User Manual
Contents
1. SHUTDOWN MODE If the controller shuts the system down for any reason other than high or low suction the user should resolve the faults listed and then press the HOME PAGE button on the controller That will take the controller back to the Home Screen Figure 7 is an example of the shut down screen If the controller has the auto start feature enabled and the controller shuts down on low suction only the controller will automatically re start after suction corrects itself The suction must get above the High Suction Range before the unit will re start If the auto start feature is disabled the controller will not restart automatically even on a suction fault CHUT DOWN ON HI LIQUID LEVEL OXYGEN ENG OIL LEVEL Emergency Kill HomePage Figure 7 Shut Down Screen TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 13 NOTES TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 14 APPENDIX A SUCTION CONTROL FEATURES OF THE TECHTROL 7250 CONTROLLER WITH VARIABLE RPM OPTION The TechTrol GasFlowTM Controller has multiple parameters that the user can set to control the suction on a vapor recovery unit The SET SYSTEM PARAMETERS section of this manual explains in detail how to set each of the control parameters The parameters include the following and each will be explained in detail 1 Suction Delay 2 Suction Relay 3 Auto Start 42. Tech Trol GasFlow 7250 Programmable Controller Users Manual VRU Model Gas Drive Unit with RPM Speed Control TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 1 Distributed by TechtTrol Inc Pawnee OK 74058 www techtrol usa com 918 762 1050 TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 2 Table of Content Table of Contents a an bs MR O RR GY HN TST ENDER EER OMTT ERO pe dan ee 3 Kit 8 6 C8 LIO TE saser erare CR HN CEN RF RFC RY WEN CRY ME 4 The Main Menu Home Screen cccccccccccecccssssssecccceececseesssececcceeeesaeeesececeseeessaunenens 4 Home Screen Button Options ese peti RODD EFA YN EFO DED NEU ODD OOO 3 PRESS TO START aY Y RE YF 3 SET POEN I e e 7 SET SYSTEM PARAMETERS bi GA nut dirt EG YDA YF AY ae YF AS y 8 DISPLAY SENSOR DATA GU erran AD CY NU Y GADO 10 ZERO SUCTIONN a rtd ced pe edd sd deca etd wed peed ea ed MEME MM MEM 11 RUN MODE crnina R d EHE CR UN RUE Cy Rd E NE CR OM M rrr UD MERE 12 SHUTDOWN MODE s cniiixteri cis iode raar kit NW anita aude cds oras sona 15 NOTES 14 APPENDIX T ast E A E A census td lv cas FOIS HN CY Y 15 Suction Delay P Ie 15 SUCOMRELAY FRY NINE HH D 15 A to Stait TY YF TCR TT CT 16 Variable RPML Pm 16 Crank Lane ran Att empts sinsin bd a do GCaD dn SOSBAN On 17 N mber of Teeth
3. Caution Do not set this parameter such that you run the machine long enough to cause damage It is the operator s responsibility to monitor sensor data and use the Emergency Shut Down switch if necessary during the lock out mode AUTO START This settings allow the user to control the unit based on suction Setting a 1 in the left column will allow the unit to automatically restart if an only if the unit is automatically killed because of a high or low suction fault The unit will restart once the suction reaches the value entered under the Suction Relay high pressure setting left column The amber light on top of the controller will flash for 10 seconds warning of the impending start BALL VALVE OPEN CLOSE The bypass throttling ball valve can be programmed to operate at a relative speed from 1 to 20 The open and close function can be set independently A setting of 1 will move the ball valve the slowest and a setting of 20 will cause the maximum speed at which the ball valve will operate The user should experiment with these settings to optimize the control For example a slower moving ball valve may allow excess pressure into the bypass DISPLAY SENSOR DATA TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 10 This button on the Home Screen will display the real time sensor values and the sensor pressure or temperature units This screen can be accessed whi
4. TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 6 HARGE 2HARGE TEMP Figure 3 Display Data Screen SET POINTS The SET POINTS button Press this button on the HOME SCREEN to change any of the set points of all sensors If you are on another subordinate screen touch the Home Page button to return to the home screen The user can set a high and low set point for all analog sensors We do this to make the controller more versatile For example you may think there is no reason to shut down on High Compressor Oil Pressure but it may actually indicate a plugged oil line and some users will use the Kill point NOTE Pressing the SET POINTS button during normal running operations will kill the motor and the user will need to go through the start sequence above once sets points are set Once the button is pressed a screen will appear that allows the user to move in and around each sensor s set point value Use the UP A DOWN F LEFT 4 and RIGHT gt arrow keys on the keypad in the lower left hand corner of the display to select the set point to be altered Then use the key and the key to change the set point When using the key the value of the set point will only advance to the maximum value of the sensor rating Also the key will advance the values by a factor of 10 This is intentional and speeds the set point settings When using the
