Page 1 VILTech micro-controller Operation and service manual...
Page 3: Important Note
Important Note: Before applying power to the control panel, all wiring to the panel should be per NEC. Specifically check for proper voltage and that the neutral is grounded at the source. An equipment ground should also be ran to the panel.
Page 4: Table Of Contents
Table of Contents Important Note: ..................................3 Domestic Terms and Conditions ............................10 Export Terms and Conditions ............................... 12 Chapter 1 ................................. 11 Spare Parts List ..................................12 Pre-Startup Check List ................................. 13 Retrofit Kit Instructions ............................... 14 Operating Procedures ................................19 Definitions ...................................
Page 5 Capacity Control .................................. 43 Manual Capacity Control ..............................43 Automatic Capacity Control ..............................43 Control Groups ..................................44 Cut-Out Setpoint .................................. 44 Cut-In Setpoint ..................................44 Control Setpoint ................................... 44 Low Alarm/Failure Setpoints ..............................44 Time Proportional Control Strategy ............................. 44 Control Deadband ................................
Page 6 SETPT Hot Key ..................................59 AUTO Start Warning Screen ............................... 59 SETPT Hot Key Screen ............................... 59 Setpoints ..................................... 60 Pressure Setpoints ................................61 Suction Pressure Control Groups ............................61 High Suction Pressure Setpoints ............................63 Discharge Pressure Setpoints .............................. 64 Oil Pressure Setpoints ................................
Page 7 Calibrate Sensors ................................. 91 Dynamic Sensor Calibration ..............................91 Static Sensor Calibration ..............................91 Passwords .................................... 92 Adding/Deleting Users ................................ 92 Screen Access Levels ................................92 Initialization ..................................92 Power Fail Reset ................................... 92 Set Factory Configuration ..............................93 Configuration ..................................93 Display ....................................
Page 8 Load Bandwidth ................................. 120 Unload Deadband ................................120 Unload Bandwidth ................................120 Sequencing Commands ..............................120 System Control Parameter and Setpoint Communication ....................120 Sequencer Operations ................................ 121 Sequencer Lead List ................................121 Enabling and Disabling the Sequencer ..........................124 Sequencer Control Groups ..............................
Page 9 Low Intermediate Pressure (Two Stage) ..........................140 Discrete Alarms .................................. 140 APPENDIX B ............................... 141 Analog and Discrete I/O ..............................141 Analog Inputs ..................................141 APPENDIX C ............................... 143 Communication Protocols ..............................143 Introduction ..................................143 Applicable Documents ..............................143 Hardware Interface Description ............................
Page 10: Domestic Terms And Conditions
Notes Page...
Page 12: Export Terms And Conditions
Spare Parts List QNTY Part# Item 3400A Microcontroller Board 3400B I/O (Digital and Analog) Board 3400C Display Interface Board 3400CG 240x128 Liquid Crystal Display 3400F Controller Fuse Pack Consisting of 1-15amp main, 3-5amp I/O 400K Controller Power Supply 3400M 120VAC Solid State Output Module 3400N 120VAC Solid State Input Module 3400R...
Page 13: Pre-Startup Check List
Chapter 1 Pre-Startup Check List Pre-Wired done at factory. The necessary field wiring connections are described below. 1. Connect power (L1) to e-stop at terminal #2. Then neutral is connected on TB5 to the middle terminal labeled “N”. Last connect ground on TB5 at the right end terminal labeled “G”.
Page 14: Retrofit Kit Instructions
Chapter 1 Retrofit Kit Instructions Belt Drive Direct Drive Mount at Motor End of Unit Mount Suction Side of Unit...
Page 15 WARNING Do no t b rin g in o r ru n an y wirin g o n top o f panel. Do no t run DC voltag e o n the sam e side as t he AC Vo lta ge. All 120V wires must enter the lowe r rig ht corn er of pan el o r all warranties...
Page 17 NOTES: 1) CONNECT ALL SENSOR DRAIN WIRES AT THIS LOCATION. 2) DOTTED WIRING REPRESENTS FIELD WIRING 3) DOTTED COMPONENTS NOT BY VILTER 4) FOR NEMA 3, 3R, 4 & 12 PANELS, ALL OPENINGS TO BE GASKETED. 5) MOTOR STARTER WIRING WILL VARY. REFER TO STARTER MANUFACTURER‘S DIAGRAM FOR ACTUAL WIRING.
Page 19: Operating Procedures
Chapter 1 General Operating Procedures Definitions Cursor is a field indicator used on data entry screens. There are four possible cursor types: * represents a number field input > represents a selectable field “ represents a string field X represents a hexadecimal field The cursor shows the user which fields are changeable on a data entry screen.
Page 20: Keypad Functions
Keypad Functions The following is a brief summary of the Viltech keypad along with a description of its individual keys. Below is a drawing of the Viltech keypad layout. Keypad Diagram...
Page 21 STOP The red STOP key causes an immediate and orderly shutdown of a compressor. This key usually has no effect on master panels. 0 – 9 The NUMBER keys select menu or hot key options. On data entry screens the number keys are used to enter numerical data.
Page 22: Main Screen Overview
Main Screen Overview is the name for a set of features common to all large character screens. CREEN The Main screen is broken down into two areas: the Display Area, and the Title Banner. The following drawing shows a representation of the main screen layout and labels each of its various areas.
Page 23: Screen Types
Screen Types Viltech information is presented to the operator using eight different types of screens. The different each use specific data entry and control procedures. The screen CREEN YPES types let the user know which screen type heading to refer to for information on the specific screens’...
Page 24: Menu Option Selection
The following table contains a list of the active keys on a menu screen and their function. KEYS FUNCTION NUMBER Used to choose a selection number. KEYPAD ENTER Used to choose the selection number that is highlighted. UP/DOWN Moves the cursor from one selection to the next either up or down. ARROW QUIT Exits from current screen to the previous screen.
Page 25: Cursors
The following table contains a list of the active keys on a data entry screen and their function. KEYS FUNCTIONS NUMBER Used to enter numerical data. KEYPAD ENTER Toggles through the available choices on a selectable field. On a number field the ENTER key is used to accept entered data and move to next field.
