Carrier Air Conditioner ZONEKIT4ZCAR User Manual

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  
2:45  
72  
68  
COOL  
HEAT  
A93208  
Fig. 1Comfort Zone System  
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.  
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  
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.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 3a 5a 2a 5a  
1
1
4
4
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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NOTE 2  
NOTE 2  
PORT #1  
PORT #2  
PORT #1  
PORT #2  
ISOSAT-01  
ISOSAT-01  
Comfort  
Zone  
I/O  
Comfort  
Zone  
I/O  
Comfort  
Zone  
I/O  
Comfort  
Zone  
I/O  
Comfort  
Zone  
I/O  
Comfort  
Zone  
I/O  
ISOSAT BUS  
PORT #1  
ISOSAT BUS  
PORT #1  
NOTE 1  
NOTE 2  
NOTE 1  
NOTE 2  
SHIELD DRAIN WIRE (TYP)  
SHIELD DRAIN WIRE (TYP)  
ISOSAT-01  
ISOSAT-01  
PORT #2  
PORT #2  
DEVICE BUS (TYP)  
DEVICE BUS (TYP)  
SHIELD DRAIN WIRE (TYP)  
PORT #1  
SHIELD DRAIN WIRE (TYP)  
PORT #1  
ISOSAT-01  
PORT #2  
ISOSAT-01  
PORT #2  
NOTES:  
1. Use butt splices, or solder,  
for shield connections. Then  
tape up shield.  
NOTES:  
1. Use butt splices, or solder,  
for shield connections. Then  
tape up shield.  
2. Do not connect the shield  
drain wire at the end of  
Communication Bus. Cut  
and tape up to avoid shorting.  
PORT #1  
PORT #1  
2. Do not connect the shield  
drain wire at the end of  
Communication Bus. Cut  
and tape up to avoid shorting.  
ISOSAT-01  
PORT #2  
ISOSAT-01  
PORT #2  
BUILDING GROUND  
TO PERSONAL COMPUTER OR MODEM  
A93249  
Fig. 3—Typical Communications Network  
PORT #1  
PORT #2  
ISOSAT-02  
Table 1—Wiring Requirements  
FROM  
COMFORT ZONE  
CENTER TO  
MAX.  
LENGTH  
(FT)  
NO.  
OF WIRES  
GAGE  
BUILDING GROUND  
3‡  
5‡  
18/22  
18/22  
200/100  
200/100  
A93250  
Four Zone Controller  
Fig. 4—Communication Network With  
An ISOSAT-02  
Remote Room Sen-  
sors  
2‡  
18/22  
200/100  
Remote Duct Sensors  
Dx Coil Sensor  
2‡  
2‡  
18/22  
18/22  
200/100  
200/100  
To prevent possible damage to Comfort Zone Center, do not  
mount on plenum, duct work, or flush against furnace.  
Home Access  
Module  
3‡  
18/22  
1000/100  
ISOSAT*  
3‡  
2
18/22  
18  
1000/100  
75  
1. Separate Comfort Zone Center cover. (See Fig. 5)  
Transformer†  
2. Mount back plate of center cover to wall using screws and  
wall anchors provided.  
* When using ISOSATS in interfacing multiple buses together, the length of  
wiring between ISOSATS cannot exceed 4000 ft with 18 gage.  
† 24 vac, 50-75 va  
3. Level back plate and tighten screws.  
‡ Shielded cable recommended to reduce noise interference.  
Step 4—Install Zone Dampers  
Step 3—Install Comfort Zone Center  
NOTE: The Comfort Zone System is approved for indoor use  
only and should never be installed with any of its components  
exposed to the elements. The enclosure must be installed with  
center cover to help prevent damage from other sources. Do not  
mount Comfort Zone Center where it will be accessible to  
children. Do not locate center in areas of the home that are noise  
sensitive since relays are energized and de-energized during  
operation and may be an annoyance. Install Comfort Zone in an  
area with a temperature range between 32°F and 120° F.  
IMPORTANT: If conditions exist for possible condensing, motor  
must be positioned for adequate draining. (See Fig. 6.)  
NOTE: If a multi-damper enabler is used to link dampers  
together, add 5va per damper to the transformer power supply  
rating. Reference multi-damper enabler Installation Instructions.  
Zone dampers may be installed in any direction.  
Install dampers so that actuator is visible for inspection and  
accessible in the event it would ever need to be serviced. The black  
mark on the end of damper shaft represents the position of damper  
blade.  
Install Comfort Zone Center in either a vertical or horizontal  
position. Locate in an area that is easily accessible in case  
servicing should be required.  
NOTE: Insulate damper using 1-1/2 in. insulation (check local  
codes). In areas where excessive condensing may occur, carefully  
insulate over the actuator assembly. Make sure insulation does not  
interfere with operation of actuator.  
NOTE: Four vent plugs and 2 bushings have been supplied. Snap  
bushings in the 1-in. diameter holes that are to be used for wiring  
and place plugs in remaining holes.  
3
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COMFORT ZONE CENTER  
BACK PLATE  
INTERCHANGEABLE  
HOLE PLUGS AND  
BUSHINGS  
POSITION  
INDICATOR  
MOUNTING  
HUB  
ANGULAR  
ROTATION  
STOPS  
45  
ACTUATOR  
HOUSING  
Comfort Zone  
Center  
QUICK BLADE  
RELEASE  
BUTTON  
COMFORT ZONE  
CENTER COVER  
MOUNTING  
BRACKET  
(RED)  
FIELD  
INSTALLED  
POWER WIRING  
A93247  
Fig. 5—Comfort Zone Center  
A95096  
Fig. 7—Damper 24-vac Connections  
DAMPER  
MOUNTING  
BRACKET  
SUPPLY  
FLEX  
ZONE DAMPER  
CONNECTOR  
A95129  
Fig. 8—Round Metal Duct Work  
1/2 STEEL STRAP  
ACTUATOR  
A95128  
Fig. 6—Damper Motor Positioning  
Before insulating the duct work, check for proper damper opera-  
tion. Apply the 24vac between COM and OPN to open the damper  
and COM and CLS to close the damper. (See Fig. 7.) The damper  
will modulate counter-clockwise to open and clockwise to close.  
A95130  
Fig. 9—Insulated Round Metal Duct Work  
If in an emergency it becomes necessary to force a damper open,  
manually press in the red quick blade release button with one hand  
and turn the mounting hub to reposition the damper shaft. Release  
the button to hold the damper shaft in the new position.  
NOTE: All zone dampers and duct work must be properly  
supported according to local codes or SMACNA standards.  
RECTANGULAR METAL DUCT WORK  
1. Make connections using S-lock and drives. (See Fig. 10.)  
To avoid noise and vibration, do not hard mount dampers to any  
solid structure such as joists.  
2. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
ROUND METAL DUCT WORK  
3. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check  
your local codes.)  
IMPORTANT: If application exists with all metal duct work  
without insulation, flex connectors must be used on each end of  
zone dampers to avoid noise and vibration.  
NOTE: All zone dampers and duct work must be properly  
supported according to local codes or SMACNA standards.  
1. Crimp end of branch duct.  
NOTE: There should be a minimum of 4 ft between zone damper  
and first branch duct if more than 1 branch duct is downstream of  
zone damper.  
2. Slip end of zone damper over end of duct work. Use  
self-tapping sheet metal screw to secure. (See Fig. 8.)  
3. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
ROUND FLEXIBLE DUCT WORK  
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check  
your local codes.)  
1. Slip 1 end of flexible duct work over 1 end of zone damper.  
(See Fig. 12.)  
4
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1/2STEEL STRAP  
S-LOCK  
SUPPLY  
A95133  
AIR DUCT  
Fig. 13—Insulated Round Flexible Duct Work  
DRIVE  
ZONE  
DAMPER  
FIBROUS  
GLASS  
DUCTWORK  
FIELD  
SUPPLIED  
SCREWS  
A92478  
ZONE  
DAMPER  
Fig. 10—Rectangular Metal Duct Work  
11/2 " TO 2"  
INSULATION  
2TO 3″  
A92480  
Fig. 14—Rectangular Fibrous Glass Duct Work  
11/2TO 2″  
INSULATION  
A95131  
Fig. 11—Insulated Rectangular Metal Duct Work  
A95134  
Fig. 15—Insulated Rectangular Fibrous Glass Duct  
Work  
ZONE  
DAMPER  
FLEXIBLE  
DUCT  
Step 5—Install Barometric Bypass Damper  
NOTE: The barometric bypass damper is a critical part of  
Comfort Zone System for control of minimum airflow and noise  
reduction. It is recommended that the bypass be installed.  
The bypass should be installed according to local codes and  
SMACNA standards. Be sure bypass is properly supported.  
For proper installation, refer to Installation Instructions packaged  
with barometric bypass.  
A95132  
Fig 12—Round Flexible Duct Work  
2. Secure flexible duct to zone damper using SMACNA or other  
approved method.  
Failure to properly install bypass damper can cause perma-  
nent damage to the HVAC equipment. For single speed  
furnace applications bypass air must never exceed 25 percent.  
3. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check  
your local codes.)  
Step 6—Install Duct Temperature Sensor  
Locate duct temperature sensor in main supply trunk after heating  
and cooling coil and before bypass damper and first branch. The  
duct temperature sensor must be radiant shielded to prevent heat  
from affecting correct air temperature.  
NOTE: All zone dampers and duct work must be properly  
supported according to local codes or SMACNA standards.  
RECTANGULAR FIBROUS GLASS DUCT WORK  
1. Insert 1 end of zone damper into 1 end of fibrous glass duct  
work approximately 2- to 3-in. (See Fig. 14.)  
1. Drill a 7/8-in. hole at location in unit where sensor will be  
installed.  
2. Screw field-supplied screws and tabs into zone damper.  
2. Remove cover and insert sensor probe through 7/8-in. hole.  
3. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
3. Drill two 1/16-in. holes to accept No. 6 screws through  
pre-drilled holes in duct temperature sensor back plate.  
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check  
your local codes.)  
4. Use two No. 6 sheet metal screws included with sensor to  
mount duct temperature sensor back plate to unit.  
5
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5. Insert 2-conductor wiring through 1 of pre-drilled holes in side  
of back plate.  
3. Connect black or white wire to terminal labeled B- and  
connect red wire to terminal labeled R+.  
4. Align sensor case with base plate then press firmly until cover  
snaps into place.  
6. Connect sensor to 2-wire conductor using provided wire nuts.  
(See Fig. 16 for connection to Comfort Zone Center.)  
Step 10—Sequence of Operation  
Step 7—Install Dx Coil Sensor  
TEMPERATURE SETPOINTS  
The Dx coil temperature sensor is recommended for use in heat  
pump with fan coil applications only. The sensor should be  
installed between Dx coil and electric heaters. It measures Dx coil  
temperature and adds extra protection for high/low temperature  
limits. The range is from 30°F to 180°F. The Dx coil sensor  
interfaces to Comfort Zone Center on terminal TB-1. (See Fig. 16.)  
To activate Dx coil temperature sensor turn T-27 on. When  
activated, the Dx coil sensor has built-in LAT setpoints of 50°F  
and 45°F in the cooling mode, and 105°F and 110°F in the heating  
mode. This is non-adjustable.  
The Comfort Zone System uses 2 temperature setpoints. The  
setpoints are displayed in the left-hand window on the 4 zone  
controller. (See Fig. 18.)  
In display window, cooling setpoint is shown on upper left and  
heating setpoint is shown on lower right.  
The temperature setpoints for any of the 4 zones can be displayed  
by the 4 zone controller. When the 4 zone controller rotary switch  
points to zone 1, setpoints for zone 1 at the 4 zone controller are  
displayed. Selecting zone 2, zone 3, or zone 4 will display  
setpoints for each of these zones which use either remote room  
sensors or smart sensors. The system is not required to have all 4  
zones installed.  
Step 8—Install Four Zone Controller  
The Four Zone Controller is the zone 1 thermostat. It is recom-  
mended to locate this in the zone occupied as the living room or  
family room for maximum comfort.  
HEATING AND COOLING COMFORT SETPOINTS  
If space temperature is between heating and cooling setpoints for  
the zone, then the zone is said to be "satisfied" with respect to  
temperatures. When a zone is "satisfied" no heating or cooling  
equipment will turn on to condition the space. For example, if  
cooling setpoint is 76°F and heating setpoint is 72°F, then a space  
temperature of 73°F is assumed to be satisfactory and no heating  
or cooling of zone is required.  
DO NOT locate controller where supply air can blow directly on  
it. Avoid locating controller where heat from any lamps, appli-  
ances, or direct sunlight will affect temperature sensor on control-  
ler. Do not locate on an outside wall or next to a return air grill.  
1. Separate base plate from main body of controller.  
2. Pull 3-wire cable for communication bus and 5-wire cable for  
controller through 3/4-in. round hole on base plate. Three-wire  
cable and 5-wire cable must be separate jacketed wiring. Do  
not use one 8-wire cable. (See Fig. 17.)  
