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Amana AVZC20 Installation & Service Reference Download Page 7

7

Voltage Ports

NOTE: 

The communicating thermostat is able to search and iden-

tify the indoor and outdoor units when power is applied to the
system.  Refer to the communicating thermostat’s installation
instruction manual for more information.

Connect low voltage communication wires (1, 2) to low voltage
pigtail provided.

T

HERMOSTAT

  W

IRING

NOTE:

A removable plug connector is provided with the control

to make thermostat wire connections. This plug may be removed,
wire connections made to the plug, and replaced.  It is STRONGLY
recommended that you do not connect multiple wires into a
single terminal without mechanically twisting the tips together
with a set of pliers. Failure to do so may result in intermittent
operation.

Typical 18 AWG thermostat wire may be used to wire the sys-
tem components.  However, communications reliability may be
improved by using a high quality, shielded, twisted pair cable for
the data transmission lines.  In either case, 250 feet is the maxi-
mum length of wire between indoor unit and outdoor unit, or
between indoor unit and thermostat.

T

WO

-W

IRE

 O

UTDOOR

, F

OUR

-W

IRE

 I

NDOOR

 W

IRING

Low voltage wiring consists of two wires between the indoor
unit and outdoor unit and four wires between the indoor unit
and thermostat.  The required wires are data lines 1 and 2, “R”
(24 VAC hot) and “C” (24 VAC common).

1

2 R C

1

2 R C

CTK04
Thermostat

Compatible

Air Handler/Furnace

Integrated Control Module

Compatible AC/HP 

Integrated Control Module

1

2 R C

System Wiring

S

TEP

 1.  C

ALCULATE

 R

EFRIGERANT

 C

HARGE

 B

ASED

 

ON

 L

INE

S

ET

 L

ENGTH

The heat pump unit is shipped with a predetermined factory
charge level as shown below.  For longer line sets greater than
15 feet, add 0.6 ounces of refrigerant per foot.

NOTICE

T

OTAL

 R

EFRIGERANT

 =

   F

ACTORY

 C

HARGE

 + (0.6 

OZ

./

FT

. * A

DDITIONAL

 F

EET

   

OF

 A

CTUAL

 L

INE

 S

ET

).

The following table shows refrigerant amounts for every 5 feet of
line.

15 (Factory Charge)

165

272

272

242

20

168

275

275

245

25

171

278

278

248

30

174

281

281

251

35

177

284

284

254

40

180

287

287

257

45

183

290

290

260

50

186

293

293

263

55

189

296

296

266

60

192

299

299

269

65

195

302

302

272

70

198

305

305

275

75

201

308

308

278

80

204

311

311

281

85

207

314

314

284

90

210

317

317

287

95

213

320

320

290

100

216

323

323

293

105

219

326

326

296

110

222

329

329

299

115

225

332

332

302

120

228

335

335

305

125

231

338

338

308

130

234

341

341

311

135

237

344

344

314

140

240

347

347

317

145

243

350

350

320

150

246

353

353

323

155

249

356

356

326

160

252

359

359

329

165

255

362

362

332

170

258

365

365

335

175

261

368

368

338

180

264

371

371

341

185

267

374

374

344

190

270

377

377

347

195

273

380

380

350

200

276

383

383

353

Unit Tonnage

Actual Line Set Length 

(ft.)

2-Ton

3-Ton

4-Ton

5-Ton

Refrigerant (Oz.)

Summary of Contents for AVZC20

Page 1: ...EPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH HEAT PUMP UNIT AVZC20 HEAT PUMP INSTALLATION SERVICE REFERENCE Index All information contained herein is subject to change without notice 2015 2016 Goodman Manufacturing Company L P 5151 San Felipe St Suite 500 Houston TX 77056 www amana hac com is a registered...

Page 2: ...l not allow for proper operation INVERTER A H MODELS CAN ONLY BE MATCHED WITH AN AV PVC AIR HANDLER OR TXV V EXPANSION VALVE KIT DAMAGE RESULTING FROM OPERATION WITH ANY OTHER COMBINATION IS NOT COVERED BY OUR WARRANTIES NOTICE Outdoor inverter units are approved for operation above 0 F in cooling mode and 20 F RH10 in heating mode with no addi tional kit necessary Damage resulting from operation ...

