Intelligent Zoned Comfort Control System
Owner’s Manual
Model 6504
Includes Operating Instructions
and Warranty Information
READ AND SAVE THESE INSTRUCTIONS
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INTELLIGENT ZONED COMFORT CONTROL MODEL 6504 – SYSTEM OVERVIEW
Thank you for purchasing a new Aprilaire Zoned Comfort Control System. We sincerely appreciate your business and are pleased
to add your name to our growing list of satisfied customers. With this purchase, you have invested in the highest quality
equipment currently available.
Please be assured that in addition to product quality, we are committed to product performance and complete customer
satisfaction. Aprilaire Intelligent Zoned Comfort Control System is comprised of several components that work together to
increase your comfort, provide the ultimate in convenience while saving you energy and money. The system is designed to work
with single or multi-stage forced air heating/cooling equipment and control 2, 3, or 4 zones.
The system integrates your Aprilaire equipment to enhance their control including:
MODEL 8570 PREMIUM THERMOSTAT
APRILAIRE AUTOMATIC HUMIDIFIERS
The Model 8570 is your interface for all system information
and control. The 8570 utilizes a menu-driven approach to
programming and operation that make it intuitive and easy
to use.
Deliver optimum humidity throughout your home. Aprilaire
Automatic Humidifiers monitor outdoor temperature to
assure the proper indoor relative humidity. Information such
as the indoor Rh and outdoor temperature are then shared to
all thermostats on the system.
MODEL 6504 INTELLIGENT ZONED COMFORT
CONTROL PANEL
VENTILATION
The Model 6504 is your central “hub” for all the components
of your Indoor Air Quality system. As many as 4 independent
zones can be controlled by the 6504 exclusively using the
8570 thermostats. Aprilaire accessories such as humidifiers
or air cleaners are controlled or share information through
the 6504.
The Model 6504 can also control essential ventilation
products such as Energy Recovery Ventilators or Fresh Air
Intake dampers. Intelligent ventilation comes from the ability
of the system to look at indoor and outdoor conditions to
control the quantity and quality of ventilation needed.
ELECTRONIC AIR CLEANERS (EAC)
DAMPERS
Aprilaire Model 5000 Electronic Air Cleaners provide the
cleanest, healthiest air possible when operated in
conjunction with your systems blower. The Model 6504
assures they work together and lets you know when it is on.
Aprilaire dampers feature patented technology that
eliminates the components most prone to failure with other
manufacturers’ dampers – “gears”. These ultra reliable
dampers are located in the systems supply duct work to
direct airflow.
ULTRAVIOLET GERMICIDAL LIGHT
Reduce the risk of fungi and mold growing on your wet
cooling coil. Annual maintenance assures continued
effectiveness and the Intelligent Zoned Comfort System
alerts you when it is time.
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INTELLIGENT ZONED COMFORT CONTROL MODEL 6504 SYSTEM
Aprilaire Model 8570
Premium Programmable
Thermostat
HVAC Equipment
Model 6504 Control Panel
Aprilaire Model 5000
Electronic Air Cleaner
Aprilaire
Zone Comfort
Damper
Aprilaire Model 8100
Energy Recovery Ventilator or
Model 8126 Ventilation Control Damper
Aprilaire Automatic
Humidifier Control
Aprilaire
Zone Comfort
Damper
Aprilaire
Automatic Humidifier
SEE MODEL 6504 INSTALLATION MANUAL FOR SPECIFIC CONNECTIONS
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MODEL 6504 CONTROL PANEL LED DESCRIPTION
LED lights on the side of the control panel indicate when the components of your Intelligent Zoned Comfort Control system
are operating:
LED
COLOR
STATUS
THIS MEANS…
Blinks once per second when 24 VAC
Power Applied – this is normal
POWER
GREEN
BLINKING
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Zone 1 Damper Open
ZONE 1
ZONE 2
ZONE 3
ZONE 4
FAN ON
VENT
RED
RED
RED
RED
RED
RED
RED
RED
RED
RED
Zone 1 Damper Closed
Zone 2 Damper Open
Zone 2 Damper Closed
Zone 3 Damper Open
Zone 3 Damper Closed
Zone 4 Damper Open
Zone 4 Damper Closed
System Blower Operating
System Blower OFF
ERV or Ventilation Control Operating
ERV or Ventilation Control OFF
Electronic Air Cleaner Operating
Electronic Air Cleaner OFF
Humidifier Operating
EAC
HUM.
