good manav ptc

1 Important Safety Instructions .............................................. 12 Shipping Inspection ............................................................ 3

2.1 Parts ............................................................................ 32.2 Handling ...................................................................... 3

3 Codes & Regulations .......................................................... 34 Replacement Parts ............................................................. 35 Pre-Installation Considerations .......................................... 3

5.1 Preparation ................................................................. 35.2 System Matches ......................................................... 35.3 Interconnecting Tubing ................................................ 35.4 Clearances .................................................................. 45.5 Horizontal Applications ................................................ 4

6 Installation Location ........................................................... 46.1 Upflow Installation ....................................................... 46.2 Horizontal Left Installation ........................................... 46.3 Downflow/Horizontal Right Installation ........................ 4

7 Refrigerant Lines ................................................................ 67.1 Tubing Size ................................................................. 67.2 Tubing Preparation ...................................................... 67.3 Tubing Connections for TXV Models .......................... 7

8 Condensate Drain Lines ................................................... 7 9 Ductwork ........................................................................... 8

9.1 Return Ductwork ......................................................... 810 Return Air Filters ............................................................... 811 Electric Heat ..................................................................... 8

11.1 No Electric Heat Installed .......................................... 912 Electrical and Control Wiring ............................................ 9

12.1 Building Electrical Service Inspection ....................... 912.2 Wire Sizing ................................................................ 912.3 Maximum Overcurrent Protection (MOP)................ 1012.4 Electrical Connections Supply Voltage ................ 1012.4.1 Air Handler Only (Non-Heat Kit Models) .............. 1012.4.2 Air Handler - Non-Circuit Breaker Heat Kits ......... 1012.4.3 Air Handler With Circuit Breaker Heat Kit ............ 1012.5 Low Voltage Connections ....................................... 1012.5.1 Thermostats ......................................................... 10

13 Achieving 2% Low Leakage Rate ................................... 1014 Start-Up Procedure ......................................................... 1115 Regular Maintenance ..................................................... 11Circulator Blower .................................................................... 13Troubleshooting ..................................................................... 17ComfortNet System ............................................................ 18Start-Up Procedure ................................................................ 19Regular Maintenance ............................................................. 20Troubleshooting ..................................................................... 23Diagnostic Codes ................................................................... 27Wiring Diagrams .................................................................... 28

RECOGNIZE THIS SYMBOLAS A SAFETY PRECAUTION.

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

AVPTC**14** 2013 Goodman Manufacturing Company, L.P.5151 San Felipe, Suite 500, Houston, TX 77056www.goodmanmfg.com - or - www.amana-hac.comP/N: IO-443A Date: November 2013

1 Important Safety InstructionsThe following symbols and labels are used throughout thismanual to indicate immediate or potential safety hazards. Itis the owners and installers responsibility to read and com-ply with all safety information and instructions accompanyingthese symbols. Failure to heed safety information increasesthe risk of personal injury, property damage, and/or productdamage.

AIR HANDLERSINSTALLATION & OPERATING INSTRUCTIONS

is a registered trademark of Maytag Corporation or its related entities and is used under license. All rights reserved.

2To prevent the risk of property damage, personal injury, or death, do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this unit.

CARBON MONOXIDE POISONING HAZARD

-

Special Warning for Installation of Furnace or Air Handling Units inEnclosed Areas such as Garages, Utility Rooms or Parking Areas

Carbon monoxide producing devices (such as an automobile, spaceheater, gas water heater, etc.) should not be operated in enclosed areassuch as unventilated garages, utility rooms or parking areas because ofthe danger of carbon monoxide (CO) poisoning resulting from the exhaustemissions. If a furnace or air handler is installed in an enclosed area suchas a garage, utility room or parking area and a carbon monoxide producingdevice is operated therein, there must be adequate, direct outsideventilation.

This ventilation is necessary to avoid the danger of CO poisoning whichcan occur if a carbon monoxide producing device continues to operate inthe enclosed area. Carbon monoxide emissions can be (re)circulatedthroughout the structure if the furnace or air handler is operating in anymode.

CO can cause serious illness including permanent brain damage or death.

B10259-216

2 Shipping InspectionAlways transport the unit upright; laying the unit on its side ortop during transit may cause equipment damage. The installershould inspect the product upon receipt for shipping damageand subsequent investigation is the responsibility of the car-rier. The installer must verify the model number, specifica-tions, electrical characteristics, and accessories are correctprior to installation. The distributor or manufacturer will notaccept claims from dealers for transportation damage or in-stallation of incorrectly shipped units.

2.1 Parts

Also inspect the unit to verify all required components arepresent and intact. Report any missing components im-mediately to Goodman or to the distributor. Use onlyfactory authorized replacement parts (see Section 5).Make sure to include the full product model number andserial number when reporting and/or obtaining serviceparts.

HIGH VOLTAGE!

Failure to do so may cause property damage,personal injury or death.

Disconnect ALL power before servicing.Multiple power sources may be present.

Installation and repair of this unit should be performedby individuals meeting the requirements of an

entry level technician as specified by the Air-Conditioning, Heating and Refrigeration Institute(AHRI). Attempting to install or repair this unit withoutsuch background may result in product damage, personal injury or death.

ONLY , at a minimum,

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

DO NOT

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

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

uninterrupted, unbroken

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

o

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

32.2 Handling

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

3 Codes & RegulationsThis product is designed and manufactured to comply withapplicable national codes. Installation in accordance with suchcodes and/or prevailing local codes/regulations is the respon-sibility of the installer. The manufacturer assumes no respon-sibility for equipment installed in violation of any codes or regu-lations.The United States Environmental Protection Agency (EPA)has issued various regulations regarding the introduc-tion and disposal of refrigerants. Failure to follow theseregulations may harm the environment and can lead tothe imposition of substantial fines. Should you have anyquestions please contact the local office of the EPA and/orrefer to EPAs website www.epa.gov.

4 Replacement PartsWhen reporting shortages or damages, or ordering repair parts,give the complete product model and serial numbers asstamped on the product. Replacement parts for this productare available through your contractor or local distributor. Forthe location of your nearest distributor consult the white busi-ness pages, the yellow page section of the local telephonebook or contact:

CONSUMER AFFAIRSGOODMAN MANUFACTURING COMPANY, L.P.

7401 SECURITY WAYHOUSTON, TEXAS 77040

(877) 254-4729

5 Pre-Installation Considerations5.1 Preparation

Keep this document with the unit. Carefully read all in-structions for the installation prior to installing product.Make sure each step or procedure is understood and anyspecial considerations are taken into account before start-ing installation. Assemble all tools, hardware and suppliesneeded to complete the installation. Some items may needto be purchased locally. Make sure everything needed toinstall the product is on hand before starting.

5.2 System Matches

The entire system (combination of indoor and outdoorsections) must be manufacturer approved and Air-Condi-tioning, Heating, and Refrigeration Institute (AHRI) listed.

NOTE: Installation of unmatched systems is not permit-ted and will void the product warranty.

5.3 Interconnecting Tubing

Give special consideration to minimize the length of re-frigerant tubing when installing air handlers. Refer to Re-mote Cooling/Heat Pump Service Manual RS6200006,and TP-107 Long Line Set Application R-410A for tubingguidelines. If possible, allow adequate length of tubingsuch that the coil may be removed (for inspection or clean-ing services) from the cabinet without disconnecting thetubing.

