Boletin Copeland Aplicación ZF y ZB

AE4-1383 R14
AE4-1383 R14 March 2016
Application Guidelines for ZF*K5E & ZB*K5E Copeland Scroll™

K5 Compressors for Refrigeration 8-17 HP with CoreSense™ Diagnostics
TABLE OF CONTENTS
Section Page Section Page
Safety Demand Wiring..................................................................13
Safety Instructions..............................................................2 Protection/Contactor Control Wiring.................................. 13
Safety Icon Explanation......................................................2 Discharge Temperature Protection with CoreSense
Instructions Pertaining to Risk of Electrical Shock, Diagnostics for K5 Compressors..................................... 13
Fire, or Injury to Persons.................................................3 Communication DIP switch Configuration......................... 13
Safety Statements..............................................................3 Cable Routing / Daisy Chain Configuration....................... 14
Terminations......................................................................14
Introduction COMMISSIONING.............................................................14
Nomenclature.....................................................................4 Stand Alone Mode.............................................................14
Approved Refrigerants.......................................................4 Modbus® Communication to CoreSense Diagnostics
Digital Compressor Operation............................................4 for K5 Compressors........................................................15
Operating Envelope............................................................5 CoreSense K5 Programming Instructions...................... 16-20
Extended ZF*K5E Operating Envelope.............................. 5 .
ZF*K5E Low Temperature K5 Compressors for Figures
Refrigeration...................................................................6 Modulation Troubleshooting..............................................21
Liquid Injection....................................................................6 Operating Maps.............................................................. 22-28
DTC Valve Specifications...................................................6 Typical Suction Tubing......................................................29
Installation of DTC Valve....................................................6 Liquid Injection Scroll with DTC Valve............................... 30
Suggested Application Techniques for All Liquid Injection .... EVI Scroll with DTC and T-fitting Adapter.......................... 30
Applications....................................................................6 EXV...................................................................................30
Vapor Injection....................................................................7. Circuit Diagram and Cycle for EVI.....................................31
Discharge Temperature Control with Vapor Injection......... 7 Downstream Extraction.....................................................31
System Configuration.........................................................7. Upstream Extraction..........................................................31
Downstream Extraction......................................................8. H/X Piping Arrangement....................................................32
Upstream Extraction...........................................................8. 8 - 17 HP Copeland Scroll Compressor Rack Mounting... 32
Heat Exchanger Piping Arrangements............................... 8 8 - 17 HP Condensing Unit Mounting................................ 32
Accumulator Requirements................................................8 CoreSense Module Wiring Schematics............................. 33
Superheat Requirements...................................................8 Discharge Thermistor Connector.......................................34
Crankcase Heater..............................................................8 Top Cap Thermistor...........................................................34
Pressure Controls...............................................................8 Discharge Line Thermistor................................................34
IPR Valve ...........................................................................8 CoreSense Terminal Box...................................................35
Motor Protection.................................................................9 K5 Communication Module DIP Switch Settings............... 35
PTC Motor Protection.........................................................9 Wiring Relay Example.......................................................35
Programmable Logic Controller Requirements.................. 9. E2 Jumpers.......................................................................35
Kriwan INT69 Module and Sensor Functional Check......... 9 RS485 Daisy Chain Connection........................................36
Motor Protector Module Voltage Supply Troubleshooting.. 9 Two Rack Daisy Chain Connection................................... 36
Sensor Troubleshooting.....................................................9 Old/New Model Comparison.............................................37
Compressor Voltage Supply Troubleshooting................... 10 Digital Compressor Cutaway View.................................... 38
Oil Management for Rack Applications............................. 10 20 Second Operating Cycle..............................................39
Discharge Mufflers.............................................................10 CoreSesne Diagnostics + EXV Operation......................... 40
Compressor Mounting.......................................................10 Digital Operation DIP Switch Settings............................... 40
Deep Vacuum Operation................................................... 11
Unbrazing System Components........................................ 11 Tables
HiPot Testing..................................................................... 11 Injection Accessories.........................................................41
Three Phase Scroll Compressors – Directional External Wrap-Around Crankcase Heaters....................... 41
Dependence.................................................................... 11 Kriwan INT69 Module Specifications................................. 41
Copeland Scroll Compressor Functional Check................ 11 K5 Compressor Additional Accessories............................. 42
K5 Compressor (8 to 17 HP) Fitting Sizes........................ 43
CoreSense™ Diagnostics Module for K5 Compressors... 12 High and Low Pressure Control Settings.......................... 43
CoreSense Module LED Overview....................................12 Digital Modulation Capacity(%) vs. Analog (V).................. 43
Product Specifications.......................................................12 CoreSense™ Diagnostics Fault Codes.............................. 44
Compressor Lead Wiring ..................................................13 CoreSense™ Diagnostics Module Troubleshooting........ 45-46
CoreSense Module Mounting............................................13 Demand Wiring..................................................................47
110-220VAC CoreSense Module Power Wiring................ 13 K5 DIP Switch Settings......................................................47
© 2016 Emerson Climate Technologies, Inc.
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AE4-1383 R14
Safety Instructions
Copeland Scroll
Copeland Scroll™
™
compressors are
compressors CoreSense™ according
withmanufactured Diagnosticsto are
the manufactured
latest U.S. andaccording
EuropeantoSafety
the latest U.S. and
European Safety Standards. Particular emphasis has been placed on the user's safety.
Standards. Particular emphasis has been placed on the user's safety. Safey icons are explained Safey icons are explained
below
below and safety instructions applicable to the products in this bulletin are grouped
and safety instructions applicable to the products in this bulletin are grouped on Page 3. Theseon Page 3. These instructions
should be retained
instructions should throughout
be retained the lifetime of
throughout thethe compressor.
lifetime You are strongly
of the compessor. You areadvised
stronglytoadvised
follow these safety
instructions.
to follow these safety instructions.
Safety Icon Explanation
DANGER indicates a hazardous situation which, if not avoided, will result

DANGER in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
WARNING result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous
CAUTION situation which, if not avoided, could result in minor or moderate injury.
NOTICE NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices

CAUTION not related to personal injury.
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AE4-1383 R14
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
ELECTRICAL SHOCK HAZARD

WARNING • 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.
PRESSURIZED SYSTEM HAZARD

WARNING • 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
WARNING • 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.
• Failure to follow these warnings could result in serious personal injury or
property damage.
COMPRESSOR HANDLING
CAUTION • Use the appropriate lifting devices to move compressors.
• 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.
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AE4-1383 R14
Introduction NOTE: For the latest approved refrigerants and

The Copeland Scroll™ refrigeration compressor product lubricants, refer to Form 93-11, Emerson Accepted
offering has developed the K5 compressor for the 8 to Refrigerants/Lubricants, or contact your Application
17 HP size range. The scope of this bulletin will cover Engineer.
the application parameters unique to the ZB*K5E and NOTE: The ZB*K5 compressors are each applicable with
ZF*K5E refrigeration scrolls with CoreSense™ technology. R-134a, however, Emerson Climate Technologies has
A new CoreSense Diagnostics module with digital released the ZB*K5B series for optimum performance
capacity control and EXV injection control has been for lower R-134a-like pressures. Performance is based
added on all K5 compressors with the part number (543- on ARI conditions. 20 °F evap 120 °F condensing. See
0209-**/998-0340-**). To see differences between the the following table for specific model numbers.
old vs new module please see Figure 19. Optimized R-134a ZB*K5B Compressors
Nomenclature Model Hertz Voltage
The Copeland Scroll compressor model numbers 60 460
ZB47K5B-TFD
include the nominal capacity at the standard 60 Hertz 50 380/420
“ARI” rating conditions with R-404A refrigerant. 60 460
ZB68K5B-TFD
Example 50 380/420
ZBD76K5E-TFD-260
Z = Copeland Scroll
B = Application (B: Medium Temperature,
F: Low Temperature) CAUTION
D = Digital Capacity POE must be handled carefully and the proper
76K = Nominal Capacity (kBtu/hr) protective equipment (gloves, eye protection, etc.)
5 = Model Variation Identifier for the must be used when handling POE lubricant. POE
K5 refrigeration scroll must not come into contact with any surface or
material that might be harmed by POE, including
E = Oil Type (POE)
without limitation, certain polymers (e.g. PVC/CPVC
TFD = Motor Version and polycarbonate).
260 = Bill of Materials
Medium Temperature Digital Compressor Operation
Approved Refrigerants The digital scroll is capable of seamlessly modulating
Model Approved its capacity from 10% to 100%. A normally closed
Application HP
Number Refrigerants (de-energized) solenoid valve is a key component for
ZF34K5E 10 R-22, achieving modulation. When the solenoid valve is in its

ZF41K5E 13 R-404A, normally closed position, the compressor operates at
Low R-407A/C, full capacity, or loaded state. When the solenoid valve
Temperature ZFD41K5E 13 R-407F
is energized, the two scroll elements move apart axially,
ZF49K5E 15 R-448A,
R-449A, or into the unloaded state. The solenoid coil must be
ZF54K5E 17 R507 controlled by the same voltage that is powering the
ZB58K5E 8 CoreSense Diagnostic module. During the unloaded
R-22, state, the compressor motor continues running, but
ZB66K5E 9 R-134a,
since the scrolls are separated, there is no compression.
ZB76K5E 10 R-404A,
Medium During the loaded state, the compressor delivers 100%
R-407A/C,
Temperature ZBD76K5E 10 capacity and during the unloaded state, the compressor
R-407F,
ZB95K5E 13 R-448A, delivers 0% capacity. A cycle consists of one loaded
ZB114K5E 15 R-449A, state and one unloaded state. By varying the time of
R507
ZBD114K5E 15 the loaded state and the unloaded state, an average
capacity is obtained. The lowest achievable capacity is
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AE4-1383 R14
10% which equates to 2 seconds of pumping during one state. By varying the time of the loaded state and the
20 second cycle. unloaded state, an average capacity is obtained. The
An example for the 20 second controller cycle: In any lowest achievable capacity is 30% which equates to 6
20 second cycle, if the loaded time is 10 seconds and seconds of pumping during one 20 second cycle.
the unloaded time is 10 seconds, the average capacity An example for the 20 second controller cycle: In any
is 50%, or if the loaded time is 5 seconds and the 20 second cycle, if the loaded time is 10 seconds and
unloaded time is 15 seconds the capacity during that the unloaded time is 10 seconds, the average capacity
20 second period is 25%. See Figure 20 for a graphical is 50%, or if the loaded time is 6 seconds and the
representation of the digital cycle, and Figure 21 for unloaded time is 14 seconds the capacity during that
a graph showing solenoid on-time vs. compressor 20 second period is 30%. See Figure 20 for a graphical
capacity. representation of the digital cycle, and Figure 21B
Medium Temperature Digital operation is controlled for a graph showing solenoid on-time vs. compressor
by the CoreSense Diagnostics module and has a capacity.
patented algorithm that allows the compressor to run
at 10%. If the compressor's discharge line temperature How it Works
rises at a high rate of change over time the CoreSense The digital scroll compressor unloads by taking
Diagnostics module will increase the compressor advantage of the Copeland Scroll compressor's
capacity until discharge line temperature is at a axial compliance. All Copeland Scroll compressors
safe operating temperature. To operate with a 10% are designed so that the compression elements can
minimum capacity please confirm that DIP switch separate axially. See Figure 20 for internal view.
1 (EXV) in the top left corner on the CoreSense
The digital solenoid can be controlled two ways with
Diagnostics module (See Figure 19) IS IN THE OFF
the CoreSense Diagnostics module:
POSITON. For correct DIP switch settings please see
Figure 23A. 1. Through a 1-5v signal. For tables of digital
capacity(%) vs. analog input (v) see Tables 7A
Low Temp Digital Compressor Operation and 7B
2. Via mod-bus communication
Due to lower mass flows the low temperature digital
compressor operation is restricted to 30%-100%. The 8.0 HP and larger digital scroll compressors
By restricting to 30% minimum capacity this ensures employ a solenoid valve that is mounted on the side
enough mass flow to the compressor for safe operation. of the compressor that vents the intermediate cavity
To operate with a 30% minimum capacity Please confirm to the low side of the compressor during the unloaded
that DIP switch 1 on the digital and EXV DIP switches state. During the loaded state the solenoid valve is de-
in the top left corner on the CoreSense Diagnostics energized and the intermediate cavity is pressurized to
Module(See Figure 19) IS IN THE ON POSITON. For load the floating seal and scrolls axially.
correct DIP switch settings please see Figure 23B.
Operating Envelope
A normally closed (de-energized) solenoid valve is a key Operating envelopes for the K5 compressors for
component for achieving modulation. When the solenoid refrigeration are depicted in Figures 2A through 2M.
valve is in its normally closed position, the compressor
operates at full capacity, or loaded state. When the Extended ZF*K5E Operating Envelope
solenoid valve is energized, the two scroll elements Figure 2I presents an extended envelope for the
move apart axially, or into the unloaded state. The ZF*K5E scroll. While this product is optimized for a low
Solenoid coil must be controlled by the same voltage temperature application, in some instances the ZF*K5E,
that is powering the CoreSense Diagnostic module. either with vapor injection or no injection at all, can be
During the unloaded state, the compressor motor applied in a medium temperature application. This may
continues running, but since the scrolls are separated, be done to use common model numbers in a system or
there is no compression. During the loaded state, the to apply vapor injection for additional cooling capacity.
compressor delivers 100% capacity and during the
unloaded state, the compressor delivers 0% capacity. When applying with vapor injection, it should be noted
A cycle consists of one loaded state and one unloaded that the total amount of internal subcooling is limited
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AE4-1383 R14
by the injection pressure at the compressor. In medium Installation of DTC Valve

