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Emerson 20/20 User's Manual

1. 5 2 Figure 6 1 Compressor Control Screen s esse sese sees sees seene 6 1 Figure 6 2 Proportional Band amp Setpoint essen 6 2 Figure 6 3 VFD One Step Control Method sss phi RF In ka ERQMIREREEEE S NRI RU UR EEG EA PROTREEL ENS QERE VE C CR IER ERFEUR IE 6 3 Figure 6 4 VFD Two Step Control Method sss ss sss esse sese 6 3 Figure 7 1 Alarms and Trips Screen esse sese eee 7 1 Figure MEER SCF COM RTT TES 8 1 Figure 9 1 Compressor Scheduling Screen sss eee 9 1 Figure 10 1 Compressor Sequencing Screen sss esse sees cesses eee 10 1 Figure 11 1 Condenser Control Screen sss sss s sese 11 1 Figure 11 2 Step Control Screen sese s esse sese eee eee 11 3 Figure 12 1 service OPTIONS Screen sss lt sss sss eps ex bat Un bas ocu neteetccciivedandesaidatianeacie sesndediacosaneviencuenboesuiede 12 1 Figure 13 1 Instruments Calibration Screen sese sese esse sees seene 13 1 Figure 14 1 Slide Calibration SCFBBPL a sese sese eee eee 14 1 Figure 14 2 Photochopper lt sss sss esse sees eee eee eee 14 3 Figure T5 T Tend a eTo ESCIeBITunecun hist Int EPIM nid MM EN MEMINI 15 1 Figure 15 2 Trend SSEUDSCIOBIR cactactenccacicatacessdencstacenon E Ep rESAr RIS GAREEER RR M MIU DES CENNCI RADAR ODORE FARE RE ENNEA EL UE 15 3 PIU Tos EVeHE Dist SCEEPD seres peso estu EEEE Tere IS TO UNDA E abu SN UIT LAM Erde 16 1 Figure 17 1 Input Output Screen sssssessceeecccccccccecececeesssssssseceeeeeecececececeeesac
2. PV 6 1 Pulse Proportional est ae Loceresescores vmi i qo Dm anu Eae Hie IPSI eEU ER IU QE CO EN UU AUN OENE NEIENT EEEE FITUS URN 6 1 Figure 6 1 Compressor Control SCLBBEL diwsscecsnsssisucdasdacosssatensesdsnetusuuusioveissscuethslsedecndsueddeseveansetacursieest 6 1 PUIG GT EN RTT TOTEM 6 2 Figure 6 2 Proportional Band amp Setpoint essen 6 2 Variable Frequency Drive VED sese eee 6 3 Figure 6 3 VFD One Step Control Method sss sese 6 3 Figure 6 4 VFD Two Step Control Method sss sese sss sese eee eee 6 3 PUT OWY Ai CONTO korena E E E E NEE 6 4 PANOW CONO an EE E E EAE EET OAN EE 6 5 CONTO Bere syr eE A A E E E A TO 6 6 Hop oad S eee aT urren n re EE TN 6 6 Capacity Slide Triggered Outputs sss 6 6 Volume Slide POSIBIGITO T SEE essere maur tert SITUE RETIA MI IU ABINEU ERI IDA ENEHLUN T QUII FID ININUNNADE EVE 6 6 c e at err m 6 6 Ee Ea Ta s TRE 6 7 DI d PE E E EATE 6 7 Es TE SCHOO mmm 6 7 OVENI EH 7 1 Alarms and Trips S BEDOIPIDS HHT 7 1 Figure 7 1 Alarmis and Trips Screen aaaea Ner aao aa ar ERT SSENT 4 OTOR EZ KET naan vry 7 1 COIIDFeSSOE IB DIES HT 7 3 Safety Failure Messages eee eee eee 7 3 Siu 8 1 Umer e v 96 n cee ene ene eee ener 8 1 Foure o W HEBES SEROBIE e E E E EE 8 1 gius p 9 1 Schedu
3. 58 0 Psig 138 2 F ress Diff 1 4 Psig ilter Diff 0 8 Psig Inj Temp 118 8 F Sep Temp 113 1 F User 08 17 2011 11 08 00 Run Hours 31 Motor mperage 0 0 Amps Figure 6 1 Compressor Control Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 6 Compressor Control As mentioned in the above paragraph the distance of the process variable from the control setpoint deter mines the size of the pulse used to move the capacity slide This is called the proportional band and is set by the Proportional Setpoint When the process variable is outside the proportional band the slide will move in the direction of the error continuously Increasing the size of the proportional band can help slow the compres sors reaction by varying loads if desired see Figure 6 2 Proportional Band amp Setpoint The Dead Band Setpoint defines area around the control setpoint where the algorithm stops adjusting the capac ity slide This area is a percentage of the proportional band By default the proportional band is set to 4 Psig and the dead band is set to 1025 of 4 Psig Making the dead band 0 4 Psig of the control setpoint Once the process variable is within the dead band the algorithm considers the compressor to be on setpoint If the op erator wishes the compressor to operate closer the set point can be set to a smaller percentage However this Prop
4. s 7 stde vate Postion T 05v 420 mA Potentiometer 6 s Volumerostion 05v 420mA Potentiometer 3 9 suetiontemperaure O aoma RoT 3 10 Discharge Temperature aoma Roo 7 n Joiseparsor Temperature 420m amp RIICID 7 12 orato Temperature 20m Roco 3 08 Process Temperature momar o 3 34 7 T Temperature aoma Roco 715 condenser ressure 05V15Y 0 10V 420 mA RTD ICTD 7 ie remote capholdsetpone 03X420mA amp RIDCID s o may O 95150 10420 mA RTDLICTO s 3s aey 05V 15Y 0 10V 420mA RTD ICTD 39 Yannis S 05V15Y 0 10V420m amp RTD ICT 2 eya R 05V 15Y 0 10V 420m amp RTD ICTD s on eys 95V 15Y 0 10V 420 mA TD ICTD fae Jannat EEZ s om ways EE mA RTD ICTD s 2 aunty 05V15Y 0 10V 420m amp RTD ICTD s 35 Jnwiiayss R 05V15Y 0 10V 420m amp RTD ICTD s 35 Jaana 95V15V 0 0V420mA RTD ICTD s o eias 9515 010V420m amp RTD ICTD NEN TN TN TN EN TN Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 3 5 Section 3 Hardware Architecture Volume Position Readsthe 0 5 volt signal back from the slide volume motor actuator to indicate current volume position Suction Temperature e Default signal is RTD Suction t
5. Suction Oil Injection Setting s In order to maintain adequate lubrication during low pressure ratio conditions the Suction Oil Injection SOI solenoid is turned ON and the capacity of the compressor is reduced The SOI solenoid will cycle ON and OFF based on the pressure ratio across the compressor e SOI Solenoid ON e Defines the Pressure ratio value at which SOI is turned ON default 2 00 Digital Output Board 1 2 e SOI Solenoid OFF e Defines the Pressure ratio value at which SOI is turned OFF default 2 04 Digital Output Board 1 2 s SOI Load Limit Defines the capacity slide position at which the compressor capacity slide will unload to if pressure ratio falls below SOI Solenoid ON set point This setpoint is not active until Auto Load disengages The SOI solenoid will also cycle on if the discharge temperature superheat reaches a value of 5 F this value is not settable Generally anytime the SOI solenoid cycles on the capacity is limited to the SOI Load Limit setpoint However this is not true if the SOI solenoid cycles on based on the discharge tem perature superheat 5 F rule If discharge temperature superheat continues to climb and reaches a value of 6 F the compressor will be inhibited from loading If discharge temperature superheat still continues to climb and reaches a value of 8 F or more then the compressor will be unloaded until the superheat drops below 8 F or the capacity
6. Liquid Injection 1 e Activates the output assigned to the liquid injection solenoid The output is connected on terminal 25 and is the 5th LED on card 2 Liquid Injection 2 Not currently enabled Remote Enabled Activates the output assigned to notify a central con trol system of the Vission 20 20 run status The out put is connected to terminal 27 and is the 7th LED on card 2 Shunt Trip e Activates the output during a false start condition and the emergency stop timer has expired This out put could be wired the a breaker with a shunt trip that feeds power to a starter to force a shutdown The output is connected to terminal 28 and is the 8th LED on card 2 Condenser Step 1 Activates the output assigned to the 1st step of the condenser The output is connected to terminal 41 and is the 1st LED on card 4 Condenser Step 2 Activates the output assigned to the 2nd step of the condenser The output is connected to terminal 42 and is the 2nd LED on card 4 Condenser Step 3 Activates the output assigned to the 3rd step of the condenser The output is connected to terminal 43 and is the 3rd LED on card 4 Condenser Step 4 Activates the output assigned to the 4th step of the condenser The output is connected to terminal 44 and is the 4th LED on card 4 Analog Outputs The Analog Output AO selections allow the operator to enter a desired value of the output then turn on the ou
7. Separator Process When the Process control is selected as the control mode this box will appear and displays the process temperature Vol Displays the position of the volume slide from 0 to 100 Anti Recycle e Displays the anti recycle time if applicable Oil Pump The oil pump on a Vilter compressor often cycles on and off depending on differential pressure This in dicator informs the operator when the oil pump is running Oil Heater The oil heater often cycles on and off depending on the separator oil temperature This indicator informs the operator when the oil heater is on Remote lock out Displays the current status of the remote lock out While on no system controller can remotely as sume control of the Vission 20 20 panel and start the compressor Menu Button When pressed navigates the operator to the menu screen Figure 4 6 Splash Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 5 lt Menu Screen Overview The menu screen is the launching point to every other section of the Vission 20 20 panel software Every screen navigated to from this screen will return to the menu screen upon exiting see Figure 5 1 Menu Screen Navigation Buttons Compressor control Navigates to the compressor control screen where the operator can set the various compressor control parameters Alarms and trips e Naviga
8. sancanaaucinvesrsaesencnenanteegsaacueeaunastenesesaeupeomasuwaundersgauntenensmietentnentiennsideaturieanes 2 2 Figure 2 4 Mixed Voltage Wiritn cccccssssssssssescccccccecccceeesssssssessessesscecesecceeeeeeessssssssssssssescsssoescs 2 2 MV TENG MEO oeeie nenn E Pans d rvbO e cepi ea x Mta dnd M MI OD UD A 2 3 Figure 2 5 Correct Transformer Wiring Method ccccccssssssssssssssseeeccecccceceeeeececeasssseeseeeeceeeeeeeees 2 3 Figure 2 6 Incorrect Transformer Wiring Method lecce eene nnns 2 3 riz Y RINT T EA 2 4 Section 3 Hardware Architecture Ga T 3 1 Figure 3 1 Hardware Architecture Overview sss esse esec eee eee 3 1 Digital input Output O M 3 2 LPI oe DOr eee E EEA E E E EREE 3 3 Analog Te seei 0m 3 4 Table 3 2 Analog NPU cT 3 5 Analog DUEB UPS ore E E E TEA E E A E 3 6 Digital amp Analog I O Boards LayOut ssssscccecccccccccsecceecesssssssseeeeceeeceeeceeeeeeeaeeeassassssseseseeeeeceeecs 3 6 Table 5 3 Analog OULD S vccsssnsacesawdaicswacedtsnuiedeeaduuunn ieena EEEE OESE E iP EEEREN TEENER 3 7 Figure 3 2 Digital I O Board Layout sss sss sese esse 3 7 KISI SIESTE 3 8 Figure 3 3 Digital Output Board Layout sss sss 3 8 Digital input Boards RTT mm 3 9 Figure 3 4 Digital Input Board Layout sss ss sss 3 9 Digital TE 6 519 BO ANS uou en e T S EEEE E OERE En 3 10 Fi
9. 35391SC 1 8 5153 Section 22 User Access Overview calibrating instrument will be available to an opera tor with this level of access The user access screen is where all operators go to log Level 3 This is considered a contractor level of ac in In the Vission 20 20 each screen has a security level cess The setpoints available at this level have the whereby allowing operators technicians and or supervi most potential of causing damage to the compressor sors the ability to modify different sets of setpoints The Therefore this access is restricted to those only with Vission 20 20 has four levels of security see Figure 22 1 the highest level of competence User Access Screen Login The user access screen is also where new operators are added changed or removed Any operator can add an additional operator but can only add an operator of less Level 0 This is the default level with no operator er or equal security level logged in The function available to the operator are very limited and basically only allows someone to start and stop the compressor Apply Level 1 This is a technician level of access All the setpoints needed to operate and adjust the perfor mance of the compressor will be available to an op erator with this level of access When selected applies the user name and password for security evaluation If the User name and password matches an existing user then the operators name will
10. Analog Aux out 1 9 Standard Input Auxiliary Input Active Input None v C Run Always Trigger Trigger Input Analog Input Digital Input Discharge Pressure v Enable If Above o v Trigger Value o o Differential 2 0 Control Method C Run Always O Trigger Q PID Control Scalable Control Q PID Control P Gain 0 0 Min Input Min Output P Gain 0 0 Reset o 0 4 0 4 0 Reset o o Max Input Max Output D Rate oo Setpoint o o No Scheduled Maintenance No Alarm Trips Present Analog Aux out 2 S Standard Input Auxiliary Input Active Input None v Trigger Input Analog Input Digital Input None Y Enable If Above Oly Trigger Value o o Differential 2 0 Control Method D Rate o 0 Setpoint o 0 Digital Inputs The Digital Inputs section of the auxiliary I O allows an operator to configure the auxiliary digital inputs The digital input can be configured to produce an alarm a trip and an inhibit on either a high or low input A low input is Ovac and a high is 120vac on the enabled input Leaving all options in their default setting will mean no action will be taken on an enable input The input will simply be available for viewing at the panel or by communications Trip Alarm Check Selecting this checkbox enables the alarms and or trip functions of the Vission 20 20 for the desired digital input The accompanying
11. Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 20 Data Backup Migrate Loading data from an older version of the Vission 20 20 software to a newer one can be complicated due to dif ferences 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 The only time an operator should have to use the following migrate but ton is if a new Vission 20 20 program is loaded over an existing Flash card see Figure 20 2 Data Backup Screen Migrate and Factory Reset Migrate e This button initiates the migrate function Suction Pressure 1 Stopped 12 4 Psig A E Migrate You should use this option when a new program image has been installed on the system and you wish to retain all previous setpoints u C un a Factory Reset G gt You should use this option when you wish to return one or more of the following screens to their factory default settings Settings S All Select Factory Reset The Factory reset button offers the operator the ability to reset all the Vission 20 20 setpoints back to the facto ry default settings or a specific database If the operator finds that a screen will not load when selected it is likely that the database associated with that screen has been corrupted
12. ed This timer defines how much time to wait for that signal before setting a trip condition High Motor Amps Safety Bypass Starting motors can typically pull much more than its rates full load amps for a short time This timer ig nores that sudden inrush of current for the specified time Emergency Stop Timer Defines the amount of time the compressor is in a False start condition before activating the Emergency stop The emergency stop output can be connected to a shunt trip in the case of a run away compressor Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 8 Timers to remove all power to the system Low Suction Pressure Safety Bypass Sets the time that the compressor is allowed to run at lower suction pressure then would usually be allow at start up High Superheat Temp Safety Changeover e This timer activates at shutdown and changes the re start parameters if the time has not been met Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 8 d Blank Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 9 lt Compressor Scheduling Overview This menu allows the operator to schedule control set point 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
13. Alarms and Trips False Start This message appears when the compressor stops and the motor auxiliary contact fails to open The message will also appear if the compressor shuts down and the amperage is 2026 of the maximum amp setting indicating that the starter is still energized Low Oil Level Trip This message appears when power is removed from the designated input module refer to wiring dia gram This safety will activate only after the oil level has been low for the time period defined by the Low Oil Separator Safety Trip Delay timer 7 4 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 8 Timers Overview The timers screen allows the operator to view and adjust timer settings associated with compressor operation amount of time Timers A general timer requiring the time to expire before the listed event can occur There are different types of timers that the operator should be aware of listed below see Figure 8 1 Timers screen Timer Setpoints Changeover Capacity Increase Start Delay The changeover timers will change from one type e At compressor startup the capacity slide position is control to another once the compressor has started and then the timer has expired held at minimum position for this time period This is to allow compressor and system conditions to stabi lize After the timer expires the slide is free to move Bypass np in
14. Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 24 lt Twin Screw Control Overview because the oil pump operation is now determined by the type of compressor that is select from the The Vission 20 20 is capable of operating a twin screw TIPO atop ailla compressor from a number of different manufacturers e Standard Selects the oil pump operation as The Vission 20 20 currently operates as a twin screw Full Time controller in the full time oil pump and the no oil pump e Stal Selects the oil pump control as No configuration see Figure 24 1 Twin Screw Control pump Screen e Menu Changes setup When selecting the twin screw option there will be other changes that occur in other menu Configuration Screen pages e To setup the Vission 20 20 panel for twin screw navi e Volume position indicator will disappear from gate to the configuration screen page 2 and select the main screen and right data panel VRS from the dropdown box label Compressor Once selected another dropdown box labeled Operation Type will appear directly below the Compressor drop down box You should also no Run oil pump alarm and trip values will be tice that the oil pump control becomes grayed out changed to default values for the twin screw TTE Condenser Control Motor Current Device Current Transformer Ambient Sensor Operation Type Standard v O 4 20ma Transmitter Refrigerant
15. Suction Press Control J Liquid Line Strainers 200 169 Setpoint 20 0 Psig S O Coupling Alignment 200 169 s Suction C Transducer Calibration 200 169 Press 55 9 Psig C RTD Calibration 200 169 emp 32 2 F Inspect Compressor 5000 4969 Discharge O Inspect Bearings 120000 119969 Press 67 9 Psig emp 138 4 F Oil ress Diff 11 4 Psig ilter Diff 0 8 Psig rs Inj Temp 116 9 F Sep Tem 111 9 F No Scheduled Maintenance User admin P P 08 19 2011 04 27 20 Motor No Alarm Trips Present Run Hours 31 ribet anes D Amis Figure 21 1 Maintenance Screen Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 21 1 Section 21 s Maintenance Notes The notes tab allows the operator to make notes to any other personnel that might have access to the Vission 20 20 Log The maintenance log tab lists all the maintenance tasks performed in descending order Date e lists the date the maintenance task was performed Time e lists the time the maintenance task was performed User lists the operator name who performed the mainte nance task Maintenance Performed e Lists the maintenance task that was performed Run Hours e Lists the run hours at which the maintenance task was performed Chart This chart is the original maintenance chart that is pro vided with the compressor 21 2 Vission 20 20 Operation and Service Manual lt Vilter Emerson
16. e Level 2 This is a supervisor level of access Setpoints be applied to the lower status bar and the operator will that require a higher level of knowledge such as be given access to screens of equal security level Suction Pressure 1 Stopped 36 4 Psig A Capacity Slide c Operators Operator Name S admin Lev2 Levi Operator Password w x o LS Z Lev3 co Suction Press Control Setpoint 20 0 Psig Suction Press 56 4 Psig emp 34 7 F Discharge Press 58 4 Psig emp 140 5 F Press Diff 1 5 Psig ilter Diff 0 6 Psig Sep Temp 113 5 F No Scheduled Maintenance User P P Inj Temp 119 2 F 08 19 2011 02 21 45 RU No Alarm Trips Present Run Hours 31 Amperage 0 0 Amps Figure 22 1 User Access Screen Login Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 22 1 22 2 Section 22 User Access Login The login tab is where an operator will enter the users name and password in order to gain access to Vission 20 20 screens Operators All operators that have been added to the Vission 20 20 user tables will be displayed in this window If a name of an operator is selected from this window the name is added to the Operator Name entry box Operator Name This entry box is for the operator s username The operator can either select the username from the op erators window or enter the username manually by touching the entry box
17. provides supplemental oil cooling based on pressure ratio When the pressure ratio rises above 5 0 the solenoid is turned on When the pressure ra tio falls back to below 4 8 the solenoid is turned off Level Switches There are two level switches in the oil separator a high and a low During normal running opera tion the oil level is above both switches When the oil level starts to drop and opens the high level switch a 10 minute timer starts When the timer elapses a flashing add oil to middle of sight glass message ap pears on the main screen When the operator adds enough oil to close the high level switch the mes sage disappears NOTICE If oil is not added and the oil level continues to drop thereby opening the low oil level switch a 10 minute timer starts again When the timer elapses the com pressor shutdowns immediately and displays Low Oil Level failure If enough oil is added to close the low level switch then this will allow the opeator to press the reset button and clear the Low Oil Level failure and Add Oil message Oil Level Messaging After Compressor Stops Thelow level switch is monitored after the compres sor stops If the switch opens after the compressor stops a two minute timer starts If the switch stays open and the timer expires a failure is generated called Lo Oil Level Fail after Stop and the compres sor is disabled from restarting until oil is added to
18. start a one hour timer is reset and starts timing If the timer times out the hot starts counter is reset When the counter reaches its preset value it will not allow another compressor start until the one hour timertimes out and resets the counter The hot starts counter therefore will be reset when the time be tween compressor starts total one hour This coun ter allows repetitive compressor starts but once the counter has reached its set point it requires a one hour window between compressor starts in order for the counter to be reset True Anti Recycle Timer Once the compressor turns off this timer will keep the compressor off for the setting of the True Anti Recycle Timer This timer is used to prevent short cy cling of the compressor Accumulative Anti Recycle Timer This timer forces a specified time between compres sor starts When the compressor starts the timer resets and starts timing and accumulates running time Once the compressor shuts down it will not be allowed to restart for the remainder of time left on the Accumulative Anti Recycle Timer Unlike the True Anti Recycle Timer if the compressor has run 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 expect
19. 1 then as the value increases to 101 the output will be triggered If the value decreases to 99 then the output will be toggled in the opposite direction Digital Relay The digital relay option is used to pass along the in formation from a digital input to another control de vice orto operate a peripheral device This output can be configured to either reflect the selected input or show the opposite value e Mirror Selecting this option will produce a high out put when the selected input is High and pro duce a low output when the selected input is low e Invert Selecting this option will produce a low out put when the selected input is high and pro duce a High output when the selected input is low Analog Inputs The Analog inputs section of the auxiliary I O screen al lows an operator to define the function of an instrument connected to the Vission 20 20 The analog inputs can be configured to simply monitor an input for informa tional purposes or used as a control input for the auxil iary digital and analog outputs The analog inputs can also be configured to alarm trip and inhibit on specified values e Alarm l Trip his drop down box allows the operator to select whether the analog input should gener ate an alarm trip or both when the input value exceeds the limits entered into the alarm and trip entry boxes e nhibit Selecting this checkbox will prevent a start if the input valu
20. 9 1 Compressor Scheduling Screen Scheduling Setpoint Schedule The options for selection are Enable amp Disable The operator is allowed to configure setpoints relat ed to schedule events but only when the schedule is disabled he operator can Enable Compressor Scheduling Feature only if Time Intervals are in order of Event 1 Suction Pressure 1 Stopped Schedule Enabied Disabled Control Mode Schedule Event 1 scheduled e Schedule Event 2 E Schedule Event 3 Schedule Evert 4 No Scheduled Maintenance No Alarm Trips Present 12 DO AM d 12 01 AAA 12 02 AM F emp 1 m D 5 5 a 4 e s s w z 1 lt Event 2 lt Event 3 lt Event 4 for all days If events are not in order invalid events are marked with caution symbolto indicate the operator to correct events and then enable feature Control Mode These drop down boxes allow selection of operat ing modes which gets switched once schedule event time is achieved The list of allowable modes depends on the number of controllers selected in the configuration screen For example if the number of Suction Pressure Control Setpoints selected is 2 and the number of Process Temperature Control Setpoints selected is 1 then Control Mode drop down box will have Unscheduled Suction Pressure SP1 Suction Pressure SP2 and Process Temperature SP1
