AE8-1384 Communications for Copeland Scroll Air Instructions

AE8-1384 Communications for Copeland Scroll Air Instructions

Safety Instructions

Copeland Scroll compressors with Core Sense™ Communications are manufactured according to the latest U.S. and European Safety Standards. Particular emphasis has been placed on the user’s safety. Safety icons are explained below and safety instructions applicable to the products in this bulletin are grouped on page 3. These instructions should be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety instructions.

Safety Icon Explanation

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE

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

CAUTION
CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.

WARNING

ELECTRICAL SHOCK HAZARD

• Disconnect and lock out power before servicing.
• Discharge all capacitors before servicing.
• Use compressor with grounded system only.
• Molded electrical plug must be used when required.
• Refer to original equipment wiring diagrams.
• Electrical connections must be made by qualified electrical personnel.
• Failure to follow these warnings could result in serious personal injury.
  

WARNING

PRESSURIZED SYSTEM HAZARD

• System contains refrigerant and oil under pressure.
• Remove refrigerant from both the high and low compressor side before removing compressor.
• Use appropriate back up wrenches on rotalock fittings when servicing.
• 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

WARNING

BURN HAZARD

• Do not touch the compressor until it has cooled down.
• Ensure that materials and wiring do not touch high temperature areas of the compressor.
• Use caution when brazing system components.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury or property damage.

CAUTION

COMPRESSOR HANDLING

• Use the appropriate lifting devices to move compressors.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in personal injury or property damage.

Safety Statements

• Refrigerant compressors must be employed only for their intended use.
• Only qualified and authorized HVAC or refrigeration personnel are permitted to install, commission and maintain this equipment.
• Electrical connections must be made by qualified electrical personnel.
• All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed.

INTRODUCTION

Overview
CoreSense™ Communications is a breakthrough innovation for 20 to 40 ton Copeland Scroll™ air conditioning compressors. The CoreSense Communications module, installed in the compressor electrical box, provides advanced diagnostics, protection, and communications that enhance compressor performance and reliability.

Features
CoreSense Communications has the following key features:

1. Motor temperature protection
2. Scroll high temperature protection
3. Missing phase protection
4. Reverse phase protection
5. Low control circuit voltage protection
6. Short cycling detection and alert
7. Communication to system controller through RS485/Modbus
8. Storage of operational history, runtime information, fault counters, etc.
9. Display of status, warning, and alert information via LEDs

CoreSense Communications provides compressor and system protection through its proprietary lockout feature.
Depending on the severity and frequency of the fault that caused the trip condition,theCoreSense Communications module can lockout the compressor contactor to prevent damage to the compressorand systemcomponents. Less severe fault conditions resulting in an occasional trip will not result in a lockout condition.

Flashing red and green LEDs communicate Status, Warning , and Alert codes to the service technician and the master controller

WARNING

CoreSense Communications modules are not interchangeable with any other brand of motor protection module that may have been previously used with Copeland Scroll compressors.

CoreSense Communications modules are not intended to be used as field retrofits for other motor protection modules that may have been previously used with Copeland Scroll compressors. The motor and scroll

thermistor circuits are configured differently for Copeland Scroll with CoreSense Communications and are not compatible with motor protection modules that were previously used.
Copeland Scroll compressors equipped with CoreSense Communicationswill have an“E”in the electrical code. An example is the 40-ton scroll, ZP485KCE-TED

Module Part Numbers
OEM and service compressors will have the CoreSense Communications module installed in the compressor electrical box. Individually packaged modules are available to the aftermarket for component replacement.
Part numbers for OEM and service applications are listed in Table 1 at the end of this bulletin.

Agency Recognition
CoreSense Communications carries the following agency recognitions:
U.L. file E253322, Volume 7, Software Class B CB Test Certificate

Product Specifications Table 2
CoreSense specifications are shown in Table 2. Many of the electrical specifications are the same as previously used electronic motor protection modules.

