Amana AVPTC31C14, AVPTC25B14, AVPTC49C14, AVPTC37B14, AVPTC37C14 Installation & Operating Instructions Manual

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AVPTC**14**

AIR HANDLERS INSTALLATION & OPERATING INSTRUCTIONS

Contents

1 Important Safety Instructions ............................................... 2

2 Shipping Inspection .............................................................. 3

3 Codes & Regulations ............................................................. 3

4 Replacement Parts ............................................................... 3

5 Pre-Installation Considerations ............................................. 3

6 Installation Location ............................................................. 3

7 Refrigerant Lines .................................................................. 5

8 Condensate Drain Lines......................................................... 8

9 Ductwork ............................................................................. 9

10 Return Air Filters .................................................................. 9

11 Electric Heat ......................................................................... 9

12 Electrical and Control Wiring ............................................... 10

13 Achieving 1.4% and

2.0% Airflow Low Leakage Rate ........................................ 11

14 24 Volt Wiring .................................................................... 11

15 Auxiliary Alarm Switch ........................................................ 12

16 AVPTC Motor Orientation................................................... 12

17 Circulator Blower ............................................................... 13

18 Heat Kit Selection ............................................................... 16

19 Troubleshooting ................................................................. 16

20 ComfortNet™ System ........................................................ 17

21 Start-Up Procedure ............................................................ 19

23 Communications Troubleshooting Chart ............................. 20

24 Air Handler Advanced Features Menu ................................ 21

25 Troubleshooting ................................................................. 22

26 Diagnostic Codes ................................................................ 26

27 Wiring Diagrams ................................................................. 27

5151 San Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com - or - www.amana-hac.com P/N: IOA-4021D Date: December 2017

NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR

REPAIR (HEREINAFTER

SHOULD SERVICE THE EQUIP MENT

FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR

SERVICE PROCED URES

FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY RESULT

JURISDICTIONS THAT REQUIRE ONE OR MORE LICENSES TO SERVICE THE EQUIPMENT

SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE

EQUIPMENT

THE EQUIP MENT SPECIFIED IN THIS MANUAL, OR ATT EM PT ING TO INSTALL, ADJUST

SERVICE OR REPAIR THE EQUIP MENT SPECIFIED IN THIS MANUAL WITHOUT PROPER

TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH

, “

SERVICE

”)

THE EQUIPM ENT SPECIFIED IN THIS MANUAL

. THE

MANUFACTURER WILL NOT BE RESPONSIBLE

. IF

YOU SERVICE THIS UNIT, YOU ASSUME RESPONSIBILITY

. IN

ADDITION, IN

. I

MPROPER INSTALLATION, ADJUSTME NT, SERVICING OR REPAIR OF

RECOGNIZE THIS SYMBOL AS A

SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

Prior to installation, thoroughly familiarize yourself with this Installation Manual. Observe all safety warnings. During installation or repair, caution is to be observed. It is your responsibility to install the product safely and to educate the customer on its safe use.

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1 Important Safety Instructions

The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards. It is the owner’s and installer’s responsibility to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of personal injury, property damage, and/or product damage.

To 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 unit.

This product is factory-shipped for use with 208/240/1/60 electrical power supply. reconfigure this air handler to operate with any other power supply.

To avoid property damage, personal injury or death due to electrical shock, this unit MUST have an uninterrupted, unbroken

electrical ground. The electrical ground circuit may consist of an appropriately sized electrical wire connecting the ground lug in the unit control box to the building electrical service panel. Other methods of grounding are permitted if performed in accordance with the National Electric Code (NEC)/American National Standards Institute (ANSI)/National Fire Protection Association (NFPA) 70 and local/state codes. In Canada, electrical grounding is to be in accordance with the Canadian Electric Code (CSA) C22.1.

When installing or servicing this equipment, safety clothing, including hand and eye protection, is strongly recommended. If installing in an area that has special safety requirements (hard hats, etc.), bserve these requirements.

DO NOT

CO can cause serious illness including permanent brain dama ge or d eath.

Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas c omo estacionamientos ó c uartos de servi cio.

Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo.

El monóxido de carbono puede causar enfermedades severas como daño cerebral perma nente ó muerte.

RISQUE D'EMPOISONNEMENT AU

MONOXYDE DE CARBONE

Do not connect to or use any device that is not designcertified by the manufacturer for use with this unit. Serious property damage, personal injury, reduced unit performance and/or hazardous conditions may result from the use of such non-approved devices.

HIGH VOLTAGE!

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

Cette ventilation est nécessaire pour éviter le danger d'intoxication au CO pouvant survenir si un appareil produisant du monoxyde de carbone con tinue de fonctionne r au sein de la zone confinée.

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2 Shipping Inspection

Always transport the unit upright; laying the unit on its side or top during transit may cause equipment damage. The installer should inspect the product upon receipt for shipping damage and subsequent investigation is the responsibility of the carrier. The installer must verify the model number, specifications, electrical characteristics, and accessories are correct prior to installation. The distributor or manufacturer will not accept claims from dealers for transportation damage or installation of incorrectly shipped units.

2.1 Parts

Also inspect the unit to verify all required components are present and intact. Report any missing components immediately to Goodman or to the distributor. Use only factory authorized replacement parts (see Section 5). Make sure to include the full product model number and serial number when reporting and/or obtaining service parts.

2.2 Handling

Use caution when transporting/carrying the unit. Do not move unit using shipping straps. Do not carry unit with hooks or sharp objects. The preferred method of carrying the unit after arrival at the job site is to carry via a two-wheel hand truck from the back or sides or via hand by carrying at the cabinet corners.

3 Codes & Regulations

This product is designed and manufactured to comply with applicable national codes. Installation in accordance with such codes and/or prevailing local codes/regulations is the responsibility of the installer. The manufacturer assumes no responsibility for equipment installed in violation of any codes or regulations.

The United States Environmental Protection Agency (EPA) has issued various regulations regarding the introduction and disposal of refrigerants. Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines.

Should you have any questions please contact the local office of the EPA and/or refer to EPA’s website www.epa.gov.

4 Replacement Parts

When reporting shortages or damages, or ordering repair parts, give the complete product model and serial numbers as stamped on the product. Replacement parts for this product are available through your contractor or local distributor. For the location of your nearest distributor consult the white business pages, the yellow page section of the local telephone book or contact:

HOMEOWNER SUPPORT

GOODMAN MANUFACTURING COMPANY, L.P.

19001 KERMIER ROAD,

WALLER, TX 77484

(877) 254-4729

5 Pre-Installation Considerations

5.1 Preparation

Keep this document with the unit. Carefully read all instructions for the installation prior to installing product. Make sure each step or procedure is understood and any special considerations are taken into account before starting installation. Assemble all tools, hardware and supplies needed to complete the installation. Some items may need to be purchased locally. Make sure everything needed to install the product is on hand before starting.

5.2 System Matches

The entire system (combination of indoor and outdoor sections) must be manufacturer approved and Air-Conditioning, Heating, and Refrigeration Institute (AHRI) listed. NOTE: Installation of unmatched systems is not permitted. Damage or repairs due to installation of unmatched systems is not covered under the warranty.

5.3 Interconnecting Tubing

Give special consideration to minimize the length of refrigerant tubing when installing air handlers. Refer to Remote Cooling/Heat Pump Service Manual RS6200006, and TP-107 Long Line Set Application R-410A for tubing guidelines. If possible, allow adequate length of tubing such that the coil may be removed (for inspection or cleaning services) from the cabinet without disconnecting the tubing.

5.4 Clearances

The unit clearance from a combustible surface may be 0". However, service clearance must take precedence. A minimum of 24" in front of the unit for service clearance is required. Additional clearance on one side or top will be required for electrical wiring connections. Consult all appropriate regulatory codes prior to determining final clearances. When installing this unit in an area that may become wet (such as crawl spaces), elevate the unit with a sturdy, nonporous material. In installations that may lead to physical damage (i.e. a garage) it is advised to install a protective barrier to prevent such damage. Always install units such that a positive slope in condensate line (1/4" per foot) is allowed.

5.5 Horizontal Applications

If installed above a finished living space, a secondary drain pan (as required by many building codes), must be installed under the entire unit and its condensate drain line must be routed to a location such that the user will see the condensate discharge.

6 Installation Location

NOTE: These air handlers are designed for indoor installation

only. The AVPTC**14** product line may be installed in one of the

upflow, downflow, horizontal left or horizontal right orientations as shown in Figures 2, 3, 4 and 5. The unit may be installed in upflow or horizontal left orientation as shipped (refer to specific sections for more information).

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Minor field modifications are necessary to convert to downflow or horizontal right as indicated in below sections.

6.1 Upflow Installation

No field modifications are mandatory; however, to obtain maximum efficiency, the horizontal drip shield, side drain pan and drain pan extension can be removed.

Side Drain Pan and Extension Removal: Refer to Figure 1, remove the two (2) screws that secure the drip shield support brackets to the condensate collectors (front and back). Unsnap the side drain pan from the main drain pan using a screw driver or any small lever. The side drain pan, drip shield brackets and the drain pan extension may now be removed. From Figure 1, drain port labeled (A) is the primary drain for this application and condensate drain line must be attached to this drain port. Drain port (a) is for the secondary drain line (if used).

Drip Pan Extension

Side Drain Pan

Screw

Drip Shield Bracket

Drip Shield

CMK0008

Condensate

Kit

AVPTC25B14 AVPTC29B14 AVPTC31C14 AVPTC49D14 AVPTC33C14 AVPTC49C14

CMK0009

Condensate

Kit

AVPTC37B14 AVPTC37C14 AVPTC61D14 AVPTC39C14

CMK0010

Condensate

Kit

AVPTC 37D 14

AVPTC59C14

AVPTC 59D 14

CMK0012

Condensate

Kit

CMK0013

Condensa te

Kit

CMK0014

Condensate

Kit

CONDENSATE KIT

TABLE 1

6.3 Downflow/Horizontal Right Installation

IMPORTANT NOTE: In the downflow application, to prevent coil pan “sweating”, a downflow kit (DFK) is available through your local Goodman distributor. The DFK is not supplied with the air handler and is required by Goodman on all downflow installations. See Table 2 for the correct DFK and follow the instructions provided for installation.

