Emerson VSG & VSSG Specifications

Single Screw Compressor PLC
Operation manual
FOR UNITS BUILT AFTER JULY 1, 2013
VSG/VSSG Standard Vilter Warranty Statement
Seller warrants all new single screw gas compression units and bare shaft 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.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
i
Important Message
READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.
The following instructions have been prepared to assist in installation, operation and removal of Vilter Single Screw
Compressors. Following these instructions will result in a long life of the compressor with satisfactory operation.
The entire manual should be reviewed before attempting to install, operate, service or repair the compressor.
A compressor is a positive displacement machine. It is designed to compress gas. The compressor must
not be subjected to liquid carry over. Care must be exercised in properly designing and maintaining the
system to prevent conditions that could lead to liquid carry over. Vilter Manufacturing is not responsible
for the system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing cannot
warrant equipment damaged by improperly protected or operating systems.
Vilter screw compressor components are thoroughly inspected at the factory. However, damage can occur
in shipment. For this reason, the equipment should be thoroughly inspected upon arrival. Any damage
noted should be reported immediately to the Transportation Company. This way, an authorized agent
can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with
no serious or costly delays. At the same time, the local Vilter representative or the home office should be
notified of any claim made.
All inquires should include the Vilter sales order number, compressor serial and model number. These can be
found on the compressor name plate on the compressor.
All requests for information, services or parts should be directed to:
Vilter Manufacturing LLC
Customer Service Department
P.O. Box 8904
5555 South Packard Ave
Cudahy, WI 53110-8904 USA
Telephone: 1-414-744-0111
Fax:1-414-744-3483
e-mail: info.vilter@emerson.com
Equipment Identification Numbers:
Vilter Order Number:
Vilter Order Number:
Vilter Order Number:
Vilter Order Number:
ii
_______________________Compressor Serial Number: _________________
_______________________Compressor Serial Number: _________________
_______________________Compressor Serial Number: _________________
_______________________Compressor Serial Number: _________________
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Table of Contents
Section Title
Section Number
VSG/VSSG Standard Vilter Warranty Statement ..................................................................................... i
Important Message................................................................................................................................ ii
Section 1 • General Information
How To Use This Manual......................................................................................................................... 1-1
Glossary of Terms................................................................................................................................... 1-2
Hardware Components .......................................................................................................................... 1-6
Wiring Requirements ............................................................................................................................. 1-9
VFD Installation Recommendations ....................................................................................................... 1-10
Section 2 • Operation Descriptions
Overview ............................................................................................................................................... 2-1
Operational Descriptions and Diagrams ................................................................................................. 2-2
Starting of the Compressor/Permissives..................................................................................... 2-2
Compressor Start-up Sequence..................................................................................................2-3
Auto Start-Stop .......................................................................................................................... 2-4
Anti-Recycle .............................................................................................................................. 2-4
Capacity Slide Control................................................................................................................ 2-4
Operating Modes ....................................................................................................................... 2-8
Load Limits and Forced Unloading..............................................................................................2-8
VFD Capacity Control ................................................................................................................. 2-10
Volume Slide Control ................................................................................................................. 2-10
Safeties ...................................................................................................................................... 2-10
Emergency Stop ........................................................................................................................ 2-10
Oil Heaters ................................................................................................................................. 2-11
Suction Oil Injection Solenoid .................................................................................................... 2-11
Suction-Discharge Equalizing Solenoid ...................................................................................... 2-11
Oil Drain Solenoid ...................................................................................................................... 2-11
2-Way Oil Mixing Valve .............................................................................................................. 2-12
Oil Injection Valve ...................................................................................................................... 2-12
Air Cooled Oil Cooler (VFD Type) ................................................................................................ 2-13
Oil Cooler Temperatures ............................................................................................................ 2-13
Oil Cooler Standby Heater .......................................................................................................... 2-13
Air Cooled Aftercooler (VFD Type) .............................................................................................. 2-14
Air Cooled Condenser (VFD Type)...............................................................................................2-15
Evaporative Condenser (VFD Type) ............................................................................................ 2-15
Air Cooled Oil Cooler (Step Type) ............................................................................................... 2-16
Air Cooled Aftercooler (Step Type) ............................................................................................. 2-17
Air Cooled Condenser (Step Type) .............................................................................................. 2-17
Water Cooled Gas Aftercooler .................................................................................................... 2-18
Water Cooled Condenser ........................................................................................................... 2-19
Liquid Injection Valve ................................................................................................................. 2-20
VPLUS Liquid Injection Pump ..................................................................................................... 2-21
Discharge Recycle Valve ............................................................................................................. 2-22
Economizer Solenoid(s) ............................................................................................................. 2-23
Hotgas Bypass Solenoid ............................................................................................................. 2-23
Venturi Oil Recovery .................................................................................................................. 2-23
Gas Scrubbers ............................................................................................................................ 2-23
Building Enclosure Devices......................................................................................................... 2-24
Periodic Slide Valve Exercise ....................................................................................................... 2-24
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
TOC - 1
Table of Contents
Section Title
Section Number
Section 3 • Overview Screens
Compressor and System Overview Screens ............................................................................................ 3-1
Gas Compressor Unit Overview Screen Example 1
VSG-2801 Compressor Unit for Natural Gas with Air Cooled VFD Type Oil Cooler........................ 3-2
Gas Compressor Unit Overview Screen Example 2
VSG-2101 Compressor Unit for Natural Gas in Enclosure with Vibration Mounting ..................... 3-3
Gas Compressor Unit Overview Screen Example 3
VSG-2101 Compressor Unit for Natural Gas with Scrubbers and Aftercooler .............................. 3-4
Refrigeration Compressor Unit Overview Screen Example 1
VSM-601 Compressor Unit for Ammonia with Liquid Injection Oil Cooling and Economizer........ 3-5
Refrigeration Compressor Unit Overview Screen Example 2
VSM-601 Compressor Unit Gas Chiller for R134a ....................................................................... 3-6
Refrigeration Compressor Unit Overview Screen Example 3
VSM-601 Compressor Unit Gas Chiller for R134a with Venturi Oil Recover and Reheater............. 3-7
Section 4 • HMI Navigation
HMI Navigation - Main Menu Screen....................................................................................................... 4-1
HMI Security .......................................................................................................................................... 4-3
Default ................................................................................................................................................. 4-3
OP1, OP2, OP3, OP4, OP5 (Operators) ................................................................................................... 4-3
Super (Supervisor) ................................................................................................................................. 4-3
Logging In.............................................................................................................................................. 4-3
Section 5 • Configuration - Supervisor Level
Configuration Screen - Supervisor (SUPER) Level .................................................................................... 5-1
Set Date/Time ........................................................................................................................................ 5-2
Define Device Names ............................................................................................................................. 5-3
User Defined Alarms and Trips ................................................................................................................ 5-4
Section 6 • Instrument Calibration
Calibration Main Screen ......................................................................................................................... 6-1
Pressure Calibration Screen.................................................................................................................... 6-2
Calibrate Pressure Instrument.................................................................................................... 6-3
Calibrate Transducer to a Known Pressure .................................................................................. 6-3
Temperature Calibration Screen ............................................................................................................. 6-4
Calibrate Temperature Instrument .............................................................................................6-4
Other Analog Calibration Screen ............................................................................................................ 6-5
Calibrate an Additional Instrument ............................................................................................ 6-5
Slide Calibration Screen ......................................................................................................................... 6-6
Calibrate Slide Valve Actuators .................................................................................................. 6-7
TOC - 2
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
Table of Contents
Section Title
Section Number
Section 7 • Compressor Control Setpoints
Setpoints and Control Screens ............................................................................................................... 7-1
Changing Setpoints ................................................................................................................... 7-1
Compressor Control Setpoints ............................................................................................................... 7-2
Compressor Control Setpoints Screen 1 - Suction Pressure ..................................................................... 7-2
Suction Pressure Control............................................................................................................ 7-2
Capacity Slide Valve ................................................................................................................... 7-3
Auto Start/Stop ......................................................................................................................... 7-3
Main Motor VFD......................................................................................................................... 7-3
Compressor Control Setpoints Screen 1 - Suction Pressure ..................................................................... 7-2
Process Temperature Control ..................................................................................................... 7-2
Capacity Slide Valve ................................................................................................................... 7-3
Auto Start/Stop ......................................................................................................................... 7-3
Main Motor VFD......................................................................................................................... 7-4
Compressor Control Setpoints Screen 1 - Discharge Pressure ................................................................. 7-5
Discharge Pressure Control ........................................................................................................ 7-5
Capacity Slide Valve ................................................................................................................... 7-5
Auto Start/Stop ......................................................................................................................... 7-6
Main Motor VFD......................................................................................................................... 7-6
Compressor Control Setpoints Screen 2 ................................................................................................. 7-7
Anti-Recycle .............................................................................................................................. 7-7
Start Up ..................................................................................................................................... 7-7
Shut Down................................................................................................................................. 7-7
Oil Separator Heaters ................................................................................................................. 7-8
Part Time Oil Pump .................................................................................................................... 7-8
Load Limits ................................................................................................................................ 7-8
Volume Slide Adjustment........................................................................................................... 7-8
Main Motor FLA ......................................................................................................................... 7-8
Compressor Control Setpoints Screen 3 ................................................................................................. 7-9
Venturi Oil Recovery .................................................................................................................. 7-9
Hotgas Bypass ........................................................................................................................... 7-9
Economizer................................................................................................................................ 7-9
Enclosure Setpoints ................................................................................................................... 7-9
Oil Flow Control ......................................................................................................................... 7-9
Periodic Slide Valve Exercise ....................................................................................................... 7-9
Section 8 • Alarm and Trip Setpoints
Alarm and Trip Setpoints ........................................................................................................................ 8-1
Alarm and Trip Setpoints Screen 1 .......................................................................................................... 8-1
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
TOC - 3
Table of Contents
Section Title
Section Number
Section 9 • Step and PID Device Control Screens
Oil Mixing Valve Screen .......................................................................................................................... 9-1
Oil Mixing Valve Setpoints.......................................................................................................... 9-1
Oil Cooler (VFD Type) Setpoints ................................................................................................. 9-2
Oil Cooler (Step Type) Setpoints ................................................................................................. 9-3
Aftercooler Screens................................................................................................................................ 9-4
Aftercooler (VFD Type) Setpoints ............................................................................................... 9-4
Aftercooler (Step Type) Setpoints .............................................................................................. 9-5
Water Cooled Aftercooler Setpoints ...........................................................................................9-6
Condenser Screens ................................................................................................................................ 9-7
Condenser (Step Type) Setpoints ............................................................................................... 9-7
Condenser (VFD Type) Setpoints ................................................................................................ 9-8
Water Cooled Condenser Setpoints............................................................................................ 9-9
Liquid Injection Valve Screen .................................................................................................................. 9-10
Liquid Injection Valve Setpoints ................................................................................................. 9-10
Liquid Injection (VPLUS Pump) Setpoints ................................................................................... 9-11
Discharge Recycle Valve Screen.............................................................................................................. 9-12
Discharge Recycle Valve Setpoints ............................................................................................. 9-12
Volume Slide Details Screen ................................................................................................................... 9-13
Volume Slide Details .................................................................................................................. 9-13
Start Menu Popup Screen....................................................................................................................... 9-14
Section 10 • Diagnostic Screens
IO/Comms Diagnostics Screen ............................................................................................................... 10-1
Event List Screen .................................................................................................................................... 10-2
Diagnostics Forced Outputs Screen ........................................................................................................ 10-3
Captured Data at Shutdown Screen ....................................................................................................... 10-4
Initial Baseline Running Data Screen ....................................................................................................... 10-5
Section 11 • Alarms, Trips, Status Information
and Troubleshooting
Alarm and Trips ...................................................................................................................................... 11-1
Alarm Listing.......................................................................................................................................... 11-2
Trip Listing ............................................................................................................................................. 11-9
Status Messages and Compressor State Indicator ................................................................................... 11-16
Troubleshooting .................................................................................................................................... 11-20
If the Compressor Will Not Start................................................................................................. 11-20
If Control Power Will Not Turn On .............................................................................................. 11-20
Section 12 • Central Controller Communications
Communication with a Central Controller/DCS ...................................................................................... 12-1
VPN Access ................................................................................................................................ 12-1
Setting Up Communications ...................................................................................................... 12-1
Watchdog Timer ........................................................................................................................ 12-1
Data that can be Read from the Compressor PLC .................................................................................... 12-1
Live Instrument Data ................................................................................................................. 12-1
Alarm and Trip Data ............................................................................................................................... 12-8
Status Data ............................................................................................................................................ 12-16
States of Discrete I/O ............................................................................................................................. 12-20
TOC - 4
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
Table of Contents
Section Title
Section Number
Section 12 • Central Controller Communications (Continued)
Compressor State Indicator.................................................................................................................... 12-25
Sending Commands to Compressor PLC (Ethernet IP Version) ................................................................ 12-25
Watchdog Bits ........................................................................................................................... 12-25
Discrete Compressor Commands ............................................................................................... 12-26
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
TOC - 5
List of Tables and Figures
Table/Figure
Section Number
Tables
Table 11-1. Alarm Listing ........................................................................................................................ 11-2
Table 11-2. Trip Listing ........................................................................................................................... 11-9
Table 11-3. Status Listing ....................................................................................................................... 11-16
Table 12-1. Engineered Units Value Interpretation (INT_OUT[x]) ........................................................... 12-2
Table 12-2. Live Instrument Data ............................................................................................................ 12-2
Table 12-3. Alarm Data........................................................................................................................... 12-8
Table 12-4. Trip Data .............................................................................................................................. 12-12
Table 12-5. Status Data .......................................................................................................................... 12-16
Table 12-6. Discrete Input States ............................................................................................................ 12-20
Table 12-7. Discrete Output States ......................................................................................................... 12-22
Table 12-8. State Indicator ..................................................................................................................... 12-25
Table 12-9. Mode Indicator .................................................................................................................... 12-25
Table 12-10. Compressor Command (Real) ............................................................................................ 12-26
Table 12-11. Compressor Command (Double Integer)............................................................................ 12-26
Figures
Figure 1-1. Compact Logix PLC Hardware Components - Exterior Side and Front .................................... 1-2
Figure 1-2. Compact Logix PLC Hardware Components - Internal Board Layout ...................................... 1-3
Figure 2-1. Compressor Startup Sequence Diagram ...............................................................................2-3
Figure 2-2. Capacity Slide Control Diagram (Example)............................................................................ 2-5
Figure 2-3. Operational Diagram - Capacity Slide, Discharge Pressure (Example) .................................... 2-6
Figure 2-4. Operational Diagram - Capacity Slide, Suction
Pressure per Process Temperature (Example) ....................................................................... 2-7
Figure 2-5. Operational Diagram - Load Limits / Forced Unloading (Example) ......................................... 2-9
Figure 2-6. Control Panel Master Power and Emergency Stop Electrical Circuit ....................................... 2-11
Figure 2-7. Operational Diagram - 2-Way Oil Mixing Valve ...................................................................... 2-12
Figure 2-8. Operational Diagram - Air Cooled Oil Cooler (VFD Type) ....................................................... 2-13
Figure 2-9. Operational Diagram - Air Cooled Aftercooler (VFD Type) ..................................................... 2-14
Figure 2-10. Operational Diagram - Air Cooled Condenser (VFD Type) .................................................... 2-15
Figure 2-11. Operational Diagram - All Air Cooled Oil Coolers (Step Type)............................................... 2-16
Figure 2-12. Operational Diagram - Air Cooled Condenser...................................................................... 2-17
Figure 2-13. Operational Diagram - Water Cooled Gas Aftercooler ......................................................... 2-18
Figure 2-14. Operational Diagram - Water-Cooled Condenser ................................................................ 2-19
Figure 2-15. Operational Diagram - Liquid Injection Valve ...................................................................... 2-20
Figure 2-16. Operational Diagram - VPLUS ............................................................................................. 2-21
Figure 2-17. Operational Diagram - Discharge Recycle Valve .................................................................. 2-22
Figure 3-1. Basic Compressor Unit Screen .............................................................................................. 3-1
Figure 3-2. Gas Compressor Unit Overview Screen Example 1,
VSG-2801 Compressor Unit for Natural Gas with Air Cooled VFD Type Oil Cooler .................. 3-2
Figure 3-3. Gas Compressor Unit Overview Screen Example 2,
VSG-2101 Compressor Unit for Natural Gas in Enclosure with Vibration Monitoring ............. 3-3
Figure 3-4. Gas Compressor Unit Overview Screen Example 3,
VSG-2101 Compressor Unit for Natural Gas with Scrubbers and Aftercooler ......................... 3-4
Figure 3-5. Refrigeration Compressor Unit Overview Screen Example 1,
VSM-601 Compressor Unit for Ammonia with Liquid Injection Oil Cooling and Economizer .. 3-5
TOC - 6
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
List of Tables and Figures
Table/Figure
Section Number
Figure 3-6. Refrigeration Compressor Unit Overview Screen Example 2,
VSM-601 Compressor Unit Gas Chiller for R134a .................................................................. 3-6
Figure 3-7. Refrigeration Compressor Unit Overview Screen Example 3,
VSM-601 Compressor Unit Gas Chiller for R134a with Venturi Oil Recovery and Reheater ..... 3-7
Figure 4-1. Main Menu Screen ................................................................................................................ 4-1
Figure 4-2. Screen Navigation Map ......................................................................................................... 4-2
Figure 4-3. Login Screen......................................................................................................................... 4-3
Figure 4-4. Login Screen Keyboard ......................................................................................................... 4-4
Figure 5-1. Configuration Screen - Supervisor Level ................................................................................ 5-1
Figure 5-2. Set Date/Time Pop-Up Screen - Supervisor Level ................................................................... 5-2
Figure 5-3. Define Device Names - Supervisor Level ................................................................................ 5-3
Figure 5-4. User Defined Alarms and Trips - Supervisor Level .................................................................. 5-4
Figure 6-1. Instrument Calibration Overview Screen .............................................................................. 6-1
Figure 6-2. Pressure Calibration Screen - 1 of 3 ....................................................................................... 6-2
Figure 6-3. Pressure Calibration Screen - 3 of 3 ....................................................................................... 6-3
Figure 6-4. Temperature Calibration Screen ........................................................................................... 6-4
Figure 6-5. Other Analog Calibration Screen .......................................................................................... 6-5
Figure 6-6. Slide Calibration Screen (Not in Calibration Mode) ................................................................6-6
Figure 6-7. Slide Calibration Screen (In Calibration Mode) ...................................................................... 6-7
Figure 6-8. Actuator Assembly ............................................................................................................... 6-8
Figure 6-9. Photo-chopper ..................................................................................................................... 6-9
Figure 7-1. Numeric Entry Pop-up Screen ............................................................................................... 7-1
Figure 7-2. Compressor Control Screen - 1 of 3 (Suction Pressure) .......................................................... 7-2
Figure 7-3. Compressor Control Screen - 1 of 3 (Process Temperature) ................................................... 7-4
Figure 7-4. Compressor Control Screen (Discharge Pressure) - 1 of 3 ...................................................... 7-5
Figure 7-5. Compressor Control Screen - 2 of 3 ....................................................................................... 7-7
Figure 7-6. Compressor Control Screen - 3 of 3 (All Options Shown) ....................................................... 7-9
Figure 8-1. Alarm and Trip Setpoints Screen - 1 of 2 ................................................................................ 8-1
Figure 8-2. Alarm and Trip Setpoints Screen - 2 of 2 ................................................................................ 8-2
Figure 9-1. Oil Mixing Valve Screen ........................................................................................................ 9-1
Figure 9-2. Oil Cooler Valve (VFD Type) Screen ....................................................................................... 9-2
Figure 9-3. Oil Cooler Valve (Step Type) Screen....................................................................................... 9-3
Figure 9-4. Aftercooler (VFD Type) Screen .............................................................................................. 9-4
Figure 9-5. Aftercooler (Step Type) Screen ............................................................................................. 9-5
Figure 9-6. Water Cooled Aftercooler Screen .......................................................................................... 9-6
Figure 9-7. Condenser (Step Type) Screen .............................................................................................. 9-7
Figure 9-8. Condenser (VFD Type) Screen ............................................................................................... 9-8
Figure 9-9. Water Cooled Condenser Screen........................................................................................... 9-9
Figure 9-10. Liquid Injection Valve Screen .............................................................................................. 9-10
Figure 9-11. Liquid Injection (VPLUS Pump) Screen ................................................................................ 9-11
Figure 9-12. Discharge Recycle Valve Screen .......................................................................................... 9-12
Figure 9-13. Volume Slide Details Screen ............................................................................................... 9-13
Figure 9-14. Start Menu ......................................................................................................................... 9-14
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
TOC - 7
List of Tables and Figures
Table/Figure
Section Number
Figure 10-1. IO/Comms Diagnostics Screen ........................................................................................... 10-1
Figure 10-2. Event List Screen................................................................................................................. 10-2
Figure 10-3. Diagnostics Forced Output Screen ...................................................................................... 10-3
Figure 10-4. Captured Data at Shutdown Screen .................................................................................... 10-4
Figure 10-5. Initial Baseline Running Data Screen ................................................................................... 10-5
Figure 11-1. Alarm/Trip/Status Bars (Main Menu Screen) ........................................................................ 11-1
Figure 11-2. Alarm Popup Screen ........................................................................................................... 11-1
Figure 11-3. Alarm/Trip/Status Bars (Main Menu Screen) ........................................................................ 11-16
TOC - 8
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
Section 1 • General Information
HOW TO USE THIS MANUAL
ADDITIONAL IMPORTANT NOTES
This manual contains instructions for the PLC. It has
been divided into 12 sections:
• Installation, operation and maintenance instructions
can be found in the associated gas compressor unit
manual and bare shaft compressor manual.
Section 1: General Information
• Due to continuing changes and unit updates, always
refer to the Vilter.com website to make sure you have
the latest manual.
Section 2: Sequence of Operation
Section 3: Overview Screens
Section 4: HMI Navigation
Section 5: Configuration - Supervisor Level
• Any suggestions of manual improvements can be
made to Vilter Manufacturing at the contact information on page ii.
Section 6: Instrument Calibration
Section 7: Compressor Control Setpoints
Section 8: Alarms and Trips Setpoints
Section 9: Step and PID Device Control Screens
Section 10: Diagnostics Screens
Section 11: Alarms, Trips, Status Information and
Troubleshooting
Section 12: Communications with a Central
Controller/DCS
It is highly recommended that the manual be reviewed
prior to servicing system parts.
Figures and tables are included to illustrate key concepts.
Safety precautions are shown throughout the manual.
They are defined as the following:
NOTICE - Notice statements are shown when there are
important information that shall be followed. Not following such notices may result in void of warranty, serious fines, serious injury and/or death.
WARNING - Warning statements are shown when there
are hazardous situations, if not avoided, will result in serious injury and/or death.
CAUTION - Caution statements are shown when there
are potentially hazardous situations, if not avoided, will
result in damage to equipment.
NOTE - Notes are shown when there are additional information pertaining to the instructions explained.
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
1 – 1
Section 1 • General Information
Glossary of Terms
Differential Pressure
The difference between two pressures.
Discharge Recycle Control Pressure
2-Way Oil Mixing Valve
Motorized valve mounted on the compressor unit that
directs hot oil to the oil cooler when needed.
Pressure of discharge gas measured at the Discharge
Recycle Valve. Used to control the Discharge Recycle
Valve.
Aftercooler Heat Exchanger
Discharge Recycle Valve
Used to cool discharge gas from the compressor.
Motorized or Air Actuated Valve that recycles discharge
gas back to the suction side of the compressor.
Aftercooler Outlet Temperature
Temperature of gas measured at the outlet of the
Aftercooler.
Alarm Warning
Discharge Pressure
Pressure of the refrigerant or gas measured at the outlet
of the compressor.
Annunciated by the compressor PLC that an operational
or process condition is abnormal. When active, alarms
will be displayed but will not shut down the compressor.
Discharge Temperature
Bearing Temperature
Economizer
Temperature of the bearings of the compressor main
motor measured by an RTD.
Intermediate pressure between suction and discharge of
the compressor, typically used to subcool liquid refrigerant to increase cooling capacity of the compressor. A
solenoid valve controlled by the compressor PLC enables
the economizer to function.
Building Enclosure
Insulated enclosure or container the compressor and
some ancillary equipment can be mounted in as a
package.
Capacity Slide Valve
Internal mechanism in the compressor that controls
compressor loading and unloading.
Capacity Slide Valve Actuator
Drive motor that moves the capacity slide valve, and
gives feedback on the position of the capacity slide valve.
Chiller
Heat Exchanger where liquid refrigerant boils off cooling a process fluid (liquid or gas, ex. natural gas, glycol,
water)
Compressor Differential Calculated
Discharge Pressure minus Suction Pressure. Monitored
to ensure compressor is equalized before starting.
Condenser
Heat exchanger that removes heat from superheated refrigerant vapor and converts it to a liquid.
Condensing Pressure:
Pressure of refrigerant vapor measured at the condenser.
1 – 2
Temperature of the refrigerant or gas measured at the
outlet of the compressor.
EPCS
EPCS stands for “Emergency Pressure Control System.”
Used where required on refrigeration applications to relieve high discharge pressure back to suction to prevent
activating a relief valve. Consists of a solenoid valve and
two pressure transmitters, one on the discharge (high)
side and one on the suction (low) side. When the discharge (high) side pressure reaches 90% of relief valve
setting, the solenoid will open and relieve high pressure
discharge gas back to suction (low) side. When either
pressure transmitter reaches 90% of their respective
high or low side relief valve settings, the compressor will
shut down.
Ethernet IP
Communication protocol used to communicate to the
compressor PLC.
Gas Equalizing Solenoid
Solenoid Valve that opens at compressor stop to equalize suction and discharge pressures.
HMI
HMI stands for “Human-Machine Interface.” The compressor HMI is a touchscreen terminal mounted in the
door of the compressor control enclosure.
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
Section 1 • General Information
Hotgas Bypass
Oil Cooler Inlet Temperature
Self-regulated valve which provides a “false load” by
recycling discharge gas to suction in refrigeration applications. Used to prevent the compressor from shutting down during low load conditions. A solenoid valve
controlled by the compressor PLC enables the Hotgas
Bypass valve to function.
Temperature of compressor oil measured at the inlet of
the oil cooler.
Inlet Scrubber
Oil Filter Differential Calculated
Vessel located on the inlet side of gas compressor or gas
chiller to remove moisture and contaminants.
Oil Filter Outlet (Manifold) Pressure minus Oil Filter Inlet
Pressure. Monitored while compressor is running to determine condition of oil filter(s).
Inlet Scrubber Inlet Pressure
Pressure of gas measured at the inlet of the inlet
scrubber.
Inlet Scrubber Outlet Pressure
Pressure of gas measured at the outlet of the inlet
scrubber.
Inlet Scrubber Pressure Drop
Oil Cooler Outlet Temperature
Temperature of compressor oil measured at the outlet
of the oil cooler.
Oil Filter Inlet Pressure
Pressure of the compressor oil measured at the inlet of
the oil filter(s).
Oil Filter Outlet (Manifold) Pressure
Pressure of the compressor oil measured between the
oil filter(s) and the compressor.
Pressure differential between inlet and outlet of the inlet scrubber. Calculated: Scrubber Inlet Pressure minus
Scrubber Outlet Pressure.
Oil Injection Temperature
Liquid Injection
Oil Separator
Method of oil cooling where liquid refrigerant is metered
into the compressor by a motorized or air actuated valve.
Vessel the compressor discharges into that separates oil
from gas or refrigerant.
Liquid Refrigerant Temperature
Oil Separator Gas Outlet Temperature
Temperature of the liquid refrigerant measured in the
chiller, also known as the evaporation temperature.
Temperature of the gas or refrigerant measured at the
outlet of the oil separator vessel.
Main Motor
Oil Separator Outlet Pressure
AC induction motor that is coupled to and drives the
compressor.
Pressure of discharge gas or refrigerant measured at the
outlet of the oil separator.
Net Oil Pressure
Oil Separator Pressure Drop Calculated
Calculated: Oil Filter Outlet (Manifold) Pressure minus
Suction Pressure. Monitored while compressor is running to ensure adequate lubrication.
Discharge Pressure minus Oil Separator Outlet Pressure.
Monitored to determine condition of coalescing elements inside the oil separator vessel.
Oil Circuit Pressure Drop
Outlet Scrubber
Calculated: Discharge Pressure minus Oil Filter Outlet
(Manifold) Pressure.
Vessel located on the outlet side of gas compressor or
gas chiller to remove moisture, oil, and/or contaminants.
Oil Cooler
Outlet Scrubber Inlet Pressure
Heat Exchanger where hot oil from the compressor is
cooled.
Pressure of gas measured at the inlet of the outlet
scrubber.
Temperature of the compressor oil going into the
compressor.
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
1 – 3
Section 1 • General Information
Outlet Scrubber Outlet Pressure
Pressure of gas measured at the outlet of the outlet
scrubber.
Outlet Scrubber Pressure Drop
Pressure differential between inlet and outlet of the outlet scrubber. Calculated: Scrubber Inlet Pressure minus
Scrubber Outlet Pressure.
PID Controller
PID stands for “Proportional Integral Derivative.” A PID
controller manipulates a control variable (example: valve
position or fan/pump speed) to maintain a process variable (example: process temperature or pressure) at a desired value (setpoint). The controller is driven by mathematical calculations that tell the control variable how to
react to changes in the process variable.
Temperature of the compressor oil in the bottom of the
oil separator vessel.
Suction Oil Injection
Method of providing additional lubrication to large
frame compressors (models 2401-3001) at compressor
start.
Suction Pressure
Pressure of the refrigerant or gas measured at the inlet
of the compressor.
Suction Temperature
Temperature of the refrigerant or gas measured at the
inlet of the compressor.
Surge Drum or Suction Accumulator
PLC
Vessel where additional liquid refrigerant may accumulate to prevent liquid from getting into the compressor.
PLC stands for “Programmable Logic Controller.” The
Compressor PLC is an industrial computer that controls
the compressor unit or Package.
Temperature Transmitter
Prelube Oil Pressure Calculated
Oil Filter Outlet (Manifold) Pressure minus Discharge
Pressure. Monitored at compressor start to ensure adequate lubrication.
Pressure Ratio
The ratio of compressor discharge pressure to suction
pressure.
Pressure Ratio Calculated
Device that measures temperature and transmits the
temperature reading as a 4-20mA signal. This 4-20mA
signal is read by the PLC and displayed as a temperature.
Trip
Compressor shutdown due to an abnormal process or
operational condition.
Venturi Oil Recovery
Method of recovering compressor oil from the chiller using solenoid valves on a cycle timer.
(Discharge Pressure) / (Suction Pressure)
VFD
Pressure Transducer or Transmitter
VFD stands for “Variable Frequency Drive.” A VFD is a
motor control device that can vary the speed of an AC
induction motor.
Device that measures pressure and transmits the pressure reading as a 4-20mA signal. This 4-20mA signal is
read by the PLC and displayed as a pressure.
Volume Slide Valve
Process Temperature
Internal mechanism in the compressor that controls the
amount of gas flowing into the compressor.
Temperature of the process fluid (liquid or gas, ex. natural gas, glycol, water) measured at the process outlet of
the chiller.
Volume Slide Valve Actuator
RTD
RTD stands for “Resistance Temperature Detector.”
RTDs use electrical resistance to measure temperature.
This resistance is read by the PLC and displayed as a
temperature.
Separator Oil Temperature
1 – 4
Drive motor that moves the volume slide valve, and
gives feedback on the position of the volume slide valve.
