Cpa Overview

June 2009
Copeland PerformanceAlert™
PerformanceAlert
Launch Package
Updated June 16
16, 2009
Launch Package
A. General Product Overview
B. Support Tools
C. Detailed Product & Technical Information
D Frequently Asked Questions

D.
3
Launch Package
1.
1 Product Description & Application
2. Features, Advantages, & Benefits
3. 11 Alert Codes
4
4. C
Communication
i ti Capability
C bilit
5. Market Research & Field Test
6. Product Value
7. Part Numbers & Accessories
8. Support Material
B Support Tools
B.
D Frequently
D. F tl Asked
A k d Questions
Q ti
4
Refrigeration Diagnostics
z Used With Copeland Brand Compressors To:
– Improve Compressor Reliability
– Provide System Diagnostics
– Enable Communication Capabilities
z Self-Contained,
Se Co ta ed, Stand
Sta d Alone
o e Module
odu e That
at Uses
Compressor As A Sensor To Diagnose Electrical
Problems And Common System Related Faults
New Retrofit
z Application: Walk-In: Recip & Scroll ✔ ✔
Industrial Recip
p & Scroll ✔ ✔
Supermarket: Scroll ✔ ✔
Discus ISD ✔
z Compatible With Copeland Brand

Single And Three Phase Scroll & Reciprocating Compressors
5
PerformanceAlert™
Gold Dealer Design Award

z Testing and Monitoring Products
Category.
z Award emphasizes need for user-
f i dl ttesting
friendly ti andd monitoring
it i ttools
l th
thatt
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’ss would install it.”
OEM it.
6
Copeland
p Compressor
p Controller Platform
Intelligent Store
Discus™
Copeland
PerformanceAlert™
Comfort Alert
•Second Generation
•UltraTech Diagnostics
C i l Diagnostics
•Commercial Di ti
Comfort Alert
Diagnostics
(First Generation)
7
Product Specifications
p
1.46 in
High Voltage (37 mm)
Connections
Discharge Line
Temperature
Probe
4.40 in
2.44 in
(112 mm)
(62 mm)
Address
Jumpers
RS485
Communication
Port
1.85 in 2.44 in
(47 mm) (62 mm)
Compressor Power
z O
Operating
ti Temp:
T -40°
40° to
t 150°F (-40°
( 40° to
t 65°C) (Lead) Wire Must Fit In
0.33 in x 0.47 in
z Storage Temp: -40° to 175°F (-40° to 80°C) (8.4 mm x 11.9 mm)
z Power Supply Range: 85-265VAC, 48-62 Hz Opening
z Working Amperage, 3-phase Module; 3.0-200A

z Maximum Contactor Coil Current Is 5 Amps
8
Compressor Controller Diagnostics Improve
Troubleshooting
g Accuracyy And Warranty
y
Service Technician Study Actual Warranty Results
Technician
%NDF
Accuracy
45%
100%
100% 43%
92%
80%
30%
60%
63%
22%
40% 15% 18%
20%
17% 0%
0%
2002 2003 2004
Entry Level Experienced
No Diagnostics Comfort Alert No Diagnostics Comfort Alert
Improved Service Lower “No Defect Found”

Technician Accuracy Warranty Failures
“My main concern is getting the equipment repaired the

first time on the first visit. . . “ – Refrigeration Contractor
9
Features, Advantages, And Benefits
Features Advantages Benefits
Predictive Monitors Compressor To Provide Early z Less System Downtime
Diagnostics Warning When System Approaches “Red z Saves Compressor
Zone” Takes Action To Prevent Failures
Zone”.
11 Diagnostic Alert Improves Speed And Accuracy Of Diagnosis z Faster Uptime And Reduces
Codes And Troubleshooting System Issues Contractor Callbacks
High Discharge 35% Of Compressor Failures Are From z Less System Downtime
Temperature Overheat Notifies When Compressor Reaches
Overheat. z Saves Compressor
Protection “Red Zone” Temperature
Motor Protection Prevents Majority Of Motor Failures zLess System Downtime
zSaves Compressor
Short Cycling Notifies When Compressor Runs Less Than 3 zLess System
y Downtime
Protection Minutes. Improves Oil Management
Low Voltage/ Phase Eliminates Need To Install Phase Alarm z Increases Compressor
Alarm Protection Reliability
yp Of
3 Types 1. Locally
y With LED z Faster Uptime
Communications 2. Remotely With ModBus
3. Fault History Retrieval With Laptop
Toll Free Technical Helps Contractors Troubleshoot System z Faster Uptime And Reduces
Support Number Contractor Callbacks
Adjustable Discharge Line Thermostat And Lockouts Can z Eliminates Nuisance Alerts
Features Be Customized To Each Application z Provides Flexibility
120 Or 230 Volt Ease Of Design And Installation z Lower Installation Costs
Compatible
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

