Emerson VSSG 291, VSSG 601, VSSG 341, VSSG 451, VSG 751 Software Manual
...
VSG & VSSG
Single Screw Compressor
Software Manual
Compact Logix PLC
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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).
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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
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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.
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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
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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
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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
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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
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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
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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
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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
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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.
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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.
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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
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· 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.
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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.
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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.
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There are three options for the Compressor Control Setpoints:
Discharge Pressure Control
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Suction Pressure Control
Process Temperature Control
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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.
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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.
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· 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.
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