ION Ion SYST0101CW User manual

Installation Instructions
A180023
NOTE: Read the entire instruction manual before starting the installation.
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NOTE: Please refer to the literature provided with the connected HVAC equipment for more
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The features and functions outlined in the Installation Instructions reflect Version 1 software.
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and literature.
US Patents: U.S. Pat No. 7,243,004, U.S. Pat No. 7,775,452, pointSET™ U.S. Pat No.
7,415,102
SYST0101CW
Ion™ System Control
™

2
Table of Contents
1. Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Quick Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1. Set Time and Date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1.1. Manually Adjust Time and Date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1.2. Setup Time Zone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1.3. Enable Time Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2. Set Dealer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1. Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2. Check Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.3. Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.3.1. Wall Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.2. Wired Remote Room Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.3.2.1. Wired Remote Room Sensor Averaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4. Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.4.1. Shielded Wire and Communication Bus Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.4.2. Damper Control Module (zoning systems only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.5. Decorative Trim Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.5.1. Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.5.2. System Control Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6. Humidifier Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.6.1. Bypass Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6.2. Fan Powered Humidifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1. Searching for Indoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2. Searching for Outdoor Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.3. Indoor Evaporator Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4. Electric Heater Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.4.1. Hydronic Heat Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.5. Searching for Zones (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.6. Filter Type Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.7. Humidifier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.8. Ultraviolet Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.9. Equipment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.10. Airflow Verification Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.11. Duct Assessment (zoned systems only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Service Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.1. Equipment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.3. Set up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.3.1. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.3.1.1. Auto Mode Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3
6.3.1.2. Heat/Cool Deadband . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.3.1.3. Offsets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3.1.4. Reset Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.3.1.5. Scheduling On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.1.6. Smart Recovery On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.3.2. Fan Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.3.2.1. Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.2.2. Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3.2.3. Dehumidification Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3.2.4. Fan Coil G-Terminal Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3.2.5. Fan Coil G-Terminal Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.3.2.6. Fan Coil G Terminal Alert Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.3.3. Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.3.3.1. Furnace Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3.3.2. AC/HP Airflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3.3.3. Furnace Staging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.3.3.4. Furnace Airflow Limits (modulating furnace only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3.3.5. Furnace Off Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.3.3.6. Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3.3.7. Furnace Dehumidifier Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3.3.8. Furnace G Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.3.9. Furnace G-Terminal Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.3.10. Furnace G Terminal Alert Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.3.4. AC/Heat Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3.4.1. Latching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.3.4.2. Cooling Lockout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.3.4.3. Defrost Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.4.4. Low Ambient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.4.5. Quiet Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.4.6. Defrost Fan Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.4.7. Brownout Disable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.4.8. Low Air Multiplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.4.9. Energy Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.5. Heat Source Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.6. Stages / Latch for SmartSense Heat Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
6.3.7. Zoning (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3.7.1. Disable Zoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
6.3.7.2. Zone Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.3.7.3. Airflow Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3.7.4. Duct Assessment Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.3.8. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.3.8.1. Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.3.8.2. Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
6.3.8.3. Ultraviolet Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.9. Utility Curtailment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.10. Hydronic Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6.4. Check out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

4
6.4.1. Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4.2. Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
6.4.3. Hydronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
6.4.4. Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
6.4.5. Heat Pump Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4.6. Heat Pump Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4.7. Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
6.4.8. Zoning (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4.8.1. Airflow Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4.8.2. Damper/Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4.8.3. Zone Duct Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
6.4.8.4. Sensor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.5. Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
6.5.1. Advanced Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.5.2. Fan Coil Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.5.3. Furnace Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.5.4. AC Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.5.5. Heat Pump Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.5.6. Zoning Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.5.7. Last 10 System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.5.8. Run/Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.5.9. Model/Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.5.10. Service Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.5.11. Energy Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.6. Refrigerant Charging: SmartSense Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.6.1. Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.6.2. Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.6.3. Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.6.4. EXV Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.7. Dealer Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.7.1. Upload Dealer Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.7.2. Manually Enter Dealer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.8. Utility Event Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7. Wireless Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
7.1. Setup and Status Information (Homeowner’s Router) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9. Statement Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
9.1. FCC Interference Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
NOTE: See the Owner’s Manual for information regarding software upgrades.

