Service and Troubleshooting

AVZC18 Inverter Heat Pump Condenser Units with R-410A Refrigerant

Blowers, Coils, & Accessories

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service.

Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE

APPROPRIATE SERVICE MANUAL BEFORE

BEGINNING REPAIRS.

WARNING

Only personnel that have been trained to install, adjust, service or repair(hereinafter, “service”) the equipment specified in this manual should service the equipment. The manufacturer will not be responsible for any injury or property damage arising from improper service or service procedures. If you service this unit, you assume responsibility for any injury or property damage which may result. In addition, in jurisdictions that require one or more licenses to service the equipment specified in this manual, only licensed personnel should servise the equipment.

Improper installation, adjustment, servicing or repair of the equipment specified in this manual, or attempting to install, adjust, service or repair the equipment specified in this manual without proper training may result in product damage, property damage, personal injury or death.

PROP 65 WARNING

FOR CALIFORNIA CONSUMERS

WARNING

Cancer and Reproductive Harm www.P65Warnings.ca.gov

0140M00517-A

For service information related to the Bluetooth® Shared

Data Loader BTSDL01 referenced in this manual, please refer to the installation instructions for the BTSDL01 at www.coolcloudhvac.com/loaderuserguide

TABLE OF CONTENTS

IMPORTANT INFORMATION ............................................. 2

PRODUCT IDENTIFICATION ............................................ 4

SYSTEM OPERATION ....................................................... 5

SERVICING ........................................................................ 9

CHECKING VOLTAGE ................................................. 9

CHECKING WIRING ..................................................... 9

CHECKNG THERMOSTAT, WIRING ........................... 9

THERMOSTAT AND WIRING ....................................... 9

CHECKING TRANSFORMER AND CONTROL

CIRCUIT ......................................................................... 9

CHECKING HIGH PRESSURE SWITCH .................. 10

CHECKING INDOOR AND OUTDOOR HI/LOW

PRESSURE SENSOR................................................. 10

CHECKING COMPRESSOR ...................................... 10

COMPRESSOR WINDING INSULATION TEST ....... 11

GROUND TEST ........................................................... 11

TESTING TEMPERATURE SENSORS AND EEV

COIL RESISTANCE..................................................... 12

TESTING EEV COIL RESISTANCE .......................... 12

TESTING REVERSING VALVE .................................. 12

AVPEC* HEATER CONTROL ..................................... 13

REFRIGERATION REPAIR PRACTICE .................... 14

LEAK TESTING (NITROGEN OR NITRO-

GEN-TRACED) ............................................................ 14

STANDING PRESSURE TEST (RECOMMENDED) . 14

EVACUATION .............................................................. 15

CHARGING .................................................................. 16

FINAL CHARGE ADJUSTMENT ................................ 16

CHECKING COMPRESSOR EFFICIENCY .............. 16

CHECKING SUBCOOLING ........................................ 16

NON-CONDENSABLES .............................................. 17

COMPRESSOR BURNOUT ....................................... 17

Copyright © 20152017, 2019, 2021 Goodman Manufacturing Company, L.P.

®

is a registered trademark of Maytag Corporation or its related companies and is used under license.

All rights reserved.

RS6215001r6

March 2021

2

IMPORTANT INFORMATION

REFRIGERANT PIPING ............................................. 18

DUCT STATIC PRESSURES AND/OR STATIC PRES-

SURE DROP ACROSS COILS ................................... 22

AIR HANDLER EXTERNAL STATIC .......................... 22

COIL STATIC PRESSURE DROP .............................. 22

INDOOR UNIT TROUBLESHOOTING ...................... 23

DIAGNOSTIC CODES ................................................ 25

SETTING THE MODE DISPLAY ................................ 28

INDOOR UNIT ERROR CODES ................................ 30

CTK04 ADDENDUM .................................................... 49

TROUBLESHOOTING ..................................................... 69

WIRING DIAGRAMS ........................................................ 81

ACCESSORIES................................................................ 83 checking heater limit control(s) (optional Electric Heaters)

84 electric heater optional item .......................................... 84 checking heater fuse link (optional electric heaters) ..... 85

IMPORTANT NOTICES FOR CONSUMERS

AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND

LABELS

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL

SERVICE INFORMATION IN THE APPROPRIATE SERVICE

MANUAL BEFORE BEGINNING REPAIRS.

WARNING

HIGH VOLTAGE !

D ISCONNECT ALL POWER BEFORE SERVICING .

M ULTIPLE POWER SOURCES MAY BE PRESENT . F AILURE

TO DO SO MAY CAUSE PROPERTY DAMAGE

,

PERSONAL

INJURY OR DEATH .

SAFE REFRIGERANT HANDLING

While these items will not cover every conceivable situation, they should serve as a useful guide.

WARNING

R

EFRIGERANTS ARE HEAVIER THAN AIR

. T

HEY CAN

“

PUSH OUT

”

THE

OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE

. T

O AVOID

POSSIBLE DIFFICULTY IN BREATHING OR DEATH :

• N EVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE . B Y

LAW

,

ALL REFRIGERANTS MUST BE RECLAIMED

.

• I

F AN INDOOR LEAK IS SUSPECTED

,

THOROUGHLY VENTILATE THE AREA

BEFORE BEGINNING WORK

.

• L

IQUID REFRIGERANT CAN BE VERY COLD

. T

O AVOID POSSIBLE FROST BITE

OR BLINDNESS , AVOID CONTACT AND WEAR GLOVES AND GOGGLES . I F

LIQUID REFRIGERANT DOES CONTACT YOUR SKIN OR EYES , SEEK MEDICAL

HELP IMMEDIATELY .

• A LWAYS FOLLOW EPA REGULATIONS . N EVER BURN REFRIGERANT , AS

P OISONOUS GAS WILL BE PRODUCED .

WARNING

T

HE

U

NITED

S

TATES

E

NVIRONMENTAL

P

ROTECTION

A

GENCY

(”EPA”)

HAS ISSUED VARIOUS REGULATIONS REGARDING THE INTRODUCTION

AND DISPOSAL OF REFRIGERANTS INTRODUCED INTO THIS UNIT

.

F

AILURE TO FOLLOW THESE REGULATIONS MAY HARM THE

ENVIRONMENT AND CAN LEAD TO THE IMPOSITION OF SUBSTANTIAL

FINES

. T

HESE REGULATIONS MAY VARY BY JURISDICTION

QUESTIONS ARISE , CONTACT YOUR LOCAL EPA OFFICE .

. S

HOULD

WARNING

D O NOT CONNECT TO OR USE ANY DEVICE THAT IS NOT DESIGN

CERTIFIED BY THE MANUFACTURER FOR USE WITH THIS UNIT . S ERIOUS

PROPERTY DAMAGE , PERSONAL INJURY , REDUCED UNIT PERFORMANCE

AND

/

OR HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF

SUCH NON APPROVED DEVICES .

WARNING

T O AVOID POSSIBLE EXPLOSION :

•N EVER APPLY FLAME OR STEAM TO A REFRIGERANT CYLINDER . I F YOU

MUST HEAT A CYLINDER FOR FASTER CHARGING

,

PARTIALLY IMMERSE

IT IN WARM WATER

.

•N

EVER FILL A CYLINDER MORE THAN

80%

FULL OF LIQUID

REFRIGERANT .

•N EVER ADD ANYTHING OTHER THAN R-410A TO A RETURNABLE

R-410A

CYLINDER

. T

HE SERVICE EQUIPMENT USED MUST BE LISTED

OR CERTIFIED FOR THE TYPE OF REFRIGERANT USE

.

•S

TORE CYLINDERS IN A COOL

,

DRY PLACE

. N

EVER USE A CYLINDER

AS A PLATFORM OR A ROLLER .

WARNING

T O PREVENT THE RISK OF PROPERTY DAMAGE , PERSONAL INJURY , OR

DEATH , DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR

OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS

APPLIANCE

.

OUTSIDE THE U.S., call 1-713-861-2500 .

(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.

IMPORTANT INFORMATION

WARNING

T

O AVOID POSSIBLE EXPLOSION

:

•U

SE ONLY RETURNABLE

(

NOT DISPOSABLE

)

SERVICE CYLINDERS WHEN

REMOVING REFRIGERANT FROM A SYSTEM .

•E NSURE THE CYLINDER IS FREE OF DAMAGE WHICH COULD LEAD TO A

LEAK OR EXPLOSION

.

•E

NSURE THE HYDROSTATIC TEST DATE DOES NOT EXCEED

5

YEARS

.

•E

NSURE THE PRESSURE RATING MEETS OR EXCEEDS

400

LBS

.

Notice:

When the outdoor unit is connected to main power, the inverter board has a small current flowing into it to be pre pared for operation when needed. Due to this, the Control

Board components have to be cooled even when the unit is not running. For this cooling operation, the condenser fan may come on at any time, including in the winter months.

Any obstruction to the outdoor fan should be avoided at all times when the unit is powered to prevent damage.

W HEN IN DOUBT , DO NOT USE THE CYLINDER .

WARNING

T

O AVOID POSSIBLE INJURY

,

EXPLOSION OR DEATH

,

PRACTICE SAFE

HANDLING OF REFRIGERANTS

.

The successful development of hermetically sealed refrigeration compressors has completely sealed the compressor’s moving parts and electric motor inside a common housing, minimizing refrigerant leaks and the hazards sometimes associated with moving belts, pulleys or couplings.

CAUTION

T

HE COMPRESSOR

PVE

OIL FOR

R-410A

UNITS IS EXTREMELY

SUSCEPTIBLE TO MOISTURE ABSORPTION AND COULD CAUSE

COMPRESSOR FAILURE . D O NOT LEAVE SYSTEM OPEN TO ATMOSPHERE

ANY LONGER THAN NECESSARY FOR INSTALLATION

.

Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the compressor motor through terminal conductors which pass through the compressor housing wall. These terminals are sealed in a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the hermetic compressor. The terminals and their dielectric embedment are strongly constructed, but are vulnerable to careless compressor installation or maintenance procedures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants.

WARNING

S

YSTEM CONTAMINANTS

,

IMPROPER SERVICE PROCEDURE AND

/

OR

PHYSICAL ABUSE AFFECTING HERMETIC COMPRESSOR ELECTRICAL

TERMINALS MAY CAUSE DANGEROUS SYSTEM VENTING .

In either of these instances, an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embedment. This loss may cause the terminals to be expelled, thereby venting the vaporous and liquid contents of the compressor housing and system.

A venting compressor terminal normally presents no danger to anyone, providing the terminal protective cover is properly in place.

If, however, the terminal protective cover is not properly in place, a venting terminal may discharge a combination of

(a) hot lubricating oil and refrigerant

(b) flammable mixture (if system is contaminated with air) in a stream of spray which may be dangerous to anyone in the vicinity. Death or serious bodily injury could occur.

Under no circumstances is a hermetic compressor to be electrically energized and/or operated without having the terminal protective cover properly in place.

See Service Section for proper servicing.

3

4

PRODUCT IDENTIFICATION

Nomenclature

A V Z C 18 024 1 A

Brand

A - Amana® Brand

Compressor

V - Variable Capacity

Type

X - AC R-410A

Z - HP R-410A

Feature Set

C - ComfortNet 4 wire ready

SEER

18 - SEER

20 - SEER

NOMENCLATURES

A

Engineering

Minor Revision

Engineering

Major Revision

Voltage

1 - 208/230 V single phase 60 Hz

2 -208/240 V single phase 50 Hz

Tonnage Nominal

024 - 2.0-ton

036 - 3.0-ton

048 - 4.0-ton

060 - 5.0-ton

A

Brand

A - Amana® Brand

Unit Applica � on

V - Mul � Posi � on Varible-Speed

Motor-Communica � ng

Cabinet Finish

P - Painted

V

Expansion Device

T - Expansion Valve

V - Inverter Tuned Expansion Valve

E - Electronic Expansion Valve

Communica � on

C - ComfortNet™ Compa � ble

P E C 25 B 1 4 AA

Engineering

Major/Minor Revision

Refrigerant Charged=

4 - R410A

Voltage

1 - 208/230 V

Cabinet Width

B: 17.5"

C: 21"

D: 24.5"

Tonnage Nominal

25 - 2.0-ton

37 - 3.0-ton

59 - 4.0-ton

61 - 5.0-ton

SYSTEM OPERATION

This section gives a basic description of heat pump condenser unit operation, its various components and their basic operation. Ensure your system is properly sized for heat gain and loss according to methods of the Air Conditioning Contractors Association (ACCA) or equivalent.

CONDENSING UNIT

The ambient air is pulled through the heat pump condenser coil by a direct drive propeller fan. This air is then discharged out of the top of the cabinet. These units are designed for free air discharge, so no additional resistance, like duct work, shall be attached.

The gas and liquid line connections on present models are of the sweat type for field piping with refrigerant type cop per. Front seating valves are factory installed to accept the field run copper. The total refrigerant charge for a normal installation is factory installed in the heat pump condenser unit.

AVZC18 models are available in 2 through 5 ton sizes and use R-410A refrigerant. They are designed for 208/230 volt single phase applications.

All AVZC18 models use a Daikin rotary compressor specifically designed for R-410A refrigerant. These models are

ComfortNetTM ready.

AVZC18 models use “FVC50K” which is NOT compatible with mineral oil based lubricants like 3GS. “FVC50K” oil

(required by the manufacturer) must be used if additional oil is required.

COOLING

The refrigerant used in the system is R-410A. It is a clear, colorless, non-toxic and non-irritating liquid. R-410A is a

50:50 blend of R-32 and R-125. The boiling point at atmospheric pressure is -62.9°F.

A few of the important principles that make the refrigeration cycle possible are: heat always flows from a warmer to a cooler body. Under lower pressure, a refrigerant will absorb heat and vaporize at a low temperature. The vapors may be drawn off and condensed at a higher pressure and tem perature to be used again.

The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes.

NOTE: The pressures and temperatures shown in the refrigerant cycle illustrations on the following pages are for demonstration purposes only. Actual temperatures and pressures are to be obtained from the “Expanded Performance Chart”.

Liquid refrigerant at condensing pressure and temperatures leaves the outdoor condensing coil through the drier and is metered into the indoor coil through indoor electronic expansion valve. As the cool, low pressure, saturated refrigerant enters the tubes of the indoor coil, a portion of the liquid immediately vaporizes. It continues to soak up heat and vaporizes as it proceeds through the coil, cooling the indoor coil down to about 48°F.

Heat is continually being transferred to the cool fins and tubes of the indoor evaporator coil by the warm system air.

This warming process causes the refrigerant to boil. The heat removed from the air is carried off by the vapor.

As the vapor passes through the last tubes of the coil, it becomes superheated. That is, it absorbs more heat than is necessary to vaporize it. This is assurance that only dry gas will reach the compressor. Liquid reaching the compressor can weaken or break compressor valves.

The compressor increases the pressure of the gas, thus adding more heat, and discharges hot, high pressure superheated gas into the outdoor condenser coil.

In the condenser coil, the hot refrigerant gas, being warmer than the outdoor air, first loses its superheat by heat trans ferred from the gas through the tubes and fins of the coil.

The refrigerant now becomes saturated, part liquid, part vapor and then continues to give up heat until it condenses to a liquid alone. Once the vapor is fully liquefied, it continues to give up heat which subcools the liquid, and it is ready to repeat the cycle.

The inverter system can stop the compressor or outdoor fan to protect the unit. The inverter system can run higher compressor speed than required from thermostat to recover compressor oil that flows.

HEATING

The heating portion of the refrigeration cycle is similar to the cooling cycle. By de-energizing the reversing valve solenoid coil, the flow of the refrigerant is reversed. The indoor coil now becomes the heat pump condenser coil, and the outdoor coil becomes the evaporator coil. The check valve at the outdoor coil will be forced closed by the refrigerant flow, thereby utilizing the outdoor expansion device. An electronic expansion valve meters the condensed refrigerant to the outdoor coil.

DEFROST CYCLE

The defrosting of the outdoor coil is controlled by the PCB and the outdoor coil temperature thermistor and defrost sensor. The outdoor coil temperature thermistor (Tm) sensor is clamped to a return bend entering the outdoor coil and the defrost sensor at bottom flowrator leg at outdoor coil outlet. Defrost timing periods of 30, 60, 90 or 120 minutes may be selected via the thermostat setting. PCB will initiate time defrost at the interval selected from the thermostat. During operation, the microprocessor on the PCB checks the coil and defrost temperature (Tm and Tb) via sensors every 5 seconds in heating mode. When the PCB detects the coil temperature to be high enough (approximately 54 °F) and defrost sensor more than 43 °F for 30 seconds, the defrost cycle is terminated and the timing period is reset. The field service personnel can also advance a heat pump to the defrost cycle by selecting “force defrost” option from thermostat.

5

6

SYSTEM OPERATION

SYSTEM STARTUP TEST

A system verification test is now required to check the equipment settings and functionality.

18 SEER Inverter units are tested by any of the following methods:

• Setting the “SUt” menu (System verification test) to

ON through the indoor unit control board push buttons.

• Setting the System verification test menu of mode dis play screen-4 to ON through the outdoor unit control board push buttons.

Once selected, it checks the equipment for approximately 5

-

- 15 minutes. System test may exceed 15 minutes if there is an error. Refer to the Troubleshooting section, if error code appears.

Before starting the SYSTEM TEST, turn off the electric heater (if applicable)

NOTE: If the unit is attempting to run SYSTEM TEST in under 20°F ambient temperature, the unit may not be able to complete the test due to low suction pressure. In such a case, re-run the SYSTEM TEST when the ambient temperature exceeds 20° F.

NOTE: BOOST MODE performance is most effective when paired with an electronic expansion valve enabled indoor unit.

BOOST MODE is ON by default and is activated when the outdoor temperature reaches 105°F. BOOST MODE can be disabled and enabled and the activation temperature adjusted in BOOST TEMP menu using the following procedure:

1. On the HOME screen, select MENU

2. From the MENU screen, select COMFORTNET™

USER MENU

3. Enter Installer password if known.

a. The password is the thermostat date code and can be obtained by selecting the red Cancel button and selecting the Dealer Information button.

b. Once recorded, click the green OK button and return to the revious step.

4. Select YES to continue.

5. Select HEAT PUMP.

6. Select SYS SETUP

7. BOOST MD turns BOOST MODE OFF or ON.

BOOST MODE is ON by default.

8. BOOST TEMP adjusts the activation temperature from 70°F to 105°F. “Always ON” option is also available to permanently engage BOOST MODE. Factory default is 105°.

9. Once satisfied with BOOST MODE adjustments, nav igate to the HOME screen by selecting the Previous

Menu button three times and then selecting HOME.

CHARGE MODE

CHARGE mode allows for charging of the system.

System operates for a duration of approximately one hour while the equipment runs at full capacity.

After one hour, the CHARGE MODE ends and the system resumes normal operation.

Before starting the CHARGE MODE, turn off the Cool or

Heat mode and electric heat (if applicable).

a. 18 SEER Inverter units are charged by any of the following methods:

• setting the “CR9” menu (Charge Mode) to ON through the indoor unit control board push buttons.

• setting the Charge mode menu of mode display screen-4 to ON through the outdoor unit control board push buttons.

b. The System will remain in charge mode (high speed) for

60 minutes before timing out.

c. Manually shut off.

BOOST MODE

BOOST MODE enables the system to operate at a higher compressor speed than rated maximum compressor speed and satisfy the structural load more effectively during higher ambient outdoor conditions. BOOST MODE is initiated by an outdoor temperature sensor located in the outdoor unit.

Please note that outdoor equipment operational sound levels may increase while the equipment is running in BOOST

MODE. Disabling BOOST MODE will provide the quietest and most efficient operation.