MODEL LIST FOR DOWNFLOW KITS

DFK-B

Downflow Kit

DFK-C

Downflow Kit

DFK-D

Downflow Kit

AVPTC25B14** AVPTC31C14** AVPTC37D14**

AVPTC29B14** AVPTC37C14** AVPTC49D14**

AVPTC35B14** AVPTC59C14** AVPTC59D14**

AVPTC37B14** AVPTC33C14** AVPTC61D14**

AVPTC39C14**

AVPTC49C14**

DOWNFLOW KIT

TABLE 2

Pna

Main Drain Pan

SIDE DRAIN PAN REMOVAL

Figure 1

6.2 Horizontal Left Installation

No field modifications are permissible for this application.

The bottom right drain connection is the primary drain for this application and condensate drain line must be attached to this drain connection. The top connection of the three drain connections on the drain pan must remain plugged for this application. The bottom left drain connection is for the secondary drain line (if used).

In applications where the air handler is installed in the horizontal left position, and the return air environment see humidity levels above 65% relative humidity coupled with total external static levels above 0.5” e.s.p., a condensate kit is available for field application. Kit nomenclature can be found in Table 1.

Refer to Figure 6 and 7 for the location of the components referenced in the following steps.

1. Before inverting the air handler, remove blower access panel and coil access panel. The coil access panel and tubing panel may remain screwed together during this procedure. Remove and retain the seven (7) screws securing the coil access panel to the cabinet and the six (6) screws securing the blower access panel to the cabinet.

2. Slide the coil assembly out using the drain pan to pull the assembly from the cabinet.

NOTE: DO NOT USE MANIFOLDS OR FLOWRATOR TO PULL THE COIL ASSEMBLY OUT. FAILURE TO DO SO MAY RESULT IN BRAZE JOINT DAMAGE AND LEAKS.

3. Removal of the center support is required on units with 21" wide cabinet. Remove and retain the two (2) screws that secure the center support to the cabinet. Remove the center support.

4. Using the drain pan to hold the coil assembly, slide the coil assembly back into the cabinet on the downflow brackets as shown in Figure 8.

5. Re-install the center support (if removed) using the two (2) screws removed in Step 4.

6. Re-install the access panels removed in Step 1 as shown in Figure 9.

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7. The bottom left drain connection is the primary drain for this application and condensate drain line must be attached to this drain connection. The top connection of the three drain connections on the drain pan must remain plugged for this application. The bottom left drain connection is for the secondary drain line (if used).

HORIZONTAL RIGHT

Figure 5

7 Refrigerant Lines

NOTE: Refrigerant tubing must be routed to allow adequate ac-

cess for servicing and maintenance of the unit.

7.1 Tubing Size

For the correct tubing size, follow the specification for the condenser/heat pump.

7.2 Tubing Preparation

All cut ends are to be round, burr free, and clean. Failure to follow this practice increases the chances for refrigerant leaks. The suction line is spun closed and requires tubing cutters to remove the closed end.

UPFLOW DOWFLOW

Figure 2 Figure 3

NOTE: If removing only the coil access panel from the unit, the filter access panel must be removed first. Failure to do so may result in panel damage.

Do not install the air handler in a location that violates the instructions provided with the condenser. If the unit is located in an unconditioned area with high ambient temperature and/or high humidity, the air handler may be subject to nuisance sweating of the casing. On these installations, a wrap of 2" fiberglass insulation with a vapor barrier is recommended.

NOTE: To prevent possible damage to the tubing joints, do not handle coil assembly with manifold or flowrator tubes. Always use clean gloves when handling coil assemblies.

NOTE: The use of a heat shield is strongly recommended when brazing to avoid burning the serial plate or the finish of the unit. Heat trap or wet rags must be used to protect heat sensitive components such as service valves and TXV valves sensing bulb.

This product is factory-shipped with R410A and dry nitrogen mixture gas under pressure. Use appropriate service tools and follow these instructions to prevent injury.

A quenching cloth is strongly recommended to prevent scorching or marring of the equipment finish when brazing close to the painted surfaces. Use brazing alloy of 5% minimum silver content.

CAUTION

Applying too much heat to any tube can melt the tube. Torch heat required to braze tubes of various sizes must be proportional to the size of the tube. Service personnel must use the appropriate heat level for the size of the tube being brazed.

HORIZONTAL LEFT

Figure 4

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Upper Tie Plate

Control

Deck

Blower

Access

Panel

Downflow

Bracket

Center

Support

Filter

Bracket

Filter

Access

Panel

INTERNAL PART TERMINOLOGY

Figure 6

Coil Slides on the downflow bracket

Access

Remove side drain pan extension for downflow application

Coil

Panel

Tubing Panel

UV Knockout

EXTERNAL PART TERMINOLOGY

Figure 7

IMPORTANT NOTE:

Ensure coil slides on the rails along the groove provided on the drain pan side walls. Failure to do so will result in improper condensate drainage.

COIL INSTALLATION FOR DOWNFLOW

Figure 8

ACCESS PANEL CONFIGURAATION

FOR DOWNFLOW

OR HORIZONTAL RGHT

Figure 9

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7.3 Tubing Connections for TXV Models

TXV models come with factory installed TXV with the bulb

pre-installed on the vapor tube.

1. Remove refrigerant tubing panel or coil (lower) access panel.

2. Remove access valve fitting cap and depress the valve stem in access fitting to release pressure. No pressure indicates possible leak.

3. Replace the refrigerant tubing panel.

4. Remove the spin closure on both the liquid and suction tubes using a tubing cutter.

5. Insert liquid line set into liquid tube expansion and slide grommet about 18" away from braze joint.

6. Insert suction line set into suction tube expansion and slide insulation and grommet about 18" away from braze joint.

7. Braze joints. Quench all brazed joints with water or a wet rag upon completion of brazing.

NOTE: The sensing bulb must be permanently located. A heat shield, heat trap, or wet rag must be used during brazing to prevent damage to the TXV valve.

a. If subcooling and superheat are low, adjust TXV to 7 to 9°F, and then check subcooling.

NOTE: To adjust superheat, turn the valve stem clockwise to increase and counter clockwise to decrease.

b. If subcooling is low and superheat is high, add charge to

raise subcooling to 7 to 9°F, and then check superheat.

c. If subcooling and superheat are high, adjust TXV valve to

7 to 9° superheat, then check subcooling.

d. If subcooling is high and superheat is low, adjust TXV valve

to 7 to 9° superheat and remove charge to lower the subcooling to 7 to 9°F.

NOTE: Do NOT adjust the charge based on suction pressure unless there is a gross undercharge.

4. Disconnect manifold set, and installation is complete

NOTE: Check the Schrader ports for leaks and tighten valve cores if necessary. Install caps finger-tight.

SUBCOOL FORMULA= SAT. LIQUID LINE TEMP - LIQUID LINE TEMP SUPERHEAT FORMULA= SUCT. LINE TEMP - SAT. SUCT. TEMP

SATURATED SUCTION PRESSURE

TEMPERATURE CHART

8. Replace access panels, suction line grommet, insulation and all screws.

SUCTION LINE WITH SPIN CLOSURE

RUBBER GROMMET

Suction Line Grommet

Figure 11

7.4 Thermal Expansion Valve System Adjustment

Run the system at Cooling for 10 minutes until refrigerant pressures stabilize. Use the following guidelines and methods to check unit operation and ensure that the refrigerant charge is within limits. Charge the unit on low stage.

1. Purge gauge lines. Connect service gauge manifold to basevalve service ports.

2. Temporarily install a thermometer on the liquid line at the liquid line service valve and 4-6’’ from the compressor on the suction line. Ensure the thermometer makes adequate contact and is insulated for best possible readings. Use liquid line temperatice to determine subcooling and vapor temperature to determine superheat.

3. Check subcooling and superheat. Systems with TXV application should have a subcooling of 7 to 9°F and superheat of 7 to 9°F

SUCTION PRESSURE

PSIG R-22 R-410A

50 26 1

52 28 3

54 29 4

56 31 6

58 32 7

60 34 8

62 35 10

64 37 11

66 38 13

68 40 14

70 41 15

72 42 16

74 44 17

76 45 19

78 46 20

80 48 21

85 50 24

90 53 26

95 56 29

100 59 31

110 64 36

120 69 41

130 73 45

140 78 49

150 83 53

160 86 56

170 90 60

SATURATED SUCTION

TEMPERATURE ºF

Page 8

SATURATED LIQUID PRESSURE

TEMPERATURE CHART

CAUTION

LIQUID PRESSURE

PSIG R-22 R-410A

200 101 70

210 105 73

220 108 76

225 110 78

235 113 80

245 116 83

255 119 85

265 121 88

275 124 90

285 127 92

295 130 95

305 133 97

325 137 101

355 144 108

375 148 112

405 155 118

415 157 119

425 n/a 121

435 n/a 123

445 n/a 125

475 n/a 130

500 n/a 134

525 n/a 138

550 n/a 142

575 n/a 145

600 n/a 149

625 n/a 152

SATURATED LIQUID

TEMPERATURE ºF

8 Condensate Drain Lines

The coil drain pan has a primary and a secondary drain with 3/4" NPT female connections. The connectors required are 3/4" NPT male, either PVC or metal pipe, and should be hand tightened to a torque of no more than 37 in-lbs. to prevent damage to the drain pan connection. An insertion depth of approximately 3/8” to 1/2” (3-5 turns) should be expected at this torque.

1. Ensure drain pan hole is not obstructed.

2. To prevent potential sweating and dripping on to finished space, it may be necessary to insulate the condensate drain line located inside the building. Use Armaflex® or similar material.

A secondary condensate drain connection has been provided for areas where the building codes require it. Pitch all drain lines a minimum of 1/4" per foot to provide free drainage. Provide required support to the drain line to prevent bowing. If the secondary drain line is required, run the line separately from the primary drain and end it where condensate discharge can be easily seen.

NOTE: Water coming from secondary line means the coil primary drain is plugged and needs immediate attention.

If secondary drain is not installed, the secondary access must be plugged.

Insulate drain lines located inside the building or above a finished living space to prevent sweating. Install a condensate trap to ensure proper drainage.

NOTE: When units are installed above ceilings, or in other locations where damage from condensate overflow may occur, it is MANDATORY to install a field fabricated auxiliary drain pan under the coil cabinet enclosure.

The installation must include a “P” style trap that is located as close as is practical to the evaporator coil. See Figure 12 for details of a typical condensate line “P” trap.

NOTE: Units operating in high static pressure applications may require a deeper field constructed “P” style trap than is shown in Figure 12 to allow proper drainage and prevent condensate overflow.

