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Emerson CORESENSE Technical Information

Diagnostics for stream refrigeration compressors
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Date of last update: Apr-15
C
S
™ D
ORE
ENSE
CoreSense™ Diagnostics for Stream Refrigeration Compressors................................................................................ 1
1
Introduction .......................................................................................................................................................... 2
2
Specifications ........................................................................................................................................................ 2
3
CoreSense Diagnostics features ........................................................................................................................... 2
3.1
Insufficient oil pressure protection .............................................................................................................. 3
3.2
Motor overheat protection .......................................................................................................................... 3
3.3
High discharge temperature protection ....................................................................................................... 3
3.4
Locked rotor protection ................................................................................................................................ 4
3.5
Missing phase protection ............................................................................................................................. 4
3.6
Low voltage protection ................................................................................................................................. 4
3.7
Voltage imbalance protection ...................................................................................................................... 4
3.8
"Jog" feature ................................................................................................................................................. 5
3.9
Crankcase heater (CCH) control .................................................................................................................... 5
3.10
Flash memory information ........................................................................................................................... 5
3.11
Modbus® communication ............................................................................................................................. 6
3.12
Reset ............................................................................................................................................................. 7
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
3.16
Oil functionality self-test option ................................................................................................................... 9
4
Electrical connections ........................................................................................................................................... 9
4.1
System wiring diagram ................................................................................................................................. 9
4.2
Terminal box and current sensing transformer connections ..................................................................... 11
4.2.1
Installation of current sensing module ............................................................................................... 11
4.2.2
CoreSense Diagnostics with Υ/Δ motors ............................................................................................ 11
4.2.3
CoreSense Diagnostics with part winding .......................................................................................... 12
5
CoreSense Diagnostics jumper settings .............................................................................................................. 13
6
CoreSense Diagnostics DIP-switch settings ........................................................................................................ 14
7
Troubleshooting .................................................................................................................................................. 15
D7.8.4/0112-0415/E
IAGNOSTICS FOR
S
R
TREAM
EFRIGERATION
Ref: D7.8.4/0112-0415/E
Application Engineering Europe
C
OMPRESSORS
1/17

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Summary of Contents for Emerson CORESENSE

  • Page 1: Table Of Contents

    ™ D ENSE IAGNOSTICS FOR TREAM EFRIGERATION OMPRESSORS CoreSense™ Diagnostics for Stream Refrigeration Compressors................1 Introduction ................................2 Specifications ................................ 2 CoreSense Diagnostics features ........................... 2 Insufficient oil pressure protection ......................3 Motor overheat protection .......................... 3 High discharge temperature protection ....................... 3 Locked rotor protection ..........................

  • Page 2: Introduction

    CoreSense™ is an ingredient brand name for compressor electronics associated with Emerson’s Copeland™ brand products. 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.

  • Page 3: Insufficient Oil Pressure Protection

    CoreSense is compatible with VFD applications by turning on the DIP-Switch 12 in the front module. The features available for VFD are limited: motor overheat protection, insufficient oil pressure protection and high discharge temperature protection. Other features are available in Control Techniques frequency inverters.

  • Page 4: Locked Rotor Protection

    Lockout alarm: manual reset is necessary. Locked rotor protection CoreSense detects the locked rotor condition of the compressor. It has trip and lockout alarms. Initial alarm will be “Trip” alarm with autoreset and 10 consecutive trip alarms will result in “Lockout” alarm which requires manual reset.

  • Page 5: Jog" Feature

    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. The control of a 480V crankcase heater is not supported by CoreSense Diagnostics. Crankcase heater Power supply Crankcase heater 115V or 230V 3.10 Flash memory information...

  • Page 6: Modbus® Communication

    3.11 Modbus® communication CoreSense Diagnostics has communication capability via a Modbus network connection. With communication enabled CoreSense warnings, trip and lockout alarms can be displayed and recorded in a pack controller with Modbus such as the iPro Rack Controller from Dixell.

  • Page 7: Reset

    Number of short cycles operation Current, voltage, power consumption measurement* *This data is not stored in CoreSense EEPROM memory. These values can be stored in a laptop using CoreSense PC Interface Software or Modbus communication. Table 3 3.14 Compressor status codes ...
  • Page 8 Auto Lockout flashes Status LED description reset Status LED troubleshooting information condition count time flashing green, compressor has been Without Insufficient oil Insufficient sufficient oil without sufficient oil pressure for 4 seconds. flashing red, compressor has been pressure oil pressure pressure for 2 minutes without sufficient oil pressure for 2 minutes.

  • Page 9: Oil Functionality Self-Test Option

    System wiring diagram Fuses and wire cable sizing must be done in accordance with all applicable electrical code standards. Figure 8 below shows the recommended basic system wiring for a compressor with CoreSense. terminal used for grounding Figure 8: Wiring diagram D7.8.4/0112-0415/E...
  • Page 10 220V or 110V Contactor DIP-switch Line Alarm Discharge temperature sensor Oil sensor Figure 9: CoreSense wiring terminals description Power supply crankcase heater Power supply control module 115V or 230V 24V AC Communication to CoreSense module 24V AC output To terminal...

  • Page 11: Terminal Box And Current Sensing Transformer Connections

    30V AC. Figure 11: Current sensing module and T-Box wiring 4.2.2 CoreSense Diagnostics with Υ/Δ motors The terminal box and the current sensing “toroid” connections are factory-installed. One of the motor power leads must be routed through the centre opening of the current sensing transformer (see Figures 12 &...

  • Page 12: Coresense Diagnostics With Part Winding

    4.2.3 CoreSense Diagnostics with part winding If using the CoreSense Diagnostics module with a part-winding start motor, one power lead of each of the windings should be passed through the current sensing transformer in the same direction (see Figures 14 & 15) to provide accurate compressor proofing.

  • Page 13: Coresense Diagnostics Jumper Settings

    JP4 factory setting is “1-2” (2 Stop Bits). Depending on the Modbus parameters, it can be switched to position “2-3” (1 Stop Bits). Do not remove JP1. This is reserved for future use. Figure 16: CoreSense circuit board D7.8.4/0112-0415/E 13/17...

  • Page 14: Coresense Diagnostics Dip-Switch Settings

    Off: Non VFD application Table 5: CoreSense Diagnostics DIP-switch setting If you use CoreSense communication, assign a unique node address to each CoreSense Diagnostics module using switches 1 through 6. a. Set the communications baud rate for the module using switch 7. “Off” = 19200 baud, “On” = 9600 baud.

  • Page 15: Troubleshooting

     The connector is not plugged of the probe is as specified vs its approximate ambient temperature. disconnected. into the CoreSense circuit Discharge temp  If the probe resistance is correct inspect the harness connector receptacle for Trip/Lockout:...
  • Page 16 Is there a communication network? If not, check that the communication Alert: Appears when there is no and pack controller has been harness is engaged at both the CoreSense module and the sensor module. communication between control lost.
  • Page 17 Flash Alarm conditions Possible failure reasons Troubleshooting measures code   Check voltage supply from the main buss. Supply voltage is not in the specified range.  Check voltage into and out of contactor. Repair or replace contactor if Trip: Appears when there is a low ...

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