Emerson VSG & VSSG Software Manual
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Emerson VSG & VSSG Software Manual

Emerson VSG & VSSG Software Manual

Single screw compressor
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VSG & VSSG
Single Screw Compressor
Software Manual
Compact Logix PLC
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Summary of Contents for Emerson VSG & VSSG

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

  • Page 3: Important Note

    Important Note Before applying power to the control panel, all wiring to the panel shall be installed per NEC. Specifically check for proper voltage and that the neutral is grounded at the source. An equipment ground should also be run to the panel. *See Wiring Instructions and Diagrams before proceeding.

  • Page 5: Table Of Contents

    Table of Contents Important Note ....................3 VSG STANDARD VILTER WARRANTY STATEMENT ..........6 Operational Flow Charts ..................7 Main Screen ..................... 15 Log On Screen ....................16 Set Up Screen ....................17 Vilter Only Screen .................... 19 Menu Screen ....................20 Compressor Alarm and Trip ................

  • Page 6: Vsg Standard Vilter Warranty Statement

    VSG STANDARD VILTER WARRANTY STATEMENT Seller warrants all new single screw gas compression units and bareshaft single screw compressors manufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a period of (a) eighteen (18) months from the date of shipment or (b) twelve (12) months from the date of installation at the end user’s location, whichever occurs first.

  • Page 7: Operational Flow Charts

    Operational Flow Charts Requirements to Start Compressor Oil Separator Temp Filter Diff Press < Volume and > Oil Sep Start Trip Start Filter Diff Capacity slides are Setpt. Trip Setpt less than 5 %. Oil Pump On: Prelub Oil Press is > Prelub Oil Start Compressor Press Reset Setpt for “Min Compressor Prelub Timer”...
  • Page 8 Suction Pressure Control Capacity Inc WAIT Suction Press > Is Cap Inc ON Timer Is Cap Inc OFF Timer Reset Cap Inc Timers Timed Out? Timed Out? Suct Press Cap Inc Setpt? Capacity Dec Suction Press < Is Cap Dec. ON Timer Is Cap Dec.
  • Page 9 Oil Cooler Fan Control PID Control (Selectable Control Optional) 30 sec delay Oil Cooler Unit Start Increase Speed outlet temp > set pt? Oil Cooler Decrease Speed outlet temp < set pt? PID Control Oil Temperature Control Valve 30 sec delay Oil injection Unit Start...
  • Page 10 Delayed Lockout Timers WARNING: FOR THE FOLLOWING SHUTDOWNS, A DELAYED RESTART MAY OCCUR: High Discharge Pressure Failure High Compressor Discharge Temp Failure High Package Outlet Temp Failure High Oil Injection Temp Failure H1= Timer Set Between .5-6 Hours. Default Value= .5 Hours Shutdown due to Shutdown Value It been *H1...
  • Page 11 Capacity Control Using Suction Pressure Control Setpoints Start Are Motor Amps > Is Disch Is Capacity Is Suct Decrease at Start Motor Amps Load Press > High Disch Inc Cap > Min Run Cap Press > Cap Inc (Expired 15 Limit ON Setpt? Press Unload (Timer)
  • Page 12 Capacity Control Using Discharge Pressure Control Setpoints Start Are Motor Amps > Motor Amps Load Is Disch Press > Cap Dec Cap Decrease at Start Limit ON Setpt? Dec ON Setpt? (Timer) (Expired 15 sec.) (Time Delay 10 sec) Is Disch Press < Cap Inc Cap Wait Disable Cap Inc...
  • Page 13 Compressor Operation with VFD Drive Check/Adjust Capacity Slide Start Compressor Start VFD at Is Control Press. Increase or Decrease the Is Capslide @ Minimum Speed Within Setpt Compressor Capacity Slides to 100% (30 Hz Typ.) Deadbands? Match Setpoints Increase or Decrease the Compressor Capacity Slides to Match Setpoints Check/Adjust VFD...

  • Page 15: Main Screen

    Main Screen Main Screen This screen contains buttons to navigate to setpoint setup screens. This screen has been designed to give the operator Status information on the compressor, oil pump, an overall view of all operating parameters affect- oil heater and run mode. ing the compressor package.

