Starzone 4000 Startup Procedures
The Starzone 4000 system is the premier VVT system that has evolved from the accumulation of the experience and knowledge Zone All Controls has aquired in manufacturing easy to use packaged VVT temperature control systems since 1987.
Each Master controller can handle up to 32 zones. The Master can control 2 stage heat/cool systems. The Master also has contacts for change-over valves, allowing the controller to interface to heat pump units. Perimeter radiation or duct heaters are controlled directly by the zone thermostat.
When the Starzone 4000 system is integrated to a common communication bus and a central computer, our Starcom software allows users to view set-point, ambient, outside, and discharge air temperatures. The user can over-ride thermostat set ponits, set damper max/min positions, set Master controllers and thermostats to heat only, or cool only operation.
The Starcom 95 software can perform trend logging, alarm logs, problem scanning, etc, but is simple enough to allow building owners to adjust settings and verify system operation.
By-Pass Damper Setup
Attached to each by-pass damper is a detailed explanation of the setup and calibration procedures for a by-pass damper.
Ensure that dip switch #8 on the Master controller is pulled down placing the Master into air balance mode.
Locate the set screw adjustment on the by-pass damper and turn it CCW until the green LED turns on indicating the damper is opening. Check to ensure the damper drives fully open. Next turn the set screw CW until the red LED turns on and drive the damper to the full closed position.
Slowly turn the adjustment screw CCW just to the point where the green LED comes on and the damper begins to open, then back off the adjustment until the LED turns red. The objective is to have the set screw adjustment as close to opening the by-pass damper as possible while still remaining fully closed.
If the by-pass damper is rapidly switching back and forth it may mean the static pressure switch is located too close to an elbow or some other source of turbulence. In this case remove and extend the air pressure hose farther down the duct where there is less turbulence. The tube should not be extended farther than 10 feet from the static pressure sensor.
Troubleshooting/Replacing the SZM-4000 Master Controller
If you have not already done so it is strongly recommended to contact our Technical Support department. In the meantime check to see if the controller's failures match any of the symptoms listed below.
All Damper lights OFF
This normally indicates a problem with the communication wiring on the thermostats. In this instance remove all but the first thermostat, and continue adding thermostats until the problem occurs. Check to ensure that there are no problems in wiring between the good thermostat and the problem stat.
The unit cycles in a heating/cooling demand every 5 minutes Check to see that the Limit alarm LED is ON or FLASHING. If this problem repeats itself regularly it could indicate a clogged filter on the AHU, or a by-pass damper that is stuck in the open position. Normally this would not indicate a problem with the Master board but rather an air supply issue with the AHU.
Fan cycles on and off every 30 seconds or does not come on at all This indicates a problem with the Master's main CPU recognizing a problem and attempting to reset itself. Swap the Master board with another Master and see if the problem follows the board.
Troubleshooting/Replacing SZT-4000 Thermostat
To replace a thermostat, first turn the power off to the system at the Master control panel. Gripping the thermostat towards the bottom of the base remove the top portion of the thermostat from the base. After installing the replacement thermostat, set the correct channel number from menu option #4.
Troubleshooting the Motor Controller Board
The motor controller LED indicates whether the actuator is driving open (green) or closed (red). If the LED is flashing green then the Motor Controller Board (MCB) has just powered up and is going through it's damper calibration procedure. If the LED is flashing red this indicates the MCB has lost communication with the thermostat. Check first by swapping the thermostat with another known good one. If the problem persists check to ensure the wiring between the thermostat and MCB is good, then replace the MCB.
From menu option #3 on the thermostat you can place the thermostat into a test mode allowing you to drive the actuator fully open and closed ensuring the MCB and actuator is operating correctly.
Starzone 3000 Troubleshooting
The Starzone 3000 system has since been discontinued however the system remains fully supported and all parts continue to be made available.
SZM 3000 Master resetting
The fan LED turns off while the fault light comes on for 25 seconds. The system is resetting because of a failure on either the Master controller board or a Satellite controller it is connected to.
Checks:
When a satellite is connected remove the S & R communication wires and replace with a jumper. If the problem goes away then the problem lies either with the Satellite controller or the communication wiring between the two.
If no satellites are connected or the board continues to fail with the jumper in place then likely there is a problem with the board, swap the board with another known good board and ensure the problem follows the board.
Limit LED is on or flashing
A flashing limit light indicates the discharge air temperature has risen above or below the discharge temperature limits and an alarm has been initiated. A system going into a high or low limit condition once during a heating/cooling demand is normal however if the system persists in cycling the limit alarm then likely you have an air supply issue such as clogged filters, or perhaps a by-pass damper stuck in the open position.
Damper lights are off then flash on for a fraction of a second.
This indicates that there is a short one of the damper outputs. Disconnect each damper one at a time until the problem disappears. Once the problem has been isolated check the wiring between the controller and damper to ensure there are no shorts.
Thermostat does not function or reads off on the computer.
To ensure the thermostat is working measure the following output voltages from the following terminals:- V to W - Should read either 16VDC constant or 32VDC to 16VDC pulsing. If the voltage remains at 32VDC this would indicate a defective Master or Satellite board.
- V to Y - Should read 16VDC constant. If you measure either 0V or 32VDC this indicates a defective stat.