Lennox Harmony III Installation Instructions Manual

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INSTALLATION INSTRUCTIONS

E2011 Lennox Industries Inc.

Dallas, Texas, USA

Table of Contents

GENERAL

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Dehumidification Accessories 2. . . . . . . . . . . . . . . .

Residential Zone Control System − Field Wiring 3. . . . . . . . .

System Components (included & separately ordered) 4. . . .

Installation planning & selecting heat/cool equipment 5. . . .

Installing Zone Control Components 6. . . . . . . . . . . . . . . . . . .

Zone Control Panel Jumpers:

General Information 8 Air Reduction 9 Air Reduction 9 Heat/Cool Staging 10

SYSTEM Configuration/E−Heat Stages 11

Common System Component Wiring 12. . . . . . . . . . . . . . . . . .

Zone Control Transformer Phasing 13. . . . . . . . . . . . . . . . . . . .

Component Specific Wiring 13. . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum CFM in Variable Speed Furnaces 14. . . . . . . . . . . . .

System Flow Diagrams 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEAT PUMP

Installing Heat Pump and accessories 16. . . . . . . . . . . . . . . . .

Zone control system wiringHeat Pump 17. . . . . . . . . . . . . . .

Heat Pump System Startup and Checkout 18. . . . . . . . . . . . . .

Heat Pump Heating Checkout − Single Zone 18

Heat Pump Heating Checkout − Multiple Zone 19

Heat Pump Heating Checkout − Central Control 19

Heat Pump Pressure Switch Checkout 20 Troubleshooting:

Zoning system with Heat Pump 21. . . . . . . . . . . . . . . . . . . .

HP Heating Operation 22

Defrost Operation 23

GAS FURNACE

Zone control system wiringGas Furnace 24. . . . . . . . . . . . .

G71MPP/SLP98/SL280V/EL296V:

Integrated Control Electrical Adjustments 25

System operation 26

Installation setup worksheet 27 G61MPV/G60UHV:

Integrated Control Electrical Adjustments 28. . . . . . . . . . . .

System Operation 30

Installation setup worksheet 32

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Harmony IIIt Zoning System

ZONING

505,023M 08/11 Supersedes 01/11

Litho U.S.A.

Retain These Instructions For Future Reference

IMPORTANT

Variable Speed Blower Motor (VSM) technology is required for use with Lennox Harmony IIIt Zone Control Systems.

Only technicians qualified for zoning installations should perform the equipment setup in this manual.

Gas Furnace Start−Up & Checkout:

Gas Heating Checkout − Single Zone 33. . . . . . . . . . . . . . .

Gas Heating Checkout − Multiple Zone 34 Gas Heating Checkout − Central Control 34

Troubleshooting:

Zoning system with Gas Furnace 35 Gas Heating Operation 36 Discharge Air Upper Limit & Differential Temp. 37

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AIR HANDLERS

Variations on common condensing unit applications:

Electric Heat, Hot Water Coil, Cooling Only 38. . . . . . . . . .

Air Handler Settings (All applicable models) 39. . . . . . . . . . . .

Installation Setup Worksheets:

CBX32MV/CBX40UHVCooling/Heating; Electric

Strip Heat (non−HP appls) 40. . . . . . . . . . . . . . . . . . . . . . . . .

CBX32MV/CBX40UHVHeat Pump; Electric Strip Heat 41

CBX32MV/CBX40UHV – Cooling Only or Cooling

with Hot Water Coil (non−HP appls) 42. . . . . . . . . . . . . . . . .

DUAL FUEL

Zone control system wiringDual Fuel 43. . . . . . . . . . . . . . . .

Dual Fuel Startup & Checklist 44. . . . . . . . . . . . . . . . . . . . . . . .

Gas Heating Checkout − Single Zone 44. . . . . . . . . . . . . . .

Gas Heating Checkout − Multiple Zone 45

Gas Heating Checkout − Central Control 46 Troubleshooting:

Zoning system with Dual Fuel 47

Dual Fuel Operation (Below Balance Point) 48

Discharge Air Upper Limit & Differential Temperatures 49

Dual Fuel Operation (Above Balance Point) 50

Defrost Operation 51 Installation Setup Worksheets:

G61MPV/G60UHV Dual Fuel; with

Honeywell 2−stage IFC control (HP appls) 52. . . . . . . . . . .

G71MPP/SLP98/SL28V0/EL296V Dual Fuel (HP appls) 53

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TROUBLESHOOTING

Operation & Troubleshooting Indicators 54. . . . . . . . . . . . . . . .

Fault Recall. Time Delays, Time Delay Override 55. . . . . . . . .

Diagnostics Codes 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Air Delivered by Blower 58. . . . . . . . . . . . . . .

PIAB Calculation Worksheet 60. . . . . . . . . . . . . . . . . . . . . . . . .

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08/11 505,023M (#10009243)

*2P0811* *P505023M*

Page 1

GENERAL

Shipping & Packing List

Items shipped with the Harmony IIIt Zone Control System include:

1 − Harmony IIIt Zone Control System unit 1 − Discharge Air Sensor

Additional itemsordered separately; include (see System Components on Page 4):

S Transformer S Dampers S Thermostats S Balance Point Sensor kit (56A87) S Pressureswitch (For Heat Pump Option):

HFC−22 (27W12); HFC−410A (27W13)

S Tee for vapor line High Pressure Switch (87071) S Defrost Tempering Kit (67M41) S Humiditrol

EDA−024B (94M41), EDA−036C (94M42), EDA−060D (94M43)

S Humiditrol

if Humiditrol

Enhanced Dehumidification Accessory (EDA),

Zoning Accessory (HZA) Kit (39W67) (required

EDA, above, is used)

Introduction

The Lennox Harmony IIIt Zone Control System manages the distribution of conditioned air to specific areas or zones in a house or small commercial building by directing heated or cooled air to occupied areas without conditioning unused areas. This improves economy while providing a balanced and comfortable environment. The system can be used in the following Lennox HVAC system applications:

Option 1.Variable speed gas furnace used with a 2-stage

condensing unit.*

Option 2.Variable speed air handler unit (with or without

electric heat) used with a 2-stage condensing unit or heat pump.*

Option 3.Variable speed gas furnace used with a 2-stage

heat pump.*

*A 1 stage condensing unit (heat pump) may be used under specific circumstances as listed in Table 3 (see Page 5).

Variations on the options described above and included in this document are: cooling−only, hot water coil, and cooling system with electric heat applications.

The Harmony IIIt zone control system uses off−the−shelf, single-stage, non-heat pump, non−power-robbing electronic thermostats and motorized dampers in any of the applications to control distribution of conditioned air to different zones. This control allows conditioning of different zones within a residence while using a single HVAC system.

The zone control system operates in two modes: central control (vacation mode) or zone control. LEDs on the zone control panel indicate the current operating mode.

When the system is in the central control mode, a de- mand from the central control thermostat results in conditioned air being directed to all of the zones. In this mode, zone 1 thermostat is designated as the controlling thermostat; other thermostats are not used.

When the system is in the zone control mode, a zone is conditioned only upon demand from that zone’s thermostat.

The zone control system is ideal for retrofit applications as well as new construction. The system controls the air volume, eliminating the need for bypass dampers in most applications. The homeowner controls the system using zone thermostats to make comfort settings for each zone.

A programmable thermostat should be used to provide a specialized heating and cooling sequence. While the system is in the zone mode, a programmable thermostat controls the temperature for its particular zone.

Optional Dehumidification Accessories

The Harmony IIIt zone control system may be used in conjunction with a Humiditrol® Enhanced Dehumidification Accessory (EDA) and which also requires a Humiditrol® Zoning Accessory (HZA). This document reflects the control which is outfitted for connection to, and control of, the EDA in a zone control system using the HZA. See Humiditrol Zoning Accessory Installation Instructions for more information.

505023M 08/11

Page 2

Residential Zone Control System − Overview of Field Wiring

THERMOSTAT (ZONE 1 OR CENTRAL CONTROL

THERMOSTAT WHEN IN VACATION MODE)

ZONE 1

GENERAL

ZONE 2

THERMOSTAT

(ZONE)

ZONE DAMPER

POWER

HUMIDITROL® ENHANCED DEHUMIDIFICATION ACCESSORY

OPTIONAL

TRANSFORMER TO POWER

ZONE CONTROL PANEL, THER-

MOSTATS AND DAMPERS;

ALSO POWERS HZA CONTROL

WHEN EDA IS USED)

HUMIDITROL ZONING ACCESSORY (HZA)

THERMOSTAT

(ZONE)

ZONE DAMPER

*ZONE 3

LEGEND −

A Five wire low voltage  18 ga. minimum B Two wire low voltage OR Three wire if Power−open, Power−closed  18 ga. minimum C INDOOR UNIT: Up to nine wire low voltage  18 ga. minimum D OUTDOOR UNIT:

− Two (3, if LSOM equipped unit) wire low voltage (single-stage condensing unit or EDA) 18 ga. minimum

− Three (4, if LSOM equipped unit) wire low voltage (two-stage condensing unit) 18 ga. minimum

− Up to seven wire low voltage (single-stage heat pump outdoor unit) 18 ga. minimum

− Up to eight wire low voltage (two-stage heat pump outdoor unit) 18 ga. minimum

E Two wire low voltage (discharge air sensor) 18 ga. minimum F Two wire low voltage (pressure switch, heat pump only)  18 ga. minimum G Two wire  18 ga. minimum H Refer to the Humiditrol® Zoning Accessory (HZA) for wiring requirements.

ZONE CONTROL SYSTEM PANEL

*NOTE − Zone 3 and zone 4 not available with single-stage outdoor unit.

*ZONE 4

ZONE DAMPER

CONDENSING

UNIT OR HEAT

PUMP OUTDOOR UNIT

DISCHARGE

AIR SENSOR

VARIABLE SPEED

FURNACE OR AIR

HANDLER

THERMOSTAT

(ZONE)

ZONE DAMPER

OUTDOOR

THERMOSTAT /

BALANCE

POINT SENSOR

Page 3

HARMONY IIIT ZONE CONTROL SYSTEM

GENERAL

System Components

The Harmony IIIt zone control system consists of the following (n − required):

n Harmony Harmony IIIt zone control panel (included) n Discharge Air sensor (included) n Thermostats (1 for each zone; ordered separately) n 24VAC Power Transformer(s) (ordered separately) n Dampers (ordered separately) n Pressure Switch and Tee w/Schrader valve (for Heat Pump

systems; ordered separately)

S Balance Point Sensor (Optional for Dual Fuel systems) S Defrost Tempering Kit (Optional for Dual Fuel systems) S Remote Vacation Switch (optional; ordered separately)

Zone Control System

The Harmony IIIt zone control system monitors electrical signals and directs control signals between thermostats, dampers, and HVAC equipment (see figure 1).

DAMPER CONNECTIONS

Figure 1. Harmony IIIt Zone Control Panel

Discharge Air Sensor (DAS)

A discharge air temperature sensor (88K38) monitors the supply air. This electronic sensor’s probe is inserted into the discharge air plenum to gather air temperature data for the zone control panel. Figure 2 shows the kit; see figure 3 (Page 6) for location of the sensor.

TEMPERATURE/RESISTANCE CHART TEMP ºF RESISTANCE (OHMS)

PRESSURE SWITCH CONNECTIONS

REDUCTION

REMOTE VACATION SWITCH; CONNECTIONS FOR HZA

30 34,566 40 26,106 50 19,904 60 15,313 70 11.884 80 9,298 90 7,332 100 5,826

JUMPERS:

STAGING

TEMP‘

HEATING−−

COOLING−−

AIR

CONT.−−

HEATING−−

DISCHARGE AIR SENSOR CONNECTIONS

TIME DELAY OVER-

RIDE

SYSTEM OPERATION LEDS

THERMOSTAT CONNECTIONS

OUTDOOR THERMOSTAT / BALANCE POINT SENSOR CONNECTIONS

PIAB

JUMPERS

SYS CONFIG & E−HEAT JUMPERS

FAULT RECALL

DIAGNOSTIC

LEDS

Figure 2. Discharge Air Sensor

24VAC CONNECTIONS

FUSES

EQUIPMENT

CONNECTIONS

Thermostats

IMPORTANT

Use only Electronic thermostats. Mechanical or electro-mechanical thermostats will not work with the Harmony IIIt zone control system.

For all zones, use thermostats that are of this type:

S electronic thermostat S single-stage S non-heat pump S non-power robbing S autochangeover or non−autochangeover S Lennox recommends that zone 1 thermostat (central [vaca-

tion] mode controller) be programmable.

S Each thermostat must have a deadband between HEAT and

COOL.

Recommended thermostats include:

S ComfortSenset 7000 model L7742U Touch Screen Ther-

mostat. (IMPORTANT! When using this thermostat, only Precision Mode dehumidification can be used wherein 2°F of over-cooling is allowed. Also, it cannot reduce the blower speed because the zone control DS signal controls the blower. Thermostat D terminal is not used.

S ComfortSenset 5000 model L5711U Touch Screen Ther-

mostat − 1 heat / 1 cool / 7−day programmable.

Transformer

The dampers, zone control panel, zone thermostats and Humiditrol® Zoning Accessory (if EDA is used) are powered by a single, field−provided 24VAC transformer. Together, the zone control panel and thermostats require 10VA; dampers require 10VA each. The transformer must have an adequate VA rating to serve all components (see recommendations in table 1).

IMPORTANT

Up to 5 dampers per zone may be connected in parallel to the zone control panel not to exceed a total of six dampers for entire system.

Also, if more than 6 dampers are used, another transformer and isolation relay will be necessary.

Table 1. 24VAC Transformer selection chart

Catalog Number

10P17 40VA 120/208/240VAC, 24VAC 3 dampers

10P87 50VA 120/208/240VAC, 24VAC 4 dampers

12P61 75VA 120/208/240VAC, 24VAC 6 dampers

83P74 _ Electrical Box (4-in. square)

Size Description

VA LOAD = Panel plus−

505023M 08/11

Page 4

System Components (Continued)

Dampers

Motorized 24VAC powered closed/spring return open dampers are standard for the Harmony IIIt zone control system. However, power-open/spring-close" and poweropen/power-close" dampers can be accommodated.

Remote Vacation Switch

The Harmony IIIt zone control panel includes connections for an optional remote vacation switch (see figure 1). The same connections are also used for connecting an op-

tional Humiditrol

Zoning Accessory Installation Instructions for de-

ditrol

tails).

