Emerson AE8-1385 Air Conditioner User Manual
Contents
1. EMERSON Climate Technologies 67 Figure 2 Module Dimensions in Millimeters 2011 Emerson Climate Technologies Printed in the U S A CoreSense Diagnostics i for Copeland Scroll Compressors T For Use With Copeland Scroll s UltraTech Compressors a a Y2 L 3 g S amp Y 8 d l Pa lt Data Port PIN 543 XXXX XX amp L As Os C US Use With Class 2 lt C Circuits Only Supply 24VAC 50 60Hz lt PROT D Power 1 5VA ahg Solenoid EMERSON E S Climate Technologies Figure 3 Terminal Locations E Sson Application Engineering Zammer EMERSON ges es Oe A Os ee DN AE8 1385 Outdoor CoreSense 2 Stage Thermostat J Y2 Y1 High Low Pressure Switch Compressor Contactor 000G SIOA Solenoid Figure 4 Wiring Diagram 2011 Emerson Climate Technologies Printed in the U S A EMERSON BSL Vi Ea AE8 1385 Table 1 Flash Code a Lockout Alert Code Code Alertcondition Condition Lockout Level Honmmal Ran Normal operation no tri Solid G2. secceeeeeeeeeees 10 12 2011 Emerson Climate Technologies Printed in the U S A 4 EE Sson Application Engineering Zammer EMERSON oto gt O ss os ne fe bs AE8 1385 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 rN DANGER 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 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 2011 Emerson Climate Technologies Printed in the U S A 4 fa ee Sson __APPlication Engineering carmen EMERSON anipe gt O E rs a a ne N AE8 1385 Instructions Pertaining to Ris
3. Flash Code 10 gt Oe os es ee es Copeland brand products AE8 1385 Table 2 Continued Compressor Moderate Run Trip Compressor is locked out after 4 consecutive or 10 total compressor moderate run trip events Open Start Circuit Current only in run circuit Open Run Circuit Current only in start circuit Over Current Protection Current to PROT is greater than 2A mps 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 Faulty metering device e Check TXV bulb installation size location and contact e Check if TXV fixed orifice is stuck closed or defective Condenser coil poor air circulation dirty blocked damaged Low refrigerant charge Run capacitor has failed Open circuit in compressor start wiring or connections e Check wiring and connectors between supply and the compressor S terminal Compressor start winding is damaged e Check compressor motor winding resistance Open circuit in compressor run wiring or connections e Check wiring and connectors between supply and the compressor R terminal Confirm proper wire routing per Figure 1 Compressor run winding is damaged e Check compressor motor winding resistance Check for contactor shorted
4. Le Fson Application Engineering amatener EMERSON os B U L L E TE I N AE8 1385 October 2011 CoreSense Diagnostics for Copeland Scroll UltraTech Air Conditioning Compressors TABLE OF CONTENTS Safety Safety INStMUCHONS cs 2 Safety Icon Explanation escncrenarsnnronscn n ann 2 Instructions Pertaining to Risk of Electrical Shock Fire or Injury to Persons rssicon NA 3 Safety Statements eo 3 Introduction OVGIVIGW csn piaren a as anaana a a A aa Na 4 Application Restrictions and Types ceeceeeeeeeeeeeeees 4 Product SpecificatiON Ss iisas iadnn a 4 Installation MOUNTING eoun E AAS 4 Terminal Descipti Msensesense ennan weansatdiands 4 Operation Compressor Protection assistans 4 Module LED Description cccccceceeeeeeeeeceeeeeeeeeeeeeetees 5 Module Operation Code Description ccceeeeeteeeees 5 Resetting Alert Codes cccecceeceeeeeeeeeeeeeennnceceeeeeeeetees 6 Service Module History Download cccceeeeeeeeeeeeeeeeeeeeneeeeeeeenaees 6 Warranty Informations csvesssiseckdsscevestiassee tear dacssetessitarverseouaeeye 6 SUP POM AEA E A A A EE AAEE 6 Figures and Tables Wires Pulled Through Module scissocssenreinhaniiesitoneea e 6 Module Dimensions in Millimeters 0 ceceeeeeeeteeeees 7 Terminal Location Sersan pak noaee a 7 Wiring Diagram sicosnsiinenesnre a a i 8 Flash Code Descriptores 9 LED Troubleshooting Information
5. 4 Os es Pe Ps off This event will cause a lockout of the compressor and indicates that the module is mis wired or the contactor coil is shorted to ground NOTICE Code 10 is not specified on the module label Resetting Alert Codes When the CoreSense Diagnostics module has detected a series of adverse conditions that have caused it to 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 or TRIP LOCK is to cycle the power to the module by disengaging the COMMON C Terminal This will not clear the seven day operating history contained in the module memory It will only clear the present ALERT or TRIP LOCK and allow for normal operation SERVICE Always disconnect and lockout the power supply before beginning electrical troubleshooting Module History Download The CoreSense Diagnostics module is capable of communicating with a personal computer tablet or laptop via Emerson Climate Technologies computer Copeland O on _ApPlication Engineering EMERSON AE8 1385 software interface and USB connection 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 For more information please contact your Emerson Climate Application
