Lennox International Inc Heating System LZP 2 User Manual

ZONING SYSTEM  
Litho U.S.A.  
© 2004 Lennox Industries Inc.  
Dallas, Texas, USA  
LZP-2  
504,926M  
5/2004  
ZONE CONTROL PANEL  
INSTALLATION INSTRUCTIONS FOR ZONE CONTROL PANELS  
USED WITH LENNOX HEATING AND COOLING EQUIPMENT  
Shipping & Packing List  
Package 1 of 1 contains the following:  
TABLE 1 – TRANSFORMERS  
(1) Model LZP-2 Zone Control Panel  
(1) Model 88K38 Temperature Sensor  
(1) Installation Instructions  
(1) Owners Manual  
Part Number  
Size  
40VA  
50VA  
75VA  
Voltage Description  
10P17  
10P87  
12P61  
83P74  
120/208/240V-24V  
120/208/240V-24V  
(1) Warranty Card  
120/208/240V-24V  
Required Components (ordered separately):  
4" Square Electrical Box  
24 VAC Transformer – The size of the transformer  
needed is determined by the total power requirements  
for the control panel, thermostats and dampers. The  
control panel and thermostats together require 10VA.  
The dampers require 10VA each. The size of the  
transformer will depend on the greatest number of  
dampers that could be energized at any given time.  
Thermostats – single-stage, electronic, 24-volt  
heat/cool thermostats which include a “C”  
(24VAC common) terminal. Do not use mechanical  
or power robbing thermostats.  
Dampers – 2 or 3-wire, 24-volt dampers required.  
NOTE – When power closed/spring open dampers  
are used, at least one zone’s dampers will not be  
energized during a call for heating or cooling.  
2-wire, power closed/spring open preferred.  
FIGURE 1 – LENNOX® MODEL LZP-2 CONTROL PANEL LAYOUT  
Page 1  
 
Installation (continued)  
4. Install and Wire the Discharge Air Temperature Sensor  
CAUTION  
As with any mechanical equipment, personal injury  
can result from contact with sharp sheet metal  
edges. Be careful when you handle this equipment.  
15"  
D/3  
D
W
CAUTION  
Before attempting to perform any service or  
maintenance, turn the electrical power to unit OFF  
at disconnect switch.  
FRONT  
The tip of the sensor must be located in a region of fully  
mixed supply of air before the take-offs (not in a dead  
air space) in order for the system to work correctly.  
a. Wire discharge air temperature probe to control  
panel using thermostat wire. Note that the  
temperature sensor is not polarity sensitive.  
b. Be sure that the tip of the sensor is located at  
least 15 inches downstream from the leaving air  
side of the evaporator in the discharge plenum,  
and 1/3 of the depth (D/3) of the plenum (D) from  
the front of the plenum (the front is the side with  
the furnace or CB access doors), and centered  
side to side. Move the adjustable bracket along  
the length of the discharge air sensor to achieve  
proper sensor tip location (tip of sensor to be  
located at W ÷ 2). The sensor can be inserted  
from any side of the plenum, as long as the tip of  
the sensor is in the correct position. See Figure 3.  
FIGURE 3 – DISCHARGE AIR SENSOR LOCATION  
IMPORTANT: The discharge air sensor is required.  
If a short or open circuit is detected between the  
Plenum Sensor terminals, the control panel will only  
respond to Zone 1 and the dampers will stay in the  
open position.  
Page 3  
 
