Manual de usuario - Emerson Climate Technologies
Contents
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18. Not applicable to single stage models 543 0038 02 and 943 0038 02 For two stage applications the Comfort Alert module requires a two stage thermostat to operate properly The Y2 thermostat wire should be connected to the Y2 input on Comfort Alert While the compressor is running Comfort Alert will provide power to the second stage cooling solenoid inside the compressor after Y2 has been energized for 5 seconds Whenever the compressor is not running Comfort Alert will not power the solenoid regardless of the state of Y2 UltraTech Solenoid COMFORT ALERT DIAGNOSTICS MODULE 543 0038 00 1 3 Phase 12 208 575 50 60Hz HPCO LPCO Three Phase Copeland Scroll 2Stage Ony ee ee INDOOR THERMOSTAT Schematic Abbrevation Descriptions Note Y2and DC SOL are not applicable for models CC Contactor 543 0038 02 and 943 0038 02 High Pressure Cut Out Switch LPCO Low Pressure Cut Out Switch Figure 4 Thermostat Contactor Control UltraTech Solenoid COMFORT ALERT DIAGNOSTICS MODULE 543 0038 00 L1 3 Phase 12 208 575 50 60Hz L3 Three Phase Copeland Scroll 2StageOnly ee A INDOOR THERMOSTAT Schematic Abbrevation Descriptions Note 2 and DC SOL are not applicable for models CC Contactor 543 0038 02 and 943 0038 02 High Pressure Cut Out Swit
19. Emerson Climate Technologies Inc shall not be liable for any incidental or consequential damages caused by the breach of any express or implied warranty Some states provinces or jurisdictions do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights that vary from state to state or province to province Units under warranty and in need of repair should be returned to an authorized wholesaler or original equipment manufacturer Patent 6 615 594 and Additional Patents Pending d 2005ECT 191 R5 10 09 Emerson Comfort Alert Copeland Copeland E M E RSO N Scroll and Ultra Tech are trademarks Emerson Electric Co one of its affiliated companies 2005 Emerson Climate Technologies Inc All rights reserved Printed in the USA sol os sdw SO 6002 N 0543 E sns 00 UOSIBW 4981 ENN A 4 10125 60 01 SH 161 1039002 sajuayed 69 919 9
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22. and 9 of this manual SIE ck TRIP LED Red indicates there is a demand signal from the thermostat but no current to the compressor is detected by the module The TRIP LED typically indicates the compressor protector is open or may indicate missing Figure 1 supply power to the compressor A flashing TRIP LED indicates the anti short cycle timer is active preventing e compressor from starting Us 1 Product Specifications Operating Temperature 40 to 150 F 40 to 65 C UL File SA8958 Storage Temperature 40 to 175 F 40 to 80 C Power Supply Range 18 30VAC 48 62 Hz Power Requirement 2 0 VA nominal without solenoid on single stage 7 0VA nominal with solenoid on two stage UL Restrictions Use only with Class 2 circuits This 543 0038 module is designed only for three phase systems with Copeland Scroll compressors that have internal overload protection The software in this Comfort Alert module is compatible with single stage 543 0038 02 or 943 0038 02 or two stage 543 0038 01 or 943 0038 01 UltraTech scroll systems 2 Dimensions A 1 85 in 47 mm D 4 40 in 112mm B 2 44 62 mm E 2 44 in 62 mm 1 46 in 37 mm A POWER Q 222 OH E E i 1 z L P Sees Protesiian 0 ALERT Figure 2 Figure 3 Model Dimensions Two Stage Model dimen
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25. voltage is present at module s R and C terminals Review 24VAC Power Wiring page 4 for R and C wiring Green LED intermittent Determine if R and Y terminals are wired in reverse module powers up only Verify module s R and C terminals have a constant when compressor runs source Review 24VAC Power Wiring page 4 for R and C wiring TRIP LED is on but system Verify Y terminal is wired properly per OEM wiring and compressor check OK diagram Verify voltage at contactor coil falls below 0 5VAC when off Verify 24VAC is present across Y and C when thermostat demand signal is present If not R and C are reverse wired TRIP LED and ALERT LED Verify R and C terminals are supplied with 19 28VAC flashing together ALERT Flash Code 3 Verify Y terminal is connected to 24VAC at contactor coil Compressor Short Cycling Verify voltage at contactor coil falls below 0 5VAC when displayed incorrectly off ALERT Flash Code 5 or 6 Check that compressor T1 and T3 wires are through Open Circuit Missing module s current sensing holes Verify Y terminal is Phase displayed connected to 24VAC at contactor coil Verify voltage at Incorrectly contactor coil falls below 0 5VAC when off ALERT Flash Code 8 Determine if module s Y terminal is connected Verify Y Welded Contactor terminal is connected to 24VAC at contactor coil Verify displayed incorrectly 24VAC is present across Y and C when thermostat demand signal is present If not R and C
