MICROPROCESSOR II INSTRUCTION MANUALS Document: MCP-12 Revision: New Effective: 3-95AAR NOTICE AAR Electromagnetic interference (EMT) can be generated whenever inductive loads such as relays, solenoids, motor starters, or motors are operated by control systems. FES control systems have power supply circuits that suppress electromagnetic interference from other equipment. Proper wiring and grounding practices help limit the effects of EMI on the control system and in most cases is all that is required. However, for installations near particularly excessive electrical noise generates, additional measures must be taken to assure proper operation. Listed below are four methods of EMI reduction. One or more of these measures may have to be taken to limit the EMI to proper levels. Surge Suppression - Surge suppressors (MOV) should be connected directly across the inductive load. If you connect them at the terminal strip, the wires connecting the I/0 modules to the inductive loads will act as antennas to radiate EMI adding to the noise problem. For AC line voltages between 105 VAC and 125 VAC a general electric V130LA10A MOV is recommended. isolation Transformer - An isolation transformer will provide further suppression of EMI from other equipment. The output devices being controlled should draw power from the same AC source as the isulation transformer, but not from the secondary of the isolation transformer. Choose a transformer with the closest standard transformer rating to the power requirements. If the transformer is too small, it will clip the peak of the sine wave. When the voltage is still above the lower voltage limit, the power supply will sense this as a low voltage and shut down the processor prematurely. If the transformer is too large, it will not provide as much isolation as a transformer of proper size. Constant-Voltage Transformer - In extreme situations where very high levels of EMI, or where the AC power source is especially “soft" and subject to unusual variations, a constant-voltage transformer should be used. The constant-voltage transformer should be sized using the same parameters to size an isolation transformer. Uninterruptible Power System - An uninterruptible power system (UPS) provides total AC line isolation and provides standby power during short power company outages. A UPS is highly recommended for computer control systems.I. SPECIFICATIONS DISPLAY Display Format Viewing Area (width & height) Character Set — Character Shape Character Size (width & height) Brightness Viewing Angle visplay Controls Nureric Keimad Alaim Of¢ CLCSURE_(NEMA_4) Size (width & height x depth) Weight MISCELLANEOUS: AC Operation Temperature Relative Humidity Mechanical Shock Vibration Battery 20 characters x 4 lines 6.2" (15.75 mm.) 2.6" (6.6 mom.) 64 character ASCIT (upper case) 5 x 7 DOT MATRIX 0.23" (5.73 mm.) x 0,33" (8.27 mm.) 3 Ft. L Minimum (Backl ight) 50° Stop/Reset, Remote Start, Local Start Auto, Hold, Manual Load, Manual Unload, External ‘Control Change Display, Step/mter, Clear 0 thru 9, +/+, Decimal Point 28" (721.2 mem.) x 24" (609.6 mam.) x 12.25" (285.75 main.) 93 Lbs. 105-130 Vac 60 Hz. 0 ~ 55° C. (Qperat ing)} 0 -"70° C, (Storage) ] Internal ° 0 50° C. (Operating)} 70° C. (Storage) Ambient 0 ~ 95% Non~condensing 2G 2.56 @ 10 ~ 100 Bz. ‘The battery on the processor board (see diagram, connect ion pawer supply boards 035-00576) is strictly for the intémal clock. This allows timing functions to be independent of panel- sower. Year, month, day of month, day of week, and current time will be maintained by the clock.Ds SPECIFICATIONS ‘The battery shelf life (not instal- led) is approximately 10 years. nce installed in the processor board, the battery life is approximately one year of accumulated panel pover off time. Note, accumulated panel power off time of one year may require years to accomplish depending on particular application. Low battery voltage in no way affects custoner entry limits (i.e. parameter limits, P alam, trip limits, etc.). Since these limits are retained in’nonvolatile memory (power independent memory). Clock functions are only effected by low battery voltage. If battery replacement is neces~ sary, use RAY O VAC BR2325-1 3 volt Lithium battery or equivalent. Battery socket is marked as to polarity for installation. (Negative toward printed circuit board, positive terminal of battery is visible when Properly installed).ALLATION INSTRUCTIONS Due to shock and vibration during shipment, modules and interconnecting cables may work loose causing malfunction or damage to unit. Before applying power for the first time after installati mn, the following items should be checked: a Check all modules to be sure that they are properly seated. Check all interconnection cables in the same manner. These connectors are located at the card edge as well as the 1/0 modules, display and keypad. Check incoming power and verify that it is approximately 115 vac. at the proper polarity with ground. This is very important since the electronics may be damaged if wired improperly. The incoming control power wires should be No. 10 GA (stranded) to handle heater load. If compressor is installed in an outside application and the temperature is below 32° F. (0° C.), control power must be applied for a short period of time to allow the power supply to warm up before starting machine. Check that field wiring connections are properly wired and correct current transformer is installed in the starter. CAUTION BEFORE DRILLING PANEL FOR FIELD WIRING CONDUIT, ETC., IT IS NECESSARY TO PROTECT THE CIRCUITRY FRON METAL FILINGS AND WIRE CLIPPINGS. CLEAN FILINGS FROM ENCLOSURE BEFORE APPLYING CONTROL POWER,IIL. A. MICROPROCESSOR CONTROL FRONT PANEL MICROPROCESSOR CONTROL FRONT PANEL CONTROL POWER SWITCH Nema 4 switch to disable microprocessor control and its’ outputs. Note: yellow wires on I/O rack indicate voltage may be present independent of Position of control power switch. These wires are inputs to the microprocessor control panel from external devices. KEYPAD The keypad can be subdivided into three function groups. 1, The three left most vertical keys are start/stop function keys. a. ‘Stop/Reset - Stops a running compressor. Resets all failures/prealarms on a stopped compressor. b. Remote: Start - Enables compressor to be remotely started via input module #16. c. Local Start - Initiates manual start up of compressor. 2, The five keys in the middle group are the capacity control: mode function keys. Each time the mode Of capacity control changes, it is automatically saved in nonvalatile memory (power independent memory). Therefore, the selected capacity mode is valid through switching of control power, power failures, or any cause of loss of power. Auto - Perform internal capacity proportional control. b. Hold ~ Discontinue loading/unloading. Manual Load - Continuous load issued. d. Manual Unload ~ Continuous unload issued. e- External Control - Capacity controlled via input module #23 (external load) and module #24 external unload).ON-OFF FRONT PANEL CONTROLS (FIGURE NO. 1)6 3. The sixteen keys in the right most group with the exception of alarm off are for data entry/examine and acknowledge. a. Alarm Off - Reset alarm output (silence alarm) does not reset alarm/prealarm condition. b. Change Display - Change to next display format for either data examine and/or data entry. Maximum of 10 different display formats may be encountered. 2 Step/Enter - Entry of data as just received in or if no new data keyed in then ‘step’ to next date entry display. Note: after entering data 'step/enter’ must be pressed again to move to next data entry. g. Clear ~ Clear (disregard) currently keyed in ata as it is no longer desired. Only functional before step/enter' is pressed, If invalid data was entered, just re-enter the proper data (key in desired value, press step/enter). For failure annunciator display performs a clear (acknowledge) function for a non-fatal failure when positioned on second line of display. See display formats section F, 'P' alarm annunciator. For prealarm annunciator display performs a point by point clear (acknowledge) function on prealarms when position on second line of display. See display formats section F, 'P! alarm annunciator. e, '0-9', '+/-', '.' = These keys are used for data entry. When entering a pressure related value i.e., suction pressure set point), the '+/-' key serves to inform the micro- processor you desire X number of inches of mercury ("Hg) when your entry is negative and X number of pounds per square inch (psi) when your entry is positive. DISPLAY UNIT The display unit serves as a feedback device to an operator entering data and has a monitor for watching control related data and operations. HOUR METER Records compressor run time.OPERATING DISPLAY (HOME DISPLAY) ANALOG DATA ANALOG FAILURE DATA COMPRESSSOR DATA FAILURE ANNUNCIATOR P ALARM ANNUNCIATOR PARAMETER LIMITS P ALARM TRIP LIMITS CALIBRATION ADJUST COMPRESSOR SET UP8 OPERATING DISPLAY (HOME DISPLAY) Home display may be divided into 13 sections (A-M) where each section display various parameters depending upon the current system status. A typical home display appears in figure #2 and has been highlighted to show the respective sections of the display. A complete list is then complimented by an indepth description of each message. Silo | UT | | x! [Uoi/] TAfoic TITReEIcVicLe] | | TT] | | lolx cir] | [oltis[cH, PH) foie PLT ii] TTT TTT Ton’ TT FIGURE #2 HOME DISPLAYMICROPROCESSOR II DISPLAYS I. HOME SCREEN: A. STOP RESET REMOTE, LOCAL FATT. REMOTE 1/0) STOP 1/0) Start/Stop Thru 1/0 Module LOCAL Seq ) Start/Stop Internal Seq. Program STOP Seq) (Duals/Two-Stage) REMOTE CM ) STOP CM ) Start/Stop Communications Port LOCAL cM ) REMOTE PB ) STOP PB ) Start/Stop Pushbutton Inputs LOCAL PB ) UL (Unload) ED (Tead) HOLD UNLD LOAD AUTO EXTL ANTIRECYCLE READY RUN RUN ALARM RUN P ALARM ALARM P ALARM START DELAY LOAD DELAY CUR'T ) Unloading due to Current or DIS P ) Disch. Press Overload sUCT 1 PROC 1 suCcT 2 PROC 2 NET OIL PRESSURE READOUT10 "RG oP °c OFF ) ON) Oil Heater State ON WHEN COMMUNICATING WITH TELE-DATA PORT. % SLIDE VALVE. SUCTION PRESSURE/PROCESS TEMPERATURE READOUT. DISCHARGE PRESSURE READOUT.ql SECTION A ii STOP "Stop" message indicates the compressor has been shut down and is enabled for possible start up. REMOTE "Remote" message indicates the following conditions cxist: a. Local start is disabled. b. Remote start input is enabled to allow a remote Signal to start and stop the machine via input module #16. LOCAL "local" message indicates the following conditions exist: a. Remote start input is disabled. b. If compressor is not running, the system is in start-up sequence or under auto-cycling control mode. FAIL "Fail" message indicates the machine is in the failure mode. "Failure annunciator" screen contains a list of failures in chronological order and "Analog Failure Pata’ screen contains the Analog data at the time of the first failure, REMOTE 1/0 "Remote 1/0" message indicates the machine was in remote mode and was started by applying 110V to input module #16. STOP 1/0 "Stop 1/0" messager indicates the machine was initially in remote mode and was stopped by removing the 110 volt input from I/O module #16 instead of the stop pushbutton. REMOTE CM “Remote CM" message indicates the machine was into the remote mode via a command from the Tele-Data Port.12 SECTION A -- continued 8. Stop CM "stop CM" message indicates the machine was placed into the stop mode via a command from the Tele-Data Port. 9. Local cM "Local CM" message indicates the machine was placed into the local mode via a command from the Tele-Data Port. 10. Remote PB "Remote PB" message indicates the machine was placed into the remote mode via the "Remote Start Pushbutton" input. (Module #5) 11. Stop PB "Stop PB" message indicates the machine was placed into the stop mode via the "Stop/Reset Pushbutton" input. (Module #4) 12, Local PB “Local PB" message indicates the machine was placed into the local mode via the "Local Start Pushbutton" input. (Module #7) SECTION 8 Blank "Blank" -- no message —- indicates that the machine is not performing any capacity adjustment at this time. 2. UL "Unload" message indicates the unload solenoid valve is currently energized to unload the machine. + LD "Load" message indicates the load solenoid valve is currently energized to load the machine. SECTION C 1, Auto "Auto" message indicates that the machine is under automatic capacity control based on suction pressure or process temperature.13 SECTION C -~ continued 2 Load "Load" message indicates the load solenoid is to be continually energized unless the compressor is overloaded or the slide valve is at maximum capacity (1008). UNLD "Unload" message indicates the unload solenoid is continually energized unless the slide valve is at minimum capacity (0%). Hold "Hold" message indicates that both the load and unload solenoids are prevented from being energized in the event the compressor is overloaded, unload commands are honored and the unload solenoid may be energized. EXTL "external" message indicates the slide valve position may be controlled via the load and unload inputs of the 1/0 rack, modules #23 and #24, respectively. SECTION D le Anti-recycle “Antirecycle" message indicates that the compressor was successfully shut down with no failures, however, the minimum restart time has not elapsed, allowing the motor sufficient time to cool. The amount of antirecycle time remaining may be examined on the "compressor data” screen and, at the user's discretion, cleared by depressing the antirecycle button located on the processor board inside the panel. (See Drawing No. 035-00576D). Ready "Ready" message indicates the machine is in the stop mode, all safeties and prealarms are reset, and the machine is ready for operator action. Run "Run" message indicates the compressor is currently running with no prealarms or failures.14 SECTION D -- continued 4. Run Alarm "Run Alarm" message will flash on the display when the compressor is running and it indicates a non-fatal failure has been detected and placed in the failure array. The non-fatal failure(s) may be examined and cleared on the "Failure Annunciator" screen. (See Failure Annunciator Screen.) Run P Alarm "Run Prealarm" will flash on the display when the compressor is running and it indicates a prealarm has been detected and placed in the prealarm array. The prealarm(s) may be examined and cleared on the "P Alarm Annunciator) screen. (See P Alarm Annunciator Screen.) Alarm “Alarm" will flash on the display and indicates the compressor has shut down and that a failure currently exists in the failure array. The failures may be examined via the "Failure Annunciator" screen. (See Failure Annunciator Screen. )" P Alarm "P: Alarm" message will flash on the display when the machine is not running and a prealarm exists in the prealarm array. The prealarm(s) may be examined and cleared on the "P Alarm Annunciator" screen. (See Prealarm Annunciator Screen.) Start Delay "Start Delay" message will be displayed for a minimum of 5 seconds each time the compressor is started. During this time, the compressor is prelubricated, the motorized check valve is opened, if required, and the slide valve is unloaded to 0% to allow the compressor to start with a minimum of motor current. The compressor will be inhibited from starting until the capacity can be reduced to below 5% slide valve or until 5 minutes have elapsed at which time a compressor unload filure will be issued. A check valve failure would be issued if the check valve failed to open.15 SECTION D -~ continued 9. Load Delay “Load Delay" will be displayed after a start delay and corresponds to a 10 second period when the compressor is running prior to any capacity control on the machine to allow the system to stabalize. SECTION E 1. CUR'T "Current" message indicates the compressor was overloaded by high motor current and unloads the compressor. 2. DIS P "Discharge Pressure" message indicates the machine was overloaded by high discharge pressure and unloads the compressor. 3. suc P "suction Pressure". While controlling on "Process Temperature", if the local suction pressure falls within "Process Temp Control Prop Band" the compressor beiny unloaded with proportionally larger and larger unload pulses in an attempt to avoid the "Process Temp Control Lo Suct" pressure or a failure results. SECTION F 1. sucT 1 "Suction 1" indicates the machine is currently being controlled based on suction pressure setpoint #1. 2. sucT 2 "Suction 2" indicates the machine is currently being controlled based on suction pressure setpoint #2. 