Emerson CoreSense Technical Information
Technical Information
Date of last update: Oct-11 Ref: D7.8.4/1011/E
Application Engineering Europe
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CoreSense™ Diagnostics for Stream Refrigeration Compressors ............................................................................... 1
1 Introduction .......................................................................................................................................................... 3
2 Specifications ........................................................................................................................................................ 3
3 Emerson CoreSense™ Diagnostics – Features ..................................................................................................... 3
3.1 “Jog” feature ................................................................................................................................................. 4
3.2 Crankcase heater (CCH) control.................................................................................................................... 4
3.3 Insufficient oil pressure protection .............................................................................................................. 5
3.4 Motor overheat protection .......................................................................................................................... 5
3.5 High discharge temperature protection ....................................................................................................... 5
3.6 Locked rotor protection ................................................................................................................................ 5
3.7 Missing phase protection ............................................................................................................................. 5
3.8 Low voltage protection ................................................................................................................................. 5
3.9 Voltage imbalance protection ...................................................................................................................... 6
3.10 Flash memory information ........................................................................................................................... 6
3.10.1 The following asset information will be saved in the flash memory (EEPROM); ................................. 6
3.10.2 Compressor running status information will be saved in the flash memory (EEPROM): ..................... 6
3.10.3 Compressor Operating Parameters ...................................................................................................... 6
3.11 Modbus® communication ............................................................................................................................. 6
3.12 Local and remote reset ................................................................................................................................. 6
3.13 Alarm history and running conditions .......................................................................................................... 7
3.14 Compressor status codes .............................................................................................................................. 7
3.15 LEDs on the module to display the failure alarms ........................................................................................ 7
4 Electrical connections ........................................................................................................................................... 9
4.1 System wiring diagram ................................................................................................................................. 9
4.2 Terminal box and current sensing transformer connections ..................................................................... 10
4.2.1 Installation of current sensing module ............................................................................................... 10
4.2.2 CoreSense™ Diagnostics with Υ/Δ motors ........................................................................................ 11
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4.2.3 CoreSense™ Diagnostics with part winding ...................................................................................... 11
5 CoreSense™ Diagnostics jumper settings .......................................................................................................... 13
6 CoreSense™ Diagnostics DIP-Switch setting ..................................................................................................... 13
7 Troubleshooting.................................................................................................................................................. 15
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Operating temperature
-32°C to 66°C
Steady load current for relay
3A
Voltage requirements
120 VAC or 240 VAC
Power rating for the module
3VA
Inrush current for relay
19A
Storage temperature
-40°C to 85°C
Voltage sensor module
24 VAC
Protection class
IP54
Nr
Feature
Nr
Feature
1
Motor Overheat Protection
8
Alarm History and Compressor Operating Conditions
2
Oil Pressure Protection
9
Crankcase Heater Control
3
Discharge Temperature Protection
10
Local and Remote Reset Capability
4
Locked Rotor Protection
11
Modbus® Communication
5
Single Phase/Missing Phase Protection
12
Power Consumption Monitoring (Voltage, Current,
Power Factor)
6
Voltage Imbalance Protection
13
Crankcase Heater Control
7
Low Voltage Protection
14
Compressor Run Status (Proofing)
1 Introduction
CoreSense™ is an ingredient brand name for compressor electronics associated with Emerson‟s Copeland® brand
products. CoreSense™ technology uses compressor as a sensor to unlock information from within the compressor
providing value added features such as advanced motor protection, diagnostics, communication.
With active protection, advanced algorithms, and features like fault history and LED indicators, CoreSense™
Diagnostics for Copeland compressors enable technicians to diagnose the past and recent state of the system,
allowing for quicker, more accurate diagnostics and less down time. The CoreSense™ Diagnostics is initially
available as standard with the 4- and 6-cylinder Stream compressors.
Figure 1: Stream compressor with CoreSense™ Diagnostic
2 Specifications
Power supply for control module (in front of the compressor) is 120VAC or 240VAC.
Table 1
3 Emerson CoreSense™ Diagnostics – Features
Table 2
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Figure 2
3.1 “Jog” feature
The reset button below the control module may be used as an emergency shutdown,
such as for clearing liquid during a start-up. After the module re-boots (approximately
3 seconds) the compressor will run again. The reset button may be pushed as necessary
to stop the compressor.
Reset button
Figure 3
3.2 Crankcase heater (CCH) control
The sensor module contains an on-board CCH control relay. An auxiliary contactor is no longer required to turn the
heater on when the compressor turns off.
The appropriate voltage supply to the CCH power input terminals (115V/230V) is required.
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3.3 Insufficient oil pressure protection
The CoreSense™ Diagnostics module replaces the mechanical oil pressure switch. Furthermore, it provides the
added value of communication for insufficient oil pressure warning and lockouts via LED flash codes and/or a
supervisory pack controller. Total insufficient oil pressure time for the compressor is stored and accumulated in the
module memory.
