Manuals+

NON-A2L FURNACE INTEGRATION KIT Installation Instructions

Attention Installing Personnel

As a professional installer, you have an obligation to know the product better than the customer. This includes all safety precautions and related items.

Prior to the actual installation, thoroughly familiarize yourself with this instruction manual. Pay special attention to all safety warnings. Often during installation or repair, it is possible to place yourself in a position which is more hazardous than when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer in its safe use.

Safety is a matter of common sense. A matter of thinking before acting. Most dealers have a list of specific good safety practices. Follow them.

The precautions listed in this installation manual are intended as supplemental to existing practices. However, if there is a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

Safety Precautions

The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards. It is the owner's and installer's responsibility to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of personal injury, property damage, and/or product damage.

⚠️ WARNING

HIGH VOLTAGE: Disconnect all power before servicing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

⚠️ WARNING

DO NOT BYPASS SAFETY DEVICES.

⚠️ WARNING

Only personnel that have been trained to install, adjust, service, maintenance or repair (hereinafter, "service") the equipment specified in this manual should service the equipment.

This equipment is not intended for use by persons (including children) with reduced physical, sensory or mental capacities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play with the equipment.

The manufacturer will not be responsible for any injury or property damage arising from improper supervision, service or service procedures. If you service this unit, you assume responsibility for any injury or property damage which may result. In addition, in jurisdictions that require one or more licenses to service the equipment specified in this manual, only licensed personnel should service the equipment. Improper supervision, installation, adjustment, servicing, maintenance or repair of the equipment specified in this manual, or attempting to install, adjust, service or repair the equipment specified in this manual without proper supervision or training may result in product damage, property damage, personal injury or death.

Items Needed in Kit

Item Qty
IO Manual 1
PCB Case contain the Dragonfly PCB 1
Connector Pin 1 1
Connector Pin 2 1
Connector Pin 3 1
Mounting hardware (screws) 4
Mounting hardware (wall anchors) 4

System Compatibility and Notes

If the installation check, as detailed in these installation instructions, does not pass successfully and cannot be resolved by calling 1-855 DAIKIN1, option 3 for further assistance, the installer must replace the furnace or modular blower with an R-32 compatible furnace or modular blower.

The Non-A2L Furnace Integration Kit was designed to support HVAC replacement market for systems containing 1) a Furnace, Indoor Coil and Outdoor Air Conditioner or Heat Pump unit, or 2) a Modular Blower, Indoor Coil and Outdoor Air Conditioner or Heat Pump unit. If either the indoor coil or outdoor unit needs to be replaced, both must be upgraded to R-32 models. If the furnace or modular blower is still operational, it does not need to be replaced.

The Non-A2L Furnace Integration Kit relies on existing functions of the currently installed furnace or modular blower control boards or PCBs to achieve the necessary mitigation function required for a system utilizing R-32 refrigerant. Therefore, it is important to verify the function of the system, as detailed in the "Verification of R-32 Leak Mitigation" section of this manual.

Note: R-32 is an A2L classified refrigerant which requires a refrigerant leakage detection system to be installed. The Non-A2L Furnace Integration Kit, when connected with an R-32 gas sensor, is a refrigerant leak detection system. The Non-A2L Furnace Integration Kit is designed to be installed externally to the cased coil and furnace. It should never be physically mounted anywhere on the cased coil or the furnace.

PCB Layout Description

The document includes images of the PCB layout showing connector labeling. Key components and connectors are visible on the Dragonfly PCB. The kit also features a RED LED and a PUSH BUTTON for status indication and testing.

The Vt_In and Vt_Out terminals are intended for use as a low voltage signal to turn on any installed ventilator if an R32 leak is detected (24VAC at 1A max). The connection between these terminals is normally open and closes if there is an R32 leak.

The Alarm output is only to be used with specific A2L accessories. Wiring instructions for using this terminal will be detailed in the installation manuals of these other accessory products. Do not use this terminal unless specifically instructed to.

Ensure that all cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges, or any other adverse environmental effects. This check should also account for the effects of aging or continual vibration from sources such as the furnace blower or modular blower.

Operating Principle

The NON-A2L FURNACE INTEGRATION KIT is designed to read R-32 sensor concentration and utilize existing functions of indoor PCBs to mitigate R-32 leakage in an unlikely event of a leak in the system. The integration kit continuously monitors the system for R-32 leaks and does not impact the normal operation of the unit when no leak/sensor fault is detected.

The integration kit has two screw terminal headers: Indoor Unit (Green) and Thermostat (Black). The integration kit is connected between the thermostat and indoor unit, and it controls the traffic of signals between them based on the R-32 concentration.