NOTE − If a remote vacation switch is connected for routing to a convenient location for end user operation, be sure the switch (field-provided) is properly labeled and instructions provided for proper operation.

DO NOT LOCATE THE REMOTE VACATION SWITCH NEXT TO OTHER HOUSE SWITCHES! THE RECOMMENDED LOCATION IS NEXT TO ZONE 1 THERMOSTAT.

Zoning Accessory controller (see Humi-

Installation planning & selecting heating and cooling equipment

GENERAL

Installation Considerations

The total HVAC system must be properly sized to provide the best comfort. Also, for best performance, zones should be similar in size so that each zone would require about the same CFM. Each zone’s ducting lengths should be similar in length whenever possible. Always attempt to keep CFM requirements per zone within 25% of the average CFM (see table 2).

If a small" zone cannot be avoided, give consideration to increasing the CFM of the small zone and linking a damper in a nearby zone that will open along with the small zone’s damper(s). The procedure for zone linking is described on Page 7.

Table 2. Adjusting for average CFM Example

Required CFM CFM adjusted to within average

Zn CFM Avg %CFM Adj Avg %CFM

1 500 2 825 1.16 825 1.12 3 775 1.09 775 1.05 4 750 1.05 750 1.02

713

0.70 600

738

0.81

Damper linked

with Zn 2

Variable Speed Blower Motor (VSM)

Indoor units with variable speed blower motors (VSM) are required to allow the zone control system to distribute adequate air to each zone. Use only units recommended in the following 3 options as only those will work with the Harmony IIIt zone control system; other types of units will not allow the Harmony IIIt zone control system to propor- tion the amount of air going to each zone.

Selecting/Installing Indoor and Outdoor Units

Outdoor units may be single or two−stage; use table 3 to determine which to use, based on the number of zones being implemented, and whether the air conditioned zones are of equal or unequal size.

Option 1

Lennox Gas Furnace with VSM only (G60UHV, G61MPV,

G71MPP, SLP98, SL280V, E296V).

S Lennox Condensing Unitas described in table 3.

Option 2

Lennox Air Handler Unit with VSM only (CBX32MV,

CBX40UHV, CB31MV, CBWMV).

S Lennox Heat Pump Unitas described in table 3.

Option 3

Lennox Gas Furnace with VSM only (G60UHV, G61MPV

G71MPP, SLP98, SL280V, E296V).

S Lennox Heat Pump Unit as described in table 3.

NOTE − Limited variations to condensing units described herein are detailed on Page 38.

Table 3. Condensing units / Heat Pump units

No. of zones

2 *Equal Single or Two−stage

2 *Unequal Two-stage only

3 or 4 Equal or Unequal Two-stage only

*Equal zones would have very similar total ducting lengths with CFM requirements within 10% of average CFM per zone. Unequal would have less similar ducting length and greater variances from average CFM (see table 2 example).

Comparative Zone sizes

Lennox Condensing Unit or Heat Pump

Page 5

HARMONY IIIT ZONE CONTROL SYSTEM

GENERAL

Installing Zone Control Components

When possible, position the sensor some distance away from the coil rather than in the immediate coil area. The Discharge Air Temperature Sensor should be located at least 10 inches above the coil.

Fasten the sensor bracket to the plenum with two self- tapping sheet metal screws.

Connect wires to DAS on zone control panel, NOT on the AHC or IFC (see figures 17 through 26).

Be sure that the tip of the sensor is located approximately 10 inches from the indoor coil in the discharge plenum, and 1/2 the depth of the plenum, and centered over the discharge airflow, side-to-side.

PLENUM

1/2

the width

of the

plenum

SENSOR MOUNTING DETAIL

Figure 3. Discharge Air Temperature Sensor installation (Typical Upflow Furnace)

Zone Control Panel

IMPORTANT

The electrical power source for the zone control system, i.e. the transformer primary, and furnace or air handler unit must be the same source. In addition, the zone control system power−up must occur at the same time or before the furnace or air handler unit is powered up.

Select an installation site for the Harmony IIIt control con- sidering the following location parameters:

S Is conveniently accessible and centrally located to facilitate

wiring from thermostats, dampers, pressure switch (if used), and HVAC equipment.

S Is in a non−condensing area (such as a closet). S Is NOT in a laundry room (nor other room in the house where

the humidity would typically be much higher than the rest of the house).

S Is NOT in any part of the building where the temperature may

exceed 150_F.

NOTE 1 − FOR UNITS WITH HUMIDITROLDischarge air sensor (DAS) MUST be located on the output side of the EDA (if used; see Humiditrol Zoning Accessory Installation 505,337M)

(254)

AIR HANDLER

SIDE VIEW

sensor centered in

discharge airflow

(ALSO see note 1)

SENSOR PROBE

see PROBE MOUNTING

DETAIL below

ECB

Electric

Heat

Strips

FURNACE

FRONT

VIEW

plenum

coil

Discharge Air Sensor

CAUTION

This device is manufactured using unpainted and pre-painted metal. Sharp sheet metal edges can cause injury. When installing the device, avoid accidental contact with sharp edges.

Install the discharge air sensor in the discharge plenum downstream from the cooling coil. Be sure that the discharge air will pass over the sensor before the air is distributed into the duct system. Typical upflow sensor applications are shown in figure 3; the sensor dimensions shown (distance from heat strips, coil, and position in plenum) also apply to other applications.

505023M 08/11

Page 6

Thermostats

Identify the best location for a thermostat in each zone. If two or more rooms are within a single zone, place the thermostat in a location that is central to all rooms. For example, if a zone contains two bedrooms, try to place the thermostat in a hallway near both bedrooms.

Do not install thermostats in drafty areas, behind doors, in corners, near radiant heat sources (appliances), near sunny windows, near concealed pipes and chimneys, nor in unconditioned spaces such as closets or exterior walls.

Transformer

Obtain an appropriately−rated transformer (see table 1, Page 4). Install the transformer in either the indoor unit or in an electrical junction box near the zone control panel.

Dampers

NOTE − The power source for the transformer must be the same power source as the indoor unit’s transformer.

Motorized dampers in the supply duct system regulate air to the zones. Some applications will be unique and require more than one damper per zone. If additional dampers are required, refer to the the wiring diagram in the Common System Component Wiring section (page 12). Also, if more than 6 dampers are used, another transformer and isolation relay will be necessary.

For more effective zone isolation, the return duct system may also be dampered by zone. Dampers for each zone must be wired in parallel. Install dampers in the desired locations; then run thermostat wire from the damper to the zone control panel and damper relays as needed.

Zone LinkingZone link a small zone to a large zone by wiring dampers in a manner similar to figure 4. Effectively, this distributes some of the small zone’s air to another zone to reduce the chance of overheating or overcooling

GENERAL

the smaller zone. Table 2 (Page 5) shows an example of an unequal zone and how to adjust to bring it within 25% of the average CFM. Figure 4 shows how the dampers may be linked to distribute some of the air from a small zone into another zone.

ZONE 1

ZONE 2

Zone

Dampers

Sm.Zone

Lg.Zone

Note: Zone Dampers are Power−Close type.

RELAY

Zone Demands to Small and Large Zones

Zone with Demand

None Small Sm.& Lg. Large

Closed (24V) Open (0V) Open (0V) Closed (24V)

Closed (24V) Open (0V) Open (0V) Open (0V)

Closed (24V) Closed (24V) Open (0V) Open (0V)

Figure 4. Zone Linking

DAMPER

This damper is linked to the zone 1 damper; it opens when Zone 1 opens to redirect some air away from Zone 1 and closes only when zone 1 damper closes.

DAMPER

Note: Zone Dampers are Power−Close type.

Zone 1 (smallest zone)

Zone 2 (largest zone)

All Zone 2 dampers open only for calls to Zone 2 calls for air.

Page 7

HARMONY IIIT ZONE CONTROL SYSTEM

GENERAL

Zone Control Panel Jumpers (General Information)

Setup for controlling equipment staging and volume of air to zones

This section provides information for installing jumpers on the zone control panel jumper banks (see figure 5). These jumpers define how the zone control system functions to control equipment staging and to deliver the proper amount of CFM to the zones.

HEATING STAGING

JUMPERS

COOLING STAGING

JUMPERS

CONTINUOUS AIR

REDUCTION JUMPERS

HEATING AIR

REDUCTION JUMPERS

PIAB

JUMPERS

SYS CONFIG & E−HEAT JUMPERS

Figure 5. Zone Control Panel Jumper Banks

CAUTION

Static electrical discharge will damage electronics.

Discharge static electricity before touching the zone control panel. Touch a grounded metal object before touching the circuit board.

Pin shown with

jumper on

ZONE 1 AT 10%.

Pin shown with

jumper on

ZONE 2 AT 0%

(allows min. cfm

airflow).

NOTE − Only zones 2, 3, & 4 have an OFF setting.

ZONE 1 ZONE 3

PIAB PIAB

ZONE 2 ZONE 4

PIAB PIAB

ZONES 3 AND 4 ARE SHOWN NOT USED (JUMPERS SET ON OFF").

Figure 7. PIAB Jumper Settings (typical)

NOTE − The blower speed may be affected by the reduction jumpers, if installed. See Page 9.

Upgrading from Harmony II®?

NOTE − If replacing a Harmony II® system, use conversion values in table 4 to maintain equivalent air settings when setting up the Harmony IIIt system.

Table 4. Air jumper positions conversion chart

Model Equivalent Positions (%)

Harmony II

Harmony IIIt 0 10 30 40 50 70 80 90

25 35 45 55 65 75 85 95

How PIAB Jumpers affect blower operation

A variable−speed motor will operate at its minimum speed or at any increment faster up to its maximum speed. The Percentage Into Adjustment Band (PIAB) jumpers control the speed variance of the motor.

When the zone control’s PIAB jumpers are set to 0%, the blower operates at the minimum air volume produced by the air handler and when set to 100%, the blower operates at maximum air volume produced by the air handler (see your air handler installation instructions for specific CFMs).

For example: if an air handler has a minimum air volume of 800 CFM, and a maximum of 1500 CFM, and the jumper is set to 0%, the air delivered to the zone will be 800 CFM. Similarly, if the jumper is set to 100%, the air delivered to the zone is 1500 CFM. By placing a jumper in the 50% position, you will direct airflow midway between the blower’s minimum and maximum CFM capacities.

PIAB JUMPER = 0%

MIN. 800 CFM

(MOTOR RUNS AT MINIMUM SPEED)

PIAB JUMPER = 50%

MID. 1150 CFM

(MOTOR RUNS AT VARIABLE SPEEDS)

PIAB JUMPER = 100%

MAX. 1500 CFM

(MOTOR RUNS AT

MAXIMUM SPEED)

Figure 6. VSM Adjustment Band Example

By installing jumpers at different % on each PIAB bank, you can direct different amounts of air volume to each zone. You must jumper a % on zone 1 and at least one other zone, and you must jumper OFF on unused zones as shown in figure 7.

Zone 1 PIAB Jumpers – 140ºF DAS

Zone 1 PIAB terminal strip has an additional jumper setting (labeled 140F DAS) that may be used for added operational flexibility (see figure 8). When the supplied jumper is in place across both pins, the discharge air sensor (DAS) upper limit will be 140°F instead of 160°F (default) to provide added operational flexibility.

HEATING STAGING

JUMPERS

COOLING STAGING

JUMPERS

CONTINUOUS AIR

REDUCTION JUMPERS

HEATING AIR

REDUCTION JUMPERS

PIAB

JUMPERS

NOTE − If the heating staging jumper is set to either 120 or 130 and the 140F DAS jumper is in place, the furnace will stage up at 115°F and down at 130°F (see Page 10).

Figure 8. 140F DAS Jumper

505023M 08/11

Page 8

Zone Control Panel Jumpers (Determining PIAB Jumper Settings)

GENERAL

Determining PIAB Jumper Settings

Table 5. Determine PIAB jumper setting

example CFM values

NOTE − Use the PIAB Calculation Worksheet on Page 60 (also see example below) to help calculate the zone control system PIAB settings.

1. From a cooling load analysis, determine what CFM is required for each zone. Also, from the air handler, determine its minimum and maximum CFM ratings.

2. Using the PIAB formula, found in Table 5 and reflected in the worksheet below, calculate the Percent Into Adjustment Band (PIAB) using the values from step 1 for each zone. Table 5 also gives example CFM values to illustrates how to determine the correct jumper for the PIAB for Zone 1 using those values.

3. Set the air selection jumper for the zone using the percent air determined in step 2. If the percent air falls between available jumper settings, select the nearest unit of ten.

4. For each zone, repeat steps 1 through 3.

Note − See page 8 for information on 140F DAS (discharge air sensor) jumper used on Zone 1 PIAB.

Zone 1 Zone 2 Zone 3 Zone 4 Min. Max.

1020 1500 720 OFF 720 2200*

*High cool jumper setting

PIAB formula

Using example values above, find PIAB for Zone 1:

PIAB (1020 − 720) = 300 =.20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PIAB Jumper setting % .20 x 100 20%. . . . . . . . . . . . . . . . . . . .

SETUP TIP!

PIAB calculations should provide a good starting point for setting jumpers. It may also be beneficial to set jumpers at a higher percentage of airflow such that the sound of air rushing is objectionable, and then reduce it incrementally by 10% until: 1) the sound of air rushing is not objectionable, and 2) ample, but not excessive, air volume is being provided to adequately heat or cool the zone.

Required CFM CFM

(Req’d CFM − min. CFM)

(Max. CFM − min. CFM)

(2220 − 720) =1500. . . . . . . . . . . . . . . . . . . . . . .

100

PIAB Calculation Example (see worksheet on Page 60 )

PIAB = [(Required CFM − Minimum CFM) / (Maximum CFM − Minimum CFM)] * 100

Sample CFM ' Required Minimum Maximum Minimum

Sample PIAB = ([___920 − 450 ] / [ 2000 − 450 ]) x 100

Sample PIAB = ([ 470 ] / [ 1550 ]) x 100

Sample PIAB = [ 0.303 ] x 100 = 30 %

Zone Control Panel Jumpers (Air Reduction)

Continuous Air Reduction Jumpers

During continuous fan mode without either a heating or cooling demand, the blower runs at the total percentage of the CFM jumper settings of the zones calling for continuous fan (not to exceed 100% of blower capacity). A continuous air reduction jumper allows the blower speed to be reduced by a percentage during continuous fan mode.

