AB PLC Manual

CENTAC
CPLC Manual
INGERSOLL-RAND
AIR COMPRESSORS
CPLC MANUAL
Copyright Notice
Copyright 2001 Ingersoll-Rand Company
THIS MANUAL IS SOLD "AS IS" AND WITHOUT ANY EXPRESSED OR IMPLIED
WARRANTIES WHATSOEVER.
Printing Date: 26-March-2001
Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air
applications. Ingersoll-Rand does not approve specialized equipment for breathing air
applications and assumes no responsibility or liability for compressors used for breathing air
service.
Version 2.24
Copyright Ingersoll-Rand Company 2001
Date of Issue: 28-May-2001
CPLC MANUAL
Table of Contents
References __________________________________________________________ 2
General - CPLC Panel _________________________________________________ 3
Control Methodology __________________________________________________ 4
Performance Control _______________________________________________________ 4
Unload _________________________________________________________________________ 4
Constant Pressure Control - Modulate ________________________________________________ 4
Energy Saving Control - Autodual ____________________________________________________ 5
How does Constant Pressure Modulation Work? ______________________________________ 5
Measuring the Discharge Pressure _______________________________________________ 6
Proportional Gain ____________________________________________________________ 6
Integral Time ________________________________________________________________ 7
Motor Current, Throttle Limit and High Load Limit ___________________________________ 8
Electro-pneumatic Controllers and Low Limit Relay (LLR) _______________________________ 9
The CPLC Advantage __________________________________________________________ 10
Surge Control ____________________________________________________________ 11
Control Methodology _____________________________________________________________ 11
Surge Detection_________________________________________________________________ 11
Insufficient Rise To Surge _______________________________________________________ 11
Changes in System Discharge Pressure____________________________________________ 12
Rapid System Demand Changes _________________________________________________ 12
Incorrect Instrumentation Output__________________________________________________ 12
How is Surge Detected? ________________________________________________________ 13
Surge Reload __________________________________________________________________ 13
Surge Indexing _________________________________________________________________ 13
Automatic Starting ________________________________________________________ 14
Communications ________________________________________________________________ 14
Auto-Hot Start __________________________________________________________________ 14
Oil System Control ___________________________________________________ 15
Prelube Pump ____________________________________________________________ 15
Oil Heater _______________________________________________________________ 15
Protection and Monitoring_____________________________________________ 16
Analog Functions _________________________________________________________ 16
Analog Inputs __________________________________________________________________ 16
Analog Outputs _________________________________________________________________ 16
Digital Functions _________________________________________________________ 16
Digital Inputs ___________________________________________________________________ 17
Digital Outputs __________________________________________________________________ 17
User Interface _______________________________________________________ 18
OUI (Operator User Interface) _______________________________________________ 18
Command Keys_________________________________________________________________ 19
Enter Key - Display Operating Mode _________________________________________________ 19
Navigation Keys_________________________________________________________________ 19
Version 2.24
Date of Issue: 28-May 2002
CPLC MANUAL
Graphic Display _________________________________________________________________ 20

Folder and Page ______________________________________________________________ 20
Status Bar ___________________________________________________________________ 21
Edit (Setpoint Changes) Mode _____________________________________________________ 21
Navigation Mode ________________________________________________________________ 22
SYSTEM Folder ________________________________________________________________ 23
INFO Folder____________________________________________________________________ 24
SETTINGS Folder _______________________________________________________________ 24
Indicator, Switch and Light Layout __________________________________________ 27
Lights _________________________________________________________________________ 27
Push Buttons ___________________________________________________________________ 28
Switches ______________________________________________________________________ 28
CPLC Tuning Procedures _____________________________________________ 29
Setting High Load Limit (HLL) ______________________________________________ 29
Setting Throttle Limit ______________________________________________________ 29
Setting Surge Indexing TL Increment ________________________________________ 30
Setting Surge Sensitivity___________________________________________________ 31
Tuning Stability __________________________________________________________ 32
Calibrating the Control Valves ______________________________________________ 32
Autodual Control Settings__________________________________________________ 33
Unload Point (Bypass Valve % Open)________________________________________________ 33
Unload Delay Time (seconds) ______________________________________________________ 33
Reload Percent _________________________________________________________________ 34
Setting the Start Time _____________________________________________________ 34
Setting the CT Ratio _______________________________________________________ 34
Inlet Unload Position ______________________________________________________ 34
Setting Set Point Ramp Rate________________________________________________ 34
Alarm and Trip Settings____________________________________________________ 35
Troubleshooting _____________________________________________________ 36
Troubleshooting Example __________________________________________________ 37
Input/Output (I/O) System __________________________________________________ 38
Vibration Monitoring System (VMS) _________________________________________________ 38
Checking Vibration Transmitter Power ___________________________________________ 39
Checking Vibration Circuit _____________________________________________________ 39
Check the Vibration Probe, and Cable ___________________________________________ 40
Checking the Vibration Probe __________________________________________________ 40
Check the BCM _____________________________________________________________ 41
Temperature Monitoring System (TMS) ______________________________________________ 42
Checking for Power to the Temperature Transmitter ________________________________ 43
Checking for a Faulty RTD ____________________________________________________ 44
Version 2.24
CPLC MANUAL
Degrees Fahrenheit versus Ohms value chart for 100 OHM Platinum RTD ______________ 45
Degrees Celsius versus Ohms value chart for 100 OHM Platinum RTD _________________ 46
Checking the RTD Transmitter _________________________________________________ 47
Checking proper operation of the BCM and wiring __________________________________ 48
Valve Control System (VCS) _______________________________________________________ 49
Checking proper operation of the I/P and positioner _________________________________ 51
Pressure Monitoring System (PMS) _________________________________________________ 52
Checking for Power to the Pressure Transmitter ___________________________________ 53
Quick check of the PT ________________________________________________________ 55
Functional PT test ___________________________________________________________ 55
Digital Input System (DIS) _________________________________________________________ 56
Checking proper operation of the digital devices ___________________________________ 57
Enclosures ______________________________________________________________ 58
NEMA 12 (IP 64) ________________________________________________________________ 58
Cooling Fan ____________________________________________________________________ 58
Control Electrical Package _________________________________________________ 58
Stage Data Package _______________________________________________________ 58
Running Unloaded Shutdown Timer _________________________________________ 58
Water Solenoid Post Run Timer _____________________________________________ 59
N.O. Contact for Remote Indication of Common Alarm and Trip __________________ 59
Communication _____________________________________________________ 60
Direct CPLC Communications with DH+ ______________________________________ 60
The CPLC Address Interface________________________________________________ 61
Documentation ______________________________________________________ 95
Glossary ___________________________________________________________ 96
Version 2.24
CPLC MANUAL
Table of Figures
Figure 1: Compressed Air System ............................................................................................................... 4
Figure 2: Modulate Control........................................................................................................................... 5
Figure 3: Autodual Control ........................................................................................................................... 5
Figure 4: Performance Control..................................................................................................................... 6
Figure 5: Proportional Band, Pb ................................................................................................................... 7
Figure 6: Proportional Plus Integral Control ................................................................................................. 7
Figure 7: TL and HLL ................................................................................................................................... 8
Figure 8: Low Limit Relay (LLR) ................................................................................................................... 9
Figure 9: CPLC Advantage ........................................................................................................................ 10
Figure 10: Rise To Surge ........................................................................................................................... 11
Figure 11: Changes in Discharge Pressure ............................................................................................... 12
Figure 12: Changes in Discharge Pressure ............................................................................................... 13
Figure 13: Plant Air System........................................................................................................................ 29
Figure 14: Troubleshooting Tree................................................................................................................ 36
Version 2.24
2 CPLC MANUAL
References
The following references were used in creating this document. All of this documentation is
recommended for a more detailed understanding of specific control modes and control panel
functions.
NEMA STANDARDS PUBLICATION NO. 250, Enclosures for Electrical Equipment (1000 Volts
Maximum), Revision 2, May 1988
NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical Equipment, 1986
Edition
Nisenfeld, A. Eli, Centrifugal Compressors: Principles of Operation and Control, Instrument
Society of America, 1982
Moore, Ralph L., Control of Centrifugal Compressors, Instrument Society of America, 1989
Doebelin, Ernest O., Control System Principles and Design, John Wiley & Sons, 1985
Rowland, James R., Linear Control Systems Modeling, Analysis, and Design, John Wiley &
Sons, 1986
Deshpande, Pradeep B. and Ash, Raymond H., Computer Process Control With Advanced
Control Applications, 2nd Edition, Instrument Society of America, 1988
CENTAC ENERGY MASTER, Version CEM230, Ingersoll-Rand Company, March 1992
White, M.H., Surge Control for Centrifugal Compressors, Chemical Engineering, December 25,
1972
Hall, James W., THERMODYNAMICS OF COMPRESSION: A Review of Fundamentals,
Instrument Society of America, 1976
Gaston, John R., Centrifugal Compressor Operation & Control: Part II "Compressor
Operation", Instrument Society of America, 1976
Gaston, John R., Antisurge Control Schemes For Turbocompressors, Chemical Engineering,
April 1982
Warnock, J. D., Methods for Control of Centrifugal and Reciprocating Compressors, Moore
Products, 1984
Harrison, Howard L. and Bollinger, John G., Introduction to Automatic Controls, Second Edition,
Harper & Row, 1969
Version 2.24
CPLC MANUAL 3
General - CPLC Panel

The CPLC panel is the microprocessor based control and monitoring system for Centac and
X-FLO centrifugal compressors. It is based on the Allen Bradley PLC-5 programmable logic
controller (PLC) hardware. The processor and Input/Output (I/O) cards will hereafter be
referred to as the Base Control Module (BCM). The CPLC handles all pressure control and
monitoring functions; as well as, control auxiliary equipment such as the main motor starter, oil
heater and prelube pump.
The CPLC panel has a processor board called the BCM. This board has a microcontroller and
memory chips that tell the rest of the panel what to do for the various input pressures,
temperatures and vibrations. All hardware for data analysis, number of input and output (I/O)
points and system memory are optimally selected for accurately controlling and protecting
Centac and X-FLO compressors.
Features of the CPLC system are:
• Ease of use ... operator friendly keypad navigation and edits.
• Unload, Modulate and Auto-Dual operating modes.
• Advanced surge detection and control.
• High current limit for main drive electric motor protection.
• First-out indication and event log to help determine the root cause of a compressor trip.
• Pop-up banner for immediate alarm/trip notification.
• Pinion vibration alarm and trip for each compression stage.
NOTE: For the purpose of consistency and clarity, all of the descriptions and examples that
follow refer to "air" for the more generic "gas". Any gas compressed by a Centac or X-FLO
compressor would also apply.
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4
Control Methodology
The CPLC utilizes performance and surge control methodologies to meet varying compressed
air system needs. The term "performance control" is used for grouping the control modes that
affect compressor power consumption through movement of the intake and discharge valves.
Performance Control
The CPLC has three standard performance control modes or methods of operation. These
modes are Unload, Modulate and Autodual for typical plant air compressors operating in
constant pressure applications. For the discussions that follow, Figure 1 depicts a compressed
air system and the relationship between the compressor and the plant air system.
Atmosphere
Silencer
Inlet
Valve Bypass
Valve Check
Plant Air System
Valve
Inlet
Compressor
Filter
Figure 1: Compressed Air System
Unload
The compressor is unloaded, when no air is being supplied to the Plant Air System, and all of
the air produced by the compressor is being vented to the atmosphere. In this mode, the inlet
valve is slightly open to allow enough air to pass through the compressor for internal cooling,
prevention of rotor instability and surge avoidance. This air is then discharged through the fully
open bypass valve to the atmosphere. Typically, the compressor is set to make a positive
pressure across the first compression stage which produces a discharge pressure something
greater than the atmospheric pressure.
The inlet valve opening required to create this positive pressure is directly related to the
horsepower consumed; therefore, careful consideration should be given to this inlet valve
position for minimizing overall power consumption.
Constant Pressure Control - Modulate

Constant pressure control is a frequently required performance control method for Centac air
compressors. If left uncontrolled, the compressor's discharge pressure would rise and fall
along the natural performance curve as system demand changed. Modulate control satisfies
the constant pressure requirement.
The performance map in Figure 2 shows Modulate control. Modulate maintains the system
discharge pressure at the system pressure set point as entered into the CPLC by the user.
CPLC MANUAL 5
Once loaded, the compressor will operate along the constant pressure line until the user
switches to Unload or presses the stop button.
Control is accomplished by modulating the inlet valve Natural
within the compressor's throttle range. When system Constant Pressure Line
Pressure
Curve
demand is less than the minimum throttled capacity, the Surge Line Design
Point
discharge pressure is maintained by modulating the Discharge Maximum

Throttle Point
bypass valve and venting some or all of the air to Pressure (MinLoad)
atmosphere. This valve is opened just prior to reaching Unloaded
the surge line. Whenever the bypass valve is open, the Inlet
Valve
inlet valve maintains its position at the minimum throttled Bypass
Valve
Throttle
Range
Natural
capacity setting. Modulate provides a constant discharge Throttle

Range
Power
Curve
pressure with variable capacity from design to zero. Surge Line

Constant Power Line
This control method is used when reliable control of the Power at

Coupling
discharge pressure is required. Modulate is the most
commonly used control method for Centac and X-FLO
compressors.
Unloaded
Capacity
Energy Saving Control - Autodual Figure 2: Modulate Control

Autodual automatically loads the machine when demand
is high and unloads the machine when demand is low.
When the compressor is controlling to pressure setpoint and demand is within the inlet valve
throttle range, constant pressure is maintained in the same manner as Modulate.
When the machine is controlling to the pressure setpoint and system demand is low, the
compressor is operated in the bypass valve throttle
range. Autodual automatically unloads the machine Natural
when the bypass valve is opened beyond the Unload Unload
Surge Line Curve
Design
Point for a programmed time period called the Unload Point
Point
Reload Point
Delay Time. The Bypass Valve Unload Point is (Reload Percent)
Discharge
selected to correspond with the check valve closing Pressure
since at this point the machine is not supplying the

system (Figure 1). The Unload Delay Timer should be Unloaded
set to prevent unloading during short excursions Bypass Inlet

Valve Valve
through the Unload Point. The Reload Percent Throttle
Range
Throttle
Range Natural
determines the System Pressure at which the machine Curve
Unload
will automatically load into the system. Power at
Point
Coupling
How does Constant Pressure Modulation Work?
The goal of constant pressure modulation is to maintain
a specified discharge pressure in the compressed air
Unloaded
system while the capacity requirements change.
Capacity
Modulate control provides constant pressure from 100
percent of the compressor's capacity to zero capacity. Figure 3: Autodual Control
Autodual control provides constant pressure from the
100 percent of the compressor's capacity to the Unload
Point.
If all plant air systems were identical in capacity usage requirements, the CPLC could be
preprogrammed to respond to those changes; however, all plant air systems are not alike. The
frequency and variability of the capacity changes means that the control logic must be flexible,
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6 CPLC MANUAL
so the CPLC utilizes proportional plus integral control algorithms to determine the magnitude of
the signal that is sent to the inlet and bypass valves. These algorithms, or programming logic,
allow the CPLC control system to be "tuned" to a specific plant air system.
Measuring the Discharge Pressure
In order to maintain constant pressure, the system discharge air pressure must be measured.
A pressure transducer is mounted in the control panel and tubed to the compressor discharge
downstream of the check valve as shown in Figure 4.
CPLC
PT
Pneumatic Tubing
Bypass
Valve
4-20 mA Check
Base
Valve
Control
Module CT Starter
Motor Compressor
Inlet
Valve
4-20 mA
Figure 4: Performance Control
This transducer sends a 4-20 mA signal to the CPLC board. The CPLC compares the
measured discharge pressure to the system pressure set point entered into the CPLC by the
user through the Operator User Interface (OUI). Depending upon the difference between these
two values the CPLC will send a 4-20 mA signal to "Modulate", open or close, the inlet and/or
bypass valve to maintain the specified system pressure set point.
Proportional Gain
Proportional control varies the signal sent to the valves as a linear response to the difference
between the actual system pressure and the system pressure set point. Valve responsiveness
can be adjusted through the CPLC with the proportional gain, Pg, set point. This scaling factor,
graphically depicted in Figure 5, is the amount of change in the input variable (actual minus set
point pressures) to cause a full scale change in the output variable (valve position).
In other words, if the pressure in the air system fluctuates frequently, it would be prudent to set
Pg to a high value to keep up with those system changes. Otherwise, if the system is very
stable, a smaller value can be used. Pg is directly related to valve life and indirectly related to
valve cycling; so, as Pg increases, valve life decreases and cycling increases.
As stated earlier, the CPLC uses a proportional plus integral control algorithm. The result of
proportional only control is offset from the controlled variable, discharge pressure. This means
that if the set point pressure is 100, the actual pressure may only be 95. The value of this offset
depends upon the proportional gain value.
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CPLC MANUAL 7
What is the valve response when the difference

between actual and set point pressures is zero?
There is no response. Proportional control only
functions when a difference or error exists. Design
Output
discharge pressure could not be attained in a Variable
(Valve
proportional only control system. Therefore, an Position) Slow Pg
integral control algorithm is added to achieve the Full Response low
desired discharge pressure. Scale
Integral Time
The offset produced by the proportional control 0
Large Change
algorithm could be eliminated by manually readjusting
the system pressure set point. Using the example
above, the set point could be reset to 105 to obtain Fast Pg hi
the 100 desired. Manually resetting the set point Full Response
Scale
would be required as the system demand fluctuated.
Integral control, also known as reset control, Output
Variable
automatically resets the desired system pressure set (Valve
Position)
point. For the CPLC, the rate at which the controller
resets the system pressure setting is known as
Integral Time, It, and is expressed in units of minutes
per repeat.
0
Smal
If precise control of the specified discharge pressure l
Change
is required, the It set point should be set for a fast Input Variable
value. It is inversely related to valve life and directly (Actual - Set Point Pressures)
related to valve cycling; so, as It decreases, valve life

Figure 5: Proportional Gain, Pg
increases and cycling decreases. For the CPLC
controlling Centac and X-FLO compressors, It values
are typically less than 1.00.
Figure 6 shows the relative
valve response over time for Opened
Proportional Band - Low
two combinations of Pg and It. Integral Time - Fast
As shown, when Pg is low and

It is fast, valve activity is
significant in both magnitude Set Point
and frequency to obtain the
desired set point. The other
scenario, Pg is high and It is Valve
slow, has relatively little valve Activity
activity, and may never reach

the set point position.
Proportional Gain and Integral
Time are variables used Proportional Band - High
Integral Time - Slow
internally by the control
system to determine valve
response and direction for a Closed
Time
given compressed air system.
Each has an optimum value
based upon the system's Figure 6: Proportional Plus Integral Control
characteristics. Determining
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8 CPLC MANUAL
these optimum values is a trial and error exercise. These set points should be re-evaluated any
time there is a major change in the compressed air system.
Up to this point, constant pressure control has been accomplished with an analog input (system
pressure) and two analog outputs (inlet valve and bypass valve position). How is motor current,
the other analog input, used for constant pressure control? When does the bypass valve
modulate as opposed to the inlet valve?
Motor Current, Throttle Limit and High Load Limit
Motor current, in units of power (normally amps), has two functions in the CPLC. The first is
over current protection for the main motor, and is referred to as high load limit (HLL). The
second function determines the point at which the bypass valve begins to modulate. This point
is called throttle limit (TL). The location of these two points are graphically depicted on the
pressure and power versus capacity curves as shown in Figure 7.
HLL is a parameter entered into the CPLC that prevents the main drive motor from overloading.
Once this value is reached, the CPLC logic limits the inlet valve from opening any further. This
action constrains the motor by limiting the amp draw to the maximum allowable service factor
amps.
When the motor is sized for cold
conditions, there are circumstances when
Tcold HLL will never be reached. For example,
Thot the value of HLL as shown in Figure 7,
Discharge Pressure
cannot be attained for the T=hot curve

because it is beyond the maximum
compressor capability; that is, the inlet
valve is fully open. This scenario never
High Load Limit (HLL)
limits the inlet valve.

