Making Sense Webinars Emerson and Our Partners Giving Insight on the Three Most Important Issues in Refrigeration Agenda Basics of Compressor Electronics – Definition of CoreSense™ Technology What Type of Data Is Available? What Are the Benefits? Applications/Real World Examples How Can Monitoring Data Across the Enterprise Help? DISCLAIMER Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures are indicated herein or that other measures may not be required. Emerging Trends Create Need for CoreSense Technology Emerging Trends: • Connectivity • Aging Contractor Workforce • System Complexity • Increasing Warranty Costs What Is CoreSense Technology: • Compressor as a Sensor • To Monitor and Interpret Compressor and System Information • Delivers Advanced Protection, Diagnostics and Communications • Enhances Performance and Reliability How Does CoreSense Technology Work? The Basics of Compressor as a Sensor Most Failures Have Early Indicators – Motor Temp and/or Motor Current and/or Disch. Temp – Historically Manifests as a Cycle of Motor Protector Trips and Resets – Usually No One Knows or Comes Until a Failure Occurs CoreSense Gathers Operating Information – Analyzes Current Signature of the Compressor – Characterizes Compressor Protector Behavior – Combines This Information to Indicate Operating Condition (Ambient, Temps, Demand, etc.) CoreSense Algorithms Use This Information to Identify: – Electrical Issues and System Faults – Escalating Patterns Leading to Catastrophic Faults Gives Facilities Managers/Contractors a Chance to Respond – Can Stop Machine in Extreme Cases (Reset) – Enables Proactive Maintenance, Service and Solutions Compressor Failure X Alert 2nd 1st Alert Alert Lock-Out Repair TIME Algorithms Built From Decades of Copeland Testing, Teardown and Operating Experience – Over 1M Units in the Field in Refrigeration, Residential, Commercial Air Conditioning, Heating, Geothermal Systems CoreSense Technology Capabilities Evolve Over Time Tcond Current & Voltage Current On & Off 2005 2010 • • • • Charge Verification Performance Monitor Liquid Floodback And Others • • • • Energy Meter Power Factor Power Quality Bearing Health • • • • • • • Locked Rotor Reverse Rotation Single-Phase Fault Compressor Overload Compressor Overheat Gross Charge Fault Internal Leaks • • • • Compressor Tripped High/Low Side Fault Motor Failure Contactor Fault current Current & Temp vs. Time (di/dt) 2000 Technology/Capability Future Algorithms Sophistication Level Compressor Signature (eMaps ) Future Progression Over Time Creates Value for OEM, Contractor and End User CoreSense Technology Is Being Rolled Out Across All of Our Major Product Platforms Discus w/CoreSense Diagnostics Scroll w/CoreSense Diagnostics Outdoor Condensing Unit CoreSense Diagnostics Module Comfort Alert and PerformanceAlert Discus w/CoreSense Protection Scroll w/CoreSense Communication Indoor Condensing Unit CoreSense Protection SecureStart™ What Type of Data Is Available? Insights Sensor Data •Comp Status On/Off •Oil Pressure •Discharge Temp. •Motor Temp. •Ambient Temp. •Comp. Current •Comp. Power Voltage •Control Circuit Voltage •Demand Signal •Contactor Status •Unloader Status •Digital Modulation Status •Low/High Pressure Cut-Out •Asset Information •Compressor Proofing •Power Consumption •Run and Fault History •Remote Diagnostics •System Operation Customer Value •Applied Cost Savings •Maintenance Savings •Energy Efficiency Multiple Ways to Access Information A) Locally at Compressor: B) Locally Thru Computer C) Locally and Remotely Thru EMS • LCD Interface • LED Indicator Lights 1. 2. 