DEHUMIDIFICATION

The thermostat reads the indoor humidity level from the

CTK04 and allows the user to set a dehumidification target based on these settings. The thermostat controls the humidity level of the conditioned space using the cooling system. Dehumidification is engaged whenever a cooling demand is present and structural humidity levels are above the target level. When this condition exists the circulating fan output is reduced, increasing system run time, over cooling the evaporator coil and ultimately removing more humidity from the structure than if only in cooling mode. The

CTK04 also allows for an additional overcooling limit setting from 0 °F to 3 °F setup through the Installer Option menu

(direction below). This allows the cooling system to further reduce humidity by lowering the temperature up to 3° F below the cooling setpoint in an attempt to better achieve desired humidity levels.

By default dehumidification needs to be turned ON at the thermostat via the Dehumidification Equipment menu.

Dehumidification can be activated at the original equipment setup by selecting the A/C with Low Speed Fan button in the Dehumidification Menu. Availability can be verified by pressing MENU on the home screen. Scroll down and if a Dehumidification button is present dehumidification is activated.

If Dehumidification is not available in the menu then it must be enabled through the Installer Options menu. Use the following procedure to enable and disable dehumidification:

SYSTEM OPERATION

1. On the CTK04 HOME screen, select MENU.

2. From the MENU screen, scroll down and select Installer Options.

3. Enter installer password if known.

a. The password is the thermostat date code and can be obtained by selecting the red Cancel button and selecting the Dealer Information button. b. Once recorded click the green OK button and return to the previous step.

4. Select YES to continue.

5. Select View / Edit Current Setup.

6. Scroll down and select Dehumidification.

7. Once open select Dehumidification Equipment: None.

8. From the Dehumidification Menu select A/C with Low

Speed Fan and click the green Done button.

9. Additional Dehumidification operational options can be selected in the resulting window.

10. Once satisfied with the selection navigate to the

HOME screen by selecting the Done button and selecting Yes to verify the changes.

11. Select Previous Menu, then the HOME to return to the main menu.

DEHUMIDIFICATION TIPS

For effective dehumidification operation:

• Ensure “Dehum” is ON through the Installer Options menu and/or in the ComfortNet User Menu (COOL

SETUP)

- If ON, the Dehumidification menu should be visible in the main menu.

• Verify the cooling airflow profile is set to “Profile D”.

- See the Cool Set-up section of the Installation Manual for complete airflow profile details.

- By default “Dehum” is ON and the cooling airflow profile is set to “Profile D”.

• For additional dehumidification control, airflow set tings are field adjustable and can be fine-tuned to a value that is comfortable for the application from a range of +15% to -15%.

- See the Heat Pump Advanced Feature Menu section of the installation manual for more detail.

FAULT CODE HISTORY

The heat pump’s diagnostics menu provides access to the most recent faults. The six most recent faults can be accessed through the control board seven segment displays.

Any consecutively repeated fault is stored a maximum of three times.

Example: A leak in the system, low refrigerant charge or an incompletely open stop valve can cause the unit to flash error code E15. This error code suggests that the unit is experiencing operation at low pressure. The control will only store this fault the first three consecutive times the fault occurs.

NOTE: The fault list can be cleared after performing maintenance or servicing the system to assist in the troubleshooting process.

7

8

SYSTEM OPERATION

COOLING CYCLE



HP/LP

ID HP/LP

Sensor

Tgi

Thermistor

Stop

Valve

(Gas)



HP/LP

OD HP/LP

Sensor



Access Tube

Ts

Thermistor

Motor

Fan





ACC

Tli

Thermistor

EEV

Filter





Filter





Filter Dryer



Stop Valve

(Liquid)



Tl

Thermistor

Indoor Unit

Reversing Valve



Check Valve



HPS

Td

Thermistor



Motor









Fan

Comp





Filter







SubACC





EEV

Check Valve





Filter





Cooling

Outdoor Unit

Ta

Thermistor

Tm

Thermistor





Tb

Thermistor

LEGEND:

Tl = Thermistor (Outdoor Liquid Temperature)

Td = Thermistor (Discharge Temperature)

Tb = Thermistor (Defrost Sensor)

Tm = Thermistor (Outdoor Coil Temperature)

Ta = Thermistor (Outdoor Air Temperature)

Tgi = Thermistor (Indoor Gas Temperature)

Tli = Thermistor (Indoor Liquid Temperature)

Ts = Thermistor (Suction Temperature)

OD HP/LP sensor = Outdoor High/Low Pressure Sensor

ID HP/LP sensor = Indoor High/Low Pressure Sensor

HPS = High Pressure Switch

SERVICING

CHECKING VOLTAGE

THERMOSTAT AND WIRING

1. Remove outer case, control panel cover, etc., from unit being tested.

With power ON:

L INE V OLTAGE NOW PRESENT .

WARNING

2. Using a voltmeter, measure the voltage across terminals

L1 and L2 of the contactor for the heat pump condenser unit or at the field connections for the air handler or heaters.

ComfortNet™ Ready Heat Pump Condenser Units:

Measure the voltage across the L1 and L2 lugs on the unitary (UC) control.

3. No reading - indicates open wiring, open fuse(s) no power or etc., from unit to fused disconnect service. Repair as needed.

4. With ample voltage at line voltage connectors, energize the unit.

Unit Supply Voltage

Voltage Min.

208/230 197

Max

253

NOTE: When operating electric heaters on voltages other than 240 volt, refer to the System Operation section on electric heaters to calculate temperature rise and air flow.

Low voltage may cause insufficient heating.

With power ON, thermostat calling for cooling/heating.

1. Use a voltmeter to check for 24 volt at thermostat wires

C and R in the indoor unit control panel.

2. No voltage indicates trouble in the thermostat, wiring or transformer source.

3. Check the continuity of the thermostat and wiring. Repair or replace as necessary.

L INE V OLTAGE NOW PRESENT .

WARNING

Resistance Heaters

With power ON:

1. Set room thermostat to a higher setting than room temperature so both stages call for heat.

2. With voltmeter, check for 24 volt at each heater relay.

3. No voltage indicates the trouble is in the thermostat or wiring.

4. Check the continuity of the thermostat and wiring.

Repair or replace as necessary.

NOTE: Consideration must be given to how the heaters are wired (O.D.T. and etc.). Also safety devices must be checked for continuity.

CHECKING TRANSFORMER AND CONTROL CIRCUIT

CHECKING WIRING

L INE V OLTAGE NOW PRESENT .

WARNING

WARNING

HIGH VOLTAGE !

D

ISCONNECT

ALL

POWER BEFORE SERVICING OR

INSTALLING . M ULTIPLE POWER SOURCES MAY BE

PRESENT

. F

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

,

PERSONAL INJURY OR DEATH

.

WARNING

HIGH VOLTAGE !

D ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING

PRESENT

. M ULTIPLE POWER SOURCES MAY BE

. F AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

,

PERSONAL INJURY OR DEATH

.

1. Check wiring visually for signs of overheating, damaged insulation and loose connections.

2. Use an ohmmeter to check continuity of any suspected open wires.

3. If any wires must be replaced, replace with comparable gauge and insulation thickness.

A step-down transformer (208/230 volt primary to 24 volt secondary) is provided with each indoor unit. This allows ample capacity for use with resistance heaters. The outdoor sections do not contain a transformer (see note below). (see indoor unit WIRING DIAGRAM)

CHECKING THERMOSTAT AND WIRING

ComfortNet™ Ready Models

Communicating Thermostat Wiring: The maximum wire length for 18 AWG thermostat wire is 250 feet.

WARNING

D ISCONNECT ALL POWER BEFORE SERVICING .

1. Remove control panel cover, or etc., to gain access to transformer.

With power ON:

L

INE

V

OLTAGE NOW PRESENT

.

WARNING

9

SERVICING

2. Using a voltmeter, check voltage across secondary voltage side of transformer (R to C).

3. No voltage indicates faulty transformer, bad wiring, or bad splices.

4. Check transformer primary voltage at incoming line voltage connections and/or splices.

5. If line voltage available at primary voltage side of transformer and wiring and splices good, transformer is inoperative. Replace.

CHECKING HIGH PRESSURE SWITCH

1. Connect manifold gauge to the air conditioner unit

2. Connect a pair of extended Molex probe tips to your

voltmeter test leads.

3. Find the suction pressure in the cool mode, or discharge

pressure in the heat mode (terminals) Locate (X17A)

connection and connect a DC voltmeter across sensor

terminals 1 and 3, (black and white wires) and record the

DC voltage.

4. Compare your readings to the detected pressure vs

output voltage in the following table. Replace the sensor

if the sensor is open, shorted, or outside of the voltage

range.

WARNING

HIGH VOLTAGE !

D

ISCONNECT

ALL

POWER BEFORE SERVICING OR

INSTALLING

. M

ULTIPLE POWER SOURCES MAY BE

PRESENT

. F

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE

,

PERSONAL INJURY OR DEATH

.

The high pressure switch senses the pressure in the compressor discharge line. If abnormally high condensing pressures develop, the contacts of the control open, breaking the control circuit before the compressor motor overloads.

This control is automatically reset.

1. Using an ohmmeter, check across the X32A connection on the outdoor unit PCB terminals of high pressure control, with wire removed. If not continuous, the contacts are open.

2. Attach a gauge to the dill valve port on the base valve.

With power ON:

800

700

600

500

400

300

200

100

0

-100

L

INE

V

OLTAGE NOW PRESENT

.

WARNING

-200

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

Output Voltage (DCV)

VOLTAGE AND PRESSURE CHARACTERISTICS

3. Start the system in charge mode and place a piece of cardboard in front of the outdoor coil, raising the condensing pressure.

4. Check pressure at which the high pressure control cutsout. If it cuts-out at 605 PSIG to -17 PSIG, it is operating normally (See causes for high head pressure in Service

Problem Analysis Guide). If it cuts out below this pressure range, replace the control.

CHECKING INDOOR AND OUTDOOR HI/LOW PRES-

SURE SENSOR

CHECKING COMPRESSOR

WARNING

Hermetic compressor electrical terminal venting can be dangerous. When insulating material which supports a hermetic compressor or electrical terminal suddenly disintegrates due to physical abuse or as a result of an electrical short between the terminal and the compressor housing, the terminal may be expelled, venting the vapor and liquid contents of the compressor housing and system.

The HI/LOW pressure sensor senses the suction pressure in cooling mode, and the discharge pressure in heating mode. Follow the following sequence to check the pressure sensor.

With Power ON:

If the compressor terminal PROTECTIVE COVER and gasket (if required) are not properly in place and secured, there is a remote possibility if a terminal vents, that the vaporous and liquid discharge can be ignited, spouting flames several feet, causing potentially severe or fatal injury to anyone in its path.

L

INE

V

OLTAGE NOW PRESENT

.

WARNING

This discharge can be ignited external to the compressor if the terminal cover is not properly in place and if the discharge impinges on a sufficient heat source.

10

SERVICING

Ignition of the discharge can also occur at the venting terminal or inside the compressor, if there is sufficient contaminant air present in the system and an electrical arc occurs as the terminal vents.

NOTE: The 2, 3, and 4 ton compressor has a terminal on the top. The 5 ton compressor has the terminals on the side. If the insulation resistance of the compressor is less than 100k Ohms between U to ground, V to ground, W to ground, replace the compressor.

Ignition cannot occur at the venting terminal without the presence of contaminant air, and cannot occur externally from the venting terminal without the presence of an external ignition source.

GROUND TEST

Therefore, proper evacuation of a hermetic system is essential at the time of manufacture and during servicing.

To reduce the possibility of external ignition, all open flame, electrical power, and other heat sources should be extinguished or turned off prior to servicing a system.

COMPRESSOR WINDING INSULATION TEST

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Remove the leads from the compressor terminals.

See warnings before removing compressor terminal cover.

2. Using a Megometer, attach one lead to ground.

3. Using the other lead of the Megometer, check the insulation between U to ground, V to ground, W to ground.

If fuse, circuit breaker, ground fault protective device, etc., has tripped, this is a strong indication that an electrical problem exists and must be found and corrected. The circuit protective device rating must be checked, and its maximum rating should coincide with that marked on the equipment nameplate.

With the terminal protective cover in place, it is acceptable to replace the fuse or reset the circuit breaker ONE TIME

ONLY to see if it was just a nuisance opening. If it opens again, DO NOT continue to reset.

The Inverter on the outdoor control board takes the position signal from the UVW line, connected with the compressor.

If the system detects a malfunction on the compressor, check the insulation resistance in accordance with the following procedure.

Disconnect all power to unit, making sure that all power legs are open.

1. DO NOT remove protective terminal cover. Disconnect the three leads going to the compressor terminals at the nearest point to the compressor.

2. Identify the leads and using an ohmmeter on the R x

10,000 scale or the highest resistance scale on your ohmmeter check the resistance between each of the three leads separately to ground (such as an unpainted tube on the compressor).

3. If a ground is indicated, then carefully remove the compressor terminal protective cover and inspect for loose leads or insulation breaks in the lead wires.

4. If no visual problems indicated, carefully remove the leads at the compressor terminals.

5. Carefully retest for ground, directly between compressor terminals and ground.

6. If ground is indicated, replace the compressor. The resistance reading should be infinity. If there is any reading on meter, there is some continuity to ground and compressor should be considered defective.

Unpainted

Refrigerant

Piping

Compressor

Terminal

TESTING COMPRESSOR WINDINGS INSULATION

11

SERVICING

WARNING

Damage can occur to the glass embedded terminals if the leads are not properly removed. This can result in terminal and hot oil discharging.

WARNING

Disconnect ALL power before servicing.

TESTING TEMPERATURE SENSORS AND EEV COIL

RESISTANCE

The AVZC ComfortNet ready heat pump models and

AVPEC indoor units are factory equipped with:

• (Ta) an outdoor air temperature sensor

• (Tm) an outdoor coil temperature sensor

• (TI) an outdoor liquid temperature sensor

• (Td) a discharge temperature sensor

• (Tb) a defrost temperature sensor

• (Tgi) an indoor gas temperature sensor

• (Tli) an indoor liquid temperature sensor

To check above sensors:

TESTING REVERSING VALVE

CHECKING REVERSING VALVE AND SOLENOID

Reversing valve used in heat pumps could potentially leak internally. Discharge gases can leak into the suction inside the valve. Compound gages will give the same symptoms as bad compressor valves or broken scroll flanks. The temperature between true suction and the suction line after the valve should not be greater than 4 degrees. Note: The center tube is always the suction line and should be cold.

TROUBLESHOOTING THE REVERSING VALVE FOR

ELECTRICAL FAILURE

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Disconnect power to the heat pump condensor.

2. Disconnect the sensor from the electric board.

3. Connect an ohmmeter across the sensor terminals. The ohmmeter should read be the resistance shown in the table THERMISTOR RESISTANCE AND TEMPERA-

TURE CHARACTERISTICS. Replace the sensor if the sensor is open, shorted, or outside the valid resistance range.

TESTING EEV COIL RESISTANCE

Place unit into the cooling mode. Test for 24 volts at the solenoid. If there is no voltage present at coil, check the control voltage. If voltage is present, loosen the nut on the top of the coil. Remove the coil, there should be slight resistance. If the slight resistance is felt, remove the coil. As you remove the coil listen carefully, an audible click should be detected. The clicking is due to the movement of the pilot valve plunger. The absence of a clicking sound indicates the plunger is stuck.

TROUBLESHOOTING MECHANICAL FAILURES ON A

REVERSING VALVE BY PRESSURE

Troubleshooting the reversing valve can be done by pressure and touch. Raise the head pressure. In the cooling mode block the fan exhaust. Once head pressure has been raised, cycle between cooling and heating and see if the piston can be freed.

To check the resistance of the EEV coil, first disconnect

EEV cable from the Control board. Make measurements of resistance between the connector pins, and then make sure the resistance falls in the range of 40 to 50Ω.

TROUBLESHOOTING MECHANICAL FAILURES ON A

REVERSING VALVE BY TEMPERATURE

When operating properly the valve contains refrigerant gases at certain temperatures. The discharge line should be the same temperature after the valves discharge line.

The true suction should be the same as the suction line after the valve. If there is a 4-degree difference, valve is leaking. When stuck in the mid-position, part of the discharge gas from the compressor is directed back to the suction side, resulting in excessively high suction pressure.

An increase in the suction line temperature through the reversing valve can also be measured. Check operation of the valve by starting the system and switching the opera-

12

SERVICING tion from COOLING to HEATING cycle. If the valve fails to change its position, test the voltage (24V) at the valve coil terminals (X25A) on outdoor unit PCB while the system is on the COOLING cycle. If voltage is registered at the coil, tap the valve body lightly while switching the system from

HEATING to COOLING, etc. If this fails to cause the valve to switch positions, remove the coil connector cap and test the continuity of the reversing valve solenoid coil. If the coil does not test continuous - replace it. If the coil test continuous and 24 volts is present at the coil terminals, the valve is inoperative - replace it.

1. Turn on power to air handler or modular.

WARNING

Line Voltage now present.

2. Check voltage between pins 1 and 4 at the 4-wire motor connector on the control board. Voltage should be between 9 and 15 VDC. Replace control if voltage is not as specified.

ELECTRIC HEAT SEQUENCER OUTPUTS

AVPEC* HEATER CONTROL (OPTIONAL)

DESCRIPTION

The AVPEC* models utilize an electronic control that provides ECM blower motor control and control of up to two electric heat sequencers. The control has thermostat inputs for variable stage of cooling/heating, two stages of electric heat, reversing valve, and dehumidification. Control input is

24 VAC.

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

FEATURES

The new air handler control includes advanced diagnostic features with fault recall, estimated CFM display via 7 segment display of control boad, and ComfortNet TM ready.

Diagnostics includes heater kit selection diagnostics, open fuse, internal control fault, data errors, and blower motor faults. Data errors are not included in the fault recall list.

Diagnostic error codes are displayed on a single red LED.

The estimated CFM is displayed on an on-board 7 segment display. For example, if the CFM is 1240CFM, 7 segment display shows “FC...A...12...40...”.

1. Turn on power to air handler or modular blower.

WARNING

Line Voltage now present.

2. Disconnect the 3-circuit harness connecting the control to the electric heater kit.

3. Provide a thermostat demand for low stage auxiliary heat

(W1). Measure the voltage between pins 1 and 3 at the on-board electric heat connector. Voltage should measure 24VAC. Replace control if no voltage is present.

The AVPEC* air handlers may be used in a fully communicating system when matched with a compatible outdoor unit and the thermostat. A fully communicating system offers advanced setup and diagnostic features.

NOTE: Allow for any built-in time delays before making voltage measurements. Any electric heater faults that are present may prevent the heater output from energizing. Verify that no heater faults are present before making voltage measurements.

BASIC OPERATION

The air handler control receives operation demand inputs from the thermostat. The control operates the variable speed blower motor at the demand as determined from the thermostat input(s). If a demand for electric heat is received, the control will provide a 24VAC output for up to two electric heat sequencers.

COMMUNICATIONS (APPLIES ONLY TO SYSTEMS

WITH COMPATABLE COMFORTNET™ OUTDOOR UNIT

AND CTK04** THERMOSTAT)

The integrated air handler control has some on-board tools that may be used to troubleshoot the network. These tools are: red communications LED, green receive (Rx) LED, and learn button. These are described below

TROUBLESHOOTING

MOTOR CONTROL CIRCUITS

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

a. Red communications LED – Indicates the status of the network. Refer to the Network Troubleshooting Chart for the LED status and the corresponding potential problem.

b. Green receive LED – Indicates network traffic. Refer to the Network Troubleshooting Chart for the LED status and the corresponding potential problem.

c. Learn button – Used to reset the network. Depress the button for approximately 2 seconds to reset the network.

13

SERVICING

Voltages between the two data lines and between each data line and common may be used to determine if the network is operating properly.

Do the following to measure the voltages on the communications data lines.

WARNING

Line Voltage now present.

1. With power on to the unit, measure voltage between

terminal “1” and terminal “C” on control board’s

thermostat connector. Voltage should be as noted in the

table below.

