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Installation Instructions
Variable Speed Ultra-High SEER Split System
These units have been designed and tested The iQ Drive System consists of an outdoor
for capacity and efficiency in accordance with unit, indoor unit, controller Thermostat and
ARI standards. These outdoor air conditioning connecting lines.
units are designed for use exclusively with
select NORDYNE G6 gas furnaces and select 1. The Outdoor Unit:
NORDYNE B5 air handlers equipped with The outdoor section consists of large heat
dedicated matched indoor coils. exchanger surface, Inverter motor Drive,
Brushless motor type rotary compressor
These instructions are primarily intended to
and an integrated drive brushless fan
assist qualified individuals experienced in the
motor coupled with a specially designed
proper installation of Heating and Air Condition-
fan blade, in addition to refrigerant valves
ing equipment including the iQ DriveTM System.
housed in sturdy attractive chassis.
Local codes may require licensed installation/
service personnel for this type of equipment.
2. The Indoor Unit:
Read all instructions carefully before starting
The matched indoor coil may be a stand
the installation.
alone cased coil intended to be installed
in NORDYNE G6 Model Gas Furnaces or
may be part of a dedicated NORDYNE B5
IMPORTANT NOTE Model Air Handler.
This equipment is one part of a total system The indoor coil is equipped with Electronic
designed for maximum efficiency, adequate Expansion Valve to precisely control
capacity and total comfort. The system must refrigerant flow over the wide range of
function as intended. Under no circumstances system capacity modulation.
any part of the system may be substituted with
other components. For the stand alone dedicated cased
coil in gas furnace, a Furnace Blower
Conversion Kit is required to allow the
THE iQ DRIVETM SYSTEM addition of required system components
such as the Integrated Drive Brushless
The iQ Drive Air Conditioning System features Indoor Blower Assembly, Interface Board,
fully variable speed compressor technology upgraded transformer and The Coil Kelvin
and variable speed indoor and outdoor motors. Controller.
The system provides variable cooling capacity
as needed modulating over a five degree F Consult Installation Instructions provided
temperature range. It operates near the nominal with the Indoor Coil and the Furnace Blower
rated capacity at the thermostat set point and Conversion Kit for details.
modulates as temperature difference between
set point and room temperature changes. The For the dedicated Air Handler, the matched
system may run at additional 18% capacity coil and all required components are
to provide rapid cooling and modulates down included. Consult Installation Instructions
to minimum capacity if the room temperature provided with the Air Handler Unit for
reaches 2 degree F below set point, then it turns details.
off if room temperature drops more than 2 degree
F below set point. The system has a built-in 3. System Controller Thermostat:
humidity control that will activate a humidifier The system controller is the master
equipment (if supplied), and reduces blower component that communicates with
speed if indoor relative humidity is greater than and controls the inverter driven system
set point (default set at 60%). components.
The Inverter in the outdoor unit receives NFPA 70) and electrical conductors and circuit
signals from compressor, heat exchanger, protection must be in compliance with information
fan motor and outdoor ambient which listed on the outdoor unit data label.
are communicated to the controller
via connections to the Indoor Interface
Board. The controller responds back with
appropriate messages for each device 2. SAFETY CONSIDERATIONS
operation command. If no message is
received for 10 seconds, the device will Pressures within the System — Split System
stop. The controller communicates with Air Conditioning equipment contains liquid and
the indoor section via the Indoor Interface gaseous refrigerant under pressure. Installation
Board which is powered by 24 VAC from and servicing of this equipment should be per-
transformer in the furnace or air handler. formed by qualified, trained personnel thoroughly
Transformer in the gas furnace MUST be familiar with this type of equipment. Under no
replaced with the one supplied in the gas circumstances should the homeowner attempt
furnace blower conversion kit. to install and/or service the equipment.
2
installed in such a manner that airflow through 6. CONNECTING REFRIGERANT
the chassis is not obstructed and that unit can TUBING
be serviced.
