Honeywell Tz 4 Manual

							PRODUCT DATA
68-0259-1
® U.S. Registered Trademark
Copyright © 2002 Honeywell •  All Rights Reserved 
TZ-4 TotalZone® Zone Control Panel
APPLICATION
The TZ-4 TotalZone Zone Control Panel controls single-stage, 
multi-stage, conventional or heat pump heat/cool equipment. 
It controls 2, 3 or 4 zones, and is expandable up to 32 zones 
with optional TotalZone® Add-A-Zone™ Four Zone Control 
Panel.
FEATURES
• Up to three stages heat and two stages cooling can be 
controlled by thermostat, built-in timer, or based on 
the percentage of zones calling.
• Controls single-stage, multi-stage, conventional, heat 
pump or dual-fuel equipment.
• Controls up to four zones and can be expanded up to 
32 zones with Add-A-Zone Control Panels.
• Uses Honeywell four-wire, single-stage, multi-stage, or 
select heat pump thermostats.
• Zone-A-Lone central setback feature.
• Purge timer protects equipment between calls for heat 
or cool with choice of panel or HVAC equipment 
controlled fan.
• System and zone damper LEDs indicate system and 
damper status.
• Individual zone fan control.
• Discharge Air Temperature Sensor for capacity control 
with adjustable high and low limits.
• Thermal circuit breaker protects panel and transformer 
from damage if miswired.
For Internet access: 
www.honeywellzoning.com
For technical support, call 1-800-828-8367.
To download Zoning literature: http://hbctechlit.honeywell.com
Contents
Application ......................................................................... 1
Features ............................................................................ 1
Specifications .................................................................... 2
Installation ......................................................................... 4
Startup and Checkout ........................................................ 12
Operation........................................................................... 12
Troubleshooting ................................................................. 17 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 2
SPECIFICATIONS
Input Ratings: 
Voltage: 20-30 Vac, 50/60 Hz.
Power: 13 VA, nominal.
Output Ratings:
1.5A run, 200,000 cycles (30 Vac). 3.5 inrush.
1.5A run, 100,000 cycles (30 Vac) 7.5A inrush.
Humidity Ratings: 
5 to 90 percent RH, non-condensing.
Temperature Ratings:
Shipping: -20° to 120°F.
Operating: -40° to 150°F.
Dimensions:  10-3/4 in. H x 12-3/4 in. W x 1-7/8 in. D.
See Fig. 1.
Mounting:  Mounts with four 1 in. no. 8 screws (provided) 
through holes in cabinet back. Wall anchors are provided.Wiring:  18-gauge wire for all equipment and system 
connections.
Wiring Connections:
Thermostat: R, C, W1/E, W2, W3/AUX, Y1, Y2, G, L, O/B
Dampers: M6 (Closed); M4 (Open); M1 (Common). 
Discharge Air Temperature Sensor (C7735A1000); DATS, 
DATS.
Zone-A-Lone: OC, OC.
Outdoor Temperature: OT, OT.
Transformer 1: R (hot), C (common).
Transformer 2: T1 (hot), T2 (common).
Equipment: Rc-Rh, W1/E, W2, W3/AUX Y1, Y2, G, O/B.
Thermostats (See Table 1):
Most conventional four-wire (R,W,Y,G) thermostats can be 
used to control conventional, heat pump, or multi-stage 
equipment. 
Manual or automatic changeover switching thermostats can 
be used. 
 Multi-stage or select heat pump thermostats can also be 
used.
Fig. 1. TZ-4 dimensions in in. (mm).
M20516
10-3/4
(273)
12-3/4
(273)1-7/8
(47) 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
3 68-0259-1
aHeat pump thermostat with single Y first-stage terminals. See Heat Pump Thermostats section and Fig. 6.bMulti-stage and heat pump thermostats are not required to control multi-stage and heat pump systems with TotalZone. They are 
used only when second stage or emergency heat control from the zone thermostat is needed.
cThe Y594R1243 must be wired to the panel using the B terminal for changeover.dCut thermostat second-stage variable heating anticipator wire (gray).eCut thermostat first-stage fixed heating anticipator wire (bare) and second-stage variable heating anticipator wire (gray).fCut thermostat second-stage cooling anticipator wire (lowest bare wire).