V-PLUS
V-PLUS stands for “Vilter Pumped Liquid Unitary
System.” It is a method of oil cooling where liquid refrigerant is pumped into the discharge line or housing by a
variable speed pump.
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
Section 1 • General Information
VPN
VPN stands for “Virtual Private Network.” A VPN connection allows remote access to the compressor PLC.
Winding Temperature
Internal winding temperature of the compressor main
motor measured by an RTD.
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
1 – 5
Section 1 • General Information
Hardware Components - PLC Exterior
Each Compact Logix PLC may differ, but below are typical components that can found in each PLC. For specific PLC
layout, refer to supplied electrical drawings.
1 - HMI Cover
5 - HMI (Panel View Plus 6)
2 - Enclosure Door
6 - Master Power
3 - Door Latch
7 - Compressor Control Reset Button
4 - Main Enclosure
8 - Emergency Stop Button
1
2
3
4
5
6
7
8
3
1 – 6
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
Section 1 • General Information
Hardware Components - Enclosure Door Interior
3
8
7
6
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
5
2
1 – 7
Section 1 • General Information
Hardware Components - Main Enclosure Interior
10 - Terminal Blocks (AC Connections)
17 - Compact Logix Power Supply
11 - Fuses
12 - Relays
18 - Compact Logix Processor with Ethernet, and
Memory Card
13 - DC Power Supplies
19 - Terminal Blocks (DC Low Voltage Connections)
14 - Ethernet Switch, 5 Port RJ45
20 - Terminal Blocks (Customer Connections)
15 - Panel Heater & Mounting (Not Shown, Field Installed) 21 - Terminal Blocks (Main Power Connections)
16 - Modules
10
21
1 – 8
11
20
12
19
13
18
16
11
17
14
16
15
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
Section 1 • General Information
Wiring Requirements
• Incoming power enters on the left bottom wall of the
PLC control enclosure. Route these conductors in the
space between the sub-panel and inside wall of the
enclosure.
• DC control, analog and communications or network
wiring enters on the right bottom wall of the PLC control enclosure.
• Wiring external to the panel per NEC (NFPA 70), ANSI
12.12.01 and UL-598A.
• Panel construction and wiring per UL-508A for all
panels and ANSI 12.12.01 and UL-698A for hazardous
locations.
• Electrical transmission, control, and alarm wiring
shall be stranded copper no smaller than #14 AWG.
Use JIC color code, unless otherwise noted.
• All control circuits from a source outside of this panel
are to be #14 AWG Orange.
• All control circuit neutrals from a source outside of
this panel are to be no smaller than #14 AWG White/
Orange Tracer.
• All analog inputs are to be connected with shielded
cable. Shield terminated at panel side and isolated at
device side.
• All shielding is to be grounded at a single point on the
chassis.
• Analog wiring must be run separate from AC wiring
and kept separate within the enclosure.
• All analog signal wiring shall be grounded at one end
only. Ground shield of signal cables.
• Use alpha P/N 2423C, 3 Cond, 18 AWG, shielded or
approved equal.
• All power sources for heating devices shall be supplied by others.
• Designated for a trip function (i.e. limit trip, sequence shutdown, etc.). Recommended hard wire
connection.
• Use alpha P/N 2422C, 2 Cond, 18 AWG, shielded or
approved equal.
• Category 6 Ethernet cable is recommended for all of
our equipment.
SEPARATION OF INTRINSICALLY SAFE CIRCUITS (IF
USED)
The intrinsically safe wiring enters on the bottom-left
wall of the PLC control enclosure.
To reduce the possibility of interconnection, additional
requirements exist for the separation of intrinsically safe
and non-intrinsically safe circuits. Exceptions to this rule
may be found in NEC Section 504-30(A)(1) and (2).
Separation by distance:
• The distance between intrinsically safe field wiring
terminals and non-intrinsically safe field wiring terminals shall be a minimum 8 inches.
• The distance between intrinsically safe field wiring
terminals and non-intrinsically safe field circuits shall
be a minimum 5 inches.
• The distance between intrinsically safe field wiring
terminals and non-intrinsically safe field circuits and
wiring shall be a minimum 5 inches.
• The distance between intrinsically safe field wiring
terminals and non-intrinsically safe internal wiring
shall be a minimum 2 inches.
• Only one customer network cable to switch.
• Unused defined as having a previous assignment.
Spare defined as no previous assignment.
• Where applicable, remove jumper between connections if used.
• All power circuits from a source outside of this panel
are to be no smaller than #12 AWG Orange.
• All power circuit neutrals from a source outside of
this panel are to be no smaller than #12 AWG White/
Orange Tracer.
• All equipment grounds must be Green/Yellow. For
ground conductors larger than #6 AWG, apply Green/
Yellow heat shrink or color conductor with marker at
both ends.
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
1 – 9
Section 1 • General Information
VFD Installation Recommendations
• All wiring to and from the Variable Frequency Drive
(VFD) starter shall conform to the National Fire
Protetcion Association 70 (NFPA-70), local codes and
the manufacturer’s guidelines and specifications.
• Where the cables to the motor are longer than 1000’,
always use a sine filter (customer must provide Vilter
with cable lengths from feeder to starter and from
starter to motor).
• Thoroughly read the manufacturer’s VFD installation
and instruction manuals.
• Line and load conductors must be separated, as
much as the starter cabinet will allow, and cannot be
in the same conduit or cable chase.
• In the event of a code and manufacturer recommendation conflict, always use the more stringent
standard.
• Only use an inverter duty rated motor built to NEMA
MG1 PART 30 & 31.
• Always used copper conductors to feed the VFD
starter and motor. Use cable with thermoset insulation such as XLPE or XHHW-2 from the VFD to motor.
• It is preferred to use VFD cable, service wire company
or equal, between the VFD and the motor per manufacturer’s instructions.
• It is preferred to use continuous metal conduit to the
VFD starter to the motor.
• If non-metallic conduit is used, VFD cable must be
used.
• By no means shall power and control cables run in
parallel - cables must be separated, as much as the
starter cabinet will allow, and cannot be in the same
conduit or cable chase.
• For analog signals, use twisted shielded control cable
rated for 600V.
• When a generator is feeding a VFD starter, use a 5%
line reactor.
• Some countries require RFI/EMI filters -- please consult country codes and standards.
• As an insurance policy against motor shaft currents,
use a split ring bearing protection ring on the motor
shaft with the non-load bearing insulated.
• If using VFD cable in metal conduit, the metal conduit must be insulated at the motor, so that the metal
conduit is not a continuous run.
• Always use flexible metallic liquid-tight conduit to
feed the motor from metallic conduit.
• Grounding conductor must run from the VFD ground
terminals directly to the motor conduit box. Always
use proper grounding techniques (Star Method) and
sized according to the NFPA 70 NEC.
• Always use bonding bushings on all conduit ends,
• Always use bonding bushings on all conduit ends,
with proper size braided copper cable bonded to the
starter panel.
• All grounding and bonding conductors and lugs must
terminate on bare metal and not to painted surfaces.
• Always use a minimum of 3% impedance line reactor
such as MTE or equal.
• Where the cables to the motor are longer than 50’,
always use a load reactor (customer must provide
Vilter with cable lengths from feeder to starter and
from starter to motor).
• Where the cables to the motor are longer than 500’,
always use a DV/DT load filter (customer must provide Vilter with cable lengths from feeder to starter
and from starter to motor).
1 – 10
Single Screw Compressor PLC Operation Manual •Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
Overview
The following are standard equipment on all compressor
units or packages that can be controlled or monitored:
data from DCS/Central Controller
• Auto Start/Stop based on process pressure or
temperature
• Control of Local/Remote from DCS/Central Controller
• Suction Pressure – Pressure of the gas measured at
the inlet of the compressor.
• Setpoint Group
Controller
• Discharge Pressure – Pressure of the gas at the outlet
of the compressor. Measured at the oil separator.
• Remote Starting and Stopping of the Compressor
• Oil Filter Inlet Pressure – Pressure of oil measured at
the inlet of the oil filter(s).
Selectable
from
DCS/Central
• The following are optional compressor unit-specific
items that can be controlled or monitored:
• Compressor Main Motor VFD Control
• Oil Manifold Pressure (Oil Filter Out) – Pressure of oil
measured after the oil filter(s).
• Main Motor Winding Temperatures
• Prelube Oil Pressure (at compressor start, Oil
Manifold – Discharge Pressure)
• Motor Vibration (up to 2 sensors)
• Main Motor Bearing Temperatures
• Net Oil Pressure (when compressor running, Oil
Manifold – Suction Pressure)
• Compressor Vibration (up to 2 sensors)
• Suction Temperature – Temperature of the gas measured at the inlet of the compressor.
• Suction Oil Injection Solenoid Valve (Used on Models
2401-3001)
• Discharge Temperature – Temperature of the gas and
oil mixture at the outlet of the compressor
• Suction-Discharge Equalizing Solenoid Valve
• Separator Oil Temperature – Temperature of the oil in
the oil separator vessel.
• Oil Injection Temperature – Temperature of the oil as
it goes into the compressor.
• Capacity Slide Valve Position - % Travel of the capacity
slide valves.
• Oil Separator Level Switch
• Oil Drain Solenoid Valve
• Oil Separator Outlet Pressure, to calculate pressure
drop across coalescing elements of oil separator
• 2-Way Oil Mixing Valve
• Air Cooled Oil Cooler (Step or VFD Type)
• Oil Cooler Inlet/Outlet Temperatures
• Volume Slide Valve Position - % Travel of the volume
slide valves.
• Oil Cooler Standby Heater
• Main Motor Amperage – Current draw by the main
motor.
• Separator Oil Heaters
The following are optional compressor unit and package
items that can be controlled or monitored, specific to refrigeration applications:
• Compressor Main Motor
• Air Cooled Condenser (Step Type or VFD Type)
• Oil Pump (Full Time or Part Time Selectable)
• Evaporative Air Cooled Condenser
• Selectable groups of setpoints for varying operating
conditions
• Water Cooled Condenser
• Oil Injection Control Valve
• Liquid Injection Oil Cooling
The following are additional software controls available
that are native to all compressor units controlled by the
compressor PLC:
• VPLUS Liquid Oil Cooling
• Monitoring of Instrument Data, Alarms, Trips, and
Machine Status by DCS/Central Controller
• Hotgas Bypass Solenoid
• Compressor Capacity control setpoint from DCS/
Central Controller
• Liquid Refrigerant Temperature – Temperature of the
liquid refrigerant in the chiller.
• Control of Compressor Loading/Unloading from
DCS/Central Controller
• Process Temperature – Temperature of the process
fluid leaving the chiller
• Economizer Port Solenoid Valves (single or dual)
• Venturi Oil Recovery
• Capacity control on External Pressure Transducer
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 1
Section 2 • Operational Descriptions
The following are optional compressor unit and package
items that can be controlled or monitored, specific to
gas compression applications:
• Up to 2 Aftercoolers
STARTING OF THE COMPRESSOR/PERMISSIVES
• Air Cooled Step Type
To run the compressor, it must me started from the
“Start Menu” screen on the control panel HMI. Pressing
“Unit Start” in the “Start Menu” screen will initiate a start
if all permissives to initiate a start are met. To initiate a
start, the following conditions must be met:
• Air Cooled VFD Type
• Water Cooled
• Inlet Scrubber
• Pressure Drop across vessel
• Control Power is ON (Emergency Stop button is not
pressed, Master Control Relay is energized or activated by remote device, indicated by pilot light on front
of panel)
• Condensate Drain
• Low/High Level Safety Switches
• Outlet Scrubber
• No Active Trips
• Pressure Drop across vessel
When a start is initiated, the compressor will start if all
permissives to run the compressor are met. If all permissives to run the compressor are not met, the control will
wait in a “standby” mode until all conditions to run are
satisfied. Any condition that the control is waiting on
is annunciated on the overview and menu screens and
logged in the Event List. To begin the compressor startup sequence, the following conditions must be met:
• Condensate Drain
• Low/High Level Safety Switches
• Discharge Recycle Valve
• Building Enclosure Devices
• Space Heaters
• Roof Exhaust Fans
• Methane %LEL Detector
• Oil Separator Gas Outlet Temperature – Temperature
of the gas measured at the discharge of the oil separator. Used to monitor the temperature of the gas
relative to dew point. If the compressor is warm and
this temperature is too low, the controller will generate an alarm.
• Oil Separator Gas Outlet Pressure – Pressure of the
gas measured at the discharge of the oil separator.
Used to monitor the pressure drop across the coalescing elements of the oil separator. When pressure drop is too high, the controller will generate an
alarm.
• Reheater Vessel and shell/tube side Temperatures –
Temperature of the gas measured at the discharge of
both the shell and tube sides of the reheater vessel.
• Periodic Slide Valve Exercising
2 – 2
Operational Descriptions and
Diagrams
• Control Power is ON (Emergency Stop button is not
pressed and Master Control Relay is energized, indicated by pilot light on front of panel)
• No Active Trips
• Compressor start has been initiated by pressing “Unit
Start” in the “Start Menu” screen.
• Remote Permissive input is ON
• Soft run permissive from the DCS/Central Controller
is ON (if control by communications selected)
• Anti-Recycle Timer is not active
• Suction – Discharge is equalized to within a settable
differential
• Auto Start control is calling for the compressor to
start, if Auto Start/Stop is Enabled.
If a start is initiated at the compressor, the machine state
indicator will indicate “Standby” and the condition the
compressor is waiting on will be annunciated on the
overview and menu screens.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
COMPRESSOR STARTUP SEQUENCE
PERMISSIVES MET &
UNIT STARTED
IDLE
MOVE CAPACITY & VOLUME
SLIDES HOME
CAPACITY & VOLUME SLIDE
POSITION < 5% TRAVEL
COMPRESSOR STOP
TRIP
AUTO CYCLE OFF
STORE (MANIFOLD MINUS DISCHARGE)
PRELUBE DIFFERENTIAL PRESSURE
ADD 1 TO PRELUBE PUMP
START COUNTER. WAIT 5
SECONDS BETWEEN EACH
PUMP START
PRELUBE
PUMP START
COUNTER = 3
START OIL PUMP
PRELUBE NOT
SATISFIED AFTER OIL
PUMP RUNS FOR 10
SECONDS (SETTABLE)
PRELUBE PRESSURE
(MANIFOLD
DIFFERENTIAL
PRESSURE) SATISFIED
FOR 3 SECONDS
START COMPRESSOR
PRELUBE PRESSURE NOT
SATISFIED FOR 3 SECONDS
TRIP
TRIP
PRELUBE PRESSURE
SATISFIED FOR 10 SECONDS
COMPRESSOR WARM-UP
OIL PUMP ON
START MODULATING VOLUME SLIDE
50 SECONDS DELAY BEFORE CAPACITY
SLIDE VALVES GO TO AUTO AND OIL
PUMP SHUTS OFF
7-15 MINUTE DELAY (MODELS 2401-3001
ONLY) BEFORE CAPACITY SLIDE
VALVES GO TO AUTO AND OIL PUMP
SHUTS OFF
COMPRESSOR RUNNING
MODULATE CAPACITY SLIDE
OIL PUMP MAY STOP ON PRESSURE RATIO
Figure 2-1. Compressor Startup Sequence Diagram
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 3
Section 2 • Operational Descriptions
AUTO START-STOP
CAPACITY SLIDE CONTROL
When enabled, the Auto Start-Stop feature will allow
the compressor to cycle on and off based on the controlled pressure or temperature. The Anti-Recycle timer
still applies when Auto Start-Stop is enabled. Additional
variables that factor in to Auto Start-Stop are described
below:
Reference examples, Figures 2-2, 2-3 and 2-4
• Auto Start Pressure/Temperature: Pressure or
Temperature at which the control will start the
compressor.
• Auto Start Delay: Amount of time that the Auto Start
Pressure/Temperature must be met before the compressor is commanded to start.
• Auto Stop Pressure/Temperature: Pressure or
Temperature at which the control will stop the
compressor.
• Auto Stop Delay: Amount of time that the Auto Stop
Pressure/Temperature must be met with the capacity slide at or below “Minimum Slide Position” before
the compressor is commanded to stop.
• Minimum Slide Position: Position the capacity slide
must be at or below before the compressor is commanded to stop.
When Auto Start-Stop control is enabled, it will function
as follows:
• When Auto Start Pressure/Temperature is met for the
Auto Start Delay Time, the compressor will be commanded to start.
• When the Auto Stop Pressure/Temperature is met
and the capacity slide has decreased to the Minimum
Slide Position for the Auto Stop Delay time, the compressor will be commanded to stop.
ANTI-RECYCLE
After the compressor main motor stops, it is not allowed
to re-start again for a settable time. This is to protect the
compressor from damage by allowing oil to drain from it
before the next start. If the Anti-Recycle timer is active,
a banner will appear on the overview and menu screens
that shows the remaining time. If a start is initiated, the
compressor state indicator will indicate “Standby” until
the Anti-Recycle timer is done. If all other permissives
are met, the compressor will re-start.
While the compressor is running, the controller will automatically adjust the position of the compressor capacity slide valve to hold the desired pressure or temperature. Three control methods are available:
• Discharge Pressure Control: Compressor loads to increase discharge Pressure to desired setpoint
• Suction Pressure Control: Compressor loads to lower
suction pressure to desired setpoint
• Process Temperature Control: Compressor Loads to
lower process temp to desired setpoint. An instrument to monitor the Process Temperature is required.
The capacity slide control of the PLC operates by periodically calculating an adjustment to the capacity slide position based on where the selected process variable is in
relation to the target setpoint. When the process pressure or temperature is far away from the setpoint, capacity slide position is adjusted by the defined maximum.
As the control pressure or temperature gets closer to
setpoint, smaller adjustments are made to the capacity
slide position. All of the variables that factor in to this
calculation are described below:
• Target pressure or Temperature – the desired suction
pressure, discharge pressure, or process temperature
that the machine will try to maintain.
• Upper Proportional Deadband – Range above Target
pressure or Temperature where no capacity slide adjustment will be made.
• Lower Proportional Deadband – Range below Target
pressure or Temperature where no capacity slide adjustment will be made.
• Upper Proportional Band – Range above Target pressure or Temperature where adjustments to capacity
slide position are made proportional to the difference between Target pressure or Temperature and
Actual. Outside this range, the adjustment made will
be the set maximum.
• Lower Proportional Band - Range below Target pressure or Temperature where adjustments to capacity
slide position are made proportional to the difference between Target pressure or Temperature and
Actual. Outside this range, the adjustment made will
be the set maximum.
• Load Interval Time – Cycle time for calculating capacity slide position adjustment when the controller
is calling for the machine to increase capacity slide
position. Where the Load Interval Time is T1, the
control will make an adjustment calculation every T1
seconds.
2 – 4
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
• Unload Interval Time – Cycle time for calculating capacity slide position adjustment when the controller
is calling for the machine to decrease capacity slide
position. Where the Load Interval Time is T2, the
control will make an adjustment calculation every T2
seconds.
range, the capacity slide position adjustment will be
a percentage of A1.
• Max Unload Adjustment per Interval – Maximum position adjustment that can be made when the control
is calling for the machine to decrease capacity slide
position. Where the Maximum Unload Adjustment
is A2, the capacity slide position will increase by A2%
every cycle of the Unload Interval Timer when outside the bandwidth range. When inside the bandwidth range, the capacity slide position adjustment
will be a percentage of A2.
• Max Load Adjustment per Interval – Maximum position adjustment that can be made when the control
is calling for the machine to increase capacity slide
position. Where the Maximum Load Adjustment is
A1, the capacity slide position will increase by A1%
every cycle of the Load Interval Timer when outside
the bandwidth range. When inside the bandwidth
When the compressor is stopped, the capacity slide will
return to its minimum position.
SUCTION PRESSURE & PROCESS TEMPERATURE
PRESSURE OR TEMPERATURE
*EVERY CYCLE OF INTERVAL TEMPERATURE, MAX LOAD
ADJUSTMENT IS MADE (CAP INCREASE)
60 PSIG
UPPER PROPORTIONAL BAND
(10 PSID)
*EVERY CYCLE OF INTERVAL TIMER, CAPACITY COMMAND WILL
INCREASE BY CALCULATED AMOUNT, PROPORTIONAL TO ERROR
51 PSIG
UPPER PROPORTIONAL DEADBAND
1 PSID (NO ADJUSTMENT)
LOWER PROPORTIONAL DEADBAND
1 PSID (NO ADJUSTMENT)
TARGET (50 PSIG)
49 PSIG
LOWER PROPORTIONAL BAND
(5 PSID)
*EVERY CYCLE OF INTERVAL TIMER, CAPACITY COMMAND WILL
DECREASE BY CALCULATED AMOUNT, PROPORTIONAL TO ERROR
45 PSIG
*EVERY CYCLE OF INTERVAL TIMER, MAX UNLOAD
ADJUSTMENT IS MADE (CAPACITY DECREASE)
DISCHARGE PRESSURE
*EVERY CYCLE, UNLOAD BY MAX UNLOAD ADJUSTMENT
105 PSIG
PRESSURE
UPPER BANDWIDTH
5 PSID
*EVERY CYCLE OF INTERVAL TIMER, MAKE
PROPORTIONAL ADJUSTMENT (CAPACITY DECREASE)
UPPER PROPORTIONAL DEADBAND
2 PSID (NO ADJUSTMENT)
LOWER PROPORTIONAL DEADBAND
2 PSID (NO ADJUSTMENT)
LOWER BANDWIDTH
10 PSID
102 PSIG
TARGET (100 PSIG)
98 PSIG
*EVERY CYCLE OF INTERVAL TIMER, MAKE
PROPORTIONAL ADJUSTMENT (CAPACITY INCREASE)
90 PSIG
*EVERY CYCLE, LOAD BY MAX LOAD ADJUSTMENT
Figure 2-2. Capacity Slide Control Diagram (Example)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 5
Section 2 • Operational Descriptions
+UPPER PROPORTIONAL BAND
+UPPER PROPORTIONAL DEADBAND
ACTUAL
PRESSURE
TARGET
-LOWER PROPORTIONAL DEADBAND
-LOWER PROPORTIONAL BAND
COMMANDED CAPACITY
SLIDE VALVE POSITION
MAX LOAD PER
INTERVAL (%)
MAX LOAD PER
INTERVAL (%)
LOAD INTERVAL
CYCLE TIME
(SECONDS)
UNLOAD INTERVAL
CYCLE TIME
(SECONDS)
Figure 2-3. Operational Diagram - Capacity Slide, Discharge Pressure (Example)
2 – 6
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
SUCTION PRESSURE
Section 2 • Operational Descriptions
TARGET
DISCHARGE
PRESSURE
CAPCITY
SLIDE
SPEED / CAPACITY
100
MOTOR
SPEED
50
0
START
10 SECOND
DELAY (FIXED)
10 SECOND
DELAY (FIXED)
Figure 2-4. Operational Diagram - Capacity Slide, Suction
Pressure per Process Temperature (Example)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 7
Section 2 • Operational Descriptions
OPERATING MODES
The loading and unloading of the compressor can be
configured to operate in several ways, depending on the
needs of the site. This mode selection is made at the
“Start Menu” screen. There are four basic modes, described below:
• Local-Auto: The compressor will adjust the position
of the capacity slide automatically using the control’s
capacity control algorithm. The target pressure or
temperature setpoint is set on the compressor’s local HMI.
• Local-Manual: The operator is in control of the capacity slide from the local HMI. When in Local-Manual
mode, the operator controls the capacity slide position using increase/decrease pushbuttons on the
compressor overview screen.
• Remote-Auto: The compressor will adjust the position of the capacity slide automatically using the
control’s capacity control algorithm. The target
pressure or temperature setpoint is defined by the
DCS/Central Controller via communications. (NOTE:
Control by Communications must be enabled to use
this mode.)
• Remote-Manual: The capacity slide position is controlled by a DCS or Central Controller. There are four
selectable methods of using Remote-Manual Control,
settable from the HMI’s configuration screen.
For safety reasons, remote mode is only enabled under
certain conditions. If these conditions are not met, the
machine will revert to local mode. To be able to enter
remote mode, the one of the following must be true:
• Auto Mode Selected, Control By Communications
Enabled.
• Manual Mode Selected, Remote Manual Control
Source is Hardwired
• Manual Mode Selected, Control by Communications
Enabled
In the event that the communications link between the
compressor PLC and the central controller/DCS is lost,
the action taken is selectable from the Configuration
screen. The machine will Trip or revert to Local mode
and continue to run depending on the selection.
The compressor PLC can be remotely commanded to
Local or Remote Mode if Control by Communications is
enabled.
NOTE
If a main motor VFD is being used for capacity control,
only discrete commands may be used in RemoteManual Control.
LOAD LIMITS AND FORCED UNLOADING
Reference example, Figure 2-5
• Caphold-Ethernet: Capacity slide valve position
commands are given by the central controller/
DCS via communications. (NOTE: Control by
Communications must be enabled to use this
method.)
To protect the compressor and process, the controller
will inhibit the compressor from loading or force it to unload if certain variables get outside of set ranges. Three
load limiting variables are continuously monitored:
• Caphold-4-20mA Hardwired: Capacity slide
valve position commands are given by the central controller/DCS via a 4-20mA analog signal.
The scaling is 4mA = 0% Capacity Slide Position,
20mA = 100% capacity slide position. Control by
Communications does not need to be enabled to
use this method.
• High Discharge Pressure
• Discrete Load/Unload – Ethernet: Capacity slide
valve increase and decrease commands are given
by the central controller/DCS via communications. (NOTE: Control by Communications must
be enabled to use this method.)
• Discrete Load/Unload – Hardwired: Capacity slide
valve increase and decrease commands are given
by the central controller/DCS via discrete hardwired inputs. Control by communications does
not need to be enabled to use this method.
In any of the above modes, all local safeties and load limits still apply and will override external commands.
2 – 8
• Low Suction Pressure
• High Main Motor Amps
There are independent Load Limit Setpoints specific to
“Setpoint 1” and “Setpoint 2” setpoint groups, allowing load limits to be specific to unique operating conditions. For each of the three variables, three setpoints are
active:
• Inhibit Loading: when this setpoint is reached, the
compressor will not be allowed to continue loading.
• Unload at: when this setpoint is reached, the capacity slide will move in the decrease direction continuously (forced unload) until the “Unload To” setpoint
is reached.
• Unload To: this is the setpoint at which the capacity slide will stop unloading from a forced unload
condition.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
When a load limit or forced unload condition is active it
will be annunciated in the status banner on the overview
and menu HMI screens, and will also be logged in the
event list.
LOW SUCTION PRESSURE
INHIBIT
LOAD
D
A
FORCE
UNLOAD TO
C
SUCTION
PRESSURE
FORCE
UNLOAD AT
B
(A) CAPACITY SLIDE WILL NOT INCREASE
(B & C) CAPACITY SLIDE WILL DECREASE UNTIL PRESSURE REACHES “C”
(D) CAPACITY SLIDE MAY INCREASE
HIGH DISCHARGE PRESSURE OR AMPS
FORCE
UNLOAD AT
B
FORCE
UNLOAD TO
DISCHARGE
PRESSURE
OR AMPS
INHIBIT
LOAD
C
A
D
(A) CAPACITY SLIDE WILL NOT INCREASE
(B & C) FORCED UNLOAD UNTIL DISCHARGE PRESSURE/AMPS REACHES “C”
(D) CAPACITY SLIDE ALLOWED TO INCREASE
Figure 2-5. Operational Diagram - Load Limits / Forced Unloading (Example)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 9
Section 2 • Operational Descriptions
VFD CAPCITY CONTROL
When a VFD is used on the compressor main motor to
control capacity, it works in conjunction with the capacity slide valve to maintain the Target pressure or
Temperature. At start, the compressor main motor
will run at 50% speed until the capacity slide reaches
its maximum position. At this point, the VFD will begin
adjusting the speed of the main motor to maintain the
target pressure or temperature. The speed adjustments
made by the controller follow the same algorithm as the
capacity slide. Additional variables that factor into the
operation of a main motor VFD are described below:
• Max Speed Increase per Interval – Maximum motor speed adjustment that can be made when the
control is calling for the machine to increase motor
speed. Where the Maximum Speed Increase is S1,
the main motor will speed up by S1% every cycle of
the Load Interval Timer when outside the bandwidth
range. When inside the bandwidth range, the motor
speed adjustment will be a percentage of S1.
• Max Speed Decrease per Interval – Maximum motor speed adjustment that can be made when the
control is calling for the machine to decrease motor
speed. Where the Maximum Speed Decrease is S2,
the main motor will slow down by S2% every cycle of
the Unload Interval Timer when outside the bandwidth range. When inside the bandwidth range, motor speed adjustment will be a percentage of S2.
SAFETIES
The compressor controller continuously monitors operational and process data and annunciates an alarm and/
or stops the machine if any condition becomes abnormal. Two levels of safeties exist when an abnormal condition is detected.
• Alarm: If active, alarms are annunciated on the compressor HMI. When activated, a popup screen showing the date and time of the alarm and alarm message
will appear. Alarms are also logged in the Event List.
An alarm serves only as a warning to the operator; if
an alarm is active the machine is still allowed to run.
• Trip: If active, trips will shut the machine down or not
allow the compressor to start. Trips are annunciated
on the compressor HMI. When activated, a popup
screen showing the date and time of the trip and
trip message will appear. Trips are also logged in the
Event List.
The “Alarm Reset” pushbutton on the overview screen
will reset any active alarms or trips if the abnormal condition has been removed.
For a comprehensive list of alarms and trips and possible
causes, see the troubleshooting guide in this manual.
EMERGENCY STOP
VOLUME SLIDE CONTROL
When the compressor is running, the volume slide valve
adjusts automatically to operating conditions for optimal efficiency. The volume slide position is determined
by a lookup table that takes into account the size and
model of compressor, type of refrigerant or gas being
compressed, capacity slide position, and pressure ratio.
An offset can be applied to the volume slide’s calculated
target position to adjust it for unique running conditions. In Compressor Control Setpoints page 2, the setpoints below are available:
• Volume Slide Adjustment Factor: amount of offset
that will be applied to the calculated volume slide position target.
• Capacity Slide Range Adjustment Factor is Applied:
The volume slide adjustment factor or offset will be
applied when the capacity slide is within this range.
The volume slide may be manually controlled, although
it is best to leave it in Auto Mode. Manual volume slide
control may be used when calculating an offset to apply
to the volume slide calculation. The volume slide mode
is settable in the “Volume Slide Details” screen.
2 – 10
When the compressor is stopped, the volume slide valve
is commanded to go to its minimum position.
Reference Figure 2-6
The Emergency Stop circuit in the compressor control
panel energizes the Master Control Relay, which provides power to PLC outputs that control actuators, heaters, motor starters, valves, etc. The Master Control Relay
may be energized by pressing the “Control Power On”
illuminated pushbutton on the door of the compressor
control panel. When the Master Control Relay is energized, the “Control Power On” pushbutton will illuminate. The following conditions must be satisfied to energize the Master Control Relay:
• Emergency Stop pushbutton on the door of the compressor control panel must be pulled out.
• Any additional Emergency stops or safety devices
tied in to the Emergency Stop circuit must be reset.
• The compressor PLC must be booted up and
operational.
• The 24-volt DC power supplies in the compressor
control panel must be powered up and OK.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
Figure 2-6. Control Panel Master Power and Emergency Stop Electrical Circuit
OIL HEATERS
OIL DRAIN SOLENOID
Immersion Heaters in the oil separator are controlled by
the compressor PLC to maintain warm oil. The heaters
cycle on and off to maintain a desired separator oil temperature range.
If installed, the oil drain solenoid valve opens for a settable time on compressor stop to allow oil to drain from
the compressor. It also opens during the prelube retry
wait periods in the prelube sequence.
SUCTION OIL INJECTION SOLENOID
Used on 401mm screw machines (models 2401-3001).
