AE4-1383 PDF R13

AE4-1383 PDF R13
AE4-1383 R14
March 2016
AE4-1383 R14
Application Guidelines for ZF*K5E & ZB*K5E Copeland Scroll™
K5 Compressors for Refrigeration 8-17 HP with CoreSense™ Diagnostics
Section
TABLE OF CONTENTS
Page Section
Safety
Safety Instructions..............................................................2
Safety Icon Explanation......................................................2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons.................................................3
Safety Statements..............................................................3
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
.
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 - 17 HP Copeland Scroll Compressor Rack Mounting... 32
8 - 17 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
Digital Compressor Cutaway View.................................... 38
20 Second Operating Cycle..............................................39
CoreSesne Diagnostics + EXV Operation......................... 40
Digital Operation DIP Switch Settings............................... 40
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
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
Tables
Injection Accessories.........................................................41
External Wrap-Around Crankcase Heaters....................... 41
Kriwan INT69 Module Specifications................................. 41
K5 Compressor Additional Accessories............................. 42
K5 Compressor (8 to 17 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
© 2016 Emerson Climate Technologies, Inc.
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Safety Instructions
™
Copeland Scroll
Scroll™
compressors are
withmanufactured
CoreSense™ according
Diagnostics
the latest U.S. and
Copeland
compressors
to are
the manufactured
latest U.S. andaccording
EuropeantoSafety
European
Safety
Standards.
Particular
emphasis
has
been
placed
on
the
user's
safety.
Safey
icons
are explained
Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained
below
below
and
safety
instructions
applicable
to
the
products
in
this
bulletin
are
grouped
on
Page
3.
These
instructions
and safety instructions applicable to the products in this bulletin are grouped on Page 3. These
should be retained
lifetime of
compressor.
You are strongly
toadvised
follow these safety
instructions
should throughout
be retained the
throughout
thethe
lifetime
of the compessor.
You areadvised
strongly
instructions.
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.
© 2016 Emerson Climate Technologies, Inc.
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Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
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.
WARNING
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.
WARNING
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.
CAUTION
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.
© 2016 Emerson Climate Technologies, Inc.
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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
17 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
ZB68K5B-TFD
Example
Voltage
60
460
50
380/420
60
460
50
380/420
ZBD76K5E-TFD-260
Z =
Copeland Scroll
B =
Application (B: Medium Temperature,
F: Low Temperature)
D =
Digital Capacity
CAUTION
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).
76K = Nominal Capacity (kBtu/hr)
5 =
Model Variation Identifier for the
K5 refrigeration scroll
E =
Oil Type (POE)
TFD = Motor Version
260 = Bill of Materials
Medium Temperature Digital Compressor Operation
Approved Refrigerants
Application
Low
Temperature
Medium
Temperature
Model
Number
HP
ZF34K5E
10
ZF41K5E
13
ZFD41K5E
13
ZF49K5E
15
ZF54K5E
17
ZB58K5E
8
ZB66K5E
9
ZB76K5E
10
ZBD76K5E
10
ZB95K5E
13
ZB114K5E
15
ZBD114K5E
15
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
R-22,
R-404A,
R-407A/C,
R-407F
R-448A,
R-449A,
R507
R-22,
R-134a,
R-404A,
R-407A/C,
R-407F,
R-448A,
R-449A,
R507
© 2016 Emerson Climate Technologies, Inc.
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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 (EXV) 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 2I 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
© 2016 Emerson Climate Technologies, Inc.
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Installation of DTC Valve
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.
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, R-407F, R-448A and R-449A 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.
• 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.
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.
EXV Valve Specifications
DTC Valve Specifications
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.
The following components are not required, but they
are recommended for liquid injection.
• Sight Glass - A sight glass can be installed before
the DTC valve to allow for visual inspection for the
presence of liquid refrigerant.
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.
• Sight Glass - A sight glass can be installed before
the EXV valve to allow for visual inspection for the
presence of liquid refrigerant.
Figures 2A through 2C are a representation of typical
systems, depicting the location of these components.
• Filter/Drier - A filter/drier can be installed upstream
© 2016 Emerson Climate Technologies, Inc.
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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 or R-448A/R-449A 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 8-17 HP scroll compressors 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.
© 2016 Emerson Climate Technologies, Inc.
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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
© 2016 Emerson Climate Technologies, Inc.
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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
Compressor Mounting
• Remove phase sensing leads from the module from
L1/L2/L3.
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.
Mounting for Rack Systems – Specially designed
steel spacers and rubber isolator pads are available
for Copeland Scroll 8 -17 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.
• 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.
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 -17 HP Copeland Scroll
condensing unit applications applying the ZB95/114
and ZF49/54, standard mounts (55-65 durometer) are
recommended (kit # 527-0210-00) Figure 8B.
For condensing units applying the ZB58/66
/ZB(D)76 and ZF34/ZF(D)41 the softer mounts
(35-45 durometer) mounts are recommended.
(Kit # 527-0116-00) Figure 8C.
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
to verify acceptable levels of sound and vibration.
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Connection Fittings, Service Valves, and Adapters
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
testing recommendations. Under no circumstances
should the Hipot or Megohm test be performed while the
compressor is under a vacuum.
The fitting sizes for 8 through 17 HP scroll compressors
are shown in Table 5.
Deep Vacuum Operation
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
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.
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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
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.
Yellow LED:
FLASHING: Alerts of an abnormal system condition
via Alert Codes
CoreSense Diagnostics™ Module for Refrigeration
Compressors
SOLID: Demand is present but no current is
detected. All protective shutdowns will auto reset in
their allotted time
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 8-17 HP K5 refrigeration scroll
compressors. By monitoring and analyzing data from
the Copeland 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.
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:
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.
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.
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)
Power Supply Range: 85-265VAC, 50-60 Hz
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.
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.
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.
CORESENSE MODULE LED OVERVIEW
CoreSense Diagnostics™ Module for Refrigeration
Compressors with Digital and EXV Capability
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.
Protection/Contactor Control Wiring for CoreSense
Diagnostics Module (543-0209-**)
CoreSense Module Mounting
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.
