CoreSense™

Technology For Sustainable Refrigeration Systems

CoreSenseCoreSense™™

Technology Technology For Sustainable Refrigeration SystemsFor Sustainable Refrigeration Systems

Sustainable Design Of Refrigeration SystemsSustainable Design Of Refrigeration SystemsSustainable Design Of Refrigeration SystemsReducing operational costs (energy andmaintenance costs) and food losses is inthe key interests of the users

Sustainable performance of refrigeration systems is very important for reducing the food losses and the operational costs

Compressor is the key component in the refrigeration system considering the investment and energy costs

CoreSense™ takes the compressor technology to the next development stage

Supermarket

Refrigeration

System

Only Durable System Optimization brings Sustainable Savings

Only Durable System Optimization Only Durable System Optimization brings Sustainable Savingsbrings Sustainable Savings

•

5-10 yrs in operation•

Refrigeration Pack•

Reactive Maintenance

•

10+ yrs in operation•

Refrigeration Pack•

Limited Maintenance2

5-15% increase in Energy Consumption

15-20% increase in

Energy Consumption

Store 1

Store 2

Equ

ipm

ent -

Ene

rgy

Con

sum

ptio

n

Time

System Optimization w/o

Monitoring

System Optimization

with

Monitoring

Source: Emerson Retail Solutions

Active Monitoring and Diagnosis For The Sustainable Performance

Active Monitoring and Diagnosis For Active Monitoring and Diagnosis For The Sustainable PerformanceThe Sustainable Performance

• Active monitoring for the performance evaluation of the compressor

• Diagnosis and communication for a quicker troubleshooting and preventive maintenance

CoreSense™

- ‘Compressor As A Sensor’

Technology

CoreSenseCoreSense™™

-- ‘‘Compressor As A SensorCompressor As A Sensor’’

TechnologyTechnology

CoreSense™

Diagnostics Monitoring Module

Sensor Module & Current Sensor in E-Box

Wiring HarnessOil Pressure Sensor

Discharge Temp Sensor

• Compressor is an active component in the refrigeration system

• Operating and electrical information at the compressor to provide an added value

CoreSense™

Main FunctionsCoreSenseCoreSense™™

Main FunctionsMain Functions- CoreSense protects, diagnoses and communicates the compressor status

- CoreSense monitors power consumption to allow the analysis of the

performance and energy costs

Mechanical Failures-

Motor Overheat

-

Insufficient Oil

-

High Discharge Temp

-

Locked Rotor

Electrical Failures

-

Missing Phase

-

Low Voltage

-

Voltage Imbalance

Bus Communication Failure

-

Monitoring CoreSense and System Controller Communication

Advanced Protection – Ensures Longer Compressor Life Time

Advanced Protection Advanced Protection –– Ensures Longer Compressor Life TimeEnsures Longer Compressor Life Time

CoreSense guarantees extended compressor life and sustainable system

Advanced Protection - Robust Hardware and Proprietary Algorithms

Advanced Protection Advanced Protection -- Robust Hardware and Proprietary AlgorithmsRobust Hardware and Proprietary Algorithms

Sensor Module inside T‐Box

‐

Reads and processes phase voltages, current values   

by using voltage sensing leads and current sensor 

module

‐ Supplies information to CoreSense Control Module

‐ Sensor Module provides following features 

‐

Locked Rotor Protection

‐

Low Voltage Protection

‐

Missing Phase Protection

‐

Voltage Imbalance Protection

‐

Crankcase Heater Control

‐

Power Consumption Monitoring

‐

Power FactorCoreSense Control Module

‐ Motor Overheat  Protection

‐ Oil Pressure Protection

‐ Discharge Temperature Protection

‐ Communication to Pack Controller via Modbus

‐ Sensor Module Communication

‐ Compressor Run Status (Proofing)

‐ EEPROM Memory

‐ Alarm History, Compressor Operating History 

‐ Local and Remote Reset capability

‐

Multi‐color LEDs to display alarms

Current Sensor in T‐Box‐

Reads current values and sends an input for the 

Sensor Module values as an input for Sensor

1

3

2

1

2

3

Diagnostics – Service Tool For A Quicker Troubleshooting

Diagnostics Diagnostics –– Service Tool For A Quicker TroubleshootingService Tool For A Quicker Troubleshooting