5
1. Safety Considerations
Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion,
fire, electrical shock, or other conditions which may cause death, personal injury or property
damage. Consult a qualified installer, service agency or your distributor or branch for
information or assistance. The qualified installer or agency must use factory-authorized kits or
accessories when modifying this HVAC system. Refer to the individual instructions packaged
with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire
extinguisher available. Read these instructions thoroughly and follow all warnings and cautions
included in literature and attached to the unit. Consult local building codes and the current
edition of the National Electrical Code (NEC) NFPA 70. In Canada, refer to the current editions
of the Canadian Electrical Code CSA C22.1.
Recognize safety information. When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand the signal words DANGER,
WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER
identifies the most serious hazards, which will result in severe personal injury or death.
WARNING signifies hazards, which could result in personal injury or death. CAUTION is used
to identify unsafe practices, which may result in minor personal injury or product and property
damage. NOTE is used to highlight suggestions which will result in enhanced installation,
reliability, or operation.
2. Introduction
The Ion™ System consists of several intelligent communicating components which include the
Ion System Control (or User Interface), communicating variable speed furnace or FCM4 fan
coil, single stage AC and HP, 2-stage AC and HP, and multi-stage AC and HP. The Ion System
Control continually communicates with each ICP communicating HVAC unit via a four-wire
connection called the communications bus. Commands, operating conditions, and other data are
passed continually between components over the communications bus.The result is a new level
of comfort, versatility, and simplicity.
NOTE: The full features of the Ion System are only available with specific ICP systems. See
the Ion System Control Product Data for compatible units and more information.
All ICP communicating furnaces or fan coils are variable-speed and multi-stage for maximum
flexibility, efficiency, and comfort. They support controlled humidification, dehumidification,
and air quality control. Either an ICP communicating, or a standard single-stage 24VAC
controlled outdoor unit may be used.
When using conventional single-stage outdoor units, the ICP communicating furnace or fan coil
provides the 24 volt signals needed to control them. When using multi-stage conventional

6
outdoor units or heat pumps, an Ion Communicating Relay Module or “CRM” (P/N
SYST0101RM) may be required to provide additional control outputs.
All system components are controlled through the wall mounted Ion System Control, which
replaces the conventional thermostat and provides the homeowner with a single wall control for
all features of the system.
3. Quick Start
NOTE: See Installation Section for installation instructions.
3.1. Set Time and Date
The time and date can either be set manually or can be synchronized with the web server. From
the main screen, touch MENU, on the bottom of the control. The TIME/DATE icon will bring
up the time and date menu.
A14215
3.1.1. Manually Adjust Time and Date
• To set the HOUR, MINUTE, MONTH, DAY, or YEAR touch the feature you wish to
change.
• Use the Up (▲) and Down (▼) buttons to make the appropriate changes.
• When you have completed all of the settings touch SAVE.
3.1.2. Setup Time Zone
The time zone can be selected by selecting the set time zone from the menu. Then select the
time zone for the location. Time zones for both US and Canada are included.
3.1.3. Enable Time Synchronization
After setting up the time zone, the time synchronization can then be done, after connection to
the Internet server. Both setting the time zone and enabling time synchronization must be done
in order to enable time synchronization.

7
3.2. Set Dealer Information
From the main screen, touch MENU, on the bottom of the control, then Down (▼) button so
that the SERVICE icon is shown. The SERVICE icon allows you to upload your contact
information into the Ion System Control.
A170243I
• Format your contact information and logo (if applicable) using the PC/MAC Desktop
application available at www.IonComfort.com, and save it to a standard micro SD card. See
Dealer Contact Information Section for more information.
• Touch the SERVICE icon for about 10 seconds, touch DEALER CONTACT
INFORMATION, and then touch UPLOAD DEALER INFORMATION.
• Place the micro SD card into the micro SD card slot on the bottom of the Ion System Control
and follow the on screen prompts.
• More detailed information can be found at www.IonComfort.com.
4. Installation
4.1. Overview
This instruction covers installation of the Ion System Control (SYST0101CW) only. Physical
installation instructions for the indoor and outdoor equipment, and accessories are provided
with each unit.
Setup, commissioning, operation, and troubleshooting of the Ion System are covered in this
installation instruction at a high level. More detailed information may be available in the ICP
communicating HVAC equipment Installation Instructions. This is the guide to connecting the
system components and commissioning the system once all physical components are installed.
Special screen prompts and start-up capabilities are provided in the Ion System to simplify and
automate the initial commissioning of the system.
• Install the Ion System Control according to this instruction.
• Install indoor unit, outdoor unit, and accessories according to their instructions.
• Wire complete system according to this instruction.

