AE-1383 R9.indd - White

AE-1383 R9.indd - White
AE4-1383 R9
October 2014
AE4-1383 R9
Application Guidelines for ZF*K5E & ZB*K5E Copeland Scroll™
K5 Compressors for Refrigeration 8-15 HP with CoreSense™ Diagnostics
Section
TABLE OF CONTENTS
Page Section
Page
Demand Wiring ................................................................. 13
Protection/Contactor Control Wiring ................................. 13
Discharge Temperature Protection with CoreSense
Diagnostics for K5 Compressors .................................... 13
Communication DIP switch Configuration ........................ 13
Cable Routing / Daisy Chain Configuration ...................... 14
Terminations ..................................................................... 14
COMMISSIONING............................................................ 14
Stand Alone Mode ............................................................ 14
Modbus® Communication to CoreSense Diagnostics
for K5 Compressors........................................................ 15
CoreSense K5 Programming Instructions ..................... 16-20
Safety
Safety Instructions ............................................................. 2
Safety Icon Explanation ..................................................... 2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons ................................................ 3
Safety Statements ............................................................. 3
Introduction
Nomenclature .................................................................... 4
Approved Refrigerants....................................................... 4
Digital Compressor Operation ........................................... 4
Operating Envelope ........................................................... 5
Extended ZF*K5E Operating Envelope ............................. 5
ZF*K5E Low Temperature K5 Compressors for
Refrigeration .................................................................. 6
Liquid Injection ................................................................... 6
DTC Valve Specifications .................................................. 6
Installation of DTC Valve ................................................... 6
Suggested Application Techniques for All Liquid Injection ...
Applications.................................................................... 6
Vapor Injection ................................................................... 7
Discharge Temperature Control with Vapor Injection ........ 7
System Configuration ........................................................ 7
Downstream Extraction ..................................................... 8
Upstream Extraction .......................................................... 8
Heat Exchanger Piping Arrangements .............................. 8
Accumulator Requirements ............................................... 8
Superheat Requirements................................................... 8
Crankcase Heater.............................................................. 8
Pressure Controls .............................................................. 8
IPR Valve .......................................................................... 8
Motor Protection ................................................................ 9
PTC Motor Protection ........................................................ 9
Programmable Logic Controller Requirements ................. 9
Kriwan INT69 Module and Sensor Functional Check ........ 9
Motor Protector Module Voltage Supply Troubleshooting . 9
Sensor Troubleshooting..................................................... 9
Compressor Voltage Supply Troubleshooting .................. 10
Oil Management for Rack Applications............................. 10
Discharge Mufflers............................................................ 10
Compressor Mounting ...................................................... 10
Deep Vacuum Operation .................................................. 11
Unbrazing System Components ....................................... 11
HiPot Testing .................................................................... 11
Three Phase Scroll Compressors – Directional
Dependence ................................................................... 11
Copeland Scroll Compressor Functional Check ............... 11
Figures
Modulation Troubleshooting ............................................. 21
Operating Maps ............................................................. 22-28
Typical Suction Tubing...................................................... 29
Liquid Injection Scroll with DTC Valve .............................. 30
EVI Scroll with DTC and T-fitting Adapter ......................... 30
EXV .................................................................................. 30
Circuit Diagram and Cycle for EVI .................................... 31
Downstream Extraction .................................................... 31
Upstream Extraction ......................................................... 31
H/X Piping Arrangement ................................................... 32
8 - 15 HP Copeland Scroll Compressor Rack Mounting .. 32
8 - 15 HP Condensing Unit Mounting ............................... 32
CoreSense Module Wiring Schematics ............................ 33
Discharge Thermistor Connector...................................... 34
Top Cap Thermistor .......................................................... 34
Discharge Line Thermistor ............................................... 34
CoreSense Terminal Box .................................................. 35
K5 Communication Module DIP Switch Settings .............. 35
Wiring Relay Example ...................................................... 35
E2 Jumpers ...................................................................... 35
RS485 Daisy Chain Connection ....................................... 36
Two Rack Daisy Chain Connection .................................. 36
Old/New Model Comparison............................................. 37
Fig 20................................................................................ 38
20 Second Operating Cycle.............................................. 39
CoreSesne Diagnostics + EXV Operation ........................ 40
Digital Operation DIP Switch Settings .............................. 40
Tables
Injection Accessories ........................................................ 41
External Wrap-Around Crankcase Heaters ...................... 41
Kriwan INT69 Module Specifications ................................ 41
K5 Compressor Additional Accessories ............................ 42
K5 Compressor (8 to 15 HP) Fitting Sizes........................ 43
High and Low Pressure Control Settings.......................... 43
Digital Modulation Capacity(%) vs. Analog (V) ................. 43
CoreSense™ Diagnostics Fault Codes ............................. 44
CoreSense™ Diagnostics Module Troubleshooting ....... 45-46
Demand Wiring ................................................................. 47
K5 DIP Switch Settings..................................................... 47
CoreSense™ Diagnostics Module for K5 Compressors .. 12
CoreSense Module LED Overview ................................... 12
Product Specifications ...................................................... 12
Compressor Lead Wiring ................................................. 13
CoreSense Module Mounting ........................................... 13
110-220VAC CoreSense Module Power Wiring ............... 13
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Safety Instructions
Copeland Scroll™ compressors with CoreSense™ Diagnostics 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 compressor. 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
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.
© 2014 Emerson Climate Technologies, Inc.
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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.
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Introduction
NOTE: For the latest approved refrigerants and
lubricants, refer to Form 93-11, Emerson Accepted
Refrigerants/Lubricants, or contact your Application
Engineer.
The Copeland Scroll™ refrigeration compressor product
offering has developed the K5 compressor for the 8 to
15 HP size range. The scope of this bulletin will cover
the application parameters unique to the ZB*K5E and
ZF*K5E refrigeration scrolls with CoreSense™ technology.
NOTE: The ZB*K5 compressors are each applicable with
R-134a, however, Emerson Climate Technologies has
released the ZB*K5B series for optimum performance
for lower R-134a-like pressures. Performance is based
on ARI conditions. 20 °F evap 120 °F condensing. See
the following table for specific model numbers.
A new CoreSense Diagnostics module with digital
capacity control and EXV injection control has been
added on all K5 compressors with the part number (5430209-**/998-0340-**). To see differences between the
old vs new module please see Figure 19.
Optimized R-134a ZB*K5B Compressors
Nomenclature
Model
The Copeland Scroll compressor model numbers
include the nominal capacity at the standard 60 Hertz
“ARI” rating conditions with R-404A refrigerant.
Hertz
ZB47K5B-TFD
ZB59K5B-TFD
Example
ZBD76K5E-TFD-260
ZB68K5B-TFD
Z =
Copeland Scroll
B =
Application (B: Medium Temperature,
F: Low Temperature)
D =
Digital Capacity
Voltage
60
460
50
380/420
60
460
50
380/420
60
460
50
380/420
CAUTION
TFD = Motor Version
POE must be handled carefully and the proper
protective equipment (gloves, eye protection, etc.)
must be used when handling POE lubricant. POE
must not come into contact with any surface or
material that might be harmed by POE, including
without limitation, certain polymers (e.g. PVC/CPVC
and polycarbonate).
260 = Bill of Materials
Medium Temperature Digital Compressor Operation
76K = Nominal Capacity (kBtu/hr)
5 =
Model Variation Identifier for the
K5 refrigeration scroll
E =
Oil Type (POE)
The digital scroll is capable of seamlessly modulating
its capacity from 10% to 100%. A normally closed
(de-energized) solenoid valve is a key component for
achieving modulation. When the solenoid valve is in its
normally closed position, the compressor operates at
full capacity, or loaded state. When the solenoid valve
is energized, the two scroll elements move apart axially,
or into the unloaded state. The Solenoid coil must be
controlled by the same voltage that is powering the
CoreSense Diagnostic module. During the unloaded
state, the compressor motor continues running, but
since the scrolls are separated, there is no compression.
During the loaded state, the compressor delivers 100%
capacity and during the unloaded state, the compressor
delivers 0% capacity. A cycle consists of one loaded
state and one unloaded state. By varying the time of
the loaded state and the unloaded state, an average
capacity is obtained. The lowest achievable capacity is
Approved Refrigerants
Application
Low
Temperature
Medium
Temperature
Model
Number
HP
ZF34K5E
10
ZF41K5E
13
ZFD41K5E
13
ZF49K5E
15
ZB58K5E
8
ZB66K5E
9
ZB76K5E
10
ZBD76K5E
10
ZB95K5E
13
ZB114K5E
15
ZBD114K5E
15
Approved
Refrigerants
R-404A,
R507,
R-407A/C,
R-22, R-407F
R-404A,
R507,
R-407A/C,
R-22,
R-134a,
R-407F
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10% which equates to 2 seconds of pumping during one
20 second cycle.
state. By varying the time of the loaded state and the
unloaded state, an average capacity is obtained. The
lowest achievable capacity is 30% which equates to 6
seconds of pumping during one 20 second cycle.
An example for the 20 second controller cycle: In any
20 second cycle, if the loaded time is 10 seconds and
the unloaded time is 10 seconds, the average capacity
is 50%, or if the loaded time is 5 seconds and the
unloaded time is 15 seconds the capacity during that
20 second period is 25%. See Figure 20 for a graphical
representation of the digital cycle, and Figure 21 for
a graph showing solenoid on-time vs. compressor
capacity.