Page 26: Field Types
Field Types This section discusses the procedures used to work with each of the as well as the general IELD YPES procedures that apply to all number entry fields. The following information applies to any field when entering numerical data: Decimal Number Entry -If the data you wish to enter has a zero in the decimal place there is no need to enter “0.”...
Page 27: Absolute Pressure Fields
Absolute Pressure Fields This field is actually a combination of numerical and selectable fields. The selectable or units section of the field allows the user to adjust the units to select vacuum or non-vacuum ranges. 1. Verify Cursor Type - locate the “*” numeric input cursor. 2.
Page 28: String Fields
String Fields is a special case alpha-numeric entry field. It is similar to a selectable field but each character TRING IELD in the string may be selected from the list of all possible letters, numbers, and special characters. 1. Verify Cursor Type - locate the “ “ “ string input cursor. 2.
Page 30: Status Screens
Status Screens are used to display a summary of significant system information. The TATUS CREENS Main Status screen in a system is usually a large character text screen or graphics screen and is the default screen displayed on the LCD. The Main Status screen will be replaced by the Active Alarm and Failure screen when a new alarm or failure exists or by the Auto-Start Warning screen if the compressor is online and ready to start.
Page 31: Confirmation Screens
Confirmation Screens is used to ask the user to confirm a selection by answering a ONFIRMATION CREEN question. This screen usually appears after the user has altered system parameters and then presses the QUIT key or to verify a system control request. Below is an example of a confirmation screen.
Page 32: Momentary Screens
Momentary Screens is used to verify certain user selections by displaying an OMENTARY CREEN informative message for three seconds. Rather than waiting for the entire three second time to elapse, the operator may press the QUIT key to end viewing of the message. The following is an example of a momentary screen.
Page 33: Information Screens
Information Screens are used to display system data to the user. The information on NFORMATION CREENS these screens may be real-time data, or a snapshot of data at the time the screen is first displayed. Information Screen The following table contains a list of the active keys on an information screen and their function.
Page 34: Access Screens
Access Screens is used to index the user into a larger set of screens. This screen is CCESS CREEN typically used in cases where more than eight screens are available for a particular option. The access screen will perform error checking on the number entered. For example, if the screen is used to access the daily schedules and the number eight is entered, the input area will flash error since there are only seven possible schedules.
Page 35: Log Screens
Log Screens are used to view recorded system information. The width and length of the CREENS log screens may be wider and longer than allowed by the LCD display area. The arrow and page keys can then be used to view the entire log. All systems are configured with the following logs: Operation Log, Trend Log, Alarm Log, Failure Log, and User Log.
Page 36: Alarms & Failures
Alarms & Failures The Viltech continually monitors the system parameters and compares them to setpoints LARM AND AILURE to inform the operator of the system status. An alarm is intended to alert the operator that an undesirable condition exists. A failure is an indication that a more severe system condition exists and may cause the system or component to shutdown.
Page 37 Active Alarms & Failures Status Screen The active function keys for this screen are described in the following table. FUNCTION UP/DOWN Scrolls line by line through the information. ARROWS CLEAR The CLEAR key is used to acknowledge and clear alarms/failures as well as to silence the alarm horn.
Page 39: Modes Of Operation
Chapter 2 Compressor Controls The following sections discuss the standard and optional features contained in the Viltech RECIP package. Modes Of Operation The RECIP Compressor package has several modes of operation. The mode is changed by using the MODE key and making a selection from the Operation mode menu. The modes of operation are as follows: 1.
Page 40: Starting The Compressor
Starting the Compressor The sequence that the RECIP compressor goes through during a start is as follows. 1. A five second minimum start delay timer is started. During this time, the capacity stages are unloaded, the logs are enabled, and any discrete I/O overrides are cleared. The compressor is now in the STARTING state.
Page 41: Remote/Auto Remote Start
Remote/Auto Remote Start I/O Control input is used to start and stop the RECIP compressor in the Auto-Remote EMOTE TART mode only. The compressor must first be placed on-line by the operator through the use of the key. Once the compressor is on-line, the Remote Start/Stop input may be energized to start the compressor.
Page 42: Stopping The Compressor
Stopping the Compressor The stopping sequence is as follows: 1. The Motor is stopped, the capacity stages are unloaded, and Cooling Control outputs are de- energized. 2. When the motor starter auxiliary contact opens within 15 seconds, the compressor will transition to the STOPPED state.
Page 43: Capacity Control
Capacity Control on a RECIP compressor is performed by adding or removing stages. Loading the APACITY ONTROL compressor adds stages which increases the compressor capacity and Unloading the compressor removes stages which decreases the compressor capacity. A stage can consist of one or more Loaders which energize to add pistons, or Unloaders which de-energize to remove pistons.
Page 44: Control Groups
Control Groups Four groups of control setpoints can be defined for use with automatic capacity control. Each setpoint group consist of a Cut-In, Cut-Out, Control, Low Alarm, and Low Failure setpoint. Cut-Out Setpoint -The Viltech will stop the compressor when the suction pressure or process temperature goes below the cut-out setpoint.
Page 45: Difference Above Setpoint
The relationship of these parameters can be seen in the time proportional control strategy diagrams shown below: Difference Above Setpoint Stages added using the fast delay timer Load Bandwidth Stages added using the normal delay timer Load Deadband No stages added or removed Control Setpoint No stages added or removed Unload Deadband...
Page 46: Sequenced Capacity Control
Sequenced Capacity Control While in the SEQUENCED mode, Automatic Capacity Control is used to adjust the capacity as documented above. This is also true for Sequenced mode in Remote control. The master panel will wait for a remote indication to start and according to the parameter setpoints in the sequencer setpoints screen then the master will turn on and off the slave panels.
Page 47: Running In Full Load Mode
Running in Full Load Mode When the command is received the Viltech disables all capacity control and locks the compressor at the fully loaded position. However, normal limiting and unloading functions will still be active. Anti-Cycle in Sequenced Mode While in the mode the anti-cycle time takes on a new role.