Recommended Dampers (See Table 2):
Ten ZD or ARD dampers maximum connected to each panel 
and a maximum of five dampers per zone when using two 
40 VA transformers. 
Use SDCR and 40 VA transformer for additional dampers 
required on one zone.
Dampers are connected to M1 Common, M4 Open, and M6 
Closed (see Fig. 7-10 for hookups).
Accessories: For required accessories, see Table 3. Table 1. Recommended Thermostats.
System Non-Programmable Programmable
Single Stage
T87F1859/Q539A1014
T87F4010/Q539A4026
T8501D1046
T8400C1016
T8400C1040
T8400C1099T8601D2027
T8600D2069
T8600D2028
T8601D2019
T8602D2018
T8602D2000
T8000C1002
T8000C1010
T8001C1019
PC8900/W8900A/C
Heat Pumpb 
Y594R1243a,c,d
Y594G1252a,e
T8411R1002
T8411R1028
T8611G2051
T8011R1006
T8011R1014
Multi-Stageb 
Y594D1347f
T8524D1015
T8624D2004
T8624D2012
Motor Terminal Damper Action
Common/M1Common
Open/M4Power Open
Closed/M6Power Close
Table 2. Recommended Dampers.
Honeywell Damper TypeRoundRectangular
Power-open/power-closed (for 
systems > 2000 cfm)MARDD643 using 
ML6161 
Motor 
Actuator
Spring-open/power-closed (for 
systems 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 4
INSTALLATION
Mounting
CAUTION
Equipment Damage Hazard. 
Do not mount TZ-4 inside HVAC equipment
Mount only on wall or on cold air return.
Identifying DIP Switches
This panel has two banks of DIP switches, DIP switch 4 (S4) 
and DIP switch 5 (S5), see Fig 15. Each bank has eight 
individual switches that are identified by two numbers; the first 
number is the bank number (4 or 5) and the second number 
identifies the individual switch. For example, DIP 5-1 is bank 
5, switch 1.
1.Mount the thermostats in each zone of the living space 
using the installation instructions provided with each 
thermostat.
2.Mount the dampers in the ductwork using the installa-
tion instructions provided with each damper.3.Mount the TZ-4 zone panel near the HVAC equipment; 
(on a wall or on the cold-air return). See Fig. 2.
4.Level the TZ-4 for appearance only.
Wiring
CAUTION
Vo l ta g e  H a z a r d .  
Can cause electrical shock or equipment damage.
Disconnect power before continuing installation.
Wiring must comply with applicable codes, ordinances, and 
regulations.
1.Connect thermostats as shown in Fig. 3-6. 
2.Connect dampers as shown in Fig. 7-10.
3.Connect C7735A Discharge Air Temperature Sensor 
(not supplied) to the DATS terminals. The wires are not 
polarized. See Fig. 13.
4.Connect Add-A-Zone panels (if used) to the AZ1 and 
AZ2 terminals. 
5.Connect the HVAC equipment to the EQUIP terminals 
on the panel. See Fig. 15-21.
6.Connect a 40 VA, 24 volt transformer to R (hot) and C 
(common). This must be a dedicated transformer and 
each TAZ-4 board also requires a transformer. See Fig. 
12.
7.The auxiliary 40 VA 24-volt transformer can be con-
nected to T1 and T2 if additional power for dampers is 
required. This second transformer is not required; how-
ever, total power consumption of panel and damper is 
limited to 40VA without it.
Fig. 2. TZ-4 mounting location. Table 3. Required Accessories (Not Supplied).
