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Application
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AE8-1351
Intelligent Store Discus™ 2.0
Table of Contents
1.0 Overview of Intelligent Store Discus™ 2.0
1.1 Functionality
1.1.1 Diagnostics
1.1.2 Communication
1.1.3 Fault History
1.2 Features
1.2.1 Compressor Protection
1.2.2 Remote Reset
1.2.3 Failsafe Operation
1.2.4 Welded Contactor Protection
1.2.5 Crank Case Heater Control
1.2.6 Start-up Delay Feature
1.2.7 “Jog” feature
1.2.8 Dipswitch Settings
1.3 Modulation Control
1.4 Application Restrictions
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
5.0 Stand Alone Installation and Operation
6.0 Compressor Status Codes
6.1
Definitions
6.2
Event Priority and Troubleshooting
6.2.1 Event Priority and Anti Short
Cycle Delay
6.2.2 LED Interpretation
6.3
Event Priority Table
6.4
Emergency Work-Around Procedures
6.5
Normal Running
6.6
Normal Off
6.7
Welded Contactor Warning
6.8
Module Low Voltage Trip
6.9
Part Winding Trip/Lockout
6.10 Connection Lost CT to Sensor
6.11 Rack Controller Lockout
6.12 Fault Temperature Probe
6.13 Fail-Safe Inoperable
6.14 Locked Rotor Trip / Lockout
6.15 No Communication
6.16 Motor Temperature Trip
6.17 Compressor ID Module Failure
6.18 No Communication to Sensor Module
6.19 Unloader Short
6.20 Unloader Open
6.21 Contactor Coil Lockout
6.22 Protector Trip
6.23 Voltage Imbalance Trip
6.24 Low Suction Pressure Trip
2.0 Installation Instructions
2.1 Mounting and Installation
2.2 Terminal Box Connections
2.2.1 Current Sensing Module
2.2.2 Fan Connections
2.3 Controller Requirements
2.4 Communications Network
2.5 Network Terminations and Cable Routing
2.5.1 RS485 Wiring Types
2.6 Intelligent Store Discus™ 2.0 Service
Instructions
2.7 Compatibility of Service Compressors
2.8 Intelligent Store Discus 2.0 Model Numbers
3.0 Intelligent Store Discus Quick Start Guide
4.0 Intelligent Store Discus 2.0 Commissioning
Procedure
4.1 Dip Switch Configuration
4.2 Network Setup
4.3 Enhanced Suction Group Setup
4.4 Associations
4.5 Proofing
4.6 Failsafe
4.7 Intelligent Store Discus 2.0 Setup Screens
4.8 Unloader Configuration
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
Crankcase Heater Control
Anti Short Cycle
MCC Value
Compressor Voltage
Compressor Frequency
Language
Voltage Balance
Inputs
Outputs
ID Configuration
Intelligent Store Discus 2.0 Navigation
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6.25
6.26
6.27
6.28
6.29
6.30
6.31
6.32
6.33
6.34
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8.0
9.0
10.0
11.0
12.0
13.0
14.0
Phase Loss Trip / Lockout
No 3-Phase Power
Low Oil Pressure Warning / Lockout
Control Module Failure Lockout
Sensor Module Failure
High Discharge Pressure Trip
Connection Lost ID to Sensor
Power Brownout Trip
Discharge Temperature Lockout
Current Overload Trip
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Compressor Changeout Instructions
Removal of 2D / 3D
Installation of 2D / 3D
Removal of 4D
Installation of 4D
Removal of 6D
Installation of 6D
Appendix
A. Terminal Box Diagram
B. Harness Wiring Diagram
C. Transformer Selection and Contactor Control
D. Dielectric Test (Hi-Pot)
E. Compressor Drawings
F. Technical Support Information
7.0 Service Instructions
7.1
Control Module Replacement
7.2
Sensor Module Replacement
7.3
ID Module Replacement
7.4
Installation Torque Values
1.0 Overview of the Emerson Climate Technologies
Intelligent Store Discus™ 2.0 Compressor
The Intelligent Store Discus™ 2.0 product line is
now available on 2D, 3D, 4D and 6D compressors
and integrates a number of important sensing and
compressor protection functions. This product
provides for on/off control of the compressor, capacity
modulation (both conventional blocked suction and
with Copeland Discus Digital® capacity modulation)
and for communication of the compressor status to the
rack controller through a network using Modbus for
Intelligent Store communication protocol. Protection
against low oil pressure, excessive discharge
temperature, high discharge pressure and low suction
pressure is standard on every Intelligent Store Discus
compressor. A 2-line liquid crystal display on the front
of the compressor indicates the operational status of
the compressor with a choice of 5 languages. An LED
on the compressor control module indicates at a glance
whether or not there are any compressor faults.
Figure 1.1
1.1 Functionality
1.1.1 Diagnostics
The “2.0 version” of this product provides the same
basic protection and feature package as the previous
“1.0” product, but with enhancements such as additional
motor protection, accessory proofing and modulation
control.
The status of the Intelligent Store Discus 2.0
compressor may be viewed at any time on the LCD
display by pushing the Display button on the front
of the control module. Normal conditions will be
accompanied by a steady green LED (light emitting
diode) on the front of the control module.
Note: Throughout this manual the term “Control
Module” refers to the electronic control box on the front
of the compressor which contains the display and reset
buttons. The “Sensor Module” is located inside the
terminal box, and the “ID Module” resides under the
terminal box and is attached to the terminal Plate.
If a fault occurs that doesn’t interfere with the ability
of the compressor to run, the LED will transition to a
flashing green. The display will provide a description
of the fault. This is referred to as a warning.
© 2008 Emerson Climate Technologies
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A trip or lockout condition will result in a flashing red
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Unlike Intelligent Store Discus 1.0, the control module
does not store the fault history record. The fault history
record is maintained by the ID module. As such, control
modules may be replaced without losing the history
record of the compressor.
LED. This is an indication of a condition that is keeping
the compressor from running.
As with all conditions, the status of the compressor and
the display code are transmitted to the rack controller
where they may be viewed.
1.2 Features
The status codes are discussed below in Section 6.0.
Troubleshooting flowcharts to assist with resolution of
each of the warnings, trips and lockouts may also be
found in Section 6.0.
1.2.1 Compressor Protection
Compressor protection may be in the form of a TRIP,
where the compressor will be shut off until the fault
condition no longer exists (and in some cases a
minimum off-time is satisfied), or a LOCKOUT. A
LOCKOUT is a condition whereby the compressor will
remain off until the fault condition no longer exists AND
the manual reset button is pushed (or power to the
control module is cycled). Lockouts may also be reset
from the E2 or remotely through Ultrasite™, including
oil pressure if remote re-set has been enabled for this
fault (this is password protected). A WARNING is a
fault that doesn’t keep the compressor from running
(an example is an open or shorted unloader coil).
1.1.2 Communications
Communication between the rack controller and each
Intelligent Store Discus™is through an RS485 network
with Modbus for Intelligent Store protocol. The twowire communication cable is daisy-chained from one
compressor to the next on each rack.
Compressor operations such as on/off control,
modulation operation, transmission of compressor
status and run proofing are all accomplished through
the communication network. Password protected
remote reset of certain compressor lockouts may also
be done through the communication network if this
functionality has been enabled through the controller.
Capacity modulation functions are discussed in detail
in Section 1.3, and in Commissioning / Suction Group
Setup Section 4.3.
The following compressor protection features are
provided on all Intelligent Store Discus compressors:
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The Emerson Retail Solutions’ controller E2, version
2.6 or higher, may be configured to send alarms
for different levels of compressor faults, such as for
warnings, trips and lockouts.
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The Failsafe mode may be configured to turn the
compressor on or off in the event of a communications
failure. This configuration is accomplished via a
dipswitch setting inside the lower cover of the control
module.
•
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•
•
1.1.3 Fault History
The 10 most recent warnings, trips or lockouts may be
observed through the E2 alarm history screen. An 8
–day log of each fault is also available as well as an
accumulated record for the history of the compressor.
High discharge pressure
Low suction pressure
Discharge temperature
Line-break motor protection (2D / 3D)
Motor temperature protection (Intelligent Store
Discus replaces the solid-state module used on
4D / 6D compressors)
Low voltage
Power interrupt motor protection
Welded contactor protection
Loss of phase motor protection
Low oil pressure (Intelligent Store Discus replaces
the Copeland® brand Sentronic+™ oil pressure
protection modules).
Part winding start failure
Locked rotor and settable MCC protection
Shorted unloader coil protection
Shorted contactor or pilot relay coil protection
The following options are available with Intelligent
Store Discus 2.0 compressors:
• Crank case heater control
• Blocked suction modulation (4D/6D compressors)
• Discus Digital™ capacity modulation (3D/4D/ 6D)
Graphing features available with the E2 controller
provide a powerful diagnostics tool to help understand
the source of system or compressor faults. Date
and time stamping of faults and alarms can help to
associate the fault with system events (such as defrost
cycles).
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
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Note: The conventional blocked suction or
Moduload valving MAY NOT be activated
to perform in a digital fashion. These valve
mechanisms have not been designed to
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work reliably in a digital fashion. Only use
this feature with Discus Digital™ modulation
hardware.
1.2.2 Remote Reset
The oil pressure lockout may be reset through the E2
or remotely through UltraSite™ if the reset option is
enabled.
The service contractor and end user policies need to
be considered when deciding whether to enable or
disable the oil pressure remote reset feature. The
default condition is to “disable” this feature.
Refer to Section 4, Figure 4.15 for enabling or
disabling this remote reset.
1.2.3 Failsafe Operation
The FAILSAFE mode may be configured at any time
by setting the #10 dipswitch to the “on” or “off” position
as desired. The failsafe condition is acted upon by
the compressor in the event that communication is lost
for 5 or more minutes. Upon the re-establishment of
communication to the rack controller the run command
from the rack controller overrides the failsafe
command.
The failsafe switch position may be changed at anytime.
However, the module must be reset before the control
module recognizes a change in the switch position.
When the compressor is running in the failsafe “on”
position, all of the compressor protection features are
enabled with the exception of welded contactor.
There are different philosophies regarding the failsafe
settings. One suggestion is to observe the typical
“percent of full load capacity” required to satisfy demand
(this is perhaps seasonal). Setting the switches to
provide this capacity (with perhaps a little reserve) is
one approach.
As with all dipswitch positions, a legend may be found
inside the lower cover of the control module that
explains the switch positions.
1.2.4 Welded Contactor Protection
Voltage is sensed at the motor terminals of the
Intelligent Store Discus compressor. If voltage is
present after the contactor has been signaled to
“open”, the module will send a welded contactor alarm
© 2008 Emerson Climate Technologies
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to the E2. The E2 then issues a run command to the
module to load the contactor, bringing all three legs of
the power supply to the compressor back on line. This
prevents a single-phase motor burn. The compressor
will run continuously until the unit is manually shut
down or the alarm is cleared in the E2. Safety devices
(pressure switches and motor protection) will attempt
to override this feature.
This is not to be confused with single-phase protection
at start-up or while running. In that case, the contactor
will be instructed to “open”, shutting down the
compressor.
1.2.5 Crank Case 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 (115 V / 230 V) is required.
1.2.6 Start-up Delay feature
To reduce the sudden in-rush of power associated with
multiple compressors starting at one time, compressor
start-ups are staggered slightly at the end of the
anti-short cycle delay. The delay is equal to 100
milliseconds x node number. Therefore node number
4 will start 0.3 seconds after node number 1. Refer to
the status code table to see which events trigger an
anti-short cycle delay.
1.2.7 “Jog” Feature
The reset button on the front of 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 30 seconds) the compressor
will run again. The reset button may be pushed as
necessary to stop the compressor.
1.2.8 Dipswitch Settings
Dipswitch selection for the address, baud rate, parity,
operating and failsafe mode selection simplify service
and start-up procedures. At initial power-up or after
pushing the Reset button, the following information will
be displayed on the LCD:
Control Module Firmware Version
Sensor Module Firmware Version
Node Address
Baud Rate
(9600 or 19200)
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Parity
Mode
Failsafe
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(Parity or No Parity)
(Network or Stand-Alone)
(ON or OFF)
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blocked suction modulation and one with Digital
modulation.
