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HVAC Zone Controls & Zoning Dampers

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Damper Wiring: Yet another 5-terminal damper style wired to SmartZone

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We confirmed today, thanks to a helpful customer, how another DuroZone damper wires using 3 wires (even though it has 5 terminals).

If your damper motors look like the one shown, wire to SmartZone as shown.

Another DuroZone model… on this model it is reported that some versions TERMINAL 4 (the blue wire shown) goes to CLOSE instead of OPEN.

If your motors looks different than this, see our other posts about damper wiring:
4-Terminal and 8-Terminal Damper Wiring

If the motors you have are not compatible with SmartZone, you still don't have to replace the whole damper.  You can replace just the motor (actuator) on just about any standard residential damper with the SmartZone / Belimo motor.

Power Open/Close Motor
from $69.99
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Zoning System Troubleshooting

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Because a zone control system interacts with so many different parts (thermostats, transformers, heating/cooling equipment, dampers & temperature sensor), a zoning system can be daunting to troubleshoot when there is a problem.  However, we have realized that there are really just a few common issues are the cause most all of the issues. With a combined 20+ years of zoning questions and technical support calls, we have tried here to boil down to the top 5 reason 99% of zoning systems have a problem.  These do not include a potential problem with the configuration of the Zone Control itself.  The troubleshooting of the zone control configuration is covered well in most Installation Guides.

1. Equipment
   Refrigerant charge, fan speed, wiring, power, etc.
   Always verify that the equipment is working properly first!
2. Thermostats
  a. Incompatible with zone panel
  b. Defective thermostat
  c. Wiring defect
3. Zone Dampers
  a. Actuator failure
  b. Mechanical failure
  c. DUCT Sizing (not enough or too much CFM)
  d. Wiring defect
4. Bypass/Relief
  a. Actuator failure
  b. Sensor (Static Pressure sensor defect)
  c. Mechanical failure
  d. Setup (Modulating calibration or weight arm setting)
  e. Orientation of installation (SPC or barometric bypass)
  f. Improper sizing (not enough CFM capacity)
  g. Wiring defect
5. Power
  a. Transformer fuse
  b. Wiring defect
  c. Primary circuit problem (shared/capacity, breaker)
  d. Improperly sized transformer (not enough VA)

For help troubleshooting your system contact the experts at zoningsupply.com directly via email or phone.

EASIEST TO TROUBLESHOOT ZONE CONTROL ON THE MARKET:

SmartZone-4X
Sale Price:$229.99 Original Price:$299.00
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Replace Honeywell Zone Controls with SmartZone

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Good video that shows the basic wiring steps for replacing a honeywell truezone with SmartZone.  The video features the HZ322 but also applies to the HZ432, HZ311, & HZ221

SmartZone-4X
Sale Price:$229.99 Original Price:$299.00
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If you have any questions about replacing your zone control with SmartZone, contact us for expert zoning support!

SmartZone can be used with any 24V Damper

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honeywell ard mard to smartzone wiring
smartzone to honeywell damper
smartzone durazone damper

There are many different models of 24VAC dampers available on the market.  Some have 2-wires, some have 3 wires, some have 5 wires and some even have 8 wire terminals.  Nearly all of these can be used with the SmartZone products (2L, 2X & 4X).  Both 2 and 3 wire dampers are straight-forward to wire and even shown in the installation guide that comes with SmartZone.  However, some of the less common types of dampers (4, 5, 6 & 8 wire) require a little more understanding.  How to wire some of them are shown below.

If you have any other type of damper, please contact us and we will help you.

 

Better dampers available from ZoningSupply:

PRO-Grade Power Zone Damper (Round)
from $99.99
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Replacing old 2-wire spring damper with a high quality ecojay damper

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UPDATE: March 2017 - NEW Dampers available now.  TAKE-OFF ROUND, INSERT ROUND & RECTANGLE Dampers all available now ... scroll down to see all damper models. OR click here.

Some older zone control panels have only two connectors for damper wiring (common & power-close).  These were designed when predominately 2-wire (spring open) dampers were used for zoning.  In recent years, 3-wire (power-open, power-close) dampers have become more common because of their low power consumption and higher reliability.  You might think you have to upgrade your zoning panel to accommodate for these preferable 3-wire dampers... not with Ecojay dampers and belimo actuators.  The wiring diagram below shows how to connect the Ecojay Power Damper to an older zone panel that is only designed to work with 2-wire dampers.