8
• Setup, commission, and operate system according to this instruction, and as supplemented in
the HVAC equipment Installation Instructions, to assure a smooth and trouble free start-up.
• Note that some detailed equipment configuration and service information may be included
with the equipment instructions. Please refer to the equipment installation instruction
manuals, and applicable technical training materials, for all devices for complete
information.
4.2. Check Equipment
Inspect equipment. File a claim with shipping company prior to installation if shipment is
damaged or incomplete.
4.3. Location
All wiring must comply with national, state, and local codes.
4.3.1. Wall Control
The Ion System Control is the command center for the Ion System. It should be located where it
is easily accessible and visible to the adult homeowner or end user. For accurate temperature
measurement, the following guidelines should be followed:
The Ion Control, Remote Room Sensors and Smart Sensors (when available) SHOULD be
mounted:
• Approximately 5-ft (1.5 m) from the floor.
• Close to or in a frequently used room, preferably on an inside partitioning wall.
• On a section of wall without pipes or ductwork.
The Ion System Control and Sensors SHOULD NOT be mounted:
• Close to a window, on an outside wall, or next to a door leading to the outside.
• Exposed to direct light or heat from a lamp, sun, fireplace, or other temperature-radiating
objects which could cause a false reading.
• Close to or in direct airflow from supply registers.
• In areas with poor air circulation, such as behind a door or in an alcove.
WARNING
!
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury or death.
Disconnect power before routing control wiring.

9
4.3.2. Wired Remote Room Sensors
A Remote Room Sensor can be used with the Ion System Control to take the place of the
control’s internal temperature sensor. This allows the Ion System Control to be mounted in areas
with less than optimal airflow (such as near an exterior door, window or in a closet). The remote
sensor can be wired to the terminal block connectors labeled S1 and S2 at the control’s
backplate, or the ZS1 and ZS1C connection at the Damper Control Module. In either case, the
Ion Control will automatically detect the Remote Room Sensor and ignore its internal
temperature sensor.
NOTE: Humidity sensing will occur ONLY at the Ion System Control. The wired Remote
Room Sensor does NOT have humidity sensing capability.
4.3.2.1. Wired Remote Room Sensor Averaging
Typically, one wired remote sensor is used but, multiple wired sensors may be used and
averaged in some applications. Averaging requires a special series-parallel wiring method with
a specific number of sensors. See figure below. It is also important to note the humidity sensor
cannot be remotely located, so do not locate the Ion System Control in an area where humidity
sensing may not be accurate.
A03233
4.4. Wiring Considerations
Ordinary thermostat wire is recommended. See Shielded Wire and Communication Bus
Configuration Section for notes on shielded wire. Continuous wire lengths over 25 ft. should
use 18 AWG wiring.
NOTE: Communications bus wiring only requires a four-wire connection; however, it is good
practice to run thermostat cable having more than four wires in the event of a damaged or
broken wire during installation.
Each communicating device in the Ion Zone System has a four-pin connector. It is
recommended that the following color code be used when wiring each device:
Sensor 1 Sensor 2
Sensor 3 Sensor 4
Damper Control
Module
ZS_
Damper Control
Module
ZS_C

