Emerson iPro SERIES Technical information

Technical Information
Date of last update: Oct-11
Ref: D7.8.4/1011/E
Application Engineering Europe
CORESENSE™ DIAGNOSTICS FOR STREAM REFRIGERATION COMPRESSORS
CoreSense™ Diagnostics for Stream Refrigeration Compressors ............................................................................... 1
1
Introduction .......................................................................................................................................................... 3
2
Specifications ........................................................................................................................................................ 3
3
Emerson CoreSense™ Diagnostics – Features ..................................................................................................... 3
4
3.1
“Jog” feature ................................................................................................................................................. 4
3.2
Crankcase heater (CCH) control.................................................................................................................... 4
3.3
Insufficient oil pressure protection .............................................................................................................. 5
3.4
Motor overheat protection .......................................................................................................................... 5
3.5
High discharge temperature protection ....................................................................................................... 5
3.6
Locked rotor protection................................................................................................................................ 5
3.7
Missing phase protection ............................................................................................................................. 5
3.8
Low voltage protection ................................................................................................................................. 5
3.9
Voltage imbalance protection ...................................................................................................................... 6
3.10
Flash memory information ........................................................................................................................... 6
3.10.1
The following asset information will be saved in the flash memory (EEPROM); ................................. 6
3.10.2
Compressor running status information will be saved in the flash memory (EEPROM): ..................... 6
3.10.3
Compressor Operating Parameters ...................................................................................................... 6
3.11
Modbus® communication ............................................................................................................................. 6
3.12
Local and remote reset ................................................................................................................................. 6
3.13
Alarm history and running conditions .......................................................................................................... 7
3.14
Compressor status codes.............................................................................................................................. 7
3.15
LEDs on the module to display the failure alarms ........................................................................................ 7
Electrical connections ........................................................................................................................................... 9
4.1
System wiring diagram ................................................................................................................................. 9
4.2
Terminal box and current sensing transformer connections .....................................................................10
4.2.1
Installation of current sensing module ...............................................................................................10
4.2.2
CoreSense™ Diagnostics with Υ/Δ motors ........................................................................................11
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Technical Information
4.2.3
D7.21.2/1011/E
CoreSense™ Diagnostics with part winding ......................................................................................11
5
CoreSense™ Diagnostics jumper settings..........................................................................................................13
6
CoreSense™ Diagnostics DIP-Switch setting .....................................................................................................13
7
Troubleshooting..................................................................................................................................................15
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D7.21.2/1011/E
Technical Information
1
Introduction
CoreSense™ is an ingredient brand name for compressor electronics associated with Emerson‟s Copeland® brand
products. CoreSense™ technology uses compressor as a sensor to unlock information from within the compressor
providing value added features such as advanced motor protection, diagnostics, communication.
With active protection, advanced algorithms, and features like fault history and LED indicators, CoreSense™
Diagnostics for Copeland compressors enable technicians to diagnose the past and recent state of the system,
allowing for quicker, more accurate diagnostics and less down time. The CoreSense™ Diagnostics is initially
available as standard with the 4- and 6-cylinder Stream compressors.
Figure 1: Stream compressor with CoreSense™ Diagnostic
2
Specifications
Power supply for control module (in front of the compressor) is 120VAC or 240VAC.
Operating temperature
Voltage requirements
Inrush current for relay
Voltage sensor module
-32°C to 66°C
120 VAC or 240 VAC
19A
24 VAC
Steady load current for relay
Power rating for the module
Storage temperature
Protection class
3A
3VA
-40°C to 85°C
IP54
Table 1
3
Emerson CoreSense™ Diagnostics – Features
Nr
Feature
Nr
Feature
1
Motor Overheat Protection
8
Alarm History and Compressor Operating Conditions
2
Oil Pressure Protection
9
Crankcase Heater Control
3
Discharge Temperature Protection
10
Local and Remote Reset Capability
4
Locked Rotor Protection
11
Modbus Communication
5
Single Phase/Missing Phase Protection
12
Power Consumption Monitoring (Voltage, Current,
Power Factor)
6
Voltage Imbalance Protection
13
Crankcase Heater Control
7
Low Voltage Protection
14
Compressor Run Status (Proofing)
®
Table 2
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Technical Information
D7.21.2/1011/E
Figure 2
3.1
“Jog” feature
The reset button below the control module may be used as an emergency shutdown,
such as for clearing liquid during a start-up. After the module re-boots (approximately
3 seconds) the compressor will run again. The reset button may be pushed as necessary
to stop the compressor.
