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Service Monitor User Manual

Danfoss Turbocor Compressors Inc.

3

ECD-00007M Rev. 1

3

Getting Started

3.1

Cable Connection

The monitoring program communicates with the
compressor via the Modbus* protocol using either the
RS232 or RS485 connection at the Chiller Interface
module. RS485 communication requires an RS485/RS232
adapter (user-supplied). RS232 communication is
recommended for cable lengths not exceeding 15 meters
(50 feet) between the PC and compressor. For cables that
run up to 100 meters (328 feet), use the RS485
communication line. Always use shielded, twisted-pair
cable for data communications

*The Modbus protocol was originally developed to exchange information
between products on the factory floor. This protocol has become a de facto
standard for exchanging data and control between PLC systems. Modbus is
a registered trademark of Modicon Corp.

3.1.1 RS232 Connection

1.

Connect one end of the RS232 cable (user-supplied) to
the DB9 connector on the Chiller Interface module; see
Figure 1.

2.

Connect the other end of the cable to an available COM
port on the PC.

3.

Confirm that jumpers JP2 and JP7 are in proper
positions before starting.

JP2 is the Modbus termination jumper. Install the
jumper if the Modbus connection is at the end of a
cable run.

Remove JP7 to enable RS-232 communication with the
PC.

3.1.2 RS485 Connection

1.

Connect the RS485/RS232 adapter directly onto the PC
COM port.

Connect the other side of the adapter to the Modbus. Figure
2 shows the PC and adapter connections to the Modbus for
a single compressor application. Ensure that the termination
jumper (JP2) on the Chiller Interface module is installed.

Figure 3 shows the PC and adapter connections to the
Modbus for a multiple compressor application. In this case,
set the termination jumper only on the Chiller Interface
module that is connected at the end of the Modbus cable
run.

Figure 1 RS232 Connector - Chiller Interface

Module

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Содержание Turbocor TT-300

Страница 1: ...SERVICE MONITOR USER MANUAL Danfoss Turbocor Compressors Inc ECD 00007M Rev 1 TWIN TURBINE CENTRIFUGAL COMPRESSOR MODEL TT 300 ...

Страница 2: ...tion Data 12 Using a Saved Configuration File 13 Controlling User Access 14 Starting and Stopping the Compressor 15 Analog Input 15 How to Start the Compressor 15 How to Stop the Compressor 15 Modbus Network 15 How to Start the Compressor 15 How to Stop the Compressor 16 Chiller Control 16 How to Start the Compressor 16 How to Stop the Compressor 16 Monitor Program Data and Controls 18 Main System...

Страница 3: ...PROM Settings 39 Compressor Controller Settings 40 Compressor Controller Alarms 41 Compressor Controller Fault Limits 43 Compressor Stepper Motor Settings 44 Stepper Motor Valve Controls 45 Analog Output Controls 47 Compressor Controller Impeller Specific Settings 49 Compressor Controller CC Critical Fault Lock Outs 50 Refrigerant 51 Compressor Event Log 51 History Data 52 Trending 53 Graphs 53 Tr...

Страница 4: ...e Monitor program is a rich user friendly graphical user interface designed to control the Turbocor compressor and to provide status information about the compressor Furthermore it can be used as a tool for troubleshooting purposes This manual describes the functions provided by the Turbocor Service Monitor program ...

Страница 5: ...ibutable is supported on the following platforms Microsoft Windows Server 2003 NET Framework 1 1 is installed as part of the operating system Windows XP Professional Windows XP Home Edition Windows 2000 Windows Millennium Edition Windows Me Windows 98 Microsoft Windows NT 4 0 Service Pack 6a The NET Framework 1 1 Re distributable cannot be installed on 64 bit computers Windows NT 4 0 Terminal Serv...

Страница 6: ...p 3 1 1 RS232 Connection 1 Connect one end of the RS232 cable user supplied to the DB9 connector on the Chiller Interface module see Figure 1 2 Connect the other end of the cable to an available COM port on the PC 3 Confirm that jumpers JP2 and JP7 are in proper positions before starting JP2 is the Modbus termination jumper Install the jumper if the Modbus connection is at the end of a cable run R...

