SEGMENT 5ZONING PRINCIPLES

INTRODUCTION TO ZONING

Static regain zones better than conventional

3 ways to zone1. Variable CFM out of the blower to

match Static Pressure / Zones calling

2. Bypass excess air• Bypass to a dump zone• Bypass to return

3. Increase the number of outlets in each zone

The Realities of Zoning Success

• Increased Available Supply static pressure when Low load zones satisfy

• Increased Branch duct velocity delivers Colder, Dryer air (more BTU’s to the space) when available supply static increases.

• Decrease in coil velocity increases BTU/CFM transfer

• Coil icing issues only occur when set point is not achieved causing extended cycle time.

ZONE PAKDAMPER SYSTEM

Up

Porch

Kitchen

Dinnette

Foyer

Office

½ Bath

Living RmFormal Dinning

Up

Mstr Closet

Mstr Bed Room

Bed Room

Bed Room

Bath

1st Floor 2nd Floor

Joe’s House

Porch

Porch

Porc

h

Zone 1 - 1st Fl Living Area (565 sq ft)

Zone 2 - 1st Fl Kitchen/Dinning Area (500 sq ft)

Zone 3 - 2nd Fl Bed Rooms (825 sq ft)

1900 Total Sq Ft

Two stage, variable speed, 70k BTU furnace

Single stage, 2 ton A/C

Zone Pak Pro-3 Zone panel

(W2 initiated when the 2nd fl zone calls w/ any 1st fl zone)

HPPro Zoning Data

Joe’s House

Data time range 16,522 min 275 hrs 11 days

Min ODT 19 deg f Max ODT 55 deg f Avg ODT 36 deg f

Total Run Time - 150 hrs 2nd stg Heat- W2 20 hrs 13%

Serving Zone 1 (1st fl Main) 111 hrs 74%Serving Zone 2 (1st fl kitch) 53 hrs 35% Serving Zone 3 (2nd fl Bd Rms) 36 hrs 24%

Serving Single Zone 72% Serving Two Zones 25% Serving All Three Zones 3%

W1 Cycle data Total cycles 589 Avg Cycle “On time” 16 MinAvg Cycle “Off time” 8 Min Avg Cycles/Hr 2

Joe’s House

Data time range 5 days

Min ODT 78 deg f Max ODT 91 deg f Avg ODT 84 deg f

Total Run Time - 39 hrs 2nd stg Blower- Y2 38 % (Y1 only 62%)

Serving Zone 1 (1st fl Main) 3 %Serving Zone 2 (1st fl kitch) 38 % Serving Zone 3 (2nd fl Bd Rms) 62 %

Serving Single Zone 70 % Serving Two Zones 29 % Serving All Three Zones 1 %

HPPro Zoning DataHPPro Zoning Data

BENEFITS OF ZONING

• Greater Occupant Comfort• Allows for Decreases in System

Capacity Demand• Increased Installation Flexibility• Reduced Energy Consumption

Market Impact

• Zoning makes any system more effective– This is especially true for heat pumps that

can at times be capacity limited. Concentrating the conditioned air to those areas that need heat or cool just makes sense.

• Staging on Capacity – Presently only the highest end equipment

has the capability to adjust its capacity based not only on thermostat demand but on equipment capacity. Space Pak has taken a large step toward making heat pumps an option for more areas of the country.

Two Zone Layout

• 1st Fl Living area is 60% of the duct capacity

• 2nd Fl Bed Room Zone is 40% of the duct capacity

2nd floor Bedroom Zone

40%

st floor Living Area 60%

Three Zone Layout

• 1st Fl Living area is 50% of the duct capacity• 2nd Fl Master suite is 25% of the duct capacity• 2nd Fl Bed Rooms 1 & 2 are 25% of the duct

capacity

Master Suite

25%

Bedroom 1

12%

Bedroom 2

13%

1st floor Living Area

50%

SEGMENT 6 ZONING COMPONENTS

STANDARD ZONE PAK FEATURES

• 2 or 3 zones with one air handler• Controls integrate with any

secondary heat source• Reliable operation provided by

Air-Driven Dampers• Easy to install vinyl tubing

Reduced Energy Consumption

• Simple 24 Volt Wiring• Quiet Operation• Pre-Programmed Controls• Convenient Packaged Systems• Unmatched Factory Support

PLENUM DAMPER PACKAGES AVAILABLE

• 8" Square 2-Zone System• 8" Square 3-Zone System• 9" Round 2-Zone System• 9" Round 3-Zone System• SmartPak System 2-Zone System• SmartPak System 3-Zone System

PACKAGES INCLUDE

• Plenum Dampers• Control Panel• 24 Volt Transformer• Tubing• Cut-Out Templates

BRANCH DAMPERS

• 2" Branch Dampers - 2/pack• 2" Branch Dampers - 5/pack• Control Panel selected separately

for 2 or 3 zones• Can be used in conjunction with

plenum dampers

ZONE PAK PRICE SHEET

Market Impact

• High efficiency equipment can be made even more efficient with the power of zoning.