21. CHANNEL 4 SIGNAL jP 10 jP 11 jp 12 JP 30 f svo OUT OUT OUT OUT po rout OUT OUT IN OUT po 420mA N OUT OUT OUT Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 3 lt Hardware Architecture Table 3 4 Analog Input Jumper Tables Continued CHANNEL 5 SIGNAL JP 13 JP 14 jp 15 JP 31 P svo OUT OUT OUT OUT 040VOI OUT OUT IN OUT Lo 1 420m N OUT OUT OUT Lo a OUT IN OUT OUT Lo 1 RD OUT OUT OT IN CHANNEL 6 SIGNAL JP 16 JP 17 jp 18 JP 2 P svo OUT OUT OUT OUT rout OUT OUT IN OUT Lo 420mA N OUT OUT OUT Lo o OUT FIN OUT OUT Lo 1 RD OUT OUT OUT IN CHANNEL 7 SIGNAL jp 19 jp 20 jP 21 jP 33 JP OUT LL T5VOT OUT OUT OUT OUT RNO OUT OUT IN OUT Lo 20mA IN OUT OUT O otc OUT IN OUT OUT pou OUT OUT IN po ACTUNOR OUT OUT OUT our P POTENTIOMETER OUT OUT OUT OUT CHANNEL 8 SIGNAL JP 22 jp 23 Jp 24 Cd o our YT ooo our 20m xem o RD ou OUT OUT OUT OUT ACTUATOR POTENTIOMETER OUT Vission 20 20 Operation and Service Manual Vilter Emerson s 35391SC 1 8 5153 3 13 Section 3 Hardware Architecture Analog Output Boards The Analog Output board convert signals form the Vission 20 20 program into a current ranging from 4mA
22. Calibration Analog Inputs This section of the Calibration screen allows the opera tor to define the parameters of an installed auxiliary ana log instrument These instruments are usually not part of a typical compressor setup but Vission 20 20 provides a way for the operator to add additional capabilities The layout of this screen is typical to the pressure and tem perature calibration screens Device Calibration e These setpoints allow the operator to define what the input from the auxiliary instrument means in terms of units and range If a temperature measuring in strument is connected then the operator would se lect temperature from the Unit drop down box then set the maximum and minimum value for the scale 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 The offset is applied to the calibrated value which should correct the error Range Here the operator defines the signal type and range transmitted by the instrument The operator can choose from several predefined ranges in the drop down box or enter a value Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 13 3 13 4 Blank Vission 20 20 Operation and Service Manual lt Vilter Emerson 3539
23. Unfortunately data corruption is always a possibility in any system So this function was designed to help the operator to regain control see Figure 20 2 Data Backup Screen Migrate and Factory Reset Reset e This button initiates the process to revert the Vission 20 20 back to the factory default settings Capacity Slide Suction Press Control Setpoint 20 0 Psig Compressor Control Compressor Sequencing Condenser Control Calibration Configuration Alarms amp Trips Timers Compressor Scheduling Maintenance Users Auxiliary I O Trend Chart Suction Press 32 4 Psig emp 48 4 F Maintenance User Access No Scheduled Maintenance i No Alarm Trips Present Refresh Ment mak Log off Discharge 100 3 Psig 123 6 F Press emp Press Diff 128 5 Psig Filter Diff 8 8 Psig Inj Temp 99 3 F Sep Temp 115 8 F User Vilter 01 02 2002 12 53 49 Run Hours 0 Motor Amperage 0 0 Amps Figure 20 2 Data Backup Screen Migrate and Factory Reset Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 20 3 20 4 Blank Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 21 s Maintenance Overview Maintenance Name This column of tasks that should be performed at the The maintenance screen is a convenient place to keep run h
24. accordance to the system demands e The bypass timers prevent certain alarm and trip checks from occurring until the compressor has started and then the time has expired Minimum Compressor Pre lube Time This is the length of time the oil pump will run after establishing Pre lube Oil Pressure to prime the oil cir Delays d cuit before starting the compressor Delays require the condition to occur for the specified Suction Pressure 1 SLOpped 36 7 Psig A Capacity Slide Value Capacity Increase Start Delay 5 sec Minimum Comp Prelube Time 5 sec Volume Slide Suction Press Control etpoint 20 0 Psig Suction Jress emp Low Oil Pressure Safety Bypass 60 sec High Filter Diff Press Safety Changeover 60 sec Oil level 1 Safety Trip Delay 60 sec Oil level 2 Safety Trip Delay 60 sec 56 7 Psig 34 7 F Low Oil Sep Temp Safety Changeover 5 min Discharge Press 58 5 Psig emp 140 5 F 6 min 23585 MR Low Oil Injection Safety Bypass Press Diff 1 4 Psig ilter Diff 0 5 Psig Inj Temp 119 7 F Sep Temp 114 0 F Menu EN Oil No Scheduled Maintenance User 08 19 2011 01 05 27 Run Hours cri Motor Amperage 0 0 Amps No Alarm Trips Present Figure 8 1 Timers Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 8 2 Section 8 Timers Low Oil Pressure Safety Bypass This is
25. adjust the motorized value By averaging the more stable oil manifold temperature and discharge temperature the control variable stabilizes and the PID is more easily tuned Please note that as stated above PID algorithms can be difficult to tune and there is no one set of PID val ues that will work The work required for a compres sor to meet the requirement of its installation vary greatly and therefore the amount of heat transfered to the oil varies just as greatly We recommend the 6 7 Section 6 lt Compressor Control operator consult PID tuning guides available from many different source before attempting to tune this PID Liquid inj Setpoint 1 e Setpoint at which the liquid solenoid will activate if in solenoid control or if the setting for the control vari able for the PID is in liquid motorized value control Liquid inj Setpoint 2 e Not yet available Oil Sep Temp Override e Defines the temperature the oil must reach before the liquid injection solenoid is allowed to be activated P Proportional Gain e Used to adjust the positioning valve in direct propor tion to the difference between the control setpoint and the discharge temperature SetPt DT error The proportional term is a unit less quantity and is used for coarse adjustment This setpoint should be set to the lowest value that gives adequate response to the control system Increasing the proportional setting increases the control s
26. and entering the name via the pop up keyboard Operator Password This entry box is for the operator s password The Suction Pressure 1 Stopped Operators Operator Name josh josh Login Operator Password Verify Password 909 Manage Accounts Security Level No Scheduled Maintenance Maintenance No Alarm Trips Present Delete password can be entered by touching the password entry box and entering the password via the pop up keyboard Manage Accounts This tab allows the addition removal and modification of authorized users see Figure 22 2 User Access Screen Manage Accounts Operators This window contains the list of authorized users al ready added to the Vission 20 20 Selecting a name from this list will add that name to the Operator Name entry box Operator Name This entry box is for the operator s username who is to be added removed or modified The operator can 6 9 Psig A Capacity Slide Di Suction Press Control Setpoint 20 0 Psig Suction Press emp 26 9 Psig a3 TE Discharge Press Temp 165 1 Psig 134 8 F Press Diff 146 4 Psig Filter Diff 4 1 Psig Inj Temp 131 1 F Sep Temp 123 6 F 03 02 2010 05 49 04 Motor Amperage 0 0 Amps Run Hours 0 Figure 22 2 User Access Screen Manage Accounts Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Se
27. auto matically and indication will be sent to operator to cor rect the setting 0 2 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 10 Compressor Sequencing Overview Compressor Name Defines Unique name of a Compressor Vission Compressor sequencing screen is where more than one 20 20 Panel on sequenced network Vission 20 20 panels can be sequenced in network using Modbus TCP These settings define how the master com pressor should control sequenced Vission 20 20 panels Pressure Control Setpoints This feature is enabled from the Configuration Screen see Figure 10 1 Compressor Sequencing Screen Compressor Sequencing screen defines settings those are used by master compressor for sequencing Compressor Sequencing e Enables Compressor Sequencing Uncheck the box to Load Rate 2 offset outer disable compressor sequencing Defines the outer pressure temp setpoint offset to Master monitor compressor load If Suction pressure pro cess temperature surpasses Load Rate 1 offset and goes beyond Load Rate 2 setpoint offset then se Slave quencing decisions are made according to Load Rate e Enables Compressor Sequencing in Slave Mode 2 timer Load Rate 1 offset inner Defines the inner pressure temp setpoint offset to e Enables Compressor Sequencing in Master Mode Capacity Slide Machine Start Time Suction Press Control Start Time s0 sec Setpoint 44 0 Psig
28. be shut down and a trip message will be displayed This timer is available if the unit is equipped with a low oil separator float switch the oil level switch is standard on all liquid injection units and optional on all others Low Oil Separator Temperature Safety Changeover e This Hirmer allows Low Oil Separator Start Temperature safety setpoint to protect the compressor against cold oil during starting After the timer has expired the Low Oil Separator Run Temperature is then active Low Oil Injection Safety Bypass e Thistimerbypassesthe Low Oil Injection Temperature Safety setpoint during start up to allow any cold oil in the oil lines and filter to pass After the timer expires the Low Oil Injection Temperature safety is active Max Restart After Power Failure This timer forces the compressor to wait for the set time period after a power failure and the panels re starts before it can be started automatically By stag gering the time settings of this timer between other compressor panels the compressors can be allowed to start automatically one at a time after a power failure This will prevent excessive load demand on the power system that could occur if all of the com pressor equipment were to start at the same time The Power up Auto Re Start x Enable option must be selected on the Configuration screen for this op tion to be active Hot Starts per Hour This counter counts compressor starts After every
29. choose between 12 hour or 24 hours clock Hour e Entry boxto set the clock hours AM or PM drop down box will available if the 12 hour format is selected Minute e Entry Box to set the clock minutes Second e Entry Box to set the clock seconds Year e Entry Box to set the current year Month e Entry Box to set the current month Day e Entry Box to set the current date Communications The communication section is the control center for all communications to the Vission 20 20 panel It is possi ble to have multiple modes of communications enabled and used However only one mode can be used to con trol the Vission 20 20 which is selected in the Active Remote Control drop down box For a complete list of communication registers please refer to the Vission 20 20 communication table Active Remote Control e Selects the mode of remote control The operator can select between Direct I O Serial or Ethernet Direct I O e Enables the Direct I O inputs Once selected a pop up will be displayed and the operator will need to choose a one of the three Direct I O options Serial Modbus RTU e Enables the Serial Modbus RTU protocol Once se lected the remainder of the serial setpoints will be available for editing Panel ID Panel Identifier used by the controller when commu nicating with multiple panels Port The Vission 20 20 has two ways to communicate on serial bus Either via the bui
30. close the low level switch Note that this failure is generated ONLY when the low level switch opens af ter the compressor stops Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 35391SC 1 8 5153 11 12 Emerson and Vilter are trademarks of Emerson Electric Co or one of its affiliated companies 2012 Emerson Climate Technologies Inc All rights reserved Printed in the USA EMERSON CONSIDER IT SOLVED
31. d vi uw U Pe aM d K 3 R58 ga he e us e Ho o S k fs ore uu T E 104dFOol e_t e P dT 4 NL LRAR A R med a Sw Se i e Ge d e T VS ga Re Ge d e 013 VILTER Figure 3 6 Analog Input Board Layout Vission 20 20 Operation and Service Manual Vilter Emerson s 35391SC 1 8 5153 3 11 Section 3 lt Hardware Architecture Analog Input Jumper Tables Thefollowing tables are used to configure each channel of the analog input board signal type and range desired by the operator see Table 2 4 Analog Input Jumper Tables 3 12 CHANNEL 1 Table 3 4 Analog Input Jumper Tables SIGNAL JP31 jp 2 Jp 3 JP 27 JP 35 a P oovar OUT OUT m OUT OUT 1 40m m OUT OUT OUT OUT tc OUT P IN OUT OUT OUT RD OUT OUT OUT IN OUT Use Analog Input 1 A when 0 5 AMP secondary current transformers are installed in the motor starter Use Analog Input 1 B when current transformers are installed in the motor starter CHANNEL 2 SIGNAL JP4 je5 jee jp 28 svor OUT OUT OUT OUT P oova OUT OUT IN OUT pT 420m IN OUT OUT OUT oT KTD ou IN OUT OUT o RD OU OUT OUT J n CHANNEL 3 siNAL jp 7 jp 8 je9 jp 29 vo OUT OUT OUT OUT P oova OUT OUT IN OUT Lo E 420m N OUT OUT OUT Lo o OUT F IN OUT OUT o 1 RD OUT OUT OT IN
32. flash ing Use the button on the Vission 20 20 panel to drive the capacity slide to its minimum 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 Then use the button to pulse the motor so that the capacity slide is just off of its minimum position and there is no tension on the motor shaft 7 Quickly press and release the BLUE CALIBRATION BUTTON on the ACTUATOR motor once The red LED will now flash at a slower rate This now instructs the ACTUATOR motor that this point is the minimum slide position This point will correspond to 0 volts AFTER the ACTUATOR calibration procedure is completed 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 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 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 mo tor that this point is the maximum slide position This point corresponds to 5 volts The ACTUATOR calibration procedure is completed Now the Capacity Channel is automatically calibrat
33. has reached the SOI Load Limit setting Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Using a Positioning Valve for Liquid Ammonia Level Control A level probe inserted in the oil separator detects liquid ammonia level Based on the level of the am monia 0 100 the level probe sends a directly pro portional 4 20 mA signal to the Vission 20 20 panel The positioning valve is then positioned based on the Positioning Valve settings graph shown in Figure 25 2 Cool Compression Control Functions Screen Looking at the graph when the compressor starts the positioning valve placement Vertical Axis is de termined based on the liquid ammonia level that is sensed in the oil separator Horizontal Axis It can be seen that as the liquid ammonia level increases corresponding to a larger mA value the positioning valve moves towards a closed position The Positioning Valve position 0 100 limits is de fined at three distinct levels Start Level lowest liquid ammonia level po sitioning valve at maximum open position Leakage normal operating position and am monia level e Overfill Leakage highest liquid ammo nia level positioning valve at minimum open position Liquid ammonia levels are defined at four distinct lev els 4 20ma limits s Start SP minimum liquid ammonia level in separator the positioning valve is maximum open Linear SP minimum level of li
34. hours 75 psig s Next 4 hours 70 psig s And so forth Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 After the 12th step running at 25 psig 48 hours will have elapsed and the new setpoint becomes 20 psig achieving the 20 psig setpoint after 48 hours After the pulldown setpoint is equal to or is less than the control setpoint the pulldown feature will disable itself Pulldown e This checkbox enables the Pulldown feature If this box is unchecked Pulldown setpoints are ignored and the operator is not allowed to edit Pulldown setpoints Initiate Pulldown at Next Start e This checkbox when enabled turns on the Pulldown process at the next start cycle Pulldown operation will work in the following manners s Pulldown only works when Control mode is Suction Pressure 1 e f not started in Suction Pressure 1 then Pulldown process will not run until stopped and restarted in Suction Pressure 1 e f started in Suction Pressure 1 and changed after start then Pulldown process will be sus pended and restart once Control mode is changed back to Suction Pressure 1 Step Pressure This setpoint defines the step decrements at which the suction pressure value will be controlled at Delay Per Step e This setpoint defines the time increment at which the compressor will be controlled at each step Stop Pressure This setpoint defines the suction pressure value at which Pull
35. operator changes Press Temp units from configu ration screen when trending feature is running then background trending is stopped Suction Pressure 1 is 40 8 01210 15 5 Psig A Capacity Slide 35 7 Psig 60 3 F 88 3 Psig 63 0 F EM 26 8 Psig 45 2 F 66 2 Psig fees Volume Slide 4 1 17 9 Psig Sa 44 2 Psig TEE B 9 Psig 15 1 F Suction Press Control 22 1 Psig siiis Setpoint 20 0 Psig us Suction 0 0 Psig rented 35 5 Psi GRE Press 35 5 Ps 0 0 Psig 0 03 0 02 5 0 02 0 01 5 0 01 0 00 5 0 00 s emp 48 4 F e Suction temp Discharge v Press 80 3 Psig S emp 42 2 F Press Diff 125 3 Psig l Sep Temp 110 1 F No Scheduled Maintenance User admin P E e Suction Press v Trace Discharge Press vw Back Maintenance Inj Temp 108 5 F 01 01 2002 12 08 09 Motor No Alarm Trips Present Run Hours o Amperage 0 0 Amps Figure 15 2 Trend Setup Screen Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 15 3 15 4 Blank Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 16 s Event List Overview This screen is designed to display compressor events in chronological order The information available on the screen is valuable for understanding the operation of the compressor and troubleshooting see Figure 16 1 Event List Screen This screen Is divided into fo
36. p Cool Compression Process Temp Control h Oil Cooling Optional Function Selection J Thermosyphon C Compressor VFD H20 Oil Cooler j iti iquid Injecti O Slide Volume Position Liquid Injection C Economizer Pressure x Superheat Monitor Cool Compression E BERE Figure 25 1 Cool Compression Control Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Condenser Control C Wetbulb Sensor Solenoids p Motorized Valve injection line into the suction chamber of the compres sor This oil and liquid provides lubrication and cooling until full pressure differential lubrication is attained As the differential pressure increases the oil and liquid am monia is now injected into the screw during the com pression process and the oil injection valve is allowed to close Setup Configuration Screen e To setup the Vission 20 20 panel for Cool Compression first ensure that an analog output card is installed in the panel and it is selected enabled from page 6 of the configuration screen see Figure 25 1 Cool Compression Control Screen Navigate to configuration page 2 and select R717 Cool Comp from the drop down box that is labeled Refrigerant Once selected Cool Compression option will ap pear in Oil Pump and Oil Cooling sections and Cool Compression gets selected automatically It will also Motor Current Device Cur
37. slide valve percentage is equal to or greater than slide valve set point 1 the output is energized When the compressor slide valve percentage is less than slide valve set point 1 the output is de energized Slide Valve Setpoint 2 Output Hot Gas Normally used for a hot gas solenoid but could be used for other devices When the compressor slide valve percentage is equal to or greater than slide valve set point 2 the output is energized When the compressor slide valve percentage is less than slide valve set point 2 the output is de energized Alarm Output e This output is energized when the system has no alarms If an alarm is issued the output de energizes and stays de energized until the alarm condition is cleared Unused e This output has no current function Liquid Injection 1 Output s Ifthe compressor has liquid injection oil cooling this output is active When the compressor is running and the discharge temperature is above the oil separator temperature override setpoint and the oil separator temperature is above the override setpoint then the output is energized The output is de energized when the discharge temperature falls below the on set point minus the solenoid differential Liquid Injection 2 Output Not Defined Remote Enabled Output e This output is energized when the Vission 20 20 panel is enabled for remote control The compres sor can be running or stoppe
38. slide to the Auto Load limit approx 30 but less than 50 It displays status message Cool Compression Capacity Hold when it is running Unless Auto load is disengaged compressor will run at auto load limit position Auto load disengages if enough Pressure Ratio is built typically more than 2 04 or setpoints are achieved 4 SOI Solenoid During normal operation if pressure ra tio drops to a lower value typically below 2 00 then it energizes SOI solenoid and maintains the position of ca pacity slide to the SOI Load limit approx 30 less than 50 26 It also displays status message Cool Compression Capacity Hold If enough Pressure Ratio is built across the compressor typically more than 2 04 it again re sumes the run mode and control normally 5 It performs Cool Compression specific checks periodi cally like Controlling the liquid level positioning valve as liquid ammonia level changes e Low high Pressure Oil Injection ports control as Pressure Ratio and Superheat temperature changes Supplemental Oil Cooling Solenoids Some cool compression units will have supplemental oil cooling solenoids One is called the suction liquid injection solenoid and is controlled via discharge su perheat When the discharge superheat reaches 5 F the solenoid is turned on When it falls back to below 4 F the solenoid is turned off An additional solenoid referenced as SV4 as called the High Press Ratio solenoid
39. stop load and force unload feature s primary pur pose is to attempt to prevent the compressor from tripping off due to particular instrument reading For example if the suction pressure drops too low the com pressor will trip off for safety reasons However the stop load amp force unload algorithm recognizes a potential trip and either stops the compressor from loading up or even unloads the compressor to prevent the trip Stop load e When this value is reached the capacity slide will not advance in any condition Force Unload e When this value is reached the capacity slide posi tion will decrease until the variable reading is below this value High Motor Amps Motor current values for stop load and force unload High Discharge Pressure e Discharge pressure value for stop load and force unload Low Suction Pressure e Suction pressure values for stop load and force unload Capacity Slide Triggered Outputs The Vission 20 20 offers two digital outputs that can be triggered at a specified capacity slide position By de fault the outputs are preselected for economizer and hot gas bypass However these preselected outputs are customizable by the operator Slide Valve Setpoint Operator editable labels for the each output Slide e Indicates the capacity slide position where the digital output is triggered State Below Setpoint Defines the state of the digital output when the slide position is b
40. the input Digital Auxiliaries Digital Inputs Enable Input 2 Enable Input 3 Enable Input 4 19 6 Set Name Motor High Temp Set Name Digital Aux in 2 Set Name Digital Aux in 3 Set Name Digital Aux in 4 E ES EN Enable Input 5 Enable Input 6 Enable Input 7 Enable Input 8 Set Name Digital Aux in 5 Set Name Digital Aux in 6 Set Name Digital Aux in 7 Set Name Digital Aux in 8 Figure 19 3 Configuration Screen Page 3 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 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 avail able from the menu screen where the operator can further define the inputs operation see Figure 19 4 Configuration Screen Page 4 Enable Input e Enables the selected analog input Set Name e Allows the operator to assign a name to the input Analog Auxilliaries Analog Inputs Enable Input 1 Set Name chiller Low Temp Enable Input 2 Set Name Analog Aux in 2 Enable Input 3 Set Name Analog Aux in 3 Enable Input 4 Set Name Analog Aux in 4 Enable Input 5 Set Name Analog Aux in 5 Enable Input 6 Set Name Analog Aux in 6 Enable Input 7 Set Name Analog Aux in 7 Enable Input
41. the operator to configure the signal type and range for incoming analog signals For the correct jumper setting for a giving application see Table 2 4 Analog Input Jumper Tables 24V GN 2 RX GB Eo SERIAL MEN 0000 E m NN m EZEN ee ija jag S8 MER L I GO O Gi gt o 99 ge K a o GA a Oo fi o 9 9 ed a we e O en MET O M ici QUEM 5 o WI LL O o li 15 Se c s o 970 CRS i y BU GM e 99s eq dess Aco 12 3 med o ke zx BIZ Z oy E 2215 zie e e o ie NAE do4dror Voltage LEDs Marked in the diagram below in Orange These LEDs indicated the correct voltage of both the 5Vdc and 24Vdc power sources Communication LEDs Marked in the diagram below in Green These LEDs Show the active communications between the digi tal output board and the Vission 20 20 CPU board Address Dipswitches Marked in the diagram below in Red These dip switches are used to assign each board its address position The addresses are binary and therefore the address of a digital output board will be address as 6 0110 7 0111 8 1000 or 9 1001 R zo o s e i1 G 147 Se Re Ge d Me TR rren a PE x ka EEIN z on a aa 4OodrFoJj e E aer DopEL f e jodro e 7 oi Re Ge ud e Co ed Me 55 S E e d 2 3 d 4E s pFoE mal e SM ke e d ERE Ro gl Re e uj 1 L
42. time in or der to increase or decrease condenser steps While in a VFD step an additional step can only be added once VFD has reached its maximum speed setpoint and the delay timers are satisfied e Similarly in a VFD step a step can only be removed once VFD has reached its minimum speed 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 Allows steps to have option for time delay in case of fan spin down Any of Out 1 to Out 4 can be sa Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 11 e Condenser Control Figure 11 2 Step Control Screen selected as Low Speed Fan through combo box E g Let s say Out 2 is selected as Low Speed Fan in Step 2 When step 2 becomes active during condenser control operation which is after Step 2 time out de lay Out 2 is left off for time as set by the operator in High to Low Speed Delay After low speed fan ener gizes then timer for Step 3 starts timing Control Toggle any of the steps On Off during Manual opera tion of Condenser Control This button is active only when Run Mode selected is Manual During Auto op eration of Condenser Control control button for ac tive step will be ON VFD Settings This page is active only when Condenser VFD is selected in Configuration Screen When a VFD Fan is used