5.4 Clearances

The unit clearance from a combustible surface may be0". However, service clearance must take precedence.A minimum of 24" in front of the unit for service clear-ance is required. Additional clearance on one side or topwill be required for electrical wiring connections. Consultall appropriate regulatory codes prior to determining finalclearances. When installing this unit in an area that maybecome wet (such as crawl spaces), elevate the unit witha sturdy, non-porous material. In installations that maylead to physical damage (i.e. a garage) it is advised toinstall a protective barrier to prevent such damage. Al-ways install units such that a positive slope in conden-sate line (1/4" per foot) is allowed.

5.5 Horizontal Applications

If installed above a finished living space, a secondarydrain pan (as required by many building codes), must beinstalled under the entire unit and its condensate drainline must be routed to a location such that the user willsee the condensate discharge.

6 Installation LocationNOTE: These air handlers are designed for indoor installa-tion only.The AVPTC**14** product line may be installed in one of theupflow, downflow, horizontal left or horizontal right orienta-tions as shown in Figures 2, 3, 4 and 5. The unit may beinstalled in upflow or horizontal left orientation as shipped (referto specific sections for more information).Minor field modifications are necessary to convert to downflowor horizontal right as indicated in below sections.6.1 Upflow Installation

No field modifications are mandatory however to obtainmaximum efficiency, the horizontal drip shield must beremoved.

Drip Shield Removal: Refer to Figure 1, remove the two(2) screws that secure the drip shield support brackets tothe condensate collectors (one screw per side). Removethe two (2) screws that secure the drip shield to the drain

4DFK-BDownflow Kit

DFK-CDownflow Kit

DFK-DDownflow Kit

AVPTC24B14** AVPTC30C14** AVPTC42D14**

AVPTC36C14** AVPTC48D14**

AVPTC60D14**

MODEL LIST FOR DOWNFLOW KITS

DOWNFLOW KITTable 1

Refer to Figure 6 and 7 for the location of the compo-nents referenced in the following steps.

1. Before inverting the air handler, remove blower accesspanel and coil access panel. The coil access panel andtubing panel may remain screwed together during thisprocedure. Remove and retain the seven (7) screws se-curing the coil access panel to the cabinet and the six(6) screws securing the blower access panel to the cabi-net.

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

NOTE: DO NOT USE MANIFOLDS OR FLOWRATORTO PULL THE COIL ASSEMBLY OUT. FAILURE TODO SO MAY RESULT IN BRAZE JOINT DAMAGEAND LEAKS.

3. Removal of the center support is required on units with21" wide cabinet. Remove and retain the two (2) screwsthat secure the center support to the cabinet. Removethe center support.

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

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

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

7. The bottom left drain connection is the primary drain forthis application and condensate drain line must be at-tached to this drain connection. The top connection ofthe three drain connections on the drain pan must re-main plugged for this application. The bottom left drainconnection is for the secondary drain line (if used).

pan. The drip shield and drip shield brackets may now beremoved.

The bottom left drain connection is the primary drain forthis application and condensate drain line must be at-tached to this drain connection. The top connection of thethree drain connections on the drain pan must remainplugged for this application. The bottom right drain con-nection is for the secondary drain line (if used).

Screw

Screw

DRIP SHIELD REMOVALFigure 1

6.2 Horizontal Left Installation

No field modifications are permissible for this application.

The bottom right drain connection is the primary drain forthis application and condensate drain line must be at-tached to this drain connection. The top connection of thethree drain connections on the drain pan must remainplugged for this application. The bottom left drain con-nection is for the secondary drain line (if used).

6.3 Downflow/Horizontal Right Installation

IMPORTANT NOTE: In the downflow application, to pre-vent coil pan sweating, a downflow kit (DFK) is avail-able through your local Goodman distributor. The DFK isnot supplied with the air handler and is required byGoodman on all downflow installations. See Table 1 forthe correct DFK and follow the instructions provided forinstallation.

5UPFLOW DOWNFLOWFigure 2 Figure 3

HORIZONTAL LEFTFigure 4

HORIZONTAL RIGHTFigure 5

DownflowBracket

CenterSupport

FilterBracket

ControlDeck

Upper Tie Plate

Filter AccessPanel

INTERNAL PART TERMINOLOGYFigure 6

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

Secondary Drain Portfor Upflow/DownflowApplication

SecondaryDrain Portfor HorizontalApplication

BlowerAccessPanel

CoilAccessPanel

TubingPanel

ThumbScrew

EXTERNAL PART TERMINOLOGYFigure 7

6Coil Slideson the

downflow bracket

IMPORTANT NOTE:Ensure coil slides on the railsalong the groove providedon the drain pan side walls. Failure to do so will resultin improper condensate drainage.

COIL INSTALLATION FOR DOWNFLOWFigure 8

ACCESS PANEL CONFIGURATION FOR DOWNFLOWOR HORIZONTAL RIGHT

Figure 9

7 Refrigerant Lines

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

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

NOTE: Refrigerant tubing must be routed to allow adequateaccess for servicing and maintenance of the unit.Do not install the air handler in a location that violates theinstructions provided with the condenser. If the unit is locatedin an unconditioned area with high ambient temperature and/or high humidity, the air handler may be subject to nuisancesweating of the casing. On these installations, a wrap of 2"fiberglass insulation with a vapor barrier is recommended.7.1 Tubing Size

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

7.2 Tubing Preparation

All cut ends are to be round, burr free, and clean. Failureto follow this practice increases the chances for refriger-ant leaks. The suction line is spun closed and requirestubing cutters to remove the closed end.

NOTE: To prevent possible damage to the tubing joints,do not handle coil assembly with manifold or flowratortubes. Always use clean gloves when handling coil as-semblies.

Applying too much heat to any tube can melt the tube. Torchheat required to braze tubes of various sizes must beproportional to the size of the tube. Service personnel mustuse the appropriate heat level for the size of the tube beingbrazed.

CAUTION

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

7.3 Tubing Connections for TXV Models

TXV models come with factory installed TXV with thebulb pre-installed on the vapor tube.

71. Remove refrigerant tubing panel or coil (lower) accesspanel.

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

3. Replace the refrigerant tubing panel.

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

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

6. Insert suction line set into suction tube expansion andslide insulation and grommet about 18" away from brazejoint.

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

REFRIGERANT BULBMUST BE POSITIONEDBETWEEN 10 & 2 OCLOCK

REFRIGERANT BULBMUST BE POSITIONEDBETWEEN 10 & 2 OCLOCK

Figure 10

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

8. Replace access panels, suction line grommet, insulationand all screws.

RUBBERGROMMET

SUCTION LINEWITH SPIN CLOSURE

Suction Line Grommet

Figure 11

8 Condensate Drain LinesThe coil drain pan has a primary and a secondary drain with3/4" NPT female connections. The connectors required are3/4" NPT male, either PVC or metal pipe, and should be handtightened to a torque of no more than 37 in-lbs. to prevent

damage to the drain pan connection. An insertion depth ofapproximately 3/8 to 1/2 (3-5 turns) should be expected atthis torque.

1. Ensure drain pan hole is not obstructed.

2. To prevent potential sweating and dripping on to finishedspace, it may be necessary to insulate the condensatedrain line located inside the building. Use Armaflex orsimilar material.

