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HVAC Zone Controls & Zoning Dampers

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What's a TON got to do with AC?

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So you've probably heard of someone refer to an air conditioner's size in terms of  "TONS".  Something like "I got a new 4 TON HVAC unit".  This refers, not to physical size, but to the capacity (ability) of the equipment to generate heat.  That's right, even air conditioning (cooling), is sized by it's ability to produce heat.  In the case of air conditioning, the heat is being "pulled" from inside the house and dispersed outside.  This is why there is always an outdoor component (the air conditioning compressor) when you have AC.

Back to TONs... most people thing of a TON as being 2000 lbs. but with regard to HVAC, a TON is a measurement of heat generation per day.

1 TON of air conditioning is a measure equivalent to the amount of heat necessary to melt 2000 lbs of ice (H20) in a 24 hour period.

ecojaytonexplain1.jpg

But how did we get there? A BTU (British Thermal Unit) is the unit we use express heat energy.  One BTU is equivalent to the amount of heat energy released when burning 1 match all the way. When rating an HVAC unit either for heating or cooling, the amount of BTUs per Hour is often sited.  It has been measured that it takes 143 BTUs to melt 1 lb of ice.  Since, 1 TON of ice is 2000lbs, It will take 2000 x 143 = 286,000 BTUs to melt 1 TON of ice.  The ice could be melted by lighting 286,000 matches all at once or by lighting one at a time... In other words, BTUs only tells us how much heat energy is necessary but not over what time period.  It could melt in 1 minute, 1 hour, or even 1 year depending on how the energy is generated.  So, to rate the output of HVAC equipment, someone decided back in the early 1900s (probably someone at Carrier) that it should be done over a 24 HR peroid (1 day).  This is how we get 286,000 BTUs / 24 hrs =~ 11,917 BTUs per hour or commonly know as 12K BTU/hr is equal to 1 TON.

ecojaytonexplain2.jpg

This means that that 4 TON AC unit you have can melt 8,000 lbs of ICE per day or about the same size block of ice as a Suburban.  That's a lot of heat energy!

ADD-A-WIRE with Zone Control

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An ADD-A-WIRE device can be used when upgrading to thermostats that need a "COMMON" wire from one that didn't have one... and there is no way to run the additional wire needed.  This device, ranging from $15 to $40 can come in very handy especially in the case of zone control where one or more thermostat does not have enough wires to accomodate a modern thermostat such as a WiFi thermostat.

Be sure to follow the wiring diagram for the specific model of "ADD-A-WIRE" as well as the system type.  Show here is the LUX Products LPB-WH Power Bridge wired to a GAS/ELECTRIC thermostat and SmartZone-4X controller, however, the basic principal is the same for any application.

lux addawire instructions.jpg

All of the different ADD-A-WIRE models come with instructions, read them carefully and follow exactly and you won't have any problems.

For more information about the method of ADD-A-WIRE when there is no way to run an extra wire from your zone panel to your equipment, check out this post:
https://zoningsupply.com/blog/upgrading-thermostats-solving-a-common-problem

From an engineering perspective this is an elegant and simple solution.  Without giving away trade secrets, the ones i have tested use the a half wave bridge using diodes at the thermostat and some simple relay logic plus the another half wave at the equipment (no micro necessary) to use only 1 wire for both Y and G signals.... brilliant.

For more information, or with any questions, please contact us.

WiFi Thermostat Roundup 2017

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Just a few short years ago, WiFi thermostats were only made by a very few companies starting with Ecobee and RadioThermostat, followed by Nest.  A couple of years pass and big names in the HVAC industry (Honeywell, Emerson, Venstar, etc) join the WiFi thermostat party.  In 2017 we have more to chose from than can easily be kept up with.  Note: All prices as of this article publish date.

All of the WiFi thermostats listed below will work with any SmartZone

I am sure there will be even more on the market in 2018, we will keep watching the WiFi thermostat bubble grow!  More than 15 are listed here (and I know they are not all listed).  If you know of any more, comment or tweet to us @zoning_supply


wifi stat - bosch connected.JPG

Bosch - $ 170, 4-Heat, 2-Cool, GE/HP, Hum, deHum, Color: White
https://www.amazon.com/dp/B073XHD8BB



TOP PICK

*Ecobee 3 - $ 169, 3-Heat, 2-Cool, Best for zoning in our opinion.
https://www.amazon.com/ecobee3-Smart-Thermostat-Works-Amazon/dp/B06W56TBLN/


wifi stat - ecobee4 w Alexa.JPG

PREMIUM CHOICE

Ecobee 4 - $ 247, 3-Heat, 2-Cool, Alexa-Enabled
https://www.amazon.com/ecobee4-Alexa-Enabled-Thermostat-Sensor-Amazon/dp/B06W2LQY6L/


wifi stat - emerson sensi color.JPG

Emerson Sensi Color Touch - $ 169, 2 Heat, 2 Cool, GE/HP
https://www.amazon.com/dp/B01N3CEUDH?psc=1


