Aprilaire Zoned Comfort Control Product Guide

Why Choose Aprilaire? Your Partner In Comfort?

Aprilaire offers a comprehensive solution for zoned comfort control, backed by robust products, extensive sales and marketing support, and unparalleled technical assistance.

1) The Right Products

• Aprilaire provides the right controls for any application, from simple low-cost panels for new construction to expandable systems for light commercial use and advanced intelligent zoning with the Model 6504.
• The most reliable dampers available, featuring a patented Flexible Link™ design that eliminates common failure points like gears.
• A full range of thermostats designed to complement Aprilaire zone control systems, ensuring optimal performance.
• A five-year warranty on all products, protecting contractor quality reputations.

2) Sales and Marketing Support

• The Aprilaire brand is well-recognized and respected, synonymous with reliable indoor air quality products.
• Free, high-quality sales literature and a consumer website (www.aprilaire.com) are available to help contractors effectively market zoning solutions.

3) Technical Support

• Local training and on-site support are available through Aprilaire's district sales managers.
• A dedicated Zoned Comfort Control expert is available to answer calls, aiming for resolution on the first contact.
• A contractor-only website (www.aprilairepartners.com) provides 24/7 access to technical documents, installation manuals, and technical bulletins.

An Overview of Aprilaire Zoned Comfort Control

Zoned Comfort Control involves dividing a home or building into separate areas ('zones') that can be independently heated or cooled based on demand. This typically means a single HVAC system controlled by multiple thermostats, with zone dampers directing conditioned air where needed.

Why would a homeowner or light commercial user need Zoned Comfort Control?

A single thermostat cannot maintain comfort throughout an entire building due to varying requirements in different areas. Factors like upper levels being warmer, south-facing rooms absorbing more sun, rooms over unconditioned spaces, and varying occupancy patterns all necessitate zoned control.

What are the components of a Zoned Comfort Control system?

The system includes:

• Forced air HVAC equipment
• A control panel
• Dampers (typically one per zone)
• Thermostats (one per zone)
• Ductwork
• Potentially a bypass damper for pressure relief.

A diagram illustrates these components: Furnace connected to a Zoned Comfort Control System panel, which is wired to Dampers and Thermostats. Other HVAC accessories like Humidifier, Air Cleaner, and ERV are also shown connected to the system.

How does Zoned Comfort Control work?

Thermostats in each zone communicate with the control panel, which then operates the HVAC equipment and controls the zone dampers in the ductwork based on thermostat demands. This ensures conditioned air is delivered precisely where and when it's needed.

When is the best time for a Zoned Comfort Control system to be installed?

Installation is easiest and least expensive in new homes. However, zoning can be added to existing systems at any time, with Aprilaire offering slip-in round dampers for easier retrofitting.

Why is pressure relief an issue with Zoned Comfort Control systems?

When zone dampers close, system pressure increases. To prevent issues like high limit shutdowns, coil freezing, or air noise, pressure relief is crucial. Methods include oversizing ductwork, using a bypass damper, or Aprilaire's exclusive 'Controlled Pressure Relief (CPR)' method, which integrates bypass into non-calling zones without affecting temperature.

The fact is that everyone benefits!

• Homeowner: True zoned comfort, lower maintenance costs, potential IAQ benefits, energy savings.
• Contractor: Wins more bids, makes more profit, achieves happy builders.
• Builder: Satisfied homeowners, potential cost control, reduced time on site.

Today's homes require Zoned Comfort Control, offering many advantages over multiple separate systems.

Designing An Aprilaire Zone System Is As Easy As 1, 2, 3

HVAC system sizing for zoning is similar to non-zoned systems, requiring Manual 'J' calculations for peak demand and room air delivery. A convenient design tool (Form #5018) is available.

Step 1: Selecting Zones

After determining the HVAC equipment, select zones based on:

• Occupancy: Group rooms with similar usage patterns.
• Exposure/Construction: Group rooms with similar load patterns (e.g., first vs. second floor, sun exposure).
• Size: Aim for zones of approximately equal size to avoid velocity issues and air noise.

Considerations:

• Open floor plans may limit temperature containment. Manage customer expectations.
• Avoid creating excessively small zones, which can lead to callbacks.