Page 48: Capacity Ramp Start Limiting
Capacity Ramp Start Limiting feature has been provided to limit capacity increases after the APACITY TART compressor starts. The operator can define the total time to limit capacity increases from the minimum capacity to 100% capacity. Once the compressor has started and the minimum capacity has been achieved, the capacity ramp timer is started, and further capacity increases will be limited.
Page 49: Staging Setup
Staging Setup The Viltech controller can be configured to operate on any compressor that performs capacity control in discrete steps. The Controller supports up to six (6) capacity steps. Each capacity step is configured to energize to unload (Unloader). Also, each capacity step can be assigned a percentage associated with that level of capacity. A capacity percentage is also assigned to the fully unloaded position.
Page 50: Setpoint Scheduling
Setpoint Scheduling is the automatic switching of Suction Pressure or Process Temperature control ETPOINT CHEDULING setpoint groups based on time of the day and day of the week. The operator can define up to seven (7) different daily time schedules and one weekly schedule. Schedule events can be manually overridden and scheduling can be enabled or disabled by the operator.
Page 51: Anti-Cycle Timer
Anti-Cycle Timer is used to avoid repeated start attempts within a user programmable period of YCLE IMER time. The Anti-Cycle timer is started with the motor and must completely count down before the motor can be started again. The duration of the Anti-Cycle timer can be adjusted from the Miscellaneous Controls.
Page 52: Operational Procedures
Operational Procedures The operator interface for the RECIP compressor is performed using LCD, keypad, and the following four hot keys: STOP SETPT LOGS MENU The following sections will explain the operating procedures associated with each of these hot keys. Momentary Screen The following table lists possible momentary screens associated with the START mode key function.
Page 54: Status Screens
Status Screens The status of the compressor can be viewed from a group of status screens as described below. Consecutive uses of the QUIT key will return the user to the main TATUS CREEN Compressor Main Status Screen shows a numerical summary of the compressor analog and state OMPRESSOR TATUS CREEN...
Page 55: Status Banner
The following table lists the various parameters displayed on the RECIP status screen. PARAMETER DESCRIPTION S1-S4, P1-P4, SY The active capacity control setpoint. S1-S4 indicate represent Suction Pressure setpoints, P1-P4 represent Process Temperature setpoints, and SY represents the Sequenced setpoint. Suction Pressure Discharge Pressure Oil Pressure...
Page 56: Current System State
Current System State The left-most highlighted status banner section displays the of the system. The following is a URRENT TATE table with a brief description of possible system states. CURRENT STATE DESCRIPTION ACYCLE XX:XX Anti-cycle count down timer has been activated to delay motor start. XX:XX is the time remaining. STOPPED Compressor is stopped.
Page 57: Alarm & Failure Area
Alarm & Failure Area The right most highlighted status banner section displays the LARM AND AILURE of the system. When a new alarm or failure occurs, this area will flash from TATUS highlighted to non-highlighted to inform the operator. The area will stop flashing but remain highlighted when the operator has used the CLEAR key to acknowledge the alarm or failure.
Page 58: Active Alarms & Failures Status Screen
Active Alarms & Failures Status Screen & F screen displays the system’s current Alarms/Failures. This screen CTIVE LARMS AILURES TATUS will be the initial screen displayed by the system when an alarm or failure first becomes active. The default status screen can be reached by simply pressing the QUIT key.
Page 59: Auto-Start Warning Screen
Auto-Start Warning Screen screen is displayed anytime the RECIP may be automatically TART ARNING started. The user can return to the system default status screen by pressing the QUIT key or cycle through all the status screens using the ENTER key. The system will return to the Auto-Start Warning screen after 10 minutes of keypad inactivity.
Page 60: Setpoints
Setpoint option allows the user to access a set of menu options used to set the ETPOINT systems various setpoints SETPOINTS 1. PRESSURE 1. SUCTION CONTROL GROUP 2. HIGH SUCTION 3. DISCHARGE 4. OIL 5. INTERMEDIATE (Two stage only) 2. TEMPERATURE 1.
Page 61: Pressure Setpoints
Pressure Setpoints The Pressure Setpoints menu allows the user adjust the various pressure related setpoints described in the following sections. Suction Pressure Control Groups This screen allows the user to set the control values for each of the RECIP’s four (4) control groups which are used for Automatic Capacity control.
Page 62 The following table lists the data entry fields on the screen and a description of their purposes. TERM DEFINITION RANGE CUT-IN Cut-in Setpoint. If Automatic or Auto-Remote mode is selected, Auto Start/Stop is enabled, the compressor is on-line, and the suction pressure rises above the Cut-in Setpoint, the compressor will start.
Page 63: High Suction Pressure Setpoints
TERM DEFINITION RANGE ACTIVE GROUP There are four possible suction pressure control groups, each with its own pressure parameters. This field is used to manually select the active setpoint group. S1 -S4 Suction Pressure Active Group Control Definitions High Suction Pressure Setpoints alarm and failure setpoints are not scheduled and are active UCTION RESSURE...
Page 64: Discharge Pressure Setpoints
Discharge Pressure Setpoints screen is used to set the discharge pressure control parameters for ISCHARGE RESSURE ETPOINTS high alarm, limiting, and ramp conditions. Discharge Pressure Setpoints Data Entry Screen The following table lists the data entry fields for the Discharge Pressure Setpoints screen. TERM DEFINITION RANGE...
Page 65: Oil Pressure Setpoints
Oil Pressure Setpoints screen allows the operator to set acceptable ranges for the oil pressure RESSURE ETPOINTS parameter to allow the Viltech to identify when the value is out of range. An example of the screen is shown below. Oil Pressure Setpoints Screen The following table lists the data entry fields and a description of their purpose.
Page 66: Intermediate Pressure Setpoints (Two Stage Only) Option
Intermediate Pressure Setpoints (Two Stage only) Option screen allows the operator to set acceptable ranges for the NTERMEDIATE RESSURE ETPOINTS intermediate pressure, and is only visible on the two stage compressor. An example of the screen is shown below. Intermediate Pressure Setpoints The following table lists the data entry fields and a description of their purposes.