Discharge Temperature Protection with CoreSense
Diagnostics for K5 Compressors
110-230VAC CoreSense Module Power Wiring
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:
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.
More information: The E2 jumpers on the Network
Interface Board should be set for “terminated”. Refer
to Figure 16.
• From the main menu select 7 (System
Configuration)
COMMISSIONING
• Press 3 (System Information)
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.
• 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 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.
NOTE: For digital capacity using an E2 controller,
an enhanced suction group must be enabled.
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.
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.
Passing the communications wire through the grommet
Modbus® Communication to CoreSense Diagnostics
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for K5 Compressors
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, DIP switch 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
Switch 2 is for Digital Capacity Control. The "ON"
* 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 R14
160
ZF*K5E Low Temperature Vapor Injection Operating Map
(65°F Return Gas)
R-404A/R-507
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/R-448A/R-449A
160
Condensing Temperature (°F)
140
120
100
Maximum
40F
Superheat
80
60
40
20
0
** DTC/EXV Liquid Injection Required with EVI for R-407A /R-407C/ R-407F/R-448A/R-449A
-50
-40
-30
-20
-10
Evaporating Temperature (°F)
Figure 2 (B)
© 2016 Emerson Climate Technologies, Inc.
22
0
10
AE4-1383 R14
ZF*K5E Low Temperature Liquid Injection Operating Map
(65°F Return Gas)
R-404A/R-507/R-407A/R-407C/R-407F/R-448A/R-449A
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)
Condensing Temperature (°F)
140
R-22
120
100
DTC/EXV Liquid
Injection Required
80
60
40
20
0
-50
-40
-30
-20
-10
Evaporating Temperature (°F)
Figure 2 (D)
© 2016 Emerson Climate Technologies, Inc.
23
0
10
AE4-1383 R14
ZB*K5E Medium Temperature Operating Map – (65°F Return Gas)
R-404A/R-507/R-407A/R-407C/R-407F
-29
160
-24
Evaporating Temperature (°C)
-19
-14
-9
-4
1
6
Condensing Temperature (°F)
H
FS
20°
SH
t to
0°F
2
it to
07A
m
4
i
R
/F L
07C
R-4
52
i
Lim
120
100
42
65°F Maximum Return Gas
32
80
22
60
12
40
Condensing Temperature (°C)
62
140
2
20
-8
0
-18
- 20
- 10
0
10
20
30
40
50
Evaporating Temperature (°F)
Figure 2 (E)
ZB*K5E Medium Temperature Operating Map – (65°F Return Gas)
-24
-19
-14
-9
-4
1
6
11
62
Condensing Temperature (°F)
140
120
°F
20
100
Su
imi
tL
ea
rh
pe
t
52
42
32
80
22
60
12
40
2
20
0
-8
-20
-10
0
10
20
30
40
50
Evaporating Temperature (°F)
Figure 2 (F)
Note: For operating maps at different return gas conditions, contact your Application Engineer.
© 2016 Emerson Climate Technologies, Inc.
24
-18
60
Condensing Temperature (°C)
-29
160
R-448A/R-449A
Evaporating Temperature (°C)
AE4-1383 R14
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 (G)
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)
Figure 2 (H)
© 2016 Emerson Climate Technologies, Inc.
25
60
70
AE4-1383 R14
ZF*K5E (Excluding ZF49K5E/ZF54K5E) Medium Temperature Operating Map
with and without Vapor Injection
R-404A/R-407A/R-407C/R-448A/R-449A/R-507/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)
© 2016 Emerson Climate Technologies, Inc.
26
20
25
30
*R-22 Not Approved for Vapor Injection
AE4-1383 R14
ZBD*76 Compressor Operating Envelope WITHOUT
CoreSense Diagnostics Controlling Digital Capacity
-29
160
-24
Evaporating Temperature (°C)
-19
-14
-9
-4
R-404A/R-507
6
1
100%-10%
100
100%-20%
Condensing Temperature (°F)
52
120
80
42
32
22
60
12
40
Condensing Temperature (°C)
62
140
2
20
-8
0
-18
- 20
- 10
0
10
20
30
40
50
Evaporating Temperature (°F)
Figure 2 (K)
ZBD*76 Compressor Operating Envelope WITHOUT
CoreSense Diagnostics Controlling Digital Capacity
-29
160
-24
Evaporating Temperature (°C)
-19
-14
-9
R-407A/R-407C/R-407F/R-448A/R-449A
1
6
-4
42
100%-10%
80
100%-30%
100
100%-50%
100%-60%
Condensing Temperature (°F)
52
120
32
22
60
12
40
Condensing Temperature (°C)
62
140
2
20
-8
0
- 20
-18
- 10
0
10
20
30
40
50
Evaporating Temperature (°F)
Figure 2 (L)
NOTE: Minimum capacity is assumed running at a continuous minimum capacity. These Minimum capacity restrictions ONLY
apply when NOT using CoreSense™ Diagnostics
NOTE: Envelope restrictions will vary slightly between refrigerants.
© 2016 Emerson Climate Technologies, Inc.
27
AE4-1383 R14
ZBD114 Compressor Operating Envelope WITHOUT
CoreSense Diagnostics Controlling Digital Capacity
-29
160
-24
Evaporating Temperature (°C)
-19
-14
-9
R-404A/R-407C/R-407F/R-448A/R-449A/R-507
1
6
-4
52
120
100%-30%
80
100%-40%
100
100%-50%
42
100%-70%
Condensing Temperature (°F)
Condensing Temperature (°C)
62
140
32
22
60
12
40
2
20
-8
0
-18
- 20
- 10
0
10
20
30
40
50
Evaporating Temperature (°F)
Figure 2 (M)
ZBD114 Compressor Operating Envelope WITHOUT
CoreSense Diagnostics Controlling Digital Capacity
-29
160
-24
Evaporating Temperature (°C)
-19
-14
-9
-4
1
6
R-407A
100%-30%
80
100%-40%
100
100%-50%
100%-70%
100%-70%
Condensing Temperature (°F)
52
120
42
32
22
60
12
40
Condensing Temperature (°C)
62
140
2
20
-8
0
- 20
-18
- 10
0
10
20
30
40
50
Evaporating Temperature (°F)
Figure 2 (N)
NOTE: Minimum capacity is assumed running at a continuous minimum capacity. These Minimum capacity restrictions ONLY
apply when NOT using CoreSense™ Diagnostics
NOTE: Envelope restrictions will vary slightly between refrigerants.