Reset button
Figure 3
3.2
Crankcase heater (CCH) control
The sensor module contains an on-board CCH control relay. An auxiliary contactor is no longer required to turn the
heater on when the compressor turns off.
The appropriate voltage supply to the CCH power input terminals (115V/230V) is required.
4/17
Technical Information
3.3
D7.21.2/1011/E
Insufficient oil pressure protection
The CoreSense™ Diagnostics module replaces the mechanical oil pressure switch. Furthermore, it provides the
added value of communication for insufficient oil pressure warning and lockouts via LED flash codes and/or a
supervisory pack controller. Total insufficient oil pressure time for the compressor is stored and accumulated in the
module memory.
CoreSense™ Diagnostics will issue a warning when oil pressure differential falls below 0.48-0.62 bar for
4 seconds.
Once the oil pressure differential falls below 0.48-0.62 bar for 2 minutes (120 sec), the module will shut the
compressor off and a “low oil pressure lockout“ will be reported. Before using the reset button, troubleshooting
needs to be done to understand the failure. The compressor will switch back on once the reset has been activated
either manually or remotely through the communication network, or when power has been cycled to the
CoreSense™ module. This feature is not applicable to Copeland compressor models 4MTL (Stream CO2
compressors) as these have no positive oil pump fitted and are “splash” lubricated.
3.4
Motor overheat protection
Using Positive Temperature Coefficient (PTC) sensors on 4M* and 6M* Stream compressor models, the
CoreSense™ Diagnostics module provides motor overheating protection. The CoreSense™ Diagnostic module
replaces the Kriwan module INT69TM.
Alarm condition:
 Trip condition: PTC Resistance > 4.5 kΩ;
 Reset condition: PTC Resistance < 2.5 kΩ; 5 min time delay.
3.5
High discharge temperature protection
Discharge temperature protection is provided using a NTC sensor in the compressor cylinder head. The sensor is
pre-installed at the factory and connected to the module. CoreSense™ will protect the compressor from high
discharge temperature conditions. If the temperature sensor detects a discharge temperature higher than 154°C,
the CoreSense™ will shut off the compressor until the temperature cools down to an acceptable level (about
130°C).
Either trip or lockout alarm can be selected by user. Default is trip alarm.
Trip/lockout value ≥ 154°C for 2 sec.
Trip alarm: Automatic reset after 2 minutes; discharge temp < 130ºC.
Lockout alarm: Manual reset is necessary.



3.6
Locked rotor protection
Appears when the rotor is mechanically seized. Locked rotor current is expected to decrease within 4 seconds after
the motor comes up to speed.
3.7
Missing phase protection
If any one of the 3 power phases is missing immediately after the compressor contactor is energized, a singlephasing condition exists.
The maximum response time shall be 1.2 seconds from the time of contactor energization.
Alarm condition: If any phase voltage < 84% of max of 3 input voltages for a period of 1 second.


Trip time: 5 minutes with automatic reset.
Lockout condition: Appears after the 10 consecutive trip alarms. Manual reset (using reset button below
the module or using remote reset by pack controller).
In the case of a part winding motor this feature is detectable for primary winding only. Missing phase, voltage
imbalance and low voltage are not detectable for the secondary winding. A missing phase can be detected during
start-up, but not while the motor is running.
3.8
Low voltage protection
Appears when there is a low supply voltage.
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D7.21.2/1011/E
Technical Information
Alarm condition: Motor compressor voltage < low voltage setting at compressor running state. The default low
voltage setting is 75% of the nominal line voltage stored in the module for 2 sec.

Trip Time: 5 minutes.
The module determines the operating frequency of the compressor. The compressor low voltage setting shall be
lowered by the same percentage as the operating frequency if less than the nominal frequency. For example if a
60 Hz nominal frequency compressor is running at 57 Hz (5% less), then the low voltage setting shall be reduced
by 5%.
3.9
Voltage imbalance protection
The purpose of this protection feature is to protect the compressor against a voltage imbalance condition that leads
to motor overheating.
A configurable setting (default = 5%) for voltage imbalance is used to determine the operating limit of the
compressor.
