Emerson VSSG 291, VSSG 601, VSSG 341, VSSG 451, VSG 751 Software Manual

VSG & VSSG

Single Screw Compressor

Software Manual

Compact Logix PLC

1

2

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.

NOTES:

• Before start-up you need to enter all system values and options, see section on Setpoint Values.

• Power circuits entry on left side of enclosure

• Instrument circuits entry on right side of enclosure

Electrical installation shall be completed by a licensed electrician qualified in field wiring

located in Class 1 Div 2 Hazardous Locations per the National Electric Code (NEC).

3

4

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

............................................................................. 24

Compressor Control Setpoints ......................................................................... 27

Additional Compressor Controls ...................................................................... 32

Compressor Setpoints and Alarms
Motor Speed Setpoints & Control Screen

................................................................... 34

.........................................................35

Diagnostics Force Output ................................................................................37

Instrument Calibration ....................................................................................38

Oil Mixing Valve ...............................................................................................43

Unit Start Screen (Start / Stop Logic)
Device Names

..................................................................................................50

................................................................47

Calibration Procedure of Optical Actuators ...................................................... 51

Calibration Procedure of Optical Actuators ...................................................... 52

Calibration Procedure of Optical Actuators ...................................................... 53

Installation Instructions For Replacement Of Optical Actuator
Slide Valve Actuator Theory of Operation

........................................................ 55

.........................54

Slide Valve Actuator Troubleshooting Guide ....................................................56

Slide Valve Actuator Troubleshooting Guide ....................................................57

Slide Valve Actuator Troubleshooting Guide ....................................................58

Command Shaft Rotation and Travel
Safety Failure Message

....................................................................................60

................................................................ 59

Safety Failure Message .................................................................................... 61

Safety Failure Message .................................................................................... 62

Version Screen .................................................................................................63

Trend Charts

....................................................................................................64

Trend Charts .................................................................................................... 65

Captured Data at Shutdown

............................................................................ 67

Appendix A: Slide Valve Actuator Troubleshooting Guide
Appendix B: Drawings and Parts Lists

5

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.

If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product
shall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation
and Buyer’s exclusive remedy hereunder and shall be conditioned upon (a) Seller’s receiving written notice
of any alleged defect within ten (10) days after its discovery, (b) payment in full of all amounts owed by
Buyer to Seller and (c) at Seller’s option, Buyer shall have delivered such products to Seller, all expenses
prepaid to its factory. Expenses incurred by Buyer in repairing or replacing any defective product
(including, without limitation, labor, lost refrigerant or gas and freight costs) will not be allowed except by
written permission of Seller. Further, Seller shall not be liable for any other direct, indirect, consequential,
incidental, or special damages arising out of a breach of warranty.

This warranty is only applicable to products properly maintained and used according to Seller’s
instructions. This warranty does not apply (i) to ordinary wear and tear, damage caused by corrosion,
misuse, overloading, neglect, improper use or operation (including, without limitation, operation beyond
rated capacity), substitution of parts not approved by Seller, accident or alteration, as determined by Seller
or (ii) if the product is operated on a gas with an H2S level above 100 PPM. In addition, Seller does not
warrant that any equipment and features meet the requirements of any local, state or federal laws or
regulations. Products supplied by Seller hereunder which are manufactured by someone else are not
warranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products
that Seller may have from the original manufacturer. Labor and expenses for repair are not covered by
warranty.

THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND
WARRANTIES, EXPRESS OR IMPLIED, AND SELLER EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Any description of the products, whether in writing or made orally by Seller or Seller’s agents,
specifications, samples, models, bulletins, drawings, diagrams, engineering sheets or similar materials used
in connection with Buyer’s order are for the sole purpose of identifying the products and shall not be
construed as an express warranty. Any suggestions by Seller or Seller’s agents regarding use, application or
suitability of the products shall not be construed as an express warranty unless confirmed to be such in
writing by Seller.

6

Requirements to Start Compressor

Operational Flow Charts

Volume and

Capacity slides are

less than 5 %.

Oil Separator Temp
> Oil Sep Start

Trip

Setpt.

Oil Pump On: Prelub Oil Press is > Prelub Oil
Press Reset Setpt for “Min Compressor Prelub
Timer” setting (Default 7 Seconds)

Critical Compressor Run Logic @ Compressor Start

Start

Compressor

Compressor

Start Mode

Prelube 5

Seconds

Satified Oil

Pressure

Filter Diff Press <

Filter Diff

Start
Trip Setpt

Is Run Oil Press >

Run Oil Press setpt?

