Vission 20/20 micro-controller Operation and service manual • Version 1.
Table of Contents Section Title Section Number How To Use This Manual......................................................................................................................... TOC-9 Standard Vilter Warranty Statement ...................................................................................................... TOC-10 Section 1 • Operational Flow Charts Requirements to Start Compressor .................................................................................................
Table of Contents Section Title Section Number Section 4 • Main Screen Overview ............................................................................................................................................... 4-1 Figure 4-1. Main Screen.......................................................................................................................... 4-1 Top Status Bar .....................................................................................................................
Table of Contents Section Title Section Number Compressor Warnings............................................................................................................................ 7-6 Section 8 • Timers Overview ............................................................................................................................................... 8-1 Timer Setpoints .........................................................................................................................
Table of Contents Section Title Section Number Figure 13-5. Instruments Calibration Screen - Analog Inputs (Page 5) ..................................................... 13-5 Analog Outputs ..................................................................................................................................... 13-6 Figure 13-6. Instruments Calibration Screen - Analog Outputs (Page 6) .................................................. 13-6 Section 14 • Slide Calibration Overview .............
Table of Contents Section Title Section Number Section 19 • Configuration Overview ............................................................................................................................................... 19-1 Units .................................................................................................................................................. 19-1 Figure 19-1. Confi guration Screen - Initial Setup (Page 1) ............................................................
Table of Contents Section Title Section Number Login .................................................................................................................................................. 22-2 Manage Accounts .................................................................................................................................. 22-2 Figure 22-2. User Access Screen - Manage Accounts ............................................................................... 22-2 VNC Account ......
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......................................................................................................................
List of Tables and Figures Table/Figure Page Number Figure 11-2. Condenser Control Screen - Page 2 ..................................................................................... 11-4 Figure 12-1. Service Options Screen - Digital Outputs (Page 1) ............................................................... 12-1 Figure 12-2. Service Options Screen - Digital Outputs (Page 2) ............................................................... 12-2 Figure 12-3.
How to Use This Manual This manual contains instructions for the Vission 20/20 Operation & Service Manual. It has been divided into 27 sections. WARNING - Warning statements are shown when there are hazardous situations, if not avoided, will result in serious injury or death. Section 1: Operational Flow Charts CAUTION - Caution statements are shown when there are potentially hazardous situations, if not avoided, will result in damage to equipment.
Standard Vilter Warranty Statement Seller warrants the products it manufactures to be free from defects in material and workmanship for a period of eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months from date of installation at the initial end users location, whichever occurs first.
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.
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 • 120 VAC • 230 VAC • 24 VAC • DC Signals • Never use conduit grounds. • If your installation site has wire-ways or conduit trays, dividers must be installed between the different voltages. Mixing Voltages DC signals • Grounds must be copper or aluminum wire.
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.
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 3-1. 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 Remote Enabled Output: • This output is energized when the Vission 20/20 panel is enabled for remote control. If the compressor parameter does not satisfy start conditions or is placed into the manual stop position, this output is de-energized. Shunt Trip: • This output is designed to be connected to a master power breaker with a shunt trip input.
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 range and calibration is set in the calibration screen. screen. Discharge Pressure Remote Caphold: • Default signal is 4-20mA. Discharge pressure transducer range and calibration is set in the calibration screen. • Default signal is 4-20mA. Active in “Direct I/O” mode. Adjusts the capacity of the compressor from 0-100%, proportional to the 4-20mA signal. Oil Filter Inlet Pressure: Auxiliary #1 - #16: • Default signal is 4-20mA.
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 LEDs: 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 LEDs indicate 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 signals 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 indicate 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 indicate 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 3-4. Analog Input Jumper Tables. Table 3-4.
Section 3 • Hardware Architecture Table 3-4.
Section 3 • Hardware Architecture Analog Output Boards Communication LEDs: The Analog Output board convert signals from 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 indicate 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 Auxiliary I/O 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.
Section 6 • Compressor Control the maximum pulse time is the same as the interval time. This means that the pulse time can be 100% of the interval time given a near continuous movement of the capacity slide. Adjusting these setpoints can be useful in slowing down the reaction time of the compressor if large thermal time contents are present in the refrigeration cycle.