Страница 7: ...Started 4 Danfoss Turbocor Compressors Inc ECD 00007M Rev 1 Figure 2 PC to Modbus Connection single compressor with 10 m cable length Figure 3 PC to Modbus Connection multiple compressors with 10 m cable length ...

Страница 8: ...etup wizard 3 3 Starting the Monitor Program To start the monitor program from the Start menu select Programs Danfoss Turbocor Monitoring Tool 3 4 User Interface 3 4 1 Monitor Program Toolbar The toolbar located under the menu bar provides the user with easy access to the monitoring windows Table 2 provides details for each icon on the toolbar NOTE Up to three windows can be displayed at one time ...

Страница 9: ...2 1 default Slave Address 1 63 1 default Expansion Valves Clicking on the Expansion Valves icon opens the Electronic Valve Data Tuning window Refer to section 6 6 Electronic Valve Data Tuning on page 33 Event Log Clicking on the Event Log icon opens the Compressor Event Log window Refer to section 6 10 Compressor Event Log on page 51 EEPROM Settings Clicking on the EEPROM Settings icon opens the E...

Страница 10: ...all communications until a cycle of the power is performed 3 Click the OK to start monitoring button 4 Compressor Configuration 4 1 Using the Setup Wizard The monitor program features a commissioning setup wizard to guide the user through the complete compressor configuration process 1 To launch the commissioning setup wizard select System Commissioning from the Advanced menu item The introduction...

Страница 11: ...ation manual to either the Entering or Leaving Chilled Water temperature input on the Chiller Interface module 6 Set the Chiller Control Set Point to the desired value 7 Set the Proportional and Integral Gain values to obtain stable control the Proportional and Integral Gain values will vary depending on the application NOTE The Integral part of the internal chiller controller is switched off unti...

Страница 12: ...xt to continue 4 1 2 Electronics Valve Control Refer to Figure 9 This section explains how to set up the expansion valves for various applications Both valves can be operated independently or in parallel For Expansion Valve 1 1 Enter the number of steps to drive the valve from fully closed to fully open Expansion valves with different numbers of steps can be used If the incorrect number of steps i...

Страница 13: ...erface module Superheat control using the compressor flange pressure and a 10K thermistor that is connected to the terminals labeled LIQT on the Chiller Interface module Superheat control using an external temperature and pressure sensor connected to the terminals on the IO pcb labeled SPARE T SPARE P Liquid Level Liquid level can be measured from one of the following sources Liquid Level 1 contro...

Страница 14: ...ooling coil A temperature sensor at the cooling coil is connected to the Leave terminals of the Chiller Interface module The analog output controls the amount of chilled water entering the cooling coil based on the air temperature setpoint Configure the analog output as follows Refer to Figure 11 1 Select the control mode for the analog output The selection determines which control variable will b...

Страница 15: ...5 and RS 232 ports as required on the Chiller Interface module to enable communication with an external PLC computer or building management system 4 1 5 Downloading and Saving Configuration Data At the end of the commissioning sequence you have the choice of either downloading the configuration data to the compressor or saving it to a file for later use To save the data to a configuration file cli...

Страница 16: ...ol Open interlock contacts on the Chiller Interface module before downloading configuration data 1 Click the Load configuration from file button refer to Figure 13 2 In the Open File dialog box browse to the location of the ttc file 3 Click Open 4 On the Download Settings form click Download to compressor button 5 When the message Done Cycle power before running the compressor appears turn OFF pow...

Страница 17: ...data and retrieve and save fault data High level User may alter all settings This level of access is reserved for users that configure motor compressor and bearing control only Upon power up of the compressor the access codes are calculated and stored in RAM memory The default user access level on power up is read only To change the access code select Access Codes from the Advanced menu item refer...

Страница 18: ...o the Chiller Interface module 3 Apply a signal between 2 and 10VDC to the Demand input 2VDC min kW min speed 10VDC max kW according to model capacity 5 1 2 How to Stop the Compressor Decrease the demand signal to 0VDC or open the contact connected to the Interlock input on the Chiller Interface module The compressor will ramp down to 0 RPM and de levitate 5 2 Modbus Network In Modbus Network mode...