3. PROC 1 "Process 1" indicates the machine is currently being controlled based on process temperature setpoint al. 4. PROC 2 "Process 2" indicates the machine is currently being controlled based on process temperature setpoint #2.16 SECTION G 1. The current net oil pressure is displayed in Section G of the display. SECTION 1. Section # is used to display the units which correspond to the form of control used in Section F. SECTION I 1. Section I describes the status of the oil preheaters as either "ON" or "OFF™. SECTION J 1. The appearance of an asterisk in Section J indicates that the machine has communicated over the Tele-Data Port within the previous minute. SECTION K 1. Section K is used to display the current percent slide valve position of the machine. SECTION L 1, Section L is used to display the current suction Pressure when the machine is being controlled on suction pressure. Section L is also used to display the current process temperature when the machine is being controlled on process temperature.7 ANALOG INPUT DATA DISPLAY ANALOG INPUT DATA DISPLAY The "Analog Input Data" display is used to display the current analog values for various transducers located throughout the machine. Upon entering the "Analog Input Data" display, three of the analog values of the machine (suction pressure, discharge pressure, and inlet oil pressure) will be displayed. Depressing the step enter key (see Figure #1) enables the operator to examine all of the analoy inputs by scrolling the display. (The bottom two lines of the display move up one line and the bottom line is replaced yith a new analog input.) The "Analog Input Data" display is arranged so the first analog value will immediately follow the last one if the display is scrolled through all of the analog values. The “Analog Input Data" display may be divided into three columns (analog value, units, description) A, B, and C, respectively, A typical "Analog Input Data" display appears in Figure #3 and has been highlighted to emphasize the respective columns of the display, A list of analog input parameters appears on the following pages along with a brief description of each.FIGURE #3 “ANALOG INPUT DATA" DISPLAY COLUMNS A. Analog Data Readout B. Associated Units + PSI 1 2. "HG 3. KPA 4. KG/cm2 5. °F 6. °c 7. AMP a 8 C. Parameters 1. Suction 2. Discharge 3, Inlet oi1 4, Oi] Filter 5. Inlet Oil 6. Discharge 7. Suction 8. Process 9. Slide Valve 10. Compressor MotorCOLUMN Cc SUCTION DISCHARGE INLET OIL OIL FILTER OIL SEPRTR INLET OIL DISCHARGE SUCTION PROCESS SLIDE VALVE COMPR MOTOR 1g ANALOG DESCRIPTIONS Suction Pressure Discharge Pressure Inlet Oil Pressure Oil Filter Pressure Oil Separator Temperature Inlet Oil Temperature Discharge Temperature Suction Temperature Process Temperature, If this option is not used, the display will ready absolute 0. (-459° F, or -273° C.) slide valve position Compressor motor current20 ANALOG FAILURE DATA The "Analog Failure Data" display will not appear unless the machine has encountered a failure and its Purpose is to save a copy of the Analog input data at the time of the failure. In the event of. multiple failures, the data retained by the "Analog Failure Data" display corresponds to the first failure which was encountered. The operation of the “Analog Failure Data" display is identical to the Analog input data display with one exception. The "Analog Failure Data" display will default to home display if the operator has not interacted with the display within the last 60 seconds and the panel has been operating in the normal mode. A typical Analog failure data display appears in Figure #4, NOTE: Depressing the Stop/Reset key (see Figure #1) will clear all failures and cause the "Analog Failure Data" screen to disappear until another failure is encountered.21 FIGURE #4 "ANALOG FAILURE DATA" DISPLAY COLUMNS A. Analog Data Readout B. Associated Units + PSI 1 2. "HG 3. KPA 4. KG/cm2 5. °F 6. °C 7. AMP 8. 8 C. Parameters Suction ae 2. Discharge 3, Inlet ofl 4. Oil Filter 5. Inlet Oi1 6. Discharge 7. Suction 8. Process 9. Slide Valve 10. Compressor Motor22 COMPRESSOR DATA DISPLAY The compressor data display is a dynamic display which is used to show three essential characteristics of the machine, the compressor I. D. number, the real time clock, and anti-recycle time remaining. A typical "compressor data” Gisplay appears in Figure No. 5 and has been highlighted to emphasize its various sections. Section A Section A is used to display the machines I. D. number which can be any number from 0 to 999. The machine I. D. number is used by the tele-data port and it enables an individual machine to be addressed uniquely. (See compressor set-up screen. ) Sections B - F Sections B thru F are used to display currently time on the real time clock which is used to control all time related functions within the machine. The sections B - F dispaly the clock in European format and are described below. Section B Section .B displays the day of the week, Sunday thru Saturday ( Sun. ~ Sat.) asterisks will be displayed here if the clock has not been set. (See compressor set-up display for additional information. ) Section ¢ Section C displays the day of the month from 1 to 31. Zeros (00) or asterisks may be displayed here if the clock has not been set. (See compressor set-up display for additional information.) Section D Section D displays the month of the year from January to December (Jan. - Dec.) asterisks will be displayed here if the clock has not been set. (See compressor set-up display for additional information.) Section E Section E displays the current year from zero (0) thru ninety-nine (99). Asterisks will be displayed here if the cluck has not been set.23 FIGURE #5 “COMPRESSOR DATA" DISPLAY A. Machine I. D. No. (0 - 999) B. Day of the week (Sun.-Sat.) C. Day of the month (1 - 31) D. Month (Jan. - Dec.) E. Year ( 00 - 99) F. Hours: Minutes (00 ~ 23: 00 - 59) G. Anti-Recycle Time Remaining (Hours: Minutes: Seconds]24 Section F Section F displays the current time in 24 hours (miliary time) format, Asterisks or zeros may be displayed in either the hours or minutes columns if the clock has not been set. (See compressor set-up display for additional information.) Section G Section G is used to display the remaining anti-recycle time in the following format. [Hours: Minutes: Seconds). Each time the compressor is started, the anti-recycle timer value (see compressor Set-Up Display) will be loaded into the anti-recycle timer and the compressor is not permitted to restart until this time has elapsed. The purpuse of the anti-recycle timer is to allow the compressor motor sufficient time to cool between restarts. The amount of anti-recycle time remaining may be eliminated at the user's Giscretion by depressing the anti-recycle button located on the processor board inside the panel (see Drawing No. 035-00576D). The compressor data display will default to "Home" display if the operator has not interacted with the display within the last 60 seconds and the panel has been operating in the normal mode.25 FAILURE ANNUNCIATOR DISPLAY If the machine detects either type of failure (fatal or non-fatal), the failure and the time it occurred will be stored in the "Failure Annunciator" display. The "Failure Annunciator" display is capable of storing as many as ten (10) consecutive failures in chronological order and the "Analog Failure Data" display is used to retain the "Analog Input Data” at the time of the first failure. woth the “Alarm Status" (Module #10) and “Control Status" (Module #12) modules are turned off each time a new failure is detected to indicate an alarm condition has arisen. The difference between a fatal and non-fatal failure is a fatal failure will shut down the machine and a non-fatal failure will not. A non-fatal failure will blink on and off indicating it may be cleared by depressing the clear key (see Figure #1). If the cause of the non-fatal failure has not been corrected, the failure will be reissued and placed at the end of the failure array. It should be pointed out that several failures are capable of being either fatal or non-fatal based on specific conditions that exist within the machine at the time of the failure. All types of failures will be discussed on an individual basis to clarify what conditions cause each type of failure. The operation of the failure annunciator dispaly is straight- forward and may be seen by examining a typical failure annunciator screen (Figure #6). Section (A) is used to display the time (Hours: Minutes) that the failure(s) occurred and Section (B) is used to describe the failure, as many as three (3) failures may be displayed at one time and additional failures may be examined by using the step/enter key to scroll the screen. (See Figure #1). The "Failure Annunciator" screen is arranged so the first failure will immediately follow the last one if the display is scrolled through all of the existing failures. The failure annunciator display will default to home display if the operator has not interacted with the display in the last 60 seconds.FIGURE #6 “FAILURE ANNUNCIATOR" DISPLAY27 "FAILURE ANNUNCIATOR" DISPLAY List of all failures: 1 am 18. 19, 20. 21. 22. 23. 24, 25. 26. Oi1 Pump 1 strt Oil Pump 2 Intlk Oil Pump 2 Strt Oil Pump 2 Intlk Low oil Press Compress Unld Overload Suc P Overload Dis P Overload Cur't Illegal strt Compress Strt Compress Intlk Compress Cur't Low Suct Press High Disch Press High Disch Temp Low Inlet Oil T High Inlet Oil T Oil Filter Press Hi Oil Press Low Oil Sep T Hi Oil Sep T Compress Shdwn Low Proc Temp varam Limit 1-34 Prealarm 1-7 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Cal Adjust 1-9 Check Valve Aux. Safety 1 Aux. Safety 2 Aux. Safety 3 Aux. Safety 4 Aux. Safety 5 Lo Oil P Pmp 1 Lo Oil P Pmp 2 Clock Fault28 FAILURE DESCRIPTIONS An oil pump #1 start failure indicates the machine attempted to start oil pump #1 and “oil pump interlock" module #36 on the I/O rack failed to detect the pumps interlock within 5 seconds. 2. Oil Pump 1 Intlk An oil pump #1 interlock failure will be issued when oil pump #1 was running and the "Oil Pump Interlock" module #36 on the I/O rack failed to detect the pumps interlock within 5 seconds. The failure will be fatal if the machine has only one oil pump. The of1 pump #1 interlock failure will not be fatal if the machine has dual oil pumps and oil pump #1 was the lead pump (oil pump #2 is back-up). A non-fatal oil pump #1 failure cannot be cleared using the "clear" key until the lead oil pump has been changed to pump #2. 3. Oil Pump 2 Strt An oil pump #2 start failure indicates the machine attempted to start oil pump #2 and "Oil Pump Interlock" module #36 on the I/O rack failed to detect the pumps interlock within 5 seconds. 4. Oil Pump 2 Intlk An oil pump #2 interlock failure will be issued if vil pump #2 was running (dual pumps) and the "oil pump interlock" module #36 on the I/O rack failed to detect the pumps interlock within 5 seconds. The failure would be fatal if pump #1 was the lead pump. The oil pump 2 interlock failure would not be fatal if oil pump #2 was the lead pump (pump #1 is back-up). A non-fatal "oil pump #2 failure" cannot be cleared using the "clear" key until the lead ofl pump as been changed to pump #1. + Low Oil Press A low oil pressure failure would be issued if the oil Pressure of the machine falls below the "oil pressure, start, lower" for 5 seconds when starting or below the "oil pressure run, lower" for 5 seconds while the compressor was running. The failure will also be issued if a minimum of ten (10) pounds of oil pressure could not be maintained during post lube.lo. 239 The low oil pressure failure will always be fatal in the start-up or shutdown modes of operation or if the machine has only one oil pump. If the machine has dual oil pumps, the low oil pressure failure would be issued as a non-fatal failure and the second oil pump started. Tf the oil pressure dropped again, or could not be built up to a satisfactory level, the low oil pressure failure would be reissued as a fatal failure, Compress Unld Compressor unload failure indicates the compressor gould not be unloaded to below 5% slide valve either in start-up or shutdown. The machine must unload to below 5% within 5 minutes in either mode of operation or the fatal failure will be issued. Overload Suc P The overload on suction pressure failure indicates the machine was controlling on process temperature and the suction pressure dropped to below the "process temp control, low suct" pressure limit in parameter limits. This safety is always fatal and is used to limit the suction pressure from being pulled to very low levels, while attempting to maintain the process temperature setpoint. Overload Dis P The overload on discharge pressure failure indicates the discharge pressure was within the "discharge pressure proportional band" located in parameter limits Gisplay for five (5) minutes. The overload on discharge Pressure failure is a non-fatal failure. (For fatal discharge pressure failure see "High Disch Press.") Overload Cur't The overload on motor current indicates the motor current exceeded the "motor current, upper" limit located in “parameter limits" display for five (5) minutes. The overload on motor current is always fatal. Illegal strt The illegal start failure indicates the machine detected either the compressor interlock or motor current and the compressor should NOT be running. This failure is fatal; however, it does start the oil pump and energize the unload output module to safeguard the compressor.ql. 12. 13. 14, 1s. 16. 30 Compress Start Compressor start failure indicates the machine attempted to start the compressor and failed to sense twenty-five percent (25%) of the "motor current, lower” limit or the compressor interlock, module #37. (See “motor current, lower" found in “parameter limits" display. The compressor start failure is alwaye fatal. Compress Intlk The compressor interlock failure indicates the compressor was running and the "compressor interlock" Module #37 located on the I/O rack failed to sense the compressors interlock for (5) seconds. The compressor interlock failure is always fatal. Compress Cur't The compressor current failure indicates the compressor was running and the machine failed to sense 10% of the "motor current, lower" limit located in parameter limits. The compressor current failure is always fatal. Low Suct Press Low suction pressure failure indicates the compressor suction pressure fell below the “suction pressure, lower" setpoint located in parameter limits display. This failure will not appear unless switch U17-6 is set to fail the machine on low suction pressure and the low suction pressure failure is always fatal. Hi Disch Press High discharge pressure failure indicates the discharge pressure of the compressor has exceeded the "discharge pressure, maximum" limit located in "parameter limits display." The discharge pressure failure acts immediately and is always fatal. High Disch Temp High discharge temperature failure indicates the discharge temperature of the compressor has exceeded the “discharge temperature, upper" limit located in "parameter limits" display. The discharge temperature failure acts immediately and is always fatal.17. 1s. 20. al. 31 Low Inlet Oil T Low inlet oil temperature failure is issued when the compressors inlet oil temperature falls below the "inlet oil, lower" limit located in the parameter limits display. The five (5) second delay for low inlet oil temperature failure is not enabled until the compressor has been running a minimum of two (2) minutes. The low inlet oil temperature failure is always fatal. Hi Inlet Oil T High inlet oil temperature failure is issued when the inlet oil temperature of the compressor exceeds the "inlet oil, upper" limit located in parameter limits display for five (5) seconds. The high inlet oil temperature failure is always fatal. Oil Filter Press Oil filter pressure drop failure is issued when the oil filter pressure exceeds the "oil filter pressure drop, max" limit located in parameter limits. Oil filter pressure drop is alway’ fatal. Hi Oil Press High oil pressure failure indicates the inlet oil pressure has exceeded either the "oil pressure start, upper" or "oil pressure run, upper" limit for 5 seconds. Both "oil pressure start, upper" and "oil pressure run, upper™ limits are located in “parameter limits" display. The high oil pressure failure is always fatal. Low Oil Sep T Low oil separator temperature failure will be issued if the oil separator temprature falls below the "oil separator temp, lower" limit located in parameter limits. Low oil separator temperature failure is non-fatal if it occurs when the compressor is running. The low oil separator temperature failure is enabled when the compressor is stopped, attempting to start a compressor with low oil separator temperature will cause an immediate fatal failure.22. 