Aprilaire Zoned Comfort Control Product Guide

Table of Contents

• Why Choose Aprilaire?
• An Overview of Aprilaire Zoned Comfort Control
• Designing an Aprilaire Zone is as Easy as 1, 2, 3
• Aprilaire Zone Comfort Control Panels
• The "Engineered Reliability" of Aprilaire Zoned Comfort Control Dampers
• Aprilaire Thermostats
• Aprilaire Zoned Comfort Control Panel Wiring Diagrams

Why Choose Aprilaire?

1. The Right Products

   • Aprilaire® offers controls for any application, from simple low-cost panels to expandable zone systems for light commercial and advanced intelligent systems like the Model 6504.
   • The most reliable dampers feature the exclusive Flexible Link™ design, eliminating failure-prone gears.
   • Aprilaire thermostats are the best choice for a complete Aprilaire Zoned Comfort Control system, though systems are compatible with most other manufacturers' thermostats.
   • Products are warranted for five full years from installation.

2. Sales and Marketing Support

   • The Aprilaire brand is recognized for reliable, simple-to-operate Indoor Air Quality products.
   • Free, high-quality sales literature is available, developed from years of marketing Zoned Comfort Control.
   • The consumer website (www.aprilaire.com) is designed to guide consumers toward a purchase decision with a problem/solution format.

3. Technical Support

   • Local representation offers on-site training and support through district sales managers.
   • Unsurpassed technical support is available via phone, with experts ready to assist.
   • A contractor-only website provides technical documents, installation manuals, and technical bulletins. Support is available 24/7 at www.aprilairecontractor.com.

An Overview of Aprilaire Zoned Comfort Control

What is a Zoned Comfort Control system?

Zoned Comfort Control divides a home or building into separate areas ('zones') for independent heating or cooling based on demand. Typically, it involves a single HVAC system controlled by multiple thermostats, with zone dampers in the ductwork directing conditioned air. A control panel coordinates equipment operation and air distribution.

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

A single thermostat cannot maintain comfort throughout a structure due to varying requirements in different areas. Factors contributing to the need for zoning include:

• Exposure: Expansive south-facing glass can cause rooms to overheat during the day and lose heat at night.
• Construction: Rooms over unconditioned spaces or slabs have different heating/cooling needs.
• Occupancy: Setting back thermostats in unoccupied areas saves energy.

What are the components of a Zoned Comfort Control system?

The system includes HVAC equipment, a control panel, dampers (one per zone, or multiple), thermostats (one per zone), and ductwork. A bypass damper may be required for pressure relief depending on the system design.

How does Zoned Comfort Control work?

Thermostats in each zone connect to the control panel, which then connects to the HVAC equipment and zone dampers. The panel interprets each zone's conditioning needs, operates the equipment (on/off), and controls damper positions (open/closed) based on thermostat signals, ensuring conditioned air is delivered where and when needed.

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

Installation is least expensive and easiest in a new home. However, Zoned Comfort Control can be added to existing systems. Aprilaire® offers a special retrofit damper for challenging retrofit applications.

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 necessary. Methods include over-sizing ductwork (70% of system airflow capacity), using a bypass damper, or Aprilaire's 'Controlled Pressure Relief (CPR)' method, which involves slightly over-sizing supply ductwork and allowing engineered bypass into closed zones. For more details, refer to the Aprilaire Design Manual, Form #5001.

Designing an Aprilaire Zone is as Easy As 1, 2, 3

HVAC SYSTEM SIZING WHEN ZONING

Designing a zoning system is similar to designing a non-zoned system. It requires sizing for peak demand using a Manual 'J' calculation and understanding the required airflow to each room, also based on Manual 'J'.

