Vission 20/20 micro-controller Operation and service manual
Table of Contents Section Title Section Number How To Use This Manual....................................................................................................................TOC-8 Section 1 • Operational Flow Charts Requirements to Start Compressor ...................................................................................................1-1 Critical Compressor Run Logic at Compressor Start ...........................................................................
Table of Contents Section Title Section Number Section 4 • Main Screen Overview ..........................................................................................................................................4-1 Figure 4-1. Digital I/O Board Layout...................................................................................................4-1 Top Status Bar ...................................................................................................................................
Table of Contents Section Title Section Number Section 10 • Compressor Sequencing Overview ..........................................................................................................................................10-1 Pressure Control Setpoints ................................................................................................................10-1 Figure 10-1. Compressor Sequencing Screen ....................................................................................
Table of Contents Section Title Section Number Section 16 • Event List Overview ..........................................................................................................................................16-1 Event list Columns.............................................................................................................................16-1 Figure 16-1. Event List Screen............................................................................................................
Table of Contents Section Title Section Number Section 20 • Data Backup Overview ..........................................................................................................................................20-1 Save / Load........................................................................................................................................20-1 Figure 20-1. Data Backup Screen - Save/Load ....................................................................................
List of Tables and Figures Table/Figure Page Number Table 3-1. Digital I/O .........................................................................................................................3-3 Table 3-2. Analog Inputs....................................................................................................................3-5 Table 3-3. Analog Outputs.................................................................................................................3-7 Table 3-4.
List of Tables and Figures Table/Figure Page Number Figure 19-4. Configuration Screen - Page 4........................................................................................19-7 Figure 19-5. Configuration Screen - Page 5........................................................................................19-8 Figure 19-6. Configuration Screen - Page 6........................................................................................19-9 Figure 20-1. Data Backup Screen - Save/Load .........
How to Use This Manual This manual contains instructions for the Vission 20/20 Operation & Service Manual. It has been divided into 25 sections. CAUTION - Caution statements are shown when there are potentially hazardous situations, if not avoided, will result in damage to equipment. Section 1: Operational Flow Charts NOTE - Notes are shown when there are addtional information pertaining to the instructions explained.
Section 1 • Operational Flow Charts Requirements to Start Compressor Volume and Capacity slides are less than 5% Oil Separator Temp >Oil Sep Start Trip Setpt Filter Diff Press < Start Filter Diff Trip Setpt Oil Pump On: Prelub Oil Press is > Prelub Oil Press Reset Setpt for “Min Compressor Prelub Timer” setting (typically 5 seconds) Start Compressor Critical Compressor Run Logic at Compressor Start Start Compressor Is Run Oil Press> Prelub Oil Press Reset setpt? (Default 5 PSI) Yes “Oil Press Bypass
Section 1 • Operational Flow Charts Suction Pressure Override Load Limit During Temperature Control Is Suction Press < Suct Press Cap Dec OFF Setpt? Yes Capacity Increase Disabled Yes Decrease compressor capacity until Suction Press > Suction Press Cap Decrease ON setpoint. No Normal Loading and Unloading No Is Suction Press < Suct Press Cap Dec ON Setpt? Figure 1-1. Operational Flow Charts (2 of 2) 1 – 2 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.8.
Section 2 • Installation Recommendations Proper Wiring Sizing • Always size wire gauges as specified by the National Electrical Code (NEC) for electronic control devices. • For improved noise immunity, install one size larger wire gauge than the NEC requirement to assure ample current-carrying capability. • Never under size wire gauges. Voltage Source • Transformers block a large percentage Electro-Magnetic Interference (EMI).
Section 2 • Installation Recommendations Grounding Each voltage level must be run in separate conduit: • Continuous grounds must be run from the utility ground to the Vission 20/20, see Figure 2-3. Grounding. • 460 VAC • Grounds must be copper or aluminum wire. • 120 VAC • Never use conduit grounds. • 24 VAC Mixing Voltages • 230 VAC DC signals • Separate different voltages from each other and separate AC from DC, see Figure 2-4. Mixed Voltage Wiring.
Section 2 • Installation Recommendations Wiring Methods • Each Vission 20/20 panel should have its own individual control transformer, see Figure 2-5. Correct Transformer Wiring Method and Figure 2-6. Incorrect Transformer Wiring Method. Figure 2-5. Correct Transformer Wiring Method Figure 2-6. Incorrect Transformer Wiring Method Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.8.
Section 2 • Installation Recommendations Best Practices • Do: • Keep AC wires away from circuit boards. • Always run conduit into the bottom or sides of an enclosure. • If the conduit must be placed in the top of an enclosure, use a water-tight conduit fitting to keep water from entering the enclosure. • The Vission 20/20 is supplied with prepunched conduit holes. Use them! • Don’t: • Don’t run wires through the Vission 20/20 enclosure that are not related to the compressor control.