An example for the 20 second controller cycle: In any
20 second cycle, if the loaded time is 10 seconds and
the unloaded time is 10 seconds, the average capacity
is 50%, or if the loaded time is 6 seconds and the
unloaded time is 14 seconds the capacity during that
20 second period is 30%. See Figure 20 for a graphical
representation of the digital cycle, and Figure 21B
for a graph showing solenoid on-time vs. compressor
capacity.
Medium Temperature Digital operation is controlled
by the CoreSense Diagnostics module and has a
patented algorithm that allows the compressor to run at
10%. If the compressor's Discharge Line temperature
rises at a high rate of change over time the CoreSense
Diagnostics module will increase the compressor
capacity until Discharge Line Temperature is at a
safe operating temperature. To operate with a 10%
minimum capacity Please confirm that Dip Switch
1 on the Digital and EXV DIP Switches in the top left
corner on the CoreSense Diagnostics Module(See
Figure 19) IS IN THE OFF POSITON. For correct DIP
switch settings please see Figure 23A.
How it Works
The digital scroll compressor unloads by taking
advantage of the Copeland Scroll compressor's
axial compliance. All Copeland Scroll compressors
are designed so that the compression elements can
separate axially. See Figure 20 for internal view.
The digital solenoid can be controlled two ways with
the CoreSense Diagnostics module:
1. Through a 1-5v signal. For tables of digital
capacity(%) vs. analog input (v) see Tables 7A
and 7B
2. Via mod-bus communication
Low Temp Digital Compressor Operation
Due to Lower mass flows the Low temperature Digital
compressor operation is restricted to 30%-100%.
By restricting to 30% minimum capacity this ensures
enough mass flow to the compressor for safe operation.
To operate with a 30% minimum capacity Please confirm
that Dip Switch 1 on the Digital and EXV DIP Switches
in the top left corner on the CoreSense Diagnostics
Module(See Figure 19) IS IN THE ON POSITON. For
correct DIP switch settings please see Figure 23B.
The 8.0 HP and larger digital scroll compressors
employ a solenoid valve that is mounted on the side
of the compressor that vents the intermediate cavity
to the low side of the compressor during the unloaded
state. During the loaded state the solenoid valve is deenergized and the intermediate cavity is pressurized to
load the floating seal and scrolls axially.
Operating Envelope
A normally closed (de-energized) solenoid valve is a key
component for achieving modulation. When the solenoid
valve is in its normally closed position, the compressor
operates at full capacity, or loaded state. When the
solenoid valve is energized, the two scroll elements
move apart axially, or into the unloaded state. The
Solenoid coil must be controlled by the same voltage
that is powering the CoreSense Diagnostic module.
During the unloaded state, the compressor motor
continues running, but since the scrolls are separated,
there is no compression. During the loaded state, the
compressor delivers 100% capacity and during the
unloaded state, the compressor delivers 0% capacity.
A cycle consists of one loaded state and one unloaded
Operating envelopes for the K5 compressors for
refrigeration are depicted in Figures 2A through 2M.
Extended ZF*K5E Operating Envelope
Figure 2H presents an extended envelope for the
ZF*K5E scroll. While this product is optimized for a low
temperature application, in some instances the ZF*K5E,
either with vapor injection or no injection at all, can be
applied in a medium temperature application. This may
be done to use common model numbers in a system or
to apply vapor injection for additional cooling capacity.
When applying with vapor injection, it should be noted
that the total amount of internal subcooling is limited
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by the injection pressure at the compressor. In medium
temperature operation, this value is typically higher
than when a ZFK5 is applied at low temperature and
therefore the minimum subcooled liquid temperature
allowable exiting the economizer is higher (depending
on the refrigerant this may be as high as 75°F). Refer
to Emerson's Product Selection Software for estimated
values by compressor model.
Installation of DTC Valve
The valve bulb must be installed in the top cap thermal
well to adequately control scroll temperatures. The
valve should be tightened on the injection fitting to
a torque of 216-245 in. lbs. (24.4 - 27.7 Nm). A 90°
orientation on the valve is recommended, however it will
function properly in any orientation. The capillary tube
connecting the valve to the bulb should be positioned
such that it does not contact the compressor during
operation. Do not bend the capillary tube within 1”
(25.4mm) of the valve.
NOTE: If applying without vapor injection the injection
port should be plugged. The vapor injection fitting is a
Rotalock design with a 1” x 14 rotalock thread size, the
fitting can be capped using the rotalock to stub tube
adaptor kit # 998-0034-18. A ½” copper line can be
inserted into the stub end of the adaptor and sealed off.
The rotalock adaptor with the supplied Teflon seal will
effectively seal the port and will not damage the fitting
or the compressor.
The DTC valve comes with an insulating cap. If this
additional height from the cap is an issue, the valve
cap could be replaced with high temperature insulation.
This should be applied to insulate and protect the valves
remote bulb assembly. This will reduce the total height
requirement by 0.5” (12.7mm).
ZF*K5E Low Temperature K5 Compressors for
Refrigeration
Suggested Application Techniques for All Liquid
Injection Applications
The low temperature models are provided with an
injection port that can be used for either liquid or vapor
injection.
For the most efficient thermal sensing, spread a thin film
of thermal grease around the DTC valve bulb/thermistor
before installing into the top cap well. However for
proper functioning of the valve this is not required.
Liquid Injection
When using the ZF*K5E scrolls for liquid injection
operation, a discharge temperature control (DTC) valve
or an EXV (Electronic Expansion Valve) must be applied.
The purpose of the DTC/EXV valve is to eliminate the
need for a standard capillary tube. The DTC/EXV valve is
approved for all refrigerants in this product range. A DTC/
EXV valve must also be used for ZF**K5E applications
with R-407A, R-407C and R-407F (R-407A/C/F) with
vapor injection via a special T-fitting adapter. Further
details and part numbers related to the DTC/EXV valve
are listed in Table 1 at the end of this bulletin.
NOTE: To ensure adequate temperature control,
take care to not damage the DTC valve bulb/
thermistor when installing. Damage of DTC valve
bulb/thermistor could result in improper injection.
DTC Valve Specifications
EXV Valve Specifications
The following components are not required, but they
are recommended for liquid injection.
The EXV valve is a 12 VDC stepper valve. It has 500
steps from fully open to fully closed. It consumes 6 watts
of power. It is controlled via the CoreSense module. It
adjusts open and closed based off the temperature read
from the Top cap thermistor.
•
• Sight Glass - A sight glass can be installed before
the DTC valve to allow for visual inspection for the
presence of liquid refrigerant.
For service purposes, a mechanical ball valve
(not provided by Emerson) is also recommended
in the liquid and vapor injection line. For the liquid
injection system to be effective, a minmum of 5°F
subcooled liquid at the at the DTC/EXV inlet is
required.
The following components are not required, but they
are recommended for liquid injection.
• Filter/Drier - A filter/drier can be installed upstream
of the injection circuit to avoid the possibility of the
DTC screen blockage due to contaminants.
•
Figures 2A through 2C are a representation of typical
systems, depicting the location of these components.
Sight Glass - A sight glass can be installed before
the EXV valve to allow for visual inspection for the
presence of liquid refrigerant.
• Filter/Drier - A filter/drier can be installed upstream
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of the injection circuit to avoid the possibility of the
EXV screen blockage due to contaminants.
ARI Low Temperature Ratings
(-25°F/105°F, R-404A)
EXV Installation
Model
The EXV valve is to be installed vertically with
stepper motor locked into position. See Figure 22 for
correct orientation. To ensure the valve has the proper
mounting, calibration and control, only the Emerson
supplied stepper valve (p/n 998-0340-**) should be
used with CoreSense Diagnostics for Copeland Scroll
K5 refrigeration compressors.
With EVI*
Without EVI*
ZF34K5E
48,100 Btu/hr
34,200 Btu/hr
ZF41K5E
57,500 Btu/hr
42,200 Btu/hr
ZFD41K5E
57,500 Btu/hr
42,200 Btu/hr
ZF49K5E
71,000 Btu/hr
50,500 Btu/hr
* Maximum possible subcooling
* Without EVI is "0" subcooling
NOTE: When using an EXV stepper valve a liquid
line shutoff solenoid will need to be installed on
the liquid line. This is in the event of a power loss that
will leave the EXV motor in it's current position and
potentially allow liquid to enter the compressor while
off. A vapor line shut off may be needed in the event of
a motor protection trip where the control circuit is not
opened. It is recommended to use a current sensing
relay to ensure that liquid line solenoid is to be closed
when compressor is off.
NOTE: For performance of ZF*K5E models with other
refrigerants, refer to the Online Product Information at
EmersonClimate.com
Discharge Temperature Control with Vapor Injection
Although using vapor injection offers some inherent
compressor cooling, when using the ZF*K5E scrolls
with R-407A/C/F and vapor injection additional cooling
is required to operate across the whole operating map of
the compressor. To provide this extra cooling a T-fitting
and DTC or EXV valve should be installed onto the
compressor's injection port. The T-fitting will meter liquid
from the DTC or EXV valve into one side of the fitting,
while vapor flows in through the otherside. See Figure
5 at the end of this bulletin for a example schematic.
This is different than the current method used on other
Copeland vapor injected scrolls (ZF*KVE models) which
use the Copeland Demand Cooling to inject liquid in the
vapor line of the compressor based on a discharge line
temperature reading.
Vapor Injection
The ZF*K5E 8-15 HP scrolls can also be applied with
vapor injection by implementing an economizer circuit
in the system. Economizing is accomplished by utilizing
a subcooling circuit similar to that shown in Figure 4 at
the end of this bulletin. This mode of operation increases
the refrigeration capacity and in turn the efficiency of
the system.