If installed, the suction oil injection solenoid feeds additional oil from the oil separator to compressor suction
on start. The valve is opened for a settable time after the
compressor main motor starts.
SUCTION-DISCHARGE EQUALIZING SOLENOID
If installed, the equalizing solenoid opens for a settable
time on compressor stop to equalize pressure between
suction and discharge of the compressor.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 11
Section 2 • Operational Descriptions
PID CONTROLS (1 OF 2)
OIL MIXING
VALVE
M
HOT OIL FROM
OIL SEPARATOR
OIL FLOW
OIL COOLER
COOL OIL FROM
OIL COOLER
VALVE POSITION
(100% OPEN)
TARGET
OIL
INJECTION
TEMPERATURE
VALVE POSITION (% OPEN)
MACHINE STARTS
Figure 2-7. Operational Diagram - 2-Way Oil Mixing Valve
2-WAY OIL MIXING VALVE
OIL INJECTION VALVE
Reference Figure 2-7
If installed, the oil injection valve is a motorized valve that
regulates the amount of oil going into the compressor.
If installed, the 2-way oil mixing valve modulates to control compressor Oil Injection Temperature. The valve is
installed in the compressor oil circuit such that when it
closes, it forces more oil through the cooler. The valve
position is adjusted to mix the correct amount of hot oil
from the oil separator and cool oil coming back from the
oil cooler.
A PID controller determines the valve position command
to maintain Oil Injection Temperature. On rising temperature the controller will command the valve to close;
on falling temperature the controller will command the
valve to open.
• When the compressor is stopped, the 2-way mixing
valve is commanded to 100% open.
• When running, the valve will remain open until Oil
Injection Temperature begins to rise, and then begin
to close.
2 – 12
The valve position is determined by a lookup table. The
percentage compressor loading determines the position
of the valve.
• When the compressor is stopped, the valve will be
commanded to 100% open.
• When the compressor is running, the valve will begin
to modulate when oil injection temperature reaches
a “Start” setpoint, adjustable on the “Compressor
Control Setpoints” screens.
• When the compressor is running, and oil injection
temperature is above the “Start” setpoint, the valve
will go to the commanded position calculated by the
controller.
NOTE
The oil injection valve must be configured to be reverse
acting. 4mA = 100% open, 20 mA = 0% open.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
TE
OIL COOLER
TEMPERATURE (OIL COOLER
OUTLET TEMPERATURE)
TARGET
OUTPUT
TEMPERATURE
START
TEMPERATURE
FAN SPEED
MINIMUM FAN
SPEED
Figure 2-8. Operational Diagram - Air Cooled Oil Cooler (VFD Type)
AIR COOLED OIL COOLER (VFD TYPE)
Reference Figure 2-8
If installed, the VFD type air cooled oil cooler is a heat
exchanger that uses one or more fans running on a VFD
to control the oil temperature at its outlet.
A PID controller adjusts the speed of the fan(s) to control
the temperature at the outlet of the oil cooler. When the
temperature of the oil at the outlet of the cooler exceeds
the desired temperature plus a deadband, the fan(s) will
increase speed to add more cooling. When outlet temperature drops below the desired temperature minus a
deadband, the fan(s) will decrease speed.
• When the compressor is stopped, the oil cooler fan(s)
will stop.
• When the compressor is running and the oil cooler outlet temperature rises above the “Oil Cooler
Start” temperature set in the “VFD Type Oil Cooler
Setpoints” screen, the fan(s) will start at a settable
minimum speed.
• When the compressor is running and the oil cooler
outlet temperature is below the deadband, the PID
controller will decrease fan speed.
OIL COOLER TEMPERATURES
It is possible to monitor Oil Cooler Inlet Temperature,
and monitor Oil Cooler Outlet Temperature if an oil cooler is not being controlled.
OIL COOLER STANDBY HEATER
If installed, a heater within the remote oil cooler is controlled by the compressor PLC to maintain warm oil. The
heater cycles on and off to maintain a desired oil cooler
outlet temperature range. Setpoints to control the Oil
Cooler Standby Heater are on the “Oil Cooler Control
Setpoints (Step or VFD Type)” Screen.
• When the compressor is running and the oil cooler
outlet temperature is above the deadband, the PID
controller will increase fan speed.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 13
Section 2 • Operational Descriptions
TE
AFTERCOOLER
AFTERCOOLER OUTLET
TEMPERATURE
TARGET
OUTPUT
TEMPERATURE
START
TEMPERATURE
FAN SPEED
MINIMUM FAN
SPEED
Figure 2-9. Operational Diagram - Air Cooled Aftercooler (VFD Type)
AIR COOLED AFTERCOOLER (VFD TYPE)
Reference Figure 2-9
If installed, the VFD type air cooled aftercooler is a heat
exchanger that uses one or more fans running on a
VFD to remove heat from the gas discharged from the
compressor. The VFD speeds up or slows down the fan
motor to control the amount of cooling done by the
aftercooler.
• When the compressor is running and the aftercooler
outlet temperature is above the deadband, the PID
controller will increase fan speed.
• When the compressor is running and the aftercooler
outlet temperature is below the deadband, the PID
controller will decrease fan speed.
A PID controller adjusts the speed of the fan(s) to maintain the outlet gas temperature of the aftercooler. When
the aftercooler outlet temperature exceeds the desired
temperature plus a deadband, the fan(s) will increase
speed to add more cooling. When aftercooler outlet
temperature drops below the desired temperature minus a deadband, the fan(s) will decrease speed.
• When the compressor is stopped, the aftercooler
fan(s) will stop.
• When the compressor is running and the gas aftercooler outlet temperature rises above the “Start
Aftercooler At” set in the “VFD Type Aftercooler
Setpoints” screen, the fan(s) will start at a settable
minimum speed.
2 – 14
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
PT
CONDENSER
TARGET
OUTPUT
PRESSURE
CONDENSING PRESSURE
START
PRESSURE
FAN SPEED
MINIMUM FAN
SPEED
Figure 2-10. Operational Diagram - Air Cooled Condenser (VFD Type)
AIR COOLED CONDENSER (VFD TYPE)
Reference Figure 2-10
If installed, the VFD type air cooled condenser is a heat
exchanger that uses one or more fans running on a VFD
to condense refrigerant vapor into a liquid. The VFD
speeds up or slows down the fan motor to control the
amount of cooling done by the condenser.
A PID controller adjusts the speed of the fan(s) to control
condensing pressure. When the condensing pressure
exceeds the desired pressure plus a deadband, the fan(s)
will increase speed to add more cooling. When condensing pressure drops below the desired temperature minus a deadband, the fan(s) will decrease speed.
• When the compressor is stopped, the condenser
fan(s) will stop.
• When the compressor is running and the oil cooler
outlet temperature rises above the “Condenser Start
Pressure” set in the “VFD Type Condenser Setpoints”
screen, the fan(s) will start at a settable minimum
speed.
• When the compressor is running and the condensing
pressure is below the deadband, the PID controller
will decrease fan speed.
EVAPORATIVE CONDENSER
If installed, an evaporative condenser incorporates a water circulating pump that mists water over the condenser to provide additional cooling.
• When using with step-type condensers, the pump
can be added or removed from the step sequence as
if it were another fan. The pump will start when the
steps that it is enabled are active.
• When using with VFD-type condensers, the pump
can be enabled or disabled by a selection on the condenser control setpoints screen. When enabled, the
pump starts at the same time as the fan.
• When the compressor is running and the condensing
pressure is above the deadband, the PID controller
will increase fan speed.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 15
Section 2 • Operational Descriptions
TE
OIL COOLER
TARGET
START
TEMPERATURE OR
PRESSURE
FANS TURNING ON
STEP #
TEMPERATURE OR
PRESSURE
FANS TURNING OFF
1 STEP ADDED
EVERY CYCLE OF
CYCLE TIMER
DEADBAND
NO STEPS ADDED
OR REMOVED
TARGET
DEADBAND
1 STEP REMOVED
EVERY CYCLE OF
CYCLE TIMER
STEP #
Figure 2-11. Operational Diagram - All Air Cooled Oil Coolers (Step Type)
AIR COOLED OIL COOLER (STEP TYPE)
Reference Figure 2-11
If installed, the step type air cooled oil cooler is a heat
exchanger that uses multiple fans to control the oil temperature at its outlet.
The controller starts and stops fans in a sequence to control the temperature at the outlet of the oil cooler. When
the temperature of the oil at the outlet of the cooler
2 – 16
exceeds the desired temperature plus a deadband, fans
will be turned on after a time delay to add more cooling.
When outlet temperature drops below the desired temperature minus a deadband, fans will be turned off after
a time delay.
• When the compressor is stopped, all oil cooler fans
are turned off.
• When the compressor is running and the oil cooler
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
outlet temperature rises above the “Oil Cooler Start”
temperature set in the “Step Type Oil Cooler
Setpoints” screen, the first fan (or group of fans) will
start.
• When the compressor is running and the oil cooler
outlet temperature is above the deadband, a fan (or
group of fans) will start each time through the “Step
Dwell Time.”
• When the compressor is running and the oil cooler
outlet temperature is below the deadband, a fan (or
group of fans) will stop each time through the “Step
Dwell Time.”
• Once started, the first fan or group of fans will remain
running until the compressor stops.
AIR COOLED AFTERCOOLER (STEP TYPE)
Reference Figure 2-11
If installed, the step type air cooled aftercooler is a heat
exchanger that uses multiple fans to remove heat from
the gas discharged from the compressor. The number
of fans that run is determined by the gas temperature at
the outlet of the aftercooler.
The controller starts and stops fans in a sequence to control the gas temperature at the outlet of the aftercooler. When the aftercooler outlet temperature exceeds
the desired temperature plus a deadband, fans will be
turned on after a time delay to add more cooling. When
aftercooler outlet temperature drops below the desired
temperature minus a deadband, fans will be turned off
after a time delay.
• When the compressor is stopped, all aftercooler fans
are turned off.
• When the compressor is running and the aftercooler
outlet temperature rises above the “Start Aftercooler
At” temperature set in the “Step Type Aftercooler
Setpoints” screen, the first fan (or group of fans) will
start.
• When the compressor is running and the aftercooler
outlet temperature is above the deadband, a fan (or
group of fans) will start each time through the “Step
Dwell Time.”
• When the compressor is running and the aftercooler
outlet temperature is below the deadband, a fan (or
group of fans) will stop each time through the “Step
Dwell Time.”
• Once started, the first fan or group of fans will remain
running until the compressor stops.
AIR COOLED CONDENSER (STEP TYPE)
Reference Figure 2-12 and 2-11 for curves
If installed, the step type air cooled condenser is a heat
exchanger that uses multiple fans to condense refrigerant vapor to a liquid. The number of fans that run is determined by the refrigerant pressure at the condenser.
The controller starts and stops fans in a sequence to
control the condensing pressure. When the condensing
pressure exceeds the desired pressure plus a deadband,
fans will be turned on after a time delay to add more
cooling. When condensing pressure drops below the
desired pressure minus a deadband, fans will be turned
off after a time delay.
• When the compressor is stopped, all condenser fans
are turned off.
• When the compressor is running and the oil cooler
outlet temperature rises above the “Condenser Start”
pressure set in the “Step Type Condenser Setpoints”
screen, the first fan (or group of fans) will start.
• When the compressor is running and the condensing pressure is above the deadband, a fan (or group
of fans) will start each time through the “Step Dwell
Time.”
• When the compressor is running and the condensing pressure is below the deadband, a fan (or group
of fans) will stop each time through the “Step Dwell
Time.”
• Once started, the first fan or group of fans will remain
running until the compressor stops.
PT
CONDENSER
Figure 2-12. Operational Diagram - Air Cooled Condenser
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 17
Section 2 • Operational Descriptions
WATER COOLED GAS
AFTERCOOLER
TE
COOLED GAS
OUT
GAS IN
COOL WATER
WARM WATER
TARGET
OUTPUT
TEMPERATURE
GAS OUTLET TEMPERATURE
START
TEMPERATURE
FAN SPEED
MINIMUM FAN
SPEED
Figure 2-13. Operational Diagram - Water Cooled Gas Aftercooler
WATER COOLED GAS AFTERCOOLER
Reference Figure 2-13
If installed, the water-cooled gas aftercooler is a heat exchanger that uses a modulating valve to control cooling
water flow to remove heat from the gas discharged by
the compressor. The valve position is adjusted to control
the amount of cooling done by the aftercooler.
• When the compressor is running and the aftercooler
outlet temperature is above the deadband, the PID
controller will increase the valve opening degree.
• When the compressor is running and the aftercooler
outlet temperature is below the deadband, the PID
controller will decrease the valve opening degree.
A PID controller adjusts the opening degree of the
modulating valve to maintain a desired temperature at
the outlet of the gas aftercooler. When the aftercooler
outlet temperature exceeds the desired pressure plus a
deadband, the valve will open further to add more cooling. When aftercooler outlet temperature drops below
the desired temperature minus a deadband, the valve
will begin to close.
• When the compressor is stopped, the valve will be
commanded to 0% open (full close).
• When the compressor is running and the condensing
pressure rises above the “Open Valve At” setpoint in
the “Water Cooled Aftercooler Setpoints” screen, the
valve will open to a settable minimum position.
2 – 18
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
WATER COOLED
CONDENSER
PT
DISCHARGE
LIQUID
COOL WATER
WARM WATER
TARGET
OUTPUT
PRESSURE
CONDENSING PRESSURE
START
PRESSURE
FAN SPEED
MINIMUM FAN
SPEED
Figure 2-14. Operational Diagram - Water Cooled Condenser
WATER COOLED CONDENSER
Reference Figure 2-14
If installed, the water-cooled condenser is a heat exchanger that uses a modulating valve to control cooling
water flow to condense refrigerant vapor into a liquid.
The valve position is adjusted to control the amount of
cooling done by the condenser.
• When the compressor is running and the condensing
pressure is above the deadband, the PID controller
will increase the valve opening degree.
• When the compressor is running and the condensing
pressure is below the deadband, the PID controller
will decrease valve opening degree.
A PID controller adjusts the opening degree of the modulating valve to control condensing pressure. When the
condensing pressure exceeds the desired pressure plus a
deadband, the valve will open further to add more cooling. When condensing pressure drops below the desired
temperature minus a deadband, the valve will begin to
close.
• When the compressor is stopped, the valve will be
commanded to 0% open (full close).
• When the compressor is running and the condensing
pressure rises above the “Condenser Start Pressure”
set in the “Water Cooled Condenser Setpoints”
screen, the valve will open to a settable minimum
position.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 19
Section 2 • Operational Descriptions
LIQUID INJECTION
VALVES
M
S
LIQUID
REFRIGERANT
TE
SUCTION
DISCHARGE
COMPRESSOR
TARGET
OUTPUT
PRESSURE
DISCHARGE TEMPERATURE
START
PRESSURE
VALVE POSITION
MINIMUM VALVE
POSITION
Figure 2-15. Operational Diagram - Liquid Injection Valve
LIQUID INJECTION VALVE
• When the compressor is stopped, the valve will be
commanded to 0% open (full closed).
Reference Figure 2-15
If installed, liquid injection is a method of oil cooling
where liquid refrigerant is injected into a port on the
compressor. A modulating valve regulates the amount
of liquid allowed into the compressor to control the
amount of cooling done by liquid injection.
A PID controller adjusts the opening degree of the modulating valve to control compressor discharge temperature (temperature of the gas and oil mixture leaving the
compressor). When the discharge temperature exceeds
the desired temperature plus a deadband, the valve will
open further to add more cooling. When discharge temperature drops below the desired temperature minus a
deadband, the valve will begin to close.
2 – 20
• When the compressor is running, the discharge temperature rises above the “Open Valve Above” setpoint and Separator Oil Temperature rises above “Oil
Separator Override Temp” in the “Liquid Injection
Valve Setpoints” screen, the valve will open to a settable minimum position.
• When the compressor is running and the discharge
temperature is above the deadband, the PID controller will increase the valve opening degree.
• When the compressor is running and the discharge
temperature is below the deadband, the PID controller will decrease valve opening degree.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
VPLUS
S
LIQUID
REFRIGERANT
SUCTION
COMPRESSOR
DISCHARGE
TE
TARGET
OUTPUT
TEMPERATURE
DISCHARGE TEMPERATURE
START
TEMPERATURE
PUMP SPEED
MINIMUM PUMP
SPEED
Figure 2-16. Operational Diagram - VPLUS
VPLUS LIQUID INJECTION PUMP
Reference Figure 2-16
If installed, VPLUS liquid injection is a method of oil cooling where liquid refrigerant is pumped through a nozzle
in the discharge housing of the compressor. A variable
speed pump regulates the amount of liquid pumped
into the compressor to control the amount of cooling.
A PID controller adjusts the speed of the VPLUS pump to
control compressor discharge temperature (temperature of the gas and oil mixture leaving the compressor).
When the discharge temperature exceeds the desired
temperature plus a deadband, the pump will increase
speed to add more cooling. When discharge temperature drops below the desired temperature minus a deadband, the pump will decrease speed.
• When the compressor is stopped, the pump is
stopped.
• When the compressor is running, the discharge
temperature rises above the “Start Pump At” setpoint and Separator Oil Temperature rises above
“Oil Separator Override Temp” in the “VPLUS Pump
Setpoints” screen, the pump will start at a settable
minimum speed.
• When the compressor is running and the discharge
temperature is above the deadband, the PID controller will increase the pump speed.
• When the compressor is running and the discharge
temperature is below the deadband, the PID controller will decrease the pump speed.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 21
Section 2 • Operational Descriptions
DISCHARGE
PRESSURE
DISCHARGE
RECYCLE
SETTING
COMPRESSOR
CONTROL
TARGET
100
DISCHARGE
RECYCLE VALVE
POSITION (% OPEN)
0
Figure 2-17. Operational Diagram - Discharge Recycle Valve
DISCHARGE RECYCLE VALVE
Reference Figure 2-17
NOTE
Discharge recycle valve must be controlled by others
when multiple compressors are connected to a
common header.
If installed, the discharge recycle valve is a motorized or
air actuated valve that recycles discharge gas back to the
suction of the compressor. The valve acts as a regulator,
opening to maintain the set pressure in the discharge
line.
A PID controller adjusts the opening degree of the valve
to maintain a desired pressure on the high pressure side
of the valve. When the recycle control pressure exceeds
the desired pressure plus a deadband, the valve will start
to open to recycle high pressure gas back to suction.
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 2 • Operational Descriptions
ECONOMIZER SOLENOID(S)
If installed, an economizer is a heat exchanger that operates at an intermediate pressure, above suction pressure
but below discharge pressure. Up to two solenoids control when the economizer becomes part of the refrigeration process.
The compressor controller opens and closes the economizer port solenoid valves based on ON and OFF capacity slide position setpoints. The economizer solenoid is
typically energized when capacity slide valve position is
above a settable value.
• When the compressor is stopped, economizer solenoid valves are closed.
• When the compressor is running, the economizer
port solenoid will open when capacity slide position is greater than the “ON Above” Setpoint in the
Compressor Control Setpoints Screens.
• When the compressor is running, the economizer
port solenoid will close when capacity slide position is
less than the “OFF Below” Setpoint in the Compressor
Control Setpoints Screens.
HOTGAS BYPASS SOLENOID
If installed, the hotgas bypass solenoid valve enables a
regulator that circulates discharge “hotgas” back to suction to simulate a load on the compressor by raising the
suction pressure. It is typically enabled on low load conditions to prevent the compressor from shutting down
on low suction pressure.
The compressor controller opens and closes the hotgas
bypass solenoid valve based on ON and OFF capacity
slide position setpoints. The hotgas bypass solenoid is
typically energized when capacity slide position is below
a settable value.
• When the compressor is stopped, the hotgas bypass
solenoid is closed.
• When the compressor is running, the hotgas bypass
solenoid will open when capacity slide position is less
than the “ON Below” Setpoint in the Compressor
Control Setpoints Screens.
• When the compressor is running, the economizer
port solenoid will close when capacity slide position is
less than the “OFF Below” Setpoint in the Compressor
Control Setpoints Screens.
VENTURI OIL RECOVERY
If installed, the venturi oil recovery system uses a group
of solenoid valves that function together to return
any oil that has accumulated in the chiller back to the
compressor. When the solenoid valves are energized,
discharge hotgas passes through a venturi to draw out
any oil that may have accumulated in the chiller. Venturi
Oil Recovery is typically used in Freon or Propane applications where the oil is less dense than the liquid refrigerant and tends to float on top.
Oil recovery is activated by a level switch that senses low
oil level in the oil separator. When activated, the venturi
oil recovery solenoids will cycle on and off by a settable
cycle timer. ON time and OFF time are settable in the
“Compressor Control Setpoints” screens.
GAS SCRUBBERS
A gas scrubber (or knockout drum) is a vessel with a
demister pad or coalescing elements installed to remove
moisture and other contaminants from the gas stream.
Gas scrubbers may be installed on the suction side or
discharge side of a gas compressor (if an aftercooler is
used, the scrubber is installed downstream of the aftercooler), or on the inlet or outlet side of a gas chiller. A
condensate pump or solenoid valve drains accumulated
moisture from the vessel.
Gas scrubbers include the following devices:
• Pressure transducers on the inlet and outlet of the
vessel – used to measure pressure drop across the
demister pad or coalescing elements to help determine when to clean or replace.
• Level switches to monitor the condensate level:
• LSH (High Level) – when liquid level reaches the
LSH level switch, an alarm is annunciated on the
compressor HMI.
• LSHH (High High Level) – when liquid level reaches the LSHH level switch, an alarm or trip is annunciated on the compressor HMI. The alarm or trip
action is configurable depending on the site and
location of the vessel. If trip action is selected, the
compressor will shut down if the LSHH is activated. Typically the purpose of the LSHH is to alarm
or shut down the compressor to prevent bringing
liquid into the compressor suction.
• LSLL (Low Low Level) – when liquid level drops below the LSLL level switch, an alarm or trip is annunciated on the compressor HMI. The alarm or trip
action is configurable depending on the site and
location of the vessel. If trip action is selected, the
compressor will shut down if the LSLL is activated.
Typically the purpose of the LSLL is to detect if the
liquid seal is lost to prevent introducing gas into
the condensate drain system.
• Condensate Drain System:
• A drain pump or solenoid valve will turn on when
the liquid level in the scrubber reaches the “Cutin”
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
2 – 23
Section 2 • Operational Descriptions
level switch.
• The drain pump or solenoid valve will turn off
when the liquid level in the scrubber drops to the
“Cutout” level switch.
• Dual pumps may be used. Selection of Pump A or
B is made in the Configuration screen.
BUILDING ENCLOSURE DEVICES
If the compressor unit is mounted inside a building enclosure, the following are monitored/controlled:
• Space Heater – maintains a desired temperature
range inside the enclosure. Space Heater ON and
OFF setpoints are in the compressor control setpoint
screens.
• Exhaust Fans – maintains a desired temperature
range inside the enclosure. Exhaust Fan ON and OFF
setpoints are in the compressor control setpoint
screens. If the methane detector %LEL reaches alarm
level, the exhaust fans will also turn on until the alarm
is cleared.
• Methane Detector – monitors the %LEL of the air
inside the enclosure. Generates an alarm and trip.
Alarm and trip setpoints are settable in the Alarm and
Trip Setpoints screen.
• Smoke Detector – If triggered by smoke within the
enclosure, will shut down the compressor and trip
the compressor emergency stop.
PERIODIC SLIDE VALVE EXERCISE
If used, the periodic slide valve exercise function moves
the slide valves if they have not moved for a settable
time to prevent them from sticking. This function applies to both capacity and volume slides.
• If the compressor is running, and the capacity slide
has not moved for the settable amount of time, the
exercise function will increase capacity slide position by 10% (if its current position is less than 50%)
or decrease capacity slide position by 10% (if its current position is greater than 50%). Once the slide has
been moved, the exercise function ‘releases’ slide to
operate to maintain desired pressure or temperature.
• If the compressor is running, and the volume slide
has not moved for the settable amount of time, the
exercise function will increase volume slide position
by 10% (if its current position is less than 50%) or decrease volume slide position by 10% (if its current position is greater than 50%). Once the slide has been
moved, the volume slide will return to the commanded position calculated by the controller.
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 3 • Overview Screens
Compressor and System Overview Screens
The Compressor and system overview screens shows
compressor status, configuration, any active alarms or
trips, and live process data. The compressor and/or process are displayed in a format similar to a P&ID diagram
with live process data shown on the screen.
From the compressor and system overview screens, all
other screens are accessed by pressing the “Main Menu”
goto screen button in the lower right of the screen. The
system overview display is accessed from the compressor overview screen and vice-versa, if a system overview
screen is displayed.
The following are some examples of different compressor and package configurations and how they are displayed on the HMI.
Figure 3-1. Basic Compressor Unit Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
3 – 1
Section 3 • Overview Screens
Gas Compressor Unit Overview Screen Example 1
VSG-2801 Compressor Unit for Natural Gas with Air Cooled VFD Type Oil Cooler
Figure 3-2. Gas Compressor Unit Overview Screen Example 1,
VSG-2801 Compressor Unit for Natural Gas with Air Cooled VFD Type Oil Cooler
3 – 2
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 3 • Overview Screens
Gas Compressor Unit Overview Screen Example 2
VSG-2101 Compressor Unit for Natural Gas in Enclosure with Vibration Monitoring
Figure 3-3. Gas Compressor Unit Overview Screen Example 2,
VSG-2101 Compressor Unit for Natural Gas in Enclosure with Vibration Monitoring
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
3 – 3
Section 3 • Overview Screens
Gas Compressor Unit Overview Screen Example 3
VSG-2101 Compressor Unit for Natural Gas with Scrubbers and Aftercooler
Figure 3-4. Gas Compressor Unit Overview Screen Example 3,
VSG-2101 Compressor Unit for Natural Gas with Scrubbers and Aftercooler
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 3 • Overview Screens
Refrigeration Compressor Unit Overview Screen Example 1
VSM-601 Compressor Unit for Ammonia with Liquid Injection Oil Cooling and Economizer
Figure 3-5. Refrigeration Compressor Unit Overview Screen Example 1,
VSM-601 Compressor Unit for Ammonia with Liquid Injection Oil Cooling and Economizer
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
3 – 5
Section 3 • Overview Screens
Refrigeration Compressor Unit Overview Screen Example 2
VSM-601 Compressor Unit Gas Chiller for R134a
Figure 3-6. Refrigeration Compressor Unit Overview Screen Example 2,
VSM-601 Compressor Unit Gas Chiller for R134a
3 – 6
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 3 • Overview Screens
Refrigeration Compressor Unit Overview Screen Example 3
VSM-601 Compressor Unit Gas Chiller for R134a with Venturi Oil Recovery and Reheater
Figure 3-7. Refrigeration Compressor Unit Overview Screen Example 3,
VSM-601 Compressor Unit Gas Chiller for R134a with Venturi Oil Recovery and Reheater
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 4 • HMI Navigation
HMI Navigation
HMI screens are accessed by using the navigation buttons on each screen. When the HMI boots up, the compressor overview screen is displayed by default. The HMI
Screens are divided into groups, all of which are accessible from the Menu Screen.
Figure 4-1. Main Menu Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
4 – 1
Section 4 • HMI Navigation
The Menu Screen allows the user to view basic compressor configuration, status, active alarms and trips, as well
as navigate to configuration, control, calibration, and diagnostics screens.
An electronic copy of the compressor PLC manual is accessed from the Menu Screen.
Main
Menu
Compressor
Overview
Compressor
Animation
(1)
(1)
(1)
(1)
Start
Menu
(1)
(1)
Gas Chiller
Reheat
Overview
Gas Chiller
Overview
Natural Gas
Overview
Natural Gas
Reheat
Overview
Refrigeration
Overview
Overview Screen is selected in
“Configuration Ͳ Authorized Users ONLY”.
Only the selected overview screen is visible.
Figure 4-2. Screen Navigation Map - Main Screens (1 of 7)
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 4 • HMI Navigation
Main
Menu
(SP)
Compressor
Control Ͳ 1 of 3
(Suction Pressure)
(PT)
Compressor
Control Ͳ 1 of 3
(Process Temperature)
(DP)
Compressor
Control Ͳ 1 of 3
(Discharge Pressure)
Compressor
Control Ͳ 2 of 3
(SP) Visible when in Suction Pressure Mode only.
(PT) Visible when in Process Temperature Mode only.
Compressor
Control Ͳ 3 of 3
(DP) Visible when in Discharge Pressure Mode only.
Alarm and Trip
Setpoints Ͳ 1 of 2
Alarm and Trip
Setpoints Ͳ 2 of 2
Figure 4-2. Screen Navigation Map - Compressor Control, Alarm and Trip (2 of 7)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
4 – 3
Section 4 • HMI Navigation
Main
Menu
Instrument Cal.
Ͳ Overview
Pressure
Calibration Ͳ 1 of 3
Temperature
Calibration Ͳ 1 of 3
Slide
Calibration
Other Analog
Device Calibration
(SUPER to Edit)
(SUPER to Edit)
(SUPER to Edit)
(SUPER to Edit)
Pressure
Calibration Ͳ 2 of 3
Temperature
Calibration Ͳ 2 of 3
(SUPER to Edit)
(SUPER to Edit)
Pressure
Calibration Ͳ 3 of 3
Temperature
Calibration Ͳ 3 of 3
(SUPER to Edit)
(SUPER to Edit)
Volume Slide
Details
Figure 4-2. Screen Navigation Map - Instrument Calibration (3 of 7)
Main
Menu
5 Minute Trend Data
Page 1
Pressures & Temp
2 Hour Trend Data
Page 1
Pressures & Temp
24 Hour Trend Data
Page 1
Pressures & Temp
5 Day Trend Data
Page 1
Pressures & Temp
24 Hour Trend Data
Page 2 ͲͲ Motor Amps,
Cap. Pos., Vol. Pos.
5 Day Trend Data Page
2 ͲͲ Motor Amps, Cap.
Pos., Vol. Pos.
5 Minute Trend Data
Page 2 ͲͲ Motor Amps,
Cap. Pos., Vol. Pos.
2 Hour Trend Data
Page 2 ͲͲ Motor Amps,
Cap. Pos., Vol. Pos.
Figure 4-2. Screen Navigation Map - Trending (4 of 7)
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 4 • HMI Navigation
Main
Menu
After Cooler 1
(Step Type)
(1)
After Cooler 1
(VFD Type)
(1)
After Cooler 1
(Water Cooled)
(1)
After Cooler 2
(Step Type)
(1)
After Cooler 2
(VFD Type)
(1)
After Cooler 2
(Water Cooled)
(1)
(1) Visibility dependant on After Cooler Selections
Figure 4-2. Screen Navigation Map - Aftercoolers (5 of 7)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
4 – 5
Section 4 • HMI Navigation
Main
Menu
Diagnostic Force
Outputs Ͳ Authorized
Users ONLY
Goto
Configure Mode
(SUPER)
(SUPER)
Diagnostic Force
Outputs Ͳ Authorized
Users ONLY
Shutdown
(SUPER)
(SUPER)
Initial Baseline Running
Data (1 of 2)
Configuration Ͳ
Authorized Users ONLY
(SUPER)
Initial Baseline Running
Data (2 of 2)
Set Date
and Time
Define Device Names Ͳ
Instrumentation
Define Device Names Ͳ
Alarm and Trip – 1
(SUPER)
(SUPER)
Define Device Names Ͳ
Devices and Vessels
Define Device Names Ͳ
Alarm and Trip Ͳ 2
(SUPER)
(SUPER)
Figure 4-2. Screen Navigation Map - Configuration, Device Names and Initial Baseline (6 of 7)
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 4 • HMI Navigation
Main
Menu
Comms
Diagnostics
Condenser
(Water Cooled)
Event List
(### Ͳ ###)
Condenser
(Step Type)
Captured Data at
Shutdown (1 of 2)
Condenser
(VFD Type)
Captured Data at
Shutdown (2 of 2)
Oil Mixing
Valve
Oil Cooler
(Step Type)
Oil Cooler
(VFD Type)
Discharge
Recycle Valve
Liquid Injection
Valve
Liquid Injection
Ͳ VPLUS Pump
Figure 4-2. Screen Navigation Map - Condenser, Oil Mixing or Cooler, Liquid Injection, Misc.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
4 – 7
Section 4 • HMI Navigation
HMI Security
SUPER
Some items and screens on the HMI require a login to be
viewed or changed.
