Mars Comfort-aire century 7602-444 User manual

www.marsdelivers.com

Installation and

Operation Manual

7602-444

Communicating Service Tool

Table of Contents

Connection ..............................................................................3

Menu Structure........................................................................4

System Conguration ..............................................................4

Airow Selection......................................................................4

Option Selection ......................................................................5

Unit Conguration....................................................................5

Pump Conguration.................................................................6

Valve Conguration .................................................................6

Multi-Unit Conguration...........................................................7

Service Mode...........................................................................8

Manual Operation....................................................................8

Control Diagnosis ....................................................................8

Dipswitch Conguration...........................................................9

Fault History ............................................................................9

Clear Fault History................................................................. 11

Revision History.....................................................................12

Equivalent Model Numbers

Heat Controller Climate Master

HE-Series TZ

HZ-Series TE

HZS-Series TES

HB-Series 0.5-5T TC

HB-Series 7-25T TL

HKV-Series TL

HRC-Series TRC

3

IOM - 7602-444 Communicating Service Tool

Comfort-Aire/Century Communicating Service Tool 7602-444 allows install and service technicians to congure and diagnose

Comfort-Aire/Century Digital Communicating Units without installing a digital communicating thermostat.

Using the Service Tool, a technician can ELECTRONICALLY:

1. Congure items like: airow, heat pump options and conguration, pump or modulating valve operation, unit family, unit

size, etc.

AND

2. Diagnose the unit by operating it manually, performing control diagnostics, viewing dip switch congurations, or by

viewing fault history and operating conditions when a fault occurred.

The Service Tool connects to the DXM2 board with a 4-Wire Connector as shown below:

P1

Alarm

Relay

Comp

Relay

O

Y1

Y2

W

G

C

R

AL1

24Vdc

EH1

EH2

P6

R

C

Off On

JW3

A

OVR

ESD

C

R

NSB

AL2

JW1

Acc1

Relay

Acc2

Relay

H

COM

NC1

NO1

COM

NC2

NO2

P3 CO

RV

LT1

LT2

LP

HP

P7

Status

Fault

R

CC

CCG

CO

S1

S2

1

12

1

4

Factory Use

(240Vac)

Com

N.O.

Fan Enable

5 1/2"

7" 6 1/2"

5"

Use 4 mounting screws

#6 sheet metal screw 1” long

1.5

3/8” standoff

Factory low

voltage Molex

connection for

unit harness

Factory low

voltage Molex

connection for

electric heat

harness

Micro

U1

Off On

P2

COH

COM

AO2

P11

Gnd T1

P10

T2 T2 T3 T3 T4 T4 T5

P9

T5

T6 T6

A0-1 A0-2

Off On

S3

RV

Relay

CCH

Relay

Test

P5

B-

Gnd

P4

A+ 24V

(240Vac)

Fan Speed

N.O.

N.C.

12V

OUT

Gnd

P8

IN

NC

P12

Note: There is only

one T1 connection

1 2 3 4

1 2 3 4 5 6 7 8

AO1

Gnd

1

Service tool

connection

DXM2

Board

DXM2DXM2

BoardBoard

1.0 Connection

� WARNING! �

WARNING!

Connecting wire harness while unit is powered on

or connecting backward may damage service tool.

4

IOM - 7602-4 Communicating Service Tool

2.0 Menu Structure

System Conguration

Airow Selection

Option Selection

Unit Conguration

Pump Conguration

Valve Conguration

Service Mode

Manual Operation

Control Diagnostics

Dipswitch Conguration

Fault History

Clear Fault History

Menu Structure

Start-up Screen

System Conguration Menu

SERVICE TOOL MENU

SYSTEM CONFIG

SERVICE MODE

ACDU03 1.00

SELECT OPTION

3.0 System Conguration

Use the System Conguration option on the start-up screen

to adjust critical equipment settings.