The selections are 75%, 50%, 25% and 0%. At the factory, the jumper is set on 0%. Set the jumper to the position equal to the amount of continuous air reduction desired. See figure 9.

NOTE − If the calculations using a reduction percentage indicated a resulting CFM lower than the blower’s minimum CFM rating, the blower will deliver its minimum CFM (see figure 6 on Page 8).

Heating Air Reduction Jumpers

NOTE − For heat pump applications, ALWAYS set the

jumper on 0%. High head pressures may result if air is re- duced during heating mode.

NOTE − For use in warm−climate areas where units have high cooling capacity with low heat capacity, ALWAYS set the jumper on 0%.

The heating air reduction jumper enables the blower speed, during heating only, to run at a reduced rate compared to the cooling blower speed.

The selections are 40%, 20% and 0%. Jumpers are set to 0% from the factory. Set the jumper to the position equal to the amount of heating air reduction desired. See figure 9.

factory

0% 25% 50%

75%

CONTINUOUS HEATING

settings

shown

0% 20% 40%

Figure 9. Air Reduction Jumper Settings

Page 9

HARMONY IIIT ZONE CONTROL SYSTEM

heating jumper Must be set on 0% for heat pump application

GENERAL

Zone Control Panel Jumpers (Heat/Cool Staging)

Heating/Cooling staging jumpers prevent any rapid staging of the equipment. This section shows the recommended settings for heating/cooling staging temperat ures and explains the temperature differentials for different equipment configurations. In the diagrams, sine waves indicate which stage operates during the rise and fall of discharge air temperature for the different heating/cooling staging jumpers. Recommended jumper settings are shown in bold type.

Heating Staging Temperature Jumper

Heating Staging temperature jumpers are used to set the temperature at which the 2nd−stage heating equipment comes ON. Its selections range from 85 − 130 (°F). The setting has a built-in differential of 20°F (except as described when 140DAS jumper is used).

During operation, when the discharge air temperature falls below the jumper setpoint, 2nd-stage heating begins. If the discharge air temperature reaches the differential temperature, 2nd-stage operation ceases and 1st-stage heating resumes until the temperature again falls below the jumper set point.

NOTE − For G71MPP and SLP98 furnaces only, the furnace ignition control will automatically adjust firing rate without a 2nd stage heat demand to match the blower airflow (CFM) requested by the Harmony IIIt zoning system. See Operation with G71MPP and SLP98" on page 26 for additional information.

Heat Pump (range: 85 − 110°F, recommended: 90). The maximum discharge air temperature at which the heat pump/electric heat is allowed to run is fixed at 135°F.

Discharge Air Temperature ºF

TIME "

1ST STAGE2ND STAGE

2ND STAGE

Gas Furnace w/140F DAS jumper (range: 100 − 130;

recommended: 120). When the 140F DAS jumper is in place (as shown to the right), the maximum discharge air temperature at which the furnace may run is fixed at 140°F. (Note the

140F DAS jumper’s impact on the differential at 120 and 130 settings):

Discharge Air Temperature ºF

TIME "

1ST STAGE2ND STAGE

2ND STAGE

105F

Discharge Air Temperature ºF

TIME "

1ST STAGE2ND STAGE

2ND STAGE

When the zone control system is applied to a heat pump with electric heat, the electric heat will be staged ON to maintain the discharge air temperature set by the heating staging jumper position.

Gas Furnace with 160°F upper limit (range: 100 − 130; recommended: 120). The maximum discharge air temper- ature at which the furnace may run is fixed at 160°F.

Cooling Staging Temperature Jumper

Cooling Staging temperature jumpers are used to set the discharge air temperature at which 2nd−stage cooling comes on. It is selectable between 50°, 55° and 60°F. A 7 degree total differential is associated with this staging temperature, beginning at the jumper setpoint, and extending to 7 degrees above the setpoint.

For any jumper setting, if the discharge air should fall to 45°F and any zone still demands cooling, the compressor will not run leaving only the blower to operate until the discharge air once again rises to 50°F and the 5 minute compressor OFF delay has been satisfied. For this reason, and to better satisfy latent loads, the jumper recommended setting is 50.

67F

62F

ºF

1ST STAGE 2ND STAGE

Discharge Air Temperature

TIME "

57F

1ST STAGE

505023M 08/11

Page 10

Zone Control Panel Jumpers (SYSTEM Configuration/E−Heat Stages)

GENERAL

SYSTEM Configuration/E−HEAT Stages Jumpers

The SYSTEM configuration jumpers must be inserted to select the type of cooling and heating system that has been installed and the E−HEAT Stages jumper defines if the system is dual fuel or defines the number of electric heating stages used.

Gas Furnace and Air Conditioning

For a gas furnace and air conditioning combinations, put the jumper on GAS (as shown) and select the

SYSTEM

Configuration

2COOL

2HP

number of equipment cooling stages by placing the cooling jumper to the appropriate site (place on

IN A/C AND GAS FURNACE CONFIGURATION, HP" AND E−HEAT" JUMPERS ARE IGNORED

1COOL for 1stage cooling or 2COOL for 2−stage cooling).

In this configuration, the maximum discharge temperature (upper temperature limit) at which the furnace is allowed to run is 160°F (except when 140FDAS jumper [as described on Page 10] is in place). At the upper limit, the zone control system removes any heat demand from the furnace for a minimum of 5 minutes and until the temperature comes back within normal operating temperatures.

While at or above the upper temperature limit, the control unit signals for continuous blower operation to those zones from which a thermostat heat demand is received. When setting up the furnace control board options, be sure to set the BLOWER-OFF DELAY to no greater than 210 SECONDS.

Heat Pump with Electric Backup Heat

For heat pump with electric backup heat, select HP position as shown in this diagram.

SYSTEM

Configuration

2COOL

2HP

GAS 1COOL 1HP

E−HEAT Stages

DF 1 2 3

E−HEAT Stages

DF 1 2 3

In this configuration, the maximum discharge temperature the electric heat or heat pump is allowed to run is 135°F. At that temperature, the zone control system removes demand from the heating unit for a minimum of 5 minutes and until the temperature returns to the normal operating temperature range. While at or above 135°F, the control unit signals for continuous blower operation to those zones from which a thermostat heat demand is received.

Select the number of equipment cooling stages by placing the COOL stages jumper to the appropriate side (1COOL or 2COOL). Similarly, set the number of Heat Pump stages (1HP or 2HP). Jumper settings on the above diagram illustrate the proper settings for a 2-stage heat pump and twostage air conditioning system.

When using a heat pump with electric backup heat, insert an E−HEAT jumper to select the total number of available electric heat stages. The diagram above shows a single heat-strip configuration.

Heat Pump− Dual Fuel heating, 1−stage or 2 Stage Heat Pump and Gas Furnace

This diagram shows a dual−fuel configuration (heat pump for heat and cool with gas backup heat).

SYSTEM

Configuration

2COOL

2HP

GAS 1COOL 1HP

E−HEAT Stages

DF 1 2 3

HP position must be jumpered for Dual Fuel applications and the E−Heat Stages jumper must be set to DF" for dual fuel operation.

NOTE − See figure 23 (Page 38), Variations on Common Applications for other jumper configurations and electrical wiring variations.

Page 11

HARMONY IIIT ZONE CONTROL SYSTEM

GENERAL

Common System Component Wiring

Use thermostat wire to connect dampers, damper transformers, and the DAS probe with the zone control system.

IMPORTANT

Avoid running any control wiring close to AC house wiring. If this cannot be avoided, limit close parallel of power and control wiring to a few feet.

Dampers and Damper Transformer Wiring

Connect dampers to the zone control panel as shown in figure 10. A total of six dampers may be connected at the

NOTE − The extended damper transformer rating should be sized to adequately handle zone dampers (1−4) plus relays (K1−K4) not to exceed class II wiring limit of 75 VA.

Combined load of zone dampers and zone relays not to exceed 60VA.

Use Lennox Part 56L68 for Zone Relays 1 through 4.

(NOT TO EXCEED 75 VA) CLASS II WIRING

EXTENDED ZONE 1 DAMPER

EXTENDED ZONE 2 DAMPER

EXTENDED ZONE 3 DAMPER

EXTENDED ZONE 4 DAMPER

120 VAC

24 VAC

damper output terminals on the zone control panel. If additional dampers are used, additional transformers and relays will be needed.

Fuse F1 will protect the damper outputs from a short circuit or overload in the damper wiring.

If dampers are applied to the return duct system, the dampers for each zone must be wired in parallel. Connect damper transformer to zone control panel terminal block. Refer to the Extended Damper Wiring section in figure 10 for wiring connections.

Discharge Air Sensor (DAS) Probe Wiring

Wire discharge air sensor probe to zone control panel. The variable immersion-temperature probe is not polarity sensitive.

ZONE CONTROL, THERMOSTATS, & DAMPERS TRANSFORMER

24 VAC

EXTENDED DAMPER TRANSFORMER (SEE NOTE)

ZONE RELAY K1

ZONE RELAY K2

ZONE RELAY K3

ZONE RELAY K4

EXTENDED DAMPER WIRING

ZONE 1 DAMPER

ZONE 2 DAMPER

ZONE 3 DAMPER

ZONE 4

DAMPER

120 VAC

Figure 10. Damper and Extended Damper Wiring Diagram

505023M 08/11

Page 12

GENERAL

Component Specific Wiring

CHECK VOLTAGE BEFORE CONNECTING ZONE CONTROL TRANSFORMER (ZONE CTRL XFMR) LEADS TO THE ZONE CONTROL PANEL CONNECTIONS

IF 0 VOLTS (AS SHOWN IN A")

THEN POLARITY IS CORRECT

IF METER READS 48 VOLTS (AS SHOWN IN B") THEN POLARITY IS RE-

VERSED; SWAP LEADS (AS SHOWN IN C") AND CONFIRM 0 VOLTS

Figure 11. Confirming Transformer Phasing (polarity) is Correct

Zone Control Transformer Phasing

Using two transformers on a single systemWhen the

Harmony IIIt zone control panel is connected to a system that has its own transformer, the phasing (or polarity) of the air handler transformer to the zone control’s add−on transformer is extremely IMPORTANT because the zone control transformer powers the DS" circuit within the zone control and then connects to the air handler DS" circuit.

The only two transformers that need correct phasing with their commons connected are the zone control and air handler transformers. Check the phasing prior to connecting the zone control transformer zone control panel’s connections. The zone control transformer primary should be the same source as the air handler to keep it uncomplicated. Use a 230 volt primary transformer with air handlers (CBX32MV / CB31MV / CBX40UHV) and use a 115 volt transformer with furnaces (G61MPV / G71MPP / SLP98 / SL280V / EL296V) and with CBWMV.

1. Connect the zone control transformer primary to the air handler voltage source (see figure 11).

2. Do not connect the zone control transformer secondary to the zone control panel at this time.

3. Connect air handler secondary common to the assumed zone control transformer common.

4. Measure voltage between air handler R" and unconnected zone control transformer secondary lead (see figure 11):

D if 0 volts (A, figure 11) then polarity is correct; connect the

leads to zone control C and R as shown.

D if 48 volts (B, figure 11) then polarity is reversed; swap

leads as shown and confirm 0 volts (C, figure 11); connect the leads to zone control C and R as shown.

5. With the correct polarity determined, connect C wire to zone control 24VAC C terminal and R wire to R terminal.

Thermostat Wiring

Using standard electronic 1-heat /1-cool non-heat pump, non-power robbing thermostats, and five−wire thermostat cable, wire units as follows:

1. Wire each thermostat to terminals Y, W, G, R, and C.

2. Run cable from each of the thermostats to the zone control panel. Mark each cable according to the zone thermostat from where it originates.

3. Strip the cables and attach each of the 5 wires to the zone control panel (see figures 17 [Page 24], 15 [Page 17], 26 [Page 43]).

Gas Furnace Wiring

IMPORTANT

The common C" terminal of the Harmony IIIt zone control panel MUST be connected to the common terminal of the integrated control, or if using a air handler, MUST be connected to the common terminal of the air handler terminal strip.

If not connected, blower may operate only at the minimum CFM or will not ramp to zone air volume.

After the furnace is installed, field wire the unit as described in the installation instructions provided with the furnace. Use thermostat wire to connect the furnace and the zone control panel and to connect the zone control panel 24V C" to the integrated control terminal strip C" (see wiring diagram in figure 17).

Condensing Unit Wiring

After the condensing unit is installed, field wire the unit as shown in the installation instructions provided with the unit. Use thermostat wire to connect the condensing unit to the zone control panel (see figure 17).

Page 13

HARMONY IIIT ZONE CONTROL SYSTEM

GENERAL

Minimum CFM in Variable Speed Furnace and Air Handlers

Harmony IIIt Zone Control system minimum CFM values for variable speed furnaces are listed in table 6. These apply to furnaces and air handlers with serial numbers indicating they were built in 2004 or later. With furnaces built before 2004, use the Harmony II furnace or air handler’s air handling data.

Zone Control system minimum air note in the installation instructions or engineering handbook for that

CAUTION

This unit is manufactured using unpainted metal. Sharp sheet metal edges can cause injury. When installing the unit, avoid accidental contact with

The control’s surfaces may be hot! Take care when making wiring connections. Failure to do so may result in personal injury.

CAUTION

sharp edges.