1.4 Application Restrictions
1.3 Modulation Control
Variable Speed – Intelligent Store Discus 2.0 is not
approved for use with variable speed drives. Other
devices on the rack may use variable speed, but
the compressor itself may not be modulated with an
inverter.
Intelligent Store Discus™ 2.0 can control blocked
suction (conventional unloading) valves or Digital
unloading valves without separate relay outputs or
the need for an IDCM module. Demand from the rack
controller to the unloader valve is through the RS 485
communication network and the actual on/off control is
facilitated by the control module.
Demand Cooling – The Intelligent Store Discus 2.0
compressor is not equipped with Demand Cooling
capability, and as such may not be used as an R-22
low temperature compressor.
Digital modulation will be available for the 3D, 4D and
6D compressor. The E2 can control any combination
of compressors, blocked suction compressors and/
or digital compressors. When more than one digital
compressor is in a suction group, only one compressor
at any given time will be operating in a “digital” mode
(i.e. modulating in a pulse-width fashion).
Low Temperature Operation – The Intelligent Store
Discus electronics are designed to operate between
-25°F and 150°F. At temperatures below 0°F the LCD
display may be “slow”, but the compressor status
information in the E2 is up-to-date.
Blocked suction (and Moduload) compressors are set
up in the suction group as stages (i.e. the compressor
is one stage and each unloader is one stage). The
total output of the compressor (horsepower or
capacity) is the sum output of each individual stage.
When an unloader stage is “on” it is producing capacity
(this is when the solenoid is de-activated, or “off”). If
you override an unloader stage “off”, the solenoid is
energized.
Modulation Control - Intelligent Store Discus 2.0
RS 485
Communication
When setting up the suction group using Digital
compressors, the compressor is one stage (regardless
of the number of unloaders). A 3D Digital, 4D Digital,
6D Digital with one unloader or a 6D Digital with 2
unloaders are all configured as one stage.
Modulation Control w/o Intelligent Store Discus
The digital control cycle is by default a 20 second
period. Within this period the output of the compressor
will be pulsed to produce (on average) the capacity
requested by the controller. The advantages of Digital
control are significant:
•
Dramatically
cycling
reduced
compressor
contactor
•
Tighter control of pressure or temperature
•
Reduced set-point error
Refer to Figure 1.2 for a comparison between the
modulation control requirements with and without
Intelligent Store Discus 2.0. The conventional control
arrangement that is depicted shows a compressor
without modulation, a compressor with conventional
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
IDCM Module
Figure 1.2 Modulation Control
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2.0 Installation Instructions
Emerson Climate Technologies, Inc. requires that all
customers review the recommended guidelines in
the published Application Engineering Bulletins, and
ensure that best engineering practices are followed
in the use of Copeland® brand compressors.
Emerson Application Engineering Bulletins can be
found on our website, www.EmersonClimate.com
under the section titled “Online Product Information."
The advice and conclusion by Emerson represents
our best judgment under the circumstances, but such
advice given and/or conclusion made, or results
obtained shall be deemed used at your sole risk.
2.1 Mounting and Installation
The Intelligent Store Discus™ is designed and
engineered for use in a supermarket rack application.
Its environmental restrictions are not different than
other Copeland Discus® compressors. As such, the
compressor must be in an equipment room, rack house
or roof enclosure to prevent direct precipitation on the
compressor. The following clearance provisions must
be considered when designing the rack for use with an
Intelligent Store Discus compressor:
• Removal of the lower cover of the control module
for access to dip-switches and the communication
network connector
• Removal of the control module for service
reasons
• Removal of the pressure switch cover (2D / 3D)
for service reasons
• Removal of the harness cover shroud (4D / 6D)
• Removal of terminal box lids for service reasons
Refer to customer drawings in Appendix F
for dimensional envelopes of Intelligent Store Discus.
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The following terminal box connections must be made
by the original equipment manufacturer:
• Module power – 24 volts AC supplied by a Class
II power supply. This powers the electronics,
unloaders, crank case heater relay, and contactor
output (to load the pilot relay or contactor). Use
AMP terminals (2x) 520184-2
• Contactor – Output connections to the contactor
pilot relay or contactor coil. Use AMP terminals
(2x) 520183-2 or 520184-2
• Crank case heater power supply – 115vac or
208/230vac. A switching relay inside the sensor
module controls the crank case heater. An
auxiliary contact on the contactor is not required.
Use AMP terminals (2x) 520194-2
• Intelligent Store Discus and Discus® compressors
use the same motor terminal connections.
While the Intelligent Store Discus compressor is
primarily intended for use in supermarket rack
applications, it is possible to utilize this technology
in other applications without a communication
network. Setting the dipswitch settings to the “stand
alone” position allows the compressor and unloaders
to be controlled by a 24 volt signal to input leads in
the terminal box. Protection, control and diagnostic
features are still functioning while in the stand-alone
control mode.
Inherent in the functionality of the control module
is short-circuit protection for the following circuits:
Unloader coil operation and contactor output.
Additional
electrical
requirements
and
specifications (such as transformer selection) are
provided in Appendix C.
Refer to Figure 2.1 for terminal box connection
locations.
2.2 Terminal Box Connections
Feature
Electrical Requirements
Intelligent Store™
Discus® Supply Voltage
(Module Power)
24 volts AC
Class II power supply
Pilot Circuit Voltage
(Contactor Output)
24 volts AC
(supplied by Intelligent Store
Discus 2.0 to the pilot relay, or
contactor)
Crank Case Heater
voltage supply
115/208/230 per customer
specification
Compressor Motor
Model Dependent
Head Fan
Per OEM Wiring
© 2008 Emerson Climate Technologies
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Figure 2.1 Terminal Box Connections
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2.2.1 Current Sensing Module
2.3 Controller Requirements
All Intelligent Store Discus™ 2.0 compressors use a
current sensing module in the terminal box. 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.
The control network utilizes an open Modbus for
Intelligent Store protocol. Rack controller manufacturers
may develop equipment to interface with and control
Intelligent Store Discus 2.0 compressors. For NonEmerson Retail Solutions products, consult with
the controller manufacturer regarding controller
compatibility with Intelligent Store Discus 2.0.
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.
For the Emerson Retail Solutions E2 controller, it
must be equipped with an Emerson Retail Solutions
Intelligent Store Discus Network Interface Board
(Emerson Retail Solutions part number 637-4890).
The controller firmware must be revision level
2.60F01 or higher.
Refer to Figure 2.2 for current sensing module lead
connections.
Refer to Emerson Retail Solutions E2 RX Refrigeration
Controller manual 026-1610 for detailed information
regarding the Intelligent Store Discus compatible rack
controller.
2.2.2 Fan Connections
• Intelligent Store Discus 2.0 compressors are not
shipped from the factory with fans installed. OEM
installation of fans should follow established
regulatory, OEM engineering and end user
specifications regarding wiring.
2.4 Communications Network
The Intelligent Store Discus and rack controller
communicate with each other using Modbus for
Intelligent Store communications protocol. The wiring
network uses RS485 hardware connections at each
node. The Intelligent Store Discus communication
cable terminates in the rack controller at an interface
card and is routed to each compressor in a daisy-chain
• Head fan requirements for Intelligent Store Discus
2.0 compressors are identical to other Discus®
compressors. Refer to Application Engineering
Bulletin 4-1135.
Sensor Module Connections
Figure 2.2 Current Sensing Module Wiring
© 2008 Emerson Climate Technologies
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Figure 2.5
RS-485 Daisy-Chain
Configuration
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Figure 2.7
Two Rack Daisy-Chain
Figure 2.6
Intelligent Store Discus Network Interface Board
format. Refer to Figures 2.5, 2.6 and 2.7.
One E2 controller can control two racks. One daisy
chain may be used for 2 racks, but two RS-485
connections are available on the Network Interface
Board if two parallel daisy-chains are preferred. The
Intelligent Store Discus Network Interface Board is
shown on Figure 2.6
The shield wire is connected to the center terminal,
or “0 volt” position. Refer to Section 6.15 for voltage
specifications and troubleshooting.
2.5.1 RS485 Communication Wiring Types
One E2 controller can control 4 suction groups, with up
to 16 stages in each suction group.
2.5 Network Terminations and Cable Routing
Each compressor (network node) has a jumper that
must be positioned to define whether or not the node
is in the middle or end of the daisy-chain. The last
compressor in the daisy-chain is “terminated” and the
jumpers must be set accordingly. The E2 jumpers
on the Network Interface Board are always set for
“terminated” (refer to Figure 2.6).
Figure 2.8
Communication Wiring and Jumper Positions
The communications wire to the compressor may be
routed into the rear of the side conduit (2D / 3D) and
along the channel which leads into the control module.
The 4D and 6D wire routing can be alongside the wire
harness and into the control module.
Appropriate use of strain reliefs will prevent damage to
the circuit board connector in the event of an accidental
mechanical load to the communication wire. Note that
the rear of the 2D / 3D conduit contains a tie-wrap
feature for anchoring the communication wire. Refer
to Figure 2.9 for photos of wire routing.
Important ! Note that the RS485 is polarity sensitive.
“Pos” wires must connect to other “Pos” terminals, and
“Neg” wires must connect to other “Neg” terminals.
© 2008 Emerson Climate Technologies
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Figure 2.9 2D / 3D Communication Wire Routing
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A shielded, twisted pair cable such as Belden #8761
(22AWG) should be used for the communication
wiring.
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2) Communication Wiring
Connect the Intelligent Store Discus 2.0 control
modules to the rack controller by configuring
the RS-485 communications network. The
communication cable terminates in the rack
controller on the Network Interface Board, and is
routed to each of the compressors in a daisy-chain
format. For communications to function properly the
termination jumpers at the rack controller and each
module should be set according to their position
in the chain. The end devices (including the rack
controller) should be set to the terminated position.
The devices in the middle of the chain should be set
to unterminated. The Intelligent Store Discus 2.0
control modules have the ability to communicate
to E2 or non-E2 rack controllers. Set the controller
jumper accordingly. Refer to Figure 3.0 below to
locate the position of the termination and controller
jumpers on each control module. For a complete
description of the communications network refer
to Section 2.4. For details on troubleshooting
problems with the communications network refer
to Section 6.15.
Refer to Sections 3, 4, 6 and 7 of this document
for commissioning, service and troubleshooting
instructions.
2.7 Compatibility of Service Compressors
The following S/Ns may be used to determine whether
service compressors are compatible with Intelligent
Store Discus hardware and accessories:
S/N 04D
S/N 04D
S/N 05D
S/N 05D
2.8 Intelligent Store Discus 2.0 Model Numbers
Factory built Discus® compressors with an S/E (the
last 3 digits in the model number) beginning with “A”
are Intelligent Store Discus 2.0 compressors. The
number defines the service valve configuration as well
as crank case heater presence and voltage.
3) Verify DIP-Switch Settings
Intelligent Store Discus 2.0 devices are equipped
with a DIP switch to set the node address. In
addition, this DIP switch determines the baud rate,
parity, control mode, and failsafe settings of the
module. Refer to Figure 3.0 below for details:
3.0 Intelligent Store Discus 2.0 Quick Start Guide
1) Module Power
Apply power to the Intelligent Store Discus 2.0
sensor modules located in the compressor terminal
box. Power requirements for the Intelligent Store
Figure 3.0 Control Module Instruction Label
© 2008 Emerson Climate Technologies
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Discus 2.0 modules is a 24VAC supply provided by
a class II transformer. For additional information on
transformer selection including VA requirements
refer to Appendix C of this document.
2.6 Intelligent Store Discus™ 2.0 Service
Instructions
2D built on or after
3D built on or after
4D built on or after
6D built on or after
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4.0 Intelligent Store™ Discus® 2.0 Commissioning
Procedure
As with other devices, the Intelligent Store Discus™
2.0 modules must first be commissioned to establish
communications with the rack controller. During
the commissioning process the E2 will recognize
the Intelligent Store Discus 2.0 modules in order as
designated by the node address settings on the module
DIP switches.
