Trane ZSASSMAL012 Zoning Assembly Operation Manual

The Trane ZSASSMAL012 is a Zoning Assembly for multiple zone applications in HVAC systems, supporting single or variable speed indoor units (furnaces or air handlers) matched with single speed, two speed, or two compressor outdoor units (straight cooling or heat pump). It includes dual fuel heat pumps, two separate straight cooling outdoor units, or packaged units. The assembly features a System Controller, Expander Board (up to four zones per board), Zone/Bypass Control Cards, and Discharge Air Temperature Sensor (DAT). It requires compatible communicating Comfort Sensors per zone for operation. Below are the key specifications and installation instructions.

Key Specifications

• Model: ZSASSMAL012 Zoning Assembly
• Components:
  • (1) Enclosure
  • (1) System Controller
  • (1) ZZEXPDAL010 Expander Board (up to 4 zones; add second for 8 zones)
  • (3) ZZCARDAL010 Zone/Bypass Control Cards (one per zone + one for modulated bypass)
  • (1) Discharge Air Temperature Sensor (DAT)
• Zoning Capacity: Up to 3 zones without bypass; 2 zones with modulated bypass (1 board); up to 7 zones with bypass (2 boards)
• Compatibility:
  • Indoor: Single or variable speed furnaces/air handlers (e.g., TWE062E)
  • Outdoor: Single speed, two speed, or two compressor (cooling/heat pump/dual fuel); two separate cooling units; packaged units (e.g., 4YCZ6, 4WCZ6, 4DCZ6)
  • Comfort Sensors (required per zone, not included): ZUSTATALMS2, ZUSTATALP52, ZUSTATALS51
• Power: 24 VAC communication
• Features:
  • Modulated bypass option for static pressure management
  • DIP switch configurable cycles per hour (e.g., 3 vs. 5 CPH) and control modes
  • Restricted mode for variable speed furnace with two-step/two-compressor heat pump (requires TAYSTAT250A + O.D.T.)
  • Hydronic heat support with relay (e.g., BAY24X042)
• Compliance: National, state, local codes; NEC Class II

Operation Instructions

Initial Setup

1. Install Components: Mount enclosure; connect System Controller, Expander Board, Zone Cards, and DAT sensor.
2. Connect Comfort Sensors: Daisy-chain or home-run to TB5 on Expander Board (terminals 1/5, 2/6, 3/7, 4/8 and C).
3. Configure DIP Switches: Set SW1 for cycles/mode; DSW-2 for outdoor unit type.
4. Power Up: Apply 24 VAC; verify communication with Comfort Sensors.

System Navigation

The System Controller manages all electrical functions based on inputs from Comfort Sensors and DAT. Sensors transmit indoor conditions and commands wirelessly or via communication wiring. Monitor via Comfort Sensor displays in each zone.

Operating Modes

1. Normal Zoning: Independent zone control via Comfort Sensors.
2. Modulated Bypass: Maintains static pressure using dedicated Zone Card.
3. Restricted Mode: For dual fuel; limits operation based on O.D.T.
4. Hydronic Heat: Activates pump relay for hot water coils.

Settings Configuration

1. DIP Switches: SW1-1 to SW1-4 for CPH and mode; SW1-3 ON for two-step/two-compressor.
2. Zone Addressing: Assign via TB5 terminals.
3. Sensor Calibration: Not applicable; check resistance for faults.

Advanced Features

1. Expansion: Add second Expander Board for up to 8 zones.
2. DAT Monitoring: Ensures proper discharge air temps.
3. Dual Fuel Integration: No Plus-One kit for single/two-stage.
4. Packaged Unit Support: Specific wiring for 4YCZ6/4WCZ6/4DCZ6.

Troubleshooting

• Failed Sensor: Disconnect leads; measure resistance after soaking—if open/shorted, replace.
  
• No Communication: Verify wiring to TB5; check Comfort Sensor compatibility.
  
• Zone Not Responding: Confirm Zone Card installation and addressing.
  
• Static Pressure Issues: Enable modulated bypass if needed.
  
• Restricted Mode Fault: Add TAYSTAT250A and O.D.T. for dual fuel.
  
• Persistent: Contact Trane service; ensure code compliance.

Installation Instructions

Warning: Qualified personnel only. Disconnect power. Follow lockout/tagout. Comply with national, state, local codes.

Pre-Installation

• Location: Mount enclosure indoors; DAT in supply duct (avoid dead air); 7/8" hole for sensor.
  
• Tools: Screwdriver, wire strippers, hole-saw (7/8"), sheet metal screws.
  
• Wire: 18-22 AWG; do not run sensor wiring with other conduit.
  
• Components: Verify all included; add Comfort Sensors per zone; second Expander for >4 zones.

Wiring Diagrams

Terminal Designations (General for System Controller and Expander Board):

Terminal	Description
TB5 (1/5, 2/6, 3/7, 4/8)	Zone Comfort Sensors
TB5 (C)	Sensor Common
DAT Leads	Discharge Air Sensor (either to terminal, other to C)
Y, W, G, O/B	Standard HVAC Outputs (field-supplied)
BK/X2	Jumper Removal for VS Units

Notes: Field-supplied wires; remove BK jumper on VS air handlers/furnaces. Specific diagrams for configurations (e.g., single speed outdoor: DSW-2 OFF; two-step: SW1-3 ON, DSW-2 ON). For packaged units, redirect terminals (e.g., 41D to D on TB3). Not compatible with ZUSTAT031 in noted setups.

Configuration Options

1. Mount enclosure and components; connect wiring per system diagram.
   
2. Set DIP switches: SW1 for CPH/mode, DSW-2 for outdoor type.
   
3. Install Zone Cards (one per zone + bypass if used).
   
4. Mount/connect DAT sensor; verify resistance.
   
5. Connect Comfort Sensors; power up and test zoning/communication.

Calculation Tool

Estimate monthly energy savings from zoning (assumes 20% efficiency gain from independent zone control; 30 days/month).