10
DX+ — Green = Data A
DX- — Yellow = Data B
C — White = 24VAC (Com)
R — Red = 24VAC (Hot)
A03193I
It is not mandatory that the above color code be used, but each communications connector in the
system MUST be wired consistently.
NOTE: Some outdoor units, typically those with multiple compressor stages, provide their own
low-voltage power source and do not require the “C” (24VAC common) and “R” (24VAC
power) connections. See the outdoor unit installation instructions for more information.
4.4.1. Shielded Wire and Communication Bus Configuration
If the thermostat wiring will be located near or in parallel with high voltage wiring, radio, TV or
Ethernet wiring, then four conductor, twisted-pair, shielded cable can be used to reduce or
eliminate potential interference. The shield wire should be connected to the C terminal, or
ground, AT THE INDOOR UNIT, ONLY. The shield wire should NOT be connected to any
terminal at the Ion System Control. Connecting the shield to ground at both ends can cause
current loops in the shield, reducing shield effectiveness.
Connect one pair of the two-pair (minimum) cable to the DX+ and DX- communication
terminals, and another pair to the C and R terminals at both ends of the cable. The shield wire
should ONLY be connected at the indoor equipment ground or C terminal. Note that some
outdoor units only require the DX+ and DX- connections. See the outdoor unit installation
instructions for more information.
WARNING
!
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing, modifying, or servicing system, the main electrical disconnect switch must
be in the OFF position. There may be more than one disconnect switch. Lock out and tag
switch with a suitable warning label.
DX+ DX- RC

11
”Daisy chain” wiring, where each communicating component is wired one after another, rather
than all components connecting a in “star” fashion to one point, is preferred. For wiring runs
over 100 feet, terminating with a 100 ohm resistor at each end of the chain can help to avoid or
mitigate electrical noise problems.
4.4.2. Damper Control Module (zoning systems only)
When used, all wiring is run back to the Ion System Damper Control Module (SYST0101ZP).
Select a location near the furnace or fan coil where wiring from the control, each Remote Room
Sensor or Smart (Zone) Sensor (when available), each damper actuator, and the equipment itself
can come together easily. The Damper Control Module is approved for indoor use only and
should never be installed with any of its components exposed to the elements. The Damper
Control Module (and zone dampers) may be installed in any area where the temperature remains
between -4°F to 158°F (-20°C to 70°C), and there is no condensation. The cover must be
installed to prevent damage from other sources. Do not locate where it will be accessible to
children. It may be mounted in either vertical or horizontal position. Remember that wiring
access is likely the most important consideration.
4.5. Decorative Trim Plate
Sold separately, a thin decorative trim plate is available to hide any marks/screw holes left from
the previous thermostat. The trim plate is captured between the backplate and the system
control. Align the trim plate around the backplate, and snap on the system control.
4.5.1. Mounting
First become familiar with all plastic assembly pieces shown on the following page. The Ion
System Control will snap together with the standard backplate supplied with the wall control.
Attach backplate using only a small hole in the wall allowing a four wire connection to pass
through. Mount the front assembly to the standard backplate. The figure below shows the
optional decorative trim plate, described in the Decorative Trim Plate Section, installed with the
standard backplate. The decorative trim plate is captured between the backplate and the system
control. Align the decorative trim plate around the backplate, and snap on the system control.
CAUTION
!
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
To prevent possible damage to the Damper Control Module, DO NOT mount on
plenum, ductwork, or flush against furnace or fan coil.

12
4.5.2. System Control Mounting
• Turn off all power to equipment.
• If an existing control or thermostat is being replaced:
– Remove existing control from wall.
– Disconnect wires from existing control.
– Discard or recycle old control.
NOTE: Mercury is a hazardous waste, if existing control contains any mercury, it MUST be
disposed of properly. The Ion System does not contain mercury.
• Select the appropriate Ion System Control mounting configuration. Use the standard
backplate (mounting plate) provided with the wall control, or add the decorative trim plate in
addition to the standard backplate if desired. See the Decorative Trim Plate Section for more
detail.
• Route wires through large hole in mounting plastic. The hole may be enlarged, if required, to
accommodate existing installations; avoid opening the wire hole more than necessary. Level
backplate against wall and mark wall through two mounting holes.
• Drill two 3/16-in (4.8 mm) mounting holes in wall where marked.
• Secure mounting plastic to wall using two screws and anchors provided.
• Adjust length and routing of each wire to reach each wire entry on the connector backplate.
Strip 1/4-in (6.4 mm) of insulation from each wire.
• Match and connect thermostat wires to proper terminals on control backplate. See wiring
diagrams in the Wiring Diagrams Section.
• Push any excess wire into the wall. Seal hole in wall to prevent any air leaks. Air leaking
from behind the wall can affect measured temperature and humidity, and can affect
operation.
• Attach Ion System Control to the mounting plastic by lining up the plastic guides on the back
of the control with the opening on the mounting plastic and push on.
• Perform installation of all other system equipment (i.e. dampers, humidifier, UV lights, etc.).
See the equipment and device installation instructions for details.
• Turn on power to equipment.
4.6. Humidifier Connections
A 24VAC bypass or fan powered humidifier may be installed.
NOTE: Do NOT use a traditional humidistat to control humidifier operation. If a humidifier is
installed, let the Ion System Control operate humidifier.

