Copeland ZFK5E ZBK5E Refrigeration compressor Application Guidelines

ZFK5E, ZBK5E refrigeration compressors offer a range of capacities from 8 to 17 HP with CoreSense™ Diagnostics. These compressors use digital capacity control to provide efficient and reliable operation. They can be used in a variety of applications including refrigeration, air conditioning, and heat pump systems.

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AE4-1383 R14

Application Guidelines for ZF*K5E & ZB*K5E Copeland Scroll

™

K5 Compressors for Refrigeration 8-17 HP with CoreSense

™

Diagnostics

March 2016

TABLE OF CONTENTS

Section Page Section Page

Safety

Safety Instructions .............................................................2

Safety Icon Explanation .....................................................2

Instructions Pertaining to Risk of Electrical Shock,

Fire, or Injury to Persons ................................................3

Safety Statements .............................................................3

Introduction

Nomenclature ....................................................................4

Approved Refrigerants.......................................................4

Digital Compressor Operation ...........................................4

Operating Envelope ...........................................................5

Extended ZF*K5E Operating Envelope .............................5

ZF*K5E Low Temperature K5 Compressors for

Refrigeration ..................................................................6

Liquid Injection ...................................................................6

DTC Valve Specifications ..................................................6

Installation of DTC Valve ...................................................6

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

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

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

Diagnostics Module Troubleshooting ....... 45-46

Demand Wiring .................................................................47

K5 DIP Switch Settings .....................................................47

AE4-1383 R14

Safety Instructions

Copeland Scroll

™

compressors are manufactured according to the latest U.S. and European Safety

Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These instructions should be retained throughout the lifetime of the compressor.

You are strongly advised to follow these safety instructions.

You are strongly advised

Safety Icon Explanation

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

CAUTION

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

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.

AE4-1383 R14

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.

Introduction

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.

A new CoreSense Diagnostics module with digital capacity control and EXV injection control has been added on all K5 compressors with the part number (543-

0209-**/998-0340-**). To see differences between the old vs new module please see

Figure 19.

Nomenclature

The Copeland Scroll compressor model numbers include the nominal capacity at the standard 60 Hertz

“ARI” rating conditions with R-404A refrigerant.

Example

ZBD76K5E-TFD-260

Z = Copeland Scroll

B = Application (B: Medium Temperature,

F: Low Temperature)

D = Digital Capacity

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

Approved Refrigerants

Application

Low

Temperature

Medium

Temperature

Model

Number

ZF34K5E

ZF41K5E

ZFD41K5E

ZF49K5E

ZF54K5E

ZB58K5E

ZB66K5E

ZB76K5E

ZBD76K5E

ZB95K5E

ZB114K5E

ZBD114K5E

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

AE4-1383 R14

NOTE: For the latest approved refrigerants and lubricants, refer to Form 93-11, Emerson Accepted

Refrigerants/Lubricants, or contact your Application

Engineer.

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.

Optimized R-134a ZB*K5B Compressors

Model

ZB47K5B-TFD

ZB68K5B-TFD

Hertz Voltage

60 460

380/420

460

380/420

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).

Medium Temperature Digital Compressor Operation

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

10% which equates to 2 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.

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.

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.

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

AE4-1383 R14

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 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.

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

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

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

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.

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.

ZF*K5E Low Temperature K5 Compressors for

Refrigeration

The low temperature models are provided with an injection port that can be used for either liquid or vapor injection.

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.

DTC Valve Specifications

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.

• Filter/Drier - A filter/drier can be installed upstream of the injection circuit to avoid the possibility of the

DTC screen blockage due to contaminants.

Figures 2A through 2C are a representation of typical systems, depicting the location of these components.

AE4-1383 R14

Installation of DTC Valve

The valve bulb must be installed in the top cap thermal well to adequately control scroll temperatures. The valve should be tightened on the injection fitting to a torque of 216-245 in. lbs. (24.4 - 27.7 Nm). A 90° orientation on the valve is recommended, however it will function properly in any orientation. The capillary tube connecting the valve to the bulb should be positioned such that it does not contact the compressor during operation. Do not bend the capillary tube within 1”

(25.4mm) of the valve.

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).

Suggested Application Techniques for All Liquid

Injection Applications

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.

• 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

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 EXV valve to allow for visual inspection for the presence of liquid refrigerant.

• Filter/Drier - A filter/drier can be installed upstream

of the injection circuit to avoid the possibility of the

EXV screen blockage due to contaminants.

EXV Installation

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.

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.

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.

An example of the additional capacity available when using vapor injection is depicted in the following table.

AE4-1383 R14

ARI Low Temperature Ratings

(-25°F/105°F, R-404A)

Model 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

Maximum possible subcooling

50,500 Btu/hr

Without EVI is "0" subcooling

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.

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.

System Configuration

There are two methods of controlling refrigerant flow at the EVI heat exchanger - downstream and upstream extraction.

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.

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.

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.

For more information on applying ZF*K5E scrolls with an economized vapor injection (EVI) circuit refer to

AE4-

1327, Economized Vapor Injection (EVI) Compressors.

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.

Superheat Requirements

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

AE4-1383 R14

suction line 6 inches (152mm) from the suction valve, to prevent liquid refrigerant floodback.

