Emerson NEXT GENERATION CORESENSE User Manual
TI_Stream_NGCS_01_E_Rev02 1/18
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
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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
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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
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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.
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5 Protection features
5.1 Oil protection
5.1.1 Insufficient 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)
5.1.2 Oil 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
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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 %.
5.2 Motor 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.
5.2.1 Static 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.
5.2.2 Dynamic 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.
5.3 High 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
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