  • Page 16: Log On Screen

    Log On Screen Log On or Off Note: An operator will be automatically logged off after 10 minutes of inactivity. Note: The machine can be run and moni- tored without logging on. To change the setup or parameters of the machine, the operator must log on.

  • Page 17: Set Up Screen

    Set Up Screen From the Main screen, touch the Setup button. After entering an authorized user name and password, the screen pictured below will appear. Pressure units,Temperature units and Suction/ Discharge Pressure control configurations are list selectable. To choose a configuration from a list: 1.) Touch the list.
  • Page 18 · Pressure Units – Select units of measure for pres- sure readings. Choices are psi, kg cm and kPa. · Temperature Units – Select units of measure for temperature. Choices are Fahrenheit or Cel- sius. · Anti-Recycle – The operator can select from the following Anti-Recycle options: True, Accumula- tive, Modified, or Hot Starts.

  • Page 19: Vilter Only Screen

    Vilter Only Screen To set and synchronize the date and time for the HMI and ControlLogix or CompactLogix processor, first con- figure the PanelView date and time then, move the PanelView’s date and time to the processor To set the date, time and regional settings in the PanelView Plus HMI: 1.

  • Page 20: Menu Screen

    Menu Screen Touch Here At the bottom of the Main screen touch the Menu button to bring up the screen shown in Figures below. Use this screen to navigate to the other setpoint screens contained within the program. Each screen has a help button to describe the function of the screen.
  • Page 21 There are three options for the Compressor Control Setpoints: Discharge Pressure Control...
  • Page 22 Suction Pressure Control...
  • Page 23 Process Temperature Control...

  • Page 24: Compressor Alarm And Trip

    Compressor Alarm and Trip Temperature Safety Changeover), this safety is · Low Suction Pressure Setpoints 1&2 – This is deactivated and the Lo Oil Separator Run Tem- the low suction pressure safety. This safety is perature is the active setpoint. active in both temperature and pressure control modes.

  • Page 25: Compressor Timer Setpoints

    Compressor Timer Setpoints To change a timer set- ting, a user with high access level must be logged on. · Capacity Decrease At Start – At compressor If the volume slide is more than 7% away from startup, the capacity motor is held at minimum the desired value, the volume slide motor is position for this time period.
  • Page 26 · Filter Differential Pressure Safety Changeover · Hot Starts / Hr Counter – This counter counts – This timer bypasses the Hi Run Filter Differen- compressor starts. After every start, a one-hour tial Pressure setting during start, to allow the timer is reset and starts timing.

  • Page 27: Compressor Control Setpoints

    Compressor Control Setpoints From the Menu screen, press the Compressor Control setpoints button. The compressor control setpoints screen will be shown. hese screens enable the operator to view and adjust settings that affect compressor control. From the Setup screen, the operator can choose the method or mode of compressor control: Compressor Control Via: 1.
  • Page 28 Discharge Pressure Control Setpoints on this screen: · Discharge Pressure On/Off – The compressor will automatically cycle ON and OFF at the setpoints entered. Discharge Pressure On/Off control is only active if the Compressor Control Via Discharge Pressure option is selected on the Setup screen. If a compressor shutdown is desired on a discharge pressure drop and a manual reset is required, set the OFF value below the Low Discharge Pressure Safety Trip value.
  • Page 29 Suction Pressure Control Setpoints on this screen: · Suction Pressure On/Off – The compressor will automatically cycle ON and OFF at the setpoints entered. Suction Pressure On/Off control is only active if the Compressor Control Via Suction Pressure option is selected on the Setup screen.
  • Page 30 Process Temperature Control Setpoints on this screen: · Process Temperature Control – Provides for a Suction Pressure Override feature. If the suction pressure should drop below the Suction Pressure Capacity Decrease OFF setpoint, the Suction Pressure Capacity Decrease OFF setpoint will override the Capacity Control F Increase and prevent the compressor capacity from increasing (loading).
  • Page 31 · Capacity Control °F Increase – The capacity of the compressor will increase when process temperature is at or above the ON setpoint, and the increase “off” timer has cycled. Capacity will continue to increase until the Capacity Control °F Increase OFF setpoint is reached. If closer system control is desired, set the ON and OFF setpoints at the same values.

