Table of Contents Table of Contents CCS Introduction CHAPTER 1 Associated Documents..............Applicable Compressor Models............ General Operating Overview CHAPTER 2 Definitions..................Keypad Functions ................. Main Screen Overview ..............Hot Key Selection ................. Screen Types ................. Menu Screens ................Data Entry Screens ..............Data Entry Procedures............
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Standard Screw Compressor - RWB Series Oil Pressure Calculations ............Oil Level Indication..............Starting the Screw Compressor............. Manual Mode................Automatic Mode ............... Remote/Auto Remote Mode............. I/O Control ................Network Control..............Sequenced Mode ..............Stopping the Screw Compressor........... Manual Mode................Automatic Mode ...............
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Table of Contents Oil Temperature Regulation............3-17 Liquid Injection Oil Cooling (Option).......... 3-17 Single Port Liquid Injection ............. 3-17 Dual Port Liquid Injection............3-17 Anti-Cycle Timer ................3-17 Power Fail Restart................. 3-18 Remote Status Information............3-18 Process Temperature Control (Option) ......... 3-18 Economizer Control (Option) ............
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Standard Screw Compressor - RWB Series Temperature Setpoints............3-40 Discharge Temperature Setpoints ........3-40 Oil Temperature Setpoints (without Liquid Injection) ..3-41 Oil Temperature Setpoints ( with Liquid Injection)..3-42 Process Temperature Control Group........ 3-43 High Process Temperature Selection ....... 3-44 Motor Current Setpoints............
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Table of Contents Menu Functions CHAPTER 5 Technical Overview ..............Logon User ................Logoff User................Automatic Log Off ............... Diagnostics Menu ..............System Information .............. View Discrete I/O..............View Analogs ............... View Dip Switches ............... View Network Comm ............Override Discrete I/O (Option) ..........Setup Menu................
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Standard Screw Compressor - RWB Series Password Control ..............5-19 Add/Delete User .............. 5-20 Screen Access Levels ............5-21 Initialization ................. 5-22 Power Fail Reset .............. 5-23 Set Factory Config ............5-24 Configuration ............... 5-25 Display ................5-26 Communication Setup ............. 5-27 Motor Configuration ............
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Table of Contents Word Range Write..............C-12 Error Messages..............C-13 Data Formats ................. C-13 Status Message Description ............C-14 Analog Inputs and Computed Parameters ........ C-14 Discrete Input and Outputs ............C-15 Alarm and Failure Data ............C-16 Equipment Data ................ C-18 Control Message Description............
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Standard Screw Compressor - RWB Series M&M R EFRIGERATION...
CCS Introduction CHAPTER 1 The Compressor Control System (CCS) is an advanced microprocessor- based control system designed for efficient and automatic control and mon- itoring of industrial refrigeration systems including screw compressors. The controller is composed of a microprocessor board, Input/Output boards, a keypad, and a Liquid Crystal Display (LCD).
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Standard Screw Compressor - RWB Series M&M R EFRIGERATION...
General Operating Overview CHAPTER 2 The following sections will give the user an overview of the general operat- ing procedures for the CCS. Definitions CCS System Manager is the person who will assign user passwords, access levels and screen access requirements. Cursor is a field indicator used on data entry screens.
Standard Screw Compressor - RWB Series Parameter is a system control value, which is displayed by the system or input by the user. Examples are suction pressure and high suction pressure alarm setpoint. Screen is a method of displaying information to the user. The system contains eight types of...
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Chapter 2: Keypad Functions The red STOP key causes an immediate and orderly shutdown of a compressor. This STOP key usually has no effect on master panels. The SHIFT key is used to switch control back and forth from the display area to the hot SHIFT keys.
Standard Screw Compressor - RWB Series Main Screen Overview The Main Screen is the name for a set of features common to all large character screens. The Main Screen is broken down into three areas: display area, hot keys, and title banner. The fol- lowing drawing shows a representation of the main screen layout and labels each of its vari- ous areas.
Chapter 2: Hot Key Selection Hot Key Selection 1. Verify Number next to a Hot Key is Highlighted - one of the numbers next to a hot key should be highlighted and flashing. (This is not the same as having the hot key command highlighted.) If there are no numbers highlighted, switch control from the display area to the hot keys by pressing the SHIFT key.
Standard Screw Compressor - RWB Series Menu Screens The Menu screen is used to present the user with choices for various system operations. Menu screens are found throughout the CCS system. The following is an example of a menu screen.
Chapter 2: Screen Types Menu Selection Procedures - Menu options are chosen similar to hot key options. 1. Verify Cursor Control - Verify that a menu option number is highlighted. If not use the SHIFT key to transfer cursor control from the hot keys to the display area. 2.
Standard Screw Compressor - RWB Series The following table contains a list of the active keys on a data entry screen and their func- tion. KEYS FUNCTION NUMBER Used to enter numerical data. KEYPAD Toggles through the available choices on a selectable field. On a number field the...
Chapter 2: Screen Types Arrow Keys - The arrow keys will accept the entered data and move the cursor to the next field. Errors - A flashing error message tells the user that the entered data is not within an acceptable range for the field. The user must clear the error before proceed- ing.
Standard Screw Compressor - RWB Series 3. ENTER/Arrow Keys - locks in the numerical data and moves the cursor across to the units section of the field. 4. Verify Cursor Type - locate the ">" selection cursor next to the units section.
Chapter 2: Screen Types 3. “.” Key - Selecting the Period (.) key puts the field into edit mode and allows the current contents of the field to be entered. 4. Arrow Keys - Allows you to move within a field to different charac- ters.