3. Modify User Adjustable Features Review/Download Compressor History Use as Data Logger 1. Modify User Adjustable Features 2. Communicate Data and Alerts to System Controller 3. Review Compressor History 4. Use as Data Logger CoreSense PC Software Provides Access to Data and Fault History • Network Configuration • Connect to Multiple Devices at Once • Module Status • Input: Motor and Scroll Sensor, Line and Control Voltage • Output: Contactor, Compressor, Trip, Lockout • Data: Scroll Temp (˚F), Control Voltage (V) • Device History • Compressor Starts and Run Time • Alarm History and10 Most Recent • Device Info • Model Number • Serial Number • Firmware Version * Note: Real-time Data Logging Also Available CoreSense Provides Information Remotely That Was Not Available Before Discharge Temperature Asset Data Compressor Current and Power Consumption CoreSense Provides Alarm History Compressor Electronics Create Value Throughout System Lifecycle $5,000 End User Prevent Equipment Failure $4,000 – $5,000 $4,500 OEM Service $4,000 End User Savings $3,500 $3,000 $2,500 $2,000 $1,500 $1,000 Maintenance Savings $1,000 – $3,500 Applied Cost and Installation Savings $400 – $2,000 Service End User $500 $0 1 2 3 4 5 6 Years 7 8 9 10 11 Applied Cost Savings Opportunities Because of Compressor Electronics Consolidation of Components Utilization of Communication Between Compressors and System Controllers: + Demand Cooling Temp. Control Sentronic Oil Monitor + + High-Pressure Protection + Motor Protection Control of Compressor, Unloader, Digital, Liquid Injection Alarm Feedback Low-Pressure Protection Eliminates up to Four Input/Output Control Points + Control and Input Points Up to $420 Applied Cost Savings per Compressor Consolidation of Components and Utilization of Communications Significantly Reduces Wiring 40% Reduction in Compressor Wiring Simplifying System Manufacturing and Installation What Impact Can CoreSense Have on Maintenance Activity and Costs? Maintenance Impact on Financials – Maintenance Typically Accounts for ~3% of Operating Expenses at ~$100–250k/store – Effectively Every $1 Spent = ~$50 in Lost Sales Potential Impact: – A 2% Reduction in Maintenance = 1.3% Increase in Profits – For a 1,000-Store Chain = $4M Increase Profits Maintenance and Troubleshooting Examples 1. High-Case Alarm 2. High Cycle Rates Failing Contactor 3. Low-Pressure Cut-Out Failure 4. Frozen Defrost Timer Providing Contractors Tools That Improve Troubleshooting Accuracy 92% 80% 60% 40% 20% 17% 100% 63% With CoreSense™ 100% Without 300 250 200 150 100 50 0 First-Time Accuracy Diagnosing a Problem With CoreSense™ Contractors (1000s) Number of Qualified Technicians 0% 2010 2015 Entry Level Experienced “My main concern is getting the equipment repaired the first time on the first visit…” Real-World Example: High-Case Temperature Alarm and Troubleshooting • First Indications: Alarm Generated for High-Case Temperature • Alarm Associated With Low Temperature Suction Group on Rack #2 Real-World Example: High-Case Temperature Alarm and Troubleshooting • Suction Group Operating Significantly Higher Than Set Point • Control Calling for 100% Capacity With All Three Stages Being “On” Real-World Example: High-Case Temperature Alarm and Troubleshooting • Three Stages in Suction Group Consist of: 1. 9 HP Comp 2. 10 HP Comp 3. 22 HP Digital Comp Real-World Example: High-Case Temperature Alarm and Troubleshooting • Summary of CoreSense Data on Compressors Reveals Discharge Line Temperature of Compressor #3 Suspiciously Low Real-World Example: High-Case Temperature Alarm and Troubleshooting Compressor #3 CoreSense Details: • Controller Calling for Compressor • Actual Compressor in “Normal Off” State • Compressor Asset Information: o M/N: 4DJXF76ME-TSK o S/N: 11J01084R Results Found Was a Bad Contactor That Could Have Resulted in Product Loss if Not Found and Replaced Real-World Example: Supermarket — Stone Mountain, GA Discus With CoreSense Diagnostics Without CoreSense Technology High Cycle Rates Result in Contactor Failures, Which Lead to Single-Phase Motor Burns, Destroying Compressors With CoreSense Technology Timeline 12/17: Contactor Making Bad Contacts 1/2: Compressor Reset => 1 Contactor Leg Failed “Single Phase” 1/2: Compressor Reset => Contactor Failed 1/2: Replace Contactor CoreSense Technology Detected Action Voltage Imbalance Shut Off Compressor Missing Phase Shut Off