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Communicating Controls Service Manual

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1. 24 VOLT THERMOSTAT 3 HEAT 2 COOL A C OR AIR OUTDOOR 3 HEAT 2 COOL HEAT PUMP HANDLER UNIT o ee DAVAC HON VA e iR 24VAC B Er 4B Yi been V eere 4 Y a 4Y2 a 40 XD W s eee e ODT2 Notes 7 24Volt Common B may not be required at the thermostat 2 and X2Thermostat wires are used on heat pumps installations only 3 ODT2 not required on a two stage auxiliary electric heater All information contained herein is subject to change without notice 24 Volt Thermostat with a Communicating Outdoor Unit Using a 24V Harness Kit ZBAYACHPO24A For instructions components and diagrams used in 5 Place the proper wiring diagram over the existing this kit order tBBAYACHPO24A Shown here is an unit wiring diagram excerpt from the kit for reference If the unit is a e 30 000 BTU heat pump use D154942 1 Be certain power to unit is DISCONNECTED 36 480 or 60 000 BTU heat pump use D154944 30 000 BTU cooling only model use D154652 2 Remove cover panel on control box compartment 36 000 48 000 or 60 000 BTU cooling only models use D154657 3 Disconnect and remove the existing communicating control harness assembly This harness
2. 75 Liquid Line Pressure Transducer DC Volts PSIG Pressure Table 76 External Accessory Temperature Senor Temperature Resistance 77 oin ere EE HD 78 Error Code 89 91 and 126 System Communicating Trouble Shooting 88 Communicating System Voltage Readings 95 Note This publication is general in nature and is intended for INSTRUCTIONAL PURPOSES ONLY It is not to be used for equipment selection application installation or specific service procedures All information contained herein is subject to change without notice Warnings and Cautions Throughout this manual there are procedures where voltage may be present and gas or refrigerant system checks may be required Read all cautions and warnings on this page before proceeding A WARNING SAFETY HAZARD THIS INFORMATION IS INTENDED FOR USE BY INDIVIDUALS POSSESSING ADEQUATE BACK GROUNDS OF ELECTRICAL AND MECHANICAL EXPE RIENCE ANY ATTEMPT TO REPAIR A CENTRAL AIR CONDITIONING PRODUCT MAY RESULT IN PER SONAL INJURY AND OR PROPERTY DAMAGE THE MANUFACTURER OR SELLER CANNOT BE RESPON SIBLE FOR THE INTERPRETATION OF THIS INFORMA TION NOR CAN IT ASSUME ANY LIABILITY IN CON NECTION WITH ITS USE A WARNING FIRE OR EX
3. 1 PRESSURE J8 lecss ADD Da Gm VP Trin 61 E l REFRIGERANT 10 Dip Switch 0 1 On 20 25 Low DT ESSURE OUT OF RANGE Cie CE CHARGING 18 ADD ECEM REC p 30 40 60 TOTAL REFRIGERANT LINE LENGTH FEET Note 1 On the Charge Assist control set the LINE LENGTH DIP SWITCHES before running system or entering CA Mode If all dip switches are in the ON position control will default to Upper Range If all dip switches are in the OFF position control will default to Lower Range Refer to Service Facts for additional information Note 2 In Two Compressor A C or heat pumps units the CA control works in the second stage cooling cycle only LEDs Y1 and Y2 will be on during the CA control charging cycle Entering CA Mode when a heat pump is operating in the heating cycle will turn the system OFF for the minimum equipment OFF time of 5 minutes After the 5 minute delay the CA control will run the 1st stage compressor for one minute Green LEDY1 on The CA 57 control will then stop
4. ow O ICM CEN 0 uU EIER ES J1 SIGNAL 198285 Y2 econ B J6 J7 MOE LIQUID T CHARGING E 3 meua aea a PRESSURERj GS ADD REC OEE VP rie 2 74 VOLTS D C Voltage read at test point VP should agree with the pressure 1 5 transducer chart 3 x C36 BARCODE DATE OF APPLY P N LABEL HERE All information contained herein 71 is subject to change without notice Trouble Shooting Charge Assist Control Fault LED Flash Code Fault LED Flash Code of 13 The fault LED will be flashing in groups of thirteen flashes This indicates that the outdoor External Ambient Temperature Sensor is reading out of range Read the DC voltage at the External Ambient Temperature Sensor EXT ODT terminal boards TB with the sensor connected or remove the sensor leads and read the resistance of the sensor Does the External Ambient Temperature and the DC voltage read at the External Ambient Temperature Sensor TB or resistance of the sensor
5. VS COMM PLUG I D DISPLAY 145 208 VOLTS D C 9000000000 0000000000 RIN AR D R B Indicates a male spade terminal Return air sensor plug DA Discharge air sensor plug terminals BK PWM blower speed terminal D R B C Y1 All information contained herein 86 is subject to change without notice Trouble Shooting Chart F 3 BLW COMM ERR Step 6 De power the Gas Furnace or the Air Handler V S Blower Motor Connect the DC voltmeter as shown and then re power the Gas Furnace or the Air Handler 0 1 52 Is there DC voltage between the indoor 0 174 door blower terminals TX and GND This DC voltage should be going up and down between 0 152 Volts DC and 0 174 Volts DC The Voltage Meter will stop reading at times and then start reading again VOLTS D C YES Repair or replace the low voltage harness going from the indoor blower to the Gas Furnace IFC NO Replace the indoor blower motor and reconnect the wire removed from the Gas Furnace IFC or the Air Handler Step 7 Is there 12 VDC at the Gas Furnace IFC or Air Gas Furnace IFC Handler low voltage plug measured between mmm p terminals 12V and GND LINE Ge E E 3 SS o ca 005 99 8 YES Repair or replace the low voltage har ness going from the Gas Furnace IFC plug to the indoor blower
6. indicates male spade terminal Return air sensor plug NDUCER DA Discharge air sensor plug terminals Furnace IFC z OO LINE 38 NEUTRAL co Wis CIRCULATOR E9 T Ee u o RX RX COM Yellow LED 4 0000000000 0000000000 L 24 Green o LED E fF Red Fault LED ay Y NALA lololo D R B C Y1 88 BK PWM blower speed terminal All information contained herein is subject to change without notice System Communication Trouble Shooting Step 2 Is there 24 volts AC power at 1 the outdoor unit Charge Assist control 2 at the furnace IFC or the air handler control board and 3 the Telephone Access Module Note If there is no 24 volt AC power at some of the communicating components the BM LED may be very dim or out or may be flashing very fast And an error code of ERR 89 my have been seen at the Comfort Sensor YES Remove all wires from D terminal at the furnace IFC or air handler terminal board Does the BM LED now come on If the BM does not come on replace the furnace IFC or the air handler control board If the BM LED comes on go to step 11 NO Restore 24 volt AC power and then test control system for proper operation Step 3 The amber COM LED
7. m 9 8lA D B CY1 IFC Control Part Cnt 04836 Heating Cycle The Furnace Integrated Furnace Control IFC receives a message from the comfort control thermostat to op erate in the first second or third stage of heat Manual Reset Flame Roll Out Limit Comfort Control Thermostat Checks Performed Before Starting a Heating Cycle The furnace s IFC will check to see if all of the limits are closed and the pressure switches for stage one PS 1 and stage two PS 2 are open These operating components are always checked before a heating cycle can begin Stage three PS 3 pressure switch is not checked until a call for third stage heat is received by the furnace s IFC The furnace s IFC will always start the heating cycle in the Second Stage of heat and then goes to First Stage heat or whatever stage the comfort control thermostat is calling for The furnace s IFC then communicates digitally with the Inducer Motor Drive Board IMDB and the Variable Speed Indoor Blower VSIB The furnace IFC signals the IMDB and the VSIB on itsTransmit Line and receives replies from these components on its Receive Line The three phase Inducer Motor speed is controlled by the output Voltage Level and the number of AC Cycles hertz supplied by the IMDB When the inducer s motor speed changes are needed the furnace s IFC will signal the IMDB which will change its output voltage and number o
8. Charge Assist Charge Assist Sequence of Operation The OUTDOOR UNIT S Charge Assist CA Control Board is a microprocessor based control which can communicate digitally with a communicating system s thermostat or can be connected to a standard 24VAC thermostat The CA control has two modes of operation In the normal operating mode the CA control will respond to the indoor thermostat call for operation The other mode of operation is the Charge Assist mode To put the outdoor unit into the Charge Assist mode press the MODE button for 1 second The control exits the normal operating mode and enters the Charge Assist mode See pages 57 and 58 for Charge Assist Procedures for a communicating system thermostat See page 60 for the Charge Assist Procedures for a standard 24VAC Thermostat system The CA control completes the following operations Turns on the first or second stage compressor Controls the two compressors minimum on and off time and the one minute time delay between stages Sends speed signals to the outdoor fan Reads the outdoor temperature and sends a digital outdoor temperature message to the communicating system thermostat Reads the Liquid Line Pressure and temperature Is also the Demand Defrost Control when applied to a Heat Pump Can diagnose System Operating Faults See LED amp Alert Codes 56 Charge Assist Control LED Indications Y 1 LED ON First Stage Compressor op
9. Heat Pump with Electric Heat Sequence 24VAC Inputs When Y1 and G are present the compressor will energize along with the blower on high speed in single stage operation or low speed in two stage operation When Y1 and Y2 are present the 2nd stage compressor in two stage equipment will energize and the blower will go to high speed When any combination W1 W2 and W3 are present the air handler control will energize appropriate heater contactor e f the cooling CFM is lower than the selected heating CFM the motor will run in the heating speed Air handler will select highest CFM When any W input is removed the corresponding Heat output will be de energized When Y1 and Y2 inputs are removed the 2nd stage compressor will turn off When G is removed the blower will turn off after the Heat Off Delay selectable has timed out Air Handler Unit Test Mode The Comfort Control should be switched to OFF before entering the Unit Test Mode via the User Interface The Test mode operates the same in Communicating Mode and 24 Volt Mode Note Unit will exit Test Mode if any one of the following conditions exists If Air Handler receives a request for operation from the Comfort Control o This includes Heating Cooling or Blower requests If a fault is detected during any phase of Test Mode except 123 f any button on the User Interface is pressed To access the Unit Test Mode scroll down through
10. 83 0000000000 0000000000 VOLTS D C All information contained herein is subject to change without notice Trouble Shooting Chart F 3 BLW COMM ERR A Gas Furnace Fault LED will be flashing a ten 10 flash code An Air Handler Fault LED will be flashing a three 3 flash code Step 1 Power is on during this step Is there 12VDC at the indoor blower low voltage plug terminals 12V and GND YES Go to step 2 NO Go to step 7 Note The colors of the low voltage V S Blower Motor wires are Gas Furnace uses a blue wire and a black wire Air Handler uses a blue wire and a brown wire V S Blower Motor Black or Brown Step 2 Is there 120 VAC at the indoor blower high voltage plug terminals YES Go to step 3 NO Repair as needed and retest Note 1 The correct line voltage is Gas Furnace 120 Volts AC Air Handler 220 Volts AC 2 The colors of the line voltage wires are Gas Furnace has a black wire and a white wire Air Handler has a black wire and a red wire V S Blower Motor Jumper on Gas Furnace only VOLTS A C All information contained herein is subject to change without notice Trouble Shooting Chart F 3 BLW COMM ERR Step 3 Set the comfort control thermostat to call for V S Blower Motor blower operation Is there DC voltage between the indoor 0 50 blower motor low voltage plug terminal RX 1 07 and GND This DC voltage should be goin
11. Trouble Shooting Chart F 2 IND COMM ERR Step 3 Cycle power to the comfort control thermostat Inducer Motor Drive Board and set it to call for heat Is there DC voltage between the inducer VCC ES motor drive board terminals RX GND TX OmO This DC voltage should be going up and VOLTS D C 0 down between 0 2 Volts DC and 1 7 Volts DC GND da Note Voltage levels may vary depending on RX 3L B Volt OHM MeterType 5 i rd YES Go to step 5 NO Go to step 4 C 2 OQ gt E ari 72 EGND L2 L1 Step 4 Set the thermostat to call for heat Gas Furnace IFC INDUCER Is there DC voltage between the Gas Furnace 9g ine IFC plug E9 terminal TX and GND This Cae B8 i DC voltage should be going up and down Bn between 0 2 Volts and 1 7 Volts DC e COM Yelow LEI D Note Voltage levels may vary depending on Volt OHM Meter Type YES Repair or replace the low voltage harness going from the Gas Furnace IFC plug E9 to the inducer motor drive board NO Replace the IFC ojooooooooo A
12. All information contained herein is subject to change without notice Trouble Shooting Chart F 2 IND COMM ERR Note Inducer Motor Drive Board LED Functions If the Green COM LED on the inducer motor drive board is flashing this is an indication that the inducer motor drive board and the Gas Furnace IFC are com municating with each other The inducer motor drive COM LED will continue to flash as long as there is a call for heat The inducer motor drive board RED STOP LED will flash on and off a few times when the Gas Furnace IFC sends a command to turn off the inducer motor The RED STOP LED is normally off Step 1 Turn power ON Is there 12 VDC at the inducer motor drive board terminals VCC and GND YES Go to step 2 NO Go to step 7 12 VOLTS D C Inducer Motor Drive Board VCC TX GND RX OOo E 2E oponon Uo Li MAT E GND o rx n d T OM LED ODSTOP LED ao lt gt ei TTA Step 2 Turn power ON Is there 120 VAC at the inducer motor drive board terminal L1 and L2 YES Go to step 3 NO Repair as needed and retest VOLTS A C 80 Inducer Motor Drive Board M e Li D aes 5 RX 0 m OCOM LED STOP LED All information contained herein is subject to change without notice
13. Control NO Unplug and re plug the Coil Temperature Sensor plug several times to insure that it is making good con tact with the Charge Assist Control plug J6 then recheck the DC voltage at plug J6 or unplug the sensor and read the resistance of the sensor IF the DC voltage and temperature or resistance and temperature does not agree with the temperature resistance and voltage Chart 1 replace the Coil Temperature Sensor Fault LED Flash Code of 7 ERR code 79 This fault code only applies to Heat Pump models in the heating or cool ing cycle During the defrost cycle the LPCO switch is not checked by the Charge Assist Control The fault LED will be flashing in groups of seven flashes This is an indication that the Low Pressure Cut Out switch LPCO is open Check the suction pressure it must be above 9 pounds Is the system suction pressure above 9 pounds YES Check the voltage at the LPCO plug J4 IF 24 volts AC is present at plug J4 unplug the LPCO and jumper the two pins of J4 together Turn off the 24 Volts AC to the Charge Assist Control and then re power the control The Fault LED should go out and the outdoor unit should come on when a call for heat or cooling is placed at the Comfort Control IF the Fault LED continues to flash in groups of seven and the out door unit will not come on replace the Charge Assist Control NO Repair Refrigerant System as needed Fault LED Flash Code of 10 This fault will only appear when
14. 60 65 80 50 FAN PRERUN DLY gt FAN PRERUN DLY unit specific NONE NONE 1 50 Model HEAT CFM options 34 1130 1130 1350 700 1000 37 1100 1100 1450 600 900 40 100 1100 1400 600 900 FAN SHRTRUN DLY NONE NONE 4m80 FAN SHRTRUN DLY 7 72m8096 FAN OFF DELAY FAN OFF DLY 65 J 1500 1500 1800 900 1200 172m10096 1 m100 NONE 1m50 2m50 3m50 HEAT CFM HEAT CFM FACTORY DEFLTS ___ FACTORY DEFLTS NO NO YES EXIT NO YES CLG 1ST STG CFM menu will not appear if STG1 is selected in CLG stages menu All information contained herein is subject to change without notice 40 Communicating Air Handler Air Handler Interface Display Assembly The indoor USER Interface Display Assembly will display the model and serial number and the following information can also be displayed The Unit Model amp Serial Number Normal Display System Status Mode of Operation Heating Cooling Fan or OFF Requested Airflow CFM when the thermostat is calling Indoor Unit s Alert Codes UnitTest Cycle Blower Motor Speed RPM when operating Last Four Alerts Replacement Part List Personality Module Serial Number e Stand alone operation with 24 Volt thermostat e Exit 24VAC Fuse The on board 24VAC automotive type fuse is in series with the 24 Volt A C terminal R The fuse w
15. 85 187 193 199 90 203 209 216 95 220 226 233 100 237 244 251 105 255 262 269 110 274 281 289 115 293 301 309 120 313 321 329 125 334 342 351 54 BLAC WHITE YELLOW GREEN BLUE BROWN BLACK BLACK BLACK BLACK BK BL x THERMALLY PROTECTED 20 INTERNALLY _ E 5 HI 768 1 p BK BL a VARIABL SPEED d OD FAN MOTOR COMMUNICATING FAIR HANDLER Q 0 49 AIT CONT900 OMFORT CONTROL All information contained herein is subject to change without notice Field Wiring Hook Up Diagrams and Charging Chart 3 4 and 5Ton Heat Pump Models Only SCHEMATIC DIAGRAM TO POWER SUPPLY PER UNIT NAMEPLATE AND LOCAL CODES A BK BL 2 SUMP HTR E BLACK BLACK TOL SUMP HTR PURPLE WH PURPLE WH BLACK BLACK q BK i THERMALLY PROTECTED 2 cs C INTERNALLY 5 MS HI 3 rs MS HI 2 BR RD RD WH OR Oo 7 04 coca ios a H1 1 oR CPR HI 1 BR RD oo n 10 2 MS L0 3 x ls on BK BK WH CPR LO OE i
16. COMM unit specific Y Model _ COOLING CFM options COOLING CFM COOLING 31 3T 3T 1 4T 2T 297 4 37 3T 3T 3 T 2T 2 T Y SAT 3 T 2T 2 T 3T PER TON gt PER 4T 4T 5T 3T 3ZT 400 400 430 E 290 310 330 350 370 65 5T 5T 3T 4T HEAT unit specific Y i Model HEAT CFM options FACTORY DEFLTS j FACTORY DEFLTS 31 1130 1130 1350 700 1000 NO NO YES 37 1100 1100 1450 600 900 Y tT 40 1100 1100 1400 600 900 EXIT EXIT 49 1400 1400 1700 800 1100 NO NO YES 65 1500 1500 1800 900 1200 Y Information Menu Information Options MODEL NUMBER gt MODEL unit specific Can be 31 37 40 49 62 65 SERIAL NUMBER SERIAL NUMBER 1 SYSTEM STATUS Options SYSTEM STATUS gt SYSTEM STATUS OFF t ON FAN REQUESTED CFM gt REQUESTED CFM REQUESTED CHI 0 Rum ON CLG HIGHEST ACTIVE COOLING STAGE t ON HP HIGHEST ACTIVE HP STAGE LAST 4 FAULTS LAST 4 FAULTS ON HT NO ALERTS Y t 4 HIGHEST ACTIVE HP STAGE INDOOR ALERTS gt INDOOR ALERTS E NO ALERTS An open box O designates a contractor sensed but not energized A closed box designates a contactor that is UNIT TEST UNIT TEST energized present or not A hyphen designates a NO INO YES conta
17. N A 15 Flash 5 Flash N A N A None 5 Flash A N A N A N A N A N A N A N A Device count 6 Flash 11 Flash 13 Flash 2 Flash N A 3 Flash N A 4 Flash Flame detected should not be present Duplicate zone Another zone is present with the same zone number _______ air filter timer is present Another air filter timer is present Discharge Air Sensor Open Error Voltage too low Voltage too high Ambient Temperature Sensor Fault Out of Range Open or Shorted Coil Temperature Sensor Fault Out of Range Open or Shorted Liquid Temperature Fault Out of Range Open or Shorted External ODT Sensor Fault Out of Range Open or Shorted Defrost Fault A Defrost Fault B and or C Defrost Fault A and B and or ERR 79 N A 7 Flash N A LPCO Fault Open outside of defrost Cycle ERR 87 ROLLOUT OPEN 4 Flash Device count Open flame rollout N A GND FAULT 6 Flash Device count Occurs when proper earth ground is not detected ERR 89 N A SYS COMM CRC IND COMM CRC BLW COMM CRC N A 10 Flash N A Fast Flash Comm system unrecognized response Inducer Motor unrecognized response Blower motor unrecognized response Communication Busy Fault SYS COMM CRC 3 Flash Fast Flash COMM System Busy Error BLW COMM CRC 3 Flash N A Serial Motor Communication Busy Error Communication Busy Fault N A 1 Fla
18. Safety Hazard Sharp Edge Hazard Be careful of sharp edges on equipment or any cuts made on sheet metal while installing or servicing Personal injury may result Where there is no complete return duct system the return connection must be run full size from the furnace to a location outside the utility room basement attic or crawl space Do NOT install return air through the back of the fur nace cabinet Do NOT install return air through the side of the fur nace cabinet on horizontal applications NOTE Minimum return air temperature is 55 F A CAUTION CONTAINS REFRIGERANT SYSTEM CONTAINS OIL AND REFRIGERANT UNDER HIGH PRESSURE RECOVER REFRIGERANT TO RELIEVE PRESSURE BEFORE OPENING SYSTEM Failure to follow proper procedures can result in personal illness or injury or severe equipment damage CAUTION LABELING WIRES LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING CAUTION BURN HAZARD DO NOT TOUCH IGNITER IT IS EXTREMELY HOT All information contained herein is subject to change without notice Communication Controls Theory Of Operation The indoor thermostat indoor unit outdoor unit and other accessories communicate using two of the three thermostat wires required in this type of installation The three wires are the Data line D Common Line B and 24VAC Power Line The
19. Silicon Nitride Ignitor Learning Routine IFC Inducer Motor Learning Routine Sequences 19 Fault DeteGctlOr eene ren eacus rta ee EY e 19 Contingency Operating Mode User Interface Display Navigation Tree s Gas Valve Adjustment Procedure 24 UnitTest 25 Venting Table i127 Sequence of Operation 24528 Pressure Switch 30 Pressure Switches Interconnecting 31 Pressure Switch Operating Pressure Chart ni Furnace Trouble Shooting Checklist 34 Furnace Alert Code Addendum 36 Communicating Air Handler 37 Communicating Mode Drawing 39 User Interface Display 41 Air Handler Sequence of Operation amp LEDs Identification 42 Unit Test Mode 2 einer tnis wD Fault LED and Error Code Addendum 46 Air Handler Trouble Shooting Checklist 47 Communicating Two Compressor Outdoor Units cech eant 48 Charge Assist Control 49 Internal Refrigerant