© 2016 Emerson Climate Technologies, Inc.
28
AE4-1383 R14
FILTER
DRIER
KEEP MIN
(SEE NOTE 6)
<12”
CONTINUOUS TUBING
(NO ELBOWS)
Notes:
SUCTION
MANIFOLD
<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.
© 2016 Emerson Climate Technologies, Inc.
29
AE4-1383 R14
Figure 3 (B)
Liquid Injection Scroll with DTC Valve
Figure 3 (C)
EVI Scroll with DTC and T-fitting Adapter
Figure 3 (D)
© 2016 Emerson Climate Technologies, Inc.
30
AE4-1383 R14
Figure 4 – Circuit Diagram and Cycle for EVI
Condenser
Outlet
LIT
VOT
Vapor Outlet to
Compressor
SIT
Vapor Out
Heat
Exchanger
Liq. In
TXV
UT
LOT
Cond. Out
SIT
TXV
Liq. Out
Vapor In
Figure 6 – Upstream Extraction
Figure 5 – Downstream Extraction
© 2016 Emerson Climate Technologies, Inc.
31
AE4-1383 R14
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
8-13HP Condensing Unit Mounting for
Models ZB95-ZB(D)114 and ZF49-54
Figure 8A
8 - 17 HP Copeland Scroll Compressor
Rack Mounting
028-0188-16
027-0186-00
527-0116-00
Figure 8C
13-17HP Condensing Unit Mounting for
Models ZB58/66, ZB(D)76 and ZF34-ZF(D)41
© 2016 Emerson Climate Technologies, Inc.
32
CoreSense Module With Pressure Safety Control
AE4-1383 R14
L1
L2
13
CoreSense Module
K1 Relay
9
14
K1 Relay
D
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
CoreSense Diagnostics with Digital and EXV capability Wiring Schematic
L2
L1
Kriwan
Module
T1
L1
T2
L2
M1
** The physical location of M1/M2 & L1/L2 have
changed on the CoreSense module **
CoreSense
Diagnostics
M2
M1
M2
INJ
SOL
CC
Current Transducer
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.
D
Digital Solenoid
(Same as Control
Circuit Voltage)
System
Control
OMB
6 Pin to EXV Coil
12VDC
Discharge Top Cap
Thermistor
1-5v Digital
Capacity Input
HPCO
LPCO
EXV Coil
Alarm
Figure 9B – CoreSense Diagnostics Module with Digital and EXV Capability
© 2016 Emerson Climate Technologies, Inc.
33
** The physical location of M1/M2 & L1/L2
have changed on the CoreSense module **
AE4-1383 R14
Line
242°F
(117°C)
Top Cap
266°F
(130°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.
© 2016 Emerson Climate Technologies, Inc.
34
Communication Module DIP Switch Settings
AE4-1383 R14
Node Addresses
1
2
3
12345
12345
12345
4
5
6
12345
12345
12345
7
8
9
“On” (UP)
12345
12345
9600
Even
Network
Terminated
Baud
Rate
Parity
Control
Mode
Network
Termination
19200
No
Parity
Stand
Alone
Not
Terminated
12345
1 2 3 4 5 6 7 8 9 10
“Off ” (Down)
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
© 2016 Emerson Climate Technologies, Inc.
35
AE4-1383 R14
(Terminated)
(Terminated)
(Terminated)
(Terminated)
Figure 17 – RS485 Daisy Chain Connection
(Terminated)
(Terminated)
(Terminated)
(Terminated)
Figure 18 – Two Rack Daisy Chain Connection
© 2016 Emerson Climate Technologies, Inc.
36
AE4-1383 R14
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
© 2016 Emerson Climate Technologies, Inc.
37
AE4-1383 R14
Intermediate
Floating
Seal Cavity
Seal Cavity Vent
Removable External
Solenoid and Coil
Figure 20
Digital Compressor Cutaway View
© 2016 Emerson Climate Technologies, Inc.
38
AE4-1383 R14
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
© 2016 Emerson Climate Technologies, Inc.
39
16
17
18
19
20
AE4-1383 R14
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
© 2016 Emerson Climate Technologies, Inc.
40
AE4-1383 R14
Table 1
Injection Accessories
Application
Injection
Refrigerants
ZB
(Medium Temp)
N/A
All
ZF
(Low Temp)
Vapor
Injection
Reference
Figure
Required Kits
Top Cap Thermistor is Factory Installed (no kits required)
404A/507
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
448A/449A
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.
© 2016 Emerson Climate Technologies, Inc.