2. Measure voltage between terminals “2” and “C”.

3. Measure voltage between terminals “1” and “2”.

4. If voltages are different than stated in the table below,

check thermostat wiring for opens/shorts.

5. The network troubleshooting chart provides additional

communications troubleshooting information.

Terminals

1 to C

2 to C

1 to 2

Nonimal dc

Voltages

> 2.5 Vdc

< 2.5 Vdc

> 0.2 Vdc

REFRIGERATION REPAIR PRACTICE

DANGER

Always remove the refrigerant charge in a proper manner before applying heat to the system.

When repairing the refrigeration system:

BRAZING MATERIALS

IMPORTANT NOTE: Torch heat required to braze tubes of various sizes is proportional to the size of the tube. Tubes of smaller size require less heat to bring the tube to brazing temperature before adding brazing alloy. Applying too much heat to any tube can melt the tube. Service personnel must use the appropriate heat level for the size of the tube being brazed.

NOTE: The use of a heat shield when brazing is recommended to avoid burning the serial plate or the finish on the unit. Heat trap or wet rags should be used to protect heat sensitive components such as stop valves, EEV, TXV and filters.

Copper to Copper Joints - Sil-Fos used without flux (alloy of 15% silver, 80% copper, and 5% phosphorous). Recommended heat 1400°F.

Copper to Steel Joints - Silver Solder used without a flux

(alloy of 30% silver, 38% copper, 32% zinc). Recommended heat - 1200°F.

LEAK TESTING (NITROGEN OR NITROGEN-TRACED)

WARNING

To avoid the risk of fire or explosion, never use oxygen, high pressure air or flammable gases for leak testing of a refrigeration system.

To avoid possible explosion, the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve. The pressure relief valve must be set to open at no more than 450 psig.

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Never open a system that is under vacuum. Air and moisture will be drawn in.

2. Plug or cap all openings.

3. Remove all burrs and clean the brazing surfaces of the tubing with sand cloth or paper. Brazing materials do not flow well on oxidized or oily surfaces.

4. Clean the inside of all new tubing to remove oils and pipe chips.

5. When brazing, sweep the tubing with dry nitrogen to prevent the formation of oxides on the inside surfaces.

6. Complete any repair by replacing the liquid line drier in the system, evacuate and charge.

Pressure test the system using dry nitrogen and soapy water to locate leaks. If you wish to use a leak detector, charge the system to 10 PSIG using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure, then apply the detector to suspect areas.

If leaks are found, repair them. After repair, repeat the pressure test. If no leaks exist, proceed to system evacuation.

STANDING PRESSURE TEST (RECOMMENDED)

Best practices dictate system should be pressure tested at 450 PSIG with nitrogen for a minimum 4 hours. Follow the procedure outlined below to test system. If leaks are found, repair them. After repair, repeat the leak pressure test described above. If no leaks exist, proceed to system evacuation and charging.

14

SERVICING

SYSTEM PRESSURE TESTING

Once all of the refrigerant line connections are completed.

Perform a 3-step nitrogen pressure test.

Break the vacuum with dry nitrogen again, bring the system pressure back up to 2-3 PSIG, and hold for 20 minutes.

3. Then, exacuate the system until it is below 500 microns and hold for 60 minutes.

1. Pressurize the system with nitrogen to 150 PSIG and hold for 3 minutes. If any pressure drops occur, locate and repair leaks and repeat step 1.

2. Pressurize the system with nitrogen to 325 PSIG and hold for 5 minutes. If any pressure drops occur, locate and repair leaks and repeat step 1.

3. Pressurize the system with nitrogen to 450 PSIG and hold for 4 hours. If any pressure drops occur, locate and repair leaks and repeat step 1.

EVACUATION

WARNING

REFRIGERANT UNDER PRESSURE!

Failure to follow proper procedures may cause property damage, personal injury or death.

IMPORTANT NOTE: Because of the potential damage to compressors, do not allow suction pressure at service valve to drop below 5 PSIG when pumping unit system down for repair. Outdoor section, depending on line set length and amount of charge in system, may not be able to hold the entire system charge.

1. Connect the vacuum pump, vacuum tight manifold set with high vacuum hoses, micron gauge and charging cylinder as shown.

2. Start the vacuum pump and open the shut off valve to the high vacuum gauge manifold only. After the compound gauge (low side) has dropped to approximately

29 inches of vacuum, open the valve to the vacuum micron gauge. See that the vacuum pump will blank-off to a maximum of 500 microns. A vacuum pump can only produce a good vacuum if its oil is non-contaminated.

LOW SIDE

GAUGE

AND VALVE

HIGH SIDE

GAUGE

AND VALVE

This is the most important part of the entire service procedure. The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air (non-condensables) and moisture from the system.

Air in a system causes high condensing temperature and pressure, resulting in increased power input and reduced performance.

Moisture chemically reacts with the refrigerant oil to form corrosive acids. These acids attack motor windings and parts, causing breakdown.

The equipment required to thoroughly evacuate the system is a vacuum pump, capable of producing a vacuum equivalent to 500 microns absolute and a micron gauge to give a true reading of the vacuum in the system

NOTE: Never use the system compressor as a vacuum pump or run when under a high vacuum. Motor damage could occur.

The triple evacuation method is recommended.

1. Evacuate the system to 4000 microns and hold for 15 minutes. Then, break the vacuum with dry nitrogen, bring the system pressure up to 2-3 PSIG, and hold for

20 minutes. Release the nirtogen.

2. Evacuate to 1500 microns and hold for 20 minutes.

800 PSI

RATED

HOSES

TO

UNIT SERVICE

VALVE PORTS

VACUUM PUMP

ADAPTER

VACUUM PUMP

CHARGING

CYLINDER

AND SCALE

EVACUATION

3. If the vacuum pump is working properly, close the valve to the micron gauge and open the high and low side valves to the high vacuum manifold set. With the valve on the charging cylinder closed, open the manifold valve to the cylinder.

4. Evacuate the system to at least 29 inches gauge before opening valve to micron gauge.

5. Continue to evacuate to a maximum of 500 microns.

Close valve to vacuum pump and watch rate of rise. If vacuum does not rise above 500 microns in three to five minutes, system can be considered properly evacuated.

6. If micron gauge continues to rise and levels off at about

15

SERVICING

2000 microns, moisture and non-condensables are still present. If gauge continues to rise a leak is present.

Repair and re-evacuate.

7. Close valve to micron gauge and vacuum pump. Shut off pump and prepare to charge.

FINAL CHARGE ADJUSTMENT

The outdoor temperature must be 65°F to 105°F. If outdoor ambient temperature is out of range, charge defined amount and don’t adjust subcooling. Set the room thermostat to CHARGE mode.

CHARGING

WARNING

REFRIGERANT UNDER PRESSURE!

* Do not overcharge system with refrigerant.

* Do not operate unit in a vacuum or at negative

pressure.

Failure to follow proper procedures may cause property damage, personal injury or death.

After system has stabilized per startup instructions, check subcooling as detailed in the following section.

In the event of system overcharge or undercharge, refrigerant in the system must be adjusted to the appropriate subcooling and superheat as specified in the following sections. Refrigerant amount should be adjusted within

+/- 0.5 lb. if the outdoor ambient temperature is greater than

65°F and less than 105°F. Manufacturer recommends that the system should be evacuated and should be charged the initial refrigerant for given line length when the ambient temperature is less than 65°F and more than 105°F. Refer to the Installation Manual to calculate refrigerant amount.

CAUTION

Use refrigerant certified to AHRI standards. Used refrigerant may cause compressor damage and is not covered by the warranty. Most portable machines cannot clean used refrigerant to meet AHRI Standards.

CAUTION

Damage to the unit caused by operating the compressor with the suction valve closed is not covered under the warranty and may cause serious compressor damage.

5. With the system still running, remove hose and reinstall both valve caps.

6. Check system for leaks.

NOTE: Subcooling information is valid only while the unit is operating at 100% capacity or 100% of compressor speed in CHARGE MODE. Compressor speed is displayed under

STATUS menu in the thermostat.

Charge the system with the exact amount of refrigerant.

See the Installation Manual for the correct refrigerant charge.

An inaccurately charged system will cause future problems.

1. When using an ambient compensated calibrated charging cylinder, allow liquid refrigerant only to enter the high side.

2. Once the system stops taking refrigerant, close the valve on the high side of the charging manifold.

3. Start the system and charge the balance of the refrigerant through the low side.

NOTE: R410A should be drawn out of the storage container or drum in liquid form due to its fractionation properties, but should be “Flashed” to its gas state before entering the system. There are commercially available restriction devices that fit into the system charging hose set to accomplish this.

DO NOT charge liquid R410A into the compressor.

CHECKING COMPRESSOR EFFICIENCY

The reason for compressor inefficiency is that the com pressor is broken or damaged, reducing the ability of the compressor to pump refrigerant vapor.

The condition of the compressor is checked in the following manner.

1. Attach gauges to the high and low side of the system.

2. Start the system and run CHARGE MODE.

If the test shows: a. Below normal high side pressure.

b. Above normal low side pressure.

c. Low temperature difference across coil.

d. Low amp draw at compressor.

And the charge is correct. The compressor is faulty - replace the compressor.

CHECKING SUBCOOLING

4. With the system still running, close the valve on the charging cylinder. At this time, you may still have some liquid refrigerant in the charging cylinder hose and will definitely have liquid in the liquid hose. Reseat the liquid line core. Slowly open the high side manifold valve and transfer the liquid refrigerant from the liquid line hose and charging cylinder hose into the suction service valve port. CAREFUL: Watch so that liquid refrigerant does not enter the compressor.

Refrigerant liquid is considered subcooled when its temperature is lower than the saturation temperature corresponding to its pressure. The degree of subcooling equals the degrees of temperature decrease below the saturation temperature at the existing pressure.

1. Attach an accurate thermometer or preferably a thermocouple type temperature tester to the liquid service valve as it leaves the condensing unit.

16

SERVICING

2. Install a high side pressure gauge on the high side (liquid) service valve at the front of the unit.

3. Record the gauge pressure and the temperature of the line.

4. Review the technical information manual or specification sheet for the model being serviced to obtain the design subcooling.

5. Compare the hi-pressure reading to the “Required Liquid

Line Temperature” chart. Find the hi-pressure value on the left column. Follow that line right to the column under the design subcooling value. Where the two intersect is the required liquid line temperature.

Alternately you can convert the liquid line pressure gauge reading to temperature by finding the gauge read ing in the R-410A Pressure vs. Temperature Chart, find the temperature in the °F. Column.

6. The difference between the thermometer reading and pressure to temperature conversion is the amount of subcooling.

Add charge to raise subcooling. Recover charge to lower subcooling.

Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.

Compressor speed is displayed under STATUS menu in the thermostat.

1. Run system at least 20 minutes to allow pressure to

stabilize. During the adjustment of subcooling, ambient

temperature should be greater than 65°F and less than

105°F. If ambient temperature is out of range, don’t adjust subcooling.

2. For best results, temporarily install a thermometer on the

liquid line at the liquid line service valve. Ensure the

thermometer makes adequate contact and is insulated for best possible readings. Use liquid line temperature to

determine sub-cooling.

3. The system subcooling should fall in the range shown in

following table. If not in that range, adjust subcooling

according to the following procedure.

a. If subcooling is low, add charge to adjust the subcooling as specified in the following table.

2 TON

3 TON

4 TON

5 TON

10-12°F

13-15°F

8-10°F

11-13°F b. If subcooling is high, remove charge to lower the subcooling to specified range.

EXAMPLE:

a. Liquid Line Pressure = 417 PSIG

b. Corresponding Temp. = 120°F.

c. Thermometer on Liquid line = 109°F.

NOTE: Not more than 0.8 lb. (13 oz.) of refrigerant be added to the system at a time to achieve the target subcooling.

It is recommended adding 4 oz. refrigerant each time, then wait 20 minutes to stabilize the system.

To obtain the amount of subcooling subtract 109°F from

120°F.

The difference is 11° subcooling. See the specification sheet or technical information manual for the design subcooling range for your unit.

2 TON

3 TON

4 TON

10-12°F

13-15°F

8-10°F

5 TON 11-13°F

There are other causes for high head pressure which may be found in the “Cooling / Heating Analysis Chart.”

If other causes check out normal, an overcharge or a system containing non-condensables would be indicated.

If this system is observed:

4. Disconnect manifold set. Installation is complete.

NON-CONDENSABLES

If non-condensables are suspected, shut down the system and allow the pressures to equalize. Wait at least 15 minutes. Compare the pressure to the temperature of the coldest coil since this is where most of the refrigerant will be. If the pressure indicates a higher temperature than that of the coil temperature, non-condensables are present.

Non-condensables are removed from the system by first removing the refrigerant charge, replacing and/or installing liquid line drier, evacuating and recharging.

1. Start the system.

2. Remove and capture small quantities of gas from the suction line dill valve until the head pressure is reduced to normal.

3. Observe the system while running a cooling performance test. If a shortage of refrigerant is indicated, then the system contains non-condensables.

COMPRESSOR BURNOUT

When a compressor burns out, high temperature develops causing the refrigerant, oil and motor insulation to decompose forming acids and sludge.

SUBCOOLING ADJUSTMENT ON EEV APPLICATIONS

NOTE: Subcooling information is valid only while the unit is operating at 100% capacity or 100% compressor speed in

CHARGE MODE.

If a compressor is suspected of being burned-out, attach a refrigerant hose to the liquid line dill valve and properly remove and dispose of the refrigerant.

NOTICE

Violation of EPA regulations may result in fines or other penalties.

17

SERVICING

Now determine if a burn out has actually occurred. Confirm by analyzing an oil sample using a Sporlan Acid Test Kit,

AK-3 or its equivalent.

Remove the compressor and obtain an oil sample from the suction stub. If the oil is not acidic, either a burnout has not occurred or the burnout is so mild that a complete clean-up is not necessary.

If acid level is unacceptable, the system must be cleaned by using the clean-up drier method.

CAUTION

Do not allow the sludge or oil to contact the skin.

Severe burns may result.

NOTE: The Flushing Method using R-11 refrigerant is no longer approved by the Manufacturer.

REFRIGERANT PIPING

The piping of a refrigeration system is very important in relation to system capacity, proper oil return to compressor, pumping rate of compressor and cooling performance of the evaporator. A bi-flow filter drier must be brazed on by the installer onsite. Ensure the bi-flow filter drier pain finish is intact after brazing. If the paint of the steel filter drier has been burned or chipped, repaint or treat with a rust preventative. The recommended location of the filter drier is before the electronic expansion valve at the indoor unit.

The liquid line must be insulated if more than 50 ft. of liquid line will pass through an area that may reach temperatures of 30° F of higher than ambient in cooling mode and/or if the temperature inside the conditioned space may reach a temperature lower than ambient in heating mode.

FVC50K oils maintain a consistent viscosity over a large temperature range which aids in the oil return to the compressor; however, there will be some installations which require oil return traps. These installations should be avoided whenever possible, as adding oil traps to the refrigerant lines also increases the opportunity for debris and moisture to be introduced into the system.

Avoid long running traps in horizontal suction line.

18

SERVICING

Hanger

Wall

Stud

Liquid Line

Strapped to

Suction Line

Liquid Line

Metal

Sleeve

Suction Line

Wrapped in Armaflex ®

FIGURE 1-1.

INSTALLATION OF REFRIGERATION PIPING FROM VERTICAL TO HORIZONTAL

IMPORTANT - Refrigerant lines must not touch wall.

Outside Wall

Suction Line Liquid Line

Wood Block

Between Studs

Wood

Block

Wire Tie

Inside Wall

Strap

Sleeve

Wire Tie

Outside Wall

Armaflex

Wrapped

®

Suction Line

Liquid

Line

Caulk

PVC Pipe

Fiberglass Insulation

I MPORTANT:

Refrigerant lines must NOT come into contact with structure.

Sleeve

Strap

FIGURE 1-2. INSTALLATION OF REFRIGERANT PIPING (VERTICAL)

NEW CONSTRUCTION SHOWN

NOTE: If line set is installed on the exterior of an outside wall, similar installation practices are to be used.

19

SERVICING

If hanging line set from a joist or rafter, use metal strapping or heavy nylon wire tires that are securely anchored.

8’

Floor Joist or

Roof Rafter

Wire Tie

(around suction line only)

Tape or Wire Tie

8’

Floor Joist or Roof Rafter

Metal Sleeve

Strapping placed around the suction line only

Tape or Wire Tie

After the suction line has been strapped to the joist or rafter at 8’ intervals, strap the liquid line to the suction line.

SECTION 3. OUTDOOR UNIT IS ABOVE THE INDOOR UNIT

1. Gas line must be sloped continuously towards the indoor unit.

2. The maximum elevation (vertical) difference between the outdoor unit and indoor unit is 100 feet.

3. The maximum line set equivalent length is 125 feet, which includes pressure losses of any elbow, bends, etc. The maximum line set actual length is 100 feet.

4. Inverted suction loop is not required at either unit.

5. An accumulator is not required for outdoor unit (accumulators are factory installed ).

20

SERVICING

Oil Trap Construction

LONG RADIUS

STREET ELL

45°

ELL

SHORT RADIUS

STREET ELL

45°

STREET

ELL

SECTION 4. OUTDOOR UNIT IS BELOW THE INDOOR UNIT

1. The maximum elevation (vertical) difference between the outdoor unit and the indoor unit is 90 feet.

2. Suction line must be installed in a manner to prevent liquid migration to the outdoor unit from the indoor unit.

The heat pump condenser unit is shipped with a predetermined factory charge level as shown in the following chart. For longer line sets greater than 15 feet, add 0.6 ounces of refrigerant per foot.

21

SERVICING

DUCT STATIC PRESSURES AND/OR STATIC PRES-

SURE DROP ACROSS COILS

COIL STATIC PRESSURE DROP

This minimum and maximum allowable duct static pressure for the indoor sections are found in the specifications section.

1. Using a draft gauge (inclined manometer), connect the positive probe underneath the coil and the negative probe above the coil.

2. A direct reading can be taken of the static pressure drop across the coil.

3. Consult unit nameplate for quantity of air.

Tables are also provided for each coil, listing quantity of air

(CFM) versus static pressure drop across the coil.

Too great an external static pressure will result in insuffi cient air that can cause icing of the coil. Too much air can cause poor humidity control and condensate to be pulled off the indoor coil causing condensate leakage. Too much air can also cause motor overloading and in many cases this constitutes a poorly designed system.

If the total external static pressure and/or static pressure drop exceeds the maximum or minimum allowable statics, check for closed dampers, dirty filters, undersized or poorly laid out duct work.

AIR HANDLER EXTERNAL STATIC

To determine proper air movement, proceed as follows:

1. Using a draft gauge (inclined manometer), measure the static pressure of the return duct at the inlet of the unit,

(Negative Pressure).

2. Measure the static pressure of the supply duct, (Positive

Pressure).

3. Add the two (2) readings together.

4. Consult unit nameplate for quantity of air.

Checking Static Pressure Single Piece Air Handler

22

 Measure static pressure of the supply duct at the outlet of the air handler.

 Measure the static pressure of the return duct at the inlet of the air handler

 Single piece air handler evaporator coil is already considered in airflow calculation

 NOTE: Both readings may be taken simultaneously and read if so desired.

SERVICING

INDOOR UNIT TROUBLESHOOTING

WARNING

HIGH VOLTAGE !

D ISCONNECT ALL POWER BEFORE SERVICING .

M ULTIPLE POWER SOURCES MAY BE PRESENT . F AILURE

TO DO SO MAY CAUSE PROPERTY DAMAGE

,

PERSONAL

INJURY OR DEATH .