20. cycle and return the control of the system to the Communicating Comfort Control The Green Status LED will be slowly flashing The CHARGED Green LED will stay ON for 1 hour STEP 5 ADD Routine If the CA control determines refrigerant is required the ADD Amber LED will turn ON and the Green CHARGED LED will begin FLASHING according to the CHARGED Green LED flash Rate Schedule Green Charged LED Blink Rate 1 sec ON OFF means the system is less than 20 PSI off target 3 4 sec ON OFF means the system is greater than 15 PSI off target 1 2 sec ON OFF means the system is greater than 10 PSI of target 1 4 sec ON OFF means the system is greater than 5 PSI off target The Green CHARGED LED will not start to blink until the system pressure is within 20 PSI of the target pressure Note For Automated charging use BAYCAKTOO1AA When utilizing a Charging accessory Solenoid Kit BAYCAKTOO 1 refer to the instructions in the kit for proper hook up When the Amber ADD LED is ON the CA control board provides a 24VAC power for the accessory solenoid The CA control will turn off the 24VAC power when the Amber ADD LED goes off When refrigerant is being added the CA control will exit the charge assist cycle if the liquid line pressure does not increase by 4 psig in 50 minutes or if the liquid line pressure does not get within the 20 psig of the required charged pressure within 1 hour Note For Manual Charging Once s
21. 1 25 W C 1 19 0 97 W C 1500 4400 C342634P62 PS3 SWT02979 2 25 W C 2 28 1 93 W C 2300 5200 C342634P62 UH3B100AC PS1 SWT03073 0 76 W C 0 05 W C 1200 3600 D342606P05 White PS2 SWT02979 1 25 W C 1 19 0 97 W C 1500 4400 C342634P62 PS3 SWT02979 2 25 W C 2 28 1 93 W C 2300 5200 C342634P62 DH3B100AC PS1 SWT03070 0 76 W C 0 05 W C 1200 3600 D342606P02 White PS2 SWT02979 1 25 W C 1 19 0 97 W C 1500 4400 C342634P62 PS3 SWT02979 2 25 W C 2 28 1 93 W C 2300 5200 C342634P62 UH3B120AC PS1 SWT03074 0 65 W C 0 05 W C 1200 3600 D342606P06 Yellow PS2 SWT02980 1 25 W C 1 19 0 97 W C 1500 4400 C342634P63 PS3 SWT02980 2 10 W C 2 12 1 79 W C 2300 5200 C342634P63 DH3B120AC PS1 SWT03071 0 65 W C 0 05 W C 1200 3600 D342606P03 Yellow PS2 SWT02980 1 25 W C 1 19 0 97 W C 1500 4400 C342634P63 PS3 SWT02980 2 10 W C 2 12 1 79 W C 2300 5200 C342634P63 Note The first stage pressure switch comes as an assembly with the H Fitting connected to it Honeywell Orifice A Orifice B Part No 005 005 Orifice D343192P01 50014119 001 033 032 White D343192P02 50014119 002 033 035 Yellow N White Housing D343192P03 50014119 003 033 039 Blue SES 1 N Black Housing N y N Orif
22. 2 Not Adjustable 35 0 2 80 0 7 0 2 Not Adjustable 35 0 2 100 0 7 0 2 Not Adjustable 35 0 2 120 0 7 0 2 Not Adjustable 3 5 0 2 Manifold pressures apply for both Natural Gas amp Propane applications Note Gas valve adjustment and manifold pressure settings on these model furnaces will be the same for both Natural Gas and LP The only change to the furnace for operation to LP will be burner orifices 51 for LP Refer to LP Conversion instructions for more detailed information All information contained herein 32 is subject to change without notice Gas Furnace Pressure Switch Matrix Chart Replacement Operating Close Open MIN MAX Factory Part Color of Number Pressure Range Inducer RPM Number H Fitting Label UH3B060AC PS1 SWTO03072 0 55 W C 0 05 W C 1200 3600 D342606P04 Blue PS2 SWTO02978 0 88 W C 0 81 0 61 W C 1500 4400 C342634P61 PS3 SWT02978 1 60 W C 1 57 1 31 W C 2300 5200 C342634P61 DH3B060AC PS1 SWT03069 0 55 W C 0 05 W C 1200 3600 D342606P01 Blue PS2 SWT02978 0 88 W C 0 81 0 61 W C 1500 4400 C342634P61 PS3 SWTO02978 1 60 W C 1 57 1 31 W C 2300 5200 C342634P61 UHS3B080AC PS1 SWTO03073 0 76 W C 0 05 W C 1200 3600 D342606P05 White PS2 SWTO02979 1 25 W C 1 19 0 97 W C 1500 4400 C342634P62 PS3 SWT02979 2 25 W C 2 28 1 93 W C 2300 5200 C342634P62 DH3B080AC PS1 SWTO03070 0 76 W C 0 05 W C 1200 3600 D342606P02 Yellow PS2 SWTO02979
23. 62 is subject to change without notice Go No GoTest for Serial Port V S Blower Motor Step 1 Remove power from the gas furnace or the air handler Unplug the serial port variable speed motor low voltage plug from the motor Connect 24 Volt AC test harness to the serial port variable speed motor low voltage plug as shown and connect red and blue wires to the 24 Volt AC Air Handler Control Board Furnace IFC DO EM 98 une E8 Plug La e ES NEUTRAL BEREBER CIRCULATOR 2 898989 Go OOP Je ES 9 9 Ic St o 9 bcn rr ae e ee ee Indicates a male spade terminal RTN Return air sensor plug DA Discharge air sensor plug terminals BK PWM blower speed terminal 550 089 20 J G 9 VS COMM Plu BEBO g 0 D R B C Y1 24 Volt AC Test Harness 34 3454 01 Serial Port V S Blower Motor Connect to 24 Volt AC BLUE WIRE Step 2 Restore power to the gas furnace or the air handler and go to step 3 All information contained herein 63 is subject to change without notice Go No GoTest for Serial Port V S Blower Motor St
24. 93 Device count Control tried to turn on gas valve but 24V not sensed Solid ON i Control senses 24V present at the gas valve when it Gas Valve Fault Y1 Relay Failure INT GV ERR should not be present Y1 OFF ERR Y1 Output OFF when it should be ON ERR 101 Y7 ONERR None Device count ERR 101 Y1 ON ERR 7 Flash N A Y1 Relay Stuck Closed Error Y1 OFF ERR Y1 Relay Stuck Open Error 1 Output ON when it should be OFF N A 10 Flash N Y2 without Y1 Miswire 24 volt mode only Y1 Relay Fault Y2 without Y1 Miswire 24V mode onl Heater Relay Fault ERR 104 HT ON ERR 4 Flash N A Heater Relay Stuck Closed Error Heater Relay Fault ERR 104 HT OFF ERR 4 Flash N A Heater Relay Stuck Open Error ERR 105 HT LK ON ERR 4 Flash N A Both Interlock Relay amp Heater Relay Stuck Closed Error Heater Interlock Relay Fault ERR 105 INTLK ON ERR 4 Flash N A acd Closed ERR 105 NTLK OFF ERR 4 Flash N A Interlock Relay Stuck Open Error External Shutdown Fault ERR 106 EXT SW OPEN 1 Flash N A External Shutdown Input Open Error Return Air Sensor Fault x N A RAS SHORT 6 Flash N A All Sensor Short Error RAS OPEN Return Air Sensor Open Error Liquid Pressure Sensor Fault N A 12 Flash N A Liquid Pressure of Range Open PM Data Corrupt Error PM Bad or Missing Fault ERR 114 PM Missing Error ID MTRERR 2 Flash Motor Mismatch Error CAP MISMATCH Comp
25. Assist need to recover refrigerant ADD AMBER LED System requires refrigerant charge Control has turned on the 24 volt AC output Use ON Charge Assist Tool BAYCAKT001AA All information contained herein 61 is subject to change without notice Outdoor Units Communicating Systems Trouble Shooting Checklist Note The Alert number or text will not be displayed at the Comfort Control or the User Interface Display Comfort Control Fault LED interface Possible Causes Display 1 Flash Standby or No 24 Volts AC to Control ERR 90 Excessive Communication CRC Errors ERR 91 No Communication Defrost Fault A See Defrost Control Service Procedure Section Defrost Fault B and or C See Defrost Control Service Procedure Section Defrost Fault A and B and or C See Defrost Control Service Procedure Section 2 Flash 3 Flash 4 Flash Ambient Temperature Sensor Fault Out of Range Open or Shorted Note 1 Coil Temperature Sensor Fault Out of Range Open or Shorted Note 1 Low Pressure Cut Out LPCO Fault Open outside of Defrost Cycle Y2 without Y1 Miswire 24 Volt mode only 5 Flash 6 Flash 7 Flash 10 Flash Liquid Temperature Fault Out of Range Open or Shorted Note 2 Liquid Pressure Sensor Fault Voltage Out of Range Open or Shorted Note 3 13 Flash External ODT Sensor Fault Out of Range Open or Shorted Note 4 ERR 114 14 Flash B
26. Furnace IFC INDUCER 7 N 88 a La 9 9 NEUTRAL J amp PEBE CIRCULATOR 2 8 9888 ca O Ey Green Status LED 8 9 9 uis rx ED o E Red Fault LED Fault LED 9 8lA D RBCY1 All information contained herein is subject to change without notice 92 System Communication Trouble Shooting Step 9 Does the outdoor unit Charge Assist control Charge Assist Board have 24 volts AC at plug J2 terminals R and B x GO ESSURE OUT OF RANGE Note When any of the Charge Assist LEDs Ga or flashing this only indicates that move some low voltage AC is present Check the 24 oo volt AC supply with a volt ohm meter r 1 3 ADD REC STATUS YES Go to step 10 a NO 24 volts AC is supplied by the outdoor unit s transformer Repair replace as DATA R B needed 1 2 PWM of Step 10 Does the outdoor unit Charge Assist control Charge Assist Board fault LED show a fault flash code of 1 f
27. Not in CA Mode CHARGING Amber HORE 3 Flashing See Stabilization Blink Rate RECOVER On Red Need to recover refrigerant unit locked out for 1 hour or press mode button to exit Charge Assist ADD On Amber System requires refrigerant charge Control has 24 volt AC output to Charge Solenoid Y1 On 151 stage compressor requests Y2 On 2nd stage compressor request Fast Flash At Power Up 20 seconds STATUS Slow Flash Green Standard operation Off Charge Assist mode or no power to control LitePort For transmitting LitePort data 4 highest priority Faults display flash codes sequentially 2 second pause between faults and 4 second pause between sequences Cycle power to ODU to clear Faults All information contained herein 73 is subject to change without notice Chart 1 Coil and Ambient Temperature Sensors Ambient Sensor Coil Sensor Thermistor Volts D C at Plug Resistance OHMS J 6 amp J 7 ONLY 0 17 78 83246 63 3 292 5 15 00 71108 25 3 110 10 12 22 60916 37 2 925 15 9 44 52332 78 2 739 20 6 67 45075 79 2 553 25 3 89 38926 99 2 370 30 1 11 33703 02 2 191 35 1 67 29253 02 2 019 40 4 44 25452 49 1 854 45 7 22 22198 45 1 697 50 10 00 19405 43 1 550 55 12 78 17002 31 1 412 60 15 56 14929 80 1 284 65 18 33 13138 29 1 166 70 21 11 11585 68 1 057 75 23 89 1023751 0 958 80 26 67 9064 99 0 867 85 29 4
28. Piping 49 Field Refrigerant Piping iD 1 1790 Low Ambient Cooling Manual Charging Instructions R 22 A C Charging Charts Schematic Diagrams eese 52 R 22 H P Charging Charts esee 54 H P Schematic Diagrams Charge Assist Sequence of 56 Charge Assist LED Indications Charge Assist Procedure Details Charge Assist Tool 59 Charge Assist Procedure for a Non Communicating 24 VAC Control 5 58 60 Charge Assist LEDs Summary 61 Charge Assist LED Flash and ERR Code Checklist 62 Trouble Shooting GO NO GOTest for Serial V S Blower Motors 63 Quick Field Test of a Serial Port V S Blower Motor 65 Charge Assist Control Trouble Shooting 67 Charge Assist Control Fault LED Flash Code and Trouble Shooting 69 Outdoor Unit s Alert Code Addendum 73 Coil and AmbientTemperature Sensors 74 Liquid Line Temperature Sensor Temperature Resistance
29. SWITCH 2 LIQUID DIP SWITCH 1 DIP SWITCH 2 DIP SWITCH 2 TEMP F LOWER MIDDLE UPPER 55 102 105 109 60 113 117 122 65 126 135 70 139 148 75 152 162 80 167 177 85 182 193 90 197 209 95 213 226 100 230 244 105 248 262 110 266 281 115 285 301 120 305 321 125 325 342 All information contained herein 53 is subject to change without notice Field Wiring Hook Up Diagrams and Charging Chart 2 5 Ton Heat Pump Models Only SCHEMATIC DIAGRAM TO POWER SUPPLY PER UNIT NAMEPLATE AND LOCAL CODES A TOL ee PURPLE WH BK CSR C MS HI 3 ML MS amp MS LO 3 BR ont somone oe CR LO 0 105 5 10 1 T R SUMP HTR SUMP HTR BLe O 0 0 0 4 8L o CB CBS 6 2 KS o EO 005 gt BK eh ma i Lem LLS aby Sy NP TRD 29 D MS LO l 5 2 Oo LPCO HL LPCO m o baie i YLIBR Ee ene eae R 22 Refrigerant Charging Chart 2 5 3 amp 4 Ton Heat Pump Models ONLY Liquid Gage Pressure PSIG LIQUID TEMP F DIP SWITCH 1 DIP SWITCH 2 DIP SWITCH 2 LOWER MIDDLE UPPER 55 105 109 114 60 117 122 126 65 130 135 139 70 143 148 153 75 157 162 168 80 172 177 183
30. Stage 1 1200 3600 Stage 2 1500 4400 Stage 3 2300 5200 Inducer RPM are the same for all models All information contained herein is subject to change without notice Three Stage Gas Furnace Standy Screen MODEL NUMBER gt SERIAL NUMBER Information Menu SERIAL NUMBER v v PART LIST Interface Display Troubleshooting Setup Menu Setup Options Current Setting COOLING CFM COOLING Shown only 1 207 24T 1 T 2T 3T when communicating outdoor unit is not CFM PER TON CFM PER TON detected 400 400 350 450 HEAT CFM HEAT OFF DLY 1350 1350 1125 1000 700 HEAT OFF DLY FACTORY DEFLTS 100s 100s 140 180 60 FACTORY DEFLTS NO NO YES EXIT MODEL NUMBER v SYSTEM STATUS REQUESTED CFM LAST 4 FAULTS INDOOR ALERTS UNIT TEST gt TEMP SENSOR _ gt v MOTOR RPM INDUCER RPM RESET LST FAULT gt CLEAR LITEPORT gt gt PM SERIAL NUM v CNTNGNCY MODE v EXIT ES c JEXT NO NO YES Information Options MODEL UH3B060ACV3VA SERIAL 61234567 SYSTEM STATUS OFF REQUESTED CFM 0 CFM LAST 4 FAULTS NO ALERTS INDOOR ALERTS NO ALERTS UNIT TEST NO NO YES TEMP SENSOR Not Availab
31. combinations The number of cooling stages can be selected via the User Interface The air handler is shipped for single stage operation When only one stage of Cooling is selected the indoor blower speed will default to Cooling HI fan speed When two stages of Cooling are selected the 1st stage CFM can be selected via the User Interface Assembly In addition the control will ignore Y2 when Y1 is not present If one stage of Cooling is selected Y2 input will be ignored by the air handler control The Cool On Delay selectable will begin when both Y1 amp are present When the Y1 amp inputs removed the blower will turn off after the Cool Off Delay selectable has timed out Note The input must be present for cooling mode to allow blower speed changes for dehumidification i e Fan Pre Run and Short Run Blower Operation vs Y1 amp Y2 Inputs A C amp Heat Pumps table 2 Y2 Y1 Single Stage 2 Stage OV OFF OFF oV 24V HI LO 24V OV OFF OFF 24V 24V HI HI Heating Operation The Air Handler control will operate blower for Heat Pump stages Mechanical Heating the same as in cooling mode Reference table 2 above If W1 W2 or W3 without Y1 Y2 or G signals are present the control will turn on the blower even if the G signal is not present The control will energize the blower in the heating speed There is no blower On or Off Delays in Electric Heat mode the Coolin
32. consists of 6 Replace the control compartment cover panel the 4 wire plug assembly J1 Disconnect remove the red wire and fuse assembly from the transformer 7 Reconnect power which was disconnected in step 1 the blue lead from the transformer the green yellow transformer ground wire the brown wire going out 8 Please retain communication harness and trans to field connections the blue wire going out to field former for possible future use connections and the double blue wire connection terminal at the lo contractor coil Also disconnect and remove the two transformer primary wires brown red wire coming from the start capacitor and the black blue wire coming from the hi contractor The transformer is no longer used and should be removed HI Contactor 4 Connect the 24 volt harness supplied with the kit to LO Contactor the control board where the communicating harness was removed connector J1 Take the double blue lead terminal and connect to the lo contractor coil where the previous blue lead was removed Route the remaining yellow blue orange red black and yellow red wires out for field connection as shown ChargeAssist Control J1 Plug If the unitis a cooling only model not a heat pump the orange and black leads will not be used and should be capped off Transformer The table below defines maximum total length of low voltage wiring from the outdoor unit to the indoor unit and to the Comfort Cont
33. control will now check the operating Conditions before continuing the CA Mode Note Pressing the MODE button at any time will stop the CA Mode cycle The CA control will then begin slowly flashing its Green STATUS LED indicating that the CA control is now in its normal operating cycle Next Outdoor Temperature ODT must be above 65 If ODT is below 65 F the ODT OUT OF RANGE Red LED will flash ON and OFF for 30 seconds This error condition causes the CHARGING STABILIZING Amber LED to flash 2 times The CA control will then exit the CA mode and the Green Status LED begins to flash slowly Next Liquid Line Temperature must be within range If this sensor is shorted or open this error condition causes an 11 flash Fault LED Next Liquid Line Pressure must be above 50 psig R 22 systems If the liquid pressure is below 50 psig The LOW PRESSURE Red LED will flash for 30 seconds This error condition causes the CA control to flash its CHARGING STABILIZING Amber LED 2 times The CA control will then exit the CA mode and it then begins flashing its Green Status LED slowly Note 65 F to 100 F is the operational limit of Charge Assist Charge Assist will work above 100 F but the results may not be as accurate as desired The service technician will need to recheck the system charge when temperatures are between 65 F to 100 58 STEP 2 Enter Stabilization Routine The CHARG
34. display WAIT then model and serial number e Set up the furnace in the contingency mode of operation at the User Interface Assembly for the first stage of heat with a 50 duty cycle See contingency mode of operation for additional details Hook Up Diagram NOTE 1 CONNECTS TO BURNER BOX 7 PRESSURE HOSE yr FIELD SUPPLIED T POSITIVE PRESSURE PORT CONNECTS TO BURNER BOX PRESSURE PORT NEGATIVE PRESSURE PORT CONNECTS TO RECOUP CELL PRESSURE PORT FIRST STAGE GAS PRESSURE ADJUSTMENT SCREW See Note 1 Remove 120 VAC power from the furnace DO NOT re power the furnace until the Green LED on the Inducer Motor Drive Board goes out Apply 120 VAC power to the furnace The furnace User Interface will display WAIT and then the display will change to the Contingency Mode STG 1 50 Let the furnace go through First Stage learning routine and its temperature rise stabilize The temperature rise and learning routine will take four minutes Read the first stage manifold gas pressure after the furnace s temperature rise has stabilized If needed adjust the gas valve s first stage of heat pressure adjustment screw to obtain the correct first stage pressure Use Final Manifold Pressure Settings table for the correct first stage pressure reading in inches of Water Column pressure User Interface Assembly INLET GAS PRESSURE PORT MANIFOLD GAS PRESSURE PORT PORT CONNECTS T
35. for the system to stabilize and again take the Liquid Line Temperature Note 55 F to 100 F is the operational limit of charge of Charge Assist Charge Assist will work above 100 F but the results may not be as accurate as desired The service technician will need to recheck the system charge when temperatures are between 55 F to 100 SUBCOOL CHARGING TABLE CORRECTIONS FOR LINE LENGTH AND RISE MAX LIFT Dip Switch 2 On 10 Dip Switch 0 1 On 10 Eu Zw zu ous tr LL Lu 2 c 51 Dip Switch 3 On 30 40 60 20 5 TOTAL REFRIGERANT LINE LENGTH FEET All information contained herein is subject to change without notice Field Wiring Hook Up Diagrams and Charging Chart 2 5 Ton Cooling Models Only SCHEMATIC DIAGRAM TO POWER SUPPLY PER UNIT NAMEPLATE AND LOCAL CODES oe COOLING ANTICIPATOR LPCO LOW PRESSURE CUTOUT SW wil CONTROL BOARD MS COMPRESSOR MOTOR CONTACTOR 1 a CBS COIL BOTTOM SENSOR ODA OUTDOOR ANTICIPATOR CF FAN CAPACITOR OFT OUTDOOR FAN THERMOSTAT 1 CH WIRE CONNECTOR ODS OUTDOOR TEMPERATURE SENSOR i CPR COMPRESSOR ODT OUTDOOR THERMOSTAT CR RUN CAPACITOR P TRD PRESSURE TRANSDUCER 2 CS STARTING CAPACITOR RHS RESISTANCE HEAT SWITCH SUMP HIR CSR CAPACITOR SWITCHING RELAY 5 SWITCHOVER VALVE SOLENOID BLACK m BLACK DFC DEFROST CONTROL SYSTEM ON OFF SWITCH 2 F INDOOR FAN RELAY TOL DISCHARGE LINE THERMOS
36. indoor unit s transformer provides 24 Volt AC Power to itself and the thermostat The outdoor unit has its own 24VAC transformer and will only require the Data Line and the Common Line for operation Three wires needed between the indoor unit and thermostat D R amp B Two wires needed between the indoor and outdoor unit D amp B The communicating system is a microprocessor based system which operates as open communications system This type of control system can be expanded easily When an additional item is added to the control system and powered up such as a communicating IFD air cleaner Telephone Access Module TAM or a communicating humidifier it will establish communications automatically with the other components in the system Each component in the system has a pre assigned electronic address V S Indoor Blower Speeds are automatically set when the Outdoor Unit is a communication type The Cooling CFM per ton and the Heating CFM can be changed at the Air Handler or Gas Furnace User Inter Face display When the system is operating all operational messages and alerts will be sent on the data line to all communicating components in the system All compatible components can read and send messages on the data line The Air Handler or the Gas Furnace control will be the Bit Master in a communicating Comfort Control system The Bit Master can be considered to be the system clock It places timing pulses
37. is a heat pump the Charge Assist Control is also the defrost control Internal Refrigerant Piping These series of two compressor units have several additions items added to the air conditioning condenser refrigerant circuit These additions make possible the use of two compressors in a single refrigerant system For the technician an understanding of these additional items is needed when normal service is performed 49 The two compressors are joined by an oil level management tube which ensures a correct oil level in both compressors As the oil circulates with the refrigerant it must be returned to the compressor in operation in order to both cool and lubricate it Since the smaller or first stage compressor operates more frequently the oil will be used more often in its system The larger compressor works less often and therefore the oil level must be monitored to see that an adequate supply is always available for its use The oil level management tube is connected on both ends by Rotolock fittings to the two compressors in the same way the suction and discharge lines are connected The same care must be used in tightening these Rotolocks as the original ones When changing a compressor raise the oil line up to prevent oil loss from the good compressor Rotolocks All Compressor Lines All information contained herein is subject to change without notice Outdoor Units Refrigerant Pipe Sizing R
38. of AC sine wave cycles is raised four steps up to increase the ignitor temperature If for some reason flame is still not proven on this retry for ignition the IFC then raise the AC Sine wave cycles four steps up F 2400 4 steps up still no light Failure to ignite 4 more steps light or lock out Stay 2200 here if it lights 2000 1800 263 265 267 269 271 273 275 277 279 TF If the flame is proven the IFC will keep this step setting If flame is not proven the IFC locks out for one hour On a power interruption the furnace control starts the igniter power at the high side of it s range and repeats the learning routine The furnace IFC will call for heat and a trial for ignition is initiated If flame is not detected the IFC will recycle the furnace two more times before lockout This learning process is employed to provide the most reliable ignition process and to extend the service life of the ignitor This control requires the correct polarity of the 120V A C wiring and a ground connection If the line voltage is low or the line polarity is reversed the IFC control will lock out the heating cycle and cause the Red Fault LED to flash six times This Ignitor can only be checked by using a OHM Meter and reading it s Resistance A good ignitor reads 11 18 ohms A bad ignitor will have a much higher resistance All information contained herein is subject to change without notice Thr