Table 6. Minimum CFM for Harmony IIIt Zone Control system with Variable Speed Blower Motors

Unit Model Number

G60DFV−36A−070 426 **SLP98xx070V36B 1/2HP motor 300

G60DFV−36B−090 523 **SLP98xx090V36C 1/2HP motor 250

G60DFV−60C−090 520 **SLP98xx090V48C 3/4HP motor 380

G60DFV−60C−110 475 **SLP98xx090V60C 1HP motor 450

G60DFV−60D−135 477 **SLP98xx110V60C 1HP motor 450

G60UHV−36A−070 426 **SLP98UH135V60D 1HP motor 450

G60UHV−36B−090 453 SL280xxV 3−ton 250

G60UHV−60C−090 478 SL280xxV 4− & 5−ton 450

G60UHV−60C−110 483 EL296xxV 2 & 3−ton 250

G60UHV−60D−135 495 EL296xxV 4−ton 380

G61MPV−36B−045 442 EL296xxV 5−ton 450

G61MPV−36B−070 458 CB31MV−41 380

G61MPV−36B−071 458 CB31MV−51, −65 399

G61MPV−36C−045 442 CBX32MV−018/024, CBX32MV−024/030 Rev 06 300

G61MPV−36C−090 479 CBX32MV−036 Rev 06 300

G61MPV−60C−090 449 CBX32MV−048, −060, −068 Rev 06 300

G61MPV−60C−091 458 **CBX40UHV−024, −030 250

G61MPV−60C−110 463 **CBX40UHV−036 380

G61MPV−60C−111 458 **CBX40UHV−042, −048, −060 450

G61MPV−60D−135 470 CBWMV (all models) 400

**G71MPP−36B−070 250

**G71MPP−36C−090 250

**G71MPP−60C−090 450

**G71MPP−60C−110 450

**G71MPP−60D−135 450

* A 3% duty cycle corresponds to the minimum CFM, and a 97% duty cycle corresponds to the maximum CFM. ** On G71MPP & SLP98 Furnaces and CBX40UHV and CBX32MV revision 06 Air Handlers, listed values in the table corre-

spond to 0% duty cycle of the Harmony IIIt Zone Control system control signal. Since the Harmony IIIt Zone Control system puts 3% at minimum, actual value may be 10−30 CFM higher.

xx: UH = up/horizontal flow; DF = down flow

CFM (min)

Unit Model Number

CFM (min)

505023M 08/11

Page 14

System Flow Diagrams

GENERAL

COOLING

DEMAND

RECEIVED

since completion

of last cooling

Energize stage 1

compressor and

ramp indoor

CFM setting

discharge air

temperature

air lower than

air 7°F or more

above cooling staging jumper

minimum runtime

in 1st stage

5 minutes

demand

Ye s

blower to

Monitor

Discharge

45°F

Discharge

setting

Ye s

4−minute

completed

Ye s

Cooling demand satisfied

Ye s

COOLING

OPERATION

AC/HP

Energize stage 2

compressor and

ramp indoor

blower to

CFM setting

Monitor

discharge air

temperature

Shutdown compressor stage 1 or 2

Continuous air

delivered to

calling zones

Discharge

air rises above

55°F

Ye s

Cooling demand satisfied

Ye s

Discharge

Ye s

air lower than

45°F

Discharge

air below cooling

staging jumper

setting

Ye s

4−minute

minimum runtime

in 2nd stage

completed

Ye s

De−energize

stage 2

Shutdown compres-

sor stages 1 and 2

and blower fan

HEATING DEMAND

RECEIVED

5 minutes

since completion

of last heating

demand

Ye s

Energize (Y1/Y2)

compressor heat

stage and ramp

indoor blower to

CFM setting

Monitor

discharge air

temperature

Discharge

air higher than

Upstage

135°F

Discharge

air below heating

staging jumper

setting

Ye s

4−minute

minimum

stage runtime

completed

Ye s

Was 2nd

stage (Y2)

running

Ye s

Heating

demand

satisfied

Ye s

HP & Electric

Order of Staging:

HP stg 1 (Y1) HP stg 2 (Y2) Elec strip stg 1 (W1) Elec strip stg 2 (W2)

Shutdown all stages com-

pressor /

electric heat

Continuous air

delivered to

calling zones

Discharge

air falls below

130°F

Ye s

Heating

demand

satisfied

Ye s

HEATING

OPERATION

Heat Strips

Energize heat strip

stage (W1/W2) and

ramp indoor blower to

CFM setting

Monitor

discharge air

temperature

Discharge

Ye s

air higher than

135°F

Discharge

air 20°F or more

above heating

staging jumper

setting

Ye s

2−mininute

minimum

stage runtime

completed

Ye s

Was 2nd

stage (W2)

running

Ye s

De−energize

furnace W1 &

Shutdown compres-

sor stages 1 and 2

and blower fan

No Upstage

Page 15

HARMONY IIIT ZONE CONTROL SYSTEM

HEAT PUMP

Installing Heat Pump and accessories

HEAT PUMP

Equipment Installation

Follow all equipment installation instructions provided with each unit.

Pressure Switch

A pressure switch (HFC−22 [27W12]; HFC−410A [27W13]) is required for applications with a Lennox heat pump (Options 2 and 3). This switch acts as a guard in case of high head pressures during 1st− and 2nd−stage heating. The switch’s cut out and cut in points are shown in table 7.

Table 7. Cut−out and Cut−in (Reset) Points

Refrigerant Cut−Out Cut−in (Reset)

HCFC−22 375 psig (2551 kPa) 275 psig (1862 kPa)

HFC−410A 550 psig (3965 kPa) 425 psig (3102 kPa)

NOTE − If a pressure switch is factory installed in the unit, do not remove the switch or switch wires.

The switch may also be fastened directly to the vapor valve service port which becomes the discharge line in heat pump heating mode (see figure 12).

Pressure Switch Wiring

Pull a two−wire thermostat cable from the field-installed pressure switch to the zone control panel and connect at the pressure switch, and at the zone control panel as shown in the connection location diagram (see figure 15).

Tee (High Pressure Switch; Heat Pumps only)

A tee (Lennox #87071) is needed to install the pressure switch along with a valve core (Schrader) for checking pressure in the vapor line during heat pump heating mode (see figure 12).

The switch may also be fastened directly to the vapor valve service port which becomes the discharge line in heat pump mode.

REVERSING

VALV E

VAPOR LINE (TO INDOOR

COIL)

Balance Point Sensor (Outdoor Thermostat)

A balance point sensor (kit 56A87, figure 13) may be implemented in a dual-fuel (Option 3) system. This thermostat monitors the outdoor temperature, compares it to the balance point setting, and signals the zone control if the reading is below the set point. The zone control then instructs the gas furnace to provide all the heating and prohibits the heat pump from attempting to fill a demand for heat.

Figure 13. Balance Point Sensor (56A87)

Defrost Tempering Kit

A defrost tempering kit (67M41) may be implemented in a dual-fuel (Option 3) system. This kit consists of a thermostat probe/switch which is installed between the furnace and the evaporator coil to turn the furnace on (at 80F) and off (at 90F) during a defrost cycle. This tempers the discharge air and protects the compressor from high refrigeration pressures during defrost. Figure 14 shows the kit; see figure 3 (Page 6) for location of the probe.

MOUNTING BRACKET

STRAIN RELIEF

LIMIT CONTROL

WHEN FULLY ASSEMBLED, TABS ARE BENT DOWN TO HOLD CONTROL AND WIRES IN PLACE.

VALVE DEPRESSOR TEE (LENNOX

87071)

NEW SERVICE

PORT

CAUTION − High Pressure Switch must be installed on open side of tee first to prevent refrigerant loss.

HIGH PRESSURE SWITCH

Figure 12. Tee & Vapor Line High Pressure

Switch

505023M 08/11

LABEL

Figure 14. Defrost Tempering Limit Control

Page 16

HEAT PUMP

PRESSURE SWITCH

21J18 (HFC−22)

27W13 (HFC−410A

DAMPERS (Spring open, power close)

Heat/cool staging

jumper settings −

page 10.

DISCHARGE AIR SENSOR 88K38 (included)

Connections for REMOTE VACATION SWITCH OR Humiditrol® Zoning Accessory

Vacation OFF for individual

Vacation ON for all zones to be

conditioned at the same time.

Emergency Heat OFF to allow

Heat Pump to provide heat.

Emergency Heat ON to force

auxiliary (backup) heat to pro-

vide all heating (disallows heat

pump from providing any heat).

NOTE: SELECT # OF HP STAGES BY PLACING JUMPER IN APPROPRIATE POSITION. (2−STG HP SHOWN)

zone control.

Air reduction

jumper settings

− page 9.

See System Configuration & E−Heat jumper settings − page 11.

PIAB jumper settings − page 8.

System Configuration & E−Heat

jumper settings − page 11.

IMPORTANT! Connectivity is NOT COMPLETE until all electrical adjustments (jumpers and wiring changes) have been made. See Air Handler Control Electrical Adjustments (Page 39).

Thermostat 2 Thermostat 1

W C Y G R

NOTE − Do not wire Y" wire(s) from the Harmony IIIt zone control panel to the air handler unit terminal strip. Doing so causes the motor to search" for proper CFM.

CONNECT TO THE

SAME POWER

SUPPLY AS THE AIR

HANDLER

VAC

ZONE CONTROL

TRANSFORMER

IMPORTANT

Connect thermostat-gauge wire to C" terminal on Heat Pump terminal strip

HEAT PUMP

IMPORTANT!

DO NOT MAKE

CONNECTIONS

TO Y1 AND Y2

SPEED AIR

240 VAC

R C Y1 Y2 O W1

NOTE BELOW!

R G W1 W2 C DS Y1 Y2

VARIABLE

HANDLER

SEE IMPORTANT

Figure 15. Harmony IIIt Zone Control System Option 2 − Lennox Heat Pump & Lennox Variable-Speed Air Handler

Page 17

HARMONY IIIT ZONE CONTROL SYSTEM

HEAT PUMP

Heat Pump System Start−Up & Checkout

IMPORTANT

The zone control system power−up must occur at the same time or before the furnace or air handler unit is powered up.

Powering the System (All Systems)

1. Adjust all thermostat settings so that no demand will occur.

2. Apply power to the zone panel transformer and to the air handler and observe the following: all four diagnostic LEDs will light; then each individual diagnostic LED will light in sequence; then all four diagnostic LEDs will light and extinguish.

3. Finally, the status light will begin to flash, indicating proper operation. Perform heat pump heating checkouts on pages 18 through 19.

Heat Pump Heating Checkout (Single Zone)

Prerequisites:

Zone 1 thermostat set to Heat

PRESSURE SWITCH LED ON

DAMPER 2,3,4 ON

DAMPER 1 OFF

ELECTRIC HEATING ON (W/EVENT 3)

(W) RED ON

EVENT SEQUENCE: 1− Y1 ON

2− Y2 (IF EQUIPPED) ON

IF NO SIGNIFICANT WARMING AFTER 4 MIN.

3− W1 ON IF NO

SIGNIFICANT WARMING AFTER 4 MIN; THEN W2; THEN W3

FAN ON

HEATING ON

OUTPUT STATUS LEDs

1. Set zone 1 thermostat for a heat demand; check:

D Zone 1 thermostat W LED on (heating demand). D Damper LED 1 off (damper open). D Damper LEDs 2, 3, and 4 on (dampers closed). D Output Heat Y1 LED on (compressor on). D Heating LED on. D Fan LED on. D Pressure Switch LED on.

The compressor in the outdoor unit begins operating in the heating mode. At approximately the same time, the indoor blower starts, operating at a speed according to the setting of the PIAB jumper for zone 1. It may take the blower 60 to 90 seconds to reach this speed.

2. If Single-Stage Heat Pump − Skip to step 3. The dis-

charge air sensor continually samples air temperature. If, after 4 minutes, air temperature is not warming significantly, the high speed compressor energizes.

D Output Heat Y2 LED on (high speed compressor).

3. The discharge air sensor continually samples air temperature. If, after (another) 4 minutes, air is not warming significantly, auxiliary heat sequence begins:

D Electric Heating (E−Heating) LED on. D Output Heat W1 on, followed by (if available, and if

necessary) W2, and then W3.

4. Remove heat demand from zone 1.

D All LEDs off, except: D Damper LEDs 2, 3, 4 on.

To check the amount of air being delivered to each zone and to confirm that each individual zone damper functions properly, repeat these steps for zones 2 − 4.

505023M 08/11

Page 18

Heat Pump Heating Checkout (Multiple Zone)

Prerequisites:

S All zone thermostats set to Heat

PRESSURE SWITCH LED ON

DAMPER 2,3,4 OFF

ELECTRIC HEATING ON (W/EVENT 3)

1. Apply heating demand to all thermostats.

D All zone thermostat W LEDs on (heat demands).

(W) RED ON

EVENT SEQUENCE: 1− Y1 ON

2− Y2 (IF EQUIPPED) ON

IF NO SIGNIFICANT WARMING AFTER 4 MIN.

3− W1 ON IF NO

SIGNIFICANT WARMING AFTER 4 MIN; THEN W2; THEN W3

HEATING ONFAN ON

OUTPUT STATUS LEDs

Heat Pump Heating Checkout (Central Control)

HEAT PUMP

D Output Heat LED Y1 on (compressor). D Heating and Fan LEDs on. D LEDs dampers 1 − 4 off (all dampers open). D Pressure Switch LED on.

The compressor in the outdoor unit begins operating in the heating mode. At approximately the same time, the indoor blower starts, operating at a speed according to the PIAB jumper settings for all zones. It may take the blower 60 to 90 seconds to reach this speed.

2. If Single-Stage Heat Pump − Skip to step 3. The dis-

charge air sensor continually samples air temperature. If, after 4 minutes, air temperature is not warming significantly, the high speed compressor energizes.

D Output Heat Y2 LED on (high speed compressor).

3. The discharge air sensor continually samples air temperature. If, after (another) 4 minutes, air is not warming significantly, auxiliary heat sequence begins:

D Electric Heating (E−Heating) LED on. D Output Heat W1 on, followed by (if available, and if

necessary) W2, and then W3.

4. Remove the heat demand from all zones.

D Input LEDs off. D Fan LED off (Blower off). D Heating LEDs off. D DamperLEDs − Last zone thermostat demand re-

moved: LED is off (this zone’s damper remains open during 3−1/2 minutepurge); Other zones damper LEDs are on during the 3−1/2 minute purge (dampers closed). After 3−1/2 minute delay, all dampers LEDs go off (dampers open).

Prerequisites:

Central mode switch on

S S Red LED on the central mode fan switch on

PRESSURE SWITCH LED ON

DAMPER 2,3,4 OFF

EVENT SEQUENCE: 1− Y1 ON

2− Y2 (IF EQUIPPED) ON

3− W1 ON IF NO

CENTRAL MODE ON

FAN ON

ELECTRIC HEATING ON (W/EVENT 3)

(W) RED ON

IF NO SIGNIFICANT WARMING AFTER 4 MIN.

SIGNIFICANT WARMING AFTER 4 MIN; THEN W2; THEN W3

HEATING ON

OUTPUT STATUS LEDs

1. Set zone 1 thermostat for a heat demand; check:

D Zone 1 thermostat W LED on (heating demand). D Output Heat Y1 LED on (compressor on). D Heating LED on. D All damper LEDs off (dampers open). D Pressure Switch LED on.

