Zonemaster ZoneSwitch V2 Damper Control System

Operation Instructions

1) Wall Controller Layout (Touchpad)

The touchpad allows control of individual zones. It features pushbuttons with LEDs for each zone, a zone name label area, and can be configured for 4-zone or 6-zone operation. The LEDs indicate the ON/OFF status of each zone.

4 - ZONE Layout: Features 4 zones, each with a pushbutton and LED.

6 - ZONE Layout: Features 6 zones, each with a pushbutton and LED.

2) Turn Zone ON/OFF

Press the pushbutton for a specific zone to turn it ON. The corresponding LED will illuminate, indicating the zone is open. Pressing the pushbutton again turns the zone OFF, and the LED will extinguish, indicating the zone is closed.

Note: In case of power failure, all zones will automatically return to their previous state once power is restored.

3) Turn Touchpad Off

To turn off all touchpad LEDs without changing the zone status, press and hold the buttons for zone 3 and zone 4 simultaneously for more than two seconds. Pressing any zone button will reactivate the touchpad, turning on the selected zone and leaving others unchanged.

This feature is useful when the air conditioning system is not in use. If the spill function is enabled, one zone will remain open, indicated by a flashing LED. Turning off the touchpad completely will extinguish all LEDs, but the zones will retain their current status.

Installation Instructions

1) Application

The Zonemaster ZoneSwitch V2 control system is designed to manage airflow from Air Conditioning (AC) units to different outlets. It is suitable for ducted reverse cycle and ducted heating systems in residential, light commercial, and apartment settings.

2) Features

• Controls up to 6 individual zones.
• Supports up to two touchpads per system.
• Features selectable spill function and spill zone.
• Dampers connect directly to the main control module in a "star" architecture.
• LED indicators display the ON/OFF status of zones.
• Touchpad can be turned off when not in use.
• Backlit LED on the mainboard illuminates port numbers for easy connection.
• Personalized zone labeling with provided stickers.
• Zones automatically resume their previous state after a power outage.
• Operates on 24 volts for safe and easy installation.

3) Components

The system includes:

• 24 VAC Transformer
• Zonemaster ZoneSwitch V2 Main Control Module
• Touchpad (up to two can be used, one is optional)
• Damper Motors (up to 6)
• Cables with latched plugs (center and left)

4) Wiring Schematic

The wiring schematic illustrates the connection between the main control module and the touchpad. Zone ports on the touchpad (Z1-Z6) correspond to specific output ports on the main module. Ensure correct connections are made.

Note: Zones on the touchpad are marked Z1, Z2, Z3, Z4, Z5, and Z6 from top to bottom.

5) Zoning areas and selecting 4-zone or 6-zone label

Air conditioned areas can be zoned based on function and usage (e.g., Family Room, Lounge, Library). Zone names are applied using provided stickers. For systems with 1-4 zones, use the 4-zone label; for 5-6 zones, use the 6-zone label. Labels are applied to the touchpad after zone names.

4 - ZONE Label

6 - ZONE Label

6) Main Module Preparation

Mount the main control module securely to a roof frame or Polyaire Diffusion Fitting (PDF). Position it equidistant from all damper motors for optimal performance.

The mainboard features a LED that illuminates zone port numbers in the dark and indicates power supply. This LED is controlled by a light switch (switch 2). Turning the switch ON illuminates the LED; turning it OFF extinguishes it.

The system includes a Spill Function, enabled by a dip switch (switch 1) on the main control module. The factory default setting is OFF. If enabled (switch set to ON), a permanent open zone is required to prevent pressure buildup when all motorized zones are closed while the AC unit is running. Refer to section 9 for spill function details.

Diagram showing the Back LED & Spill switch on the main module with ON/OFF positions.

7) Touchpad Preparation

a) Exploded Diagram: An exploded view of the touchpad assembly is provided, showing its components.

b) Pushbutton (on Touchpad) and Zone output ports (on Main module): Pushbutton Z1 on the touchpad controls zone output Z1 on the main control module. The LED for the button indicates the zone status. The diagram shows the relationship between the touchpad pushbuttons and the main control module's zone output ports.

c) Applying Zone Names to Zones: Apply correct zone names using the provided stickers to ensure users are aware of each zone's location. Preset names are available, and blank stickers can be used for custom names. After applying the name sticker, peel off the protective covering film.