Installation (continued)  
5. Install the required transformer selected from Table 1  
DO NOT USE the HVAC equipment transformer to  
power the control panel. Refer to the instructions  
provided with the transformer.  
6. Install the thermostats. Refer to the instructions  
provided with the thermostat.  
Any 24-volt electronic thermostat with a C(24 VAC  
common) terminal can be used. Power robbing  
thermostats can cause unintended operation –  
DO NOT use mechanical or power robbing  
thermostats. Table 2 lists the required terminals  
and recommended Lennox thermostats:  
18 AWG thermostat wire minimum recommended.  
Sizing the Transformer:  
The system requires approximately 10 VA for the  
control panel and thermostats and 10 VA for each  
damper. The size of the transformer will depend on the  
greatest number of dampers that could be energized  
at any given time (at least one zones dampers will not  
be energized during a heating or cooling call when  
using power close, spring open dampers). The size of  
the transformer must not exceed 75VA. If the value is  
greater than 75VA, some dampers will need to be  
powered by a separate transformer refer to Field  
Wiring Damper Diagram 2 on page 6.  
18 AWG thermostat wire minimum recommended.  
TABLE 2 – THERMOSTAT REQUIREMENTS  
Recommended  
Type  
Terminals  
Thermostat  
SignatureStat 1H/1C  
(51M26)  
HEAT/COOL R, C, W, Y, G  
Elite 1H/1C (49M55)  
For instance, if you have 3 dampers, then you would  
require 10VA for the system, 20VA (10VA X 2) for the  
dampers for a total of 30VA, so catalog number 10P17  
would be an adequate transformer size at 40VA.  
Thermostat Terminal  
Function  
24 VAC Hot  
24 VAC Common  
Heat  
R
C
W
Y
TABLE 1 – TRANSFORMERS  
Part Number  
10P17  
Size  
40VA  
50VA  
75VA  
Voltage Description  
120/208/240V-24V  
Cool  
G
Fan  
10P87  
120/208/240V-24V  
7. Install the dampers. Refer to the instructions provided  
with the damper.  
12P61  
120/208/240V-24V  
83P74  
4" Square Electrical Box  
18 AWG thermostat wire minimum recommended.  
The transformers listed in this chart include a plate  
mount for a 4" square electrical box.  
Page 4  
 
Bypass Damper Sizing  
When fewer than the maximum number of zones are  
calling for heating or cooling, an excess volume of air is  
delivered, and because of the excess air, an excess  
amount of static pressure is produced as well. Zone  
systems often require a bypass duct to relieve this  
pressure. A properly sized barometric bypass damper  
must be installed in the bypass duct which is run  
between the supply and return air duct systems (see  
Figure 4). The barometric damper and the bypass duct  
must be sized to accommodate the excess static  
pressure from the supply duct.  
Example:  
Total System air volume: 2000 cfm  
Air volume of smallest zone: 600 cfm  
Bypass requirement: 2000 - 600 = 1400 cfm  
In this example, the bypass duct should be sized to  
handle the 1400 cfm excess pressure created when  
only the smallest zone has a demand. For bypass  
damper air volume capacities, see Table 3.  
TABLE 3  
The bypass tap in the return air duct must be at least  
6 ft. from the furnace /air handler to ensure that the hot  
or cold air coming off of the plenum has time to mix  
with the return air before it passes through the air  
handler again. The provided discharge air sensor will  
prevent any damage to the equipment from overheating  
or coil freeze-up by interrupting the HVAC equipment.  
Round  
Rectangular  
8 in. dia. 400 cfm  
10 in. dia. 750 cfm  
12 in. dia. 1200 cfm  
14 in. dia. 1800 cfm  
16 in. dia. 2400 cfm  
12 x 8 1000 cfm  
12 x 10 1200 cfm  
12 x 12 1400 cfm  
20 x 8 1600 cfm  
20 x 10 2000 cfm  
20 x 12 3000 cfm  
The bypass damper and duct should be sized to handle  
the excess pressure created when the smallest zone is  
operating alone (worst case). To size the bypass  
damper, subtract the total air volume capacity of the  
smallest zone from the total air volume of the system.  
Refer to the parts and supplies catalog for information  
on available barometric bypass dampers.  
ZONE 1  
THERMOSTAT  
BYPASS  
DAMPER  
ZONE 1  
BYPASS DUCT  
ZONE  
DAMPER  
SUPPLY  
AIR  
HEATING/  
COOLING  
UNIT  
RETURN  
AIR  
DISCHARGE  
AIR SENSOR  
ZONE  
DAMPER  
6 ft. (1.8 m)  
TRANSFORMER  
FOR  
DAMPERS,  
PANEL AND  
THERMOSTATS  
ZONE  
CONTROL  
PANEL  
ZONE 2  
THERMOSTAT  
ZONE 2  
FIGURE 4 – BYPASS DAMPER INSTALLATION  
Page 5  
 
