Vission 20/20 micro-controller Operation and service manual • Version 2.
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.
Important Message READ CAREFULLY BEFORE OPERATING YOUR COMPRESSOR. The following instructions have been prepared to assist in operation of Vilter Vission 20/20 micro-controllers. The entire manual should be reviewed before attempting to operate. Vilter micro-controllers are thoroughly inspected at the factory. However, damage can occur in shipment. For this reason, the equipment should be thoroughly inspected upon arrival. Any damage noted should be reported immediately to the Transportation Company.
Table of Contents Section Title Section Number Standard Vilter Warranty Statement ...................................................................................................... i Important Message................................................................................................................................ ii How To Use This Manual.........................................................................................................................
Table of Contents Section Title Section Number Pulldown Control ................................................................................................................................... 6-8 Control Mode......................................................................................................................................... 6-11 Stop load & Force unload .......................................................................................................................
Table of Contents Section Title Section Number Section 14 • Slide Calibration Overview ............................................................................................................................................... 14-1 Capacity Slide Valve Potentiometer ........................................................................................................ 14-1 Volume Slide Valve Potentiometer ................................................................................................
Table of Contents Section Title Section Number Digital Outputs ...................................................................................................................................... 19-9 I/O Configuration ................................................................................................................................... 19-10 Section 20 • Data Backup Overview ...................................................................................................................
Table of Contents / List of Tables and Figures Section Title Section Number Appendix A • Vission 20/20 Troubleshooting Guide Vission 20/20 Troubleshooting Guide..................................................................................................... A-1 Appendix B • Vission 20/20 Application Procedures Vission 20/20 Application Procedures ....................................................................................................
List of Tables and Figures Table/Figure Page Number Figure 6-11. Compressor Control Screen - Misc. 2 (Economizer & Hot Gas Bypass Control) ..................... 6-12 Figure 6-12. Compressor Control Screen - Oil Control & Liquid Injection Control .................................... 6-14 Figure 7-1. Alarms and Trips Screen - Page 1 ........................................................................................... 7-1 Figure 7-2. Alarms and Trips Screen - Page 1 as Level 2 User ....................
List of Tables and Figures Table/Figure Page Number Figure 20-1. Data Backup Screen - Save/Load ......................................................................................... 20-1 Figure 20-2. Data Backup Screen - Migrate and Factory Reset ................................................................. 20-3 Figure 20-3. Data Backup Screen - Setpoints Report ............................................................................... 20-4 Figure 21-1. Maintenance Screen - Checklist ........
How to Use This Manual NOTE Manual revision should match software version. This manual contains instructions for the Vission 20/20 Operation & Service Manual. It has been divided into 28 sections. It is highly recommended that the manual be reviewed prior to servicing the Vission 20/20 system parts. Figures and tables are included to illustrate key concepts. Safety precautions are shown throughout the manual.
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 2.
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 and Figure 2-6. Figure 2-5. Correct Transformer Wiring Method Figure 2-6. Incorrect Transformer Wiring Method Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
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. 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). • Industrial temperature range design. Figure 3-1.
Section 3 • Hardware Architecture Digital Input/Output (I/O) Trip Output: Refer to Table 3-1. • 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. Discharge Pressure • Default signal is 4-20mA. Discharge pressure transducer range and calibration is set in the calibration screen. Oil Filter Inlet Pressure: • Default signal is 4-20mA. Oil filter pressure transducer range and calibration is set in the calibration screen. Oil Manifold Pressure: • Default signal is 4-20mA. Oil manifold pressure transducer range and 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 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. • 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 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. • 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. • 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 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. • 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. 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. 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. These LEDs show the active communications between the digital output board and the Vission 20/20 CPU board.
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. 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. 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. 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) 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. Control Parameter Boxes: • The parameter boxes provide updated data on several key control parameters.
Section 4 • Main Screen Bottom Status Bar Log off Button: 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. Maintenance Button: • Pressing the maintenance button will give the operator access to the maintenance charts and sign off tables. User Access Button: • This button takes the operator to another login screen to create additional users.
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. 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. 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: Auxiliary I/O • Navigates to the instrument calibration screen where the operator can calibrate all of the system sensors. • Navigates to the auxiliary I/O screen where an operator can configure any auxiliary instruments or devices. Slide Calibration: Configuration: • Navigates to the slide calibration screen where the operator can calibrate the capacity and volume slide actuators.
Section 6 • Compressor Control Overview Suction Pressure Control and Process Temperature Control 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 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. 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.
Section 6 • Compressor Control 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. NOTE When the Pumpdown feature is enabled, the Autocycle setpoints are automatically disabled.
Section 6 • Compressor Control Figure 6-4. Compressor Control Screen - Discharge Pressure Control 6 – 4 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
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 6-5. 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 Capacity Slide Position: • 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. gives adequate control system response. Increasing the proportional setting increases the control system’s sensitivity to small process fluctuations and the tendency to hunt. VFD Speed: • Defines the minimum and maximum speed for the motor speed.
Section 6 • Compressor Control Rapid Cycling VFD Control The VFD page is where the operator can tune the motor VFD for desired rapid cycling VFD operation, see Figure 6-8. A Vilter compressor uses the variable speed of a VFD controlled motor to vary the amount of work or capacity of the compressor. The rapid Cycling VFD control will keep capacity slide loaded to maximum and vary the motor speed to achieve the required work or capacity. For example, if the compressor needs to load to 100% of its capacity.
Section 6 • Compressor Control Oil Restriction Offset: • This is the differential offset around Oil Restriction Setpoint. For example, if Oil Restriction Setpoint is set to 1800 RPM and Oil Restriction Offset is set to 5 RPM, then as Compressor VFD RPM decreases to 1795 RPM, then Oil Solenoid Digital Output will be turned ON. If Compressor VFD RPM increases to 1805 RPM, then Oil Solenoid Digital Output will be turned OFF.
Section 6 • Compressor Control see Figure 6-9. If Pulldown is enabled, this feature will only function when the compressor is running in local Auto, Auto Sequencing mode and the Control mode is Suction Pressure 1. The Pulldown feature provides a method to slowly pull the suction pressure down to operating conditions. The pulldown method used is to step the suction pressure down over a defined time interval. Example: Assume the suction pressure is at 85 psig and the setpoint we want to get to is 20 psig.
Section 6 • Compressor Control Initiate Pulldown at Next Start: • This checkbox when enabled, turns on the Pulldown process at the next start cycle, Pulldown operation will work in the following manners: • Pulldown only works when Control mode is Suction Pressure 1. • If not started in Suction Pressure 1 then Pulldown process will not run until stopped and restarted in Suction Pressure 1.
Section 6 • Compressor Control 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. The operator can also switch from setpoint 1 and setpoint 2 for each control method. What is available in this dropdown box is dependent on the number and type of control selected in the configuration screen, see Figure 6-10.
Section 6 • Compressor Control Capacity Slide Triggered Outputs Port 2 follows the setpoint of Economizer Port 1. Active: 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 6-11. • Check box to enable the digital output. There is no check box for enabling Economizer Port 2 digital output.
