Carrier Air Conditioner ZONEKIT2ZCAR User Manual

ZONEKIT2ZCAR  
WeatherMaker® Two-Zone  
Installation and Start-Up Instructions  
NOTE: Read the entire instruction manual before starting the  
installation.  
This symbol indicates a change since the last issue.  
TABLE OF CONTENTS  
PAGE  
Safety Considerations.....................................................................1  
Installation Considerations.............................................................1  
Introduction ....................................................................................1  
®
COMFORT ZONING SYSTEM  
Installation...................................................................................1-4  
Sequence Of Operation...............................................................4-7  
Thermostat Wiring......................................................................6-8  
Care And Maintenance ..................................................................8  
Troubleshooting ........................................................................9-11  
Wiring Diagrams.....................................................................12-16  
Wiring Diagram Notes.................................................................16  
Y2 T'stat  
Equpimt  
Fnc  
HP  
RC-RH  
Jumper  
Emergency  
Heat  
Y1  
R
Z
o
n
e
HP  
Fnc  
C1  
Op  
3
G
W1  
W2  
C
Y1  
Y2  
DTO  
Off  
Fnc Ht  
w/oF  
C
1
On  
Off  
WARNING!  
Z
o
n
e
C1  
Op  
On w/F  
HOT parts  
under this label  
G
Y2  
Y1  
R
W1  
W2  
C
24 VAC  
C
2
Rev  
W1  
W2  
Sensors  
RC  
B O  
Y2  
Y1 W1  
W2 G  
RH  
HP  
Duct  
Equipment Term.  
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 infor-  
mation 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.  
Fig. 1—WeatherMaker Two-Zone SystemA97292  
(Shown Without Cover)  
5. Use separate isolated transformer to supply power to Weath-  
erMaker Two-Zone Center. (40va minimum, class 2, trans-  
former, field supplied)  
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.  
6. Load calculations must be performed to determine equipment  
size. Equipment selection is matched to block load. It is  
imperative equipment is not over sized.  
7. Ductwork must be designed based off the sum of peak plus 25  
percent oversize. It is imperative ductwork is not under sized.  
Recognize safety information. This is the safety-alert symbol  
.
INTRODUCTION  
When you see this symbol on the unit or in instructions and  
manuals, be alert to the potential for personal injury.  
The WeatherMaker Two-Zone System allows the air conditioning  
and heating equipment to control temperatures in 2 distinct spaces  
or zones within a building. Each zone has independent temperature  
settings controlled by a thermostat.  
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.  
NOTE: Thermostats are purchased separately.  
The comfort temperature settings can change automatically  
through the use of schedules if programmable thermostats are  
selected. This allows WeatherMaker Two-Zone to change the  
temperature settings in zones to reflect occupancy or usage. The  
WeatherMaker Two-Zone System uses motorized air volume  
control dampers (also called zone dampers) to regulate the flow of  
conditioned air into the zones.  
INSTALLATION CONSIDERATIONS  
1. Install in non-condensing area with ambients between 32°F  
and 150°F.  
2. Use vibration isolators (flex connectors) on zone dampers and  
ductwork to minimize noise.  
INSTALLATION  
3. Place dampers away from areas that may be noise sensitive.  
Step 1—Check Equipment and Jobsite  
4. TXV is required in air conditioning and heat pump applica-  
tions.  
INSPECT EQUIPMENT — File claim with shipping company,  
prior to installation, if shipment is damaged or incomplete.  
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. 809-500  
Printed in U.S.A.  
Form ZONEKIT-8SI  
Pg 1  
6-97  
Replaces: ZONEKIT-2SI  
 
1/2 STEEL STRAP  
ZONE  
DAMPER  
FLEXIBLE  
DUCT  
Fig. 5—Insulated Round Metal DuctworkA95130  
A95132  
Fig 8—Round Flexible Ductwork  
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check  
your local codes.) (See Fig. 9.)  
NOTE: All zone dampers and ductwork must be properly sup-  
ported according to local codes or SMACNA standards.  
S-LOCK  
1/2STEEL STRAP  
SUPPLY  
AIR DUCT  
DRIVE  
ZONE  
DAMPER  
A95133  
A92478  
Fig. 6—Rectangular Metal Ductwork  
Fig. 9—Insulated Round Flexible Ductwork  
2. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
RECTANGULAR FIBROUS GLASS DUCTWORK  
1. Insert 1 end of zone damper into 1 end of fibrous glass  
ductwork approximately 2 to 3 in. (See Fig. 10.)  
3. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check  
your local codes.) (See Fig. 7.)  
FIBROUS  
GLASS  
DUCTWORK  
11/2 " TO 2"  
INSULATION  
FIELD  
SUPPLIED  
SCREWS  
ZONE  
DAMPER  
2TO 3″  
A92480  
Fig. 10—Rectangular Fibrous Glass Ductwork  
2. Screw field-supplied screws and tabs into zone damper.  
3. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuators  
A95131  
Fig. 7—Insulated Rectangular Metal Ductwork  
4. Insulate damper using 1-1/2-in. to 2-in. insulation. (Check  
your local codes.) (See Fig. 11.)  
NOTE: All zone dampers and ductwork must be properly sup-  
ported according to local codes or SMACNA standards.  
NOTE: There should be a minimum of 4 ft between the zone  
damper and the first branch duct if more than 1 branch duct is  
downstream of the zone damper.  
ROUND FLEXIBLE DUCTWORK  
11/2TO 2″  
INSULATION  
1. Slip 1 end of flexible ductwork over 1 end of zone damper.  
(See Fig. 8.)  
2. Secure the flexible duct to zone damper using SMACNA or  
other approved method.  
A95134  
Fig. 11—Insulated Rectangular Fibrous Glass  
Ductwork  
3. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
3
 
