• AE10-1264


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    • Abstract: AE10-1264AE10-1264-R8 THE ELECTRONIC MOTOR PROTECTOR Revised June, 2004Copeland compressors using solid state protection have The solid state modules have been developed to

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AE10-1264
AE10-1264-R8 THE ELECTRONIC MOTOR PROTECTOR Revised June, 2004
Copeland compressors using solid state protection have The solid state modules have been developed to
PTC (Positive Temperature Coefficient) internal sensors with interpret the sensors resistance. The modules
an avalanching resistance in the event of high tempera- Kriwan INT369B/C/R, TI 41AA1600E, 31AA1600E
tures. The sensors are calibrated for proper motor protec- and TI 15AA1600B/C, or Robertshaw MP50 and
tion. 3450 are electrically inter- changeable. If replac-
ing one of the older style modules with a new Kriwan
Copeland will be phasing in a new supplier for solid state INT369R, TI 41AA1600E, or 31AA1600E an
modules and sensors semi-hermetic reciprocating compres- adapter plate, and a wiring harness is required.
sors. The new supplier will be Kriwan Industrie-Elektronic These will be included with the new module kit.
GmbH. The new Kriwan modules (INT369R) and sensors
are UL recognized and are identical in performance, fit, and
function. No wiring changes are required. They also passed
all tests for equivalency and reliability. The change to Kriwan
sensors in 4D/6D new production compressors will begin
in September 2003, through the summer of 2004. The part
number wholesalers purchase will not change, but the mod-
ule part number in that kit will change as this transition oc-
curs. All Texas instruments (TI), and Robertshaw will be
obsolete (2004). Also any previous Robertshaw system
with low resistance sensors (MP13,23,and 33)has been
obsoleted (1981).
998-0524-10 Module Kit
071-0581-00 Kriwan Module INT369R
003-0764-00 Adaptor Plate
929-0001-01 Wire Harness INT369R
Figure 1
120/208/240 VAC 208/240 VAC 120 VAC
Connection Connection Connection
41AA Wiring Connections For Module 31AA Wiring Connections For Module 31AA Wiring Connections For Module
Figure 2 Figure 3 Figure 4
© 2004, 1998 Copeland Corporation.
1 Printed in the U.S.A.
AE10-1264
To
Compressor
testing the nuisance tripping has been eliminated thus
providing reliable service.
The TI 31AA requires a jumper connection to accept
either 120 vac or 208/240 vac! See Figures 3 and 4.
All other modules required two models, one for 120VAC
and another for a 208/240 VAC power source.
Control Specification for Kriwan Sensors and
Kriwan INT369R Module. (After 2004)
The resistance of the sensor will vary from 30 ohms
(cold) to 20,000 ohms (hot). Reset values after a pro-
tector trip are from 2700-4500 ohms. The three sen-
sors have one lead connected together to form a com-
mon connection point (C). The other leads are con-
Kriwan INT 369
nected to a separate terminal (S1, S2, and S3).
The modules can time out from the follow conditions:
• High Motor Temperature
Wiring Connections For Module • Low Line Voltage to Module
Figure 5 • Power Outage
Supply Voltage
Module Electrical Connections (See Figure 5)
The Kriiwan INT369R and the 41AA will accept either
M1 – M2 Compressor Contactor Control Circuit 2.5A
120/208/240 vac without the use of a jumper connec-
Max 600VA
tion. See Figures 1 and 2. These modules utilize a
transformer power supply design, which simplifies in-
When the proper voltage is present and the motor
stallation by eliminating the need to use a jumper wire
temperature is within limits the “M1-M2” circuit is
to select between a 120v or 240v power supply. This
closed and the pilot circuit is energized after the
upgrade also yields a significant improvement over the
two minute off-cycle time delay. If the motor tem-
old design in its ability to compensate for large voltage
perature rises beyond safe limits, the resistance of
fluctuation spikes that could occur. In the past there have
the motor sensors rises, causing the control circuit
been in certain situations, problems with nuisance trip-
to open.