43. 1SC 1 8 5153 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 Button Slide actuators and to establish Vission 20 20 control parameters It is important that the operator uses cau tion while operating in this screen see Figure 14 1 Slide Calibration Screen The normal safety checks that pre vent the slide from colliding with the mechanical stops are overridden When the calibration process is complet ed and the operator exits the screen Both actuator will return the slides back to their minimum positions Button When the operator presses and holds this button the output associated with capacity slide increase is energized If the actuator does not turn in the cor rect direction when this button is pressed then the This section provides critical information and control pa operator will have to alter how the actuator is wired rameters related to the capacity slide actuator The to the panel cap display shows the actual value in percent of the ca pacity slide with out any conditioning that might be ap plied to the other capacity position displays In addition The Vission 20 20 uses the Min Limit and Max Limit setpoint to define an area within the When the operator presses and holds this button the output associated with capacity slide
44. 3 3 Digital Output Board e Marked in the diagram below in Green These LED s Show the active communications between the digi Layout ii tal output board and the Vission 20 20 CPU board Sianal LED Address Dipswitches na S bi Ba e Marked in the diagram below in Red These dip e Marked in the diagram below in Blue These LED s in switches are used to assign each board its address dicated when a 120Vac output is being produced position The addresses are binary and therefor the address of a digital output board will either be ad dress as 1 0001 or 2 0010 24V GND RE12001 m Us wi L S c12 919 O Oo C6 1uF p o SLS O o A O O Qe oto Ql c5 o PE Ea o Ro o uF C2 oj co o llel 1 o 5 Jo amp le 2 oj 5 Je oel 3 o a e SIL 4 Oo Oo liel 5 U Jg R5 TE e ax eL he i po e R L E S TEN g SS7 C1O TX sr OAEO PERIIT LED2 eL di z2 cof REVTMENE SRL UT SERIAL BEEN 325 046 0010 R3 24 GND gal 120 e cw OOOO J2 Figure 3 3 Digital Output Board Layout 3 8 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 3 Hardware Architecture Digital Input Boards The digital input board convert 120Vdc signals from ex ternal devices to signal for the Vission 20 20 program All the signals are digital in that the only two states avail able or either on or off See board layout Figure 3 4 Digital Input Board Layout S
45. 53 Solution Dirt or debris is blocking one or both Clean the optocoupler slots with a optocoupler slots cotton swab and rubbing alcohol Adjust the photochopper so that the fence extends further into the optocoupler slots Make sure the motor brake operates freely and the photochopper will not contact the optocouplers when the shaft is pressed down Tape the end of the white wire in the panel and make sure that it cannot touch metal Clean the boards with an electronics cleaner or compressed air The calibrate button is stuck down Try to free the stuck button The position sensor has failed Replace the actuator Depress the button quickly and then let go Each second the button is held down counts as another press Tape the end of the white wire in the panel and make sure that it cannot touch metal Increase the distance between the EMI source and the actuator Install additional metal shielding ma terial between the EMI source and the actuator or cable Recalibrate Get the motor brake to where it op erates freely and then recalibrate Replace the actuator Try to realign or replace the actuator Get the motor brake to where it op erates freely and then recalibrate 14 5 Section 14 lt Slide Calibration Table 14 2 Slide Valve Troubleshooting Guide 2 of 2 Problem Reason Solution There is a rapid clicking noise when The position sensor s EEPROM Re EEE N the motor is operat
46. 8 Set Name Analog Aux in 8 Enable Input 9 Enable Input 10 Enable Input 11 Enable Input 12 Enable Input 13 Enable Input 14 Enable Input 15 Enable Input 16 Set Name Analog Aux in 9 Set Name Analog Aux in 10 Set Name Analog Aux in 11 Set Name Analog Aux in 12 Set Name Analog Aux in 13 Set Name Analog Aux in 14 Set Name analog Aux in 15 Set Name analog Aux in 16 Figure 19 4 Configuration Screen Page 4 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 19 7 Section 19 Configuration Analog Outputs The Vission 20 20 has several Analog outputs that the operator can choose how the outputs will be used Once an output is enabled the Auxiliary I O screen will be available from the menu screen where the operator can further define the outputs operation see Figure 19 5 Configuration Screen Page 5 Enable Output s Enables the selected analog output Set Name Allows the operator to assign a name to the output Auxillary Outputs Analog Outputs CO Enable Output 1 Set Name Analog Aux out 1 Enable Output 2 Set Name Analog Aux out 2 Digital Outputs Cl Enable Output 1 Set Name Digital Aux out 1 Enable Output 2 Set Name Digital Aux out 2 BEE O Figure 19 5 Configuration Screen Page 5 Digital Outputs The Vission 20 20 has several Digital outputs that the operator ca
47. CT ee PnP Ee pe gu Model 501 Refrigerant R717 Cool Comp Other K Factor VFD Fan Compressor Control Controllers Condenser Control Ambient Sensor Wetbulb Sensor Optional Function Selection The following options are additional features of the Vission 20 20 that can be selected Some of these op tions will not be available for selection unless the proper I O cards are installed and enabled see Figure 19 2 Configuration Screen Page 2 Compressor VFD e Enables the compressor motor VFD option Slide Volume Position s Unused Economizer Pressure e Enables the economizer pressure input Superheat Monitor e Enables the superheat safety algorithms Superheat T SAT vs Oil Sep Temp T SAT vs Oil Sep Temp Delay l sec T SAT vs Disch Temp T SAT vs Disch Temp Delay 1 sec l F 1 F oil Pump No Pump Suction Pressure Control Cycling t 3 Full Time Process Temp Control s Cool Compression Oil Cooling Optional Function Selection Thermosyphon Compressor VFD C H20 Oil Cooler me 2 Liquid Injection CI Slide Volume Position misil l LC Economizer Pressure Superheat Monitor Cool Compression Pumps 57 Solenoids n Motorized Valve Separator Velocity Factor 1 Factor 2 Factar 3 Motor Current Device Current Transformer 3 4 20ma Transmitter fo
48. EE E E T EE 19 2 TOUSE MET TOTIS 19 2 PIU rey ClO DN DT TT 19 2 Restart On Power PalluFe assessor oa cette S CEDAR E HI PrbRE I Mab 19 3 COIDressorSedueritiliQ usos css cts teeter adus enou mde aseec auri usse ca sies dux bo caue abu equ dr catu cut Eure Ds u d cUpRUU DUM Le RF ESRe PERDE 19 3 TEI m RR 19 3 Kodel amp HANC FIR TET 19 3 Figure 19 2 Configuration Screen Page 2 vesscssrssvsravsscasensddiucensweeredueaesonsederusebsedivpeasevensehespsesvsumeescenets 19 4 COITIDEBSSOFCOHBEDDL TT 19 4 Optional Function Selection PENNE TTE 19 4 Condensor uel erna E EE AE EEE E E 19 5 OPUN D a E EE A E O E E E E 19 5 OOO NING oei R E E 19 5 MOOT ad guia DCV OC TP 19 5 Figure 19 3 Configuration Screen Page 3 sese eee 19 6 BE EM ai E TT 19 6 Andog INDU seas E T Em 19 7 Figure 19 4 Configuration Screen Page 4 ssssscccccssssssssesssssssssssssssssssceccecceceeeececsssssssssssssscsscescs 19 7 Figure 19 5 Configuration Screen Page 5 issurscasaspousderceanouwne eee 19 8 Anao Owi DUT PNE m 19 8 Digi OUS eee Nem 19 8 fiere e Rm Ue 19 9 Figure 19 6 Configuration Screen Page ecc ien e ek 2 eee SEV eee 19 9 TOC 4 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Table of Contents Section Title Section Number Section 20 Data Backup gui e 20 1 DANG Eae E TU Tm 20 1 Figure 20 1 Data Backup Screen S
49. EMI and Vission 20 20 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 2 lt Installation Recommendations Grounding Continuous grounds must be run from the util ity ground to the Vission 20 20 see Figure 2 3 Grounding e Grounds must be copper or aluminum wire e Never use conduit grounds Mixing Voltages Separate different voltages from each other and separate AC from DC see Figure 2 4 Mixed Voltage Each voltage level must be run in separate conduit s 460 VAC e 230 VAC e 120 VAC e 24 VAC DC signals e If your installation site has wire ways or conduit trays dividers must be installed between the different Wiring voltages PLANT SUPPLY TRANSFORMER 3 PHASE _ BUS GROUND s BUS ALUMINUM 9r COPPER TRANSFORMER we GROUND apt el COPPER P di GROUNDED CONTROL TRANSFORMER 4 ESIEAR SECONDARY S CIRCUIT BREAKER OR FUSE Figure 2 3 Ground Wiring PLANT TRANSFORMER 3 PHASE NEN GN BUS GROUND BUS pe 460 VOLT SEPARATE 120 VOLT CIRCUIT CONDUIT Hf n e CIRCUIT Figure 2 4 Mixed Voltage Wiring 2 2 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 2 lt Installation Recommendations Wiring Methods Each Vission 20 20 panel should have its own indi vidual control transformer see Figure 2 5 Correct Transformer Wiring Method and Figure 2 6 In
50. Ea ES ESEN ECI EJ E Page Maintenance No Alarm Trips Present Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 12 1 12 2 Section 12 Service Options of the volume actuator The output is connected to terminal 15 and is the 5th LED down on card 1 Volume Decrease Motor Activates the output assigned to the decrease input of the volume actuator The output is connected to terminal 16 and is the 6th LED down on card 1 Oil Separator Heater Activates the output assigned to the oil separator heater The output is connected to terminal 17 and is the 7th LED down on card 1 Trip Deactivates the output during a trip or inhibit con dition This is a reverse acting output The output is connected to terminal 18 and is the bottom LED on card 1 Slide Valve Setpoint 1 Economizer e Activates the output typically assigned to the econo mizer solenoid but can be changed by the operator The output is connected to terminal 21 and is the 1st LED on card 2 Slide Valve Setpoint 2 Hot Gas Bypass e Activates the output typically assigned to the hot gas bypass solenoid but can be changed by the operator The output is connected to terminal 22 and is the 2nd LED on card 2 Alarm e Activates the output during an alarm condition This is areverse acting output The output is connected to terminal 23 and is the 3rd LED on card 2
51. Out Button When pressed activates the remote lock out option This is a safety feature that prevents any external de vices from assuming control and starting the com pressor To release the remote lock out the operator must press the unit start button and then the remote button when the start dialog box appears Alarm Reset Button When pressed clears any current alarms trips or status messages that may be displayed on the infor mation bar Note if the condition that created the alarm trip or status message still exits the message will reappear Capacity Slide Volume Slide 4 8 Yo Suction Press Control Suction Discharge Figure 4 3 Parameter Bar Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Volume Slide Section 4 s Main Screen Parameter Bar Continued e The suction box shows the current suction pressure and suction temperature Unit Start Button he discharge box shows the current dis e When pressed a start dialog box will appear that charge pressure and discharge temperature will give the operator a number of run options Auto he oil box shows the pressure differential Manual Remote or auto sequencing see Figure 4 4 which is calculated as oil filter out pressure mi Unit Start Pop Up Window nus suction pressure Filter differential is calcu lated as oil filter in pressure minus oil filter out Control Parameter Boxes pressure Inj Te
52. 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 Capacity Load Unload Timers s One of the following Capacity Load Unload rate timers are used to make sequencing decisions peri odically Suction Pressure Process Temperature set points are monitored to identify which one of the fol lowing timers to be used Load Rate 1 Inner e f Suction Pressure Process Temperature goes be yond Load Rate 1 setpoint offset then Load Rate 1 timer is used to make periodic sequencing decisions Load Rate 2 Outer e f Suction Pressure Process Temperature surpasses Load Rate 1 offset and goes beyond Load Rate 2 set point offset then Load Rate 2 timer is used to make periodic sequencing decisions Unload Rate 1 Inner e If Suction Pressure Process Temperature goes below Unload Rate 1 setpoint offset then Unload Rate 1 timer is used to make periodic sequencing decisions Unload Rate 2 Outer e If Suction Pressure Process Temperature surpasses Unload Rate 1 offset and goes below Unload Rate 2 setpoint offset then Unload Rate 2 timer is used to make periodic sequencing decisions Compressor Sequencing Table Compressor sequencing table menu allows operator to view and adjust settings those are used for com pressor sequencing Equipment Options of this combo box are updated automatical ly Thi
53. R717 v _ Wetbulb Sensor Other K Factor 1 Compressor Control Prelube oil pump alarms and trip values will be changed to default values for the twin screw VFD Fan Controllers Oil Pump No Pump Suction Pressure Control 2 Cycling Full Time C Process Temp Control p Pumps p Oil Cooling Thermosyphon Optional Function Selection C Compressor VFD H20 Oil Cooler O Slide Volume Position Liquid Injection C Economizer Pressure Solenoids Superheat Monitor Motorized Valve 99 gt Figure 24 1 Twin Screw Control Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 24 1 Section 24 lt Twin Screw Control Operation Once the twin screw is configured its operation is very similar as the single screw and all options that are avail able 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 control ler To counteract the capacity slide drift problem the twin screw manual mode operation has an added anti drift feature that automatically maintains the position of the hydraulic actuator 24 2 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 25 Cool Compression Cont
54. Stop Ti 90 op Time sec Suck Press 7 9 Psig 111 0 F emp Advance Sequence Configuration Equalized Load Enable Sync Sequencing Parameters Sync 2 Refresh Menu 2 ANE ome EN Oil Discharge Press emp 121 5 Psig 22 3 F eee Press Diff 307 6 Psig Filter Diff 10 7 Psig Inj Temp 127 5 F Sep Tem 118 3 F No Scheduled Maintenance User admin p p 08 18 2011 04 45 44 Motor No Alarm Trips Present Run Hours Amperage 1 5 Amps Figure 10 1 Compressor Sequencing Screen Vission 20 20 Operation and Service Manual e Vilter Emerson s 35391SC 1 8 5153 10 1 10 2 Section 10 lt Compressor Sequencing monitor compressor load If Suction pressure pro cess temperature goes beyond Load Rate 1 setpoint offset then sequencing decisions are made according to Load Rate 1 timer Suction Pressure Process Temperature Control Setpoint e The target setpoints are read only values here These setpoints can be changed by logging on to Compressor Control Screen Unload Rate 1 Offset inner Defines the inner pressure temp setpoint to moni tor compressor load If Suction Pressure Process Temperature Control drops below Unload Rate 1 set point offset then sequencing decisions are made ac cording to Unload Rate 1 timer Unload Rate 2 Offset outer Defines the outer Pressure Temp setpoint offset to monitor compressor load If Suction
55. Time Proportional Dead Band Auto cycle Enable Start Pressure Start Delay Stop Pressure Stop Delay Min Slide Position Setpoint 2 30 o Psig 4 0 sec 4 0 sec m Psig 10 0 96 4 0 sec 4 0 sec 4 0 Psig 10 0 in order to maintain the control setpoint The control setpoint can either be process temperature control set point or suction pressure control setpoint depending on what the operator has selected as the control mode The proportion control uses the Interval Time Setpoint to define the time the algorithm waits to read the cur rent setpoint and calculates the error from the process control setpoint Based on the error from setpoint the algorithm calculates a pulse time in which the capacity slide is moved in the direction of the error The further away the process variable is from the control setpoint the larger the corrective pulse will be The duration of the pulse is limited by the Pulse Time Setpoint By de fault the maximum pulse time is the same as the interval time This means that the pulse time can be 100 of the interval time given a near continuous movement of the capacity slide Adjusting these setpoints can be useful in slowing down the reaction time of the compressor if large thermal time contents are present in the refrigera tion cycle Capacity Slide Volume Slide Suction Press Control Setpoint 20 0 Psig Suction Press 56 2 Psig emp 32 4 F Discharge Press emp
56. Vission 20 20 micro controller Operation and service manual VILTER hack eis Table of Contents Section Title Section Number How HOSE PES Manual RT Section 1 Operational Flow Charts Requirements to Start COITIDEBSSOE sss ceociecessasverancosacsnesscuetesuncdenies aeoesvbssivedencdonteedevecsaatecesteeeineeunenes 1 1 Critical Compressor Run Logic at Compressor Start ssseeceeeccccccccccceeeeeesssssssseeeeceeeceeeeceeeeeeees 1 1 Compressor Amperage Load Limiting cccccccsssssssssssssssscseececcecccccseceeeeeecsessssseeseeeeececececeeseeeeeeeaaes 1 1 Figure 1 1 Operational Flow Charts sscccsnccssaccessasievecssavaccsnacewsusiesdeeduwssssvescciesedoeneddecsmuseseenensveiveccaseassys 1 1 High Discharge Pressure Load LiIMiting cccccccccccccccccecsssssssssesesceccccceccccceeeaccecassseseseeeeeceececeeeees 1 1 Suction Pressure Override Load Limit During Temperature Control eee ee 1 2 Section 2 Installation Recommendations PROOF WVU Ts SIZING users cioe ee aac eoeo ient lesen emit need HbE EP PRSE P E E sid suse Diae Ne sent S P EeREEL Mn aU M UN Pp EM RUE 2 1 NOM AGS SOULCO ee E E E E ES E O E E E EE 2 1 Figure 2 1 Vission 20 20 with Individual Transformer sss sss esse esec 2 1 Figure 2 2 EMI and Vission 20 20 M 2 1 GEO ne n S Ne mU mm 2 2 TEST VOJE eE E E ATE TO EO Ec 2 2 Beca ae E E E E E EE 2 2 Figure 2 3 Ground Wiring
57. a log input in the Vission 20 20 are made available for con trolling a digital output Analog Input Selecting the Analog Input radio button fills the Active Input drop down box with all available analog inputs One of the analog inputs can then be selected to control the digital outputs Digital Input Selecting the Digital Input radio button fills the Active Input drop down box with all available digital inputs One of the digital inputs can then be selected to control the digital outputs Run Always Selecting this checkbox enables the function that controls the digital output to operate only when the compressor is running or runs all the time Analog Trigger The analog trigger toggles the digital output based on a specified value plus the specified differential value Analog Trigger value This defines the specified value in which the output will toggle This is an absolute value and not based on units For example 100 could mean temperature or pressure depending on the type of input selected N O amp NJC Choosing the Normally Open N O or Normally Closed N C radio buttons defines what the output will be above or below the trig ger value In the N O setting the output will be off Ovac while the input value is below the trig ger value e Differential his is the differential around the trigger val ue For example if a trigger value of 100 is en tered with a differential of
58. ading Figure 1 1 Operational Flow Charts 2 of 2 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 2 lt Installation Recommendations CODE 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 am ple current carrying capability Never under size wire gauges Voltage Source e Transformers block a large percentage of CONTROL TRANSFORMER CIRCUIT BREAKER ORFUSE L ISOLATED SECONDARY CIRCUIT Electro Magnetic Interference EMI The Vilter Vission 20 20 should be isolated with its own con trol transformer for the most reliable operation see Figure 2 1 Vission 20 20 with Individual Transformer Connecting the Vilter Vission 20 20 to breaker panels and central control transformers exposes the Vission 20 20 to large amounts of EMI emitted from the other devices connected to the secondary terminals of the transformer This practice should be avoided if possible see Figure 2 2 EMI and Vission 20 20 PRIMARY GROUND GROUNDED NEUTRAL Figure 2 1 Vission 20 20 with Individual Transformer CONTROL TRANSFORMER 7 CIRCUIT BREAKER OR FUSE PRIMARY GROUND GROUNDED NEUTRAL NON ISOLATED SECONDARY CIRCUIT Figure 2 2
59. amp Trip This is the high discharge temperature safety The alarm or trip will be activated if the discharge tem perature rises above the setpoint value Low Oil Separator Start Temperature Alarm amp Trip This is the starting low oil separator temperature safety The compressor is prevented from starting or running if the oil in the separator is below the alarm value After a time delay setting of the Oil Separator Temperature Safety Changeover timer this safety is deactivated and the Low Oil Separator Run Temperature alarm and safety setpoints become active Low Oil Separator Run Temperature Alarm amp Trip This is the running low oil separator temperature 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 set points become active The alarm or trip will be acti vated if the oil temperature in the separator drops below the setpoint value Low Oil Injection Temperature Alarm amp Trip This is the low oil injection safety The alarm and trip setpoints are bypassed at start for a time pe riod setting of the Oil Injection Temperature Safety Changeover timer The alarm and trip will be acti vated after the time delay has expired High Oil Injection Temperature Alarm amp Trip This is the high oil injection temperature safety The alarm or trip
60. ar red e Informs the operator that the compressor motor was stopped due the condition listed in the informa tion bar Compressor trips are designed to protect the equipment and any personnel operating the equipment Suction Pressure 1 Stopped 36 2 Psig A Figure 4 2 Top Status Bar Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 4 s Main Screen Parameter Bar 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 but tons see Figure 4 3 Parameter Bar Capacity Slide Indicator Shows the position of the capacity slide from 0 to 100 via a horizontal blue bar The buttons below the indicator are used in manual capacity control The button will decrease the capacity position and the button will increase the position Volume Slide Indicator Shows the position of the volume slide from 075 to 10026 via a horizontal blue bar In some cases in crease and decrease buttons will appear below the volume indicator The buttons only appear if the op erator who is logged on has sufficient privileges If available the buttons work to increase and decrease the volume slide position in the same manner as the capacity slide Stop Button When pressed stops the compressor in all cases Remote Lock
61. as op tions for selection e f Control Mode is selected as Unscheduled and Time set in an event is achieved then control mode will not get switched Hence Control Mode can be set 19 7 Psig A Capacity Slide 100 0 Volume Slide suction Press Control Setpoint 20 0 Psig Suction Press 1 Saturday 39 7 Psig 33 1 F Discharge Press 165 1 Psig 125 9 F 03 02 2010 04 46 29 M GE Or perage 0 0 Amps Run Hours 0 Figure 9 1 Compressor Scheduling Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 9 lt Compressor Scheduling as Unscheduled if operator does not want to use all 4 events per day Time This setpoint allows selection of Hours Minutes and AM PM values for an event When time set for an event is achieved control mode will get changed as selected for that event Therange of values allowed to set for Hours setpoint is0 12for 12 hour format and 0 23 for 24 hour for mat The range of values allowed to set for Minutes setpoint is 0 59 AM PM selection is active for se lection only when Time Format selected in configura tion screen is 12 hour When scheduling feature is enabled and No of control lers for Suction Pressure Control amp Process Temperature Control are changed in configuration screen which makes control modes selected in compressor schedul ing screen as invalid then feature will get disabled
62. auto cycle feature will operate normally NOTE When the Pump down Feature is enabled the Auto cycle setpoints are automatically disabled Pump down mode will cause the compressor to cycle off via the Pump down Stop Pressure setpoint and will not allow the compressor to start again Enable e Enables the Auto cycle control Uncheck the box to disable the Auto cycle set points Start Pressure e When the suction pressure meets or exceeds this set point the compressor will start Start Delay Delays the compressor from starting when the suc tion pressure meets or exceeds this setpoint Stop Pressure e When the suction pressure meets or falls below this setpoint the compressor will stop Stop Delay Delays the compressor from stopping when the suc tion pressure meets or exceeds this setpoint Minimum Slide Position The minimum capacity slide position that the com pressor is allowed to run at Variable Frequency Drive VFD The VFD page is where the operator can tune the mo tor VFD for desired operation A Vilter compressor uses the variable speed of a VFD controlled motor to vary the amount of work or capacity of the compressor The basic one step VFD control will use the capacity slide to control the first half of the total available capacity and the motor speed to control the second half of the total available capacity see Figure 6 3 VFD One Step Control Method For example if the compresso
63. ave LOad sss 20 1 AE ES E NETTE TEE DTE mm 20 3 FC COI A ci RUD 20 3 Figure 20 2 Data Backup Screen Migrate and Factory Reset sse 20 3 Section 21 Maintenance s dig pe CTC CIWS E Figure 21 1 Maintenance Screen e a NOTOS E E EEE EEE EEE Oe CHa M U Section 22 User Access gui Me a POD DW YOEO U CO Figure 22 1 User Access Screen Login ss sss sss sss ssscsssssssssssrsssgg sega e osa aes sasa aessa aaeeea nanas nn as Figure 22 2 User Access Screen Manage Accounts eee Foret tt e C RT WR E KaRa GE AC OCIS erre dupomqu d d uns dv E E E E VIR EPdI E 2I LrNURa GE EVEN MEIUU S VISA UNE Screen Security LOVES us cest ox ERIS CER TE n NOSEN TENUERE PERDER RENTENE redo Y pL O Terni Table 22 1 Security Access Levels sees eee eee Section 23 Help Screen sg fre m SSI RE UTOS caer C Figaro 23 1 HelpSEF TT Figure 25 2 Version Pop Up SCEBOT sss ssss sss ss ssssssssesss sassa esaeas cosa red nue eana aaaea aan anne as S
