Using Compressor Electronics Data
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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