Copeland Installation Instructions CoreSense Protection ESC1AFPT-CC-901 for Air Conditioning Copeland Scroll Compressors Manuals & Guides

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AE8-1391 R5

WARNING

AE8-1391 R5

Installation Instructions

CoreSense

™

Protection ESC1AFPT-CC-901

for Air Conditioning Copeland Scroll

Table of Contents

Description................................................................1

Precautions...............................................................1

Specications ...........................................................1

Mounting/Installation.................................................2

Operation .................................................................2

Warranty Information ................................................2

Support ....................................................................2

Wiring/Diagrams ....................................................3-4

Code Description Table ............................................4

Description

The CoreSense™ Protection module is a single-pole contactor designed for aftermarket use in residential air conditioning and heat pump applications utilizing Copeland Scroll™ compressors. CoreSense Protection modules combine the functionality of a standard system contactor with compressor diagnostic and protection capabilities. Through built-in CoreSense technology, this device will shut down the compressor when critical system faults are detected. CoreSense Protection

modules maintain the same wiring conguration as a

standard contactor and are easily installed in the unit electrical panel. By using the compressor as a sensor, the onboard diagnostics helps the service technician more accurately troubleshoot system and compressor fault conditions. Flashing LEDs communicate ALERT and LOCK codes to the service technician. CoreSense Protection modules feature advanced switching technology, extending contact life 4 to 5 times over a standard contactor. The sealed relay helps prevent contact arcing, pitting, and traditional problems with rodents, insects and debris.

Precautions

• Installation should be done by a qualied heating and air conditioning contractor or licensed electrician.

• The CoreSense Protection module FLA and LRA ratings must be equal to or greater than the FLA and LRA ratings of the contactor being replaced.

• All wiring must conform to local and national electrical codes and ordinances.

• This control is a precision instrument and should

November 2015

™

Compressors

be handled carefully. Rough handling or distorting components could cause the control to malfunction.

• Follow manufacturer’s recommended installation/ service instructions to ensure proper operation.

• The CoreSense Protection module has no serviceable parts.

Failure to comply with the following warning could result

SHOCK HAZARD

FIRE HAZARD

Specications

Operating Condition:

Electrical Rating

Recommended Terminal Torque Values - L1, L2, T1, T2

in personal injury or property damage

- Disconnect and lockout electric power before

servicing.

- L2 is not switched off and is energized at all

times.

- Do not exceed the specied voltage.

- Protect the control from direct contact with water

(dripping, spraying, rain, etc.).

- If the control has been in direct contact with water,

replace the control.

- Wiring errors can cause improper and dangerous

operation. Label all wires before disconnection when servicing controls.

- Safety route and secure wiring after installation.

Operating Temperature ............ -40°C to 65°C

Storage Temperature ............... -40°C to 80°C

Line voltage Input .................... 208-240 VAC

Frequency ..................................... 50/60Hz Single Phase

Full Load Amperes (FLA) ......... 40 Amp Maximum

Locked Rotor Amperes (LRA) .... 180 Amp Maximum

Control Voltage (A1, A2) .......... 24 VAC at 50/60 Hz

#4-6 AWG......................45 In-lbs

#8 AWG.........................40 In-lbs

#10-14 AWG...................35 In-lbs

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Application Restrictions

NOTICE

The CoreSense Protection module is designed

and qualied for use with ZP and ZR single-phase

Copeland Scroll non-modulating and UltraTech™ compressors. The CoreSense Protection module is not designed for use with Copeland™ reciprocating or Copeland Scroll variable speed compressors.

Mounting/Installation

To comply with U.L. 1995 section 33.2, the high voltage connections (L1, L2, T1, and T2) must be at least 1/2" from any grounded metal part.

1. Disconnect and lockout the power supply.

2. Before removing the wires from the existing contactor, label all of the wires so they can be connected to the correct connections on the CoreSense Protection module. After the wires are labeled and disconnected, remove the existing contactor.

3. The CoreSense Protection module is mounted using four mounting holes. See Figure 1 for mounting hole locations.

4. Using No. 8 or 10 self tapping screws, mount the CoreSense Protection module in place of the existing contactor. Use caution when drilling holes or using self tapping screws.

5. Connect the line, load, and control voltage wiring to the CoreSense Protection module. The

CoreSense Protection module is polarized, meaning that the high voltage input must be connected to the L1-L2 connections. When connecting 24VAC control voltage to the module, be sure to use a fully insulated spade end to minimize the possibility of short circuiting between A1 & A2 terminals. Refer

to a typical wiring diagram in Figure 3.

a. T1 and T2 are both screw and ¼ spade

connections.

b. L1 and L2 are lug connections. Please see

specifications for recommended torque values.

c. A1 and A2 are 1/4 spade connections.

One fully insulated spade quick disconnect supplied with each CoreSense Protection module. (Wire gauge 14-16 AWG)

AE8-1391 R5

Operation

How It Works

The CoreSense Protection module can be used to replace a single-pole contactor. It requires a 24 VAC signal to engage a long life relay to energize the

compressor and fan. When demand is satised, the

module will de-energize and the compressor and fan will shut down.