Humidifier OFF
Heating Equipment Operating
Heating Equipment OFF
Cooling Equipment Operating
Cooling Equipment OFF
HEAT
COOL
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BASIC OPERATION OF YOUR ZONED COMFORT CONTROL SYSTEM
Your Aprilaire Zoned Comfort System will allow you to increase your comfort by directing conditioned air to separate areas
(zones) based upon each zones thermostat setting. To operate the system, just set or program each zones thermostat to your
desired comfort and set-back settings.
When there is a heating or cooling call from any zone, the appropriate heating or cooling equipment will be turned on. The
dampers in zones not requiring heating or cooling will close and the conditioned air will be directed to the calling zone(s) until the
thermostat is satisfied.
Aprilaire Zoned Comfort Control is a heat call priority system. This means that there are certain times when heating calls will
take precedence over cooling calls. This occurs if two calls for opposing modes exist simultaneously while the system is idle, in
which case the heat call will be satisfied first. In all other cases a first-call, first-serve approach is taken satisfying the zone(s)
that call first. If, however, a call for opposing mode exists for a minimum of 20 minutes during equipment operation, the system
with shut down for an equipment protection minimum off time then changeover to satisfy the new call. The heating and cooling
equipment will not operate at the same time.
Your zone control system is designed to direct conditioned air only to the rooms served by that zone’s thermostat. However, due
to the open design of today’s homes, it may not be possible to maintain drastic temperature differences between zones. Closing
interior doors is a good way to reduce the air exchange between zones and increase the temperature difference between them.
The following sections describe how to make Heating, Cooling, and Emergency Heat calls as well as how your Aprilaire
Intelligent Zoned Comfort Control System can control the other pieces of your HVAC system.
HVAC CONTROL DETAILS
HEATING OPERATION (ALL MODELS OF EQUIPMENT)
To start heating:
1. Set your Model 8570 programmable thermostat to the Heat mode. This is accomplished by selecting HEAT from the
Mode Menu. Consult the Model 8570 Owner’s Manual for details.
03/31/04 8:32 AM
OUTDOOR
20˚
03/31/04 8:32 AM
OUTDOOR
20˚
MAIN MENU
MODE MENU
HEAT MODE
FAN AUTO
OFF
FAN AUTO
SET DATE AND TIME
HOLD
PROGRAM
FAN
MODE - HEAT/COOL/ETC.
SETTINGS
OFF
AUTO
HEAT
COOL
71˚
MENU
SETPOINT
HEAT 70
EMERGENCY HEAT
71˚
INFO
MENU
EXIT SELECT
BACK SELECT
INFO
2. Adjust the thermostat set point to a temperature higher than the displayed room temperature, using the Up button, so that
a Heat call is initiated. Again, consult your thermostat Owner’s Manual for details on how to do this properly.
HOLD TIL 4:00PM
OUTDOOR
20˚
03/31/04 8:32 AM
HOLD THIS
TEMPERATURE
UNTIL 4:00PM
HEATING
FAN ON
HEAT MODE
FAN AUTO
OUTDOOR
20˚
HEAT
68˚
MENU
68˚
MENU
SETPOINT
HEAT 72
SETPOINT
HEAT 68
72˚
RESUME
PROG.