The outdoor-unit compressor begins operating in the heating mode (low−speed if 2-stage compressor). At approximately the same time, the indoor blower starts, operating at a speed according to the PIAB jumper settings for all zones. It may take the blower 60 to 90 seconds to reach this speed.

2. If Single-Stage Heat Pump − Skip to step 3. The discharge air sensor continually samples air temperature. If, after 4 minutes, air temperature is not warming significantly, the high speed compressor energizes.

D Output Heat Y2 LED on (high speed compressor).

3. The discharge air sensor continually samples air temperature. If, after (another) 4 minutes, air is not warming significantly, auxiliary heat sequence begins:

D Electric Heating (E−Heating) LED on. D Output Heat W1 LED on, followed by (if available,

and if necessary) W2, and then W3.

4. Remove the heat demand from zone 1. Upon removal of the demand from zone 1, check:

D Zone 1 thermostat W LED off (no heat demand). D Output Heat Y1, (Y2) LED(s) off. D Fan and Heating LEDs off.

Page 19

HARMONY IIIT ZONE CONTROL SYSTEM

HEAT PUMP

Pressure Switch Checkout

The high pressure switch is a normally closed (N.C.) autoreset high pressure switch located in the compressor discharge line or on the suction valve service port. The switch is factory set to open when operating pressures rise and close when the pressure drops (see table 8). The intent of the switch is to protect the outdoor unit from abnormally high operating pressures during mild weather heating days. The green pressure LED comes on when the HP pressure switch is closed indicated normal condensing pressures.

Table 8. High Pressure Switch Operation

Refrigerant Open on pressure rise (psig) Close on pressure fall (psig)

HFC−22 375 275

HFC−410A 550 425

1. Connect refrigerant gauges to the outdoor unit vapor line.

2. Establish a compressor heating demand and allow system to begin operating (see heat pump heating checkout section for details). Note that the green pressure switch LED comes on.

3. Allow system to operate several minutes so refrigerant pressures can balance.

4. Momentarily block the return air opening and observe the high pressure gauge. When hot gas line pressure reaches the open on" pressure (see table 8) and the green pressure switch LED turns off, an error code will be set in the zone control system, DIAGs 1 and 4 will turn on, and outdoor unit will stage down and turn off if the switch does not close within 90 seconds. Afterwards, backup heat will be used to satisfy the demand.

5. Remove the restriction. When hot gas pressure drops below the close on" pressure, the green pressure switch LED will turn on and all DIAGs should turn off.

505023M 08/11

Page 20

TroubleshootingZoning system with Heat Pump

HEAT PUMP

- Are thermostats wired correctly?

- Does zone control system respond appropriately to demand?

- Does electronic thermostat have relay switching output? If relay with SCR output is used, not, isola-

tion relays may need to be used.

- 24VAC supplied to each thermostat terminal R from zone control system?

- Check each thermostat for output signal when calling. Heating output W1? Cooling output Y1?

- Pressure Switch installed in correct position?

- Does switch open when high pressure condition is simulated (tem-

porarily blocking airflow in heating mode)?

- Does zone control system respond appropriately when high pres-

sure condition is simulated (temporarily disconnecting switch simulates high pressure).

- Do dampers respond to demand? 0

volts AC = open. 24 volts AC = closed. Dampers should drive closed when 24 volts is jumpered to damper motor.

PRESSURE

SWITCH

THERMOSTATS

- Is wiring correct & in good condition?

DAMPERS

- Is discharge

probe installed?

- Is probe located

in discharge air plenum as described on Page 6?

- Is it wired cor-

rectly?

Heating/cooling

staging jumper

settings − page 10.

PIAB jumper settings − page 8.

- Line Voltage to transformer?

- 24VAC from transformer to zone control panel?

- Are all wire connections good? Are all wire connections correct?

Thermostat 2 Thermostat 1

W C Y G R

ZONE PANEL TRANSFORMER

VAC

TO AIR HANDLER

POWER SUPPLY

240 VAC

- C" connected

to C"?

- Fuses OK?

DISCHARGE AIR SENSOR

HUMIDITROL ZONING

ACCESSORY CONTROL

- Have heating and cooling

staging jumpers been set for desired 2nd stage operation?

- Are continuous & heating air re-

duction jumpers set correctly? On heat pumps, Heating Air Reduction must be 0%.

- Do jumpers provide appropriate

speed reduction? If no, check indoor unit before replacing zone control panel.

- Are PIAB jumpers set correctly?

- Only 1 jumper per Zone? (Zone

Control System Jumper Settings [Page 8])

Air reduction

jumper

settings −

page 9.

- Are jumpers set cor-

rectly for auxiliary heat and cooling? (Page 11)

System Configuration & E−Heat

jumper settings − page 11.

- Error code present?

If so, see troubleshooting/diagnostic section of this manual (Page 56).

- Does outdoor unit respond to demand?

- Is it operating properly?

- Test Defrost. Does outdoor unit initiate and

terminate defrost correctly?

- W1 energized during defrost?

- Does zone control system respond appropri-

ately during defrost?

- Are appropriate outputs energized in re-

sponse to demand?

- Does zone control system energize ap-

propriate outputs? During Cooling? During Heating? During Defrost? During Emer. Heating?

- 24VAC from furnace transformer to R?

- Does indoor unit respond to outputs? Cool-

ing? Heating? Defrost? Emer. Heating?

- Does blower speed change as zone de-

mand changes? If no, does DS output vary from 0 to 25VDC?

HEAT PUMP

R C Y1 Y2 O W1

R G W1 W2 C DS Y1 Y2

VARIABLE

SPEED AIR

HANDLER

- Verify Air Handler

jumpers/links cut or removed (see Page 39)

- Verify NO connections

made to Y1 or Y2.

Figure 16. Lennox Heat Pump & Lennox Variable-Speed Air Handler

Page 21

HARMONY IIIT ZONE CONTROL SYSTEM

HEAT PUMP

TroubleshootingHeat Pump Heating Operation

HEATING DEMAND

RECEIVED

5−minutes

since completion

of last heating

demand

Ye s

The maximum discharge air temperature at which the heat pump/electric heat is allowed to run is fixed at 135°F.

When the zone control system is applied to a heat pump with electric heat, the electric heat will be staged ON to

maintain the discharge air temperature set by the heating staging jumper position.

REFER TO DEFROST DIAGRAM DIAGRAM (Page 23).

Energize 1st compressor stage; ramp indoor blower to heating stag-

ing jumper setting

Monitor

discharge air

temperature

Discharge

air above than

135ºF

Discharge

air below heating

staging jumper

setting

Ye s

4−minute

minimum runtime

in 1st stage

completed

Ye s

Heating demand satisfied

Ye s

stages 1 and 2

and blower fan

Ye s

Shutdown

compressor

ORDER OF STAGING:

HP stg 1 (Y1) HP stg 2 (Y2) Elec strip stg 1 (W1) Elec strip stg 2 (W2)

Shutdown all

compressor stages

and electric heat

Continuous air

delivered to

calling zones

5 min delay

complete

Ye s

Discharge

air below

130ºF

Ye s

Heating demand

satisfied

Ye s

Energize next heat stages

Multiple stages stage on

and off to maintain heating

staging jumper setting

discharge air

temperature

air above than

Ye s

air 20ºF above

heating staging

jumper setting

minimum runtime

in 2nd stage

De−energize

Monitor

Discharge

135ºF

Discharge

Ye s

2−minute

completed

Ye s

W1 & W2 @furnace

505023M 08/11

Page 22

TroubleshootingDefrost Operation

need for defrost

control energizes

NORMAL HEAT PUMP OPERATION

Defrost

control detects

cycle

Ye s

Heat Pump

enters defrost

Harmony III

all compressor

stages

HEAT PUMP

Dual Fuel

Harmony III

sends signal to

W1 at indoor unit

Defrost

completed

Heating

demand

satisfied

Ye s

De−energize

all compressor

stages

Defrost

Ye s

Tempering

Defrost

period exceeds

20 minutes

Ye s

Harmony III control

de−energizes all

compressor stages − uses

auxiliary heat to complete

existing heat demand

HP cycles W1 OFF at

90ºF and ON at 80ºF

Ye s

during defrost cycle.

Page 23

HARMONY IIIT ZONE CONTROL SYSTEM

GAS FURNACE

Wiring for Gas Furnace and Outdoor AC Unit

Thermostat 2 Thermostat 1

W C Y G R W C Y G R

CONNECT TO

THE SAME

POWER

SUPPLY AS

THE GAS

FURNACE

DAMPERS (Spring open, power close)

DISCHARGE AIR SENSOR 88K38 (included)

Connections for REMOTE VACATION SWITCH OR Humiditrol® Zoning Accessory

Vacation OFF for individual

Vacation ON for all zones to be

conditioned at the same time.

Emergency Heat OFF to allow

Heat Pump to provide heat.

Emergency Heat ON to force

auxiliary (backup) heat to pro-

vide all heating (disallows heat

pump from providing any heat).

zone control.

Heat/cool staging

jumper settings −

Air reduc-

tion jumper

settings −

page 9.

page 10.

PIAB jumper settings − page 8.

140F DAS

jumper

pages 8

& 10.

ON G71MPP & SLP98 Furnace − W2 Not required, but may be connected to increase firing rate.

VAC

ZONE CONTROL

TRANSFORMER

120

VAC

IMPORTANT

Connect thermostat-gauge wire to integrated control C" terminal

NOTE − Do not wire Y" wire(s) from the Harmony IIIt zone control panel to the furnace terminal strip. Doing so causes the motor to search" for proper CFM.

2-Stage Condensing Unit shown (No Y2 wire on 1−Stage Unit)

Y1 Y2 C R

NOTE BELOW!

R G W1 W2 C

IMPORTANT!

DO NOT

MAKE CON-

NECTIONS TO Y1 AND

DS Y1

Y2 Variable Speed Furnace

SEE IMPORTANT

NOTE: SELECT # OF COOL STAGES BY PLACING JUMPER IN APPROPRIATE POSITION. (2−STG CLG SHOWN)

See System Configuration & E−Heat jumper settings − page 11.

Figure 17. Harmony IIIt Zone Control System Option 1 −

Lennox Variable-Speed Gas Furnace & 1− or 2-Stage Air Conditioner

505023M 08/11

IMPORTANT! Connectivity is NOT COMPLETE until all elec- trical adjustments (jumpers and wiring changes) have been made. See Integrated Control Electrical Adjustments (beginning on Page 28).

Page 24

GAS FURNACE

VSM Furnace IFC Electrical Adjustments (G71MPP, SLP98, SL280V, EL296V)

NOTE − Follow all equipment installation instructions provided with each unit.

The variable-speed motor (VSM) in the furnace is controlled by the integrated furnace control (IFC). Adjustment of these drive controls is made by cutting the clippable on-board links and selecting DIP switch settings. This is described in the following paragraphs.

The G71MPP, SLP98, SL280V, and EL296V blower motor speed must be adjusted to produce the zoning CFM requirements managed by the zone control system.

The Harmony III zone control´s pulse width modulated (PWM) output signal is connected to the DS terminal on the furnace control. The PWM signal, along with any other thermostat request (G, W1, or W1+W2), controls fan speed linearly between the minimum and maximum CFM for the furnace as determined by the cool speed DIP switches (see G71MPP & SLP98 Installation Instructions for settings).

Locate the integrated control in the furnace control box area. Before connecting the zone control panel to the integrated control, complete the applicable electrical adjustments shown in figures 18 or 19.

Electrical Adjustments

1. In all casescut the clippable on-board link W914 Dehum − Harmony

(between R & DS, see figure 18); if not cut, the zone control panel DS fuse will blow.

2. DO NOT CUT the clippable on-board link W915 2 Stage Compr (between Y1 & Y2).

HUM

EAC

Do NOT cut any wires in the variable speed motor harness.

ON−BOARD LINKS:

W915 2 Stage Compr (Y1 to Y2)DO NOT CUT

W951 Heat Pump (R to O)DO NOT CUT

W914 Dehum − Harmony (R to DS)CUT IN ALL CASES

Figure 18. G71MPP & SLP98 Integrated Furnace Control (IFC) Electrical Adjustments

Electrical Adjustments

1. In all casescut the clippable on-board link W914 Dehum − Harmony (between R & DS, see figure 18); if not cut, the zone control panel DS fuse will blow.

2. DO NOT CUT the clippable on-board link W915 2 Stage Compr (between Y1 & Y2).

Do NOT cut any wires in the variable speed motor harness.

ON−BOARD LINKS:

W915 2 Stage Compr (Y1 to Y2)DO NOT CUT

W951 Heat Pump (R to O)DO NOT CUT

W914 Dehum − Harmony (R to DS)CUT IN ALL CASES

I + I −CRI + I −

W1W2GY2Y1CCRDHLODS

Figure 19. SL280V & EL296V Integrated Furnace Control (IFC) Electrical Adjustments

Page 25

HARMONY IIIT ZONE CONTROL SYSTEM

GAS FURNACE

Set the upper limit of blower CFM as follows:

1. Determine the maximum system CFM requirements (sum of all the individual zones).

2. From the Blower Motor Performance tables (see G71MPP, SLP98, SL280V, EL296V Furnace Installation Instructions) determine the HIGH speed cool DIP switch setting that corresponds to this CFM.

3. Set the HIGH speed cool DIP switch setting on the integrated control to this value.

NOTE − The lower limit of blower CFM is factory set. It is not field adjustable.

The minimum airflow achieved by the G71MPP, SLP98, SL280V, EL296V when connected to a Harmony IIIt zone control is listed in the table 6 (see page 14).

A 3% duty cycle corres ponds to the minimum CFM, and a 97% duty cycle corresponds to the maximum CFM.

NOTE − Any on/off delays present for a heating or cooling sequence are still present with Harmony IIIt zone control operation.

VSM Furnace System Operation (G71MPP, SLP98, SL280V, EL296V)

The dehumidification on−board clippable link W914 Dehum − Harmony (R to DS) on the G71MPP, SLP98, SL280V, and EL29V integrated control must be cut for operation with the Harmony III zone control (see figure 18). Once the link is cut, the presence of the Harmony III zone control system, versus a standard dehumidification control, is automatically detected by the integrated control.

IMPORTANT − DO NOT alter blower harness!

When the integrated control is properly connected to a Harmony IIIt zone control, operation is as follows:

S Integrated control DIP switches 1 and 2, which configure the control for operation with various types of thermostats,

are ignored.