39. on the data line to indicate to the other connected devices exactly when their data bits can be transmitted on the data line bus All information contained herein is subject to change without notice Communication Controls Theory Of Operation 900 Series Comfort Control nn RR E The communicating system s comfort control is a true thermostat sensing indoor dry bulb temperature and relative humidity When the thermostat senses the in door air temperature or humidity has changed from the set point it will send an operational message on the data line All units that are connected to the data line will read this operational message The unit or units being called for will start and run on first stage a gas furnace will start in the second stage of operation and then go back to the first stage of operation The thermostat also sends blower speed information Operation is similar to a standard two stage thermo stat When the indoor temperature does not move back towards the thermostat set point in a given time period or the temperature continues to move away from the set point the thermostat will change its op erational message on the data line The new message will be a call for the next stage of operation When the indoor temperature moves back towards the set point the thermostat will again change its operational mes sage on the data line and the units running will then go back to first stage of operation When the indoor t
40. once and there will be a several second delay before the gas furnace s Inducer motor and indoor blower is shut down The User Interface Assembly will display CHECK FUSE when the last four faults are displayed All information contained herein is subject to change without notice Variable Speed Indoor Blower Motor Operation Serial Port Communication The Serial Port Communication type of variable speed motor operates the same as the 24 volt controlled V S type except the on off control and speed signals are now a digital command signal The Motor module re ceives the command signal and replies back to the in door product control board This type of motor module is not preprogrammed at the factory The horsepower operating speeds maximum RPM and direction of ro tation information are stored in the Personality Mod ule which is located on the Gas Furnace Control IFC or an Air Handler Control AHC When the system is powered up the V S Motor programming informa tion stored in the Personality Module is sent to the V S Motor module The Serial Port Communication V S Motor has four low voltage wires plugged into it The four wires are 1 The TX wire which is used to send all digital information 2 The RX wire which is used to receive all digital information 3 24 Volt AC and DC common wire 4 12 Volt DC wire The 12 volts are supplied by the IFC or AHC control and used to power the input and output circuits
41. optic couplers in the V S Motor V S Motor IFC or IMDB RX TX TX RX Common Common 12 Volt gt gt gt 12 Volt Single phase 120 or 240 volts AC power is applied to the motor module and IS NOT turned on or off by the IFC or AHC The V S Motor module converts the AC power to DC power Some of the DC voltage is reduced to power the microprocessor inside the V S Motor module A communication fault will appear if line volt age is removed from the V S Motor module and the IFC or AHC system is then repowered When blower operation is called for the V S Motor module turns the DC power on and off to each leg of its three phase mo tor in a rotating manner The V S Motor Module will increase the voltage and number of Hertz it applies to its three phase motor to increase its speed or de crease the voltage and Hertz to slow it down The V S Motor module monitors the motor s RPM and power and compares this information to its programmed in formation If the RPM and power do not align with the programmed information the V S Motor module will change its output voltage and Hertz to bring the airflow back in line with its program All information contained herein is subject to change without notice Three Stage Gas Furnace HIGH TEMPERATURE LIMIT SWITCH ELECTRICAL JUNCTION BOX 2ND STAGE PRESSURE SWITCH 3RD STAGE PRESSURE SWITCH TRANSFORMER VENT MOTOR DRIVE BOARD INT
42. second stage LEARNED SPEED The furnace IFC flashes its Red Fault LED three times repeatedly No Alert message is sent to the comfort control thermostat The furnace IFC will keep operating at second stage of heat until the thermostat sends a different signal When the furnace IFC sees PS 3 close it signals the V S indoor blower to operate at its third stage heating airflow The furnace IFC enters a time delay so the heat exchanger and the recuperative cell warms up to its third stage operating temperature At the end of this time delay the inducer s discharge air temperature will be at its third stage operating temperature and the density of the products of combustion will be stabilized The furnace will now signal the IMDB to reduce the inducer speed in steps until PS 3 opens When PS 3 opens the furnace IFC will NOTE this Inducer Motor RPM The furnace IFC then adds an additional number of RPM to the third stage NOTED RPM The furnace IFC will now store this learned operating inducer RPM in its memory and use it for third stage heat calls it receives in the future The IFC will now signal the Inducer Motor Drive Board to increase the Inducer Motors speed to its learned RPM for third stage operation All information contained herein is subject to change without notice Three Stage Gas Furnace Faults Detected During Third Stage Learning Routine If PS 3 is closed the furnace IFC will send a signal to the IMDB to sl
43. set up may be required at the indoor thermostat for approved equipment combinations and their accessories reference page 6 Approved Combinations The information supplied by the outdoor unit is used by the indoor unit to set up the indoor blower airflow CFM and any delays needed The thermostat uses the information from the indoor and outdoor units to configure the thermostat for the number stages of compressor operation Air Conditioner or Heat Pump type of heat fossil fuel or electricity and number of stages of heat installed No dip switches to set Fault Detection amp Alert Signaling The thermostat indoor and outdoor units can provide notification of system faults When a fault is detected by the indoor unit outdoor unit or thermostat a coded message is sent on the Data Line to the thermostat and will be displayed as an Alert The thermostat will turn on the red Service LED and the display will switch back and forth between the main screen and an Alert screen The Alert screen will show the diagnostic Err code number When multiple fault codes exist at the same time it will cycle through up to 5 max by showing the next code each time it comes to the diagnostic screen The thermostat will not switch back and forth when on any other screen The service LED will not be used for signaling emergency heat or anything else when the thermostat has received an Alert message Communication between Furnace IFC and V S Mot
44. the Liquid Line Temperature Sensor Fault LED Flash Code of 12 The fault LED will be flashing in groups of twelve flashes This indicates that the Liq uid Pressure Sensor is reading out of range 1 Read the DC voltage at the Liquid Line Pressure Sensor plug J9 test point and the 24 AC volt common terminal T5 with the sensor plugged in 2 Read the liquid line pressure with a calibrated high pressure gage Does the liquid line pressure and the DC voltage read at the Liquid Pressure Sensor plug J9 test point VP and the 24 volt AC terminal T5 agree with the pressure shown on the liquid line pressure and voltage chart 43 Note The pressure transducer is only used by the Charge Assist Control during the charge assist cycle YES Replace the Charge Assist Control NO If there is 4 9 volts DC between the black common wire and the red power wire at pressure plug J9 and the pressure and voltage measured do not match the liquid line pressure and voltage chart replace the pres sure transducer If there is no voltage between the black common wire and the red power wire or the 4 9 volts DC is lower than 4 9 volts DC unplug the transducer and recheck the voltage at plug J9 If the voltage at the pressure plug J9 with the pressure transducer unplugged now reads 4 9 volts replace the transducer If the voltage at the pressure plugs remains low when the transducer is unplugged replace the Charge Assist Control R Yi B J10 COILT AMBIENTT EXT ODT
45. user interface scroll down to the INDOOR ALERT screen Press the nterbutton to see the alert message What is now displayed If IND COMM ERR is displayed go to chart F 2 If BLW COMM ERR is displayed go to chart F 3 If NO ALERTS is displayed go to step 9 All information contained herein 90 is subject to change without notice System Communication Trouble Shooting Step 6 Check the thermostat wire going to the Comfort Sensor The B thermostat wires going from B terminal at the furnace IFC or air handler terminal board must go to the B terminal on the Comfort Sensor If the B and R wires are crossed the Comfort Sensor will have a display but it will not communicate and Err 91 will be displayed Check for 10 to 12 Volts DC at the thermostat sub base terminals D and B This voltage comes from the furnace IFC or Air handler control board Is the Comfort Sensor wired correctly and is the10 to 12 Volts DC present YES Go to step 7 NO Repair or replace the thermostat wire VOLTS D C Step 7 Turn power off to the furnace or air handler Disconnect the Comfort Sensor and sub base and reconnect it to the furnace IFC or air handler terminal board with a short piece of thermostat wire Disconnect all other wires connected to the D terminal at the furna
46. will now signal the Inducer Motor Drive Board IMDB to increase the Inducer Motors IMDB and speed to its learned RPM for first stage operation The IFC signals the indoor V S blower to operate at the programmed first stage heating airflow Whenever the furnace is powered up or after a RESET the furnace IFC will not go through a learning 20 routine for the third stage of heat until it receives a call for the third stage of heat Third Stage Inducer Learning Routine When the furnace IFC receives a digital signal for the third stage of heat from the comfort control thermostat it will begin the inducer motor learning routine for third stage heat The furnace will start the heating cycle in second stage if not already on and then begin the third stage learning routine The furnace checks Pressure Switch Three PS 3 it must be open When the furnace IFC sees PS 3 open it will send a digital signal to the Inducer Motor Drive Board IMDB to run the inducer motor at the preset factory third stage RPM The furnace IFC looks for the PS 3 pressure switch to close The furnace IFC will continue to signal the IMDB to increase the inducer motors speed in steps if PS 3 does not close when the preset factory third stage RPM is reached The maximum RPM for the third stage heat is set at 5200 RPM If PS 3 is not closed when the Inducer reaches 5200 RPM the furnace IFC will signal the IMDB to reduce the inducer motor speed in steps to its
47. 1 52 101 1 62 111 1 72 120 1 81 130 1 91 140 2 03 152 2 13 161 2 23 171 2 33 181 2 43 190 2 52 200 2 65 212 2 74 222 2 84 231 2 94 241 3 04 250 3 14 260 3 26 272 All information contained herein 76 is subject to change without notice Chart 4 External Accessory Temperature Sensor BAYSENO1ATEMPA T deg F T deg C External Thermistor Volts D C at EXT ODT Resistance OHMS Terminal Board TB1 Only 0 1778 85137 6 828 5 15 00 72741 6 3 7 10 12 22 62326 4 3 5 15 9 44 53550 0 3 4 20 6 67 46133 2 32 25 3 89 39848 1 zu 30 1 11 345073 2 9 35 1 67 29957 0 297 40 4 44 26070 1 2 6 45 7 22 22741 5 2 4 50 10 00 19883 9 2 2 55 12 78 17424 8 60 15 56 15303 6 1 9 65 18 33 13469 6 1 8 70 21 11 11880 5 1 6 75 23 89 10500 4 15 80 26 67 9299 3 1 4 85 29 44 8251 8 122 90 32 22 7336 4 95 35 00 6534 7 1 0 100 37 78 5831 4 1 0 105 40 56 5213 1 0 9 110 43 33 4668 5 0 8 115 46 11 4188 0 0 7 120 48 89 3763 3 0 7 125 51 67 33871 0 6 130 54 44 3053 5 0 6 135 5722 27571 0 5 140 60 00 2493 2 0 5 All information contained herein 77 is subject to change without notice Trouble Shooting ERR 91 Displayed at the Comfort Control When ERR 91 is displayed at the comfort control thermostat will go to OFF At the Gas Furnace or Air Handler is the COM LED flashing slowly in groups of 2 3 4 or 5 flashes indi
48. 2 is subject to change without notice Trouble Shooting Chart F 2 IND COMM ERR Chart Step 6 De power the Gas Furnace Connect the DC volt as shown and then re power the Gas Furnace Is there DC voltage between the inducer motor drive board terminal TX and GND This DC voltage should be going up and down between 0 145 Volts DC and 0 208 Volts DC YES Repair or replace the low voltage harness NO Replace the inducer motor drive board and reconnect the wire that was removed from the Gas Furnace IFC plug E9 145 208 VOLTS D C Inducer Motor Drive Board VCC X GND RX gaga of a Li B RX 0 T u LED STOP LED T QO lt gt eir Step 7 Is the 12 VDC at the Gas Furnace IFC plug E9 measured between terminals 12V and GND YES Repair or replace the low voltage harness going from the Gas Furnace IFC plug E9 to the inducer motor drive board NO Replace the Gas Furnace IFC Gas Furnace IFC INDUCER 88 LINE Go 8 EN ca 59595 T 6 BM Green LED COM Yellow LED
49. 4 8042 90 0 785 90 32 22 7149 96 0 710 95 35 00 6368 17 0 642 100 37 78 5682 28 0 581 105 40 56 5079 31 0 526 110 43 33 4548 19 0 476 115 46 11 4079 48 0 431 120 48 89 3665 07 0 391 125 51 67 3298 03 0 355 130 54 44 2972 36 0 322 135 57 22 2682 92 0 292 140 60 00 2425 25 0 266 145 62 78 2195 49 0 242 150 65 56 1990 31 0 220 74 All information contained herein is subject to change without notice Chart 2 Liquid Line Temperature Sensor Liquid Line Sensor Thermistor Volts D C at Liquid Resistance OHMS T Plug J 8 ONLY 50 10 00 19405 43 2 189 55 12 78 17002 31 2 029 60 15 56 14929 80 1 876 65 18 33 13138 29 1 730 70 21 11 11585 68 1 592 75 23 89 10237 51 1 461 80 26 67 9064 99 2 239 85 29 44 8042 90 1 226 90 32 22 7149 96 1 121 95 35 00 6368 17 1 024 100 3778 5682 28 0 934 105 40 56 5079 31 0 852 110 43 33 4548 19 0 777 115 46 11 4079 48 0 709 120 48 89 3665 07 0 646 125 51 67 3298 03 0 589 130 54 44 2972 36 0 537 135 57 22 2682 92 0 490 140 60 00 2425 25 0 447 145 62 78 2195 49 0 409 150 65 56 1990 31 0 373 All information contained herein 75 is subject to change without notice Chart 3 Liquid Line Pressure Transducer Voltage to Pressure Reference Chart DC volts Pressure PSIG 0 81 31 0 91 41 1 00 51 1 10 60 1 20 70 1 32 82 1 42 92
50. 90 186 191 197 95 201 207 213 100 218 224 230 105 235 241 248 110 252 259 266 115 271 278 285 120 289 297 305 125 309 317 325 All information contained herein 52 is subject to change without notice Field Wiring Hook Up Diagrams and Charging Chart 3 4 and 5 Ton Cooling Models Only SCHEMATIC DIAGRAM TO POWER SUPPLY PER UNIT NAMEPLATE AND LOCAL CODES A SUMP HTR BK BL BLACK 0 7 BLACK TOL SUMP HTR BLACK O BLACK perar BR RD THERMALLY PROTECTED x INTERNALLY Dum MS HI 2 Br CPR HI IOL E BK WH 10 10 E BK BK BL FU R0 O O L Wc eme uu 2 GREEN VARIABLE L BLUE SPEED d e 1 YELLOW COMMUNICATING AIT CONT900 AIR HANDLER COMFORT 5 CONTROLLER 3 BK Ko 00 ofan LLS BR E27 BR SNP TRD e D Wo G F 4 un gt O 0 1 1 0 BR aim onlin O spem lg of _ R 22 Refrigerant Charging Chart R 22 Refrigerant Charging Chart 3 amp 4 Ton Cooling Models ONLY 5 Ton Cooling Models ONLY Liquid Gage Pressure PSIG Liquid Gage Pressure PSIG DIP SWITCH 2 DIP
51. BL 2 3 4 5 el FU RR AIA E 00 0 a 1ABL L BLUE SPEED BROWN OD FAN WHITE g YELLOW id CB DT n tps COMMUNICATING AIT CONT900 J6 e AIR HANDLER COMFORT CT RES CONTROL js ODS i BK 2 fn LJ I 7 i LLS ip I BR ef BR aN P TRD ne N 80 2 gt MS LO 33 O 0 LPCO E MS HI t BO voo LPCO oF adoj O C4 YL BR R 22 Refrigerant Charging Chart R 22 Refrigerant Charging Chart 2 5 3 amp 4 Ton Heat Pump Models ONLY 5 Ton Heat Pump Models ONLY Liquid Gage Pressure PSIG Liquid Gage Pressure PSIG LIQUID LIQUID DIP SWITCH 1 DIP SWITCH2 DIP SWITCH 2 TEMP DIP SWITCH 1 DIP SWITCH 2 DIP SWITCH 2 TEMP F LOWER MIDDLE UPPER LOWER MIDDLE UPPER 55 109 114 118 39 105 199 T 60 122 126 131 60 117 122 126 12 135 65 130 135 139 5 5 70 143 148 153 0 Did 122 159 75 157 162 168 75 162 168 174 80 172 177 183 80 177 183 189 85 187 193 199 85 193 199 205 90 203 209 216 90 209 216 222 95 220 226 233 95 226 233 240 100 237 244 251 100 244 251 258 105 255 262 269 105 262 269 277 110 274 281 289 110 281 289 297 115 293 301 309 115 301 309 317 120 313 321 329 120 321 329 338 125 334 342 351 125 342 351 360 All information contained herein is subject to change without notice 55
52. Blower now come on YES Err 91 is being caused by the Inducer Motor Drive Board Check for 120 volts AC at the Inducer Motor Drive Board power plug if 120 volts AC is present at the IMDB power plug replace the IMDB NO Check for the following DC voltage at the furnace IFC plug E8 This is the plug going to the indoor blower Read the voltage with the blower motor plug connected to the furnace IFC Plug E8 pin labeled 12V and the next pin labeled RX should read 12 volts DC Connect the volt meter to the B C terminal on the low voltage terminal strip and the pin in plug E8 Is the voltage correct YES If the 12 volts DC is present at both pins in plug E8 the fault is with the harness or the indoor blower motor Perform the 24 Volt AC GO NO GOTest for Serial Port V S Blower Motor on page 63 NO If the DC voltage is low or not present at the furnace plug E8 pins 12V and RX unplug the wire from plug E8 and again check for the DC voltage at these two pins The voltage should read 12 volts DC at these two pins Is the 12 volts DC voltage present at both pins YES Fault is in the harness or the indoor blower motor SeeTrouble Shooting Chart F 3 BLW COMM ERR on page 84 for additional information NO Fault is the furnace IFC replace the furnace IFC Last Four Faults A FEE indoor Alerts IND COMM ERR BLW COMM ERR
53. Communicating een 6n nfnffeff Controls Service Manual Duijoousa qnojj 831A19S e npojy 55922 euoudoja sjuguoduio uomnejedg 0 109u Table of Contents Warnings and Cautions 2 Theory of Operation Communicating Controls essen 3 Dehumidification 4 COMMUNICA ONS reser direi deer periere item EE iore 5 Equipment Setup cerae rni cria a causes 5 Alert Signaling iori tein 5 Approved 6 Alert Code Addendu rri aic terne Recette oca 7 Low Voltage Wiring Diagram Communicating Indoor and Communicating Outdoor Typ nasasda aaa 9 24 VoltThermostat with a Communicating Air Handler and a Communicating Outdoor Unit converted to a 24 Volt Control using Harness Kit 2 10 Communicating Indoor and a Single Stage Outdoor i 12 Common Components User Interface Assembly sssssssseeeeeeeenee 13 Personality Module Variable Speed Indoor Blower Motor Serial Port Communication ccccccccccceesessssseeeeeeeeeeeeeeeeses 14 Three Stage Gas Furnaces i i E 15 Heating Cycle Checks and Limits 16 Inducer Motor Drive Board sens 17
54. DX3 120 Propane See Note 1 See Note 1 25 25 All information contained herein 27 is subject to change without notice Three Stage Gas Furnace Furnace Sequence of Operation The comfort control thermostat signals 17 the Furnace IFC for First Stage Heat 16 IFC checks all limits 10 amp Pressure Switches PS 1 2 3 9 IFC signals the Variable Speed Inducer Drive IMDB 8 to start the Vent Motor 8 and go to its second stage speed Furnace always lights off in second stage 9 IFC sees 24 Volt AC signal from Pressure Switches PS 1 amp PS 2 when they close 9 This proves Vent Motor is moving the correct amount of combustion air through the furnace and vent system IFC starts the Hot Surface Igniter learning routine warm up time cycle 6 IFC turns on the Gas Valve 11 Trial for Ignition is five seconds The IFC proves Ignition by the flame current sensing method 7 If flame is not detected the IFC will cycle the furnace three times to try and prove flame and then the IFC locks out for one hour The IFC will send an Alarm Code It will also flash its Red Fault LED two times repeatedly If flame is detected the IFC will start the heat exchanger warm up time delay for the indoor blower 45 Seconds later the IFC signals the Indoor Blower 4 to come on and run at its second stage heat speed The IFC then signals the Inducer Motor Drive Board IMDB 8 to ramp down the vent mo
55. EED MOTOR USER INTERFACE o Or whenever power is interrupted to the furnace and is then restored The furnace IFC communicates the following information with the Indoor V S Blower Motor o Rotation Direction o Speed amp Max CFM o Start amp Stop Commands Also Checks the V S Motor horsepower HP and will send an error message if HP is not correct The furnace IFC controls the Heating Cycles CFM all other airflows are controlled by the comfort control thermostat Silicon Nitride Hot Surface Igniter o IFC uses the proven Adaptive Learning Routine providing reliable ignition and prolonging the life of the Hot Surface Igniter ComfortR indoor blower Ramp cycle and cooling airflows are set at the comfort control thermostat No Dip Switches to set Heating V S Indoor Blower Motor time delay to off selectable at the User Interface Module These furnaces can only be controlled by a communicating comfort control The thermostat and furnace communicate digitally with each other The Data and Common thermostat wires are used for communications The furnace provides 24 Volts A C power to operate the thermostat All information contained herein is subject to change without notice Three Stage Gas Furnace ey Oe LINE S8 Os o NEUTRAL bc CIRCULATOR Yellow LED 0000000000 0000000000 Green Status LED e Q HH ries Red Fault LED