Page 3: ...LOSION ENSURE THE HYDROSTATIC TEST DATE DOES NOT EXCEED 5YEARS ENSURE THE PRESSURE RATING MEETS OR EXCEEDS 400PSIG WHEN IN DOUBT DO NOT USE CYLINDER WARNING REFRIGERANTS ARE HEAVIER THAN AIR THEY CAN PUSH OUT THE OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE TO AVOID POSSIBLE DIFFICULTY IN BREATHING OR DEATH NEVER PURGE REFRIGERANT INTO AN ENCLOSEDROOM OR SPACE BY LAW ALL REFRIGERANTS MUST BERECLA...

Page 4: ...ontact with the tubing Use an insulated or suspension type hanger Keep both lines separate and always insulate the gas line Insulation is necessary to prevent condensation from forming and dropping from the gas line Armflex or satisfactory equiva lent with 3 8 min wall thickness is recommended In severe conditions hot high humidity areas 1 2 insulation may be re quired Insulation must be installed...

Page 5: ... If the paint of the steel filter drier has been burned or chipped repaint or treat with a rust preventative The recommended location of the filter drier is before the expansion device at the indoor unit NOTE Be careful not to kink or dent refrigerant lines Kinked or dented lines will cause poor performance or compressor damage Do NOT make final refrigerant line connection until plugs are removed ...

Page 6: ...ROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK WIRING MUST CONFORM WITH NEC OR CEC AND ALL LOCAL CODES UNDERSIZED WIRES COULD CAUSE POOR EQUIPMENT PERFORMANCE EQUIPMENT DAMAGE OR FIRE WARNING TO AVOID THE RISK OF FIRE OR EQUIPMENT DAMAGE USE COPPER CONDUCTORS WARNING GROUNDING REQUIRED ALWAYS INSPECT AND USE PROPER SERVICE TOOLS LACK OF INSPECTION OR IMPROPER TOOLS MAY CAUSE EQUIPME...

Page 7: ...red wires are data lines 1 and 2 R 24 VAC hot and C 24 VAC common 1 2 R C 1 2 R C CTK04 Thermostat Compatible Air Handler Furnace Integrated Control Module Compatible AC HP Integrated Control Module 1 2 R C System Wiring STEP 1 CALCULATE REFRIGERANT CHARGE BASED ON LINE SET LENGTH The heat pump unit is shipped with a predetermined factory charge level as shown below For longer line sets greater th...

Page 8: ...eat the sealing sur faces Do not introduce liquid refrigerant from the cylinder into the crankcase of the compressor as this may damage the compres sor Break vacuum by fully opening liquid and gas base valve ATTENTIONINSTALLER IMPORTANTNOTICE Please read carefully before installing this unit For AVZC20 do not install the 24 Volt Transformer that is included with the CTK04 Thermostat in the Heat Pu...

Page 9: ...here is an error Refer to the Troubleshooting section Before starting the SYSTEM TEST turn off the electric heater or gas furnace 1 Ensure the thermostat is installed 2 Apply power to outdoor and indoor units 3 Start up After the application information is entered the initial system test must be run FOR INVERTER H P SYSTEM USING COMFORTNET DO NOT INSTALL A TRANSFORMER NOTICE The HOME screen will b...

Page 10: ...The password is the Date Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom 6 Select YES to continue 7 From the ComfortNet USER MENU select HEAT PUMP NOTE Screen may show air handler or furnace depending on the type of system installed ...

Page 11: ...t to run for its duration 5 15 minutes EQUIP TEST SCREEN will show the system test is ON once selected System test will operate the outdoor unit and the indoor unit through a series of startup tests Please proceed to the next step and allow for startup tests to complete Do not interrupt power to outdoor unit indoor unit or thermostat during system test ...

