Copeland Compressor Electronics Module User Manual
Introduction
Thank you for purchasing the Copeland compressor electronics module and related kits. This next-generation module offers advanced diagnostics, intelligent protection, and communication features to enhance compressor performance and reliability. It assists contractors and service providers in troubleshooting commercial refrigeration systems by providing valuable information to diagnose issues quickly and accurately, significantly reducing costly downtimes.
Connecting to the Mobile App
Access critical compressor information conveniently via the mobile app. Real-time data and compressor conditions are downloaded to your smartphone, helping service technicians identify potential problems before they occur and prevent system downtimes. Historical data aids in analyzing and resolving issues in the field.
The module stores running data every 20 seconds, retaining approximately 72 hours of effective running time. Data is not recorded during compressor downtime. Old data is overwritten by new data upon restart. It is recommended to select specific time periods for downloading historical data to manage download times.
Step 1: Search for "Copeland Electronics Module" in your device's app store (iOS App Store or Android Google Play) and install it.
Step 2: Enable Bluetooth on your device, search for the Copeland electronics module, and pair with "Emerson xxxxxxxx" (where xxxxxxxx is the serial number on the module sticker).
Product Features and Technical Specifications
The control module monitors the refrigeration scroll compressor's operation using various sensors. If an unsafe condition is detected, it shuts down the compressor by de-energizing the contactor coil and displays an alarm code.
The module is available in two versions: Plus 5 and Plus 4, designed for different compressor platforms.
Module Product Specifications
| Module Part Number | 571-0106-00 | 571-0107-00 |
| Type Code | Plus 5 | Plus 4 |
| T1/T2 Power Supply & Frequency | 115-240 Vac, 50-60Hz | 115-240 Vac, 50-60Hz |
| Allowable Voltage Range | 97-264 Vac | 97-264 Vac |
| T1/T2 Low Voltage Trip | 90/170 Vac | 90/170 Vac |
| T1/T2 Low Voltage Reset | 95/185 Vac | 95/185 Vac |
| Power Consumption | 25 VA | 25 VA |
| M1/M2 Contact Rating | 2.5A, 240Vac | 2.5A, 240Vac |
| Alarm Contact Rating | 2.5A, 240Vac | 2.5A, 240Vac |
| Solenoid Valve Contact Rating | 0.4A, 240Vac | 0.4A, 240Vac |
| Motor Temperature Overheat Trip Resistance | > 4.5KΩ ± 25% | NA |
| Open Motor Thermistor Trip Resistance | >220KΩ | NA |
| Shorted Motor Thermistor Trip Resistance | <40Ω | NA |
| Motor Temperature Reset Resistance | < 2.75KΩ | NA |
| Reset Time After Motor Trip | 30 minutes | NA |
| Ambient temperature range | -30° to 70°C | -30° to 70°C |
| Approvals | UL, CE | UL, CE |
| Protection Class | IP20 | IP20 |
Terminal Designations
| Terminal | Description | 571-0106-00 Plus 5 | 571-0107-00 Plus 4 |
| T1/T2 | Module power supply, 115-240 VAC, 50-60Hz | ||
| L1/L2/L3 | Phase inputs corresponding to compressor input power L1-L2-L3 | ||
| M1/M2 | Normally open control circuit contacts; M2-M1 should be wired in series with the compressor contactor coil | ||
| A/B | Compressor start/stop demand signal, from low pressure switch or thermostat | ||
| Valve | Solenoid valve terminal (For oil return in Rack application) | ||
| DPT | Connect to motor and scroll discharge port temperature sensors | ||
| DLT | Connect to discharge line temperature sensor | ||
| VIT/VOT | Vapor in sensor and vapor out sensor terminal (EVI compressor is required) | ||
| OLS | Oil level sensor terminal (Optional, required in single unit or rack application) | ||
| EXV | EXV terminal | ||
| Alarm | Alarm terminal, output to buzzer | ||
| TTL | For PC interface and RS485 communication (Requires a separated transition board) | ||
| Recall | Recall button to display diagnosis data via LED |
Key Functions
| Key Functions | 571-0106-00 Plus 5 | 571-0107-00 Plus 4 |
| Motor protection | ||
| Motor temperature overheat protection | ||
| Locked rotor protection | ||
| Motor missing phase protection | ||
| Reverse phase protection | ||
| Advanced protection | ||
| Discharge temperature overheat protection | ||
| Compressor running short cycling protection | ||
| Module low voltage protection | ||
| Injection control via EXV | ||
| Liquid injection control | ||
| Vapor injection control | ||
| Oil level management (To be released) | ||
| Oil level protection via oil level sensor | ||
| Oil return via solenoid valve | ||
| Diagnosis & data management | ||
| LED matrix display running status and alarm history | ||
| Read the running information | ||
| Download history data (total 72 hours effective running time data storage) | ||
| Communication | ||
| Alarm terminal output to buzzer | ||
| Bluetooth connection to mobile phone | ||
| PC interface or RS485 communication via TTL terminal (To be released) |
Dip-Switch Setting
The dip-switch settings configure compressor discharge temperature control targets, oil level control enablement, and injection control modes (liquid or vapor injection superheat target).
