Nortek iQ Drive User manual

Variable Speed Ultra-High SEER Split System
These units have been designed and tested
for capacity and efficiency in accordance with
ARI standards. These outdoor air conditioning
units are designed for use exclusively with
select NORDYNE G6 gas furnaces and select
NORDYNE B5 air handlers equipped with
dedicated matched indoor coils.
Outdoor Air Conditioner
Installation Instructions
These instructions are primarily intended to
assist qualified individuals experienced in the
proper installation of Heating and Air Condition-
ing equipment including the iQ DriveTM System.
Local codes may require licensed installation/
service personnel for this type of equipment.
Read all instructions carefully before starting
the installation.
IMPORTANT NOTE
This equipment is one part of a total system
designed for maximum efficiency, adequate
capacity and total comfort. The system must
function as intended. Under no circumstances
any part of the system may be substituted with
other components.
THE iQ DRIVETM SYSTEM
The iQ Drive Air Conditioning System features
fully variable speed compressor technology
and variable speed indoor and outdoor motors.
The system provides variable cooling capacity
as needed modulating over a five degree F
temperature range.It operates near the nominal
rated capacity at the thermostat set point and
modulates as temperature difference between
set point and room temperature changes. The
system may run at additional 18% capacity
to provide rapid cooling and modulates down
to minimum capacity if the room temperature
reaches 2 degree F below set point, then it turns
off if room temperature drops more than 2 degree
F below set point. The system has a built-in
humidity control that will activate a humidifier
equipment (if supplied), and reduces blower
speed if indoor relative humidity is greater than
set point (default set at 60%).
The iQ Drive System consists of an outdoor
unit, indoor unit, controller Thermostat and
connecting lines.
1. The Outdoor Unit:
The outdoor section consists of large heat
exchanger surface, Inverter motor Drive,
Brushless motor type rotary compressor
and an integrated drive brushless fan
motor coupled with a specially designed
fan blade, in addition to refrigerant valves
housed in sturdy attractive chassis.
2. The Indoor Unit:
The matched indoor coil may be a stand
alone cased coil intended to be installed
in NORDYNE G6 Model Gas Furnaces or
may be part of a dedicated NORDYNE B5
Model Air Handler.
The indoor coil is equipped with Electronic
Expansion Valve to precisely control
refrigerant flow over the wide range of
system capacity modulation.
For the stand alone dedicated cased
coil in gas furnace, a Furnace Blower
Conversion Kit is required to allow the
addition of required system components
such as the Integrated Drive Brushless
Indoor Blower Assembly, Interface Board,
upgraded transformer and The Coil Kelvin
Controller.
Consult Installation Instructions provided
with the Indoor Coil and the Furnace Blower
Conversion Kit for details.
For the dedicated Air Handler, the matched
coil and all required components are
included. Consult Installation Instructions
provided with the Air Handler Unit for
details.
3. System Controller Thermostat:
The system controller is the master
component that communicates with
and controls the inverter driven system
components.
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2
The Inverter in the outdoor unit receives
signals from compressor, heat exchanger,
fan motor and outdoor ambient which
are communicated to the controller
via connections to the Indoor Interface
Board. The controller responds back with
appropriate messages for each device
operation command. If no message is
received for 10 seconds, the device will
stop. The controller communicates with
the indoor section via the Indoor Interface
Board which is powered by 24 VAC from
transformer in the furnace or air handler.
Transformer in the gas furnace MUST be
replaced with the one supplied in the gas
furnace blower conversion kit.
1. GENERAL INFORMATION
Read the following instructions completely
before performing the installation.
CAUTION:
This unit is charged with R-410A
refrigerant. DO NOT under any
circumstances use any other
refrigerant besides R-410A in this
unit. Use of another refrigerant will
damage this unit.
Condensing Unit Section — Unit is factory
charged with refrigerant charge adequate to
operate the outdoor section with the indoor
matched coil or air handler, and 15 feet of
refrigeration line.
NOTE: DO NOT USE ANY PORTION OF THE
REFRIGERANT CHARGE FOR PURGING OR
LEAK TESTING.
Matching coils and Air Handlers are shipped
with a small pressurized holding charge to
keep contaminants out.To release the pressure,
read the indoor section installation instructions
carefully.