23. 24, 25. 26. 32 High Oil Sep T High o11 separator temperature indicates the oil separator temperature exceeded the "oil separator temp, upper" limit located in parameter limits. The high oil separator temperature failure is always fatal. Compress Shdwn Compressor shut down failure indicates the compressor was given the stop command and the machine detected either compressor interlock or motor current which should have disappeared within eight (8) seconds. This failure is fatal, however; it does start the oil pump and energizes the unload output module to safeguard the compressor. Low Process Temperature Low process temperature failure indicates the process temperature fell below the “process temp, lower" setpoint located in parameter limits display. This failure will not appear unless switch U17-6 is set to fail the machine on low process temperature. A low process tempreature failure is always fatal. Param Limit 1-34 Parameter limit failure is issued when one or several of the machine parameter limits are outside their respective entry limits. The number which follows the parameter limit message corresponds to the first parameter that is out of range. If more than 1 parameter is out of range, the parameter limit failure will be issued for the first parmeter that is incorrect. when the problem with the intial parameter has been corrected, and the failure has been cleared, the failure will be reissued for the next incorrect parameter... and so on until all of the parameters are within their respective limits. Parameter limits failure is always fatal. Prealarm 1-7 Prealarm limit failure is issued when one or several of the prealarm limits of the machines are outside their respective entry limits. The number which follows the prealarm limit message corresponds to the first prealarm that is out of range. If more than one prealarm is out of range, the prealarm limit failure will be issued for first parameter that is incorrect. When the problem with the initial problem has been corrected, and the failure has been cleared. The failure will be reissued for the next incorrect prealarm . and so on until all of the prealarms are with their respective limits. Prealarm limit failure is always fatal.27. 28. 29- 33. 34. 33 Cal Adjust 1-9 Calibration adjust failure is issued when one or several of the calibration offsets of the machines are outside their respective entry limits. The number which follows the calibration adjust message corresponds to the first calibration offset that is out of range. If more than one calibration offset is out of range, the "cal adjust" failure will be issued for the first calibration offset that is incorrect. When the problem with the initial calbiration offset has been corrected, and the failure has been cleared, the failure will be reissued for the next calibration offset that is incorrect . . . and so on until all of the calibration offsets are within their respective limits. Calibration failure is always fatal. Check Valve (Motorized Check Valve Only) Check valve failure is issued when the machine has attempted to open or close the motorized check valve and the action could not be performed. The machine will attempt to open the check valve for up to 60 seconds and if the "open check valve" input Module #32 on the I/O rack has not been sensed, the "check valve" failure will be issued. The machine will attempt to close the check valve at shut down for up to 45 seconds and if the "close check valve" input Module #33 on the 1/0 rack has not been sensed, the “check valve" failure will be issued. If the compressor is running and the check valve would start to close the compressor will shut down on check valve failure. The check valve failure is always fatal. Aux. Safeties 1-5 Auxiliary safeties 1-5 are used for optional safeties which would be switched from any device that can provide a normally closed set of contacts. Typical devices are vibration switches, float switches temperature switches, pressure switches, etc. If the contacts of a safety are opened for five (5) seconds, the respective auxiliary safety will be issued. Lo Oil P Pmp 1 Low oil pressure on pump #1 failure is issued when the machine has dual oil pumps with pump #1 as the lead pump and the oil pressure falls below the lag cil pump start limit for five (5) seconds. The low oil pressure on pump #1 failure is always non-fatal.35. 36. 34 Lo Oil P Pmp 2 Lo vil pressure on pump #2 failure is issued when the machine has dual oil pumps with pump #2 as the lead pump and the oil pressure falls below the lag oil pump start limit for five (5) seconds. The low oil pump start limit for five (5) seconds. The low oil pressure on pump #2 failure is always non-fatal. Clock Fault The clock fault failure is issued when a problem has arisen with the machines real time clock. The clock fault failure is always non-fatal.35 PREALARM ANNUNCIATOR DISPLAY If the machine detects a prealarm, the prealarm and the time it occurred will be stored in “prealarm annunciator™ display. The “prealarm annunciator" display is capable of storing as many as ten (10) consecutive prealarms in chronological order and the “"prealarm status" Module #29 is de-energized each time a prealarm condition has arisen. The operator may clear a prealarm by first placing it directly under the "prealarm annunciator” message on the Gisplay, using the “step/enter" key. The prealarm will then blink on and off indicating it may be cleared by depressing the "clear" key. (See Figure #1) If the cause of the prealarm has not been corrected, the prealarm will be reissued and placed at the end of the prealarm array. The operation of prealarm annunciator display may be seen by examining a typical prealarm annunciator display (Figure #7). Section (A) is used to display (day of week: Hours: Minute] that the prealarm(s) occurred and Section (B) is used to describe the prealarm. As many as three (3) prealarms may be displayed at one time and additional Prealarms may be examined by using the step/enter key to scroll the screen. (See Figure #1). The prealarm annunciator display is arranged so the first prealarm will immediately follow the last one if the display is scrolled through all of the existing prealarms. The "prealarm annunciator" display will default to "home" display if the operator has not interacted with the display within the last sixty (60) seconds and the panel has been operating in the normal mode.FIGURE #7 "“PRE-ALARM ANNUNCIATOR" DISPLAYPREALARM ANNUNCIATOR DISPLAY List of All Prealarms 1, Lo Suct 1 P 2. Lo Suct 2 P 3. Hi Suct 1 P 4. Hi Suct 2 P + lo Proc 1 T 6. Lo Proc 2 T 7. Hi Proc 1T Hi Proc 2 T Hi Oil Fil P 10. Hi Motor Cur 11, Lo Oil Sep T 12. Hi Oil Sep T 13. Hi Disch P 14, Hi Disch T 15. Lo Disch T 16. Hi oi1 P 17. Lo Oil P 18, Hi Oil T 19. Lo O11 T 20. Lo Line volt 21. Low Suct P 22. Aux Palarm 1 23. Aux Palarm 2 24. Aux Palarm 3 25. Aux Palarm 4 26. Aux Palarm 5 27. Aux Palarm 6 28. Aux Palarm 738 PREALARM DESCRIPTIONS Low Suct 1 P Low suction 1 pressure prealarm indicates the machine was controlling on suction pressure setpoint #1 and the suction pressure fell below the "Suction 1 Press Lower limit located in "P Alarm Trip Limits" display. Low Suct 2 P Low suction 2 pressure prealarm indicates the machine was controlling on suction pressure setpoint #2 and the suction pressure fell below the "Suction 2 Press, Lower" limit located "P Alarm Trip Limits" display. Hi Suct 1 P Hi suction 1 pressure prealarm indicates the machine was controlling on suction pressure setpoint #1 and the suction pressure exceeded the "Suction 1 Pressure, Upper" limit located in "P Alarm Trip Limits" display. High Suct 2 P Hi suction 2 pressure prealarm indicates the machine was controlling on suction pressure setpoint #2 and the suction pressure exceeded the "Suction 2 Press, Upper™ limit located in "P Alarm Trip Limits" display. Lo Proc 1 T Low process 1 temperature prealarm indicates the machine was controlling on process temperature setpoint #1 and the process temperature fell below the "Process 1 Temp, Lower" limit located in "P Alarm Trip Limits” display. Low Proc 2 T Low process 2 temperature prealarm indicates the machine was controlling on process temperature setpoint #2 and the process temperature fell below the "Process 2 Temp, Lower" limit located in "P Alarm Trip Limits" display. Proc 1 T Hi process 1 temperature prealarm indicates the machine was controlling on process temperature setpoint #1 and the process temperature exceeded the “Process 1 Temp, Upper" limit located in "P Alarm Trip Limits" display.10. ql. 12. 13. 14. 1s. 39 Hi Proc 2 Temp Hi process 2 temperature prelarm indicates the machine was controlling on process temperature setpoint #2 and the process temperature exceeded the process 2 temp, upper limit located in "P Alarm Trip Limits" display. Hi Oil Fil P High oil filter pressure prealarm indicates the oil filter pressure differential has exceeded the “Oil Filter Pressure, Drop, Max." limit located in "P Alarm Trip Limits" display. Hi Motor Cur High motor current prealarm indicates the compressor motor current has exceeded the motor current, upper limit located in "P Alarm Trip Limits" display. Lo Oil Sep T Low oil separator prealarm indicates the oil separator temperature has fallen below the “oil separator heater, lower" limit located in "P Alarm Trip Limits" display. Hi Oil Sep T High oil separator prealarm indicates the oil separator temperature has exceeded the "Oil Separator Heater, Upper” limit located in "P Alarm Trip Limits" display. Hi Disch P High discharge pressure prealarm indicates the discharge pressure has exceeded the "Discharge Pressure, Maximum" limit located in "P Alarm Trip Limits" display.. Hi Disch T High discharge temperature prealarm indicates the discharge temperature has exceeded the "Discharge Temp, Upper Limit" located in "P Alarm Trip Limit" display. Lo Disch T Low discharge temperature prealarm indicates the discharge temperature has fallen below the "Disch Temp, Lower" limit located in "P Alarm Trip Limits" display.40 16. Hi Oil P High oil pressure prealarm indicates the oil pressure has exceeded the "Oil Press Run, Upper" limit located in "P Alarm Trip Limits" display. 17. Lo Oil PB Low oil pressure prealarm indicates the oil pressure has fallen below the "Oil Press Run, Lower" limit located in "P Alarm Trip Limits" display. 18. Hi Oi1 T High oil temperature prealarm indicates the inlet oil temperature has exceeded the "Inlet Oil Temp, Upper" limit located in "P Alarm Trip Limits" display. 19. Lo oi1 T Low oil temperature prealarm indicats the inlet oil temperature has fallen below the "Inlet Oil Temp, Lower" limit located in "P Alarm Trip Limits" display. 20. Lo Line Volt Low line voltage prealarm indicates the AC Line voltage to the machine has fallen below 92 volts AC; however, the five (5) volt power supply is still maintaining its voltage. 21. Lo Suct PB Low suction pressure prealarm indicates the machine was controlling on process temperature and the suction pressure fell below the "Process Temperature Control, Low Suction" pressure limit located in "P Alarm Trip Limits" display. 22. = 28. Aux Palarm 1-7 Auxiliary prealarms 1-7 are used for optional prealarms which would be switched from any device that can provide a normally closed set of contacts. Typical devices arc vibration switches, float switches, temperature swtiches, pressure switches, etc. The inputs for auxiliary prealarms are made via the I/O rack and if the prealarm contacts are opened, the respective prealarm will be issued.al PARAMETER LIMITS DISPLAY Parameter limits display is used to enter various setpoints which are used to control and protect the machine. A typical parameter limits display appears in Figure No. 8 and may be divided into four (4) basic sections. These sections include the Header (parameter limits) and Sections A-C. Section A is a two line description which is used to describe the parameter that may be entered along with its current value. In the example (Figure #8), process #1 temperature setpoint is currently 48.0° F. If the operator wished to change the process 1 temperature setpoint, he would simply key in the new value (Section C) and depress the "Step/Enter" key. The new data would then replace the old setpoint in Section A and the operator would be prompted for additional input. Each parameter has high and low limits that have been set for it in order to protect the machine. I£ the operator attempted to enter data which was below the minimum, the display would warn the operator about the minimum limit by flashing “min = ****" in Section B. Similarly, if the operator attempted to enter data which was above the maximum, the display would warn the operator about the maximum limit by flashing “max = ***** in section B. In either case, the data that was entered would be discarded and the operator would be prompted to “enter value >" again. In the event the operator made an entry error or has changed his mind, the data may be cleared before it is entered by simply depressing the "clear" key, If the data was already entered when the mistake was discovered, the data may he replaced by entering new data and overwriting it. If no data is entered, and the "Step/Enter" key was depressed, the parameter limits display will advance to the next available parameter. A complete list of all the parameter limits (1-43) appear on the following parts of this manual. This list is subdivided. based upon the type of control “pressure or temperature” that is being used, the position of the service, normal mode DIP switch, and the number of oil pumps. When the machine is being controlled on process temperature and suction pressure (switching between) the operator will see the parameters as they appear in Table #1. (See Table #1).42 When the machine is being controlled based on suction pressure, the parameters limits will appear as table #2 indicates. (See Table #2) When the machine is being controlled based on process temperature, the parameter limits display will appear as Table #3 indicates. (See Table #3) The display of the parameters will be limited to the discharge pressure proportional band, if the machine is operating in the normal mode. This feature prevents unauthoried personal from changing the machine safeties. (Sec dipswitch settings). The "Parameter Limits" display will default to “Home Display" if the operator has not interacted with the display within the last 60 seconds and the panel-has been operating in the normal mode. EIR FIGURE #8 “PARAMETER LIMITS" DISPLAY43 PARAMETER LIMITS DISPLAY Process Temp or Suction Pressure Control (Table #1) 1. Process 1 temp, setpoint 2. Process 1 temp, upper 3. Process 1 temp, lower 4. Process 2 temp, setpoint 5. Process 2 temp, upper 6. Process 2 temp, lower 7. Suction 1 press, setpoint 8. Suction 1 press, upper 9. Suction 1 press, lower 10. Suction 2 press, setpoint 11. Suction 2 press, upper 12. Suction 2 press, lower 13, Oil filter pressure, drop max 14. Discharge pressure, prop band NORMAL MODE SERVICE MODE 15. Motor current, upper 16. Motor current, lower 17. Motor current, prop band 18. Oil separator heater, setpoint 19. Oil separator temp, upper 20. Oil separator temp, lower 21. Capacity load - unload, period 22, Suction 1 pressure, prop band 23, Suction 1 pressure, dead band 24, Suction 2 pressure, prop band 25. Suction 2 pressure, dead band26. 27. 28. 29. 30. 3. 32. 33. 34. 35. 36. 37, 38. 39. 40. 41. 42. 43. 44. 45. 46. Process Process Process Process Process Process Process 44 1 temp, prop band 1 temp, dead band 2 temp, prop band 2 temp, dead band temp control, lo suct temp control, prop band temp control, lo adjust Slide valve position, setpoint 1 Slide valve position, setpoint 2 Slide valve position, setpoint 3 Slide valve position, minimum Discharge pressure, maximum Discharge temp, upper Discharge temp, lower Lag oil pump start, oil press Oil pressure start, upper Oil pressure start, lower Oi pressure run, upper Oil pressure run, lower Inlet oil temp, upper Inlet oil temp, lower45 PARAMETER LIMITS DISPLAY Suction Pressure Control (Table #2) 1. Suction 1 press, setpoint 2. Suction 1 press, upper 3. Suction 2 press, lower 4, Suction 2 press, setpoint 5. Suction 2 press, upper 6. Suction 2 press, lower 7, Oil filter press, drop, max. 8. Discharge press, prop band NORMAL MODE, SERVICE MODE 9. Motor current upper 10. Motor current lower 11. Motor current prop band 12. Oil separator heater, setpoint 13. Oil separator temp, upper 14, Oil separator temp, lower 15. Capacity load/unload period 16. Suction 1 press, prop band 17, Suction 1 press, dead band 18. Suction 2 press, prop band 19. Suction 2 press, dead band 20. Slide valve setpoint 1 21. Slide valve setpoint 2 22, Slide valve setpoint 3 23. Slide valve position minimum 24. Discharge pressure maximum 25. Discharge temp upper26. Tete 28. 