Page 12: ...s to clear STEP 4 SET THERMOSTAT TO CHARGE MODE Please follow the following sequence to enter CHARGE MODE CHARGE mode allows for charging of the system System op erates for a duration of approximately one hour while the equipment runs at full capacity After one hour the CHARGE MODE ends and the system resumes normal thermostat operation Before starting the CHARGE MODE turn off the electric heater ...

Page 13: ...staller password The password is the Date Code located on the thermostat and is available by entering the EQUIPMENTSTATUSmenuand scrolling to the bottom 4 Select YES to continue 5 SelectHEATPUMP 6 SelectMAINTENANCE ...

Page 14: ...rmostat is set for FAN only mode If charging is not complete after 1 hour repeat 7 and 8 Refer to STEP 5 and STEP 6 for refrigerant charge level adjustment 9 To terminate CHARGE MODE select CHARGE mode screen again Press OFF Press DONE to terminate CHARGE MODE 10 Once CHARGE MODE is complete and has been terminated navigate to HOME screen Enter normal operation with temperature offset or thermosta...

Page 15: ...kwise to increase and counter clockwise to decrease b If subcooling is low and superheat is 7 to 9 F add charge to rise subcooling to 7 to 9 F then check superheat c If subcooling is low and superheat is high add charge to rise subcooling to 7 to 9 F then check superheat d If subcooling is 7 to 9 F and superheat is high adjust the TXV valve to 7 to 9 F superheat then check subcooling e If subcooli...

Page 16: ... that outdoor equipment operational sound lev els may increase while the equipment is running in BOOST MODE Disabling BOOST MODE will provide the quietest and most efficient operation NOTE BOOST MODE is applicable only for AVZC200 1AB or later revision BOOST MODE performance is most effec tive when paired with an electronic expansion valve enabled indoor unit BOOST MODE is ON by default and is act...

Page 17: ...password The password is the Date Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom 4 Select YES to continue 5 Select HEAT PUMP 6 Select SYS SETUP COOL SET UP ...

Page 18: ... MODE is ON by default 8 BOOST TEMP adjusts the activation temperature from 70 F to 105 F Always ON option is also available to permanently engage BOOST MODE Factory default is 105 F Heat Pump SYS SETUP BOOST MD Heat Pump SYS SETUP BOOST TEMP 105F ...

Page 19: ...st be enabled through the Installer Options menu Use the fol lowing procedure to enable and disable dehumidification 1 On the CTK04 HOME screen select MENU 2 From the MENU screen scroll down and select Installer Options 3 Enter installer password if known a The password is the thermostat date code and can be obtained by selecting the red Cancel button and selecting the Dealer Information button b ...

Page 20: ... most recent to least recent Any consecutively repeated fault is stored a maximum of three times Example A leak in the system low refrigerant charge or an incom pletely open stop valve can cause the unit to flash error code E15 This error code suggests that the unit is experiencing operation at low pressure The control will only store this fault the first three consecutive times the fault occurs N...

Page 21: ... up to the full demand airflow Profile C also has a one 1 minute 100 OFF delay 100 CFM OFF OFF Profile D default ramps up to 50 of the demand for 1 2 minute then ramps to 82 of the full cooling demand airflow and operates there for approximately 7 1 2 minutes The motor then steps up to the full demand airflow Profile D has a 1 2 minute at 50 airflow OFF delay OFF OFF Airflow Tables COOL RUN VALUES...

Page 22: ...frost temperature sensor and outdoor liquid temperature sensor reading Current system operation mode COOLING COOLING STARTUP HEATING HEATING STARTUP DEFROST OIL RETURN STOP Displays ON or OFF status ON indicates that the reduction mode is operating and the compressor is running at a lower speed than the cooling load would normally require Displays a 0 100 value based on a ratio of the requested co...

Page 23: ...ngage BOOST MODE SUBMENU ITEM INDICATION USER MODIFIABLE OPTIONS COMMENTS System Verification Test SYSTEM TEST ON or OFF System Verification Test must be run after installation This is approximately a 5 15 minute test If the thermostat is set to COOL mode the system will enter CHARGE mode upon completion otherwise it will stop Force Defrost Cycle FORCE DF CYCLE ON or OFF This will make the unit ru...

Page 24: ...he range selected in the COOL RPS RANGE menu Select the appropriate compressor RPS for the installed system configuration SUBMENU ITEM USER MODIFIABLE OPTIONS COMMENTS HT Reset YES or NO Selecting to default factory setting Heat Airflow Trim Hi 15 to 15 in 3 increments Selects the Heating airflow trim amount Heat Airflow Trim Int 15 to 15 in 3 increments Selects the Heating airflow trim amount Hea...

Page 25: ...URE TRANSDUCER H LPT HIGH PRESSURE SWITCH HPS DS1 DS2 DIP SWITCH SEG1 SEG3 7 SEGMENT DISPLAY Z1C Z4C FERRITE CORE BS1 BS3 PUSH BUTTON SWITCH RVC REVERSING VALVE COIL M1C COMPRESSOR MOTOR M1F FAN MOTOR NOTE 1 1 OFF ON DS1 1 OFF ON DS2 V W U Z3C COIL CIRCUIT LIQUID LINE DISCHARGE LINE DEFROST COLOR CODE RD RED BR BROWN GR GREEN BK BLACK WH WHITE YL YELLOW BL BLUE GY GRAY PU PURPLE 1 THE POSITION OF ...

Page 26: ...RD L2A L1A RD BK TRANSFORMER 208 240 V 3 1 2 24V L1C L2C TERMINAL BLOCK FIELD WIRING H LPT GND INVERTER BOARD COMPRESSOR TERMINAL ORIENTATION X32A X108A GR Z1C Z2C Z3C X12A COIL CIRC UIT DEFROST LIQUID LINE DISCHARGE LINE V W U GR BK BK WH BK 1 OFF ON DS2 2 NOTE 1 BS1 BS2 BS3 X52A SHARE DATA X111A FIN THERMISTOR SEE NOTE 3 NOTE 3 NOTE 1 1 OFF ON DS1 2 GY BK THERMISTOR TEMPERAT URE SENSOR MOTOR HIG...

Page 27: ... DISCHARGE LINE NOTE 1 1 OFF ON DS2 BR BK COLOR CODE RD RED BR BROWN GR GREEN BK BLACK WH WHITE YL YELLOW BL BLUE OR ORANGE GY GRAY CURRENT SENSOR 2 NOTE 1 1 OFF ON DS1 2 1 THE POSITION OF THE SELECTOR SWITCHES DS1 DS2 INDICATE FACTORY SE 2 MOTOR OVERLOAD PROTECTION PROVIDED BY INVERTER SEE TABLE 3 USE COPPER CONDUCTORS ONLY 4 CLASS 2 WIRE NOT ES THERMISTOR TEMPERATURE SENSOR MOTOR HIGH LOW PRESSU...

Page 28: ...MENT POSITION USING A VOM WHILE PAYING ATTENTION NOT TO TOUCH THE CHARGED AREA 4 IMMEDIATELY AFTER MEASURING THE RESIDUAL VOLTAGE DISCONNECT THE CONNECTORS OF THE OUTDOOR UNIT S FAN MOTOR IF THE FAN BLADE ROTATES BY STRONG WIND BLOWING AGAINST IT THE CAPACITOR WILL BE CHARGED CAUSING THE DANGER OF ELECTRICAL SHOCK WARNING Žæ t à ï ª L é ƒR ƒ ƒf ƒ ƒT Ìi à j Ì i à j ƒR ƒ ƒf ƒ ƒT Žæ t à ï ª L é VC T ...

Page 29: ...THE STATIC ELECTRICITY FROM YOUR BODY TO PREVENT FAILURE OF THE PC BOARD 3 MEASURE THE RESIDUAL VOLTAGE IN THE SPECIFIED MEASUREMENT POSITION USING A VOM WHILE PAYING ATTENTION NOT TO TOUCH THE CHARGED AREA 4 IMMEDIATELY AFTER MEASURING THE RESIDUAL VOLTAGE DISCONNECT THE CONNECTORS OF THE OUTDOOR UNIT S FAN MOTOR IF THE FAN BLADE ROTATES BY STRONG WIND BLOWING AGAINST IT THE CAPACITOR WILL BE CHA...

Page 30: ...HE STATIC ELECTRICITY FROM YOUR BODY TO PREVENT FAILURE OF THE PC BOARD 3 MEASURE THE RESIDUAL VOLTAGE IN THE SPECIFIED MEASUREMENT POSITION USING A VOM WHILE PAYING ATTENTION NOT TO TOUCH THE CHARGED AREA 4 IMMEDIATELY AFTER MEASURING THE RESIDUAL VOLTAGE DISCONNECT THE CONNECTORS OF THE OUTDOOR UNIT S FAN MOTOR IF THE FAN BLADE ROTATES BY STRONG WIND BLOWING AGAINST IT THE CAPACITOR WILL BE CHAR...

Page 31: ...X Gas stop valve does not fully open X X X X X X X X X Line set restriction X X X X X X X X X X Line set length is too long X X X Blocked filter dryer X X X X X X X X X X OD EEV coil failure X X X X X X X X X X X X X X X X OD EEV failure X X X X X X X X X X X X X X X X Check valve failure Leakage X X X X X X X High Pressure switch failure X Pressure sensor failure X X X X X X X X X X X X Discharge...

Page 32: ... stop valve does not fully open X X X X X X Line set restriction X X X X X X X X X X Line set length is too long X X X X X Blocked filter dryer X X X X X X X X X X OD EEV coil failure X X X X OD EEV failure X X X Check valve failure Blocked X X X X X X X X X High Pressure switch failure X Pressure sensor failure X X X X X X X Discharge temp sensor failure X X X X X X X X X Coil temp sensor failure...

Page 33: ...frequent low pressure faults Control has determined continued operation is acceptable This indicates they may be a problem with the equipment Stop valve not completely open Restriction in refrigerant lines Low refrigerant charge Refrigerant leak Low pressure sensor inoperable or not properly connected Indoor fan motor not functioning correctly Faulty TXV Faulty control board Check the opening of s...

Page 34: ...compressor Repair replace if needed 32 E32 HI TEMP CTRL1 This error indicates the equipment is experiencing high temperature faults on the outdoor control board Ambient air conditions too high Cooling bracket screw s missing or not properly fastened 2 4 ton only No or poor thermal grease coating between cooling plumbing and cooling bracket on control board 2 4 ton only Outdoor fan low speed 5 ton ...

Page 35: ...ded Replace control board if necessary 38 E38 COMP VOLTAGE The control has detected a voltage related issue with the compressor High or low voltage from supply The compressor wire is lost phase Faulty control board Correct low high line voltage condition Contact local utility if needed Check the wire between control board and compressor Replace control board if necessary 39 E39 OD CTRL FAIL5 Indic...

Page 36: ...r motor Indoor fan motor not properly connected Too much static pressure Check ID fan motor wiring and connectors Repair replace if needed Check ID fan motor Replace if needed B9 Eb9 LOW ID AIRFLOW Estimated airflow from motor is lower than the airflow requirement Failed indoor blower motor Indoor fan motor not properly connected Too much static pressure Check ID fan motor wiring and connectors Re...

Page 37: ...s and the corresponding potential problem LEARN button Used to reset the network Depress the button for approximately 5 seconds to reset the network LED Status Indication Probable Causes Corrective Actions Off Nominal condition None none 1Flash Communications Failure Unknown packet is received Depress learn bu on 2Flash Out of box reset Control power up Learn bu on depressed None Off No power Comm...

Page 38: ...tion Each mode has its own corresponding Screen within the display itself which allows the user to navigate and use the features Example The Fault Code is accessed and displayed from Screen 0 of the 7 segment display The Fault History is accessed and display using Screen 1 of the display etc FAULT CODE FAULT HISTORY MONITORING SETTING MODE 1 SETTING MODE 2 MODE Fault Code Display Fault Code Histor...

Page 39: ... shows the most recent fault To access hold the RECALL button for 5 seconds at screen 0 To access hold the RECALL button for 5 seconds at screen 1 To access hold the RECALL button To access hold the RECALL and TEST buttons simultaneously To return to SCREEN 0 of the display press the LEARN button for 5 seconds at screen 2 for 5 seconds at screen 2 The first digit displays the SCREEN Hold RECALL Pr...

Page 40: ...SCREEN This mode will allow the user to see the six most recent system faults For a list of the fault codes please see the TROUBLESHOOTING tables in this document 1 SCREEN 0 SCREEN 1 The display will change to SCREEN 1 Displays 2nd most recent Fault code 6th most recent Fault Code Hold RECALL Press RECALL Press RECALL Press RECALL Press RECALL ...

Page 41: ...setting Press RECALL Press RECALL Item number Display flickers at 1 second intervals Value MONITORING MODE NAVIGATION SCR This screen allows the user to monitor system variables as shown in the tables at the end of this section EEN 2 OFF ON Blink interval 0 4 sec On 0 4 sec Off Hold RECALL Press RECALL Press RECALL Press RECALL ...

Page 42: ...stem settings as shown in the tables at the end of this section SCREEN 0 Press RECALL Press RECALL to increase the value Press TEST to change setting Press RECALL Press TEST to complete setting and return to setting mode SCREEN 2 Press LEARN SCREEN 3 Press RECALL Press RECALL OFF ON Blink interval 0 4 sec On 0 4 sec Off ...

Page 43: ...e the number Press RECALL Press TEST to change setting Press RECALL Press TEST to complete setting and return to setting mode Press RECALL Press RECALL Press RECALL SCREEN 0 OFF ON Blink interval 0 4 sec On 0 4 sec Off Press RECALL Press RECALL SCREEN 4 Setting Mode 2 allows the user to change system settings See table in back of this section ...

Page 44: ...e 0 Stop 1 Cooling Start up 2 Heating Start up 3 Oil Return Operation 4 Heating Operation 5 Defrost Operation 6 Cooling Operation 3 Compressor Reduction Mode 0 OFF 1 ON 4 demand unit Cut off the decimal first place 5 act demand unit Cut off the decimal first place 6 Requested ID CFM unit CFM Multiply by 10 7 Reported ID CFM unit CFM Multiply by 10 8 Outdoor FAN RPM unit RPM Multiply by 10 9 Ta Out...

Page 45: ...m Low 0 15 1 12 2 9 3 6 4 3 5 0 6 3 7 6 8 9 9 12 10 15 11 Heat ON Delay 0 5sec 1 10sec 2 15sec 12 Heat OFF Delay 0 30sec 1 50sec 2 70sec 3 90sec Setting Setting No Contents Setting Installer Serviceman Notes 1 Maximum Defrost Interval 0 30min 1 60min 2 90min 3 120min 2 Set Maximum Current N A Future Use 3 Vertical Rise 0 Same Level 1 Outdoor Lower 2 Indoor Lower 4 System Verification Test 0 ON 1 O...

Page 46: ...e airflow If cleaning of the outdoor coil becomes necessary hire a qualified servicer Inexperienced people could easily puncture the tubing in the coil Even a small hole in the tubing could eventually cause a large loss of refriger ant Loss of refrigerant can cause poor operation and or severe equipment damage Do not use a condensing unit cover to protect the outdoor unit during the winter unless ...

Page 47: ...ll ductwork roof curbs and electrical connections Check gas piping for leaks Verify gas pressure to the unit is within the range specified on the serial plate Check to ensure that all fan blades and wheels are secure Check refrigerant piping for rubbing and leaks Repair if necessary Check unit wiring to ensure it is not in contact with refrigerant piping or sharp metal edges Check all electrical c...

Page 48: ...e Cooling Supply Air Temperature Blower Amps Condenser Fan Amps ELECTRICAL Total External Static Pressure Air Flow Discharge Circuit Heating Supply Air Temperature PRESSURES Gas Inlet Pressure Gas Manifold Pressure BLOWER EXTERNAL STATIC PRESSURE Return Air Static Pressure Supply Air Static Pressure Supply Voltage Compressor Amps Start Up Fill in the blanks from the Status Screen on the CTK04 Ther...

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