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

12
Copeland PerformanceAlert
Technical Support
z Technical Support Provided For:
– Installation Assistance
– System Troubleshooting
– Copeland PerformanceAlert Module Operation
z Call Toll Free: 1-888-367-9950

or
z Email: PerformanceAlert.SWSupport@Emerson.com
13
Communication Capability
A) Connect To External LED B) Connect To Computer C) Connect To CPC Controller
(RMCC, E1, or E2)
Gateway
CPA
RS 485 to
USB
Copeland
converter
PerformanceAlert
Module
PC
Control
1. View Alert Codes At An 1. Modify User Adjustable 1. Modify User Adjustable Features
Accessible Position Features
2. Communicate Data & Alerts To
2. Review/Download System Controller
Compressor History
3. Review Compressor History
3. Use As Data Logger
4. Use As Data Logger 14
z Status
– Compressor Status (On/Off/Trip/Lockout)
– Fault Code
– Current, Voltage, Discharge Line Temperature
z Alarm History
– Total # of Alarms
– 10 Most Recent Alarms
– Weekly
W kl Record
R d Of Alarms
Al
z Compressor History
– # off C
Compressor St
Starts
t
– # of Compressor Run Hours
– # of Compressor Starts/Day
– # of Compressor Run Hrs/Day
15
Software Interface
RS 485 to
USB
Copeland
converter
PerformanceAlert
Module
PC
16
Enables Intelligent Store
Store™
9Integrated Products Work Better Together
Intelligent Store
Discus 2.0 E2 v2.6
Copeland Gateway → E2,

E2 E1
E1, &
PerformanceAlert RMCC
Copeland
PerformanceAlert
E2 v2.? Directly 9Platform Applies To Retrofit Applications
Intelligent Store™ Platform Architecture
Information
Compone
Server
Emerso
Regulatory
Compliance
on
ents
Easy Cost
Emerson Co
Communic
Savings
Multiple
ontrols/
cation
Sites
Easy
Maintenance
Intelligent Store Leverages
Connectivity
3rd Party
Emerson Devices And
Services To Deliver
Repair vs.
Replace
ep ace Customer Benefits Globallyy
Simple User Customer ProAct® Store Components/

Interface Benefits Software Control Systems
Market Research And
Customer Proof Points
Market Research
The Copeland PerformanceAlert Generated Relatively Strong Appeal
Among Both End Users And Contractors:
z They Acknowledged There Is A Need For This Kind Of Product…
That “The Compressor Is Probably The Least Protected Component”
z They Liked The “Package” Of Functional Benefits Contained In
Copeland PerformanceAlert, Which Provided The Capability To:
– “Save” Equipment From Ruinous Conditions
– Provide Diagnostic
g 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
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
Field Test Success
Walk--In – Sidney, OH
Walk
z The Copeland PerformanceAlert Detected A “Trip” Alert Code
– History Data Revealed The ‘Trip’ Code Occurred At Least Once A Day
z 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
– I t d The
Instead Th Compressor
C Run
R Continuously
C ti l Ran
R Until
U til The
Th Compressor
C
Heated Up And The Compressor Protector Tripped
• Generating The “Trip Alert” On Copeland PerformanceAlert
– After The Compressor Cooled, The Protector Reset, And Repeated The
Ab
Above Cycle
C l
z After Diagnosing The System, Eck Refrigeration Determined The LPCO
Was Sticking And Therefore Never Breaking The Control Circuit
– The LPCO Was Replaced
p Correcting
g The System
y Defect
z 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
Field Test Success
Supermarket Rack – Grove City, OH
z 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
z 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
z 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
p
Consumption
21
PerformanceAlert™
™
Opportunities
• Replace Existing Accessories (i.e. Phase