ping of the module due to motor noise generation in
specific locations. Through extensive laboratory and field
INT369R # 071-0581-00
Spec. (120 v) (240 v)
Line Voltage 120 +10% -20% 50/60 HZ 208/240 +10% -15% 50/60 HZ
Low Voltage Trip 85 VAC +/- 5.5 VAC 170 VAC +/- 10 VAC
Low Voltage Reset < 94.5 VAC < 184 VAC
Low Voltage Responds .20 +/- 15 secs Same
Trip Resistance 13k +/- 3k ohms Same
Reset Resistance 3.25k +/- .5k Same
Resistance responds .3 +/- .2 Secs. Same
Trip Time 120s +/- 20s Same
Temperature Range -40 ºF to 158 ºF Same
Relay Contact Rating 2.5 amps 600VA Same
© 2004, 1998 Copeland Corporation.
Printed in the U.S.A. 2
AE10-1264
L1 – L2 Module Supply Line Voltage 120/208/240 VAC b. 208/240 VAC module: Cut-Out Voltage 170 ± 8
Volts in normal ambient Cut-In Voltage 5 Volts
These are to be connected to a power source of the above cut-out.
proper voltage, normally the line terminals on the com-
pressor motor contactor or the control circuit transformer c. Dual voltage (TI 31AA module)120VAC or 208/
as required. The power requirement is very low, approxi- 240 VAC. Depending on the voltage supplied,
mately 6 VA. 120 VAC or 208/240 VAC, the low voltage cut-
out of the 31AA is the same as either 2.a.,or 2.b.
S1 – S2 – S3 Motor Sensor Connections
d. Dual voltage (TI 41AA module)120/208/240 VAC
C Common Lead Motor Sensors depending on the voltage supplied,120 VAC or
208/240 VAC, low voltage cut out of the 41AA is
Control Specification for T.I. Sensors Using the 41AA, as follows
31AA, 15AA, or the Mp50 (Before 2004)
i. 120 VAC module: cut-out voltage 85 +/-5.5
1. The resistance of the sensor will vary from 500 ohms volts in normal ambient, cut-in voltage 3 volts
(cold) to 20,000 ohms (hot).Reset values after a pro- above cut-out. Low voltage response delay
tector trip are from 2700-4500 ohms. The three sen- 0.2 +/-15 secs.
sors have one lead connected together to form a com-
mon connection point (C). The other leads are connected ii. 280/240 VAC module: cut-out voltage 170 +/
to a separate terminals (S1,S2,S3). -10 volts in normal ambient, cut-in volt- age
3 volts above cut-out voltage.
2. Low Voltage Cut-Out:
Note: Normal ambient conditions. (59 °F to
a. 120 VAC module: Cut-Out Voltage 85 ±4.5 Volts in 89.6 °F)15 °C to 32 °C
normal ambient. Cut-In Voltage 4 Volts above cut-
out. Low Voltage response delay 0.2 ±15 seconds. 3. Off cycle timer 120 second ±15%with normal ambient
4. The output device, the triac (TI 15AA) or the relay
(TI 31AA, TI 41AA, Robertshaw, or Kriwan) has a
rating of 2.5 amps 24 VAC to 240 VAC.
Typical Line Voltage Circuit Without Pumpdown
Figure 6
© 2004, 1998 Copeland Corporation.
3 Printed in the U.S.A.
AE10-1264
Basic Motor Protection If the system design is such that the operating con-
trols are wired to the module power circuit, the time
The solid state sensor protectors provide excellent pro- delay will provide two minute short cycle protection. If
tection against high motor temperatures resulting from the system refrigerant charge is small enough so that
locked rotor, loss of charge, or motor overload. The com- a pump down control circuit is not required, the con-
bination of low voltage sensing and time delay provide trol devices may be mounted in the line circuit as in
positive protection against low voltage conditions which Figure 6. This provides the maximum electrical pro-
can occur in the pilot circuit in the event of a single phase tection against short cycling or contactor chattering.
