AE8-1368 R2 December 2012 AE8-1368 R2 CoreSense™ Diagnostics v2.11 for Copeland Discus™ Compressors Table of Contents 1.0 Overview 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 1.1 Functionality 1.1.1 Diagnostics 1.1.2 Communication 1.1.3 Fault History 1.2 Features 1.2.1 Compressor Protection 1.2.2 Remote Reset 1.2.3 Failsafe Operation 1.2.4 Welded Contactor Protection 1.2.5 Crank Case Heater Control 1.2.6 Start-up Delay Feature 1.2.7 “Jog” feature 1.2.8 Dipswitch Settings 5.
AE8-1368 R2 6.26 6.27 6.28 6.29 6.30 6.31 Control Module Failure Lockout Sensor Module Failure High Discharge Pressure Trip Discharge Temperature Lockout Current Overload Trip Rapid Compressor Cycling with Constant Demand 6.32 Discharge Temperature Probe Fault Trip 6.33 Comp Low Voltage Trip/Lockout 7.0 Service Instructions 7.1 7.2 7.3 7.4 7.5 7.6 7.7 8.0 Compressor Changeout Instructions 9.0 Removal Of 2D / 3D 10.0 Installation Of 2D / 3D 11.0 Removal Of 4D 12.0 Installation Of 4D 13.0 Removal Of 6D 14.
AE8-1368 R2 As with all conditions, the status of the compressor and the display code are transmitted to the rack controller where they may be viewed. The status codes are discussed below in Section 6.0. Troubleshooting flowcharts to assist with resolution of each of the warnings, trips and lockouts may also be found in Section 6.0. 1.1.2 Communications Communication between the rack controller and each CoreSense Diagnostics module is through an RS485 network with MODBUS.
AE8-1368 R2 1.2.2 Remote Reset The oil pressure lockout may be reset through the E2 or remotely through Site Manager if the reset option is enabled. This is not to be confused with single-phase protection at start-up or while running. In that case, the contactor will be instructed to “open”, shutting down the compressor. The service contractor and end user policies need to be considered when deciding whether to enable or disable the oil pressure remote reset feature.
AE8-1368 R2 Digital modulation will be available for the 3D, 4D and 6D compressor. The E2 can control any combination of compressors, blocked suction compressors and/ or digital compressors. When more than one digital compressor is in a suction group, only one compressor at any given time will be operating in a “digital” mode (i.e. modulating in a pulse-width fashion). Blocked suction (and Moduload) compressors are set up in the suction group as stages (i.e.
AE8-1368 R2 2.1 Mounting and Installation The Copeland Discus compressor with CoreSense Diagnostics is designed and engineered for use in a supermarket rack application. Its environmental restrictions are not different than other Copeland Discus™ compressors. As such, the compressor must be in an equipment room, rack house or roof enclosure to prevent direct precipitation on the compressor.
AE8-1368 R2 Refer to Figure 2.2 for sensor module lead connections. regarding the CoreSense Diagnostics compatible rack controller. 2.2.2 Fan Connections 2.4 Communications Network • Copeland Discus compressors with CoreSense Diagnostics are not shipped from the factory with fans installed. OEM installation of fans should follow established regulatory, OEM engineering and end user specifications regarding wiring.
AE8-1368 R2 “terminated” (refer to Figure 2.6). 2.5.1 RS485 Communication Wiring Types The communications wire to the compressor may be routed into the rear of the side conduit (2D / 3D) and along the channel which leads into the control module. The 4D and 6D wire routing can be alongside the wire harness and into the control module. A shielded, twisted pair cable such as Belden #8761 (22AWG) should be used for the communication wiring.
AE8-1368 R2 2.8 CoreSense Diagnostics v2.11 Model Numbers Factory built Discus compressors with an S/E (the last 3 digits in the model number) beginning with “A” are Copeland Discus compressors with CoreSense Diagnostics. Models with an S/E that begins with "AD" are equipped with Demand Cooling. The remaining numbers define the service valve configuration as well as crankcase heater presence. 3.0 CoreSense Diagnostics v2.11 Quick Start Guide 1) Module Power Apply power to the CoreSense Diagnostics v2.