115/230 VAC, 50 HZ
Allowable Voltage Range| 18 – 30 VAC| 85 – 265 VAC
T2/T1 Low Voltage Trip| 18 VAC| 85/170 VAC
T2/T1 Low Voltage Reset| 19 VAC| 95/185 VAC
Power Consumption| 5 VA| 5 VA
M1/M2 Contact Rating| 2.5A Max| 2.5A Max
Motor Temperature Trip Resistance| > 4.5KΩ ± 25%| > 4.5KΩ ± 25%
Open Motor Thermistor Trip Resistance| >220KΩ| >220KΩ
Shorted Motor Thermistor Trip Resistance| <40Ω| <40Ω
Temperature Reset Resistance| < 2.75KΩ| < 2.75KΩ
Scroll Temperature Trip Resistance| < 2.4KΩ| < 2.4KΩ
Open Scroll Thermistor Trip Resistance| >370KΩ| >370KΩ
Shorted Scroll Thermistor Trip Resistance| <1KΩ| <1KΩ
Scroll Temperature Reset Resistance| > 5.1KΩ| > 5.1KΩ
Reset Time After Trip| 30 minutes| 30 minutes
Operating Temperature| -40° to 150°F (-40° to 65°C)| -40° to 150°F (-40° to 65°C)
Storage Temperature| -60° to 175°F (-51° to 80°C)| -60° to 175°F (-51° to 80°C)
Scroll High Temp. Trip Set Point| 284°F (165°C)| 284°F (165°C)
Scroll High Temp. Reset Set Point| 230°F (135°C)| 230°F (135°C)

INSTALLATION

Mounting
As mentioned above, CoreSense Communications will be shipped already installed in the compressor electrical box.
Two holding tabs secure the module in the box. To remove the module depress the holding tabs and remove the module.

WARNING
Always disconnect and lockout the power supply before removing the compressor electrical box cover for servicing.

Terminal Description and Basic Field Wiring
Figure 2 at the end of this bulletin shows the CoreSense Communications module. Figures 1a and 1b are the terminal box wiring diagrams. An explanation of the terminal designations follows:
T2-T1: Module power supply, 24 or 120/240 VAC. L1-L2-L3: Phase inputs corresponding to compressor input power L1-L2-L3.

M2-M1: Normally open control circuit contacts; M2-M1 should be wired in series with the compressor contactor.
A (+), GND, B (-): RS485 communications

Temperature Plug: See Figure 3 for identification of the PTC, NTC, and common connections.
When multiple CoreSense Communications modules are networked, a shielded, twisted pair cable such as Belden #8761 (22 AWG) should be used for the communication wiring.

NOTICE
The RS485 is polarity sensitive. When “daisy chaining” modules the A (+) must connect to other A (+) terminals and B (-) must connect to other B (-) terminals.

Dielectric (Hipot) Testing

CAUTION

Use caution with high voltage and never hipot when compressor is in a vacuum.
U.L. sets the requirement for dielectric strength testing and should be consulted for the appropriate voltage and leakage values. CopelandClimate Technologies does not recommend hipot testing at voltages higher than 1,000 VAC.

OPERATION

WARNING
The CoreSense Communications module is a recognized safety device and must be used with all compressors that have TE* electrical codes.

A solid green LED indicates the module is powered and operation is normal. A solid red LED indicates an internal problem with the module. See the Troubleshooting section of thisbulletin formore information onwhat todoif the red LED is solid.

CoreSense Communications communicates Warning codes via a green flashing LED. Warning codes do not result in a trip or lockout condition. Alert codes are communicated via a red flashing LED. Alert codes will result in a trip condition and possibly a lockout condition.

Warning Codes (Green LED Flash Code)
Code 1 – Loss of Communication The module will flash the green Warning LED one time indicating the module has not communicated with the master controller for longer than 5 minutes. Once communication is reinitiated, the Warning will be cleared.
Code 2 – Reserved For Future Use
Code 3 – Short Cycling

The module will flashthe greenWarning LEDthree times indicating the compressor has short cycled more than 48 times in24hours. A short cycle is defined as compressor runtime of less than 3 minutes. The Warning will be activated when the “Short Cycling” dipswitch (#10) is “off” or in the “down” position. When fewer than 48 short cycles are accumulated in 24 hours the Warning code will be cleared.