Alarm condition:
 Trip: When the voltage imbalance > 5% (configurable).
 Reset: Automatic reset after 5 min; voltage imbalance < 5%.
3.10 Flash memory information
Emerson Climate Technologies can provide a software to access EEPROM information.
3.10.1 The following asset information will be saved in the flash memory (EEPROM);





Compressor model number
Compressor serial number
Compressor model number modified
Compressor serial number modified
Sensor module firmware revision
3.10.2 Compressor running status information will be saved in the flash memory (EEPROM):





Number of compressor running hours
Number of compressor starts
Number of resets and type of reset
Accumulated runtime without good oil pressure
Number of relay cycles
3.10.3 Compressor Operating Parameters





Current
Voltage
Power factor
Power consumption
Discharge temperature values
3.11 Modbus® communication
®
CoreSense™ Diagnostics has communication capability via a Modbus network connection. With communication
enabled, CoreSense™ warnings, trips and lockouts can be displayed and recorded in a pack controller such as the
iPro Rack Controller from Dixell.
®
The CoreSense™ Diagnostics module is compatible with any other pack controller that has Modbus protocol.
3.12 Local and remote reset
The CoreSense™ Diagnostics module is equipped with a reset button placed below the control module. The reset
button may be pushed as necessary to stop the compressor.
The CoreSense™ Diagnostics module is equipped with a remote reset capability, such that if a compressor is off in
a lockout condition, the user can remotely restart the compressor through their rack controller or compatible remote
access software.
NOTE: Service contractor and end user policies need to be considered when deciding whether or not to
use the remote reset feature in the pack controller.
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D7.21.2/1011/E
Technical Information
3.13 Alarm history and running conditions
Operating information
Alarm history
Number of compressor running hours -
8 days alarm history
Accumulated running time without good oil
pressure
Most recent 10 alarms
Number of switching cycles
Total number of alarms since the compressor first
operation
Compressor power consumption*
Current, voltage, power factor*
*This data is not stored in CoreSense™ EEPROM memory. These values can be stored in a laptop using CoreSense™ PC
®
Interface Software or Modbus communication.
Table 3
3.14 Compressor status codes





Steady green: An indication of normal operation. There are no faults or issues with the compressor.
Flashing green: An indication that there is an alert (warning) condition. The compressor can still be
running.
Flashing orange: An indication that the compressor has tripped with auto reset.
Flashing red: An indication that the compressor is in lockout state.
Solid red: An indication that the control module has failed.
3.15 LEDs on the module to display the failure alarms
For warning/alert (green), trip and lockout (red), the flash count is defined as 0.1 second „on‟ and 0.4 second „off‟
with a 2-second pause before the flash count repeats (timings are +/- 50 ms).
Definitions:
 Trip: The module has shut off the compressor due to a fault condition. The compressor will be available to
run when the fault condition no longer exists, and the minimum off time has been satisfied.
 Lockout: The module has shut off the compressor due to a fault condition. The compressor will be
available to run again when the fault condition has been cleared and manual or remote reset is done.
Alert alarms
Compressor will not turn off.
Trip alarms
Compressor turns off for some
time with automatic reset.
Lockout alarms
Compressor turns off.
Manual reset necessary.
Figure 4
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Technical Information
LED
flashes
count
Status LED description
1
Low Oil
Pressure
2
Auto
reset
time
NA
Low Oil
Pressure
N/A
NA
Motor
Protection
Trip
NA
2 min
3
Discharge
Temp.
Discharge
Temp.
4
Current
Sensor
Fault
NA
NA
NA
5
Communica
tion Error
NA
NA
NA
6
NA
Locked
Rotor
Locked
Rotor
5 min
7
NA
Missing
Phase
Missing
Phase
5 min
8
N/A
Low Voltage
Low
Voltage
5 min
9
N/A
Voltage
Imbalance
Discharge
2 min
Temp.
Voltage
5 min
Imbalance
Lockout
condition
D7.21.2/1011/E
Status LED troubleshooting information
If flashing green, compressor has been
without sufficient oil pressure for 4 seconds.
If flashing red, compressor has been
without sufficient oil pressure for 2 minutes.