CoreSense™ Diagnostics will issue a warning when oil pressure differential falls below 0.48-0.62 bar for
4 seconds.
Once the oil pressure differential falls below 0.48-0.62 bar for 2 minutes (120 sec), the module will shut the
compressor off and a “low oil pressure lockout“ will be reported. Before using the reset button, troubleshooting
needs to be done to understand the failure. The compressor will switch back on once the reset has been activated
either manually or remotely through the communication network, or when power has been cycled to the
CoreSense™ module. This feature is not applicable to Copeland compressor models 4MTL (Stream CO2
compressors) as these have no positive oil pump fitted and are “splash” lubricated.
3.4 Motor overheat protection
Using Positive Temperature Coefficient (PTC) sensors on 4M* and 6M* Stream compressor models, the
CoreSense™ Diagnostics module provides motor overheating protection. The CoreSense™ Diagnostic module
replaces the Kriwan module INT69TM.
Alarm condition:
Trip condition: PTC Resistance > 4.5 kΩ;
Reset condition: PTC Resistance < 2.5 kΩ; 5 min time delay.
3.5 High discharge temperature protection
Discharge temperature protection is provided using a NTC sensor in the compressor cylinder head. The sensor is
pre-installed at the factory and connected to the module. CoreSense™ will protect the compressor from high
discharge temperature conditions. If the temperature sensor detects a discharge temperature higher than 154°C,
the CoreSense™ will shut off the compressor until the temperature cools down to an acceptable level (about
130°C).
Either trip or lockout alarm can be selected by user. Default is trip alarm.
Trip/lockout value ≥ 154°C for 2 sec.
Trip alarm: Automatic reset after 2 minutes; discharge temp < 130ºC.
Lockout alarm: Manual reset is necessary.
3.6 Locked rotor protection
Appears when the rotor is mechanically seized. Locked rotor current is expected to decrease within 4 seconds after
the motor comes up to speed.
3.7 Missing phase protection
If any one of the 3 power phases is missing immediately after the compressor contactor is energized, a singlephasing condition exists.
The maximum response time shall be 1.2 seconds from the time of contactor energization.
Alarm condition: If any phase voltage < 84% of max of 3 input voltages for a period of 1 second.
Trip time: 5 minutes with automatic reset.
Lockout condition: Appears after the 10 consecutive trip alarms. Manual reset (using reset button below
the module or using remote reset by pack controller).
In the case of a part winding motor this feature is detectable for primary winding only. Missing phase, voltage
imbalance and low voltage are not detectable for the secondary winding. A missing phase can be detected during
start-up, but not while the motor is running.
3.8 Low voltage protection
Appears when there is a low supply voltage.
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Alarm condition: Motor compressor voltage < low voltage setting at compressor running state. The default low
voltage setting is 75% of the nominal line voltage stored in the module for 2 sec.
Trip Time: 5 minutes.
The module determines the operating frequency of the compressor. The compressor low voltage setting shall be
lowered by the same percentage as the operating frequency if less than the nominal frequency. For example if a
60 Hz nominal frequency compressor is running at 57 Hz (5% less), then the low voltage setting shall be reduced
by 5%.
3.9 Voltage imbalance protection
The purpose of this protection feature is to protect the compressor against a voltage imbalance condition that leads
to motor overheating.
A configurable setting (default = 5%) for voltage imbalance is used to determine the operating limit of the
compressor.
Alarm condition:
Trip: When the voltage imbalance > 5% (configurable).
Reset: Automatic reset after 5 min; voltage imbalance < 5%.
3.10 Flash memory information
Emerson Climate Technologies can provide a software to access EEPROM information.
3.10.1 The following asset information will be saved in the flash memory (EEPROM);
Compressor model number
Compressor serial number
Compressor model number modified
Compressor serial number modified
Sensor module firmware revision
3.10.2 Compressor running status information will be saved in the flash memory (EEPROM):
Number of compressor running hours
Number of compressor starts
Number of resets and type of reset
Accumulated runtime without good oil pressure
Number of relay cycles
3.10.3 Compressor Operating Parameters
Current
Voltage
Power factor
Power consumption
Discharge temperature values
3.11 Modbus® communication
CoreSense™ Diagnostics has communication capability via a Modbus® network connection. With communication
enabled, CoreSense™ warnings, trips and lockouts can be displayed and recorded in a pack controller such as the
iPro Rack Controller from Dixell.
The CoreSense™ Diagnostics module is compatible with any other pack controller that has Modbus® protocol.
3.12 Local and remote reset
The CoreSense™ Diagnostics module is equipped with a reset button placed below the control module. The reset
button may be pushed as necessary to stop the compressor.
The CoreSense™ Diagnostics module is equipped with a remote reset capability, such that if a compressor is off in
a lockout condition, the user can remotely restart the compressor through their rack controller or compatible remote
access software.
NOTE: Service contractor and end user policies need to be considered when deciding whether or not to
use the remote reset feature in the pack controller.
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