troubleshooting guide

INTEGRATED CONTROL MOTOR (ICM2)

Cancels: New TI 557A-48-1

3/15/97

CONTENTS

Page

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 1-5

ICM2 Selection Modes . . . . . . . . . . . . . . . . . . . . . . . . . .

1

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . .

5

I. Continuous Fan Operation . . . . . . . . . . . . . . . . . .

5

II. Cooling Mode, 557A and 657A Units . . . . . . . . .

5

III. Cooling Mode, 658A and 589A Units . . . . . . . . .

5

IV. Heating Mode, 658A and 589A Units . . . . . . . . . .

5

V. Electric Heat Mode . . . . . . . . . . . . . . . . . . . . . . . .

5

VI. Heat Pump, Heating with Auxiliary

Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

VII. ICM2 Control Power . . . . . . . . . . . . . . . . . . . . . . .

5

VIII. Low-Voltage Circuit Fusing . . . . . . . . . . . . . . . . .

5

IX. Motor Power Connections . . . . . . . . . . . . . . . . . .

5

OPERATING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

I. Fan Will Not Turn On from Thermostat . . . . . . .

5

II. Fan Will Turn On, but Electric Heat

Stages Will Not . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

III. Easy Select Board Fuse Keeps Blowing . . . . . .

6

IV. Motor Does Not Run . . . . . . . . . . . . . . . . . . . . . .

7

V. Motor Shaft Does Not Rotate Smoothly . . . . . . .

7

VI. Motor Does Not Run Smoothly . . . . . . . . . . . . . .

7

VII. Motor Does Not Stop Running . . . . . . . . . . . . . .

7

TROUBLESHOOTING SUMMARY . . . . . . . . . . . . . . . . . . 8-16

UNIT

557A

589A

657A

658A

WARNING:

GENERAL

This manual contains information to assist in troubleshooting operating problems and errors associated with the

Integrated Control Motor (ICM2). The ICM2 is used in the units listed in Table 1.

Table 1 — Units With ICM2

UNIT SIZE

048,060

048,060

048,060

048,060

Before performing service or repair operations on unit, turn off main unit power. Electrical shock could cause personal injury.

COMPONENT DESCRIPTION

The ICM2 (Fig. 1) is powered with high voltage at all times.

It is pre-programmed and contains airflows for all modes of operation.

The ICM2 reacts to changes in system static pressures to maintain constant airflow. The blower delivers requested airflow up to about 0.7 in. of static pressure.

The ICM2 will not operate with high voltage alone; low voltage must be applied to the control plug for the motor to run.

The ICM2 is first fed high voltage through the 5-pin connector. As this occurs, the AC power is rectified to DC by a diode module. After rectification, the DC signal is electronically communicated and fed in sequential order to stator windings. The frequency of communication pulses determines motor speed.

The rotor is permanently magnetized.

The ICM2 interfaces with the Easy Select Board (Fig. 2 and

3). Setting up desired system airflow is accomplished through selections made on the Easy Select Board. Power for the system is supplied from a 230-vac, 60 Hz line. A class 2 voltage

(24 vac nominal) transformer is used for thermostat connections. The transformer is located either in, or below, the main unit control box, depending on the unit. The secondary (SEC) side of the transformer is connected to the control box. The

24-vac secondary circuit includes a socket, soldered into the circuit at SEC2, to receive a 5-amp automotive-type fuse.

ICM2 SELECTION MODES

Connections to the thermostat are made at leads connected through P1 of the Easy Select Board. Eighteen 0.187-in.

quick-connect terminals comprise the field select taps, which provide programming selection for ICM2. Wiring for the 5 selection modes is listed in Table 2.

Table 2 — ICM2 Selection Mode Wiring

MODE

AUX Heat Range

AC/HP Size

Type

AC/HP CFM Adjust

AC/HP Time Delay

WIRE COLOR

Violet

Blue

Orange

Black

Gray

LEGEND

AC — Air Conditioning

HP — Heat Pump

The 557A, 589A, 657A and 658A units are factory-set to operate properly with system components. See Fig. 4 for factory default settings. To reconfigure a basic system, refer to information printed on the circuit board next to select pins, and to base unit installation instructions. Move the 5 selection wires to match the components used.

DO NOT REMOVE

1 2 3 4 5

POWER CONNECTOR

9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8

CONTROL CONNECTOR

OPTIONAL

SAFETY

GROUND

Table 3 — Allowable Airflows for AUX HEAT

AUX HEAT

Cfm

Gas Heat Input Size

(Btuh)

80,000

100,000

120,000

140,000

Electric Heater Package

(5-10 kW)

EASY SELECT BOARD TERMINAL

1 2 3 4

1300 1400 1600 1700

X

X

X

X

X

X

X

X

X

X

X

X

X

X

B. AC/HP SIZE

The preset factory default selection for AC/HP Size is 400 cfm per ton. The selection pins are configured for 350 cfm per ton at terminals 1 and 3, and 400 cfm per ton at terminals 2 and 4.