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.

Contact your Emerson Climate Technologies representative regarding any exceptions to the above requirements.

Crankcase Heater

Crankcase heaters are required, on outdoor systems, when the system charge exceeds 17 lbs.

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.

Pressure Controls

Both high and low pressure controls are required. The minimum and maximum pressure setpoints are shown in Table 4.

IPR Valve

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.

Motor Protection

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.

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.

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.

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.

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

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:

Motor Protector Module Voltage Supply

Troubleshooting

• Verify that all wire connectors are maintaining a good mechanical connection. Replace any connectors that are loose.

AE4-1383 R14

• Measure the voltage across T1-T2 to ensure proper supply voltage.

• 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. 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.

a) During normal operation, this resistance value should read less than 4500 ohms ±20%.

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.

• Replace all wire leads and use a voltmeter to verify the M1-M2 contacts are closed.

• If the M1-M2 contacts remain open and S1-S2 are less than 2500 ohms, remove leads from the S1-

S2 contacts and jumper together, using a 100 ohm resistor.

CAUTION

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.

Compressor Voltage Supply Troubleshooting

• Remove phase sensing leads from the module from

L1/L2/L3.

• Use a voltmeter to measure the incoming 3 phase voltage on L1/L2/L3.

WARNING: L1/L2/L3 could

be at a potential up to 600VAC.

• Ensure proper voltage on each phase.

• Remove power to the module for a minimum of 5 seconds to reset and replace all wire leads. Reenergize the module. If the M1-M2 contacts are open with proper voltage to T1-T2, L1/L2/L3 and proper resistance to S1-S2 then the module is faulty and should be replaced.

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.

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.

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.

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.

AE4-1383 R14

Compressor Mounting

Compressor mounting must be selected based on application. Consideration must be given to sound reduction and tubing reliability. Some tubing geometry or “shock loops” may be required to reduce vibration transferred from the compressor to external tubing.

Mounting kit part numbers are listed in

Table 4.

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.

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.

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.

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.

Connection Fittings, Service Valves, and Adapters

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.

A low pressure control is required for protection against deep vacuum operation. See Pressure Control section for proper set points. ( Table 6)

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.

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.

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

AE4-1383 R14

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.

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.

Three Phase Scroll Compressors – Directional

Dependence

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.

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.

1. Verify proper unit voltage.

2. Normal motor winding continuity and short to ground checks can be used to determine proper motor resistance or if an internal short to ground has developed.

3. With service gauges connected to the suction and discharge pressure fittings, turn on the compressor. If suction pressure falls below normal levels the system is either low on charge or there is a flow blockage.

4. If the suction pressure does not drop and the discharge pressure does not rise, reverse any two of the compressor power leads and reapply power to verify the compressor was not wired to run in the reverse direction.

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.

CoreSense Diagnostics

™

Module for Refrigeration

Compressors

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.

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.

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.

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.

AE4-1383 R14

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 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

SOLID: Demand is present but no current is detected. All protective shutdowns will auto reset in their allotted time

Red LED:

FLASHING: Indicates the CoreSense module is locked out on the flashing Alert Code. Manual power cycle reset is required to restart the compressor

Green LED:

FLASHING: Alert Codes that do NOT have a protective shutdown associated with them.

Blue LED:

Flashing indicates alert codes for Digital only. Alert

Codes that do NOT have a protective shutdown associated with them. A solid Blue LED represents compressor unloaded.

Some troubleshooting tips for the CoreSense module are listed in Table 9 at the end of this document.

Product Specifications

Operating Temp: -40° to 150°F (-40° to 65°C)

Storage Temp: -40° to 175°F (-40° to 80°C)

Power Supply Range: 85-265VAC, 50-60 Hz

Working amperage for CT module: 3-200A

NOTE: The CoreSense module is not accurate below

3 Amps. If the current drawn by the compressor during operation falls below 3 Amps, the module may indicate a nuisance fault condition and alarm.

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.

NOTE: The 2X current reading may need to be addressed at the system or rack controller.

The CoreSense module connections are standard male electrical flag terminals.

Maximum continuous contactor coil current is 2A with a max inrush current of 20A.

Compressor Lead Wiring

The compressor leads must be routed through the holes in the CT module marked T1, T2, and T3.

Only the compressor lead wires should be placed through the CT module.

CoreSense Module Mounting

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.

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.

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.

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

AE4-1383 R14

Protection/Contactor Control Wiring for CoreSense

Diagnostics Module (543-0174-**)

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.

Protection/Contactor Control Wiring for CoreSense

Diagnostics Module (543-0209-**)

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

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.

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.

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

compressor system with communications to the E2:

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).

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:

• From the main menu select 7 (System

Configuration)

• Press 3 (System Information)

• Press 1 (General Controller Info)

• Access the Serial Communications Tab by pressing CTRL + 3

• Use the Page Down button or scroll down to view the settings for COM4

3. Switch 7 defines the communication parity. The default parity setting for the CoreSense Diagnostics module is no parity. If the switch is set to “on” the module will communicate using even parity. The parity setting must match the parity setting of the rack controller.