6. 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 www EmersonClimate com Support For more information visit www EmersonClimate com or contact Emerson Climate Technologies Inc at 1 888 EMR 9950 Figure 1 Wires Pulled Through Module 2011 Emerson Climate Technologies Printed in the U S A Econ Application Engineering Zapster EMERSON ots gt S O es rs es i ns ee AE8 1385 ALERT TRIP LOCK 37 Sy Ea CoreSense Diagnostics for Copeland Scroll Compressors Flash Event q Long Run Time Compressor Pressure Trip 3 Pressure Switch Cycling E 4 Locked Rotor R 5 Compressor Mod Run Trip 6 Open Start Circuit 7 Open Run Circuit 8 Welded Contactor 9 Low Voltage E 62 B C BD 112 Two Stage Control DC SOL operating range 18 28VDC Compressor second stage is energized when Y amp Y2 are 24VAC j Active Protection S D PROT breaks 24VAC common leg of compressor contactor coil Reset codes and PROT lockout by removing 24VAC to module
7. on the Copeland Scroll UltraTech compressor Oe rs es Pe Ps OPERATION 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 solid state switch in the module thereby cutting power to the contactor and de energizing the compressor Module LED Description POWER LED Green indicates the module is powered with 18 to 28 volts ALERT LED Yellow communicates an abnormal system condition through a 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 Table 1 TRIP LOCK LED Red indicates either a TRIP or LOCK condition e TRIP is indicated by a solid illumination of the LED This means the compressor is not running and demand is present at the module e LOCK is indicated by a flashing LED correlating to a LOCK condition in which the module will prevent the compressor f
8. to ground 2 Check for mis wiring to the PROT terminal 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 products at 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 2011 Emerson Climate Technologies Printed in the U S A 12
9. Failure to follow these warnings could result in personal injury or property damage e Use the appropriate lifting devices to move compressors e Personal safety equipment must be used Safety Statements e Refrigerant compressors must be employed only for their intended use e Only qualified and authorized HVAC or refrigeration personnel are permitted to install commission and maintain this equipment e Electrical connections must be made by qualified electrical personnel All valid standards and codes for installing servicing and maintaining electrical and refrigeration equipment must be observed 2011 Emerson Climate Technologies Printed in the U S A Os rs es Pe Ps INTRODUCTION Overview 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
10. erminal 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 A signal above 6VAC indicates the thermostat wants the compressor to be on while 0 6VAC signal indicates the thermostat wants the compressor to be off SECOND STAGE DEMAND Y2 The demand Y and second stage demand Y2 terminals require a 24VAC signal measured with respect to the COMMON C terminal when there is a call for heating or cooling A signal above 10VAC indicates the thermostat wants the Ultratech solenoid to be energized while 0 10VAC signal indicates the thermostat wants the Ultratech solenoid to be deenergized PROTECTION PROT The protection terminal is internally connected to the COMMON terminal through a solid state switch POWER R The module requires a constant 24VAC supply power to this terminal The module must receive an independent power supply in order to operate properly See Figure 4 Thermostat Communication L Provides a 24V signal to an indoor thermostat indicating the number of ALERT flashes displayed on the module Reference thermostat manual for available capability Solenoid DC SOL Provides a connection to the Copeland Scroll UltraTech second stage compressor solenoid This solenoid is internal to the compressor and has a voltage range of 18 to 28VDC Please refer to bulletin AE 1311 for information
11. 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 Application Restrictions and Types The CoreSense Diagnostics 571 0072 00 module is designed and qualified for use with ZPS K5 single phase Copeland Scroll UltraTech compressors Product Specifications Operating Temp 40 to 150 F 40 to 65 C Storage Temp 40 to 175 F 40 to 80 C Supply Voltage 18 to 28VAC 48 to 62Hz Module Current Sensing Range 2 to 30A Maximum Power Consumption 2 5 VA Excluding solenoid load INSTALLATION Mounting Four 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 Locate the module near the compressor contactor wire routing for compressor run common and start wires will be easier in this position The module can be mounted in any orientation and LEDs should be visible for ease of service The compressor s run R common C and start S wires are routed through the holes in the CoreSense module marked R C and S See Figure 1 2011 Emerson Climate Technologies Printed in the U S A Copeland on _ApPlication Engineering EMERSON AE8 1385 Terminal Description The terminals for the CoreSense Diagnostics module are spade terminals e COMMON C The 24 volt common t