Code 4 – Open/Shorted Scroll Thermistor The module will flash the greenWarning LEDfour times indicating the scroll NTC thermistor has a resistance value that indicates an open/shorted thermistor (see Table 2). The Warning will be cleared when the resistance value is in the normal range.

Alert/Lockout Codes (Red LED Flash Code)
Code 1 – Motor High Temperature

The module will flash the red Alert LED one time indicating the motor PTC circuit has exceeded 4.5K Ohms ± 25%. A code 1 Alert will open the M2-M1 contacts. The Alert will reset after 30 minutes and the M2-M1 contacts will close if the resistance of the motor PTC circuit is below 2.75K Ohms. Five consecutive Code 1 Alerts will lockout the compressor. Once the module has locked outthe compressor, a power cycle or Modbus reset command will be required for the lockout to be cleared.

Code 2 – Open/Shorted Motor Thermistor The module will flash the red Alert LED two times  indicating the motor PTC thermistor circuit has aresistance value that indicates an open/shorted thermistor chain (see Table 2). A Code 2 Alert will open the M2-M1 contacts. The Alert will reset after 30 minutes and the M2-M1 contacts will close if the resistance of the motor PTC circuit is back in the normal range. The module will lockout the compressor if the trip condition exists for longer than 6 hours

Once the module has locked out the compressor, a power cycle or Modbus reset command will be required to clear the lockout.

Code 3 – Short Cycling

The module will flash the red Alert LED three times indicating the compressor is locked out due to short cycling. A Code 3 Alert will open the M2-M1 contacts.
Code 3 will be enabled when the “Short Cycling” dipswitch (#10) is “on” or in the “up” position and the compressor has exceeded the number of short cycles configured by the user in a 24 hour period. Once the module has locked out the compressor, a power cycle or Modbus reset command will be required to clear the lockout.

Code 4 – Scroll High Temperature The module will flash the red Alert LED four times indicating the scroll NTC circuit is less than 2.4K Ohms. A Code 4 Alert will open the M2-M1 contacts. The Alert will reset after 30 minutes and the M2-M1 contacts will close if the resistance of the scroll NTC circuit is higher than 5.1K Ohms. The module will lockout the compressor if the number of Code 4 Alerts exceeds the user configurable number of Code 4 events within a 24 hour period. Once the module has locked out the compressor, a power cycle or Modbus reset command will be required to clear the lockout.

Code 5 – Reserved for Future Use

Code 6 – Missing Phase

The module will flash the red Alert LED six times indicating a missing phase in one of the three leads to the compressor. A Code 6 Alert will open the M2-M1 contacts. The Alertwill reset after 5 minutes and the M2- M1 contacts will close if the missing phase condition is not present.

Code 7 – Reverse Phase The module will flash the red Alert LED seven times indicating a reverse phase in two of the three leads to the compressor. A Code 7 Alert will open the M2- M1 contacts. The module will lockout the compressor after one Code 7 Alert. A power cycle or Modbus reset command will be required to clear the lockout.

Code 8 – Reserved for Future Use

Code 9 – Module Low Voltage The module will flash the red Alert LED nine times indicating low module voltage (see Table 2) on the T2- T1 terminals for more than 5 seconds. A Code9 Alert will open the M2-M1 contacts. The Alert will reset after 5 minutes and the M2-M1 contacts will close if the T2-T1 voltage is above the reset value in Table 2.
Please see Table 6 for a summary of Warning and Alert codes and troubleshooting information.

Resetting Alert Codes
Resetting Alert codescan beaccomplished intwo different ways. First, Alert codes can be reset manually by cycling power to the module (disconnect T2 or T1 for 5 seconds). The second way to resetAlert codes is to send a Modbus reset command from the master controller.