4. Switch 8 is used to set the network mode (on) for the module. The default setting is stand alone mode (off). Network mode will generate a communications error if the rack controller fails to communicate with the device. For standalone mode, no communications are expected so the communication error is blocked.

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.

A shielded, twisted pair cable such as Belden #8761

(22AWG) should be used for the communication wiring.

Passing the communications wire through the grommet

AE4-1383 R14

in the plastic housing will help reduce abrasion to the wiring. Appropriate strain relief is recommended.

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.

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.

COMMISSIONING

Modules using a communications network must be commissioned as part of the E2 rack controller setup.

The commissioning process uploads compressor asset information (model and serial number) into the rack controller for future reference. Once the commissioning process is completed, the controller will supervise and communicate with the module unless the node is deleted. 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.

NOTE: For digital capacity using an E2 controller, an enhanced suction group must be enabled.

The CoreSense Diagnostics module does not need to communicate to the rack controller in

order to provide compressor protection. Using the communication process is optional, but provides for information flow to the controller for proofing, remote reset, asset information, and fault history and compressor status. Skip to section titled

Stand Alone

Mode if the communication feature will not be used.

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).

Modbus

Communication to CoreSense Diagnostics

for K5 Compressors

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.

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 a description of the DIP switches please see

Figures 13 and 14.

Digital and EXV DIP Switches

Switch 1 is for Liquid injection being controlled by the

EXV. The "ON" position enables the EXV.

Switch 2 is for Digital Capacity Control. The "ON"

AE4-1383 R14

position enables Digital Capacity.

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.

For all other standard Modbus, DIP switch 4 should be in the OFF position.

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.

Switch 6 Is for Lockouts enabled. The "ON" position will enable lockouts

* These guidelines are based on E2 firmware version 3.0 and are subject to change. Contact your Emerson representative or refer to the

operation manual for more details on configuring an E2 module.

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

AE4-1383 R14

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.

6. From the Network Setup Menu select 1. Network Summary

AE4-1383 R14

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.

AE4-1383 R14

11. Press

“Online”. to return to the Network Summary screen. The device should now be

Repeat steps 8-10 to address the remaining CoreSense K5 modules.

12. Once all the devices are addressed, press

Network Summary. to save changes and exit the

13. Press to enter the Main Menu. Select 7. System Configuration .

14. From the System Configuration Menu select 7. Network Setup

AE4-1383 R14

15. From the Network Setup Menu, select 4. Controller Associations . Then Select 4. Compressor

(Press Enter)

16. Highlight the Suction Group

2 field, select F4: Look Up (Press F4) and select the appropriate suction group for the device and press Enter.

AE4-1383 R14

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)

AE4-1383 R14

Start

Is the compressor running?

Is the compressor overheated?

Yes

Allow time to cool

Yes

Observe the compressor suction & discharge pressures

Perform troubleshooting to determine why the compressor isn’t running

Put the system back into operation and retest

WARNING!

Disconnect and lockout the power before proceeding

Remove one wire from the modulation coil

Are pressures changing with the modulation cycle?

Yes

Measure the voltage at the modulation coil terminals

Operation is normal

Measure the resistance of the coil

Coil has continuity and isn’t grounded?

Yes

Replace modulation valve, follow valve replacement instructions

Replace modulation coil

Put the system back into operation and retest

Is voltage present, coinciding with the modulation cycle?

Yes

Troubleshoot the modulation control

Figure 1 – Modulation Troubleshooting

160

ZF*K5E Low Temperature Vapor Injection Operating Map

(65°F Return Gas)

R-404A/R-507

140

120

100

-50 -40 0 -30 -20 -10

Evaporating Temperature (°F)

Figure 2 (A)

AE4-1383 R14

160

ZF*K5E Low Temperature Vapor Injection** Operating Map

(65°F Return Gas)

R-407A /R-407C /R-407F/R-448A/R-449A

140

120

100

-50

Maximum

40F

Superheat

-40

** DTC/EXV Liquid Injection Required with EVI for R-407A /R-407C/ R-407F/R-448A/R-449A

-30 -20 -10

Evaporating Temperature (°F)

0 10

Figure 2 (B)

160

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

140

120

100

-50 -40

DTC/EXV Liquid

Injection Required

0 10 -30 -20 -10

Evaporating Temperature (°F)

Figure 2 (C)

AE4-1383 R14

-50

140

ZF*K5E Low Temperature Liquid Injection Operating Map

(65°F Return Gas)

R-22

120

100

DTC/EXV Liquid

Injection Required

-40 0 -30 -20 -10

Evaporating Temperature (°F)

Figure 2 (D)

160

ZB*K5E Medium Temperature Operating Map – (65°F Return Gas)

R-404A/R-507/R-407A/R-407C/R-407F

-29 -24 -19

Evaporating Temperature (°C)

-14 -9 -4 1 6

140

120

100

- 20 - 10

R-407A

Limit to 20°F SH

R-407C/F Limit to 20°F SH

65°F Maximum Return Gas

-8

-18

0 10 20

Evaporating Temperature (°F)

Figure 2 (E)

AE4-1383 R14

ZB*K5E Medium Temperature Operating Map – (65°F Return Gas)

R-448A/R-449A

160

-29 -24 -19

Evaporating Temperature (°C)

-14 -9 -4 1 6 11

140

120

100

20°F Superheat Limi t

-8

-18

-20 -10 0 10 20 30

Evaporating Temperature (°F)

Figure 2 (F)

40 50

Note: For operating maps at different return gas conditions, contact your Application Engineer.