Field Wiring  
DIAGRAM 1 – FIELD WIRING  
DIAGRAM 2 – DAMPER WIRING WITH SEPARATE TRANSFORMER  
Page 6  
 
Pin Jumper Settings (see Figure 5)  
DISCHARGE AIR SENSOR HT-140/160: This jumper  
controls the temperature at which the heating equipment  
will cut out to prevent overheating. For a high limit  
temperature of 140°F, move the jumper to the 140”  
position. For a high limit temperature of 160°F, leave the  
jumper in the 160position.  
IMPORTANT: The temperature sensor is required.  
If a short or open circuit is detected between the  
Discharge Air Sensor (DAS) terminals, the control  
panel will only respond to Zone 1 and the dampers  
will not close.  
FIGURE 5 – PIN JUMPER SETTINGS  
ELECTRIC/GAS: If electric heat is to be used, move the  
jumper to the ELECTposition. This will turn on the fan  
(G output terminal) with a heat call (W output terminal).  
If the jumper is in the GASposition, it is assumed that  
the heating equipment will control the fan operation.  
DISCHARGE AIR SENSOR CL-45/40: This jumper  
controls the temperature at which the cooling  
equipment will cut out to prevent freezing the indoor  
coil. For a low limit temperature of 45°F, leave the  
jumper in the 45position. For a low limit temperature  
of 40°F, move the jumper to the 40position. To  
maintain optimum operation, it is recommended to leave  
this setting at 45.  
NO PURGE / PURGE: If the NO PURGE / PURGE  
jumper is moved to the PURGEpurge position, the G  
terminal will remain energized for a one minute purge  
delay following the completion of a cooling call. If the  
jumper is moved to the NO PURGEposition, the G  
terminal will de-energize immediately following the  
completion of a cooling call. The NO PURGE setting is  
designed for use with systems where the furnace or air  
handler has a built in fan purge. The NO PURGE  
damper hold time is longer than the PURGE setting due  
to the Lennox furnaces installer settable maximum  
blower off delay of 3 minutes. The following chart details  
the zone panel outputs and damper hold times when a  
heating or cooling call is satisfied:  
Purge  
No Purge  
Damper Hold Time  
Jumper Settings  
Mode  
Output  
G1  
Damper Hold Time  
1 minute  
Output  
No G,  
No G,  
No G,  
No G,  
Cooling  
Heating  
Cooling  
Heating  
3-1/2 minutes  
3-1/2 minutes  
3-1/2 minutes  
3-1/2 minutes  
Heat/Cool  
Gas  
No G  
G1  
1 minute  
1 minute  
Heat/Cool  
Elect.  
G1  
1 minute  
1The G terminal will remain energized for 1 minute.  
LEDs  
POWER Blinks during normal operation. Starts to  
blink approximately 6 seconds after power up.  
ZONE 1 Damper and ZONE 2 Damper Lights when  
the Normally Open (NO) damper terminal for that zone  
is energized (i.e. LEDs show which zones are NOT  
receiving conditioning when the HVAC equipment is  
operating).  
G,Y and W Lights when respective equipment outputs  
are energized. The W LED will flash if the heating high  
temperature limit has been reached. The Y LED will flash  
if the cooling low temperature limit has been reached.  
Page 7  
 
Sequence of Operation  
A Time Delay Override (TDO) button is available on the  
control panel to speed up the internal timer by a factor  
of 60 for system checkout. One second of holding down  
the button relates to one minute of speed up time in the  
control.  
Heat/Cool Changeover: When a call for heating or  
cooling exists and an opposing call is made from  
another zone, a 20 minute timer is activated. If the  
original call is not satisfied within that 20-minute time  
period, the call will be interrupted, turning the equipment  
off and allowing for the normal fan purge cycle and  
minimum equipment off time. The opposing call will then  
be answered. After 20 minutes, if the original call still  
exists, the opposing call will be interrupted and the  
original call can once again be recognized.  
HEATING AND COOLING EQUIPMENT OPERATION  
Heating Operation  
When a zone makes a call for Heat, the W output  
terminal will energize. The G terminal will also energize  
if the ELECTRIC/GAS jumper is in the ELECT position.  
The W terminal de-energizes when (1) all zones stop  
calling for Heat, (2) the call has exceeded the heat/cool  
changeover time limit while a cooling call exists or (3)  
the call is interrupted by the high limit setting. When the  
W terminal is de-energized, a minimum off time delay of  
4 minutes must elapse before it can be energized again.  
High/Low Limit Temperature: The high/low limit  
temperature settings are designed to prevent the heat  
exchanger from overheating or the cooling coil from  
freezing. The temperature sensor in the supply duct  
senses the discharge air temperature and interrupts the  
heating/cooling equipment (depending on the Heat and  
Cool temperatures set on the control panel) before  
overheating/freezing occurs. When a heating/cooling  
call is interrupted by the high/low temperature limit, the  
zone control panel turns the equipment off and  
energizes the G terminal (if not already energized). The  
W or Y LED on the control panel will flash during a  
high/low limit temperature interrupt. Once the  
Fan Purge Time Delay  
If the ELECTRIC/GAS jumper is in the ELECT  
position and the PURGE/NO PURGE jumper is in the  
PURGE position, the G terminal will remain energized  
for one minute after the W terminal is de-energized.  
The NO PURGE setting is the preferred purge control  
setting for Lennox equipment. Lennox equipment  
includes controls which sequence the indoor fan off  
after a call for heat has been satisfied.  
temperature drops/rises 10°F and the minimum off time  
has expired, the equipment is turned back on if the call  
for conditioning still exists. The Heating/Cooling LED will  
stop flashing.  
If the ELECTRIC/GAS jumper is set in the GAS  
position, the G terminal does not turn on during purge  
regardless of the position of the PURGE or NO  
PURGE switch. Lennox furnaces will control the  
purge though the furnace control board cool down  
feature. The cool down time is often adjustable at the  
furnace control board up to 3.5 minutes. NO PURGE  
is the preferred method of purge when this zone  
panel is applied to Lennox equipment.  
IMPORTANT: Should a short or open circuit be  
detected across the DAS terminals, the zone system  
will respond only to Zone 1 and the dampers will  
not energize.  
Cooling Operation  
When a zone makes a call for Cooling, the Y and G  
terminals will energize. The Y terminal de-energizes  
when (1) all zones stop calling for Cooling, (2) the call  
has exceeded the heat/cool changeover time limit while  
a heat call exists or (3) the call is interrupted by the low  
limit temperature setting. When the Y terminal is de-  
energized, a minimum off time delay of 4 minutes must  
elapse before it can be energized again.  
Fan Purge Time Delay  
If the PURGE/NO PURGE jumper is in the PURGE  
position, the G terminal will remain energized for one  
minute after the Y terminal is de-energized. If the  
jumper is in the NO PURGE position, the G terminal  
will de-energize immediately.  
Page 8  
 