Page 67: Temperature Setpoints
Temperature Setpoints The TEMPERATURE SETPOINTS menu allows the user to set temperature related setpoints described in the following sections.Discharge Temperature Setpoints Discharge Temperature Setpoints screen allows the operator to set acceptable ISCHARGE EMPERATURE ETPOINTS ranges for the RECIP discharge temperatureand second discharge temperature (DT2) for 12 & 16 single stage compressors.
Page 68: Oil Temperature Setpoints
Oil Temperature Setpoints screen allows the operator to set acceptable ranges for the EMPERATURE ETPOINTS RECIP oil temperature. Oil Temperature Setpoints Screen The following table lists the data entry fields and a description of their purposes. TERM DEFINITION RANGE HIGH FAILURE The compressor will be failed (stopped) when the oil temperature exceeds this value.
Page 69: Process Temperature Control Group
Process Temperature Control Group screen is used to set-up the Process Temperature control ROCESS EMPERATURE ONTROL ROUP parameters when the Process Temperature Control option is enabled. Process Temperature Control Group TERM DEFINITION RANGE CUT-IN Cut-in Setpoint. If Automatic or Auto-Remote mode is selected, Auto Start/Stop is enabled, the compressor is on-line, and the process temperature rises above the Cut-in Setpoint, the compressor will start.
Page 70: High Process Temperature Setpoints
Process Temperature Active Group Control Screen TERM DEFINITION ACTIVE GROUP There are four possible process temperature control groups, each with it’s own temperature control parameters. This field is used to manually select the active setpoints group. Process Temperature Active Group Control Definitions High Process Temperature Setpoints The HIGH PROCESS TEMPERATURE SETPOINTS screen is only visible when the Process Temperature Control option is enabled.
Page 71: Note Page
Note Page Intermediate Temperature Setpoints (Two Stage only) screen is only visible on a Two Stage compressor. NTERMEDIATE EMPERATURE ETPOINTS Intermediate Temperature Setpoints The following table lists the parameters displayed on the Process Temperature Setpoints screen. TERM DEFINITION RANGE HIGH FAILURE A failure is reported and the compressor is shutdown when the Intermediate Temperature rises above the High Failure setpoint 32 - 392 DEGF HIGH ALARM...
Page 72: Capacity Setpoints
Capacity Setpoints screen allows the operator to set acceptable ranges for minimum Capacity APACITY ETPOINTS and Ramp Start Parameters as shown in the following example. Capacity Setpoint Screen Capacity Setpoint Screen The following table lists the data entry fields and a description of their purposes. TERM DEFINITION RANGE...
Page 73: Scheduling
Scheduling function allows the user to create and modify schedules to control the changing of Suction CHEDULING Pressure or Process Temperature Setpoints based on the day of the week and time of day. The following sections will describe the various screens associated with this function. Scheduling 1.
Page 74: Active Group
Active Group screen allows the user to select the current active group. This setting will be active CTIVE ROUP until a scheduling change or the operator modifies it. An example of the screen is shown below. Active Group Screen The following table lists the data entry fields and a description of their purposes. TERM DEFINITION RANGE...
Page 75: Weekly Schedule
Weekly Schedule screen is used to define which of the seven available daily schedules is to be EEKLY CHEDULE assigned to each day of the week as shown in the following example screen. Weekly Schedule Screen The following table lists the data entry fields and a description of their purposes. TERM DEFINITION RANGE...
Page 76 Schedule 1 To Schedule 7 The seven all have a standard format allowing the user to select up to 8 schedule changes AILY CHEDULES per day. The following example shows the standard format for all seven of the daily schedules. DAILY SCHEDULE hh:mm:ss NUMBER...
Page 77: Cap Control
The following table lists the data entry fields and a description of their purposes. TERM DEFINITION RANGE SCHED TIME The time of day the control group will be changed to the selected group. Valid Time GROUPS The control group number to be used after the scheduled time occurs. G1-G4 Daily Schedule 1 Definitions CAP Control...
Page 78: Process Temperature Control Setpoints
The following table lists the data entry and information fields on the screen and a description of their purposes. PARAMETER DEFINITION RANGE NORMAL Adjusts the sensitivity of the time proportional control routine. 0 - 20 PSID BANDWIDTH CONTROL The capacity will not be adjusted if the suction pressure is within DEADBAND the control deadband.
Page 79: Misc Control
The following table lists the data entry and information fields on the screen and a description of their purposes. TERM DEFINITION RANGE NORMAL Adjusts the sensitivity of the time proportional control routine. BANDWIDTH 0 - 20 DEG CONTROL The capacity will not be adjusted if the Process Temperature is within DEADBAND the control deadband.
Page 80: Logs Hot Key
The following table lists the data entry fields and a description of their purposes. TERM DEFINITION RANGE AUTO START/STOP When Auto Start/Stop is Enabled, the compressor ENABLE/ will start and stop automatically in the Automatic and DISABLE Auto-Remote modes. POWER FAIL RESART When Power Fail Restart is Disabled, the compressor ENABLE/ will be forced off-line after a power failure occurs.
Page 81: Chapter 3
Chapter 3 Logging Functions The Viltech records the systems parameters and conditions for later use in a set of logs. Each log has a limit on the number of entries that it can store, so as the log fills-up the oldest entries are replaced by the most recent ones.
Page 82: Trend Log
Trend Log The format of the TREND LOG is identical to the operations log. The Trend Log allows the user to define the recording interval (Default 15 minutes) and has a limit of 255 recorded data entries. A special entry is made to the Trend Log when certain events occur similar to the Operations Log.
Page 83: Logging Functions Operating Procedures
Logging Functions Operating Procedures The LOG FUNCTION is accessed by the operator through the LOGS hot key. This hot key allows the user to view or erase any of the systems available logs. A diagram of the available menu options under the LOGS hot key is shown below. The operator simply selects the menu item of the log they wish to access using standard menu screen operating procedures.
Page 84: Operations And Trend Logs
Operations and Trend Logs The OPERATIONS AND TREND LOGS typically store the same parameters. The only difference is the time interval at which entries are made. The logs will also indicate which parameters have caused an alarm or failure by placing an indicator next to the responsible parameter.