Power Up Delay
When CoreSense Communications is cycled off, there is a thirteen to fifteen second delay before the module is active.
If the fault that initiated the Alert code is absent after one of the above resets is performed, the Alert code will be cleared and CoreSense will allow normal operation. If the fault is still present after the reset is performed the fault code will continue to be displayed via the green or red flashing LED.

COMMISSIONING

Communications

Programming knowledge and a familiarity with Modbus will be required by the system designer to use the communications features of CoreSense Communications. CoreSense Communications has opto-isolated RS485 for the physical layer. The communication protocol is Standard Modbus and Copeland Modbus. CoreSense Communications willact as the Modbus slave, while the master will be implemented in a system controller, PC software, or any other equivalent external device. Use of the communications feature of CoreSense Communications allows the master access to much of the data that resides in the CoreSense Communications module. Copeland Modbus has six message categories:

1. Device ID Messages
2. CoreSense Status Messages
3. CoreSense History Status Messages
4. Configuration Messages
5. Command Messages
6. Firmware Update Messages

CoreSense status, configuration, history, and device information messages available to the master include those listed in Table 4.

The history status messages give the order in which the Warning/Alert has happened, with the total compressor run time. Information about the Warning/Alert occurrence during the last 7 days and the cumulative Warning/Alert counter are also available.

For more information on CoreSense Communications features and to request Modbus maps please contact your Application Engineer.

DIP Switch Configuration

DIP switch selection for the Modbus address, baud rate, parity, and other operating conditions simplify service and start-up procedures. Table 5 lists the purpose of each switch

NOTICE

The module must be reset after changing any of the DIP switch settings for changes to take effect.
CoreSense Communications modules are shipped from the factory with the DIP switches set to default settings for standalone operation. Default settings are shown in Table
5. Switch 1 is turned “on” as part of a quality control check to verify communications capability of the module before it leaves the compressor manufacturing plant. Switch 9 is also turned “on” for TE* motor code. All other DIP switch default settings are in the “off” position.

NOTICE

If DIP switch settings are inadvertently changed, the compressor will operate, but could have some loss of protection. Scroll temperature protection and short cycle protection could be disabled.
The following stepscovertheDIP switchsettingsthroughout the commissioning process for a multiple compressor system with communications.

1. Switches 1 through 5 are used for setting the device address. DIP switch 1 is the least significant bit (LSB) and switch 5 is the most significant bit (MSB). DIP switch addresses 0 through 31 are shown in Figure4. Each CoreSense Communications module that is daisy chained and connected to a master controller must have a unique node address (as determined by the DIP switch settings).
2. Switch 6 defines the communication baud rate for the CoreSense Communications module. If the switch is “off”, the baud rate is 19200. If the switch is “on” the baud rate is 9600. The baud rate of each CoreSense Communications module should be set to match the master controller baud rate.
3. Switch 7definesthe communicationsparity.Thedefault parity setting for the CoreSense Communications module is no parity. If the switch is set to “on” the module will communicate using even parity. The parity setting must match the parity setting of the master controller.
4. Switch 8 defines the control mode. The default setting is standalone mode (off). If communications with a master controller is desired, switch 8 should be turned “on” to network.
5. Switch 9 defines the thermistor configuration. If the compressorhas avoltage code of TE, the compressor has PTC and NTC thermistors for motor and scroll temperature protection. If the compressor voltage code is TW, the compressor has only PTC thermistors for motor and scroll temperature protection. The default setting is “on” for PTC and NTC thermistor types.
6. Switch 10 enables short cycling protection if turned “on”. The default setting is “off”.