AE8-1368 R2 The E2 should look like Figure 4.1. 4.1 Dip Switch Configuration CoreSense Diagnostics v2.11 devices are equipped with a DIP switch to set their node address. In addition, this DIP switch determines the baud rate, parity, control mode, and failsafe settings of the module. Refer to Figure 4.2 below for details: To ensure proper communications, follow these steps: 1.
AE8-1368 R2 the network setup by following these steps: 2. Press 7 (Network Setup) 1. From the main menu select 7 (System Configuration) 2. Press 7 (Network Setup) 3. Press 2 (Connected I/O Boards and Controllers) 4. Press Ctrl + 3 (ECT Tab) 3. Press 1 (Network Summary) The E2 should look like Figure 4.5 4. Highlight the appropriate CoreSense Diagnostics device and press F4: Commission 5. Select the desired address and press Enter. Verify the address and press Enter again.
AE8-1368 R2 This will open the suction group setup screen as shown below in Figure 4.7. • From this screen you can edit the name of the suction group, select the control type, and enter the number of stages. The number of stages can be determined as follows: • • A standard compressor (no unloader) will count as one stage. • A compressor equipped with digital unloading will count as one stage. A compressor with one bank of standard unloading will count as two stages.
AE8-1368 R2 1. Press F2 (Next Tab) until the Stage Setup screen is displayed. 2. Under Type, select Comp for compressor, Unld for unloader, or Dgtl for digital. 3. Under Capacity, enter the compressor capacity in BTU/hr or the compressor horsepower for each stage. The E2 will use this value as the expected output for each stage and w ill cycle the stages according to the required demand.
AE8-1368 R2 While running in failsafe mode the compressor will continue to run until either a fault occurs or until communications is re-established with the rack controller. This is to say that the only system controls in place to cycle the compressor are the high and low pressure safety controls. The trip/reset values for the high and low pressure controls are 360/250psi and 3/10psi (-2/8psi for R407A and R407C compressors) respectively.
AE8-1368 R2 3. Press F5 (Setup) language voltage imbalance demand cooling 4. Press F2 (Next Tab) The E2 screen should look like Figure 4.11 4.8 Unloader Configuration The unloader configuration settings are preloaded at the factory and will match the requirements of the compressor. The Unloader Mod Type setting of Digital is for digital unloading only. For compressors without unloaders or for those with non-digital unloading (blocked suction) the Unloader Mod Type should be set to None.
AE8-1368 R2 4.15 Language The LCD display on the CoreSense Diagnostics control module can be set to display messages in multiple languages. The available options are English, Spanish, Portuguese, French and German. 4.16 Voltage Imbalance The voltage imbalance setting determines the maximum percentage of voltage imbalance on the three compressor phases. If the measured voltage exceeds the imbalance setting, the module will alarm and shut down the compressor. The default setting for this parameter is 5%. 4.
AE8-1368 R2 As with other alarms in the E2, the alarms associated with the Copeland Discus compressorswith CoreSense Diagnostics can be programmed for different levels. To view the alarm settings navigate to the Alarms tab by pressing Ctrl+8. modules using the E2 rack controller follow these steps: 1. From the main menu select 5 (Configured Applications) 2. Press 104 (ISD 2.0) The E2 screen should look like Figure 4.15. The E2 should look like Figure 4.16.
AE8-1368 R2 the voltage at each compressor terminal. In addition, the starting current is shown as Locked Rtr Cur. (Note: This value is the first cycle peak current and will be slightly higher than the published steady state RMS locked rotor value). Power factor and power consumption are also listed. In addition to compressor run history, the CoreSense Diagnostics v2.11 module also retains a history log of the most recent alarms. To access this information, press Ctrl+8.
AE8-1368 R2 The screen will display each of the related events in a table format with an indication of whether the event has occurred. The columns labeled 1 through 8 at the top represent days of the week with number 1 being the current day of operation. In addition, the count column serves as a running counter of each alarm since the device has been commissioned. In the event that a compressor needs to be replaced, this history information will be zeroed when a new control module is connected.
AE8-1368 R2 • Flashing Green: An indication that there is a warning condition. The compressor can still be running. • Flashing Red: An indication that the compressor has tripped or is in lockout state. • Solid Red: An indication that the control module has failed. 6.1 Definitions • Trip: The module has shut off the compressor due to a fault condition. The compressor will be available to run when the fault condition no longer exists, and the minimum off time has been satisfied.