The schematic shows a system configuration for the
economizer cycle. A heat exchanger is used to provide
subcooling to the refrigerant (HX) before it enters the
evaporator. This subcooling process provides the
increased capacity gain for the system, as described
above. During the subcooling process a small amount
of refrigerant is evaporated and superheated. This
superheated refrigerant is then injected into the mid
compression cycle of the scroll compressor and
compressed to discharge pressure. This injected vapor
also provides cooling at higher compression ratios, similar
to liquid injection of standard ZF scroll compressors. The
benefits provided will increase as the compression ratio
increases, thus, more gains will be made in summer
when increased capacity may actually be required.
NOTE: Just as with liquid injection operation, when
using the DTC valve with vapor injection ensure that
the thermal bulb and discharge thermistor are well
insulated.
When using vapor injection with R-404A/R-507,
the DTC/EXV valve and T-fitting are not required. A
discharge line thermistor is supplied with the CoreSense
Diagnostics assembly (more information on CoreSense
Diagnostics is found later in this bulletin). The thermistor
should be placed no more than 6 inches (15.2 cm) from
the discharge of the compressor. Only when using DTC
valve The thermistor should be well insulated to ensure
accurate temperature sensing on the discharge line.
An example of the additional capacity available when
using vapor injection is depicted in the following table.
System Configuration
There are two methods of controlling refrigerant flow at
the EVI heat exchanger - downstream and upstream
extraction.
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suction line 6 inches (152mm) from the suction valve,
to prevent liquid refrigerant floodback.
Downstream Extraction
The downstream extraction is the preferred method
employed in the United States. In downstream
extraction the TXV is placed between the liquid outlet
and vapor inlet of the heat exchanger. The advantage
of downstream extraction is that subcooling is ensured
because the liquid is further subcooled as it flows
through the heat exchanger. Therefore, more subcooled
liquid enters the TXV which increases the probability
that the valve will not hunt. The disadvantage with this
method is that it is not as efficient as the upstream
method; however, the difference is too small for
practical purposes. See Figure 5.
Another method to determine if liquid refrigerant is
returning to the compressor is to accurately measure
the temperature difference between the compressor
oil crankcase and the suction line. During continuous
operation we recommend that this difference be a
minimum of 50°F (27°C). This “crankcase differential
temperature” requirement supersedes the minimum
suction superheat requirement in the last paragraph. To
measure oil temperature through the compressor shell,
place a thermocouple on the bottom center (not the side)
of the compressor shell and insulate from the ambient.
During rapid system changes, such as defrost or ice
harvest cycles, this temperature difference may drop
rapidly for a short period of time. When the crankcase
temperature difference falls below the recommended
50°F (27°C), our recommendation is the duration should
not exceed a maximum (continuous) time period of two
minutes and should not go lower than a 25°F (14°C)
difference.
Upstream Extraction
In upstream extraction the TXV is placed between
the condenser and the heat exchanger. The TXV
regulates the flow of subcooled refrigerant out of the
condenser and into the heat exchanger. With this type
of configuration there is a potential for flash gas which
would cause the valve to hunt. See Figure 6.
Contact your Emerson Climate Technologies
representative regarding any exceptions to the above
requirements.
Heat Exchanger Piping Arrangements
Best subcooling effect is assured if counter flow of
gas and liquid is provided as shown (see Figure 7).
In order to guarantee optimum heat transfer, the plate
heat exchanger should be mounted vertically and
vapor should exit it at the top.
Crankcase Heater
Crankcase heaters are required, on outdoor systems,
when the system charge exceeds 17 lbs.
For more information on applying ZF*K5E scrolls with
an economized vapor injection (EVI) circuit refer to AE41327, Economized Vapor Injection (EVI) Compressors.
Table 2 includes crankcase heaters intended for use
only where there is limited access. The heaters are
not equipped for use with electrical conduit. Where
applicable electrical safety codes require heater lead
protection, a crankcase heater terminal box should be
used. Recommended crankcase heater terminal cover
and box numbers are also listed in Table 2 If there
are any questions concerning the application, contact
Application Engineering.
Accumulator Requirements
Due to the Copeland Scroll compressor's inherent
ability to handle liquid refrigerant in flooded start and
defrost operation conditions, accumulators may not
be required. An accumulator is required on single
compressor systems with refrigerant charges over
17 lbs. On systems with defrost schemes or transient
operations that allow prolonged, uncontrolled liquid
return to the compressor, an accumulator is required
unless a suction header of sufficient volume is used to
prevent liquid migration to the compressor.
Pressure Controls
Both high and low pressure controls are required. The
minimum and maximum pressure setpoints are shown
in Table 4.
IPR Valve
Superheat Requirements
There is no internal pressure relief valve in these larger
horsepower scrolls. Therefore a high pressure control
located prior to any shut-off valves is mandatory. There
is an access port located on the compressor discharge
rotalock fitting to accommodate this control.
In order to assure that liquid refrigerant does not return
to the compressor during the running cycle, attention
must be given to maintaining proper superheat at the
compressor suction inlet. Emerson recommends a
minimum of 20°F (11°C) superheat, measured on the
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Motor Protection
• Measure the voltage across T1-T2 to ensure proper
supply voltage.
Motor protection in the K5 compressor for refrigeration
is either by internal line break (ILB) or solid state
protection with positive temperature coefficient (PTC)
sensors. The type of motor protection is based on
the compressor motor version. An "F" in the second
character indicates line break while a "W" indicates PTC
protection. For example, a ZF34K5E-TFC has ILB and
a ZB95K5E-TWC uses PTC sensors.
• Determine the control voltage by using a voltmeter
and then measure the voltage across the M1-M2
contacts:
a) If the measured voltage is equal to the control
volts then the M1-M2 contacts are open.
b) If the measurement is less than 1 volt and the
compressor is not running, then the problem is
external to the motor protector module.
PTC Motor Protection
There are four PTC (Positive Temperature Coefficient)
internal thermistors connected in series that react
with avalanching resistance in the event of high
temperatures. The thermistors are used to sense motor
temperatures. The thermistor circuit is connected to
the protector module terminals S1 and S2. When any
thermistor reaches a limiting value, the module interrupts
the control circuit and shuts off the compressor. After the
thermistor has cooled sufficiently, it will reset. However,
the module has a 30 minute time delay before reset
after a thermistor trip.
c) If the voltage is greater than 1 volt but less than
the control voltage, the motor protector module
is faulty and should be replaced.
Sensor Troubleshooting
• Remove the leads from S1-S2, and then by using an
Ohmmeter to measure the resistance of the incoming
leads.
CAUTION
Use an ohmmeter with a maximum of 9 VDC for
checking – do not attempt to check continuity
through the sensors with any other type of
instrument. Any external voltage or current
may cause damage requiring compressor
replacement.
Programmable Logic Controller Requirements
If the INT69 (071-0660-00) module is applied in
conjunction with a Programmable Logic Controller, it is
important that a minimum load is carried through the
M1-M2 control circuit contacts.
a) During normal operation, this resistance value
should read less than 4500 ohms ±20%.
The minimum required current through the module
relay contacts needs to be greater than 100 milliamps
but not to exceed 5 amps. If this minimum current is
not maintained, this has a detrimental effect upon the
long-term contact resistance of the relay and may result
in false compressor trips.
b) If the M1-M2 contacts are open, the measured
S1-S2 value is above 2750 ohms ±20% and
the compressor has been tripped less then 30
minutes then the module is functioning properly.
• If the S1-S2 wire leads read less than 2750 ohms
±20% and the M1-M2 contacts are open, reset
the module by removing the power to T1-T2 for a
minimum of 5 seconds.
PLC operated control circuits may not always provide
this minimum current. In these cases modifications
to the PLC control circuit are required. Consult your
Application Engineering Department for details.
Kriwan INT69 Module and Sensor Functional Check
• Replace all wire leads and use a voltmeter to verify
the M1-M2 contacts are closed.
Module specifications are listed in Table 3 at the end of
this bulletin. Refer to Figure 9 for wiring schematic. The
following field troubleshooting procedure can be used
to evaluate the solid state control circuit:
• If the M1-M2 contacts remain open and S1-S2 are
less than 2500 ohms, remove leads from the S1S2 contacts and jumper together, using a 100 ohm
resistor.
CAUTION
Motor Protector Module Voltage Supply
Troubleshooting
Compressor should start at this time. HOWEVER
DO NOT LEAVE JUMPER IN PLACE FOR
NORMAL SYSTEM OPERATIONS. THE JUMPER
IS USED FOR DIAGNOSTIC PURPOSES ONLY.
• Verify that all wire connectors are maintaining a good
mechanical connection. Replace any connectors that
are loose.
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Compressor Voltage Supply Troubleshooting
to verify acceptable levels of sound and vibration.
• Remove phase sensing leads from the module from
L1/L2/L3.
Compressor Mounting
Compressor mounting must be selected based on
application. Consideration must be given to sound
reduction and tubing reliability. Some tubing geometry
or “shock loops” may be required to reduce vibration
transferred from the compressor to external tubing.
Mounting kit part numbers are listed in Table 4.
• Use a voltmeter to measure the incoming 3 phase
voltage on L1/L2/L3. WARNING: L1/L2/L3 could
be at a potential up to 600VAC.
• Ensure proper voltage on each phase.
• Remove power to the module for a minimum of 5
seconds to reset and replace all wire leads. Reenergize the module. If the M1-M2 contacts are open
with proper voltage to T1-T2, L1/L2/L3 and proper
resistance to S1-S2 then the module is faulty and
should be replaced.