29. 30. 31. 32. 33. 46 Discharge temp lower Lag oil pump start, oil press * Oil pressure start upper Oil pressure start, lower Oil pressure run, upper Oil pressure run, lower Inlet oil temp, upper Inlet oil temp, lower47 PARAMETER LIMITS DISPLAY Process Temperature Control (Table #3) 1. Process 1 temp setpoint 2. Process 1 temp upper 3. Process 1 temp lower 4. Process 2 temp setpoint 5. Process 2 temp upper 6. Process 2 temp lower 7. Oil filter press drop max. 8. Dischrge press prop band NORMAL MODE SERVICE MODE 9. Motor current upper 10. Motor current lower 11. Motor current prop band 12. Oil separator heater setpoint 13, Oil separator temp upper 14, Oil separator temp lower 18. Capacity load/unload period 16. Process 1 temp prop band 17, Process 1 temp dead band 18. Process 2 temp prop band 19. Process 2 temp dead band 20. Process temp control lo suct 21, Process temp control prop band 22. Process temp control LD adjust 23. Slide valve position setpoint 1 24, Slide valve position setpoint 2 25, Slide valve position setpoint 326. zr 28. 29. 30. 31. 32. 33. 34, 35. 36. 48 Slide valve position minimum Discharge pressure maximum Discharge temp upper Discharge temp lower Lag oil pump Oil pressure Oil pressure Oil pressure Oil pressure start oil press start upper start lower run upper run lower Inlet oil temp upper Inlet oil temp lower49 PARAMETER LIMITS Process 1 Temp Setpoint Process 1 temperature setpoint is the process temperature that is to be maintained by the machine under capacity control mode #1. Process 1 Temp Upper Process 1 temperature upper is used to start the compressor when the machine is under auto on-off cycling based on process temperature control mode #1. DIP switch U17-6 must be set for on-off cycling in order for this parameter to be used. Process 1 Temp Lower Process 1 temperature lower may be used to fail the machine on low process temperature or shut down the compressor under auto on-off cycling. In the closed position dipswitch U17-6 sets the machine to fail on “Low Proc Temp" failure. If the process temperature falls below "Process 1 Temp Lower" in the open position, dipswitch U17~6 will shut down the compressor when the process temperature has fallen below process 1 temperature lower and not restart it until the process temperature has exceeded process 1 temperature upper. Process 2 Temp Setpoint Process 2 temperature setpoint is the process temperature that is to be maintained by the machine under capacity control mode #2. Process 2 Temp Upper Process 2 temperature upper is used to start the compressor when the machine is under and on-off cycling based on process temperature control mode #2. Dipswitch U17~6 must be set for on-off cycling in order for this parameter to be used. Process 2 Temp Lower Process 2 temperature lower may be used to fail the machine on low process temperature or shut down the compressor under auto on-off cycling. In the closed position, dipswitch U17-6 sets the machine to fail on "low process temp" failure if the process temperature falls below "Process 2 Temp Lower." In the open position, dipswitch U17-6 will shut down the compressor when the process temperature has fallen below process 2 temperature lower and not restart it until the process temperature has exceeded the "Process 2 Temperature, Upper."10. ll. 12. 50 Suction 1 Press Setpoint Suction 1 pressure setpoint is the suction pressure that is to be maintained by the machine under control mode #1. Suction 1 Press Upper Suction 1 pressue upper is used to start the compressor when the machine is under on-off cycling based on suction pressure control mode #1. Dipswitch U17-6 must be set for on-off cycling in order for this parameter to be used. Suction 1 Press Lower Suction 1 pressure lower may be used to fail the machine on low suction pressure or shut down the compressor under auto on-off cycling. In the closed position, dipswitch U17-6 sets the machine to fail on "Low Suct P Failure" if the suction pressure falls below "Suction 1 Pressure Lower." In the open position, dipswitch 017-6 will shut down the compressor when the suction pressure has fallen below suction 1 pressure lower and will not restart until the suction pressure has exceeded the “Suction 1 Pressure Upper." Suction 2 Press Setpoint Suction 2 Pressure Setpoint is the suction pressure that is to be maintained by the machine under control mode #2. Suction 2 Press Upper Suction 2 pressure upper is used to start the compressur when the machine is under on-off cycling based on suction pressure control mode #2 dipswitch U17-6 must be set for on-off cycling in order for this parameter to be used. Suction 2 Press Lower Suction 2 pressure lower may be used to fail the machine on low suction pressure or shut down the compressor under auto on-off cycling. In the closed position, dipswitch U17-6 sets the machine to fail on “Low Suct P" failure if the suction pressure falls below "Suction 2 Pressure Lower." In the open position, dipswitch U17-6 will shut down the compressor when the suction pressure has fallen below suction 2 pressure lower and wil not restart until the suction pressure has exceeded the "Suction 2 Pressure, Upper."13. 14. 1s. 16. 51 Oil Filter Pressure, Drop, Max. Oil filter pressure drop maximum is Lhe maximum oil Pressure differential across the oil filter that is permitted before the machine will issue an "Oil Filter Press" failure. (See Failure Annunciaor Display). Discharge Pressure, Prop Band The discharge pressure proportional band may be best explained by examining the following graph. (See Figure #9) DISCHARGE PRESSURE MAXIMUM MAXIMUM SETPOINT @ 245 LBS 215 Les UL DISCHARGE 40 LB PROPORTIONAL BAND PRESSURE 205 Las Joo FIGURE #9 DISCHARGE PRESSURE OVERLOAD The discharge pressure proportional band is subtracted from the discharge pressure maximum to form the limit where discharge pressure overload is initiated. In this case, if the discharge pressure exceeds 205 lbs. the machine will begin to issue proportional unloads. The width of the unload pulses is proportional to the position of the pressure within the proportional band as illustrated above. (See capacity control section for additional information.) Motor Current Upper Motor current upper limit is the point where the machine will initiate an overload on high motor current. If the motor current exceeds the motor current upper, the machine will begin to issue proportional unloads. (See Figure #10). Motor Current Lower Motor current lower limit is the point where the machine will initiate load pulse intervention based on high motor current. (See Figure #10). The motor current lower limit is also used to calculate the Compress Cur't" failure trip point.17. 1g. 19. 20. 52 Motor Current Prop. Band The motor current proportional band is added ‘o the motor current as Figure #10 indicates and forms the region where an overload on motor current would occur. In this case, the motor current upper is set at 300 amps with a proportional band of 10 amps. p 310 AM ra! UL pn edo 300 AMP ! MOTOR CURRENT to UPPER @ 300 AMPS compnesson CURRENT LOAD PULSE INTERVENTION 250 AMP ce MOTOR CURRENT LOWER @ 250 AMPS FIGURE #40 MOTOR CURRENT OVERLOAD If the motor current exceeds 300 amps, the machine will begin to issue proportional unloads. The width of the pulses is proportional to the magnitude of the current if the current reaches 310 amps or greater, a continuous unload will be issued. If the overload condition cannot be satisfied within five (5) minutes an "Overload Cur't" failure will be issued. Oil Separator Heater Setpoint Oil separator heater setpoint is the temperature at which the oil separator is to be maintained with + 1-1/2 degree differential. Oil Separator Temp Upper The oil separator temperature upper limit is used as the setpoint where the high oil separator temperature (hi oil sep T) failure will be issued. Oil Separator Temp Lower The oil separator temperature lower limit is used as the setpoint where the low oil separator temperature (lo oil sep T) failure will be issued.21. 22. 23. 53 Capacity Load/Unload Period Capacity load/unload period is the maimum width of the pulse which may be used for capacity control. (see capacity control.) Suction 1 Pressure Prop Band Suction 1 pressure proportional band is used to determine the ranges of suction pressure where propurtional control is to be used when the machine is under capacity control mode #1. The proportional band(s) are shown in Figure #11 to illustrate their respective positions in connection with the setpoint and dead band. If the suction pressure rises beyond the dead band, the machine will begin to issue proportional load pulses to satisfy the demand and maintain the setpoint within the dead band. Similarly, if the suction pressure falls below the dead band, the machine will begin to issue proportional unload pulses to maintain the setpoint. (See Figure #11.) Suction 1 Pressure Dead Band The suction 1 pressure dead band is the amount of pressure on either side of the suction pressure #1 setpoint where no auto capacity control functions are to be performed. (See Figure #11.) CONTINUOUS LOAD PROPORTIONAL BAND (LD) 1/2 DEAD BANO DEAD BAND SETPOINT 4/2 DEAD BAND PROPORTIONAL BAND (UL) CONTINUOUS UNLOAD FIGURE #11 PROPORTIONAL & DEAD BAND ILLUSTRATION24. 25. 26. 27. 54 Suction 2 Pressure Prop Band Suction 2 pressure proportional band is used to determine the ranges of suction pressure where proportional control is to be used when the machine is under capacity control mode #2, The operation of suction 2 pressure proportional band is siiilar to suction 1 pressure proportional band. (See suction 1 pressure proportional band and Figure #11.) Suction 2.Pressure Dead Band The suction 2 pressure dead.band is the amount of pressure on either side of the suction pressure #2 setpoint where no auto capacity ‘control functions are to be performed. (See Figure #11). Process 1 Temp Prop Band Process 1 temperature proportional band is used to determine the ranges of process temperature where proportional control is to be used when the machine i under capacity control mode #1. The proportional bands are shown in Figure #11 to illustrate their respective positions in conjunction with the setpoint and dead band. 1f the process temperature rises beyond the dead band, the machine will begin to issue proportional load pulses in order to maintain the setpoint within the dead band. Similarly, if the process temperature falls below the dead band, the machine will begin to issue prportional unload pulses to maintain the setpoint. (See Figure #11.) Process 1 Temp Dead Band The process 1 temperature dead band is the number of degrees on either side of the process temperature #1 setpoint where no auto capacity control functions are to be performed. (See Figure #11.) Process 2 Temp Prop Band Process 2 temperature proportional band is used to determine the ranges of process temperature where proportional control is to be used when the machine is under capacity control mode #2. The operation of process 2 temperature proportional band is similar to process 1 temperature proportional band. (See Process 1 temperature proportional band and Figure #11.)29, 30. 3h. 32. 55 Process 2 Temp Dead Band The process 2 temperature dead band is the number of degrees on either side of the process temperature #2 setpoint where no auto capacity control functions are to be performed. (See Figure #11.) Process Temp Control, Lo Suct Process temperature control, low suction preeure trip point is a safety which prevents the suction pressure from being pulled excessively low while attempting to maintain a process temperature. (See Figure #12.) Process Temp Control Prop Band Process temperature control proportional band ( ap) is added Lo the process temperature control, low suction pressure trip to provide a region where the machine would attempt to unload prior to failing on low suction pressure. If the suction pressure is within the process temperature, control proportional band pressure for five (5) minutes the machine will fail on “override suct P." (See Figure #12.) PROCESS TEMP CONTROL, LD ADJUST SUCTION PRESSURE PROCESS TEMP CONTROL PROP BAND es |5—= 6, s L___ PROCESS TEMP CONTROL, LOW SUCT. TRIP POINT FIGURE #42 PROCESS TEMPERATURE CONTROL SAFETIES Process Temp Control LD Adjust The process temperature control, load adjust is the point where the machine will initiate load pulse intervention based on low suction pressure. This pressure parameter must always be greater than the sum Of the process temperature control, low suction pressure trip point and the process temp control, proportional band. (A p) (See Figure #12.)33. 34. 35. 36. 37. 38. 39. 56 Slide Valve Position Setpoint 1 Slide valve position setpoint #1 is used to enter the position of the slide valve (capacity) at which the “slide valve setpoint 1" module #30 on the I/O rack will be energized. Slide Valve Position Setpoint 2 Slide valve position setpoint #2 is ueed to enter the position of the slide valve (capacity) at which the "slide valve setpoint #2" module #31 on the I/O rack willbe energized. Slide Valve Position, Setpoint 3 Slide valve position setpoint #3 is used to enter the position of the slide valve (capacity) at which the “slide valve setpoint #3" module #35 on the I/O rack will be energized. Slide Valve Position Minimum Slide valve position, minimum is used to "block" the slide valve from being unloaded below a minimum capacity while the machine is running. This setpoint is not valid while the machine is being started or shut down. (See capacity control, minimum slide valve setpoint.) Discharge Pressure Maximum The discharge pressure maximum limit is used to fail the machine immediately if the discharge pressure reaches it. The discharge pressure maximum is also used to calculate proporational unloads in conjunction with the discharge pressure proportional band. (See discharge pressure proportional band and Figure #9.) Dischrge Temp Upper The discharge temperature upper limit is a setpoint where the high discharge temperature failure "High Disch Temp" will be issued. Discharge Temp. Lower Reserved for future use. (Not enabled).40. al. 42. 43. 4a. 45. 45, 57 Lag Oi1 Pump Start Lag oil pump start will only be displayed if the machine has dual oil pumps. The lag oil pump start display is used to enter the oil pressure at which the second oil pump would be started in an attempt to build oil pressure. This parameter limit will generate either the "Lo Oil P Pmp 2" or "Lo Oil P Pmp 1" failure based on which pump has failed (lead pump at time of the failure). Oil Pressure Start Upper Oil pressure start upper limit is used to enter the maximum oil pressure that may exist while still allowing the compressor to start. Exceeding the oil pressure start upper limit for 5 seconds will generate "Hi Oil Press" failure, Oil Pressure Start Lower Oil pressure start lower limit is used to enter the minimum oil pressure that may exist while still allowing the compressor to start. Falling below oil pressure start lower limit for five seconds will generate a "Lo Oil Press" failure. Oil Pressure Run Upper Oil pressure run upper limit is used to enter the maximum oil pressure that may exist while the compressor is running. Exceeding the oil pressure upper for five seconds will genrate a "Hi Oil Press" failure. Oil Pressure Run Lower Oil pressure run lowr limit is used to enter the minimum oil pressure that may exist while the compressor is running. Falling below oil pressure run, lower limit for five seconds will generate a "Lo Oil Press" failure. Inlet Oil Temp Upper Inlet oil temperature upper limit is used to enter the maximum temperature the inlet oil may achieve without generating a "Hi Inlet Oil T" failure. Inlet Oil Temp Lower Inlet oil temperature lower limit is used to enter the minimum temperature the inlet vil may fail to without generating a "Lo Inlet Oil T" failure.PREALARM TRIP LIMITS DISPLAY Prealarm trip limits display is used to enter the setpoints - which are used to trigger the prealarms of the machines. A typical prealarm trip limits display appears in Figure #13 and may be divided into four (4) sections. These sections include the header and Sections A-C. Section A is a two line description of the prealarm that may be entered along with its current value. In the example (Figure #13) "Process 1 Temperature Upper" limit is currently 58.0° F, If the operator wished to change the limit, he would simply key in the new value (Section C) and press the "Step/Enter" key. The new limit would then replace the old one in Section A and the operator would be prompted for additional input. Each prealarm has @ set of minimum and maximum limits that have been set for it. If the operator attempted to enter data which was below the minimum, the display would warn the operator about the minimum limit by flashing it "Min = ****" in Section B. Similarly, if the operator attempted to enter data which was above the maximum, the display woud warn the operator about the maximum limit by flashing it "Max = ****" in Section B. In either case the data that was entered would be discarded and the operator would be prompted to “Enter Value >" again. In the event the operator made an entry error or changed his mind, the data may be cleared before it is entered by simply depressing the clear key. If the data was already entered when the mistake was discovered, the.data may be replaced by entering the new data and overwriting it. If no data is entered and the “Step/enter" key was depressed, the prealarm trip limits display will advance to the next prealarm. A list of all settable prealarm trip limits (1-20) appears on the following page of this manual. The list is subdivided based upon the type of control “pressure or temperature" that is being used. When the machine is being controlled on process temperature and suction pressure (switching between) the operator will see the prealarm trip limits as they appear in Table #4, (See Table #4) When the machine is being controlled based on suction pressure, the prealarm trip limits will appear as Table #5 indicates. (See Table #5).59 When the machine is being controlled based on process temperature, the prealarm trip limits will appear as Table #6 indicates. (See Table #6) The "Prelarm Trip Limits" display will default to "Home" display if the operator has not interacted with the display within the past 60 seconds and the panel has been operating in the normal mode. P| AILIAIRIM, [T LIT/MI/TIs| | EMP) | | || | FIGURE #43 “PRE-ALARM TRIP LIMITS" DISPLAY60 PREALARM TRIP LIMITS DISPLAY Process temperature or suction pressure control (Table #4) ne lo. ll. 12. 