AE8-1368 R2 Module Function Architecture Control Module Sensor Module Controller Communications Sensor Module Communications Contactor Operation Unloader Operation Motor Temperature Protection (4D/6D) Pressure Switch Status Demand Cooling Operation Discharge Temperature Oil Pressure Protection Supply Voltage Protection Configuration Settings Model Number Operating History Advanced Motor Protection • Locked Rotor • Missing Phase • Current Overload • Voltage Imbalance • Low Motor Voltage • Part Winding St
AE8-1368 R2 6.
AE8-1368 R2 Control module LCD Display Control module LED Delay Time Discharge temperature trip “Discharge Temp” “Trip” Flashing RED Max of ASCD and 2 min Warning Loss of communication between control module& E2 “No Communication” “Failsafe ON” (or OFF) Flashing GREEN NA 24 Warning sensor module failure “Sensor Module” “Failure” Flashing GREEN NA 25 Warning Loss of Communication (control to sensor module) “No Communication” “To Sensor module” Flashing GREEN NA 26 Warning Low oil p
AE8-1368 R2 6.4 Emergency Work-Around Procedures False motor trips or lockouts: In the event that a compressor fails to run due to an electronic module failure, the following work-around procedures are listed to assist the technician with gaining temporary control of the compressor until replacement parts may be obtained. The situations listed below will not compromise the fundamental safe operation of the compressor or agency listed motor protection features.
AE8-1368 R2 6.5 Normal Running Has the rack controller issued a run command? Yes Is the compressor running? Yes Normal Operation No No Normal Running: • • • Demand is present Current > 5 amps Motor voltage is present • No faults The control module will display amperage and discharge temperature © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. Does the E2 show a status code of “No communication to Control Module”? Yes Normal Operation.
AE8-1368 R2 Normal – OFF Fail Safe - OFF 6.6 • • • • No Demand Motor Current < 5 amps No Voltage No Communication; Fail Safe Set For “Off” Yes Is the compressor OFF? Has the rack controller issued a run command? No Yes Has the contactor been manually closed? Does the rack controller show a status code of “No Communication to Control Module”? No No Yes Is compressor Current < 5 Amps? Yes Normal Operation. A run command has not been issued by the rack controller.
AE8-1368 R2 Forced Run Welded Contactor Warning 6.
AE8-1368 R2 Module Low Voltage Trip 6.8 Sensor Module input voltage must be greater than 16.5 volts Check the Sensor Module supply voltage at the leads connected to the terminal labeld “24 VAC IN” in the terminal box. Is the voltage below 16.5 volts? Normal Operation. Check the supply voltage at the transformer. Correct the low voltage condition. Voltage must be above 16.5 V for module to reset. Verify proper transformer VA rating and wiring size (See Appendix C). Replace the transform if necessary.
AE8-1368 R2 6.9 Connection Lost CT to sensor CT is the Current Sensing Transducer, located in the terminal box. It is the round “toroid” that one of the motor power leads passes through. This code is generated when it is unplugged from the Sensor Module, or the motor power lead isn’t passing through the CT.
AE8-1368 R2 6.10 Rack Controller Lockout The rack controller, in rare instances, may determine that it is necessary to shut down the compressor Investigate the cause of the shutdown and reset the E2 alarm in order to restart the compressor © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 6.11 Fault Temperature Probe The temperature probe is an “NTC” device. Its resistance increases with decreasing temperature. This fault is generated by an “open” thermistor circuit, and as such will generate a reading of a low temperature (-40F or +327F with some versions of control module). This assessment is only made if the control module temperature is greater than -30F. Temperature probe connections should be coated with NyoGel 760G lubricant.
AE8-1368 R2 Fail-Safe Inoperable 6.12 The fail-safe feature exists for conditions involving the loss of communication to the controller (wire failure, controller failure, etc.). In the event of an electronics failure of the control module, the use of an emergency jumper may be used to force the compressor “on” while still utilizing the high and low pressure switches on the compressor.
