Emerson VSG & VSSG Software Manual Download

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VSG & VSSG

Single Screw Compressor

Software Manual

Compact Logix PLC

Summary of Contents for VSG & VSSG

Page 1: ...1 VSG VSSG Single Screw Compressor Software Manual Compact Logix PLC ...

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Page 3: ...the panel See Wiring Instructions and Diagrams before proceeding NOTES Before start up you need to enter all system values and options see section on Setpoint Values Power circuits entry on left side of enclosure Instrument circuits entry on right side of enclosure Electrical installation shall be completed by a licensed electrician qualified in field wiring located in Class 1 Div 2 Hazardous Loca...

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Page 5: ...tion Procedure of Optical Actuators 51 Calibration Procedure of Optical Actuators 52 Calibration Procedure of Optical Actuators 53 Installation Instructions For Replacement Of Optical Actuator 54 Slide Valve Actuator Theory of Operation 55 Slide Valve Actuator Troubleshooting Guide 56 Slide Valve Actuator Troubleshooting Guide 57 Slide Valve Actuator Troubleshooting Guide 58 Command Shaft Rotation...

Page 6: ...instructions This warranty does not apply i to ordinary wear and tear damage caused by corrosion misuse overloading neglect improper use or operation including without limitation operation beyond rated capacity substitution of parts not approved by Seller accident or alteration as determined by Seller or ii if the product is operated on a gas with an H2S level above 100 PPM In addition Seller does...

Page 7: ...ter Diff Press Run Trip setpt Oil Separator Temp Safety Changeover Timer expires 5 min after start Is Oil Sep Temp Lo Oil Sep Run Reset setpt Run Run Filter Diff Press Failure Lo Run Oil Sep Temp Failure No Yes No Yes Yes No Yes Compressor Amperage Load Limiting High Disch Pressure Load Limit Is Motor Amps FLA ON Setpt Is Motor Amps Max OFF Setpt Normal Loading Unloading Capacity Decrease until Am...

Page 8: ...ress Alarm Setpt Lo Suction Press Alarm Is Cap Inc ON Timer Timed Out Is Cap Inc OFF Timer Timed Out Capacity Inc WAIT Capacity Dec Is Cap Dec ON Timer Timed Out Is Cap Dec OFF Timer Timed Out Reset Cap Dec Timers Yes Yes Yes No No No No Yes Yes Yes No Suction Pressure Safety No Is Suction Press Suct Press Trip Setpt Lo Suction Press Failure Yes Yes No No ...

Page 9: ... Speed Unit Start 30 sec delay Yes Yes Oil Cooler outlet temp set pt Oil Cooler outlet temp set pt No No Oil Temperature Control Valve Modulate valve Modulate valve Unit Start 30 sec delay Yes Yes Oil injection temp set pt Oil injection temp set pt No No PID Control PID Control ...

Page 10: ... Set Between 5 6 Hours Default Value 5 Hours H2 Timer Set Between 4 100 Hours Minimum and Default Value 4 Hours H2 must be equal to or greater than 4 x H1 Yes Yes No No Yes No Shutdown Due to Power Failure 1 min Delay Have There Been 3 Shutdowns of This Same Condition in H4 Hours Auto Restart if All Other Values Are In Range Lockout Requires Manual Restart Has It been H3 Hours Since Shutdown H3 Ti...

Page 11: ... Disch Press High Disch Press Unload OFF Setpt Is Capacity Min Run Cap OFF Setpt Is Suct Press Cap Inc ON Setpt Inc Cap Timer Disable Cap Inc Increase Cap Timer Is Suct Press Cap Dec ON Setpt No Yes No No Yes Yes Yes Yes No No Yes Yes Is Disch Press High Disch Press Unload ON Setpt Dec Cap Timer Yes No Capacity Control Using Suction Pressure Control Setpoints Dec Cap Timer No Change No Change ...