The System Conguration information will be automatically

obtained from each communicating control in the system.

Note 1: The Airow Selection menu (section 3.1) will not be

present if the connected communicating control system has

no blower.

Note 2: The Pump Conguration menu (section 3.4) will

not be present if the connected communicating control is

congured for No Loop Conguration (OTHER).

Note 3: The Valve Conguration menu (section 3.5) will

not be present if the connected communicating control is

congured for No Loop Conguration (OTHER).

3.1 AIRFLOW SELECTION

Adjust the airow settings for each system operating mode

using the up/down arrow buttons. Press the center button to

select each item.

• Airow Settings (defaults stored in control) -

valid range: obtained from control (in 25 CFM

increments)

• Blower O󰀨 Delay (default 60 seconds) – valid

range: 0 to 255 seconds (in 5 second increments)

NOTE 1: The Airow Settings will only be present if the

connected communicating control is congured for ECM

blower.

NOTE 2: If multiple units are connected to one thermostat,

refer to section 3.6 for unit selection.

SYSTEM CONFIGURATION

AIRFLOW SELECTION

OPTION SELECTION

UNIT CONFIG TES026

PUMP CONFIGURATION

SELECT OPTION

PREVIOUS SELECT

or 7602-444

5

IOM - 7602-444 Communicating Service Tool

Option Selection Menu

Unit Conguration Menu

OPTION SELECTION

MOTORIZED VALVE OFF

COMPRESSOR ASCD 0

SELECT OPTION

PREVIOUS SELECT

NOTE: “Motorized Valve” used here refers to a two-position

motorized water valve, not to be confused with the modulating

motorized water valve found in the LOOP CONFIG.

3.2 OPTION SELECTION

This option allows the conguration of heat pump options to

be modied.

Adjust the Option settings using the up/down arrow buttons.

Press the center button to select each item.

• Motorized Valve (defaults stored in control) – valid

range: O󰀨, On “On” delays compressor start until

the valve is fully open.

• Compressor ASCD (Anti-Short Cycle Delay (default

stored in control) – valid range: 5 to 8 (in 1 minute

increments)

NOTE 1: The Compressor Anti-Short Cycle Delay setting

provides equipment protection by forcing the compressor to

wait a few minutes before restarting.

NOTE 2: If multiple units are connected to one thermostat,

refer to section 3.6 for unit selection.

3.3 UNIT CONFIGURATION

Adjust the Unit Conguration settings including Heat

Pump Family, Heat Pump Size, Blower Type, and Loop

Conguration using the up/down arrow buttons. Press the

center button to select each item.

• Heat Pump Family (default stored in control) –

valid range: TE, TY, TES, TEP, TRT, TSM, TSL

• Heat Pump Size (default stored in control) – valid

range: depends on Heat Pump Family setting

• Blower Type (default stored in control) – valid

range: NO BLOWER, 2-SPD PSC, COM ECM-V,

1-SPD PSC, 2-SPD CTM, PWM ECM, VFD

• Loop Cong (default stored in control) – valid

range: Other, VS PUMP, MOD VALVE

Airow, pump and valves can be congured from ‘System

Conguration’ screen.

Select ‘VS PUMP PARALLEL’ when applying an internal

variable speed ow controller with other ow controllers on a

single loop in parallel.

NOTE: Refer to section 3.6.3 for multi-unit conguration

instructions.