Standard Screw Compressor - RWB Series 4. Arrow Keys - Allows you to move within a field to different charac- ters. 5. Number Keys - These keys are used to enter numbers into a char- acter. 6. Clear Key - This key is used to clear the contens of the entire field.
Chapter 2: Screen Types The following table contains a list of the active keys on a status screen and their function. FUNCTION SHIFT Switches control between the display area and the hot key options. ENTER Scrolls through the set of available status screens. PG UP/PG DN/ RIGHT/LEFT Pages forward or back through the available status screens.
Standard Screw Compressor - RWB Series The following table contains a list of the active keys on a confirmation screen and their function. KEYS FUNCTION NUMBER Used to select a response number. KEYPAD ENTER Used to select the highlighted response number.
Chapter 2: Screen Types The following table contains a list of the active keys on a momentary screen and their function. FUNCTION QUIT Stops display of the message before the three second time limit expires. Momentary Screen Keys Information Screens Information screens are used to display system data to the user.
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Standard Screw Compressor - RWB Series required to clear the error and enter a correct value. The data entry process is described in more detail in the data entry section. The following is an example of an access screen. M & M REFRIGERATION...
Chapter 2: Screen Types Log Screens Log screens are used to view recorded system information. The width and length of the log screens may be wider and longer than allowed by the LCD display area. The arrow and page keys can then be used to view the entire log. All systems are configured with the following logs: Operation Log, Trend Log, Alarm Log, Failure Log, and User Log.
Standard Screw Compressor - RWB Series Alarms & Failures The CCS continually monitors the system parameters and compares them to alarm and fail- ure setpoints to inform the operator of the system status. An alarm is intended to alert the operator that an undesirable condition exists.
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Chapter 2: Alarms & Failures M & M REFRIGERATION 8:32 1. START ACTIVE ALARMS & FAILURES STATS HH:MM:SS TYPE DESCRIPTION STATE 3. MODE HH:MM:SS TYPE DESCRIPTION STATE 4. SETPT 5. SCHED 6. CNTRL 7. MISC 8. LOGS 9. MENUS state mode alarm Active Alarms &...
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Standard Screw Compressor - RWB Series 2-20 M&M R EFRIGERATION...
Compressor Controls CHAPTER 3 The following sections discuss the standard and optional features contained in the CCS Screw Compressor package. Modes Of Operation The Screw Compressor package has several modes of operation. The mode is changed by using the MODE hot key and making a selection from the operation mode menu.
Standard Screw Compressor - RWB Series Lubrication System The RWB screw compressor is designed to be self-lubricating. The oil being supplied to the compressor is at discharge pressure and the oil porting to all parts of the compressor is below discharge pressure. The normal process of gas compression allows the com- pressor to act as its own oil pump.
Chapter 3: Starting the Screw Compressor Oil Pressure Calculations The Oil Pressure and Oil Filter Pressure values are computed using a combination of the Oil Pressure After Filter, Oil Pressure Before Filter, and Discharge Pressure transducers. The following formulas are used: For a Full Lube Oil Pump the oil pressure is always computed as: Oil Pressure = Oil Pressure After Filter - Discharge Pressure.
Standard Screw Compressor - RWB Series allowed to start. If the slide valve position does not move below 5% within 5 minuets, the compressor will be failed on START SLIDE POSITION. Once the motor starts, the slide valve position is monitored while the compressor is coming up to speed. If the slide valve position...
Chapter 3: Starting the Screw Compressor Automatic Mode In Automatic mode the compressor can be started automatically based on suction pres- sure or process temperature. Automatic starting is enabled on the Miscellaneous Control screen under the MISC hot key. Once the Auto Start/Stop feature is enabled the operator must place the compressor on-line using the START hot key.
Standard Screw Compressor - RWB Series Stopping the Screw Compressor The stopping sequence is as follows: 1. The Motor is stopped. 2. Once the starter has disengaged the slide valve is moved to the fully unloaded posi- tion (below 5%). If the slide valve does not respond within two (2) minutes, the stop sequence is failed on OEM STOP SLIDE POSITION HIGH.
Chapter 3: Capacity Control Sequenced Mode When the STOP command is received from the master sequencer, the CCS will stop the screw compressor automatically and leave it on-line for sequenced operation. While stopped on-line, the compressor is available for sequencing and in standby waiting for commands.
Standard Screw Compressor - RWB Series Control Groups Four groups of control setpoints can be defined for use with automatic capacity con- trol. Each setpoint group consist of a cut-in, cut-out, control, and low alarm and fail- ure setpoints. The control associated with these pressures is as follows;...
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Chapter 3: Capacity Control slowly to control parameter changes. While the control parameter is outside the band- width values the slide valve is continuously loaded or unloaded. Long Pulse - This is the longest amount of time used to move the slide valve while loading or unloading the compressor.
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Standard Screw Compressor - RWB Series Pressure Difference Above Setpoint Continous Load Load Bandwidth Slide Valve Movement Time Computed Based on Pressure Difference Load Deadband No Slide Valve Movement Control Setpoint No Slide Valve Movement Unload Deadband Slide Valve Movement Time...
Chapter 3: Capacity Control Remote Capacity Control I/O Control When remote operation is desired using discrete I/O signals, and the compressor is in the Remote mode, capacity control is performed using the Remote Load and Remote Unload inputs. The relationship of these signals to slide valve movement is shown in the following table.
Standard Screw Compressor - RWB Series Network Control When the Network Communications option is enabled, and the compressor is in the Auto-Remote mode, capacity control is performed using Automatic Capacity Control. The control setpoint is selected using setpoint messages from a remote computer.