Important Note: The following commissioning
instructions pertain to E2 controllers with version
2.60F01 or later firmware. If you have an earlier
version of firmware we recommend that you upgrade
to the latest version available.
To determine the firmware revision level in the E2
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follow these steps:
1. From the main menu select 7 (System
Configuration)
2. Press 3 (System Information)
3. Press 4 (Firmware Revision)
The E2 should look like Figure 4.1.
4.1 Dip Switch Configuration
Intelligent Store Discus 2.0 devices are equipped with
a DIP switch to set their node address. In addition, this
DIP switch determines the baud rate, parity, control
mode, and failsafe settings of the module. Refer to
Figure 4.2 below for details:
To ensure proper communications, follow these steps
(refer to Figure 4.2 for further details):
1. Each Intelligent Store Discus device that is
connected to a rack controller should have a
unique node address (as determined by the DIP
switch settings).
2. The communications jumper should be set for
E2 communication if connected to an E2 rack
controller.
3. The last Intelligent Store Discus device in the
daisy-chain should have the communication
jumper in the “terminated” position. In addition,
the E2 should have the communication jumpers
in the “terminated” position.
4. The parity for each of the Intelligent Store Discus
devices should be set to none. This can be
accomplished by setting DIP switch number 8 to
the down position.
Figure 4.1 Firmware Revision
Figure 4.2 Control Module Instruction Label
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5. The baud rate for each of the Intelligent Store
Discus™ devices should be set according to the
rack controller. To determine the baud rate in the
E2, follow these steps:
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Enter the number of Intelligent Store Discus devices
under ECT Devices (Intelligent Store Discus 2.0).
To establish communications with the new devices
follow these steps:
a. From the main menu select 7 (System
Configuration)
1. From the main
Configuration)
b. Press 3 (System Information)
c.
T
menu
select
7
(System
2. Press 7 (Network Setup)
Press 1 (General Controller Info)
3. Press 3 (Controller Setup)
d. Access the Serial Communications Tab by
pressing CTRL + 3
The E2 should look like Figure 4.5 below.
4. Highlight the appropriate Intelligent Store Discus
device and press F4: Set Address
e. Use the Page Down button or scroll down to
view the settings for COM4
5. Press 3 (Scan Network for ECT Devices). You
will be prompted to enter the starting and ending
The E2 should look like Figure 4.3 below.
Be sure that the DIP switch settings on each module
for the Intelligent Store Discus devices match the
settings for COM4.
4.2 Network Setup
Once the DIP switch settings have been verified for
each Intelligent Store Discus module, you will need to
establish communications with the new devices. Begin
the network setup by following these steps:
1. From the main
Configuration)
menu
select
7
(System
2. Press 7 (Network Setup)
3. Press 2 (Connected I/O Boards and Controllers)
The E2 should look like the Figure 4.4.
Figure 4.4 Connected I/O Devices Screen
Figure 4.3 Serial Communications Setup Screen
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Figure 4.5 Controller Setup Screen
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addresses. The starting address should be 1 and
the ending address should be equal to the number
of Intelligent Store Discus™ units connected to
the rack controller.
6. Press Enter
7. The E2 will locate all of the Intelligent Store
Discus devices and order them according to the
node addresses of their respective DIP switches.
8. Once the scan is complete the E2 should
display a message of: Scan Complete No Errors
Encountered. If any errors are displayed, refer to
Section 6.15 of this manual for details regarding
the communications network.
Notice that once the commissioning process has
been completed, the Identifier column will now show
each compressor serial number. To further verify that
the Intelligent Store Discus units are communicating
properly you can check the online status of the modules
by following these steps:
1. From the main
Configuration)
menu
select
7
(System
2. Press 7 (Network Setup)
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3. Press F4 (Lookup) and select Enhanced Suction
Group from the option list.
4. Enter the number of suction groups controlled by
this E2.
5. When prompted by the E2 to edit the application,
Press Y for yes.
This will open the suction group setup screen as shown
below in Figure 4.7.
From this screen you can edit the name of the suction
group, select the control type, and enter the number of
stages. The number of stages can be determined as
follows:
•
In order for the E2 to control compressor operation the
proper input and output values must be entered into
the system. This is accomplished by creating a suction
group application in the rack controller. Programming
N
2. Press 1 (Add Application)
•
4.3 Enhanced Suction Group Setup
I
From the Main Menu:
1. Press 6 (Add/Delete Application)
•
The E2 should look like Figure 4.6 below.
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of the suction group will depend upon the system
as well as the options desired by the end user. The
following section covers the steps necessary to setup
the sample rack shown in Figure 4.8 on the following
page.
•
3. Press 1 (Online Status)
A standard compressor (no unloader) will count
as one stage.
A compressor equipped with digital unloading will
count as one stage.
A compressor with one bank of standard unloading
will count as two stages.
A compressor with two banks of standard
unloading (6D only) will count as three stages.
To continue the suction group setup process:
1. Press F2 (Next Tab) until the Stage Setup screen
Figure 4.7 Enhanced Suction General
Setup Screen
Figure 4.6 Online Status Screen
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is displayed.
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Intelligent Store Discus™ device must be associated
with its appropriate suction group. To make these
associations, follow these steps:
2. Under Type, select Comp for compressor, Unld
for unloader, or Dgtl for digital.
3. Under HP/Amps enter the compressor horsepower
for each stage.
1. From the main
Configuration)
menu
select
7
(System
2. Press 7 (Network Setup)
Note: For a compressor equipped with an unloader
(blocked suction or Moduload, but NOT digital) the
horsepower should be divided between the compressor
and unloader stages. A compressor with an unloader
can be considered to be two different compressors
from a control standpoint. When the suction group
status screen shows the unloader to be “OFF” and
the comp (compressor) to be “ON’, the compressor
is running “unloaded”, i.e. the unloaded portion of
the compressor is not contributing to generation of
capacity. If the comp and unloader are both “ON”, the
compressor is running at full capacity.
3. Press 5 (Controller Associations)
4. Press 4 (Intelligent Store Discus Compressor)
The E2 should look like Figure 4.9 (on following
page.)
Select the appropriate suction group next to each
Intelligent Store Discus device. (Note that the use of
an Enhanced Suction Group is necessary when using
Intelligent Store Discus.) Then enter the appropriate
stage numbers. The example in Figure 4.9 shows
five compressors with a selection of standard, blocked
suction and digital unloading.
When these steps have been completed, the
compressor setup screen(s) should look like Figure
4.8 below.
4.5 Proofing
4.4 Associations
Also located on the Intelligent Store Discus
Associations Screen are the settings for compressor
In order the provide compressor control, each
Figure 4.8 Enhanced Suction Stage Setup Screen(s)
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system charging may be accomplished by supplying
pilot circuit power to the Intelligent Store Discus
compressor with the rack controller OFF. After 5 minutes
the Intelligent Store Discus will send a run command to
the contactor/pilot relay. Compressors with power to
the contactors will then RUN with protection features in
place (e.g. suction and discharge pressure, discharge
temperature, motor protection).
Figure 4.9 Intelligent Store Discus
Associations Screen
proofing. Proofing verifies that the compressors are
turning ON and OFF as commanded by the suction
group requirements. With proofing enabled the rack
controller compares the digital command sent to the
Intelligent Store Discus™ module with a digital output
from the module. If the two values are not equal for
an amount of time longer than the programmed proof
delay, the rack controller will display a Proof Fail
condition for that module. The rack controller will
deactivate the Proof Fail once the module proofing
output matches the command from the E2.
To configure proofing simply highlight the appropriate
cell under the Proof column. Use the Previous/Next
buttons on the E2 to toggle between the YES and NO
settings. The rack controller will make the necessary
associations between the module and suction group.
While running in failsafe mode the compressor will
continue to run until either a fault occurs or until
communications is re-established with the rack
controller. This is to say that the only system controls
in place to cycle the compressor are the high and low
pressure safety controls. The trip/reset values for the
high and low pressure controls are 360/250psi and
3/10psi respectively. While it is not recommended to
run the compressors in failsafe mode for long periods,
it may be desirable to use adjustable low pressure
cutouts to stage the compressors. This will allow for
finer compressor control over the fixed value switch.
To apply an adjustable pressure cutout you may simply
wire it in place of the existing pressure switch.
4.7 Intelligent™ Store Discus® 2.0 Setup Screens
To access the configuration screens for the ISD
modules follow these steps:
1. From the main menu press 5 (Configured
Applications)
2. Press 104 (ISD 2.0)
3. Highlight the desired ISD device and press F5
(Setup)
The E2 screen should look like Figure 4.10 below:
4.6 Failsafe
The compressor failsafe mode may be configured by
setting the number 10 DIP switch located on each
Intelligent Store Discus control module. With the switch
in the up position the compressor will be set for failsafe
ON in the event that communications with the rack
controller is lost for 5 or more minutes. If the switch
is in the down position the compressor will be set for
failsafe OFF. Keep in mind that once a DIP switch
setting is changed, a reset of the control module
is required for the control module to recognize the
change.
The default setting for all Intelligent Store Discus
compressors leaving the Copeland factory is failsafe
“ON”. If the rack has not yet been commissioned,
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Figure 4.10 ISD Setup Screen (General Tab)
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On the General tab the device name is displayed. The
default naming convention is shown as the device
type (ISD2) followed by the device number (equal to
the node address). If it is desired to have the device
renamed in terms of the suction group for easier
identification simply type over the default information
using the E2 keypad. Note that the name is limited
to 14 characters. If additional characters are needed,
information may be entered in the cell next to Long
Name.
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4.9 Crankcase Heater Control
The parameter labeled ISD CCH control determines
whether the heater is to be controlled by the module
or by an external means such as an auxiliary contact.
Setting this value to “enabled” allows the heater to be
controlled by the Intelligent™ Store Discus® module.
The parameter labeled Crankcase Algorithm determines
how the Intelligent Store Discus module will control the
switching of the heater. With this parameter set to
continuous, the heater will be activated any time that
the compressor is OFF. This operation is the same
as if the heater were controlled by a set of auxiliary
contacts
To access additional configuration settings for the
module Press Ctrl+2 to navigate to the Setup tab.
The E2 screen should look like Figure 4.11.
4.10 Anti Short Cycle
The parameter labeled Anti Short Cycle determines
the minimum off time for compressors before they
restart. This value is set to reduce the number of start/
stop cycles on the compressor. The default value is
0.1 minutes or 6 seconds. This value may be set from
0.1 to 2 minutes.
4.11 MCC Value
The parameter labeled MCC Value is the maximum
continuous current for the compressor. This value
is set to provide additional motor protection for the
compressor. This value is programmed based upon
the current requirements of each compressor model.
(For dual voltage motors, the MCC value will be set
to the 460 volt value. If the compressor is run at a
different voltage the MCC value may be adjusted
accordingly).
Figure 4.11 ISD Setup Screen (Setup Tab)
The parameters that can be set from this screen
include:
unloaders
crankcase heater control
anti-short cycle time
maximum continuous current (MCC)
compressor voltage
compressor frequency
language
voltage imbalance
4.12 Compressor Voltage
The value for compressor voltage is preloaded at the
factory. If the compressor is to be operated at a voltage
other than the value listed, the proper voltage must be
entered into this field.
4.13 Compressor Frequency
The value for compressor frequency is preloaded at
the factory. If the compressor is to be operated at
a frequency other than the value listed, the proper
frequency must be entered into this field.
4.8 Unloader Configuration
The unloader configuration settings are preloaded
at the factory and will match the requirements of the
compressor. The settings for Unloader Mod Type are
for digital unloading only. For compressors without
unloading or with non-digital unloading the Unloader
Mod Type should be set to None.
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4.14 Language
The LCD display on the Intelligent Store Discus control
module can be set to display messages in multiple
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languages. The available options are English, Spanish,
Portuguese, French and German.
4.15 Voltage Imbalance
The voltage imbalance setting determines the
maximum percentage of voltage imbalance on the
three compressor phases. If the measured voltage
exceeds the imbalance setting, the module will alarm
and shut down the compressor. The default setting for
this parameter is 5%.