AE8-1368 R2 Locked Rotor Trip / Lockout 6.13 A detected locked rotor condition (at start-up or while running) will shut the compressor off for 5 minutes. After 5 minutes, an attempt will be made to run again if demand is still present. After 10 consecutive locked rotor trips, the control module will transition to a LOCKOUT condition A reset is necessary in order for the module to run again. If the compressor is locked out, RESET the module to enable it to run again.
AE8-1368 R2 No Communication 6.14 a “No Communication” will be shown on the ISD display. It will be seen in the E2 detail status screen as the ISD Display Code, and the Network Status will be “Offline”. After 5 minutes of no communication, the control module of the compressor will revert to the Failsafe run state.
AE8-1368 R2 6.
AE8-1368 R2 Motor Temperature Trip 6.15 Motor temperature protection for 4D and 6D compressors utilizes 3 temperature sensors in the motor. The temperature sensor resistance is measured by the control module to determine whether or not to shut down the motor. The motor temperature set point is not configurable (it is a fixed value).
AE8-1368 R2 6.16 No Communication to Sensor Module This code results when the sensor module communication harness is unplugged for 1 minute, or the control module fails to communicate with the sensor module for 1 minute Remove the Bottom cover of the control module Is the control module to sensor module communication harness properly plugged into the connector (see photo below)? No Properly plug the harness into the connector Yes Open the terminal box (Caution: High Voltage on Terminal Posts).
AE8-1368 R2 Unloader Short 6.17 The unloader short protects the harness and electronics from high current (2 s 0.5 Amps) associated with a shorted coil or harness. The control module must be reset to allow the unloader to be operated again.
AE8-1368 R2 Unloader Open 6.18 The “open” unloader coil detection is based on a low current flow (<200 mA) through the unloader coil. This feature is disabled for the Demand Cooling solenoid coil Unplug the connector to the unloader coil Is the coil resistance greater than 120 ohms? (nominal coil resistance 6 Ω) Yes Replace the unloader coil No With the unloader output plugged in, force the unloader stage “off” to energize the circuit. Measure voltage across the coil.
AE8-1368 R2 Contactor Coil Lockout 6.19 Turn off the pilot circuit and “open” the motor power breaker. The contactor coil lockout protects the circuit from high current (3 + 0.5 amps) resulting from a “shorted” coil or harness. The control module must be re-set to clear the lockout. Unplug the contactor output leads at the contactor (or pilot relay).
AE8-1368 R2 Protector Trip 6.20 This fault pertains to 2D and 3D compressors with internal line break protectors. The presence of motor voltage without current flow is the symptom used to detect a protector trip. Current flow is measured by the Current Sensing Module (“CT”, for Current Transducer) Is the compressor running? Yes Possible Causes: 1.) Motor lead not passing through CT 2.) CT not plugged into sensor module, or pins in connector not engaged 3.
AE8-1368 R2 6.21 Voltage Imbalance Trip Check compressor power supplied to the contactor. Is the voltage difference between any of the power leads greater than the percentage that is set in the E2? See the configuration tab for this compressor. No Reset the sensor module by turning off the pilot circuit power. Note: Before turning the module on, wait approximately 5 seconds to allow for a proper reset. Yes Normal Operation.
AE8-1368 R2 Low Suction Pressure Trip 6.
AE8-1368 R2 6.23 Phase Loss Trip / Lockout A phase loss trip occurs if one or two phases of the motor are not receiving voltage. The compressor will shut off and remain off for 5 minutes before trying again. If the phase loss occurs for 10 consecutive attempts, a lockout will occur. A lockout requires that the module be reset to allow the compressor to run. Every successful re-start will decrement the lockout counter by one.
AE8-1368 R2 No 3-Phase Power 6.24 No 3-phase power fault occurs if a run command has been sent from the control module to the contactor (or pilot relay) and voltage isn’t present at the motor terminals. This will not result in a lockout condition; If demand remains, the compressor will continue to attempt to run until voltage at the motor is present. This fault will typically occur during start-up.
AE8-1368 R2 Normal Running Low Oil Pressure 6.25 Followed By Low Oil Pressure Lockout Is oil present in the sight glass? Yes Is the harness connector at the oil pump pressure sensor fully engaged? No Reconnect No Install jumper across the harness connector pins No Resolve reservoir oil supply problem or oil level control setting issues Yes Disconnect harness at the sensor.