INFO
BACK SAVE
The LED labeled “HEAT”, on the zone panel enclosure will indicate if the board is making a call for heat. If the equipment does
not come on right away, it may be due to the minimum-off time delay. Four minutes must elapse after the last heating cycle
before it can come on again. This built in feature ensures that the heating equipment does not cycle too frequently, shortening
the life of the equipment.
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COOLING OPERATION (ALL MODELS OF EQUIPMENT)
1. Set your Model 8570 programmable thermostat to the Cool mode. This is accomplished by selecting COOL from the
Mode Menu. Consult your thermostat Owner’s Manual for details.
2. Adjust the thermostat set point to a temperature lower than the displayed room temperature, using the Down button, so that
a Cool call is initiated. Again, consult your thermostat Owner’s Manual for details on how to do this properly.
An LED labeled “COOL”, on the zone panel enclosure will indicate if the board is making a call for cooling. If your air conditioning
does not come on right away it may be due to the minimum-off time delay. Four minutes must elapse after the last air conditioner
cycle before it can come on again. This built-in feature ensures that the air conditioner does not cycle too frequently, which can
reduce the life of your equipment.
EMERGENCY HEAT OPERATION (Heat Pump Equipment ONLY)
Emergency Heat operation is also available if you have a heat pump and the zone panel was set up for heat pump operation
during the initial installation performed by your installer.
The Model 8570 thermostat can initiate the emergency heat mode. This is accomplished by selecting EMERGENCY HEAT from the
Mode Menu. Consult your thermostat Owner’s Manual for details.
Then, by placing the thermostat’s set point above the current temperature, Emergency Heat will energize until the thermostat is
satisfied. If any other zone should call for heat during the Emergency Heat call, it too will be satisfied by the Emergency Heat source.
NOTE: Emergency Heat is generally much more expensive to operate than the Heat Pump. Use only when necessary.
Your equipment may not include Emergency Heat.
DAMPER OPERATION
When the Aprilaire Intelligent Zoned Comfort Control Panel receives a call and turns on the appropriate equipment, it also
automatically closes the dampers that serve the non-calling zones and opens those in the calling zones. When all calls are
satisfied, the Control Panel initiates a purge cycle. During the purge cycle, the dampers maintain their last position to direct air to
the zone(s) that were calling, not affecting non-calling zones. After this purge cycle, all dampers open.
An LED on the zone panel enclosure will indicate if the damper for a zone is closed.
FAN OPERATION
The Aprilaire Intelligent Zoned Comfort Control Panel allows you to control fan operation from any zone. Dampers in zones not
calling for fan will close. If continuous fan operation is desired in all zones, the fan must be on in each zone. An LED labeled
“FAN ON”, on the zone panel enclosure will indicate if the HVAC fan is on. This can be done by selecting “ON” from the Fan
Menu on the thermostat and then selecting “YES” when prompted to “CHANGE ALL THERMOSTATS”.
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ACCESSORY CONTROL DETAILS
ELECTRONIC AIR CLEANER OPERATION
The Model 6504 is equipped with control capabilities for your Electronic Air Cleaner to assure its operation during all times the
system blower is active. In addition, there is an LED labeled “EAC” on the control panel to display that the air cleaner is running.
Your thermostat has a built-in monitor to alert you when it’s time to change the media in your air cleaner. Consult your thermostat
owners’ manual for details.
VENTILATION CONTROL OPERATION
The Model 6504 is equipped with control capabilities for either an Energy Recovery Ventilator (ERV) or a fresh air intake damper.
Consult your installer to determine which type of ventilation was installed.
