LONG LINE SET APPLICATION

R-410A

Line Set

Requirements For Long Line Sets

1. A crankcase heater must be installed on any compressor (if crankcase heater is not already factory installed)

2. Hard start assist kit is required.

3. Use of a thermostatic expansion valve (TXV) is required in all long line set applications. Unit must be charged to 6º ± 1ºF subcooling at the indoor unit.

4. Heat Pump Application Only. Liquid line solenoid must be installed less than 2 feet from the outdoor unit.

Lists the equivalent length gained from adding bends to the suction line.

Properly size the suction line to minimize capacity loss.

Losses From Suction Line Elbows (Equivalent Length, Ft.)

L = Length of trap must be more than Indoor Unit Height (H)

1. The maximum elevation (vertical) between the outdoor unit and the indoor unit is 80 feet. 2. Suction line must be installed to prevent liquid migration to outdoor unit from indoor unit. 3. An inverted trap is installed on the suction line before the inlet of indoor unit. The top of the inverted loop must be above the top of the indoor unit coil. Support and secure the loop. 4. An accumulator is required to be added (external to the outdoor unit, within 2 feet of the unit) for air conditioning installations. Do NOT install an accumulator in the suction line set in heat pump applications.

Outdoor Unit Is Below Indoor Unit

Inverted Loop – Oil Traps

An oil trap at the indoor unit is required if the elevation difference exceeds 80‘ feet. The trap can be constructed of standard refrigerant fitting

1. Suction line must be sloped continuously towards the indoor unit. 2. The maximum elevation (vertical) difference between the outdoor unit and indoor unit is: a. not restricted in this configuration (must adhere to maximum equivalent length). b. 80 feet for single stage heat pump units. c. 25 feet for two stage units. 3. Inverted suction loop is not required at either unit. 4. An accumulator is not required for air conditioners (accumulators are factory installed on heat pumps).

Outdoor Unit Is Above Indoor Unit

P Traps – Oil Traps

Installation of Refrigeration Piping From Vertical to Horizontal

Pipe Installation

Installation of Refrigerant Piping (Horizontal)

Long Line Set Applications

• Why ComfortNet

• Installation Ease and System Benefits

• Communications Explained

• Components Affected

• Initial Setup

• Communications Harmonized Across Platforms

ComfortNet System

We Listened… “Do not want to run extra wires”, “Configuring the Setup is Complicated”

Traditional System Communicating System

More Complex Easy to Install

• “Complex To Install”

• “Only 1 Of My Crews Can Install”

• “It Requires A Service Tech”

• “Now All Of My Crews Can Install”

• “I Can Concentrate On Quality of

Installation More”

• “[Helps Prevent] Improper Airflow

Adjustments” 12

Instruction Sheet

Homeowners Guide

Outdoor

Transformer

Outdoor

Connector Indoor

Connector UltraTech Thermostat

CKT 04

ComfortNet Thermostat Kit

No Dip Switch

Settings – Plug

and Play

FURNACE FOUND

System is Automatically Configured When Turned On

No Special Wires

Required

No Running New

Wires For High

End Systems

Standard 18 WG

– Up To 100 Feet

Use Existing Wiring for Communications

Standard/ Legacy

UltraTech Thermostat Kit

Keys

IFC Low Voltage Connections

• Can Be Installed With Typical AWG #18 Thermostat Wire Or With Shielded Twisted-Pair Cable

• 100 Feet Maximum From Stat To Furnace Or Furnace To Outdoor Unit

• Twist Two Conductors Together Before Placing Under Screw

• No Splices!!!!!!