If space temperature in a zone falls below heating setpoint, then  
that zone needs to have heat added to zone which will raise space  
temperature back to heating setpoint. For example, if heating  
setpoint is 72°F and space temperature is 70°F, then space  
temperature must be raised 2 degrees in order for zone to be  
satisfied. In this case, temperature "heating demand" for zone is  
2°F. (72°F minus 70°F.)  
NOTE: Insulate or seal field wiring feed through hole to reduce  
draft.  
3. Mount base plate using provided screws, starting screw in  
round hole first then second screw in slotted hole. On drywall  
it is recommended to use provided plastic wall anchors.  
Otherwise, if space temperature in a zone rises above cooling  
setpoint, then that zone needs to have heat removed from zone  
which will lower space temperature back to cooling setpoint. For  
example, if cooling setpoint is 76°F and space temperature is 77°F,  
space temperature must be lowered 1° in order for zone to be  
satisfied. In this case, "cooling demand" for zone is 1°F. (77°F  
minus 76°F.)  
NOTE: If mounting controller using an electrical box, mount base  
plate using pair of horizontal holes.  
4. Level base plate and tighten screw in slotted hole first, then  
the screw in round hole.  
5. Connect the 3 wires for communication bus and the 5 wires for  
controller to base plate terminal screws. (See Fig. 16.) Ensure  
that there are no excess or bare wires exposed.  
Comfort Zone allows owner or installer to set ranges for comfort  
setpoints along with maximum and minimum temperatures which  
can be used by system.  
6. Plug base plate connector into back of main body and ensure  
it is secure into connector located on back of 4 zone  
controller’s main body. Ensure connectors and main body are  
secure.  
Comfort Zone allows both heating and cooling comfort setpoints  
to operate in a 14° span. The heating and cooling temperature  
"spans" can be set to allow for a selected range of operation.  
Rotary switch position 9 sets base temperatures for both heating  
and cooling spans.  
7. Align main body with base plate and snap into place.  
Step 9—Install Remote Room Sensors or  
Smart Sensors (Optional)  
When switch is set to 9, both heating and cooling base tempera-  
tures are displayed and each can be modified by using up/down  
setpoint buttons. The base temperatures are the same for all 4  
zones.  
Comfort Zone may have up to 4 zones. The 4 zone controller  
controls zone 1. Remote room sensors or smart sensors control the  
other 3 zones. If using a smart sensor, a smart sensor power pack  
must be used. The remote sensors should be located 5 ft above the  
floor and must be less than 200 ft away from Comfort Zone Center.  
If cooling base temperature is set to 68°F, then cooling comfort  
range will be 68°F to 82°F. If heating base temperature is set to  
54°F, then heating comfort range will be 54°F to 68°F.  
DO NOT locate sensors where supply air can blow directly on  
them. Avoid locating sensors where heat from any lamps, appli-  
ances, or direct sunlight will affect temperature sensor on room  
sensors. Do not locate on an outside wall or next to a return air  
grill.  
1. Separate the 2 parts of sensor and mount back plate with  
provided flat-head screw.  
2. Pull a 2-wire conductor through hole on right-hand side.  
6
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Zone Dampers  
24 VAC Transformer  
(Field Supplied)  
To  
HVAC  
System  
50 VAC req. for basic  
4 damper system. Please  
see Page 1, Electrical  
Rating for details.  
#16 AWG to  
Grounded to Water Pipe  
or Solid Electrical Ground  
PWR. 24VAC  
ZN4  
BYPASS  
ZN3  
ZN2  
ZN1  
CL OP COM CL OP COM CL OP COM CL OP COM CL OP COM  
Power  
COMFORT ZONE I/O  
COMM  
BUS HAM  
COMM BUS  
CONTROLLER  
CHR-06  
W
W
W
LAT  
W
W
W
ZT2  
R
R
R
R
R
R
SHIELD  
GROUND  
W R  
G
W R  
G
ZT4 ZT3  
DX OAT  
72  
2:45  
68  
Zone 2*  
Zone 3*  
Zone 4*  
4-Zone Controller  
Zone 1  
Dx Coil  
Sensor  
(optional)  
Outside Air  
Sensor  
(optional)  
Duct  
Sensor  
Remote Room  
Sensors  
Communication Bus  
Custom Cable  
CALLOUT TO PHONE PHONE LINE  
POWER  
COMM BUS  
B Y G W R  
B Y G W R  
B Y G W R  
Home Access Module  
(optional)  
Smart Sensor Power Pack  
(optional)  
* It is recommended that a 5 wire cable be used to install  
Remote Room Sensors to allow  
for future upgrade to Smart Sensors.  
Smart Sensor  
(optional)  
A94311  
Fig. 16—Comfort Zone System Wiring Diagram  
7
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5. Set the zone damper positions based upon zone demand.  
5 WIRE CONDUCTOR  
(INTERFACE BOARD)  
6. Energize additional stages of heating or cooling if demand  
warrants.  
3 WIRE CONDUCTOR  
(COMM BUS)  
7. Continue to adjust zone dampers as conditions within zones  
change.  
COMM BUS  
8. Turn off heating or cooling equipment when all zones are  
within 0.5°F of desired comfort setpoint.  
GRN  
RED  
GREEN  
RED  
WHITE  
RED  
YELLOW  
BLUE  
GREEN  
WHITE  
9. Open all zone dampers when equipment is turned off.  
WHT  
RED  
This is the basic Sequence of Operation for the Comfort Zone  
system. The actual control of dampers, HVAC equipment, and  
system fan will change with configuration of system. Depending  
upon configuration, Comfort Zone can control heat pumps, fur-  
naces, and dual fuel applications.  
YEL  
BLU  
GRN  
WHT  
SELECTION OF A REFERENCE ZONE IN THE SYSTEM  
The first step in any heating or cooling cycle requires Comfort  
Zone to evaluate zones, determine if heating or cooling is needed,  
and select a Reference Zone.  
FIELD WIRING  
(FEED THRU)  
I/O BOARD  
A93231  
The Comfort Zone system actively looks at Comfort Setpoints and  
space temperature in all zones. If any zone in system has a demand  
of 1.5°F or more, then Comfort Zone will prepare to operate  
heating or cooling equipment to reduce demand.  
Fig. 17—Wiring Four Zone Controller  
Changing the base temperatures will change the Comfort  
Temperature Setpoints used in the system schedules. Always  
set the Base Temperatures prior to programming the system  
schedules.  
First, Comfort Zone will select a reference zone in the system. The  
reference zone will be zone with greatest demand. The zone  
damper serving reference zone will be forced fully open and will  
remain fully open as long as that zone is used as reference.  
Comfort Zone also uses a minimum temperature and a maximum  
temperature for comfort setpoints. The minimum and maximum  
temperatures are the same for all 4 zones.  
As long as any zone in system has a demand greater than or equal  
to 1.5°F, then Reference Zone will be selected by zone with  
greatest demand. Once all zones have a demand less than 1.5oF,  
Reference Zone selection will not change until demand in that  
zone is below 0.5°F. At this point Comfort Zone will re-select  
Reference Zone and position that particular zone damper fully  
open.  
The Maximum Temperature is only used for cooling. It is set by  
selecting Rotary Switch Position S-2. The Maximum Temperature  
setting is used when a temperature above the 14° span is selected.  
If Cooling Base Temperature is set to 68°F and cooling setpoint is  
82°F, any attempt to raise cooling setpoint will select Maximum  
Temperature.  
The objective of Reference Zone is to ensure that zone with  
greatest demand is receiving as much conditioned air as system  
will allow. It also gives Comfort Zone system a point of reference  
in observing response of zones to equipment operation.  
The Minimum Temperature is only used for heating. It is set by  
selecting Rotary Switch Position S-3. The Minimum Temperature  
setting is used when a temperature below the 14 ° span is selected.  
If Heating Base Temperature is set to 54°F, any attempt to lower  
heating setpoint below 54°F will select Minimum Temperature.  
PRE-POSITIONING DAMPERS AND STARTING  
THE SYSTEM FAN  
Both Maximum and Minimum Temperatures are intended for use  
with schedules or setpoints which are extreme compared to normal  
building temperatures.  
In order to minimize noise and enhance system operation, Comfort  
Zone maintains all zone dampers full open prior to starting system  
fan or heating or cooling equipment. The intent is to provide  
HVAC equipment with unrestricted duct work and reduce pressure  
surges. Comfort Zone also fully opens dampers whenever a  
heating or cooling cycle is completed and system fan is shutting  
down. If Fan Switch on 4 zone controller is set to Auto, then all  
zone dampers will remain fully open until next heating or cooling  
cycle.  
Comfort Zone also has one additional set of temperature settings.  
These are Vacation Setpoints. The Vacation Setpoints are heating  
and cooling setpoints to be used in all 4 zones whenever 4 zone  
controller rotary switch is turned to "Vacation." The Vacation  
option is used to place entire building in setback during long  
unoccupied periods without danger of freezing or extreme  
heat/humidity.  
The other reason for opening dampers is to provide unrestricted  
duct work to other equipment which is not directly controlled by  
Comfort Zone. One example may be Heat Recovery Ventilator. If  
Comfort Zone is not actively controlling HVAC system, then it  
must not impose any control influences (i.e., closed zone dampers)  
on system and prevent proper operation of other devices.  
SEQUENCE OF EVENTS FOR A NORMAL HEATING OR  
COOLING CYCLE  
Given Comfort Setpoints and space temperature for zones within  
system, Comfort Zone will determine if active heating or cooling  
is required. If so, Comfort Zone will perform the following:  
For Fan operation, switch settings on 4 zone controller and system  
configuration can change actual operation.  
1. Select a reference zone.  
2. Make sure all zone dampers are fully open.  
3. Energize HVAC equipment fan.  
If Auto Fan Off For Heating option (Rotary switch position  
number T-9) is ON, then Comfort Zone will only energize fan for  
cooling cycles. This option is intended for furnaces which will  
control their own fan internally.  
4. Energize heating or cooling equipment. The equipment may  
be a compressor, furnace, strip heater, etc.  
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If Fan Switch on 4 zone controller is set to ON instead of Auto,  
then system fan will run continuously. Any time Comfort Zone is  
operating fan, it will be in active control of system.  
The damper positions in table are also used during a Float Mode.  
A zone with a demand of 0.5°F will be set to position number 5.  
The actual control of zone dampers by Comfort Zone system can  
be modified using 3 configurable options. These are Maximum  
Damper Position, Minimum Damper Position, and Ventilation  
Mode.  
NOTE: If Auto Fan Off For Heating option (rotary switch  
position T-9) is ON, and Fan Switch on the 4 zone controller is  
ON, Comfort Zone will operate fan full time.  
These options apply to all zone dampers simultaneously. Any  
dampers servicing Zone 1 cannot be configured differently than  
those servicing Zone 2. The options are as follows:  
Operating fan continuously will place Comfort Zone in a Float  
Mode any time no active heating or cooling is taking place. During  
Float Mode, Comfort Zone will position zone dampers based upon  
demand in each zone. Comfort Zone will check air temperature in  
duct work and allow air into zones if it will help zones reduce their  
individual demands. For example, if temperature of air in duct  
work is 65°F, cooling comfort setpoint for a zone is 72°F, and  
space temperature is 73°F, then Comfort Zone will open damper  
servicing that zone and allow cooler air into space.  
1. The Maximum Damper Position (rotary position number  
S-4) sets maximum open damper position for all 4 zones. The  
allowable range for this option is damper positions number 8  
through number 15 (fully open). The factory default is 15. The  
only time zone dampers will exceed this position is if system  
fan is off or zone dampers are being calibrated.  
Ventilation Mode is only in effect when temperature of supply air  
is between 65°F and 80°F. Ventilation Mode establishes minimum  
position of zone dampers and is intended to help air movement  
throughout zones and reduce chance of having areas which are  
stagnant or have high humidities with respect to rest of system.  
The changes to dampers are detailed in the next section "Control-  
ling the Zone Dampers."  
2. The Minimum Damper Position (rotary position number  
S-5) sets minimum open damper position for all 4 zones. The  
allowable range for this option is damper positions number 0  
through number 7. The factory default is number 0 (fully  
closed). If Ventilation Mode (rotary position T-25) is turned  
OFF, then minimum damper position will be an absolute  
minimum regardless of operating mode. If Ventilation Mode  
is turned ON, then minimum damper position will be mini-  
mum position during a Ventilation Mode only and dampers  
will be allowed to fully close at any other time.  
CONTROLLING THE ZONE DAMPERS  
The zone dampers have a total of 16 possible positions or  
increments which are numbered 0 (zero) through 15. Position  
number 0 is fully closed and position number 15 is fully open.  
While damper servicing reference zone remains fully open, all  
other zone dampers are positioned by selecting a position equal to  
demand of space in tenths of a degree. (See Table 2.)  
3. Ventilation Mode (rotary position T-25). If Ventilation Mode  
is turned ON, then any time air inside supply air duct work is  
between 65°F and 80°F, system will be in a "Ventilation  
Mode". During a Ventilation Mode all zone dampers will have  
a minimum position which is set by Minimum Damper  
Position (rotary position S-5). The zone dampers are not  
allowed to fully close as long as supply air temperature  
remains within the 65°F-80°F range. If supply air temperature  
falls outside the 65°F-80°F range, then zone dampers may  
fully close.  