Designing the Zone System

Refer to the Aprilaire® Zoned Comfort Control Design Guide (Form #5001) for complete details. The basic steps are:

1. Selecting Zones

   Determine which rooms will form each zone based on:

   • Occupancy: Group rooms with similar usage patterns (e.g., bedrooms together, or living/dining/kitchen together).
   • Exposure/Construction: Group rooms with similar load patterns (e.g., first floor vs. second floor, south-facing vs. north-facing).
   • Size: Ideally, zones should be approximately equal in size to avoid velocity and air noise issues.

   Additional thoughts:

   • In open floor plans, containing temperatures within zones is more challenging; manage customer expectations.
   • Avoid creating too many small zones, as this can lead to unequal comfort and callbacks.

2. Determine Bypass Method

   Options for pressure relief include:

   • Controlled Pressure Relief (CPR) method: Aprilaire's unique method that doesn't require a bypass damper, minimizing system costs. It ensures at least 85% of design airflow across the coil and limits temperature impact on non-calling zones to less than 1°F. This method is ideal for new residential construction. Positives: Assures proper airflow, simplifies installation, lowers system costs. Negatives: May not apply to existing systems; each zone must be at least 25% of total system airflow.
   • Bypass Damper method: Allows standard ductwork sizing. Pressure relief is managed by a bypass damper directing excess airflow back to the return or a dump zone. Sizing is based on (Total system CFM - Smallest zone CFM). Positives: Uses existing duct design methods, good retrofit option. Negatives: Potential for bypassed air to condition return/dump zone; requires plenum temperature control.
   • Oversize method: Sizing ductwork (main and branches) for approximately 70% of total system airflow. Positives: No bypass damper needed, low likelihood of air noise. Negatives: Higher duct material cost, requires more space, may affect air velocity/throw.

3. Selecting Zone System Components

   Choose components based on:

   • Control panel: Consider equipment type (heat/cool, heat pump, single/multi-stage), number of zones, and desired features (e.g., Model 6504 for changing settings from any thermostat).
   • Dampers: Select the correct type and size.
   • Thermostats: Select the correct type and size.

Aprilaire Zone Comfort Control Panels

Step One: Select A Zoned Comfort Control Panel

Key questions before choosing a panel:

1. What type of equipment do you want to control? Conventional heat/cool systems (furnace/AC) or heat pumps (air-to-air, water source, dual fuel).
2. Is the equipment single-stage or multi-stage? Multi-stage equipment may require a multi-stage control panel if the panel or thermostats are to provide staging.
3. How many zones will you be controlling? Based on home evaluation and user needs. Consider panels with extra zones for future expansion.

Control Panel Selection Guide:

The following pages detail additional features for the Aprilaire Zoned Comfort Control system.

6202 and 6203 Control Panels

These are simple, cost-effective panels for single-stage heat/cool systems. Model 6202 supports two zones, and Model 6203 supports two or three zones. They are ideal for new construction or as add-ons.

*An available “C” terminal (24-volt common) in each zone can be used for 24-volt powered thermostats.

Consumer Benefits

• Any Zone Sets Mode: True independent control for each zone.
• Continuous Fan by Zone: Individual zone thermostats can call for fan operation.
• Zone Changeover Based on Time: Alternates modes to satisfy opposing calls.
• Fan Purge: Directs air to the last zone(s) calling.
• Short Cycle Protection: Protects HVAC equipment from frequent cycling.
• Maintenance Free: No adjustments needed after installation.

Contractor Benefits

• Plenum Temperature Control (Adjustable): Protects equipment from extreme temperatures due to reduced airflow.
• L.E.D. Status Indicators: Simplify start-up and troubleshooting.
• Time Delay Override: Speeds checkout.
• Works with Two or Three Wire Dampers: Compatible with older panels.
• Fuse Protection: Protects the panel against mis-wiring.
• Extra Fuse on Board: For convenience.
• Adjustable Purge Timing: Compatible with all brands.
• Electric/Non-Electric Switch: Proper control for electric or fossil fuel furnaces.