UNIT CONFIGURATION

CURRENT CONFIG TE026

HEAT PUMP FAMILY TE

HEAT PUMP SIZE 026

BLOWER TYPE ECM

LOOP CONFIG VS PUMP

SELECT OPTION

PREVIOUS SAVE

Equivalent Model Numbers

Heat Controller Climate Master

HE-Series TZ

HZ-Series TE

HZS-Series TES

HB-Series 0.5-5T TC

HB-Series 7-25T TL

HKV-Series TL

HRC-Series TRC

6

IOM - 7602-4 Communicating Service Tool

VARIABLE SPD INTERNAL

PUMP CONFIGURATION

LOOP OPTION SINGLE

PUMP CONTROL FIXED

HEATING STAGE 1 60%

COOLING STAGE 2 75%

COOLING STAGE 1 50%

COOLING STAGE 2 70%

PREVIOUS SELECT

3.4 PUMP CONFIGURATION

vFlow™ vs internal ow control pump can be controlled either

through temperature di󰀨erential (Delta T) or can be set to

specic speed (xed; % of full speed for each heat and cool

stage).

Can be congured for either single pumping or parallel

pumping.

Congure temperature di󰀨erentials at the thermostat for

vFlow™ units with an internal ow control pump.

Adjust the Pump Conguration settings using the up/down

arrow buttons. Press the center button to select each item.

• Heating Delta T (default stored in control) –

valid range: 4 to 12ºF (in 1ºF increments)

• Cooling Delta T (default stored in control) –

valid range: 9 to 20ºF (in 1ºF increments)

Maximum Heat LWT (valid range based on specic model;

refer to model IOM). Minimum Cool LWT (valid range based

on specic model; refer to model IOM).

NOTE: Refer to section 3.6.3 for multi-unit conguration

instructions.

To control vs pump by xed speed, select ‘Pump Control’,

press , use down arrow to select ‘Fixed’, and press to

save.

Default stored in control. Valid range: 15% - 90% (in 1%

increments)

Heating Stage 1 Cooling Stage 1

Heating Stage 2 Cooling Stage 2

If Pump Conguration is set to ‘VS PUMP PARALLEL’, valid

range changes to 50-90% (in 1% increments).

3.5 VALVE CONFIGURATION

Congure temperature di󰀨erentials at the thermostat for

vFlow™ units with a motorized modulating valve.

Adjust the Valve Conguration settings using the up/down

arrow buttons. Press the center button to select each item.

• Heating Delta T (default stored in control) –

valid range: 4 to 12ºF (in 1ºF increments)

• Cooling Delta T (default stored in control) –

valid range: 9 to 20ºF (in 1ºF increments)

NOTE 1: Minimum and Maximum degree values are shown

only when the control is congured with the appropriate

values.

NOTE 2: Refer to section 3.6.3 for multi-unit conguration

instructions.

3.5.1 MODULATING VALVE OFF POSITION

For certain commercial multi-unit applications, the modulating

valve can be kept slightly open by choosing values 3.3-4.0.

MODULATING VALVE

CONFIGURATION

OFF POSITION 0.0

VALVE CONTROL DELTA T

HEATING DELTA T 7 F

COOLING DELTA T 10 F

MAXIMUM HEAT LWT 80 F

MINIMUM COOL LWT 40 F

PREVIOUS SELECT

VARIABLE SPD INTERNAL

PUMP CONFIGURATION

LOOP OPTION PARALLEL

PUMP CONTROL DELTA T

HEATING DELTA T 7 F

COOLING DELTA T 10 F

MAXIMUM HEAT LWT 80 F

MINIMUM COOL LWT 40 F

PREVIOUS SELECT

7

IOM - 7602-444 Communicating Service Tool

Two

connections

on DXM2

board to allow

for multi-unit

installation

Or

AIRFLOW SELECTION

TT026 S N - - - - - 1 2 3 4

TT026 S N - - - - - 5 6 7 8

TT038 S N - - - - - 9 0 1 2

PREVIOUS SELECT

OPTION SELECTION

TT026 S N - - - - - 1 2 3 4

TT026 S N - - - - - 5 6 7 8

TT038 S N - - - - - 9 0 1 2

PREVIOUS SELECT

3.6 MULTI-UNIT CONFIGURATION

If multiple units are connected to one 7602-457 thermostat

upon unit start-up, the thermostat will automatically register

the serial numbers of all units connected to it.