3
making any electrical connections to the outdoor from obstructions and debris, and all equipment
unit. Refer to wiring diagrams in this literature for access/control panel cover is in place.
wiring of system components.
Indoor Unit — Consult the installation instruc-
Outdoor Unit Connections — The outdoor unit tions of the indoor unit (i.e.; air handler, indoor
requires both power and control circuit electrical coil and furnace) for details regarding installation.
connections. Refer to the unit wiring diagram/ Ensure wiring is secure and correct.
schematic for identification and location of out-
door field wiring interfaces. Air Filters — Ensure air filters are clean and in
place prior to operating the equipment.
Control Circuit Wiring — The outdoor unit is
Ensure that the unit has been properly and
designed to operate from a 24 VAC Class II
securely grounded and that power supply con-
control circuit. Control circuit wiring must comply
nections have been made at both the facility
with the latest version of the “National Electrical
power interface and outdoor unit.
Code” (ANSI/NFPA 70) and with applicable local
codes having jurisdiction.
Controller Thermostat — Connect the Outdoor
Controller Thermostat Connections — Con- section low voltage wiring to the Indoor section
nections to controller unit should be made in interface board. Using standard 4-wires thermo-
accordance with the instructions supplied with stat cable, connect controller thermostat to the
unit, and with the instructions supplied with the indoor section interface board.
indoor equipment. System requires the use of
shielded cable. Using extreme caution, apply power to the sys-
tem and inspect the wiring for evidence of open,
Electrical Power Wiring — Electrical power shorted, and/or improperly wired circuits.
wiring shall comply with the current provisions
of the National Electrical Code (ANSI/NFPA 70) Controller Thermostat screen will be lit and
and with applicable local codes having jurisdic- calibration of indoor blower assembly will begin.
tion. Use of shielded (metal lined sealtite or Initial screen will display indoor and outdoor
rigid ) conduit is required. Electrical conductors temperatures and installer will be able to select
shall have minimum circuit ampacity in compli- functions and program all modes of operation.
ance with the outdoor unit rating label. The
facility shall employ electrical circuit protection NOTE: The Controller Thermostat is designed
at a current rating no greater than that indicated to display information screens for use by the
on the outdoor unit rating label. installer and homeowner.
Ensure electrical power to the unit is The controller screens display all pertinent
off prior to performing the following system information in normal operation. When
steps. Failure to do so may cause necessary, important messages may be se-
personal injury or death. quenced along the top line to indicate conditions
that need attention.
Outdoor Unit — Ensure the outdoor coil, the
inverter heat sink and the top of the unit are free The controller is also designed to function as an
important service and troubleshooting tool.
4
INSTALLER SETTINGS SCREEN: FAN Option:
Select this option to set desired indoor blower op-
1- From “Installer Settings”, select “Model eration mode (Auto, On or Programmed). If “On”
Configuration”. Screen will display is selected, blower will run at heating speed.
“single stage” or “multi stage”.
2- Select appropriate option. Screen will MENU Option:
display “Input rate” and “temp rise” for Select “MENU” option to input the following:
the installed furnace. Set Date & Time, Hold Temp info, Program of
3- Input data from furnace installed. Operation, Fan, Mode, Settings and Security
4- Press “select button” following each Lockout).
selection or the up and down arrows
to access displayed options. Press Note: “Fan” and “Mode” may be selected from
“Previous arrow” to scroll between Main Screen directly.
screens.
5- From “Installer Settings”, select “Acces- 1- SET DATE AND TIME: Follow prompted
sories” option. Screen will display ac- screens after each selection is made.
cessories. Input pertinent selections 2- HOLD: Select from “Vacation” or “Per
6- Each accessory selected will be manent”
followed with additional screens for 2A- From “Vacation Hold Screen” set
scheduling maintenance and service. desired “Hold temperatures for “Heat”
Input appropriate recommended ser- and/or “Cool”.
vice schedules. 2B- The following screen prompts the date
7- From “Installer Settings”, select “Input and time entry for the desired hold.