Section 3 • Hardware Architecture Overview The Vission 20/20 control panel utilizes X-86 PC technology with a Linux operating system. For hardware architecture, see Figure 3-1 Hardware Architecture Overview. The Vission 20/20 has the following attributes: • Low power, Industrial rated X-86 CPU. • 15” XGA, high resolution LCD display. (Outdoor viewable LCD optional). • 8-wire touch screen operator interface. • Flexible and expandable I/O. • NEMA-4 enclosure (NEMA-4X optional).
Section 3 • Hardware Architecture Digital Input/Output (I/O) Trip Output: Refer to Table 2-1. Digital I/O. • This output is energized when the system has no Trips. If a trip is issued, the output de-energizes and stays de-energized until the trip condition is cleared. Compressor Start Output: • When the Vission 20/20 signals the compressor to start, this output is energized. When the Vission 20/20 signals the compressor to stop, this output is de-energized.
Section 3 • Hardware Architecture Table 3-1.
Section 3 • Hardware Architecture High Level Shutdown Input: Condenser Step #3 Output: • This input must be energized in order for the compressor to operate. If de-energized, the compressor will shut down and issue a high level trip. • This output is enabled when condenser control option is selected. A condenser fan or pump will be turned on or off by this output. Oil Level Float Switch #1 Input: Condenser Step #4 Output: • Used for Cool Compression.
Section 3 • Hardware Architecture Table 3-1. Digital I/O (2 of 2) Description Board I/O # 5 33 Auxiliary Output #1 OUTPUT 5 34 Auxiliary Output #2 OUTPUT 5 35 Auxiliary Output #3 OUTPUT 5 36 Auxiliary Output #4 OUTPUT 5 37 Auxiliary Input #5 INPUT 5 38 Auxiliary Input #6 INPUT 5 39 Auxiliary Input #7 INPUT 5 40 Auxiliary Input #8 INPUT Table 3-2.
Section 3 • Hardware Architecture Volume Position: % Slide Valve Position: • Reads the 0-5 volt signal back from the slide volume motor actuator to indicate current volume position. • 4-20mA signal that transmits the slide valve position for remote monitoring. Suction Temperature: Motorized Valve (V+): • Default signal is RTD. Suction temperature calibration is set in the calibration screen.
Section 3 • Hardware Architecture Table 3-2. Analog Inputs (2 of 2) Description Board I/O # 9 28 Auxiliary #12 0-5V, 1-5 V, 0-10V, 4-20 mA, RTD, ICTD 9 29 Auxiliary #13 0-5V, 1-5 V, 0-10V, 4-20 mA, RTD, ICTD 9 30 Auxiliary #14 0-5V, 1-5 V, 0-10V, 4-20 mA, RTD, ICTD 9 31 Auxiliary #15 0-5V, 1-5 V, 0-10V, 4-20 mA, RTD, ICTD 9 32 Auxiliary #16 0-5V, 1-5 V, 0-10V, 4-20 mA, RTD, ICTD Table 3-3.
Section 3 • Hardware Architecture Digital Output Boards Voltage LED’s: The digital output board convert signals generated by the Vission 20/20 program into 120Vac signals that can be energize or signal other devices. All the signals are digital in that the only two states available or either on or off. See board layout, Figure 3-3. Digital Output Board Layout. • Marked in the diagram below in Orange. These LED’s indicated the correct voltage of both the 5Vdc and 24Vdc power sources.
Section 3 • Hardware Architecture Digital Input Boards Voltage LEDs: The digital input board convert 120Vdc signals from external devices to signal for the Vission 20/20 program. All the signals are digital in that the only two states available or either on or off. See board layout, Figure 3-4. Digital Input Board Layout. • Marked in the diagram below in Orange. These LEDs indicated the correct voltage of both the 5Vdc and 24Vdc power sources. Communication LEDs: • Marked in the diagram below in Green.
Section 3 • Hardware Architecture Digital In-Out Boards Voltage LEDs: The digital input - output board convert signals generated by the Vission 20/20 program into 120Vac signals as well as detect external 120Vac inputs to signal the Vission 20/20 program. All the signals are digital in that the only two states available or either on or off. See board layout, Figure 3-5. Digital Input-Output Board Layout. Signal LEDs: • Marked in the diagram below in Blue or outputs and light blue for inputs.
Section 3 • Hardware Architecture Analog Input Boards Voltage LEDs: The analog input board convert varying DC signals into a signal that can interpreted by the Vission 20/20 program. The signals are considered analog because the input DC signal can vary from the minimum value to the maximum value. See board layout, Figure 3-6. Analog Input Board Layout. • Marked in the diagram below in Orange. These LEDs indicated the correct voltage of both the 5Vdc and 24Vdc power sources.
Section 3 • Hardware Architecture Analog Input Jumper Tables The following tables are used to configure each channel of the analog input board signal type and range desired by the operator, see Table 2-4. Analog Input Jumper Tables. Table 3-4.
Section 3 • Hardware Architecture Table 3-4.