Table 2—Zone Damper Positions  
Damper Position Versus Zone Demand  
DAMPER  
POSITION  
DEMAND °F  
DEMAND °C  
0
NOTE: If Ventilation Mode option (rotary position T-25) is  
turned ON, and Minimum Damper Position (rotary position S-5) is  
set to position 0, there is no difference between Float Mode and  
Ventilation Mode. In other words, Ventilation Mode option has  
no effect on system.  
0
0
Fully Closed  
1
2
0.1  
0.2  
0.3  
0.4  
0.5  
0.6  
0.7  
0.8  
0.9  
1.0  
1.1  
1.2  
1.3  
1.4  
0.06  
0.11  
0.17  
0.22  
0.28  
0.33  
0.39  
0.44  
0.50  
0.55  
0.61  
0.67  
0.72  
0.78  
3
4
OPERATING THE HEATING AND COOLING EQUIPMENT  
5
Before any heating or cooling equipment is started, Comfort Zone  
must first choose between heating or cooling. For most of the year  
there is little question as to the need for heat or cooling. But for  
portions of the year, particularly during mid-season, a building  
may have simultaneous needs for both heating and cooling.  
6
7
8
9
10  
11  
12  
13  
14  
The first step in selecting heating or cooling is the determination of  
a Reference Zone. If there is a single zone which has greatest  
demand, then it will become the Reference Zone and Comfort  
Zone will start equipment based upon needs of that zone. If 2 zones  
have same "greatest demand" but in different modes (1 needs  
heating and the other needs cooling), then Comfort Zone will  
select mode which has greatest number of zones which require  
same mode.  
15  
1.5  
0.83  
Fully Opened  
For example, a zone which has a 1.0°F demand will have damper  
set to position number 10 while a zone which has a demand of  
0.5°F will have damper set to position number 5. A demand of 0  
(zero) will fully close zone damper. Any zone which has a demand  
greater than 1.5°F will remain fully open.  
CONTROL STRATEGY FOR HEATING / COOLING STAGES  
The Comfort Zone system will attempt to minimize use of  
additional stages of heating or cooling equipment. In an ideal case,  
building conditioning needs can be supplied by first stage cooling  
or first stage heating alone.  
Notice that positions are based upon tenths of a degree Fahrenheit.  
If Comfort Zone has Celsius Temperature Display option (rotary  
position T-2) turned on, the damper control is still based upon  
Fahrenheit scale.  
For most heat pump applications, there may be only 2 or 3 stages  
of heat depending upon type of emergency heater present. For a  
heat pump, secondary heat source will generally be an electric strip  
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Table 3—Heating System Option Vs. Type of Heater Used  
FAN ON  
FOR COOLING ONLY  
TOGGLE:  
HEAT PUMP  
SYSTEM TOGGLE:  
T-6  
TWO STAGE  
HEAT PUMP  
TOGGLE: T-26  
DUAL FUEL  
SYSTEM SWITCH:  
S-7  
HEATER TYPE USED  
IN SYSTEM  
T-9  
Single-Stage Heat Pump  
Two-Stage Heat Pump  
On  
On  
Off  
On  
0oF (off)  
0oF (off)  
Off  
Off  
Heat Pump/Furnace Dual  
Fuel  
On  
On  
Off  
On  
10 to 60oF  
Off  
Off  
Two-Stage Heat Pump,  
Furnace Dual Fuel*  
0°F  
Furnace Heat Only  
Strip Heater Only  
Off  
Off  
Off  
Off  
0oF (off)  
0oF (off)  
On or Off  
Off  
* Refer to 2-speed heat pump Installation and Start-Up Instructions for details regarding 2-speed heat pump operation. It is recommended that heat pump control board  
controls operation of this equipment and not Comfort Zone.  
Table 4—Available Heating and Cooling Stages Vs. System Type  
TYPE OF HVAC  
COOLING STAGE 1  
COOLING STAGE 2  
HEAT STAGE 1  
HEAT STAGE 2  
HEAT STAGE 3  
HEAT STAGE 4  
EQUIPMENT USED  
Cooling Only, any Heater Type  
Single-Stage Heat Pump  
Two-Stage Heat Pump  
Y1  
Y1  
Y1  
Y2  
--  
W1  
Y1  
Y1  
W2  
W1  
Y2  
--  
--  
--  
W2  
W1  
Y2  
W2  
For cooling applications, the second stage of an air conditioner is not necessarily more expensive to operate than first stage. But additional cooling can drive down the  
efficiency of a 2-speed air conditioner and longer use of first stage alone tends to deliver better humidity control in moist climates. Again, because of these advantages,  
Comfort Zone will attempt to minimize use of second stage cooling. This is not as great of a concern for a heating application, because the majority of small air  
conditioning systems sold today (5 tons and below) are single-stage cooling only.  
heater. The electric strip heat is much more expensive to operate  
when comparing cost per unit of heat. Because auxiliary stages of  
heating tend to be more expensive to operate, Comfort Zone  
attempts to keep number of stages at a minimum.  
For cooling only applications with any type of heater, Comfort  
Zone will only control 2 stages of heat. If system uses a heat pump,  
then Comfort Zone will control 3 stages of heat. The additional  
stage is heat pump compressor contact. The auxiliary heat is still  
2 stages. If system uses a 2 stage heat pump, then Comfort Zone  
will control 4 stages of heat, 2 stages for heat pump and 2 stages  
for auxiliary heat.  
CONFIGURATION OPTIONS FOR EQUIPMENT  
OPERATION  
Comfort Zone has several configurable options which allow it to  
control different types of HVAC equipment and change the  
manner in which the equipment is controlled. This first group must  
be set given the type of HVAC equipment installed. These include:  
The Comfort Zone Relay Pack outputs are shown in Table 4. The  
Y1 and Y2 contacts are used for compressor contacts only.  
Comfort Zone operates heat pumps by energizing compressor  
contacts and controlling reversing valve through Reversing Valve  
(RV) relay output. The W1 and W2 contacts are always used for  
heat sources. These are heating only units such as furnaces, strip  
heaters, etc. The relay outputs for Comfort Zone 1.4 are shown in  
Table 4.  
1. Heat Pump Operation (Rotary Position T-6).  
2. Two-Stage Heat Pump (Rotary Position T-26).  
3. Dual Fuel trip temperature (Rotary Position S-7).  
4. Auto Fan Off For Heat (Rotary Position T-9).  
The second group modifies the way the HVAC equipment is  
controlled. These include:  
Under no circumstances may the W1 and Y1 contacts on the  
relay pack be jumpered together. This is a common practice  
for many heat pump installations but will cause improper  
operation of the Comfort Zone (1.4 or greater) system.  
1. Comfort Trend Staging (Rotary Position T-8).  
2. System Mode Reselect (Rotary Position T-22).  
3. High/Low Temperature Limits Enabled (Rotary Position  
T-10).  
STARTING THE HVAC EQUIPMENT  
4. High Temperature Trip Limit (Rotary Position S-6).  
5. Dx Sensor (Rotary Position T-27).  
Once Comfort Zone selects a mode, controller will use configu-  
ration options to modify control of HVAC equipment. The  
controller first selects number of stages of heating and cooling that  
may be applied to building load. The "available" stages are  
determined by Reference Zone temperature demand and are shown  
in Table 5.  
6. Smart Start (Heat Pump Strip Heat Economy Feature)  
The first options which must be set are based upon the type heater  
or heaters used. These are shown in Table 3. The only option  
which appears to impact cooling operation is Two-Stage Heat  
Pump which implies the availability of 2 stages of cooling. In  
reality there are no changes to cooling control scheme.  
Using Table 5, if Reference Zone has a 2.3°F demand, then  
Comfort Zone may use 2 stages of cooling or 2 stages of heating.  
The HVAC equipment may not have 3 stages of heat or even 2  
stages of cooling. The table is only used to determine what  
equipment Comfort Zone is allowed to turn on at any given time  
during a heating or cooling cycle. Actual operation of stages  
depends on other variables as well.  
Comfort Zone assumes that there are always 2 stages of cooling  
present. These are connected to the Comfort Zone Relay Pack on  
the Y1 and Y2 contacts.  
RELAY PACK TO HVAC EQUIPMENT CONNECTIONS  
Given system configuration, Comfort Zone can determine number  
of heating stages that it will actually control and which relay  
outputs will be used to control each stage of heat. Comfort Zone  
can control up to 4 stages of heat depending upon system  
configuration.  
Normally Comfort Zone will start equipment operation when it has  
a demand of 1.5°F or greater. In some cases, Comfort Zone will be  
facing a demand greater than 1.5°F when a mode is starting. This  
can occur when user changes setpoints in a zone or if a schedule  
change has reset the Comfort Setpoints.  
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heat and switch into a cooling mode. Once cooling demand is  
satisfied (or System Mode Reselect dictates a switch), Comfort  
Zone will revert to a heating mode in order to try and satisfy that  
demand.  
Table 5—HVAC Equipment Stages  
Vs. Zone Demand  
HEATING & COOLING  
DEMAND °F  
DEMAND °C  
EQUIPMENT STAGES  
First-Stage Cooling  
Second-Stage Cooling  
First-Stage Heating  
Second-Stage Heating  
Third-Stage Heating  
Fourth-Stage Heating  
The need for System Mode Reselect usually indicates some type of  
system problem. Common use of System Mode Reselect may be  
caused by poor or improper duct work, open windows or doors,  
HVAC equipment failure, improper equipment sizing, etc. The  
need for System Mode Reselect usually occurs in larger installa-  
tions where zone use or occupancy may vary widely. For residen-  
tial application, the need for System Mode Reselect is normally not  
frequent unless the building has unusual architectural features or  
problems with HVAC system.  
1.5  
2.0  
1.5  
2.0  
2.5  
3.0  
0.83  
1.11  
0.83  
1.11  
1.39  
1.67  
NOTE: Comfort Zone uses a 3-minute timer to delay start of  
second-stage (heating or cooling). This timer is started whenever  
first-stage heating or cooling is energized. This delay cannot be  
overridden or disabled.  
High/Low Temperature Limits is an option that allows Comfort  
Zone to control equipment stages and position dampers based upon  
temperature of supply air leaving HVAC equipment. As the  
Comfort Zone system operates through a heating or cooling cycle,  
zone demands and damper positions will change. This changes  
actual tonnage or BTUH that is applied to HVAC equipment. The  
tonnage generated by HVAC equipment must equal tonnage  
placed into zones. If zone’s airflow decreases, cooling equipment  
will tend to drive down supply air temperatures. Conversely,  
heating equipment will tend to drive up supply air temperatures.  
STAGE CONTROL DURING EQUIPMENT OPERATION  
As shown earlier, Comfort Zone has 6 configurable options which  
help govern equipment operation. They are:  
1. Comfort Trend Staging (Rotary Position T-8).  
2. System Mode Reselect (Rotary Position T-22).  
With High/Low Temperature Limits turned ON, Comfort Zone  
will detect this condition and take corrective action. The first step  
taken by Comfort Zone will be to start turning off extra stages of  
equipment. this will continue until either the Leaving Air Tem-  
perature problem is corrected or system is operating on first-stage  
heating or cooling only.  
3. High/Low Temperature Limits Enabled (Rotary Position  
T-10).  
4. High Temperature Trip Limit (Rotary Position S-6).  
5. Dx Sensor (Rotary Position T-27).  
6. Smart Start (Heat Pump Strip Heat Economy Feature)  
If system is operating on first-stage heating or cooling, Comfort  
Zone will begin to gradually open zone dampers. This can continue  
until system has become a fully-open constant-volume system if  
needed. The objective is to provide required heating or cooling as  
best as possible prior to shutting off equipment. In practice the  
control tends to match equipment capacity to zone demands and  
will seldom revert back to a fully-open system.  
Comfort Trend Staging and High/Low Temperature Limits  
control the use of extra stages of heating and cooling. Both can be  
turned off by the installer but the use of these options is highly  
recommended.  
Comfort Trend Staging is used by Comfort Zone as an aid to  
decide if second-stage (heating or cooling) is needed. The system  
must have at least 1 zone with a demand equal to or greater than  
2.0oF to allow use of second stage. Comfort Trend looks at  
temperature inside zone and watches trend over time. If zone  
demand is being lowered by first-stage operation, second stage is  
not energized. Stage 1 would remain ON and Stage 2 would  
remain OFF as long as temperature and trend continued to  
improve.  
The Leaving Air Temperature control can also indicate problem  
zones within a system which are not receiving sufficient airflow. If  
1 area (or zone) within a building has difficulty becoming satisfied  
then there may be a sizing problem or an obstruction in duct work  
supplying that zone.  
To use the Leaving Air Temperature Control, 3 options must be  
setup properly. They are:  
Comfort Trend Staging uses a 6-minute timer and a record of the  
Reference Zone demand to control second stage. When Comfort  
Trend Staging starts, demand in Reference Zone is recorded and  
temperature in zone is continuously monitored. If demand in  
Reference Zone is reduced (temperature is approaching comfort  
setpoints), then 6-minute timer is restarted and new demand is  
recorded. If 6-minute timer expires and demand is the same or has  
grown greater, Comfort Zone will start second stage.  