Liquid and Suction Lines — Refrigerant grade
copper tubing should be used when installing
the system. Suction line tubing should be fully
insulated.
Field Connections for Electrical Power
Supply — All wiring must comply with latest
version of the “National Electrical Code” (ANSI/
NFPA 70) and electrical conductors and circuit
protection must be in compliance with information
listed on the outdoor unit data label.
2. SAFETY CONSIDERATIONS
Pressures within the System — Split System
Air Conditioning equipment contains liquid and
gaseous refrigerant under pressure.Installation
and servicing of this equipment should be per-
formed by qualified, trained personnel thoroughly
familiar with this type of equipment. Under no
circumstances should the homeowner attempt
to install and/or service the equipment.
Labels, Tags, Precautions — When working
with this equipment, follow all precautions in the
literature, on tags, and on labels provided with
the equipment.Read and thoroughly understand
the instructions provided with the equipment prior
to performing the installation and operational
checkout of the equipment.
Brazing Operations — Installation of equipment
requires brazing operations. Safety codes must
be complied with. Safety equipment (e.g. safety
glasses, work gloves, fire extinguisher, etc.) must
be used when performing brazing operations.
WARNING:
Ensure all electrical power to the unit
is OFF prior to installing or servicing
the equipment. Failure to do so may
cause personal injury or death.
3. SITE PREPARATION
Unpacking Equipment — Remove the
cardboard carton and user’s manual from the
equipment. Take care not to damage the tubing
connections when removing the carton.
Inspect for Damage — Inspect the equipment
for damage prior to installing the equipment at
the job site.
Preferred Location of the Outdoor Unit —
Conduct a survey of the job site to determine the
optimum location for installing the outdoor unit.
Overhead obstructions, poorly ventilated areas
and areas subject to accumulation of debris
should be avoided. The outdoor unit must be

3
installed in such a manner that airflow through
the chassis is not obstructed and that unit can
be serviced.
Facility Prerequisites — Electrical power
must be supplied to the equipment. Electrical
power supplied must be adequate for proper
operation of the equipment. The system must
be wired and provided with circuit protection in
accordance with local building codes and the
National Electrical Code.
Minimum Circuit Ampacity — Electrical wir-
ing to the equipment must be compatible and in
compliance with the minimum circuit ampacity
listed on the outdoor unit data label.
Maximum Fuse/ Circuit Breaker Size — Circuit
protection for the outdoor unit must be compat-
ible with the maximum fuse/ circuit breaker size
listed on the outdoor unit data label.
4. INSTALLING THE OUTDOOR UNIT
Slab Mount — The site selected for a slab
mount installation requires a stable foundation
not subject to erosion. The slab should be level
and anchored (if necessary) prior to placing the
unit on the slab.
Cantilever Mount —The cantilever mount
should be designed with adequate safety factor
to support the weight of the unit, and for loads
subjected to the mount during operation.Installed
equipment should be adequately secured to the
cantilever mount and leveled prior to operation
of the equipment.
Roof Mount — The method of mounting
should be designed so as not to overload roof
structures nor transmit noise to the interior of
the structure.
Refrigerant and electrical lines should be routed
through suitably waterproofed openings to pre-
vent leaking into structure.
5. INSTALLING THE INDOOR UNIT
The indoor section should be installed before
proceeding with routing of the refrigerant piping.
Consult the installation instructions of the indoor
unit (i.e.; air handler, indoor coil and furnace) for
details regarding installation.
6. CONNECTING REFRIGERANT
TUBING
CAUTION:
This system utilizes R-410A refrigerant
with PVE oil. When servicing, cover
or seal openings to minimize the
exposure of the refrigerant system
to air and prevent accumulation of
moisture and other contaminants.
General — Once the outdoor and indoor unit
placement has been determined, route refrig-
erant tubing between them in accordance with
sound installation practices. Refrigerant tubing
should be routed in a manner that minimizes the
length of tubing and the number of bends in the
tubing. Refrigerant tubing should be supported
in a manner that the tubing will not vibrate or
abrade during system operation. Tubing should
be kept clean of foreign debris during instal-
lation. Refrigerant lines that exceed 75 ft in
length and 20 ft in vertical elevation difference
are not recommended. The maximum inter-
connecting refrigerant line length is 100 feet,
and the maximum vertical elevation difference
between the indoor and outdoor sections shall
not exceed 50 feet.