AUXALARM

ACC-OUT

(Accessory)

ACC-IN

(Accessory)

TB5 TB4 TB2 TB1

X8A

C R 2 1

FUSE

CPU LED

RX LED

STATUS LED

X12A

X13A

Micro

Processor

X15A

SEG2 7seg

SEG1 7seg

X5A X3A

EEV

COIL PRESSURE SENSOR THERMISTOR

INDOOR UNIT PCB

AUXILIARY ALARM SWITCH

The control is equipped with two Auxiliary Alarm terminals, labeled TB4 and TB5, which are typically utilized in series with a condensate switch but could also be used with compatible CO2 sensors or fire alarms.

The auxiliary alarm switch must be normally closed and open when the alarm occurs. For example, a normally closed condensate switch will open when the base pan’s water level reaches a particular level. The control will respond by turning off the blower motor and displaying the proper fault codes. If the switch is later detected closed for 30 seconds, normal operation resumes and the error message is removed. The switch is closed as part of the default factory setting. The error will be maintained in the equipment’s fault history.

CIRCULATOR BLOWER

This air handler is equipped with a variable speed circulator blower. This blower provides several automatically-adjusted blower speeds. The Specification Sheet applicable to your model provides an airflow table, showing the relationship between airflow (CFM) and external static pressure (E.S.P.).

NOTE: Upon start up in communicating mode the circuit board may display an “Ed” error. This is an indication that the dip switches on the control board need to be configured in accordance with the Electric Heating Airflow Table. Con figuring the dip switches and resetting power to the unit will clear the error code.

23

ELECTROSTATIC DISCHARGE (ESD) PRECATIONS

NOTE: Discharge body’s static electricity before touching unit. An electrstaic can adversly affect electrical compo nents.

Fault

Recall

7 Segment

Diagnostic

Displays

Use the following precautions during air handler installation and servicing to protect the integrated control module from damage. By putting the air handler, the control, and ther person at the same electrostatic potentential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (ungrounded) blowers.

FAULT RECALL

The integrated control module is equipped with a momentary push-button switch that can be used to display the last six faults on the 7 segment LED display. To display the faults, follow the steps below.

1. Disconnect all power to the blower. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the air handler blower near the control. Any tools held in a person’s hand during grounding will be discharged.

3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.

4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a blower. Return any old or new controls to their containers before touching any ungrounded object.

NOTE: The integrated control module must be in Standby

Mode (no thermostat inputs).

1. Press FAULT RECALL button (for 2 to 5 seconds). The 7 segment LED display will blink “--”.

NOTE: If FAULT RECALL button is not pressed long enough (for 2 to 5 seconds, the control goes back to

Standby Mode. If the button is pressed for 5 to 10 seconds, control goes back to Standby Mode.

2. Release the FAULT RECALL button. The 7 segment

LED display will show the most recent fault.

3. Subsequent pressing of the FAULT RECALL button will recall a previous fault. At the end of the faults, the 7 segment LED display will show “--” and go back to Standby

Mode.

DIAGNOSTIC CHART

NOTE: Consecutively repeated faults are displayed a maximum of three times. If the FAULT RECALL button is left untouched longer than 3 minutes, the control goes back to

Standby Mode.

WARNING

HIGH VOLTAGE!

T O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK , DISCONNECT ELECTRICAL POWER

BEFORE PERFORMING ANY SERVICE OR MAINTENANCE

.

To clear the error code history:

1. Press FAULT RECALL button until the 7 segment LED display blinks “--”.

2. Release the FAULT RECALL button. The 7 segment

LED display will show “88” and clear the faults.

Refer to the Troubleshooting Chart at the end of this manual for assistance in determining the source of unit operational problems. The 7 segment LED display will provide any active fault codes. An arrow printed next to the display indicates proper orientation (arrow points to top of display).

See following image.

NOTE: If FAULT RECALL button is help pressed for longer than 15 seconds, control goes back to Standby Mode.

24

SERVICING

DIAGNOSTIC CODES

7 SEGMENT LED

DISPLAY d1 d4 b0

EF d0

On

Eb

Ed

E5 b3 b4 b1 b2 b6 b7 b9

DESCRIPTION OF CONDITION

Normal Operation

NO HTR KIT INSTALLED - SYSTEM CALLING FOR AUXILIARY HEAT (Minor Error Code)

HEATER KIT DIP SWITCHES NOT SET PROPERLY

FUSE OPEN

AUXILIARY SWITCH OPEN

DATA NOT ON NETWORK

INVALID DATA ON NETWORK

INVALID BLUETOOTH® SHARED DATA LOADER BTSDL01 DATA

BLOWER MOTOR NOT RUNNING

BLOWER MOTOR COMMUNICATION ERROR

BLOWER MOTOR HP (Horse power) MISMATCH

BLOWER MOTOR OPERATING IN POWER, TEMP., OR SPEED LIMIT

BLOWER MOTOR CURRENT TRIP OR LOST ROTOR

OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP

INCOMPLETE PARAMETER SENT TO MOTOR

LOW INDOOR AIRFLOW (Minor Error Code) (without EH mode)

9b

70

73

74

75

77

LOW INDOOR AIRFLOW

(Major Error Code) (EH mode only)

EEV DISCONNECTION DETECTED

LIQUID SIDE THERMISTOR ABNORMALITY

GAS SIDE THERMISTOR ABNORMALITY

PRESSURE SENSOR ABNORMALITY

INDOOR UNIT - THERMOSTAT COMMUNICATION ERROR

(STARTUP OPERATION & DURING OPERATION)

Hu

FC

FH

F

H1

H2 dF

HUMIDIFICATION DEMAND

(Running without heating)

FAN COOL - COMMUNICATING MODE ONLY (Fan Demand-Cool)

FAN HEAT - COMMUNICATING MODE ONLY (Fan Demand-Heat)

FAN ONLY (Fan Demand-Manual)

ELECTRIC HEAT LOW (Heat Demand, Back-up Heat Demand)

ELECTRIC HEAT HIGH (Heat Demand, Back-up Heat Demand)

DEFROST - COMMUNICATING MODE ONLY (note: defrost is displayed as H1 in a legacy setup)

ERROR MESSAGE

--

(No Display)

Check Heater Kit Dip Switches

BLOWN FUSE

Auxiliary Contacts Open

Data Not Yet On Network

Invalid Data On Netwrok

Invalid BTSDL01 data

Blower Motor Not Running

Blower Communication Error

Blower Motor HP Mismatch

(No Display)

Blower Trip or Lost Rotor

Voltage or Temperature Trip

Incomplete Parameters Sent to Motor

(No Display)

LOW ID AIR EH MODE

EEV OPEN CKT

LIQ TEMP FLT

GAS TEMP FLT

PRESSURE FLT

TSTAT ID NO COM

--

--

--

--

--

--

--

25

SERVICING

2-digit 7 segment displays

digit 7 segment displays on indoorcontrol board show current status of state, error code and airflow.

2.

“ * * “

State code

(2sec.)

“ _ E “

Error

(2sec.)

"A...12...40...".

“ _ A “

(2sec.)

“ _ _ “

No display

(0.5sec.)

“ _ _ “

No display

(0.5sec.)

“ _ _ “

No display

(0.5sec.)

“ * * “ “ _ _ “

Error code

(2sec.)

No display

(0.5sec.)

For example, if the CFM is 1240CFM,7 segmentdisplayshows

“ * * “

Upper 2-digit of

CFM (2sec.)

“ _ _ “

No display

(0.5sec.)

“ * * “

Lower 2-digit of

CFM (2sec.)

“ _ _ “

No display

(0.5sec.)

indoorunit.In the event indoorunit error codeto solvethe error.

7 Segment LED

Display (State)

Description of Condition

(No Display) INTERNAL CONTROL FAULT/NO POWER

On

FC

FH

STANDBY, WAITING FOR INPUTS

FAN COOL-COMMUNICATING MODE ONLY

(Aux Heat Demand)

FAN HEAT-COMMUNICATING MODE ONLY

(Aux Heat Demand)

_F

H1

H2

FAN ONLY (Fan Demand-Manual)

ELECTRIC HEAT LOW (Heat Demand, Back-up

Heat Demand)

ELECTRIC HEAT HIGH (Heat Demand, Back-up

Heat Demand) dF

Hu

DEFROST COMMUNICATING MODE ONLY

HUMIDITY RUNNING WITHOUT HEATING

(Humidificat on Demand)

1. State

2. Whenthe unit is havingsomemajorerrorcodein normalmode,2-digit7 segment displays keep showing error code.

2. Error code

26

SERVICING

2-digit 7 segment displays

3. Whenthe unit is havingsomeminorerrorcodein normalmode,2-digit7 segmentdisplaysshowerror codeand air

fl

owstatus.

2. Error code 3. Air fl ow

4. Whenthe unit is havingsomeminorerrorcodeduringdefrostopera

�

onin normalmode,2-digit7 segmentdisplaysshowstate“dF”, errorcodeand air

fl

owstatus.

1. State (dF) 2. Error code 3. Air fl ow

5. Whenthe unit is havingsomeminorerrorcodein emergencymode,2-digit7 segmentdisplaysshow state(EE) and errorcode.

1. State (EE) 2. Error code

27

SERVICING SETTING THE MODE DISPLAY

MODE DISPLAY INTRODUCTION

A 2-digit display is provided on the printed circuit board (PCB) as a backup tool to the thermostat for accessing error codes and erasing error code history of the indoor unit. Follow the information provided in this section to learn how to use the mode display.

DISPLAY

The display consists of 2 digits.

DISPLAY BUTTON LAYOUT

The display buttons shown can be used to navigate and select items:

FAULT CODE HISTORY NAVIGATION

This mode will allow the user to see the six most recent system faults. Please follow the flow chart to navigate to error codes from screen zero.

For a list of the fault codes, please see the TROUBLESHOOTING tables in this document.

It is also possible to erase all the diagnostics codes from this menu.

28

SETTING THE MODE DISPLAY SERVICING SETTING THE MODE DISPLAY

29

SERVICING INDOOR UNIT ERROR CODES

30

Shared Data Loader BTSDL01

D

INDOOR UNIT ERROR CODES SERVICING INDOOR UNIT ERROR CODES

31

SERVICING

ADVANCED USER MENU

SUBMENU ITEM

Clear Faults

Fault 1

Fault 2

Fault 3

Fault 4

Fault 5

Fault 6

DIAGNOSTICS

INDICATION/USER

MODIFIABLE OPTIONS

COMMENTS

NO or YES Selecting "YES" clears the fault history.

Most recent HP fault

2nd most recent HP fault

3rd most recent HP fault

4th most recent HP fault

5th most recent HP fault

6th most recent HP fault

SUBMENU ITEM

Time Stamp (TS)

Mode (MD)

Compressor Reduction Mode (CRM)

Requested and Actual % Demand (RAD)

Requested and Reported ID CFM (RAF)

Outdoor Air Temperature and Outdoor

Fan Status (ATOF)

Discharge Temperature and Outdoor

Coil Temperature (DCT)

Defrost sensor and Outdoor Liquid

Temperature (DLT)

Pressure Sensor and Suction

Temperature (PSDST)

STATUS

COMMENTS

Provides compressor run time in hours.

Current system operation mode (COOLING, COOLING STARTUP, HEATING, HEATING

STARTUP, DEFROST, OIL RETURN, STOP).

Displays ON or OFF status. ON indicates that the reduction mode is operating and the compressor is running at a lower speed than the cooling/heating load would normally require.

Displays a 0-100% value, based on a ratio of the requested cooling demand to what the system is actually providing.

Compares the requrested indoor airflow to what the indoor equipment has reported.

Displays the outdoor air temperature and outdoor coil temperature as well as outdoor fan speed(TAP). 0:Off; 1:Low Tap; 2:Medium Tap; 3:High Tap

Displays the discharge temperature and outdoor coil temperature sensor readings.

Displays the defrost temperature sensor and outdoor liquid temperature sensor reading.

Displays the low pressure sensor reading which is taken slightly upstream of the suction accumulator and outdoor suction temperature sensor reading.

32

SERVICING

ADVANCED USER MENU

SUBMENU ITEM

Reset System Setup Options to Factory

Defaults (SYS SETUP RESET)

SET MAX CURRENT

VERTICAL RISE

BOOST MODE (BOOST MD)

BOOST MODE TEMPERATURE

(BOOST TEMP)

SYSTEM SETUP (SYS SETUP)

USER MODIFIABLE OPTIONS COMMENTS

NO or YES Selecting "YES" resets this menu to factory default settings.

N/A Future use.

Same Level, Outdoor Lower, or

Indoor Lower

If the outdoor & indoor units are within +/- 15 ft. vertical distance, select SAME LEVEL. If the outdoor unit is more than 15 ft. below the indoor unit, select OUTDOOR

LOWER. If the outdoor unit is more than 15 ft. above the indoor unit, select INDOOR L

ON or OFF

BOOST MD turns BOOST MODE OFF or ON. See BOOST

MODE section of this manual for more details.

Always ON, 70, 75, 80, 85, 90, 95,

100, 105°F

BOOST TEMP adjusts the activation temperatire from 70°F to 105°F. An "Always ON" option is also available to permanently engage BOOST MODE.

SUBMENU ITEM

EQUIPMENT TEST (EQUIP TEST)

INDICATION/USER

MODIFIABLE OPTIONS

COMMENTS

System Verification Test (SYSTEM TEST) ON or OFF

System Verification Test must be run after installation.

This is approximately a 5-15 minute test. If the thermostat is set to COOL mode, the system will enter CHARGE mode upon completion, otherwise it will stop.

Force Defrost Cycle (FORCE DF CYCLE) ON or OFF This will make the unit run in defrost mode.

SUBMENU ITEM

PUMP DOWN

CHARGE MODE

SYSTEM MAINTENANCE

USER MODIFIABLE OPTIONS COMMENTS

ON or OFF

Enter PUMP DOWN Mode. This procedure runs the equipment for approximately 15 minutes and allows accumulation of refrigerant at the outdoor unit for purposes of removing & replacing the indoor unit or outdoor unit.

ON or OFF

Enter Charging Mode. This allows for a steady system operation for a duration of approximately 1 hour to allow for refrigerant charging of the system via the suction charge port. The system will stop after completion.

33

SERVICING

ADVANCED USER MENU

SUBMENU ITEM

CL Reset

Cool Airflow Trim Hi (C TR H)

Cool Airflow Trim Int (C TR I)

Cool Airflow Trim Low (C TR L)

Cool Airflow Profile

Cool ON Delay

Cool OFF Delay

Dehumidification Select

COOL SETUP

USER MODIFIABLE OPTIONS

YES or NO

-15% to +15% in 3% increments

-15% to +15% in 3% increments

-15% to +15% in 3% increments

A, B, C, or D

5, 10, 20, 30 seconds

30, 60, 90, 120 seconds

ON or OFF

COMMENTS

Selecting to default factory setting.

Selects the cooling airflow trim amount.

Selects the cooling airflow trim amount.

Selects the cooling airflow trim amount.

Selects the cooling airflow profile.

Selects the indoor blower ON delay.

Selects the indoor blower OFF delay.

Selecting OFF disables dehumidification; selecting

ON enables dehumidification.

SET COOLING RUN VALUES (CL RUN VALUES)

SUBMENU ITEM

Maximum Compressor RPS Range for Cooling

(COOL RPS RANGE)

USER MODIFIABLE OPTIONS

Five different compressor RPS ranges will be provided.

COMMENTS

Select the appropriate range for the installed system configuration.

Maximum Compressor RPS Selection for Cooling

(COOL RPS SELECT)

Ten compressor RPS values will be provided within the range selected in the COOL RPS RANGE menu

Select the appropriate compressor RPS for the installed system configuration.

SUBMENU ITEM

HT Reset

Heat Airflow Trim Hi (H TR H)

Heat Airflow Trim Int (H TR I)

Heat Airflow Trim Low (H TR L)

Heat ON Delay

Heat OFF Delay

Maximum Defrost Interval

HEAT SETUP

USER MODIFIABLE OPTIONS

YES or NO

-15% to +15% in 3% increments

-15% to +15% in 3% increments

-15% to +15% in 3% increments

5, 10, 15 seconds

30, 50, 70, 90 seconds

30 min., 1hr., 1.5hrs. and 2hrs.

COMMENTS

Selecting to default factory setting.

Selects the Heating airflow trim amount.

Selects the Heating airflow trim amount.

Selects the Heating airflow trim amount.

Selects the indoor blower ON delay.

Selects the indoor blower OFF delay.

Selects time defrost interval

SET HEATING RUN VALUES (HT RUN VALUES)

SUBMENU ITEM

Maximum Compressor RPS Range for Heating

USER MODIFIABLE OPTIONS

Five different compressor RPS

COMMENTS

Select the appropriate range for the installed system

(HEAT RPS RANGE) ranges will be provided.

configuration.

Maximum Compressor RPS Selection for Heating

(HEAT RPS SELECT)

Ten compressor RPS values will be provided within the range selected in the HEAT RPS RANGE menu

Select the appropriate compressor RPS for the installed system configuration.

34

SERVICING

EMERGENCY MODE FOR EEV APPLICABLE INDOOR

UNIT

1. HEATING EMERGENCY MODE

Emergency mode is to only be used in a situation where communication between equipment (broken wires) or a failed thermostat cannot be immediately corrected or replaced. This mode will allow for cooling or heating to be activated without the need of communication wires or a thermostat. Once corrections have been made to wiring or the thermostat, emergency mode must be turned off and the system returned to normal operation (this applies to both the indoor and outdoor units). Note: Emergency mode does not control to a specific room temperature set point.

Exact room temperature achieved is related to the building load at the time emergency mode is activated. This is only a temporary solution.

At first inspection, if the outdoor unit is displaying one of the following error codes: E51 (outdoor communication error),

Eb0 (no indoor airflow), Eb9 (low indoor airflow), Ed2 (In in emergency mode must be limited to a minimum and with the unit is resolved and system operates in normal mode.

door unit is too small and cannot provide airflow of outdoor unit) or the indoor unit is displaying error code E77 (no thermostat communications) it is acceptable to use emergency mode if the equipment cannot be immediately fixed.

Cycling power to the equipment may temporarily clear error codes, but doing so may not fix the underlying problem.

Note: If after initial power up communication issues occur due to faulty wires or a thermostat these error codes may not be displayed.

In emergency mode, the unit will function according to the mode selected on the appropriate dip switches. Operation should be viewed as a temporary solution before the issue

Emergency Heating mode is to be used when communication between the indoor unit and thermostat is not functioning properly. This mode will run the electric heat strips independently of any thermostat in one of two modes:

High Heat Level or Low Heat Level. Dip Switch Bank DS-6

(specifically dip switches S-21 and S-22) on the indoor con trol is used to engage emergency heating mode. Default setting for these two dip switches are in the OFF position

(S21 set to ON and S22 set to ON will enable Low Heat

Level Emergency Mode. S21 set to OFF and S22 set to

ON will enable High Heat Level Emergency Mode). Note: once equipment has been fixed, these dip switches must be placed back in the OFF position. During operation, the indoor fan and electric heater kit will be turned on and off at following intervals based on the Heat Level selected. 2 stage electric heater kits will be energized in stage 2.

High Heat Level

Low Heat Level

Heating On Heating Off

8 minutes 8 minutes

7 minutes 15 minutes

Emergency Heat Mode Airflow: DIP switches S-9, S-10,

S-11 and S-12 must be set to the correct size electric heat kit that has been installed. These are located on dip switch bank DS-3 of the indoor control. See the Switch Bank

DS-3 Indoor Control Board Settings table to properly select heater kit size.

To activate heating emergency mode, appropriately select switches S-21 and S-22 from dip switch bank DS-6 on the indoor control board depending on the heat level required in accordance with the Switch Bank DS-6 Indoor Control

Board Settings table.

NOTE: During the heating emergency mode, outdoor unit must stop operation. Once the communication is established, heating emergency mode must be terminated so that the system resumes operation in normal mode. To eliminate the heating emergency mode, dip switches S-21 and S-22 from dip switch bank DS-6 on the indoor control board must be set back to default factory settings (normal operating mode).