M it ) While
Monitor) Whil PProviding
idi Additional
Additi l Value
V l
• Provides Discharge Line Temperature Protection
• Provides Compressor Proofing
• Reduce Time To Service System
• Troubleshoot Repeat Compressor Failures
• Trouble
T bl Stores
St Applications
A li ti
22
Application Value
One Device – Multiple Functions
Extra Hardware Used On
Protection/Diagnostic Costs
Alternative Method Your
Feature
Low
o High
g Systems?
Discharge Line Temperature Discharge Line

$18 $25
Protection Thermostat
Phase Protection Phase Monitor $30 $50
Guaranteed On/Off
Short Cycling Protection $10 $15
Timers
Verify Compressor
Current Relay $10 $15
Operation
Copeland PerformanceAlert Performs All These Functions
23
Additional Walk
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

$25K/60,000pcs)
000pcs) $0 50
$0.50 Each
• Systems Easier To Diagnose
• Technical Support Number Fields Calls
– User Adjustable Features And 120/230V Compatible Ease Of Use
24
Walk--In End-
Walk End-User Value
Potential Annual Savings:
z 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
g 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
z Greater Refrigeration Uptime
– Reduced Food Loss & Spoilage $$$
– Contractor Saved The Day Because Saved System
And Eliminated Downtime Priceless
z Energy Savings
– Discharge Line Overheat Protection TBD
– Low Voltage Protection TBD
– Short Cycling / Min On & Off TIme TBD
$148
* Assumes 10 Year Life
25
Supermarket
Supe a et End
End--User Value Story
y
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 9 9
• Reduced Energy Consumption 9 9
• Improves Remote Monitoring & Services 99 9
*Assume 6 Compressors/Rack, 3 Racks/Store

*Assume Contractor Labor Rate: $100/Hr
26
Available On Copeland Condensing Units
27
Part Numbers & Accessories
Item Description Part Number
Single Pack *
3-Phase Scroll Module 943-0057-00
((Samples
p or Aftermarket):
)
3-Phase Recip Module 943-0055-00
1-Phase Scroll / Recip Module 943-0053-00
* Si
Single
l Pack
P k Includes:
I l d Module,
M d l Discharge
Di h Line
Li Temperture
T t Probe,
P b
Discharge Line Temperature Probe Strap, External LED, User
Manual, Defect Code Sticker, & Troubleshooting Guide Sticker
Bulk Pack (OEM):

3-Phase Scroll Module 543-0057-05
3-Phase Recip Module 543-0055-04
1-Phase
ase Sc
Scroll
o / Recip
ec p Module
odu e 543-0053-03
5 3 0053 03
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) Used To Measure Discharge Temperatures. 085-0204-00
Or Thermistor
28
Used To Secure Discharge Temperature

g Line
Discharge
Probe To Discharge Line
Temperature Probe Clip
Discharge Line Size: 3/8 in (0.375 in) 032-0688-00

5/16 in (0.313 in) 032-0688-01
1/2 iin (0 500 iin))
(0.500 032 0688 02
032-0688-02
1 - 1/8 in (1.125 in) 032-0688-03
7/8 in (0.875 in) 032-0688-04
1 - 5/8 in (1.625 in) 032-0688-05
1 - 3/8 in (1.375 in) 032-0688-06
1/4 in (0.250 in) 032-0688-07
Used To Secure Discharge Temperature

Discharge Line 032-0689-00
Probe To Discharge Line
Temperature Probe Strap
29
Allows LED Alerts To Be Viewed From A

E t
External
l LED 039 0020 00
039-0020-00
Easily Accessible Position
Enables Copeland PerformanceAlert