Throttle Limit (TL)
When ambient conditions produce the

T=cold curve, the compressor will not be
able to achieve the maximum capacity
because it is beyond the HLL value.
Since HLL is less than or equal to the
motor nameplate FLA times the adjusted
Power at Coupling
service factor, the maximum compressor

capacity at T=cold could only be reached if
the motor were sized for the T=cold
condition.
TL is the power value at which the CPLC
transfers modulation control from the inlet
to the bypass valve. The reason for this
transfer, is to prevent the compressor from
entering into a surge condition. The
Capacity - Mass Flow bypass valve vents air to the atmosphere;
therefore, once TL is reached, the
compressor continues to produce a
Figure 7: TL and HLL
constant amount of air. Part of this air
Version 2.24
CPLC MANUAL 9
System Compressor Compressor Open Position

Required Operating Output Inlet Bypass Discharge
Capacity State Capacity Valve Valve Pressure Power
0 Off 0 0 100 0 0
0 Unloaded 10 10 100 >P0 20
100 Full Load 100 100 0 P2 100
75 MinLoad 75 70 0 P2 80
50 MinLoad 75 70 25 P2 80
25 MinLoad 75 70 50 P2 80
0 MinLoad 75 70 100 P2 80
goes to the Plant Air System, and the remainder is blown off. Even though the Plant Air System
receives only a portion of the air produced, the amount of power remains constant.
The table above presents seven capacity requirements for a plant air system. At each of the
capacities, the table shows the compressor output, valve position, discharge pressure and
power. Each of these values represents a percentage and are examples only. P2 is the
specified discharge pressure and P0 is the barometric pressure.
From the table above, once the system required capacity moves below 75 percent, the
compressor still produces 75 percent capacity with 80 percent of the power. If the system
needs only 25 percent capacity, it will still have to pay for 80 percent of the power. This is why
it is important to open the bypass valve at the last possible moment; therefore, setting TL
properly is critical for efficient energy management.
Electro-pneumatic Controllers and Low Limit Relay (LLR)

Prior to 1986, most all Centac compressors used an electro-pneumatic control panel. These
panels had a pressure controller that utilized a Low Limit Relay (LLR) setting instead of TL to
prevent surge.
The LLR is a device in the control panel that is set based upon a very specific inlet valve
position. As the demand decreases, the inlet valve
begins to close. Just prior to surge, the LLR is set T=cold
based upon the current inlet valve position. For

constant pressure modulation, when the inlet valve T=hot
reaches the LLR setting, the bypass valve would

begin to open, surge is prevented and the Discharge
compressor continues to modulate with demand. Pressure
This methodology works well for constant pressure

control. However, it is not always as efficient as the
CPLC with a TL setting, because, any time the inlet
temperature changes, a new LLR position needs to LLRcold LLR
hot
be set. Changing ambient temperatures exist for Power
T=cold
most applications. at
Coupling
T=hot
As an example, during the spring in Mayfield,
Kentucky the temperature at night may get as cold Wasted
as 45 degF (7 degC) and can get as hot as 70 degF Energy
(52 degC) during the day. If the LLR is set at night,

Capacity - Volume Flow
LLRcold, the compressor could potentially surge
during the day if the demand decreases below the Figure 8: Low Limit Relay (LLR)
LLRhot position (see Figure 8). Most operators will
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10 CPLC MANUAL
not allow this to occur, so they set LLR for the hottest condition, which is a more conservative
value.
When the LLR is set during the day, LLRhot, or for the hottest condition and demand continues
to decrease at night, the bypass valve will begin to open at the LLRhot position; even though it
does not need to be opened until the LLRcold position. Since the bypass valve opens
prematurely, energy is wasted. This situation exists because LLR is based upon a fixed inlet
valve position.
This valve position is directly related
to the compressor volume flow rate
(ICFM, M3/HR), where PositionIV is
RTInlet
PositionIV ∝V ∝
Inlet Valve Position, V is Volume Flow
Rate, R is the Universal Gas
PInlet
Constant, TInlet is the Inlet Air
Temperature and PInlet is the Inlet Air Pressure. As the inlet air temperature changes, the
volume of air that the compressor produces also changes. Since the LLR is established based
upon a volume flow measurement (valve position), it should be adjusted with changes in inlet
temperature.
The CPLC Advantage

The CPLC does not require a reset of TL for changes in inlet temperature because TL is based
upon power (amps) which is directly related to a mass flow rate (SCFM, NM3/HR, LB/MIN,
KG/S).
GHP = H ad
×W I × V ×η
motor
× PF × 3
GHP =
η ad
× 33,000 and 746
where Had-Adiabatic Head, W-Mass Flow,
T=cold
ηad-Adiabatic Efficiency, I-Motor Current T=hot
(amps), V-Motor Voltage, ηmotor-Motor

Efficiency and PF-Motor Power Factor. Discharge
Pressure
As shown in Figure 9, the slope of the
surge line varies with changes in ambient
conditions. However, this change in slope Throttle Limit (TL)
is relatively small compared to the change T=cold

in inlet temperature.
T=hot
Since the change is relatively small, only a Wasted Energy
small amount of energy is wasted by not Power at

resetting TL for a changing ambient Coupling
temperature. The amount of savings Amps
between using TL and LLR depends upon
the difference in temperature and the
difference in the LLR and TL set points.
Therefore, the CPLC Advantage is power Capacity - Mass Flow
Version 2.24
Copyright Ingersoll-Rand Company
Figure 9: CPLC Advantage 2001
CPLC MANUAL 11
savings. The amount of power savings depends upon the frequency that ambient conditions
are changing, TL and LLR are not being modified on a regular basis and the compressor is
being throttled beyond the compressor's maximum throttle capacity. Power savings up to ten
percent can be realized for applications that require excessive throttling and large ambient
temperature fluctuations.
Surge Control
Surge is the reversal of flow within a dynamic compressor that takes place when the capacity
being handled is reduced to a point where insufficient pressure is being generated to maintain
flow. This condition can potentially damage the compressor if it is severe and is allowed to
remain in that state for a prolonged period; therefore, control and prevention is required.
Control Methodology
Surge prevention is accomplished by opening the bypass valve prior to reaching the surge
point. The point at which the bypass valve opens is TL. By blowing a portion of the air to the
atmosphere, the compressed air system gets the air that it demands. The compressor avoids
surge because it is still producing a constant air capacity.
Surge Detection
Even though the CPLC controls to prevent surge, it can still occur. Insufficient rise to surge,
rapid changes in system discharge pressure, and various other reasons exist for a compressor
to surge.
Insufficient Rise To Surge T=cold
Rise to surge is the percentage of the

compressor's surge pressure to Rise
discharge pressure (see Figure 10). To T=hot
Surge
When an insufficient rise to surge Discharge
situation exists, small fluctuations in Pressure
the air system demand and ambient
temperature can cause the
compressor to surge.
From Figure 10, when T=cold, there is
sufficient rise to surge. As the ambient Capacity
temperature increases to T=hot, the Figure 10: Rise To Surge
amount of rise to surge decreases
because the discharge pressure is
remaining constant and the natural curve is changing with temperature.
Typically sufficient rise to surge exists when a ten percent rise to surge can be achieved for the
hottest ambients that are expected for the site. If this design criteria is followed, the control
system should be able to prevent surge for variations in air demand and inlet temperature. The
same design methodology applies for changes in cooling water temperature for multi-stage
compressors.
Version 2.24
12 CPLC MANUAL
Changes in System Discharge

Pressure
TL corresponds to a specific constant
discharge pressure; therefore, if the
discharge pressure changes, TL must be
reset to properly control surge. As
shown in Figure 11, when the discharge TL2
pressure is changed from point 1 to 2, a Discharge
Pressure TL1
surge can occur at point 2 if TL is not
reset.
Changes in system discharge pressure
also apply, but more subtly, when the
compressor begins to age. Dirty inlet
filter elements and fouled coolers can Capacity - Mass Flow
change the compressor's natural curve;
so TL should be checked periodically to Figure 11: Changes in Discharge Pressure
prevent surge from an incorrect setting.
Rapid System Demand Changes

When the system demand varies rapidly over a wide range of capacity, the controller may not
react fast enough to open the bypass valve to prevent surge. The CPLC reads discharge
pressure, motor amps, and approximately twenty other pressure and temperature inputs; plus
controls the inlet and bypass valve position. The time required to do all of this approximately
100 milliseconds. When the controller is too slow to react, it is referred to as "driving through
TL". The only prevention for a situation like this is to set TL at a more conservative value. The
only negative implication to this is reduced energy savings, because the bypass valve is opened
early.
Incorrect Instrumentation Output

If the instrumentation, defined in Figure 4, is improperly calibrated or gives inaccurate readings,
the compressor could surge even though the CPLC thinks it should not. Areas of concern are
insufficient power air, incorrect valve transducer calibration, and repeatability of both inlet and
bypass valves. If the valves are being sent signals for specific movements and they do not
respond by moving to the new positions, then the CPLC has very little chance of correctly
controlling surge, or even the discharge pressure.
As discussed earlier, the CPLC uses motor current as the standard method for determining
when to open the bypass valve. The time to begin opening the bypass valve is near TL amps.
The equation,
I× V × η × PF × 3
motor
GHP =
746
indicates that horsepower is directly related to current; it is, but it is also related to voltage. This
is not normally a concern because voltage is primarily constant. However, there are some
locations where extreme voltage variations do exist. In these circumstances, the CPLC cannot
Version 2.24
CPLC MANUAL 13
correctly determine when it reaches TL and a surge can occur. For these applications, an
optional watts transducer can be used to avoid this situation.
How is Surge Detected?

Note that it has been shown that even though the CPLC has surge prevention logic, a surge
can still occur. The CPLC has a surge detection system comprised of a surge pressure
transducer and motor current transformer (see Figure 12). The CPLC senses surge when the
rate of change in last stage discharge pressure and the rate of change in motor current are
greater than the surge sensitivity setpoint value. When this occurs, the CPLC will alarm and
unload the compressor.
CPLC PT Bypass
PT Valve
Pneumatic Tubing
4-20 mA Check
Base
Valve
Control
Module CT Starter
Motor Compressor
Inlet
Valve
4-20 mA
Figure 12: Changes in Discharge Pressure
Surge Reload
When a surge occurs, the compressor will unload. When the surge reload feature is enabled,
the compressor will unload, wait approximately five seconds for the system to stabilize and
automatically reload to the operating pressure. This process will repeat up to three times within
a ten minute period. If the compressor surges four times in ten minutes, the compressor will
remain unloaded until an operator presses the reset button.
Surge Indexing
Since the setting of TL is sensitive to many variables in a compressed gas system, there is
potential for the setting to require adjustment throughout the operation of the compressor.
When TL is set incorrectly, one of two things can happen. When TL is set too high, the
compressor will consume excessive power at MinLoad. When TL is set too low, the
compressor is allowed to go past the surge line and surge occurs. Surge Indexing corrects the
situation when TL is set too low by automatically adjusting TL to a higher value upon a surge.
The indexed setting will remain in effect until TL is manually changed on the Operator User
Interface, or the Reset button is held for more than five seconds. When TL is manually
changed, the Surge Indexing TL is automatically changed to match the new setting and when
reset, the Surge Indexing TL is reset to the Throttle Limit.
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14 CPLC MANUAL
Automatic Starting
NOTE: Most electric motors are only rated for two cold starts or one hot start per hour. It is the
operator’s responsibility not to exceed the electric motor’s limitation. The control system allows
the compressor to be started when the compressor is ready, not the motor.
Remote start and stop through the DH+ port and Auto-Hot Start are the two options for
automatically starting and stopping with the CPLC. With the Auto-Hot Start option a
local/remote selector switch is provided on the device plate.
Communications
Remote starting and stopping can be accomplished through the DH+ communication port in
various ways. See the section on Communications that follows for these options. Again, panel
power must be on, all utilities must be running and permissives satisfied in order for the start-up
to proceed.
Auto-Hot Start
Normally purchased in multiple compressor applications where backup air is required, this
automatic starting option allows the compressor to be started when the system air pressure is
below a user selected set point pressure.
Panel power must be on, all utilities must be running, the LOCAL/REMOTE (AUTO HOT
START ENABLE/DISABLE) selector switch must be in remote mode and all permissives
satisfied in order for the start-up to proceed. Solenoid water valves are provided for each
intercooler to reduce water consumption when the compressor is not running. A post run timer
is also included in the Auto Hot Start logic to de-energize the water solenoid valves twenty
minutes after a compressor trip to allow the oil to cool.
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CPLC MANUAL 15
Oil System Control

The CPLC panel provides control of the prelube pump and lube oil heater in the starting
sequence, during normal operation and after compressor stop or trip.
Prelube Pump
The prelube pump is started when the panel power is on and Seal Air is present. The prelube
pump stops after the compressor start button is pushed and the programmable timer “Start
Time” has expired. The pump does not come on again until the Stop key is pressed, and will
remain on until the panel power is turned off or Seal Air is lost.
Oil Heater
The oil heater is thermostatically controlled. When the oil temperature is below the set point
temperature, the oil heater is energized, above the set point temperature it is de-energized.
The oil heater control does not have any interaction with the microprocessor board and is
designed to operate with the control panel de-energized as long as three phase power is
available.
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16 CPLC MANUAL
Protection and Monitoring

Each CPLC base module has analog inputs, digital inputs, analog outputs and digital outputs
for control, protection and monitoring. These input functions provide the CPLC with information
about the compressor. The CPLC board uses the output functions to communicate to the user
and perform actions like starting the compressor and turning on the prelube pump. All of these
inputs and outputs are required to interface physical actions to and from the electronics.
Analog Functions
An analog function is one in which an electrical signal represents a specific pressure,
temperature, vibration and current input; or valve position output. As these inputs and outputs
fluctuate, the electrical signal to and from the microprocessor board also fluctuates
proportionally to the amount of change.
Analog Inputs
Analog inputs are used for protection, monitoring and control. Every input used for protecting
the compressor is programmed for alarm and trip indication. Each of these functions is pre-
programmed with the function title, engineering units, range, alarm and trip values, so no
configuration is required upon receipt by the customer.
The CPLC uses pressure transmitters to measure pressure, resistance temperature detectors
(RTD) and transmitters to measure temperature, eddy current based vibration transmitters to
measure shaft vibration, and a current transformer to measure the motor current.
The CPLC logic used for the protective alarm and trip functions is as follows: if the actual value
of the input is greater than or equal to the alarm or trip value, indicate the condition. This logic
is used for all inputs except, low oil pressure and temperature where the logic is reversed. To
prevent nuisance alarms and trips, all standard analog inputs use an alternate alarm and trip
value during the stopped, starting, and coasting states. The alternate setpoints cannot be
edited through the Operator User Interface.
Analog Outputs
Analog output functions are for inlet and bypass valve positioning. These are only output
functions. The standard configuration for a CPLC has no input information as to the valve
location. The CPLC calculates the position based upon where the valves are supposed to be
and sends those signals to the valves.
Digital Functions
A digital function is one in which the presence of an electrical signal indicates ON or YES, and
the lack of that signal represents OFF or NO. This is analogous to a light switch that has only
two states, ON or OFF. The term "discrete" is also used instead of digital in many instances.
The term that will be used throughout this documentation shall be digital.
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CPLC MANUAL 17
Digital Inputs
The digital inputs provide status of field switches. Emergency Stop and Low Seal Air Pressure
trip are standard. Any of these inputs can be configured as an alarm or trip. All inputs operate
on 24 VDC power.
Digital Outputs
The digital outputs are used by the CPLC to start the prelube pump, energize the main starter
contacts, indicate that an alarm or trip condition exists, and indicate that the E-Stop has been
pressed. Outputs can operate on 24 VDC power.
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18 CPLC MANUAL
User Interface
OUI (Operator User Interface)
User interface is defined as the means by which people interact with the compressor control
system. The key component of "easy to use" is that most operations are accomplished using
the touch screen of the Allen Bradley 6182 Industrial Computer display.
The CPLC OUI consists of five command buttons (Start, Stop, Load, Unload, and Reset), four
navigation keys (Page Up, Page Down, Info, and Settings), an Edit mode selection key (Enter)
and a Backspace key. These keys in conjunction with the pixel graphics display make up the
user interface to the compressor.
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CPLC MANUAL 19
Command Keys
These keys “command” the compressor to perform actions as specified in the following table.
When any of these keys are pressed the action will be logged in the event log.
Name Function
Starts the compressor.

Start
Engages Modulate or Autodual control

Load mode.
Unloads the compressor.

Unload
Stops the compressor. This button

Stop should be pressed instead of the E-
Stop for normal operation.
Clears all trip latches. Required to be
Reset pressed after a trip condition to restart
the compressor.
Enter Key - Display Operating Mode

The Enter key is used to accept setpoint changes in EDIT mode.
Navigation Keys
FOLDER NAVIGATION
To move among the tabbed folders, simply touch the Folder associated with the desired folder
on the display. The first page of the selected folder will automatically appear in the screen.
PAGE NAVIGATION
To move among each folder’s pages, press the PAGE UP and PAGE DOWN buttons located
on the right side of each page.
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20 CPLC MANUAL
Graphic Display
The Allen Bradley 6182 Industrial Computer allows us to provide a flexible interface between
the user and the compressor. The display has three distinct regions as shown in the diagram
below.
Folders
SYSTEM INFO SETTINGS
System Inlet
Page
Pressure 100.3 Valve 92 Page Folder
up Navigation
Pressure Bypass Buttons
Setpoint 100 Valve 0 Page
Down
Motor
Current 107 Compressor
Status
14 JUL 99 12:00:00
Status Load Selected Page

Bar
Loaded Remote 1/2 Number
Compressor Compressor
Operating Start Unload Load Stop Control
State Location
Command
Keys
Graphics Display Area Definitions
Folder and Page

In the design of this system, it is important to provide much of the information required to
operate and troubleshoot the compressor. The tabbed folder with multiple pages metaphor has
been used to reduce the complexity of traversing at least ten pages of information. The
SYSTEM folder provides information about the compressor system, the INFO folder gives
various types of information about the unit and the SETTINGS folder is used to perform
compressor setup.
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CPLC MANUAL 21
Status Bar
The Status Bar provides four distinct types of information (Compressor Operating State,
Compressor Status, Compressor Control Location and Page Number). This region is always
visible from any folder and page combination.
The Compressor Operating State Field displays the compressor operating state in large text so
that the operator can at a glance determine the compressor’s current operating state. The
possible operating states are Waiting for the power on timer to expire (typically two minutes),
motor Coasting after a stop or trip, Starting (compressor accelerating), compressor Not
Ready to start, compressor Ready to start, Surge Unload (unloaded due to surge), A-D
Unloaded (Autodual unload), compressor is in the process of Unloading, compressor is
Unloaded, MinLoad (compressor operating at the minimum throttle point), MaxLoad (driver is
at high load limit), compressor is in the process of Loading, compressor is Loaded, and Full
Load (inlet valve is 100 percent open).
The Compressor Status Field messages are Trip, E-Stop (emergency stop button pressed),
RMT-Stop (a remote stop has been pressed), Alarm, Unload Selected (the unload key is
pressed), and Load Selected (the load key is pressed).
The Compressor Control Location Field messages are Local or Automatic (automatic starting
is enabled). This indication is provided to indicate to the operator that Auto Hot Start is in
control of the compressor and the compressor may start without the local operator initiating any
commands.
These three fields combine to provide the operator with the necessary information to create a
cursory determination of the status of the compressor. When a more thorough determination is
required, the operator can get additional detail by looking through the other pages in the
system.
The Page Number indicates the current page for the current folder with the number of pages in
the folder. The number of pages is given so that the user always knows where he is in the
system.
Edit (Setpoint Changes) Mode

Setpoints for a particular parameter can be edited by following these steps:
- Touch the Display associated with the value to be edited
- On the pop up pad that opens, use the number keys to enter the new desired value.
Note that the acceptable range for the parameter is given in the pop up pad.
- Press the enter key.
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22 CPLC MANUAL
Navigation Mode
Navigation mode is active when a folder name (SYSTEM, INFO or SETTINGS) is highlighted.
Navigation from folder to folder is accomplished by touching the Function Key for the desired
folder.
SYSTEM Folder INFO Folder SETTINGS Folder
SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS
System
Pressure 105.0 Inlet
Valve 95 SYSTEM
SYSTEM
- PAGE
- PAGE
1
2 Password
Setpoint Changes
* *
Disabled
* *
SYSTEM - PAGE 3
Pressure
Setpoint 105.0 Bypass
Valve 0 SYSTEM
SYSTEM
- PAGE
- PAGE
4
5
Language Units
CONFIGURE INFO - PAGE 1
Motor
Current 323.4 SCREEN INFO -
INFO -
PAGE 2
PAGE 3
English
Spanish
psig
kg/cm2
degF
degC
mils
mils
Running Hours: 11445 23JUL97 12:00:00
Load Selected
Loaded Remote 1/4 Loaded Load Selected
Remote 1/3 Loaded Load Selected
Remote 1/6