56. EFRIGERANT PIPING MAXIMUM LINEAR LENGTH 80 FEET OUTDOOR UNIT e Pipe sizing is also straight forward e 2 5 ton 3 ton units use 3 8 inch liquid lines and 7 8 inch vapor or gas lines e Four and five ton units use 3 8 inch liquid lines and 1 1 8 inch vapor or gas lines e Above sizes are used for both cooling and heat pump models VARIABLE SPEED MAXIMUM VARIABLE RISE SPEED 25 FEET OUTDOOR MAXIMUM UNIT DROP 25 FEET SPEED Ductwork Low Ambient Cooling Size ductwork carefully 1st and 2nd stage airflow Pay special attention to register selection that supplies the best airflow and quiet operation Indoor section is a variable speed furnace or air handler Systems are manufactured to 50 F outdoor temperature and with an Evaporator Defrost Control EDC to 30 F outdoor temperature All information contained herein is subject to change without notice Two Compressor Manual Charging Instructions It is recommended installing only ARI rated indoor and outdoor systems All dual compressor split systems models are ARI rated with only TXV indoor systems The benefit of installing approved indoor and outdoor split systems are maximum efficiency optimum performance and the best overall system reliability The following charging method is therefore prescribed for systems with an indoorTXV Subcooling in the cooling mode is the only recommended man
57. EGRATED FURNACE CONTROL Features Three Stages of heat provide better comfort control 1st Stage 40 Typical Input o 2nd Stage 65 Typical Input o 3rd Stage 100 Typical Input Communicating Control System equals simple installation limited diagnoses at the thermostat greater diagnoses capabilities at the Furnace s User Interface Module System operation and set point changes can be done via telephone with aTelephone Access Module when installed Variable speed operation of the 3 Phase Inducer Motor will allow furnace operation with up to 200 equivalent feet of vent pipe and pipe fittings Variable Speed Indoor Blower will provide more efficient operation while maintaining rated airflow over a greater range of conditions Has a Heating Test Cycle which will cycle the furnace through it three stages of heat rapidly Capable of stand alone operation Contingency Mode duty cycling of heat Convertible to Propane Gas change orifices only Operates on Propane at 3 5 manifold pressure To ensure the furnace s heating efficiency the furnace IFC will go through a RESET to the Inducer s Motor s learning routine after o 150 Cycles in First Stage Heat o 100 Cycles in Second Stage Heat 50 Cycles in Third Stage Heat 15 BURNER SIGHT GLASS FLAME ROLL OUT SWITCH MANUAL RESET PRESSURE SWITCH THREE STAGE GAS VALVE VARIABLE SPEED VENT MOTOR AND BLOWER TCO LIMIT DOOR SWITCH V S SP
58. GING STABILIZING H 5 Glo mic status vp carte PERSONALITY MODULE OOO O DATA R B OOO ve 2 PWM BARCODE DATE MFC APPLY P N LABEL HERE All information contained herein 69 is subject to change without notice Trouble Shooting Charge Assist Control Fault LED Flash Code Fault LED Flash Codes of 2 3 or 4 flashes go to defrost control trouble shooting Procedures These Faults are not reported to the Comfort Control as Err codes Fault LED Flash Code of 5 ERR code 67 will be displayed at the Comfort Control The fault LED will be flashing in groups of five flashes This indicates that the outdoor Ambient Temperature Sensor is reading out of range At the Charge Assist control read the DC voltage at the Ambient Temperature Sensor plug J7 with the sensor plugged in or unplug the sensor and read the resistance of the sensor Does the ambient temperature and the DC voltage or its resistance in ohms read at the Ambient Temperature Sensor plug J7 agree with the temperature resistance and voltage chart 1 YES Unplug and re plug the Ambient Temperature Sensor plug several times to insure it is making good con tact with the control pins Turn off the 24 Volts AC to the Charge Assis
59. Handler Control Board ELEC HT VS COMM PLUG 1 E 4g S E AG E e Qe o HD DISPLAY m TO e e i e e UR 3 e 9 e e 25 0000000000 P MODE ee e mo e e 5 e ceo 2 p se 9 Geo STATUS xm ru TTT TTT 5 LED Humidifier N O e jumiditier N P su Ta Sth e e ee COMLED BMLED e e e e e 5 EE e e e e ee ee 5 gt 9 senice pug oniy _ 10 E v a9 Fe 2000 Fe wv 9 9 00 EE P Indicates a male spade terminal Return air sensor plug DA Discharge air sensor plug terminals BK PWM blower speed terminal Status LED The Status LED will turn on solid at power up during the initialization sequence Slow Flash No call Fast Flash Call for heat cool or fan only On Open Fuse or control faults Bit Master BM LED BM Clock Signal LED Green LED on when AHC Clock is working 42 COM LED Communication COM LED Amber LED ON when first powered up LED Flashes the number of communicating components in the system ex communicating stat and furnace will equal two flashes Fault LED Refer to page 46 All information contain
60. ING STABILIZING Amber LED will begin to flash The CA control will then indicate the time it will take for the refrigerant system to stabilize by flashing its CHARGING STABILIZING Amber LED CHARGING STABILIZING LED Blink Rate Schedule 1 sec ON OFF means the system is 6 20 minutes away from being stable 3 4 sec ON OFF means the system is 4 6 minutes away from being stable 1 2 sec ON OFF means the system is 2 4 minutes away from stable 1 4 sec ON OFF means the system is 1 2 2 minutes away from stable The CA control may run the system for up to twenty minutes to insure the refrigerant system is at a steady operating state Once the system is at a steady operating state the CA control will enter the Charging Routine STEP 3 CHARGING Routine The CA determine if the system is control will now Correctly Charged go to STEP 4 CHARGING stab LED OFF CHARGED LED ON STATUS LED FLASHING Under Charged go to STEP 5 ADD LED ON CHARGED LED FLASHING STATUS LED OFF Overcharged go to STEP 6 RECOVER LED SYSTEM LOCKED OFF FOR 1 HOUR STATUS LED ON All information contained herein is subject to change without notice Charge Assist Procedure Details STEP 4 If the CA control determines the system is correctly charged the CHARGING STABILIZING Amber LED will be turned OFF and the CHARGED Green LED will be turned ON The CA control will then exit the charge assist
61. Interface will not be updated Alert flash code will not be implemented for initial release 126 Equipment Change Alert Notes COMM communication errors may also be flashed on Fault LED LitePort transmissions will be allowed during ON flash codes Fuse alert notification level would show on Comfort Control but when fuse is open the COMM bus has no power Notes 4 highest priority Faults display flash codes sequentially 2 second pause between faults and 4 second pause between Notes sequences Cycle power to ODU to clear Faults Comfort Control will switch to OFF until this fault condition clears 2 A device has changed since auto discovery see Installer Guide ISU 0706 to reset Pub 18 HD32D2 2 Revision 3 08 07 2007 All information contained herein 8 is subject to change without notice Communication Controls Theory Of Operation With Communicating Outdoor Unit COMFORT INDOOR OUTDOOR CONTROL UNIT UNIT DATA D lt 0 24VAC HOT R 24VAC B 4B x Y2 2 Field Wiring Diagram Communicationg Indoor Unit Communicating Outdoor Unit All information contained herein 9 is subject to change without notice 24 Volt Thermostat with a Communicating Outdoor Unit Using a 24V Harness Kit ZBAYACHPO24A
62. O BURNER BOX PRESSURE PORT THIRD STAGE PRESSURE ADJUSTMENT SCREV See Note 1 Note 1 Dust Cap Cover Removed for gas pressure adjustment Replace Dust Caps when adjustments are complete and the manifold pressure is being read All information contained herein is subject to change without notice Three Stage Gas Furnace FINAL MANIFOLD PRESSURE SETTING inches W C Furnace Input Rate KBTU hr istStage _ 2ndStage 3rd Stage 60 0 7 0 2 Not Adjustable 3 5 0 2 80 0 7 0 2 Not Adjustable 3 5 0 2 100 0 7 0 2 Not Adjustable 3 5 0 2 120 Not Adjustable Manifold pressures apply for Natural Gas amp Propane applications Note Gas valve adjustment and manifold pressure settings on these model furnaces will be the same for both Natural Gas and LP The only change to the furnace for operation to LP will be burner orifices 51 for LP Refer to LP Conversion instructions for more detailed information First Stage Adjustment Clockwise To Decrease Or Counter Clockwise To Increase Pressure Once the first stage gas pressure is adjusted turn the gas valve switch to the OFF position Operate the furnace for two more minutes to cool down the heat exchanger The furnace IFC will stop the first stage 5096 duty heating cycle after ten minutes To manually exit the first stage contingency cycle remove 120 VAC power from the furnace DO not re power the furnace until the Green LED on the Induc
63. Open Error HT ON ERR Heater Relay Stuck Closed Error 4 Flash N A SS ERR 104 104 Heater Relay Fault HT OFF ERR Heater Relay Stuck Open Error DAS RNG ERR Discharge Air Temperature Range Error x 8 Discharge Air Temperature Upper 5 Flash N A DAS TEENS ERR 118 118 Discharge Air Limit Error Temperature Fault DAS LL ERR Discharge Air Temperature Lower Limit Error 5 Flash DAS SHORT N A 52 Discharge Air Discharge Air Sensor Short Error DAS OPEN Sensor Fault Discharge Air Sensor Open Error 6 Flash N A RAS RNG ERR N A 117 Return Air Return Air Temperature Range Error Temperature Fault RAS SHORT Return Air Sensor Short Error 6 Flash N A N A 110 Return Air Sensor Fault RAS OPEN Return Air Sensor Open Error Y1 ON ERR Y1 Relay Stuck Closed Error 7 Flash N A ERR 101 101 Y1 Relay Fault OFF ERR Y1 Relay Stuck Open Error 8 Flash N A TWIN ERROR N A 19 Twinning Fault Air Handler Twinning Error DEMAND ERR Heat Cool Demand Conflict Error 9 Flash N A N A 123 Demand Configuration HT CFG ERR Electric Heat Configuration Error updated If Air Handler processor is reset or fuse is open COMM Alert cannot be reported if the processor is reset the User Interface will not be Alert flash code will not be implemented for initial release COMM communication errors may also be flashed on Fault LED LitePort transmissions will be allowed during ON flash codes Fuse alert notification level would show on Comf
64. PLOSION HAZARD FAILURE TO FOLLOW THE SAFETY WARNINGS EX ACTLY COULD RESULT IN SERIOUS PERSONAL IN JURY PROPERTY DAMAGE OR DEATH IMPROPER SERVICING COULD RESULT IN DANGEROUS OPERA TION SERIOUS PERSONAL INJURY PROPERTY DAM AGE OR DEATH A WARNING SERVICE PROCEDURES HAZARD BODILY INJURY CAN RESULT FROM HIGH VOLTAGE ELECTRICAL COMPONENTS FAST MOVING FANS AND COMBUSTIBLE GAS FOR PROTECTION FROM THESE INHERENT HAZARDS DURING INSTALLATION AND SERVICING THE ELECTRICAL SUPPLY MUST BE DISCONNECTED AND THE MAIN GAS VALVE MUST BE TURNED OFF IF OPERATING CHECKS MUST BE PERFORMED WITH THE UNIT OPERATING IT IS THE TECHNICIAN S RESPONSIBILITY TO RECOGNIZE THESE HAZARDS AND PROCEED SAFELY A WARNING Voltage Hazard Disconnect power to the unit before removing the blower door Allow a minimum of 10 seconds for IFC power supply to discharge to 0 volts Failure to follow this warning could result in property damage personal injury or death A WARNING CARBON MONOXIDE POISONING HAZARD FAILURE TO FOLLOW THE SERVICE AND OR PERIODIC MAINTENANCE INSTRUCTIONS FOR THE FURNACE AND VENTING SYSTEM COULD RESULT IN CARBON MONOXIDE POISONING OR DEATH A WARNING FIRE OR EXPLOSION HAZARD SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF SHUT OFF THE GAS VALVE TO THE UNIT BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH CAUTION
65. T OUT OF RANGE LED RED Ambient Temperature must be above 65 F to enter CA Below 65 F flash ODT of Range LED 1 sec ON OFF for 30 sec and flash CHARGING LED 5 times per sec for 2 sec Exit CA COM LED AMBER OFF no power ON solid at power up Flash device count when in communication number of communicating products connected in system Rapid flashes followed by a pause indicates disrupted communications CRC errors Y1 LED GREEN ON Ist stage compressor requests Y2 LED GREEN ON 2nd stage compressor request STATUS LED GREEN Fast Flash At Power Up 20 seconds Slow Flash Standard operation OFF Charge Assist mode LitePort LED GREEN Occasional flash For transmitting LitePort data CA procedure allows 1 hour to get within 20 psi of Charged and 50 minutes to move 4 psi Otherswise Time Out CHARGED LED GREEN ON Charge is Correct 1 sec ON OFF 15 20 PSI off target 3 4 sec ON OFF 10 15 PSI off target 1 2 sec ON OFF 5 10 PSI off target BLINKING 1 4 sec ON OFF PSI off target CHARGING STABILIZING AMBER LED 1 sec ON OFF 6 20 minutes away from a steady operating state 3 4 sec ON OFF 4 6 minutes away from a steady operating state 1 2 sec ON OFF 2 4 minutes away from a steady operating state BLINKING 1 4 sec ON OFF 1 2 2 minutes away from a steady operating state RECOVER RED LED ON Exit Charge
66. TAGE THIRD STAGE FRONT SIDE OF SWITCH The closing negative pressure in inches of water col umn is printed on the switch label These two switches are an assembly Separate switch es are not available 2 PRESSURE SWITCH SWITCHES 2 amp 3 ARE MOUNTED BACKTO BACK GRAY SIDETO GRAY SIDE WHICH HAVE AN INTERCONNECTING PRESSURE PORT All information contained herein is subject to change without notice Three Stage Gas Furnace Honeywell Multi Stage Automatic Gas Valve Burner Box The gas furnace manifold gas pressure is modulated in steps by the pressure difference of the positive inlet burner air pressure and the negative outlet air pres sure of the recuperative cell These two pressures are connected to the gas valve These two pressures are used to set the gas valve s pressure regulator for the correct operating pressure for the stage of operation being called for by the furnace IFC 1st Stage Pressure Switch 2 4 amp 3 Stage Pressure Switch 4 23 st POSITIVE PRESSURE PORT E SA NEGATE PRESSURE PORT x To 1 Stage FONNEGISTO BERNER PONPRESSURE CONNECTS TO RECOUP CELL PRESSURE PORT P ressu re Switch Important Brass orifices located in these two legs H Fitting must be installed in this orientation Furnace Input Rate FINAL MANIFOLD PRESSURE SETTING inches W C KBTU hr 1st Stage 2nd Stage 3rd Stage 60 0 7 0
67. TAT TOL SUMP WIR H HEATING ANTICIPATOR m HEATING COOL IMG THERMOSTAT 0m A 5 PURPLE WH BLACK BLACK HPCO HIGH PRESSURE CUTOUT SW TSH HEATING THERMOSTAT TOL INTERNAL OVERLOAD PROTECTOR z LLS 110010 LINE SENSOR BK THERMALLY PROTECTED r WARNING CAUTION 65 a INTERNALLY HAZARDOUS VOLTAGE USE COPPER CONDUCTORS ONLY gt CSR 1 HI NS HI 2 DISCONNECT ALL ELECTRIC POWER UNIT TERMINALS ARE NOT DESIGNED eR RD prot l INCLUDING REMOTE DISCONNECTS TO ACCEPT OTHER TYPES OF T BEFORE SERVICING CONDUCTORS FAILURE TO DISCONNECT POWER FAILURE TO DO SO MAY CAUSE BEFORE SERVICING CAN CAUSE DAMAGE TO THE EQUIPMENT SEVERE PERSONAL INJURY OR DEATH COLOR OF WIRE BK BL BLACK WIRE WITH BLUE MARKER COLOR OF MARKER BK BLACK OR ORANGE YL YELLOW BL BLUE RD RED GR GREEN BR BROWN WH WHITE PR PURPLE NOTES 1 LOW VOLTAGE FIELD WIRING MUST BE 18 AWG MIN BLACK mmm GREEN L EE BROWN mmi WHITE mace HAE ru D o PROTECTED UNDER PRIMARY um c SINGLE PHASE CONDITIONS AIR HANDLER CONFORT CONTROLLER oof le Ss YL OR 2 lo Q MET R 22 Refrigerant Charging Chart 2 5 Ton Cooling Models ONLY Liquid Gage Pressure PSIG LIQUID DIP SWITCH 1 DIP SWITCH 2 DIP SWITCH 2 TEMP F LOWER MIDDLE UPPER 55 94 98 102 60 105 109 113 65 117 121 126 70 130 134 139 75 143 147 152 80 156 161 167 85 171 176 182
68. VS COMM Jumper 24 Volts A C into pin 3 and 4 in the blower motor low voltage plug removed from the furnace IFC or the air handler control board The blower motor should start to run after a short delay The blower motor should run at 75 96 of it S programmed torque Does the blower motor run control must be set up for a communicating system not a 24 Volt A C control system If the Air Handler control setup is correct replace the Air Handler control board NO Go to step 3 MOTOR LOW VOLTAGE PLUG All information contained herein is subject to change without notice Indoor Serial Port Variable Speed Blower Motor Test Step 3 Jumper 24 Volts A C in to the blower motor low voltage plug pin 3 and pin 4 The blower motor should start to run after a short delay The blower motor should run at 75 96 of it s programmed torque Does the blower motor run YES Repair or replace the blower low voltage harness NO Replace the blower motor e e 00 e LOW VOLTAGE CONTROL PLUG All information contained herein 66 is subject to change without notice Trouble Shooting the Outdoor Unit s Charge Assist Control COILT RY B J10 X2 B DATA rl om J1 SIGNAL CEN 0 MAP gt Y2 ECON B D25 AMBIENTT EXT ODT iow Ut OW a QS E 9 ol O ranis i E Ec ore pco 9 wo
69. ace or the Air Handler At the Gas Furnace IFC or the Air Handler control board remove the wire from the terminal RX in the low voltage plug going to Black the indoor blower low voltage plug When the RX wire is removed from the low voltage plug put the low voltage plug back into the Gas Furnace IFC or the Air Handler control board Detail 1 Push down on the wire connector latch clip on the side of the plug and pull the RX wire from the low voltage plug Plug the low voltage plug back into the IFC Blue Push down here See Detail 1 Detail 2 Connect a digital DC voltmeter to the RX wire removed from the low voltage plug and the B C terminal at the low voltage terminal board Detail 3 Re power the Gas Furnace Gas Furnace IFC o QQ LINE Is there DC voltage between the wire removed 2L from the Gas Furnace IFC or the Air Handler P icd control board plug low voltage terminal RX ze Do COM Yelow LED and the low voltage terminal B C going up and down between 0 152 Volts DC and 0 174 Volts DC The Votage Meter will stop reading at times and then start reading again YES Replace the Gas Furnace IFC or the Air Handler control board NO Go to step 6 Do not reconnect the RX wire
70. ad or Missing PM Duplicate ODTemperature Sensor 15 Flash 2 different units are reporting the Outdoor Temperature Breaker or Outdoor Unit Disconnect OFF ERIS 120 Outdoor Transformer Field Thermostat Wiring The last four fault codes will be display sequentially 2 second pauses between faults and 4 second pauses between sequences Cycle power or 24 volt to outdoor unit to clear faults 11 Flash 12 Flash Note 1 Check the Ambient Coil Temperature Sensor plug and its wire harness Check the sensor resistance and its temperature and then compare to Chart 1 in the Charge Assist Control Trouble Shooting Section Note 2 Check the Liquid Line Temperature Sensor plug and its wire harness Check the sensor resistance and its temperature and then compare to Chart 2 in the Charge Assist Control Trouble Shooting Section Note 3 Check the Liquid Line Pressure Sensor plug and then check its DC voltage at its test point VP and the 24 Volt AC common Read the Liquid Line Pressure at the Liquid Line Service Valve and compare the DC Voltage and the Liquid Line Pressure to Chart 3 in the Charge Assist Control Trouble Shooting Section Note 4 Check the Accessory External Ambient Temperature Sensor connected to terminal board TB1 and its wire harness Check the sensor resistance and its temperature and then compare them to Chart 4 4 in the Charge Assist Control Trouble Shooting Section All information contained herein
71. age heat pump is installed with a three stages gas furnace the thermostat can only call for two stages of auxiliary heat as shown above When the thermostat calls for first stage auxiliary heat the fur nace IFC will operate the furnace in the second stage of heat When the thermostat calls for second stage aux iliary heat the furnace IFC will operate the furnace in the third stage of heat All information contained herein is subject to change without notice Alert Code Addendum Alert Alert Group Pressure Switch Failure EN Low Flame Signal 10 Ignition Means Fault Communicating Equipment Air Outdoor Handler Unit X Comfort Control N A ERR 10 ERR 18 Alert Notification User Interface Displa PS3 OPEN PSscLosED PS2 OPEN PS2 CLOSED PS1 OPEN PS1 CLOSED LO FLAME SNS IGNITER ERR TRIAC ERR CNTRL FAULT t Fault LED 3 Flash COM LED Device count Alert Description Open Pressure Switch third stage Shorted Pressure Switch third stage Open Pressure Switch second stage Shorted Pressure Switch second stage Open Pressure Switch first stage 6 Flash Device count Igniter fault Triac fault Solid ON 8 Flash Flame current is low but still strong enough to allow operation 18 Control Failure 18 Control Failure 18 CNTRL FAULT TWIN ERROR Solid ON 8 Flash N A Device count Internal Control Error Internal
72. agree with the external temperature resistance and voltage chart 4 Note The temperature displayed at the Comfort Sensor requires five minutes to stabilize If the External Ambient Temperature Sensor circuit is not connected to a sensor the Charge Assist Control automatically use the unit Internal Ambient Temperature Sensor connected to the Ambient Sensor plug 7 YES Turn off the 24 Volts to the Charge Assist Control and then re power the control If the thirteen flash codes continue to be displayed replace the Charge Assist Control Note Disconnect the External Ambient Temperature Sensor and re power the control system The Charge Assist Control will now use the internal Ambient Sensor NO When the DC voltage and temperature do not agree with the external temperature resistance temperature resistance and voltage Chart 4 replace the External Ambient Temperature Sensor Fault LED Flash Code of 14 Error code of ERR 114 will be reported to the Comfort Control This indicates that the Personality Module plugged into the Charge Assist Control is unplugged or its stored information is not usable Is the Personality Module plugged into the Charge Assist Control YES Turn off the 24 volt AC supply to the Charge Assist Control and then re power Fault code should clear itself if the fault code does not clear itself replace the Personality Module Note To order a Personality Module you must have the complete model and seria
73. and 55 Locate your liquid line temperature in the left column of the R 22 Refrigerant Charging Chart and the intersecting liquid line pressure under the lower middle or upper column The correct column was determined in step 4 Add refrigerant to raise the pressure to match the table or remove refrigerant to lower the pressure Again wait twenty 20 minutes for the system conditions to stabilize before adjusting the charge again 8 When the system is correctly charged you can refer to the System Pressure Curves in the unit s Service Facts to verify typical performance 9 Return the indoor thermostat to the customer original set point Example e 1 Refrigerant Line Lift 15 feet 2 Total Refrigerant Line Length 30 feet With these Lift and Total Line Length dimension the Subcooling Charging Table corrections indicates that the Dip Switch 2 should be turned on and to use the Middle column on the R 22 Refrigerant Charging Chart when Manually Charging the system Your temperature tester shows that the Liquid Line temperature is 95 F On the R 22 Refrigerant Charging Chart in the column labeled LIQUID TEMP F go to your Liquid Line Temperature of 95 F At the 95 F Liquid Line Temperature on the chart go across the chart to the DIP SWITCH 2 MIDDLE column The pressure displayed at this point is 226 Add refrigerant to increase the pressure or recover refrigerant to decrease the pressure Wait twenty 20 minutes
