Carrier SYSTXCC4ZC01 User Manual

SYSTXCC4ZC01  
Infinity Damper Control  
Installation and Start-Up Instructions  
GER, WARNING, and CAUTION. These words are used with  
the safety-alert symbol. DANGER identifies the most serious  
hazards, which will result in severe personal injury or death.  
WARNING signifies a hazard, 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 is used to highlight suggestions which  
will result in enhanced installation, reliability, or operation.  
INSTALLATION CONSIDERATIONS  
Before the actual installation of a zoning system can begin,  
decisions need to be made to determine the number and location of  
zones and sensors. This affects duct and damper selections.  
This instruction covers the physical installation and start up of the  
Infinity Damper Control. Use this instruction to guide the actual  
installation process after all the air side decisions have been made.  
One Damper Control is capable of handling up to four zones of  
operation. When greater than four zones are required, a second  
Damper Control Module is needed for zones 5 through 8 (8 zones  
maximum).  
Infinity Damper Control  
SYSTXCC4ZC01  
A97040  
NOTE: Read the entire instruction manual before starting the  
installation.  
1. Install the Infinity Zone Control (User Interface) and Remote  
Room Sensors in non-condensing areas with ambient tempera-  
tures between 32° F. and 120° F. Install Dampers and Infinity  
Damper Control in non-condensing areas with ambient tem-  
peratures between -4° F. to 158° F., (-20° to 70° C).  
This symbol indicates a change since the last issue.  
TABLE OF CONTENTS  
SAFETY CONSIDERATIONS.....................................................1  
INSTALLATION CONSIDERATIONS.......................................1  
INTRODUCTION..........................................................................1  
2. A TXV is required on the indoor coil when used with all  
residential split system equipment.  
INSTALLATION...........................................................................2  
Check Equipment and Job Site...........................................2  
Component Location and Wiring Considerations ..............2  
Install Components..............................................................3  
Install Zone Dampers ..........................................................3  
Final Wiring.........................................................................4  
Additional Damper Control Board Setup...........................5  
Optional Transformer Requirements...................................5  
System Startup.....................................................................5  
3. Proper equipment selection and duct sizing are important in a  
zoned system.  
4. DO NOT USE a bypass damper with the Infinity Zoning  
System. Addition of a bypass will cause improper operation.  
Airflow management will be performed by the User Interface  
algorithms. The User Interface will monitor the system and  
will maintain proper airflow through the heating / cooling  
equipment.  
TROUBLESHOOTING .................................................................7  
INTRODUCTION  
SAFETY CONSIDERATIONS  
The Infinity Zoning System allows air conditioning and heating  
equipment to control temperatures and humidity in up to 8 distinct  
spaces, or zones, within a building. Each zone has independent  
temperature settings. The comfort temperature settings can change  
automatically through the use of schedules. This allows the Infinity  
System to change temperature settings in zones to reflect occu-  
pancy or usage. For example, the end user can condition bedrooms  
in a home from 5:00 PM through 7:00 AM or the kitchen from  
3:00 PM through 6:00 PM. The Infinity System uses motorized air  
volume control dampers (also called zone dampers) to regulate  
flow of conditioned air into zones. In this manner, the system can  
selectively heat or cool certain portions of a building depending  
upon space temperature requirements.  
Improper installation, adjustment, alteration, service, maintenance,  
or use can cause fire, electrical shock, or other conditions that 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 product.  
Refer to the individual instructions packaged with the kits or  
accessories when installing. Follow all safety codes and wear  
safety glasses. Have fire extinguisher available. Read these in-  
structions thoroughly and follow all warnings or cautions attached  
to the unit. Consult local and state building codes and Sheet Metal  
and Air Conditioning National Association (SMACNA) for special  
installation requirements.  
Each zone requires a motorized zone damper to control the air  
supplied to it and a zone sensor to sense temperature in each zone.  
There are three types of zone sensors available and may be used in  
combination:  
This is the safety-alert symbol  
. When you see this symbol on  
the equipment and in the instruction manual, be alert to the  
potential for personal injury. Understand the signal words DAN-  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab misc. misc.  
1
4
PC 101  
Catalog No. 809-50012  
Printed in U.S.A.  
Form DAMP4ZC-1SI  
Pg 1  
04-04  
Replaces: NEW  
Step 3Install Components  
INSTALL INFINITY DAMPER CONTROL The Infinity  
Damper Control is designed so that wires can enter it from behind,  
above, or below. Plan wire routing before mounting Damper  
Control.  