Section 6 • Compressor Control Volume Slide Position Offset algorithm runs. Rate Dead Band: These setpoints offer the ability to alter the Volume position table to take advantage of potential energy savings. Since the volume position is a function of the capacity position, the offset to the volume is based on the position of the capacity slide. The volume offset can be applied to the entire capacity slide range or just a portion using the Capacity Range minimum and maximum setpoints.
Section 6 • Compressor Control 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. The algorithm compares the actual discharge temperature against the Liquid Inj. Setpoint 1. The difference between these is the error.
Section 6 • Compressor Control 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.
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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. Reference Figure 7-3. Prelube Oil Pressure (Alarm & Trip): • This is the prelube oil pump failure safety.
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 Delays: 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. • Delays require the condition to occur for the specified amount of time. Timers: • A general timer requiring the time to expire before the listed event can occur.
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 symbol to indicate the operator to correct events and then enable feature. 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. Scheduling Setpoint Schedule: • The options for selection are “Enable” & “Disable”.
Section 9 • Compressor Scheduling 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. AM/PM selection is active for selection only when Time Format selected in configuration screen is 12 hour.
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 setpoint offset then sequencing decisions are made according to Unload Rate 1 timer. Unload Rate 2 Offset (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. 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. CFM: Equipment: • Options of this combo box are updated automatically.
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 10 • Compressor Sequencing Configuration Overview COMPRESSOR SETUP FOR SLAVE COMPRESSOR SEQUENCING 1. Log onto each of the slave compressors one by one and navigate to the Configuration screen (reference Screen1). 2. Enable the ethernet port and select the Modbus TCP protocol. The Configuration screen allows the operator to; 3. Enable the sequencing in slave mode. • Enable / disable compressor sequencing. 4. Setup a unique ethernet IP address for each slave.
Section 10 • Compressor Sequencing At this point the slave compressor will begin multicasting its status information over the network at a rate of every 15 seconds. (After the Master Compressor is configured, the slave information will be populated to the Sequencing menu of the Master Compressor.) 11. Exit out of the configuration screen and then put slave in remote mode by pressing Unit Start->Remote. Figure 10-5.
Section 10 • Compressor Sequencing COMPRESSOR SETUP FOR MASTER COMPRESSOR SEQUENCING NOTE The master compressor will ALWAYS be priority#1 compressor – and act as the trim compressor. So this must be taken into account when deciding which compressor is to act as the master compressor. 1. Log onto the master compressor and navigate to the Configuration screen (see Figure 10-6). 2. Enable the Compressor Sequencing check box and select “Master”. 3.
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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. 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 2.
Section 12 • Service Options Overview Reference Figure 12-1. 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 . Digital Outputs Compressor Start: • Activates the output assigned to the compressor motor starter.
Section 12 • Service Options Volume Increase Motor: Reference Figure 12-2. • 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. Slide Valve Setpoint # 1 (Economizer): 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.
Section 12 • Service Options Liquid Injection # 1: Reference Figure 12-3 and Figure 12-4. • Activates the output assigned to the liquid injection solenoid. The output is connected on terminal 25 and is the 5th LED on card 2. Condenser / Remote Oil Cooler Step # 1: Liquid Injection # 2: • Activates the output assigned to the 1st step of the Condenser / Remote Oil Cooler. The output is connected to terminal 41 and is the 1st LED on card 4. • Not currently used.
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 2.
Section 12 • Service Options Analog Outputs 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. 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. The output is connected to AO #3 on card 10.
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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 value, the 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 Offset: Range: • 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. The offset is applied to the calibrated value which should correct the error. • Here the operator defines the signal type and range transmitted by the instrument.
Section 13 • Instruments Calibration Max (mA): Apply Changes: • If the 20ma output has an unacceptable amount of error. The operator can use the “+” & “-” buttons to adjust the output • Min (mA) and Max (mA) values are stored to database on press of this button. Offset (mA) value which is used to correct 4mA or 20mA output is hence not saved until this button is pressed.
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. 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 Calibrate Slide Valve Actuators Assuming that the actuator motors have not been calibrated, the transmitter output of the actuator motor will fluctuate wildly until they are calibrated. To prevent damage to actuator motors, do not connect the Power Cable (Yellow TURCK cable) or the Position Transmitter Cable (Gray TURCK cable) until instructed to do so in this procedure. 1. Open the plastic cover of the capacity motor by removing four screws.
Section 14 • Slide Calibration Figure 14-3. Menu Screen and Slide Calibration Button (Vission 20/20) 14 – 4 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Section 14 • Slide Calibration 8. Use the “+” button on the Vission 20/20 to drive the capacity slide to its maximum mechanical stop position. This will be apparent by a slowing of the motor rotation and a winding sound from the actuator motor. When you hear the motor wind-up, release the “+” button. 9. Quickly press and release the BLUE CALIBRATION BUTTON on the ACTUATOR motor once. The RED LED will stop flashing. This now instructs the ACTUATOR motor that this point is the maximum slide position.
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. 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 2.
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 2.
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 2.
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 The digital outputs section of the Auxiliary I/O screen allows an operator to configure the auxiliary digital outputs, see Figure 18-2. 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 tendency to hunt. • 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. There are two pages of auxiliary output configuration; each consists of two analog auxiliary outputs. For Auxiliary Outputs Screens, see Figures 18-6 and 18-7.
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. 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. Psig, Bar, and Kpa are the possible selections and the units will be displayed for every pressure value throughout the screens.
Section 19 • Configuration Time & Date Serial (Modbus RTU): 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 parameters 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 Compressor Sequencing Anti-Recycle defines the method of motor protection due to repeated motor starts. The operator has 3 choices of protection. Hot starts allow 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 Control Optional Function Selection Vilter compressors typically run in one of two control modes, suction pressure or process temperature control, see Figure 19-2. 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.
Section 19 • Configuration Discharge Superheat Monitor: # Pumps: • Enables the discharge superheat safety algorithms. Discharge superheat monitor works only with R717. Discharge superheat monitor and suction superheat monitor features are mutually exclusive. • Not currently used Vilter Only Settings Rapid Cycling VFD: • Enables Rapid Cycling VFD Algorithm for controlling Compressor VFD Analog Output. Oil Flow Control: • Enables option for oil flow control.
Section 19 • Configuration Motor Current Device The Vission 20/20 can read the motor current in a couple of different ways. The following selections defines the method, see Figure 19-2. Current Transformer: • This defines the input used for motor current when a current transformer is used. 4-20ma Transformer: • This defines the input used for motor current. 19 – 6 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 1.
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. 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. 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. 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. Digital Input/Output 2: Digital Output 1: Analog Input 2: • Not editable by the operator.
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. 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.
Section 20 • Data Backup Setpoints Report All/ Select: The setpoints report screen offers the operator the ability to generate setpoints report for all screens. The reports are stored as .csv files and can be saved to a USB drive from Save/Load screen by selecting Setpoints Report option in Data Items during backup of database. .CSV file can be imported in any spread sheet application. During the course of operation, operator can generate reports any time, see Figure 20-3.
Section 21 • Maintenance Overview Maintenance Name: The maintenance screen is a convenient place to keep track of 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. • This column of tasks that should be performed at the run hours indicated in Maintenance interval column.