41
Conduit Ready Box for
Crankcase Heater
998-7029-00
AE4-1383 R14
Table 4
K5 Compressor for Refrigeration Additional Accessories
Accessory
Mounting Parts
Service Valve
Kits
Rotalock to Stub
Tube Adapter
Kits
Motor Protection
Oil Monitoring
OMB (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
using ZB95-ZB(D)114, ZF49-ZF54)
Hard Mounting Parts Kit (for parallel rack applications)
35-45 Durometer Mounting Parts Kit (for single compressor application
using ZB58/66, ZB(D)76 and ZF34, ZF(D)41)
Suction and Discharge Service Valves with Seals
Suction Rotalock Service Valve with Seal - 1 3/8" Stub Tube
Discharge Rotalock Service Valve with Seal - 7/8" Stub Tube
Discharge Rotalock to Stub (1 1/4" 12 Thread to 7/8" Sweat)
Suction Rotalock to Stub (1 3/4" 12 Thread to 1 3/8" Sweat)
Vapor & Liquid Injection Rotalock to Stub (1" 14 Thread to 1/2" Sweat)
External Motor Protection Module for ZB95K5E-TWC, ZB(D)114K5E-TWC,
ZB(D)114K5E-TWE
Oil Management Control w/ Junction Box 24V 50/60Hz
Oil Management Control w/ Series Relief Connector 24V 50/60Hz
Copeland Scroll OMB Adapter for K5 Refrigeration Scroll
Copeland Scroll OMB Adaptor for K5 Refrigeration Scroll (after May 2013)
CoreSense Module for K5 Refrigeration Scroll (Pre January 2015)
CoreSense Current Sensor Module for K5 Refrigeration Scroll
CoreSense Module for K5 Refrigeration Scroll (After January 2015)
Thermistor Kit (Includes Top Cap and Discharge Line Thermistors)
Top Cap Thermistor Kit (Top Cap Thermistor Only)
120V, 93W Wrap Around, 48" Lead Length 018-0091-21
240V, 93W Wrap Around, 48" Lead Length 018-0091-22
480V, 93W Wrap Around, 48" Lead Length 018-0091-23
575V, 93W Wrap Around, 48" Lead Length 018-0091-24
Conduit Ready Box for Crankcase Heater
DTC Kit - 250°F Set Point DTC with 268°F Thermistor for Liquid Injection
and R-407A/C/F Vapor Injection
Liquid Injection Adapter (For R407A/C/F Vapor Injection Applications Only)
EXV Liquid Injection Valve Kit (Includes EXV Valve with Compressor
Connection & Wiring
120V Digital Solenoid Coil
240V Digital Solenoid Coil
Digital Wire for CoreSense Analog Input
Digital Solenoid Coil Wire (CoreSense Module to Digital Solenoid Coil)
998-0060-04
998-0060-09
998-0341-00
998-0342-00
Closed Loop Digital Controller (Single Compressor Applications)
998-0189-00
© 2016 Emerson Climate Technologies, Inc.
42
527-0210-00
998-0178-00
527-0116-00
998-5100-27
998-0510-46
998-0510-39
998-0034-08
998-0034-13
998-0034-18
971-0641-00
65365
65366
66077
66652
943-0151-00
943-0159-00
943-0209-00
998-0176-00
998-0229-00
918-0047-00
918-0047-01
918-0047-02
918-0047-03
998-7029-00
998-0500-03
998-0177-00
998-0340-00
AE4-1383 R14
Table 5
K5 Compressor for Refrigeration (8 to 17 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
R-134A
2 in. Hg Min.
335 psig Max
--4 psig min.
263 psig max
Table 7A
Low Temperature Digital Modulation
Capacity(%)/Analog (V)
R-22 / R-407A / R-407C/
R-407F / R-448A/ R-449A
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
© 2016 Emerson Climate Technologies, Inc.
43
AE4-1383 R14
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
ää
1
High Discharge Temp – see diagram for setting
Yes
20 Min.
4
ä
2
Excess System Limit Trips 4 consecutvie system limit trips
having 1-15 min runtime each
Yes
5 Min.
No Lockout
ä
3
Excessive Demand Cycling Default is 240 cycles per 24 hr. period
No
-
-
ää
4
Locked Rotor Compressor did not start within alloted time
Yes
20 Min.
4
ä
5
Demand Present No current detected over 4 hr. period
No
-
-
ää
6
Phase Loss Detected
Yes
20 Min.
10
ä
7
Reversed Phase Detected
Yes
Until
Module Is
Reset
1
ä
8
Welded Contactor Current detected without demand1
No
-
-
ä
ä
ä
ä
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
-
-
ä
ä
ä
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.
© 2016 Emerson Climate Technologies, Inc.
44
AE4-1383 R14
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. Possible loss of refrigerant charge
2. Blocked condenser
3. Verify that discharge valve is open
4. On low temperature scroll compressors check
liquid injection
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
© 2016 Emerson Climate Technologies, Inc.
45
AE4-1383 R14
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.
1. Possible loss of refrigerant charge
2. Blocked condenser
3. Verify that discharge valve is open
4. On low temperature scroll compressors check
liquid injection
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
© 2016 Emerson Climate Technologies, Inc.
46
AE4-1383 R14
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.
© 2016 Emerson Climate Technologies, Inc.
47
CoreSense™ Diagnostics for Copeland Scroll™ K5 Refrigeration Compressors
Modbus® Specification
Table of Contents
2.0 General Description .................................................... 2
4.2 Data Signaling Rate................................................................... 4
4.2.1 Baud Rate Selection ............................................................... 4
4.2.2 Parity Selection....................................................................... 4
4.2.3 Stop Bits ................................................................................. 4
4.3 Labeling ..................................................................................... 4
4.4 Connector .................................................................................. 4
4.5 Wiring and Connections ............................................................ 4
3.0 Module Type Identification ......................................... 2
5.0 Data Link Layer ........................................................... 4
3.1 CoreSense Diagnostics Pre January 2015 DIP Switch Settings &
Configurations ................................................................................. 2
3.1.1 Main DIP Switch Board .......................................................... 3
3.1.2 Communication DIP Switch Board ......................................... 3
3.2 CoreSense Diagnostics After January 2015 DIP Switch Settings
& Configurations .............................................................................. 3
3.2.1 Main DIP Switch Board .......................................................... 3
3.2.2 Communication DIP Switch Board ......................................... 3
5.1 Node Address ............................................................................ 4
5.2 RTU Transmission Mode ........................................................... 5
5.3 Response Message Timeout ..................................................... 5
1.0 Introduction ................................................................. 2
1.1 Abbreviations............................................................................. 2
1.2 Intent ......................................................................................... 2
1.3 Scope ........................................................................................ 2
1.4 References ................................................................................ 2
4.0 Physical Layer ............................................................. 3
4.1 Topology.................................................................................... 3
4.1.1 Wire Used ............................................................................... 3
4.1.2 Bus Bias ................................................................................. 3
4.1.3 Termination ............................................................................ 4
©2016 Emerson Climate Technologies, Inc. All rights reserved.
