CoreSense™ Protection for Copeland Discus™ compressors

CoreSense™ Protection for Copeland Discus™ compressors
AE8-1367 R4
January 2015
AE8-1367 R4
CoreSense™ Protection for Copeland Discus™ Compressors
Table of Contents
Safety
Safety Instructions .................................................. 2
Safety Icon Explanation .......................................... 2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons....................................... 3
Safety Statements................................................... 3
Overview
Nomenclature.......................................................... 4
Protection ................................................................ 4
Oil Protection .......................................................... 4
Reverse Jog Feature .............................................. 4
Motor Protection by Positive Temperature
Coefficient (PTC) Sensors .................................... 4
High Discharge Temperature Protection (Optional) .. 4
Communication (Optional) ...................................... 5
Remote Reset ......................................................... 5
Fault History ............................................................ 5
Application Usage ................................................... 5
Specifications .......................................................... 5
Basic Wiring Diagrams............................................ 5
Variable Frequency Drives ...................................... 5
Copeland Digital™ Discus/ Conventional Unloader
Compressors ........................................................ 5
Copeland Demand Cooling ..................................... 5
Installation
Mounting ................................................................. 5
Terminal Box and Current Sensing Toroid
Connections.......................................................... 5
Power Connections ................................................. 6
Pilot Circuit Wiring................................................... 6
Alarm Circuit Wiring (Optional) ............................... 6
Stand-Alone Mode .................................................. 6
Communication Network (Optional) ........................ 6
Cable Routing/Daisy Chain Configuration .............. 6
Terminations............................................................ 6
Commissioning
DIP Switch Configuration ........................................ 6
Jumper Settings ...................................................... 7
Network Setup in Emerson Retail
Solutions' E2.......................................................7-14
Enabling Discharge Temperature Lockout in
the E2 ................................................................15-17
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Operation
Status Codes/LED Diagnostics .............................. 17
Event Priority.......................................................... 17
Performing a Remote Reset In the E2 Alarm
Screen ................................................................. 18
Emergency Bypass of a Damaged Motor
Temperature (PTC) Protection Sensor ................ 19
Figures
CoreSense Protection on Copeland Discus
Compressors ........................................................ 20
Key Components on the CoreSense Protection
Module .................................................................. 20
E2 Alarm Table For CoreSense Protection ............ 21
Basic Wiring Diagram ............................................ 21
CoreSense Protection with Copeland Digital
Compressor Controller ......................................... 22
CoreSense Protection with Copeland Demand
Cooling ................................................................. 22
Motor Lead Routed through Current Sensing
Toroid .................................................................... 22
Current Sensing Toroid .......................................... 23
Routing of Motor Leads for a Part Winding Start
Motor..................................................................... 23
Polarity Indicator LED on CoreSense Protection
Module .................................................................. 23
RS485 Daisy Chain Connection ............................ 24
Two Rack Daisy Chain Connection........................ 24
RS-485 Communications Network Board .............. 24
Default DIP Switch Settings ................................... 24
Default Jumper Settings......................................... 25
Emergency Bypass of Damaged Motor
Temperature (PTC) protection sensor .................. 25
Tables
Purpose of DIP Switch Settings ............................. 26
Green LED Flash Codes ........................................ 26
Yellow LED Flash Codes........................................ 26
Red LED Flash Codes ........................................... 27
Event Priority for CoreSense Protection Faults ..... 27
Reference Drawings
2D Discus with CoreSense .................................... 28
3D Discus with CoreSense .................................... 29
4D Discus with CoreSense .................................... 30
6D Discus with CoreSense .................................... 31
AE8-1367 R4
Safety Instructions
Copeland Discus™ compressors with CoreSense™ technology are manufactured according to the latest U.S. and
European Safety Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained
below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These instructions
should be retained throughout the lifetime of the compessor. You are strongly advised to follow these safety
instructions.
Safety Icon Explanation
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION, used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
NOTICE
CAUTION
© 2015 Emerson Climate Technologies, Inc.
NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices
not related to personal injury.
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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
WARNING
WARNING
CAUTION
ELECTRICAL SHOCK HAZARD
• Disconnect and lock out power before servicing.
• Discharge all capacitors before servicing.
• Use compressor with grounded system only.
• Molded electrical plug must be used when required.
• Refer to original equipment wiring diagrams.
•
• Failure to follow these warnings could result in serious personal injury.
PRESSURIZED SYSTEM HAZARD
• System contains refrigerant and oil under pressure.