ELECTRICAL OPERATION HAZARD  
Failure to follow this caution will result in euipment damage  
or improper operation.  
Condensation can damage the actuator. When dampers are  
located in an unconditioned space, condensation is likely to  
occur in cooling. To prevent condensation and losses, all  
dampers and ductwork in unconditioned space must be  
insulated or otherwise protected.  
1. Remove cover to access mounting holes.  
2. Mount back plate to wall using screws and wall anchors  
provided.  
3. Level back plate and tighten screws.  
INSTALL ZONING USER INTERFACE (see Infinity Zone  
Control Installation Instructions for details).  
Whenever condensation might occur, it is recommended that a  
plastic actuator cover (p/n, DAMPACTXXCOV) be used over the  
actuator. These covers can help prevent condensation on actuators  
by locking out ambient humidity. Insulation may be applied over  
the cover to minimize heat transfer.  
NOTE: Improper wiring of the ABCD connector will cause the  
Infinity Zoning System to operate improperly. Check to make sure  
all wiring is correct before proceeding with installation or turning  
on power.  
To install, place the cover over actuator and seal in place over the  
surrounding insulation with duct tape on all four sides. Sealing  
need not be perfect because there will be positive pressure inside  
the cover. Do not mount the dampers with their actuators hanging  
directly beneath the ductwork. It is best to mount the actuator  
facing in either the three or nine oclock position.  
INSTALL REMOTE ROOM SENSORS —  
1. Separate the sensor cover and mounting back plate by squeez-  
ing the top and bottom of the cover together firmly by  
grasping the raised top and bottom ridges. This will release the  
cover. Mount to wall using provided screws and anchors.  
2. Pull a 2-conductor wire through hole on right-hand side.  
For specific duct types, follow instructions below:  
3. Recommended connection is BLACK to either terminal,  
WHITE to remaining terminal (sensor terminals are not  
marked for polarity because polarity is not important).  
Stranded or common bell wire may be used. Lengths up to  
1000 ft. will contribute no noticeable error.  
NOTE: All zone dampers and ductwork must be properly sup-  
ported according to local codes or SMACNA standards.  
ROUND METAL DUCTWORK  
1. Crimp end of branch duct.  
2. Slip end of zone damper over end of ductwork. Use self-  
tapping sheet metal screw to secure.  
4. Push any extra wire into wall and seal hole to prevent air  
leaks. Align sensor cover with base plate then press firmly  
until cover snaps into place.  
3. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
INSTALL ZONING SMART SENSOR See Infinity Zoning  
Smart Sensor Installation Instructions for details.  
4. If dampers are applied in an unconditioned space, insulate  
damper using 1-1/2 inch to 2 inch insulation (See Fig. 2).  
Step 4INSTALL ZONE DAMPERS  
Proper selection and sizing of dampers is very important for proper  
system operation. Be sure to consult the Damper Product Data  
Digest for assistance in making these selections. Selection and  
sizing information is not provided in this installation instruction.  
RECTANGULAR DUCTWORK  
1. Make connections using S-lock and drives (See Fig. 3).  
2. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
Zone dampers are available in round, rectangular, and slip-in  
design and may be installed in any position. Install dampers so that  
actuator is visible for inspection and accessible in the event it  
would need to be serviced. The black mark on the end of the  
damper shaft represents position of damper blade. To wire damper,  
locate terminals labeled: OPN (open); COM (common); CLS  
(closed; and wire appropriately (see Fig. 1 for Damper 24 VAC  
connection).  
3. If dampers are applied in an unconditioned space, insulate  
damper using 1-1/2 inch to 2 inch insulation (See Fig. 4).  
ROUND FLEXIBLE DUCTWORK  
1. Slip one end of flexible ductwork over end of zone damper  
(See Fig. 5).  
2. Secure flexible duct to zone damper using SMACNA or other  
approved method.  
If duct system requires multiple dampers for a single zone, up to  
5 dampers (maximum) may be wired in parallel. For all applica-  
tions, including retrofit, it is recommended to use only current  
dampers with direct-drive style actuators. DO NOT use older  
damper with crank-arm style actuators.  
3. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
4. If dampers are applied in an unconditioned space, insulate  
damper using 1-1/2 inch to 2 inch insulation (See Fig. 6).  
RECTANGULAR FIBROUS GLASS DUCTWORK  
If an actuator is removed from a damper for any reason, it must be  
properly aligned when it is reinstalled. This can be done by  
rotating the actuator and the blade to their closed positions and  
then tightening the actuator (set screw) to the shaft. This assures  
alignment at the closed position. (Pressing the quick blade release  
button allows the actuator to be manually turned).  