Jumper Setting
CoreSense Communications modules are shipped with the jumper installed. For standalone operation the jumper should remain installed. For daisy chained applications the jumper should remain installed for the modules on the ends of the daisy chain. All other jumpers in the sequence of daisy chained modules should be removed. The jumper can be removed using miniature electronics needle nose pliers.
PC Interface Software
PC interface software is available from Copeland Online Product Information (OPI). The PC interface software allows the design engineer access to status, configuration, history, and data logging via a computer. This method of connecting and communicating with CoreSense is very helpful during the unit development stage if CoreSense is in stand-alone mode and notcommunicating with a master controller.

The RS-485/USB adapterused to connectthe laptopto the CoreSense is Copeland part number 929-0011-00. For more information on the PC interface software, how to obtain it, and a tutorial on its use, please contact your Application Engineer.
SERVICE
Field Service
Service compressors will be shipped with the CoreSense Communications module installed in the compressor terminal box. Special attention should be given to the module DIP switch settings of the compressor being replaced so the DIP switch settings can be transferred to the module of the replacement compressor. As mentioned earlier, the CoreSense Communications module is a recognized safety device and shall be used only with approved compressors with TE* motor codes.

NOTICE

If a compressor with CoreSense Communications fails in the field, the CoreSense module shouldremain with the failed compressor so Copeland technicians can download the CoreSense data to assist with determining the root cause of compressor failure.
Troubleshooting

WARNING
Always disconnect and lockout the power supply before removing the compressor electrical box cover for servicing.
For troubleshooting purposes, the scroll and motor thermistor circuits are similar to those of other Copeland.

Scrolls with one exception, the scroll thermistor is a negative temperature coefficient (NTC) type thermistor.
This means that as the dis-charge temperature increases, the resistance of the thermistor decreases. The motor has positive temperature coefficient (PTC) type thermistors; as themotortemperature increases,so does the resistance of thethermistor chain.Tomeasure the resistance of thePTC and NTC circuits simply remove the temperature plug from the CoreSense module and measure the resistance in the appropriate pins shown in Figure 3. The measured values should be in the ranges listed in Table 2. For information on trouble shooting causes of high motor and scroll temperatures please refer to the application engineering bulletin for the compressor.

A loss of communications with the master controller for more than five minutes is communicated via a green flash code 1 if DIP switch #8 is enabled. CoreSense Communications has no provisions to detect incorrect wiring neither between daisy chained modules nor to the master controller. Ideally, the master controller will contain advanced troubleshooting menus for help in diagnosing communications issues between the master controller and the CoreSense module.

NOTICE

In some rarecases communication betweenthemaster controller and the CoreSense module is problematic.
Reversing the polarity will re-initiate communication.
To reverse polarity:

1. Adjust CoreSense to negative
2. Adjust master controller to positive

115/230 VAC, 50 HZ
Allowable Voltage Range| 18 – 30 VAC| 85 – 265 VAC
T2/T1 Low Voltage Trip| 18 VAC| 85/170 VAC
T2/T1 Low Voltage Reset| 19 VAC| 95/185 VAC
Power Consumption| 5 VA| 5 VA
M1/M2 Contact Rating| 2.5 A Max| 2.5 A Max
Motor Temperature Trip Resistance| > 3.52 kΩ ± 25%| > 3.52 kΩ ± 25%
Open Motor Thermistor Trip Resistance| > 220 kΩ| > 220 kΩ
Shorted Motor Thermistor Trip Resistance| < 41 Ω| < 41 Ω
Temperature Reset Resistance| < 2.2 kΩ| < 2.2 kΩ
Scroll Temperature Trip Resistance| < 1.33 kΩ| < 1.33 kΩ
Open Scroll Thermistor Trip Resistance| > 324.3 kΩ| > 324.3 kΩ
Shorted Scroll Thermistor Trip Resistance| < 1k Ω| < 1k Ω
Scroll Temperature Reset Resistance| > 2.66 kΩ| > 2.66 kΩ
Reset Time After Trip| 30 minutes| 30 minutes
Operating Temperature| -40° to 150°F (-40° to 65°C)| -40° to 150°F (-40° to 65°C)
Storage Temperature| -40° to 150°F (-40° to 65°C)| -40° to 150°F (-40° to 65°C)
Scroll High Temp. Trip Set Point| 329°F (165°C)| 329°F (165°C)
Scroll High Temp. Reset Set Point| 275°F (135°C)| 275°F (135°C)