Section 6 • Compressor Control Pressure safety trip value. This will shut down the compressor and a Reset will be required to restart it. • Enables the Auto-cycle control. Uncheck the box to disable the Auto-cycle set-points. 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.
Section 6 • Compressor Control Variable Frequency Drive (VFD) Settings Control The VFD page is where the operator can tune the motor VFD for desired operation, see Figure 6-4. Compressor Control Screen - VFD Settings Control. A Vilter compressor uses the variable speed of a VFD controlled motor to vary the amount of work or capacity of the compressor.
Section 6 • Compressor Control • Defines the minimum and maximum positions for the capacity slide. While in 1 step control these values should be 0% for minimum and 100% for maximum. VFD Speed: • Defines the minimum and maximum speed for the motor speed. While in 1 step control these values should reflect the full range of the VFD. 2 Step VFD Control: • Enables the second step in the VFD control algorithm.
Section 6 • Compressor Control Pumpdown Control prevented from shutting down prematurely via the Auto-cycle Stop setpoint by automatically ignoring the Auto-cycle feature. NOTE For use of compressor control screen - page 4, see Cool Compression Control in Section 25. The Pumpdown Control defines a method of “pumping” down a chiller, which is to draw off refrigerant from the chiller. This feature can be enabled or disabled from this page, see Figure 6-7.
Section 6 • Compressor Control Stop Pressure. Min Slide Position: • The minimum capacity slide is the setpoint that the compressor is allowed to run at. By forcing the compressor capacity to operate at a value above minimum, we insure that the suction pressure will be pulled down to the Stop Pressure setpoint. Pumpdown Operation (Run/Stop): • This button starts/stops the Pumpdown operation. This button is active only when compressor is in local Auto mode and Control Mode Configured is Suction Pressure.
Section 6 • Compressor Control Auto Cycle Differential: • This setpoint defines the offset pressure values for Auto Cycle Start Pressure and Stop Pressure from the Suction Pressure setpoint. Auto Cycle Start Pressure setpoint will be Suction Pressure setpoint incremented by this setpoint pressure value, while Auto Cycle Stop Pressure value will be Suction Pressure setpoint decremented by this setpoint pressure value. When Pulldown feature is enabled, Pumpdown checkbox is automatically grayed out.
Section 6 • Compressor Control advance in any condition. Capacity Slide Triggered Outputs Force Unload: High Discharge Pressure: The Vission 20/20 offers two digital outputs that can be triggered at a specified capacity slide position. By default, the outputs are preselected for economizer and hot gas bypass. However, these preselected outputs are customizable by the operator, see Figure 6-9. Compressor Control Screen - Misc. 2 (Economizer & Hot Gas Bypass Control).
Section 6 • Compressor Control position is below the “Slide %” setpoint. The operator can choose between “N.O.” or “N.C.”. This setpoint is not available for Economizer Port 2, so Economizer Port 2 follows the setpoint of Economizer Port 1. Active: • Check box to enable the digital output. There is no check box for enabling Economizer Port 2 digital output.
Section 6 • Compressor Control Oil Control Liquid Injection These setpoints determine how the Vission 20/20 will manage the oil of the compressor, see Figure 6-10. Compressor Control Screen - Oil Control & Liquid Injection Control. The setpoints is this section are to control the behavior of the liquid refrigerant injected into the compressor for oil cooling purposes.
even further. Oil Sep. Temp. Override: Liquid Injection Control using a 4-20ma motorized valve. • When a motorized valve is used to control the amount of liquid being injected into the compressor the previously mentioned setpoints have a slightly different function. The Oil Sep. Temp. Override is still used in controlling the injection solenoid, however the Liquid Inj. Setpoint 1 is now used as the target temperature for the PID Algorithm that controls the position of the motorized valve.