S The zone control sends a W1 Signal to the furnace which goes through its normal ignition sequence as described in

the G71MPP, SLP98, SL280V, and EL29V installation instructions.

S The blower will start and operate at the minimum blower speed after a 45 second delay. S After the temperature of the DAS rises above 100ºF the zone control will provide a PWM signal to the furnace on termi-

nal DS based upon the Zone PIAB Jumper selections (and the heating air reduction jumper).

S The blower speed (CFM) is set according to the pulse width modulated (PWM) signal from the Harmony IIIt zone con-

trol.

S The blower speed adjusts immediately with PWM adjustments. S The furnace firing rate is based on current operating CFM and internal lookup table for midpoint temperature rise. If

resulting firing rate is below minimum firing rate, it will operate at minimum fire rate. Accordingly, if resulting firing rate is above maximum firing rate, it will operate at maximum firing rate.

S Firing rate adjusts anytime the PWM deviates by more than 5% (e.g. 60% > 65%).

NOTE − Integrated control DIP switches 14 thru 19 are not disabled, and can be used in conjunction with Harmony III to increase or decrease airflow volume during heating operation.

NOTE − DIP switches 14−19 adjust firing rate when Harmony is detected. Air volume is controlled by Harmony. The furnace looks at air volume and determines proper firing rate based on DIP switch 14−19 settings. See G71MPP & SLP98 Installation Instructions for adjustment options.

S Integrated Control W2 terminal to Harmony IIIt zone control:

Since the furnace automatically adjusts firing rate to match CFM to achieve a target temperature rise, connection of Harmony IIIt zone control to W2 terminal on the integrated control is not required.

With W2 connected, lower firing rates can be used for W1 demand usually resulting in greater comfort levels per zone. If temperature cannot be maintained, then W2 will quickly increase firing rates to satisfy demand.

If discharge air temperature is too low, the integrated control W2 can be connected to Harmony IIIt zone control to cause the furnace to increase firing rate. Every two minutes, the integrated control looks at W2. If W2 is ON, the firing rate increases by 5%. This 5% increase is added to the desired firing rate as determined by the PWM. Therefore, if a 50% duty cycle corresponds to a 70% firing rate, after 2 minutes of W2, that same 50% duty cycle will correspond to a 75% firing rate. This will last for the remainder of the heat cycle.

When W2 goes from ON to OFF, the integrated control decreases the firing rate by 5%.

505023M 08/11

Page 26

GAS FURNACE

Harmony IIIt Installation Setup Worksheets

G71MPP, SLP98, SL280V, EL296VCooling/Heating; (Non−Heat Pump Applications)

Job Name: Indoor Unit Model: Outdoor Unit Model:

Indoor Unit setup:

- Cut on−board link W914 DEHUM OR HARMONY (R to DS) on furnace IFC control (if not cut, fuse will blow in Harmony III zone control board)

- W2 connection from Harmony III to SLP98 or G71MPP is optional – see Harmony III / furnace installation instructions for details

- DIP switch settings (ON or OFF):

1 OFF (DIP switch 1 – leave at factory setting – ignored by Harmony III) 2 OFF (DIP switch 2 – leave at factory setting – ignored by Harmony III) 3 OFF (DIP switch 3 – leave at factory setting – ignored by Harmony III) 4 ON (DIP switches 4 & 5 determine heating blower off" delay – recommended 180 seconds) 5 ON I 6 OFF (DIP switches 6 & 7 – leave at factory setting – ignored by Harmony III) 7 OFF I 8 (DIP switches 8 & 9 – cooling blower speed – determines maximum system cfm – see G71MPP blower tables) 9 I

10 (DIP switches 10 & 11–cooling blower adjust–determines maximum system cfm – see G71MPP blower tables) 11 I 12 OFF (DIP switches 12 & 13 – leave at factory setting – ignored by Harmony III) 13 OFF I 14 OFF (DIP switches 14,15,&16 – sets low fire, minimum capacity, firing rate − DEFAULT SETTING SHOWN & IS

15 OFF I 16 OFF I 17 OFF (DIP switches 17,18,&19 – sets high fire, 100% capacity, firing rate − DEFAULT SETTING SHOWN & IS

18 OFF I 19 OFF I

Harmony IIIt Panel setup:

- Heating staging jumper (circle one): 85 90 100 110 120 130 (Recommended 120 deg−F)

- Zone 1 PIAB 140F DAS jumper in place (circle one): Yes No (see Harmony III install instructions for info)

- Cooling staging jumper (circle one): 50 55 60 (select desired discharge air temp during cooling)

- Cont. Air Reduction jumper (circle one): 0 25 50 75 (% airflow reduction for continuous fan operation)

- Heating Air Reduction jumper (circle one): 0 20 40 (% air flow reduction for heating mode)

- System Configuration jumpers (circle one): HP GAS (Set to GAS)

- Stages (circle one): 2COOL 1COOL (Set to match condenser, 1 or 2 stage)

- Stages (circle one): 2HP 1HP (ignored for gas heat, non−heat pump application)

- E−HEAT Stages (circle one): DF 1 2 3 (ignored for gas heat, non−heat pump application)

- Desired total system cfm with all zones calling− _________ Total system cfm per tables− __________ Minimum cfm− ________

- Zone 1 – Name ___________________ Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________

- Zone 2 – Name ___________________ Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________

- Zone 3 – Name ___________________ Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________

- Zone 4 – Name ___________________ Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________

NOTEAll of the above are recommended starting" positions for the SLP98 or G71MPP DIP switches and Harmony III jumpers. Slight variations may be required during system start up and operation checks.

RECOMMNEDED STARTING POINT– see Harmony III/furnace install instruction)

Field Wiring Checklist:

- Indoor Unit Wiring Completed:

- DS" on Harmony III to DS" on indoor unit connected,

- "C" on indoor unit connected to Harmony III transformer C",

- No connection to Y1" or Y2" on indoor unit.

- Outdoor Unit Wiring Completed.

- Thermostat and Damper Wiring Completed.

- Discharge Sensor wired to Harmony III.

Page 27

HARMONY IIIT ZONE CONTROL SYSTEM

GAS FURNACE

VSM Furnace IFC Electrical Adjustments (G61MPV & G60UHV)

NOTE − Follow all equipment installation instructions provided with each unit.

Variable-speed furnaces are equipped with an integrated furnace control (IFC). The blower motor speed must be adjusted, by DIP switch setting selection, to produce the cfm required when all the zones are demanding heating or cooling which is managed by the zone control system.

Locate the integrated control in the furnace control box area. Switch settings on the control affect blower CFM. Before connecting the zone control panel to the integrated control, complete the applicable electrical adjustments as shown in figure

20.

Electrical Adjustments

1. In all casescut the clippable on−board link W914 Dehum −

Harmony (between R & DS, shown left).

2. DO NOT CUT clippable on−board link W951 Heat Pump (be-

tween R & O).

3. DO NOT CUT clippable on−board link W915 2 Stage Compr

(between Y1 & Y2).

4. Be sure T’STAT jumper is on TWO".

5. In all casescut and tape wires 2 & 13 on the motor end of

the VSM harness connecting the integrated control to the motor (see figure 21).

ON−BOARD LINKS:

W951 HEAT PUMPDO NOT CUT

W914 DEHUM − HARMONYCUT IN ALL CASES

W915 2 STAGE COMPRDO NOT CUT

IMPORTANT

Be sure to cut jumper W914; if not cut, the zone control panel DS fuse will blow.

Electrical Adjustments

1. In all casescut the clippable on−board link W914 Dehum −

Harmony (between R & DS, shown left).

2. DO NOT CUT clippable on−board link W951 Heat Pump (be-

tween R & O).

3. DO NOT CUT clippable on−board link W915 2 Stage Compr

(between Y1 & Y2).

4. Be sure to set "T’STAT Heat Stages" to "ON" (2−stage).

5. In all casescut and tape wires 2 & 13 on the motor end of

the VSM harness connecting the integrated control to the motor (see figure 21).

Figure 20. G61MPV & G60UHV Integrated Furnace Control Electrical Adjustments

505023M 08/11

ON−BOARD LINKS:

W915 2 STAGE COMPRDO NOT CUT

W951 HEAT PUMPDO NOT CUT

W914 DEHUM − HARMONYCUT IN ALL CASES

Page 28

VSM Furnaces IFC Electrical Adjustments (G61MPV & G60UHV [cont’d])

J46 PLUG FROM THE MOTOR

GAS FURNACE

TO MOTOR J/P49

CUT AND TAPE WIRE #13 (FURNACE APPLICATION ONLY)

VIEW FROM WIRE ENTRY SIDE OF PLUG

VIEW LOOKING DIRECTLY INTO WIRE ENTRY SIDE OF PLUG

CUT & TAPE WIRE #2

LOOK FOR RIDGE TO IDENTIFY PIN 1 POSITION

VIEW FROM MATING SIDE OF PLUG

Figure 21. Integrated Control Cable Modifications for G61MPV/G60UHV Furnaces

Set the upper limit of blower CFM as follows:

1. Determine the maximum system CFM requirements (sum of all the individual zones).

2. From the Blower Motor Performance table (see unit installation instructions) determine the HIGH Speed cool DIP switch setting that corresponds to this CFM.

3. Set the HIGH Speed cool DIP switch setting on the control to this value.

NOTE − The lower limit of blower CFM is factory set. It is not field adjustable. See table 6 on page 14 for minimum airflow values for specific furnace models.

Page 29

HARMONY IIIT ZONE CONTROL SYSTEM

GAS FURNACE

VSM Furnace System Operation (G61MPV & G60UHV)

This section describes the operation of the zone control in a system that uses a gas furnace.

Zone Thermostats

Only electronic thermostats with a C" terminal may be used with the zone control system. The zone control system distinguishes between heat pump and heat/cool applications via the SYSTEM jumper placement on the zone control panel.

1. Cool / Heat / Auto−Changeover ModesZone thermostats send a heating or cooling signal to the zone control panel. Thermostat servicing zone 1 is the central control thermostat. Zones 2, 3 and 4 each have their own thermostat. Thermostats may be standard or autochangeover type.

Heat and cool demands present at the same time from different zones (opposing demands) are satisfied on a first come first served basis. If a heating demand and a cooling demand reach the zone control panel at the same time, the heating demand is satisfied first. If opposing demands persist, the system will work to satisfy the current demand for a maximum of 20 minutes, then switch over and try to satisfy the opposing demand for a maximum of 20 minutes. When either demand is satisfied, the system works to satisfy the other demand.

NOTE − Allowing opposing demands to persist may consume excess energy. If this condition continues, check the installation (i.e. zone arrangement, supply registers, return registers, zone loads etc.) and make adjustments as necessary. Table 9 shows the time delays that may be expected when opposing demands are received from the zone thermostats.

The zone control system acknowledges a new or opposing demand as soon as it is received by illuminating that zone’s thermostat input lights. If the first demand is not satisfied by the time the delays elapse, the system switches over and begins satisfying the opposing demand. During the switch-over, a delay may be imposed before the system begins satisfying the new demand.

2. Fan On / Auto ModeZone thermostats can send a continuous fan signal to the zone control system. The zone control system will signal the blower to supply air to zones calling for continuous fan while no other conditioning calls exist. When the zone control system receives a conditioning call while satisfying a demand for continuous fan, it signals the damper controlling the continuous-fan zone to close. After the conditioning demand is satisfied, the continuous-fan zone damper is signaled to reopen.

Balance Point Setting

(Dual Fuel Systems) Balance Point Sensor (kit 56A87) communicates with the zone control panel whether or not to force the Gas Furnace to satisfy heating demands, based on a comparison of the Balance Point setting with the outdoor temperature. Terminals 2−3 close on temperature fall to lock out heat pump.

Zone Mode

The zone control mode (Vacation switch OFF) utilizes the zone control system’s full potential. While in this mode, the zone control system will respond to demands from any zone, controlling dampers and regulating blower CFM to maintain comfort. When the system is in zone mode, the zone control system responds to demands from any zone thermostat. (Switch settings are shown in figures 17 through 26.)

The only OPEN supply-air dampers are those zones from which a demand was received; all other dampers are CLOSED. The blower operates at a speed based on the position of the Zone PIAB selection jumpers (and the heating air reduction jumper, if a call for heat is present).

NOTE − To ensure that the zone control performs optimally, avoid mixing air between the zones.

Central (Vacation) Mode

When in central mode (Vacation switch ON), the system responds only to heating or cooling demands from the central control (Zone 1) thermostat; all zones will receive conditioned air. All dampers remain open and the blower operates at full speed (minus the amount selected by the heating air reduction jumper). (Switch settings are shown in figures 17 through 26.)

In Fan−Auto mode, the blower will cycle on and off with each demand. During gas or electric-strip heating, the blower may continue after the end of a demand until the heater is cooled sufficiently.

Cooling Operation

When the Harmony IIIt zone control system receives a thermostat cooling call, the following events occur:

S The zone control checks to make sure it has been at

S When timed−off delay is satisfied, the zone control

S The zone control checks the discharge air sensor for

S If, at any time, the discharge air sensor measures a

least 5 minutes since the last cooling call ended to prevent starting against high head pressures.

starts the outdoor unit with 1st−stage compressor and slowly increases the indoor blower speed to achieve proper CFM. Four minutes must elapse at this state to allow the system to reach steady−state operation before staging again.

proper temperature. If measured temperature is 7ºF or more above the cooling staging jumper setting, then Y2 energizes (if available). If both stages of cooling are energized and 4 minutes has elapsed since the last staging event, and the discharge air sensor (DAS) detects a temperature less than the cooling staging jumper, then Y2 is staged off.

temperature of 45ºF or below, the zone control de−energizes the Y1 and/or Y2 output, stopping the compressor and preventing the indoor coil from freezing up. The compressor will not be energized again until the temperature at the DAS rises by 10ºF and the timed−off delay expires. During this time, continuous fan is supplied to the zones calling for cooling.

505023M 08/11

Page 30

VSM Furnace System Operation (G61MPV & G60UHV [cont’d})

Heating Operation

Gas furnaceIn this system, when the zone control re-

ceives a thermostat heating demand, the following events occur:

S The zone control sends a W1 signal to the furnace, which

goes through its normal ignition sequence, except that while the temperature at the DAS is below 100ºF, the zone control instructs the blower to run at minimum speed.