AccessoryDescriptionBypass Rating
(cfm)
40 VA 
transformers AT140D1046 
(PMT-40)—
Capacity 
protectorC7735A1000—
Outdoor 
Temperature 
Sensor
(Required for 
dual-fuel 
applications)C7089B1000—
Round static 
pressure 
regulator 
damperSPRD7
SPRD8
SPRD9
SPRD10
SPRD12
SPRD14
SPRD16300 
400 
600 
750 
1200 
1800 
2400 
Rectangular 
static pressure 
regulator 
damperSPRD12x8
SPRD12x10
SPRD12x12
SPRD20x8
SPRD20x10
SPRD20x121000 
1200 
1400 
1600 
2000 
3000 
M20517
WATER 
HEATERTZ-4E
LEC
TR
ONIC
 AIR 
CL
EA
N
ER
RETURNAIR
TZ-4
OPTIONAL
LOCATION
FURNACE 
OR BOILER
HIGH
 EFFICIENCY
AIR CLEANER 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
5 68-0259-1
Wiring Diagrams (Fig. 3 and 4)
Conventional Thermostats
Conventional (RWYG) thermostats can be used to control 
conventional, multi-stage, and heat pump equipment. If the 
thermostat has a common terminal, it is wired to C on the 
panel, see Fig. 3. A multi-stage thermostat is wired with the 
second and third stage of heat to W2 and W3 on the panel 
thermostat connections, and with the second stage of cooling 
to Y2. Leave the zone O/B thermostat jumper on the TZ-4 
disconnected. See Single and Multi-Stage Operation in the 
Operation section for instructions on staging the TZ-4.
The PC8900 with the W8900A or W8900C can be used as a 
zone thermostat. See Fig. 4 for hookup. This thermostat can 
be used to control up to 2 heat and 2 cool stages of 
conventional equipment. When used to control heat pump 
equipment, the W8900A is recommended.
Connect a jumper on the W8900 from Rc to Rh as shown in 
Fig. 4. Wire terminals R and C to a transformer. If the system 
current draw is within specifications, the R and C on the 
W8900 could alternately be connected to R and C on the    
TZ-4. The PC8900/W8900 draws 5 VA.
Fig. 3. Typical single-stage thermostat wiring.
M20509B
G
C
R
Y
W
COMMON (C) TERMINAL IS USED ONLY BY THERMOSTATS
THAT REQUIRE A COMMON WIRE.
MULI-STAGE THERMOSTATS ARE WIRED SIMILARLY BUT WITH
Y2 AND W2 USED FOR SECOND STAGE COOL AND HEAT.
THIRD STAGE OF HEAT (W3) CAN BE WIRED TO W3/AUX.
LEAVE O/B JUMPER ON TZ-4 DISCONNECTED.TZ-4 THERMOSTAT
CONNECTORS
TYPICAL SINGLE STAGE
THERMOSTAT WIRING1
2
3
1
3
2 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 6
Fig. 4. PC8900 with W8900A,C Thermostat wiring.
Heat Pump Thermostats
Select a heat pump thermostat from Table 1. If the thermostat 
selected has a separate Y1 and W1 wire, as shown in Fig. 5,   
leave the zone O/B thermostat type jumper on the TZ-4 
disconnected, and wire as shown in Fig. 5.If the PC8900/W8900 /Thermostat is used in a heat pump 
application, use the W8900A, not the W8900B, and wire as 
shown in Fig. 4.
M20508B
W8900A/C IS RECOMMEDED FOR CONVENTIONAL AND HEAT PUMP APPLICATIONS. THE W8900B CANNOT
SWITCH THE PANEL TO EMERGENCY HEAT.
LEAVE O/B JUMPER ON TZ-4 DISCONNECTED.TZ-4 THERMOSTAT
CONNECTORS1
2
1
S1
S
T1
T
OUT
OUT
LED
G
Y2
Y1
W1
W2
1
2
3
4
GND
C
R
RH
RC
HUM
HUM
VNT
VNT
W8900A,C PC8900
CO2
1234
2
24 VAC
120 VAC 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
7 68-0259-1
.
Fig. 5. Heat pump thermostat with separate Y1 and W1 
terminals and multi-stage thermostat wiring.
If the thermostat selected from Table 1 has a single Y terminal 
for first stage heat and cool, wire as shown in Fig. 6. Wire 
either O or B (not both) from the thermostat to the O/B 
terminal on the panel. Locate the O/B thermostat jumper on 
the TZ-4 near each zone thermostat wiring terminal. Connect 
the jumper if O was used or leave disconnected if B was used. 