• Remove refrigerant from both the high and low compressor side before
removing compressor.
•
• Never install a system and leave it unattended when it has no charge,
a holding charge, or with the service valves closed without electrically
locking out the system.
• Use only approved refrigerants and refrigeration oils.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury.
BURN HAZARD
• Do not touch the compressor until it has cooled down.
• Ensure that materials and wiring do not touch high temperature areas of
the compressor.
• Use caution when brazing system components.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury or
property damage.
COMPRESSOR HANDLING
• Use the appropriate lifting devices to move compressors.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in personal injury or
property damage.
Safety Statements
• Refrigerant compressors must be employed only for their intended use.
•
install, commission and maintain this equipment.
•
• All valid standards and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
© 2015 Emerson Climate Technologies, Inc.
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AE8-1367 R4
OVERVIEW
™
The CoreSense Protection module (CPM) for Copeland
Discus™ compressors combines oil and motor protection
into one module, as well as offers optional protection
against high discharge temperature and communication
compatibility with Modbus communication devices.
Display LEDs clearly indicate the operational status of
the compressor and whether or not there are any active
compressor warnings, trips or lockouts active.
The CoreSense Protection product line is now
available on Copeland™ 2D, 3D, 4D, 6D and 4MTLS
(CO2) Discus™ compressors and integrates a number
of important sensing and compressor protection
functions. Some key components for the CoreSense
Protection module are labeled in Figures 1 and 2 at
the end of this bulletin.
Nomenclature
Factory built Discus™ compressors with an S/E (the
last 3 digits in the model number) beginning with “C”
are CoreSense Protection compressors. For example,
3DS3F46KL-TFD-C00.
PROTECTION
Motor Protection by Positive Temperature
Coefficient (PTC) Sensor
CoreSense Protection replaces the Kriwan module
INT369R and provides motor protection for
Copeland Discus 4D/6D compressors, and Discus
2D/3D compressors with FS_ and ES_ motors. The
CoreSense Protection module will communicate a
motor protection trip when the resistance caused by
an increasing motor temperature has risen above 13 K
Ohms. The compressor will restart once the resistance
drops below 3.2 K Ohms and a five minute off time has
been achieved.
For Discus compressors with AWX/M/D motors and
4MTLS (CO2) compressors, the motor resistance trip
occurs when the resistance has risen above 4.5 K
Ohms. The compressor will restart once the resistance
drops below 2.75 K Ohms and a five minute off time
has been achieved.
High Discharge Temperature Protection (Optional)
CAUTION
Oil Protection
CoreSense Protection replaces mechanical oil
pressure sensing devices, the current Sentronic+™ as
well as older versions of the Copeland Sentronic™ oil
pressure control. Furthermore, it provides the added
value of communication of low oil pressure warnings,
oil pressure trips and oil pressure lockouts via LED
codes and/or a supervisory rack controller, such as
Emerson Retail Solutions’ E2. Insufficient oil pressure
time for the compressor is stored and accumulated in
the module memory. Once the total time accumulated
for bad oil pressure (a reading less than 7-9 PSID)
exceeds 120 seconds, the module will shut the
compressor off and a “low oil pressure lockout” will be
reported. The compressor will turn back on once the
reset has been activated either manually or remotely
through the communication network, or when power
has been cycled to the CoreSense Protection module.
Reverse Jog Feature
The compressor will stop as long as the reset button on
the bottom of the CoreSense Protection module is held
in. This can be used for clearing liquid during a start-up.
After the module re-boots (approximately 3 seconds)
© 2015 Emerson Climate Technologies, Inc.
the compressor will run again. The reset button may
be pushed as necessary to stop the compressor.
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Compressor head temperatures can be very
hot. Care must be taken to ensure that wiring or
other materials which could be damaged by these
temperatures do not come into contact with these
potentially hot areas.
CoreSense Protection for Copeland Discus™
compressors can also provide valuable discharge
temperature protection. By installing the temperature
probe into the head of the Discus compressor and
connecting to the CPM, CoreSense will protect
the compressor from high discharge temperature
conditions. If the temperature sensor detects a head
temperature greater than 310°F, the CoreSense will trip
the compressor off until the temperature cools down to
an acceptable level (about 267°F). A high discharge
temperature lockout can also be enabled through
the E2. Navigating the E2 setup screens (including
enabling a high discharge temperature lockout) are
discussed later in this bulletin.
For more information on the protection features, LED
status codes, event priority and troubleshooting of
CoreSense Protection refer to the section titled Status
Codes/LED Diagnostics.