Installation - Wiring

Thermostat Wiring GMVC (Legacy)

• Network Code displayed at Integrated Furnace Control

• Thermostat displays Network Code plus detailed description

RUN

SCHEDULE

ADVANCE

D Hi Limit

Sw

IFC

Call For Service E3

IFC

E3

Hi Limit

Sw

Call For Service

Network Codes Locally Network Code Details at the Thermostat

• Integrates Components & Adds New, Customizable Features

• Building Block For Communicating Systems

• Differentiates Equipment As Base SEER Rises

• Reduces Manufacturing And Warranty Costs

Controls & Protects

UC

Incorporated

HPS, LPS, Coil Temp, OD Air Temp

Contactor

Defrost

Comfort Alert

Unitary Control Overview (UC)

#1 - Contactor Replaced By Sealed Switch

#2 - Status Indication & Integrated Diagnostics

• System Operational Status Displayed

• Comfort Alert™ With Active Protection

• Can Display at Thermostat L Terminal

• Easy Push Button Fault Recall, Faults Retained During Power Outages

#3 - Short Cycle Protection, Voltage & Pressure Switch Monitoring

• 30 Second Minimum Run, 3 Minute Minimum Off

• High & Low Voltage Alerts

• Pressure Switch Alerts & Lockouts

#4 - UltraTech™ 2-Speed Compressor & OD Fan Control

• Latching, No Chatter

• Insects and Contaminants Can’t Get In

• Simple Manual Operation By Push Button

#5 - Time/Temp Defrost Heat Pump Control

Better Reliability

Reduced Warranty

Homeowner Peace of Mind

Fast, Accurate Service

Reduced Warranty

Homeowner Peace of Mind

Fast, Accurate Service

Better Reliability

Reduced Warranty

Homeowner Peace of Mind

Simplified Wiring

Fewer SKUs, Faster Assembly

How the System is Integrated

Comfort Alert Current Sensors

7 Pin Legacy Terminal Block

Compressor Connections

Air, Coil Temp Inputs

Field Power Connections

Reversing Valve, Low Pressure Cutoff, and High Pressure Cutoff

Defrost Interval Timing 30, 60, 90, & 120min

Compressor Solenoid Plug Fan Plug

Test, Fault Recall, Forced Defrost Buttons

Fuse

Compressor Relay

CCH Terminal

Unitary Control Board

Unitary Control Board

Lug Connections

Sealed Switch After 1.1M Cycles

Contactor After 287k Cycles

A/C H/P Control Board

Optical Sensor Looks for Arcing

and Adjusts Open/Close Timing to

Achieve Zero Cross Switching

Optical Sensor Views Relay

Contact Operation

AC

Sine

Wave

Arc Zone

Arc Zone

Optical Control Prevents Damage

The UC Sealed Switch Has Been Qualified Using The Most

Severe Residential Compressor Load Per Copeland. Units

Have Performed Over 1 Million Cycles (How many years?)

12 Electrical Load

Test Stands With

Data Acquisition

Contactor

287K Cycles

UC Switch

302K Cycles

UC Compressor Switching Test Stands at Copeland

• “Test” Push Button- press for 5 seconds to manually test operation of compressor & outdoor fan

• “Recall” Fault Recall, Will retain the 6 most recent faults including a maximum of 3 consecutive identical faults

• Forced defrost by pushing “Test” & “Recall” at the same time

• Also has a selectable shutdown & restart delay for noise abatement during defrost