Step 5—Install Barometric Bypass Damper  
• Energize HVAC equipment fan.  
• Energize heating or cooling equipment. The equipment may be  
a compressor, furnace, strip heater, etc.  
• Set zone damper to the open or closed position based upon  
individual zone demand.  
• Energize additional stages of heating or cooling if the thermostat  
demand warrants.  
• Turn off heating or cooling equipment when all zones are  
satisfied.  
• Open all zone dampers when equipment is turned off (after 90  
sec delay).  
NOTE: The barometric bypass damper is a critical part of the  
WeatherMaker Two-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 the bypass is properly supported.  
For proper installation, refer to the Installation Instructions pack-  
aged with the barometric bypass.  
This is the basic sequence of operation for the WeatherMaker  
Two-Zone System. The actual control of the dampers, HVAC  
equipment, and system fan will change with the configuration of  
the system. Depending upon the configuration, WeatherMaker  
Two-Zone can control heat pumps, furnaces, and dual fuel  
applications, (dual fuel will require a third party relay interface).  
Failure to properly install the bypass damper can cause  
permanent damage to the HVAC equipment. For single-speed  
furnace applications, the bypass air must never exceed 25  
percent.  
Step 6—Install Leaving Air Temperature Duct Sensor  
Step 2—Selection of a System Mode  
Locate duct temperature sensor in main supply trunk after heating  
and cooling coil and before the bypass damper and before the first  
branch. The duct sensor must be radiant shielded to prevent heat  
from affecting the correct air temperature.  
The first step in any heating or cooling cycle requires Weather-  
Maker Two-Zone to receive an input from any thermostat located  
in a zone. WeatherMaker Two-Zone will then prepare to operate  
the heating or cooling equipment as requested by the thermostat.  
(See Fig. 12.)  
1. Drill 1/4-in. hole at location in supply trunk where sensor will  
be installed.  
Step 3—Pre-Positioning Dampers and Starting  
System Fan  
2. Insert sensor in hole and use as template to mark 2 mounting  
holes.  
In order to minimize noise and enhance system operation, Weath-  
erMaker Two-Zone maintains fully open zone dampers prior to  
starting the system fan or the heating/cooling equipment. The  
intent is to provide the HVAC equipment with unrestricted  
ductwork and to reduce pressure surges. WeatherMaker Two-Zone  
also fully opens the dampers whenever a heating or cooling cycle  
is completed (this is done after a 90 sec delay). All zone dampers  
will remain fully open until the next heating or cooling cycle.  
3. Drill two 1/16-in. holes to accept No. 6 screws through  
pre-drilled holes in duct temperature sensor back plate.  
4. Use 2 No. 6 sheet metal screws to mount duct temperature  
sensor to unit.  
5. Connect sensor to 2-conductor wire using provided wire nuts.  
(See Fig. 12 for connection to equipment controller.)  
Step 7—Install Heat Pump (HP) Temperature Sensor  
The other reason for opening the dampers is to provide unrestricted  
ductwork to other equipment which is not directly controlled by  
WeatherMaker Two-Zone. One example may be a Heat Recovery  
Ventilator. If WeatherMaker Two-Zone is not actively controlling  
the HVAC system, then it must not impose any control influences  
(such as closed zone dampers) on the system and prevent proper  
operation of other devices.  
The HP temperature sensor is required in all heat pump/fan coil  
installations. It is not used in dual fuel (heat pump/furnace  
installation.) It measures the indoor coil temperature. The sensor is  
to be installed downstream of the indoor coil, but before the  
electric heaters. It can be installed through the wall of the fan coil  
or may be located entirely inside the fan coil near the blower inlet.  
Anchor firmly in place with cable ties so that it cannot interfere  
with the blower wheel. To activate the HP temperature sensor,  
remove factory supplied resistor from HP terminal block and  
replace with sensor leads. When activated, the HP temperature  
sensor has built in LAT set points of 50°F and 45°F in the cooling  
mode, and 105°F and 110°F in the heating mode. This is  
non-adjustable. (See Fig. 12 for connection to WeatherMaker  
Two-Zone center.)  
Only the zone 1 thermostat controls continuous fan operation.  
When the zone 1 thermostat has the fan selector switch in the  
AUTO position, the fan will operate only when the heating and  
cooling equipment is operating. When the zone 1 thermostat has  
the fan selector switch in the ON position, the fan will operate  
continuously. Zone 2 will not control this.  
Step 4— HVAC Equipment Connections  
The WeatherMaker Two-Zone relay outputs are shown in Table 1.  
The Y1 and Y2 contacts are used for the compressor contactor  
only. WeatherMaker Two-Zone operates the heat pump by ener-  
gizing the compressor contactor and controlling the reversing  
valve through the O 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 WeatherMaker  
Two-Zone are shown in Table 1.  
SEQUENCE OF OPERATION  
Step 1—Sequence of Events for a Normal Heating or  
Cooling Cycle  
The thermostats will determine if active heating or cooling is  
required. If so, the WeatherMaker Two-Zone System will perform  
the following:  
• Make sure all zone dampers are fully open.  
Table 1—Available Heating and Cooling Stages Versus System Type  
TYPE OF HVAC  
EQUIPMENT USED  
REVERSING VALVE  
REVERSING VALVE  
O
COOLING STAGE 1 COOLING STAGE 2  
HEAT STAGE 1 HEAT STAGE 2  
O
Single-Stage Heat  
Pump  
Y1  
Y1  
Y1  
Y2  
Y2  
Energized  
Energized  
Y1/W1  
Y1/W1  
W1  
W2  
W2  
W2  
De-energized  
De-energized  
2-Stage Heat Pump  
Cooling Only, any  
Heater Type  
4
 
