Emerson Comfort Alert 543-0033-00 Bedienungsanleitung

User’s Manual

543-0033-00

943-0033-00

™

Comfort Alert™

Diagnostics – Faster Service And Improved Accuracy

The Comfort Alert diagnostics module is a breakthrough innovation for troubleshooting

heat pump and air conditioning system failures. The module installs easily in the electrical

box of the outdoor unit near the compressor contactor. By monitoring and analyzing

data from the Copeland Scroll

compressor and the thermostat demand, the module

can accurately detect the cause of electrical and system related failures without any

sensors. A ﬂ ashing LED indicator communicates the ALERT code and guides the service

technician more quickly and accurately to the root cause of a problem.

NOTE:

This module does not provide safety protection! The Comfort Alert module

is a monitoring device and cannot shut down the compressor directly.

LED Description (Figure 1)

POWER LED (Green): indicates voltage is present at

the power connection of the module.

ALERT LED (Yellow): communicates an abnormal system

condition through a unique ﬂ ash code. The ALERT LED

will ﬂ ash a number of times consecutively, pause and then

repeat the process. The number of consecutive ﬂ ashes,

deﬁ ned as the Flash Code, correlates to a particular

abnormal condition. Detailed descriptions of specific

ALERT Flash Codes are shown in two tables on pages 8

and 9 of this manual.

TRIP LED (Red): indicates there is a demand signal from

the thermostat but no current to the compressor is detected

by the module. The TRIP LED typically indicates the

compressor protector is open or may indicate

missing supply power to the compressor.

Product Speciﬁ cations

Operating Temperature: -40° to 150° F (-40° to 65° C)

Storage Temperature: -40° to 175° F (-40° to 80° C)

Power Supply Range: 18-30VAC, 48-62 Hz

Power Requirement: 1.5 VA nominal (without solenoid on)

6.0VA nominal (with solenoid on)

UL Restrictions: Use only with Class 2 circuits.

This Comfort Alert module is designed only for single-phase systems with Copeland

scroll compressors that have internal overload protection.

The software in this Comfort

Alert module has been optimized for two stage UltraTech™ scroll systems.

Figure 1

UL File #SA8958

Module Dimensions (Figure 2):

A. 1.85 in (47 mm) D. 4.40 in (112mm)

B. 2.44 in (62 mm) E. 2.44 in (62 mm)

C. 1.46 in (37 mm)

Hardware Installation

Four #8 or #10 self drilling or sheet metal screws, at least ½” length, are required for

installation of the Comfort Alert module. The maximum screw torque is 20 in.-lbs. Locate

the Comfort Alert module near the compressor contactor (wire routing for compressor

run, common and start wires will be easier in this position). Mount the Comfort Alert

module so all LEDs are visible from a comfortable viewing position. The module will

operate in any mounting orientation. For ease of reading labels, the module should be

oriented so that the green POWER LED is at the top.

WARNING

Hazardous voltage inside air conditioning system.

Disconnect power before installing or servicing module.

Module must be installed and serviced only by qualiﬁ ed

personnel.

Figure 2

Compressor Wire Routing (Figure 3)

The scroll compressor’s run (R), common (C) and start (S) wires are routed through the

holes in the Comfort Alert module marked “R,” “C” and “S.” The common (C) wire need

not be routed through the module for it to operate properly.

24VAC Power Wiring

The Comfort Alert module requires

a constant nominal 24VAC power

supply. The wiring to the module’s R

and C terminals must be directly from

the indoor unit or thermostat. The

module cannot be powered by the C

terminal on a defrost board or other

control board without experiencing

nuisance alerts. Refer to

Figure 5

When constant 24VAC (R wire) is not

present in the outdoor unit, use one of

the spare wires in the thermostat cable

to bring power to the module. Connect

the other end of the spare wire to R at

the indoor unit or thermostat. Refer to

wiring schematic in

Figure 4 and 5

Thermostat Demand Wiring

The Comfort Alert module requires a thermostat demand signal to operate properly. The

thermostat demand signal input, labeled Y on the module, should always be connected

to the compressor contactor coil so that when the coil is energized, the demand signal

input is 24VAC. When the coil is not energized, the demand signal input should be less

than 0.5VAC.