115/230 VAC. 50 Hz
Allowable Voltage Range| 18 – 30 VAC| 85 – 265 VAC
T2/T1 Low Voltage Trip| 18 VAC| 85/170 VAC
T2/T1 Low Voltage Reset| 19 VAC| 95/185 VAC
Power Consumption| 5 VA| 5 VA
M1/M2 Contact Rating| 2.5 A max| 2.5 A max
Motor Temperature Trip Resistance| > 3.52 kΩ ± 25%| > 3.52 kΩ ± 25%
Open Motor Thermistor Trip Resistance| > 220 kΩ| > 220 kΩ
Shorted Motor Thermistor Trip Resistance| < 41 Ω| < 41 Ω
Temperature Reset Resistance| < 2.2 kΩ| < 2.2 kΩ
Scroll Temperature Trip Resistance| < 1.66 kΩ| < 1.66 kΩ
Open Scroll Thermistor Trip Resistance| > 324.3 kΩ| > 324.3 kΩ
Shorted Scroll Thermistor Trip Resistance| < 1k Ω| < 1k Ω
Scroll Temperature Reset Resistance| > 3.43 kΩ| > 3.43 kΩ
Reset Time After Trip| 30 minutes| 30 minutes
Operating Temperature| -40° to 150°F (-40° to 65°C)| -40° to 150°F (-40° to 65°C)
Storage Temperature| -40° to 150°F (-40° to 65°C)| -40° to 150°F (-40° to 65°C)
Scroll High Temp. Trip Set Point| 311°F (155°C)| 311°F (155°C)
Scroll High Temp. Reset Set Point| 257°F (125°C)| 257°F (125°C)

Table 3 – CoreSense Communications Accessory Parts

Table 4 – CoreSense Modbus Map

NOTE: Number of registers value to be send in the query = Number in the column “Message Length With Zero Stuffing” / 2 (e.g. number of reg required to read “Seven day Warning history with cumulative count” is 36 (72/2)

Read Only Data

Read Write Data
Write Only Data

Parameters can be read using Function code 4 (Read Input Register)

Location in Hex|

Parameter

| Message Length in Bytes| Message Length With Zero Stuffing|

Description

300| CoreSense Module Firmware Version|

8

|

16

|
308| CoreSense Module Model Number|

12

|

24

314| ASSET Serial Number|

12

|

24

320| ASSET Model Number|

18

|

36

332| CoreSense Module Serial Number|

11

|

22

33D| Division Name|

29

|

58

35A| Product Code|

9

|

18

363| Product Name|

7

|

14

36A|

Product type

| 1|

2

36B| Endian Convention|

1

|

2

36C| Dip switch Setting|

2

|

2

Unused (18 bytes)
380| Alarm Code| 1| 2| 0  – Normal Operation1  – Loss of Communication to E22 – Open OR Short Spare Thermistor Warning3  – Open OR Short Scroll Thermistor Warning4  – Short Cycle Warning5  – Module Low Voltage Trip6  – Spare High Temperature Trip7  – Missing Phase Trip8  – Scroll High Temperature Trip9  – Motor Thermistor Open OR Short Trip10  – Motor High Temperature Trip11  -Short Cycle Lockout12  – Spare High Temperature Lockout13  – Motor High Temperature Open OR Short Lockout14  – Reverse Phase Lockout15  – Missing Phase Lockout16 – Scroll High Temperature Lockout17  – Motor High Temperature Trip Lockout18 – P47 Module Failure