If flashing orange, compressor is turned
off because motor temperature has
NA
exceeded set point. (3 series PTCs; 1 input)
(Trips at 4.5K Ohms, and will reset when
below 2.75K Ohms.)
If flashing green, the discharge
temperature probe is open or disconnected.
If flashing orange, discharge temperature
has exceeded set point; compressor is
Exceeds max
turned off for 2 minutes before resetting.
set point
If flashing red, discharge temperature has
(configured in
exceeded set point and the compressor is
EEPROM from
locked out.
iPRO)
(The customer has configured the module
to lock out when the DLT temperature
exceeds the maximum set point.) DLT
probe is FACTORY INSTALLED
If flashing green, current sensor is
NA
disconnected from the module. Compressor
run state is not known by module.
Communication between Control module
and iPro (/System) Controller has been lost.
Communication between Control module
NA
and Sensor module has been lost.
Configuration miss-match between SW
configuration from iPro and HW (network
mode)
If flashing orange, compressor failed to
start, and excessive current may be present
in the compressor. The compressor is
10 consecutive turned off and will remain off for 5 minutes.
If flashing red, compressor failed to start,
events
and excessive current may be present in
the compressor. The compressor is locked
out after 10 consecutive events.
If flashing orange, compressor is turned
10 consecutive off due to missing phase.
events
If flashing red, the compressor is locked out
after 10 consecutive missing phase alarms.
If flashing orange, compressor is turned
10 consecutive off due to low compressor voltage.
If flashing red, the compressor is locked
events
out after 10 consecutive low voltage alarms.
If flashing orange, compressor is turned
10 consecutive off due to voltage imbalance.
If flashing red, the compressor is locked
events
out after 10 consecutive voltage imbalance.
Without
sufficient oil
pressure for 2
minutes
Table 4
8/17
Technical Information
4
Electrical connections
4.1
System wiring diagram
D7.21.2/1011/E
Fuses and wire cable sizing must be done in accordance with all applicable electrical code standards. Figure 5
below shows the recommended basic system wiring for a compressor with CoreSense™.
Figure 5: Wiring diagram
Figure 6: CoreSense™ wiring terminals description
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Technical Information
D7.21.2/1011/E
Figure 7: CoreSense™ module with current sensor
4.2
Terminal box and current sensing transformer connections
For space reasons inside the compressor terminal box wires L1 and L2 connected to the sensor module need to be
exchanged in such a way that the black wire is connected to terminal 2 (V) and the white wire goes to terminal 1
(U) on the terminal plate as shown on the drawing. This results in that the current of L2 is sensed instead of L1.
4.2.1
Installation of current sensing module
One of the motor power leads passes through the “toroid” (current
sensing module). Information from the current sensing module is
used to determine running amps, power consumption and locked
rotor conditions. There are 3 voltage sensing leads attached to the
motor terminals and connected to the sensor module. Two of the
leads are white, and one is black. For proper calculation of power
factor and motor power it is necessary for the black voltage sensing
lead and the power lead through the current sensing module to be
connected to the same motor terminal.
Class II transformers have a maximum VA (Volt-Ampere) rating of
less than 100 and a maximum secondary output of 30 VAC.
Figure 8: Current sensing module and T-Box wiring
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Technical Information
4.2.2
D7.21.2/1011/E
CoreSense™ Diagnostics with Υ/Δ motors
Terminal box and the current sensing “toroid” connections are
factory-installed. One of the motor power leads must be routed
through Current Sensing Transformer (see Figures 9 & 10 below).
Figure 9: Current sensing transformer
Figure 10: Wiring sensor module and leads routed through the current sensor
One motor lead must be routed through the centre opening of the current sensing transformer.
4.2.3
CoreSense™ Diagnostics with part winding
If using the CoreSense™ Diagnostics module with a part-winding start motor, one power lead of each of the
windings should be passed through the current sensing transformer in the same direction (see Figures 10 and 11)
to provide accurate compressor proofing. If the leads (L2 and L8 in picture below) are not routed in the same
direction, the running current may indicate close to zero.
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Technical Information
D7.21.2/1011/E
Figure 11: Wiring part winding
Figure 12: Wiring Sensor module and leads routed through the current sensor
12/17
Technical Information
5
D7.21.2/1011/E
CoreSense™ Diagnostics jumper settings
The last compressor in the daisy-chain must be “terminated” by moving the jumper from JP5 to JP3. For all other
compressors the jumper should remain in the default JP5 position.