NOTE:

Factory installed modules may have different thermostat demand signal

wiring. Follow manufacturer’s wiring instructions when replacing module.

NOTE:

After the thermostat demand signal is connected, verify Y is phased

properly with C by measuring 24VAC across Y and C when demand is present.

Figure 3

Figure 4 Air Conditioning Schematic

Figure 5 Heat Pump Schematic

Two Stage Indoor Thermostat

Ultra Tech

Solenoid

529-0369-00

HPCO HTCO

LPCO

DC SOL

Y2 CRLY1

Comfort Alert

Diagnostics

Module

543-0033-00

Y2 CRLY1

Indoor Unit

Terminal Block

Two Stage Indoor Thermostat

Ultra Tech

Solenoid

529-0369-00

HPCO HTCO

LPCO

DC SOL

Y2 CRLY1

Comfort Alert

Diagnostics

Module

543-0033-00

Y2 CRLY1

Indoor Unit

Terminal Block

Defrost

Board

Schematic Abbrevation Descriptions

HTCO High Temperature Cut Out Switch CC Compressor Contactor

HPCO High Pressure Cut Out Switch

LPCO Low Pressure Cut Out Switch

Thermostat Second Stage Cooling Wiring

This Comfort Alert module requires a two stage thermostat to operate properly. The

Y2 thermostat wire coming into the outdoor unit

should be connected to

he Y2 input

on Comfort Alert

While the compressor is running, Comfort Alert will provide power to the second stage

cooling solenoid inside the compressor after Y2 has been energized for 5 seconds.

Whenever the compressor is not running, Comfort Alert will not power the solenoid,

regardless of the state of Y2. If Alert codes 1 or 9 appear while the compressor is

running, Comfort Alert will turn off the solenoid to prevent solenoid damage from

overheating conditions.

L Terminal

Wiring

The L connection is used to communicate Alert codes to compatible White-Rodgers

thermostats. The L terminal of the thermostat should be connected directly to the Comfort

Alert L terminal.

On select White-Rodgers thermostats, an icon on the thermostat display will ﬂ ash at

the same rate as the Comfort Alert yellow Alert LED. An advanced option on these

thermostats is to lock out the compressor when certain Alert codes are detected indicating

impending compressor damage. Refer to White-Rodgers thermostat manuals for more

information.

DC SOL Connection

The two pin DC SOL connector provides a connection to the Copeland UltraTech

second stage compressor solenoid. This solenoid is internal to the compressor. This

24VDC solenoid will not operate properly if 24VAC is applied to the compressor solenoid

terminals.

To reduce the VA load of the solenoid on the system, Comfort Alert uses a phase control

method to reduce the DC voltage to the solenoid to the minimum level required to keep

the solenoid pulled in. As the 24VAC supply voltage varies, Comfort Alert intelligently

changes the solenoid DC voltage supply to minimize power consumption.

A voltmeter

attached to the DC SOL output will measure 4-18VDC, when solenoid should be

energized, depending on the level of the 24VAC supply.

Interpreting The Diagnostic LEDs

When an abnormal system condition occurs, the Comfort Alert module displays the

appropriate ALERT and/or TRIP LED. The yellow ALERT LED will ﬂ ash a number of

times consecutively, pause and then repeat the process. To identify a Flash Code

number, count the number of consecutive ﬂ ashes. Every time the module powers

up, the last ALERT Flash Code that occurred prior to shut down is displayed for one

minute.

Installation Veriﬁ cation

To verify the installation of Comfort Alert is correct, two functional tests can be performed.

Disconnect power from the compressor and force a thermostat call for cooling. The red

Trip LED should turn on indicating a compressor trip as long as 24VAC is measured at

the Y terminal. If the red LED does not function as described, refer to

Table 1

to verify

the wiring.

Disconnect power from the compressor and 24VAC from Comfort Alert. Remove the

wire from the Y terminal of Comfort Alert, reapply 24VAC power to Comfort Alert and

reconnect power to the compressor. Force a thermostat call for cooling and when the

Compressor starts to run, the yellow Alert LED will begin ﬂ ashing a Code 8 indicating

a Welded Contactor. Disconnect power from the compressor and 24VAC from Comfort

Alert. While Comfort Alert is off, reattach the wire to the Y terminal. Reapply power to

compressor and 24VAC to Comfort Alert, the yellow Alert LED will ﬂ ash the previous

code 8 for 1 minute and then turn off. If the yellow LED does not function as described,

refer to

Table 1

to verify the wiring.

