A. General Product Overview. B. Support Tools. C. Detailed Product & Technical Information

Transcription

1 June 2009

2 Launch Package Updated June 16, 2009

3 Launch Package A. General Product Overview B. Support Tools C. Detailed Product & Technical Information D. Frequently Asked Questions 3

4 Launch Package A. General Product Overview 1. Product Description & Application 2. Features, Advantages, & Benefits Alert Codes 4. Communication Capability 5. Market Research & Field Test 6. Product Value 7. Part Numbers & Accessories 8. Support Material B. Support Tools C. Detailed Product & Technical Information D. Frequently Asked Questions 4

5 Refrigeration Diagnostics Used With Copeland Brand Compressors To: Improve Compressor Reliability Provide System Diagnostics Enable Communication Capabilities Self-Contained, ed, Stand Alone Module That Uses Compressor As A Sensor To Diagnose Electrical Problems And Common System Related Faults New Retrofit Application: Walk-In: Recip & Scroll Industrial Recip & Scroll Supermarket: Scroll Discus ISD Compatible With Copeland Brand Single And Three Phase Scroll & Reciprocating Compressors 5

6 Gold Dealer Design Award Testing and Monitoring Products Category. Award emphasizes need for userfi friendly testing ti and monitoring i tools that t provide accurate and timely information. Judges Comments This is innovation from a recognized leader in the market, what else can be said. It would be wonderful if more OEM s would install it. 6

7 Copeland Compressor Controller Platform Intelligent Store Discus Comfort Alert Second Generation UltraTech Diagnostics Commercial C i l Diagnostics Copeland PerformanceAlert Comfort Alert Diagnostics (First Generation) 7

8 Product Specifications High Voltage Connections 1.46 in (37 mm) Discharge Line Temperature Probe Address Jumpers 2.44 in (62 mm) 4.40 in (112 mm) RS485 Communication Port 1.85 in (47 mm) 2.44 in (62 mm) Operating Temp: -40 to 150 F (-40 (40 to 65 C) Storage Temp: -40 to 175 F (-40 to 80 C) Power Supply Range: VAC, Hz Working Amperage, 3-phase Module; A Maximum Contactor Coil Current Is 5 Amps Compressor Power (Lead) Wire Must Fit In 0.33 in x 0.47 in (8.4 mm x 11.9 mm) Opening 8

9 Compressor Controller Diagnostics Improve Troubleshooting Accuracy And Warranty Technician Accuracy 100% 80% 60% Service Technician Study 92% 63% 100% %NDF 45% 30% Actual Warranty Results 40% 18% 15% 43% 22% 20% 0% 17% Entry Level No Diagnostics Experienced Comfort Alert 0% No Diagnostics Comfort Alert Improved Service Technician Accuracy Lower No Defect Found Warranty Failures My main concern is getting the equipment repaired the first time on the first visit... Refrigeration Contractor 9

10 Features, Advantages, And Benefits Features Advantages Benefits Predictive Diagnostics Monitors Compressor To Provide Early Warning When System Approaches Red Zone. Takes Action To Prevent Failures Less System Downtime Saves Compressor 11 Diagnostic Alert Improves Speed And Accuracy Of Diagnosis Faster Uptime And Reduces Codes And Troubleshooting System Issues Contractor Callbacks High Discharge 35% Of Compressor Failures Are From Less System Downtime Temperature Overheat. Notifies When Compressor Reaches Saves Compressor Protection Red Zone Temperature Motor Protection Prevents Majority Of Motor Failures Less System Downtime Saves Compressor Short Cycling Notifies When Compressor Runs Less Than 3 Less System Downtime Protection Minutes. Improves Oil Management Low Voltage/ Phase Eliminates Need To Install Phase Alarm Increases Compressor Alarm Protection Reliability 3 Types Of 1. Locally With LED Faster Uptime Communications 2. Remotely With ModBus 3. Fault History Retrieval With Laptop Toll Free Technical Support Number Adjustable Features 120 Or 230 Volt Compatible Helps Contractors Troubleshoot System Faster Uptime And Reduces Contractor Callbacks Discharge Line Thermostat And Lockouts Can Be Customized To Each Application Eliminates Nuisance Alerts Provides Flexibility Ease Of Design And Installation Lower Installation Costs