Connect second stage, auxiliary heat to W2.
When using two- or three-stage heat pump thermostats with 
single Y first-stage hookup, place a jumper from W2 to Y2 on 
the TZ-4 thermostat connections. See Fig. 7.
See Single and Multi-Stage Operation in the Operation 
section for instructions on staging the TZ-4.ARD or ZD Dampers
Wire the ARD or ZD Damper to the panel as shown in Fig. 8. 
Multiple dampers can be wired in parallel. Use these dampers 
on systems up to 2000 cfm.
AOBD Dampers
Wire the AOBD dampers to the panel as shown in Fig. 9. Two 
AOBD can be wired in tandem as shown in Fig. 10. More than 
two AOBD dampers require the Slave Damper Control Relay 
(SDCR).
Fig. 6. Heat pump thermostat with single Y thermostat 
wiring.
M20506B
G
C
R
Y W1L
W2
E
B
O
COMMON (C) TERMINAL IS USED ONLY BY THERMOSTATS
THAT REQUIRE A COMMON WIRE.
JUMP E TERMINAL TO W1 FOR EMERGENCY HEAT.
LEAVE O/B JUMPER ON TZ-4 DISCONNETED.TZ-4 THERMOSTAT
CONNECTORS
HEAT PUMP THERMOSTAT WITH
SEPARATE Y1 AND W1 
THERMOSTAT WIRING1
2
3
12
3
M20507B
G
C
R
Y1 W1L
W2
E
B
O
COMMON (C) TERMINAL IS USED ONLY BY THERMOSTATS
THAT REQUIRE A COMMON WIRE.
NORMALLY, CONNECT E ON THERMOSTAT TO W1 ON PANEL. 
ALTERNATIVELY, INSTALL JUMPER FROM E TO Y1 ON 
THERMOSTAT.
CONNECT O/B TERMOSTAT JUMPER ON TZ-4 PANEL IF
USING O FROM THERMOSTAT; DISCONNECT IF USING B.TZ-4 THERMOSTAT
CONNECTORS
HEAT PUMP THERMOSTAT WITH
SINGLE Y THERMOSTAT WIRING1
2
3
1
3
2 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 8
Fig. 7. Heat pump thermostat with 3-stage heat, 2-stage 
cool single Y thermostat wiring.
Fig. 8. Wiring ARD or ZD damper to panel.Fig. 9. Wiring AOBD damper to panel.
Fig. 10. Wiring two AOBD dampers in parallel.
MARD Dampers or Dampers Using an ML6161 Motor 
Actuator
Wire the MARD Damper or ML6161 Actuator to the panel as 
shown in Fig. 11. These are floating control actuators, but are 
controlled as two-position devices on the TZ-4 panel. Multiple 
dampers can be wired in parallel. 
The ML6161 Motor causes the damper LED to illuminate 
green constantly. WIre a relay as shown in Fig. 12 to restore 
damper position indication.
Use the MARD or D643 with the ML6161 on systems above 
2000 cfm.
Fig. 11. Wiring MARD Damper or ML6161 Actuator to 
panel. M20891
G
C
R
Y1 Y2L
W3
E
B
O
COMMON (C) TERMINAL IS USED ONLY ON THERMOSTATS
THAT REQUIRE A COMMON WIRE.
ALTERNATIVELY, JUMPER E THERMOSTAT TERMINAL TO Y1 FOR 
EMERGENCY HEAT.
CONNECT O/B JUMPER ON TZ-4 WHEN USING O OR DISCONNECT
WHEN USING B FOR CHANGEOVER.