64. board They are clearly marked on the board silkscreen legend and are oriented at a 45 angle 7 OOK OK OOK OOK OK OK GRO OK OK OR OK GRO OK GRO OK GR OK GB OK 14 8 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 15 Trend Chart Overview Chart Operation This screen allows the operator to view and adjust set tings for the trend chart see Figure 15 1 Trend Chart Screen Trending feature can be started amp stopped from this screen Up to four variables can be selected for plot ting 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 The operator can select from viewing the plot to selecting which variables and time intervals to show as often as necessary The Start Stop vertical axis scaling and offset for each variable plotted e is based on its range of values over the entire data plot ted on screen The data available for display is 120 hours maximum Pen Selection Pen selection allows operator to select different pens for plotting of data on the screen The operator can select None as an option for disabling plotting of data for particular pen Options in pen selection drop down box will depend on channels selected in Trend Setup screen This button allows the operator to start stop trend feature When trend feature is not running button will display Start and wil
65. can try pressing the Refresh button at the bottom of the screen Unfortunately not all USB flash drives are compatible with the Vission 20 20 and will never show up as available device Select Folder File e This window displays the folders and files contained in the USB flash drive selected in the Available Devices window The information from the Vission 20 20 will be contained into a zip file So a zip file will have to be selected to load or overwritten when saved Once a zip files is selected the name will be shown in the filename window Unmount By pressing the Unmount button any USB drive se lected in the Available Devices window will be dis connected from the operating system and can be safely removed from the USB port Back The back button returns the operator to the preced ing window display of files and folders Filename This window is where the operator can give a name to a saved backup file This field will automatically be populated if a file is selected in the Select Folder File window Settings Using this table the operator can choose to save or load all or part of the information contained in the Vission 20 20 Data Items Using this table the operator can choose to save or load all or part of the information contained in the Vission 20 20 according to checkbox selections Save Load Button e This button initiates the save or load process 20 2 Vission 20 20
66. card 1 Capacity Increase Motor Digital Outputs Activates the output assigned to the increase input of the capacity actuator The output is connected to terminal 13 and is the 3rd LED down on card 1 The digital output buttons are momentary toggle but tons The output will be active while the operator hashis Capacity Decrease Motor finger on the button The output will deactivate when e Activates the output assigned to the decrease input the operators finger is removed The operator can mea of the capacity actuator The output is connected to sure the output at the terminal block or view the output terminal 14 and is the 4th LED down on card 1 by watching the LEDs located on the cards Velumedncresse Nigkor Activates the output assigned to the increase input Suction Pressure 1 Stopped 36 1 Psig A Capacity Slide H Digital Outputs Status Compressor Start Volume Slide Suction Press Control Setpoint 20 0 Psig Oil Pump Start Capacity Increase Motor Capacity Decrease Motor Volume increase Motor Suction Press 56 1 Psig emp 33 3 F Volume Decrease Motor Oil Separator Heater Discharge Press 57 8 Psig emp 139 3 F num z Press Diff 1 1 Psig User ilter Diff 0 6 Psig Inj Temp 118 1 F No Scheduled Maintenance 08 19 2011 03 50 22 mem Run Hours Amperage 0 0 Amps Sep Temp 113 1 F Figure 12 1 Service Options Screen Alarm ol OBO ORO HOR oO HH SO A
67. configura tion parameters and calibration settings to a USB memory device In addition this allows the restora tion of previously saved database files Main Navigates back to the main screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 6 gt Compressor Control Overview The compressor control screen is where an operator can set the majority of the compressor settings These set ting define howthe compressor will operate and respond to changing loads The compressor control screen con sists of several screens but in order not to overwhelm the operator with options many of the screens may not be visible How the compressoris configured in the configu ration screen will determine what screens are displayed Itisimportant to note that there isn t one correct way to set these parameters Every application is different and requires the operator to tune these settings to achieve the best operation see Figure 6 1 Compressor Control Screen Pulse Proportional Control The Vission 20 20 uses a pulse proportional control method to control the compressor capacity slide valve Suction Pressure 1 iS Ke e el 10 36 2 Psig A Suction Pressure Control Setpoint 1 20 0 Psig 4 0 sec 4 0 sec 4 0 Psig 10 0 4 0 sec 4 0 sec 4 0 Psig 10 0 96 Pressure Control Setpoint Capacity Increase Interval Pulse Time Proportional Dead Band Capacity Decrease Interval Pulse
68. correct Transformer Wiring Method PLANT TRANSFORMER 3 PHASE BUS O Ro a O O AO uw P wm BUS Figure 2 5 Correct Transformer Wiring Method PLANT TRANSFORMER 3 PHASE BUS e GROUND BUS H N G H N G H N G Figure 2 6 Incorrect Transformer Wiring Method Vission 20 20 Operation and Service Manual e Vilter Emerson s 35391SC 1 8 5153 2 3 Section 2 lt Installation Recommendations Best Practices e Do Keep AC wires away from circuit boards e Always run conduit into the bottom or sides of an enclosure e 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 e he Vission 20 20 is supplied with pre punched conduit holes Use them e Don t Don t run wires through the Vission 20 20 enclosure that are not related to the compres sor control Don t add relays timers transformers etc in the Vission 20 20 enclosure without first check ing with Vilter s Don trun conduit into the top of an enclosure Don t run refrigerant tubing inside the enclosure Don t drill metal enclosures without taking proper precautions to protect circuit boards from damage 2 4 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 3 lt Hardware Architecture Overview The Vission 20 20 control panel utilizes X 86 PC tech
69. cted into the compressor the pre viously 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 The PID algorithm tries to drive the error to zero by moving the positioning valve to allow more or less liquid refrigerant to be injected into the compressor PID algorithm can be notoriously hard to tune As a result the Vission 20 20 offers a couple of addi tional features to help control wild fluctuations in oil temperatures that could result in the compres sor tripping off The operator can choose to enable the minimum value position that automatically sets the liquid injection motorized value to the specified value whenever the discharge temperature has fallen below the Liquid inj Setpoint 1 This feature nearly eliminates the overshoot of the PID in the downward direction and reduces the chance of the compressor tripping off due to low oil temperature The operator can also choose to use an average of the discharge temperature and the oil manifold temperature as the control variable The discharge temperature can vary quite drastically forcing the PID algorithm to drasti cally
70. ction 22 User Access either select the username from the operators win dow or enter the username manually by touching the entry box and entering the name via the pop up keyboard Operator Password e This entry box is for the operator s password The password can be entered by touching the password entry box and entering the password via the pop up keyboard Verify Password e This entry box is to verify the operator s password Verifying the password can be entered by touching the Verify Password entry box and entering the password via the pop up keyboard Security Level s 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 Add Update Pressingthis button will initiate the creation or modi fication of the specified account Delete s Pressing this button will delete the specified account Screen Security Levels The following table lists all screen and their base secu rity levels The majority of the screens have more than one security level The base security level gives the user access to the setpoints that can change to performance of the compressor The secondary security level is typi cally level 3 and is reserved for those setpoints that re quire great care and knowledge of the system in order to change safely Table 22 1 Security Access Levels Security Access Levels Page Use
71. d but is available to the remote system If the compressor has an alarm or is placed into the manual stop position this output is de energized Shunt Trip s Not defined Comp Motor Starter Auxiliary Contact This input looks for a feedback signal from the com pressor starter confirming that the compressor starter is energized Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 3 Hardware Architecture Table 3 1 Digital I O 1 of 2 Board I O 2 Description Type L is hightea shutdown 19 oiltevelFoat switch 20 oneeirosswichiz zr Remoteserpomejrzsdedion z Rmeesunisep 23 Remote Capacity increase 24 Remote Capacity Decrease a 3 3 m m 3 3 32 niaya 1 2 3 4 5 7 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 J Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT INPUT INPUT INPUT INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT INPUT INPUT INPUT INPUT UJ l 3 4 Section 3 Hardware Architecture High Level Shutdown Input e This input must be energized in order for the com pressor to operate If
72. d Qtqindiibtu p evita eau teo Ma URDU Re 1 1 Figure 2 1 Vission 20 20 with Individual Transformer cesses eee rennen nennen 2 1 Figure 2 2 EMI and Vission 20 20 10 2 1 Figure ees UTS T 2 2 Figure 2 4 Mixed Voltage Wiring sss sss sese sese 2 2 Figure 2 5 Correct Transformer Wiring Method sss ss sss sss 2 3 Figure 2 6 Incorrect Transformer Wiring Method sss sss sss 2 3 Figure 3 1 Hardware Architecture Overview sss ss sss sese sees sees eee eee eee 3 1 Figure 3 2 Digital I O Board Evo f sss sss esse essen 3 7 Figure 3 3 Digital Output Board Layout sss sese 3 8 Figure 3 4 Digital Input Board LayOut ccccccccccccccccccceesssssssseeeeecceccceeceeceeeeecseasssseseseeeeceeeeeeeeees 3 9 Figure 3 5 Digital Input Output Board Layout eee esee eese esee nnns 3 10 Figure 3 6 Analog Input Board Layout sss sese sese 3 11 Figure 3 7 Analog Output Board LaVOUE sss essen 3 14 Figure 4 1 Digital I O Board Layout sss sss esse esse 4 1 Figure 2 2 OP Status DUE 22 arietes soca sosecne ace E NE 4 2 Figure 4 3 Parameter Balt cosstavsanessvasanesaverinadsnwssastcngienceasieacaausnansianenaieuaseisesianasaisaosesan ouasapioswdcewbenuienies 4 3 Figure 4 4 Unit Start Pop Up WINdOW acessasucsesicassdensosasacte ser nisnedsasonmemeniaseraqaadaneutecaqiecsunantaanageuntisiens 4 4 Figure 4 5 Bottom Status Bar eT 4 5 Figure hl ASI SC ECI HHHH 4 6 Figure 5 1 Men Sreem TT T
73. d out and hence the user will not be able to oper ate Pumpdown feature This is done to keep Pumpdown and Pulldown features mutually exclusive Pulldown Control The Pulldown Control defines a method of slowly pull ing the suction pressure down from a high value This is sometimes required on systems that have liquid recircu lation systems or on new building to prevent structural damage by limiting the rate at which to build is cooled This feature can be enabled or disabled from this menu which is the part of Compressor Control Screen If Pulldown is enabled this feature will only function when the compressoris 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 set point we want to get to is 20 psig The operator wants to allow 48 hours of pulldown time Pick a reasonable step pressure of 5 psig for every step This defines a change of 80 20 60 psig Note First step is applied immediately So first step starts at 85 5 80 psig s Number of steps delta 60 psig change 1 step 5 psig 12 steps Delay per Step 48 hours 12 steps 4 hours step s So for the first 4 hours the compressor runs at 80 psig s Next 4
74. de Valve Position e 4 20mA signal that transmits the slide valve position for remote monitoring Motorized Valve V For a cool compression compressor this 4 20mA signal controls a motorized valve to regulate the liq uid refrigerant level in the oil separator For a liquid injection application on a standard single screw this 4 20mA signal controls a motorized valve to regulate the liquid refrigerant injected into the compressor for oil cooling purposes Digital amp Analog I O Boards Layout It is important to install the boards in the proper layout For the correct digital and analog input output I O board layout see Figure 3 2 Digital I O Board Layout Dipswitches Each board has a dipswitch which sets its communi cations address so that it can communicate with the CPU board The dipswitch settings must be correct or the I O will not function Jumpers e Jumpers are required on the analog boards to con figure them for the type of sensors used The jumper table for the analog board shows the optional jump er configurations for sensors other than the default Vilter standard If a different sensor is to be used the jumpers on the analog board need to be changed In addition the configuration for this sensor must be changed in the Instrument Calibration screen The following illustrations show the Vilter default con figurations for the Vission 20 20 Vission 20 20 Operation and Service Manual Vilter Emer
75. de energized the compressor will shut down and issue a high level trip Oil Level Float Switch 1 Input Usedfor Cool Compression Oil Level Float Switch 2 Input Usedfor Cool Compression Remote Select 1 2 Input e This input enables or disables remote I O control Energizing this input enables the Remote Capacity Increase and Remote Capacity Decrease inputs Remote Start Stop Input e f the compressor is enabled for remote I O control this input is enabled Energizing this input will issue a start for the compressor as long as it is available to run De energizing this input stops the compressor Remote Capacity Increase Input NOTE The scan interval on the remote increase and decrease inputs is approximately ONE SECOND Please take that into account when developing a control scheme using the remote increase and remote decrease inputs for compressor control e f the compressor is enabled for remote I O control this inputis enabled Operational only when the com pressor is running Energizing this input will increase the slide valve position The slide valve will continuously increase as long as this input is energized The slide valve will not in crease when this input is de energized Remote Capacity Decrease Input Operational only when the compressor is running This input is enabled if the compressor is enabled for remote I O control Energizing this input will de crease the slide valve position Th
76. decrease is energized If the actuator does not turn in the cor rect direction when this button is pressed then the operator will have to alter how the actuator is wired to the panel Capacity Slide Valve Potentiometer Software limit setpoint Suction Pressure 1 SLOopped 37 5 Psig A Capacity Slide Analog Inputs eei en inn n tmt ettet rar natn in tn tette nte nettes Suction Press Em 1 0 AJD bit Value Calibrated Value ins STT Volume Slide Oil Filter In Press Device Calibration Channel Calibration Default Devices Offset Oil Manifold Press Adjustment Condenser Press 0 414 5 psia 4 20ma v Total Offset rM ae cni MN o Suction Press Control Economizer Press O Custom Device Range Setpoint 20 0 Psig Min I O jumpers selection 14 7 Psig BiG Onin vw Suction Max Press 57 5 Psig 400 Psig emp 36 0 F Discharge Press 59 1 Psig emp 140 9 F oe E d DD ress Diff 0 9 Psig Sep Temp 114 7 F No Scheduled Maintenance User p p Inj Temp 120 6 F 08 19 2011 10 49 52 Temm No Alarm Trips Present Run Hours 31 cmm cem Figure 14 1 Slide Calibration Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 14 1 14 2 Section 14 lt Slide Calibration mechanical stops for normal slide travel These soft ware limits purpose is to prevent the slide from actu ally hitting the
77. 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 Slide Valve Troubleshooting Guide 1 of 2 Problem The actuator cannot be calibrated The actuator goes into calibration mode spontaneously The actuator does not transmit the correct position after a power loss There is a rapid clicking noise when the motor is operating Reason The photochopper fence extends less than about half way into the optocoupler slots The white calibrate wire in the grey Turck cable is grounded Dirt and or condensation on the position sensor boards are causing it to malfunction Push button is being held down for more that 34 second when going through the calibration procedure The white calibrate wire in the grey Turck cable is grounding intermittently A very strong source of electromag netic interference EMI such as a contactor is in the vicinity of the actuator or grey cable The motor was manually moved while the position sensor was not powered The motor brake is not working properly The position sensor s EEPROM memory has failed The photochopper is misaligned with the slotted optocouplers The motor brake is not working properly Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 51
78. down operation will get completed When suction pressure value is equal to or goes below this setpoint Pulldown feature disables itself Also Pulldown and Initiate Pulldown at Next Start checkboxes will be automatically deselected as nor mally this is one time use feature Auto Cycle Differential This setpoint defines the offset pressure values for Auto Cycle Start Pressure and Stop Pressure from the Suction Pressure setpoint Auto Cycle Start Pressure setpoint will be Suction Pressure setpoint increment ed by this setpoint pressure value while Auto Cycle Stop Pressure value will be Suction Pressure setpoint decremented by this setpoint pressure value When Pulldown feature is enabled Pumpdown checkbox is automatically grayed out Similarly when Pumpdown feature is enabled Pulldown checkbox is automatically 6 5 6 6 Section 6 lt Compressor Control grayed out and hence the user will not be able to op erate Pulldown feature This is done to keep Pulldown amp Pumpdown features mutually exclusive Control Mode This drop down box gives the operator the ability to change the type of control mode such as suction pres sure control or process temperature control The opera tor 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 se lected in the configuration screen Stop Load and Force Unload The
79. drop down box gives the operator the flexibility to choose whether the alarm and or tip occurs if the input is high or low Capacity Slide Suction Press Control Setpoint 20 0 Psig Scalable Control Min Output Suction Press 4 0 4 0 emp Max Input Max Output Press 88 1 Psig 20 0 20 0 emp 63 2 F Menu EN Oil Press Diff 119 0 Psig Filter Diff 8 5 Psig User Vilter Inj Temp 108 5 F Sep Temp 110 1 F 01 07 2002 11 00 36 Run Hours e Min Input 42 0 Psig 45 0 F Discharge Motor mperage 0 0 Amps Figure 18 1 Auxiliary Input Output Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 18 1 18 2 Section 18 Auxiliary Input Output Inhibit Check Selecting this checkbox enables the inhibit function of the Vission 20 20 for the desired digital input An inhibit check prevents the compressor from starting if the condition is true where a trip will shut down the compressor after it as started The inhibit can be selected to inhibit on a high or low input and can be selected to work with or without the alarm and trip function Digital Outputs The digital outputs section of the Auxiliary I O screen al lows an operator to configure the auxiliary digital out puts 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 an
80. e USB drive Selecting a folder will open that folder and display any sub folders of PDF documents Screen Features De e Pressing the unmount button will disconnect the USB Manual Tab drive from the Vission 20 20 operating system Once e Contains the list of available manual sections to be the device has been remove from the device list the displayed in the display window USB drive can be safely removed USB tab Refresh The operator as the option to view other manuals Pressingthis button will reread the USB ports and dis typically Vilter compressor manuals on the Vission play any new USB drives 20 20 from a USB drive If there are any PDF type documents on a connected USB drive the names Suction Pressure 1 gt He 0 el 16 1 6 Psig A Capacity Slide Manual uss Menu Screen installation Recomme Main Screen User Access Slide Calibration Volume Slide Maintenance Event List Twin Screw Control Operational Flow Char Input Output SS Suction Press Control Service Options x Cetnoint an n E Configuration Compressor Sequenc The compressor contro 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 wads The compressor contra screen cons ists of several screens but in order not to Overview Suction t gt Compressor Control Trend Chart overwhelm operator with op
81. e exceeds the alarm limit values e ow Alarm his defines the lower limit of the input value that when exceeded will generate an alarm Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 18 Auxiliary Input Output e High Alarm his defines the upper limit of the input value that when exceeded will generate an alarm Low Trip Defines the lower limit of the input value that when exceeded will generate a trip High Trip Definesthe 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 out puts There are two pages of auxiliary output configura tion each consists of two analog auxiliary outputs Active Input Active Input can be selected from avail able standard analog inputs or auxiliary inputs Selected Active Input gets mapped to auxiliary output e Run Always e Run Always option can be selected to en able mapped auxiliary output irrespective of the compressor s run state If Run Always is not selected then the mapped auxiliary output is enabled only when compressor is running e Trigger e Trigger configuration is used to enable dis able auxiliary output according to the config ured trigger input Trigger input can be selected from available standard analog inputs auxiliary analog i
82. e slide valve will continuously decrease as long as this input is ener gized The slide valve will not decrease when this in put is de energized Condenser Step 1 Output This output is enabled when condenser control op tion is selected A condenser fan or pump will be turned on or off by this output Condenser Step 2 Output This output is enabled when condenser control op tion is selected A condenser fan or pump will be turned on or off by this output Condenser Step 3 Output This output is enabled when condenser control op tion is selected A condenser fan or pump will be turned on or off by this output Condenser Step 4 Output This output is enabled when condenser control op tion is selected A condenser fan or pump will be turned on or off by this output Auxiliary Inputs 1 8 Optional inputs that can be configured as an alarm or trip Typically connected to external switched devices Auxiliary Outputs 1 4 Optional inputs that can be configured as an alarm or trip Typically connected to external switched devices Analog Inputs Refer to Table 2 2 Analog Inputs Motor Current s Defaultisa0 5 Amp current transformer CT Current transformer ratio is set in the calibration screen Suction Pressure Default signal is 4 20mA Suction pressure trans ducer range and calibration is set in the calibration screen Discharge Pressure e Default signal is 4 20mA Disc
83. ecasssssssseeseeeeeeeeecs 17 1 Figure 18 1 Auxiliary Input Output Screen sss eee eee sese eee 18 1 Figure 19 1 Configuration Screen Page T sese 19 1 Figure 19 2 Configuration Screen Page 2 ecassn th dtd eee eee 19 4 Figure 19 3 Configuration Screen Page 3 cccccccccccccceccccecsssssssseeeseceeecececceeceeeeceessssesseseceeeeeeeeecs 19 6 TOC 6 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 List of Tables and Figures Table Figure Figure 19 4 Configuration Screen Page 4 ssssssssssssssssssssssssssssssssssseeeeesessasseessssseees Figure 19 5 Configuration Screen Page 5 eee eeee eese eeee sees enn n nnn nhan aa nuuaas Figure 19 6 Configuration Screen Page pD sese esse sese esse essen Figure 20 1 Data Backup Screen Save LOad sss essen Figure 20 2 Data Backup Screen Migrate and Factory Reset eeeeeeeee ST UTS Te Ts Wiha Cea CS CLS CIN sassen nnna EE Eas Figure 22 1 User Access Screen LOG MMi sss ssssssss sss s essen nenen Figure 22 2 User Access Screen Manage ACCOUuntS sss sees eee sees eee Figure 23 1 Help Screen scrsssecsrsveasnseurssrcnsandawnsncnnenvewsbnwnsannaveensnondenstaulnantansseunemaianseswnnnies Figure 23 2 Version Pop Up SOCEM iscissi anaE E vas an Ti RE Figure 24 1 Twin Screw Control Screen esses eese eese essen ee eene nennt annuas Figure 25 1 Cool Com
84. ection 24 Twin Screw Control OV AT rec s IHE Figure 24 1 Twin Screw Control Screen sss sss sees eee eee grise E E E E E E EE m Section 25 Cool Compression Control GUAE TE OU mE sd MT T Figure 25 1 Cool Compression Control SCIEN eoo orsa avs rnv eee Figure 25 2 Cool Compression Control Functions Screen cesses eene EO EDE UT Operational Differences from Single Screw eee eee Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 TOC 5 List of Tables and Figures Table Figure Page Number ie puces M 3 3 Table 3 2 Andlog NPU betae tu S tote TuS ordre pesce pude eter PURI dati oO aria OEE EEEIEE EEVEE RNEER E E ON MR UPC 3 5 EIE ANa OUTPUTS TOUT TETUTUTTTM 3 7 Table 3 4 Analog Input Jumper Tables sss sss sese esse sese 3 12 Table 14 1 Command Shaft Rotation Required By Actuator ccce eene 14 4 Table 14 2 Slide Valve Troubleshooting Guide sss sese sese 14 5 Table 14 3 LED Blink Codes and Troubleshooting Guide cesses 14 7 Table 22 1 Security Access Levels sees eee eee 22 3 Figure 1 1 Operational Flow ChaltScescisestserres eeudt deed hasse ee tty rh ctdeU ev a