• CCH output, powered if the compressor has not run within the last two hours

Features

A/C H/P Control Board

L.E.D’S

Unitary Control Board

Status

Message

Display

LED Display Yellow

Diagnostic

Red Active

Protection Green Status Red Y1 LED

Low Side Fault LOW SIDE FAULT 1 Flash OFF OFF ON if Y1 Present,

OFF if Y1 not Present

Low Pressure CO

Trip LPS OPEN 1 Flash OFF ON

ON if Y1 Present,

OFF if Y1 not Present

LPCO Lockout (3

Trips) LPS LOCKOUT 1 Flash ON ON

ON if Y1 Present,

OFF if Y1 not Present

High Side Fault HIGH SIDE FAULT 2 Flashes OFF OFF ON if Y1 Present,

OFF if Y1 not Present

High Pressure CO

Trip HPS OPEN 2 Flashes OFF ON

ON if Y1 Present,

OFF if Y1 not Present

HPCO Lockout (3

Trips) HPS LOCKOUT 2 Flashes ON ON

ON if Y1 Present,

OFF if Y1 not Present

Short Cycling CMPR SHRT CYCLE 3 Flahes OFF OFF ON if Y1 Present,

OFF if Y1 not Present

Locked Rotor LOCKED ROTOR 4 Flashes ON OFF ON if Y1 Present,

OFF if Y1 not Present

Open Circuit OPEN CIRCUIT 5 Flashes OFF OFF ON if Y1 Present,

OFF if Y1 not Present

Open Start Circuit OPEN START 6 Flashes OFF OFF ON if Y1 Present,

OFF if Y1 not Present

Open Start Circuit

Lockout OPEN START LOCK 6 Flashes ON OFF

ON if Y1 Present,

OFF if Y1 not Present

Open Run Circuit OPEN RUN 7 Flashes OFF OFF ON if Y1 Present,

OFF if Y1 not Present

Open Run Circuit

Lockout OPEN RUN LOCK 7 Flashes ON OFF

ON if Y1 Present,

OFF if Y1 not Present

Low Line Voltage LOW LINE VOLT 8 Flashes OFF OFF ON if Y1 Present,

OFF if Y1 not Present

High Line Voltage HIGH LINE VOLT 8 Flashes OFF ON ON if Y1 Present,

OFF if Y1 not Present

Low Pilot Voltage

LOW SECOND VOLT

9 Flashes OFF OFF

ON if Y1 Present,

OFF if Y1 not Present

Comp Protector

Open Not Displayed ON ON OFF

ON if Y1 Present,

OFF if Y1 not Present

Comfort Alert Active Protection

Y1

Green

Yellow

Red

Y Call LED

Status LED

Diagnostics LED

Active Protection LED

Unitary Control Board

• Y1 Indicator –Red LED, on solid to indicate the presence of Y1.

• Flashes slow when the unit has a Y demand but is not operating, example, due to faults or lockouts

Y1 Y Call LED

Unitary Control Board

Unitary Control Board

G Status / Mode LED

Y Diagnostics LED

These two LED’S will operate together in different combinations of steady on/ flashing to indicate faults

Green LED will also indicate mode by the number of flashes

1= Low Cool, 2= High Cool,

3= Low Heat, 4= High Heat,

Slow = Defrost

Unitary Control Board

R Active Protection LED

The operation of this LED usually indicates a more serious fault such as an open compressor circuit or locked rotor

Learn Button

Communication

Status (Blinks

Twice During

Power up)

Future Use Bias

Termination

Receiving Data

Flashing Green

LED (Blinks while

communicating)

Standard Communications Circuit on Every Control

• System Problems Included Bad Capacitors, Broken Wires, Bad Contactors And Overcharged Refrigerant

• Measure Technician’s Accuracy On First Diagnosis

• Diagnostics For Single Phase Scroll Compressors • Detects System And Electrical Problems Without Adding Sensors • Can Communicate Fault Codes To Enabled W-R Thermostats

63%

17%

100%

92%

0%

20%

40%

60%

80%

100%

Entry Level Experienced

No Diagnostics

Comfort Alert

(Votech Student) (3 – 12 Years)

Troubleshooting Accuracy Study

Now located on the Board

Comfort Alert Diagnostics Reduce “No Defect Found” Warranty Returns

Definition: Protective Lockouts That Prevent Compressor Operation When Damage Could Occur

Controls & Protects

1. Low Pressure: 3 trips in one Y call = lockout

2. High Pressure: 3 trips in one Y call = lockout

3. Locked Rotor: 4 runs attempted each lasting < 15 seconds and tripping the protector = lockout

4. Open Start Circuit: When sensed by Comfort Alert 4 retries are attempted at 5 minute intervals before lockout. One normal run before lockout clears fault.