C. TYPE

The type is a preset factory default selection. The factory setting is AC for 589A and 557A units. For 658A units, the factory setting is AC. For 657A units the factory setting is

HP. The HPC provides the same airflow as the AC selection.

OPTIONAL

SAFETY

GROUND

CONTROL

CONNECTOR

POWER

CONNECTOR

DRAIN

HOLE

Fig. 1 — Integrated Control Motor 2

A. AUX HEAT RANGE

Airflow for 658A and 589A units is a preset factory selection. The airflow selection must not be set lower than the default. Refer to Table 3 for the allowable airflows.

Airflow for 657A, 557A units requires the installer to select the auxiliary heat airflow that best suits the installation. Refer to installation instructions for electric heaters. See

Table 3 for available airflow.

Each select pin is configured for a certain airflow. The airflow will be supplied in the emergency heat mode, which is the heating mode on units with electric heat as the primary heating source.

For heat pump units, the ICM2 will run whichever is higher; heat pump airflow or electric heat airflow. The preset factory default selection is the highest airflow. This helps ensure safe heater operation.

LEGEND

IFO — Indoor (Evaporator) Fan On

JW — Jumper Wire

Fig. 2 — Easy Select Board

D. AC/HP CFM ADJUST

The preset factory default selection is MED. Selections HI and LO will adjust the airflow supplied for all operation modes.

Refer to Table 4. The selection options are provided for the installer to meet individual installation needs (static compensation, noise, etc.).

Table 4 — Airflow Percentage Difference From

Nominal (MED Setting)

MODE

LO ADJUST

HI ADJUST

FAN ONLY COOLING HEATING HEAT PUMP

−15%

15%

−12.5%

12.5%

−15%

15%

−10%

10%

—2—

L SEC 2 SEC 1 O Y/Y2 W2 G Y1

1

2

3

4

5

6

7

8

9

10

P1

L

R

C

O

Y/Y2

Y1

G

E/W1

W2

W3

JW1

JW2

D2

D1

D3

D4

D5

AC/HP

TIME DELAY

GRY

1

2

3

4

AC/HP

CFM ADJUST

BLK

LO

MED

HI

TYPE

ORN

AC

HPC

HP

AC/HP

SIZE

BLU

1

2

3

4

AUX HEAT

RANGE

VIO

1

2

3

4

P2

1

2

3

4

5

6

7

E/W1/W2

G

R

Y/Y2

Y1

JW3

IFO

R2

2W

R3

2W

R1

2W

Fig. 3 — Easy Select Board Circuitry

LEGEND

IFO — Indoor Fan On

JW — Jumper Wire

VIO

BLU

ORN

BLK

GRY

1300

1400

30 sec ON/

60 sec OFF

1

1

1

AC

LO

589A, 658A MODELS

AUX. HEAT RANGE

2

1400 1600

AC/HP SIZE

2

1600 1750

TYPE

HPC

AC/HP CFM ADJUST

MED

AC/HP TIME DELAY

2

0 sec ON/

0 sec OFF

0 sec ON/

30 sec OFF

3

3

3

HP

HI

4

1750

2000

4

0 sec ON/

45 sec OFF

4

VIO

BLU

ORN

BLK

GRY

1300

1400

30 sec ON/

60 sec OFF

1

1

1

AC

LO

557A MODELS

AUX. HEAT RANGE

2

1400 1600

AC/HP SIZE

2

1600 1750

TYPE

HPC

AC/HP CFM ADJUST

MED

AC/HP TIME DELAY

2

0 sec ON/

0 sec OFF

0 sec ON/

30 sec OFF

3

3

3

HP

HI

4

1750

2000

4

0 sec ON/

45 sec OFF

4

VIO

BLU

ORN

BLK

GRY

1300

1400

30 sec ON/

60 sec OFF

1

1

1

AC

LO

657A MODELS

AUX. HEAT RANGE

2

1400 1600

AC/HP SIZE

2

1600 1750

TYPE

HPC

AC/HP CFM ADJUST

MED

AC/HP TIME DELAY

2

0 sec ON/

0 sec OFF

0 sec ON/

30 sec OFF

3

3

3

HP

HI

4

1750

2000

4

0 sec ON/

45 sec OFF

4

FACTORY DEFAULT SETTING

NOTE: The AC/HP SIZE setting is Terminal 2 for size 048 and Terminal 4 for size 060.

Fig. 4 — Factory Default Settings

—4—

E. AC/HP TIME DELAY

Four motor operation delay profiles are provided to customize and enhance system operation. These selections include an option for no delays, which may be used during service procedures. When other components, such as Integrated Gas

Control (IGC), are used to perform the delay function the preset factory default setting is terminal 2 for 658A and 589A units.

Also available is a 30-second ON/60-second OFF delay profile at terminal 1. This profile may be used to allow system coils time to heat or cool, and may minimize some cold blow in heat pump operation.

A 30-second OFF delay at terminal 3 and a 45-second OFF delay at terminal 4 are optional.