NOTE: Multiple units may be connected directly to the 7602-

457 thermostat or connected to one another in series, as

shown by the gure below.

3.6.1 MULTI-UNIT AIRFLOW SELECTION

In section 3.1, when an installer selects “Airow Selection”

from the System Conguration menu, the installer may

choose the unit to congure by the last 4 digits of its serial

number from the following screen.

3.6.2 MULTI-UNIT OPTION SELECTION

In section 3.2, when an installer selects “Option Selection”

from the System Conguration menu, the installer may

choose the unit to congure by the last 4 digits of its serial

number from the following screen.

3.6.3 Multi-Unit, Unit, Pump, & Valve Conguration

To congure Unit, Pump, and Valve options in sections 3.3-

3.5, the thermostat must be connected to only one unit at a

time.

8

IOM - 7602-4 Communicating Service Tool

4.0 Service Mode

4.1 MANUAL OPERATION

Manual Operation mode allows service personnel to manually

command operation for any of the thermostat outputs, blower

speed, as well as pump speed or valve position to help

troubleshoot specic components.

NOTE 1: The ECM Airow adjustment will not be present if the

connected communicating control (DXM2) is not congured for

ECM (section 3.1).

NOTE 2: The Pump Speed adjustment will not be present

if the connected communicating control (DXM2) is not

congured for Pump (section 3.4).

NOTE 3: The Valve Position adjustment will not be present if

the connected communicating control (DXM2) is congured for

Valve (section 3.5).

4.2 CONTROL DIAGNOSTICS

Control Diagnostics mode allows service personnel to view

the status of all physical inputs, switches and temperature

sensor readings, as well as the operational status of the heat

pump at the thermostat.

Navigate between diagnostic screens using the left/right

arrow buttons.

NOTE: The Pump Status will not be present if the connected

communicating control (DXM2) is not congured for Pump

(section 3.4).

SERVICE MODE

MANUAL OPERATION

CONTROL DIAGNOSTICS

DIPSWITCH CONFIG

FAULT HISTORY

CLEAR FAULT HISTORY

SELECT OPTION

PREVIOUS SELECT

MANUAL OPERATING MODE

Y1 COMM OUTPUT OFF

Y2 COMM OUTPUT OFF

WCOMM OUTPUT OFF

O COMM OUTPUT OFF

GCOMM OUTPUT OFF

HCOMM OUTPUT OFF

DH COMM OUTPUT OFF

ECM AIRFLOW 0

PUMP SPEED 0%

TEST MODE OFF

SELECT OPTION

PREVIOUS SELECT

CONTROL STATUS

TEMPERATURES

LT1 TEMP 38.1

LT2 TEMP 79.9

COMP DISCHARGE 157.7

HOT WATER EWT 121.5

LEAVING AIR 75.1

LEAVING WATER 73.3

ENTERING WATER 78.5

CONTROL VOLTAGE 26.4

ECM BLOWER RPM 550

ECM TARGET CFM 800

ECM BLWR STATIC N/A

PREVIOUS NEXT

CONTROL DIAGNOSTICS

HP SWITCH CL

LOC SWITCH CL

Y1 PHYSICAL INPUT ON

Y2 PHYSICAL INPUT OFF

W PHYSICAL INPUT OFF

O PHYSICAL INPUT ON

G PHYSICAL INPUT ON

H PHYSICAL INPUT OFF

EMERG SHUTDOWN OFF

NIGHT SETBACK OFF

OVR INPUT OFF

PREVIOUS NEXT

CONTROL DIAGNOSTICS

PUMP OPERATION

PUMP SPEED 60%

PUMP WATTS 140

FLOW RATE GPM 7.4

9

IOM - 7602-444 Communicating Service Tool

4.3 DIPSWITCH CONFIGURATION

Dipswitch Conguration mode allows the service personnel

to view the status of all dipswitch settings for the connected

communicating control (DXM2/AXM) at the thermostat.