12. k of Electrical Shock Fire or Injury to Persons ELECTRICAL SHOCK HAZARD e Failure to follow these warnings could result in serious personal injury Disconnect and lock out power before servicing e Discharge all capacitors before servicing e Use compressor with grounded system only e Molded electrical plug must be used when required e Refer to original equipment wiring diagrams Electrical connections must be made by qualified electrical personnel e e PRESSURIZED SYSTEM HAZARD Failure to follow these warnings could result in serious personal injury System contains refrigerant and oil under pressure Remove refrigerant from both the high and low compressor side before removing compressor Use appropriate back up wrenches on rotalock fittings when servicing Never install a system and leave it unattended when it has no charge a holding charge or with the service valves closed without electrically locking out the system Use only approved refrigerants and refrigeration oils Personal safety equipment must be used e e e BURN HAZARD e Failure to follow these warnings could result in serious personal injury or property damage e Do not touch the compressor until it has cooled down e Ensure that materials and wiring do not touch high temperature areas of the compressor e Use caution when brazing system commponents e Personal safety equipment must be used COMPRESSOR HANDLING e
13. l 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 or ten total Code 5 events are recorded the module will lockout the compressor and flash red five times Code 6 Open Start Circuit The module will lockout the compressor and flash red six times if the module detects a demand signal in the Y terminal and current in the R winding of the compressor but no current is detected in the S winding of the compressor for 2 seconds Code 7 Open Run Circuit The module will lockout the compressor and flash red seven times if the module detects a demand signal in the Y terminal and current in the S winding of the compressor but no current is detected in the R winding of the compressor for 2 seconds Code 8 Welded Contactor The module will flash yellow eight times if it has detected line currents in the S and R windings and demand is absent for 15 seconds Code 9 Low Voltage The module will flash nine times if the module supply voltage drops below 17VAC for 2 seconds The module will prevent the compressor from starting until adequate voltage is established Code 10 Over Current Protection When the current at the PROT terminal is greater than 2A for 40ms the module will flash a Code 10 The red LED will flash 10 times with the yellow LED remaining
14. ltage Outdoor unit power disconnect is open Compressor circuit breaker or fuse s is open Broken wire or connector is not making contact High pressure switch open if present in system Compressor contactor has failed open Low refrigerant charge 2 Evaporator blower is not running e 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 Evaporator coil is frozen e Check for low suction pressure e Check for excessively low thermostat setting e Check evaporator airflow coil blockages or return air filter e Check ductwork or registers for blockage Faulty metering device e Check TXV bulb installation size location and contact e Check if TXV fixed orifice is stuck closed or defective Liquid line restriction filter drier blocked if present in system Thermostat is malfunctioning e Check thermostat sub base or wiring for short circuit e Check thermostat installation location level Condenser fan is not running e Check fan capacitor e Check fan wiring and connectors e Check fan motor for failure or blockage High head pressure e Check high pressure switch if present in system e Check if system is overcharged with refrigerant e Check for non condensable in system Condenser coil poor air circulation dirty blocked da
15. maged Return air duct has substantial leakage Time delay relay or control board defective 2 If high pressure switch present go to Flash Code 2 information 10 EMERSON Yellow ALERT Flash Code 4 Yellow ALERT Flash Code 5 Yellow ALERT Flash Code 8 Yellow ALERT Flash Code 9 Red LOCKOUT Flash Code 2 Yellow Off Red LOCKOUT Flash Code 3 Yellow Off Red LOCKOUT Flash Code 4 Yellow Off Copeland gt S O n es os nn N AE8 1385 Table 2 Continued 1 Run capacitor has failed 2 Low line voltage contact utility if voltage at disconnect is low Locked Rotor check wiring connections 3 Excessive liquid refrigerant in compressor 4 Compressor bearings are seized e Measure compressor oil level 1 Evaporator blower is not running e Check blower relay coil and contacts e Check blower motor capacitor e Check blower motor for failure or blockage e Check evaporator blower wiring and connectors Compressor Moderate Run e Check indoor blower control board Trip e Check thermostat wiring for open circuit 2 Faulty metering device e Check TXV bulb installation size location and contact e Check if TXV fixed orifice is stuck closed or defective 3 Condenser coil poor air circulation dirty blocked damaged 4 Low refrigerant charge Welded Contactor 1 Compressor contactor has failed closed Compressor always runs 2 Thermostat demand signal not connected to