11 Diagnostic Alert Codes Code Feature Benefit Red Comp Trip Identification Indicates Compressor Not Running Yellow 1 High Discharge Protection Predicts Compressor Overheating. Saves Compressor Yellow 2 System Component Trip Diagnoses Safety Feature Has Tripped Yellow 3 Short Cycling Protection Predicts Contactor/Comp Failures. Saves Compressor Yellow 4 Locked Rotor Alarm Diagnoses Compressor Not Starting Yellow 5 Open Circuit Detection Diagnoses Loss Of Power To Compressor Yellow 6 Missing Phase / Open Run Predicts Motor Burn. Saves Compressor Yellow 7 Reverse Phase / Open Start Verifies Compressor Power Correct Yellow 8 Welded Contactor Alarm Predicts Compressor Failure. Forces Compressor To Run To Save Compressor Yellow 9 Low Voltage Alarm Prevents Contactor Chatter & Compressor Failure Yellow 10 Lost Communication Diagnoses Issues With External Communication Yellow 11 Open/Short DLT Circuit Diagnoses Issues With Discharge Line Thermostat Sensor Includes Technical Support Number To Help Contractors Troubleshoot

12 Most Common Compressor Failure Modes 40% 35% 30% 25% 20% 15% 10% 5% Heat (Hi Comp. Ratio, Return Gas, etc.) nt ing) Refrigeran art Or Runn Liquid R (Flooded Sta 0% Alert Code Yellow 3, 4 Yellow Yellow 1,11 Coverage 6, 7, 8, 9 2, 5 Contam mination Motor Burn d No Defe ect Foun Total Addressed Is 59% 12

13 Copeland PerformanceAlert Technical Support Technical Support Provided For: Installation Assistance System Troubleshooting Copeland PerformanceAlert Module Operation Call Toll Free: or 13

14 Communication Capability A) Connect To External LED B) Connect To Computer C) Connect To CPC Controller (RMCC, E1, or E2) Gateway CPA Copeland PerformanceAlert Module RS 485 to USB converter PC Control 1. View Alert Codes At An Accessible Position 1. Modify User Adjustable Features 2. Review/Download Compressor History 3. Use As Data Logger 1. Modify User Adjustable Features 2. Communicate Data & Alerts To System Controller 3. Review Compressor History 4. Use As Data Logger 14

15 Copeland PerformanceAlert Communication Capability Status Compressor Status (On/Off/Trip/Lockout) Fault Code Current, Voltage, Discharge Line Temperature Alarm History Total # of Alarms 10 Most Recent Alarms Weekly Record Of Alarms Compressor History # of Compressor Startst # of Compressor Run Hours # of Compressor Starts/Day # of Compressor Run Hrs/Day 15

16 Copeland PerformanceAlert Software Interface Copeland PerformanceAlert Module RS 485 to USB converter PC 16

17 Copeland PerformanceAlert Enables Intelligent Store Integrated Products Work Better Together Intelligent Store Discus 2.0 E2 v2.6 Copeland PerformanceAlert Gateway E2, E1, & RMCC Copeland PerformanceAlert E2 v2.? Directly Platform Applies To Retrofit Applications

18 Intelligent Store Platform Architecture Regulatory Compliance Information Server Emerso on Compone ents Easy Cost Savings Easy Maintenance Repair vs. Replace Multiple Sites Intelligent Store Leverages Emerson Devices And Services To Deliver Customer Benefits Globally Emerson Co Communic ontrols/ cation C 3 rd Party onnectivity Simple User Interface Customer Benefits ProAct Software Store Control Components/ Systems

19 Market Research And Customer Proof Points Market Research The Copeland PerformanceAlert Generated Relatively Strong Appeal Among Both End Users And Contractors: They Acknowledged There Is A Need For This Kind Of Product That The Compressor Is Probably The Least Protected Component They Liked The Package Of Functional Benefits Contained In Copeland PerformanceAlert, Which Provided The Capability To: Save Equipment From Ruinous Conditions Provide Diagnostic Information That Could Make Trouble- Shooting Easier And Faster When you purchase a new piece of equipment, you got to look at pricing. But I m not going to spend less money for something I am going to have twice the repairs for and have more downtime with product loss and dysfunction at the store level- we need to be open 100% of the time. - End User My main concern is getting the equipment repaired the first time on the first visit. The main goal is that they get serviced quickly and we correct the problem. - Contractor 19