Mounting for Rack Systems – Specially designed
steel spacers and rubber isolator pads are available
for Copeland Scroll 8 -15 HP rack applications. This
mounting arrangement limits the compressors motion
thereby minimizing potential problems of excessive
tubing stress. Sufficient isolation is provided to prevent
vibration from being transmitted to the mounting
structure. This mounting arrangement is recommended
for multiple compressor rack installations. See Figure
8A for a detail of this mounting system.
Oil Management for Rack Applications
Copeland Scroll K5 refrigeration compressors may be
used on multiple compressor parallel rack applications.
This requires the use of an oil management system to
maintain proper oil level in each compressor crankcase.
The sight glass connection supplied can accommodate
the mounting of the oil control devices.
Condensing Units – For 8 -15 HP Copeland Scroll
condensing unit applications, standard mounts (55-65
durometer) are recommended. The mounting system
for K5 refrigeration scroll condensing units is depicted
in Figure 8B.
Unlike semi-hermetic compressors, scroll compressors
do not have an oil pump with accompanying oil pressure
safety controls. Therefore, an external oil level control
is required.
Tubing Considerations – Proper tube design must be
taken into consideration when designing the tubing
connecting the scroll to the remaining system. The
tubing should provide enough “flexibility” to allow
normal starting and stopping of the compressor
without exerting excessive stress on the tube joints. In
addition, it is desirable to design tubing with a natural
frequency away from the normal running frequency of
the compressor. Failure to do this can result in tube
resonance and unacceptable tubing life. Figure 3A
is an example of an acceptable tubing configuration.
The OMB oil level management control combines the
functions of level control and timed compressor shutoff should the level not come back to normal within
a set period of time. This device has been found to
provide excellent performance in field tests on scroll
compressors and is recommended for parallel system
applications. Refer to Table 4 for oil monitoring
accessory part numbers.
Immediately after system start-up the oil reservoir
level will fluctuate until equilibrium is reached. It is
advisable to monitor the oil level during this time to
assure sufficient oil is available. This will prevent
unnecessary trips of the oil control system. Additional
information on oil management in Copeland Scroll
compressors can be found in Application Engineering
bulletin AE17-1320.
CAUTION
These examples are intended only as guidelines
to depict the need for flexibility in tube designs.
In order to properly determine if a design is
appropriate for a given application, samples should
be tested and evaluated for stress under various
conditions of use including voltage, frequency,
and load fluctuations, and shipping vibration. The
guidelines above may be helpful; however, testing
should be performed for each system designed.
Discharge Mufflers
Gas flow through scroll compressors is continuous with
relatively low pulsation. External mufflers applied to
piston compressors may not be required on Copeland
Scroll compressors. Due to system variability individual
tests should be conducted by the system manufacturer
Connection Fittings, Service Valves, and Adapters
The fitting sizes for 8 through 15 HP scrolls are shown
in Table 5.
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Deep Vacuum Operation
testing recommendations. Under no circumstances
should the Hipot or Megohm test be performed while the
compressor is under a vacuum.
WARNING
Do not run a Copeland Scroll compressor in a deep
vacuum. Failure to heed this advice can result in
arcing of the Fusite pins and permanent damage
to the compressor.
NOTE: The solid state electronic module components
and internal sensors are delicate and can be damaged
by exposure to high voltage. Under no circumstances
should a high potential test be made at the sensor
terminals or sensor leads connected to the module.
Damage to the sensors or module may result.
A low pressure control is required for protection against
deep vacuum operation. See Pressure Control section
for proper set points. (Table 6)
Three Phase Scroll Compressors – Directional
Dependence
Scroll compressors (as with any refrigerant compressor)
should never be used to evacuate a refrigeration or air
conditioning system. See AE-1105 for proper system
evacuation procedures.
Scroll compressors are directional dependent; i.e. they
will compress in one rotational direction only. Three
phase scrolls will rotate in either direction depending
on power phasing. Since there is a 50/50 chance of
connected power being “backwards”, contractors should
be warned of this. Appropriate instructions or notices
should be provided by the OEM.
Unbrazing System Components
WARNING
If the refrigerant charge is removed from a scroll
unit by bleeding the high side only, it is sometimes
possible for the scrolls to seal, preventing pressure
equalization through the compressor. This may
leave the low side shell and suction line tubing
pressurized. If a brazing torch is then applied to the
low side, the pressurized refrigerant and oil mixture
could ignite as it escapes and contacts the brazing
flame. It is important to check both the high and low
sides with manifold gauges before unbrazing or in
the case of assembly line repair, remove refrigerant
from both the high and low sides. Instructions
should be provided in appropriate product literature
and assembly (line repair) areas.
Verification of proper rotation can be made by observing
that the suction pressure drops and the discharge
pressure rises when the compressor is energized.
No time delay is required on three phase models to
prevent reverse rotation due to brief power interruptions.
The CoreSense module will provide reverse rotation
protection.
Copeland Scroll Compressor Functional Check
Copeland Scroll compressors do not have internal
suction valves. It is not necessary to perform functional
compressor tests to check how the compressor will
pull suction pressure. This type of test may damage a
scroll compressor. The following diagnostic procedure
should be used to evaluate whether a Copeland Scroll
compressor is functioning properly.
High Potential (Hipot) Testing
Many Copeland™ compressors are configured with the
motor below the compressor. As a result, when liquid
refrigerant is within the compressor shell the motor can
be immersed in liquid refrigerant to a greater extent than
with compressors with the motor mounted above the
compressor. When Copeland compressors are hipot
tested and liquid refrigerant is in the shell, they can
show higher levels of leakage current than compressors
with the motor on top because of the higher electrical
conductivity of liquid refrigerant than refrigerant vapor
and oil. This phenomenon can occur with any compressor
when the motor is immersed in refrigerant. The level of
current leakage does not present any safety issue. To
lower the current leakage reading, the system should
be operated for a brief period of time to redistribute the
refrigerant to a more normal configuration and the system
hipot tested again. See bulletin AE4-1294 for megohm
1. Verify proper unit voltage.
2. Normal motor winding continuity and short to
ground checks can be used to determine proper
motor resistance or if an internal short to ground
has developed.
3. With service gauges connected to the suction
and discharge pressure fittings, turn on the
compressor. If suction pressure falls below normal
levels the system is either low on charge or there
is a flow blockage.
4. If the suction pressure does not drop and the
discharge pressure does not rise, reverse any two
of the compressor power leads and reapply power
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to verify the compressor was not wired to run in
the reverse direction.
The LEDs will flash a number of times consecutively,
pause and then repeat the process. To identify an alert
code number, count the number of consecutive flashes.
Detailed descriptions of specific alert codes are shown
in Table 8.
The operational compressor current draw should
be compared to published performance curves at
the operating conditions (pressures and voltages).
Significant deviation (± 15%) from published values
may indicate a faulty compressor.
The CoreSense module will continue to display the alert
code until the condition returns to normal or if module
power is cycled to the device.
CoreSense Diagnostics™ Module for Refrigeration
Compressors
Yellow LED:
The CoreSense Diagnostics module (see Figure 19)
for Copeland Scroll refrigeration compressors (referred
to as “the CoreSense module” in this document) is a
breakthrough innovation for troubleshooting refrigeration
system faults. The CoreSense module is installed in
the electrical box of all 8-15 HP K5 refrigeration scroll
compressors. By monitoring and analyzing data from
the Copeland brand compressors via module power,
discharge line thermistor, and the current transducer
(referred to as “CT” in this document), the CoreSense
module can accurately detect the cause of electrical
and system related issues. A flashing LED indicator
communicates the alert code and guides the service
technician more quickly and accurately to the root cause
of a problem.
FLASHING: Alerts of an abnormal system condition
via Alert Codes
SOLID: Demand is present but no current is
detected. All protective shutdowns will auto reset in
their allotted time
Red LED:
FLASHING: Indicates the CoreSense module is
locked out on the flashing Alert Code. Manual power
cycle reset is required to restart the compressor
Green LED:
FLASHING: Alert Codes that do NOT have a
protective shutdown associated with them.
Blue LED:
The CoreSense module can provide both compressor
protection and lockout capability. Compressor
protection means that the CoreSense module will trip
the compressor when any of the following severe alert
conditions (Codes 1, 2, 4, 6, 7 or 9) are detected. A trip
condition is when the protector on a compressor opens
and stops current flow into the compressor motor. As a
result, the compressor shuts down. A trip condition will
reset after short cycle time and when trip condition is
not present.
Flashing indicates alert codes for Digital only. Alert
Codes that do NOT have a protective shutdown
associated with them. A solid Blue LED represents
compressor unloaded.
Some troubleshooting tips for the CoreSense module
are listed in Table 9 at the end of this document.
Product Specifications
Operating Temp: -40° to 150°F (-40° to 65°C)
Storage Temp: -40° to 175°F (-40° to 80°C)
If lockout is enabled and a preset number of alarm
events happen, the CoreSense module will not allow
the compressor to start (Codes 1, 4, 6 or 7) until the
situation is corrected and the module is manually
reset. The module can be reset by cycling power to
the module.
Power Supply Range: 85-265VAC, 50-60 Hz
Working amperage for CT module: 3-200A
NOTE: The CoreSense module is not accurate below
3 Amps. If the current drawn by the compressor during
operation falls below 3 Amps, the module may indicate
a nuisance fault condition and alarm.
CORESENSE MODULE LED OVERVIEW
CoreSense Diagnostics™ Module for Refrigeration
Compressors with Digital and EXV Capability
In low current application it is applicable to loop the
power leads through the current sensor twice to double
the current value the sensor reads and eliminate the low
current nuisance trips.