NOTE: In the emergency operation, the operating status will not be shown in the thermostat status menu or on the outdoor 7-segment displays. The 7-segment displays on indoor control board will display “EE”.

35

SERVICING

Upon start up in emergency mode the circuit board may display an “Ed” error. This is an indication that the DIP switches on the control board need to be configured in accordance with the Electric Heating Airflow Table. Configuring the DIP switches to the unit will clear the error code.

Heater Kit

Selection

No Heater

First

Second

Third

Fourth

Fifth

Sixth

Seventh

Switch Bank DS-3

Indoor Control Board Settings

Heater kW

AVPEC25B14A* AVPEC37C14A* AVPEC59D14A* AVPEC61D14A*

10

X

6

8

X

-

3

5

8

10

15

19

X

-

5

6

8

10

15

20

X

-

5

6

8

10

15

20

25

-

5

6

S-9

OFF*

ON

ON

ON

ON

ON

ON

ON

Dip Switch Setting

S-10 S-11

OFF*

ON

ON

ON

ON

OFF

OFF

OFF

OFF*

ON

ON

OFF

OFF

ON

ON

OFF

S-12

OFF*

ON

OFF

ON

OFF

ON

OFF

ON

Emergency Mode

Switch Bank DS-6

Indoor Control Board Settings

Function

Normal operation

Cooling Emergency mode/Fan only Emergency mode

Heating Emergency mode (High heat level)

Heating Emergency mode (Low heat level)

S-21

OFF*

ON

OFF

ON

S-22

OFF*

OFF

ON

ON

Emergency Mode

Switch Bank DS-2

Outdoor Control Board Settings

Function

Normal operation

Cooling Emergency mode (Low cool Level)

Cooling Emergency mode (Medium cool Level)

Cooling Emergency mode (High cool level)

NOTE: Default factory settings are marked with *.

S-1

OFF*

ON

OFF

OFF

S-2

OFF*

OFF

ON

OFF

36

SERVICING

2. COOLING EMERGENCY MODE

Cooling emergency mode is to be used when communication between the indoor and outdoor units is not functioning properly and temporary cooling operation is required. This mode enables the outdoor unit and indoor unit to run independently of each other. There are two key steps to setup

Cooling Emergency Mode. a) Select the appropriate airflow on the indoor unit and enable emergency indoor airflow operation (using Dip switches S-13 and S-14 of Switch Bank DS-4 on the indoor unit to select desired 25%, 50%, 75% or 100% airflow. In addition, set switch bank DS-6 dip switches

S-21 to ON and S-22 to OFF enabling emergency indoor fan).

Low Cool

Level

Medium

Cool Level

High Cool

Level

ON time

7 minutes

8 minutes

15 minutes

OFF time

15 minutes

10 minutes

6 minutes

Avg.

Run Time

30%

50%

70%

Note: This mode does not require a thermostat. Any thermostat requests will be ignored while in emergency operation.

b) Select the desired cooling level at the outdoor unit (there are 3 levels available: Low Cool Level, Medium Cool

Level, High Cool Level selectable by dip switch bank

DS-2 on the outdoor unit). See Dip Switch Position

DS2-1 and DS2-2 Table for cooling level selection.

NOTE: Set indoor DS-4 (Indoor fan setting) and DS-6 (Indoor emergency mode enable) before setting outdoor DS-2 dip switch settings. Otherwise, the compressor may be damaged in operation.

Switch Bank DS-4

Indoor Fan Settings

Note: When proper communication is established, these switches must be returned to default settings

Function Value

25

50

SW13

OFF

ON*

SW14

OFF

OFF*

SW15

-

-

SW16

-

-

The compressor speed will automatically adjust based on the outdoor ambient temperature. If ambient temperature is higher than 95 ° F, the outdoor unit can operate at 100% compressor speed. If ambient temperature is lower than

70° F, the unit will run at 50% compressor speed. Between

95 ° F and 70 ° F, the compressor speed will adjust linearly as shown.

Fan Only

Speed %

75 OFF ON ON* -

Compressor

Capacity

100 ON ON OFF -

During operation the indoor unit will provide constant airflow as selected (even if the compressor has stopped). The indoor unit will continue to operate the electronic expansion valve for refrigerant super heat control and the compressor

.

will cycle at the interval selected by dip switch bank DS-2

100%

50%

70F 95F

Ambient temp

37

SERVICING

Dipswitch

Default Factory Se

�

ngs

Switch # Se

�

ng Func

�

on

ID DS-1

ID DS-2

ID DS-3

ID DS-4

ID DS-5

ID DS-6

OD DS-1

OD DS-2

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

23

24

1

2

21

22

1

2

17

18

19

20

* Must be set at factory setting to operate the normal mode.

** Must be set at factory setting indoor unit with EEV. It’s prohibited to change setting.

ON

OFF

ON

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

No Use

No Use

No Use

No Use

No Use

No Use

No Use

No Use

Heater Kit Selec � on in Emergency Mode

Heater Kit Selec � on in Emergency Mode

Heater Kit Selec � on in Emergency Mode

Heater Kit Selec � on in Emergency Mode

Allow in Emergency Mode

(Fan Emergency Mode)

Allow in Emergency Mode (Fan Emergency Mode)

EEV Enable**

No Use

Emergency EEV Opening

Emergency EEV Opening

EEV Emergency Mode**

No Use

Emergency mod e (Cooling and Hea�ng Emergency Mode)

Emergency mod e (Cooling and Hea�ng Emergency Mode)

No Use

No Use

CT Communica � on Enable*

CT Communica � on Enable*

Cooling Emergency mode*

Cooling Emergency mode*

38

SERVICING

COOLING EMERGENCY MODE WIRING FOR TXV AP-

PLICABLE INDOOR UNIT

Cooling emergency mode is available when using a TXV applicable indoor unit. To energize the blower at the appropriate speed, standard Legacy wiring is required. The image below shows how the thermostat input terminals are to be wired when selecting a cooling airflow. Note: the blower will run continuously with this wiring which is required. The outdoor unit will cycle as described in the Cooling Emergency Mode section when appropriate dip switch modes are set.

1 2 R C G W1 W2 Y1 Y2 0

DEHUM

INDOOR UNIT INTEGRATED CONTROL MODULE

Note: Emergency heating mode is not available with TXV applicable indoor units. If communications still exist between the indoor unit and thermostat, the thermostat should be used to provide heating calls.

39

SERVICING SETTING THE MODE DISPLAY

MODE DISPLAY INTRODUCTION

A 3-digit display is provided on the Control board as a backup tool to the thermostat for reading faults, fault history, monitoring and setting up the unit. Follow the information provided in this section to learn how to use the mode display.

DISPLAY

The display consists of 3 digits.

OFF

ON

Blink interval: 0.4 sec. On - 0.4 sec. Off

SEG1 SEG2 SEG3

DISPLAY BUTTON LAYOUT

The display buttons shown can be used to navigate and select items:

TEST

OR

RECALL LEARN LEARN RECALL

Examples of button layout are shown above.

Identify correct display buttons on your unit Control board.

TEST

MODES

There are 5 modes which can be accessed using the setting display:

FAULT CODE, FAULT HISTORY, MONITORING, SETTING MODE 1 and SETTING MODE 2.

To enter any of these modes, use the schemes shown in this section. Each mode has its own corresponding “Screen #” within the display itself which allows the user to navigate and use the features. (Example: The Fault Code is accessed and displayed from

“Screen 0” of the 7-segment display. The Fault History is accessed and display using

“Screen 1” of the display, etc.)

MODE

Fault Code Display

Fault Code History

Monitoring Mode

Setting Mode 1

Setting Mode 2

FUNCTION

Present fault (if any).

6 Recent faults stored.

*Monitors system values.

*Can change system settings

*Can change system settings.

DISPLAY SCREEN #

0 (Default)

1

2

3

4

*See tables at the end of this section.

40

SETTING THE MODE DISPLAY SERVICING

SETTING THE MODE DISPLAY

NAVIGATING THROUGH THE DISPLAY SCREENS

SCREEN

0

SCREEN 1

SCREEN 2

SCREEN 3

The home or default screen on the display. This shows the most recent fault.

To access, hold the RECALL button for 5 seconds at screen 0.

SCREEN 4

To access, hold the RECALL button for 5 seconds at screen 1.

To access, hold the RECALL button for 5 seconds at screen 2 .

To access, hold the RECALL and TEST buttons simultaneously

To return to SCREEN 0 of the display, press the LEARN button.

for 5 seconds at screen 2.

Press LEARN

The first digit displays the SCREEN #.

Press LEARN

< SCREEN

0 >

Hold RECALL

< SCREEN

1 >

Hold

RECALL

Press RECALL Button to change fault code history

Press LEARN

< SCREEN 2 >

Hold

RECALL

Hold RECALL and TEST

41

SERVICING

SETTING THE MODE DISPLAY

FAULT CODE HISTORY NAVIGATION

< SCREEN

1>

This mode will allow the user to see the six most recent system faults.

For a list of the fault codes, please see the TROUBLESHOOTING tables in this document.

< SCRE

EN 1 >

Press

RECALL

< SCREE

N 0 >

Hold RECALL Press LEARN

The display will change to

< SCREEN 1 >.

Press RECALL to change Fault code history.

Displays most recent Fault code.

Press RECALL.

Displays 2nd most recent Fault code.

Press RECALL.

Press RECALL.

(6th most recent Fault Code)

42

SETTING THE MODE DISPLAY

SERVICING

MONITORING MODE NAVIGATION

< SCR

EEN 2 >

This screen allows the user to monitor system variables as shown in the tables at the end of this section.

< SCREE

N 1 >

< SCREE

N 0 >

Hold RECALL

SETTING THE MODE DISPLAY

OFF

ON

Blink interval:

0.4 sec. On - 0.4 sec. Off

Press LEARN

< SCREEN 2 >

Press RECALL to increase the value.

Press RECALL.

Press

RECALL

Press RECALL.

Press TEST to confirm the setting.

Press RECALL.

Press RECALL.

Item number

Display flickers at 1 second intervals.

Value

43

SERVICING

SETTINGS MODE 1 NAVIGATION

< SCREEN 3 >

Setting Mode 1 allows the user to adjust system settings as shown in the tables at the end of this section.

< SCREEN 0 >

< SCREEN 2 >

Hold RECALL.

SETTING THE MODE DISPLAY

OFF

ON

Press LEARN.

Blink interval:

0.4 sec. On - 0.4 sec. Off

< SCREEN 3 >

Press RECALL to increase the value.

Press RECALL.

Press

RECALL.

Press RECALL.

Press TEST to change setting.

Press RECALL.

Press TEST to complete setting and return to setting mode.

44

SETTING THE MODE DISPLAY

SERVICING

SETTINGS MODE 2

< SCREEN 4 >

Setting Mode 2 allows the user to change system settings. See table in back of this section.

< SCREEN 2 >

Hold RECALL and TEST.

< SCREEN 0 >

Press LEARN.

SETTING THE MODE DISPLAY

OFF

ON

Blink interval:

0.4 sec. On - 0.4 sec. Off

< SCREEN 4 >

Press RECALL to increase the number.

< Changing setting display >

Press RECALL.

Press

RECALL

Press RECALL.

Press TEST to change setting.

Press RECALL.

Press

RECALL.

Press RECALL.

Press RECALL.

Press TEST to complete setting and return to setting mode.

45

SERVICING

SCREEN 0 (Display FAULT CODE)

Setting

No.

1

Contents

Fault code (present)

SCREEN 1 (Display FAULT CODES)

Setting

No.

1

2

3

4

5

6

Contents

Fault code (latest)

Fault code (2nd)

Fault code (3rd)

Fault code (4th)

Fault code (5th)

Fault code (6th)

SCREEN 2 (MONITOR MODE)

Setting

No.

1

Contents

Compressor operation time

Notes

Notes

Latest

2nd

3rd

4th

5th

6th

7-SEGMENT DISPLAY

2 Operation code

5

9

10

11

6

7

8

12

13

14

15

3

4

Compressor Reduction Mode

% demand act % demand

Requested ID CFM

Reported ID CFM

Outdoor FAN TAP

Ta (Outdoor Air Temperature)

Td (Discharge Temperature)

Tm (Outdoor Coil Temperature)

Tb (Defrost Sensor Temperature)

Tl (Liquid Temperature)

Pressure Sensor

Ts (Suction Temperature)

Notes unit ： hr (Multiply by 200,)

0: Stop

1: Cooling Start-up

2: Heating Start-up

3: Oil Return Operation

4: Heating Operation

5: Defrost Operation

6: Cooling Operation

0:OFF,1:ON unit ： %

(Cut off the decimal first place.) unit ： %

(Cut off the decimal first place.) unit ： CFM (Multiply by 10) unit ： CFM (Multiply by 10)

0: Off; 1: Low Tap; 2: Medium Tap; 3: High Tap unit ： F unit ： F unit ： F unit ： F unit ： F unit ： PSI unit ： F

46

7-SEGMENT DISPLAY

SERVICING

SCREEN 3 (SETTING MODE 1)

Setting

No.

Contents

1 Cool Airflow Trim High

2 Cool Airflow Trim Int

3 Cool Airflow Trim Low

4

5

6

7

Cool Profile

Cool ON Delay

Cool OFF Delay

Dehumidfication Select

8 Heat Airflow Trim High

9

10

11

12

Heat Airflow Trim Int

Heat Airflow Trim Low

Heat ON Delay

Heat OFF Delay

Setting

0:-15% 6:3%

1:-12% 7:6%

2:-9% 8:9%

3:-6% 9:12%

4:-3% 10:15%

5:0%

0:-15% 6:3%

1:-12% 7:6%

2:-9% 8:9%

3:-6% 9:12%

4:-3% 10:15%

5:0%

0:-15% 6:3%

1:-12% 7:6%

2:-9% 8:9%

3:-6% 9:12%

4:-3% 10:15%

5:0%

0:A 2:C

1:B 3:D

0:5sec.

2:20sec.

1:10sec. 3:30sec.

0:30sec.

2:90sec.

1:60sec. 3:120sec.

0:ON 1:OFF

0:-15% 6:3%

1:-12% 7:6%

2:-9% 8:9%

3:-6% 9:12%

4:-3% 10:15%

5:0%

0:-15% 6:3%

1:-12% 7:6%

2:-9% 8:9%

3:-6% 9:12%

4:-3% 10:15%

5:0%

0:-15% 6:3%

1:-12% 7:6%

2:-9% 8:9%

3:-6% 9:12%

4:-3% 10:15%

5:0%

0:5sec.

2:15sec.

1:10sec.

0:30sec.

2:70sec.

1:50sec. 3:90sec.

7-SEGMENT DISPLAY

Notes

47

SERVICING

SCREEN 4 (SETTING MODE 2)

Setting

No.

4

9

10

7

8

11

12

1

2

3

Maximum Defrost Interval

Set Maximum Current

Vertical Rise

Contents

System Verification Test

Force Defrost Cycle

Pump Down

Charge Mode

Maximum Compressor RPS for Cooling

Maximum Compressor RPS for Heating

BOOST MODE Selection

Setting

0: 30min.

1: 60min.

2: 90min.

3: 120min.

N/A

0:Same Level

1:Outdoor Lower

2:Indoor Lower

0:ON 1:OFF

0:ON 1:OFF

0:ON 1:OFF

0:ON 1:OFF

*

*

0:ON , 1:OFF

13 BOOST MODE Temperature

0:105F , 1:100F, 2:95F,

3:90F, 4:85F, 5:80F, 6:75F,

7:70F, 8:Always ON

NOTE : Parameters as per factory setting are highlighted in bold and underlined.

Notes

Future Use

48

SERVICING

CTK04** COMFORTNET™ THERMOSTAT

OVERVIEW

CTK04 ADDENDUM

TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING

The ComfortNet™ system (or CT system) is a system that includes a ComfortNet compatible modular blower heat pump condenser with a CTK04** thermostat. The table below compares the valid CT systems.

Low voltage wiring consists of two wires between the indoor unit and outdoor unit and four wires between the indoor unit and the thermostat. The required wires are: (a) data lines,

1 and 2; (b) thermostat “R” (24 VAC hot) and “C” (24 VAC common).

1 2 C R

Communic a� ng Thermostat

( In case of CTK04AE )

CT compatible Air Handler or Modular Blower

CT compatible

Heat Pump Unit

Full CT system benefits & features

A ComfortNet heating/air conditioning system differs from a legacy/traditional system in the manner in which the indoor unit, outdoor unit and thermostat interact with one another.

In a traditional system, the thermostat sends commands to the indoor and outdoor units via analog 24 VAC signals.

It is a one-way communication path in that the indoor and outdoor units typically do not return information to the thermostat.

1

1

2

2

R

R

C

C

125 �. (*)

Air Handler Blower

Gas Furnace or Module Blower

Integrated Control Module

250 �. (*)

Outdoor unit

Integrated Control Module

On the other hand, the indoor unit, outdoor unit, and thermostat comprising a ComfortNet system “communicate” digitally with one another. It is now a two-way communications path. The thermostat still sends commands to the indoor and outdoor units. However, the thermostat may also request and receive information from both the indoor and outdoor units. This information may be displayed on the

CT thermostat. The indoor and outdoor units also interact with one another. The outdoor unit may send commands to or request information from the indoor unit. This two-way digital communications between the thermostat and subsystems (indoor/outdoor unit) and between subsystems is the key to unlocking the benefits and features of the Comfort -

Net system.

( * ) Allowable Maximum Length

SYSTEM WIRING

SYSTEM WIRING USING FOUR-WIRES

Two wires only may be utilized between the indoor and outdoor units. For this wiring scheme, only the data lines, 1 and 2, are required between the indoor and outdoor units.

Two-way digital communications is accomplished using only two wires. The thermostat and subsystem controls are powered with 24 VAC Thus, a maximum of 4 wires between the equipment and thermostat is all that is required to operate the system.

CTK04 WIRING

NOTE: A removable plug connector is provided with the control to make thermostat wire connections. This plug may be removed, wire connections made to the plug, and replaced. It is strongly recommended that you do not connect more than two wires into a single terminal in the field because there is a risk of the wires becoming loose. Failure to do so may result in intermittent operation.

Typical 18 AWG thermostat wire may be used to wire the system components. However, communications reliability may be improved by using a high quality, shielded, twisted pair cable for the data transmission lines. In either case,

250 feet is the maximum length of wire between indoor unit and outdoor unit, or between indoor unit and thermostat.

Please use a thermostat model later than CTK04AE.

49

SERVICING

THERMOSTAT MENU SCREEN

SYSTEM START-UP TEST

NOTICE

O N INITIAL POWER START UP , THE OUTDOOR UNIT WILL DISPLAY CODE

E11,

SIGNALING THAT INITIAL

SYSTEM

TEST MUST BE RUN

. F

OLLOW

THE C OMFORT N ET ™ SETUP SCREEN TO ENTER APPLICATION UNIQUE

INFORMATION

. S

EE

C

OMFORT

N

ET THERMOSTAT MANUAL FOR

DETAILED INFORMATION .

A system test is now required to check the equipment settings and functionality. Once selected, it checks the equipment for approximately 5 - 15 minutes. System test may exceed 15 minutes if there is an error. Refer to the Troubleshooting section, if error code appears.

Before starting the SYSTEM TEST, turn off the electric heater and gas furnace.

NOTE: If the unit is attempting to run SYSTEM TEST in under 20° F ambient temperature, the unit may not be able to complete the test due to low suction pressure. In such a case, re-run the SYSTEM TEST when the ambient temperature exceeds 20° F.

1. Ensure the thermostat is installed.

2. Apply power to outdoor and indoor units.

3. Start-up.

After the application information is entered, the initial system test must be run.