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28. Comfort Alert Commercial Diagnostics 543 0038 01 543 0071 00 543 0038 02 943 0038 01 943 0038 02 User s Manual EMERSON Comfort Alert Diagnostics Faster Service And Improved Accuracy The Comfort Alert diagnostics module is a breakthrough innovation for troubleshooting and protecting three phase Copeland Scroll compressors The module installs easily in the electrical box of the condensing unit near the compressor contactor By monitoring and analyzing data from the Copeland Scroll compressor and the thermostat demand the module can accurately detect the cause of electrical and system related failures and protect the compressor A flashing LED indicator communicates the ALERT code and guides the service technician more quickly and accurately to the root cause of a problem NOTE This module provides compressor protection and will shut down the compressor when compressor damaging conditions are detected LED Description Figure 1 POWER LED Green indicates voltage is present at the power connection of the module Ck ALERT LED Yellow communicates an abnormal system condition through unique flash code The ALERT LED will flash a number of times consecutively pause and then repeat the process The number of consecutive flashes defined as the Flash Code correlates to a particular abnormal condition Detailed descriptions of specific ALERT Flash Codes are shown in two tables on pages 8
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30. are reverse wired Verify voltage at contactor coil falls below 0 5VAC when off ReviewThermostat Demand Wiring page 4 fdr Y and C wiring Table 1 11 Warranty Information Emerson Climate Technologies Inc warrants its enclosed 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 This warranty is valid for the original purchaser from the date of initial purchase and is not transferable Keep the original sales receipt Proof of purchase is required to obtain warranty replacement Dealers or service centers selling this product do not have the right to alter modify or in any way change the terms and conditions of this warranty This warranty does not cover normal wear of parts or damage resulting from any of the following negligent use or misuse of the product use on improper voltage or current use contrary to the operating instructions disassembly repair or alteration by anyone other than Emerson Climate Technologies Inc Further the warranty does not cover acts of God such as fire flood hurricanes and tornadoes EMERSON CLIMATE TECHNOLOGIES INC MAKES NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO THE COMFORT ALERT MODULE
31. ch LPCO Low Pressure Cut Out Switch Figure 5 Comfort Alert Contactor Control UltraTech Solenoid COMFORT ALERT DIAGNOSTICS MODULE 543 0038 00 1 3 Phase 12 208 575VAC 50 60Hz L3 Three Phase Copeland Scroll 2 Stage Only SYSTEM CONTROLLER 11 12 Controller Inputs 01 02 Controller Outputs R C Controller Power Note Y2and DC SOL are not applicable for models 543 0038 02 and 943 0038 02 Figure 6 System Controller Schematic L Terminal Wiring The L connection is used to communicate Alert codes to compatible White Rodgers thermostats An icon on the thermostat display will flash at the same rate as the Comfort Alert yellow Alert LED The L terminal of the thermostat should be connected directly to the Comfort Alert L terminal Refer to White Rodgers thermostat manuals for more information DC SOL Connection Not applicable to single stage models 543 0038 02 and 943 0038 02 The two pin DC SOL connector provides a connection to the Copeland UltraTech second stage compressor solenoid This solenoid is internal to the compressor This 24VDC solenoid will not operate properly if 24VAC is applied to the compressor solenoid terminals To reduce the VA load of the solenoid on the system Comfort Alert uses a phase control method to reduce the DC voltage to the solenoid to the minimum level required to keep the solenoid pulled in As the 24VAC supply voltage varies Comfort Ale
32. e devices For best troubleshooting results automatic reset cutout switches should be used Comfort Alert monitors patterns of behavior and will protect the system and provide diagnostics when multiple cutout events are detected Interpreting The Diagnostic LEDs When an abnormal system condition occurs the Comfort Alert module displays the appropriate ALERT and or TRIP LED The yellow ALERT LED will flash a number of times consecutively pause and then repeat the process To identify a Flash Code number count the number of consecutive flashes Every time the module powers up the last ALERT Flash Code that occurred prior to shut down is displayed for one minute If the yellow ALERT LED is on solid more than 2 amps are conducted through the PROT terminal The contactor coil may be shorted or the PROT terminal miswired Some ALERT codes indicate a compressor damaging condition and the Comfort Alert module will shut down and lock out the compressor Refer to the tables on pages 8 and 9 to identify ALERT codes that result in a lock out Installation Verification for Model 543 0038 00 To verify the installation of Comfort Alert is correct a functional test can be performed Force a Call for cooling The compressor will not immediately begin to run This is due to the anti short cycle timer The anti short cycle time lasts for 3 minutes and is indicated by flashing the Trip LED After the anti short cycle timer expires the compressor should run M
