Aprilaire 6303 Thermostat User Manual

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SAFETY INSTRUCTIONS  
ZONED COMFORT CONTROL SYSTEM  
Read this Installation Manual before beginning installation of the Aprilaire Zoned Comfort Control System.  
For questions call Research Products Corporation at (800) 334-6011.  
5
. Excessive pressure across a bypass  
evaporative type humidifier may cause high air  
velocity in the humidifier, resulting in water  
being blown into the ductwork. Refer to Design  
Guide for humidifier installation instructions.  
. Install an outdoor thermostat to prevent non-  
seasonal equipment starts if using auto  
changeover thermostats.  
WARNING  
CAUTION  
1
. 120 Volts may cause serious injury from  
electrical shock. Sudden operation may cause  
serious injury from moving parts. Leave power  
disconnected until installation is complete.  
. Sharp edges may cause serious injury from  
cuts. Use care when making duct openings and  
handling ductwork.  
1. Installation must be done in accordance with  
all applicable codes.  
2. Installer should touch a grounded metal object  
before handling the Aprilaire control panel to  
avoid potential loss of internal computer  
programs due to static discharge.  
3. A zoned comfort control system may not  
control temperature properly unless the  
heating and cooling system is properly sized  
and balanced.  
4. Insufficient air flow or excessive temperatures  
through the heating and cooling system could  
result in equipment damage. Refer to the  
manufacturer’s recommendations for minimum  
safe airflow and temperature requirements.  
6
2
3
7
. Do not mount the control panel on any part of  
the heating/cooling equipment or ductwork.  
. Do not install control panel where  
. The Aprilaire Zoned Comfort Control System is  
designed for indoor use only. Do not expose  
any component of the zone control system to  
moisture. Do not mount any Aprilaire Zoned  
Comfort Control equipment where it may be  
accessible to children.  
8
temperatures exceed 158°F (70°C).  
INSTALLATION  
CAUTION: Installer must touch a  
grounded metal object before  
handling the Aprilaire Zoned  
Comfort Control panel to avoid  
potential loss of programs due to  
static discharge.  
MOUNTING HOLE  
ENCLOSURE BASE  
2
PLACES  
CONTROL BOARD  
MOUNTING HOLE  
PLACES  
2
1
. MOUNT THE CONTROL PANEL  
Four holes are provided on the back of the  
unit for mounting. (See Figure 1)  
Mount indoors using #8 or #10 screws (field  
supplied).  
Mount in location where the temperature will  
not exceed 158°F and will not drop below  
freezing (32°F).  
“THROUGH-THE-WALL”  
WIRING HOLE,  
2
PLACES  
E-HE  
AT  
OF  
ON  
F
Do not mount on foundation walls, or on the  
HVAC equipment or ductwork. These  
locations can cause the enclosure to become  
cooler than the surrounding air, which can  
cause moisture to condense on the  
enclosure.  
E-HE  
AT  
OFF  
ON  
#
8 SCREWS (Field Supplied)  
ENCLOSURE  
COVER  
FIGURE 1  
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2
. MOUNT THE 8052 PLENUM TEMPERATURE SENSOR (provided)  
IMPORTANT: Do not mount the sensor in direct line-of-sight of the heat exchanger,  
cooling coils, or UV lights as they may cause the sensor to report false temperature  
readings.  
ZONED COMFORT CONTROL:  
MOUNT PLENUM SENSOR IN  
SHADED AREA  
Locate the sensor in the supply trunk, after the heat exchanger and cooling coils and  
before the zone dampers (shaded areas). (See Figure 2)  
Mount the 8052 Sensor according to Installation Instructions provided with the sensor.  
Wire the 8052 Sensor to the Plenum Sensor terminals on the zoned comfort control panel  
before power is applied to control panel.  
Measure the resistance across the Plenum Sensor terminals (before power is applied to  
the panel) and confirm that it roughly corresponds to the ambient temperature values  
listed in the table below.  
ZONE DAMPERS  
Ambient Temperature (°F)  
Resistance (kΩ)  
3
4
5
6
7
8
9
0
0
0
0
0
0
0
7.8  
7.2  
6.6  
6.0  
5.4  
4.8  
4.2  
3.6  
UPFLOW  
FURNACE  
FIGURE 2  
90-690  
100  
NOTE: In order for the control panel to recognize a sensor, it must be wired to the panel before power is applied.  
3
. PROVIDE CONTROL SYSTEM POWER  
Install a transformer, separate from the transformer provided for the HVAC equipment, to provide power for the control panel, thermostats and  
dampers. The size of the transformer depends on the greatest number of dampers that will be energized at any given time. If more than 6  
dampers could be powered at one time, install dedicated damper transformers and a Model 8028 Damper Power Distribution Panel. Use the table  
below to size the added transformer(s). Aprilaire Flexible Link Dampers require 12 VA per damper. Multiply the number of dampers by 12 and  
select a transformer that meets or exceeds this value.  