Section 3 • Hardware Architecture Analog Output Boards Communication LED’s: The Analog Output board convert signals form the Vission 20/20 program into a current ranging from 4mA to 20mA, see Figure 3-7. Analog Output Board Layout. Voltage LEDs: • Marked in the diagram below in Orange. These LEDs indicated the correct voltage of both the 5Vdc and 24Vdc power sources. • Marked in the diagram below in Green.
Section 4 • Main Screen Overview The Main Screen is the first screen encountered when powering up the Vission 20/20 Panel, see Figure 4-1. Main Screen. This screen is designed as the starting point for all succeeding screens and provides as much information as possible at a glance. The Main Screen is divided into four sections. Three of the sections are static; Top Status Bar, Bottom Status Bar and Parameters Bar.
Section 4 • Main Screen Top Status Bar The standard view of the status bar shows three pieces of information. From left to right , the bar shows the control method, the current run mode, and the difference between the desired control setpoint and the actual value of the processes control value, see Figure 4-2. Top Status Bar. The status bar also has an alternate function where it displays to the user any information that requires user attention or intervention.
Section 4 • Main Screen Parameter Bar Stop Button: The main purpose of the Parameter Bar is to display the common operational parameters that the operator would be most concerned with. It also gives the operator access to critical buttons such as the stop and start buttons, see Figure 4-3. Parameter Bar. Capacity Slide Indicator: • Shows the position of the capacity slide from 0% to 100% via a horizontal blue bar. The buttons below the indicator are used in manual capacity control.
Section 4 • Main Screen Parameter Bar (Continued) • The suction box shows the current suction pressure and suction temperature. Unit Start Button: • The discharge box shows the current discharge pressure and discharge temperature . • When pressed, a start dialog box will appear that will give the operator a number of run options; Auto, Manual, Remote, or auto sequencing, see Figure 4-4. Unit Start Pop-Up Window.
Section 4 • Main Screen Bottom Status Bar screen to create additional users. The bottom status bar gives the operator easy access to some basic functions and information. The functions are available via the four button, see Figure 4-5. Bottom Status Bar. Maintenance Button: • Pressing the maintenance button will give the operator access to the maintenance charts and sign off tables.
Section 4 • Main Screen Splash Screen Process: The splash screen is the dynamic portion of the screen that will change as the operator navigates through the Vission 20/20 panel screen, see Figure 4-6. Splash Screen. The main screen shows a graphic of a Vilter compressor with a number of data boxes spread across the screen. Also on the top left are several indicators. • When the Process control is selected as the control mode, this box will appear and displays the process temperature.
Section 5 • Menu Screen Overview Compressor scheduling: The menu screen is the launching point to every other section of the Vission 20/20 panel software. Every screen navigated to from this screen will return to the menu screen upon exiting, see Figure 5-1. Menu Screen. Navigation Buttons • Navigates to the compressor scheduling screen where the operator can set the scheduler to change the control method at settable dates and times.
Section 5 • Menu Screen Instrument calibration: • Navigates to the instrument calibration screen where the operator can calibrate all of the system sensors. Slide calibration: • Navigates to the slide calibration screen where the operator can calibrate the capacity and volume slide actuators. Trend chart: • Navigates to the trend chart screen where the operator can select up to four parameters for graphical historical data trending.
Section 6 • Compressor Control Overview The compressor control screen is where an operator can set the majority of the compressor settings. These setting define how the compressor will operate and respond to changing loads. The compressor control screen consists of several screens but in order not to overwhelm the operator with options, many of the screens may not be visible. How the compressor is configured in the configuration screen will determine what screens are displayed.
Section 6 • Compressor Control As mentioned in the above paragraph, the distance of the process variable from the control setpoint determines the size of the pulse used to move the capacity slide. This is called the proportional band and is set by the Proportional Setpoint. When the process variable is outside the proportional band, the slide will move in the direction of the error continuously.
Section 6 • Compressor Control The auto-cycle function will operate only in local “Auto” mode and Direct I/O “Remote Auto” mode. If the auto-cycle feature is enabled while running in any other remote mode, the function will simply be ignored. However, the Minimum slide position will continue to be respected in Remote “Auto” mode. If the compressor changes from a remote mode back to Local “Auto” mode, the auto-cycle feature will operate normally.
Section 6 • Compressor Control NOTE VFD installation is not covered in this manual. A VFD that is not properly installed and configured has the potential of causing intermittent and dangerous problems. Please consult your VFD manual. 1 Step VFD Control: • Enables the first step in the VFD control algorithm. This check box is not deselectable by the operator. Capacity Slide Position: • Defines the minimum and maximum positions for the capacity slide.
Section 6 • Compressor Control This button is active only when compressor is in local Auto mode and Control Mode Configured is Suction Pressure. This button will display “Run” when Pumpdown operation has not started or stopped, while button will display “Stop” when Pumpdown operation is running. When Pumpdown feature is enabled, Pulldown checkbox is automatically grayed out.