Stage# Pressure Temperature Vibration Event Name Date Time High Load Limit (HLL) 400.0
1 30 95 0.25 1 Low Oil Pressure Trip 970720 09:18:44 Throttle Limit (TL) 100.0
2 106 93 0.22 2 Low Oil Pressure Alarm 970720 09:18:43
3 Reset key pressed 970720 09:18:34 Surge Indexing Enabled
Oil 18 115 4 Low Oil Pressure Trip 970720 09:08:43 Surge Indexing TL Increment 1.0
Water 80 5 Low Oil Pressure Alarm 970720 08:58:23 Surge Indexing TL 100.0
6 Load key pressed 970720 08:24:01
Surge Reload Enabled
7 Start key pressed 970720 08:23:12
8 Power up 970720 08:18:33 Surge Sensitivity 9
Load Selected
Loaded Remote 2/4 Not Ready Trip
Remote 2/6
Digital Inputs PB IT
Starter Feedback Active Power On Hours 12338 Inlet Valve
E-Stop Pressed Running Hours 11445 Pressure 10 0.5
Loaded Hours 11223 MinLoad (TL) 25 0.5
Low Seal Air Trip Number of Starts 35
MaxLoad (HLL) 100 0.5
Bypass Valve
Pressure 10 0.5
Load Selected
Remote 3/6
SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS

Digital Outputs
Control Mode
Prelube Pump Running
Manual
CR1
Modulate
Remote Trouble
Autodual
Reload Percent 98
Unload Point (BV % Open) 1
Unload Delay Time 1
Load Selected
Remote 4/6
Start Timer 20
CT Ratio 60
Inlet Unload Position 15.0
Setpoint Ramp Rate 5.0
FOLDER NAVIGATION Loaded Load Selected

Remote 5/6
To move among the tabbed folders, touch the Function Key associated with the desired folder
tab. SYSTEM INFO SETTINGS
Alarm Trip
PAGE NAVIGATION Stage 1 Temperature 120 125
To move among the pages, press the PAGE UP-F8 and Stage 1 Vibration 0.80 1.00
Stage 2 Temperature 120 125
PAGE DOWN-F16 buttons. Stage 2 Vibration 0.75 0.95
Oil Pressure 18 16
High Oil Temperature 120 125
Low Oil Temperature 100 95
Load Selected
Loaded Remote 6/6
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CPLC MANUAL 23
SYSTEM Folder
The SYSTEM folder provides information about the compressor system. The number of pages
in this folder is at least four, but could be more for two stage machines with special analog
options purchased or for compressors with three stages
or more.
This page shows the main compressor operating
System
Pressure 105.0 Inlet
Valve 95 parameters, running hours, date and time. The System
Pressure
Setpoint 105.0 Bypass
Valve 0 Pressure and Pressure Setpoint are in units as defined
Motor
Current 323.4 by the Settings page, Motor Current is in Amps and
Running Hours: 11445 23JUL97 12:00:00 valve positions are in percent open. Pressure Setpoint,
Load Selected
Loaded Remote 1/4 can be changed by pressing the associated Function
System Pressure Page Key to get into Edit Mode, when manual is enabled, the
valve positions can also be edited.
The Analog Input page provides the actual value for each
stage pressure, temperature and vibration, oil pressure SYSTEM INFO SETTINGS
and temperature. If additional analog inputs have been Stage# Pressure Temperature Vibration
purchased or 1
2
30
106
95
93
0.25
0.22
more stages Oil 18 115

exist as Water 80
Digital Inputs
standard, it is
Starter Feedback Active likely that an Load Selected
E-Stop Pressed
additional page
Loaded Remote 2/4
Low Seal Air Trip
Analog Input Page
or pages will be
added. The units
Load Selected are as defined by the Settings page. There are no
Loaded Remote 3/4
changeable setpoints on this page.
Digital Input Page
The Digital Input page shows the current state of the
digital (discrete) inputs for the system. The number of
inputs will vary depending upon the number of optional inputs purchased. A check in the box to
the left of the text indicates a TRUE condition; whereas no check indicates a FALSE condition.
For example, a check mark in the “E-Stop Pressed” boxed means that the Emergency Stop
push button has been pressed. It is possible to have multiple Digital Input pages. There are no
changeable setpoints on this page.
The Digital Output page is similar to the Digital Input
page except that it shows the current state of the digital SYSTEM INFO SETTINGS
(discrete) outputs for the system. The number of Digital Outputs
Prelube Pump Running
outputs will vary depending upon the number of optional CR1
items purchased. A check in the box to the left of the text Remote Trouble
indicates a TRUE condition; whereas no check indicates

a FALSE condition. It is possible to have multiple Digital
Output pages. There are no changeable setpoints on Loaded Load Selected
Remote 4/4
this page.
Digital Output Page
The SYSTEM folder’s four pages give the current
operating status for the compressor. The User is always within two keystrokes of all operating
parameters.
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24 CPLC MANUAL
INFO Folder
The INFO folder contains the OUI key map, the compressor event log and the hour meters.
There are no changeable setpoints in this folder.
The OUI key map will be the default page on power up. The keys are labeled in English and
the local language, depending upon the current
language selected.
SYSTEM INFO SETTINGS The Event Log details the last 100 “events” that have
Event Name Date Time
1Low Oil Pressure Trip
occurred. Each “event” has a date and time stamp.
970720 09:18:44
2
3
Low Oil Pressure Alarm
Reset key pressed
An “event” is defined as any Alarm, Trip, Command
970720 09:18:43
970720 09:18:34
4
5
Low Oil Pressure Trip
Low Oil Pressure Alarm
(Start, Stop, Load, Unload, Reset, and Acknowledge)
970720 09:08:43
970720 08:58:23
6
7
Load key pressed
Start key pressed
Key Press, Remote Command executed,
970720 08:24:01
970720 08:23:12
8Power up Communication Command executed, E-Stop pressed,
970720 08:18:33
Trip
Not Ready Remote Module Power Up, Module Power Down, Surge
2/3
Event Log Page

Unload, MinLoad Reset, MinLoad Clamp and Auto
Start/Stop when the Auto Hot Start Function is
purchased. First-out indication for all Alarms and Trips
is satisfied by this log. Any time an Alarm or Trip is indicated on the Status Bar, the detail for
that fault is included here.
The event labeled as “1” is the newest event and “100” is the oldest event. Once the list is full,
each new event knocks off the last event.
Events are shown in a list on Info page 2. To see older events, use the Up/Down buttons to
scroll through the list. Any time a Trip occurs, the system will send the display to the first Event
Log page.
The next page shows the hour meters and number of
starts. Power On Hours is the time that the panel
power has been on. The Running Hours is the amount Power On Hours
Running Hours
12338
11445
of time that the compressor has been operating Loaded Hours
Number of Starts
11223
35
between each start and stop sequence. The Loaded
Hours is the amount of time that the compressor has
been running and not running unloaded. It can also be Load Selected
defined as the number of hours that the inlet valve is Loaded Remote 3/3
not in the Inlet Unload Position. The Number of Hour Meters Page
(Compressor) Starts is self-explanatory.
NOTE: Most electric motors are only rated for two cold starts or one hot start per hour. It is the
operator’s responsibility not to exceed the electric motor’s limitation. The control system allows
the compressor to be started when the compressor is ready, not the motor.
SETTINGS Folder
The SETTINGS folder is used for compressor setup. In this folder, the User will enter
performance and control operating parameters, analog health monitoring settings for Alarm and
Trip conditions, control mode selection, setpoint changes, password, and user interface
language. This folder is the primary location for editing setpoints.
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CPLC MANUAL 25
The Password is used for determining whether

SYSTEM INFO SETTINGS Setpoint Changes can be made. The Password takes
four numbers. If the Password is entered properly,
Password * * * *
Setpoint Changes Disabled Setpoint Changes will be enabled; otherwise, they are
Language Units disabled. This enabling and disabling applies to all
English psig degF mils changeable setpoints except, Pressure Setpoint,
Spanish kg/cm2 degC mils
Throttle Limit, language selection and the Password,
Load Selected
Loaded Remote 4/4 these items are always modifiable.
Password, Language and Units Page
Each control system is shipped with English language
and standard units of measure. The pressures are
displayed in units of psig, temperatures in units of
degF and vibrations in units of mils. A second set can be provided to be localized for the
customer. Language support will be provided as standard for English, all European languages
required for the CE Mark, and Chinese. Others will be available as required and translations
can be obtained. This system has the ability for any language because of the graphics display.
Asian character support will require additional screens because these characters require four
times the number of pixels. There are no limitations
on the units of measure. Each analog input has its
own scaling factor and offset. SYSTEM INFO SETTINGS
The Anti-surge Settings Page has all of the settings High Load Limit 400.0
Throttle Limit 100.0
for controlling surge conditions. High Load Limit Surge Indexing Enabled
(HLL), Throttle Limit (TL), Surge Indexing TL Surge Indexing TL Increment 1.0
Surge Indexing TL 100.0
Increment and Surge Indexing TL are all in units of Surge Reload Enabled
power (normally amps). Surge Sensitivity 9
Load Selected
The High Load Limit setting (HLL) prevents the

Loaded Remote 4/6
compressor driver from overloading. Anti-Surge Settings Page
IMPORTANT: This value should not exceed the value

determined in the section titled Setting High Load
Limit (HLL). Failure to set this properly could result in damage to the motor.
The checkbox for Surge Indexing Enabled allows the user to turn on or off Surge Indexing.
When shipped, Surge Indexing is disabled. To turn it on, move to this feature and press the up
or down arrow key. This action will toggle the value between on and off. To reset Surge
Indexing, hold the reset key for at least five seconds. The indication that it has been reset will
be in the event log. The event message “MinLoad Reset” will be displayed. Another indication
will be that the Throttle Limit value will equal the Surge Indexing TL value.
NOTE: Surge Indexing TL is the power value used to determine when the bypass valve opens.
Surge Indexing TL will always be equal to or greater than the Throttle Limit value.
IMPORTANT: When Surge Indexing is enabled and the compressor surges several times, the
compressor will begin bypassing air sooner than when Surge Indexing is disabled. You should
periodically reset Surge Indexing to prevent excessive air bypass.
The Surge Reload Enabled checkbox allows the user to turn off or on the Surge Reload feature.
This is the feature that automatically reloads the compressor after a surge.
The Surge Sensitivity setting has a range from one (1) to ten (10) where one is not sensitive (a
“soft” surge condition could exist without being identified) and ten is very sensitive (a “soft”
surge condition would be identified). We ship the machine with a default value of nine (9). This
setting will pick up most all surge conditions.
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26 CPLC MANUAL
IMPORTANT: Repeated surging can cause damage to the compressor; therefore, use caution
when desensitizing this setting.
The Control Parameters Page is used for matching the
control system to the local application. The
PB IT
Inlet Valve Pressure 10 0.5
Proportional Band (PB) and Integral Time (IT) settings
Bypass Valve Pressure 10 0.5 are provided for both the inlet valve, bypass valve,
MinLoad 25 0.5
MaxLoad 100 0.5
minimum load and maximum load control regions.
This gives the controller precise control for modeling
Load Selected
the air system over the entire operating range of the
Loaded Remote 1/6 compressor. The PB setting has no units and the IT
Control Parameters Page setting is in units of repeats per second. Each of these
values may be changed as needed.

The Control Mode Selection Page allows the User to
Control Mode
select between the two standard control modes, Manual
Modulate and Autodual. This selection process is Modulate
Autodual
performed with the radio button selector. To change Reload Percent 98
Unload Point (BV % Open) 1
the selection, press the Up or Down arrow key. Unload Delay Time 1
Load Selected
Reload Percent, Unload Point and Unload Delay Time Loaded Remote 3/6
are all changeable setpoints for Autodual control.
Control Mode Selection Page
Unload Delay Time is in units of seconds.
Manual valve control is enabled by checking the
Manual checkbox. In this mode, the inlet valve may be stroked when the compressor is not
running, and the bypass valve can stroked at any time. If a surge condition occurs while
manually controlling these valves, the CPLC will
automatically take over the valves.
Start Timer 20
This page contains miscellaneous control settings.
CT Ratio 60 Additional settings will be added for “special” features.
Inlet Unload Position 15.0
Setpoint Ramp Rate 5.0 Start Time is the length of time prior to enabling the
loading of the compressor. Typically, this time
includes the starter transition time (Y-D time). When
Load Selected
Loaded Remote 5/6 this timer expires, the prelube pump will turn off and
the compressor is enabled for loading.
Miscellaneous Settings Page
CT Ratio is the ratio of the current transformer primary
to the secondary; i.e., if the CT primary winding is 300
and the secondary winding is 5, then the CT Ratio is 60. Alarm Trip
The Inlet Unload Position is the position of the inlet valve Stage 1 Vibration 0.80 1.00
when in the unload state. This value is in percent of inlet Stage 2 Vibration 0.75 0.95
valve open and has a range of 0 to 50. Oil Pressure 18 16
High Oil Temperature 120 125
Low Oil Temperature 70 65
Setpoint Ramp Rate is used to prevent system pressure Load Selected
overshoot during compressor loading. The units of Loaded Remote 2/6
measure are one pressure unit per 0.1 seconds. Alarm and Trip Settings page
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CPLC MANUAL 27
The Alarm and Trip Settings Page provides the means for changing the analog health
monitoring values. The number of inputs varies depending upon the number of compression
stages and optional inputs. Additional pages will be added as needed after this page. All line
items are changeable for the Alarm and Trip setpoints.
General Sequence of Operation
To Start and
Load a
Compressor
1
Press
Reset
2
Look for
"Ready"
Press
3
Start
4 Press
Load
To Unload and
Press Unload Press
Stop a Wait 20 Sec. Stop
Compressor
5 6
Indicator, Switch and Light Layout

In addition to the CPLC OUI there may be a variety of indicators, switches, and lights mounted
on the control panel door. In conjunction with the CPLC OUI these devices make up the User
Interface for the CPLC. A typical device layout consists of the following lights, push-buttons,
selector switches.
Lights
The lights provided are the green CONTROL POWER ON light, which is integral with the
control power switch, the amber PRELUBE PUMP RUNNING light, and the red TROUBLE
INDICATION light.
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28 CPLC MANUAL
Push Buttons
The red EMERGENCY STOP push button stops the compressor any time that it is pressed.
This push button is used to initiate a stop in the case of an emergency.
Switches
The POWER ON selector switch turns the panel power on or off.
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CPLC MANUAL 29
CPLC Tuning Procedures

When commissioning a new compressor, troubleshooting an existing compressor, or tuning a
system, the following procedures may be required. The procedures are performed, and any
changes required are made through the CPLC OUI. For instructions on how to use the OUI
refer to the section titled User Interface. The following figure will be referenced in the
procedures.
PT
1 PT Bypass
2 Valve
Pneumatic Tubing
Block
Valve
4-20 mA Check
Base
Valve
Control
Module CT Starter
Motor Compressor
Plant Air System

Inlet
Valve
4-20 mA
Inlet Filter
Figure 13: Plant Air System
Setting High Load Limit (HLL)

The High Load Limit Setpoint keeps the motor within the allowable current range. To determine
the value for HLL, an Adjusted Service Factor (ASF) is multiplied by the motor full load amps
(FLA). The (ASF) is found by obtaining the motor service factor from the motor nameplate and
selecting the adjustment factor from the table below. The motor full load amps is found on the
motor nameplate.
Motor Service Factor Adjusted Service Factor
1.15 1.05
1.25 1.10
Example: HLL = FLA X ASF

FLA: 134 Amps
motor service factor: 1.15
HLL: 140
Setting Throttle Limit
Throttle Limit establishes the minimum flow through the machine when loaded, it is the
maximum point of inlet valve throttling. If system demand is below this throttle point, the
compressor must bypass air or unload. If flow were allowed to go below TL, the machine would
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30 CPLC MANUAL
eventually hit the surge line and surge. By stopping inlet valve throttling at TL the machine is
kept out of surge. To find the TL setting, the machine is run into the surge line, and the value
of load (amps, kilowatts, SCFM) at surge is recorded. The recorded value is then incremented
by five percent and set as the value for TL.
1. Before continuing this procedure, verify the following:
a) The inlet and bypass control valves have been calibrated.
b) The machine is running unloaded.
c) The block valve at the inlet to the plant air system (Figure13) is closed.
d) The pressure setpoint is set to the pressure at which the machine is going to operate.
2. Set initial Throttle Limit estimates.
a) In the Settings Folder, select the Edit Data cell for Throttle Limit.
b) Increment or decrement the value to achieve a value of approximately 95% of full load amps.
3. Preset the manual bypass valve position to 100.
a) On the OUI select the Settings Folder and enable manual valve control by highlighting the
manual check box. NOTE: When Manual is enabled, both control valves can be positioned
while stopped, while only the Bypass Valve can be positioned when Loaded.
b) Switch to the System Folder Page 1.
c) Use the appropriate Function Key to select the bypass valve.
d) Increment the value to position the valve to 100 percent.
4. Load the compressor by pressing the Load Key.
5. Find the throttled surge point.
a) Slowly decrement the bypass valve position until the last stage discharge pressure equals the
pressure setpoint.
b) Allow the system to stabilize at MinLoad. It the system does not stay at MinLoad, slightly
decrement the valve position to force the machine to throttle to MinLoad.
c) Decrement (TL) 2%.
d) Verify the last stage pressure equals the pressure setpoint and adjust the bypass valve position
if necessary.
e) Repeat 5.2-4 until the compressor surges.
6. Increase Throttle Limit by five percent.
7. Exit Throttle Limit editing by pressing the Enter Key.
8. Unload the machine.
9. Disable manual valve control by unchecking the manual check box.
Setting Surge Indexing TL Increment

When Surge Indexing is enabled, the TL increment value is the amount added to the Surge
Indexing TL upon a surge. The Surge Indexing TL will stop being incremented when and if the
value reaches HLL.
Version 2.24
CPLC MANUAL 31
Setting Surge Sensitivity

The Surge Sensitivity setting should be set sensitive enough to detect a surge, yet not trigger
on spurious noise in the system. To set the surge sensor the machine is forced to surge by
running the machine at MinLoad and the Throttle Limit setpoint is dropped until the machine
audibly surges. The process is repeated until the correct setting is found.
1. Before continuing this procedure, verify the following:
a) The plant can tolerate a pressure disturbance when the machine surges.
b) Surge Indexing is disabled.
c) Surge Reload is disabled.
d) The pressure setpoint is set to the pressure at which the machine is going to operate.
e) The machine is running unloaded.
2. Set the initial Surge Sensitivity setting to 9.
a) In the Settings Folder, push the Edit Data key for Surge Sensitivity.
b) Increment or decrement the value to achieve a setting of 9.
3. Press the Load Key.
4. Run the compressor at MinLoad at pressure. The machine can be forced to MinLoad and
pressure by either:
a) Running the plant at a higher pressure than pressure setpoint.
b) Decreasing load in the plant.
c) Verify the compressor is at pressure by observing the last stage pressure on Page 2 of the
Settings Folder.
5. Find the throttled surge point.
a) Select the Throttle Limit cell in the Settings Folder and slowly decrement the value until the
machine surges. Typically the machine will make a puffing or popping noise upon surge, this is
your indication surge has occurred.
6. Press the Unload Key.
7. Determine if Surge was recorded.
a) Inspect the Status Bar. If the message Surge Unload is displayed surge was recorded, if the
message is not displayed surge was not recorded.
8. Check the Surge Sensitivity setting.
a) If the surge was recorded, the setting may be correct or the Surge Sensor may be too sensitive,
skip to the too sensitive step which follows.
b) If the surge was not recorded, the setting is not sensitive enough, skip to the not sensitive
enough step which follows.
9. Surge Sensor too sensitive.
a) Select the Surge Sensitivity Setting in the Settings Folder.
b) Decrease the value for Surge Sensitivity by 0.1.
c) Press the Reset Key.
d) Skip to step 11.
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32 CPLC MANUAL
10. Surge Sensor not sensitive enough.