A secondary condensate drain connection has been providedfor areas where the building codes require it. Pitch all drainlines a minimum of 1/4" per foot to provide free drainage.Provide required support to the drain line to prevent bowing.If the secondary drain line is required, run the line separatelyfrom the primary drain and end it where condensate dischargecan be easily seen.NOTE: Water coming from secondary line means the coilprimary drain is plugged and needs immediate attention.

Insulate drain lines located inside the building or above afinished living space to prevent sweating. Install a conden-sate trap to ensure proper drainage.

NOTE: When units are installed above ceilings, or in otherlocations where damage from condensate overflow mayoccur, it is MANDATORY to install a field fabricated auxiliarydrain pan under the coil cabinet enclosure.

CAUTIONIf secondary drain is not installed, the secondaryaccess must be plugged.

The installation must include a P style trap that is locatedas close as is practical to the evaporator coil. See Figure 12for details of a typical condensate line P trap.NOTE: Trapped lines are required by many local codes. Inthe absence of any prevailing local codes, please refer to therequirements listed in the Uniform Mechanical Building Code.A drain trap in a draw-through application prevents air frombeing drawn back through the drain line during fan operationthus preventing condensate from draining, and if connectedto a sewer line to prevent sewer gases from being drawn intothe airstream during blower operation.Field experience has shown condensate drain traps with anopen vertical Tee between the air handler and the conden-sate drain trap can improve condensate drainage in someapplications, but may cause excessive air discharge out ofthe open Tee. Goodman does not prohibit this type of drainbut we also do not recommend it due to the resulting air leak-age. Regardless of the condensate drain design used, it isthe installers responsibility to ensure the condensate drainsystem is of sufficient design to ensure proper condensateremoval from the coil drain pan.

8Air Handler

3" MIN.POSITIVE LIQUIDSEAL REQUIRED

AT TRAP

DrainConnection

2" MIN.

Figure 12Use of a condensate removal pump is permitted when nec-essary. This condensate pump should have provisions forshutting off the control voltage should a blocked drain occur.A trap must be installed between the unit and the conden-sate pump.

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

9 DuctworkThis air handler is designed for a complete supply and returnductwork system.To ensure correct system performance, the ductwork is to besized to accommodate 350-450 CFM per ton of cooling withthe static pressure not to exceed 0.5" in w.c. Refer to ACCAManual D, Manual S and Manual RS for information on ductsizing and application. Flame retardant ductwork is to be usedand sealed to the unit in a manner that will prevent leakage.NOTE: A downflow application with electric heat must havean L-shaped sheet metal supply duct without any outlets orregisters located directly below the heater.9.1 Return Ductwork

DO NOT LOCATE THE RETURN DUCTWORK IN ANAREA THAT CAN INTRODUCE TOXIC, OR OBJEC-TIONABLE FUMES/ODORS INTO THE DUCTWORK.The return ductwork is to be connected to the air han-dler bottom (upflow configuration).

Do not operate this product without all the ductwork attached.

10 Return Air FiltersEach installation must include a return air filter. This filteringmay be performed at the air handler using the factory filterrails or externally such as a return air filter grille. When usingthe factory filter rails, a nominal 16x20x1, 20x20x1 or24x20x1 (actual dimension must be less than 23-x20) fil-ter can be installed on a B, C and D cabinet respectively (thecabinet size is the seventh letter of the model number).

11 Electric HeatRefer to the installation manual provided with the electric heatkit for the correct installation procedure. All electric heat mustbe field installed. If installing this option, the ONLY heat kitsthat are permitted to be used are the HKS series. Refer tothe air handler units Serial and Rating plate or the HKS speci-fication sheets to determine the heat kits compatible with agiven air handler. No other accessory heat kit besides theHKS series may be installed in these air handlers.

The heating mode temperature rise is dependent upon thesystem airflow, the supply voltage, and the heat kit size (kW)selected. Use data provided in Tables 2, 3 and 4 to deter-mine the temperature rise (F).

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

TR = (kW x 3412) x (Voltage Correction) x 1.08 / CFMWhere: TR = Temperature Rise

kW = Heater Kit Actual kW3412 = Btu per kWVC* = .96 (230 Supply Volts)

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

1.08 = ConstantCFM = Measured Airflow

*VC (Voltage Correction)NOTE: The Temperature Rise Tables can also be used toestimate the air handler airflow delivery. When using thesetables for this purpose set the room thermostat to maximumheat and allow the system to reach steady state conditions.Insert two thermometers, one in the return air and one in thesupply air. The temperature rise is the supply air temperatureminus the return air temperature. Using the temperature risecalculated, CFM can be estimated from the TR formula above.See Technical Manual and/or Service Manual for moreinformation.

911.1 No Electric Heat Installed

If no electric heat accessory kit is installed, a cover platemust be installed over the opening for electric heat. Thiscover plate kit is available from Goodman and Amanabrand distributors.

3 5 6 8 10 15 19/20 25800 12 19 23 31 371000 9 15 19 25 30 441200 8 12 15 21 25 37 49 621400 7 11 13 18 21 32 42 531600 6 9 12 15 19 28 37 461800 5 8 10 14 16 25 33 412000 5 7 9 12 15 22 30 37

CFM HEAT KIT NOMINAL kW

230/1/60 SUPPLY VOLTAGE - TEMP. RISE FTable 2

3 5 6 8 10 15 19/20 25800 11 18 22 30 35

1000 9 14 18 24 28 421200 7 12 15 20 24 35 47 591400 6 10 13 17 20 30 40 511600 6 9 11 15 18 27 35 441800 5 8 10 13 16 24 31 392000 4 7 9 12 14 21 28 35



3 5 6 8 10 15 19/20 25800 10 17 21 28 33

1000 8 13 17 22 27 401200 7 11 14 19 22 33 45 561400 6 10 12 16 19 29 38 481600 5 8 10 14 17 25 33 421800 5 7 9 12 15 22 30 372000 4 7 8 11 13 20 27 33



3 5 6 8 10 15 19 20 21 or 25AVPTC24B14 730 780 850 950 1025 NR NR NR NRAVPTC30B14 730 780 850 950 1025 NR NR NR NRAVPTC36C14 NR 1200 1260 1320 1380 1440 1500 NR NRAVPTC42D14 850** 1400 1630 1630 1670 1720 NR 1800 NRAVPTC48D14 NR 1400 1630 1630 1670 1720 NR 1815 1850AVPTC60D14 NR 1620 1670 1720 1750 1780 NR 1850 1850

Heater Kit (Kw)

MINIMUM CFM REQUIRED FOR HEATER KITSTable 5

Please refer to page 16 for specific heater kit application guidelines.

12 Electrical and Control WiringIMPORTANT: All routing of electrical wiring must be madethrough provided electrical knockouts. Do not cut, punctureor alter the cabinet for electrical wiring.12.1 Building Electrical Service Inspection

This unit is designed for single-phase electrical supplyonly. DO NOT OPERATE ON A THREE-PHASEPOWER SUPPLY. Measure the power supply to theunit. The supply voltage must be measured and be inagreement with the unit nameplate power requirementsand within the range shown.

Nominal Input Minimum Voltage Maximum Voltage208 - 240 197 253

ELECTRICAL VOLTAGETable 6

12.2 Wire Sizing

Wire size is important to the operation of your equip-ment. Use the following check list when selecting theappropriate wire size for your unit.

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

HIGH VOLTAGE!

