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We have had the same problem at my company only it is with Zonex damper control boards. It is only on duel fuel set ups and is completely random. Even to the point that we have the set up on the basement system as the attic system and only one or the other would fail. The only way we solved it was to change to a different damper control board. At first we were looking at the honeywell 8000 stats we installed. Apparently this year honeywell made a change to these stats and combine the Aux and E terminal. Well the Zonex board does not like a call for Y and W at the same time. So every time the stat would stage up to include Aux and Y the board would shut down. But even after correcting that issue the problems continued. Since changing board manufactures we have not been back into those homes.

thanks ... one could say "I had my lunch handed to me on this one".

Thank you for letting us know what it took. some York boards and wiring to me is a little difficult (york gaurd VI) as we don't see many of them. but with the zone board thrown in congratulations.

dogboy

Originally Posted by JBocc

As suggested by DogBoy in his last thread on this topic I am providing an update and what i feel is the solution this problem.
First.... I am most certain at one point I was dealing with two issues. The first was Problem A the overheating with out a call for heat. Then I find problem B which was W and O present giving the compressor lockout fault codes shifting to emergency heat and causing the problems as previously posted. Correct Problem B thinking I got it ....but oh no Problem A comes back some 20 days and this time it finally clicks that this is happening when ambient is below BP.
I spoke with both Honeywell and York again... I 'll break out each their points below

YORK

Given that the defrost control board in this heat pump controls the staging of W1out and W2out to the A/H W1 and W2 based on BP and LTCO setting. It was felt it would be best to disable the same functional control that was set up the zone panel to lock out the aux heat until below 35 ( same as BP setting in Heat pump defrost board). and just let heat pump control stage W1 and W2. A call for compressor on Y in conjunction with W ( based on BP will or will not energize W1 and after 15 min w2) A call on W without a compressor is acknowledged as emergency heat and w1 and w2 are energized as required.

After a Q&A with my 3rd honeywell tech on this problem and explaining what I described above I asked him to explain the out put signals. He stated to me that W1/E only energizes on a aux/emergency heat call and w2 energizes on a aux/supplemental call with compressor. That caught me off guard and I asked him to repeat it and I wrote what he said to be sure I heard him right .He suggested I remove the jumper on the zone panel and wire w2 to the defrost control board...what about the emergency heat call as it goes thru the defrost control board??? the jumper remains in place.

Trying to incorporate the zone panel lockout and trying to utilize the rudimentary wiring diagram of the installation manual I wired w2 from the panel to w2 on the AH in conjunction with w2 coming from defrost control board...so I must of had a emergency heat signal and a supplemental heat signal at the same time below BP . That must have caused a back feed to latch the dry contact closed even though there was no call for either heat

so today
I disabled the zone control aux heat LO
removed the w2 to w2 wire
test all functions above and below BP based on todays ambient

I feel pretty good about this.... feel like a bit of a dumb ass as well. my other zone jobs went off with out a hitch but I second guessed the little voice when I was wiring this as I could not find my reference drawing from the previous installs

Sounds to me like you got it whooped, bravo bravo. Controls can get a little confusing sometimes. Best thing I've found is to sit down and get out the box of crayons and draw a picture then get back at it.

As suggested by DogBoy in his last thread on this topic I am providing an update and what i feel is the solution this problem.
First.... I am most certain at one point I was dealing with two issues. The first was Problem A the overheating with out a call for heat. Then I find problem B which was W and O present giving the compressor lockout fault codes shifting to emergency heat and causing the problems as previously posted. Correct Problem B thinking I got it ....but oh no Problem A comes back some 20 days and this time it finally clicks that this is happening when ambient is below BP.
I spoke with both Honeywell and York again... I 'll break out each their points below

YORK

Given that the defrost control board in this heat pump controls the staging of W1out and W2out to the A/H W1 and W2 based on BP and LTCO setting. It was felt it would be best to disable the same functional control that was set up the zone panel to lock out the aux heat until below 35 ( same as BP setting in Heat pump defrost board). and just let heat pump control stage W1 and W2. A call for compressor on Y in conjunction with W ( based on BP will or will not energize W1 and after 15 min w2) A call on W without a compressor is acknowledged as emergency heat and w1 and w2 are energized as required.

After a Q&A with my 3rd honeywell tech on this problem and explaining what I described above I asked him to explain the out put signals. He stated to me that W1/E only energizes on a aux/emergency heat call and w2 energizes on a aux/supplemental call with compressor. That caught me off guard and I asked him to repeat it and I wrote what he said to be sure I heard him right .He suggested I remove the jumper on the zone panel and wire w2 to the defrost control board...what about the emergency heat call as it goes thru the defrost control board??? the jumper remains in place.