a) Select the Surge Sensitivity Setting in the Settings Folder.
b) Increase the value for Surge Sensitivity by 0.1.
c) Press the Reset Key.
11. Repeat the procedure until the Surge Sensitivity setting is found which just catches a surge
but does not miss a surge.
a) Return to step 3.
12. Restore all values but Surge Sensitivity.
Tuning Stability
The CPLC controls stability with four Proportion Integral Derivative (PID) control loops. When
the machine is running above the MinLoad point and below the MaxLoad point, pressure is
regulated with the Inlet Valve control loop. When the machine is running at the MinLoad point,
pressure is regulated with the Bypass Valve control loop and motor current is regulated with the
Throttle Limit control loop. When the machine is running at MaxLoad motor current is regulated
with the High Load Limit control loop. For each PID loop, Proportional and Integral parameters
are used to stabilize the system, the derivative term is not editable via the OUI. For a definition
of the parameters and their effect on stability, refer to the section titled “How does Constant
Pressure Modulation Work.” The proportional and integral terms are labeled by their respective
loops, Inlet Valve, Bypass Valve, Throttle Limit, and High Load Limit.
Calibrating the Control Valves

The purpose of this procedure is to position the inlet and bypass valves by opening and closing
each valve from the CPLC analog outputs. The valves should be adjusted to physically
correspond with the valve positions displayed on the OUI.
1. Stop the compressor. NOTE: Performing this procedure while the compressor is
operating may cause serious damage.
2. On the OUI enable Setpoint changes by entering the password on the Settings Folder.
3. Verify the OUI status bar displays “Ready” or “Not Ready.”
4. On the OUI select the Settings Folder and enable manual valve control by highlighting the
manual check box. NOTE: When Manual is enabled, both control valves can be
positioned while stopped, while only the Bypass Valve can be positioned when Loaded.
5. Switch to the System Folder Page 1.
6. Use the appropriate Function Key to select the valve requiring positioning.
7. Use the keypad to increment and decrement the valve position sent to the valve. NOTE:
For the Inlet and Bypass Valves the displayed position corresponds to percent open.
8. Disable manual valve control by blanking the manual check box.
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CPLC MANUAL 33
Autodual Control Settings

For a detailed definition of the Autodual control mode, refer to the section titled “Control
Methodology.” The procedure for tuning Autodual requires the setting of the following
variables:
Unload Point (Bypass Valve % Open)

The Bypass Valve Unload Point is selected to correspond to the check valve closing as shown
in Figure 13, since at this point the machine is not supplying the system. This position is found
by running the machine at MinLoad and monitoring the System and Discharge pressures.
When the System pressure is 5% of setpoint greater than the last stage pressure as shown in
the System Folder, the check valve is assumed to be closed.
Example: Given the following conditions the Unload Point would be set at 35.
Variable Case 1 Case 2
Pressure Setpoint 100 100
PT1 (system pressure) 100 100
PT2 (last stage pressure) 100 94
Bypass Valve Position 13 35
Assumed check valve position Open Closed
1. Run the machine at MinLoad by elevating the system pressure no more than 3% or
decrease the pressure setpoint no more than 3%.
2. Monitor the difference between the Discharge and System Pressures by using the System
Folder Pages 1 and 2.
3. When the Discharge Pressure is approximately 5% of setpoint less than the System
Pressure record the Bypass Valve Position.
4. Enter the recorded Bypass Valve Position as the Unload Point.
Unload Delay Time (seconds)

The Unload Delay Timer should be set to prevent unloading during short excursions through the
Unload Point. Typically, when the check valve closes, system demand requires the check valve
to open again soon thereafter due to the demand being on the verge of requiring the
compressor. If the compressor had unloaded when the check valve first closed, a reload would
be immediately required and the machine would go through the automatic unload/load cycle
until demand was consistently low enough to keep the check valve closed. For this reason, the
timer is used to inhibit the unload until demand has consistently remained low.
1. Run the compressor at MinLoad by either:
a) Running the plant at a higher pressure than pressure setpoint.
b) Shedding load in the plant.
2. Determine delay time.
a) Observe time when bypass valve first hits unload point.
b) Observe time when bypass valve remains below unload point, typically less than 300 seconds.
c) Enter the time difference as the Delay Time.
Version 2.24
34 CPLC MANUAL
Reload Percent
The Reload Percent determines the System Pressure at which the machine will automatically
load into the system. This value should be set according to the customer’s minimum
acceptable system pressure.
Setting the Start Time

The Start Time is set to the transition time of a built-in reduced voltage starter or the
acceleration time of a customer supplied starter. This procedure requires the Inlet Unload
Position to have been set.
1. Initially set the Start Time to 25 Seconds. Caution: Damage to the starter contacts could
result if starter transition occurs before the compressor is up to full speed.
2. Stop the compressor.
3. On the OUI record the time and press the start button.
4. Wait for the compressor to stop accelerating and again record the time.
5. Calculate the difference between the two values and enter as the Start Time.
Setting the CT Ratio

Locate the CT and find the rating which is typically printed on the side of the CT. Divide the
primary by the secondary and enter the value as the CT Ratio.
Example: CT is printed with 600:5, the value entered is 120.
Inlet Unload Position

The purpose of this variable is to set the inlet valve position when the machine is running
unloaded. For a description of the Unloaded state refer to the section titled “Unload.”
1. If the inlet valve is a butterfly type, enter an initial value for Inlet Unload Position of 15. If
the inlet valve is an inlet guide vane type, enter an initial value for Inlet Unload Position of
5.
2. Start the machine. If during startup the motor trips on overload, is drawing what is
considered excessive amperage or sounds labored, stop the machine and decrease the
Unload Position by 2.
3. Run the machine in the Unloaded state and monitor the first stage pressure.
4. Adjust the Unload Position to achieve 1 PSIG on the first stage discharge, or until a
positive pressure is felt at the first stage trap bypass.
5. If the inlet air temperature is relatively cold, increase the setting 2%, this will accommodate
hot day operation.
Setting Set Point Ramp Rate

Setpoint ramp rate determines the rate at which the machine transitions from unloaded to
loaded. The setting should be set as high as possible without creating excessive overshoot
when the machine enters the system.
1. Verify the machine is unloaded by the “Unloaded” message in the OUI Status Bar.
Version 2.24
CPLC MANUAL 35
2. Determine overshoot.
a) Load the machine.
b) Monitor the pressure overshoot.
3. If overshoot is excessive.
a) Decrease the Setpoint Ramp Rate.
b) Repeat step 2.
4. If overshoot is satisfactory and time to load is excessive.
a) Increase the Setpoint Ramp Rate.
b) Repeat step 2.
5. If overshoot is satisfactory and time to load is satisfactory the Setpoint Ramp Rate is
correct.
Alarm and Trip Settings

The values for vibration, temperature, pressure etc. alarm and trip setpoints are located on the
electrical schematic. These values determine when the controller will indicate an alarm or trip
condition.
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36 CPLC MANUAL
Troubleshooting
The following procedures provide direction on troubleshooting the CPLC System, control panel,
and associated instrumentation. Faults are either Event Logged, which means the fault is
displayed in the INFO Folder on the OUI, or Non-Event Logged. The distinction helps to
expedite the troubleshooting process.
When a control system fault is suspected, the following diagram is used to categorize the fault.
The section following the diagram breaks each category down into specific items which can
cause a particular fault.
A CONTROL
SYSTEM FAULT IS
SUSPECTED
THE FAULT IS LOGGED IN THE FAULT IS NOT LOGGED IN

THE EVENT LOG. THE EVENT LOG
COMPRESSOR RELATED I/O FAULT CONTROL PROBLEMS
Compressor fails to Load, fails to trip, fails to

Temperature, pressure, load, valve, etc.
Event correctly indicates a problem. start, surging, etc.
readings incorrect.
(Refer to the compressor operating manual) (Refer to the CMC Tuning Procedures section)
(Refer to the Input/Output (I/O) System)
STABILITY PROBLEMS
Inlet valve, bypass valve, or control variables

(mass flow, system pressure, Kw, amps) are
unstable.
(Refer to the CPLC Tuning Procedures Section)
Figure 14: Troubleshooting Tree
Version 2.24
CPLC MANUAL 37
Troubleshooting Example
The following example will serve as a guide to follow when troubleshooting specific problems.
Problem Indication: INFO
SYSTEM SETTINGS
Plant air pressure is low and the CPLC OUI is found Event Name Date Time
1 Low Oil Pressure Trip 970720 09:18:44
as shown. 2 Low Oil Pressure Alarm 970720 09:18:43
3 Reset key pressed 970720 09:18:34
4 Low Oil Pressure Trip 970720 09:08:43
5 Low Oil Pressure Alarm 970720 08:58:23
6 Load key pressed 970720 08:24:01
7 Start key pressed 970720 08:23:12
Probable Cause Determination: 8 Power up 970720 08:18:33
Trip
1. The machine Tripped on Low Oil Pressure, which Not Ready Remote 2/4
means the oil pressure was below the Oil

Pressure Trip Value. Figure 14 leads to the assumption that the problem is either
compressor or I/O related, because the fault is Event Logged. There are two most likely
causes for this event.
a) Actual oil pressure is low.
i) The prelube pump is found to be running and installation of a calibrated
pressure sensor shows the actual oil pressure to be above the Oil Pressure
Trip Value. Therefore, the mechanical system is operating correctly.
b) The value read by the CPLC is incorrect.
i) The oil pressure value displayed on Page 2 of the System Folder shows the oil
pressure to be below the test sensor reading and erratic. Additionally, all other
analog input readings are normal and not erratic. Therefore, the problem can
be isolated to the oil pressure analog input circuit.
ii) The Pressure Monitoring System (PMS) troubleshooting table, found in the
following section “The Pressure Monitoring System” identifies the probable
cause for an erratic reading as a loose wire/terminal/connector and specifies
Troubleshooting Procedure PMS #1 and 2 as the appropriate procedures.
Trouble Procedure Execution:
Step 1 of PMS #1 requires disconnecting of the pressure transducer (PT) wires at the
transmitter. When this step is performed, one of the connections is found to be intermittent.
When the poor connection is corrected, the erratic reading on the OUI becomes solid.
Version 2.24
38 CPLC MANUAL
Input/Output (I/O) System

Vibration Monitoring System (VMS)
Description:
The vibration transmitter is used to convert the proximity probe signal into a 4 -20 mA signal
which is monitored by the CPLC. The system is based on a 15 foot (4.575 m) total electrical
length.
Component specifications:
Transmitter:
• 100 mv/mil = 0.1 volt per 0.001 in (0.0254 mm)
• 4 mil (0.1016 mm) scale
• 4-20 mA output
Probe:
• Gap setting 0.030 to 0.060 in (0.762 to 1.524 mm), 0.050 in (1.27 mm) is nominal gap
• Probe gap corresponds to 3 to 6 volts VDC, 5 VDC nominal
• Probe ohmic value 7-12 ohms
Troubleshooting:
The following table identifies typical problems, probable causes, and appropriate procedures for
verifying the probable cause:
Typical Problem Probable Cause Troubleshooting Procedure
Zero OUI readout Open circuit/cable disconnected VMS #2, 3, 4
(when compressor is Loss of power to transmitter VMS #1
running)
Malfunctioning transmitter VMS #2
Transmitter not calibrated VMS #2
Erratic OUI readout Loose wire/terminal/connector VMS #2, 3, 4
Incorrect OUI readout Any VMS #1, 2, 3, 4, 5
Version 2.24
CPLC MANUAL 39
Checking Vibration Transmitter Power VMS #1

1. Connect a DC voltmeter to the
+ and - terminals of the
transmitter.
XXXXX XXXXX XXXXX
2. With control power on, there XXXXX XXXXX XXXXX
should be approximately 24 VDC mA

VDC present at the terminals.
3. If approximately 24 VDC is not
VAC
present; see the section titled Ω
mA COM V Ω
“Control Power System.”
NOTE: Under no circumstances To BCM J1 Connector
(See electrical
should the vibration transmitter zero schematic for point).
or span be adjusted. Calibration of

4 TO 100
20 mA mV/MIL
Vibration
the vibration transmitter requires + -
COM
NON-CONTACT VIBRATION
TRANSMITTER
TEST
transmitter
special tooling and calibration PART NO. 1X9247
S/N
4
XXXXXX
fixtures. Contact the factory if

20 mA =
100
PROBE
calibration is required. INGERSOLL RAND
Checking Vibration Circuit VMS #2

1. With control power on, check the dc
voltage at the COM and TEST terminals
on the transmitter. A reading of 3 to 6
VDC should be present [this corresponds XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
to a 0.030 to 0.060 inches (0.762 to VDC mA
1.524 mm)] probe gap.

2. If less than 3 volts is present the probe VAC Ω
gap may be incorrect, or a short circuit mA COM V Ω
may exist. Check the cable connections

and cable.
3. If more than 6 volts is present the probe
Compressor casing
gap may be incorrect, or an open circuit
may exist. Check the cable connections
and cable.
4. If no voltage exists, the transmitter may
Vibration transmitter
be faulty. Remove control power and 4 TO
20 mA
100
mV/MIL
swap connections with another + -

COM
NON-CONTACT VIBRATION
TRANSMITTER
TEST
transmitter and test. PART NO. 1X9247
S/N
20 mA =
4
XXXXXX
100 Vibration probe

PROBE
Probe extension cable

INGERSOLL RAND
Version 2.24
40 CPLC MANUAL
Check the Vibration Probe, and Cable VMS #3

1. Turn control power off and disconnect Probe connector
the probe extension cable from the

transmitter. XXXXX XXXXX XXXXX
2. Check resistance of the extension cable

XXXXX XXXXX XXXXX
VDC mA
Probe cable
and probe together, the reading should
be 7 to 20 ohms. VAC Ω
mA COM V Ω
Compressor
casing
Connect test lead

to outer shell.
Connect test lead

to inner pin.
Probe extension
cable
Vibration probe
Checking the Vibration Probe VMS #4

1. Turn control power off and disconnect
Connect test lead
the probe extension cable from the to outer shell.
Probe connector
transmitter.
2. Check resistance of the probe alone, the XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
reading should be 7 to 12 ohms. VDC mA

Probe cable
VAC Ω
mA COM V Ω
Vibration probe
Connect test lead

to inner pin.
Version 2.24
CPLC MANUAL 41
Check the BCM VMS #5

1. With control power off connect a 4 to-20 mA simulator at the input points of the
suspected faulty device at connector A/I input, slot 4 (see electrical schematic for
connection points).
2. Turn control power on and vary the signal. If the value tracks according to the table
below, the wiring is faulty.
Verify the connector at J1 is fully seated. If the value does not track correctly, the BCM
may be faulty.
Allen Bradley Analog Input Card
Analog Inputs, (4-20mA)
4-20 mA SURCE OR
2 WIRE SIMULATOR
mA OUT
2 WIRE
OFF
MODEL CL-XXX
BATTERY
CHECK
00.0% - 100%
XXXXXX
555
LOOP
ON
00.0%
100%
DIAL
Conversion chart
mA percent Mils mA
(from simulator) (on OUI) (from simulator)
100% 4.0 20
50% 2.0 12
0% 0.0 4
Version 2.24
42 CPLC MANUAL
Temperature Monitoring System (TMS)

Description:
An RTD (Resistance Temperature Detector-2 Wire) with external transmitter is used by the
CPLC for temperature monitoring. An RTD resistance (ohmic value) varies with temperature.
The resistance is converted to a 4-20 mA signal by a transmitter for monitoring by the CPLC
analog input channel.
Component specification:
Probe:
• 100 ohm Platinum resistance at 32 degF (0 degC). Two types are used:
Transmitter:
• The transmitter may be mounted in the RTD connection head fitting or in the control panel
enclosure. The transmitter is supplied 24 VDC and outputs 4-20mA over a fixed range of
either 0 to 200 degF (-17.7 to +93.3 degC) , or 0-500 degF (-17.7 to +260 degC).
Troubleshooting:
Typical Problem Probable Cause Troubleshooting
Procedure
High OUI readout High resistance connection TMS #4
Transmitter not calibrated TMS #3
RTD failure TMS #2
Transmitter failure TMS #3
Low OUI readout Transmitter failure TMS #3
RTD failure TMS #2
Transmitter not calibrated TMS #3
Erratic OUI readout Loose terminal connection TMS #4
RTD internal wire fault TMS #2
Transmitter failure TMS #3
Incorrect OUI readout Transmitter not calibrated TMS #3
RTD or transmitter failure TMS #2, 3
Any TMS #1, 2, 3, 4
Version 2.24
CPLC MANUAL 43
Checking for Power to the Temperature Transmitter TMS #1

1. Disconnect the wires at terminals #1 and #2 on the transmitter and connect a voltmeter
to these wires.
2. With control power on, there should be approximately 24 VDC present at the terminals.
3. If approximately 24 VDC is not present, see the section titled “Control Power System.”
XXXXX XXXXX XXXXX
XXXXX XXXXX XXXXX
VDC mA
123 4
VAC Ω
mA COM V Ω
RTD
Temperature transmitter
Version 2.24
44 CPLC MANUAL
Checking for a Faulty RTD TMS #2