temperature operation, this value is typically higher The valve bulb must be installed in the top cap thermal
than when a ZFK5 is applied at low temperature and well to adequately control scroll temperatures. The
therefore the minimum subcooled liquid temperature valve should be tightened on the injection fitting to
allowable exiting the economizer is higher (depending a torque of 216-245 in. lbs. (24.4 - 27.7 Nm). A 90°
on the refrigerant this may be as high as 75°F). Refer orientation on the valve is recommended, however it will
to Emerson's Product Selection Software for estimated function properly in any orientation. The capillary tube
values by compressor model. connecting the valve to the bulb should be positioned
NOTE: If applying without vapor injection the injection such that it does not contact the compressor during
port should be plugged. The vapor injection fitting is a operation. Do not bend the capillary tube within 1”
Rotalock design with a 1” x 14 rotalock thread size, the (25.4mm) of the valve.
fitting can be capped using the rotalock to stub tube The DTC valve comes with an insulating cap. If this
adaptor kit # 998-0034-18. A ½” copper line can be additional height from the cap is an issue, the valve
inserted into the stub end of the adaptor and sealed off. cap could be replaced with high temperature insulation.
The rotalock adaptor with the supplied Teflon seal will This should be applied to insulate and protect the valves
effectively seal the port and will not damage the fitting remote bulb assembly. This will reduce the total height
or the compressor. requirement by 0.5” (12.7mm).
ZF*K5E Low Temperature K5 Compressors for
Refrigeration Suggested Application Techniques for All Liquid
Injection Applications
The low temperature models are provided with an
injection port that can be used for either liquid or vapor For the most efficient thermal sensing, spread a thin film
injection. of thermal grease around the DTC valve bulb/thermistor
before installing into the top cap well. However for
Liquid Injection proper functioning of the valve this is not required.
When using the ZF*K5E scrolls for liquid injection • For service purposes, a mechanical ball valve
operation, a discharge temperature control (DTC) valve (not provided by Emerson) is also recommended
or an EXV (Electronic Expansion Valve) must be applied. in the liquid and vapor injection line. For the liquid
The purpose of the DTC/EXV valve is to eliminate the injection system to be effective, a minmum of 5°F
need for a standard capillary tube. The DTC/EXV valve is subcooled liquid at the at the DTC/EXV inlet is
approved for all refrigerants in this product range. A DTC/ required.
EXV valve must also be used for ZF**K5E applications
with R-407A, R-407C, R-407F, R-448A and R-449A with NOTE: To ensure adequate temperature control,
vapor injection via a special T-fitting adapter. Further take care to not damage the DTC valve bulb/
details and part numbers related to the DTC/EXV valve thermistor when installing. Damage of DTC valve
are listed in Table 1 at the end of this bulletin. bulb/thermistor could result in improper injection.
DTC Valve Specifications EXV Valve Specifications

The following components are not required, but they The EXV valve is a 12 VDC stepper valve. It has 500
are recommended for liquid injection. steps from fully open to fully closed. It consumes 6 watts
of power. It is controlled via the CoreSense module. It
• Sight Glass - A sight glass can be installed before adjusts open and closed based off the temperature read
the DTC valve to allow for visual inspection for the from the Top cap thermistor.
presence of liquid refrigerant.
The following components are not required, but they
• Filter/Drier - A filter/drier can be installed upstream are recommended for liquid injection.
of the injection circuit to avoid the possibility of the
DTC screen blockage due to contaminants. • Sight Glass - A sight glass can be installed before
the EXV valve to allow for visual inspection for the
Figures 2A through 2C are a representation of typical presence of liquid refrigerant.
systems, depicting the location of these components.
• Filter/Drier - A filter/drier can be installed upstream
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AE4-1383 R14
of the injection circuit to avoid the possibility of the

EXV screen blockage due to contaminants. ARI Low Temperature Ratings
(-25°F/105°F, R-404A)
EXV Installation Model With EVI* Without EVI*
The EXV valve is to be installed vertically with ZF34K5E 48,100 Btu/hr 34,200 Btu/hr
stepper motor locked into position. See Figure 22 for
ZF41K5E 57,500 Btu/hr 42,200 Btu/hr
correct orientation. To ensure the valve has the proper
mounting, calibration and control, only the Emerson ZFD41K5E 57,500 Btu/hr 42,200 Btu/hr
supplied stepper valve (p/n 998-0340-**) should be ZF49K5E 71,000 Btu/hr 50,500 Btu/hr
used with CoreSense Diagnostics for Copeland Scroll * Maximum possible subcooling
K5 refrigeration compressors. * Without EVI is "0" subcooling
NOTE: When using an EXV stepper valve a liquid
line shutoff solenoid will need to be installed on NOTE: For performance of ZF*K5E models with other
the liquid line. This is in the event of a power loss that refrigerants, refer to the Online Product Information at
will leave the EXV motor in it's current position and EmersonClimate.com
potentially allow liquid to enter the compressor while
off. A vapor line shut off may be needed in the event of Discharge Temperature Control with Vapor Injection
a motor protection trip where the control circuit is not Although using vapor injection offers some inherent
opened. It is recommended to use a current sensing compressor cooling, when using the ZF*K5E scrolls
relay to ensure that liquid line solenoid is to be closed with R-407A/C/F or R-448A/R-449A and vapor injection
when compressor is off. additional cooling is required to operate across the
whole operating map of the compressor. To provide this
Vapor Injection extra cooling a T-fitting and DTC or EXV valve should
The ZF*K5E 8-17 HP scroll compressors can also be installed onto the compressor's injection port. The
be applied with vapor injection by implementing an T-fitting will meter liquid from the DTC or EXV valve
economizer circuit in the system. Economizing is into one side of the fitting, while vapor flows in through
accomplished by utilizing a subcooling circuit similar to the otherside. See Figure 5 at the end of this bulletin
that shown in Figure 4 at the end of this bulletin. This for a example schematic. This is different than the
mode of operation increases the refrigeration capacity current method used on other Copeland vapor injected
and in turn the efficiency of the system. scrolls (ZF*KVE models) which use the Copeland
Demand Cooling to inject liquid in the vapor line of the
The schematic shows a system configuration for the
compressor based on a discharge line temperature
economizer cycle. A heat exchanger is used to provide
reading.
subcooling to the refrigerant (HX) before it enters the
evaporator. This subcooling process provides the NOTE: Just as with liquid injection operation, when
increased capacity gain for the system, as described using the DTC valve with vapor injection ensure that
above. During the subcooling process a small amount the thermal bulb and discharge thermistor are well
of refrigerant is evaporated and superheated. This insulated.
superheated refrigerant is then injected into the mid When using vapor injection with R-404A/R-507,
compression cycle of the scroll compressor and the DTC/EXV valve and T-fitting are not required. A
compressed to discharge pressure. This injected vapor discharge line thermistor is supplied with the CoreSense
also provides cooling at higher compression ratios, similar Diagnostics assembly (more information on CoreSense
to liquid injection of standard ZF scroll compressors. The Diagnostics is found later in this bulletin). The thermistor
benefits provided will increase as the compression ratio should be placed no more than 6 inches (15.2 cm) from
increases, thus, more gains will be made in summer the discharge of the compressor. Only when using DTC
when increased capacity may actually be required. valve The thermistor should be well insulated to ensure
An example of the additional capacity available when accurate temperature sensing on the discharge line.
using vapor injection is depicted in the following table.
System Configuration
There are two methods of controlling refrigerant flow at
the EVI heat exchanger - downstream and upstream
extraction.
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AE4-1383 R14
Downstream Extraction suction line 6 inches (152mm) from the suction valve,
to prevent liquid refrigerant floodback.
The downstream extraction is the preferred method
employed in the United States. In downstream Another method to determine if liquid refrigerant is
extraction the TXV is placed between the liquid outlet returning to the compressor is to accurately measure
and vapor inlet of the heat exchanger. The advantage the temperature difference between the compressor
of downstream extraction is that subcooling is ensured oil crankcase and the suction line. During continuous
because the liquid is further subcooled as it flows operation we recommend that this difference be a
through the heat exchanger. Therefore, more subcooled minimum of 50°F (27°C). This “crankcase differential
liquid enters the TXV which increases the probability temperature” requirement supersedes the minimum
that the valve will not hunt. The disadvantage with this suction superheat requirement in the last paragraph. To
method is that it is not as efficient as the upstream measure oil temperature through the compressor shell,
method; however, the difference is too small for place a thermocouple on the bottom center (not the side)
practical purposes. See Figure 5. of the compressor shell and insulate from the ambient.
During rapid system changes, such as defrost or ice
Upstream Extraction
harvest cycles, this temperature difference may drop
In upstream extraction the TXV is placed between rapidly for a short period of time. When the crankcase
the condenser and the heat exchanger. The TXV temperature difference falls below the recommended
regulates the flow of subcooled refrigerant out of the 50°F (27°C), our recommendation is the duration should
condenser and into the heat exchanger. With this type not exceed a maximum (continuous) time period of two
of configuration there is a potential for flash gas which minutes and should not go lower than a 25°F (14°C)
would cause the valve to hunt. See Figure 6. difference.
Heat Exchanger Piping Arrangements Contact your Emerson Climate Technologies
representative regarding any exceptions to the above
Best subcooling effect is assured if counter flow of requirements.
gas and liquid is provided as shown (see Figure 7).
In order to guarantee optimum heat transfer, the plate Crankcase Heater
heat exchanger should be mounted vertically and
Crankcase heaters are required, on outdoor systems,
vapor should exit it at the top.
when the system charge exceeds 17 lbs.
For more information on applying ZF*K5E scrolls with
Table 2 includes crankcase heaters intended for use
an economized vapor injection (EVI) circuit refer to AE4-
only where there is limited access. The heaters are
1327, Economized Vapor Injection (EVI) Compressors.
not equipped for use with electrical conduit. Where
Accumulator Requirements applicable electrical safety codes require heater lead
protection, a crankcase heater terminal box should be
Due to the Copeland Scroll compressor's inherent used. Recommended crankcase heater terminal cover
ability to handle liquid refrigerant in flooded start and and box numbers are also listed in Table 2 If there
defrost operation conditions, accumulators may not are any questions concerning the application, contact
be required. An accumulator is required on single Application Engineering.
compressor systems with refrigerant charges over
17 lbs. On systems with defrost schemes or transient Pressure Controls
operations that allow prolonged, uncontrolled liquid
Both high and low pressure controls are required. The
return to the compressor, an accumulator is required
minimum and maximum pressure setpoints are shown
unless a suction header of sufficient volume is used to
in Table 4.
prevent liquid migration to the compressor.
IPR Valve
Superheat Requirements
There is no internal pressure relief valve in these larger
In order to assure that liquid refrigerant does not return
horsepower scrolls. Therefore a high pressure control
to the compressor during the running cycle, attention
located prior to any shut-off valves is mandatory. There
must be given to maintaining proper superheat at the
is an access port located on the compressor discharge
compressor suction inlet. Emerson recommends a
rotalock fitting to accommodate this control.
minimum of 20°F (11°C) superheat, measured on the
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AE4-1383 R14
Motor Protection • Measure the voltage across T1-T2 to ensure proper