AE8-1368 R2 6.26 Control Module Failure Lockout Reset the Control Module by pressing the “Reset” button on the front of the unit Does the module continue to display the “Control Module Failure Lockout” code? No The module has returned to Normal Operation Yes Reset the module by turning it off and back on. Note: Before turning the module on, wait approximately 5 seconds to allow for a proper reset.
AE8-1368 R2 6.27 Sensor Module Failure Reset the Control Module by pressing the “Reset” button on the front of the unit Does the module continue to display the “Sensor Module Failure” code? No The module has returned to Normal Operation Yes Reset the sensor module by turning off the pilot circuit power. Note: Before turning the module on, wait approximately 5 seconds to allow for a proper reset.
AE8-1368 R2 6.28 High Discharge Pressure Trip Is the Service Valve Open? Open the Valve No Yes Is the system discharge pressure above the preset trip point? Yes Resolve system pressure issue Yes Replace the switch if it fails to reset below 250 psi. No Check the continuity across the pressure switch. Is the circuit open? No Verify that the connections to the pressure switches are tight and made properly. Refer to Figure 5.
AE8-1368 R2 6.29 Discharge Temperature Trip / Lockout Does this compressor have liquid injection? Yes See Section 6.
AE8-1368 R2 6.
AE8-1368 R2 Current Overload Trip 6.30 This fault is a result of continuous compressor current that exceeds the configuration (MCC) limit by 10% for 60 seconds as determined by the current sensing transducer. This is independent of the compressor protector or motor temperature sensors. The comp will auto-reset after 2 minutes (plus any remaining anti-short cycle time).
AE8-1368 R2 Rapid Compressor Cycling with Constant Demand; Contactor Chatter 6.31 Inspect for: • Loose connection in the contactor coil power circuit • Loose connection at the white sensor module connector that supplies 24V to the control module. Re-size the connector pin sockets or replace the harness. Reference 6.8 – Module Low Voltage Trip • High pressure switch intermittent open circuit. Refer to 6.3, High Pressure Discharge Pressure Trip.
AE8-1368 R2 6.32 Discharge Temperature Probe Fault Trip This fault occurs when there is an “open” temperature probe circuit and the compressor is configured to run with Demand Cooling Refer to 6.12, Fault Temperature probe, to resolve the temperature probe fault condition © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 6.33 Comp Low Voltage Trip / Lockout* *This condition will result in a Lockout after 10 consecutive events Are the sensor module voltage sensing lease connected to the motor terminals? No Connect as shown in Figure 2.2 Yes Is the proper 3-phse voltage being supplied to the compressor? Yes Confirm that the CoreSense module has been programmed with the proper voltage setting (refer to section 4.7) © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 7.0 Service Instructions 7.2 Sensor Module Replacement 7.1 Control Module Replacement The CoreSense Diagnostics compressor sensor module relays information concerning the compressor current and voltage to the control module. If a failure would occur to the sensor module the control module would display "No Communications to Sensor Module". While the compressor would remain functional, enhanced motor protection features would be disabled.
AE8-1368 R2 • • 24VAC input power to the sensor module 24VAC output power to the control module 4. Remove the two retaining nuts securing the sensor module to the terminal box and remove the module. 5. Install the new module by reversing the steps listed above. When re-connecting the compressor voltage sensors be sure that the black lead is connected to the compressor terminal corresponding to the current sensor. 6.
AE8-1368 R2 7.5 Temperature Probe Inspection Erroneous temperature probe readings may be due to “sprung” connections at the harness, or corrosion on the harness connector surfaces. A reading of approximately 0F and a display code of “Fault Temp Probe Trip” is indicative of an open circuit or poor electrical connection. Unplug the temperature probe from the harness and measure the probe resistance to determine whether the probe itself is faulty. a torch.
AE8-1368 R2 Figure 7.1 2D/3D CoreSense Diagnostics v2.11 Assembly Reference Drawing 8. Remove access cover on control module (two screws). 9. Unplug RS-485 communications plug. 10. Unplug the harness to the oil pressure switch. 11. Remove housing cover nuts securing control module mounting plate to compressor. (x2) 12. Remove control module and harness assembly as a unit by pulling it off towards the front of the compressor. 13.