Step 2: Determine Bypass Method

Several methods manage pressure relief:

• Controlled Pressure Relief (CPR) method: Aprilaire's unique method that doesn't require a bypass damper, minimizing costs. It ensures minimum airflow across the coil and minimal temperature impact on non-calling zones. Ideal for new construction; requires zones to represent at least 25% of total system airflow.
• Bypass Damper method: Allows existing duct design methods to be used. Excess airflow is bypassed back to the return or a dump zone. Common for retrofits. Bypass damper sizing is calculated based on total system CFM minus the smallest zone CFM.
• Oversize method: Ductwork in each zone is sized for approximately 70% of total system airflow. No bypass damper needed but can be costly due to materials and space requirements.

Step 3: Selecting Zone System Components

Select components based on:

• Control Panel: Type of equipment (heat/cool, heat pump, single/multi-stage), number of zones, and additional features needed (e.g., remote control via Model 6504).
• Dampers: Correct type and size for the job.
• Thermostats: Correct type.

Aprilaire Zone Comfort Control Panels

Choosing a control panel involves answering three key questions:

1. Type of equipment: Conventional heat/cool or heat pump? Aprilaire systems work with gas/electric furnaces, air-to-air/water source heat pumps, and dual-fuel systems.
2. Stage: Single-stage or multi-stage equipment? Single-stage panels suffice if equipment handles staging; multi-stage panels are needed if thermostats or the panel manage staging.
3. Number of zones: Determine based on home evaluation and user needs. Consider a panel with an extra zone for future expansion.

A table summarizes panel compatibility:

6202 and 6203 Control Panels

Features: Simple, cost-effective, designed for single-stage heat/cool systems. Ideal for new construction or retrofits. Model 6202 for 2 zones, 6203 for 2-3 zones.

• Consumer Benefits: Independent zone control, continuous fan by zone, zone-based changeover, fan purge, short cycle protection, maintenance-free.
• Contractor Benefits: Adjustable plenum temperature control, LED status indicators, time delay override, works with 2 or 3-wire dampers, fuse protection, adjustable purge timing, electric/non-electric switch compatibility.

6303 Control Panel

Features: Easiest heat pump control, designed for single-stage heat pump systems. Can use 4-wire heat/cool thermostats or a heat pump thermostat in zone one. Auxiliary heat controlled by timer.

• Consumer Benefits: Same as 6202/6203.
• Contractor Benefits: Same as 6202/6203, plus thermostat flexibility (any 4-wire heat/cool or heat pump thermostat in zone 1).

6404 Control Panel

Features: The "One" control panel for any zoning application (2-12 zones). Configurable for single/multi-stage, heat/cool, or heat pump. Suitable for residential and light commercial. Model 6402 expansion panel expands zones from 4 to 12.

• Consumer Benefits: Same as 6202/6203, plus vacation operation, LED status indicators visible through cover.
• Contractor Benefits: Same as 6202/6203, plus single control for all equipment types, selectable staging options (time, thermostat input, zone count), accessory terminals (humidifier, EAC), dual fuel operation.

6504 Control Panel

Features: The ultimate in comfort, convenience, and control. Works with all HVAC equipment types. Uses premium Model 8570 thermostats with simple 4-wire connections. Integrates with Aprilaire automatic humidifier control for RH and outdoor temp sharing. Features menu-driven operation, global changes, and built-in ventilation control.

• Consumer Benefits: Unparalleled comfort/convenience (control any zone from any thermostat, global changes), enhanced humidifier performance, displays outdoor temp/indoor RH, maintenance reminders with contractor contact info, proper ventilation control.
• Contractor Benefits: Simplifies system selling, provides enhanced system capabilities, simple installation (4-wire thermostat, self-diagnostics, auto recognition), dual fuel operation.

The "Engineered Reliability" of Aprilaire Zoned Comfort Control Dampers

Aprilaire residential dampers feature a patented Flexible Link™ design, eliminating gears for enhanced reliability. The motor rotates a spool, which shortens the Flexible Link, causing a spring-loaded lever arm to rotate the blade. When power is off, the spring returns the blade to the open, 'Fail-Safe' position.

Rectangular Dampers

Available in residential and light commercial sizes. Residential sizes use the Flexible Link™ design; light commercial sizes use matched actuators.