SEQUENCE OF OPERATION

I. CONTINUOUS FAN OPERATION

The thermostat closes circuit R to G. The G signal is sent directly to ICM2.

II. COOLING MODE, 557A AND 657A UNITS

The thermostat closes circuit R to G, R to Y/Y2, R to O, and

R to Y1 (heat pump only) for single speed. The Y/Y2 signal is sent directly to ICM2. On heat pump units, Y1 signal is also sent directly to ICM2.

III. COOLING MODE, 658A AND 589A UNITS

Thermostat closes, closing circuits from R to G, R to Y1, R to Y2 and O (658A units only). All but the G signal are sent to ICM2 directly. The G signal is not sent directly because the JW3 jumper is cut to prevent feedback in heating mode.

The G signal is sent to the Integrated Gas Control (IGC) board, where the indoor fan contacts closes and energize the IFO

(Indoor Fan On) terminal. It is then sent to the ICM2 directly.

IV. HEATING MODE, 658A AND 589A UNITS

A. 658A Units

For heat pumps, the thermostat closes, closing circuits R to

G, R to Y1 and R to Y/Y2. Y1 and Y/Y2 are sent to ICM2 directly. The IGC board sends the G signal to ICM2 through the IFO terminal.

B. 589A Units

Thermostat closes, closing circuit from R to W1. Signal is sent to both the IGC board and the ICM2. When the indoor fan contacts close on the IGC board, a 24-volt signal is sent to

ICM2 through the IFO terminal.

V. ELECTRIC HEAT MODE

Thermostat closes circuit R to W2, W3, or E. The terminal block positions W2, W3 and E are tied together by jumpers

JW1 and JW2. These jumpers are provided for future flexibility staging of electric heater banks. When staging is a requirement, the installer must cut jumpers and wires in thermostats, following common procedure and practice. The 3 electric heater inputs are also interlocked through diodes D1, D2, and D3 to motor input W.

VI. HEAT PUMP, HEATING WITH AUXILIARY HEAT

Thermostat closes circuits R to Y/Y2 and R to Y1, with R to

W2, W3 or E (and R to O in case of defrost). In the event that electric heating is called for by the thermostat while heat pump is operating in heat or defrost mode, the electric heating signal will appear at motor connector pin 1. If necessary, the motor will modify airflow output to provide an airflow that is safe for operation of electric heater.

VII. ICM2 CONTROL POWER

The ICM2 control power is supplied for R circuit through runs to motor control connector pin 5, then through motor control harness to motor. The C side of low voltage control power circuit is connected by printed circuit runs to motor connector pins 3 and 4, then through motor control harness to motor.

VIII. LOW-VOLTAGE CIRCUIT FUSING

Low-voltage circuit is fused by a board-mounted 5-amp automotive-type fuse placed in series with transformer SEC2 and R circuit. The C circuit of transformer is referenced to chassis ground through a printed-circuit run at SEC1, connected to a metal standoff marked ‘Ground Screw Required.’

A ground screw must be in place or erratic motor operation may result.

IX. MOTOR POWER CONNECTIONS

The high-voltage 230-vac power input to the Easy Select Board is provided through line side of contactor to plug 4 of motor. High voltage terminals are 4 and 5. Terminal 3 is ground connection.

OPERATING PROBLEMS

WARNING: Turn off all power to unit before performing any service procedure to avoid the possibility of electric shock and personal injury.

I. FAN WILL NOT TURN ON FROM THERMOSTAT

This may indicate a problem with high voltage connections.

Perform the following checks:

1. Check power leads L1 and L2. If L1 and L2 are not receiving power the system cannot function.

2. Check 5-pin connector at motor for 230 volts, or check for continuity.

3. Check the low-voltage transformer leads. Be sure they are wired correctly.

4. Check output voltage of transformer secondary side

SEC1 and SEC2. Ensure transformer output is approximately 24 vac. If transformer output is 0 vac and the transformer is receiving correct input voltage (208 v or

240 v), then the transformer must be replaced.

If the transformer output is 24 vac, check the Easy Select

Board voltage as follows:

Check low-voltage fuse (Fig. 2). If fuse is blown, replace it.

The transformer cannot supply power to the Easy Select Board with a loose or blown fuse.

If the fuse blows when the unit has power supplied to it, the system likely has one of the following problems:

• Electrical short or miswiring. Check control circuit.

• Transformer load exceeding maximum of 40 va. If the load is excessive, the low-voltage 5-amp fuse will blow to protect the transformer. Check relays for excessive current draw.

Refer to Tables 5 and 6 for Easy Select Board male/female quick connect terminals and connections.

—5—

II. FAN WILL TURN ON, BUT ELECTRIC HEAT STATES WILL

NOT

Perform the following checks:

1. Check relay wirings, fuses to electric heaters (if applicable), and voltage to relay. All relays numbered one receive a 24-vac signal. If the correct voltage is being received, check if relay is closing. If the relay is not closing, relay must be replaced.

