coresense technology for sustainable refrigeration systems
TRANSCRIPT
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