Failure to do so may cause property damage,personal injury or death.

Disconnect ALL power before servicing.Multiple power sources may be present.

HIGH VOLTAGE!To avoid property damage, personal injury or death due to electrical shock, this unit MUST have an

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

uninterrupted, unbroken

10

Wire used must carry the Minimum Circuit Ampac-ity (MCA) listed on the units Series and Rating Plate.

Refer to the NEC (USA) or CSA (Canada) for wire siz-ing. The unit MCA for the air handler and the optionalelectric heat kit can be found on the unit Series andRating Plate.

Wire must be sized to allow no more than a 2% volt-age drop from the building breaker/fuse panel tothe unit.

Wires with different insulation temperature rating havevarying ampacities - be sure to check the temperaturerating used.

Refer to the latest edition of the National Electric Codeor in Canada the Canadian Electric Code when deter-mining the correct wire size.

12.3 Maximum Overcurrent Protection (MOP)

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

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

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

12.4 Electrical Connections Supply Voltage

IMPORTANT NOTE: USE COPPER CONDUCTORSONLY.

Knockouts are provided on the air handler top paneland sides of the cabinet to allow for the entry of thesupply voltage conductors, as shown in Figure 13. Ifthe knockouts on the cabinet sides are used for electri-cal conduit, an adapter ring must be used in order tomeet UL1995 safety requirements. An NEC or CECapproved strain relief is to be used at this entry point.Some codes/municipalities require the supply wire tobe enclosed in conduit. Consult your local codes.

Side ofCabinet

Top ofCabinet

KNOCK-OUT FOR ELECTRICAL CONNECTIONSFigure 13

12.4.1 Air Handler Only (Non-Heat Kit Models)

The power supply connects to the stripped black andred wires contained in the air handler electrical com-partment. Attach the supply wires to the air handlerconductors as shown in the unit wiring diagram usingappropriately sized solderless connectors or other NECor CEC approved means. A ground lug is also providedin the electrical compartment. The ground wire fromthe power supply must be connected to this ground lug.

12.4.2 Air Handler - Non-Circuit Breaker Heat Kits

A terminal block is provided with the HKS kit to attachthe power supply and air handler connections. Followthe HKS Installation Manual and wiring diagram for com-plete wiring details.

12.4.3 Air Handler With Circuit Breaker Heat Kit

The air handler has a plastic cover on the upper ac-cess panel that will require either one or both sectionsto be removed to allow the heat kit circuit breaker(s) tobe installed. The circuit breakers have lugs for powersupply connection. See the HKS Installation Instructionsfor further details.

12.5 Low Voltage Connections

Several combinations of low voltage schemes are pos-sible, depending on the presence of a heat kit andwhether the heat kit is single-stage or multi-stage,whether the outdoor section is an air conditioner or heatpump, and whether the system is setup with a commu-nicating or traditional thermostat. The 24V-control volt-age connects the air handler to the room thermostatand condenser. Low voltage wiring must be copperconductors. A minimum of 18AWG must be used forinstallations up to 50 and 16AWG for installations over50. Low voltage wiring must be connected through thetop of the cabinet or either side. See the ThermostatWiring section of this manual for typical low voltagewiring connections.

13 Achieving 2% Low Leakage RateEnsure all the gaskets remain intact on all surfaces as shippedwith the unit. These surfaces are areas between the uppertie plate and coil access panel, blower access and coil ac-cess panels, and between the coil access and filter accesspanels. Ensure upon installation, that the plastic breaker coveris sitting flush on the blower access panel and all accesspanels are flush with each other and the cabinet. With theserequirements satisfied, the unit achieves less than 2% air-flow leakage when tested in accordance with ASHRAE Stan-dard 193.

11

14 Start-Up Procedure

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

All panels must be in place and secured. For Air Tightapplication, gasket must be positioned at prescribedlocations to achieve 2% leakage.

Tubing must be leak free.

Condensate line must be trapped and pitched to allowfor drainage.

Low voltage wiring is properly connected.

Auxiliary drain is installed when necessary and pitchedto allow for drainage.

Unit is protected from vehicular or other physical dam-age.

Return air is not obtained from, nor are there any returnair duct joints that are unsealed in, areas where theremay be objectionable odors, flammable vapors or prod-ucts of combustion such as carbon monoxide (CO),which may cause serious personal injury or death.

15 Regular Maintenance

HIGH VOLTAGE!Disconnect ALL power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

The only item required to be maintained on a regular basis bythe user is the circulating air filter(s). Filter should be cleanedor replaced regularly, typically once per month. A certifiedservice technician must perform all other services.IMPORTANT NOTE: If thumb screws are used to access thefilter, ensure the washer installed on the screw behind theaccess panel remains in place after re-installation.

24 VOLT THERMOSTAT WIRING - NON-COMMUNICATINGTHERMOSTAT CONNECTIONS

NOTE: Wire routing must not interfere with the circulatorblower operation or routine maintenance.The air handlers integrated control module provides termi-nals for Y1 and Y2 and W1 and W2 thermostat con-nections. This allows the air handler to support the systemsshown in the following table. Refer to the following figures fortypical connections to the integrated control module. Ther-mostat wiring entrance holes are located in the top of theblower. Wire routing must not interfere with circulator bloweroperation or routine maintenance.

COOLING HEAT PUMP HEATING ELECTRIC HEATING

1-STAGE ------ 1- or 2-STAGE2-STAGE ------ 1- or 2-STAGE1-STAGE 1-STAGE ------2-STAGE 2-STAGE ------1-STAGE 1-STAGE 1- or 2-STAGE2-STAGE 2-STAGE 1- or 2-STAGE

NOTE: A removable plug connector is provided with thecontrol to make thermostat wire connections. This plug maybe removed, wire connections made to the plug, and replaced.It is STRONGLY recommended that you do not connectmultiple wires into a single terminal. Wire nuts arerecommended to ensure one wire is used for each terminal.Failure to do so may result in intermittent operation.

Air Handler IntegratedControl Module

Typical Single-Stage Cool, Single-Stage Heat Thermostat

Dehumidistat[Optional]

Remote Condensing Unit(Single-Stage AC)

NEU

HOT

1 2 R C G W1 Y1 Y2 O DEHUM

R C G W1 Y1

R C Y

Place Jumper Between Y1and O for Proper

Dehumidification Operationand Proper Ramping

Profile Operation

W2

Typical Single-Stage Cooling with Single-Stage Heating______________________________________

Air Handler IntegratedControl Module

Typical Two-Stage Cool, Two-Stage Heat Thermostat


Remote Condensing Unit(Two-Stage AC)

NEU

HOT

1 2 R C G W1 W2 Y1 Y2 O DEHUM

R C G W1 W2 Y1 Y2

R C Y1 Y2

Place Jumper Between Y1and O for Proper

Dehumidification Operationand Proper Ramping

Profile Operation

Typical Two-Stage Cooling with Two-Stage Heating

12

1 2 R CAir Handler

Integrated Control Module

Typical Single-Stage Cool,Single-Stage Heat

Heat Pump Thermostat


G W1 W2 Y1 Y2 O DEHUM

Remote Condensing Unit(Single-Stage HP)

NEU

HOT

W/ER C G Y1 O

R C W1 Y O

Typical Single-Stage Heat Pump with Auxiliary/EmergencyHeating

1 2 R CAir Handler

Integrated Control Module

Typical Two-Stage Cool,Two-Stage Heat

Heat Pump Thermostat


G W1 W2 Y1 Y2 O DEHUM

Remote Condensing Unit(Two-Stage HP)

NEU

HOT

W/ER C G W2 Y1 Y2 O

R C W1 Y1 Y2 O

Typical Two Stage Heat Pump heating and Auxiliary/Emergency Heating

24 VOLT DEHUMIDISTAT WIRING - NON-COMMUNICATINGTHERMOSTAT CONNECTIONSThe optional usage of a dehumidistat allows the air handlerscirculator blower to operate at a slightly lower speed during acombined thermostat call for cooling and dehumidistat callfor dehumidification. This lower blower speed enhances de-humidification of the conditioned air as it passes through theAC coil. For proper function, a dehumidistat applied to thisair handler must operate on 24 VAC and utilize a switch whichopens on humidity rise.To install/connect a dehumidistat:

1. Turn OFF power to air handler.

2. Secure the dehumidistat neutral wire (typically the whitelead) to the screw terminal marked DEHUM on the airhandlers integrated control module.

