Emerson Copeland Scroll K5 Series Application Bulletin
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Emerson Copeland Scroll K5 Series Application Bulletin

Application guidelines for zfk5e & zbk5e copeland scroll k5 compressors for refrigeration 8-15 hp with coresense diagnostics
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AE4-1383 R5
Application Guidelines for ZF*K5E & ZB*K5E Copeland Scroll
K5 Compressors for Refrigeration 8-15 HP with CoreSense
Section
Safety
Safety Instructions ............................................................. 2
Safety Icon Explanation ..................................................... 2
Fire, or Injury to Persons ................................................ 3
Safety Statements ............................................................. 3
Nomenclature .................................................................... 4
Approved Refrigerants....................................................... 4
Operating Envelope ........................................................... 4
Extended ZF*K5E Operating Envelope ............................. 4
Refrigeration ...................................................................... 5
DTC Valve Specifications .................................................. 5
Installation of DTC Valve ................................................... 5
Vapor Injection ................................................................... 5
System Configuration ........................................................ 6
Downstream Extraction ..................................................... 6
Upstream Extraction .......................................................... 6
Heat Exchanger Piping Arrangements .............................. 6
Refrigeration ...................................................................... 6
Superheat Requirements................................................... 6
Crankcase Heater.............................................................. 7
Pressure Controls .............................................................. 7
IPR Valve .......................................................................... 7
Motor Protection ................................................................ 7
PTC Motor Protection ........................................................ 7
Module Voltage Supply Troubleshooting ........................... 7
Sensor Troubleshooting..................................................... 7
Oil Management for Rack Applications.............................. 8
Discharge Mufflers ............................................................. 8
Compressor Mounting ....................................................... 8
Deep Vacuum Operation ................................................... 9
Unbrazing System Components ........................................ 9
HiPot Testing ..................................................................... 9
Dependence .................................................................... 9
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Application Engineering
Application Engineering
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CoreSense Module LED Overview .....................................10
Product Specifications ........................................................11
Compressor Lead Wiring ...................................................11
CoreSense Module Mounting .............................................11
Demand Wiring ...................................................................11
Protection/Contactor Control Wiring ...................................11
Diagnostics for K5 Compressors ......................................11
Communication Dipswitch Configuration ............................11
Terminations .......................................................................12
COMMISSIONING ..............................................................12
Stand Alone Mode ..............................................................12
for K5 Compressors..........................................................12
CoreSense K5 Programming Instructions ....................... 13-17
Operating Maps ............................................................... 18-21
Typical Suction Tubing........................................................22
Liquid Injection Scroll with DTC Valve ................................23
EVI Scroll with DTC and T-fitting Adapter ...........................23
Circuit Diagram and Cycle for EVI ......................................23
Downstream Extraction ......................................................24
Upstream Extraction ...........................................................24
H/X Piping Arrangement .....................................................24
8 - 15 HP Condensing Unit Mounting .................................24
CoreSense Module Wiring Schematics ..............................25
Discharge Thermistor Connector ........................................26
Top Cap Thermistor ............................................................26
Discharge Line Thermistor .................................................26
CoreSense Terminal Box ....................................................27
Wiring Relay Example ........................................................28
E2 Jumpers ........................................................................28
RS485 Daisy Chain Connection .........................................29
Two Rack Daisy Chain Connection ....................................29
Tables
Injection Accessories ..........................................................30
External Wrap-Around Crankcase Heaters ........................30
Kriwan INT69 Module Specifications ..................................30
K5 Compressor Additional Accessories ..............................31
K5 Compressor (8 to 15 HP) Fitting Sizes..........................31
High and Low Pressure Control Settings............................31
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Diagnostics Fault Codes ...............................32
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Demand Wiring ...................................................................35
K5 DIP Switch Settings .......................................................35
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AE4-1383 R5
December 2012
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Diagnostics
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Summary of Contents for Emerson Copeland Scroll K5 Series

  • Page 1: Table Of Contents

    Copeland Scroll Compressor Functional Check ....10 High and Low Pressure Control Settings......31 CoreSense ™ Diagnostics Fault Codes .......32 CoreSense Diagnostics Module Troubleshooting ..33-34 ™ Demand Wiring ..............35 K5 DIP Switch Settings ............35 © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 2: Safety Instructions

    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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 3: Instructions Pertaining To Risk Of Electrical Shock, Fire, Or Injury To Persons

    • 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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 4: Introduction

    (depending ZB114K5E on the refrigerant this may be as high as 75°F). Refer to Emerson's Product Selection Software for estimated Note! For latest approved refrigerants and lubricants, values by compressor model. refer to Form 93-11, Emerson Accepted Refrigerants/ Lubricants, or contact your Application Engineer.

  • Page 5: Zf*K5E Low Temperature K5 Compressors For Refrigeration

    Liquid Injection • For service purposes, a mechanical ball valve (not When using the ZF*K5E scrolls for liquid injection provided by Emerson) is also recommended in the operation, a discharge temperature control (DTC) liquid and vapor injection line. valve must be applied. The purpose of the DTC valve For the liquid injection system to be effective, a is to eliminate the need for a standard capillary tube.

  • Page 6: Discharge Temperature Control With Vapor Injection

    System Configuration must be given to maintaining proper superheat at the compressor suction inlet. Emerson recommends a There are two methods of controlling refrigerant fl ow at minimum of 20°F (11°C) superheat, measured on the...