Emerson Sensi - $ 99, 1 Heat, 1 Cool, GE/HP
https://www.amazon.com/dp/B00HHE6CW2?psc=1


wifi stat - nest.JPG

Nest - $ 249, 3-Heat, 2-Cool
https://www.amazon.com/dp/B0131RG6VK/





wifi stat -Honeywell 7-day.JPG

Honeywell Basic 7-day - $ 90, 1-Heat, 1-Cool, GE, Color: White (Yes this is WiFi--even though it doesn't look like anything other than an inexpensive thermostat)
https://www.amazon.com/dp/B00Y6M2OUC/




wifi stat - Lux Pro Black.JPG
wifi stat - Lux Pro.JPG

VALUE CHOICE #1

Lux PRO GEO - $ 115, Geofencing, Mount Vertical or Horizontal, Color: Black or White
https://www.amazon.com/Lux-Products-GEO-WH-Thermostat-Amazon/dp/B010PTKWW6/


wifi stat - RadioThermostat.JPG

RadioThermostat - $ 99, 2-Heat, 2-Cool, GE/HP, Modules for Zigbee & Z-Wave
https://www.amazon.com/Radio-Thermostat-Programmable-Enabled-Controls/dp/B00KQS35XA/


wifi stat - Vine.JPG

VALUE CHOICE #2

*Vine - $ 99, Settings Knob, Color Screen & Night-Light
https://www.amazon.com/Vine-Programmable-Thermostat-Touchscreen-Nightlight/dp/B01JU1DZN8/



Any information in this article should be verified with the manufacturer of each product listed.  Specifications, prices & availability are all subject to change and will not be kept current on this post.  Please email us if you have any questions.

ALSO NOTE:  We (I) have not been paid or compensated in any way for this article by any of the manufacturers of these products.  I have not even received any free product... anything reviewed has been purchased through retail outlets and tested with SmartZone zone control products for the use of ZoningSupply.com customers.  This information is not intended to be exhaustive or claim expert knowledge about all of these thermostats.  Thank you.

Zoning for comfort and / or economy... basics of HVAC Zoning

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We have explained in other posts on ZoningSupply.com, when it comes to HVAC zoning, each application must be evaluated individually.  Situations vary widely from building to building, but, in all cases HVAC Zone Control puts the user (homeowner, building manager, etc) in control of comfort.

Let's rewind, what is zoning?  Homes and buildings that have "central" heating and air conditioning typically have 1 thermostat that controls the whole house temperature.  With zoning, multiple thermostats can be placed throughout the house to better control temperature throughout.  SmartZone connects to all of the thermostats & automatically controls dampers (air valves) installed in the air ducts.  These air ducts direct air from the heating & cooling equipment to the different areas or "zones" of the home/building.  The dampers allow SmartZone to direct air only where needed.

Once a SmartZone has been installed, you will have the ability to set each of the zone thermostats to whatever temperature or settings you desire.  SmartZone will, within reason, keep each zone at the correct temperature by running the equipment and directing hot or cold air into the zones only when necessary.  This achieves the purpose of comfort control to manage hot or cold areas of your home. 

As for energy savings, if some of the zones are rarely used and can stay off for a sufficient amount of time, the equipment will run for a shorter time to heat or cool the rest of the building.  This and other applications that allow the user to turn off or set-back one or more of the zones can, in some cases, result in energy savings.  Some sources have published % energy savings possible with zoning, however, this is too arbitrary to have any real meaning.  Like stated at the beginning, every application is different & the real possibility of energy savings is in the hands of the user and how the thermostats are set. 

Zoning is an amazing solution to comfort issues and gives the user ultimate control over comfort throughout the home or building.  However, zone control is NOT a magic bullet for energy savings.  HVAC Zoning only puts more control in the hands of the user & it is ultimately the thermostats and how they are set that determines potential energy savings.

Use Wifi thermostats with SmartZone for ultimate control over comfort and energy use.

Use Wifi thermostats with SmartZone for ultimate control over comfort and energy use.

The reality is that in a normal home with one thermostat, the only way to get more "comfort" is to spend more energy (ie run the AC or heat).  With zoning, you can stay more comfortable in some areas while reducing run-time by not heating/cooling other areas.

SmartZone is the best hvac zone control for upgrades or new-installs.  Order today and install yourself of call any HVAC contractor in your area for installation.

Spring is HVAC maintenance season... think about Zone Control.

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With warmer weather approaching, upstairs or certain areas of your home can become uncomfortably warm without SmartZone. HVAC zone control can make the entire home more comfortable in the hottest Summer months. 

