Emerson NEXT GENERATION CORESENSE User Manual

Date of last update: Jun-20

Ref: TI_Stream_NGCS_01_E_Rev02

Application Engineering Europe

NEXT GENERATION CORESENSE™

FOR COPELAND STREAM™ COMPRESSORS

1	Introduction ............................................................................................................................................................		3
2	Specifications ........................................................................................................................................................		3
3	Next Generation CoreSense features ...................................................................................................................		4
4	Warnings, trips and lockouts .................................................................................................................................		4
5	Protection features ................................................................................................................................................		5
5.1		Oil protection.................................................................................................................................................	5
	5.1.1 Insufficient oil pressure protection ............................................................................................................		5
	5.1.2 Oil level protection (optional) ....................................................................................................................		5
5.2		Motor overheat protection .............................................................................................................................	6
	5.2.1	Static overheat protection .........................................................................................................................	6
	5.2.2	Dynamic overheat protection ....................................................................................................................	6
5.3		High discharge temperature protection.........................................................................................................	6
5.4		Current protection .........................................................................................................................................	7
	5.4.1	Locked rotor protection .............................................................................................................................	7
	5.4.2	MOC protection.........................................................................................................................................	7
	5.4.3	Switching frequency overstepping protection ...........................................................................................	7
	5.4.4 MOC detection at first start .......................................................................................................................		7
5.5		Phase / voltage monitoring ...........................................................................................................................	8
	5.5.1 Missing phase protection / Phase failure protection .................................................................................		8
	5.5.2	Undervoltage protection............................................................................................................................	8
	5.5.3	Overvoltage protection..............................................................................................................................	8
	5.5.4	Voltage imbalance protection ...................................................................................................................	8
	5.5.5	Welded contactor protection .....................................................................................................................	8
	5.5.6	Part-winding protection .............................................................................................................................	9
6	Variable frequency drive mode..............................................................................................................................		9
7	Emergency mode ..................................................................................................................................................		9
8	LEDs on the terminal box cover ..........................................................................................................................		10
8.1		Compressor status codes ...........................................................................................................................	10
8.2		Failure alarms displayed by LEDs ..............................................................................................................	11
9	Alarm history........................................................................................................................................................		11
10	Reset button ........................................................................................................................................................		12
11	Crankcase heater control ....................................................................................................................................		12
12	Power consumption measurement......................................................................................................................		12
13	Data port for communication with Next Gen CoreSense module app ................................................................		12
TI_Stream_NGCS_01_E_Rev02			1/18

13.1		Connectivity ................................................................................................................................................	13
14	Modbus module (optional) ...................................................................................................................................		13
15	Next Gen CoreSense module app ......................................................................................................................		13
16	Electrical connections..........................................................................................................................................		14
16.1		Basic connections .......................................................................................................................................	14
16.2		Wiring diagrams ..........................................................................................................................................	14
17	List of tables and figures......................................................................................................................................		18

TI_Stream_NGCS_01_E_Rev02

2/18

1 Introduction

CoreSense™ is an ingredient brand name for compressor electronics associated with Copeland™ branded compressors. The CoreSense technology uses the compressor as a sensor to unlock information from within the compressor, providing value-added features such as advanced motor protection, diagnostics, power consumption measurement and communication.

With active protection, advanced algorithms, and features like fault history and LED indicators, the Next Generation CoreSense (or Next Gen CoreSense) for Copeland brand compressors enables technicians to diagnose the past and recent state of the system, allowing for quicker, more accurate diagnostics and less downtime. Next Gen CoreSense is available as standard with the 4- and 6-cylinder Stream compressors.

The advantages of the Next Gen CoreSense module versus other protection modules are the response speed and the overall protection scheme. All protection features are functional right after compressor start and the module will stop the compressor in less than a second if a harming situation is detected.

Figure 1: Next Generation CoreSense module

2 Specifications

The Next Gen CoreSense module is located and prewired in the terminal box. All required parameters are flashed during the production of the compressor.

The power supply for the control module can be 115V AC or 230V AC.

Operating ambient temperature	-30 °C to 70 °C
Storage temperature	-30 °C to 80 °C
Voltage requirements	115-230 VAC - 50/60Hz
Protection class	IP00

Table 1: Next Gen CoreSense specifications

Figure 2: Next Gen CoreSense inside the terminal box

TI_Stream_NGCS_01_E_Rev02

3/18

3 Next Generation CoreSense features

Next Gen CoreSense is a modular system. This modular design gives the customers the flexibility to choose individual protection and/or control levels. It is possible to extend the compressor protection from just basic functions to a high tier protection to enlarge the lifetime of the compressor.