AE8-1367 R4
Basic System Wiring Diagram
Optional CoreSense Parts
Kit Number
Description
985-0109-50
High Discharge Temperature
Protection Probe
WARNING
Fusing and wire sizing must be done in accordance
to all applicable electrical code standards.
Communication (Optional)
CoreSense Protection has an optional communication
capability via a Modbus network connection. With
communication enabled, CoreSense warnings, trips
and lockouts can be displayed and recorded in a rack
controller such as the E2.
Figure 4 shows the recommended basic system wiring
for a Copeland Discus compressor with CoreSense
Protection.
Variable Frequency Drives
CoreSense Protection may be used with variable
frequency drives. Refer to AE-1369 for more information
on Copeland Discus with variable frequency drives.
Remote Reset
NOTICE
Service contractor and end user policies need to
be considered when deciding whether or not to
use the remote reset feature in the E2.
Digital / Conventional Unloaded Compressors
CoreSense Protection for Copeland Discus is
equipped with a remote reset capability, such that if a
compressor is off in a lockout condition, the user can
remotely restart the compressor through their E2 rack
controller or compatible remote access software (e.g.
UltraSite™). To set up remote reset via the E2, refer to
section titled Performing a Remote Reset In the E2
Alarm Screen.
CoreSense Protection may be used with Copeland
Discus Digital™ as well as conventionally unloaded
compressors. Refer to Figure 5 for recommended
wiring with the Copeland Digital Compressor Controller.
Note: When applying Discus Digital with CoreSense
Technology, the discharge temperature protection
can be done via the Digital Compressor Controller.
Use the temperature probe provided with the Digital
Compressor. Otherwise the optional temperature
probe available for CoreSense can be used and one
resistor can be placed across the T1-T2 on the DCC
Fault History
Demand Cooling
Compressor faults are recorded within the CPM and
if communicating with an E2 can also be stored in the
E2 and CoreSense Alarm Tables for the past seven
days. An example of the E2 Alarm Table is shown in
Figure 3.
CoreSense Protection is compatible with Copeland
Demand Cooling™. However, the discharge temperature
protection is provided by the Demand Cooling module.
Discharge temperature information will not be
communicated to the CoreSense Protection module.
For more information on Copeland Demand Cooling,
refer to AE4-1287. Wiring of CoreSense Protection with
Copeland Demand Cooling is shown in Figure 6.
Application Usage
Specifications
Operating Temperature: Between -25°F and 150°F
Voltage Requirements: 110 VAC or 220 VAC
Inrush Current for Relay: 19A
Steady load current for Relay : 3A
Power rating for the module: 3VA
Storage temperature: Between -40°F and 185°F
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INSTALLATION
Mounting
CoreSense Protection is designed and engineered for
use in many refrigeration applications. 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
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when designing a system for use with a CoreSense
Protection compressor:
• Removal of the cover of the module for access
to dip-switches and the communication network
connector
• Removal of the module for service reasons
• Removal of terminal box lids for service reasons
Dimensional reference drawings for the 2D, 3D, 4D
and 6D Discus with CoreSense Protection are found
at the end of this document.
Terminal Box and Current Sensing Toroid
Connections
Terminal box and the current sensing toroid
connections are installed at the factory. One of
the motor power leads must be routed through
the center opening in the toroid (refer to Figures
7 and 8). The current sensing toroid is used to
determine if the compressor is running.
If using CoreSense Protection with a part winding
start motor, power leads L1 and L7 both should
be passed through the center opening in the
same direction (see Figure 9) to provide accurate
compressor proofing.
Power Connections
The following power connections must be made
by the original equipment manufacturer:
• Module power: 110/220 volts AC
• Pilot circuit wiring: Pilot Circuit is wired
through the L and M terminal. The L and
M terminals are connected together when
CoreSense Protection is not detecting any
faults. L&M are an open circuit when the
module is powered off or detecting a fault
condition.
• Alarm circuit wiring: The L and A terminals
are connected together when a fault is
detected or when the module is powered off.
• Refer to Figure 4 for basic wiring of the CPM.
Stand Alone Mode
If running a Discus with CoreSense protection
without communication to a rack controller,
DIP switch 9 should be set to "Off." Otherwise,
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nuisance communication alarms will occur,
indicated by a flashing Code 5. If using the
discharge temperature probe for high discharge
temp protection, DIP switch 10 should be set to
"On". All other switches and jumpers can be left
in their factory setting positions.
For more information on configuring the DIP
switch refer to DIP Switch Configuration on
page 8.