Page 12: ...Cap Inc ON Setpt No Yes Yes No Dec Cap Timer Inc Cap Timer Yes No change No Capacity Control Using Discharge Pressure Control Setpoints Are Motor Amps Motor Amps Load Limit ON Setpt Time Delay 10 sec Are Motor Amps Motor Amp Load Limit OFF Setpt Dec Cap Timer Yes Yes Disable Cap Inc No No Change No ...

Page 13: ...crease or Decrease the Compressor Capacity Slides to Match Setpoints Is Capslide 100 Increase or Decrease the Compressor Capacity Slides to Match Setpoints Increase or Decrease Motor Speed Rate Defined by VFD PID Parameters Is Control Press Setpoint Is Motor Speed Min No Yes No Yes No No Check Adjust Capacity Slide Check Adjust VFD Yes ...

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Page 15: ...s Hour meter Motor amperage Compressor operating conditions Main Screen This screen has been designed to give the operator an overall view of all operating parameters affect ing the compressor package This screen should alwaysbedisplayedwhenmaintenanceitemsand setpoint items are not being performed Status information such as Alarms and Trips are displayed on the screen ...

Page 16: ...nfiguredsuchthattheirpasswords may be changed To change a User s password touch the Password box or the abc button then enter the old password new password and confirm the new password ToLogOff TouchtheLogOffbutton Thiswillreturn to the DEFAULT low level user The DEFAULT user may navigate to most screens but cannot change settings Log On or Off Note An operator will be automatically logged off aft...

Page 17: ...ts Temperature units and Suction Discharge Pressure control configurations are list selectable To choose a configuration from a list 1 Touch the list 2 Touch the Up or Down Arrow to move the greencursor alongsideofthedesiredconfigura tion 3 Touch the Enter button This will highlight green the chosen configuration Set Up Screen Touch Here ...

Page 18: ...redvariableisused in making loading capacity control decisions The choice selected here determines which setpoints are made available for adjustment on the Compressor Control Setpoints screen Slide Non Movement Alarm enable and dis ablebuttonspermitselectingwhetheranalarm should be generated when failure of slides to move is detected Reset After Power Fail When Auto is selected the compressor will...

Page 19: ...alues 7 When finished touch the Close button to exit the Time Date Regional Settings screen 8 IMPORTANT Clear the log files of the PanelView after changing the PanelView Date and or time a Touch or scroll to the File Management field then touch the Enter Button b Touch or scroll to the Delete Files field then touch the Enter button c Touch or scroll to the Delete Log Files field then touch the Ent...

Page 20: ...Instructions on page 21 Menu Screen Touch Here Set To change a value the operator must first press the SET button and then the text field of the value they want to modify A number pad will pop up for ease in entry Help This screen will provide more information to the user about the operation of the microprocessor Event List provides a chronological event listing Chart Provides a line graph showing...

Page 21: ...21 Discharge Pressure Control There are three options for the Compressor Control Setpoints ...

Page 22: ...22 Suction Pressure Control ...

Page 23: ...23 Process Temperature Control ...

Page 24: ...arator temperature safety The compressor is prevented from starting or running if the oil in the separator is below the trip value After a time delay Oil Separator Temperature Safety Changeover this safety is deactivated and the Lo Oil Separator Run Tem perature is the active setpoint LowOilSeparatorRunTemperature Thisisthe running low oil separator temperature safety After a time delay Oil Separa...

Page 25: ...yfromthedesiredvolumeratio themo tor is pulsed once toward the desired volume If the volume slide is more than 7 away from the desired value the volume slide motor is continuouslyenergizeduntilthevalveiswithin 2 ofthedesiredvalue Iftheactualposition is within 2 of the desired value no adjust ment will be made Minimum Compressor Prelube Timer This is the length of time the oil pump will run after e...