3. Secure the dehumidistat hot wire (typically the blacklead) to the screw terminal marked R on the airhandlers integrated control module.

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

5. To enable the dehumidification function, move the de-humidification dip switch (S7) from OFF to ON. Seefollowing figure.

6. Turn ON power to air handler.

ON

OFF

Move to theON positionto enable

dehumidification

S5 S6 S7 S8

Dip Switches - Dehumidification Enable

AUXILIARY ALARM SWITCHThe control is equipped with two Auxiliary Alarm terminalslabeled CAS which can be utilized with communicating modesetups (typically used for condensate switch wiring but couldbe used with compatible C02 sensors or fire alarms).Legacy mode useIn a legacy system (Non-communicating), this feature is notoperational. Any auxiliary alarm switch must be used to in-terrupt the Y1 signal either to the indoor or outdoor unit.

CASSWITCH

Communication mode useThis feature can be activated or deactivated through thethermostat user menus. An auxiliary alarm switch must benormally closed and open when the base pans water levelin the evaporator coil reaches a particular level. The con-trol will respond by turning off the outdoor compressor anddisplay the proper fault codes. If the switch is detectedclosed for 30 seconds, normal operation resumes and theerror message will be removed.

AVPTC MOTOR ORIENTATIONIf the unit is in the upflow position, there is no need to rotatethe motor. If the unit is in the downflow position, loosen mo-tor mount and rotate motor as shown in the AVPTC MotorOrientation figure below. Be sure motor is oriented with thefemale connections on the casing down. If the motor is notoriented with the connections down, water could collect inthe motor and may cause premature failure.

FEMALE CONNECTIONS

SIDE VIEW

WAR

NINGSOFTW

ARE VER.

TOP

FRONT VIEW

AVPTC Motor Orientation

13

COM

THTR

DE

CAS

HUM

O

R

21

C

2

1

ST4

ST3

ST2

ST1

3A

C

Y2

24VAC

FUSE

W1W2

R

C

G

W1

W2

Y1

3

2

Dip Switches

Green CFM LED

Seven SegmentLED

AuxiliaryAlarms

Communicating Board

CIRCULATOR BLOWERThis air handler is equipped with a multi-speed circulatorblower. This blower provides ease in adjusting blower speeds.The Specification Sheet applicable to your model provides anairflow table, showing the relationship between airflow (CFM)and external static pressure (E.S.P.), for the proper selectionof heating and cooling speeds. The heating blower speed isshipped set at 21kW or 25kW, and the cooling blower speedis set at D. These blower speeds should be adjusted by theinstaller to match the installation requirements so as to pro-vide the correct electric heating CFM and correct cooling CFM.Use the CFM LED (green) to obtain an approximate airflowquantity. The green CFM LED blinks once for each 100 CFMof airflow.

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

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

30,000/12,000 = 2.5 Tons

2. Determine the proper airflow for the cooling system. Mostcooling systems are designed to work with airflows be-tween 350 and 450 CFM per ton. Most manufacturersrecommend an airflow of about 400 CFM per ton.

Example: 2.5 tons X 400 CFM per ton = 1000 CFMThe cooling system manufacturers instructions must bechecked for required airflow. Any electronic air cleaners orother devices may require a specific airflow; consult installa-tion instructions of those devices for requirements.

3. Knowing the air handler model, locate the high stagecooling airflow charts in the Specification Sheet appli-cable to your model. Look up the cooling airflow deter-mined in step 2 and find the required cooling speed andadjustment setting.

Example: An AVPTC30C14 air handler installed witha 2.5 ton air conditioning system. The airflow needed is1000 CFM. Looking at the cooling speed chart forAVPTC30C14, find the airflow closest to 1000 CFM. Acooling airflow of 1000 CFM can be attained by settingthe cooling speed to C and the adjustment to 0 (noadjustment).

14

4. Locate the blower speed selection DIP switches on theintegrated control module. Select the desired coolingspeed tap by positioning switches 1 and 2 appropriately.If airflow adjustment is required, set dip switch S8 (trimenable) to ON (trim enable default is off). Then selectthe desired adjust tap by positioning switches S3 andS4 appropriately. Refer to the following Airflow AdjustTaps figure for switch positions and their correspondingtaps. Verify CFM by counting the number of times thegreen CFM LED blinks.

1

2

1

2

1

2

1

2

OFF OFF OFF OFFON ON ON ON

Tap A Tap B

Cooling Airflow Speed Tap (*indicates factory setting)

Tap C Tap D*

3

4


+5% -5%

Airflow Adjust Taps (*indicates factory setting)

+10% -10%

3

43

4

3

4

Dip Switches - Cooling Airflow and Airflow Adjust Taps

5. Continuous fan speeds that provide 25, 50, 75, and 100%of the air handlers maximum airflow capability are se-lectable via dip switches S12 and S13.

If the air handlers maximum airflow capability is 2000CFM and 25% continuous fan speed is selected, the con-tinuous fan speed will be 0.25 x 2000 CFM = 500 CFM.

12

13

12

13

12

13

12

13


25% 50%*

Fan Only Selection (*indicates factory setting)

75% 100%

12

13

12

13

12

13

12

13


Fan Only Selection (*indicates factory setting)

6. The multi-speed circulator blower also offers severalcustom ON/OFF ramping profiles. These profiles maybe used to enhance cooling performance and increasecomfort level. The ramping profiles are selected usingDIP switches 5 and 6. Refer to the following DipSwitches - Cooling Airflow Ramping Profiles figure forswitch positions and their corresponding taps. Refer tothe bullet points below for a description of each ramp-ing profile. Verify profile selection by counting the greenCFM LED blinks and timing each step of the rampingprofile.

NOTE: Upon start up in communicating mode the circuit board may display an Ec error. This is an indication that the dipswitches on the control board need to be configured in accordance with the Electric Heating Airflow Table. Configuringthe dip switches and resetting power to the unit will clear the error code.

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

S9

S10


21 kW* or25 kW*

19 kW or20 kW

Electric Heating Airflow (*indicates factory setting)

15 kW 10 kW


8 kW 6 kW 5 kW 3 kW

S11

S9

S10

S11

S9

S10

S11

S9

S10

S11

S9

S10

S11

S9

S10

S11

S9

S10

S11

S9

S10

S11

15

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

OFF100% CFM 100% CFM

1 min

OFF

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

50% CFM

1/2 min

100% CFM 100% CFM

1 minOFF OFF

Profile C ramps up to 82% of the full cooling demandairflow and operates there for approximately 7 1/2 min-utes. The motor then steps up to the full demand air-flow. Profile C also has a one (1) minute 100% OFFdelay.