Communication Network (optional)
Rack Controller Requirements
The control network utilizes Modbus for CoreSense
protocol. Rack controller manufacturers may
develop equipment to interface with and control
CoreSense Protection compressors. For nonEmerson Retail Solutions products, consult with
the controller manufacturer regarding controller
compatibility with CoreSense Protection.
Modbus map available upon request. Consult
your Emerson representative.
For the Emerson Retail Solutions E2 controller, it
should be equipped with an Emerson Retail Solutions
RS-485 communications network board. (Emerson
Retail Solutions part number 237-4890). The controller
firmware must be revision level 3.0 or higher. Refer
to Emerson Retail Solutions E2 RX Refrigeration
Controller manual 026-1610 for more detailed
information.
The E2 network interface board has two communication
ports available. The E2 network interface board is
shown on Figure 13.
Cable Routing / Daisy Chain Configuration
A shielded, twisted pair cable such as Belden #8761
(22AWG) should be used for the communication wiring.
Passing the communications wire through the grommet
in the plastic housing will help reduce abrasion to the
wiring. Appropriate strain relief is recommended.
Note: The RS485 is polarity sensitive. “Pos” wires
must connect to other “Pos” terminals, and “Neg” wires
must connect to other “Neg” terminals. The shield wire
is connected to the center terminal, or “0 volt” position.
If the polarity is correct, red and green LEDs on circuit
board will flash. If incorrect, the red LED will remain on.
Refer to Figure 10.
AE8-1367 R4
CoreSense Protection and the rack controller
communicate with each other using Modbus
protocol. The communication cable is wired from
the rack controller to the first compressor. Additional
compressors are wired in a daisy chained configuration.
Refer to Figures 11 and 12.
Terminations
The last compressor in the daisy chain must be
“terminated” by moving the jumper from the JP5
position to the(JP3) position. The last compressor in
the daisy chain bust be terminated. For CoreSense
modules built prior to 2015, this is done by moving
the jumper from the JP5 position to the JP3 position.
The inside cover of the module has instructions which
show this configuration. For CoreSense Modules built
after Dec. 2014, the termination is done by moving the
position of the jumper on JP3 to 2 and 3. Again, refer
to the inside cover illustration on the module. For all of
the other compressors, the jumper should remain in
the default position.
For more information on setting the jumpers,
refer to section titled Jumper Settings on page
9. More information on the CoreSense Protection
module jumpers can be found in the section titled
Commissioning.
The E2 jumpers on the Network Interface Board should
be set for “terminated” (refer to Figure 13).
COMMISSIONING
Modules using a communications network must be
commissioned as part of the E2 rack controller setup.
The commissioning process uploads compressor
asset information (model and serial number) into
the rack controller for future reference. Once the
commissioning process is completed, the controller
will supervise and communicate with the module
unless the node is deleted.
The CoreSense Protection module does not need
to communicate to the rack controller in order to
provide compressor oil and motor protection.
Using the communication process is optional and
provides a means as an exchange of information from
the controller to the CoreSense modules for proofing,
remote reset, asset information, fault history and
compressor status. Skip to section titled Stand Alone
Mode if the communication feature will not be used.
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The commissioning process begins by assigning a
unique node address to each module. The address is
established by the setting of a DIP switch in the module.
DIP Switch Configuration
DIP switch selection for the Modbus address, baud
rate, parity, and other operating conditions simplify
service and start-up procedures. Table 1 at the end
of this bulletin lists the purpose for each switch. See
Figure 14 for more information on DIP switch settings.
To access the DIP switch remove the four CoreSense
Protection module cover screws. Then remove the
cover.
Note: Press the reset button after changing any of the
DIP settings for changes to take effect.
The following steps cover the DIP switch settings
throughout the commissioning process for a multiple
compressor system with communications to the E2:
1. Switches 1 through 6 are used for setting the
address. Each CoreSense Protection device that
is connected to a rack controller must have a
unique node address (as determined by the DIP
switch settings).
2. Switch 7 defines the communications baud rate for
the CoreSense Protection module. If the switch is
“off”, the baud rate is 19200. If the switch is “on”
the baud rate is 9600. The baud rate for each of
the CoreSense Discus™ devices should be set
to match the rack controller. The default baud
rate is 19200 (“off”) for the CoreSense Protection
module. To determine the baud rate in the E2,
follow these steps:
• From the main menu select 7 (System
Configuration)
• Press 3 (System Information)
• Press 1 (General Controller Info)
• Access the Serial Communications Tab by
pressing CTRL + 3
• Use the Page Down button or scroll down to
view the settings for COM4
3. Switch 8 defines the communication parity. The
default parity setting for the CoreSense Protection
module is no parity. If the switch is set to “on” the
module will communicate using even parity. The
AE8-1367 R4
parity setting must match the parity setting of the
rack controller.
positons 2 and 3 are the unterminated positions.
