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AE8-1391 R5
November 2015
AE8-1391 R5
Installation Instructions
CoreSense™ Protection ESC1AFPT-CC-901
for Air Conditioning Copeland Scroll™ Compressors
Table of Contents
be handled carefully. Rough handling or distorting
components could cause the control to malfunction.
Description................................................................1
Precautions...............................................................1
Specifications............................................................1
Mounting/Installation.................................................2
Operation ..................................................................2
Warranty Information.................................................2
Support.....................................................................2
Wiring/Diagrams.....................................................3-4
Code Description Table.............................................4
• Follow manufacturer’s recommended installation/
service instructions to ensure proper operation.
• The CoreSense Protection module has no
serviceable parts.
WARNING
Failure to comply with the following warning could result
in personal injury or property damage
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 configuration 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.
SHOCK HAZARD
-- Disconnect and lockout electric power before
servicing.
-- L2 is not switched off and is energized at all
times.
FIRE HAZARD
-- Do not exceed the specified 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.
Specifications
Operating Condition:
Operating Temperature............. -40°C to 65°C
Storage Temperature................ -40°C to 80°C
Precautions
Electrical Rating
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
• Installation should be done by a qualified 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.
Recommended Terminal Torque Values - L1, L2, T1, T2
#4-6 AWG......................45 In-lbs
#8 AWG.........................40 In-lbs
#10-14 AWG...................35 In-lbs
• All wiring must conform to local and national
electrical codes and ordinances.
• This control is a precision instrument and should
© 2015 Emerson Climate Technologies, Inc. All rights reserved.
1
AE8-1391 R5
Operation
Application Restrictions
How It Works
The CoreSense Protection module is designed
and qualified 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.
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 satisfied, the
module will de-energize and the compressor and fan
will shut down.
Mounting/Installation
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.
NOTICE
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.
Functional Test
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.
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.
3. The CoreSense Protection module is mounted
using four mounting holes. See Figure 1 for
mounting hole locations.
LED Description
RUN/ALERT LED
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.
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 flash code. The green LED will flash
consecutively, pause, and then repeat. The number
of consecutive flashes is defined as the flash code.
See Table 1 for a description of alert codes.
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.
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 flash consecutively, pause and then
repeat when the compressor lockout feature is active.
The number of consecutive flashes, defined as the
flash code, describes a particular lockout code. See
Table 1 for a description of lockout codes.
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.
Resetting And Clearing Alert/Lock Codes
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)
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/
© 2015 Emerson Climate Technologies, Inc. All rights reserved.
2
AE8-1391 R5
Support
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.
For more information visit EmersonClimate.com, or
contact Emerson Climate Technologies, Inc. at 1-888EMR-9950.
Warranty Information
Scan the QR code to go
directly to this product's
page on our website.
The CoreSense Protection module ESC1AFPT-CC-9XX
used for field 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 specifically 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 field. HVACR
Fault Finder PC Edition kit (9989-0099-01) with software
and cable. For more information, please contact your
Emerson Climate Technologies Application Engineer.
Figure 1
Figure 2 – Contactor Dimensions (inches)
© 2015 Emerson Climate Technologies, Inc. All rights reserved.
3
AE8-1391 R5
C
R
C
Condenser
Fan
Compressor
S
S
R
Fan/Compressor Capacitor
C
F
H
T2
T1
High Pressure
Cut-Out
Low Pressure
Cut-Out
A1
CoreSense Protecon
Contator
24VAC
A2
Crankcase
Heater
Line Side High Voltage
Load Side High Voltage
24VAC Control Voltage
Oponal Component
L1
L2
L2
L1
GND
Figure 3 – Wiring Diagram Example
Table 1 – Code Description
Alert Code
Alert Condition
Lockout Level
Lockout Code
Solid Green
Normal operation
N/A
N/A
Code1
Green Flash 1
Long run time. Compressor is on, running for more than 18 hours.
(Code1 is disabled when unit is in Heat Pump mode.)
N/A
N/A
Code2
Green Flash 2
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.
4 consecutive
overload trips
Red: Flash 2
Code3
Green Flash 3
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.
4 consecutive or 10
total overload trips
Red: Flash 3
Code4
Green Flash 4
Locked rotor. Compressor internal overload trips within 12 sec after
power is applied. Internal overload doesn't reset within 35 sec.
10 consecutive
overload trips
Red: Flash 4
Code5
Green Flash 5
Compressor runs for 15 min to 18 hrs followed by a compressor
internal overload trip lasting longer than 7 min. Possible low charge
condition.
4 consecutive or 10
total overload trips
Red: Flash 5
Code6
Green Flash 6
Low line voltage. L1-L2 voltage drops below 180 VAC. CoreSense
will energize when L1-L2 voltage is greater than 190 VAC.
N/A
N/A
Solid Red
Compressor internal overload is open and CoreSense Protection is
energized with 24 VAC.
N/A
N/A
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 affiliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifications
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.
© 2015 Emerson Climate Technologies, Inc. All rights reserved.
4
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