1. High/Low Temperature Limits Enabled (Rotary Position  
T-10).  
2. High Temperature Trip Limit (Rotary Position S-6).  
3. Dx Coil Sensor For Leaving Air Temperature Checking  
(Rotary Position T-27).  
First, High/Low Temperature Limits Enabled must be turned  
ON. This is the ON-OFF switch for the control option. The  
temperature used for this control is measured by Remote Duct  
Sensor and (optionally) the Dx Coil Sensor.  
Comfort Trend works for all stages of heating and cooling  
operation.  
Comfort Trend staging will be used if rotary Position T-8 is turned  
ON. If T-8 is turned OFF, then second stage will be energized  
whenever Reference Zone demand meets or exceeds 2.0°F and  
after 3-minute delay.  
The High Temperature Trip Limit (Rotary Position S-6) is  
supply air temperature for heating that the Leaving Air Tempera-  
ture control uses to detect a problem during heating modes only.  
The Comfort Zone thermostat will display a number between 05  
and 55°F. The actual temperature is 100°F greater, such that the  
actual range is 105°F to 155°F. Comfort Zone cannot display the  
100’s digit.  
System Mode Reselect allows Comfort Zone to switch between  
heating and cooling even if current system demand has not been  
satisfied. For example, if Comfort Zone is providing heat, System  
Mode Reselect allows Comfort Zone to look at any cooling needs  
which may also exist in the building. If cooling demand exceeds  
heating demand for 20 minutes, Comfort Zone will stop providing  
Selecting the Offset Temperature picks the temperature when  
Comfort Zone will start taking action to correct the Leaving Air  
Temperature. If limit temperature is between 105°F and 109°F,  
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then temperature at which first stage will be shut down will be  
offset 5°F above limit value (110°F to 114°F). If limit temperature  
is between 110°F and 155°F, then temperature at which first stage  
will shut down will be offset 20°F above limit value (130°F to  
175°F). For Cooling modes the temperature is fixed at 50°F (10°C)  
for starting the control and 45°F (7.2°C) for turning off first-stage  
cooling.  
Table 6—Programmable Options-Settings  
SETTING  
NO.  
FACTORY  
DEFAULT  
SETTING NAME  
VALUE  
S-1  
S-2  
S-3  
S-4  
S-5  
S-6  
S-7  
4 Zone Controller Bus Address  
Maximum Cooling Setpoint  
Minimum Heating Setpoint  
Maximum Damper Position  
Ventilation/Minimum Damper Position  
High Temperature Trip Limit  
Dual Fuel Setpoint  
4-64  
80-95  
4
85  
65  
15  
0
34-64  
8-15  
0-7  
The heating value must be set given the type of heater used in the  
system. This is for the final heat source. So a heat pump with  
strip heat would use a temperature appropriate for strip heaters. A  
furnace application may have a setting in the 130°F to 155°F  
range. Strip heaters may fall into a 115°F to 130°F range. Heat  
pump only systems may use 105°F to 115°F. Check equipment  
manufacturer recommendations and verify setting is in accordance  
with UL, NFPA, or any applicable Local or State Building Codes.  
If there is any question about what may be an appropriate  
temperature setting, use conservative (low) temperatures.  
105-155  
0 or 10-60  
105  
0
ZONE 1 Address of 4 zone controller  
ZONE 2 Address must be 1 less than zone 1  
ZONE 3 Address must be 2 less than zone 1  
ZONE 4 Address must be 3 less than zone 1  
To set address of a Smart Sensor, rotary switch position 1 on  
Smart Sensor must be selected first.  
Dx Coil Sensor For Leaving Air Temperature (Rotary Position  
T-27) allows Comfort Zone to use a Dx Coil Sensor in addition to  
Remote Duct Sensor for Leaving Air Temperature Checking. The  
Dx Coil Sensor is used in heat pumps with fan coil applications  
and will be located after the Dx coil and before any strip heaters.  
This sensor is only active during heat pump operation. The  
temperature setting for this sensor is fixed at 105°F for initiating  
the control option and 110°F for shutting down first stage.  
2. Maximum Cooling Setpoint (S-2)  
This is the highest temperature value to which cooling setpoint  
can be adjusted. All zones will use same value. The maximum  
cooling setpoint can be programmed from 80°F to 95°F. This  
allows cooling setpoints to be programmed above normal  
range.  
Example: Maximum cooling setpoint is programmed at 92°  
F. The temperature range for cooling setpoint is 70° F to 84°F.  
When the COOL setpoint up button is pressed to adjust  
cooling setpoint above 84°F, setpoint will jump to 92°F.  
Heat Pump-Strip Heat Economy Feature (Smart Start). This is  
an automatic control within Comfort Zone and not a selectable  
option. The Smart Start feature is used whenever primary source of  
heat is a heat pump. As such, the Heat Pump toggle (Rotary  
Position T-6) must be turned ON. Smart Start is designed to help  
minimize use of strip heat or emergency heat whenever a large  
heating demand occurs due to a scheduled setpoint change. Smart  
Start looks at scheduled comfort setpoints for the next hour. If  
scheduled setpoints will make system provide heat, Smart Start  
will start heat pump an hour early. Smart Start will operate until  
zone demand is brought within 0.5°F (0.28°C) of the next hour’s  
heat setpoint or setpoints change due to the schedule (the hour  
expires).  
3. Minimum Heating Setpoint (S-3)  
This is the lowest temperature value to which heating setpoint  
can be adjusted. All zones will use same value. The minimum  
heating setpoint can be programmed from 34°F to 64°F. This  
allows heating setpoints to be programmed below normal  
range.  
Example: Minimum heating setpoint is programmed at 56°  
F. The temperature range for heating setpoint is 66° F to 80°F.  
When the HEAT setpoint down button is pressed to adjust  
heating setpoint below 66°F, setpoint will jump to 56°F.  
Smart Start assumes auxiliary heat is more expensive to operate  
when compared to heat pump and it assumes that heat pump is a  
relatively "slow" source of heat. Smart Start allows a zone to  
recover from a setback or unoccupied period and use the most  
economic source of heat in doing so. The idea of using a setback  
or unoccupied schedule is to save money in operating costs. There  
is little incentive to use schedules if zone is heated with most  
expensive source of heat available.  
4. Maximum Damper Position (S-4)  
This is the highest open position to which a damper will  
change. Full open is designated as position 15. Maximum  
open damper position can be programmed between 8 (half  
open) and 15, in increments of 1. All zone dampers will use  
the same programmed maximum value.  
5. Ventilation/Minimum Damper Position (S-5)  
When there is no demand for cooling or heating, this is the  
minimum position that every zone damper will maintain as  
long as air temperature in duct work is between 65°F and  
80°F. Full closed is designated as position 00. Minimum open  
damper position can be programmed between 7 (half-open)  
and 00, in increments of 1. All zone dampers will use the same  
programmed ventilation value.  
Step 11—Configuring Four Zone Controller  
PROGRAMMABLE OPTIONS-SETTINGS  
Turn zone selector dial to position S. (See Fig. 18.) The controller  
display shows setting number and its value.  
The upper 2 digits show the setting’s number and the lower 2 digits  
show the value of setting.  
6. High Temperature Trip Limit (S-6)  
Press the COOL up or down setpoint buttons to change setting  
number and the HEAT up or down setpoint buttons to change  
value. Refer to Table 6 for settings and their definitions.  
The trip temperatures limits are duct temperatures used to turn  
HVAC equipment off to prevent damage to equipment.  
Temperature values are measured by duct temperature sen-  
sors.  
1. Zone Controller Bus Address (S-1)  
This setting establishes the identity of the 4 zone controller on  
the Carrier communication bus.  
The low temperature trip limits are 50°F (turn off second-stage  
cooling) and 45°F (turn off first-stage cooling) and cannot be  
changed.  
NOTE: Remote room sensors do not require addressing.  
If using optional Smart Sensors, they must be addressed as  
follows:  
The second-stage high temperature trip limit can be pro-  
grammed from 105°F to 155°F.  
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If a value of 105 to 110 is selected (second-stage heating is  
turned off at this value) then the first-stage high temperature  
trip limit is the programmed value plus 5°F (first-stage is  
turned off).  
If a value of 111 to 155 is selected (second-stage heating is  
turned off) then the first-stage high temperature trip limit is the  
programmed value plus 20°F (first stage is turned off).  
Example 1:  
High temperature trip limit selected is 105°F. (Shown as 05 in  
controller display.)  
Second-stage heat will turn off when duct temperature sensor  
measures a temperature greater than 105°F.  
First-stage heat will turn off when duct temperature sensor  
measures a temperature greater than 110°F.  
Example 2: High temperature trip limit selected is 140°F.  
(Shown as 40 in controller display.)  
Second-stage heat will turn off when duct temperature sensor  
measures a temperature greater than 140°F.  
First-stage heat will turn off when duct temperature sensor  
measures a temperature greater than 160°F.  
Table 7—Wiring Diagram Reference  
For Fig. 19 and 20  
FAN COIL WITH AIR CONDITIONER  
INDOOR UNIT (FIG. 19)  
FA4A  
OUTDOOR UNIT  
FB4A  
FC4B  
FK4A  
FK4B  
Single-Stage  
Air Conditioner  
A
A
D
B
E
Two-Speed  
Air Conditioner  
C†  
FURNACE WITH AIR CONDITIONER  
INDOOR UNIT (FIG. 20)  
58WAV  
58PAP 58ZAV  
58RAP 58PAV  
58GFA 58RAV  
OUTDOOR UNIT  
58TUA  
58TMA  
58VUA/VCA 58DFA 58SXC 58MVP  
58EFA 58DXC  
58SXA 58EJA  
58DXA 58MXA  
58MCA  
7. Dual Fuel Setpoint (S-7)  
Single-Speed  
Air Conditioner  
A* B  
D E*  
B
B
C
H
C
This option is used with a system that has a heat pump and  
another heat source (possibly gas) that should not run at the  
same time as heat pump. When any heat pump is on, all  
auxiliary heat will be off, and vice versa.  
Two-Speed  
Air Conditioner  
F†  
G†  
H I †  
* KGATT0101VSP (Optional) Two-stage relay kit— may help to control over  
conditioning.  
† Latent capacity control—Required, field supplied. See 2-speed Installation  
Instructions.  
NOTE: The auxiliary heat must always have greater heating  
ability than the heat pump at low outdoor temperatures for this  
option to have any value.  
NOTE: If Dual Fuel setpoint is set to 0, then this option is  
disabled. If Dual Fuel option is used, an outside air temperature  
sensor or refrigerated air sensor must be used.  
Table 8—Wiring Diagram Reference  
For Fig. 21 and 22  
FAN COIL WITH HEAT PUMP  
INDOOR UNIT (FIG. 21)  
When dual fuel setpoint variable is set to outdoor temperature  
(10°F to 60°F) that is the crossover point between running  
heat pump or using auxiliary heat as the preferred method of  
heating.  
The setpoint is used only when the first stage of heating is  
brought on. If outdoor temperature is above setpoint, heat  
pump (Y1) is energized. If outdoor temperature is below  
setpoint, auxiliary heat (W1) is used. If heat pump is started  
and outdoor temperature goes below setpoint, dual fuel option  
is not used for that heating cycle.  
FA4A  
FB4A  
FC4B  
OUTDOOR UNIT  
FK4A  
FK4B  
Single-Stage  
Heat Pump  
A
A
D
B
E
Two-Speed  
Heat Pump  
C†  
FURNACE WITH HEAT PUMP  
INDOOR UNIT (FIG. 22)  
58WAV  
58PAP 58ZAV  
58RAP 58PAV  
PROGRAMMABLE OPTIONS-TOGGLES  
Turn zone selector dial to position T. (See Fig. 18.) The controller  
display shows setting number and its value.  
58GFA 58RAV  
OUTDOOR UNIT  
58TUA  
58TMA  
58VUA/VCA 58DFA 58SXC 58MVP  
58EFA 58DXC  
The upper left 2 digits show setting number while the right side  
shows the value of ON or OFF.  
58SXA 58EJA  
58DXA 58MXA  
58MCA  
Press the COOL up or down setpoint buttons to change toggle  
number and the HEAT up or down setpoint buttons to change  
status of toggle. (See Table 11.)  
Single-Speed  
Heat Pump  
A** B* **  
E** F* **  
C
C
D
I
D
I
Two-Speed  
Heat Pump  
G†  
H†  
Step 12—Wiring Diagrams  
* KGATT0101VSP (Optional) Two-stage relay kit—may help to control over  
Refer to Tables 7 and 8 for wiring diagram reference information.  
Step 13—Start-Up  
conditioning.  
† Latent capacity control—Required, field supplied. See 2-speed Installation  
Instructions.  
** Field-supplied isolation relay.  
1. Verify that zone number for remote room sensors and corre-  
sponding zone damper wire connections are the same in the  
Comfort Zone Center.  
4. Make sure that the 3 wire communication bus cable for the 4  
zone controller is not run in same conduit, or use same cable  
jacket, as the 5 wire conductor of the 4 zone controller.  