Drain

Connection

Air Handler

POSITIVE LIQUID SEAL REQUIRED

AT T R AP

2" MIN.

3" MIN.

Figure 12

NOTE: Trapped lines are required by many local codes. In the

absence of any prevailing local codes, please refer to the requirements listed in the Uniform Mechanical Building Code.

A drain trap in a draw-through application prevents air from being drawn back through the drain line during fan operation thus preventing condensate from draining, and if connected to a sewer line to prevent sewer gases from being drawn into the airstream during blower operation.

Use of a condensate removal pump is permitted when necessary. This condensate pump should have provisions for shutting off the control voltage should a blocked drain occur. A trap must be installed between the unit and the condensate pump.

IMPORTANT NOTE: The evaporator coil is fabricated with oils that may dissolve styrofoam and certain types of plastics. Therefore, a removal pump or float switch must not contain any of these materials. Tip: Priming the “P” trap may avoid improper draining at the initial installation and at the beginning of the cooling season.

Page 9

9 Ductwork

This air handler is designed for a complete supply and return ductwork system.

To ensure correct system performance, the ductwork is to be sized to accommodate 350-450 CFM per ton of cooling with the static pressure not to exceed 0.5" in w.c. Refer to ACCA Manual D, Manual S and Manual RS for information on duct sizing and application. Flame retardant ductwork is to be used and sealed to the unit in a manner that will prevent leakage.

NOTE: A downflow application with electric heat must have an Lshaped sheet metal supply duct without any outlets or registers located directly below the heater.

9.1 Return Ductwork

DO NOT LOCATE THE RETURN DUCTWORK IN AN AREA THAT CAN INTRODUCE TOXIC, OR OBJECTIONABLE FUMES/ ODORS INTO THE DUCTWORK. The return ductwork is to be connected to the air handler bottom (upflow configuration).

10 Return Air Filters

Each installation must include a return air filter. This filtering may be performed at the air handler using the factory filter rails or externally such as a return air filter grille. When using the factory filter rails, a nominal 16x20x1”, 20x20x1” or 24x20x1” (actual dimension must be less than 23-½”x20”) filter can be installed on a B, C and D cabinet respectively (the cabinet size is the seventh letter of the model number).

11 Electric Heat

Do not operate this product without all the ductwork attached.

Refer to the installation manual provided with the electric heat kit for the correct installation procedure. All electric heat must be field installed. If installing this option, the ONLY heat kits that are permitted to be used are the HKS series. Refer to the air handler unit’s Serial and Rating plate or the HKS specification sheets to determine the heat kits compatible with a given air handler. No other accessory heat kit besides the HKS series may be installed in these air handlers.

The heating mode temperature rise is dependent upon the system airflow, the supply voltage, and the heat kit size (kW) selected. Use data provided in Tables 3, 4 and 5 to determine the temperature rise (°F).

CFM

800 121923313756 1000 9 1519253044 1200 8 12152125374962 1400 7 11131821324253 1600 6 9 12 15 19 28 37 46 1800 5 8 10 14 16 25 33 41 2000 5 7 9 1215223037

3 5 6 8 10 15 19/20 25

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

HEAT KIT NOMINAL kW

Table 2

CFM

800 111822303554 1000 9 1418242842 1200 7 12152024354759 1400 6 10131720304051 1600 6 9 11 15 18 27 35 44 1800 5 8 10 13 16 24 31 39 2000 4 7 9 12 14 21 28 35

3568101519/2025

HEAT KIT NOMINAL kW

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

Table 3

CFM

800 1017212833

1000 8 1317222740 1200 7 11141922334556 1400 6 10121619293848 1600 5 8 10 14 17 25 33 42 1800 5 7 9 12 15 22 30 37 2000 4 7 8 11 13 20 27 33

3568101519/2025

HEAT KIT NOMINAL k W

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

Table 4

Model

3 5 6 8 10 15 19 20 25

AVPTC25B14 550 650 700 800 850 875

AVPTC29B14 550 650 700 800 875 875

AVPTC35B14 550 650 700 800 875 1050

AVPTC37B14 550 650 700 800 875 1050

AVPTC33C14 600 700 750 875 950 950

AVPTC39C14 850 900 1000 1170 1345

AVPTC49C14 1170 1170 1170 1170 1345 1345

AVPTC31C14 600 850 900 1000 1170 1345 1345

AVPTC37C14 850 900 1000 1170 1345 1345

AVPTC59C14 1170 1170 1170 1170 1345 1345

AVPTC37D14 1240 1240 1240 1240 1520 1520 AVPTC59D14 1240 1240 1240 1240 1520 1520 AVPTC49D14 1250 1300 1500 1550 1720 AVPTC61D14 1250 1300 1500 1550 1780 1850 1850

HEATER (kW)

1345

MINIMUM CFM REQUIREMENTS FOR HEATER KITS

Table 5

NOTE: For installations not indicated above the following formula is to be used:

TR = (kW x 3412) x (Voltage Correction) / (1.08 x CFM)

Where: TR = Temperature Rise

kW = Heater Kit Actual kW 3412 = Btu per kW VC* = .96 (230 Supply Volts)

= .92 (220 Supply Volts) = .87 (208 Supply Volts)

1.08 = Constant CFM = Measured Airflow

VC* (Voltage Correction)

NOTE: The Temperature Rise Tables can also be used to estimate the air handler airflow delivery. When using these tables for this purpose set the room thermostat to maximum heat and allow the system to reach steady state conditions. Insert two thermometers, one in the return air and one in the supply air. The temperature rise is the supply air temperature minus the return air temperature. Using the temperature rise calculated, CFM can be estimated from the TR formula above. See Spec Sheets and/or Service Manual for more information.

Page 10

12 Electrical and Control Wiring

IMPORTANT: All routing of electrical wiring must be made through

provided electrical knockouts. Do not cut, puncture or alter the cabinet for electrical wiring.

12.1 Building Electrical Service Inspection

This unit is designed for single-phase electrical supply only.

DO NOT OPERATE ON A THREE-PHASE POWER SUPPLY. Measure the power supply to the unit. The supply voltage must be measured and be in agreement with the unit nameplate power requirements and within the range shown.

Nominal Input Minimum Voltage Maximum Voltage

208-240 197 253

ELECTRICAL VOLTAGE

Table 6

• Wire must be sized to allow no more than a 2% voltage

drop from the building breaker/fuse panel to the unit.

• Wires with different insulation temperature rating have varying ampacities - be sure to check the temperature rating used.

Refer to the latest edition of the National Electric Code or in Canada the Canadian Electric Code when determining the correct wire size.

12.3 Maximum Overcurrent Protection (MOP)

Every installation must include an NEC (USA) or CEC (Canada) approved overcurrent protection device. Also, check with local or state codes for any special regional requirements.

Protection can be in the form of fusing or HACR style circuit breakers. The Series and Rating Plate provides the maximum overcurrent device permissible.

12.2 Wire Sizing

Wire size is important to the operation of your equipment. Use the following check list when selecting the appropriate wire size for your unit.

FIRE HAZARD! To avoid the risk of property damage, personal injury or fire, use only copper conductors.

HIGH VOLTAGE!

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

HIGH VOLTAGE! To avoid property damage, personal injury or death due to electrical shock, this unit MUST have an uninterrupted, unbroken electrical ground circuit may consist of an appropriately sized electrical wire connecting the ground lug in the unit control box to the building electrical service panel. Other methods of grounding are permitted if performed in accordance with the National Electric Code (NEC)/American National Standards Institute (ANSI)/National Fire Protection Association (NFPA) 70 and local/state codes. In Canada, electrical grounding is to be in accordance with the Canadian Electric Code (CSA) C22.1.

electrical ground. The

• Wire used must carry the Minimum Circuit Ampacity (MCA) listed on the unit’s Series and Rating Plate.

• Refer to the NEC (USA) or CSA (Canada) for wire sizing. The unit MCA for the air handler and the optional electric heat kit can be found on the unit Series and Rating Plate.

NOTE: Fuses or circuit breakers are to be sized larger than the equipment MCA but not to exceed the MOP.

12.4 Electrical Connections – Supply Voltage

IMPORTANT NOTE: USE COPPER CONDUCTORS ONLY.

Knockouts are provided on the air handler top panel and sides of the cabinet to allow for the entry of the supply voltage conductors, as shown in Figure 13. If the knockouts on the cabinet sides are used for electrical conduit, an adapter ring must be used in order to meet UL1995 safety requirements. An NEC or CEC approved strain relief is to be used at this entry point. Some codes/municipalities require the supply wire to be enclosed in conduit. Consult your local codes.

Top of

Cabinet

Side of

Cabinet

KNOCK-OUT FOR ELECTRICAL CONNECTIONS

Figure 13

12.4.1 Air Handler Only (Non-Heat Kit Models)

The building supply connects to the stripped black and red wires contained in the air handler electrical compartment cavity. A ground screw is also contained in this area. Attach the Supply wires to the air handler conductors as shown in the unit wiring diagram using appropriately sized solderless connectors or other NEC or CEC approved means.

Page 11

12.4.2 Air Handler - Non-Circuit Breaker Heat Kits

A terminal block is provided with the HKS kit to attach the power supply and air handler connections. Follow the HKS Installation Manual and wiring diagram for complete wiring details.

12.4.3 Air Handler With Circuit Breaker Heat Kit

The air handler has a plastic cover on the upper access panel that will require either one or both sections to be removed to allow the heat kit circuit breaker(s) to be installed. The circuit breakers have lugs for power supply connection. See the HKS Installation Instructions for further details.

12.5 Low Voltage Connections

Several combinations of low voltage schemes are possible, depending on the presence of a heat kit and whether the heat kit is single-stage or multi-stage, whether the outdoor section is an air conditioner or heat pump, and whether the system is setup with a communicating or traditional thermostat. The 24V-control voltage connects the air handler to the room thermostat and condenser. Low voltage wiring must be copper conductors. A minimum of 18 AWG must be used for installations up to 100 feet. Low voltage wiring must be connected through the top of the cabinet or either side. See the “Thermostat Wiring” section of this manual for typical low voltage wiring connections.