Section 6 • Compressor Control grayed out and hence, the user will not be able to operate Pulldown feature. This is done to keep Pulldown & Pumpdown features mutually exclusive. Slide Valve Setpoint: • Operator editable labels for the each output. Slide %: • Indicates the capacity slide position where the digital output is triggered. Control Mode This drop down box gives the operator the ability to change the type of control mode such as suction pressure control or process temperature control.
Section 6 • Compressor Control Load Anticipating Liquid Injection Solenoid Control ONLY The purpose of the load anticipating algorithm is to reduce the amount of overshoot of the capacity slide position while the compressor attempts to meet the control setpoint. This advanced feature of the Vission 20/20 closely monitors the rate of change of the process variable and compares it to the control setpoint.
Section 6 • Compressor Control operator consult PID tuning guides available from many different source before attempting to tune this PID. Liquid inj. Setpoint 1: • Setpoint at which the liquid solenoid will activate if in solenoid control or if the setting for the control variable for the PID is in liquid motorized value control. Liquid inj. Setpoint 2: • Not yet available Oil Sep. Temp. Override: • Defines the temperature the oil must reach before the liquid injection solenoid is allowed to be activated.
Section 7 • Alarms and Trips Overview Alarms and Trips Setpoints The Alarms and Trips screen allows the operator to view and adjust settings for compressor safety and alarm settings, see Figure 7-1. Alarms and Trips Screen. Vission 20/20 uses Alarms as a way to notify the operator of running parameters that if left unchecked could result in the compressor shutting down due to a trip. Trips are the conditions that exceed the safety limits of the compressor or refrigeration system and stops the compressor.
Section 7 • Alarms and Trips selected in the Control Mode dropdown selection found in the Compressor Control screen. An alarm or trip will be activated on a drop in process temperature below the setpoint value. Low Suction Temperature (Alarm & Trip): • This is the low suction temperature safety. The alarm or trip will be activated if the suction temperature drops below the setpoint value. High Discharge Temperature (Alarm & Trip): • This is the high discharge temperature safety.
Section 7 • Alarms and Trips Compressor Inhibits The Vission 20/20 uses several start inhibits to prevent the compressor from starting to protect the compressor and the refrigeration system. While starting the compressor, the inhibits are checked first before the oil pump is started or the motor is started. The failed starts due to an inhibit does not count toward any of the antirecycle timers including hot starts. The Inhibits uses the alarm setpoint to trigger an aborted start and message.
Section 7 • Alarms and Trips False Start • This message appears when the compressor stops and the motor auxiliary contact fails to open. The message will also appear if the compressor shuts down and the amperage is 20% of the maximum amp setting, indicating that the starter is still energized. Low Oil Level Trip • This message appears when power is removed from the designated input module, refer to wiring diagram.
Section 8 • Timers Overview amount of time. Timers: The timers screen allows the operator to view and adjust timer settings associated with compressor operation. There are different types of timers that the operator should be aware of listed below, see Figure 8-1. Timers Screen. Timer Setpoints Changeover: Capacity Increase Start Delay: • The changeover timers will change from one type control to another once the compressor has started and then the timer has expired.
Section 8 • Timers Low Oil Pressure Safety Bypass: • This is the length of time in which the normal Low (Run) Oil Pressure setpoints will be adjusted by the values of the Pre-lube Oil Pressure setpoints. After the timer has expired, the normal Low Oil Pressure setpoints become active. failure. This will prevent excessive load demand on the power system that could occur if all of the compressor equipment were to start at the same time.
Section 8 • Timers to remove all power to the system. Low Suction Pressure Safety Bypass: • Sets the time that the compressor is allowed to run at lower suction pressure then would usually be allow at start up. High Superheat Temp Safety Changeover: • This timer activates at shutdown and changes the restart parameters if the time has not been met. Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.8.
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Section 9 • Compressor Scheduling Overview This menu allows the operator to schedule control setpoint switching during the day and week. This feature can be enabled and disabled from the Compressor Schedule screen. Up to four setpoint “switch” events can be scheduled per day, see Figure 9-1. Compressor Scheduling Screen. Scheduling Setpoint Schedule: • The options for selection are “Enable” & “Disable”.
Section 9 • Compressor Scheduling as “Unscheduled” if operator does not want to use all 4 events per day. Time: • This setpoint allows selection of Hours, Minutes and AM/PM values for an event. When time set for an event is achieved, control mode will get changed as selected for that event. • The range of values allowed to set for Hours setpoint is 0 – 12 for 12 hour format and 0 – 23 for 24 hour format. The range of values allowed to set for Minutes setpoint is 0 – 59.
Section 10 • Compressor Sequencing Overview Compressor Name: Compressor sequencing screen is where more than one Vission 20/20 panels can be sequenced in network using Modbus TCP. These settings define how the master compressor should control sequenced Vission 20/20 panels. This feature is enabled from the Configuration Screen, see Figure 10-1. Compressor Sequencing Screen. • Defines Unique name of a Compressor / Vission 20/20 Panel on sequenced network.