Sequence of Operation (continued)  
CONTINUOUS FAN OPERATION  
A call for Fan from any zone will initiate the G  
equipment output terminal. The normally open (NO)  
damper terminal at all zones not calling for continuous  
fan will be energized.  
DAMPER OPERATION  
The NOoutput will be energized and the NCoutput  
will be de-energized for any zone not calling for heating  
or cooling while the equipment output is energized and  
during the damper purge time delay. During equipment  
operation or during the damper purge time delay,  
should all zones stop calling for heating or cooling, the  
damper terminals will remain in the position they were  
in before all zones stopped calling.  
Damper Purge Time Delay  
When the Purge/No Purge jumper is at No Purge,  
the damper purge time delay is 3.5 minutes and  
begins when the equipment output(s) turn off. NO  
PURGE is the preferred method of purge control for  
Lennox furnaces and air conditioners. When the  
jumper is at Purge, the damper purge time delay is  
one (1) minute.  
Page 9  
 
Troubleshooting  
DETECTING HVAC SYSTEM PROBLEMS  
Possible Solution  
Symptom  
Pressure switch open.  
Consult condensing unit manual for possible cause.  
Compressor is off due to internal overload protector.  
Consult condensing unit manual for possible cause.  
Condensing unit receiving signal but will not turn on.  
Condenser control board anti short cycle timer is not  
yet expired. Most anti short cycle timers are 5 minutes  
or less, if the unit does not start after 5 minutes consult  
the condensing unit manual for possible causes.  
A high static condition exists. Move the sensor  
further down stream to sense air that has mixed more  
thoroughly. Be sure not to place the senor past  
the take offs. High static pressure must be corrected.  
Furnace tripped the primary limit, but the  
zone panel does not indicate that the discharge  
air limit has been exceeded.  
Bypass tap is too close to inlet of air handler.  
Adjust bypass tap in the return air duct so that is further  
away from the furnace. This will give the air more of a  
chance to be tempered with room return air before  
entering the air handler again.  
Limit on furnace open. Check position of DAS in  
the plenum and move further down stream if possible.  
High static condition must be corrected.  
Air handler receiving signal but will not turn on.  
DAS limit jumper needs to be moved to a lower setting.  
Trouble shoot air handler see air handler  
documentation.  
Page 10  
 