Section 7 • Alarms and Trips Overview side tabs in the input/output screens and are very useful as a troubleshooting tool for the operator. The Alarms and Trips screen allows the operator to view and adjust settings for compressor safety and alarm settings. For Alarms and Trips Screen Pages refer to Figures 7-1, 7-2, 7-3 and 7-4. The Vission 20/20 uses Warnings as a way to notify the operator of parameters that may inhibit the compressor when started.
Section 7 • Alarms and Trips modes. An alarm or trip will be activated if the suction pressure falls below the setpoint values. High Discharge Pressure (Alarm & Trip): • This is the high discharge pressure safety. The alarm or trip will be activated if the discharge pressure rises above the setpoint value. High Process Temperature (Alarm only) • This alarm is active when the process temperature is at or above the setpoint value. There is no trip setpoint.
Section 7 • Alarms and Trips safety. After a time delay, (setting of the Oil Separator Temperature Safety Changeover timer), the Low Oil Separator Start Temperature is bypassed and Low Oil Separator Run Temperature alarm and safety setpoints become active. The alarm or trip will be activated if the oil temperature in the separator drops below the setpoint value. Low Oil Injection Temperature (Alarm & Trip): • This is the low oil injection safety.
Section 7 • Alarms and Trips After a time delay, (setting of the High Superheat Temperature Safety Changeover timer), this safety is deactivated and the High Superheat Run Temperature alarm and safety setpoints become active. The trip will be activated if the superheat temperature from start rises above the superheat temperature plus the setpoint value. There is no ALARM setpoint. Use Figure 7-3. Alarms and Trips Screen - Page 3.
Section 7 • Alarms and Trips normal setpoint values after the Oil Pressure Bypass timer has expired. This time limit is set on the Timer menu screen. Run oil pressure is defined as manifold pressure minus suction pressure. High Filter Differential Pressure Start (Alarm & Trip): • This safety allows a higher than normal filter differential pressure to exist during the first minute after a compressor starts.
Section 7 • Alarms and Trips Oil Pressure Safety Bypass timer times out. Compressor Warnings Low Oil Injection Temp Trip High Level Shutdown Warning • This message will appear when the Oil Injection temperature falls below the Low Oil Injection Temperature trip setpoint. This message will also appear when the Oil Injection temperature fails to rise above the Low Oil Injection Temperature reset setpoint after the Low Oil Injection Temp Bypass timer times out.
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. For Timer Screen Pages, see Figures 8-1 and 8-2. Timer Setpoints Use Figure 8-1. Timers Screen - Page 1. Capacity Increase Start Delay: Changeover: • At compressor startup, the capacity slide position is held at minimum position for this time period.
Section 8 • Timers Low Oil Pressure Safety Bypass: Low Oil Separator Temperature Safety Changeover: • 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. • This timer allows Low Oil Separator Start Temperature safety setpoint to protect the compressor against cold oil during starting.
Section 8 • Timers for a time period that exceeds the setpoint of the Accumulative Anti-Recycle Timer, then when the compressor shuts down, it will be allowed to restart immediately. Compressor Interlock Bypass: • Once the Vission 20/20 has sent a command to the compressor starter to start, a return signal is expected. This timer defines how much time to wait for that signal before setting a trip condition.
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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 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 Section 19 for Compressor Sequencing. Pressure / Temperature Control Setpoints Compressor Sequencing screen defines settings those are used by master compressor for sequencing.
Section 10 • Compressor Sequencing Unload Rate 2 Offset (outer): Load Rate 2 (Outer): • Defines the outer Pressure/Temp setpoint offset to monitor compressor load. If Suction Pressure/ Process Temperature drops below Unload Rate 1 offset and goes below Unload Rate 2 setpoint offset, then sequencing decisions are made according to Unload Rate 2 timer.
Section 10 • Compressor Sequencing Compressor Sequencing Table Compressor sequencing table menu allows operator to view and adjust settings those are used for compressor sequencing, see Figure 10-3. Compressor Sequencing Screen - Page 3. NOTE Switching a compressor control to OFF when running in auto seq mode puts respective slave compressor into local auto mode. This feature is used to add or remove slave compressors to sequence table when running in auto sequence mode.
