CoreSense™ Diagnostic Modules for Copeland Scroll™ Refrigeration Compressors

Table of Contents

• Safety Instructions
• Introduction
• CoreSense Diagnostics Module Overview
• CoreSense Module LED Overview
• CoreSense Diagnostics Part Number and Compressor Applications
• Product Specifications
• CoreSense Module Mounting
• Network DIP Switch Configuration
• Compressor DIP Switch Configuration
• CoreSense Diagnostics Wiring
• Module Wiring Diagrams
• Alert Codes & Troubleshooting Tips
• Kits & Accessories

Safety Instructions

CoreSense™ Diagnostic modules for Copeland Scroll™ refrigeration compressors are manufactured according to the latest U.S. and European Safety Standards. Emphasis has been placed on the user's safety. Safety icons are explained 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. Users are strongly advised to follow these safety instructions.

Safety Icon Explanation

• DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
• NOTICE: Used to address practices not related to personal injury.
• CAUTION (without safety alert symbol): Used to address practices not related to personal injury.

Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

• 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.
  • Electrical connections must be made by qualified electrical personnel.
  • Failure to follow these warnings could result in serious personal injury.
• 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.
• 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.
• 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.
• Only qualified and authorized HVAC or refrigeration personnel are permitted to install, commission, and maintain this equipment.
• Electrical connections must be made by qualified electrical personnel.
• All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed.

Introduction

The CoreSense™ Diagnostics module for Copeland Scroll™ refrigeration compressors (referred to as 'the CoreSense module' in this document) is a breakthrough innovation for monitoring and protecting the compressor, as well as alerting the contractor to refrigeration system faults. It can also perform digital unloading, liquid injection control, and detect the cause of system-related issues by monitoring the discharge line temperature and current.

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 is factory installed in the electrical box of all Copeland Scroll 7.5-15 HP ZB*K5 & ZF*K5 refrigeration compressors. Refer to bulletin AE4-1383 for further information on the 7.5-15 HP ZB*K5 & ZF*K5 scroll compressors. It is also offered as a panel mount for an aftermarket solution from Emerson Distribution Services for the (ZB*KC & ZF*K4/KV & ZS*K4) compressors. Refer to Table 5 for Copeland Scroll model number identification. The CoreSense modules offered on the different compressor families are not interchangeable due to different current operating ranges of the compressors.

CoreSense Diagnostics Module Overview

Current Signal Input

This connector is where the current transducer (CT) is plugged into the CoreSense module. In the documentation, this input is labeled 'Current'. For 7.5 -15 HP ZB*K5 & ZF*K5 models, the minimum compressor running current is 3 Amps, and for the (ZB*KC & ZF*K4/KV & ZS*K4) 2-7.5 HP compressors, it is 1 Amp. This input is used to tell the CoreSense module the running state of the compressor. Compressor protective alert codes, injection, and modulation control will only be active when the current transducer is plugged in and current is sensed through the CT.

1-5V Analog Input

1-5V analog input supplied from a separate device, controller, etc., for digital modulation. This would utilize the input labeled ‘DIG 1-5V’. A separate demand input is not required if this input is used. Digital modulation can also be performed via communication and would eliminate the need for a separate 1-5 V analog input.

Discharge Temperature Input

In the documentation, the discharge temperature thermistor input is labeled 'Temp'. CoreSense can utilize both discharge line temperature probes and top cap probes for various compressor applications. When the probe is plugged into the thermistor input, the CoreSense module identifies the probe type (line or top cap) based on pin locations. Refer to Tables 2 & 3 for specific probe part numbers.

RS485 Network Communication

Digital modulation commands are communicated via RS485 network communications to the CoreSense module. If controlling through network communications, 1-5V and demand inputs are not used for this configuration.