6.0 Application Layer ........................................................ 5
6.1 Available Functions ................................................................... 5
6.2 Data Types ................................................................................ 5
6.3 Functions Supported ................................................................. 6
6.3.1 Input Register (Command 0x04) ............................................ 6
6.3.2 Hold Register (Command 0x03, 0x06, 0x10) ....................... 12
7.0 Troubleshooting ........................................................ 14
1.0 Introduction
1.4 References
The CoreSense™ Diagnostics module for Copeland
Scroll™ K5 refrigeration compressors provides the
protection, diagnostics and communication features to
the 8-15 HP scroll compressors. By monitoring and
analyzing data from the Copeland Scroll compressors,
the module can accurately detect the cause of electrical
and system related issues. If an unsafe condition is
detected, the module trips the compressor. A flashing
LED indicator displays the ALERT code and guides the
service technician more quickly and accurately to the
root cause of a problem.
For the details of the Modbus specification, refer to the
Modicon Modbus Protocol Reference Guide
PI–MBUS–300 Rev. J.
The module also has an RS485 isolated
communication port, by which the modules
communicate with the system controller or the network
master. The details of the communication are provided
in this document.
1.1 Abbreviations
Table 1: Abbreviations
Abbreviation
Meaning
RTU
Remote Terminal Unit
DLT
Discharge Line Temperature
OAC
Overall Alarm Count (Total
number of alarms since the
module has been installed)
CRC
Cyclic Redundancy Check
CMD
Command
1.2 Intent
This document defines standard usage of the Modbus
protocol specification for CoreSense Diagnostics
modules for Copeland Scroll K5 refrigeration
compressors. This will allow third party controllers to
easily communicate to our products using a standard
Modbus interface.
1.3 Scope
This document only defines the Modbus options that
are used in the CoreSense Diagnostics module for
Copeland Scroll K5 refrigeration comperssors; it is not
intended to replace the Modbus protocol specification.
Also, this specification defines the common usage of
the physical layer and data link layers and some parts
of the application layer interface.
©2016 Emerson Climate Technologies, Inc. All rights reserved.
2.0 General Description
Modbus uses a three layer protocol:
Physical Layer: The hardware interface.
Data Link Layer: Defines the reliable exchange of
messages .
Application Layer: Defines message structures for the
exchange of application specific information.
Modbus has some required features, some
recommended features, and some optional features.
This specification starts with the physical layer and then
works up to the application layer. The application layer
defined in this specification defines the standard
Modbus memory map and data interchange.
Modbus is a protocol with a single master and multiple
slave devices. The master device initiates all
messages. The master device is typically a system
controller and the slave devices are the CoreSense
modules.
3.0 Module Type Identification
Two modules are used with Copeland Scroll K5
refrigeration
compressors
with
CoreSense
Diagnostics. The two modules can easily be
differentiated by the physical look of the module. The
pre January 2015 module has black plastic casing,
while the new modules are gray with a silver banner.
See pictures below to differentiate.
The main difference between the two is that the new
module has EXV and digital capacity control.
3.1 CoreSense Diagnostics Pre January 2015 DIP
Switch Settings & Configurations
There are two DIP switch panels on CoreSense
Diagnostics module for Copeland Scroll K5
refrigeration compressors.
3.2.1 Main DIP Switch Board
Main DIP
Switch
Board
Communication
DIP Switch
Board
Figure 4: After January 2015 Main DIP Switch Board
Figure 1: Pre January 2015 CoreSense™ Diagnostics DIP
Switch Panels
3.1.1 Main DIP Switch Board
DIP Switches 1-5 are reserved for future use. DIP
switch 6 is used to enable/disable lockouts. The UP
position enables lockout and the DOWN position
disables lockout.
3.1.2 Communication DIP Switch Board
3.2.2 Communication DIP Switch Board
See 3.1.2 for details.
4.0 Physical Layer
This layer defines the hardware interface to the
network.
4.1 Topology
The CoreSense Diagnostics module for Copeland
Scroll K5 refrigeration compressors uses the ‘two-wire’
configuration (two signal wires plus a ground). The
standard configuration will be to directly wire to the
cable forming a daisy-chain.
4.1.1 Wire Used
Figure 2: Pre & After January 2015 Communication DIP
Switch Board
The recommended wire will be Belden 8761 that is a
22 AWG shielded twisted pair. The shield is also used
as the circuit ground.
3.2 CoreSense Diagnostics After January 2015 DIP
Switch Settings & Configurations
Main DIP
Switch
Board
Communication
DIP Switch
Board
Figure 3: After January 2015 CoreSense™ Diagnostics DIP
Switch Panels
Figure 5: Recommended Communication Wire
4.1.2 Bus Bias
All master devices must provide a means to bias the
network. The recommended pull-down on the RS485
‘+’ output is a 511 ohm resistor, but up to a 1K ohm
resistor is acceptable. The recommended pull-up
resistor on the RS485 ‘-’ output is a 511 ohm resistor,
but up to 1K ohms is acceptable. These bias resistors
can either be always enabled or they can be enabled
through jumpers. The bias is applied at one point in the
network.
4.1.3 Termination
The last slave in the network shall have a 150 ohm
resistor for termination. In this module, there is a
termination DIP switch on the communication DIP
switch panel. Position 10 DIP switch is used for
termination. See Figure 2 for reference. The last
CoreSense module in the network shall be terminated
by sliding DIP switch 10 up, to the ON position. For the
other CoreSense modules in the network, DIP switch
10 shall be down, in the OFF position.
4.2 Data Signaling Rate
The communications port default settings are 19200,
no Parity, 8 data, 2 Stop bits. The baud rate (19200 or
9600), parity (even or no parity) and stop bits (1 bit or 2
bit) are user selectable through DIP switches. Data
length is not configurable. See Figure 2 Error!
Reference source not found. and Figure 4 for DIP
switch reference.
•
•
Middle Connection is not labeled and is
ground
‘+’ Positive
See Figure 6 for reference.
4.4 Connector
A three position screw cable connector is used for
Modbus communication.
4.5 Wiring and Connections
The Modbus wiring should be connected to module
connector ‘-’, ‘GND’, ‘+’
4.2.1 Baud Rate Selection
CoreSense Diagnostics Modbus communication baud
rate setting is configurable to either 19200 or 9600
through DIP switch number 6 on the communication
panel. See Figure 2.
ON = 9600
OFF = 19200 (Default)
4.2.2 Parity Selection
CoreSense Protection Modbus communication parity is
user configurable (even or no parity) through DIP
switch number 7. See Figure 2.