160

150

140

130

120

110

100

ZB*K5E Medium/High Temperature Operating Map

(65°F Return Gas)

R-22

10 20 30 40

Evaporating Temperature (°F)

Figure 2 (G)

50 60

AE4-1383 R14

ZB*K5E High Temperature Operating Map

(20F Superheat)

180

160

140

120

100

R-134a

10 20 30 40

Evaporating Temperature (°F)

Figure 2 (H)

60 70

AE4-1383 R14

140

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*

120

100

-15 -10 -5

65°F Maximum Return Gas

0 5 10 15

Evaporating Temperature (°F)

20 25 30

*R-22 Not Approved for Vapor Injection

AE4-1383 R14

160

-29

140

120

100

- 20

ZBD*76 Compressor Operating Envelope WITHOUT

CoreSense Diagnostics Controlling Digital Capacity

-24 -19

Evaporating Temperature (°C)

-14 -9 -4 1

R-404A/R-507

- 10 40

-8

-18

0 10 20

Evaporating Temperature (°F)

Figure 2 (K)

ZBD*76 Compressor Operating Envelope WITHOUT

CoreSense Diagnostics Controlling Digital Capacity

-24 -19

Evaporating Temperature (°C)

-14 -9 -4

R-407A/R-407C/R-407F/R-448A/R-449A

1 6

160

-29

140

120

100

-8

- 20 - 10 0 10 20

Evaporating Temperature (°F)

Figure 2 (L)

40 50

-18

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.

AE4-1383 R14

ZBD114 Compressor Operating Envelope WITHOUT

CoreSense Diagnostics Controlling Digital Capacity

-24 -19

Evaporating Temperature (°C)

R-404A/R-407C/R-407F/R-448A/R-449A/R-507

-14 -9 -4 1 6

160

-29

140

120

100

- 20 - 10 0 10 20

Evaporating Temperature (°F)

Figure 2 (M)

ZBD114 Compressor Operating Envelope WITHOUT

CoreSense Diagnostics Controlling Digital Capacity

-24 -19

Evaporating Temperature (°C)

-14 -9 -4 1 6

R-407A

-18

-8

160

-29

140

120

100

-8

- 20 - 10 0 10 20

Evaporating Temperature (°F)

Figure 2 (N)

30 40 50

-18

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.

FILTER

DRIER

KEEP MIN

(SEE NOTE 6)

AE4-1383 R14

SUCTION

MANIFOLD

<12”

CONTINUOUS TUBING

(NO ELBOWS)

<30”

Notes:

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.

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)

AE4-1383 R14

Figure 4 – Circuit Diagram and Cycle for EVI

Heat

Exchanger

LIT

SIT

VOT

Condenser

Outlet

Vapor Outlet to

Compressor

TXV

LOT

Figure 5 – Downstream Extraction

Vapor Out

Liq. In

SIT

Cond. Out

TXV

Liq. Out

Vapor In

Figure 6 – Upstream Extraction

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

027-0383-00

STEEL SPACER

KIT# 998-0178-00

Figure 8A

8 - 17 HP Copeland Scroll Compressor

Rack Mounting

027-0400-00

RUBBER GROMMET

KIT #527-0210-00

Figure 8B

8-13HP Condensing Unit Mounting for

Models ZB95-ZB(D)114 and ZF49-54

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

CoreSense Module With Pressure Safety Control

K1 Relay

AE4-1383 R14

K1 Relay

CoreSense Module

*Kriwan

Module

INJ

Sol

OMB

Alarm

LPCO

HPCO

* 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

Figure 9A – CoreSense Module with Pressure Safety Control

CoreSense Diagnostics with Digital and EXV capability Wiring Schematic

** The physical location of M1/M2 & L1/L2 have changed on the CoreSense module **

Note: If Kriwan module is used, wire in series with CoreSense module, as indicated in diagram.

If Kriwan module is not used, wire M1 directly from safety circuit to M1 on CoreSense & M2 from contactor coil to M2 on CoreSense module.

** System control point only needed for fixed capacity compressors.

System

Control

LPCO

HPCO

OMB

Kriwan

Module

CoreSense

Diagnostics

INJ

SOL

Current Transducer

Discharge Top Cap

Thermistor

Digital Solenoid

(Same as Control

Circuit Voltage)

6 Pin to EXV Coil

12VDC

1-5v Digital

Capacity Input

EXV Coil

Alarm

Figure 9B – CoreSense Diagnostics Module with Digital and EXV Capability

** The physical location of M1/M2 & L1/L2 have changed on the CoreSense module **

Note: If Kriwan module is used, wire in series with

CoreSense module, as indicated in diagram.

If Kriwan module is not used, wire M1 directly from safety circuit to M1 on CoreSense & M2 from contactor coil to M2 on CoreSense module.