condition on a three phase circuit. Field experience indi- With larger refrigerant charges (see AE Bulletin 22-
cates that under these single phase conditions, the con- 1182), a pumpdown system is essential to protect the
trol voltage can fall to a level that will cause the contactor compressor against liquid refrigerant. Figure 7 shows
to drop out. Removing the compressor from the line can a typical circuit, with the liquid line solenoid wired
allow the voltage to increase enough to again pull in the through the protectors to prevent refrigerant migration
contactor, setting up a cycle of contactor chatter that in the event of a protector trip. This circuit uses the
can destroy either the contactor or the compressor or Sentronic oil pressure switch with its jumper from “L”
both. The low voltage protection feature removes the to “2” removed so the Sentronic control switch (“L
compressor from the line in the event of low voltage “to “M “) can be isolated from its control circuit power
(“brown- out”) conditions. The module locks the com- connections (“L “and “120 “or “240 “). The time
pressor off the line until the voltage rises to the cut-in delay would be energized in the event of a short circuit
setting. The time delay provides a two minute delay be- protector trip, low voltage, or a break in the power sup-
fore restarting each time the power circuit is opened, ply to the module. The time delay is not energized on
providing protection against “blips” in the power supply opening of the high or low pressure switches. Since it
or a chatter condition in the line power circuit. Service is not connected in the “T1 -T2” power circuit.
and test personnel must be alert to this feature since it
is possible in checking the compressor or system, power Solid State Components
may be applied, disconnected, and reapplied in less than
two minutes. In such case the time delay feature will There are two major components in the protection sys-
prevent operation until the time delay has expired, and tem.
this may be misinterpreted by service personnel as a
module malfunction.
+
Schematic Control Circuit Continuous Pumpdown
with off Cycle Refrigerant Control
Figure 7
© 2004, 1998 Copeland Corporation.
Printed in the U.S.A. 4
AE10-1264
1. The protector sensors are mounted internally 1. If the compressor has been operating and has
in the motor windings. The characteristics of the tripped on the protector, allow the compressor to
sensor are such that a change in temperature cool for at least one hour before checking. This al-
causes a change in the sensor’s electrical resis- lows time for the motor to cool and the control cir-
tance, the relation between temperature and re- cuit to reset.
sistance remains stable and exact, so that cali-
bration of the protection system can be made on WARNING! BEFORE CHECKING THE TI 31AA
the basis of resistance readings. MODULE OR ITS ATTACHED SENSOR
WIRING,BE AWARE THAT THE SENSOR TERMI-
2. The control module is a sealed enclosure con- NAL “C “, HAS THE SAME VOLTAGE AS
taining a relay or triac, transformer, and several TERMINAL”L1 “!
electronic components. Leads from the internal
motor sensors are connected to the module as 2. Disconnect control circuit power to de energize the
shown on the wiring diagrams. While the exact module. Connect a jumper wire across the “control
internal circuitry is quite complicated, basically circuit (“M1-M2”) terminals on the module control
the module senses the change in resistance of circuit terminal board. This will bypass the “control
the sensors. As the motor temperature rises or contact” of the module.
falls, the resistance also rises or falls, triggering
the action of the control circuit at predetermined 3. Reconnect control circuit power. If the compressor
opening and closing settings. will not operate with the jumper wire installed, then
the problem is external to the solid state protection
The TI 41AA and also the TI 31AA module may be used system. If the compressor operates with the mod-
on either 120 VAC or 208/240 VAC. All other modules ule bypassed, but will not operate when the jumper
must have separate models for 120 VAC and 208/ 240 wire is removed, then the control circuit relay or triac
VAC. Any module output device can handle pilot in the module is open.
circuit voltages from 24 V to 240 VAC, since there
is no internal connection between the output de- 4. If after allowing time for motor cooling, the protec-
vice circuit and the line power connection. tor still remains open, the motor sensors may be
checked as follows (see Figure 8):
The solid state module cannot be repaired in the field,
and if the cover is opened or the module physically a. Disconnect control circuit power to de energize
damaged, the warranty on the module is voided. No the module. Remove the jumper of Step 2. Re-
attempt should be made to adjust or repair this mod- move wiring connections from the sensor and
ule, and if it becomes defective, it must be returned common terminals on the module control circuit
intact for warranty replacement. terminal board.