Unused (18 bytes) – continued

381| **** Input and Output status| **** 4| **** 4| 0x0001 – PTC Status (OK-1/Not OK-0)0x0002 – Scroll High Temp NTC Status (OK-1/Not OK-0) 0x0004 – Spare Temp NTC Status (OK-1/Not OK-0) 0x0008 – L1 Voltage Status (Present-1/Absent-0) 0x0010 – L2 Voltage Status (Present-1/Absent-0) 0x0020 – L3 Voltage Status (Present-1/Absent-0) 0x0040 – Line Phase Voltage Status (OK-1/Not OK-0) 0x0080 – Line Reverse Voltage Status (OK-1/Not OK-0) 0x0100 – Pilot Voltage Status (OK-1/Not OK-0)
385| Scroll Temperature Value| 2| 2| (Scroll High Temp Sensor Value) Range = -0°C to 655.36°C
387| Spare Temperature Value| 2| 2| (Spare Temp Sensor Value) Range = -0°C to 655.36°C
389| Pilot Voltage Value| 2| 2| Pilot Voltage Value – Range 0 to 655.36 V
Unused (117 bytes)
400| Ten most recent alarms with time stamp| 40| 60|
428| Compressor run history with cumulative count| 11| 20
433| Compressor start history with cumulative count| 19| 20
446| Short Cycle history with cumulative count| 11| 20
Unused (30 bytes)
46F| Seven day Warning history withcumulative count| 40| 72|
497| Seven day Trip history with cumulative count| 60| 108
4D3| Seven day Lockout history with cumulative count| 70| 126

Table 4 – CoreSense Modbus Map Continued

Parameters can be read using Function code 3 (Read Holding Register)

Location in Hex| Parameter| Message Length in Bytes| Message Length With Zero Stuffing
100| Customer Id Code| 4| 8
104| Customer Location| 17| 34
115| Customer Name| 17| 34
126| Compressor Model Number Modified| 18| 36
138| Compressor serial number| 12| 24
144| Application code| 3| 6
147| Temperature code| 4| 8
14B| Refrigerant code| 7| 14
152| Functional Configuration| 2| 2
154| Compressor run time to count as short cycle| 1| 2
155| Scroll High Temp Trip| 2| 2
157| Scroll High Temp Reset| 2| 2
15A| Future Use| 1| 2
15B| Future Use| 2| 2
15D| Future Use| 2| 2
15F| No. of Events to Scroll High Temp Lockout| 1| 2
160| No. of Events to Short Cycling Warning/Lockout| 1| 2

Parameters can be write using Function code 16 (Preset Multiple Registers)

**Location in Hex| ****Parameter| Message Length in Bytes| Message Length With Zero Stuffing| ****Range| ****Default
100| Customer Id Code| 4| 8| |
104| Customer Location| 17| 34
115| Customer Name| 17| 34
126| Compressor Model Number Modified| 18| 36
138| Compressor serial number| 12| 24
144| Application code| 3| 6
147| Temperature code| 4| 8
14B| Refrigerant code| 7| 14
152| Functional Configuration| 2| 2
154| Compressor run time to count as short cycle| 1| 2| Range: 1 min to 6 min| 3
155| Scroll High Temp Trip| 2| 2| Range: 110 deg C to 150 deg C| 140
****157| ** Scroll High Temp Reset| 2| 2| Note: Reset set point value should be always (Trip set point value – 30 deg C)|
15A| Future Use| 1| 2| |
15B| Future Use| 2| 2| |
15D| Future Use| 2| 2| |
15F| No. of Events to Scroll High Temp Lockout| 1| 2| Range: 4 to 36| 20
160| *No. of Events to Short Cycling Warn- ing/Lockout| 1| 2| Range: 20 to 200| 48
**16A| ** Write Command| 2| 2| Options: 0x0800 (Alarm Reset) & 0x8000 (Module Reset)|

Table 5 – DIP Switch Purpose

1 Thermistor Configuration: TE = PTC & NTC (3 wire connectors), TW = PTC only (2 wire connectors)

Table 6 – CoreSense™ Communications LED Flash Code Information

The flash code number corresponds to the number of LED flashes, followed by a pause, and then the flash code is repeated. A lockout condition produces a red flash, followed by a pause, a solid red, a second pause, and then repeated.