IMPORTANT NOTE: For a 4-zone system, use zones Z2, Z3, Z4, and Z5 on the touchpad and connect damper motors to the corresponding ports on the main module. For a 6-zone system, use Z1 through Z6. For systems with fewer than 4 or 6 zones, blank stickers can be used on unused zone recesses.

d) Applying 4-Zone or 6-Zone Label: Apply the appropriate zone label (4-zone or 6-zone) to the touchpad after applying the zone names. Peel the label from the sticker and affix it within the designated recess. Remove the protective covering film.

NOTE: For a 4-zone system, use Z2, Z3, Z4, and Z5 on the touchpad and connect damper motors to the relevant ports Z2, Z3, Z4, and Z5 on the main module.

8) Installing the Touchpad

a) Opening the Touchpad Cover: Insert a flat head screwdriver into the gaps at the bottom of the casing and twist gently to open the cover. Slide the back cover off.

Diagram showing how to insert a screwdriver and twist to open the case, and the back case opening.

b) Mounting the Back Cover: Position the back cover on the wall at approximately 1.5m height. Mark screw positions and the cut-out for the socket. Cut the hole, retrieve the touchpad cable from the main module, and plug it into the touchpad. Mount the back cover securely.

c) Attaching the Front Cover: Attach the front cover to the back cover. The system can accommodate two touchpads, connected to touchpad ports T1 and T2 on the mainboard. These ports are interchangeable.

9) Setting Spill Function

The Spill Function automatically opens a damper to prevent pressure buildup in the duct when all other dampers are closed. Any zone can be set as the spill zone, but bedrooms are not recommended due to potential discomfort from temperature variations. Zones near the return air grille are suggested.

To set the spill function: turn the spill function switch ON on the mainboard. By default, zone 2 is the spill zone. To select a different zone, press and hold the ON/OFF button for that zone for 5 seconds. The LEDs will flash to confirm the setting. Releasing the button stabilizes the setting. If all zones are closed, the spill zone will open automatically, indicated by a slowly flashing LED. Turning on any zone from the touchpad deactivates spilling.

For 4-zone touchpads, press and hold buttons for zone 2 and zone 5 simultaneously until all LEDs flash to disable pushbuttons for zones 1 and 6 and close those zones. Accidental touches on zones 1 and 6 will not activate them. To restore normal operation, press and hold buttons for zone 1 and zone 6 simultaneously until all LEDs flash.

Ensure unused zones are closed to prevent improper spill function operation and potential duct damage.

NOTE: If the spill function is set, choose an installed zone with a motorized damper connected.

10) Troubleshooting Guide

Appendix A - Specifications

Electrical Requirements

• Power supply: 24VAC ± 10%
• Line frequency: 50 Hz
• Fast Blow Fuse: 1.5A M205

Transformer

• Input Voltage: 240VAC, 50 Hz
• Output Voltage: 24VAC, 50 Hz
• Wattage: 24W

Components Power Consumption

• Touchpad: 0.5 VA
• Main Control Module: 2VA

Zone Output

• Output Voltage: 24VAC, 50Hz
• Current: 200mA (1 damper motor)

Environmental Requirements

• Operating temperature: 0°C to 60°C
• Altitude: 0 to 2000 meters
• Operating relative humidity: 10% to 80%
• Avoid static electricity hazards
• Avoid electromagnetic radiation sources
• Avoid dust contamination
• Avoid highly corrosive environments

Maximum Single Cable Length

• Control Cable (Centre Latched): 20 metres
• Data Cable (Left Latched): 10 metres

Appendix B - Zonemaster Cable Tester

The Zonemaster cable tester (Item Number: 657089) is used to test RJ12 cables before installation, reducing diagnostic time.

1) Application of the Cable Tester

Tests all RJ12 cables to ensure proper function before system installation.

2) Features of the Cable Tester

• Tests Centre Latched and Left Latched RJ12 cables.
• Portable, quick, and easy to use.
• Bright LEDs indicate faulty cables in dark areas.
• Operates on a 9V battery.
• User instructions are provided.

Testing Functions: Tests standard RJ12 cables and left latched RJ12 cables. Zonemaster control products use straight-through cable connections for both data and control.

Test Procedure:

1. Plug one end of the RJ12 cable into the socket on the main tester and the other end into the socket on the remote tester.
2. Observe the lights on the main and remote testers to identify cable status.