• Airflow can be manipulated based on zone weight so we have a lesser need for bypass which impact actual delivered efficiency.

Market Impact

• Humidity Control comfort is not just about temperature. Humidity has a large impact on how comfortable we feel.

• The Zone Pak Pro™ provides systems for humidification and positive control of the bypass humidifier duct.

• The Zone Pak Pro™ allows you to run a dehumidification cycle using standard equipment. You no longer need equipment with a dedicated “Dehum” cycle. Fight moisture build up and mold in humid climates. Keep everyone more comfortable.

Market Impact

• The Zone Pak Pro™ Steps out of the 20th century and into the 21st.– It has been designed to give contractors

abilitites that have never been available before.

– It has a great new look. The LCD screen makes a statement to today’s tech savvy consumers

– It is entirely software driven. There are no dip switches. The adaptive program walk installers and technicians through with no confusion.

– Use ANY thermostats that make sense for your application. Zones 2-4 use only 4 or 5 wire heat/cool stats. New installers will have no problems with this unit.

SEGMENT 7ZONING RULES

Design Design ConsiderationsConsiderations

• Design DX systems with 2 or 3 zones Design DX systems with 2 or 3 zones max.max.– Unlimited with Chiller applicationsUnlimited with Chiller applications

• All zones must have a All zones must have a minimumminimum of of 3.5 outlets per ton – (per zone)3.5 outlets per ton – (per zone)– 4 ton system4 ton system

• 4 x 3.5 = 14 outlets per zone 4 x 3.5 = 14 outlets per zone minimumminimum

• 3 zones x 14 outlets = 42 outlets 3 zones x 14 outlets = 42 outlets totaltotal

• 42 outlets divided by 4 tons = 10 42 outlets divided by 4 tons = 10 outlets/ton outlets/ton

• 2 zone systems can be designed 2 zone systems can be designed with as high as 5 outlets per ton per with as high as 5 outlets per ton per zone zone (10/ton total outlets)(10/ton total outlets)

• Not recommended to use a bypass Not recommended to use a bypass duct on DX coil systemsduct on DX coil systems

Basic 2 and 3 Zone SystemMinimum Outlet Required In Each Zone

System Tonnage

2 Zone # of Outlets in each Zone

2 ZoneSystem Total

Outlets

3 ZoneOutlets in each Zone

3 ZoneSystem Total

Outlets

2 7 7 w/ 14 7 21

2.5 9 9 w/ 18 9 27

3 11 11 w/ 22 11 33

3.5 12-13 12 w/ 24 12 36

4 14 14 w/ 28 14 42

5 18 18 w/ 36 18 54

MD

MD

Zo

ne

2D

am

pe

r

Zone 1Damper

RA

AH

3 ton 2 Zone (3 ton X 3.5 = 11 outlets per zone minimum)Z-1 = 15 Outlets (5/ton)Z-2 = 11 Outlets (3.5/ton min)26 outlets Total = 8.5 / Ton

Zone 2 Load requires 6 Outlets

Zone 1 Load requires 15 Outlets

MD

MDMD

2.5 ton/ 3 Zone2.5 ton X 3.5 / ton = 9 outlets / zone

27 Outlets Total = 10.5/Ton Duct sizes

Square – 8.5" x 8.5"Round

Common Trunk - 9"Zone Trunk - 7"

Zone 2Damper

Zone 3Damper

Zone 1Damper

RA

AH

2.5 ton/ 3 Zone (2.5 ton X 3.5 / ton = 9 outlets / zone)27 outlets Total = 10.5 / Ton

MD

MD

Zo

ne

2D

am

pe

r

Zo

ne

1D

am

pe

r

4 ton/ 2 Zone4 ton X 3.5 / ton = 14 outlets / zone

28 outlets equals 7/ton Total Optional – up to 5 Outlets/Ton/Zone

Duct sizesSquare

Trunk 9.5" x 9.5"Round

Common Trunk - 10"Zone Trunk - 7"

RA

AH

4 ton/ 2 Zone (4 ton X 3.5 / ton = 14 outlets / zone)28 outlets Total = 7 / Ton (2 Zone Option - 5 Outlets/Ton/Zone)

2.5 ton/ 2 Zone (2.5 ton X 3.5 / ton = 9 outlets / zone)18 outlets Total = 7 / Ton (2 Zone Option - 5 Outlets/Ton/Zone)

Duct sizesSquare – 8.5" x 8.5" (All Duct)RoundCommon Trunk - 9"Zone Trunk - 7"

