Emerson Coresense Diagnostics Manual

AE8-1379 R2 February 2015
CoreSense™Diagnostics
for Copeland Scroll™Air Conditioning Compressors
TABLE OF CONTENTS
Section Page
Introduction................................................................................................. 4
CoreSense Diagnostics Part Numbers........................................................ 4
Application Restrictions and Types.............................................................. 4
Product Specifications................................................................................. 4
Installation................................................................................................... 4
Terminal Description ................................................................................... 4
Compressor Protection................................................................................ 5
Module LED Description.............................................................................. 5
Module Operation/Code Description............................................................5
Resetting Alert codes.................................................................................. 5
Module History Download............................................................................ 6
Warranty Information................................................................................... 6
Support....................................................................................................... 6
Figures and Tables
Two-Wire Diagram - Typical Cooling Application......................................7
Three-Wire Diagram - Typical Heat Pump Application............................. 7
Three-Wire Diagram - Typical Cooling Application...................................7
Module Dimensions................................................................................. 8
Quick Reference Table............................................................................ 9
CoreSense Diagnostics LED Troubleshooting Information......................10
© 2015 Emerson Climate Technologies 1

AE8-1379 R2
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.
SafetyIconExplanation
DANGER
WARNING
CAUTION
NOTICE
CAUTION
© 2015 Emerson Climate Technologies
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.
2

AE8-1379 R2
Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons
WARNING
WARNING
WARNING
CAUTION
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.
© 2015 Emerson Climate Technologies 3

AE8-1379 R2
Introduction
CoreSense™Diagnostics is a breakthrough innovation
for troubleshooting residential air-conditioning and heat
pump systems. The CoreSense Diagnostics module
is easily installed in the unit electrical panel near the
compressor contactor. By using the compressor as a
sensor, CoreSense Diagnostics helps the service
technician more accurately troubleshoot system and
compressor fault conditions.
CoreSense Diagnostics also provides compressor
and system protection through its proprietary lockout
feature. Depending on the severity and frequency of
the fault that caused the trip condition, the CoreSense
Diagnostics module can lockout the compressor
contactor to prevent damage to the compressor and
system components. Less severe fault conditions
resulting in an occasional trip will not result in a lockout
condition.
Flashing LEDs communicate ALERT and LOCK
codes to the service technician.
CoreSense Diagnostics Part Numbers
Version OEM Part Number Service P/N
Two Wire AC: 571-0066-00 971-0066-00
Three Wire HP: 571-0067-00 971-0067-00
Application Restrictions and Types
The CoreSense Diagnostics module is designed
and qualified for use with ZP*K5 and ZR*K5 single-
phase Copeland Scroll
™
fixed speed compressors.
CoreSense Diagnostics is not designed for use with
Copeland Scroll Variable Speed or Ultratech™branded
scroll compressors.
The CoreSense Diagnostics module is available in
two-wire and three-wire configurations. The two-wire
module (571-0066-00) uses the demand signal (Y)
to power the module. The two-wire module is used
primarily in split system cooling applications where 24
volts may not be available at the outdoor unit to power
the module. The three-wire module (571-0067-00) is
powered continuously by (R) and (C) and is ideal for
all packaged unit applications, and for split systems
applications where (R) and (C) are available at the
outdoor unit. See Figures 1 and 2.
Product Specifications
Operating Temp: - 40° to 150°F (- 40° to 65°C)
Storage Temp: - 60° to 175°F (- 49° to 80°C)
Supply Voltage: 19 to 28VAC , 48 to 62Hz
© 2015 Emerson Climate Technologies
Working amperage for module: 2 to 30A
Maximum Power Consumption: 1.5 VA
Installation
Two #8 or #10 self tapping or sheet metal screws are
required for installation of the module. The maximum
mounting screw torque is 20 in.lbs. The module can be
mounted in any orientation and LEDs should be visible
for ease of service.
The COMMON lead wire for the compressor must be
routed through the current sensing hollow opening at
the top of the module.
NOTICE
The top cover of the module is not designed to be
removed.
The current sensor is capable of measuring a minimum
of 2 amps. If the compressor current is less than
2 amps during normal operation, then loop the
compressor COMMON lead wire through the
current sensing port two times.
CAUTION
The terminals of the module are in close
proximity to each other and care must be used to
prevent terminal to terminal shorting. Shorting the
terminals may destroy the module and/or the
transformer used to power the module.
For module dimensions and terminal identification,
refer to Figure 4.
Terminal Description
The terminals for the CoreSense Diagnostics module
are ¼”spade terminals.
•COMMON (C)
The 24 volt common terminal for module power.
•DEMAND (Y)
The demand terminal requires a 24VAC signal
measured with respect to the COMMON (C)
terminal when there is a call for heating or
cooling.
•PROTECTION (PROT)
The protection terminal is internally wired to the
COMMON terminal through a normally closed
set of contacts.
•POWER (R)
This terminal is only on the 571-0067-00 three-
wire version. The module requires a constant
24VAC supply power to this terminal.
4