1. Turn control power off.
2. Check ohms versus temperature. Use
an Ohmmeter and the following tables to
determine if the RTD is faulty. Vary the XXXXX XXXXX XXXXX
temperature to the RTD and check the XXXXX XXXXX XXXXX
ohms around the normal operating VDC mA
range.
VAC Ω
mA COM V Ω
Thermometer
RTD
32 DEGF
Ice water
Version 2.24
CPLC MANUAL 45
Degrees Fahrenheit versus Ohms value chart for 100 OHM Platinum RTD
°F 0 1 2 3 4 5 6 7 8 9
0 93.01 93.22 93.44 93.66 93.88 94.10 94.32 94.54 94.76 94.98
10 95.20 95.42 95.63 95.85 96.07 96.29 96.51 96.73 96.95 97.17
20 97.38 97.60 97.82 98.04 98.26 98.47 98.69 98.91 99.13 99.35
30 99.56 99.78 100.00 100.20 100.40 100.70 100.90 101.10 101.30 101.50
40 101.70 102.00 102.20 102.40 102.60 102.80 103.00 103.30 103.50 103.70
50 103.90 104.10 104.30 104.60 104.80 105.00 105.20 105.40 105.60 105.80
60 106.10 106.30 106.50 106.70 106.90 107.10 107.40 107.60 107.80 108.00
70 108.20 108.40 108.70 108.90 109.10 109.30 109.50 109.70 109.90 110.20
80 110.40 110.60 110.80 111.00 111.20 111.50 111.70 111.90 112.10 112.30
90 112.50 112.70 113.00 113.20 113.40 113.60 113.80 114.00 114.30 114.50
100 114.70 114.90 115.10 115.30 115.50 115.80 116.00 116.20 116.40 116.60
110 116.80 117.00 117.30 117.50 117.70 117.90 118.10 118.30 118.50 118.80
120 119.00 119.20 119.40 119.60 119.80 120.00 120.20 120.50 120.70 120.90
130 121.10 121.30 121.50 121.70 122.00 122.20 122.40 122.60 122.80 123.00
140 123.20 123.40 123.60 123.90 124.10 124.30 124.50 124.70 124.90 125.20
150 125.40 125.60 125.80 126.00 126.20 126.40 126.60 126.90 127.10 127.30
160 127.50 127.70 127.90 128.10 128.30 128.60 128.80 129.00 129.20 129.40
170 129.60 129.80 130.00 130.30 130.50 130.70 130.90 131.10 131.30 131.50
180 131.70 132.00 132.20 132.40 132.60 132.80 133.00 133.20 133.40 133.60
190 133.90 134.10 134.30 134.50 134.70 134.90 135.10 135.30 135.50 135.80
200 136.00 136.20 136.40 136.60 136.80 137.00 137.20 137.40 137.70 137.90
210 138.10 138.30 138.50 138.70 138.90 139.10 139.30 139.60 139.80 140.00
220 140.20 140.40 140.60 140.80 141.00 141.20 141.40 141.70 141.90 142.10
230 142.30 142.50 142.70 142.90 143.10 143.30 143.50 143.80 144.00 144.20
240 144.40 144.60 144.80 145.00 145.20 145.40 145.60 145.90 146.10 146.30
250 146.50 146.70 146.90 147.10 147.30 147.50 147.70 147.90 148.20 148.40
260 148.60 148.80 149.00 149.20 149.40 149.60 149.80 150.00 150.20 150.50
270 150.70 150.90 151.10 151.30 151.50 151.70 151.90 152.10 152.30 152.50
280 152.70 153.00 153.20 153.40 153.60 153.80 154.00 154.20 154.40 154.60
290 154.80 155.00 155.20 155.40 155.70 155.90 156.10 156.30 156.50 156.70
300 156.90 157.10 157.30 157.50 157.70 157.90 158.10 158.40 158.60 158.80
310 159.00 159.20 159.40 159.60 159.80 160.00 160.20 160.40 160.60 160.80
320 161.00 161.30 161.50 161.70 161.90 162.10 162.30 162.50 162.70 162.90
330 163.10 163.30 163.50 163.70 163.90 164.10 164.30 164.60 164.80 165.00
340 165.20 165.40 165.60 165.80 166.00 166.20 166.40 166.60 166.80 167.00
350 167.20 167.40 167.60 167.80 168.10 168.30 168.50 168.70 168.90 169.10
360 169.30 169.50 169.70 169.90 170.10 170.30 170.50 170.70 170.90 171.10
370 171.30 171.50 171.80 172.00 172.20 172.40 172.60 172.80 173.00 173.20
380 173.40 173.60 173.80 174.00 174.20 174.40 174.60 174.80 175.00 175.20
390 175.40 175.60 175.80 176.00 176.30 176.50 176.70 176.90 177.10 177.30
400 177.50 177.70 177.90 178.10 178.30 178.50 178.70 178.90 179.10 179.30
410 179.50 179.70 179.90 180.10 180.30 180.50 180.70 180.90 181.10 181.30
420 181.50 181.80 182.00 182.20 182.40 182.60 182.80 183.00 183.20 183.40
430 183.60 183.80 184.00 184.20 184.40 184.60 184.80 185.00 185.20 185.40
440 185.60 185.80 186.00 186.20 186.40 186.60 186.80 187.00 187.20 187.40
450 187.60 187.80 188.00 188.20 188.40 188.60 188.80 189.00 189.20 189.40
460 189.70 189.90 190.10 190.30 190.50 190.70 190.90 191.10 191.30 191.50
470 191.70 191.90 192.10 192.30 192.50 192.70 192.90 193.10 193.30 193.50
480 193.70 193.90 194.10 194.30 194.50 194.70 194.90 195.10 195.30 195.50
490 195.70 195.90 196.10 196.30 196.50 196.70 196.90 197.10 197.30 197.50
500 197.70 197.90 198.10 198.30 198.50 198.70 198.90 199.10 199.30 199.50
Version 2.24
46 CPLC MANUAL
Degrees Celsius versus Ohms value chart for 100 OHM Platinum RTD
°C 0.00 0.62 1.23 1.85 2.47 3.09 3.70 4.32 4.94 5.56
-17.78 93.01 93.22 93.44 93.66 93.88 94.10 94.32 94.54 94.76 94.98
-12.22 95.20 95.42 95.63 95.85 96.07 96.29 96.51 96.73 96.95 97.17
-6.67 97.38 97.60 97.82 98.04 98.26 98.47 98.69 98.91 99.13 99.35
-1.11 99.56 99.78 100.00 100.22 100.43 100.65 100.87 101.08 101.30 101.52
4.44 101.74 101.95 102.17 102.39 102.60 102.82 103.04 103.25 103.47 103.69
10.00 103.90 104.12 104.34 104.55 104.77 104.98 105.20 105.42 105.63 105.85
15.56 106.07 106.28 106.50 106.71 106.93 107.14 107.36 107.58 107.79 108.01
21.11 108.22 108.44 108.66 108.87 109.09 109.30 109.52 109.73 109.95 110.16
26.67 110.38 110.60 110.81 111.03 111.24 111.46 111.67 111.89 112.10 112.32
32.22 112.53 112.75 112.96 113.18 113.39 113.61 113.82 114.04 114.25 114.47
37.78 114.68 114.89 115.11 115.32 115.54 115.75 115.97 116.18 116.40 116.61
43.33 116.83 117.04 117.25 117.47 117.68 117.90 118.11 118.32 118.54 118.75
48.89 118.97 119.18 119.39 119.61 119.82 120.04 120.25 120.46 120.68 120.89
54.44 121.11 121.32 121.53 121.75 121.96 122.17 122.39 122.60 122.81 123.03
60.00 123.22 123.43 123.65 123.87 124.08 124.30 124.51 124.73 124.94 125.16
65.56 125.37 125.58 125.79 126.01 126.22 126.43 126.65 126.86 127.07 127.28
71.11 127.50 127.71 127.92 128.13 128.35 128.56 128.77 128.98 129.20 129.41
76.67 129.62 129.83 130.04 130.26 130.47 130.68 130.89 131.10 131.32 131.53
82.22 131.74 131.95 132.16 132.38 132.59 132.80 133.01 133.22 133.43 133.65
87.78 133.86 134.07 134.28 134.49 134.70 134.91 135.12 135.34 135.55 135.76
93.33 135.97 136.18 136.39 136.60 136.81 137.02 137.24 137.45 137.66 137.87
98.89 138.08 138.29 138.50 138.71 138.92 139.13 139.34 139.55 139.76 139.97
104.44 140.18 140.39 140.60 140.81 141.02 141.24 141.45 141.66 141.87 142.08
110.00 142.29 142.50 142.71 142.92 143.13 143.34 143.55 143.76 143.97 144.18
115.56 144.39 144.59 144.80 145.01 145.22 145.43 145.64 145.85 146.06 146.27
121.11 146.48 146.69 146.90 147.11 147.32 147.53 147.73 147.94 148.15 148.36
126.67 148.57 148.78 148.99 149.20 149.41 149.61 149.82 150.03 150.24 150.45
132.22 150.66 150.87 151.08 151.28 151.49 151.70 151.91 152.12 152.33 152.54
137.78 152.74 152.95 153.16 153.37 153.58 153.78 153.99 154.20 154.41 154.62
143.33 154.82 155.03 155.24 155.45 155.66 155.86 156.07 156.28 156.49 156.69
148.89 156.90 157.11 157.32 157.52 157.73 157.94 158.15 158.35 158.56 158.77
154.44 158.98 159.18 159.39 159.60 159.80 160.01 160.22 160.42 160.63 160.84
160.00 161.05 161.25 161.46 161.67 161.87 162.08 162.29 162.49 162.70 162.91
165.56 163.11 163.32 163.52 163.73 163.94 164.14 164.35 164.56 164.76 164.97
171.11 165.17 165.38 165.59 165.79 166.00 166.20 166.41 166.62 166.82 167.03
176.67 167.23 167.44 167.64 167.85 168.06 168.26 168.47 168.67 168.88 169.08
182.22 169.29 169.49 169.70 169.90 170.11 170.32 170.52 170.73 170.93 171.14
187.78 171.34 171.55 171.75 171.96 172.16 172.37 172.57 172.78 172.98 173.19
193.33 173.39 173.59 173.80 174.00 174.21 174.41 174.62 174.82 175.03 175.23
198.89 175.44 175.64 175.84 176.05 176.25 176.46 176.66 176.86 177.07 177.27
204.44 177.48 177.68 177.88 178.09 178.29 178.49 178.70 178.90 179.11 179.31
210.00 179.51 179.72 179.92 180.12 180.33 180.53 180.73 180.94 181.14 181.35
215.56 181.55 181.75 181.95 182.16 182.36 182.56 182.77 182.97 183.17 183.38
221.11 183.58 183.78 183.98 184.19 184.39 184.59 184.80 185.00 185.20 185.40
226.67 185.60 185.81 186.01 186.21 186.41 186.62 186.82 187.02 187.22 187.43
232.22 187.63 187.83 188.03 188.24 188.44 188.64 188.84 189.04 189.25 189.45
237.78 189.65 189.85 190.05 190.25 190.46 190.66 190.86 191.06 191.26 191.46
243.33 191.67 191.87 192.07 192.27 192.47 192.67 192.87 193.08 193.28 193.48
248.89 193.68 193.88 194.08 194.28 194.48 194.68 194.88 195.09 195.29 195.49
254.44 195.69 195.89 196.09 196.29 196.49 196.69 196.89 197.09 197.29 197.49
260.00 197.69 197.89 198.09 198.29 198.49 198.70 198.90 199.10 199.30 199.50
NOTE: This chart converted from Fahrenheit chart using formula degC= ((degF-32)/1.8)
Version 2.24
CPLC MANUAL 47
Checking the RTD Transmitter TMS #3

1. With control power off, connect a 100 ohm resistor to terminals #3 and #4 of the
transmitter.
2. Turn control power on, the OUI reading should be 32 degF (0 degC) ±10%.
3. If the reading is not within specification, the transmitter may be faulty.
123 4 100
OHM
Temperature transmitter
Version 2.24
48 CPLC MANUAL
Checking proper operation of the BCM and wiring TMS #4

1. Ensure control power is off. At the affected RTD transmitter, disconnect the wires at
transmitter terminal #1 and #2. Connect a 4-20mA source to these terminals (Observe
correct polarity). Power up the control panel and then vary the simulator output.
2. At 12 mA (50%) the OUI should read 1/2 the RTD transmitter range; 100 or 250 degF
(37.7 or 121.1 degC) The readout should change as the simulator output is varied.
3. If the reading on the OUI is incorrect or does not change, turn control power off and
reconnect the 4 to 20 mA simulator at the respective terminals at connector J1, (see
electrical schematic for connection points).
4. Turn control power on and observe the OUI readout while varying the 4-20mA. If the
reading is correct there is an open or short in the wire or terminals connecting the CPLC
to the RTD transmitter. If reading is not correct the BCM may be faulty.
4-20 mA SURCE OR
2 WIRE SIMULATOR
mA OUT
2 WIRE
OFF
MODEL CL-XXX
BATTERY
CHECK
00.0% - 100%
XXXXXX
555
LOOP
ON
00.0%
100%
DIAL
Version 2.24
CPLC MANUAL 49
Valve Control System (VCS)

Description:
The BCM generates a 4-20 mA signal for valve control. The signal is wired to the I/P (current to
pressure) transducer for conversion to a pneumatic signal for positioning the inlet or bypass
control valve.
Specification:
• 4-20mA input = 3 to 15 psi output
• 60 to 120 psig instrument air input to I/P
Troubleshooting:
IV or BV not operating Failure of BCM VCS #1
Positioner or actuator malfunction VCS #2
Failure of I/P VCS #2
Version 2.24
50 CPLC MANUAL
Checking proper operation of the BCM and wiring VCS #1

1. With control power off, lift the wires at the suspected circuit and install a test meter
capable of reading milliamps as shown below, (the pin numbers are found on the
electrical schematic).
2. Restore control power.
3. If the meter reads 4 mA , the BCM is satisfactory.
4. If 4 mA is not present, refer to the section titled “Control Power System.”
5. Restore connections.
6. Remove control power.
7. Lift wires at suspected I/P, and install meter as in previous step.
8. Restore control power.
If the meter reads 4 mA, the BCM and wiring is satisfactory.
Allen Bradley Analog Output Card
Analog Outputs, (4-20mA)
Pin 1
XXXXX XXXXX XXXXX
XXXXX XXXXX XXXXX
VDC mA
VAC Ω
mA COM V Ω
Version 2.24
CPLC MANUAL 51
Checking proper operation of the I/P and positioner VCS #2

1. Connect a 4-20 mA simulator to the I/P.
2. Ensure instrument air is present at the supply connection on the I/P.
3. Vary the simulator between 4-20 mA. The output of the I/P and the positioner should
follow. If the valve tracks the 4-20 mA signal correctly the I/P and the positioner are
satisfactory.
BATTERY LOOP
CHECK ON
mA OUT 100%
OFF DIAL
2 WIRE 00.0%
XXXXXX
MODEL CL-XXX
00.0% - 100% INGERSOLL-RAND
Centrifugal Compressor Division
2 WIRE SIMULATOR
4-20 mA SURCE OR
Highway 45 South
Mayfield, KY. 42066
Parts Service (800) 247-8640
555
Version 2.24
52 CPLC MANUAL
Pressure Monitoring System (PMS)

Description:
A Pressure Transducer (PT) is used to convert pressure (psi) to a 4-20 mA signal for monitoring
by the CPLC.
Component specification:
• 0-50 psig (344.75 kPa) range
• 0-200 psig (1379 kPa) range
• Power = 24 VDC
Troubleshooting:
Zero OUI readout Open circuit/cable PMS #1, 2
disconnected
Loss of power to transmitter PMS #1
Malfunctioning transmitter PMS #3, 4
Erratic OUI readout Loose wire/terminal/connector PMS #1,2
Incorrect OUI readout Any PMS #1, 2, 3, 4
Version 2.24
CPLC MANUAL 53
Checking for Power to the Pressure Transmitter PMS #1

1. Ensure control power is off. Disconnect the wires at the suspect PT and connect a
voltmeter to these wires.
2. With control power on, there should be approximately 24 VDC present at the terminals.
3. If approximately 24 VDC is not present, see the section titled “Control Power System.”
XXXXX XXXXX XXXXX
XXXXX XXXXX XXXXX
SPAN
VDC mA
VAC Ω
INGERSOLL RAND
mA COM V Ω
Version 2.24
54 CPLC MANUAL
Checking proper operation of the BCM and wiring PMS #2

1. Ensure control power is off. Disconnect the wires at the suspect PT and connect a 4-20
mA source to the lifted wires (Observe correct polarity).
2. Restore control power and then vary the simulator output.
3. At 12 mA (50%) the OUI should read 1/2 the PT range. The readout should change as
the simulator output is varied.
4. If the reading on the OUI is incorrect or does not change, turn control power off and
reconnect the 4 -20 mA simulator at the respective terminals at connector J1, (see
electrical schematic for connection points).
5. Turn control power on and observe the OUI readout while varying the 4-20 mA. If the
reading is correct there is an open or short in the wire or terminals connecting the CPLC
to the PT. If the reading is not correct the BCM may be faulty.
4-20 mA SURCE OR
2 WIRE SIMULATOR
mA OUT
2 WIRE
OFF
MODEL CL-XXX
BATTERY
CHECK
00.0% - 100%
XXXXXX
555
LOOP
ON
00.0%
100%
DIAL
Version 2.24
CPLC MANUAL 55
Quick check of the PT PMS #3

1. Connect an ohmmeter to the disconnected wires coming from the PT.
2. If there is no continuity either the wiring or the PT is faulty.
XXXXX XXXXX XXXXX
XXXXX XXXXX XXXXX
VDC mA
VAC Ω
mA COM V Ω
SPAN
INGERSOLL RAND
Functional PT test PMS #4

1. Remove control power.
2. Remove the PT and connect a regulated air supply to the pressure connection. Power
up the CPLC and vary the regulated air supply. The OUI should read the pressure being
applied.
Version 2.24
56 CPLC MANUAL
Digital Input System (DIS)

Description:
The digital input devices associated with the CPLC are on/off devices which turn on or off the
associated CPLC digital input.
Typical digital device name and type:
1. Low seal air pressure (Pressure)
2. Low cooling water flow (Flapper)
3. Low oil level (Float)
4. High condensate level (Float)
5. Dirty inlet filter (Differential pressure)
6. Dirty oil filter (Differential pressure)
7. High motor temperature (Thermistor)
Troubleshooting:
False alarm or trip Faulty device DIS #1
Faulty wiring DIS #1
Version 2.24
CPLC MANUAL 57
Checking proper operation of the digital devices DIS #1

1. Verify approximately 120 VAC is present as described in the section titled
“Troubleshooting the Power System.”
2. If approximately 120 VAC is present, install a multimeter with VAC selected between the
appropriate pins (the input pin can be determined from the electrical schematic, or wire
number).
3. Ensure the digital device is not in the trip condition, the meter should read 0 VAC.
4. Actuate the switch, the meter should read approximately 120 VAC.
Digital (Discrete)
Inputs (120VAC)
XXXXX XXXXX XXXXX
XXXXX XXXXX XXXXX
VDC mA
VAC Ω
mA COM V Ω Seal Air Switch
Version 2.24
58 CPLC MANUAL
Options
This section details the various standard options that are available for the CPLC. Some of the
options listed are provided standard on some models, and will be indicated as such.
Enclosures
The CPLC has three panel enclosures available; NEMA 12 (IP 64) which is standard, and
optional NEMA 4 (IP 65) and NEMA 4X (IP 65). The panel is machine mounted. All electrical
devices are mounted and wired where practical.
NEMA 12 (IP 64)

NEMA 12 is the standard enclosure for all compressors with CPLC panels. NEMA defines this
rating as "... intended for indoor use primarily to provide a degree of protection against dust,
falling dirt, and dripping non-corrosive liquids. They shall meet drip, dust, and rust-resistance
design tests. They are not intended to provide protection against conditions such as internal
condensation." Typically this type of enclosure is applied for most indoor applications.
Cooling Fan
The cooling fan is supplied on all standard CPLC enclosures, where a wye-delta motor starter is
present, the Control Electrical Package is included, or the ambient temperature exceeds 40
degC. This keeps the internal temperature below the maximum operating temperature allowed.
This action effectively extends the operating life of the control components. A filter and gasket
are added to attain a NEMA 12 rating.
Control Electrical Package

The Control Electrical Package consists of a Control Transformer, Prelube Pump Starter, and
Oil Heater Contactor(s). This option allows the customer to bring a single source of electrical
power to the compressor to run all of the compressor package accessories; thereby, making
compressor installation easier.
Stage Data Package

For monitoring of interstage pressure and temperatures, the Stage Data Package can be
added. As standard, the CPLC comes with temperature readout, alarm and trip for the next to
last compression stage and compressor discharge pressure indication. When selected, each
stage gets temperature and pressure measurements on the downstream side of each stage's
cooler. For compressors without built-in aftercoolers, the last stage diffuser temperature is
measured. Each temperature has readout, alarm and trip capability while the pressures are
readout only.
Running Unloaded Shutdown Timer

The intent of this option is to save energy by shutting the compressor off during extended
periods of unloaded operation. When the running unloaded shutdown timer is enabled, the
auto-dual control mode should be selected, this provides for automatic unloading of the
machine.
Version 2.24
CPLC MANUAL 59
Water Solenoid Post Run Timer

This optional panel function is used to shut off water flow to the air and oil coolers after the
compressor is stopped. It is accomplished by sending a signal to close the solenoid operated
water valves.
N.O. Contact for Remote Indication of Common Alarm and

Trip
A normally open contact for individual remote indication closes whenever an alarm or trip
occurs. This allows a customer to have remote indication of compressor alarm, trip or both.
Version 2.24
60 CPLC MANUAL
Communication
Customers may want to communicate to the CPLC control systems for remote compressor
control and monitoring. This communication capability provides for flexibility in the customer's
compressed air operation through remote start and stop, data gathering for preventative
maintenance, and incorporation into plant-wide control system.
The major avenue for communicating with the CPLC is via DH+ protocol. This requires a
communications device with the appropriate driver software to perform the desired panel
functions. The DH+ interface can communicate with any serial device that has a DH+ System.
Software must be written by the customer or his representative to suit his individual needs for
remote control and monitoring. Since the customer writes this interface, the system can be as
flexible as the customer desires.
Direct CPLC Communications with DH+

For the descriptions that follow, a device can be a Personal Computer (PC), Programmable
Logic Controller (PLC), Distributed Control System (DCS) or any other device that can transmit,
receive and interpret an DH+ formatted signal over a hardware link. In the descriptions that
follow, the PC and PLC serial devices are not specific to manufacturers or operating systems.
All DH+ interfaces require custom interface software and custom application software. The
interface software allows a specific device and operating system to transmit, receive and
interpret data from a CPLC control system. The application software tells the CPLC control
system what to do; for example, start compressor when ready, stop compressor after midnight
and retrieve the current data and save to a disk file.
Currently there are hundreds of different devices using different operating systems and
languages in the industrial equipment world. Therefore, the practicality of having an interface
for many systems is limited. Custom interfaces must be written as required by the hardware
and operating system used.
The application software is only limited by the capabilities of the hardware and the imagination
of the developer. For example, one developer may have two compressors. In this application
the developer wants a screen to display the compressor interstage pressure and temperatures
for both machines with various other compressor data. A second developer has five
compressors. He also wants to display the same data, but this time for all five machines. The
only way this is done is through changing the application software (custom modification).
The developer may write functions to read and display data, log that data to some magnetic
media for storage, change compressor set points, sequence the compressors for efficient
operation and network additional devices, such as pumps, dryers, etc., into the system. All of
these functions require specially written application software for the intended use.
Version 2.24
CPLC MANUAL 61
The CPLC Address Interface
Please refer to the documentation provided separately for the Allen Bradley Data Highway +
Communications. Available data and addresses from the CPLC follows.
TYPE NAME SPECIFIER