1a. 14. 15. 16. 7. 1g. 1g. 20. Process 1 Temp, Upper Process 1 Temp, Lower Process 2 Temp, Upper Process 2 Temp, Lower Process Temp Control, Lo Suct Suction 1 Press, Upper Suction 1 Press, Lower Suction 2 Press, Upper Suction 2 Press, Lower Oil Filter Press, Drop Max. Motor Current, Upper Oil Separator Temp, Upper Oil Separator Temp, Lower Discharge Pressure, Maximum Discharge Temp, Upper Discharge Temp, Lower Oil Pressure Run, Upper Oil Pressure Run, Lower Inlet Oil Temp, Upper Inlet Oil Temp, Lower61 PREALARM TRIP LIMITS DISPLAY Suction pressure control (Table #5) Suction 1 Press, Upper 2. Suction 1 Press, Lower 3. Suction 2 Press, Upper 4, Suction 2 Press, Lower 5. Oi1 Filter Press, Drop Max. 6. Motor Current, Upper 7, Oil Separator Temp, Upper ®. Oil Separator Temp, tower 9. Discharge Pressure, Maximum 10. Discharge Temp, Upper ll, Discharge Temp, Lower 12, Oil Pressure Run, Upper 13. Oi1 Pressure Run, Lower 14, Inlet Oi1 Temp, Upper 15. Inlet Oil Temp, Lower62 PREALARM TRIP LIMITS DISPLAY Process temperature control (Table #6) 1. Process 1 Temp, Upper 2. Process 1 Temp, Lower 3. Process 2 Temp, Upper 4, Process 2 Temp, Lower 5. Process Temp Control, Lo Suct 6. Oil Filter Press, Drop Max. 7. Motor Current, Upper 8. Oil Separator Temp, Upper 9. Oil Separator Temp, Lower 10, Discharge Pressure, Maximum ll, Discharge Temp, Upper 12. Discharge Temp, Lower 13. Oil Pressure Run, Upper 14, Oil Pressure Run, Lower 15. Inlet Oil Temp, Upper 16. Inlet Oil Temp, Lowerts 5. 63 PREALARM TRIP LIMITS DESCRIPTIONS Process 1 Temp, Upper The Process 1 Temperature, Upper Prealarm Limit is used as a high limit for the process temperature when the machine is running on control point #1. Exceeding this temperature will generate a "Hi Proc 1 T" prealarm. Process 1 Temp, Lower The Process 1 Temperature, Lower Prealarm Limit is used as a lower limit for the process temperature when the machine is running on control point #1. Falling below this temperature will generate a "Lo Proc 1 T" alarm. Process 2 Temp, Upper The Process 2 Temperature, Upper Prealarm Limit is used as a high limit for the process temperature which the machine is running on control point #2. Exceeding this temperature will generate a "Hi Proc 2 T" prealarm. Process 2 Temp, Lower The Process 2 Temperature, Lower Prealarm Limit is used as a lower limit for the process temperature when the machine is running on control point #1. Falling below this temperature will generate a "Lo Proc 2 T" prealarm. Process Temp Control, Lo Suct The Process Temperature Control, Low Suction Pressure Prealarm Limit is used as a lower limit for suction pressure when the machine is controlling on process temperature. Falling below this pressure will generate a "Low Suct P" prealarm. Suction 1 Press, Upper The Suction 1 Pressure, Upper Prealarm Limit is used as a high limit for the suction pressure when the machine is running on control point 1. Exceeding this pressure will generate a "Hi Suct 1 P" prealarm. Suction 1 Press, Lower The Suction 1 Pressure, Lower Prealarm Limit is used as a low limit for the suction pressure when the machine is running on control point 1. Falling below this pressure will generate a "Lo Suct 1 P* prealarm.10. ql. 12. 13. 14, 15. 64 Suction 2 Pressure, Upper The Suction 2 Pressure, Upper Prealarm Limit is used as a high limit for suction pressure when the machine is running on control point 2. Exceeding this pressure will generate a "Hi Suct 2 P" prealarm. Suction 2 Pressure, Lower The Suction 2 Pressure Lower Prealarm Limit is used as @ low Limit for suction pressure when he machine is running on control point 2, Falling below this precsure will generate a “Lo Suct 2 P" prealarm. Oil Filter Pressure Drop, Max The oil filter pressure drop maximum is a prealarm limit on the oil filter pressure differential. If the differential pressure across the oil filter exceeds this pressure 2 "Hi Oil Fil P" prealarm will be generated. Motor Current, Upper The Motor Current Upper is a prealarm limit on the compressor motor current and if the motor current exceeds this current, a "Hi Motor Cur" prealarm will be generated. Qil Separator Temp, Upper The Oil Separator Temperature Upper is a prealarm limit on the oil separator temperature and exceeding this temperature will generate a “Hi Oil Sep T" prealarm. Oil Separator Temp, Lower The oil separator temperature lower is a prealarm limit on the oil separator temperature and falling below it will generate a "Lo Oil Sep T" prealarm. Discharge Temp, Upper The discharge temperature upper is a prealarm limit on the discharge temperature of the compressor and exceeding this temperature will generate a "Hi Disch T" prealarm Discharge Temp, Lower The discharge temperature lower is a prealarm limit on the discharge temperature of the compressor and falling below this temperature will generate a "Lo Disch T" prealarm.16. 17, 18. 19. 65 Oil Pressure Run, Upper The Oil Pressure Run, Upper is a prealarm limit on the oil pressure and exceeding this pressure will generate a “Hi Oi1 PE" prealarm. Oil Pressure Run, Lower The Oil Pressure Run, Lower is a prealarm limit on the oil pressure and falling helow this pressure will generate a "Lo Oil P™ prealarm. Inlet Oil Temp, Upper The Inlet Oil Temperature Upper is a prealarm limit on the inlet oil temperature and exeeding this temperature will generate a "Hi Oil T" prealarm. Inlet Oil Temp, Lower The inlet oil temperature lower is a prealarm limit on the inlet oil temperature and exceeding this temperature will generate a "Lo Oil T™ prealarm.66 CALIBRATION ADJUST DISPLAY Calibration adjust display is used to adjust the calibration of the various transducers on the compressor package through the use of he keypad. Due to the extreme importance that is palced on the calibration of the machine, the calibration display is protected by two methods. First, under the normal mode of operation, the calirration ca not he adjusted. The calibration of a machine can culy be adjusted while the machine is in the se'v'ce mode. Once in the service mode, the operator must move to the "Warning" display and wait for 15 seconds before the .achine will allow him to enter the calibration display. The "Change Display," "Stop/Reset" and the capacity control keys are the ouJy keys that are honored in the “Warning” display. If any other key is depressed, the bottom line of the warning screen will be rewritten to tell the operator to "Piease Wait" and a typical warning screen appears in Figure #14, The calibration of the machine is not difficult to adjust because the operator only has to know the correct value of the temperature or pressure which is to be calibrated. A typical "Calibration Adjust" display appears in Figure #15 and may be divided into three sections -- A, B and C. Section A is used to display the name of the transducer that is being calibrated and its current output. In Figure #15, the suction pressure is currently 12.9 psi. If the operator wished to change the calibration to 13.5 psi, he would simply key it into Section C and depress the "Step/Enter" key. The new value will then replace the old one in Section A if the calibration was within the range of the machine. Each calibration adjustment has a maximum positive and negative adjustment range. If the operator attempted to enter data which exceeded the negative adjustment, the display would warn the operator by displaying "Neg. Adjust Exceeded" in Sections B and C. The machine would then be given the maximum negative adjustment and would prompt the operate to "Enter Value >." Similarly, if the operator exceeded the maximum positive adjustment, the display would warn the oprator by displaying "Pos Adjust Exceeded" in Sections B and C. The machine would then be given the maximum positive adjustment and would prompt the operator to "Enter Value >." The oprator will be warned if a transducer is at a maximum adjustment immediately upon entering the calibration of that transducer. This adjustment warning serves as a reminder to the operator that the transducer is calibrated as far as possible and should be investigated further.FIGURE #14 "WARNING" DISPLAY U CIT BIRIAIT|IIOIN ION PIRIE EINTIER// VIALE! | Ltt FIGURE #15 “CALIBRATION ADJUST" DISPLAY68 In the event the operator made an entry error or changed his mind, the data may be cleared before it is entered by simply depressing the "clear" key. If the data was already entered when the mistake was discovered, the data may be replaced by entering the new data and overwriting it. If no data is entered and the "Step/inter" key was depressed, the calibration adjust display will advance to the next transducer. A complete list of all calibration adjustments and a brief description of each appears on the following pages of this manual.Suction Pressure -- Discharge Pressure ~~ Inlet Oil Pressure -- Oil Filter Pressure -- Oil Separator Temp -- Inlet Oil Temp -- Discharge Temp -- Suction Temp -- Process Temp -- 69 Compressor Suction Pressure Compressor Discharge Pressure Net Oil Pressure at the Inlet to the Compressor (Net Oil Pressure = Inlet Oil Pressure - Discharge Pressure) Oil Pressure Differential Across the Oil Filter Oil Separator Temperature Oil Temperature at the Inlet to the Compressor Compressor Discharge Temperature Compressor Suction Temperature Process Temperature at some Location Remote to the Machine70 COMPRESSOR SET UP DISPLAY SET Compressor set up display is used to enter information which is related to the control of the machine. The format of the displays in compressor set up display set differ based on the type of data that is to be entered and may be catagorized into three (3) basic types (control time, time/date, and general). In order to clarify the operation of the different formats, the catagories will be discussed on an individual basis beginning below. A list of all compressor set up displays along with their respective display formats appears on one of the following pages of this report. Control Time Format A "Control Time" format display is used to enter time data that controls a specific event. The time data that may be entered under control-time format is day of the week, hours, and minutes. A typical display using control time format is shown in Figure #16 and has been divided into four sections. Section B is used to describe the purpose of the time data that is being entered and Section C is used to display the actual time as [day of week - hours: minutes]. In Figure #16, the timed event will occur on a daily basis at 3:02 a.n. The letter D will be displayed instead of a zero for the day of the week and is used to represent the control of an event on a daily basis. The day of the week may also be any number (1 - 7) which represents Sunday - Saturday, respectively, in order to control the event on a weekly basis. If a control-time entry is put into or taken out of daily control "D" its related control-time entry will also receive the same day of the week. Entering control-time data is very straightforward. Upon entering the display, the minutes column will be blinking on and off indicating the minutes may be entered. The operator may then key the minutes into Section D and depress the "Step/Enter" key which will place the minutes into Section C. Depressing the "Step/Enter™ key once more will advance the entry to the hours column which will blink accordingly. The operator would then key the hours (24 hour format) into Section D and depress the "Step/enter" key to enter them in Section C, Depressing the "Step/Enter" key once again will advance the entry to the day of the week column which will begin to blink. The operator would then key in the day of the week (0 - 7) into Section D and depress the "Step/Enter" key. If the "Step/Enter" key is depressed with no data in Section D, the display will advance to the next column immediately. Depressing the "Step/Enter™ key in the day of the week column with no data entered will advance to the next available display.PLATT TT © FIGURE #16 "COMPRESSOR SET UP" DISPLAY CONTROL-TIME FORMAT72 Each of the time-data displays has a set of minimum and maximum limits. If the operator attempted to enter data which was above the maximum limit, the display would warn the operator about the maximum limit by flashing "Max = **" in Section A. Similarly, if the operator attempted to enter data which was below the minimum limit, the display would warn the operator about the minimum limit by flashing "Min = **" in Section A. Time/Date Entry The Time/Date Entry display is used to enter the time and date into the real time clock within the machine. A typical time/date entry display appears in Figure #17 and may be divided into six sections (A - F). Entering the time and date is very straight forward. Upon entering a time/date entry display the minutes (Section £) will be blinking on and off indicating they may be entered. The data may then be keyed into Section F and entered by depressing the Step/Enter key. The operator may also move to the next section by depressing the Step/Enter key without entering any data. This process would then be repleated until the entry of the time/date data has been completed. Both the day of the week, and the months are entered by using numbers which correspond to the appropriate abbrevia- tions. The months (Jan. - Dec.) are represented by the number 1 through 12 and the days of the week (Sun. - Sat.) are represented by numbers 1 thru 7. No time/date enteries will be sent to the real time clock until the display has left the time/date entry display. Each of the time/date entries has a set of minimum and maximum limits. If the operator attempts to enter data which was below the minimum limit, the display would warn the operator about the minimum limit by flashing "Min **," “Similarly, if the operator attempted to enter data that exceeded the maximum limit, the display would warn the operator about the maximum limit by flashing "Max = **,." In either case, the data entered would be discarded. General Format A typical compressor set up display, using the General Format display, appears in Figure #18 and may be divided into three basic sections. Section B is a two line description which is used to describe the entry along with its current value. In Figure #18 the anti-recycle timer is currently set to 20 minutes. I£ the operator wishes to change the anti-recycle timer, he would simply set in the new value (Section C) and depress the "Step/Enter" key. The new data would then replace the old data in Section B and the operator would be prompted to “enter Value.FIGURE #17 “COMPRESSOR SET UP" DISPLAY TIME-DATE ENTRY O N I N ERE WACOELE FIGURE #18 “COMPRESSOR SET UP" DISPLAY GENERAL FC AMAT74 Bach General Format display has a minimum and maximum limit that has been set for it. If the operator attempted to enter data which was below the