16. module Low Supply Voltage 1 Control Circuit transformer is overloaded Voltage below 18V 2 Low line voltage contact utility if voltage at disconnect is low 1 Condenser fan is not running e Check fan capacitor e Check fan wiring and connectors e Check fan motor for failure or blockage 2 High head pressure e Check high pressure switch if present in system e Check if system is overcharged with refrigerant e Check for non condensable in system 3 Condenser coil poor air circulation dirty blocked damaged 4 Return air duct has substantial leakage Compressor Pressure Trip Compressor is locked out after 4 consecutive or 10 total compressor pressure trip events Pressure Switch Cycling Compressor is locked out after 4 consecutive or 10 total pressure cycling events 1 Time delay relay or control board defective 2 If high pressure switch present go to Flash Code 2 information 1 Run capacitor has failed 2 Low line voltage contact utility if voltage at disconnect is low e Check wiring connections 3 Excessive liquid refrigerant in compressor 4 Compressor bearings are seized e Measure compressor oil level Locked Rotor Compressor is locked out after 10 consecutive locked rotor events 11 2011 Emerson Climate Technologies Printed in the U S A EMERSON Red LOCKOUT Flash Code 5 Yellow Off Red LOCKOUT Flash Code 6 Yellow Off Red LOCKOUT Flash Code 7 Yellow Off Red LOCKOUT
17. nds N A N A Code9 Low Voltage Module has detected a 24 VAC supply Yellow Flash 9 voltage below 17 VAC 1 VAC for 2 seconds Code10 Over Current Protection PROT terminal has above a 2A Red Flash 10 input for more than 40 milliseconds Red Fleet 40 2011 Emerson Climate Technologies Printed in the U S A a a a Copeland brand products EMERSON gt O E a os nn N AE8 1385 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 brown out conditions Solid Green RUN Module has power and Supply voltage is present at module terminals 1 operating normally Compressor protector is open Solid Red TRIP Yellow ALERT Flash Code 1 Yellow ALERT Flash Code 2 Yellow ALERT Flash Code 3 Thermostat demand signal Y is present but the compressor is not running Long Run Time Low Refrigerant Charge Compressor is running extremely long run cycles Compressor Pressure Trip High Refrigerant Charge Discharge pressure out of limits or compressor overloaded Pressure Switch Cycling Compressor is running only briefly due to pressure switch cycling 2011 Emerson Climate Technologies Printed in the U S A e Check for high head pressure e Check compressor supply vo
18. reen a kia Code1 Long run time Compressor is running for more than 18 hours at full load Code1 is disabled in Heat Pump N A N A Yellow Flash 1 mode Compressor Pressure trip Compressor runs for 12sec Code2 i s i Yellow Flash 2 to 15min followed by a compressor trip condition lasting STOW maS longer than 7min 4x consecutive 10x total Red Flash 2 Pressure switch cycling Compressor runs for 12sec to Code 3 i Yellow Flash 15min followed by a compressor trip lasting between ellow Flash 3 35sec to 7min Code4 Locked rotor Compressor trips within a compressor run 3 Yellow Flash 4 time of 12sec and does not start within 35sec Me ONE SOUNE E E 4x consecutive 10 total Red Flash 3 Code5 Compressor moderate run trip Compressor runs for 4x consecutive 10x total Red Flash 5 15min to 18hrs followed by a compressor trip lasting Yellow Flash 5 longer than 7min Code6 Open start circuit Module has detected Y or Y1 and Red Flash 6 current in the R winding of the compressor and no 1 occurrence Red Flash 6 Gamas current in the S winding of the compressor for 2 seconds Code7 Open run circuit Module has detected Y or Y1 and Red Flash 7 current in the S winding of the compressor and no current 1 occurrence Red Flash 7 Co maS in the R winding of the compressor for 2 seconds Code8 Welded Contactor Module has detected line currents N A N A Yellow Flash 8 in R and S windings and Y or Y1 is at 0 VAC for 15 seco
19. rom starting Module Operation Code Description 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 This code is inactive for heat pumps Code 2 Compressor Pressure Trips The module will flash yellow two times when the compressor operates from 12 seconds to 15 minutes followed by a trip condition lasting longer than 7 minutes When four consecutive or ten total Code 2 events are recorded the module will lockout the compressor and flash red two times 2011 Emerson Climate Technologies Printed in the U S A Copeland on _ApPlication Engineering EMERSON AE8 1385 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 or ten total Code 3 events are recorded the module will lockout the compressor and flash red three times Code 4 Locked Rotor Trip 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 ten 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 wil
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