Copeland™ Compressor Electronics for Stream Compressors
Guide for the Replacement of CoreSense™ Diagnostics
Date of last update: Jul-21
Ref: TI_Stream_NGCS_05_E_Rev02
Application Engineering Europe
1. Differences between Copeland™ Compressor Electronics and CoreSense™ Diagnostics
1.1 Location
The Copeland compressor electronics module (formerly Next Generation CoreSense) is located within the terminal box of the Stream compressor. In contrast, the CoreSense Diagnostics module was situated outside the terminal box, adjacent to the oil pump. This relocation necessitates some cabling modifications when replacing the CoreSense Diagnostics module with the Copeland compressor electronics module.
CoreSense Diagnostics: Module located externally, next to the oil pump.
Copeland Compressor Electronics: Module located inside the terminal box.
1.2 Sensors and Connections
Both modules gather similar information, but the specific sensors and their locations may differ, and all connections are distinct. The replacement kit includes all necessary parts.
| CoreSense Diagnostics | Copeland Compressor Electronics | |
|---|---|---|
| Oil pressure sensor | Sentronic sensor | OPS3 sensor & switch |
| Discharge temperature sensor | NTC, Sensor located in the cylinder head | PT1000, Located in the terminal box |
| Current sensor | Located in the terminal box | Located in the terminal box |
| Sensor module | NO | NO |
| Modbus connection | Option | Option via an additional module |
1.3 Terminal Box and Cover
The terminal box and its cover share the same dimensions but have specific features requiring replacement. The Copeland compressor electronics terminal box includes an additional hole for the reset button, and its cover features a window for viewing the LEDs.
2. Replacing CoreSense Diagnostics with Copeland Compressor Electronics and Accessories
WARNING: High voltage! Danger of electric shock! Ensure the main power supply to the compressor is turned off before opening the terminal box or working on electrical equipment. Never open the electrical box in rainy weather if the isolating switch is on.
Complete kits for replacing CoreSense Diagnostics with Copeland compressor electronics are available with the following references:
- Kit for Stream with oil pump: N° 5406738
- Kit for Stream without oil pump (small CO2 models): N° 3271343
These kits contain all necessary parts for the replacement, including the terminal box and its cover. Any parts or components not required for the Copeland compressor electronics module must be removed and replaced with accessories compatible with the new module.
2.1 Parts to be Removed
Parts and components specific to the CoreSense Diagnostics module must be removed.
Description of Figure 1: A diagram illustrating the main components of the CoreSense Diagnostics module on a Copeland compressor. It shows the control module, a sensor module and current sensor located in a terminal box (T-box), an oil pressure sensor, a wiring harness, and a discharge temperature sensor.
2.1.1 Parts in Terminal Box
The sensor module with its bracket and the current sensor must be removed. The steps are:
- Disconnect the main power supply to the compressor.
- Unscrew the four screws on the corners of the terminal box cover and open it.
- Disconnect the power supply to the terminal and the three voltage sensing leads connected to the motor terminals and the sensor module.
- Disconnect the power supply to the sensor module and all other connections (crankcase heater, communication to CoreSense Diagnostics module, current sensor).
- Remove the sensor module and the current sensor.
Description of Figure 2: Two images. The first shows a sensor module with its bracket and a separate current sensor. The second image displays the interior of a terminal box with wiring and connection points.
2.1.2 External Parts
- Remove the CoreSense control module with its bracket.
- Remove the cable harness from the terminal box.
- Remove the terminal box.
2.1.3 Sensors in Compressor Body
CAUTION: Contact with POE lubricant can cause material damage. Handle POE lubricant with care and use appropriate protective equipment (gloves, eye protection). Avoid contact with surfaces or materials that POE might damage, including certain polymers like PVC/CPVC and polycarbonate.
Both the discharge temperature and the oil pressure differential sensors need replacement, requiring the system to be opened. Prepare the compressor according to industry standards before changing these parts.
- Close the suction service valve.
- Pump down the compressor.
- Disconnect power to the compressor.
- Close the discharge service valve and the oil supply valve (if applicable).
- Depressurize the compressor.
NOTE: The two removed sensors should be replaced immediately with the new ones.
2.2 Installation of the Copeland Compressor Electronics Module
2.2.1 Replacement of the Oil Sensor
- Unscrew the existing oil sensor from the oil pump.
- Remove the yellow cap from the new OPS3 oil sensor.
- Install the new oil sensor into the oil pump using the copper gasket, tightening to 60 to 75 Nm.
- Remove the white cap and screw the electronic switch (black part) to the brass sensor, tightening to a maximum of 10 Nm.
Description of Figure 3: Images show the OPS3 oil pressure sensor with a yellow cap and the associated electronic switch with a cable.
2.2.2 Replacement of the Discharge Temperature Sensor
- Unscrew the existing discharge sensor from the cylinder head.
- Install the new discharge temperature sensor into the cylinder head, using Loctite or sealing tape on the thread, tightening to 15 Nm.
- Remove the yellow cap and connect the cable to the sensor, tightening to a maximum of 10 Nm.
Description of Figure 4: An image displays the discharge temperature sensor with its cable.
2.2.3 Replacement of the Terminal Box
Once the terminal box is empty, remove the old one and replace it with the new terminal box.
2.2.4 Parts in Terminal Box
The current sensor and the Copeland compressor electronics module are installed in the terminal box using their respective brackets.
Description of Figure 5: Images show a current sensor with a mounting bracket and the Copeland compressor electronics module with its connectors.
Description of Figure 6: Images show the interior of the terminal box, with one view showing the installed current sensor and the other showing the internal wiring and terminal connections for the Copeland compressor electronics.
2.2.5 Connections
After replacing the parts, connect the cables as follows:
- Motor PTC cable from terminals 5 and 6 to S1 and S2 at the terminal plate.
- Current sensor (T1) to terminals 9 and 10 (CM).
- Reset button to terminals 14 and 13 (Reset).
- Discharge gas temperature sensor to terminals 7 and 8 (DGT).
- Oil pressure sensor to terminals 11 and 12 (OPS).
- Connect three cables for each winding for phase monitoring to module terminals U1-V1-W1, U2-V2-W2 (PM).
- Connect Earth to PE.
- Connect power supply (230 V or 115 V) to terminals 1 (N) and 2 (L1) (PS). Both polarities are acceptable.
- Connect crankcase heater to terminals 3 and 4 (CH). Ensure the crankcase heater has the same power supply (115 VAC or 230 VAC) as the Copeland compressor electronics module.
- Set the jumper position according to the starting method and motor type.
- Connect the power supply to the terminal plate. Caution: Power leads from the same phase must pass through the current sensor in the same direction (refer to T1 on the electrical diagram).
- Connect the control circuit phase (L) to terminal 19.
Refer to the wiring diagrams for more details.
2.2.6 Stream with Copeland Compressor Electronics – Wiring Diagrams
IMPORTANT: For Stream CO2 small and medium compressor models (4MTL-05 to 4MTL-30 & 4MSL-03 to 4MSL-15), the blue terminal positions (1U, 2V, 3W, 7Z, 8X, 9Y) in the diagrams are applicable. For all other Stream compressor models, the terminal positions correspond to the black positions. Factory connections are correct; do not reverse them.
Legend:
| Code | Description | Code | Description |
|---|---|---|---|
| B1 | Discharge gas sensor | DGT | Discharge gas temperature monitoring |
| B2 | Oil level watch (TraxOil) | OW | Digital oil level watch |
| B3 | Oil differential pressure switch (OPS) | OPS | Oil differential pressure protection |
| B11 | High-pressure switch | AR | Alarm relay |
| B12 | Low-pressure switch | DS | Run/control signal |
| CTR2 | DP Gateway | CH | Control oil heater |
| E1 | Heater | PTC | Motor thermal protection |
| F1,F2,F3 | Compressor fuses | PM | Phase monitoring |
| F4, F5 | Fan fuses | PS | Power supply |
| F6 | Module and heater fuse | Q15 | Fan contactor |
| F7 | Control circuit fuse | Q13 | Compressor contactor Δ (if Y/Δ start) |
| H1 | Diagnosis LED | CM | Current monitoring |
| K11 | Time relay for part-winding (if used) | ||
| M2 | Fan motor | ||
| Q11 | Compressor contactor | ||
| Q12 | Compressor contactor Y (if Y/Δ start) | ||
| Q14 | Compressor contactor 2nd part-winding (if used) | ||
| SB1 | Reset button | ||
| Y21 | Solenoid valve capacity control 1 | ||
| Y22 | Solenoid valve capacity control 2 | ||
| T1 | Current sensor |
Description of Figure 7: A wiring diagram illustrating the electrical connections for Copeland compressor motors (AW series) configured for part-winding start. It shows power input (L1, L2, L3, N, PE), fuses (F1, F2, F3), contactors (Q11, Q14, Q15), a current transformer (T1), motor M1 terminals (U1, V1, W1, U2, V2, W2), and various sensor/control connections (PTC, PM, CM). It also shows a separate circuit for a fan motor (M2) and power supply (PS) with crankcase heater (CH).
Description of Figure 8: A wiring diagram for Direct Start configuration with part-winding motors (AW series). Similar to Figure 7 but shows a different contactor arrangement (Q11) for direct start.
Description of Figure 9: A wiring diagram for Star/Delta motors (EW series). It shows power input, fuses, multiple contactors (Q11, Q12, Q13, Q14, Q15) for managing the star and delta configurations, current transformer (T1), motor M1 terminals, and control connections. It also includes fan motor (M2), power supply (PS), and crankcase heater (CH).
Description of Figure 10: A comprehensive wiring diagram showing the control circuit, protections, and starting methods (part-winding, Star/Delta) for AW and EW motors. It includes components like control circuit power supply (F7), control device, various sensors/protections (DGT, OPS, Reset, OW, DS, AR), contactors (Q11, Q14, K11, K12, Q12, Q13, Q15), solenoid valves (Y21, Y22), and a DP Gateway (CTR2).
Description of Figure 11: A wiring diagram specifically for the Direct Start configuration, focusing on the control circuit, protections, and connections. It shows control circuit power supply (F7), control device, sensors/protections (DGT, OPS, Reset, OW, DS, AR), contactor (Q11), solenoid valves (Y21, Y22), and DP Gateway (CTR2).
3. Terminal Box Cover
WARNING: Compressor terminal box cover open! Danger of electric shock! Always ensure that the compressor terminal box cover is properly closed before restarting the unit.
The terminal box must be replaced with the one provided in the kit to enable viewing of the LED indicators. The status LEDs, in green, orange, and red, are visible through the window on the top of the terminal box.
Description of Figure 12: An image shows the Copeland compressor electronics module terminal box. Labels point to a "Reset button" and a status indicator area with three LEDs: "POWER ON" (green), "ALERT" (orange), and "TRIP (AUTO RESET)" or "LOCKOUT (MANUAL RESET)" (red).
