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Application Engineering

BULLETIN

AE8-1328 R6

Copeland

™

Digital Compressor Controller

Application Engineering

BULLETIN

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 ................................................................. 4

Specications ............................................................. 4

Installation ................................................................... 4

Compressor Wiring .................................................. 5

Low Voltage Terminals ............................................. 5

High Voltage Terminals ............................................ 5

(24VAC, 24COM) Digital Compressor Controller

Power ................................................................... 6

(C1, C2) System Controller Demand ....................... 6

(P1, P2, P3, P4) System Pressure Input .................. 6

(P5, P6) System Pressure Output ............................ 6

(T1, T2) Discharge Temperature Input ..................... 6

(A1, A2) Alarm Relay ................................................ 6

(M1, M2) Compressor Contactor .............................. 6

(L1, L2) Control Power ............................................. 6

(U1, U2) Unloader Solenoid ..................................... 6

(V1, V2) Vapor Injection Solenoid / (U3, U4 on

IDCM) Blocked Suction Solenoid .......................... 7

Compressor Start and Shut Down ........................... 7

Compressor Running ............................................... 7

Digital Compressor Controller LEDs ........................ 7

Flash Code Troubleshooting ....................................7-9

Testing

OEM Testing ............................................................. 9

Testing the Installed Digital Compressor Controller . 9

Input Tests ................................................................ 9

Output Tests ............................................................. 9

Demand Cooling with Copeland Digital

Compressor Controller .............................................. 9

Figures & Tables

Compressor Controller Wiring Diagram...................... 10

Digital Compressor Controllers................................... 11

Digital Compressor Controller Differences ................. 11

20 Second Cycle Controller: 543-0024-00 20;

543-0086-01 ........................................................... 11

15 Second Cycle Controller: 543-0024-01 ................. 12

20 Second Cycle Controller: 543-0088-00 ................. 12

20 Second Cycle Controller: 543-0194-00 ................. 12

Thermistor Temperature/Resistance Values ............... 13

Demand Signal Vs. Modulation Graph (P/N

543-0024-00, 543-0024-01, & 543-0086-01) .......... 14

Demand Signal vs. Modulation Graph

(P/N 543-0088-00) .................................................. 14

Demand Signal vs. Modulation Graph

(P/N 543-0194-00) .................................................. 15

Service Panel Label (Form 052-2401-00) for

Controller Part No. 543-0024-00 and

543-0024-01 ............................................................ 16

Service Panel Label (Form 052-2402-00) for 4D

Controller 543-0088-00............................................ 16

Service Panel Label (Form 052-2843-000) for 6D

Controller 543-0194-00............................................ 17

TABLE OF CONTENTS

Section Page Section Page

AE8-1328 R6

March, 2014

Summary of content (17 pages)