1. Insert one end of zone damper into end of fibrous glass  
ductwork approximately 2 to 3 inches (See Fig. 7).  
2. Use field supplied screws to secure duct board to zone  
damper.  
3. Properly seal joint using duct tape, mastic, or other approved  
method. Do not allow mastic to come in contact with actuator.  
4. If dampers are applied in an unconditioned space, insulate  
damper using 1-1/2 inch to 2 inch insulation (See Fig. 8).  
3
SET SCREW  
SET SCREW  
MOUNTING HUB  
ZONE  
DAMPER  
FLEXIBLE  
DUCT  
3/16"  
GAP  
MOUNTING HUB  
ACTUATOR  
HOUSING  
PLASTIC COVER  
QUICK BLADE  
RELEASE  
CLS COM OPN  
Fig. 5 Round Flexible Duct Work  
CLS  
COM  
A95132  
OPN  
1/2STEEL STRAP  
(CLS) CLOSED  
(COM) COMMON  
(OPN) OPEN  
3/16"  
GAP  
ANTI-ROTATION  
MOUNTING SCREW  
ANTI-ROTATION  
MOUNTING SCREW (5/16")  
Fig. 1 Damper 24-vac Connections  
C03024  
1/2STEEL STRAP  
Fig. 6 Insulated Round Flexible Duct Work  
A95133  
FIBROUS  
GLASS  
DUCTWORK  
FIELD  
SUPPLIED  
SCREWS  
ZONE  
DAMPER  
Fig. 2 Insulated Round Metal Duct Work  
A95130  
2TO 3″  
Fig. 7 Rectangular Fibrous Glass Duct Work  
S-LOCK  
A92480  
SUPPLY  
AIR DUCT  
11/2TO 2″  
INSULATION  
DRIVE  
ZONE  
DAMPER  
Fig. 8 Insulated Rectangular Fibrous Glass Duct  
Work  
Fig. 3 Rectangular Metal Duct Work  
A95134  
A92478  
are in parallel with each other. Use either terminal block to connect  
the Zoning User Interface, Smart Sensor(s), variable-speed indoor  
unit and 2-speed communicating outdoor unit (if applied). If more  
than four zones are required (up to 8 zones maximum), see  
Step6 and Fig. 10 for Additional Damper Control Board Setup  
for Zones 5-8.  
11/2 " TO 2"  
INSULATION  
VENTILATOR WIRING The Infinity Damper Control can  
control a Carrier Heat Recovery Ventilator or Energy Recovery  
Ventilator (HRV / ERV). Connect the four wires from the  
ventilator control board (see ventilator installation instructions for  
details) to the connector labeled (YRGB). This label identifies the  
color of the wire to match the ventilator wire colors (Y=yellow,  
R=red, G=green, B=blue or black). If you have two Infinity  
Damper Controls, connect the ventilator to the control for zones 1  
through 4.  
Fig. 4 Insulated Rectangular Metal Duct Work  
A95131  
Step 5FINAL WIRING  
LEAVING AIR TEMPERATURE / HEAT PUMP TEM-  
PERATURE (LAT/HPT) SENSORS These inputs on the  
Infinity Damper Control are used only for diagnostic purposes and  
Bring all damper and sensor wires together at the Infinity Damper  
Control. Make all system wiring connections as indicated in Fig. 9.  
The two ABCD bus connections on the Infinity Damper Control  
4
NOT required for regular use. Traditionally, the LAT/HPT sensors  
were required for temperature / equipment monitoring. The Infin-  
ity Zoning System does not require these because the User  
Interface algorithms will perform temperature and airflow man-  
agement without use of these sensors. If desired, one or both  
sensors may be used in monitoring leaving air temperature and / or  
indoor coil air temperature. Consideration and / or flexibility will  
now permit using one of these sensors in the return air duct giving  
the dealer an option to view both entering and leaving air  
temperature at the User Interface. If applied, connect sensors to the  
LAT / HPT terminals (See Fig. 9, System Wiring, for connection  
to Infinity Damper Control). LAT is monitored by both AC and HP  
systems. LAT and HPT are both monitored only in HP systems.  
FUSE A 1-amp automotive type fuse is used to protect the  
Infinity Damper Control from over current on the damper drive  
outputs. If this fuse fails, damper wiring should be inspected for  
shorts. Also, no more than five damper motors should be con-  
nected to a single damper output. Fuse should always be replaced  
with an identical 3 amp automotive fuse.  