Compressor No 3-Phase Shut Off Compressor Supermarket End User Avoided Compressor Failure and Saved Approximately $6,000 Real-World Example: Walk-In Cooler at Convenience Store Discus With CoreSense Protection Without CoreSense Technology LPCO Failed Compressor to Run Continuously, Pulling Itself Into a Vacuum, Overheating Compressor and Causing Repeated Protector Trips With CoreSense Technology Timeline CoreSense Technology Detected Action 3/3: LPCO Fails, Resulting to Call for Cooling All the Time Normal Demand --- 3/3: Suction Pressure Drops Below Setpoint, System Continues to Run and Pulls Into Vacuum Compressor Overheats and Protector Trips Protector Trip Sends Alarm Compressor Cools and Protector Resets Compressor Runs and Provides Cooling, So No Temperature Rise in Walk-In Process Repeats Return to Normal and Protector Trip Sends Alarm 3/3 3/3: Because of Notification, Contractor Arrives on Site Because of CoreSense Notification CoreSense Utilized to Complete Troubleshooting Convenience Store Avoided Compressor Failure, Saving Over $6,000 Real-World Example: Walk-In Cooler at Butcher Scroll K5 With CoreSense Diagnostics Without CoreSense Technology Defrost Timer Froze Over Would Not Allow Compressor to Run With CoreSense Technology Timeline 6/5: Thermostat Calling for Cooling but Defrost Timer Stuck, Opening Control Circuit and Compressor Won’t Run 6/5: After Four Hours, Control Circuit Does Not Reset 6/5: Because of Notification, Contractor Arrives on Site Because of CoreSense Notification CoreSense Technology Detected Action System Trip Sends Warning Open Circuit (No Power at Compressor) Sends Alarm CoreSense Utilized to Complete Troubleshooting Butcher Avoided Losing Meat in Walk-In Freezer, Saving Over $10,000 CoreSense Significantly Reduces Compressor Failure Rates Compressor Year over Year Failure Rates 0.90% 0.80% Legacy Equipment Annual Failures Rates 0.70% 0.60% 42% Reduction 0.50% 0.40% Equipment w/ CoreSense 0.30% 0.20% 0.10% 0.00% 1 2 3 Years 4 Maintenance Savings of ~$350K per Year 5 Stakeholders Throughout Channel Benefit From Utilizing CoreSense End User Traditional Easier Field Installations Improved System Start-Up Lower Maintenance Cost Greater Refrigeration Uptime Reduced Spoilage Reduced Refrigerant Leaks OEM Integrated Electronics Applied Cost Savings Less Parts to Design and Inventory Simplified Rack Wiring Better Quality – “Wiring Is #1 Quality Problem With Racks” Differentiated Product Increased Throughput Contractor Simpler System Start-Up Reliability Serviceability Additional Comp Info Faster Diagnosis Emerson Climate Technologies Better Compressor Protection Fault History How Have Other Industries Used This Type of Technology? Source: OnStar System Dashboard Providing Insight to Each Component and System Operation Our Digital Platform Now Watches Over 2M Fixtures and Processes 50M+ Alarms Cumulative Savings of Over $100M Delivered to Customers Through Remote Services Over the Last 10 Years Using Data Across Enterprise to Identify Opportunities and Improve Performance Enterprise-Level Monitoring Using Store-Level Data Across Enterprise to Improve Total Cost of Ownership Critical Rack Alarms Maintenance and Energy Perspective: • Identify Top Issues by Occurrence and by Site Location • Establish “Best of Class” Benchmark and Identify Worst-Performing Stores • Focus Improvement by Prioritizing Equipment Replacements and Maintenance Efforts Systems Will Continue to Get Smarter and Have Greater Connectivity… Today’s Supermarket Rack Controller Remote Monitoring Smart Racks Store Controller EXV Smart Compressors Smart Case Smart Condensing Units Case Controls … Allowing Customers to Improve Refrigeration System Total Cost of Ownership (Applied Costs/Operating Costs/Maintenance Costs) Thank You! Questions and Answers DISCLAIMER Although all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures are indicated herein or that other measures may not be required.
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