74. cating number of devices OR is it flashing fast If the COM LED is flashing slowly in groups of 2 3 4 or 5 go to Chart F 1 If the COM LED is flashing fast go to System Communication Troubleshooting section on page 94 Air Handler Control Board 5 88 ELEC HT nO VS COMM PLUG I D Sage s A E 25202 O 9 OOOO MTR DS P Hi Lee e y oed see Ae M 9 e 9 C XUI STATUS eas E E LED wo E 5 e D Humidifier N O i Electronic Air Cl Suen Terminas fae od e __ 4 BMLED e iC 5 AMP e Py Comfort trol Plug Low Voltage Input Plug Terminal D FUSE ice plug only gn 0 2929000000000 FA AN OM 5 7 Fey ey x a 39 4 Ww w NWS 24VAC EXT SW XFMR TOROS Indicates male spade terminal RTN Return air sensor plug DA Discharge air sensor plug terminals BK PWM blower speed terminal Gas Furnace IFC INDUCER 7 9 29 LINE we E 59 neu
75. ce IFC or air handler terminal board Turn power back on to the furnace or air handler Does the Comfort Sensor and furnace IFC or air handler now communicate YES Err 91 is being caused by the thermostat wire or its routing Repair or reroute or replace the thermostat wire NO Replace the Comfort Sensor D R 1 Furnace IFC or Air Handler Board All information contained herein 91 is subject to change without notice System Communication Trouble Shooting Step 8 Does the furnace IFC or air handler fault LED show a fault flash code YES Go to step 5 NO Go to step 9 Air Handler Control Board 55 Z8 ELEC HT 5o Om z5 82 8 amp DISPLAY aa gt C 4 see g z ww eI E 2 Humidifier i Electronic Air Cleaner ET Switch Terminos Switch Terminals 6 LED 1 2 e ee BMLED e e eo Auxiliary Comfort e M ontrol Plu e service plug 93 6 99 eee _ A b SW SO DA 2 RIN AR D R B RTN Return air sensor plug DA Discharge air sensor plug terminals BK PWM blower speed terminal P Indicates a male spade terminal
76. control failure Air Handler Twinning Error Shorted Pressure Switch first stage Twinning Fault Twinning Fault Flame lost or Ignition failure Soft lockout due to flame lost or ignition retries High Temp Limit Fault Flame Detect Fault N A ERR 27 ERR 34 TWIN ERROR RECYCLE RETRY RECYCLE LO RETRY LO AUX LIMIT HIGH LIMIT IND LIMIT N A FLAME ERROR None 2 Flash N A Device count Device count Twinning Not Allowed with Variable Speed Flame is off when flame should be detected Furnace tries to relight itself Furnace tries to light but no flame is detected 10 recycles within a single call for heat will cause 1hr lockout 3 ignition attempts in a row within a single call for heat results in 1 hr lockout Open Reverse Flow Heat exchanger temperature too high Could be caused by low airflow or fan failure N A The device needs to be replaced Line Polarity Fault pa Ea POLARITY ERR 6 Flash Voltage reverse polarit 5 Flash Device count 50 Duplicate OD Temp ____ EN Discharge Air Sensor Fault 53 Faulty Outdoor Sensor 54 Faulty Humidity Sensor gt AC Line Fault Temp Sensor Fault Defrost Fault 89 Equipment Missing Communication Busy Fault X ERR 37 ERR 38 ERR 39 None N A ERR 53 ERR 54 N A None N A N A N A N A DAS SHORT DAS OPEN N A N A AC VOLTS LOW AC VOLTS HI N A N A
77. ctor not sensed and not energized SNSR1 SNSR2 DLT2 1 MOTOR RPM gt MOTOR RPM 0 RPM i t RESET LST FAULT gt RESET LST FAULT YES NO NO f CLEAR LITEPORT gt CLEAR LITEPORT NO NO YES 1 RESET HEAT SENSE RESET HT SENSE X NO NO YES PART LIST gt PART LIST CNT HHHHE PM SERIAL NUM gt SERIAL NUM THHHHBE EXIT gt EXIT NO NO YES Notes Shown only when Outdoor Communicating Unit is not detected X indicates actual number of heat banks detected under reset menu All information contained herein 39 is subject to change without notice Communicating Mode Drawing 24 Volt Mode continued CMFRT CNT MODE 24VAC 24VAC COMM denotes the current setting m minutes 24V Mode unit specific Model Setup Options COOLING CFM options Setup Menu COOLING CFM 3T 3T 3 T 2T 2 T 3 T 34T 2T 2 T 3T CFMPERTON CFM PER TON 49 4T 57 3T 3ZT 400 400 430 450 290 310 330 350 370 5T 3T 34T 4T CLG STAGES unit specific 5101 51761 5162 ___31 50 50 55 65 80 CLG 157 STG CLG 1ST STG 37 50 50 55 65 80 40 55 55 65 80 50 CONT FAN 9 CONT FAN 49 2935 65 B0 50 0 0 0 0 0 50 50 7596 100 2596 65 60
78. cycle the variable speed indoor blower and the three stage gas furnace through its three stages of heat at the User Interface Assembly e The Unit Test Cycle will be entered at the User Interface assembly e The test cycle can only be entered when the thermostat is not calling and the furnace IFC is not reporting a fault Disconnect the Data wire D from the furnace IFC terminal block to ensure the UnitTest Cycle will not be interrupted All information contained herein is subject to change without notice Three Stage Gas Furnace Scroll down using the V button at the User Interface Display until you see UNIT TEST then press ENTER UNIT TEST and lt NO NO will be displayed Use the 4 or gt arrow button to change the NO to a YES and then press ENTER ARE YOU SURE and NO NO will now be displayed Use the lt or gt arrow button to change the NO to a YES and then press ENTER UNIT TEST and STAGE OFF will now be displayed The variable speed indoor blower will then be turned on by the IFC for 10 seconds and then off UNIT TEST and STAGE OFF will now be displayed The Furnace IFC will now start the variable speed inducer motor and then go through the igniter warm up cycle The Furnace IFC will turn on the gas valve and when the burner flame is detected the user interface display will change 26 UNIT TEST and STAGE 2 will now be displayed The furnace IFC will now be in second stage heat and 45 seconds after flam
79. d Heating airflow CA cycle is compatible with ENHANCED Mode 24 VAC Step 2 A technician must set the indoor system thermostat to call for the SECOND STAGE of COOLING The indoor CONTROL must be set low enough to ensure the system continues to run in SECOND STAGE of COOLING throughout the CA mode cycle The CA control will exit the CA mode CYCLE if the system control does not stay in the SECOND STAGE cooling cycle The CA Control must see 24 volts call on both Y1 andY2 60 24 VAC Step 3 Press the mode button on the CA board and follow the CA procedures starting with STEP 1 in the Communicating Comfort Control Section above 24 VAC Step 4 After the CA control exits the CA mode CYCLE the technician must then return the NON COMMUNICAT ING 24 volt indoor CONTROL to the desired customer setting Note 65 F to 100 F is the operational limit of Charge Assist Charge Assist will work above 100 F but the results may not be as accurate as desired The service technician will need to recheck the system charge when temperatures are between 65 F to 100 All information contained herein is subject to change without notice Charge Assist Summary Of The Module and Its LEDs LOW PRESSURE LED RED Liquid Pressure must be above 50 psig to enter CATM Below 50 psig turn on LOW Pressure LED for 30 sec and flash CHARGING RED LED 5 times per sec for 2 sec Exit CATM OD
80. d on the line voltage it is reading This reduced number of AC sine wave cycles per second reduces the effective voltage R M S applied to the SiNi ignitor per second If the line voltage is low the number of cycles will go up or if the line voltage is high the number of cycles is reduced 60 Hertz AC Sine Wave One Cycle time 1 60 of a Second Number of cycles per second affects the effective voltage or voltage R M S R M S Root Mean Square The value assigned to an alternating current or voltage that results in the same power dissipation in a fixed resistance as DC current or voltage of the same numerical value One or more cycles are turned off by the control to control the R M S voltage supplied to the silicon nitride ignitor Cycle Turned Off X 1 P Learning Process After each successful ignition the number of AC sine wave cycles are reduced The lower number of AC sine waves reduces the effective voltage applied to the ignitor and this lowers it s maximum temperature After each successful ignition attempt the burner lights then the number of cycles are reduced During this learning program the number of cycles will become too low and the gas fails to ignite 18 F 2300 2200 2100 2000 1900 1800 4 STEPS UP BELOW IGNITION TEMPERATURE 1 2 3 4 5 6 7 8 9 10111213 14 15 16 17 18 TFI A retry is initiated by the IFC and the number
81. door unit A C or Heat Pump When the request for cooling is received the AHC will energize the blower When the request to terminate cooling is received the blower will be de energized once any user selected fan off delays have expired The Charge Assist Control in the outdoor unit will control the sequence of the compressor s and the outdoor fan speed Call for 2nd Stage Cooling Communicating A C or Heat Pump When request for 2nd Stage Cooling is received the AHC will change the blower speed to 2nd stage airflow When the request to terminate 2nd Stage Cooling is received the blower will return to 1st stage airflow 43 Heating Electric Heat Only When the request for heat is received the AHC will energize the blower and heating contactors The number of heating stages needed is determined by the Comfort Control If a blower request for a higher airflow is received the AHC will energize the blower at the higher airflow When the request to terminate heat is received the AHC will turn off the heat contactors and the blower will be de energized Heat Pump Only Applications Communicating Heat Pump When the request for mechanical heat is received the AHC shall energize the blower When the request for mechanical heat is terminated the AHC will de energize the blower once any user selected fan off delays have expired Note In Communicating Mode the Air Handler will not operate a non communicating Heat Pump H
82. e AC Volt Meter to the pressure switch being tested then go to step 5 Drawing 2 5 The AC Volt Meter should read 24 Volts AC until the inducer motor comes up to speed to create the op erating pressure needed to close the switch See the pressure switch s label being tested or the Gas Furnace Pressure Switch Matrix Chart for the switch s operating pressure If the pressure switch being tested does not close when the operating pressure is reached the switch must be replaced 1 Stage Pressure Switch All information contained herein 30 is subject to change without notice Three Stage Gas Furnace Pressure Switches And Interconnecting Hose Diagram FIRST STAGE PRESSURE SWITCH 7 ORIFICE STAGE ONE FRONT SIDE ORIFICE BACK SIDE There is an orifice installed in the black tee This tee amp orifice assembly is connected to the black side of pressure switch 1 The orifice amp tee assembly is not universal The orifice is sized for the furnace s BTU input capacity Pressure switch 1 has two black and two gray pres sure ports The black side of pressure switch 1 is con nected to the furnace s burner box The gray side of the switch is connected to the recoupitive cells cold header tee 1 PRESSURE SWITCH GRAY SIDE 3 PRESSURE SWITCH RECOUP CELL COLD HEADER DRAIN 31 BACK SIDE OF SWITCH BURNER BOX SECOND AND THIRD STAGE PRESSURE SWITCHES SECOND S
83. e is detected the furnace will call for the variable speed indoor blower UNIT TEST and STAGE 3 will now be displayed The furnace IFC will ramp up the variable speed inducer motor and the indoor variable speed blower to third stage operation for a few seconds UNIT TEST and STAGE 1 will now be displayed The furnace IFC will ramp down the variable speed inducer motor and the indoor variable speed blower to first stage operation for a few seconds The Model and Serial Number will now be displayed The variable speed indoor blower will now be operated for the heat exchanger cool down cycle and then be turned off Reconnect the Data wire to the D terminal of the furnace IFC All information contained herein is subject to change without notice Three Stage Gas Furnace Vent Length Table for Variable Speed Vent Motor Models Only Maximum Vent Length Table Installation instructions must be followed for installation of the venting system Maximum Vent Length Equivalent Feet Notes Direct Vent 2 Pipe System Models api eh E pi UC1 DC1 amp UX1 DX1 2 Pipe 2 5 Pipe 3 Pipe 4 Pipe 1 Notallowed UC1 UX1 040 060 60 80 100 130 2 Minimum vent length for all models 3 horizontal and vertical UC1 UX1 080 50 80 100 130 UX1C080A9601 See Note 1 60 100 130 3 The INLET Air of one pipe systems require the insta
84. e the or arrows to select the YES and then press ENTER Are you Sure and NO NO will now be displayed With a NO NO question being asked Use the or arrows to select the YES and then press ENTER Turn 120 VAC power off When the Green LED on the Inducer Drive Motor Board goes out turn 120 VAC power back on When the furnace is operating in the Contingency Mode Stand Alone Operating Cycle the User Interface will display the following information The top line will say CNTNGNCY Mode The bottom line will show the operating stage number STG 1 2 or 3 selected and the percent number 10 50 selected All furnace operating limits pressure switches and communications between the IFC and the IMDB and the V S Indoor Blower will be monitored for proper safe operation of the furnace The 4 gt A and ENTER buttons do not function in the contingency mode of operation To exit the Contingency Mode of operation turn off the 120VAC power to the furnace The Contingency Mode Stand Alone Operation will stop for any of the following reasons 1 A signalis received from the thermostat Data wire D from the thermostat reconnected to the furnace IFC D terminal block 2 Power removed from the furnace and then turned back on 3 The furnace operation 4 A fault is detected by the furnace IFC Fault LED will be flashing a fault code Inducer RPM IFC enters a RESET mode of Minimum RPM Maximum RPM
85. eat Pump amp Electric Heat Applications Communicating Heat Pump When the request for electric and mechanical heat is received the AHC will energize the blower at auxiliary heat airflow and turn on the electric heat contactors The number of heating contactors stages of electric heat installed and available is determined by the Comfort Control If a blower request for a higher airflow is received the AHC will energize the blower at the higher airflow When the request to terminate electric heat is received the AHC will turn off the corresponding heater outputs If the mechanical heat demand remains the AHC will keep blower energized at mechanical heat airflow When the request to terminate mechanical heat is received the AHC will de energize the blower once any user selected fan off delays have expired Heat Pump amp Electric Heat Applications Non communicating Heat Pump Operation of the in ComfortLink with a non communicating Heat Pump is not allowed All information contained herein is subject to change without notice Air Handler Sequence of Operation 24V Mode Continuous Fan When only the G is energized the control will energize the blower for fan only operation When the G input turns off the control turns off the blower immediately Cooling Operation When the air handler receives Y1 or Y1 amp Y2 demands the 1st or 2nd stage blower will be selected depending on the Y1 amp Y2 input
86. ed herein is subject to change without notice Air Handler Sequence of Operation Communicating Mode Continuous Fan Note CONTINUOUS fan mode during COOLING operation may not be appropriate in humid climates If the indoor air exceeds 60 relative humidity or simply feels uncomfortably humid it is recommended that the fan only be used in the AUTO mode When a request is received without a Heat Cool Demand the air handler control AHC will energize the blower at the speed for Continuous Fan operation When the request is removed the AHC will turn off the blower immediately Proprietary Humidity Control When enabled this feature will disable any blower off delays and disable continuous fan mode when the indoor humidity is above the dehumidification setpoint This will help prevent coil condensation from being evaporated back into the air stream Note This feature ISU 0388 is not shown unless some form of dehumidification control is selected Call for Cooling Non communicating outdoor unit A C Only When a request for cooling is received the AHC will energize the blower and the Y1 relay to activate the outdoor unit contactor When the request to terminate Cooling is received the Y1 relay will be turned off and the blower will be de energized once any user selected fan off delays have expired Note In Communicating Mode the Air Handler will not operate a non communicating Heat Pump Communicating out
87. ee Stage Gas Furnace So f m 98 une BOr CIRCULATOR Br ts Green LED E9 E8 pr Spy o o off ox COM Yellow LED EE al ex Em IFC LEDs BM Clock Signal LED Green LED on when IFC Clock is working Communication COM LED Amber LED ON when first powered up LED Flashes the number of communicating components in the system ex communicating stat and furnace will equal uu two flashes cub m Status LED Slow flash no call for heat o Fast flash call for heat Green Status LED 7 CO o H Fault LED 900 Fi nnm Will flash to signal a fault see fault code 000 p agal Will flash the last four faults detected when the furnace is re powered AAI Will only flash a fault code when the furnace is s receiving a call for heat FAULT LED Flash Codes The furnace IFC checks the pressure switches PS 1 and PS 2 They both must be open before heating 2 Flash External Lockout Retries or Recycles exceeded cycle can begin 3 Flash Pressure Switch Inducer Error The furnace s IFC sends a digital signal to the Inducer 4 Flash Open Limit Switch Motor Drive Board IMDB to
88. em perature is back to the set point temperature and the minimum run time for the equipment has been met the thermostat will send another new operational mes sage that the system is to shut down and any indoor blower off delays will begin Indoor Dehumidification Control Cycle When the indoor humidity in the cooling cycle is above the thermostat humidity set point the thermostat mes sage being sent can cause the system to continue to run to a maximum of three degrees below the ther mostat set point This will help control humidity under light loads conditions This cycle is adjustable from 1 to 3 degrees in the Installer Setup Menu 0380 and 0383 Refer to Comfort Control Installer s Guide setup menu for complete menu Minimum compressor run time is three minutes Minimum compressor off time is five minutes Frost Control cycle is used when a humidifier is in stalled and the control system has an outdoor tem perature sensor installed The frost control works by reducing the humidity level in the home when out door conditions can cause condensation or frost to form on windows The factory setting is five To re duce the condensation or frost on the windows low er the number If the humidity is too low in the home at the factory setting of five increase the number See advanced thermostat setup for programming setup instructions All information contained herein is subject to change without notice Reliable Commu
89. ep 3 Does the serial port variable speed motor start and run after a short delay to turn on YES Serial port variable speed motor is good Check the furnace IFC or the air handler control board NO Go to step 4 Step 4 Is there 120 Volts at the gas furnace or 240 Serial Port V S Blower Motor Volts AC at the air handler serial port variable speed motor SPVS motor high voltage plug YES If the motor turns freely replace the SPVS motor NO Repair as needed and retest VOLTS A C All information contained herein 64 is subject to change without notice Indoor Serial Port Variable Speed Blower Motor Test Air Handlers blower motor correct voltage is 240 Volts A C and there is no jumper wire connecting pin 1 and pin 2 together YES Go to step 2 NO Correct line voltage fault Step 1 Is the line voltage to the blower motor high voltage plug pin 4 and pin 5 correct Furnace blower motor correct voltage is 120 Volts A C and a factory jumper wire must be present connecting pin 1 and pin 2 together FURNACES ONLY PIN 1 amp 2 JUMPERED TOGETHER Step 2 Disconnect the blower motor s low voltage YES harness from the furnace s IFC or the air Furnace Replace the Furnace IFC handler s control board Air Handler Check the Air Handler s control setup If the Air Handler is connected to a Furnace IFC plug is E8 communicating thermostat the Air Handler Air Handler s plug is
90. er Motor Drive Board goes out Turn the gas valve switch to the ON position Again turn on the 120 VAC power to the furnace Set up the furnace in the CONTINGENCY MODE of operation at the User Interface Assembly for the third stage of heat with a 50 duty cycle then depower and then repower the furnace Let the furnace go through the stage 3 learning routine and its temperature rise to stabilize This temperature rise and learning routine will take three to four minutes The dust cap screw covering the third stage pressure adjustment screw must be in place during manifold gas pressure readings Remove the dust cap and adjust the gas valve third stage of heat pressure adjustment screw one turn Third Stage Adjustment Counter Clockwise To Decrease Or Clockwise To Increase Pressure Replace and tighten the dust cap for the third stage adjustment screw and then read the manifold pressure again This procedure may need to be repeated until the manifold gas pressure is 3 5 of Water Column pressure Once the third stage gas pressure is adjusted turn the gas valve switch to the OFF position Operate the furnace for two more minutes to cool down the heat exchanger 25 Remove 120 VAC power from the furnace DO not re power the furnace until the Green LED on the Inducer Motor Drive Board goes out Turn the gas valve switch to the ON position Again operate the furnace in the contingency mod of operation in first stage of heat
91. eration e Y 1 and Y2 LEDs Flashing CA control system is in the one minute compressor off time delay period before going to Second Stage compressor operation Y 1 LED andY 2 LED ON Second Stage Compressor operation Y 1 LED Flashing CA control system is in the one minute compressor off time delay period before going back to FIRST stage compressor operation Status LED Slow Flash CA control in the normal operating mode Status LED Fast Flash At power up this LED will flash fast for 20 seconds Status LED OFF CA control is in the Charge Assist Mode Com LED ON At power up this LED will be on for 20 seconds Com LED Flashing The number of Flashes equals the number of communicating controls talking on the Data Line Example A communicating system thermostat a communicating indoor unit a communicating outdoor unit 2 Three Flashes Fault LED Flashing When the CA control detects a fault it will flash this LED a different number of times for each fault detected See chart on page 75 The following LEDs are used during the CA mode cycle only LOW PRESSURE ODT CHARGING STABILIZING ADD REC and the CHARGED LED All information contained herein is subject to change without notice Charge Assist Procedure Details Figure 1 coll T AMBIENTT EXT ODT Bs J10 I3 z Ts a Er Le J6 LIQUID T D 597 O eo E IARGING