Section 21 • Maintenance Notes User: The notes tab allows the operator to make notes to any other personnel that might have access to the Vission 20/20. • Lists the operator name who performed the maintenance task. Maintenance Performed: • Lists the maintenance task that was performed. Run Hours: Log • Lists the run hours at which the maintenance task was performed. The maintenance log tab lists all the maintenance tasks performed in descending order, see Figure 21-2.
Section 21 • Maintenance Figure 21-3. Maintenance Screen - Chart Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
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Section 22 • User Access Overview 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. • Level 0 – This is the default level with no operator logged in.
Section 22 • User Access Login Operator Password: The login tab is where an operator will enter the users name and password in order to gain access to Vission 20/20 screens. • 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. Operators: Manage Accounts • All operators that have been added to the Vission 20/20 user tables will be displayed in this window.
Section 22 • User Access Operator Name: Security Level: • This entry box is for the operator’s username who is to be added, removed or modified. The operator can 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. • Select a security level for the account being added or modified. Only levels that are equal to or less than the operator’s own security level will be shown.
Section 22 • User Access VNC Account Change VNC Port Number Port Number: Vission 20/20 panels can be accessed remotely by using a VNC client over TCP/IP network. This tab allows the operator to change default VNC Password and VNC Port number, see Figure 22-3. Change VNC Password • The operator will change the port number for VNC server by touching the entry box and typing via the pop-up keyboard. Default port number is 5900. Operator can assign port number ranging between 5900 to 6000.
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 will have to navigate through the file structure of the USB drive to find the documents. The top box in the USB drive will display any USB drives mounted to the Vission 20/20 OS.
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 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 Limit” setpoint to define an area within the 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.
Section 24 • Twin Screw Control Twin Screw Oil Pressure The twin screw compressor has two separate oil pressure settings. They are named “Prelub Oil Pressure” and “Run Oil Pressure” in the Alarm and Trips Menu. Both of these oil pressures are calculated in the same way - defined as “Filter Outlet Pressure minus Discharge Pressure.
Section 24 • Twin Screw Control setpoints are forced into the Run Oil Pressure Alarm and Trip settings. By default, the Prelub Oil Pressure Alarm and Trip setpoints and the Run Oil Pressure Alarm and Trip settings are the same values, however these settings are adjustable. In some cases it may be advantageous to set the Prelub Oil Pressure Alarm and Trip setpoints to a lower value than the Run Oil Pressure Alarm and Trip setpoints.
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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 Auto Load 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 from Single Screw Once the Cool Compression is configured, most setup options available for a single screw are also available for Cool Compression. However, there are significant operational differences that are mostly associated with the compressor safeties: injection solenoid and is controlled via discharge superheat. When the discharge superheat reaches 5°F, the solenoid is turned on.
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. This screen will only be active if the Remote Oil Cooler Control option has been enabled from the Configuration Screen, see Section 19. Run Mode: The Remote Oil Cooler Control operation allows the cycling of fans and pumps in order to maintain a specific Remote Oil Cooler Temperature.
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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Appendix B • Vission 20/20 Application Procedures Contents Vission 20/20 Compressor Control Setup ............................................................................................... B-3 Vission 20/20 Compressor Control Setpoints Setup................................................................................ B-7 Vission 20/20 Compressor Sequencing Setup......................................................................................... B-11 Database Backup Procedure...................
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Appendix B • Vission 20/20 Application Procedures Vission 20/20 Compressor Control Setup SCOPE Vission 20/20 programs – version 4550.1 and later. Pulldown The Pulldown feature provides a method of slowly pulling the suction pressure down from a high value, by slowly lowering the suction pressure control setpoint over a time period. This feature is sometimes required on systems that have liquid recirculation systems.
Appendix B • Vission 20/20 Application Procedures Figure B-1. Pulldown Setpoints SETPOINT SELECTION EXAMPLE The following example is to illustrate the selection of setpoints for the Pulldown feature. The values picked are NOT representative of actual field applications. Assumptions and Variables: • Current suction pressure is at 80 psig • Target suction pressure is 20 psig. (This defines a change of 60 psig). • Time duration allowed to get to setpoint is 10 days (240 hours) of Pulldown time.
Appendix B • Vission 20/20 Application Procedures Pulldown OPERATION EXAMPLE Assumptions: • Compressor is off • Pulldown is selected • “Initiate Pulldown at Next Start” is selected • Current suction pressure = 80 PSIG • Auto-cycle setpoints are enabled • Pulldown setpoints are setup per the Setpoint Selection Example Variables: • Step Pressure = 5.0 PSIG • Delay Per Step = 20 hours • Stop Pressure = 20 PSIG • Auto-cycle Differential = 4 PSIG Operator presses Unit Start Auto button and the compressor starts.
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Appendix B • Vission 20/20 Application Procedures Vission 20/20 Compressor Control Setpoints Setup To enable the two setpoint operation, do the following: • In the section “Compressor Control”, enter “2” for each control in the “# Controllers” box. SCOPE Vission 20/20 programs – version 4550.1 and later COMPRESSOR CONTROL SETPOINTS COMPRESSOR SETPOINT #1 AND SETPOINT #2 Navigate to the Compressor Control screen and enter in the desired control setpoints for both Setpoint 1 and Setpoint 2.
Appendix B • Vission 20/20 Application Procedures Figure B-3. Compressor Control Setpoint 1 and Setpoint 2 Setup B-8 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures CONTROL MODE DROPDOWN BOX SAFETY SETPOINTS In Figure B-4, the Control Mode dropdown box allows selection of the active setpoints. In Figure B-5, the Alarm and Trip Safety setpoints also have Setpoint 1 and Setpoint 2 settings. These should be set up for proper operation when operating. To change from Setpoint 1 to Setpoint 2 being the active setpoint, do the following: • Select the Control Mode dropdown box, and then select Setpoint 2.
Appendix B • Vission 20/20 Application Procedures SERIAL OR ETHERNET OPERATION AND SETPOINT 1 AND SETPOINT 2 SELECTION Refer to Table B-4, for register information for setting the active setpoint. Figure B-5. Alarm and Trip Safety Setpoints for Setpoint 1 and Setpoint 2 B - 10 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures Vission 20/20 Compressor Sequencing Setup SCOPE Vission 20/20 programs – version 4550.1 and later OVERVIEW Compressor sequencing in the Vission 20/20 panel is carried out by utilizing the Ethernet communication port using Modbus TCP protocol. Future program releases will accommodate using the serial RS-485 Modbus RTU port. This will give the Vission 20/20 control panel the ability to sequence Vission control panels acting as Master Control.
Appendix B • Vission 20/20 Application Procedures master compressor ONLY. (The slave compressor(s) load and unloading is setup in the master Compressor Sequencing menu). The Auto-cycle settings can also be setup for the Master Compressor, to establish settings of when the Master compressor will automatically cycle on and off. NOTE The proportional control settings affect the loading and unloading of the master compressor only.
Appendix B • Vission 20/20 Application Procedures The master compressor controls the slave compressors based on the master compressor control setpoints as well as the setpoints entered in the master compressor sequencing menu. Page 1 of the master compressor sequencing menu (see Figure B-8) allows the operator to view and adjust settings which are used for compressor sequencing.