Filter Dryer Installation—A liquid line filter dryer
is supplied with unit and must be installed in the
liquid line of the system.If the installation replaces
a system with a filter dryer already present in
the liquid line, the filter dryer must be replaced
with the one supplied with the unit.
7. MAKING ELECTRICAL
CONNECTIONS
WARNING:
Turn off all electrical power at main
circuit box before wiring electrical
power to the outdoor unit. Failure to
comply may cause severe personnel
injury or death.
Wiring Diagram — A wiring diagram/ schematic
is located on the inside cover of the electrical box
of the outdoor unit.The installer should become
familiar with the wiring diagram/ schematic before

4
making any electrical connections to the outdoor
unit. Refer to wiring diagrams in this literature for
wiring of system components.
Outdoor Unit Connections — The outdoor unit
requires both power and control circuit electrical
connections. Refer to the unit wiring diagram/
schematic for identification and location of out-
door field wiring interfaces.
Control Circuit Wiring — The outdoor unit is
designed to operate from a 24 VAC Class II
control circuit.Control circuit wiring must comply
with the latest version of the “National Electrical
Code” (ANSI/NFPA 70) and with applicable local
codes having jurisdiction.
Controller Thermostat Connections — Con-
nections to controller unit should be made in
accordance with the instructions supplied with
unit, and with the instructions supplied with the
indoor equipment. System requires the use of
shielded cable.
Electrical Power Wiring — Electrical power
wiring shall comply with the current provisions
of the National Electrical Code (ANSI/NFPA 70)
and with applicable local codes having jurisdic-
tion. Use of shielded (metal lined sealtite or
rigid ) conduit is required. Electrical conductors
shall have minimum circuit ampacity in compli-
ance with the outdoor unit rating label. The
facility shall employ electrical circuit protection
at a current rating no greater than that indicated
on the outdoor unit rating label.
Disconnect Switch — An electrically compatible
disconnect switch must be within line of sight of
the outdoor unit. This switch shall be capable of
electrically de-energizing the outdoor unit.
8. STARTUP AND CHECKOUT
WARNING:
Ensure electrical power to the unit is
off prior to performing the following
steps. Failure to do so may cause
personal injury or death.
Outdoor Unit — Ensure the outdoor coil, the
inverter heat sink and the top of the unit are free
from obstructions and debris, and all equipment
access/control panel cover is in place.
Indoor Unit — Consult the installation instruc-
tions of the indoor unit (i.e.; air handler, indoor
coil and furnace) for details regarding installation.
Ensure wiring is secure and correct.
Air Filters — Ensure air filters are clean and in
place prior to operating the equipment.
Ensure that the unit has been properly and
securely grounded and that power supply con-
nections have been made at both the facility
power interface and outdoor unit.
ControllerThermostat — Connect the Outdoor
section low voltage wiring to the Indoor section
interface board. Using standard 4-wires thermo-
stat cable, connect controller thermostat to the
indoor section interface board.
Using extreme caution, apply power to the sys-
tem and inspect the wiring for evidence of open,
shorted, and/or improperly wired circuits.
Controller Thermostat screen will be lit and
calibration of indoor blower assembly will begin.
Initial screen will display indoor and outdoor
temperatures and installer will be able to select
functions and program all modes of operation.
NOTE: The Controller Thermostat is designed
to display information screens for use by the
installer and homeowner.
At initial installation, from “OFF” screen, press
the Up and Down buttons simultaneously for
5-10 seconds to display the “Installer Settings
Menu Screen”.This screen prompts the installer
to input system configuration, unit size, furnace
information, accessories installed, desired set-
tings in cooling and heating, and humidity setting
if different from default setting.Installer may also
input recommended service schedule and dealer/
contractor information for future use.
The controller screens display all pertinent
system information in normal operation. When
necessary, important messages may be se-
quenced along the top line to indicate conditions
that need attention.
The controller is also designed to function as an
important service and troubleshooting tool.

5
INSTALLER SETTINGS SCREEN:
1- From“Installer Settings”, select “Model
Configuration”. Screen will display
“single stage” or “multi stage”.
2- Select appropriate option. Screen will
display “Input rate” and “temp rise” for
the installed furnace.
3- Input data from furnace installed.