20 Field Test Success Walk-In Sidney, OH The Copeland PerformanceAlert Detected A Trip Alert Code History Data Revealed The Trip Code Occurred At Least Once A Day A Resulting Service Call By Eck Refrigeration Uncovered That The System Was: Pulling Down Past The Low Pressure Cut-Out Where The Compressor Should Have Shut Down Instead The Compressor Run Continuously Ran Until The Compressor Heated Up And The Compressor Protector Tripped Generating The Trip Alert On Copeland PerformanceAlert After The Compressor Cooled, The Protector Reset, And Repeated The Above Cycle After Diagnosing The System, Eck Refrigeration Determined The LPCO Was Sticking And Therefore Never Breaking The Control Circuit The LPCO Was Replaced Correcting The System Defect Without Copeland PerformanceAlert This Diagnosis Would Have Been Very Difficult The Technician Would Have Had To Be On Site When The Compressor Protector Tripped To Realize There Was A Problem Without Intervention, The Compressor Protector Would Have Eventually Fatigued & The Compressor Would Have Failed Due To Overheating 20

21 Field Test Success Supermarket Rack Grove City, OH The Copeland PerformanceAlert Detected An Discharge Line Temperature Sensor Failure Alert Code On A 4D Compressor With Blocked Suction Unloading Copeland PerformanceAlert Was Used To Log The Discharge Temperature Over Time The Logged Data Showed The Discharge Temperature Was Not Decreasing When The Compressor Was Shut Off This Indicated The Compressor Was Experiencing A High To Low Leak After Diagnosing The System, It Was Determined That The Compressor Had An Incorrect Solenoid Valve On The Blocked Suction Unloader Causing The High To Low Leak The Solenoid Was Replaced Correcting The System Defect Without Copeland PerformanceAlert This Diagnosis Would Not Have Been Possible Without Intervention, The System Would Have Continued To Run At An Elevated Suction Pressure With Reduced Capacity & High Energy Consumption 21

22 Opportunities Replace Existing Accessories (i.e. Phase Monitor) While Providing Additional Value Provides Discharge Line Temperature Protection Provides Compressor Proofing Reduce Time To Service System Troubleshoot Repeat Compressor Failures Trouble Stores Applications 22

23 Application Value One Device Multiple Functions Protection/Diagnostic Feature Alternative Method Extra Hardware Costs Low High Used On Your Systems? Discharge Line Temperature Protection Discharge Line Thermostat $18 $25 Phase Protection Phase Monitor $30 $50 Short Cycling Protection Guaranteed On/Off Timers $10 $15 Verify Compressor Operation Current Relay $10 $15 Copeland PerformanceAlert Performs All These Functions 23

24 Copeland PerformanceAlert Additional Walk-In OEM Value Lower Warranty Costs (1 Claim x $600 - $2500 * 1%): $6 - $25 Each Less Phone Calls To OEM Because: (1/4 Man = $25K/60,000pcs) 000pcs) $0.50 Each Systems Easier To Diagnose Technical Support Number Fields Calls User Adjustable Features And 120/230V Compatible Ease Of Use 24

25 Copeland PerformanceAlert Walk-In End-User Value Potential Annual Savings: Greater Refrigeration Uptime = Improved Reliability / Lower Maintenance Cost Prevent 1 Compressor Failure Over Life 1 Failures X $300-$1500 compressor / 10 yr = $90 Faster Diagnosis Of Failure Modes Reduces Time by ½ Hour X $90-$120 per Hour X 4 Calls Over Life = $20 External Monitoring Reduces Contractor Time Reduces Time by ½ Hour X $90-$120 per Hour X 4 Calls Over Life = $20 Eliminate 1 Service Callback Over Life Service Call: $90 - $270 / 10 yr = $18 Greater Refrigeration Uptime Reduced Food Loss & Spoilage $$$ Contractor Saved The Day Because Saved System And Eliminated Downtime Priceless Energy Savings Discharge Line Overheat Protection TBD Low Voltage Protection TBD Short Cycling / Min On & Off TIme TBD $148 * Assumes 10 Year Life 25

26 Copeland PerformanceAlert Supermarket et End-User Value Story PerformanceAlert Potential Annual Store * Savings Expanded Condensed Lower Maintenance Cost Faster Compressor Diagnosis (X Hrs/Month) 1½ 1 X Hrs/Month *$100/Hr * 12 Months/Yr $1800 $1200 Eliminate Misdiagnosis Return Visits (X Visits/Yr) 1 1 X Visit/Yr * $450/Visit $450 $450 Prevent Compressor Failures (X Failures/10 Years) 2 2 X Compressor Failures * ($6000 Parts&Labor) / 10 Years $1200 $1200 Quantifiable Annual Savings Per Store: $3450 $2850 Quantifiable Annual Savings Per Device: $191 $158 Greater Refrigeration Uptime Reduced Energy Consumption Improves Remote Monitoring & Services *Assume 6 Compressors/Rack, 3 Racks/Store *Assume Contractor Labor Rate: $100/Hr 26