minimum limit, the display would warn the operator about the minimum limit by flashing "Min = **#*4," Similarly, if the operator attempted to enter data that exceeded the maximum, the display would warn the operator about the maximum limit by flashing "Max = *##*,* In either case the data that was entered would be discarded and the operator would be promoted to “Enter Value." Tf the operator made an entry error, or changed his mind, the data may be cleared before it is entered by simply depressing the “Clear Key". If the data was already entered hen the mistake was discovered, the data may be replaced by entering new data and overwriting it. If no data is entered, the "Step/enter" key will advance the display to the next available display.75 COMPRESSOR SET UP DISPLAY Display/Forr. 1. Control Mode Press = 0/Temp General 2. Contre. Change, Time Cntrl PT 1 on General 3. Control Caange, Time Cntrl PT 2 On General 4. Module #39 Timer, On Timr Control Time 5. Mod le #39 Timer, Off Timr Control Time 6. Log Xeport, Interval General 7. Timr/'Date Entry Time/Date 3. Tead Oi Pump Select General — itveiSe 9. Identification Number .0#) General 10. Anti-Recysle Timer General 11. Motor Current XFormr Ratio General76 COMPRESSOR SET UP DISPLAY Control Mode Control mode display may or may not appear depending on DIP switch U17-5. If dipswitch U17-5 is open, the control mode display will not appear. (See dipswitch) The control mode display is used to determine the type of control (suction pressure or process temperature) that the machine will use. The operator has two choices "0" for suction pressure or a "1" for process temperature. If a zero "0" is entered, the machine will be controlled on suction pressure setpoints 1 or 2. The zero will also force the parameter limits and prealarm limits to only display data relating to suction pressure control. (See parameter limits and prealarm trip limits). If a one "1" is entered, the machine will be controlled on process temperature setpoints 1 or 2. The "one" will also force the parameter limits and prealarm limits to only display data relating to process temperature control. (See parameter limits and prealarm trip limits.) Control Change, Time Control PT 1 On Control change time, control point 1 on display is used to enter the day of the week and time of day the machine will switch from controlling on setpoint #2 to setpoint #1. The setpoint may be either a temperature of a pressure (see control mode). The use of "control change, time control point 1 on" will be disabled if dipswitch 017-7 is not closed. (See dipswitch) For an illustration of how "Control PT 1 On" and "Control PT 2 on" may bo ewitched. See “Safety/Control ~ Timer Output Module" description. Control Change, Time Control PT 2 On Control change time, control point 2 on display is used to enter the day of the week and time of day the machine will switch from controlling on setpoint #1 to setpoint #2. The setpoint may be either a temperature or a pressure (see control mode). The use of “Control Change, Time Control Point 1 On" will be disabled if dipswitch U17-7 is not closed. (See dipswitch) For an illustration of how “Control PT 1 On" and "Control PT 2 On" may be switched, see "Safety/Control - Timer Output Module" description.7 Module #39, On Time Module #39, on time is used to switch on Module #39 of the I/O rack at a specific Lime. The timer is capable of timing an event on either a weekly or daily basis. (see control time mode.} For an illustration of how "Module #39 on Time" and "Module 439, Off Time" may be switched, see "Safety/Control - Timer Output Module" description. Module #39, O£f Time Module #39, off time is used to turn off Module #39 of the I/O rack at a specific time. The timer is capable of timing an event on either a weekly or daily basis. (See control time mode.) For an illustration of how "Module "39, Off Time" and "Module #39 On Time" may be switched, see "Safety/Control - Timer Output Module" description. Log Report Interval Log report interval is used to enter the time between log reports issued via the Tele-Data Port. Placing a zero for the log report interval terminates the transmission of log reports. If communications are not used with the machine, the log report interval should be set to zero "0." (See Tele-Data Port Instructions for additional information.) Time/Date Entry Time/date entry display is used to set the real time clock which is used to control all time related functions within the machine. (See Time/Date Entry.) Lead Oil Pump Select Lead oil pump select is used to enter the number of oil pumps (1 or 2) and if dual oil pumps are used, which pump will start first. The lead oil pump select is limited to 0, lor 2. Entering a "0" indicates the machine has one oil pump which is oil pump #1. Entering a "1" indicates the machine has dual oil pumps and oil pump #1 will be started first with oil pump #2 acting as back-up. Entering a "2" indictes the machine has dual oil pumps and oil pump #2 will be started first with oil pump #1 acting as back-up.78 Identification Number (I #) The compressor I1.D, Number is used by the "Tele-Data Port" and it allows a machine to be addressed on an individual basis. (See communications.) Anti-Recycle Timer The anti-recycle timer display is used to enter the minimum amount of time that may elapse before the compressor may be restarted. This timer is used to allow the compressor motor sufficient time to cool between restarts. The anti-recycle timer may be circumvented by depressing the anti-recycle button located on the processor board. (See compressor data display.) Motor Current Transformer Motor current display is used to enter the compressor motor CT ratio which is used to sense motor current. The motor current CT ratio may be entered in even 100 amp increments from 100 to 1200 amps, using a motor current display. (See Figure #19.) Upon entering the display the hundreds multiplier will be flashing indicating it may be entered. The operator may then enter any whole number between 1 and 12 to achieve the desired transformer ratio via the “Step/Enter" key. If the operator attempts to enter data which was below the minimum limit, the display would warn the operator by displaying "Min = **," Similarly, if the operator attempted to enter data that exceeded the maximum limit, the display would warn the operator about the maximum limit. The display would warn the operator about the maximum limit by flashing "Max = **," In either case, the data entered would be discarded.PIRE o n oA! |sieit Cc U OR a URRENT| |x 7 oO D 10 a|alal= ER! iv _| | [4lojok: js ALIVIE} >| | | l FIGURE #19 "COMPRESSOR SET UP" DISPLAY MOTOR CURRENT FORMAT80 v. Control Concepts A. Self-Diagnostics 1G On initial power up of the microprocessor control panel the following self-diagnostic tests are performed. + The 5 volt DC power supply is monitored for low voltage. If low voltage is detected, the first line of the display will show “Svpc." This message will persist as long as the condition exists. b. The microprocessors RAM (Random Access Memory) is tested. If any cell in memory does not pass the diagnostics test, the first line of the display will show "RAM". The message persists as long as the condition exists. ¢. The internal clock module is tested. If the clock does not pass its diagnostics test, a non-fatal failure will result. The failure message “clock fault" will be visible in the failure annunciator screen. o If a low line voltage condition is detected, the message “Low Line Voltage" will be on the first line of the display. This will occur if the line voltage dips below 92 VAC. No compressor control is allowed in this state. e. A “Panel Reset" message will be on the first line of the display if line voltage if 85 VAC or less has been detected. ‘The microprocessor control panel will self-initiate a reset function if this condition occurs. The following self-diagnostic tests are performed on a continual basis after having completed the power up diagnostics. a. With the exception of the "RAM" test all the power up diagnostics are also performed on a continual basis. b. Additionally all the customer entries (parameter limits, P alarm trip limits, calibration adjust, etc.) to the microprocessor control panel are compared to their maximum and minimum allowable values to confirm data integrity.81 If any customer entry tests out of range an appropriate failure message will result. If the failure is of the type "PARAM LIMIT xx" it will be a fatal failure (cause a running compressor to shutdown or prevent a compressor start). The "Xx" will be replaced with the particular parameter limit in concern. Refer to the explanation on "Failure Annunciator" display per failure message description and method to resolve failure condition. The two other potential failure messages concerning customer entry points are 1, "PREALARM XX" and 2, "CAL ADJUST XxX." Again, the "Xx" will be replaced by the particular limit in concern, the later two failures are non-tatal in nature (will not shutdown compressor or prevent start). In all cases, the alarm module will be in the alarmed state and the failure(s) will be placed in the failure annunciator. B. Input/Output (1/0) Modules Pushbutton Controls via Input Modules The pushbutton input modules in the following discussion provide the same functions as their respective keypad buttons on the front panel of the microprocessor control unit. a. Stop/Reset pushbutton input module #4 provides capability to stop and/or reset the compressor and it potential failures and prealarms through a customer installed N.C. (normally closed) momentary switch. This input functions as a fail safe input such that if a loss of power is detected (pushbutton pushed or control power failure), the compressor will immediately initiate shutdown procedures. Local start pushbutton input module #7 is activated through a customer installed N.O. (normally open) momentary switch. A manual start of the compressor is initiated when a 110 vac signal is applied to this input module. A momentary voltage is all that is necessary. Remote pushbutton input module #5 is activated through a customer installed N.0. (normally open) momentary switch. The compressor will be put into a remote mode when a 110 vac signal is applied to this input module. Amomentary voltage is all that is necessary. In this mode the compressor can be started and stopped through the remote sequence start/stop module #16.82 "Remote Enabled" output module (#34 on 1/0 rack). This module will be energized if external capacity control mode is selected and any of the remote modes ("Remote,", "Remote I0," "Remote CM," "Remote PB") is valid. "Control Status" output module (#12 on I/O rack). With only one exception, this module will be energized any time one of the following messages is valid. The only exception is during the oil pump test procedure. a. Local b. Local CM c. Local PB d. Local Seq e. Remote £. Remote CM g. Remote PB h. Remote I0 "Anti-Recycle" output module (#27 on I/O rack) This module will be energized when the compressor is started and will remain energized until the amount of anti-recycle time as selected in the compressor set up display section has elapsed. The amount of anti-recycle time remaining is available for examination in the "Compressor Data" display. No restarts of the compressor will be allowed as long as this module is energized. This is a safety for the protection of the compressor motor. If it is absolutely necessary to restart the compressor before the anti-recycle time has elapsed, it is possible to cancel the remaining time. A momentary press on the switch "S1" of the processor board inside the microprocessor control panel will cancel the remaining time. It should be noted that this is an override to a safety that should only be used with the consciousness of the potential overheating of the compressor motor windings.a3 5. "Timer" Output Module (#39 on I/O Rack) This module provides a timer type control function, The timer output module can be programmed to cycle once per day or once per week. Soe "Compressor Sct Up" display explanation for procedure to program "Module #39 Timer." Also, refer to hardware specifications for maximum ratings for output module. This module is not required for the control of the screw compressor. It need not be enabled if you have no need for a timer function. The module can be disabled by entering the same time for both "on-time" and "off-time." The shortest period of time for either an on cycle or an off cycle is one minute. Therefore, the extreme condition for a daily cycle would be a one minute on or off duty and twenty-three hours fifty-nine minutes OFF or ON duty. The following diagrams show the status of the module in both the daily cycle and the weekly cycle. DAILY CYCLE DAY OF WEEK (0) TIME TIME OF DAY HR: MIN OF DAY HR: MIN 00: 00: 00 00: 00: 00 8:00 = 8:00 = J ON TIME OFF TIME 42: 00: 00 42: 00: 00 18:00 = 18:00 = OFF TIME ON TIME 23: 59: 59 S FIGURE #20 23: 59: 58Day OF WEEK SUN (1) MON (2) TUE (3) WED (4) THR (5) FRI (6) SAT (7) 84 WEEKLY CYCLE DAY HR: MIN DAY OF DAY HR: MIN WEEK SUN (4) 2 800 = 2 8:00 = ON TIME MON (2) OFF TIME TUE (3) WED (4) THR (5) 6 18:00 = FRI (6) 6 18:00 = OFF TIME ON TIME SAT (7) FIGURE #21 Slide valve setpoint Slide valve setpoint Slide valve setpoint Slide valve setpoint These output modules capacity slide valve respective setpoints. output modules #1 (module #30 on I/O rack) #2 (module #31 on I/O rack) #3 (module #35 on I/O rack) will be energized when the reading exceeds their See "Parameter Limits" display explanation for setting procedure.85 Auxiliary safety input modules Auxiliary safety #1 (module #15 on 1/0 rack) Auxiliary safety #2 (module #13 on 1/0 rack) Auxiliary safety #3 (module #17 on I/0 rack) Auxiliary safety #4 (module # 8 on 1/0 rack) Auxiliary safety #5 (module # 9 on I/O rack) These modules are provided for additional safety protection to the compressor package. Each module can generate a failure and shut down a running compressor or inhibit a compressor start. These modules are available for customer defined usage. If an auxiliary safety function is not desired, then that particular module must either be replaced by a shorting plug (refer to connection, power supply and boards diagram for proper installation, FES Drawing No. 035-00576D) or a 110 VAC signal must be applied to the respective terminals by the I/O rack. These input modules function in a fail safe manner. If a loss of voltage is detected (or snorting plug removed) for 5 seconds continuous through any auxiliary input module, the respective failure message will result. Auxiliary prealarm input modules Auxiliary prealarm #1 (module #3 on I/O rack) Auxiliary prealarm #2 (module #6 on 1/0 rack) Auxiliary prealarm #3 (module #19 on I/O rack) Auxiliary prealarm #4 (module #22 on 1/0 rack) Auxiliary prealarm #5 (module #26 on I/O rack) Auxiliary prealarm #6 (module #28 on I/O rack) These modules are provided for additional prealarm detection by the microprocessor panel. Each module can generate a prealarm condition and will do so immediately upon detection. These input modules function in a fail sale manner. A loss of input voltage or removal of shorting plug will result in the respective prealarm condition.10. ll. 86 If any prealarm function is not desired, then that particular module must cither be replaced by a shorting plug (refer to connection, power supply and boards diagram for proper installation) or a 110 VAC signal must be applied to the respective terminals on the I/O rack. "Alarm Status" output module (module #10 on I/O rack) Under normal operating conditions (no failures), this module will be energized (110 VAC). Any failure will cause this module to be de-energized. It is possible to reset the alarm status module by pressing the keypad "Alarm Off" key on the microprocessor control front panel. Any subsequent failure will sound the alarm again. Another means of resetting the alarm status output module is by pressing the “Stop/Reset" key. Although, if the failure condition persists, the alarm will again be sounded (module de-energized). "Remote Sequence Start/Stop" input module (module #16 on I/O rack) This module provides a means of starting and stopping the compressor on the basis of Presence and absence of a 110 VAC signal. ‘The required conditions for this function are: a. Microprocessor control panel must be in a remote mode. Press "Remote" on keypad on front panel or press remote pushbutton (if available) or enter "Remote" via communica- tions port. b. Anti-recycle time must be zero. "Control Press/Temp Select" input module (module #11 on I/O rack) With switch 5 of DIP switch pack U17 in the open position, the "Control Press/Temp Select" input module will cause the capacity control mode to either be compressor suction pressure or process temperature. Suction pressure is valid when 0 VAC is present or no input module is installed. Process temperature becomes the valid capacity control mode when 110 VAC is present on the input module or if a shorting jumper is installed. | With Switch 5 of DIP switch pack U17 in the vlosed position, the function of this module is disabled.12. 