Motor protection in the K5 compressor for refrigeration supply voltage.
is either by internal line break (ILB) or solid state • Determine the control voltage by using a voltmeter
protection with positive temperature coefficient (PTC) and then measure the voltage across the M1-M2
sensors. The type of motor protection is based on contacts:
the compressor motor version. An "F" in the second a) If the measured voltage is equal to the control
character indicates line break while a "W" indicates PTC volts then the M1-M2 contacts are open.
protection. For example, a ZF34K5E-TFC has ILB and
a ZB95K5E-TWC uses PTC sensors. b) If the measurement is less than 1 volt and the
compressor is not running, then the problem is
PTC Motor Protection external to the motor protector module.
There are four PTC (Positive Temperature Coefficient) c) If the voltage is greater than 1 volt but less than
internal thermistors connected in series that react the control voltage, the motor protector module
with avalanching resistance in the event of high is faulty and should be replaced.
temperatures. The thermistors are used to sense motor
temperatures. The thermistor circuit is connected to Sensor Troubleshooting
the protector module terminals S1 and S2. When any • Remove the leads from S1-S2, and then by using an
thermistor reaches a limiting value, the module interrupts Ohmmeter to measure the resistance of the incoming
the control circuit and shuts off the compressor. After the leads.
thermistor has cooled sufficiently, it will reset. However,
the module has a 30 minute time delay before reset CAUTION
after a thermistor trip. Use an ohmmeter with a maximum of 9 VDC for
checking – do not attempt to check continuity
Programmable Logic Controller Requirements through the sensors with any other type of
If the INT69 (071-0660-00) module is applied in instrument. Any external voltage or current
conjunction with a Programmable Logic Controller, it is may cause damage requiring compressor
important that a minimum load is carried through the replacement.
M1-M2 control circuit contacts. a) During normal operation, this resistance value
The minimum required current through the module should read less than 4500 ohms ±20%.
relay contacts needs to be greater than 100 milliamps b) If the M1-M2 contacts are open, the measured
but not to exceed 5 amps. If this minimum current is S1-S2 value is above 2750 ohms ±20% and
not maintained, this has a detrimental effect upon the the compressor has been tripped less then 30
long-term contact resistance of the relay and may result minutes then the module is functioning properly.
in false compressor trips.
• If the S1-S2 wire leads read less than 2750 ohms
PLC operated control circuits may not always provide ±20% and the M1-M2 contacts are open, reset
this minimum current. In these cases modifications the module by removing the power to T1-T2 for a
to the PLC control circuit are required. Consult your minimum of 5 seconds.
Application Engineering Department for details.
• Replace all wire leads and use a voltmeter to verify
Kriwan INT69 Module and Sensor Functional Check the M1-M2 contacts are closed.
Module specifications are listed in Table 3 at the end of • If the M1-M2 contacts remain open and S1-S2 are
this bulletin. Refer to Figure 9 for wiring schematic. The less than 2500 ohms, remove leads from the S1-
following field troubleshooting procedure can be used S2 contacts and jumper together, using a 100 ohm
to evaluate the solid state control circuit: resistor.
Motor Protector Module Voltage Supply CAUTION

Troubleshooting Compressor should start at this time. HOWEVER
DO NOT LEAVE JUMPER IN PLACE FOR
• Verify that all wire connectors are maintaining a good
NORMAL SYSTEM OPERATIONS. THE JUMPER
mechanical connection. Replace any connectors that
IS USED FOR DIAGNOSTIC PURPOSES ONLY.
are loose.
9
AE4-1383 R14
Compressor Voltage Supply Troubleshooting Compressor Mounting