COOLING HEAT PUMP HEATING ELECTRIC HEATING

1-STAGE ------ 1- or 2-STAGE 2-STAGE ------ 1- or 2-STAGE 1-STAGE 1-STAGE -----2-STAGE 2-STAGE -----1-STAGE 1-STAGE 1- or 2-STAGE

2-STAGE 2-STAGE 1- or 2-STAGE

Table 7

Typical Single-Stage Cool,

Single-Stage Heat Thermostat

RCG

12RCG

W1 Y1

W1 Y1 Y2

Remote Condensing Unit

(Single-Stage AC)

Typical Single-Stage Cooling with Single-Stage Heating

Figure 14

Place Jumper Between Y1

and O for Proper

Dehumidification Operation

and Proper Ramping

Profile Operation

Air Handler Integrated

DEHUM

NEU

HOT

Control Module

Dehumidistat

[Optional]

13 Achieving 1.4% and 2.0% Airflow Low Leakage Rate

Ensure all the gaskets remain intact on all surfaces as shipped with the unit. These surfaces are areas between the upper tie plate and coil access panel, blower access and coil access panels, and between the coil access and filter access panels. Ensure upon installation, that the plastic breaker cover is sitting flush on the blower access panel and all access panels are flush with each other and the cabinet. With these requirements satisfied, the unit achieves less than 1.4% airflow leakage @ 0.5 inch wc static pressure and less than 2% airflow leakage @1inch wc static pressure when tested in accordance with ASHRAE Standard 193.

14 24 Volt Wiring

14.1 24 Volt Thermostat Wiring - Non-Communicating Thermostat Connections

NOTE: Wire routing must not interfere with the circulator blower operation or routine maintenance. The air handler’s integrated control module provides terminals for “Y1” and “Y2” and “W1” and “W2” thermostat connections. This allows the air handler to support the systems shown in the following table. Refer to the following figures for typical connections to the integrated control module. Thermostat wiring entrance holes are located in the top of the blower. Wire routing must not interfere with circulator blower operation or routine maintenance.

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 multiple wires into a single terminal. Wire nuts are recommended to ensure one wire is used for each terminal. Failure to do so may result in intermittent operation.

12RCG

12RC

Typical Two-Stage Cool,

Two-Stage Heat Thermostat

RCG

W1 W2 Y1 Y2

Y1 Y2

Remote Condensing Unit

(Two-Stage AC)

Place Jumper Between Y1

and O for Proper

Dehumidification Operation

and Proper Ramping

Profile Operation

Air Handler Integrated

DEHUM

NEU

HOT

Control Module

Dehumidistat

[Optional]

Typical Two-Stage Cooling with Two-Stage Heating

Figure 15

RCG

W/E

W1 W2 Y1 Y2

W1 Y

Remote Condensing Unit

(Single-Stage HP)

Typical Single-Stage Cool,

Single-Stage Heat

Heat Pump Thermostat

DEHUM

ir Handler

Integrated Control Module

NEU

Dehumidistat

HOT

[Optional]

Typical Single-Stage Heat Pum

with Auxiliary/Emergency Heating

Figure 16

Page 12

RCG

12RC

Remote Condensing Unit

W/E

W2 Y1 Y2

W1 W2 Y1 Y2

W1 Y1 Y2

(Two-Stage HP)

Typical Two-Stage Cool,

Two-Stage Heat

Heat Pump Thermostat

DEHUM

Integrated Control Module

NEU

HOT

ir Handler

Dehumidistat

[Optional]

Typical Two Stage Heat Pump Heating

and Auxiliary/Emergency Heating

Figure 17

14.2 24 Volt Dehumidistat Wiring - Non-Communicating Thermostat Connections

The optional usage of a dehumidistat allows the air handler’s circulator blower to operate at a slightly lower speed during a combined thermostat call for cooling and dehumidistat call for dehumidification. This lower blower speed enhances dehumidification of the conditioned air as it passes through the AC coil. For proper function, a dehumidistat applied to this air handler must operate on 24 VAC and utilize a switch which opens on humidity rise.

To install/connect a dehumidistat:

15 Auxiliary Alarm Switch

The control is equipped with two Auxiliary Alarm terminals labeled CAS which can be utilized with communicating mode setups (typically used for condensate switch wiring but could be used with compatible C02 sensors or fire alarms).

Legacy mode use In a legacy system (Non-communicating), this feature is not op-

erational. Any auxiliary alarm switch must be used to interrupt the Y1 signal either to the indoor or outdoor unit.

Communication mode use

This feature can be activated or deactivated through the thermostat user menus. An auxiliary alarm switch must be normally closed and open when the base pan’s water level in the evaporator coil reaches a particular level. The control will respond by turning off the outdoor compressor and display the proper fault codes. If the switch is detected closed for 30 seconds, normal operation resumes and the error message will be removed.

SWITCH

CAS

1. Turn OFF power to air handler.

2. Secure the dehumidistat neutral wire (typically the white lead) to the screw terminal marked “DEHUM” on the air handler’s integrated control module.

3. Secure the dehumidistat hot wire (typically the black lead) to the screw terminal marked “R” on the air handler’s integrated control module.

4. Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the air handler. NOTE: Ground wire may not be present on all dehumidistats.

5. To enable the dehumidification function, move the dehumidification dip switch (S7) from OFF to ON. See following figure.

S5 S6 S7 S8

OFF

Dip Switches -

Dehumidification Enable

Figure 18

Move to the ON position

to enable

dehumidification

Figure 19

16 AVPTC Motor Orientation

If the unit is in the upflow position, there is no need to rotate the motor. If the unit is in the downflow position, loosen motor mount and rotate motor as shown in the AVPTC Motor Orientation figure below. Be sure motor is oriented with the female connections on the casing down. If the motor is not oriented with the connections down, water could collect in the motor and may cause premature failure.

FRONT VIEW

FEMALE CONNECTIONS

AVPTC Motor Orientation

Figure 20

SIDE VIEW

RNING

SOFTW

RE VER.

TOP

6. Turn ON power to air handler.

Page 13

Seven Segment

LED

Green CFM LED

W1W2

ST1

ST4

24VAC

COM

FUSE 3A

ST3

CAS

HUM

ST2

Auxiliary

Alarms

C 2 1 R

Dip Switches

Communicating Board

17 Circulator Blower

This air handler is equipped with a multi-speed circulator blower. This blower provides ease in adjusting 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.), for the proper selection of heating and cooling speeds. The heating blower speed shipped is set at 21kW or 25kW, and the cooling blower speed is set at “D”. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct electric heating CFM and correct cooling CFM.

Use the CFM LED (green) to obtain an approximate airflow quantity. The green CFM LED blinks once for each 100 CFM of airflow.

1. Determine the tonnage of the cooling system installed with the air handler. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs.

Example: Cooling Capacity of 30,000 BTU/hr.

30,000/12,000 = 2.5 Tons

2. Determine the proper airflow for the cooling system. Most cooling systems are designed to work with airflows between 350 and 450 CFM per ton. Most manufacturers recommend an airflow of about 400 CFM per ton.

Example: 2.5 tons X 400 CFM per ton = 1000 CFM

Figure 21

The cooling system manufacturer’s instructions must be checked for required airflow. Any electronic air cleaners or other devices may require a specific airflow; consult installation instructions of those devices for requirements.

3. Knowing the air handler model, locate the high stage cooling airflow charts in the Specification Sheet applicable to your model. Look up the cooling airflow determined in step 2 and find the required cooling speed and adjustment setting.

Example: An AVPTC31C14 air handler installed with a 2.5

ton air conditioning system. The airflow needed is 1000 CFM. Looking at the cooling speed chart for AVPTC31C14, find the airflow closest to 1000 CFM. A cooling airflow of 1000 CFM can be attained by setting the cooling speed to “C” and the adjustment to “0” (no adjustment).

4. Locate the blower speed selection DIP switches on the integrated control module. Select the desired “cooling” speed tap by positioning switches 1 and 2 appropriately. If airflow adjustment is required, set dip switch S8 (trim enable) to ON (trim enable default is off). Then select the desired “adjust” tap by positioning switches S3 and S4 appropriately. Refer to the following Airflow Adjust Taps figure for switch positions and their corresponding taps. Verify CFM by counting the number of times the green CFM LED blinks, see page 13 for LED locations.

Page 14

SPEED SELECTION DIP SWITCHES

COOL

SELECTION

SWITCHES

TAPS1S2S3S4S5S6S12S13

A OFF OFF OFF OFF OFF OFF OFF OFF

B ON OFF ON OFF ON OFF ON OFF

C OFF ON OFF ON OFF ON OFF ON

D ONONONONONONON ON

PROF ILES PRE-RU N SHOR T-RUN OFF DELAY

TO SET AIRFLOW

AIRFLOW. Determine the corresponding TAP (A, B, C, D). Set DIP switches S1 and S2 to the appropriate ON / OFF positions. (2) Select model and installed electric heater size. Set DIP switches S9, S10 and S11 to the appropriate ON / OFF positions. (3) If airflow adjustment is required, set TRIM ENABLE SWITCH S8 to ON (OFF = 0% Trim) and set S3 and S4 to appropriate ON / OFF positions. TAP A is +5%, TAP B is -5%, TAP C is +10%. TAP D is - 10%.

TO SET COMFORT MODE:

profiles above). Set DIP switc hes S5 and S6 to appropriate ON / OFF positions.

DEHUMIDIFICATION:

be reduced to 85% of nominal value during cool call when DEHUM command is present. To disable, set S7 to OFF.

CONTINUOUS FAN S PEED

the 4 continuous fan speeds, TAP A is 25%, TAP B is 50%, TAP C is 75%, TAP D is 100%.

NOTES:

1. Airflow data shown applies to legacy mode operation only. For a fully communica ting system, please see the outdoo r un it's insta llation instruc tions fo r cooling and heat pump airflow data. See ComfortNet System-Airflow Consideration section for details.