There are two settings adjusted through dip switches on the Model 6504
DIP SWITCHES LOCATED
ON MODEL 6504 CONTROL PANEL
Control Panel that control the amount of ventilation that will be delivered to
your home. One is the Vent Cycle and the other is the Vent Time. Here’s how
it works: if you set the Vent Cycle to 1 hour and the Vent Time to 15 minutes,
you will get 15 minutes of ventilation every hour. It is important to understand
that the ventilation requirement (15 minutes per hour in this example) may be
satisfied during a heating, cooling or continuous fan call initiated by your
thermostat or from the control panel itself. For example, if, during the one
hour Vent Cycle, your HVAC equipment only turned on for 10 minutes, you
would get ventilation during that 10 minutes of equipment run time, and then
the control panel would turn on the fan during the last 5 minutes of the Vent
Cycle to ensure that you receive the full 15 minutes of ventilation.
VENT TIME – Sets the amount of time that the ERV will operate or the
Ventilation Damper will be open during the Vent Cycle Period.
15 minutes
30 minutes
45 minutes
60 minutes
VENT CYCLE – Sets the period over which the amount of ventilation run time
will be summed. For example, if the Vent Time is set for 30 minutes and the
Vent Cycle is set for 1 hour, the ERV or Ventilation Damper will be operated for
30 minutes per hour.
1 Hour
2 Hours
3 Hours
4 Hours
An Energy Recovery Ventilator (ERV) like the Aprilaire Model 8100, exchanges heat and moisture from the indoor air to the
outdoor air ensuring that air is pre-conditioned before entering your home or office. The control panel will not limit ventilation
when controlling an ERV. Use of a Ventilation Damper is an economical way to get outdoor air into your home or office, but unlike
the ERV it does not pre-condition the air. Control of a ventilation damper is enhanced by the Model 6504 Control Panel when an
outdoor temperature sensor is installed with your system and enhanced even more when an Aprilaire Automatic Humidifier has
been installed. Direct ventilation from outside can increase the heating or cooling load on your heating and cooling equipment or
cause uncomfortably cool or warm drafts. Bringing in moist air can cause the indoor relative humidity to reach uncomfortable,
“stuffy feeling” levels. With an outdoor temperature sensor installed, the control panel will discontinue ventilation if the outdoor
temperature is above 100°F or lower than 0°F, and will limit ventilation to occur only when the heat is on when the outdoor
temperature is between 20°F and 0°F. When an Aprilaire Automatic Humidifier is installed, ventilation is also discontinued when
the indoor relative humidity is above 55% RH and the outdoor temperature is above 50°F.
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VENTILATION DAMPER OPERATING LIMITS
100
SECTION A
50
SECTION B
SECTION C
20
0
SECTION A
55
INDOOR RELATIVE HUMIDITY (%)
SECTION A: Controller will not ventilate due to temperature extremes
SECTION B: Controller will ventilate according to timer settings
SECTION C: Controller will ventilate only when heating is on according to the timer settings
90-713
HUMIDIFIER OPERATION
The Intelligent Zoned Comfort System works with your Aprilaire Automatic Humidifier Control (AHC) to enhance the performance
of your whole house humidifier.
The HUM LED on the control will turn on when the humidifier is operating. Humidification, using a whole house humidifier, can
only occur when the heat is on, or when the fan has been set to operate continuously (FAN ON shown on the thermostat). Your
Intelligent Zoned Comfort System can also keep the fan running if the humidification need has not been met. If the AHC senses
that humidification is still required when the heating system is about to turn off, the Intelligent Zoned Comfort System will keep
your fan operating until the need is met, or for 15 minutes. To prevent rapid cycling of your HVAC equipment, the blower will be
operated for no less than 5 minutes.
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INTELLIGENT SHARING OF INFORMATION
Your Intelligent Zoned Comfort Control System goes beyond the functionality already described to give you the ultimate in
convenience. The system allows you to control, make changes, or monitor the following parameters from any one or all of
your thermostats.
• Mode of operation – Heat, Cool, Off or Emergency Heat
• Fan operation
• Hold status: Temporary, Holiday or Permanent
• Outdoor temperature
• Indoor relative humidity
• Extend blower operation for enhanced humidifier operation
• Service Indicators
– Change air filter
– Service humidifier
– Change UV lamp
– HVAC service
You also have the ability to program the zones name or identification to personalize and simplify your system.