Troubleshooting (continued)  
DETECTING HEATING, COOLING AND FAN PROBLEMS  
Symptom  
Possible Solution  
No power to control panel. Green Normal Flashing”  
LED should be blinking, if not apply power to  
24VAC inputs of control panel. Check fuse.  
Nothing comes on.  
Single transformer system. Install jumper between RC  
and RH at HVAC Equipment outputs of control panel.  
Interlock switch on furnace is open close access doors.  
Thermostat is not calling for heat. Check voltage at  
the thermostat W input on the control panel.  
Heat will not come on.  
Zone 2 calling while open or short at DAS inputs is  
causing control panel to respond only to Zone 1.  
Thermostat is power robbing or mechanical. Only use  
line powered electronic thermostat with a C terminal.  
Single transformer system. Install jumper between RC  
and RH at HVAC equipment outputs of control panel.  
Thermostat is not calling for cooling. Check voltage  
at the thermostat Y input on the control panel.  
Thermostat could be invoking a timed off delay.  
Cooling will not come on.  
Zone 2 calling while open or short at DAS inputs is  
causing control panel to respond only to Zone 1.  
Zone panel could be invoking a timed off delay.  
Thermostat is power robbing or mechanical. Only use  
line powered electronic thermostat with a C terminal.  
Check if G is energized at the zone panel.  
Check if G is energized at the thermostat.  
Check if G is energized at the air handler.  
Fan will not come on.  
System requires the Discharge Air sensor. If DAS is not  
installed, only Zone 1 calls will be recognized and dampers  
will not operate. Disconnect power to the control panel,  
install the DAS and restore power to the control panel.  
Dampers do not position on a call for heating,  
cooling or fan. Heat, cooling or fan will not come on  
when the Zone 2 thermostat is calling.  
ELECT/GAS jumper set to ELECT change setting  
Fan immediately comes on with heat call.  
to GAS.  
After a cool call, the fan stops then starts right  
away only to stop a short while later.  
HVAC system has built in duct purge. Set PURGE/NO  
PURGE jumper on control panel to NO PURGE.  
Discharge air temperature exceeds set limit.  
Allow discharge air to cool 10° below set limit and  
allow timed off delay to expire.  
Fan is running but no heat, and W LED is blinking.  
Discharge air temperature dropped below set limit.  
Allow discharge air to warm 10° above set limit and  
allow timed off delay to expire.  
Fan is running but no cooling, and Y LED is blinking.  
Both the Y and W LEDs are blinking.  
An open or short in the DAS sensor has been detected.  
Install or repair the sensor.  
Page 11  
 
Troubleshooting (continued)  
Symptom  
DETECTING DAMPER PROBLEMS  
Possible Solution  
DAS shorted or open causing the panel to only respond  
to zone 1 inputs while not closing any dampers.  
Damper opens when it should be closed.  
Damper wired incorrectly. Spring open power close  
dampers should be connected between NO and  
C terminals.  
DAS shorted or open causing the panel to only respond  
to zone 1 inputs while not closing any dampers.  
Damper will not close.  
Damper motor faulty.  
CHECKING THERMOSTAT VOLTAGES  
Using a digital voltmeter (DVM) measure the AC voltage supplied at the R and C terminals of the Thermostat  
inputs on the control panel for the zone in question. This voltage should be same as the voltage supplied to the  
control panel 24VAC terminals. Make a call for heat, cooling or fan. Measure the voltage across the terminal that  
should be energized (i.e. W for heat, Y for cooling, etc.) and the C terminal. This should be the same voltage as  
there is between the R and C terminals. Measure the voltage across a terminal that should NOT be energized  
and the C terminal; this voltage should be zero.  
DISCHARGE AIR SENSOR CHECKOUT  
The discharge air sensor is a temperature dependent resistor; the higher the temperature, the lower the  
resistance. In order to confirm the sensor is working, both sensor leads must be disconnected from the zone  
panel board. Using a digital voltmeter (DVM) set to read resistance, touch the leads from the sensor to the  
probes of the DVM. Take care not to create a parallel resistance path through your body by touching both probes  
with your fingers or a faulty reading will be obtained. At 77F, the resistance of the sensor will be 10K ohm. If the  
sensor is cooler than 77F, the resistance will be higher, if it is warmer, the resistance will be lower. After reading  
the resistance at room temperature, warm the tip of the sensor by holding it in the palm of your hand, and take  
another resistance reading. This reading should be noticeable lower than the room temperature reading.  
Temperature (°F)  
Resistance (ohms)  
65  
70  
75  
80  
85  
90  
13476  
11884  
10501  
9298  
8249  
7333  
The zone panel is well equipped to monitor the operation of the probe and determine if a failure has occurred.  
The probe should be considered an integral (but replaceable) part of the zone panel. The zone panel will indicate  
if the probe is operating improperly and needs to be replaced.  
B2203458  
10006259  
Page 12  
 

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