  • Page 32: Additional Compressor Controls

    Additional Compressor Controls · High Discharge Pressure Unloading Setpoints temperature below the ONsetpoint energizes – Active in Suction Pressure or Process Tempera- the oil separator heater. On an increase in oil ture Capacity Control mode. These setpoints separator temperature above the OFF setpoint, limit the compressor from loading at high the oil heater is de-energized.
  • Page 33 · Oil Separator Heater Temperature – This con- trol limit determines when the oil separator · Volume Slide Adjustment Factor – This value is heater is energized. A decrease in oil separator normally zero (0) and will not require changing. temperature below the ON setpoint energizes However, if the system operating conditions the oil separator heater.

  • Page 34: Compressor Setpoints And Alarms

    Compressor Setpoints and Alarms · Prelube Oil Pressure – If the oil pressure does not · High Filter Differential Pressure Run – This safety rise above the reset setting for a time exceeding setpoint is active when the compressor is in the Minimum Compressor Prelube Time and the run cycle.

  • Page 35: Motor Speed Setpoints & Control Screen

    Motor Speed Setpoints & Control Screen VFD SCREEN SETTINGS Settings: Auto Button: Choosing Auto will do the following: While the fan is off the Output Mode will be forced to Manual Mode. When the fan starts, it will remain in Manual Mode at the Initial Speed for the period defined as Delay Auto.
  • Page 36 Max Speed Detect: Setting for PLC program detection of maximum speed. This setting will not limit the speed of the VFD. Generally, this setting is useful only when sequencing of multiple devices is used. Minimum Speed: This is the minimum speed that the PLC will send to the VFD. This is active in Manual Mode and in Auto Mode.

  • Page 37: Diagnostics Force Output

    Diagnostics Force Output WARNING: Be sure to remove all outputs from Forced-On mode before exiting this screen! To force an output, a user with high level access must be logged on first. Without sufficient access, the out- puts display without force buttons. Touch the Logon button or Set button to prompt the Logon screen. At the Logon screen, enter the user name (case sensitive) then the user’s password (case sensitive) then press the <-| enter button.

  • Page 38: Instrument Calibration

    Instrument Calibration To calibrate, a user with high level access must be logged on first. Without sufficient access, the raw input values and calibrated values display without “Calibrate” buttons. Touch the Logon button or Set button to prompt the Logon screen. At the Logon screen, enter the user name (case sensitive) then the user’s password (case sensitive) then press the <-| enter button.
  • Page 39 Instrument Calibration...
  • Page 40 Instrument Calibration Pressures Confirm the “mA Reading” value (the raw mA value at the analog module) is correct and stable. If not already done, set the Minimum mA to 4.00 If not already done, set the Maximum mA to 20.00 Set the Minimum Pressure to the actual minimum pressure at 4mA as marked on the transducer.
  • Page 41 Instrument Calibration Motor Amps Confirm the “mA Reading” value (the raw mA value at the analog module) is correct and stable. If not already done, set the Minimum mA to 4.00. This is the minimum mA expected from the current transmitter at 0 motor amps.
  • Page 42 Instrument Calibration Temperatures All RTDs are 100 ohm Pt and are scaled as such via hard-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: Oil Mixing Valve

    Oil Mixing Valve Various types of oil coolers can be used to maintain the oil injection temperature, usually either a water-cooled shell-&-tube heat exchanger mounted locally or a remotely located air- cooled fan-coil unit. In either case, the oil temperature control valve operates the same. A two-way ball valve is located in the main oil line between the oil separator and the compressor.
  • Page 44 2.0 Control Action The ball valve can rotate through a full 360° arc. The actuator restricts the ball to a 90° arc of travel. The actuator is powered (120V or 24V) all the time. The position target signal from the compressor controller is a 4-20mA analog value. There is no feedback position from the actuator.
  • Page 45 100% OPEN Oil flow stream is entirely bypassing the oil cooler 99% to 1% OPEN Oil flow stream is partially by-passing the oil cooler and partially diverted to the oil cooler 0% OPEN Oil flow stream is entirely diverted to the oil cooler 7.0 Control Settings The oil temperature control setpoints are entered on the compressor controller screen “Oil Mixing Valve PID (Oil Return from Cooler)”.