TAG Local:2:C
TAG Local:2:I
TAG Local:3:C
TAG Local:3:I
TAG Local:3:O
TAG Local:4:C
TAG Local:4:I
TAG Local:5:C
TAG Local:5:I
TAG Local:6:C
TAG Local:6:I
TAG Local:6:O
TAG Above_HLL
TAG Above_HLL_Min
TAG Above_IVUP_Min
TAG Above_PSP
TAG Above_PSP_Min
TAG Above_TL_Min
TAG Ad_unload_tmr
TAG AlarmResetKey
TAG ALARM_TRIP_BYPASS
TAG Alternate_AT_Enabled
TAG Alt_RightPwd
TAG Alt_WrongPwd
TAG Analysis_Log_Trigger
TAG ASurge
TAG ASurge_Enabled
TAG Autodual_C
Version 2.24
62 CPLC MANUAL
TAG Autodual_Unload
TAG Auto_Load
TAG Auto_Start
TAG Auto_Start_Pressure
TAG Auto_Stop
TAG Auto_Stop_Timer
TAG a_actual_current
TAG a_coast_relay
TAG a_current_zero
TAG a_delay_cr1
TAG a_hot_delay
TAG a_hot_start
TAG a_speed_nrml
TAG a_speed_zero
TAG a_starter_fail_delay
TAG a_start_rust
TAG a_start_stop
TAG a_zero_current
TAG Bat_Var_11
TAG Bat_Var_12
TAG Below_HLL_Max
TAG Below_IVUP_Max
TAG Below_PSP_Max
TAG Below_TL_Max
TAG Bv_Closed_Value
TAG Bv_Open_Value
TAG BV_PRESSURE_GAIN
TAG BV_PRESSURE_GAIN_DISPLAY
TAG BV_PRESSURE_IT
TAG BV_PRESSURE_IT_DISPLAY
TAG BV_Pressure_PID
TAG BV_P_PID_ENABL
TAG BV_Unload_Rate
ALIAS Bypass_Valve_C Local:6:O.Ch1Data
Version 2.24
CPLC MANUAL 63
TAG Bypass_Valve_CV
TAG Bypass_Valve_Display
TAG Bypass_Valve_Manl
TAG Bypass_Valve_Output
TAG Bypass_Valve_Tieback
TAG b_cooldown
TAG CEM_COM_C
TAG CEM_PSP
TAG Coasting
TAG Coast_Timer
TAG Coast_Timer_Preset
TAG Coast_Timer_Preset_Display
TAG COMPRESSOR_CONTROL_LOCATION
TAG COMPRESSOR_OPERATING_STATE
TAG COMPRESSOR_STATUS
TAG COM_Acknowledge
TAG COM_Load
TAG COM_Mode
TAG COM_Reset
TAG COM_Start
TAG COM_Stop
TAG COM_Unload
TAG Cond_Blow
TAG Cond_Level
ALIAS CR1 Local:3:O.Data.1
TAG CR2
TAG CR3
ALIAS CT_INPUT Local:4:I.Ch15Data
TAG CT_Ratio
TAG CT_Ratio_Display
TAG Current_Pressure_Ratio
TAG Current_Rate_SP
TAG Current_Zero_Offset
TAG Dirty_Inlet_Filter
TAG Dirty_Oil_Filter
TAG Discharge_Temp
Version 2.24
64 CPLC MANUAL
TAG Discharge_TempX10
TAG Discharge_Temp_HA
TAG Discharge_Temp_HAV
TAG Discharge_Temp_HAV2
TAG Discharge_Temp_HAV_In
TAG Discharge_Temp_HT
TAG Discharge_Temp_HTV
TAG Discharge_Temp_HTV2
TAG Discharge_Temp_HTV_In
TAG DI_Acknowledge
TAG DI_Auto_Start_Enabled
TAG DI_Cond_Level_1
TAG DI_Cond_Level_1_Timer
TAG DI_Cond_Level_2
TAG DI_Cond_Level_2A
TAG DI_Cond_Level_2A_Timer
TAG DI_Cond_Level_3
TAG DI_Cond_Level_4
TAG DI_Cond_Level_5
TAG DI_Motor_Temp
TAG DI_Oil_Level
TAG DI_Remote
TAG DI_Remote_Comm
TAG DI_Remote_load
TAG DI_Remote_Start
TAG DI_Reset
Version 2.24
CPLC MANUAL 65
TAG DI_RUST_Enabled
ALIAS DI_Seal_Air Local:2:I.Data.1
ALIAS DI_Starter_Feedback Local:2:I.Data.2
TAG DI_Surge
TAG DI_Trip
TAG DI_Water_Flow
TAG DO_Cooling_Water
TAG Driver_Rotating
TAG Drv_Mot_Sync
TAG drv_mot_sync_inv
TAG DStarterFailed
TAG d_unload
TAG Eng_RightPwd
TAG Eng_WrongPwd
TAG ErrorFlagAI
TAG ErrorFlagAI1
TAG ErrorFlagAI10
TAG ErrorFlagAI11
TAG ErrorFlagAI12
TAG ErrorFlagAI13
TAG ErrorFlagAI14
TAG ErrorFlagAI15
TAG ErrorFlagAI16
TAG ErrorFlagAI17
TAG ErrorFlagAI18
TAG ErrorFlagAI19
TAG ErrorFlagAI2
TAG ErrorFlagAI20
TAG ErrorFlagAI21
TAG ErrorFlagAI22
TAG ErrorFlagAI23
TAG ErrorFlagAI24
TAG ErrorFlagAI25
TAG ErrorFlagAI3
TAG ErrorFlagAI4
TAG ErrorFlagAI5
Version 2.24
66 CPLC MANUAL
TAG ErrorFlagAI6
TAG ErrorFlagAI7
TAG ErrorFlagAI8
TAG ErrorFlagAI9
TAG EVF0P01LAN
TAG EVF0P02LAN
TAG EVF0P03LAN
TAG EVF0P0BVL
TAG EVF0P0BVR
TAG EVF0P0IVL
TAG EVF0P0IVR
TAG EvtCount
ALIAS E_Stop Local:2:I.Data.0
ALIAS E_STOP_PUSHED_LIGHT Local:3:O.Data.3
TAG F0P
TAG F1P
TAG F2P
TAG First_Alarm_R
TAG First_Trip_R
TAG High_Oil_Pressure_Shutoff
TAG HLL
TAG HLL_Display
TAG HLL_PID
TAG HLL_Tol
TAG Horn
TAG HostEvent_1
TAG HostEvent_10
TAG HostEvent_11
TAG HostEvent_12
TAG HostEvent_13
TAG HostEvent_14
TAG HostEvent_15
TAG HostEvent_16
TAG HostEvent_17
Version 2.24
CPLC MANUAL 67
TAG HostEvent_18
TAG HostEvent_19
TAG HostEvent_2
TAG HostEvent_20
TAG HostEvent_21
TAG HostEvent_22
TAG HostEvent_23
TAG HostEvent_24
TAG HostEvent_25
TAG HostEvent_26
TAG HostEvent_3
TAG HostEvent_4
TAG HostEvent_5
TAG HostEvent_6
TAG HostEvent_7
TAG HostEvent_8
TAG HostEvent_9
TAG HostEvent_tmp19
ALIAS Inboard_Bearing_TempX10 Local:4:I.Ch9Data
TAG Inboard_Bearing_Temp_HA
TAG Inboard_Bearing_Temp_HAV
TAG Inboard_Bearing_Temp_HAV2
TAG Inboard_Bearing_Temp_HAV_In
TAG Inboard_Bearing_Temp_HT
TAG Inboard_Bearing_Temp_HTV
TAG Inboard_Bearing_Temp_HTV2
TAG Inboard_Bearing_Temp_HTV_In
TAG Inboard_Bearing_VIBX100
TAG Inboard_Bearing_VIB_HA
TAG Inboard_Bearing_Vib_HAV
TAG Inboard_Bearing_Vib_HAV2
TAG Inboard_Bearing_Vib_HAV_In
TAG Inboard_Bearing_VIB_HT
TAG Inboard_Bearing_Vib_HTV
TAG Inboard_Bearing_Vib_HTV2
TAG Inboard_Bearing_Vib_HTV_In
Version 2.24
68 CPLC MANUAL
TAG Inlet_Filter_DP
TAG Inlet_Filter_DP_HAV
TAG Inlet_Filter_DP_HAV_In
ALIAS Inlet_Valve_C Local:6:O.Ch0Data
TAG Inlet_Valve_HLLPID_CV
TAG Inlet_Valve_Manl
TAG Inlet_Valve_PPID_CV
TAG Inlet_Valve_Tieback
TAG Inlet_Valve_TLPID_CV
ALIAS Inlet_Water_Temp Local:4:I.Ch5Data
TAG Inlet_Water_Temp_HA
TAG Inlet_Water_Temp_HAV
TAG Inlet_Water_Temp_HAV_In
TAG Inlet_Water_Temp_HT
TAG Inlet_Water_Temp_HTV
TAG Inlet_Water_Temp_HTV_In
TAG Input
TAG Input_Bypass_Enabled
TAG IVUP_Tol
TAG IV_FREEZ_ENABL
TAG IV_HLDOPN_ENABL
TAG IV_HLLPID_ENABL
TAG IV_HLL_GAIN
TAG IV_HLL_GAIN_DISPLAY
TAG IV_HLL_IT
TAG IV_HLL_IT_DISPLAY
TAG Iv_Open_Value
TAG IV_PPID_ENABL
TAG iv_ppid_enabl_arm
TAG iv_ppid_enabl_os
TAG IV_PRESSURE_GAIN
TAG IV_PRESSURE_GAIN_DISPLAY
TAG IV_PRESSURE_IT
TAG IV_PRESSURE_IT_DISPLAY
Version 2.24
CPLC MANUAL 69
TAG IV_PRESSURE_PID
TAG IV_P_PID_P
TAG IV_RMPUNL_ENABL
TAG IV_STARTPOS
TAG IV_STRTPOS_ENABL
TAG IV_STRTPOS_TMR
TAG IV_TLPID_ENABL
TAG IV_TLSEEK_ENABL
TAG IV_TL_GAIN
TAG IV_TL_GAIN_DISPLAY
TAG IV_TL_IT
TAG IV_TL_IT_DISPLAY
TAG IV_Unld_Pos
TAG IV_Unload_Pos
TAG IV_Unload_Pos_Display
TAG IV_Unload_Rate
TAG IV_UNL_ENABL
TAG j_ad_disabl
TAG j_ad_enabl
TAG j_ad_enabl_arm
TAG j_ad_enabl_os
TAG j_ad_grt_unloadpt
TAG j_ad_les_unloadpt
TAG j_ad_load_disabl
TAG j_ad_load_enabl
TAG j_ad_load_enabl_arm
TAG j_ad_load_enabl_os
TAG j_ad_load_entrl
TAG j_ad_lopress
TAG j_ad_lo_press
TAG j_ad_tmr_disabl
TAG j_ad_tmr_enabl
TAG j_ad_tmr_enabl_arm
TAG j_ad_tmr_enabl_os
TAG j_ad_tmr_entrl
TAG j_ad_unload_disabl
Version 2.24
70 CPLC MANUAL
TAG j_ad_unload_enabl
TAG j_ad_unload_enabl_arm
TAG j_ad_unload_enabl_os
TAG j_ad_unload_entrl
TAG j_bv_closed
TAG j_bv_closed1
TAG j_bv_disabl
TAG j_bv_enabl
TAG j_bv_enabl_arm
TAG j_bv_enabl_os
TAG j_bv_hldcls_disabl
TAG j_bv_hldcls_enabl
TAG j_bv_hldcls_enabl_arm
TAG j_bv_hldcls_enabl_os
TAG j_bv_hldcls_entr
TAG j_bv_hldopn1
TAG j_bv_hldopn_disabl
TAG j_bv_hldopn_enabl
TAG j_bv_hldopn_enabl_arm
TAG j_bv_hldopn_enabl_os
TAG j_bv_hldopn_entr
TAG j_bv_manl_disabl
TAG j_bv_manl_enabl
TAG j_bv_manl_enabl_arm
TAG j_bv_manl_enabl_invrt
TAG j_bv_manl_enabl_os
TAG j_bv_manl_entr
TAG j_bv_open
TAG j_bv_open1
TAG j_bv_p_pid_disabl
TAG j_bv_p_pid_enabl_arm
TAG j_bv_p_pid_enabl_os
TAG j_bv_p_pid_entr
TAG j_bv_p_pid_invrt
Version 2.24
CPLC MANUAL 71
TAG j_bv_rmpopn_disabl
TAG j_bv_rmpopn_enabl
TAG j_bv_rmpopn_enabl_arm
TAG j_bv_rmpopn_enabl_os
TAG j_bypass_corr
TAG j_clear_ndx_val
TAG j_disabl_1
TAG j_freez_iv_disabl
TAG j_frstscan_inv
TAG j_highpr
TAG j_hightol
TAG j_hldcls_enabl_arm
TAG j_hldcls_enabl_os
TAG j_hldop_hll_exit
TAG j_hllchk_sat
TAG j_HLLlesHLL_Tol
TAG j_HLLplsHLL_Tol
TAG j_hll_chk
TAG j_hll_chngd
TAG j_hll_hldopn_exit
TAG j_hll_last
TAG j_hll_unsat
TAG j_IgeHLLlesHLL_Tol
TAG j_IgeTLlesTL_Tol
TAG j_IgtHLLplsHLL_Tol
TAG j_IgtTLplsTL_Tol
TAG j_IleHLLplsHLL_Tol
TAG j_IleTLplsTL_Tol
TAG j_IltHLLlesHLL_Tol
TAG j_IltTLlesTL_Tol
TAG j_IVgeIVUPlesIVUPTol
TAG j_IVgtIVUPplsIVUPTol
TAG j_IVleIVUPplsIVUPTol
TAG j_IVltIVUPlesIVUPTol
TAG j_IVUPlesIVUP_Tol
TAG j_IVUPplsIVUP_Tol
Version 2.24
72 CPLC MANUAL
TAG j_iv_0_disabl
TAG j_iv_0_enabl
TAG j_iv_0_enabl_arm
TAG j_iv_0_enabl_os
TAG j_iv_at_unl
TAG j_iv_disabl
TAG j_iv_enabl
TAG j_iv_enabl_arm
TAG j_iv_enabl_os
TAG j_iv_freez_enabl_arm
TAG j_iv_freez_enabl_os
TAG j_iv_hldopn_disabl
TAG j_iv_hldopn_enabl_arm
TAG j_iv_hldopn_enabl_os
TAG j_iv_hllpid_enabl_arm
TAG j_iv_hllpid_enabl_os
TAG j_iv_llpid_disabl
TAG j_iv_open
TAG j_iv_ppid_disabl
TAG j_iv_ppid_enabl_arm
TAG j_iv_ppid_enabl_os
TAG j_iv_ppid_entr
TAG j_iv_rmpunl_disabl
TAG j_iv_rmpunl_enabl_arm
TAG j_iv_rmpunl_enabl_os
TAG j_iv_strtpos_disabl
TAG j_iv_strtpos_enabl_arm
TAG j_iv_strtpos_enabl_os
TAG j_iv_strtpos_entr
TAG j_iv_tlpid_disabl
TAG j_iv_tlpid_enabl_arm
TAG j_iv_tlpid_enabl_os
TAG j_iv_tlseek_disabl
TAG j_iv_tlseek_enabl_arm
Version 2.24
CPLC MANUAL 73
TAG j_iv_tlseek_enabl_os
TAG j_iv_tl_exit
TAG j_iv_unl_disabl
TAG j_iv_unl_enabl_arm
TAG j_iv_unl_enabl_os
TAG j_iv_unl_entr
TAG j_lopress
TAG j_lowtol
TAG j_mtemp
TAG j_ndx_disabld
TAG j_ndx_disabld_arm
TAG j_ndx_disabld_disabl
TAG j_ndx_disabld_os
TAG j_ndx_enabl_os
TAG j_ndx_frstscan
TAG j_ndx_incr_disabl
TAG j_ndx_incr_enabl
TAG j_ndx_incr_enabl_arm
TAG j_ndx_incr_enabl_os
TAG j_ndx_incr_os
TAG j_ndx_mntr_disabl
TAG j_ndx_mntr_enabl
TAG j_ndx_mntr_enabl_arm
TAG j_ndx_mntr_enabl_os
TAG j_ndx_val
TAG j_not_mod_and_adual
TAG j_power_on_1
TAG j_power_on_2
TAG j_power_on_3
TAG j_power_on_l
TAG j_pp_hldopn_exit
TAG j_pp_hll_exit
TAG j_pp_tl_exit
TAG j_psplespsp_tol
TAG j_pspplspsp_tol
TAG j_reload_percent
Version 2.24
74 CPLC MANUAL
TAG j_reload_pressure
TAG j_reset
TAG j_rmp_entr
TAG j_rstkey_5s
TAG j_rst_mtrpall_not
TAG j_rst_mtrpall_not_dly
TAG j_set_tlchktohll_disabl
TAG j_set_tlchktohll_enabl
TAG j_set_tlchktohll_enabl_arm
TAG j_set_tlchktohll_enabl_os
TAG j_set_tlchktoouitl_disabl
TAG j_set_tlchktoouitl_enabl
TAG j_set_tlchktoouitl_enabl_arm
TAG j_set_tlchktoouitl_enabl_os
TAG j_set_tlchktoreftmp_disabl
TAG j_set_tlchktoreftmp_enabl
TAG j_set_tlchktoreftmp_enabl_arm
TAG j_set_tlchktoreftmp_enabl_os
TAG j_speed_sat
TAG j_srg_ndx
TAG j_stopped
TAG j_syspresgtpsp
TAG j_syspreslepsp
TAG j_test
TAG j_test1
TAG j_test2
TAG j_test3
TAG j_tlchktmpcmpr_disabl
TAG j_tlchktmpcmpr_enabl
TAG j_tlchktmpcmpr_enabl_arm
TAG j_tlchktmpcmpr_enabl_os
TAG j_tlchktmp_disabl
TAG J_TLCHKTMP_DISABL_ENABL
TAG j_tlchktmp_disabl_enabl_arm
Version 2.24
CPLC MANUAL 75
TAG j_tlchktmp_disabl_enabl_os
TAG j_tlchktmp_enabl
TAG j_tlchktmp_mon_disabl
TAG j_tlchktmp_mon_enabl
TAG j_tlchktmp_mon_enabl_arm
TAG j_tlchktmp_mon_enabl_os
TAG j_tlchk_settoHLL
TAG j_tlchk_settoTL
TAG j_TLlesTL_Tol
TAG j_tlndxtmp
TAG j_tlndxtmp_chngd
TAG j_tlndxtmp_last
TAG j_TLplsTL_Tol
TAG j_tlreftmp_chngd
TAG j_tlreftmp_sat
TAG j_tl_chd
TAG j_tl_chngd
TAG J_TL_GRT_HLL
TAG j_tl_last
TAG j_tl_sat
ALIAS K_RSV_BV Bypass_Valve_Display
ALIAS K_RSV_BV_MANUAL_VALUE Bypass_Valve_Display
ALIAS K_RSV_BV_PRESSURE_GAIN BV_PRESSURE_GAIN
ALIAS K_RSV_BV_PRESSURE_GAIN_DISPLAY BV_PRESSURE_GAIN_DISPLAY
ALIAS K_RSV_BV_PRESSURE_IT BV_PRESSURE_IT
ALIAS K_RSV_BV_PRESSURE_IT_DISPLAY BV_PRESSURE_IT_DISPLAY
ALIAS K_RSV_COAST_TIMER Coast_Timer_Preset
ALIAS K_RSV_COAST_TIMER_DISPLAY Coast_Timer_Preset_Display
ALIAS K_RSV_COMPRESSOR_STATUS COMPRESSOR_STATUS
ALIAS K_RSV_CONTROL_LOCATION COMPRESSOR_CONTROL_LOCATION
ALIAS K_RSV_COOLING_WATER_HA Inlet_Water_Temp_HA
ALIAS K_RSV_COOLING_WATER_HAV Inlet_Water_Temp_HAV_In
ALIAS K_RSV_COOLING_WATER_HAV_DISPLAY Inlet_Water_Temp_HAV
ALIAS K_RSV_COOLING_WATER_HT Inlet_Water_Temp_HT
ALIAS K_RSV_COOLING_WATER_HTV Inlet_Water_Temp_HTV_In
ALIAS K_RSV_COOLING_WATER_HTV_DISPLAY Inlet_Water_Temp_HTV
Version 2.24
76 CPLC MANUAL
ALIAS K_RSV_COOLING_WATER_TEMP Inlet_Water_Temp