Chapter 3: Capacity Control Current, the CCS informs the master sequencer that no further capacity increases are possible and additional compressors may be needed. Running in Full Load Mode When the Full Load command is received the CCS disables all capacity control and locks the slide valve at the fully loaded position.
Standard Screw Compressor - RWB Series Compressor is Unloaded High Unload Compressor is Limited High Limit Ramp Unload Ramp Limit Parameter Value Compressor Ramp Start Duration Time After Compressor Start Ramp Figure Slide Valve Position Ramp Start Limiting The Slide Valve Position Ramp Start feature has been provided to limit capacity increases after the compressor starts.
Chapter 3: Setpoint Scheduling Unload Solenoid Configuration The unload solenoid for the A -Series compressors has two configurations, In the original configuration, the solenoid is normally closed, energized to unload the com- pressor. In later versions, the unload solenoid is normally open, and is de-energized to unload the compressor.
Standard Screw Compressor - RWB Series Variable Vi Slide Stop Control Vi refers to the volumetric ratio of the screw compressor. The Vi is computed by taking the ratio of the volume of gas when compression begins to the volume of gas when discharge begins.
Chapter 3: Oil Temperature Regulation Oil Temperature Regulation The oil temperature in the oil separator is regulated when the screw compressor is stopped. The temperature is maintained above the oil heater setpoint with a deadband of +5 degrees. When the compressor is stopped and the Oil Sump Temperature falls below the Heater Con- trol setpoint, the oil heaters will be turned on.
Standard Screw Compressor - RWB Series Power Fail Restart The operator can define a power fail restart time from the miscellaneous time setpoint screen. If the CCS is reset manually or due to a loss of power the down time is calculated and com- pared to this setpoint.
Chapter 3: Economizer Control (Option) Economizer Control (Option) The Economizer Control option provides an intermediate pressure port located between the primary suction and discharge ports on the screw compressor. The Economizer Solenoid out- put is used to control the flow of liquid into the economizer vessel or to control a suction sole- noid at the economizer port.
Standard Screw Compressor - RWB Series Operational Procedures The operator interface for the screw compressor is performed using LCD, keypad, and the fol- lowing nine hot keys: • START • STATS • MODE • SETPT • SCHED • CNTRL •...
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Chapter 3: Operational Procedures The following screen is an example of one of the possible momentary screens that may appear after answering yes to the Start Confirmation screen. The possible momentary screens will vary depending on the individual system configuration. M &...
Standard Screw Compressor - RWB Series STATS Hot Key The STATS hot key will allow the user to return quickly to the main Status screen. The operator may select the Compressor Status screen or the Compressor Graphics screen as the default main Status screen. The Quit key will always return the user to the currently selected main Status screen.
Chapter 3: Operational Procedures Manual control of the slide valve is discussed in the Capacity Control section and alarms and failures are discussed in the Alarm/Failure section of this manual. The following table lists the various parameters displayed on the screw status screen. PARAMETER DESCRIPTION The active capacity control setpoint.
Standard Screw Compressor - RWB Series System Current State The left-most highlighted status banner section displays the current state of the system. The following is a table with a brief description of possible system states. CURRENT DESCRIPTION STATE ACYCLE Anti-cycle count down timer has been activated to delay motor start.
Chapter 3: Operational Procedures Alarm & Failure Area The right most highlighted status banner section displays the Alarm and Failure Status of the system. When a new alarm or failure occurs, this area will flash from highlighted to non-highlighted to inform the operator. The area will stop flashing but remain highlighted when the operator has used the CLEAR key to acknowl- edge the alarm or failure.
Standard Screw Compressor - RWB Series Energy Status Screen The Energy Status screen displays the motor current and the computed energy con- sumption information. M & M REFRIGERATION 8:32 ENERGY STATUS 1. START STATS 3. MODE MOTOR CURRENT XXXX.X AMPS 4.
Chapter 3: Operational Procedures Operating Hours Screen The Operating Hours Status screen allows the operator to view the compressor’s cur- rent running hours since its last start and the total number of hours the system has been in operation since installation In addition, the number of compressor starts is accumulated for today, yesterday, and the overall total.
Standard Screw Compressor - RWB Series Variable VI Status Screen The Variable Vi Status screen displays information pertaining to the Variable Vi Con- trol option. M & M REFRIGERATION 8:32 1. START VARIABLE VI STATUS STATS 3. MODE VI POSITION X.XX...
Chapter 3: Operational Procedures Economizer Status Screen (Option) The Economizer Status screen displays information pertaining to the Economizer Control option. This screen is only present if the Economizer Control option is enabled. M & M REFRIGERATION 8:32 1. START ECONOMIZER STATUS STATS 3.
Standard Screw Compressor - RWB Series Active Alarms & Failures Status Screen The Active Alarms & Failures status screen displays the system's current Alarms/Fail- ures. This screen will be the initial screen displayed by the system when an alarm or failure first becomes active.
Chapter 3: Operational Procedures Auto-Start Warning Screen The Auto-Start Warning screen is displayed anytime the screw may be automatically started. The user can return to the system default status screen by pressing the QUIT key or cycle through all the status screens using the ENTER key. The system will return to the Auto-Start Warning screen after 10 minutes of keypad inactivity.
Standard Screw Compressor - RWB Series MODE Hot Key The MODE hot key allows the operator to select the system's operational mode. When the MODE hot key is selected, a menu screen displays the available modes contained on the system. This menu screen could have up to six mode options: Manual, Automatic, Remote, Auto-Remote, Sequenced, and Local.
Chapter 3: Operational Procedures Remote Mode The Remote mode is only available if the Remote option is enabled. It is primarily used for systems where another control system is responsible for starting, stopping, and capacity control. Remote mode uses an external Remote Start/Stop input and Remote Load and Unload inputs for capacity control.