  1. R-32 Concentration Detection: The integration kit is connected to a refrigerant sensor that detects R-32 concentration. The sensor transmits the concentration, and the integration kit acts based on it.
  2. Safe Level: When R-32 concentration is at a safe level, the integration kit does not interfere between the thermostat and indoor unit; all signals are passed through.
  3. High Concentration or Fault: When R-32 concentration is above a certain level, or if the R-32 sensor or integration kit encounters a fault, the integration kit energizes the G (fan) terminal in the indoor unit by sending a 24VAC signal. It also disconnects the R signal to the thermostat and/or disconnects ClimateTalk® communication, as applicable. This action terminates all HVAC operation (Cooling or Heating) while keeping the main blower on to dissipate any refrigerant gas.

Pre-Checks

The NON-A2L FURNACE INTEGRATION KIT works successfully if the following conditions are met for the thermostat and furnace or modular blower. Consult the user manual of the thermostat and furnace or modular blower to verify these conditions. If the thermostat or furnace or modular blower does not conform to these common operating principles, contact technical service to identify a compatible thermostat and/or furnace or modular blower. Do not install an R-32 coil and/or outdoor unit if the thermostat or the furnace or modular blower is not compatible.

  1. Standard 24VAC Thermostat: Verify that the thermostat's R signal is the source for Y1/Y2, W1/W2, G, and other signals. Disconnect the R signal at the thermostat. If the thermostat powers off, it is compatible. If it remains powered (via alternate source or battery), activate cooling and heating calls by adjusting the setpoint. In either case, the indoor unit and outdoor unit should not operate in COOLING or HEATING mode, respectively.
  2. Non-communicating Indoor Unit: When a G call is presented, the blower fan must activate within 15 seconds. Verify this by putting the system in FAN ONLY mode. The blower should activate within 15 seconds after the thermostat provides 24VAC on the G terminal.
  3. Communicating Indoor Unit: Communicating indoor units must prioritize 24VAC calls over ClimateTalk® communication and activate the blower fan within 15 seconds when a G call is presented over a 24VAC signal. This applies to all ComfortNet systems. For ComfortBridge systems, a firmware upgrade may be required. Ensure the latest firmware is installed via the CoolCloud app before installing the R-32 Coil and outdoor unit.

Tools Needed: A 1/8" flat head screwdriver.

Identification: Identify thermostat wires in the indoor unit and note them down to help with later identification.

Indoor Unit Terminal Color of the Wire from Thermostat Color of the Wire to Outdoor Unit Color of the Wire to EEV Unit
R
C
G
Y1
Y2
W1
W2
DH
O
1
2

Recommendation: A flexible light source is recommended to illuminate indoor unit terminals hands-free and ensure sufficient light.

ClimateTalk is a trademark of Emerson Electric Co.

Work Scope

During installation of the kit:

  1. Disconnect wires coming from the thermostat and outdoor unit to the indoor unit.
  2. Connect appropriate wires from the thermostat to the integration kit's "Thermostat" terminals.
  3. Use new wires to connect the integration kit's "Indoor Unit" terminals to the indoor unit.
  4. If applicable, disconnect 4 wires for the EEV coil from the Indoor unit and connect them to the Dragonfly's "Indoor Unit" terminal per the wiring diagram provided.
  5. Complete the verification step: Verify normal operation, verify mitigation function, and verify system returns to normal operation.
  6. Install and mount the kit.

Consult the "WIRING FOR VARIOUS CONTROL SYSTEMS" section to understand the scope of wiring.

Installation Steps

Running the system test is mandatory for all installations. The HVAC system must not complete commissioning until the installation steps listed in this manual have been successfully completed.