NOTICE

F OR INVERTER H EAT P UMP C ONDENSER SYSTEM USING C OMFORT N ET ,

DO NOT INSTALL A TRANSFORMER .

The HOME screen will be displayed showing information similar to one of the adjacent screens. Select

MENU. Make sure the thermostat is in OFF mode and select SYSTEM MENU. Choose OFF before SYSTEM

VERIFICATION test.

NOTE: Either screen may be displayed.

SYSTEM TEST must be run for all installations.

System will not operate without a completed initial

SYSTEM TEST.

NOTE: The thermostat screen may indicate to run a

SYSTEM VERIFICATION test.

50

CTK04 ADDENDUM

CTK04 ADDENDUM

SERVICING

4. From the MENU screen, scroll down and select Comfort-

Net™ USER MENU.

5. Enter Installer password. (The password is the Date

Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom.)

6. Select YES to continue.

7. From the ComfortNet USER MENU, select HEAT PUMP.

Note: Screen may show air handler or furnace depending on the type of system installed.

CTK04 ADDENDUM

51

SERVICING

8. Next, scroll down and select EQUIP TEST.

9. Select SYSTEM TEST.

10.Select ON to run the SYSTEM TEST.

Press DONE to initiate test.

11.Allow the system test to run for its duration (5-15 minutes). EQUIP TEST SCREEN will show the system test is ON once selected.

System test will operate the outdoor unit and the indoor unit through a series of startup tests.

Please proceed to the next step and allow for startup tests to complete. Do not interrupt power to outdoor unit, indoor unit, or thermostat during system test.

52

CTK04 ADDENDUM

CTK04 ADDENDUM

SERVICING

12.Press Previous Menu button and navigate to HOME screen and allow test to finish. The display similar to the one at the right will be displayed after SYSTEM TEST completes. Test is complete only when CODE 11 notice clears from BOTH the thermostat display AND the seven segment LED display on the outdoor unit. Please wait for test to complete and for both codes to clear.

SET THERMOSTAT TO CHARGE MODE

Please follow the following sequence to enter CHARGE

Mode.

CHARGE mode allows for charging of the system. System operates for a duration of approximately one hour while the equipment runs at full capacity. After one hour, the charge mode ends and the system resumes normal thermostat operation.

Before starting the charge mode, turn off the electric heater and gas furnace.

1. On the HOME screen, select MENU.

NOTE: Ensure the thermostat is in the OFF mode.

Select

SYSTEM menu. Choose OFF before CHARGE MODE.

2. From the MENU screen, scroll down and select

COMFORTNET™ USER MENU.

CTK04 ADDENDUM

53

SERVICING

3. Enter Installer password. (The password is the Date

Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom).

4. Select YES to continue.

5. Select HEAT PUMP.

6. Select MAINTENANCE.

CTK04 ADDENDUM

54

CTK04 ADDENDUM

SERVICING

7. Select CHARGE Mode.

8. Select ON. Press DONE to initiate CHARGE Mode.

(System will then run for 1 hour and either return to cooling or heating mode depending on if the mode thermostat is set at COOL or HEAT MODE from the SYSTEM menu on the main screen.

If charging is not complete after 1 hour, repeat 7. and 8.

Refer to S-103 for refrigerant charge level adjustment.

9. To terminate CHARGE MODE, select CHARGE Mode screen again. Press OFF. Press DONE to terminate

CHARGE MODE.

10.Once CHARGE MODE is complete and has been terminated, navigate to HOME screen. Enter normal operation with temperature offset or thermostat schedule, as desired.

CTK04 ADDENDUM

55

SERVICING

SET THERMOSTAT TO ADJUST MAXIMUM

COMPRESSOR SPEED

Please follow the following sequence to enter MAXIMUM compressor speed.

Maximum compressor speed at which the outdoor unit will operate in cooling or heating mode can be changed using thermostat. Maximum compressor speed can be changed to get the required capacity or efficiency. Once the maxi mum speed is set, the system operates between the set maximum speed and default low speed.

1. On the HOME screen, select MENU

2. From the MENU screen, select COMFORTNET™ USER

MENU.

3. Enter Installer password. (The password is the Date

Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom).

56

CTK04 ADDENDUM

CTK04 ADDENDUM

SERVICING

4. Select YES to continue.

5. Select HEAT PUMP.

6. Select

CL RUN VALUES: for cooling mode

HT RUN VALUES: for heating mode

7.Select Cool/HEAT RPS RANGE.

Press Cool RPS Range (for cooling mode) or HEAT RPS

RANGE (heating mode) to select the range in which the desired Maximum compressor speed falls.

CTK04 ADDENDUM

Menu > ComfortNet User Menu

Changing these se

�

ngs could cause improper opera

�

on of your HVAC equipment! Would you like to con

�

nue?

Yes No

Menu > ComfortNet User Menu

Help

Air Handler

Heat Pump

57

SERVICING

8. Select Cool RPS SELECT(cooling mode) or HEAT RPS

SELECT (heating mode).

Select the desired Maximum compressor speed

CTK04 ADDENDUM

58

9. Once Maximum compressor speed is set, navigate to

HOME screen. Enter normal operation with temperature offset or thermostat schedule, as desired.

HOME

Tue, Apr 1,2014

1:00 pm

OUTDOOR

69°

STATUS cool mode

FAN SYSTEM

39 % Humidity

MENU

SET TO

76°

Set Thermostat to Adjust Indoor Air CFM trim

1. On the HOME screen, select MENU HOME

Tue, Apr 1,2014

11:17 pm

STATUS heat mode

FAN SYSTEM

74°

63 % Humidity following schedule

MENU

SET TO

62°

2. From the MENU screen, select COMFORTNET™ USER

MENU

HOME FAN SYSTEM

Security Se

�

ngs

Dealer Informa

�

on

Installer Op

�

ons

ComfortNet User Menu

MENU

CTK04 ADDENDUM

SERVICING

3. Enter Installer password. (The password is the Date

Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom).

4. Select YES to continue.

CTK04 ADDENDUM

5. Select HEAT PUMP.

6. Select

Cool Setup: Cooling Mode

HEAT SETUP: Heating Mode

59

SERVICING

7. User can change the airflow trim at high, intermediate and low compressor for cooling and heating mode.

Select:

Cool Airflow Trim Hi: high speed cooling

Cool Airflow Trim Int: intermediate speed cooling

Cool Airflow Trim Low: low speed cooling

Heat Airflow Trim Hi: high speed heating

Heat Airflow Trim Int: intermediate speed heating

Heat Airflow Trim Low: low speed heating

Under each trim setting, the airflow can be increased or decreased by a certain percentage. The increment that can be changed depends on the production date.

8. Once Cool Airflow Trim is set, navigate to HOME screen.

Enter normal operation with temperature offset or ther mostat schedule, as desired.

CTK04 ADDENDUM

60

CTK04 ADDENDUM

SERVICING

SET THERMOSTAT TO ADJUST INDOOR AIRFLOW

PROFILE, COOL/HEAT ON DELAY AND COOL/HEAT

OFF DELAY DEFROST

1. Please follow the sequence 1. to .6 of Set Thermostat To

Adjust Indoor Air CFM trim

CTK04 ADDENDUM

2. Select

Cool Set-up for Cool Airflow Profile, Cool ON Delay

or Cool OFF Delay

Heat Set-up for Heat ON Delay or Heat OFF Delay

Heat Airflow Profile, DEFROST

3. Once Cool Set-up / Heat Set-up settings are complete, navigate to HOME screen.

61

SERVICING

SET THERMOSTAT TO FORCE DEFROST CYCLE

Follow the following sequence to Force a defrost cycle.

NOTE: Unit will need to wait another 6 minutes before starting another force defrost cycle.

1. On the HOME screen, select MENU.

2. From the MENU screen, select COMFORTNET™ USER

MENU.

3. Enter Installer password. (The password is the Date

Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom).

4. Select YES to continue.

62

CTK04 ADDENDUM

CTK04 ADDENDUM

SERVICING

5. Select HEAT PUMP.

6. Select EQUIP TEST.

7. Select FORCE DF CYCLE.

8. Select ON. Press DONE to initiate FORCE DEFROST

CYCLE.

CTK04 ADDENDUM

63

SERVICING

SET THERMOSTAT TO PUMP DOWN

Please follow the following sequence to enter PUMP

DOWN to accumulate the refrigerant to outdoor unit.

Do not operate Cool ON or Heat ON mode to enter PUMP

DOWN. Before starting the PUMP DOWN operation, change indoor fan trim, delay and profile back to default and stop electric heater and gas furnace. Remove if no trim feature. In this operation, the gas valve and liquid service valve should be opened.

NOTE: Manufacturer recommends to set PUMP DOWN using 7-segment display. For more information, see section

Set 7-segment mode display to PUMP DOWN. If difficulty is encountered using 7-segment display, use the thermostat as an alternative method. See section SET 7-SEGMENT

MODE DISPLAY TO PUMP DOWN.

1. On the HOME screen, select MENU.

2. From the MENU screen, select COMFORTNET™ USER

MENU.

3. Enter installer password. (The password is the Date

Code located on the thermostat and is available by entering the equipment status menu and scrolling to the bottom.)

64

CTK04 ADDENDUM

CTK04 ADDENDUM

SERVICING

4. Select YES to continue.

5. Select HEAT PUMP .

6. Select MAINTENANCE.

7. Select PUMP DOWN.

CTK04 ADDENDUM

65

SERVICING

8. Select ON. Press DONE to initiate PUMP DOWN.

Approximately one minute later, the compressor should start operating. Check the amperage at the compressor wiring to see the compressor operation status. Close liquid service valve approximately two minutes after compressor has come on. Compressor will stop automatically then close the gas service valve immediately.

9. To terminate PUMP DOWN, select PUMP DOWN screen again. Press OFF. Press DONE to terminate PUMP

DOWN.

10. Once PUMP DOWN is set, navigate to HOME screen.

After finishing PUMP DOWN operation, unit will stop automatically. Unit will show error code “E11” after the

PUMP DOWN operation starts.

NOTE: Refrigerant cannot be collected to the outdoor unit completely if the system is overcharged or if there is a delay in closing the liquid service valve and gas service valve.

Evacuate the leftover refrigerant from the system using a recovery machine.

CTK04 ADDENDUM

66

CTK04 ADDENDUM

SERVICING

SET 7-SEGMENT MODE DISPLAY TO PUMP DOWN

Please follow the following sequence to enter PUMP

DOWN to accumulate the refrigerant to outdoor unit.

Do not operate COOL ON or HEAT ON mode to enter

PUMP DOWN. Before starting the PUMP DOWN operation, change indoor fan trim, delay and profile back to default and stop electric heater and gas furnace. Remove if no trim feature. In this operation, the gas and liquid service valve should be opened.

1. Set 7-segment display to SCREEN 4 (SETTING MODE

2) Setting No. 8 and change the display from “-01” to

“-00”. System will then automatically start PUMP DOWN operation.

For information on how to set 7-segment display, see the section SETTING THE MODE DISPLAY in this manual.

2. Approximately one minute later, the compressor should start operating. Check the amperage at the compressor wiring to see the compressor operation status. Unit display error code E11 (System verification Test) once the

PUMP DOWN operations starts.

3. Close liquid service valve approximately two minutes after compressor has come on.

4. Compressor will come to a stop automatically. Close the suction service valve immediately after the compressor stops. After completion of PUMP DOWN, unit shows error code “E11”.

NOTE: Refrigerant cannot be collected to the outdoor unit completely if the system is overcharged or if there is a delay in closing the liquid service valve and suction service valve.

Evacuate the left over refrigerant from the system using a recovery machine.

SET THERMOSTAT TO CHECK SYSTEM STATUS

1. Follow the sequence 1. to 5. of Set Thermostat to

Adjust Indoor Air CFM trim.

2. Select STATUS.

CTK04 ADDENDUM

67

SERVICING

3. Follow screen for System Status.

TS

MD

CRM

RAD

RAF

Time Stamp (Compressor run time)

Current system operational Mode

(cooling, cooling startup, heating, heating startup, oil return, defrost, stop)

Compressor Reduction Mode

Requested and Actual percentage Demand

(Requested Demand, Actual cooling/heating provided)

Requested and Reported ID airflow

(Requested CFM, Actual CFM)

ATOF Outdoor Air Temperature and Outdoor Fan STATUS

DCT

DLT

Discharge Temperature, Outdoor Coil Temperature

Defrost sensor temperature, Outdoor Liquid

Temperature

PSDST Pressure Sensor and Outdoor Suction Temperature

HEAT PUMP WITH OUTDOOR TEMPERATURE

LOCKOUTS

It is recommended to set the outdoor temperature lockouts during the initial thermostat set up. This will enable the compressor to be turned off and switch heating source from refrigeration to auxiliary/secondary heating under low ambient conditions.

Backup heat lockout temperature will enable auxiliary/secondary heating to be turned on when outdoor temperature is much higher than indoor temperature, compressor might stop operating under this circumstance.

Backup Heat Lockout

Temperature

(-)

OFF

Compressor Lockout

Temperature

(F°)

15

In order to access the compressor lockout temperature,

Press MENU and scroll down to press INSTALLER OP-

TIONS . Enter the date code (password) when prompted.

Choose VIEW / EDIT CURRENT SETUP and COMPRES-

SOR LOCKOUT / BALANCE POINT will be under HEAT /

COOL CONTROL OPTIONS . For more information please refer to COMFORTNET™ CTK04 Communicating Thermostat SYSTEM INSTALLATION GUIDE.SYSTEM INSTALLA-

TION GUIDE.

68

CTK04 ADDENDUM

HEAT PUMP

RPM

CTK04 ADDENDUM

TROUBLESHOOTING

HEATING ANALYSIS CHART

POSSIBLE CAUSE

X IN ANALYSIS GUIDE INDICATE

"POSSIBLE CAUSE"

Liquid stop valve does not fully open

Gas stop valve does not fully open

Line set restriction

Line set length is too long

Blocked filter-dryer

OD EEV coil failure

OD EEV failure

ID EEV coil failure

ID EEV failure

Check valve failure – Leakage

High Pressure switch failure

Pressure sensor failure

Suction temp sensor failure

Discharge temp sensor failure

Coil temp sensor failure

Defrost sensor failure

Liquid temp sensor failure

Ambient temp sensor failure

OD recirculation

ID recirculation

Dirty OD Heat-exchanger

Dirty ID Heat-exchanger

Outdoor Ambient temp is too high

Outdoor Ambient temp is too low

ID suction temp is too high

ID suction temp is too low

Mixture of non-condensible gas

OD fan motor failure

RV failure

RV coil failure

Over charge

Under charge

Leak

ID failure

OD Control Board failure

Compressor failure

Cooling loop is not attached

Cooling loop grease is not enough

Low ID CFM

Outdoor Normal Temperature Operating Range: 17-62°F

Indoor Normal Temperature Operating Range: 65-85°F

X

X

X

X

X

X

X

X

X

X X

X X

X X

X X X

X X X

X X X

X

X

X

X

X

X

X

X X X X X X X X X X X X X X

X X X X X X X X X X X X X X

X

X

X

X

X

X

X

X

X X X X X

X X X X X X

X X X X X X

X X X X

X

X

X

X

X X X X X X X

X X X X

X X X X

X X X X

X X X X X X X

X X X X

X

X

X X X

X X X

X X

X

X

X

X

X X X

X

X

X

X

X

X

X X

X X

X X

X X

X

X

X

X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X

X

X

X

X

X

X

X X X

X X

X X

X X

X X

X

X X X

X X X

X X X X

X X X

X X X X X

X X X

X X X

X X

X X

X X

X X

X X

X X

X X X X X X X X X X X X X X

X X X X

X X

X X

X

X X X

X X X

X X X

X X X

Outdoor Normal Temperature Operating Range: 67-115°F / Indoor Normal Temperature Operating Range: 65 - 85°F

X

X X

X

X

X

X X

X

X X X X

X

X X X

X

X

X

X

X

X

X

X

X X

X X

X

X X X

X

X

X X X

X

X

X

X

X

X X

X X

X X

X X

WARNING

A VOID CONTACT WITH THE CHARGED AREA .

•N EVER TOUCH THE CHARGED AREA BEFORE CONFIRMING THAT THE RESIDUAL VOLTAGE IS 50 VOLTS OR LESS .

1. S HUT DOWN THE POWER AND LEAVE THE CONTROL BOX FOR 10 MINUTES .

2. M AKE SURE TO TOUCH THE E ARTH GROUND TERMINAL TO RELEASE THE STATIC ELECTRICITY FROM YOUR BODY ( TO PREVENT FAILURE OF THE PC BOARD ).

3. M EASURE THE RESIDUAL VOLTAGE IN THE SPECIFIED MEASUREMENT POSITION USING A VOM WHILE PAYING ATTENTION NOT TO TOUCH THE CHARGED AREA .

4. I MMEDIATELY AFTER MEASURING THE RESIDUAL VOLTAGE , DISCONNECT THE CONNECTORS OF THE OUTDOOR UNIT ’ S FAN MOTOR . (I F THE FAN BLADE ROTATES BY

STRONG WIND BLOWING AGAINST IT , THE CAPACITOR WILL BE CHARGED, CAUSING THE DANGER OF ELECTRICAL SHOCK .)

69

TROUBLESHOOTING

COOLING ANALYSIS CHART

POSSIBLE CAUSE

X IN ANALYSIS GUIDE INDICATE

"POSSIBLE CAUSE"

Liquid stop valve does not fully open

Gas stop valve does not fully open

Line set restriction

Line set length is too long

Blocked filter-dryer

OD EEV coil failure

OD EEV failure

ID EEV coil failure

ID EEV failure

Check valve failure – Blocked

High Pressure switch failure

Pressure sensor failure

Suction temp sensor failure

Discharge temp sensor failure

Coil temp sensor failure

Defrost sensor failure

Liquid temp sensor failure

Ambient temp sensor failure

OD recirculation

ID recirculation

Dirty OD Heat-exchanger

Dirty ID Heat-exchanger

Outdoor Ambient temp is too high

Outdoor Ambient temp is too low

ID suction temp is too high

ID suction temp is too low

Mixture of non-condensible gas

OD fan motor failure

RV failure

RV coil failure

Over charge

Under charge

Leak

OD Control Board Failure

ID Failure

Compressor failure

Cooling loop is not attached

Cooling loop grease is not enough

Low ID CFM

Outdoor Normal Temperature Operating Range: 67-115°F

Indoor Normal Temperature Operating Range: 65 - 85°F

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X X

X X X

X X X

X X

X X X

X X X

X X X

X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X

X X X X X X X X X

X

X X X X

X X X

X

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X X

X X X X X

X X X

X X X

X

X

X X X

X

X

X

X

X

X X X

X

X

X

X

X

X

X

X

X X

X

X X

X X

X

X

X

X

X

X X

X

X

X

X X X

X X X

X X X X

X X X X

X X X X

X X X

X X X X X

X X X

X X X X X

X X X

X X X X X

X

X

X X X X X

X X X X

X X X

X X X X

X

X X X X

X

X

X X X

X X X X X X X X X X X X X X X X X

X X X X X X X X

X X X

X X X

X X X

X X X X X

Outdoor Normal Temperature Operating Range: 17-62°F / Indoor Normal Temperature Operating Range: 65 - 85°F

X

X

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X X

X

X

X

X

X

WARNING

70

A VOID CONTACT WITH THE CHARGED AREA .

•N EVER TOUCH THE CHARGED AREA BEFORE CONFIRMING THAT THE RESIDUAL VOLTAGE IS 50 VOLTS OR LESS .

1. S HUT DOWN THE POWER AND LEAVE THE CONTROL BOX FOR 10 MINUTES .

2. M AKE SURE TO TOUCH THE E ARTH GROUND TERMINAL TO RELEASE THE STATIC ELECTRICITY FROM YOUR BODY ( TO PREVENT FAILURE OF THE PC BOARD ).