Page 85: Alarm And Failure Logs
Alarm and Failure Logs are records of the system alarm and failure conditions. LARM AND AILURE The screen format is the same for both logs, except for the TYPE column. The following is an example of the first page of the Alarm log. PG 1/2 ALARM LOG hh:mm:ss...
Page 86: User Log
User Log is a record of the last 50 user logon’s for the system. The following is an example of the first page of a typical User Log screen. PG 1/2 USER LOG hh:mm:ss TIME DATE USER hh:mm:ss AM mm/dd/yy hh:mm:ss AM mm/dd/yy hh:mm:ss AM...
Page 87: Clear All Logs
Clear All Logs menu entry provides a method of erasing all the data currently LEAR contained in all the logs available on your system. After choosing to clear all logs the user will be prompted by a confirmation screen to verify the selection. If the user decides to continue with the clearing of the logs, a momentary screen will appear with a message stating that the logs have been erased.
Page 89: Logon User
Chapter 4 Menu Functions The MENUS hot key allows the user to access miscellaneous screens that do not fall under one of the other hot key categories. The system supports the following four additional menus: Logon User Logoff User Diagnostics System Set-up Technical Overview Additional menus are available for system logon and logoff, basic system information for diagnostic purposes...
Page 90 Diagnostics Menu menu option permits the user to view basic information about the system. The information IAGNOSTICS can then be used to readily troubleshoot problems when they occur. Most of the screens available under this menu option are view-only screens and information displayed cannot be changed by the user. There are a few screens available which have selected parameters for which data entry is possible.
Page 91: Set-Up Menu
Set-up Menu menu allows the user to perform miscellaneous set-up changes, which are used to configure the system. Set Clock screen allows the user to enter the current day and date. The system clock may be set LOCK to a 12 or 24 hour mode. The correct hour, minute and second for the current time must be entered as 24 hour time.
Page 92: Passwords
Passwords The Viltech system manager will assign user numbers, passwords, screen read and write access levels and screen access requirements for all users. A user is defined as an individual or group of individuals who will be using the system. Each user of the Viltech can be assigned a numeric password to define their operating privileges. The system manager’s password will initially be assigned by Vilter Manufacturing upon system configuration and may be changed by the system manager if desired.
Page 93: Set Factory Configuration
Set Factory Configuration SET FACTORY CONFIG will initialize the system using the preset default factory configuration values. All the system setpoints and calibration data should be recorded either manually or electronically prior to performing a Factory Configuration. Configuration menu contains menu items which need to be configured once at system startup or which ONFIGURATION do not typically require modification.
Page 94: Operational Procedures
Operational Procedures A diagram of the screens available under the MENUS hot key is shown below. Note that some screens are optional and may not be accessible on all compressors. MENUS 1. LOGON USER 2. LOGOFF USER 3. DIAGNOSTICS 1. SYSTEM INFO 2.
Page 95: Logon User
Logon User To log onto the system the user selects the option and enters the appropriate OGON user password. Once a password is accepted the system allows access according to the restrictions preset by the Viltech system manager. Below is an example of a logon. Logon User Screen The following table lists the data entry fields and a description of their purpose.
Page 96: Diagnostics
Diagnostics menu option permits the user to view and in some cases alter basic information about the IAGNOSTICS system. The menu selections include viewing System Information, Viewing IO, Analogs; and viewing Network Communications. Diagnostics Screen System Information screen is used to provide the user with the system options and software configuration YSTEM NFORMATION status.
Page 97: View Discrete I/O
The following table lists the various parameters displayed on the screen. PARAMETER DEFINITION VILTER, INC. The name and version number of the installed software. RECIP COMP. VO.XX BUILD DATE The date the system was last built. INIT DATE The date the system was intiaited. RESET DATE The date and time the system was last reset.
Page 98: View Analogs
Discrete I/O Rack 1B Screen The following table lists the various parameters displayed on the screen. PARAMETER DEFINITION The discrete channel number NAME The name of the discrete signal. Shows whether the discrete is an input or an output. STATE The current state of the discrete signal.
Page 99 The following table lists the various parameters displayed on the screen. PARAMETER DEFINITION The analog channel number. NAME The name of the analog signal. V ALUE The decimal value of the analog input. The hexidecimal value of the analog input. Analog Input Definitions...
Page 100: Communication Status
Communication Status The Communication Status screen allows the user to monitor the status of the system’s communication links. The screen shown below is an example of a Communication Status screen. COMMUNICATION STATUS hh:mm:ss MODEM MASTR STATUS FAIL FAIL FAIL FAIL LAST ERR TOTAL ERR XXXX...
Page 101: Override Discrete I/O
Override Discrete I/O screens allow discrete Inputs and Outputs to be simulated whenever the VERRIDE ISCRETE compressor is stopped (some channels are not assigned). Any overridden channels will be restored to normal when the compressor is started. Override Discrete I/O Rack 1A Screen Override Discrete I/O Rack 1B Screen The following table lists the various parameters displayed on the screen.
Page 102: Set-Up
Set-up menu allows the user to perform miscellaneous set-up changes, which are used to configure the system. The menu selections include Set Time and Date, Calibrate Sensors, Password Control, Initialization, and Configuration. Set-up Menu Screen Set Clock The SET CLOCK screen allows the user to change the date, clock mode or time of day for the system. The clock mode gives the user the ability to display time in 24 hour or 12 hour modes.
Page 103: Calibrate Sensors
The following table lists the data entry fields and a description of their purpose. TERM DEFINITION RANGE The current day of the week. SUN - SAT DATE The current date entered as month, day, and year. All six digits must be entered. For example, to set the date to March 2nd, 2001, enter 03 02 01.
Page 104: Dynamic Sensor Calibration
Dynamic Sensor Calibration DYNAMIC SENSOR CALIBRATION is described more fully on page 87 of this chapter. DYNAMIC CALIBRATION hh:mm:ss NAME V ALUE SUCTION PRESS XXX.X PSIG DISCHARGE PRESS XXX.X PSIG OIL PRESS XXX.X PSIG DISCHARGE TEMP XXX.X DEGF OIL TEMP XXX.X DEGF SUCTION TEMP XXX.X DEGF...