Unloading capacities for Copeland Scroll refrigeration compressors are as follows:

• ZB*KC & ZF*K4/KV & ZS*K4, 2-7.5 HP: 10 to 100%
• ZB*K5 & ZF*K5, 7.5-15 HP Low Temp: 30 to 100%
• ZB*K5 & ZF*K5, 7.5-15 HP Med Temp: 10 to 100%

Liquid Injection Output

The CoreSense module can also provide liquid injection for Low Temp scroll compressors. This connector is a 12VDC output to a stepper motor that drives the EXV that is plumbed to the compressor. In the documentation, this output is labeled 'LIQUID INJ'.

Please note that the EXV for the compressor families are not interchangeable due to different orifice sizes:

• ZB*KC & ZF*K4/KV, 4-7.5 HP: 1.3 mm EXV
• 2-4 HP ZF*K4 low temp models: Not yet approved for use with the CoreSense Diagnostics Liquid Injection.
• ZB*K5 & ZF*K5, 7.5-15 HP: 1.8 mm EXV

Refer to Table 3 for EXV, stepper motor, and extension cable part numbers.

Solenoid Output

The solenoid output labeled 'SOL' on the CoreSense module can be used for either digital capacity control or liquid line solenoid. For digital compressors (ZFD/ZBD), Emerson recommends using this output for digital capacity control vs. liquid line solenoid. For digital low temperature compressors using liquid injection (ZFD*K5 or K4), use a current sense relay for the liquid line solenoid.

• Digital Solenoid: This is a 110VAC/220VAC solenoid output (labeled 'SOL') which is used to control the digital operation.
• Liquid Line Solenoid: For fixed capacity compressors, the liquid line solenoid can also be controlled by the CoreSense module, by using the 'SOL' output. This eliminates the need for a separate relay to control the liquid line solenoid supplying the liquid injection EXV.

NOTE: Refer to Table 3 for kit details and extension cables for remote mount 4-7.5 HP models.

CoreSense Module LED Overview

The CoreSense module has four LEDs: green, yellow, red, and blue, that are on the face of the module. These LEDs will flash compressor codes or stay solid depending upon the code that is being annunciated by the CoreSense module.

The CoreSense module can shut down the compressor if an abnormal condition is detected. This is performed by opening the M1-M2 relay on the CoreSense, which is wired in series with the compressor contactor coil. For a list of protective alerts and features, see Figure 11.

There are different categories of flashing codes that the CoreSense Module can annunciate: (Green) normal operation, (Yellow) tripped condition, (Red) lockout, and (Blue) demand error codes and unloading status.

The CoreSense module will trip the compressor 'OFF' when any of the following severe alert conditions (Codes 1, 2, 4, 6, 7 or 9) are detected. Refer to Table 2 for Fault Code Identification. Alert code 7, reverse phase detection, is the only severe alert code that defaults to a lockout and cannot be configured. A trip condition is when the CoreSense pilot circuit relay interrupts the contactor, which results in stopping the compressor motor. A trip condition will automatically allow the compressor to run once the trip condition is satisfied and a protective off time has elapsed.

A lockout event results in the CoreSense module shutting down the compressor and not allowing it to restart until the situation is corrected and the module is manually reset. A manual reset is done by cycling power to the module. Other codes can be configured to lockout, including high discharge temperature, locked rotor, and phase loss. See Error! Reference source not found. for more information on the default number of consecutive trips before a lockout. These default values can be configured through the E2 or PCIF.

Error! Reference source not found. indicates how to read the LED codes. If an alert code is present, the CoreSense module will continue to annunciate the code until the condition is cleared or module power is cycled.

• Green LED: SOLID: Normal compressor operation. FLASHING: Alert codes that do NOT have a protective shutdown associated with them.
• 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 once tripped condition is satisfied and a protective off time has elapsed.
• Red LED: FLASHING: Indicates the CoreSense module is locked out on the flashing alert code. Manual power cycle reset is required to clear the lockout and restart the compressor.
• Blue LED: FLASHING: Indicates demand error codes. SLOW FLASHING: Indicates digital unloader is energized. This time varies based on capacity request (2-20 seconds).

For an explanation of each code and troubleshooting tips, refer to Table 2 at the end of this document.

CoreSense Diagnostics Part Number & Compressor Applications

There are two different CoreSense module part numbers for refrigeration scroll compressors: p/n 543-0209-00 for the ZB*K5 & ZF*K5 and p/n 543-0223-00 for the ZB*KC & ZF*K4/KV & ZB*KC & ZS*K4 compressor families. This is due to the difference in the compressor operating current ranges. It is important to select the correct part number per the compressor family to avoid nuisance trips.

• 2 -7.5 HP (ZB*KC & ZF*K4/KV & ZS*K4): CoreSense P/N 543-0223-00 (Panel Mounted). The CoreSense module is not accurate below 1 Amp. If the current drawn by the compressor during operation falls below 1 Amp, the module may indicate a nuisance trip.
• 7.5-15 HP (ZB*K5 & ZF*K5): CoreSense P/N 543-0209-00 (T-Box Mounted). 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 trip.

NOTE: In low current applications, it is applicable for both modules to loop the power leads through the current sensor twice. This will double the current value the CoreSense module reads and eliminate the low current nuisance trip.

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
• CoreSense Compressor Amperage Detection Range:
  • ZB*KC & ZF*K4/KV & ZS*K4, 1-76 Amps, 2- 7.5HP
  • ZB*K5 & ZF*K5, 3-200 Amps, 7.5 - 15HP

Maximum continuous contactor coil current is 2A with a max inrush current of 20A. The CoreSense module connections are 1¼ in male terminals.

CoreSense Module Mounting

• 2 -7.5 HP (ZF*KC/KV & ZB*KC & ZS*K4): CoreSense is offered as a panel mounted solution for the 2-7.5 HP Copeland Scroll refrigeration compressors. These kits are offered through Emerson Distribution Services. See Table 3 for kit number information. Figure 2 shows the panel mounted solution for a refrigeration application. It should be noted that the module is not IP rated and requires an electrical enclosure for protection from the elements. Care should be taken to place the module in a location where it will not get wet.
• 7.5-15 HP (ZB*K5 & ZF*K5): The CoreSense module will come pre-mounted inside the compressor terminal box from the factory. 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. The CoreSense module is installed inside the terminal box with a torque of 8 inch pounds. See Figure 3.

Network DIP Switch Configuration

Figure 4 shows the two DIP switch panels. The brown DIP switch panel has 10 positions and is located near the center of the CoreSense module. The blue DIP switch panel has 6 positions and is in the upper left corner of the CoreSense module.

Switches 1-5

Switches 1 through 5 are used for setting the node address for each CoreSense module. The CoreSense module uses a binary addressing for switches 1-5. The unique combination of these switches will define the node address 1-31. Use Table 1 as a reference to setting node addresses.

Switch 6

CoreSense Diagnostics Modbus® communication baud rate setting is configurable to either 19200 or 9600 through DIP switch 6 on the 10 position dip switch.

• ON = 9600
• OFF = 19200 (Default)

The baud rate for each of the CoreSense devices should be set to match the rack controller. 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

Switch 7

CoreSense Diagnostics Modbus® communication parity is user configurable (even or no parity) through DIP switch number 7.

• ON = even parity
• OFF = no parity (default)

The parity setting must match the parity setting of the rack controller.

Switch 8

Switch 8 is used to set the module to be in network mode or standalone.

• ON = Network Mode
• OFF = Standalone (Default)

Network mode will generate a communications error if the rack controller fails to communicate with the device. For standalone mode, no communications are expected, so the communication error is blocked. The CoreSense Diagnostics module 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. A shielded, twisted pair cable such as Belden #8761 (22AWG) should be used for the communication wiring. Passing the communications wire through the grommet in the plastic housing will help reduce abrasion to the wiring. Appropriate strain relief is recommended.

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 AE1383 section titled Modbus® Communication to CoreSense Diagnostics for K5 Compressors or an E2 manual for more details on commissioning scroll compressors with an Emerson Retail Solutions E2 rack controller.

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

More information: The E2 jumpers on the Network Interface Board should be set for 'terminated'.

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.

Switch 9

Switch 9 is NOT used.

Switch 10

The last compressor in the daisy chain must be 'terminated' by setting DIP switch 10 to the 'on' position. For all other compressors, switch 10 should remain in the 'off' position.

Compressor DIP Switch Configuration

Switch 1

Switch 1 is used to enable liquid injection EXV control. The 'on' position enables the EXV control via the CoreSense module.

Switch 2

Switch 2 is used to enable digital capacity control. The 'on' position enables digital capacity control via the CoreSense Module.

ZB*KC & ZF*K4/KVE & ZB*K5: 10 -100 % Capacity for 4-7.5 HP compressors & Medium Temp 7-15HP K5 compressors

ZF*K5: 30 -100% Capacity for Low Temp 7-15 HP K5 compressors

Switch 3

Switch 3 is used for failsafe mode. The 'ON' position will allow the compressor to run at full load if communications between the CoreSense module and the rack controller is lost. If in the 'off' position, the compressor turns off if communication is lost between the two devices.

Switch 4

Switch 4 affects standard Modbus®. For applications using IPRO™™ or XWeb™™ (Dixell) 'non-standard Modbus®', turn switch 4 'on'. For standard Copeland ™™ Modbus, the DIP switch orientation doesn't matter. For all other standard Modbus®, DIP switch 4 should be in the 'off' position.

CoreSense TM 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.

Switch 5

Switch 5 is used to return module to factory defaults. By resetting the module, all configurations and module history will be erased. To reset, switch 5 must transition from 'off' to 'on' within 5 seconds of module power up.

Switch 6

Switch 6 is used to enable/disable lockouts. The 'on' position will enable lockouts for the following codes: high discharge temperature, missing phase, and locked rotor. Reverse phase is automatically a lockout and cannot be configured. If this switch is 'on', each of these lockouts can be individually configured to a specific number of trips before a lockout. This is done over communications or via the PCIF Software (available at Emerson.com/OPI).

CoreSense Diagnostics Wiring

Current Transducer (P/N 543-0159-00)

A current transducer (CT) is used in conjunction with the CoreSense module to detect the running state of the compressor. The compressor power wires T1, T2, and T3 must be routed from the contactor through the CT L1, L2, and L3, respectively, to detect the running state of the compressor. It is important that the compressor power wires are routed in respect to the markings on the current transducer. For 7-15 HP K5 compressors, the CT is mounted in the terminal box. For 4-7.5 HP applications, the CT is mounted in the panel near the CoreSense module. An extension cable is available for 4-7.5 HP applications if needed.

NOTE: Only the compressor lead wires should be placed through the CT module. If the compressor lead wires do not match the L1, L2, and L3 Current Transducer holes, the compressor current measurement will be incorrect.

110-230VAC CoreSense Module Power Wiring

The CoreSense module requires 110-230VAC power between the L1 and L2 terminals on the module. The module should remain powered through all states of compressor on/off operation. Refer to wiring schematic examples shown in the following section.

Module Wiring Diagrams

There are 3 basic applications that require specific wiring schematics and DIP switch configurations:

1. Fixed Capacity using the Demand Input (Figure 11)
2. Digital Compressors using Analog Input for the modulation (Figure 12)
3. Digital or Non-Digital compressors using control via communications (Figure 13)

It should be noted that CoreSense modules with p/n 543-0209-00 and 543-0223-00 have a normally open M1-M2 relay and that will only close when the demand is present. This eliminates the need for a cycling device to be supplied externally from the module. On a detected tripped or lockout condition, the CoreSense module will de-energize the M1-M2 relay to stop the motor from running.

1. Fixed Capacity Using Demand Input

Figure 11 shows the wiring diagram for a fixed capacity compressor using a demand signal. The demand signal must be supplied from a control relay and wired to the 'D' terminal of the module. It is preferred the demand wired upstream of any other device in the pilot circuit.

NOTE: Referring to Figure 11, the Blue DIP Switch #2 is 'OFF' for fixed capacity.

2. Digital Compressors Using Analog Input for Modulation

Figure 12 shows the wiring for Digital Compressors using analog input for the modulation. The network dip switch #8 must be in the 'OFF' position for the digital control when using a 1-5V analog input. A demand wire is not required to be run to the 'd' terminal. The 1-5V analog signal for the digital will close the module relay from normally open to closed when the compressor is called to run.

NOTE: Referring to Figure 6, Brown DIP Switch #8 is 'OFF' for Digital Operation with Analog Input. Also, referring to Figure 8, Blue DIP Switch #2 is 'ON' for Digital Operation.

3. Digital and Non-Digital Compressors Using Control Via Communications

Figure 13 shows the wiring diagram for a digital or non-digital application using an E2 controller. Demand is supplied via communications and a wire is not required to be run to the 'd' terminal. The communications must be hooked up to the E2, and the module brown dip switch #8 must be 'ON' and the blue dip switch #2 must be 'ON' for the digital control to work. There is no 1-5 V analog input used to control the digital in this arrangement because digital control is provided via the E2. This is the easiest way of wiring for digital control if an E2 is present.

NOTE: Referring to Figure 6, Brown DIP Switch #8 is 'ON' for Digital Operation via Communications. Also, referring to Figure 8, Blue DIP Switch #2 is 'ON' for Fixed Capacity.

For E2 commissioning please refer to the following instructions.

CoreSense Diagnostics E2 Programming Instructions

1. Press the Menu button to enter the Main Menu. Select 7. System Configuration.

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

3. From the Network Setup Menu select 2. Connected I/O Boards and Controllers.

4. From the Setup Screen go to the C3: ECT Tab (Press Ctrl + 3).

5. In Option #9, enter the number of K5 compressors being controlled by the E2.

Press the Menu button to save changes and return to the previous screen.

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

7. The CoreSense™ K5 devices should be present on the Network. Select the CoreSense K5 module to be commissioned. Press F4: Commission.

8. Select the Modbus® that the CoreSense device is connected to. (If only Modbus® network is connected, this step will automatically complete itself, skip to step 9).

9. From the Modbus® Device Menu select an unused space that matches the DIP switch Address of the CoreSense device and press Enter.

10. Verify the address matches the address assigned by the CoreSense module's DIP switch settings and press Enter.

11. Press the Menu button to return to the Network Summary screen. The device should now be 'Online'. Repeat steps 8-10 to address the remaining CoreSense K5 modules.

12. Once all the devices are addressed, press the Menu button to save changes and exit the Network Summary.

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

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

15. From the Network Setup Menu, select 4. Controller Associations. Then Select 4. Compressor (Press Enter).

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

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).

Alert Codes & Troubleshooting Tips

Table 2 is an explanation of the alert codes for the CoreSense and what the flash codes mean. It is also available on the inside of the terminal box lid on all 7-15 HP K5 compressors or as part of the 4-7.5 HP kits. Table 3 provides some troubleshooting tips for the alert codes. There are 4 colors that can flash from the module: green - all is okay, yellow - there has been a system trip, and this will auto reset once the trip has cleared, red - is a lockout and will require a manual reset on the contractor's part. This means the power must be cycled to the CoreSense. Blue is used for digital applications and will light up when the scroll set is unloaded. There are also troubleshooting tips to help identify and fix the issue.

Further information and tips are also available at Emerson.com/OPI.

Table 2: Alert Code Descriptions

¹Code 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 Emerson.com/OPI. Refer to AE4-1383 for more details.

Table 3: CoreSense Diagnostics Module Troubleshooting

Kits & Accessories

Kits and accessories are available through Emerson Distribution Services. Below are references for the kit part numbers you will need when ordering parts. Please note that there are different lists for 7.5-15 HP ZB*K5 & ZF*K5 and 2- 7.5 HP (ZB*KC & ZS*K4 & ZF*K4/KV) scroll compressors when searching for kit numbers. Additional information and kit numbers for 7.5-15 HP ZB*K5 & ZF*K5 scroll compressors can be found in AE4 1383.

Table 4: CoreSense Diagnostics Service Kits for K5 Compressors (ZB*K5 & ZF*K5)

Table 5: Compressor Model Identification