Emerson Copeland Scroll K5 Series User guide

1
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Application Engineering
BULLETIN
Application Guidelines for ZF*K5E & ZB*K5E Copeland Scroll™
K5 Compressors for Refrigeration 8-15 HP with CoreSense™Diagnostics
AE4-1383 R5 December 2012
TABLE OF CONTENTS
Section Page Section Page
Safety
Safety Instructions.............................................................2
Safety Icon Explanation..................................................... 2
Instructions Pertaining to Risk of Electrical Shock,
Fire, or Injury to Persons ................................................3
Safety Statements .............................................................3
Introduction
Nomenclature ....................................................................4
Approved Refrigerants.......................................................4
Operating Envelope........................................................... 4
Extended ZF*K5E Operating Envelope.............................4
ZF*K5E Low Temperature K5 Compressors for
Refrigeration......................................................................5
Liquid Injection for Discharge Temperature Protection........4
DTC Valve Specifications .................................................. 5
Installation of DTC Valve ................................................... 5
Suggested Application Techniques for the DTC Valve ......5
Vapor Injection...................................................................5
Discharge Temperature Control with Vapor Injection ........6
System Configuration ........................................................6
Downstream Extraction .....................................................6
Upstream Extraction..........................................................6
Heat Exchanger Piping Arrangements ..............................6
ZB*K5E Medium Temperature K5 Compressors for
Refrigeration......................................................................6
Superheat Requirements...................................................6
Crankcase Heater..............................................................7
Pressure Controls.............................................................. 7
IPR Valve ..........................................................................7
Motor Protection ................................................................7
PTC Motor Protection........................................................7
Programmable Logic Controller Requirements .................7
Kriwan INT69 Module and Sensor Functional Check........ 7
Module Voltage Supply Troubleshooting ...........................7
Sensor Troubleshooting.....................................................7
Compressor Voltage Supply Troubleshooting ...................8
Oil Management for Rack Applications..............................8
Discharge Mufflers.............................................................8
Compressor Mounting .......................................................8
Connection Fittings, Service Valves and Adapters ............ 9
Deep Vacuum Operation ................................................... 9
Unbrazing System Components........................................ 9
HiPot Testing ..................................................................... 9
Three Phase Scroll Compressors – Directional
Dependence ....................................................................9
Copeland Scroll Compressor Functional Check............... 10
CoreSense™Diagnostics Module for K5 Compressors ....10
CoreSense Module LED Overview.....................................10
Product Specifications........................................................11
Compressor Lead Wiring ...................................................11
CoreSense Module Mounting.............................................11
110-220VAC CoreSense Module Power Wiring .................11
Demand Wiring...................................................................11
Protection/Contactor Control Wiring...................................11
Discharge Temperature Protection with CoreSense
Diagnostics for K5 Compressors......................................11
Communication Dipswitch Configuration............................11
Cable Routing / Daisy Chain Configuration........................12
Terminations .......................................................................12
COMMISSIONING..............................................................12
Stand Alone Mode ..............................................................12
MODBUS Communication to CoreSense Diagnostics
for K5 Compressors..........................................................12
CoreSense K5 Programming Instructions .......................13-17
Figures
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 Copeland Scroll Compressor Rack Mounting ....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
K5 Communication Module DIP Switch Settings................28
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
CoreSense™Diagnostics Fault Codes ...............................32
CoreSense™Diagnostics Module Troubleshooting .........33-34
Demand Wiring...................................................................35
K5 DIP Switch Settings.......................................................35

2
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Safety Instructions
Copeland Scroll™compressors with CoreSense™Diagnostics technology are manufactured according to the
latest U.S. and European Safety Standards. Particular emphasis has been placed on the user's safety. Safey
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 indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
CAUTION, without the safety alert symbol, is used to address practices
not related to personal injury.
DANGER
WARNING
CAUTION
NOTICE
CAUTION

3
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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.
•
• Failure to follow these warnings could result in serious personal injury.
PRESSURIZED SYSTEM HAZARD
• System contains refrigerant and oil under pressure.
• Remove refrigerant from both the high and low compressor side before
removing compressor.
•
• Never install a system and leave it unattended when it has no charge,
a holding charge, or with the service valves closed without electrically
locking out the system.
• Use only approved refrigerants and refrigeration oils.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury.
BURN HAZARD
• Do not touch the compressor until it has cooled down.
• Ensure that materials and wiring do not touch high temperature areas of
the compressor.
• Use caution when brazing system components.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in serious personal injury or
property damage.
COMPRESSOR HANDLING
• Use the appropriate lifting devices to move compressors.
• Personal safety equipment must be used.
• Failure to follow these warnings could result in personal injury or
property damage.
Safety Statements
• Refrigerant compressors must be employed only for their intended use.
•
install, commission and maintain this equipment.
•
• All valid standards and codes for installing, servicing, and maintaining electrical and
refrigeration equipment must be observed.
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
WARNING
WARNING
CAUTION