The table below illustrates.  
Highest Number of Powered Dampers  
VA Required  
36 VA or less  
48 VA  
Select Transformer  
3
or Less  
40 VA  
50 VA  
75 VA  
4
5
60 VA  
6
72 VA  
75 VA  
7
or More  
No. of Dampers* 12  
75 VA + 40 VA / 3 Dampers  
4
. SET UP THE CONTROL PANEL FOR THE APPLICATION  
Z1 HC/Z1 HP is set according to the type of thermostat installed in Zone 1. If a heat/cool thermostat is used in Zone 1, place the pin jumper  
block on the left two pins (Z1 HC). While set as Z1 HC, emergency heat can only be controlled with the on board E-HEAT switch. If a heat pump  
thermostat is used in Zone 1, place the pin jumper block on the right two pins (Z1 HP). Using a heat pump thermostat in Zone 1 allows for  
emergency heat control from the Zone 1 thermostat.  
GAS/ELECTRIC refers to the auxiliary heat source. If gas (or propane or oil) heat is to be used, place the pin jumper block on the left two pins  
(
GAS). This will allow the auxiliary heating equipment to control the fan operation through the use of a plenum switch. If electric heat is to be  
used, place the pin jumper block on the right two pins (ELECTRIC).  
PURGE/NO PURGE determines whether the zone control panel or the equipment will control the fan purge. If set to PURGE, pin jumper block on  
left two pins, the G terminal and any energized damper terminals will remain energized for a one-minute purge delay following the completion  
of a cool call, regular heat call or an electric auxiliary heat call. If set to NO PURGE, pin jumper block on right two pins, the G terminal will de-  
energize immediately and any energized damper will remain energized for 3.5 minutes following the completion of a call. The NO PURGE  
setting is designed for use with systems where the equipment has a built-in fan purge.  
HT-160/120: If using a plenum temperature sensor, this jumper controls the temperature at which the heating equipment will cut out to prevent  
overheating. Set the high limit temperature that is appropriate for the equipment being used. For a high limit temperature of 160°F, place the pin  
jumper block on the left two pins (HT-160). For a high limit temperature of 120°F, place the pin jumper block to the right two pins (120).  
CL-45/40: If using a plenum temperature sensor, 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, place the pin jumper block on the left two pins (CL-45). For a low limit temperature  
of 40°F, place the pin jumper block to the right two pins (40).  
5
.WIRE THE SYSTEM  
Use standard 18 or 20 gauge thermostat wire, color coded wherever possible to simplify troubleshooting. The wiring diagram and the  
THERMOSTAT SELECTION guide below are to be used to guide you through wiring the system.  
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6
. THERMOSTAT SELECTION  
Any single stage heating and cooling thermostat can be used in zones 1 through 3. Zone 1 (only) has the option of using a single stage heat pump  
thermostat with an O terminal. Each thermostat must be capable of being turned off either through subbase or as a function of the thermostat.  
Thermostat Requirements  
Type: HEAT/COOL  
Zones 1–3)  
THERMOSTAT TERMINALS: R (24V-hot),  
W (1st Stage Heat), Y (1st Stage Cool), G (Fan)  
RECOMMENDED THERMOSTATS:  
Aprilaire 8344, 8363, or 8570  
(
*See Note  
Type: HEAT PUMP  
Zone 1 Only)  
THERMOSTAT TERMINALS: R (24V-hot),  
O (Reversing Valve-cool), W (Auxiliary Heat),  
Y (Compressor), G (Fan)  
RECOMMENDED THERMOSTATS:  
Aprilaire 8346, 8365, or 8570  
(
*See Note  
*
Note: The C terminal (24V-common) in each zone of the control panel can be used for 24 volt powered thermostats.  
Terminal definitions (refer to thermostat manufacturer literature for matching terminals).  
7
. SEQUENCE OF OPERATION  
Heat/Cool Thermostat Input Definitions: Heat = W, Cool =Y, Fan = G  
Heat Pump Thermostat Input Definitions: Heat = Y, Cool = Y + O, Fan = G, Aux. Heat = Y + W, Emergency Heat = W  
Fan Operation: A call for Fan from any zone will initiate the G equipment output terminal. The “NO” contact of the damper terminal for a zone not  
calling for Fan also energizes, while the “NC” contact de-energizes.  