Страница 19: ...sure measurement NOTE The Chiller Interface interlock switch must be closed and no errors present for the compressor to start up and run 5 3 1 How to Start the Compressor Open the Chiller Control window Select Window Chiller Control from the menu bar or click on the Chiller Control icon located below the menu bar On the Chiller Control form check the Chiller Enable Status box The compressor will r...

Страница 20: ...Service Monitor User Manual Danfoss Turbocor Compressors Inc 17 ECD 00007M Rev 1 Figure 18 Chiller Control Form ...

Страница 21: ...to quickly view the following major compressor parameters AC input power compressor demand shaft speed suction temperature pressure discharge temperature pressure IGV open To view the General Data Page select Window Main System from the menu bar Table 4 provides a description of the General Data Page parameters The General Data Page also plots the following parameters with respect to time evaporat...

Страница 22: ...t the compressor flange as measured by the suction temperature pressure transducer Suction Temperature The actual suction temperature at the compressor flange as measured by the suction temperature pressure transducer Suction Pressure The actual suction pressure at the compressor flange as measured by the suction pressure transducer IGV Open of Inlet guide vane opening 0 0 means the vanes are at 9...

Страница 23: ...shows the calibration data of the latest calibration performed The Stored Calibration column shows the calibration data of the latest saved calibration data The Diff column shows the difference between the Latest Check value and the Stored Calibration value Clicking on the Save Calibration button stores the data from the Latest Check as the Stored Calibration data Clicking on the Save Data To File...

Страница 24: ...n Formula Fixed Voltage FRY Min Voltage FRY Max Voltage FRY Offset Difference between the y component of the front radial sensor center and the y component of the front touchdown bearing center Refer to Figure 22 FRY HW Offset Hardware offset BRX Gain Gain Formula Fixed Voltage BRX Min Voltage BRX Max Voltage BRX Offset Difference between the x component of the rear radial sensor center and the x ...

Страница 25: ...or 5 From the menu bar select Advanced Bearing Calibration The Startup Check Calibration Data window appears as shown in Figure 20 6 Click on Perform Calibration The message Bearing Calibration in Progress appears Observe if the compressor makes a distinctive knocking noise this confirms the calibration is in progress Do not click on Save Calibration 7 Open the Compressor Event Log window From the...

Страница 26: ...et Interpretation Only the difference between the Latest Check offset and the Stored Calibration offset is important The Latest Check offset value or the Stored Calibration offset value by itself has no significance The change between the offset values signifies a change in the area of shaft orbit 6 3 Compressor Control The Compressor Controller window allows the user to Control the suction pressu...

Страница 27: ...Monitor Program Data and Controls 24 Danfoss Turbocor Compressors Inc ECD 00007M Rev 1 Figure 24 Compressor Controller Form ...

Страница 28: ...er is mounted to a common discharge line in the case of multiple compressors Discharge Pressure The actual discharge gauge pressure at the compressor flange as measured by the discharge pressure transducer Suction Temperature The actual suction temperature at the compressor flange as measured by the suction temperature pressure transducer SCR Temperature Temperature of the SCR heat sink plate Disc...

Страница 29: ... servicing or troubleshooting the compressor Total Compression Ratio Ratio of the absolute discharge pressure and the absolute suction pressure Estimated Minimum Speed Estimated minimum RPM the compressor can run at with a fully open inlet guide vane Maximum Speed Maximum RPM the compressor can run at for a given set of inlet and outlet conditions Compressor Display Units Button Changes the measur...

Страница 30: ... Alarms This section describes the possible Critical Faults and Compressor Alarms displayed in the Compressor Controller window Table 7 provides a description of the possible cause of the fault alarm If a compressor controller fault alarm occurs it is an indication that the EEPROM fault alarm limit setting has been exceeded Check that the EEPROM fault alarm limit settings are adequate for the curr...

Страница 31: ...T To change a parameter setting double click the variable field scroll or type in the new setting and press Enter It is important to press Enter as this causes the user input to be validated 3 Phase Over Current Fault Alarm Excessive system load usually due to compressor pumping liquid Note A 3 Phase Over Current fault will lock out the compressor The compressor will have to be powered down and re...