4
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
CAUTION
POE must be handled carefully and the proper
protective equipment (gloves, eye protection, etc.)
must be used when handling POE lubricant. POE
must not come into contact with any surface or
material that might be harmed by POE, including
without limitation, certain polymers (e.g. PVC/CPVC
and polycarbonate).
Operating Envelope
Operating envelopes for the K5 compressors for
refrigeration are depicted in Figures 1A through 1H at
the end of this bulletin.
Extended ZF*K5E Operating Envelope
Figure 1H presents an extended envelope for the
ZF*K5E scroll. While this product is optimized for a low
temperature application, in some instances the ZF*K5E,
either with vapor injection or no injection at all, can be
applied in a medium temperature application. This may
be done to use common model numbers in a system or
to apply vapor injection for additional cooling capacity.
When applying with vapor injection, it should be noted
that the total amount of internal subcooling is limited
by the injection pressure at the compressor. In medium
temperature operation, this value is typically higher
than when a ZFK5 is applied at low temperature and
therefore the minimum subcooled liquid temperature
allowable exiting the economizer is higher (depending
on the refrigerant this may be as high as 75°F). Refer
to Emerson's Product Selection Software for estimated
values by compressor model.
Note! If applying without vapor injection the injection
port should be plugged. The vapor injection fitting is a
Rotalock design with a 1” x 14 rotalock thread size, the
fitting can be capped using the rotalock to stub tube
adaptor kit # 998-0034-18. A ½” copper line can be
inserted into the stub end of the adaptor and sealed off.
The rotalock adaptor with the supplied Teflon seal will
effectively seal the port and will not damage the fitting
or the compressor.
Introduction
The Copeland Scroll™ refrigeration compressor product
offering has developed the K5 compressor for the 8 to
15 HP size range. The scope of this bulletin will cover
the application parameters unique to the ZB*K5E
and ZF*K5E refrigeration scrolls with CoreSense™
technology.
Nomenclature
The Copeland Scroll compressor model numbers
include the nominal capacity at the standard 60 Hertz
“ARI” rating conditions with R-404A refrigerant.
Example
ZB76K5E-TFD-260
Z= Copeland Scroll
B= Application (B: Medium Temperature,
F: Low Temperature)
76K = Nominal Capacity (kBtu/hr)
5= Model Variation Identifier for the
K5 refrigeration scroll
E= Oil Type (POE)
TFD = Motor Version
260 = Build of Materials
Approved Refrigerants
Application Model
Number HP Approved Refrigerants
Low
Temperature
ZF34K5E 10 R-404A, R-507,
R-407A/C, R-22,
R-407F
ZF41K5E 13
ZF49K5E 15
Medium
Temperature
ZB58K5E 8
R-404A, R-507,
R-407A/C, R-22,
R-134a, R-407F
ZB66K5E 9
ZB76K5E 10
ZB95K5E 13
ZB114K5E 15
Note! For latest approved refrigerants and lubricants,
refer to Form 93-11, Emerson Accepted Refrigerants/
Lubricants, or contact your Application Engineer.
Note! The ZB*K5 compressors are each applicable with
R-134a, however, Emerson Climate Technologies has
released the ZB*K5B series for optimum performance
for lower R-134a-like pressures. See following table for
specific model numbers.
Optimized R-134a ZB*K5B Compressors
Model Hertz Voltage Capacity EER
ZB47K5B-TFD 60 460 46,500 7.38
50 380/420 38,500 7.33
ZB59K5B-TFD 60 460 49,600 7.04
50 380/420 59,500 7.04
ZB68K5B-TFD 60 460 68,700 7.25
50 380/420 57,000 7.25