Communication Package 943-0143-00
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 021-0341-00
021 0341 00
Package
Enables Copeland PerformanceAlert

E2 Gateway Communication To A E2, E1, or RMCC 943-3730-00
Facility Management System
30
Supportt Material
Suppo ate a
Play
Video
Ad Campaign Installation Video

Website
S l Presentation
Sales P t ti Sell Sheet Application
A li ti
Engineering Bulletin
31
Launch Package
B Support Tools
B.
1. Website
2. Marketing
g Bulletin
3. Press Release
4. Brochure
5
5. “It
It Knows
Knows. So you
you’ll
ll Know”
Know Ad
6. AE Bulletin
7. ComfortAlert Success
D. Frequently Asked Questions
32
Webpage
Information Available
1 Overview Presentation
1.
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
www.EmersonClimate.com/CopelandPerformanceAlert
33
Marketing Bulletin / Press Release
34
Brochure
35
“It
It Knows. So You
You’ll
ll Know”
Know Ad
36
Application Engineering Bulletin
37
Comfort Alert Diagnostics
TM
Faster Service And Improved Accuracy
500,000 Pieces Sold In 2006

38
Launch Package
B Support Tools
B.
1 Installation
1. I t ll ti Instructions
I t ti
(Wiring Diagrams, Lockout, Jumper addresses, etc)
2 Interface Software
2.
3. Alert Code Details
D Frequently Asked Questions

D.
39
Installation
z The Correct Copeland PerformanceAlert™

Module Must Be Matched To The Compressor
For Which It Is Applied
z If The Wrong Module Is Installed, The Alert

Codes For System Faults Will Function
Incorrectly
y
z The Module May Indicate System Faults That

Are Not Present Or
O Fail To Indicate System
S
Faults That Are Present
40
Wiring Diagram –
Thermostat Control
CPA Copeland PerformanceAlert
L Line
C Common
P Protection
Y Demand
DLT Discharge Line Temperature
RS-485
RS 485 Communication Port
HPCO High Pressure Cut Out Switch
LPCO Low Pressure Cut Out Switch
CNTR Compressor Contactor Coil
41
Wiring Diagrams –
LPCO Control
L Line
C Common
P Protection
Y Demand
HPCO High Press
Pressure
re C
Cutt O
Outt S
Switch
itch
CPA Copeland PerformanceAlert module
42
Wiring Diagrams –
Copeland
p PerformanceAlert On/Off Time
L Line
C Common
P Protection
Y Demand
HPCO High Press
Pressure
re C
Cutt O
Outt S
Switch
itch
CPA Copeland PerformanceAlert module
43
Wiring Diagrams –
Multiple Compressor
MULTIPLE COMPRESSOR RACK WIRING
CC
CPA T1 L1 3 Phase
T2 L2 208 - 575VAC
T3 L3 50/60Hz
1 HPCO LPCO
L
L
CONTROL
N
N VOLTAGE
PROT 120 -240VAC
DEMAND 50/60Hz
DLT
RS -485
PORT
2
P55 T1
T2
T3
EMAND #2
EMAND #n
D EMAND #1
n P55 T1
T2
T3
RS-485
DE
DE
CONTROLLER I/O BOARD
Gateway
44
Wiring Example
45
Compressor
p Lead & “Extra Load” Wiring
g
NO “Extra Load” “Extra Load”
Preferred Method Non-Desirable

Non Desirable Method
Incorrect Method
Extra Load = Fan Wiring “Extra Load”
Crankcase Heater Across T1 and T3 Can
Etc Lead To Nuisance
Code 6 Alarms
46
A) Connect To External LED B) Connect To Computer C) Connect To CPC Controller
(RMCC, E1, or E2)
Gateway
CPA
RS 485 to
USB
Copeland
converter
PerformanceAlert
Module
PC
Control
1. View Alert Codes At An 1. Modify User Adjustable 1. Modify User Adjustable Features
Accessible Position Features
2. Communicate Data & Alerts To
2. Review/Download System Controller
Compressor History
3. Review Compressor History
3. Use As Data Logger
4. Use As Data Logger 47
Daisy Chain Modules For Communications
Set each module with a

different address from 1 to 30
by placing jumpers in AD1 to
AD5 Use
AD5. U TRMNTR jumperj on
last module.
RS485 Cable
48
Jumper
p Addressing g
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,
Address
Jumpers select
l the
h termination
i i resistors.
i The
Th PerformanceAlert
P f Al
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
co u cat o capab
capability
ty
Address AD4 AD3 AD2 AD1