** System control point only needed for fixed capacity compressors.

Top Cap

266°F

(130°C)

Line

242°F

(117°C)

Identification Tag Color

No Tag Orange Tag

Figure 10 – Discharge Thermistor Connector (Viewed from Wire Side)

Nominal Shutdown Temperature

AE4-1383 R14

Top Cap

Thermistor

Figure 11 – Top Cap 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.

Figure 12 – Discharge Line Thermistor

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.

Communication Module DIP Switch Settings

AE4-1383 R14

Node Addresses

1 2 3 4 5

9600 Even Network Terminated

Baud

Rate

Parity

Control

Mode

Network

Termination

19200

Parity

Stand

Alone

Not

Terminated

“On” (UP)

“Off ” (Down)

1 2 3 4 5 6 7 8 9 10

Position 9 is not used

Figure 13 – K5 Communication Module DIP Switch Settings

Figure 14 – Digital and EXV DIP Switches

Terminal 5, Demand Wire

Terminal 9, Jumper To

Terminal 13

Terminal 13, L1 and Jumpered to Terminal 9

Terminal 14, L2

Figure 15 – Wiring Relay Example

Figure 16 – E2 Jumpers

Figure 17 – RS485 Daisy Chain Connection

Figure 18 – Two Rack Daisy Chain Connection

AE4-1383 R14

Compressor

Operation

DIP Switches

Diagnostic

LED Lights

Module

Communication

DIP Switches

Current Toroid Plugin

Digital Input 1-5V

(Analog Input)

Top Cap Thermistor

Modbus

Communication

Plugin

Control Circuit

Ground Screw

Module Power 110V/220V

AE4-1383 R14

Digital Solenoid

Voltage Output

(110/220V)

Liquid Injection

Output (cord provided)

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

Intermediate

Floating

Seal Cavity

Seal Cavity Vent

Removable External

Solenoid and Coil

Figure 20

Digital Compressor Cutaway View

AE4-1383 R14

20 Second Operating Cycle

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

1 2 3 4 5 6 7 8 10 20

Solenoid On -Time (Seconds)

Figure 21A

ZBD*K5E Digital Operation Cycle Time

AE4-1383 R14

Figure 21B

ZFD*K5E Digital Operation Cycle Time

AE4-1383 R14

1. Top Cap Temperature

Sensor

CoreSense

™

Diagnostics + EXV Operation

2. Input Signal to CoreSense

Module

3. CoreSense

Module

543-0209-00

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

Liquid Line Input to the

Valve (Liquid line Solenoid will be needed)

4. CoreSense

Output

T-Fitting with EXV for

Wet Injection Application

Medium Temperature Digital Operation

10%-100%

Enables Digital Operation

Figure 22

Low Temperature Digital Operation

30%-100% and Enables Liquid Injection

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

AE4-1383 R14

Application Injection Refrigerants

(Medium Temp)

N/A All

(Low Temp)

Vapor

Injection

Liquid

Injection

404A/507

407A/C/F

448A/449A

All

Table 1

Injection Accessories

Required Kits

Reference

Figure

See

Figure 21

Top Cap Thermistor is Factory Installed (no kits required)

998-0229-00: Top Cap Thermistor Kit

*Top Cap Thermistor is factory installed on -260 BOM

998-0500-03: 250°F DTC Kit Including Temperature Probe

998-0177-00: DTC Vapor Injection Adapter

See

Figure 21

See

Figure 3C

998-0500-03: 250°F DTC Kit Including Temperature Probe See

Figure 3B

Crankcase

Heater Kit P/N

918-0047-00

918-0047-01

918-0047-02

918-0047-03

Crankcase

Heater P/N

018-0091-00

018-0091-01

018-0091-02

018-0091-03

Table 2

External Wrap-Around Crankcase Heaters

Volts

120

240

480

575

Watts

Lead Length

(in)

Ground Wire

Length (in)

Conduit Ready Box for

Crankcase Heater

998-7029-00

Table 3

Kriwan INT69 Module Specifications

Emerson P/N

Emerson Kit P/N

Manufacture P/N

T1-T2 Module Power

Voltage Supply

Frequency

M1-M2 Module Output Contacts

071-0660-00

971-0641-00

Kriwan 22 A 601

120/240V

50/60 Hz

Maximum Voltage

Maximum Current

Minimum Current

S1-S2 Thermal Protection

Trip Out Resistance

Reset Resistance

Reset Time

Manual Reset

264 VAC

2.5 Amps

100 milliamps

4500 ±20%

2750 ±20%

30 min ±5 min.

T1-T2 interrupt for minimum of 5 sec.