5
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
ZF*K5E Low Temperature K5 Compressors for
Refrigeration
The low temperature models are provided with an
injection port that can be used for either liquid or vapor
injection.
Liquid Injection
When using the ZF*K5E scrolls for liquid injection
operation, a discharge temperature control (DTC)
valve must be applied. The purpose of the DTC valve
is to eliminate the need for a standard capillary tube.
The DTC valve is approved for all refrigerants in
this product range. A DTC valve must also be used
for ZF**K5E applications with R-407A, R-407C and
R-407F (R-407A/C/F) with vapor injection via a special
T-fitting adapter. Further details and part numbers
related to the DTC valve are listed in Table 1 at the
end of this bulletin.
DTC Valve Specifications
The following components are not required, but they
are recommended for liquid injection.
• Sight Glass - A sight glass can be installed before
the DTC valve to allow for visual inspection for the
presence of liquid refrigerant.
• Filter/Drier - A filter/drier should be installed
upstream of the injection circuit to avoid the
possibility of the DTC screen blockage due to
contaminants.
Figures 2A through 2C are a representation of typical
systems, depicting the location of these components
Installation of DTC Valve
The valve bulb must be installed in the top cap thermal
well to adequately control scroll temperatures. The
valve should be tightened on the injection fitting to
a torque of 216-245 in. lbs. (24.4 - 27.7 Nm). A 90°
orientation on the valve is recommended, however it will
function properly in any orientation. The capillary tube
connecting the valve to the bulb should be positioned
such that it does not contact the compressor during
operation. Do not bend the capillary tube within 1”
(25.4mm) of the valve.
The DTC valve comes with an insulating cap. If this
additional height from the cap is an issue, the valve
cap could be replaced with high temperature insulation.
This should be applied to insulate and protect the valves
remote bulb assembly. This will reduce the total height
requirement by 0.5” (12.7mm).
Suggested Application Techniques for the DTC
Valve
For the most efficient thermal sensing, spread a thin film
of thermal grease around the DTC valve bulb before
installing into the top cap well. However for proper
functioning of the valve this is not required.
• For service purposes, a mechanical ball valve (not
provided by Emerson) is also recommended in the
liquid and vapor injection line.
For the liquid injection system to be effective, a
minmum of 5°F subcooled liquid at the at the DTC inlet
is required.
Note! To ensure adequate temperature control,
take care to not damage the DTC valve bulb when
installing.
Vapor Injection
The ZF*K5E 8-15 HP scrolls can also be applied with
vapor injection by implementing an economizer circuit
in the system. Economizing is accomplished by utilizing
a subcooling circuit similar to that shown in Figure 3 at
the end of this bulletin. This mode of operation increases
the refrigeration capacity and in turn the efficiency of
the system.
The schematic shows a system configuration for
the economizer cycle. A heat exchanger is used to
provide subcooling to the refrigerant before it enters
the evaporator. This subcooling process provides the
increased capacity gain for the system, as described
above. During the subcooling process a small amount
of refrigerant is evaporated and superheated. This
superheated refrigerant is then injected into the mid
compression cycle of the scroll compressor and
compressed to discharge pressure. This injected vapor
also provides cooling at higher compression ratios, similar
to liquid injection of standard ZF scroll compressors. The
benefits provided will increase as the compression ratio
increases, thus, more gains will be made in summer
when increased capacity may actually be required.
An example of the additional capacity available when
using vapor injection is depicted in the following table.
ARI Low Temperature Ratings
(-25°F/105°F, R-404A)
Model With EVI* Without EVI*
ZF34K5E 48,100 Btu/hr 34,200 Btu/hr
ZF41K5E 57,500 Btu/hr 42,200 Btu/hr
ZF49K5E 71,000 Btu/hr 50,500 Btu/hr
* Maximum possible subcooling
* Without EVI is “0” subcooling

6
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Note: For performance of ZF*K5E models with other
refrigerants, refer to the Online Product Information at
www.emersonclimate.com
Discharge Temperature Control with Vapor Injection
Although using vapor injection offers some inherent
compressor cooling, when using the ZF*K5E scrolls
with R-407A/C/F and vapor injection additional cooling
is required to operate across the whole operating
map of the compressor. To provide this extra cooling
a t-fitting and DTC valve should be installed onto the
compressor's injection port. The t-fitting will meter
liquid from the DTC valve into one side of the fitting,
while vapor flows in through the otherside. See Figure
4C at the end of this bulletin for a example schematic.
This is different than the current method used on other
Copeland vapor injected scrolls (ZF*KVE models) which
use the Copeland Demand Cooling to inject liquid in the
vapor line of the compressor based on a discharge line
temperature reading.
Note! Just as with liquid injection operation, when using
the DTC valve with vapor injection ensure that the
thermal bulb is well insulated.
When using vapor injection with R-404A/R-507, the
DTC valve and t-fitting are not required. A discharge line
thermistor is supplied with the CoreSense diagnostics
assembly (more information on CoreSense diagnostics
is found later in this bulletin). The thermistor should
be placed no more than 6 inches (15.2 cm) from the
discharge of the compressor. The thermistor should be
well insulated to ensure accurate temperature sensing
on the discharge line.
System Configuration
There are two methods of controlling refrigerant flow at
the EVI heat exchanger - downstream and upstream
extraction.
Downstream Extraction
The downstream extraction is the preferred method
employed in the United States. In downstream
extraction the TXV is placed between the liquid outlet
and vapor inlet of the heat exchanger. The advantage
of downstream extraction is that subcooling is ensured
because the liquid is further subcooled as it flows
through the heat exchanger. Therefore, more subcooled
liquid enters the TXV which increases the probability
that the valve will not hunt. The disadvantage with this
method is that it is not as efficient as the upstream
method; however, the difference is too small for
practical purposes. See Figure 4.
Upstream Extraction
In upstream extraction the TXV is placed between
the condenser and the heat exchanger. The TXV
regulates the flow of subcooled refrigerant out of the
condenser and into the heat exchanger. With this type
of configuration there is a potential for flash gas which
would cause the valve to hunt. See Figure 5.
Heat Exchanger Piping Arrangements
Best subcooling effect is assured if counter flow of
gas and liquid is provided as shown (see Figure 6).
In order to guarantee optimum heat transfer, the plate
heat exchanger should be mounted vertically and
vapor should exit it at the top.
For more information on applying ZF*K5E scrolls with
an economized vapor injection (EVI) circuit refer to AE4-
1327, Economized Vapor Injection (EVI) Compressors.
Accumulator Requirements
Due to the Copeland Scroll compressor's inherent
ability to handle liquid refrigerant in flooded start and
defrost operation conditions, accumulators may not
be required. An accumulator is required on single
compressor systems with refrigerant charges over
17 lbs. On systems with defrost schemes or transient
operations that allow prolonged, uncontrolled liquid
return to the compressor, an accumulator is required
unless a suction header of sufficient volume is used to
prevent liquid migration to the compressor.
Superheat Requirements
In order to assure that liquid refrigerant does not return
to the compressor during the running cycle, attention
must be given to maintaining proper superheat at the
compressor suction inlet. Emerson recommends a
minimum of 20°F (11°C) superheat, measured on the
suction line 6 inches (152mm) from the suction valve,
to prevent liquid refrigerant floodback.
Another method to determine if liquid refrigerant is
returning to the compressor is to accurately measure
the temperature difference between the compressor
oil crankcase and the suction line. During continuous
operation we recommend that this difference be a
minimum of 50°F (27°C). This “crankcase differential
temperature” requirement supersedes the minimum
suction superheat requirement in the last paragraph. To
measure oil temperature through the compressor shell,
place a thermocouple on the bottom center (not the side)
of the compressor shell and insulate from the ambient.
During rapid system changes, such as defrost or ice
harvest cycles, this temperature difference may drop