Appendix B • Vission 20/20 Application Procedures Unload Rate 2 Offset (Outer) • Defines the outer pressure setpoint offset to monitor compressor unload. If Suction pressure / proc temp goes surpasses the Control Setpoint minus unload rate 1 offset and then goes beyond Control Setpoint minus unload rate 2 offset then sequencing decisions are made according to unload rate 2 timer. Users below security level 2 (Supervisor) are not allowed to edit the sequencing settings. Example: automatically.
Appendix B • Vission 20/20 Application Procedures greater the priority of the compressor. Operator should choose the priorities of the compressors. Example: Configured step = 5 % Example: Configured min cap = 10 % “1” is highest priority. Configured max cap = 80 % Compressor with priority “2” has higher priority than compressor with priority “4”.
Appendix B • Vission 20/20 Application Procedures (decrease) the slave compressor capacity . When a slave compressor has been unloaded to its MIN CAP setpoint, and the suction pressure is still less than a value of unload rate 1 offset for the time period of the unload rate 1 timer, a calculation of the operating CFM of the slave compressor is made. This value is compared against the available CFM of the other running compressors. If enough CFM is available, then the machine stop timer is started.
Appendix B • Vission 20/20 Application Procedures Auto sequencing can be started (from the master compressor) by selecting the green Unit Start button and pressing the “Auto Seq” button.
Appendix B • Vission 20/20 Application Procedures In this example, during unloading cycle when suction pressure falls below a value less than configured unload rate 1 value (20 – 2 = 18 psig) for the time period of the unload rate 1 timer , then the program picks the lowest priority compressor (slave 3) from the list and starts unloading the compressor. The program unloads slave 3 as per steps configured till it reaches its Min Cap setpoint.
Appendix B • Vission 20/20 Application Procedures Database Backup Procedure Upgrading the program in the 20/20 panel normally involves replacing the flashcard. Note that all compressor operation setpoints, calibration values and maintenance information is held on the flashcard. So when upgrading to a new program (new flashcard), the task is simplified by using the “Database Backup” and “Database Restore” function provided in the 20/20 to migrate the database of the original flashcard to the new flashcard.
Appendix B • Vission 20/20 Application Procedures that is identified. After seeing this message, it will take a minute or so before the 20/20 boots up properly. 1. Once the 20/20 panel is booted back up, Press the “USER ACCESS” button – which is the new wording for the Logon button. Logon. Now insert the thumbdrive back into the USB port. 2. Navigate to the Data Backup screen. You should again see the USB thumbdrive listed under the “Available Devices.” 3.
Appendix B • Vission 20/20 Application Procedures Flashcard Replacement Procedure 12. Compressor Runtime. Before powering down to replace the flashcard, copy down all of the follow operating setpoints and configuration information. REPLACE FLASH CARD 1. Remove power from Vission 20/20 panel. RECORD OPERATING SETPOINTS AND CONFIGURATION INFORMATION 2. Remove old flashcard and install new flashcard and power panel back up. 1. Configuration Screen - Page 1 a.
Appendix B • Vission 20/20 Application Procedures Figure B-9. Flashcard Replacement B - 22 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures Danfoss Liquid Injection Valve Setup NOTE Consult the VSS / VSM / VSR Unit Manual for proper Danfoss ICM valve setup procedure. Figure B-10. Configuration Screen - Page 2 (Oil Cooling section) Figure B-11. Compressor Control Menu - Page 4 (Liquid Injection settings) The Danfoss Liquid Injection valve is selected from the Configuration Screen - Page 2 (Under Oil Cooling Section.
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Appendix B • Vission 20/20 Application Procedures User Access Menu This menu allows the operator to assign user accounts. The 20/20 will be shipped with a Level 3 operator and password pre-assigned to the installing contractor. He can then assign all users with security levels as needed. The procedure to assign user access levels is to first press the User Access button. The User Access screen will appear with the preassigned level 3 operator name visible within the Operators section.
Appendix B • Vission 20/20 Application Procedures Compressor Control Control setpoint level 0 Set/Change/Modify within supervisor set constraints All control setpoints level 1 All remaining control setpoints are modifiable in level 1 Proportional band level 1 Deadband level 1 Interval/pulse time level 1 Auto-cycle setpoints level 1 Enable/Disable and modify all setpoints Pumpdown setpoints level 1 Enable/Disable and modify all setpoints Pulldown setpoints level 1 Enable/Disable and modif
Appendix B • Vission 20/20 Application Procedures Remote Control and Monitoring of 20/20 Panel INTRODUCTION This document provides the reader with guidelines to successfully communicate to and integrate with the Vilter 20/20 control panel.
Appendix B • Vission 20/20 Application Procedures Figure B-12. Serial Communication Ports on Single Board Computer P12 = RS485 Serial Modbus RTU connector * P14, P18 = USB Serial Modbus RTU connectors P8 = Ethernet RJ45 connector The 20/20 offers two solutions for serial communications. The first option is connector P12 which uses traditional serial UART hardware. The second option uses the USB ports, P14 or P18. These ports require the use of an inexpensive, industrial USB to RS422/RS485 convertor.
Appendix B • Vission 20/20 Application Procedures Figure B-13. Vission 20/20 Single Board Computer with USB to RS422/RS485 Convertor (VPN3485C) on USB port P18 The above photo shows a typical connection for using one of the USB ports (in this case P18) for Modbus RTU serial communications. The USB port has a USB to RS422/RS485 convertor attached to it (VPN 3485C). One side of the convertor attaches to the USB port.
Appendix B • Vission 20/20 Application Procedures Figure B-14. Selecting USB Port for Serial Communication The Vission 20/20 panel allows designating the USB port to be used for serial Modbus RTU communication from the Configuration screen. A USB device must be plugged into one of the USB ports in order for the “Serial USB” option to appear from the drop-down box. B - 30 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures NETWORK TOPOLOGY USING VPN3485MS DEVICE AS A NETWORK CONVERTOR RS422/RS485 Networking Topology In Figure B-16 is a typical connection wiring diagram for using the device as an RS422 to RS485 convertor/ isolator. Many articles have been written about the different topologies of RS422/RS485 networks. Vilter recommends that a daisy chain topology be used for any RS422/RS485 network that incorporates a Vilter 20/20 panel as a network slave node.
Appendix B • Vission 20/20 Application Procedures USING THE DEVICE AS A NETWORK ISOLATOR/ REPEATER (Reference Figure B-17) 1. A DC power supply is required to power the device ( +10vDC to +30vDC) 2. Dip switches on each side of the device must be configured for the baud rate of the network. Figure B-17. Wiring Diagram – VPN3485MS Device as Network Isolator/Repeater Table B-2. Baud Rate Selection B - 32 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures Table B-3. RS422/485 Switch Settings Figure B-18. VPN3485MS DIN Rail Mounted Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures ETHERNET NETWORK TOPOLOGY The configuration of the plant Ethernet network might be dictated by the plant IT department. One common configuration is the star type topology, where a master device will connect to a switch, and all devices participating on the network (Vission 20/20 panels) will also be connected to the switch. All Vission 20/20 panels would have unique static IP addresses and the master would communicate to each. Figure B-19.
Appendix B • Vission 20/20 Application Procedures ADDITIONAL NETWORK CONFIGURATIONS FOR ACCESS VIA INTERNET There are many network configurations that will allow access to the Vilter 20/20 panels via an internet connection. Cost and network support is a consideration when the plant IT department has restrictions about outside access. It is recommended to work with them to setup an acceptable network. The configurations below are examples only.