• CoreSense™

guides the service technician for a quicker service

• Guides service personnel for the step by step troubleshooting

Diagnostic Information Details

Alarm History

•Most recent 10 alarm events

•Previous 8 days alarm history

•Alarms count since compressor first

operation

Compressor Running Status Information

•Number of hours w/o good oil pressure

•Number of short cycles

•Compressor Starts

Asset Information•Compressor Model and Serial Number

•Customer Name and Location

Diagnostics – Service Tool For Preventive Maintenance

Diagnostics Diagnostics –– Service Tool For Preventive MaintenanceService Tool For Preventive Maintenance

CoreSense facilitates preventive maintenance–

Provides detailed present and past status of the system

–

Ex: Number of hours of compressor running w/o good oil pressure

Alarm history – an example of previous 8 days alarms

Diagnostics- Troubleshooting Information

DiagnosticsDiagnostics-- Troubleshooting InformationTroubleshooting Information

• Troubleshooting instructions both electronically (QR Code -

Smartphone)

and in the guidelines facilitate a quicker troubleshooting

Communication – Local and Remote Access

Communication Communication –– Local and Remote AccessLocal and Remote Access

1) Status LED On CoreSense

1.

Multi-color Status LEDs

2.

Indicate Nature Of Failure

3.

Enables Quick Troubleshooting

Local Troubleshooting

2) Connect To Computer

1.

Modify User Adjustable Features

2.

Download Compressor Fault History

3.

Use As Data Logger

Service Engineer On Site

3) Connect to Pack Controller

1.

Modify Adjustable Features

2.

Download Fault History

3.

Use As Data Logger

Modbus Protocol

Modbus Communication –

Allows 24x7 Monitoring Remotely

Modbus Communication Modbus Communication ––

Allows 24x7 Allows 24x7 Monitoring RemotelyMonitoring Remotely

Individual monitoring of every compressor w/ Modbus communication possible

Quick access to compressor operating status and alarm information avoids costly site visits

Provides open Modbus® protocol –allows communication with different system controllers

Power Monitoring –

Facilitates Energy Costs Management

Power Monitoring Power Monitoring ––

Facilitates Energy Facilitates Energy Costs ManagementCosts Management

Current, voltage and power monitoring of individual compressor in the refrigeration system

Local and remote Access to the information through PC interface or system controller via Modbus

Allows energy costs monitoring and detect abnormal system behavior

CoreSense™

Diagnostics - Main Benefits

CoreSenseCoreSense™™

Diagnostics Diagnostics -- Main BenefitsMain Benefits

Reference Field Site - ICA KVANTUM Supermarket in Sweden

Reference Field Site Reference Field Site -- ICA KVANTUM Supermarket in SwedenICA KVANTUM Supermarket in Sweden

ICA Kvantum Supermarket in Varberg,

Sweden

In Sweden 1350 ICA Kvantum retail stores

First CO2 installation in Sweden and in

Europe

Stream CO2 w/ CoreSense Diagnostics

installed on 21st Jun 2012

CO2 Refrigeration Pack for LT and MT ApplicationCO2 Refrigeration Pack for LT and MT ApplicationCO2 Refrigeration Pack for LT and MT ApplicationRefrigeration pack for Low and Medium

Temp with CO2 refrigerant

Medium Temp:

–

5 compressors

–

Model Type: 4MTL-30X

–

one compressor is inverter driven

Low Temp:

–

2 compressors

–

Model Type: 4MSL-30X; 4MSL-25X

–

one compressor is inverter driven

Refrigeration Pack w/ Stream CO2 Compressors Refrigeration Pack w/ Stream CO2 Compressors Refrigeration Pack w/ Stream CO2 Compressors

Stream CO2 Compressor Stream CO2 Compressor with CoreSensewith CoreSense™™

DiagnosticsDiagnostics

Technical Details:–

Design Pressures: 135 Bar (High), 90 Bar (Low)–

Burst Pressures In Excess Of Safety Factor 3–

Oil Splasher -

Lubrication At Constant & Variable Speed

–

Large Discharge Chamber To Reduce Pulsations–

Availability Of 3 Sight Glasses–

1 Oil Port For Oil Equalization In Parallel System–

Low Sound Level, Vibration & Pulsation–

Inverter : 30 To 70 Hz –

Cylinder Head & Discharge Plenum Design Minimizing Heat Transfer To Suction

Protection & Reliability–

Copeland®

CoreSense™

Diagnostics–

Discharge Temperature Protection–

Individual Compressor Power Consumption Monitoring–

Integrated High And Low Pressure Relief Valve

Access to Present and Past Status of the Compressor

Access to Present and Past Status of the Access to Present and Past Status of the CompressorCompressor