Страница 32: ... generating current component Earth Leakage Current Motor current that leaks to ground due to an insulation fault Calculated Total Power Calculated 3 phase input power in kW Requested Motor Power Requested motor power in kW Value is a function of the compressor model designation and demand percentage The demand percentage is set through the Loading Demand max power in the Compressor Controller win...

Страница 33: ... Three Phase Mains Voltage Calculated three phase mains voltage Three Phase Current Calculated three phase mains current DC Bus Regulation Percentage of maximum DC Bus output voltage DC Bus Voltage DC Bus Voltage as measured at the inverter Graph Amps Id Iq Graphical representation of the torque generating current Id and the flux generating current Iq versus time Under normal conditions when the m...

Страница 34: ...tion valve thus causing the motor to overwork and generate too much current DC Bus Over Voltage Detected DC bus voltage exceeds acceptable voltage range Motor High Current Warning The AC input voltage is too low or the compressor is overloaded due to wet gas or exceeded compressor capacity Motor High Current Fault The AC input voltage is too low or the compressor is overloaded due to wet gas or ex...

Страница 35: ...n page 23 Axial Unbalance Percentage unbalance of total allowable axial displacement Front Radial Unbalance Percentage unbalance of total allowable front radial displacement Rear Radial Unbalance Percentage unbalance of total allowable rear radial displacement Axial Bearing Force Amps Current required to counteract axial unbalance force Front X Bearing Force Amps Current required to counteract fro...

Страница 36: ... representation of the front radial orbit of the shaft Percentile shown at the bottom right hand corner indicates the average front orbit displacement Note The domain of the graph shows half of the allowable area of shaft displacement However if the shaft orbit is shown to exceed 500 units in any direction then there is excessive shaft vibration possibly caused by a surge of gas flow Table 10 Bear...

Страница 37: ...t Controls controls the output labeled Analog on the Chiller Interface module Table 13 describes the analog output control parameters NOTE The measurement unit metric imperial displayed depends on the measurement unit previously set To verify or change the measurement unit refer to section 6 3 Compressor Control on page 23 IMPORTANT To change a parameter setting double click the variable field scr...

Страница 38: ... the compressor s own internal control algorithm to determine the best mix of speed control inlet guide vane opening and load balance valve opening Auto Manual In automatic mode the compressor has complete control over the stepper motor output In Manual mode the user is able to enter the valve position Process Value Value of the controlled variable selected from the Control Mode Valve Open Ratio o...

Страница 39: ...ing Percentage of maximum voltage sent to the terminals on start of the compressor The analog output will hold at this position until start delay timer has expired Analog Output Start Delay Amount of time from compressor start to hold the voltage at the startup percentage Value is in seconds and starts to count down when the drive enables Analog Setpoint Desired value of the controlled variable An...

Страница 40: ...out the chiller controller parameters NOTE The measurement unit metric imperial displayed depends on the measurement unit previously set To verify or change the measurement unit refer to section 6 3 Compressor Control on page 23 IMPORTANT To change a parameter setting double click the variable field scroll or type in the new setting and press Enter It is important to press Enter as this causes the...

Страница 41: ...Chiller Control Mode selected Leaving Chiller Set Point deg C deg F the controlled variable is either the leaving chiller water or air temperature Entering Chiller Set Point deg C deg F the controlled variable is either the entering chiller water or air temperature Evaporating Temperature Set Point deg C deg F the controlled variable is the evaporating saturated suction temperature Chiller Control...

Страница 42: ...ation 6 8 2 EEPROM Log Resets Selecting the Eeprom Log Resets tab allows the user to Reset the fault frequency counters Reset the fault captures Reset the load profile counters i e the power demand counters Reset the event log The Eeprom Log Resets is only accessible by authorized service personnel 6 9 EEPROM Settings To access the EEPROM Settings select Window Eeprom Settings from the menu bar or...

Страница 43: ...Controller Settings Table 15 EEPROM Settings Compressor Controller Parameters Parameter Description Control Mode Displays the source of demand for the compressor Calibration Manual Control Analog Input Modbus Network or Chiller Control Refer to 6 3 1 Compressor Control Modes on page 26 for further details Display Units Displays the measurement unit used The options are Metric Units kPa ºC ºK Imper...