Step 6ADDITIONAL DAMPER CONTROL BOARD  
SETUP  
If you have more than four zones, a second Infinity Damper  
Control must be used and both dip switch settings on the second  
board supporting zones 5 through 8 must be moved to the right.  
The ABCD bus connector must be wired between both Infinity  
Damper Controls.  
To install - Locate LAT sensor in main supply trunk after heating  
and cooling coil and before first branch. The LAT sensor is radiant  
shielded to prevent heat from affecting correct air temperature.  
Step 7Transformer Requirements  
The Infinity Zoning System has a lower power draw from the  
system transformer than previous controls. It also drives only 2  
zone damper outputs at a time. As a result, up to 8 zones each with  
up to 5 dampers, plus a smart sensor, can be handled without  
increasing the size of the system transformer or adding a second  
zoning transformer.  
1. Drill a 1/4 inch hole at location in supply trunk where sensor  
will be installed.  
2. Insert sensor in hole and use as a template to mark the 2  
mounting holes.  
3. Drill two 1/16 inch holes to accept No. 6 screws through  
pre-drilled holes in duct temperature sensor back plate.  
Use of the transformer provided in the furnace or fan coil is  
recommended without change in all zoning applications except  
those having a System Access Module (SAM). The SAM requires  
a separate transformer.  
4. Use two No. 6 sheet metal screws to mount duct temperature  
sensor to unit.  
5. Connect sensor to 2-conductor wire using provided wire nuts.  
For those who still want more transformer capacity, a 60 VA  
system transformer may be used in place of the supplied 40 VA  
part.  
The HPT sensor (in heat pump applications) measures the tem-  
perature of the air leaving the indoor coil. The sensor is 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 (See Fig. 9).  
Step 8System Start-Up  
Follow the system start-up process outlined in the Infinity Zone  
Control Installation Instructions for details.  
LED INDICATORS Under normal operation, the Yellow and  
Green LEDs will be on continuously (solid). If the Infinity Damper  
Control does not receive communications with the User Interface,  
the Green LED will not be on. If there are faults present, the  
Yellow LED indicator will blink a two-digit status code. The first  
digit will blink at a fast rate, the second at a slow rate.  
STATUS CODE  
DESCRIPTION  
Communication Failure  
Damper Fuse Failed  
Board Failure  
16 =  
24 =  
45 =  
46 =  
Low Input Voltage  
5
2-spd.  
Outdoor  
Unit  
A B C D  
Zoning User Interface &  
Smart Sensor(s)  
Connection  
Ventilator  
Unit  
ABCD Connection:  
Y R G B  
A = Green: RS485+  
B = Yellow: RS485-  
C = White: 24VAC (COM)  
Optional -  
Leaving Air & Heat Pump  
Temperature Sensor  
Indoor  
Unit  
A B C D  
A B C D  
A B C D  
D = Red:  
24VAC (HOT)  
Y R G B  
LAT COM HPT  
A B C D  
Optional  
Zone-1  
Sensor _  
F U S E  
ZS1  
ZS1C  
See Note _  
CLS1  
COM1  
OPN1  
Zone-1  
Damper  
DIP Switch  
Zone-2  
Sensor  
ZS2  
ZS2C  
CLS2  
COM2  
OPN2  
Zone-2  
Damper  
OFF  
Dampers:  
CLS_ = Close  
COM_ = Common  
OPN_ = Open  
Zone-3  
Sensor  
ZS3  
ZS3C  
CLS3  
COM3  
OPN3  
Zone-3  
Damper  
Status LEDs  
Yellow  
Green  
Zone-4  
Sensor  
ZS4  
ZS4C  
CLS4  
COM4  
OPN4  
Zone-4  
Damper  
Damper Control Module, Zones 1 - 4  
Notes:  
_ ABCD CONNECTORS ARE IN PARALLEL WITH EACH OTHER. USE EITHER TERMINAL BLOCK FOR ANY ABCD CONNECTION.  
_
INSTALLING ZONE-1 REMOTE ROOM SENSOR WILL OVERRIDE USER INTERFACE TEMPERATURE SENSOR.  