2. Airflow blink codes are approximations of actual airflow.

ADJUST

SELECTION

SWITCHES

PROFILE

SELECTION

SWITCHES

CONTINUOUS

FAN

SPEED

---- ---- 60 SEC. / 100%

---- 30 SEC. / 50% 60 SEC. / 100%

---- 7.5 MIN. / 82% 60 SEC. / 100%

30 SEC. / 50% 7.5 MIN. / 82% 30 SEC. / 50%

: (1) Select model and desired HIGH STAGE COOLING

Select desired Comfort Mode Profile. (see

To enable, set DIP switc h S7 to ON. Cooling airflow will

: Use DIP switches S12 and S13 to select one of

Cooling/Heat Pump Airflow Table

MODEL

Tap Low S tage High Sta ge

A 410 610 AV PTC25 B14 AVPTC35B14

B 565 840

C 650 970

D 685 1020

A 375 610 AVPTC29B14 AVPTC37B14

B 545 795

C 630 930

D 740 1085

A 450 675

AVPTC33C14

B 520 780

C 660 985

D 750 1115

A 665 990

AVPTC39C14

B 770 1150

C 815 1215

D 910 1360

A 710 875

AVPTC49C14

B 745 1225

C 880 1410

D 975 1595

A 595 870 AVPTC31C14 AVPTC37C14

B 705 1050

C 835 1260

D 870 1315

A 610 875

AVPTC59C14

B 810 1225

C 940 140

D 1070 1595

A 590 865

AVPTC37D14

B 700 1055

C 770 1210

D 885 1375

A 1040 1445

AVPTC59D14

B 1260 1790

C 16330 1890

D 1395 1990

A 820 1195

AVPTC49D14

B 895 1320

C 995 1460

D 1056 1530

A 1080 1630

AVPTC61D14

B 1210 1820

C 1280 1925

D 1350 2025

NOTE: Airflow blink codes are approximations of actual airflow. Airflows provided are at 0.3 static.

DIP SWITCH SETTING & AIRFLOW TABLE FOR ELECTRIC HEAT

HTR KW S9 S10 S11 AVPTC25B14 AVPTC29B14

3ONONON

5ONONOFF

6ONOFFON

8ONOFFOFF

10 OFF ON ON

15 OFF ON OFF

19* OFF OFF ON 1345 1345

20 OFF OFF ON 21 OFF OFF O FF

25* OFF OFF OFF 1850

Note: Airflow data shown applies to the electric heat only in either legacy mode or communicating mode operation * Within thermostat user menu CTK0* communicating thermostat will display 20KW for OFF- OFF- ON dip switch selection, 21kW for OFF -OFF-OFF dip swi th s ele cti on.

NR - Not ra ted †† For match up with a 3 ton outdoor unit Airflow for 5kW up to 15kW heater kits s hall be set to 1300 cfm speed ta p of ON-OFF-ON

††† For match up with a 3.5 ton outdoor unit: Heater kit appli caƟon shall not exceed 20kW Airflow for 5 kW up to 20kW heater kits s hall be s et to 1500 cfm speed ta p of ON-OFF-OFF

550 550 550

650 650 650

700 700 700

800 800 800

850 875 875

875 875 1050

AVPTC35B14 AVPTC37B14

AVPTC33C14 AVPTC39C14 AVPTC49C14 AVPTC37C14 AVPTC59C14 AVPTC37D14 AVPTC59D14 AVPTC49D14 II

600

700 850 11 70

750 900 11 70

875 100 0 1170

950 117 0 1170

950 134 5 1345

850 1170 1240 1240 1250 1250 850

900 1170 1240 1240 1300 1300 900

1000 1170 1240 1240 1500 1500 1000

1170 1170 1240 1240 1550 1550 1170

1345 1345 1520 1520 1720 1780 1345

1345 1345 1345

1520 1 520 1850

AVPTC61D14 III AV PTC31C14

600

Page 15

5. Continuous fan speeds that provide 25, 50, 75, and 100% of the air handler’s maximum airflow capability are selectable via dip switches S12 and S13.

If the air handler’s maximum airflow capability is 2000 CFM and 25% continuous fan speed is selected, the continuous fan speed will be 0.25 x 2000 CFM = 500 CFM.

6. The multi-circulator blower also offers several custom ON/ OFF ramping profiles. These profiles may be used to enhance cooling performance and increase comfort level. The ramping profiles are selected using DIP switches 5 and 6. Refer to the following Dip Switches - Cooling Airflow Ramping Pro- files figure for switch positions and their corresponding taps. Refer to the bullet points below for a description of each ramping profile. Verify profile selection by counting the green CFM LED blinks and timing each step of the ramping profile.

Ta p A Ta p B

OFF OFF OFF OFFON ON ON ON

Tap C Tap D*

25% 50%*

OFF

S12

S13

S12

S13

Fan Only Selection (*indicates factory setting)

OFF

75% 100%

OFF

ON ON

S12

S13 S13

OFFON

Figure 24

• Profile A provides only an OFF delay of one (1) minute at 100% of the cooling demand airflow.

OFF

100% CFM 100% CFM

1 min

Figure 26

OFF

• Profile B ramps up to full cooling demand airflow by first stepping up to 50% of the full demand for 30 seconds. The motor then ramps to 100% of the required airflow. A one (1) minute OFF delay at 100% of the cooling airflow.

Cooling Airflow Speed Tap (*indicates factory setting)

Figure 22

+5% -5%

OFF OFF OFF OFFON ON ON ON

Airflow Adjust Taps (*indicates factory setting)

+10% -10%

Dip Switches -

Cooling Airflow and Airflow Adjust Taps

Figure 23

21 kW* or

25 kW*

OFF OFF OFF OFFON ON ON ON

S10

S11

19 kW or

20 kW

S10

S11

15 kW 10 kW

S10

S11

S10

S11

OFF

50% CFM

1/2 min

100% CFM

OFF

1 min

Figure 27

• Profile C ramps up to 82% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile C also has a one (1) minute 100% OFF delay.

OFF

100% CFM

Figure 28

OFF

8 kW 6 kW 5 kW 3 kW

OFF OFF OFF OFFON ON ON ON

S10

S11

S10

S11

S10

S11

S10

S11

NOTE: Upon start up in communicating mode the circuit board may display an “Ec” 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 and resetting power to the unit will clear the error code.

Within the thermostat user menu, CTK0* communicating thermostat will display 20 kW for OFF-OFF-ON dip switch selection and 21 kW for OFF-OFF-OFF dip switch selection.

Electric Heating Airflow (*indicates factory setting)

Figure 25

Page 16

• Profile D ramps up to 50% of the demand for 1/2 minute, then ramps to 82% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/2 minute at 50% airflow OFF delay.

18 Heat Kit Selection

For heat kit selection, see the Specification Sheet for each

specific Air Handler.

19 Troubleshooting

OFF

Figure 29

Tap A* Tap B Tap C Tap D

OFF OFF OFF OFFON ON ON ON

Dip Switches - Cooling Airflow Ramping Profiles

Figure 30

OFF

7. If an electric heater kit has been installed, determine the heater kilowatt (kW) rating. Using the Electric Heat Airflow table on page 14, set dip switches 9, 10, and 11 for the installed heater. The adjust setting (already established by the cooling speed selection) also applies to the electric heater kit airflow. Thus, the electric heater airflow is adjusted by the same amount. This does not apply to systems setup with a communicating thermostat. See Set-Up section in the AIR HANDLER ADVANCED FEATURES MENU on page 21. Verify selected CFM by counting the green CFM LED blinks.

If an electric heater kit has not been installed, set dip switches 9, 10, and 11 to any valid heater kit setting (see airflow table for valid settings). This will prevent an Ec Error code from being displayed.

NOTE: For installations not indicated in the preceding Temperature Rise Tables, the following formula is to be used:

TR = (kW x 3412) x (Voltage Correction) / (1.08 x CFM)

Where: TR = Temperature Rise kW = Heater Kit Actual kW 3412 = Btu per kW Voltage Correction =.96 (230 Supply Volts)

=.92 (220 Supply Volts) =.87 (208 Supply Volts)

1.08 = Constant CFM = Measured Airflow

NOTE: The Temperature Rise Tables can also be used to determine the air handler airflow delivery. When using these tables for this purpose set the room thermostat to maximum heat and allow the system to reach steady state conditions. Insert two thermometers, one in the return air and one in the supply air. The temperature rise is the supply air temperature minus the room air temperature. Use HKR specification sheets to determine the HKR available for a given air handler.

19.1 Electrostatic Discharge (ESD) Precautions

NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. 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 the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (ungrounded) blowers.

WARNING

HIGH VOLTAGE!

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER

BEFORE PERFORMING ANY SERVICE OR MAINTENANCE

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.

19.2 Diagnostic Chart

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 Figure 31.

7 Segment Diagnostic Display

Figure 31

Page 17

19.3 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. The control must be in Standby Mode (no thermostat inputs) to use the feature. Depress the push-button for approximately two seconds and less than five seconds. The LED display will then display the six most recent faults beginning with the most recent fault and decrementing to the least recent fault. The faults may be cleared by depressing the button for greater than five seconds.

NOTE: Consecutively repeated faults are displayed a maximum of three times. Example: A clogged return air filter causes the air handler’s motor to repeatedly enter a limiting condition. The control will only store this fault the first three consecutive times the fault occurs.

20 ComfortNet™ System

20.1 Overview

The ComfortNet system is a system that includes a ComfortNet compatible air handler and air conditioner or heat pump with a CTK0* thermostat. Any other system configurations are considered invalid ComfortNet systems and must be connected as a traditional (or non-communicating) system (see the 24 VOLT THERMO-

STAT WIRING - NON-COMMUNICATING THERMOSTAT CONNECTIONS section for

details). A ComfortNet heating/air conditioning system differs from a non-

communicating/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 oneway communication path in that the indoor and outdoor units typically do not return information to the thermostat.

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 ComfortNet 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 ComfortNet system.

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.

20.1 Airflow Consideration

Airflow demands are managed differently in a fully communicating system than they are in a non-communicating wired system. The system operating mode (as determined by the thermostat) determines which unit calculates the system airflow demand. If the indoor unit is responsible for determining the airflow demand, it calculates the demand and sends it to the ECM motor. If the outdoor unit or thermostat is responsible for determining the demand, it calculates the demand and transmits the demand along with a fan request to the indoor unit. The indoor unit then sends the demand to the ECM motor. The table below lists the various ComfortNet systems, the operating mode, and airflow demand source.

For example, assume the system is a heat pump matched with an air handler. With a call for low stage cooling, the heat pump will calculate the system’s low stage cooling airflow demand. The heat pump will then send a fan request along with the low stage cooling airflow demand to the air handler. Once received, the air handler will send the low stage cooling airflow demand to the ECM motor. The ECM motor then delivers the low stage cooling airflow. See the applicable ComfortNet air conditioner or heat pump installation manual for the airflow delivered during cooling or heat pump heating.

In continuous fan mode, the CTK0* thermostat provides the airflow demand. Depending on which CTK0* thermostat has been installed three or four continuous fan speeds may be available. If the thermostat provides three speeds (low, medium, high) they correspond to 25%, 50% and 75%, respectively, of the air handlers’ maximum airflow capability. If the thermostat provides four continuous fan speeds then a 100% airflow option is added. During continuous fan operation, the thermostat sends a fan request along with the continuous fan demand to the air handler. The air handler, in turn, sends the demand to the ECM motor. The ECM motor delivers the requested continuous fan airflow.