4.16 Inputs
The compressor input values for each module are
located on the Input tab. To navigate to this screen
press Ctrl+3.
Figure 4.13 ISD Setup Screen (Outputs Tab)
The E2 should look like Figure 4.12.
commissioning process. This takes place when the
compressor associations are made. Refer to Section
4.4 of this document for additional details concerning
this process.
4.18 ID Configuration
The ID Config tab contains information about the
compressor identification such as the model and serial
number. To navigate to this screen press Ctrl+7.
The E2 should look like Figure 4.14.
It also contains additional fields for Customer ID,
Customer Name, and Location. These fields are
provided for the end user and are meant to be populated
during the commissioning process. This identification
Figure 4.12 ISD Setup Screen (Inputs Tab)
The input values as shown are automatically mapped
by the E2 during the commissioning process. This
takes place when the compressor associations are
made. Refer to Section 4.4 of this document for
additional details concerning this process.
4.17 Outputs
Similarly, the compressor output values for each
module are located on the Output tab. To navigate to
this screen press Ctrl+4.
The E2 should look like Figure 4.13.
As with the input values, the output values as shown
are automatically mapped by the E2 during the
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Figure 4.14 ISD Setup Screen (ID Config Tab)
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information can be useful when performing remote
compressor diagnostics.
As with other alarms in the E2, the alarms associated
with the Intelligent™ Store Discus® compressors
can be programmed for different levels. To view the
alarm settings navigate to the Alarms tab by pressing
Ctrl+8.
The E2 screen should look like Figure 4.15.
Figure 4.16 ISD Summary Screen
select the desired device using the arrow key and
press “Enter”.
The E2 screen should now look like Figure 4.17.
Figure 4.15 ISD Setup Screen (Alarms Tab)
Use the Previous/Next buttons on the E2 to scroll
through the various settings of:
Alarm
Failure
Notice
Disabled
4.19 Intelligent Store™ Discus® 2.0 Navigation
To access information from the Intelligent Store Discus
2.0 modules using the E2 rack controller follow these
steps:
Figure 4.17 ISD Compressor Information Screen
1. From the main menu select 5 (Configured
Applications)
2. Press 104 (ISD 2.0)
This screen provides additional compressor information
such as the model and serial number. It also provides
run history information such as compressor run time
and the number of compressor starts. If the compressor
is equipped with unloaders the unloader run time will
also be displayed. For more detailed information
about each compressor highlight the compressor
name as shown on figure 2.0 and press Enter. Press
6 (Detailed Status).
The E2 should look like Figure 4.16.
This screen provides a general summary of all ISD
devices that are connected to the rack controller. It
gives information on the run status as well as more
detailed information such as the discharge temperature
and current draw of each compressor. This screen
also shows the status of the device such as whether it
is online or alarming. To view additional information,
© 2008 Emerson Climate Technologies
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The E2 screen should look like Figure 4.18 (on the
following page.)
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navigate to the History tab by pressing Ctrl+6.
The E2 screen should look like Figure 4.20.
Figure 4.18 ISD Detailed Status Screen
(Inputs Tab)
There are many useful screens located in the detailed
status area. To monitor the status of the compressor
motor, navigate to the Windings tab by pressing
Ctrl+5.
The E2 screen should look like Figure 4.19.
Figure 4.20 ISD Detailed Status Screen
(History Tab)
While basic compressor information such as run hours
is listed on the ISD summary screen, the history screen
includes additional information such as a short cycle
counter and low oil run time. This information can be
useful in diagnosing compressor issues.
In addition to compressor run history, the Intelligent™
Store Discus® 2.0 module also retains a history log of
the most recent alarms. To access this information,
press Ctrl+8.
The E2 screen should look like Figure 4.21.
Figure 4.19 ISD Detailed Status Screen
(Windings Tab)
This screen shows the current draw of the motor and
the voltage at each compressor terminal. In addition,
the starting current is shown as Locked Rtr Cur.
(Note: This value is the first cycle peak current and
will be slightly higher than the published steady state
RMS locked rotor value). Power factor and power
consumption are also listed.
For more information on the compressor run history
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Figure 4.21 ISD Detailed Status Screen
(Alarm History Tab)
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The screen will display the last ten alarms that have
occurred with alarm number one being the most
recent. To determine the time at which a particular
alarm has occurred, consult the E2 alarm screen which
will display a time stamp of each event.
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in a table format with an indication of whether the event
has occurred. The columns labeled 1 through 8 at the
top represent days of the week with number 1 being
the current day of operation. In addition, the count column serves as a running counter of each alarm since
the device has been commissioned. In the event that
a compressor needs to be replaced, this history information will be zeroed when a new compressor Identification Module is connected.
For a running count of all ISD related events and
alarms press Ctrl+9 to access the Alarm Table tab.
The E2 screen should look like Figure 4.22.
5.0 Stand-Alone Installation and Operation
The screen will display each of the ISD related events
A Stand-Alone control configuration has been
established to allow control of the compressor
contactor and unloader(s) in a condensing unit or
other application when the network mode is not used.
Control of the contactor and unloader is through a
24 volt AC signal supplied to spare leads inside the
terminal box.
Please refer to Figure 5.1 of the wiring diagram that
shows the 24 volt power supply and the stand-alone
input connections. It is important that the 24 volt signal
to the input leads comes from the same leg of the
transformer as the left-hand side sensor module power
lead. There is no danger or risk of electrical damage
if the input comes off of the other transformer leg, but
the input demands will not function.
Note that the dipswitch settings must be set for “Stand
Alone” control. Dipswitch #9 must be “down” to enable
stand alone input. Note that a change in the dipswitch
position will not be seen by the control module unless
Figure 4.22 ISD Detailed Status Screen
(Alarm Table Tab)
Demand input Orange
Unloader 2 input Violet
Unloader 1 input Yellow
Class II 24
VAC Power
Supply
● ●
●
Demand (on-off) and
Unloaders are from the
Power Leg that Connects
to the Connector Tab on
the Left Side
Harness to
Control
Module
24V Power Black
24V Power White
Terminal Box
Figure 5.1 Stand-Alone Input Power Supply
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the “reset” button has been pushed after the dipswitch
is repositioned.
•
A 24 volt signal to the demand input will turn the
compressor “on”.
•
A 24 volt signal to the unloader will energize
the unloader (energizing the unloader reduces
compressor capacity.)
•
Failsafe operation is not enabled when in standalone mode.
Stand-alone operation may be enabled for service
reasons even if a communication network is used.
Communication of information is not affected by
operation in the stand-alone mode. To convert back
to Network mode, the reset button must be pushed
for the control module to recognize the new dipswitch
position.
6.0 Compressor Status Codes
The control module of the Intelligent Store Discus™
2.0 has a LED & LCD to display the compressor status.
The bicolor LED provides basic diagnostics to aid in
troubleshooting of the system or compressor.
•
Steady Green: An indication of normal operation.
There are no faults or issues with the compressor.
•
Flashing Green: An indication that there is a warning
condition. The compressor can still be running.
•
Flashing Red: An indication that the compressor
has tripped or is in lockout state.
•
Solid Red: An indication that the control module
has failed.
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display, meaning that multiple events may occur at
the same time and the highest priority event will be
displayed on the LCD screen and on the E2 screen.
This priority is in general a function of how critical the
fault is. Lockouts have priority over trips, and trips
have priority over warnings. The lowest priority events
are those that are considered “normal” conditions.
The table includes not only the description of the event
but also the display text and the corresponding LED
behavior on the front of the control module. Without
having to activate the LCD display (by pushing the
“display” button), the LED will convey the compressor
status: lockout or trip (flashing red), warning (flashing
green), or normal (steady green).
After a trip occurs the compressor will run when the
condition that leads to the trip is cleared. Many of the
trip conditions have a minimum off-time associated
with them (i.e. if the condition clears itself very quickly,
the minimum off-time requirement must still be satisfied
before the compressor will run). This minimum off-time
is listed in the last column of the table below.
Between normal run cycles and after trips the antishort-cycle time delay must also be satisfied. By
default this setting is 0.1 minutes (6 seconds). If the
minimum anti-short-cycle delay (ASCD) controls the
start of the compressor there will be an additional
delay of 0.1 seconds x the node number (e.g. node #7
will have a delay of 0.7 seconds). The purpose of this
feature is to prevent compressors from starting at the
same time, thereby significantly reducing the electrical
in-rush that the main bus will see.
6.2.2 LED Interpretation
6.1 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 NOT
be available to run when the fault condition has
been cleared until the reset button is pushed or
a remote reset has been activated or the module
has been power cycled.
6.2 Event Priority and Troubleshooting
6.2.1 Event Priority and Anti-Short-Cycle Delay
To aid with the troubleshooting process, the event
priority table is shown below. There is a hierarchy of
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There are two surface mount LED’s beside the RS485
communication connector on the control module.
These are useful when diagnosing communication
issues between the rack controller and the control
module.
The left side LED is amber and indicates the receipt
of a communication transmission. The right side LED
is red and indicates a transmission from the control
module to rack controller.
There is a bi-color LED in the sensor module that is
green when power is available, and flashes red when
there is an alarm condition associated with a condition
that is sensed by the sensor module.
Refer to Figure 6.1 on following page for a description
of the functionality of each module.