Login accounts are described below, each with its default password and level of access.
• This user account is intended for site supervisors,
managers, and superintendents.
• Default Password: 1
• Permissions
• May start and stop the machine
DEFAULT
• May change Remote-Local and Auto-Manual
modes
• This is the user account that is active when the HMI
boots up or the user logs out of another user account.
• May Operate the machine in Manual mode
• Permissions:
• May view setpoints, calibration data, and
diagnostics
• May start and stop the machine
• May change setpoints
• May change Remote-Local and Auto-Manual
modes
• May force Discrete and Analog outputs on the PLC
• May view setpoints, calibration data, and
diagnostics
• May make changes to machine configuration
selections
LOGGING IN
OP1, OP2, OP3, OP4, OP5
• These user accounts are intended for operators.
• Default Password: 1
• Permissions
• May start and stop the machine
• May change Remote-Local and Auto-Manual
modes
• May Operate the machine in Manual mode
• May view setpoints, calibration data, and
diagnostics
To log on, press the “Log On” button. The “Log On” button is located in the Upper-Right corner of most screens,
and in the lower right corner of the menu screen. The
login pop-up screen will appear, see Figure 4-3.
Enter User Name and password using the pop-up keyboard, see Figure 4-4.
It is recommended to log out when finished. Every login
is recorded in the compressor control’s event list. After
10 minutes of inactivity, the HMI will automatically log
out the current user.
• May change setpoints
Figure 4-3. Login Pop-up Screen
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 4 • HMI Navigation
Figure 4-4. Login Screen Keyboard
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
4 – 9
4 – 10 / Blank
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 5 • Configuration - Supervisor Level
Configuration Screen - Supervisor Level
NOTE
Some screens may have inverted colors for ease of
readability.
by the user are included on this screen. To change option selections, press on the list selector and use the up,
down, and enter buttons on the lower side of the screen.
Most of the configuration that is specific to the compressor or package is completed at the factory and not accessible to the user. The options that may be configured
Figure 5-1. Configuration Screen - All Options Shown (Supervisor Level)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
5 – 1
Section 5 • Configuration - Supervisor Level
DATE AND TIME
Allows the Real Time Clock in the PLC to be set. Pressing
“Set Date and Time” will bring up the “Set Date and
Time” pop-up screen.
• Date and Time must be set in 24-hour format.
• Pressing “Set Date and Time” will set the PLC time
clock.
• The HMI time clock will automatically synchronize to
the PLC time clock.
Figure 5-2. Set Date/Time Pop-Up Screen - Supervisor Level
REMOTE OPERATION
For the compressor control to accept commands from a
DCS or Central Controller, Control by Communications
must be enabled. For more details on remote operation, see Section 8, Communication with DCS/Central
Controller.
• Control by Communications
• If enabled, allows a central controller/DCS to send
commands to the compressor PLC
• If disabled, allows a central controller/DCS to read
data only.
• Communications Watchdog and Communication
Fault Action
• The settable watchdog time defines the amount
of time a loss in communications can be detected
before triggering a communication fault
• Action Taken on Communication Fault is
selectable:
• Alarm and Revert to local mode – The compressor controller will generate an alarm, and
change the mode to local-auto. The machine
will continue to run (if running) in local mode.
• Trip Machine – Communication Fault will shut
the machine down.
• Remote Manual Control Source – Defines how the capacity slide will be operated in remote Manual mode.
• Caphold-Ethernet: Caphold values are sent
to compressor via Ethernet IP. The capacity slide will go to the desired value. (Control By
Communications must be enabled)
• Caphold-4-20mA hardwired: command signal
sent to compressor via 4-20mA input, scaled
0-100%.
• Discrete Load/Unload - Ethernet. Turning on a bit
will cause the compressor to increase or decrease
Capacity. (Control By Communications must be
enabled)
• Discrete Load/Unload – Hardwired: Discrete
Increase and Decrease commands via Physical
Inputs.
• If a VFD is selected, only discrete increase and decrease commands are supported. The compressor program will handle the transitioning of increasing/decreasing capacity slide to increasing/
decreasing drive speed.
•
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 5 • Configuration - Supervisor Level
PROCESS VARIABLE SOURCE
OIL PUMP OPERATION
Defines the pressure data used to control the capacity
slide.
Determines operation of the oil pump.
• Local Hard-Wired Transducer – capacity slide and
auto start/stop is controlled by the suction/discharge
pressure transducer mounted on the compressor
unit or package.
• Common/Remote – capacity slide and auto start/
stop is controlled by suction/discharge header pressure data from a DCS/Central Controller. On loss of
communications, the compressor control will either shut down the compressor or revert to the local transducer based on the “Communication Fault
Action” setting.
• Full Time – the oil pump will run continuously when
the compressor is running.
• Part Time – the oil pump will run at compressor startup but will stop if there is enough differential pressure from discharge-suction.
See the compressor start sequence in Section X
“Operational Descriptions” for more information on the
functionality of the oil pump.
MOTOR RTDs
Selects if Motor Winding and Bearing Temperatures are
being monitored by the controller.
CONTROL MODE
Defines the pressure or temperature the compressor will try to maintain. See Section X “Operational
Descriptions” for more information on the functionality
of each control mode.
SELECT SETPOINT 1 / 2
Determines which group of setpoints is active – used
when a machine could be run in 2 unique sets of operating conditions, ex. High/low stage swing compressor.
AUTO START-STOP
Enables or Disables the auto start-stop function. See
Section X “Operational Descriptions” for more information on the functionality of the auto start-stop function.
SCHEDULED MAINTENANCE TIMER
Optional function that can be set up to display maintenance reminders after a settable amount of runtime. When the accumulated runtime reaches the set
“Maintenance Interval” time, a status message will appear on the overview and menu screens indicating the
text entered in the “Message” field.
INLET / OUTLET SCRUBBER PUMP A / B
If the inlet and/or outlet scrubbers include dual condensate pumps, this selection determines which pump is
active.
CHANGE PASSWORD
Pressing the “Change Password” button opens the
“Change Password” pop-up screen, see Figure 5-3 To
change a password on an account, the user must be
logged in under that account.
Figure 5-3. Change Password Pop-Up Screen - Supervisor Level
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
5 – 3
Section 5 • Configuration - Supervisor Level
PANELVIEW CONFIGURATION
Pressing the “Panelview Configuration” button closes
the compressor control application running on the HMI
and opens the Factory Talk View ME Station configuration screens.
INITIAL RUNNING DATA
Pressing the “Initial Running Data” Button opens the
Initial Running Data Screen which shows baseline data
logged when the compressor was new. See Section X
“Diagnostics Screens” for more information.
DEVICE NAMES
Pressing the “Device Names” button navigates to the
Define Device Names screens. See “Define Device
Names” later in this section for more information.
BACK TO MENU
Pressing the “Back to Menu” button navigates back to
the main menu screen.
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 5 • Configuration - Supervisor Level
Editing Device Names
DEVICES AND VESSELS
The “Device Names” group of screens allows a user
logged in as “SUPER” to edit names shown on the screen
identifying compressor unit and package equipment,
instrumentation, and alarm and trip designations. To
edit the text fields in this group of screens, press on the
string input button and use the popup keyboard to edit
the text.
The user may navigate to other screens within the
“Define Device Names” group by using the navigation
buttons on the right side of the screen.
In Figure 5-4, this screen allows the user to edit device
names shown on the screen for devices, vessels, and
equipment installed on the compressor unit or package.
Typically, the device names entered in this group of
screens are the designations for each device, instrument, or alarm that relate it back to the P&ID diagram.
The “Device Names” group of screens is divided into
three sections, see Figure 5-3.
Figure 5-4. Define Device Names - Devices and Vessels (Supervisor Level)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
5 – 5
Section 5 • Configuration - Supervisor Level
INSTRUMENTATION
In Figure 5-5, this screen allows the user to edit device
names shown on the screen for instrumentation installed on the compressor unit or package.
Figure 5-5. Define Device Names - Instrumentation (Supervisor Level)
5 – 6
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 5 • Configuration - Supervisor Level
ALARM AND TRIP
In Figure 5-6, this screen allows the user to edit the alarm
and trip designation text that appears in the alarm and
trip banners, alarm pop-up screen, and event list.
In addition, messages for 5 user-defined alarms and trips
may be defined on this screen.
Figure 5-6. Define Device Names - Alarm and Trip 1 (Supervisor Level) (1 of 2)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
5 – 7
Section 5 • Configuration - Supervisor Level
Figure 5-6. Define Device Names - Alarm and Trip 2 (Supervisor Level) (2 of 2)
5 – 8
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 6 • Instrument Calibration
Calibration Main Screen
NOTE
Some screens may have inverted colors for ease of
readability.
Pressing the “Instrument Calibration” navigation button
on the menu screen opens the instrument calibration
group of screens. This group of screens allows the user
to view and edit calibration data for specific instruments
installed on the compressor unit or package.
From the main menu, pressing the “Instrument
Calibration” button navigates to the calibration overview
screen, see Figure 6-1. The calibration overview screen
shows information related to all instruments installed
on the compressor unit or package, including their raw
values, base units (used internally in the program) and
as displayed. Calibration of specific instruments is accessed using the navigation buttons on the right side of
the screen.
Figure 6-1. Instrument Calibration Overview Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
6 – 1
Section 6 • Instrument Calibration
Pressure Calibration Screen
In Figure 6-2, the temperature calibration group of
screens allows the user to change the pressure units
displayed on the screen as well as calibrate pressure
instruments.
The following pressure units are available for display:
• PSIG (Pounds/square inch gage)
• PSIA (Pounds/square inch absolute)
• kPa[A] (Kilopascals absolute)
Pressure units are specific to individual pressure instruments. Changing the pressure display units for a transducer also converts all pressure setpoints related to that
transducer to the new selected units.
• kPa[G] (Kilopascals gage)
• kg/cm2[A] (Kilograms/square centimeter absolute)
• kg/cm2[G] (Kilograms/square centimeter gage)
• inHg (inches of mercury) – Vacuum is shown in inHg,
positive pressure is shown in PSIG
• inWC (gage)
• Bar[A] (absolute)
• Bar[G] (gage)
• Torr[A] (absolute)
• Torr[G] (gage)
Figure 6-2. Pressure Calibration Screen - 1 of 3
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 6 • Instrument Calibration
CALIBRATE PRESSURE INSTRUMENT
CALIBRATE TRANSDUCER TO A KNOWN PRESSURE
To calibrate a pressure instrument, proceed with the following steps:
There are two options when calibrating a transducer to
a known pressure.
1.
Select the units that the transducer is calibrated
in. For example, for a transducer calibrated 0-200
PSIA, the transducer units selected shall be ‘PSIA.’
For a transducer calibrated -30inHg to 30PSIG, the
transducer units selected shall be “inHg.”
2.
Select the units that the pressure will be displayed
in on the HMI.
3.
Enter the raw mA range (typically 4-20mA)
4.
Enter the Span of the instrument. For a 0-200 PSIA
transducer, Enter “0” for XDCR Min and “200” for
XDCR Max.
NOTE
Differential pressures does not require calibration,
but the differential pressure display units can be
selected.
OPTION 1
1.
Open the pressure transducer to a known pressure.
2.
Adjust the Offset value until the “Displayed” value
is equal to the known pressure.
OPTION 2
1.
Open the pressure transducer to a known pressure.
2.
Enter the known pressure (in transducer units) into
“Target Value.” The controller will calculate an offset based on the known pressure that was entered.
Figure 6-3. Pressure Calibration Screen - 3 of 3
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
6 – 3
Section 6 • Instrument Calibration
Temperature Calibration Screen
The temperature calibration group of screens allows the
user to change the temperature units displayed on the
screen as well as calibrate temperature instruments.
Four Temperature units are available for display:
CALIBRATE TEMPERATURE INSTRUMENTS
There two types of temperature instruments that can be
calibrated, RTDs and temperature transmitters.
To calibrate an RTD, proceed with the following steps.
NOTE
Typically, RTDs are very accurate and do not require
calibration.
• Fahrenheit
• Celsius or Centigrade
1.
Expose the RTD to a known temperature (such as a
slurry of crushed ice and water).
• Rankine (Absolute Fahrenheit temperature scale)
2.
Enter an offset so the displayed temperature is
equal to the known temperature.
Temperature units can be changed by touching on the
list selector in any temperature calibration screen and
using the up, down, and enter buttons. Changing the
temperature display units also converts all temperature
setpoints to the new selected units.
To calibrate a temperature transmitter, proceed with
the following steps.
1. Enter the raw mA range (typically 4-20mA).
• Kelvin (Absolute Celsius temperature scale)
2.
Enter the span of the transmitter in degrees
Fahrenheit. For a 32-392 Fahrenheit transmitter,
Enter “32” for XDCR Min and “392” for XDCR Max.
Figure 6-4. Temperature Calibration Screen
6 – 4
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 6 • Instrument Calibration
Other Analog Device Calibration
The Other Analog Device Calibration Screen allows the
user to calibrate additional 4-20mA input devices.
4-20mA devices that can be calibrated:
• Main Motor Amperage
• Main Motor VFD Speed
• Compressor and Motor Vibration Sensors
CALIBRATE AN ADDITIONAL INSTRUMENT
To calibrate an additional instrument, proceed with the
following steps.
1.
Enter the raw mA range (typically 4-20mA).
2.
Enter the Span of the transmitter.
3.
Enter minimum scale value in “XDCR Min” and full
scale value for “XDCR Max.”
• Methane Detector
Figure 6-5. Other Analog Calibration Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
6 – 5
Section 6 • Instrument Calibration
Slide Calibration Screen
The slide calibration screen allows the user to calibrate
slide valve actuators.
Both the capacity and volume slide actuators should be
calibrated when one or more of these have occurred:
• Compressor unit starting up for the first time.
Slide Calibration Overview:
• A new actuator motor has been installed.
• Must be logged in as “SUPER” to calibrate slides.
• There is an error code flashing on the actuator’s
circuit board - an attempt to recalibrate should be
made.
• Press “Enter Slide Calibration” To Activate Slide
Calibration Mode, see Figure 6-7. (Machine MUST be
stopped to enter slide calibration mode. Machine will
not be allowed to start if slide calibration is active.)
• Use up/down pushbuttons to move slide actuators.
• Table in slide calibration screen indicates the correct
rotation of the slide valve command shaft.
• Enter minimum and maximum raw values in numerical entry fields.
• The range of travel is not correct and the command
shaft travel is physically correct.
• The compressor is pulling high amperage, the calibration of the volume slide should be checked.
• An actuator does not unload below 5%, or an actuator that doesn’t move.
• Something is not working properly such as the actuators, RTDs or transducers.
Figure 6-6. Slide Calibration Screen (Not in Calibration Mode)
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 6 • Instrument Calibration
CALIBRATE SLIDE VALVE ACTUATORS
Slide valve actuators must be installed prior to calibration. Refer to Slide Valve Actuator Installation procedure
in VSG/VSSG Compressor Unit manual (35391SSG). The
following steps pertain to calibrating one slide valve actuator. Repeat procedure to calibrate other slide valve
actuator.
WARNING
After stopping the compressor, allow the compressor
and surrounding components to cool down prior
to servicing. Failure to comply may result in serious
injury.
CAUTION
Do not calibrate in direct sunlight. Failure to comply
may result in damage to equipment.
To calibrate optical actuators, proceed with the following steps.
1.
Stop compressor unit and allow to cool.
2.
Remove screws securing actuator cover to actuator
assembly. As a reference see Figure 6-8.
CAUTION
Wires are attached to the connector on the actuator
cover. Handle actuator cover with care to prevent
damage to wires. Failure to comply may result in
damage to equipment.
3.
Carefully lift actuator cover from actuator assembly
and tilt towards the Turck connector. Raise cover
high enough to be able to press the blue calibration
button and be able to see the red LED on top of the
assembly.
4.
From main screen:
• Press Main Menu > Instrument Calibration >
Calibrate Slides
5.
Logging on with high-level access will prompt
the Calibrate button to appear on Instrument
Calibration Overview screen.
Figure 6-7. Slide Calibration Screen (In Calibration Mode)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
6 – 7
Section 6 • Instrument Calibration
6.
Select the Min or Max position of the slide valve to
be calibrated.
NOTE
The “Slide calibration” screen displays twice the
actuator output voltage. Both these values (% volume
and % capacity) are meaningless until calibration has
been completed.
NOTE
When the increase and decrease arrow buttons do
not correspond to the increase and decrease shaft
rotations, swap the blue and brown wires of the
“power cable”. This will reverse the rotation of the
actuator/command shaft.
7.
Press increase or decrease arrows to move the slide
valve and check for the correct rotation.
NOTE
When the actuator is in calibration mode, it outputs
0V when the actuator is running and 5V when it
is still. The actuator voltage will fluctuate during
calibration. After the actuator has been calibrated, 0V
output will correspond to the minimum position and
5V to the maximum position.
8.
9.
Quickly press and release the blue push button on
the actuator one time. This places the actuator in
calibration mode. The red LED will begin flashing
rapidly.
CAUTION
DO NOT CONTINUE TO ENERGIZE THE ACTUATOR
MOTOR AFTER THE SLIDE HAS REACHED THE
MECHANICAL STOP. Doing so may cause mechanical
damage to the motor or shear the motor shaft key.
When the slide has reached the mechanical stop
position, press the button in the center of the photochopper to release the brake, and thereby release the
tension on the actuator motor.
Use the down arrow button to drive the slide valve
to its minimum “mechanical stop” position. Do not
continue to run the actuator in this direction after
the slide valve has reached the stop. Doing so may
cause damage to the actuator or the slide valve.
10. Press down and release on the photo-chopper shaft
to disengage the brake, releasing tension from the
motor mount, see Figure 6-9.
11. Use the up arrow button to pulse the actuator to
where the slide is just off of the mechanical stop
and there is no tension on the motor shaft.
12. Quickly press and release the blue button on the
actuator again. The red LED will now flash at a slower rate indicating that the minimum slide valve position (zero position) has been set.
13. Use the up arrow button to drive the slide to its
maximum “mechanical stop” position. Do not
continue to run the actuator in this direction after
the slide valve has reached the stop. Doing so may
cause damage to the actuator or the slide valve.
14. Press down and release on the photo-chopper shaft
to disengage the brake, releasing tension from the
motor mount.
15. Use the down arrow button to pulse the actuator to
where the slide is just off of its mechanical stop and
there is no tension on the motor shaft.
View Rotate 180°
Actuator
Assembly
Actuator
Plastic Cover
Red LED
Blue
Calibrate
Button
Figure 6-8. Actuator Assembly
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 6 • Instrument Calibration
16. Quickly press and release the blue button on the
actuator one more time. The red LED will stop
flashing. The actuator is now calibrated and knows
the minimum and maximum positions of the slide
valve it controls. Now the capacity or volume channel of the PLC can be calibrated.
17. Use the down arrow button to move the actuator
towards its minimum position while watching the
mV readout on the screen. Discontinue pressing
the down arrow button when the mV reading is approximately 500 mV.
The controller will automatically energize the actuator and drive it back to its minimum position
(below 5%) for pre-start-up.
NOTE
Now the current ‘Capacity” or the current ‘Volume”
value will be displayed on the Main screen and Slide
Calibration screen.
24. Gently lower the plastic cover over the top of the
actuator to where it contacts the base and O-ring
seal.
CAUTION
18. Now use the down arrow and up arrow buttons to
position the slide valve until a value close to 300 mV
is achieved. Then, press the “Set Min” button in the
capacity or volume slide valve window to tell the
controller that this is the minimum mV position.
Do not over tigten screws. Failure to comply may
result in damage to equipment.
19. Use the up arrow button to rotate the actuator towards its maximum position while watching the
mV readout on the controller screen. Discontinue
pressing the up arrow button when the mV reading
of approximately 4800 mV is achieved.
26. Repeat procedure to calibrate other slide valve
actuator.
25. Check and make sure the cover is seated properly,
then gently tighten the four #10 screws.
20. Pulse the up arrow button to carefully move the
slide valve until the mV readout “saturates”, or
stops increasing. This is around 4800 mV Record
mV maximum reading.
21. Pulse the down arrow button until the mV just start
to decrease. (This is the point where the channel
drops out of saturation). Adjust mV value to 300
mV below recorded maximum mV.
22. Press the “Set Max” button.
23. Press the “Calibration Main” button to complete
calibration and exit the “Slide Calibration” screen.
Press down on Photochopper to release tension
from motor shaft.
Figure 6-9. Photo-chopper
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 7 • Compressor Control Setpoints
Setpoints and Control Screens
The setpoint and control screens relate to the operation
and control of the compressor. Process and operational
setpoints for the compressor and other equipment are
adjustable within this group of screens.
CHANGING SETPOINTS
To change setpoints within the setpoint and control
screens, the user must be logged in. Setpoints that may
be adjusted by the logged in user appear as a white
button that shows the current value of the setpoint.
Setpoints that may not be adjusted by the logged in user
(or if no user is logged in) appear as text only and cannot
be changed.
Pressing on a numeric entry opens the numeric entry
pop-up screen, see Figure 7-1.
• In Figure 7-1, the Suction Pressure Control screen,
the current value of the setpoint is highlighted by a
green box.
• In Figure 7-1, the numeric entry pop-up screen, the
range of values above the numerical buttons is the
acceptable range that can be entered. If a value outside this range is entered the HMI will not accept it.
• To enter a new setpoint, use the numerical keypad
and enter key.
• To close the numerical input pop-up screen without
changing the setpoint, push the “ESC” key.
Acceptable Range
Current Setpoint Value
Figure 7-1. Numeric Entry Pop-up Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
7 – 1
Section 7 • Compressor Control Setpoints
Compressor Control Setpoints
NOTE
Screens may have inverted colors for ease of
readability.
Compressor control setpoints can be controlled by
suction pressure, process temperature or discharge
pressure. Depending on which control scheme is chosen, compressor control screen 1 of 3 will display that
chosen option.
Compressor Control Setpoints Screen 1 - Suction Pressure
The Compressor Control Setpoints page 1 (Suction
Pressure) screen appears when navigating to
“Compressor Control Setpoints” from the menu screen
when Suction Pressure control is selected. Setpoints for
desired suction pressure, capacity slide valve control,
auto start-stop, and main motor VFD are settable within
this screen. For more information and operational descriptions, see section 2 “Operational Descriptions.”
SUCTION PRESSURE CONTROL
The following groups of setpoints are settable. If multiple groups of setpoints are being used, the active
group of setpoints is designated by the “Setpoint 1” or
“Setpoint 2” text being shown in green. Auto Start/Stop
and Main Motor VFD Setpoints will appear if selected.
• Upper and Lower Proportional Band: This is a range
of pressures above and below the Target Suction
Pressure. Within this range, the controller will make
proportionally smaller adjustments to capacity slide
position.
• Target Suction Pressure: This is the desired suction
pressure the compressor will try to maintain.
• Upper and Lower Deadband: This is a range of pressures above and below the Target Suction Pressure.
Within this range, no capacity slide position adjustments will be made.
Figure 7-2. Compressor Control Screen - 1 of 3 (Suction Pressure)
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 7 • Compressor Control Setpoints
CAPACITY SLIDE VALVE
• Load/Unload Interval time: This is the cycle time between making capacity slide position adjustments.
• Max Load/Unload Adjustment per interval: This is the
maximum amount the capacity position command
may be adjusted by every time through the Load/
Unload Cycle timer.
• Auto Stop Delay: Amount of time Auto Stop pressure
must be met before the compressor will be commanded to stop.
• Minimum Slide Position: Slide position must be below this setpoint (indicating the compressor is fully
unloaded) before the compressor will be commanded to stop.
AUTO START/STOP
MAIN MOTOR VFD
• Auto Start Pressure: When suction pressure is above
this setpoint for the Auto Start Delay Time, the compressor will be commanded to start.
• Max Speed Increase/Decrease per interval: This is the
maximum amount the main motor speed command
may be adjusted by every time through the Load/
Unload Cycle timer.
• Auto Stop Pressure: When suction pressure is below
this setpoint and capacity slide position is below
Minimum Slide Position for the Auto Stop Delay time,
the compressor will be commanded to stop.
• Auto Start Delay: Amount of time Auto Start pressure must be met before the compressor will be commanded to start.
• Forced Unload Rate: If a forced unload condition exists and the main motor is running above 50% speed,
this is the rate it will decelerate until it reaches 50%
speed and the capacity slide begins unloading.
Compressor Control Setpoints Screen 1 - Process Temperature
The Compressor Control Setpoints page 1 (Process
Temperature) screen appears when navigating to
“Compressor Control Setpoints” from the menu
screen when Process Temperature control is selected.
Setpoints for desired process temperature, capacity
slide valve control, auto start-stop, and main motor VFD
are settable within this screen. For more information
and operational descriptions, see section 2 “Operational
Descriptions.”
CAPACITY SLIDE VALVE
The following groups of setpoints are settable. If multiple groups of setpoints are being used, the active
group of setpoints is designated by the “Setpoint 1” or
“Setpoint 2” text being shown in green. Auto Start/Stop
and Main Motor VFD Setpoints will appear if selected.
AUTO START/STOP
PROCESS TEMPERATURE CONTROL
• Target Process Temperature: This is the desired process temperature the compressor will try to maintain.
• Upper and Lower Deadband: This is a range of temperatures above and below the Target Process
Temperature. Within this range, no capacity slide
position adjustments will be made.
• Upper and Lower Proportional Band: This is a range
of temperatures above and below the Target Process
Temperature. Within this range, the controller will
make proportionally smaller adjustments to capacity
slide position.
• Load/Unload Interval time: This is the cycle time between making capacity slide position adjustments.
• Max Load/Unload Adjustment per interval: This is the
maximum amount the capacity position command
may be adjusted by every time through the Load/
Unload Cycle timer.
• Auto Start Temperature: When process temperature
is above this setpoint for the Auto Start Delay Time,
the compressor will be commanded to start.
• Auto Stop Temperature: When process temperature
is below this setpoint and capacity slide position
is below Minimum Slide Position for the Auto Stop
Delay time, the compressor will be commanded to
stop.
• Auto Start Delay: Amount of time Auto Start temperature must be met before the compressor will be
commanded to start.
• Auto Stop Delay: Amount of time Auto Stop temperature must be met before the compressor will be commanded to stop.
• Minimum Slide Position: Slide position must be below this setpoint (indicating the compressor is fully
unloaded) before the compressor will be commanded to stop.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
7 – 3
Section 7 • Compressor Control Setpoints
MAIN MOTOR VFD
• Max Speed Increase/Decrease per interval: This is the
maximum amount the main motor speed command
may be adjusted by every time through the Load/
Unload Cycle timer.
Forced Unload Rate: If a forced unload condition exists
and the main motor is running above 50% speed, this is
the rate it will decelerate until it reaches 50% speed and
the capacity slide begins unloading.
Figure 7-3. Compressor Control Screen - 1 of 3 (Process Temperature)
7 – 4
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 7 • Compressor Control Setpoints
Compressor Control Setpoints Screen 1 - Discharge Pressure
The Compressor Control Setpoints page 1 (Discharge
Pressure) screen appears when navigating to
“Compressor Control Setpoints” from the menu screen
when Discharge Pressure control is selected. Setpoints
for desired discharge pressure, capacity slide valve control, auto start-stop, and main motor VFD are settable
within this screen. For more information and operational
descriptions, see section 2 “Operational Descriptions.”
pressures above and below the Target Discharge
Pressure. Within this range, no capacity slide position adjustments will be made.
• Upper and Lower Proportional Band: This is a range
of pressures above and below the Target Discharge
Pressure. Within this range, the controller will make
proportionally smaller adjustments to capacity slide
position.
The following groups of setpoints are settable. If multiple groups of setpoints are being used, the active
group of setpoints is designated by the “Setpoint 1” or
“Setpoint 2” text being shown in green. Auto Start/Stop
and Main Motor VFD Setpoints will appear if selected.
CAPACITY SLIDE VALVE
DISCHARGE PRESSURE CONTROL
• Max Load/Unload Adjustment per interval: This is the
maximum amount the capacity position command
may be adjusted by every time through the Load/
Unload Cycle timer.
• Target Discharge Pressure: This is the desired discharge pressure the compressor will try to maintain.
• Load/Unload Interval time: This is the cycle time between making capacity slide position adjustments.
• Upper and Lower Deadband: This is a range of
Figure 7-4. Compressor Control Screen - 1 of 3 (Discharge Pressure)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
7 – 5
Section 7 • Compressor Control Setpoints
AUTO START/STOP
• Auto Start Pressure: When discharge pressure is
above this setpoint for the Auto Start Delay Time, the
compressor will be commanded to start.
• Auto Stop Pressure: When discharge pressure is below this setpoint and capacity slide position is below
Minimum Slide Position for the Auto Stop Delay time,
the compressor will be commanded to stop.
• Auto Start Delay: Amount of time Auto Start pressure must be met before the compressor will be commanded to start.
• Auto Stop Delay: Amount of time Auto Stop pressure
must be met before the compressor will be commanded to stop.
• Minimum Slide Position: Slide position must be below this setpoint (indicating the compressor is fully
unloaded) before the compressor will be commanded to stop.
MAIN MOTOR VFD
• Max Speed Increase/Decrease per interval: This is the
maximum amount the main motor speed command
may be adjusted by every time through the Load/
Unload Cycle timer.
• Forced Unload Rate: If a forced unload condition exists and the main motor is running above 50% speed,
this is the rate it will decelerate until it reaches 50%
speed and the capacity slide begins unloading.
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 7 • Compressor Control Setpoints
Compressor Control Setpoints Screen 2
ANTI-RECYCLE
before compressor is allowed to start.
• Anti-Recycle Time: Defines the minimum amount of
time after the compressor stops before it is allowed
to start again.
• Prelube Retry Wait Time: Amount of wait time before oil pump restarts if prelube oil pressure is not
achieved.
START UP
• Prelube Time After Motor Start: Amount of time that
minimum prelube pressure must be maintained after
compressor main motor starts.
• The “Start Up” Group of setpoints defines parameters for the compressor start sequence. For more
information on the compressor start sequence, see
Section 2 Operational Descriptions.
• Maximum Comp. Differential to Start: Compressor
Discharge-Suction Pressures must be equalized to
within this setpoint to start the compressor.
• Minimum Prelube Pressure: Prelube pressure that
must be achieved by the oil pump before the compressor is allowed to start.
• Prelube Time Before Motor Start: Amount of time
that minimum prelube pressure must be maintained
• Warmup Time: Amount of warmup time the compressor will run with the oil pump on and capacity
slide valve at minimum position before it will start
loading.
• Suction Oil Injection ON time at start: Amount of
time the suction oil injection solenoid will be energized after the start of the main motor, if installed.
SHUT DOWN
• Suction-Discharge Equalizing Solenoid ON Time (at
Stop): Amount of time the equalizing line solenoid
Figure 7-5. Compressor Control Screen - 2 of 3
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
7 – 7
Section 7 • Compressor Control Setpoints
will be energized after the compressor main motor
stops, if installed.