The CoreSense module has the ability to shut down the
compressor if the compressor contactor coil is wired
through the M1-M2 relay.
NOTE: The 2X current reading may need to be
addressed at the system or rack controller.
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The CoreSense module connections are standard male
electrical flag terminals.
Protection/Contactor Control Wiring for CoreSense
Diagnostics Module (543-0174-**)
Maximum continuous contactor coil current is 2A with
a max inrush current of 20A.
The M1-M2 relay on the CoreSense module is a normally
open relay. When the module is powered and there are
no protective faults, the relay is energized and does not
cycle on/off. On a detected protection condition, the
CoreSense module will de-energize the relay to stop the
motor from running. The relay is not used as a cycling
device for normal compressor operation. The cycling
device must be supplied externally from the module.
Compressor Lead Wiring
The compressor leads must be routed through the holes
in the CT module marked T1, T2, and T3. Only the
compressor lead wires should be placed through
the CT module.
CoreSense Module Mounting
Protection/Contactor Control Wiring for CoreSense
Diagnostics Module (543-0209-**)
The CoreSense module will come pre-mounted inside
the compressor terminal box. The module is mounted
so all LEDs are in front of the light pipes in the terminal
covers so codes are visible when the terminal box cover
is installed on the terminal box. The CoreSense module
should be installed inside the terminal box with a torque
of 8 inch pounds.
The M1-M2 relay on the CoreSense module is a
normally open relay. M1-M2 relay cycles with demand of
the compressor. This eliminates the need for The cycling
device to be supplied externally from the module. On a
detected protection condition, the CoreSense module
will de-energizethe relay to stop the motor from running.
110-230VAC CoreSense Module Power Wiring
Discharge Temperature Protection with CoreSense
Diagnostics for K5 Compressors
The CoreSense module requires 110-230VAC power
between to the L1 and L2 terminals. The module should
remain powered through all states of compressor on/off
operation. Refer to wiring schematic examples.
Copeland Scroll K5 compressors for refrigeration with
CoreSense Diagnostics come standard with discharge
temperature protection. Depending on the application
and refrigerant a certain mode of protection will be
used whether it is a top cap thermistor or DTC valve
with discharge line thermistor or an EXV valve with a
top cap thermistor. The CoreSense module identifies
the protection device based on the pin locations in the
connector. Figures 10 and 11 depict the installation of
the top cap thermistor and discharge line thermistor,
respectively.
NOTE: The physical Location of L1 and L2 have
changed on 543-0209-**. Confirm correct location of
L1 and L2 wiring. Reference Figure 19.
Demand Wiring for (543-0174-**)
The CoreSense module requires a demand signal to
operate properly. The demand signal input, labeled
D on the module, should always be connected to the
compressor demand so that the demand signal input
is 110 or 220VAC with respect to L2. See Figure 9A
for proper wiring diagrams. Choose the appropriate
diagram depending on how the demand signal will be
fed to the module.
Table 1 at the end of this bulletin identifies the discharge
temperature protection device by application and
refrigerant. Table 4 identifies the service part numbers
for those devices.
Communication DIP Switch Configuration
The communication module on the CoreSense
Diagnostics module is equipped with a 10 switch DIP
switch used for selection of the Modbus® address, baud
rate, parity, and other operating conditions to simplify
service and start-up procedures. See Figure 13. For
more information on DIP switch settings, Table 11 lists
the purpose for each switch.
Demand Wiring for (543-0209-**)
For CoreSense Diagnostics module (543-0209-**) a
demand relay is no longer needed. Control voltage
(110/220V) is needed at the D terminal. For digital
models the D terminal is used to monitor control
voltage only. The demand signal comes from the
RS485 network OR the 1-5V analog input. For fixed
capacity models the demand signal input comes from
the D terminal, and is 110 or 220VAC with respect to
L2. See Figure 9B for proper wiring diagram
NOTE: Cycle power 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
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compressor system with communications to the E2:
Passing the communications wire through the grommet
in the plastic housing will help reduce abrasion to the
wiring. Appropriate strain relief is recommended.
1. Switches 1 through 5 are used for setting the
address. Each CoreSense Diagnostics device that
is connected to a rack controller must have a unique
node address (as determined by the DIP switch
settings).
NOTE: The RS485 is polarity sensitive. “+” wires
must connect to other “+” terminals, and “-” wires
must connect to other “-” terminals. The shield wire is
connected to the center terminal, or “0 volt” position.
2. Switch 6 defines the communications baud rate for
the CoreSense Diagnostics 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 devices should be set to match the rack
controller. The default baud rate is 19200 (“off”) for
the CoreSense Diagnostics module. To determine
the baud rate in the E2, follow these steps:
Terminations
The last compressor in the daisy chain must be
“terminated” by setting the DIP switch number 10 to the
"on" (up) position. For all other compressors the number
10 DIP switch should remain in the "off" (down) position.
•
From the main menu select 7 (System
Configuration)
More information: The E2 jumpers on the Network
Interface Board should be set for “terminated”. Refer
to Figure 16.
•
Press 3 (System Information)
COMMISSIONING
•
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
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. Refer to section titled Modbus®
Communication to CoreSense Diagnostics for K5
Compressors for more details on commissioning the
K5 scrolls in an Emerson Retail Solutions E2 rack
controllers.
3. Switch 7 defines the communication parity. The
default parity setting for the CoreSense Diagnostics
module is no parity. If the switch is set to “on” the
module will communicate using even parity. The
parity setting must match the parity setting of the
rack controller.
4. Switch 8 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.
NOTE: For digital capacity using an E2 controller,
an enhanced suction group must be enabled.
The CoreSense Diagnostics module does not
need to communicate to the rack controller in
order to provide compressor protection. Using
the communication process is optional, but provides
for information flow to the controller for proofing,
remote reset, asset information, and fault history and
compressor status. Skip to section titled Stand Alone
Mode if the communication feature will not be used.
Cable Routing / Daisy Chain Configuration
A second set of DIP switches are used for compressor
operation. See Table 12 for default configuration and
application guidelines for DIP switches. The CoreSense
Diagnostics module can communicate with a rack
controller 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 16 and 17.
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.
Stand Alone Mode
If running a K5 with CoreSense Diagnostics without
communication to a rack controller, DIP switch 8 should
be set to "Off" (down).
A shielded, twisted pair cable such as Belden #8761
(22AWG) should be used for the communication wiring.
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Modbus® Communication to CoreSense Diagnostics
for K5 Compressors
Switch 2 is for Digital Capacity Control. The "ON"
position enables Digital Capacity.
K5 Compressors equipped with a communication
module are capable of communicating via open
Modbus® to a rack controller. The steps on the following
pages are provided to commission K5 scrolls in an
Emerson E2 with firmware version 3.0 or newer. For
other rack controllers, contact the manufacturer.
Switch 3 is for Failsafe. The "ON" position will allow the
compressor to run at 100% if communications is lost. If
in the "OFF" position the compressor will become off if
communications is lost.
Switch 4 – Affects standard Mobus. For applications
using IPRO or XWeb (Dixell) 'non-standard Modbus'
turn SW4 ON Standard Emerson Climate Technologies
Modbus, the DIP switch orientation doesn't matter.
CoreSense Diagnostics with EXV and digital capability
uses two sets of DIP switches: a communication set
with 10 DIP switches on the center of the module, and
a compressor operation set with 6 DIP switches on the
top left corner of the module.
For all other standard Modbus, Dipswitch 4 should be
in the OFF position.
*
For a description of the DIP switches please see
Figures 13 and 14.
SW5: Is to return to factory defaults for all configuration
and erase the module history, use SW5 to reset the
module. To reset SW5 must transition from off to on
within 5 seconds of module power up.
Digital and EXV DIP Switches
Switch 1 is for Liquid injection being controlled by the
EXV. The "ON" position enables the EXV.
Switch 6 Is for Lockouts enabled. The "ON" position will
enable lockouts
* These guidelines are based on E2 firmware version 3.0 and are subject to change. Contact your Emerson representative or refer to the
operation manual for more details on configuring an E2 module.
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CoreSense K5 Programming Instructions
1. Press
to enter the Main Menu. Select 7. System Configuration.
2. From the System Configuration Menu select 7. Network Setup
3. From the Network Setup Menu select 2. Connected I/O Boards and Controllers
4. From the Setup Screen go to the C3: ECT Tab (Press Ctrl + 3)
5. In Option #9, enter the number of K5 compressors being controlled by the E2.
Press
to save changes and return to the previous screen.
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6. From the Network Setup Menu select 1. Network Summary
7. The CoreSense™ K5 devices should be present on the Network. Select the CoreSense K5
module to be commissioned. Press F4: Commission
8. Select the Modbus® that the CoreSense device is connected to. (If only Modbus® network is
connected, this step will automatically complete itself, skip to step 9)
9. From the Modbus® Device Menu select an unused space that matches the DIP switch
Address of the CoreSense device and press Enter..
10. Verify the address matches the address assigned by the CoreSense module’s DIP switch
settings and press Enter.
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11. Press
to return to the Network Summary screen. The device should now be
“Online”.
Repeat steps 8 -10 to address the remaining CoreSense K5 modules.
12. Once all the devices are addressed, press
Network Summary.
13. Press
to save changes and exit the
to enter the Main Menu. Select 7. System Configuration.
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14. From the System Configuration Menu select 7. Network Setup
15. From the Network Setup Menu, select 4. Controller Associations . Then Select 4. Compressor
(Press Enter)
16. Highlight the Suction Group2 field, select F4: Look Up (Press F4) and select the appropriate
suction group for the device and press Enter.