Please refer to Figure 15B.
4. Switch 9 is used to set the network mode (on)
for the module. The default setting is stand
alone mode (off). Network mode will generate a
communications error if the rack controller fails
to communicate with the device. For standalone
mode, no communications are expected so the
communication error is blocked.
JP 4 is used when a CoreSense module is interfacing
a Dixell™ X-Web device. Positions 1 and 2 are 2
stop bits and positions 2 and 3 are 1 stop bit. Please
contact Applicaiton Engineering for further information
about this application.
5. Switch 10 enables the optional discharge
temperature probe. If the switch is set to “on’
the CoresSense Protection module will expect a
discharge temperature probe. If the switch is set
to “off” the CoreSense Protection module will not
respond to the discharge temperature probe. The
default setting is discharge temperature probe
disabled (off).
6. Switch 11 is for oil protection circuit test. The test
is preformed while the compressor is off. The test
is started once the switch 11 is switched from the
"OFF" to "ON" position within the first 5 seconds
of module power up OR the first 5 seconds of
pressing the RED reset button. This test tests
for oil pressure. Since the compressor is off it
will see no oil pressure and will result in an open
contactor OR the L and M relay will be open on
the Coresense module.
7. Switch 12 is not used in CoreSense Protection
applications and should be left in the "off" default
setting.
Jumper Settings
10 Position DIP Switch CoreSense:
The communications jumper(JP4)should be set for
ECT Modbus if connected to an E2 rack controller
(jumper pins 1-2). Use jumper pins 2-3 for other
controllers. See Figure 15A.
The last CoreSense Protection device in the daisychain should have a communication jumper in the
“terminated” (JP3) position. All other modules should
have a jumper in the JP5 position. In addition, the
E2 should have the communication jumpers on
the communication card (typically COM4) in the
“terminated” position.
12 Position DIP Switch CoreSense:
JP positions 1 and 2 are the terminated position and
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Note: JP1 should not be removed.
Network Setup in Emerson Retail Solutions’ E2
NOTICE
The following section describes network set up
with an E2 v3.0. Before beginning network setup,
Emerson Climate Technologies recommends
updating to the latest E2 firmware. For other
controllers or newer versions of E2, contact your
controller manufacturer representative.
Once the DIP switch and jumper settings have been
verified for each CoreSense module, you will need to
establish communications with the new devices. Begin
the network setup by following the steps on the next
page:
AE8-1367 R4
Note! Before Making Any Changes In The E2 Setup, You Must Log In To
The E2 By Pressing
And Entering The Appropriate Username And
Password
1. Press
to Enter the Main Menu. Select 5. Configured Applications.
2. From the Configured Applications Menu Select 1. Suction Groups
3. Select the Suction Group The CoreSense Devices Will Be Associated To. This Will Bring Up
The Suction Group Status Screen.
4. Press F5 To Enter The Suction Group Setup Screen
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AE8-1367 R4
5. From C1:General Tab, Input The Number Of Stages (Unloader Banks Are Counted As An
Individual Stage)
6. Tab Over To C7: Stage Setup (Ctrl +7) To Modify The Stage Type Press F4: Look Up
7. For Example, If A Stage Is An Unloader, Select Unld (Press U) From The Option List Selection
Menu
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AE8-1367 R4
8. Tab Over To The C8: Stage Outs Tab (Press F2 or Ctrl+8)
9. Select the Stage To Be Setup And Define the Board Accordingly to Match The Relay Output
Board Using F4: Look Up
10. Enter the Relay Point Under the Point Field. Repeat For Each Stage, Then Press
To Exit
and Save Changes
11. Press
to Enter the Main Menu. Select 7. System Configuration.
12. From the System Configuration Menu Select 7. Network Setup.
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AE8-1367 R4
13. From the Network Setup Menu Select 2. Connected I/O Boards and Controllers
14. From the Setup Screen Go To The C3: ECT Tab (Press Ctrl + 3)
15. In Option #5, Enter The Number Of Discus Compressors Being Controlled By The E2.
Press
To Save Changes And Return To The Previous Screen.