Zoning System Wiring Diagram  
Zones 1 - 4  
Fig. 9 System Wiring  
A03161  
Connect to Zones 1-4  
Damper Control  
For Zones 5-8, a second Damper  
Control Module must be applied  
Module  
A B C D  
No Connection  
Y R G B  
LAT COM HPT  
A B C D  
A B C D  
Zone-5  
Sensor  
F U S E  
ZS1  
ZS1C  
See Note _  
CLS1  
COM1  
OPN1  
Zone-5  
Damper  
DIP Switch  
Zone-6  
Sensor  
ZS2  
ZS2C  
CLS2  
COM2  
OPN2  
Zone-6  
Damper  
ON  
Dampers:  
CLS_ = Close  
COM_ = Common  
OPN_ = Open  
ON = Zones 5-8  
Zone-7  
Sensor  
ZS3  
ZS3C  
CLS3  
COM3  
OPN3  
Zone-7  
Damper  
Yellow Green  
Zone-8  
Sensor  
ZS4  
ZS4C  
CLS4  
COM4  
OPN4  
Zone-8  
Damper  
Damper Control Module, Zones 5 - 8  
Notes:  
_ FOR ZONES 5 THROUGH 8: A SECOND DAMPER CONTROL MODULE IS REQUIRED. BUS CONNECTION  
ABCD MUST BE CONNECTED BETWEEN BOTH DAMPER CONTROL MODULES.  
_ SET BOTH DIP SWITCH POSITIONS TO ON (right position) AT SECOND MODULE ONLY TO ACTIVATE ZONES 5-8.  
Zoning System Wiring Diagram  
Zones 5 - 8  
Fig. 10 Additional Damper Control  
Board Setup for Zones 5 - 8  
A03162  
6
Damper Control  
Module  
Damper Control  
Module  
ZS_  
ZS_C  
Sensor 1  
Sensor 2  
Sensor 3  
Sensor 4  
Fig. 11 Remote Room Sensor Averaging  
4-Sensor Application (series- parallel)  
A03233  
TROUBLESHOOTING  
Zoning User Interface Display says, Outdoor Unit Not  
Found, when applied with a two-speed communicating out-  
door unit:  
Zoning User Interface Control does not power up:  
1. Recheck wiring to ABCD on all devices. Make sure all colors  
match for every terminal.  
1. Recheck wiring to ABCD connector on outdoor unit. Make  
sure all colors match for every terminal.  
Zoning User Interface cannot find Zones 5 through 8:  
2. Make sure power is applied to the indoor unit, and the Yellow  
and Green LEDs are lit on the Infinity Damper Control.  
1. Make sure zone module 5 - 8 has the dip switches set to the far  
right.  
3. Check for 24 VAC between the C and D terminals at the User  
Interface terminal block.  
2. Recheck wiring to the ABCD connections.  
Zoning User Interface can find zones 5 - 8 but not 1 - 4:  
4. Check fuse at indoor unit circuit board and Infinity Damper  
Control.  
1. Make sure zone module 1 - 4 has the dip switches set to the far  
left.  
Zoning User Interface Display says, Indoor Unit Not Found:  
2. Recheck wiring to the ABCD connections.  
1. Recheck wiring to ABCD on all devices. Make sure all colors  
match for every terminal.  
Some zones do not provide enough comfort (a noticeable  
difference exists between the actual room temperature and  
operating set point or equipment does not turn on)  
2. Press side button at User interface to try again.  
3. Check power to indoor unit.  
1. The zone airflow limit may be set too low. Perform the zone  
airflow limit checkout procedure. See Infinity Zoning System  
User Interface installation instructions for details.  
4. Disconnect all ABCD connections from every device and only  
reconnect the User Interface to the indoor unit. If the indoor  
unit is identified by the User Interface, then another device on  
the ABCD connection may be at fault. Reconnect each  
devices ABCD connection one at a time and perform a  
Re-Install from the Service Menu after each connection is  
made. If one or more devices are not found after reconnecting  
the last device, the last device may be suspect.  
Some zones provide too much airflow and are noisy:  
1. The zone airflow limit may be set too high. Perform the zone  
airflow limit checkout procedure. See Infinity Zoning System  
User Interface installation instructions for details.  
Zone dampers do not move:  
1. Check fuse located on Infinity Damper Control. If fuse failed,  
check damper wiring and inspect for shorts. No more than five  
damper motors should be connected to a single damper output.  
Fuse should be replaced with an identical 3 amp automotive  
fuse.  
5. If the ABCD connection only contains an indoor unit and a  
User Interface, then the wiring, indoor unit control board, or  
User Interface may be at fault.  
7
Copyright 2004 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231  
damp4zc1si  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab misc. miscP.C 101 Replaces: NEW  
1
4
Catalog No. 809-50012  
Printed in U.S.A.  
Form DAMP4ZC-1SI  
Pg 8  
04-04  

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