Standard Screw Compressor - RWB Series SETPT Hot Key The SETPT hot key allows the user to access a set of menu options used to set the sys- tems various setpoints SETPT PRESSURE SUCTION CONTROL GROUP HIGH SUCTION DISCHARGE OIL FILTER...
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Chapter 3: Operational Procedures day mm/dd/yy hh:mm:ss SUCTION PRESSURE CONTROL GROUPS ACTIVE GROUP > S1 GROUP S1 GROUP S2 GROUP S3 GROUP S4 -------- -------- -------- -------- CUT-IN XX.X PSIG XX.X PSIG XX.X PSIG XX.X PSIG CONTROL XX.X PSIG XX.X PSIG XX.X PSIG XX.X PSIG CUT-OUT...
Standard Screw Compressor - RWB Series High Suction Pressure Setpoints The High Suction Pressure alarm and failure setpoints are not scheduled and are active regardless of which group is in control. M & M REFRIGERATION 8:32 HIGH SUCT SETPTS 1. START 2.
Chapter 3: Operational Procedures Discharge Pressure Setpoints The Discharge Pressure Setpoints screen is used to set the discharge pressure control parameters for high alarm, limiting, and ramp conditions day mm/dd/yy hh:mm:ss DISCHARGE PRESSURE SETPOINTS HIGH FAILURE XXX.X PSIG HIGH ALARM XXX.X PSIG HIGH UNLOAD XXX.X PSIG...
Standard Screw Compressor - RWB Series Oil Pressure Setpoints The Oil Pressure Setpoints screen allows the operator to set acceptable ranges for the oil pressure parameter to allow the CCS to identify when the value is out of range. An example of the screen is shown below.
Chapter 3: Operational Procedures Oil Filter Pressure Setpoints The Oil Filter Setpoints screen allows the operator to set an acceptable range for the oil filter pressure as shown in the following example. The displayed oil pressure is a computed value. The computation of this value is NOTE: different based on the compressor model.
Standard Screw Compressor - RWB Series Temperature Setpoints The Temperature Setpoints menu allows the user to set temperature related set- points described in the following sections. Discharge Temperature Setpoints The Discharge Temperature Setpoints screen allows the operator to set accept- able ranges for the screw discharge temperature.
Chapter 3: Operational Procedures Oil Temperature Setpoints (without Liquid Injection) The Oil Temperature Setpoints screen allows the operator to set acceptable ranges for the screw oil temperature and oil sump temperature regulation. M & M REFRIGERATION 8:32 OIL TEMP SETPTS 1.
Standard Screw Compressor - RWB Series Oil Temperature Setpoints ( with Liquid Injection) The liquid injection option adds two additional setpoint to the oil temperature set- point screen. An example of the optional oil temperature setpoint screen is as fol- lows.
Chapter 3: Operational Procedures Process Temperature Control Group The Process Temperature Control Group screen is used to setup the Process Temperature control parameters when the Process Temperature Control option is enabled. day mm/dd/yy hh:mm:ss PROCESS TEMPERATURE CONTROL GROUPS ACTIVE GROUP GROUP P1 GROUP P2 GROUP P3...
Standard Screw Compressor - RWB Series High Process Temperature Selection The High Process Temperature Setpoints screen is only visible when the Process Temperature Control option is enabled. M & M REFRIGERATION 8:32 1. START PROCESS TEMP SETPTS 2. STATS 3. MODE HIGH FAILURE XXX.X...
Chapter 3: Operational Procedures Motor Current Setpoints The Motor Current Setpoints screen is used to set the motor current control parame- ters for high alarm, limiting, and ramp conditions. day mm/dd/yy hh:mm:ss MOTOR CURRENT SETPOINTS HIGH FAILURE XXX.X PSIG HIGH ALARM XXX.X PSIG HIGH UNLOAD XXX.X PSIG...
Standard Screw Compressor - RWB Series Slide Valve Setpoints The Slide Valve Setpoints screen allows the operator to set acceptable ranges for minimum slide valve position as shown in the following example. SLIDE VALVE POSITION day mm/dd/yy hh:mm:ss SETPOINTS AUTO CAPACITY MAX POSITION XXXX.X PCT...
Chapter 3: Operational Procedures SCHED Hot Key The Scheduling function allows the user to create and modify schedules to control the changing of suction pressure setpoints based on the day of the week and time of day. The following sections will describe the various screens associated with this function. SCHED CONTROL ACTIVE GROUP...
Standard Screw Compressor - RWB Series Active Group The Active Group screen allows the user to select the current active group. This set- ting will be active until a scheduling change or the operator modifies it. An example of the screen is shown below.
Chapter 3: Operational Procedures Active Schedule The Active Schedule screen allows the user to change the current active daily sched- ule. This setting will be active until a scheduling change or the user modifies it. An example of the screen is shown below. M &...
Standard Screw Compressor - RWB Series Weekly Schedule The Weekly Schedule screen is used to define which of the seven available daily schedules is to be assigned to each day of the week as shown in the following exam- ple screen.
Chapter 3: Operational Procedures Schedule 1 To Schedule 7 The seven Daily Schedules all have a standard format allowing the user to select up to 8 schedule changes per day. The following example shows the standard for- mat for all seven of the daily schedules. DAILY SCHEDULE day mm/dd/yy hh:mm:ss EVENT...
Standard Screw Compressor - RWB Series CNTRL Hot Key The CNTRL hot key allows the user to access a set of menu options used to set the sys- tems control features. CNTRL 1. SUCTION PRESS 2. PROCESS TEMP 3. ECONOMIZER 4.