Sys tem

Air Conditioner +

Air Handler

Hea t Pump + A ir

Handler

Sys tem

Operating Mode

Cooling A ir Conditioner

Heating A ir Handler

Continuous Fan Thermostat

Cooling Heat Pump

Heat Pump Heating

Only

HP + Electric Heat

Strips

Electric Heat Strips

Only

Airflow Dem and

Source

Heat Pump

> of Heat Pump or Air

Han dl er Demand

Air Handler

Continuous Fan Thermostat

Figure 32

Page 18

20.2 Control Wiring

NOTE: Refer to section Electrical Connections for 208/230 volt line connections to the air handler.

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 multiple wires into a single terminal. Wire nuts are recommended to ensure one wire is used for each terminal. Failure to do so may result in

intermittent operation.

Typical 18 AWG thermostat wire may be used to wire the system components. One hundred and fifty (150) feet is the maximum length of wire recommended between indoor unit and outdoor unit, or between indoor unit and thermostat.

Only the data lines 1 and 2 are required between the indoor and outdoor units. A 40VA, 208/230 VAC to 24 VAC transformer must be installed in the outdoor unit to provide 24 VAC power to the outdoor unit’s electronic control. See kit instructions for mounting and wiring instructions.

CTK04

20.5 Diagnostics

Accessing the air handler’s diagnostics menu provides ready access to the last six faults detected by the air handler. Faults are stored most recent to least recent. Any consecutively repeated fault is stored a maximum of three times. Example: A clogged return air filter causes the air handler’s motor to repeatedly entera limiting condition. The control will only store this fault the first three consecutive times the fault occurs.

NOTE: It is highly recommended that the fault history be cleared after performing maintenance or servicing the air handler.

20.6 Network Troubleshooting

The ComfortNet system is a fully communicating system, and thus, constitutes a network. Occasionally the need to troubleshoot the network may arise. 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. Refer to the Communications Troubleshooting Chart at the end of this manual for error codes, possible causes and corrective actions.

• 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

COMMUNICATIONS TROUBLESHOOTING CHART indicates

the LED status and the corresponding potential problem.

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

20.4 ComfortNet™ System Advanced Features

The ComfortNet system permits access to additional system information, advanced set-up features, and advanced diagnostic/ troubleshooting features. These advanced features are organized into a menu structure. See the AIR HANDLER ADVANCED FEATURES MENU section for layout of menu shortcuts.

20.7 System Troubleshooting

NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information. Refer to the Troubleshooting Chart at the end of this manual for a listing of possible air handler error codes, possible causes and corrective actions.

Page 19

21 Start-Up Procedure

• Prior to start-up, ensure that all electrical connections are properly sized and tightened.

• All panels must be in place and secured. For Air Tight application, neoprene gasket must be positioned at prescribed locations to achieve low airflow as stated in section 13.

• Tubing must be leak free.

• Unit should be elevated, trapped and pitched to allow for drainage.

• Low voltage wiring is connected.

• Auxiliary drain is installed when necessary and pitched to allow for drainage.

• Drain pan and drain tubing has been leak checked.

• Return and supply ducts are sealed.

• Unit is elevated when installed in a garage or where flammable vapors may be present.

• Unit is protected from vehicular or other physical damage.

• Return air is not obtained from any areas where there may be objectionable odors, flammable vapors or products of combustion such as carbon monoxide (CO), which may cause serious personal injury or death.

22 Regular Maintenance

HIGH VOLTAGE!

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

The only item to be maintained on a regular basis by the user is the circulating air filter(s). Filter should be cleaned or replaced regularly. A certified service technician must perform all other services.

NOTE: THESE INSTRUCTIONS ARE SPECIFICALLY FOR AVPTC MODELS. DO NOT USE THESE DIAGRAMS FOR ANY OTHER MODELS. SEE SEPARATE INSTALLATION AND OPERATING INSTRUCTIONS FOR ATUF, ARUF, ARPT, ADPF, AND ASPF MODELS.

NOTICE: THIS PRODUCT CONTAINS ELECTRONIC COMPONENTS WHICH REQUIRE A DEFINITE GROUND. PROVISIONS ARE MADE FOR CONNECTION OF THE GROUND. A DEDICATED GROUND FROM THE MAIN POWER SUPPLY OR AN EARTH GROUND MUST BE PROVIDED.

Page 20

23 Communications Troubleshooting Chart

LED LED

Status

1 Flash

Red

Communications

LED

2 Flashes

1 Steady

Flash

Green Receive

LED

Rapid

Flashing On Solid

Off

Indication Possible Causes Corrective Action(s) Notes & Cautions

• Normal condition • None • None • None

• Communications

Failure

• Out-of-box reset • Control power up

• No power

• Communications

error

• No network found • Broken/ disconnected

• Normal network

traffic

• Data 1/ Data 2 miss-wire

• Communications Failure

• Learn button depressed

• No power to air handler

• Open fuse

• Communications error

data wire(s)

• Air handler is installed as a legacy/ traditional system

• Control is “talking” on network as expected

• Data 1 and data 2 wires reversed at air handler, thermostat, or CT™ compatible outdoor AC/HP

• Short between data 1 and data 2 wires

• Short between data 1 or data 2 wires and R (24VAC) or C (24VAC common)

• Depress Learn Button

• Verify that bus BIAS

and TERM dipswitches are in the ON position.

• None • None

• Check fuses and

circuit breakers; replace/reset

• Replace blown fuse

• Check for shorts in

low voltage wiring in air handler/system

• Reset network by depressing learn button

• Check data 1/ data 2 voltages

• Check communications wiring (data 1/ data 2 wires)

• Check wire connections at terminal block

• Verify air handler installation type (legacy/ traditional or communicating)

• Check data 1/ data 2 voltages

• None • None

• Check

communications wiring (data 1/ data 2 wires)

• Check wire connections at terminal block

• Check data 1/ data 2 voltages

• Depress once quickly for a powerup reset

• Depress and hold for 2 seconds for an out-of-box reset

• Turn power OFF prior to repair

• Verify wires at terminal blocks are securely twisted together prior to inserting into terminal block

• Verify data1 and data voltages as described above

• Turn power OFF prior to repair

• Verify wires at terminal blocks are securely twisted together prior to inserting into terminal block

• Verify data1 and data voltages as described above

Page 21

24 Air Handler Advanced Features Menu

CONFIGURATION

Submenu Item

Electric Heat Size (HTR KW)

Motor HP (1/2, 3/4, or 1 MTR HP)

Heat ON Delay (HT ON) Displays the electric heat indoor blower ON delay.

Heat OFF Delay (HT OFF) Dis plays the elec tric heat indoor blower OFF delay.

Submenu Item Indication/User Modifiable Options Comments

Fault 1 (FAULT #1) Most recent modular fault For display only

Fault 2 (FAULT #2) Next most recent modular fault For display only

Fault 3 (FAULT #3) Next most recent modular fault For display only

Fault 4 (FAULT #4) Next most recent modular fault For display only

Fault 5 (FAULT #5) Next most recent modular fault For display only

Fault 6 (FAULT #6) Least recent modular fault For display only

Clear Fault History (CLEAR) NO or YES Selecting “YES” clears t he fault history

Consecutively repeated faults are shown a maximum of 3 times

NOTE:

Displays t he size in kW of the selected elec tric heaters.

Displays t he air handler indoor blower motor horsepower.

Indication (for Display Only; not Use r Modifiable)

DIAGNOSTICS

IDENTIFICATION

Submenu Item

Model Number (MOD NUM) Displays t he modular blower model number

Serial Number (SER NUM) Displays the modular blower serial number (Optional)

Software (SOFTWARE) Displays the application software revision

Submenu Item Use r Modifia ble Options Comments

Heat Airflow Trim (HT TRM) -10% to +10% in 2% increments, default is 0%

Submenu Item

Mode (MODE) Displays t he current air handler operating mode

CFM (CFM) Displays the airflow for the current operating mode

Indication (for Display Only; not Use r Modifiable)

SET-UP

STATUS

Indication (for Display Only; not Use r Modifiable)

Trims the heating airflow by the selected amount.

Page 22

25 Troubleshooting

Notes & Cautions

Corrective Actions

Possible Causes

x Normal operation x None x Normal operation

x Turn power OFF prior to

x Verify electric heat dipswitch

x Heater kit selected via

repair.

x Use memory card for

settings

x Verify the installed electric

dipswitches is too large for

heater kits in shared data set

the specific model.

heater is valid for the air

BEFORE turning power

x Insert memory card

handler blower. Check

nameplate or Specification

ON. Memory card may

Sheet applicable to your

be removed after data is

loaded.

model* for allowable heater

kit(s).

x Turn power off before

x Verify shared data set is

repair.

the specific model.

BEFORE turning power

ON. Memory card may

be removed after data is

removing memory card.

x Turn power OFF prior to

x Use memory card for

x Insert memory card

correct for the specific model.

Re-populate data using

correct memory card if

required.

settings

heater is valid for the air

dipswitches is too small for

x Verify the installed electric

heater kits in shared data set

handler blower. Check

x Verify electric heat dipswitch

x Heater kit selected via

loaded.

removing memory card.

x Turn power off before

nameplate or Specification

Sheet applicable to your

model* for allowable heater

kit(s).

correct for the specific model.

Re-populate data using

x Verify shared data set is

repair.

the specific model.

BEFORE turning power

ON. Memory card may

be removed after data is

loaded.

removing memory card.

x Turn power OFF prior to

x Use memory card for

x Insert memory card

settings

heater is valid for the air

handler blower. Check

nameplate or Specification

Sheet applicable to your

correct memory card if

required.

x Verify electric heat dipswitch

x Verify the installed electric

dipswitches is doesn’t match

heater kits in shared data set

x Heater kit selected via

model* for allowable heater

x Turn power off before

kit(s).

correct for the specific model.