2. Check for blown diodes. If diodes are blown it is likely that a plug is miswired. Easy Select Board must be replaced if diode is bad.

3. Check if traces on back of Easy Select Board are overheated. If traces are overheated, there likely has been a high-voltage short, or high-voltage has been applied to a low-voltage circuit. This can be prevented by ensuring the Easy Select Board has been correctly wired prior to applying power.

III. EAST SELECT BOARD FUSE KEEPS BLOWING

When the low-voltage fuse blows, it is likely that the transformer would have blown had the low-voltage fuse not been in circuit to protect it. The fuse usually blows when there is high current drawn on the transformer, high-voltage applied to the low-voltage circuit, or a direct secondary short.

When there is high current drawn on the transformer, it is most likely because the transformer has been shorted or the system is drawing more va than the transformer rating allows. When fuse blows because of high voltage, the system has mixed high and low voltage signals.Perform the following checks:

1. Check transformer, thermostat and control box wiring.

2. Check to be sure low-voltage and high-voltage wiring are connected to proper terminals.

3. Check va draw on transformer. If va draw is more than va rating of the transformer, fuse will blow. Transformer must be replaced with one that has a higher va rating.

FEMALE CONNECTION SIZE

0.25 x 0.032

0.187 x 0.032

Table 5 — Male/Female Quick Connect Terminals

MALE CONNECTION

Y/Y2

Y1

SEC1

SEC2

IFO

O

AUX1

AUX2

G

RED

L

UNITS 557A, 589A, 657A, 658A

High and single speed

Low speed compressor

Secondary connection from transformer (24 vac). This connection is common to chassis ground through eyelet marked GROUND SCREW

REQUIRED.

Secondary connection from transformer (24 vac)

Indoor Fan ON terminal

4-Way valve

Low voltage ground for auxiliary option (24 vac)

Low voltage output for auxiliary option (24 vac)

Indoor Fan

Common to R screw terminal and SEC2

This connection is a field termination for use in connection leads (L) of thermostat. There is no connection of this terminal with control circuitry.

TYPE

CONNECTION

Thermostat

Connection

Integrated Control

Motor 2

TYPE

CONNECTOR

10-Pin

Header

7-Pin

Header

PIN NO.

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

Pin 6

Pin 7

Pin 8

Pin 9

Pin 10

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

Pin 6

Pin 7

Table 6 — Connections and Connector

DESCRIPTION

L — This connection is a field termination for use in connecting leads (L) of thermostat. There is no connection of this terminal with control circuitry.

R — Connection for R signal to thermostat (24 vac)

C — Connection for C terminal to thermostat (24 vac common)

O — Connection for O signal from thermostat

Y/Y2 — Connection for Y signal from thermostat

Y1 — Connection for low-speed compressor operation

G — Connection for G signal from thermostat

E/W1 — Connection for E signal from thermostat/W1 on Gas Heat

W2 — Connection for W2 signal from thermostat

W3 — Connection for W3 signal from outdoor thermostat

Diode OR output of E/W1 or W3 or W2 thermostat signals

Thermostat G signal

Common to C, SEC1, and chassis ground

Common to C, SEC1, and chassis ground

Common to R and SEC2 (via 5-amp fuse)

Thermostat Y/Y2 signal

Thermostat Y1 signal

—6—

IV. MOTOR DOES NOT RUN

Perform the following checks:

1. Check all plugs and receptacles on ICM2 circuit board and motor for bad connections. Be sure all plugs are fully seated.

2. Verify that there are approximately 230 v at terminals of contactor. If not, determine if high-voltage is entering the unit.

3. Verify that there is a low-voltage control signal to the motor. The motor receives control signals through the

7-pin motor plug P2. The voltage output of each pin in the plug will be different, depending on mode or operation. Table 7 lists voltage present in each pin of 7-pin plug for each operating mode. Testing should be done between the points listed in Table 7, and the common

C screw terminal. If all the values of any one of the operating modes check out, and the motor still fails to run, it is likely the motor is defective and will need replacement.

V. MOTOR SHAFT DOES NOT ROTATE SMOOTHLY

The motor shaft normally does not run smoothly. This is due to steps in rotation, called motor cogging. The cogging is caused by permanent magnets passing each pole in the motor.

However, the shaft should not require excessive force to turn.

If shaft is very difficult to turn, motor control or bearings have failed and the motor must be replaced.

VI. MOTOR DOES NOT RUN SMOOTHLY

Perform the following check:

Check blower wheel for damage and determine if blower wheel is out of balance. If it is not defective, the motor will likely need replacement.

VII. MOTOR DOES NOT STOP RUNNING

Perform the following checks:

1. Check for good ground between motor ground lead, transformer common lead, and control board. If this does not stop the motor, continue to Step 2.

2. Remove all thermostat wiring. If this makes the motor stop, it means the circuit board is faulty and must be replaced. If it does not stop, continue to Step 3.