Page 105: Static Sensor Calibration
Static Sensor Calibration is described more fully on page 87 of this chapter. TATIC ENSOR ALIBRATION STATIC CALIBRATION hh:mm:ss NAME SUCTION PRESS XXX.X XXX.X PSIA DISCHARGE PRESS XXX.X XXX.X PSIG OIL PRESS XXX.X XXX.X PSIA DISCHARGE TEMP XXX.X XXX.X DEGF OIL TEMP XXX.X XXX.X DEGF...
Page 106: Password Control
Password Control The Viltech system manager will assign each user a password to define their operating privileges. The password sets privileges for screen read and write access. The read access level defines the access level required to view a screen, while the write access level defines the access level required to change data on a screen.
Page 107: Add/Delete User
Add/Delete User screen will allow for the addition or deletion of a user. This ELETE function is performed by creating or deleting a password and corresponding access levels for a particular user. An example of the screen is shown below. ADD DELETE USERS hh:mm:ss LEVEL...
Page 108: Access Levels
Access Levels Screen Access authorization levels are selected for various screen sections using the screen. This allows the system manager to restrict user access CREEN CCESS EVELS to certain areas of the system. An example of a Screen Access Level screen is shown below.
Page 109: Initialization
Initialization menu selection under the Set-up group includes Power Fail Reset, Setpoint Save/Restore, Save NITIALIZATION Restore Status, and Set Factory Config. These screens are discussed further in the following sections. Initialization Screen Power Fail Reset Selection of this initialization option causes the software to restart using the current setpoints as if a power failure occurred.
Page 110: Set Factory Config
1. Set Factory Config This selection allows the user to reset the system to factory default values. When the user selects the menu option a confirmation screen will be displayed asking the user to verify that he wishes ACTORY ONFIG to reset the system to the original factory configuration.
Page 111: Configuration
4. Configuration menu selection allows the user to set-up various basic system parameters ONFIGURATION for the display and operation of the compressor. These parameters are usually set-up once and never change. Configuration Screen Display screen allows the user to configure the display units for all analog parameters ISPLAY and panel name.
Page 112: Comm Setup
Comm Setup The following screen is a sample COMMUNICATIONS SET-UP screen for Modbus Commu- nications. Communications Screen The following table list the data entry fields and a description of their purpose. TERM DEFINITION RANGE BAUD RATE Selects the baud rate for Modbus 2400/4800/ 9600/ 19200 serial communications.
Page 113: Set Op Stats
Set Op Stats screen is used to reset the total runtime hours and number of PERATING TATUS starts following a board change or software update. Set Operating Status Screen The following table list the data entry fields and a description of their purpose. TERM DEFINITION RANGE...
Page 114: Setup Stages
Setup Stages The following is a sample STAGING CONFIGURATION STATUS screen. Staging Configuration Status Screen The following table list is the data entry fields and a description of their purpose. TERM DEFINITION RANGE STAGE NUMBER This field displays the reference number used to identify the state number STAGE OUTPUT...
Page 115: Control Configuration
Control Configuration The following screen enables alarm and fail or fail out and selects the refrigerant. Control Configuration Screen Adjust Contrast This screen allows you to change the contrast of the display. Adjust Contrast Screen...
Page 116: Variable Frequency Drive Option
Variable Frequency Drive Option When VFD is enabled, a Proportional-Integral-Derivative (PID) algorithm is used to generate a 4-20mA control signal to the VFD. The VFD in turn varies the frequency and voltage to the motor resulting in slower or faster speeds.
Page 117 VFD Single Channel Analog Output Card and Jumper Settings. Definitions of the terms used in the Motor Speed screen. Term Definition Range Proportional Adjusts the speed based on how far the control 0:1000 Constant parameter currently is from the control setpoint. A higher P term causes a greater speed changes when far from the setpoint.
Page 118: Sequencer Control
Sequencer Control The control function is responsible for the management of a group of compressors to control a refrigeration load. The following sections will present the user with both a technical overview and the operating procedures for sequencer control. Sequencer Technical Section In a typical refrigeration system several compressors may be used to provide the required tonnage to control the refrigeration load.
Page 119: Sequencer System Control Parameters
Sequencer System Control Parameters A sequencer uses a sensor value and compares this value to an operator defined setpoint to control the refrigera- tion load. This system control parameter may be a suction pressure, a process temperature or any other reading that provides an accurate indication of the required refrigeration load.
Page 120: Difference Above Setpoint
The relationship of these parameters can be seen in the sequencer control strategy diagram shown below. Difference Above Setpoint Stages added using the fast delay timer Load Bandwidth Stages added using the normal delay timer Load Deadband No stages added or removed Control Setpoint No stages added or removed Unload Deadband...
Page 121: System Control Parameter And Setpoint Communication
System Control Parameter and Setpoint Communication The sequencer continuously sends the setpoint and system control parameter to all the compressors in its lead list. Sending the setpoint eliminates the need to setup every compressor individually and allows the sequencer to schedule setpoint changes.
Page 122 Lead list Processing The sequencer processes through the lead list starting and stopping compressors as required. Lead list changes, unavailable compressors, or a failure on one or more machines will cause special processing to be performed. This special processing is described in the following sections: Lead List Changes When the operator changes the sequencer lead list, no compressors will be stopped or started immediately.
Page 123 Sequencer Status Every compressor in a sequencer’s lead list is assigned a sequencer status which can be viewed on the sequencer status page. The following list describes the possible status conditions. : UNAVAIL -The compressor is not available to the sequencer. STANDBY -The compressor is available to the sequencer.
Page 124: Enabling And Disabling The Sequencer
NO FAILURES -A failure takes a compressor off-line and makes it unavailable for sequenced operation. When a compressor determines that it can no longer make capacity adjustments to reduce the system control parameter it informs the sequencer that it is fully loaded. Compressors are fully loaded when all of their stages are in use.