27 Available On Copeland Condensing Units Copeland PerformanceAlert 27

28 Copeland PerformanceAlert Part Numbers & Accessories Item Description Part Number Single Pack * (Samples or Aftermarket): 3-Phase Scroll Module Phase Recip Module Phase Scroll / Recip Module *Si Single Pack kincludes: Module, Discharge Line Temperture Probe, Discharge Line Temperature Probe Strap, External LED, User Manual, Defect Code Sticker, & Troubleshooting Guide Sticker Bulk Pack (OEM): 3-Phase Scroll Module Phase Recip Module Phase asescroll / Recip ecpmodule odue When Using Bulk Pack Modules You Will Also Need The Discharge Line Temeprature Probe For The Modulae To Operate Correctly Discharge Line Temperature Probe (NTC) Or Thermistor Used To Measure Discharge Temperatures

29 Copeland PerformanceAlert Part Numbers & Accessories Item Description Part Number Discharge Line Temperature Probe Clip Used To Secure Discharge Temperature Probe To Discharge Line Discharge Line Size: 3/8 in (0.375 in) /16 in (0.313 in) /2 in (0.500 in) /8 in (1.125 in) /8 in (0.875 in) /8 in (1.625 in) /8 in (1.375 in) /4 in (0.250 in) Discharge Line Temperature Probe Strap Used To Secure Discharge Temperature Probe To Discharge Line

30 Copeland PerformanceAlert Part Numbers & Accessories Item Description Part Number Allows LED Alerts To Be Viewed From A External lled Easily Accessible Position Communication Package Enables Copeland PerformanceAlert Communication To A PC Package Includes: RS485 Connector, RS485 to USB Adaptor, Communications Software, & Instructions Manual Allows User To Leave RS485 Connector At RS485 Connector Multiple Sites When Using Communication Package Enables Copeland PerformanceAlert E2 Gateway Communication To A E2, E1, or RMCC Facility Management System 30

31 Support Material a Play Video Website Ad Campaign Installation Video Sales Presentation ti Sell Sheet Application Engineering Bulletin 31

32 Launch Package A. General Product Overview B. Support Tools 1. Website 2. Marketing Bulletin 3. Press Release 4. Brochure 5. It Knows. So you ll Know Ad 6. AE Bulletin 7. ComfortAlert Success C. Detailed Product & Technical Information D. Frequently Asked Questions 32

33 Webpage Information Available 1. Overview Presentation 2. Marketing Bulletin 3. Press Release 4. Brochure 5. It Knows. So You ll Know Ad 6. Frequently Asked Questions 7. AE Bulletin 8. Communications Software 33

34 Marketing Bulletin / Press Release 34

35 Brochure 35

36 It Knows. So You ll Know Ad 36

37 Application Engineering Bulletin 37

38 Comfort Alert TM Diagnostics Faster Service And Improved Accuracy 500,000 Pieces Sold In

39 Launch Package A. General Product Overview B. Support Tools C. Detailed Product & Technical Information 1. Installation ti Instructions ti (Wiring Diagrams, Lockout, Jumper addresses, etc) 2. Interface Software 3. Alert Code Details D. Frequently Asked Questions 39

40 Installation The Correct Copeland PerformanceAlert Module Must Be Matched To The Compressor For Which It Is Applied If The Wrong Module Is Installed, The Alert Codes For System Faults Will Function Incorrectly The Module May Indicate System Faults That Are Not Present Or Fail To Indicate System Faults That Are Present 40

41 Wiring Diagram Thermostat Control CPA L C P Y DLT RS-485 HPCO LPCO CNTR Copeland PerformanceAlert Line Common Protection Demand Discharge Line Temperature Communication Port High Pressure Cut Out Switch Low Pressure Cut Out Switch Compressor Contactor Coil 41

42 Wiring Diagrams LPCO Control L C P Y HPCO LPCO CNTR CPA DLT Line Common Protection Demand High Pressure Cut Out Switch Low Pressure Cut Out Switch Compressor Contactor Coil Copeland PerformanceAlert module Discharge Line Temperature 42

43 Wiring Diagrams Copeland PerformanceAlert On/Off Time L C P Y HPCO LPCO CNTR CPA DLT Line Common Protection Demand High Pressure Cut Out Switch Low Pressure Cut Out Switch Compressor Contactor Coil Copeland PerformanceAlert module Discharge Line Temperature 43