S After the temperature at the DAS rises above 100ºF, the zone

control slowly increases the CFM delivered until it reaches the correct setting. During a call for heat, the zone control stages the furnace up and down to maintain the discharge air temperature between the heating staging jumper setting and 20ºF above this jumper setting. There is a minimum 3 minute delay between staging events.

NOTE − See page 26 for additional notes on operation with G71MPP & SLP98 furnace.

Heat Pump with Electric HeatIn this system, when the zone control receives a thermostat heating call, the following events occur:

S The zone control starts the heat pump on 1st−stage. S If after 4 minutes, the temperature at the DAS is not within the

proper range (heating staging jumper setting and heating staging jumper setting +20) the unit stages up or down, accordingly.

S If the air temperature cannot be maintained using the heat

pump alone, the zone control starts the electric heating stages. Should the discharge temperature exceed 135ºF, the compressor (and any electric heat that may be on) is turned off and continuous fan runs (if the demand for heat remains) until the air temperature falls below 130ºF and the minimum timed−off delay expires.

S If the heat pump goes into defrost mode, the zone control en-

ergizes all stages of compressor and the 1st−stage of electric heat. If the defrost process lasts longer than 20 minutes, the zone control, presuming a defrost board failure, de−energizes the heat pump and instructs electric heat to service the remainder of the current heating call. (The heat pump will be tried again on the next heating call.)

Dual Fuel−Heat Pump with Gas FurnaceIn this system, when it receives a thermostat heating call, the zone control responds in one of two ways:

1. Outdoor temperature below balance point (balance point sensor closed, red Balance Point Sensor LED on): the zone control sends a W1 signal to the fur- nace to satisfy heat demands, staging the furnace to maintain discharge air temperatures between 110ºF and 130ºF.

2. Outdoor temperature above balance point (balance point sensor open, red Balance Point Sensor LED off): the heat pump is first used to satisfy the demand. If, after 20 minutes, the heat pump fails to maintain the required discharge air temperature, the zone control will discontinue using the heat pump and initiate furnace heating. (A five−minute delay exists between stopping the heat pump and starting the furnace.) In this mode, all heating calls for the next three hours are serviced with the gas furnace. Also, diagnostic lights 2, 3, and 4 blink to indicate that the zone control is operating within this 3−hour furnace lock−in time. During this time, the zone control stages the furnace to maintain discharge air temperatures between 110ºF and 130ºF. After the 3−hour delay expires, the heat pump will again be tried on the next heating call.

Defrost Tempering (Optional)

frost Operation on Page 23 for Defrost Tempering operation.

Emergency heat mode

When the unit is setup for heat pump and the emergency heat switch is turned on, the unit will satisfy all heating demands with electric backup heat or, in a dual fuel system, the heat demand is satisfied by the gas furnace.

Humiditrol® mode (Enhanced Dehumidification Accessory)

When the unit is equipped for dehumidification (Enhanced Dehumidification Accessory and Humiditrol® Zoning Accessory installed), the unit will satisfy all demands for dehumidification. Refer to supplemental kit information Dehumidification Interface Kit for Harmony IIIt Zone Control.

GAS FURNACE

If installed, refer to De-

Page 31

HARMONY IIIT ZONE CONTROL SYSTEM

GAS FURNACE

Harmony IIIt Installation Setup Worksheets

G61MPV/G60UHVCooling/Heating; with Honeywell 2−stage IFC control (non−Heat Pump applications)

Job Name: Indoor Unit Model: Outdoor Unit Model:

Indoor Unit setup:

- Cut on−board link W914 DEHUM OR HARMONY (R to DS) on furnace IFC control (if not cut, fuse will blow in zone control board)

- Cut and tape wires from pin # 2 and pin #13 on plug J46 of the VSM wiring harness routed from the motor to the Furnace Integrated control.

- Furnace IFC Control DIP switch settings (ON or OFF):

1 OFF (DIP switch 1 must be set to Off for 2−stage heating operation)

2 OFF (DIP switch 2 determines 2nd stage heat time delay & is ignored by Harmony III)

3 ON (DIP switches 3 & 4 determines heating blower off delay, recommended is 180 sec)

4 ON I

5 DIP switches 5 & 6 determines 2nd stage cooling blower speed or maximum system air vol.)

6 I

7 (DIP switches 7 & 8 determine blower adjust" setting for maximum system air volume)

8 I

9 OFF (DIP switches 9 & 10 determines cooling blower ramping profile & is ignored by Harmony III)

10 OFF I

11 OFF (DIP switches 11&12 determines heating blower speed & is ignored by Harmony III)

12 ON I

Harmony IIIt Panel setup:

- Heating staging jumper (circle one): 85 90 100 110 120 130 (Recommended 120 deg−F)

- Zone 1 PIAB 140F DAS jumper in place (circle one): Yes No (see install instructions for info)

- Cooling staging jumper (circle one): 50 55 60 (select desired discharge air temp during cooling)

- Cont. Air Reduction jumper (circle one): 0 25 50 75 (% airflow reduction for continuous fan operation)

- Heating Air Reduction jumper (circle one): 0 20 40 (% air flow reduction for heating mode)

- System Configuration jumpers (circle one): HP GAS (Set to GAS)

- Stages (circle one): 2COOL 1COOL (Set to match condenser, 1 or 2 stage)

- Stages (circle one): 2HP 1HP (ignored for gas heat, non−heat pump application)

- E−HEAT Stages (circle one): DF 1 2 3 (ignored for gas heat, non−heat pump application)

- Desired total system cfm with all zones calling− _________ Total system cfm per tables− _________ Minimum cfm− _________

- Zone 1 – Name:____________ Desired cfm:____________ PIAB Setting: ____________% Actual cfm: ____________

- Zone 2 – Name:____________ Desired cfm:____________ PIAB Setting: ____________% Actual cfm: ____________

- Zone 3 – Name:____________ Desired cfm:____________ PIAB Setting: ____________% Actual cfm: ____________

- Zone 4 – Name:____________ Desired cfm:____________ PIAB Setting: ____________% Actual cfm: ____________

NOTEAll of the above are recommended starting positions for DIP switches and Harmony III jumpers. Slight variations may be required during system start up and operation checks.

Field Wiring Checklist:

- Indoor Unit Wiring Completed:

- DS" on Harmony III to DS" on indoor unit connected,

- "C" on indoor unit connected to Harmony III transformer C",

- No connection to Y1" or Y2" on indoor unit.

- Outdoor Unit Wiring Completed.

- Thermostat and Damper Wiring Completed.

- Discharge Sensor wired to Harmony III.

505023M 08/11

Page 32

GAS FURNACE

Furnace System Start−Up & Checkout

IMPORTANT

The zone control system power−up must occur at the same time or before the furnace or air handler unit is powered up.

Powering the System (All Systems)

1. Adjust all thermostat settings so that no demand will occur.

2. Apply power to the zone panel transformer and to the furnace and observe the following: all four diagnostic LEDs will light; then each individual diagnostic LED will light in sequence; then all four diagnostic LEDs will light and extinguish.

3. Finally, the status light will begin to flash, indicating proper operation. Perform the gas heating checks on pages 33 through 34.

Gas Heating Checkout (Single Zone)

Prerequisites:

S Zone 1 thermostat set to Heat

DAMPER 2,3,4 ON

DAMPER 1 OFF

FAN ON

(W) RED ON

W1 ON

HEATING ON

OUTPUT STATUS LEDs

1. Set zone 1 thermostat for a heat demand; check:

D Zone 1 thermostat W LED on (heating demand). D Damper 1 LED off (damper open). D Damper 2, 3, and 4 LEDs on (dampers closed). D Output Heat W1 LED on (furnace on). D Heating LED on.

The furnace begins ignition sequence after zone 1 has demanded heat. The zone control system will start the furnace blower on low speed (0 PIAB) 45 seconds after the combustion cycle has begun.

2. When 100ºF warm air is sensed by the discharge air sensor, the fan LED will light and the blower will slowly increase to speed required by the zone calling. The blower operates at speed setting of PIAB jumper for zone 1 and the jumper for heating air reduction. It may require 60 − 90 seconds to reach this speed.

3. Set zone 1 thermostat for NO heat demand; check:

D Zone 1 thermostat W LED off (no heat demand). D Output Heat W1 LED off. D Fan LED off. D Heating LED off. D Damper LEDs 2−4 remain on until after 3-1/2 min-

ute purge; then off. To check the amount of air being delivered to each zone and to confirm that each individual zone damper functions properly, repeat these steps for zones 2 − 4.

Page 33

HARMONY IIIT ZONE CONTROL SYSTEM

GAS FURNACE

Gas Heating Checkout (Multiple Zone)

Prerequisites:

All zone thermostats set to Heat

(W) RED ON

W1 ON

DAMPER 2,3,4 OFF

FAN ON

Gas Heating Checkout (Central Control)

HEATING ON

OUTPUT STATUS LEDs

1. Set all zone thermostats for a heat demand; check for the following:

D All zone thermostat W LEDs on (heat demands). D LEDs dampers 1 − 4 off (all dampers open). D Output Heat W1 LED on (furnace on). D Heating LED on.

The furnace begins ignition sequence after a heat demand is detected. The zone control system will start the furnace blower on low speed (0 PIAB) 45 seconds after the combustion cycle has begun.

2. When 100ºF warm air is sensed by the discharge air sensor, the fan LED comes on and the blower will slowly increase to speed required by the zones calling. The blower operates at a speed equivalent to the sum of all zone PIAB jumpers but at a maximum not to exceed the setting of the heating air reduction jumper. It may take the blower 60 to 90 seconds to reach this speed.

3. Set all zone thermostats for NO heat demands; check:

D Output Heat W1 LED off. D Heating LED off. D Fan LED off (blower turns off after delay). D All zone thermostat W LEDs off. D DamperLEDs − Last zone thermostat demand re-

moved: LED is off (this zone’s damper remains open during 3−1/2 minutepurge); other zones damper LEDs are on during the 3−1/2 minute purge (dampers closed). After 3−1/2 minute delay, all dampers LEDs go off (dampers open).

Prerequisites:

Central mode switch on

S S Red LED on the central mode fan switch on

(W) RED ON

CENTRAL

DAMPER 2,3,4 OFF

MODE ON

FAN ON

HEATING ON

OUTPUT STATUS LEDs

W1 ON

1. Set zone 1 thermostat for a heat demand; check:

D Zone 1 thermostat W LED on (heating demand). D Output Heat W1 LED on (furnace on). D Heating LED on. D All damper LEDs off (damper open).

2. The furnace will begin its ignition sequence after Zone 1 has demanded heat. The zone control system will start the furnace blower on low speed (0 PIAB air) 45 seconds after the combustion cycle has begun.

3. When 100ºF warm air is sensed by the discharge air sensor, the fan LED will light and the blower will slowly increase to speed. The blower will operate at a speed equivalent to the PIAB calculated for all zones calling, taking into account the heating air reduction jumper position. It may take the blower 60 to 90 seconds to reach this speed.

4. Remove the heat demand from zone 1 (no heat input or output and no blower demand). Upon removal of the demand from zone 1, check:

D Zone 1 thermostat W LED off (no heat demand). D Output Heat W1 LED off. D Fan LED off. D Heating LED off.

After 3−1/2 minute purge time, furnace blower turns off.

505023M 08/11

Page 34

Troubleshooting DiagramZone system with Gas Furnace

GAS FURNACE

- Are thermostats wired correctly?

- Does zone control system respond appropriately to demand?

- Heat/cool thermostat used? (Must not use heat pump thermostat.)

- Does electronic thermostat have relay switching output? If not, isolation relays may need to be used.

- 24VAC supplied to each thermostat terminal R from zone control system?

- Check each thermostat for output signal when calling. Heating output? Cooling output?

THERMOSTATS

- (No pressure Switch should be installed.)

- Do dampers respond to demand? 0

volts AC = open. 24 volts AC = closed. Dampers should drive closed when 24 volts is jumpered to damper motor.

- Is wiring correct & in good condition?

DAMPERS

- Is discharge

probe installed?

- Is probe located

in discharge air plenum as described on Page 6?

- Is it wired cor-

rectly?

DISCHARGE

AIR SENSOR

HUMIDITROL ZONING

ACCESSORY CONTROL

- Have heating and cooling

staging jumpers been set for desired 2nd stage operation?

- Are continuous & heating air re-

duction jumpers set correctly?

- Do jumpers provide appropriate

speed reduction? If no, check indoor unit before replacing zone control panel.

Heating/cooling

staging jumper

settings − page 10.

Air reduction

jumper

settings −

page 9.

PIAB jumper settings − page 8.

140F DAS

jumper

pages 8

& 10.

System Configuration & E−Heat

jumper settings − page 11.

- Line Voltage to transformer?

- 24VAC from transformer to zone control panel?

- Are all wire connections good? Are all wire connections correct?

Thermostat 2 Thermostat 1

W C Y G R

ZONE PANEL TRANSFORMER

VAC

VARIABLE SPEED

FURNACE

POWER SUPPLY

120 VAC

- C" connected

to C"?

- Fuses OK?

2-STAGE

CONDENSING

UNIT

Y1 Y2 C R

R G W1 W2 C DS Y1 Y2

TO FURNACE

- Are PIAB jumpers set correctly?

- Only 1 jumper per Zone? (Zone Control

System Jumper Settings (Page 8) (NOTE: Zone 1 may have a second jumper on 140F DAS pins)

- Has 140F DAS jumper been installed (if

required; see Page 8 & 10)?

- Are jumpers set cor-

rectly for furnace and cooling? (Page 11)

Figure 22. Option 1 − Lennox Variable-Speed Gas Furnace and Lennox Condensing Unit

- Error code present? If

so, see troubleshooting/ diagnostic section of this manual (Page 56).

Page 35

- Does outdoor unit respond to

demand?

- Is it operating properly?

- Are appropriate outputs ener-

gized in response to demand?

- Does zone control system en-

ergize appropriate outputs? During Cooling? During Heating?

- 24VAC from furnace transform-

er to R?

- Does furnace respond to out-

puts?

- Does blower speed change as

zone demand changes? If no, does DS output vary from 0 to 25VDC?

HARMONY IIIT ZONE CONTROL SYSTEM

- Verify Furnace jump-

ers/links cut or removed (see Pages 28 −

25) Page 39)

- Verify NO connections

made to Y1 or Y2.