Page 125: Alarm And Failure Setpoints
Overriding Schedule Actions Using the schedule setup screen the operator can temporarily override scheduling actions. The active lead list, active schedule, and active group can be changed. Overrides may be altered after a schedule change occurs but may only last until the next scheduled activity occurs. Alarm and Failure Setpoints The control parameter used to sequence compressors is monitored by the Viltech for alarm processing.
Page 126: Sequencer Operating Procedures
Sequencer Operating Procedures The sequencer function will use a SEQ hot key to allow the operator to adjust the controls for the various sequencers contained in the system. The following sections describe the various procedures used in the sequencer function. Sequencer Status Screen The presence of a SEQ hot key will add at least one sequencer status screen to the list of status screens.
Page 127: Seq Hot Key
SEQ Hot Key Following is a menu diagram for the SEQ hot key. This menu diagram is for a system with only one sequencer. If the system has more than one sequencer, multiple sequencer setup selections will be available. Additional menu selections for control setpoints, control groups, and high alarm setpoints are present if the system contains multiple system control parameters.
Page 128 Sequencer Control The sequencer control screen allows the operator to enable or disable the sequencer. If process temperature is an option, it may also be selected from this screen. Sequencer Control Screen Sequencer Setpoints On the next page is an example of a sequencer control setpoints screen. If the sequencer can use multiple system control parameters, a menu will allow selection of control setpoints for each param- eter.
Page 129 Sequencer Control Setpoints Screen The following table lists the data entry fields and a description of their purposes. The ranges for these parameters will vary based on the type of system control parameter used. PARAMETER DEFINITION RANGE SEQ NORMAL BANDWIDTH The sequencer load and unload normal 0 - 20 PSID bandwidth define when normal staging...
Page 130 PARAMETER DEFINITION RANGE COMP NORMAL BANDWIDTH The compressor load and unload normal 0 - 20 PSID bandwidth define when the compressor will increase or decrease capacity. If the difference between the setpoint and system control parameter is greater than the bandwidth the compressor will load or unload continuously.
Page 131: Lead List B
Lead List The sequencer lead list defines the order that the compressors will be added or removed. The “NONE” selection is used to allow the operator to remove a compressor from the lead list. The user should make sure no duplicate entries exist in the lead list and that no two sequencers contain the same compressor at the same time.
Page 132: Control Group Select
Control Group Select The sequencer control group select screen permits the user to set the control, low alarm, and low failure setpoints for the different control groups. Below is an example of a sequencer control group select screen. If the sequencer contains multiple system control parameters, a menu will allow selection of control groups for each parameter.
Page 133: Schedule Setup
Schedule Setup The schedule setup screen is used to enable/disable scheduling along with setting the weekly schedules and performing scheduling overrides. An example of a schedule setup screen is shown below. Sequencer Schedule Setup Screen The following table lists the various parameters displayed on the master sequencer setup screen. TERM DEFINITION RANGE...
Page 134: Daily Schedules
Daily Schedules The daily schedules are reached by entering the schedule number on the schedule access screen. Below is an example of a daily schedule screen. Sequencer Daily Schedule Screen The following table lists the data entry fields and description of their purposes. TERM DEFINITION RANGE...
Page 135: High Alarm
High Alarm The high alarm setpoints screen allows the operator to adjust the high alarm and failure setpoints. If the sequencer supports multiple system control parameters, a menu will allow selection of high alarm setpoints for each parameter. An example of the high alarm setpoints screen is shown below. SequencerHigh Alarm Screen The following table lists the data entry fields and description of their purposes.
Page 136: Addendum For Pump Down Program For Viltech
Addendum for Pump Down Program for VILTech The VILTech needs to be setup for Remote operation, Auto Start/Stop enabled, and Suction Pressure control. The Process Temperature control is not an option for capacity control and is used instead to control the Chiller Liquid Valve. When the controller is On-Line, the Remote Start/Stop input energizes, and the Process Tem- perature input is above the High Temperature Cut-In setpoint;...
Page 137 The Process Temperature Cut-In/Cut-Out setpoints used for control are taken from the setpoint group associated with the current Suction Pressure control group. For example, if Suction Pressure Group 2 is currently selected for control, the Process Temperature setpoints will also be taken from Group 2. The following Hardware needs to be installed for the Pump Down program to function: •...
Page 139: Alarm And Failure Data
APPENDIX A Alarm and Failure Data The Alarm and Failure Data Appendix provides a table which describes all of the analog and discrete alarms in the system. The level column describes the type of alarm or failure and the Default column lists the factory setpoint for analog alarms. Analog Alarms Parameter Name Level...
Page 140: High Intermediate Pressure (Two Stage)
Parameter Name Level Default Comments High Intermediate Pressure (Two Stage) Alarm 58PSIG Spare (One Stage) Low Intermediate Pressure (Two Stage) Alarm 45PSIG Spare (One Stage) Low Intermediate Pressure (Two Stage) Fail 40PSIG Spare (One Stage) Discrete Alarms The Micro checks the state of the Motor Output and Aux Input.
Page 141: Analog And Discrete I/O
APPENDIX B Analog and Discrete I/O The Analog and Discrete I/O section identifies the channel assignments for sensor inputs, control outputs, and status inputs for various compressor models. Analog Inputs RECIP Compressor-Analog Inputs TYPE CHANNEL NAME RANGE UNITS SENSOR TYPE Press Suction Press 0: 200...
Page 143: Communication Protocols
APPENDIX C Communication Protocols Introduction The hardware interface and software protocol are defined for performing serial communications with the Viltech using the Modbus RTU protocol. In this case, the implementation of the protocol is limited to the sub-set of the complete set of possible message types.
Page 144: Hardware Interface Description
Hardware Interface Description Hardware Requirements The Vilter 400 Series Compressor uses the on-board COMM 1 port for Modbus RTU communications. The hard- ware configuration for both protocols is 5-volt RS-485 or RS422 multi-drop. Interface Connections Physical interface connections for Modbus communications are made at COMM 1 located on the left side of the main microprocessor board next to the corner.
