor for
the proper frequency of maintenance. Frequency may vary depending upon geographic areas.
19
A93510
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
Unit Familiarization
Maintenance
Installation Overview
Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training
zonekit2
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 1 4 4
PC 101
Catalog No. 809-573
Printed in U.S.A.
Form ZONEKIT-2SI
Pg 20
8-95
Replaces: ZONEKIT-1SI
Tab 3a 5a 2a 5a