85. ed based on the calibration settings made to the actuator Remove Cover Press Down On Photochopper Figure 14 2 Photochopper CAUTION Do not over tigten screws Failure to comply may result in damage to equipment 10 Gently lower the plastic cover to where it contacts the base and O ring seal After making sure that the cover is not binding gently tighten the four 10 Phillips screws 11 Repeat the same procedure for the Volume slide motor 14 3 Section 14 lt 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 Command Shaft Rotation Required By Actuator Command Shaft Rotation Compressor Model NUS Capacity Volume Increase Decrease Increase Decrease CCW N N N 101 C C i o 00 Ccw Ccw Ccw 291 CCW 301 CCW 401 CCW 601 VSM 601 VSS CCW 791 14 4 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 14 lt 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
86. eep the position sensor circuitry alive long enough for the motor to come to a complete stop and then save the motor position to non volatile EEPROM memory When power is restored the saved motor position is read from EEPROM memory and the actuators resumes normal function This scheme is not foolproof If the motor is moved manually while the power is off or the motor brake has failed allowing the motor to free wheel for too long after the position sen sor looses power the actuator will loose its calibrated position A brake failure can sometimes be detected by the po sition sensor If the motor never stops turning after a power loss the position sensor detects this knows it will be lost and goes immediately into calibrate mode when power is restored Slide Valve Actuator Calibration for Optical Style Motors Assuming that the actuator motors have not been cali brated 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 re moving the four 10 Pan Head Phillips screws Gently lift the cover and tilt it toward the TURCK connectors Raise the cover enough to be able to press the blue calibrate button and to be able to see the red LED on the top of the asse
87. elow the Slide setpoint The operator can choose between N O or N C Active Check box to enable the digital output Volume Slide Position Offset These setpoints offer the ability to alter the Volume po sition table to take advantage of potential energy sav ings Since the volume position is a function of the ca pacity 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 por tion using the Capacity Range minimum and maximum setpoints Volume Slide Adjustment The value in percentage of the volume slide offset Capacity Range Defines the range that the volume position slide off set will be applied Soft Load This setpoint is used to slow the loading of the compres sor In some refrigeration systems a loading compres sor can have dramatic effects on the system parameters This setpoint allows an operator to reduce the continu ous load pulse as defined in the proportional control sec tion to a percent duty cycle Soft load Defines the duty cycle of the continuous load pulse At 100 the continuous pulse will truly be continu ous At 50 the continuous pulse would be reduced to half time on and half time off in the time interval defined in the proportional control section Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 6 lt Com
88. emperature calibra tion is set in the calibration screen Discharge Temperature Default signal is RTD Discharge temperature calibra tion is set in the calibration screen Oil Separator Temperature Default signal is RTD Oil separator temperature cali bration is set in the calibration screen Oil Manifold Temperature e Default signal is RTD Oil manifold temperature cali bration is set in the calibration screen Process Temperature e Default signal is 4 20mA Process temperature cali bration and range are set in the calibration screen Chiller Inlet Temperature Default signal is 4 20mA Measures separator level Chiller Inlet Temperature calibration and range are set in the calibration screen Condenser Pressure s Default signal is 4 20mA Condenser pressure trans ducer range and calibration is set in the calibration screen Remote Caphold s Default signal is 4 20mA Active in Direct I O mode Adjusts the capacity of the compressor from 0 100 proportional to the 4 20mA signal Auxiliary 1 16 Flexible analog inputs that can be configured to con trol alarm or trip Analog Outputs Refer to Table 2 3 Analog Outputs Compressor VFD 4 20mA output to control compressor motor speed with a Variable Frequency Drive VFD Condenser VFD s 4 20mA output to control one condenser fan which is interleaved between the remaining condenser steps for smoother control Sli
89. ens will be displayed in Model amp Refrigerant The values in this section provides the Vission 20 20 algorithm critical information on how to efficiently and safely control the compressor see Figure 19 2 Configuration Screen Page 2 Compressor Drop down box to select the compressor type This selection is critical for proper volume slide control Model Drop down box to select the compressor size This selection is critical for proper volume slide control Refrigerant s Drop down box to select the type of refrigerant This selection is critical for proper volume slide control Other K Factor Optional setting to adjust volume slide control 19 3 Section 19 Configuration Compressor Control Vilter compressors typically run in one of two control modes suction pressure or process temperature con trol see Figure 19 2 Configuration Screen Page 2 Suction Pressure Control This defines the suction pressure input as the pro cess variable and all controls will be based on suction pressure The operator has the option to select up to two controllers where each can have its own set of setpoints Process Temp Control This defines the process temperature input as the process variable and all controls will be based on the process temperature The operator has the option to select up to two controllers where each can have its own set of setpoints COTESEERCRMEDCERETERESNTATETUUN E
90. ential of causing intermittent and dangerous problems Please consult your VFD manual 1 Step VFD Control Enables the first step in the VFD control algorithm This check box is not deselectable by the operator Capacity Slide Position s Defines the minimum and maximum positions for the capacity slide While in 1 step control these values should be 0 for minimum and 100 for maximum VFD Speed Defines the minimum and maximum speed for the motor speed While in 1 step control these values should reflect the full range of the VFD 2 Step VFD Control Enablesthe second step in the VFD control algorithm Capacity Slide Position Defines the minimum and maximum position of the capacity slide in the 2 step VFD control VFD Speed Defines the minimum and maximum speed for the motor in the 2 step VFD control P Proportional gain setpoint Used to adjust the motor speed action in direct pro portion to the difference between the control set point and the process variable SP PV error This is a unit less quantity and is used for coarse adjustment This setpoint should be set to the lowest value that gives adequate control system response Increasing the proportional setting increases the control sys tem s sensitivity to small process fluctuations and the tendency to hunt Integral reset setpoint s Used to adjust the capacity control action integrating the error over time to account for a smal
91. er Diff Press Safety Changeover timer expires 60 sec after start Run Oil Press Failure Yes Is Filter Diff gt Hi Filter Diff Press Run Trip Setpt for 5 seconds Oil Separator Temp Safety Changeover Oil Sep Temp gt Lo Oil Sep Run Reset Yes Timer expires 5 min after start N Yes Lo Run Oil Sep Temp Failure Run Filter Diff Press Failure Compressor Amperage Load Limiting High Discharge Pressure Load Limiting Capacity Increase Capacity Increase Yes Disabled Yes WP Disabled Is Motor Amps gt FLA ON Setpt Is Dsch Press gt Cutin ON Setpt No No Is Motor Amps gt FLA OFF Setpt Is Dsch Press gt Cutout OFF Setpt Capacity Decrease Yes until Amps lt FLA x 1 0625 Capacity Decrease until Dsch Press lt ON Setpt x 1 0625 Normal Loading and Normal Loading and Unloading Unloading Figure 1 1 Operational Flow Charts 1 of 2 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 1 1 Section 1 Operational Flow Charts Suction Pressure Override Load Limit During Temperature Control Is Suction Press lt Suct Press Cap Dec OFF Setpt Capacity Increase Yes Disabled No Is Suction Press lt Suct Press Cap Dec ON Setpt Decrease compressor capacity until Suction Press gt Suction Press Cap Decrease ON setpoint Normal Loading and Unlo
92. er of starts per hour before setting an hour to the anti recy cle timer The number of starts is set in the timer page Accumulative immediately adds time to the anti recycle timer once the compressor is started and the time can be set in the timers screen True anti recycle adds to the anti recycle timer once the compressor is shutdown The motor of the compressor can not be restarted as long as there is anti recycle time left and the operator can view this time on the top left corner of the main screen Restart On Power Failure This feature of the Vission 20 20 offers the ability to de fine how the Vission 20 20 will handle a power failure This can also be useful to allow system controller to re gain control of the Vission panel without the need for operator intervention Always When selected initiates a start after the panel pow ers back up after a power failure but only if the com pressor was running before the power failure and starts the compressor in Auto mode Never e When selected prevents any automatic action once the panel powers back up after a power failure Timed When selected initiates a start after the panel pow ers back up after a power failure and the operator set timer runs out When there are multiple compressor in a larger system it is recommended that the opera tor gives each compressor a different start times A restart will only occur if the compressor was running before the power failu
93. ercentage with which a compressor is allowed to run Minimum capacity value takes preference on first step value Max Cap Defines the highest capacity in percentage with which a compressor is allowed to run Maximum ca pacity value takes preference over last step value Machine Start Time e Machine start timer shows the time in seconds that the Master Compressor will hold before starting slave compressor once Start decision is taken Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 10 lt Compressor Sequencing Status Symbols e Status symbols shows status of Slave compressors on the sequencing table Please see Application Notes for more details qP Slave Compressor is detected but is not configured in the sequencing table Default If slave Compressor is not present Slave Compressor is configured in sequencing table but is not configured in Remote mode Slave Compressor configured in sequencing table and is in ready to run state Slave Compressor is running with Alarm condition Slave Compressor stopped due to Error Condition GB lt el LIE Slave Compressor running at maximum capacity without any error 23 Slave Compressor under active control of Master Compressor M Slave Compressor running into its stop timer will be stopped Machine Stop Time Machine Stop timer shows the time in sec that the Master Compressor will hold before stopping sla
94. for con denser control operation the speed of the VFD is con trolled using PID algorithm P Proportional gain Used to adjust the fan speed action in direct propor tion to the difference between the control setpoint and the process variable SP PV error The pro portional term is a unit less quantity and is used for coarse adjustment This setpoint should be set to the lowest value that gives adequate control system re sponse Increasing the proportional setting increases the control system s sensitivity to small process fluc tuations and the tendency to hunt Integral reset e Used to adjust the capacity control action integrat ing the error over time to account for a small er ror that has persisted for a long time This quantity is used for fine adjustment This setpoint is used to Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 smooth out process variations This setpoint should be set high enough to prevent hunting but not too high or it will cause control system overshoot D Derivative rate Used to adjust the capacity control action account ing for how fast the error is changing positively or negatively Maximum Speed e This setpoint defines the maximum speed in percent age for Condenser VFD Fan at which it should run for continuous step delay time to increase condens er steps E g let s say setpoint is kept at 95 Then condenser VFD fan wil
95. from a USB flash drive back to the Vission 20 20 Save Selecting save allows the operator to save the Vission 20 20 data to a USB flash drive using the information provided further down the screen The bottom but ton will be labeled Save when this is selected 12 4 Psig A Capacity Slide 0 0 96 Volume Slide Back t Suction Press Control Setpoint 20 0 Psig Suction Press emp Maintenance 32 4 Psig 48 6 F v Trend Chart Discharge Press emp 100 2 Psig 122 9 F Oil Press Diff 128 3 Psig ilter Diff 8 8 Psig Inj Temp 99 1 F Sep Temp 115 8 F User Vilter 01 02 2002 12 53 20 Run Hours o d Le d Ta Amperage 0 0 Amps Figure 20 1 Data Backup Screen Save Load Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 20 1 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 in formation 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 If the USB flash drive that is plugged in by the operator is not showing up then the operator
96. gure 3 5 Digital Input Output Board Layout sss esse sese e sees eee 3 10 Analog Input Boards e mc 3 11 Figure 3 6 Analog Input Board Layout esse essen 3 11 Analog Input Jumper Tables coo eee V pe ER eee eee 3 12 Table 3 4 Analog Input Jumper Tables ssssssssecceeccceccecceeeeccessssesssseeeceecceceseeseeeeacsessssesessees 3 12 LT T ssa E STE E DD 3 14 Figure 3 6 Analog Output Board Layout sss essen 3 14 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 TOC 1 Table of Contents Section Title Section Number Section 4 Main Screen gu Me aes 4 1 Figure 4 1 Digital I O Board PAV OUE sss sss esse esse 4 1 WO SENS T sas see ernst aw enee 4 2 Figure d27 TOD Status IDEE crosa eE E ENEE E 4 2 EAE E E E AEE E EE I ES E A EE AA E E E A E A 4 3 Figure 4 3 TTS 9 T 4 3 Figure 4 4 Unit Start Pop Up WINGOW sss sss sss sees 4 4 BOCCO SCAU T E se rececuseeenacacancu cent E E E 4 5 Figure 4 5 Botiom Statis Bar areca etter atta eee net ede A ASEN Era EAEra EEEREN 4 5 LETS PESTS K EEA E T N E A E E AEA AE S E A T 4 6 Figure 4 6 Splash SEPT HH 4 6 Section 5 Menu Screen BT 5 1 Navigator BUT OM S 055292 5 2 928 00 00085592 0 92 0 2 5 05929 6t suas bue Lead EE 5 1 Figure H Menu SCEE NE RT 5 2 GPL M E E E
97. harge pressure trans ducer range and calibration is set in the calibration screen Oil Filter Inlet Pressure e Default signal is 4 20mA Oil filter pressure trans ducer range and calibration is set in the calibration screen Oil Manifold Pressure e Default signal is 4 20mA Oil manifold pressure trans ducer range and calibration is set in the calibration screen Economizer Pressure s Default signal is 4 20mA Economizer pressure trans ducer range and calibration is set in the calibration screen Slide Valve Position Reads the 0 5 volt signal back from the slide posi tion motor actuator to indicate current slide valve position Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 3 Hardware Architecture Board 5 Table 3 1 Digital I O 2 of 2 IIO Description Auxiliary Output 1 Auxiliary Output 2 Auxiliary Output 3 Table 3 2 Analog Inputs 1 of 2 i I I i i i Type OUTPUT OUTPUT OUTPUT OUTPUT INPUT INPUT INPUT INPUT Board IJ O 2 Description Type 6 1 Motor Current 4 20 mA 0 5A s 2 Sones U5X15V0 0V420mA s 3 bsdwgemesue 05V15V0 0V420m s 4 Joiner inetPressre 05V15V030420m s 5 Tamas 05V15V0 10V 4120m amp s 6 economizer Pressure 05V 15v 0 0V 420m
98. he first screen encountered when powering up the Vission 20 20 Panel see Figure 4 1 Main Screen This screen is designed as the starting point for all succeeding screens and provides as much in formation as possible at a glance The Main Screen is di vided into four sections Three of the sections are static Suction Pressure 1 Stopped Anti Recycle 00 00 Oil Pump Off Oil Heater Off Remote Lock Out On 56 2 Psig 34 0 F 58 2 Psig 139 8 F In 58 5 Psig Out 57 7 Psig Diff 0 8 Psig 112 1 F Maintenance User Access No Scheduled Maintenance No Alarm Trips Present Top Status Bar Bottom Status Bar and Parameters Bar These three sections of the main screen will remain vis ible while navigating through other screens and provide a constant view of critical information The splash screen is the only dynamic section All navigation to any other screens will be performed through the Main Screen 36 2 PsigA Capacity Slide Volume Slide 4 8 9 Suction Press Control 20 0 Psig Suction 56 2 Psig 34 0 F 58 2 Psig emp 139 8 F ess Diff 1 5 Psig Filter Diff 0 8 Psig 118 1 F Sep Temp 112 1 F User 08 17 2011 10 47 57 Run Hours Figure 4 1 Main Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 4 1 Section 4 s Main Screen Top Status Bar The standard view of the status bar shows three pieces of informat
99. her on or off See board layout Figure 3 5 output board and the Vission 20 20 CPU board Digital Input Output Board Layout 3 pu P Address Dipswitches e Marked in the diagram below in Red These dipswitch Signal LEDs es are used to assign each board its address position Marked in the diagram below in Blue or outputs and The addresses are binary and therefore the address light blue for inputs These LEDs indicate when a of a digital output board will either be address as 4 120Vac output is being produced or a 120Vac signal 0100 or 5 0101 is detected R 0000 GND GA 24 VDC E T OIIO RA VDC 1 4 o00uF 3le3t 9 5 MS RE12001 RE12001 ULN2803 RE12001 RE12001 PIC16F876SP L 0000000000000 cg OJro lur C10 OJAro TE M SERIAL NENNEN 325 046 0012 1 24V GND 25m 0000 Figure 3 5 Digital Input Output Board Layout C11 OJrFo ul 3 10 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 3 Hardware Architecture Analog Input Boards The analog input board convert varying DC signals into a signal that can interpreted by the Vission 20 20 pro gram The signals are considered analog because the input DC signal can vary from the minimum value to the maximum value See board layout Figure 3 6 Analog Input Board Layout Configuration Jumpers Marked in the diagram below in Purple The jumpers allow
100. ic operation of condenser con trol selected when control of the condenser is re quired to run even when the compressor is off Manual Mode for controlling condenser control op eration manually Operator controls the operation by manual stepping using an on off toggle button at each step Capacity Slide Suction Press Control Setpoint 20 0 Psig Suction ress emp 56 3 Psig 33 1 F eee Discharge Press emp OFF OFF OFF OFF OFF 68 3 Psig 138 7 F Oil ress Diff 11 2 Psig ilter Diff 1 0 Psig Inj Temp 118 1 F Sep Temp 112 4 F User 08 19 2011 04 30 22 i Motor Amperage 0 0 Amps Run Hours Figure 11 1 Condenser Control Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 11 1 11 Section 11 Condenser Control Condenser Press This is the read only parameter and it displays the present value of condenser pressure Condenser Setpoint Thisis the condenser pressure setpoint that needs to be maintained Upper Deadband This is the condenser pressure setpoint upper dead band value No additional condenser capacity is add ed when the condenser is selected for automatic step control and the condenser pressure falls within this deadband Lower Deadband This is the condenser pressure setpoint lower dead band value Condenser capacity is not reduced when the condenser is selected for automatic step contr
101. igh Discharge Pressure Alarm amp Trip e 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 Low Process Temperature Alarm amp Trip e This is the low control temperature safety This safety is active when process temperature control has been 36 1 Psig A Capacity Slide Volume Slide 47 Suction Press Control Setpoint 20 0 Psig Suction Press 56 1 Psig emp 33 3 F Discharge Press 58 1 Psig emp pk Ba B a Menu a EN Oil Press Diff 1 4 Psig Filter Diff 0 4 Psig User Lev2 Inj Temp 118 3 F Sep Temp 112 8 F 08 17 2011 10 50 31 Run Hours 31 Motor Amperage 0 0 Amps Figure 7 1 Alarms and Trips Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 7 2 Section 7 Alarms and Trips selected in the Control Mode dropdown selection found in the Compressor Control screen An alarm or trip will be activated on a drop in process tempera ture below the setpoint value Low Suction Temperature Alarm amp Trip Thisis the low suction temperature safety The alarm or trip will be activated if the suction temperature drops below the setpoint value High Discharge Temperature Alarm
102. ignal LEDs Marked in the diagram below in light Blue These LEDs indicated when a 120Vac input is detected Voltage LEDs Marked in the diagram below in Orange These LEDs indicated the correct voltage of both the 5Vdc and 24Vdc power sources Communication LEDs Marked in the diagram below in Green These LEDs Show the active communications between the digi tal output board and the Vission 20 20 CPU board Address Dipswitches Marked in the diagram below in Red These dip switches are used to assign each board its address position The addresses are binary and therefor the address of a digital input board can only be addressed as 3 0011 lel 1 ole 2 e 3 ollo 4 cle 5 J9 c5 00uF of px 325 046 0011 24V GND Figure 3 4 Digital Input Board Layout Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 3 9 Section 3 Hardware Architecture Digital In Out Boards Voltage LEDs Marked in the diagram below in Orange These LEDs The digital input output board convert signals gener indicated the correct voltage of both the 5Vdc and ated by the Vission 20 20 program into 120Vac signals 24N dc power sources as well as detect external 120Vac inputs to signal the Communication LEDs ME Marked in the diagram below in Green These LEDs All the signals are digital in that the only two states avail show the active communications between the digital able or eit
103. ignal sent by the instrument Default Devices s By selecting this option the operator will have access via a drop down box of several common devices The Suction Pressure 1 SLOopped 37 5 Psig A Capacity Slide Calibrated Value 57 5 Psi Volume Slide Suction Press Control Setpoint 20 0 Psig Adjustment Total Offset Suction Press emp 57 5 Psig 36 0 F Discharge Press 59 1 Psig emp 140 9 F Oil ress Diff 0 9 Psig ilter Diff 0 6 Psig Inj Temp 120 6 F Sep Temp 114 7 F User 08 19 2011 10 49 52 Run Hours 31 Motor Amperage 0 0 Amps Figure 13 1 Instruments Calibration Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 13 1 13 2 Section 13 s Instruments Calibration devices are predefined and if one is selected then all the setpoints will be set for the operator Custom Device This option allows the operator to choose the mini mum and maximum value of the instrument being used Offset Oncethe 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 Range This option is available when the cu
104. ing The section defines how the Vission 20 20 will monitor and or control the temperature of the compressor oil see Figure 19 2 Configuration Screen Page 2 Thermosyphon This defines the compressor oil cooling method as thermosyphon H20 Oil Cooler This defines the compressor oil cooling method as water heat exchange Liquid Injection This defines the compressor oil cooling method as liquid refrigerant injection Solenoids e Enables the solenoid for liquid injection control Motorized Valve Enables the motorized value for liquid injection con trolled by PID settings 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 Configuration Screen Page 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 5 Section 19 Configuration Digital Inputs The Vission 20 20 has several digital inputs that the op erator can choose how the input will be used Once an input is enabled the Auxiliary I O screen will be avail able from the menu screen where the operator can further define the inputs operation see Figure 19 3 Configuration Screen Page 3 Enable Input Enablesthe selected digital input Set Name e Allows the operator to assign a name to
105. ing Continued memory has failed P i The photochopper is misaligned with theslotted optocouplers Try to realign or replace the actuator Adjust the photochopper so that the fence extends further into the optocoupler slots A motor bearing has failed Replace the actuator There is a loose connection in the Tighten screw terminal blocks There is a rapid clicking noise when the motor is operating The photochopper is positioned too low on the motor shaft EM There is a loose or dirty connection Clar nd wanton The motor operates in one direction l a the yellow Turck cable g only y The position sensor has failed Replace the actuator There is a broken motor lead or As Replace the actuator winding The motor will resume operation The thermal switch has tripped be when it cools This could be caused cause the motor is overheated by a malfunctioning control panel The motor will not move in either ot ee direction Any of the reasons listed in The mo See above tor operates in one direction only The command shaft is jammed Free the command shaft Broken gears in the gear motor Replace the actuator The motor runs intermittently This could be caused by a malfunc l Motor is overheating and the ther un eek several minutes on several minutes mal switch is tripping tioning control panel Consult the off factory Bad thermal switch Replace the actuator The motor runs sporadically Any
106. int the oil heater will turn on Note there is a 5 F differen tial associated with this setpoint For example when set at 100 F the heater will turn on at 95 F and off at 105 F Liquid Injection The setpoints is this section are to control the behavior of the liquid refrigerant injected into the compressor for oil cooling purposes The liquid injection solenoid con trol is based off of discharge temperature whether the compressor uses just an injection solenoid or a motor ized valve in conjunction with the solenoid Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Liquid Injection Solenoid Control ONLY e When using only the liquid injection solenoid the so lenoid is activated once the value of discharge tem perature meets or exceeds the value of Liquid inj Setpoint 1 and the value of oil separator tempera ture meets or exceeds the value of Oil Sep Temp Override The injection solenoid will deactivate if either of setpoints are not met This will prevent situ ations where the discharge temperature may rise quickly but the oil temperature is still very cold By preventing the liquid injection solenoid from turning on at this point the oil separator will not be subjected to additional liquid refrigerant that would cool the oil even further Liquid Injection Control using a 4 20ma motorized valve e When a motorized valve is used to control the amount of liquid being inje