In automatic changeover, the zoning system works on a first come  
first serve basis. If 1 zone is calling for heating and the other for  
cooling, the zone which sent its demand to the I/O center first will  
operate the equipment in that mode until that zone is satisfied.  
If you encounter a situation where 1 zone seems to have poor  
ductwork, then the WeatherMaker Two-Zone system is capable of  
reverting back to a fully open, constant-volume system. If this  
condition persists, it should always be looked upon as an indication  
of a HVAC problem, not a WeatherMaker Two-Zone problem.  
Step 5—Duct Temperature Optimizer (DTO)  
Step 6—Electronic Thermostat Connection with  
WeatherMaker Two-Zone Control  
For Monitoring Leaving Air Temperature  
As the WeatherMaker Two-Zone System operates through a  
heating or cooling cycle, the zone demands will change. This  
changes actual load that is applied to the HVAC equipment. If the  
zone airflow decreases, the cooling equipment will tend to lower  
supply-air temperatures which could tend to exceed the LAT trip  
limits. Conversely, the heating equipment will tend to raise the  
supply-air temperatures which could exceed high trip limits. In  
cooling, when the LAT reaches the non-adjustable low tempera-  
ture trip limit (50°F) the LAT algorithm begins operating, closed  
dampers are initially opened 3 positions, then 1 position every 20  
sec there after until full open. WeatherMaker Two-Zone will not  
shut down second-stage cooling (if used); however, if temperature  
continues to drop to 45°F, the zoning system will turn off both  
stages of cooling. If the temperature improves, the system will stay  
in the duct temperature optimizer mode until the LAT reaches  
55°F or higher. At 55°F the LAT algorithm will reset and return  
dampers to their original position. In the heating mode, Weather-  
Maker Two-Zone will perform the same duct temperature optimi-  
zation. The trip limits will be determined by the jumper setting.  
(See Fig. 12.) This will continue until the LAT problem is  
corrected.  
Carrier electronic non-programmable and programmable thermo-  
stats can be connected to the WeatherMaker Two-Zone. See  
pre-sale literature for thermostat part numbers.  
NOTE: The zone control board is only capable of 2-stage heat  
and 2-stage cool operation. Fig. 13 and 14 will reflect these  
applications only. Review and understand the following items  
before installing.  
THERMOSTAT SETUP  
1. Thermostat will not operate unless both R and C are connected  
to zone module input.  
2. If selected thermostat is a heat pump (HP) or 2-speed (2S)  
model, convert thermostat to air conditioning operation. This  
will assure that Y signals are generated for cooling, and W  
signals are generated for heating from thermostat to zone  
module input. The thermostat O/W2 output will now be the  
second-stage heat call. If installation is a heat pump system,  
the zone control board will provide proper output signal to  
heat pump.  
3. Select "Zoning" option on thermostat. This will disable the  
Timeguard and 4-cycle per hr (cph) protection built into  
thermostat. Let zone control board perform the Timeguard and  
cycle protection. Refer to thermostat Installation Instruction  
under Zoning for more detail.  
This control helps WeatherMaker Two-Zone System cope with  
installations where the air conditioning system may suffer from  
poor ductwork, improperly sized heating or cooling equipment,  
and/or improper settings of the barometric bypass damper. This  
control is especially useful in retrofit applications where the size  
and routing of the ductwork may not be entirely known or  
satisfactory.  
4. The zone 1 thermostat is the only thermostat that can control  
continuous fan operation with zoning. Connect G between  
zone 1 thermostat and zone 1 input on zone control module.  
The duct temperature optimizer works by controlling how cold or  
hot the air inside the supply-air duct gets by monitoring the  
temperature of the air inside the supply-air system.  
5. Follow all safety and installation considerations outlined in the  
thermostat Installation Instructions.  
ZONE CONTROL BOARD SETUP  
Whenever WeatherMaker Two-Zone is providing heating or cool-  
ing, the zone within the home that is asking for conditioned air will  
always have its damper fully open. The other zone in the system  
may or may not have an open damper depending upon its  
particular needs. If the ductwork is too small (or the air  
conditioner/heater is too large), then the zone requiring condi-  
tioned air may not be able to take enough air to allow your  
equipment to operate properly. WeatherMaker Two-Zone will  
detect this, and open up the closed damper allowing the equipment  
to continue to operate.  
1. Configure zone control board jumper for Tstat (thermostat)  
Fnc option only. Do not use Tstat HP option. When Tstat Fnc  
is selected this will setup control inputs to recognize Y1 and  
Y2 for first- and second-stage cooling, W1 and W2 for first-  
and second-stage heating.  
2. Configure zone control board for either Equipmt (equipment),  
HP or Fnc. When a heat pump system is used, Equipmt HP  
mode should be selected. The zone control board will provide  
the proper output signal to the heat pump. When a gas/electric  
furnace is used, Equipmt Fnc mode should be selected for  
proper output signal.  
3. Configure zone control board for either Fnc Ht, w/f (with fan),  
or w/of (without fan). With Fan mode should be selected when  
a heat pump is installed and fan is needed to come on  
immediately with demand. Without Fan mode should be  
selected when fan is controlled by gas/electric furnace.  
The duct temperature optimizer may be disabled on the  
control center. A 10k resistor can be installed in place of the  
duct sensor at the terminal block. By disabling the duct  
temperature optimizer, the LAT safety algorithm is removed  
from the system.  
4. Configure zone control board for either DTO On or Off. When  
DTO On is selected (Factory default) and if a LAT trip occurs,  
closed dampers will begin opening to try and keep equipment  
running by maintaining proper air temperatures. However, if  
LAT temperatures exceed their limits, equipment will start  
staging down. When DTO Off is selected, equipment will  
stage down. Closed dampers will not open on inial trip,  
however if LAT temperatures exceed their limits, control will  
lockout and damper will open.  
It is highly recommended that you use this control option. The  
heating LAT is adjustable for the duct sensor. In this Installation  
Instruction, you will find the section showing an adjustment for the  
heating LAT. (See Fig. 12.) It is very important that this tempera-  
ture is properly set. For gas or oil furnaces, the temperature limit  
will be in the higher temperature range. For heat pumps the  
temperature setting should always be in the lower temperature  
range.  
5
 