• Residential Features: Power-close/spring-open, two-wire installation, 24VAC, 6W, 10VA, 60Hz, synchronous motor, impedance protected, adjustable stop, installs in 4.25" slot.
• Light Commercial Features: Direct coupled, power-close/spring-open, two-wire, 24VAC, 5W, 7VA, NEMA 2 enclosure, adjustable stop, 35 in./lb. torque, installs in 5.25" slot.

A table lists available sizes and stock numbers for Rectangular Dampers, with options for Side Mount and Bottom Mount configurations.

Round Dampers

Available in various sizes for rigid metal or flex duct. Features adjustable blade positioning and integrated foam seal.

• 6600 Series (Zone): Normally-open/power-close operation.
• 6500 Series (Ventilation): Normally-closed/power-open operation.

Specifications include 2-wire installation, 24VAC, 6W, 10VA, synchronous motor, impedance protected, and adjustable stop.

A table lists available sizes and stock numbers for Round Dampers.

Barometric Bypass Dampers

Simple to install and adjust, weight-activated for pressure relief. Available in round sizes.

Product Features: Left or right hand mounted weight arm, integrated foam seal, horizontal or upflow orientation, crimped end for easy install, rigid construction.

A table lists available sizes and stock numbers for Barometric Bypass Dampers.

Static Pressure Bypass Dampers

Provide heightened control, beneficial for large systems and variable speed applications. Features a 24-volt modulating actuator, solid-state pressure sensor, adjustable pressure range (0.17 to 2 inches), LED indicator, and integrated neoprene seal.

A table lists available sizes and stock numbers for Static Pressure Bypass Dampers.

Round Slip-In Dampers

Designed for easy retrofitting in existing homes without costly duct modification. Available in 4", 5", 6", 7", 8", and 10" diameters.

Features: Affordable solution for true comfort, reliable, maintenance-free operation.

A table lists model numbers, sizes, overall dimensions, weight, power requirements, and resistance for Round Slip-In Dampers.

Aprilaire Thermostats

Aprilaire offers a complete line of thermostats for all applications, including zoned systems. Selection depends on whether a programmable or non-programmable unit is needed, the type of equipment to control, and customer feature requirements.

Thermostat Categories:

• Non-Programmable
• Programmable
• Programmable with Event-Based™ Air Cleaning
• Programmable Touchscreen
• Programmable Touchscreen with Humidity Control
• Wireless
• Intelligent Zoning
• Home Automation (Communicating Thermostat)

8400 Series Thermostats

Easy to install, program, and operate. Programmable models are user-friendly. Integrates with Aprilaire products for service reminders.

• Consumer Benefits: Energy savings, convenient service reminders, avoids hot/cold spots (circulate fan mode), easy-to-read display, outdoor temperature display (optional), more comfort (progressive recovery).
• Contractor Benefits: Built-in dual fuel operation, large backlit display, dual power, maintenance reminders, circulate fan mode, custom contractor imprinting.

Models include 8444, 8446, 8448 (Non-Programmable), 8463, 8465, 8466, 8476 (Programmable).

8570 Thermostat

The "One" thermostat for all applications (heat/cool, heat pump, single/multi-stage, residential/light commercial). Features a large, backlit, menu-driven display for intuitive operation.

• Consumer Benefits: Simple programming, large backlit display, equipment monitors (filter, humidifier, HVAC service), displays outdoor temp/indoor RH (with optional sensor/humidifier), vacation hold, progressive recovery, permanent program memory.
• Contractor Benefits: Universal system compatibility, built-in dual fuel operation, simple programming, intelligent installation options, integration with Aprilaire humidifier/6504 panel, custom contractor imprinting, maintenance reminders.

8600 Thermostat

A universal touchscreen thermostat perfect for various applications. Features an exclusive message center with real language instructions for easy installation.

• Consumer Benefits: Large 10.3 sq. in. touchscreen, intuitive interface, message center, equipment monitors, avoids hot/cold spots (circulate fan), outdoor temp display (optional), multiple hold options, progressive recovery, permanent program memory.
• Contractor Benefits: Real language programming, universal system compatibility, built-in dual fuel operation, dual power, custom contractor imprinting, maintenance reminders.

8620 Thermostat

Offers control over multi-stage HVAC and IAQ products (air cleaning, humidification, dehumidification, ventilation). Features real language programming and a backlit touchscreen display.