2. Check that AC power wires (dampers and transformer) are  
kept away from DC wires (remote room sensors, 4 zone  
controller, communication bus) leading up to, and in the  
Comfort Zone Center.  
5. On a remote room sensor follow wire guide stamped on base  
by terminal screws in order to keep polarity and voltages  
correct. Otherwise sensor will not work properly.  
3. Check location of 4 zone controller and remote room sensors  
to make sure that they are not near heat producing devices  
such as lamps, sunlight, and appliances.  
6. Make sure duct temperature sensor is placed in supply air duct  
work, downstream of furnace and evaporator coil, and up-  
stream of bypass damper.  
13  
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7. Write down on a piece of paper AND GIVE TO THE  
OWNER a list showing what rooms are controlled by what  
dampers, and their corresponding zone numbers. Keep list for  
your future use.  
13. Instruct owner to call 800 number supplied with Comfort Zone  
Center to receive free "How to use Comfort Zone" video tape.  
14. For toggle settings for configuration see Programmable  
Toggles and Options and Table 9.  
8. Instruct owner to turn cool switch OFF in the fall, and turn it  
ON in the spring.  
Step 14—Programming Schedules  
The 4 zone controller is the program center for the Comfort Zone  
System. The 4 zone controller provides the ability to program  
system for unique demands of each zone at different times during  
the day and week. See Fig. 18 to become familiar with various  
parts of the 4 zone controller.  
9. Make sure emergency heat switch is in the OFF position. If a  
gas furnace is used this switch should never be turned on. It is  
for heat pumps only.  
10. Be sure and set clock to correct time of day. You only need to  
do this when you first power up system, or after a power  
outage lasting longer than 8 hours.  
SYSTEM SWITCHES  
System switches select desired equipment operation.  
Heat Switch  
11. Go to rotary switch setting 2 on the 4 zone controller. Check  
calibration of room sensor. Do same for zones 2, 3, and 4  
(rotary switch 3-4-5). Sensors must be calibrated.  
OFF—Heat will not come on.  
AUTO—Heat will come on when any zone is more than 1.5°F  
12. Instruct owner in operation of Comfort Zone System  
below desired heat setpoint.  
CONTROLLER DISPLAY  
INDICATES ZONE SETPOINTS, ZONE TEMPERATURES,  
AND PROGRAMMING INFORMATION AND  
ALLOWS SETPOINT ADJUSTMENT.  
CLOCK DISPLAY  
INDICATES THE CURRENT TIME AND DAY  
AND THE START TIMES/WEEKLY PERIODS  
DURING PROGRAMMING.  
AM  
AM  
FOUR  
ZONE  
CONTROLLER  
SET  
SELECT  
TIME/TEMP  
MIN/HR/DAY  
8
OPTIONS  
9
T
SET  
TIME/TEMP  
SCHEDULES  
ZONE  
1
SELECT  
MIN/HR/DAY  
8
SCHEDULES  
ZONE  
2
7
5
HOLD  
TEMPERATURES  
ADVANCE  
TIME/DAY  
6
ZONE  
3
OFF AUTO  
HEAT  
AUTO OFF  
COOL  
AUTO  
ON  
OFF  
ON  
ZONE  
4
4
HOLD  
TEMPERATURES  
ADVANCE  
TIME/DAY  
FAN  
EMERGENCY HEAT  
3
1
VACATION  
2
PROGRAMMING ADJUSTMENT BUTTTONS  
ALLOWS FOR PROGRAMMING WEEKLY PERIODS, START TIMES  
FOR EACH ZONE AND SETS THE CLOCK FOR DAY AND TIME.  
S
OPTIONS  
9
T
ZONE 1  
8
ZONE 2  
7
5
6
ZONE 3  
ZONE 4  
OFF AUTO  
HEAT  
AUTO OFF  
COOL  
AUTO  
ON  
OFF  
ON  
FAN  
EMERGENCY HEAT  
4
!
1
3
VACATION  
2
SYSTEM SWITCHES  
PROVIDES FOR SELECTION OF HEAT, COOL,  
FAN AND EMERGENCY HEAT OPERATION.  
ZONE SELECTOR DIAL  
PROVIDES ACCESS TO INFORMATION AND PROGRAMMING  
FOR EACH ZONE AND SELECTION OF VACATION MODE.  
OPTION AREA IS FOR USE BY INSTALLATION/SERVICE.  
A93232  
Fig. 18—Four Zone Controller  
14  
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Cool Switch  
Setting The Clock  
The clock display will normally show hour, minutes, AM or PM,  
and day.  
OFF—Cooling will not come on.  
AUTO—Cooling will come on when any zone is more than 1.5°F  
1. Set minutes.  
above desired cool setpoint.  
Press SELECT MIN/HR/DAY button once.  
Fan Switch  
Press ADVANCE TIME/DAY button to scroll to proper  
minutes.  
ON—Fan will stay on continuously (recommended).  
AUTO—Fan will come on only when heating or cooling is  
required.  
2. Set hour.  
Press SELECT MIN/HR/DAY button once again.  
Emergency Heat Switch (Heat Pump Systems only)  
Press ADVANCE TIME/DAY button to scroll to proper hour,  
AM or PM.  
OFF—Electric strip heat will not come on unless there is a zone  
more than 2°F below desired heat setpoint and comfort trend  
demand has been satisfied.  
3. Set day.  
ON—When any zone requires heat, electric strip heat will turn on.  
The compressor will remain off.  
Press SELECT MIN/HR/DAY button once again.  
Press ADVANCE TIME/DAY button to scroll to proper day.  
4. Return to normal operation.  
CONTROLLER DISPLAY  
Press SELECT MIN/HR/DAY button once again. The newly  
programmed time will be displayed.  
When set for normal operation, the 4 zone controller display shows  
current zone temperature setpoints and allows adjustment of these  
setpoints using setpoint buttons. By pressing both heating or  
cooling setpoint buttons simultaneously, controller will lock in and  
display temperatures for that zone. To release, push both buttons  
simultaneously again. This will only work when T-20 is off.  
Programming Schedules  
1. Enter Program Mode  
Press SET TIME/TEMP SCHEDULES button to enter pro-  
gram mode. The program mode and current zone will be  
shown on controller display.  
ZONE SELECTOR DIAL  
2. Select a zone.  
To view setpoints for each zone, turn zone selector dial to zone  
number you wish to view.  
Turn rotary switch to the zone to be programmed.  
3. Select a weekly period.  
The setpoints for selected zone will be displayed in controller  
display.  
The clock display will show MTWTHF.  
Program Schedules  
Pressing ADVANCE TIME/DAY button selects weekly pe-  
riod to be programmed.  
Each zone has 3 different weekly periods, (Weekdays, Saturday,  
and Sunday) and up to 4 different possible combinations of heating  
and cooling setpoints that can be programmed to provide auto-  
matic climate control depending upon day of week and time of  
each day. Each zone can be programmed independently. (See  
Table 9.)  
Pressing button 1 time will change clock display to SA.  
A second press will change display to SU.  
A third press returns display to MTWTHF.  
4. Program time periods.  
There are 4 start times that can be programmed in each weekly  
period.  
NOTE: All zones must be programmed.  
Table 9—Example Weekly Schedule  
Press SELECT MIN/HR/DAY button to program start times  
for selected weekly period.  
WEEKDAYS  
SATURDAY  
SUNDAY  
Pressing SELECT MIN/DAY/HR button once shows first  
program start time on clock display and setpoints, with the  
word PROGRAM for this start time on controller display.  
6 AM  
72/70  
85/65  
70/68  
85/65  
7 AM  
72/68  
85/65  
70/68  
85/65  
8 AM  
72/70  
85/65  
70/68  
85/65  
8 AM  
5 PM  
10 AM  
2 PM  
10 AM  
7 PM  
10 PM  
11 PM  
10 PM  
Additional presses display start times 2, 3, 4, and then back to  
weekly period display.  
WEEKLY PERIOD  
Cooling Setpoint/Heating Setpoint  
Start Time  
NOTE: While in program mode, if a period of 4-1/2 minutes  
passes without a change to some value, the controller will return to  
normal operation.  
Vacation Mode  
5. Program start time  
Vacation mode displays current vacation temperature setpoints and  
allows adjustment of these setpoints using setpoint buttons. These  
setpoints are used by all zones until selector dial is returned to 1 of  
the zone selection positions. At all times, the setpoints displayed  
will be the temperature range that the system will maintain.  
NOTE: Start times must be programmed in chronological order  
and must be in the same day. Any times before previous time  
period will be ignored. In the WRONG example below, periods 2  
and 4 will be ignored.  
RIGHT  
6 AM - TIME PERIOD 1  
8 AM - TIME PERIOD 2  
5 PM - TIME PERIOD 3  
9 PM - TIME PERIOD 4  
This mode can also be used to maintain entire home at 1 constant  
temperature-typically when unoccupied.  
NOTE: If Fan Switch is set to ON, fan will continue to run in  
vacation mode.  
WRONG 6 AM - TIME PERIOD 1  
2 AM - TIME PERIOD 2  
To enter vacation mode, turn selector dial to VACATION. The  
word "VACATION" will appear on controller display whenever  
system is in this mode. Set vacation mode setpoints.  
9 PM - TIME PERIOD 3  
5 PM - TIME PERIOD 4  
15  
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Press ADVANCE TIME/DAY button until desired start time  
is displayed.  
Table 10—Temperature Sensor Calibrations  
ZONE SELECTOR  
DIAL  
SENSOR TO BE  
CALIBRATED  
6. Adjust setpoints.  
Damper Service  
Position  
Adjust setpoints using up and down buttons until desired  
temperatures for the selected time period appear in display.  
These setpoints will be used during the time period currently  
displayed in clock window.  
Position 1  
Position 2  
Position 3  
Position 4  
Position 5  
Position 6  
Zone 1 Temperature  
Sensor  
Zone 2 Temperature  
Sensor  
7. Complete time period programming.  
Repeat 4 through 6 to program remaining weekly period start  
times. Each weekly period can be programmed with 4 differ-  
ent time periods.  
Zone 3 Temperature  
Sensor  
Zone 4 Temperature  
Sensor  
8. Complete weekly schedule.  
Duct Temperature  
Sensor  
After completing start time programming, press SELECT  
MIN/HR/DAY until MTWTHF reappears in clock display.  
Outside Air  
Temperature Sensor  
Position 7  
Position 8  
Position 9  
Repeat steps 3 through 7 to program weekly periods. Once  
finished, this will complete programming of 1 zone.  
Dx Coil Sensor  
Base Temperature Set-  
point Scale  
9. Program a different zone.  
To program a different zone, turn rotary switch to desired zone  
to be programmed and repeat 2 through 8.  
Bypass Damper Pressure Relief Limit  
10. Exit program mode.  
We do not encourage using a motorized bypass damper. Using a  
barometric bypass damper is the preferred method to control  
operating pressures in supply duct.  
Exit program mode by pressing SET TIME/TEMP SCHED-  
ULES button.  
Overriding Programming  
The display shows zone number in the upper left digits, and the  
lower right digits show damper position. The left hand setpoint  
buttons will toggle the zone number (1-4) and also to 5 where  
collective damper position is programmed in for bypass. When it  
is toggled to position 5 and annunciator is toggled from OFF to ON  
with right hand buttons, controller totals all damper positions and  
stores them. While displaying 1-4, the damper for that zone can be  
directed to any position with right hand buttons. The collective  
damper position that is programmed at position 5 is the minimum  
total damper open position. The largest minimum open position is  
60 (4 zones with 15 positions each). The number that is pro-  
grammed in will be the minimum total damper open positions that  
bypass will try to maintain. The bypass damper positions are 1 for  
every 3 that the total needs. (Example: The maximum total is 60,  
but only 3 dampers are open. This is only 45, so bypass takes 60,  
subtracts 45, comes up with 15, and divides this number by 3. The  
result is 5, so bypass goes to position 5.)  
To override time programming, press any setpoint button. This  
will also adjust setpoints for override period. Once setpoints are  
adjusted, they will not change until the next programmed time  
period for that zone.  
If HOLD TEMPERATURES button is pressed, then current  
setpoints will not change with time, but remain at last values  
entered for as long as hold mode is active.  
To release hold mode, press HOLD TEMPERATURE button a  
second time.  
The controller display will show the word HOLD whenever hold  
mode is active.  
Temperature Sensor Calibration  
NOTE: Temperature sensors are factory calibrated; however,  
field calibration is recommended.  
The setpoint display shows actual temperature (Fahrenheit or  
Celsius).  
Step 15—Accessories  
The upper left-hand corner of display indicates the whole number  
value. The lower right-hand corner indicated the tenths.  
Refer to individual Installation Instructions packaged with kits or  
accessories when installing.  
Pressing either HEAT or COOL button raises or lowers displayed  
temperature by 1/10 of a degree.  
HOME ACCESS MODULE  
The Home Access Module (HAM) is designed to detect Comfort  
Zone System errors. The HAM can report when system is  
operating correctly, or when an error is detected. The HAM can  
automatically call an ACS dealer or the ACS National Response  
Center.  
If temperature readings are not stable within 0.5°F, refer to  
troubleshooting section for details.  