B
G
H
A
F
J
I
D
K
4
E
C
Y
Y
2
1
R
1
2
3
2
3
Thermostat  
Zone 2  
L
CL  
OP  
C
M
Zone  
1
Damper  
N
W
W
C
CL  
OP  
C
Zone  
2
Damper  
1
Duct  
G
Y1  
HP  
W
R
1
C
Rc  
Y2  
O
Y
1
W
W
1
2
24v  
W
2
Rh  
B
Y2  
G
Thermostat  
Zone 1  
Sensors  
24 VAC  
Power  
Equipment  
A97293  
ZONE 1  
I/O CENTER CONNECTIONS  
ZONE 2  
I/O CENTER CONNECTIONS  
G
Y2 Y1  
R
W1 W2  
C
Y2 Y1  
R
W1 W2  
C
*
*
G
Y2 Y1  
R
W1 W2  
C
Y2 Y1  
R
W1 W2  
C
THERMOSTAT/SUBBASE  
CONNECTIONS  
THERMOSTAT/SUBBASE  
CONNECTIONS  
ONLY HOOKUP "C" WHEN SUPPLIED BY THERMOSTAT  
ONLY HOOKUP "C" WHEN SUPPLIED BY THERMOSTAT  
*
*
HOOKUP WHEN USING APPLICABLE TWO-STAGE  
THERMOSTATS WITH TWO-STAGE EQUIPMENT  
HOOKUP WHEN USING APPLICABLE TWO-STAGE  
THERMOSTATS WITH TWO-STAGE EQUIPMENT  
A93494  
A93495  
Fig. 12—WeatherMaker Two-Zone Circuit Board with Standard Thermostat Wiring  
6
 
NON-PROGRAMMABLE  
ELECTRONIC  
NON-PROGRAMMABLE  
ELECTRONIC  
TWO-ZONE BOARD  
THERMOSTAT  
INPUT  
TWO-ZONE BOARD  
THERMOSTAT  
INPUT  
THERMOSTAT  
MODEL AC  
THERMOSTAT  
MODEL HP  
24 VAC HOT  
R
C
R
C
24 VAC HOT  
R
C
R
C
24 VAC COMM  
24 VAC COMM  
HEAT STAGE 1 W/W1  
W1  
Y1  
G
HEAT STAGE 1 W/W1  
W1  
Y1  
G
COOL STAGE 1  
FAN  
Y/Y2  
G
COOL STAGE 1  
FAN  
Y/Y2  
G
*
*
W2  
Y2  
Y2  
HEAT STAGE 2  
O/W2  
Y1  
B
W2  
SINGLE-STAGE HEAT,  
SINGLE-STAGE COOL  
N/A  
N/A  
N/A  
SEE NOTES 1 AND 3  
L
TWO-STAGE HEAT,  
SINGLE-STAGE COOL  
S1  
S2  
OUTDOOR  
SENSOR  
CONNECTION  
SEE NOTES 1, 2, AND 3  
NON-PROGRAMMABLE  
ELECTRONIC  
TWO-ZONE BOARD  
THERMOSTAT  
INPUT  
THERMOSTAT  
MODEL 2S  
24 VAC HOT  
R
C
R
C
24 VAC COMM  
HEAT STAGE 1 W/W1  
W1  
Y2  
G
WIRING DIAGRAM NOTES:  
COOL STAGE 2  
FAN  
Y/Y2  
G
1. * Hook up G on zone 1 thermostat only.  
2. Cut R19 jumper on thermostat.  
3. Disable timeguard and cycle protection in thermostat by setting  
it to ZONE mode. Refer to thermostat Installation Instructions for  
details on how to do this.  
*
HEAT STAGE 2  
COOL STAGE 1  
N/A  
O/W2  
Y1  
B
W2  
Y1  
TROUBLE  
L
S1  
S2  
OUTDOOR  
SENSOR  
CONNECTION  
TWO-STAGE HEAT,  
TWO-STAGE COOL  
SEE NOTES 1, 2, AND 3  
A97294  
Fig. 13—Electronic Non-Programmable Thermostat Wiring Diagrams  
NOTE: An HP temperature sensor must be used with a heat pump  
application using electric strip heat. This is necessary in case the  
DTO is set to the Off position.  
cooling (Y1) and heat pump modes. The time guard can be cleared  
by using the comprotec override feature. Second-stage (Y2) and  
(W2) will have a 5-minute delay between stages and also can be  
cleared using the comprotec override feature.  
Timeguard  
Maximum Cycle Rate  
The WeatherMaker Two-Zone provides equipment protection with  
an internal 5-minute timeguard delay. This delay is present upon  
initial power up. There is also a 5-minute timeguard delay for all  
The WeatherMaker Two-Zone will allow a maximum of 4  
equipment cycles per hr or 1 every 15 minutes when a heating or  
cooling mode is activated. When a demand exists, and internal  
7
 