33. emand signal to operate properly The thermostat demand signal input labeled Y on the module should be connected directly to the compressor contactor coil so that when the coil is energized the demand signal is 24VAC When the coil is not energized the demand signal input should be less than 0 5VAC Refer to wiring schematic in Figure 4 An alternate thermostat wiring approach is to connect the demand signal directly to the Comfort Alert and allow the module to control the contactor directly Allowing Comfort Alert to control the contactor directly will prevent voltage drops in long thermostat wire runs Refer to wiring schematic in Figure 5 NOTE Factory installed modules may have different thermostat demand signal wiring Follow manufacturer s wiring instructions when replacing module System Controller Demand Wiring The Comfort Alert module can also be connected to a system controller refer to Figure 6 for wiring schematics The PROT terminal may be monitored by the controller instead of providing protection if the controller shuts down the compressor on severe Alerts The 10kohm resistor must be added externally and forces the controller input to 24VAC when the PROT terminal is open When the PROT terminal is closed the controller input will be OVAC NOTE After the thermostat demand signal is connected verify Y is phased properly with C by measuring 24VAC across Y and C when demand is present Thermostat Second Stage Cooling Wiring
34. gh Comfort Alert Compressor contactor has failed open Red TRIP The anti short cycle timer 3 minutes in module is preventing compres LED Flashing sor restart Module locks out compressor when compressor damaging ALERT codes appear Lockout ALERT codes are noted in the Status LED Description During a compressor lock out 24VAC power must be removed from module to manually reset Yellow ALERT LED On Solid Yellow ALERT Flash Code 2 Yellow ALERT Flash Code 3 Code 3 lockout is disabled for 543 0071 00 Yellow ALERT Flash Code 4 Yellow ALERT Flash Code 5 A short circuit or over current condition exists on PROT terminal System Pressure Trip Discharge pressure out of limits or compressor over loaded if no high pressure switch in system LOCKOUT Short Cycling Compressor is running only briefly LOCKOUT Locked Rotor LOCKOUT Open Circuit 1 Compressor contactor coil shorted 2 Electrical load too high for PROT circuit maximum 1 Amp 3 24 V AC wired directly to PROT terminal 1 High head pressure 2 Condenser coil poor air circulation dirty blocked damaged Condenser fan is not running If low pressure switch is open Refer to Code 3 for troubleshooting If low pressure switch is open a Low refrigerant charge b Evaporator blower is not running c Evaporator coil is frozen d Faulty metering device e Condenser coil is dirty f Liquid line restric
35. ing at the same time means control circuit voltage is too low for operation Resetting Alert Codes Alert codes can be reset manually and automatically The manual method to reset an Alert code is to cycle the power to Comfort Alert off and on For automatic reset Comfort Alert continues to monitor the compressor and system after an Alert is detected If conditions return to normal the Alert code is turned off automatically ALERT codes that result in compresor lockout can only be reset manually ALERT codes that result in a lockout can only be reset manually NOTE Comfort Alert cannot be applied on compressors that are powered by a variable frequency drive The changing frequency will cause nuisance codes to appear 10 NOTE correct Comfort Alert model must be used for the application refer to the Product Specification section on page 2 If the wrong model is installed the ALERT Flash Codes for system faults will function incorrectly the Comfort Alert module may indicate system faults that are not present or fail to indicate system faults that are present NOTE Miswiring the Comfort Alert module will cause false LED codes Table 1 describes LED operation when the module is miswired and what troubleshooting action is required to correct the problem Miswired Module Indication Recommended Troubleshooting Action Green LED is not on Determine if both R and C module terminals are module does not power up connected Verify