Yes

Yes

Start Compressor

Is

Run Oil Press >

Run Oil Press

setpt?

Reset

(Default 40 PSI)

No

Run Oil Press Failure

“Filter Diff Press Safety

Changeover” timer expires

(60 sec after start).

Compressor Amperage Load Limiting

Is

Motor Amps >

FLA (ON

)

Setpt?

Yes

No

Capacity INC Disabled

No

Is

Motor Amps >

Max (OFF

)

Setpt?

Yes

Is

Filter Diff < Hi Filter

Diff Press Run Trip

setpt?

No

Oil Separator Temp
Safety Changeover

Yes Yes

Timer expires. (5 min
after start)

Is

Oil Sep Temp > Lo

Oil Sep Run Reset

setpt:?

No

Run Filter Diff Press Failure Lo Run Oil Sep Temp Failure

High Disch Pressure Load Limit

Is
Normal Loading &
Unloading

Disch Press >

Cutin (ON

)

Normal Loading &

No

Unloading

Setpt?

Yes

Capacity INC Disabled

No

Capacity Decrease
until Amps < FLA x

1.0625

Is

Disch Press >

Cutout (OFF

Setpt?

)

Capacity Decrease until

Yes

DischPress < ON Setpt x

1.0625

Yes

Run

7

Suction Pressure Control

Is

Suction Press >

Suct Press Cap Inc

Setpt?

No

No

Is

Suction Press <

Suct Press Cap

Dec Setpt?

Suction Pressure Safety

Capacity Inc

No No

Yes Yes Yes

Is Cap Inc ON Timer

Timed Out?

No

WAIT

Is Cap Inc OFF Timer

Timed Out?

Capacity Dec

Is Cap Dec. ON Timer

Yes Yes Yes

Timed Out?

Is Cap Dec. OFF Timer

Timed Out?

No

Reset Cap Inc Timers

Reset Cap Dec Timers

Suct Press Alarm

No

Is

Suction Press <

Setpt?

No

Is

Suction Press <

Suct Press Trip

Setpt?

Yes

Yes

Lo Suction Press

Alarm

Lo Suction Press

Failure

8

Oil Cooler Fan Control

(Selectable Control Optional)

Unit Start

Oil Cooler

outlet temp >

set pt?

NoNo

Oil Cooler

outlet temp <

set pt?

Yes

Yes

PID Control

30 sec

delay

Increase Speed

Decrease Speed

Oil Temperature Control Valve

Unit Start

No No

Oil injection

temp > set pt?

Oil injection

temp < set pt?

Yes

Yes

PID Control

30 sec

delay

Modulate valve

Modulate valve

9

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

Shutdown due to

Operational

Failure

1 min Delay

Auto Restart if All Other Values

Are In Range

WARNING: INCASE OF A POWER FAILURE A DELAYED RESTART MAY OCCUR:

Shutdown Due

to Power Failure

Power Re-

establishing

Is

Shutdown Value

Below Reset

Value?

No

Yes

No

No

Lockout

Requires

Manual Restart

Yes Yes

No

Has
It been *H1
Hours Since

Shutdown?

Have

There Been 3 Shutdowns of “Any

of the Above Failure Conditions”

in H2 Hours

Yes

Has
It been *H3
Hours Since

Shutdown?

H1= Timer Set Between .5-6 Hours.
Default Value= .5 Hours

Yes

H2= Timer Set Between 4-100 Hours.
Minimum and Default Value= 4 Hours
H2 must be equal to or greater than 4 x H1

H3= Timer Set Between .5-6 Hours.
Default Value= .5 Hours

Auto Restart if All Other Values

Are In Range

Yes

10

1 min Delay

Was Compressor

Running During Power

Failure?

No

No

No

Lockout

Requires

Manual Restart

Have

There Been 3 Shutdowns

of This Same Condition

in H4 Hours

H4= Timer Set Between 4-100 Hours.
Minimum and Default Value= 4 Hours
H4 must be equal to or greater than 4 x H3

Yes

Capacity Control Using Suction Pressure Control Setpoints

Start

Are Motor

Has

Decrease at Start

(Expired 15

sec.)

Yes No No Yes Yes

Amps >

Motor Amps Load

Setpt?

Limit ON

(Time Delay

10 sec)

Press > High Disch

Is Disch

Press Unload

OFF

Setpt?

Is Capacity

> Min Run Cap

OFF

Setpt?

Is Suct

Press > Cap Inc

ON

Setpt?

Inc Cap
(Timer)

No

Wait

Yes

Disable Cap Inc

Are Motor

Amps >

Motor Amp Load Limit

OFF

Setpt?