7
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
rapidly for a short period of time. When the crankcase
temperature difference falls below the recommended
50°F (27°C), our recommendation is the duration should
not exceed a maximum (continuous) time period of two
minutes and should not go lower than a 25°F (14°C)
difference.
Contact your Emerson Climate Technologies
representative regarding any exceptions to the above
requirements.
Crankcase Heater
Crankcase heaters are required, on outdoor systems,
when the system charge exceeds 17 lbs.
Table 2 includes crankcase heaters intended for use
only where there is limited access. The heaters are
not equipped for use with electrical conduit. Where
applicable electrical safety codes require heater lead
protection, a crankcase heater terminal box should be
used. Recommended crankcase heater terminal cover
and box numbers are also listed in Table 2 If there
are any questions concerning the application, contact
Application Engineering.
Pressure Controls
Both high and low pressure controls are required. The
minimum and maximum pressure setpoints are shown
in Table 4 at the end of this bulletin.
IPR Valve
There is no internal pressure relief valve in these larger
horsepower scrolls. Therefore a high pressure control
located prior to any shut-off valves is mandatory. There
is an access port located on the compressor discharge
rotalock fitting to accommodate this control.
Motor Protection
Motor protection in the K5 compressor for refrigeration is
either by internal line break (ILB) or solid state protection
with positive temperature coefficient (PTC) sensors. The
type of motor protection is based on the compressor
motor version. An "F" in the second character indicates
line break while a "W" indicates PTC protection. For
example, a ZF34K5E-TFC has ILB and a ZB95K5E-
TWC uses PTC sensors.
PTC Motor Protection
There are four PTC (Positive Temperature Coefficient)
internal thermistors connected in series that react
with avalanching resistance in the event of high
temperatures. The thermistors are used to sense motor
temperatures. The thermistor circuit is connected to the
protector module terminals S1 and S2.
When any thermistor reaches a limiting value, the
module interrupts the control circuit and shuts off the
compressor. After the thermistor has cooled sufficiently,
it will reset. However, the module has a 30 minute time
delay before reset after a thermistor trip.
Programmable Logic Controller Requirements
If the INT69 (071-0660-00) module is applied in
conjunction with a Programmable Logic Controller, it is
important that a minimum load is carried through the
M1-M2 control circuit contacts.
The minimum required current through the module
relay contacts needs to be greater than 100 milliamps
but not to exceed 5 amps. If this minimum current is
not maintained, this has a detrimental effect upon the
long-term contact resistance of the relay and may result
in false compressor trips.
PLC operated control circuits may not always provide
this minimum current. In these cases modifications
to the PLC control circuit are required. Consult your
Application Engineering Department for details.
Kriwan INT69 Module and Sensor Functional Check
Module specifications are listed in Table 3 at the end of
this bulletin. Refer to Figure 2 for wiring schematic. The
following field troubleshooting procedure can be used
to evaluate the solid state control circuit:
Motor Protector Module Voltage Supply
Troubleshooting
• Verify that all wire connectors are maintaining a good
mechanical connection. Replace any connectors that
are loose.
• Measure the voltage across T1-T2 to ensure proper
supply voltage.
• Determine the control voltage by using a voltmeter
and then measure the voltage across the M1-M2
contacts:
a) If the measured voltage is equal to the control
volts then the M1-M2 contacts are open.
b) If the measurement is less than 1 volt and the
compressor is not running, then the problem is
external to the motor protector module.
c) If the voltage is greater than 1 volt but less than
the control voltage, the motor protector module
is faulty and should be replaced.
Sensor Troubleshooting
• Remove the leads from S1-S2, and then by using an
Ohmmeter to measure the resistance of the incoming
leads.