Chapter 3: Operational Procedures The following table lists the data entry and information fields on the screen and a description of their purposes. PARAMETER DEFINITION RANGE NORMAL Adjusts the sensitivity of the time proportional control routine. 0 - 20 PSID BANDWIDTH CONTROL The slide valve will not be adjusted if the suction pressure is within...
Standard Screw Compressor - RWB Series The following table lists the data entry fields and a description of their purposes. PARAMETER DEFINITION RANGE NORMAL Adjusts the sensitivity of the time proportional control routine. 0 - 20 DEG BANDWIDTH CONTROL The slide valve will not be adjusted if the Process Temperature is...
Chapter 3: Operational Procedures The following table lists the data entry fields and a description of their purposes. PARAMETER DEFINITION RANGE AUTO CONTROL MAN ON Selects the operational mode for the Economizer. MODE MAN OFF When the Economizer is in Automatic mode, the Economizer CUT-IN Solenoid output will be energized when the Slide Valve Position is 0 - 100 PCT...
Standard Screw Compressor - RWB Series MISC Hot Key The Miscellaneous Control screen provides setpoints and controls for various system parameters. MISCELLANEOUS CONTROL day mm/dd/yy hh:mm:ss AUTO START/STOP DISABLE POWER FAIL RESTART DISABLE POWER FAIL RESTART DELAY XXX.X MIN CAPACITY CONTROL PARAMETER...
Chapter 3: Operational Procedures LOGS Hot Key The LOGS hot key is fully described in Chapter 4, Logging Functions. MENUS Hot Key The MENUS hot key is fully described in Chapter 5, Menu Functions. . 3-57 M&M R EFRIGERATION...
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Standard Screw Compressor - RWB Series 3-58 M&M R EFRIGERATION...
Logging Functions CHAPTER 4 The CCS records the systems parameters and conditions for later use in a set of logs. Each log has a limit on the number of entries that it can store, so as the log fills-up the oldest entries are replaced by the most recent ones.
Standard Screw Compressor - RWB Series Logging Functions Technical Overview The following sections will discuss the overall function of each of the five standard logs as well as the optional KW and System Logs. Operations Log The Operations Log displays a list of the system operating conditions for the last hour at 30-second intervals and has a limit of 255 recorded data entries.
Chapter 4: Logging Functions Technical Overview KW Log (Optional) The KW Log is an optional daily log included when the KW Monitoring option is included in the system. It is used to record the periodic totals for Demand KW, Peak Demand, and Daily, Weekly, Monthly and Yearly usage.
Standard Screw Compressor - RWB Series Logging Functions Operating Procedures The Log Function is accessed by the operator through the LOGS hot key. This hot key allows the user to view or erase any of the systems available logs. A diagram of the available menu options under the LOGS hot key is shown below.
Chapter 4: Logging Functions Operating Procedures Operations and Trend Logs The Operations and Trend Logs typically store the same parameters. The only difference is the time interval at which entries are made. The logs will also indicate which parame- ters have caused an alarm or failure by placing an indicator next to the responsible param- eter.
Standard Screw Compressor - RWB Series Alarm and Failure Logs The Alarm and Failure Logs are records of the system alarm and failure conditions. The screen format is the same for both logs, except for the TYPE column. ALARM LOG...
Chapter 4: Logging Functions Operating Procedures User Log The User Log is a record of the last 50 user logons for the system. The following is an example of a typical User Log screen. USER LOG day mm/dd/yy hh:mm:ss USER TIME DATE NUMBER...
Standard Screw Compressor - RWB Series KW Log (optional) If the option is supported by your system configuration, data for KW usage is entered in the optional KW Log daily at midnight and can be reviewed by accessing the KW Log function.
Chapter 4: Logging Functions Operating Procedures Clear Logs The Clear Logs function is typically not available to the user. A special one-time password is required from M&M to access this function. Please contact the M&M service depart- ment if you desire to clear the logs. Clear Std Log The Clear Std (Standard) Logs menu entry provides a method of erasing all the data currently contained in the six logs available for a standard system configuration.
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Standard Screw Compressor - RWB Series 4-10 M&M R EFRIGERATION...
Menu Functions CHAPTER 5 The MENUS Hot Key allows the user to access miscellaneous screens that do not fall under one of the other hot key categories. The system supports the following four additional menus: • Logon User • Logoff User •...
Standard Screw Compressor - RWB Series Diagnostics Menu The Diagnostics menu option permits the user to view basic information about the sys- tem. The information can then be used to readily troubleshoot problems when they occur. Most of the screens available under this menu option are view-only screens and informa- tion displayed cannot be changed by the user.
Chapter 5: Technical Overview Override Discrete I/O (Option) The Override Discrete I/O screen allows the user to set the state of certain discrete outputs. It also allows the user to simulate certain discrete inputs to an active or inac- tive state. This feature is for diagnostics purposes only and will only function if the system is off-line.
Standard Screw Compressor - RWB Series Static Sensor Calibration Static calibration is performed to reset or restore sensor calibration values after a hardware, software or factory configuration change. The previous dynamic cali- bration results are shown on the Static Sensor Calibration screen to allow the user to re-enter the values manually or perform a Restore operation to reset the minimum and maximum range values for the previous calibration results.
Chapter 5: Technical Overview Initialization The Initialization menu selection under the Setup group allows the user to reset the system or restore factory setpoints. Power Fail Reset Choosing Power Fail Reset causes the software to restart using current setpoints as if a power failure occurred. Set Factory Configuration Set Factory Config will initialize the system using the preset default factory config- uration values.