Compressor Status

• Actual Alarm Status

• Power Consumption

• Current, Voltage, Power Factor

• Discharge Temp Value

Compressor Configuration

• Asset Information

• Adjusting Threshold Values

• Firmware release version

Alarm History

• Most

recent

10

Alarms

• Last 8 days alarm history

• Number of starts/short cycles

• Cumulative total of alarms

• Number of hours w/o good oil pressure

Access to Present and Past Status of the Compressor –

Operating Information

Access to Present and Past Status of the Access to Present and Past Status of the Compressor Compressor ––

Operating InformationOperating Information

Discharge Line Temperature 94Phase 1 Compressor Voltage 398Phase 2 Compressor Voltage 396Phase 3 Compressor Voltage 400Compressor Current 27Start Current 190Pow er Factor 0.82Pow er Consumption 15.261

Analog Data

Compressor Run Status ONCompressor Alert Status NoneOil Pressure NormalMotor Protector NormalCrankcase heater OFF

Status

Access to Present and Past Status of the Compressor –

Alarm Information

Access to Present and Past Status of the Access to Present and Past Status of the Compressor Compressor ––

Alarm InformationAlarm Information

Parameters Today Today - 1 Today - 2 Today - 3 Today - 4 Today - 5 Today - 6 Today - 7 Cumulative TotalOpen Head Temp probe Alert 0Low Oil Pressure Alert 0No Communication to Sensor Module Alert 0No Communication to Rack Controller Alert X 2Discharge Temperature Trip 0Compressor Low Voltage Trip 0Motor Temp Trip Control Module 0Low Oil Pressure Lockout 0Discharge Temperature Lockout 0Control Module Failure Lockout 0Connection Lost Transducer to Sensor Alert 0Voltage Imbalance Trip 0Phase Loss Trip 0Locked Rotor Trip 0Protector Trip 0Locked Rotor Lockout 0Phase Loss Lockout 0Compressor Low Voltage Lockout 0

Alarm Hisory

CoreSense™

Modbus Communication – Allows integration into System Controller

CoreSenseCoreSense™™

Modbus Communication Modbus Communication –– Allows integration into System ControllerAllows integration into System Controller

Remote Monitoring and Easy Integration of CoreSense into System Architecture

Remote Monitoring and Easy Integration of Remote Monitoring and Easy Integration of CoreSense into System ArchitectureCoreSense into System Architecture

CoreSense™

Technology – What it means to the customer?

CoreSenseCoreSense™™

Technology Technology –– What it means to the customer?What it means to the customer?

“We (Green & Cool) as aggregates builders welcomes an expanded "intelligence" of the components we install in our units, CoreSense is a distinctive example of development that will bring user friendliness and reliability.

With our easy to use control system and new features, including calculation of cooling capacity produced, plant owners have the opportunity to follow their energy consumption and available cooling power, fully in line with the demands that

will be made in the future.”

Micael Antonsson, Technical Director

“We (Green & Cool) as aggregates builders welcomes an expanded "intelligence" of the components we install in our units, CoreSense is a distinctive example of development that will bring user friendliness and reliability.

With our easy to use control system and new features, including calculation of cooling capacity produced, plant owners have the opportunity to follow their energy consumption and available cooling power, fully in line with the demands that

will be made in the future.”

Micael Antonsson, Technical Director

Using ‘Compressor as a Sensor’ technology in compressors reaches the next development phase

–

Extended compressor life–

Predicts the problems even before they occur

–

Quick troubleshooting and preventive maintenance–

Remote monitoring through Modbus®

protocol

–

Power consumption monitoring for energy costs optimizationCoreSense™ guarantees reliable and sustainable performance

SummarySummarySummary

Stream HFC

with CoreSense

Digital Stream with CoreSense

Stream CO2

with CoreSenseCopeland Scroll®

with CoreSense

(Option –

in Planning)CoreSense™

Diagnostics –

Standard Scope of Delivery

Thank you for your attentionThank you for your attentionThank you for your attention