3. M EASURE THE RESIDUAL VOLTAGE IN THE SPECIFIED MEASUREMENT POSITION USING A VOM WHILE PAYING ATTENTION NOT TO TOUCH THE CHARGED AREA .

4. I MMEDIATELY AFTER MEASURING THE RESIDUAL VOLTAGE , DISCONNECT THE CONNECTORS OF THE OUTDOOR UNIT ’ S FAN MOTOR . (I F THE FAN BLADE ROTATES BY

STRONG WIND BLOWING AGAINST IT , THE CAPACITOR WILL BE CHARGED, CAUSING THE DANGER OF ELECTRICAL SHOCK .)

TROUBLESHOOTING

ClimateTalk

Fault Code

PCB LED

Display

Transmitted ClimateTalk

Message

22

23

24

25

26

27

28

29

30

32

E22

E23

E24

E25

E26

E27

E28

E29

E30

E32

HI DISCH TEMP

DISCH TEMP FAIL

HPS OPEN

AIR SENSOR FLT

PRESSURE SENSOR

COIL TEMP FAIL1

COIL TEMP FAIL2

LIQ TEMP FAIL

OD CTRL FAIL3

HI TEMP CTRL1

Thermostat Fault Probable Causes

OUTDOOR UNIT- ERROR CODES

Corrective Actions

This error indicates the equipment is experiencing frequent high discharge temperature faults.

Discharge thermistor is not put on correct position.

● Discharge thermistor inoperable or improperly connected

● Discharge thermistor is put on incorrect position or off

● Low refrigerant charge

● Overcharge

● Faulty compressor

● Check discharge thermistor resistance and connections; Repair/replace as needed

● Check discharge thermistor position

● Check refrigerant charge level; Adjust if needed

● Check the compressor; Repair/replace if needed

The control has detected that the

Discharge Temperature Sensor is out of range.

The high pressure switch is open.

● Discharge thermistor inoperable or ● Check discharge thermistor resistance and improperly connected

● High pressure switch (HPS) inoperable

● Check resistance on HPS to verify operation; Replace if needed

The outdoor air temperature sensor is open or shorted.

The control determines that the pressure sensor is not reacting properly.

● Faulty outdoor thermistor sensor or disconnect

● Low pressure sensor inoperable or not properly connected

The control has detected that the

Outdoor Defrost Sensor is out of range.

The control has detected that the

Outdoor Coil Temperature Sensor is out of range.

The control has detected that the Liquid

Temperature Sensor is out of range.

● Outdoor defrost thermistor inoperable or not properly connected

● Outdoor coil thermistor inoperable or not properly connected

Indicates the control board may need to be replaced.

This error indicates the equipment is experiencing high temperature faults on the outdoor control board.

● Liquid thermistor inoperable or not properly connected

● Wiring to control board disconnected

● Faulty control board

● Noise

● Ambient air conditions too high

● Cooling bracket screw(s) missing or not properly fastened

● No or poor thermal grease coating between cooling plumbing and cooling bracket on control board

● No flow or limited flow through control board cooling circuit (potential restriction in line or low refrigerant)

● Stop valve not completely open

● Inspect and test sensor; Replace sensor if needed

● Check the connection to low pressure sensor;

Repair/replace if needed

● Check the connection to OD defrost thermistor;

Repair/replace if needed

● Check the connection to OD coil thermistor; Repair if needed

● Check the connection to liquid thermistor;

Repair/replace if needed

● Check wiring to control board; Repair as needed

● Replace control board if necessary

● Cycle power; re-try during usable ambient temperature range

● Verify cooling bracket screws in place and secure;

Secure fasteners as needed

● Check thermal grease inside cooling bracket on control board; Apply additional grease as needed

● Check for restriction in line

● Check refrigerant charge level; Adjust if needed

● Check the opening of stop valve, should be full open;

Repair/replace if needed

33

34

-

E34

HI TEMP CTRL2

CURRENT SPIKE

This error indicates the equipment is experiencing high temperature faults on the outdoor control board. Control has determined continued operation is acceptable. This indicates they may be a problem with the equipment.

● Ambient air conditions too high

● Cooling bracket screw(s) missing or not properly fastened

● No or poor thermal grease coating between cooling plumbing and cooling bracket on control board

● No flow or limited flow through control board cooling circuit (potential restriction in line or low refrigerant)

● Stop valve not completely open

● Cycle power; re-try during usable ambient temperature range

● Verify cooling bracket screws in place and secure;

Secure fasteners as needed

● Check thermal grease inside cooling bracket on control board; Apply additional grease as needed

● Check for restriction in line

● Check refrigerant charge level; Adjust if needed

● Check the opening of stop valve, should be full open;

Repair/replace if needed

Board detected a high current condition.

This indicates the potential for a short circuit.

● Current spike in supply

● Stop valve not completely open

● The compressor wire is lost phase

● Faulty control board

● Faulty compressor

● Check power supply for in-rush current during start-up or steady state operation

● Check the opening of stop valve, should be full open;

Repair/replace if needed

● Check the wire between control board and compressor

● Replace control board if necessary

● Check the compressor; Repair/replace if needed

71

OUTDOOR UNIT

TROUBLESHOOTING

ClimateTalk

Fault Code

PCB LED

Display

Transmitted ClimateTalk

Message

35

36

37

38

39

40

41

42

43

E35

E36

E37

E38

E39

E40

E41

E42

E43

HIGH CURRENT

STARTUP ERROR

OD CTRL FAIL4

COMP VOLTAGE

OD CTRL FAIL5

COMP MISMATCH

LOW REFRIGERANT

LOW LINE VOLT

HIGH LINE VOLT

Thermostat Fault

The control has detected a voltage related issue with the compressor.

Indicates the control board may need to be replaced.

● Thermistors inoperable or improperly connected

● Faulty control board

Control determines that its compressor requirement is different than the compressor capability.

The control has detected a low refrigerant condition.

Control detects a low power supply voltage condition.

Control detects a high power supply voltage condition.

Probable Causes

Board detected a high current condition.

The control encountered an abnormal condition during the startup procedure.

Indicates the control board may need to be replaced.

● Short circuit condition

● Stop valve not completely open

● Overcharge

● Faulty control board

● Faulty compressor

● Blocked/restricted condenser coil and/or lines

● The compressor wire is lost phase

● Inconsistent compressor load

● Faulty control board

● Faulty control board

● High or low voltage from supply

● The compressor wire is lost phase

● Faulty control board

●

●

Bluetooth Shared Data Loader BTSDL01

Control board mismatch

● Refrigerant leak

● Low refrigerant charge

● Thermistors inoperable or not properly connected

● Low line voltage supply

● High line voltage supply

OUTDOOR UNIT- ERROR CODES

Corrective Actions

● Check installation clearances.

● Check the opening of stop valve, should be full open;

Repair/replace if needed

● Check refrigerant charge level; Adjust if needed

● Replace control board if necessary

● Check the compressor; Repair/replace if needed.

● Check and clean condenser coil and/or lines

● Check the wire between control board and compressor

● Replace control board if necessary

● Replace control board if necessary

● Correct low/high line voltage condition; Contact local utility if needed

● Check the wire between control board and compressor

● Replace control board if necessary

● Check the connection to thermistors; Repair/replace if needed

● Replace control board if necessary

● Check Bluetooth Shared Data Loader BTSDL01 data

vs. Heat Pump model

● Verify control board size vs. Heat Pump model;

Replace control board if necessary

● Test for system leaks using leak test procedure

● Check refrigerant charge level; Adjust if needed

● Checkthe connection to thermistor; Repair/replace if needed

● Check circuit breakers and fuses; Replace if needed

● Verify unit is connected to power supply as specified on rating plate

● Correct low line voltage condition; Contact local utility if needed

● Verify unit is connected to power supply as specified on rating plate

● Correct high line voltage condition; Contact local utility if needed

44

45

E44

E45

OP TEMP RANGE

NO COOLING TEST

The control detects the outdoor temperature outside recommended operational range. Unit may continue to operate normally.

● Ambient air conditions too high or low

The control is unable to start the Cooling mode test because indoor heat has been turned on by thermostat. Please set thermostat to off position.

● Heat provided by secondary heating source

● Cycle power; re-try during usable ambient temperature range

● Turn off heater using thermostat before running AHRI mode

47

48

49

50

51

52

E47

E48

E49

E50

E51

-

NO SYS VER TEST

NO PUMP DOWN

NO CHARGE MODE

LINE VOLT CTRL

OD COMM ERROR

COMP FAIL MINOR

The control is unable to start the System

Verification test because indoor heat has been turned on by thermostat. Please set thermostat to off position.

● Heat provided by secondary heating source ● Turn off heater using thermostat before operation

The control is unable to enter the Pump

Down Mode because indoor heat has been turned on by thermostat. Please set thermostat to off position.

The control is unable to enter Charging

Mode because indoor heat has been turned on by thermostat. Please set thermostat to off position.

● Heat provided by secondary heating source ● Turn off heater using thermostat before operation

● Heat provided by secondary heating source ● Turn off heater using thermostat before operation

This indicates there is a voltage issue on the control board. See service manual for troubleshooting information.

This indicates potential communication issues have been detected by the outdoor control board.

This error indicates the equipment is experiencing frequent compressor faults.

Control has determined continued operation is acceptable. This indicates they may be a problem with the equipment.

● High or low voltage from supply

● Faulty control board

● Communication wiring disconnected

●

●

●

Stop valve not completely open

The compressor wire is lost phase

Compressor motor failure

● Correct low/high line voltage condition; Contact local utility if needed

● Replace control board if necessary

●

●

●

●

Check communication wiring; Repair as needed

Check the opening of stop valve, should be full open;

Repair/replace if needed

Check the wire between control board and compressor

Inspect compressor motor for proper function;

Replace if necessary

72

OUTDOOR UNIT- ERROR CODES

TROUBLESHOOTING

ClimateTalk

Fault Code

PCB LED

Display

Transmitted ClimateTalk

Message

54 EEV MINOR

Thermostat Fault

This error indicates the equipment is experiencing frequent low discharge superheat faults.

Control has determined continued operation is acceptable. This indicates they may be a problem with the equipment.

55 HI DIS TEMP MIN

Probable Causes

OUTDOOR UNIT- ERROR CODES

● Thermistors inoperable or improperly connected

● Faulty indoor EEV or indoor EEV coil

● Faulty control board

Corrective Actions

● Check the connection to thermistors; Repair/replace if needed

● Check indoor EEV; Replace if needed

● Check indoor EEV coil; Replace if needed

● Replace control board if necessary

This error indicates the equipment is experiencing frequent high discharge temperature faults. Control has determined continued operation is acceptable. This indicates they may be a problem with the equipment.

● Discharge thermistor inoperable or improperly connected

● Discharge thermistor is put on incorrect position or off

● Low refrigerant charge

● Overcharge

● Faulty compressor

● Check discharge thermistor resistance and connections; Repair/replace as needed

● Check discharge thermistor position

● Check refrigerant charge level; Adjust if needed

● Check refrigerant charge level; Adjust if needed

● Check the compressor; Repair/replace if needed

56 E56 SUCT TEMP FAIL

The control has detected if the Outdoor

Suction Temperature Sensor is out of range.

● Suction thermistor inoperable or not properly connected

● Check the connection to suction thermistor;

Repair/replace if needed

57

B0

B9

-

Eb0

Eb9

CL LOOP SWEAT

NO ID AIRFLOW

LOW ID AIRFLOW

This indicates the control is sensing sweating on the cooling loop.

The estimated airflow from indoor subsystem is near to 0 CFM.

Estimated airflow from motor is lower than the airflow requirement.

● Refrigerant Leak

● Low refrigerant charge

● Faulty indoor EEV or indoor EEV coil

● Thermistors inoperable or improperly connection

● Failed indoor blower motor

● Indoor fan motor not properly connected

● Too much static pressure

● Failed indoor blower motor

● Indoor fan motor not properly connected

● Too much static pressure

● Test for system leaks using leak test procedure

● Check refrigerant charge level; Adjust if needed

● Check indoor EEV; Replace if needed

● Check indoor EEV coil; Replace if needed

● Check the connection to thermistors; Repair/replace if needed

● Check ID fan motor wiring and connectors;

Repair/replace if needed

● Check ID fan motor; Replace if needed

● Check ID fan motor wiring and connectors;

Repair/replace if needed

● Check ID fan motor; Replace if needed

D0

D1

Ed0

Ed1

NO NET DATA

INVALID DATA

Control board does not have the necessary data for it to properly perform its functions.

Control board does not the appropriate data needed to properly perform its functions.

● Heat Pump is wired as part of a communicating system and integrated control module does not contain any shared data.

● Heat Pump is wired as part of a communicating system and integrated control module contains invalid shared data or network data is invalid for the integrated control module.

● Replace control board if necessary

● Replace control board if necessary

D2

11

Ed2

E11

SYSTEM MISMATCH

RUN SYS TEST

The airflow requirement is greater than the airflow capability of the indoor subsystem.

● Heat Pump is wired as part of a communicating system and outdoor unit requires airflow greater than indoor unit's airflow capability

● Shared data is incompatible the system or missing parameters

● Communication wiring has loose connection.

● Indoor unit without EEV.

● Verify shared data is correct for your specific model;

Repopulate data if required

● Check communication wiring. Repair as needed.

Items below are messages only displayed on the thermostat screen.

This test is required at startup. Installer should navigate to the ComforrtNet User

Menu, choose Heat Pump, then

EQUIP TEST and SYSYTEM TEST.

Selecting ON will run the required test.

Display will clear once testing is complete.

● Incomplete SYSTEM TEST

● SYSTEM TEST is running

MESSAGE ONLY

73

TROUBLESHOOTING

NETWORK TROUBLESHOOTING

OUTDOOR UNIT

Communications is achieved by taking the difference between a positive dc signal and a negative dc signal.

The positive dc signal is termed “data 1” or “1’. Data 1 is positive with respect to ground (or common). The negative dc signal is termed “data 2” or “2”. Data 2 is negative with respect to ground (or common).

Verify that the bus DS1 dip switches are in the ON position.

Data 1 should be approximately 2.8 volt dc. Data 2 should be approximately 2.2 volt dc. The voltage difference between data 1 and data 2 should be approximately 0.6 volt dc.

If the voltage difference is not .6 VDC, turn OFF DS1 switches Data 1 and Data 2. Reset Power and check for

.6 DCV.

The ComfortNet™ system is a fully communicating system, constituting a network. Occasionally the need to troubleshoot the network may arise. The integrated control module has some on-board tools that can be used to troubleshoot the network. These tools are: red communications

LED, green receive (Rx) LED, and the learn button.

• Red communications LED – Indicates the status of the network. The table below indicates the LED status and the corresponding potential problem.

• Green receive LED – Indicates network traffic. The table

below indicates the LED status and the corresponding

potential problem.

• LEARN button – Used to reset the network. Press the button for approximately 5 seconds to reset the network.

2

1

ON OFF

LED COLOR

Red Communications LED

(H1P)

Green Receive LED

(H2P)

LED Status

Off

1 Flash

2 Flash

Off

Indication

Nominal condition

Communications Failure

Out-of-box reset

No power

Communications error

1 Steady Flash No network found

Rapid Flashing

On Solid

Nominal network traffic

Data 1/Data 2 miss-wire

Probable Causes

● None

● Unknown packet is received

● Control power up

● Learn button depressed

● none

Corrective Actions

● Depress learn button

● None

● No power to Outdoor unit

● Open fuse

● Communication error

● Check circuit breakers and fuses; Replace if needed

●Reset network by depressing learn button

● Check communication wires (data 1/ data 2 wires);

Replace if needed

● Broken/ disconnected communication wire(s)

● AC is installed as a legacy/ traditional system

● Check communication wires (data 1/ data 2 wires);

Replace if needed

● Check installation type (legacy/ traditional or communicating)

● Check data 1/ data 2 voltages

● Control is "talking" on network as expected ● none

● Data 1 and data 2 wires reversed at indoor unit, thermostat, or outdoor unit

● Short between data 1 and data 2 wires

● Short between data 1 or data 2 wires

● Check communication wires (data 1/ data 2 wires);

Replace if needed

● Check data 1/ data 2 voltages

74

OUTDOOR UNIT TROUBLESHOOTING

TEMP TEMP

1.18

1.02

0.89

0.78

0.68

0.60

0.53

0.47

0.42

0.37

2.14

1.83

1.58

1.36

4.16

3.50

2.96

2.51

16.10

13.04

10.63

8.71

7.18

5.95

4.96

111.99

85.49

65.84

51.09

39.96

31.50

25.01

20.00

Tm : Coil

TI : Liquid

Tb : Defrost

Tgi: Indoor Gas

Tli: Indoor Liquid

Thermistor

Resistance

R （ k Ω ）

Volts

DC （ V)

364.43

267.00

197.81

148.10

4.58

4.45

4.29

4.09

2.74

2.44

2.16

1.89

3.86

3.61

3.33

3.04

0.30

0.26

0.23

0.20

0.56

0.48

0.41

0.35

1.64

1.42

1.22

1.04

0.89

0.76

0.65

0.17

0.15

0.13

0.12

0.10

0.09

0.08

0.07

0.06

0.06

105

110

115

120

85

90

95

100

65

70

75

80

50

55

60

125

130

135

140

145

150

30

35

40

45

10

15

20

25

0

5

-10

-5

( ℃ )

-30

-25

-20

-15

185

194

203

212

149

158

167

176

86

95

104

113

122

131

140

50

59

68

77

14

23

32

41

(F)

-22

-13

-4

5

221

230

239

248

257

266

275

284

293

302

Tl : Liquid

2.14

1.83

1.58

1.36

4.16

3.50

2.96

2.51

16.10

13.04

10.63

8.71

7.18

5.95

4.96

Thermistor

Resistance

R （ k Ω ）

364.43

267.00

197.81

148.10

111.99

85.49

65.84

51.09

39.96

31.50

25.01

20.00

1.18

1.02

0.89

0.78

0.68

0.60

0.53

0.47

0.42

0.37

THERMISTOR RESISTANCE VALUE

Td : Discharge

Volts

0.30

0.26

0.23

0.20

0.56

0.48

0.41

0.35

1.64

1.42

1.22

1.04

0.89

0.76

0.65

2.74

2.44

2.16

1.89

3.86

3.61

3.33

3.04

DC （ V)

4.58

4.45

4.29

4.09

0.17

0.15

0.13

0.12

0.10

0.09

0.08

0.07

0.06

0.06

43.63

36.26

30.27

25.38

21.37

18.06

15.33

13.06

184.11

147.37

118.68

96.13

78.29

64.10

52.76

Thermistor

Resistance

R （ k Ω ）

4759.15

3454.24

2533.62

1877.01

1403.82

1059.45

806.47

618.95

478.76

373.11

292.86

231.44

11.17

9.59

8.25

7.13

6.18

5.37

4.69

4.10

3.59

3.16

Ta : Ambient

-

-

-

-

-

-

-

-

16.13

13.07

10.65

8.73

7.18

-

-

Thermistor

Resistance

R （ k Ω ）

362.48

265.99

197.31

147.86

111.88

85.43

65.80

51.10

39.99

31.54

25.06

20.04

-

-

-

-

-

-

-

-

-

-

Volts

1.77

1.58

1.41

1.25

2.64

2.41

2.18

1.97

4.13

3.95

3.76

3.56

3.34

3.11

2.87

4.62

4.53

4.41

4.28

4.86

4.82

4.77

4.70

DC （ V)

4.96

4.94

4.92

4.90

1.11

0.99

0.87

0.77

0.68

0.61

0.54

0.48

0.42

0.37

Volts

-

-

-

-

-

-

-

-

1.64

1.42

1.22

1.05

0.89

-

-

2.74

2.44

2.16

1.89

3.86

3.61

3.33

3.04

DC （ V)