  • Page 47: Unit Start Screen (Start / Stop Logic)

    Unit Start Screen (Start / Stop Logic) Unit Start Button Pressing this button will invoke a floating button panel, called Unit Start. The operational mode of the compressor unit can 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.
  • Page 48 Auto Button In this mode the compressor will respond to its on-board settings for start, stop, load and unload commands. Manual Button In this mode the compressor will respond to operator inputs from the HMI screen. They Capacity and Volume Slide Valve Position can be adjusted by the up and down arrows that appear on the main screen.
  • Page 49 Stop Button Pressing this button will stop the compressor unit. If the compressor unit is in Central mode when the Stop button is pressed, the compressor controller enters Local-Stop-Lock mode. The central system controller will no longer be able to command the compressor controller. To return to any operational mode, see the description of Local-Stop-Lock Release Button below.

  • Page 50: Device Names

    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: Calibration Procedure Of Optical Actuators

    Calibration Procedure of Optical Actuators ACTUATOR MOTOR CONTROL MODULE CALIBRATION PROCEDURE 1. Open the plastic cover of the capacity mo- 4. Press INC and DEC to move the slide valve and tor by removing the four #10 screws. Cau- check for the correct rotation. See Table 1 for Ac- tion: there are wires attached to the con- tuator/command shaft rotation specifications.

  • Page 52: Calibration Procedure Of Optical Actuators

    Calibration Procedure of Optical Actuators Press down on the photochopper shaft to disen- 8. Note: The “Slide calibration” screen on the Con- gage the brake, releasing tension from the motor trol Panel has a “Current” window, which displays mount. Use the INC button to pulse the actuator twice the actuator output voltage.

  • Page 53: Calibration Procedure Of Optical Actuators

    Calibration Procedure of Optical Actuators 15. Use the INC button to rotate the actuator towards its maximum position while watch- ing the millivolt readout on the controller screen. Discontinue pressing the INC button when the millivolt reading in the “Current” window is approximately 4800 millivolts.

  • Page 54: Installation Instructions For Replacement Of Optical Actuator

    Installation Instructions For Replacement Of Optical Actuator CAUTION: WHEN INSTALLING THE OPTICAL SLIDE MOTOR, LOOSEN LOCKING COLLAR BEFORE SLID- ING THE COLLAR DOWN THE SHAFT. DO NOT USE A SCREWDRIVER TO PRY LOCKING COLLAR INTO POSITION. OVERVIEW Calibration of an optical slide valve actuator is a two step process that must be done for each actuator installed on the compressor.

  • Page 55: Slide Valve Actuator Theory Of Operation

    Slide Valve Actuator Theory of Operation Slide Valve Actuator Theory of Operation This scheme is not foolproof. If the motor is moved The slide valve actuator is a gear-motor with a posi- manually while the power is off or the motor brake tion sensor.

  • Page 56: Slide Valve Actuator Troubleshooting Guide

    Slide Valve Actuator Troubleshooting Guide The actuator cannot be cali- Clean the optocoupler slots with Dirt or debris is blocking one or a Q-Tip and rubbing alcohol. both optocoupler slots brated Adjust the photochopper so that The photochopper fence extends the fence extends further into the less than about half way into the optocoupler slots.

  • Page 57: Slide Valve Actuator Troubleshooting Guide

    Slide Valve Actuator Troubleshooting Guide The motor was manually moved The actuator does not trans- Recalibrate. while the position sensor was not mit the correct position after a powered. power loss The motor brake is not working Get the motor brake to where properly it operates freely and then recalibrate.

  • Page 58: Slide Valve Actuator Troubleshooting Guide

    Slide Valve Actuator Troubleshooting Guide The motor runs sporadically Bad thermal switch Replace the actuator. Any of the reasons listed in “The mo- See above. tor will not move in either direction” The motor runs but output Stripped gears inside the gear motor Replace the actuator.