Damper Service Mode  
The Damper Service Mode can be selected to check full operation  
of each zone damper independently. The controller display shows  
zone number in the upper left digits, and damper position in the  
lower right digits. The left hand setpoint buttons will toggle the  
zone number (1-4) and 5.  
NOTE: The HAM must be programmed via Report Logger or PC  
Command Center Software prior to installation.  
SMART SENSOR AND SMART SENSOR POWER PACK  
NOTE: No. 5 not used for damper service mode, see below for  
details when setting motorized bypass damper pressure relief limit.  
NOTE: These 2 accessories must be used together.  
The Smart Sensor provides the ability to view and adjust setpoints  
in zone where sensor is located.  
When this mode is selected, all 4 zone dampers are activated and  
opened to position 15. (See Table 2.) Fan will energize. Use right  
hand setpoint buttons to toggle down from position 15 to position  
0. This feature can verify that each zone damper is operating  
properly by manually opening and closing each zone. When rotary  
switch dial is moved onto another position, Damper Service Mode  
will be cleared and controller will resume normal operation.  
The Smart Sensor replaces a Remote Room Sensor and requires a  
single 5-wire conductor instead of a 2-wire conductor.  
OUTSIDE AIR DAMPER  
The outside air damper allows fresh outside air into building.  
16  
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OUTSIDE AIR TEMPERATURE SENSOR  
When any zone cannot maintain room temperature within 5°F of  
desired setpoint for a period of 20 minutes, a comfort trend error  
is declared. This error is transparent and will not be shown on  
controller display. If a Home Access Module (HAM) is on the  
system, the ACS dealer or national ACS response center will  
receive a call identifying this error.  
The Outside Air Temperature Sensor must be used whenever an  
Outside Air Damper is installed. An Outside Air Temperature  
Sensor must also be used for dual fuel applications.  
Step 16—Troubleshooting  
This section contains information to assist you in troubleshooting  
problems and errors associated with the Comfort Zone System.  
The most common operating problems and different types of errors  
associated with the Comfort Zone System are:  
Operating Problems—No display, flashing display, and flashing  
HEAT or COOL annunciators. Comfort Zone controller selects a  
system mode but does not energize heating/cooling unit.  
Hardware Failure (HF) Errors—Occur when Comfort Zone  
controller detects a problem with 1 of its own components or an  
associated device.  
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 or  
User’s Manual for the proper frequency of maintenance. Fre-  
quency of maintenance may vary depending upon geographic area.  
Leave system manual with homeowner.  
Explain system operation and maintenance procedures outlined in  
User’s Manual.  
Storage Failure (SF) Errors—Occur when Comfort Zone con-  
troller detects and replaces faulty data contained within its memory  
with factory selected default values.  
Transparent Errors—Occur when Comfort Zone controller de-  
tects a system or zone operating problem.  
17  
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Table 11—Toggle Summary  
TOGGLE SETTING  
ON  
OFF  
DEFAULT  
Timeguard delay is 30 sec, overrides 5-minute delay be-  
tween de-energizing and re-energizing HVAC stages. This  
option automatically returns to OFF after 30 sec timeout. If  
equipment has been shut down due to a leaving air tem-  
perature trip, the timeguard override has no effect.  
Time delay is standard 5 minutes be-  
tween de-energizing and re-energizing  
HVAC stages.  
(T1)-Timeguard Override  
OFF  
Temperature and setpoints are displayed  
in Fahrenheit degrees.  
(T2)-Celsius Display  
(T3)-2400 Baud Rate  
(T4)-Error Code Display  
Temperature and setpoints are displayed in Celsius degrees.  
OFF  
ON  
Communication baud rate is 2400.  
Communications baud rate is 4800.  
Non-critical errors are displayed.*; when set to ON both  
SF/HF errors are displayed.  
Only critical errors are displayed.  
ON  
The system broadcasts the time on communication bus with The system does not broadcast time or  
(T5)-Enable Broadcast  
ON  
every scan.  
outside air temperatures on bus.  
Heat Pump mode  
First-stage heat pump will energize Y1 to turn compressor  
on.  
No heat pump operation. Used for electric  
heat or gas furnace. W1 will be energized  
for heat.  
OFF  
(T6)-Heat Pump Operation  
The system assumes that an outside air temperature sensor  
is attached and will broadcast outside air temperature on  
communication bus if enable broadcast is turned on.  
The outside air temperature sensor is not  
attached.  
(T7)-Outside Air Temperature  
(T8)-Comfort Trend Staging  
(T9)-Auto Fan Off For Heat  
OFF  
ON  
The system will energize the second stage only if zone de-  
mand exceeds 2˚F and the zone temperature has not im-  
proved at least 0.1˚F for 6 minutes. The 6 minute timer is  
reset if the zone temperature trend is improving.  
A 2˚F demand alone will energize the  
second stage after timeguard between  
stages has been satisfied.  
When the fan switch is set to AUTO, the system will not en-  
ergize the fan during heat modes. This allows the equipment  
to control fan operation for proper heat exchanger warm-up.  
The fan relay is energized during heating  
and cooling.  
OFF  
The system will check leaving air temperature (measured by  
the duct sensor) for excessive heating and cooling limits.  
Cool limits are fixed at 50˚ F (second-stage cool de-  
Operates the same as ’ON’ position, but  
dampers will not modulate open in a LAT  
(T10)-High/Low Temperature Limits  
ON  
energized) and 45˚ F (first-stage cool de-energized). Heating trip.  
limits are programmable between 105˚/110˚ to 155˚/175˚F.  
Rotary switch positions 1 through 7 and S on controller dis-  
play will display dashes.  
(T11)-Installer Switch Lockout  
All switch positions operate normally.  
OFF  
OFF  
The outside air damper is forced to a minimum position of 2 The outside air damper is set to the posi-  
when fan is on.  
(T12)-Force Outside Air Ventilation  
tion the system requests.  
The system assumes a smart sensor is attached to zone 2.  
The 4 zone controller will read zone temperature and set-  
points for zone 2 via the 3-wire communication bus at 1 ad- the remote room sensor.  
dress below controller.  
The system reads zone 2 temperature via  
(T13)-Smart Sensor Attached For Zone 2  
(T14)-Smart Sensor Attached For Zone 3  
(T15)-Smart Sensor Attached For Zone 4  
OFF  
OFF  
OFF  
The system assumes a smart sensor is attached to zone 3.  
The 4 zone controller will read zone temperature and set-  
points for zone 3 via the 3-wire communication bus at 2 ad- the remote room sensor.  
dresses below controller.  
The system reads zone 3 temperature via  
The system assumes a smart sensor is attached to zone 4.  
The system reads zone 4 temperature via  
the remote room sensor.  
The 4 zone controller will read zone temperature and set-  
points for zone 4 via the 3-wire communications bus at 3  
addresses below controller.  
(T16)-Zone 2 Active  
(T17)-Zone 3 Active  
(T18)-Zone 4 Active  
Zone 2 is being used.  
Zone 2 is not being used.  
Zone 3 is not being used.  
Zone 4 is not being used.  
ON  
ON  
ON  
Zone 3 is being used.  
Zone 4 is being used.  
The system will use outside air as first-stage cooling and  
mechanical cooling as second stage. When outside air tem- The system will use only mechanical  
(T19)-Economizer  
OFF  
perature drops below 65˚ F, damper will modulate 10 per-  
cent open. Full open in cooling.  
cooling.  
The controller display will alternate between setpoints and  
zone temperatures.  
The controller display will continuously  
show setpoints.  
(T20)-Enable Alternate Display  
OFF  
OFF  
The system will operate fifth motorized damper as an out-  
side air damper.  
The system will operate fifth motorized  
damper as a motorized bypass damper.  
(T21)-Outside Air Damper Attached  
The system will re-evaluate demand while still in a mode. If  
simultaneous demand exists and demand for opposite mode The system will not change modes until  
(T22)-System Mode Reselect  
OFF  
exceeds demand for current mode for 20 minutes the sys-  
tem will change modes.  
current mode has been satisfied.  
The system will report a transparent error when any zone  
cannot be maintained within 5˚ F for longer than 20 minutes.  
(T23)-System Error Checking  
(T24)-50 Hz Operation  
The system will not report error.  
OFF  
OFF  
The system will be set to operate using  
60 hz power source.  
The system will be set to operate using 50 hz power source.  
Damper position will not go below mini-  
mum damper position, which is set as S5,  
even when the duct temperature is too  
cold or too hot.  
When duct temperature is below 65˚F or above 80˚F damper  
will go fully closed, i.e., below minimum damper position in  
order to avoid over conditioning zone.  
(T25)-Ventilation Mode  
OFF  
Y2 will be used to turn on second stage of a 2-stage com-  
pressor in a heat pump system.  
(T26)-Two Stage Heat Pump  
(T27)-Dx Sensor for LAT Checking  
(T28)-Cool Without Fan  
Second-stage operation will be canceled.  
Dx Sensor is ignored for LAT checking.  
OFF  
OFF  
OFF  
Dx Sensor will be LAT checked in addition to Duct Tempera-  
ture Sensor. (T-10 must also be on)  
The fan will not be energized. The cooling equipment must  
provide a way to turn fan on.  
The fan relay is energized anytime there  
is a cooling demand.  
* Pressing any setpoint button when a hardware error exists causes a reset if in a run position.  
18  
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Table 12—Operating Problems  
SYMPTOM  
POSSIBLE CAUSE  
Thermostat is not receiving power.  
1. Verify that comfort zone center is receiving 24 vac. (50 va minimum required with 4 motorized  
dampers, 5 va for each additional motorized damper.)  
2. Check that the thermostat is receiving a steady 10 VDC across the red and white wires at the  
system controller terminal block on the comfort zone, I/O board, and on the Red/White terminals  
on the base plate of the 4 zone controller.  
No Display  
Low voltage.  
1. Verify that the comfort zone center is receiving 24 vac. (50 va minimum required with motorized  
dampers, 5 va for each additional motorized damper.)  
2. Check that the thermostat is receiving a steady 10 VDC across the red and white wires at the  
system controller terminal block on the comfort zone, I/O board, and on the red/white terminals  
on the base of the 4 zone controller.  
Blinking Temperature Display  
3. Check that the yellow or blue wires are connected properly and not broken at the system control-  
ler terminal block on the comfort zone I/O board and on the yellow/blue terminal on the base of  
the 4 zone controller.  
4. Verify that the terminals are properly installed on the base plate of the controller.  
5. Wiring connector block for smart sensor could be defective.  
1. Check to see if high/low temperature trip limits have been exceeded.  
2. Temperature sensor is improperly wired or defective.  
Blinking HEAT or COOL Annunciator  
Cooling or Heating is Requested But 1. Must have at least 1 zone with a demand greater than 1.5° F from setpoints.  
The HEAT or COOL Annunciator is  
not displayed  
2. Check system switches. They must be set to AUTO or ON to operate.  
3. Have you waited for timeguard (5 minutes) to expire?  
1. Check that the LEDs on the CHR06 relay pack are indicating the correct relay is closed. If not,  
check for a bad relay.  
2. Measure voltage across common (red) and any de-energized relay. Voltage should be 24 vac.  
3. Apply 24 vac directly across relay.  
COOL or HEAT Annunciator is Lit  
But Cool or Heat is Not On  
1. Verify that there are no obstructions binding the damper blade or shaft.  
2. Check for 24 vac across common and either the open or close terminals.  
3. Check stop switch. If defective, replace actuator.  
4. Verify that motor is operating correctly.  
Damper Will Not Open or Close  
5. Check damper fuse.  
1. Make sure bypass damper is working properly.  
2. Verify that duct work is properly sized.  
System is Too Noisy  
1. Check for drafts.  
2. Use shielded cable.  
Unstable Temperature Readings  
1. Make sure that the sensor wire is not run in parallel with any wires carrying AC voltage.  
2. Disconnect all other sensors from the comfort zone I/O board and check to see if the sensor  
reading is still fluctuating.  
3. Disconnect all other sensors from the comfort zone panel and check to see if the problem still  
exists.  
4. Disconnect the 4 zone controller and re-wire it directly to the I/O board with a separate  
5-conductor cable.  
5. If all sensors are still fluctuating, replace the 4 zone controller.  
6. If only 1 sensor is fluctuating, disconnect that sensor from the I/O board and re-wire it directly to  
the I/O board using a separate 2-conductor cable.  
Room Sensors Fluctuating  
7. If the sensor still has the problem, replace the I/O board.  
8. Verify if shielded or non-shielded cable is being used.  
9. If shielded, follow through the remaining steps. If non-shielded, go to No. 6.  
10. Verify that the shield is connected to the comfort zone panel and that the panel is properly  
grounded to the chassis.  
11. Remove the shield wire and check to see if the problem still exists.  
12. Verify that the shield wire has been clipped off at the sensor end and is not touching any other  
wires or any exposed metal.  
13. Ensure that there is a solid electrical ground on the electric power box.  
19  
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Table 13—Storage Failure Errors  
Error Display (Dial Position T4) must be turned on.  