16. From the Network Setup Menu Select 1. Network Summary
17. The Discus Devices Should Be Present On The Network. Select The Discus To Be
Commissioned. Press F4: Commission
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AE8-1367 R4
18. From the Modbus Device Menu Select an Unused Space That Matches The DIP Switch
Address Of The CoreSense Device And Press Enter.
19. Verify The Address Matches The Address Assigned By The CoreSense Module’s DIP Switch.
20. Press
To Return To The Network Summary Screen. The Device Should Now Be “Online”.
Repeat Steps 8-10 To Address The Remaining CoreSense Devices.
21. Once All The Devices Are Addressed, Press
Network Summary.
To Save Changes And Exit The
Once All CoreSense Devices
Are Addressed The E2 Should
Show Them All “Online”
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AE8-1367 R4
22. Press
to Enter the Main Menu. Select 7. System Configuration.
23. From the System Configuration Menu Select 7. Network Setup.
24. From the Network Setup Menu, Select 4. Controller Associations . Then Select 4. Compressor
(Press Enter)
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25. Highlight The Suction Group2 Field Select F4: Look Up (Press F4) And Select The Appropriate
Suction Group For The Device And Press Enter.
2 For
More Information On Setting Up Suction Groups In The E2 Consult Your Emerson Retail
Solutions Representative
26. Scroll Over To The Comp Stage And Type In The Compressor Stage. CoreSense Protection
Provides Proofing Only On The Compressor Not Its Unloaders
Note! The Compressor Stage Number Should Correspond To The Stage Numbers in the Suction
Group Setup (Step 7)
27. Press
To Exit And Save Your Changes.
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AE8-1367 R4
Enabling Discharge Temperature Lockout in the E2
The default setting for CoreSense using Discharge Temperature protection is only a trip alarm. When the head temperature of the compressor rises above 310°F, the compressor will shut off until the temperature falls below 267°F.
If it is preferred to have the compressor shut off and stay off in a high discharge temperature condition, a discharge
temperature lockout can be enabled in the E2. The following steps discuss enabling a discharge temperature lockout in the CoreSense device.
Note! Before Making Any Changes In The E2 Setup, You Must Log In To
The E2 By Pressing
And Entering The Appropriate Username And
Password
1. Press
to Enter the Main Menu. Select 7. System Configuration.
2. From the System Configuration Menu Select 7. Network Setup
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3. From the Network Setup Menu Select 1. Network Summary
4. Select The Discus Being Set Up For Discharge Temperature Lockout Capability
And Press F5: Setup
5. From The Setup Screen Go To C2: Setup (Ctrl +2).
6. In The “Dsch Temp Lock” Field Press
To Set Field To “Enabled .”
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7. Go To C8: Alarms (Ctrl +8).
8. In The “DschTmpLockType” Field Press
To Set To “Alarm”
9. Press
To Exit And Save Changes. Repeat Steps 4-9 For Each CoreSense Device.
OPERATION
Status Codes / LED Diagnostics
The status codes are summarized in Tables 2- 4 at the
end of this bulletin.
Event Priority
If the module sees more than one event at a time it
will choose to display the highest priority event on the
LEDs and on the E2. The alarm priorities are defined in
Table 5 where “1” is the highest priority.
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AE8-1367 R4
Performing a Remote Reset in the E2 Alarm Screen
NOTICE
Service contractor and end user policies need to be considered when deciding whether or not to use the
remote reset feature in the E2.
The following section discusses the procedures for reseting a CoreSense alarm remotely from the E2. Any alarm in
the E2 can be reset provided the condition that caused the alarm has been resolved and established time delays
have been satisfied.
1. Press
to Enter the Alarm Screen of The E2.
2. Select The Alarm To Be Reset and Press F2:Alarm Rst. Press A To Reset The Advisory.
3. The Alarm Table Will Now Show That The Alarm Has Been Reset.
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Emergency Bypass of a Damaged Motor
Temperature (PTC) Protection Sensor
CAUTION
At no time should more than one motor sensor be
bypassed.
In the unlikely event that one sensor may be damaged
and have an open or shorted circuit, CoreSense
Protection will prevent compressor operation (and
display a motor protection alarm) even though the
motor may be in perfect condition. If such a situation
should be encountered in the field, an emergency
means of operating the compressor can be used until
such time as a replacement can be made. Connect
a properly sized resistor between the CoreSense
Protection motor leads and the common sensor
terminal in the compressor terminal box. This indicates
to the control module an acceptable resistance in the
damaged sensor circuit, and compressor operation
can be restored (see Figure 16). If an internal sensor is
shorted, the wire from the sensor to the sensor terminal
should be disconnected when installing the resistor. In
effect, the compressor will continue operation with two
leg protection rather than three leg protection. While
this obviously does not provide the same high degree
of protection, it does provide a means of continuing
compressor operation with a degree of safety.