44 Wiring Diagrams Multiple Compressor MULTIPLE COMPRESSOR RACK WIRING 1 CPA T1 T2 T3 CC HPCO LPCO L1 L2 L3 3 Phase VAC 50/60Hz L N PROT DEMAND DLT L N CONTROL VOLTAGE VAC 50/60Hz RS -485 PORT 2 P55 T1 T2 T3 n P55 T1 T2 T3 RS-485 EMAND #1 D DE EMAND #2 DE EMAND #n Gateway CONTROLLER I/O BOARD 44

45 Wiring Example 45

46 Compressor Lead & Extra Load Wiring NO Extra Load Extra Load Preferred Method Non-Desirable Method Extra Load = Fan Crankcase Heater Etc Incorrect Method Wiring Extra Load Across T1 and T3 Can Lead To Nuisance Code 6 Alarms 46

47 Communication Capability A) Connect To External LED B) Connect To Computer C) Connect To CPC Controller (RMCC, E1, or E2) Gateway CPA Copeland PerformanceAlert Module RS 485 to USB converter PC Control 1. View Alert Codes At An Accessible Position 1. Modify User Adjustable Features 2. Review/Download Compressor History 3. Use As Data Logger 1. Modify User Adjustable Features 2. Communicate Data & Alerts To System Controller 3. Review Compressor History 4. Use As Data Logger 47

48 Communication Capability Daisy Chain Modules For Communications RS485 Cable Set each module with a different address from 1 to 30 by placing jumpers in AD1 to AD5. Use TRMNTR jumper on last module. 48

49 Jumper Addressing Address Jumpers The PerformanceAlert module has a 7-position user configurable header where jumpers can be set. These jumpers are used to configure the PerformanceAlert modules address, select the termination resistors. The PerformanceAlert modules ships with 6 jumpers populated, AD1, AD2, AD3, AD4, AD5 and RSRVD. These jumpers will need to be changed when setting one or multiple PerformanceAlerts up for communication cat o capability Address AD4 AD3 AD2 AD1 invalid jumper jumper jumper jumper 04 - jumper jumper - jumper 06 - jumper jumper jumper jumper jumper 08 jumper jumper - - jumper 10 jumper - jumper - 11 jumper - jumper jumper 12 jumper jumper jumper jumper - jumper 14 jumper jumper jumper - LED blink jumper jumper jumper jumper Jumpers AD1 thru AD5 are used for The PerformanceAlert module address selection. Valid jumper - module address is from 1 to 30. Address 0 is invalid and occurs when all switches are left open; with this setting no 07 jumper jumper jumper communication may be possible with the device. When connecting an external LED ALL jumpers need to be in place. j p j p 49

50 Copeland PerformanceAlert Software Interface Copeland PerformanceAlert Module RS 485 to USB converter PC 50

51 Copeland PerformanceAlert Software Interface 51

52 Copeland PerformanceAlert Software Interface 52

53 Diagnostic Alert Codes Alert Code Code 1 Code 2 Code 3 Code 4 Code 5 Code 6 Code 7 Code 8 Code 9 Code 10 Code 11 System Condition High Discharge Temp Diagnostic Alert Light Blinks 1 Time System Pressure Trip Blinks 2 Times Short Cycling Locked Rotor Open Circuit Missing Phase Reverse Phase Welded Contactor Low Voltage Lost Communication Open/Short Temp Circuit Blinks 3 Times Blinks 4 Times Blinks 5 Times Blinks 6 Times Blinks 7 Times Blinks 8 Times Blinks 9 Times Blinks 10 Times Blinks 11 Times Trip Lockout YES YES NO YES NO NO YES YES NO NO YES YES YES YES NO NO YES NO NO NO NO NO Codes 1, 4, 6, And 7 Are Serve Alert Codes And Will Shut Down The Compressor for 20 min (default setting); Compressor Will Lockout Only When Lockout Is Activated 53

54 Alert Display Copeland PerformanceAlert Displays Last Alert At Each Power Up Displays Code If An Alert Occurred During Last Power Cycle Display Lasts For One Minute After Power Cycle If Multiple Alerts Occur, PerformanceAlert Displays The First Code That Is Detected Allows Technician To Determine The Root Cause Example Low Line Voltage Leads To Locked Rotor Condition On Compressor PerformanceAlert Displays Low Voltage Code Even While Locked Rotor Events Are Occurring 54

