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Problems with Zonex system and heat getting downstairs

9.4K views 9 replies 5 participants last post by  DOGBOY  
#1 · (Edited)
Hi, I hope someone on here could offer me some advice. I have a California Economizer system (now Zonex) that was installed when my house was built in 1999. I cannot find the model anywhere on anything. When I bought the house last year (2010) the home inspector noticed that the past owner had propped open one of the 2 main ducts. He suggested in his report that I ask that the owners take out the stick that was propping it open so that it could function correctly. I wish I would have caught on then that something was wrong and there was a *reason* it was being propped open!!

Flash forward 6 months, and winter hits (the AC was fine all summer). There is no heat downstairs. (It's a two level house, 2100 sf, bedrooms upstairs, living areas downstairs, no basement, on a slab, one HVAC unit). I call a heating and air company. They say that they don't work on Zonex, but that they think a circuit board is bad and thus the 2nd duct isn't opening correctly. I call Zonex, I order the exact circuit board in question, the company comes back out, says it won't control the duct, and charges me to not install it (!). I then call a 2nd company, who comes out and says they don't know whats wrong either, but they could install a whole new Honeywell zone system for xxx (LOTS!), and replace the main ducts and both sensors for the thermostats. I don't have that much extra money at the moment, unfortunately. (I just bought a house!)

So I got through last winter with the use of the gas fireplace downstairs. But now I'm approaching winter number two in my house, and I have to figure out what to do so that there is heat downstairs. I know that the cathedral ceiling in the living room is keeping it from being super warm, but the whole downstairs is so cold -- and it seems that both companies I've called can't diagnose the problem. I am thinking possibly there is a blocked duct? All the ducts in the attic are flexible ducts, and they are held up by nylon straps. It looks like a spaceship in the attic -- ducts *everywhere!* Also, I can't figure out why the old owners would have the duct they had propped open, as apparently its the upstairs duct (and the upstairs gets heat and air fine, and the duct will open fine).

Both sensors will come on, but nothing seems to make heat come out downstairs (AC didn't really come out downstairs either, but since cold air falls it was fine all summer). You can feel the tiniest bit of airflow, but it's just not coming out the way it needs to to give heat to downstairs.

Any advice on what to do -- or what direction to point the HVAC people to? Thank you so much!
 
#3 ·
I am quite familiar with Zonex. If I understand you corectly you have two zones. One feeds upstairs and the other downstairs. You should have two thermostats. How large are the dampers, are the motors warm to the touch,and what is the size or model of your furnace.Post some pictures.
 
#4 ·
We have Zonex zoning in our office.

My guess is the damper for downstairs is bad, that's usually why a damper is propped open. Shouldn't be that hard to figure out but selling a new system is LOTS better commission than a damper. Seems you need a service tech, one who will repair, not try to sell you new.
 
#6 ·
Thanks for the replies. I will try to take some pictures this morning. The AC unit outside is Lennox - so I'm assuming the furnace is too. Everything in the attic is very difficult to get to and seemingly unlabeled, but I will see if I can figure out how many BTUs the furnace is.

I tried getting both upstairs and downstairs themostats (sensors?) to call for heat last night, then went up and looked around to see if I could tell if any flexible tubing was blocked or if I saw anything obvious wrong. Some of the Zonex things I've read online say that there should be an LED light if the damper is powered closed, but there are no LED lights that I could see. I will try to feel for warmth when I go back up to take pictures.

Is it possible to replace a broken Zonex (California Economizer) damper with a new damper from a different company? Perhaps I could request the company I've been calling to do that. They are not a Lennox company, but they do have a good reputation in my community. The dampers are 16 inch.
 
#7 ·
It would be helpful to know what system you have. This information can be located on the printed circuit board.You more than likely have a DIGI3U or a DIGITRACT 4. Your damper motor has probably been disconnected do to the poor duct design.How large is your home. You mentioned 2100 sf is this the total or just the upstairs. I think what is happening in your home is that when both dampers called for heating or cooling the air will flow down the path of least resistance. Two 16" dampers are fairly large for a average home. Sounds as if it was installed to operate as either upstairs or downstairs but not simultaneously. Thats just my hunch and if that is the case what a crazy design.
 
#8 ·
It appears to be a 101 DIGI, if I'm interpreting it right. I took a picture of the upstairs thermostat/sensor so you could see. The whole house is 2100 sf. I also took a picture of the circuit board in the laundry room which controls the whole unit on/off and fan. In an ideal world I'd like to replace these 1970s looking thermostats with something programmable, but don't even know if that's possible with this kind of system. I keep looking in the Nashville area, and can't find anyone that claims to work on Zonex.

Thanks again for the replies!
 
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