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2 For
more information on setting up suction groups in the E2, consult your Emerson Retail
Solutions representative.
17. Scroll over to the Comp Stage and type in the compressor stage. (CoreSense Protection
provides proofing only on the compressor.)
Note! The compressor stage number should correspond to the stage numbers in the suction
group setup (Step 7)
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Start
Is the compressor
running?
No
Is the compressor
overheated?
Yes
Allow time to cool
WARNING!
Disconnect and lockout
the power before
proceeding
Put the system back into
operation and retest
Remove one wire from
the modulation coil
No
Perform troubleshooting
to determine why the
compressor isn’t
running
Observe the compressor
suction & discharge
pressures
Are pressures
changing with the
modulation
cycle?
Yes
Operation
is normal
Yes
Measure the resistance
of the coil
No
Measure the voltage at
the modulation coil
terminals
Coil has continuity
and isn’t grounded?
No
Replace modulation
coil
Yes
Is voltage present,
coinciding with the
modulation cycle?
No
Replace modulation
valve, follow valve
replacement
instructions
Troubleshoot the
modulation control
Yes
Figure 1 – Modulation Troubleshooting
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Put the system back into
operation and retest
AE4-1383 R9
ZF*K5E Low Temperature Vapor Injection** Operating Map
(65°F Return Gas)
R-404A/R-507
160
Condensing Temperature (°F)
140
120
100
80
60
40
20
0
-50
-40
-30
-20
-10
Evaporating Temperature (°F)
0
10
Figure 2 (A)
ZF*K5E Low Temperature Vapor Injection** Operating Map
(65°F Return Gas)
R-407A /R-407C /R-407F
160
Condensing Temperature (°F)
140
120
100
Maximum
40F
Superheat
80
60
40
20
** DTC/EXV Liquid Injection Required with EVI for R-407A /R-407C/ R-407F
0
-50
-40
-30
-20
-10
Evaporating Temperature (°F)
Figure 2 (B)
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0
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ZF*K5E Low Temperature Liquid Injection Operating Map
(65°F Return Gas)
R-404A/R-507/R-407A/R-407C/R-407F
160
Condensing Temperature (°F)
140
120
100
DTC/EXV Liquid
Injection Required
80
60
40
20
0
-50
-40
-30
-20
-10
Evaporating Temperature (°F)
0
10
Figure 2 (C)
ZF*K5E Low Temperature Liquid Injection Operating Map
(65°F Return Gas)
R-22
Condensing Temperature (°F)
140
120
100
DTC/EXV Liquid
Injection Required
80
60
40
20
0
-50
-40
-30
-20
-10
Evaporating Temperature (°F)
Figure 2 (D)
© 2014 Emerson Climate Technologies, Inc.
23
0
10
AE4-1383 R9
ZB*K5E Medium Temperature Operating Map
(65°F Return Gas)
R-404A/R-507/R-407A/R-407C/R-407F
160
Condensing Temperature (°F)
140
120
t to
/F
07C
i
Lim
20F
SH
R-4
100
65°F Maximum Return Gas
80
60
40
20
0
-20
-10
0
10
20
30
Evaporating Temperature (°F)
40
50
Figure 2 (E)
ZB*K5E Medium/High Temperature Operating Map
(65°F Return Gas)
R-22
160
Condensing Temperature (°F)
150
140
130
120
110
100
90
80
70
60
0
10
20
30
40
Evaporating Temperature (°F)
50
60
Figure 2 (F)
Note: For operating maps at different return gas conditions, contact your Application Engineer.
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
ZB*K5E High Temperature Operating Map
(20F Superheat)
R-134a
Condensing Temperature (°F)
180
160
140
120
100
80
60
0
10
20
30
40
50
Evaporating Temperature (°F)
60
70
Figure 2 (G)
ZF*K5E (Excluding ZF49K5E) Medium Temperature Operating Map
with and without Vapor Injection
R-404A/R-507/R-407A/R-407C/R-22*
140
Condensing Temperature (°F)
120
100
80
60
65°F Maximum Return Gas
40
20
0
-15
-10
-5
0
5
10
15
Evaporating Temperature (°F)
Figure 2 (H)
© 2014 Emerson Climate Technologies, Inc.
25
20
25
30
*R-22 Not Approved for Vapor Injection
AE4-1383 R9
ZBD*K5E R-404A, R-407A Compressor Operating Envelope WITH
CoreSense Diagnostics Controlling Digital Capacity
160
140
120
100
80
60
40
20
0
-20
-10
0
10
20
Figure 2 (I)
© 2014 Emerson Climate Technologies, Inc.
26
30
50
AE4-1383 R9
ZBD76 R-404A Compressor Operating Envelope WITHOUT
CoreSense Diagnostics Module Controlling Digital Capacity
160
100%-20%
120
100%-10%
140
100
80
60
40
20
0
-20
-10
0
10
20
30
40
50
Figure 2 (J)
ZBD76 R-407A Compressor Operating Envelope WITHOUT
CoreSense Diagnostics Module Controlling Digital Capacity
160
140
100%-10%
80
100%-30%
100
100%-50%
100%-60%
120
60
40
20
0
-20
-10
0
10
20
30
40
Figure 2 (K)
NOTE: Minimum capacity is assumed running at a continuous minimum capacity.
These Minimum capacity restrictions ONLY apply when NOT using CoreSense Diagnostics
© 2014 Emerson Climate Technologies, Inc.
27
50
AE4-1383 R9
ZBD114 R-404A Compressor Operating Envelope WITHOUT
CoreSense Diagnostics Module Controlling Digital Capacity
160
140
100%-30%
80
100%-40%
100
100%-50%
100%-70%
120
60
40
20
0
-20
-10
0
10
20
30
40
50
Figure 2 (L)
ZBD114 R-407A Compressor Operating Envelope WITHOUT
CoreSense Diagnostics Module Controlling Digital Capacity
160
140
100%-30%
100%-40%
80
100%-50%
100
100%-70%
100%-80%
120
60
40
20
0
-20
-10
0
10
20
30
40
Figure 2 (M)
NOTE: Minimum capacity is assumed running at a continuous minimum capacity.
These Minimum capacity restrictions ONLY apply when NOT using CoreSense Diagnostics
© 2014 Emerson Climate Technologies, Inc.
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50
AE4-1383 R9
FILTER
DRIER
SUCTION
MANIFOLD
KEEP MIN
(SEE NOTE 6)
<12”
CONTINUOUS TUBING
(NO ELBOWS)
Notes:
<12”
<30”
Figure 3 (A)
Typical Suction Tubing
(1) The above tubing configurations are guidelines to minimize tube stress.
(2) Follow similar guidelines for discharge tubing and oil return tubing as needed.
(3) If a run over 30” is required, intermediate clamps may be necessary.
(4) Do not hang weights on tubing (e.g. filter drier on suction tubing) except after clamps or close to the header.
(5) This dimension should be made as short as possible but still insuring a proper braze joint.
(6) The above tubing recommendations are based on “no elbow joints”. The use of continuous tubing is preferred.
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Figure 3 (B)
Liquid Injection Scroll with DTC Valve
Figure 3 (C)
EVI Scroll with DTC and T-fitting Adapter
Figure 3 (D)
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Figure 4 – Circuit Diagram and Cycle for EVI
Condenser
Outlet
LIT
VOT
Vapor Outlet to
Compressor
SIT
Vapor Out
Heat
Exchanger
Cond. Out
Liq. In
TXV
UT
SIT
TXV
LOT
Liq. Out
Vapor In
Figure 6 – Upstream Extraction
Figure 5 – Downstream Extraction
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
VO = Vapor temperature leaving H/X
VI = Vapor temperature entering H/X
LI = Liquid temperature entering H/X
LO = Subcooled liquid leaving H/X
Figure 7 – H/X Piping Arrangement
028-0188-22
SLEEVE
102-0283-00
WASHER
027-0115-00
RUBBER PAD
027-0400-00
RUBBER GROMMET
027-0383-00
STEEL SPACER
KIT #527-0210-00
KIT# 998-0178-00
Figure 8B
8 - 15 HP Condensing Unit
Mounting
Figure 8A
8 - 15 HP Copeland Scroll Compressor
Rack Mounting
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
L1
L2
13
CoreSense Module
K1 Relay
14
K1 Relay
D
9
5
*Kriwan
Module
M1
INJ
Sol
M1
M2
M2
T1
L1
T2
L2
CC
OMB
Alarm
LPCO
* Note - If Kriwan is used wire in series with
CoreSense module. If not used directly connect
M1 to M1, M2 to M2, T1 to L1, T2 to L2
HPCO
Figure 9A – CoreSense Module with Pressure Safety Control
** The physical location of M1/M2 & L1/L2 have
changed on the CoreSense module **
Note: If Kriwan module is used, wire in series
with CoreSense module, as indicated in diagram.
If Kriwan module is not used, wire M1 directly
from safety circuit to M1 on CoreSense & M2
from contactor coil to M2 on CoreSense module.
** System control point only needed for fixed
capacity compressors.
Figure 9B – CoreSense Diagnostics Module with Digital and EXV Capability
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Top Cap
266°F
(130°C)
Line
242°F
(117°C)
Identification Tag Color
No Tag
Orange Tag
Figure 10 – Discharge Thermistor Connector (Viewed from Wire Side)
Nominal Shutdown Temperature
Top Cap
Thermistor
Figure 11 – Top Cap Thermistor
Figure 12 – Discharge Line Thermistor
The top cap thermistor should be installed with dielectric grease applied on the probe. When attaching
the probe to the compressor, a high temperature silicone
type sealant should be used not only to adhere the probe
to the compressor, but to also prevent any moisture from
entering the thermal well.
