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COMPRESSOR ELECTRONICS Unlock advanced diagnostics, communication and protection for improved system performance and reliability.
Matthew Neidlinger Manager – Marketing & Planning, Compressor Electronics
Filename/Presenter-Topic: 2/18/2013 3 Emerson Confidential
CoreSenseTM Technology Addresses Industry Needs
What It Is: • Compressor as a sensor technology • To monitor and interpret compressor
and system information • Delivers advanced protection,
diagnostics and communications • Enhances performance and reliability
Emerging Trends: • Connectivity • System complexity • Increasing warranty costs • Aging contractor workforce • Improving quality reputation
Filename/Presenter-Topic: 2/18/2013 4 Emerson Confidential
CoreSense™ Technology Brings Value To Customers
Improve System Total Cost Of Ownership
o Early Detection Or Warning Can Prevent Compressor Failure
o Minimize Product Loss Or Damage By Preventing Equipment Damage
o Active Protection Drives A Reduction In Warranty Claim Costs
Reduce Maintenance Cost & Service Time
o Faster Diagnostics, Easier/More Accurate Troubleshooting
o Remote Troubleshooting
o Greater Uptime
Better Understanding Of Systems Operations
o Data Collection & Fault History
o Remote Asset Information
o Eliminate Future Pain Points And Nuisances
o Build Better Systems Moving Forward
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Filename/Presenter-Topic: 2/18/2013 5 Emerson Confidential
How Does CoreSense™ Technology Work? The Basics Of Compressor As A Sensor • CoreSense Gathers Operating Information
– Analyzes Current Signature Of The Scroll Compressor
– Characterizes Compressor Protector Behavior
– Combines This Information With Other Information To Indicate Operating Condition (Ambient, Temps, Demand, etc.)
• CoreSense Algorithms Use This Information To Identify
– Conditions Leading To Out Of Envelope Operation
– System Faults, Electrical Issues
– Escalating Patterns Leading To Catastrophic Faults
• Algorithms Are Built From Decades Of Copeland Scroll Compressor Testing, Teardown And Operating Experience
– Over 2M Units In The Field In Refrigeration, Residential, Commercial Air Conditioning, Heating, Geothermal Systems
TIME
Repair
Compressor Failure
Lock-Out
1st Alert
2nd Alert
X Alert
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-40 -20 0 20 40 60
Con
dens
ing
Tem
p
Evaporating Temp
CoreSense Provides Broad Protection Covering Adverse Conditions
HPCO Setting LP
CO
Set
ting
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-40 -20 0 20 40 60
Con
dens
ing
Tem
p
Evaporating Temp
CoreSense Provides Broad Protection Covering Adverse Conditions
HPCO Setting LP
CO
Set
ting
Sources: ● Coil Leaks ● Field Braze Joint Leaks ● Initial Undercharge Overheating Of Compressor Internals Endlife = OverloadMotor/Bearing Failure
Sources: ● Factory Overcharge ● Initial Installation ● Improper Maintenance Excessive Wear Of Compressor Internals Endlife = Motor/Bearing Failure
Sources: ● Inadequate Indoor Air Flow (IDFF) ● TXV Failure (Closed) ● Contactor Welded ● Defrost Board Failure Excessively High Compression Ratio Endlife = Motor/Bearing Failure
Hig
h D
isch
arge
Pre
s.
Sources: ● Condenser Fan Failure ● Dirty/Blocked Condenser Coil ● Clogged Filter Drier ● Reversing Valve Failure Excessively High Discharge Pressures Endlife = Motor/Overload Failure
Loss of LubricationSources: ● Oil Traps In Refrigerant Lines ● Accumulator Clogged ● Inadequate Long Line Installation ● OEM Run Test Compressor Runs With Few Symptoms Until Bearing Loads Exceed Oil Film Load Capabilities. Endlife = Catastrophic Bearing Failure
*.ppt 2/18/2013 12:25 PM 8
60
70
80
90
100
110
120
130
140
150
160
170
180
-40 -20 0 20 40 60
Con
dens
ing
Tem
p
Evaporating Temp
CoreSense Provides Broad Protection Covering Adverse Conditions
HPCO Setting LP
CO
Set
ting
Sources: ● Coil Leaks ● Field Braze Joint Leaks ● Initial Undercharge Overheating Of Compressor Internals Endlife = OverloadMotor/Bearing Failure
Sources: ● Factory Overcharge ● Initial Installation ● Improper Maintenance Excessive Wear Of Compressor Internals Endlife = Motor/Bearing Failure
Sources: ● Inadequate Indoor Air Flow (IDFF) ● TXV Failure (Closed) ● Contactor Welded ● Defrost Board Failure Excessively High Compression Ratio Endlife = Motor/Bearing Failure
Hig
h D
isch
arge
Pre
s.
Sources: ● Condenser Fan Failure ● Dirty/Blocked Condenser Coil ● Clogged Filter Drier ● Reversing Valve Failure Excessively High Discharge Pressures Endlife = Motor/Overload Failure
Loss of LubricationSources: ● Oil Traps In Refrigerant Lines ● Accumulator Clogged ● Inadequate Long Line Installation ● OEM Run Test Compressor Runs With Few Symptoms Until Bearing Loads Exceed Oil Film Load Capabilities. Endlife = Catastrophic Bearing Failure
CoreSense: Code 1 ALERT
Code 5 LOCKOUT
CoreSense: Code 3 LOCKOUT Code 5 LOCKOUT
CoreSense: Code 3 LOCKOUT Code 2 LOCKOUT
CoreSense Future
Innovation
CoreSense: Code 3 LOCKOUT Code 2 LOCKOUT
9 Emerson Confidential
Discus w/ CoreSense Protection
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
CoreSense Protection
Indoor Condensing Unit
Scroll w/ CoreSense Communication
Comfort Alert & PerformanceAlert
SecureStart™
10 Emerson Confidential
CoreSense™ Diagnostics For Single Phase Applications ● CoreSense™ Diagnostics Module For ZP*K5 And ZR*K5 Single-Phase, Copeland
Scroll® Fixed Capacity Compressors (1.5 – 5 HP)
● OEM’s Integrating New CoreSense™ Technology
● CoreSense™ Branding Replacing Comfort Alert
● AE Bulletin AE8-1379
● More information at: www.emersonclimate.com/coresense
Version OEM Part Number
Service Part Number
Two Wire AC 571-0066-00 971-0066-00 Three Wire HP 571-0067-00 971-0067-00
UltraTech 571-0072-00 971-0072-00
11 Emerson Confidential
CoreSense™ Communications For Three Phase Commercial Applications
●Compressor Models – ZP235KCE, ZP235KCE, ZP236KCE, ZP285KCE – ZP296KCE, ZP385KCE, ZP485KCE
●CoreSense™ Communications Module Part Numbers
●AE Bulletin AE8-1384 ●More information at:
www.emersonclimate.com/coresense
Voltage OEM Part Number
Service Part Number
24 571-0065-04 971-0065-04 120/240 571-0064-05 971-0064-05
Filename/Presenter-Topic: 2/18/2013 12 Emerson Confidential 12 Emerson Confidential
CoreSense Protection™ For Aftermarket & Retrofit Applications
Available Spring 2013
More information at: www.emersonclimate.com/coresense