Standard Screw Compressor - RWB Series Operational Procedures A diagram of the screens available under the MENUS Hot Key is shown below. Note that some screens are optional and may not be accessible on all compressors. MENUS 1. LOGON USER 2.
Chapter 5: Operational Procedures Logon User To log onto the system the user selects the Logon User option and enters the appropriate user password. Once a password is accepted the system allows access according to the restrictions preset by the CCS system manager. Below is an example of a logon screen. M &...
Standard Screw Compressor - RWB Series Diagnostics The Diagnostics menu option permits the user to view and in some cases alter basic infor- mation about the system. The menu selections include viewing System Information, View- ing IO, Analogs, and dip switches; and viewing Network Communications.
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Chapter 5: Operational Procedures System Information The System Information screen is used to provide the user with the system options and software configuration status. An example of a System Information screen is shown below. SYSTEM INFORMATION day mm/dd/yy hh:mm:ss M & M REFRIGERATION INC, COPYRIGHT 2000 FRAME STATISTICS M&M SCREW mm dd yyyy hh:mm:ss v2.05...
Standard Screw Compressor - RWB Series View Discrete I/O The View Discrete I/O screens are information screens used for viewing purposes only as shown in the following example. SCREW day mm/dd/yy hh:mm:ss DISCRETE I/O RACK 1A NAME STATE NAME STATE...
Chapter 5: Operational Procedures View Analogs The View Analog Inputs screen can be viewed by the operator and will be displayed on a screen similar to the following example. Screen Type - Information SCREW day mm/dd/yy hh:mm:ss ANALOG INPUTS NAME VALUE UNIT HEX NAME VALUE UNIT HEX...
Standard Screw Compressor - RWB Series View Dip Switches The screen shown below is an example of the View Dip Switches screen used for ver- ifying the position of the dip switches on the microprocessor board. NOTE: Dip switches should only be adjusted by qualified personnel.
Chapter 5: Operational Procedures View Network Comm The View Network Comm screen allows the user to monitor the status of the system's communication links. The screen shown below is an example of a View Network Comm screen. COMMUNICATIONS STATUS mm/dd/yy hh:mm:ss MODEM MASTER...
Standard Screw Compressor - RWB Series Override Discrete I/O The Override Discrete I/O screens allow discrete Inputs and Outputs to be simulated whenever the compressor is stopped (some channels are not assigned). Any overrid- den channels will be restored to normal when the compressor is started.
Chapter 5: Operational Procedures Setup The Setup menu allows the user to perform miscellaneous setup changes, which are used to configure the system. The menu selections include Set Time Date, Calibrate Sensors, Password Control, Initialization, and Configuration. M & M REFRIGERATION 8:32 1.
Standard Screw Compressor - RWB Series Set Date & Time The Set Date & Time screen allows the user to change the date, clock mode or time of day for the system. The clock mode gives the user the ability to display time in 24 hour or 12 hour modes.
Chapter 5: Operational Procedures Calibrate Sensors The Calibrate Sensors menu allows the user to adjust the range of sensor inputs. There are two types of calibration, Dynamic and Static. Dynamic calibration is used primarily for accurate calibration of sensor inputs where the sensor is being compared to known system conditions.
Standard Screw Compressor - RWB Series Dynamic Sensor Calibration Dynamic Sensor Calibration is described more fully in the Technical Overview section of this chapter. SCREW COMPRESSOR day mm/dd/yy hh:mm:ss DYNAMIC SENSOR CALIBRATION NAME VALUE UNIT NAME VALUE UNIT -- -------------------- ------- ----...
Chapter 5: Operational Procedures Static Sensor Calibration Static Sensor Calibration is described more fully in the Technical Overview sec- tion of this chapter. SCREW COMPRESSOR day mm/dd/yy hh:mm:ss STATIC SENSOR CALIBRATION SENSOR NAME UNIT SENSOR NAME UNIT ------------------- ------ ------ ---- ------------------- ----- ----- ---- SUCTION PRESS...
Standard Screw Compressor - RWB Series Add Delete User screen and the Screen Access Level screen which are discussed in the following sections. M & M REFRIGERATION 8:32 1. START PASSWORD CONTROL 1.ADD/DELETE USERS 2. STATS 2.SCREEN ACCESS LEVELS 3. MODE 4.
Chapter 5: Operational Procedures The following table lists the data entry fields and a description of their purpose. TERM DEFINITION RANGE PASSWORD The desired password for each user. 0 - 999999 The desired read and write levels for each user. The first 0 - 9 LEVEL digit is the read level and the second is the write level.
Standard Screw Compressor - RWB Series Initialization The Initialization menu selection under the Setup group includes Power Fail Reset and Set Factory Config. These screens are discussed further in the following sec- tions. M & M REFRIGERATION 8:32 1. START INITIALIZATION 1.POWER FAIL RESET...
Chapter 5: Operational Procedures Power Fail Reset Selection of this initialization option causes the software to restart using the cur- rent setpoints as if a power failure occurred. When the user selects Power Fail Reset, a confirmation screen will be displayed asking the user to verify that he wishes to reset the system.
Standard Screw Compressor - RWB Series Set Factory Config This selection allows the user to reset the system to factory default values. When the user selects the Set Factory Config menu option a confirmation screen will be displayed asking the user to verify that he wishes to reset the system to the origi- nal factory configuration.
Chapter 5: Operational Procedures Configuration The Configuration menu selection allows the user to setup various basic system parameters for the display and operation of the compressor. These parameters are usually setup once and never change. M & M REFRIGERATION 8:32 1.