Protection Capabilities

The CoreSense Protection module utilizes proprietary algorithms to protect the compressor and system from repeated trips of the compressor internal overload. When the module detects a pattern of repetitive overload trips, as described in Table 1, it will activate a lockout feature to not energize the compressor.

Functional Test

A compressor activation, or 'Test' button, is located on the top of the module. This button can be used to start the compressor and fan and verify operation. This button is an immediate On/Off switch. It will immediately energize the module when pressed, and will immediately de-energize when released.

LED Description

RUN/ALERT LED

A solid green LED indicates the module is powered and the compressor/system is running normally. Abnormal system conditions are indicated through

a unique green ash code. The green LED will ash

consecutively, pause, and then repeat. The number

of consecutive ashes is dened as the ash code.

See Table 1 for a description of alert codes.

TRIP/LOCK LED

A solid red LED indicates the compressor's internal overload is open. The CoreSense Protection module detects a demand signal, however no current to the compressor is detected by the module.

The red LED will ash consecutively, pause and then

repeat when the compressor lockout feature is active.

The number of consecutive ashes, dened as the ash code, describes a particular lockout code. See

Table 1 for a description of lockout codes.

Resetting And Clearing Alert/Lock Codes

Alert and Lock codes are recorded as events in the memory of CoreSense Protection and the respective code will be displayed via the green and red LEDs until the faults are reset and cleared. To reset and clear Alert/

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AE8-1391 R5

Lock codes, the high voltage must be cycled off/on to the L1-L2 CoreSense Protection connections. Alert/Lock codes will not be reset when the 24 VAC is cycled off/ on to the CoreSense Protection module.

Warranty Information

The CoreSense Protection module ESC1AFPT-CC-9XX

used for eld replacement of conventional contactors

carry a limited warranty for defects in material and workmanship under normal use and regular service and maintenance that appear within sixty (60) months from the date the products are purchased and returned to Emerson within sixty-eight (68) months from the

date of manufacture. Except as specically stated

herein, Emerson’s standard terms and conditions of sale for Copeland brand products, which is available at

EmersonClimate.com, shall apply.

Module History Download

The CoreSense Protection module is capable of communicating with a personal computer, tablet, or laptop via Emerson Climate Technologies computer software interfaces (HVACR Fault Finder PC Edition) and USB connection (TTL-232R-5V-WE), in order to download and store fault history and module operation time. This information can be used to help diagnose and

review data from troubled systems in the eld. HVACR

Fault Finder PC Edition kit (9989-0099-01) with software and cable. For more information, please contact your Emerson Climate Technologies Application Engineer.

Support

For more information visit EmersonClimate.com, or contact Emerson Climate Technologies, Inc. at 1-888EMR-9950.

Scan the QR code to go directly to this product's page on our website.

Figure 1

Figure 2 – Contactor Dimensions (inches)

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AE8-1391 R5

Condenser

Fan

Compressor

SRR

Fan/Compressor Capacitor

Low Pressure

Cut-Out

High Pressure

Cut-Out

CoreSense Protecon

Contator

GND

24VAC

Crankcase

Heater

Line Side High Voltage Load Side High Voltage 24VAC Control Voltage Oponal Component

Solid Green Normal operation N/A N/A

Code1

Green Flash 1

Code2

Green Flash 2

Code3

Green Flash 3

Code4

Green Flash 4

Code5

Green Flash 5

Code6

Green Flash 6

Solid Red

The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or implied, regarding the products or services

described herein or their use or applicability. Emerson Climate Technologies, Inc. and/or its afliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specications

of such products at any time without notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user.

Figure 3 – Wiring Diagram Example

Table 1 – Code Description

Alert Code Alert Condition Lockout Level Lockout Code

Long run time. Compressor is on, running for more than 18 hours. (Code1 is disabled when unit is in Heat Pump mode.)

Compressor runs for 30 sec to 15 min followed by a compressor internal overload trip lasting longer than 7 min. Possible low or high pressure switch trip.

Compressor runs for 12 sec to 15 min followed by a compressor internal overload trip lasting between 35 sec to 7 min. Possible pressure switch cycling.

Locked rotor. Compressor internal overload trips within 12 sec after power is applied. Internal overload doesn't reset within 35 sec.

Compressor runs for 15 min to 18 hrs followed by a compressor internal overload trip lasting longer than 7 min. Possible low charge condition.

Low line voltage. L1-L2 voltage drops below 180 VAC. CoreSense will energize when L1-L2 voltage is greater than 190 VAC.

Compressor internal overload is open and CoreSense Protection is energized with 24 VAC.

4 consecutive or 10

N/A N/A

4 consecutive overload trips

total overload trips

10 consecutive

overload trips

total overload trips

N/A N/A

Red: Flash 2

Red: Flash 3

Red: Flash 4

Red: Flash 5