Appendix B • Vission 20/20 Application Procedures Example 2 In Figure B-21, this example shows a PC connected to the internet, running a VNC client program which accesses the Vission 20/20 panels by specifying an IP address assigned to a company router. There would be a separate IP address for each 20/20 panel in the plant. Figure B-21.
Appendix B • Vission 20/20 Application Procedures Example 4 In Figure B-23, this example shows a hybrid network. An off campus PC and smartphone is connected to the internet, running VNC client programs which accesses the Vission 20/20 panels by specifying an IP address along with a router port designation. Each Vission 20/20 panel has an assigned router port. The company router is a wireless router which is also forms a wired LAN network.
Appendix B • Vission 20/20 Application Procedures REMOTE COMPRESSOR CONTROL VIA COMMUNICATIONS panel, the polling rate to the 20/20 panel can’t be unlimited, it needs to be governed. A compressor control scheme that is accomplished via communications must follow some general rules. The Vission 20/20 panel does not have a separate processor to handle communications from a computer or PLC. All tasks that the panel needs to accomplish are done by a single processor.
Appendix B • Vission 20/20 Application Procedures Figure B-24. Typical Block Diagram of a Multi-Compressor Control Scheme (2 of 4) Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures Figure B-24. Typical Block Diagram of a Multi-Compressor Control Scheme (3 of 4) B - 40 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures Figure B-24. Typical Block Diagram of a Multi-Compressor Control Scheme (4 of 4) The actual control scheme that you use will depend upon the response of the process that you are trying to control. Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures CONFIGURATION SCREEN SETUP FOR REMOTE CONTROL THROUGH COMMUNICATIONS (Reference the “Communication” section of Figure B-25) Once the port is setup properly, communication can be established. You will be able to read from and write (see note) to registers. NOTE For Ethernet control: 1. Configure “Active Remote Control” as Ethernet. 2. At the bottom of the column, check the “Ethernet” box. 3. Configure Ethernet I/P address. 4.
Appendix B • Vission 20/20 Application Procedures registers within the Modbus range of 40500 through 40513 can occur. If Remote Lock is ON, then writes within this region cannot occur. These registers are the compressor control registers (Start, Stop, Caphold etc). Remote Lock is typically used to lock out a PLC or central computer while the operator is operating the compressor locally. The Remote Lock button is located directly below the Compressor STOP button.
Appendix B • Vission 20/20 Application Procedures Modbus Register 40502 - Remote Capacity Control Selection • 0 = Auto Capacity Control. This selection defines that the 20/20 will control compressor capacity from its internal Control Setpoints. • 1 = Pulse Load/Unload. This selection defines that the 20/20 will control compressor capacity from contents of Pulse Load register 40504 and Pulse Unload register 40505. • For correlation between register content and pulse value, see Table B4.
Appendix B • Vission 20/20 Application Procedures NOTE Both Process Temp Control and Suction Pressure Control must both be enabled from the Configuration screen to do this.
Appendix B • Vission 20/20 Application Procedures scale) away from the current position, then energize the capacity slide for a time that is proportional to the amount it is away from the new target position. To say it another way – the further you are away from the new target position – the longer the slide is energized in the proper direction. This control region is called the proportional band region. 3.
Appendix B • Vission 20/20 Application Procedures power is restored, which means it will not accept any “writes” via communication, within the Compressor Command register region, until someone walks up to the panel and presses Unit Start-> Remote. 2. Never • The compressor will not restart after power is restored.
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Appendix B • Vission 20/20 Application Procedures Phoenix Contact PSM-ME-RS485/ RS485-P Isolator The Phoenix Contact isolator/repeater is used to electrically isolate the RS485 signal from the network and to improve the signal strength of the RS485 signal over long distances. It has the added benefit of active noise suppression since it regenerates the active signal in relation to time and amplitude.
Appendix B • Vission 20/20 Application Procedures Test 1 The first test measured the noise on the active network WITHOUT the Phoenix Contact PSM-ME isolator installed in the network, see Figure B-26. The Phoenix Contact PSM-ME repeater/isolator was removed from the circuit and the USB/RS485 convertor was wired directly to the Vission 20/20 RS485 serial port. The following screen capture from the scope shows the amount of noise on the network signals, see Figure B-27. Figure B-27.
Appendix B • Vission 20/20 Application Procedures Vessel Level Control Setup for 20/20 Panel INTRODUCTION This document provides guidelines to successfully setup a vessel level control function in the Vilter 20/20 control panel. Vessel level control is achieved using a level probe wired to an auxiliary analog input channel of the 20/20, thereby providing a 4-20ma signal proportional to the vessel liquid level.
Appendix B • Vission 20/20 Application Procedures Step 2: Selection and Naming of Auxiliary Analog Outputs used for Level Control Navigate to page 5 of the Configuration screen and select the analog output(s) that will be used modulating the positioning valve(s) on the vessel(s). Also provide a name for the analog output(s). You’ll need to reference your wiring diagram to determine which analog output(s) need to be enabled.
Appendix B • Vission 20/20 Application Procedures Step 3: Selection and Naming of Auxiliary Analog Inputs used for Level Control Navigate to page 4 of the Configuration screen and select the analog inputs(s) that will be used for sensing the 4-20ma signal from the vessel(s) level probe(s). Also provide a name for the analog input(s). You’ll need to reference your wiring diagram to determine which analog inputs need to be enabled.
Appendix B • Vission 20/20 Application Procedures Step 4: Instrument Calibration Screen Setup of Auxiliary Analog Inputs. Now that the auxiliary analog inputs have been selected and named, the scaling for the inputs needs to be setup. Navigate to Instrument Calibration screen page 4 and setup the auxiliary analog input(s). These inputs are 4-20ma signals and the scaling will be setup so that: a.
Appendix B • Vission 20/20 Application Procedures Step 5: Auxiliary I/O (Analog Inputs) Alarm and Trip Setup If an alarm or trip setpoint for the vessel level is desired, then navigate to Auxiliary I/O page 3 and setup any alarm or trip function for the vessel level.
Appendix B • Vission 20/20 Application Procedures Step 6: Setup of Analog Output for Vessel Level Control – PID Level Control Navigate to Auxiliary I/O page 6 and setup analog output control for vessel level. Figure B-34. PID Level Control (Auxiliary I/O – Page 6) CHILLER LEVEL CONTROL Suppose we are trying to maintain a level of liquid in a chiller. As the level decreases, we want to stroke a positioning valve “more open” to allow more liquid to feed into the chiller.
Appendix B • Vission 20/20 Application Procedures With the above setting, the response of the Aux1: Chiller Level 4,20 Output is seen to be; % Level Input Aux1 Analog Output 50 % = 4 ma (fully closed position) 45 % = 8 ma 40 % = 12 ma 35 % - 16 ma 30 % = 20 ma (fully open position) So a 20 % change in vessel level will cause the positioning valve to go from a closed position to fully open position. Decreasing the gain (P term) to 12.
