Emerson VSSG 451, VSSG 601, VSG 301, VSG361, VSG 401 Operation Manual

VSG/VSSG compact logix PLC

Operation manual

FOR UNITS BUILT BEFORE JULY 1, 2013

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).

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

3

4/Blank

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

Table of Contents

Important Note .................................................................................................3

VSG/VSSG 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 Timer Setpoints ...........................................................................26

Compressor Control Setpoints ......................................................................... 28

Additional Compressor Controls ...................................................................... 33

Compressor Setpoints and Alarms ................................................................... 34

Motor Speed Setpoints & Control Screen ......................................................... 36

Diagnostics Force Output ................................................................................ 38

Instrument Calibration ....................................................................................39

Oil Mixing Valve ............................................................................................... 45

Unit Start Screen (Start / Stop Logic) ................................................................ 48

Device Names ..................................................................................................51

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

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

Calibration Procedure of Optical Actuators ...................................................... 54

Installation Instructions For Replacement Of Optical Actuator ......................... 56

Slide Valve Actuator Theory of Operation ........................................................ 57

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

Command Shaft Rotation and Travel ................................................................ 60

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

Version Screen .................................................................................................65

Trend Charts .................................................................................................... 66

Captured Data at Shutdown ............................................................................69

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

5

VSG/VSSG 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

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

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

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

7

Suction Pressure Control

Operational Flow Charts

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

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

Operational Flow Charts

Oil Cooler Fan Control

(Selectable Control Optional)

Oil Cooler

Unit Start

outlet temp >

set pt?

Oil Cooler

outlet temp <

set pt?

Oil Temperature Control Valve

PID Control

30 sec

delay

Yes

NoNo

Yes

Increase Speed

Decrease Speed

PID Control

Unit Start

Oil injection

temp > set pt?

No No

Oil injection

temp < set pt?

Yes

Yes

30 sec

delay

Modulate valve

Modulate valve

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

9

Operational Flow Charts

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

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

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

Operational Flow Charts

Capacity Control Using Suction Pressure Control Setpoints

Start

Has

Decrease at Start

(Expired 15

sec.)

No

Wait

Are Motor

Amps >

Motor Amps Load

Yes No No Yes Yes

Motor Amp Load Limit

Setpt?

Limit ON

(Time Delay

10 sec)

Yes

Disable Cap Inc

Are Motor

Amps >

Setpt?

OFF

Yes

Dec Cap

(Timer)

No Change No Change

Is Disch

Press > High Disch

Press Unload

OFF

Setpt?

Yes

Disable Cap Inc

Is Disch

Press > High Disch

Press Unload

Setpt?

ON

Yes

Dec Cap

(Timer)

Is Capacity

> Min Run Cap

OFF

Setpt?

No

Increase Cap

(Timer)

Is Suct

Press > Cap Inc

ON

Setpt?

No

Is Suct Press< Cap

Setpt?

Dec ON

Yes

Dec Cap

(Timer)

No

Inc Cap
(Timer)

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

11

Operational Flow Charts

Capacity Control Using Discharge Pressure Control Setpoints

Start

Are Motor

Has
Decrease at Start
(Expired 15 sec.)

Yes

Amps >

Motor Amps Load

Limit ON

Setpt?

(Time Delay

10 sec)

No

Is Disch Press > Cap

Dec ON

Setpt?

Yes

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

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

Operational Flow Charts

Compressor Operation with VFD Drive

Start

Compressor

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?

Check/Adjust Capacity Slide

No

Increase or Decrease the

Compressor Capacity Slides to

No

No

No

Match Setpoints

Increase or Decrease the

Compressor Capacity Slides to

Match Setpoints

Increase or Decrease Motor Speed

@ Rate Defined by VFD PID

Parameters

Is Capslide @

100%

Yes

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

13

14/Blank

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

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.

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

15

Log On or Off

Log On Screen

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

To Log On: Enter your User Name (case sensitive)
and Password (case sensitive) then touch the <_|
enter key.

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.

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.

16

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

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

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

17

Set Up Screen

· Setpoint #1/#2 Select – The operator can select

the compressor to run with setpoint #1 or #2
settings.

· Oil Pump Selection – The operator can select
the compressor to use either oil pump #1 or #2
when compressor has a second oil pump.

· Pressure Units – Select units of measure for pres-
sure readings. Choices are PSIG, PSIA, kPa [A],
kPa [G], kg/cm² [A], kg/cm² [G], Hg (vac) [G], WC
[A], WC [G], Bar [A], Bar [G], Torr [A], Torr [G].

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

· 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.

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.

· Oil Pump Option #1 – The operator can choose
the method the compressor oil pump operates.

· Suction Pressure Sensor Mode – The operator
can select local or remote sensor mode. Remote
sensor mode is typically used when compressors
are installed in parallel.

· 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.

· Capacity & Volume Slide Non-Movement – Alarm
enable and disable 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

18

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

Vilter Only Screen

To synchronize the PanelView date and time to the Conrol Logix date and time:

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

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

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

19

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.

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

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

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

Refer to the Log on/off Instructions on page 16.

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

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

Menu Screen

There are three options for the Compressor Control Setpoints:

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL

Discharge Pressure Control

21

Menu Screen

22

Suction Pressure Control

VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL