Lennox Harmony III Installation Instructions Manual
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Lennox Harmony III Installation Instructions Manual

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E2011 Lennox Industries Inc.
Dallas, Texas, USA
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Air Reduction
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G71MPP/SLP98/SL280V/EL296V:
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08/11
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INSTALLATION
INSTRUCTIONS
Harmony IIIt Zoning System
ZONING
505,023M
08/11
Supersedes 01/11
Retain These Instructions For Future Reference
Variable Speed Blower Motor (VSM) technology is
required for use with Lennox Harmony IIIt Zone
Control Systems.
Only technicians qualified for zoning installations
should perform the equipment setup in this manual.
Gas Furnace Start−Up & Checkout:
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Electric Heat, Hot Water Coil, Cooling Only
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Installation Setup Worksheets:
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Honeywell 2−stage IFC control (HP appls)
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Litho U.S.A.
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Summary of Contents for Lennox Harmony III

  • Page 1: Table Of Contents

    Supersedes 01/11 Retain These Instructions For Future Reference IMPORTANT Variable Speed Blower Motor (VSM) technology is required for use with Lennox Harmony IIIt Zone Control Systems. Only technicians qualified for zoning installations should perform the equipment setup in this manual.

  • Page 2: General

    The system controls the air vol- Introduction ume, eliminating the need for bypass dampers in most ap- The Lennox Harmony IIIt Zone Control System manages plications. The homeowner controls the system using the distribution of conditioned air to specific areas or zones zone thermostats to make comfort settings for each zone.

  • Page 3: Residential Zone Control System − Field Wiring

    GENERAL Residential Zone Control System − Overview of Field Wiring ZONE 1 ZONE 2 THERMOSTAT (ZONE 1 OR CENTRAL CONTROL THERMOSTAT THERMOSTAT WHEN IN VACATION MODE) (ZONE) ZONE DAMPER ZONE DAMPER CONDENSING TRANSFORMER TO POWER POWER UNIT OR HEAT ZONE CONTROL PANEL, THER- PUMP OUT- MOSTATS AND DAMPERS;...

  • Page 4: System Components (Included & Separately Ordered)

    HVAC equipment (see figure 1). Lennox recommends that zone 1 thermostat (central [vaca- tion] mode controller) be programmable. Each thermostat must have a deadband between HEAT and COOL.

  • Page 5: Installation Planning & Selecting Heat/Cool Equipment

    Lennox Air Handler Unit with VSM only (CBX32MV, damper(s). The procedure for zone linking is described on CBX40UHV, CB31MV, CBWMV). Page 7. Lennox Heat Pump Unit as described in table 3. Table 2. Adjusting for average CFM Example Option 3 Required CFM...

  • Page 6: Installing Zone Control Components

    GENERAL Installing Zone Control Components NOTE 1 − FOR UNITS WITH HUMIDITROL Discharge air sensor When possible, position the sensor some dis- (DAS) MUST be located on the output side of the EDA (if used; see tance away from the coil rather than in the imme- PLENUM Humiditrol Zoning Accessory Installation 505,337M) diate coil area.
  • Page 7 GENERAL Thermostats Identify the best location for a thermostat in each zone. If the smaller zone. Table 2 (Page 5) shows an example of two or more rooms are within a single zone, place the ther- an unequal zone and how to adjust to bring it within 25% of mostat in a location that is central to all rooms.

  • Page 8: Zone Control Panel Jumpers: General Information

    GENERAL Zone Control Panel Jumpers (General Information) Setup for controlling equipment staging and ZONE 1 ZONE 3 Pin shown with PIAB PIAB volume of air to zones jumper on This section provides information for installing jumpers on ZONE 1 AT 10%. the zone control panel jumper banks (see figure 5).

  • Page 9: Air Reduction

    GENERAL Zone Control Panel Jumpers (Determining PIAB Jumper Settings) Determining PIAB Jumper Settings Table 5. Determine PIAB jumper setting example CFM values NOTE − Use the PIAB Calculation Worksheet on Page 60 Required CFM (also see example below) to help calculate the zone con- Zone 1 Zone 2 Zone 3...

  • Page 10: Heat/Cool Staging

    GENERAL Zone Control Panel Jumpers (Heat/Cool Staging) Heating/Cooling staging jumpers prevent any rapid stag- ing of the equipment. This section shows the recom- mended settings for heating/cooling staging temperatures and explains the temperature differentials for different equipment configurations. In the diagrams, sine waves in- dicate which stage operates during the rise and fall of dis- charge air temperature for the different heating/cooling staging jumpers.

  • Page 11: System Configuration/E−Heat Stages

    GENERAL Zone Control Panel Jumpers (SYSTEM Configuration/E−Heat Stages) SYSTEM Configuration/E−HEAT Stages In this configuration, the maximum discharge temperature the electric heat or heat pump is allowed to run is 135°F. At Jumpers that temperature, the zone control system removes de- The SYSTEM configuration jumpers must be inserted to mand from the heating unit for a minimum of 5 minutes and select the type of cooling and heating system that has...

  • Page 12: Common System Component Wiring

    24 VAC exceed class II wiring limit of 75 VA. Combined load of zone dampers and ZONE zone relays not to exceed 60VA. RELAY K1 Use Lennox Part 56L68 for Zone EXTENDED Relays 1 through 4. ZONE 1 DAMPER ZONE 1...

  • Page 13: Zone Control Transformer Phasing

    GENERAL Component Specific Wiring CHECK VOLTAGE BEFORE CONNECTING ZONE CONTROL TRANSFORMER (ZONE CTRL XFMR) LEADS TO THE ZONE CONTROL PANEL CONNECTIONS IF 0 VOLTS (AS SHOWN IN A") IF METER READS 48 VOLTS (AS SHOWN IN B") THEN POLARITY IS RE- THEN POLARITY IS CORRECT VERSED;...

  • Page 14: Minimum Cfm In Variable Speed Furnaces

    GENERAL Minimum CFM in Variable Speed Furnace and Air Handlers Harmony IIIt Zone Control system minimum CFM values for variable speed furnaces are listed in table 6. These apply to furnaces and air handlers with serial numbers indicating they were built in 2004 or later. With furnaces built before 2004, use ®...

  • Page 15: System Flow Diagrams

    GENERAL System Flow Diagrams COOLING HEATING COOLING HEATING DEMAND DEMAND OPERATION OPERATION RECEIVED RECEIVED AC/HP HP & Electric 5 minutes 5 minutes Heat Strips since completion since completion of last cooling of last heating demand demand Order of Staging: HP stg 1 (Y1) Energize (Y1/Y2) Energize stage 1 Energize stage 2...

  • Page 16: Heat Pump

    A pressure switch (HFC−22 [27W12]; HFC−410A [27W13]) ing is below the set point. The zone control then instructs is required for applications with a Lennox heat pump (Op- the gas furnace to provide all the heating and prohibits the tions 2 and 3). This switch acts as a guard in case of high heat pump from attempting to fill a demand for heat.

  • Page 17: Zone Control System Wiring Heat Pump

    Electrical Adjustments (Page 39). See System Configuration & E−Heat jumper settings − page 11. Figure 15. Harmony IIIt Zone Control System Option 2 − Lennox Heat Pump & Lennox Variable-Speed Air Handler Page 17 HARMONY IIIT ZONE CONTROL SYSTEM...

  • Page 18: Heat Pump System Startup And Checkout

    HEAT PUMP Heat Pump System Start−Up & Checkout IMPORTANT The zone control system power−up must occur at the same time or before the furnace or air handler unit is powered up. Powering the System (All Systems) 1. Adjust all thermostat settings so that no demand will occur. 2.

  • Page 19: Heat Pump Heating Checkout (Multiple Zone)

    HEAT PUMP Heat Pump Heating Checkout (Multiple Zone) Prerequisites: Output Heat LED Y1 on (compressor). Heating and Fan LEDs on. All zone thermostats set to Heat LEDs dampers 1 − 4 off (all dampers open). Pressure Switch LED on. The compressor in the outdoor unit begins operating in the heating mode.

  • Page 20: Heat Pump Pressure Switch Checkout

    HEAT PUMP Pressure Switch Checkout The high pressure switch is a normally closed (N.C.) autoreset high pressure switch located in the compressor discharge line or on the suction valve service port. The switch is factory set to open when operating pressures rise and close when the pressure drops (see table 8).

  • Page 21: Troubleshooting Zoning System With Heat Pump

    Heating? Defrost? Emer. Heating? Does blower speed change as zone de- mand changes? If no, does DS output vary from 0 to 25VDC? Figure 16. Lennox Heat Pump & Lennox Variable-Speed Air Handler Page 21 HARMONY IIIT ZONE CONTROL SYSTEM...

  • Page 22: Hp Heating Operation

    HEAT PUMP Troubleshooting Heat Pump Heating Operation HEATING DEMAND RECEIVED The maximum discharge air tempera- ture at which the heat pump/electric heat is allowed to run is fixed at 135°F. When the zone control system is ap- REFER TO DEFROST DIAGRAM DIAGRAM plied to a heat pump with electric heat, 5−minutes...

  • Page 23: Defrost Operation

    Harmony III sends signal to W1 at indoor unit Defrost Defrost period exceeds completed 20 minutes Heating Harmony III control demand de−energizes all satisfied compressor stages − uses auxiliary heat to complete existing heat demand De−energize all compressor stages...

  • Page 24: Gas Furnace

    See Integrated Control Electrical Adjustments (begin- See System Configuration & E−Heat jumper settings − page 11. ning on Page 28). Figure 17. Harmony IIIt Zone Control System Option 1 − Lennox Variable-Speed Gas Furnace & 1− or 2-Stage Air Conditioner Page 24 505023M 08/11...

  • Page 25: Integrated Control Electrical Adjustments

    The Harmony III™ zone control´s pulse width modulated (PWM) output signal is connected to the DS terminal on the furnace control. The PWM signal, along with any other thermostat request (G, W1, or W1+W2), controls fan speed linearly between the minimum and maximum CFM for the furnace as determined by the cool speed DIP switches (see G71MPP &...

  • Page 26: System Operation

    The dehumidification on−board clippable link W914 Dehum − Harmony (R to DS) on the G71MPP, SLP98, SL280V, and EL29V integrated control must be cut for operation with the Harmony III™ zone control (see figure 18). Once the link is cut, the presence of the Harmony III™...

  • Page 27: Installation Setup Worksheet

    Indoor Unit setup: - Cut on−board link W914 DEHUM OR HARMONY (R to DS) on furnace IFC control (if not cut, fuse will blow in Harmony III zone control board) - W2 connection from Harmony III to SLP98 or G71MPP is optional – see Harmony III / furnace installation instructions for details - DIP switch settings (ON or OFF): (DIP switch 1 –...

  • Page 28: Integrated Control Electrical Adjustments

    GAS FURNACE VSM Furnace IFC Electrical Adjustments (G61MPV & G60UHV) NOTE − Follow all equipment installation instructions provided with each unit. Variable-speed furnaces are equipped with an integrated furnace control (IFC). The blower motor speed must be adjusted, by DIP switch setting selection, to produce the cfm required when all the zones are demanding heating or cooling which is managed by the zone control system.
  • Page 29 GAS FURNACE VSM Furnaces IFC Electrical Adjustments (G61MPV & G60UHV [cont’d]) J46 PLUG FROM THE MOTOR TO MOTOR J/P49 LOOK FOR RIDGE TO IDENTIFY PIN 1 CUT AND TAPE POSITION CUT & TAPE WIRE #13 (FURNACE APPLICATION ONLY) WIRE #2 VIEW FROM WIRE ENTRY SIDE OF PLUG VIEW FROM MATING SIDE OF PLUG VIEW LOOKING DIRECTLY INTO WIRE ENTRY SIDE OF PLUG...

  • Page 30: System Operation

    GAS FURNACE VSM Furnace System Operation (G61MPV & G60UHV) This section describes the operation of the zone control in Zone Mode a system that uses a gas furnace. The zone control mode (Vacation switch OFF) utilizes the zone control system’s full potential. While in this mode, the Zone Thermostats zone control system will respond to demands from any Only electronic thermostats with a C"...
  • Page 31 GAS FURNACE VSM Furnace System Operation (G61MPV & G60UHV [cont’d}) Heating Operation Dual Fuel−Heat Pump with Gas Furnace In this sys- tem, when it receives a thermostat heating call, the zone control responds in one of two ways: Gas furnace In this system, when the zone control re- 1.

  • Page 32: G61Mpv/G60Uhv

    - Zone 4 – Name:____________ Desired cfm:____________ PIAB Setting: ____________% Actual cfm: ____________ NOTE All of the above are recommended starting positions for DIP switches and Harmony III jumpers. Slight variations may be required during sys- tem start up and operation checks.

  • Page 33: Gas Heating Checkout − Single Zone

    GAS FURNACE Furnace System Start−Up & Checkout IMPORTANT The zone control system power−up must occur at the same time or before the furnace or air handler unit is powered up. Powering the System (All Systems) 1. Adjust all thermostat settings so that no demand will occur. 2.

  • Page 34: Gas Heating Checkout − Multiple Zone

    GAS FURNACE Gas Heating Checkout (Multiple Zone) Prerequisites: 1. Set all zone thermostats for a heat demand; check for the following: All zone thermostats set to Heat All zone thermostat W LEDs on (heat demands). LEDs dampers 1 − 4 off (all dampers open). Output Heat W1 LED on (furnace on).

  • Page 35: Troubleshooting: Zoning System With Gas Furnace

    Does furnace respond to out- puts? Does blower speed change as zone demand changes? If no, does DS output vary from 0 to 25VDC? Figure 22. Option 1 − Lennox Variable-Speed Gas Furnace and Lennox Condensing Unit Page 35 HARMONY IIIT ZONE CONTROL SYSTEM...

  • Page 36: Gas Heating Operation

    GAS FURNACE Troubleshooting Gas Heating Operation HEATING DEMAND RECEIVED REFER TO DISCHARGE AIR 3−Minutes UPPER LIMIT DIAGRAM since completion (Page 37) FOR UPPER LIMIT of last heating AND DIFFERENTIAL DETAILS. demand Energize W2 Energize W1 @ @ furnace furnace; Ramp indoor blower to minimum CFM Monitor...

  • Page 37: Discharge Air Upper Limit & Differential Temp

    GAS FURNACE Troubleshooting Discharge Air Upper Limit & Differential Temperatures Furnace energized Monitor discharge air temperature Discharge air upper limit is 160ºF unless 140F DAS jumper installed discharge air at upper limit Differential is 20ºF above heating staging jumper setting with the following exception: Does discharge air...

  • Page 38: Air Handlers

    AIR HANDLERS AIR HANDLERS Variations on Common Condensing Unit Applications Heating/Cooling Equipment Installation NOTE − Be sure to remove the factory installed jumper bar between W1 to W2 and W2 to W3 (CBX40 or CBX32MV Follow all equipment installation instructions provided with rev 06) or remove the jumper wires between R to W1 and R each unit.

  • Page 39: Air Handler Settings (All Applicable Models)

    AIR HANDLERS Air Handler Control Electrical Adjustments (All model VSM Air Handlers) Electrical Adjustments Communicating CBX32MV (revision 06) and CBX40UHV (all) Electrical Adjustments As shown in this diagram, make the following adjustments: CUT on board 1. Cut on board link R to DS Link R−DS (Dehum or Harmony).

  • Page 40: Installation Setup Worksheets: Cbx32Mv/Cbx40Uhv Cooling/Heating; Electric Strip Heat (Non−Hp Appls)

    - Zone 4 – Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________ NOTE All of the above are recommended starting positions for DIP switches and Harmony III jumpers. Slight variations may be required during sys- tem start up and operation checks.

  • Page 41: Cbx32Mv/Cbx40Uhv Heat Pump; Electric Strip Heat

    - Zone 4 – Desired cfm ____________ PIAB Setting ____________% Actual cfm ____________ NOTE All of the above are recommended starting positions for DIP switches and Harmony III jumpers. Slight variations may be required during sys- tem start up and operation checks.

  • Page 42: Cbx32Mv/Cbx40Uhv - Cooling Only Or Cooling With Hot Water Coil (Non−Hp Appls)

    - Outdoor Unit Wiring Completed. - Thermostat and Damper Wiring Completed. - Discharge Sensor wired to Harmony III and if a hot water coil is used, the sensor must be located down stream of the hot water coil. Page 42...

  • Page 43: Dual Fuel

    (beginning on Page 28). See System Configuration & E−Heat jumper settings − page 11. Figure 26. Harmony IIIt Zone Control System Option 3 − Lennox Heat Pump & Lennox Variable-Speed Gas Furnace (Dual Fuel) Page 43 HARMONY IIIT ZONE CONTROL SYSTEM...

  • Page 44: Dual Fuel Startup & Checklist

    DUAL FUEL Dual Fuel System Start−Up & Checkout IMPORTANT The zone control system power−up must occur at the same time or before the furnace or air handler unit is powered up. Powering the System (All Systems) 1. Adjust all thermostat settings so that no demand will occur. 2.

  • Page 45: Gas Heating Checkout − Multiple Zone

    DUAL FUEL Dual Fuel Gas Heating Checkout (Multiple Zone) Prerequisites: 1. Set all zone thermostats for a heat demand; check for All zone thermostats set to Heat. the following: Balance Point Sensor set at higher temperature than outdoor BPS-sensed temperature (red balance point sensor LED All zone thermostat W LEDs on (heat demands).

  • Page 46: Gas Heating Checkout − Central Control

    DUAL FUEL Dual Fuel Gas Heating Checkout (Central Control) Prerequisites: 1. Set zone 1 thermostat for a heat demand; check: Central mode switch on. Red LED on the central mode fan switch on. Zone 1 thermostat W LED on (heating demand). Output Heat W1 LED on (furnace on).

  • Page 47: Troubleshooting Zoning System With Dual Fuel

    Does blower speed change as zone demand changes? If no, does DS output vary from 0 to 25VDC? Figure 28. Option 3 − Lennox Heat Pump & Lennox Variable-Speed Gas Furnace (Dual Fuel) Page 47 HARMONY IIIT ZONE CONTROL SYSTEM...

  • Page 48: Dual Fuel Operation (Below Balance Point)

    DUAL FUEL Troubleshooting Dual Fuel Operation (Below Balance Point) HEATING DEMAND RECEIVED Ambient See Above Balance temp. Below Point Sensor Balance Point setpoint flow diagram Sensor setpoint (Page 50). 3−Minutes REFER TO DISCHARGE AIR since completion UPPER LIMIT DIAGRAM (Page 49) FOR UPPER LIMIT of last heating AND DIFFERENTIAL DETAILS.

  • Page 49: Discharge Air Upper Limit & Differential Temperatures

    DUAL FUEL Troubleshooting Discharge Air Upper Limit & Differential Temperatures Furnace energized Monitor discharge air temperature Discharge air upper limit is 160ºF unless 140F DAS jumper installed discharge air at upper limit Differential is 20ºF above heating staging jumper setting with the following exception: Does discharge air...