SF ERROR CODE  
DESCRIPTION  
SOLUTION  
01  
02  
Temperature Programming Error  
Time Period Programming Error  
Reprogram the scheduled temperatures.  
Reprogram the scheduled time periods.  
1. Turn selection dial to position 2.  
2. Change temperature value.  
3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.  
Zone 1 Temperature Calibration Out  
of Range  
03  
04  
05  
06  
07  
08  
09  
1. Turn selection dial to position 3.  
2. Change temperature value.  
3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.  
Zone 2 Temperature Calibration Out  
of Range  
1. Turn selection dial to position 4.  
2. Change temperature value.  
3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.  
Zone 3 Temperature Calibration Out  
of Range  
1. Turn selection dial to position 5.  
2. Change temperature value.  
3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.  
Zone 4 Temperature Calibration Out  
of Range  
1. Turn selection dial to position 6.  
2. Change temperature value.  
3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.  
Duct Temperature Calibration Out of  
Range  
1. Turn selection dial to position 7.  
2. Change temperature value.  
3. Return selection dial to any run mode position. Valid temperature range = 30°—120°F.  
Outside Temperature Calibration Out  
of Range  
1. Turn selection dial to position 8.  
2. Change temperature value.  
3. Return selection dial to any run mode position. Valid temperature range = 30°—180°F.  
Dx Coil Temperature Calibration Out  
of Range  
1. Turn selection dial to position S.  
2. Select variable number 6.  
3. Enter a new value.  
10  
11  
LAT Error  
4. Return selection dial to any run mode position.  
1. Turn selection dial to position S.  
2. Verify correct address of the 4 zone controller is as shown in the Programming and Operation  
Section.  
Device Address Error  
3. Verify smart sensor address(es) are as shown in the Programming and Operation Section.  
1. Turn selection dial to position T2, T11, T12, T18, T20, T22, and T24.  
2. Check and correct the configuration.  
3. Return selection dial to any run mode position.  
12  
13  
14  
Configuration Error  
Configuration Error  
Configuration Error  
1. Turn selection dial to position T4, T5, T6, T13, and T17.  
2. Check and correct the configuration.  
3. Return selection dial to any run mode position.  
1. Turn selection dial to position T7, T8, T9, T10, T19, T21, T23, and T25.  
2. Check and correct the configuration.  
3. Return selection dial to any run mode position.  
1. Turn selection dial to position T26 and T27.  
2. Check and correct the configuration.  
3. Return selection dial to any run mode position.  
15  
16  
Configuration Error  
Configuration Error  
Push HOLD button on/off.  
1. Turn the error display T4 off.  
2. Change any setpoint.  
3. Turn the error display T4 on.  
4. Return selection dial to any run mode position.  
17  
Current Setpoints  
1. Turn the error display T4 off.  
2. Turn the selection dial to Vacation.  
3. Change any setpoint.  
18  
Vacation Setpoints  
4. Turn the error display T4 on.  
5. Return selection dial to any run mode position.  
1. Turn selection dial to position S.  
Maximum/Minimum Temperature Set-  
points  
2. Change the maximum cooling setpoint (S2). Must be outside 14° range.  
3. Change the minimum heating setpoint (S3). Must be outside 14° range.  
4. Return selection dial to any run mode position.  
19  
20  
1. Turn the selection dial to position S.  
Maximum/Minimum Damper Ventila-  
tion  
2. Change the maximum damper position (S4). Default = 15.  
3. Change the vent damper position (S5). Default = 0.  
4. Return selection dial to any run mode position.  
1. Turn the selection dial to position 1.  
21  
22  
23  
Bypass Damper Total  
Baud Rate  
2. Re-program bypass damper pressure relief limit according to instructions on Programming Sec-  
tion.  
1. Turn selection dial to position T1.  
2. Toggle the baud rate twice (T3).  
3. Return selection dial to any run mode position.  
1. Turn selection dial to position S7.  
2. Change the value.  
Dual Fuel Trip Temperature Error  
3. Return selection dial to any run mode position.  
1. Turn selection dial to position 9.  
2. Set base temperatures. Do not overlap with 14° maximum cooling/minimum heating set point  
range.  
24  
Base Temperatures Error  
3. Return selection dial to any run mode position.  
20  
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Table 14—Hardware Failure Errors  
Error Display (Dial Position T4) must be turned on.  
HF ERROR CODE  
40  
DESCRIPTION  
SOLUTION  
Bad sensor, shorted or open.  
1. Check wiring and sensor.  
Zone 1 Temperature Sensor  
2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F.  
Bad sensor, shorted or open.  
41  
42  
43  
44  
45  
46  
47  
Zone 2 Temperature Sensor  
Zone 3 Temperature Sensor  
Zone 4 Temperature Sensor  
Duct Temperature Sensor  
Outside Air Temperature Sensor  
Dx Coil Sensor  
1. Check wiring and sensor.  
2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F.  
Bad sensor, shorted or open.  
1. Check wiring and sensor.  
2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F.  
Bad sensor, shorted or open.  
1. Check wiring and sensor.  
2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F.  
Bad sensor, shorted or open.  
1. Check wiring and sensor.  
2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F.  
Bad sensor, shorted or open.  
1. Check wiring and sensor.  
2. Replace failed sensor, if necessary. Valid temperature range = -30°—120°F.  
Bad sensor, shorted or open.  
1. Check wiring and sensor.  
2. Replace failed sensor, if necessary. Valid temperature range = 30°—180°F.  
Controller can not communicate on bus.  
1. Check 3-wire bus between controller and comfort zone center.  
2. Replace faulty controller/center boards, if necessary  
Bus Access Error  
Cannot communicate with zone 2 smart sensor.  
1. Turn toggle 13 off if there is no smart sensor attached to zone 2.  
2. Check wiring between sensor and comfort center.  
3. Verify correct address.  
48  
49  
50  
Zone 2 Smart Sensor  
Zone 3 Smart Sensor  
Zone 4 Smart Sensor  
4. Must be addressed 1 less than 4 zone controller’s address.  
Cannot communicate with zone 3 smart sensor.  
1. Turn toggle 14 off if there is no smart sensor attached to zone 3.  
2. Check wiring between sensor and comfort center.  
3. Verify correct address.  
4. Must be addressed 2 less than 4 zone controller’s address.  
Cannot communicate with zone 4 smart sensor.  
1. Turn toggle 15 off if there is no smart sensor attached to zone 4.  
2. Check wiring between sensor and comfort center.  
3. Verify correct address.  
4. Must be addressed 3 less than 4 zone controller’s address.  
51  
52  
53  
Clock Not Ready  
No correction possible.  
Parker Custom Chip Not Ready  
Non-Volatile RAM Not Ready  
No correction possible. Fatal error.  
No correction possible. Fatal error.  
21  
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STANDARD  
SINGLE SPEED  
AIR CONDITIONER  
STANDARD  
SINGLE SPEED  
AIR CONDITIONER  
COMFORT ZONE SYSTEM  
FAN COIL  
COMFORT ZONE SYSTEM  
FAN COIL  
Red  
Red  
UNIT 24 VAC (R)  
R
C
UNIT 24 VAC (R)  
R
C
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
C
Y
C
Y
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
Y1  
Y/Y2  
W2  
G
White  
Brown  
Green  
Orange  
Black  
Y
W2  
W3  
G
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
O
O
L
L
W3  
E
E
A93227  
A93296  
A
B
2-SPEED  
AIR CONDITIONER  
(38TD)  
2-SPEED  
AIR CONDITIONER  
(38TD)  
COMFORT ZONE CENTER  
FAN COIL  
COMFORT ZONE CENTER  
FAN COIL  
Red  
Red  
UNIT 24 VAC (R)  
R
C
R
C
R
C
UNIT 24 VAC (R)  
R
C
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
G
W2  
Y
White  
Brown  
Green  
Orange  
Black  
Y
W2  
G
Y2  
Y1  
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
E
E
W3  
L
W3  
L
L
L
O
Y1  
Y2  
D
A94033  
H
R1  
Latent Capacity Control (LCC)  
R1 = Relay DPST, Pilot Duty,  
24-v coil (HN61KK324) or Equivalent.  
H = Humidistat, opens on humidity  
rise (HL38MG026)  
C
A94032  
Fig. 19—Typical Wiring Diagrams (Fan Coil with Air Conditioner)  
22  
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2-SPEED  
AIR CONDITIONER  
(38TD)  
COMFORT ZONE CENTER  
FAN COIL  
Red  
R
C
UNIT 24 VAC (R)  
R
C
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Blue  
White  
Brown  
Green  
Orange  
Black  
Y1  
Y/Y2  
W2  
G
Y1  
Y2  
RV-COOL (O)  
OR  
RV-HEAT (O)  
L
L
E
W3  
E
A94034  
Fig. 19—Typical Wiring Diagrams (Fan Coil with Air Conditioner) Continued  
23  
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STANDARD  
SINGLE SPEED  
AIR CONDITIONER  
STANDARD  
SINGLE SPEED  
AIR CONDITIONER  
COMFORT ZONE CENTER  
VARIABLE SPEED  
COMFORT ZONE CENTER  
FURNACE  
FURNACE  
Red  
Red  
UNIT 24 VAC (R)  
UNIT 24 VAC (R)  
R
C
R
C
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
C
Y
C
Y
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
White  
Brown  
Green  
Orange  
Black  
Y
W
G
Y
W
G
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
A93220  
(KGATT0101VSP)  
B
RELAY  
COIL  
Black  
1
3
NOTE: Put set-up Switch  
(P5)  
No. 2 at the control  
board to the ON  
CONNECTION AT  
CONTROL BOARD  
position (up) when using  
Two Stage Relay Kit  
KGATT0101VSP  
Accessory (Optional)  
A93219  
A
STANDARD  
SINGLE-SPEED  
AIR CONDITIONER  
2-SPEED  
AIR CONDITIONER  
(38TD)  
COMFORT ZONE CENTER  
VARIABLE SPEED  
FURNACE  
COMFORT ZONE CENTER  
FURNACE  
Red  
UNIT 24 VAC (R)  
R
Y
R
Red  
Yellow  
UNIT 24 VAC (R)  
R
C
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Y2  
Yellow  
Blue  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
C
Y
Blue  
White  
Brown  
Green  
Orange  
Black  
W
G
White  
Brown  
Green  
Orange  
Black  
Y/Y2  
W/W1  
W2  
C
C
Y1  
L
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
G
NOTE: Locking furnace into "low fire" may help prevent over conditioning  
in the heating mode. This will allow the furnace to stage between  
low and high fire. Before using this feature read furnace Installation  
Instructions for two-stage operation. Connect "W2" from the  
Comfort Zone Center to "W2" on the furnace control board.  
A94036  
D
See Furnace Installation Instructions For Details Involving  
Set-Up Switch Configuration and Two-Stage Furnace Operation.  
A94035  
C
Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner)  
24  
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2-SPEED  
AIR CONDITIONER  
(38TD)  
2-SPEED  
AIR CONDITIONER  
(38TD)  
COMFORT ZONE CENTER  
VARIABLE SPEED  
COMFORT ZONE CENTER  
FURNACE  
FURNACE  
Red  
Red  
UNIT 24 VAC (R)  
UNIT 24 VAC (R)  
R
Y
R
R
C
R
C
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Y2  
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
White  
Brown  
Green  
Orange  
Black  
W
G
G
W
Y
C
C
Y1  
L
Y1  
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
L
NOTE: Put set-up switch No. 2  
at the control board to  
the ON position (up)  
when using Two Stage  
Relay Kit  
(KGATT0101VSP)  
RELAY  
Y2  
Black  
KGATT0101VSP  
COIL  
Accessory (Optional).  
R1  
H
1
3
(P5)  
CONNECTION AT  
CONTROL BOARD  
E
A94037  
Latent Capacity Control (LCC)  
R1 = Relay DPST, Pilot Duty,  
24-v coil (HN61KK324) or Equivalent.  
H = Humidistat, opens on humidity  
rise (HL38MG026)  
A94038  
2-SPEED  
AIR CONDITIONER  
(38TD)  
F
COMFORT ZONE CENTER  
FURNACE  
Red  
UNIT 24 VAC (R)  
R
C
R
C
2-SPEED  
Yellow  
AIR CONDITIONER  
(38TD)  
FURNACE  
COOL 1 (Y1)  
Blue  
COOL 2 (Y2)  
COMFORT ZONE CENTER  
White  
G
W
Y
HEAT 1 (W1)  
Brown  
Red  
HEAT 2 (W2)  
UNIT 24 VAC (R)  
R
C
R
C
Green  
Yellow  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Y1  
Orange  
Blue  
RV-COOL (O)  
OR  
Black  
White  
Brown  
Green  
Orange  
Black  
Y/Y2  
W/W1  
W2  
Y2  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
L
G
Y2  
Y1  
L
H
NOTE: Locking furnace into "low fire" may help prevent over conditioning  
in the heating mode. This will allow the furnace to stage between  
low and high fire. Before using this feature read furnace Installation  
Instructions for two-stage operation. Connect "W2" from the  
Comfort Zone Center to "W2" on the furnace control board.  
R1  
Latent Capacity Control (LCC)  
See Furnace Installation Instructions For Details Involving  
Set-Up Switch Configuration and Two-Stage Furnace Operation.  