Страница 44: ...rating saturated suction temperature Chiller Control Set Point Value at which the controlled variable selected through Control Mode shall be maintained Chiller Enable Status Checked chiller able to run Unchecked chiller will not run Proportional Gain Control loop Proportional gain 0 to 100 Integral Gain Control loop Integral gain or reset 0 to 100 Startup Parameters Refer to 6 3 Compressor Control...

Страница 45: ...ture at the compressor flange as measured by the discharge temperature pressure transducer Suction Pressure The actual suction gauge pressure at the compressor flange as measured by the suction pressure transducer Cavity Temperature Temperature of the superheated gas moving past the shaft Leaving Temperature Leaving water temperature as measured from the 10K thermistor connected to the terminals m...

Страница 46: ...essor will tolerate before activating a fault Once a fault occurs the compressor motor will trip and the fault will be reported in the Compressor Controller window as well as in the Event Log window An authorized user may change the following fault limits to adapt to the application needs Suction Pressure Leaving Temperature Total Compression Ratio All other fault limits cannot be altered as chang...

Страница 47: ...rter Discharge Temperature The actual discharge temperature at the compressor flange as measured by the discharge temperature pressure transducer Suction Pressure The actual suction gauge pressure at the compressor flange as measured by the suction pressure transducer Cavity Temperature Temperature of the superheated gas moving past the shaft Leaving Temperature Leaving water temperature as measur...

Страница 48: ...c expansion valve connected to EXV1 at the Chiller Interface module Similarly select the EXV 2 Settings tab to view the control settings for the electronic expansion valve 2 EXV 2 EXV 2 refers to the electronic expansion valve connected to EXV2 at the Chiller Interface module Table 18 describes the EXV settings To update the EXV settings refer to section 6 6 Electronic Valve Data Tuning on page 33...

Страница 49: ...Monitor Program Data and Controls 46 Danfoss Turbocor Compressors Inc ECD 00007M Rev 1 Figure 34 EEPROM Settings Stepper Motor Valve 1 Controls ...

Страница 50: ...rminals on the IO pcb labeled SPARE T SPARE P 5 Liquid Level 1 control using a level sensor connected to the terminals on the Chiller Interface module labeled LIQ LEV1 6 Liquid Level 2 control using a level sensor connected to the terminals on the Chiller Interface module labeled LIQ LEV2 7 Load Balance control uses the compressors own internal control algorithm to determine the best mix of speed ...

Страница 51: ...Monitor Program Data and Controls 48 Danfoss Turbocor Compressors Inc ECD 00007M Rev 1 Figure 35 EEPROM Settings Analog Output Controls ...

Страница 52: ...module The options are Load Balance Valve Discharge Pressure Inlet Guide Vane Superheat Flange TP Superheat FlangeP EWT Superheat FlangeP LIQT Suction Pressure Leaving Temp Entering Temp Liquid Temp Auto Manual Selects the compressor control mode In automatic mode the compressor has complete control over the stepper motor output In Manual mode the user is able to enter the valve position Analog Ou...

Страница 53: ...occurred within the Moving Window Hold Time of 30 minutes Anti start temperature alarm Inverter temperature alarm Cavity temperature alarm SCR temperature alarm The compressor will continue to operate even if the aforementioned alarms occur However if any or a combination of the aforementioned alarms occurs more than the allowable Limit of Alarms in Buffer within the Moving Window Hold Time of 30 ...

Страница 54: ...occurred and the Description column provides details about the event or fault In the case of a compressor fault check the timestamp of the fault To help in troubleshooting the compressor fault look at all the events and faults that occurred before the fault i e events and faults logged with an earlier timestamp Particularly pay attention to the information logged immediately before the fault occur...

Страница 55: ...t event being displayed 6 11 History Data The Compressor History Data window provides the user with information about the compressor energy usage To view the Compressor History Data window select Window Load Profile from the menu bar or click on the Load Profile Graphs icon located below the menu bar Figure 38 Event Log Window ...

Страница 56: ...pressor History Data Table 20 Compressor History Data Parameters Parameter Description Graph Power Demand vs Hours The graph shows the number of hours the compressor has been in operation for a given power demand The statistical values of operating hours for each 10 of power demand is displayed in the Load Profile Data section Total Time Online Total time the compressor has been running Total Ener...