Trying to incorporate the zone panel lockout and trying to utilize the rudimentary wiring diagram of the installation manual I wired w2 from the panel to w2 on the AH in conjunction with w2 coming from defrost control board...so I must of had a emergency heat signal and a supplemental heat signal at the same time below BP . That must have caused a back feed to latch the dry contact closed even though there was no call for either heat

so today
I disabled the zone control aux heat LO
removed the w2 to w2 wire
test all functions above and below BP based on todays ambient

I feel pretty good about this.... feel like a bit of a dumb ass as well. my other zone jobs went off with out a hitch but I second guessed the little voice when I was wiring this as I could not find my reference drawing from the previous installs

not yet. i am going back on saturday to try something out. i will post the good the bad and the uuug

Have you you figured it out yet? People need to post more of the solutions on these threads.

dogboy

Originally Posted by DOGBOY

well if you watched it go into defrost and back out without locking the strip heat on when t-stat satisfies then I am wrong and do apologize.

However here is the York tech I talk to. Jim Hamilton 423-296-1911 he is out of Knoxville tn and is with M & A supply.

dogboy

Thanks for the number. Wrt defrost I did forced defrost testing to check that possibility and each time it was no issue.. No need too apologize I appreciate any and all comments.

well if you watched it go into defrost and back out without locking the strip heat on when t-stat satisfies then I am wrong and do apologize.

However here is the York tech I talk to. Jim Hamilton 423-296-1911 he is out of Knoxville tn and is with M & A supply.

dogboy

Originally Posted by DOGBOY

I think it will be defrost causing this and not aux. If a number in usa will work i can get it monday.

dogboy

I have tested the defrost numerous times to try and prove. Will be checking in with the customer this morning to see if the problem is still occurring after the lock out temperature was changed to 25

I think it will be defrost causing this and not aux. If a number in usa will work i can get it monday.

dogboy

I am not so sure there is a tech support network for york. At least not in canada, as I have never been given a number to call and when I did a number to call the response was to fill out a form and that was not replied too either.
The same problem occurred again this morning. So to try and narrow it down a little further I had the customer set the aux heat lockout temp to 25 from 35. We have been below 35 the last 2 mornings and coming out of nighttime setback the aux heat may not be deenergizing once set point is met which sort of points to that as I have previously posted yesterday what I found when I arrived on site

you need to call york tech support. The unit is wired wrong. what is happening is when aux heat is called for whether by t-stat or def. it is locking the aux. heat on even when the t-stat drops the call for heat the unit will still heat until it manually (Somebody disconnecting something) looses power . I believe you could say it is being kept on by a holding circuit. I am not familiar with york enough to remember what i did to correct the wiring. If your unit is not doing this I do apologize for butting in.

dogboy

Intermittent short in wires from heat pump to AH maybe. But doing your test is a good idea.

Well the saga continues.... since the control boards were changed. The erratic heat on has resurfaced. this time no fault code as was previously indicated. No call for heat at stats, zone panel showed no heat calls, heat pump was off, all zones were 3-6 degrees above set point, electric heat energized , IDF on high DAT 89F. )Measured at equipment terminal strip test point w1/e and w2 (jumped) to common from AH- 26 volts. Disconnected w1 wire from board to equipment- it de-energized fan and heat strip. Measured w1/e and w2 to common 0 volts , measured exposed w1 wire to common 0 volts.....WTF explain to me where the voltage went. As a test i am considering removing the zone control and going to a single stat... lock the dampers open to prove either controls or equipment because each are saying not me .. but then again.

my test fuse has been in for ten days and there has been no issues after changing the indoor and outdoor control boards. So the fused "o" to ground was removed last night and connected to defrost control board. No happy dance yet....just cautiously optimistic.

Did you figure this out?

If not it could be wired incorrectly at the outdoor unit. I do not remember right now but it does have something to do with outputs maybe y1, y2 and w2. York had to send me a wiring diagram for the gas furnace to match up to the heatpump as the supplied furnace and supplied h/p did not show how to wire correctly.

dogboy

The defrost board can't open a zone. So it has to be in the panel. Or he has RF interference he doesn't know about.

If u got o and w is it present to the zone board or just out of the board or not at all, this is easy to figure out when conditions are present. Could be board in cu or zone board or tstat or stat wire. U need to determine where o signal originates.

Sounds like you got it whipped.