Jumpers AD1 thru AD5 are used invalid - - - -
for The PerformanceAlert 01 - - - jumper
module address selection.
selection Valid 02 - - jumper -
03 - - jumper jumper
module address is from 1 to 30.
04 - jumper - -
Address 0 is invalid and occurs
05 - jumper - jumper
when all switches are left open; 06 - jumper jumper -
with this setting no 07 - jumper jumper jumper
communication may be 08 jumper - - -
possible with the device. 09 jumper - - jumper
10 jumper - jumper -
When connecting an external 11 jumper - jumper jumper
LED ALL jumpers need to be in 12 jjumper
p jjumper
p - -
place. 13 jumper jumper - jumper
14 jumper jumper jumper -
LED blink jumper jumper jumper jumper
49
Software Interface
RS 485 to
USB
Copeland
converter
PerformanceAlert
Module
PC
50
Software Interface
51
Software Interface
52
Diagnostic
g Alert Codes
Alert Code System Condition Diagnostic Alert Light Trip Lockout
Code 1 High Discharge Temp Blinks 1 Time YES YES
C d 2
Code S t
System P
Pressure Trip
Ti Bli k 2 Ti
Blinks Times NO YES
Code 3 Short Cycling Blinks 3 Times NO NO
Code 4 Locked Rotor Blinks 4 Times YES YES
Code 5 Open Circuit Blinks 5 Times NO NO
Code 6 Missing Phase Blinks 6 Times YES YES
Code 7 Reverse Phase Blinks 7 Times YES YES
Code 8 Welded Contactor Blinks 8 Times NO NO
Code 9 Low Voltage Blinks 9 Times YES NO
Code 10 Lost Communication Blinks 10 Times NO NO
Code 11 Open/Short Temp Blinks 11 Times NO NO
Circuit
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
Alert Display
p y
z 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
z 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
Troubleshooting Tips
z Green LED “Power” is On
– PerformanceAlert Has Power
z Green LED “Power” Is Flashing

– PerformanceAlert Has Power; Demand Signal Is Present And Minimum Off Time Is
Active
– O
Once Minimum
Mi i Off Time
Ti Is
I Met
M t Compressor
C Will St
Startt Normally
N ll
z Red “Trip” LED Is On