4- Press “select button” following each
selection or the up and down arrows
to access displayed options. Press
“Previous arrow” to scroll between
screens.
5- From“Installer Settings”, select“Acces-
sories” option. Screen will display ac-
cessories. Input pertinent selections
6- Each accessory selected will be
followed with additional screens for
scheduling maintenance and service.
Input appropriate recommended ser-
vice schedules.
7- From “Installer Settings”, select “Input
Dealer Info” option. Screen will display
pertinent selections. Follow screen
prompts and save “Completed Dealer
Info Screen”.
8- From “Installer Settings”, select “Hu-
midity Settings” option. Screen will
display available selections. Select
from “Humidify only”, “Dehumidify
only”, “Both” or “None”.
9- From “Installer Settings”, select “Re-
store Factory Defaults” if so desired.
10- From“Installer Settings”, select“Charg-
ing Mode”to run system at nominal set-
ting for proper charging conditions.
MAIN SCREEN:
The iQ Drive controller thermostat main screen
displays system normal operating information. It
displays Outdoor and Indoor temperatures, Set
points in cooling and heating, humidity and mode
of operation for system and indoor fan.In addition,
it displays four options to select from:
TEMP Option:
Select this option to temporarily override program
setting until next program interval is activated.
MODE Option:
Select this option to choose operating mode
(Cool, Heat, Auto or Off ).
FAN Option:
Select this option to set desired indoor blower op-
eration mode (Auto, On or Programmed). If “On”
is selected, blower will run at heating speed.
MENU Option:
Select “MENU” option to input the following:
Set Date & Time, Hold Temp info, Program of
Operation, Fan, Mode, Settings and Security
Lockout).
Note: “Fan” and “Mode” may be selected from
Main Screen directly.
1- SET DATE ANDTIME:Follow prompted
screens after each selection is made.
2- HOLD: Select from “Vacation” or “Per
manent”
2A- From “Vacation Hold Screen” set
desired “Hold temperatures for “Heat”
and/or “Cool”.
2B- The following screen prompts the date
and time entry for the desired hold.
Follow same steps for “Permanent
Hold”.
3- PROGRAM: Select to set weekdays,
weekends, every day or individual days
programming. The prompted screens
allow four settings per day.Input desired
program and save.
4- FAN: Select from “Auto”, “On” or “Pro-
grammed Fan”. The “Programmed
Fan Settings” allows fan to run as
programmed in step 3.
5- MODE: Select from “OFF”, “AUTO”,
“COOL” or “HEAT”.
6- SETTINGS: Use this screen to scroll
through options such as:
6A- SCREEN SETTINGS: Set preferred
screen settings such as “Temp scale”,
“Clock setting”,“Language”,“Contrast”
and “Backlight On Time”.
6B- OFFSET: Set temperature offsets,
humidity offset, heat anticipator and
heat differential.
6C- CYCLES PER HOUR: Set the
maximum allowed heating cycles per
hour.
6D- AUTO CHANGEOVER:Select “Auto or
Manual Change” and select the “Auto
ChangeoverTime”to input desired time
interval between cooling and heating
changeover.
6E- PROGRAM SETTINGS:Select “Smart
Recovery”, “Events per Day” and “In-
termittent Fan”.

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When Smart recovery is selected, the
controller adjusts operating span to
match set program. Events per day
selection define number of daily air
changes required based on residential
or business choices.
When Intermittent Fan is selected, the
fan may be programmed to turn on for
selected periods of time at selected
time intervals if no call for cooling or
heating is present. Follow instructions
of each option to set program.
6F- SERVICE INFORMATION:This screen
lists components status and faults if
any.Scroll up and down to obtain“Fault
Status” showing active fault and last 5
faults, “Compressor Status”, “Outdoor
fan Status”, “Indoor fan Status”, “Tem-
perature Status” and option to “Clear
Fault History”.
7. SECURITY LOCKOUT: Select from
“Temp Adjust Only” or “Total Keypad
Lockout”options.A PIN number may be
input.This PIN number will be needed
for future system settings and adjust-
ments.
9. OPERATING INSTRUCTIONS
To Operate System in Cooling:
From MODE Screen, select AUTO or COOL.
From Main Screen use the down arrow to set
cooling temperature below room temperature.
Verify that the indoor fan calibration is performed
and that system starts running.