ON = even parity
OFF = no parity (Default)
4.2.3 Stop Bits
CoreSense Diagnostics Modbus communication stop
bits is user configurable to either be 1 or 2 stop bit. DIP
switch number 4 on the main DIP switch board is used
to configure stop bit. See Figure 4.
ON = 1 stop bits
OFF = 2 stop bits (Default)
Note: Even parity will always be 1 stop bit.
4.3 Labeling
The module has a RS485 port with the connector pins,
labeled from top to bottom as:
•
‘-’ Negative
Figure 6: CoreSense™ Diagnostics Modbus Connection
Important! Note that 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.
5.0 Data Link Layer
Modbus uses master/slave protocol where there is a
single master device that initiates all messages. The
Data Link Layer defines the reliable transfer of a
message transferred from the master to one or more
slave devices and the reliable transfer of the response
message (when the command message is sent to a
single device). The CoreSense module is a slave in the
network and the rack controller is the master.
5.1 Node Address
The DIP switch setting combination gives the node
address. The combination positions 1 through 5 will be
used to define a node address from 1 to 31. Use Figure
7 and Table 2 for reference.
Note: To enable a DIP switch changes, power to the
module must be cycle.
5.2 RTU Transmission Mode
The Modbus communication in the CoreSense module
uses the RTU mode. The default character framing will
be an 11 bit character as follows:
Figure 7: Switches 1 to 5 are used to set the module
Modbus address
•
•
•
1 start bit
8 data bits
2 stop bit (or if ‘even parity’ is selected 1 stop
bit and 1 parity bit)
Table 2: Node Address DIP Configurations
A standard 2 byte CRC is used for frame verification.
5.3 Response Message Timeout
As per the Modbus specification each device can
define its own maximum timeout for the response to be
sent to a request, the maximum timeout for the module
is 1 sec.
6.0 Application Layer
The Application Layer defines the type of messages
that will be sent and the format of the messages.
6.1 Available Functions
Table 3: Standard Modbus Function Codes
Standard Modbus Function Codes Supported by
CoreSense™ Diagnostics for Ref K5 Scroll
Switch
Number
Function
Code
1
0x04
2
0x03
3
0x06
4
0x10
Function
Name
Read Input
Registers
Read
Holding
Registers
Write Single
Register
Write
Multiple
Registers
Register
Access
Input
Register
Read Only
Holding
Register
Read/Write
Holding
Register
Read/Write
Holding
Register
Read/Write
6.2 Data Types
Modbus requires that all multiple byte data be sent in
Big Endian format. In Big Endian system, the most
significant value in the sequence is stored at the lowest
storage address (i.e. first).
6.3 Functions Supported
6.3.1 Input Register (Command 0x04)
Table 4: Input Register (Command 0x04)
Address
(Hex)
Start Stop
0000
001C
0022
002A
001B
0021
0029
0030
0077
0077
0078
0078
0079
0079
007A
007A
007B
007B
007C
007C
007D
007D
007E
007E
007F
007F
0080
0080
0081
0081
0082
0082
0083
0083
0084
0084
0085
0086
0087
0088
008E
008E
008F
0090
009B
009C
009D
009E
009B
009C
009D
009E
Contents
Division Name
Product Name
Product Code
Module Version Number
Quantity
Data Description
28
6
8
7
'X'
'X'
'X'
'X'
Seven Days of
Compressor Run Time
7
Seven Days of
Compressor Start Times
7
Total Compressor Run
Time
Total Compressor Start
Times
Protection Trip For Seven
Days
Protection Trip After
Power Up
Ten Most Recent Alarm
2
2
1
2
1
1
1
1
Today compressor run time
One counter means 6 minutes
Today-1 compressor run time
One counter means 6 minutes
Today-2 compressor run time
One counter means 6 minutes
Today-3 compressor run time
One counter means 6 minutes
Today-4 compressor run time
One counter means 6 minutes
Today-5 compressor run time
One counter means 6 minutes
Today-6 compressor run time
One counter means 6 minutes
Today compressor start times
One counter means 1 time
Today-1 compressor start times
One counter means 1 time
Today-2 compressor start times
One counter means 1 time
Today-3 compressor start times
One counter means 1 time
Today-4 compressor start times
One counter means 1 time
Today-5 compressor start times
One counter means 1 time
Today-6 compressor start times
One counter means 1 time
One counter means 1 hours
0-4294967295
One counter means 1 start
0-4294967295
One counter means one time
0-65535
One counter means one time
0 - 4294967295
Alarm Id of tenth most recent alarm
Alarm Id of ninth most recent alarm
Alarm Id of eighth most recent alarm
Alarm Id of seventh most recent alarm
009F
00A0
00A1
00A2
00A3
00A4
009F
00A0
00A1
00A2
00A3
00A4
1
1
1
1
1
1
00AA
00AA
Eight Days Alarm History
of DLT Fault
5
00AB
00AB
Eight Days Alarm History
of CT Fault Warning
6
00AC
00AC
Eight Days Alarm History
of Loss Comm From E2
Warning
7
00AF
00AF
Eight Days Alarm History
of Short Cycling Warning
10
00B0
00B0
Eight Days Alarm History
of Open Circuit Warning
11
00B1
00B1
Eight Days Alarm History
of Welded Contactor
Warning
12
00B4
00B4
Eight Days Alarm History
of High Discharge Line
Temperature Alarm
15