5. those will be discussed separately If the unit drops below the low set value the ball TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 15 valve will remain in the bypass mode until the suction pressure reaches the high set limit At that time it will move to the sale gas mode Set these values far enough apart so that the ball valve does not continue to chatter This feature really needs to be tuned as a site by site function Auto Start The user can select the auto start feature by selecting a 1 in the appropriate box The process is discussed above If the suction delay is exceeded while the suction is either above or below the shut down set points not the suction relay set values the controller will allow the compressor to automatically restart as soon as the suction exceeds the high suction relay value Note that if the unit shuts down on high suction it will automatically try to restart So set the high kill on suction high enough so as not to allow that to happen Variable RPM If the user has a variable RPM option then the engine range also needs to be set at the Govenors of America GOA Controller See the Manual supplied with that unit This will operate in conjunction with the ball valve Suction Relay The best way to explain this is with an example Here are the system settings High suction kill set at 20 psi Low suction kill set at 6 psi High suction Relay set at 15 psi
6. key the value will only decrease to the minimum value of the sensor rating Also note that the key will decrement the value by 1 See Figure 4 TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 7 The user should assure that the value of the H SP High Set Point is greater than the value set to the corresponding L SP Low Set Point When complete press the Home Page button to return to the Home Screen Note By depressing and holding the or button during set point changes the set point will change at an accelerated rate HRRGE PRESS IRRGE TEMP GEN ae NE OIL PRESS NE TEMP H Ie Pi Homel age Figure 4 Set Point Screen SET SYSTEM PARAMETERS Press this button to change the operations of the items detailed below Note Pressing the SET SYSTEM PARAMETERS button during normal running operations will kill the engine and the user will need to go through the start sequence above once maintenance sets points are set Once the button is pressed a screen will appear that allows the user to move in and around each sensor s or function set point value Use the UP A DOWN V LEFT lt and RIGHT arrow keys on the keypad located in the lower left hand corner of the screw to select the set point to be altered Then use the key and the key to change the set point When using the key the value of the set point will only advance to the maximu
7. Low suction relay set at 9 psi High engine range set to 1800 RPM through GOA Low motor range set to 1200 RPM through GOA Suction Delay 20 Sec Toa a Remember that all sites are different and the system will need to be tuned per site You should set the High suction kill above the High Suction Relay the Low Suction Kill below the Low Suction Relay and have a acceptable spread between them When the units starts assume that pressure is above 15 psi and we have exceeded the lockout timer The ball valve will be in the sale mode The engine RPM will be at the high setting for the engine range or 1800 RPM Now that pressure will start dropping As the pressure drops below 9 psi the engine RPM will also drop to the low RPM setting of 1200 If the suction continues to drop to below 6 psi the then the suction delay timer activates If the suction stays below 6 psi for 20 seconds the unit will shut down on Low Suction If the Auto Start is enabled and no other shut down faults occurred the compressor will restart once the PSI reaches 15 psi and the cycle repeats TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 16 Crank Time Crank Attempts This is the time that the engine will try to crank during startup The PLC will look for engine oil and RPM to determine if the unit has started If not it will try again It will try for the number of attempts entered and if it fails to start it will fault on crank atte
8. Variable RPM 5 Crank Time 6 Crank Attempts 7 Number of Teeth 8 Automatic Blow Down 9 Throttling Ball Valve Suction Delay The controller is designed to monitor all variables that are displayed on the Display Sensor Data screen If any of these parameters exceed or fall short of the set points the controller will shut down the unit Suction Delay allows the user to set a delay to shutdown on high or low suction only This allows time for the controller through control of the ball valve and motor speed control both of which will be discussed time to bring the suction under control before the controller shuts the system down on suction fault Use caution when setting this value Setting it too long could cause adverse effects on the tanks Setting it two short will not allow sufficient time for the controller to make the modifications needed Use this in combination with the other controllable parameters Suction Relay This value allows the user to set a high parameter and a low parameter These values control the bypass ball valve In normal operation when the suction is above the low value the ball valve will be in the sale gas mode It will allow vapor gas to be sent to the production line When the suction pressure drops below the low set value the controller will put the ball valve into the bypass mode and thus stops moving gas Do not confuse these values with the shutdown set points They have a different function In addition
9. FFR NN UN FO FN NY TF FN RF NR 17 TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 3 TechTrol GasFlow 7250 Programmable Controller Users Manual Introduction The TechTrol GasFlow programmable controller will continuously monitor and control critical conditions on the gas compressor The 7250 model is specific to the gas drive units and controls the RPM of the gas drive based on input suction in addition to other critical parameters Features of the controller include a high resolution graphics Touch screen menu driven user selectable commands and a variety of control features selectable by the user to help maintain suction in the vapory recovery mode The user can set parameters that will be discussed later that will allow the controller to precisely control the suction of the vapor recovery of tanks and other similar operations Multiple control features will allow for fine tuning of almost any vapor recovery system The Main Menu Home Screen The main screen or the Home screen is where the user will always start to get to any of the settable parameters on the controller The Home screen displays the serial number compressor company s name web site address and the RUN HOURS The RUN HOURS accumulates whenever the oil pressure is above the low set point It only accumulates hours No minutes or seconds are displayed See Figure 1 The Touch Menu buttons across t