6303 Control Panel

The easiest heat pump control available. Designed for single-stage compressor, heat pump systems. Can use four-wire heat/cool thermostats or a heat pump thermostat in zone one for emergency heat control. Auxiliary heat is controlled by a fixed timer. Simple and low cost, ideal for new construction or existing homes.

*An available “C” terminal (24-volt common) in each zone can be used for 24-volt powered thermostats.

Consumer Benefits

• Any Zone Sets Mode: True independent control for each zone.
• Continuous Fan by Zone: Individual zone thermostats can call for fan operation.
• Zone Changeover Based on Time: Alternates modes to satisfy opposing calls.
• Fan Purge: Directs air to the last zone(s) calling.
• Short Cycle Protection: Protects HVAC equipment from frequent cycling.
• Maintenance Free: No adjustments needed after installation.

Contractor Benefits

• Plenum Temperature Control (Adjustable): Protects equipment from extreme temperatures.
• Thermostat Flexibility: Use four-wire heat/cool or heat pump thermostats.
• L.E.D. Status Indicators: Simplify start-up and troubleshooting.
• Time Delay Override: Speeds checkout.
• Works with Two or Three Wire Dampers: Compatible with older panels.
• Adjustable Purge Timing: Compatible with all brands.
• Electric/Non-Electric Switch: Proper control for electric or fossil fuel furnaces.

6404 Control Panel

The "One" control panel for applications from two to twelve zones. It supports single- or multi-stage, heat/cool, or heat pump systems, suitable for residential or light commercial use. Simple four-wire thermostats are used in all zones. Offers flexible staging options (time, number of zones calling, or multi-stage thermostats).

The Model 6402 expansion panel expands the Model 6404 from four to twelve zones.

Consumer Benefits

• Any Zone Sets Mode: True independent control.
• Continuous Fan by Zone: Individual zone thermostats can call for fan operation.
• Vacation Operation: Allows setback operation from a designated zone one.
• Zone Changeover Based on Time: Alternates modes to satisfy opposing calls.
• L.E.D. Status Indicators: Visible through the cover for troubleshooting.
• Fan Purge: Directs air to the last zone(s) calling.
• Short Cycle Protection: Protects HVAC equipment.
• Maintenance Free: No adjustments needed.

Model 6402 Zone Expansion Panel

• L.E.D. indicators simplify start-up and troubleshooting.
• Fuse protected.
• Easy wire 45° angled terminals.

Contractor Benefits

• Plenum Temperature Control (Adjustable): Protects equipment from extreme temperatures.
• Single Control for All Equipment Types: Operates systems up to twelve zones.
• Thermostat Flexibility: Supports single- or multi-stage heat/cool or heat pump thermostats.
• L.E.D. Status Indicators (Visible Through Cover): Simplifies troubleshooting.
• Selectable Staging Options: Stage by time, thermostat input, or number of zones calling.
• Time Delay Override: Speeds checkout.
• Works with Two or Three Wire Dampers: Compatible with older panels.
• Adjustable Purge Timing: Compatible with all brands.
• Accessory Terminals: Control humidifiers, air cleaners, etc.
• Dual Fuel Operation: Control heat pumps with fossil fuel auxiliary heat.

6504 Control Panel

The ultimate control panel for customers demanding the best. It controls all HVAC equipment types and offers state-of-the-art features. Utilizes a Model 8570 premium thermostat in each zone with a simple, four-wire connection. Also connects to Aprilaire® automatic humidifier control for RH level and outdoor temperature sharing. Features menu-driven operation for easy use, zone control from any thermostat, and built-in ventilation control.

Consumer Benefits

• Unparalleled Comfort and Convenience: Control temperature by zone need. "Global changes" allow system-wide adjustments from any thermostat. Enhanced humidifier performance. View outdoor temperature and indoor RH. Maintenance reminders.
• Assures Proper Ventilation: Built-in control for fresh air dampers, preventing extreme indoor air temperatures.
• Simplest Operation: Model 8570 thermostat features intuitive menu-driven programming.