100% CFMOFF OFF

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

OFFOFF

S5

S6

S5

S6

S5

S6

S5

S6


Tap A* Tap B Tap C Tap D

Dip Switches - Cooling Airflow Ramping Profiles

7. If an electric heater kit has been installed, determine theheater kilowatt (kW) rating. Using the Electric Heat Air-flow table on page 16, set dip switches 9, 10, and 11 forthe installed heater. The adjust setting (already estab-lished by the cooling speed selection) also applies to theelectric heater kit airflow. Thus, the electric heater air-flow is adjusted by the same amount. This does not ap-ply to systems setup with a communicating thermostat.See Set-Up section in the AIR HANDLER ADVANCED FEA-TURES MENU on page 22. Verify selected CFM by count-ing the green CFM LED blinks.

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

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

TR = (kW x 3412) x (Voltage Correction) x (1.08 x CFM)Where: TR = Temperature RisekW = Heater Kit Actual kW3412 = Btu per kWVoltage Correction =.96 (230 Supply Volts)

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

1.08 = ConstantCFM = Measured Airflow

NOTE: The Temperature Rise Tables can also be used todetermine the air handler airflow delivery. When using thesetables for this purpose set the room thermostat to maximumheat and allow the system to reach steady state conditions.Insert two thermometers, one in the return air and one in thesupply air. The temperature rise is the supply air temperatureminus the room air temperature.Use HKR specification sheets to determine the HKR avail-able for a given air handler.

16

HTR kW 9 10 11 AVPTC24B14A AVPTC30C14A AVPTC36C14A AVPTC42D14A AVPTC48D14A AVPTC60D14A3 ON ON ON 730 730 NR 850** NR NR5 ON ON OFF 780 780 1200 1400 1400 16206 ON OFF ON 850 850 1260 1630 1630 16708 ON OFF OFF 950 950 1320 1630 1630 1720

10 OFF ON ON 1025 1025 1380 1670 1670 175015 OFF ON OFF NR NR 1440 1720 1720 178019* NR NR 1500 NR NR NR20 NR NR NR 1800 1815 1850

21 or 25* OFF OFF OFF NR NR NR NR 1850 1850

ELECTRIC HEAT AIRFLOW TABLE

OFF OFF ON

B ------- 30 sec/50% 60 sec/100%

Speed Selection Dip Switches

A OFF OFF OFF OFF OFF OFF

TAP S1 S2 S3 S4 S5 S6

B ON OFF ON OFF ON OFF

A ------- -------- 60 sec/100%

To set Airflow: (1) Select model and desired High Stage CoolingAirflow. Determine the corresponding tap (A, B, C, D). Set dipswitches S1 and S2 to the appropriate ON / OFF positions.(2) Select model and installed electric heater size. Set dipswitches S9, S10, and S11 to the appropriate ON / OFF positions.(3) If airflow adjustment is required set Trim Enable Switch toS8ON (OFF = 0% Trim) and set S3 and S4 to appropriate ON / OFFpositions. Tap A is +5%,Tap B is -5%, Tap C is +10%, Tap D is-10%.

D ON ON ON ON ON ON

Cool Adjust ProfileSelection Selection Selection Switches Switches Switches

Notes:1. Airflow data shown applies to legacy mode operation only. For a fully communicating system, please see the outdoor unit's installation instructions for cooling and heat pump airflow data. See ComfortNet System-Airflow Consideration section for details.2. Airflow blink codes are approximations of actual airflow.

Profiles Pre-Run Short-Run OFF Delay

C OFF ON OFF ON OFF ON

C ------- 7.5 min/82% 60 sec/100%

D 30 sec/50% 7.5 min/82% 30 sec/50%

To

Set Comfort

mode: Select desired Comfort Mode Profile (seeprofiles above). Set dip switches S5 and S6 to appropriate ON /OFF positions.Dehumidification: To enable, set dip switch S7 to ON. Coolingairflow will be reduced to 85% of nominal value during cool callwhen Dehum command is present. To disable, set S7 to OFF.

Continuous

Fan

Speed: Use dip switches S12 and S13 to selectone of 4 continuous fan speeds, Tap A is 25%. Tap B is 50%, TapC is 75%, Tap D is 100%.

ContinuousFan

Speed

S12 S13

OFF

ON

OFF

ON

OFF

OFF

ON

ON

Model Speed tap Low stage(CFM)High stage

(CFM)A 410 610B 565 835C 660 970D 765 1125A 440 610B 605 835C 740 1020D 885 1225A 500 725B 700 1000C 930 1330D 1120 1600A 560 800B 763 1090C 994 1420D 1225 1750A 900 1350B 1035 1550C 1140 1700D 1200 1800A 1210 1610B 1365 1815C 1450 1920D 1525 2025

AVPTC60D14**

Cooling/Heat Pump Airflow Table

AVPTC24B14**

AVPTC30C14**

AVPTC36C14**

AVPTC42D14**

AVPTC48D14**

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

Note: Airflow data shown applies to the electric heat only in either legacy mode or communicating mode operation* Within thermostat user menu, CTK0* communicating thermostat will display 20 kW for OFF-OFF-ON dip switch selection and 21 kW for OFF-OFF-OFF dip switch selection.NR - Not rated For match up with a 2 ton outdoor unit: Heater kit application shall not exceed 10 kW. Airflow for 5 kW up to 10 kW heater kits shall be set to 850 cfm speed tap of ON-ON-ON. For match up with a 3 ton outdoor unit: Heater kit application shall not exceed 15 kW. Airflow for 5 kW up to 15 kW heater kits shall be set to 1400 cfm speed tap of ON-ON-OFF. For match up with a 3.5 ton outdoor unit: Heater kit application shall not exceed 20 kW. Airflow for 5 kW up to 20 kW heater kits shall be set to 1620 cfm speed tap of ON-ON-OFF.** 3 kW heater kit is not applicable for this indoor application.

17

TROUBLESHOOTING

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONSNOTE: Discharge bodys static electricity before touchingunit. An electrostatic discharge can adversely affect electricalcomponents.Use the following precautions during air handler installationand servicing to protect the integrated control module fromdamage. By putting the air handler, the control, and the per-son at the same electrostatic potential, these steps will helpavoid exposing the integrated control module to electrostaticdischarge. This procedure is applicable to both installed anduninstalled (ungrounded) blowers.

1. Disconnect all power to the blower. Do not touch theintegrated control module or any wire connected to thecontrol prior to discharging your bodys electrostaticcharge to ground.

2. Firmly touch a clean, unpainted, metal surface of the airhandler blower near the control. Any tools held in apersons hand during grounding will be discharged.

3. Service integrated control module or connecting wiringfollowing the discharge process in step 2. Use cautionnot to recharge your body with static electricity; (i.e., donot move or shuffle your feet, do not touch ungroundedobjects, etc.). If you come in contact with an ungroundedobject, repeat step 2 before touching control or wires.

4. Discharge your body to ground before removing a newcontrol from its container. Follow steps 1 through 3 ifinstalling the control on a blower. Return any old ornew controls to their containers before touching anyungrounded object.