8
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
CAUTION
Use an Ohmmeter with a maximum of 9 VDC for
checking – do not attempt to check continuity
through the sensors with any other type of
instrument. Any external voltage or current
may cause damage requiring compressor
replacement.
a) During normal operation, this resistance value
should read less than 4500 ohms ±20%.
b) If the M1-M2 contacts are open, the measured
S1-S2 value is above 2750 ohms ±20% and
the compressor has been tripped less then 30
minutes then the module is functioning properly.
• If the S1-S2 wire leads read less than 2750 ohms
±20% and the M1-M2 contacts are open, reset
the module by removing the power to T1-T2 for a
minimum of 5 seconds.
• Replace all wire leads and use a voltmeter to verify
the M1-M2 contacts are closed.
• If the M1-M2 contacts remain open and S1-S2 are
less than 2500 ohms, remove leads from the M1-
M2 contacts and jumper together, using a 100 ohm
resistor.
CAUTION
Compressor should start at this time. HOWEVER
DO NOT LEAVE JUMPER IN PLACE FOR
NORMAL SYSTEM OPERATIONS. THE JUMPER
IS USED FOR DIAGNOSTIC PURPOSES ONLY.
• Go to Compressor Supply Voltage Troubleshooting.
Compressor Voltage Supply Troubleshooting
• Remove phase sensing leads from the module from
L1/L2/L3.
• Use a voltmeter to measure the incoming 3 phase
voltage on L1/L2/L3. WARNING: L1/L2/L3 could
be at a potential up to 600VAC.
• Ensure proper voltage on each phase.
• Remove power to the module for a minimum of 5
seconds to reset and replace all wire leads. Re-
energize the module. If the M1-M2 contacts are open
with proper voltage to T1-T2, L1/L2/L3 and proper
resistance to S1-S2 then the module is faulty and
should be replaced.
Oil Management for Rack Applications
Copeland K5 refrigeration scrolls may be used on
multiple compressor parallel rack applications. This
requires the use of an oil management system to
maintain proper oil level in each compressor crankcase.
The sight glass connection supplied can accommodate
the mounting of the oil control devices.
Unlike semi-hermetic compressors, scrolls do not have
an oil pump with accompanying oil pressure safety
controls. Therefore, an external oil level control is
required.
The OMB Oil Level Management Control combines
the functions of level control and timed compressor
shut-off should the level not come back to normal
within a set period of time. This device has been found
to provide excellent performance in field tests on
scroll compressors and is recommended for parallel
system applications. Refer to Table 5 for Oil Monitoring
accessory part numbers.
Immediately after system start-up the oil reservoir
level will fluctuate until equilibrium is reached. It is
advisable to monitor the oil level during this time to
assure sufficient oil is available. This will prevent
unnecessary trips of the oil control system. Additional
information on oil management in Copeland Scroll
compressors can be found in Application Engineering
bulletin AE17-1320.
Discharge Mufflers
Gas flow through scroll compressors is continuous with
relatively low pulsation. External mufflers applied to
piston compressors may not be required on Copeland
Scroll compressors. Due to system variability individual
tests should be conducted by the system manufacturer
to verify acceptable levels of sound and vibration.
Compressor Mounting
Compressor mounting must be selected based on
application. Consideration must be given to sound
reduction and tubing reliability. Some tubing geometry
or “shock loops” may be required to reduce vibration
transferred from the compressor to external tubing.
Mounting kit part numbers are listed in Table 4 at the
end of this bulletin.
Mounting for Rack Systems – Specially designed
steel spacers and rubber isolator pads are available
for Copeland Scroll 8 -15 HP rack applications. This
mounting arrangement limits the compressors motion
thereby minimizing potential problems of excessive
tubing stress. Sufficient isolation is provided to prevent
vibration from being transmitted to the mounting
structure. This mounting arrangement is recommended
for multiple compressor rack installations. See Figure
7A for a detail of this mounting system.