Contractor Benefits

• Simplifies System Selling Process: Presents a complete Aprilaire Indoor Air Quality system.
• Simple Installation: Easy four-wire thermostat connection. Self-diagnostic features. Automatic thermostat recognition. System test button.
• Dual Fuel Operation: Control of heat pumps with fossil fuel auxiliary heat.

The "Engineered Reliability" of Aprilaire Zoned Comfort Control Dampers

Aprilaire® residential dampers feature a technological breakthrough with the Flexible Link™ design, eliminating failure-prone gears. The simple, ultra-reliable design uses a motor to rotate a spool, which shortens the Flexible Link, causing a spring-loaded LEVER ARM to rotate the blade. When power is removed, a spring returns the blade to the open, "Fail-Safe" position.

Rectangular Dampers

Available in sizes for residential and light commercial applications. Residential sizes use the Flexible Link™ design; larger commercial sizes use actuators matched for torque requirements.

Replacement Parts

• Model 6992: Motor (gear shaft) for older Aprilaire and PerfectTemp™ dampers.
• Model 6993: Motor (shaft with two flat sides) for Flexible Link™ style dampers.
• Model 6997: Direct couple motor for light commercial dampers.

Rectangular Dampers Table: Lists sizes (8" to 30") and stock numbers for side mount and bottom mount configurations, with nominal widths and heights.

Residential Features

• Power-Close/Spring-Open Operation
• Two Wire Installation
• 24VAC, 6W, 10VA
• 60Hz Synchronous Type Motor
• Impedance Protected for Continuous Stall
• Adjustable Stop
• Installs in 4.25 inch slot in duct

Light Commercial Features (Shaded)

• Direct Coupled, Power-Close/Spring-Open
• Two Wire Installation
• 24VAC, 5W, 7VA
• NEMA 2 Enclosure
• Adjustable Stop
• 35 In./Lb. Torque
• Installs in 5.25 inch slot in duct

Round Dampers

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

Replacement Parts

• Model 6992: Motor (gear shaft) for 18" and 20" round dampers.
• Model 6993: Motor (shaft with two flat sides) for Flexible Link™ style round dampers.

Round Dampers Table: Lists sizes (6" to 20") and stock numbers for Zone (normally-open/power-close) and Ventilation (normally-closed/power-open) types.

6600 Series Specifications

• Power-Close/Spring-Open Operation
• Two Wire Installation
• 24VAC, 6W, 10VA
• 60Hz Synchronous Type Motor
• Impedance Protected for Continuous Stall
• Adjustable Stop (in closed position)

6500 Series Specifications

• Power-Open/Spring-Close Operation
• Two Wire Installation
• 24VAC, 6W, 10VA
• 60Hz Synchronous Type Motor
• Impedance Protected for Continuous Stall
• Adjustable Stop (in open position)

Barometric Bypass Dampers

Simple to install and adjust, available in sizes for zoning applications. Features weight-activated pressure relief.

Round Dampers Table: Lists sizes (8" to 16") and stock numbers for barometric pressure relief.

Product Features

• Left or right hand mounted weight arm
• Integrated foam seal
• Horizontal or up flow orientation
• Crimped end for easy installation
• Rigid construction

Static Pressure Bypass Dampers

Provide heightened control for zoning, beneficial in large systems and those using variable speed. Features power-activated pressure relief.

Replacement Parts

• Model 6994: Motor for static pressure dampers
• Model 6995: Replacement pressure switch
• Model 6996: Tube and probe kit

Round Dampers Table: Lists sizes (8" to 20") and stock numbers for static pressure relief.

Product Features

• 24 Volt Modulating Actuator
• Solid State Pressure Sensor
• Adjustable Pressure Range - 0.17 to 2 Inches
• Pressure Adjustment L.E.D.
• Integrated Neoprene Seal
• Blade Position Indicator

Retrofit Damper

The first spring-return damper designed for insertion into a six-inch round branch duct, making zoning affordable for homes without costly duct modification. Provides true comfort, enhanced customer satisfaction, and reliable, maintenance-free operation.