Re-populate data using

x Verify shared data set is

correct memory card if

required.

service.

x Turn power OFF prior to

service

x Check overflow pan and

evaporation coil.

x High water level in the

ComfortNet™

None None

Thermostat Only

Message Code

HTR TOO

Fault Description

x Heater kit selected via

x Normal operation

Codes

Characters

Will Alternate

7-Segment LED

LARGE

dipswitches is too

large for heater kits

specified in shared

SMALL

HTR TOO

data set

x Heater kit selected via

dipswitches is too

small for heater kits

specified in shared

data set

MATCH

NO HTR

dipswitches does not

heater kits specified in

x Heater kit selected via

shared data set

Fault

Aux Alarm

x Aux switch open

Symptoms of Abnormal Operation

(Legacy & ComfortNet™ Thermostat)

call for W1 or Auxiliary/Emergency

heat

provides the indicated error code.

Service” icon illuminated

x LED display is ON continuously

x Electric heaters fail to energize on a

x Integrated control module LED display

“Check Air Handler” message

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

x Electric heat airflow is higher than

expected on a call for W1 or

Auxiliary/Emergency heat

x Integrated control module LED display

provides the indicated error code.

expected on a call for W1 or

Auxiliary/Emergency heat

x Electric heat airflow is higher than

provides the indicated error code.

x Integrated control module LED display

EF error code.

x ComfortNet™ thermostat “Call for

Service”.

Page 23

25 Troubleshooting (Sheet 2 of 4)

repair.

control module fuse with

3A automotive fuse.

control module with

correct replacement part

x Turn power OFF prior to

x Replace integrated

volt power to air handler

blower and integrated control

module.

x Assure 208/230 volt and 24

Possible Causes Corrective Actions Notes & Cautions

or 24 volt wire improperly

x Manual disconnect switch OFF

module fuse (3A). Replace if

x Check integrated control

connected or loose

an internal fault

x Blown fuse or circuit breaker

x Integrated control module has

“Electrostatic Discharge”

x Read precautions in

necessary.

208/230 volt and 24 volt

circuits. Repair as necessary.

x Check for possible shorts in

section of manual.

x Replace bad integrated

control module.

repair

the specific model.

x Turn power OFF prior to

x Use memory card for

using memory card.

x Populate shared data set

contain any shared data.

x Air handler blower does not

repair

BEFORE turning power

ON. Memory card may

be removed after data is

loaded.

cleared once data is

loaded.

x Insert memory card

x Error code will be

x Turn power off before

removing memory card

the specific model.

x Turn power OFF prior to

x Use memory card for

set using memory card.

x Populate correct shared data

contain an appropriate shared

data set.

x Air handler blower does not

BEFORE turning power

ON. Memory card may

be removed after data is

x Insert memory card

loaded.

x Error code will be

cleared once data is

loaded.

x Turn power OFF prior to

x Verify shared data set is

x Shared data set on memory

repair

x Use memory card for

correct for the specific model.

Re-populate data using

card has been rejected by

integrated control module

the specific model.

BEFORE turning power

ON. Memory card may

be removed after data is

loaded.

cleared once data is

loaded.

x Insert memory card

correct memory card if

required.

x Error code will be

x Turn power off before

removing memory card

ComfortNet™

Thermostat Only

Codes

7-Segment LED

FAULT

Message Code

INTERNAL

Fault Description

to air handler blower

x No 208/230 volt power

No Display

Characters

Will Alternate

or no 24 volt power to

integrated control

module

breaker

x Blown fuse or circuit

DATA

NO NET

module has an internal

fault.

x Integrated control

x Data not yet on

network.

INVALID

x Invalid data on

DATA

network.

INVALID

x Invalid memory card

MC DATA

data.

Symptoms of Abnormal Operation

(Legacy & ComfortNet™ Thermostat)

provides no signal.

Service” icon illuminated

x ComfortNet™ thermostat “Call for

“Check Air Handler” message

x ComfortNet™ thermostat scrolls

x Air handler blower fails to operate

x Integrated control module LED display

provides indicated error code.

x Air handler blower fails to operate.

x Integrated control module LED display

Service” icon illuminated.

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

provides indicated error code.

Service” icon illuminated.

x Air handler blower fails to operate.

x Integrated control module LED display

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

operation.

provides indicated error code.

Service” icon illuminated.

x Operation different than expected or no

x Integrated control module LED display

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

Page 24

25 Troubleshooting (Sheet 3 of 4)

Notes & Cautions

Corrective Actions

Possible Causes

x Turn power OFF prior to

x Tighten or correct wiring

x Loose wiring connection at

repair

x Replace circulator motor

connection.

x Check circulator blower

circulator motor power leads

or circulator motor power

with correct

replacement part.

motor. Replace if necessary.

leads disconnected.

x Failed circulator blower motor.

repair

x Turn power OFF prior to

connection.

x Tighten or correct wiring

circulator motor control leads.

x Loose wiring connection at

with correct

replacement part.

x Replace circulator motor

motor. Replace if necessary.

x Check circulator blower

x Check integrated control

module.

x Failed circulator blower motor.

x Failed integrated control

control module with

x Replace integrated

module. Replace if

necessary.

correct replacement

part.

x Turn power OFF prior to

x Verify circulator blower motor

x Incorrect circulator blower

repair

x Replace motor with

horse power is the same

specified for the specific air

motor in air handler blower.

x Incorrect shared data set in

correct replacement

part.

x Use memory card for

handler blower model.

Replace is necessary.

x Verify shared data set is

integrated control module.

the specific model

x Insert memory card

correct for the specific model.

Re-populate data using

for installation requirements.

x See "Installation Instructions"

x Turn power OFF prior to

x Check filters, filter

x Abnormal motor loading,

repair.

grills/registers, duct system,

and air handler blower/coil air

sudden change in speed or

torque, sudden blockage of air

inlet/outlet for blockages.

handler blower/coil air inlet or

outlet.

x High loading conditions,

blocked filters, very restrictive

ductwork, blockage of air

handler blower/coil air inlet or

outlet.

BEFORE turning power

ON. Memory card may

be removed after data is

loaded.

cleared once shared

data and motor horse

power match.

removing memory card

x Error code will be

correct memory card if

required.

x Turn power off before

x Turn power OFF prior to

x Check filters for blockage.

x Blocked filters.

repair.

Clean filters or remove

obstruction.

x Restrictive ductwork.

x Undersized ductwork.

x Check ductwork for blockage.

x High ambient temperatures.

Remove obstruction. Verify

all registers are fully open.

x Verify ductwork is

appropriately sized for

system. Resize/replace

ductwork if necessary.

ComfortNet™

Thermostat Only

MOTOR

Message Code

NOT RUN

Fault Description

motor is not running

x Circulator blower

Codes

Characters

Will Alternate

7-Segment LED

when it should be

running.

MOTOR

x Integrated control

COMM

module has lost

MOTOR

MISMATCH

communications with

circulator blower

motor.

x Circulator blower

motor horse power in

shared data set does

not match circulator

blower motor horse

power.

MOTOR

x Circulator blower

LIMITS

motor is operating in a

power, temperature, or

speed limiting

condition.

MOTOR

x Circulator blower

TRIPS

motor senses a loss

rotor control.

x Circulator blower

motor senses high

current.

Symptoms of Abnormal Operation

(Legacy & ComfortNet™ Thermostat)

provides indicated error code.

Service” icon illuminated.

“Check Air Handler” message.

provides indicated error code.

Service” icon illuminated.

x Air handler blower fails to operate.

x Integrated control module LED display

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

x Air handler blower fails to operate.

x Integrated control module LED display

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

provides indicated error code.

Service” icon illuminated.

x Air handler blower fails to operate.

x Integrated control module LED display

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

performance.

x Air handler blower operates at reduced

provides b3 error code.

x Airflow delivered is less than expected.

x Integrated control module LED display

provides indicated error code.

Service” icon illuminated.

x Air handler blower fails to operate.

x Integrated control module LED display

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

Page 25

25 Troubleshooting (Sheet 4 of 4)

Notes & Cautions

Corrective Actions

Possible Causes

repair

x Turn power OFF prior to

obstructions. Remove and

x Check circulator blower for

blower housing.

x Obstruction in circulator

correct replacement

part.

x Replace motor with

repair/replace wheel/motor if

necessary.

x Check circulator blower motor

bearings.

x Seized circulator blower motor

x Failed circulator blower motor.

repair.

correct replacement

part.

x Turn power OFF prior to

x Replace wheel with

blower. Verify line voltage to

blower is within the range

specified on the air handler

blower rating plate.

hander blower.

x High ambient temperatures.

for installation requirements.

x See "Installation Instructions"

shaft rotation and motor.

Replace motor if necessary.

x Check power to air handler

handler blower.

x High AC line voltage to air

x Low AC line voltage to air

repair.

x Turn power OFF prior to

module. Verify control is

x Check integrated control

module.

x Error with integrated control

x Replace with correct

populated with correct shared

x Motor has a locked rotor

replacement part(s).

x Use memory card for

data set. See data errors

above for details.

condition.

the specific model.

x Check for locked rotor

BEFORE turning power

ON.

removed after data is

x Memory card may be

loaded

x Insert memory card

condition (see error code

above for details).

x Turn power off before

repair.

removing memory card.

x Turn power OFF prior to

Clean filters or remove

obstruction.

Remove obstruction. Verify

all registers are fully open.

appropriately sized for

system. Resize/replace

x Check filters for blockage.

x Blocked filters.

x Restrictive ductwork.

x Check ductwork for blockage.

x Undersized ductwork.

ductwork if necessary.

x Verify ductwork is

ComfortNet™

MTR

Thermostat Only

LCKD

Message Code

Fault Description

motor fails to start 10

x Circulator blower

Codes

Characters

Will Alternate

7-Segment LED

ROTOR

consecutive times.

MOTOR

x Circulator blower

VOLTS

motor shuts down for

over or under voltage

condition.

x Circulator blower

motor shuts down due

to over temperature

condition on power

module.

MOTOR

x Circulator blower

PARAMS

motor does not have

enough information to

LOW ID

AIRFLOW

operate properly.

Motor fails to start 40

consecutive times.

demanded.

x Airflow is lower than

Symptoms of Abnormal Operation

(Legacy & ComfortNet™ Thermostat)

provides indicated error code.

Service” icon illuminated.

x Air handler blower fails to operate.

x Integrated control module LED display

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

provides indicated error code.

Service” icon illuminated.

x Air handler blower fails to operate.

x Integrated control module LED display

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

provides indicated error code.