9
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Condensing Units – For 8 -15 HP Copeland Scroll
condensing unit applications, standard mounts (55-65
durometer) are recommended. The mounting system
for K5 refrigeration scroll condensing units is depicted
in Figure 7B.
Tubing Considerations – Proper tube design must be
taken into consideration when designing the tubing
connecting the scroll to the remaining system. The
tubing should provide enough “flexibility” to allow normal
starting and stopping of the compressor without exerting
excessive stress on the tube joints. In addition, it is
desirable to design tubing with a natural frequency away
from the normal running frequency of the compressor.
Failure to do this can result in tube resonance and
unacceptable tubing life. Figure 2 is an example of an
acceptable tubing configuration.
CAUTION
These examples are intended only as guidelines
to depict the need for flexibility in tube designs.
In order to properly determine if a design is
appropriate for a given application, samples should
be tested and evaluated for stress under various
conditions of use including voltage, frequency,
and load fluctuations, and shipping vibration. The
guidelines above may be helpful; however, testing
should be performed for each system designed.
Connection Fittings, Service Valves, and Adapters
The fitting sizes for 8 through 15 HP scrolls are shown
in Table 5.
Deep Vacuum Operation
WARNING
Do not run a Copeland Scroll compressor in a deep
vacuum. Failure to heed this advice can result in
arcing of the Fusite pins and permanent damage
to the compressor.
A low pressure control is required for protection against
deep vacuum operation. See Pressure Control section
for proper set points. (Table 6)
Scroll compressors (as with any refrigerant compressor)
should never be used to evacuate a refrigeration or air
conditioning system. See AE-1105 for proper system
evacuation procedures.
Unbrazing System Components
WARNING
If the refrigerant charge is removed from a scroll
unit by bleeding the high side only, it is sometimes
possible for the scrolls to seal, preventing pressure
equalization through the compressor. This may
leave the low side shell and suction line tubing
pressurized. If a brazing torch is then applied to the
low side, the pressurized refrigerant and oil mixture
could ignite as it escapes and contacts the brazing
flame. It is important to check both the high and low
sides with manifold gauges before unbrazing or in
the case of assembly line repair, remove refrigerant
from both the high and low sides. Instructions
should be provided in appropriate product literature
and assembly (line repair) areas.
High Potential (Hipot) Testing
Many of the Copeland brand compressors are configured
with the motor below the compressor. As a result, when
liquid refrigerant is within the compressor shell the motor
can be immersed in liquid refrigerant to a greater extent
than with compressors with the motor mounted above
the compressor. When Copeland brand compressors are
Hipot tested and liquid refrigerant is in the shell, they can
show higher levels of leakage current than compressors
with the motor on top because of the higher electrical
conductivity of liquid refrigerant than refrigerant vapor
and oil. This phenomenon can occur with any compressor
when the motor is immersed in refrigerant. The level of
current leakage does not present any safety issue. To
lower the current leakage reading, the system should
be operated for a brief period of time to redistribute the
refrigerant to a more normal configuration and the system
Hipot tested again. See bulletin AE4-1294 for Megohm
testing recommendations. Under no circumstances
should the Hipot or Megohm test be performed while the
compressor is under a vacuum.
Note: The solid state electronic module components
and internal sensors are delicate and can be damaged
by exposure to high voltage. Under no circumstances
should a high potential test be made at the sensor
terminals or sensor leads connected to the module.
Damage to the sensors or module may result.
Three Phase Scroll Compressors – Directional
Dependence
Scroll compressors are directional dependent; i.e. they
will compress in one rotational direction only. Three
phase scrolls will rotate in either direction depending
on power phasing. Since there is a 50/50 chance of
connected power being “backwards”, contractors should
be warned of this. Appropriate instructions or notices
should be provided by the OEM.
Verification of proper rotation can be made by observing
that the suction pressure drops and the discharge
pressure rises when the compressor is energized.

10
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
No time delay is required on three phase models to
prevent reverse rotation due to brief power interruptions.
The CoreSense module will provide reverse rotation
protection.
Copeland Scroll Compressor Functional Check
Copeland Scroll compressors do not have internal
suction valves. It is not necessary to perform functional
compressor tests to check how the compressor will
pull suction pressure. This type of test may damage a
scroll compressor. The following diagnostic procedure
should be used to evaluate whether a Copeland Scroll
compressor is functioning properly.
1. Verify proper unit voltage.
2. Normal motor winding continuity and short to
ground checks can be used to determine proper
motor resistance or if an internal short to ground
has developed.
3. With service gauges connected to the suction
and discharge pressure fittings, turn on the
compressor. If suction pressure falls below normal
levels the system is either low on charge or there
is a flow blockage.
4. If the suction pressure does not drop and the
discharge pressure does not rise, reverse any two
of the compressor power leads and reapply power
to verify the compressor was not wired to run in
the reverse direction.
The operational compressor current draw should
be compared to published performance curves at
the operating conditions (pressures and voltages).
Significant deviation (± 15%) from published values
may indicate a faulty compressor.
CoreSense Diagnostics™Module for Refrigeration
Compressors
The CoreSense Diagnostics module (see Figure 12)
for Copeland Scroll refrigeration compressors (referred
to as “the CoreSense module” in this document) is a
breakthrough innovation for troubleshooting refrigeration
system faults. The CoreSense module is installed in
the electrical box of all 8-15 HP K5 refrigeration scroll
compressors. By monitoring and analyzing data from
the Copeland brand compressors via module power,
discharge line thermistor, and the current transducer
(referred to as “CT” in this document), the CoreSense
module can accurately detect the cause of electrical
and system related issues. A flashing LED indicator
communicates the alert code and guides the service
technician more quickly and accurately to the root cause
of a problem.
The CoreSense module can provide both compressor
protection and lockout capability. Compressor
protection means that the CoreSense module will trip
the compressor when any of the following severe alert
conditions (Codes 1, 2, 4, 6, 7 or 9) are detected. A trip
condition is when the protector on a compressor opens
and stops current flow into the compressor motor. As a
result, the compressor shuts down. A trip condition will
reset after short cycle time and when trip condition is
not present.
If lockout is enabled and a preset number of alarm
events happen, the CoreSense module will not allow
the compressor to start (Codes 1, 4, 6 or 7) until the
situation is corrected and the module is manually
reset. The module can be reset by cycling power to
the module.
CoreSense Module LED Overview
The CoreSense module, under abnormal detected
conditions, has the ability to shut down the compressor
if the compressor contactor coil is wired through the
M1-M2 relay.
The LEDs will flash a number of times consecutively,
pause and then repeat the process. To identify an alert
code number, count the number of consecutive flashes.
Detailed descriptions of specific alert codes are shown
in Table 7.
The CoreSense module will continue to display the alert
code until the condition returns to normal or if module
power is cycled to the device.
Yellow LED:
FLASHING: Alerts of an abnormal system condition
via Alert Codes
SOLID: Demand is present but no current is
detected. All protective shutdowns will auto reset in
their allotted time
Red LED:
FLASHING: Indicates the CoreSense module is
locked out on the flashing Alert Code. Manual power
cycle reset is required to restart the compressor
Green LED:
FLASHING: Alert Codes that do NOT have a
protective shutdown associated with them.
Some troubleshooting tips for the CoreSense module
are listed in Table 8 at the end of this document.