92. exchanger cool down cycle Contingency Mode Stand Alone Operation Stand Alone Operation can only be entered at the User Interface Assembly 1 Stand Alone Operation can be set up to operate the furnace in Heating Only 2 When the thermostat is not communicating with the furnace IFC Disconnect the Data wire D from the furnace IFC terminal block 3 When the furnace IFC is not flashing a fault code at its Fault LED Turn 120 VAC power off When the Green LED on the Inducer Drive Motor Board goes out turn 120 VAC power back on e Scroll down using the down arrow YW at the User Interface Display until you see CNTNGNCY Mode then press the Enter button e CNTNGNCY Mode and 4 STAGE P will be displayed Press the Enter button STAGE and lt OFF OFF will be displayed A First Second or Third stage of heat must be selected Use the 4 or gt arrows to select the stage of heat wanted and then push the Enter button and then the V button DUTY CYCLE and 10 will be displayed A duty cycle must now be selected from 10 to 5096 A 1096 duty cycle will run the furnace for 2 minutes and then off for 18 minutes A 5096 duty cycle will run the furnace for 10 minutes and then be off for 10 minutes These duty cycles will be repeated 3 times per hour Use the 4 or gt arrows to select a duty cycle and then push the Enter button and then the V button Start and NO NO will now be displayed With a NO NO question being asked Us
93. f combustion will stabilize The furnace IFC now signals the V S indoor blower to run at the programmed second stage heating airflow The furnace IFC will now start its inducer second stage heat airflow learning routine The furnace IFC will signal the Inducer Motor Control Board IMCB to begin to reduce the Inducer Motor speed in steps Inducer motor speed is reduced until the furnace IFC sees PS 2 open When PS 2 opens the furnace IFC will NOTE the Inducers Motor RPM The furnace IFC then adds an additional number of RPM to the inducer s motor second stage NOTED RPM The additional number of RPM plus this NOTED RPM is the learned second stage inducer operating RPM The furnace IFC now stores this learned operating inducer RPM for second stage heat in its memory The furnace IFC will use this stored learned operating inducer RPM for second stage heat calls it receives in the future If the furnace IFC is still receiving only a call for first stage operation it will now start the learning routine for first stage The furnace IFC will then continue to reduce the inducer motor s RPM in steps until the furnace IFC sees PS 1 open When PS 1 opens the furnace IFC will NOTE this Inducer Motor RPM The furnace IFC then adds an additional number of RPM to the first stage NOTED RPM The furnace IFC now stores this learned operating inducer RPM in its memory and uses it for first stage heat calls it receives in the future The IFC
94. f hertz An increase in voltage and an increase in the number of hertz from the IMDB will cause the inducer motor to run faster All information contained herein is subject to change without notice Three Stage Gas Furnace Power Output To Inducer Motor U EGNDW V e oeno Communication COM LED Green Inducer Motor Drive Board LED S COM LED ON No Call For Inducer Motor Uo 65 009 HS COM LED FLASHING Call For Inducer Motor Operation g STOP LED OFF ON Only Flashes When VCC 12 VDC Input E IFC Signals Inducer TX Data Output Motor Drive Board GND Ground Common To Turn Off RX Data Input LED QO STOP LED Note 1 When IMDB amp IFC are not communicating the User Interface will display no data when inducer RPM is selected EGND L2 L1 Power Plug 120 V A C Input All information contained herein 17 is subject to change without notice Silicon Nitride Ignitor Learning Routine The ignitor is constructed of a tungsten heater element and silicon nitride ceramic insulators The voltage rating of the ignitor is 80 volts R M S which is less than the line voltage applied to the furnace therefore the control will reduce the number of cycles it supplies to the SiNi ignitor per second The control checks the line voltage constantly and when a call for heat is received the control sets the number of cycles it is going to supply to the ignitor base
95. for heat 19 Fault Detection During Second Stage Heat Learning Routine If PS 1 and PS 2 are not closed when the inducer reaches 4400 RPM the furnace IFC will signal the IMDB to shut down the inducer motor The IFC flashes its Red Fault LED three times repeatedly for thirty seconds This thirty second inducer off period is done so any accumulated water that may be in the vent system can drain out The IFC will repeat this cycle three times if needed before it locks out for one hour See Trouble Shooting Pressure Switch procedure After the thirty second off period the IFC will stop flashing the Fault LED and then will signal the IMDB to again start the inducer motor and go to the preset factory second stage heat RPM All information contained herein is subject to change without notice Three Stage Gas Furnace When PS 1 and PS 2 switches do close the furnace IFC will then start the ignition cycle The IFC now starts the Igniter warm up cycle See Silicon Nitride Ignitor Learning Routine Near the end of the warm up cycle the furnace IFC will turn on the Gas Valve When the burner flame is detected by the furnace IFC a forty five second time delay for indoor blower operation begins The forty five second time delay allows the heat exchanger and the recuperative cell to warm up By the end of this delay time the inducer s discharge air temperature will be at its operating temperature and the density of the products o
96. g 7 up and down between 0 50 Volts DC and 1 07 VOLTS D C Volts DC The Volt Meter will stop reading at times and then start reading again YES Go to step 5 NO Go to step 4 Step 4 Set the comfort control thermostat to call for Gas Furnace IFC blower operation INDUCER 99 m Is there DC voltage between the Gas Furnace coe IFC plug E8 Terminal TX and GND This in y arca DC voltage should be going up and down e mh e between 0 5 volts DC and 1 07 volts DC This voltage reading will stop reading at times and 4 start again o on SLED YES Repair or replace the low voltage harness going from the Gas Furnace IFC plug E8 or the Air Handler plug to VS COMM going to the indoor blower low voltage plug NO Replace the Gas Furnace IFC or the Air Handler control board VS COMM PLUG I D oo oo oo oo RIN AR D R B Indicates a male spade terminal Return air sensor plug DA Discharge air sensor plug terminals BK PWM blower speed terminal All information contained herein 85 is subject to change without notice Trouble Shooting Chart F 3 BLW COMM ERR Step 5 De power the Gas Furn
97. g Off Delay only applies after the Heat Pump Mechanical Heat turns off If more than one stage of Electric Heat demand is called the Heat calls W1 W2 and W3 will be ener gized at least 0 5 seconds apart 44 Electric Heat Only Sequence 24VAC Input When the W1 and G are present the control will energize the 1st heater contactor and blower at the heating speed selected via the User Interface G is not required WhenW2 is present the control will energize the 2nd stage heater contactor When W3 is present the control will energize the 3rd stage heater contactors When W1 W2 or W3 is removed the corresponding contactor will de energize When the G input is removed the control will turn off the blower immediately no Heat Off Delay G is not required Heat Pump Only Sequence 24VAC Input e When Y1 are present the compressor will be energized along with the blower on high speed in single stage operation or low speed in two stage operation When Y1 and Y2 are present the 2nd stage compressor in two stage equipment will energize and the blower will go to high speed Air handler must be set for 2 stage operation When Y2 and Y1 inputs are removed the 2nd stage compressor will turn off When G is removed the blower will turn off after the Heat Off Delay selectable has timed out All information contained herein is subject to change without notice Air Handler Sequence of Operation 24V Mode
98. ice A u E H Fitting Label Pressure Switch H Fitting a Black Side to Switch Pan gt White Side to Mounting Ri Jh car b b Orifice on White Side pointing to the outside All information contained herein 33 is subject to change without notice Gas Furnace Communicating Systems Trouble Shooting Checklist Note Alert ERR Codes will only be displayed at the thermostat when a call for heat is being sent by the thermo stat The Red LED will be ON at the thermostat The Furnace IFC Status LED will be flashing fast the Fault LED will be flashing a fault code Note The Alert number will not be displayed at the thermostat Comfort Control Alert Fault LED User Interface Display Possible Causes ERR 1 3 Flash System Status OFF Last 4 Faults PS 1 Pressure Switch PS 1 2 or 3 possible failure 2 3 Open or Closed PS 1 amp 2 Open Furnace Drain System stopped up PS 1 amp 2 Open Inducer Motor Drive Board or Inducer Motor PS 1 2 or 3 Open Vent or Ventilation system problems ERR 4 8 Flash System Status OFF Flame Sensing Rod Coated or failure Burner not Last 4 Faults Lo grounded good Flame Sensing Rod position Low FLAME SNS Gas Pressure or IFC ERR 10 6 Flash System Status OFF Ignitor Open or Wiring IFC failure Last 4 Faults IGNITOR Trica ERR ERR 18 ON System Status OFF IFC failure Last 4 Faults CHECK CNTRL or CNTRL FAULT ERR 22 2 F
99. ill protect against short circuit conditions external to the control If the fuse opens the control remains powered and will turn on its Fault LED If the system is running it will shut down all operation An air handler s auxiliary heat will turn off at once There will be a several second delay before the indoor blower is shut down The User Interface Assembly will display CHECK FUSE The air handler can operate using the Communicating System or with 24VAC thermostat inputs The air handler control will default to the communicating system operation on initial power up and will ignore any 24VAC input signals while in that state The control mode can be changed to 24VAC at the User Interface The control will operate the indoor blower motor and electric heat contactors LVTB Function conus 24VAC Power Pin 9 24VAC Common Pin 10 D Data Line Comfort Controls System Only Pin 8 W WIA Input 1 Stage Heating AUX Pin 6 W2 Input 2 Stage Heating AUX Pin 5 W3 Input 3 Stage Heating AUX Pin 4 Y1 Input 1 Stage Compressor Pin 11 Y2 Input 274 Stage Compressor Pin 12 G Input Continuous Fan Blower Pin 7 O Input Heat Pump Cooling Pin 13 BK Input Humidistat Option PWM Input Pin 3 DA 1 Discharge Air Sensor Input Pin 1 Future DA 2 Discharge Air Sensor Input Pin 2 Future Air Temperature Inputs Future Return Air Sensor input Thermistor input which mea
100. k Voltage Voltage Voltage Voltage No Call For OVAC OVAC OVAC OVAC Electric Heat 24VDC 24VDC OVDC Call For OVAC OVAC OVAC Electric Heat 0VDC 24VAC Two Stages of Electric Heat Installed B J COMMON PIN 1 PIN 2 PIN 3 PIN 4 Interlock Voltage Voltage Voltage Voltage No Call For OVAC OVAC OVAC OVAC Electric Heat 24VDC 24VDC 24VDC Call For OVAC Electric Heat 24VAC 24VAC Three Stages of Electric Heat Installed B J COMMON PIN 1 PIN 2 PIN 3 PIN 4 Interlock Voltage Voltage Voltage Voltage No Call For OVAC OVAC OVAC OVAC Electric Heat 24VDC 24VDC 24VDC 24VDC Call For OVAC Electric Heat 0VDC 72 Note When measuring voltage at pins 1 2 3 or 4 the other meter lead should be connected to the trans former 24V common All information contained herein is subject to change without notice Literature Order Number File No Pub No 34 4093 01 1 08 Supersedes Stocking location Since the manufacturer has a policy of continuous product improvement it reserves the right to change design and specifications without notice 2008 Trane All rights reserved
101. l number from the unit it goes into NO Turn off the 24 volt AC supply and the plug the Personality Module back into its socket J12 Re power the Charge Assist Control the fault code should clear itself Fault LED Flash Code of 15 This indicates that there are multiple External AmbientTemperature sensors installed Only one or four sensors can be connected to the EXT terminal board on the Charge Assist Control All information contained herein 72 is subject to change without notice Alert Code Addendum Charge Assist CA LEDs Description Display Liquid pressure below 50 psig Liquid pressure must be above 50 psig to enter CA LOW On Note LOW pressure LED will be on for 30 seconds and the CHARGING LED will flash 5 times per second for 2 seconds then exit CA Red Ambient Temperature below 65 F ODT Flashing Ambient Temperature must be above 65 F to enter CA Note ODT LED will flash 1 sec ON OFF for 30 seconds and the CHARGING LED will flash 5 times per second for 2 seconds then exit CA On Solid at power up Off No power COM Amber Flash device count when in communication Flashing number of communicating products connected in system Rapid flashes followed by a pause indicates disrupted communications CRC errors On Charge is Correct CHARGED Off Green Charged or not in CA Mode None Flashing See Charging Blink Rate Off
102. lash ow DT YES Check the DC voltage at test plug J2 dires terminals D If this voltage is 16 to 17 B O dq volts DC this indicates that the D or B or both CHARGING X STABILIZING A thermostat wires coming from the furnace CD E D or air handler are open Repair or replace the ADD REC STATUS thermostat wire 16 17 TE CHARGED NO Normal voltage at this point is 12 5 volts CED DC Go to step 11 VOLTS D C All information contained herein is subject to change without notice 93 System Communication Trouble Shooting Step 11 Connect one wire at a time back onto the D terminal of the furnace IFC or air handler terminal board These are the wires removed in step 2 Does the BM LED stay on solid and bright when each wire is reconnected one at a time to the D terminal YES Check the control system for proper operation NO When a thermostat wire is reconnected to the D terminal and the BM LED goes out goes dim or starts flashing this indicates that this is the circuit which is causing the ERR or fault Remove this thermostat wire and determine where this thermostat wire goes then go to step 12 Step 12 Go to the component that is being fed by the thermostat wire that was determined to be creating the Err or fault in step 11 and disconnect the thermostat wire going to that component Now go back to the furnace or air handler and reconnect the therm
103. lash System Status OFF Low flame current Flame Flame Detected Last Four Faults Sensing Rod Low gas pressure Then lost RECYCLE LO Burner The difference from ERR20 amp ERR22 is RETRY LO Flame was detected and then lost with an ERR22 ERR26 4 Flash System Status OFF Dirty Filter Blower motor AUX LIMIT or HIGH LIMIT Inoperative wrong blower speed Duct Work Restrictions 9 Flash System Status OFF Furnace being over fired IND LIMIT 4 Flash System Status OFF AUX LIMIT LO HIGH LIMIT LO IND LIMIT LO ERR34 5 Flash System Status OFF GAS Valve IFC or Wiring FLAME ERROR ERR87 4 Flash System Status OFF Inducer Motor running slow ROLLOUT OPEN Vent or ventilation problem ROLLOUT LO Furnace being Over Fired ERR90 10 Flash System Status OFF Communications Errors SYS COMM CRC EMI getting into control System or wiring or IND COMMM or a control Component CRC or BLW COMM CRC ERR93 ON System Status OFF Furnace wiring or jumper added EXT GV ERR Replace Furnace Control INT GV ERR ERR101 N A System Status Furnace IFC Y1 OFF ERR Furnace IFC Y1 ON ERR 34 All information contained herein is subject to change without notice Gas Furnace Communicating Systems Trouble Shooting Checklist Alert Codes continued Comfort Control Alert Fault LED User Interface Display Possible Causes N A TWIN ERROR Not approved Twinning Fault for V S models 2 Flash System Status OFF Ignitor p
104. le For Future Use SNSR1 SNSR1 SNSR2 DLT2 1 MOTOR RPM 0 RPM INDUCER RPM 0 RPM RESET LST FAULT NO NO YES CLEAR LITEPORT NO NO YES PART LIST CNT PM SERIAL NUM 612345 CNTNGNCY MODE NOT AVAILABLE with data line connected and active EXIT NO NO YES 22 CNTNGNCY MODE OR NO YES YES no data line connected See Contingency Mode menu on next page All information contained herein is subject to change without notice Three Stage Gas Furnace Interface Display Troubleshooting continued CNINGNCY MODE NO YES YES no data line connected _LCNTNGNCY MODE STAGE STAGE OFF OFF 123 DUTY CYCLE 10 10 20 30 40 50 START NO NO YES EXIT NO NO YES ARE YOU SURE NO YES NO Note Contingency Mode Setup and Operation is explained on page 21 All information contained herein 23 is subject to change without notice Three Stage Gas Furnace Three Stage Gas Valve Manifold Pressure Adjustment Procedures Turn off the 120VAC power to the furnace e Turn the screw inside the Manifold Gas Pressure Port once counter clockwise to open the port Connect a field supplied U Tube Manometer with field supplied rubber tubes and tees to the three stage furnace as shown in the hook up diagram Remove the thermostat wire from the furnace s IFC D terminal Apply 120 VAC power to the furnace The furnace User Interface will
105. ll information contained herein 81 is subject to change without notice Trouble Shooting Chart F 2 IND COMM ERR Step 5 De power the Gas Furnace At the Gas Furnace IFC remove the wire from the terminal RX at the E9 plug going to the inducer motor drive Black Detail 1 Push down on the wire connector latch clip on the side of the plug and pull the RX wire from the E9 plug Plug the E9 back into the IFC Blue Detail 2 Connect a digital DC Voltmeter to the RX wire removed from E9 plug and the B C low ush down here voltage terminal board See Detail 1 Detail 3 Re power the Gas Furnace Gas Furnace IFC Is the DC voltage between the wire removed from the Gas Furnace IFC plug E9 Terminal RX QQ and the low voltage terminal B C going up and down between 0 145 Volts DC and 0 208 Volts DC LINE NEUTRAL CIRCULATOR 6600 HO p m BM Green LED YES Replace the Gas Furnace IFC NO Go to step 6 Do NOT reconnect the RX wire p OUR 989 Green Status LED o 500 Fio ooo Red Fault LED BAA D R BICY1 145 208 VOLTS D C D R B C Y1 All information contained herein 8
106. llation of a 90 elbow UC1 UX1 100 See Note 1 40 100 130 to prevent dust and debris from falling straight into the furnace and a UC1 UX1 120 See Note 1 15 60 130 2 horizontal or vertical straight pipe DC1 DX1 040 60 80 100 130 section connected below the elbow DC1 DX1 060 50 80 100 130 4 This appliance requires a special venting system Refer to installation DC1 DX1 080 45 80 100 130 instructions for parts list and method DC1 DX1 100 See Note 1 80 100 130 DC1 DX1 120 See Note 1 15 60 130 5 letter may be or T Non Direct Vent 1 Pipe System 6 Use of vent pipe smaller than 3 in diameter is not permitted for UH3 amp UCT UX1 amp DH3 models in propane applications DC1 DX1 040 060 30 80 50 Ten pisos epe UC1 UX1 amp DC1 DX1 080 40 80 80 130 7 Maximum vent length is 150 for UH3 amp DH3 models in propane ap UX1C080A9601 See Note 1 60 80 130 plications at an altitude of 0 7 000 feet UC1 UX1 100 See Note 1 40 80 130 8 Maximum vent length is 100 for UH3 amp DH3 models in propane ap UC1 UX1 amp DC1 DX1 120 See Note 1 25 70 130 plications at an altitude of 7000 9 500 DC1 DX1 100 See Note 1 80 80 130 feet For UH3 and DH3 Propane Applications See Notes 6 9 9 Maximum vent length is 38 for UH3 amp DH3 models in propane applica Models 6 tions at an altitude of 9 500 12 000 UY DY amp UX DX R 2 Pipe 2 5 Pipe 3 Pipe 4 Pipe feet UX2 DX2 am
107. low voltage harness NO Replace the IFC BM Green LED COM Yelow LED 0000000 0000000 Indicates a male spade terminal RTN Return air sensor plug Discharge air sensor plug terminals BK PWM blower speed terminal All information contained herein 87 is subject to change without notice System Communication Trouble Shooting Step 1 Turn off the power to the furnace or air handler Remove the blower door to be able to see the furnace IFC or air handler control board LEDs and their User Interface display On an air handler installation the User Interface display must be temporarily set aside to be able to view the LEDs Restore the power to the furnace or the air handler and watch the green BM LED and the amber COM LED Does the green BM LED come on solid and bright Note BM LED must glow brightly with no flashing YES Go to step 3 NO Go to step 2 Electronic Air Cleaner Switch Terminals c Air Handler Control Board VS COMM PLUG 1 0 DISPLAY 2 5 AMP FUSE ry Comfort ol Plug scopus ony 24VAC EXT SW XFMR RIN AR DR B
108. nature of the fault The last four faults will be available for display at any time via the User Interface The stored Fault Codes can be cleared using the User Interface Fault LED Alert Group Alert Description Solid ON t N A CNTRL FAULT t ERR 18 18 Control Failure Internal Control Error Solid ON t N A CHECK FUSE t N A 92 Fuse Failure 24V Fuse Open Error 1 Flash N A EXT SW OPEN ERR 106 106 External Shutdown Fault External Shutdown Input Open Error PM MEM ERR PM Data Corrupt Error PM MISSING ERR 114 PM Missing Error ID MTR ERR Motor Mismatch Error 2 Flash N A 114 PM Bad or Missing Fault PM UNIT ERR PM Unit Data Error CAP MISMATCH N A Compressor Capacity Mismatch Error PM DATA ERR PM Data Section Error NO SYS CLK COMM Bit Master Clock Error 3 Flash Fast Flash Communication SYS COMM ERR ERR 91 91 Inactive Fault COMM Heat Cool Demand Error 3 Flash N A BLW COMM ERR Serial Motor Communication Inactive Error 3 Flash Fast Flash SYS COMM CRC N A 90 Communication COMM System Busy Error 3 Flash N A BLW COMM CRC Busy Fault Serial Motor Communication Busy Error HT4LK ON ERR Both Interlock Relay amp Heater Relay Heater Interlock Stuck Closed Error amp Fash WWA INTLK ON ERR ERR 103 198 Relay Fault Interlock Relay Stuck Closed Error NTLK OFF ERR Interlock Relay Stuck