JP4 should be set “1-2” if connected to an iPro rack controller. Set JP4 to “2-3” for other pack controllers.
Do not remove JP1. This is reserved for future use.
Figure 13
6
CoreSense™ Diagnostics DIP-Switch setting
Figure 14: CoreSense™ Diagnostics DIP-Switch setting
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Technical Information
D7.21.2/1011/E
Assign a unique node address to each CoreSense™ diagnostics module using switches 1 through 5.
a. Set the communications baud rate for the module using switch 7. “Off” = 19200 baud, “On” = 9600 baud.
The baud rate for each module should be set to match the rack controller.
b. Set switch 8 to “Off” for no parity, to “On” for even parity.
c. Set switch 9 to “Off” for stand-alone mode, to “On” for network mode. Network mode will generate a
communications error if the rack controller fails to communicate with the device. For stand-alone mode, no
communications are expected so the communication error is blocked.
d. Factory default setting is “On” for dip-switch 10, ie, discharge temperature protection. If you want to
disconnect the discharge temperature sensor, turn off dip-switch 10.
Push the reset button after changing the switch settings.
Ensure that the dip-switch settings on each module match the settings for the selected controller communication
port.
Information in this document is subject to change without notification.
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D7.21.2/1011/E
Technical Information
7
Troubleshooting
Flash
code
Alarm conditions
Possible failure reasons
Warning:
Appears
when
the
differential oil pressure is less than
0.48 – 0.62 bar for 4 seconds.
1
Insufficient
pressure
oil
Lockout:
Appears
when
the
differential oil pressure is less than
0.48 – 0.62 bar for 2 minutes
continuous, or intermittent but
determined to be unsafe.
Trip: Appears when the PTC
Thermistor resistance is > 4.5 kΩ.
2
Motor overheat
Lockout:
Appears
when
consecutive motor overheat
alarms occur.
10
trip
Loose wiring connections between
CoreSense™ module and oil
sensor.
Faulty oil sensor (missing O-ring
or clogged sensor screen).
Faulty oil pump.
Clogged strainer screen or worn
bearings.
Motor rotor
seized.
is
mechanically
Open circuit in harness.
Connector pin not engaging at
connector on control module
Faulty CoreSense™ module.
Troubleshooting measures
Verify the oil level present in the sight glass. If the oil is not present, resolve reservoir
oil supply problem or oil level control setting issues.
Verify that the harness is fully engaged to the sensor.
Measure oil pump differential pressure. If less than 7 to 9 psi, inspect for clogged oil
screen, faulty oil pump, liquid floodback or worn bearings.
If good oil pressure exists, measure resistance across the oil sensor while the
compressor runs. If the sensor resistance is "open" inspect for clogged sensor screen
or missing O-ring.
If sensor resistance is "closed", temporarily jumper across the harness connector pins
(do not damage the pins!) while the compressor runs. If the oil warning does not go
away, verify harness connector engagement at the module circuit board.
In case of trip alarm, allow the motor to cool down for a minimum of 2 minutes (it may
take longer) and the compressor will start automatically.
In case of lockout alarm or multiple trips, check PTC resistance when the motor is cold
(off for at least an hour). If resistance is high, inspect for faulty sensor or loose
connection under terminal plate.
If resistance is low, inspect for loose terminal strip connections, harness connection
failure at circuit board, open harness circuit or high motor temp due to return gas
temperature, motor voltage or load condition.
Open discharge probe (faulty).
3
Discharge temp
protection
Warning: When the
discharge
temperature sensor is defective or
disconnected.
Trip/Lockout: When the discharge
temperature is > 154°C for 2
seconds.
The probe connection has not
been made to the harness
connector.
The connector is not plugged into
the CoreSense™ circuit board.
The Discharge temperature has
exceeded the maximum limit
154°C.
Blocked condenser.
If there is a warning, verify proper probe connection to the harness and proper
harness connection into the circuit board.
If there is a warning, unplug the discharge temp probe and verify if the resistance of
the probe is as specified vs its approximate ambient temperature.
If the probe resistance is correct inspect the harness connector receptacle for damage
and apply NyoGel 760G connector lubricant.
Trip or Lockout: resolve system issues (high superheat, high head pressure), inspect
for mechanical damage that can lead to high temps (valve plate gasket, suction or
discharge valve failure).