To set system operation, select MENU from the
Main Screen and follow the instructions listed
under previous section.
To Operate Furnace in Heating:
From MODE Screen, select AUTO or HEAT.
From Main Screen use the up arrow to set heating
temperature above room temperature.
If system has been properly configured, heating
will start to operate.
To Shut Off the System:
The system is designed to continuously operate
within a wide range of speeds to provide ultimate
comfort, adequate matched to load capacity and
maximum efficiency. It will turn off automatically
if required. However if there is a need to shut off
the system, select OFF from Operating Mode
Screen.
To Operate Indoor Blower Only:
Select FAN from MAIN menu screen, then
select ON for continuous blower operation or
Programmed Fan for intermittent option.
NOTE: The controller is programmed to start
a Fan Calibration occurrence every week and
every time the power is lost.This function starts
the indoor blower and calibrates air volume to
motor speed.
10. SYSTEM PROTECTION
MEASURES
The Inverter Driver is designed to provide a full
scale of protection measures against conditions
that may cause compressor and/or other
components failure. When a protection function
is triggered, the Inverter trips and communicates
the fault description to the controller which will
display an error code or component fault status.To
release the trip, correct the fault cause, turn power
off, and then turn it on after few seconds.
Protection Functions:
1- Low Voltage Protection: If the voltage
becomes lower than design minimum,
the output of inverter is interrupted.
2- Over Voltage Protection: Inverter will
trip if voltage becomes higher than design
maximum.
3- Over Current Protection: Inverter will
trip if the converter output current is
exceeded due to load short circuit or
ground fault.
4- Over Heat Protection: Inverter has
a heat sink that rids it from excessive
temperatures. If temperature sensor
exceeds 194 Fahrenheit, Inverter will
trip.
5- Over Speed Protection: Inverter will trip
if compressor speed is increased to 1.5
times the allowed rated speed.

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6- Abnormal Rotation Protection:Inverter
will trip if abnormal rotation of compressor
is detected due to improper wiring.
7- Sensors Error Protection: The out-
door air temperature sensor controls
maximum compressor speed allowed
for safe operation and the compressor
discharge temperature sensor monitor
maximum allowed compressor tempera-
ture.Inverter will trip if these sensors are
open or shorted.
8- Microprocessor Error Protection: If
abnormality of the CPU is detected,
the inverter will trip. Abnormality may
be caused by external electromagnetic
noise.
9- Communication Error Protection:
Inverter will trip if communication with
the main controller fails.
NOTE: Tripping of the Inverter is input into the
controller memory up to 5 times occurrences.
Other System Protections:
Low Pressure Switch — A low pressure switch
is factory installed and located in the suction line
internal to the outdoor unit.The switch is designed
to protect the compressor from a loss of charge.
Under normal conditions, the switch is closed.
If the suction pressure falls below 35 psig, then
the switch will open and its signal to the inverter
will open. The inverter will then send signal to
the controller to turn unit off and displays fault
message. The switch will close again once the
suction pressure increases to 60 psig.
High Pressure Switch — A high pressure
switch is factory installed and located in the
compressor discharge line internal to the outdoor
unit. The switch is designed to de-energize the
unit when excessive pressure occurs due to
abnormal conditions. Under normal conditions,
the switch is closed. If the discharge pressure
rises above 575 psig, then the switch will open
and de-energize the outdoor unit. The switch
will close again once the discharge pressure
decreases below 460 psig.
Diagnostics and Troubleshooting:
The controller Thermostat Unit is designed to
provide service personnel with detailed descrip-
tion of faults that may cause system malfunction,
as well as messages indicating maintenance
required.
Only qualified service personnel shall get into
“Service Information Menu” screen to define the
fault and make the appropriate correction.
“SERVICE NEEDED” Display:
The controller will change screen color to RED
and displays “SERVICE NEEDED”, System
information and Fault detected in the Service
needed menu screen.
If Compressor error is detected, it displays
“COMP ERROR” followed by code number
(see below).
If Blower error is detected, it displays “BLOWER
ERROR” followed by code number (see be-
low).
Other possible errors displayed are:
Too Hot Out
Comp Overload
Low Gas Pressure
COMM Error 10, for indoor motor
COMM Error 20, for outdoor motor
COMM Error 30, for Furnace
An Inverter Keypad diagnosis tool may be used to
help service the outdoor unit at site.See column
“Display of Inverter panel” for fault codes.
Table 1 describes possible errors and corrective
measures.

8
Table 1. Interpreting the Diagnostic Codes
Code No.
Fault
Indication
Possible
Cause
Display of
inverter panel Check item
Finding and
correction
1 Sensor error
Outdoor temp
thermistor shorted
or disconnected.
E.-A1
1- Check thermistor resistance at
normal temperature (60~95°F)
(1-2pin of CN7)
Out of range
10~25k.ohms,
Replace thermistor.
2- Reset the power supply and
run.
Display E-A1,
Replace inverter
Discharge temp
thermistor shorted
or disconnected.
E.-A2
1- Check thermistor resistance at
normal temperature (60~95°F)
(1-2pin of CN8)
Out of range
30~80k.ohms,
Replace thermistor.
2- Reset the power supply
and run
Display E-A2,
Replace inverter
IPM temp thermistor
shorted or
disconnected.
E.-A3
1- Check thermistor resistance at
normal temperature (60~95°F)
(1-2pin of CN9)
Out of range
30~80k.ohms,
Replace thermistor.
2- Reset the power supply
and run
Display E-A3,
Replace inverter.
2 Under voltage Low voltage of
inverter E.-LV
1- Check supply voltage
Equal or over 187V
AC, possible power
interruption
Less than 187VAC,
Check power supply.
2- Reset to the rated voltage
and run
Display E-LV, Replace
inverter.
3 Over voltage High voltage of
inverter O.V.
1- Check supply voltage
Under 253VAC,
possible strong wind
Over 253VAC, check
power supply.
2- Reset to the rated voltage
and run
Display O.V., Replace
inverter/fan motor
5 Over speed Compressor over
speed O.S. Reset to the rated voltage and run
Display O.S., Replace
inverter.
8 Over current
Over current of
power module
(hardware)
O.C.
1- Check compressor resistance
Out of range
0.3~1.ohms,
Replace compressor.
2- Disconnect comp wires Display O.C.,
Replace inverter.
Reset power supply and run Display E.ROT.,
Check wiring.
Replace inverter and run Display O.C.,
Replace compressor.
Over current of
power module
(software)
O.C.-C.
1- Check compressor resistance
Out of range
0.3~1.ohms,
Replace compressor.
2- Disconnect comp wires Display O.C.,
Replace inverter.
Reset power supply and run Display E.ROT.,
Check wiring.
Replace inverter and run Display O.C., Replace
compressor.
9 Over heat Over heat of power
module O.H.
1- Check outdoor temperature
Equal or above 125F,
unit not allowed to
run.
2- Check the screws of power
module Secure loose screws
3- Check IPM heat sink fins Clear obstructions
4- Check fan rotation Secure fan to motor
shaft if screw is loose.
5- Check IPM thermistor
resistance at normal temperature
(60~95°F) (1-2pin of CN9)
Out of range
30~80k.ohms,
Replace thermistor.
6- Reset power supply and run Display O.H., Replace
inverter.

9
Adjustment of Refrigerant Charge:
CAUTION:
Split system air conditioner equipment
contains liquidand gaseousrefrigerant
under pressure. Adjustment of
refrigerant charge should only be
done by qualified, trained personnel
thoroughly familiar with this type of
equipment. Under no circumstances
should the homeowner attempt to
install and/or service this equipment.
Failure to comply with this warning
could result in equipment damage,
personal injury or death.
NOTE: The unit MUST be charged at nominal
speed setting. See “Installer Settings Screen”
and select “Charging Mode” to run system at
nominal speed.
Unit Tonnage
System Charge
R-410A Oz.
2 Ton 160
3 Ton 168
4 Ton 188
Code No.
Fault
Indication
Possible
Cause
Display of
inverter panel Check item
Finding and
correction
10 Rotation error
Abnormal comp
rotation E.ROT.
1- Check comp wiring
connection (TA4,TA5,TA6)
Secure loose wiring/
terminals.
2- Reset power supply and run
Display E.ROT.,
Replace inverter.
3- Replace inverter and run
Display E.ROT.,
Replace compressor.