Yes

Dec Cap

(Timer)

Yes

Disable Cap Inc

Is Disch

Press > High Disch

Press Unload

ON

Setpt?

Yes

No Change No Change

Dec Cap
(Timer)

No

Increase Cap

(Timer)

No

Is Suct Press< Cap

Dec ON

Setpt?

Yes

Dec Cap

(Timer)

No

11

Capacity Control Using Discharge Pressure Control Setpoints

Start

Are Motor

Has
Decrease at Start
(Expired 15 sec.)

Yes Yes

Amps >

Motor Amps Load

Limit ON

Setpt?

(Time Delay

10 sec)

No

Is Disch Press > Cap

Dec ON

Setpt?

Dec Cap

(Timer)

No

Wait

Yes

Disable Cap Inc

Are Motor

Amps >

Motor Amp Load Limit

OFF

Setpt?

Yes

Dec Cap

(Timer)

No

No

Change)

No

Is Disch Press < Cap

Inc ON

Setpt

No

Yes

Inc Cap
(Timer)

No

change

12

Compressor Operation with VFD Drive

Start

Compressor

Check/Adjust Capacity Slide

No

Start VFD at

Minimum Speed

(30 Hz Typ.)

Is Control Press.

Within Setpt

Deadbands?

Yes

Check/Adjust VFD

Is Control Press @

Setpoint?

Yes

Is Motor Speed @

Min?

No

No

Increase or Decrease the

Compressor Capacity Slides to

Match Setpoints

Increase or Decrease the

Compressor Capacity Slides to

Match Setpoints

Increase or Decrease Motor Speed

@ Rate Defined by VFD PID

Parameters

No

Is Capslide @

100%

Yes

13

14

Main Screen

Main Screen

This screen has been designed to give the operator
an overall view of all operating parameters affect­ing the compressor package. This screen should

always be displayed when maintenance items and
setpoint items are not being performed.

Status information such as Alarms and Trips are
displayed on the screen.

This screen contains buttons to navigate to setpoint
setup screens.

Status information on the compressor, oil pump,
oil heater and run mode.

Start/Stop buttons.

Hour meter.

Motor amperage.

Compressor operating conditions.

15

Log On or Off

Log On Screen

Note: An operator will be automatically
logged off after 10 minutes of inactivity.

Note: The machine can be run and moni­tored without logging on. To change the
setup or parameters of the machine, the
operator must log on.

Press Log on Button and the above screen will ap­pear. When altering setpoints, log on is necessary.
Select appropriate user name and enter password
to change/access setpoints.

To Log On: Touch the current User Name in the white
User Name box to display the keypad. Enter your User
Name (case sensitive) and Password (case sensitive)
then touch the <_| enter key.

Some Users are configured such that their passwords
may be changed. To change a User’s password,
touch the Password box or the “abc” button then
enter the old password, new password and confirm
the new password.

To Log Off: Touch the Log Off button. This will return
to the DEFAULT low-level user. The DEFAULT user
may navigate to most screens but cannot change
settings.

16

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. 2.) Touch the Up or Down Arrow to move the
green cursor “>” along side of the desired configura­tion. 3.) Touch the Enter button. This will highlight­green the chosen configuration.

Touch Here

17

· Pressure Units – Select units of measure for pres-
sure readings. Choices are psi, kg cm2 and kPa.

· Temperature Units – Select units of measure
for temperature. Choices are Fahrenheit or Cel­sius.

· Anti-Recycle – The operator can select from the
following Anti-Recycle options: True, Accumula­tive, Modified, or Hot Starts. These select the
strategy used to prevent excessive start/stop
cycles of the compressor. Timers and counters
used to enforce anti-recycling are adjusted and
monitored in the Compressor Timer Settings
screen, reached from the Menu screen. Help
for the Timer Settings screen explains how the
different settings and strategies operate.

· Compressor Control Via – Operator can choose
the method or mode of compressor control.
This determines which measured variable is used
in making loading (capacity control) decisions.
The choice selected here determines which
setpoints are made available for adjustment on
the Compressor Control Setpoints screen.

· Slide Non-Movement – Alarm enable and dis-
able buttons permit selecting whether an alarm
should be generated when failure of slides to
move is detected.

· Reset After Power Fail – When Auto is selected,
the compressor will attempt to restart on pow­ering up if it was running in ‘Auto’ when powered
down and enabling conditions are met. When
‘Manual’ is selected, the compressor powers up
into the ‘Stop’ mode and an explicit command
to run is required from an operator or comms
channel.

