5.0 AIR HANDLER Comfort Control 2 System INTERFACE BOARD
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- Eustacia Boone
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1 5.0 AI HANDLE omfort ontrol 2 System INTEFAE OAD FIGUE 8 THE AI HANDLE ONTOL OAD EQUIPPED WITH THE omfort ontrol 2 System The HPL-series of air handlers are designed to operate with conventional 24VA controls or with a serial communicating system. For the omfort ontrol 2 System, you must have: An air handler equipped with the omfort ontrol 2 System A condensing unit or heat pump equipped with omfort ontrol 2 System A omfort ontrol 2 thermostat If your equipment does not meet this criteria, you must wire it using conventional 24VA thermostat control wiring. eference Section omfort ontrol 2 ONTOL WIING The omfort ontrol 2 requires four (4) control wires for unit operation: 24VA 24VA common 1 Data wire 1 2 Data wire 2 Wiring sizing for omfort ontrol 2 is identical to systems using low voltage 24V wires. Note: omfort ontrol 2 requires a minimum 18 AWG. IMPOTANT: When using omfort ontrol 2, do not make any connections to the 24VA thermostat wires. If any connections are made to the G, W1, W2,,,, or ODD wires, the omfort ontrol 2 control will assume the control is being used with a traditional thermostat and will IGNOE ANY OMMUNIATIONS USING DATA WIE 1 AND DATA WIE 2. IMPOTANT: lass 2 low voltage control wire should not be run in conduit with power wiring and must be separated from power wiring, unless lass 1 wire of proper voltage rating is used. The four 18AWG low voltage control wires must be installed from the thermostat to the indoor unit and from indoor unit to the outdoor unit. The wire length between the thermostat and indoor unit should not be greater than 100 feet. The wire length between the indoor unit and outdoor unit should not be greater than 125 feet. Low voltage control connections are made by extending wires from top of air handler using wire nuts. See wiring diagrams attached to indoor and outdoor sections to be connected. omfort ontrol 2 System ONTOL WIING 15
2 Do not leave excess field control wiring inside unit, pull excess control wire to outside of unit and provide strain relief for field wiring on inside of cabinet at point wiring penetrates cabinet. Make sure, after installation, separation of control wiring and power wiring has been maintained. FIGUE 9 TYPIAL The omfort ontrol 2 System WIING DIAGAM Indoor Unit 1 2 ommunicating Thermostat 1 2 Outdoor Unit 1 2 omfort ontrol 2 System ONTOL WIING WIING INFOMATION Line Voltage Field Installed Factory Standard 5.2 omfort ontrol 2 System ONTOL OAD The HPL series air handler control, Figure 8, has the following features: Memory ard The memory card stores all information needed for unit operation. Once the system is wired for serial communications, this information is shared with the thermostat and outdoor unit. This shared data is available if one of the components in the system needs to be replaced. An automotive-style AT blade fuse for transformer protection (3 amp). An on-board LED to indicate blower FM. An J-11 port for use with a diagnostic tool. Inputs for field installed supply and return air temperature sensors (available in kit XHT-A01) DIP switches for airflow adjustments IMPOTANT: The DIP switches are NOT used when the air handler is wired for serial communications. Airflow adjustments are performed via the thermostat or a diagnostic tool. Installation Verification Term and bias dip switches should be on. 24V A power on & must be present at the control for the air handler to operate, reference Figure 9. Line voltage must be present at the control for indoor blower operation. The X Data LED will flash green in normal operation. A flashing green light indicates 24VA is present and the data wires 1 and 2 are wired properly. IMPOTANT: If the X DATA LED is solid green, data wire 1 and data wire 2 are not properly connected. Typically, the connections are switched, i.e. data wire 1 is wired to the data wire 2 connection and data wire 2 is wired to the data wire 1 connection. Verify wiring and correct the polarity at the two data wires. IMPOTANT: Diagnostic port is for the diagnostic tool only. Do not attempt to connect components using a telephone cord. Damage will occur. IMPOTANT: Diagnostic port is not a phone jack. onnecting to a telephone or telephone system will result in damage. 