FIELD INSTALLED JUMPER FROM Y2 TO W2 ON PANEL 
THERMOSTAT CONNECTIONS.TZ-4
THERMOSTAT
CONNECTORS
HEAT PUMP THERMOSTAT WITH
SINGLE Y THERMOSTAT WIRING1
2
3
4
14
3
2
4M6 M4
M1
56
123Z
X
DAMPER MOTOR FIELD JUMPER
M19067
MOTOR TERMINALS
4M6 M4
M1
56
12
3
DAMPER MOTORS
M19068
MOTOR TERMINALS
456
123Z
XZ
X
FIELD JUMPER
M1 M4
M20136A
ZONE PANEL
CONNECTIONS
M6
CW
COM
CCW MARD 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
9 68-0259-1
Fig. 12. MARD or ML6161 Damper Motor Actuator using 
R8222 Relay wiring.
Transformer
1.Wire the transformers to the panel as shown in Fig. 13. 
One 40 VA, 24 Vac transformer controls up to five ARD 
or ZD dampers.
2.Connect the transformer to terminals R and C. 
3.Add the auxiliary transformer if six to ten ARD or ZD 
dampers are used. 
a. Wire auxiliary transformer to terminals T1 and T2. 
b. It is important that these two transformers be wired 
in phase. If they are wired out of phase, the internal 
circuit breaker trips and the board de-powers. If this 
occurs, remove power, correct the wiring and 
restore power to the board.
IMPORTANT
If more than five dampers are required for one zone 
or if more than ten dampers are used for the TZ-4, 
use the Slave Damper Control Relay (SDCR). Fig. 13. Wiring transformer(s) to panel.
Discharge Air and Outdoor Temperature Sensors
Wire the C7735A Discharge Air Temperature Sensor (DATS) 
to the panel as shown in Fig. 14. The Purge LED (yellow) 
flashes in all modes except purge if no DATS is connected to 
the TZ-4 or if there is a problem with the DATS or the wiring. 
For dual fuel applications, connect the C7089 Outdoor 
Temperature Sensor as shown in Fig. 14.
Fig. 14. Wiring C7735A Discharge Air Temperature Sensor 
(DATS) to panel. 
Add-A-Zone Panel
Remove power from TZ-4 before connecting AZ-1 and AZ-2.
Wire the Add-A-Zone (TAZ-4) Panel to the TotalZone (TZ-4) 
Panel as shown in Fig.15. Up to seven TAZ-4 Panels can be 
wired to one TZ-4 panel to control up to 32 zones. 
COM
CCW
CWML6161
R8222 RELAY ZONE CONTROL PANEL
DAMPER TERMINALS
M20548A
M6M4 M1RC
R
C
T1
T2
C
R C R
24 VAC, 40 VA 
Transformer
(Required if
more than
four dampers) 24 VAC, 40 VA 
Transformer
DAMPER
XFRM
PANEL
XFRM
M20518
M20519
DATS
DATS DATSOT
OT OT
Sensor 
						

							TZ-4 TOTALZONE® ZONE CONTROL PANEL
68-0259-1 10
Fig. 15. TotalZone Add-A-Zone wiring.
Conventional Equipment
Wire the heating and cooling equipment to the equipment 
terminals on the TZ-4 Panel as shown in Fig. 16. 
Conventional Equipment: Set DIP switch 5-1 to on.
Electric Furnaces: Set DIP switch 5-6 to off to energize the fan 
with a call for heat.
Hydro-Air: Wire the zone valve or circulator relay to the Rh 
and W1 equipment terminals. (If the circulator relay has 
powered terminals, remove the Rh Rc jumper.) Set DIP switch 
5-6 to off to energize the fan with a call for heat.
Oil Heat: Wire the oil primary T, T terminals to the Rh and W 
equipment terminals. (If the oil primary has powered 
terminals, remove the Rh Rc jumper.)
Multi-Stage: Wire the equipment as shown in Fig. 16 using the 
W2 and W3 terminals for second and third stages of heat. 
Wire Y2 for second stage of cooling.
See Single and Multi-Stage Operation in the Operation 
section to configure DIP switches 4-1, 4-2, 4-3, and 4-4.
M20362
TotalZone Panel
TotalZone
Add-A-Zone Panel
AZ1 DIP-SWITCHES
AZ2AZ1
AZ2
AZ1
AZ2TO NEXT
ADD-A-ZONE
PA N E L
54321O
N