DIAGNOSTIC CHART

HIGH VOLTAGE!TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.

WARNING

Refer to the Troubleshooting Chart at the end of this manualfor assistance in determining the source of unit operationalproblems. The 7 segment LED display will provide any ac-tive fault codes. An arrow printed next to the display indi-cates proper orientation (arrow points to top of display). Seefollowing image.

7 SegmentDiagnosticDisplay

Heat Kit Selection

ModelHKSX03XC

HKSX05XC

HKSX06XC

HKSX08XC

HKSX10XC

HKSC05XC

HKSC08XC

HKSC10XC

HKSC15XA

HKSC15XB

HKSC15XF

HKSC19CA

HKSC19CB

HKSC20DA

HKSC20DB

HKSC20XF

HKSC25DC

AVPTC24B14 X X X X X X X X

AVPTC30C14 X X X X X X X X

AVPTC36C14 X X X X X X X X X X X X

AVPTC42D14 X X X X X X X X X X X X X

AVPTC48D14 X X X X X X X X X X X X X X

AVPTC60D14 X X X X X X X X X X X X X X

C Circuit breaker option

18

FAULT RECALLThe integrated control module is equipped with a momentarypush-button switch that can be used to display the last sixfaults on the 7 segment LED display. The control must be inStandby Mode (no thermostat inputs) to use the feature. De-press the push-button for approximately two seconds andless than five seconds. The LED display will then display thesix most recent faults beginning with the most recent faultand decrementing to the least recent fault. The faults maybe cleared by depressing the button for greater than five sec-onds.

NOTE: Consecutively repeated faults are displayed amaximum of three times. Example: A clogged return air filtercauses the air handlers motor to repeatedly enter a limitingcondition. The control will only store this fault the first threeconsecutive times the fault occurs.

COMFORTNET SYSTEM

OVERVIEWThe ComfortNet system is a system that includes aComfortNet compatible air handler and air conditioner or heatpump with a CTK0* thermostat. Any other system configura-tions are considered invalid ComfortNet systems and mustbe connected as a traditional (or non-communicating) sys-tem (see the 24 VOLT THERMOSTAT WIRING - NON-COMMUNICATINGTHERMOSTAT CONNECTIONS section for details).A ComfortNet heating/air conditioning system differs from anon-communicating/traditional system in the manner in whichthe indoor unit, outdoor unit and thermostat interact with oneanother. In a traditional system, the thermostat sends com-mands to the indoor and outdoor units via analog 24 VACsignals. It is a one-way communication path in that the in-door and outdoor units typically do not return information tothe thermostat.On the other hand, the indoor unit, outdoor unit, and thermo-stat comprising a ComfortNet system communicate digitallywith one another. It is now a two-way communications path.The thermostat still sends commands to the indoor and out-door units. However, the thermostat may also request andreceive information from both the indoor and outdoor units.This information may be displayed on the ComfortNet ther-mostat. The indoor and outdoor units also interact with oneanother. The outdoor unit may send commands to or re-quest information from the indoor unit. This two-way digitalcommunications between the thermostat and subsystems (in-door/outdoor unit) and between subsystems is the key tounlocking the benefits and features of the ComfortNet sys-tem.Two-way digital communications is accomplished using onlytwo wires. The thermostat and subsystem controls are pow-ered with 24 VAC Thus, a maximum of 4 wires between theequipment and thermostat is all that is required to operatethe system.

AIRFLOW CONSIDERATIONAirflow demands are managed differently in a fully commu-nicating system than they are in a non-communicating wiredsystem. The system operating mode (as determined by thethermostat) determines which unit calculates the system air-flow demand. If the indoor unit is responsible for determin-ing the airflow demand, it calculates the demand and sendsit to the ECM motor. If the outdoor unit or thermostat is re-sponsible for determining the demand, it calculates the de-mand and transmits the demand along with a fan request tothe indoor unit. The indoor unit then sends the demand tothe ECM motor. The table below lists the various ComfortNetsystems, the operating mode, and airflow demand source.

System System Operating Mode Airflow Demand Source

Cooling Air Conditioner

Heating Air Handler

Continuous Fan Thermostat

Cooling Heat Pump

Heat Pump Heating Only

Heat Pump

HP + Electric Heat Strips

> of Heat Pump or Air Handler Demand

Electric Heat Strips Only Air Handler

Continuous Fan Thermostat

Air Conditioner + Air Handler

Heat Pump + Air Handler

For example, assume the system is a heat pump matchedwith an air handler. With a call for low stage cooling, theheat pump will calculate the systems low stage coolingairflow demand. The heat pump will then send a fanrequest along with the low stage cooling airflow demand tothe air handler. Once received, the air handler will send thelow stage cooling airflow demand to the ECM motor. TheECM motor then delivers the low stage cooling airflow.See the applicable ComfortNet air conditioner or heatpump installation manual for the airflow delivered duringcooling or heat pump heating.In continuous fan mode, the CTK0* thermostat provides theairflow demand. Depending on which CTK0* thermostat hasbeen installed three or four continuous fan speeds may beavailable. If the thermostat provides three speeds (low,medium, high) they correspond to 25%, 50% and 75%,respectively, of the air handlers maximum airflow capability.If the thermostat provides four continuous fan speeds then a100% airflow option is added. During continuous fan operation,the thermostat sends a fan request along with the continuousfan demand to the air handler. The air handler, in turn, sendsthe demand to the ECM motor. The ECM motor delivers therequested continuous fan airflow.

19

CTK0* THERMOSTAT WIRINGNOTE: Refer to section Electrical Connections for 208/230volt line connections to the air handler.NOTE: A removable plug connector is provided with thecontrol to make thermostat wire connections. This plug maybe removed, wire connections made to the plug, and replaced.It is STRONGLY recommended that you do not connectmultiple wires into a single terminal. Wire nuts arerecommended to ensure one wire is used for eachterminal. Failure to do so may result in intermittent operation.Typical 18 AWG thermostat wire may be used to wire thesystem components. One hundred (100) feet is the maxi-mum length of wire between indoor unit and outdoor unit, orbetween indoor unit and thermostat.

FOUR-WIRE INDOOR AND OUTDOOR WIRINGTypical wiring will consist of four wires between the indoorunit and outdoor unit and between the indoor unit and ther-mostat. The required wires are: (a) data lines, 1 and 2; (b)thermostat R (24 VAC hot) and C (24 VAC common).

1 2 R C

1 2 R C

CTK0*Thermostat

CT CompatibleAir Handler BlowerIntegrated Control Module

CT Compatible AC/HPIntegrated Control Module

1 2 R C

System Wiring Using Four-Wires

TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRINGTwo wires only may be utilized between the indoor and out-door units. For this wiring scheme, only the data lines, 1 and2, are required between the indoor and outdoor units. A40VA, 208/230 VAC to 24 VAC transformer must be installedin the outdoor unit to provide 24 VAC power to the outdoorunits electronic control. See kit instructions for mountingand wiring instructions. Four wires are required between theindoor unit and thermostat.