• Oil Drain Solenoid ON Time (at Stop): Amount of
time the oil drain solenoid will be energized after the
compressor main motor stops, if installed.
VOLUME SLIDE ADJUSTMENT
• Volume Slide Adjustment Factor: Offset that will be
applied to the calculated volume slide target.
OIL SEPARATOR HEATERS
• Capacity Slide Range Adj. Factor is Applied: The
Volume Slide Adjustment Factor will be applied when
capacity slide valve position is within the defined
range.
• Defines separator oil temperature setpoints to control the oil separator heaters.
MAIN MOTOR FLA
PART TIME OIL PUMP
• This is a convenience calculation to aid in setting motor amps load limit setpoints.
• If selected, defines the pressure ratios at which the oil
pump will stop above and re-start below.
LOAD LIMITS
For more information on load limits and forced unloading, see Section 2 Operational Descriptions.
• Low Suction Pressure Inhibit Loading: compressor
will not be allowed to load if Suction Pressure falls below this setpoint.
• Low Suction Pressure Unload At: Compressor will begin continuously unloading if Suction Pressure falls
below this setpoint.
• Low Suction Pressure Unload To: If forced unloading
is active, the compressor will unload continuously until Suction Pressure reaches this setpoint.
• High Discharge Pressure Inhibit Loading: compressor
will not be allowed to load if Discharge Pressure rises
above this setpoint.
• High Discharge Pressure Unload At: Compressor will
begin continuously unloading if Discharge Pressure
rises above this setpoint.
• High Discharge Pressure Unload To: If forced unloading is active, the compressor will unload continuously
until Discharge Pressure reaches this setpoint.
• High Motor Amps Inhibit Loading: compressor will
not be allowed to load if Main Motor Amperage rises
above this setpoint.
• High Motor Amps Unload At: Compressor will begin
continuously unloading if Main Motor Amperage rises above this setpoint.
• High Motor Amps Unload To: If forced unloading is
active, the compressor will unload continuously until
Main Motor Amperage reaches this setpoint.
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 7 • Compressor Control Setpoints
Compressor Control Setpoints Screen 3
VENTURI OIL RECOVERY
• Cycle Time: Defines the ON and OFF time for the
venturi oil recovery solenoids, if installed.
HOTGAS BYPASS
• ON/OFF Capacity Slide Position: Defines the capacity slide valve positions the hotgas bypass
solenoid will turn ON below and OFF above, if
installed.
ECONOMIZER
ENCLOSURE SETPOINTS
• Enclosure Heater: Defines Enclosure Temperature
setpoints to control the enclosure space heaters.
• Enclosure Roof Vents: Defines Enclosure
Temperature setpoints to control the enclosure
roof vents/exhaust fans.
OIL FLOW CONTROL
• Oil Flow Control Start Temp (Oil Injection): Defines
the oil injection temperature at which the oil flow
control valve will modulate. Below this temperature the valve will remain 100% open.
• Port 1: Defines the capacity slide valve positions
the economizer port 1 solenoid(s) will turn ON
above and OFF below, if installed.
PERIODIC SLIDE VALVE EXERCISE
• Port 2: Defines the capacity slide valve positions
the economizer solenoid(s) will turn ON above
and OFF below, if installed.
Cycle Time: Defines the amount of time of slide valve
non-movement to activate the periodic slide valve exercise function, if enabled.
Figure 7-6. Compressor Control Screen - 3 of 3 (All Options Shown)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
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7 – 10 / Blank
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 8 • Alarm and Trip Setpoints
Alarm and Trip Setpoints
NOTE
Screens may have inverted colors for ease of
readability.
The compressor controller continuously monitors operational and process data and annunciates an alarm and/
or shuts the compressor down if any condition becomes
abnormal. The alarm and trip points for some of the operational and process data are adjustable by the user in
the alarm and trip setpoints screens. The alarm and trip
setpoints are interlocked such that a low alarm may not
be set lower than a low trip, and a high trip may not be
set below a high alarm.
Actual values of the specific operational and process
data is shown in the column in the middle of the screen.
Setpoints are only shown for applicable alarm and trip
points. When alarms or trips are specific to “Setpoint 1”
or “Setpoint 2” setpoint groups, the alarm or trip point
will only be active when the associated setpoint group
is active.
Alarm and Trip Setpoints Screen 1
• Suction Pressure Setpoint 1 and 2: Low Alarm and
Low Trip setpoints for compressor suction pressure.
• Discharge Pressure Setpoint 1 and 2: High Alarm
and High Trip setpoints for compressor discharge
pressure.
• Net Oil Pressure - Start: Low Alarm and Low Trip setpoints for net oil pressure (oil manifold pressure –
suction pressure) during compressor warmup.
• Net Oil Pressure – Run: Low Alarm and Low Trip setpoints for net oil pressure (oil manifold pressure –
suction pressure) after compressor warmup.
• Oil Filter Differential Pressure – Start: High Alarm and
High Trip setpoints for pressure drop across the oil
filter(s) at compressor start.
• Oil Filter Differential Pressure – Run: High Alarm and
High Trip setpoints for pressure drop across the oil
filter(s) after oil filter differential changeover timer
expires
Figure 8-1. Alarm and Trip Setpoints Screen - 1 of 2
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
8 – 1
Section 8 • Alarm and Trip Setpoints
• Motor Winding Temperature: High Alarm and High
Trip setpoints for temperature of the main motor
windings, if motor winding RTDs are installed.
• Motor Bearing Temperature: High Alarm and High
Trip setpoints for temperature of the main motor
bearings, if motor bearing RTDs are installed.
• Process Temperature: Low Alarm, Low Trip, and High
Alarm setpoints for process temperature, if it is being
controlled or monitored.
• Liquid Refrigerant Temperature: Low Alarm and Low
Trip for temperature of the liquid refrigerant in the
chiller, if it is being monitored.
cooler, if it is being controlled or monitored.
• Separator Oil Temp Changeover Time: Time after
compressor starts when separator oil temperature
alarm and trip transitions from start setpoints to run
setpoints.
• Oil Filter Differential Changeover Time: Time after
compressor starts when oil filter differential alarm
and trip transitions from start setpoints to run
setpoints.
• Main Motor FLA: Convenience calculation for setting
main motor amperage alarms and trips.
• Motor Amps: High Alarm and High Trip for main motor current.
• Oil Cooler Outlet Temperature: Low and High Alarms
for temperature of the oil at the outlet of the oil
Figure 8-2. Alarm and Trip Setpoints Screen - 2 of 2
8 – 2
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 9 • Step and PID Device Control Screens
Oil Mixing Valve Screen
OIL MIXING VALVE SETPOINTS
• Target Oil Injection Temp: Defines the desired temperature of oil entering the compressor. The mixing
valve will adjust to maintain this temperature.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to valve
position.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Oil Mixing Valve Force: Allows the user to manually force the oil mixing valve to a settable position.
Activating the Oil Mixing Valve Force pushbutton
will command the oil mixing valve to go to the set
position, and will override calculations from the PID
Controller.
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
Figure 9-1. Oil Mixing Valve Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
9 – 1
Section 9 • Step and PID Device Control Screens
OIL COOLER (VFD TYPE) SETPOINTS
• Start Oil Cooler Above: Defines the temperature the
oil cooler fans will come on at minimum speed.
• Target Oil Cooler Outlet Temperature: Defines the desired temperature of oil at the outlet of the oil cooler.
The oil cooler fan speed will adjust to maintain this
temperature.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to fan speed.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Minimum Speed: Defines the minimum oil cooler fan
speed.
• Plenum Heater ON Temp: Defines the oil cooler outlet temperature at which the oil cooler plenum heater
turns ON (if used).
• Plenum Heater OFF Temp: Defines the oil cooler outlet temperature at which the oil cooler plenum heater
turns OFF (if used).
• Oil Cooler Fan VFD Force: Allows the user to manually force the oil cooler fan(s) to a settable speed.
Activating the Oil Cooler Fan VFD Force pushbutton
will command the oil cooler fan(s) to go to the set
speed, and will override calculations from the PID
Controller.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
Figure 9-2. Oil Cooler (VFD Type) Screen
9 – 2
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 9 • Step and PID Device Control Screens
OIL COOLER (STEP TYPE) SETPOINTS
• Start Oil Cooler Above: Defines the temperature the
first oil cooler step will come on.
• Target Oil Cooler Outlet Temperature: Defines the desired temperature of oil at the outlet of the oil cooler.
The controller will cycle fans on and off to maintain
this temperature.
• Plenum Heater OFF Temp: Defines the oil cooler outlet temperature at which the oil cooler plenum heater
turns OFF (if used).
• Oil Cooler Fan Configuration: Truth table that defines
which fan outputs are turned on in each step.
• Deadband: Range above and below setpoint where
the controller will not add or remove any steps.
• Step Dwell Time: Amount of time Oil Cooler Outlet
Temperature must be outside the deadband to add
or remove a step.
• Plenum Heater ON Temp: Defines the oil cooler outlet temperature at which the oil cooler plenum heater
turns ON (if used).
Figure 9-3. Oil Cooler (Step Type) Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
9 – 3
Section 9 • Step and PID Device Control Screens
Aftercooler Screens
AFTERCOOLER (VFD TYPE) SETPOINTS
• Start Aftercooler Above: Defines the temperature the
aftercooler fans will come on at minimum speed.
• Target Aftercooler Outlet Temperature: Defines the
desired temperature of gas at the outlet of the aftercooler. The aftercooler fan speed will adjust to maintain this temperature.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to fan speed.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Minimum Speed: Defines the minimum aftercooler
fan speed.
• Aftercooler VFD Force: Allows the user to manually force the aftercooler fan(s) to a settable speed.
Activating the Aftercooler VFD Force pushbutton
will command the aftercooler fan(s) to go to the set
speed, and will override calculations from the PID
Controller
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
Figure 9-4. Aftercooler (VFD Type) Screen
9 – 4
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 9 • Step and PID Device Control Screens
AFTERCOOLER (STEP TYPE) SETPOINTS
• Start Aftercooler Above: Defines the temperature the
first aftercooler step will come on.
• Target Aftercooler Outlet Temperature: Defines the
desired temperature of gas at the outlet of the aftercooler. The controller will cycle fans on and off to
maintain this temperature.
• Deadband: Range above and below setpoint where
the controller will not add or remove any steps.
• Step Dwell Time: Amount of time Aftercooler Outlet
Temperature must be outside the deadband to add
or remove a step.
• Aftercooler Fan Configuration: Truth table that defines which fan outputs are turned on in each step.
Figure 9-5. Aftercooler (Step Type) Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
9 – 5
Section 9 • Step and PID Device Control Screens
WATER COOLED AFTERCOOLER SETPOINTS
• Open Valve Above: Defines the temperature the aftercooler water supply valve will open to minimum
position.
• Target Aftercooler Outlet Temperature: Defines the
desired temperature of gas at the outlet of the aftercooler. The aftercooler water supply valve position
will adjust to maintain this temperature.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to water
supply valve positon.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Minimum Valve Open: Defines the minimum water
supply valve position.
• Aftercooler Valve Force: Allows the user to manually force the aftercooler water supply valve to a settable position. Activating the Aftercooler Valve Force
pushbutton will command the aftercooler water supply valve to go to the set position, and will override
calculations from the PID Controller.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
Figure 9-6. Water Cooled Aftercooler Screen
9 – 6
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 9 • Step and PID Device Control Screens
Condenser Screens
CONDENSER (STEP TYPE) SETPOINTS
• Start Condenser Above: Defines the pressure the first
condenser step will come on.
• Target Condensing Pressure: Defines the desired
pressure of gas at the condenser. The controller will
cycle fans on and off to maintain this temperature.
• Deadband: Range above and below setpoint where
the controller will not add or remove any steps.
• Step Dwell Time: Amount of time Condensing pressure must be outside the deadband to add or remove
a step.
• Condenser Fan Configuration: Truth table that defines which fan outputs are turned on in each step.
If a condenser pump is installed, the truth table also
defines which steps the pump output is turned on.
Figure 9-7. Condenser (Step Type) Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
9 – 7
Section 9 • Step and PID Device Control Screens
CONDENSER (VFD TYPE) SETPOINTS
• Start Condenser Above: Defines the temperature the
condenser fans will come on at minimum speed.
• Target Condensing Pressure: Defines the desired
pressure of gas at the condenser. The condenser fan
speed will adjust to maintain this pressure.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to fan speed.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Minimum Speed: Defines the minimum condenser
fan speed.
• Condenser VFD Force: Allows the user to manually force the condenser fan(s) to a settable speed.
Activating the Condenser VFD Force pushbutton
will command the condenser fan(s) to go to the set
speed, and will override calculations from the PID
Controller.
• Condenser Pump Enable: If installed, this selector defines if the condenser pump will be commanded to
run when the condenser fan VFD starts.
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
Figure 9-8. Condenser (VFD Type) Screen
9 – 8
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 9 • Step and PID Device Control Screens
WATER COOLED CONDENSER SETPOINTS
• Open Valve Above: Defines the pressure at which the
aftercooler water supply valve will open to minimum
position.
• Target Condensing Pressure: Defines the desired
pressure of gas at the condenser. The condenser water supply valve position will adjust to maintain this
pressure.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to water
supply valve positon.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Minimum Valve Open: Defines the minimum water
supply valve position.
• Condenser Valve Force: Allows the user to manually
force the condenser water supply valve to a settable
position. Activating the Condenser Valve Force pushbutton will command the condenser water supply
valve to go to the set position, and will override calculations from the PID Controller.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
Figure 9-9. Water Cooled Condenser Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
9 – 9
Section 9 • Step and PID Device Control Screens
Liquid Injection Valve Screens
LIQUID INJECTION VALVE SETPOINTS
• Open Valve Above: Defines the temperature at which
the liquid injection valve will open to minimum
position.
• Target Discharge Temperature: Defines the desired
temperature of gas and oil discharging from the compressor. The liquid injection valve position will adjust
to maintain this temperature.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to the liquid
injection valve positon.
• Oil Separator Override Temperature: Separator Oil
Temperature must be above this temperature for the
liquid injection to operate.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Minimum Valve Open: Defines the minimum liquid
injection valve position.
• Liquid Injection Valve Force: Allows the user to manually force the liquid injection valve to a settable position. Activating the Liquid Injection Valve Force
pushbutton will command the liquid injection valve
to go to the set position, and will override calculations from the PID Controller.
Figure 9-10. Liquid Injection Valve Screen
9 – 10
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 9 • Step and PID Device Control Screens
LIQUID INJECTION (VPLUS PUMP) SETPOINTS
• Start Pump At: Defines the temperature at which the
VPLUS pump will start at its minimum speed.
• Target Discharge Temperature: Defines the desired
temperature of gas and oil discharging from the compressor. The VPLUS pump will adjust speed to maintain this temperature.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to the
VPLUS pump speed.
• Oil Separator Override Temperature: Separator Oil
Temperature must be above this temperature for the
VPLUS pump to operate.
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Minimum Pump Speed: Defines the minimum speed
of the VPLUS pump.
• VPLUS Pump Force: Allows the user to manually force
the VPLUS pump to a settable speed. Activating the
VPLUS Pump Force pushbutton will command the
VPLUS pump to go to the set speed, and will override
calculations from the PID Controller.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
Figure 9-11. Liquid Injection (VPLUS Pump) Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
9 – 11
Section 9 • Step and PID Device Control Screens
Discharge Recycle Valve Screen
DISCHARGE RECYCLE VALVE SETPOINTS
• Target Recycle Control Pressure: Defines the pressure at which the discharge recycle valve will begin
to open.
• Deadband: Range above and below setpoint where
the controller will not make adjustments to the recycle valve position.
• PID Tuning: PID Calculations displayed to aid in tuning the PID loop.
• Loop Update Time: Defines the PID controller loop
time. The PID calculation will update every cycle of
the loop update timer.
• Integral Gain (Ki): Defines the Integral Constant of
the PID calculation.
• Derivative Gain (Kd): Defines the Derivative Constant
of the PID Calculation.
• Discharge Recycle Valve Force: Allows the user to
manually force the discharge recycle valve to a settable position. Activating the Discharge Recycle Valve
Force pushbutton will command the discharge recycle valve to go to the set position, and will override
calculations from the PID Controller.
• Proportional Gain (Kp): Defines the Proportional
Constant of the PID calculation.
Figure 9-12. Discharge Recycle Valve Screen
9 – 12
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 9 • Step and PID Device Control Screens
Volume Slide Details Screen
VOLUME SLIDE DETAILS
• Shows details of the volume slide calculation.
• Allows the user to put the volume slide in manual
mode. (Must be logged in as “SUPER”).
10 Minute Timer
• Volume slide will switch back to Auto Mode after 10
minutes of idle in Manual Mode
Figure 9-13. Volume Slide Details Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
9 – 13
Section 9 • Step and PID Device Control Screens
Start Menu Popup Screen
Pressing “Start Menu” on the compressor or system
overview screen will open the “Start Menu” popup
screen. The “Start Menu” screen allows the user to
change operating modes and start the compressor.
• Auto: Pressing the Auto pushbutton puts the compressor loading control in Auto mode.
• Remote: Pressing the remote pushbutton puts the
compressor loading control in remote mode. The
remote mode pushbutton will only be visible if the
configuration is correct
• Unit Start: Pressing the Unit Start pushbutton initiates a compressor start.
• Local: Pressing the Local pushbutton puts the compressor loading control in local mode.
• Manual: Pressing the Manual pushbutton puts the
compressor loading control in Manual mode.
For more information on operating modes, see Section 2
Operational Descriptions.
Figure 9-14. Start Menu Popup Screen
9 – 14
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 10 • Diagnostic Screens
IO/Comms Diagnostics Screen
COMMS DIAGNOSTICS AND I/O STATUS
NOTE
Some screens may have inverted colors for ease of
readability.
The IO/Comms Diagnostics Screen is divided into 3
sections.
• SYSTEM INFORMATION
• Shows basic information about the Compressor
PLC panel: Vilter sales order number, Software
revision, IP addresses, hardware information, and
firmware revisions of compressor PLC and HMI.
• BITS/REALS FROM DCS:
• Shows commands from a central controller or
DCS to verify communications setup with a central controller or DCS.
• LOCAL I/O STATUS
• Shows a graphic representation of the compressor PLC’s local I/O modules and the raw data specific to each channel.
• Use the following rules to interpret the data:
• Discrete inputs and outputs: Green = ON
• Analog Inputs (voltage): The number shown
for a specific channel represents the voltage
signal being read in millivolts. Ex: a value of
2500 indicates 2500 millivolts or 2.5 volts.
• Analog Inputs and outputs (4-20mA): The
number shown for a specific channel represents the signal in .001 mA. Ex: a value of
4000 indicates 4.000 mA.
• RTD Inputs: The number shown for a specific
channel represents the temperature reading
in Fahrenheit times 10. Ex: a value of 730 indicates 73.0 degrees Fahrenheit.
Figure 10-1. IO/Comms Diagnostics Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
10 – 1
Section 10 • Diagnostic Screens
Event List Screen
The event list is a running log of alarm, trip, and status
information. The event list shows the last 400 events
logged by the compressor PLC, most recent is at the top
of the screen. Each event is logged with a time and date
stamp.
To scroll through past events, use the navigation buttons
at the bottom of the screen.
Figure 10-2. Event List Screen
10 – 2
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 10 • Diagnostic Screens
Diagnostics Forced Outputs Screen
The force outputs screen allows a user logged in as
“SUPER” to force discrete and analog outputs to verify
operation of devices on the compressor unit or package.
Outputs that are available to force depend on the configuration for a specific compressor machine or package.
• Pressing a force button forces ON the PLC output for
that particular device. If there is an associated analog output (speed or position command) the keyed
in value will be applied to that output. Pressing the
force button again removes the force.
• Pressing “Clear all Forces” removes all active forces.
CAUTION
Do not overfill oil separator and suction header
with oil. Wait at least 30 minutes prior to starting
compressor. Failure to comply may result in damage
to equipment.
Figure 10-3. Diagnostics Forced Output Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
10 – 3
Section 10 • Diagnostic Screens
Captured Data at Shutdown Screen
The captured data at shutdown screen shows process
and operational data at the time the compressor shuts
down. Data from the last 5 shutdowns are logged. Each
shutdown is given a time and date stamp. The most recent shutdown is on the left.
Figure 10-4. Captured Data at Shutdown Screen
10 – 4
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 10 • Diagnostic Screens
Initial Baseline Running Data Screen
The Initial Baseline Running Data screen shows data collected when the compressor is first started up. Vilter
Service Technicians or Engineers only may log this data.
This is to give a reference point for comparing operational and process data to a baseline set of data collected
when the compressor or package was new.
Figure 10-5. Initial Baseline Running Data Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
10 – 5
10 – 6 / Blank
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Alarm Listing
ALARMS AND TRIPS
Process and Operational data of the compressor unit is
continuously monitored by the compressor PLC. If an
abnormal condition is detected, an alarm or trip will be
annunciated.
• Alarms
• Warns of an abnormal condition. Compressor
may continue to run.
A scrolling display at the top of the overview and menu
screens shows all active alarms and trips, see Figure
11-1.
Trips are shown in the red banner, alarms are shown in
the yellow banner.
When a new alarm or trip is triggered, the alarm popup
screen will appear showing the most recent alarm or
trip, see Figure 11-2.
• Trips
• Compressor will shut down if active.
Figure 11-1. Alarm/Trip/Status Bars (Main Menu Screen)
Figure 11-2. Alarm/Trip Popup Screen
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 1
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Alarm Listing
The following table shows all possible alarms and trips and possible causes. Some alarms and trips are application
specific, and do not apply unless a specific option is selected.
To reset alarms or trips press the “Alarm Reset” Button on the overview screen. If the condition is cleared, the alarm
will reset. If the condition is not cleared, the alarm will remain active.
Table 11-1. Alarm Listing
Alarm Message
Cause(s)
Notes
(A001) Alarm: (Unassigned)
(A002) Alarm: PLC to Central Comms Loss of Communication with DCS/
Faulted
Central - Settable Communications
Watchdog Timer Expired. (Alarm
and Revert to Local Selected on
Communication Failure.)
(A003) Alarm: High Main Motor
Amps
Watchdog Active if Control by
Communications is selected
Main Motor Amps exceeds Motor
Amps High Alarm setpoint.
(A004) Alarm: (Unassigned)
(A005) Alarm: (Unassigned)
(A006) Alarm: Low Separator Oil
Level
Oil Separator Level Switch has
opened indicating drop in Separator
Oil Level. (Alarm action Selected)
Active if Oil Separator Level Switch
Selected.
(A007) Alarm: Not Assigned
(A008) Alarm: Not Assigned
(A009) Alarm: Not Assigned
(A010) Alarm: Not Assigned
(A011) Alarm: Low Suction
Temperature
Suction Temperature falls below
"Suction Temperature" Low Alarm
Setpoint.
(A012) Alarm: High Discharge
Temperature
Discharge Temperature exceeds
"Discharge Temperature" High Alarm
Setpoint.
(A013) Alarm: Low Oil Separator
Temperature - Start
Separator Oil Temperature is Below
"Separator Oil Temperature - Start"
Low Alarm Setpoint when compressor is off or Oil Separator Start-Run
Timer has not expired.
(A014) Alarm: Low Oil Separator
Temperature - Run
Separator Oil Temperature is
Below "Separator Oil Temperature
- Run" Low Alarm Setpoint After
Oil Separator Start-Run Timer has
expired.
(A015) Alarm: Low Oil Injection
Temperature
Oil Injection Temperature is Below
"Oil Injection Temperature" Low
Alarm Setpoint after compressor has
completed pre-lube and warm up
stages.
(A016) Alarm: High Oil Injection
Temperature
Oil Injection Temperature exceeds
"Oil Injection Temperature" High
Alarm Setpoint
11 – 2
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Alarm Message
Cause(s)
Notes
(A017) Alarm: Low Process
Temperature
Process Temperature falls below
Process Temperature Low Alarm
Setpoint in Process Temperature
control or if displaying Process
Temperature.
Active if controlling or displaying
Process Temperature
(A018) Alarm: High Process
Temperature
Process Temperature exceeds
Process Temperature High Alarm
Setpoint in Process Temperature
control or if displaying Process
Temperature.
Active if controlling or displaying
Process Temperature
(A019) Alarm: (Unassigned)
(A020) Alarm: Low Liquid Refrigerant Liquid Refrigerant Temperature
Temperature
falls below Liquid Refrigerant
Temperature Low Alarm Setpoint
if displaying Liquid Refrigerant
Temperature
(A021) Alarm: Low Suction Pressure
Stpt. 1
Setpoint 1 is selected and Suction
Pressure falls below Suction Pressure
Low Alarm.
(A022) Alarm: Low Suction Pressure
Stpt. 2
Setpoint 2 is selected and Suction
Pressure falls below Suction Pressure
Low Alarm.
(A023) Alarm: High Discharge
Pressure Stpt. 1
Setpoint 1 is selected and Discharge
Pressure falls below Discharge
Pressure High Alarm.
(A024) Alarm: High Discharge
Pressure Stpt. 2
Setpoint 2 is selected and Discharge
Pressure falls below Discharge
Pressure High Alarm.
(A025) Alarm: Low Net Oil Pressure
- Run
Net Oil Pressure (Oil Manifold
Pressure - Suction Pressure) falls
below Net Oil Pressure Low Alarm
Setpoint after prelube and warmup
are complete.
Active if displaying Liquid Refrigerant
Temperature
(A026) Alarm: Unassigned
(A027) Alarm: High Oil Filter
Differential - Start
Oil Filter Differential (Filter In
Pressure - Oil Manifold Pressure)
exceeds Oil Filter Differential - Start
High Alarm Setpoint when compressor is running and before Oil Filter
Differential Start-Run Changeover
Timer expires.
(A028) Alarm: High Oil Filter
Differential - Run
Oil Filter Differential (Filter In
Pressure - Oil Manifold Pressure)
exceeds Oil Filter Differential - Run
High Alarm Setpoint when compressor is running and after Oil Filter
Differential Start-Run Changeover
Timer expires.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 3
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Alarm Message
(A029) Alarm: Low Oil Pressure
- Start
Cause(s)
Notes
Net Oil Pressure (Oil Manifold
Pressure - Suction Pressure) falls
below Net Oil Pressure Low Alarm
Setpoint after before Warmup is
complete
(A030) Alarm: (Unassigned)
(A031) Alarm: Out of Range: Oil
Cooler Inlet Temp
Oil Cooler Inlet Temperature
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA (if using a 4-20mA
Temperature Transmitter).
Active if Displaying Oil Cooler Inlet
Temperature
(A032) Alarm: Out of Range: Oil
Cooler Outlet Temp
Oil Cooler Outlet Temperature
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA (if using a 4-20mA
Temperature Transmitter).
Active if Controlling an Oil Cooler
or Displaying Oil Cooler Outlet
Temperature
(A033) Alarm: Out of Range:
Condensing Pressure
Condensing Pressure Instrument is
Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA.
Active if Controlling a Condenser
(A034) Alarm: Out of Range:
Aftercooler 1 Outlet Temp
Aftercooler 1 Out Temperature
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA (if using a 4-20mA
Temperature Transmitter).
Active if Controlling Aftercooler 1
(A035) Alarm: Out of Range:
Aftercooler 2 Outlet Temp
Aftercooler 2 Out Temperature
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA (if using a 4-20mA
Temperature Transmitter).
Active if Controlling Aftercooler 2
(A036) Alarm: Out of Range: Inlet
Scrubber Inlet Pressure
Inlet Scrubber Inlet Pressure
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA.
Active if Inlet Scrubber is Present
(A037) Alarm: Out of Range: Inlet
Scrubber Outlet Pressure
Inlet Scrubber Outlet Pressure
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA.
Active if Inlet Scrubber is Present
(A038) Alarm: Out of Range: Outlet
Scrubber Inlet Pressure
Outlet Scrubber Inlet Pressure
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA.
Active if Outlet Scrubber is Present
(A039) Alarm: Out of Range: Outlet
Scrubber Outlet Pressure
Outlet Scrubber Outlet Pressure
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA.
Active if Outlet Scrubber is Present
11 – 4
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Alarm Message
Cause(s)
Notes
(A040) Alarm: Out of Range:
Discharge Recycle Control Pressure
Discharge Recycle Control Pressure
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA.
Active if Controlling Discharge
Recycle Valve
(A041) Alarm: Out of Range: Oil
Separator Outlet Pressure
Oil Separator Outlet Pressure
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA.
Active if Displaying Oil Separator
Outlet Pressure
(A048) Alarm: High Motor Phase A
Temperature
Phase A Motor Winding
Temperature exceeds Motor
Winding Temperature High Alarm
Setpoint
Active if Displaying Motor Winding
Temperatures
(A049) Alarm: High Motor Phase B
Temperature
Phase B Motor Winding Temperature Active if Displaying Motor Winding
exceeds Motor Winding
Temperatures
Temperature High Alarm Setpoint
(A050) Alarm: High Motor Phase C
Temperature
Phase C Motor Winding Temperature Active if Displaying Motor Winding
exceeds Motor Winding
Temperatures
Temperature High Alarm Setpoint
(A051) Alarm: Motor DE Bearing
Temperature
Drive End Motor Bearing
Active if Displaying Motor Bearing
Temperature exceeds Motor Bearing Temperatures
Temperature High Alarm Setpoint
(A052) Alarm: Motor ODE Bearing
Temperature
Opposite Drive End Motor Bearing
Active if Displaying Motor Bearing
Temperature exceeds Motor Bearing Temperatures
Temperature High Alarm Setpoint
(A053) Alarm: High Motor Vibration
- Sensor 1
Motor Vibration exceeds Motor
Vibration High Alarm Setpoint
(Sensor 1)
Active if Displaying Motor Vibration
Sensor 1
(A054) Alarm: High Motor Vibration
- Sensor 2
Motor Vibration exceeds Motor
Vibration High Alarm Setpoint
(Sensor 2)
Active if Displaying Motor Vibration
Sensor 2
(A055) Alarm: High Compressor
Vibration - Sensor 1
Compressor Vibration exceeds
Compressor Vibration High Alarm
Setpoint (Sensor 1)
Active if Displaying Compressor
Vibration Sensor 1
(A056) Alarm: High Compressor
Vibration - Sensor 2
Compressor Vibration exceeds
Compressor Vibration High Alarm
Setpoint (Sensor 2)
Active if Displaying Compressor
Vibration Sensor 2
(A057) Alarm: Inlet Scrubber High
Level
Inlet Scrubber High Liquid Level
Switch Activated
Active if Vane Type Inlet Scrubber is
Present
(A042) Alarm: Unassigned
(A043) Alarm: Unassigned
(A044) Alarm: (Unassigned)
(A045) Alarm: (Unassigned)
(A046) Alarm: (Unassigned)
(A047) Alarm: (Unassigned)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 5
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Alarm Message
Cause(s)
Notes
(A058) Alarm: Inlet Scrubber High
High Level
Inlet Scrubber High High Liquid Level Active if Vane Type Inlet Scrubber is
Switch Activated (Selected Action = Present
ALARM)
(A059) Alarm: Inlet Scrubber Low
Low Level
Inlet Scribber Low Low Level Switch
Activated (Selected Action =
ALARM)
Active if Vane Type Inlet Scrubber is
Present
(A060) Alarm: Upper Inlet Scrubber
High Level
Inlet Scrubber Upper Section High
Level Switch Activated
Active if Coalescing Type Inlet
Scrubber is Present
(A061) Alarm: Upper Inlet Scrubber
High High Level
Inlet Scrubber Upper Section
High High Level Switch Activated
(Selected Action = ALARM)
Active if Coalescing Type Inlet
Scrubber is Present
(A063) Alarm: Lower Inlet Scrubber
High Level
Inlet Scrubber Lower Section High
Level Switch Activated
Active if Coalescing Type Inlet
Scrubber is Present
(A064) Alarm: Lower Inlet Scrubber
High High Level
Inlet Scrubber Lower Section High
High Level Switch Activated
Active if Coalescing Type Inlet
Scrubber is Present
(A066) Alarm: Inlet Scrubber
Condensate Pump Starter Fault
Inlet Scrubber Condensate Pump
Commanded to run, run confirmation not received.