  • Page 50: Dual Fuel Operation (Above Balance Point)

    DUAL FUEL Troubleshooting Dual Fuel Operation (Above Balance Point HEATING DEMAND RECEIVED Ambient temp. Above Balance Point sensor setpoint See Below Balance Point sensor setpoint flow diagram (Page 48) Heat pump locked out (see NOTE) REFER TO DISCHARGE AIR 5−min UPPER LIMIT DIAGRAM lapse since- (Page 49) FOR UPPER LIMIT...

  • Page 51: Defrost Operation

    Harmony III sends signal to W1 at indoor unit Defrost Defrost period exceeds completed 20 minutes Heating Harmony III control demand de−energizes all satisfied compressor stages − uses auxiliary heat to complete existing heat demand De−energize all compressor stages...

  • Page 52: G61Mpv/G60Uhv Dual Fuel; With

    - Zone 4 – Name:____________ Desired cfm:____________ PIAB Setting: ____________% Actual cfm: ____________ NOTE All of the above are recommended starting positions for DIP switches and Harmony III jumpers. Slight variations may be required during sys- tem start up and operation checks.

  • Page 53: G71Mpp/Slp98/Sl28V0/El296V Dual Fuel (Hp Appls)

    Indoor Unit setup: - Cut on−board link W914 DEHUM OR HARMONY (R to DS) on furnace IFC control (if not cut, fuse will blow in Harmony III zone control board) - W2 connection from Harmony III to SLP98 or G71MPP is optional – see Harmony III / furnace installation instructions for details - DIP switch settings (ON or OFF): (DIP switch 1 –...

  • Page 54: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING Operation & Troubleshooting Indicators Zone Control Panel LEDs The zone control system operation is indicated by light emitting diodes (LEDs) located on the zone control panel. In addition to operating condition, the LEDs provide valuable information system troubleshooting. The LEDs (shown in figure 29) are thermostat, diagnostic, and output status.

  • Page 55: Fault Recall. Time Delays, Time Delay Override

    TROUBLESHOOTING Fault Recall & Time Delay Override When the Time Delay Override is pressed and held, the internal clock speeds up by a factor of 60. This overrides the current time delay and permits the next event to occur. Table 9 identifies the time delays used by the system. When the Fault Recall button is pressed and released (clicked), the fault codes are displayed (10 most recent).

  • Page 56: Diagnostics Codes

    TROUBLESHOOTING Blower Speed Checkout The indoor blower speed should vary as zone demand changes. The fan speed LED varies in brightness as the blower varies in speed. The brighter the LED, the more CFM being delivered. Blower speed can also be viewed by attaching an electronic voltmeter between DS and any C terminal on the zone control panel.
  • Page 57 TROUBLESHOOTING (0−off;1−on) Fail-safe Code Diag LED Fault (System Indicated 1234 Remedy Shut Down) 1100 Unsteady This error occurs when a thermostat changes state repeatedly and rapidly, thermostat indicating that the thermostat is making intermittent contact and needs atten- input tion. The offending thermostat will be ignored for 4 minutes after the zone control system detects the problem.

  • Page 58: Troubleshooting Air Delivered By Blower

    TROUBLESHOOTING Troubleshooting Air Delivered By Blower The actual CFM delivered to each zone will be determined 5. Determine total air delivered during a continuous blower call Calculate these totals using the formu- by the zone control system settings, blower motor control las and examples in Table 13.
  • Page 59 TROUBLESHOOTING Troubleshooting Air Delivered By Blower (continued) Table 12. Determine total heating CFM delivered Table 13. Determine total continuous CFM delivered Example values Example values Jumpers Jumpers Cont. Air Heating Cont. Air Heating Reduction Air Red. Min. Max. Reduction Air Red. Min.

  • Page 60: Piab Calculation Worksheet

    PIAB Calculation Worksheet PIAB Calculation Worksheet PIAB = [(Required CFM − Minimum CFM) / (Maximum CFM − Minimum CFM)] * 100 Sample CFM ' Required Minimum Maximum Minimum Sample PIAB = ([___920 − ] / [ 2000 − x 100 Sample PIAB = ([ ] / [ 1550...

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