AE8-1379 R2
Compressor Protection
The CoreSense Diagnostics module utilizes proprietary
algorithms to protect the compressor and system from
repeated trips of system pressure controls and the
compressor internal overload. The protection terminal
of the module should be wired in series with the system
low pressure and high pressure cutouts, as well as
the compressor contactor. When the module detects a
series of trips as described below, it will activate a
lockout feature that opens the normally closed protection
contacts in the module, thereby cutting power to the
contactor and shutting off the compressor.
Module LED Description
RUN/ALERT LED (Yellow)
A solid yellow LED indicates the module is powered
and the compressor/system is running normally.
Abnormal system conditions are indicated through
a unique yellow flash code. The Yellow RUN/ALERT
LED will flash consecutively, pause and then repeat
when adverse conditions are detected within the
compressor or system. The number of consecutive
flashes, defined as the flash code, correlate to a
particular abnormal condition. See Tables 1 and 2.
TRIP/LOCK LED (Red)
A solid red LED indicates the compressor is in a
TRIP state where the module detects the presence
of a demand signal from the thermostat, however
no current to the compressor is detected by the
module. A compressor trip typically indicates the
compressor's internal overload is open or may
indicate missing supply power to the compressor.
The Red TRIP/LOCK LED will flash consecutively,
pause and then repeat when the compressor lockout
feature is active. The number of consecutive flashes,
defined as the flash code, correlate to a particular
lock condition. See Table 2. (Note: The Yellow
Run/Alert LED will be turned off)
Module Operation/Code Description
The following is a description of the protection coding
of the CoreSense Diagnostics module:
Code 1 - Long Run Time
The module will flash yellow one time when the
compressor operates for longer than 18 continuous
hours. This is an alert code only, and the module will
not lockout the compressor for this condition.
Code 2 - Compressor (Pressure) Trips
The module will flash yellow two times when the
compressor operates from 12 seconds to 15 minutes
© 2015 Emerson Climate Technologies
followed by a trip condition lasting longer than seven
minutes. When four consecutive Code 2 events are
recorded, the module will lockout the compressor
and flash red two times.
Code 3 - Pressure Switch Cycling
The module will flash yellow three times when
the compressor operates from 12 seconds to 15
minutes followed by a trip condition lasting between
35 seconds to 7 minutes. When four consecutive
Code 3 events are recorded, the module will lockout
the compressor and flash red three times. A lockout
will also occur in the case that 10 events have been
recorded without resetting the alert.
Code 4 - Locked Rotor Trips
The module will flash yellow four times when the
compressor trips within 12 seconds of operation, and
does not reset and start within 35 seconds. When 10
consecutive Code 4 events are recorded the module
will lockout the compressor and flash red four times.
Code 5 - Compressor (Moderate Run) Trip
The module will flash yellow five times when the
compressor has operated between 15 minutes
and 18 hours, followed by a compressor trip lasting
longer than 7 minutes. When four consecutive Code
5 events are recorded, the module will lockout the
compressor and flash red five times. A lockout will
also occur if ten Code 5 events are recorded without
resetting the alert (see Resetting Alert Codes
below).
Code 9 - Over-Current Protection
When the current at the PROT terminal is greater
than 2A for 40ms, the module will flash a Code 9.
The red LED will flash 9 times with the yellow LED
remaining off. This alert indicates that the module is
mis-wired or the contactor coil is shorted to ground.
NOTICE
Code 9 is not specified on the module label.
Low Supply Voltage
If the 24 VAC supply voltage to the module drops
below the required amount to power the processors,
the processor will be continuously reset. Both LEDs
may flicker, and the alerts on the module will be
reset.
Resetting Alert Codes
When the CoreSense Diagnostics module has detected
a series of adverse conditions that have caused it to
5