The specifications for the emergency resistor are as
follows:
One watt (or larger), 2200 ohm ±10%resistor
© 2015 Emerson Climate Technologies, Inc.
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Compressor
Terminal Box
CoreSense Protection
Oil Pressure Sensor
CoreSense Protection
Wiring Harness
CoreSense Protection
Module (CPM)
Figure 1 – CoreSense Protection on Copeland Discus Compressors
Red/
Green
LED
Yellow
LED
Reset
Button
Figure 2 – Key Components on the
CoreSense Protection Module
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Figure 3 – E2 Alarm Table For CoreSense Protection
1
There are a select few 2D/3D Discus compressors that also use PTC Sensors. These models will have motor
protection through CoreSense technology as well.Compressors with PTCs are indicated by an "S" in the second
character of the electrical code, e.g. 4DH3R22ML-TSK-C00.
L1
L2
120v
240v
2
M
L
HP
LP
T’Stat
A
CoreSense Terminal Strip
C
Contactor
Coil
Alarm
Indicator
Figure 4 – Basic Wiring Diagram
© 2015 Emerson Climate Technologies, Inc.
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120 VAC
240 VAC
L1
L2
C
24VAC
CONTROLLER
POWER
COMMON
+5VDC
SIGNAL
1 – 5 VDC
Demand
Signal;
From
System
Controller
Optional
Suction
Pressure
Transducer
Input
24COM
24VAC
C1
C2
C3
C4
P1
P2
P3
P4
P5
P6
T1
T2
T3
T4
T5
T6
COMMON
SIGNAL
+5VDC
SUPPLY
COMMON
+5VDC
Optional
0 – 5VDC
Suction
Pressure
Output
Discharge
Temperature
Probe *
* For applications with Discus Digital
and Copeland Demand Cooling a
5kOhm, 1W resistor should be installed
at T1 and T2 on the Digital Compressor
Controller, and the Demand Cooling
Temperature Probe should be used. For
more information on the Copeland Digital
Compressor Controller refer to AE-1328.
V2
120v
240v
DIGITAL
UNLOADER
SOLENOID
V1
U2
U1
2
M2
M1
M
L2
L1
L
A1
A2
ALARM
RELAY
OUTPUT
Control And
Limit
Switches
COMPRESSOR POWER
WIRE T1
A
CoreSense Terminal Strip
Figure 5
CoreSense Protection with Copeland Digital Compressor Controller
L1
* Note: The
CoreSense Module
Is Dual Rated for
120v / 240v. The
Demand Cooling
Module Must Be
Matched To The
Line Voltage
* 120v or
240v
L2
CoreSense
Module Terminal
Strip
Demand
Cooling Module
L
2
L
M
Current Sensor Connector
120v
240v
M
CC
Current
Sensor
A
Control
Temp.
Sensor
A
S
Injector Control
Switch
Injection
Solenoid
L1
L2
Contactor
Figure 6 – CoreSense Protection with
Copeland Demand Cooling
© 2015 Emerson Climate Technologies, Inc.
Figure 7 – One motor lead must be routed through
the center opening of the current sensing toroid.
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Current Sensing Toroid
Motor Sensors
Current
Sensor
Contactors
Power Leads L1
and L7 In Same Direction
Through Current Sensor
One Motor
Lead Passing
Through The
Toroid
Terminal
Plate
Figure 9 – Routing of motor leads through the
current sensor for a part winding start motor.
Figure 8 – Current Sensing Toroid
Figure 10A – Polarity Indicator LED on
CoreSense Protection Modules Prior to 2015
© 2015 Emerson Climate Technologies, Inc.
Figure 10B – Polarity Indicator LED on
CoreSense Protection Modules 2015 and After
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(Terminated)
(Terminated)
(Terminated)
(Terminated)
(Terminated)
(Terminated)
(Terminated)
(Terminated)
Figure 12 – Two Rack Daisy Chain Connection
Figure 11 – RS485 Daisy Chain Connection
Figure 13 – RS-485 Communications Network
Board (Emerson Retail Solutions P/N 237-4890)
Figure 14 – Default CoreSense Protection DIP Switch Settings
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Figure 15A
10 Position Jumper Settings on CoreSense Protection Modules Prior to 2015
Figure 15B
Default Jumper Settings on CoreSense Protection Modules 2015 and After
© 2015 Emerson Climate Technologies, Inc.