5.3 USING THE ON-OAD LED TO DETEMINE LOWE FM The FM LED indicates blower output by flashing one (1) flash for every 100 FM of airflow. The LED will pause 1/10 second between each flash. 5.4 AIFLOW ADJUSTMENTS WITH THE omfort ontrol 2 System The HPL air handler omfort ontrol 2 System may operate using the omfort ontrol 2 or via traditional thermostat wiring. When the air handler is wired for the omfort ontrol 2 using Data wire 1 and Data wire 2, the DIP switches on the omfort ontrol 2 control have NO affect on the airflow. 16
3 IMPOTANT: When using the omfort ontrol 2, the DIP switches have no affect on airflow or on air handler performance. 5.5 OOLING AIFLOW SETTINGS (Y TONNAGE) The HPL-series of air handlers automatically set cooling airflow when using the omfort ontrol 2 System. The air handler detects the tonnage of the condensing unit/heat pump and sets airflow for optimum performance and comfort. efer to Table 2 for the airflow provided when the HPL air handler is matched to the (-)PL heat pump. TALE 1 HPL AIFLOW WHEN MATHED TO THE (-)PL HEAT PUMP Tonnage of heat Airflow (cfm) pump 2 nd Stage 1 st Stage (-)PL-024JE (-)PL-036JE (-)PL-048JE (-)PL-060JE ble X.X (-)HPL airflow when matched to the (-)PL heat pump 5.6 OOLING AIFLOW ADJUSTMENT The omfort ontrol 2 System control board does allow the installer to tweak the cooling airflow +/-10% to suit the installation. When using the omfort ontrol 2 System, the airflow can only be adjusted using the serial communicating thermostat or a service tool. To adjust the airflow, go to the airflow adjustment menu and select the desired adjustment. (eference Table 2.) TALE 2 AIFLOW ADJUSTMENT SELETION TALE Selection None +10% -10% Table X.X Airflow Adjustment Selection Table. IMPOTANT: ooling airflow adjustment is accessible via the omfort ontrol 2 thermostat or via a service tool. efer to their instructions to access the cooling airflow adjustment menu. NOTE: ooling airflow adjustments are in effect for cooling operation only. They are ignored when in heating mode or when electric heat is activated. 5.7 HEATING AIFLOW ADJUSTMENT The omfort ontrol 2 control does allow the installer to tweak the heating airflow +/-10% to suit the installation. When using omfort ontrol 2 System, the airflow can only be adjusted using the omfort ontrol 2 thermostat or a service tool. To adjust the airflow, go to the airflow adjustment menu and select the desired adjustment. (eference Table 3.) omfort ontrol 2 System ONTOL WIING TALE 3 AIFLOW ADJUSTMENT SELETION TALE Selection None +10% -10% Table X.X Airflow Adjustment Selection Table. IMPOTANT: Heating airflow adjustment is accessible via the omfort ontrol 2 thermostat or via a service tool. efer to their instructions to access the heating airflow adjustment menu. NOTE: Heating airflow adjustments are in effect for heat pump operation only. They are ignored when in cooling mode or when electric heat is activated. 17
4 5.8 ELETI HEAT AIFLOW The HPL-series of air handlers are factory programmed to provide adequate airflow for electric heat (auxiliary heat). Airflow for electric heat is fixed and cannot be field adjusted. TALE 4 ELETI HEAT AIFLOW Thermostat Electric Heat Airflow Input 2-ton 3-ton 4-ton 5-ton W1 or W2 800 FM 1200 FM 1600 FM 1800 FM omfort ontrol 2 System ONTOL WIING TALE 5 ODD TEMINAL INDOO AMIENT ONDITION HIGH HUMIDITY LOW HUMIDITY INPUT TO ODD TEMINAL (FOM HUMIDISTAT) Ø VA 24 VA 5.9 OOLING MODE DEHUMIDIFIATION The serial communicating control is shipped with On Demand Dehumidification (ODD) turned OFF. On Demand Dehumidification may be activated from the serial communicating thermostat when the serial communicating thermostat has an on-board humidity sensor. IMPOTANT: On Demand Dehumidification is accessible via the serial communicating thermostat or via a service tool. efer to their instructions to access the ODD airflow adjustment menu OOLING DELAY POFILES The HPL air handler is factory configured