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Module Function Architecture
Sensor Module
Advanced Motor Protection
• Locked Rotor
• Missing Phase
• Current Overload
• Voltage Imbalance
• Low Motor Voltage
• Part Winding Start
Monitor
• Welded Contactor
Detection
Crank Case Heater Control
Voltage Sensing
Control Module
Controller Communications
Sensor Module Communications
Contactor Operation
Unloader Operation
Motor Temperature Protection (4D/6D)
Pressure Switch Status
Discharge Temperature
Oil Pressure Protection
Supply Voltage Protection
Configuration Settings
Model Number
Operating History
Module to Module
Communications
Current Sensing
Module
Current Measuring
Figure 6.1
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6.3 Event Priority Table
Control module
LCD Display
Control module
LED
Delay Time
Control module failure
“Control Module”
“Failure Lockout”
Solid RED
NA
Lockout
Repeated Phase loss for 10
times
“Phase Loss”
“Lockout”
Flashing RED
NA
3
Lockout
Repeated locked rotor for 10
times
“Locked Rotor”
“Lockout”
Flashing RED
NA
4
Lockout
Contactor coil over current
“Contactor Coil“
“Lockout”
Flashing RED
NA
5
Lockout
Discharge temperature lockout
“Discharge Temp”
“Lockout”
Flashing RED
NA
6
Lockout
Discharge pressure lockout
“High Discharge”
“Pressure Lockout”
Flashing RED
NA
7
Lockout
Low Oil Pressure lockout
“Low Oil Pressure”
“Lockout”
Flashing RED
NA
8
Lockout
Repeated Part Winding trip
for 10 times
“Part Winding”
“Lockout”
Flashing RED
NA
9
Lockout
Disabled by rack controller
“Rack Controller”
“Lockout”
Flashing RED
NA
10
Trip
High discharge pressure
“High Discharge”
“Pressure Trip”
Flashing RED
ASCD
11
Trip
Motor Temp Sensor Trip
“Motor Temp Trip”
“Control module”
Flashing RED
Max of ASCD and 2 min
12
Trip
Phase loss trip
“Phase Loss Trip”
Flashing RED
Max of ASCD and 5 min
13
Trip
Locked Rotor Trip
“Locked Rotor”
“Trip”
Flashing RED
Max of ASCD and 5 min
14
Trip
Welded Contactor Warning
“Welded Contactor”
“Warning”
Flashing RED
NA
15
Warning
Low Suction Pressure
“Low Suction”
“Pressure Trip”
Flashing Red
ASCD
16
Trip
Voltage Imbalance
“Voltage“
“Imbalance Trip”
Flashing RED
Max of ASCD and 5 min
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Trip
Current Over load trip
“Current Overload”
“Trip”
Flashing RED
Max of ASCD and 5 min
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Trip
No 3-phase compressor power “No 3-Phase Power”
“Trip”
Flashing RED
NA
20
Trip
Current Overload
“Current Overload”
“Trip”
Flashing Red
Max of ASCD and 5 min
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Trip
Part Winding Start Failure
“Part Winding”
“Trip”
Flashing RED
Max of ASCD and 5 min
22
Trip
Module Supply voltage Trip
“Module Low”
“Voltage Trip”
Flashing RED
ASCD
23
Trip
Compressor low voltage trip
“Compressor Low”
“Voltage Trip”
Flashing RED
Max of ASCD and 2 min
Priority Type
Event
1
Lockout
2
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
22
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AE8-1351
Control module
LCD Display
Control module
LED
Delay Time
Compressor brown-out trip
“Power Brownout”
“Trip”
Flashing RED
ASCD
Trip
Discharge temperature trip
“Discharge Temp”
“Trip”
Flashing RED
Max of ASCD and 2 min
26
Warning
Loss of communication
between control module& E2
“No Communication”
“Failsafe ON” (or OFF)
Flashing
GREEN
NA
27
Warning
sensor module failure
“Sensor Module”
“Failure”
Flashing
GREEN
NA
28
Warning
Loss of Communication
(control to sensor module)
“No Communication”
“To Sensor module”
Flashing
GREEN
NA
29
Warning
Failed compressor ID module
“Compressor ID”
“Module Failed”
Flashing
GREEN
NA
30
Warning
Connection lost between
compressor ID module &
sensor module
“Connection Lost”
“ID To Sensor”
Flashing
GREEN
NA
31
Warning
Low oil pressure warning
“Normal Running”
“Low Oil Pressure”
Flashing
GREEN
NA
32
Warning
Connection lost between CT & “Connection Lost”
sensor module
“CT To Sensor”
Flashing
GREEN
NA
33
Warning
Unloader2 over-current
warning
“Normal Running”
“Unloader1 Short”
Flashing
GREEN
NA
34
Warning
Unloader2 over-current
warning
“Normal Running”
“Unloader2 Short”
Flashing
GREEN
NA
35
Warning
Unloader1 open circuit
“Normal Running”
“Unloader1 Open”
Flashing
GREEN
NA
36
Warning
Unloader1 open circuit
“Normal Running”
“Unloader2 Open”
Flashing
GREEN
NA
37
Warning
Open Thermistor
“Normal Running”
“Fault Temp Probe”
Flashing
GREEN
NA
38
Warning
Unloader2 over-current
warning
“Normal Off”
“Unloader1 Short”
Flashing
GREEN
NA
39
Warning
Unloader2 over-current
warning
“Normal Off”
“Unloader2 Short”
Flashing
GREEN
NA
40
Warning
Unloader2 open circuit
“Normal Off”
“Unloader1 Open”
Flashing
GREEN
NA
41
Warning
Unloader2 open circuit
“Normal Off”
“Unloader2 Open”
Flashing
GREEN
NA
42
Warning
Open Thermistor
“Normal Off”
“Fault Temp Probe”
Flashing
GREEN
NA
43
Normal
Normal Run
“Normal Running”
Solid GREEN
NA
44
Normal
Normal Off
“Normal Off”
Solid GREEN
NA
45
Normal
Anti Short cycle timer running
“Anti short cycle”
“Time XX.X m Left”
Solid GREEN
NA
Priority Type
Event
24
Trip
25
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
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False motor trips or lockouts:
6.4 Emergency Work-Around Procedures
In the event that a compressor fails to run due to an
electronic module failure, the following work-around
procedures are listed to assist the technician with
gaining temporary control of the compressor until
replacement parts may be obtained. The situations
listed below will not compromise the fundamental safe
operation of the compressor or agency listed motor
protection features. There will be some increased risk
of compressor damage associated with the loss of the
module’s functionality. The service technician must
determine whether the risks of temporarily running the
compressor in this situation are warranted.
Refer to the troubleshooting charts in the following
sections before resorting to these emergency service
options.
Controller fails to call the compressor “on” but
network communication is active:
Unplug the RS485 connector at the control module.
Set the “failsafe” dipswitch to the “run” position and
then press the control module “reset” button. After 5
minutes the compressor will run in the failsafe mode.
Pressure switch and motor protection features will
still function.
Failed discharge temperature probe resulting in
false discharge temperature trip:
Unplug the discharge temperature probe. This will
generate “Fault Temperature Probe” warnings but
will not prevent the compressor from running.
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
E
24
Faults that are associated with the sensor module
or current sensing transducer (see Figure 6.1
above) are advanced protection features beyond
the basic motor temperature or current limiting
protection available on all discus compressors. If
troubleshooting leads to the conclusion that the
trips or lockouts are false, the sensor module
communication harness may be unplugged from
the control module. This will generate a “no
communication to sensor module” warning but will
allow the compressor to run. If the sensor module
communication is unplugged - all of the advanced
motor protection features will be bypassed. If the
problem is associated with the Current Sensing
Module itself, this may be unplugged from the
sensor module leaving fundamental communication
between the sensor and control module intact.
Emergency By-Pass Procedure:
Refer to Section 6.14; Fail-Safe Inoperable.
Application Engineering
B
6.5
U
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Normal Running
Has the rack controller
issued a run command?
No
Communications
Delay of several
seconds between E2
screen and compressor
response
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
T
25
Yes
Normal Operation
AE8-1351
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AE8-1351
Normal - OFF
6.6
Is the compressor OFF?
L
Yes
Has the rack controller
issued a run command?
No
Yes
Has the contactor been
manually closed ?
Does the rack controller
show a status code of “No
Communication to Control
Module”?
Yes
No
Normal Operation. A run
command has not been
issued by the rack controller .
The module does not detect
a running compressor when
the contactor is manually
closed.
A communication delay of
several seconds is normal
between the display
status and the
compressor status
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
26
No
Yes
Normal Operation. A
run command has not
been issued by the rack
controller
Normal Operation. The module
has gone into “loss of
communications” mode and the
failsafe setting is “off”. Refer to
secion 6.16 for communications
troubleshooting.
Note: After every shut-down, there is a predetermined off-time before the compressor
is allowed to run again. This is shown as
“Anti Short Cycle Time xx.x Left” The
default setting is 0.1 minutes, configurable
through the setup option for each
compressor (see “Configured Applications”
on the E2 menu).
Application Engineering
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Forced Run
Welded Contactor Warning
6.7
Note: An open high or low pressure
switch will interrupt the welded
contactor protection feature by opening
the contactor circuit
Throw the compressor
motor breaker to shut
down the compressor
Note: Welded Contactor looks for the presence of motor
voltage after the command to “open” the contactor has been
sent. The E 2 will re-load the contactor to prevent single phase damage to the motor.
Clear the welded
contactor alarm in the
E2
Three scenarios can generate symptoms of a welded
contactor: 1) A welded or sticking contactor, 2) A welded or
sticking pilot relay or 3) A welded or sticking relay switch onboard the control module.
Measure voltage at the
contactor or pilot relay
coil (whichever is driven
by the output from the
ISD compressor)
Is voltage
present?
The following procedure may be followed to help diagnose
the problem .
Yes
Failed ISD control
module relay.
Replace control
module
No
Does relay or
contactor remain
stuck?
Yes
Replace the contactor
or relay that has failed
No
Intermittent weld of
contactor, pilot relay or
control module relay.
Replace component that
appears damaged or
continue to monitor closely
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
27
Application Engineering
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AE8-1351
6.8
Module Low Voltage Trip
Warning: The compressor power connections are high voltage. Disconnect power to
the compressor before accessing connections in the terminal box .
Normal Operation. Check the supply
voltage at the transformer. Correct the
low voltage condition. Voltage must be
above 16.5V for the Module to reset.
Replace the transformer if necessary.
Yes
Check the Sensor Module supply voltage at the
leads connected to the terminals labeled “24VAC
IN” in the t-box. Is the voltage below 16.5V?
No
Reconnect the sensor module power
leads. Check the voltage on pins 4 and
15 of the 18-pin AMP connector to the
control module. Is the voltage below
16.5V?
Yes
Check the pins in the AMP
connectors for proper
connection and be sure that
plugs are completely engaged
No
Check the continuity of the wires in the cable
harness from pins 4 and 15 of the 18-pin AMP
connector. Do the readings indicate a poor
connection or broken wire?
Yes
Replace
Wiring
Harness
Note: The 24VAC supply voltage to the control module is also used to provide power unloader coil (s) if present . In the
event of intermittent low voltage trips it may be helpful to check the transformer output voltage while overriding the
unloader coil ON with the rack controller. This can be done by forcing the unloader stage OFF.
If powering of the unloader coil (s) causes the supply power to the module to drop below 16.5V, check to be sure that
the transformer meets the proper VA requirements. Refer to Appendix C of this manual for information concerning
proper transformer selection.
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
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AE8-1351
Part Winding Trip / Lockout
6.9
This fault is enabled on part winding start compressors with two current sensing transducers. It is generated if after 2 seconds of
loading the first contactor current is not detected coming from the second contactor.
The trip will reset after 5 minutes and attempt to start again if demand is still present.
10 consecutive trips will generate a lockout. Reset the module to run the compressor.
Does each contactor have
a motor power lead going
to its own CT?
Re-route one of
the motor leads.
Each contactor
should have one
power lead going
to its own CT.
No
Yes
Troubleshoot cause of contactor
delay. Possible reasons:
1.) Breaker thrown
2.) Delay timer fault
3.) Contactor coil failure
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
29
Application Engineering
B
6.10
U
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AE8-1351
Connection Lost CT to sensor
CT is the Current Sensing Module (Current
Transducer), located in the terminal box. It is the
round “toroid” that one of the motor power leads
passes through.
Verify if the CT connector is
connected to the sensor module
No
Connect the 4 pin
Current Sensor
connector into the
sensor module
Yes
Is there continuity between pin 3 & 4
of the Current Sensing connector ?
The resistance should be less
than 1 ohm
No
Replace the Current
Sensing Module
Resistance across these pins is less than
1 ohm
Yes
When the compressor is
running, are Amps and Volts
correctly displayed on the ISD:
Details / Windings tab?
No
Faulty sensor
module or
connector misinstalled
Current Sensing Module connection
to Sensor Module
Current Sensing Module
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
30
Yes
Inspect the wire
harness connector
to assure that the
pins are fully
engaged
Application Engineering
B
U
6.11
L
L
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Rack Controller Lockout
Has the Module override
been manually set to “ON” in
the E2?
No
The E2 has sensed a
condition where it was
necessary to turn the
compressor(s) OFF.
Yes
Check the alarm screen
in the E2 to determine
why it has disabled the
compressors.
Determine Reason
E2 Override Set to
“On”
Correct Reason
and Set E2
Override to “Off”
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
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AE8-1351
Application Engineering
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AE8-1351
Fault Temperature Probe
6.12
The temperature probe is an “NTC” device . Its resistance increases with decreasing
temperature. This fault is generated by an “open” thermistor circuit, and as such will generate
a reading of a low temperature (-40F or +327 F with some versions of control module ). This
assessment is only made if the control module temperature is greater than -30F.
Normal Operation
Connect the
harness to the
temperature probe
No
Is the discharge
temperature probe
properly connected to the
harness?
Replace
temperature probe
Thermometer
Temp. (F°)
Yes
No
Calculated Sensor
Resistance (Ohms)
59
60.8
62.6
64.4
66.2
141426
135000
128907
123129
117639
68
69.8
71.6
73.4
75.2
112437
107478
102762
98289
94041
77
78.8
80.6
82.4
84.2
90000
86139
82476
78984
75663
86
87.8
89.6
91.4
93.2
72504
69480
66609
63864
61254
95
96.8
98.6
100.4
102.2
58770
56394
54126
51966
49914
104
105.8
107.6
109.4
47943
46053
44262
42543
Opened harness
circuit. Verify that
the harness is fully
engaged to the low
voltage connector
at the control
module. Perform
continuity check of
harness to isolate
fault. Refer to the
wiring diagram in
the appendix.
Unplug the
temperature probe
and check the
resistance of the
probe vs the
attached table
Does the probe indicate
the correct resistance?