Model 6706 - Damper Specifications

• Duct Size: 6" round
• Overall Size: 3.3"(H)x 8.0"(W)x 8.3"(D)
• Weight: 1 lb.
• Power Requirement: 10 VA @ 24 VAC
• Resistance: 0.008" W.C. @ 700 fpm

Consumer Benefits

• Comfort: Temperature where and when desired.
• Convenience: Automatic system operation.
• Energy Savings: Conditions only areas that need it.

Contractor Benefits

• Profitable: Economical solution for customer comfort needs.
• Easy Installation: Simply cut a slot, insert, and secure.
• Installer Friendly: L.E.D. illuminates when closed for easy check-out.
• Reliable: "No gears" technology for long life.
• Fail Safe: Spring-open operation assures airflow.

Model 8028 Power Distribution Panel

Simplifies installation when damper count exceeds control panel fuse rating. Aids troubleshooting and provides a clean appearance.

Model 8028 - Power Distribution Panel Specifications

• Max. Damper Power Input Per Zone: 100 VA @ 24 VAC
• Damper Fuse Size: 5 A fast acting (spare supplied)
• Control Input Current Draw (Zone A & B): 50 mA @ 24 VAC
• Max. No. of Aprilaire Dampers Per Zone: 10
• Max. Wire Size: 18 AWG
• Application Temperature / RH: 140°F / 90% RH (non-condensing)

Aprilaire Thermostats

Step Three: Select A Thermostat

Aprilaire offers a complete line of thermostats for all applications, including Zoned Comfort Control. Selection involves determining if a programmable or non-programmable unit is needed, the type of equipment to control and zone panel compatibility, and understanding customer needs. A Good-Better-Best approach is recommended.

• Best: Model 8570 - The all-in-one thermostat for all applications. Field configurable for programmable or non-programmable operation, controls all HVAC equipment types, and offers advanced features.
• Better: 8300 Series - Battery-powered models, requiring no extra wires for replacement. Features air filter/water panel service monitors, adjustable calibration, and simplified programming.
• Good: 8200 Series - Provides basic, affordable control. Hardwired, requires a common connection (“C” terminal), ideal for new construction or zoning where wiring is feasible.

8570 Thermostat

The "One" Thermostat for heat/cool or heat pump, single- or multi-stage applications. Offers exceptional value due to ease of installation, programming, and operation. Features a large, backlit display with "at-a-glance" information, menu-driven operation, and equipment monitors.

Consumer Benefits

• Simplest Programming and Operation Available (menu-driven).
• Large Backlit Display for easy viewing.
• Equipment Monitors (air filter, humidifier, HVAC service reminders).
• Displays Outdoor Temperature and Indoor Relative Humidity.
• Holiday Feature for temporary overrides.
• Progressive Recovery (selectable) for optimal set point achievement.
• Permanent Program Memory.
• Automatic Daylight Savings Time Adjustment (selectable).

Contractor Benefits

• Ideal for residential and light commercial.
• Controls single- or multi-stage equipment.
• Compatible with virtually all equipment types.
• Selectable operation: programmable or non-programmable.
• Customer Retention: Displays contractor name/phone number.
• Simplest Programming and Operation reduces nuisance calls.
• Intelligent installation options.
• Connects to Aprilaire humidifier control or Model 6504 zone control panel.
• View or control other thermostats through Model 6504.
• Extends blower operation for humidification.

8300 Series Thermostat

Provides exceptional value for ease of installation, programming, and operation. Programmable models include pre-programmed Energy Star settings. Integrates with other Aprilaire products for service reminders.