4.58

4.45

4.28

4.09

-

-

-

-

-

-

-

-

-

-

75

21.0

22.1

23.2

24.3

25.4

26.4

27.4

28.5

11.3

12.6

13.8

15.1

16.3

17.5

18.7

19.8

29.5

30.5

31.2

32.2

33.2

34.1

35.1

35.5

36.9

5.9

7.3

8.6

10.0

0.0

1.5

3.0

4.5

-13.8

-11.9

-10.1

-8.3

-6.5

-4.5

-3.2

-1.6

46

48

50

52

38

40

42

44

30

32

34

36

22

24

26

28

PSIG °F

12

14

16

18

20

-37.7

-34.7

-32.0

-29.4

-36.9

-24.5

-22.2

-20.0

-17.9

-15.8

102

104

106

108

110

112

94

96

98

100

86

88

90

92

78

80

82

84

70

72

74

76

62

64

66

68

54

56

58

60

TROUBLESHOOTING PRESSURE TEMPERATURE

63.8

64.5

65.1

65.8

66.4

67.0

67.7

68.3

58.4

59.0

59.8

60.5

61.1

61.8

62.5

63.1

68.9

69.5

70.1

70.7

71.4

72.0

72.6

73.2

73.8

52.5

53.3

54.0

54.8

55.5

56.2

57.0

57.7

46.3

47.1

47.9

48.7

49.5

50.3

51.1

51.8

148

150

152

154

140

142

144

146

132

134

136

138

124

126

128

130

PSIG °F

114

116

118

120

122

37.8

38.7

39.5

40.5

41.3

42.2

43.0

43.8

44.7

45.5

204

206

208

210

212

214

196

198

200

202

188

190

192

194

180

182

184

186

172

174

176

178

164

166

168

170

156

158

160

162

R-410A Pressure vs. Temperature Chart

270

272

274

276

262

264

266

268

254

256

258

260

246

248

250

252

238

240

242

244

230

232

234

236

PSIG

216

218

220

222

224

226

228

302

304

306

308

294

296

298

300

310

312

314

316

286

288

290

292

278

280

282

284

86.9

87.4

87.9

88.4

88.9

89.4

89.9

90.4

82.7

83.3

83.8

84.3

84.8

85.4

85.9

86.4

78.4

78.9

79.5

80.0

80.6

81.1

81.6

82.2

°F

74.3

74.9

75.5

76.1

76.7

77.2

77.8

94.8

95.2

95.7

96.2

96.6

97.1

97.5

98.0

90.9

91.4

91.9

92.4

92.8

93.3

93.8

94.3

98.4

98.9

99.3

99.7

372

374

376

378

364

366

368

370

356

358

360

362

348

350

352

354

340

342

344

346

332

334

336

338

PSIG

318

320

322

324

326

328

330

404

406

408

410

396

398

400

402

412

414

416

418

388

390

392

394

380

382

384

386

110.0

110.4

110.8

111.2

111.6

112.0

112.4

112.6

106.6

107.1

107.5

107.9

108.3

108.8

109.2

109.6

103.3

103.7

104.2

104.6

105.1

105.4

105.8

106.3

°F

100.2

100.7

101.1

101.6

102.0

102.4

102.9

116.2

116.6

117.0

117.3

117.7

118.1

118.5

118.8

113.1

113.5

113.9

114.3

114.7

115.0

115.5

115.8

119.2

119.6

119.9

120.3

450.0

126.0

452.0

126.3

454.0

126.6

456.0

127.0

458.0

127.3

460.0

127.7

462.0

128.0

464.0

128.3

466.0

128.7

468.0

129.0

470.0

129.3

472.0

129.7

474.0

130.0

476.0

130.3

478.0

130.7

480.0

131.0

PSIG °F

420.0

120.7

422.0

121.0

424.0

121.4

426.0

121.7

428.0

122.1

430.0

122.5

432.0

122.8

434.0

123.2

436.0

123.5

438.0

123.9

440.0

124.2

442.0

124.6

444.0

124.9

446.0

125.3

448.0

125.6

482.0

131.3

484.0

131.6

486.0

132.0

488.0

132.3

490.0

132.6

492.0

132.9

494.0

133.3

496.0

133.6

498.0

133.9

500.0

134.0

502.0

134.5

504.0

134.8

506.0

135.2

508.0

135.5

510.0

135.8

512.0

136.1

514.0

136.4

516.0

136.7

518.0

137.0

520.0

137.3

612

616

620

624

596

600

604

608

580

584

588

592

564

568

572

576

548

552

556

560

536

538

540

544

PSIG

522

524

526

528

530

532

534

676

680

684

688

660

664

668

672

692

696

644

648

652

656

628

632

636

640

148.4

149.0

149.5

150.1

150.6

151.2

151.7

152.3

143.9

144.5

145.0

145.6

146.2

146.7

147.3

147.9

139.8

140.1

140.4

141.0

141.6

142.1

142.7

143.3

°F

137.6

137.9

138.3

138.6

138.9

139.2

139.5

157.1

157.7

158.2

158.7

159.2

159.8

160.3

160.8

161.3

161.8

152.8

153.4

153.9

154.5

155.0

155.5

156.1

156.6

76

PRESSURE TEMPERATURE TROUBLESHOOTING

Required Liquid Line Temperature

406

416

427

439

364

374

384

395

326

335

345

354

291

299

308

317

LIQUID PRESSURE

AT SERVICE VALVE (PSIG)

189

195

202

208

215

222

259

266

274

283

229

236

243

251

450

462

474

486

499

511

112

114

116

118

104

106

108

110

120

122

124

126

128

96

98

100

102

88

90

92

94

80

82

84

86

72

74

76

78

64

66

68

70

8

58

60

62

114

116

118

120

106

108

110

112

98

100

102

104

90

92

94

96

122

124

126

82

84

86

88

74

76

78

80

66

68

70

72

58

60

62

64

116

118

120

122

124

108

110

112

114

100

102

104

106

92

94

96

98

84

86

88

90

76

78

80

82

68

70

72

74

60

62

64

66

REQUIRED SUBCOOLING TEMPERATURE (°F)

10

56

12

54

56

58

58

60

62

64

14

52

54

56

66

68

70

72

74

76

78

80

82

84

86

88

90

92

94

96

98

100

102

104

106

108

110

112

114

116

118

120

122

104

106

108

110

96

98

100

102

112

114

116

118

120

88

90

92

94

80

82

84

86

72

74

76

78

64

66

68

70

56

58

60

62

16

50

52

54

102

104

106

108

94

96

98

100

110

112

114

116

118

86

88

90

92

78

80

82

84

70

72

74

76

62

64

66

68

54

56

58

60

18

48

50

52

77

TROUBLESHOOTING

WARNING

HIGH VOLTAGE !

D

ISCONNECT

ALL

POWER BEFORE SERVICING OR

INSTALLING

. M

ULTIPLE POWER SOURCES MAY BE

PRESENT

. F

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE , PERSONAL INJURY OR DEATH .

INSTALL THE ELECTRICAL BOARD

When working on a service port, ensure that no refrigerant and/or compressor oil is sprayed onto the electrical board.

This could damage the board’s functionality.

CAUTION

W

HEN REPLACING THE ELECTRICAL BOARD

,

DO

NOT

TOUCH THE

HATCHED AREAS

. B

EFORE INSTALLING THE NEW ELECTRICAL BOARD

,

BE

SURE TO WIPE THE GREASE OFF THE REFRIGERANT TUBING

. E

XERCISE

CAUTION TO NOT DAMAGE THE ELECTRICAL CONNECTIONS

.

D

ISCONNECT AS NEEDED

.

UNINSTALL THE ELECTRICAL BOARD

When uninstalling the main electrical board, remove the screws holding the cover in place. If board replacement is attempted without following proper uninstallation procedure, the refrigerant piping might be damaged. Always replace the grease with new grease on heat sink used for cooling.

Not replacing grease may result in insufficient cooling and may damage the electrical board.

1. Wipe the stale grease completely from the installed piping. If you reinstall the control board, make sure to wipe clean the heat sink on the board. Coat the surface with the standard quantity of the specified new grease.

2. Carefully slide the sheet metal plate back in and fix the screws B.

3. Do not apply force to the parts on the control board. Hold the control board plate NOT the control board.

4. Ensure that the liquid tube does not come in contact with any part of the PCB assembly.

5. Gently fit the tube in the heat sink troughs. Ensure good contact.

6. Close the cover, slide it downwards, fix it with the nails

(two nails) and tighten fixing screws A so that the piping is tightly connected.

Use the grease that is provided with the service parts

.20

1. Remove the fixing screw A.

2. Lift the cover and open it in the direction shown in the figure.

Cover

Heat Sink for Cooling

Fixing

Screw A

.20

Make sure that you are coating evenly

Screw A

Nail

Refrigerant Tubing

3. Remove fixing screws B affixing the sheet metal plate.

4. Carefully slide the sheet metal plate with the electrical board behind the refrigerant tubing as shown.

Tightening Torque:

14.1±1.7 lbf-in

Tighten with a driver until the position where a tightening torque increases suddenly.

Then extra-tighten by 30° to 40º.

Nail

PCB ASSY

SLIDE

RAIL

PCB

MOUNTING

PLATE

PCB

78

TROUBLESHOOTING

WARNING

A

VOID CONTACT WITH THE CHARGED AREA

.

•N EVER TOUCH THE CHARGED AREA BEFORE CONFIRMING THAT THE RESIDUAL VOLTAGE IS 50 VOLTS OR LESS .

1. S

HUT DOWN THE POWER AND LEAVE THE CONTROL BOX FOR

10

MINUTES

.

2. M AKE SURE TO TOUCH THE E ARTH GROUND TERMINAL TO RELEASE THE STATIC ELECTRICITY FROM YOUR BODY ( TO PREVENT

FAILURE OF THE

PC

BOARD

).

3. M EASURE THE RESIDUAL VOLTAGE IN THE SPECIFIED MEASUREMENT POSITION USING A VOM WHILE PAYING ATTENTION NOT TO

TOUCH THE CHARGED AREA .

4. I

MMEDIATELY AFTER MEASURING THE RESIDUAL VOLTAGE

,

DISCONNECT THE CONNECTORS OF THE OUTDOOR UNIT

’

S FAN

MOTOR

. (I

F THE FAN BLADE ROTATES BY STRONG WIND BLOWING AGAINST IT

,

THE CAPACITOR

WILL BE CHARGED,

CAUSING

THE DANGER OF ELECTRICAL SHOCK .)

2-3 TON

CCapacitor Voltage

C+

79

TROUBLESHOOTING

WARNING

A

VOID CONTACT WITH THE CHARGED AREA

.

•N EVER TOUCH THE CHARGED AREA BEFORE CONFIRMING THAT THE RESIDUAL VOLTAGE IS 50 VOLTS OR LESS .

1. S

HUT DOWN THE POWER AND LEAVE THE CONTROL BOX FOR

10

MINUTES

.

2. M AKE SURE TO TOUCH THE E ARTH GROUND TERMINAL TO RELEASE THE STATIC ELECTRICITY FROM YOUR BODY ( TO PREVENT

FAILURE OF THE

PC

BOARD

).

3. M EASURE THE RESIDUAL VOLTAGE IN THE SPECIFIED MEASUREMENT POSITION USING A VOM WHILE PAYING ATTENTION NOT TO

TOUCH THE CHARGED AREA .

4. I

MMEDIATELY AFTER MEASURING THE RESIDUAL VOLTAGE

,

DISCONNECT THE CONNECTORS OF THE OUTDOOR UNIT

’

S FAN

MOTOR

. (I

F THE FAN BLADE ROTATES BY STRONG WIND BLOWING AGAINST IT

,

THE CAPACITOR

WILL BE CHARGED,

CAUSING

THE DANGER OF ELECTRICAL SHOCK .)

4-5 TON

80

CCapacitor Voltage

C+

WIRING DIAGRAM

AVZC180241**, AVZC180361**, AVZC180481**, AVZC180601**

COIL CIRCUIT

DEFROST

LIQUID LINE

DISCHARGE

LINE

RVC

Wiring is subject to change. Always refer to wiring diagram on the unit for the most up to date wiring.

81

WIRING DIAGRAM

230 VAC

208 VAC

230 VAC TR2 (S

208 VAC

~ ~

24V THERMOSTAT CONNECTIONS

S20 8 S19 S17 S16 4 S15 S13 12 11 S 10 S S9 S

S7 S8 S5 S6

S3 S4 S1 S2

RAM MONITOR

FLASH WRITER

S24 2 S23 S21

SHARE DATA

82

Wiring is subject to change. Always refer to wiring diagram on the unit for the most up to date wiring.

ACCESSORIES

AV**PEC

HEATER KIT

MODELS

AVPEC25B14A*

AVPEC37C14A*

AVPEC59D14A*

AVPEC61D14A*

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X

X

X

X

*Revision level taht may or may not be designated.

NOTE: Airflow selection should meet the minimum requirements as mentioned in the air handler Installation instructions.

X

X X

For heater kit installation, it is important to set the capacity of the electric heater at Set-up menu on the thermostat and

DIP switch on indoor unit control board. For more information, please see indoor unit I/O manual.

VALID SWITCH SETTINGS

Heater Kit Heater kW

Selection AVPEC25B14A* AVPEC37C14A* + AVPEC59D14A* ++ AVPEC61D14A*

No heater

First

Second

Third

-

3

5

6

-

5

6

8

-

5

6

8

-

5

6

8

Fourth

Fifth

Sixth

Seventh

8

10

X

X

10

15

19

X

10

15

20

X

10

15

20

25

Dip Switch Setting Indoor PCB DS Bank 3

S-9

OFF

ON

ON

ON

ON

ON

ON

ON

S-10

OFF

ON

ON

ON

ON

OFF

OFF

OFF

S-11

OFF

ON

ON

OFF

OFF

ON

ON

OFF

S-12

OFF

ON

OFF

ON

OFF

ON

OFF

ON

+For match up with a 2 ton outdoor unit: Heater kit application shall not exceed 10 kW.

++For match up with a 3 ton outdoor unit: Heater kit application shall not exceed 15 kW.

NOTE: For emergency mode heating, set the dipswitch on PCB. For heating mode, use the thermostta user menu.

83

ACCESSORIES

CHECKING HEATER LIMIT CONTROL(S) (OPTIONAL

ELECTRIC HEATERS)

Each individual heater element is protected with an automatic rest limit control connected in series with each element to prevent overheating of components in case of low airflow. This limit control will open its circuit at approximate ly 150°F. to 160°F and close at approximately 110°F.

WARNING

Disconnect ALL power before servicing.

1. Remove the wiring from the control terminals.

2. Using an ohmmeter test for continuity across the

normally closed contacts. No reading indicates the

control is open - replace if necessary. Make sure the

limits are cool before testing.

IF FOUND OPEN - REPLACE - DO NOT WIRE AROUND.

CHECKING HEATER ELEMENTS

Optional electric heaters may be added, in the quantities shown in the spec sheet for each model unit, to provide electric resistance heating. Under no condition shall more heaters than the quantity shown be installed. static pressure external to the unit. The installation manual supplied with the blower coil, or the blower performance table in the service manual, shows the CFM for the static measured.

Alternately, the system CFM can be determined by operating the electric heaters and indoor blower WITHOUT having the compressor in operation. Measure the temperature rise as close to the blower inlet and outlet as possible.

If other than a 240V power supply is used, refer to the

BTUH CAPACITY CORRECTION FACTOR in the following chart.

BTUH CAPACITY CORRECTION FACTOR

SUPPLY VOLTAGE

MULTIPLICATION FACTOR

250 230 220 208

1.08

.92

.84

.75

EXAMPLE: Five (5) heaters provide 24.0 KW at the rated

240V. Our actual measured voltage is 220V, and our measured temperature rise is 42°F. Find the actual CFM:

Answer: 24.0KW, 42°F Rise, 240 V = 1800 CFM from the

TEMPERATURE RISE chart on the right.

Heating output at 220 V = 24.0KW x 3.413 x .84 = 68.8

MBH.

Actual CFM = 1800 x .84 Corr. Factor = 1400 CFM.

HIGH VOLTAGE!

Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Disassemble and remove the heating element(s).

2. Visually inspect the heater assembly for any breaks in

the wire or broken insulators.

3. Using an ohmmeter, test the element for continuity - no

reading indicates the element is open. Replace as

necessary.

ELECTRIC HEATER (OPTIONAL ITEM)

Optional electric heaters may be added, in the quantities shown in the specifications section, to provide electric resis tance heating. Under no condition shall more heaters than the quantity shown be installed.

NOTE: The temperature rise table is for sea level installations. The temperature rise at a particular KW and CFM will be greater at high altitudes, while the external static pressure at a particular CFM will be less.

CFM

HEAT KIT NOMINAL kW

800

1000

1200

1400

1600

1800

2000

5

5

7

6

9

8

3 5 6 8 10 15 19/20 25

12 19 23 31 37

15

12

11

9

8

7

19

15

13

12

10

9

25

21

18

15

14

12

30

25

21

19

16

15

44

37

32

28

25

22

49

42

37

33

30

62

53

46

41

37

230/1/60 SUPPLY VOLTAGE - TEMP. RISE °F

The low voltage circuit in the air handler is factory wired and terminates at the location provided for the electric heater(s). A minimum of field wiring is required to complete the installation.

Other components such as a Heating/Cooling Thermostat and Outdoor Thermostats are available to complete the installation.

CFM

800

1000

1200

1400

1600

1800

2000

HEAT KIT NOMINAL kW

6

5

4

9

7

6

3 5 6 8 10 15 19/20 25

11 18 22 30 35

14

12 15 20 24 35

10 13 17 20 30

9

8

7

18

11

10

9

24

15

13

12

28

18

16

14

42

27

24

21

47

40

35

31

28

59

51

44

39

35

220/1/60 SUPPLY VOLTAGE - TEMP. RISE °F

The system CFM can be determined by measuring the

84

ACCESSORIES

CFM

HEAT KIT NOMINAL kW

800

1000

1200

1400

1600

1800

2000

5

4

6

5

8

7

3

10

10

8

7

7

5

17

13

11

12

10

9

8

6

21

17

14

16

14

12

11

8

28

22

19

19

17

15

13

10

33

27

22

15 19/20 25

40

33

29

25

22

20

45

38

33

30

27

56

48

42

37

33

208/1/60 SUPPLY VOLTAGE - TEMP. RISE °F

HEATER (kW)

Model

3 5 6 8 10 15 19 20 25

AVPEC25B14* 550 650 700 715 875

AVPEC37C14* 850 900 1000 1120 1220 1250

AVPEC59D14*

AVPEC61D14*

990 1110 1200 1240 1520

1030 1150 1250 1320 1650

1520

1690 1715

MINIMUM CFM REQUIRED FOR HEATER KITS

HTR

KW

3.0

KW

ELECTRIC HEATER CAPACITY BTUH

4.7

KW

6.0

KW

7.0

KW

9.5

KW

14.2

KW

19.5

KW

21.0

KW

BTUH 10200 16200 20400 23800 32400 48600 66500 71600

NOTE: The link is designed to open at approximately

333°F. DO NOT WIRE AROUND - determine reason for failure.

FORMULAS:

Heating Output = KW x 3.413 x Corr. Factor

Actual CFM = CFM (from table) x Corr. Factor

BTUH = KW x 3.413

BTUH = CFM x 1.08 x Temperature Rise (T)

CFM = KW x 3.413

1.08 x T

T = BTUH

CFM x 1.08

CHECKING HEATER FUSE LINK

(OPTIONAL ELECTRIC HEATERS)

Each individual heater element is protected with a one time fuse link which is connected in series with the element. The fuse link will open at approximately 333°.

WARNING

Disconnect ALL power before servicing.

1. Remove heater element assembly so as to expose fuse link.

2. Using an ohmmeter, test across the fuse link for continuity - no reading indicates the link is open. Replace as necessary.

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86

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