Active if Controlling a condensate
Pump on Inlet Scrubber
(A067) Alarm: Outlet Scrubber High
Level
Outlet Scrubber High Liquid Level
Switch Activated
Active if Vane Type Outlet Scrubber
is Present
(A068) Alarm: Outlet Scrubber High
High Level
Outlet Scrubber High High Liquid
Level Switch Activated (Selected
Action = ALARM)
Active if Vane Type Outlet Scrubber
is Present
(A069) Alarm: Outlet Scrubber Low
Low Level
Outlet Scribber Low Low Level
Switch Activated (Selected Action =
ALARM)
Active if Vane Type Outlet Scrubber
is Present
(A070) Alarm: Upper Outlet
Scrubber High Level
Outlet Scrubber Upper Section High
Level Switch Activated
Active if Coalescing Type Outlet
Scrubber is Present
(A071) Alarm: Upper Outlet
Scrubber High High Level
Outlet Scrubber Upper Section
High High Level Switch Activated
(Selected Action = ALARM)
Active if Coalescing Type Outlet
Scrubber is Present
(A073) Alarm: Lower Outlet
Scrubber High Level
Outlet Scrubber Lower Section High
Level Switch Activated
Active if Coalescing Type Outlet
Scrubber is Present
(A074) Alarm: Lower Outlet
Scrubber High High Level
Outlet Scrubber Lower Section High
High Level Switch Activated
Active if Coalescing Type Outlet
Scrubber is Present
Outlet Scrubber Condensate Pump
Commanded to run, running confirmation not received.
Active if Controlling a Condensate
Pump on Outlet Scrubber
User defined Alarm 1
Message Defined in "Device Names"
Screens
(A062) Alarm: (Unassigned)
(A065) Alarm: (Unassigned)
(A072) Alarm: (Unassigned)
(A075) Alarm: (Unassigned)
(A076) Alarm: Outlet Scrubber
Condensate Pump Starter Fault
(A077) Alarm: (Unassigned)
(A078) Alarm: (Unassigned)
(A079) Alarm:
11 – 6
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Alarm Message
Cause(s)
Notes
(A080) Alarm:
User Defined Alarm 2
Message Defined in "Device Names"
Screens
(A081) Alarm:
User Defined Alarm 3
Message Defined in "Device Names"
Screens
(A082) Alarm:
User defined Alarm 4
Message Defined in "Device Names"
Screens
(A083) Alarm:
User defined Alarm 5
Message Defined in "Device Names"
Screens
(A089) Alarm: Oil Cooler Fan VFD
Fault
Fault Contact open on Oil Cooler
VFD
If controlling a VFD Type Oil Cooler
(A090) Alarm: Oil Cooler Fan (Step
Type) Starter Fault
Oil Cooler Fan commanded to start,
running confirmation not received.
If controlling a Step Type Oil Cooler
(A093) Alarm: Aftercooler 1 Fan VFD
Fault
Fault Contact open on Aftercooler 1
VFD
If controlling a VFD Type Aftercooler
1
(A094) Alarm: Aftercooler 1 Fan
(Step Type) Starter Fault
Aftercooler 1 Fan commanded to
start, running confirmation not
received.
If controlling a Step Type Aftercooler
1
(A095) Alarm: Aftercooler 2 Fan VFD
Fault
Fault Contact open on Aftercooler 2
VFD
If controlling a VFD Type Aftercooler
2
(A096) Alarm: Aftercooler 2 Fan
(Step Type) Starter Fault
Aftercooler 2 Fan commanded to
start, running confirmation not
received.
If controlling a Step Type Aftercooler
2
(A097) Alarm: Economizer High
Level
Economizer High Liquid Level Switch
Activated
If monitoring the liquid level in
economizer vessel
(A098) Alarm: Chiller High Level
Chiller High Liquid Level Switch
Activated
If monitoring the liquid level in
chiller vessel
(A099) Alarm: Air Cooled Condenser
Fan VFD Fault
Fault Contact open on Condenser 1
VFD
If controlling a VFD Type Condenser
(A100) Alarm: Air Cooled Condenser
(Step Type) Starter Fault
Condenser Fan commanded to start, If controlling a Step Type Condenser
run confirmation not received.
(A084) Alarm: (Unassigned)
(A085) Alarm: (Unassigned)
(A086) Alarm: (Unassigned)
(A087) Alarm: (Unassigned)
(A088) Alarm: (Unassigned)
(A091) Alarm: (Unassigned)
(A092) Alarm: (Unassigned)
(A101) Alarm: Unassigned
(A102) Alarm: Unassigned
(A103) Alarm: (Unassigned)
(A104) Alarm: (Unassigned)
(A105) Alarm: (Unassigned)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 7
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Alarm Message
(A106) Alarm: High Methane Gas
%LEL
Cause(s)
Methane Concentration in Building
Exceeds Methane Gas %LEL High
Alarm Setpoint.
Notes
If compressor is in an enclosure
(A107) Alarm: (Unassigned)
(A108) Alarm: Low Oil Cooler Out
Temperature
Oil Cooler Outlet Temperature falls
If controlling an oil cooler or displaybelow Oil Cooler Outlet Temperature ing Oil Cooler Outlet Temperature
- Low Alarm Setpoint
(A109) Alarm: High Oil Cooler Out
Temperature
Oil Cooler Outlet Temperature exIf controlling an oil cooler or displayceeds Oil Cooler Outlet Temperature ing Oil Cooler Outlet Temperature
- High Alarm Setpoint
(A110) Alarm: High Enclosure
Temperature
Temperature inside Enclosure exceeds Enclosure Temperature - High
Setpoint
If compressor is in an enclosure
(A111) Alarm: (Unassigned)
(A112) Alarm: (Unassigned)
(A113) Alarm: (Unassigned)
(A114) Alarm: (Unassigned)
(A115) Alarm: (Unassigned)
(A116) Alarm: (Unassigned)
(A117) Alarm: (Unassigned)
(A118) Alarm: (Unassigned)
(A119) Alarm: (Unassigned)
(A120) Alarm: (Unassigned)
(A121) Alarm: (Unassigned)
(A122) Alarm: (Unassigned)
(A123) Alarm: (Unassigned)
(A124) Alarm: (Unassigned)
(A125) Alarm: (Unassigned)
(A126) Alarm: (Unassigned)
(A127) Alarm: (Unassigned)
11 – 8
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Trip Listing
Table 11-2. Trip Listing
Trip Message
Cause(s)
Notes
(T001) Trip: MCR Not Energized/EStop Active
Emergency Stop Button on PLC
panel Pressed, Loss of Power
(T002) Trip: PLC to Central Comms
Faulted
Loss of Communication with DCS/
Watchdog Active if Control by
Central - Settable Communications
Communications is selected
Watchdog Timer Expired. (Action on
Comm Failure = Trip)
(T003) Trip: High Main Motor Amps
Main Motor Amps exceeds Motor
Amps High Trip setpoint.
(T004) Setpoint out of Range - See
Menu Screen
(T005) Trip: False Start Detected
Main motor was detected running
when not commanded to run.
(T006) Trip: Low Separator Oil Level
Oil Separator Level Switch has
opened indicating drop in Separator
Oil Level. (Trip action Selected)
Active if Oil Separator Level Switch
Selected.
(T007) Trip: Faulted I/O Module
Connection or Module Type
(T008) Trip: Main Motor Starter Fault Main Motor Starter Fault Contact has
opened.
(T009) Trip: Main Motor Feedback
Fault/Overload
Main Motor is commanded to run,
Running confirmation not received.
(T010) Trip: Main Motor Shunt Trip
Activated
Shutdown Active.
(T011) Trip: Low Suction
Temperature
Suction Temperature falls below
"Suction Temperature" Low Trip
Setpoint.
(T012) Trip: High Discharge
Temperature
Discharge Temperature exceeds
"Discharge Temperature" High Trip
Setpoint.
(T013) Trip: Low Oil Separator
Temperature - Start
Separator Oil Temperature is Below
"Separator Oil Temperature - Start"
Low Trip Setpoint when compressor is off or Oil Separator Start-Run
Timer has not expired.
(T014) Trip: Low Oil Separator
Temperature - Run
Separator Oil Temperature is Below
"Separator Oil Temperature - Run"
Low Trip Setpoint After Oil Separator
Start-Run Timer has expired.
Note: Output energized to activate
a power removal device to protect
the compressor when a false start is
detected.
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 9
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Trip Message
Cause(s)
Notes
(T015) Trip: Low Oil Injection
Temperature
Oil Injection Temperature is Below
"Oil Injection Temperature" Low Trip
Setpoint after compressor has completed pre-lube and warm up stages.
(T016) Trip: High Oil Injection
Temperature
Oil Injection Temperature exceeds
"Oil Injection Temperature" High Trip
Setpoint
(T017) Trip: Low Process
Temperature
Process Temperature falls below
Process Temperature Low Trip
Setpoint in Process Temperature
control or if displaying Process
Temperature.
Active if controlling or displaying
Process Temperature
(T020) Trip: Low Liquid Refrigerant
Temperature
Liquid Refrigerant Temperature
falls below Liquid Refrigerant
Temperature Low Trip Setpoint
if displaying Liquid Refrigerant
Temperature
Active if displaying Liquid Refrigerant
Temperature
(T021) Trip: Low Suction Pressure
Stpt. 1
Setpoint 1 is selected and Suction
Pressure falls below Suction Pressure
Low Trip Setpoint.
(T022) Trip: Low Suction Pressure
Stpt. 2
Setpoint 2 is selected and Suction
Pressure falls below Suction Pressure
Low Trip Setpoint.
(T018) Trip: (Unassigned)
(T019) Trip: (Unassigned)
(T023) Trip: High Discharge Pressure Setpoint 1 is selected and Discharge
Stpt. 1
Pressure falls below Discharge
Pressure High Trip Setpoint.
(T024) Trip: High Discharge Pressure Setpoint 2 is selected and Discharge
Stpt. 2
Pressure falls below Discharge
Pressure High Trip Setpoint.
(T025) Trip: Low Net Oil Pressure
- Run
Net Oil Pressure (Oil Manifold
Pressure - Suction Pressure) falls
below Net Oil Pressure Low Trip
Setpoint after prelube and warmup
are complete.
(T026) Trip: Failed To Reach Prelube
Pressure - Start Sequence Aborted
Failed to maintain required prelube
pressure for required time during
start-up.
(T027) Trip: High Oil Filter
Differential - Start
Oil Filter Differential (Filter In
Pressure - Oil Manifold Pressure)
exceeds Oil Filter Differential - Start
High Trip Setpoint when compressor is running and before Oil Filter
Differential Start-Run Changeover
Timer expires.
11 – 10
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Trip Message
Cause(s)
(T028) Trip: High Oil Filter
Differential - Run
Oil Filter Differential (Filter In
Pressure - Oil Manifold Pressure)
exceeds Oil Filter Differential - Run
High Trip Setpoint when compressor is running and after Oil Filter
Differential Start-Run Changeover
Timer expires.
(T029) Trip: Low Oil Pressure - Start
Net Oil Pressure (Oil Manifold
Pressure - Suction Pressure) falls
below Net Oil Pressure Low Trip
Setpoint after before Warmup is
complete
Notes
(T030) Trip: (Unassigned)
(T031) Trip: Out of Range: Suction Pr Suction Pressure Instrument is
Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA
(T032) Trip: Out of Range: Discharge
Pr
Discharge Pressure Instrument is
Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA
(T033) Trip: Out of Range: Manifold
Pr
Oil Manifold Pressure Instrument is
Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA.
(T034) Trip: Out of Range: Filter Inlet
Pr
Oil Filter Inlet Pressure Instrument
is Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA
(T035) Trip: Out of Range: Suction
Temp
Suction Temperature Instrument is
Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA (if using a 4-20mA Temperature
Transmitter).
(T036) Trip: Out of Range: Discharge
Temp
Discharge Temperature Instrument
is Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA (if using a 4-20mA Temperature
Transmitter).
(T037) Trip: Out of Range: Oil Sep
Temp
Separator Oil Temperature
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA (if using a 4-20mA
Temperature Transmitter).
(T038) Trip: Out of Range: Oil
Injection Temp
Oil Injection Temperature
Instrument is Disconnected or Raw
value is less than 3.5 mA or Greater
than 20.5 mA (if using a 4-20mA
Temperature Transmitter).
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 11
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Trip Message
Cause(s)
Notes
(T039) Trip: Out of Range: Main
Motor Amps
Main Motor Current Transmitter is
Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA.
(T040) Trip: Out of Range: Capacity
Slide Position
Capacity Slide Cable is Disconnected
or Raw value is less than 0 mV or
Greater than 5200 mV.
(T041) Trip: Out of Range: Volume
Slide Position
Volume Slide Cable is Disconnected
or Raw value is less than 0 mV or
Greater than 5200 mV.
(T042) Trip: Out of Range: Process
Temp
Process Temperature Instrument is
Disconnected or Raw value is less
than 3.5 mA or Greater than 20.5
mA (if using a 4-20mA Temperature
Transmitter).
(T043) Trip: Out of Range: Motor
RTD Phase A
Winding RTD is disconnected or
faulty
(T044) Trip: Out of Range: Motor
RTD Phase B
Winding RTD is disconnected or
faulty
(T045) Trip: Out of Range: Motor
RTD Phase C
Winding RTD is disconnected or
faulty
(T046) Trip: Out of Range: Motor
RTD ODE
Bearing RTD is disconnected or
faulty
(T047) Trip: Out of Range: Motor
RTD DE
Bearing RTD is disconnected or
faulty
(T048) Trip: High Motor Phase A
Temperature
Phase A Motor Winding Temperature Active if Displaying Motor Winding
exceeds Motor Winding
Temperatures
Temperature High Trip Setpoint
(T049) Trip: High Motor Phase B
Temperature
Phase B Motor Winding Temperature Active if Displaying Motor Winding
exceeds Motor Winding
Temperatures
Temperature High Trip Setpoint
(T050) Trip: High Motor Phase C
Temperature
Phase C Motor Winding Temperature Active if Displaying Motor Winding
exceeds Motor Winding
Temperatures
Temperature High Trip Setpoint
(T051) Trip: High Motor DE Bearing
Temperature
Drive End Motor Bearing
Active if Displaying Motor Bearing
Temperature exceeds Motor Bearing Temperatures
Temperature High Trip Setpoint
(T052) Trip: High Motor ODE Bearing Opposite Drive End Motor Bearing
Active if Displaying Motor Bearing
Temperature
Temperature exceeds Motor Bearing Temperatures
Temperature High Trip Setpoint
(T053) Trip: High Motor Vibration Sensor 1
11 – 12
Motor Vibration exceeds Motor
Vibration High Trip Setpoint (Sensor
1)
Active if Displaying Motor Vibration
Sensor 1
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Trip Message
Cause(s)
Notes
(T054) Trip: High Motor Vibration Sensor 2
Motor Vibration exceeds Motor
Vibration High Trip Setpoint (Sensor
2)
Active if Displaying Motor Vibration
Sensor 2
(T055) Trip: High Compressor
Vibration - Sensor 1
Compressor Vibration exceeds
Compressor Vibration High Trip
Setpoint (Sensor 1)
Active if Displaying Compressor
Vibration Sensor 1
(T056) Trip: High Compressor
Vibration - Sensor 2
Compressor Vibration exceeds
Compressor Vibration High Trip
Setpoint (Sensor 2)
Active if Displaying Compressor
Vibration Sensor 2
(T057) Trip: (Unassigned)
(T058) Trip: Inlet Scrubber High High Inlet Scrubber High High Liquid Level Active if Vane Type Inlet Scrubber is
Level
Switch Activated (Selected Action = Present
TRIP)
(T059) Trip: Inlet Scrubber Low Low
Level
Inlet Scrubber Low Low Level Switch
Activated (Selected Action = TRIP)
Active if Vane Type Inlet Scrubber is
Present
Inlet Scrubber Upper Section
High High Level Switch Activated
(Selected Action = TRIP)
Active if Coalescing Type Inlet
Scrubber is Present
Inlet Scrubber Lower Section
High High Level Switch Activated
(Selected Action = Trip)
Active if Coalescing Type Inlet
Scrubber is Present
(T068) Trip: Outlet Scrubber High
High Level
Outlet Scrubber High High Liquid
Level Switch Activated (Selected
Action = TRIP)
Active if Vane Type Outlet Scrubber
is Present
(T069) Trip: Outlet Scrubber Low
Low Level
Outlet Scribber Low Low Level
Switch Activated (Selected Action =
TRIP)
Active if Vane Type Outlet Scrubber
is Present
Outlet Scrubber Upper Section
High High Level Switch Activated
(Selected Action = TRIP)
Active if Coalescing Type Outlet
Scrubber is Present
Outlet Scrubber Lower Section
High High Level Switch Activated
(Seelcted Action = TRIP)
Active if Coalescing Type Outlet
Scrubber is Present
(T060) Trip: (Unassigned)
(T061) Trip: Upper Inlet Scrubber
High High Level
(T062) Trip: (Unassigned)
(T063) Trip: (Unassigned)
(T064) Trip: Lower Inlet Scrubber
High High Level
(T065) Trip: (Unassigned)
(T066) Trip: (Unassigned)
(T067) Trip: (Unassigned)
(T070) Trip: (Unassigned)
(T071) Trip: Upper Outlet Scrubber
High High Level
(T072) Trip: (Unassigned)
(T073) Trip: (Unassigned)
(T074) Trip: Lower Outlet Scrubber
High High Level
(T075) Trip: (Unassigned)
(T076) Trip: (Unassigned)
(T077) Trip: (Unassigned)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 13
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Trip Message
Cause(s)
Notes
(T078) Trip: (Unassigned)
(T079) Trip:
User defined Trip 1
Message Defined in "Device Names"
Screens
(T080) Trip:
User Defined Trip 2
Message Defined in "Device Names"
Screens
(T081) Trip:
User Defined Trip 3
Message Defined in "Device Names"
Screens
(T082) Trip:
User defined Trip 4
Message Defined in "Device Names"
Screens
(T083) Trip:
User defined Trip 5
Message Defined in "Device Names"
Screens
(T101) Trip: EPCS Safety Active
- Low/Suction
Low Side/Suction Pressure Exceeds
EPCS Low Side Relief Setpoint
Active if EPCS Safety Selected.
(T102) Trip: EPCS Safety Active
- High/Discharge
High Side/Discharge Pressure
Exceeds EPCS High Side Relief
Setpoint
Active if EPCS Safety Selected.
(T084) Trip: (Unassigned)
(T085) Trip: (Unassigned)
(T086) Trip: (Unassigned)
(T087) Trip: (Unassigned)
(T088) Trip: (Unassigned)
(T089) Trip: (Unassigned)
(T090) Trip: (Unassigned)
(T091) Trip: (Unassigned)
(T092) Trip: (Unassigned)
(T093) Trip: (Unassigned)
(T094) Trip: (Unassigned)
(T095) Trip: (Unassigned)
(T096) Trip: (Unassigned)
(T097) Trip: (Unassigned)
(T098) Trip: Chiller High Level
(T099) Trip: (Unassigned)
(T100) Trip: (Unassigned)
(T103) Trip: (Unassigned)
(T104) Trip: (Unassigned)
(T105) Trip: (Unassigned)
(T106) Trip: High Methane Gas %LEL
Methane Concentration in Building
If compressor is in an enclosure
Exceeds Methane Gas %LEL High Trip
Setpoint.
(T107) Trip: (Unassigned)
11 – 14
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Trip Message
Cause(s)
(T108) Trip: Smoke Detector Tripped Smoke Detector Trip Contact
opened, detected smoke in compressor enclosure
Notes
If compressor is in an enclosure
(T109) Trip: (Unassigned)
(T110) Trip: High Enclosure
Temperature
Temperature inside Enclosure exceeds Enclosure Temperature - High
Trip Setpoint
If compressor is in an enclosure
(T111) Trip: Out of Range: 4-20 mA
Caphold Target
4-20mA Caphold Input is
Disconnected or Raw Value is less
than 3.5 mA or greater than 20 mA
If remote manual mode active and
4-20mA caphold selected as Remote
Manual Source
(T112) Trip: Out of Range: Building
Temperature
Building Temperature RTD Input is
Disconnected or Raw Value is less
than 3.5 mA or greater than 20 mA
(If using 4-20mA Transmitter)
If compressor is in an enclosure
(T113) Trip: Out of Range: Methane
Detector
Methane Detector is Disconnected
or Raw Value is less than 3.5 mA or
greater than 20 mA
If compressor is in an enclosure
(T114) Trip: Out of Range: EPCS Low
Pressure
Low Side EPCS Relief Instrument is
Disconnected or Raw Value is less
than 3.5 mA or greater than 20 mA
Active if EPCS Safety Selected.
(T115) Trip: Out of Range: EPCS High High Side EPCS Relief Instrument is
Pressure
Disconnected or Raw Value is less
than 3.5 mA or greater than 20 mA
Active if EPCS Safety Selected.
(T116) Trip: Out of Range: Motor
Vibration 1
Motor Vibration 1 Instrument is
Disconnected or Raw Value is less
than 3.5 mA or greater than 20 mA
If Motor Vibration Sensor 1 is
installed
(T117) Trip: Out of Range: Motor
Vibration 2
Motor Vibration 2 Instrument is
Disconnected or Raw Value is less
than 3.5 mA or greater than 20 mA
If Motor Vibration Sensor 2 is
installed
(T118) Trip: Out of Range:
Compressor Vibration 1
Compressor Vibration 1 Instrument
is Disconnected or Raw Value is less
than 3.5 mA or greater than 20 mA
If Compressor Vibration Sensor 1 is
installed
(T119) Trip: Out of Range:
Compressor Vibration 2
Compressor Vibration 2 Instrument
is Disconnected or Raw Value is less
than 3.5 mA or greater than 20 mA
If Compressor Vibration Sensor 2 is
installed
(T120) Trip: (Unassigned)
(T121) Trip: (Unassigned)
(T122) Trip: (Unassigned)
(T123) Trip: (Unassigned)
(T124) Trip: (Unassigned)
(T125) Trip: (Unassigned)
(T126) Trip: (Unassigned)
(T127) Trip: (Unassigned)
(T128) Trip: (Unassigned)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 15
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Status Messages and Compressor State Indicator
Status messages are used to indicate compressor status information to the user. Status messages are used to inform
the user of any of the following conditions.
• Anti-Recycle Timer is active
• Compressor is in standby mode and is waiting for one or more conditions to be met
• State of the Compressor Startup Sequence
• Load Limits and Forced Unloading
• Slide Calibration is active
• Compressor PLC has automatically reverted to Local-Auto mode on loss of communications with central controller or DCS (if this function is enabled)
• A user is logged in
• An output is forced
• Scheduled Maintenance is due (if this function is enabled)
• Slide valve exercising is active (if this function is enabled)
Status messages are shown in a green scrolling banner at the top of the overview and menu screens.
Figure 11-3. Alarm/Trip/Status Bars (Main Menu Screen)
Table 11-3. Status Listing
Status Message
Notes
(S001) Status: Compressor Stopped
Displayed in the Event List only
(S002) Status: Compressor Started
Displayed in the Event List only
(S003) Status: NOT USED
(S004) Status: True Anti-Recycle Active: Remaining:
XX:XX
Shows remaining anti-recycle time
(S005) Status: NOT USED
(S006) Status: Waiting to Start: Discharge-Suction Not
Equalized
Compressor PLC is waiting for compressor DischargeSuction to be equalized to within a settable differential
before the compressor will start.
(S007) Status: Waiting to Start: Remote Run Permissive
Input
Compressor PLC is waiting for a contact closure on the
remote run permissive input before the compressor
will start
(S008) Status: Waiting to Start: Soft Run Permissive from
DCS/Central
Compressor PLC is waiting for a run command from
the central controller or DCS (if control by communications is enabled)
(S009) Status: Auto Cycle Stop - Suction Pressure
Auto Start-Stop function is enabled and "Stop" Pressure
has been reached.
(S010) Status: Auto Cycle Stop - Process Temperature
Auto Start-Stop function is enabled and "Stop"
Temperature has been reached.
11 – 16
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Status Message
(S011) Status: Auto Cycle Stop - Discharge Pressure
Notes
Auto Start-Stop function is enabled and "Stop" Pressure
has been reached.
(S012) Status: Compressor Prelube
(S013) Status: Compressor Prelube Failed, Retry in XX
Seconds
Shows remaining time until the compressor prelube
cycle will re-start
(S014) Status: Oil Pump Transition
(S015) Status: Compressor Warmup - Hold at Minimum
Capacity Slide Position
Shows remaining warmup time until compressor will
begin loading.
(S016) Status: Loading Inhibited: Low Suction Pressure
(S017) Status: Loading Inhibited: High Discharge Pressure
(S018) Status: Loading Inhibited: High Motor Amps
(S019) Status: Forced Unload: Low Suction Pressure
(S020) Status: Forced Unload: High Discharge Pressure
(S021) Status: Forced Unload: High Motor Amps
(S022) Status: Slide Valve Calibration Active
(S023) Status: Comms Faulted, Reverted to Local Mode
If "Control by Communications" is enabled and "Alarm
and Revert to Local" is selected as the communications
fault action.
(S024) Status: User SUPER Logged In
(S025) Status: User OP1 Logged In
(S025) Status: User OP2 Logged In
(S025) Status: User OP3 Logged In
(S025) Status: User OP4 Logged In
(S025) Status: User OP5 Logged In
(S030) Status: Main Motor FORCED ON
(S031) Status: NOT USED
(S032) Status: Oil Pump FORCED ON
(S033) Status: Oil Cooler VFD FORCED ON
(S034) Status: Oil Cooler Fan 1 FORCED ON
(S035) Status: Oil Cooler Fan 2 FORCED ON
(S036) Status: Oil Cooler Fan 3 FORCED ON
(S037) Status: Oil Cooler Fan 4 FORCED ON
(S038) Status: Oil Cooler Fan 5 FORCED ON
(S039) Status: Oil Cooler Fan 6 FORCED ON
(S040) Status: Oil Cooler Fan 7 FORCED ON
(S041) Status: Oil Cooler Fan 8 FORCED ON
(S042) Status: Oil Cooler Fan 9 FORCED ON
(S043) Status: Oil Cooler Fan 10 FORCED ON
(S044) Status: Aftercooler 1 VFD FORCED ON
(S045) Status: Aftercooler 1 Fan 1 FORCED ON
(S046) Status: Aftercooler 1 Fan 2 FORCED ON
(S047) Status: Aftercooler 1 Fan 3 FORCED ON
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 17
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Status Message
Notes
(S048) Status: Aftercooler 1 Fan 4 FORCED ON
(S049) Status: Aftercooler 1 Fan 5 FORCED ON
(S050) Status: Aftercooler 1 Fan 6 FORCED ON
(S051) Status: Aftercooler 1 Fan 7 FORCED ON
(S052) Status: Aftercooler 1 Fan 8 FORCED ON
(S053) Status: Aftercooler 1 Fan 9 FORCED ON
(S054) Status: Aftercooler 1 Fan 10 FORCED ON
(S055) Status: Aftercooler 2 VFD FORCED ON
(S056) Status: Aftercooler 2 Fan 1 FORCED ON
(S057) Status: Aftercooler 2 Fan 2 FORCED ON
(S058) Status: Aftercooler 2 Fan 3 FORCED ON
(S059) Status: Aftercooler 2 Fan 4 FORCED ON
(S060) Status: Aftercooler 2 Fan 5 FORCED ON
(S061) Status: Aftercooler 2 Fan 6 FORCED ON
(S062) Status: Aftercooler 2 Fan 7 FORCED ON
(S063) Status: Aftercooler 2 Fan 8 FORCED ON
(S064) Status: Aftercooler 2 Fan 9 FORCED ON
(S065) Status: Aftercooler 2 Fan 10 FORCED ON
(S066) Status: Condenser Fan VFD FORCED ON
(S067) Status: Condenser Fan 1 FORCED ON
(S068) Status: Condenser Fan 2 FORCED ON
(S069) Status: Condenser Fan 3 FORCED ON
(S070) Status: Condenser Fan 4 FORCED ON
(S071) Status: Condenser Fan 5 FORCED ON
(S072) Status: Condenser Fan 6 FORCED ON
(S073) Status: Condenser Fan 7 FORCED ON
(S074) Status: Condenser Fan 8 FORCED ON
(S075) Status: Condenser Fan 9 FORCED ON
(S076) Status: Condenser Fan 10 FORCED ON
(S077) Status: Condenser Water Valve FORCED ON
(S078) Status: VPLUS Pump FORCED ON
(S079) Status: Liquid Injection Valve Air SOV FORCED ON
(S080) Status: Discharge Recycle Air SOV FORCED ON
(S081) Status: Oil Mixing Valve FORCED ON
(S082) Status: Oil Injection Valve FORCED ON
(S083) Status: Alarm Indication FORCED ON
(S084) Status: Trip Indication FORCED ON
(S085) Status: Oil Separator Heaters FORCED ON
(S086) Status: Suction Oil SOV FORCED ON
(S087) Status: Gas EQ SOV FORCED ON
(S088) Status: Economizer SOV FORCED ON
11 – 18
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Status Message
Notes
(S089) Status: Hotgas SOV FORCED ON
(S090) Status: Venturi Oil Recovery SOVs FORCED ON
(S091) Status: Inlet Scrubber Drain Pump/SOV FORCED
ON
(S092) Status: Inlet Scrubber Backup SOV FORCED ON
(S093) Status: Outlet Scrubber Drain Pump/SOV FORCED
ON
(S094) Status: Outlet Scrubber Backup SOV FORCED ON
(S095) Status: Enclosure Vent Fans FORCED ON
(S096) Status: Enclosure Heaters FORCED ON
(S097) Status: Evap Condenser Pump FORCED ON
(S098) Status: EPCS Low Side SOV FORCED ON
(S099) Status: EPCS High Side SOV FORCED ON
(S100) Status: Oil Cooler STBY Heaters FORCED ON
(S101) Status: Alarm Horn FORCED ON
(S102) Status: Stacklight - Amber FORCED ON
(S103) Status: Stacklight - Red FORCED ON
(S104) Status: INLET SCRUBBER - PUMP 2 FORCED ON
(S105) Status: OUTLET SCRUBBER - PUMP 2 FORCED ON
(S106) Status: OIL DRAIN SV FORCED ON
(S107) Status: Economizer Port 2 FORCED ON
(S108) Status: Shunt Trip FORCED ON
(S109) Status: User MGR Logged In
(S110) Status: Setpoint 1 Active
Displayed in the Event List only
(S111) Status: Setpoint 2 Active
Displayed in the Event List only
(S112) Status: Scheduled Maintenance Due
The message entered in the settable maintenance
timer dialog will appear in the status banner and event
list
(S113) Status: Aftercooler 1 Valve Forced
(S114) Status: Aftercooler 2 Valve Forced
(S115) Status: Capacity Slide Exercise Active
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
11 – 19
Section 11 • Alarms, Trips, Status Information & Troubleshooting
Troubleshooting
IF THE COMPRESSOR WILL NOT START
In order to initiate a start at the compressor, make sure all permissives to initiate a start are met.