Most homes with a single thermostat have some issues with keeping everyone, everywhere in the house comfortable.  With SmartZone, thermostats are places throughout the home to achieve comfort everywhere... and if you choose to turn off some of the areas (zones), you can even save energy.  Most importantly, however, SmartZone can make your home more comfortable than it is now.  See the slides below for how it works.

How it works...

  1. SmartZone is connected to several Thermostats placed in "zones" throughout the home or building.
  2. SmartZone is connected to the Air Conditioning (AC) and Heating equipment.
  3. Dampers (air valves) are installed in the existing ducts that connect to room vents in the "zones."
  4. SmartZone controls the AC & Heating equipment AND opens/closes dampers to control air to the zones based on the thermostats.

There is obviously a lot more to HVAC Zone control than the above bullet points.  Bypass & static pressure, duct sizing & damper leakage, thermostat & equipment types, equipment modes & changeover, compressor staging, emergency & auxiliary heat... and much more.  The good news is that SmartZone takes the guess work out of the potential complications of zoning.  Check out more about why SmartZone is the best choice here.

Hot upstairs "bonus" room? Cold downstairs during the winter?

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SmartZone HVAC Zone control

These and many other common problems can occur during the winter months when the heater is running more than normal.  This can especially happen in areas that have cooling systems to handle warm and hot summer months.  The duct is often designed to be optimized in the summer months and when heat season rolls around, the airflow balance is all wrong.  The solution is Zone Control.  Even in the best designed duct systems, dampers are often used to balance the airflow on site.  This is tedious and inexact... but with SmartZone controls and power dampers, your home can be comfortable everywhere year round.

"I have personally been in too many to count homes with two stories that NEED zoning... there is nothing wrong with the equipment capacity or the ductwork, they just need the ability to direct airflow in the areas that need it in different seasons of the year or even times of day"  -- SmartZone Contractor

See how it works in more detail here

2016: QUESTIONS from ONLINE CUSTOMERS

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QUESTION: Will SmartZone replace Honeywell Trol-a-temp?

ANSWER: The SmartZone-4X is a "drop-in" replacement for all of the Honeywell boards.

Photo by spates/iStock / Getty Images

QUESTION: I live in Toronto, Ontario, Canada. Are there any qualified installers for the Smart Zone dampers?

ANSWER: Although we have customers in other parts of Canada, we do not have any specific HVAC contractor customers in Toronto. Any reputable HVAC contractor with previous experience installing zoning should be able to install the Ecojay SmartZone controls or dampers. Many do-it-yourself folks have also successfully installed Ecojay's controls/dampers without difficulty. If your contractor is not specifically familiar with SmartZone controls they can reach our technical support line, 844-ZONE-123, for assistance if needed. Feel free to contact us with additional questions.


QUESTION: I have an old DuroZone system (model SMZ-SW) that has stopped working and am looking for a replacement solution and have been researching the Smartzone option.  I have a few questions and wanted to see if you could help me.

  1. I'm not sure what has failed with the DuroZone system, but I wanted to first see if I replaced the controller with the Smartzone controller if it would work.  Will the Smartzone controller work with the DuroZone dampers ?
  2. Would you be able to put me in touch with an installer who could do the installation and testing of the smartzone controller ?  I'm not overly handy and would prefer a knowledgeable installer to do the install and tests.

ANSWER:

  1. Ecojay's SmartZone products are compatible with your current DuroZone controller.  Your existing thermostats and dampers are normally compatible with SmartZone.as well. Wiring the dampers into SmartZone may be different depending on the model dampers you have. We can provide damper wiring instructions when you or your installer inform us the damper models you have. 
  2. The change out of your existing Durozone controller should be simple for any competent hvac contractor even if they haven't used Smartzone before.  Zoning Supply can also be contacted for technical support toll free if you or the installer need technical assistance. 

QUESTION: I have a Honeywell Chronotherm 111 system with one main panel and three mercury thermostat controllers. I have been informed that my control panel is inoperative and three dampers have failed. I would like to upgrade the system with out
losing the capability/control of the temperature in each room. I am in dire need to correct/improve my system with the Honeywell product.

ANSWER: The Honeywell Chronotherm III thermostat (models T8600, T8601 & T8603) are 24VAC powered according to Honeywell's spec sheet and should be compatible with any Ecojay SmartZone controller.


QUESTION: My customer has a Carrier/Parker zone system, not sure what version. I want to replace the complete system minus the dampers. Currently there is a main controller, bypass controller and six zones. The bypass could be converted to a dump zone. Wireless is also an option. What do you think?

ANSWER:  From our knowledge of the Carrier-Parker controls, it is VVT control system  and Carrier released two generations of the product line that we know of.  One or both generations used dampers that had DC powered, multi-position actuators. Carrier has also tended to use a more proprietary control flow using a pulsed or multi-position damper actuator which do not have an internal stop switch.  SmartZone outputs 24VAC continuously on either the OPEN damper circuit or CLOSE damper circuit with the actuator using an internal stop switch to switch off power when it reaches stop in either open or close position. This is typical of most conventional residential/light commercial zone control brands and product-lines today. If your customer's current system does not match this specification you will need to change out the damper actuators if installing Ecojay SmartZone or any other major 24VAC brand control product. Ecojay's damper actuators have a torque rating of 18 in-lb/2 Nm and can work with a round or square shaft of 1/4" to 5/8" diameter.
SmartZone is expandable up to 20 zones, capable of 2C/3H stages and is compatible with any conventional 24VAC controlled equipment including heat pump or heat pump with dual fuel. SmartZone is also compatible with all off the shelf 24VAC thermostats. If you are able to supply the specific product model your customer is using I can probably be more specific about the compatibility issues.


SmartZone-4X
Sale Price:$229.99 Original Price:$299.00
Quantity:
Add To Cart

QUESTION: I have a Honeywell Trol-a-temp Model MABS-2 422041-2 with a Mastertrol Add-a-zone model MAZ-1 TAT422027. This is a 4 zone electric system, heat pump with Emergency heat. I have the Master which control s the Emergency heat plus e thermostats. I would like to upgrade the Panel so that I can put a digital thermostat as the master.

ANSWER: SmartZone-4X will work for you.
http://zoningsupply.com/buy/smartzone-4x


QUESTION: I am looking to use this product with a 2 zone system that has 2 wire dampers. I have to power 4 dampers per zone. Will this produced do so? I am using 8" round dampers and there are 4 per floor.

ANSWER: All Ecojay SmartZone controls are compatible with 2 and 3 wire dampers. They can even be mixed on the same zone. SmartZone can support up to four 2 wire dampers (up to ten 3 wire dampers) on each zone.  Dampers and thermostats are powered from the SmartZone controller. It is important to determine the VA capacity of the transformer needed to power SmartZone as the number of devices powered from the controller increase. In your installation, the transformer used to power the SmartZone controller will need to support the power demand of the zone controller (12VA), 8 dampers (2-wire dampers at 7-10VA each), and 2 thermostats (2VA each). Total potential transformer VA demand from these components collectively total 96VA (12+80+4). However, assuming your 2 wire dampers are power close/spring open, power demand from the dampers will occur only when the dampers are closed. With a 2 zone system, you will never see both zones closed at the same time (all dampers default to open when no zones are calling) so your maximum power demand will be only from 4 dampers. This changes the maximum potential power demand to 62VA (12+40+4). A 75VA - 24VAC transformer will be capable of providing adequate power for your system. This size transformer is readily available on Ebay and many other web stores.  If your 2 wire dampers are power open/spring close (this type is typically used only for fresh air ventilation) then you will need a transformer with a VA capacity of 100VA minimum.  Visit our zoningsupply.com website and review the ZS2X/4X installation guide for more information on installation. Thank you for contacting Zoning Supply with your question. We appreciate your interest in our SmartZone products.


QUESTION: The 9580 thermostat uses delta T (difference between actual room and called for temps) as part of the staging calculation.  If the staging function of the thermostat is replaced by the zone controller, how does the controller get delta T, or is is not used?  If not, ow does it determine staging...is it rate of temp change sensed by the probe?

ANSWER: SmartZone uses algorithms based on time and supply air temperature (as measured at the supply air plenum) to control staging. Each time the equipment is started SmartZone will require a minimum run time in stage 1 before it will consider staging. This initial run time allows for the equipment to achieve a stable temperature in heat or cool before determining if staging up is necessary. After the initial run time requirement is achieved SmartZone compares supply air temperature to the cut-in temperature settings and will stage up if conditions are met. When the equipment is running stage 2 SmartZone will compare supply air temperature to the cut-out temperature and will return to stage 1 if conditions are met. SmartZone staging algorithms will vary the time and temperature elements based on equipment type (gas/electric or heat pump) and mode of operation (cool or heat). The SmartZone Installation manual included with your product provides detailed information about the sequence of operations for adjusting staging settings including the specific algorithms used for each equipment type and their modes of operation.

 

SmartZone on TV - Greenovate Episode: Austin, TX

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I believe this first aired in 2006 - making this system at least 10 years old.  I have made contact with the homeowner through the original installer and it turns out that it is still working great.  Since then, they have upgraded to NEST thermostats but nothing else has changed.  They are considering upgrading the equipment to higher efficiency stuff that is available now but still want to keep SmartZone in place.