(open resistance exceeds
2MΩ )
Yes
Temporarily “short”
across the sensor
connectors on the
harness. Do not
distort the connectors
when doing this.
Yes
Does the error code remain?
(a shorted probe will give a
reading of 327F)
No
Low Voltage Connector
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
32
Intermittent probe
failure, loose
connector pins or
intermittent
harness failure
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Fail-Safe Inoperable
6.13
The fail-safe feature exists for conditions involving the loss
of communication to the controller (wire failure, controller
failure, etc.). In the event of an electronics failure of the
control module, the use of an emergency jumper may be
used to force the compressor “on” while still utilizing the
high and low pressure switches on the compressor.
Connect the jumper between the contactor
connection that goes to the black contactor
output wire
When using this jumper , note that the following protection
features are bypassed at your own risk:
Connect the other end of the jumper to one
of the low pressure switch tabs . If the
compressor fails to run , reconnect the low
pressure switch wire and then connect the
jumper to the other tab
4D / 6D motor protection is disabled
Oil pressure protection
Discharge temperature protection
All protection features provided by the sensor module
Unloader operation
2D and 3D line-break protection is still operable with this
by-pass arrangement
Emergency By -Pass Jumper
Terminal Box
Demand input Orange
Unloader 2 input Violet
Unloader 1 input Yellow
Class II 24
VAC Power Supply
1
Oil
Pressure
Wiring Side
Views
Black
Or
Unloaders
Black
Or
Or
White
LPCO
HPCO
Jumper
Motor Sensors Not
on 2D / 3D
Emerg
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
33
1
Blue
Blue 2D / 3D only
Blue 2D / 3D only
Blue 2D / 3D only
Blue 2D / 3D only
Blue
Yellow
Yellow
Violet
Violet
24V Power White
S S S C
Contactor
3 2
RED
RED
24V Power Black
Contactor
Output
6 5 4
Blue
11
Disch
Temp
Probe
Application Engineering
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AE8-1351
Locked Rotor Trip / Lockout
6.14
A detected locked rotor condition (at start-up or while running) will shut the compressor off for
5 minutes. After 5 minutes, an attempt will be made to run again if demand is still present.
After 10 consecutive locked rotor trips , the control module will transition to a LOCKOUT
condition A reset is necessary in order for the module to run again.
If the compressor is locked out, RESET the module to enable it to run again.
Does the compressor appear
to start before the control
module shuts it down for
locked rotor?
No
Normal Operation
Perform normal locked
rotor diagnosis (voltage,
valve plate, etc)
Yes
Normal Operation
perform normal
locked rotor
diagnosis (voltage,
valve plate, etc)
Yes
Does the compressor continue
to draw high (above MCC)
current even though it
appears to start ?
No
Temporarily
disconnect the
communication
line to the sensor
module (at the
sensor module or
at the control
module)
Does the compressor start?
(unplugging the comm line
disables this protection
feature)
No
Yes
Note: This locked rotor value is the
peak locked rotor amperage
recorded for this start cycle. It will
typically be much greater than the
listed locked rotor value which is a
steady-state RMS value
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
34
Compare locked rotor
and running AMPS
history at the E2 for
this compressor vs
others. Suspect faulty
CT if values are not
reasonable and actual
values do not agree
with displayed values
Electrical or
mechanical fault
with compressor or
system
Application Engineering
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AE8-1351
No Communication
6.15
“No Communication” will be shown on the ISD display. It
will be seen in the E2 detail status screen as the ISD
Display Code, and the Network Status will be “Offline”.
After 5 minutes of no communication, the control module
of the compressor will revert to the Failsafe run state.
The control module must be “on” and
the RS485 connector must be plugged
in to the control module and to the E2
controller (see E2 connection in photo
on the right)
Yes
This flow chart assumes that the initial commissioning
process has been completed to establish the node on the
network.
Communication
Card and
Connector
Are termination jumpers
properly set (At compressor and
at E2)? Is Parity jumper “down”
for use with E2?
Yes
Does each compressor on the
network have a unique
address?
Yes
Look at amber LED on
the left side of the control
module RS485
connector
Are the amber lights
on all compressors
continuously on ?
No
Yes
With a common
transformer, left Yes
side power
connector tabs to
use a common
supply leg, and
each right tab to
use a common
supply leg (see
schematic below)
Yes
Is there 2.3 to 2.6 volts
at the control module
RS485 connector?
No
Comm Wire Fault
Plug in the interface
board connector.
Measure voltage at the
control module
connector
Verify that there are no
unfiltered variable
frequency drives that are
generating excessive
electrical noise
No
24 v
Sensor
Module
Sensor
Module
Figure 1.0
Fair-Rite Filter
Installed on RS-485
Communication Line
Polarity of power connections for common transformer
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
Yes
35
Correct the polarity
of the wires at the
RS485 connector
on this compressor
Unplug the RS485
connector(s) from
the network interface
board and check DC
voltage (left pin to
center, right pin to
center)
Set dipswitches for
correct node and
“reset” module
Do you have one
transformer powering
more than one sensor
module?
Is the amber light of this
compressor
continuously on ?
No
Correct the polarity
of wires at RS485
connector at E2
No
Set termination
jumpers
No
Yes
2.3 to 2.6 volts
DC?
No
- Verify that the
shield connection
is made at the E2
RS485 connector
- Faulty interface
board in E2
Verify polarity of the white/black
power supply leads going to the
control module. Refer to wiring
diagram in appendix. White
lead is by the connector latch at
the sensor module and goes to
control module pin #4.
If electrical noise is suspected ,
a communication noise filter
from “Fair-Rite Products Corp.
p/n 0431173551 may be
installed on the communication
line. See figure 1.0. Three
passes through the filter are
recommended.
Faulty control module
Application Engineering
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AE8-1351
Motor Temperature Trip
6.16
Motor temperature protection for 4D and 6D compressors utilizes 3 temperature sensors in the motor.
The temperature sensor resistance is measured by the control module to determine whether or not to
shut down the motor. The motor temperature set point is not configurable (it is a fixed value ).
Normal reset requires that the compressor be off for 2 minutes and the sensor temperatures be below
a reset resistance (see below)
Caution: High Voltage Inside
Terminal Box
Check the motor sensor
resistance (this may be checked
at the control module by
unplugging the low voltage
harness
Allow the
compressor to cool
for one hour.
Then, check the
motor sensors per
AE10-1264 step 4
if the fault persists
If one sensor is
bad it may be
bypassed per
AE10-1264 step 5
No
Are the
sensors within
spec?
Yes
Does the fault
remain?
No
C S1 S2 S3
OR Bk Bk Bk
Resolve source of
high motor
temperature
Low Voltage Connector
Open end view of low voltage harness,
unplugged from the control module
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
36
Motor Sensor Resistance
Values:
Cold:
20 – 100 ohms
Reset after trip: 2750 ohms
Yes
Possible Causes:
1.) Open circuit in harness
2.) Connector pin not
engaging at connector on
control module
3.) Faulty control module
Application Engineering
B
6.17
U
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T
I
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Compressor ID Module Failure
The ID module is under the terminal box and
stores the compressor history and
configuration information.
It is a good practice to turn off the pilot circuit
power before plugging / unplugging the ID
module connection.
Is the ID module connected to the sensor
module lead? (See figure below)
No
Turn off the 24V pilot circuit
power and then fully secure
the connector from the
sensor module to the ID
module
Yes
Temporarily plug a
service ID module
onto the sensor
module connector
Faulty ID module. Install
service ID module
Yes
No
Turn on the 24V pilot circuit
power. Did the error message
go away?
Did the error message go away?
No
Replace the sensor
module
ID Module Housing
Terminal Plate
Lift Locking
Tab with
Finger
Before
Removing
Connector
Sensor Module
Lead Connector
Sensor Module
Lead
Compressor
Body
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
37
AE8-1351
Application Engineering
B
U
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No Communication to Sensor Module
6.18
Remove the
Bottom cover of the
control module
Is the control module to sensor module
communication harness plugged into the
connector (see photo below)?
No
Plug the harness into the
connector
Yes
Open the terminal
box of the
compressor
(Caution: High
Voltage on Terminal
Posts)
Yes
Make sure that the sensor
module/control module
communication harness
connections are engaged.
If communication fault
continues, reset the control
module. If the problem
persists after reset, the
sensor module or control
module may be faulty. Start
by replacing the sensor
module
Yes
Is the LED on the top edge of the
sensor module blinking green?
No
Reset control module.
If problem persists, the
sensor module or
control module may be
faulty. Start by
replacing the sensor
module
Communication Harness Connector Locations on Control and Sensor Module
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
38
AE8-1351
Application Engineering
B
U
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Unloader Short
6.19
The unloader short protects the harness and electronics from high current (2
± 0.5 Amps) associated with a shorted coil or harness. The control module
must be reset to allow the unloader to be operated again.
Unplug the
connector to the
unloader coil
Is the coil
resistance less
than 5 ohms?
Replace the
unloader coil
Yes
No
With the unloader
output unplugged,
force the unloader
stage “off” to
energize the circuit
Does the Unloader Short
fault still appear ?
Yes
Compressor harness short or
failed control module
No
Replace coil
(failure under
load)
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
39
AE8-1351
Application Engineering
B
U
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L
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T
Unloader Open
6.20
The “open” unloader coil detection is based on
a low current flow (<200 mA) through the coil.
Unplug the
connector to the
unloader coil
Is the coil resistance greater
than 120 ohms? (nominal coil
resistance 6 Ω)
Yes
Replace the
unloader coil
No
With the unloader
output plugged in,
force the unloader
stage “off” to
energize the
circuit. Measure
voltage across the
coil.
Is the coil getting
approximately 24 volts AC
across it?
Yes
Suspect intermittent open
circuit in harness
No
Harness failure or
control module
relay output
failure.
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
40
I
N
AE8-1351
Application Engineering
B
U
L
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Contactor Coil Lockout
6.21
Turn off the pilot circuit and
“open” the motor power
breaker.
The contactor coil lockout protects the circuit from high current (3 + 0.5
amps ) resulting from a “shorted” coil or harness. The control module
must be re-set to clear the lockout.
Unplug the contactor output
leads at the contactor (or pilot
relay). Measure the contactor
(or pilot relay) coil resistance
Is the coil resistance less
than the mfgs’ minimum
specified?
Yes
Replace the relay
or contactor coil
No
With the contactor
output unplugged,
turn on pilot circuit
and send a “run”
command
Does the compressor
generate a “No 3-phase
power” fault?
No
Does the compressor still
generate a contactor coil
lockout?
Yes
Replace coil
(failure under
load)
© 2008 Emerson Climate Technologies
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Yes
Compressor harness short or
failed control module
- Unplug the contactor output
connectors in the terminal
box and repeat the test to
help determine the location
of the wiring short.
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6.22
This fault pertains to 2D and 3D compressors with internal line
break protectors. The presence of motor voltage without current
flow is the symptom used to detect a protector trip. Current flow
is measured by the Current Sensing Module (“CT”, for Current
Transducer)
Is the
compressor
running?
Yes
Possible Causes :
1.) Motor lead not passing through CT
2.) CT not plugged into sensor module, or pins
in connector not engaged
3.) Faulty CT – check resistance of CT through
pins 1 and 2 of the connector (see below)
4.) Faulty sensor module
No
Normal Operation
The internal protector
has tripped. The
compressor will restart
when the motor has
adequately cooled
4
3
2
View of the open end of
the CT connector that
plugs into the sensor
module
Resistance between pins
1 and 2 = 60 – 80 ohms
© 2008 Emerson Climate Technologies
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Voltage Imbalance Trip
Check compressor power supplied to the
contactor. Is the voltage difference between
any of the power leads greater than 5 %?
Reset the sensor module by
turning off the pilot circuit power.
Note: Before turning the module
on, wait approximately 5 seconds
to allow for a proper reset.
No
Yes
Normal Operation. Voltage
imbalances that are 5% or greater
can cause overheating and
subsequent damage to the
compressor motor. Address the
voltage imbalance before
restarting the compressor
Does the module return to
normal operation?