Section 10 • Compressor Sequencing monitor compressor load. If Suction pressure / process temperature goes beyond Load Rate 1 setpoint offset then sequencing decisions are made according to Load Rate 1 timer. Suction Pressure/Process Temperature Control Setpoint: • The target setpoints are read only values here. These setpoints can be changed by logging on to “Compressor Control” Screen. Unload Rate 1 Offset (inner): • Defines the inner pressure/temp setpoint to monitor compressor load.
Section 10 • Compressor Sequencing Status Symbols: • Status symbols shows status of Slave compressors on the sequencing table. Please see Application Notes for more details. Slave Compressor is detected but is not configured in the sequencing table. Default, If slave Compressor is not present. Slave Compressor is configured in sequencing table but is not configured in “Remote” mode. Slave Compressor configured in sequencing table and is in ready to run state.
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Section 11 • Condenser Control Overview Condenser Control Setpoint: This screen allows the operator to view and adjust condenser setpoint settings associated with condenser operation. This screen will only be active if the Condenser Control option has been enabled from the Configuration Screen, see Figure 11-1. Condenser Control Screen. Run Mode: The Condenser Control operation allows the cycling of fans and pumps in order to maintain a specific condensing pressure.
Section 11 • Condenser Control Condenser Press: Summer/Winter Auto Switch: • This is the read only parameter and it displays the present value of condenser pressure. • This checkbox when enabled allows profiles to switch automatically depending on ambient temperature setpoint when Run Mode is “Auto”. When ambient temperature falls below ambient temperature setpoint, winter profile is used. Similarly when ambient temperature is above ambient temperature setpoint, summer profile is used.
Section 11 • Condenser Control Figure 11-2. Step Control Screen selected as Low Speed Fan through combo box. E.g.: Let’s say Out #2 is selected as Low Speed Fan in Step 2. When step 2 becomes active during condenser control operation which is after Step 2 time-out delay, Out #2 is left off for time as set by the operator in High to Low Speed Delay. After low speed fan energizes, then timer for Step 3 starts timing. Control: • Toggle any of the steps On/Off during Manual operation of Condenser Control.
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Section 12 • Service Options Overview Compressor Start: The Service Option screen allows the operator the ability to force individual digital or analog outputs ON. This feature is used for diagnostic purposes during initial setup and/or if the operator suspects an issue with the outputs. The buttons in this screen are not available while the compressor is running, see Figure 12-1 Service Options Screen. • Activates the output assigned to the compressor motor starter.
Section 12 • Service Options of the volume actuator. The output is connected to terminal 15 and is the 5th LED down on card 1. Volume Decrease Motor: • Activates the output assigned to the decrease input of the volume actuator. The output is connected to terminal 16 and is the 6th LED down on card 1. Oil Separator Heater • Activates the output assigned to the oil separator heater. The output is connected to terminal 17 and is the 7th LED down on card 1.
Section 13 • Instruments Calibration Overview The Instrument Calibration screen allows the operator to define how the Vission 20/20 will interpret the signal from any devices attached to the panel’s analog inputs. The instrument calibration screen is organized up to six pages. Each page is then divided into several left side selected tabs. Each tab will be headed with an information bar labeled “I/O” that give the basic information for that device.
Section 13 • Instruments Calibration devices are predefined and if one is selected, then all the setpoints will be set for the operator. • 20mA: • Defines the maximum value in amps represented by a 20ma inputs. Custom Device: • This option allows the operator to choose the minimum and maximum value of the instrument being used. • Enter Desired Value: • The operator enters the correct current value. Each entry will recalculate the point-slope calculations of the current calibration.
Section 13 • Instruments Calibration Analog Inputs This section of the Calibration screen allows the operator to define the parameters of an installed auxiliary analog instrument. These instruments are usually not part of a typical compressor setup but Vission 20/20 provides a way for the operator to add additional capabilities. The layout of this screen is typical to the pressure and temperature calibration screens.
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Section 14 • Slide Calibration Overview this section displays the value of the actuator signals in millivolts in the “input Value” display box. The Slide Calibration screen is used in calibrating the slide actuators and to establish Vission 20/20 control parameters. It is important that the operator uses caution while operating in this screen, see Figure 14-1. Slide Calibration Screen. The normal safety checks that prevent the slide from colliding with the mechanical stops are overridden.
Section 14 • Slide Calibration mechanical stops for normal slide travel. These software limits purpose is to prevent the slide from actually hitting the mechanical stops which could result in a number of undesirable consequences. By default, the software limits are set to 150mV from either end point. The position percentage is calculated from the software limits. Therefore, it is possible to read a value greater than 100% or less than 0% if inertial carries the slides after these limits are reached.