Service” icon illuminated.

x Air handler blower fails to operate.

x Integrated control module LED display

“Check Air Handler” message.

x ComfortNet™ thermostat “Call for

x ComfortNet™ thermostat scrolls

x Air handler blower operates at reduced

performance or operates on low stage

when high stage is expected.

provides indicated error code.

x Integrated control module LED display

Page 26

26 Diagnostic Codes

7 SEGMENT LED

(characters will

alternate)

(no di s play) INTE RNAL CONTROL F AULT / NO POW E R

DESCRIPTION OF CONDITION

On STANDBY, WAITING FOR INPUTS

Ed HEATER KIT DIP SWITCHES NOT SET PROPERLY Eb NO HTR KIT INSTALLED - SYSTEM CALLING FOR AUXILIARY HEAT E5 FUSE OPEN

EF AUXILIARY SWITCH OPEN

d0 DATA NOT ON NETWORK d1 INVALID DATA ON NETWORK d4 INV ALID ME MORY CA RD DATA b0 BLOWER MOTOR NOT RUNNING b1 BL OW ER MOTOR COMM UNICATION ERROR b2 BLOWER MOTOR HP MISMATCH b3 BLOWER MOTOR OPERATING IN POWER, TEMP., OR SPEED LIMIT b4 BLOWER MOTOR CURRENT TRIP OR LOST ROTOR b5 BLOWER MOTOR ROTOR LOCKED b6 OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP

b7 INCOMPL ETE PARAMETER S E NT TO MOTO R

b9 LOW INDOOR AIRFLOW C1 LOW STAGE COOL - LEGACY MODE ONLY C2 HIGH STAGE COOL - LEGACY MODE ONLY P1 LOW STAGE HEAT PUMP HEAT - LEGACY MODE ONLY P2 HIGH STAGE HEAT PUMP HEAT - LEGACY MODE ONLY

h1 EMERGENCY HEAT LOW - COMMUNICATING MODE ONLY

h2 EMERGENCY HEAT HIGH - COMMUNICATING MODE ONLY

FC FA N CO OL - COMM UNICATING MODE ONLY FH FAN HEAT - COMMUNICATING MODE ONLY

FFAN ONLY H1 ELECTRIC HEAT LOW H2 ELECTRIC HEAT HIGH

DEFROST - COMMUNICATING MODE ONLY

(note: defrost is di splayed as H1 in a legacy setup)

GREEN CFM LED - EACH FLASH REPRESENTS 100CFM (USE FOR AIRFLOW

AP PROXIMATION ONLY) - EXA MPLE : 8 FLASHES = 800CFM

0140A00079-A

Page 27

27 Wiring Diagrams

WARNING

HIGH VOLTAGE!

MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO

DISCONNECT ALL POWER BEFORE SERVICING.

MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

PL1

PL2

6 5

SEE

NOTE 7

40 VA TRANSFORMER, SEE NOTE 1

230 VAC

208 VAC

4 CIRCUIT HEATER

CONNECTOR

SEE NOTE 5

SEE NOTE 6

CONNECTOR

ECM MOTOR

HARNESS

SEE NOTE 6

COOL AF PROFILE

S5 S6 S7 S8

DIP SWITCHES

24 VAC

7 SEGMENT

DIAGNOSTIC

DISPLAY

TRIM ENABLE

DEHUM ENABLE

SEE NOTE 6

HTR KIT(KW)

S10

4 CIRCUIT MOTOR

COM

STATUS

LED

CFM LED

AF SELECT

S2 S3 S4

FAULT

RECALL

TRIM %

TWO-STAGE INTEGRATED CONTROL MODULE

CIRCULATOR BLOWER

1 2

3 4

RX LED

S11

24 V 3 A

SEE NOTE 8

DEHUM

CONT FAN

S13

S12

GRND

COM

FUSE

CAS

GRND

DISCONNECT

24 V THERMOSTAT CONNECTIONS

FUSE 3 A

24V THERMOSTAT CONNECTIONS

MICRO

DEHUM

GRND

INDOOR

AIR

CIRCULATOR

BLWRLEARN

208/230 VAC

W1 (1)

W2 (2)

CAS (1)

CAS (2)

+VDC (1)

RX (2)

TX (3)

GRND (4)

COM

INTEGRATED CONTROL MODULE

24 VAC

HEAT 1 COIL/R1

HEAT 2 COIL/ R2

CONDENSATE SWITCH

GRND

40 VA TRANSFORMER

INDOOR

CIRCULATOR

AIR

BLWR

GRND

NOTES:

1. PLACE RED WIRES ON TRANSFORMER TERMINAL 2 FOR 208 VAC OPERATION.

2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING.

3. IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THIS UNIT MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105°C. USE COPPER CONDUCTORS ONLY.

4. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N.E.C AND LOCAL CODES.

5. TO RECALL THE LAST 6 FAULTS, MOST RECENT TO LEAST RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE IN STANDBY (NO THERMOSTAT INPUTS)

6. RED STATUS LED PROVIDES NETWORK STATUS. GREEN RX LED INDICATES NETWORK TRAFFIC. USE LEARN BUTTON TO RESET NETWORK.

7. DISCARD CONNECTOR PL1 WHEN INSTALLING OPTIONAL HEAT KIT.

8. THE CONDENSATE ALARM SWITCH (CAS) TERMINALS CAN ONLY BE UTILIZED WITH COMMUNICATING MODE SETUPS AND MUST BE ENABLED WITH A COMMUNICATING THERMOSTAT. THIS FEATURE IS NOT OPERATIONAL WITH LEGACY SYSTEMS.

USE N.E.C CLASS 2 WIRE.

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

INTEGRATED CONTROL

LOW VOLTAGE (24V)

LOW VOLTAGE FIELD

HI VOLTAGE (230V)

HI VOLTAGE FIELD

JUNCTION

TERMINAL

INTERNAL TO

EQUIPMENT GRND

FIELD GRND

FIELD SPLICE

RESISTOR

OVERCURRENT

PROT. DEVICE

PLUG CONNECTION

COLOR CODES: PK ---- PINK

BR ---- BROWN WH ---- WHITE BL ---- BLUE

GY ---- GRAY

RD ---- RED

YL ---- YELLOW OR ---- ORANGE

PU ---- PURPLE

GN ---- GREEN

BK ---- BLACK

0140A00244-B

Page 28

27 Wiring Diagrams

3-Phase Heat Kit

WARNING

HIGH VOLTAGE!

MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

DISCONNECT ALL POWER BEFORE SERVICING.

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

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AIR HANDLER

AIR HANDLER HOMEOWNER’S ROUTINE MAINTENANCE RECOMMENDATIONS

We strongly recommend a bi-annual maintenance checkup be performed before the heating and cooling seasons begin by a qualified servicer.

REPLACE OR CLEAN FILTER

IMPORTANT NOTE: Never operate unit without a filter installed as dust and lint will build up on internal parts resulting in loss of

efficiency, equipment damage and possible fire. An indoor air filter must be used with your comfort system. A properly maintained filter will keep the indoor coil of your comfort

system clean. A dirty coil could cause poor operation and/or severe equipment damage. Your air filter or filters could be located in your furnace, in a blower unit, or in “filter grilles” in your ceiling or walls. The installer of your

air conditioner or heat pump can tell you where your filter(s) are, and how to clean or replace them. Check your filter(s) at least once a month. When they are dirty, replace or clean as required. Disposable type filters should be replaced.

Reusable type filters may be cleaned. You may want to ask your dealer about high efficiency filters. High efficiency filters are available in both electronic and non-electronic

types. These filters can do a better job of catching small airborne particles.

MOTORS

Indoor and outdoor fan motors are permanently lubricated and do not require additional oiling.

ALUMINUM INDOOR COIL CLEANING (QUALIFIED SERVICER ONLY)

This unit is equipped with an aluminum tube evaporator coil. The safest way to clean the evaporator coil is to simply flush the coil with water. This cleaning practice remains as the recommended cleaning method for both copper tube and aluminum tube residential evaporator coils.

It has been determined that many coil cleaners and drain pan tablets contain corrosive chemicals that can be harmful to aluminum tube and fin evaporator coils. Even a one-time application of these corrosive chemicals can cause premature aluminum evaporator coil failure. Any cleaners that contain corrosive chemicals including, but not limited to, chlorine and hydroxides, should not be used.

An alternate cleaning method is to use one of the products listed in TP-109* to clean the coils. The cleaners listed are the only agents deemed safe and approved for use to clean round tube aluminum coils. TP-109 is also available on the web site in Partner Link > Service Toolkit.

NOTE: Ensure coils are rinsed well after use of any chemical cleaners.

BEFORE YOU CALL YOUR SERVICER

• Check the thermostat to confirm that it is properly set.

• Wait 15 minutes. Some devices in the outdoor unit or in programmable thermostats will prevent compressor operation for awhile, and then reset automatically. Also, some power companies will install devices which shut off air conditioners for several minutes on hot days. If you wait several minutes, the unit may begin operation on its own.

• Check the electrical panel for tripped circuit breakers or failed fuses. Reset the circuit breakers or replace fuses as necessary.

• Check the disconnect switch near the indoor furnace or blower to confirm that it is closed.

• Check for obstructions on the outdoor unit . Confirm that it has not been covered on the sides or the top. Remove any obstruction that can be safely removed. If the unit is covered with dirt or debris, call a qualified servicer to clean it.

• Check for blockage of the indoor air inlets and outlets. Confirm that they are open and have not been blocked by objects (rugs, curtains or furniture).

• Check the filter. If it is dirty, clean or replace it.

• Listen for any unusual noise(s), other than normal operating noise, that might be coming from the outdoor unit. If you hear unusual noise(s) coming from the unit, call a qualified servicer.

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CUSTOMER FEEDBACK

We are very interested in all product comments. Please fill out the feedback form on one of the following links:

Goodman® Brand Products: (http://www.goodmanmfg.com/about/contact-us). Amana® Brand Products: (http://www.amana-hac.com/about-us/contact-us). You can also scan the QR code on the right for the product brand you purchased to be directed to the feedback page.

PRODUCT REGISTRATION

Thank you for your recent purchase. Though not required to get the protection of the standard warranty, registering your product is a relatively short process, and entitles you to additional warranty protection, except that failure by California and Quebec residents to register their product does not diminish their warranty

rights.

For Product Registration, please register as follows: Goodman® Brand products: (https://www.goodmanmfg.com/product-registration). Amana® Brand products: (http://www.amana-hac.com/product-registration) You can also scan the QR code on the right for the product brand you purchased to be directed to the Product Registration page.

GOODMAN® BRAND

AMANA® BRAND

5151 San Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com - or - www.amana-hac.com