Appendix B • Vission 20/20 Application Procedures Figure B-35. Proportional Level Control (Auxiliary I/O – Page 6) B - 58 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures VPLUS (AC Motor) Setup Procedure for 20/20 Panel This document provides instructions to help setup the Vission 20/20 for VPLUS control. INTRODUCTION ADDITIONAL HARDWARE This document provides guidelines to setup AC Motor VPLUS oil cooling system control on the Vission 20/20 panel. In order to control the VPLUS pump motor VFD, an analog output card is required.
Appendix B • Vission 20/20 Application Procedures Figure B-37. Digital Output Card Wiring to VPLUS Liquid Injection Solenoid The liquid injection solenoid needs to be wired to Digital Output board #2, output location #5. B - 60 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures VISSION 20/20 SOFTWARE SETUP Step 1: Configuration Screen Selection of Installed Boards installed into the Vission 20/20 panel have been selected or “checked”. You should have the additional board #10 installed (analog output board) and selected. Log on and navigate to the Configuration screen, page number 6. Insure that all boards that are physically Continue to Step 2. Figure B-38.
Appendix B • Vission 20/20 Application Procedures Step 2: Setup and selection of Oil Cooling from page 2 of the Configuration screen The oil cooling VPLUS algorithm must be enabled from the configuration screen. The algorithm used for this is the same one that is used to control the oil cooling motorized positioning valve. Navigate to page 2 of the Configuration screen. In the middle column, towards the bottom of page 2 are the Oil Cooling selections, see Figure B-39.
Appendix B • Vission 20/20 Application Procedures Step 3: Setup and selection of VPLUS / Motorized Valve Configuration. • Setpoint : 135 deg F. The oil cooling VPLUS control parameters must now be setup. Navigate to the last page of the Compressor Control settings page. Setup the Motorized Control Valve setting as show below in Figure B-40. • Minimum Valve Open Percent = De-selected. • Motorized Valve Control: P = 25.0 I = 1.0 D = 4.0 • Avg. with Oil Manifold Temperature = De-selected.
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Appendix B • Vission 20/20 Application Procedures VPLUS (DC Motor) Setup Procedure for 20/20 Panel INTRODUCTION This document provides guidelines to setup a DC Motor VPLUS oil cooling system control on the Vission 20/20 panel. SCOPE then sends a varying 4-20ma signal to a Dart speed control board – which varies the speed of a DC motor. The speed of the motor controls the amount of liquid refrigerant that is injected into the compressor to provide oil cooling.
Appendix B • Vission 20/20 Application Procedures Figure B-42. Temperature Controller Wiring Removed After removing the temperature controller wiring, the wiring diagram will look like Figure B-42. B - 66 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures HARDWARE WIRING Interconnect wiring between the Vission 20/20 panel and the VPLUS panel now needs to be done. 1. First make sure that the VPLUS panel and the Vission 20/20 panel control power comes from the same source. 2. Next, the Vission 20/20 analog output card must be wired to the Dart speed controller board. The analog output that is used for this is AO#4, see Figure B-43. Wires from AO#4 will land on wires 106 and 107, see Figure B-42. 3.
Appendix B • Vission 20/20 Application Procedures Figure B-44. Digital Output Card Wiring to VPLUS CRV Relay Terminal 104 B - 68 Vission 20/20 • Operation and Service Manual •Vilter/Emerson • 35391SC 2.
Appendix B • Vission 20/20 Application Procedures VISSION 20/20 SOFTWARE SETUP Step 1: Configuration Screen Selection of Installed Boards installed into the 20/20 panel have been selected or “checked”. You should have the additional board #10 installed (analog output board) and selected. Continue to step 2. Logon and navigate to the Configuration screen, page number 6. Insure that all boards that are physically Figure B-45.
Appendix B • Vission 20/20 Application Procedures Step 2: Setup and selection of Oil Cooling from page 2 of the Configuration screen The oil cooling VPLUS algorithm must be enabled from the configuration screen. The algorithm used for this is the same one that is used to control the oil cooling motorized positioning valve. Navigate to page 2 of the Configuration screen. In the middle column, towards the bottom of page 2 are the Oil Cooling selections, see Figure B-46.
Appendix B • Vission 20/20 Application Procedures Step 2: Setup and selection of Oil Cooling from page 2 of the Configuration screen The oil cooling VPLUS algorithm must be enabled from the configuration screen. The algorithm used for this is the same one that is used to control the oil cooling motorized positioning valve. Navigate to page 2 of the Configuration screen. In the middle column, towards the bottom of page 2 are the Oil Cooling selections (reference Figure 6 below).
Appendix B • Vission 20/20 Application Procedures Step 3: Setup and selection of VPLUS / Motorized Valve Control PID parameters. The oil cooling VPLUS control parameters must now be setup. Navigate to the last page of the Compressor Control settings page. Setup the Motorized Control Valve setting as show in Figure B-47. Depending upon the size of the oil separator, the P term may have to be adjusted to give proper response of the 4-20ma signal to the Dart Speed controller board for the VPLUS motor.
Appendix B • Vission 20/20 Application Procedures Vission 20/20 Communication Table • All ENUM variables are of INT type • ALL F-INT data types represent floating point values as INT types multiplied by 10 • All Pressures are in Psig • All Temperatures are in Fahrenheit • Modbus TCP addressing is PLC-style (Base 1) addressing • On Error, Modbus TCP server only returns an error code of “Illegal Data Address” • All registers returned (INT and F-INT) are 2-bytes long • For Ethernet/IP, use INT data type and PL
Appendix B • Vission 20/20 Application Procedures 17 N51:1 40052 Oil Pump INT 0 = OFF, 1 = ON Read 18 N51:2 40053 Capacity Increase ENUM 19 N51:3 40054 Capacity Decrease ENUM 20 N51:4 40055 Volume Increase INT 0 = OFF, 1 = ON Read 21 N51:5 40056 Volume Decrease INT 0 = OFF, 1 = ON Read 22 N51:6 40057 Oil Separator Heater INT 0 = OFF, 1 = ON Read 23 N51:7 40058 Trip INT 0= OFF, 1=ON (ON when no Trip) Read 24 N51:8 40059 Slide Valve Setpoint #1 INT 0 = OFF, 1
Appendix B • Vission 20/20 Application Procedures 53 N52:13 40113 Chiller Inlet Temperature F-INT Read 54 N52:14 40114 Condenser Pressure F-INT Read 55 N52:15 40115 Remote Setpoint F-INT Read 56 N52:16 40116 Auxiliary 1 F-INT Read 57 N52:17 40117 Auxiliary 2 F-INT Read 58 N52:18 40118 Auxiliary 3 F-INT Read 59 N52:19 40119 Auxiliary 4 F-INT Read 60 N52:20 40120 Auxiliary 5 F-INT Read 61 N52:21 40121 Auxiliary 6 F-INT Read 62 N52:22 40122 Auxiliary 7
Appendix B • Vission 20/20 Application Procedures 83 N54:3 40253 Pressure Ratio F-INT Read 84 N54:4 40254 Volume Ratio F-INT Read 85 N54:5 40255 Superheat Discharge Temp. F-INT Read 86 N54:6 40256 Superheat Suction Temp. F-INT (2nd release) Read 87 N54:7 40257 Superheat Oil Sep. Temp.