Navigate between conguration screens using the left/right

arrow buttons.

NOTE: The unit control dipswitch settings cannot be changed

from the thermostat or conguration/diagnostics tool.

S1 Dipswitch Status

S2 Dipswitch Status

S3 Dipswitch Status

Fault History

CONTROL CONFIGURATION

DIPSWITCH S1

1 ON UPS ENABLED

2 ON DUAL COMP STG 1

3 ON HEAT PUMP TSTAT

4 ON RV O THERMOSTAT

5 ON DEHUMID OFF

6 ON EH2 AUX HEAT

7 ON BOILERLESS

8 ON SEE DXM2 AOM

PREVIOUS NEXT

CONTROL CONFIGURATION

DIPSWITCH S2

1 ON \ ACCESSORY 1

2 ON ACCESSORY 2

3 ON/

4 ON \ ACCESSORY 2

5 ON ACTIVE W/ COMP

6 ON /

7 ON H DEHUM INPUT

8 ON FACTORY SETTING

PREVIOUS NEXT

CONTROL CONFIGURATION

DIPSWITCH S3

1 ON FACTORY SETTING

2 OFF HWG TEST OFF

3 OFF HWG SP 125

4 OFF HWG DISABLED

JW3 LT1 SETTING WELL

LAST 5 FAULTS

LT1 LOW WATER TEMP

NO FAULT

4.4 FAULT HISTORY

Fault History mode displays the ve most recent stored fault

codes for the connected communicating control (DXM2).

Navigate between control fault codes using the up/down

arrow buttons. Press the center button to view more

information about the highlighted fault code.

10

IOM - 7602-4 Communicating Service Tool

4.4.1 Temperature Conditions

Displays detailed temperature readings that were

recorded at the time the fault occurred

4.4.0 Fault Conditions Menu

4.4.2 Flow Conditions

Displays detailed blower and pump speed / valve posi-

tion readings that were recorded at the time the fault

occurred.

4.4.3 Input/Output Conditions

Displays the status of all physical and communicated

inputs, switches, and control outputs that were re-

corded at the time the fault occurred.

FAULT CONDITION MENU

LT1 LOW WATER TEMP

HEAT 1 11:11 AM 11/14

FAULT TEMP CONDITIONS

FAULT FLOW CONDITIONS

FAULT I/O CONDITIONS

FAULT CONFIG COND

FAULT POSSIBLE CAUSES

PREVIOUS SELECT

FAULT TEMPERATURE CONDITIONS

LT1 LOW WATER TEMP

HEAT 1 11:11 AM 11/14

LT1 TEMP 28.1

LT2 TEMP 97.3

HOT WATER EWT 121.5

COMP DISCHARGE 157.7

LEAVING AIR 92.7

LEAVING WATER 34.9

ENTERING WATER 42.1

CONTROL VOLTAGE 26.4

LT1 LOW WATER TEMP

HEAT 1 11:11 AM 11/14

TSTAT SAFETY OUTPT

CONV COMM HPS

Y1 Y1 LOC CC

Y2 Y2 CO RV

W W ACC1

OOOUTPT ACC2

GGFAN AL1

H H HWG EH1

OVR DH PUMP EH2

LT1 LOW WATER TEMP

HEAT 1 11:11 AM 11/14

ECM TARGET CFM 800

ECM BLOWER RPM 550

FLOW RATE GPM 6.5

PUMP SPEED 60%

PUMP WATTS 140

LOOP CONFIG VS PUMP

PREVIOUS SINGLE

FAULT FLOW CONDITIONS

LT1 LOW WATER TEMP

HEAT 1 11:11 AM 11/14

ECM TARGET CFM 800

ECM BLOWER RPM 550

VALVE POSITION 10.0V

LOOP CONFIG MOD VALVE

PREVIOUS MIN POS

Mars Comfort-Aire Century 7602-444 User manual

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