  • Page 7: Crankcase Heater

    • Remove the leads from S1-S2, and then by using an temperatures. The thermistor circuit is connected to the Ohmmeter to measure the resistance of the incoming protector module terminals S1 and S2. leads. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 8: Compressor Voltage Supply Troubleshooting

    This mounting arrangement is recommended Copeland K5 refrigeration scrolls may be used on for multiple compressor rack installations. See Figure multiple compressor parallel rack applications. This 7A for a detail of this mounting system. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 9: Connection Fittings, Service Valves And Adapters

    If the refrigerant charge is removed from a scroll pressure rises when the compressor is energized. unit by bleeding the high side only, it is sometimes © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 10: Copeland Scroll Compressor Functional Check

    Table 8 at the end of this document. communicates the alert code and guides the service technician more quickly and accurately to the root cause of a problem. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 11: Product Specifications

    AE4-1383 R5 Product Specifications cycles off or goes into a scheduled pump down. Refer to the wiring diagram in Figure 8 for more detail. Emerson Operating Temp: -40° to 150°F (-40° to 65°C) recommends a general purpose / industrial relay with Storage Temp: -40°...

  • Page 12: Cable Routing / Daisy Chain Configuration

    CoreSense Diagnostics for K5 Compressors for more default parity setting for the CoreSense Diagnostics details on commissioning the K5 scrolls in an Emerson module is no parity. If the switch is set to “on” the Retail Solutions E2 rack controllers.

  • Page 13: Coresense K5 Programming Instructions

    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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
  • Page 14 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 Swi settings and press Enter. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
  • Page 15 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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
  • Page 16 Then Select 4. Compressor (Press Enter) 16. Highlight The Suction Group Field Select F4: Look Up (Press F4) And Select The Appropriate Suction Group For The Device And Press Enter. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
  • Page 17 Application Engineering AE4-1383 R5 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 )

  • Page 18: Figures Operating Maps

    ZF*K5E Low Temperature Vapor Injection** Operating Map (65°F Return Gas) R-407A /R-407C /R-407F Maximum Superheat ** DTC Liquid Injection Required with EVI for R-407A /R-407C/ R-407F Evaporating Temperature (°F) Figure 1B © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
  • Page 19 R-404A/R-507/R-407A/R-407C/R-407F DTC Liquid Injection Required Evaporating Temperature (°F) Figure 1C ZF*K5E Low Temperature Liquid Injection Operating Map (65°F Return Gas) R-22 DTC Liquid Injection Required Evaporating Temperature (°F) Figure 1D © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
  • Page 20 Evaporating Temperature (°F) Figure 1E ZB*K5E Medium/High Temperature Operating Map (65°F Return Gas) R-22 Evaporating Temperature (°F) Figure 1F Note: For operating maps at different return gas conditions, contact your Application Engineer. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
  • Page 21 Figure 1G ZF*K5E (Excluding ZF49K5E) Medium Temperature Operating Map with and without Vapor Injection R-404A/R-507/R-407A/R-407C/R-22* 65°F Maximum Return Gas Evaporating Temperature (°F) *R-22 Not Approved for Vapor Injection Figure 1H © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 22: Typical Suction Tubing

    (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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 23: Liquid Injection Scroll With Dtc Valve

    Application Engineering AE4-1383 R5 Figure 2B Figure 2C Liquid Injection Scroll with DTC Valve EVI Scroll with DTC and T-fitting Adapter Figure 3 – Circuit Diagram and Cycle for EVI © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 24: Downstream Extraction

    027-0400-00 RUBBER GROMMET 027-0383-00 KIT #527-0210-00 KIT# 998-0178-00 STEEL SPACER Figure 7B Figure 7A 8 - 15 HP Condensing Unit 8 - 15 HP Copeland Scroll Compressor Mounting Rack Mounting © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 25: Coresense Module Wiring Schematics

    CoreSense Module. If not used directly connect M1 to M1, M2 to M2, T1 to L1, T2 to L2 Figure 8 – Wiring Schematic with Pressure Safety Control or System Control © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 26: Discharge Thermistor Connector

    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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 27: Coresense Terminal Box

    Control Voltage L2 Control Voltage L1 Motor Protection Module L1 L2 (if needed) Wire from Relay Communication Pressure Cable Back Controls to M2 Thermistor CoreSense Diagnostics Module Figure 12 CoreSense Terminal Box © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 28: K5 Communication Module Dip Switch Settings

    Terminal 9, Jumper To Terminal 13 Terminal 5, Demand Wire Terminal 13, L1 and Jumpered to Terminal 9 Terminal 14, L2 Figure 14 – Wiring Relay Example Figure 15 – E2 Jumpers © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 29: Rs485 Daisy Chain Connection

    Application Engineering AE4-1383 R5 (Terminated) (Terminated) (Terminated) (Terminated) Figure 16 – RS485 Daisy Chain Connection (Terminated) (Terminated) (Terminated) (Terminated) Figure 17 – Two Rack Daisy Chain Connection © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 30: Injection Accessories

    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. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 31: K5 Compressor Additional Accessories

    2 in. Hg Min. ZF* K5E High 400 psig max 335 psig Max 17 psig min. 4 psig min. 37 psig min. ZB*K5E High 450 psig max 263 psig max 381 psig max © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 32: Coresense ™ Diagnostics Fault Codes

    Lockouts Can Be Enabled By Dip Switch 6 Setting Code 8 Displays For 24 Hr After Last Detection The M1-M2 relay only opens during a protection shutdown. To reset module, cycle module power. © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 33: Coresense ™ Diagnostics Module Troubleshooting

    System Trip 1. Excessive suction pressure or discharge Yellow Alert LED Four consecutive compressor trips after pressure 2 Flashes run time of 1-15 minutes each 2. Improper wiring © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.
  • Page 34 2. Compressor current could be too low. Refer to Demand signal is present but current is 7 Flashes specifications. not detected in the correct sequence 3. Verify presence of all legs of power line © 2012 Emerson Climate Technologies, Inc. Printed in the U.S.A.

  • Page 35: Demand Wiring

    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.

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