AE8-1368 R2 Figure 7.3 4D CoreSense Diagnostics v2.11 Assembly Reference Drawing 6. Install the terminal box on the compressor by routing the harness leads through the provided opening in the bottom of the box. Secure to the compressor using the four anchor screws. 7. Secure the wiring harness assembly to the terminal box by installing two screws. 8.
AE8-1368 R2 • Remove terminal box grounding strap • Remove the compressor motor sensor leads • Disconnect the compressor voltage sensing leads • Remove terminal box anchor screws holding the box to the compressor 7. Reconnect the pressure controls to wiring harness (HPCO-RED leads and LPCO-BLUE leads). 4. Remove the side cover to access the high pressure control. 10. Reconnect the harness to the head temperature probe and unloader (if present). 5.
AE8-1368 R2 Figure 7.5 6D CoreSense Diagnostics v2.11 Assembly Reference Drawing 14.0 Installation of the compressor (6D) 1. Mount the new compressor in the rack, lifting and maneuvering the compressor in a manner to prevent personal injury and damage to the other compressors on the rack. 2. Transfer the temperature sensor and pressure control fittings to the head and body of the new compressor. Use of a thread sealing compound is recommended. 3.
AE8-1368 R2 Appendix A © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 ACROSS THE LINE CONNECTED PART WINDING START CONNECTED LINE VOLTAGE 400-460 02 01 03 ACROSS THE LINE CONNECTED LINE VOLTAGE 200-240 CONTROL CIRCUIT VOLTAGE 01 02 03 01 02 03 L1 L2 L3 L1 L2 L3 T1 T2 T3 C1 T1 T2 T3 C2 LINE VOLTAGE 200-240 02 01 C1 03 TD 1 2 3 7 8 9 5 6 4 C2 1 2 3 7 8 9 1 2 3 7 8 9 052-2435-00 02/09 TD CONTROLS CONTACTOR CONTROL CIRCUIT 4 WIRING DIAGRAM 5 4 5 6 120/240 VAC INPUT CONTROL MODULE COMM CLASS 2 TRANSFORMER EXTERNAL
AE8-1368 R2 PART WINDING START CONNECTED ACROSS THE LINE CONNECTED LINE VOLTAGE CONTROL CIRCUIT VOLTAGE 01 02 03 01 02 03 L1 L2 L3 L1 L2 L3 T1 T2 T3 C1 T1 T2 T3 C2 LINE VOLTAGE 02 01 C1 03 TD C2 1 2 3 7 8 9 1 2 3 7 8 9 052-2436-00 02/09 TD CONTROLS CONTACTOR CONTROL CIRCUIT WIRING DIAGRAM 120/240 VAC INPUT CONTROL MODULE COMM CLASS 2 TRANSFORMER EXTERNAL POWER SUPPLY 24 VAC OUTPUT ELECTRICAL SYMBOL LEGEND C1 MODULE POWER 24 VAC CCH POWER COMPRESSOR WIRING HARNESS T1
AE8-1368 R2 ACROSS THE LINE CONNECTED MOTOR WINDING CONNECTIONS LINE VOLTAGE 1 02 1 2 03 2 3 3 WIRING DIAGRAM 120/240 VAC INPUT CONTROL MODULE COMM CLASS 2 TRANSFORMER EXTERNAL POWER SUPPLY 24 VAC OUTPUT MODULE POWER 24 VAC CCH POWER COMPRESSOR WIRING HARNESS CCH T1 T2 T3 BLACK WHITE WHITE CURRENT SENSOR 1 L1 L2 L3 BLACK WHITE CURRENT SENSING CONTACTOR USE COPPER CONDUCTORS ONLY. WHEN CHECKING MOTOR PROTECTION SYSTEM: USE MINIMUM 75° C (167° F) WIRE FOR AMPACITY DETERMINATION.
AE8-1368 R2 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 Appendix B v © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 Appendix C Transformer Selection And Contactor Control Power requirements for controlling CoreSense Diagnostics v2.11 compressor operation must be provided by a Class 2 24VAC transformer. This voltage is used for powering the CoreSense Diagnostics v2.11 module, crankcase heater relay, unloaders, pilot duty relay or contactor coil. This voltage can be used for contactor coils providing the total load on the class 2 transformer does not exceed 100VA.