Status| Fault Condition| Code Fault Description| Code Reset Description| Trouble Shooting Information
---|---|---|---|---
Solid Green| Normal Operation| Module is powered and operation is normal| N/A| N/A
Solid Red| Module Malfunction| Module has internal fault| N/A| 1) Reset module by removing power from T2- T12)  Replace module
Warning LED Flash
Green Flash Code 1| Loss of Communication| Module and master controller have lost communications with each other for morethan 5 minutes| Whencommunications are confirmed| 1)  Check the control wiring2)  Verify dipswitch 8 is “on”
Green Flash Code 2| Future Use| N/A| N/A| N/A
Green Flash Code 3| Short Cycling| Run time of less than 3 minutes; number of shortcycles exceeds 48 in 24 hours| < 48 short cycles in 24 hours|

1. Check system charge and pressure control setting2)  Adjust set-point of temperature controller3)  Install anti-short cycling control
   Green Flash Code 4| Open/ Shorted Scroll Thermistor| Ω > 370K or Ω < 1K| 5.1K < Ω < 370K| 1) Check for poor connections at module and thermistor fusite2)  Check continuity of thermistor wiring harness
   Green Flash Code 5| Future Use| N/A| N/A| N/A

Alert/Lockout LED Flash

Red Flash Code 1| **Motor High Temperature| ** Ω > 4.5K ± 25%;Lockout after 5 Alerts| Ω < 2.75K and 30 minutes| 1)  Check supply voltage2) Check system charge & superheat3)  Check contactor
**** Red Flash Code 2| **Open/Shorted Motor Thermistor| ** Ω > 220K or Ω < 40;Lockout after 6 hours| **** 40 < Ω < 2.75K and 30minutes| 1) Check for poor connections at module and thermistor fusite2)  Check continuity ofthermistor wiring harness
**** Red Flash Code 3| **Short Cycling| Run time of less than 3 minutes; Lockout if the number of Alerts exceeds the number configured by the user in 24 hours| ** Interrupt power to T2-T1 or performModbus reset command| 1) Check system charge and pressure control setting2) Adjust set-point of temperature controller3) Install anti-short cycling control
**** Red Flash Code 4| **Scroll High Temperature| Ω < 2.4K; Lockout if the number of Alerts exceeds the number configured by the user in 24 hours| ** Interrupt power to T2-T1 or perform Modbus reset command| 1) Check system charge and superheat2) Check system operating conditions3) Check for abnormally low suction pressure
Red Flash Code 5| Future Use| N/A| N/A| N/A
Red Flash Code 6| **Missing Phase| ** Missing phase| After 5 minutes and missing phase condition is notpresent| 1)  Check incoming power2) Check fuses/breakers3)  Check contactor
Red Flash Code 7| **Reverse Phase| ** Reverse phase; Lockout after 1 Alert| ** Interrupt power to T2-T1 or performModbus reset command| 1) Check incoming phase sequence2)  Check contactor3) Check module phasing wires A-B-C
Red Flash Code 8| Future Use| N/A| N/A| N/A
** Red Flash Code 9| **Module Low Voltage| ** Low voltage on T2-T1 terminals1| After 5 minutes and the voltage is back in the normal range| 1)  Verify correct module p/n2) Check VA rating of transformer3) Check for blown fuse in transformer secondary

Figure 1a – Terminal Box Wiring Diagram (Excluding Models Listed Below)

Figure 1b – ZP236/296 Terminal Box Wiring Diagram

Figure 1c – ZP233/293, YA219/275 & YP233/293 Terminal Box Wiring Diagram

Figure 2 – Core Sense Communications Module

Figure 3 – Thermistor Circuit Cable

Figure 4 – Modbus Addressing

The contents of this publication are presented for informational purposes only and they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Copeland reserves the right to modify the designs or specifications of such products at any time without notice. Copeland does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Copeland product remains solely with the purchaser and end-user.

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