10. Solenoid Relay or ball valve operation This feature allows you to set the pressure range that will activate the ball valve to either bypass or sale gas mode The left column is the high pressure side in which the bypass valve will go TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 9 to the sale gas mode and will no longer bypass gas The right column is the low pressure side in which the bypass valve will go into bypass mode and will bypass gas until i e not allow gas to flow to the process line Once the ball valve is in the bypass mode it will remain there until one of two situations develop 1 The suction pressure builds up and exceeds the high pressure or sale pressure set parameters or 2 The unit runs out of gas for bypass and shuts down on low suction pressure If a throttling ball valve is connected to the bypass line it will attempt to adjust to the upper setting It gives more control over the bypass mode RUN HOURS Unit Run Hours For maintenance purposes the run hours can be reset with every oil and or filter change If a cumulative run time is kept and the unit receives a program upgrade you can reset the run hours to the value on the unit at the time of the upgrade LOCK OUT TIMER The user can set this variable for the start up lockout timer On startup the sensors will not be monitored for a fault condition until this timer counts down to zero
11. ensor input will not have been changed The suction sensor must be connected during the zero mode Do not zero the suction sensor while it is disconnected from the cable or controller This will result in false suction sensor readings NOTE For tank applications where the suction is read in inches water column or Ounces the suction sensor should be recalibrated zeroed at least every thirty 30 days to insure the accuracy of the suction pressure system RUN MODE Once the compressor starts the unit is considered to be in the RUN MODE While in the run mode the DISPLAY DATA screen will show the current value of all sensors While the compressor is running and after the lockout timer expires the controller will monitor the sensor values If the values exceed the HIGH SET POINT or fall short of the LOW SET POINT the controller will deactivate the run relay and kill the compressor At that time all faults will be displayed on the screen The user can correct the faults and restart the compressor The following is an example of the controller shutdowns there may be more or less values for your controller HIGH LOW SUCTION HIGH LOW DISCHARGE HIGH LOW OIL PRESSURE EXCESSIVE VIBRATION RPM HIGH LOW COMPRESOR OIL PRESSURE HIGH LOW ENGINE OIL PRESSURE LOW ENGINE OIL LEVEL HIGH ENGINE TEMPERATURE HIGH LOW COMPRESSOR TEMPERATURE TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 12
12. he bottom of the screen give the user access to all of the functions and settable parameters of the controller You can return to the Home screen from any subordinate screen by touching the Home Page button located in the lower right hand corner of all subordinate screens Each of the touch buttons across the bottom of the Home Screen will be discussed in detail Appendix A will cover tips on how to tune the controller to best monitor and control the vapory recovery system TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 4 ON 7200 0001 ToehTrol Ine l oehnoloqu Loadors in Controle GasFlow 7260 by ToehTrol Ine www tochtrol uca com Run Houre V an Arsdale P hotography g Figure one Home Screen 7260 shown Home Screen Button Options From the Home Screen and the MAIN MENU select one of the buttons across the bottom of the screen as follows PRESS TO START The Press to Start button by its name is the button you push when you are ready to start the compressor Once it is pressed you will see the screen shown in Figure 2 Note the instructions on the screen as follows RESET RED EMERGENCY STOP BUTTON PULL OUT THEN PRESS START BUITON TO START It may seem redundant that you are required to press two start buttons but it is important that everyone around the compressor is aware that the unit will start Once the Press to Start button is pressed the
13. ion as expected To complete a calibration of the ball valve proceed as follows This procedure will externally mechanically reset the open and closed position for electric actuators with the DPS module installed when the units gets moved off zero See Figure 9 1 Remove the power supply to the actuator Remove connector or turn power off the power connector is the large gray one on the far left side TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 17 Oe pM Ber Lp un 11 TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 Remove the small black center connector from the actuator Place the ball valve in Manual Mode Adjust the ball valve to the closed position with the handle on top Turn the ball valve to Auto Mode On the small black plug on the actuator center connector short pin 3 to Earth Ground pin Use a wire with clips to connect pins Turn the power back on to the actuator and wait until the LED goes solid Remove the short wire between pin 1 and pin E on the DPS plug The actuator will then go through a mechanical position reset When the reset is complete closed to open and back to closed then turn the power back off Re connect small black center connector and turn power back on to test the actuator Q Figure 9 Throttling Ball Valve page 18