PROGRAMMABLE  
ELECTRONIC  
THERMOSTAT  
MODEL AC  
PROGRAMMABLE  
ELECTRONIC  
THERMOSTAT  
MODEL HP  
TWO-ZONE BOARD  
THERMOSTAT  
INPUT  
TWO-ZONE BOARD  
THERMOSTAT  
INPUT  
24 VAC HOT  
FAN  
R
R
24 VAC HOT  
FAN  
R
R
G
G
G
G
*
*
HEAT STAGE 1 W/W1  
W1  
Y1  
W2  
HEAT STAGE 1 W/W1  
W1  
Y1  
W2  
COOL STAGE 1  
Y/Y2  
O/W2  
Y1/W2  
COOL STAGE 1  
HEAT STAGE 2  
N/A  
Y/Y2  
O/W2  
Y1/W2  
N/A  
N/A  
Y2  
C
Y2  
C
24 VAC COMM  
C
B
24 VAC COMM  
C
B
N/A  
N/A  
N/A  
N/A  
L
L
S1  
S2  
S1  
S2  
OUTDOOR  
SENSOR  
CONNECTION  
SINGLE-STAGE HEAT,  
SINGLE-STAGE COOL  
OUTDOOR  
SENSOR  
CONNECTION  
TWO-STAGE HEAT,  
SINGLE-STAGE COOL  
SEE NOTES 1 AND 3  
SEE NOTES 1, 2, AND 3  
PROGRAMMABLE  
ELECTRONIC  
THERMOSTAT  
MODEL 2S  
TWO-ZONE BOARD  
THERMOSTAT  
INPUT  
COOL STAGE 1 Y1/W2  
Y1  
G
FAN  
G
*
HEAT STAGE 1 W/W1  
W1  
Y2  
W2  
R
WIRING DIAGRAM NOTES:  
COOL STAGE 2  
HEAT STAGE 2  
24 VAC HOT  
Y/Y2  
O/W2  
R
1. * Hook up G on zone 1 thermostat only.  
2. Set thermostat dip switch A to ON.  
3. Set thermostat dip switch C to ON. This will disable  
timeguard and cycle protection in thermostat by setting  
it to ZONE mode. Refer to thermostat Installation Instructions  
for details on how to do this.  
C
24 VAC COMM  
N/A  
C
B
TROUBLE  
L
S1  
S2  
OUTDOOR  
SENSOR  
CONNECTION  
TWO-STAGE HEAT,  
TWO-STAGE COOL  
SEE NOTES 1, 2, AND 3  
A97295  
Fig. 14—Electronic Programmable Thermostat Wiring Diagrams  
timer will start counting down 15, 14, 13...0 minutes. Once the  
timer expires the control will allow a new mode to restart the  
equipment. The internal time, as well as the cooling 5-minute  
timeguard can be cleared by using the comprotec override feature.  
CARE AND MAINTENANCE  
For continuing optimum performance and to minimize possible  
equipment failure, it is essential that periodic maintenance be  
performed on this equipment. Consult your servicing contractor for  
the proper frequency of maintenance. Frequency may vary depend-  
ing upon geographic areas.  
8
 
TROUBLESHOOTING  
This section contains information to assist you in troubleshooting  
problems and errors associated with the WeatherMaker Two-Zone  
system. See Table 2.  
High Heating Temperature Trip Limit Setting —  
When DTO is On, temperature is sensed by duct  
temperature sensor. When the duct temperature  
reaches this temperature setting, the duct temperature  
optimizer is enabled.  
B
Step 1—System Diagram, Jumpers, and Switches  
If the LAT is exceeded then heating will turn off.  
NOTE: For correct control board operation, it must have either a  
NOTE: HP temperature sensor is recommended for  
all heat pump applications.  
sensor attached or a 10k resistor in place at the duct and HP inputs.  
NORMAL GAS/  
ELECTRICAL  
SETTING  
EQUIPMENT  
SHUTOFF  
TEMPERATURE  
NORMAL HEAT  
PUMP SETTING  
Fnc—Gas/electric thermostat is installed in  
each zone.  
1
Tstat  
155°F  
155°F  
175°F  
164°F  
153°F  
143°F  
132°F  
121°F  
110°F  
Must be in this position to function prop-  
erly.  
147°F  
138°F  
130°F  
122°F  
113°F  
105°F  
147°F  
138°F  
130°F  
122°F  
113°F  
105°F  
HP—DO NOT USE.  
Fnc—Air conditioning equipment installed  
is a cooling only unit.  
2
Equipmt  
HP—Air conditioning equipment installed  
is a heat pump.  
Emergency Heat Switch—This switch should remain  
in the OFF position for both furnace and heat pump  
operation. It should be switched to the ON position  
only upon heat pump compressor failure to provide  
emergency heat.  
W/O FAN—When demand for heating ex-  
ists, fan is controlled by gas/electric fur-  
nace.  
C
D
3
Fnc Ht  
W/FAN—When demand for heating exists,  
fan comes on immediately (heat pump  
only).  
ON  
OFF  
DTO Off—When supply-air temperatures  
approach a trip limit, HVAC equipment  
will turn off. Dampers do not open until  
equipment is locked out by control.  
Comprotec Override—Momentarily short  
pins together for temporary equipment time  
delay override.  
4
DTO  
DTO On—When supply-air temperatures  
approach a trip limit, closed dampers open  
to maintain proper air temperatures.  
J6 jumper—Connects Rc and Rh inter-  
nally.  
E
F
Damper Fuse—Protects damper from electrical dam-  
age (3 Amp).  
A
Emergency heat LED—Will turn on when  
emergency heat is on.  
Red LED—Used for diagnostic errors.  
G
H
Green LED—Flashes once every second  
for normal operation, alternates with red  
LED for diagnostic errors.  
9
 