3. Remove the 7-pin plug. If motor still runs, replace motor.

Table 7 — Motor Control Test Values

OPERATING MODE

Electric

1-Speed AC

2-Speed AC, Low Speed

2-Speed AC, High Speed

1-Speed HP

1-Speed HP

2-Speed HP, Low Speed

2-Speed HP, Low Speed

2-Speed HP, High Speed

2-Speed HP, High Speed

Continous Fan

SCREW TERMINALS

HAVING 24 VAC

Heating R W2

Cooling R Y/Y2

Cooling R Y1

Cooling R Y/Y2

Cooling R Y/Y2

Heating R Y/Y2

Cooling R

Heating R

Y1

Y1

Cooling R Y/Y2

Heating R Y/Y2

R G

W3* E*

G

G

G

G

G

G

G

Y1

Y1

O

O

G O

G

W

Pin 1

24 vac

0

0

0

0

0

0

0

0

0

0

LEGEND

AC — Air Conditioning

HP — Heat Pump

*Pin 1 has 24 vac with or without jumpers whenever any individual heater input or any combination of heater inputs are energized.

G

Pin 2

0

24 vac

24 vac

24 vac

24 vac

24 vac

24 vac

24 vac

24 vac

24 vac

24 vac

VOLTAGES — 7-PIN PLUG P2

C

Pin 3

0

0

0

0

0

0

0

0

0

0

0

C

Pin 4

0

0

0

0

0

0

0

0

0

0

0

R

Pin 5

Y/Y2

Pin 6

24 vac 0

24 vac 24 vac

24 vac

24 vac

24 vac

24 vac

0

24 vac

24 vac 24 vac

24 vac 24 vac

0

0

Y

Pin 7

0

0

24 vac

0

0

0

24 vac

24 vac

24 vac 24 vac 24 vac

24 vac 24 vac 24 vac

24 vac 0 0

—7—

TROUBLESHOOTING SUMMARY

Use Table 8 and Fig. 5-12 in troubleshooting.

Table 8 — Troubleshooting Summary

SYMPTOM

Motor runs in some operation modes, but not in others.

Circuit board will not operate.

Motor is hard to turn manually.

Motor does not stop running.

Motor does not operate.

CAUSE

Poor connection between components

Burnt components

Blown fuse

Blown transformer

Motor control or bearing failure

Faulty circuit board, thermostat

Faulty motor

Burnt components

REMEDY

Check wiring harness connectors (see Note 1).

Check for a good ground connection between motor ground lead and circuit board screw.

Check thermostat connections (Note 2).

Check for burn traces or burnt components. If present, replace circuit board.

Check 5-amp fuse.

Check for 24v between SEC1 and SEC2.

If no voltage present, check transformer.

Replace motor.

Test circuit board by removing 7-pin plug from circuit board.

If motor stops, it is a problem with the circuit board or thermostat.

Test thermostat by disconnecting it from circuit board.

If motor fails to stop running once 7-pin plug is removed from circuit board, replace motor.

Replace motor and verify that drip loop is present on connection wires.

LEGEND

SEC — Secondary

NOTES:

1. To check wiring harness, shut off power to unit. Remove 5-pin plug from motor. Never

remove 5-pin plug from motor with power on. Check for 24v between pin-1 and pin-12 on the 16-pin plug. If no voltage is present, replace wiring harness. If voltage is present, jumper terminals R-Y/Y2 on circuit board and check for 24v between pin-12 and pin-14 and pin-16 (see below).

16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

16-PIN PLUG

2. To check thermostat, remove thermostat wires from circuit board. Jumper screw terminals one at a time as follows: R-G, R-Y/Y2, R-Y1 and R-W2 to check connections.

—8—

Fig. 5 — Wiring Diagram, Units 658A048,060; 208/230-1-60

—9—

LEGEND

AWG — American Wire Gage

BR

C

CAP

CB

— Blower Relay

— Contactor, Compressor

— Capacitor

— Circuit Breaker

COMP — Compressor Motor

CR

CTD

DB

DFT

DR

— Compressor Relay

— Compressor Time Delay

— Defrost Board

— Defrost Thermostat

— Defrost Relay

EQUIP — Equipment

FL

FS

FU

— Fuse Link

— Flame Sensor

— Fuse

GND

GVR

HLR

HR

HS

HV

TRAN

I

ICM

— Ground

— Gas Valve Relay

— Heater Lockout Relay

— Heater Relay (Strip

Heat)

— Hall Effect Sensor

— High-Voltage

Transformer

— Ignitor

— Integrated Control

IDM

IFM

IFO

IGC

LPS

LR

LS

MGV

OAT

OFM

QT

RS

RVS

Motor

— Induced-Draft Motor

— Indoor-Fan Motor

— Indoor-Fan On

— Integrated Gas Control

— Low-Pressure Switch

— Lockout Relay

— Limit Switch

— Main Gas Valve

— Outdoor-Air Thermostat

— Outdoor-Fan Motor

— Quadruple Terminal

— Rollout Switch

— Reversing Valve

Solenoid

SEC — Secondary

TRAN — Transformer

Field Splice

Marked Wire

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Splice

Splice (Marked)

Factory Wiring

Field Control Wiring

Field Power Wiring

Accessory or Optional

Wiring

To Indicate Common

Potential Only, Not to Represent Wiring

NOTES:

1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent.