Section 10 • Compressor Sequencing Step: Machine Start Time: • This parameter would decide stepwise increment or decrement value in percentage of the compressor capacity. In the case when last step makes total capacity greater than maximum capacity, total capacity will get reduced to maximum capacity. Same is applicable when last step makes total capacity lower than minimum capacity takes priority.
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 Manual: High to Low Speed Fan Delay: • Mode for controlling condenser control operation manually. Operator controls the operation by manual stepping using an on/off toggle button at each step. • This is a time delay for the fan spin down in case of 2- speed motor/dual speed fan. Condenser Press: • This is the condenser pressure setpoint that needs to be maintained.
Section 11 • Condenser Control Low Speed Fan: • Allows steps to have option for time delay in case of fan spin down. Any of Out #1 to Out #4 can be 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.
Section 11 • Condenser Control Figure 11-2. Condenser Control Screen - Page 2 11 – 4 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
Section 12 • Service Options Overview Use Figure 12-1. Service Options Screen - Digital Outputs (Page 1) 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 . Compressor Start: • Activates the output assigned to the compressor motor starter.
Section 12 • Service Options Volume Increase Motor: • Activates the output assigned to the increase input 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.
Section 12 • Service Options 24 and is the 4th LED down on card 2. Liquid Injection # 1: • Activates the output assigned to the liquid injection solenoid. The output is connected on terminal 25 and is the 5th LED on card 2. Liquid Injection # 2: • Not currently used. Remote Enabled: • Activates the output assigned to notify a central control system of the Vission 20/20 run status. The output is connected to terminal 27 and is the 7th LED on card 2.
Section 12 • Service Options Condenser / Remote Oil Cooler Step # 4: • Activates the output assigned to the 4th step of the Condenser / Remote Oil Cooler. The output is connected to terminal 44 and is the 4th LED down on card 4. Figure 12-4. Service Options Screen - Digital Outputs for Remote Oil Cooler (Page 3) 12 – 4 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
Section 12 • Service Options Analog Outputs % Slide Valve Position The Analog Output (AO) selections allow the operator to enter a desired value of the output then turn on the output, see Figure 12-5. Service Options Screen - Analog Outputs (Page 4). The operator will have to measure the output using meter capable of measuring a 4-20mA signal. Compressor VFD: • Sets the analog output assigned to the Slide Value position used to inform a central control system of the capacity position.
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Section 13 • Instruments Calibration Overview calibrated through the Vission 20/20. 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 Motor Current Custom Device: • This option allows the operator to choose the minimum and maximum value of the instrument being used. Offset: • Once the two point calibration is completed, it is not uncommon for there to be a small error. By entering the value of the error from the calibrated value and the actual value into the adjustment entry box, that error will be added/subtracted from the total offset.
Section 13 • Instruments Calibration displayed motor current may still be off slightly. In this case reenter the desired value and the displayed value should get progressively closer. total error offset of entries from the “Enter Desired Value” setpoint. Current Transformer Ratio: • Primary 4-20mA Scale: • Defines the upper value of the current transformer. • 4mA: • Not editable by the operator. Defines the minimum value in amps represented by a 4ma inputs.
Section 13 • Instruments Calibration Remote Capacity Analog Inputs The remote capacity input allows a system controller such as the PLC to control the capacity position during direct I/O control. 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.
Section 13 • Instruments Calibration uncommon for there to be a small error. By entering the value of the error from the calibrated value and the actual value into the adjustment entry box, that error will be added/subtracted from the total offset. The offset is applied to the calibrated value which should correct the error. Range: • Here the operator defines the signal type and range transmitted by the instrument. The operator can choose from several predefined ranges in the dropdown box or enter a value.
Section 13 • Instruments Calibration Analog Outputs the output will go to either 4ma or 20 ma. The operator can then measure the output for accuracy. The Analog output card of the Vission 20/20 generates a 4 – 20mA signal to any attached devices. However, it is not uncommon that small difference in the board components might result in small difference in the output. So this screen offers the operator the ability to fine tune the upper and lower output values, see Figure 13-6.