No
Are the voltage sensing leads
connected properly? Refer to
figure 6.24
No
Repair the connections
Figure 6.24 Voltage Lead Connections
© 2008 Emerson Climate Technologies
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Yes
Normal Operation.
The module has
sensed a voltage
imbalance condition.
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Low Suction Pressure Trip
6.24
Is the suction pressure
below 5 psi?
No
Will the pressure
switch reset within
specified range?
Yes
No
Normal Operation
Compressor will
restart when
suction pressure
increases above
reset level
Replace Low
Pressure Cut Out
Switch
2D / 3D
Yes
Normal Operation
Low Pressure Switch Settings:
Opens 1 – 5 psi
Closes 8 – 12 psi
4D
Low Pressure Cut Out Switch Locations
© 2008 Emerson Climate Technologies
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6D
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Phase Loss Trip / Lockout
6.25
A phase loss trip occurs if one or two phases of the motor are not
receiving voltage. The compressor will shut off and remain off for 5
minutes before trying again. If the phase loss occurs for 10
consecutive attempts, a lockout will occur. A lockout requires that
the module be reset to allow the compressor to run. Every
successful re-start will decrement the lockout counter by one .
Normal Operation
Determine cause
of missing phase
or voltage
imbalance
Voltage sensing
leads not
connected to motor
terminals.
No
Is full voltage present at
each terminal when the
contactor is loaded?
Missing Phase Voltage Imbalance
During Start-up
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
Yes
Note that during a
light- load running
condition, the
missing-phase
voltage imbalance
may not be very
large
Missing Phase Voltage Imbalance
While Running
45
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No 3-Phase Power
6.26
No 3-phase power fault occurs if a run command has been sent
from the control module to the contactor (or pilot relay) and voltage
isn’t present at the motor terminals. This will not result in a lockout
condition; If demand remains , the compressor will continue to
attempt to run until voltage at the motor is present. This fault will
typically occur during start -up. While running , loss of 3-phase
power will yield a “brown- out trip”.
Faulty contactor
coil, pilot relay coil
or rack wiring
Normal Operation
Main breaker is
thrown or other
compressor power
supply issue
Yes
No
Is the
compressor
running?
Is the compressor
contactor or pilot relay
closed?
Yes
No
Is 24v present at
“Contactor Output” of
harness in T-Box?
Yes
No
Voltage sensing
leads not
connected to
motor terminals,
or faulty sensor
module
© 2008 Emerson Climate Technologies
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Open harness or
Faulty control module
relay
46
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Normal Running Low Oil Pressure
6.27
Followed By
Low Oil Pressure Lockout
Is oil present in the
sight glass?
Yes
Is the harness from the
Control Module fully engaged
into the oil pressure sensor?
No
Reconnect
No
Install jumper across
the harness connector
pins
No
Resolve reservoir oil
supply problem or oil
level control setting
issues
Yes
Disconnect harness at the
sensor. Is the oil pump sensor
“open” while the compressor
runs?
Yes
Verify proper engagement
of connector onto sensor
Measure oil pump
pressure. Is the pressure
greater than 7– 9 psi?
Yes
Does the Module
display change to
“Normal Running”?
Yes
No
No
Faulty Sensor.
Check for missing
o-ring or clogged
sensor screen
Loose harness
connection in front box.
If all connections are
tight, replace Module
Compressor Issue.
Possible Causes: Faulty oil
pump. Clogged strainer
screen. Worn bearings.
© 2008 Emerson Climate Technologies
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6.28
Control Module Failure Lockout
Reset the Control
Module by pressing the
“Reset” button on the
front of the unit
Does the module continue to
display the “Control Module
Failure Lockout” code?
No
The module has
returned to
Normal Operation
Yes
Reset the module by turning it off
and back on. Note: Before turning
the module on, wait approximately 5
seconds to allow for a proper reset.
Yes
Does the module continue to
display the “Control Module
Failure Lockout” code?
No
The module has
returned to
Normal Operation
Yes
Replace the
Control Module
© 2008 Emerson Climate Technologies
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The Control Module Failure Lockout code results when
the module fails an internal diagnostic test.
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Sensor Module Failure
Reset the Control
Module by pressing the
“Reset” button on the
front of the unit
Does the module continue to
display the “Sensor Module
Failure” code?
No
The module has
returned to
Normal Operation
Yes
Reset the sensor module by turning
off the pilot circuit power. Note:
Before turning the module on, wait
approximately 5 seconds to allow for
a proper reset.
Yes
Does the module continue to
display the “Sensor Module
Failure” code?
No
The module has
returned to
Normal Operation
Yes
Replace the
Sensor Module
Note: The compressor will continue to run
without a functioning sensor module, however,
there will not be enhanced motor protection
The Sensor Module Failure code results when the
module fails an internal diagnostic test.
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High Discharge Pressure Trip
Is the Service
Valve Open?
No
Open the Valve
Yes
Is the system discharge
pressure above the preset
trip point?
Yes
Resolve system
pressure issue
Yes
Replace the switch
if it fails to reset
below 250 psi.
No
Check the continuity
across the pressure switch.
Is the circuit open?
No
Verify that the connections
to the pressure switches
are made properly.
High Pressure Settings
Opens 360 psi
Resets 250 psi
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Connection lost ID to Sensor
The ID module is under the terminal box and
stores the compressor history and
configuration information.
It is a good practice to turn off the pilot circuit
power before plugging / unplugging the ID
module connection.
Is the ID module connected to
the sensor module lead? (See
photo below)
No
Turn off the 24V pilot circuit
power and then fully secure
the connector from the
sensor module to the ID
module
Yes
Temporarily plug a
service ID module
onto the sensor
module connector
Faulty ID module. Install
service ID module
Yes
No
Turn on the 24V pilot circuit
power. Did the error message
go away?
Did the error message go away?
No
Replace the sensor
module
ID Module Housing
Terminal Plate
Lift Locking
Tab with
Finger
Before
Removing
Connector
Sensor Module
Lead Connector
Sensor Module
Lead
Compressor
Body
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Power Brownout Trip
Check the power switch to the
module. Has the unit been turned
OFF?
Yes
Normal Operation. In the event that a
module is switched OFF for service, the
display will briefly show “Power Brownout
Trip” before powering down
No
Check the module supply
voltage. Is it below 12VAC?
Yes
Normal Operation. Diagnose the low
voltage condition. Replace the transformer
if necessary.
The Power Brownout Trip code results when module
power drops below 12VAC for a minimum of 2 cycles
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Discharge Temperature Lockout
Is the head probe reading
properly? Compare to table below
by measuring probe resistance
No
Replace the
head probe
Yes
Is the system
operating with
sufficient superheat?
Thermometer
Temp. (F°)
Calculated Sensor
Resistance (Ohms)
59
60.8
62.6
64.4
66.2
141426
135000
128907
123129
117639
68
69.8
71.6
73.4
75.2
112437
107478
102762
98289
94041
77
78.8
80.6
82.4
84.2
90000
86139
82476
78984
75663
86
87.8
89.6
91.4
93.2
72504
69480
66609
63864
61254
95
96.8
98.6
100.4
102.2
58770
56394
54126
51966
49914
104
105.8
107.6
109.4
47943
46053
44262
42543
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No
Adjust the
System
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Current Overload Trip
This fault is a result of continuous compressor current that exceeds the configuration (MCC) limit by 10% for 60
seconds as determined by the current sensing transducer. This is independent of the compressor protector or
motor temperature sensors.
For dual-voltage motors (the 3rd motor character in the model number, such as 4DT3F76KL-TSK-XXX, is a “K”
or “N” ), the MCC represents the 460V value. If the compressor is running at 230V, the MCC is double that
of the listed value.
The compressor will auto-reset after 2 minutes (plus any remaining anti-short cycle time).
The MCC (maximum continuous current)
may be edited through the E2 setup screen
for each compressor
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7.0 Service Instructions
7.2 Sensor Module Replacement
7.1 Control Module Replacement
The Intelligent Store Discus compressor sensor module
relays information concerning the compressor current
and voltage to the control module. If a failure would
occur to the sensor module the control module would
display "No Communications to Sensor Module". While
the compressor would remain functional, enhanced
motor protection features would be disabled. The
features affected are:
- Locked Rotor Protection
In the event of a control module failure, contact an
Emerson Climate Technologies Wholesaler to obtain
a replacement device. The last two digits of the part
number (XX) designate the software version loaded
into the module. The control module used for Intelligent
Store Discus™ 2.0 is universal for all 2D, 3D, 4D, and
6D compressors.
- Welded Contactor Protection
To perform the installation of the new control module
follow these steps:
- Voltage Imbalance Protection
- Low Voltage Protection
1. Remove power to the affected control module.
Once power has been removed, both the LCD
and LED display on the front of the module will
be dark.
Basic compressor motor protection based on internal
line break sensors (2D/3D) or PTC's (4D/6D) will still
be present.
2. Access the control module electrical connections
by removing the access cover at the bottom of
the module.
In the event of a sensor module failure, contact an
Emerson Wholesaler to obtain a replacement device.
There are two versions of the sensor module depending
upon the application. Part number 543-0062-XX
is the standard version of the sensor module used
on compressors without part-winding start. Part
number 543-0082-XX is the sensor module used on
compressors with part-winding start. The last two
digits of the part number (XX) designate the software
version loaded into the module.
3. Unplug all of the control module connections
located on the bottom edge of the control module
circuit board.
4. Remove the remaining four screws that secure
the control module to the mounting plate.
5. Note the DIP switch settings. If the module was
operating properly before failure, transfer those
settings to the new control module. Otherwise
refer to Section 4.1 to determine the proper
settings. The same can be said for both the
controller and termination jumpers on the new
control module.
To perform the installation of the new control module
follow these steps:
1. Remove power to the affected device. Be sure
to switch power off to both the compressor and
module. Always turn off compressor power
before working on connections in the compressor
terminal box. Once power has been removed,
both the LCD and LED display on the sensor
module will be dark. If the module in question
is powering a crankcase heater, be sure that this
power is switched as well.
6. Attach the new control module to the mounting
plate using the four screws removed in step 4.
7. Make all harness connections removed in step
number 3.
8. Apply power to the module. Once powered,
the control module will display the DIP switch
settings on the LCD. Verify that these settings are
correct. With the proper DIP switch settings, the
new module will be ready for normal operation.
No further commissioning of the device is
necessary.
2. Remove the terminal box cover to access the
sensor module. The LED on the sensor module
should be dark indicating that 24V power has
been removed.
3. Disconnect all connections going to the sensor
module. These connections include:
9. Using the provided packaging from the
replacement module, return the failed unit to your
Emerson Climate Technologies Wholesaler for a
refund on your core charge.
© 2008 Emerson Climate Technologies
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•
Compressor ID Module
•
Compressor Voltage Sensors (x3)
•
Current Sensor (x2 if compressor is partwinding start)
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Crankcase Heater Supply and Power (if
present)
•
24VAC input power to the sensor module
•
24VAC output power to the control module
4. Remove the two retaining nuts securing the
sensor module to the terminal box and remove
the module.
5. Install the new module by reversing the steps
listed above. When re-connecting the compressor
voltage sensors be sure that the black lead
is connected to the compressor terminal
corresponding to the current sensor.
6. When inserting the compressor ID module cable
and connector through the terminal box, be
sure to secure the grommet in the provided slot.
This grommet protects the cable from wear and
abrasion.
7. Once the new module has been secured to the
terminal box replace the terminal box cover and
secure in place.
8. Before applying power to the compressor
and module be sure that the connector to the
compressor ID module has been connected.
9. Apply power to the compressor and module.
Once the unit has been powered up the control
module should display a message of Normal
Running or Normal OFF.
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2. Unplug the connector to the ID module.
3. Using a small chisel, extract the ID module
retaining rivet.
4. Install the new ID module to the compressor
terminal plate using the installed rivet. In the event
that the old rivet was damaged during extraction,
you may attach the new ID module to the terminal
plate using the supplied adhesive tape.