5. Open Run Circuit: Same response as #4.

Lockouts can be cleared by cycling 24V to the UC

control, or pressing the “TEST” button

Unitary Control Active Protection Increases System Reliability

1

2 R

C

1 2 R C G W1 W2 Y1 Y2 O Dehum

1 2 R C

CTK01AA

Communicating

Furnace

Communicating

A/C or H/P

•Recommended Wiring For Fully Communicating System

•Strongly Recommended For Dual Fuel

Outdoor Transformer supplied with CTK01AA

Installation - Wiring

1

2 R

C

1 2 R C G W1 W2 Y1 Y2 O Dehum

1 2 R C

CTK01AA

Communicating

Furnace

Communicating

A/C or H/P

•Optional Wiring For Fully Communicating System

Installation - Wiring

1

2 R

C

1 2 R C G W1 W2 Y1 Y2 O Dehum

CTK01AA

Communicating

Furnace

• Wiring For Communicating Furnace With Non- Communicating A/C

C Y Non-Communicating A/C

Installation - Wiring

Coil Protection - Louvers

• Two louver panels.

– Easy To Remove

• Narrower Louver Pattern

– 2 1/2” Louver – Previous 3 ¼”

– More Steel Bands

• Louver Formed In The Tool

– Conforms To Base & Top

Outstanding Features

Scroll 1-1/2 to 25 HP

Scroll Ultra - Tech

Copeland Compressors

Access Port

• Latch Holes On Four Sides Of The Base – Weather & Security

Reasons – Done From Outside The

Unit – Use Goodman Kit #ABK-20

For Anchoring

• Greater Drainage In The Base

• Coil Track In Base

Latch hole

Outstanding Features

• Two screws remove the cover

• Removable panel

• Ground with lug connection

• Room for field installed

accessories

Outstanding Features

High Voltage Lines

High Voltage Connection

Route power supply and ground wires through the high voltage port and terminate in accordance with the wiring diagram provided inside the control panel cover.

1. Disconnect high voltage electrical supply. Remove control panel cover

from unit.

2. Turn on line voltage. Using a volt meter measure the voltage across the

terminals L1 and L2 of the contactor of the unit.

3. No reading – indicates open wiring , open fuses or no power. Repair as

needed.

4. With ample voltage at line voltage connectors (220 volts + or – 10%),

energize the unit.

5. Measure the voltage with the unit starting and operating. Determine the

LOCKED ROTOR VOLTAGE.

6. Should voltage fall below the minimum voltage . Check the line wire size.

Long runs of wire can cause low voltage. If wire size is adequate, notify

power company of high or low voltage.

Checking Voltage

Is the actual voltage available at the compressor during starting, locked

rotor, or a stalled condition.

To measure Locked Rotor Voltage attach a voltmeter to the run “R” and

common “C” terminals or to the “T1” and “T2” terminals on the contactor.

Start the unit and allow the compressor to run several seconds, then shut

the unit down. Immediately attempt to restart the unit while measuring the

Locked Rotor Voltage.

Should voltage fall below the minimum voltage . Check the line wire size. Long runs of wire can cause low voltage. If wire size is adequate, notify power company of high or low voltage

Locked Rotor Voltage

1. Check wiring visually for signs of overheating,

damaged insulations and loose connections.

2. Use an ohmmeter to check continuity of any

suspected open wires.

3. If any wires must be replaced , replace with

comparable gauge and insulation thickness.

Check Wiring

Disconnect electrical power supply:

1. Remove control panel cover on furnace or air handler. To gain access

to the transformer.

2. Turn power ON: Line voltage is now present.

3. Using a voltmeter, check voltage across secondary voltage side of

transformer(R to C).

4. No Voltage indicates faulty transformer, bad wiring,or bad splices.

5. Check transformer primary voltage at incoming line voltage

connections.

6. If line voltage available at primary voltage side of transformer wiring is

good , transformer is inoperative . Replace .

Checking Transformer and Control Circuit

Reversing Valve

1. Valve won’t shift from cooling to heating

2. Valve won’t shift from heating to cooling

3. Valve starts to shift but doesn’t complete the reversing action

4. Valve suffers apparent leak when shifting from one mode to other

Reversing Valve Problems

Solenoid w/feeder tubes

Pilot Valve

Reversing Valve

True Suction tube

Hot Gas

Discharge tube

Pilot Valve Tubes

Reversing Valve