13. 87 "Cap Control Point #2" input module With swich 7 of DIP switch pack U17 in the open position, the "Cap Control Point #2" input module will cause the capacity control setpoint to switch between the two allowable setpoints. Capacity control setpoint #1 is valid when 0 VAC is present or no input module is installed or no shorting jumper is used. When 110 VAC is applied to this input module or no module is installed and a shorting jumper ic used, then the capacity control setpoint #2 is valid. With switch 7 of DIP switch pack U17 in the closed position, this function of this module is disabled. “Prealarm Status" oul put module (Module #29 on I/O Rack) Upper normal operating conditions (no prealarms), this module will be energized (110 VAC). Any prealarm will cause this module to be de-energized. It is possible to reset the prealarm status module by pressing the keypad "Alarm Off" key on the microprocessor control front panel. Any subsequent prealarm will sound the alarm again. Another means of resetting the prealarm status output module is by pressing the "Clear" key when on the "Prealarm Annunciation" screen, to clear the prealarm condition. If the condition persists, the prealarm will again be sounded (module de-energized).88 DIP Switch Settings (Refer to Drawing No. 035-00576D) The three (3) sets of DIP switches, U16, U17 and U18 are on the processor board. They are used to select various operating modes of the microprocessor panel as described belo 1. ule a. 1116 sw#l (Keypad/Screen Operation) When OPEN, all of the display sections are available to the operator. Also, the operator may remain in any display section as long as desired. When CLOSED, some of the display sections are not available to the operator. and some sections that are available, have restricted access. Also, on all display sections except ANALOG INPUT DATA, the home screen will return if no keys are depressed for a period of 60 seconds. The display sections that are not available are: Calibration Adjust. The display sections that have limited access are: PARAMETER LIMITS ~ past Discharge Pressure Proportional Band COMPRESSOR SETUP - past Time/Date Entry U16 sw#2 (Log Pass Originator) When OPEN, this microprocessor panel is enabled to initiate sequential logging. When CLOSED, this microprocessor panel will not initiate sequential logging. Typically, only the firet microprocessor panel in a multiple compressor Tele-Data configuration is enabled as the log pass originator. When this panel has time entered in the "Log Report Interval" display, and the log report interval times out, the panel will issue a log report and then send a code to the next panel in the Tele-Data loop to log.89 The next panel issues a log report and then sends a code to the next panel and so on. In this manner, each microprocessor panel in the Tele-Data loop issues a log report in sequence. Note that only the first micro~ Processor panel in the loop may be enabled as log pass originator and have time in the “Log Report Interval" display. All other microprocessor panels must have log pass originator supressed and no time in the “Log Report Interval" display. U16 sw#3 (Alarm Auto Log) When OPEN, and an alarm condition occurs, the microprocessor panel automatically issues a log report. When CLOSED, a lng report is not iseued when an alarm condition occurs. Ul6 swe Not Assigned U16 sw#5 (Keypad Lockout) When OPEN, and the front panel keyswitch is activated, data entry via the numeric section of the keypad is disabled. The other sections of the keypad are still enabled. When CLOSED, and the front panel keyswitch is activated, the entire keypad is disabled. When the front panel keyswitch is deactiated, or if it is not installed, the DIP ewitch is not functional. UL6 sw#6 -~ Not Assigned U16 swt7 & sw#8 (Baud Rate) These two DIP switches work together to select the character transmission rate (Baud Rate) of the communications port. Four different baud rates may be selected with these switches, as indicated by the chart on Drawing No. 035-00567D.90 U1T sw#l -- Not Assigned U17 sw#2 -- Not Assigned UL7 sw#3 -- Not Assigned UL7 sw#4 -- Not Assigned ULT sw#5 -- (Suction Pressure - Process Temperature Capacity Control Select) When OPEN, the input module “Control Press/ Temp Select" determines if capacity control is based on pressure or temperature. When CLOSED, then a display in the "Compressor Set Up" display section determines if capacity control is based on pressure or temperature. The display, which may be changed via the keypad or a Tele-Data command, is "Control Mode Press/Temp." U17 sw#6 (Low Suction Pressure -- Low Process Temperature Control Mode) When OPEN, automatic on-off cycling is selected. When the capacity control is based on suction pressure, if the suction pressure rises to the "Suction Pressure Upper" parameter, the compressor will start and commence capacity control. If the suction pressure drops to the "Suction Pressure Lower" parameter, the compressor will stop. When the capacity control is based on Process temperature, if the process temperature rises to the "Process Temperature Upper™ parameter, the compressor will start and commence capacity control. I£ the process temperature drops to the "Process Temperature Lower" parameter, the compressor will stop. The on-off cycle may be repeated indefinately. When CLOSED, safety shutdown is selected. If the upper or lower limits are reached, a failure will occur.91 U17 sw#7 (Setpoint 1 - Setpoint 2 Change) When OPEN, the input module "Cap Control Setpoint #2" determines which setpoint is selected. When CLOSED, then two displays in the “Compressor Set Up" display section determine which setpoint is selected. The displays, which may be changed via the keypad or a Tele-Data command are "Control Change Time Setpoint #1 On" and "Control Change Time Setpoint #2 On." U17 sw#8 -- Not Assigned U18 sw#1 (Oil Pump Test) When OPEN, the oil pump test is enabled. Depressing the "Local Start" key on the keypad starts the oil pump. The oil pump may be stopped by depressing the "Stop/Reset" key on the keypad or by moving the DIP switch to the CLOSED position. The oil pump test may be used to verify proper operation of the pump starter, the pump, and the oil pressure regulator. The slide valve indication’ may also be checked for proper calibration by depressing the "Load" and "Unload" keys on the keypad. When CLOSED, the oil pump test is disabled. U18 sw#2 -- Not Assigned U18 sw#3 -- Not Assigned U18 sw#4 -- Not Assigned U18 sw#5 -- Not Assigned U18 sw#6 -- Not Assigned92 D. Compressor Stopped Control Sequence a Oil Separator Heater Control Control of the oil separator heater only takes place when the compressor is shutdown. The microprocessor control panel will cycle the oil heaters output module on and off to maintain the desired oil temperature as entered in the "Parameter Limits" section display labeled "Oil Separator Heater Setpoint." The oil separator heater will be cycled off when the oil separator temperature exceeds oil separator heater setpoint plus 1.5 degrees Fahrenheit. The heater will be cycled on when the oil separator temperature dips below the oil separator heater setpoint minus 1.5 degrees Fahrenheit. If the oil separator temperature exceeds the entry for “Oil Separator Upper" when the compressor is not running, a non-fatal error message “Hi Oil Sep T" will result. I£ the oil separator temperature is lower than the entry for "Oil Separator Lower" when a compressor start is in process, a failure “Lo Oil Sep T* and a compressor shutdown will result. If the oil separator temperature exceeds or dips below the oil separator upper or lower prealarm setting when the compressor is not running, the appropriate prealarm will result. "Lo Oil Sep T" and "Hi Oil Sep T" are the respective prealarm messages. The above mentioned failures and prealarms result immediately on detection.93 £. Compressor Start Sequence (Upseq) 1 Check the anti-recycle time. a. If it is timed out, proceed. b. If time reamins, the compressor is not allowed to start. Check the oil separator temperature. a. If it is above the lower limit, proceed. b. It it is below the lower limit, signal "Lo Oil Sep T" failure and abort the start-up. Check the discharge pressure. If it is not within 10 psi of the maximum limit, proceed. b. If it is within 10 psi of the maximum limit, signal "Hi Disch Press" failure and abort the start-up. Indicate the "Start Delay" message on home screen. Activate the unload soleniod output. Activate the open motorized check valve output. A 1 second on, 1 second off pulse is actually issued for purposes of slow vessel equilization. Activate the oil pump starter output. Check the oil pump starter interlock a, If it is made within 5 seconds, proceed. b. If not, signal "Oil Pmp Strt" failure and abort the start-up. Check the oil pressure. @. Tf it is within the starting limits for 5 seconds within a 20 second period, proceed. b. If the oil pressure is lower than the Oil Pressure Start Lower parameter, signal "Lo Oil Press" failure and abort the start-up. c, I£ the oil pressure is higher than the Oil Pressure Start Upper parameter, signal “Hi Oil Press" failure and abort the start-up.10. ql. 12. 13. 14. 15. 16. 17. 18. 19. 20. 94 Check the slide valve position. a. I£ it is less than 5% within 5 minutes, deactivate the unload solenoid output and proceed. b. If not, signal "Compress Unld" failure and abort the start-up. Check the motorized check valve. a. If it is open within 59 seconds, deactiveate the open motorized check valve output and proceed. b. If not, signal "Check Valve" failure and abort the start-up. Activate the compressor starter output. Indicate the "Load Delay" message on home screen. Check the compressor starter interlock. a. If it is made within 5 seconds, proceed. If not, signal "Compress Strt" failure and abort the start-up. Check the compressor motor current. a. If it is greater than 1/4 of the lower limit, proceed. I£ not, signal "Compress Strt" failure and abort the start-up. Start the load delay timer. Start the anti-recycle countdown timer. Check the load delay timer. + If it is timed out, proceed. b. If not, exit. Start the oil temperature failure test delay timer. Go to "Run" status.95 F. Compressor Running Control Sequence 1 In addition to the prealarm checks that are made independent of compressor run status, the following prealarm checks are only made while the compressor is running. a Depending on the current selection of capacity control (suction pressure or process temperature), the following prealarm messages may occur due to excessive or insufficient pressure or temprature. "LO SUCT 1 P™ Low Suction 1 Pressure "HI SUCT 1 Pm High Suction 1 Pressure "LO SUCT 2 PB" Low Suction 2 Pressure "RI suCT 2 Pt High Suction 2 Pressure "LO PROC 1 1" Low Process 1 Temperature "HI PROC 1 7" High Process 1 Temperature "LO PROC 2 T" Low Process 2 Temperature "HI PROC 2 T" High Process 2 Temperature The "1" and "2" in the above prealarm messages are used to depict the setpoint which was valid at the time the prealarm condition resulted. In the event process temperature is the controlling medium, another prealarm check is made. A check is made to insure that the suction pressure as monitored at the compressor exceeds the value entered for "P Alarm Trip Limits Process Temp Control Lo Suct. Otherwise, the following prealarm message will be issued "Lo Suct P." Note this message does not have a "1" or a "2" to differentiate this prealarm from those when suction pressure is the controlling medium.96 c. In addition the following prealarm messages may occur if the monitored Analog Data value exceeds or dips below its respective "Hi" or "Lo" prealarm setpoint. “Hi Oil Fil P™ High Oil Filter Pressure Drop "Lo Disch T" Low Discharge Temperature "Hi Motor Cur" High Compressor Motor Current "Hi Oil Press" High Inlet Oil Pressure "Lo Oil Press" Low Inlet Oil Pressure “Hi Oil Temp" High Inlet Oil Temperature "Low oil Temp" Low Inlet Oil Temperature The following are additional safety checks made while the compressor is running and their associated failure messages: a. "Lo Oil Press” Low Oil Pressure -- inlet oil pressure dipped below the "Oil Press Run Lower" safety parameter limit for 5 seconds continuously. Compressor shutdown results. b. "Hi Oil Press" High Oil Pressure -- inlet oil pressure exceeded the "Oil Press Run Upper" safety parameter limit for 5 seconds continuously. Commpressor shutdown results. c. “Oil Fltr Press" High Oil Filter Pressure Drop -- oil filter pressure drop exceeded the safety parameter limit for 5 seconds continuously. Compressor shutdown results. a. "Lo Inlet oi1 T Low Inlet Oil Temperature -- inlet oil temperature dipped below the safety parameter limit for 5 seconds continuously. Compressor shutdown results.97 "Hi Inlet oil T™ High Tnlet Oil Temperature -- inlet oil temperature exceeded the safety parameter limit for 5 seconds continuously. Compressor shutdown results. "Oil Pmp 1 Intlk* Oil Pump #1 Interlock -- a 5 second continuous loss of oil pump #1 interlock was detected. This condition results in a compressor shutdown, (If the compressor package is not equipped with dual oil pumps or even with dual oil pumps if 0 (zero) is entered for the "Compressor Set-Up" screeen labeled “Lead Oil Pump Select." If A "1" is entered for "Lead Oil Pump Select," then #1 oil pump is considered lead oil pump and #2 oil pump is considered lag oil pump. In this case, A 1 second continuous loss of oil Pump #1 interlock (rather than 5 seconds) will result with this non-fatal (compressor will not shutdown) error message and the starting of the #2 oil pump (lag oil pump). This failure message could also be the result of absence of oil pump #1 interlock for 5 seconds, while attempting to start #1 oil pump when it is the lag oil pump and #2 is the lead oil pump. In the later case compressor shutdown results. NOTE: When 0 (zero) is entered for "Lead Oil Pump Select," #1 oi1 pump is assumed to be the only oil pump on the compressor package. "Oil Pump 2 Intlk" Oil Pump #2 Interlock -- this failure message can only occur if a "1" or "2" was entered in the "Compressor Set-Up" screen labeled "Lead Oil Pump Select." This message can either be fatal (results in compressor shutdown) or non-fatal (no compressor shutdown). If #2 oil pump is lead oil pump and a 2 second loss of interlock is detected, then this message results as a non-fatal message and the #1 oil pump is started.98 If #1 oil pump is the lead oil pump and it fails for any reason, then #2 oil pump (lag oil pump) will be started. If when attempting to start oil pump #2, no interlock is detected within 5 seconds, then this message results as a fatal failure message. “Compress Intlk" Compressor Interlock -- A 5 second continuous loss of compressor interlock was detected. This condition results in a compressor shutdown. "Compress Cur't" Compressor Motor Current -- the compressor motor current dipped below 10% of the safety parameter limit "Motor Current Lower" for 5 seconds continuous. This condition results in a compressor shutdown. "Lo Oil P Pmp 1" Low Oil Pressure Pump # 1 -- while pump #1 is lead oil pump as per “Lead Oil Pump Select" entry in the "Compressor Set-Up Screens," thio non-fatal failure message is used if the oil pressure dips below the "Lag Oil Pump Start". Oil pressure entry value or 5 seconds continuously "Lag Oil Pump Start" screen is a “Parameter Limits" entry screen which is only accessible when the entry for “Lead Oil Pump Select" is non-zero. Oil pump #2 will be started when this condition occurs. "Lo Oil P Pmp 2" Low Oil Pressure Pump #2 -~ while pump #2 is lead oil pump, this non-fatal failure message is issued if the oil dips below the “Lag Oil Pump Start" oil pressure entry value for 5 seconds, continuously. Oil pump #1 will be started when this condition occurs.99 Dual Oil Pump Control (only valid if "Lead Oil Pump Select" is non-zero) If a "1" or "2" is entered into the "Lead Oil Pump Select" display on the "Compressor Set-Up" section, while the compressor is running, the newly selected lead oil pump will be started. Therefore, it is possile to have both oil pumps started and running at the same time. If at any time while both oil pumps are running, the oil pressure exceeds the "Lag oil Pump Start" value plus 10 psi, the new lead will be allowed to continue to run and the other pump (previously "Lead" now considered "Lag") will be stopped. If the same value was entered into the "Lead oil Pump Select" as is currently displayed, then no effective change in lead oil pump selection occurs and the above action is not taken. If while attempting to change lead pump selection the "Examine Failures" message is encountered, refer to the explanation on display entry covering “Compressor Set-Up Lead Oil Pump Select" to resolve this condition. An automatic start of the lag oil pump will result if the oil pressure dips below the "Lag Oil Pump Start" oil pressure value for 5 seconds continuous. A non-fatal failure will result for the lead oil pump concerning low oil pressure (see g. and k. of previous Section B) when the oil pressure exceeds "Lag Oil Pump Start" value plus 10 psi. The lead oil pump will be stopped. An automatic start of the lag oil pump will also result if a 1 second loss of oil pump interlock is detected. A non-fatal failure will result for the lead oil pump concerning interlock (see £ and g. of previous Section B) when the oil pressure exceeds "Lag Oil Pump Start" value plus 10 psi. The lead oil pump will be stopped.100 3. Capacity Control Mode Selection -- The capacity control mode is selected by depressing the appropriate key on the keypad. The modes of capacity control that may be selected are Hold, Unload, Load, Externai and Auto. A description of each mode appears below. 