Page 26: ...y is set Hot Starts Hr Counter This counter counts compressorstarts Aftereverystart aone hour timer is reset and starts timing If the timer times out the hot starts counter is reset When the counter reaches it s preset value it will not allow another compressor start until the one hour timer times out and resets the counter In other words the hot starts counter will be resetwhenthetimebetweencompr...

Page 27: ...l Oncethemethodischosen theappropriatesetpointsarethendisplayedontheCompressorControlSetpoints screen The compressor will decide when to increase or decrease capacity by comparing the controlled variable to the setpoints The maximum on time and minimum off time settings for slide actuator motors can be used to reduce hunting or improve response time The default settings of 3 and 20 seconds respect...

Page 28: ...ty Increase OFF setpoint is reached If closer system control is desired set the ON and OFF setpoints at the same values This will essentially eliminate any differential between the ON and OFF setpoints Discharge Pressure Capacity Decrease The capacity of the compressor will decrease when discharge pressure is at or below the ON setpoint and the decrease off timer has cycled Capacity will continue ...

Page 29: ...Suction Pressure Capacity Increase OFF setpoint is reached If closer system control is desired set the ON and OFF setpoints at the same values This will essentially eliminate any differential between the ON and OFF setpoints SuctionPressureCapacityDecrease Thecapacityofthecompressorwilldecreasewhensuctionpressure isatorbelowtheONsetpoint andthedecrease off timerhascycled Capacitywillcontinuetodecr...

Page 30: ... setpoint This will help stabilize the suction pressure allowing for the process temperature to be gradually pulled down The Suction Pres sureCapacityDecreaseONandOFFsetpointscanviewedoradjustedbytemporarilyselecting Processor Control Via Suction Pressure on the Setup screen Note Capacity Control for Refrigeration Only CapacityControl FOn Off ThecompressorwillautomaticallycycleONandOFFatthesetpoin...

Page 31: ...s active only if the Compressor Control Via Process Temperature option is selected on the Setup screen Capacity Control F Decrease The capacity of the compressor will decrease when process temperature is at or below the ON setpoint and the increase off timer has cycled Capacity will continue to decrease until the Capacity Control F Decrease OFF setpoint is reached If closer system control is desir...

Page 32: ...re This con trol limit determines when the oil separator heater is energized A decrease in oil separator temperature below the ONsetpoint energizes the oil separator heater On an increase in oil separator temperature above the OFF setpoint the oil heater is de energized High Discharge Pressure Unloading Setpoints Active in Suction Pressure or Process Tempera ture Capacity Control mode These setpoi...

Page 33: ...main there until the suction pressure reduces and the compressor cycles off on the Suction Pressure On Off control setpoint Volume Slide Adjustment Factor This value is normally zero 0 and will not require changing However if the system operating conditions show the volume ratio is not at the optimum value for the system this value can be adjusted upordowntopermitthemostefficientposition ing of th...

Page 34: ...mer Setpoints screen For the single screw compressor oil pressure is defined as manifold pressure minus suction pressure High Filter Differential Pressure Start This safetysetpointisactivewhenthecompressoris in the start cycle An alarm or trip will be active ifthefilterinletpressureexceedsthefilteroutlet pressure by the setpoint value HighFilterDifferentialPressureRun Thissafety setpoint is active...

Page 35: ...as Delay Auto 3 After the Delay Auto time expires the Output Mode will change to Auto Mode 4 In Auto Mode the VFD is enabled to increase and decrease speed to maintain the temperature set tings 5 Increase At High setting where an increase of speed is desired 6 Decrease At Low setting where a decrease of speed is desired 7 Initial Speed Desired forced speed to start the fan at as described above No...

Page 36: ...rget overshooting 10 Gain This value is factory set to 2 50 but may be set from 0 1 to 99 For VFDs Gain is a multiplica tion factor used in a calculation to determine an adjustment to the speed each set interval This interval is defined as the Increase Rate or Decrease Rate Factory settings for Increase Rate and De crease Rate are 2 to 5 seconds Manual Button Choosing Manual will do the following ...