ALIAS K_RSV_CR1 CR1
ALIAS K_RSV_CT_RATIO CT_Ratio
ALIAS K_RSV_CT_RATIO_DISPLAY CT_Ratio_Display
ALIAS K_RSV_ESTOP_PRESSED E_STOP_PUSHED_LIGHT
ALIAS K_RSV_E_STOP E_Stop
ALIAS K_RSV_HLL HLL
ALIAS K_RSV_HLL_DISPLAY HLL_Display
ALIAS K_RSV_HLL_GAIN IV_HLL_GAIN
ALIAS K_RSV_HLL_GAIN_DISPLAY IV_HLL_GAIN_DISPLAY
ALIAS K_RSV_HLL_IT IV_HLL_IT
ALIAS K_RSV_HLL_IT_DISPLAY IV_HLL_IT_DISPLAY
ALIAS K_RSV_INBOARD_BEARING_TEMP Inboard_Bearing_TempX10
ALIAS K_RSV_INBOARD_BEARING_TEMP_HA Inboard_Bearing_Temp_HA
ALIAS K_RSV_INBOARD_BEARING_TEMP_HAV Inboard_Bearing_Temp_HAV_In
ALIAS K_RSV_INBOARD_BEARING_TEMP_HAV_DISPLAY Inboard_Bearing_Temp_HAV
ALIAS K_RSV_INBOARD_BEARING_TEMP_HT Inboard_Bearing_Temp_HT
ALIAS K_RSV_INBOARD_BEARING_TEMP_HTV Inboard_Bearing_Temp_HTV_In
ALIAS K_RSV_INBOARD_BEARING_TEMP_HTV_DISPLAY Inboard_Bearing_Temp_HTV
ALIAS K_RSV_INDEXING_TL_VALUE MinLoad_SP
ALIAS K_RSV_IV Inlet_Valve_C
ALIAS K_RSV_IV_MANUAL_VALUE Inlet_Valve_Manl
ALIAS K_RSV_IV_PRESSURE_GAIN IV_PRESSURE_GAIN
ALIAS K_RSV_IV_PRESSURE_GAIN_DISPLAY IV_PRESSURE_GAIN_DISPLAY
ALIAS K_RSV_IV_PRESSURE_IT IV_PRESSURE_IT
ALIAS K_RSV_IV_PRESSURE_IT_DISPLAY IV_PRESSURE_IT_DISPLAY
ALIAS K_RSV_IV_TL_GAIN IV_TL_GAIN
ALIAS K_RSV_IV_TL_GAIN_DISPLAY IV_TL_GAIN_DISPLAY
ALIAS K_RSV_IV_TL_IT IV_TL_IT
ALIAS K_RSV_IV_TL_IT_DISPLAY IV_TL_IT_DISPLAY
ALIAS K_RSV_IV_UNLOAD_POSITION IV_Unload_Pos
ALIAS K_RSV_IV_UNLOAD_POSITION_DISPLAY IV_Unload_Pos_Display
ALIAS K_RSV_LOAD LoadKey
ALIAS K_RSV_LOADED_HOURS LOADED_HOURS
Version 2.24
CPLC MANUAL 77
ALIAS K_RSV_MANUAL_VALVE MMODE

ALIAS K_RSV_MODULATE_AUTODUAL MODE
ALIAS K_RSV_MOTOR_CURRENT Motor_Current
ALIAS K_RSV_MOTOR_STATORA_TEMP Phase_A_Temp
ALIAS K_RSV_MOTOR_STATORA_TEMP_HA Phase_A_Temp_HA
ALIAS K_RSV_MOTOR_STATORA_TEMP_HAV Phase_A_Temp_HAV_In
ALIAS K_RSV_MOTOR_STATORA_TEMP_HAV_DISPLAY Phase_A_Temp_HAV
ALIAS K_RSV_MOTOR_STATORA_TEMP_HT Phase_A_Temp_HT
ALIAS K_RSV_MOTOR_STATORA_TEMP_HTV Phase_A_Temp_HTV_In
ALIAS K_RSV_MOTOR_STATORA_TEMP_HTV_DISPLAY Phase_A_Temp_HTV
ALIAS K_RSV_MOTOR_STATORB_TEMP Phase_B_Temp
ALIAS K_RSV_MOTOR_STATORB_TEMP_HA Phase_B_Temp_HA
ALIAS K_RSV_MOTOR_STATORB_TEMP_HAV Phase_B_Temp_HAV_In
ALIAS K_RSV_MOTOR_STATORB_TEMP_HAV_DISPLAY Phase_B_Temp_HAV
ALIAS K_RSV_MOTOR_STATORB_TEMP_HT Phase_B_Temp_HT
ALIAS K_RSV_MOTOR_STATORB_TEMP_HTV Phase_B_Temp_HTV_In
ALIAS K_RSV_MOTOR_STATORB_TEMP_HTV_DISPLAY Phase_B_Temp_HTV
ALIAS K_RSV_MOTOR_STATORC_TEMP Phase_C_Temp
ALIAS K_RSV_MOTOR_STATORC_TEMP_HA Phase_C_Temp_HA
ALIAS K_RSV_MOTOR_STATORC_TEMP_HAV Phase_C_Temp_HAV_In
ALIAS K_RSV_MOTOR_STATORC_TEMP_HAV_DISPLAY Phase_C_Temp_HAV
ALIAS K_RSV_MOTOR_STATORC_TEMP_HT Phase_C_Temp_HT
ALIAS K_RSV_MOTOR_STATORC_TEMP_HTV Phase_C_Temp_HTV_In
ALIAS K_RSV_MOTOR_STATORC_TEMP_HTV_DISPLAY Phase_C_Temp_HTV
ALIAS K_RSV_MULTILIN_TRIP Multilin_Trip
TAG K_RSV_NOT_RUNNING_AND_NOT_STARTING
ALIAS K_RSV_NUMBER_OF_STARTS NUMBER_OF_STARTS
ALIAS K_RSV_OIL_PRESSURE Oil_Pressure
ALIAS K_RSV_OIL_PRESSURE_LA Oil_Pressure_LA
ALIAS K_RSV_OIL_PRESSURE_LAV Oil_Pressure_LAV_In
ALIAS K_RSV_OIL_PRESSURE_LAV_DISPLAY Oil_Pressure_LAV
ALIAS K_RSV_OIL_PRESSURE_LT Oil_Pressure_LT
ALIAS K_RSV_OIL_PRESSURE_LTV Oil_Pressure_LTV_In
ALIAS K_RSV_OIL_PRESSURE_LTV_DISPLAY Oil_Pressure_LTV
ALIAS K_RSV_OIL_TEMP Oil_Temp
ALIAS K_RSV_OIL_TEMP_HA Oil_Temp_HA
Version 2.24
78 CPLC MANUAL
ALIAS K_RSV_OIL_TEMP_HAV Oil_Temp_HAV_In

ALIAS K_RSV_OIL_TEMP_HAV_DISPLAY Oil_Temp_HAV
ALIAS K_RSV_OIL_TEMP_HT Oil_Temp_HT
ALIAS K_RSV_OIL_TEMP_HTV Oil_Temp_HTV_In
ALIAS K_RSV_OIL_TEMP_HTV_DISPLAY Oil_Temp_HTV
ALIAS K_RSV_OIL_TEMP_LA Oil_Temp_LA
ALIAS K_RSV_OIL_TEMP_LAV Oil_Temp_LAV_In
ALIAS K_RSV_OIL_TEMP_LAV_DISPLAY Oil_Temp_LAV
ALIAS K_RSV_OIL_TEMP_LT Oil_Temp_LT
ALIAS K_RSV_OIL_TEMP_LTV Oil_Temp_LTV_In
ALIAS K_RSV_OIL_TEMP_LTV_DISPLAY Oil_Temp_LTV
ALIAS K_RSV_OPERATING_STATE COMPRESSOR_OPERATING_STATE
ALIAS K_RSV_OUTBOARD_BEARING_TEMP Outboard_Bearing_TempX10
ALIAS K_RSV_OUTBOARD_BEARING_TEMP_HA Outboard_Bearing_Temp_HA
ALIAS K_RSV_OUTBOARD_BEARING_TEMP_HAV Outboard_Bearing_Temp_HAV_In
ALIAS K_RSV_OUTBOARD_BEARING_TEMP_HAV_DISPLAY Outboard_Bearing_Temp_HAV
ALIAS K_RSV_OUTBOARD_BEARING_TEMP_HT Outboard_Bearing_Temp_HT
ALIAS K_RSV_OUTBOARD_BEARING_TEMP_HTV Outboard_Bearing_Temp_HTV_In
ALIAS K_RSV_OUTBOARD_BEARING_TEMP_HTV_DISPLAY Outboard_Bearing_Temp_HTV
ALIAS K_RSV_PASSWORD PASSWORD
ALIAS K_RSV_POWER_ON POWER_ON_HOURS
ALIAS K_RSV_PRELUBE Prelube
ALIAS K_RSV_RELOAD_PERCENT Reload_Percent
ALIAS K_RSV_RELOAD_PERCENT_DISPLAY Reload_Percent_Display
ALIAS K_RSV_RESET AlarmResetKey
ALIAS K_RSV_RUNNING_HOURS RUNNING_HOURS
ALIAS K_RSV_SEAL_AIR DI_Seal_Air
ALIAS K_RSV_SETPOINT_CHANGES_ENABLED Unprotected
ALIAS K_RSV_SETPOINT_RAMP_RATE PSP_Ramp_Rate
ALIAS K_RSV_SETPOINT_RAMP_RATE_DISPLAY PSP_Ramp_Rate_Display
ALIAS K_RSV_STAGE1_PRESSURE Local:4:I.Ch2Data
ALIAS K_RSV_STAGE1_TEMP Stage_1_TempX10
ALIAS K_RSV_STAGE1_TEMP_HA Stage_1_Temp_HA
ALIAS K_RSV_STAGE1_TEMP_HAV Stage_1_Temp_HAV_In
Version 2.24
CPLC MANUAL 79
ALIAS K_RSV_STAGE1_TEMP_HAV_DISPLAY Stage_1_Temp_HAV

ALIAS K_RSV_STAGE1_TEMP_HT Stage_1_Temp_HT
ALIAS K_RSV_STAGE1_TEMP_HTV Stage_1_Temp_HTV_In
ALIAS K_RSV_STAGE1_TEMP_HTV_DISPLAY Stage_1_Temp_HTV
ALIAS K_RSV_STAGE1_VIB Stage_1_VIBX100
ALIAS K_RSV_STAGE1_VIB_HA Stage_1_VIB_HA
ALIAS K_RSV_STAGE1_VIB_HAV Stage_1_Vib_HAV_In
ALIAS K_RSV_STAGE1_VIB_HAV_DISPLAY Stage_1_Vib_HAV
ALIAS K_RSV_STAGE1_VIB_HT Stage_1_VIB_HT
ALIAS K_RSV_STAGE1_VIB_HTV Stage_1_Vib_HTV_In
ALIAS K_RSV_STAGE1_VIB_HTV_DISPLAY Stage_1_Vib_HTV
ALIAS K_RSV_STAGE2_PRESSURE Local:4:I.Ch3Data
ALIAS K_RSV_STAGE3_PRESSURE Surge_PTX
Version 2.24
80 CPLC MANUAL

ALIAS K_RSV_START StartKey
ALIAS K_RSV_STARTER_FAILED DStarterFailed
ALIAS K_RSV_STARTER_FEEDBACK DI_Starter_Feedback
ALIAS K_RSV_START_TIMER Start_Timer_Preset
ALIAS K_RSV_START_TIMER_DISPLAY Start_Timer_Preset_Display
ALIAS K_RSV_STOP StopKey
ALIAS K_RSV_SURGE_INDEX_TL_INC TL_Ndx_Incr_Val
ALIAS K_RSV_SURGE_INDEX_TL_INC_DISPLAY TL_Ndx_Incr_Val_Display
ALIAS K_RSV_SURGE_RELOAD_ENABLE Surge_Reload_Enabled
ALIAS K_RSV_SURGE_SENSITIVITY Surge_SENSITIVITY
ALIAS K_RSV_SURGE_SENSITIVITY_DISPLAY Surge_SENSITIVITY_Display
ALIAS K_RSV_SURGE_UNLOAD Surge_Unload
ALIAS K_RSV_SYSTEM_PRESSURE System_Pressure
ALIAS K_RSV_TL TL
ALIAS K_RSV_TROUBLE RI_Trouble
ALIAS K_RSV_UNLOAD UnloadKey
ALIAS K_RSV_UNLOAD_DELAY_TIME Unload_Delay_Timer_Preset
ALIAS K_RSV_UNLOAD_DELAY_TIME_DISPLAY Unload_Delay_Timer_Preset_Display
ALIAS K_RSV_UNLOAD_POINT Unload_Point
ALIAS K_RSV_UNLOAD_POINT_DISPLAY Unload_Point_Display
ALIAS K_RSV_USER_PSP User_PSP
ALIAS K_RSV_USER_PSP_DISPLAY User_PSP
TAG Level_1_Condensate_HA
TAG Level_2A_Condensate_HA
Version 2.24
CPLC MANUAL 81
TAG LOADED_COUNTER
TAG LOADED_HOURS
TAG LOADED_TIMER
TAG LoadKey
TAG Load_C
TAG Load_R
TAG Low_Oil_Level_A
TAG Low_Seal_Air
TAG Low_Water_Flow_T
TAG Manual_C
TAG Manual_Tool_Enabled
TAG Master_Alarm_All
TAG Master_Alarm_Silenced
TAG Master_Alarm_Timer
TAG Master_Surge_All
TAG Master_Trip_All
TAG Master_Trip_Silenced
TAG MaxLoad_CV
TAG MaxLoad_SP
TAG Minload_Clamped
TAG MinLoad_CV
TAG MINLOAD_RESET
TAG MinLoad_SP
TAG MinLoad_SP_temp
TAG MMODE
TAG MODE
TAG Modulate_C
TAG Motor_Current
TAG Motor_Temp_Trip
ALIAS Multilin_Trip Local:2:I.Data.3
TAG M_alt_at_disabled
TAG m_al_tr_bypass_tmr
TAG m_arm
TAG m_asurge
TAG m_asurge_arm
Version 2.24
82 CPLC MANUAL
TAG m_commode_eq_1
TAG m_commode_eq_2
TAG m_detect_timer
TAG m_foursurgesin10
TAG m_hi_oil_prs
TAG m_inc_surgecnt
TAG m_lockout
TAG m_manoui_arm
TAG m_manoui_os01
TAG m_manoui_os10
TAG m_mantool_arm
TAG m_mantool_os01
TAG m_mantool_os10
TAG m_manual_disabled
TAG m_notready
TAG m_oneshot
TAG m_prev_cur
TAG m_prev_prs
TAG m_rate_current
TAG m_rate_pressure
TAG m_rate_temp1
TAG m_rate_temp2
TAG m_rate_temp3
TAG m_rate_temp4
TAG m_reload_timer_up
TAG m_reset_surgecnt
TAG m_s1t
TAG m_s2t
TAG m_s3t
TAG m_s4t
TAG m_surge
TAG m_surgec
TAG m_surgecnt_eq_1
TAG m_surgecnt_eq_2
Version 2.24
CPLC MANUAL 83
TAG m_surgecnt_eq_3
TAG m_surgecnt_eq_4
TAG m_surgecnt_eq_5
TAG m_surgep
TAG m_surget
TAG m_surget0
TAG m_surget1
TAG m_surget2
TAG m_surge_1
TAG m_surge_2
TAG m_surge_3
TAG m_surge_4
TAG m_surge_counter
TAG m_surge_reload
TAG m_surge_temp
TAG m_surge_timer1
TAG m_surge_timer2
TAG m_surge_timer3
TAG m_surge_timer4
TAG m_temp1
TAG m_temp2
TAG m_temp3
TAG m_temp4
TAG m_temp_latch
TAG m_temp_sum
TAG m_temp_sum1
TAG m_temp_sum2
TAG Near_HLL
TAG Near_IVUP
TAG Near_PSP
TAG Near_TL
TAG NT_Acknowledge
TAG NT_Load
TAG NT_Mode
TAG NT_Reset
TAG NT_Start
Version 2.24
84 CPLC MANUAL
TAG NT_Stop
TAG NT_Unload
TAG NUMBER_OF_STARTS
TAG NUMBER_OF_STARTS_COUNTER
TAG Oil_Filter_DP
TAG Oil_Filter_DP_HAV
TAG Oil_Filter_DP_HAV_In
ALIAS Oil_Pressure Local:4:I.Ch1Data
TAG Oil_Pressure_HA
TAG Oil_Pressure_HAV
TAG Oil_Pressure_HAV_In
TAG Oil_Pressure_LA
TAG Oil_Pressure_LAV
TAG Oil_Pressure_LAV_In
TAG Oil_Pressure_LT
TAG Oil_Pressure_LTV
TAG Oil_Pressure_LTV_In
ALIAS Oil_Temp Local:4:I.Ch14Data
TAG Oil_Temp_HA
TAG Oil_Temp_HAV
TAG Oil_Temp_HAV_In
TAG Oil_Temp_HT
TAG Oil_Temp_HTV
TAG Oil_Temp_HTV_In
TAG Oil_Temp_LA
TAG Oil_Temp_LAV
TAG Oil_Temp_LAV_In
TAG Oil_Temp_LT
TAG Oil_Temp_LTV
TAG Oil_Temp_LTV_In
TAG OK2Load
ALIAS Outboard_Bearing_TempX10 Local:4:I.Ch10Data
TAG Outboard_Bearing_Temp_HA
TAG Outboard_Bearing_Temp_HAV
Version 2.24
CPLC MANUAL 85
TAG Outboard_Bearing_Temp_HAV2
TAG Outboard_Bearing_Temp_HAV_In
TAG Outboard_Bearing_Temp_HT
TAG Outboard_Bearing_Temp_HTV
TAG Outboard_Bearing_Temp_HTV2
TAG Outboard_Bearing_Temp_HTV_In
TAG Outboard_Bearing_VIBX100
TAG Outboard_Bearing_VIB_HA
TAG Outboard_Bearing_Vib_HAV
TAG Outboard_Bearing_Vib_HAV2
TAG Outboard_Bearing_Vib_HAV_In
TAG Outboard_Bearing_VIB_HT
TAG Outboard_Bearing_Vib_HTV
TAG Outboard_Bearing_Vib_HTV2
TAG Outboard_Bearing_Vib_HTV_In
TAG Panelview_Handshake
TAG Panelview_Notification
TAG PASSWORD
TAG Password_Timer
ALIAS Phase_A_Temp Local:4:I.Ch11Data
TAG Phase_A_Temp_HA
TAG Phase_A_Temp_HAV
TAG Phase_A_Temp_HAV_In
TAG Phase_A_Temp_HT
TAG Phase_A_Temp_HTV
TAG Phase_A_Temp_HTV_In
ALIAS Phase_B_Temp Local:4:I.Ch12Data
TAG Phase_B_Temp_HA
TAG Phase_B_Temp_HAV
TAG Phase_B_Temp_HAV_In
TAG Phase_B_Temp_HT
TAG Phase_B_Temp_HTV
TAG Phase_B_Temp_HTV_In
ALIAS Phase_C_Temp Local:4:I.Ch13Data
TAG Phase_C_Temp_HA
TAG Phase_C_Temp_HAV
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86 CPLC MANUAL
TAG Phase_C_Temp_HAV_In
TAG Phase_C_Temp_HT
TAG Phase_C_Temp_HTV
TAG Phase_C_Temp_HTV_In
TAG POWER_ON_COUNTER
TAG POWER_ON_HOURS
TAG POWER_ON_TIMER
ALIAS Prelube Local:3:O.Data.0
TAG Pressure_Rate_SP
TAG Pressure_Size_Factor
TAG Press_ok
TAG Prev_Load
TAG Process_CV
TAG Process_SP
TAG PRTUNLD_INCL
TAG PSP
TAG PSP_Ramp_Rate
TAG PSP_Ramp_Rate_Display
TAG PSP_Tol
TAG Reload_Percent
TAG Reload_Percent_Display
TAG Reset_C
TAG Reset_R
TAG RI_Alarm
TAG RI_Auto_Start_Enabled
TAG RI_Bypass
TAG RI_HLL
TAG RI_Ready
TAG RI_Remote
TAG RI_Remote_Comm
TAG RI_Running_Unloaded
TAG RI_Surge
TAG RI_TL
TAG RI_Trip
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CPLC MANUAL 87
ALIAS RI_Trouble Local:3:O.Data.2