Standard Screw Compressor - RWB Series Display The Display Setup screen allows the user to configure the display units, default status screen, and the compressor model for use in displaying the proper graph- ics image. DISPLAY SETUP day mm/dd/yy hh:mm:ss...
Chapter 5: Operational Procedures Communication Setup The following table is a sample Communications Setup screen for DF1 and Mod- bus Communications. COMMUNICATIONS SETUP mm/dd/yy hh:mm:ss MODBUS RTU PROTOCOL (COMM1) DF1 PROTOCOL (EXT PORT_2) ---------------------------- ------------------------- UNIT NUMBER UNIT NUMBER BAUD RATE 9600 BAUD RATE 9600...
Standard Screw Compressor - RWB Series Motor Configuration The following table is a sample Motor Configuration screen. M & M REFRIGERATION 8:32 1. START MOTOR CONFIG 2. STATS 3. MODE CT SIZE XXX.X AMPS 4. SETPT MOTOR VOLTS VOLT 5. SCHED POWER FACTOR XXX.X...
Chapter 5: Operational Procedures Set Operating Status The Set Operating Status screen is used to reset the total runtime hours and num- ber of starts following a board change or software update. M & M REFRIGERATION 8:32 1. START SET OPERATING STATUS 2.
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Alarm and Failure Data APPENDIX A The Alarm and Failure Data Appendix provides a table which describes all of the analog and discrete alarms in the system. The Level column describes the type of alarm or failure and the Default column lists the fac- tory setpoint for analog alarms.
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Standard Screw Compressor - RWB Series PARAMETER NAME LEVEL DEFAULT COMMENTS Low Oil Pressure Alarm M,D,HW Series = 22 PSIG S series = 15 PSIG A series = 15 PSIG with pump A series = 50 PSIG without pump Low Oil Pressure...
Appendix A: Discrete Alarms Discrete Alarms Parameter Name Level Comments Memory Initialized Alarm Frame Overrun Alarm Timer Allocation Fail RAM Size Failure Low Fail Indicates a hardware problem with the RAM Chip. Power Low Reset Fail The Power has drooped below a threshold but did not completely go away.
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Standard Screw Compressor - RWB Series Parameter Name Level Comments VI Sensor Fail A Series and RWB: VI Sensor Oil Level Float Fail HX Series: Oil level Float Spare All Others: Spare Oil Flow Switch Fail A Series: Oil Flow Switch...
Analog and Discrete I/O APPENDIX B The Analog and Discrete I/O section identifies the channel assignments for sensor inputs, control outputs, and status inputs for various compressor models. Analog Inputs Screw Compressor - Analog Inputs TYPE CHANNEL NAME RANGE UNITS SENSOR TYPE PRESS SUCTION PRESS 0 : 200...
Standard Screw Compressor - RWB Series Discrete I/O RACK 1 TYPE CHANNEL NAME STATE STATE NOTES OUTPUT COMPRESSOR MOTOR OUTPUT MAIN OR PRE-LUBE OIL PUMP MOTOR OUTPUT SLIDE VALVE LOAD SOL (All Others) CLOSED OPEN CAPACITY 100% (RDB) OUTPUT SLIDE VALVE UNLOAD SOL (All Others)
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Appendix B: Discrete I/O RACK 1 TYPE CHANNEL NAME STATE STATE NOTES INPUT REMOTE UNLOAD (All Others) Option REMOTE 100% CAPACITY (RDB) INPUT REMOTE START/STOP Option INPUT REMOTE SETPOINT SELECT A Option INPUT REMOTE SETPOINT SELECT B Option OUTPUT VI INCREASE SOL (All Others) CLOSED OPEN Option...
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Communication Protocols APPENDIX C Introduction The hardware interface and software protocol are defined for per- forming serial communications with the M&M Screw Compressor Computer Control System (CCS). Two open protocols are defined in this document, Modbus RTU and Allen-Bradley (AB) DF1. In each case, the implementation of each protocol is limited to the sub-set of the complete set of possible message types.
Standard Screw Compressor - RWB Series Hardware Interface Description Hardware Requirements The M&M Screw compressor uses the on-board COMM 1 port for Modbus communica- tions and PORT 2 on the optional Communications Expansion board for DF1 communica- tions. The hardware configuration for both protocols is 5-volt RS-422.
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Appendix C: Hardware Interface Description The following pin-outs apply to the Comm 0 port of the PLC/5-60 programmable controller. RS-232C RS-422A RS-423 RS-232C RS-422A RS-423 C.GND C.GND C.GND NOT USED TXD.OUT SEND COM TXD.OUT TXD.OUT TXD.OUT RXD.IN RXD.OUT NOT USED RXD.IN REC COM RXD.IN...
Standard Screw Compressor - RWB Series Message Addressing Each compressor is required to have a unique address referred to as the unit number. The unit number is initially set using dip switch SW1 on the main microprocessor board. However, the actual unit number can be changed through software by setting the Modbus or DF1 unit number on the appropriate setup screen on the controller.
Appendix C: Software Interface Description Software Interface Description Protocol Overview All communications with the M&M screw controller is on a request-response basis. The main computer is the “master” and the M&M controller is the “slave”. All messages will originate on the master with the slave responding as required. Status Only or Status and Control Options The screw compressor microprocessor communications supports two options.
Standard Screw Compressor - RWB Series MODBUS Protocol Description All transactions will be performed using the Modbus RTU transmission mode. All mes- sages will be terminated with a two-byte CRC-16. The Modbus ASCII transmission mode is not supported. The default software configuration for Modbus is shown below. Where a parameter can be changed, a range of options is also shown.