Abnormal rotation of
outdoor FM E.-FAn
1- Check connection of FM
wiring (CN3) Secure connection
2- Reset power supply and run
Display E.-Fan,
Replace inverter/ fan
motor
20 Communication
error
Communication
error at indoor or
outdoor
E.-485
1- Check connection of
communication cable
(CN11,CONTROLLER)
Verify and secure
loose Connections
2- Check SW2 position
Set SW2 to ON (lower
side)
3- Reset power supply and run
Display E.-485,
Replace inverter.
4- Replace inverter and run
Display E.-485,
Replace controller or
Indoor fan motor.
91 System Parameter
error
DIP-SW switching
error E.-DS.
1- Check the setting of DSW
tonnage
Set the DSW switch to
match tonnage.
2- Reset the power supply
and run
Display E.-DS,
Replace inverter.
EEPROM data
failure E.-PR. Reset power supply and run
Display E.-PR.,
Replace inverter.
CAU trip CAU. Reset power supply and run
Display CAU.,
Replace inverter.
99 CPU error
System Error E.-CT Reset power supply and run
Display E.-CT,
Replace inverter.
CPU Error Err. Reset power supply and run
Display Err., Replace
inverter.
Table 1. Interpreting the Diagnostic Codes (Continued)
Table 2. System Charge

10
Refrigerant Charging Charts
For Cooling Mode of Operation
200
225
250
275
300
325
350
375
400
425
450
475
500
525
550
60 65 70 75 80 85 90 95 100 105 110 115 120 125 130
Liquid Temperature (F)
Liquid Pressure (psig)
Remove refrigerant when above the curve
Add refrigerant when below the curve
2,3, and 4 Ton iQ Drive Charging Chart
Procedure for charging outdoor unit at out-
door temperatures above 65 F:
1. With the system at nominal speed
steady state, measure the liquid refrig-
erant pressure in psig at the service
valve.
2. Measure the liquid refrigerant tem-
perature in Fahrenheit at the service
valve.
3. For the temperature measured, de-
termine the liquid refrigerant pressure
from the appropriate charging chart
below.
4. If the pressure measured in step 1 is
less than the required liquid refrigerant
pressure determined in step 4, then
there is too little charge in the system.
Add refrigerant and repeat steps 1
through 3 until the system is correctly
charged.
5. If the pressure measured in step 1 is
greater than the required liquid refrig-
erant pressure determined in step 4,
then there is too much charge in the
system.Remove refrigerant and repeat
steps 1 through 3 until the system is
correctly charged.

11
Legend
Field Wiring
Factory Wiring:
Low Voltage High Voltage
INVERTER
REACTOR
O.D.
FAN MOTOR
OUTDOOR POWER
SUPPLY
LPS
HPS
1234567
654321
TA 6 TA 5
TA 8 TA 1
TA 2
TA 3
TA 7
T2
T1
L1
GRD.
CONTACTOR
L2
TA 4
CN7
CABLE
THRU TORIODAL RING
CN8
CN11
GND
DX-
DX+
1
2
3
4
1
2
FUSE
FUSE
THRU TORIODAL RING
TO L.V. BARRIER
BLACK
CN3
CN6
MARK
STAMP
“TO W”
“TO V”
T
S“TO U”
*TERMINALS ON COMPRESSOR ARE NOT MARKED. USE RELATIVE LOCATION OF TERMINALS TO THE MARK STAMP TO IDENTIFY PROPER MARKING.