AE4-1383 R14

Table 4

K5 Compressor for Refrigeration Additional Accessories

Accessory

Mounting Parts

Service Valve

Kits

Rotalock to Stub

Tube Adapter

Kits

Oil Monitoring

OMB (Emerson

Flow Controls

P/Ns)

CoreSense

Diagnostics

Crankcase

Heater Kits

Liquid Injection

Components

Digital Kits &

Components

Part Description

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)

P/N

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

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

943-0159-00

943-0209-00

998-0176-00

998-0229-00

918-0047-00

918-0047-01

918-0047-02

575V, 93W Wrap Around, 48" Lead Length 018-0091-24

Conduit Ready Box for Crankcase Heater

918-0047-03

998-7029-00

DTC Kit - 250°F Set Point DTC with 268°F Thermistor for Liquid Injection and R-407A/C/F Vapor Injection

998-0500-03

Liquid Injection Adapter (For R407A/C/F Vapor Injection Applications Only) 998-0177-00

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)

65365

65366

66077

66652

943-0151-00

998-0340-00

998-0060-04

998-0060-09

998-0341-00

998-0342-00

Closed Loop Digital Controller (Single Compressor Applications) 998-0189-00

AE4-1383 R14

Table 5

K5 Compressor for Refrigeration (8 to 17 HP) Fitting Sizes

Fitting

Suction Rotalock Connection

Discharge Rotalock Connection

Liquid/Vapor Injection Rotalock Connection

Size (in.) -Thread

1 3/4"-12

1 1/4"-12

1"-14

Model

ZF* K5E

ZB*K5E

Table 6

High and Low Pressure Control Settings

Control Type

Low

High

Low

High

R-404A / 507

0 psig min.

400 psig max

17 psig min.

450 psig max

R-134A

---

4 psig min.

263 psig max

R-22 / R-407A / R-407C/

R-407F / R-448A/ R-449A

2 in. Hg Min.

335 psig Max

37 psig min.

381 psig max

Table 7A

Low Temperature Digital Modulation

Capacity(%)/Analog (V)

Digital

Capacity %

100%

90%

80%

70%

60%

50%

40%

30%

Analog

Voltage Input

(Volts)

5.00

4.60

4.20

3.80

3.40

3.00

2.60

2.20

Digital

Solenoid

On time

(Seconds)

Table 7B

MediumTemperature Digital Modulation

Capacity(%)/Analog (V)

Digital

Capacity %

100%

Analog

Voltage Input

(Volts)

5.00

Digital

Solenoid

On time

(Seconds)

90%

80%

4.60

4.20

70%

60%

50%

40%

3.80

3.40

3.00

2.60

30%

20%

10%

2.20

1.80

1.40

AE4-1383 R14

Table 8

R1011 Alert Code Descriptions

Alert Code Code Description

Protection

Shutdown

(Default)

Protection

Off Time

(Default)

Lockout feature is NOT enabled from the factory except on code 7

Consecutive

Detections

Until Lockout

ä ä

High Discharge Temp – see diagram for setting

ä ä

Excess System Limit Trips -

4 consecutvie system limit trips having 1-15 min runtime each

Excessive Demand Cycling -

Default is 240 cycles per 24 hr. period

Locked Rotor -

Compressor did not start within alloted time

Demand Present -

No current detected over 4 hr. period

ä ä

Phase Loss Detected

Yes

20 Min.

5 Min.

20 Min.

No Lockout

Reversed Phase Detected

Yes

20 Min.

Until

Module Is

Reset

Welded Contactor -

Current detected without demand

Low Module Voltage

Module Communications Error

Discharge Temperature Sensor Error

Current Transducer Error

Yes

5 Min.

No Lockout

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

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.

AE4-1383 R14

CoreSense

™

Table 9

Diagnostics Module Troubleshooting

Status LED Description Status LED Troubleshooting Information Status LED

Green Alert LED

Solid

Green Alert LED

3 Flashes

Module has power

Short Cycling

2 to 480 run cycles in 24hours ending with normal

Alert Default is set to 240 per 24 hours

Green Alert LED

5 Flashes

Green Alert LED

8 Flashes

Open Circuit

Demand signal is present but no compressor current for four hours

Welded Contactor

No demand signal, but current has been detected in one or both phases

Displayed for 24 hrs after last detection

Supply voltage is present at module terminals

1. Check pressure or temperature control

2. Possible loss of refrigerant

3. Blocked Condenser

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

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

Green Alert LED

11 Flashes

Green Alert LED

12 Flashes

Loss of Communication

Communication lost between rack controller and module for 10 minutes or more

Discharge Temperature Sensor Error

Short or Open Circuit Detected

Current Transducer (CT) Error

1. Check communications wiring

2. Verify wiring follows application guidelines

Yellow Alert LED

Solid

Yellow Alert LED

1 Flash

Yellow Alert LED

2 Flashes

Trip

Demand present, no current is detected

High Discharge Line Temperature Trip

See inside label to determine cut out temp.

System Trip

Four consecutive compressor trips after run time of 1-15 minutes each

1. Check discharge temperature sensor wiring and mounting

2. Verify sensor is not shorted. 86k @ 77°F

1. Verify CT is plugged into module

2. Verify CT is not shorted

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

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

1. Excessive suction pressure or discharge pressure

2. Improper wiring

AE4-1383 R14

Status LED

Yellow Alert LED

4 Flashes

Yellow Alert LED

6 Flashes

Yellow Alert LED

9 Flashes

Red Alert LED

1 Flash

Red Alert LED

4 Flashes

Red Alert LED

6 Flashes

Red Alert LED

7 Flashes

CoreSense

™

Diagnostics Module Troubleshooting (Continued)

Status LED Description

Locked Rotor

Compressor is drawing current without rotating or four consecutive compressor trips after run time of 1-15 seconds

Missing Phase

Demand signal is present but current is missing in one phase

Low Voltage Detected

Control voltage dips below 85V for

110V or 170V for 220V

LOCKED OUT ON:

High Discharge Line Temperature Trip

See inside label to determine cut out temp.