Red LED—Displays ON when first-stage heat is  
energized.  
Red LED—Displays ON when fan is energized.  
I
M
N
O
Red LED—Displays ON when first-stage cooling is  
energized.  
Red LED—Displays ON when second-stage heat  
is energized.  
J
K
Red LED—Displays ON when second-stage cooling is  
energized.  
J2 (Not Shown)—Cut for 50 hz operation. Lo-  
cated under plastic housing approximately 1 in.  
above comprotec override.  
Red LED—Displays ON when reversing valve is ener-  
gized.  
L
Table 2—Troubleshooting  
ERROR DESCRIPTION  
LED CODES  
ACTION REQUIRED  
Green flashes 1 time every sec and no  
other LEDs are flashing.  
Normal operation.  
None.  
Wait until duct temperature cools below  
exceeded temperature trip. (Heat leaving  
air temperature trip limits set at LAT limits  
POT on central control circuit board; range  
is 110° to 175°F.)  
Green flashes 1 time and Red flashes 1  
time  
Duct temperature sensor. First-stage heat  
limit exceeded; heat will be locked out.  
Wait until duct temperature cools below  
exceeded temperature trip. Range is 105°  
to 155°F.  
Green flashes 1 time and Red flashes 2  
times  
Duct temperature sensor. Second-stage  
heat limit exceeded.  
Green flashes 1 time and Red flashes 3  
times  
Duct temperature sensor. First-stage cool  
limit exceeded; cool will be locked out.  
Wait until duct temperature raises above  
exceeded temperature trip (45°F).  
Green flashes 1 time and Red flashes 4  
times  
Duct temperature sensor. Second-stage  
cool limit exceeded.  
Wait until duct temperature raises above  
exceeded temperature trip (50°F).  
Green flashes 1 time and Red flashes 5  
times  
HP temperature sensor. First-stage heat  
limit exceeded; heat will be locked out.  
Wait until HP temperature cools below ex-  
ceeded temperature trip. Fixed at 110°F.  
Green flashes 2 times and Red flashes 1  
time  
HP temperature sensor error. Second-  
stage heat limit exceeded.  
Wait until HP temperature cools below ex-  
ceeded temperature trip. Fixed at 105°F.  
Green flashes 2 times and Red flashes 2  
times  
HP temperature sensor. First-stage cool  
limit exceeded; cool will be locked out.  
Wait until duct temperature raises above  
exceeded temperature trip (45°F).  
Green flashes 2 times and Red flashes 3  
times  
HP temperature sensor. Second-stage cool  
limit exceeded.  
Wait until duct temperature raises above  
exceeded temperature trip (50°F).  
1. Verify that duct temperature sensor or  
10k ohm resistor is attached to control cen-  
ter at duct temperature connectors.  
Green flashes 2 times and Red flashes 4  
times  
1. Duct temperature sensor.  
2. Temperature sensor is shorted.  
2. Replace duct temperature sensor.  
1. Verify that duct temperature sensor or  
10k ohm resistor is attached to control cen-  
ter at duct temperature connectors.  
Green flashes 2 times and Red flashes 5  
times  
1. Duct temperature sensor.  
2. Temperature sensor is open.  
2. Replace duct temperature sensor.  
1. Verify that HP temperature sensor or  
10k ohm resistor is attached to control cen-  
ter at HP temperature connectors.  
Green flashes 3 times and Red flashes 1  
time  
1. HP temperature sensor.  
2. Temperature sensor is shorted.  
2. Replace HP temperature sensor.  
1. Verify that HP temperature sensor or  
10k ohm resistor is attached to control cen-  
ter at HP temperature connectors.  
Green flashes 3 times and Red flashes 2  
times  
1. HP temperature sensor.  
2. Temperature sensor is open.  
2. Replace HP temperature sensor.  
1. Check for short circuits on damper wire  
connections at the dampers and control  
center.  
Green flashes 3 times and Red flashes 3  
times  
Damper fuse blown.  
2. Replace damper fuse.  
3. Check damper operation, may need to  
be replaced.  
Green flashes 3 times and Red flashes 4  
times  
Fatal control center circuit board failure.  
Replace control center.  
10  
 
Table 3 shows a temperature/ohm/voltage relationship to help aid in troubleshooting the WeatherMaker Two-Zone System. This table will  
evaluate both the Duct/HP temperature sensor operation. Use a digital multimeter to perform the following:  
To verify a sensor is good, disconnect both leads from the I/O board and measure the resistance through the sensor. Match ohm reading to table  
and compare temperature reading on table to ambient temperature surrounding sensor (Accuracy should be ± 5-10 percent). Example: if 10.92k  
ohms are measured, this equals approximately 73°F.  
To verify if I/O board is normal, reattach sensor to I/O board, set meter to 5vdc, and measure voltage across terminal connections. Match voltage  
reading to temperature reading in chart. The ambient temperature surrounding sensor should be ± 5-10 percent. Example: 2.61vdc is  
approximately 73°F.  
Table 3—Temperature/Ohm/Voltage Relationship  
TEMP °F  
30  
OHMS  
34,367  
32,654  
31,030  
29,498  
28,052  
26,686  
25,396  
24,171  
23,013  
21,918  
20,883  
19,903  
18,972  
18,090  
17,255  
16,464  
15,714  
15,000  
14,323  
13,681  
13,071  
12,493  
11,942  
11,418  
VOLTS  
3.873  
3.828  
3.781  
3.734  
3.686  
3.637  
3.587  
3.537  
3.485  
3.433  
3.381  
3.328  
3.274  
3.220  
3.165  
3.111  
3.056  
3.000  
2.944  
2.889  
2.833  
2.777  
2.721  
2.666  
TEMP °F  
73  
OHMS  
10,921  
10,449  
10,000  
9571  
9164  
8776  
8407  
8056  
7720  
7401  
7096  
6806  
6530  
6266  
6014  
5774  
5546  
5327  
5117  
4918  
4727  
4544  
4370  
4203  
VOLTS  
2.610  
2.555  
2.500  
2.445  
2.391  
2.337  
2.284  
2.231  
2.178  
2.127  
2.075  
2.025  
1.975  
1.926  
1.878  
1.830  
1.784  
1.738  
1.692  
1.648  
1.605  
1.562  
1.521  
1.480  
TEMP °F  
117  
118  
120  
122  
124  
126  
127  
129  
131  
133  
135  
136  
138  
140  
142  
144  
145  
147  
149  
151  
153  
154  
156  
158  
OHMS  
4042  
3889  
3743  
3603  
3469  
3340  
3217  
3099  
2986  
2878  
2774  
2675  
2579  
2488  
2400  
2315  
2235  
2157  
2083  
2011  
1943  
1876  
1813  
1752  
VOLTS  
1.439  
1.400  
1.362  
1.324  
1.288  
1.252  
1.217  
1.183  
1.150  
1.117  
1.086  
1.055  
1.025  
0.996  
0.968  
0.940  
0.913  
0.887  
0.862  
0.837  
0.813  
0.790  
0.767  
0.745  
TEMP °F  
160  
162  
163  
165  
167  
169  
171  
172  
174  
176  
178  
180  
181  
183  
185  
187  
189  
190  
OHMS  
1693  
1637  
1582  
1530  
1480  
1431  
1385  
1340  
1297  
1255  
1215  
1177  
1140  
1104  
1010  
1037  
1005  
974  
VOLTS  
0.724  
0.703  
0.683  
0.663  
0.645  
0.626  
0.608  
0.591  
0.574  
0.558  
0.542  
0.527  
0.512  
0.497  
0.483  
0.470  
0.457  
0.444  
32  
75  
34  
77  
36  
79  
37  
81  
39  
82  
41  
84  
43  
86  
45  
88  
46  
90  
48  
91  
50  
93  
52  
95  
54  
97  
55  
99  
57  
100  
102  
104  
106  
108  
109  
111  
113  
115  
59  
61  
63  
64  
66  
68  
70  
72  
WIRING DIAGRAMS  
Table 4—Wiring Diagram Reference  
OUTDOOR  
UNIT  
SINGLE-SPEED  
AIR CONDITIONER  
TWO-SPEED  
AIR CONDITIONER  
SINGLE-SPEED  
HEAT PUMP  
TWO-SPEED  
HEAT PUMP  
Single-Stage Furnace  
Two-Stage Furnace  
Typical Fan Coil  
Fig. 15  
Fig. 19  
Fig. 20  
Fig. 21  
Fig. 22  
Fig. 23  
Fig. 24  
Fig. 25  
Fig. 26  
Fig. 27  
Fig. 16  
Fig. 28  
Fig. 17  
Fig. 29  
FK4C Fan Coil  
Fig. 18  
Fig. 30  
11  
 