13
4.6.1. Bypass Humidifier
A bypass humidifier should be wired directly to the furnace or fan coil HUM and 24VAC COM
terminals. The Ion System Control will automatically energize the HUM output during a call for
humidification.
4.6.2. Fan Powered Humidifiers
Most fan powered humidifiers produce internal 24VAC in order to energize upon a switch or
contact closure. For this application, a 24VAC N.O. Isolation Relay (DPST) MUST be used to
prevent mixing the internal humidifier power with the indoor equipment transformer. Applying
24VAC isolation relay coil to furnace or fan coil HUM and COM terminals will allow the Ion
System Control to automatically energize the HUM output during a call for humidification. The
N.O. relay contacts will be used to energize the humidifier. See Fan Powered Humidifier
installation instructions for more details.
5. Commissioning
This section addresses initial power up (or commissioning) of a new Ion System Control. The
control will communicate and identify all components in the Ion System. The following is a
typical example for an ICP communicating variable-speed furnace / fan coil with a 2-stage
air-conditioner / heat pump (including dual fuel system). The process may vary for other types
of systems. See the ICP communicating HVAC equipment Installation Instructions for more
details, as provided.
5.1. Searching for Indoor Unit
The Ion System Control will light up and display the Ion System logo and then begin the
commissioning process by displaying “Searching for indoor unit”.
NOTE: If the Ion System-compatible indoor equipment (package unit indoor section, gas
furnace or fan coil) cannot be found, the control will display “Indoor unit not found”. This
MUST be corrected before the initial power up sequence can continue, proceeding to the next
section, “Searching for outdoor unit.” If it is not corrected, the Ion System Control will go into
its DEMO operating mode. If a control is operating in Demo mode and you wish to install it
with equipment, navigate to the Installer menu and perform a re-install to re-learn the
equipment.
TIP: Troubleshoot communication bus problems by removing all but the indoor unit and
system control from the communication bus circuit. As each bus segment is verified, connect
the next component and continue to troubleshoot as required.

14
5.2. Searching for Outdoor Unit
NOTE: The Ion System Control will then proceed to communicate with the outdoor unit by
displaying “Searching for outdoor unit”. If the outdoor unit cannot be found, the control will
display “Outdoor unit not found”.
• Select the appropriate unit installed; then, touch NEXT.
• The installer will first be instructed to select the appropriate size of the outdoor unit; then,
touch SELECT.
A13118
5.3. Indoor Evaporator Selection
If a furnace is installed with a SmartSense™ multi-stage AC or HP system, a screen will appear
to select the installed indoor evaporator coil. This selection is used to adequately calculate the
refrigerant charge required while in the heat pump charging screens under Refrigerant Charging
SmartSense™ Systems Section. Select “other” for non-ICP evaporators.
5.4. Electric Heater Selection
If the indoor equipment is a fan coil, the control will display “Searching for heater” until one is
found. If the electric heater is not self-identifying, the select heater screen will appear. Touch the
appropriate heater size; then, touch SELECT.
AC1Stage — 1-stage air conditioner
*AC2Stage —
*. Communicationing Relay Module (CRM) may be required for these selections to be
displayed.
2-stage air conditioner
*HP1Stage — 1-stage heat pump
*HP2Stage — 2-stage heat pump
None — No outdoor unit installed