Figure 3: Inside view of the Next Gen CoreSense module, with the modular boards

Basic features

Motor overheat protection	High discharge temperature protection
Insufficient oil pressure protection	Oil level protection (in combination with Emerson TraxOil)
Current protection	Phase failure protection
Voltage imbalance protection	Undervoltage and overvoltage protection
Power consumption measurement	Part-winding protection
Crankcase heater control	Welded contactor protection
Switching frequency overstepping protection	Connection with computer, Android or iOS device
LEDs on the terminal box cover	Reset button for manual reset

Table 2: List of basic features

4 Warnings, trips and lockouts

Next Gen CoreSense provides 3 different protection levels. Each of them has its own LED colour.

▪Warning alarms: Compressor will continue to run.

▪Trip alarms: Compressor turns off for defined time with automatic reset.

The compressor was stopped due to a fault condition. The compressor will restart when the fault condition is cleared and the defined off time has elapsed.

▪Lockout alarms: Compressor turns off, manual reset is necessary.

The compressor was stopped due to a fault condition. The compressor will restart when the fault condition is cleared and a manual reset using the reset button has been done. If a Modbus extension module is mounted, the reset can be done via Modbus.

TI_Stream_NGCS_01_E_Rev02

4/18

5 Protection features

5.1Oil protection

5.1.1Insufficient oil pressure protection

The Next Gen CoreSense module receives an input from the oil pressure differential sensor (OPS3) located in the oil pump.

The module replaces the mechanical oil pressure switch. Furthermore, it provides the added value of communication for insufficient oil pressure warning and lockout 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.

The module will issue a warning when the oil pressure differential falls below 0.95 bar for 4 seconds. Once the oil pressure differential falls below 0.95 bar for 2 minutes, the module will trip the compressor 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 manually activated.

NOTE: This feature is not applicable to Stream CO2 compressors that do not have an oil pump fitted and are "splash" lubricated.

OPS3 Oil Pressure Switch sensor technical data:

▪Permitted ambient temperature: -30 °C to 90 °C

▪Protection Class: IP45

Figure 4: OPS3 Oil Pressure Switch and electronic part (delivered connected)

5.1.2Oil level protection (optional)

The oil protection is achieved with an OW4/5 TraxOil watch device and OM3/4/5 TraxOil level monitoring device.

The TraxOil uses a hall sensor to measure the oil level. A magnetic float (unaffected by foaming oil) changes its position according to the oil level. The hall sensor converts the magnetic field changes into an equivalent signal, which is used by the integrated electronic controller to monitor and display the actual oil level with LEDs.

Figure 5: TraxOil OW5 Oil watch device

Figure 6: Sight glass level control zones

TI_Stream_NGCS_01_E_Rev02

5/18

	LEDs			Status			Function
	•		Oil level in green zone (60 – 40 %)				OK
	• •			Oil level in green zone (60 – 40 %)			OK
	•		Oil level in yellow zone (40 – 25 %)				OK
	•			Oil level in red zone (25 – 0 %)			Warning or
							trip

Table 3: LED code legend

The oil watch device is not part of the standard compressor delivery; it will have to be connected to the Next Gen CoreSense module via terminals 15 and 16.

Two connection possibilities can be chosen in the Next Gen CoreSense module app:

▪Closed when OK:

o Default setting after activation

o Connect Blue (BU) and Black (BK) wires

▪Open when OK:

o Connect Brown (BN) and Black (BK) wires

The user has the possibility to select between a warning or trip condition if the oil level is below 25 %.

5.2Motor overheat protection

By using Positive Temperature Coefficient (PTC) thermistors on 4M* and 6M* Stream compressor models, Next Gen CoreSense provides motor overheating protection.

Two chains of three thermistors each connected in series are embedded in the motor windings in such a manner that the temperature of the thermistors can follow with little inertia.

5.2.1Static overheat protection

The Next Gen CoreSense module will trip the compressor if the motor windings are getting too hot.

Standard condition:

▪ Total resistance of the thermistor chains @ 25 °C ≤ 1.8 kΩ

Alarm condition:

▪Trip condition: PTC resistance > 4.5 kΩ;

▪Reset condition: PTC resistance < 2.75 kΩ; 5 min time delay.

Trip due to sensor failure:

▪Short circuit: PTC resistance < 20 Ω;

▪Open circuit: PTC resistance > 20 kΩ.

5.2.2Dynamic overheat protection

If the motor winding temperature increases in a short period (>240ohm/400ms), the module will trip the compressor. The compressor will restart after 5 minutes.

5.3High discharge temperature protection

Discharge temperature protection is provided using a PT1000 sensor in the compressor cylinder head.

The sensor is pre-installed at the factory and connected to the Next Gen CoreSense module. The module will protect the compressor from high discharge temperature conditions. If the temperature sensor detects a discharge temperature higher than 154 °C, the module will shut off the compressor until the temperature cools down to an acceptable level (20 K below setpoint).

The configurable range of trip settings is 108 °C to 154 °C and the reset value is 83 °C to 134 °C.

▪Trip value ≥ 154 °C for 0.5 sec

▪Trip alarm: automatic reset after 2 minutes; discharge temp < 130 °C

TI_Stream_NGCS_01_E_Rev02

6/18