R
KELVIN CONTROLLER
MOTOR
20 21 22 23 24
123456 7 8 9 10 11 12
R
C
Y
G
W
3 Amp Fuse TWIN
COM
24 V
HUM
Neutrals
41 52
63
7
8 9
4 5
6
1
2
3
EAC
HUM
M1
M2
M3
HEAT
COOL
L1
XFMR
Unused Motor
Leads
EAC
NOISE FILTER
RCW2 WH
R
P3
O.D.UNIT
I.D. BLOWER
THERMOSTAT
TWIN
DX+
DX-
GND
24 VAC
DX-
DX+ GRD
COIL THERMISTOR
TEMP
SENSOR
COIL
ESX COIL
PRESSURE TRANSDUCER
TEMP. SENSOR SUCTION (I.D. COIL)
120V
24V
FOR FUTURE USE
C W2 RH R W1 H 0 Y2 Y1 G L V
A B GD OD ID GD
THRU CORE RING
THRU CORE
RING
POWER CABLE
CABLE
CONTROLLER
THERMOSTAT
THRU CORE RING
OUTDOOR TEMP THERMISTOR
COMP DISCH TEMP THERMISTOR INTERFACE
BOARD
BLACK
GREEN
GREEN
GREEN
WHITE
RED
RED
RED
BLACK
BLACK
ORANGE
BLUE
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
BLACK
YELLOW
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK BLACK
YELLOW
BLACK
BLACK
BLACK
RED
YELLOW
YELLOW
WHITE
WHITE
GRAY
BLACK
WHITE
GREEN
BLACK
BLACK
RED
YELLOW
ORANGE
WHITE
WHITE
WHITE W/BLACK STRIPE
BLACK W/ WHITE STRIPE
GREEN
GREEN
GREEN
WHITE
GREEN
BLACK
RED
RED
WHITE
BLUE
BLUE
BROWN
BROWN
RED
BLACK
CABLE
CABLE
CONTROL
CABLE
PLUG CONNECTOR
Outdoor Unit/Furnace Wiring Diagram

INTERFACE BOARD
PRESSURE TRANSDUCER
TEMP. SENS. SUC.
KELVIN CONTROLLER
ESX
COIL
CONTROL
CABLE
20 21 22 23 24
123456 7 8 9 10 11 12
RCH
W
W2
R
C W2 RH R W1 H 0 Y2 Y1 G L V
A B GD OD ID GD
P3
COIL THERMISTOR
TEMP
SENSOR
COIL
DX+
DX-
GND
GND
24 VAC
DX-
DX+
GND
DX-
DX+
CONTROLLER
THERMOSTAT
THRU CORE RING
PLUG CONNECTOR
Legend
Field Wiring
Factory Wiring:
Low Voltage High Voltage
INVERTER
REACTOR
O.D.
FAN MOTOR
OUTDOOR TEMP THERMISTOR
COMP DISCH TEMP THERMISTOR
CABLE
CABLE
CABLE
OUTDOOR POWER
SUPPLY
LPS
HPS
1234567
654321
TA 6 TA 5
TA 8 TA 1
TA 2
TA 3
TA 7
T2
T1
L1
GRD.
CONTACTOR
L2
TA 4
CN7
CABLE
THRU TORIODAL RING TO L.V. BARRIER
CN8
CN11
GND
DX-
DX+
1
2
3
4
1
2
FUSE
FUSE
THRU CORE RING
CN3
CN6
I.D. MOTOR
INDOOR POWER SUPPLY
POWER
CABLE
1234567
PLUG
CONNECTOR
POWER FILTER
Y1
P3
L2
L2
L2 COM
24 VAC
COM
L1
L1
XFMR
W2
W1
O
Y/Y2
HEATER PLUG
KIT
G
R
C
CUT WIRES TO REMOVE PLUG HOUSING WHEN HEATER KIT IS NOT INSTALLED.
TRANSFORMER
208V/240V 24V
MARK
STAMP
“TO W”
“TO V”
T
S“TO U”
*TERMINALS ON COMPRESSOR ARE NOT MARKED. USE RELATIVE LOCATION OF TERMINALS TO THE MARK STAMP TO IDENTIFY PROPER MARKING.
R
TWIN
THRU CORE RING
CABLE
THRU TORIODAL RING
TO L.V. BARRIER
BLACK
YELLOW
YELLOW
WHITE
WHITE
BLUE
GRAY
GRAY
GRAY
GRAY
WHITE
WHITE
WHITE
WHITE
GREEN
GREEN
GREEN
BLACK
ORANGE
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
RED
WHITE
GREEN
RED
RED
RED
RED
RED
RED
GREEN
GREEN
GREEN
RED
RED
RED
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK BLACK
ORANGE
BLUE
YELLOW
YELLOW
YELLOW
YELLOW
BLACK
BLACK
BLACK
BLACK
YELLOW
YELLOW
YELLOW
BLACK
Outdoor Unit/Air Handler Wiring Diagram
708592A (Replaces 7085920)
Specifications and illustrations subject to change
without notice and without incurring obligations.
Printed in U.S.A. (06/06)
INSTALLER: PLEASE LEAVE THESE
INSTALLATION INSTRUCTIONS
WITH THE HOMEOWNER
¢708592A¤
708592A