· Min Run Capacity – When enabled, the Minimum
Run Capacity setting on the Addition Compres­sor Setpoints screen operates as described in the
help for that screen. When multiple compressor
sequencing is used, selecting Disable here does
not interfere with use of the Min Run Capacity
setting in the sequencing logic.

18

Vilter Only Screen

To set and synchronize the date and time for the HMI and ControlLogix or CompactLogix processor, first con­figure 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. Display the Vilter Only Screen (This screen has restricted access).

2. Touch the PanelView Configuration button.

3. Wait approximately 30 seconds while the PanelView application shuts down then loads.

4. Touch the Thermal Settings button.

5. Scroll to or touch the Time/Date/ Regional Settings field then touch the Enter button.

6. Set the Date, Regional Settings. Time and Time Zone as applicable. Touch OK after setting each
screens’ values to accept the new values.

7. When finished, touch the Close button to exit the Time/Date/Regional Settings screen.

8. IMPORTANT: Clear the log files of the PanelView after changing the PanelView Date and/or time.
a. Touch or scroll to the File Management field then touch the Enter Button.
b. Touch or scroll to the Delete Files field then touch the Enter button.
c. Touch or scroll to the Delete Log Files field then touch the Enter button.
DO NOT DELETE APPLICATIONS! DO NOT DELETE FONTS!
d. Touch “Yes” to delete the log files.
e. Touch the Close button twice to return to the Terminal Settings screen.

9. Touch the Close button twice again to return to the Terminal Settings screen.

10. Touch the Reset button then “Yes” button to reset the PanelView.

To synchronize the ControlLogix or CompactLogix date and time to the PanelView date and time:

1. Display the Vilter Only Screen (This screen has restricted access).

2. Touch the “Touch to Synchronize CLX Clock to HMI” button.

19

Touch Here

Menu Screen

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.

There are several buttons that are common for all menu screens:

Return to Menu – This button always returns you to the Menu screen

Logon To Edit – The user is allowed to view data at all screen levels but cannot edit data until a login has occurred.

Refer to the Logon Instructions on page 21.

Set – To change a value, the operator must first press the SET button and then the text field of the value they

want to modify. A number pad will pop up for ease in entry.

Help – This screen will provide more information to the user about the operation of the microprocessor.

Event List – provides a chronological event listing.

Chart – Provides a line graph showing process values over a range of time.

Auto – Places the capacity slides into automatic mode. In automatic mode, the capacity slide moves according

to control setpoint information.

Manual – Places the capacity slides into manual mode. In manual mode, the capacity slide moves moves based

on input from the operator.

20

There are three options for the Compressor Control Setpoints:

Discharge Pressure Control

21

22

Suction Pressure Control

Process Temperature Control

23

Compressor Alarm and Trip

· Low Suction Pressure Setpoints 1&2 – This is
the low suction pressure safety. This safety is
active in both temperature and pressure control
modes. An alarm or trip will be active on a drop
in suction pressure below the setpoint value.

· High Discharge Pressure Setpoints 1&2 This is
the high discharge pressure safety. The alarm or
trip will be active on a rise in discharge pressure
above the setpoint value.

· Low Suction Temperature – This is the lowest
allowable Suction temperature. The compres­sor will not be allowed to run if the Suction
Temperature is below the trip setting.

· High Discharge Temperature – This is the high
discharge temperature safety. The alarm or
trip will be active if the discharge temperature
should rise above the setpoint value.

· Low Oil Separator Start Temperature – This is the
starting low oil separator temperature safety.
The compressor is prevented from starting or
running if the oil in the separator is below the
trip value. After a time delay (Oil Separator

Temperature Safety Changeover), this safety is
deactivated and the Lo Oil Separator Run Tem­perature is the active setpoint.

· Low Oil Separator Run Temperature – This is the
running low oil separator temperature safety.
After a time delay (Oil Separator Temperature
Safety Changeover), the Lo Oil Separator Start
Temperature is bypassed and Lo Oil Separator
Run Temperature is the active setpoint. The
alarm or trip will be active if the oil temperature
of the separator drops below the setpoint value.

· Low Oil Injection Temperature – This is the low
oil injection safety. The alarm or trip will be
active if oil injection temperature drops below
setpoint value after a time delay (Oil Injection
Temperature Safety Changeover).

· High Oil Injection Temperature – This is the high
oil injection temperature safety. The alarm or
trip will be active on a rise in oil injection tem­perature above the setpoint value.

24

Compressor Timer Setpoints

To change a timer set­ting, a user with high
access level must be
logged on.

· Capacity Decrease At Start – At compressor
startup, the capacity motor is held at minimum
position for this time period. After the timer
expires, the slide is free to move in accordance
to the system demands.