55 Troubleshooting Tips Green LED Power is On PerformanceAlert Has Power Green LED Power Is Flashing PerformanceAlert Has Power; Demand Signal Is Present And Minimum Off Time Is Active Once Minimum i Off Time Is Met Compressor Will Start t Normally Red Trip LED Is On Thermostat Demand Signal Y Is Present, But The Compressor Is Not Running Compressor Protector Is Open, Check For High Head Pressure, Compressor Supply Voltage, And Circuit Breaker, Safety Cutout Switches Open, Failed Compressor Contactor, If Lockout Is Activated The PerformanceAlert Will Trip Compressor When Alert Codes 1, 4, 6, 7 And 9 Are Present Rack Controller Calling Compressor To Run, But Compressor Is Off And PerformanceAlert Does Not Indicate A Trip. Check For Motor Protection Module Presence And Status 55

56 Resetting Alert Codes Severe Alert Off Time When Codes 1, 4, 6, or 7 Are Present The Default Off Time Is 20 Minutes. Off Time Adjustable Using Software, Minimum 10 Minutes, Max 40 Minutes Automatic Reset Transient Alerts Will Automatically Reset Code 1 Will Clear When Discharge Line Temperature Reaches Normal Temp (Below 230 F or Below Set Points 170 to 280 F ) Codes 2, 3, 4 Will Clear After Four Normal Run Cycles Open Circuit it (Code 5) &W Welded dcontactor t (Code 8) Clears After One Normal On/Off Cycle Codes 6 & 7 Will Clear After One Normal Cycle Code 9 Low Voltage Resets When Voltage Rises Above 85 Volts For A 110 Volt Coil, Or Above 170 Volts For A 220 Volt Coil Manual Reset When The Lockout Feature Is Activated Alerts Codes 1, 2, 4, 6, And 7, Will Not Automatically Reset A Manual Reset Is Required All Alert Codes Can Be Manually Reset By Cycling Power To The PerformanceAlert 56

57 Alert & Lockout Logic Alert Code Cause Effect/Troubleshoot Protection Code 1: High When Discharge Temp Passes Set Check Liquid Injection When Used Display Alert & Discharge Line Point. Default is 230 On LT Scroll Models Lockout Temp Adjustable 170 to 280 Loss Of Ref, Blocked Condenser Code 2: System Pressure Trip 4 Consecutive Compressor Trips Indicating High Or Low Pressure Trip Compressor Running Several Minutes Before Trip; No Cooling Display Alert Code 3: Short Cycling 240 Run Cycles In 24 Hours Ending With Normal Shutdown Check Pressure & Temp Control Intermittent Demand Signal Display Alert Loss Of Ref, Blocked Condenser High Suction Pressure Code 4: Locked Rotor 4 Consecutive Compressor Trips After Run Time Of 1 to 15 Secs Indicating Compressor Won t Start Low Line Voltage, Bad Wiring Connection, Compressor Seized, Failed Run Cap (1 phase) Display Alert & Lockout Code 5: Open Demand Signal Is Present But No Breaker or Fuse Is Open, Failed Display Alert Circuit Compressor Current For 4 Hours Compressor Contactor, Bad Wiring Connection, Low Contactor Coil Voltage, Check Manual Pressure Controls (reset) Code 6: Missing Phase 1 phase- Demand Present But Current Is Missing i In Start t Circuit. it 3 phase- Demand Present But Current Is Missing In Run Circuit. During Pump Down Compressor Amp Draw Is Below Min. Detection Check For Open Circuit, Failed Contactor t Run Cap, Verify Current On All Legs, Check Compressor Motor Windings, Verify Wiring. Double Wrap Wire Through T1, T3 To Increase Amp Detection Display Alert & Lockout

58 Alert & Lockout Logic Alert Code Cause Effect/Troubleshoot Protection Code 7: Open 1 phase- Demand Present But Check For Open Circuit, Failed Display Alert & Circuit/Reverse Lockout Phase Code 8: Welded Contactor Current Is Missing In Run Circuit. 3 phase- Demand Signal Is Present But Current Is Not Detected In The Correct Sequence. No Demand Signal But Current Has Been Detected In One Or Both Phases Contactor Run Cap, Verify Current On All Legs, Check Compressor Motor Windings, Verify Wiring Thermostat Demand Signal Not Connected To Module, Control Circuit Transformer Is Overloaded, Check Wiring Code 9: Low Supply Voltage Low Line Voltage Or Low Secondary Pilot Voltage Control Voltage Below 85 V for A 110 V Or 170 V for 220 V, Contactor May Chatter; Compressor May Draw High/Locked Rotor Current. Check Supply Voltage And Wiring Connections Display Alert Display Alert & Lockout Code 10: Lost Communication o Lost Between ee Check Communication o Wiring And Display Alert Communication Rack Controller And Module Jumper On TRMNTR For 10 Mins. Or More Code 11: Open/Short Temp Circuit Discharge Temperature Sensor Is Shorted Or Open Circuit Check Discharge Temperature Sensor Wiring, Mounting, And Resistance. Display Alert 58