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 trending options through the Trend Setup screen, see Figure 15-2. Trend Setup Screen. Trend Setup screen can be accessed by pressing the Setup button when the 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. There are four pages of Input / Outputs (I/O) available for viewing, see Figures 17-1, 17-2, 17-3 , 17-4 and 17-5. 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, for example, see Figure 17-6. Up to five Freeze pages can be saved.
Section 17 • Input / Output Figure 17-2. Input/Output Screen - Page 2 Figure 17-3. Input/Output Screen - Page 3 17 – 2 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
Section 17 • Input / Output Figure 17-4. Input/Output Screen - Page 4 Figure 17-5. Input/Output Screen - Page 4 (Remote Oil Cooler Enabled) Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
Section 17 • Input / Output Figure 17-6. Input/Output Screen - Freeze Data Page 17 – 4 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
Section 18 • Auxiliary Input / Output Overview 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. Setting up one or more of the auxiliary inputs or outputs start with the configuration screen.
Section 18 • Auxiliary Input / Output Digital Outputs Digital Relay: The digital outputs section of the Auxiliary I/O screen allows an operator to configure the auxiliary digital outputs, see Figure 18-2. Auxiliary I/O Screen - Digital Outputs (Page 2). The digital output can be configured to activate (go High, 120vac) based on either a digital input or a specified level on an analog input. Every digital and analog input in the Vission 20/20 are made available for controlling a digital output.
Section 18 • Auxiliary Input / Output Figure 18-2. Auxiliary I/O Screen - Digital Outputs (Page 2) Figure 18-3. Auxiliary I/O Screen - Analog Inputs (Page 3) Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
Section 18 • Auxiliary Input / Output • Defines the upper limit of the input value that when exceeded will generate a trip. Analog Outputs I = Integral (reset): • Used to integrate the error over time, to account for a small error that has persisted for a long time. This quantity is used for fine adjustment. This setpoint is used to smooth out process variations. This setpoint should be set high enough to prevent hunting but not too high or it will cause control system overshoot.
Section 18 • Auxiliary Input / Output Figure 18-4. Auxiliary I/O Screen - Analog Inputs (Page 4) Figure 18-5. Auxiliary I/O Screen - Analog Inputs (Page 5) Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
Section 18 • Auxiliary Input / Output Figure 18-6. Auxiliary I/O Screen - Analog Outputs (Page 6) Figure 18-7. Auxiliary I/O Screen - Analog Outputs (Page 7) 18 – 6 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
Section 19 • Configuration Overview Press Units: The configuration screen is where most of the Vission 20/20 features are enabled and configured. The initial setup of the Vission 20/20 will generally start here, see Figure 19-1. Configuration Screen - Initial Setup (Page 1). 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 Time & Date selected, the remainder of the serial setpoints will be available for editing. This section sets the time and date of the Vission 20/20. Accurate time and date are accentual for accurate 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.
Section 19 • Configuration Anti-Recycle Anti-Recycle defines the method of motor protection 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.
Section 19 • Configuration Compressor Sequencing Compressor Name: The compressor sequencing is a feature of the Vission 20/20 that allows the operator to setup as many as five compressor to automatically start, stop and maintain system loads. The compressor that is designated as the master will monitor systems parameter and make decisions on how many compressor are required to meet the load as efficiently as possible.
Section 19 • Configuration selection is critical for proper volume slide control. Condenser Control Model: • Drop-down box to select the compressor size. This selection is critical for proper volume slide control. Refrigerant: • Drop-down box to select the type of refrigerant. This selection is critical for proper volume slide control. Other (K-Factor): • Optional setting to adjust volume slide control.
Section 19 • Configuration to 100 % valve open. Oil Cooling The section defines how the Vission 20/20 will monitor and/or control the temperature of the compressor oil, see Figure 19-2. Configuration Screen - Page 2. Thermosyphon: • This defines the compressor oil cooling method as thermosyphon. H20 Oil Cooler: • This defines the compressor oil cooling method as water heat exchange. Liquid Injection: • This defines the compressor oil cooling method as liquid refrigerant injection.