To initiate a start, the following conditions must be met:
• Control Power is ON (Emergency Stop button is not pressed and Master Control Relay is energized, indicated by
pilot light on front of panel)
• No Active Trips
If a start has been initiated and the compressor has not started, it is in standby mode. When in standby mode, the
status banner will indicate the condition that is preventing the compressor from starting.
IF CONTROL POWER WILL NOT TURN ON
If unable to turn on control power/reset an emergency stop, check the following conditons:
To energize the Master Control Relay, the following conditions must be met:
• Compressor PLC Panel must be supplied with 120VAC power.
• “Master Power” Selector Switch must be ON
• Local Emergency Stop pushbutton (mounted on PLC enclosure door) must be pulled out.
• DC power supplies must be powered up and functional, “DC OK” Relay must be energized.
• Compactlogix processor must be powered up and functional, “PLC OK” Output must be ON.
• Optional/External Emergency Stop Devices are not tripped.
11 – 20
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Communication with a Central
Controller/DCS
Central Controller/DCS. It is only necessary to write
watchdog logic when the Central Controller/DCS is
sending commands to the compressor PLC. If reading
data only, the Watchdog timer is not used.
IIt is possible for a central controller/DCS to read live
data and other information from the compressor PLC as
well as send commands to the compressor PLC. The following section outlines the PLC addresses that are used
for interface between the Compressor PLC and central
controller/DCS.
The watchdog timer works by “passing a bit” back and
forth between the Compressor PLC and central controller/DCS. If the compressor PLC sees the bit in the same
state for a settable watchdog time, the communications
are faulted. The Communication fault action is selectable between “Alarm and Revert to Local Mode” or “Trip
Machine.” If “Alarm and Revert to Local Mode” is selected, the compressor will continue to run if running. If
“Trip Machine” is selected, the compressor will trip and
shut down. The settable watchdog time and communications fault action are selected on the Configuration
Screen.
VPN ACCESS
VPN access allows Vilter engineers and technicians connect remotely to the compressor PLC for greater ease of
support and troubleshooting. If possible, it is recommended that VPN access be provided.
To allow VPN access to a compressor PLC, the following
are required:
• A physical Ethernet Connection from the compressor
PLC to the site control network
• IP address, Subnet Mask, and Gateway address must
be defined for each compressor PLC and HMI on the
site control network
• A VPN server linked to the site control network
• VPN server login information
SETTING UP COMMUNICATIONS
The compressor PLC communicates using the Ethernet
IP protocol. Communication to other devices compatible with Ehternet IP is as simple as setting up CIP message instructions and does not require any additional
hardware other than that required for the physical
connection.
Interface Data in the compressor PLC is organized into
arrays for simple access of data. For example, all live
instrument data is arranged into a single block 200 elements long. To get all of the data, only one message
would need to be configured to read an array of registers, Data type REAL, Length of 200. See the communication tables below for specifics.
NOTE
The watchdog bits that are used are:
• Compressor to Central/DCS: BOOL_OUT[0].0
• Central/DCS to Compressor: BOOL_IN[0].0
When the Compressor PLC sees BOOL_IN[0].0 OFF it will
turn BOOL_OUT[0].0 ON. To maintain the handshake,
the Central Controller/DCS shall Turn BOOL_IN[0].0 ON
when it sees BOOL_OUT[0].0 ON.
Data that can be Read from the
Compressor PLC
LIVE INSTRUMENT DATA
Tags “REAL_OUT[0]” through “REAL_OUT[99]” present
the live data values as they appear on the HMI screen
in the selected engineering units. The Tags “REAL_
OUT[100]” through “REAL_OUT[199]” present all live
data values in base units, which are PSIA for pressures
and Degrees Fahrenheit for Temperatures. For data other
than Pressures and Temperatures, the engineering units
are fixed and not selectable, and will appear the same in
“REAL_OUT[0]” through “REAL_OUT[99]” as they will in
“REAL_OUT[100]” through “REAL_OUT[199].” The engineering units selected are presented in the tags “INT_
OUT[0]” through “INT_OUT[99].”
Setting up communications using a protocol other
than Ethernet IP is possible (Example Modbus RTU
or Modbus TCP), but additional hardware, software,
programming, and setup are required.
WATCHDOG TIMER
A watchdog timer is used to monitor the status of the
communication link between the compressor PLC and
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 1
Section 12 • Communications with a Central Controller/DCS
Table 12-1. Engineered Units Value Interpretation (INT_OUT[x])
Pressure Units
INT_OUT[x] Value
Temperature Units
INT_OUT[x] Value
PSIG
0
Degrees Fahrenheit
0
PSIA (PSID)
1
Degrees Celsius
1
kPa[A] (kPa[D])
2
Kelvin
2
kPa[G]
12
Degrees Rankine
3
kg/cm^2[A] (kg/cm^2[D])
3
kg/cm^2[G]
13
inHg (vac) PSIG (pressure)
4
inWC
15
Bar[A] (Bar[D])
6
Bar[G]
16
Torr[A] (Torr[D])
7
Torr[G]
17
Table 12-2. Live Instrument Data
Live Instrument Data: "REAL_OUT" (Data Type = REAL, Length = 200)
Interface Tag
Description
Units
REAL_OUT[0]
Suction Temperature
INT_OUT[0]
REAL_OUT[1]
Discharge Temperature
INT_OUT[1]
REAL_OUT[2]
Oil Separator Temp
INT_OUT[2]
REAL_OUT[3]
Oil Injection Temp
INT_OUT[3]
REAL_OUT[4]
Oil Separator Outlet Temp
INT_OUT[4]
REAL_OUT[5]
INT_OUT[5]
REAL_OUT[6]
Suction Pressure
INT_OUT[6]
REAL_OUT[7]
Discharge Pressure
INT_OUT[7]
REAL_OUT[8]
Filter In Pressure
INT_OUT[8]
REAL_OUT[9]
Filter Out Pressure
INT_OUT[9]
REAL_OUT[10]
Oil Separator Out Pressure
INT_OUT[10]
REAL_OUT[11]
Oil Separator Pressure Drop
INT_OUT[11]
REAL_OUT[12]
Filter Differential Pressure
INT_OUT[12]
REAL_OUT[13]
Net Oil Pressure
INT_OUT[13]
REAL_OUT[14]
Oil Circuit Pressure Drop
INT_OUT[14]
REAL_OUT[15]
INT_OUT[15]
REAL_OUT[16]
Main Motor Amps
Amps
REAL_OUT[17]
Volume Slide Postion
% Position
REAL_OUT[18]
Capacity Slide Position
% Position
REAL_OUT[19]
Oil Mixing Valve Commanded Postion
% Position
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Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
Units
REAL_OUT[20]
Phase A Winding Temp
INT_OUT[20]
REAL_OUT[21]
Phase B Winding Temp
INT_OUT[21]
REAL_OUT[22]
Phase C Winding Temp
INT_OUT[22]
REAL_OUT[23]
ODE Bearing Temp
INT_OUT[23]
REAL_OUT[24]
DE Bearing Temp
INT_OUT[24]
REAL_OUT[25]
Motor Vibration 1
in/sec
REAL_OUT[26]
Motor Vibration 2
in/sec
REAL_OUT[27]
Compressor Vibration 1
in/sec
REAL_OUT[28]
Compressor Vibration 2
in/sec
REAL_OUT[29]
Compressor VFD Commanded Speed
% Speed
REAL_OUT[30]
Compressor VFD Actual Speed
% Speed
REAL_OUT[31]
REAL_OUT[32]
INT_OUT[31]
Process Temp
INT_OUT[32]
REAL_OUT[33]
Liquid Refrigerant Temp
INT_OUT[33]
REAL_OUT[34]
Liquid Injection Commanded Postion
% Position
REAL_OUT[35]
VPLUS Commanded Speed
% Speed
REAL_OUT[36]
Oil Cooler Inlet Temp
INT_OUT[36]
REAL_OUT[37]
Oil Cooler Outlet Temp
INT_OUT[37]
REAL_OUT[38]
REAL_OUT[39]
INT_OUT[38]
Oil Cooler Fan Commanded Speed
REAL_OUT[40]
% Speed
INT_OUT[40]
REAL_OUT[41]
Aftercooler 1 Outlet Temp
INT_OUT[41]
REAL_OUT[42]
Aftercooler 2 Outlet Temp
INT_OUT[42]
REAL_OUT[43]
Aftercooler 1 VFD Speed
% Speed
REAL_OUT[44]
Aftercooler 2 VFD Speed
% Speed
REAL_OUT[45]
INT_OUT[45]
REAL_OUT[46]
Discharge Recycle Control Pressure
INT_OUT[46]
REAL_OUT[47]
Discharge Recycle Commanded Postion
% Position
REAL_OUT[48]
INT_OUT[48]
REAL_OUT[49]
INT_OUT[49]
REAL_OUT[50]
Condensing Pressure
INT_OUT[50]
REAL_OUT[51]
Condenser VFD Speed
% Speed
REAL_OUT[52]
INT_OUT[52]
REAL_OUT[53]
Inlet Scrubber Inlet Pressure
INT_OUT[53]
REAL_OUT[54]
Inlet Scrubber Outlet Pressure
INT_OUT[54]
REAL_OUT[55]
Inlet Scrubber Pressure Drop
INT_OUT[55]
REAL_OUT[56]
Outlet Scrubber Inlet Pressure
INT_OUT[56]
REAL_OUT[57]
Outlet Scrubber Outlet Pressure
INT_OUT[57]
REAL_OUT[58]
Outlet Scrubber Pressure Drop
INT_OUT[58]
REAL_OUT[59]
REAL_OUT[60]
INT_OUT[59]
Building Temperature
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
INT_OUT[60]
12 – 3
Section 12 • Communications with a Central Controller/DCS
Interface Tag
REAL_OUT[61]
Description
Methane Detector LEL
Units
% LEL
REAL_OUT[62]
INT_OUT[62]
REAL_OUT[63]
INT_OUT[63]
REAL_OUT[64]
INT_OUT[64]
REAL_OUT[65]
EPCS Low Side Pressure
INT_OUT[65]
REAL_OUT[66]
EPCS High Side Pressure
INT_OUT[66]
REAL_OUT[67]
INT_OUT[67]
REAL_OUT[68]
INT_OUT[68]
REAL_OUT[69]
INT_OUT[69]
REAL_OUT[70]
Runtime Hours
Hours
REAL_OUT[71]
Runtime Mins
Minutes
REAL_OUT[72]
Resettable Runtime Hours
Hours
REAL_OUT[73]
Resettable Runtime Min
Minutes
REAL_OUT[74]
Current/Last Runtime Hours
Hours
REAL_OUT[75]
Current/Last Runtime Min
Minutes
REAL_OUT[76]
INT_OUT[76]
REAL_OUT[77]
INT_OUT[77]
REAL_OUT[78]
INT_OUT[78]
REAL_OUT[79]
INT_OUT[79]
REAL_OUT[80]
INT_OUT[80]
REAL_OUT[81]
INT_OUT[81]
REAL_OUT[82]
INT_OUT[82]
REAL_OUT[83]
INT_OUT[83]
REAL_OUT[84]
INT_OUT[84]
REAL_OUT[85]
INT_OUT[85]
REAL_OUT[86]
INT_OUT[86]
REAL_OUT[87]
INT_OUT[87]
REAL_OUT[88]
INT_OUT[88]
REAL_OUT[89]
INT_OUT[89]
REAL_OUT[90]
INT_OUT[90]
REAL_OUT[91]
INT_OUT[91]
REAL_OUT[92]
INT_OUT[92]
REAL_OUT[93]
INT_OUT[93]
REAL_OUT[94]
INT_OUT[94]
REAL_OUT[95]
INT_OUT[95]
REAL_OUT[96]
INT_OUT[96]
REAL_OUT[97]
INT_OUT[97]
REAL_OUT[98]
INT_OUT[98]
REAL_OUT[99]
INT_OUT[99]
REAL_OUT[100]
Suction Temperature
DEGF
REAL_OUT[101]
Discharge Temperature
DEGF
12 – 4
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
Units
REAL_OUT[102]
Oil Separator Temp
DEGF
REAL_OUT[103]
Oil Injection Temp
DEGF
REAL_OUT[104]
Oil Separator Outlet Temp
DEGF
REAL_OUT[106]
Suction Pressure
PSIA
REAL_OUT[107]
Discharge Pressure
PSIA
REAL_OUT[108]
Filter In Pressure
PSIA
REAL_OUT[109]
Filter Out Pressure
PSIA
REAL_OUT[110]
Oil Separator Out Pressure
PSIA
REAL_OUT[111]
Oil Separator Pressure Drop
PSID
REAL_OUT[112]
Filter Differential Pressure
PSID
REAL_OUT[113]
Net Oil Pressure
PSID
REAL_OUT[114]
Oil Circuit Pressure Drop
PSID
REAL_OUT[116]
Main Motor Amps
Amps
REAL_OUT[117]
Volume Slide Postion
% Position
REAL_OUT[118]
Capacity Slide Position
% Position
REAL_OUT[119]
Oil Mixing Valve Commanded Postion
% Position
REAL_OUT[120]
Phase A Winding Temp
DEGF
REAL_OUT[121]
Phase B Winding Temp
DEGF
REAL_OUT[122]
Phase C Winding Temp
DEGF
REAL_OUT[123]
ODE Bearing Temp
DEGF
REAL_OUT[124]
DE Bearing Temp
DEGF
REAL_OUT[125]
Motor Vibration 1
in/sec
REAL_OUT[126]
Motor Vibration 2
in/sec
REAL_OUT[127]
Compressor Vibration 1
in/sec
REAL_OUT[128]
Compressor Vibration 2
in/sec
REAL_OUT[129]
Compressor VFD Commanded Speed
% Speed (100%=60Hz)
REAL_OUT[130]
Compressor VFD Actual Speed
% Speed (100%=60Hz)
REAL_OUT[132]
Process Temp
DEGF
REAL_OUT[133]
Liquid Refrigerant Temp
DEGF
REAL_OUT[134]
Liquid Injection Commanded Postion
% Position
REAL_OUT[135]
VPLUS Commanded Speed
% Speed
REAL_OUT[136]
Oil Cooler Inlet Temp
DEGF
REAL_OUT[137]
Oil Cooler Outlet Temp
DEGF
Oil Cooler Fan Commanded Speed
% Speed (100%=60Hz)
REAL_OUT[141]
Aftercooler 1 Outlet Temp
DEGF
REAL_OUT[142]
Aftercooler 2 Outlet Temp
DEGF
REAL_OUT[105]
REAL_OUT[115]
REAL_OUT[131]
REAL_OUT[138]
REAL_OUT[139]
REAL_OUT[140]
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 5
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
Units
REAL_OUT[143]
Aftercooler 1 VFD Speed
% Speed (100%=60Hz)
REAL_OUT[144]
Aftercooler 2 VFD Speed
% Speed (100%=60Hz)
REAL_OUT[146]
Discharge Recycle Control Pressure
PSIA
REAL_OUT[147]
Discharge Recycle Commanded Postion
% Position
REAL_OUT[150]
Condensing Pressure
PSIA
REAL_OUT[151]
Condenser VFD Speed
% Speed (100%=60Hz)
REAL_OUT[153]
Inlet Scrubber Inlet Pressure
PSIA
REAL_OUT[154]
Inlet Scrubber Outlet Pressure
PSIA
REAL_OUT[155]
Inlet Scrubber Pressure Drop
PSIA
REAL_OUT[156]
Outlet Scrubber Inlet Pressure
PSIA
REAL_OUT[157]
Outlet Scrubber Outlet Pressure
PSIA
REAL_OUT[158]
Outlet Scrubber Pressure Drop
PSIA
REAL_OUT[160]
Building Temperature
DEGF
REAL_OUT[161]
Methane Detector LEL
% LEL
REAL_OUT[165]
EPCS Low Side Pressure
PSID
REAL_OUT[166]
EPCS High Side Pressure
PSID
Runtime Hours
Hours
REAL_OUT[171]
Runtime Mins
Minutes
REAL_OUT[172]
Resettable Runtime Hours
Hours
REAL_OUT[173]
Resettable Runtime Min
Minutes
REAL_OUT[174]
Current/Last Runtime Hours
Hours
REAL_OUT[175]
Current/Last Runtime Min
Minutes
REAL_OUT[145]
REAL_OUT[148]
REAL_OUT[149]
REAL_OUT[152]
REAL_OUT[159]
REAL_OUT[162]
REAL_OUT[163]
REAL_OUT[164]
REAL_OUT[167]
REAL_OUT[168]
REAL_OUT[169]
REAL_OUT[170]
REAL_OUT[176]
REAL_OUT[177]
REAL_OUT[178]
REAL_OUT[179]
REAL_OUT[180]
REAL_OUT[181]
REAL_OUT[182]
12 – 6
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
Units
REAL_OUT[183]
REAL_OUT[184]
REAL_OUT[185]
REAL_OUT[186]
REAL_OUT[187]
REAL_OUT[188]
REAL_OUT[189]
REAL_OUT[190]
REAL_OUT[191]
REAL_OUT[192]
REAL_OUT[193]
REAL_OUT[194]
REAL_OUT[195]
REAL_OUT[196]
REAL_OUT[197]
REAL_OUT[198]
REAL_OUT[199]
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 7
Section 12 • Communications with a Central Controller/DCS
Alarm and Trip Data
Alarm and Trip Data is presented in Double Integer Format. To interpret the Alarm and Trip data, it is necessary to address the specific bits of the Double Integer.
Table 12-3. Alarm Data
Interface Tag
ALARMS AND TRIPS (Data Type = DINT)
Description
BOOL_OUT[1].0
(A001) Alarm: (Unassigned)
BOOL_OUT[1].1
(A002) Alarm: PLC to Central Comms Faulted
BOOL_OUT[1].2
(A003) Alarm: High Main Motor Amps
BOOL_OUT[1].3
(A004) Alarm: (Unassigned)
BOOL_OUT[1].4
(A005) Alarm: (Unassigned)
BOOL_OUT[1].5
(A006) Alarm: Low Separator Oil Level
BOOL_OUT[1].6
(A007) Alarm: Not Assigned
BOOL_OUT[1].7
(A008) Alarm: Not Assigned
BOOL_OUT[1].8
(A009) Alarm: Not Assigned
BOOL_OUT[1].9
(A010) Alarm: Not Assigned
BOOL_OUT[1].10
(A011) Alarm: Low Suction Temperature
BOOL_OUT[1].11
(A012) Alarm: High Discharge Temperature
BOOL_OUT[1].12
(A013) Alarm: Low Oil Separator Temperature - Start
BOOL_OUT[1].13
(A014) Alarm: Low Oil Separator Temperature - Run
BOOL_OUT[1].14
(A015) Alarm: Low Oil Injection Temperature
BOOL_OUT[1].15
(A016) Alarm: High Oil Injection Temperature
BOOL_OUT[1].16
(A017) Alarm: Low Process Temperature
BOOL_OUT[1].17
(A018) Alarm: High Process Temperature
BOOL_OUT[1].18
(A019) Alarm: High Suction Temperature
BOOL_OUT[1].19
(A020) Alarm: Low Liquid Refrigerant Temperature
BOOL_OUT[1].20
(A021) Alarm: Low Suction Pressure Stpt. 1
BOOL_OUT[1].21
(A022) Alarm: Low Suction Pressure Stpt. 2
BOOL_OUT[1].22
(A023) Alarm: High Discharge Pressure Stpt. 1
BOOL_OUT[1].23
(A024) Alarm: High Discharge Pressure Stpt. 2
BOOL_OUT[1].24
(A025) Alarm: Low Net Oil Pressure - Run
BOOL_OUT[1].25
(A026) Alarm: Unassigned
BOOL_OUT[1].26
(A027) Alarm: High Oil Filter Differential - Start
BOOL_OUT[1].27
(A028) Alarm: High Oil Filter Differential - Run
BOOL_OUT[1].28
(A029) Alarm: Low Oil Pressure - Start
BOOL_OUT[1].29
(A030) Alarm: (Unassigned)
BOOL_OUT[1].30
(A031) Alarm: Out of Range: Oil Cooler Inlet Temp
BOOL_OUT[1].31
(A032) Alarm: Out of Range: Oil Cooler Outlet Temp
BOOL_OUT[2].0
(A033) Alarm: Out of Range: Condensing Pressure
12 – 8
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[2].1
(A034) Alarm: Out of Range: Aftercooler 1 Outlet Temp
BOOL_OUT[2].2
(A035) Alarm: Out of Range: Aftercooler 2 Outlet Temp
BOOL_OUT[2].3
(A036) Alarm: Out of Range: Inlet Scrubber Inlet Pressure
BOOL_OUT[2].4
(A037) Alarm: Out of Range: Inlet Scrubber Outlet Pressure
BOOL_OUT[2].5
(A038) Alarm: Out of Range: Outlet Scrubber Inlet Pressure
BOOL_OUT[2].6
(A039) Alarm: Out of Range: Outlet Scrubber Outlet Pressure
BOOL_OUT[2].7
(A040) Alarm: Out of Range: Discharge Recycle Control Pressure
BOOL_OUT[2].8
(A041) Alarm: Out of Range: Oil Separator Outlet Pressure
BOOL_OUT[2].9
(A042) Alarm: Unassigned
BOOL_OUT[2].10
(A043) Alarm: Unassigned
BOOL_OUT[2].11
(A044) Alarm: (Unassigned)
BOOL_OUT[2].12
(A045) Alarm: (Unassigned)
BOOL_OUT[2].13
(A046) Alarm: High Oil Separator Pressure Drop
BOOL_OUT[2].14
(A047) Alarm: Low Oil Separator Outlet Temp (Dew Point)
BOOL_OUT[2].15
(A048) Alarm: High Motor Phase A Temperature
BOOL_OUT[2].16
(A049) Alarm: High Motor Phase B Temperature
BOOL_OUT[2].17
(A050) Alarm: High Motor Phase C Temperature
BOOL_OUT[2].18
(A051) Alarm: Motor DE Bearing Temperature
BOOL_OUT[2].19
(A052) Alarm: Motor ODE Bearing Temperature
BOOL_OUT[2].20
(A053) Alarm: High Motor Vibration - Sensor 1
BOOL_OUT[2].21
(A054) Alarm: High Motor Vibration - Sensor 2
BOOL_OUT[2].22
(A055) Alarm: High Compressor Vibration - Sensor 1
BOOL_OUT[2].23
(A056) Alarm: High Compressor Vibration - Sensor 2
BOOL_OUT[2].24
(A057) Alarm: Inlet Scrubber High Level
BOOL_OUT[2].25
(A058) Alarm: Inlet Scrubber High High Level
BOOL_OUT[2].26
(A059) Alarm: Inlet Scrubber Low Low Level
BOOL_OUT[2].27
(A060) Alarm: Upper Inlet Scrubber High Level
BOOL_OUT[2].28
(A061) Alarm: Upper Inlet Scrubber High High Level
BOOL_OUT[2].29
(A062) Alarm: (Unassigned)
BOOL_OUT[2].30
(A063) Alarm: Lower Inlet Scrubber High Level
BOOL_OUT[2].31
(A064) Alarm: Lower Inlet Scrubber High High Level
BOOL_OUT[3].0
(A065) Alarm: Inlet Scrubber High Pressure Drop
BOOL_OUT[3].1
(A066) Alarm: Inlet Scrubber Condensate Pump Starter Fault
BOOL_OUT[3].2
(A067) Alarm: Outlet Scrubber High Level
BOOL_OUT[3].3
(A068) Alarm: Outlet Scrubber High High Level
BOOL_OUT[3].4
(A069) Alarm: Outlet Scrubber Low Low Level
BOOL_OUT[3].5
(A070) Alarm: Upper Outlet Scrubber High Level
BOOL_OUT[3].6
(A071) Alarm: Upper Outlet Scrubber High High Level
BOOL_OUT[3].7
(A072) Alarm: (Unassigned)
BOOL_OUT[3].8
(A073) Alarm: Lower Outlet Scrubber High Level
BOOL_OUT[3].9
(A074) Alarm: Lower Outlet Scrubber High High Level
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 9
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[3].10
(A075) Alarm: Outlet Scrubber High Pressure Drop
BOOL_OUT[3].11
(A076) Alarm: Outlet Scrubber Condensate Pump Starter Fault
BOOL_OUT[3].12
(A077) Alarm: (Unassigned)
BOOL_OUT[3].13
(A078) Alarm: (Unassigned)
BOOL_OUT[3].14
(A079) Alarm:
BOOL_OUT[3].15
(A080) Alarm:
BOOL_OUT[3].16
(A081) Alarm:
BOOL_OUT[3].17
(A082) Alarm:
BOOL_OUT[3].18
(A083) Alarm:
BOOL_OUT[3].19
(A084) Alarm: (Unassigned)
BOOL_OUT[3].20
(A085) Alarm: (Unassigned)
BOOL_OUT[3].21
(A086) Alarm: (Unassigned)
BOOL_OUT[3].22
(A087) Alarm: (Unassigned)
BOOL_OUT[3].23
(A088) Alarm: (Unassigned)
BOOL_OUT[3].24
(A089) Alarm: Oil Cooler Fan VFD Fault
BOOL_OUT[3].25
(A090) Alarm: Oil Cooler Fan (Step Type) Starter Fault
BOOL_OUT[3].26
(A091) Alarm: (Unassigned)
BOOL_OUT[3].27
(A092) Alarm: (Unassigned)
BOOL_OUT[3].28
(A093) Alarm: Aftercooler 1 Fan VFD Fault
BOOL_OUT[3].29
(A094) Alarm: Aftercooler 1 Fan (Step Type) Starter Fault
BOOL_OUT[3].30
(A095) Alarm: Aftercooler 2 Fan VFD Fault
BOOL_OUT[3].31
(A096) Alarm: Aftercooler 2 Fan (Step Type) Starter Fault
BOOL_OUT[4].0
(A097) Alarm: Economizer High Level
BOOL_OUT[4].1
(A098) Alarm: Chiller High Level
BOOL_OUT[4].2
(A099) Alarm: Air Cooled Condenser Fan VFD Fault
BOOL_OUT[4].3
(A100) Alarm: Air Cooled Condenser (Step Type) Starter Fault
BOOL_OUT[4].4
(A101) Alarm: Unassigned
BOOL_OUT[4].5
(A102) Alarm: Unassigned
BOOL_OUT[4].6
(A103) Alarm: (Unassigned)
BOOL_OUT[4].7
(A104) Alarm: (Unassigned)
BOOL_OUT[4].8
(A105) Alarm: (Unassigned)
BOOL_OUT[4].9
(A106) Alarm: High Methane Gas %LEL
BOOL_OUT[4].10
(A107) Alarm: (Unassigned)
BOOL_OUT[4].11
(A108) Alarm: Low Oil Cooler Out Temperature
BOOL_OUT[4].12
(A109) Alarm: High Oil Cooler Out Temperature
BOOL_OUT[4].13
(A110) Alarm: High Enclosure Temperature
BOOL_OUT[4].14
(A111) Alarm: (Unassigned)
BOOL_OUT[4].15
(A112) Alarm: (Unassigned)
BOOL_OUT[4].16
(A113) Alarm: (Unassigned)
BOOL_OUT[4].17
(A114) Alarm: (Unassigned)
BOOL_OUT[4].18
(A115) Alarm: (Unassigned)
12 – 10
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[4].19
(A116) Alarm: (Unassigned)
BOOL_OUT[4].20
(A117) Alarm: (Unassigned)
BOOL_OUT[4].21
(A118) Alarm: (Unassigned)
BOOL_OUT[4].22
(A119) Alarm: (Unassigned)
BOOL_OUT[4].23
(A120) Alarm: (Unassigned)
BOOL_OUT[4].24
(A121) Alarm: (Unassigned)
BOOL_OUT[4].25
(A122) Alarm: (Unassigned)
BOOL_OUT[4].26
(A123) Alarm: (Unassigned)
BOOL_OUT[4].27
(A124) Alarm: (Unassigned)
BOOL_OUT[4].28
(A125) Alarm: (Unassigned)
BOOL_OUT[4].29
(A126) Alarm: (Unassigned)
BOOL_OUT[4].30
(A127) Alarm: (Unassigned)
BOOL_OUT[4].31
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 11
Section 12 • Communications with a Central Controller/DCS
Table 12-4. Trip Data
Interface Tag
TRIPS (Data Type = Double Integer)
Description
BOOL_OUT[11].0
(T001) Trip: MCR Not Energized/E-Stop Active
BOOL_OUT[11].1
(T002) Trip: PLC to Central Comms Faulted
BOOL_OUT[11].2
(T003) Trip: High Main Motor Amps
BOOL_OUT[11].3
(T004) Setpoint out of Range - See Menu Screen
BOOL_OUT[11].4
(T005) Trip: False Start Detected
BOOL_OUT[11].5
(T006) Trip: Low Separator Oil Level
BOOL_OUT[11].6
(T007) Trip: Faulted I/O Module Connection or Module Type
BOOL_OUT[11].7
(T008) Trip: Main Motor Starter Fault
BOOL_OUT[11].8
(T009) Trip: Main Motor Feedback Fault/Overload
BOOL_OUT[11].9
(T010) Trip: Supplemental Shutdown Active
BOOL_OUT[11].10
(T011) Trip: Low Suction Temperature
BOOL_OUT[11].11
(T012) Trip: High Discharge Temperature
BOOL_OUT[11].12
(T013) Trip: Low Oil Separator Temperature - Start
BOOL_OUT[11].13
(T014) Trip: Low Oil Separator Temperature - Run
BOOL_OUT[11].14
(T015) Trip: Low Oil Injection Temperature
BOOL_OUT[11].15
(T016) Trip: High Oil Injection Temperature
BOOL_OUT[11].16
(T017) Trip: Low Process Temperature
BOOL_OUT[11].17
(T018) Trip: (Unassigned)
BOOL_OUT[11].18
(T019) Trip: High Suction Temperature
BOOL_OUT[11].19
(T020) Trip: Low Liquid Refrigerant Temperature
BOOL_OUT[11].20
(T021) Trip: Low Suction Pressure Stpt. 1
BOOL_OUT[11].21
(T022) Trip: Low Suction Pressure Stpt. 2
BOOL_OUT[11].22
(T023) Trip: High Discharge Pressure Stpt. 1
BOOL_OUT[11].23
(T024) Trip: High Discharge Pressure Stpt. 2
BOOL_OUT[11].24
(T025) Trip: Low Net Oil Pressure - Run
BOOL_OUT[11].25
(T026) Trip: Failed To Reach Prelube Pressure - Start Sequence Aborted
BOOL_OUT[11].26
(T027) Trip: High Oil Filter Differential - Start
BOOL_OUT[11].27
(T028) Trip: High Oil Filter Differential - Run
BOOL_OUT[11].28
(T029) Trip: Low Oil Pressure - Start
BOOL_OUT[11].29
(T030) Trip: (Unassigned)
BOOL_OUT[11].30
(T031) Trip: Out of Range: Suction Pr
BOOL_OUT[11].31
(T032) Trip: Out of Range: Discharge Pr
BOOL_OUT[12].0
(T033) Trip: Out of Range: Manifold Pr
BOOL_OUT[12].1
(T034) Trip: Out of Range: Filter Inlet Pr
BOOL_OUT[12].2
(T035) Trip: Out of Range: Suction Temp
BOOL_OUT[12].3
(T036) Trip: Out of Range: Discharge Temp
BOOL_OUT[12].4
(T037) Trip: Out of Range: Oil Sep Temp
BOOL_OUT[12].5
(T038) Trip: Out of Range: Oil Injection Temp
12 – 12
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[12].6
(T039) Trip: Out of Range: Main Motor Amps
BOOL_OUT[12].7
(T040) Trip: Out of Range: Capacity Slide Position
BOOL_OUT[12].8
(T041) Trip: Out of Range: Volume Slide Position
BOOL_OUT[12].9
(T042) Trip: Out of Range: Process Temp
BOOL_OUT[12].10
(T043) Trip: Out of Range: Motor RTD Phase A
BOOL_OUT[12].11
(T044) Trip: Out of Range: Motor RTD Phase B
BOOL_OUT[12].12
(T045) Trip: Out of Range: Motor RTD Phase C
BOOL_OUT[12].13
(T046) Trip: Out of Range: Motor RTD ODE
BOOL_OUT[12].14
(T047) Trip: Out of Range: Motor RTD DE
BOOL_OUT[12].15
(T048) Trip: High Motor Phase A Temperature
BOOL_OUT[12].16
(T049) Trip: High Motor Phase B Temperature
BOOL_OUT[12].17
(T050) Trip: High Motor Phase C Temperature
BOOL_OUT[12].18
(T051) Trip: High Motor DE Bearing Temperature
BOOL_OUT[12].19
(T052) Trip: High Motor ODE Bearing Temperature
BOOL_OUT[12].20
(T053) Trip: High Motor Vibration - Sensor 1
BOOL_OUT[12].21
(T054) Trip: High Motor Vibration - Sensor 2
BOOL_OUT[12].22
(T055) Trip: High Compressor Vibration - Sensor 1
BOOL_OUT[12].23
(T056) Trip: High Compressor Vibration - Sensor 2
BOOL_OUT[12].24
(T057) Trip: (Unassigned)
BOOL_OUT[12].25
(T058) Trip: Inlet Scrubber High High Level
BOOL_OUT[12].26
(T059) Trip: Inlet Scrubber Low Low Level
BOOL_OUT[12].27
(T060) Trip: (Unassigned)
BOOL_OUT[12].28
(T061) Trip: Upper Inlet Scrubber High High Level
BOOL_OUT[12].29
(T062) Trip: (Unassigned)
BOOL_OUT[12].30
(T063) Trip: (Unassigned)
BOOL_OUT[12].31
(T064) Trip: Lower Inlet Scrubber High High Level
BOOL_OUT[13].0
(T065) Trip: (Unassigned)
BOOL_OUT[13].1
(T066) Trip: (Unassigned)
BOOL_OUT[13].2
(T067) Trip: (Unassigned)
BOOL_OUT[13].3
(T068) Trip: Outlet Scrubber High High Level
BOOL_OUT[13].4
(T069) Trip: Outlet Scrubber Low Low Level
BOOL_OUT[13].5
(T070) Trip: (Unassigned)
BOOL_OUT[13].6
(T071) Trip: Upper Outlet Scrubber High High Level
BOOL_OUT[13].7
(T072) Trip: (Unassigned)
BOOL_OUT[13].8
(T073) Trip: (Unassigned)
BOOL_OUT[13].9
(T074) Trip: Lower Outlet Scrubber High High Level
BOOL_OUT[13].10
(T075) Trip: (Unassigned)
BOOL_OUT[13].11
(T076) Trip: (Unassigned)
BOOL_OUT[13].12
(T077) Trip: (Unassigned)
BOOL_OUT[13].13
(T078) Trip: (Unassigned)
BOOL_OUT[13].14
(T079) Trip: User Defined Trip 1
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 13
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[13].15
(T080) Trip: User Defined Trip 2
BOOL_OUT[13].16
(T081) Trip: User Defined Trip 3
BOOL_OUT[13].17
(T082) Trip: User Defined Trip 4
BOOL_OUT[13].18
(T083) Trip: User Defined Trip 5
BOOL_OUT[13].19
(T084) Trip: (Unassigned)
BOOL_OUT[13].20
(T085) Trip: (Unassigned)
BOOL_OUT[13].21
(T086) Trip: (Unassigned)
BOOL_OUT[13].22
(T087) Trip: (Unassigned)
BOOL_OUT[13].23
(T088) Trip: (Unassigned)
BOOL_OUT[13].24
(T089) Trip: (Unassigned)
BOOL_OUT[13].25
(T090) Trip: (Unassigned)
BOOL_OUT[13].26
(T091) Trip: (Unassigned)
BOOL_OUT[13].27
(T092) Trip: (Unassigned)
BOOL_OUT[13].28
(T093) Trip: (Unassigned)
BOOL_OUT[13].29
(T094) Trip: (Unassigned)
BOOL_OUT[13].30
(T095) Trip: (Unassigned)
BOOL_OUT[13].31
(T096) Trip: (Unassigned)
BOOL_OUT[14].0
(T097) Trip: (Unassigned)
BOOL_OUT[14].1
(T098) Trip: Chiller High Level
BOOL_OUT[14].2
(T099) Trip: (Unassigned)
BOOL_OUT[14].3
(T100) Trip: (Unassigned)
BOOL_OUT[14].4
(T101) Trip: EPCS Safety Active - Low/Suction
BOOL_OUT[14].5
(T102) Trip: EPCS Safety Active - High/Discharge
BOOL_OUT[14].6
(T103) Trip: (Unassigned)
BOOL_OUT[14].7
(T104) Trip: (Unassigned)
BOOL_OUT[14].8
(T105) Trip: (Unassigned)
BOOL_OUT[14].9
(T106) Trip: High Methane Gas %LEL
BOOL_OUT[14].10
(T107) Trip: (Unassigned)
BOOL_OUT[14].11
(T108) Trip: Smoke Detector Tripped
BOOL_OUT[14].12
(T109) Trip: (Unassigned)
BOOL_OUT[14].13
(T110) Trip: High Enclosure Temperature
BOOL_OUT[14].14
(T111) Trip: Out of Range: 4-20 mA Caphold Target
BOOL_OUT[14].15
(T112) Trip: Out of Range: Building Temperature
BOOL_OUT[14].16
(T113) Trip: Out of Range: Methane Detector
BOOL_OUT[14].17
(T114) Trip: Out of Range: EPCS Low Pressure
BOOL_OUT[14].18
(T115) Trip: Out of Range: EPCS High Pressure
BOOL_OUT[14].19
(T116) Trip: Out of Range: Motor Vibration 1
BOOL_OUT[14].20
(T117) Trip: Out of Range: Motor Vibration 2
BOOL_OUT[14].21
(T118) Trip: Out of Range: Compressor Vibration 1
BOOL_OUT[14].22
(T119) Trip: Out of Range: Compressor Vibration 2
BOOL_OUT[14].23
(T120) Trip: (Unassigned)
12 – 14
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[14].24
(T121) Trip: (Unassigned)
BOOL_OUT[14].25
(T122) Trip: (Unassigned)
BOOL_OUT[14].26
(T123) Trip: (Unassigned)
BOOL_OUT[14].27
(T124) Trip: (Unassigned)
BOOL_OUT[14].28
(T125) Trip: (Unassigned)
BOOL_OUT[14].29
(T126) Trip: (Unassigned)
BOOL_OUT[14].30
(T127) Trip: (Unassigned)
BOOL_OUT[14].31
(T128) Trip: (Unassigned)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 15
Section 12 • Communications with a Central Controller/DCS
Status Data
Compressor Status Data is presented in Double Integer Format. To interpret the compressor status data, it is necessary to address the specific bits of the Double Integer.