59 Discharge Temp. Trip (Code 1) Copeland PerformanceAlert Detects A Code 1 When: Discharge Line Temperature Reaches/Passes Set Point Interpretation: Discharge Line Temperature Passes Default Setting Of 230 Or Passes Adjustable Set Points Between 170 to 280 Root Causes Blocked Condenser Coils Condenser Fan Not Running Severe Loss Of Charge Faulty Pressure/Temperature Controls Check Liquid Injection On LT Scroll 59

60 Sensing System Pressure Trip (Code 2) Copeland PerformanceAlert Detects A Code 2 When: Four Consecutive Protector Trips Occur After Compressor Run Time Of 1-15 Minutes Interpretation: High/Low Pressure Condition Causes Compressor To Run Briefly Before Tripping Root Causes Excessive Suction Or Discharge Pressure Improper Wiring Defective Start, Run, & Relay Components 60

61 Sensing Short Cycling (Code 3) Copeland PerformanceAlert Detects A Code 3 When: A Pattern Of Short Cycles Emerges 2 To 480 Compressor Run Cycles In 24 Hours Ending In With Normal Shutdown No Protector Trips Are Detected For Code 3 Interpretation: Compressor Is Running Only Short Periods Of Time Root Causes Blocked Condenser High Suction Pressure Severe Loss Of Charge Faulty Thermostat Intermittent Contactor Bad Wiring 61

62 Sensing Locked Rotor (Code 4) Copeland PerformanceAlert Detects A Code 4 When: Four Consecutive Protector Trips Occur After Compressor Run Time Of 1 to 15 Seconds Interpretation: Compressor Is Attempting To Start But Cannot Root Causes Low Line Voltage Compressor Bearings Are Seized Failed Run Cap (1-Phase) Bad Wiring Excessive Liquid 62

63 Sensing Open Circuit (Code 5) Copeland PerformanceAlert Detects A Code 5 When: Demand Signal Is Present But No Compressor Current For 4 Hours Interpretation: Power Is Not Connected To Compressor Root Causes Power Disconnected (Fuse, Switch, Etc.) Failed Compressor Protector/Contactor High Pressure Switch Open (Manual Re-set) Compressor Windings Are Damaged Open Circuit Differentiates Between Temporary Trips And Permanent Trips 63

64 Sensing Missing Phase (Code 6) Copeland PerformanceAlert Detects A Code 6 When: (3 Phase Only) Current Is Not Present In All Three Phases T1 & T3 Directly Sensed T2 Sensed By Phase Shift Interpretation: One Winding Of Compressor Not Getting Power Root Causes Improper Wiring (Correct Order Of Phases) Failed Contactor Compressor Current Could Be Too Low 64

65 Open Start t Circuit (Code 6) Copeland PerformanceAlert Detects A Code 6 When: (1 Phase Only) Demand Is Present But Current Is Missing In Start Circuit Interpretation: One Winding Of Compressor Not Getting Power Root Causes Run Capacitor Has Failed Open Circuit In Compressor Start Wiring or Connection Compressor Start Winding Is Damaged Compressor Current Too Low 65

66 Sensing Reverse e Phase (Code 7) Copeland PerformanceAlert Detects A Code 7 When: (3 Phase Scroll Only) Demand Signal Is Present But Current Is Not Detected In The Correct Sequence Interpretation: Scroll Compressor Will Run Backwards Root Causes Miswiring Of 3 Phase Power 66

67 Open Run Circuit (Code 7) Copeland PerformanceAlert Detects A Code 7 When: (1 Phase Only) Demand Is Present But Current Is Missing In Start Circuit Interpretation: One Winding Of Compressor Not Getting Power Root Causes Open Circuit In Compressor Run Wiring or Connection Compressor Run Winding Is Damaged Compressor Current Too Low 67

68 Sensing Welded Contactor (Code 8) Copeland PerformanceAlert Detects A Code 8 When: No Demand Signal But Current Has Been Detected In One Or Both Phases Interpretation: Compressor Contactor Has Failed Closed Root Causes Welded Contactor Control Circuit Transformer Is Overloaded Thermostat Demand Signal Not Connected To Performance Alert 68