2. Set heat anticipator at .6.

3. Use copper conductors only.

4. ICM board connections.

UNIT

658A

1

TERMINAL NO.

2 3

CFM

4

(VIO)

Aux,

Heat

Range

(BLU)

AC/HP

Size

1300

1400

1400 1600

1600 1750

1750

2000

(GRY)

AC/HP

Time

Delay

30 sec.

ON

1 min.

OFF

0 sec.

ON

0 sec.

OFF

0 sec.

ON

30 sec.

OFF

0 sec.

ON

45 sec.

OFF

LED INDICATIONS

ERROR MODE LED INDICATION

Normal Operation

Hardware Failure

Fan ON/OFF Delay

Modified

Limit Switch Fault

Flame Sense Fault

5 Consecutive Limit

Switch Faults

Ignition Lockout Fault

Inducer Switch Fault

Rollout Switch Fault

Internal Control Fault

ON

OFF

1 FLASH

2 FLASH

3 FLASH

4 FLASH

5 FLASH

6 FLASH

7 FLASH

8 FLASH

Fig. 6 — Wiring Diagram, Units 658A048,060; 208/230-3-60

—10—

LEGEND

AWG

BR

C

CAP

CB

COMP

CR

CTD

DB

DFT

DR

EQUIP

FL

FS

FU

GND

— American Wire Gage

— Blower Relay

— Contactor, Compressor

— Capacitor

— Circuit Breaker

— Compressor Motor

— Compressor Relay

— Compressor Time Delay

— Defrost Board

— Defrost Thermostat

— Defrost Relay

— Equipment

— Fuse Link

— Flame Sensor

— Fuse

— Ground

IGC

IP

LPS

LR

LS

MGV

NEC

OAT

GVR

HLR

HR

HS

—

—

—

—

Gas Valve Relay

Heater Lockout Relay

Heater Relay (Strip Heat)

Hall Effect Sensor

I

HV TRAN — High-Voltage Transformer

— Ignitor

ICM

IDM

IFM

IFO

—

—

—

—

Integrated Control Motor

Induced-Draft Motor

Indoor-Fan Motor

Indoor-Fan On

—

—

—

—

—

—

—

—

Integrated Gas Control

Internal Protector

Low-Pressure Switch

Lockout Relay

Limit Switch

Main Gas Valve

National Electrical Code

Outdoor-Air Thermostat

OFM

QT

RS

RVS

SEC

TH

TRAN

— Outdoor-Fan Motor

— Quadruple Terminal

— Rollout Switch

— Reversing Valve Solenoid

— Secondary

— Thermostat-Heating

— Transformer

Field Splice

Marked Wire

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Splice

Splice (Marked)

Factory Wiring

Field Control Wiring

Field Power Wiring

Accessory or Optional

Wiring

To Indicate Common

Potential Only, Not to Represent Wiring

NOTES:

1. If any of the original wire furnished must be replaced, it must be replaced with type

90 C wire or its equivalent.

2. Set heat anticipator at .6.

3. Use copper conductors only.

4. ICM board connections.

UNIT

658A

1

TERMINAL NO.

2 3

CFM

4

(VIO)

Aux,

Heat

Range

(BLU)

AC/HP

Size

1300

1400

1400

1600

1600

1750

1750

2000

(GRY)

AC/HP

Time

Delay

30 sec.

ON

1 min.

OFF

0 sec.

ON

0 sec.

OFF

0 sec.

ON

30 sec.

OFF

0 sec.

ON

45 sec.

OFF

LED INDICATIONS

ERROR MODE LED INDICATION

Normal Operation

Hardware Failure

Fan ON/OFF Delay

Modified

Limit Switch Fault

Flame Sense Fault

5 Consecutive Limit

Switch Faults

Ignition Lockout Fault

Inducer Switch Fault

Rollout Switch Fault

Internal Control Fault

ON

OFF

1 FLASH

2 FLASH

3 FLASH

4 FLASH

5 FLASH

6 FLASH

7 FLASH

8 FLASH

NOTES:

1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent.

2. Use copper conductors only.

3. ICM board connections.

UNIT

589A

(VIO)

Aux,

Heat

Range

(BLU)

AC/HP

Size

1

TERMINAL NO.

2 3

CFM

1300 1400

1400 1600

1600

1750

4

1750

2000

(GRY)

AC/HP

Time

Delay

30 sec.

ON

1 min.

OFF

0 sec.

ON

0 sec.

OFF

0 sec.

ON

30 sec.

OFF

0 sec.

ON

45 sec.