TWO-ZONE SYSTEM  
2-STAGE OR  
VARIABLE-SPEED  
FURNACE  
TWO-ZONE SYSTEM  
RH  
G
SINGLE-STAGE  
FURNACE  
RH  
G
R
G
R
SINGLE-SPEED  
AIR CONDITIONER  
SINGLE-SPEED  
AIR CONDITIONER  
W2  
W1  
Y1  
Y2  
O
G
W
Y
W2  
W/W1  
Y/Y2  
C
W2  
W1  
Y1  
Y2  
O
Y
C
Y
C
C
B
B
RC  
A97296  
RC  
Fig. 15—Single-Stage Furnace  
With Single-Speed Air Conditioner  
A97297  
Fig. 16—Two-Stage or Variable-Speed Furnace  
With Single-Speed Air Conditioner  
TWO-ZONE SYSTEM  
SINGLE-SPEED  
AIR CONDITIONER  
TWO-ZONE SYSTEM  
SINGLE-SPEED  
RH  
G
TYPICAL  
FAN COIL  
AIR CONDITIONER  
RH  
FK4C  
FAN COIL  
C
R
G
W2  
W1  
Y1  
Y2  
O
DH  
C
Y
W2  
W1  
Y1  
Y2  
O
J1 JUMPER  
C
R
C
G
W2  
W3  
G
Y
W1  
W2  
*
Y/Y2  
O
L
*
*
*
*
B
Y/Y2  
Y1  
REMOVE J2 JUMPER  
FOR HEAT STAGING AND  
CONNECT W2 TO W2  
B
E
RC  
See notes 1 and 3  
O
RC  
Y1  
See note 1  
A97298  
A97299  
Fig. 17—Typical Fan Coil  
With Single-Speed Air Conditioner  
Fig. 18—FK4C Fan Coil  
With Single-Speed Air Conditioner  
12  
 
2-SPEED  
AIR CONDITIONER  
2-SPEED  
AIR CONDITIONER  
SINGLE-STAGE  
2-STAGE OR  
VARIABLE-SPEED  
FURNACE  
TWO-ZONE SYSTEM  
FURNACE  
TWO-ZONE SYSTEM  
R
RH  
G
R
G
R
RH  
G
R
G
W
C
Y
W2  
W/W1  
Y/Y2  
C
W2  
W1  
Y1  
Y2  
O
C
W2  
W1  
Y1  
Y2  
O
Y2  
Y1  
Y2  
C
*
Y
Y1  
B
See note 2  
B
See notes 2 and 3  
RC  
RC  
A97300  
A97301  
Fig. 19—Single-Stage Furnace  
With 2-Speed Air Conditioner  
Fig. 20—Two-Stage or Variable-Speed Furnace  
With 2-Speed Air Conditioner  
2-SPEED  
2-SPEED  
AIR CONDITIONER  
AIR CONDITIONER  
TYPICAL  
FAN COIL  
TWO-ZONE SYSTEM  
FK4C  
FAN COIL  
TWO-ZONE SYSTEM  
J1 JUMPER  
R
C
RH  
G
R
C
DH  
R
R
C
RH  
G
G
C
W2  
W1  
Y1  
Y2  
O
W2  
G
W1  
W2  
Y1  
REMOVE J2 JUMPER  
FOR HEAT STAGING AND  
CONNECT W2 TO W2  
W2  
W1  
Y1  
Y2  
O
*
Y2  
Y/Y2  
*
E
W3  
Y1  
Y2  
*
L
Y/Y2  
O
*
O
L
B
*
Y1  
Y1  
B
RC  
See note 1  
RC  
See notes 1, 2, and 3  
A97302  
A97303  
Fig. 21—Typical Fan Coil  
With 2-Speed Air Conditioner  
Fig. 22—FK4C Fan Coil  
With 2-Speed Air Conditioner  
13  
 