• Consumer Benefits: Controls temperature, air purity (Event-Based™ Air Cleaning), humidity, and ventilation. Large touchscreen, multiple hold options, permanent program memory.
• Contractor Benefits: Grow sales (IAQ products), improve customer satisfaction, universal system compatibility, built-in dual fuel operation, dual power, maintenance reminders, custom imprinting.

8710 Thermostat

Aprilaire's first wireless thermostat, offering ultimate installation flexibility. A two-piece system: Thermostat and Control Module.

• Consumer Benefits: 7-day programmable or non-programmable, copy function, auto changeover, backlight, 5-year warranty.
• Contractor Benefits: Wireless control (up to 100' range), universal compatibility (single/multi-stage, heat pump/heat/cool), easy addressing, built-in dual fuel, adjustable differential, optional staging by time, installer settable temp limits.

8800 Thermostat

The communicating thermostat for Aprilaire's HVAC Automation System. Integrates with the Model 8826 System Controller for remote control via computer. Compatible with home automation packages.

• Consumer Benefits: Browser-based GUI, remote accessibility, stand-alone operation, system alerts, flexible fan control, heat/cool schedules, multiple master schedules, holiday schedules, password protection.
• Contractor Benefits: "One" thermostat for business, ideal for residential/light commercial, controls single/multi-stage equipment, compatible with most equipment types, less complex/costly than other systems.

8910 Thermostat

The Home Comfort Control integrates heating/cooling, humidification/dehumidification, air cleaning, and ventilation into one touchscreen interface. Connects to an Equipment Control Module.

• Consumer Benefits: Total control of IAQ and HVAC, controls humidity, air purity, fresh air, and temperature. Large touchscreen, multiple hold options, permanent program memory.
• Contractor Benefits: Grow sales (IAQ products), improve customer satisfaction, easy/predictable install (3 wires), universal system compatibility, built-in dual fuel operation, dual power, maintenance reminders, custom imprinting.

Thermostat Accessories

• Model 8051 Flush Mount Sensor: Allows remote thermostat mounting, can be painted/wallpapered.
• Model 8052 Outdoor/Duct Sensor: For outdoor or duct installation, compatible with zone control panels.
• Model 8053 Surface Mount Sensor: For indoor mounting, prevents thermostat tampering, ideal for light commercial.
• Model 8022 3-wire to 4-wire Adapter: Provides an extra wire without pulling new cable, ideal for equipment upgrades or bypassing broken wires.
• Model 8023 Thermostat Adapter Plate: Covers wall marks from previous thermostats, simplifies installation.
• Model 8024 Universal Relay Pack: General purpose, 24-volt, three-relay dry contact switching device.

Aprilaire Zoned Comfort Control Panel Wiring Diagrams

Detailed wiring diagrams and terminal designations are provided for Aprilaire control panels, along with product specifications and transformer requirements.

Aprilaire Model 6202 and 6203 Control Panels

Terminal Designations: R (24V hot), C (24V common), W (Heat), Y (Cool), G (Fan), NC (Normally Closed damper), NO (Normally Open damper), RH (Heating transformer), RC (Cooling transformer), 24VAC (Voltage source).

Product Specifications: Rated Voltage 20-30 VAC, Rated Current 3 amp, Fuse Rating 3 amp, Max Ambient Temp 140°F.

Aprilaire Model 6303 Control Panel

Terminal Designations: Includes R, C, W/W2, Y, G, O, B, NC, NO, RH, RC, 24VAC. Designed for heat pump systems.

Product Specifications: Similar to 6202/6203, with selectable plenum sensor high limit (120-160°F).

Aprilaire Model 6404 Control Panel

Terminal Designations: Extensive list including R, C, W/W1, Y/Y1, G, W2, Y2, O, B, 2S, RH, RC, HUM, EAC, NC, NO, A&B (Expansion panel). Supports multi-stage and heat pump operation.

Product Specifications: Similar to previous models, with selectable plenum sensor high limit (140-170°F).

Aprilaire Model 6504 Control Panel

Terminal Designations: Comprehensive set including R, C, I+, I-, ZA, ZB, ODT, PLENUM SENSOR, ERV/Vent, AHC, EAC, HUM, and outputs for dampers, HVAC equipment, and accessories. Features dip switches for configuration.

Product Specifications: Similar to 6404, with selectable plenum sensor high limit (140-170°F).