Plus 5 Module: 571-0106-00
| Location | Bit 1 | Bit 2 | Bit 3 | Bit 4 |
| OFF | Discharge port temperature control target at 120°C (OFF) | Disable oil level control (OFF) | Disable injection (ON-OFF) | Vapor Injection 5K Superheat (OFF-OFF) |
| ON | Discharge line temperature control target at 110°C (ON) | Enable oil level control (ON) | Liquid Injection (ON-ON) | Vapor Injection 10K Superheat (OFF-ON) |
Plus 4 Module: 571-0107-00
| Location | Bit 1 | Bit 2 | Bit 3 | Bit 4 |
| OFF | Discharge line temperature control target at 110°C (OFF) | Disable oil level control (OFF) | Disable Injection (ON-OFF) | Vapor Injection 5K Superheat (OFF-OFF) |
| ON | Discharge line temperature control target at 95°C (ON) | Enable oil level control (ON) | Liquid Injection (ON-ON) | Vapor Injection 10K Superheat (OFF-ON) |
Typical Application Examples
| Compressor models | Bit 1 | Bit 2 | Bit 3 | Bit 4 | Typical applications | |
| Plus 5 Module: 571-0106-00 | ||||||
| ZFI96, ZFI122, ZFI140 | Discharge port temperature control target at 120°C | Disable oil level control | OFF | OFF | Vapor Injection 5K Superheat | DPT + Vapor Injection 5K (Default factory setting) |
| Discharge port temperature control target at 120°C | Disable oil level control | OFF | ON | Vapor Injection 10K Superheat | DPT + Vapor Injection 10K (for glide-refrigerants) | |
| Discharge port temperature control target at 120°C | Enable oil level control | ON | OFF | Vapor Injection 5K Superheat | DPT + Vapor Injection 5K + Oil Level Control | |
| Discharge port temperature control target at 120°C | Disable oil level control | ON | ON | Disable Injection | DPT + Disable Injection (Default factory setting) | |
| ZB150, ZB190, ZB220 | Discharge port temperature control target at 120°C | Disable oil level control | OFF | OFF | Vapor Injection 5K Superheat | DPT + Disable Injection (for customers who do not use Copeland EVI control kits) |
| Discharge port temperature control target at 120°C | Disable oil level control | OFF | ON | Vapor Injection 10K Superheat | DPT + Disable Injection + Oil Level Control | |
| Discharge port temperature control target at 120°C | Enable oil level control | ON | OFF | Vapor Injection 5K Superheat | DPT + Liquid Injection (enable liquid injection to suction line) | |
| Discharge port temperature control target at 120°C | Disable oil level control | ON | ON | Disable Injection | DPT + Liquid Injection (Default factory setting) | |
| Plus 4 Module: 571-0107-00 | ||||||
| ZFI09-ZFI81 | Discharge line temperature control target at 110°C | Disable oil level control | OFF | OFF | Vapor Injection 5K Superheat | DLT + Vapor Injection 5K (Default factory setting) |
| Discharge line temperature control target at 110°C | Disable oil level control | OFF | ON | Vapor Injection 10K Superheat | DLT + Vapor Injection 10K (for glide-refrigerants) | |
| Discharge line temperature control target at 110°C | Enable oil level control | ON | OFF | Vapor Injection 5K Superheat | DLT + Vapor Injection 5K + Oil Level Control | |
| Discharge line temperature control target at 110°C | Disable oil level control | ON | ON | Disable Injection | DLT + Disable Injection (for customers who do not use Copeland EVI control kits) | |
| ZSI06-ZSI21 | Discharge line temperature control target at 110°C | Disable oil level control | OFF | OFF | Liquid injection | DLT 110°C + Liquid Injection (Default factory setting) |
| Discharge line temperature control target at 95°C | Enable oil level control | ON | OFF | Liquid injection | DLT 95°C + Liquid Injection | |
| Non-functional | Disable oil level control | OFF | ON | Disable Injection | Disable Injection + Oil Level Control | |
| ZB58-ZB114 | Non-functional | Enable oil level control | ON | ON | Disable Injection | Non-functional |
Alarm Code Definition and Troubleshooting Reference
This section details alarm codes, their descriptions, fault conditions, and troubleshooting steps for both Plus 5 and Plus 4 modules.