RA

MD

MD

Zone 1Damper

Zone 1Damper

AH

MD

Zone 2Damper

MD

Zone 2Damper

Air Schematic

Com

N/O

N/C

Com

N/O

N/C

Vacuum Side of Pump

-30” to -40” WC

Pressure Side of Pump

40” to 50” WC

24 V DC Solenoid

+ + 1 2 3 4

24 VAC

24 V DC Solenoid

AirBoss-2 PC Brd

R

W1

W2

Y1

Y2

G

O

C

R

W1

W2

Y1

Y2

G

O

C

R W1 W2 Y1 Y2 G O B C

HVAC OUTPUT

ZONE SOLENOID

ZO

NE

1

ZO

NE

2

PUMP

N/O to Vacuum

N/C to Pressure

On

MPS

Off

To Zone 2 dampers

To Zone 1 dampers

De-energized 0 VDC Energized 24 VDC

Reverse-Acting Dump OutletsThe Alternative to Bypass CFM

• Add additional outlets to dump areas that are controlled by reverse acting dampers and open when larger zones close.– Be careful not to overdue it

Dump (static relief) Zone

MDMD

Zone 2Damper

Zone 3Damper

Zone 1Damper

RA

AH

MD

Rev ActDamper

Vaulted Ceiling AreaZone Panel

MD

USING THE ACM TO SET BACK AND MATCH 2 SPEED

CONDENSERSTEP # 1 – REFER TO THE CFM SET FOR MAXIMUM

CONDENSER CAPACITY.STEP # 2 – DETERMINE THE SET BACK CAPACITY

OF THE CONDENSER. ALL MANUFACTURERSSET BACK A % OF TOTAL CAPACITY. SOMESET BACK 30%, 35%, 40% OR 50%.

STEP # 3 MULTIPLY THE TOTAL CFM FOR MAXIMUM CAPACITY BY THE % SET BACK. THIS WILL GIVE YOU A CFM TO SUBTRACT FROM THE TOTAL.

STEP # 4 SUBTRACT THE % CFM FROM STEP 3 FROM THE TOTAL.STEP # 5 FIND THE SET BACK CFM ON THE ACM AMP CHARTSTEP # 6 SET THE ACM BY READING AMPS TO THE MINIMUM POSITION.

Dump (static relief) Zone

MDMD

Zone 2Damper

Zone 3Damper

Zone 1Damper

RA

AH

MD

Rev ActDamper

Vaulted Ceiling AreaZone Panel

MD

Pressure TransmitterExcessive Static Press

Pump Pressure @ 45”wc

.012” Restrictor

Supply Duct

Variable Pressure 0” to 20”wc

Pressure Transmitter

Variable “Bleed-Off”

H V Control1” to 2” Press range

3 Zone with 6” Round Bypass Duct“On A chiller”

MDMD

Zone 2Damper

Zone 3Damper

Zone 1Damper

RA

AH

ModuPassDamper

Zone Panel

MD

MD

Market impact

• Programmability– The Setup Wizard walks the installer

through a series of very simple setup parameters.

– The setup worksheet gives the installation manager or Comfort consultant an easy way to tell installers just how they want the system to be configured.

– Once the Setup Wizard is complete the parameters are “burned” into non-volatile memory. Loosing power will not reset your settings.

ZONEPAK PRO PANEL

ZONE PAK PRO

ZONEPAK PRO PANEL

Setup Wizard

• The first time the system is powered up the Installer must run through all of the Setup questions. This sets all of the default settings.

• Subsequent times if no changes are made in 30 seconds the system will power up using it’s current default settings

Stage on Demand

• The Zone Pak Pro™ accepts two-stage inputs from the Zone 1 thermostat.

• Demand will be recognized and served.

Stage on Capacity

• Heat pumps provide a finite amount of heat or cool in any given operating mode.

• This graph shows a simple single-stage scenario. – Call starts – ∆T (the change in

temperature over any given time) increases rapidly as the refrigerant starts to circulate

– ∆T starts to decrease, finally going to zero as the equipment capacity is reached.

Zone Pak Pro PanelCapacity Staging

Heating cycle initiated

2nd stage Heat initiated

Heating cycle reaches “Steady State” LAT above “Min heating LAT” setting

Pre-Set LAT Min (Leaving Air Temp Minimum)

3rd stage Heat initiated

Zone Weighting

• Zone weighting gives The Zone Pak Pro™ several distinct advantages– We are able to stage

up the air handler independently of the condenser based on the amount of ductwork being served. This reduces or eliminates the need to bypass increasing system effectiveness.

– Priority can be based on the cumulative zone weight calling for any particular service.

Air Handler Control

• Staging the Air Handler(s) independently from the condensers gives us a very powerful tool to affect comfort.

• Only stage up the Air Handler when there is enough ductwork open to accept the air provided.– Throttle back the air

handler for dehumidification.