107. int to define an area within the mechani cal 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 soft ware limits are set to 150mV from either end point The position percentage is calculated from the soft ware 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 Slide Valve Operation The slide valve actuator is a gear motor with a position sensor The motor is powered in the forward and reverse directions from the main computer in the control panel The position sensor tells the main computer the position of the slide valve The main computer uses the position and process information to decide where to move the slide valve next During calibration the position sensor records the high and low count of motor turns The operator tells the position sensor when the actuator is at the high or low position with the push button Refer to the calibration instructions for the detailed calibration procedure The position sensor can get lost if the motor is moved while the position sensor is not powered To prevent this the motor can only be moved electrically while the position sensor is powered When the position sen sor loses power power is cut to the motor A capaci tor stores enough energy to k
108. ion From leftto right the bar shows the con trol method the current run mode and the difference between the desired control setpoint and the actual value of the processes control value see Figure 4 2 Top Status Bar The status bar also has an alternate function where it dis plays to the user any information that requires user at tention or intervention It accomplishes this by changing the status bar s color and or flashing a additional infor mation bars over the standard status bar view Standard Bar blue e Indicates a condition where the compressor motor is not running Standard Bar green e Informs the operator that the compressor motor is currently running Information Bars will flash their information over the top of the status bar The operator will see the status bar and then one or more information bars in a repetitive sequence Information Bar blue Shows various operational modes that are different than normal running condition An example of this would be a load limit condition The compressor is not able to completely load due to some parameter like high motor current and therefore the operator is notified via this type of information bar Information bar yellow This typically indicates an Alarm condition Alarm conditions do not stop the compressor but it is meant to alert the operator of conditions that if corrective action is not taken then a compressor trip can result Information b
109. ion available is provide by two status bars one for maintenance activities and the other for any alarms or trips that might be active To the right of the status bars are positions for displaying the cur rent user if any are logged in the date and time and the total run hours of the compressor User 08 17 2011 10 47 57 Run Hours 31 Figure 4 5 Bottom Status Bar Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 4 s Main Screen Splash Screen The splash screen is the dynamic portion of the screen that will change as the operator navigates through the Vission 20 20 panel screen see Figure 4 6 Splash Screen The main screen shows a graphic of a Vilter com pressor with a number of data boxes spread across the screen Also on the top left are several indicators Discharge s Displays the discharge pressure and temperature Oil Filter Displays the oil filter inlet pressure oil filter outlet pressure and oil differential pressure across the oil filter Suction Displays the suction pressure and temperature Motor Displays the motor current When the motor VFD is enabled this box will also display the motor RPM Separator Displays the temperature of the oil in the separator 76 Cap Displays the position of the capacity slide from 0 to 100 Suction 56 2 Psig 34 0 F Discharge Motor 58 2 Psig Oil Filter In 58 5 Psig Out 57 7 Psig Diff 0 8 Psig
110. is 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 amp Trip This safety allows a higher than normal filter differ ential pressure to exist during the first minute after a compressor starts This allows time for cold oil that is present in the oil piping and filters to be passed and replaced with warmer oil After a time delay set ting of the Filter Diff Pressure Safety Changeover timer this safety is deactivated and the High Filter Differential Pressure Run alarm and safety setpoints become active An alarm or trip will be active if the filter differential Filter Inlet Pressure minus Filter Outlet Pressure exceeds the setpoint value High Filter Differential Pressure Run Alarm amp Trip e This safety setpoint is active when the compres sor has started and the Filter Diff Pressure Safety Changeover timer has timed out An alarm or trip will be active if the filter differential Filter Inlet Pressure minus Filter Outlet Pressure exceeds by the setpoint value High Motor Amps e This safety setpoint is active after the Volume Decrease At Start Timer expires this timer is not set table by the operator A trip will occur if the motor amperage exceeds the safety setpoint value For a motor with a 1 15 Service Factor the trip setpoint should be set at 125 of the motor full load amper age value The a
111. l Power Up Power Up Power Up Power Up Power Up Power Up Power Up Ment User 08 19 2011 03 53 24 Run Hours 31 Figure 16 1 Event List Screen 16 1 16 2 Blank Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 17 Input Output Overview This screen displays Live Data of all the analog points and digital points being monitored see Figure 17 1 Input Output Screen There are four pages of Input Outputs I O available for viewing This screen also takes a snapshot of all the I O points if the compressor experiences a trip condition and saves this data as Freeze pages Up to five Freeze pages can be saved The oldest Freeze page will be removed when more than five Freeze events occur These Freeze events can be downloaded to a USB drive though the Data Backup screen Suction Pressure 1 Stopped 35 9 Psig A Capacity Slide i ew aa E 08 19 2011 03 53 06 PM 08 19 2011 03 52 18 PM 08 19 2011 03 51 47 PM 08 19 2011 03 50 55 PM 08 19 2011 03 50 08 PM 08 19 2011 03 48 39 PM 08 19 2011 03 25 04 PM 08 19 2011 03 25 04 PM 08 19 2011 03 21 05 PM 08 19 2011 02 25 46 PM 08 19 2011 02 24 22 PM 08 19 2011 02 22 12 PM 08 19 2011 02 21 06 PM 08 19 2011 02 20 06 PM 08 19 2011 02 19 01 PM 08 19 2011 02 18 20 PM 08 19 2011 02 17 40 PM Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Power Up Power Up Power Up Powe
112. l be green in color While trend feature is running button will display Stop and will be red in color When Stop button is pressed trend data is saved to a file Zoom In Out These buttons allow the operator to adjust the num ber of data points plotted on the screen At maximum 35 7 Psig 60 3 F 88 3 Psig 63 0 F 26 8 Psig Bu 66 2 Psig naf 17 9 Psig 30 1 F 44 2 Psig Tem 8 9 Psig PACK 22 1 Psig debui 0 0 Psig oan 0 0 Psig 9 03 0 02 5 0 02 0 01 5 0 01 0 00 5 0 00 e Suction Press v Discharge Press vw No Scheduled Maintenance User 01 01 2002 Maintenance Te galla Figure 15 1 Trend Chart Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Suction Temp v 12 08 09 No Alarm Trips Present Run Hours U Capacity Slide 0 0 T Volume Slide 4 1 Suction Press Control Setpoint 20 0 Psig Suction Press emp 35 5 Psig 48 4 F Discharge Press emp 80 3 Psig 42 2 F Oil Press Diff 125 3 Psig ilter Diff 8 6 Psig Inj Temp 108 5 F Sep Temp 110 1 F Motor perage 0 0 Amps 15 1 15 2 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 button
113. l error that has persisted for along time This quantity is used for fine adjustment This setpoint is used to smooth out process variations This setpoint should be set high enough to prevent hunting but low enough to pre vent control system overshoot D Derivative rate setpoint e Used to adjust the capacity control action accounting for how fast the error is changing positively or nega tively A standard PID loop variable it is not used for our applications Pumpdown Control The Pumpdown Control defines a method of pumping down a chiller which is to draw off refrigerant from the chiller This feature can be enabled or disabled from this menu which is the part of Compressor Control Screen If Pumpdown is enabled this feature will only function when the compressor is running in local Auto Mode and Control Mode Configured is Suction Pressure If Pumpdown Feature is enabled then The Auto cycle functionality is ignored Pumpdown mode will cause the compressor to cycle off via the Pumpdown Stop Pressure setpoint Normally the Pumpdown Stop Pressure setpoint will be set lower than the Auto cycle Stop setpoint Therefore as the suction pressure is pulled down the compressor is prevented from shutting down prematurely via the Auto cycle Stop setpoint by automatically ignoring the Auto cycle feature The compressor will be placed into Stop mode af ter the suction pressure is equal to or goes below the P
114. l have to run at speed of 95 or more to advance to next step Maximum Speed can be set as 100 which is when analog output at which condenser VFD fan is connected reaches to 20mA in its normal range of 4 20 mA Minimum Speed e This setpoint defines the minimum speed in percent age for Condenser VFD Fan at which it should run for continuous step delay time to decrease condenser steps E g let s say setpoint is kept at 5 Then con denser VFD fan will have to run at speed 5 or less to advance to next step Minimum Speed can be set as 0 which is when analog output at which condens er VFD fan is connected reaches 4mA in its normal range of 4 20 mA 11 3 11 4 Blank Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 12 Service Options Overview Compressor Start Activatesthe output assigned to the compressor mo The Service Option screen allows the operator the abil tor starter The output is connected to terminal 11 ity to force individual digital or analog outputs ON This and is the 1st LED on card 1 feature is used for diagnostic purposes during initial Oil Pump Start setup and or if the operator suspects an issue with the P outputs The buttons in this screen are not available Activates the output assigned to the oil pump The while the compressor is running see Figure 12 1 Service output is connected to terminal 12 and is the 2nd Options Screen LED down on
115. larm setpoint should be set at 120 of the motor full load amperage value Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 7 Alarms and Trips Compressor Inhibits The Vission 20 20 uses several start inhibits to prevent the compressor from starting to protect the compres sor and the refrigeration system While starting the compressor the inhibits are checked first before the oil pump is started or the motor is started The failed starts due to an inhibit does not count toward any of the anti recycle timers including hot starts The Inhibits uses the alarm setpoint to trigger an aborted start and message All inhibits will be logged in the event list Safety Failure Messages Low Suction Pressure Trip This message will appear when the suction pressure falls below the safety setting of the Low Suction Pres sure Trip Setpoint No 1 or No 2 High Discharge Pressure Trip This message will appear when the discharge pres sure exceeds the safety setting of the Hi Dsch Press Trip Setpoint No 1 or No 2 Low Suction Temp Trip This message will appear when the suction tempera ture falls below the safety setting of the Low Suction Temperature Trip setpoint High Discharge Temp Trip This message will appear when the discharge tem perature rises above the safety setting of the High Discharge Temperature Trip setpoint Low Oil Separator Temp Trip This message will ap
116. ling etOi TTE 9 1 Figure 9 1 Compressor Scheduling Screen sss sees eee eee eee 9 1 TOC 2 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Table of Contents Section Title Section Number Section 10 Compressor Sequencing VETVE aca esiies 10 1 Pressure Control 5El DONTE S tssxscacceinassnvaczatsoanvectosszusnvenciesouess ured TENEN i 10 1 Figure 10 1 Compressor SEQUENCING Screen sss ss sss sss sss sss sss sesa egas neesan aaaea n aaaeeeaa aaaeeeaa 10 1 Section 11 Condenser Control Sua T M 11 1 Condenser RTA STR R eT v PLI TISSU PIE UFU NV ris a E TUE Us EE E TUS SOUL UN ONU ERU EVI METODI RENE US 11 1 Figure 11 1 Condenser Control Screen sss esse sese 11 1 EE ONIUL ON e 11 2 Figure 11 2 Step Control Screen cosetacacesieccdesucuslaetstleassia reese cneneriondundssnoneusenso ueitendusdvons uusetsrnintacsnuntenes 11 3 VFO SETIO cd EE E E AEA E E O RE 11 3 Section 12 Service Options giu Mt E 12 1 Digar ROTE eT TT m 12 1 Figure 12 1 Service Options Screen E 12 1 AST eT Ke Heer ra E A E E E E EET 12 2 Section 13 Instruments Calibration ga T m P 13 1 Pressure and Temperature Inputs sese eee 13 1 Figure 13 1 Instru
117. lt in serial port P12 or through one of the USB ports This drop down box allows the operator to chose which one will be used Baud Rate Setsthe Baud Rate for the serial communication Data Bits s Fixed at 8 Data bits Stop Bits Identifies the end of character for re synchronizing Parity Identifies the type of error detection Ethernet Enables the Ethernet port Once selected the re mainder of the Ethernet setpoints will be available for editing Panel ID Panel Identifier used by the controller when commu nicating with multiple panels IP Address e Entry box to set the IP address Subnet Mask e Entry box to set the Subnet Mask Gateway e Entry box to set the Gateway address Protocol s Drop down box to select the type of protocol used to remotely control the Vission 20 20 Touchscreen The Calibrate button changes the screen into touch screen calibration mode Calibrating the touchscreen is only required if the operator finds that the pointer ar row no longer follows his finger The calibration mode requires the operator to touch the four corners of the touchscreen and then the accept button Anti Recycle Anti Recycle defines the method of motor protection Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 19 Configuration due to repeated motor starts The operator has 3 choices of protection Hot starts allows only a certain numb
118. mbly see Figure 14 2 Photochopper 2 Remove actuator motor cover s 3 Log In on the Vission 20 20 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 14 lt Slide Calibration 4 From the main screen select the Menu button 5 On the menu screen select the Slide Calibration but ton When the Slide Valve Calibration screen appears then you can safely connect the Power Cable Yellow TURCK cable and the Position Transmitter Cable Gray TURCK cable to the Capacity motor Press or to move the slide valves to check the rotation See Table 1 below for proper shaft rotation If for any reason the or command on the panel does not correspond to the slide increase or decrease swap the blue amp brown wires of the Yellow TURCK cable in the control panel to reverse the rotation of the motor CAUTION DO NOT CONTINUE TO ENERGIZE THE ACTUATOR MOTOR AFTER THE SLIDE HAS REACHED THE MECHANICAL STOP Doing so may cause mechanical damage to the motor or shear the motor shaft key When the slide has reached the mechanical stop position press the button in the center of the photochopper to release the brake and thereby release the tension on the actuator motor 6 Quickly press and release the BLUE CALIBRATION BUTTON on the ACTUATOR motor once This instructs the ACTUATOR motor to enter the calibration mode The red LED on the actuator control board will begin
119. mechanical stops which could result ina 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 val ue greater than 100 or less than 0 if inertial carries the slides after these limits are reached Volume Slide Valve Potentiometer This section provided critical information and con trol parameters related to the volume slide actuator The Vol display shows the actual value in percent of the volume slide with out any conditioning that might be applied to the other volume position dis plays In addition this section displays the value of the actuator signals in millivolts in the input Value display box Button When the operator presses and holds this button the output associated with volume slide decreases is energized If the actuator does not turn in the cor rect direction when this button is pressed then the operator will have to alter how the actuator is wired to the panel Button When the operator presses and holds this button the output associated with volume slide increase is energized If the actuator does not turn in the cor rect direction when this button is pressed then the operator will have to alter how the actuator is wired to the panel Software limit setpoint The Vission 20 20 uses the Min Limit and Max Limit setpo
120. ments Calibration Screen cesses sese eee eee 13 1 iis so p UNGAR er 13 2 PETTUS prs al EHH 13 2 LST eee T 13 2 Section 14 Slide Calibration giu cr 14 1 Capacity Slide Valve PoLebptlOFmgEel uoo eecid av eR aeo EYE Uv dr poete k kx bn rb PE VEERRV VPE ERE VER P UE EE FEE UNA abERUA 14 1 Figure 14 1 Slide Calibration Screen sss sese eee eee 14 1 Volume Slide Valve Potentiometer oi cosdantosudtaecasiscosesucnstonsubdescsiusdsledeoinerteusesasbrastuaesinbesehenvarccisoteasetenes 14 2 side Vilve eT Ta 14 2 Slide Valve Actuator Calibration for Optical Style MOtOFS cccccccccccccecceeeessssssseeesceeeceeeceeeeeeeees 14 2 Figure 14 2 Te sse 14 3 Command Shaft Rota HON iune a EEE EEEE 14 4 Table 14 1 Command Shaft Rotation Required By Actuator ccce eee 14 4 Slide Valve Troubleshooting Guide sss essen 14 5 Table 14 2 Slide Valve Troubleshooting Guide sss sese sese 14 5 Slide Valve Actuator Troubleshooting Guide Blink Code cccccccccccccccececeeesssssssseceeceeeeceeeceeeeeens 14 7 Table 14 3 LED Blink Codes and Troubleshooting Guide eese 14 7 Section 15 Trend Chart giu qc Y Y 15 1 acid SION Nm 15 1 Figure 15 1 Trend Chart Screen sees esse es
121. mp is the temperature of the The parameter boxes provide updated data on sev oil at the oil injection port and Sep Temp is the eral key control parameters temperature of the oil in the separator he top box indicates the desired control hecotorbocsbowethemotercmrant setpoint that is set in the Compressor Control Screen In the case that the Run mode is in re mote capacity control this box will show the desired capacity position Capacity Slide Auto Manual Remote Volume Slide 4 8 96 Auto Seq Cancel Figure 4 4 Unit Start Pop Up Window 4 4 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 4 s Main Screen Bottom Status Bar The bottom status bar gives the operator easy access to some basic functions and information The functions are available via the four button see Figure 4 5 Bottom Status Bar Maintenance Button Pressing the maintenance button will give the op erator 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 Log off Button Pressing the log off button logs off the correct user if any are logged in Help Button Pressing the help button takes the operator to the help screen where the operator can access an opera tion and service manual and also get access to pro gram information Status Bars e The informat
122. n choose how the output will be used Once an output is enabled the Auxiliary I O screen will be available from the menu screen where the operator can further define the outputs operation see Figure 19 5 Configuration Screen Page 5 Enable Output e Enables the selected digital output Set Name e Allows the operator to assign a name to the output Enable Output 3 Set Name analog Aux out 3 Enable Output 4 Set Name Analog Aux out 4 Enable Output 3 Set Name Digital Aux out 3 Enable Output 4 Set Name Digital Aux out 4 19 8 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 19 Configuration I O Configuration 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 se lected see Figure 19 6 Configuration Screen Page 6 Digital Output 1 Not editable by the operator Identifies that the Digital Output card 1 is enabled Digital Output 2 Not editable by the operator Identifies that the Digital Output card 2 is enabled Digital Input 1 Not editable by the operator Identifies that the Digital Input card 1 is enabled VO Configuration Digital Output 1 Digital Output 2 Digital Input 1 Digital Input Output 1 v Digital Input O
123. ne Figure 19 2 Configuration Screen Page 2 19 4 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 19 Configuration Condenser Control The values in this section enables the condenser con trol feature of the Vission 20 20 Once selected the checkboxes will become available for selection and the condenser control screen will be available via the menu screen Some of the options check boxes in this section may not be available for selection unless the proper I O cards are installed and enabled see Figure 19 2 Configuration Screen Page 2 Ambient Sensor Enables the ambient temperature option for the con denser control algorithm Wetbulb Sensor Enables the wetbulb temperature override option for the condenser control algorithm VFD Fan Enables the VFD output option for the condenser control algorithm Oil Pump This section defines how the Vission 20 20 will control the oil pump see Figure 19 2 Configuration Screen Page 2 No Pump Disables all functions for oil pump control Cycling Enables option for cycling oil pump Oil pump is cy cled on and off depending on compressor differential pressure Full Time Enables option for full time oil pump Oil pump will always be running while the compressor is running Pumps Notcurrently used Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Oil Cool
124. next fan or pump is turned on This method allows the smoothest condenser control by spacing the VFD between the fan and pump steps while maintaining a condenser pressure that matches the setpoint Run Mode Condenser Press 1224 Psig Ambient Temp Run Never Condenser Setpoint 220 0 Psig Wetbulb Temp O Run With Comp O Run Always Upper Deadband s 0 Psig Wetbulb Offset 5 0 F l Volume Slide J Manual Lower Deadband 5 0 Psig Switch Temp 32 0 F Profile High to Low Speed Fan Delay fas sec _ Wettbulb Override Step Control Summer Winter Auto Switch Summer v Steps Out 1 Out 2 Out 3 Out 4 VFD Step Delay Low Speed Fan Control StepT T L L fas sec None v Step 2 B B fas sec None v Step 3 L E B m fas sec None iy step4 LJ L fas sec None v Step 5 L L L i m fis sec None v Maintenance User Access No Scheduled Maintenance No Alarm Trips Present Condenser Control Setpoint Run Mode Run Mode allows the selection of different modes of op eration for condenser control The choices for selection are Run Never The mode of operation by default Condenser Control operation will not be performed when this mode is active Run With Comp Automatic operation of condenser control selected when control of the condenser is re quired to only run when the compressor is running Run Always Automat
125. ng as a de vice is connected to the associated input there will be a value in this display box The Calibrated Value dis play box shows the end result of the calibration process Therefore any changes to the calibration setpoint will effect what value is shown see Figure 13 1 Instruments Calibration Screen All instruments are calibrated using a two point linear Analog Inputs eei en inn n tmt ettet rar natn in tn tette nte nettes 1 0 _ Suction Press er 1383 Discharge Press Oil Filter In Press Device Calibration De Default Devices Oil Manifold Press Condenser Press 0 414 5 psia 4 20ma ha Economizer Press Custom Device Min 147 Psig Max 400 Psig E No Alarm Trips Present Channel Calibration Offset Range I O jumpers selection 4ma 20ma v No Scheduled Maintenance calibration process Any device that has a non linear re sponse to environmental stimuli will not be able to be calibrated through the Vission 20 20 Pressure and Temperature Inputs The most commonly used instruments are tempera ture and pressure sensors The first two pages of the Instrument Calibration screen are dedicated to these instruments Each tab on these two pages are divided into two sec tions Device Calibration and Channel Calibration The device calibration section is where the operation param eters of the instrument is defined The channel calibra tion defines the type of s
126. njection Temp Trip This message will appear when the Oil Injection tem perature falls belowthe 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 High Oil Injection Temp Trip This message will appear when the Oil Injection temperature rises above the High Oil Injection Temperature trip setpoint High Filter Differential Trip This message will appear if the Filter Differential Pressure rises above the High Fltr Diff Press Start setpoint before the Filter Differential Pressure Safety Changeover timer times out High Filter Differential Trip This message will appear if the Filter Differential pressure rises above the High Fltr Diff Press Run setpoint after the Filter Differential Pressure Safety Changeover timer times out High Motor Current Trip This message will appear if the motor amperage rises above the Hi Motor Amps trip setpoint Compressor Interlock Trip This message will appear if the Motor Auxiliary con tact fails to close before the Compressor Starter Auxiliary Contact Bypass timer times out Refer to wiring diagram High Level Shutdown Trip This message will appear when power is removed fromthe input module that is designated as Auxiliary 1 Safety please refer to your wiring diagram 7 3 Section 7
127. nol ogy with a Linux operating system For hardware archi tecture see Figure 3 1 Hardware Architecture Overview The Vission 20 20 has the following attributes Low power Industrial rated X 86 CPU 15 XGA high resolution LCD display Outdoor view able LCD optional 8 wire touch screen operator interface Flexible and expandable I O NEMA 4 enclosure NEMA 4X optional Industrial temperature range design Touch Screen DC Power Figure 3 1 Hardware Architecture Overview Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 3 Hardware Architecture Digital Input Output I O Refer to Table 2 1 Digital I O 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 Oil Pump Start Output Whenthe Vission 20 20 signals the oil pump to start this output is energized When the Vission 20 20 sig nals the oil pump to stop this output is de energized Capacity Increase Output This output is only active when the compressor is running When the Vission 20 20 determines that the compressor should increase capacity by moving the slide valve to a higher percentage this output is energized Once the slide valve reaches 100 this output will not energize Capacity Decrease Output This output is only active when the compre