AE8-1368 R2 Table C-2 shows the recommended class 2 transformer for individual compressor models for CoreSense Diagnostics v2.11 applications when a pilot duty relay is used. Table C-2 (Recommended Minimum Class 2 Transformers for Compressor Models Using a Stancor Pilot Duty Relay) Class 2 Transformer Size Model VA Inrush VA Sealed CoreSense Diagnostics v2.11 With Pilot Duty Relay 2D 27.78 13.78 40VA 3D No Unloader 27.28 13.78 40VA 3D One Unloader 65.18 31.78 40VA 4D No Unloader 27.78 13.
AE8-1368 R2 Example of transformer size calculation when contactor is directly powered by the class 2 transformer: Again, use the same 3D example with one unloader, calculate the total inrush VA and steady state VA for devices that will be powered. Refer to Table C-4 for VA values. The contactor selected for this example is a Square D NEMA size 00. The contactor specification indicates 33 VA sealed and 165 VA inrush.
AE8-1368 R2 Example Of Determining Wire Length: 25 FT Contactor Transformer TOTAL LENGTH OF WIRE = 4 STRANDS X 25 FT TOTAL LENGTH OF WIRE = 100 FT Table C-6 Wire Sizing Recommended Secondary (24V) Minimum American Wire Size (AWG) These Sizes Will Keep Voltage Drops To Less Than One Volt With XFMR Producing Rated Current Continuous VA XFMR Nameplate 25 Linear Ft. Wire Size AWG 50 Linear Ft. Wire Size AWG 75 Linear Ft. Wire Size AWG 100 Linear Ft.
AE8-1368 R2 Wiring schematic showing the use of a pilot duty relay to control contactor with system voltage and/or 24 volt direct control of contactor from CoreSense Diagnostics v2.11 module: Figure C-1 Using Pilot Duty Relay for Contactor Coil © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 Appendix D Dielectric Test (Hi-Pot), Megger, of Copeland Discus Compressors with CoreSense Diagnostics Fitted with Sensors and Control Module. (4 & 6 D Models) WARNING: Performing Hi Voltage test to a compressor must be performed by an experienced and qualified individual. Hi Voltage is dangerous and could result in severe damage to equipment, personal injuries, or death. Follow all specifications, local and national codes, and procedures when performing Hi Voltage test. Steps to follow: 1. 2.
AE8-1368 R2 Appendix E 2D Drawing With Demand Cooling © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 3D Drawing With Demand Cooling © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 4D Drawing With Demand Cooling © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 6D Drawing With Demand Cooling © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
© 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. 80 brand products CONFIDENTIALITY NOTICE THIS DRAWING AND INFORMATION CONTAINED HEREIN ARE THE EXCLUSIVE PROPERTY OF EMERSON CLIMATE TECHNOLOGIES, INC. AND SHALL BE RETURNED UPON DEMAND AND SHALL NOT BE REPRODUCED IN WHOLE OR IN PART TO ANYONE ELSE OR USED, WITHOUT THE WRITTEN CONSENT OF EMERSON CLIMATE TECHNOLOGIES, INC.
© 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A. 81 brand products CONFIDENTIALITY NOTICE THIS DRAWING AND INFORMATION CONTAINED HEREIN ARE THE EXCLUSIVE PROPERTY OF EMERSON CLIMATE TECHNOLOGIES, INC. AND SHALL BE RETURNED UPON DEMAND AND SHALL NOT BE REPRODUCED IN WHOLE OR IN PART TO ANYONE ELSE OR USED, WITHOUT THE WRITTEN CONSENT OF EMERSON CLIMATE TECHNOLOGIES, INC.
AE8-1368 R2 4D Compressor Drawing © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 6D Compressor Drawing © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
AE8-1368 R2 Appendix F Technical Support For technical support or assistance in resolving issues with the Copeland Discus compressor with CoreSense Diagnostics, contact the Emerson Retail Solutions support line. The contact number is (770)-425-2724. Emerson Retail Solutions does not provide parts support. Contact your Emerson Climate Technologies Wholesaler for service parts.