| Alarm LED Code | Fault Type | Description | Plus 5 | Plus 4 | Fault Condition | Trouble shooting reference |
| 0 | ON | Normal operation | NA | NA | NA | NA |
| 0 | Flash | Normal compressor power off | NA | NA | NA | NA |
| 1 | Flash Trip | Discharge temperature overheating | > control target +15°C; 10 minutes reset time after trip | 1/ Check refrigerant charge, system leaks. 2/ Check superheat, expansion valve, suction tube insulation. 3/ Check pressures, low/high pressure switches. 4/ Inspect liquid/vapor injection system, EXV for damage/blockage. 5/ Check compressor current, potential wear due to oil loss. | ||
| 2 | Flash Trip | Discharge temperature sensor short circuit | < 500Ω; 10 minutes reset time after trip | 1/ Check sensor connection to module. 2/ Check sensor wiring continuity, replace sensor. | ||
| 3 | Flash Warning | Discharge temperature sensor open circuit | > 1000KΩ; 10 minutes reset time after trip | 1/ Check sensor connection to module. 2/ Check sensor wiring continuity, replace sensor. | ||
| 4 | Flash Warning | Vapor in temperature sensor short circuit | < 500Ω; 10 minutes reset time after trip | 1/ Check sensor connection to module. 2/ Check sensor wiring continuity, replace sensor. | ||
| 5 | Flash Warning | Vapor in temperature sensor open circuit | > 500KΩ; 10 minutes reset time after trip | 1/ Check sensor connection to module. 2/ Check sensor wiring continuity, replace sensor. | ||
| 6 | Flash Warning | Vapor out temperature sensor short circuit | < 500Ω; 10 minutes reset time after trip | 1/ Check sensor connection to module. 2/ Check sensor wiring continuity, replace sensor. | ||
| 7 | Flash Warning | Vapor out temperature sensor open circuit | > 500KΩ; 10 minutes reset time after trip | 1/ Check sensor connection to module. 2/ Check sensor wiring continuity, replace sensor. | ||
| 8 | Flash Trip | Module input voltage is low | < 170/95V; 5 minutes reset time after trip | 1/ Check supply voltage. 2/ Replace module. | ||
| 9 | Flash Lockout | Module internal fault | Module malfunction | 1/ Reset power supply. 2/ Replace module. | ||
| A | Flash Warning | Module internal Bluetooth component fault | 5 times consecutive communication error | 1/ Reset power supply. 2/ Replace module. | ||
| C | Flash Lockout | Module version fault | Internal configuration fault | 1/ Replace module. | ||
| E | Flash Trip | Motor temperature sensor overheating | > 4.5KΩ; 30 minutes reset time after trip | 1/ Check supply voltage. 2/ Check refrigerant charge and superheat. 3/ Check compressor operating envelope. 4/ Check contactor. | ||
| F | Flash Lockout | Motor temperature sensor overheating lockout | 5 times consecutive trip | 1/ Check supply voltage. 2/ Check refrigerant charge and superheat. 3/ Check contactor. | ||
| G | Flash Trip | Motor temperature sensor short circuit | < 40Ω; 30 minutes reset time after trip | 1/ Check sensor connection to module. | ||
| H | Flash Lockout | Motor temperature sensor open circuit | > 220KΩ; 30 minutes reset time after trip | 1/ Check sensor connection to module. | ||
| J | Flash Trip | Phase missing | 5 minutes reset time after trip | 1/ Check incoming power supply. 2/ Check fuses/breakers. 3/ Check contactor. | ||