TAG RMT_Acknowledge
TAG RMT_Load
TAG RMT_Reset
TAG RMT_Start
TAG RMT_Stop
TAG RMT_Trip
TAG RMT_Unload
TAG Rst_Key_5S
TAG Running
TAG RUNNING_COUNTER
TAG RUNNING_HOURS
TAG RUNNING_TIMER
TAG SelEvtEnd
TAG SelEvtLastOnDisp
TAG SelEvtNum
TAG SF
TAG Silence
TAG Speed
TAG Speed_Input
TAG Speed_Input_LA
TAG Speed_Input_LAV
TAG Speed_Input_LT
TAG Speed_Input_LTV
TAG Speed_Zero_Offset
TAG Srg_Ndx_Enabl
ALIAS Stage_1_TempX10 Local:4:I.Ch6Data
TAG Stage_1_Temp_HA
TAG Stage_1_Temp_HAV
TAG Stage_1_Temp_HAV2
TAG Stage_1_Temp_HAV_In
TAG Stage_1_Temp_HT
TAG Stage_1_Temp_HTV
TAG Stage_1_Temp_HTV2
TAG Stage_1_Temp_HTV_In
ALIAS Stage_1_VIBX100 Local:5:I.Ch0Data
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88 CPLC MANUAL
TAG Stage_1_VIB_HA
TAG Stage_1_Vib_HAV
TAG Stage_1_Vib_HAV2
TAG Stage_1_Vib_HAV_In
TAG Stage_1_VIB_HT
TAG Stage_1_Vib_HTV
TAG Stage_1_Vib_HTV2
TAG Stage_1_Vib_HTV_In
TAG Stage_1_Water_Temp
TAG Stage_1_Water_Temp_HA
TAG Stage_1_Water_Temp_HAV
TAG Stage_1_Water_Temp_HAV_In
TAG Stage_1_Water_Temp_HT
TAG Stage_1_Water_Temp_HTV
TAG Stage_1_Water_Temp_HTV_In
TAG Stage_2_Temp_HA
TAG Stage_2_Temp_HT
TAG Stage_2_VIB_HA
TAG Stage_2_Vib_HAV
TAG Stage_2_VIB_HT
TAG Stage_2_Vib_HTV
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CPLC MANUAL 89
TAG Stage_3_Temp_HA
TAG Stage_3_Temp_HT
TAG Stage_3_VIB_HA
TAG Stage_3_Vib_HAV
TAG Stage_3_VIB_HT
TAG Stage_3_Vib_HTV
TAG Stage_4_TempX10
TAG Stage_4_Temp_HA
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90 CPLC MANUAL
TAG Stage_4_Temp_HT
TAG Stage_4_VIBX100
TAG Stage_4_VIB_HA
TAG Stage_4_Vib_HAV
TAG Stage_4_VIB_HT
TAG Stage_4_Vib_HTV
TAG Stage_5_TempX10
TAG Stage_5_Temp_HA
TAG Stage_5_Temp_HT
TAG Stage_5_VIBX100
TAG Stage_5_VIB_HA
TAG Stage_5_Vib_HAV
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CPLC MANUAL 91
TAG Stage_5_VIB_HT
TAG Stage_5_Vib_HTV
TAG Starter_Failure
TAG Starter_Failure_Enabled
TAG Starting
TAG StartKey
TAG Start_C
TAG Start_Disable
TAG Start_Enabled
TAG Start_R
TAG Start_Timer
TAG Start_Timer_Preset
TAG Start_Timer_Preset_Display
TAG StopKey
TAG Stop_C
TAG Stop_R
TAG Strtr_Fail_Enabl
TAG Surge_ndx_TL_Value
TAG Surge_OS
ALIAS Surge_PTX Local:4:I.Ch4Data
TAG Surge_Reload_Enabled
TAG Surge_SENSITIVITY
TAG Surge_SENSITIVITY_Display
TAG Surge_Timer_120ms
TAG Surge_TTX
TAG Surge_Unload
ALIAS System_Pressure Local:4:I.Ch0Data
Version 2.24
92 CPLC MANUAL
TAG Temperature_Rate_SP
TAG test
TAG Timer_120ms
TAG TL
TAG TL_Ndx_Incr_Val
TAG TL_Ndx_Incr_Val_Display
TAG TL_PID
TAG TL_Tol
TAG t_adjust_down
TAG t_adjust_up
TAG t_adjust_valve
TAG t_bad_start
TAG t_blowing_off
TAG t_cem_delay
TAG t_cem_timeout
TAG t_disabled
TAG t_dismode
TAG t_down_is_ok
TAG t_enabled
TAG t_endack
TAG t_endload
TAG t_endmode
TAG t_endreset
TAG t_endstart
TAG t_endstop
TAG t_endunld
TAG t_full_ppid
TAG t_go_down
TAG t_go_up
TAG t_havemode
TAG t_have_valve
TAG t_high_pid
TAG t_hold_still
TAG t_h_mc_point
Version 2.24
CPLC MANUAL 93
TAG t_isblow
TAG t_is_ramp
TAG t_load_pushed
TAG t_low_pid
TAG t_l_mc_point
TAG t_max_adjust
TAG t_max_scale
TAG t_mc_is_high
TAG t_mc_is_low
TAG t_mc_pcnt
TAG t_mc_span
TAG t_min_adjust
TAG t_newmode
TAG t_nocommode
TAG t_not_active
TAG t_no_adjust
TAG t_no_bypass
TAG t_no_need_ramp
TAG t_no_ramp
TAG t_no_track
TAG t_p_g_psp
TAG t_p_is_high
TAG t_p_is_low
TAG t_p_l_psp
TAG t_p_scale
TAG t_recv_cmnd
TAG t_set_psp
TAG t_srr_temp
TAG t_srr_track
TAG t_start_pushed
TAG t_temp_a
TAG t_temp_l
TAG t_temp_m
TAG t_temp_r
TAG t_temp_s
TAG t_temp_u
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94 CPLC MANUAL
TAG t_test
TAG t_unload_pushed
TAG t_up_is_ok
TAG t_user_ppid_p
TAG t_valve_v
TAG UI_AltLanguage
TAG UnloadKey
TAG unload_c
TAG Unload_Delay_Timer_Preset
TAG Unload_Delay_Timer_Preset_Display
TAG Unload_Point
TAG Unload_Point_Display
TAG Unload_R
TAG Unprotected
TAG User_PSP
TAG Waiting
TAG Wait_Timer
Version 2.24
CPLC MANUAL 95
Documentation
Electrical Schematic, Pneumatic Schematic, and Panel Outline drawings are provided
as standard after order placement. Control Logic diagrams are considered
proprietary and are not available.
Version 2.24
96 CPLC MANUAL
Glossary
The following glossary is universal. Some terms do not apply to all CPLC systems.
Ad_unload_tmr Autodual unload timer. The time delay, in seconds, at which the
machine will be unloaded after the bypass valve has passed and stayed
below the unload point when Autodual is active.
ASF Adjusted Service Factor. The Ingersoll-Rand supplied value for
determining HLL.
Auto_Start_Pressure The system pressure, in pressure setpoint units, at which the machine
will start when either auto hot or cold start is active.
Bat_Var_1 Battery Backed Variable 1. Password character 1 that is entered by the
user to enable set point changes. This value is compared to the system
password character 1.
Bat_Var_5 Battery Backed Variable 5. The power on hour meter.
Bat_Var_6 Battery Backed Variable 6. The running hours hour meter.
Bat_Var_7 Battery Backed Varable 7. The loaded hour meter.
Bat_Var_8 Battery Backed Variable 8. The number of starts counter.
BCM Base Control Module. Allen Bradley processor card.
Bv_Closed_Value Bypass Valve Closed Value. This setting determines the value at which
the bypass valve is considered closed. This value is used in logic to
determine when to release the inlet valve from throttle limit control and
enable the inlet valve for pressure control etc.
Bv_Open_Value Bypass Valve Open Value. This setting determines the value at which
the bypass valve is considered open. This value is used in logic to
determine when to release the inlet valve for unloading.
BV_P_PID_D Bypass Valve Pressure PID Derivative. The Bypass valve pressure
control derivative constant, dimensionless.
BV_P_PID_I Bypass Valve Pressure PID Integral. The Bypass valve pressure control
integral constant, dimensionless.
BV_P_PID_P Bypass Valve Pressure PID Proportional. The Bypass valve pressure
control proportional constant, dimensionless.
BV_Unload_Rate Bypass Valve Unload Rate. This setting determines the rate at which
the bypass valve will open during an unload sequence.
Bypass_Valve_C Bypass Valve Command. The position, in percent open, sent to the
bypass valve by the controller. This is the value of an analog output.
Bypass_Valve_Manl Bypass Valve Manual. The manual bypass valve position, in percent
open.
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CPLC MANUAL 97
CPLC, CPLC System Any combination of CPLC control components which when combined
create a control system. The typical CPLC system consists of a Base
Control Module (BCM), Operator User Interface (OUI), and Power
Supply (PS). A common variation on the typical system is the addition
of a Universal Communications Module (UCM).
Coast_Timer The time interval, in seconds, between a compressor stop or trip and the
motor coming to a complete stop. The timer is used to inhibit restarting.
Compressor Load, The power consumption of the compressor. It is typically indicated in
Load amps, kilowatts, SCFM, etc.
Control Variable, The variable being regulated. When at MinLoad the control variable is
Process Variable load for the inlet valve and System Pressure for the bypass valve.
When at MaxLoad the control variable is load and when loaded the
control variable is System Pressure.
CT Input Channel The current transformer Input Channel. This always equals five (5).
CT_Ratio Current Transformer Ratio. The current transformer ratio used in
displaying the motor current; e.g. 600:5 = 120.
Current_Rate_SP The current rate set point for the analog surge sensor.
degC Degrees Celsius, Centigrade
degF Degrees Fahrenheit
Digital Device A device which is either on or off ie. The N.C. contact on the seal air
switch.
Discharge Pressure The gas pressure between the last stage of compression and the check
valve.
ERAM Erasable Random Access Memory.
FLA Motor Full Load Amps. The motor amperage at full load, this value is
found on the motor nameplate.
High Load Limit See HLL
HLL High Load Limit. The load that the controller maintains when at
MaxLoad.
I/O Input/Output. The interface between the compressor and the control
system. This term generically applies to the entire interface circuit
including sensor, wiring, and junction points.
Inlet Unload Position The position of the inlet valve during starting, coasting, and unloaded..
Inlet_Valve_C Inlet Valve Command. The position, in percent open, sent to the inlet
valve by the controller. This is the value of an analog output.
Inlet_Valve_Manl Inlet Valve Manual. The manual inlet valve position, in percent open.
Integral Time The corrective action to the proportional band to ensure that the system
air pressure is maintained at the system pressure set point. This value
is expressed in repeats per second and represents the number of times
per second the integral control acts on the proportional band as a
corrective action.
IV_HLL_PID_D Inlet Valve High Load Limit PID Derivative. The inlet valve high load limit
IV_HLL_PID_I Inlet Valve High Load Limit PID Integral. The inlet valve high load limit
control integral constant, dimensionless.
IV_HLL_PID_P Inlet Valve High Load Limit PID Proportional. The inlet valve high load
limit control proportional constant, dimensionless.
IV_P_PID_D Inlet Valve Pressure PID Derivative. The inlet valve pressure control
derivative constant, dimensionless.
IV_P_PID_I Inlet Valve Pressure PID Integral. The inlet valve pressure control
IV_P_PID_P Inlet Valve Pressure PID Proportional. The inlet valve pressure control
proportional constant, dimensionless.
IV_TL_PID_D Inlet Valve Throttle Limit PID Derivative. The inlet valve throttle limit
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98 CPLC MANUAL
IV_TL_PID_I Inlet Valve Throttle Limit PID Integral. The inlet valve throttle limit control
IV_TL_PID_P Inlet Valve Throttle Limit PID Proportional. The inlet valve throttle limit
control proportional constant, dimensionless.
IV_Unld_Pos Inlet Valve Unload Position. Inlet valve position when the compressor is
running unloaded.
IV_Unload_Rate Inlet Valve Unload Rate. This setting determines the rate at which the
inlet valve will open during an unload sequence.
m_rate_current The steady state current rate value.
m_rate_pressure The steady state pressure rate value.
mA Milliampere
Manual_C Manual Control. (1) Enables and (0) disables manual valve control.
MaxLoad The message displayed on the OUI Status Bar when the machine is
running at High Load Limit.
MinLoad The message displayed on the OUI Status Bar when the machine is
running at Throttle Limit.
Motor_Current Motor current, in amps.
Oil_Pressure Oil pressure.
Oil_Pressure_LAV Oil Pressure Low Alarm Value.
Oil_Pressure_LTV Oil Pressure Low Trip Value.
Oil_Temp_HAV Oil Temperature High Alarm Value.
Oil_Temp_HTV Oil Temperature High Trip Value.
Oil_Temp_LAV Oil Temperature Low Alarm Value.
Oil_Temp_LTV Oil Temperature Low Trip Value.
Oil_Temperature Oil temperature.
OUI Operator User Interface.
PASSWD1 Password Variable 1. This is the system password character 1.
PID Proportional, Integral, Derivative. The parameters used to adjust the
behavior of PID control loops.
Pressure_Rate_SP The pressure rate set point for the analog surge sensor.
PROM Programmable Read Only Memory.
Proportional Band The change in system air pressure that causes full travel of the inlet
valve. This value is expressed as a percentage of the system air
pressure set point.
PSP_Ramp Pressure Set Point Ramp Rate. The rate at which the system pressure
set point is incremented to the user system pressure set point. This is
used to prevent system pressure overshoot when loading the
compressor.
PSP_Tol Pressure Setpoint Tolerance. This setting determines the pressure
value tolerance at which valve control transitions between states; i.e.,
load limit to pressure control.
RAM Random Access Memory.
Reload_Percent The reload pressure, in percent of user system pressure set point, at
which the machine will load when Autodual is active.
RTD Resistance Temperature Detector.
Serial Device A Personal Computer (PC), Programmable Logic Controller (PLC),
Distributed Control System (DCS) or any other device that can transmit,
receive and interpret an RS232 formatted signal.
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CPLC MANUAL 99
Setpoint Ramp Rate The gradual increase of the system pressure set point during a loading
operation of the compressor. The ramping of the system pressure set
point helps to smooth the transition and prevents a pressure overshoot
in the air system upon initial compressor loading.
Stage(n)_Temp Stage (n) Temperature. This air temperature for stage “n”, where “n”
can be 1, 2, 3, 4 or 5, is measured at the discharge from the inter or
after cooler. This is the value of an analog input.
Stage(n)_Temp_HAV Stage (n) Temperature High Alarm Value. This is an air temperature set
point for the high alarm value. This applies to stage “n”, where “n” can
be 1, 2, 3, 4 or 5.
Stage(n)_Temp_HAV2 Stage (n) Temperature High Alarm Value during running, coasting or
stopped.. This is an air temperature set point for the high alarm value of
the 2x multiplier. This applies to stage “n”, where “n” can be 1, 2, 3, 4 or
5.
Stage(n)_Temp_HTV Stage (n) Temperature High Trip Value. This is an air temperature set
point for the high trip value. This applies to stage “n”, where “n” can be
1, 2, 3, 4 or 5.
Stage(n)_Temp_HTV2 Stage (n) Temperature High Trip Value during running, coasting or
stopped.. This is an air temperature set point for the high trip value of
the 2x multiplier. This applies to stage “n”, where “n” can be 1, 2, 3, 4 or
5.
Stage(n)_Vib Stage (n) Vibration. This vibration for stage “n”, where “n” can be 1, 2,
3, 4 or 5. This is the value of an analog input.
Stage(n)_Vib_HAV Stage (n) Vibration High Alarm Value. This is a vibration set point for
the high alarm value. This applies to stage “n”, where “n” can be 1, 2, 3,
4 or 5.
Stage(n)_Vib_HAV2 Stage (n) Vibration High Alarm Value during running, coasting or
stopped. This is a vibration set point for the high alarm value of the
2x multiplier. This applies to stage “n”, where “n” can be 1, 2, 3, 4 or 5.
Stage(n)_Vib_HTV Stage (n) Vibration High Trip Value. This is a vibration set point for the
high trip value. This applies to stage “n”, where “n” can be 1, 2, 3, 4 or
5.
Stage(n)_Vib_HTV2 Stage (n) Vibration High Trip Value during running, coasting or stopped..
This is a vibration set point for the high trip value of the 2x multiplier.
This applies to stage “n”, where “n” can be 1, 2, 3, 4 or 5.
Start_Timer The time interval, in seconds, between pressing the Start button and the
compressor is running at full speed. The timer is used to transition wye
delta starters, inhibit loading, deenergize the prelube pump, and disable
the alternate alarm and trip setpoints..
Status Bar The Status Bar provides four distinct types of information (Compressor
Operating State, Compressor Status, Compressor Control Location and
Page Number). This region is always visible from any folder and page
combination.
Surge Indexing A method of automatically increasing the setting of TL upon a surge.
Surge Indexing TL The setpoint which the inlet valve controls to at MinLoad.
Surge_PTX Surge Pressure Transducer. Surge_PTX is mounted between the last
compression stage and the check valve.
System Pressure The pressure at the location of the system pressure transducer.
Throttle Limit See TL
TL Throttle Limit. Establishes the minimum flow through the machine when
loaded, it is the maximum point of inlet valve throttling. If system
demand is below this throttle point, the compressor must bypass air to
maintain pressure setpoint or unload.
TL increment value When Surge Indexing is enabled, the TL increment value is the amount
added to the Surge Indexing TL upon a surge. The Surge Indexing TL
Version 2.24
100 CPLC MANUAL
will stop being incremented when and if the value reaches HLL.
TL_Tol Throttle Limit Tolerance. This setting determines the load value
tolerance at which inlet valve control transitions from pressure control to
throttle limit control.
UCM Universal Communications Module.
Unload_Point The bypass valve position, in percent open, at which the Autodual
unload timer will start timing to unload the compressor when Autodual is
active.
User_PSP User Pressure Set Point. The local control pressure set point.
VDC Volts Direct Current
Wait_Timer The delay interval, in seconds, between power up and the ready state.
Version 2.24

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CENTAC

Copyright 2001 Ingersoll-Rand Company

Printing Date: 26-March-2001

Graphic Display _________________________________________________________________ 20

General - CPLC Panel

Figure 1: Compressed Air System

Constant Pressure Control - Modulate

discharge pressure is maintained by modulating the Discharge Maximum

atmosphere. This valve is opened just prior to reaching Unloaded

capacity setting. Modulate provides a constant discharge Throttle

pressure with variable capacity from design to zero. Surge Line

This control method is used when reliable control of the Power at

Energy Saving Control - Autodual Figure 2: Modulate Control

since at this point the machine is not supplying the

set to prevent unloading during short excursions Bypass Inlet

determines the System Pressure at which the machine Curve

Figure 4: Performance Control

What is the valve response when the difference

related to valve cycling; so, as It decreases, valve life

As shown, when Pg is low and

activity, and may never reach

cannot be attained for the T=hot curve

limits the inlet valve.

When ambient conditions produce the

service factor, the maximum compressor

System Compressor Compressor Open Position

Electro-pneumatic Controllers and Low Limit Relay (LLR)

based upon the current inlet valve position. For

reaches the LLR setting, the bypass valve would

This methodology works well for constant pressure

as 45 degF (7 degC) and can get as hot as 70 degF Energy

(52 degC) during the day. If the LLR is set at night,

The CPLC Advantage

(amps), V-Motor Voltage, ηmotor-Motor

is relatively small compared to the change T=cold

Since the change is relatively small, only a Wasted Energy

small amount of energy is wasted by not Power at

Insufficient Rise To Surge T=cold

Rise to surge is the percentage of the

Changes in System Discharge

Rapid System Demand Changes

Incorrect Instrumentation Output

How is Surge Detected?

Figure 12: Changes in Discharge Pressure

Oil System Control

Protection and Monitoring

Starts the compressor.

Engages Modulate or Autodual control

Unloads the compressor.

Stops the compressor. This button

Enter Key - Display Operating Mode

SYSTEM INFO SETTINGS

Status Load Selected Page

Graphics Display Area Definitions

Folder and Page

Edit (Setpoint Changes) Mode

SYSTEM Folder INFO Folder SETTINGS Folder

SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS

SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS

SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS

SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS

SYSTEM INFO SETTINGS

FOLDER NAVIGATION Loaded Load Selected

SYSTEM INFO SETTINGS