Section 14 • Slide Calibration 4. From the main screen select the Menu button. 5. On the menu screen select the Slide Calibration button. When the “Slide Valve Calibration” screen appears, then you can safely connect the Power Cable (Yellow TURCK cable) and the Position Transmitter Cable (Gray TURCK cable) to the Capacity motor. Press “+” or “-” to move the slide valves to check the rotation. (See Table 1 below for proper shaft rotation).
Section 14 • Slide Calibration Command Shaft Rotation The following table describes the rotation direction required by the actuator. Every optical actuator has the ability to be wired to rotate in either direction. Energizing the blue actuator wire results in a CCW rotation and energizing the brown wire results in a CW rotation, see Table 14-1. Command Shaft Rotation Required By Actuator. Table 14-1.
Section 14 • Slide Calibration Slide Valve Troubleshooting Guide The Analog output card of the Vission 20/20 produces a 4–20mA signal to any attached devices. However, it is not uncommon that small differences in the board components might result in small differences in the output. So this screen offers the operator the ability to fine tune the upper and lower output values, see Table 14-2. Slide Valve Troubleshooting Guide. Table 14-2.
Section 14 • Slide Calibration Table 14-2. Slide Valve Troubleshooting Guide (2 of 2) Problem There is a rapid clicking noise when the motor is operating. (Continued) There is a rapid clicking noise when the motor is operating. The motor operates in one direction only. The motor will not move in either direction. The motor runs intermittently, several minutes on, several minutes off. The motor runs sporadically. The motor runs but output shaft will not turn.
Section 14 • Slide Calibration Slide Valve Actuator Troubleshooting Guide Blink Code Vilter actuators communicate problems discovered by the internal diagnostics to the technician by LED blink codes. Only one blink code is displayed, even though it is possible that more than one problem has been detected. The actuator motor will not operate until the error code is cleared by pressing the blue bottom, see Table 14-3. LED Blink Codes and Troubleshooting Guide. Table 14-3.
Section 14 • Slide Calibration Table 14-3. LED Blink Codes and Troubleshooting Guide (2 of 2) Flash Pattern * = ON Meaning - = OFF The motor is overheated. The actuator motor will not run until it cools. Once the motor cools, the actuator will resume normal operation. *--*--*----------------- Motor overheating is sometimes a problem in hot humid environments when process conditions demand that the slide valve actuators reposition often.
Section 15 • Trend Chart Overview Chart Operation This screen allows the operator to view and adjust settings for the trend chart, see Figure 15-1. Trend Chart Screen. Trending feature can be started & stopped from this screen. Up to four variables can be selected for plotting on screen. Each variable is assigned one of four colors; the plotted trace and the vertical axis labels for a variable will be in its assigned color.
Section 15 • Trend Chart zoom level operator can view 3 minutes of trend data and Zoom In button will be inactive. At minimum zoom level operator can view full 120 hours of trend data and Zoom Out button will be inactive. Back/Forward: • These buttons allow the operator to move the plot and view trend data at different time intervals. • Forward button will be inactive when the operator is viewing the first data point plotted on the screen (i.e. when time interval is displaying 0:00).
Section 15 • Trend Chart Setup The operator can modify options for pen selection dropdown box from trend setup screen, see Figure 15-2. Trend Setup Screen. Trend setup screen will appear on press of Setup button when trending feature is not running. Trend Setup screen allows the operator to select a maximum of 10 analog I/O channels for trending. The operator can also set a path for trend data files from the drop-down box in the setup screen.
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Section 16 • Event List Overview Time: This screen is designed to display compressor events in chronological order. The information available on the screen is valuable for understanding the operation of the compressor and troubleshooting, see Figure 16-1. Event List Screen. This screen Is divided into four columns and can list up to 128 separate events. The operator can download the information on the event list through the Data Backup Screen. • Displays the time of the event in HH:MM:SS format.
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Section 17 • Input / Output Overview This screen displays “Live Data” of all the analog points and digital points being monitored, see Figure 17-1. Input/Output Screen. There are four pages of Input / Outputs (I/O) available for viewing. This screen also takes a snapshot of all the I/O points if the compressor experiences a trip condition and saves this data as Freeze pages. Up to five Freeze pages can be saved. The oldest Freeze page will be removed when more than five Freeze events occur.
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Section 18 • Auxiliary Input / Output Overview Digital Inputs: The Auxiliary Input/Output (I/O) section of the Vission 20/20 gives the operator flexibility to add peripheral instruments and/or devices such as motors, valves and solenoids. With these additions, customer configurable I/Os are useful in expanding the functions of the Vission 20/20 where it was not explicitly designed to control, see Figure 18-1. Auxiliary Input/Output Screen.
Section 18 • Auxiliary Input / Output Inhibit Check: • Selecting this checkbox enables the inhibit function of the Vission 20/20 for the desired digital input. An inhibit check prevents the compressor from starting if the condition is true where a trip will shut down the compressor after it as started. The inhibit can be selected to inhibit on a high or low input and can be selected to work with or without the alarm and trip function off (0vac) while the input value is below the trigger value.