Alarm Id of sixth most recent alarm
Alarm Id of fifth most recent alarm
Alarm Id of most fourth recent alarm
Alarm Id of third most recent alarm
Alarm Id of second most recent alarm
Alarm Id of most recent alarm
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 6 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 8 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 9 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 12 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 13 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 14 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 17 - Present)
00B5
00B5
Eight Days Alarm History
of System Trip Alert
16
00B6
00B6
Eight Days Alarm History
of Locked Rotor Alert
17
00B7
00B7
Eight Days Alarm History
of Missing Phase Alert
18
00B8
00B8
Eight Days Alarm History
of Reverse Phase Alert
19
00BA
00BA
Eight Days Alarm History
of Module Low Voltage
Alert
21
00C6
00C6
Eight Days Alarm History
of High Discharge
Temperature Lockout
33
00C7
00C7
Eight Days Alarm History
of Locked Rotor Lockout
35
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 18 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 19 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 20 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 21 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 23 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 35 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 37 - Present)
00C9
00C9
Eight Days Alarm History
of Missing Phase Lockout
36
00CA
00CA
Eight Days Alarm History
of Reverse Phase Lockout
37
00E3
00E3
OAC of DLT Fault
5
00E4
00E4
OAC of CT Fault Warning
6
00E5
00E5
00E8
00E8
00E9
00E9
00EA
00EA
00ED
00ED
00EE
00EE
00EF
00EF
00F0
00F0
00F1
00F1
00F3
00F3
00FF
00FF
0101
0101
0102
0102
0103
0103
OAC of Loss Comm From
E2 Warning
OAC of Short Cycling
Warning
OAC of Open Circuit
Warning
OAC of Welded Contactor
Warning
OAC of High Discharge
Line Temperature Alarm
OAC of System Trip Alert
OAC of Locked Rotor
Alert
OAC of Missing Phase
Alert
OAC of Reverse Phase
Alert
OAC of Module Low
Voltage Alert
OAC of High Discharge
Temperature Lockout
OAC of Locked Rotor
Lockout
OAC of Missing Phase
Lockout
OAC of Reverse Phase
Lockout
7
10
11
12
15
16
17
18
19
21
33
35
36
37
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 38 - Present)
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
(0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
(0 - Not present / 39 - Present)
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
One counter means one times
0 - 65535
0117
0117
Current Alert
1
0118
0118
Previous Alert
1
1:Normal off
2: Normal Running
101:Temperature Probe Failure Warning
106:DLT Open Warning
107:DLT Short Warning
108:CT Fault Warning
109:Loss Comm From E2 Warning
112:Short Cycling Warning
113:Open Circuit Warning
114:Welded Contactor Warning
117:Module Failure
118:Modulation Code1
119:Modulation Code2
120:Modulation Code3
200:High Discharge Line Temperature Alarm
201:System Trip Alert
202:Locked Rotor Alert
203:Missing Phase Alert
204:Reverse Phase Alert
206:Module Low Voltage Alert
300:High Discharge Temperature Lockout
301:System Trip Lockout
302:Locked Rotor Lockout
303:Missing Phase Lockout
304:Reverse phase Lockout
311:Module Failure Lockout
101:Temperature Probe Failure Warning
106:DLT Open Warning
107:DLT short Warning
108:CT Fault Warning
109:Loss Comm From E2 Warning
112:Short Cycling Warning
113:Open Circuit Warning
114:Welded Contactor Warning
117:Module Failure
118:Modulation Code1
119:Modulation Code2
120:Modulation Code3
200:High Discharge Line Temperature Alarm
201:System Trip Alert
202:Locked Rotor Alert
203:Missing Phase Alert
204:Reverse Phase Alert
206:Module Low Voltage Alert
300:High Discharge Temperature Lockout
301:System Trip Lockout
302:Locked Rotor Lockout
303:Missing Phase Lockout
304:Phase Loss Lockout
311:Module Failure Lockout
011B
011B
System Status
1
011C
011C
DIP Switch_1
1
011D
011D
DIP Switch_2
1
0122
0122
Low Voltage Set point
1
0123
0123
Input Status 1
0126
0126
Output Status1
0129
0129
012E
012E
012F
012F
0130
0130
0132
0132
0133
0133
LRA Peak Current
1
0134
0134
MAX RMS Current
1
Discharge Temperature
Value
Compressor Power
Frequency
Module Power Voltage
Compressor Current Y
Phase
Compressor Current B
Phase
1
1
1
1
1
1
Bit0 - Demand Status (1 = Demand Present)
Bit1 - Compressor Running (1 = TRUE/0=False)
Bit2 - Injection Present (1=TRUE/0=FALSE)
Bit3 - TRUE if Top Cap Thermistor is installed
Bit4 - TRUE if 193F DTC valve thermistor is installed
Bit5 - TRUE if solenoid is open
Bit6 - Operating Voltage (1= 230V, 0 = 110V)
Bit7 - Line Frequency (1 = Frequency is 50Hz., 0 = 60 Hz)
Comm Board DIP Switch:
BIT15 - DS15 : (1 - ON / 0 - OFF)
BIT14 - DS14 : (1 - ON / 0 - OFF)
BIT13 - DS13 : (1 - ON / 0 - OFF)
……………………………….
BIT1 - DS1 : (1 - ON / 0 - OFF)
BIT0 - DS0 : (1 - ON / 0 - OFF)
Logic Board Dip Switch:
BIT15 - DS15 : (1 - ON / 0 - OFF)
BIT14 - DS14 : (1 - ON / 0 - OFF)
BIT13 - DS13 : (1 - ON / 0 - OFF)
……………………………….