Page 37: ...he Logon screen on the Logon button on the main menu and on the Setup screen Once a user with sufficient access is logged on force buttons appear To force an output on touch its button The Main Compressor Motor Starter button and Starter Reset buttonaremomentary onbuttonswhiletheothersaremaintainedbuttons Forced onbuttonsdisplaygreen On Off output status displays to the right of each button Return...

Page 38: ...n the Setup screen Once a user with sufficient access is logged on Calibrate buttons appear The following items can be calibrated from this screen Suction Pressure Transducer Discharge Pressure Transducer Oil Manifold Pressure Transducer Oil Filter Inlet Pressure Transducer Motor Amperage Oil Cool ing Fan Feedback Suction Temperature RTD Discharge Temperature RTD Oil Separator Temperature RTD Oil ...

Page 39: ...39 Instrument Calibration ...

Page 40: ... done set the Maximum mA to 20 00 Set the Minimum Pressure to the actual minimum pressure at 4mA as marked on the transducer Set the Maximum Pressure to the actual maximum pressure at 20mA as marked on the transducer Set the Offset to zero unless required otherwise The offset value adds to the resultant linearly scaled value and results in the Calibrated Value which is used for control ...

Page 41: ...set the Maximum mA to 20 00 This is the maximum mA possible from the current transmitter Set the Minimum Ratio value of the current transformer Enter a 0 for zero amps Set the Maximum Ratio value of the current transformer For example if the CT has a 250 5 rating enter 250 as the Maximum Ratio value Set the Offset to zero unless required otherwise The offset value adds to the resultant linearly sc...

Page 42: ...d coded configuration in the PLC input module The Raw T Reading is defined as the scaled value from the RTD input module Set the Offset to zero unless required otherwise The offset value adds to the raw temperature reading scaled value to result in the Calibrated Value which is used for control ...

Page 43: ...The ball valve is installed with the ball closed 1 2 The actuator mounts on the ball valve stem Flats on the ball valve stem indicate the position of the ball OPEN stem flats are with the flow CLOSED stem flats are across the flow 1 3 On smaller valves the ball valve stem flats are nearly hidden between the stem extension and the stem lock nut The locking tabs on the stem lock nut are across the f...

Page 44: ...compressor starts the valve remains fully open 100 until the oil injection temperature rises above the control setpoint 4 4 When the oil injection temperature rises above the control setpoint the oil temperature control valve will begin to close 4 5 The hot oil from the oil separator begins to divert to the oil cooler mixing the hot and cooled oil flow streams together downstream of the oil temper...

Page 45: ...4 Lift the actuator off the valve stem 8 5 Rotate the actuator to the desired position 8 6 Slide actuator down on the valve stem 8 7 Secure the actuator to the valve mounting bracket with four cap screws 8 8 Re connect the electrical leads at the actuator 8 9 Restore 120V and 24V power to the actuator NOTE The ball valve and the actuator must always be assembled in the CLOSED position See Section ...

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Page 47: ...n be selected from the Unit Start button panel The compressor unit does not start when the green Unit Start button on the main screen is pressed Unit Start Window Local Button The Local button is used to put the compressor controller into Local mode This is the default mode for the compressor controller In Local mode the compressor unit must be operated in Auto or Manual mode ...

Page 48: ...de the compressor is controlled by digital input signals 1 Remote Start Input Permissive Start Stop for the compressor 2 Remote Increase Input Increases the Capacity Slide Valve 3 Remote Decrease Input Decrease the Capacity Slide Valve Remote Capacity Hold Button From Local mode Remote Caphold button can be pressed to put the compressor controller in Central mode Central mode allows for external c...

