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
To Next Page
Need help?
General