128. nputs or digital inputs Trigger value and differential in combination with trigger type enable if above On or enable if below Off enables or disables auxiliary output Control Auxiliary outputs can be PID Controlled or Scalable Controlled P Proportional gain Used to adjust the auxiliary output in direct propor tion to the difference between the control setpoint and the active input The proportional term is a unit less quantity and is used for coarse adjustment This Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 setpoint should be set to the lowest value that gives adequate control system response Increasing the proportional setting increases the control system s sensitivity to small process fluctuations and the ten dency to hunt Integral reset Used to integrate the error over time to account for a small error that has persisted for a long time This quantity is used for fine adjustment This setpoint is used to smooth out process variations This setpoint should be set high enough to prevent hunting but not too high orit will cause control system overshoot D Derivative rate Used to account for how fast the error is changing positively or negatively Scalable Control Minimum Input Maximum Input hese setpoints defines minimum and maxi mum Input range for configured active input Minimum Output Maximum Output hese setp
129. ob lem analysis or tuning improvements A logging buffer holds 5 minutes of data sampled at 10 second intervals When the logging buffer fills with 5 minutes of data it is automatically transferred to a temp csv file A temp trend file will hold up to 1MB of accumulated data When the temp file has accumulated 1MB of data data from temp file is written to new trend file and temp file is overwritten with new data in logging buffer till next 1MB of data When a total of 15MB of trend data is accu mulated and the logging buffer has filled with another 5 minutes of data to write the file with the oldest trend data is deleted Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 15 Trend Chart Setup The operator can modify options for pen selection drop down box from trend setup screen see Figure 15 2 Trend Setup Screen Trend setup screen will appear on press of Setup but ton when trending feature is not running Trend Setup screen allows the operator to select a maximum of 10 analog I O channels for trending The operator can also set a path for trend data files from the drop down box in the setup screen The USB will appear as an option in drop down box only when a USB drive is mounted on the panel If there is no space available on the USB or when the USB isunmounted from the panel and USB is selected for sav ing trend files trend data files will be written to hard disk If the
130. of the reasons listed in The mo ar See above tor will not move in either direction Stripped gears inside the gear rotor or the armature has come unpressed Replace the actuator from the armature shaft The motor runs but output shaft will not turn 14 D Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 14 lt 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 actua tor 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 LED Blink Codes and Troubleshooting Guide 1 of 2 Flash Pattern 2 ON OFF Tom ee mm Calibration step 1 Calibration step 2 Meaning This indicates a zero span This error can only occur dur ing calibration The typical cause is forgetting to move the actuator when setting the upper limit of the span If this is the case press the blue button to restart the calibration procedure This error can also occur if either or both of the slotted optocouplers are not working If this is the case the slide valve actuator will have to be replaced The operation of the slotted optocouplers can be tes
131. oints defines minimum and maxi mum output The Auxiliary output produces a linear value based on these settings 18 3 18 4 Blank Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 19 Configuration Overview The configuration screen is where most of the Vission 20 20 features are enabled and configured see Figure 19 1 Configuration Screen Page 1 The initial Setup of the Vission 20 20 will generally start here Depending on what is selected different portions of the Vission 20 20 will be available to the operator Units This section sets how values will be represented through out the program Temp Units Drop down box to select the temperature units from Fahrenheit and Celsius Once selected all screen temperatures will be displayed in the chosen units Press Units Communications Temp Units F v Press Units Psiqg lt Order Num 1 E CN Panelo h Run Hours Port P12 RS485 Ww Time Restart on Power Failure Format e Always Baud Rate 9600 3 24 hour e Never j Timed 12 hour Data Bits 9 8 Remote Lock Off Current ups 9 2 Boot in Remote Direct I O Hour 01 PM v Parity Even Minute fos v Ethernet Second a6 Panel iD om IP Address Gateway Protocol 7 Boo Figure 19 1 Configuration Screen Page 1 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Active Remote Con
132. ol and the condenser pressure falls within this deadband Ambient Temp This is the read only parameter and it displays the present value of ambient temperature This is dis played only when Ambient Sensor is enabled from Configuration Screen Wetbulb Temp This is the read only parameter and it displays the present value of wetbulb temperature This is dis played only when Wetbulb Sensor is enabled from Configuration Screen Wetbulb Offset e This is the offset value from wetbulb temperature as the override point Switch Temp e This is the ambient temperature setpoint used for au tomatic switching of profile from summer to winter and vice versa Profile Selection Profileselection allows operator to have two different output profiles for summer and winter Operator can have different selection of fans pumps amp VFD in five steps of step control table Different profiles allow inclusion exclusion of water pumps in cold weather when summer winter auto switch is enabled This selection is inactive when Run mode is Auto and Summer Winter Auto Switch is enabled High to Low Speed Fan Delay This is a time delay for the fan spin down in case of 2 speed motor dual speed fan Summer Winter Auto Switch This checkbox when enabled allows profiles to switch automatically depending on ambient temperature setpoint when Run Mode is Auto When ambient temperature falls below ambient temperature set point
133. on examines the previous setpoint databases compares it with newer program setpoint da tabase and moves the old information into the new pro gram In addition this screen also allows the operator to reset all values to the factory defaults All of the information saved to the USB flash drive is open information Meaning none of the information is encrypted and the operator is free to examine it The log files are all saved as simple ASCII text and the databases can be examined with SQLite Suction Pressure 1 SLODDed Save Load 9S 9 Save Q Load E Available Devices Select Folder File LJ MM VINEIS SU de NS e dm NAN d media usbO f db08062013 zip 71 123 zip 2 CO JIL ARAL AAS 4 i o w Unmount gt Filename mediajusboj Settings All O Select Compressor Control Alarms amp Trips Configuration Calibration Maintenance No Scheduled Maintenance No Alarm Trips Present Timers x Compressor Sequencing Compressor Scheduling Condenser Control Users Auxiliary 1 0 Data Items C Run Hours L Maintenance Logs Event List Freeze Data L Trend Data Refresh e The Refresh button is used to initiate a scan of the USB ports and list any devices found in the Available Devices window Save Load Save Load section is where the operator can either save the Vission 20 20 setpoints and log information to a USB flash drive or load
134. ortional Band Control Setpoin Proportional Band Time Interval 1 Time Interval 2 will result in the capacity slide excessively moving to maintain the setpoint and could over heat the actuator or shorten the actuators operational life Auto Cycle The auto cycle setpoints define the control points in which the compressor will automatically cycle on and off when the compressor has been placed into Auto run mode These setpoints can be enabled or disabled using the check box A delay can be entered to momen tarily delay the start or stop from immediately occurring when the setpoint is met If a compressor shutdown is desired on a suction pressure drop and a manual reset is required set the OFF value below the Low Suction Pressure safety trip value This will shut down the com pressor and a Reset will be required to restart it Time Interval 3 Figure 6 2 Proportional Band amp Setpoint Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 6 lt Compressor Control The auto cycle function will operate only in local Auto mode and Direct I O Remote Auto mode If the au to 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 compres sor changes from a remote mode back to Local Auto mode the
135. ours indicated in Maintenance interval column track of the the maintenance performed and any upcom Selectthe checkbox from the maintenance task name ing maintenance recommended by Vilter Based on this and press update button to perform the sign off page banners will be displayed on the lower status bar Maintenance Interval Hours Yellow banners are to warn the operator of any upcom ing maintenance and red banners indicate maintenance that is overdue see Figure 20 1 Maintenance Screen This column indicates the Run hours at which the task in the first column should be performed When a task is selected the maintenance interval will change to reflect the next interval Checklist Time Remaining Hours This column indicates the Run hours left before the The check list is where the operator will perform the maintenance task should be performed maintenance sign off Once the operator has selected the item to sign off pressing the Update button at the bottom of the page will perform the sign off operation and list the maintenance performed in the maintenance log Suction Pressure 1 is eJejer To 35 9 Psig A Capacity Slide Maintenance Time Remaining interval Hours Hours o C oil Change 5000 4969 l C Oil Analysis 5000 4969 Volume Slide 8 OlilFilters 200 169 Spas Nr V o mi 2 7 L_ Oil Strainer 200 169 Coalescing Elements 30000 29969 5 O Suction Screen 200 169
136. pear when the Oil Separator Temp is below the Low Oil Separator Start Temp Trip setpoint In addition this message will appear after the Oil Separator Temp Safety Changeover timer times out and the Oil Separator temperature fails to rise above the Low Oil Separator Start Temp Reset af ter the compressor is started Low Oil Separator Temp Trip This message will appear when the Oil Separator Temp is below the Low Oil Separator Run Temp Reset setpoint after the Oil Separator Temp Safety Changeover timer times out Low Process Temp Trip This message will appear when the Process Control Temperature falls below the safety setting of the Lo Control Temperature Trip Setpoint Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Prelube Oil Pump Inhibit This message will appear when the Prelube Oil Pressure Manifold minus Discharge has remained below the Prelube Oil Pressure Reset setpoint The oil pump will try to generate prelube pressure for the time period of the Low Oil Pressure Safety Bypass timer setting Low Oil Pressure Trip This message will appear when the Running Oil Pressure Manifold minus Suction has remained be low the low Oil Pressure Reset setpoint when the Oil Pressure Bypass Start timer times out This message will also appear when the Running Oil Pressure falls below the Low Oil Pressure trip setpoint after the Low Oil Pressure Safety Bypass timer times out Low Oil I
137. pression Control Screen sss esse esse sese sese eee eee Figure 25 2 Cool Compression Control Functions Screen sese sees sees ee esse eee eee eee Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Page Number END OF TOC TOC 7 TOC 8 How to Use This Manual This manual contains instructions for the Vission 20 20 Operation amp Service Manual It has been divided into 25 sections Section 1 Operational Flow Charts Section 2 Installation Recommendations Section 3 Hardware Architecture Section 4 Main Screen Section 5 Menu Screen Section 6 Compressor Control Section 7 Alarms amp Trips Section 8 Timers Section 9 Compressor Scheduling Section 10 Compressor Sequencing Section 11 Condensor Control Section 12 Service Options Section 13 Instruments Calibration Section 14 Slide Calibration Section 15 Trend Chart Section 16 Event List Section 17 Input Output Section 18 Auxiliary Input Output Section 19 Configuration Section 20 Data Backup Section 21 Maintenance Section 22 User Access Section 23 Help Screen Section 24 Twin Screw Control Section 25 Cool Compression Control 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 They are defined as the following WARNING Warning statements a
138. pressor Control Load Anticipating The purpose of the load anticipating algorithm is to re duce the amount of overshoot of the capacity slide posi tion while the compressor attempts to meet the control setpoint This advanced feature of the Vission 20 20 closely monitors the rate of change of the process vari able and compares it to the control setpoint If the pro cess variable is changing in the direction of the control setpoint at the specified rate or greater then the normal command to move the capacity slide is interrupted The rate is calculated between time intervals set in the pro portional control section of this screen Enable Load Anticipation Algorithm Allows the operator to choose if the load anticipation algorithm runs Rate Dead Band Defines the rate at which the capacity slide move ment will be interrupted This value is an absolute val ue of the process variable For example the default value is 0 25 If the control mode is suction pressure then this value is 0 25 Psig or if process temperature is the control mode then the value would be 0 25 F Oil Control These setpoints determine how the Vission 20 20 will manage the oil of the compressor Oil Pump Press Restart Ratio The on and off setpoints define when the oil pump will cycle on and off if the oil pump is selected to cycle from the configuration screen Oil Separator Heater Temp When the oil temperature falls below this setpo
139. puts e Enter Desired Value The operator enters the correct current value Each entry will recalculate the point slope calcu lations of the current calibration e Total Error Not editable by the operator Displays the to tal error offset of entries from the Enter Desired Value setpoint Current Transformer Ratio e Primary Defines the upper value of the current transformer Secondary Not editable by the operator Defines the minimum value of the current transformer e Enter Desired Value he operator enters the value of the cor rect current value Each entry will recalculate the point slope calculations of the current calibration e Total Error Not editable by the operator Displays the to tal error offset of entries from the Enter Desired Value setpoint Remote Capacity The remote capacity input allows a system controller such as the PLC to control the capacity position during direct I O control Control Input This drop down box is not used at this time Scale e Defines the minimum and maximum Capacity posi tion between 0 amp 100 for the 4 20ma input Offset e Used to correct any error in the capacity position By entering a value into the Adjustment entry box that value will be added to the total offset displayed in the total offset entry box Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 13 s Instruments
140. quid ammonia for normal operating position Upper SP maximum level of liquid ammonia for normal operating position e Max SP maximum liquid ammonia level po sitioning valve is minimum open position main taining some leakage On Alarms and Trips screen Low Oil Separator Start Temperature High Filter Diff Start Pressure settings are disabled On Timers screen Oil Level 1 Safety Trip Delay Oil Level 2 Safety Trip Delay settings are disabled 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 25 3 25 4 Section 25 Cool Compression Control operational differences that are mostly associated with the compressor safeties 1 The Cool Compression program ignores Low Oil Separator Alarm Trip at start High Filter Differential at start Prelube Oil Pressure Alarm and Trip Run Oil Pressure Alarm and Trip Pressure Ratios are monitored instead High Discharge Temp Alarm and Trip Discharge Temp Superheat is monitored Low Suction Temp Alarm and Trip e Low Oil Injection Temp Alarm and Trip High Oil Injection Temp Alarm and Trip 2 SOI solenoid is forced on for first 60 seconds of run ning and 10 minutes after compressor is stopped 3 Auto Load Enabled When Auto Load is engaged at start it then maintains the position of capacity
141. r Level Event List Level 0 Input Output States Trend Chart Help Alarms amp Trips Compressor Scheduling Compressor Sequencing Condenser Control Compressor Control Maintenance Data Backup Instrument Calibration Service Option Configuration Slide Calibration Timers Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Level 0 Level 0 Level 0 Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Level 1 Level 2 Level 2 Level 2 Level 2 Level 2 Level 3 required for constraints Level 3 required for constraints Level 3 required for constraints Level 3 required to upload data Level 3 required for pages 3 6 Level 3 required for constraints 22 3 22 d Blank Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 23 Help Screen Overview will be listed in this section The operator will have to navigate through the file structure of the USB drive to find the documents The top box in the USB drive will Use this screen to receive help on other setpoint screens display any USB drives mounted to the Vission 20 20 contained within the software These help files can be accessed from any screen The help files describe the Ee functionality of that screen as well as compressor opera Touching one of the listed USB devices will select that tion see Figure 23 1 Help Screen device and list any files or PDF documents contained on th
142. r Up Power Up Stopped Auto Remote Comm Time out Remote Power Up Power Up Power Up Power Up Power Up Power Up Power Up Power Up Volume Slide 0 0 96 Suction Press Control Suction ia User 08 19 2011 03 53 24 Run Hours 31 Figure 17 1 Input Output Screen 17 1 17 2 Blank Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 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 see Figure 18 1 Auxiliary Input Output Screen Setting up one or more of the auxiliary inputs or out puts start with the configuration screen In order to en able the auxiliary I O the Vission 20 20 must first be equipped with one of the available expandable I O cards and the card must be selected on page 6 of the configu ration screen Once the appropriate card is available then the operator will be permitted to enable and name the desired auxiliary I O The operator can then navigate to the Auxiliary I O screen where the operator can define how that I O will operate Suction Pressure 1 Stopped 22 0 Psig A Analog Outputs
143. r needs to load to 10026 of its capacity The control algorithm will first move the capacity slide to its maximum position then the motor speed will ramp up to its maximum speed In the unloading direction the motor speed will ramp down to its minimum speed then the capacity slide will move to its minimum position The two step control method works much like the one step method but divides the control into four sections see Figure 6 4 VFD Two Step Control Method While loading the compressor will first move the capacity slide to the maximum set for step one then speed up the motor to its maximum speed for the same step Once step one has completed the control algorithm will again move the capacity slide to the maximum position and the maximum speed of step two At this point the com pressor would be fully loaded Unloading occurs in the reverse direction The two step control method is not typical for most installations and is normally used when a Vilter engineer recommends it Cap Max Value amp VFD Min Value Cap Min Value VFD Max Value Total Compressor Capacity Figure 6 3 VFD One Step Control Method Step 1 Step 2 Figure 6 4 VFD Two Step Control Method Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 6 4 Section 6 lt Compressor Control NOTE VFD installation is not covered in this manual A VFD that is not properly installed and configured has the pot
144. re and starts the compressor in Auto mode Remote Lock Off When selected turns the remote lock out off when the panel powers up Select this option if the opera tor wishes a system controller to regain control of the Vission 20 20 without human interference Boot in Remote Direct I O When selected places the panel into remote mode when the panel powers up Select this option when under direct I O control and the system controller is to gain control of the Vission 20 20 without human interference Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Compressor Sequencing The compressor sequencing is a feature of the Vission 20 20 that allows the operator to setup as many as five compressor to automatically start stop and maintain system loads The compressor that is designated as the master will monitor systems parameter and make deci sions on how many compressor are required to meet the load as efficiently as possible Compressor Sequencing Enables the compressor sequencing algorithms and allows access to the compressor sequencing screen Master Identifies the panel as the master while in sequencing control Slave e Identifies the panel as a slave while in sequencing control Compressor Name Unique identifier that is broadcasted to all other Vission 20 20 units in the sequencing network Language Allows the operator to select the language in which all scre
145. re shown when there are hazardous situations if not avoided will result in se rious injury or death CAUTION Caution statements are shown when there are potentially hazardous situations if not avoided will result in damage to equipment NOTE Notes are shown when there are addtional infor mation pertaining to the instructions explained NOTICE Notices are shown when there are important information that can help avoid system failure For additional information pertaining to the Vission 20 20 refer to www Vission2020 net documents Information that can be found on the site are e Manuals e Release Advisories e Application Notes e Videos Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 1 Operational Flow Charts Requirements to Start Compressor Volume and Oil Separator Temp Filter Diff Press Capacity slides are gt Oil Sep Start Trip Start Filter Diff Trip less than 596 Setpt Setpt Oil Pump On Prelub Oil Press is Prelub Oil Press Reset Setpt for Min Compressor Prelub Timer Start Compressor setting typically 5 seconds Critical Compressor Run Logic at Compressor Start Start Compressor Oil Press Bypass at Comp Run Oil Press Run Oil Press Prelub Oil Press d Run Oil Press Yes Start timer Yes S Reset setpt Pa Reset setpt Default 5 PSI P Default 40 PSI after start No Run Oil Press Failure Filt
146. rent Transformer 4 20ma Transmitter 25 1 Section 25 Cool Compression Control enable Superheat Monitoring on the screen As previously described Cool Compression compressor does not have an oil pump Instead it has a suction oil injection solenoid to pro vide oil and liquid ammonia for lubrication and cooling Cool Compression liquid injection 1 and liq uid injection 2 outputs will operate as high low pressure ratio solenoid outputs Control Functions In the Compressor Control Menu special cool compres sion control functions are now available see Figure 25 2 Cool Compression Control Functions Screen These new functions are e Auto Load Suction Pressure 1 Stopped 41 0 Psig A aran Auto Load Start 30 SOI Solenoid ON 2 0 2 04 20 SO Solenoid OFF Auto Load Timer 10 0 min SOI Load Limit Danfos Valve Linear Control 5 Liquid Ammonia Level Start SP Linear SP Upper SP Max SP Page 3 4 5 6 No Scheduled Maintenance No Alarm Trips Present Suction Oil Injection Setting High Press Ratio Solenoid co B feo ps e Suction Oil Injection Settings e Danfoss Positioning Valve Settings Auto Load e Auto load operation will force the compressor to load to a minimum value once the compressor has started By loading the compressor to a minimum value and maintaining this capacit
147. rol 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 separa tor 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 ammo nia being added to the separator The cooling occurs through the entire compression and separation process The Cool Compression compressor does not have an oil pump When the Cool Compression compressor unit is commanded to start the control panel first insures that the slide valves are at their minimum positions The suc tion oil injection solenoid SOI is energized allowing a path for oil to flow into the compressor The compressor now starts There is an initial pressure drop in the suc tion chamber of the compressor and a corresponding increase in pressure on the discharge of the compres sor This creates a pressure differential that forces the oil and liquid ammonia mixture through the suction oil Compressor VSS v Model 451 v Ambient Sensor R717 Cool Comp i rtm rmm trm tmn rem rmn rete an tanran neterinetartsrttetratreres ne reme rtm mee mea meene T Other K Factor f Compressor Control Refrigerant _ VFD Fan Controllers Oil Pump J No Pump Suction Pressure Control 2 Cycling Full Time Pumps
148. s 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 Back but ton will be inactive when the operator is viewing the last data point on the screen i e when time interval is displaying 120 00 At minimum zoom level Back amp Forward buttons will be inactive Trace This button allows the operator to move a white cur sor line across all four trend lines and receive a read out of all four variables at that point in time When the Trace button is pressed cursor position is displayed along with value of all four variables on the screen Hold e This button allows the operator to stop the data from advancing on the display without stopping the trend feature When the Hold button in pressed Hold Time is displayed on the screen Trace Back lt Forward gt These buttons allow the operator to move a white cursor line across trend lines and view trend data value at that point These buttons will only be active when Trace button is pressed When these buttons are pressed cursor is moved and trace position is up dated on the screen Setup This button allows operator to open the Trend Setup screen This button is inactive when the trend feature is running Trend Data Storage The trend analysis screen shows recorded data for pr