Dealer Info” option. Screen will display Follow same steps for “Permanent
pertinent selections. Follow screen Hold”.
prompts and save “Completed Dealer 3- PROGRAM: Select to set weekdays,
Info Screen”. weekends, every day or individual days
8- From “Installer Settings”, select “Hu- programming. The prompted screens
midity Settings” option. Screen will allow four settings per day. Input desired
display available selections. Select program and save.
from “Humidify only”, “Dehumidify 4- FAN: Select from “Auto”, “On” or “Pro-
only”, “Both” or “None”. grammed Fan”. The “Programmed
9- From “Installer Settings”, select “Re- Fan Settings” allows fan to run as
store Factory Defaults” if so desired. programmed in step 3.
10- From “Installer Settings”, select “Charg- 5- MODE: Select from “OFF”, “AUTO”,
ing Mode” to run system at nominal set- “COOL” or “HEAT”.
ting for proper charging conditions. 6- SETTINGS: Use this screen to scroll
through options such as:
MAIN SCREEN: 6A- SCREEN SETTINGS: Set preferred
screen settings such as “Temp scale”,
The iQ Drive controller thermostat main screen “Clock setting”, “Language”, “Contrast”
displays system normal operating information. It and “Backlight On Time”.
displays Outdoor and Indoor temperatures, Set 6B- OFFSET: Set temperature offsets,
points in cooling and heating, humidity and mode humidity offset, heat anticipator and
of operation for system and indoor fan. In addition, heat differential.
it displays four options to select from: 6C- CYCLES PER HOUR: Set the
maximum allowed heating cycles per
TEMP Option: hour.
Select this option to temporarily override program 6D- AUTO CHANGEOVER: Select “Auto or
setting until next program interval is activated. Manual Change” and select the “Auto
Changeover Time” to input desired time
MODE Option: interval between cooling and heating
Select this option to choose operating mode changeover.
(Cool, Heat, Auto or Off ). 6E- PROGRAM SETTINGS: Select “Smart
Recovery”, “Events per Day” and “In-
termittent Fan”.
5
When Smart recovery is selected, the comfort, adequate matched to load capacity and
controller adjusts operating span to maximum efficiency. It will turn off automatically
match set program. Events per day if required. However if there is a need to shut off
selection define number of daily air the system, select OFF from Operating Mode
changes required based on residential Screen.
or business choices.
To Operate Indoor Blower Only:
When Intermittent Fan is selected, the
fan may be programmed to turn on for Select FAN from MAIN menu screen, then
selected periods of time at selected select ON for continuous blower operation or
time intervals if no call for cooling or Programmed Fan for intermittent option.
heating is present. Follow instructions
of each option to set program. NOTE: The controller is programmed to start
a Fan Calibration occurrence every week and
6F- SERVICE INFORMATION:This screen every time the power is lost. This function starts
lists components status and faults if the indoor blower and calibrates air volume to
any. Scroll up and down to obtain “Fault motor speed.
Status” showing active fault and last 5
faults, “Compressor Status”, “Outdoor 10. SYSTEM PROTECTION
fan Status”, “Indoor fan Status”, “Tem-
MEASURES
perature Status” and option to “Clear
Fault History”.
The Inverter Driver is designed to provide a full
scale of protection measures against conditions
7. SECURITY LOCKOUT: Select from
that may cause compressor and/or other
“Temp Adjust Only” or “Total Keypad
components failure. When a protection function
Lockout” options. A PIN number may be
is triggered, the Inverter trips and communicates
input. This PIN number will be needed
the fault description to the controller which will
for future system settings and adjust-
display an error code or component fault status.To
ments.
release the trip, correct the fault cause, turn power
off, and then turn it on after few seconds.
9. OPERATING INSTRUCTIONS
To Operate System in Cooling: Protection Functions:
From MODE Screen, select AUTO or COOL. 1- Low Voltage Protection: If the voltage
From Main Screen use the down arrow to set becomes lower than design minimum,
cooling temperature below room temperature. the output of inverter is interrupted.
Verify that the indoor fan calibration is performed
and that system starts running. 2- Over Voltage Protection: Inverter will
trip if voltage becomes higher than design
To set system operation, select MENU from the maximum.
Main Screen and follow the instructions listed
under previous section. 3- Over Current Protection: Inverter will
trip if the converter output current is
To Operate Furnace in Heating: exceeded due to load short circuit or
ground fault.
From MODE Screen, select AUTO or HEAT.
From Main Screen use the up arrow to set heating 4- Over Heat Protection: Inverter has
temperature above room temperature. a heat sink that rids it from excessive
temperatures. If temperature sensor
If system has been properly configured, heating exceeds 194 Fahrenheit, Inverter will
will start to operate. trip.
To Shut Off the System: 5- Over Speed Protection: Inverter will trip
if compressor speed is increased to 1.5
The system is designed to continuously operate times the allowed rated speed.
within a wide range of speeds to provide ultimate
6
6- Abnormal Rotation Protection: Inverter the switch is closed. If the discharge pressure
will trip if abnormal rotation of compressor rises above 575 psig, then the switch will open
is detected due to improper wiring. and de-energize the outdoor unit. The switch
will close again once the discharge pressure
7- Sensors Error Protection: The out- decreases below 460 psig.
door air temperature sensor controls
maximum compressor speed allowed Diagnostics and Troubleshooting:
for safe operation and the compressor
discharge temperature sensor monitor The controller Thermostat Unit is designed to
maximum allowed compressor tempera- provide service personnel with detailed descrip-
ture. Inverter will trip if these sensors are tion of faults that may cause system malfunction,
open or shorted. as well as messages indicating maintenance
required.
8- Microprocessor Error Protection: If
abnormality of the CPU is detected, Only qualified service personnel shall get into
the inverter will trip. Abnormality may “Service Information Menu” screen to define the
be caused by external electromagnetic fault and make the appropriate correction.
noise.
“SERVICE NEEDED” Display:
9- Communication Error Protection: The controller will change screen color to RED
Inverter will trip if communication with and displays “SERVICE NEEDED”, System
the main controller fails. information and Fault detected in the Service
needed menu screen.
NOTE: Tripping of the Inverter is input into the
controller memory up to 5 times occurrences. If Compressor error is detected, it displays
“COMP ERROR” followed by code number
Other System Protections: (see below).
Low Pressure Switch — A low pressure switch If Blower error is detected, it displays “BLOWER
is factory installed and located in the suction line ERROR” followed by code number (see be-
internal to the outdoor unit.The switch is designed low).
to protect the compressor from a loss of charge.
Under normal conditions, the switch is closed. Other possible errors displayed are:
If the suction pressure falls below 35 psig, then Too Hot Out
the switch will open and its signal to the inverter Comp Overload
will open. The inverter will then send signal to Low Gas Pressure
the controller to turn unit off and displays fault COMM Error 10, for indoor motor
message. The switch will close again once the COMM Error 20, for outdoor motor
suction pressure increases to 60 psig. COMM Error 30, for Furnace
High Pressure Switch — A high pressure An Inverter Keypad diagnosis tool may be used to
switch is factory installed and located in the help service the outdoor unit at site. See column
compressor discharge line internal to the outdoor “Display of Inverter panel” for fault codes.
unit. The switch is designed to de-energize the
unit when excessive pressure occurs due to Table 1 describes possible errors and corrective
abnormal conditions. Under normal conditions, measures.