The discharge line thermistor should be attached to
the discharge about 6 inches from the discharge of the
compressor and is only used with a DTC valve
Note! Although not depicted in this figure, the thermistor
should be well insulated to ensure accurate temperature
sensing.
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Node Addresses
1
2
3
12345
12345
12345
4
5
6
12345
12345
12345
7
8
9
“On” (UP)
12345
9600
Even
Baud
Rate
Parity
Control
Mode
Network
Termination
19200
No
Parity
Stand
Alone
Not
Terminated
12345
Network
Terminated
“Off ” (Down)
12345
1 2 3 4 5 6 7 8 9 10
Position 9 is not used
Figure 13 – K5 Communication Module DIP Switch Settings
Figure 14 – Digital and EXV DIP Switches
Terminal 5, Demand Wire
Terminal 9, Jumper To
Terminal 13
Terminal 13, L1
and Jumpered
to Terminal 9
Terminal 14, L2
Figure 15 – Wiring Relay Example
Figure 16 – E2 Jumpers
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
(Terminated)
(Terminated)
(Terminated)
(Terminated)
Figure 17 – RS485 Daisy Chain Connection
(Terminated)
(Terminated)
(Terminated)
(Terminated)
Figure 18 – Two Rack Daisy Chain Connection
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Compressor
Operation
DIP Switches
Current Toroid Plugin
Digital Input 1-5V
(Analog Input)
Diagnostic
LED Lights
Top Cap Thermistor
Module
Communication
DIP Switches
Modbus®
Communication
Plugin
Ground Screw
Control Circuit
Digital Solenoid
Voltage Output
(110/220V)
Liquid Injection
Output (cord
provided)
Module Power 110V/220V
Areas highlighted in red circles show differences from the old
CoreSense™ Diagnostics module to the new. Digital control
and EXV control have been added to the module. The physical
location of (M1,M2) and (L1,L2) has also changed.
Figure 19 – Comparison of old and new modules
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Floating Seal Cavity
Seal Cavity
Seal Cavity Vent
Removable External
Solenoid and Coil
Figure 20
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
20 Second Operating Cycle
100%
90%
Compressor Capacity (Percent of Full Load)
80%
70%
60%
50%
40%
30%
20%
10%
0%
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Solenoid On -Time (Seconds)
Figure 21A
ZBD*K5E Digital Operation Cycle Time
Figure 21B
ZFD*K5E Digital Operation Cycle Time
© 2014 Emerson Climate Technologies, Inc.
39
16
17
18
19
20
AE4-1383 R9
CoreSense™ Diagnostics + EXV Operation
1. Top Cap Temperature
Sensor
4. EXV Stepper Motor. Changes
Valve Opening and Closing
Depending on the CoreSense
Output Signal
Liquid out from the Valve and
in to the Compressor
EXV Valve Assembly
Kit 998-0340-00 Includes…
• Stepper Motor with Cable
• Valve Body
• Brazed Fitting
2. Input Signal
to CoreSense
Module
Liquid Line Input to the
Valve (Liquid line Solenoid
will be needed)
3. CoreSense
Module
543-0209-00
4. CoreSense
Output
T-Fitting with EXV for
Wet Injection Application
Figure 22
Medium Temperature Digital Operation
10%-100%
Low Temperature Digital Operation
30%-100% and Enables Liquid Injection
Enables Digital Operation
Enables Digital Operation
Figure 23A – Medium Temp
ZBD*K5E Digital Operation DIP Switch Settings
Figure 23B – Low Temp
ZFD*K5E Digital Operation DIP Switch Settings
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Table 1
Injection Accessories
Application
Injection
Refrigerants
ZB
(Medium Temp)
N/A
All
Top Cap Thermistor is Factory Installed (no kits required)
404A/507
ZF
(Low Temp)
Vapor
Injection
Reference
Figure
Required Kits
998-0229-00: Top Cap Thermistor Kit
See Figure 21
See Figure 21
*Top Cap Thermistor is factory installed on -260 BOM
407A/C/F
998-0500-03: 250°F DTC Kit Including Temperature Probe
998-0177-00: DTC Vapor Injection Adapter
See Figure 3C
All
998-0500-03: 250°F DTC Kit Including Temperature Probe
See Figure 3B
Liquid
Injection
Table 2
External Wrap-Around Crankcase Heaters
Crankcase
Heater Kit P/N
Crankcase
Heater P/N
Volts
Watts
Lead Length
(in)
Ground Wire
Length (in)
918-0047-00
018-0091-00
120
90
48
48
918-0047-01
018-0091-01
240
90
48
48
918-0047-02
018-0091-02
480
90
48
48
918-0047-03
018-0091-03
575
90
48
48
Table 3
Kriwan INT69 Module Specifications
Emerson P/N
071-0660-00
Emerson Kit P/N
971-0641-00
Manufacture P/N
Kriwan 22 A 601
T1-T2 Module Power
Voltage Supply
120/240V
Frequency
50/60 Hz
M1-M2 Module Output Contacts
Maximum Voltage
264 VAC
Maximum Current
2.5 Amps
Minimum Current
100 milliamps
S1-S2 Thermal Protection
Trip Out Resistance
4500 ±20%
Reset Resistance
2750 ±20%
Reset Time
Manual Reset
30 min ±5 min.
T1-T2 interrupt for minimum of 5 sec.
© 2014 Emerson Climate Technologies, Inc.
41
Conduit Ready Box for
Crankcase Heater
998-7029-00
AE4-1383 R9
Table 4
K5 Compressor for Refrigeration Additional Accessories
Accessory
Mounting Parts
Service Valve
Kits
Rotalock to
Stub Tube
Adapter Kits
Motor Protection
Oil Monitoring
OEM (Emerson
Flow Controls
P/Ns)
CoreSense
Diagnostics
Crankcase
Heater Kits
Liquid Injection
Components
Digital Kits &
Components
Part Description
P/N
55-65 Durometer Mounting Parts Kit (for single compressor applications)
527-0210-00
Hard Mounting Parts Kit (for parallel rack applications)
998-0178-00
Suction and Discharge Service Valves with Seals
998-5100-27
Suction Rotalock Service Valve with Seal - 1 3/8" Stub Tube
998-0510-46
Discharge Rotalock Service Valve with Seal - 7/8" Stub Tube
998-0510-39
Discharge Rotalock to Stub (1 1/4" 12 Thread to 7/8" Sweat)
998-0034-08
Suction Rotalock to Stub (1 3/4" 12 Thread to 1 3/8" Sweat)
998-0034-13
Vapor & Liquid Injection Rotalock to Stub (1" 14 Thread to 1/2" Sweat)
998-0034-18
External Motor Protection Module for ZB95K5E-TWC,
ZB(D)114K5E-TWC, ZB(D)14K5E-TWE
971-0641-00
Oil Management Control w/ Junction Box 24V 50/60Hz
065365
Oil Management Control w/ Series Relief Connector 24V 50/60Hz
065366
Copeland Scroll OMB Adapter for K5 Refrigeration Scroll
066077
CoreSense Module for K5 Refrigeration Scroll (Pre April 2014)
943-0151-00
CoreSense Current Sensor Module for K5 Refrigeration Scroll
943-0159-00
CoreSense Module for K5 Refrigeration Scroll (After April 2014)
998-0351-00
Thermistor Kit (Includes Top Cap and Discharge Line Themistors)
998-0176-00
Top Cap Thermistor Kit (Top Cap Thermistor Only)
998-0229-00
120V, 90W Wrap Around, 48" Lead Length 018-0091-00
918-0047-00
240V, 90W Wrap Around, 48" Lead Length 018-0091-01
918-0047-01
480V, 90W Wrap Around, 48" Lead Length 018-0091-02
918-0047-02
575V, 90W Wrap Around, 48" Lead Length 018-0091-03
918-0047-03
Conduit Ready Box for Crankcase Heater
998-7029-00
DTC Kit - 250F Set Point DTC With 268F Thermistor for Liquid Injection
and 407A/C Vapor Injection
998-0500-03
Liquid Injection Adapter (for 407A/C Vapor Injection Applications Only)
998-0177-00
EXV Liquid Injection Valve Kit (Includes EXV Valve with Compressor
Connection & Wiring)
998-0340-00
120 V Digital Solenoid Coil
998-0060-03
240 V Digital Solenoid Coil
998-0060-04
Digital Wire for CoreSense Analog Input
998-0341-00
Digital Solenoid Coil Wire (CoreSense Module to Digital Solenoid Coil)
998-0342-00
Closed Loop Digital Controller (Single Compressor Applications)
998-0189-00
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Table 5
K5 Compressor for Refrigeration (8 to 15 HP) Fitting Sizes
Fitting
Size (in.) -Thread
Suction Rotalock Connection
1 3/4"-12
Discharge Rotalock Connection
1 1/4"-12
Liquid/Vapor Injection Rotalock Connection
1"-14
Table 6
High and Low Pressure Control Settings
Model
Control Type
R-404A / 507
ZF* K5E
Low
High
0 psig min.
400 psig max
ZB*K5E
Low
High
17 psig min.
450 psig max
Table 7A
Low Temperature Digital Modulation
Capacity(%)/Analog (V)
R-134A
--4 psig min.
263 psig max
R-22 / R-407A /
R-407C/R-407F
2 in. Hg Min.