· Compressor Starter Auxiliary Contact Bypass –
This timer is used to bypass the motor amperage
input at start. After the timer times out, the
program determines if the motor starter has
pulled in by testing the amperage channel. If
the program determines that the starter did not
“pull in”, then the compressor will fail on “Motor
Starter Fail” message.

· Volume Slide Adjustment Timer – This timer
determines the intervals the volume slide is
adjusted. If the volume slide is between 2½% &
7% away from the desired volume ratio, the mo­tor is pulsed once toward the desired volume.

If the volume slide is more than 7% away from
the desired value, the volume slide motor is
continuously energized until the valve is within
2½% of the desired value. If the actual position
is within 2½% of the desired value, no adjust­ment will be made.

· Minimum Compressor Prelube Timer – This is
the length of time the oil pump will run after
establishing the Prelube Oil Pressure, to prime
oil circuit before starting the compressor.

· Oil Pressure Bypass At Compressor Start – This
timer bypasses the Low Oil Pressure limits.
The timer starts when the compressor starts.
After the timer has cycled, the Low Oil Pressure
setpoint is active.

· Prelube Oil Pump Time Limit – This timer puts
a limit on how long the prelube oil pump is al­lowed to run without establishing the Prelube
Oil Pressure.

25

· Filter Differential Pressure Safety Changeover
– This timer bypasses the Hi Run Filter Differen­tial Pressure setting during start, to allow the
Hi Start Filter Differential Pressure to protect
against High Filter Differential during start. Af­ter the timer has cycled, the Hi Run Differential
Pressure Safety is active.

· Low Oil Separator Level Bypass Timer – This
timer bypasses the low oil level switch for mo­mentary drops in the oil level. If the switch is still
open after the Low Oil Separator Level Bypass
Timer has timed out, the compressor will be shut
down and an alarm will be displayed. This timer
is available if the unit is equipped with a low oil
separator float switch. The oil level switch is
standard on all liquid injection units and optional
on all others.

· Auto Restart After Power Failure – This timer
forces the microprocessor to wait for the set
time period after a power failure before start­ing the compressor unit. By staggering the
time settings, the compressors can be allowed
to start automatically, one at a time, after a
power failure. This prevents excessive loads on
the power system that could be caused by all of
the equipment coming online at the same time.
The Power-Up Auto Start operator option must
be selected on the Setup screen for this option
to be active.

· Oil Separator Temperature Safety Changeover
– This timer allows Low Oil Separator Start
Temperature Safety setpoint to protect the
compressor against cold oil during starting.
After the timer has cycled, the Low Oil Separator
Run Temperature is then active.

· Low Oil Injection Temperature Bypass – This
timer bypasses the Low Oil Injection Tempera­ture Safety Setpoint during start-up. After the
timer cycles, the Low Oil Injection Temperature
Safety is set.

· Hot Starts / Hr Counter – This counter counts
compressor starts. After every start, a one-hour
timer is reset and starts timing. If the timer
times out, the hot starts counter is reset. When
the counter reaches it’s preset value, it will not
allow another compressor start until the one­hour timer times out and resets the counter.
In other words, the hot starts counter will be
reset when the time between compressor starts
total one hour. This counter allows repetitive
compressor starts, but once the counter has
reached its set point, it requires a one-hour
window between compressor starts in order
for the counter to be reset. Note: if this option

is chosen an arrow will appear alongside its
current value. When active a point will appear.

· True Anti-Recycle Timer – Once the compressor
turns off, the timer will keep the compressor
off for the setting of True Anti-Recycle Timer.
This timer is used to prevent short cycling of the
compressor. Note: if this option is chosen an

arrow will appear alongside its current value.
When active a point will appear.

· Accumulative Anti-Recycle Timer – This timer
also forces a specified time between compres­sor starts. When the compressor starts, the
timer resets then starts timing and accumulates
running time. Once the compressor shuts
down, it will not be allowed to restart for the
remainder of the time left on the Accumula­tive Anti-Recycle Timer. Unlike the True Anti­Recycle Timer, if the compressor has run for a
time period that exceeds the setpoint of the
Accumulative Anti-Recycle Timer, then when
the compressor shuts down, it will be allowed
to restart immediately. The compressor restart
options (Hot Starts or Anti-Recycle Timers) are
selected from the Setup screen. One additional
Anti-Recycle Timer that can be selected from
the Setup screen is the Modified Anti-Recycle
Timer. Note: if this option is chosen an arrow

will appear alongside its current value. When
active a point will appear.

26