Page 146: Message Addressing
Message Addressing Each compressor is required to have a unique address referred to as the unit number. The unit number is initially set using dip switch SW1 on the main microprocessor board. However, the actual unit number can be changed through software by setting the Modbus unit number on the appropriate set-up screen on the controller.
Page 148: Software Interface Description
Software Interface Description Protocol Overview All communications with the Vilter Reciprocating Compressor Controller is on a request-response basis. The main computer is the “master” and the Viltech controller is the “slave”. All messages will originate on the master with the slave responding as required.
Page 149: Modbus Protocol Description
MODBUS Protocol Description All transactions will be performed using the Modbus RTU transmission mode. All messages will be terminated with a two-byte CRC-16. The Modbus ASCII transmission mode is not supported. The default software configuration for Modbus is shown below. Where a parameter can be changed, a range of options is also shown.
Page 150: Preset Single Register
Preset Single Register The Preset Single Register function code (0x06) is used to change the contents of a single register within the Viltech controller. Any register within the Control Message and Setpoint Messages may be changed as long as the address and data are within the valid range.
Page 151: Error Messages
Error Messages The Modbus protocol provides for the return of error codes in the event of a data error within a correctly formatted message block. When the Viltech controller detects an error within a read or write message, the message response will contain an error code instead of the expected data response.
Page 152: Status Message Description
Status Message Description The status message is a read-only message containing analog, discrete, alarm and state data. NOTE: Some data in the status message may not apply to your particular compressor, depending on optional equipment and features. The Status Message includes the following types of data: •...
Page 154: Alarm And Failure Data
Alarm and Failure Data...
Page 155 Alarm and Failure Data (Continued)
Page 156 Alarm and Failure Data (Continued)
Page 157: Equipment Data
Equipment Data Alarm Status Table Bits 7 6 5 4 3 2 1 0 X X X X X X X X Alarm Active Failure Active Alarm is Non-Fatal Failure is Non-Fatal Alarm Acknowledge New Alarm Acknowledge New Failure Acknowledge Not Used Compressor Mode Table...
Page 158: Compressor State Table
Compressor State Table...
Page 159: Last Recip Start Status Table
Last RECIP Start Status Table...
Page 160: Control Message Description
Control Message Description The Control Message is a read/write message containing fields to start and stop the compressor, change the compressor mode, and change the control setpoint group number. The contents of the Control Message are shown in the following table and described further in the paragraphs below.
Page 161: Network In Control Command
Network In Control Command The Network In Control command is used to allow the network to enable or disable itself from controlling the system. When set to zero, the contents of the remainder of the Control Message, the Suction Pressure Setpoint Message, and the Process Temperature Set-point Message will be ignored.
Page 162: Set Comressor Capacity Command
Set Compressor Mode Command The Set Compressor mode command is used to change the current active mode of the compressor. Normally, only the Remote mode is used by the master. The SEQ, Sequence, mode is then automatically controlled by setpoints and loaded and unloaded automatically. Auto-Remote mode allows the master to provide the control setpoint and the compressor will load and unload to maintain the current active setpoint.
Page 163: Acknowledg/Clear Active Alarm Command
Acknowledge/Clear Active Alarm Command The Acknowledge/Clear Active Alarm command is used by the master computer to silence the audible alarm horn and to clear alarms from the active alarm display. After each new alarm or failure, the first control message received with this word set will only silence the audible alarm horn.
Page 164: Suction Pressure Setpoint Message Description
Suction Pressure Setpoint Message Description The Suction Pressure Setpoint message is a read/write message used to display or change the four Suction Pressure control group setpoints. Suction Pressure setpoints may be read or written individually or in groups. The master is responsible for setting the correct starting address, number of registers, and the register data for the message block.
Page 165: Process Temperature Setpoint Message Description
Process Temperature Setpoint Message Description The Process Temperature Setpoint message is a read/write message used to display or change the four Process Temperature control group setpoints. This command is only used if the Process Temperature control option is enabled. Process Temperature setpoints may be read or written individually or in groups. The master is responsible for setting the correct starting address, number of registers, and the register data for the message block.
Page 166: Condensor Control
Appendix D - Condensor Control (Important Note) Main Screen The main screen has been designed to give the operator an overall view of the operating parameters. This screen should always be displayed when setpoint and manual operation items are not being performed and contains buttons to navigate to Auto Setpoints and Manual Operations.
Page 167 Automatic Mode To enter Automatic Mode touch the AUTO MODE button. The button will light up and the words Aut will appear on the screen. In Automatic mode the Stage operation will be selected automatically based on the designated Discharge Pressure. To set these points see “Auto Setup Screen”...
Page 168 Auto Setup Screen From the Main screen, touch the AUTO SETUP button. To specify the setpoints for Pressure, Dead Band, or Timer touch the num- ber inside the green rectangle to bring up a keypad, as shown below. In this screen you can specify the appropriate value for the given parameter. When finished touch the Ent button to return to the Auto Setup Screen.
Page 169 Manual Mode To enter Manual Mode touch the MANUAL MODE button. The button will light up and the words MAN will appear on the screen. Also the up and down toggle arrows will appear. From the main screen you can move up and down through the stages by pressing the up or down toggle arrows.
Page 170 Stages 1 and 3 are on as shown above. IMPORTANT NOTE: THE OPERATOR SHOULD SHUT OFF ALL STAGES BEFORE EXITING MANUAL OVERRIDE SCREEN. Exiting the Manual Override screen will not change the status of the steps selected. Entering into Auto Mode or Off Mode from the Main Screen will shut off the stages until you enter Manual Mode again.
Page 171 Condenser operation will no longer be controlled by the HMI. The operator will have to control the stages at the motor starter by using either HAND or OFF.
Page 174 35391VT Rev. 4 (7/13) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its afﬁ liated companies. © 2012 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.

Emerson Vilter VilTech Operation And Service Manual

Chapter 1

Chapter 2

Setpoints

Chapter 3

Chapter 4

Sequencer Control

Appendix A

Appendix B

Appendix C

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Summary of Contents for Emerson Vilter VilTech

Table of Contents