– Thermostat Demand Signal Y Is Present
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
z 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
Resetting Alert Codes
z Severe Alert Off Time
– When Codes 1, 4, 6, or 7 Are Present The Default Off Time Is 20
Minutes. Off Time Adjustable
j Using
g Software, Minimum 10 Minutes,
Max 40 Minutes
z 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
O Circuit
Ci it (Code
(C d 5) & WWelded
ld d C
Contactor
t t (Code
(C d 8) Clears
Cl Aft
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
z 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
Alert & Lockout Logic
g
Alert Code Cause Effect/Troubleshoot Protection
Code 1: High
g When Dischargeg Temp p Passes Set Check Liquid
q Injection
j When Used Display
p y 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 4 Consecutive Compressor Trips Compressor Running Several Display Alert
Pressure Trip Indicating High Or Low Pressure Trip Minutes Before Trip; No Cooling
Code 3: Short 240 Run Cycles In 24 Hours Ending Check Pressure & Temp Control Display Alert
Cycling With Normal Shutdown
Intermittent Demand Signal
Loss Of Ref, Blocked Condenser
High Suction Pressure
Code 4: Locked 4 Consecutive Compressor Trips After Low Line Voltage, Bad Wiring Display Alert &
Rotor Run Time Of 1 to 15 Secs Indicating Connection, Compressor Seized, Lockout
Compressor Won’t Start Failed Run Cap (1 phase)
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 1 phase- Demand Present But Current Check For Open Circuit, Failed Display Alert &
Ph
Phase I Missing
Is Mi i In
I Start
St t Circuit.
Ci it 3 phase-
h C t t R
Contactor Run CCap, V
Verify
if CCurrentt L k t
Lockout
Demand Present But Current Is On All Legs, Check Compressor
Missing In Run Circuit. During Pump Motor Windings, Verify Wiring.
Down Compressor Amp Draw Is Below Double Wrap Wire Through T1, T3
Min. Detection To Increase Amp Detection
Alert & Lockout Logic
Alert Code Cause Effect/Troubleshoot Protection
Code 7: Open 1 phase- Demand Present But Check For Open Circuit,
Circuit Failed Display Alert &
Circuit/Reverse Current Is Missing In Run Contactor Run Cap, Verify Current Lockout
Phase Circuit. 3 phase- Demand On All Legs, Check Compressor
Signal Is Present But Current Is Motor Windings, Verify Wiring
Not Detected In The Correct
Sequence.
Code 8: Welded No Demand Signal But Current Thermostat Demand Signal Not Display Alert
Contactor Has Been Detected In One Or Connected To Module, Control
Both Phases Circuit Transformer Is Overloaded,
Check Wiring
Code 9: Low Low Line Voltage Or Low Control Voltage Below 85 V for A 110 Display Alert &
Supply Voltage Secondary Pilot Voltage V Or 170 V for 220 V,
V Contactor May Lockout
Chatter; Compressor May Draw
High/Locked Rotor Current. Check
Supply Voltage And Wiring
Connections
Code 10:
0 Lost
ost Co
Communication
u cat o Lost
ost Between
et ee C ec Co
Check Communication
u cat o Wiring
g And
d Display
sp ay Alert
et
Communication Rack Controller And Module Jumper On TRMNTR
For 10 Mins. Or More
Code 11: Discharge Temperature Sensor Check Discharge Temperature Display Alert
Open/Short Temp Is Shorted Or Open Circuit Sensor Wiring , Mounting, And
Circuit Resistance
Resistance.
58
Discharge Temp. Trip (Code 1)
z Copeland PerformanceAlert™ Detects A Code 1
When:
– Discharge Line Temperature Reaches/Passes
Set Point
z Interpretation: Discharge Line Temperature

P
Passes D f lt S
Default Setting
tti Of 230° Or
O Passes
P
Adjustable Set Points Between 170° to 280°
z Root Causes
– Blocked Condenser Coils
– Condenser Fan Not Running
– Severe Loss Of Charge
– Faulty Pressure/Temperature Controls
– Check Liquid Injection On LT Scroll
59
Sensing System Pressure Trip (Code 2)
z Copeland PerformanceAlert™ Detects A Code 2
When:
– Four Consecutive Protector Trips Occur After
Compressor Run Time Of 1-15 Minutes
z Interpretation: High/Low Pressure Condition

C
Causes C
Compressor T To R
Run B
Briefly
i fl BBefore
f
Tripping
z Root Causes
– Excessive Suction Or Discharge Pressure
– Improper Wiring
– Defective Start,
Start Run , & Relay Components
60
Sensing Short Cycling (Code 3)
z 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
z Interpretation: Compressor Is Running Only

Short Periods Of Time
z Root Causes
– Blocked Condenser
– High Suction Pressure
– Severe Loss Of Charge
– Faulty Thermostat
– Intermittent Contactor
– Bad Wiring
61
Sensing Locked Rotor (Code 4)
– Four Consecutive Protector Trips Occur After
Compressor Run Time Of 1 to 15 Seconds
z Interpretation: Compressor Is Attempting To

St t But
Start B tCCannott
z Root Causes
– Low Line Voltage
– Compressor Bearings Are Seized
– Failed Run Cap (1-Phase)
– Bad Wiring
– Excessive Liquid
62
Sensing Open Circuit (Code 5)
– Demand Signal Is Present But No Compressor
Current For 4 Hours
z Interpretation: Power Is Not Connected To