AE8-1379 R2
lockout the compressor, and after the issue has been
resolved, it is necessary to manually reset the module
in order to clear the present alert code.
The primary way of clearing the code and resetting
the alert is to press the reset button located on the
module. Note: Pressing the reset will require a pin
or mini/electronics screwdriver. This button must be
pressed and held for a minimum of one second for the
module to be reset. Pressing the reset button clears
the immediate lock code and the seven day operating
history. It will not clear the permanent module history.
In the case of the three-wire module, the codes can be
reset or cleared by cycling power to the module. This
can be done by disengaging the Common (C) terminal.
This will not clear the seven day operating history.
Note: For the 571-0066-00 module, if a fault is present, it
is expected that the thermostat demand will remain
present and the module will stay powered and function
similar to the 571-0067-00 module. If the thermostat
demand cycles off, then the 571-0066-00 module will
reset and alert will clear.
Module History Download
The CoreSense Diagnostics module is capable of
communicating with a personal computer, tablet, or
laptop, via Emerson Climate Technologies computer
software interfaces (HVACR Fault Finder PC Edition)
and USB connection (TTL-232R-5V-WE), in order to
download and store fault history and module operation
time. This information can be used to help diagnose
and review data from troubled systems in the field.
HVACR Fault Finder PC Edition kit (9989-0099-
01) with software and cable. For more information,
please contact your Emerson Climate Technologies
Application Engineer.
Warranty Information
Emerson Climate Technologies, Inc. warrants its
diagnostic module to be free from defects in materials
and workmanship under normal use for a period of one
year from the date of purchase or twenty months from
manufacture, whichever comes first. During this period,
Emerson Climate Technologies, Inc. will replace any
defective diagnostic module without charge.
For more information on product warranty please visit
EmersonClimate.com
Support
For more information visit EmersonClimate.com,
or contact Emerson Climate Technologies, Inc. at
1-888-EMR-9950.
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. Emerson Climate Technologies, Inc. reserves the right to modify the designs or specifications of such productsat any time without
notice. Emerson Climate Technologies, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Emerson Climate Technologies, Inc. product remains solely with the purchaser and end-user.
© 2015 Emerson Climate Technologies 6

AE8-1379 R2
Contactor Coil
HPCO LPCO
P
PROT
Indoor C C
Unit Y Y
CoreSense Module
Figure 1
571-0066-00 Two-Wire Diagram
HPCO LPCO
T1
Defrost Board
Indoor C
Unit Y
R
ASC T2
Y C R
Contactor Coil
P PROT
C
Y
R
CoreSense Module
Figure 2
571-0067-00 Three-Wire Diagram
Contactor Coil
HPCO LPCO
P
PROT
Indoor
Unit C C
Y Y
R R
CoreSense Module
Figure 3
571-0067-00 Three-Wire Diagram
© 2015 Emerson Climate Technologies 7

AE8-1379 R2
Current
Sensor Opening
Reset Bu on
Yellow LED
Red LED
PROT
Y (3 Wire Only) C Data Port
(Not Present on 2 Wire)
R (3 Wire Only)
Y (2 Wire Only)
Figure 4
Dimensions are in Millimeters
© 2015 Emerson Climate Technologies 8

AE8-1379 R2
Table 1 - Quick Reference Table
Alert Code
Alert Condition Lock Level Lock
Indication
Normal Run
Solid Yellow
Code1
Yellow Flash 1
Normal operation, no trip.
Long run time. Compressor is on running for more
than 18 hours. (Code1 is disabled in Heat Pump
mode.)
N/A N/A
N/A N/A
Code2 Compressor (pressure) trip. Compressor runs for Red: Flash 2
Yellow Flash 2 12 sec to 15 min followed by a compressor trip 4x consecutive
condition lasting longer than 7 min. Yellow: Off
Code3
Yellow Flash 3
Code4
Yellow Flash 4
Code5
Yellow Flash 5
Pressure switch cycling. Compressor runs for 12
sec to 15 min followed by a compressor trip lasting
between 35 sec to 7 min.
Locked rotor. Compressor trips within a compressor
run time of 12 sec and does not start within 35 sec.
Compressor (moderate run) trip. Compressor runs
for 15 min to 18 hrs followed by a compressor trip
lasting longer than 7 min.
4x consecutive Red: Flash 3
or 10x total
Yellow: Off
Red: Flash 4
10x consecutive Yellow: Off
4x consecutive Red: Flash 5
or 10x total
Yellow: Off
Code9 Current >2A Red: Flash 9
Red Flash 9 The current to the PROT terminal is greater than 2A for 40ms Yellow: Off
Trip
Solid Red
Demand is present, but compressor is not running N/A N/A
© 2015 Emerson Climate Technologies 9