Heating Operation: When a zone makes a call for heat, the B, Y and G output terminal will energize. The “NO” contact of the damper terminal for  
any zone not calling for Heat also energizes, while the “NC” contact de-energizes. Following a 4-minute minimum on time, the Y terminal will de-  
energize 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. Any energized damper terminals remain energized for a one-minute purge (if set to PURGE) or a  
3.5 minute purge (if set to NO PURGE). Should the same call exist for 20 minutes, the W terminal will also energize (if set to ELECTRIC) or the W  
terminal will energize immediately after the Y and G terminals de-energize (if set to GAS). Following a 2-minute minimum on time (if set to GAS) or  
immediately (if set to ELECTRIC), the W terminal will de-energize at the end of the heat call. When the W terminal is de-energized, it has a 4  
minute minimum off time if set to GAS or no minimum off time if set to ELECTRIC. When the Y terminal is de-energized, a minimum off time delay  
of 4 minutes must elapse before it can energize again. The B terminal remains energized until there is a call for cooling.  
Cooling Operation: When a zone makes a call for Cooling, the O, Y and G terminals will energize. The “NO” contact of the damper terminals in  
any zone not calling for Cooling also energizes, while the “NC” contact de-energizes. Following a 4-minute minimum on time, 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 setting. The G terminal and any energized damper terminals remain energized for a one-minute purge delay  
if set to PURGE. If set to NO PURGE, the G terminal de-energizes immediately and any energized damper terminals remain energized for a 3.5-  
minute purge delay. When the Y terminal is de-energized, a minimum off time of 4 minutes must elapse before it can be energized again. The O  
terminal remains energized until there is a call for heat.  
Emergency Heat Operation: Thermostat control of Emergency Heat only exists in Zone 1 when a Heat Pump thermostat is installed. In this case,  
the first call for Emergency Heat sets the system to the Emergency Heat mode of operation. All subsequent calls for heat by other zones are  
recognized as Emergency Heat calls until Zone 1 calls for normal heat or cooling.  
If Zone 1 is configured as a heat/cool thermostat, Emergency heat can only be initiated by turning the E-HEAT switch on the zone control panel to  
the ON position. When the E-HEAT switch is in the ON position, all calls for normal heating will be recognized as Emergency Heat calls. The  
system will remain in Emergency Heat mode until the E-HEAT switch is moved to the OFF position, at which point calls for heat will once again be  
answered with normal heating.  
When a call for Emergency Heat is recognized, the Y terminal will de-energize (if energized) after a 4 minute minimum on time, after which the B  
and W terminals (and G terminal if set to ELECTRIC) will energize. Following a 2-minute minimum on time (if set to GAS) or immediately (if set to  
ELECTRIC), the W terminal will de-energize 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. Any energized damper terminals remain energized for a one-  
minute purge (if set to PURGE) or a 3.5 minute purge (if set to NO PURGE). When the W terminal is de-energized, it has a 4 minute minimum off  
time if set to GAS or no minimum off time if set to ELECTRIC.  
Heat/Cool Changeover: When a call for heat/cool exists and an opposing call is made from another zone, a changeover time limit of 20 minutes  
begins at the time that the opposing call is made. 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.  
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. An 8052 Sensor mounted in the supply duct senses the delivered 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). Once the temperature drops/rises 10°F, the equipment is turned back on if the call for conditioning still exists.  
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TROUBLESHOOTING  
SYMPTOM  
CAUSE  
Normal Flashing LED not flashing  
No power to control panel - check power wiring  
-
TSTATS not operating properly. If Zone 1 is set up as a heat pump thermostat, it requires an O + Yfor cool call  
No Heat call or Cool call  
and Y for a heat call.  
-
-
-
-
4 minute minimum off time delay in effect - push TDO  
Missing jumper between equipment RH&RC - required for single transformer systems  
Equipment interrupt due to high/low temperature limit  
Heat/Cool Changeover limit in effect and an opposing call is being answered in another zone  
Minimum on time delay in effect (2 minutes for heat, 4 minutes for cool)  
Won't stop calling  
Heat calls being satisfied with Emergency Heat  
-
Heat Pump TSTAT installed in Zone 1: If Zone 1 is in Emergency Heat mode, all heat calls from other zones will be  
satisfied with Emergency Heat until Zone 1 makes a compressor call (normal heat or cool call).  
Onboard E-HEAT switch is in the ON position and all calls for heat answered with Emergency Heat  
-
No Emergency Heat Call  
-
-
Zone 1 W terminal not energized or energized with Y terminal  
Onboard E-HEAT switch in the OFF position (Heat/Cool TSTATS installed in all zones)  
L O C r O o T A H E  
T O U F A N A  
O F F  
L O C O  
T A H E  
T A E H E  
T O U N A F A  
O F F  
C O O  
T A H E  
A L T I O O N P  
L
D
I R U E Q R E  
T S O R F D E  
L 1  
L 2  
1
0006007 11.05  
P.O. BOX 1467 • MADISON, WI 53701-1467  
Call toll-free 1-800/334-6011 • Fax 608/257-4357  
©2005 Research Products Corporation  
Printed in USA  
B2203179C  

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