Troubleshooting The Installation

Depending on the system conﬁ guration, some ALERT Flash codes may not be active.

The presence of safety switches affects how the system alerts are displayed by this

module. Refer to

Figures 4 & 5

for safety switch wiring.

Resetting Alert Codes

Alert codes can be reset manu

ally and automatically. The manual method to reset an Alert

code is to cycle the power to Comfort Alert off and on.

For automatic reset, Comfort Alert

continues to monitor the compressor and system after an Alert is detected. If conditions

return to normal, the Alert code is turned off automatically.

Com

fort Alert Part Numbers

OEM P/N

Service P/N

Copeland Scroll Compressor Application

543-0010-00

943-0010-00

Single Stage Air Conditioning

543-0012-00

943-0012-00

All Heat Pump and Two Stage A/C

543-0032-00

943-0032-00

Single Stage A/C & Heat Pump

543-0033-00

943-0033-00

Two Stage A/C & Heat Pump

Status LED

Status LED Description

Status LED Troubleshooting Information

Green “POWER”

Module has power

Supply voltage is present at module terminals

Red “TRIP”

Thermostat demand signal

Y is

present, but the

compressor is

not

running

1.Compressor protector is open

•Check for high head pressure

•Check compressor supply voltage

2.Outdoor unit power disconnect is open

3.Compressor circuit breaker or fuse(s) is open

4.Broken wire or connector is not making contact

5.Low pressure switch open if present in system

6.Compressor contactor has failed open

Yellow “ALERT”

Flash Code 1

Long Run Time

Compressor

running extremely

long run

cycles

1.Low refrigerant charge

2.Evaporator blower is not running

•Check blower relay coil and contacts

•Check blower motor capacitor

•Check blower motor for failure or blockage

•Check evaporator blower wiring and connectors

•Check indoor blower control board

•Check thermostat wiring for open circuit

3.Evaporator coil is frozen

•Check for low suction pressure

•Check for excessively low thermostat setting

•Check evaporator airﬂ ow (coil blockages or return air ﬁ lter)

•Check ductwork or registers for blockage

4.Faulty metering device

•Check TXV bulb installation (size, location and contact)

•Check if TXV/ﬁ xed oriﬁ ce is stuck closed or defective

5. Condenser coil is dirty

6. Liquid line restriction (ﬁ lter drier blocked if present in system)

7. Compressor Second Stage Cooling Wiring

•Solenoid plug not connected

•Y2 not wired at Comfort Alert

8. Thermostat is malfunctioning

•Check thermostat sub-base or wiring for short circuit

•Check thermostat installation (location, level)

9.Comfort Alert failure

Yellow “ALERT”

Flash Code 2

System Pressure Trip

Discharge or suction

pressure out of limits or

compressor overloaded

1. High head pressure

•Check high pressure switch if present in system

•Check if system is overcharged with refrigerant

•Check for non-condensable in system

2. Condenser coil poor air circulation (dirty, blocked, damaged)

3.Condenser fan is not running

•Check fan capacitor

•Check fan wiring and connectors

•Check fan motor for failure or blockage

4.Return air duct has substantial leakage

5.If low pressure switch present in system, check Flash

Code 1 information

Status LED

Status LED Description

Status LED Troubleshooting Information

Yellow “ALERT”

Flash Code 3

Short Cycling

Compressor is running

only brieﬂ y

1. Thermostat demand signal is intermittent

2. Time delay relay or control board defective

3. If high pressure switch present go to Flash Code 2 information

4. If low pressure switch present go to Flash Code 1 information

Yellow “ALERT”

Flash Code 4

Locked Rotor

1.Run capacitor has failed

2.Low line voltage (contact utility if voltage at disconnect is low)

•Check wiring connections

3.Excessive liquid refrigerant in compressor

4.Compressor bearings are seized

•Measure compressor oil level

Yellow “ALERT”