109. ne operation without a thermostat Duty Cycling of gas equipment Contingency Mode e Exit Personality Module The communicating microprocessor controls in the indoor and outdoor units have a Personality Module plugged onto their control The Personality Module PM contains the following system specific informa tion Type of indoor unit air handler or gas furnace Variable speed or four speed indoor blower and horsepower of blower The number of stages of heat Type of the outdoor unit AC or HP Number of compressor stages 1 2 or 3 Size of the outdoor unit Indoor Air Flow and Delays Alerts The stored information is downloaded into the unit s controller when the unit is powered up This informa tion is sent to other microprocessor controls connect ed to the Data Line Note Do not remove the Personality Module PM from its control board it is model number and serial number specific to this unit If the PM is unplugged from its control board after the system is powered up the system will continue to op erate If the PM is not plugged back onto the control board an ERROR message will be displayed at the thermostat 24VAC Fuse The on board 24VAC automotive type fuse is in series with the 24VAC terminal R If the fuse opens the con trol s microprocessor remains powered If the system is running it will shut down all operation A gas furnace s gas valve or an air handler s auxiliary heat will turn off at
110. nications To insure that the message being sent by a component ex thermostat indoor or outdoor unit is not being over written by another components operational message noise or electrical interference the sending component will monitor its own operational message on the data line The message must match the original message If the message does not match the sending components original message it will stop sending its message and try again later When a good operating message has been received by the indoor and the outdoor unit the system will begin to operate The Indoor and Outdoor units use this operating message Equipment Setup until a different operational message is received This operating message is being sent repeatedly If the system is running and the units do not receive a good operating message within four minutes the system will shut down This four minute run time prevents the system from shutting down if a component receives a corrupted operating message A corrupted message could be caused by two components sending a message at the same time over written message noise or electrical interference noise on the data line When commutations are reestablished the system will again operate When the system is powered up the microprocessors in the thermostat indoor unit outdoor unit and other accessories will establish communications with each other This is known as a plug and play system A minimum amount of
111. or or Inducer Motor Drive Board V S Motor IFC or IMDB RX 4 4 4 4 4 TX TX RX Common Common 12 Volt 12 Volt All information contained herein is subject to change without notice Clearing Alerts and Approved Combinations Clearing Alerts When a fault or faults are corrected and the faults are cleared at that unit s microprocessor that micropro cessor will quit sending the coded fault message The thermostat will then turn off the red Service LED and quit switching the display back and forth between the normal display and the Alert screen display Approved Combinations 4H 3C HP w 1 Aux 1 EH gas or electric 4H 2C HP w 2 Aux 2 EH gas or electric 4H 1C HP w 3 Aux 3 EH gas or electric 3H 3C HP w 0 Aux 0 EH 3H 2C HP w 1 Aux 1 EH gas or electric 3H 1C HP w 2 Aux 2 EH gas or electric 2H 2C HP w 0 Aux 0 EH 2H 1C w 1 Aux 1 EH gas or electric 1H 1C w 0 Aux EH 3H 3C conventional gas or electric 2H 3C conventional gas or electric 1H 3C conventional gas or electric 0H 3C conventional 3H 2C conventional gas or electric 2H 2C conventional gas or electric 1H 2C conventional gas or electric 0H 2C conventional The following sequence of operation will occur when there are more stages of heat installed than the ap proved combinations list above shows Example When a two st
112. ort Control but when fuse is open the COMM bus has no power Comfort Control will switch to OFF until this fault condition clears Ait information contained herein 46 is subject to change without notice Air Handler Communicating Systems Trouble Shooting Checklist Comfort Control bes COMM User Interface Alert LED Display ERR 18 Solid ONF N A CONTROL FAULTt Cycle power A H control NO DISPLAY Solid ONt N A CHECK FUSEt 24 Volt fuse on A H control A SYS COMM ERR will also be displayed as one of the last four faults ERR 91 3 Flash Fast Flash NO SYS CLK SYS COMM ERR control see Trouble Shooting Procedure 91 TS 91 3 Flash N A BLW COMM ERR ERR Not Displayed 3 Flash Fast Flash SYS COMM CRC Field Thermostat Wiring seeTS 91 ERR Not Displayed 3 Flash N A BLW COMM Check Indoor Blower Low Voltage Cable check Indoor Blower Motor ERR 101 7 Flash N A Y1 ON ERR A H control Y1 relay failure Y1 OFF ERR Replace A H control ERR 104 4 Flash N A HT ON ERR Check W1 W2 W3 for 24VAC call No 24VAC call replace A H control HT OFF ERR Check Electric Heat Plug on A H control No 24VAC replace A H control ERR 105 4 Flash HT LK ON ERR N A INTLK ON ERR Replace A H control INTLK OFF ERR ERR 106 1 Flash N A EXT SW OPEN Check Field Wiring Safety Interlock Float Switch ERR 114 2 Flash PM MEM ERR Cycle power if fault doe
113. osition Wiring Furnace IFC Gas Valve No Last 4 Faults Gas Flame Sensing Rod Burner RECYCLE RETRY 6 Flash System Status OFF 120 VAC power wires reversed POLARITY ERR White and Black wires reversed N A System Status On Or OFF High or Low Voltage being AC VOLTS LO Supplied to the Furnace AC VOLTS HI 6 Flash System Status OFF Furnace not Grounded GND FAULT 10 Flash System Status OFF Thermostat Field wire SYS COMM ERR Furnace IFC NO SYS CLK V S BLOWER Motor BLW COMM ERR Inducer Motor Drive Board IND COMM ERR N A System Status OFF CHECK FUSE N A System Status Repower IFC replace PM DATA BAD Check thermostat set up for O D OD CAP ERR Unit size 35 All information contained herein is subject to change without notice Gas Furnace Alert Code Addendum Alert Notification Alert Description Alert G Fault LED COM LED Meu d Control Display Code RECYCLE Flame is off when flame should be N A 20 Flame lost or detected Furnace tries to relight itself Ignition failure RETRY Furnace tries to light but no flame is detected 2 Flash Device count 10 recycles within a single call for Soft lockout due heat will cause 1 hr lockout a t flame lost r 3 ignition at
114. ostat wire that was determined in step 11 to be the circuit causing the problem Does the BM now stay on solid and bright YES This proves the thermostat wire going to this component is good NO This ERR or fault is being caused by the thermostat wire Repair as needed or replace the thermostat wire All information contained herein 94 is subject to change without notice Communicating System Voltage Readings Note These measurements to be made at component s LVTB Thermostat subbase or field wiring connections at outdoor unit Line Voltage applied to unit Normal Operating Voltage R Power 24 Volts A C D Data 12 Volts D C Common B terminal is common for A C and D C voltage readings Furnace Air Handler Comfort Control TAM or Outdoor Unit R to B 24 Volts A C D to 12 Volts D C If you read R to D you will read 12 Volts D C or 24 Volts A C depending on how you set up your volt meter Voltage readings made at the Furnace or Air Handler LVTB R to B 0 Volts A C With 24 Volts A C to control board and fuse is ok change control board D to B 0 Volts D C 24 Volts A C ok change control board Voltage readings made at the Comfort Control Subbase 24 Volts A C and 12 Volts D C ok at the Furnace or Air Handler LVTB R to B 0 Volts A C Open thermostat wire or B D to B 0 Volts D C Open thermostat wire D Voltage readings made at the Outdoor Unit D
115. ow down the Inducer Motor in steps trying to get PS 3 to open The furnace IFC will reduce the Inducer Motor s speed in steps until Pressure Switch PS 2 opens If PS 3 does not open when this speed is reached the furnace IFC will again signal the IMDB to increase the Inducer Motor back to the second stage LEARNED Speed The furnace IFC then starts flashing its Fault LED three times repeatedly No Alert message is sent to the comfort control thermostat The furnace IFC will keep operating the furnace at its second stage of heat After operating this way for one hour the furnace IFC will again check to see if PS 3 is open or can be opened If PS 3 is now open or can be opened the furnace IFC will go through its learning routine for third stage heat The furnace IFC will stop flashing its Fault LED When the Comfort Control Thermostat is Satisfied When the furnace IFC receives a signal to go down to a lower stage of operation it will signal the Inducer Motor Drive Board IMDB to lower the speed of the Inducer Motor in steps to the learned speed for that stage of operation When the comfort control thermostat is satisfied it will send a new digital signal to the furnace IFC to shut down the heating cycle The furnace IFC now turns off the gas valve e When the furnace IFC sees the burners have shut down no flame current it will begin the time delay period to off for the inducer motor purge cycle and the V S Indoor Blower heat
116. p UH2 DH2 E adita B UX3 DX3 amp UH3 DH3 Altitude Altitude 0 7 000 FT PI 0 2134 M 060 200 Note 6 200 Note 6 200 Note 7 200 Note 7 Additional Notes 080 50 Note 6 120 Note 6 200 Note 7 200 Note 7 1 One SHORT radius 90 elbow is equiva lent to 10 of 3 pipe and one LONG 100 See Note 1 60 Note 6 200 Note 7 200 Note 7 radius elbow is equivalent to 6 of 3 120 See Note 1 See Note 1 200 Note 7 200 Note 7 pipe One 90 elbow is equivalent to 7 5 of 2 1 2 pipe and 5 of 2 pipe Two 45 DH3 DX3 120 Propane See Note 1 See Note 1 100 100 elbows equal one 90 elbow Altitude Altitude 7 000 FT PI 9500 FT PI 2134 M 2896 M 2 The termination tee or bend must be 060 100 Note 6 100 Note6 100 Note8 100 Note 8 included in the total numbers of el bows If BAYVENT100A termination kit 080 25 Note 6 60 Note 6 100 Note 8 100 Note 8 is used the equivalent length of pipe is 5 feet 100 See Note 1 30 Note 6 100 Note 8 100 Note 8 120 See Note 1 See Note 1 100 Note 8 100 Note 8 3 Ba oo are field supplied ex DH3 DX3 120 Propane See Note 1 See Note 1 50 50 4 Low temperature icing on vent inlet or Altitude Altitude 9 500 FT PI 12 000 FT PI 2896 M 3658 M termination may cause pressure switch 060 50 Note6 50 Note6 50 9 50 Note 9 problems 080 See Note 1 30 Note 6 50 Note 9 50 Note 9 100 amp 120 See Note 1 See Note 1 50 Note 9 50 Note 9 DH3
117. point Before the indoor temperature reaches the comfort control thermostat 17 set point the thermostat will signal the Furnace IFC to go back to first stage operation Or if the comfort control thermostat 17 sees the indoor temperature is not moving back towards its set point in time or the indoor temperature is still moving away from thermostat s set point it will signal the furnace IFC to go toThird Stage Heat The IFC signals the Inducer Motor Drive Board IMDB 8 to ramp the vent motor in steps to its learned third stage RPM speed As the Vent Motor Speed increases the amount of gas coming through the gas valve will increase When the IFC sees the 24 Volt AC Signal from Pressure Switch 3 PS 3 9 closing the IFC will then signal the indoor blower 4 to go to itsThird Stage Heat speed The comfort control thermostat will continue to monitor the indoor temperature and send signals to the IFC to operate at different stages or go to off so it can maintain the indoor temperature at the homeowner s set point All information contained herein is subject to change without notice Three Stage Gas Furnace 115 VOLT 60 HZ 1 PH POWER SUPPLY PER LOCAL CODE IFC 10 INDUCER FLAME REVERSE PRIMARY imm ROLL OUT LIMIT switcH SWITCH L SWITCH Gas 1 11 STATUSO i VALVE FAULT 12 ASSEMBLY 13 14 15 16 17 Communicating Thermostat All information con
118. ral 9 co SSGHESH cincuraror oOo 0 0 E9 ES ee COM Yellow LED Green LED E o e 9 COM Yellow LED Green Status LED fs o ooo Red Fault LED OOO Q e Hu ALA 0 D R B C Y1 V All information contained herein 78 is subject to change without notice Trouble Shooting Chart F 1 ERR 91 Displayed at the Comfort Control Step 1 At the User Interface Assembly scroll down to the LAST 4 FAULTS and press the nte button Step 2 What is now displayed on the User Interface Display If IND COMM ERR is displayed go to Trouble Shooting Chart F 2 IND COMM ERR on page 80 If BLW COMM ERR is displayed is the Green LED on the Inducer Motor Drive Board on YES Perform 24 Volt AC GO NO GOTest for Serial Port V S Blower Motor see page 63 NO 1 Unplug the wires going into plug E9 on the furnace IFC these wires go from the furnace IFC to the Inducer Motor Drive Board IMDB 2 At the Comfort Control set the fan to the ON position 3 Turn the power off to the furnace for 30 seconds and then back on 4 The User Interface will display wait until the furnace IFC goes through the power up routine Does the Indoor
119. ressor Capacity Mismatch Error PM Data Section Error Data Section is Corrupt but PM is useable Compressor size does not match capacity in PM Blower HP OEM does not match PM Data No PM N A PM DATA ERR PM DATA ERR CAP MISMATCH ID MTR ERR PM MISSING Device count PM UNIT ERR PM MEM ERROR N A ERR 114 N A ERR 114 ERR 114 Bad or Missing PM Primary Copy of Unit Data File is Corrupt Primary and Secondary copies of Unit Data File are Corrupt PM Data Corrupt Error or PM Missing Error PM Unit Data Error or PM Data Section Error Bad or Missing PM N A 14 Flash 117 x N A RASRNGERR 6 Flash DAS RNG ERR Discharge Air Temperature Range Error ERR 118 DAS UL ERR 5 Flash N A Discharge Air Temperature Upper Limit Error DAS LL ERR Discharge Air Temperature Lower Limit Error TS 1 SHORT Temperature sensor 1 shorted TS 1 OPEN Temperature sensor 1 open Di t TS 2 SHORT VIER TONN Temperature sensor 2 shorted Temperature Sensor Failure TS 2 OPEN Temperature sensor 2 open DEMAND ERR N A Heat Cool Demand Conflict Error D d Confi tion Fault SSS 9 Flash 125 acs M CFG ERR m NIA Electric Heat Configuration Error Equipment does not match 126 valve stored at startup T Handler processor is reset or fuse is open COMM Alert cannot be reported if the processor is reset the User
120. rmation contained herein 68 is subject to change without notice Trouble Shooting Charge Assist Control Fault LED Flash Code Charge Assist Control LED Flash Code Trouble Shooting Procedures If the Comfort Control is displaying an Err code of 89 or 91 or if the Charge Assist Control Fault LED is flashing a 1 flash code go to trouble shooting procedures for Err code 89 or 91 Comfort Control Fault LED Description Display 90 Excessive Communication CRC Errors ERR 90 1 Flash No Communication 91 ERR 91 Loss of Clock Signal 2 Flash Defrost Fault A 3 Flash 68 Defrost Fault B and or C None 4 Flash Defrost Fault A and B and or C 5 Flash Ambient Temperature Sensor Fault Out of Range Open or Shorted 6 Flash neg i Coil Temperature Sensor Fault Out of Range Open or Shorted 7 79 LPCO Fault Open outside of defrost Cycle ERR 79 10 Flash 102 Y2 without Y1 Miswire 24 volt mode only 11 Flash 67 Liquid Temperature Fault Out of Range Open or Shorted None 12 Flash 113 Liquid Pressure Sensor Fault Out of Range Open or Shorted 13 Flash 67 External ODT Sensor Fault Out of Range Open or Shorted 14 Flash 114 Bad or Missing PM ERR 114 15 Flash 50 Duplicate OD temperature sensor None J10 COILT AMBIENTT EXT ODT ow DT l OF RANGE ESSURE EL EN ES D J7 TBI LIQUID T CHAR
121. rol NEC Class 1 Wiring 24 Volts Wire Size Max Wire Length All information contained herein 11 is subject to change without notice Comfort Control with a Single Stage 24 Volt Controlled A C COMFORT INDOOR SINGLE STAGE A C CONTROL UNIT OUTDOOR UNIT DATA D 9 D 24VAC HOT R bi H 24VAC lp B 0 d p SUUS YT potett Y1 Field Wiring Diagram Communicationg Indoor Unit Non Communicating A C Outdoor Unit All information contained herein 12 is subject to change without notice Gas Furnace and Air Handler Common Components User Interface Assembly The indoor User Interface Assembly will display the model and serial number during normal unit opera tion In addition the following information can also be accessed through the display The Units Model amp Serial Number Normal Display System Status Mode of Operation Heating Stage 1 2 or 3 Cooling Stage 1 2 or 3 or OFF thermostat not calling Requested Airflow CFM when the thermostat is calling Indoor Unit s Alert Codes Unit Test Cycle Heating Cycle Only Blower Motor Speed RPM when operating Fossil Fuel Draft Inducer Speed RPM when operat ing Last Four Alerts Replacement Part List Personality Module Serial Number Stand alo
122. rrent is low but still strong enough to allow operation 9Flash Device count IND LIMIT ERR 26 26 High Temp Limit Fault 79 ges temperature too high Could be caused by low airflow or fan failure SYS COMM CRC 2 Comm system unrecognized response IND COMM CRC N A 90 BE Inducer Motor unrecognized response BLW COMM CRC Blower motor unrecognized response 10 Flash Fast Flash BLW COMM ERR Blower motor no Comm response IND COMM ERR Inducer motor no Comm response ERR 91 91 Communication Fault SYS COMM EER Loss of heat cool demand NO SYS CLK Loss of clock signal Solid ON Device count CNTRL FAULT ERR 18 18 Control Failure Internal control failure None Device count TWIN ERROR N A 19 Twinning Fault Twinning Not Allowed with Variable Speed PM DATA ERR N A Data Section is Corrupt but PM is useable CAP MISMATCH Compressor size does not match capacity in PM ID MTR ERR ERR 114 Blower HP OEM does not match PM Data None Device count PM MISSING 114 Bad or Missing PM No PM PM UNIT ERR N A Primary Copy of Unit Data File is Corrupt Primary and Secondary copies of eres Unit Data File are Corrupt AC VOLTS LOW Voltage too low None Device count N A 59 AC Line Fault AC VOLTS HIGH Voltage too high None Device count CHECK FUSE N A 92 Fuse 24V Fuse Open Y1 OFF ERR Y1 Output OFF when it should be ON None Device count ERR 101 101 Y1 Relay Failure put DFW a should be 0 Y1 ON ERR Y1 Output ON when it should be OFF TS 1 SHORT Temperature sen
123. run the inducer motor at 5 Flash Flame Sensed when no flame should be present the preset factory second stage heat RPM 6 Flash Reversed Polarity or Ignitor Triac Fault The furnace s IFC looks for the PS 1 and PS 2 pressure a switches to close A 24 Volt A C Signal goes to the 7 Flash External Gas Valve Circuit Error 5 furnace IFC when pressure switch closes 8 Flash Low Flame Sense e The furnace IFC will continue to signal the IMDB to 9 Flash Open Inducer Limit Switch increase the inducer speed in steps if PS 1 and PS 2 10 Flash Communication Error are not closed when the preset factory second stage Solid ON Internal GV IFC Error heat RPM UCM stage t at maximum rst n Solid ON with Solid Internal IFC Error two Ho edi STATUS ON 1S Sea i IFC Inducer Learning Routine Sequence The furnace IFC will go through an Inducer Learning Routine for each stage of heat The Learning Routine is done to determine the correct amount of ventilation air for complete combustion Too much ventilation air will reduce the furnace s AFUE efficiency rating The inducer motor s speed for each stage may be different for each installation due to the different length and size of the ventilation pipe vent pipe number of pipe fittings used and the type of vent cap installed The Inducer Learning Routine is repeated each time the furnace IFC does a RESET or is powered up and the furnace s IFC receives a call
124. s locked out by the Low Pressure Cut Out Switch Repair system as needed If there is no 24 Volts AC at plug J4 replace the Charge Assist Control Push in and hold the Mode switch on the Charge Assist Control for 1 second Does the Status LED now flash slowly YES Go to step 4 NO Replace the Charge Assist Control Is there 24 Volts AC at plug J3 between its pins Y1 and B or Y2 and B Note There should be 24 Volts present only between pinsY1 B when the Amber LEDY1 is or 24 Volts AC between pins Y2 and B when the Amber LED Y2 is on YES Charge Assist Control is working correctly fault is with the unit s wiring it s contactors or it s compressor NO Replace the Charge Assist Control MODE CHARGING pec status DATA R B oo Gib a C O O O J2 m Ji Y2c IOlres 1 Y2C PWM ux 164 R165 VOLTS A C ve Olres o BUM IN C A c BARCODE DATE OF MFC SL 3 C33 APPLY P N LABEL HERE Connect this meter lead to Y1 or Y2 at plug J3 All info
125. s not clear replace PM N A PM MISSING Put PM in A H Control ID MTR ERR Cycle power check for correct ID Blower Motor H P ERR Not Displayed 2 Flash PM UNIT ERR Cycle power replace PM N A CAP MISMATCH Cycle power outdoor unit must match the size of ID unit Replace outdoor unit s PM PM DATA ERR Cycle power replace A H PM ERR 118 5 Flash DAS RNG ERR Check Discharge Air Sensor N A DAS UL ERR Discharge air temperature too high check indoor air flow DAS LL ERR Discharge air temperature too low check indoor air flow ERR Not Displayed 5 Flash N A DAS SHORT Discharge Air Sensor DAS OPEN ERR Not Displayed 6 Flash N A RAS RNG ERR Check Return Air Sensor ERR Not Displayed 6 Flash N A RAS SHORT Check Return Air Sensor RAS OPEN ERR Not Displayed 8 Flash N A TWIN ERROR 2 A H detected on the same buss NO operation permitted ERR Not Displayed 9 Flash N A DEMAND ERR More stages of Auxiliary Heat wired up than control system can control HT CFG ERR Notes t If Air Handler processor is reset or fuse is open COMM Alert cannot be reported if the processor is reset the User Interface will not be updated Alert flash code will not be implemented for initial release COMM communication errors may also be flashed on Fault LED t LitePort transmissions will be allowed during ON flash codes Fuse alert notification level would show on Comfort Control but when Fuse is open the COMM bus has no po
126. sh N A Excessive Communication CRC Errors Communication Busy Fault Communication Inactive Fault N A NO SYS CLK None 3 Flash N A Fast Flash Comm line busy and no idle has been detected COMM Bit Master Clock Error SYS COMM ERR 3 Flash Fast Flash COMM Heat Cool Demand Error BLW COMM ERR 3 Flash N A Serial Motor Communication Inactive Error Communication Fault BLW COMM ERR IND COMM ERR SYS COMM ERR NO SYS CLK 10 Flash Fast Flash Blower motor no Comm response Inducer motor no Comm response Loss of heat cool demand Loss of clock signal Communication Fault _ ECT Sa __ ____ Lo xs LS X E X x X N A 1 Flash Fast Flash Fast Flash No Communication Communication Fault N A Loss of Clock Signal Comm line is dead and no bits have been received All information contained herein is subject to change without notice Alert Code Addendum Alert Communicating Equipment Alert Notification I i I ipti Code Alert Group Air um Outdoor Comfort User Interface Fault LED COM LED Alert Description Handler Unit Control Displa Fuse N A CHECK FUSE None N A 24V Fuse Open Fuse Failure x CHECK FUSE Solid ON N A 24V Fuse Open Error Control senses 24V present at the gas valve when it 7 Flash not b t EXT GV ERR should not be present ERR