with optimum ON/OFF delays to maximize energy efficiency and comfort. In certain situations, the installer may choose an alternate profile to tweak the system operation for the building load and to maximize comfort. The alternate profiles are defined below: IMPOTANT: On Demand Dehumidification, ODD, is the preferred method to maximize comfort with little or no loss of energy efficiency. If using ODD, do NOT use any of the alternate profiles. Only use the factory default profile. Use of the alternate profiles with ODD will decrease energy efficiency with no gain in comfort. Profile A Factory default profile. Air Handler On Delay Delay Duration (second) % ated Airflow Off Delay (seconds) HPL-HM2421 No Delay N/A 45 HPL-HM3621 No Delay N/A 45 HPL-HM4824 No Delay N/A 45 HPL-HM6024 No Delay N/A 45 Profile Quiet Start profile The Quiet Start profile is configured to bring the blower up to 50% airflow for 30 seconds before advancing to 100% airflow. This helps to minimize the blower noise at system startup. On Delay Air Handler Delay Duration (second) % ated Airflow Off Delay (seconds) HPL-HM HPL-HM HPL-HM HPL-HM Profile Humid profile The humid profile is configured to run the blower at 80% airflow for about the first four minutes of system operation to remove more moisture from the conditioned space. On Delay Air Handler Delay Duration (second) % ated Airflow Off Delay (seconds) HPL-HM HPL-HM HPL-HM HPL-HM Profile D Dry limate profile The Dry limate profile is configured for areas that require little to no additional dehumidification. On Delay Air Handler Delay Duration (second) % ated Airflow Off Delay (seconds) HPL-HM HPL-HM HPL-HM HPL-HM
5 WIE OLO ODE K LAK G GEEN P PUPLE Y YELLOW OWN GY GAY ED L LUE O OANGE W WHITE FIGUE 10 TYPIAL 2-STAGE THEMOSTAT: HEAT PUMP WITH ELETI HEAT (-)HPL Air Handler W1 W2 G ODD WIING INFOMATION Line Voltage - Field Installed - Factory Standard DIP SWITH POSITIONS ON OFF Typical Two-Stage Thermostat G E/W1 W2 Y Y/L L W/ P (-)PL Heat Pump Outdoor Unit FIGUE 12 TYPIAL TWO-STAGE THEMOSTAT: (-)PL HEAT PUMP WITH ELETI HEAT USING A TWO-STAGE THEMOSTAT WITH DEHUMIDIFIATION* (-)HPL Air Handler W1 W2 G ODD S1 WIING INFOMATION Line Voltage -Field Installed -Factory Standard S2 S3 S4 DIP SWITH POSITIONS ON S5 S6 Typical Two-Stage Thermostat S7 S8 G E/W1 W2 DHM Y Y/L L D (-)PL Heat Pump Outdoor Unit *See Section 5.17 for proper DIP switch selection. L W/ P L D FIGUE 11 TYPIAL TWO-STAGE THEMOSTAT: (-)PL HEAT PUMP WITH ELETI HEAT USING A HUMIDISTAT FO DEHUMIDIFIATION*. (-)HPL Air Handler W1 W2 G ODD WIING INFOMATION Line Voltage -Field Installed - Factory Standard (-)HPL Air Handler W1 W2 G WIING INFOMATION Line Voltage -Field Installed -Factory Standard DIP SWITH POSITIONS ON OFF ODD S1 S2 S3 S4 Typical Two-Stage Thermostat G E/W1 W2 Typical Two-Stage Thermostat G E/W1 W2 DHM L Humidistat Y Y/L L W/ P Y Y/L L W/ P (-)PL Heat Pump Outdoor Unit FIGUE 13 (-)PL HEAT PUMP WITH ELETI HEAT USING A TWO-STAGE THEMOSTAT WITH DEHUMIDIFIATION* AND A MALFUNTION LIGHT DIP SWITH POSITIONS ON *See Section 5.17 for proper DIP switch selection. S5 S6 S7 S8 L D (-)PL Heat Pump Outdoor Unit *See Section 5.17 for proper DIP switch selection. L D ONVENTIONAL THEMOSTAT WIING OFF S1 S2 S3 S4 S5 S6 S7 S8 OFF S1 S2 S3 S4 S5 S6 S7 S8 19
6 ONVENTIONAL THEMOSTAT WIING 5.11 ONVENTIONAL 24VA THEMOSTAT ONTOL WIING The (-)PL series of heat pumps allow the installer to use conventional 24VA control wiring and a conventional thermostat for proper unit operation. IMPOTANT: The preferred method of unit installation and operation is by the omfort ontrol 2 System, which allows access to the fault history of the system. This diagnostic information is not available when the (-)PL unit is using a conventional thermostat. eference section 5.1 omfort ontrol 2 System ontrol Wiring. Thermostat control wiring requires a minimum of eight (8) wires for proper unit operation: 24VA 24VA common G onstant Fan W1 First stage electric heat W2 Second stage electric heat First stage operation Second stage operation Heat pump operation Optional wiring: ODD On demand humidification NOTE: W1 and W2 may be jumpered together to energize all the electric heat when a call for electric heat is received. NOTE: When using 24VA thermostat control wiring, the serial communicating control will ignore any inputs to Data wire 1 and Data wire 2. IMPOTANT: lass 2 low voltage control wire should not be run in conduit with power wiring and must be separated from power wiring, unless lass 1 wire of proper voltage rating is used. Low voltage control wiring should be 18 AWG color-coded (105 minimum). For lengths longer than 100 ft., 16 AWG wire should be used. Low voltage control connections are made by extending wires from top of air handler using wire nuts. See wiring diagrams attached to indoor and outdoor sections to be connected Do not leave excess field control wiring inside unit, pull excess control wire to outside of unit and provide strain relief for field wiring on inside of cabinet at point wiring penetrates cabinet. Make sure, after installation, separation of control wiring and power wiring has been maintained USING THE ON-OAD LED TO DETEMINE LOWE FM The FM LED indicates blower output by flashing one (1) flash for every 100 FM of airflow. The LED will pause 1/10 second between each flash OOLING AIFLOW SETTINGS FIGUE 14 DIP SWITH SETTING FO OOLING AIFLOW 20
7 The HPL-series of air handlers are factory configured to for proper airflow. The cooling airflow (AF) is fixed and the DIP switch settings have no effect on airflow. The factory setting is: TALE 6 AIFLOW SETTINGS WHEN USING TADITIONAL 24VA THEMOSTAT ooling Airflow 2-ton 3-ton 4-ton 5-ton FM Table X.X Airflow settings when using traditional 24VA thermostat IMPOTANT: The DIP switches are active only when using conventional a 24VA thermostat. If using the omfort ontrol 2 System, refer to Section 5.13 for adjusting airflows. FIGUE 15 DIP SWITH SETTING FO HEAT PUMP AIFLOW 5.14 HEATING AIFLOW ADJUSTMENT The HPL-series of air handlers are factory configured to for proper airflow. The heat pump airflow (PAF) is fixed and the DIP switch settings have no effect on airflow. The factory setting is: TALE 7 AIFLOW SETTINGS WHEN USING TADITIONAL 24VA THEMOSTAT Heating Airflow 2-ton 3-ton 4-ton 5-ton FM Table X.X Airflow settings when using traditional 24VA thermostat IMPOTANT: The DIP switches are active only when using conventional a 24VA thermostat. If using the omfort ontrol 2 System, refer to Section 5.14 for adjusting airflows. ONVENTIONAL THEMOSTAT WIING FIGUE 16 DIP SWITH SETTING FO AIFLOW ADJUSTMENTS 21
8 5.15 AIFLOW ADJUSTMENT (TIM) ooling and heat pump airflow can be adjusted +/-10% to suit the installation. To adjust the airflow, set DIP switches 5 & 6 per Table 8: TALE 8 AIFLOW ADJUSTMENT SELETION TALE ONVENTIONAL THEMOSTAT WIING DIP Switch Settings Airflow Adjustments 2-ton 3-ton 4-ton 5-ton Position Switch 5 Switch 6 A OFF OFF ON OFF OFF ON D ON ON Table X.X Airflow Adjustment Selection Table. IMPOTANT: The DIP switches are active only when using conventional a 24VA thermostat. If using the omfort ontrol 2 System, refer to Section 5.15 for adjusting airflows. NOTE: Airflow adjustment is active for cooling and heat pump operation only. They are ignored when electric heat is activated ELETI HEAT AIFLOW The HPL-series of air handlers are factory programmed to provide adequate airflow for electric heat (auxiliary heat). Airflow for electric heat is fixed and cannot be field adjusted. Thermostat Electric Heat Airflow Input 2-ton 3-ton 4-ton 5-ton W1 or W2 800 FM 1200 FM 1600 FM 1800 FM 5.17 OOLING MODE DEHUMIDIFIATION FIGUE 17 ON DEMAND DEHUMIDIFIATION DIP SWITH Figure X On Demand Dehumidification DIP Switch The HPL-series air handler is shipped with On Demand Dehumidification (ODD) turned OFF. On Demand Dehumidification is used in conjunction with a traditional 24VA thermostat equipped with an on-board humidity sensor. Activate ODD by turning DIP switch 7 ON. ODD operation is controlled by the indoor humidity sensed at the thermostat. Operation is: Normal Humidity (humidity ELOW the thermostat set point): Normal Humidity A 24VA signal is applied to the ODD terminal esult Full rated airflow is delivered by the blower High Humidity (humidity AOVE the thermostat set point): High Humidity No signal applied to the ODD terminal esult Airflow is reduced by a preset amount to increase latent capacity The HPL air handler is programmed to provide maximum efficiency and optimum humidity removal. When high humidity is detected, the air handler reduces cooling airflow defined in Table 9. 22