PAGE 1
Application Engineering Application Engineering B B U U L LL E L T EI T N I AE8-1328 R6 N March, 2014 AE8-1328 R6 Copeland™ Digital Compressor Controller TABLE OF CONTENTS 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.......................
PAGE 2
Application Engineering B U L L E T I N AE8-1328 R6 Safety Instructions Copeland Scroll™ compressors 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 compessor. You are strongly advised to follow these safety instructions.
PAGE 3
Application Engineering B U L L E T I N AE8-1328 R6 Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons WARNING ELECTRICAL SHOCK HAZARD • Disconnect and lock out power before servicing. • Discharge all capacitors before servicing. • Use compressor with grounded system only. • Molded electrical plug must be used when required. • Refer to original equipment wiring diagrams. • • Failure to follow these warnings could result in serious personal injury.
PAGE 4
Application Engineering Application Engineering B BU U L LL E LT EI Introduction The Digital Compressor Controller is the electronics interface between the Copeland Scroll Digital ™ compressor or the Copeland Discus Digital™ compressor and the system controller. The Digital Compressor Controller is designed only for single phase Copeland Scroll Digital compressors and three phase Copeland Scroll Digital and Discus Digital compressors.
PAGE 5
Application Engineering B U L L E T I AE8-1328 R6 N A service panel label (Form Numbers: 052-240100, 052-2402-00, and 052-2843-00) describing the terminals and ALERT flash codes is included with each Digital Compressor Controller. This label should be in a visible location for the technician when he is troubleshooting the system. See Figures 7-9. NOTE! Do not bundle low voltage wires with compressor power or high voltage wires.
PAGE 6
Application Engineering B U L L E NOTE! To avoid damaging the Digital Compressor Controller do not connect wires to terminals C3, C4, T3, T4, T5 or T6. I N (P5, P6) System Pressure Output If a pressure transducer is connected to the System Pressure Input terminals, the System Pressure Output provides an analog output of the filtered suction pressure.
PAGE 7
Application Engineering B U L L E (U1, U2) Unloader Solenoid I N the solenoid valve is de-energized, the compressor capacity is 100%. When the solenoid valve is energized, the compressor capacity is zero. Therefore, the capacity achieved is the time average capacity, which is a variable from 10 – 100%. The Unloader Solenoid output is a triac output. The maximum continuous solenoid load is 0.5A and the peak inrush current is 6A. The maximum solenoid operating voltage is 250VAC.
PAGE 8
Application Engineering B U L L E Flash codes 3, 4, 5, and 9 activate the two minute anticycle timer. Flash code 2 activates the 30 minute timer. I N compressor as long as the system controller demand is above 1.44VDC. There is no lockout feature for this ALERT. All LEDs flashing at the same rate indicates 24VAC supply is too low for operation. All LEDs on solid at the same time indicates Digital Compressor Controller failure.
PAGE 9
Application Engineering B U L L E I N Input Tests compressor contactor may have welded contacts or the contacts may be mechanically jammed. The compressor will continue to run in this condition since the Digital Compressor Controller cannot open the compressor contactor. Thermistor Input – disconnect the discharge temperature sensor wires from terminals T1 and T2. If functioning normally, the Digital Compressor Controller should display a Code 6 unless a previous ALERT code was present.
PAGE 10
Application Engineering B U ** 1-5VDC DEMAND SIGNAL FROM SYSTEM CONTROLLER 24VAC CONTROLLER POWER L L E T I V2 C1 COMMON +5VDC SIGNAL C3 COMMON P1 SIGNAL +5VDC SUPPLY P2 OPTIONAL 0-5VDC SUCTION PRESSURE OUTPUT P4 M1 +5VDC P6 L2 T1 L1 T2 DISCHARGE TEMPERATURE THERMISTOR T3 A1 T4 OR 5kOhm, 1W RESISTOR (for Demand Cooling Applications) DIGITAL UNLOADER SOLENOID U1 M2 P5 VAPOR INJECTION SOLENOID U2 P3 COMMON *** OPTIONAL V1 C2 C4 OPTIONAL SUCTION PRESSURE TRANSDUCER INPUT
PAGE 11
Application Engineering B U L L E T I AE8-1328 R6 N Table 1 – Digital Compressor Controllers Part Number Duty Cycle Time (sec) 2-Minute Anti Short Cycle Timer Delay Application 543-0024-00 20 Yes Refrigeration - Scroll 943-0024-01 543-0024-01 15 Yes Air Conditioning - Scroll 943-0086-00 543-0086-01 20 No Refrigeration - Scroll & Discus (3D) 943-0088-00 543-0088-00 20 No Refrigeration - Discus (4D) 943-0194-00 543-0194-00 20 No Refrigeration - Discus (6D) Kit Number Tabl
PAGE 12
Application Engineering B U L L E T I AE8-1328 R6 N Table 4 15 Second Cycle Controller: 543-0024-01 Demand Signal (VDC) Loaded % Unloaded% Time Loaded Time Unloaded % Digital Compressor Capacity 1.00 Off Off Off Off 0% 1.44 10% 90% 1.5 seconds 13.5 seconds 10% 3.00 50% 50% 7.5 seconds 7.5 seconds 50% 4.20 80% 20% 12 seconds 3 seconds 80% 5.
PAGE 13
Application Engineering B U L L E T I AE8-1328 R6 N Table 7 Thermistor Temperature/Resistance Values Deg C Deg F Resistance (kOhms) Deg C Deg F Resistance (kOhms) -40 -40 2889.60 70 158 15.07 -35 -31 2087.22 75 167 12.73 -30 -22 1522.20 80 176 10.79 -25 -13 1121.44 85 185 9.20 -20 -4 834.72 90 194 7.87 -15 5 627.28 95 203 6.77 -10 14 475.74 100 212 5.85 -5 23 363.99 105 221 5.09 0 32 280.82 110 230 4.45 5 41 218.41 115 239 3.
PAGE 14
Application Engineering B U L L E T I AE8-1328 R6 N Figure 4 Demand Signal Vs. Modulation Graph (P/N 543-0024-00, 543-0024-01, & 543-0086-01) 100% 5.00 90% Unloader Modulation 80% 3.95 70% 60% Compressor Off 50% 40% 2.90 30% 20% 10% 0% 0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 Demand Signal (VDC) Figure 5 Demand Signal vs. Modulation Graph (P/N 543-0088-00) © 2014 Emerson Climate Technologies, Inc. Printed in the U.S.A. 14 4.8 5.
PAGE 15
Application Engineering B U L L E T I AE8-1328 R6 N 100 5.0 90 Unloader Modula on (%) 80 70 66 60 3.64 50 40 33 30 Compressor ON 2.33 Compressor OFF 20 10 Blocked Suc on - Loaded Digital - Unloaded Compressor ON Blocked Suc on Unloaded Digital - Unloaded 0 0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 Demand Signal (VDC) 4.0 Figure 6 Demand Signal vs. Modulation Graph (P/N 543-0194-00) © 2014 Emerson Climate Technologies, Inc. Printed in the U.S.A. 15 4.4 4.8 5.
PAGE 16
Application Engineering B U L L E T I N AE8-1328 R6 Copeland Scroll Digital™ Compressor Controller Low Voltage Terminals 24 COM Module Power 24 VAC Module Power C1 Demand Input C2 Demand Input + P1 Pressure Common P2 Pressure Input P3 Pressure Power 5VDC P4 Pressure Shield P5 Pressure Output P6 Pressure Output + T1 Discharge Temp Sensor T2 Discharge Temp Sensor High Voltage Terminals A1 Alarm Relay Out A2 Alarm Relay Out L1 Control Voltage N L2 Control Voltage L M1 Contactor M2 Contactor U1 Unloa
PAGE 17
Application Engineering B U L L E T I N AE8-1328 R6 Copeland™ 6D Digital Compressor Controller Low Voltage Terminals 24 COM Module Power 24 VAC Module Power C1 Demand Input C2 Demand Input + P1 Pressure Common P2 Pressure Input P3 Pressure Power 5VDC P4 Pressure Shield P5 Pressure Output P6 Pressure Output + T1 Discharge Temp Sensor T2 Discharge Temp Sensor High Voltage Terminals A1 Alarm Relay Out A2 Alarm Relay Out L1 Control Voltage N L2 Control Voltage L M1 Contactor M2 Contactor U1 Digital S