15
A13119
5.4.1. Hydronic Heat Application
The Ion System Control supports two types of Hydronic Heat applications:
1. Hot water coil in combination with an FCM4 fan coil and heat pump, or hot
water coil as sole heat source with an FCM4 fan coil.
2. Non-zoned FE fan coil combined with radiant hot water heat.
In either application, a Hydronic Heat kit should be installed in place of an electric heater. See
FCM4 fan coil Product Data for accessory part number. The system will self-identify that
hydronic heat has been installed during electric heater selection. The system will treat the hot
water coil as either auxiliary heat in a heat pump application, or the sole heat source. Setup
options for Hydronic Heat applications are described in the setup section of this instruction.
NOTE: The daily airflow verification test will take place even when the radiant hydronic heat
option is selected.
5.5. Searching for Zones (If Applicable)
NOTE: This feature is only available with specific ICP communicating indoor units. See the
Ion System Control Product Data for compatible units and more information.
“Zoning - Searching” will appear on the screen to determine if any zones are present. The
screen will show Zone 1, Zone 2, etc. and indicate all zones having either a Remote Room
Sensor, or smart sensors (when available) associated with them. After each zone has been
identified, touch NEXT.

16
A12185i
5.6. Filter Type Selection
The installer will next be prompted to select the air filter type installed with the Ion System.
After the selection is made, touch NEXT.
• Air Filter: 1-in. to 4-in. media filter
• EAC: high voltage electronic air cleaner
• Air Purifier: high performance air filtration system
5.7. Humidifier Installation
Next, the installer will be prompted to select whether a humidifier is installed in the system.
Select YES or NO, then touch NEXT.
5.8. Ultraviolet Lights Installation
Next, the installer will be prompted to select whether ultraviolet lights are installed in the
system. Select YES or NO, then touch NEXT.
5.9. Equipment Summary
The equipment summary screen will appear after accessories have been selected. This screen
will give a summary of all equipment automatically found or manually selected. If an incorrect
selection was made, touch RE-INSTALL to restart the installation process. See the ICP
Communicating HVAC equipment Installation Instructions for more details, as provided.
A13120I
Example: Equipment Summary Screen

17
5.10. Airflow Verification Check
NOTE: This feature is only available with specific ICP communicating indoor units. See the
Ion System Control Product Data for compatible units and more information.
The airflow verification check screen will appear next, as the system performs this operation.
This process will take about 1-1/2 minutes to complete. When completed, a screen will appear
displaying the results of the check.
If the system has an indoor unit equipped with a previous-version CFM-controlled blower
system the screen will display the static pressure (in inches of water) across the equipment at the
expected highest delivered airflow. If the blower RPM is greater than 1200, a warning will
appear, but equipment operation and the dirty filter detection operation will not be affected.
Press NEXT when the airflow verification check is complete.
If the system has an indoor unit equipped with an updated-version CFM-controlled blower
system, the screen will display the static pressure (in inches) across the equipment at a
pre-determined target airflow CFM. If the achieved (actual) CFM is unacceptably below the
target CFM, a yellow notice will appear to invite the user to see the associated information
screen; equipment operation and the dirty filter detection operation will not be affected. Press
NEXT when the airflow verification check is complete.
NOTE: The airflow verification check occurs at initial installation, or when FULL
INSTALLATION or AIRFLOW VERIFICATION TEST are selected in the
INSTALLATION & SERVICE menu.
5.11. Duct Assessment (zoned systems only)
NOTE: This feature is only available with specific ICP communicating indoor units. See the
Ion System Control Product Data for compatible units and more information.
The duct assessment screen will be displayed next for zoned systems. Touch NEXT to start
Duct Assessment. Duct Assessment will measure the relative size of the ductwork, up to and
through the dampers. These measurements are used to control the correct amount of airflow in
the zoned system. Status messages will appear on the screen to indicate what the system is
doing. The process will take approximately two minutes per zone. The duct assessment will
override a call for heat or cool.
A duct assessment will automatically occur each day at a user selectable time. The factory
default time is 1:00 p.m. local time but, may be changed by entering the Zoning Setup menu. If
there is an active call for heating or cooling, the system will wait until the call is satisfied before
it performs the duct assessment. The system will first open all zones and drive the blower to 175
CFM/ton of cooling (or the minimum indoor unit’s airflow, whichever is greater). It will then
take a static pressure measurement. The system will then close all zones and open one zone at a
time, taking a static pressure measurement for each zone.