Section 18 • Auxiliary Input / Output • High Alarm: • This defines the upper limit of the input value, that when exceeded will generate an alarm. • Low Trip: • Defines the lower limit of the input value that when exceeded will generate a trip. • High Trip: • Defines the upper limit of the input value that when exceeded will generate a trip. Analog Outputs This screen allows to map any standard analog input or auxiliary input to any of the four analog auxiliary outputs.
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Section 19 • Configuration Overview The configuration screen is where most of the Vission 20/20 features are enabled and configured, see Figure 19-1. Configuration Screen - Page 1. The initial Setup of the Vission 20/20 will generally start here. Depending on what is selected, different portions of the Vission 20/20 will be available to the operator. • Drop-down Box to select the pressure units.
Section 19 • Configuration logging and troubleshooting. Setting these parameter will set the hardware clock embedded in the Vission 20/20 CPU. If the time is not retained after powering down the panel, the operator should check and/or replace the coin style battery on the panel SBC behind the touchscreen. Format: • Selection to choose between 12 hour or 24 hours clock. Hour: • Entry box to set the clock hours. AM or PM drop-down box will available if the 12 hour format is selected.
Section 19 • Configuration due to repeated motor starts. The operator has 3 choices of protection. Hot starts allows only a certain number of starts per hour before setting an hour to the anti-recycle timer. The number of starts is set in the timer page. Accumulative immediately adds time to the anti-recycle timer once the compressor is started and the time can be set in the timers screen. True anti-recycle adds to the anti-recycle timer once the compressor is shutdown.
Section 19 • Configuration Compressor Control Optional Function Selection Vilter compressors typically run in one of two control modes, suction pressure or process temperature control, see Figure 19-2. Configuration Screen - Page 2. The following options are additional features of the Vission 20/20 that can be selected. Some of these options will not be available for selection unless the proper I/O cards are installed and enabled, see Figure 19-2. Configuration Screen - Page 2.
Section 19 • Configuration Condenser Control Oil Cooling The values in this section enables the condenser control feature of the Vission 20/20. Once selected the checkboxes will become available for selection and the condenser control screen will be available via the menu screen. Some of the options check boxes in this section may not be available for selection unless the proper I/O cards are installed and enabled, see Figure 19-2. Configuration Screen - Page 2.
Section 19 • Configuration Digital Inputs The Vission 20/20 has several digital inputs that the operator can choose how the input will be used. Once an input is enabled, the Auxiliary I/O screen will be available from the menu screen where the operator can further define the inputs operation, see Figure 19-3. Configuration Screen - Page 3. Enable Input #: • Enables the selected digital input. Set Name: • Allows the operator to assign a name to the input. Figure 19-3.
Section 19 • Configuration Analog Inputs The Vission 20/20 has several Analog inputs that the operator can choose how the input will be used. Once an input is enabled, the Auxiliary I/O screen will be available from the menu screen where the operator can further define the inputs operation, see Figure 19-4. Configuration Screen - Page 4. Enable Input #: • Enables the selected analog input. Set Name: • Allows the operator to assign a name to the input. Figure 19-4.
Section 19 • Configuration Analog Outputs Digital Outputs The Vission 20/20 has several Analog outputs that the operator can choose how the outputs will be used. Once an output is enabled, the Auxiliary I/O screen will be available from the menu screen where the operator can further define the outputs operation, see Figure 19-5. Configuration Screen - Page 5. The Vission 20/20 has several Digital outputs that the operator can choose how the output will be used.
Section 19 • Configuration I/O Configuration Digital Input/Output 1: • Enables the optional digital input/output card 1 If any additional I/O card are added to Vission 20/20, this is where these cards are enabled for use by the Vission 20/20 algorithms. Some feature of the Vission 20/20 will not be available unless specific expansions cards are selected, see Figure 19-6. Configuration Screen - Page 6. Digital Input/Output 2: Digital Output 1: Analog Input 2: • Not editable by the operator.
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Section 20 • Data Backup Overview Refresh: The database backup screen provides the operator a way to extract information out of the Vission 20/20 for backup purposes or diagnostics, see Figure 20-1 Data Backup Screen. Through this screen, the operator can download all the Setpoint Databases, Maintenance Logs, Event Lists, Freeze Data, Trend Data and Compressor Run Hours to a portable USB flash drive.
Section 20 • Data Backup Load: • Selecting load allows the operator to load data from a USB flash drive to the Vission 20/20 using the information provided further down the screen. The bottom button will be labeled “Load” when this is selected. Available Devices: • This window displays any USB flash drive plugged into one of the Vission 20/20 USB ports. Once one of the available devices is selected, then the drives contents will be displayed in the “Select Folder / File” window.
Section 20 • Data Backup Migrate: Factory Reset: Loading data from an older version of the Vission 20/20 software to a newer one can be complicated due to differences in databases. This migrate function closely examines each field in the database being loaded and determines whether it can be used in the new program. The Migrate function is executed automatically when a data is loaded from a USB flash drive.