AE8-1379 R2
Table 2
CoreSense Diagnostics LED Troubleshooting Information
Flash Code number corresponds to the number of LED flashes, followed by a pause and then repeated.
TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation.
Status Description Troubleshooting Information
Solid Yellow “RUN”Module has power and operating
normally
Supply voltage is present at module terminals
1. Compressor protector is open
•Check for high head pressure
•Check compressor supply voltage
Thermostat demand signal Y is
Solid Red “TRIP”present, but the compressor is
not running
2. Outdoor unit power disconnect is open
3. Compressor circuit breaker or fuse(s) is open
4. Broken wire or connector is not making contact
5. High pressure switch open if present in system
6. Compressor contactor has failed open
“ALERT”Flash Codes
1. Lowrefrigerant charge
2. Evaporator blower is not running
•Check blower relay coil and contacts
•Check blower motor capacitor
•Check blower motor for failure or blockage
•Check evaporator blower wiring and connectors
•Check indoor blower control board
•Check thermostat wiring for open circuit
Long Run Time; Compressor
Yellow “ALERT”is running extremely long run
Flash Code 1 cycles indicative of low capacity
due to a system low-side fault
3. Evaporator coil is frozen
•Check for low suction pressure
•Check for excessively low thermostat setting
•Check evaporator airflow (coil blockages or return air filter)
•Check ductwork or registers for blockage
4. Faulty metering device
•Check TXV bulb installation (size, location and contact)
•Check if TXV/fixed orifice is stuck closed or defective
5. Liquid line restriction (filter drier blocked if present in system)
6. Thermostat is malfunctioning
•Check thermostat sub-base or wiring for short circuit
•Check thermostat installation (location, level)
1. Condenser fan is not running
•Check fan capacitor
•Check fan wiring and connectors
Yellow “ALERT”
Flash Code 2 Compressor (Pressure) Trip;
Discharge pressure out of limits
or compressor overloaded
•Check fan motor for failure or blockage
2. High head pressure
•Check high pressure switch if present in system
•Check if system is overcharged with refrigerant
•Check for non-condensable in system
3. Condenser coil poor air circulation (dirty, blocked, damaged)
1. Thermostat demand signal is intermittent
Yellow “ALERT”Short Cycling; Compressor is
Flash Code 3 running only briefly 2. Time delay relay or control board defective
3. Low or high pressure switch is cycling
© 2015 Emerson Climate Technologies 10

AE8-1379 R2
Status Description Troubleshooting Information
1. Run capacitor has failed
2. Lowline voltage (contact utility if voltage at disconnect is low)
Yellow “ALERT”
Flash Code 4 Locked Rotor •Check wiring connections
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
•Measure compressor oil level
1. Evaporator blower is not running
•Check blower relay coil and contacts
•Check blower motor capacitor
•Check blower motor for failure or blockage
•Check evaporator blower wiring and connectors
Yellow “ALERT”Compressor (Moderate Run)
Flash Code 5 Trip •Check indoor blower control board
•Check thermostat wiring for open circuit
2. Faulty metering device
•Check TXV bulb installation (size, location and contact)
•Check if TXV/fixed orifice is stuck closed or defective
3. Condenser coil poor air circulation (dirty, blocked, damaged)
4. Lowrefrigerant charge
“LOCK”Flash Codes
1. Condenser fan is not running
•Check fan capacitor
Compressor (Pressure) Trip;
Red “LOCK”Compressor is locked out
Flash Code 2 after 4 consecutive or 10 total
Yellow Off compressor (pressure) trip
events
•Check fan wiring and connectors
•Check fan motor for failure or blockage
2. High head pressure
•Check high pressure switch if present in system
•Check if system is overcharged with refrigerant
•Check for non-condensable in system
3. Condenser coil poor air circulation (dirty, blocked, damaged)
Red “LOCK”Short Cycling; Compressor is 1. Thermostat demand signal is intermittent
Flash Code 3 locked out after 10 consecutive 2. Time delay relay or control board defective
Yellow Off short cycling events 3. If high pressure switch present go to Flash Code 2 information
1. Run capacitor has failed
2. Lowline voltage (contact utility if voltage at disconnect is low)
Red “LOCK”Locked Rotor; Compressor is
Flash Code 4 locked out after 10 consecutive
Yellow Off locked rotor events
•Check wiring connections
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
•Measure compressor oil level
1. Evaporator blower is not running
•Check blower relay coil and contacts
•Check blower motor capacitor
•Check blower motor for failure or blockage
Compressor (Moderate Run)
Red “LOCK”Trip; Compressor is locked out
Flash Code 5 after 4 consecutive or 10 total
Yellow Off compressor (moderate run) trip
events
•Check evaporator blower wiring and connectors
•Check indoor blower control board
•Check thermostat wiring for open circuit
2. Faulty metering device
•Check TXV bulb installation (size, location and contact)
•Check if TXV/fixed orifice is stuck closed or defective
3. Condenser coil poor air circulation (dirty, blocked, damaged)
4. Lowrefrigerant charge
© 2015 Emerson Climate Technologies 11