  1. Identify the type of control system being installed:
    • Non-Communicating System: Indoor/outdoor units use standard thermostat inputs (Y, W, G).
    • ComfortBridge Communicating System: Indoor unit has a ComfortBridge control, connected to the outdoor unit via terminals 1 and 2. The indoor unit connects to the thermostat using standard inputs (Y, W, G). Note: Ensure all available software updates for the indoor control board are made via the Cool Cloud HVAC Phone Application before proceeding (check specific version requirements for 2 Stage, Modulating, and Ultra Low NOx Furnaces).
    • ComfortBridge Non-Communicating System: Indoor unit has a ComfortBridge control, but the outdoor unit is wired as non-communicating using standard thermostat inputs (Y, W). Terminals 1 and 2 on the indoor unit's ComfortBridge control are present but not in use. Note: Ensure all available software updates for the indoor control board are made via the Cool Cloud HVAC Phone Application before proceeding (check specific version requirements for 2 Stage, Modulating, and Ultra Low NOx Furnaces).
    • ComfortNet Communicating System: Indoor unit, Outdoor unit, and Thermostat are all connected using terminals labeled 1 and 2.
    • ComfortNet Communicating System with EEV Coil: Indoor unit, Outdoor unit, EEV Coil, and Thermostat are all connected using terminals labeled 1 and 2.
    • ComfortNet Mixed Mode System: Indoor unit and communicating thermostat are connected using terminals labeled 1 and 2. A single-stage non-communicating outdoor AC unit is controlled by the indoor control board's Y terminal.
    • ComfortNet Non-Communicating System: Indoor and/or outdoor unit has a ComfortNet control but is not wired using terminals 1 and 2. All wiring uses standard thermostat inputs (Y, W, G).
  2. Wire Connections: Using the appropriate wiring diagram, make all wire connections using standard thermostat wire. It is not recommended to insert multiple wires into a single terminal block; using wire nuts is recommended. Note: For ComfortNet systems using a 4-pin green connector (1, 2, R, C), replace it with the included 5-pin green connector which has an added G terminal.
  3. R-32 Sensor Connection: Connect the R-32 sensor from the coil to the Non-A2L Furnace Integration Kit control board (4-pin connection point). Attention! Ensure the A2L sensor is kept in its original location and correctly mounted in the sensor bracket after connecting it to the kit. Important: If the sensor is not connected before powering up, the system will enter leak mitigation mode and may remain there for approximately 5 minutes, even after power cycling. Connect the sensor before powering up.
  4. Power Up and Initial Check: Turn power on to indoor and outdoor units. Ensure the thermostat is in the OFF mode (no cooling or heating calls). The red LED on the control board should start flashing slowly (2 seconds on, 2 seconds off) if functioning properly. Note: The indoor blower may run temporarily after power is applied but will turn off automatically. Any errors will be indicated by the red LED; address these before proceeding.
  5. Communicating System Check: If a communicating system (ComfortNet or ComfortBridge) is installed, wait until the thermostat or phone application clearly identifies both the indoor and outdoor units before proceeding. Note: For ComfortNet Mixed Mode Systems, where the indoor unit is communicating but the outdoor unit is not, proceed once the thermostat identifies the indoor unit.
  6. System Mode Testing: Test all modes of operation (Fan Only, Cooling, Heating) to ensure they are functioning properly. This step confirms basic system operation before testing the integration kit's functionality.
  7. R-32 Leak Mitigation Verification (Mandatory):
    • 7-1. For Systems with a 24VAC Non-Communicating Outdoor Air Conditioner or Heat Pump: Perform the R-32 leakage test for all modes (Cooling, Heating, Emergency heating, Constant fan, Idle). Each test takes approximately 2-15 minutes.
      1. Set the thermostat to an operation mode and ensure the system is running. Note the mode being tested; repeat for other modes.
      2. Locate and press the push button on the integration kit control twice (within 5 seconds). Relays will switch, and the Red LED will flash rapidly during the 5-minute test mode.
      3. The selected HVAC operation (compressor, electric heat, gas heat) should turn off within a short period (Electric/Gas Heat: within 30 seconds; Outdoor Unit: within 2 minutes). Note: If operation continues beyond these times, the kit is not functioning properly; re-check wiring.
      4. The indoor blower will begin to operate within 30 seconds and remain running. Note: Blower speed may ramp up or down. If a communicating thermostat is installed, a loss of communications error might be displayed; this is acceptable if other HVAC operations turn off.
      5. Once steps c and d are confirmed, the test is successful. Wait for the full 5-minute test to expire, or press the push button once to exit early.
      6. Wait for the system to return to its previous state to confirm automatic recovery, then repeat tests for other HVAC modes. It is crucial to verify proper function for all modes. Note: If the kit is not functioning properly for any mode, re-check wiring and do not proceed until resolved.
    • 7-2. For Systems with a Communicating Outdoor Air Conditioner or Heat Pump: Perform the R-32 leakage test for all modes (Cooling, Heating, Emergency heating, Constant fan, Idle).
      1. Set the thermostat to an operation mode and ensure the system is running. Note the mode being tested; repeat for other modes.
      2. Disconnect the R32 sensor from the integration kit control board. Relays will switch after 5 seconds, and the LED will display a sensor communication fault (3 flashes followed by a 5-second delay).
      3. Electric heat or gas heat should turn off within 30 seconds. The communicating outdoor unit may take up to 12 minutes to turn off. Note: If operation continues beyond 2 minutes (heat) or 12 minutes (outdoor unit), the kit is not functioning properly; re-check wiring.
      4. The indoor blower will begin to operate within 30 seconds and remain running. Note: Blower speed may ramp up or down. If a communicating thermostat is installed, a loss of communications error might be displayed; this is acceptable if other HVAC operations turn off.
      5. Once steps c and d are confirmed, the test is successful. Reconnect the R32 sensor. The on-board LED will turn solid once the sensor is detected and remain in this mode for 5 minutes before exiting. Note: Power cycling bypasses this delay.
      6. Wait for the system to return to its previous state to confirm automatic recovery, then repeat tests for other HVAC modes. It is crucial to verify proper function for all modes. Note: If the kit is not functioning properly for any mode, re-check wiring and do not proceed until resolved.