Flash Code 5

Open Circuit

1.Outdoor unit power disconnect is open

2.Compressor circuit breaker or fuse(s) is open

3.Compressor contactor has failed open

•Check compressor contactor wiring and connectors

•Check for compressor contactor failure (burned, pitted or open)

•Check wiring and connectors between supply and compressor

•Check for low pilot voltage at compressor contactor coil

4.High pressure switch is open and requires manual reset

5.Open circuit in compressor supply wiring or connections

6.Unusually long compressor protector reset time due to

extreme ambient temperature

7.Compressor windings are damaged

•Check compressor motor winding resistance

Yellow “ALERT”

Flash Code 6

Open Start Circuit

Current only in run circuit

1.Run capacitor has failed

2.Open circuit in compressor start wiring or connections

•Check wiring and connectors between supply and the

compressor “S” terminal

3.Compressor start winding is damaged

•Check compressor motor winding resistance

Yellow “ALERT”

Flash Code 7

Open Run Circuit

Current only in start circuit

1.Open circuit in compressor run wiring or connections

•Check wiring and connectors between supply and the

compressor “R” terminal

2.Compressor run winding is damaged

•Check compressor motor winding resistance

Yellow “ALERT”

Flash Code 8

Welded Contactor

Compressor always runs

1.Compressor contactor has failed closed

2.Thermostat demand signal not connected to module

Yellow “ALERT”

Flash Code 9

Low Voltage

Control circuit < 17VAC

1.Control circuit transformer is overloaded

2.Low line voltage (contact utility if voltage at disconnect is low)

•Check wiring connections

Flash Code number corresponds to a number of LED ﬂ ashes, followed by a pause and then repeated.

TRIP and ALERT LEDs ﬂ ashing at same time means control circuit voltage is too low for operation.

NOTE:

The correct Comfort Alert model must be used for the application (refer

to the Product Speciﬁ cation section on pages 2 and 3). If the wrong model is

installed, the ALERT Flash Codes for system faults will function incorrectly: the

Comfort Alert module may indicate system faults that are not present or fail to

indicate system faults that are present.

NOTE:

Miswiring the Comfort Alert module will cause false LED codes. Table 1

describes LED operation when the module is miswired and what troubleshooting

action is required to correct the problem.

Miswired Module Indication Recommended Troubleshooting Action

Green LED is not on, Determine if both R and C module terminals are

module does not power up connected. Verify voltage is present at module’s R and

C terminals. Review

24VAC Power Wiring

(page 4) for

R and C wiring.

Green LED intermittent, Determine if R and Y terminals are wired in reverse.

module powers up only Verify module’s R and C terminals have a constant

when compressor runs source. Review

24VAC Power Wiring

(page 4) for R

and C wiring.

TRIP LED is on but system Verify Y terminal is connected to 24VAC at contactor

and compressor check OK coil. Verify voltage at contactor coil falls below 0.5VAC

when off.

Verify 24VAC is present across Y and C when

thermostat demand signal is present. If not, R and C are

reverse wired.

TRIP LED and ALERT LED Verify R and C terminals are supplied with 19-28VAC.

ﬂ ashing together

ALERT Flash Code 3 Verify Y terminal is connected to 24VAC at contactor coil.

(Compressor Short Cycling) Verify voltage at contactor coil falls below 0.5VAC when

displayed incorrectly off.

ALERT Flash Code 5, 6 or 7 Check that compressor run and start wires are through

(Open Circuit, Open Start Circuit module’s current sensing holes. Verify Y terminal is

or Open Run Circuit) displayed connected to 24VAC at contactor coil. Verify voltage at

incorrectly contactor coil falls below 0.5VAC when off.

ALERT Flash Code 6 (Open Check that compressor run and start wires are routed

Start Circuit) displayed for Code 7 through the correct module sensing holes.

(Open Run Circuit) or vice versa

ALERT Flash Code 8 Determine if module’s Y terminal is connected. Verify Y

(Welded Contactor) terminal is connected to 24VAC at contactor coil. Verify

displayed incorrectly 24VAC is present across Y and C when thermostat

demand

signal is present. If not, R and C are reverse

wired. Verify voltage at contactor coil falls below 0.5VAC

when off. Review

Thermostat Demand Wiring

(page 4) for

Y and C wiring

Table 1

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