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Section 21 • Maintenance Overview Maintenance Name: The maintenance screen is a convenient place to keep track of the the maintenance performed and any upcoming maintenance recommended by Vilter. Based on this page, banners will be displayed on the lower status bar. Yellow banners are to warn the operator of any upcoming maintenance and red banners indicate maintenance that is overdue, see Figure 20-1. Maintenance Screen.
Section 21 • Maintenance Notes The notes tab allows the operator to make notes to any other personnel that might have access to the Vission 20/20. Log The maintenance log tab lists all the maintenance tasks performed in descending order. Date: • Lists the date the maintenance task was performed. Time: • Lists the time the maintenance task was performed. User: • Lists the operator name who performed the maintenance task. Maintenance Performed: • Lists the maintenance task that was performed.
Section 22 • User Access Overview calibrating instrument will be available to an operator with this level of access. The user access screen is where all operators go to log in. In the Vission 20/20, each screen has a security level, whereby allowing operators, technicians and/or supervisors the ability to modify different sets of setpoints. The Vission 20/20 has four levels of security, see Figure 22-1. User Access Screen - Login. • Level 0 – This is the default level with no operator logged in.
Section 22 • User Access Login The login tab is where an operator will enter the users name and password in order to gain access to Vission 20/20 screens. Operators: • All operators that have been added to the Vission 20/20 user tables will be displayed in this window. If a name of an operator is selected from this window, the name is added to the “Operator Name” entry box. Operator Name: • This entry box is for the operator’s username.
Section 22 • User Access either select the username from the operators window or enter the username manually by touching the entry box and entering the name via the pop-up keyboard. Operator Password: • This entry box is for the operator’s password. The password can be entered by touching the password entry box and entering the password via the pop-up keyboard. Verify Password: • This entry box is to verify the operator’s password.
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Section 23 • Help Screen Overview Use this screen to receive help on other setpoint screens contained within the software. These help files can be accessed from any screen. The help files describe the functionality of that screen as well as compressor operation, see Figure 23-1. Help Screen. Screen Features: will be listed in this section. The operator will have to navigate through the file structure of the USB drive to find the documents.
Section 23 • Help Screen Back: • Pressing the back button will rewrite the file/folder list with the previous folder level. Display Window: • This window displays the context of the manual. Fullscreen: • Pressing this button expand the display window to fit the entire screen. Page: • Enter the page number the operator wishes to be displayed in the display window. Previous: • Changes the page in the display window one page less then what was showing.
Section 24 • Twin Screw Control Overview The Vission 20/20 is capable of operating a twin screw compressor from a number of different manufacturers. The Vission 20/20 currently operates as a twin screw controller in the full time oil pump and the no oil pump configuration, see Figure 24-1. Twin Screw Control Screen. because the oil pump operation is now determined by the type of compressor that is select from the “Type” drop-down box. • Standard - Selects the oil pump operation as “Full Time”.
Section 24 • Twin Screw Control Operation Once the twin screw is configured, its operation is very similar as the single screw and all options that are available for single screw configuration are also available for twin screw. The only operational difference is the manual mode of operation. Twin screw compressors can experience leaky slide seals that can cause the capacity slide to drift after it has been positioned by the controller.
Section 25 • Cool Compression Control Overview The cool compression compressor operation is similar to the standard single screw compressor units, except there is no external oil cooler to the unit. A blanket of liquid ammonia lies on top of the oil in the oil separator. The liquid ammonia level is regulated by sensing the liquid ammonia level with a level probe, and using a positioning valve to vary the amount of liquid ammonia being added to the separator.
Section 25 • Cool Compression Control enable Superheat Monitoring on the screen. • As previously described, Cool Compression compressor does not have an oil pump. Instead it has a suction oil injection solenoid to provide oil and liquid ammonia for lubrication and cooling. • Cool Compression liquid injection 1 and liquid injection 2 outputs will operate as high / low pressure ratio solenoid outputs.
Section 25 • Cool Compression Control • Auto Load Timer • This timer defines the maximum time that the Auto Load operation will be engaged. After the timer expires, Auto Load will be disengaged. • Auto load will be disengaged when one of the following conditions occur; • Pressure ratio reaches a value of 2.0 or greater. • Compressor has been running for 10 minutes (defined by Auto Load Timer). • Suction pressure setpoint has been reached.
Section 25 • Cool Compression Control operational differences that are mostly associated with the compressor safeties: 5.0, the solenoid is turned on. When the pressure ratio falls back to below 4.8, the solenoid is turned off. 1. The Cool Compression program ignores, • Low Oil Separator Alarm / Trip at start Level Switches • High Filter Differential at start • There are two level switches in the oil separator, a “high” and a “low”. During normal running operation, the oil level is above both switches.
35391SC 1.8.5153 (11/12) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. © 2012 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.