7
Fault Possible Display of Finding and
Code No. Indication Cause inverter panel Check item correction
1- Check thermistor resistance at Out of range
Outdoor temp normal temperature (60~95°F) 10~25k.ohms,
thermistor shorted E.-A1 (1-2pin of CN7) Replace thermistor.
or disconnected. 2- Reset the power supply and Display E-A1,
run. Replace inverter
1- Check thermistor resistance at Out of range
Discharge temp normal temperature (60~95°F) 30~80k.ohms,
1 Sensor error thermistor shorted E.-A2 (1-2pin of CN8) Replace thermistor.
or disconnected. 2- Reset the power supply Display E-A2,
and run Replace inverter
1- Check thermistor resistance at Out of range
IPM temp thermistor normal temperature (60~95°F) 30~80k.ohms,
shorted or E.-A3 (1-2pin of CN9) Replace thermistor.
disconnected. 2- Reset the power supply Display E-A3,
and run Replace inverter.
Equal or over 187V
AC, possible power
1- Check supply voltage interruption
Low voltage of Less than 187VAC,
2 Under voltage E.-LV
inverter Check power supply.
2- Reset to the rated voltage Display E-LV, Replace
and run inverter.
Under 253VAC,
possible strong wind
1- Check supply voltage
High voltage of Over 253VAC, check
3 Over voltage O.V.
inverter power supply.
2- Reset to the rated voltage Display O.V., Replace
and run inverter/fan motor
Compressor over Reset to the rated voltage and Display O.S., Replace
5 Over speed O.S.
speed run inverter.
Out of range
1- Check compressor resistance 0.3~1.ohms,
Replace compressor.
9
Procedure for charging outdoor unit at out- 4. If the pressure measured in step 1 is
door temperatures above 65 F: less than the required liquid refrigerant
pressure determined in step 4, then
1. With the system at nominal speed there is too little charge in the system.
steady state, measure the liquid refrig- Add refrigerant and repeat steps 1
erant pressure in psig at the service through 3 until the system is correctly
valve. charged.
2. Measure the liquid refrigerant tem- 5. If the pressure measured in step 1 is
perature in Fahrenheit at the service greater than the required liquid refrig-
valve. erant pressure determined in step 4,
3. For the temperature measured, de- then there is too much charge in the
termine the liquid refrigerant pressure system. Remove refrigerant and repeat
from the appropriate charging chart steps 1 through 3 until the system is
below. correctly charged.
550
525
500
Remove refrigerant when above the curve
475
Liquid Pressure (psig)
450
425
400
375
350
325
300
275
250 Add refrigerant when below the curve
225
200
60 65 70 75 80 85 90 95 100 105 110 115 120 125 130
Liquid Temperature (F)
10
*TERMINALS ON COMPRESSOR
ARE NOT MARKED. USE RELATIVE
CABLE
LOCATION OF TERMINALS TO THE
GREEN
MARK STAMP TO IDENTIFY PROPER
RED
MARKING. BLACK O.D.
ORANGE FAN MOTOR
BLUE
“TO W” YELLOW
T REACTOR
LPS
YELLOW BLACK
YELLOW BLACK
S MARK R
STAMP “TO U”
TA6 TA5 TA4
1 2 3 4 5 6 7
BLACK
BLACK
“TO V” CN3 6 5 4 3 2 1
CN6 PLUG
THRU CORE TEMP BLACK
CONNECTOR
RED RING SENSOR RED
YELLOW COIL
1 BLACK OUTDOOR TEMP CONTROL
THRU TORIODAL 2 THERMISTOR CABLE
CN7
CONTROLLER
RING 3 P3
COIL
THERMOSTAT
4
THERMISTOR MOTOR
1 BLACK COMP DISCH TEMP
I.D. BLOWER
CN8 2 THERMISTOR INTERFACE C
INVERTER THRU CORE
BOARD W2
RING
DX+ POWER RH
GND GREEN
DX- CABLE R
DX- WHITE A
GRD W1
DX+ RED O.D. UNIT B
THRU CORE H
GD
CN11
BLACK
WHITE
RING
GREEN
OD
R RED 0 ID
DX+ YELLOW Y2 GD
Y1
THRU TORIODAL RING DX- WHITE
G
TO L.V. BARRIER
THERMOSTAT
TWIN
TA3 RED
YELLOW
BLACK
YELLOW BLACK
WHITE
BLACK
HPS GREEN 24V 120V
FUSE
CABLE TEMP.