Table 12-5. Status Data
Interface Tag
STATUS (Data Type = DINT, Length = 10)
Description
BOOL_OUT[21].0
(S001) Status: Compressor Stopped
BOOL_OUT[21].1
(S002) Status: Compressor Started
BOOL_OUT[21].2
(S003) Status: NOT USED
BOOL_OUT[21].3
(S004) Status: True Anti-Recycle Active
BOOL_OUT[21].4
(S005) Status: NOT USED
BOOL_OUT[21].5
(S006) Status: Waiting to Start: Discharge-Suction Not Equalized
BOOL_OUT[21].6
(S007) Status: Waiting to Start: Remote Run Permissive Input
BOOL_OUT[21].7
(S008) Status: Waiting to Start: Soft Run Permissive from DCS/Central
BOOL_OUT[21].8
(S009) Status: Auto Cycle Stop - Suction Pressure
BOOL_OUT[21].9
(S010) Status: Auto Cycle Stop - Process Temperature
BOOL_OUT[21].10
(S011) Status: Auto Cycle Stop - Discharge Pressure
BOOL_OUT[21].11
(S012) Status: Compressor Prelube
BOOL_OUT[21].12
(S013) Status: Compressor Prelube Failed
BOOL_OUT[21].13
(S014) Status: Oil Pump Transition
BOOL_OUT[21].14
(S015) Status: Compressor Warmup - Hold at Minimum Capacity Slide Position
BOOL_OUT[21].15
(S016) Status: Loading Inhibited: Low Suction Pressure
BOOL_OUT[21].16
(S017) Status: Loading Inhibited: High Discharge Pressure
BOOL_OUT[21].17
(S018) Status: Loading Inhibited: High Motor Amps
BOOL_OUT[21].18
(S019) Status: Forced Unload: Low Suction Pressure
BOOL_OUT[21].19
(S020) Status: Forced Unload: High Discharge Pressure
BOOL_OUT[21].20
(S021) Status: Forced Unload: High Motor Amps
BOOL_OUT[21].21
(S022) Status: Slide Valve Calibration Active
BOOL_OUT[21].22
(S023) Status: Comms Faulted, Reverted to Local Mode
BOOL_OUT[21].23
(S024) Status: User SUPER Logged In
BOOL_OUT[21].24
(S025) Status: User OP1 Logged In
BOOL_OUT[21].25
(S026) Status: User OP2 Logged In
BOOL_OUT[21].26
(S027) Status: User OP3 Logged In
BOOL_OUT[21].27
(S028) Status: User OP4 Logged In
BOOL_OUT[21].28
(S029) Status: User OP5 Logged In
BOOL_OUT[21].29
(S030) Status: Main Motor FORCED ON
BOOL_OUT[21].30
(S031) Status: NOT USED
BOOL_OUT[21].31
(S032) Status: Oil Pump FORCED ON
BOOL_OUT[22].0
(S033) Status: Oil Cooler VFD FORCED ON
12 – 16
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[22].1
(S034) Status: Oil Cooler Fan 1 FORCED ON
BOOL_OUT[22].2
(S035) Status: Oil Cooler Fan 2 FORCED ON
BOOL_OUT[22].3
(S036) Status: Oil Cooler Fan 3 FORCED ON
BOOL_OUT[22].4
(S037) Status: Oil Cooler Fan 4 FORCED ON
BOOL_OUT[22].5
(S038) Status: Oil Cooler Fan 5 FORCED ON
BOOL_OUT[22].6
(S039) Status: Oil Cooler Fan 6 FORCED ON
BOOL_OUT[22].7
(S040) Status: Oil Cooler Fan 7 FORCED ON
BOOL_OUT[22].8
(S041) Status: Oil Cooler Fan 8 FORCED ON
BOOL_OUT[22].9
(S042) Status: Oil Cooler Fan 9 FORCED ON
BOOL_OUT[22].10
(S043) Status: Oil Cooler Fan 10 FORCED ON
BOOL_OUT[22].11
(S044) Status: Aftercooler 1 VFD FORCED ON
BOOL_OUT[22].12
(S045) Status: Aftercooler 1 Fan 1 FORCED ON
BOOL_OUT[22].13
(S046) Status: Aftercooler 1 Fan 2 FORCED ON
BOOL_OUT[22].14
(S047) Status: Aftercooler 1 Fan 3 FORCED ON
BOOL_OUT[22].15
(S048) Status: Aftercooler 1 Fan 4 FORCED ON
BOOL_OUT[22].16
(S049) Status: Aftercooler 1 Fan 5 FORCED ON
BOOL_OUT[22].17
(S050) Status: Aftercooler 1 Fan 6 FORCED ON
BOOL_OUT[22].18
(S051) Status: Aftercooler 1 Fan 7 FORCED ON
BOOL_OUT[22].19
(S052) Status: Aftercooler 1 Fan 8 FORCED ON
BOOL_OUT[22].20
(S053) Status: Aftercooler 1 Fan 9 FORCED ON
BOOL_OUT[22].21
(S054) Status: Aftercooler 1 Fan 10 FORCED ON
BOOL_OUT[22].22
(S055) Status: Aftercooler 2 VFD FORCED ON
BOOL_OUT[22].23
(S056) Status: Aftercooler 2 Fan 1 FORCED ON
BOOL_OUT[22].24
(S057) Status: Aftercooler 2 Fan 2 FORCED ON
BOOL_OUT[22].25
(S058) Status: Aftercooler 2 Fan 3 FORCED ON
BOOL_OUT[22].26
(S059) Status: Aftercooler 2 Fan 4 FORCED ON
BOOL_OUT[22].27
(S060) Status: Aftercooler 2 Fan 5 FORCED ON
BOOL_OUT[22].28
(S061) Status: Aftercooler 2 Fan 6 FORCED ON
BOOL_OUT[22].29
(S062) Status: Aftercooler 2 Fan 7 FORCED ON
BOOL_OUT[22].30
(S063) Status: Aftercooler 2 Fan 8 FORCED ON
BOOL_OUT[22].31
(S064) Status: Aftercooler 2 Fan 9 FORCED ON
BOOL_OUT[23].0
(S065) Status: Aftercooler 2 Fan 10 FORCED ON
BOOL_OUT[23].1
(S066) Status: Condenser Fan VFD FORCED ON
BOOL_OUT[23].2
(S067) Status: Condenser Fan 1 FORCED ON
BOOL_OUT[23].3
(S068) Status: Condenser Fan 2 FORCED ON
BOOL_OUT[23].4
(S069) Status: Condenser Fan 3 FORCED ON
BOOL_OUT[23].5
(S070) Status: Condenser Fan 4 FORCED ON
BOOL_OUT[23].6
(S071) Status: Condenser Fan 5 FORCED ON
BOOL_OUT[23].7
(S072) Status: Condenser Fan 6 FORCED ON
BOOL_OUT[23].8
(S073) Status: Condenser Fan 7 FORCED ON
BOOL_OUT[23].9
(S074) Status: Condenser Fan 8 FORCED ON
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 17
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[23].10
(S075) Status: Condenser Fan 9 FORCED ON
BOOL_OUT[23].11
(S076) Status: Condenser Fan 10 FORCED ON
BOOL_OUT[23].12
(S077) Status: Condenser Water Valve FORCED ON
BOOL_OUT[23].13
(S078) Status: VPLUS Pump FORCED ON
BOOL_OUT[23].14
(S079) Status: Liquid Injection Valve Air SOV FORCED ON
BOOL_OUT[23].15
(S080) Status: Discharge Recycle Air SOV FORCED ON
BOOL_OUT[23].16
(S081) Status: Oil Mixing Valve FORCED ON
BOOL_OUT[23].17
(S082) Status: Oil Injection Valve FORCED ON
BOOL_OUT[23].18
(S083) Status: Alarm Indication FORCED ON
BOOL_OUT[23].19
(S084) Status: Trip Indication FORCED ON
BOOL_OUT[23].20
(S085) Status: Oil Separator Heaters FORCED ON
BOOL_OUT[23].21
(S086) Status: Suction Oil SOV FORCED ON
BOOL_OUT[23].22
(S087) Status: Gas EQ SOV FORCED ON
BOOL_OUT[23].23
(S088) Status: Economizer SOV FORCED ON
BOOL_OUT[23].24
(S089) Status: Hotgas SOV FORCED ON
BOOL_OUT[23].25
(S090) Status: Venturi Oil Recovery SOVs FORCED ON
BOOL_OUT[23].26
(S091) Status: Inlet Scrubber Drain Pump/SOV FORCED ON
BOOL_OUT[23].27
(S092) Status: Inlet Scrubber Backup SOV FORCED ON
BOOL_OUT[23].28
(S093) Status: Outlet Scrubber Drain Pump/SOV FORCED ON
BOOL_OUT[23].29
(S094) Status: Outlet Scrubber Backup SOV FORCED ON
BOOL_OUT[23].30
(S095) Status: Enclosure Vent Fans FORCED ON
BOOL_OUT[23].31
(S096) Status: Enclosure Heaters FORCED ON
BOOL_OUT[24].0
(S097) Status: Evap Condenser Pump FORCED ON
BOOL_OUT[24].1
(S098) Status: NOT USED
BOOL_OUT[24].2
(S099) Status: EPCS SOV FORCED ON
BOOL_OUT[24].3
(S100) Status: Oil Cooler STBY Heaters FORCED ON
BOOL_OUT[24].4
(S101) Status: Alarm Horn FORCED ON
BOOL_OUT[24].5
(S102) Status: Stacklight - Amber FORCED ON
BOOL_OUT[24].6
(S103) Status: Stacklight - Red FORCED ON
BOOL_OUT[24].7
(S104) Status: INLET SCRUBBER - PUMP 2 FORCED ON
BOOL_OUT[24].8
(S105) Status: OUTLET SCRUBBER - PUMP 2 FORCED ON
BOOL_OUT[24].9
(S106) Status: OIL DRAIN SV FORCED ON
BOOL_OUT[24].10
(S107) Status: Economizer Port 2 FORCED ON
BOOL_OUT[24].11
(S108) Status: Supplemental Shutdown FORCED ON
BOOL_OUT[24].12
(S109) Status: User MGR Logged In
BOOL_OUT[24].13
(S110) Status: Setpoint 1 Active
BOOL_OUT[24].14
(S111) Status: Setpoint 2 Active
BOOL_OUT[24].15
(S112) Status: Maintenance Due
BOOL_OUT[24].16
(S113) Status: Aftercooler 1 Valve Forced
BOOL_OUT[24].17
(S114) Status: Aftercooler 2 Valve Forced
BOOL_OUT[24].18
(S115) Status: Capacity Slide Exercise Active
12 – 18
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[24].19
(S116) Status: Volume Slide Exercise Active
BOOL_OUT[24].20
(S117) Status: Volume Slide In Manual Mode
BOOL_OUT[24].21
NOT USED
BOOL_OUT[24].22
(S119) Status: Compressor Ready
BOOL_OUT[24].23
(S120) Status: NOT USED
BOOL_OUT[24].24
(S121) Status: NOT USED
BOOL_OUT[24].25
(S122) Status: NOT USED
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 19
Section 12 • Communications with a Central Controller/DCS
States of Discrete I/O
States of the Discrete Inputs and Outputs is presented in Double Integer Format. To interpret the IO State data, it is
necessary to address the specific bits of the Double Integer.
Table 12-6. Discrete Input
Interface Tag
Discrete Input States (Data Type = DINT)
Description
BOOL_OUT[31].0
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].1
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].2
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].3
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].4
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].5
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].6
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].7
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].8
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].9
Aftercooler 1 Fan Aux Contact (Step Type)
BOOL_OUT[31].10
Aftercooler 1 VFD Faulted (VFD Type)
BOOL_OUT[31].11
Aftercooler 1 VFD Running
BOOL_OUT[31].12
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].13
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].14
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].15
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].16
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].17
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].18
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].19
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].20
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].21
Aftercooler 2 Fan Aux Contact (Step Type)
BOOL_OUT[31].22
Aftercooler 2 VFD Faulted (VFD Type)
BOOL_OUT[31].23
Aftercooler 2 VFD Running
BOOL_OUT[31].24
Chiller/Surge Drum High Level Alarm
BOOL_OUT[31].25
Chiller/Surge Drum High Level Trip
BOOL_OUT[31].26
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[31].27
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[31].28
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[31].29
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[31].30
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[31].31
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[32].0
Condenser Fan Aux Contact (Step Type)
12 – 20
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[32].1
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[32].2
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[32].3
Condenser Fan Aux Contact (Step Type)
BOOL_OUT[32].4
Evap Condenser Pump Running
BOOL_OUT[32].5
Condenser VFD Faulted (VFD Type)
BOOL_OUT[32].6
Condenser VFD Running
BOOL_OUT[32].7
E-stop OK and MCR energized
BOOL_OUT[32].8
NOT USED
BOOL_OUT[32].9
NOT USED
BOOL_OUT[32].10
Inlet Scrubber Condensate Pump Aux Contact
BOOL_OUT[32].11
Inlet Scrubber Condensate Pump Aux Contact
BOOL_OUT[32].12
Lower Inlet Scrubber High Alarm (Coalescing)
BOOL_OUT[32].13
Lower Inlet Scrubber High Trip (Coalescing)
BOOL_OUT[32].14
Upper Inlet Scrubber High Alarm (Coalescing)
BOOL_OUT[32].15
Upper Inlet Scrubber High Trip (Coalescing)
BOOL_OUT[32].16
Inlet Scrubber Condensate Drain Cutin Switch
BOOL_OUT[32].17
Inlet Scrubber Condensate Drain Cutout Switch
BOOL_OUT[32].18
Inlet Scrubber High Alarm (Vane type)
BOOL_OUT[32].19
Inlet Scrubber High Trip (Vane Type)
BOOL_OUT[32].20
Inlet Scrubber Low Level (Vane Type)
BOOL_OUT[32].21
Compressor Main Motor Aux Contact
BOOL_OUT[32].22
Compressor Main Motor Fault
BOOL_OUT[32].23
Main Motor Cooling Blower Running
BOOL_OUT[32].24
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[32].25
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[32].26
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[32].27
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[32].28
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[32].29
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[32].30
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[32].31
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[33].0
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[33].1
Oil Cooler Fan Aux Contact (Step Type)
BOOL_OUT[33].2
Oil Cooler VFD Faulted (VFD Type)
BOOL_OUT[33].3
Oil Cooler VFD Running
BOOL_OUT[33].4
Oil Recovery Enable Switch
BOOL_OUT[33].5
Oil Separator Low Level Switch
BOOL_OUT[33].6
Outlet Scrubber Condensate Pump Aux Contact
BOOL_OUT[33].7
Outlet Scrubber Condensate Pump Aux Contact
BOOL_OUT[33].8
Lower Outlet Scrubber High Alarm (Coalescing)
BOOL_OUT[33].9
Lower Outlet Scrubber High Trip (Coalescing)
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 21
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[33].10
Upper Outlet Scrubber High Alarm (Coalescing)
BOOL_OUT[33].11
Upper Outlet Scrubber High Trip (Coalescing)
BOOL_OUT[33].12
Outlet Scrubber Condensate Drain Cutin Switch
BOOL_OUT[33].13
Outlet Scrubber Condensate Drain Cutout Switch
BOOL_OUT[33].14
Outlet Scrubber High Alarm (Vane type)
BOOL_OUT[33].15
Outlet Scrubber High Trip (Vane Type)
BOOL_OUT[33].16
Outlet Scrubber Low Level (Vane Type)
BOOL_OUT[33].17
User Defined Alarm Input 1
BOOL_OUT[33].18
User Defined Alarm Input 2
BOOL_OUT[33].19
User Defined Alarm Input 3
BOOL_OUT[33].20
User Defined Alarm Input 4
BOOL_OUT[33].21
User Defined Alarm Input 5
BOOL_OUT[33].22
Remote Manual Capacity Decrease Input
BOOL_OUT[33].23
Remote Manual Capacity Increase Input
BOOL_OUT[33].24
Remote Permissive hardwired input
BOOL_OUT[33].25
User Defined Trip Input 1
BOOL_OUT[33].26
User Defined Trip Input 2
BOOL_OUT[33].27
User Defined Trip Input 3
BOOL_OUT[33].28
User Defined Trip Input 4
BOOL_OUT[33].29
User Defined Trip Input 5
BOOL_OUT[33].30
Smoke Detector Input
BOOL_OUT[33].31
Table 12-7. Discrete Output
Interface Tag
Discrete Output States (Data Type = DINT)
Description
BOOL_OUT[36].0
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].1
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].2
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].3
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].4
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].5
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].6
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].7
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].8
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].9
Aftercooler 1 Fan Starter (Step Type)
BOOL_OUT[36].10
Aftercooler 1 VFD Start Command
BOOL_OUT[36].11
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].12
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].13
Aftercooler 2 Fan Starter (Step Type)
12 – 22
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[36].14
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].15
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].16
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].17
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].18
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].19
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].20
Aftercooler 2 Fan Starter (Step Type)
BOOL_OUT[36].21
Aftercooler VFD Start Command
BOOL_OUT[36].22
Alarm Indication (0=ALARM)
BOOL_OUT[36].23
Enclosure Alarm Horn
BOOL_OUT[36].24
Capacity Decrease Output
BOOL_OUT[36].25
Capacity Increase Output
BOOL_OUT[36].26
Water Cooled Condenser Air Solenoid
BOOL_OUT[36].27
Condenser Fan Starter (Step Type)
BOOL_OUT[36].28
Condenser Fan Starter (Step Type)
BOOL_OUT[36].29
Condenser Fan Starter (Step Type)
BOOL_OUT[36].30
Condenser Fan Starter (Step Type)
BOOL_OUT[36].31
Condenser Fan Starter (Step Type)
BOOL_OUT[37].0
Condenser Fan Starter (Step Type)
BOOL_OUT[37].1
Condenser Fan Starter (Step Type)
BOOL_OUT[37].2
Condenser Fan Starter (Step Type)
BOOL_OUT[37].3
Condenser Fan Starter (Step Type)
BOOL_OUT[37].4
Condenser Fan Starter (Step Type)
BOOL_OUT[37].5
Condenser Pump Starter (If Step Type)
BOOL_OUT[37].6
Condenser Pump Starter (If VFD Type)
BOOL_OUT[37].7
Condenser VFD Start Command
BOOL_OUT[37].8
Discharge Recycle Air Supply Solenoid
BOOL_OUT[37].9
Economizer Port 1
BOOL_OUT[37].10
Economizer Port 2
BOOL_OUT[37].11
Enclosure Roof Vent Fans
BOOL_OUT[37].12
Enclosure Heaters
BOOL_OUT[37].13
EPCS High Side Relief Solenoid
BOOL_OUT[37].14
N/A
BOOL_OUT[37].15
Suction-Discharge Equalizing Solenoid
BOOL_OUT[37].16
Hotgas Bypass Valve
BOOL_OUT[37].17
Inlet Scrubber Backup Drain Solenoid
BOOL_OUT[37].18
Inlet Scrubber Condensate Pump Starter
BOOL_OUT[37].19
Inlet Scrubber Condensate Pump Starter (or SV)
BOOL_OUT[37].20
Liquid Injection Air Supply Solenoid
BOOL_OUT[37].21
NOT USED
BOOL_OUT[37].22
NOT USED
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 23
Section 12 • Communications with a Central Controller/DCS
Interface Tag
Description
BOOL_OUT[37].23
Main Motor Start Command
BOOL_OUT[37].24
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[37].25
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[37].26
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[37].27
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[37].28
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[37].29
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[37].30
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[37].31
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[38].0
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[38].1
Oil Cooler Fan Starter (Step Type)
BOOL_OUT[38].2
Oil Cooler Standby Heater
BOOL_OUT[38].3
Oil Cooler VFD Start Command
BOOL_OUT[38].4
Oil Drain Solenoid
BOOL_OUT[38].5
Oil Mix Valve Air Supply Solenoid
BOOL_OUT[38].6
Oil Pump Starter
BOOL_OUT[38].7
Oil Separator Heaters
BOOL_OUT[38].8
Outlet Scrubber Backup Drain Solenoid
BOOL_OUT[38].9
Outlet Scrubber Condensate Pump Starter
BOOL_OUT[38].10
Outlet Scrubber Condensate Pump Starter (or SV)
BOOL_OUT[38].11
N/A
BOOL_OUT[38].12
Amber Stacklight
BOOL_OUT[38].13
Red Stacklight
BOOL_OUT[38].14
Suction Oil Injection Solenoid
BOOL_OUT[38].15
Trip Indication (0=TRIP)
BOOL_OUT[38].16
Venturi Oil Recovery Output
BOOL_OUT[38].17
Volume Decrease Output
BOOL_OUT[38].18
Volume Increase Output
BOOL_OUT[38].19
VPLUS Pump Start Command
BOOL_OUT[38].20
PLC OK Relay (0=PLC triggered E-Stop)
BOOL_OUT[38].21
Supplemental Shutdown Output
BOOL_OUT[38].22
BOOL_OUT[38].23
BOOL_OUT[38].24
BOOL_OUT[38].25
BOOL_OUT[38].26
BOOL_OUT[38].27
BOOL_OUT[38].28
BOOL_OUT[38].29
BOOL_OUT[38].30
BOOL_OUT[38].31
12 – 24
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
Section 12 • Communications with a Central Controller/DCS
Compressor State and Mode Indicator
The state of the compressor state indicator shown on the compressor and system overview screens can be monitored.
Table 12-8. State Indicator
State Indicator (Data Type = DINT, Length = 1)
Tag
Description
COMP_STATE_IND
Compressor State Indicator
State
Description
0
Stopped
1
Standby
2
Moving Slides to Minimum Position
3
Pre-lube
4
Pre-lube - Compressor Starting
5
Compressor Warm-up
6
Running
Table 12-9. Mode Indicator
Mode Indicator (Data Type = DINT, Length = 1)
Tag
Description
MODE_IND
Compressor State Indicator
State
Description
1
Local-Auto
2
Local-Manual
3
Remote-Auto
4
Remote-Manual
Sending Commands to Compressor PLC (Ethernet IP Version)
To send commands to the Compressor PLC, Control by Communications must be enabled from the Configuration
screen and the watchdog must show that communications between the Compressor PLC and Central Controller/DCS
are not faulted. On a communication fault, the commands from the Central controller will stay in their last state/value
in the compressor PLC.
WATCHDOG BITS
NOTE
When PLC Sees BOOL_IN[0].0 OFF it will turn BOOL_OUT[0].0 ON. DCS Shall Turn BOOL_
IN[0].0 ON when it sees BOOL_OUT[0].0 ON to maintain the handshake.
TO DCS: BOOL_OUT[0].0
FROM: BOOL_IN[0].0
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
12 – 25
Section 12 • Communications with a Central Controller/DCS
Table 12-10. Compressor Command (Real)
Compressor Commands: “REAL_IN” (Data Type = REAL)
Interface Tag
Description
Units
REAL_IN[0]
Remote Discharge Pressure Setpoint
PSIA
REAL_IN[1]
Remote Process Temp Setpoint
PSIA
REAL_IN[2]
Remote Suction Pressure Setpoint
PSIA
REAL_IN[3]
Common Discharge Header Pressure From DCS
PSIA
REAL_IN[4]
Common Suction Header Pressure From DCS
PSIA
REAL_IN[5]
Capacity Slide Position Command From DCS
% Position
DISCRETE COMPRESSOR COMMANDS
Discrete Compressor commands are presented in
Double Integer Format. To send discrete commands,
it is necessary to address the specific bits of the Double
Integer.
If Control by communications is enabled from the
Configuration Screen, the soft run command (BOOL_
IN[1].5) must be held HIGH in addition to the remote
permissive physical input.
Table 12-11. Compressor Command (Double Integer)
Interface Tag
Write Data: “BOOL_IN” (Data Type = DINT)
Description
BOOL_IN[1].0
Soft Capacity Decrease Command from DCS
BOOL_IN[1].1
Soft Capacity increase Command from DCS
BOOL_IN[1].2
Local Mode Command from DCS
BOOL_IN[1].3
Remote Mode Command from DCS
BOOL_IN[1].4
Reset Alarms from DCS
BOOL_IN[1].5
Soft Run Command from DCS
BOOL_IN[1].6
Command to Switch to Setpoint 1
BOOL_IN[1].7
Command to Switch to Setpoint 2
BOOL_IN[1].8
BOOL_IN[1].9
BOOL_IN[1].10
BOOL_IN[1].11
BOOL_IN[1].12
BOOL_IN[1].13
BOOL_IN[1].14
BOOL_IN[1].15
12 – 26
Single Screw Compressor PLC Operation Manual • Vilter/Emerson • 35391CM
35391CM Rev. 0 (8/13) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. © 2013 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.