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 - Digital Auxiliaries (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 - Analog Auxiliaries (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 - Analog Outputs (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 - I/O Configuration (Page 6).
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. Checklist The check list is where the operator will perform the maintenance sign-off, see Figure 21-1.
Section 21 • Maintenance Notes Time: • Lists the time the maintenance task was performed. The notes tab allows the operator to make notes to any other personnel that might have access to the Vission 20/20. User: • Lists the operator name who performed the maintenance task. Maintenance Performed: Log • Lists the maintenance task that was performed. The maintenance log tab lists all the maintenance tasks performed in descending order, see Figure 21-2. Maintenance Screen - Log.
Section 21 • Maintenance Figure 21-3. Maintenance Screen - Chart Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
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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.
Section 22 • User Access Verify New Password: Update: • The operator will re-enter the password by touching the entry box and typing the password via the popup keyboard. • Pressing this button will initiate the modification of the specified VNC account Port number. Update: • Pressing this button will initiate the modification of the VNC account. Change VNC Port Number Port Number: • The operator will change the port number for VNC server by touching the entry box and typing via the pop-up keyboard.
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. Screen Features: connected USB drive, the names 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: Previous: • Pressing the back button will rewrite the file/folder list with the previous folder level. • Changes the page in the display window one page less then what was showing. Display Window: Next: • This window displays the context of the manual. • Changes the page in the display window one page more then what was showing. Fullscreen: • Pressing this button expand the display window to fit the entire screen.
Section 24 • Twin Screw Control Overview • Standard - Selects the oil pump operation as “Full Time”. 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. • Stal - Selects the oil pump control as “No pump”.
Section 24 • Twin Screw Control Operation 24-2. Slide Valve Calibration - Twin Screw Control. 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 24 • Twin Screw Control 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. Position Signal Type: Compressor Bump Pop-Up Window • This window allows the operator to bump the compressor to flush out any oil in the compressor after a slide valve calibration, see Figure 24-3. Slide Valve Calibration - Twin Screw Bump Pop-Up Window.
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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 will be disengaged when one of the following conditions occur; Using a Positioning Valve for Liquid Ammonia Level Control • Pressure ratio reaches a value of 2.0 or greater. • A level probe inserted in the oil separator detects liquid ammonia level. Based on the level of the ammonia (0-100%), the level probe sends a directly proportional 4-20 mA signal to the Vission 20/20 panel.
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.
Section 26 • Remote Oil Cooler Overview Remote Oil Cooler Setpoint This screen allows the operator to view and adjust Remote Oil Cooler setpoint settings associated with Remote Oil Cooler operation, see Figure 26-1. Remote Oil Cooler Screen (Page 1). This screen will only be active if the Remote Oil Cooler Control option has been enabled from the Configuration Screen, see Section 19.
Section 26 • Remote Oil Cooler Manual • Mode for controlling Remote Oil Cooler operation manually. Operator controls the operation by manual stepping using an on/off toggle button at each step. setpoint and the delay timers are satisfied. Step Delay acts as “ON” timer while loading and acts as “OFF” timer while unloading for the same step. Low Speed Fan: • This is the Remote Oil Cooler Temperature setpoint that needs to be maintained. • Allows steps to have option for time delay in case of fan spin down.
Section 26 • Remote Oil Cooler Maximum Speed: Minimum Speed: • This setpoint defines the maximum speed in percentage for Remote Oil Cooler VFD Fan at which it should run for continuous step delay time to increase Remote Oil Cooler steps. E.g. let’s say setpoint is kept at 95%. Then Remote Oil Cooler VFD fan will have to run at speed of 95% or more to advance to next step.
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Appendix A • Vission 20/20 Troubleshooting Guide Vission 20/20 Troubleshooting Guide In the event of a problem with the Vilter Vission 20/20, the help screen, along with your electrical drawings will help determine the cause. NOTICE Before applying power to the Vission 20/20 control panel, all wiring to the panel should be per the National Electrical Code (NEC). Specifically check for proper voltage and that the neutral is grounded at the source. An equipment ground should also be run to the panel.
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35391SC 1.9 (1/13) 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.