WHITE
BLACK
RED
BLUE
BLUE
WHITE
SENSOR GREEN
BROWN
BROWN
YELLOW
BLACK
SUCTION
BLACK
BLACK
BLACK
GREEN
YELLOW
FUSE (I.D. COIL)
T1 T2 PRESSURE
NOISE
CONTACTOR
CABLE
WHITE
FILTER
GREEN
BLACK
TRANSDUCER FOR FUTURE USE
20 21 22 23 24
WHITE W/BLACK STRIPE
BLACK W/ WHITE STRIPE
L1 L2
KELVIN
GRD.
Y
ESX COIL
CABLE
ORANGE
GRAY
BLACK
RED
YELLOW
G
OUTDOOR POWER
SUPPLY W
9 6 3
BLACK
8 5 2
7 4 1
WHITE
Legend
Field Wiring Neutrals
Unused Motor
Factory Wiring: Leads
BLACK
Low Voltage 6 3
EAC HUM
M1
M2
M3
5 2
HEAT
EAC
COOL
L1
High Voltage
XFMR
HUM
4 1
11
*TERMINALS ON COMPRESSOR
ARE NOT MARKED. USE RELATIVE
CABLE
LOCATION OF TERMINALS TO THE
GREEN
MARK STAMP TO IDENTIFY PROPER
RED
MARKING. BLACK O.D.
ORANGE FAN MOTOR
BLUE
“TO W” YELLOW
T REACTOR
708592A
LPS
YELLOW BLACK
CONTROLLER
YELLOW BLACK THERMOSTAT
S MARK R
STAMP “TO U”
TA6 TA5 TA4 TEMP
1 2 3 4 5 6 7
BLACK
BLACK
“TO V” CN3 6 5 4 3 2 1
SENSOR
COIL CABLE C
CN6
THRU CORE BLACK
W2
RED RING RH
¢708592A¤
YELLOW RED
1 BLACK OUTDOOR TEMP R
THRU TORIODAL RING A
2 THERMISTOR W1
TO L.V. BARRIER CN7 COIL B
3 H
THERMISTOR P3 GD
4
DX+ OD
1 BLACK COMP DISCH TEMP INTERFACE DX- 0 ID
CN8 2 THERMISTOR THRU Y2
BOARD GND GD
CORE Y1
INVERTER
RING G
DX+
GND GREEN
DX- L
DX- WHITE
GND V
DX+ RED
CN11 CABLE THRU
BLACK CORE
INSTALLATION INSTRUCTIONS
GREEN DX- SUPPLY
TA7 BLACK GND GREEN
TA2
CABLE 24 VAC
TA3
YELLOW
BLACK
R C W2 W H
TWIN
HOUSING WHEN
BLACK
BLACK
BLACK
GREEN
1 2 3 4 5 6 7 8 9 10 11 12 WHITE
YELLOW
FUSE
I.D. BLACK
MOTOR
T1 T2 ESX
CONTACTOR
GREEN
WHITE
RED
BLACK
GREEN
BLACK
GRAY
COIL
ORANGE
YELLOW
CABLE
L1 L2
GRD.
L1
L1
L2
L2
GRAY
XFMR
RED
L2 COM
Y1
WHITE W2
P3
WHITE
1 2 3 4 5 6 7
COM
Legend
24 VAC
Field Wiring
Factory Wiring: RED
Low Voltage
208V/240V 24V
High Voltage
GRAY
TRANSFORMER
GRAY
RED