Appendix C: Software Interface Description Preset Single Register The Preset Single Register function code (0x06) is used to change the contents of a single register within the M&M controller. Any register within the Control Message and Setpoint Messages may be changed as long as the address and data are within the valid range.
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Standard Screw Compressor - RWB Series NOTE: 0x80 has been added to the function code. Unit Address 0x?? Function Code 0x90 Error Code 0x03 0x?? The following error codes are supported: ERROR CODE DEFINITION CODE Illegal Function. The function code in the message is not supported.
Appendix C: Software Interface Description DF1 Protocol Description All DF1 transactions will be performed with the M&M controller acting as a Slave unit on the network (peer-to-peer communications are not supported). All messages are termi- nated with a one-byte BCC checksum character. Transaction numbers, and message polling are required (read message responses will not return data without a poll com- mand).
Standard Screw Compressor - RWB Series Protected Typed Logical Write The following elements are required to access the data in the Control Message and Setpoint Messages using the Protected Typed Logical Write command. Control com- mands and setpoints may be written individually or in blocks. The master is responsi- ble for setting the correct element number and byte size for the message block.
Appendix C: Data Formats Error Messages The DF1 protocol provides for the return of error codes in the event of a data error within a correctly formatted message block. When the M&M controller detects an error within a read or write message, the message response will contain an extended error code (EXT STS).
Standard Screw Compressor - RWB Series Status Message Description The status message is a read-only message containing analog, discrete, alarm and state data. NOTE: Some data in the status message may not apply to your particular compressor, depending on optional equipment and features.
Appendix C: Status Message Description Discrete Input and Outputs Modbus Hex Byte Input/ Active Word Word Offset Parameter Name Output State Address Address N10: 19 40020 0026 COMPRESSOR MOTOR OUTPUT HIGH MAIN OR PRE-LUBE OIL PUMP MOTOR (Option) OUTPUT HIGH SLIDE VALVE LOAD OPTION (All Others) OUTPUT HIGH CAPACITY 75% (RDB)
Standard Screw Compressor - RWB Series Alarm and Failure Data Modbus Hex Byte Word Word Offset Parameter Name Level Address Address N10: 21 40022 002A HIGH SUCTION PRESSURE FAIL HIGH SUCTION PRESSURE ALARM LOW SUCTION PRESSURE ALARM LOW SUCTION PRESSURE...
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Appendix C: Status Message Description Alarm and Failure Data (Continued) Modbus Hex Byte Word Word Offset Parameter Name Level Address Address N10: 23 40024 002E MEMORY INITIALIZED ALARM FRAME OVERRUN ALARM TIMER ALLOCATION FAIL RAM SIZE FAILURE LOW FAIL POWER LOW RESET FAIL POWER FAIL RESET FAIL...
Standard Screw Compressor - RWB Series Alarm and Failure Data (Continued) Modbus Hex Byte Word Word Offset Parameter Name Level Address Address N10: 25 40026 0032 MASTER SHUTDOWN FAIL ECP COMM SHUTDOWN FAIL DF1 COMM SHUTDOWN FAIL VI SENSOR (A, RWB)
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Appendix C: Status Message Description 40039 004C Spare 40040 004E Spare Alarm Status Table Bits 7 6 5 4 3 2 1 0 X X X X X X X X | | | | | | | | | | | | | | | +- Alarm Active | | | | | | +--- Failure Active...
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Standard Screw Compressor - RWB Series Compressor State Table Screw State Definition Value Anti Cycle Stopped Starting Running Loading Unloading Limited - Motor Current Limited - Slide Valve Position Limited - Discharge Pressure Forced unload - Motor Current Forced unload - Discharge Pressure...
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Appendix C: Status Message Description Last Screw Start Status Table Last Start Status Value Start Disabled, Anti-Cycle Timer Running Start Disabled, Screw Failed Start Disabled, Screw Already Running Start Disabled, Start Already in Progress Screw Starting, Auto Screw Starting, Man Screw Online, Auto-Remote Screw Online, Remote Screw Online, Sequenced...
Standard Screw Compressor - RWB Series Control Message Description The Control Message is a read/write message containing fields to start and stop the compres- sor, change the compressor mode, and change the control setpoint group number. The contents of the Control Message are shown in the following table and described further in the paragraphs below.
Appendix C: Control Message Description Network In Control Command The Network In Control command is used to allow the network to enable or disable itself from controlling the system. When set to zero, the contents of the remainder of the Con- trol Message, the Suction Pressure Setpoint Message, and the Process Temperature Set- point Message will be ignored.
Standard Screw Compressor - RWB Series Set Compressor Mode Command The Set Compressor mode command is used to change the current active mode of the compressor. Normally, only the Remote and Auto-Remote modes are used by the mas- ter. Remote mode, when the network is in control, allows the master to provide load and unload commands for capacity control.
Appendix C: Control Message Description Set Economizer Mode Command The Set Economizer mode command is used to change the current active mode of the economizer but only when the economizer option is installed and the compressor is in Remote or Auto-Remote modes. Manual Start opens the economizer solenoid anytime the compressor is running.
Standard Screw Compressor - RWB Series Suction Pressure Setpoint Message Description The Suction Pressure Setpoint message is a read/write message used to display or change the four Suction Pressure control group setpoints. Suction Pressure setpoints may be read or written individually or in groups. The master is responsible for setting the correct starting address, number of registers, and the register data for the message block.
Appendix C: Process Temperature Setpoint Message Description Process Temperature Setpoint Message Description The Process Temperature Setpoint message is a read/write message used to display or change the four Process Temperature control group setpoints. This command is only used if the Process Temperature control option is enabled. Process Temperature setpoints may be read or written individually or in groups.
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