High-Potential (Hi-Pot) Testing b. CAUTION: Use Ohmmeter with a maximum 9
VAC for checking. The sensors are sensitive,
The solid state sensors and the electronic components easily damaged, and no attempt should be made
in the solid state module are delicate, and can be dam- to check continuity through them with other than
aged by exposure to high voltage. Under no circum-
stances should a high potential test be made at the
sensor terminals with the sensor leads connected to
the solid state module. Even though the power and C
pilot circuit leads are not connected, the module can Check Resistance
be damaged. Between Terminals
C and S1, S2, or S3
S1, S2, S3
Field Trouble Shooting
In the event the motor compressor is inoperable or is Note: Remove Wiring
Connections to
not operating properly, the solid state control circuit may Module Before
Checking Resistance
be checked as follows:
Checking Resistance Through
Solid State Sensors
Figure 8
© 2004, 1998 Copeland Corporation.
5 Printed in the U.S.A.
AE10-1264
an ohmmeter. Any external voltage or current 5. If the sensors have the proper resistance, and are
applied to the sensors may cause damage requir- below 2700 ohms, the compressor will run with the
ing compressor replacement. control circuit bypassed, but will not run when con-
nected properly, the solid state module is defec-
c. Measure the resistance from each sensor termi- tive, and must be replaced. The replacement mod-
nal to the common terminal. The resistance ule must be the same voltage and be compatible
should be in the following range: 30 ohms Kriwan with the original module on the compressor.
post year 2004 or 500 ohms pre year 2004 T.I.
sensors (cold) to 20,000+ ohms (hot compressor Emergency Bypass of a Damaged Solid State
tripped!) Sensor
Resistance readings in this range indicate the sen- In the unlikely event that ONE sensor may be dam-
sors are good. A resistance approaching zero in- aged and have an open or shorted circuit, the control
dicates a short; a resistance approaching infinity module will prevent compressor operation even though
indicates an open connection. Proper operation the motor may be in perfect condition. If such a situa-
of the control system is dependent on a continu- tion should be encountered in the field, an emergency
ous parallel circuit through all three sensors with means of operating the compressor can be used until
no individual resistance reading higher than such time as a replacement can be made. Discon-
10,000 ohms. On initial start-up, and after any nect the lead from the solid state module and the faulty
module trip due to high temperatures, the resis- module control circuit terminal board sensor connec-
tance of the sensors must be below the module tion; S1, S2 or S3. Connect a properly sized resistor
reset point before the module circuit will close. between the solid state module lead and the common
Reset values are 2700-4500 ohms. sensor terminal in the compressor terminal box. This
indicates to the control module an acceptable resis-
tance in the damaged sensor circuit, and compressor
operation can be restored (see Figure 9). If an inter-
nal sensor is shorted, the wire from the sensor to the
sensor terminal should be disconnected when install-
ing the resistor. In effect, the compressor will con-
tinue operation with two leg protection rather than three
leg protection. While this obviously does not provide
the same high degree of protection, it does provide a
means of continuing compressor operation with a de-
gree of safety. The protector cut-in and cut-out points
will be reduced by approximately 7°F to 10°F, but un-
der normal operating conditions this should present
no problem.
Note: At no time should more than one motor
sensor be bypassed.
The specifications for the emergency resistor are as
follows:
One watt (or larger), 2200 ohm ±10%resistor
Emergency Bypass of Damaged
Solid State Sensor
Figure 9 AE 1264 R8 (5/04)
Emerson Climate Technologies and the Emerson Climate Technologies logo
are service marks and trademarks of Emerson Electric. All other trademarks
are property of their respective owner.
© 2004, 1998 Copeland Corporation.
Printed in the U.S.A. 6


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