36. onitor the ALERT and Trip LEDs The Alert and Trip LEDs should remain off during this portion of the test Disconnect power to the compressor while the call for cooling is 7 still active The TRIP LED will again flash for the duration of the anti short cycle time after the anti short timer expires the Trip LED will illuminate and remain solid as long as the compressor power remains disconnected and demand is still present If the red LED does not function as described refer to Table 1 to verify the wiring Installation Verification for Models 543 0038 01 943 0038 01 543 0071 00 543 0038 02 943 0038 02 Disconnect power to the compressor and force a call for cooling The red TRIP LED will immediately come on solid If the red LED does not function as described refer to Table 1 to verify the wiring Note For these models the anti short cycle feature will become active after one hour of total run time or after 50 normal run cycles which ever comes first Status LED Status LED Description Status LED Troubleshooting Information Green POWER Module has power Supply voltage is present at module terminals Red TRIP Thermostat demand signal 1 Compressor protector is open LED On Solid Y is present but the com Condensing unit power disconnect is pressor is not running open Compressor circuit breaker or fuse s is open Broken supply wires or connector is not making contact Compressor power wires not routed throu
37. rt intelligently changes the solenoid DC voltage supply to minimize power consumption A voltmeter attached to the DC SOL output will measure 4 18VDC when solenoid should be energized depending on the level of the 24VAC supply 6 PROT Terminal The PROT terminal provides the compressor protection functionality for Comfort Alert If a compressor damaging code is active the PROT terminal interrupts the common leg of the compressor contactor coil This terminal is rated for a maximum of 1 Amp 24 VA and is only compatible with AC coils The compressor contactor coil must use the same supply voltage as the Comfort Alert power supply R and C The PROT terminal will allow the compressor contactor to be energized whenever demand Y is present no alert codes are present and the anti short cycle timer 3 minutes is not active The PROT terminal will force the compressor contactor to be deenergized whenever Y is not present Certain Alert codes will trip and or lock out the compressor if the condition is serious and no cooling is being provided The anti short cycle timer is active on every compressor shut down If the demand Y is present while the timer is still active the PROT terminal will keep the compressor contactor from energizing until the timer is complete The red TRIP LED will flash while the compressor is held off Safety Cutout Devices The Comfort Alert protection is not a substitute for safety cutout protectiv
38. sions Single Stage A Hazardous voltage inside air conditioning system Discon nect power before installing or servicing module Module WARNING ETa ETA Modal Hardware Installation Four 8 10 self drilling or sheet metal screws at least 12 length are required for installation of the Comfort Alert module The maximum screw torque is 20 in lbs Locate the Comfort Alert module near the compressor contactor wire routing for compressor run common and start wires will be easier in this position Mount the Comfort Alert module so all LEDs are visible from a comfortable viewing position The module will operate in any mounting orientation For ease of reading labels the module should be oriented so that the green POWER LED is at the top Compressor Wire Routing Figure 4 The scroll compressor s T1 T2 and T3 wires are routed through the holes in the Comfort Alert module marked T1 T2 and T3 The T2 wire need not be routed through the module for it to operate properly 3 24VAC Power Wiring The Comfort Alert module requires a constant nominal 24VAC power supply The wiring to the module s R and C terminals must be directly from the control transformer The module cannot receive its power from another device that will interrupt the 24VAC power supply Refer to wiring schematics in Figures 4 5 and 6 Thermostat Demand Wiring The Comfort Alert module requires a thermostat d
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40. tion filter drier blocked if present If high pressure switch is open go to Flash Code 2 information Intermittent thermostat demand signal System or control board defective Low line voltage to compressor Excessive liquid refrigerant in compressor Compressor bearings are seized 1 Condensing unit power disconnect is open 2 Compressor circuit breaker or fuses are open 3 Compressor contactor has failed open 4 High pressure switch is open and requires manual reset 5 Broken supply wires or connector is not making contact 6 Unusually long compressor protec tor reset time due to extreme ambient temperature 7 Compressor windings are damaged Yellow ALERT Missing Phase 1 Compressor fuse is open on one phase Flash Code 6 LOCKOUT 2 Broken wire or connector on one phase 3 Compressor motor winding is damaged 4 Utility supply has dropped one phase Yellow ALERT Reverse Phase 1 Compressor running backward due to Flash Code 7 LOCKOUT supply phase reversal Yellow ALERT Welded Contactor 1 Compressor contactor has failed closed Flash Code 8 Compressor always runs 2 Thermostat demand signal not con nected to module Yellow ALERT Low Voltage 1 Control circuit transformer is overloaded Flash Code 9 Control circuit lt 18VAC 2 Low line voltage to compressor Flash code number corresponds to a number of LED flashes followed by a pause and then repeated TRIP and ALERT LED s flash
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