Consult your Model 8570 Thermostat Owners’ Manual for details.
SYSTEM PRESSURE RELIEF
With a Zone Control System, some form of pressure relief must be designed into the system to assure proper operation and reduce
the possibility of noise due to airflow. The method of pressure relief that has been designed into your system could include use of
a bypass damper or the Aprilaire method of controlled pressure relief. With the controlled pressure relief method, a predetermined
amount of air is allowed to pass through a closed damper. The amount of air that is passed by each damper (the bypass) is not
enough to cause a noticeable temperature change in a non-calling zone, but is enough to relieve the higher system pressures.
So, if you feel small amounts of air entering into a non-calling zone, what you are feeling is the bypass air.
Remember, this bypass is normal and provides pressure relief for the system without causing a noticeable change
in temperature within that zone.
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LIMITED WARRANTY
Your Research Products Corporation Aprilaire® Intelligent Zoned Comfort Control System is expressly warranted for five (5) years
from date of installation to be free from defects in materials or workmanship.
Research Products Corporation’s exclusive obligation under this warranty shall be to supply, without charge, a replacement for
any part of the intelligent zone control system which is found to be defective within such five year period and which is returned
no later that thirty (30) days after said five year period by you to either your original supplier or to Research Products Corporation
Madison, WI 53701, together with the model number and installation date of the unit.
THIS WARRANTY SHALL NOT OBLIGATE RESEARCH PRODUCTS CORPORATION FOR ANY LABOR COSTS AND SHALL NOT APPLY
TO DEFECTS IN WORKMANSHIP OR MATERIALS FURNISHED BY YOUR INSTALLER AS CONTRASTED TO DEFECTS IN THE
INTELLIGENT ZONE CONTROL SYSTEM ITSELF.
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO
THE AFORESAID FIVE YEAR PERIOD. RESEARCH PRODUCTS CORPORATION’S LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES, OTHER THAN DAMAGES FOR PERSONAL INJURIES, RESULTING FROM ANY BREACH OF THE AFORESAID IMPLIED
WARRANTIES OR THE ABOVE LIMITED WARRANTY, IS EXPRESSLY EXCLUDED. THIS LIMITED WARRANTY IS VOID IF THIS UNIT
IS NOT INSTALLED BY A QUALIFIED HEATING AND AIR CONDITIONING CONTRACTOR. IF THE LIMITED WARRANTY IS VOID DUE
TO FAILURE TO USE A QUALIFIED CONTRACTOR, ALL DISCLAIMERS OF IMPLIED WARRANTIES SHALL BE EFFECTIVE UPON
INSTALLATION.
Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or
consequential damages, so the above exclusions or limitations may not apply to you.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
WARRANTY REGISTRATION
Please… Take a few minutes to visit us on-line at
to register your Aprilaire product.
If you do not have on-line access, please mail a postcard with your name,
address, phone number, product purchased and date of purchase to:
Research Products Corporation
P.O. BOX 1467
Madison, WI 53701
Thank you!
Your Warranty Registration information will not be sold or shared outside of this company.
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™
iHVAC = Intelligent Solutions for Indoor Air
Aprilaire offers an entire line of premium Indoor Air Quality products that are designed and installed to work even
better together and set a new standard for performance and reliability. Intuitive to use. Easy to maintain. Aprilaire
products installed and serviced by qualified iHVAC contractors enhance your comfort, health and energy efficiency.
™
Aprilaire Indoor Air Quality products with Engineered Simplicity
• Humidifiers • Air Cleaners • Dehumidifiers • Electronic Thermostats
• Zoned Comfort Control • Ventilation • UV Germicidal Lamps
10006210 11.06
B2203364B
©2006 Research Products Corporation
Printed in USA
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