GAS FURNACE

TroubleshootingGas Heating Operation

HEATING DEMAND

RECEIVED

3−Minutes

since completion

of last heating

demand

Energize W1 @

furnace; Ramp

indoor blower to

minimum CFM

setting

Discharge

air above

100°F

Ye s

Ramp indoor

blower to

heating staging

jumper setting

REFER TO DISCHARGE AIR UPPER LIMIT DIAGRAM (Page 37) FOR UPPER LIMIT

Ye s

Monitor

discharge air

temperature

discharge

air at upper

De−energize

W1 @ furnace

limit

Discharge

air below heating

staging jumper

setting

Ye s

3−Minutes

minimum run time

in 1st stage

completed

Ye s

Heating demand

satisfied

Ye s

AND DIFFERENTIAL DETAILS.

Shut down all

heat stages

Continuous air

delivered to

calling zones

5 min delay

complete

Discharge

air falls to

130°F

Heating demand satisfied

Ye s

Energize W2

@ furnace

Monitor

discharge air

temperature

discharge

air at upper

Ye s

limit

Does

discharge air

temp. meet

heating staging

differential

3−Minutes

minimum run time

in 2nd stage

completed

De−energize

Heating

demand

satisfied

Ye s

Hold dampers

open for 3½

minutes

505023M 08/11

BLOWER

SHUTDOWN

Page 36

TroubleshootingDischarge Air Upper Limit & Differential Temperatures

Furnace

energized

Monitor

discharge air

temperature

Discharge air upper limit is 160ºF unless 140F DAS jumper installed

Ye s

Differential is 20ºF above heating staging jumper setting with the following exception:

Differential is 15ºF if the 140F DAS jumper is in place on PIAB 1 terminals and heating staging jumper is on 120 or 130.

discharge

air at upper

limit

Does

discharge air

temp. meet

heating staging

differential

Ye s

GAS FURNACE

To / from the

appropriate

gas heating or

dual fuel diagram

3−minute

minimum run-

time com-

pleted

Ye s

Page 37

HARMONY IIIT ZONE CONTROL SYSTEM

AIR HANDLERS

Variations on Common Condensing Unit Applications

Heating/Cooling Equipment Installation

Follow all equipment installation instructions provided with each unit.

Air Handler Wiring

After the air handler unit is installed, field wire the line voltage as shown in the installation instructions provided with the unit. Use thermostat wire to connect the air handler to the zone control panel (see figure 15) and to connect wire from zone control panel 24V C" to air handler terminal strip C".

COOLING WITH ELECTRIC HEAT

S System configuration jumpers:

HP; 1COOL or 2COOL.

S E−Heat stage jumper set on #

agreeing with # of available heat stages.

S E−HEAT Selector Switch always

ON.

S As applicable, cut jumpers and

harness wires (see Blower Control Adjustments − Air Handlers on Page 39).

HOT WATER COIL (CBWMV, CBX32MV or CBX40UHV)

S System configuration jumpers:

GAS; 1COOL or 2COOL; Others do not matter.

S AHC (prior to revision 06): Cut or remove 24 volt jumper Y1

to DS.

S AHC (revision 06): Cut R to DS clippable link on air handler

control.

S CBWMV has no K20 relay, therefore wiring harness modifi-

cation (shown in figure 25, Page 39) is not required.

− Cut or remove 24v jumper Jumper Y1 to DS

− Remove Pink wire from TB1−W1 to J46−2 on CBWMV

NOTE − K212 field hookup relay must be field provided on the CBX32MV or CBX40.

NOTE − DAS must be located downstream of the cooling coil and HW coil

NOTE − Be sure to remove the factory installed jumper bar between W1 to W2 and W2 to W3 (CBX40 or CBX32MV rev 06) or remove the jumper wires between R to W1 and R to W2 (CBX32MV prior to rev 06).

Variations

Several variations may be required for specific applications. Figure 23 shows alternate wiring and describes specific jumper configurations and other special modifications required for each variation. Aside from the variations described in figure 23, the connectivity is the same as shown in figure 17 (Page 24).

COOLING ONLY

S System configuration jumpers:

GAS; 1COOL or 2COOL; Others do not matter.

S As applicable, cut jumpers and harness

wires (see Blower Control Adjustments

− Air Handlers on Page 39).

HEATING ONLY

NOTE − JUMPER between RC and RH must be in place on the control!

For any option or variation, connect thermostat wire between C" on terminal strip(s) of controlled equipment and zone control panel 24VAC C" terminal.

Y1 Y2

W1−Def

G W1 W2 W3

Equipment

IMPORTANT!

DO NOT MAKE

CONNECTIONS

TO Y1 AND Y2

Condensing

Unit

Y1 Y2 C R

R G W1 W2 W3 C DS Y1 Y2

VSM Air

Handler

with Elec-

tric Heat

Y1 Y2

W1−Def

G W1 W2 W3

Equipment

Condensing

IMPOR-

TANT! DO

NOT MAKE

CONNECTIONS TO

Y1 AND Y2

Unit

VSM

Handler

CBWMV AND CBX32MV OR

CBX40UHV USED

Y2 C

WITH HOT WATER

COIL

R G W1 W2 C DS

K212 FIELD

HOOKUP

RELAY MUST BE PROVIDED ON CBX32MV

Air

OR CBX40

TO BOILER OR ZONE CONTROL

Y1 Y2

W1−Def

G W1 W2 W3

Equipment

Condensing

IMPORTANT!

DO NOT MAKE

CONNECTIONS

TO Y1 AND Y2

Unit

VSM Air

Handler

Y1 Y2 C R

R G W1 W2 C DS Y1 Y2

Figure 23. Harmony IIIt Zone Control System − Variations on Common Applications

505023M 08/11

Page 38

AIR HANDLERS

Air Handler Control Electrical Adjustments (All model VSM Air Handlers)

Electrical AdjustmentsCommunicating CBX32MV (revision 06) and CBX40UHV (all)

Electrical Adjustments

As shown in this diagram, make the following adjustments:

1. Cut on board link R to DS (Dehum or Harmony).

2. Remove Jumper Bars from W1 to W2 and W2 to W3.

3. DO NOT CUT on board links Y1−Y2 2 STAGE COMPR and R−O HEAT PUMP

Y1−Y2 2 Stage Compr

and R−0 Heat Pump

CUT on board

Link R−DS

DO NOT CUT on board links

Remove

W1−W2 and W2−W3

Jumper Bars from the

terminal strip

Figure 24. Electrical Adjustments for Air Handler Control CBX32MV (revision 06) & CBX40UHV (all)

Electrical AdjustmentsNon−communicating CBX32MV (prior to revision 06), CB31MV and CBWMV

These air handler blower motors are controlled by the BDC3 drive control; CFM adjustment Is by jumper setting selection.

Locate the BDC3 board in the blower control box. Before connecting the zone control panel to the BDC3 board, complete all of the applicable electrical adjustments as shown in figure 25.

NOTE − Before cutting wires or jumpers, be sure your installation is not affected by Variations on Common Condensing Unit Applications" figure 23 (Page 38).

Electrical Adjustments

As shown in this diagram, make the following adjustments: In all cases except Cooling Only" or CBWMV units:

1. CUT wire near the BDC3 board JP1 pin 2

2. tape exposed end of short JP1 pin 2 wire

3. re−route wire connected to K20 terminal 4; strip end and connect to terminal G" (K20 wiring change not required on CBWMV)

If CBWMV, remove pink wire TB1−W1 to J46−2

Except for Cooling Only" units, remove any jumper(s) between R − W2 or R − W3

DO NOT CUT jumper R − O

JP1

BDC3

K20 INDOOR BLOWER RELAY

Figure 25. Electrical Adjustments for Air Handler Control CBX32MV (pre−rev. 06), CB31MV & CBWMV

Set the upper limit of blower CFM as follows:

1. Determine the maximum system CFM requirements (sum of all the individual zones).

2. From the Blower Motor Performance table in the unit’s installation instructions, determine the COOL Speed jumper setting that corresponds to this CFM; then set the COOL Speed jumper setting on the BDC3 board to this value.

For more information on setting blower speed, refer to section on Blower Speed and Adjustment" in the blower unit’s installation instructions.

DO NOT CUT Jumper Y1 − Y2

In all cases, CUT Jumper DS − Y1

Page 39

HARMONY IIIT ZONE CONTROL SYSTEM

AIR HANDLERS

Harmony IIIt Installation Setup Worksheets

CBX32MV/CBX40UHVCooling/Heating; Electric Strip Heat (non−Heat Pump applications)

Job Name: Indoor Unit Model: Outdoor Unit Model:

CBX40UHV and CBX32MV Revision 06 Indoor Unit setup:

- Cut on−board link R to DS DEHUM or HARMONY"

- Remove any factory−installed jumpers bars from W1 to W2 or W2 to W3.

- Air Handler Control jumper settings:

COOL: This setting, along w/ ADJUST setting, determines maximum system CFM (See blower tables)

ADJUST: Setting affects both heating and cooling blower speeds (see blower tables to determine setting)

HEAT: HIGH Heating blower speed selectioin – Ignored by Harmony III

DELAY: 4 Cooling blower ramping – Ignored by Harmony III

BLOWER ONLY CFM: Continuous fan speed – Ignored by Harmony III

EVENHEAT: EVENHEAT is not used with Harmony III

CBX32MV prior to Revision 06 Indoor Unit setup:

- Remove DS to Y1 jumper

- The wire from K20 terminal 4 to BDC3 board JP1 pin 2 must be re−routed to establish an electrical connection between K20 terminal 4 and terminal G. Cut

the wire near JP1 pin 2. Using the wire still connected to K20 terminal 4, strip the cut end and connect it to terminal G. Tape the exposed end of the short JP1pin 2 wire (See Harmony III Installation Instructions for more details).

- Remove any factory−installed jumpers between terminal R and W1, W2, or W3.

- BDC3 control clip jumper settings:

COOL: This setting, along w/ ADJUST setting, determines maximum system CFM (See blower tables)

ADJUST: Setting affects both heating and cooling blower speeds (see blower tables to determine setting)

HEAT: 4 Heating blower speed selectioin – Ignored by Harmony III

DELAY: 4 Cooling blower ramping – Ignored by Harmony III

Harmony IIIt Panel setup:

- Heating staging jumper (circle one): 85 90 100 110 120 130 (Recommended 120 deg−F)

- Zone 1 PIAB 140F DAS jumper in place (circle one): Yes No

- Cooling staging jumper (circle one): 50 55 60 (select desired discharge air temp during cooling to stage compressor)

- Cont. Air Reduction jumper (circle one): 0 25 50 75 (% airflow reduction for continuous fan operation)

- Heating Air Reduction jumper (circle one): 0 20 40 (% air flow reduction for heating mode)

- System Configuration jumpers (circle one): HP GAS (Set to HP)

- Stages (circle one): 2COOL 1COOL (Set to match condenser, 1 or 2 stage)

- Stages (circle one): 2HP 1HP (Ignored for non−heat pump – w/ strip heat applications – setting does not matter)

- E−HEAT Stages (circle one): DF 1 2 3 (Set to # of strip ht stages (<8KW=1)(>8KW & <30KW=2)( 30KW=3)

- Emergency Heat switch on Harmony III zone panel must be set to ON.

- Desired total system cfm with all zones calling− ___________ cfm, Actual total system cfm− ___________

- CB unit minimum" cfm ____________ (determined by unit spec as listed below unit blower table)

- Zone 1 – Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________

- Zone 2 – Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________

- Zone 3 – Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________

- Zone 4 – Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________

NOTEAll of the above are recommended starting positions for DIP switches and Harmony III jumpers. Slight variations may be required during system start up and operation checks.

Field Wiring Checklist:

- Indoor Unit Wiring Completed:

- DS" on Harmony III to DS" on indoor unit connected,

- "C" on indoor unit connected to Harmony III transformer C",

- No connection to Y1" or Y2" on indoor unit.

- Outdoor Unit Wiring Completed.

- Thermostat and Damper Wiring Completed.

- Discharge Sensor wired to Harmony III.

505023M 08/11

Page 40

AIR HANDLERS

Harmony IIIt Installation Setup Worksheets (continued)

CBX32MV/CBX40UHVHeat Pump; Electric Strip Heat

Job Name: Indoor Unit Model: Outdoor Unit Model:

CBX40UHV and CBX32MV Revision 06 Indoor Unit setup:

- Cut on−board link R to DS DEHUM or HARMONY"

- Remove any factory−installed jumpers bars from W1 to W2 or W2 to W3.

- Air Handler Control jumper settings:

COOL: This setting, along w/ ADJUST setting, determines maximum system CFM (See blower tables)

ADJUST: Setting affects both heating and cooling blower speeds (see blower tables to determine setting)

HEAT: HIGH Heating blower speed selectioin – Ignored by Harmony III

DELAY: 4 Cooling blower ramping – Ignored by Harmony III

BLOWER ONLY CFM: Continuous fan speed – Ignored by Harmony III

EVENHEAT: EVENHEAT is not used with Harmony III

CBX32MV prior to Revision 06 Indoor Unit setup:

- Remove DS to Y1 jumper

- The wire from K20 terminal 4 to BDC3 board JP1 pin 2 must be re−routed to establish an electrical connection between K20 terminal 4 and terminal G. Cut

- Remove any factory−installed jumpers between terminal R and W1, W2, or W3.

- BDC3 control clip jumper settings:

COOL: This setting, along w/ ADJUST setting, determines maximum system CFM (See blower tables)

ADJUST: Setting affects both heating and cooling blower speeds (see blower tables to determine setting)

HEAT: 4 Heating blower speed selectioin – Ignored by Harmony III

DELAY: 4 Cooling blower ramping – Ignored by Harmony III

Harmony IIIt Panel setup:

- Heating staging jumper (circle one): 85 90 100 110 120 130 (Recommended 90 deg−F)

- Zone 1 PIAB 140F DAS jumper in place (circle one): Yes No

- Cooling staging jumper (circle one): 50 55 60 (select desired discharge air temp during cooling to stage compressor)

- Cont. Air Reduction jumper (circle one): 0 25 50 75 (% airflow reduction for continuous fan operation)

- Heating Air Reduction jumper (circle one): 0 20 40 (Must be set to 0% on heat pump systems)

- System Configuration jumpers (circle one): HP GAS (Set to HP)

- Stages (circle one): 2COOL 1COOL (Set to match condenser, 1 or 2 stage)

- Stages (circle one): 2HP 1HP (Set to heat pump stages, 1 or 2 stage)