1, Hold -- When selected, neither load nor unload pulses are generated, unless there is an OVERLOAD CONDITION as described below. 2. Unload -- When selected, a 100% unload pulse width is generated. 3, Load -- When selected, a 1008 load pulse width is generated, unless there is a LOAD PULSE INTERVENTION CONDITION or an OVERLOAD CONDITION as described below. 4. External -- When selected, load and unload pulse widths are generated in accordance to the status of the “External Load" and "External Unload" input modules, unless there is a LOAD PULSE INTERVENTION CONDITION, an OVERLOAD CONDITION, or the slide valve is below the minimum slide valve setpoint as described below. If the input module pulse on time or off time is less than 0.1 seconds, the time is ignored. The minimum output pulse width is 0.25 seconds. If both input modules are energized simultaneously, an unload pulse will be generated. 5. Auto ~~ When selected, the microprocessor control generates unload or load pulses based on a control setpoint and other parameters in a formula as described below, unless there is a LOAD PULSE INTERVENTION CONDITION or an OVERLOAD CONDITION as described below.101 Auto capacity control may be based on suction pressure or process temperature. If DIP switch U17 sw#5 is open, then the input module "Control Press/Temp Select" determines if capacity control is based on pressure or temperature. If the DIP switch is closed, then a display in the "Compressor Set Up" display section determines if capacity control is based on pressure or temperature. The display, which may be changed via the keypad or a Tele-Data command, is "Control Mode Press/Temp." ‘Two different setpoints may also be used, called setpoint 1 and setpoint 2. If DIP switch U17 sw#7 is open, then the input module "Cap Control Setpoint #2" determines which setpoint is selected. If the DIP switch is closed, then two displays in the "Compressor Set Up" display section determine which setpoint is selected. The displays, which may be changed via the keypad or a Tele-Data command are "Control Change Time Setpoint 1 On" and "Control Change Time Setpoint 2 on". Switching from setpoint 1 to setpoint 2 could be used to adjust the compressor from a daytime production load to a reduced nighttime or weekend load. If the capacity control is set for AUTO, based on suction pressure, and the suction pressure is below the setpoint, the microprocessor calculates an unload pulse width based on the following formula: UNLOAD WIDTH = PERIOD (SPsp - SP ~ (SPdb/2)) / SP pb If the capacity control is set for AUTO, based on suction pressure, and the suction pressure is above the setpoint, the microprocessor calculates a load pulse width based on the tollowing formula: LOAD WIDTH = PERIOD (SP - SPsp ~ (SPdb/2)) / SPpb PERIOD = Capacity Load-Unload Period (parameter) SP = Suction Pressure SPsp = Suction Pressure Setpoint (parameter) SPab = Suction Pressure Dead Band (parameter) SPpb = Suction Pressure Proportional Band (paraneter)102 Process temperature control operates similarly to suction pressure control with the temperature parameters being substituted into the formulas instead of the pressure parameters. There are three additional parameters that are only valid when operating in process temperature control and they are used in LOAD PULSE INTERVENTION CONDITION and OVERLOAD CONDITION as described below. These parameters are LOAD ADJUST, PROPORTIONAL BAND AND LOW SUCTION. Setpoint 2 operates similarly to setpoint 1, with the setpoint 2 parameters being substituted into the formulas instead of the setpoint 1 parameters. b. Minimum Slide Valve Setpoint -- When either EXTERNAL or AUTO mode are selected and if an OVERLOAD CONDITION or LOAD PULSE INTERVENTION CONDITION does not exist, minimum slide valve setpoint is enabled. If the slide valve position is at or less than the minimum slide valve setpoint, the microprocessor will generate a 0% unload pulse width. If the slide valve position is less than the minimum slide valve setpoint by more than 2%, the microprocessor will generate a 50% load width until the slide valve position is at or greater than the minimum slide valve setpoint. c. Load Pulse Intervention Condition -- When a load pulse is calculated by a.LOAD, EXTERNAL, or AUTO mode selection, it is possible for this calculation to be overridden by two conditions: 1. When motor current exceeds the lower setpoint, the following formula is used to calculate the maximum allowable load width, which is compared to the previously calculated load width. The smaller of the two load widths is issued. MAX LD WIDTH = PERIOD (0,99 * MCUP ~ MC) / (0.99 * MCUP - MCL) PERIOD = Capacity Load-Unload Period (parameter) MC = Motor Current Motor Current Upper (parameter) MCLH = Motor Current Lower (parameter)103 The above formula proportionally trims the allowable load pulse until the actual motor current reaches 99% of the motor current upper setpoint. The amount of amps between 99% and 1008 is used as a dead band. In this dead band zone, no load pulses are allowed. Thus, the compressor works to maintain maximum allowable motor current without overshooting in either load or unload, thereby eliminating hunting actions. 2. When in AUTO mode and process temperature control is selected, if the suction pressure is less than the "LOAD ADJUST" Parameter, the following formula is used to calculate the maximum allowable load width, which is compared to the previously calculated load width. The smaller of the two load widths is issued. . MAX LD WIDTH = PERIOD (LAPB + SP -LA) / LAPB IAPB = LA ~ LS - PB PERIOD = Capacity Load—Unload Period (parameter) LAPB_ = Load Adjust Proportional Band SP Suction Pressure 1A Process Temperature Control Loai Adjust (parameter) Is Process Temperature Control Low Suction (parameter) PB == Process Temperature Control Proportional Band (parameter) Overload Condition Two different types of overload conditions may occur, If an overload is detected, a proportional unload pulse is calculated, issued to the module, and the appropriate overload message is displayed on the home screen. The minimum unload pulse issued is 1/4 second. This is done because as the calculated unload pulse gets smaller and smaller when the overload condition is about to be resolved, if the pulse gets too small, the compressor will not unload enough to reset the overload condition.104 If an overload persists for 5 minutes, a fatal failure will be issued. The three types of overload are as follow: a. When motor current exceeds the upper setpoint, the following formula is used to calculate the minimum unload width, which is compared to the previously calculated unload width. The larger of the two unload widths is issued. The compressor will nut be permitted to load for any reason until the motor current drops below 99% of the motor current upper setpoint. MIN UNLD WIDTH = PERIOD (MC - MCUP) / MCPB PERIOD = Capacity Load-Unload Period (parameter) MC = Motor Current MCUP = Motor Current Upper (parameter) MCPB_ = Motor Current Proportional Band (parameter)105 b. When in Auto mode and process temperature control is selected, if the suction pressure is within the proportional band (SP > LS +PB), the following formula is used to calculate the minimum allowable unload width, which is compared to the previously calculated unload width. The larger of the two unload widths is issued. The compressor will not be permitted to load for any reason until the suction pressure rises above the proportional band. MIN UNLD WIDTH = PERIOD (LS + PB- SP) / PB PERIOD = Capacity Loai-Unload Period (parameter) sP Suction Pressure Is Process ‘Temperature Control Low Suction (parameter) FB = Process ‘Temperature Cntrol Proportional Band (parameter) NOTE: It is possible for a manual unload request or an external unload request to output a longer unload pulse than is required by the OVERLOAD CONDITION logic. Compressor Shutdown Sequence (DNSEQ) 1, Deactivate the compressor starter output. 2, Activate the unload solenoid output. 3. Check the compressor starter interlock. If it is released within 8 seconds, proceed. If not, signal "Compressor Shdwn" failure. Deactivate the oil pump starter output for 5 seconds. If the compressor starter interlock releases, proceed. If not, reactivate the oil pump starter output to protect the compressor, and continue checking the compressor starter interlock until it releases, then proceed.4, 10. ll. 12. 106 Check the compressor motor current. a, If it is less than 5 amps within 8 seconds, proceed. b. If not, signal "Compress Shdwn" failure. Deactivate the oil pump starter output for 5 seconds. If the compressor motor current is less than 5 amps, proceed. If not, reactivate the oil pump starter output to protect the compressor, and continue checking the compressor motor current until it drops below 5 amps, then proceed. Activate the close motorized check valve output. Check the slide valve position. a. If it is less than 5% within 5 minutes, proceed. b. If not, indicate "Compress Unld" failure and proceed. Deactivate the unload solenoid output. Deactivate the oil pump starter output. Check the motorized check valve. a. If it is closed within 45 seconds, proceed. b. If not, signal "Check Valve" failure and proceed. Deactivate the close motorized check valve output. Check the oil pump starter interlock. a. If it is released within 5 seconds, proceed. b. It not, signal "Oil Pmp Intlk" failure and proceed. Indicate "Stop" message on home screen.107 FES LPIT CONTROL, DIAGNOSTICS } INITIALIZE PIT SELF DIAGNOSTIC TESTS J START OTL PUMP.108 or PRESSURE oK?, ENERGIZE UNLOAD, SOLENOIO No. YES PULSE OFEN MOTORIZED. CHECK VALVE START COMPRESSOROPERATE CAPACITY CONTROL Yes PRE-ALARM, No SELF DIAGNOSTIC TESTS NO stopSAVE PARAMETERS OTSPLAY FAILURES ‘TURN ON ALARM Y ‘SHUTOOKN COMPRESSOR (IF ON) ‘SHUTOOWN ‘OTL PUMP (IF oN) 110 ALARM DISPLAY PRE-ALARM IN PRE~ALARM "ANNUNCTATOR, TURN ON ALARMqll SHUTOOKN Y stop COMPRESSOR DELAY 8 Sec. cose URW ow woFoRtze0 ona ave oe orseuay ite Suaseo y =r oseiterte rae ae ey oan oot clbaetty comettonSHUT OFF OTL PUMP DELAY 5 SEC 112 DISPLAY ANTI-RECYCLE113 VI. Troubleshooting A. Power Supply (Reference Drawing No. 035-00576D) The following sections require making accurate D.C. voltage readings. A digital multimeter (DMM) is recommended. 1. Valid Voltage Settings a. The +15 VDC supply voltage should read between 14.5 VDC and +15.5 VDC for proper operation. This can be measured between ground (negative meter probe) and +15 volt as shown on the drawing. If adjustment is necessary, see the following section on voltage adjustment. b. The -15 VDC supply voltage should read between -14.5 VDC and -15.5 VDC for proper operation. This can be measured between ground (negative meter probe) and -15 volt as shown on the drawing. No adjustment is available or this voltage. c. The +5 VDC supply voltage should read between +5.1 VDC and 5.3 VDC for proper operation. This can be measured between ground (negative meter probe) and +5V as shown on the drawing. If adjustment is necessary, see the following section on voltage adjustment. 2. Voltage Adjustment Power supply adjustments require a short shut down time. No power supply adjustments should be made with power supply connector connected to the processor board. First switch off panel power with the control switch on front of panel. Next, disconnect power connector to processor board and switch panel power on again. Locate proper voltage adjustment potentiometer (pot) on power supply. The adjustment pots are on the painted circuit board below the power supply housing and are visible through the holes in the top frame of the power supply. A 1/8" x 4" Xcelite R-184 screwdriver (preferably non-conductive) can be used. Care must be taken if using a conductive screwdriver not to touch anything other than the adjustment pot.114 a. +5 VDC adjustment pot increases voltage if turned clockwise and decreases voltage when turned counterclockwise. Proper operating voltage is +5.1 VDC to +5.3 voc. b. +15 VDC adjustment pot decreases voltage if turned clockwise and increases voltage when turned counterclockwise. Proper operating voltage is +14.5 VDC to +15.5 ‘VDC. Upon completion of power supply adjustment, switch off panel power, reconnect power supply connector to processor board, switch panel power on again. If the +5 volt DC supply is properly adjusted, the 5 volt DC range indicator on the processor board will glow green. If the range indicator is red, then the +5 volt DC is adjusted too low or too high. Motor Current Calibration (Reference Drawing No. 035-00576D): If this is initial calibration of machine, it should be verified that the proper CT ratio was selected for this application. While in the service mode enter the "Compressor Set Up" mode display. Push the "Step/Enter™ Key until "Motor Current Xformer Ratio" is displayed. Valid entries are from 100:5 to 1200:5. If necessary enter proper data and press "Step/Enter." No adjustment is provided to zero the motor current as this is accommodated through hardware. Start the compressor and load to 1008, if possible, but at least to 50%. Place in hold for constant load (motor current should remain constant while making this adjustment.) Using a hand held clamp on amprobe, put it around every wire going through the CT. While monitoring motor current on the analog data display, adjust the motor current span pot on the processor board until the readings on both the display and clamp on amprobe coincide.11s C. Slide Valve Calibration (Reference Drawing 035-00576D) A Without the compressor runnin a Set DIP switch U18 switch #1 to the open position. “Oil Pump Test" is enabled. Press the “Local Start" key and “vil pmp Tst" -~ should be displayed. The oil pump (lead oil pump if 2 installed) should also be running. Press "Unload" to provide a continuous unload signal. After 1 or 2 minutes, it can be assumed the slide valve has reached the full unload position. Adjust the slide valve zero pot on the processor board until the display indication changes between 0% and 1%. No value less than 0 will be displayed. Therefore, it is important to adjust as just mentioned. Press the "Load" key to provide a continuous load signal. After 1 to 2 minutes, it can be assumed the slide valve has reached its full load position. Adjust the slide valve span pot on the processor board until the display indication changes between 99% and 100%. No value greater than 100 will be displayed. Therefore, it is important to adjust as just mentioned. Repeat c - g as necessary until full side valve travel results in 0% to 100% readings without further adjustment. Set DIP switch U18 switch #1 to the closed position.MICRO II/MicroMASTER ADDENDUM CAUTION: DO NOT USE THE PROCESS TEMPERATURE PROBE AS A PROTECTIVE DEVICE IN CRITICAL TEMPERATURE APPLICATIONS SUCH AS CHILLER LOW TEMPERATURE FREEZESTATS, ETC. IN LIEU OF AN EXTERNAL LOW TEMPERATURE. SAFETY DEVICE CONNECTED TO AN AUXILIARY SAFETY SHUTDOWN. IF THE PROCESS IS SWITCHED FROM TEMPERATURE TO SUCTION PRESSURE CONTROL, ALL PROCESS TEMPERATURE PARAMETERS ARE IGNORED AND WILL NOT SHUTDOWN THE EQUIPMENT ON LOW TEMPERATURE. AN EXTERNAL LOW TEMPERATURE SWITCH SHOULD BE INSTALLED AND CONNECTED TO AN AUXILIARY SAFETY INPUT TO THE MICROPROCESSOR. THIS EXTERNAL SWITCH SHOULD BE SET TO OPEN ON LOW TEMPERATURE ESTABLISHING A FAILSAFE CIRCUIT.