If you are planing to replace the zone controller with SmartZone, this diagram is NOT necessary.

If you have any questions, call or email us.

Why a temperature sensor is so important with Zoning

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Equipment Protection

Protecting the equipment from running too hot or too cold is very important consideration when selecting zoning panel.  By the nature of zoning, airflows in the duct work are being adjusted as zones open and close. Even in Pressure Relief is adequately designed using a bypass or other method, temperatures across the coil and the furnace can fluctuate.  An example is on a mild 60 degree day, a single small zone calls for heat.  In this case, a large percentage of already “heated” air is being re-circulated or forced back through the furnace to be “re-heated.”  This condition can cause temperatures that will cause the fail-safe temperature sensor to trip on the equipment.  The same thing can happen in the cooling mode with consequences that look like frozen coils and potentially damaged compressors.

The need for protection has OFTEN been overlooked with zoning and has caused many failures that have been generically blamed on “zoning.” Much of the negative feelings about zoning has been caused by this problem.  The solution is available on most modern panels:  A supply air temperature sensor (discharge air) that allows the zoning panel to cut off the equipment when the temperature is too high or too low.

Staging

The zoning panel used here is determined by the equipment being used on the application.  If the equipment is single stage,  any zoning panel available should work that meets the other guidelines described here.  When multiple stages are being used, there are many less options.  First of all, many inexpensive zoning panels do not control more than one stage (although most of these don’t meet other criteria described in this book either).  Secondly, and often overlooked is the staging control method.  Many available boards simply control second or third stage based on time alone.  In other words… if stage one is on for 8 minutes, turn on stage two.  More accurately, some panels include a 2nd stage lockout if only one zone is calling.  Best of all, some panels available use a supply temperature sensor to stage based on both time and temperature.  With a temp sensor controlling stating the most efficient use of equipment can be made, not to mention the protection from freeze or overheating it provides.

 
Replacement: Supply Air Sensor
$20.00
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SmartZone Static Pressure Control for Modulating Bypass

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Why SmartZone Static Pressure Control so much better?  It's pre-wired, saving lots of time and hassle.

Much better than the competition... more accurate and the easiest by far to install.  The video below shows that a typical static pressure control takes more than 4X as long to install when compared to the same ECOJAY SmartZone Static Pressure Control (ASPC)

Air Pressure Switch (Bypass Control)
$69.99
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What type of damper is best Spring or Power?

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smartzone damper sizes.png
smartzone 8 inch spring damper.png

Damper Type Selection

There are two basic types of dampers available in mass today.  Although, there are other damper types such a “balloon” type and pneumatic controlled dampers (used more commonly on DDC systems not included), for this context we will discuss these two main types of dampers:

  • Spring Open or Close (Spring Damper)
  • Power Open & Power Close (Power Damper)

Power Dampers

Power Open /Power Close dampers use three wires to either power open or power close.   They zone panel is responsible for supplying a 24VAC signal to either the PO (Power Open) or PC (Power Closed) terminal of these dampers.  This type of damper was traditionally reserved for “higher-end” or commercial applications because of the cost.  In recent years, however, motor prices have decreased and power dampers have become much more affordable (often no more expensive than the spring equivalent especially when labor and reliability are factored in.)  Primary advantages of Power Dampers include lower power consumption, quiet operation and more reliable parts.  Given the choice, Power Dampers, are almost always preferable.  The only exception to this is when code requires Spring Dampers.

PRO-Grade Power Zone Damper (Round)
from $99.99
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Spring Dampers

The way Spring Dampers work is they have a motor that, when energized by the zoning panel, it closes the damper.  When the damper is ready to open, the motor stops powering the damper closed and a spring opens the damper blade back up.  Spring Dampers have been used in an “economy” application for many years.  The two primary advantages of a Spring Damper are: 1. If the system loses power they “fail” open… but if the system loses power, the equipment isn’t going to be running either and therefore will not matter in MOST cases.  2. They only require two wires for operation.  One of the negative arguments against Spring Dampers has historically been reliability.  This mostly a result of one of its benefits… the cost.  The inherent lifecycle of any spring actuated mechanism (even if it is in the millions) is less reliable than a system that doesn’t include this potential failure point.   In addition to this, the motor that is used has to be a very specific model that allows for running backwards without damage yet still has to be powerful enough to overcome the spring trying to pull the blade in the opposite direction.  This leads to probably the BIGGEST downfall of using a Spring Damper - the power consumption.  Most Spring Dampers on the market use 3 to 4 times the power of the equivalent Power Damper (10-12 VA vs. 2-3VA).  This could be the difference in using a standard sized transformer and having to go to a very large (and expensive) over-sized transformer.   In summary: spring dampers are NOT recommended unless absolutely necessary for some reason.

Spring Zone Damper
from $99.99
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The parts that make an HVAC Zoning System

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Elements of Zoning

A Zoning System consists of 4 primary pieces:

  1. Thermostats

  2. Zoning Control Panel

  3. Dampers

  4. Equipment

1. Thermostats

SmartZone Thermostat Zoning

Thermostats are used in just the same way that a typical thermostat is used except with a zoning system there is ONE thermostat located in each area or “zone.”  Instead of connecting these thermostats to the equipment like a typical application, with zoning all the thermostats are connected to the Zoning Panel.  Suggest purchasing on Amazon.com or from wherever 24VAC thermostats are sold.

2. Zoning Control Panel

SmartZone-4X
Sale Price:$229.99 Original Price:$299.00
 

The Zoning Panel is the “brains” of the operation.  This computer-like electronic board, reads the calls from all the thermostats and makes decisions about what to energize on the equipment (heat, cool or fan) AND which dampers to open or close.  Zoning Control Panels come in MANY shapes, sizes, and colors but with SmartZone you are just selecting the number of zones)

3. Dampers

 

Not only are the thermostats connected to the Zoning Panel but so are the dampers.  A damper is to airflow in the duct like a faucet is to water in a pipe.  In other words, the damper acts like a valve in the duct system to divert air to the zones where it is needed.

4. Equipment

Finally, the Equipment is also connected to the Zoning Panel.  The equipment refers to the heating and cooling (HVAC) unit.  This can come in many shapes, sizes, and configurations.  In order to apply zoning to any equipment, the correct zoning Panel mush be chosen.  Some Zone Panels are very specific and can only be used with certain types of equipment while some are much more versatile and can be used on almost ANY type of equipment used.


The above four parts make up the pieces of a Zoning System, but since in a standard system you already have two of these parts (THERMOSTAT and EQUIPMENT).  The addition of a zoning system really consists of adding only two different parts, a ZONING PANEL and DAMPERS.   This makes zoning one of the easiest and affordable ways to gain the much desired improvement of comfort and efficiency.  With these parts installed properly a user can enjoy the ability for both added comfort and increased energy savings.

2, 3, or 4 Zone KITS
from $599.00
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What size dampers do I need?

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Damper Size Selection

Typically in an existing install, the duct size will determine the damper sizes needed.  But if starting with a new duct system 2 variables must be known to determine damper sizes.

  • Total CFM of System

Calculate using the “whole house load” with maximum diversity.

  • Zone CMF (needed for each Zone)

 Total the rooms associated with each zone separately to get the “Zone CFM” (No diversity)

Round Damper Sizes

Round damper sizes range from 4” to 18” typically in 1” increments up to 10” and in 2” increments up to 18”.  There are two numbers that must be used when designing a zoning system with regard to all dampers.  

Ecojay smartzone damper sizes
  1. Design CFM – Used to properly size the dampers based on a maximum FPM air velocity at the register to avoid air noise and still provide enough throw to heat or cool the space.  (Typical acceptable FPM 600 to 800)

  2. Max CFM – The maximum amount of air that might move through a damper if it is the only zone open.  This assumes the pressure relief is also sized properly (see Pressure Relief below).  This will result in more air noise but must be kept at an acceptable level (no more than 900 FPM).

The chart shows the recommended round damper sizes to be uses for Design and Max CFM. 

NOTE: These are rough estimates & other duct restriction variables could affect the size damper needed.  Consult an HVAC professional if you are unsure.

Replace a Honeywell 4 Zone with SmartZone-4X

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UPGRADE your system with an easier & better zoning control.  The SmartZone-4X is a drop in replacement for many zone control systems.  This is a quick diagram showing where to plug in the wires after disconnecting them from your old HONEYWELL system.

Honeywell HZ432, HZ-432, HZ322, HZ-322, HZ311, HZ-311, HZ221, HZ-221 can all be replaced by the SmartZone-4X in most cases.  For more information go to http://www.smartzoning.com