OFF

LEGEND

ICM

IDM

IFM

IGC

LS

MGV

NEC

OFM

PWR

QT

AWG

BR

C

CAP

— American Wire Gage

— Blower Relay

— Contactor

— Capacitor

COMP — Compressor Motor

CR — Combustion Relay

EQUIP — Equipment

FL — Fuse Link

FS

FU

GND

GVR

HS

HV

I

TRAN

—

—

—

—

—

—

—

Flame Sensor

Fuse

Ground

Gas Valve Relay

Hall Effect Sensor

High-Voltage

Transformer

Ignitor

— Integrated Control Motor

— Induced-Draft Motor

— Indoor-Fan Motor

— Integrated Gas Control

— Limit Switch

— Main Gas Valve

— National Electrical Code

— Outdoor-Fan Motor

— Power

— Quadruple Terminal

RS

SEC

—

—

Rollout Switch

Secondary

TRAN — Transformer

Field Splice

Terminal (Marked)

Terminal (Unmarked)

Splice

Splice (Marked)

Factory Wiring

Field Control Wiring

Field Power Wiring

Accessory or

Optional Wiring

To Indicate Common

Potential Only, Not to

Represent Wiring

Fig. 7 — Wiring Diagram, Units 589A048,060; 208/230-1-60

—11—

NOTES:

1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent.

2. Use copper conductors only.

3. ICM board connections.

UNIT

589A

(VIO)

Aux,

Heat

Range

(BLU)

AC/HP

Size

1

TERMINAL NO.

2 3

CFM

1300 1400

1400 1600

1600

1750

4

1750

2000

(GRY)

AC/HP

Time

Delay

30 sec.

ON

1 min.

OFF

0 sec.

ON

0 min.

OFF

0 sec.

ON

30 sec.

OFF

0 sec.

ON

45 sec.

OFF

LEGEND

I

ICM

IDM

IFM

IGC

LS

MGV

NEC

OFM

PWR

QT

AWG

BR

C

CAP

—

—

—

—

American Wire Gage

Blower Relay

Contactor

Capacitor

COMP — Compressor Motor

CR — Combustion Relay

EQUIP — Equipment

FL

FS

FU

GND

GVR

HS

HV

TRAN

— Fuse Link

— Flame Sensor

— Fuse

— Ground

— Gas Valve Relay

— Hall Effect Sensor

— High-Voltage Transformer

— Ignitor

— Integrated Control Motor

— Induced-Draft Motor

— Indoor-Fan Motor

— Integrated Gas Control

— Limit Switch

— Main Gas Valve

— National Electrical Code

—

—

—

Outdoor-Fan Motor

Power

Quadruple Terminal

RS

RT

— Rollout Switch

— Red Terminal

SEC — Secondary

TRAN — Transformer

Field Splice

Terminal (Marked)

Terminal (Unmarked)

Splice

Splice (Marked)

Factory Wiring

Field Control Wiring

Field Power Wiring

Accessory or

Optional Wiring

To Indicate Common

Potential Only, Not to

Represent Wiring

Fig. 8 — Wiring Diagram, Units 589A048,060; 208/230-3-60

—12—

UNIT

657A

(VIO) Aux, Heat Range

(BLU) AC/HP Size

1

TERMINAL NO.

2 3

CFM

1300 1400 1600

1400 1600 1750

4

1750

2000

(GRY) AC/HP Time Delay

30 sec.

ON

1 min.

OFF

0 sec.

ON

0 sec.

OFF

0 sec.

ON

30 sec.

OFF

0 sec.

ON

45 sec.

OFF

NOTES:

1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent.

2. Set heat anticipator at .6.

3. Use copper conductors only.

4. For ICM board connections, see table.

AWG

C

— American Wire Gage

— Contactor, Compressor

CAP — Capacitor

COMP — Compressor Motor

CTD

DB

DFT

DR

—

—

—

—

Defrost Board

Defrost Thermostat

Defrost Relay

LEGEND

SEC — Secondary

TRAN — Transformer

Compressor Time Delay

EQUIP — Equipment

FL — Fuse Link

FU

GND

—

—

Fuse

Ground

HR

ICM

IFM

IFO

—

—

—

—

Heater Relay (Strip Heat)

Integrated Control Motor

Indoor-Fan Motor

Indoor-Fan On

IP

LPS

— Internal Protector

— Low-Pressure Switch

MOCP — Maximum Overcurrent

Protection

NEC

OF

OFM

QT

RVS

—

—

—

—

—

National Electrical Code

Outdoor Fan

Outdoor-Fan Motor

Quadruple Terminal

Reversing Valve Solenoid

Field Splice

Marked Wire

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Splice

Splice (Marked)

Factory Wiring

Field Control Wiring

Field Power Wiring

Accessory or

Optional Wiring

To Indicate Common

Potential Only, Not to

Represent Wiring

Fig. 9 — Wiring Diagram, Units 657A048,060; 208/230-1-60

—13—

UNIT

657A

(VIO) Aux, Heat Range

(BLU) AC/HP Size

1

TERMINAL NO.

2 3

1300 1400

CFM

1600

1400 1600 1750

4

1750

2000

(GRY) AC/HP Time Delay

30 sec.