Models to Complete Installations:

• Model 8344: Non-Programmable, Single-Stage Heat/Cool or Heat Pump (no auxiliary heat)
• Model 8346: Non-Programmable, Single-Stage Heat Pump w/Auxiliary Heat
• Model 8348: Non-Programmable, Multi-Stage Heat/Cool
• Model 8363: Programmable, Single-Stage Heat/Cool
• Model 8365: Programmable, Single-Stage Heat Pump w/Auxiliary Heat
• Model 8368: Programmable, Multi-Stage Heat/Cool

Consumer Benefits

• Large Backlit Display.
• Water Panel Change-Indicator.
• Filter Change-Indicator.
• Adjustable Field Offsets.
• Simple to Program (includes "DONE" message, instructions on cover, simplified buttons).

Contractor Benefits

• Easy Installation (fits over existing thermostats, angled terminals, mounts easily, battery-powered).
• Imprint Company Logo and Phone Number.

8200 Series Thermostat

Ideal for volume installations where reliability, basic features, and economy are key. Suitable for new construction and replacement. Assured compatibility with all brands and system types. Straight-forward, simple-to-wire design.

Models to Complete Installations:

• Model 8244: Non-Programmable, Single-Stage Heat/Cool or Heat Pump (no auxiliary heat)
• Model 8246: Non-Programmable, Single-Stage Heat Pump w/Auxiliary Heat
• Model 8263: Programmable, Single-Stage Heat/Cool or Heat Pump (no auxiliary heat)
• Model 8265: Programmable, Single-Stage Heat Pump w/Auxiliary Heat

Consumer Benefits

• Easy to Program (Models 8263 & 8265).
• Large Backlit Display.
• Progressive Recovery (Models 8263 & 8265).
• Set Points Displayed.
• Permanent Hold.
• Temporary Hold.
• Resumed Comfort After Power Loss.

Contractor Benefits

• Hard Wired, 24 Volts (no battery issues).
• Electronic Accuracy (+/- 1° differential).
• Field Calibration.
• Reset Function.
• Soft Touch Buttons.
• Cycle Rate Adjustment.
• Compressor Lockout Protection.

Thermostat Accessories

• Model 8051 Flush Mount Sensor: Remotely mounts thermostat out of view, can be painted/wallpapered. Attaches to Model 8570 with two wires.
• Model 8052 Outdoor/Duct Sensor: For outdoor or duct installation, compatible with zone control panels. Bracket removable for radiant floor applications.
• Model 8053 Surface Mount Sensor: Remotely mounts thermostat out of view, designed for indoor installation, ideal for commercial applications to prevent tampering.
• Model 8022 3-wire to 4-wire Adapter: Combines two thermostat terminals with a diode pair to use a single wire, avoiding new cable runs. Useful for equipment upgrades.
• Model 8023 Thermostat Adapter Plate: Covers marks left by old thermostats, matches Aprilaire colors, pre-marked holes for easy 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 the following Aprilaire control panel models:

• APRILAIRE MODEL 6202 AND 6203 CONTROL PANELS: Includes wiring diagram for single-stage furnace and air conditioner application, terminal designations, product specifications, transformer requirements, and additional installation features.
• APRILAIRE MODEL 6303 CONTROL PANEL: Includes wiring diagram for single-stage heat pump with auxiliary heat application, terminal designations, product specifications, transformer requirements, and additional installation features.
• APRILAIRE MODEL 6404 CONTROL PANEL: Includes wiring diagram, control panel terminal designations, product specifications, transformer requirements, and additional installation features.
• APRILAIRE MODEL 6504 CONTROL PANEL: Includes wiring diagram, detailed control panel terminal designations with numbered explanations, product specifications, and additional installation features.

We're here to help

Technical Support: 800-334-6011. Available 7:00 a.m. - 5:00 p.m. Central Standard Time.

Contractor Website: www.aprilairecontractor.com. A library of product literature, installation instructions, and technical documents is available 24/7.

Local District Sales Manager: Contact via voice mail at 800-334-6011.

Aprilaire
PO Box 1467, Madison, WI 53701 • 800-334-6011 • www.aprilairecontractor.com