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

LOCKED OUT ON:

10 Missing Phase Detections

Demand signal is present but current is missing in one phase

LOCKED OUT ON:

1 Reverse Phase Detected

Demand signal is present but current is not detected in the correct sequence

Status LED Troubleshooting Information

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

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

1. Low line voltage (contact utility if voltage at disconnect is low)

2. Check wiring connections

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

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

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

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

AE4-1383 R14

Table 10 – Demand Wiring

Demand Wiring Kit (998-0188-00)

Item

Control Voltage

110/120 220/240

Relay Socket 032-0766-00

Relay 040-1086-00 040-0187-00

Table 11 – K5 Dip Switch Settings

Dip Switch

Number

1 Through 5

On Off

Modbus

Module Address

Baud Rate= 9600 Baud Rate= 19,200

Even Parity

Network

Terminated

No Parity

Stand Alone

Not Used

Not Terminated

Table 12

CoreSense™ Module DIP Switch Scenarios

Application

Digital?

Compressor

SW1: EXV Enabled

SW2: Digital Enabled

SW3: Failsafe On/Off

Medium Temperature

Digital Non-Digital

ZBD**K5E ZB**K5E

Off Off

Off

Digital

ZFD**K5E

Off

Low Temperature

Non-Digital

ZF**K5E

Off

SW4: 1 or 2 Stop Bits

SW5: Reset to Default

SW6: Lockout Enabled

Application

SW2: Digital Control

Off

All

On for

Rack

Off w

XC643

Off

All

Off

Liq Inj

On for

Rack

Off w

XC643

Off

VI 407A

On for

Rack

Off w

XC643

Option To Use Open Triac

Off

VI 404A Liq Inj VI 407A VI 404A

On for

Rack

Off w

XC643

Off

*Liquid Inj. Line Solenoid n/a n/a No No Yes Yes 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)

Off

Off n/a

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.

CoreSense™ Diagnostics for Copeland Scroll™ K5 Refrigeration Compressors

Modbus

Specification

Table of Contents

1.0 Introduction ................................................................. 2

1.1 Abbreviations ............................................................................. 2

1.2 Intent ......................................................................................... 2

1.3 Scope ........................................................................................ 2

1.4 References ................................................................................ 2

2.0 General Description .................................................... 2

3.0 Module Type Identification ......................................... 2

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

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

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

5.0 Data Link Layer ........................................................... 4

5.1 Node Address ............................................................................ 4

5.2 RTU Transmission Mode ........................................................... 5

5.3 Response Message Timeout ..................................................... 5

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

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.

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

RTU

DLT

OAC

CRC

CMD

Meaning

Remote Terminal Unit

Discharge Line Temperature

Overall Alarm Count (Total number of alarms since the module has been installed)

Cyclic Redundancy Check

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.

1.4 References

For the details of the Modbus specification, refer to the

Modicon Modbus Protocol Reference Guide

PI–MBUS–300 Rev. J.

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 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

Figure 2: Pre & After January 2015 Communication DIP

Switch Board

3.2 CoreSense Diagnostics After January 2015 DIP

Switch Settings & Configurations

Main DIP

Switch

Board

Figure 4: After January 2015 Main 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

The recommended wire will be Belden 8761 that is a

22 AWG shielded twisted pair. The shield is also used as the circuit ground.

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.

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

• 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’, ‘+’

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.

Figure 7: Switches 1 to 5 are used to set the module

Modbus address

Table 2: Node Address DIP Configurations

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:

• 1 start bit

• 8 data bits

• 2 stop bit (or if ‘even parity’ is selected 1 stop bit and 1 parity bit)

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

0x04

0x03

0x06

0x10

Function

Name

Read Input

Registers

Read

Holding

Registers

Write Single

Write

Multiple

Registers

Register

Input

Holding

Access

Read Only

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 001B Division Name

001C 0021 Product Name

0022 0029 Product Code

002A 0030 Module Version Number

0077 0077

0078 0078

0079 0079

007A 007A

Seven Days of

Compressor Run Time

007B 007B

007C 007C

007D 007D

007E 007E

007F 007F

0080 0080

0081 0081

Seven Days of

Compressor Start Times

0082 0082

0083 0083

0084 0084

0085

0087

008E

0086

0088

008E

008F 0090

009B 009B

009C 009C

009D 009D

009E 009E

Total Compressor Run

Time

Total Compressor Start

Times

Protection Trip For Seven

Days

Protection Trip After

Power Up

Ten Most Recent Alarm

Quantity

Data Description

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

'X'

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 009F

00A0 00A0

00A1 00A1

00A2 00A2

00A3 00A3

00A4 00A4

00AA 00AA

Eight Days Alarm History of DLT Fault

00AB

00AC

00AF

00B0

00B1

00B4

00AB

00AC

00AF

00B0

00B1

00B4

Eight Days Alarm History of CT Fault Warning

Eight Days Alarm History of Loss Comm From E2

Warning

Eight Days Alarm History of Short Cycling Warning

Eight Days Alarm History of Open Circuit Warning

Eight Days Alarm History of Welded Contactor

Warning

Eight Days Alarm History of High Discharge Line

Temperature Alarm

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)

……………………………..