11
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
Product Specifications
Operating Temp: -40° to 150°F (-40° to 65°C)
Storage Temp: -40° to 175°F (-40° to 80°C)
Power Supply Range: 85-265VAC, 50-60 Hz
Working amperage for CT module: 3-200A
NOTE: The CoreSense module is not accurate below
3 Amps. If the current drawn by the compressor during
operation falls below 3 Amps, the module may indicate
a nuisance fault condition and alarm.
The CoreSense module connections are standard male
electrical flag terminals.
Maximum continuous contactor coil current is 2A with
a max inrush current of 20A.
Compressor Lead Wiring
The compressor leads must be routed through the holes
in the CT module marked T1, T2, and T3. Only the
compressor lead wires should be placed through
the CT module.
CoreSense Module Mounting
The CoreSense module will come pre-mounted inside
the compressor terminal box. The module is mounted
so all LEDs are in front of the light pipes in the terminal
covers so codes are visible when the terminal box cover
is installed on the terminal box.
110-220VAC CoreSense Module Power Wiring
The CoreSense module requires 115-230VAC power
between to the L1 and L2 terminals. The module should
remain powered through all states of compressor on/off
operation. Refer to wiring schematic examples.
Demand Wiring
The CoreSense module requires a demand signal to
operate properly. The demand signal input, labeled
D on the module, should always be connected to the
compressor demand so that the demand signal input
is 110 or 220VAC with respect to L2. See Figure 8
for proper wiring diagrams. Choose the appropriate
diagram depending on how the demand signal will be
fed to the module.
For K5 refrigeration scrolls with CoreSense diagnostics,
a relay (indicated by K1 in Figure 8) needs to be installed
in series with the "Demand" circuit. The normally open
relay should close when demand is present. When the
coil is not energized, the demand signal input should
be less than 0.5VAC. This is to avoid a "Demand, No
Current" alert (steady yellow LED) when the compressor
cycles off or goes into a scheduled pump down. Refer to
the wiring diagram in Figure 8 for more detail. Emerson
recommends a general purpose / industrial relay with
mounting socket. The relay contacts should be rated for
5A at 250VAC and the coil needs to match the system's
control voltage (typically 220/240 or 110/120 VAC).
For demand wiring kit see Table 9. For an example of
wiring the relay see Figure 14.
Protection/Contactor Control Wiring
The M1-M2 relay on the CoreSense module is a normally
open relay. When the module is powered and there are
no protective faults, the relay is energized and does not
cycle on/off. On a detected protection condition, the
CoreSense module will de-energize the relay to stop the
motor from running. The relay is not used as a cycling
device for normal compressor operation. The cycling
device must be supplied externally from the module.
Discharge Temperature Protection with CoreSense
Diagnostics for K5 Compressors
Copeland Scroll K5 compressors for refrigeration with
CoreSense diagnostics come standard with discharge
temperature protection. Depending on the application
and refrigerant a certain mode of protection will be
used whether it is a top cap thermistor or DTC valve
with discharge line thermistor. The CoreSense module
identifies the protection device based on the pin
locations in the connector (see Figure 9). Figures 10
and 11 depict the installation of the top cap thermistor
and discharge line thermistor, respectively.
Table 1 at the end of this bulletin identifies the discharge
temperature protection device by application and
refrigerant. Table 4 identifies the service part numbers
for those devices.
Communication DIP Switch Configuration
The communication module on the CoreSense
Diagnostics module is equipped with a 10 switch DIP
switch used for selection of the MODBUS address, baud
rate, parity, and other operating conditions to simplify
service and start-up procedures. See Figure 13. For
more information on DIP switch settings, Table 10 lists
the purpose for each switch.
Note! Cycle power after changing any of the DIP settings
for changes to take effect.
The following steps cover the DIP switch settings
throughout the commissioning process for a multiple
compressor system with communications to the E2:

12
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
1. Switches 1 through 5 are used for setting the
address. Each CoreSense Diagnostics device
that is connected to a rack controller must have a
unique node address (as determined by the DIP
switch settings).
2. Switch 6 defines the communications baud rate for
the CoreSense Diagnostics module. If the switch
is “off”, the baud rate is 19200. If the switch is “on”
the baud rate is 9600. The baud rate for each of the
CoreSense devices should be set to match the rack
controller. The default baud rate is 19200 (“off”) for
the CoreSense Diagnostics module. To determine
the baud rate in the E2, follow these steps:
• From the main menu select 7 (System
Configuration)
• Press 3 (System Information)
• Press 1 (General Controller Info)
• Access the Serial Communications Tab by
pressing CTRL + 3
• Use the Page Down button or scroll down to
view the settings for COM4
3. Switch 7 defines the communication parity. The
default parity setting for the CoreSense Diagnostics
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
rack controller.
4. Switch 8 is used to set the network mode (on) for the
module. The default setting is stand alone mode (off).
Network mode will generate a communications error
if the rack controller fails to communicate with the
device. For standalone mode, no communications
are expected so the communication error is blocked.
1 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.
Cable Routing / Daisy Chain Configuration
CoreSense diagnostics can communicate with a rack
controller using MODBUS protocol. The communication
cable is wired from the rack controller to the first
compressor. Additional compressors are wired in a daisy
chained configuration. Refer to Figures 16 and 17.
A shielded, twisted pair cable such as Belden #8761
(22AWG) should be used for the communication wiring.
Passing the communications wire through the grommet
in the plastic housing will help reduce abrasion to the
wiring. Appropriate strain relief is recommended.
Note! The RS485 is polarity sensitive. “+” wires
must connect to other “+” terminals, and “-” wires
must connect to other “-” terminals. The shield wire is
connected to the center terminal, or “0 volt” position.
Terminations
The last compressor in the daisy chain must be
“terminated” by setting the DIP switch number 10 to the
"on" (up) position. For all other compressors the number
10 DIP switch should remain in the "off" (down) position.
More information: The E2 jumpers on the Network
Interface Board should be set for “terminated”. Refer
to Figure 15.
COMMISSIONING
Modules using a communications network must be
commissioned as part of the E2 rack controller setup.
The commissioning process uploads compressor asset
information (model and serial number) into the rack
controller for future reference. Once the commissioning
process is completed, the controller will supervise and
communicate with the module unless the node is deleted.
Refer to section titled MODBUS Communication to
CoreSense Diagnostics for K5 Compressors for more
details on commissioning the K5 scrolls in an Emerson
Retail Solutions E2 rack controllers.
The CoreSense Diagnostics module does not
need to communicate to the rack controller in
order to provide compressor protection. Using
the communication process is optional, but provides
for information flow to the controller for proofing,
remote reset, asset information, and fault history and
compressor status. Skip to section titled Stand Alone
Mode if the communication feature will not be used.
The commissioning process begins by assigning a
unique node address to each module. The address is
established by the setting of a DIP switch in the module.
Stand Alone Mode
If running a K5 with CoreSense diagnostics without
communication to a rack controller, DIP switch 8 should
be set to "Off" (down).
MODBUS Communication to CoreSense Diagnostics
for K5 Compressors
K5 Compressors equipped with a communication
module are capable of communicating via open
MODBUS to a rack controller. The steps on the following
pages are provided to commission K5 scrolls in an
Emerson E2 with firmware version 3.0 or newer. For
other rack controllers, contact the manufacturer.

13
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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.
CoreSense K5 Programming Instructions

14
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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 1 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 Swi tch
settings and press Enter.

15
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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.

16
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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.

17
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
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)

18
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
0
20
40
60
80
100
120
140
160
-50 -40 -30 -20 -10 0 10
Condensing Temperature (°F)
Evaporating Temperature (°F)
ZF*K5E Low Temperature Vapor Injection** Operating Map
(65°F Return Gas)
R-404A/R-507
Figure 1A
0
20
40
60
80
100
120
140
160
-50 -40 -30 -20 -10 0 10
Condensing Temperature (°F)
Evaporating Temperature (°F)
ZF*K5E Low Temperature Vapor Injection** Operating Map
(65°F Return Gas)
** DTC Liquid Injection Required with EVI for R-407A /R-407C/ R-407F
Maximum
40F
Superheat
R-407A /R-407C /R-407F
Figure 1B

19
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
0
20
40
60
80
100
120
140
-50 -40 -30 -20 -10 0 10
Condensing Temperature (°F)
Evaporating Temperature (°F)
ZF*K5E Low Temperature Liquid Injection Operating Map
(65°F Return Gas)
DTC Liquid
Injection Required
R-22
Figure 1D
0
20
40
60
80
100
120
140
160
-50 -40 -30 -20 -10 0 10
Condensing Temperature (°F)
Evaporating Temperature (°F)
ZF*K5E Low Temperature Liquid Injection Operating Map
(65°F Return Gas)
DTC Liquid
Injection Required
R-404A/R-507/R-407A/R-407C/R-407F
Figure 1C

20
Application Engineering
BULLETIN
AE4-1383 R5
© 2012 Emerson Climate Technologies, Inc.
Printed in the U.S.A.
60
70
80
90
100
110
120
130
140
150
160
0 102030405060
Condensing Temperature (°F)
Evaporating Temperature (°F)
ZB*K5E Medium/High Temperature Operating Map
(65°F Return Gas)
R-22
Figure 1F
Note: For operating maps at different return gas conditions, contact your Application Engineer.
0
20
40
60
80
100
120
140
160
-20-100 1020304050
Condensing Temperature (°F)
Evaporating Temperature (°F)
ZB*K5E Medium Temperature Operating Map
(65°F Return Gas)
R-404A/R-507/R-407A/R-407C/R-407F
65°F Maximum Return Gas
R-407C/F Limit to 20F SH
Figure 1E