• Remove phase sensing leads from the module from Compressor mounting must be selected based on
L1/L2/L3. application. Consideration must be given to sound
• Use a voltmeter to measure the incoming 3 phase reduction and tubing reliability. Some tubing geometry
voltage on L1/L2/L3. WARNING: L1/L2/L3 could or “shock loops” may be required to reduce vibration
be at a potential up to 600VAC. transferred from the compressor to external tubing.
Mounting kit part numbers are listed in Table 4.
• Ensure proper voltage on each phase.
Mounting for Rack Systems – Specially designed
• Remove power to the module for a minimum of 5 steel spacers and rubber isolator pads are available
seconds to reset and replace all wire leads. Re- for Copeland Scroll 8 -17 HP rack applications. This
energize the module. If the M1-M2 contacts are open mounting arrangement limits the compressors motion
with proper voltage to T1-T2, L1/L2/L3 and proper thereby minimizing potential problems of excessive
resistance to S1-S2 then the module is faulty and tubing stress. Sufficient isolation is provided to prevent
should be replaced. vibration from being transmitted to the mounting
structure. This mounting arrangement is recommended
Oil Management for Rack Applications
for multiple compressor rack installations. See Figure
Copeland Scroll K5 refrigeration compressors may be 8A for a detail of this mounting system.
used on multiple compressor parallel rack applications.
Condensing Units – For 8 -17 HP Copeland Scroll
This requires the use of an oil management system to
condensing unit applications applying the ZB95/114
maintain proper oil level in each compressor crankcase.
and ZF49/54, standard mounts (55-65 durometer) are
The sight glass connection supplied can accommodate
recommended (kit # 527-0210-00) Figure 8B.
the mounting of the oil control devices.
For condensing units applying the ZB58/66
Unlike semi-hermetic compressors, scroll compressors
/ZB(D)76 and ZF34/ZF(D)41 the softer mounts
do not have an oil pump with accompanying oil pressure
(35-45 durometer) mounts are recommended.
safety controls. Therefore, an external oil level control
(Kit # 527-0116-00) Figure 8C.
is required.
Tubing Considerations – Proper tube design must be
The OMB oil level management control combines the
taken into consideration when designing the tubing
functions of level control and timed compressor shut-
connecting the scroll to the remaining system. The
off should the level not come back to normal within
tubing should provide enough “flexibility” to allow
a set period of time. This device has been found to
normal starting and stopping of the compressor
provide excellent performance in field tests on scroll
without exerting excessive stress on the tube joints. In
compressors and is recommended for parallel system
addition, it is desirable to design tubing with a natural
applications. Refer to Table 4 for oil monitoring
frequency away from the normal running frequency of
accessory part numbers.
the compressor. Failure to do this can result in tube
Immediately after system start-up the oil reservoir resonance and unacceptable tubing life. Figure 3A
level will fluctuate until equilibrium is reached. It is is an example of an acceptable tubing configuration.
advisable to monitor the oil level during this time to
assure sufficient oil is available. This will prevent CAUTION
unnecessary trips of the oil control system. Additional These examples are intended only as guidelines
information on oil management in Copeland Scroll to depict the need for flexibility in tube designs.
compressors can be found in Application Engineering In order to properly determine if a design is
bulletin AE17-1320. appropriate for a given application, samples should
be tested and evaluated for stress under various
Discharge Mufflers conditions of use including voltage, frequency,
Gas flow through scroll compressors is continuous with and load fluctuations, and shipping vibration. The
relatively low pulsation. External mufflers applied to guidelines above may be helpful; however, testing
piston compressors may not be required on Copeland should be performed for each system designed.
Scroll compressors. Due to system variability individual
tests should be conducted by the system manufacturer
to verify acceptable levels of sound and vibration.
10
AE4-1383 R14
Connection Fittings, Service Valves, and Adapters lower the current leakage reading, the system should
The fitting sizes for 8 through 17 HP scroll compressors be operated for a brief period of time to redistribute the
are shown in Table 5. refrigerant to a more normal configuration and the system
hipot tested again. See bulletin AE4-1294 for megohm
Deep Vacuum Operation testing recommendations. Under no circumstances
should the Hipot or Megohm test be performed while the
WARNING compressor is under a vacuum.
Do not run a Copeland Scroll compressor in a deep NOTE: The solid state electronic module components
vacuum. Failure to heed this advice can result in and internal sensors are delicate and can be damaged
arcing of the Fusite pins and permanent damage by exposure to high voltage. Under no circumstances
to the compressor. should a high potential test be made at the sensor
A low pressure control is required for protection against terminals or sensor leads connected to the module.
deep vacuum operation. See Pressure Control section Damage to the sensors or module may result.
for proper set points. (Table 6)
Three Phase Scroll Compressors – Directional
Scroll compressors (as with any refrigerant compressor) Dependence
should never be used to evacuate a refrigeration or air
conditioning system. See AE-1105 for proper system Scroll compressors are directional dependent; i.e. they
evacuation procedures. will compress in one rotational direction only. Three
phase scrolls will rotate in either direction depending
Unbrazing System Components on power phasing. Since there is a 50/50 chance of
connected power being “backwards”, contractors should
WARNING be warned of this. Appropriate instructions or notices
If the refrigerant charge is removed from a scroll should be provided by the OEM.
unit by bleeding the high side only, it is sometimes Verification of proper rotation can be made by observing
possible for the scrolls to seal, preventing pressure that the suction pressure drops and the discharge
equalization through the compressor. This may pressure rises when the compressor is energized.
leave the low side shell and suction line tubing
pressurized. If a brazing torch is then applied to the No time delay is required on three phase models to
low side, the pressurized refrigerant and oil mixture prevent reverse rotation due to brief power interruptions.
could ignite as it escapes and contacts the brazing The CoreSense module will provide reverse rotation
flame. It is important to check both the high and low protection.
sides with manifold gauges before unbrazing or in
Copeland Scroll Compressor Functional Check
the case of assembly line repair, remove refrigerant
from both the high and low sides. Instructions Copeland Scroll compressors do not have internal
should be provided in appropriate product literature suction valves. It is not necessary to perform functional
and assembly (line repair) areas. compressor tests to check how the compressor will
pull suction pressure. This type of test may damage a
High Potential (Hipot) Testing
scroll compressor. The following diagnostic procedure
Many Copeland™ compressors are configured with the should be used to evaluate whether a Copeland Scroll
motor below the compressor. As a result, when liquid compressor is functioning properly.
refrigerant is within the compressor shell the motor can
1. Verify proper unit voltage.
be immersed in liquid refrigerant to a greater extent than
with compressors with the motor mounted above the 2. Normal motor winding continuity and short to
compressor. When Copeland compressors are hipot ground checks can be used to determine proper
tested and liquid refrigerant is in the shell, they can motor resistance or if an internal short to ground
show higher levels of leakage current than compressors has developed.
with the motor on top because of the higher electrical 3. With service gauges connected to the suction
conductivity of liquid refrigerant than refrigerant vapor and discharge pressure fittings, turn on the
and oil. This phenomenon can occur with any compressor compressor. If suction pressure falls below normal
when the motor is immersed in refrigerant. The level of levels the system is either low on charge or there
current leakage does not present any safety issue. To is a flow blockage.
11
AE4-1383 R14
4. If the suction pressure does not drop and the The LEDs will flash a number of times consecutively,
discharge pressure does not rise, reverse any two pause and then repeat the process. To identify an alert
of the compressor power leads and reapply power code number, count the number of consecutive flashes.
to verify the compressor was not wired to run in Detailed descriptions of specific alert codes are shown
the reverse direction. in Table 8.
The operational compressor current draw should The CoreSense module will continue to display the alert
be compared to published performance curves at code until the condition returns to normal or if module
the operating conditions (pressures and voltages). power is cycled to the device.
Significant deviation (± 15%) from published values Yellow LED:
may indicate a faulty compressor.
FLASHING: Alerts of an abnormal system condition
CoreSense Diagnostics™ Module for Refrigeration via Alert Codes
Compressors
SOLID: Demand is present but no current is
The CoreSense Diagnostics module (see Figure 19) detected. All protective shutdowns will auto reset in
for Copeland Scroll refrigeration compressors (referred their allotted time
to as “the CoreSense module” in this document) is a
breakthrough innovation for troubleshooting refrigeration Red LED:
system faults. The CoreSense module is installed in FLASHING: Indicates the CoreSense module is
the electrical box of all 8-17 HP K5 refrigeration scroll locked out on the flashing Alert Code. Manual power
compressors. By monitoring and analyzing data from cycle reset is required to restart the compressor
the Copeland compressors via module power, discharge
Green LED:
line thermistor, and the current transducer (referred to
as “CT” in this document), the CoreSense module can FLASHING: Alert Codes that do NOT have a
accurately detect the cause of electrical and system protective shutdown associated with them.
related issues. A flashing LED indicator communicates Blue LED:
the alert code and guides the service technician more
quickly and accurately to the root cause of a problem. Flashing indicates alert codes for Digital only. Alert
Codes that do NOT have a protective shutdown
The CoreSense module can provide both compressor associated with them. A solid Blue LED represents
protection and lockout capability. Compressor compressor unloaded.
protection means that the CoreSense module will trip
the compressor when any of the following severe alert Some troubleshooting tips for the CoreSense module
conditions (Codes 1, 2, 4, 6, 7 or 9) are detected. A trip are listed in Table 9 at the end of this document.
condition is when the protector on a compressor opens Product Specifications
and stops current flow into the compressor motor. As a
result, the compressor shuts down. A trip condition will Operating Temp: -40° to 150°F (-40° to 65°C)
reset after short cycle time and when trip condition is Storage Temp: -40° to 175°F (-40° to 80°C)
not present.
Power Supply Range: 85-265VAC, 50-60 Hz
If lockout is enabled and a preset number of alarm
Working amperage for CT module: 3-200A
events happen, the CoreSense module will not allow
the compressor to start (Codes 1, 4, 6 or 7) until the NOTE: The CoreSense module is not accurate below
situation is corrected and the module is manually 3 Amps. If the current drawn by the compressor during
reset. The module can be reset by cycling power to operation falls below 3 Amps, the module may indicate
the module. a nuisance fault condition and alarm.
In low current application it is applicable to loop the
CORESENSE MODULE LED OVERVIEW
power leads through the current sensor twice to double
CoreSense Diagnostics™ Module for Refrigeration the current value the sensor reads and eliminate the low
Compressors with Digital and EXV Capability current nuisance trips.
The CoreSense module has the ability to shut down the NOTE: The 2X current reading may need to be
compressor if the compressor contactor coil is wired addressed at the system or rack controller.
through the M1-M2 relay.
12
AE4-1383 R14
The CoreSense module connections are standard male Protection/Contactor Control Wiring for CoreSense
electrical flag terminals. Diagnostics Module (543-0174-**)
Maximum continuous contactor coil current is 2A with The M1-M2 relay on the CoreSense module is a normally
a max inrush current of 20A. open relay. When the module is powered and there are
no protective faults, the relay is energized and does not
Compressor Lead Wiring cycle on/off. On a detected protection condition, the
The compressor leads must be routed through the holes CoreSense module will de-energize the relay to stop the
in the CT module marked T1, T2, and T3. Only the motor from running. The relay is not used as a cycling
compressor lead wires should be placed through device for normal compressor operation. The cycling
the CT module. device must be supplied externally from the module.
Protection/Contactor Control Wiring for CoreSense
CoreSense Module Mounting
Diagnostics Module (543-0209-**)
The CoreSense module will come pre-mounted inside
The M1-M2 relay on the CoreSense module is a
the compressor terminal box. The module is mounted
normally open relay. M1-M2 relay cycles with demand of
so all LEDs are in front of the light pipes in the terminal
the compressor. This eliminates the need for The cycling
covers so codes are visible when the terminal box cover
device to be supplied externally from the module. On a
is installed on the terminal box. The CoreSense module
detected protection condition, the CoreSense module
should be installed inside the terminal box with a torque
will de-energizethe relay to stop the motor from running.
of 8 inch pounds.
Discharge Temperature Protection with CoreSense
110-230VAC CoreSense Module Power Wiring
Diagnostics for K5 Compressors
The CoreSense module requires 110-230VAC power
Copeland Scroll K5 compressors for refrigeration with
between to the L1 and L2 terminals. The module should
CoreSense Diagnostics come standard with discharge
remain powered through all states of compressor on/off
temperature protection. Depending on the application
operation. Refer to wiring schematic examples.
and refrigerant a certain mode of protection will be
NOTE: The physical Location of L1 and L2 have used whether it is a top cap thermistor or DTC valve
changed on 543-0209-**. Confirm correct location of with discharge line thermistor or an EXV valve with a
L1 and L2 wiring. Reference Figure 19. top cap thermistor. The CoreSense module identifies
the protection device based on the pin locations in the
Demand Wiring for (543-0174-**) connector. Figures 10 and 11 depict the installation of
The CoreSense module requires a demand signal to the top cap thermistor and discharge line thermistor,
operate properly. The demand signal input, labeled respectively.
D on the module, should always be connected to the Table 1 at the end of this bulletin identifies the discharge
compressor demand so that the demand signal input temperature protection device by application and
is 110 or 220VAC with respect to L2. See Figure 9A refrigerant. Table 4 identifies the service part numbers
for proper wiring diagrams. Choose the appropriate for those devices.
diagram depending on how the demand signal will be
fed to the module. Communication DIP Switch Configuration
The communication module on the CoreSense
Demand Wiring for (543-0209-**) Diagnostics module is equipped with a 10 switch DIP
For CoreSense Diagnostics module (543-0209-**) a switch used for selection of the Modbus® address, baud
demand relay is no longer needed. Control voltage rate, parity, and other operating conditions to simplify
(110/220V) is needed at the D terminal. For digital service and start-up procedures. See Figure 13. For
models the D terminal is used to monitor control more information on DIP switch settings, Table 11 lists
voltage only. The demand signal comes from the the purpose for each switch.
RS485 network OR the 1-5V analog input. For fixed NOTE: Cycle power after changing any of the DIP
capacity models the demand signal input comes from settings for changes to take effect.
the D terminal, and is 110 or 220VAC with respect to The following steps cover the DIP switch settings
L2. See Figure 9B for proper wiring diagram throughout the commissioning process for a multiple
13
AE4-1383 R14
compressor system with communications to the E2: in the plastic housing will help reduce abrasion to the
1. Switches 1 through 5 are used for setting the wiring. Appropriate strain relief is recommended.
address. Each CoreSense Diagnostics device that NOTE: The RS485 is polarity sensitive. “+” wires
is connected to a rack controller must have a unique must connect to other “+” terminals, and “-” wires
node address (as determined by the DIP switch must connect to other “-” terminals. The shield wire is
settings). connected to the center terminal, or “0 volt” position.
2. Switch 6 defines the communications baud rate for
Terminations
the CoreSense Diagnostics module. If the switch
is “off”, the baud rate is 19200. If the switch is “on” The last compressor in the daisy chain must be
the baud rate is 9600. The baud rate for each of the “terminated” by setting the DIP switch number 10 to the
CoreSense devices should be set to match the rack "on" (up) position. For all other compressors the number
controller. The default baud rate is 19200 (“off”) for 10 DIP switch should remain in the "off" (down) position.
the CoreSense Diagnostics module. To determine More information: The E2 jumpers on the Network
the baud rate in the E2, follow these steps: Interface Board should be set for “terminated”. Refer
• From the main menu select 7 (System to Figure 16.
Configuration)
COMMISSIONING
• Press 3 (System Information)
Modules using a communications network must be
• Press 1 (General Controller Info) commissioned as part of the E2 rack controller setup.
• Access the Serial Communications Tab by The commissioning process uploads compressor
pressing CTRL + 3 asset information (model and serial number) into
the rack controller for future reference. Once the
• Use the Page Down button or scroll down to
commissioning process is completed, the controller will
view the settings for COM4
supervise and communicate with the module unless
3. Switch 7 defines the communication parity. The the node is deleted. Refer to section titled Modbus®
default parity setting for the CoreSense Diagnostics Communication to CoreSense Diagnostics for K5
module is no parity. If the switch is set to “on” the Compressors for more details on commissioning the
module will communicate using even parity. The K5 scrolls in an Emerson Retail Solutions E2 rack
parity setting must match the parity setting of the controllers.
rack controller.
NOTE: For digital capacity using an E2 controller,
4. Switch 8 is used to set the network mode (on) an enhanced suction group must be enabled.
for the module. The default setting is stand
The CoreSense Diagnostics module does not
alone mode (off). Network mode will generate a
need to communicate to the rack controller in
communications error if the rack controller fails
order to provide compressor protection. Using
to communicate with the device. For standalone
the communication process is optional, but provides
mode, no communications are expected so the
for information flow to the controller for proofing,
communication error is blocked.
remote reset, asset information, and fault history and
Cable Routing / Daisy Chain Configuration compressor status. Skip to section titled Stand Alone
Mode if the communication feature will not be used.
A second set of DIP switches are used for compressor
operation. See Table 12 for default configuration and The commissioning process begins by assigning a
application guidelines for DIP switches. The CoreSense unique node address to each module. The address is
Diagnostics module can communicate with a rack established by the setting of a DIP switch in the module.
controller using Modbus® protocol. The communication
Stand Alone Mode
cable is wired from the rack controller to the first
compressor. Additional compressors are wired in a daisy If running a K5 with CoreSense Diagnostics without
chained configuration. Refer to Figures 16 and 17. communication to a rack controller, DIP switch 8 should
be set to "Off" (down).
A shielded, twisted pair cable such as Belden #8761
(22AWG) should be used for the communication wiring. Modbus® Communication to CoreSense Diagnostics
Passing the communications wire through the grommet
14
AE4-1383 R14
for K5 Compressors position enables Digital Capacity.

K5 Compressors equipped with a communication Switch 3 is for Failsafe. The "ON" position will allow the
module are capable of communicating via open compressor to run at 100% if communications is lost. If
Modbus® to a rack controller. The steps on the following in the "OFF" position the compressor will become off if
pages are provided to commission K5 scrolls in an communications is lost.
Emerson E2 with firmware version 3.0 or newer. For
Switch 4 – Affects standard Mobus. For applications
other rack controllers, contact the manufacturer.
using IPRO or XWeb (Dixell) 'non-standard Modbus'
CoreSense Diagnostics with EXV and digital capability turn SW4 ON Standard Emerson Climate Technologies
uses two sets of DIP switches: a communication set Modbus, the DIP switch orientation doesn't matter.
with 10 DIP switches on the center of the module, and
For all other standard Modbus, DIP switch 4 should be
a compressor operation set with 6 DIP switches on the
in the OFF position.
top left corner of the module.
*
For a description of the DIP switches please see
Figures 13 and 14. SW5: Is to return to factory defaults for all configuration
and erase the module history, use SW5 to reset the
Digital and EXV DIP Switches module. To reset SW5 must transition from off to on
Switch 1 is for Liquid injection being controlled by the within 5 seconds of module power up.
EXV. The "ON" position enables the EXV. Switch 6 Is for Lockouts enabled. The "ON" position will
Switch 2 is for Digital Capacity Control. The "ON" 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.
15
AE4-1383 R14
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
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.
16
AE4-1383 R14
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.
17
AE4-1383 R14
11. Press 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 to save changes and exit the
Network Summary.
13. Press to enter the Main Menu. Select 7. System Configuration.
18
AE4-1383 R14
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 Group2 field, select F4: Look Up (Press F4) and select the appropriate
suction group for the device and press Enter.
19
AE4-1383 R14
2 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)
20
AE4-1383 R14
Start
WARNING!
Is the compressor Is the compressor Disconnect and lockout
Allow time to cool
running? No overheated? Yes the power before
proceeding
Yes No
Perform troubleshooting
Observe the compressor
to determine why the Put the system back into Remove one wire from
suction & discharge
compressor isn’t operation and retest the modulation coil
pressures
running
Are pressures
changing with the Operation Measure the resistance
modulation Yes is normal of the coil
cycle?
No
Measure the voltage at