00B5 00B5

Eight Days Alarm History of System Trip Alert

00B6 00B6

Eight Days Alarm History of Locked Rotor Alert

00B7 00B7

Eight Days Alarm History of Missing Phase Alert

00B8 00B8

Eight Days Alarm History of Reverse Phase Alert

00BA 00BA

Eight Days Alarm History of Module Low Voltage

Alert

00C6 00C6

Eight Days Alarm History of High Discharge

Temperature Lockout

00C7 00C7

Eight Days Alarm History of Locked Rotor Lockout

BIT7 - Today-7:

(0 - Not present / 17 - Present)

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

00CA 00CA

Eight Days Alarm History of Reverse Phase Lockout

00E3

00C9

00E3

Eight Days Alarm History of Missing Phase Lockout

OAC of DLT Fault

00E4 00E4 OAC of CT Fault Warning

00E5

00E8

00E9

00EA

00E5

00E8

00E9

00EA

00ED 00ED

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

00EE 00EE OAC of System Trip Alert

00EF

00F0

00F1

00F3

00FF

0101

0102

0103

00EF

00F0

00F1

00F3

00FF

0101

0102

0103

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

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

0118 0118 Previous Alert

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

011C

011D

0122

0123

011B

011C

011D

0122

0123

System Status

DIP Switch_1

DIP Switch_2

Low Voltage Set point

Input Status 1

0126 0126 Output Status1

0129

012E

0129

012E

Discharge Temperature

Value

Compressor Power

Frequency

012F 012F Module Power Voltage

0130

0132

0130

0132

Compressor Current Y

Phase

Compressor Current B

Phase

0133 0133 LRA Peak Current

0134 0134 MAX RMS Current

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

013A 013A EXV open position

013B 013B

Analog Input Voltage

Value

013C 013C Minimum Capacity

013D 013D Analog Input Request

013E 013E

Compressor Running

Capacity

0173 0174 Total No. of Short Cycles

0x00 - Solenoid not used

0x01 - Solenoid is used for EXV

0x02 - Solenoid is used for digital modulation

0~100 means 0%~100%

0~500 means 0~5.00V

10~100 means 10%~100%

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

0025 0036 Compressor Module Number

0037 0042 Compressor Serial Number

0051 005C Module Part Number

005D 0069 Module Serial Number

Quantity

0076 0076 EXV Control Type

0077 0077

EXV Position for Manual

Control

0078 0078 Proportionality Coefficient Set

0079 0079 Integral Coefficient Set

007A 007A Differential Coefficient Set

007B 007B PID Sample Time

007D 007D PID Set Point Value Set

0080 0080 Minimum On Time

0081 0081 Minimum Off Time

0085 0085

Alert Trigger Parameters

Configuration

0086 0086

Data Description

'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

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 ;

0088

0089

008A

009A

00B4

0088

0089

008A

009A

00B4

Alert Off Time Configuration

Lockout Status

Configuration1

00B6 00B6

00B8 00B8

00B9 00B9

Lockout Events

00BA 00BA

00D0 00D0 Module Status Configuration

00D4 00D4 UL1 Capacity Request

00D6 00D6 Unloader Modulation Period

Range: -70 to 585.35 °F

Reset point =( Word -7000 )/100 (°F)

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

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).

Table 6: Debugging Tool

The request and response is hex value.

Request for version number

1 . 0 1 R 0 0

2 0

E 0

Key features

Digital capacity control
CoreSense™ Diagnostics
8-17 HP capacity range
Suitable for refrigeration, air conditioning and heat pump systems
Optimized for R-404A refrigerant
Extended ZF*K5E operating envelope
Liquid injection
Vapor injection

Frequently asked questions

Approved refrigerants include R-22, R-134a, R-404A, R-407A/C, R-407F, R-448A, R-449A, and R507. For the most up to date refrigerant information, refer to Form 93-11, Emerson Accepted Refrigerants/Lubricants, or contact your Application Engineer.

Digital capacity control allows the compressor to modulate its capacity from 10% to 100%. This is achieved by using a solenoid valve that opens and closes to allow refrigerant to bypass the compressor. This allows the compressor to operate at the most efficient capacity for the given load.

CoreSense™ Diagnostics is a module that provides diagnostic information and control for the compressor. This information can be used to monitor the health of the compressor, troubleshoot problems, and optimize system performance.

Liquid injection is a technique used to increase the cooling capacity of a refrigeration system. It involves injecting liquid refrigerant into the compressor, which helps to cool the compressor and improve efficiency. Liquid injection is typically used in low-temperature applications.

Vapor injection is similar to liquid injection, but instead of injecting liquid refrigerant, it injects vapor into the compressor. This technique is also used to improve cooling capacity and efficiency in low-temperature applications, and is particularly effective at higher compression ratios.

For rack applications, use specially designed steel spacers and rubber isolator pads to limit the compressor's motion and minimize potential problems of excessive tubing stress. This mounting arrangement also helps to prevent vibration from being transmitted to the mounting structure.

Both high and low pressure controls are required. Refer to Table 4 in the document for the minimum and maximum pressure setpoints.