A94040  
H
R1 = Relay DPST, Pilot Duty,  
24-v coil (HN61KK324) or Equivalent.  
H = Humidistat, opens on humidity  
rise (HL38MG026)  
A94039  
G
Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) Continued  
25  
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2-SPEED  
AIR CONDITIONER  
(38TD)  
COMFORT ZONE CENTER  
FURNACE  
Red  
UNIT 24 VAC (R)  
R
C
R
C
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Blue  
White  
Brown  
Green  
Orange  
Black  
W/W1  
W2  
G
Y1  
RV-COOL (O)  
OR  
RV-HEAT (O)  
Y/Y2  
NOTE:  
Locking furnace into  
"low fire" may help  
prevent over  
conditioning in the  
heating mode. This will  
allow the furnace to  
stage between low and  
high fire. Before using  
this feature read  
L
Y2  
H
furnace Installation  
Instructions for two-  
stage operation.  
Connect "W2" from the  
Comfort Zone Center  
to "W2" on the furnace  
control board.  
Latent Capacity Control (LCC)  
R1 = Relay DPST, Pilot Duty,  
24-v coil (HN61KK324) or Equivalent.  
H = Humidistat, opens on humidity  
rise (HL38MG026)  
See Furnace Installation  
Instructions For Details  
Involving Set-Up Switch  
Configuration and Two-  
Stage Furnace Operation.  
A93219  
I
Fig. 20—Typical Wiring Diagrams (Furnace with Air Conditioner) Continued  
26  
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STANDARD  
SINGLE SPEED  
HEAT PUMP  
STANDARD  
SINGLE SPEED  
HEAT PUMP  
COMFORT ZONE CENTER  
FAN COIL  
COMFORT ZONE SYSTEM  
FAN COIL  
Red  
Red  
R
C
R
C
UNIT 24 VAC (R)  
UNIT 24 VAC (R)  
R
C
R
C
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
White  
Brown  
Green  
Orange  
Black  
Y
W2  
W3  
G
Y
Y1  
Y/Y2  
W2  
G
W2  
Y
W2  
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
O
O
O
O
L
L
E
W3  
E
A93242  
A93243  
A
B
2-SPEED  
HEAT PUMP  
(38YD)  
2-SPEED  
HEAT PUMP  
(38YD)  
COMFORT ZONE SYSTEM  
FAN COIL  
COMFORT ZONE SYSTEM  
FAN COIL  
Red  
Red  
UNIT 24 VAC (R)  
R
C
R
C
R
UNIT 24 VAC (R)  
R
C
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
C
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
G
W2  
Y
White  
Brown  
Green  
Orange  
Black  
Y
W2  
G
Y2  
W2  
W2  
Y1  
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
E
O
O
W3  
L
W3  
L
W3  
L
W3  
L
O
O
E
Y2  
Y1  
A94043  
H
D
R1  
Latent Capacity Control (LCC)  
R1 = Relay DPST, Pilot Duty,  
24-v coil (HN61KK324) or Equivalent.  
H = Humidistat, opens on humidity  
rise (HL38MG026)  
A94042  
C
Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump)  
27  
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2-SPEED  
HEAT PUMP  
(38YD)  
COMFORT ZONE SYSTEM  
FAN COIL  
Red  
R
UNIT 24 VAC (R)  
R
C
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
C
Blue  
White  
Brown  
Green  
Orange  
Black  
Y1  
Y/Y2  
W2  
G
Y1  
Y2  
W2  
RV-COOL (O)  
OR  
RV-HEAT (O)  
O
O
L
L
W3  
E
W3  
A94044  
E
Fig. 21—Typical Wiring Diagrams (Fan Coil with Heat Pump) Continued  
28  
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STANDARD  
SINGLE SPEED  
HEAT PUMP  
STANDARD  
SINGLE SPEED  
HEAT PUMP  
COMFORT ZONE CENTER  
VARIABLE SPEED  
COMFORT ZONE CENTER  
VARIABLE SPEED  
FURNACE  
FURNACE  
Red  
Red  
R
R
UNIT 24 VAC (R)  
UNIT 24 VAC (R)  
R
Y
R
Y
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
White  
Brown  
Green  
Orange  
Black  
W
G
W2  
W
G
W2  
C
C
O
Y
C
C
O
Y
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
(KGATT0101VSP)  
RELAY  
COIL  
Black  
R1  
R1  
1
3
(P5)  
CONNECTION AT  
CONTROL BOARD  
R1 = Relay DPST, Pilot Duty,  
24-v coil (HN61KK324)  
or Equivalent.  
A93234  
NOTE: Put set-up Switch  
No. 2 at the control  
board to the ON  
A
R1 = Relay, DPST, Pilot Duty,  
24-v coil (HN61KK324)  
or Equivalent.  
position (up) when using  
Two Stage Relay Kit  
KGATT0101VSP  
Accessory (Optional)  
A93298  
B
STANDARD  
SINGLE SPEED  
HEAT PUMP  
STANDARD  
SINGLE-SPEED  
HEAT PUMP  
COMFORT ZONE CENTER  
FURNACE  
COMFORT ZONE CENTER  
FURNACE  
Red  
Red  
R
Y
R
Y
UNIT 24 VAC (R)  
UNIT 24 VAC (R)  
R
Y
R
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Y/Y2  
Blue  
Blue  
COOL 2 (Y2)  
White  
White  
Brown  
Green  
Orange  
Black  
W
G
W2  
W/W1  
W2  
G
W2  
HEAT 1 (W1)  
Brown  
HEAT 2 (W2)  
Green  
FAN (G)  
C
C
O
C
O
Orange  
RV-COOL (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
OR  
Black  
C
RV-HEAT (O)  
A93235  
C
NOTE: Locking furnace into "low fire" may help prevent over conditioning  
in the heating mode. This will allow the furnace to stage between  
low and high fire. Before using this feature read furnace Installation  
Instructions for two-stage operation. Connect "W2" from the  
Comfort Zone Center to "W2" on the furnace control board.  
See Furnace Installation Instructions For Details Involving  
Set-Up Switch Configuration and Two-Stage Furnace Operation.  
A94045  
D
Fig. 22—Typical Wiring Diagram (Furnace with Heat Pump)  
29  
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2-SPEED  
HEAT PUMP  
(38YD)  
2-SPEED  
HEAT PUMP  
(38YD)  
COMFORT ZONE CENTER  
VARIABLE SPEED  
FURNACE  
COMFORT ZONE CENTER  
VARIABLE SPEED  
FURNACE  
Red  
Red  
UNIT 24 VAC (R)  
UNIT 24 VAC (R)  
R
C
R
C
R
C
R
C
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
White  
Brown  
Green  
Orange  
Black  
G
W
Y
G
W
Y
W2  
Y2  
W2  
Y2  
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
W3  
L
W3  
L
(KGATT0101VSP)  
O
O
Y1  
Y1  
RELAY  
COIL  
Black  
1
3
R1  
R1  
(P5)  
CONNECTION AT  
CONTROL BOARD  
R1 = Relay DPST, Pilot Duty,  
R1 = Relay DPST, Pilot Duty,  
24-v coil (HN61KK324) or Equivalent.  
24-v coil (HN61KK324) or Equivalent.  
A94046  
NOTE: Put set-up Switch  
No. 2 at the control  
board to the ON  
E
position (up) when using  
KGATT0101VSP  
A94047  
2-SPEED  
HEAT PUMP  
(38YD)  
Accessory (Optional)  
F
COMFORT ZONE CENTER  
FURNACE  
Red  
UNIT 24 VAC (R)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
R
C
R
C
Yellow  
Blue  
White  
Brown  
Green  
Orange  
Black  
G
W
Y
W2  
Y1  
RV-COOL (O)  
OR  
RV-HEAT (O)  
W3  
L
O
Y2  
H
R1  
Latent Capacity Control (LCC)  
R1 = Relay DPST, Pilot Duty,  
24-v coil (HN61KK324) or Equivalent.  
H = Humidistat, opens on humidity  
rise (HL38MG026)  
A94048  
G
Fig. 22—Typical Wiring Diagrams (Furnace with Heat Pump) Continued  
30  
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2-SPEED  
HEAT PUMP  
(38YD)  
2-SPEED  
HEAT PUMP  
(38YD)  
COMFORT ZONE CENTER  
FURNACE  
COMFORT ZONE CENTER  
FURNACE  
Red  
Red  
R
C
UNIT 24 VAC (R)  
UNIT 24 VAC (R)  
R
C
R
R
C
Yellow  
Yellow  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
COOL 1 (Y1)  
COOL 2 (Y2)  
HEAT 1 (W1)  
HEAT 2 (W2)  
FAN (G)  
C
Blue  
Blue  
White  
Brown  
Green  
Orange  
Black  
White  
Brown  
Green  
Orange  
Black  
G
W
Y
Y/Y2  
W/W1  
W2  
Y2  
W3  
W2  
W2  
Y1  
RV-COOL (O)  
OR  
RV-HEAT (O)  
RV-COOL (O)  
OR  
RV-HEAT (O)  
G
O
L
W3  
L
Y1  
O
Y2  
NOTE: 38YD – with dual fuel, use the 38YD “Furnace Interface” and  
“Balance Point” feature on the heat pump control to operate  
dual fuel option. Configure the 4-Zone controller to act as  
if it were controlling a single speed heat pump. Turn (T-6) ON.  
Turn (T-9 & T-26) OFF. Set (S-7) to 0. (Let the 38YD perform  
the dual fuel optimization).  
H
In addition, lock furnace into “low fire”. This may help prevent over  
conditioning during the back-up heat (furnace) mode. This will also  
allow the furnace to stage between low and high fire. Before using  
this feature read furnace Installation Instructions for two-stage  
operation. Connect “W2” from the Comfort Zone Center to “W2” on  
the furnace control board.  
R1  
Latent Capacity Control (LCC)  
See Furnace Installation Instructions For Details Involving  
Set-Up Switch Configuration and Two-Stage Furnace Operation.  
R1 = Relay DPST, Pilot Duty,  
38YDA – with dual fuel, same as above, however in addition if  
(T-26) is turned “ON”, and stage 2 latch pot is set to zone position,  
4 stages of heat are possible.  
24-v coil (HN61KK324) or Equivalent.  
H = Humidistat, opens on humidity  
rise (HL38MG026)  
A94049  
See Heat Pump Installation Instructions For Details Involving  
Two-Speed Configuration and Operation.  
H
A94312  
I
Fig. 22—Typical Wiring Diagrams (Furnace with Heat Pump) Continued  
31  
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Comfort Zone Configuration Table  
FACTORY  
RECORD  
JOB SETTING  
TOGGLE  
DESCRIPTION  
DEFAULT  
OFF  
OFF  
ON  
T1  
T2  
Timeguard Override  
Celsius Temperature Display  
2400 Baud Rate  
T3  
T4  
Error Code Display  
ON  
T5  
Enable Broadcast  
ON  
T6  
Heat Pump Operation  
Outside Air Temp Sensor Attached  
Comfort Trend Setting  
Auto Fan Off For Heat  
High/Low Temperature Limits  
Installer Switch Lockout  
Force Outside Air Ventilation  
Smart Sensor Attached For Zone 2  
Smart Sensor Attached For Zone 3  
Smart Sensor Attached For Zone 4  
Zone 2 Active  
OFF  
OFF  
ON  
T7  
T8  
T9  
OFF  
ON  
T10  
T11  
T12  
T13  
T14  
T15  
T16  
T17  
T18  
T19  
T20  
T21  
T22  
T23  
T24  
T25  
T26  
T27  
T28  
SETTING  
S-1  
S-2  
S-3  
S-4  
S-5  
S-6  
S-7  
ROTARY  
09  
OFF  
OFF  
OFF  
OFF  
OFF  
ON  
Zone 3 Active  
ON  
Zone 4 Active  
ON  
Economizer  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
Alternating Display  
Outside Air Damper Attached  
System Mode Reselect  
System Error Checking  
50 Hz Operation  
Ventilation Mode  
Two-Stage Heat Pump  
Dx Sensor For LAT Checking  
Cool Without Fan  
4 Zone Controller Bus Address  
Max Cooling Setpoint  
Min Heating Setpoint  
04  
85  
65  
Max Damper Position  
Ventilation Damper Position  
High Temp Trip Limit  
15  
00  
105  
00  
Dual Fuel Setpoint  
Base Temp Setpoint Scale  
Calibrate Dx Coil Sensor  
08  
07  
Calibrate Outside Air Temp Sensor  
Calibrate Duct Temperature Sensor  
Calibrate Zone 4 Temp Sensor  
Calibrate Zone 3 Temp Sensor  
Calibrate Zone 2 Temp Sensor  
Calibrate Zone 1 Temp Sensor  
Damper Service Position  
06  
05  
04  
03  
02  
01  
Copyright 1995 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231  
zonekt4c  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 3a 5a 2a 5a  
1
1
4
4
PC 101  
Catalog No. 809-568  
Printed in U.S.A.  
Form ZONEKIT4-1SI  
Pg 32  
7-95  
Replaces: 920415-3SI  
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