1 2 R C

1 2 R C

CTK0*Thermostat

CT CompatibleAir Handler BlowerIntegrated Control Module

CT CompatibleAC/HP IntegratedControl Module

40VA Transformer

208/230 VAC 24 VAC

1 2 R C

System Wiring using Two-Wires between Air Handler and AC/HP and Four-Wires between Air Handler and Thermostat

COMFORTNET SYSTEM ADVANCED FEATURESThe ComfortNet system permits access to additional systeminformation, advanced set-up features, and advanced diag-nostic/troubleshooting features. These advanced featuresare organized into a menu structure. See the AIR HANDLERADVANCED FEATURES MENU section for layout of menushortcuts.

DIAGNOSTICSAccessing the air handlers diagnostics menu provides readyaccess to the last six faults detected by the air handler. Faultsare stored most recent to least recent. Any consecutivelyrepeated fault is stored a maximum of three times. Example:A clogged return air filter causes the air handlers motor torepeatedly enter a limiting condition. The control will only storethis fault the first three consecutive times the fault occurs.

NOTE: It is highly recommended that the fault history becleared after performing maintenance or servicing the airhandler.

NETWORK TROUBLESHOOTINGThe ComfortNet system is a fully communicating system, andthus, constitutes a network. Occasionally the need to trouble-shoot the network may arise. The integrated air handler con-trol has some on-board tools that may be used to trouble-shoot the network. These tools are: red communications LED,green receive (Rx) LED, and learn button. Refer

to the Communications Troubleshooting Chart at the end ofthis manual for error codes, possible causes and correctiveactions

Red communications LED Indicates the status of thenetwork. The table below indicates the LED status andthe corresponding potential problem.

Green receive LED Indicates network traffic. Thetable below indicates the LED status and the corre-sponding potential problem.

Learn button Used to reset the network. Depressthe button for approximately 2 seconds to reset thenetwork.

SYSTEM TROUBLESHOOTING

NOTE: Refer to the instructions accompanying theComfortNet compatible outdoor AC/HP unit fortroubleshooting information.Refer to the Troubleshooting Chart at the end of this manualfor a listing of possible air handler error codes, possiblecauses and corrective actions.

20

START-UP PROCEDURE Prior to start-up, ensure that all electrical connections

are properly sized and tightened.

All panels must be in place and secured. For Air Tightapplication, neoprene gasket must be positioned at pre-scribed locations to achieve 2% leakage.

Tubing must be leak free.

Unit should be elevated, trapped and pitched to allowfor drainage.

Low voltage wiring is connected.

Auxiliary drain is installed when necessary and pitchedto allow for drainage.

Drain pan and drain tubing has been leak checked.

Return and supply ducts are sealed.

Unit is elevated when installed in a garage or whereflammable vapors may be present.

Unit is protected from vehicular or other physical dam-age.

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

REGULAR MAINTENANCE

HIGH VOLTAGE!Disconnect ALL power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

The only item to be maintained on a regular basis by the useris the circulating air filter(s). Filter should be cleaned or re-placed regularly. A certified service technician must performall other services.

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

NOTICE: THIS PRODUCT CONTAINS ELECTRONICCOMPONENTS WHICH REQUIRE A DEFINITEGROUND. PROVISIONS ARE MADE FOR CONNEC-TION OF THE GROUND. A DEDICATED GROUNDFROM THE MAIN POWER SUPPLY OR AN EARTHGROUND MUST BE PROVIDED.

21

COMMUNICATIONS TROUBLESHOOTING CHART

LED LED Status

Indication Possible Causes Corrective Action(s) Notes & Cautions

Off x Normal condition x None x None x None 1 Flash x Communications

Failure x Communications

Failure x Depress Learn Button x Verify that bus BIAS

and TERM dipswitches are in the ON position.

x Depress once quickly for a power-up reset x Depress and hold

for 2 seconds for an out-of-box reset

Red Communications

LED

2 Flashes x Out-of-box reset x Control power up x Learn button

depressed

x None x None

Off x No power x Communications

error

x No power to air handler x Open fuse x Communications error

x Check fuses and circuit breakers; replace/reset x Replace blown fuse x Check for shorts in

low voltage wiring in air handler/system x Reset network by

depressing learn button x Check data 1/ data 2

voltages

x Turn power OFF prior to repair

1 Steady Flash

x No network found x Broken/ disconnected data wire(s) x Air handler is installed

as a non-communicating/ traditional system

x Check communications wiring (data 1/ data 2 wires) x Check wire

connections at terminal block x Verify air handler

installation type (non-communicating/ traditional or communicating) x Check data 1/ data 2

voltages

x Turn power OFF prior to repair x Verify wires at

terminal blocks are securely twisted together prior to inserting into terminal block x Verify data1 and

data voltages as described above

Rapid Flashing

x Normal network traffic

x Control is talking on network as expected

x None x None

Green Receive LED

On Solid x Data 1/ Data 2 miss-wire

x Data 1 and data 2 wires reversed at air handler, thermostat, or ComfortNet compatible outdoor AC/HP x Short between data 1

and data 2 wires x Short between data 1

or data 2 wires and R (24VAC) or C (24VAC common)

x Check communications wiring (data 1/ data 2 wires) x Check wire

connections at terminal block x Check data 1/ data 2

voltages

x Turn power OFF prior to repair x Verify wires at

terminal blocks are securely twisted together prior to inserting into terminal block x Verify data1 and

data voltages as described above

22

AIR HANDLER ADVANCED FEATURES MENU

Submenu Item Indication (for Display Only; not User Modifiable )Electric Heat Size (HTR KW) Displays the size in kW of the selected electric heaters.Motor HP (1/2, 3/4, or 1 MTR HP) Displays the air handler indoor blower motor horsepower.

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

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

CONFIGURATION

Submenu Item Indication/User Modifiable Options Comments

Fault 1 (FAULT #1) Most recent fault For display onlyFault 2 (FAULT #2) Next most recent fault For display onlyFault 3 (FAULT #3) Next most recent fault For display onlyFault 4 (FAULT #4) Next most recent fault For display onlyFault 5 (FAULT #5) Next most recent fault For display onlyFault 6 (FAULT #6) Least recent fault For display onlyClear Fault History (CLEAR) NO or YES Selecting YES clears the fault

historyNOTE: Consecutively repeated faults are shown a maximum of 3 times

DIAGNOSTICS

Submenu Item Indication (for Display Only; not User Modifiable )Model Number (MOD NUM) Displays the air handler model numberSerial Number (SER NUM) Displays the air handler serial number (Optional)Software (SOFTWARE) Displays the application software revision

IDENTIFICATION

Submenu Item User Modifiable Options CommentsHeat Airflow Trim(HT TRM)

-10% to +10% in 2% increments, default is 0%

Trims the heating airflow by the selected amount.

Auxiliary Alarm ON / OFF Enable or disable Auxiliary Alarm input

SET-UP

Submenu Item Indication (for Display Only; not User Modifiable)Mode (MODE) Displays the current air handler operating modeCFM (CFM) Displays the airflow for the current operating mode

STATUS

23

TROUBLESHOOTINGC

om

fort

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pto

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no

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all f

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24

TROUBLESHOOTINGC

om

fort

Net

Th

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tom

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per

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om

fort

Net

T

her

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stat

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ent

LE

D

Co

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volt

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hand

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spec

ific

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card

B

EF

OR

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card

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or c

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dat

a is

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valid

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k.

INV

ALI

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hand

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ppro

pria

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set u

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card

. x

good manav ptc

Documents

air handler

electric heat

tubing connections

heat kit models

installation considerations

installation location

upflow installation

tubing preparation