Appendix B • Vission 20/20 Application Procedures 99 N55:10 40410 Current Run Mode ENUM 0 = Idle Read 1 = Waiting 2 = Starting 3 = Manual 4 = Auto (Internal Capacity Control) 5 = Remote Auto (Internal Capacity Control) 6 = Remote Load/ Unload 7 = Remote Capacity Hold % 8 = Remote Ready (Idle) 9 = Direct I/O Auto Capacity 10 = Direct I/O Manual Capacity 11 = Direct I/O Capacity Hold % 12 = Auto Sequencing 100 N55:11 40411 Load Limiting Condition WORD "Bit 0 = High Motor Amps Bit 1 = High Discharge
Appendix B • Vission 20/20 Application Procedures "0 = R11 1 = R12 2 = R13 3 = R22 4 = R113 5 = R114 6 = R134a 7 = R290 - Propane 8 = R404a 9 = R500 10 = R502 11 = R503 12 = R507 13 = R717 14 = R717 - Cool Comp 15 = R744 - CO2 16 = R771 17 = R1270 Propylene 18 = Natural Gas 19 = Other" Read 104 N55:15 40415 Refrigerant ENUM 105 N55:16 40416 Runtime Hours (x1000) INT 106 N55:17 40417 Runtime Hours (1-999) INT 107 N55:18 40418 Remote Lock Mode INT 0 = OFF, 1 = ON Read Read Read Comman
Appendix B • Vission 20/20 Application Procedures 112 N56:4 40504 Remote Pulse Load F-INT "0 = Stop Pulse 10 = 1 Second Pulse 15 = 1.5 Second Pulse 20 = 2 Second Pulse … 145 = 14.5 Second Pulse 150 = 15 Second Pulse" ReadWrite 113 N56:5 40505 Remote Pulse Unload F-INT "0 = Stop Pulse 10 = 1 Second Pulse 15 = 1.5 Second Pulse 20 = 2 Second Pulse ... 145 = 14.
Appendix B • Vission 20/20 Application Procedures 126 N57:4 40554 Cap Dec Proportional Band Setpoint #1 F-INT ReadWrite 0.5 20.0 127 N57:5 40555 Setpoint #2 (Pressure, Temp) F-INT ReadWrite (-15.0, -100.0) (200.0, 150.0) 128 N57:6 40556 Cap Inc Time Interval Setpoint #2 F-INT ReadWrite 0.5 5.5 129 N57:7 40557 Cap Inc Proportional Band Setpoint #2 F-INT ReadWrite 0.5 20.0 130 N57:8 40558 Cap Dec Time Interval Setpoint #2 F-INT ReadWrite 0.5 5.
Appendix B • Vission 20/20 Application Procedures 148 N58:8 40578 Stop Delay Time Setpoint #2 INT ReadWrite 0 300 149 N58:9 40579 Minimum Slide Position Setpoint #2 INT ReadWrite 0 100 Pumpdown 150 N59:0 40590 Stop Pressure Setpoint #1 F-INT ReadWrite -15.0 200.
Appendix B • Vission 20/20 Application Procedures 167 N61:5 40615 Low Suct Press Force Unload Setpoint #1 F-INT Read 168 N61:6 40616 High Motor Amps Stop Load Setpoint #2 F-INT Read 169 N61:7 40617 High Motor Amps Force Unload Setpoint #2 F-INT Read 170 N61:8 40618 High Disch Press Stop Load Setpoint #2 F-INT Read 171 N61:9 40619 High Disch Press Force Unload Setpoint #2 F-INT Read 172 N61:10 40620 Low Suct Press Stop Load Setpoint #2 F-INT Read 173 N61:11 40621 Low Su
Appendix B • Vission 20/20 Application Procedures 189 N62:2 40642 Slide Valve Setpoint #1 Enabled INT 0 = Disabled, 1 = Enabled Read 190 N62:3 40643 Slide Valve Setpoint #2 Enabled INT 0 = Disabled, 1 = Enabled Read 191 N62:4 40644 Oil Pump Press. Restart Ratio (ON) F-INT Read 192 N62:5 40645 Oil Pump Press. Restart Ratio (OFF) F-INT Read 193 N62:6 40646 Oil Sep. Heater Temp.
Appendix B • Vission 20/20 Application Procedures 215 N71:3 40703 SOI Solenoid ON F-INT Read 216 N71:4 40704 SOI Solenoid OFF F-INT Read 217 N71:5 40705 SOI Load Limit INT Read 218 N71:6 40706 High Press Ratio Solenoid ON F-INT Read 219 N71:7 40707 High Press Ratio Solenoid OFF F-INT Read 220 N71:8 40708 Start SP F-INT Read 221 N71:9 40709 Linear SP F-INT Read 222 N71:10 40710 Upper SP F-INT Read 223 N71:11 40711 Max SP F-INT Read 224 N71:12 40712 Sta
Appendix B • Vission 20/20 Application Procedures Alarms/Trips (Page 2) 241 N64:0 40800 Low Suction Temp. Alarm F-INT ReadWrite -100.0 210.0 242 N64:1 40801 Low Suction Temp. Trip F-INT ReadWrite -100.0 210.0 243 N64:2 40802 High Disch. Temp. Alarm F-INT Read 244 N64:3 40803 High Disch. Temp. Trip F-INT Read 245 N64:4 40804 Low Oil Sep. Start Temp. Alarm F-INT Read 246 N64:5 40805 Low Oil Sep. Start Temp. Trip F-INT Read 247 N64:6 40806 Low Oil Sep. Run Temp.
Appendix B • Vission 20/20 Application Procedures 265 N65:6 40836 High Filter Diff. Run Press. F-INT Alarm Read 266 N65:7 40837 High Filter Diff. Run Press. F-INT Trip Read 267 N65:8 40838 High Motor Amps Alarm F-INT Read 268 N65:9 40839 High Motor Amps Trip F-INT Read 269 N65:10 40840 Low Run Pressure Ratio Alarm F-INT ReadWrite 1.4 4.9 270 N65:11 40841 Low Run Pressure Ratio Trip F-INT ReadWrite 1.4 4.