Compressor
z Root Causes
– Power Disconnected (Fuse, Switch, Etc.)
– Failed Compressor Protector/Contactor
– High Pressure Switch Open (Manual Re-set)
– Compressor Windings Are Damaged
z Open Circuit Differentiates Between Temporary

Trips And Permanent Trips
63
Sensing
Se s g Missing
ss g Phase
ase (Code 6)
Detects A Code 6 When: (3 Phase Only)
– Current Is Not Present In All Three Phases
• T1 & T3 Directly Sensed
• T2 Sensed By
y Phase Shift
z Interpretation: One Winding Of Compressor Not

Getting Power
z R tC
Root Causes
– Improper Wiring (Correct Order Of Phases)
– Failed Contactor
– Compressor Current Could Be Too Low
64
Open Start
Ope Sta t Circuit
C cu t (Code 6)
– Demand Is Present But Current Is Missing In
Start Circuit

G tti Power
Getting P
z Root Causes
– Run Capacitor Has Failed
– Open Circuit In Compressor Start Wiring or
Connection
– Compressor Start Winding Is Damaged
– Compressor Current Too Low
65
Sensing
Se s g Reverse
e e se Phase
ase (Code 7))
Detects A Code 7 When: (3 Phase Scroll Only)
– Demand Signal Is Present But Current Is Not
Detected In The Correct Sequence
z Interpretation: Scroll Compressor Will Run

B k
Backwardsd
z Root Causes
– Miswiring Of 3 Phase Power
66
Open Run Circuit (Code 7)
– Demand Is Present But Current Is Missing In
Start Circuit

G tti Power
Getting P
z Root Causes
– Open Circuit In Compressor Run Wiring or
Connection
– Compressor Run Winding Is Damaged
– Compressor Current Too Low
67
Sensing Welded Contactor (Code 8)
– No Demand Signal But Current Has Been
Detected In One Or Both Phases
z Interpretation: Compressor Contactor Has

F il d Closed
Failed Cl d
z Root Causes
– Welded Contactor
– Control Circuit Transformer Is Overloaded
– Thermostat Demand Signal Not Connected To
Performance Alert
68
Sensing Low Voltage (Code 9)
– Control Voltage Is Below 85 Volts For A 110 Volt
Coil, Or Below 170 Volts For A 220 Volt Coil
z Interpretation: Low Voltage Condition Exists,

M Draw
May D Hi
High/Lock
h/L k Rotor
R t C Currentt
z Root Causes
– Control Transformer Overloaded
– Line Voltage Low
69
Sensing Lost Communication (Code 10)
– Communication Is Lost Between Rack
Controller/Computer And Performance Alert For
10 Mins. Or More.
z IInterpretation:
t t ti Copeland
C l d Performance
P f Alert
Al t Can
C
Not Communicate To Rack Controller Or
Computer When Downloading Information
z R tC
Root Causes
– Bad Wire Connection
– Missing Jumper On Performance Alert Terminal
TRMNTR
70
Sensing
Se s g Open/Short
Ope /S o t Temp
e p Circuit
C cu t (Code 11))
– The Discharge Temperature Sensor Is Shorted
Or Is An Open Circuit
z Interpretation: Discharge Temp Sensor Not