Coil has continuity Replace modulation
the modulation coil
and isn’t grounded? No coil
terminals
Yes
Replace modulation
Is voltage present,
Troubleshoot the valve, follow valve Put the system back into
coinciding with the
No modulation control replacement operation and retest
modulation cycle?
instructions
Yes
Figure 1 – Modulation Troubleshooting
21
AE4-1383 R14
ZF*K5E Low Temperature Vapor Injection Operating Map

(65°F Return Gas) R-404A/R-507
160
140
Condensing Temperature (°F)
120
100
80
60
40
20
0
-50 -40 -30 -20 -10 0 10
Evaporating Temperature (°F)
Figure 2 (A)
ZF*K5E Low Temperature Vapor Injection** Operating Map

(65°F Return Gas)
R-407A /R-407C /R-407F/R-448A/R-449A
160
140
120
100
Maximum
80 40F
Superheat
60
40
20
** DTC/EXV Liquid Injection Required with EVI for R-407A /R-407C/ R-407F/R-448A/R-449A
0
-50 -40 -30 -20 -10 0 10
Figure 2 (B)
22
AE4-1383 R14
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
160
140
120
100
DTC/EXV Liquid
Injection Required
80
60
40
20
0
-50 -40 -30 -20 -10 0 10
Figure 2 (C)
ZF*K5E Low Temperature Liquid Injection Operating Map

(65°F Return Gas)
R-22
140
120
100
DTC/EXV Liquid
80 Injection Required
60
40
20
0
-50 -40 -30 -20 -10 0 10
Figure 2 (D)
23
AE4-1383 R14
ZB*K5E Medium Temperature Operating Map – (65°F Return Gas)

R-404A/R-507/R-407A/R-407C/R-407F
Evaporating Temperature (°C)
-29 -24 -19 -14 -9 -4 1 6
160
62
140
Condensing Temperature (°C)

H
FS
20° SH
52
120 t to
i 0°F
Lim 2
4 07A i m it to
-
R /F L 42
07C
100 R-4
65°F Maximum Return Gas 32
80
22
60
12
40
2
20 -8
0 -18
- 20 - 10 0 10 20 30 40 50
Figure 2 (E)
ZB*K5E Medium Temperature Operating Map – (65°F Return Gas)

R-448A/R-449A
Evaporating Temperature (°C)
-29 -24 -19 -14 -9 -4 1 6 11
160
62
140
t
imi 52
tL
120
rhea
pe
Su
°F 42
20
100
32
80
22
60
12
40
2
20 -8
0 -18
-20 -10 0 10 20 30 40 50 60
Figure 2 (F)
Note: For operating maps at different return gas conditions, contact your Application Engineer.
24
AE4-1383 R14
ZB*K5E Medium/High Temperature Operating Map

(65°F Return Gas)
160 R-22
150
140
130
120
110
100
90
80
70
60
0 10 20 30 40 50 60
Figure 2 (G)
ZB*K5E High Temperature Operating Map

(20F Superheat)
180 R-134a
160
140
120
100
80
60
0 10 20 30 40 50 60 70
Figure 2 (H)
25
AE4-1383 R14
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*
140
120
100
80
60
65°F Maximum Return Gas

40
20
0
-15 -10 -5 0 5 10 15 20 25 30
Evaporating Temperature (°F) *R-22 Not Approved for Vapor Injection
26
AE4-1383 R14
ZBD*76 Compressor Operating Envelope WITHOUT

CoreSense Diagnostics Controlling Digital Capacity
Evaporating Temperature (°C) R-404A/R-507
-29 -24 -19 -14 -9 -4 1 6
160
62
140

52
120
100%-10%
42
100
100%-20%
32
80
22
60
12
40
2
20 -8
0 -18
- 20 - 10 0 10 20 30 40 50
Figure 2 (K)
ZBD*76 Compressor Operating Envelope WITHOUT

Evaporating Temperature (°C) R-407A/R-407C/R-407F/R-448A/R-449A
-29 -24 -19 -14 -9 -4 1 6
160
62
140 Condensing Temperature (°C)
52
120
42
100%-60%
100%-50%
100%-30%
100%-10%
100
32
80
22
60
12
40
2
20 -8
0 -18
- 20 - 10 0 10 20 30 40 50

Figure 2 (L)
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.
27
AE4-1383 R14
ZBD114 Compressor Operating Envelope WITHOUT

Evaporating Temperature (°C) R-404A/R-407C/R-407F/R-448A/R-449A/R-507
-29 -24 -19 -14 -9 -4 1 6
160
62
140

52
120
42
100%-30%
100%-70%
100%-50%
100%-40%
100
32
80
22
60
12
40
2
20 -8
0 -18
- 20 - 10 0 10 20 30 40 50
Figure 2 (M)
ZBD114 Compressor Operating Envelope WITHOUT

Evaporating Temperature (°C) R-407A
-29 -24 -19 -14 -9 -4 1 6
160
62
140
52
120
100%-30%
42
100%-70%
100%-50%
100%-40%
100%-70%
100
32
80
22
60
12
40
2
20 -8
0 -18
- 20 - 10 0 10 20 30 40 50

Figure 2 (N)
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.
28
AE4-1383 R14
FILTER
DRIER SUCTION
MANIFOLD
KEEP MIN
(SEE NOTE 6)
<12”
<12”
CONTINUOUS TUBING
(NO ELBOWS) <30”
Figure 3 (A)
Notes: 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.
29
AE4-1383 R14
Figure 3 (B) Figure 3 (C)

Liquid Injection Scroll with DTC Valve EVI Scroll with DTC and T-fitting Adapter
Figure 3 (D)
30
AE4-1383 R14
Figure 4 – Circuit Diagram and Cycle for EVI
Condenser
LIT
Outlet
VOT
Vapor Outlet to
Compressor
SIT
Vapor Out Cond. Out
Heat
Exchanger
Liq. In
UT TXV
TXV SIT
LOT
Liq. Out
Vapor In
Figure 5 – Downstream Extraction Figure 6 – Upstream Extraction
31
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
027-0400-00
RUBBER GROMMET
027-0383-00 KIT# 998-0178-00 KIT #527-0210-00
STEEL SPACER
Figure 8A Figure 8B
8 - 17 HP Copeland Scroll Compressor 8-13HP Condensing Unit Mounting for
Rack Mounting 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
32
CoreSense Module With Pressure Safety Control
AE4-1383 R14
L1
L2
13 14
K1 Relay CoreSense Module

K1 Relay
D
9 5
*Kriwan
M1
Module
M1 INJ
Sol
M2
M2
T1 L1
CC
T2 L2
OMB
Alarm
* Note - If Kriwan is used wire in series with

HPCO
LPCO 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
L1 L2
Kriwan CoreSense
Module Diagnostics
T1 L1
T2 L2
INJ
M2 M1 M2 SOL
M1
** The physical location of M1/M2 & L1/L2 have
changed on the CoreSense module ** CC
Current Transducer
Note: If Kriwan module is used, wire in series
D Discharge Top Cap
with CoreSense module, as indicated in diagram. Thermistor
Digital Solenoid
(Same as Control
If Kriwan module is not used, wire M1 directly Circuit Voltage)
from safety circuit to M1 on CoreSense & M2
1-5v Digital
from contactor coil to M2 on CoreSense module. System Capacity Input
6 Pin to EXV Coil
Control OMB 12VDC
** System control point only needed for fixed
capacity compressors.
LPCO HPCO
EXV Coil
Alarm
Figure 9B – CoreSense Diagnostics Module with Digital and EXV Capability
33
** The physical location of M1/M2 & L1/L2
have changed on the CoreSense module **
AE4-1383 R14
Top Cap Line

266°F 242°F
(130°C) (117°C)
Identification Tag Color

No Tag Orange Tag
Figure 10 – Discharge Thermistor Connector (Viewed from Wire Side)

Nominal Shutdown Temperature
Top Cap
Thermistor
Figure 11 – Top Cap Thermistor Figure 12 – Discharge Line Thermistor

The top cap thermistor should be installed with di- The discharge line thermistor should be attached to
electric grease applied on the probe. When attaching the discharge about 6 inches from the discharge of the
the probe to the compressor, a high temperature silicone compressor and is only used with a DTC valve
type sealant should be used not only to adhere the probe Note! Although not depicted in this figure, the thermistor
to the compressor, but to also prevent any moisture from should be well insulated to ensure accurate temperature
entering the thermal well. sensing.
34
Communication Module DIP Switch Settings AE4-1383 R14
Node Addresses
“On” (UP)
9600 Even Network Terminated
1 4 7
12345 12345 12345
Baud Control Network
Parity
Rate Mode Termination
2 5 8
12345 12345 12345
No Stand Not
19200
Parity Alone Terminated
3 6 9 “Off ” (Down)
12345 12345 12345
Position 9 is not used

1 2 3 4 5 6 7 8 9 10
Figure 13 – K5 Communication Module DIP Switch Settings
Figure 14 – Digital and EXV DIP Switches
Terminal 9, Jumper To
Terminal 13
Terminal 5, Demand Wire
Terminal 13, L1
and Jumpered
to Terminal 9
Terminal 14, L2
Figure 15 – Wiring Relay Example
Figure 16 – E2 Jumpers
35
AE4-1383 R14
(Terminated)
(Terminated)
(Terminated)
(Terminated)
Figure 17 – RS485 Daisy Chain Connection
(Terminated)
(Terminated)
(Terminated)
(Terminated)
Figure 18 – Two Rack Daisy Chain Connection
36
AE4-1383 R14
Compressor
Operation
DIP Switches
Current Toroid Plugin
Digital Input 1-5V
Diagnostic (Analog Input)
LED Lights
Top Cap Thermistor
Module Modbus®
Communication Communication
DIP Switches Plugin
Ground Screw
Control Circuit Module Power 110V/220V
Areas highlighted in red circles show differences from the old

CoreSense™ Diagnostics module to the new. Digital control
Digital Solenoid Liquid Injection and EXV control have been added to the module. The physical
Voltage Output Output (cord location of (M1,M2) and (L1,L2) has also changed.
(110/220V) provided)
Figure 19 – Comparison of old and new modules
37
AE4-1383 R14
Intermediate
Floating
Seal Cavity
Seal Cavity Vent
Removable External
Solenoid and Coil
Figure 20
Digital Compressor Cutaway View
38
AE4-1383 R14
20 Second Operating Cycle

100%
90%
80%
Compressor Capacity (Percent of Full Load)
70%
60%
50%
40%
30%
20%
10%
0%
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Solenoid On -Time (Seconds)
Figure 21A
ZBD*K5E Digital Operation Cycle Time
Figure 21B
ZFD*K5E Digital Operation Cycle Time
39
AE4-1383 R14
CoreSense™ Diagnostics + EXV Operation

1. Top Cap Temperature
Sensor
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

2. Input Signal Kit 998-0340-00 Includes…
to CoreSense • Stepper Motor with Cable
Module • Valve Body
• Brazed Fitting
Liquid Line Input to the

Valve (Liquid line Solenoid
will be needed)
3. CoreSense T-Fitting with EXV for
4. CoreSense Wet Injection Application
Module Output
543-0209-00
Figure 22
Medium Temperature Digital Operation Low Temperature Digital Operation

10%-100% 30%-100% and Enables Liquid Injection
Enables Digital Operation Enables Digital Operation
Figure 23A – Medium Temp Figure 23B – Low Temp

ZBD*K5E Digital Operation DIP Switch Settings ZFD*K5E Digital Operation DIP Switch Settings
40
AE4-1383 R14
Table 1
Injection Accessories
Reference
Application Injection Refrigerants Required Kits
Figure
ZB
N/A All Top Cap Thermistor is Factory Installed (no kits required) See Figure 21
(Medium Temp)
998-0229-00: Top Cap Thermistor Kit
404A/507 See Figure 21
*Top Cap Thermistor is factory installed on -260 BOM
Vapor
ZF Injection 407A/C/F 998-0500-03: 250°F DTC Kit Including Temperature Probe
See Figure 3C
(Low Temp) 448A/449A 998-0177-00: DTC Vapor Injection Adapter
Liquid
All 998-0500-03: 250°F DTC Kit Including Temperature Probe See Figure 3B
Injection
Table 2
External Wrap-Around Crankcase Heaters
Crankcase Crankcase Lead Length Ground Wire Conduit Ready Box for
Volts Watts
Heater Kit P/N Heater P/N (in) Length (in) Crankcase Heater
918-0047-00 018-0091-00 120 90 48 48
918-0047-01 018-0091-01 240 90 48 48
998-7029-00
918-0047-02 018-0091-02 480 90 48 48
918-0047-03 018-0091-03 575 90 48 48
Table 3
Kriwan INT69 Module Specifications
Emerson P/N 071-0660-00

Emerson Kit P/N 971-0641-00
Manufacture P/N Kriwan 22 A 601
T1-T2 Module Power
Voltage Supply 120/240V
Frequency 50/60 Hz
M1-M2 Module Output Contacts
Maximum Voltage 264 VAC
Maximum Current 2.5 Amps
Minimum Current 100 milliamps
S1-S2 Thermal Protection
Trip Out Resistance 4500 ±20%
Reset Resistance 2750 ±20%
Reset Time 30 min ±5 min.
Manual Reset T1-T2 interrupt for minimum of 5 sec.
41
AE4-1383 R14
Table 4
K5 Compressor for Refrigeration Additional Accessories
Accessory Part Description P/N

55-65 Durometer Mounting Parts Kit (for single compressor applications
527-0210-00
using ZB95-ZB(D)114, ZF49-ZF54)
Mounting Parts Hard Mounting Parts Kit (for parallel rack applications) 998-0178-00
35-45 Durometer Mounting Parts Kit (for single compressor application
527-0116-00
using ZB58/66, ZB(D)76 and ZF34, ZF(D)41)
Suction and Discharge Service Valves with Seals 998-5100-27
Service Valve
Suction Rotalock Service Valve with Seal - 1 3/8" Stub Tube 998-0510-46
Kits
Discharge Rotalock Service Valve with Seal - 7/8" Stub Tube 998-0510-39
Rotalock to Stub Discharge Rotalock to Stub (1 1/4" 12 Thread to 7/8" Sweat) 998-0034-08
Tube Adapter Suction Rotalock to Stub (1 3/4" 12 Thread to 1 3/8" Sweat) 998-0034-13
Kits Vapor & Liquid Injection Rotalock to Stub (1" 14 Thread to 1/2" Sweat) 998-0034-18
External Motor Protection Module for ZB95K5E-TWC, ZB(D)114K5E-TWC,
Motor Protection 971-0641-00
ZB(D)114K5E-TWE
Oil Management Control w/ Junction Box 24V 50/60Hz 65365
Oil Monitoring
OMB (Emerson Oil Management Control w/ Series Relief Connector 24V 50/60Hz 65366
Flow Controls Copeland Scroll OMB Adapter for K5 Refrigeration Scroll 66077
P/Ns)
Copeland Scroll OMB Adaptor for K5 Refrigeration Scroll (after May 2013) 66652
CoreSense Module for K5 Refrigeration Scroll (Pre January 2015) 943-0151-00
CoreSense Current Sensor Module for K5 Refrigeration Scroll 943-0159-00
CoreSense
CoreSense Module for K5 Refrigeration Scroll (After January 2015) 943-0209-00
Diagnostics
Thermistor Kit (Includes Top Cap and Discharge Line Thermistors) 998-0176-00
Top Cap Thermistor Kit (Top Cap Thermistor Only) 998-0229-00
120V, 93W Wrap Around, 48" Lead Length 018-0091-21 918-0047-00
Crankcase
Heater Kits
Conduit Ready Box for Crankcase Heater 998-7029-00
DTC Kit - 250°F Set Point DTC with 268°F Thermistor for Liquid Injection
998-0500-03
and R-407A/C/F Vapor Injection
Liquid Injection
Liquid Injection Adapter (For R407A/C/F Vapor Injection Applications Only) 998-0177-00
Components
EXV Liquid Injection Valve Kit (Includes EXV Valve with Compressor
998-0340-00
Connection & Wiring
120V Digital Solenoid Coil 998-0060-04
240V Digital Solenoid Coil 998-0060-09
Digital Kits & Digital Wire for CoreSense Analog Input 998-0341-00
Components
Digital Solenoid Coil Wire (CoreSense Module to Digital Solenoid Coil) 998-0342-00
Closed Loop Digital Controller (Single Compressor Applications) 998-0189-00
42
AE4-1383 R14
Table 5
K5 Compressor for Refrigeration (8 to 17 HP) Fitting Sizes
Fitting Size (in.) -Thread

Suction Rotalock Connection 1 3/4"-12
Discharge Rotalock Connection 1 1/4"-12
Liquid/Vapor Injection Rotalock Connection 1"-14
Table 6
High and Low Pressure Control Settings
R-22 / R-407A / R-407C/

Model Control Type R-404A / 507 R-134A
R-407F / R-448A/ R-449A
Low 0 psig min. 2 in. Hg Min.
ZF* K5E ---
High 400 psig max 335 psig Max
Low 17 psig min. 4 psig min. 37 psig min.
ZB*K5E
High 450 psig max 263 psig max 381 psig max
Table 7A Table 7B
Low Temperature Digital Modulation MediumTemperature Digital Modulation
Capacity(%)/Analog (V) Capacity(%)/Analog (V)
Digital Digital
Analog Analog
Digital Solenoid Digital Solenoid
Voltage Input Voltage Input
Capacity % On time Capacity % On time
(Volts) (Volts)
(Seconds) (Seconds)
100% 5.00 0 100% 5.00 0
90% 4.60 2 90% 4.60 2
80% 4.20 4 80% 4.20 4
70% 3.80 6 70% 3.80 6
60% 3.40 8 60% 3.40 8
50% 3.00 10 50% 3.00 10
40% 2.60 12 40% 2.60 12
30% 2.20 14 30% 2.20 14
20% 1.80 16
10% 1.40 18
43
AE4-1383 R14
Table 8
R1011 Alert Code Descriptions
Protection Protection Consecutive

Alert Code Code Description Shutdown Off Time Detections
(Default) (Default) Until Lockout
Lockout feature is NOT enabled from the factory except on code 7
ää 1 High Discharge Temp – see diagram for setting Yes 20 Min. 4

Excess System Limit Trips -
ä 2 4 consecutvie system limit trips Yes 5 Min. No Lockout
having 1-15 min runtime each
Excessive Demand Cycling -
ä 3 No - -
Default is 240 cycles per 24 hr. period
Locked Rotor -
ää 4 Yes 20 Min. 4
Compressor did not start within alloted time
Demand Present -
ä 5 No - -
No current detected over 4 hr. period
ää 6 Phase Loss Detected Yes 20 Min. 10
Until
ä 7 Reversed Phase Detected Yes Module Is 1
Reset
Welded Contactor -
ä 8 No - -
Current detected without demand1
ä 9 Low Module Voltage Yes 5 Min. No Lockout
ä 10 Module Communications Error No - -
ä 11 Discharge Temperature Sensor Error No - -
ä 12 Current Transducer Error No - -

Digital Alert Codes:
ä 1 Loss of analog demand – Check analog voltage
ä 2 Network mode ON, 1-5V input present – Check position of DIP switch #8
ä 3 Network model OFF, receiving Modbus® communication – Check position of DIP switch #8
Lockouts can be enabled by DIP switch 6 setting

1
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.
44
AE4-1383 R14
Table 9
CoreSense™ Diagnostics Module Troubleshooting
Status LED Status LED Description Status LED Troubleshooting Information

Green Alert LED
Module has power Supply voltage is present at module terminals
Solid
Short Cycling
Green Alert LED 1. Check pressure or temperature control
2 to 480 run cycles in 24hours ending
2. Possible loss of refrigerant
3 Flashes with normal
3. Blocked Condenser
Alert Default is set to 240 per 24 hours
1. Compressor circuit breaker or fuse(s) is open
2. Compressor contactor has failed open
3. High pressure switch is open and requires
Green Alert LED Open Circuit manual reset
Demand signal is present but no 4. Open circuit in compressor supply wiring or
5 Flashes compressor current for four hours connections
5. Long compressor protector reset time due to
high ambient temperature
6. Compressor windings are damaged
1. Contactor welded closed
Welded Contactor 2. Control circuit transformer is overloaded
Green Alert LED No demand signal, but current has 3. Demand signal not connected to module
8 Flashes been detected in one or both phases - Demand signal could be from T-Stat or
Displayed for 24 hrs after last detection rack controller
4. Verify Wiring
Loss of Communication
Green Alert LED Communication lost between rack 1. Check communications wiring
10 Flashes controller and module for 10 minutes or 2. Verify wiring follows application guidelines
more
Green Alert LED 1. Check discharge temperature sensor wiring
Discharge Temperature Sensor Error
and mounting
11 Flashes Short or Open Circuit Detected
2. Verify sensor is not shorted. 86k @ 77°F
Green Alert LED 1. Verify CT is plugged into module
Current Transducer (CT) Error
12 Flashes 2. Verify CT is not shorted
1. Compressor protector is open
- Check for high head pressure
- Check compressor supply voltage
Yellow Alert LED 2. Compressor circuit breaker or fuse(s) is open
Trip
3. Broken wire or connector is not making
Solid Demand present, no current is detected
contact
4. Safety cutout switches open (HPCO, LPCO,
OMB, etc.)
5. Compressor contactor has failed open
1. Possible loss of refrigerant charge
Yellow Alert LED High Discharge Line Temperature Trip 2. Blocked condenser
See inside label to determine cut out 3. Verify that discharge valve is open
1 Flash temp. 4. On low temperature scroll compressors check
liquid injection
Yellow Alert LED System Trip 1. Excessive suction pressure or discharge
Four consecutive compressor trips after pressure
2 Flashes run time of 1-15 minutes each 2. Improper wiring
45
AE4-1383 R14
CoreSense™ Diagnostics Module Troubleshooting (Continued)
Status LED Status LED Description Status LED Troubleshooting Information

1. Low line voltage (contact utility if voltage at
Locked Rotor disconnect is low)
Yellow Alert LED Compressor is drawing current without 2. Verify presence of all legs of power line
4 Flashes rotating or four consecutive compressor 3. Excessive liquid refrigerant in compressor
trips after run time of 1-15 seconds 4. Compressor bearings are seized
5. Verify operating current
1. Improper wiring. Correct order of phases in
wires
Yellow Alert LED Missing Phase
2. Failed contactor. Check contacts for pitting
Demand signal is present but current is
6 Flashes 3. Compressor current could be too low. Refer to
missing in one phase
specifications.
4. Verify presence of all legs of power line
Yellow Alert LED Low Voltage Detected 1. Low line voltage (contact utility if voltage at
Control voltage dips below 85V for disconnect is low)
9 Flashes 110V or 170V for 220V 2. Check wiring connections
1. Possible loss of refrigerant charge
LOCKED OUT ON:
Red Alert LED 2. Blocked condenser
High Discharge Line Temperature Trip
3. Verify that discharge valve is open
1 Flash See inside label to determine cut out
4. On low temperature scroll compressors check
temp.
liquid injection
1. Low line voltage (contact utility if voltage at
LOCKED OUT ON:
disconnect is low)
Red Alert LED 4 Consecutive Locked Rotors Detected
Compressor is drawing current without
4 Flashes 3. Excessive liquid refrigerant in compressor
rotating or four consecutive compressor
4. Compressor bearings are seized
trips after run time of 1-15 seconds
5. Verify operating current
LOCKED OUT ON: wires.
Red Alert LED 10 Missing Phase Detections 2. Failed contactor. Check contacts for pitting.
6 Flashes Demand signal is present but current is 3. Compressor current could be too low. Refer to
missing in one phase specifications.
LOCKED OUT ON:
Red Alert LED wires.
1 Reverse Phase Detected
2. Compressor current could be too low. Refer to
7 Flashes Demand signal is present but current is
specifications.
not detected in the correct sequence
46
AE4-1383 R14
Table 10 – Demand Wiring

Demand Wiring Kit (998-0188-00)
Control Voltage
Item
110/120 220/240
Relay Socket 032-0766-00
Relay 040-1086-00 040-0187-00
Table 11 – K5 Dip Switch Settings

Dip Switch
On Off
Number
1 Through 5 Modbus® Module Address
6 Baud Rate= 9600 Baud Rate= 19,200
7 Even Parity No Parity
8 Network Stand Alone
9 Not Used
10 Terminated Not Terminated
Table 12
CoreSense™ Module DIP Switch Scenarios
Application Medium Temperature Low Temperature

Digital? Digital Non-Digital Digital Non-Digital
Compressor ZBD**K5E ZB**K5E ZFD**K5E ZF**K5E
SW1: EXV Enabled Off Off On On
Factory Default
SW2: Digital Enabled On Off On Off

SW3: Failsafe On/Off Off Off Off Off
SW4: 1 or 2 Stop Bits Off Off Off Off
SW5: Reset to Default Off Off Off Off
SW6: Lockout Enabled Off Off Off Off
Application All All Liq Inj VI 407A VI 404A Liq Inj VI 407A VI 404A
On for On for On for On for
Off Off Off Off
Rack Rack Rack Rack
Adjust
SW2: Digital Control

Off w Off w Off w Off w
Off Off Off Off
XC643 XC643 XC643 XC643
Option To Use Open Triac
*Liquid Inj. Line Solenoid n/a n/a No No Yes Yes No n/a
*To use open Triac you must have a non digital compressor with switch number 2 set to the OFF position.
(Triac is normally open)
Needed, Same as Different Than Not Needed, No Change

Factory Default Factory Default 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.
47
CoreSense™ Diagnostics for Copeland Scroll™ K5 Refrigeration Compressors
Modbus® Specification
Table of Contents
1.0 Introduction ................................................................. 2 4.2 Data Signaling Rate................................................................... 4

1.1 Abbreviations............................................................................. 2 4.2.1 Baud Rate Selection ............................................................... 4
1.2 Intent ......................................................................................... 2 4.2.2 Parity Selection....................................................................... 4
1.3 Scope ........................................................................................ 2 4.2.3 Stop Bits ................................................................................. 4
1.4 References ................................................................................ 2 4.3 Labeling ..................................................................................... 4
4.4 Connector .................................................................................. 4
2.0 General Description .................................................... 2 4.5 Wiring and Connections ............................................................ 4
3.0 Module Type Identification ......................................... 2 5.0 Data Link Layer ........................................................... 4
3.1 CoreSense Diagnostics Pre January 2015 DIP Switch Settings & 5.1 Node Address ............................................................................ 4
Configurations ................................................................................. 2 5.2 RTU Transmission Mode ........................................................... 5
3.1.1 Main DIP Switch Board .......................................................... 3 5.3 Response Message Timeout ..................................................... 5
3.1.2 Communication DIP Switch Board ......................................... 3
3.2 CoreSense Diagnostics After January 2015 DIP Switch Settings 6.0 Application Layer ........................................................ 5
& Configurations .............................................................................. 3 6.1 Available Functions ................................................................... 5
3.2.1 Main DIP Switch Board .......................................................... 3 6.2 Data Types ................................................................................ 5
3.2.2 Communication DIP Switch Board ......................................... 3 6.3 Functions Supported ................................................................. 6
6.3.1 Input Register (Command 0x04) ............................................ 6
4.0 Physical Layer ............................................................. 3 6.3.2 Hold Register (Command 0x03, 0x06, 0x10) ....................... 12
4.1 Topology.................................................................................... 3
4.1.1 Wire Used ............................................................................... 3 7.0 Troubleshooting ........................................................ 14
4.1.2 Bus Bias ................................................................................. 3
4.1.3 Termination ............................................................................ 4
©2016 Emerson Climate Technologies, Inc. All rights reserved.

1.0 Introduction 1.4 References
The CoreSense™ Diagnostics module for Copeland For the details of the Modbus specification, refer to the
Scroll™ K5 refrigeration compressors provides the Modicon Modbus Protocol Reference Guide
protection, diagnostics and communication features to PI–MBUS–300 Rev. J.
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 2.0 General Description
and system related issues. If an unsafe condition is
detected, the module trips the compressor. A flashing Modbus uses a three layer protocol:
LED indicator displays the ALERT code and guides the Physical Layer: The hardware interface.
service technician more quickly and accurately to the
root cause of a problem. Data Link Layer: Defines the reliable exchange of
messages .
The module also has an RS485 isolated
communication port, by which the modules Application Layer: Defines message structures for the
communicate with the system controller or the network exchange of application specific information.
master. The details of the communication are provided Modbus has some required features, some
in this document. recommended features, and some optional features.
This specification starts with the physical layer and then
1.1 Abbreviations works up to the application layer. The application layer
Table 1: Abbreviations defined in this specification defines the standard
Modbus memory map and data interchange.
Abbreviation Meaning Modbus is a protocol with a single master and multiple
RTU Remote Terminal Unit slave devices. The master device initiates all
messages. The master device is typically a system
DLT Discharge Line Temperature controller and the slave devices are the CoreSense
Overall Alarm Count (Total modules.
OAC number of alarms since the
module has been installed)
3.0 Module Type Identification
CRC Cyclic Redundancy Check
Two modules are used with Copeland Scroll K5
CMD Command
refrigeration compressors with CoreSense
Diagnostics. The two modules can easily be
differentiated by the physical look of the module. The
1.2 Intent pre January 2015 module has black plastic casing,
This document defines standard usage of the Modbus while the new modules are gray with a silver banner.
protocol specification for CoreSense Diagnostics See pictures below to differentiate.
modules for Copeland Scroll K5 refrigeration The main difference between the two is that the new
compressors. This will allow third party controllers to module has EXV and digital capacity control.
easily communicate to our products using a standard
Modbus interface. 3.1 CoreSense Diagnostics Pre January 2015 DIP
Switch Settings & Configurations
1.3 Scope
There are two DIP switch panels on CoreSense
This document only defines the Modbus options that Diagnostics module for Copeland Scroll K5
are used in the CoreSense Diagnostics module for refrigeration compressors.
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.

3.2.1 Main DIP Switch Board
Main DIP
Switch
Board
Communication
DIP Switch
Board
Figure 4: After January 2015 Main DIP Switch Board
Figure 1: Pre January 2015 CoreSense™ Diagnostics DIP
Switch Panels 3.2.2 Communication DIP Switch Board
See 3.1.2 for details.
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 4.0 Physical Layer
position enables lockout and the DOWN position
disables lockout. This layer defines the hardware interface to the
network.
3.1.2 Communication DIP Switch Board
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

Figure 2: Pre & After January 2015 Communication DIP The recommended wire will be Belden 8761 that is a
Switch Board 22 AWG shielded twisted pair. The shield is also used
as the circuit ground.
3.2 CoreSense Diagnostics After January 2015 DIP
Switch Settings & Configurations
Main DIP
Figure 5: Recommended Communication Wire
Switch
Board 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
Communication resistor is acceptable. The recommended pull-up
DIP Switch resistor on the RS485 ‘-’ output is a 511 ohm resistor,
Board 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
Figure 3: After January 2015 CoreSense™ Diagnostics DIP
Switch Panels
network.
4.1.3 Termination • Middle Connection is not labeled and is
The last slave in the network shall have a 150 ohm ground
resistor for termination. In this module, there is a • ‘+’ Positive
termination DIP switch on the communication DIP
See Figure 6 for reference.
switch panel. Position 10 DIP switch is used for
termination. See Figure 2 for reference. The last 4.4 Connector
CoreSense module in the network shall be terminated
by sliding DIP switch 10 up, to the ON position. For the A three position screw cable connector is used for
other CoreSense modules in the network, DIP switch Modbus communication.
10 shall be down, in the OFF position.
4.5 Wiring and Connections
4.2 Data Signaling Rate
The Modbus wiring should be connected to module
The communications port default settings are 19200, connector ‘-’, ‘GND’, ‘+’
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. Figure 6: CoreSense™ Diagnostics Modbus Connection
ON = 9600 Important! Note that RS485 is polarity sensitive. ‘+’
OFF = 19200 (Default) wires must connect to other ‘+’ terminals and ‘-’ wires
must connect to other ‘-’ terminals. The shield wire is
4.2.2 Parity Selection connected to the center terminal.
CoreSense Protection Modbus communication parity is
user configurable (even or no parity) through DIP
5.0 Data Link Layer
switch number 7. See Figure 2.
Modbus uses master/slave protocol where there is a
ON = even parity
single master device that initiates all messages. The
OFF = no parity (Default) Data Link Layer defines the reliable transfer of a
message transferred from the master to one or more
4.2.3 Stop Bits slave devices and the reliable transfer of the response
CoreSense Diagnostics Modbus communication stop message (when the command message is sent to a
bits is user configurable to either be 1 or 2 stop bit. DIP single device). The CoreSense module is a slave in the
switch number 4 on the main DIP switch board is used network and the rack controller is the master.
to configure stop bit. See Figure 4.
5.1 Node Address
ON = 1 stop bits
The DIP switch setting combination gives the node
OFF = 2 stop bits (Default) address. The combination positions 1 through 5 will be
used to define a node address from 1 to 31. Use Figure
Note: Even parity will always be 1 stop bit.
7 and Table 2 for reference.
4.3 Labeling Note: To enable a DIP switch changes, power to the
The module has a RS485 port with the connector pins, module must be cycle.
labeled from top to bottom as:
• ‘-’ Negative
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
Figure 7: Switches 1 to 5 are used to set the module
• 8 data bits
Modbus address
• 2 stop bit (or if ‘even parity’ is selected 1 stop
Table 2: Node Address DIP Configurations 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 Function Function