| K | Flash Lockout | Phase missing lockout | 5 minutes reset time after trip | 1/ Check incoming power supply. 2/ Check fuses/breakers. 3/ Check contactor. | ||
| L | Flash Lockout | Phase reverse lockout | Phase Reverse | 1/ Check incoming phase sequence. 2/ Check contactor. 3/ Change module phasing wires L1-L2-L3. | ||
| M | Flash Warning | Compressor forced running | Module detected trip error but compressor still running | 1/ Check contactor contacts. 2/ Check M1-M2 output shorting. 3/ Check if control wiring bypasses M1-M2. | ||
| N | Flash Warning | Compressor short cycling warning (Default) | Compressor running <1 min for 1 cycle, >48 cycles in 24 hrs | 1/ Check refrigerant charge and pressure control setting. 2/ Check thermostat setting. | ||
| P | Flash Lockout | Compressor short cycling lockout (Manual configuration) | Compressor running <1 min for 1 cycle, >48 cycles in 24 hrs | 1/ Check refrigerant charge and pressure control setting. 2/ Check thermostat setting. |
Liquid Injection and Vapor Injection Control Kits
Copeland offers liquid injection and vapor injection control kits with 1.8m or 4.5m wire lengths.
Liquid Injection Control Kits
| Part number with 1.8m wire length(1) | Part number with 4.5m wire length | Applicable ZSI models | EXV valve orifice size (Identification code) |
| 562-0471-00 | NA | ZSI06-ZSI21 | Ø1.3mm (TS113C03) |
| (1) 562-0471-00 is included in ZSI compressor bill of materials (BOM536/539) | |||
Vapor Injection Control Kits
| Part number with 1.8m wire length | Part number with 4.5m wire length | Applicable ZFI models | EXV valve orifice size (Identification code) |
| 562-0471-01 | 562-0471-02 | ZFI09-ZFI26 | Ø1.3mm (TS113C03) |
| 562-0471-03 | 562-0471-04 | ZFI36-ZFI39 | Ø1.65mm (TS116C03) |
| 562-0471-05 | 562-0471-06 | ZFI50-ZFI59 | Ø1.65mm (TS116C03) |
| 562-0471-07 | 562-0471-08 | ZFI68-ZFI81 | Ø1.8mm (TS118C03) |
| 562-0460-00 | 562-0460-01 | ZFI96-ZFI140 | Ø2.4mm (TS124C03) |
Injection Control Kits BOM Breakdown
| Injection Control Kits | Part number with 1.8m wire length | Applicable Compressor Models | Part number with 4.5m wire length | |||
| ZSI06-ZSI21 | ZFI09-ZFI26 | ZFI36-ZFI39 | ZFI50-ZFI59 | ZFI68-ZFI81 | ZFI96-ZFI140 | |
| 1 Control module | 562-0471-00 | 562-0471-01 | 562-0471-03 | 562-0471-05 | 562-0471-07 | 562-0460-00 |
| 571-0107-00 | 571-0107-00 | 571-0107-00 | 571-0107-00 | 571-0107-00 | with Comp | |
| 2 Module bracket | 074-1855-00 | 074-1855-00 | 074-1855-00 | NA | NA | NA |
| 3 Blots group | 521-0355-00 | 521-0355-00 | 521-0355-00 | NA | NA | NA |
| 4 DLT/DPT sensor | 543-0317-00 | 543-0317-00 | 543-0317-00 | 543-0317-00 | 543-0317-00 | with Comp |
| 5 Vapor in/out sensor | NA | 043-0285-00 | 043-0285-00 | 043-0285-00 | 043-0285-00 | 043-0285-00 |
| 6 EXV filter | 013-0212-00 | 013-0212-00 | 013-0212-00 | 013-0212-00 | 013-0212-00 | 013-0212-00 |
| 7 EXV-coil | 023-0111-00 | 023-0111-00 | 023-0111-00 | 023-0111-00 | 023-0111-00 | 023-0111-00 |
| 8 EXV-valve | 010-0240-00 | 010-0240-00 | 010-0240-01 | 010-0240-01 | 010-0240-02 | 010-0240-03 |
| 9 Gland Cable - single hole | NA | NA | NA | 036-1868-00 | 036-1868-00 | 036-1868-00 |
| 10 Gland Cable - 7 holes | NA | NA | NA | 036-1869-00 | 036-1869-00 | 036-1869-00 |
| 11 Tube for sensor | 028-3998-00 | 028-3998-00 | 028-3998-00 | 028-3998-00 | 028-3998-00 | 028-3998-00 |