  • Page 59: Command Shaft Rotation And Travel

    Command Shaft Rotation and Travel NOTES: The large gear on the command shaft has 50 teeth. The teeth are counted when moving the com- mand shaft from the minimum stop position to the maximum stop position. The manual operating shaft on the gear motor should be turned the opposite direction of the desired command shaft rotation.

  • Page 60: Safety Failure Message

    Safety Failure Message Suction Pressure SP#1 Fail - This message will appear when the suction pressure falls below the safety setting of the Lo Suction Pressure Trip Setpoint No. 1. In addition, this message will appear when the suction pressure reading rises above 300 PSI, indicating an open transducer or bad analog channel.

  • Page 61: Safety Failure Message

    Safety Failure Message Oil Separator Start Temp Fail – This message will appear when the Oil Separator Temp is below the Low Oil Separator Start Temp Trip setpoint. In addition this message will appear after the Oil Separator Temp Safety Changeover timer times out and the Oil Separator temperature fails to rise above the Low Oil Separator Start Temp Reset after the compressor is started.

  • Page 62: Safety Failure Message

    Safety Failure Message Filter Inlet Pressure Fail – This message will appear with the manifold pressure rises above 300 PSI or falls below 30” Hg. Start Filter Diff Press Fail – This message will appear if the Filter Differential pressure rises above the High Fltr Diff Press – Start setpoint before the Filter Differential Pressure Safety Changeover timer times out.

  • Page 63: Version Screen

    Version Screen This screen lists a hard-coded version description of the PanelView-Plus HMI file and active information regarding the ControlLogix processor. Active Logix processor information are real-time statuses via the Ethernet link between the HMI and the Logix processor. Logix processor information displayed: 1.

  • Page 64: Trend Charts

    Trend Charts The trend analysis screens display historic data of the last 300,000 records of analog values. The following historical chart periods are available by touching the buttons along the right side of the screen: 3 minutes, 15 minutes, 30 minutes, 1 hour, 2 hours, 6 hours, 12 hours, 1 day, 2.5 days, 5 days. * Back button: Displays chart of previous period.

  • Page 65: Trend Charts

    Trend Charts The standard values recorded are: Pressures - displayed on page 1: Suction Pressure Displayed as a bold, solid blue line Discharge Pressure Displayed as a bold, solid bright-green line Oil Injection Differential Pressure Displayed as a bold, solid red line Oil Filter Differential Pressure Displayed as a bold, solid pink line Temperatures - displayed on page 1:...
  • Page 66 Troubleshooting: Problem: Trend charts no longer display historical data but only update with real-time data which re- initializes each time the chart is displayed. Cause: Time and/or Date of HMI was changed so logged data file cannot be sensible. Solution: From the Vilter Only screen (password protected) Clear the log files of the PanelView. a.

  • Page 67: Captured Data At Shutdown

    Captured Data at Shutdown The Captured at Shutdown screen shows data captured prior to compressor shutdown.
  • Page 78 COMPONENT IDENTIFICATION COMPONENT IDENTIFICATION FUSE REPLACEMENT VILTER PART CL1, DIV 2 VILTER PART CL1, DIV 2 VILTER PART ITEM QUANTITY MANUFACTURE NUMBER DESCRIPTION APPROVED ITEM QUANTITY MANUFACTURE NUMBER DESCRIPTION APPROVED ITEM MANUFACTURE NUMBER DESCRIPTION ALLEN BRADLEY 3252AA COMPACT LOGIX PROSESSOR 1.5M MEMORY WITH ETHERNET ALLEN BRADLEY 3090BCD2 FUSE BLOCK TERMINAL...
  • Page 80 Contact Person Salesman 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...
  • Page 86 P.O. Box 8904 Cudahy, WI 53110-8904 P: 414-744-0111 F: 414-744-1769 (04/2010) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affi liated companies. ©2010 Emerson Climate Technoligies, Inc. All rights reserved. Printed in the USA. 35391CL Rev. 3...

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