Register Access
Number Code Name
Read Input Input
1 0x04 Read Only
Registers Register
Read
Holding
2 0x03 Holding Read/Write
Register
Registers
Write Single Holding
3 0x06 Read/Write
Register Register
Write
Holding
4 0x10 Multiple Read/Write
Register
Registers
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) Contents Quantity Data Description
Start Stop
0000 001B Division Name 28 'X'
001C 0021 Product Name 6 'X'
0022 0029 Product Code 8 'X'
002A 0030 Module Version Number 7 'X'
Today compressor run time
0077 0077
One counter means 6 minutes
Today-1 compressor run time
0078 0078
0079 0079
Seven Days of Today-3 compressor run time
007A 007A 7
Compressor Run Time One counter means 6 minutes
007B 007B
007C 007C
007D 007D
Today compressor start times
007E 007E
One counter means 1 time
Today-1 compressor start times
007F 007F
0080 0080
Seven Days of Today-3 compressor start times
0081 0081 7
Compressor Start Times One counter means 1 time
0082 0082
0083 0083
0084 0084
Total Compressor Run One counter means 1 hours
0085 0086 2
Time 0-4294967295
Total Compressor Start One counter means 1 start
0087 0088 2
Times 0-4294967295
Protection Trip For Seven One counter means one time
008E 008E 1
Days 0-65535
Protection Trip After One counter means one time
008F 0090 2
Power Up 0 - 4294967295
009B 009B 1 Alarm Id of tenth most recent alarm
009C 009C 1 Alarm Id of ninth most recent alarm
Ten Most Recent Alarm
009D 009D 1 Alarm Id of eighth most recent alarm
009E 009E 1 Alarm Id of seventh most recent alarm
009F 009F 1 Alarm Id of sixth most recent alarm
00A0 00A0 1 Alarm Id of fifth most recent alarm
00A1 00A1 1 Alarm Id of most fourth recent alarm
00A2 00A2 1 Alarm Id of third most recent alarm
00A3 00A3 1 Alarm Id of second most recent alarm
00A4 00A4 1 Alarm Id of most recent alarm
BIT0 - Today:
(0 - Not present / 1 - Present)
BIT1 - Today-1:
Eight Days Alarm History
00AA 00AA 5 (0 - Not present / 1 - Present)
of DLT Fault
……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
00AB 00AB 6 (0 - Not present / 1 - Present)
of CT Fault Warning
……………………………..
BIT7 - Today-7:
BIT0 - Today:
Eight Days Alarm History BIT1 - Today-1:
00AC 00AC of Loss Comm From E2 7 (0 - Not present / 1 - Present)
Warning ……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
00AF 00AF 10 (0 - Not present / 1 - Present)
of Short Cycling Warning
……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
00B0 00B0 11 (0 - Not present / 1 - Present)
of Open Circuit Warning
……………………………..
BIT7 - Today-7:
BIT0 - Today:
00B1 00B1 of Welded Contactor 12 (0 - Not present / 1 - Present)
Warning ……………………………..
BIT7 - Today-7:
BIT0 - Today:
Eight Days Alarm History (0 - Not present / 1 - Present)
00B4 00B4 of High Discharge Line 15 BIT1 - Today-1:
Temperature Alarm (0 - Not present / 1 - Present)
……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
of System Trip Alert
……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
of Locked Rotor Alert
……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
of Missing Phase Alert
……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
of Reverse Phase Alert
……………………………..
BIT7 - Today-7:
BIT0 - Today:
00BA 00BA of Module Low Voltage 21 (0 - Not present / 1 - Present)
Alert ……………………………..
BIT7 - Today-7:
BIT0 - Today:
00C6 00C6 of High Discharge 33 (0 - Not present / 1 - Present)
Temperature Lockout ……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
00C7 00C7 35 (0 - Not present / 1 - Present)
of Locked Rotor Lockout
……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
00C9 00C9 36 (0 - Not present / 1 - Present)
of Missing Phase Lockout
……………………………..
BIT7 - Today-7:
BIT0 - Today:
BIT1 - Today-1:
00CA 00CA 37 (0 - Not present / 1 - Present)
of Reverse Phase Lockout
……………………………..
BIT7 - Today-7:
One counter means one times
00E3 00E3 OAC of DLT Fault 5
0 - 65535
00E4 00E4 OAC of CT Fault Warning 6
0 - 65535
OAC of Loss Comm From One counter means one times
00E5 00E5 7
E2 Warning 0 - 65535
OAC of Short Cycling One counter means one times
00E8 00E8 10
Warning 0 - 65535
OAC of Open Circuit One counter means one times
00E9 00E9 11
Warning 0 - 65535
OAC of Welded Contactor One counter means one times
00EA 00EA 12
Warning 0 - 65535
OAC of High Discharge One counter means one times
00ED 00ED 15
Line Temperature Alarm 0 - 65535
00EE 00EE OAC of System Trip Alert 16
0 - 65535
OAC of Locked Rotor One counter means one times
00EF 00EF 17
Alert 0 - 65535
OAC of Missing Phase One counter means one times
00F0 00F0 18
Alert 0 - 65535
OAC of Reverse Phase One counter means one times
00F1 00F1 19
Alert 0 - 65535
OAC of Module Low One counter means one times
00F3 00F3 21
Voltage Alert 0 - 65535
OAC of High Discharge One counter means one times
00FF 00FF 33
Temperature Lockout 0 - 65535
OAC of Locked Rotor One counter means one times
0101 0101 35
Lockout 0 - 65535
OAC of Missing Phase One counter means one times
0102 0102 36
Lockout 0 - 65535
OAC of Reverse Phase One counter means one times
0103 0103 37
Lockout 0 - 65535
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
0117 0117 Current Alert 1
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
0118 0118 Previous Alert 1
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
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
011B 011B System Status 1
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)
011C 011C DIP Switch_1 1 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)
011D 011D DIP Switch_2 1 BIT13 - DS13 : (1 - ON / 0 - OFF)
……………………………….
BIT1 - DS1 : (1 - ON / 0 - OFF)
BIT0 - DS0 : (1 - ON / 0 - OFF)
One counters means 0.01V
0122 0122 Low Voltage Set point 1
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
0123 0123 Input Status 1
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
0126 0126 Output Status1 1 follow:
BIT0 - Output Contactor Relay Status (Open-0 / Closed – 1)
Discharge Temperature (Discharge temp sensor value/100)-70
0129 0129 1
Value Range = -70.0ºF -585.35ºF
Compressor Power Frequency measurement of compressor pilot circuit
012E 012E 1
Frequency Unit : Hz
Module Voltage = Value / 100
012F 012F Module Power Voltage 1
Range 0 to 655.35 Volts
Compressor Current Y CT1 Current = Value / 100
0130 0130 1
Phase Range : 0 - 655.35Amps
Compressor Current B CT3 Current = Value / 100:
0132 0132 1
Phase Range : 0 - 655.35Amps
LRA Peak Current = Value / 100
0133 0133 LRA Peak Current 1
Range : 0 - 655.35 Amps
Max Running Current :
0134 0134 MAX RMS Current 1 Unit : 0.01Amps
0 - 655.35A
0x00 - Solenoid not used
0139 0139 Solenoid Work Status 1 0x01 - Solenoid is used for EXV
0x02 - Solenoid is used for digital modulation
013A 013A EXV open position 1 0~100 means 0%~100%
Analog Input Voltage
013B 013B 1 0~500 means 0~5.00V
Value
013C 013C Minimum Capacity 1 10~100 means 10%~100%
013D 013D Analog Input Request 1 10~100 means 10%~100%
Compressor Running
013E 013E 1 10~100 means 10%~100%
Capacity
One counter means 1 cycle
0173 0174 Total No. of Short Cycles 2
0-4294967295
6.3.2 Hold Register (Command 0x03, 0x06, 0x10)

Table 5: Hold Register (Command 0x03, 0x06, 0x10)
Address
(Hex) Contents Quantity Data Description
Start Stop
0025 0036 Compressor Module Number 18 'X'
0037 0042 Compressor Serial Number 12 'X'
0051 005C Module Part Number 12 'X'
005D 0069 Module Serial Number 13 'X'
0x00 – Automatic based on the temperature;
0076 0076 EXV Control Type 1 0x01 - Manual control
Default: Automatically
if the EXV control type is automatic, then ignore this
EXV Position for Manual
0077 0077 1 item;
Control
0~100 means the EXV open is 0%~100%
0078 0078 Proportionality Coefficient Set 1 0~65535 means 0~655.35
0079 0079 Integral Coefficient Set 1 0~65535 means 0~655.35
007A 007A Differential Coefficient Set 1 0~65535 means 0~655.35
007B 007B PID Sample Time 1 One Counter Means One Second (1~50s)
0~65535 means -70~585.35°F
The temperature value
007D 007D PID Set Point Value Set 1
= ( (( High byte << 8) + Low byte) - 7000) / 100
The default value should be: 255°F
Default : 6 seconds
0080 0080 Minimum On Time 1 Unit : 1 Seconds
Range : 0 - 65535 seconds
Default : 6 seconds
0081 0081 Minimum Off Time 1 Unit : 1 Seconds
Range : 0 - 65535 seconds
DLT temp trip set point value,
Unit : 0.01°F ;
0085 0085
Range: -70 to 585.35 °F
Alert Trigger Parameters
20 Set point = (Word - 7000 )/ 100 (°F)
Configuration
Default: 297°F
0086 0086 DLT temp trip reset point value,
Unit : 0.01°F ;
Range: -70 to 585.35 °F
Reset point =( Word -7000 )/100 (°F)
Short Cycle Events

0088 0088 Default : 240
0 – 65535
Open Circuit Delay Time
Default : 180 minutes
0089 0089
Unit : 1 minute
Range : 180 – 360
Low Voltage Set point
Unit : 0.01 v
008A 008A
Range : 0 - 655.35v
The master only can read and can’t write to this unit.
DLT Alert off Time - Unit 1 minutes
009A 009A Alert Off Time Configuration 26 Default : 20 Minutes
Range : 10 - 40
BIT0 - High Discharge Temperature Lockout Status:
1 - Enable / 0 - Disable
BIT3 - Locked Rotor Lockout Status:
Lockout Status
00B4 00B4 1 BIT5 - Missing Phase Lockout Status:
Configuration1
BIT6 - Reverse Phase Lockout Status:
Others bit: Not used.
DLT Trip Lockout Events (Range 0-0xFFFF)
00B6 00B6
Default val=0xFFFF
Locked Rotor Trip Lockout Events (Range 0-0xFFFF)
00B8 00B8
Default val=0xFFFF
Lockout Events 20 Missing Phase Lockout Events (Range 0-0xFFFF)
00B9 00B9
Default val=0xFFFF
Reverse Phase Lockout Events (Range 0-0xFFFF)
00BA 00BA Default val=0xFFFF
The master only can read and can’t write to this unit.
BIT0 - Compressor Run:
(0 - Stop / 1 - Run)
00D0 00D0 Module Status Configuration 1
BIT1 - Remote Reset:
(0 - No Action / 1 - Remote Reset)
Default : 0-9%
00D4 00D4 UL1 Capacity Request 1 Unit : 1%
Valid Range : 0% - 100%
Default : 20 Seconds
00D6 00D6 Unloader Modulation Period 1 Unit : 1 Seconds
Range : 0 - 65535 Seconds
Response
7.0 Troubleshooting 0 0 1 0 3 0 2 0 3 0 3 0 5 0 3 0 3 8 1
8 4 0 0 1 0 E 0 0 0 1 0 2 0 1 0 1 7 4
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
Address
Length
request
CMD
CRC
Start
and
response is
hex value.
Request for
0 0 0 0 0 0 5 9
version
8 4 0 2 0 8 0 5
number
Address
Bytes
CMD
CRC
1 . 0 1 R 0 0

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AE4-1383 R14

AE4-1383 R14 March 2016

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

© 2016 Emerson Climate Technologies, Inc.

Safety Icon Explanation

DANGER indicates a hazardous situation which, if not avoided, will result

NOTICE NOTICE is used to address practices not related to personal injury.

CAUTION, without the safety alert symbol, is used to address practices

© 2016 Emerson Climate Technologies, Inc.

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

ELECTRICAL SHOCK HAZARD

PRESSURIZED SYSTEM HAZARD

© 2016 Emerson Climate Technologies, Inc.

Introduction NOTE: For the latest approved refrigerants and

© 2016 Emerson Climate Technologies, Inc.

© 2016 Emerson Climate Technologies, Inc.

by the injection pressure at the compressor. In medium Installation of DTC Valve

DTC Valve Specifications EXV Valve Specifications

© 2016 Emerson Climate Technologies, Inc.

of the injection circuit to avoid the possibility of the

© 2016 Emerson Climate Technologies, Inc.

© 2016 Emerson Climate Technologies, Inc.

Motor Protection • Measure the voltage across T1-T2 to ensure proper

Motor Protector Module Voltage Supply CAUTION

© 2016 Emerson Climate Technologies, Inc.

Compressor Voltage Supply Troubleshooting Compressor Mounting

© 2016 Emerson Climate Technologies, Inc.

© 2016 Emerson Climate Technologies, Inc.

© 2016 Emerson Climate Technologies, Inc.

© 2016 Emerson Climate Technologies, Inc.

© 2016 Emerson Climate Technologies, Inc.

for K5 Compressors position enables Digital Capacity.

© 2016 Emerson Climate Technologies, Inc.

CoreSense K5 Programming Instructions

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

Press to save changes and return to the previous screen.

© 2016 Emerson Climate Technologies, Inc.

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

© 2016 Emerson Climate Technologies, Inc.

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

© 2016 Emerson Climate Technologies, Inc.

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

© 2016 Emerson Climate Technologies, Inc.

© 2016 Emerson Climate Technologies, Inc.

Measure the voltage at

Figure 1 – Modulation Troubleshooting

© 2016 Emerson Climate Technologies, Inc.

ZF*K5E Low Temperature Vapor Injection Operating Map

ZF*K5E Low Temperature Vapor Injection** Operating Map

© 2016 Emerson Climate Technologies, Inc.

ZF*K5E Low Temperature Liquid Injection Operating Map

ZF*K5E Low Temperature Liquid Injection Operating Map

© 2016 Emerson Climate Technologies, Inc.

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

Condensing Temperature (°C)

65°F Maximum Return Gas 32

Evaporating Temperature (°F)

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

Evaporating Temperature (°F)

Application Guidelines for ZFK5E & ZBK5E Copeland Scroll™