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Terminal Strip
Internal Motor
Sensor Leads
C
2200 OHM
Resistor
S1
S2
S3
Open Sensor
O
OO
Black
Harness With
Motor Sensor
Leads
Figure 16
Emergency Bypass of Damaged Motor Temperature (PTC) Protection Sensor
© 2015 Emerson Climate Technologies, Inc.
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Table 1
DIP switch Number
On
Off
1 through 6
Modbus Module Address
7
Baud Rate = 9600
Baud Rate = 19,200
8
Even Parity
No Parity
9
Network Mode
Stand Alone
10
Enable Discharge Temp Probe
No Probe
Table 2 – Green LED Flash Codes
#
Flashes
Green LED – Warning Condition (The Compressor May Run With These Conditions)
1
Low oil pressure – Indicates that the device has detected low oil pressure for longer than 2
seconds. The compressor is able to run, because not enough time has elapsed without oil pressure
to cause a shutdown. The warning will clear if 2 seconds of good oil pressure is detected.
2
Not used
3
Discharge Temperature Probe Open Or Disconnected – The system is not reading temperature
data from the discharge temperature sensor input. The compressor is able to run when this condition
is present. The condition will clear if the system reads valid temperature data from the probe for
more than 2 seconds.
4
Current Sensor Disconnected – The current sensor is not connected to the system. The
compressor continues to run. The condition will clear when the current sensor is connected to the
module for more than two seconds.
5
Communication Error Between Coresense Protection Module And E2 – The rack controller is
not communicating with the CoreSense module. The compressor continues to run. The condition
will clear when a valid message is received from the rack controller.
Table 3 – Yellow LED Flash Codes
#
Flashes
Yellow LED – Trip Condition
(Compressor Stops until Condition Clear and/or Time Delay has Expired)
1
Not used
2
Motor Protector Trip – The motor temperature sensors are too hot. The compressor is tripped off
for at least 2 minutes and until the motor temperature sensors have cooled off.
3
Discharge Temperature – The head temperature probe has detected a temperature greater than
310°F. The compressor is off for at least 2 minutes and until the compressor has cooled off.
4
Not used
5
Not used
© 2015 Emerson Climate Technologies, Inc.
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Table 4 – Red LED Flash Codes
#
Flashes
Red LED – Lockout Condition (RESET Required)
1
Low Oil Pressure Lockout – The compressor has accumulated 2 minutes of run time with
insufficient oil pressure.
2
Not used
3
Discharge Temperature - The head temperature probe has detected a temperature greater than
310°F and Discharge Temperature Lockout has been enabled in the rack controller.
4
Not used
5
Not used
Table 5 – Event Priority for CoreSense Protection Faults
Priority
Event
E2 Alarm Display
CPM LED
1
CoreSense Protection Module
Failure
"Module Failure Lockout"
Steady RED
2
Discharge Temperature Lockout
"Discharge Temp Lockout"
Flashing RED 3 Counts
3
Low Oil Pressure lockout
"Low Oil Pressure Lockout"
Flashing RED 1 Count
4
Motor Protector Trip
"Motor Temp Trip"
Flashing YELLOW 2 Counts
5
Discharge Temperature Trip
"Discharge Temp Trip"
Flashing YELLOW 3 Counts
6
Loss Of Communication
Between CPM & E2
"No Communication"
Flashing GREEN 5 Counts
7
E2 Config Mismatch
“E2 config mismatch”
Flashing GREEN 5 Counts
8
9
RESERVED FOR FUTURE USE
Low Oil Pressure Warning
10
"Low Oil Pressure"
Flashing Green 1 Count
RESERVED FOR FUTURE USE
11
Open Thermistor
"Fault Temp Probe"
Flashing GREEN 3 Counts
12
Normal Run
"Normal Running"
Solid GREEN
13
Normal Off
"Normal Off"
Solid GREEN
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REFERENCE DRAWINGS
Figure 17 – Dimensional Drawing for 2D Discus With CoreSense Protection
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Figure 18 – Dimensional Drawing for 3D Discus With CoreSense Protection
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Figure 19 – Dimensional Drawing for 4D Discus With CoreSense Protection
© 2015 Emerson Climate Technologies, Inc.
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Figure 20 – Dimensional Drawing for 6D Discus With CoreSense Protection
© 2015 Emerson Climate Technologies, Inc.
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