14. le the compressor is running or not running as long as the power is on No values can be changed while viewing this screen You can press the Home Page button to return to the Home Screen See Figure 3 This screen is automatically displayed after the start sequence is followed and completed ZERO SUCTION This button pressed from the Home Page will allow the user to zero the value of the suction sensor NOTE This will kill the motor and the user will need to go through the start sequence above once the suction sensor has been zeroed Press the button and follow the instructions on the screen See Figure 6 THIS WILL ZERO THE SUCTION CENSOR PRESES ZERO BUTTON TO CONTINUE OR HOMEPAGES TO CANCEL Figure 6 Zero Suction Sensor TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 11 THIS WILL ZERO THE SUCTION SENSOR PRESS ZERO SUCTION BUTTON TO CONTINUE OR EXIT TO CANCEL If the user chooses the ZERO SUCTION button the current value of the suction sensor will be set in the controller to zero The user should assure that the suction sensor is properly connected to the controller and then has no pressure or suction on the sensor It should be at atmospheric pressure before the ZERO SUCTION button is pressed The user can abort this function by pressing the Home Page button If the Home Page button is pressed the display will return to the Home Screen and the s
15. m value of the programmed function or sensor by a factor of 10 When using the key the value will TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 8 only decrease to the minimum value of the programmed function or sensor by a factor of 1 See Figure 5 Figure 5 Set System Parameters Following are the features the user can set on the Set System Parameters screen SUCTION DELAY On A vapor recovery system the suction can change rapidly due to the compressor s ability to quickly evacuate a system We do not want the compressor to continually shut down on low or high suction immediately upon a fault There are other features of the controller that will try to compensate for the low or high suction that will be discussed later This allows the user to select a time delay while in suction fault to delay the shutdown It works kind of like the lockout timer The suction delay can be set for up to two minutes 120 seconds and down to zero minutes The system will poll the current reading every three 3 seconds while in a fault mode and if at the end of the delay period the set point is still peyond the set limit the machine will shut down on the LOW or HIGH SUCTION fault It will then be displayed in the readout The value in the left column is the only one that you need to set in the suction delayrow The right column has no affect SUCTION RELAY Bypass Valve
16. mpts Blow Down Pressure Set this pressure to the desired blow down pressure The controller will blow down to this pressure before attempting to auto start Number of Teeth Number of teeth should match the number of teeth on the flywheel This is what the sensor uses to calculate RPM Automatic Blow Down If the unit is equipped with automatic blow down there will be a ball valve installed in the blow down line When the start sequence is started the PLC will check the discharge pressure If the pressure is above 20 psi the ball valve will open until the pressure drops below 20 psi Once it drops below 20 psi the start sequence will commence Throttling Motorized Ball Valve The throttling ball valve is used in the bypass and for automatic blow down when required See the wiring diagram for your unit for installation Generally the ball valve is operated in the Auto mode The black know located on the front of the ball valve allows the user to select between Auto and Manual When in the manual mode the handle on top can be used to manually adjust the position of the ball valve Note the handle direction represents the position of the opening of the ball valve Do not try to manually adjust the ball valve position when in the Auto mode From time to time it may be necessary to calibrate the motorized ball valve If the ball valve does not go to the fully closed position or to the fully open posit
17. system will count down for ten TechTrol Inc GasFlow User s Manual Rev A 10 July 2011 page 5 10 seconds and the amber light on top of the controller will flash giving warning that the unit is about to start At the end of the ten second countdown the motor will soft start provided the red emergency shutdown button on the side of the controller has been cleared i e pulled out See Figure 2 Note you can kill the unit any time by pressing the red emergency shutdown button RESET EMERGENCY STOP BUTTON THEN PREG THE START BUTTON TO START HomePage Figure 2 Start Screen At the end of the countdown the system will engage and start cranking The user can set the duration of the crank cycle and the number of cranks as will be discussed later Once the unit has started the sensor data display screen will appear and the values of the sensors will show on the display See Figure 3 Note that because of the flexibility of these controllers all sensors values for your unit may or may not be displayed in the manual At startup a user programmable lockout timer will be covered later The sensors values are displayed but they are not monitored for shutdown during the lockout period The operator will need to manually monitor the equipment during this lockout period The RED EMERGENCY SHUT DOWN SWITCH located on the side of the controller can be pushed in the event an emergency kill is required
Download Pdf Manuals
Related Search