SINGLE-SPEED  
HEAT PUMP  
INTERFACE  
CONTROL  
(KHAIC0101AAA)  
SINGLE-STAGE  
FURNACE  
TWO-ZONE SYSTEM  
R
RH  
G
C
G
R
R
GT  
GF  
RF  
W2  
W1  
Y1  
Y2  
O
W
WF  
Y
E
HP  
W2  
O
O
HP  
OT  
Y
1
3
Y
HP  
B
2
OUTDOOR  
RC  
THERMOSTAT  
YT  
(KHAOT0301FST)  
E
T
C
C
See notes 4, 5, 6, and 7  
A97304  
Fig. 23—Single-Stage Furnace With Single-Speed Heat Pump  
2-STAGE OR  
VARIABLE-SPEED  
FURNACE  
SINGLE-SPEED  
HEAT PUMP  
INTERFACE  
CONTROL  
(KHAIC0101AAA)  
TWO-ZONE SYSTEM  
R
RH  
G
W2  
C
R
GT  
GF  
RF  
G
W2  
W1  
Y1  
Y2  
O
R
WF  
W/W1  
E
HP  
W2  
O
Y/Y2  
O
HP  
OT  
Y
1
3
Y
HP  
B
2
OUTDOOR  
RC  
THERMOSTAT  
YT  
(KHAOT0301FST)  
E
T
C
C
See notes 4, 5, 6, 7, and 8  
A97305  
Fig. 24—Two-Stage or Variable-Speed Furnace With Single-Speed Heat Pump  
14  
 
TWO-ZONE SYSTEM  
RH  
SINGLE-SPEED  
HEAT PUMP  
TWO-ZONE SYSTEM  
RH  
SINGLE-SPEED  
HEAT PUMP  
FK4C  
TYPICAL  
FAN COIL  
FAN COIL  
G
W2  
W1  
Y1  
Y2  
O
G
W2  
W1  
Y1  
Y2  
O
C
J1 JUMPER  
R
C
DH  
R
C
R
C
R
G
G
W2  
W2  
W3  
J2 JUMPER  
W1  
W2  
Y/Y2  
O
W2  
Y
*
Y
Y/Y2  
*
O
O
B
O
B
*
L
RC  
Y1  
*
E
RC  
See notes 1 and 3  
See note 1  
*
Y1  
A97307  
A97306  
Fig. 26—FK4C Fan Coil  
With Single-Speed Heat Pump  
Fig. 25—Typical Fan Coil  
With Single-Speed Heat Pump  
2-SPEED  
HEAT PUMP  
2-SPEED  
HEAT PUMP  
2-STAGE OR  
SINGLE-STAGE  
FURNACE  
VARIABLE-SPEED  
FURNACE  
TWO-ZONE SYSTEM  
TWO-ZONE SYSTEM  
R
C
R
RH  
G
R
G
RH  
G
R
C
W2  
W/W1  
Y/Y2  
C
G
W
Y
W2  
W1  
Y1  
Y2  
O
W2  
W1  
Y1  
Y2  
O
W2  
Y2  
Y1  
W2  
Y2  
C
*
Y1  
Y1  
*
O
O
O
W3  
B
B
W3  
RC  
RC  
See notes 2, 5, 6, 7, 9, 10, and 11  
See notes 2, 3, 5, 6, 7, 8, 9, 10, and 11  
A97308  
A97309  
Fig. 27—Single-Stage Furnace  
Fig. 28—Two-Stage or Variable-Speed Furnace  
With 2-Speed Heat Pump  
With 2-Speed Heat Pump  
15  
 
2-SPEED  
HEAT PUMP  
TYPICAL  
FAN COIL  
2-SPEED  
TWO-ZONE SYSTEM  
RH  
TWO-ZONE SYSTEM  
RH  
HEAT PUMP  
R
C
R
C
FK4C  
FAN COIL  
G
W2  
W1  
Y1  
Y2  
O
G
W2  
W1  
Y1  
Y2  
O
C
C
DH  
R
G
J1 JUMPER  
R
W2  
Y2  
O
W2  
*
Y/Y2  
G
*
O
J2 JUMPER  
W1  
W2  
Y1  
Y/Y2  
O
W3  
W3  
W2  
Y1  
Y2  
O
*
L
*
E
B
B
*
Y1  
RC  
Y1  
RC  
W3  
See notes 1, 2, 9, and 11  
See notes 1, 2, 3, 9, and 11  
A97310  
A97311  
Fig. 29—Typical Fan Coil With 2-Speed Heat Pump Fig. 30—FK4C Fan Coil With 2-Speed Heat Pump  
WIRING DIAGRAM NOTES  
1. Refer to fan coil Installation Instructions for proper wiring.  
2. Refer to outdoor unit Installation Instructions for latent kit requirements.  
3. Terminals marked with * may not be present on equipment.  
4. Interface control transformer must be in phase with furnace transformer to get high-speed fan during heat pump operation.  
5. Heat pump MUST have a high-pressure switch for dual-fuel applications.  
6. Two-Zone Control does not know that dual fuel is applied. Do not use thermostat AUTO CHANGEOVER mode with dual-fuel  
applications, keep both thermostats in same mode (heating or cooling).  
7. Configure Two-Zone Control board (jumpers) for:  
(J1) T-stat = Fnc  
(J3) Equipmt = HP  
(J4) Fnc Ht = w/fan  
(J5) LAT = Set LAT jumper high enough to allow furnace to come on during defrost and second-stage operation.  
(J7) DTO = On  
8. Furnace must control its own second-stage heat operation, via the furnace control algorithm.  
9. Refer to outdoor equipment Installation Instructions for proper set up.  
10. Select Furnace Interface option, Balance Point, and Defrost Time on 2-speed heat pump control board.  
11. DO NOT select "ZONE" position on 2-speed heat pump control board. In heating mode, heat pump outdoor temperature sensor will control  
the compressor low- and high-speed change.  
Copyright 1997 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231  
zkit8si  
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. 809-500  
Printed in U.S.A.  
Form ZONEKIT-8SI  
Pg 16  
6-97  
Replaces: ZONEKIT-2SI  
 

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