Page 49: ...the compressor controller If this does not stop the compressor then the main power disconnect must be opened Local Stop Lock Release Button If the Stop key is pressed when in Central mode the controller goes into Local Stop Lock mode In Local Stop Lock the controller prevents the compressor from being remotely started Press Local Stop Lock Release to take the Controller out of Local Stop Lock mode...

Page 50: ...50 Device Names To change Device Name go into the vilter Only screen and press Create Device Names From the Device Name Screen press the corresponding text window to change the name of the device ...

Page 51: ...installing a new optical actuator re connect the yellow and gray cables Calibration Procedure of Optical Actuators 4 Press INC and DEC to move the slide valve and checkforthecorrectrotation SeeTable1forAc tuator command shaft rotation specifications 5 Note If the increase and decrease buttons do not correspond to increase or decrease shaft rotation swap the blue and brown wires of the power cable ...

Page 52: ...he slide valve it controls Now the capacity or volume channel of the PLC can be calibrated 13 Use the DEC button to move the actuator to wardsitsminimumpositionwhilewatchingthe millivolt readout on the Control Panel screen Discontinue pressing the DEC button when the millivolt reading the Current window above the Set Min button is approximately 500 mil livolts 14 Now use the DEC and INC buttons to...

Page 53: ...he Set Max button 19 Press the Main button to complete calibra tion and exit the Slide Calibration screen The controller will automatically energize the actuator and drive it back to its mini mum position below 5 for pre start up 20 Note Now the Current Cap or the Current Vol valuewillbedisplayedinthewindowonthe Main screenandthe SlideCalibration screen 21 Gently lower the plastic cover over the t...

Page 54: ... the minimum and maximum ro tational positions of the slide valve it controls The calibrated actuator will output 0 VDC at the minimum position and 5 VDC at maximum posi tion 2 Aftertheactuatormotorcontrolmodulehasbeen calibrated for 0 5 Volts the controlling channel corresponding to the actuator motor either the capacity or volume has to be calibrated This in structsthePLCtolearntherotational0 po...

Page 55: ...ausethemotorisconnectedtothe slide valve by gears knowing the motor position means knowing the slide valve position During calibration the position sensor records the high and low count of motor turns The operator tells the position sensor when the actuator is at the high or low position with the push button Refer to the calibration instructions for the detailed calibra tion procedure The position...

Page 56: ...tor or grey cable There is an intermittent failure of the position sensor The motor brake is not work ing properly see theory section above Clean the optocoupler slots with a Q Tip and rubbing alcohol Adjust the photochopper so that thefenceextendsfurtherintothe optocoupler slots Make sure the motor brake operates freely and thephotochopperwillnotcontact the optocouplers when the shaft is pressed ...

Page 57: ...nd the ther mal switch is tripping Recalibrate Getthemotorbraketowhere it operates freely and then recalibrate Replace the actuator Try to realign or replace the actuator Adjust the photochopper so thatthefenceextendsfurther into the optocoupler slots Replace the actuator Tighten Clean and tighten Replace the actuator Replace the actuator Themotorwillresumeopera tion when it cools This could be ca...

Page 58: ...easons listed in The mo tor will not move in either direction Stripped gears inside the gear motor orthearmaturehascomeun pressed from the armature shaft Replace the actuator See above Replace the actuator The motor runs sporadically The motor runs but output shaft will not turn ...

Page 59: ...tonthegearmotorshouldbeturnedtheoppositedirectionofthedesired command shaft rotation c The capacity and volume control motors are equipped with a brake if it is necessary to operate the control motors manually the brake must be disengaged The brake can be disengaged by pushing on the motor shaft on the cone end The shaft should be centered in its travel Do not use excessive force manually operatin...

Page 60: ...ge will appear when the discharge pressure reading falls below 30 Hg indicating a shorted transducer Discharge Pressure SP 2 Fail This message will appear when the discharge pressure exceeds the safety setting of the Hi Dsch Press Trip Setpoint No 2 In addition this message will appear when the discharge pressure reading falls below 30 Hg indicating a shorted transducer Suction Temp Fail This mess...