18
The system will then close all zones and take a pressure measurement, getting a value for the
duct leakage up to and through the dampers. With these static pressure measurements, the
system will calculate the relative size of each zone as well as the percent leakage through the
dampers at the end of the process, the display will show the relative size of each zone duct.
If the Ion System Control detects an error (damper not moving or damper wired backwards), it
will perform the duct assessment again. If it still detects a damper problem, it will default the
measurements into equal sizes, with 10% leakage, and display the zone number for the
suspected zone damper.
NOTE: The daily duct assessment will occur even if static pressure monitoring is disabled. This
is done to ensure that the system will continue to provide proper airflow for all installed
equipment, since duct system changes may occur at any time, such as opened or closed
registers.
After the duct assessment is complete, touch NEXT.
6. Service Menu
The Service menus contain a set of vital information. This information enables the installer or
service person to view a summary of what has been installed, etc. This information is not
covered in the Owner’s Manual.
To enter service menus, touch menu, then touch and hold the SERVICE icon, for at least ten
seconds, until the icon turns green. The following screens are available in installation and
service. To return to the previous screen, touch BACK. To exit the Service menus, touch
DONE.
NOTE: See the Owner’s Manual for information regarding software upgrades.
NOTE: The user “selection of temperature units” affects the user screens only. The service
screens use degree F only. The user “selection of temperature units” is under the display icon on
the main menu.
A170181I_2

19
6.1. Equipment Summary
Touch EQUIPMENT SUMMARY to show indoor unit type and model number, outdoor unit
type (and model number if a 2-stage unit), filter type, any accessories that are installed, and the
number of zones in the system. To return to the previous screen, touch BACK. To exit the
Service menus, touch DONE.
6.2. Installation
Touch INSTALLATION to perform the start-up process in order to learn all equipment in
system. Select FULL INSTALLATION, then touch NEXT to initiate the process.
Touch Airflow Verification Test to perform a duct assessment. This can be done if duct
modifications have been made since installation of the Ion System Control. Duct assessment
can be performed without performing a full system install.
NOTE: This feature is only available with specific ICP communicating indoor units. See the
Ion System Control Product Data for compatible units and more information.
6.3. Set up
A13130
NOTE: Depending upon the equipment installed, the following options will be displayed. See
the ICP communicating HVAC equipment Installation Instructions for more details, as
provided.
• Indoor:
– Furnace
– Fan coil
• Outdoor:
– AC/Heat pump
Once the equipment has been selected, the appropriate menus will be displayed.
6.3.1. Thermostat
First touch SETUP, then touch THERMOSTAT to set up the parameters for the Ion System
Control.

20
6.3.1.1. Auto Mode Set Up
Once the auto changeover option has been selected, touch SAVE.
•Enable or Disable: Choose to enable or disable auto changeover mode. Default = Enable
•Simultaneous Heat/Cool: Choose to turn simultaneous heat cool demand feature on or off.
Available only with Ion Zone Systems. Default = Off
NOTE: This feature is only available with specific ICP communicating indoor units. See the
Ion System Control Product Data for compatible units and more information.
• If Simultaneous Heat/Cool is turned ON, Auto changeover time is grayed out and shows
N/A.
• If Simultaneous Heat/Cool is turned OFF, Auto changeover time: Adjustable from 5 to 120
minutes. Default = 30 minutes
NOTE: AUTO mode is intended to switch between Heating and Cooling modes based on
temperature demand. A gradual auto transition is the energy-conscious default that will satisfy
the majority of customers. Some customers might have significant and simultaneous heating
and cooling demands in different zones. To address this need, a special simultaneous heating
and cooling demand auto mode could be enabled by the Installer. The simultaneous heating and
cooling demand auto mode will result in higher energy usage but benefit the customer with
greater comfort.
A160183_2
6.3.1.2. Heat/Cool Deadband
The minimum difference enforced between heating and cooling desired temperatures. The
deadband does not change when the user changes between Fahrenheit (°F) and Celsius (°C). Ex:
A 2° deadband will be 2°F or 2°C and does not change with units, °F and °C. This can allow one
setting to “push” the other to maintain this difference. When the correct deadband is set, touch
SAVE.
•Deadband: Adjustable from 0 to 6°. Default = 2°
6.3.1.3. Offsets
This option allows calibration (or deliberate miscalibration) of the temperature and humidity
sensors. These offsets are added to the actual temperature/humidity values. See also Zone