127. sor 1 shorted TS 1 OPEN Temperature Temperature sensor 1 open N D t _ N A 119 nun M TS 2 SHORT Sensor Failure Temperature sensor 2 shorted TS 2 OPEN Temperature sensor 2 open Comfort Control will switch system to OFF until this fault condition clears 36 All information contained herein is subject to change without notice Communicating Air Handler CONTROL BOARD INSIDE BOX USER BREAKER INTERFACE AUX HEATER CHOKE TRANSFORMER not on all models HIGH VOLTAGE 5 PIN POWER PLUG VS MOTOR LOW VOLTAGE 4 PIN CONTROL PLUG TERMINAL BOARD All information contained herein 37 is subject to change without notice Communicating Air Handler User Interface Access Plate Control Board Enclosure Air Handler Control Board All information contained herein 38 is subject to change without notice Communicating Mode Drawing Communicating Mode denotes the current setting Standy Screen Setup Menu Setup Options m minutes CMFRT CNT COMFORT CNT SERIAL NUMBER comm 17905 gt MODE COMM COMM 24VAC 24VAC 24VAC
128. sures the temperature of the air as it enters the Air Handler Discharge Air Sensor input Thermistor input which measures the temperature of the air as it exits the Air Handler Serial Port Variable Speed Motor A 4 wire harness enables communication between the serial port variable speed blower and the air handler control board VS Com Plug Pin1 12VDC Power Pin2 RX Motor to Control Data Line Pin 3 Common Pin4d TX Control to Motor Data Line See page 42 for location of VS COM plug All information contained herein is subject to change without notice Air Handler Sequence of Operation Electric Heater Terminals A 4 wire harness provides 24V output to the electric heater contactors Humidifier Terminals HUM A set of contacts male terminals will close for operation of a humidifier when the control is in heating mode and the blower is operating Pin 1 Ist stage electric heat 24V to 240VAC operation 1 amp max Pin2 2nd stage electric heat Pin3 3rd stage electric heat Electronic Air Cleaner Terminals EAC Pin4 Common s A set of contacts 4 OC male terminals will close for operation of the air cleaner anytime the blower is operating 24V to 240VAC operation 1 amp max Air
129. t Control and then re power the control If the 5 flash codes continue to be displayed replace the Charge Assist Control NO Unplug and re plug the Ambient Temperature Sensor plug J7 several times to insure that it is making good contact with the Charge Assist Control plug then recheck the DC voltage at plug J7 or unplug the sensor and read the resistance of the sensor IF the DC voltage or resistance at plug J7 and the ambient tem perature still does not agree with the temperature resistance and voltage Chart1 replace the Ambient Temperature Sensor Fault LED Flash Code of 6 ERR code 67 will be displayed on heat pump Comfort Controls only This sensor is used only on heat pump models The fault LED will be flashing in groups of six flashes This indicates that the Coil Temperature Sensor is reading out of range Read the DC voltage at the Charge Assist Control CoilTemperature Sensor plug J6 with the sensor plugged in or unplug the sensor and read the resistance of the sensor Does the coil temperature and the DC voltage or its resistance in ohms read at the Coil Temperature Sensor plug J6 agree with the temperature resistance and voltage chart 1 YES Unplug and re plug the Coil Temperature Sensor plug J6 several times to insure it is making good con tact with the control pins Turn off the 24 Volts AC to the Charge Assist Control and then re power the control If the 6 flash codes continue to be displayed replace the Charge Assist
130. tained herein 29 is subject to change without notice Three Stage Gas Furnace Pressure Switch Testing 3 Check for 24 Volts AC coming to the pressure switch see drawing 3 Connect one lead of the AC Volt Meter to the B C terminal of the gas fur nace low voltage terminal board and the other AC Volt Meter lead will be connected to one pressure switch terminal one at a time to see if 24 Volts AC is being supplied to the pressure switch If 24 1 Connect a slope gauge or magnehelical gauge to the recoup cell cold header and the burner box fittings using field supplied tees and hoses see drawing 1 g Volts AC is present at both pressure switch termi nals the pressure switch is closed and it must be Drawing 1 replaced Check the following furnace s compo nents if 24 Volts AC is not being supplied to the pressure switch 5 amp fuse transformer wiring and the furnace IFC SN Brown Drawing 3 1st Stage Pressure Switch SLOPE GAUGE Heat Exchanger Cold Header Field Supplied 2 Connect an AC Volt Meter to the pressure switch being tested Connect the meter leads to the pressure switch terminals see drawing 2 The AC Volt Meter should read 24 Volts AC if the 24 Volts AC is present at the switch go to step 4 if the 24 Volts AC is not read go to step 3 Brown D R B C Y1 4 Set the comfort control thermostat to call for heat Connect th
131. tempts in a row within a ignition retries RETRY LO i single call for heat results in 1 hr lockout PS3 OPE Open Pressure Switch third stage PS3 CLOSED Shorted Pressure Switch third stage PS2 OPEN i Open Switch d st 3 Flash Device count N A 1 Pressure Switch ____ _ E eee PS2 CLOSED Failure Shorted Pressure Switch second stage PS1 OPE Open Pressure Switch first stage PS1 CLOSED Shorted Pressure Switch first stage AUX LIMIT Open Reverse Flow Heat exchanger temperature too ERR 26 High Temp high Could be caused by low airflow or fan failure 4 Flash Device count Limit Fault Open High Limit Heat exchanger temperature too high HIGH LIMIT Could be caused by low airflow fan failure ROLLOUT OPEN ERR 87 87 Roll Out Fault Open flame rollout 5 Flash Device count FLAME ERROR ERR 34 34 Flame Detect Fault Flame detected should not be present POLARITY ERR N A 33 Line Polarity Fault Voltage reverse polarity GND FAULT N A 88 Ground Fault Occurs when proper earth ground is not detected 6 Flash Device count IGNITER ERR ERR 10 10 Ignition gni er Tau TRIAC ERR Means Fault Triac Fault 7 Flash EXT GV ERR Control senses 24V present at the gas valve when it should not be present Device count ERR 93 93 Gas Valve Fault Control tried to turn on gas valve but 24V not sensed Solid ON INT GV ERR Control senses 24V present at the gas valve when it should not be present 8Flash Device count LO FLAME SNS N A 4 Low Flame Signal Flame cu
132. the User Interface Information Menu until you see the Unit Test option Press ENTER When prompted select YES and press ENTER When the User Interface displays ARE YOU SURE Select YES and press ENTER to begin the UnitTest The Unit Test will perform the following steps without delays User Interface displays UNIT TEST BLWR e Start Blower at 50 airflow for 10 seconds Go to 100 airflow for 10 seconds User Interface displays UNIT TEST COOL e EnergizeY1 relay for 15 seconds with 100 airflow e De energize Y1 relay and go to Electric Heat airflow User Interface displays UNIT TEST HEAT Energize blower interlock and stage 1 heat relay After 1 second energize stage 2 heat relay After 1 more second energize stage 3 heat relay e After 5 seconds de energize blower interlock stage 1 2 amp 3 heat relays User Interface displays UNIT TEST EXIT Displayed for three seconds Note Airflow is default or programmed selections All information contained herein is subject to change without notice Air Handler LED Fault Code Fault LED The Fault LED will be turned on at power up and will remain on for a short time period and then turned off When no faults are present the Fault LED will blink once every 20 seconds This blink is a data output not field usable Alert Notification When a fault has been detected the control will flash the Fault LED for a specified number of times to indi cate the
133. the Charge Assist Control in being operated with a standard 24 volt AC thermostat non communicating type and thermostat leads Y1 and Y2 are reversed All information contained herein 70 is subject to change without notice Trouble Shooting Charge Assist Control Fault LED Flash Code Fault LED Flash Code of 11 The fault LED will be flashing in groups of eleven flashes This indicates that the Liquid Line Temperature Sensor is reading out of range At the Charge Assist Control read the DC voltage at the Liquid Temperature Sensor plug J8 with the sensor plugged in or unplug the sensor and read the resistance of the sensor Does the liquid line temperature and the DC voltage or resistance read at the Liquid Temperature Sensor plug J8 agree with the temperature resistance and voltage chart 2 YES Unplug and re plug the Liquid Line Temperature Sensor several times to insure it is making good contact with the control pins Turn off the 24 Volts AC to the Charge Assist Control and then re power the control If the 11 flash codes continue to be displayed replace the Charge Assist Control NO Unplug and re plug the Liquid Line Temperature Sensor plug several times to insure that it is making good contact with the Charge Assist Control plug then recheck the DC voltage or resistance IF the DC volt age and temperature or resistance still does not agree with the Liquid Line temperature resistance and volt age Chart 2 replace
134. the first stage compressor enter a 1 minute delay and start flashing the Green LEDs 1 and Y2 Then the CA control will start the second stage compressor Green LEDs Y1 and Y2 will then be ON The CA control now starts its Charge Assist cycle Note 3 Personality Module PM contains model specific information needed for system operation Do Not Remove Note 4 The word WAIT will be displayed on the Communicating Comfort Control when the system is in the CA mode The Communicating Comfort Control does not control the system operation when the system is running in the CA Mode Any changes in the Communicating Comfort Control programming made during the CA mode of operation will become effective after the CA mode ends All information contained herein is subject to change without notice Charge Assist Procedure Details Charge Assist CA Procedure with a Communicating Comfort Control The Communicating Comfort Control will auto configure the system size and airflow requirement at power up The CA Mode will set the indoor blower to 100 override any blower delays and will turn on 2nd stage compressor Green LEDs Y1 and Y2 will be ON The Green Status LED will be turned OFF STEP 1 Press MODE button see fig 1 for 2 seconds to enter the CA Mode cycle The CA control takes control of the system and overrides the Communicating Comfort Control The Green STATUS LED is turned OFF The CA
135. ting section Is the Status LED flashing slowly YES Go to step 4 NO If the Status LED is out go to step 5 if the Status will not stop flashing fast replace the Charge Assist Control All information contained herein is subject to change without notice 67 Trouble Shooting the Outdoor Unit s Charge Assist Control Step 4 Step 5 Step 6 RY B J10 AMBIENTT EXT ODT Low a esee Se E 3E cen o WS emm R164 8165 MAP v2 Econ B J6 TBI m 5027 LIQUID T ene no presunen Ga PERSONALITY ee GE EM e t GEE Does Y1 or Y2 LEDs come on when a call for compressor operation is placed at the Comfort Sensor thermostat or the 24 Volt AC control thermostat Note 1 When the Comfort Sensor thermostat is set up for compressor operation and WAIT is displayed on the sensor display there will be a five minute delay beforeY1 orY2 will come on Note 2 A 24 Volt AC digital thermostat may have a time delay when the cooling set point is changed to prevent compressor short cycling YES Go to step 6 NO On an A C unit replace the Charge Assist Control Heat Pumps units only check for 24 Volts AC across Charge Assist Control LPCO plug J4 The fault LED should be flashing in groups of seven flashes if the LPCO switch is open If 24 Volts AC is present the Heat Pump i
136. to B 16 5 Volts D C Open thermostat wire D D to B 13 6 Volts D C Open thermostat wire B When outdoor unit is off no 24VAC data line voltage stays at 12VDC This 12VDC is supplied by the communicating indoor unit When outdoor unit is on 24VAC present and D field thermostat wire is open the data line voltage will read 16 5 VDC Voltage readings made at TAM R to B 0 Volts A C Open thermostat wire R or B D to B 0 Volts D C Open thermostat wire D Communicating Voltage to Blower Motor and Furnace Inducer Drive Board FURNACE IFC The following voltage readings are to be made at plugs E8 or E9 with motor harness connected 12V to GND 12 Volts D C RX to GND 12 Volts D C TX to GND 0 Volts D C NOTE The TX may have a voltage of 0 5 to 1 5 Volts D C when Air Handler control board is first powered up This may also occur if the blower motor and Air Handler control board are not communicating with each other Air Handler The following voltage readings are to be made at plug VS COMM with motor harness connected 12 VCC brown wire to B C 12 Volts D C RX purple wire to B C 12 Volts D C TX orange wire to B C 0 Volts D C B C blue wire Air Handler Electric Heat Plug ELEC HT 4 3 2 1 JOOU E104 ELEC HT Plug Voltage Reading One Stage of Electric Heat Installed B J COMMON PIN 1 PIN 2 PIN 3 PIN 4 Interloc
137. tor in steps to the first stage vent motor speed This reduction in steps of the Vent Motor Speed will cause the Gas Flow through the Gas Valve to go down in steps which will reduce the chances of a burner flame out When the IFC sees the 24 Volt AC signal from Pressure Switch 2 PS 2 9 go away it will then signal the Indoor Blower 4 to go to the First Stage Heat speed The comfort control thermostat 17 will continue to call for first stage heat operation until the indoor temperature is back at the comfort control thermostat set point or if the comfort control thermostat 17 sees the indoor temperature is not moving back towards its set point in time or the indoor temperature is still moving away from comfort control thermostat set point it will Signal the IFC 17 to go to second stage heat The comfort control thermostat 17 then signals the Furnace IFC for second Stage Heat 28 The IFC 8 signals the Inducer Motor Drive Board IMDB 8 to ramp the Vent Motor up in steps to its Learned Second Stage RPM speed AS the Vent Motor 8 speed increases the amount of gas coming through the gas valve will increase When the IFC sees the 24 Volt AC Signal from Pressure Switch 2 PS 2 9 closing the IFC will then signal the Indoor Blower 4 to go to its Second Stage Heat Speed The comfort control thermostat 17 will continue to call for second stage heat operation until the indoor temperature moves back toward its set
138. ual method of charging above 55 F ambient temperatures and below 100 F When the ambient temperature is above 100 F charge the system to 10 F of subcooling at the liquid line just passed the service valve It is important to return and check the system charge when the outdoor temperature is between 55 F and 100 F to verify the system charge For best results the indoor temperature should be kept between 70 F to 80 F Add system heat if needed 3 At startup or whenever charge is removed or added the system must be operated for a minimum of twenty 20 minutes to stabilize before accurate measurements can be made 4 Determine the total refrigerant line length and height lift if the indoor section is above the condenser Turn on one 1 Dip switch on the Charge Assist board to the ON position as indicated in the Correction Table to the Lower Middle or Upper ON position Turn on only one switch on the Charge Assist board A Dip Switch does not have to be turned on for the manual charging method 5 Turn the indoor thermostat down to a low setting to insure the system will operate at second stage operation during this charging procedure Indoor blower should automatically go to second stage cooling air flow 6 Measure the Liquid LineTemperature and Refrigerant Pressure at the Liquid LINE Service Valve 7 R 22 Refrigerant charging charts for the listed models ONLY These charts are on pages 52 53 54
139. ufficient charge has been added the Amber ADD LED will turn OFF and the Green CHARGED LED will be turned ON When the Amber ADD LED turns OFF stop adding refrigerant The Green CHARGED LED will stay 59 on for 5 minutes while the unit runs The CA control will now exit the Charge Assist cycle and return control to Communicating Comfort Control Charge Assist Tool Part No BAYCAKTOO1AA O CHARGE ASSIST LIQUID gt d PURI A 9 DO NOT INSTALL BACKWARDS HOOK UP TO REFRIGERANT BOTTLE FIRST CH je BD A STEP 6 Recover Routine If the CA control determines there is excessive refrigerant in the system the REC Red LED will be turned ON The CA control will lock the system off for one hour and it will them exit the CA cycle The REC Red LED will stay ON for 1 hour The CA control lock out period can be stopped by pressing the MODE button for 1 second Status LED will be off during lockout All information contained herein is subject to change without notice Charge Assist Procedure for a NON Communicating 24 VAC Control System 24 VAC Step 1 Installations using indoor units with 24 volts require the technician to set up the Variable Speed VS Air Handler or VS Furnace with the DIP switches for the size of the equipment installed Unit tonnage CFM per ton 350 400 450 required the blower delays an
140. ve PRESSURE 77 Clg CHARGING 9 rH C56 e STABILIZING 4 ADD REC STATUS GN VP ii 1 ADD REC STATUS R164 R165 OOO O DS13 R164 R165 y Dre 1 Y2C PWM 2 5 34 C33 C31 1 Y2C PWM APPLY P N LABEL HERE Step 2 Step 3 Is there 24 Volts AC at the Charge Assist Control at plug J2 pins R and B YES Go to step 2 for a communicating system For a 24 Volt AC control system go to step 4 NO Restore the 24 Volt AC power to the outdoor unit Note 1 A communicating system the 24 Volt AC is supplied by the Outdoor Units transformer Note 2 A 24 Volt AC control system the 24 Volt AC power is supplied by the Indoor Unit s transformer Is the Charge Assist Control s COM LED flashing the correct number of times Example A system that has a communicating thermostat a communicating furnace or air handler and a communicating outdoor unit the COM LED should be flashing in groups of three flashes YES The Charge Assist control is communicating with the control system Go to step 3 NO The COM LED is flashing fast go to the trouble shooting ERR code 89 or 91 trouble shoo
141. wer A H Air Handler TS PM Personality Module ID Indoor SYS System BLW Indoor Blower Motor COMM Communication CRC Circuit HT Heater Trouble Shooting Procedure Number LK Interlock INTLK Interlock EXT External SW Switch MTR Motor CAP Compressor Capacity DAS Discharge Air Sensor RAS Return Air Sensor All information contained herein 47 is subject to change without notice Two Compressor Outdoor Units Features and Benefits e Efficiency e 2 Wire Control System with Alert Signaling with Communication System e Refrigerant System Efficiency Monitored Charge Assist e Single Side Service 48 HI Contactor LO Contactor ChargeAssist Control J1 Plug Transformer Ten Year Warranty on All Parts Variable Speed Outdoor Fan Motor Compressor Sound Shields Unit can be controlled with a Standard 24VAC Volt Thermostat All information contained herein is subject to change without notice Outdoor Units Theory of Operation Charge Assist Control The Outdoor unit s Charge Assist Control Board is located in the outdoor unit The Charge Assist Control sequences the two compressors one at a time provides compressor time delays does fault diagnostics and when the Charge Assist cycle is entered by the service technician the Charge Assist Control can determines if the refrigerant system is correctly charged under charged or over charged the outdoor unit
142. will normally flash rapidly for a few seconds when the system is powered up and then go to a slow flash rate of 1 2 or 3 or more flashes What is the amber COM LED doing Slowly flashing 1 flash and after three minutes it then goes to a fast flash This means the furnace IFC or the air handler control board is not communicating with anything Go to step 7 Flashing in groups of 2 3 or more flashes This means the furnace IFC or the air handler control board is communicating with the Comfort sensor and some of the other components in the system The number of flashes in the group is the number of things that are communicating with each other Go to step 4 Flashing in groups of 2 3 or more flashes for three minutes and then goes to a fast flash rate This means that the Comfort Sensor and the furnace IFC or air handler control board are not communicating Go to step 6 Step 4 How many communicating components are connected in this system The furnace IFC or air handler count as one the thermostat counts as two the outdoor unit counts as three if the outdoor unit is a communicating type and a telephone access module would count as four Does the number of communicating components agree with the flash code count of the furnace IFC or air handler COM LED YES Go to step 5 NO Go to step 8 All information contained herein 89 is subject to change without notice System Communication Trouble Shooting Step 5 At the
143. with a 50 96 duty cycle Re adjust the first stage pressure adjustment screw if the adjustment of the third stage adjustment affected the first stage setting If the first stage pressure adjustment screw setting is now changed you will have to again go to the third stage heat and check its operating pressure If the third stage operating gas pressure has again changed you will have to adjust it again and then recheck the first stage operating gas pressure Adjust the first stage and third stage pressure adjustment screws until minimum interaction between the two are seen When the correct operating gas valve pressures are obtained turn the furnace off Remove the field supplied manometer tubing and the tee installed at the beginning steps and TIGHTEN DOWN THE MANIFOLD DUST CAPS and the GAS PRESSURE PORT SCREW Reconnect the thermostat data line to the D terminal of the furnace Turn on the 120V power to the furnace With the thermostat data line connected to the furnace and communications between the thermostat and the furnace re established the furnace operation will now be controlled by the comfort control thermostat NUMBER MAIN BURNER ORIFICE OF DRILL SIZE BURNERS NAT GAS 60 000 3 45 51 80 000 4 45 51 100 000 5 45 51 120 000 6 45 51 Gas Valve Opening Characteristics Propane Convertible Valve Supplier Yes burner Unit Test Cycle A qualified technician can

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