5. Re-install the connector to the ID module.
6. Apply power to the compressor and module.
Note: Replacement ID modules have been preprogrammed with the basic model specific information
including motor protection configuration settings and
discharge temperature trip/reset points. They have
not been programmed with specific compressor
identification information such as model and serial
number. To populate this information refer to Section
4.18 of this manual.
7.4 Installation Torque Values
Component
The Intelligent Store Discus™ 2.0 ID Module is
programmed at the factory with information specific
to each compressor. Included in this information are
the programmable settings as well as the compressor
identification. The Intelligent Store Discus sensor
module reads this information and uses it to determine
the appropriate levels of protection (MCC protection
for example). If the data present on the ID module
has been corrupted or the ID module is damaged or
missing, the system will not be able to operate with
full protection enabled. In the event of an ID module
failure contact an Emerson Wholesaler. Refer to
Appendix E of this document to determine the proper
part number. Note: 2D/3D compressors require a
different ID module than 4D/6D compressors.
To replace the compressor ID module follow these
steps:
1. Remove power to the compressor and module
that you wish to service.
© 2008 Emerson Climate Technologies
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Torque Value
Control Module Mounting
Screws
85-105
in*lb
Control Module Mounting
Bracket Nuts
42-50
ft*lb
Sensor Module Mounting Nuts
7.3 ID Module Replacement
AE8-1351
26-31
in*lb
High Pressure Cutout
170-200
in*lb
Low Pressure Cutout
170-200
in*lb
Temperature Probe
170-200
in*lb
26-31
in*lb
Current Sensor Mounting Nuts
Motor Terminal Nuts
75-85
in*lb
Solenoid Valve Nuts/Bolts
42-50
ft*lb
120-180
in*lb
Schrader Fittings (1/8" NPT)
8.0 Compressor Changeout Instructions
The following instructions assume that the same
control module and sensor module will be used on the
new compressor. If these modules are to be replaced,
refer to Section 7.0 of this document. Replacement
compressors will not be equipped with a compressor
ID module. To obtain a replacement, contact an
Emerson Wholesaler.
Refer to Appendix E to
determine the appropriate part number. Note: 2D/3D
compressors require a different ID module than 4D/6D
compressors.
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Figure 7.1 2D/3D Intelligent Store Discus 2.0 Assembly Reference Drawing
9. Remove access cover on control module (two
screws).
10. Unplug RS-485 communications plug.
11. Unplug the harness to the oil pressure switch.
12. Remove housing cover nuts securing control
module mounting plate to compressor. (x2)
13. Remove control module and harness assembly
9.0 Removal of the Compressor (2D/3D)
1. Turn off power to the compressor, crankcase
heater, and Intelligent Store Discus™ modules.
2. Isolate the compressor and evacuate per accepted
industry practice.
3. Unplug the compressor ID connector below the
terminal box.
4. Inside the terminal box:
• Remove compressor power terminal lugs
• Disconnect/Unplug connections to the sensor
module including:
○ voltage sensing leads
○ crankcase heater output
○ communication cable (to control module)
○ 24VAC power output (to control module)
○ Remove terminal box anchor screws
holding the box to the compressor (4x)
5. Remove screws that secure wiring harness
assembly to terminal box (2x)
6. Lift off terminal box.
7. Remove side cover screws to access pressure
controls (2x)
8. Unplug leads to high and low pressure switch,
temperature probe, and unloader (if present).
© 2008 Emerson Climate Technologies
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Figure 7.2 2D/3D Terminal Box Connections
57
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Figure 7.3 4D Intelligent Store Discus 2.0 Assembly Reference Drawing
as a unit by pulling it off towards the front of the
compressor.
14. Remove the compressor from the rack using
proper tools and procedures to assure safety,
and to prevent damage to the rack or other
compressors.
10.0 Installation of the compressor (2D/3D)
1. Mount the new compressor in the rack, lifting
and maneuvering the compressor in a manner to
prevent personal injury and damage to the other
compressors on the rack.
2. Install the control module and harness assembly
on the new compressor as a unit.
3. Install the housing cover nuts securing the control
module mounting plate to the compressor. (x2)
4. Transfer the temperature sensor and pressure
control fittings to the head and body of the new
compressor. Use of a thread sealing compound
is recommended. Connect temperature probe to
wiring harness.
5. Install high pressure cutout switch (RED DOT 360 psi) on the head, and low pressure cutout
switch (WHITE DOT - 3 psi) on the compressor
body. Double Check Positions! Connect pressure
© 2008 Emerson Climate Technologies
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controls to wiring harness (HPCO-RED leads and
LPCO-BLUE leads).
6. Install the terminal box on the compressor by
routing the harness leads through the provided
opening in the bottom of the box. Secure to the
compressor using the four anchor screws.
7. Secure the wiring harness assembly to the
terminal box by installing two screws.
Figure 7.4 4D Terminal Box Connections
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pressure control.
6. Unplug leads to high and low pressure switches,
temperature probe, and unloader (if present).
7. Remove access cover on control module (two
screws).
8. unplug all harness connections at the control
module.
9. Unplug RS-485 communications plug.
10. Unplug the harness to the oil pressure switch.
11. Lift off terminal box with the wiring harness
attached.
12. Remove the two nuts securing the control module
mounting bracket to the compressor
13. Remove control module from the compressor.
14. Remove the compressor from the rack using
proper tools and procedures to assure safety,
and to prevent damage to the rack or other
compressors.
8. Inside the terminal box
• Connect compressor power terminal lugs
• Connect wires to the sensor module
including:
○ voltage sensing leads
○ crankcase heater output
○ communication cable (to control module)
○ 24VAC power output (to control module)
9. Reconnect the RS-485 communications plug.
10. Reconnect the harness to the oil pressure sensor.
11. Install the newly acquired compressor ID module
to the compressor terminal plate using the
supplied rivet. In the event that your replacement
compressor is not equipped with the proper drilled
hole to receive the mounting rivet, you may attach
the new ID module to the terminal plate using the
supplied adhesive tape.
12. Reinstall the connector to the ID module.
13. Replace the terminal box cover and secure with
two screws.
14. Reinstall the side cover over the pressure
controls.
15. Reinstall the control module access cover and
secure with two screws.
16. Apply power to the compressor and Intelligent
Store Discus™ modules.
12.0 Installation of the Compressor (4D)
1. Mount the new compressor in the rack, lifting
and maneuvering the compressor in a manner to
prevent personal injury and damage to the other
compressors on the rack.
2. Transfer the temperature sensor and pressure
control fittings to the head and body of the new
compressor. Use of a thread sealing compound
is recommended.
3. Install high pressure cutout switch (RED DOT 360 psi) on the head, and low pressure cutout
switch (WHITE DOT - 3 psi) on the compressor
body. Double Check Positions!
4. Install the terminal box on the compressor.
Secure to the compressor using the four anchor
screws.
5. Inside the terminal box
• Connect compressor power terminal lugs
• Connect terminal box grounding strap
• Connect motor sensor leads
• Connect the compressor voltage sensing
leads
6. Install the control module mounting bracket on
the compressor.
7. Reconnect the pressure controls to wiring harness
(HPCO-RED leads and LPCO-BLUE leads).
8. Reconnect all plugs at the control module
including the RS-485 communications plug.
9. Reconnect the harness to the oil pressure
sensor.
10. Reconnect the harness to the head temperature
probe and unloader (if present).
11. Install the newly acquired compressor ID module
Note: Replacement ID modules have been preprogrammed with the basic model specific information
including motor protection configuration settings and
discharge temperature trip/reset points. They have
not been programmed with specific compressor
identification information such as model and serial
number. To populate this information refer to Section
4.18 of this manual.
11.0 Removal of the Compressor (4D)
1. Turn off power to the compressor, crankcase
heater, and Intelligent Store Discus modules.
2. Isolate the compressor and evacuate per accepted
industry practice.
3. Unplug the compressor ID connector below the
terminal box.
4. Inside the terminal box
• Remove compressor power terminal lugs
• Remove terminal box grounding strap
• Remove the compressor motor sensor leads
• Disconnect the compressor voltage sensing
leads
• Remove terminal box anchor screws holding
the box to the compressor
5. Remove the side cover to access the high
© 2008 Emerson Climate Technologies
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Figure 7.5 6D Intelligent Store Discus 2.0 Assembly Reference Drawing
12.
13.
14.
15.
16.
to the compressor terminal plate using the
supplied rivet. In the event that your replacement
compressor is not equipped with the proper drilled
hole to receive the mounting rivet, you may attach
the new ID module to the terminal plate using the
supplied adhesive tape.
Reinstall the connector to the ID module.
Reinstall the side cover and secure with four
screws
Replace the terminal box cover and secure with
two screws.
Reinstall the control module access cover and
secure with two screws.
Apply power to the compressor and Intelligent
Store Discus™ modules.
3. Unplug the compressor ID connector below the
terminal box.
4. Inside the terminal box
• Remove compressor power terminal lugs
• Remove terminal box grounding strap
• Remove the compressor motor sensor leads.
• Disconnect the compressor voltage sensing
leads
• Remove terminal box anchor screws holding
the box to the compressor
5. Remove access cover on control module (two
screws).
6. Unplug all harness connections at the control module
including the RS-485 communications plug.
Note: Replacement ID modules have been preprogrammed with the basic model specific information
including motor protection configuration settings and
discharge temperature trip/reset points. They have
not been programmed with specific compressor
identification information such as model and serial
number. To populate this information refer to Section
4.18 of this manual.
13.0 Removal of the compressor (6D)
1. Turn off power to the compressor, crankcase
heater, and Intelligent Store Discus modules.
2. Isolate the compressor and evacuate per accepted
industry practice.
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
60
Figure 7.6 6D Terminal Box Connections
Application Engineering
B
U
L
L
E
7. Disconnect the oil pressure and head temperature
harness from the compressor.
8. Remove side cover and control module mounting
nuts (6x).
9. Remove the side cover and control module as an
assembly to access the high and low pressure
controls.
10. Unplug leads to high and low pressure switches,
and unloaders (if present).
11. Lift off terminal box with the wiring harness
attached.
12. Remove the compressor from the rack using
proper tools and procedures to assure safety,
and to prevent damage to the rack or other
compressors.
I
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AE8-1351
6. Reconnect the pressure controls to wiring harness
(HPCO-RED leads and LPCO-BLUE leads).
7. Reinstall the side cover and control module as an
assembly. Fasten to compressor with mounting
nuts (6x).
8. Reconnect all plugs at the control module
including the RS-485 communications plug.
9. Reconnect the harness to the oil pressure
sensor.
10. Reconnect the harness to the head temperature
probe and unloaders (if present).
11. Install the newly acquired compressor ID module
to the compressor terminal plate using the
supplied rivet. In the event that your replacement
compressor is not equipped with the proper drilled
hole to receive the mounting rivet, you may attach
the new ID module to the terminal plate using the
supplied adhesive tape.
12. Reinstall the connector to the ID module.
13. Replace the terminal box cover and secure with
two screws.
14. Reinstall the control module access cover and
secure with two screws.
15. Apply power to the compressor and Intelligent
Store Discus™ modules.
14.0 Installation of the compressor (6D)
1. Mount the new compressor in the rack, lifting
and maneuvering the compressor in a manner to
prevent personal injury and damage to the other
compressors on the rack.
2. Transfer the temperature sensor and pressure
control fittings to the head and body of the new
compressor. Use of a thread sealing compound
is recommended.
3. Install high pressure cutout switch (RED DOT 360 psi) on the head, and low pressure cutout
switch (WHITE DOT - 3 psi) on the compressor
body. Double Check Positions!
4. Install the terminal box on the compressor.
Secure to the compressor using the four anchor
screws.
5. Inside the terminal box
• Connect compressor power terminal lugs
• Connect terminal box grounding strap
• Connect motor sensor leads
• Connect the compressor voltage sensing
leads
© 2008 Emerson Climate Technologies
Printed in the U.S.A.
T
Note: Replacement ID modules have been preprogrammed with the basic model specific information
including motor protection configuration settings and
discharge temperature trip/reset points. They have
not been programmed with specific compressor
identification information such as model and serial
number. To populate this information refer to Section
4.18 of this manual.
61
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