69 Sensing Low Voltage (Code 9) Copeland PerformanceAlert Detects A Code 9 When: Control Voltage Is Below 85 Volts For A 110 Volt Coil, Or Below 170 Volts For A 220 Volt Coil Interpretation: Low Voltage Condition Exists, May Draw High/Lock Rotor Current Root Causes Control Transformer Overloaded Line Voltage Low 69

70 Sensing Lost Communication (Code 10) Copeland PerformanceAlert Detects A Code 10 When: Communication Is Lost Between Rack Controller/Computer And Performance Alert For 10 Mins. Or More. Interpretation: t ti Copeland Performance Alert Can Not Communicate To Rack Controller Or Computer When Downloading Information Root Causes Bad Wire Connection Missing Jumper On Performance Alert Terminal TRMNTR 70

71 Sensing Open/Short Temp Circuit (Code 11) Copeland PerformanceAlert Detects A Code 11 When: The Discharge Temperature Sensor Is Shorted Or Is An Open Circuit Interpretation: Discharge Temp Sensor Not Sensing Temperature/Working Root Causes Not Wired To Performance Correctly Bad Sensor 71

72 Launch Package A. General Product Overview B. Support Tools C. Detailed Product & Technical Information D. Frequently Asked Questions 72

73 FAQ s Qs Can I use Copeland PerformanceAlert on any compressor? No. Only on 1 & 3 phase Refrigeration Copeland Brand compressors with a working amperage range of amps. Suggested applications include Supermarket, Walk-In, and in the future Transport applications. What about on old Copeland compressors? Same requirements apply. What is the estimated installation time? Depending on the application, the estimated time is 30 mins. How do I know which wires to put through which holes in the Copeland PerformanceAlert for phase reversal function? The Copeland PerformanceAlert is labeled T1, T2, T3. Is the voltage range adjustable? No. Copeland PerformanceAlert automatically adjusts to either 120V or 230V applications. How many alarm codes will it store? The Copeland PerformanceAlert stores the ten most recent alarms along with a 7-Day alarm history and has enough memory to store a count all alarm codes experienced during the life of the module. How many alarm codes will it display? The LED displays one code at a time, however if using the communication software all codes can be reviewed. Does it display the last fault code first or last? If there are multiple alert or fault codes the LED will display the first fault/alert code that is detected first. If there is no current fault code none will be displayed. However, upon cycling power to the Copeland PerformanceAlert the last fault code created will be displayed for 1 minute after power up. Is the discharge temperature function adjustable with a laptop? Yes, by using the communication software the discharge temperature limit can be adjusted from 170 to

74 FAQ s Qs What is the compressor power wire gauge limitation? The compressor wire opening dimensions are 0.33 x 0.47 (4 to 6 gauge depending on wire insulation thickness). Where is the location and access to the jumpers on the Copeland PerformanceAlert? External access behind the discharge line temperature sensor input. Where do I go to get this product? You can buy the Copeland PerformanceAlert install on system by your OEM or you can buy it directly from Copeland Authorize and Emerson Full Line Wholesalers. Who is going to support the installation of this product? There is a technical support number EMR-9950 or contact your wholesaler s Copeland technical specialist or your Emerson Climate Technologies District Sales Manager. Do I need addition tools to get the data from my compressor to my computer? Yes, once Copeland PerformanceAlert is installed, you will need a communication kit which will contain everything you need to access the compressor and system data on your computer. What applications does this device support? Supermarkets and Walk-ins, (in the future Transport). What are the main error codes this device covers? See descriptions of alarm codes What s the warranty? 1 year. 74

75 FAQ s Qs Will double wrapping the compressor lead wires cause the compressor to shut down for high amps? No, There is No high amp detection. However double wrapping is recommended when a system is operating towards the low end of the Copeland PerformanceAlert amp specification of 3.0 amps. Can you connect more than one compressor to Performance Alert? No, one Copeland PerformanceAlert per compressor. Will it shut down the compressor? Yes, if contactor coil or system protection is wired in to the P terminal. Protective codes, 1, 4, 6, 7, 9 will trip the compressor with a off time of 20 minutes (default setting). Also if the lockout is activated the compressor will shut down and will not restart when you have codes 1, 4, 6, 7, a manual re-set is required. What is a manual re-set? A manual re-set is when you cycle power to the Copeland PerformanceAlert OFF/ON. 75