335 psig Max
37 psig min.
381 psig max
Table 7B
MediumTemperature Digital Modulation
Capacity(%)/Analog (V)
Digital
Capacity %
Analog
Voltage Input
(Volts)
Digital
Solenoid
On time
(Seconds)
Digital
Capacity %
Analog
Voltage Input
(Volts)
Digital
Solenoid
On time
(Seconds)
100%
5.00
0
100%
5.00
0
90%
4.60
2
90%
4.60
2
4.20
4
80%
4.20
4
80%
70%
3.80
6
70%
3.80
6
60%
3.40
8
60%
3.40
8
50%
3.00
10
50%
3.00
10
40%
2.60
12
40%
2.60
12
30%
2.20
14
30%
2.20
14
20%
1.80
16
10%
1.40
18
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Table 8
R1011 Alert Code Descriptions
Alert Code
Protection
Shutdown
(Default)
Code Description
Protection Consecutive
Off Time
Detections
(Default) Until Lockout
Lockout feature is NOT enabled from the factory except on code 7

1
High Discharge Temp – see diagram for setting
Yes
20 Min.
4

2
Excess System Limit Trips 4 consecutvie system limit trips
having 1-15 min runtime each
Yes
5 Min.
No Lockout

3
Excessive Demand Cycling Default is 240 cycles per 24 hr. period
No
-
-

4
Locked Rotor Compressor did not start within alloted time
Yes
20 Min.
4

5
Demand Present No current detected over 4 hr. period
No
-
-

6
Phase Loss Detected
Yes
20 Min.
10

7
Reversed Phase Detected
Yes
Until
Module Is
Reset
1

8
Welded Contactor Current detected without demand1
No
-
-




9
Low Module Voltage
Yes
5 Min.
No Lockout
10
Module Communications Error
No
-
-
11
Discharge Temperature Sensor Error
No
-
-
12
Current Transducer Error
No
-
-



1
2
3
Digital Alert Codes:
Loss of analog demand – Check analog voltage
Network mode ON, 1-5V input present – Check position of DIP switch #8
Network model OFF, receiving Modbus® communication – Check position of DIP switch #8
Lockouts can be enabled by DIP switch 6 setting
1
Code 8 displays for 24 hours after last detection
The M1-M2 relay only opens during a protection shutdown. To reset module, cycle module power.
Module must be reset for DIP switch changes to take effect.
For technical support call 1-888-367-9950 or visit EmersonClimate.com
Refer to AE4-1383 for more details.
© 2014 Emerson Climate Technologies, Inc.
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AE4-1383 R9
Table 9
CoreSense™ Diagnostics Module Troubleshooting
Status LED
Status LED Description
Status LED Troubleshooting Information
Green Alert LED
Solid
Module has power
Supply voltage is present at module terminals
Green Alert LED
3 Flashes
Short Cycling
2 to 480 run cycles in 24hours ending
with normal
Alert Default is set to 240 per 24 hours
1. Check pressure or temperature control
2. Possible loss of refrigerant
3. Blocked Condenser
Green Alert LED
5 Flashes
Open Circuit
Demand signal is present but no
compressor current for four hours
1. Compressor circuit breaker or fuse(s) is open
2. Compressor contactor has failed open
3. High pressure switch is open and requires
manual reset
4. Open circuit in compressor supply wiring or
connections
5. Long compressor protector reset time due to
high ambient temperature
6. Compressor windings are damaged
Green Alert LED
8 Flashes
Welded Contactor
No demand signal, but current has
been detected in one or both phases
Displayed for 24 hrs after last detection
1. Contactor welded closed
2. Control circuit transformer is overloaded
3. Demand signal not connected to module
- Demand signal could be from T-Stat or
rack controller
4. Verify Wiring
Green Alert LED
10 Flashes
Loss of Communication
Communication lost between rack
controller and module for 10 minutes or
more
1. Check communications wiring
2. Verify wiring follows application guidelines
Green Alert LED
11 Flashes
Discharge Temperature Sensor Error
Short or Open Circuit Detected
1. Check discharge temperature sensor wiring
and mounting
2. Verify sensor is not shorted. 86k @ 77°F
Green Alert LED
12 Flashes
Current Transducer (CT) Error
1. Verify CT is plugged into module
2. Verify CT is not shorted
Yellow Alert LED
Solid
Trip
Demand present, no current is detected
1. Compressor protector is open
- Check for high head pressure
- Check compressor supply voltage
2. Compressor circuit breaker or fuse(s) is open
3. Broken wire or connector is not making
contact
4. Safety cutout switches open (HPCO, LPCO,
OMB, etc.)
5. Compressor contactor has failed open
Yellow Alert LED
1 Flash
High Discharge Line Temperature Trip
See inside label to determine cut out
temp.
1.
2.
3.
4.
Yellow Alert LED
2 Flashes
System Trip
Four consecutive compressor trips after
run time of 1-15 minutes each
1. Excessive suction pressure or discharge
pressure
2. Improper wiring
© 2014 Emerson Climate Technologies, Inc.
45
Possible loss of refrigerant charge
Blocked condenser
Verify that discharge valve is open
On low temperature scroll compressors check
liquid injection
AE4-1383 R9
CoreSense™ Diagnostics Module Troubleshooting (Continued)
Status LED
Status LED Description
Status LED Troubleshooting Information
Yellow Alert LED
4 Flashes
Locked Rotor
Compressor is drawing current without
rotating or four consecutive compressor
trips after run time of 1-15 seconds
1. Low line voltage (contact utility if voltage at
disconnect is low)
2. Verify presence of all legs of power line
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
5. Verify operating current
Yellow Alert LED
6 Flashes
Missing Phase
Demand signal is present but current is
missing in one phase
1. Improper wiring. Correct order of phases in
wires
2. Failed contactor. Check contacts for pitting
3. Compressor current could be too low. Refer to
specifications.
4. Verify presence of all legs of power line
Yellow Alert LED
9 Flashes
Low Voltage Detected
Control voltage dips below 85V for
110V or 170V for 220V
1. Low line voltage (contact utility if voltage at
disconnect is low)
2. Check wiring connections
Red Alert LED
1 Flash
LOCKED OUT ON:
High Discharge Line Temperature Trip
See inside label to determine cut out
temp.
Red Alert LED
4 Flashes
LOCKED OUT ON:
4 Consecutive Locked Rotors Detected
Compressor is drawing current without
rotating or four consecutive compressor
trips after run time of 1-15 seconds
1. Low line voltage (contact utility if voltage at
disconnect is low)
2. Verify presence of all legs of power line
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
5. Verify operating current
Red Alert LED
6 Flashes
LOCKED OUT ON:
10 Missing Phase Detections
Demand signal is present but current is
missing in one phase
1. Improper wiring. Correct order of phases in
wires.
2. Failed contactor. Check contacts for pitting.
3. Compressor current could be too low. Refer to
specifications.
4. Verify presence of all legs of power line
Red Alert LED
7 Flashes
LOCKED OUT ON:
1 Reverse Phase Detected
Demand signal is present but current is
not detected in the correct sequence
1. Improper wiring. Correct order of phases in
wires.
2. Compressor current could be too low. Refer to
specifications.
3. Verify presence of all legs of power line
© 2014 Emerson Climate Technologies, Inc.
46
1.
2.
3.
4.
Possible loss of refrigerant charge
Blocked condenser
Verify that discharge valve is open
On low temperature scroll compressors check
liquid injection
AE4-1383 R9
Table 10 – Demand Wiring
Demand Wiring Kit (998-0188-00)
Control Voltage
Item
110/120
Relay Socket
220/240
032-0766-00
Relay
040-1086-00
040-0187-00
Table 11 – K5 Dip Switch Settings
Dip Switch
Number
On
1 Through 5
Modbus® Module Address
Off
6
Baud Rate= 9600
Baud Rate= 19,200
7
Even Parity
No Parity
8
Network
Stand Alone
9
Not Used
10
Terminated
Not Terminated
Table 12
CoreSense™ Module DIP Switch Scenarios
Factory Default
Application
Low Temperature
Digital?
Digital
Non-Digital
Digital
Non-Digital
Compressor
ZBD**K5E
ZB**K5E
ZFD**K5E
ZF**K5E
SW1: EXV Enabled
Off
Off
On
On
SW2: Digital Enabled
On
Off
On
Off
SW3: Failsafe On/Off
Off
Off
Off
Off
SW4: 1 or 2 Stop Bits
Off
Off
Off
Off
SW5: Reset to Default
Off
Off
Off
Off
SW6: Lockout Enabled
Off
Off
Off
Off
All
All
Liq Inj
VI 407A
VI 404A
Liq Inj
VI 407A
VI 404A
On for
Rack
Off
On for
Rack
On for
Rack
On for
Rack
Off
Off
Off
Off w
XC643
Off
Off w
XC643
Off w
XC643
Off w
XC643
Off
Off
Off
n/a
n/a
Yes
Yes
No
n/a
Application
Adjust
Medium Temperature
SW2: Digital Control
Option To Use Open Triac
*Liquid Inj. Line Solenoid
No
No
*To use open Triac you must have a non digital compressor with switch number 2 set to the OFF position.
(Triac is normally open)
Needed, Same as
Factory Default
Different Than
Factory Default
Not Needed, No Change
to Factory Default
The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding the products or
services described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or its affiliates (collectively "Emerson"), as applicable, reserve the right to modify the
design or specifications of such products at any time without notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for
proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user.
© 2014 Emerson Climate Technologies, Inc.
47
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