• Controlling fan speed provides another tool for customizing your customers’ comfort.– Provides warmer air

delivery to single zone callers.

• Reduce or Eliminate the need for bypass.

2 Stg Heat Pump

Air Handler/ V spd Furnace

Y1 Y2

YI Y2 Y1 Y2 CAir Handler Condenser

HPP HVAC outputY1 Y2 C

HPPro

Humidification

• On a call from a humidistat:– Send a

24VAC signal to the humidifier

– Open a damper in the humidifier bypass ductwork

• Eliminates the homeowner’s need to open or close a manual damper

Dehumidification

• Standard Equipment– On a call from a

Dehumidistat:• If cooling back

off one cooling speed setting

• If not cooling start the condenser and low speed fan

• Run the system on and off on a user defined cycle period.

– Inhibited during heating cycles

• Lennox Signature/Carrier Infinity– Pass the call to

the proprietary equipment

– Inhibited during heating cycles

The Zone Pak Pro™ has the ability to operate as a whole house dehumidifier.

Built-In Controls

• Balance Point Calculations – no need for an outdoor thermostat.

• Resistance Heat Lockout control holds off resistance heat above a given temperature to comply with utility regulations or incentive programs

• Low-ambient cooling – no need for a low-ambient kit, ZPP inhibits cooling below an adjustable temperature automatically.

• Outdoor Reset Controls – adjusts Leaving Air Temperature requirements as outside air temperature changes.

• Leaving Air Controls – protects HVAC equipment

Leaving Air Temperature SensorHeating

• Protects the HVAC Equipment from extreme temperatures

• Heating LAT trips 2nd stage 10oF below setpoint*, and the 1st Stage at setpoint.

•1st stage is reconnected on a temperature fall of 15o and 4 minute off-time.

•Up staging is inhibited within 15o of the setpint

•Calls that contain a W will use the Backup Heat LAT Setting

*The LAT System is a secondary control. It should be set inside factory limits.

Leaving Air Temperature SensorCooling

• Protects the coil from freezing

• Cooling LAT trips 2nd stage 5oF above setpoint*, and the 1st Stage at setpoint.

•1st Stage is reconnected after a temperature rise of 10o and 4 min off-time.

•Up staging is inhibited within 10o of the setpoint

*The LAT System is a secondary control. It should be set inside factory limits.

Equipment Integration

• The Zone Pak Pro™ has been designed with all the features you need to control virtually any heat pump.– All Electric– Dual Fuel– Geothermal

Thermostats

• Zone 1 – Use any thermostat that provides the features you need. Heat/cool or Heat pump, single or two-stage, wired or wireless. You can use the thermostat that gives you the control you want.

• Zones 2-4 Use simple 4 or 5 wire heat cool thermostats. This simplifies installation and planning.

Software Driven

• The key to the flexibility and adaptive nature of the Zone Pak Pro™ is the fact that it is 100% software driven. – Most settings and timers are field

adjustable – System changes and upgrades

can be sent by email– System will be more end-user

friendly

Set up Wizard zpp

The Setup Worksheet

Prompt Description Setting

1 Zone 1 - Thermostat TypeHeat pump or Heat/Cool - defines how input sigals will be interpreted.

2 Zone 1 - Thermostat Weight

Assigns a relative weight for each zone. Can be for 10% to 90%. Determines when the air handler stages up. Zone 1

3 Zone 2 - Thermostat Weight Zone 2

4 Zone 3 - Thermostat Weight Zone 3

5 Zone 4 - Thermostat Weight Zone 4

6 Minimum HeatDefines the minimum acceptable temperature for the LEAVING Air Tempeature during a heating call

7 Maximum CoolDefines the maximum acceptable temperature for the LEAVING Air Tempeature during a cooling call

8 Back-up TypeEll the HPP what equipment it will be working with. Electric strips or Fossil Fuel

9 Balance PointEnter the temperature you want to change over to Fossil Fuel Backup furnace.

10 Heat Strip Lock-outEnter the temperature above which you do NOT want heat strips to be turned on.

11 Min OAT for CoolingBuilt-in Low Ambient Kit. Set temperature below which you do NOT want cooling

12 Low LAT LimitLow Limit for Leaving Air Temperature. Set temperature to shut down the 1st stage compressor

13 High LAT LimitHigh Limit for Leaving Air Temperature. Set temperature to shut down the 1st stage compressor

14 High LAT Limit with W High LAT Limit for backup heat system

15 Cool O/BSet which cycle energizes reversing valve. Defualt is "O" O/B Terminal will be hot for a cooling call

16 Staging ThresholdSet % weight that will allow airhandler to stage up with compressors.

Zone Pak Pro™ Setup Worksheet

Apply the Template

Cut out the Triangle

Insert the Damper

Twist into Position

Fasten with Zip Screws

Attach the Air Line

Finished!