Appendix B • Vission 20/20 Application Procedures 288 N66:17 40917 High Superheat Temp Safety Changeover (minutes) INT Read Compressor Scheduling (Military Time) 289 N67:0 41000 Sunday Event #1 Control Mode ENUM ReadWrite (See Notes) 0 6 290 N67:1 41001 Sunday Event #1 Hour INT ReadWrite (See Notes) 0 23 291 N67:2 41002 Sunday Event #1 Minute INT ReadWrite (See Notes) 0 59 292 N67:3 41003 Sunday Event #2 Control Mode ENUM ReadWrite (See Notes) 0 6 293 N67:4 41004 Sun
Appendix B • Vission 20/20 Application Procedures 299 N67:10 41010 Sunday Event #4 Hour INT ReadWrite (See Notes) 0 23 300 N67:11 41011 Sunday Event #4 Minute INT ReadWrite (See Notes) 0 59 301 N67:12 41012 Monday Event #1 Control Mode ENUM ReadWrite (See Notes) 0 6 302 N67:13 41013 Monday Event #1 Hour INT ReadWrite (See Notes) 0 23 303 N67:14 41014 Monday Event #1 Minute INT ReadWrite (See Notes) 0 59 304 N67:15 41015 Monday Event #2 Control Mode ENUM ReadWrite
Appendix B • Vission 20/20 Application Procedures 311 N67:22 41022 Monday Event #4 Hour INT ReadWrite (See Notes) 0 23 312 N67:23 41023 Monday Event #4 Minute INT ReadWrite (See Notes) 0 59 313 N67:24 41024 Tuesday Event #1 Control Mode ENUM ReadWrite (See Notes) 0 6 314 N67:25 41025 Tuesday Event #1 Hour INT ReadWrite (See Notes) 0 23 315 N67:26 41026 Tuesday Event #1 Minute INT ReadWrite (See Notes) 0 59 316 N67:27 41027 Tuesday Event #2 Control Mode ENUM ReadW
Appendix B • Vission 20/20 Application Procedures 323 N67:34 41034 Tuesday Event #4 Hour INT ReadWrite (See Notes) 0 23 324 N67:35 41035 Tuesday Event #4 Minute INT ReadWrite (See Notes) 0 59 325 N67:36 41036 Wednesday Event #1 Control Mode ENUM ReadWrite (See Notes) 0 6 326 N67:37 41037 Wednesday Event #1 Hour INT ReadWrite (See Notes) 0 23 327 N67:38 41038 Wednesday Event #1 Minute INT ReadWrite (See Notes) 0 59 328 N67:39 41039 Wednesday Event #2 Control Mode E
Appendix B • Vission 20/20 Application Procedures 335 N67:46 41046 Wednesday Event #4 Hour INT ReadWrite (See Notes) 0 23 336 N67:47 41047 Wednesday Event #4 Minute INT ReadWrite (See Notes) 0 59 337 N67:48 41048 Thursday Event #1 Control Mode ENUM ReadWrite (See Notes) 0 6 338 N67:49 41049 Thursday Event #1 Hour INT ReadWrite (See Notes) 0 23 339 N67:50 41050 Thursday Event #1 Minute INT ReadWrite (See Notes) 0 59 340 N67:51 41051 Thursday Event #2 Control Mode EN
Appendix B • Vission 20/20 Application Procedures 347 N67:58 41058 Thursday Event #4 Hour INT ReadWrite (See Notes) 0 23 348 N67:59 41059 Thursday Event #4 Minute INT ReadWrite (See Notes) 0 59 349 N67:60 41060 Friday Event #1 Control Mode ENUM ReadWrite (See Notes) 0 6 350 N67:61 41061 Friday Event #1 Hour INT ReadWrite (See Notes) 0 23 351 N67:62 41062 Friday Event #1 Minute INT ReadWrite (See Notes) 0 59 352 N67:63 41063 Friday Event #2 Control Mode ENUM ReadWr
Appendix B • Vission 20/20 Application Procedures 359 N67:70 41070 Friday Event #4 Hour INT ReadWrite (See Notes) 0 23 360 N67:71 41071 Friday Event #4 Minute INT ReadWrite (See Notes) 0 59 361 N67:72 41072 Saturday Event #1 Control ENUM Mode ReadWrite (See Notes) 0 6 362 N67:73 41073 Saturday Event #1 Hour INT ReadWrite (See Notes) 0 23 363 N67:74 41074 Saturday Event #1 Minute INT ReadWrite (See Notes) 0 59 364 N67:75 41075 Saturday Event #2 Control ENUM Mode Read
Appendix B • Vission 20/20 Application Procedures 371 N67:82 41082 Saturday Event #4 Hour INT ReadWrite (See Notes) 0 23 372 N67:83 41083 Saturday Event #4 Minute INT ReadWrite (See Notes) 0 59 373 N67:84 41084 Comp Schedule Enable/ Disable INT 0 = Disable, 1 = Enable ReadWrite (See Notes) Compressor Sequencing 374 N68:0 41100 Control Setpoint (Pressure, Temp) F-INT Read 375 N68:1 41101 Load Rate 1 offset (Pressure, Temp) F-INT ReadWrite 0.0 100.
Appendix B • Vission 20/20 Application Procedures 387 N69:2 41172 High to Low Speed Fan Delay (seconds) INT ReadWrite 5 30 388 N69:3 41173 Condenser Setpoint F-INT ReadWrite 100.0 150.0 389 N69:4 41174 Upper Deadband F-INT ReadWrite 0.5 20.0 390 N69:5 41175 Lower Deadband F-INT ReadWrite 0.5 20.0 391 N69:6 41176 Wetbulb Offset F-INT ReadWrite 0.5 20.0 392 N69:7 41177 Switch Temp F-INT ReadWrite 25.0 45.
Appendix B • Vission 20/20 Application Procedures 411 N69:26 41196 Step #2 Out#3 Enabled (Summer, Winter) INT 0 = Disabled, 1 = Enabled ReadWrite 412 N69:27 41197 Step #3 Out#3 Enabled (Summer, Winter) INT 0 = Disabled, 1 = Enabled ReadWrite 413 N69:28 41198 Step #4 Out#3 Enabled (Summer, Winter) INT 0 = Disabled, 1 = Enabled ReadWrite 414 N69:29 41199 Step #5 Out#3 Enabled (Summer, Winter) INT 0 = Disabled, 1 = Enabled ReadWrite 415 N69:30 41200 Step #1 Out#4 Enabled (Summer,
Appendix B • Vission 20/20 Application Procedures 431 N69:46 41216 Step #2 Low Speed Fan (Summer, Winter) ENUM "0 = None 1 = Out # 1 2 = Out # 2 3 = Out # 3 4 = Out # 4" Read 432 N69:47 41217 Step #3 Low Speed Fan (Summer, Winter) ENUM "0 = None 1 = Out # 1 2 = Out # 2 3 = Out # 3 4 = Out # 4" Read 433 N69:48 41218 Step #4 Low Speed Fan (Summer, Winter) ENUM "0 = None 1 = Out # 1 2 = Out # 2 3 = Out # 3 4 = Out # 4" Read 434 N69:49 41219 Step #5 Low Speed Fan (Summer, Winter) ENUM
Appendix B • Vission 20/20 Application Procedures 446 N77:0 41340 Anti-Recycle ENUM "0 = True AntiRecycle 1 = Accumulative Anti-Recycle 2 = Hot Starts" Read 447 N77:1 41341 Restart On Power Fail ENUM "0 = Always 1 = Never 2 = Timed 3 = Remote Lock Off 4 = Boot in Remote (Direct I/O)" ReadWrite 448 N77:2 41342 Suction Press. Control Available INT 0 = No, 1 = Yes Read 449 N77:3 41343 Suction Press. Control # of Setpoints INT 450 N77:4 41344 Process Temp.
Appendix B • Vission 20/20 Application Procedures N77:21 41361 Discharge Press. Control # of Setpoints INT Read NOTES • Analog Outputs: spare1 / spare2 / spare3 – send a floating point value between 4.0 and 20.0 to drive a 4-20 mA signal output (assumes proper calibration) • Statuses: Alarm Status Word(s) – currently only 17 alarms, so only Alarm Status Word 1 and 2 are used, with each position indicating an alarm (MSB to LSB [Bit 15, Bit 14, Bit 13, ...
Appendix B • Vission 20/20 Application Procedures If control mode being set isn’t active in configuration, command will result in error.
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