R-32 Leak Mitigation Performance

If an R-32 leak is detected, the Non-A2L Furnace Integration Kit control will automatically enter R-32 Mitigation mode. This mode provides the same performance as seen during the test mode, ensuring all HVAC system functionality (Heating and Cooling) is off while the indoor blower runs. After the R-32 sensor no longer detects refrigerant, the system will remain in mitigation mode for an additional 5 minutes. During this period, the red LED will change from a rapid flashing pattern to being continuously on. After 5 minutes, the kit will allow the system to return to normal operation, and the red LED will start a slow flashing pattern again (2 seconds on, 2 seconds off).

A2L Status Codes

The following table describes the status codes indicated by the LED on the control board:

Mode Definition LED Flashing Pattern Red LED Status / Recommended Actions Notes
1 Normal Operation No faults to report Slow LED flashing pattern (2 seconds on and 2 seconds off) No action The controls and sensor are working properly.
2 R-32 Leak Alarm R-32 leak is currently being detected Fast LED Flashing Pattern Identify where the leak is coming from and address the leak. After R-32 leak or alarm has been cleared, the unit will remain in alarm mode for 5 minutes before returning to normal operation.
3 Delay Mode LED will be on continuously Check HVAC performance (Cooling and Heating Modes). Check system pressures and lines for any leaks. Re-Check HVAC performance after addressing any issues. After any alarm or fault, it is required to remain in R-32 mitigation mode for 5 minutes.
4 System Verification Mode Manual test run by contractor to simulate R-32 Leak Alarm (test will last for 5 minutes max) Fast LED Flashing Pattern No actions needed To enter system verification test mode, press the button on the control 2 times within 5 seconds. The control will enter a simulated R-32 Leak Alarm state and remain in that mode for 5 minutes. After 5 minutes, the control will return to Normal Operation automatically. If the contractor wants to end the test early, they need to press the button one time.
5 Control Board Internal Fault Control board has detected an issue with the R-32 detection system LED will flash 2 times and then be off for 5 seconds before repeating the pattern 1) Unplug and plug the R-32 sensor back in. Cycle power to the system. 2) If control is in Normal Operation or Delay mode, there is no more issue. If not, continue with diagnostics. 3) Unplug R-32 sensor and leave unplugged. Cycle power to the system. 4) If control still displays "Control Board Internal Fault" (2 flash pattern) replace the control. If control now displays "R-32 Sensor Communication Fault" (3 flash pattern) replace the sensor. These steps will determine if the error is on the board or external to the board.
6 R-32 Sensor Communication Fault Control board does not have communications with R-32 sensor LED will flash 3 times and then be off for 5 seconds before repeating the pattern 1) Unplug and plug the R-32 sensor back in. Cycle power to the system. 2) If control is in Normal Operation or Delay mode, there is no more issue. If not, continue with diagnostics. 3) If control still displays "R-32 Sensor Communication Fault" (3 flash pattern), replace both the sensor and the PCB. If the control cannot talk to the sensor, there could be a problem with the sensor, a problem with the sensor harness, or a problem internal to the control. The field will not be able to measure anything to reliably fix this error assuming the connector is properly secured to the control. Replacing both is the only option.
7 R-32 Sensor Fault R-32 Sensor has reported an internal issue LED will blink 4 times and then be off for 5 seconds before repeating the pattern 1) Unplug and plug the R-32 sensor back in. Cycle power to the system. 2) If control is in Normal Operation or Delay mode, there is no more issue. If not, continue with diagnostics. 3) If control still displays "R-32 Sensor Fault" (4 flash pattern), replace the sensor. This means communications to the sensor are perfectly fine. The sensor itself is reporting an internal fault.

Wiring Diagrams Overview

The document provides detailed wiring diagrams for various control systems to illustrate the connections required for the NON-A2L Furnace Integration Kit. These diagrams cover the following system types:

These diagrams detail the connections between the Integration Kit's terminals (Thermostat, Indoor Unit, R32 Sensor Connector) and the respective components of each system type, including 24VAC power sources.

Customer Feedback

Daikin, Goodman, and Amana encourage customer feedback. Please use the provided links to submit feedback for Daikin Products (https://daikincomfort.com/contact-us), Goodman® Brand Products (http://www.goodmanmfg.com/about/contact-us), and Amana® Brand Products (http://www.amana-hac.com/about-us/contact-us). QR codes are also available for each brand to direct you to the feedback page.

The document is from Daikin Comfort Technologies Manufacturing, L.P., located at 19001 Kermier Rd., Waller, TX 77484.

Amana is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.

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