ON

1 min.

OFF

0 sec.

ON

0 sec.

OFF

0 sec.

ON

30 sec.

OFF

0 sec.

ON

45 sec.

OFF

LEGEND

NOTES:

1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent.

2. Set heat anticipator at .6.

3. Use copper conductors only.

4. For ICM board connections, see table.

AWG

C

— American Wire Gage

— Contactor, Compressor

CAP — Capacitor

COMP — Compressor Motor

CTD — Compressor Time Delay

DB

DFT

— Defrost Board

— Defrost Thermostat

DR — Defrost Relay

EQUIP — Equipment

FL

FU

GND

HR

—

—

—

—

Fuse Link

Fuse

Ground

Heater Relay (Strip Heat)

ICM

IFM

IFO

IP

— Integrated Control Motor

— Indoor-Fan Motor

— Indoor-Fan On

— Internal Protector

LPS

LS

— Low-Pressure Switch

— Limit Switch

MOCP — Maximum Overcurrent

Protection

NEC

OFM

QT

RVS

— National Electrical Code

— Outdoor-Fan Motor

— Quadruple Terminal

— Reversing Valve Solenoid

Fig. 10 — Wiring Diagram, Units 657A048,060; 208/230-3-60

SEC — Secondary

TRAN — Transformer

Field Splice

Marked Wire

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Splice

Splice (Marked)

Factory Wiring

Field Control Wiring

Field Power Wiring

Accessory or

Optional Wiring

To Indicate Common

Potential Only, Not to

Represent Wiring

—14—

UNIT

557A

(VIO) Aux, Heat Range

(BLU) AC/HP Size

1

1300

1400

TERMINAL NO.

2 3

1400

CFM

1600

1600 1750

4

1750

2000

(GRY) AC/HP Time Delay

30 sec.

ON

1 min.

OFF

0 sec.

ON

0 sec.

OFF

0 sec.

ON

30 sec.

OFF

0 sec.

ON

45 sec.

OFF

LEGEND

AWG

C

—

—

American Wire Gage

Contactor, Compressor

CAP — Capacitor

COMP — Compressor Motor

EQUIP — Equipment

FL — Fuse Link

FU

GND

—

—

Fuse

Ground

HR

ICM

IFO

NEC

— Heater Relay (Strip Heat)

— Integrated Control Motor

— Indoor-Fan On

— National Electrical Code

OFM

QT

— Outdoor-Fan Motor

— Quadruple Terminal

SEC — Secondary

TRAN — Transformer NOTES:

1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent.

2. Number(s) indicates the line location of contacts. A bracket over (2) numbers signifies single pole double throw contacts. An underlined number signifies a normally closed contact. Plain numbers (no lines), signify a normally open contact.

3. Set heat anticipator at .6 amp for first stage and .3 amp for second stage.

4. Use copper conductors only.

5. For ICM board connections, see table.

Field Splice

Marked Wire

Fig. 11 — Wiring Diagram, Units 557A048,060; 208/230-1-60

—15—

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Splice

Splice (Marked)

Factory Wiring

Field Control Wiring

Field Power Wiring

Accessory or

Optional Wiring

To Indicate Common

Potential Only, Not to

Represent Wiring

UNIT

557A

(VIO) Aux, Heat Range

(BLU) AC/HP Size

1

1300

1400

TERMINAL NO.

2 3

1400

CFM

1600

1600 1750

4

1750

2000

(GRY) AC/HP Time Delay

30 sec.

ON

1 min.

OFF

0 sec.

ON

0 sec.

OFF

0 sec.

ON

30 sec.

OFF

0 sec.

ON

45 sec.

OFF

LEGEND

AWG

C

— American Wire Gage

— Contactor, Compressor

CAP — Capacitor

COMP — Compressor Motor

EQUIP — Equipment

FL

FU

—

—

Fuse Link

Fuse

GND

HR

ICM

IFM

IFO

NEC

OFM

QT

—

—

—

—

—

—

—

—

Ground

Heater Relay (Strip Heat)

Integrated Control Motor

Indoor-Fan Motor

Indoor-Fan On

National Electrical Code

Outdoor-Fan Motor

Quadruple Terminal

SEC — Secondary

TRAN — Transformer

NOTES:

1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent.

2. Number(s) indicates the line location of contacts. A bracket over (2) numbers signifies single pole

Field Splice double throw contacts. An underlined number signifies a normally closed contact. Plain numbers

(no lines), signify a normally open contact.

3. Set heat anticipator at .6 amp for first stage and .3 amp for second stage.

4. Use copper conductors only.

5. For ICM board connections, see table.

Fig. 12 — Wiring Diagram, Units 557A048,060; 208/230-3-60

Marked Wire

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Splice

Splice (Marked)

Factory Wiring

Field Control Wiring

Field Power Wiring

Accessory or Optional

Wiring

To Indicate Common

Potential Only, Not to Represent Wiring

Copyright 1997 Carrier Corporation CATALOG NO. BDP-3355-700