9 TALE 9 ODD AIFLOW EDUTION Table X.X ODD Airflow eduction IMPOTANT: The DIP switches are active only when using conventional a 24VA thermostat. If using the omfort ontrol 2 System, refer to Section 5.17 for adjusting airflows. (efer to Section 5.9.) NOTE: ODD airflow adjustments are active for cooling operation only. They are ignored when the heat pump is in heating mode or when electric heat is activated. TALE 10 SELETION EXPLANATION: ON DEMAND DEHUMIDIFIATION Air Handler ooling Airflow eduction 2-ton 85% 3-ton 4-ton 80% 5-ton SWITH 7 POSITION ON ODD INPUT 2-TON 5.18 OOLING DELAY POFILES OOLING AIFLOW - FM ooling delay profiles are not available when the HPL air handler is controlled using a conventional 24VA thermostat. These profiles are available only when the air handler is wired for the omfort ontrol 2 System. efer to Section 5.10 for omfort ontrol 2 ooling Delay Profiles wiring AI HANDLE DIAGNOSTI ODES 3-TON 4-TON 5-TON NONE VA Descriptions of the air handler omfort ontrol 2 diagnostic codes are provided below. These codes can be displayed at the thermostat or via a diagnostic tool. IMPOTANT: Air handler diagnostic codes are available at the thermostat when the system is wired for omfort ontrol 2. ONVENTIONAL THEMOSTAT WIING 23
10 AI HANDLE DIAGNOSTI ODES Descriptions of the I diagnostic codes are provided below: 7-Segment LEDs Display ode Diagnostic Description Status/Possible ause Troubleshooting Information d1 No Shared Data The control board does not have shared data. eplace memory card with correct system information d3 Airflow FM Mismatch The air handler cannot supply the required airflow for proper system operation Misapplied/wrong indoor air mover replace with properly sized air handler/furnace. d4 (Device) Memory ard Invalid for Device The memory card is missing or the data in the memory card does not match the data in the control. d5 ard Hardware onflict The motor horsepower is not correct for the air handler heck memory card to ensure it matches device heck if memory card is present ONVENTIONAL THEMOSTAT WIING d6 LW HP NFLT lower Horsepower conflict The horsepower data in the memory card does not match the motor horsepower. d7 LWE MFG NFLT The System does not have any data on the installed motor. d8 Old Shared Data System data is obsolete 60 LW FLT UN The EM motor is running but has a fault LW FLT NO UN The EM motor is not operating eplace the air handler motor with the correct horsepower motor. eplace the memory card with correct system information. eplace the motor with correct horsepower motor. eplace the memory card with correct system information. heck memory card to ensure it matches device eplace the memory card with correct system information. If system will not operate, order new memory card to update system information. TEST the EM for proper operation. Make sure the EM motor wiring harness is plugged into the EM motor and control board. Test the EM motor for proper operation. 68 EM No Signal The EM motor is not communicating to the air handler control board. Make sure the EM motor wiring harness is plugged into the EM motor and control board. Test the EM motor for proper operation using a service tool. 81 eturn Air Sensor Out of ange The resistance of the sensor out of range for normal operation. Make sure the sensor is plugged into the air handler control board. heck the resistance of the sensor. eplace if it is out of tolerance. 82 Supply Air Sensor Out of ange The resistance of the sensor out of range for normal operation. Make sure the sensor is plugged into the air handler control board. heck the resistance of the sensor. eplace if it is out of tolerance. 93 Internal ontrol Fault The air handler control is not functioning. heck control for proper system operation. eplace control 24
5.0 AIR HANDLER EQUIPPED WITH THE COMFORT CONTROL 2 SYSTEM INTERFACE BOARD
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