Possible loss of refrigerant.
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D7.21.2/1011/E
Technical Information
Flash
code
4
Connection lost
CT to sensor
5
Communication
Error
6
Locked rotor
7
Missing phase
Alarm conditions
Possible failure reasons
Warning: Appears when the signal
from
current
sensor
is
not
communicated to the sensor module.
The current sensor is not
connected to the sensor module.
Faulty current sensor.
Faulty sensor module.
Warning: Appears when there is no
communication
between
control
module and sensor module or rack
controller
Communication
between
CoreSense™ control module and
rack controller has been lost.
Communication
between
the
CoreSense™ control module and
the sensor module has been lost.
Trip: Appears when the excessive
current is present in the compressor.
Refer AE bulletin for more details.
Motor rotor is mechanically seized.
Excessive current present in the
compressor.
Lockout:
Appears
when
10
consecutive locked rotor trip alarms
occur.
Damaged valve plates in cylinder
head.
Trip: Appears when there is a missing
phase / single phasing.
Loose wiring connections at the
terminals inside compressor T-Box.
Lockout:
Appears
consecutive missing
alarms occur.
Worn out contactors.
when
phase
10
trip
Line break in one of the phases.
Troubleshooting measures
Verify if the CT connector is connected to the sensor module. If not connect the 4-pin
current sensor connector into the sensor module.
Verify if there is continuity between pin 3 & 4 (closest to the latch) of the current
sensing connector. The resistance should be less than 1 Ω. If the resistance is
greater than 1 Ω, replace the current sensing module. Be certain that the receptacles
are fully engaged in the connector block.
Verify if the Amp and Volts values are correctly displayed. If not, inspect the wire
harness connector to ensure that the pins are fully engaged.
If the above-mentioned trouble shooting measures didn't give the positive results, the
reason is faulty sensor module or mis-installed connector. Replace the faulty sensor
module with new one.
Is there a communication network? If not, set the network dip-switch to "stand-alone"
and press reset.
Is there a communication network? If not, verify that the communication harness is
engaged at both the CoreSense™ module and the sensor module.
If the LED on the top edge of the sensor module is dark, verify 24VAC power to the
sensor module, or replace the sensor module.
If communication network amber light is continuously on, reverse the communication
wire polarity. If voltage between centre pin and the right or left pin isn't 2.3-2.6VDC,
inspect for communication wire failure or wire strands that are "shorting" between the
wires or to ground.
Verify that motor voltage is adequate (+/- 10% of nominal rated voltage), especially
during the starting event.
Start compressor with no load. If it does start with no load, inspect the valve plate(s)
for damage or look for other causes of leak-back.
Verify voltage supply from the main power buss.
Verify voltage into and out of contactor (Repair or replace contactor if necessary).
Verify that motor electrical connections are tight at the compressor motor terminals.
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D7.21.2/1011/E
Technical Information
Flash
code
Alarm conditions
Possible failure reasons
Supply voltage
specified range.
8
Low voltage
Trip: Appears when there is a low
compressor voltage.
is
not
in
Troubleshooting measures
the
Loose wiring connections at the
terminal plate.
Worn out contactors.
Faults
with
other
electrical loads.
peripheral
Loose wiring connections at the
compressor terminal plate inside TBox.
9
Voltage
imbalance
Trip: Appears when the voltage
imbalance value exceeds the set
value (default 5%).
Worn out contactors.
Faults
with
other
electrical loads.
peripheral
Single phasing conditions.
Verify voltage supply from the main buss.
Verify voltage into and out of contactor (repair or replace contactor if necessary).
Measure voltage at the compressor terminal (refer to AE10-1244, Recommended
Contactor Selection for 3-Phase Motor Control – Power Supply Problems).
Verify that motor electrical connections are tight at the compressor.
Verify that there are not any faults with other peripheral electrical loads (for example
fan motors).
Verify voltage supply from the main buss.
Verify voltage into and out of contactor (repair or replace contactor if necessary).
Measure voltage at the compressor terminal (refer to AE10-1244, Recommended
Contactor Selection for 3-Phase Motor Control– Power Supply Problems).
Verify that motor electrical connections are tight at the compressor.
Verify that there are not any faults with other peripheral electrical loads (for example
fan motors).
17/17