Страница 57: ...file From the File menu select Open Go to the Turbocor_Install_Dir Turbocor Inc directory select the desired csv data file to be loaded and click on Open The stored data begins to playback on the graphs The playback speed may be adjusted from the PlayBackSpeed menu NOTE The measurement unit metric imperial displayed depends on the measurement unit previously set To verify or change the measurement...

Страница 58: ...ut Stepper 1 Position Ratio of the actual number of steps sent to the stepper motor over the maximum number of steps the motor is allowed to drive Range 0 100 Stepper 2 PV Controlled variable maintained by the stepper motor 2 output Stepper 2 Position Ratio of the actual number of steps sent to the stepper motor over the maximum number of steps the motor is allowed to drive Range 0 100 Cooling Sol...

Страница 59: ... Charts 2 For the Temperatures graph the trends of the following parameters may be viewed simultaneously Suction Temperature Discharge Temperature Liquid Temperature Entering Air Water Temperature Leaving Air Water Temperature Evaporating Temperature Condensing Temperature For the Energy Demand Usage graph the trends of the following parameters may be viewed simultaneously Actual Mains Power Input...

Страница 60: ... Save button to create the log file The log file is saved in csv format and may be viewed using a spreadsheet editor such as Microsoft Excel After creating the log file the Save button becomes a Stop button Click on the Stop button anytime to stop recording the trends to the log file The trending log file records the date and time when the parameters are logged and it records all parameters regard...

Страница 61: ...f inputs The inputs are generated automatically when the serial port connection has been established refer to 3 5 Serial Port Connection on page 6 However if the compressor is offline i e the serial port connection has not been established then it is possible to calculate the estimated compressor capacity and performance To do so input the following parameters in the input section Suction pressure...

Страница 62: ...e Current Index located above the Descriptive Fault Information box is the index of the fault that occurred for which the compressor state is being described The timestamp when the Current Index fault occurred is also shown above the Descriptive Fault Information box For a description of the fault that occurred look under the descriptive fault information ID 47 to 51 where the motor bearing and co...

Страница 63: ...Data from the menu bar An Acquiring Data message box appears After the Acquiring Data message box disappears click on the Data Preview button to view the compressor data The acquired data may be saved to file by clicking on the Save Data to File button NOTE The measurement unit metric imperial displayed depends on the measurement unit previously set To verify or change the measurement unit refer t...

Страница 64: ...Service Monitor User Manual Danfoss Turbocor Compressors Inc 61 ECD 00007M Rev 1 Figure 46 Compressor Data Capture Screen ...

Страница 65: ...e compressor flange as measured by the discharge temperature pressure transducer 9 Cavity Temperature Temperature of the superheated gas moving past the shaft 10 Controller PCB Temperature Temperature of the BMCC board 11 Backplane Temperature Temperature of the Backplane 12 Stepper PCB Temperature Temperature of the Serial Driver 13 Entering Water Temperature Temperature as measured from the 10K ...

Страница 66: ...ted or de levitated 32 Ax Un balance Percentage unbalance of total allowable axial displacement 33 Fr Un balance Percentage unbalance of total allowable front radial displacement 34 Br Un balance Percentage unbalance of total allowable rear radial displacement 35 Ax Force Amps Current required to counteract axial unbalance force 36 Fx Force Amps Current required to counteract front x unbalance for...

Страница 67: ...nd or chiller control supplied demand Analog Input Mode Example Calculate the actual 3ph power set point for a 75ton TT300W 75TR 460 480V compressor running with a suction pressure of 340 kPa a compression ratio of 2 80 and an input voltage level of 6 50 VDC Recall that for analogue input mode the input voltage range is 0 10VDC with a deadband of 2VDC Thus the demand for a 6 50 VDC input is demand...

Страница 68: ...v 1 For a reference pressure of 356kPa at 283ºK The referred power is determined to be PWRref 24 783 2 80 14 06 55 32 kW The actual maximum power is PWRmax 55 32 340 356 52 83 kW The desired 3 phase power input is then Desired power 52 83 562 29 69 kW ...

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