Page 61: ...PrelubeOilPressure ManifoldminusDischarge hasremainedbelowthe Prelube Oil Pressure Reset setpoint The Prelube Oil Pressure must be above the Prelube Oil Pressure for a time period of the Minimum Compressor Prelube time It will continue to try to do this for a time period of the Prelube Oil Pump Time Limit When the Prelube Oil Pressure fails to achieve this then the failure message will occur Low O...

Page 62: ... if the motor amperage rises above the Hi Motor Amps trip setpoint Motor Starter Aux Contact Fail This message will appear if the Motor Auxiliary contact fails to close before the Compressor Starter Auxiliary Contact Bypass timer times out Refer to wiring diagram Auxiliary Safety 1 Input Fail This message will appear when power is removed from the input module that is designated as Aux iliary 1 Sa...

Page 63: ...played 1 Processor Name Name assigned by Vilter to the Logix processor 2 Mode Remote Run Run Program 3 Revision Revision of the processor 4 Status OK Faulted Date and Time of both the PanelView Plus unit and of the Logix processor are displayed here for opera tor or service technician use Confirm that the dates and times of the HMI and Logix processor are equal If unequal follow instructions for s...

Page 64: ...art is displaying the period of 7PM to 8PM After pressing the End button the chart will continue to update End button Returns display from any displayed period to current period with current time oriented to the right side of the chart For example if the real time is 7PM and the chart is displaying the period of 1PM to 2PM pressing the End button will display the period of 6PM to 7PM After pressin...

Page 65: ...ayed as a dashed dark grey line Oil Separator Temperature Displayed as a dashed yellow line Oil Injector Temperature Displayed as a dashed dark green line Other Values displayed on page 2 Compressor Motor Amperage Displayed as a bold solid blue line Capacity Displayed as a bold solid bright green line Volume Displayed as a bold solid red line As a standard values of 11 analog items are recorded ev...

Page 66: ...he PanelView a Touch or scroll to the File Management field then touch the Enter button b Touch or scroll to the Delete Files field then touch the Enter button c Touch or scroll to the Delete Log Files field and touch the Enter button DO NOT DELETE APPLICATIONS DO NOT DELETE FONTS d Touch Yes to delete the log files e Touch the Close button twice to return to the Terminal Settings screen f Touch t...

Page 67: ...67 Captured Data at Shutdown The Captured at Shutdown screen shows data captured prior to compressor shutdown ...

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Page 78: ... COMPACTLOGIX 4 CHANNEL ANALOG CUR VOLT INPUT MODULE YES 33 2 MAGNACRAFT 3091EFS 11 PIN 3PDT 2 AMP RELAY YES FU8 ALLEN BRADLEY 3090BD2 2 AMP TIME DLEAY FUSE 9 1 ALLEN BRADLEY 3252S COMPACT LOGIX RIGHT END CAP TERMINATOR YES 34 2 MAGNACRAFT 3091EFS1 OCTAL 11 PIN RELAY BASE YES FU9 ALLEN BRADLEY 3090RD2 4 AMP TIME DLAY FUSE 10 1 ALLEN BRADLEY 3252U1 INDUSTRAL ETHERNET SWITCH 5 PORT RJ45 10 100TX YES...

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Page 80: ...lesman Project Engineer Type of Skid Type of Gas Type of System Classification UL Approval Power Voltage Available Control Voltage Estimated Ship Date Engineered Set Point Info Order Receipt Date Job Site Set point Info ...

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Page 86: ...erson Electric Co or one of its affi liated companies 2010 Emerson Climate Technoligies Inc All rights reserved Printed in the USA Vilter Manufacturing LLC P O Box 8904 Cudahy WI 53110 8904 P 414 744 0111 F 414 744 1769 EmersonClimate com 35391CL Rev 3 ...

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