| 12 Spring clip | 032-0962-00 | 032-0962-00 | 032-0962-00 | 032-0962-00 | 032-0962-00 | 032-0962-00 |
| 13 Pin connector group | 521-0398-00 | 521-0398-00 | 521-0398-00 | 521-0398-00 | 521-0398-00 | 521-0398-00 |
Module Installation and Field Retrofit
Module Installation
ZFI20-39, ZSI06-21: The module is installed in a separate bracket box and fixed into the condensing unit system.
Module Bracket: Two holding tabs secure the module in the compressor terminal box or the module bracket box. To remove, depress the holding tabs and lift the module.
ZFI50-81: For ZFI50-81 Summit scroll compressors, this module can be installed in the compressor terminal box.
ZB150-220, ZFI96-140: For these large scroll compressors, the module is shipped already installed in the compressor terminal box.
Field Retrofit Steps
The new generation Copeland compressor electronics modules are intended for field retrofits of older ZSI liquid injection, ZFI vapor injection, large ZFI scroll P47 CoreSense, and vapor injection control modules.
ZS106-ZS121
- Remove old module kits (control board, transformer, box, DLT sensor).
- Replace with new module, module bracket, and DLT sensor. EXV can be reused.
- Refer to the new wiring diagram.
ZFI20-ZFI81
- Remove old EVI module kits (control board, transformer, box, DLT sensor, Vapor-in/out sensors).
- Replace with new module, module bracket (for ZFI09-ZFI39), cable glands (for ZFI50-ZFI81), DLT sensor, and Vapor-in/out sensors. EXV can be reused.
- Refer to the new wiring diagram.
ZFI96-ZFI140
- Remove old EVI module kits (control board, transformer, box, DLT sensor, Vapor-in/out sensors).
- Remove the old P47 module from the compressor terminal box.
- Replace with the new module and Vapor-in/out sensors. EXV can be reused.
- Refer to the new wiring diagram.
Wiring Diagrams
The following diagrams illustrate recommended wiring configurations for various compressor models and module types.
Plus 4 Single Phase Wiring Diagram (ZSI06-ZSI14 Compressor)
This diagram shows the connections for a single-phase compressor using the Plus 4 module, including power supply, control signals, sensors (DLT, VIT/VOT), and output for alarms and EXV.
Plus 4 Three Phase Wiring Diagram (ZSI06-ZSI21, ZFI09-ZFI81 Compressor)
This diagram details the wiring for three-phase compressors with the Plus 4 module, covering power inputs (L1, L2, L3), control circuits, sensors, and communication interfaces.
Plus 5 Wiring Diagram (ZFI96-ZFI140 Compressor)
This diagram illustrates the wiring for three-phase compressors with the Plus 5 module, featuring connections for power, motor phases, sensors (DPT, VIT/VOT), control signals, and communication ports.
Note: Always refer to the specific wiring diagram applicable to your compressor model and module version. Ensure all connections are made according to the diagram for safe and proper operation.
Contact Information
For inquiries or support, please refer to the contact details provided on the cover page of the original document. Key contact regions include Asia Pacific, Australia, China (Beijing, Guangzhou, Shanghai), India (Mumbai, Pune), Egypt, Japan, Middle East & Africa, Philippines, South Africa, Saudi Arabia, South Korea, Thailand, and United Arab Emirates.
Visit Copeland.com for more information.