BIT1 - DS1 : (1 - ON / 0 - OFF)
BIT0 - DS0 : (1 - ON / 0 - OFF)
One counters means 0.01V
0- 655.35V
BIT0 - Demand Status (1 = Demand Present)
BIT1 - Compressor Running (1 = TRUE/0=False)
BIT2 - Injection Present (1=TRUE/0=FALSE)
BIT3 - TRUE if Top Cap Thermistor is installed
BIT4 - TRUE if 250 DTC valve thermistor is installed
BIT5 - TRUE if solenoid is open
BIT6 - Operating Voltage(1 = 230V, 0 - 110V)
BIT7 - Line Frequency(1 - Frequency is 50H, 2 -Frequency
is 60H)
BIT8 - TRIP status: 1 - TRIP / 0 - Normal
The output is high if corresponding bit is set. Bit masks
follow:
BIT0 - Output Contactor Relay Status (Open-0 / Closed – 1)
(Discharge temp sensor value/100)-70
Range = -70.0ºF -585.35ºF
Frequency measurement of compressor pilot circuit
Unit : Hz
Module Voltage = Value / 100
Range 0 to 655.35 Volts
CT1 Current = Value / 100
Range : 0 - 655.35Amps
CT3 Current = Value / 100:
Range : 0 - 655.35Amps
LRA Peak Current = Value / 100
Range : 0 - 655.35 Amps
Max Running Current :
Unit : 0.01Amps
0 - 655.35A
0139
0139
Solenoid Work Status
1
013A
013A
1
013B
013B
1
0~500 means 0~5.00V
013C
013D
013C
013D
1
1
10~100 means 10%~100%
10~100 means 10%~100%
013E
013E
EXV open position
Analog Input Voltage
Value
Minimum Capacity
Analog Input Request
Compressor Running
Capacity
0x00 - Solenoid not used
0x01 - Solenoid is used for EXV
0x02 - Solenoid is used for digital modulation
0~100 means 0%~100%
1
10~100 means 10%~100%
0173
0174
Total No. of Short Cycles
2
One counter means 1 cycle
0-4294967295
6.3.2 Hold Register (Command 0x03, 0x06, 0x10)
Table 5: Hold Register (Command 0x03, 0x06, 0x10)
Address
(Hex)
Start Stop
Contents
Quantity
0025
0037
0051
005D
0036
0042
005C
0069
Compressor Module Number
Compressor Serial Number
Module Part Number
Module Serial Number
18
12
12
13
0076
0076
EXV Control Type
1
0077
0077
EXV Position for Manual
Control
1
0078
0079
007A
007B
0078
0079
007A
007B
Proportionality Coefficient Set
Integral Coefficient Set
Differential Coefficient Set
PID Sample Time
1
1
1
1
007D
007D
PID Set Point Value Set
1
0080
0080
Minimum On Time
1
0081
0081
Minimum Off Time
1
0085
0085
Alert Trigger Parameters
Configuration
20
0086
0086
Data Description
'X'
'X'
'X'
'X'
0x00 – Automatic based on the temperature;
0x01 - Manual control
Default: Automatically
if the EXV control type is automatic, then ignore this
item;
0~100 means the EXV open is 0%~100%
0~65535 means 0~655.35
0~65535 means 0~655.35
0~65535 means 0~655.35
One Counter Means One Second (1~50s)
0~65535 means -70~585.35°F
The temperature value
= ( (( High byte << 8) + Low byte) - 7000) / 100
The default value should be: 255°F
Default : 6 seconds
Unit : 1 Seconds
Range : 0 - 65535 seconds
Default : 6 seconds
Unit : 1 Seconds
Range : 0 - 65535 seconds
DLT temp trip set point value,
Unit : 0.01°F ;
Range: -70 to 585.35 °F
Set point = (Word - 7000 )/ 100 (°F)
Default: 297°F
DLT temp trip reset point value,
Unit : 0.01°F ;
Range: -70 to 585.35 °F
Reset point =( Word -7000 )/100 (°F)
0088
0088
0089
0089
008A
008A
009A
009A
Alert Off Time Configuration
26
00B4
00B4
Lockout Status
Configuration1
1
00B6
00B6
00B8
00B8
00B9
00B9
Lockout Events
20
00BA
00BA
00D0
00D0
Module Status Configuration
1
00D4
00D4
UL1 Capacity Request
1
00D6
00D6
Unloader Modulation Period
1
Short Cycle Events
Default : 240
0 – 65535
Open Circuit Delay Time
Default : 180 minutes
Unit : 1 minute
Range : 180 – 360
Low Voltage Set point
Unit : 0.01 v
Range : 0 - 655.35v
The master only can read and can’t write to this unit.
DLT Alert off Time - Unit 1 minutes
Default : 20 Minutes
Range : 10 - 40
BIT0 - High Discharge Temperature Lockout Status:
1 - Enable / 0 - Disable
BIT3 - Locked Rotor Lockout Status:
1 - Enable / 0 - Disable
BIT5 - Missing Phase Lockout Status:
1 - Enable / 0 - Disable
BIT6 - Reverse Phase Lockout Status:
1 - Enable / 0 - Disable
Others bit: Not used.
DLT Trip Lockout Events (Range 0-0xFFFF)
Default val=0xFFFF
Locked Rotor Trip Lockout Events (Range 0-0xFFFF)
Default val=0xFFFF
Missing Phase Lockout Events (Range 0-0xFFFF)
Default val=0xFFFF
Reverse Phase Lockout Events (Range 0-0xFFFF)
Default val=0xFFFF
The master only can read and can’t write to this unit.
BIT0 - Compressor Run:
(0 - Stop / 1 - Run)
BIT1 - Remote Reset:
(0 - No Action / 1 - Remote Reset)
Default : 0-9%
Unit : 1%
Valid Range : 0% - 100%
Default : 20 Seconds
Unit : 1 Seconds
Range : 0 - 65535 Seconds
Response
7.0 Troubleshooting
If the module communication doesn’t respond, here is
a list with some general steps for troubleshooting:
1. Check the wiring connection. Ensure the
wiring is correctly connected and the
connector is not loose.
2. Check the power to the CoreSense module.
Check the power supply line and ensure the
power is on and green LED is on.
3. Check the module network address. The
address should match the address that the
master has requested. Note: for the module,
the address 0 is invalid.
4. Check your master data format setting.
Ensure the master node data format setting is:
RTU mode, 1 start bit, 8 data bit, no parity bit,
2 stop bit.
5. Check the master node baud rate setting.
First, set your master node baud rate as
19200 and then try to communicate with the
module. If the module does not respond, then
set to 9600 baud rate and try again.
A third party PC debugging tool can also be used by
sending the query shown in Table 6 for getting the
firmware version number.
The response indicates the Version Number as
1.01R00 (this version number is only for an example,
may change for different models).
.
0
0 5
8 0
1
©2016 Emerson Climate Technologies, Inc. All rights reserved.
R
9
5
0
0
CRC
1
0 0
2 0
The
request
and
response is
hex value.
CRC
0 0
4 0
Length
CMD
0
8
Start
Address
Request for
version
number
Address
CMD
Bytes
Table 6: Debugging Tool
0 0 1 0
8 4 0 0
3 0 2 0 3 0 3 0 5 0 3 0 3 8 1
1 0 E 0 0 0 1 0 2 0 1 0 1 7 4
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