S
Sensing
i Temperature/Working
T t /W ki
z Root Causes
– Not Wired To Performance Correctly
– Bad Sensor
71
Launch Package
B Support Tools
B.
D. Frequently Asked Questions
Q
72
FAQ’s
Qs
z Can I use Copeland PerformanceAlert on any compressor? No. Only on 1 & 3 phase
Refrigeration Copeland Brand compressors with a working amperage range of 3.0-200 amps.
Suggested applications include Supermarket, Walk-In, and in the future Transport applications.
z What about on old Copeland compressors? Same requirements apply.
z What is the estimated installation time? Depending on the application, the estimated time is 30
mins.
z 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.
z Is the voltage range adjustable? No. Copeland PerformanceAlert automatically adjusts to
either 120V or 230V applications.
z 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.
z How many alarm codes will it display? The LED displays one code at a time,
time however if using
the communication software all codes can be reviewed.
z 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.
displayed However,
However upon cycling power to the Copeland PerformanceAlert the last fault
code created will be displayed for 1 minute after power up.
z 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 280°. 73
FAQ’s
Qs
z 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).
z Where is the location and access to the jjumpers
p on the Copeland
p PerformanceAlert? External
access behind the discharge line temperature sensor input.
z 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.
z Who is going to support the installation of this product? There is a technical support number 1-
888-EMR-9950 or contact your wholesaler’s Copeland technical specialist or your Emerson
Climate Technologies District Sales Manager.
z Do I need
D d addition
dditi tools
t l to
t gett the
th data
d t from
f my compressor to
t my computer?
t ? Yes,
Y 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.
z What applications does this device support? Supermarkets and Walk-ins, (in the future
T
Transport).
t)
z What are the main error codes this device covers? See descriptions of alarm codes 1-11.
z What’s the warranty? 1 year.
74
FAQ’s
Qs
z 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
3 0 amps.
amps
z Can you connect more than one compressor to Performance Alert? No, one Copeland
PerformanceAlert per compressor.
z Will it shut down the compressor?
p Yes,, if contactor coil or system
y p
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.
z What is a manual re-set? A manual re-set is when y
you cycle
y p
power to the Copeland
p
PerformanceAlert OFF/ON.
75

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June 2009

C. Detailed Product & Technical Information

D Frequently Asked Questions

z Compatible With Copeland Brand

Gold Dealer Design Award

z Working Amperage, 3-phase Module; 3.0-200A

Improved Service Lower “No Defect Found”

“My main concern is getting the equipment repaired the

Includes Technical Support Number To Help Contractors Troubleshoot

Total Addressed Is 59%

z Call Toll Free: 1-888-367-9950

Copeland Gateway → E2,

Simple User Customer ProAct® Store Components/

z After Diagnosing The System, It Was Determined That The Compressor

z Without Copeland PerformanceAlert This Diagnosis Would Not Have

• Replace Existing Accessories (i.e. Phase

Discharge Line Temperature Discharge Line

Phase Protection Phase Monitor $30 $50

Copeland PerformanceAlert Performs All These Functions

– Less Phone Calls To OEM Because: (1/4 Man = $25K/60

– User Adjustable Features And 120/230V Compatible Ease Of Use

• Lower Maintenance Cost

• Greater Refrigeration Uptime 9 9

• Reduced Energy Consumption 9 9

• Improves Remote Monitoring & Services 99 9

*Assume 6 Compressors/Rack, 3 Racks/Store

1-Phase Scroll / Recip Module 943-0053-00

Bulk Pack (OEM):

3-Phase Recip Module 543-0055-04

Used To Secure Discharge Temperature

Discharge Line Size: 3/8 in (0.375 in) 032-0688-00

Used To Secure Discharge Temperature

Allows LED Alerts To Be Viewed From A

Enables Copeland PerformanceAlert

Allows User To Leave RS485 Connector At

Enables Copeland PerformanceAlert

Ad Campaign Installation Video

Faster Service And Improved Accuracy

500,000 Pieces Sold In 2006

D Frequently Asked Questions

z The Correct Copeland PerformanceAlert™

z If The Wrong Module Is Installed, The Alert

z The Module May Indicate System Faults That

Preferred Method Non-Desirable

Set each module with a

Address AD4 AD3 AD2 AD1

z If Multiple Alerts Occur, PerformanceAlert Displays The First

z Green LED “Power” Is Flashing

z Red “Trip” LED Is On

z Interpretation: Discharge Line Temperature

z Interpretation: High/Low Pressure Condition

z Interpretation: Compressor Is Running Only

z Interpretation: Compressor Is Attempting To

z Interpretation: Power Is Not Connected To

z Open Circuit Differentiates Between Temporary

z Interpretation: One Winding Of Compressor Not

z Interpretation: One Winding Of Compressor Not

z Interpretation: Scroll Compressor Will Run

z Interpretation: One Winding Of Compressor Not

z Interpretation: Compressor Contactor Has

z Interpretation: Low Voltage Condition Exists,

z Interpretation: Discharge Temp Sensor Not

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