149. s contains names of all the compressors in the network communicating with Master compressor Equipment name can be selected from drop down list Same Equipment name should not be configured more than once in Sequencing table Control e Inclusion exclusion of compressor partaking in the sequencing can be decided on basis of this toggle button Compressors can be included excluded by toggling ON OFF 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 CFM column is read only These values are updat ed automatically when Equipment combo box is changed This indicates Slave compressor capacity in CFM Priority s This defines priorities of Compressors on the network This priority will decide the sequence in which com pressors will be turned on and off during sequence cycle Lower the priority number greater the priority of the compressor Step This parameter would decide stepwise increment or decrement value in percentage of the compressor capacity In the case when last step makes total ca pacity greater than maximum capacity total capac ity will get reduced to maximum capacity Same is applicable when last step makes total capacity lower than minimum capacity takes priority Min Cap e Defines the lowest capacity in p
150. scharge Press emp 58 2 Psig 139 3 F Oil ress Diff 1 3 Psig ilter Diff 0 8 Psig Inj Temp 118 3 F Sep Temp 113 1 F 08 17 2011 10 46 30 Motor mperage 0 0 Amps Figure 5 1 Menu Screen Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 5 lt Menu Screen Instrument calibration e Navigates to the instrument calibration screen where the operator can calibrate all of the system sensors Slide calibration e Navigates to the slide calibration screen where the operator can calibrate the capacity and volume slide actuators Trend chart e Navigates to the trend chart screen where the opera tor can select up to four parameters for graphical his torical data trending Event list e Navigates to the event list screen where the operator can view the systems events such as trips or alarms in descending chronological order Input output states Allows viewing of the live data of all analog and digi tal input and outputs Also allows viewing of a snap shot of all analog and digital input and outputs at the time of the last compressor fault event Auxiliary I O e Navigates to the auxiliary I O screen where an op erator can configure any auxiliary instruments or devices Configuration e Navigates to configuration screens where the initial system parameters are configured Data backup Allows the operator to backup setpoints
151. se eee 15 1 Tend RR eK ca RD TE 15 2 o qiio 15 3 Figure 15 2 Trend Setup SCRE CMs epiac thesi Sene nsin eUn EEEE anna EEIE SEENEN E EENEN Oar OETA SEROK 15 3 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 TOC 3 Table of Contents Section Title Section Number Section 16 lt Event List OV SIR cA ON TRTRENCEUK A w ee M 16 1 Event list COIUNMIMNS ccccecceccsccecccccesccccanconccecceccecceccsccenccssenscnscnsecceccacocscnscessenconscacssecsesacesccsconss 16 1 Figure MiG B Event DISESOEBBE estates ete esu omes eine ccc are ec dace ok enc ec ESEESE 16 1 Section 17 Input Output S i2 KT H 17 1 Figure e I npu Output Scree eos e nmi trece FIDES EIAS 2RVI SENTO eeann iS OENE UO EE PIU SUO T TUS RUS UNIES 17 1 Section 18 Auxiliary Input Output SUI e 18 1 Bis TNNT 18 1 Figure 18 1 Auxiliary Input Output Screen sss eee sese eee eee 18 1 Digital ta ETT Ut 18 2 PAO InpliES E E E E E AA VU TUTO A E A 18 2 Pando OUTPUTS oe E TT 18 3 Soy pice AE EEE T E EAE A 18 3 COTTET E E E E E E T E E 19 1 L AEE PAE A NE PAYE A ETIN E I EA E E E E 19 1 HNES RHH 19 1 Figure 19 1 Configuration Screen Page T sese 19 1 OMAP EI CO a E E
152. son 35391SC 1 8 5153 Section 3 lt Hardware Architecture Table 3 2 Analog Inputs 2 of 2 Board I O Description Type 9 28 T 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 JlAuxiliry414 0 5V 1 5 V 0 10V 4 20 mA RTD ICTD 9 3 Auxiliary 15 0 5V 1 5 V 0 10V 4 20 mA RTD ICTD 9 32 Auilarys6 0 5V 1 5 V 0 10V 4 20 mA RTD ICTD Table 3 3 Analog Outputs Board I O 2 Description Type C o 3 slide vave postion om ow o4 Motorized Valve Cool Compression or Liquid aA nA Injection V io s sesejumsed 49m L1 s Spare unused O T io e sesejunsed Om Analog IN 1 Address 6 jux tcI oe i 1 i F 1 Figure 3 2 Digital I O Board Layout Vission 20 20 Operation and Service Manual e Vilter Emerson s 35391SC 1 8 5153 e J Section 3 Hardware Architecture Digital Output Boards Voltage LED s Marked in the diagram below in Orange These LED s The digital output board convert signals generated by indicated the correct voltage of both the 5Vdc and the Vission 20 20 program into 120Vac signals that can 24Vdc power sources be energize or signal other devices All the signals are Communication LED s digital in that the only two states available or either on or off See board layout Figure
153. ssor is running When the Vission 20 20 determines that the compressor should decrease capacity by moving the slide valve to a lower percentage this output is energized Once the slide valve reaches 0 this out put will not energize Volume Increase Output This output is only active when the compressor is running When the Vission 20 20 determines that the compressor should increase Volume Index VI by moving the volume slide to a higher percentage this output is energized Once the volume slide reaches 100 this output will not energize Volume Decrease Output Thisoutputisonly active when the compressoris run ning When the Vission 20 20 determines that the compressor should decrease Volume Index VI by moving the volume slide to a lower percentage this output is energized Once the volume slide reaches 0 this output will not energize Oil Sump Heater Output This output is active and energized when the oil separator temperature is lower than the oil separator temperature setpoint It is de energized when the oil separator temperature is higher than the oil separa tor temperature setpoint Trip Output 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 Slide Valve Setpoint 41 Output Economizer Normally used for an economizer solenoid but could be used for other devices When the compressor
154. stom device op tion is chosen Here the operator defines the signal type and range transmitted by the instrument The operator can choose from several predefined ranges in the drop down box or enter a value Motor Current The Vission 20 20 has two options for measuring motor current A 4 20mA signal transmitted from an external device or a 0 bAmp AC current Transformer The type of device being used is selected in the confiquration screen The motor current tab has the ability to calibrate both measurement options through the 4 20mA scale and current transformer ratio sections However the device type that is selected in the configuration screen will be the only section that will be available to the operator The calibration differs from all other calibration proce dures in that the motor current must be calibrated while the compressor is running at close to full load amps as possible In addition the operator will need to enter a value into the Enter Desired Value entry box that is equal to the measured value in amps by a calibrating measurement device After entering the measured val ue the displayed motor current may still be off slightly In this case reenter the desired value and the displayed value should get progressively closer 4 20mA Scale e 4mA Not editable by the operator Defines the minimum value in amps represented by a 4ma inputs e 20mXA Defines the maximum value in amps repre sented by a 20ma in
155. t put 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 compressor VFD The output is connected to AO 1 on card 10 Condenser VFD Sets the analog output assigned to the condenser VFD The output is connected to AO 2 on card 10 Slide Valve Position 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 Liquid injection Motorized Valve Sets the analog output assigned to the liquid injec tion motorized value position The output is connect ed to AO 4 on card 10 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 13 Instruments Calibration Overview The Instrument Calibration screen allows the operator to define how the Vission 20 20 will interpret the signal from any devices attached to the panel s analog inputs The instrument calibration screen is organized up to six pages Each page is then divided into several left side selected tabs Each tab will be headed with an informa tion bar labeled I O that give the basic information for that device The A D bit Value display box shows the unmodified value read by the Vission 20 20 analog to digital converters This display box is not affected by any changes to the calibrations settings As lo
156. ted as follows 1 Manually rotate the motor shaft until the aluminum photochopper fence is not blocking either of the opto coupler slots 2 Using a digital multimeter measure the DC voltage between terminal 3 of the small terminal block and TP1 on the circuit board see Note 1 The measurement should be between 0 1 and 0 2 Volts 3 Next measure the DC voltage between terminal 3 and TP2 on the circuit board You should measure be tween 0 1 and 0 2 Volts A motor over speed occurred At some time during operation the motor armature spun too fast for the encoder to measure A nonfunctional motor brake is usually to blame This error means that the slide valve actuator is no longer transmitting accurate position information The actuator should be recalibrated as soon as possible after the cause of the over speed is identified and corrected This error will not clear until the actuator is re calibrated Note 1 TP1 and TP2 are plated thru holes located close to the slotted optocouplers on the board They are clearly marked on the board silkscreen legend Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 14 7 Section 14 lt Slide Calibration Table 14 3 LED Blink Codes and Troubleshooting Guide 2 of 2 Flash Pattern Meaning ON OFF The motor is overheated The actuator motor will not run until it cools Once the motor cools the actuator will resume normal operation Mo
157. testothe alarms and trips screen where the op erator can set the various alarm and trip parameters Timers Navigates to the timer screen where the operator can set the various time related parameters Compressor scheduling Navigates to the compressor scheduling screen where the operator can set the scheduler to change the control method at settable dates and times Compressor sequencing Navigates to the compressor sequencing screen where the operator can set up compressor to se quence up to four other compressors This is also sometimes known as lead lag control Condenser control Navigates to the condenser control screen where the operator can set up local condenser control parameter Vilter VFD Notcurrently available Service options Navigates to the service options screen where the operator can manually turn on off digital and analog outputs for maintenance and diagnostics purposes 35 9 Psig A Suction Pressure 1 S10 0 01 lt 10 Alarms and Trips Instrument Calibration Timers Slide Calibration Trend Chart Event List Input Output States Auxiliary lO No Scheduled Maintenance User Compressor Scheduling Compressor Sequencing Gondenser Control Vilter VED No Alarm Trips Present Run Hours 31 Capacity Slide Volume Slide Suction Press Control Setpoint 20 0 Psig Suction Press 55 9 Psig emp 33 3 F Di
158. 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 High Filter Differential Pressure Safety Changeover This timer bypasses the High Filter Differential Run Pressure safety settings when the compressor starts It defines how long the High Filter Differential Start Pressure setpoints will be active after the compres sor starts After the timer has expired then the High Filter Differential Run Pressure safety setpoints will be active Oil Separator Level 1 Safety Trip Delay This timer bypasses the low oil level switch for mo mentary drops in the oil level This timer activates when the low oil level switch opens and deactivates when the switch closes If the switch is still open af ter the timer has timed out the compressor will be shut down and a trip message will be displayed This timer is available if the unit is equipped with a low oil separator float switch the oil level switch is standard on all liquid injection units and optional on all others Oil Separator Level 2 Safety Trip Delay e This timer bypasses the low oil level switch for mo mentary drops in the oil level This timer activates when the low oil level switch opens and deactivates when the switch closes If the switch is still open af ter the timer has timed out the compressor will
159. tions many of the screens may not be visible How the Teme compressor is configured in the configuration screen wil determine what screens are he Timers displayed itis important to note that there isn t one correct way to set these parameters Every application is diferent and requires the operator to tune these setting to achieve the best operation Discharge Alarms and Trips Help REJ Pulse Proportional Control gt gt User Vilter 05 16 2012 06 00 47 Run Hours Figure 23 1 Help Screen Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 23 1 Section 23 Help Screen Back Pressing the back button will rewrite the file folder list with the previous folder level Display Window This window displays the context of the manual Fullscreen Pressing this button expand the display window to fit the entire screen Page s Enter the page number the operator wishes to be dis played in the display window Previous Changes the page in the display window one page less then what was showing Next Changes the page in the display window one page more then what was showing Version Pressing the Version button displays a pop up screen that gives the operator information of the version of software running on the Vission 20 20 see Figure 23 2 Version Pop Up Screen Figure 23 2 Version Pop Up Screen 23 2 Vission 20 20
160. to 20mA see Figure 3 7 Analog Output Board Layout Voltage LEDs Marked in the diagram below in Orange These LEDs indicated the correct voltage of both the 5Vdc and 24Vdc power sources Communication LED s 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 Address Dipswitches Marked in the diagram below in Red These dipswitch es are used to assign each board its address position The addresses are binary and therefore the address of a digital output board will only be addressed as 10 1010 ote Se 4 R17 C4 i VDC Geos eU SVOG te R16 R19 Ce ka 1 000 uF R10 f E oops a he oot c jag Ed Ee GALEK C6 1uF 1 non ue 9 el EC nE 9 ik ke O iD O Yael 1 35K eg EKETA n o O R35 RR J9 o 5 o L TES sl GED of 2 o nM TE C2 1u R R4 3e Ayal o ES loro LZ o o Starke SCT Sal o She aem Me ni o M33 Me UKo cio o4I 0 622 Sze SG uy RS lr RIG pu ge 139K ee c19 o t 0 ord lr E ae SRK Rg2 O O o o R58 R61 C11 tur C17 TUE Sua Vix c20 O I 9 e Me em R Ra na SDE he EE Ge Kho ASIT ee LEE a e 325 046 0014 RX SERIAL Tx REV 1 NN VILTER Figure 3 7 Analog Output Board Layout 3 14 Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 4 s Main Screen Overview The Main Screen is t
161. tor overheating is sometimes a problem in hot humid environments when process conditions demand that the slide valve actuators reposition often Solutions are available consult your Vilter authorized distributor for details Another possible cause for this error is a stuck motor thermal switch The thermal switch can be tested by measuring the DC voltage with a digital multimeter be tween the two TS1 wire pads see Note 2 If the switch is closed normal operation you will measure 0 Volts The 24V supply voltage is low This will occur momen tarily when the actuator is powered up and on power down DX E P E Ro 3 2 pool o o E E E If the problem persists measure the voltage using a digital multimeter between terminals 3 and 4 of the small terminal block If the voltage is less than 24V the problem is in the supply to the board If the voltage is gt 24V replace the actuator The EEPROM data is bad This is usually caused by loss of 24V power before the calibration procedure was com pleted The actuator will not move while this error code is being displayed To clear the error calibrate the actua tor If this error has occurred and the cause was not loss of 24V power during calibration the EEPROM memory is bad and the actuator will need to be replaced Microcontroller program failure Please notify your Vilter authorized distributor Note 2 The TS1 wire pads are where the motor thermal switch leads solder into the circuit
162. trol Ethernet E Direct 170 gt Auto Capacity Serial Modbus RTU 192 168 1 98 Subnet Mask 255 255 255 0 192 168 1 1 Modbus TCP s 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 Order Num e Identifies the Order number of the purchase of the compressor This Number will be needed If the opera tor requires help from Vilter Run Hours Offers the ability to change the compressor run hours This is typically used when replacing an older micro controller on and existing compressor with a new Vission 20 20 Time amp Date This section sets the time and date of the Vission 20 20 Accurate time and date are accentual for accurate Touchscreen Calibrate i i i F P f Anti Recycle Hot Starts w Compressor Sequencing Master Slave Compressor Name None Language English v 19 1 19 2 Section 19 Configuration logging and troubleshooting Setting these parameter will set the hardware clock embedded in the Vission 20 20 CPU If the time is not retained after powering down the panel the operator should check and or re place the coin style battery on the panel SBC behind the touchscreen Format e Selection to
163. uld result in the compressor shutting down due to a trip Trips are the conditions that exceed the safety limits of the com pressor or refrigeration system and stops the compres sor Trips are always displayed as a red banner and alarms are yellow banners on the top and bottoms status bars Alarms and trip conditions are also logged to provide an operational history for the operator Both alarms and trips will be logged in the event list accessible from the menu screen Trips also trigger the input output screen to take a snapshot of all input and output values as freeze screen The freeze screens are available as left side tabs in the input output screens and are very useful as a troubleshooting tool for the operator Suction Pressure 1 Low Suction Pressure Setpoint No 1 Setpoint No 2 High Discharge Pressure Setpoint No 1 Setpoint No 2 High Process Temperature Setpoint No 1 100 0 F None Setpoint No 2 120 0 F None Low Process Temperature Setpoint No 1 Setpoint No 2 No Scheduled Maintenance SLOpped m Hg Lo Hg 2 0 Hg 210 0 Psig 220 0 Psig 220 0 Psig 230 0 Psig No Alarm Trips Present Alarms and Trips Setpoints Low Suction Pressure Alarm amp Trip This is the low suction pressure safety This safety is active in both temperature and pressure control modes An alarm or trip will be activated if the suc tion pressure falls below the setpoint values H
164. umpdown Stop Pressure Pumpdown This checkbox enables the Pumpdown feature If this box is unchecked Pumpdown setpoints are ig nored and the user is not allowed to edit Pumpdown setpoints Stop Pressure This setpoint defines the suction pressure value at which the compressor will cycle off Normally this setpoint is set below the Suction Pressure Auto cycle Stop Pressure setpoint Stop Delay This setpoint delays the compressor from stopping when the suction pressure is equal to or less than the Stop Pressure Min Slide Position he minimum capacity slide is the setpoint that the compressor is allowed to run at By forcing the compressor capacity to operate at a value above minimum we insure that the suction pressure will be pulled down to the Stop Pressure setpoint Pumpdown Operation Run Stop This button starts stops the Pumpdown operation Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 6 lt Compressor Control This button is active only when compressor is in local Auto mode and Control Mode Configured is Suction Pressure This button will display Run when Pumpdown operation has not started or stopped while button will display Stop when Pumpdown op eration is running When Pumpdown feature is enabled Pulldown check box is automatically grayed out Similarly when Pulldown feature is enabled Pumpdown checkbox is automatically graye
165. ur columns and can list up to 128 separate events The operator can download the information on the event list through the Data Backup Screen Event list Columns Date Displays the date of the event in MM DD YYYY format Suction Pressure 1 Stopped Time e Displays the time of the event in HH MM SS format Event Type Displays the type of message for a particular listing Common type are Start Stop Trip Inhibit Alarm and System These help the operator to understand the meaning of the message in the next column Message Displays the informational string that describes the event 35 9 Psig A Capacity Slide Bes We ana 08 19 2011 03 53 06 PM Power Up 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 08 19 2011 03 52 18 PM 03 51 47 PM 03 50 55 PM 03 50 08 PM 03 48 39 PM 03 25 04 PM 03 25 04 PM 03 21 05 PM 02 25 46 PM 02 24 22 PM 02 22 12 PM 02 21 06 PM 02 20 06 PM 02 19 01 PM 02 18 20 PM 02 17 40 PM System System System Stop Start Alarm Start System System System System System System System System Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Power Up Power Up Power Up Volume Slide Power Up m Voli Stopped 0 0 96 Auto Remote Comm Time out Remote Power Up L Press Contro
166. utput 2 Digital Input Output 1 Enables the optional digital input output card 1 Digital Input Output 2 Enablesthe optional digital input output card 2 Analog Input 1 Not editable by the operator Identifies that the Analog Input card 1 is enabled Analog Input 2 Not editable by the operator Identifies that the Analog Input card 2 is enabled Analog Input 3 Enables the optional Analog input card 3 Analog Input 4 Enables the optional Analog input card 4 Analog Output Enablesthe optional Analog Output card Analog Input 1 Analog Input 2 Analog Input 3 Analog Input 4 Analog Output Figure 19 6 Configuration Screen Page 6 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 19 9 19 10 Blank Vission 20 20 Operation and Service Manual lt Vilter Emerson 35391SC 1 8 5153 Section 20 Data Backup Overview The database backup screen provides the operator a way to extract information out of the Vission 20 20 for backup purposes or diagnostics see Figure 20 1 Data Backup Screen Through this screen the operator can download all the Setpoint Databases Maintenance Logs Event Lists Freeze Data Trend Data and Compressor Run Hours to a portable USB flash drive That information can then be uploaded back to the Vission 20 20 in the case of data corruption or to update the Vission program Built in migrate functi
167. ve compressor once Stop decision is taken Refresh Compressor Sequencing table is automatically re freshed every 1 minute Pressing Refresh button refreshes the status of the Compressor Sequencing table on Master Compressor NOTE Before Configuring Sequencing table on Master Compressor log on to slave compressors one by one and enable sequencing in slave mode put slave in remote mode Then log on to Master Compressor and wait till all slaves show up their names under equipment List Vission 20 20 Operation and Service Manual Vilter Emerson s 35391SC 1 8 5153 10 3 10 4 Blank Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 11 s Condenser Control Overview This screen allows the operator to view and adjust con denser setpoint settings associated with condenser op eration This screen will only be active if the Condenser Control option has been enabled from the Configuration Screen see Figure 11 1 Condenser Control Screen The Condenser Control operation allows the cycling of fans and pumps in order to maintain a specific condens ing pressure The five different steps in step control al low selection of fans pumps and VFD in one or more steps When a VFD is employed VFD is allowed to reach maximum speed if additional capacity is needed the next fan or pump is turned on The VFD will modulate down and then once it is back up to 100 again then the
168. will be activated if the oil injection tem perature rises above the setpoint value Pre lube Oil Pressure Alarm amp Trip This is the pre lube oil pump failure safety If the pre lube oil pressure does not rise above the alarm setting with in 60 seconds for a minimum time set at Minimum Comp Pre lube Time then the start sequence will be aborted The Minimum Comp Pre lube Time is set on the Timer screen The pre lube oil pressure is defined as manifold pressure minus dis charge pressure This safety insures adequate lubri cation of the the compressor at startup Low Run Oil Pressure Alarm amp Trip This is the running oil pressure safety The normal alarm and trip setpoints of this safety are messaged as soon as the compressor starts The Pre lube Oil Pressure Alarm and Trip setpoints are substituted into this safety setpoints for a time ofthe Oil Pressure Bypass timer typically 60 seconds After this timer expires then the setpoints return back to the normal settings The action of adjusting the setpoints for about a minute allows the Run Oil Pressure to build up to normal running pressures after the compressor starts After the Oil Pressure Bypass Timer has ex pired the Oil Pressure must be above the normal set points or else an Alarm or Trip will occur An alarm or trip will be active if the oil pressure drops below the normal setpoint values after the Oil Pressure Bypass timer has expired Th
169. winter profile is used Similarly when ambient temperature is above ambient temperature setpoint summer profile is used Wetbulb Override This checkbox when enabled gives the operator a functionality to control energy wastage When the condenser temperature reaches wetbulb tempera ture plus the operator given offset then the con denser control operation does not add additional steps This is done as it is not possible to lower the temperature anymore and by adding more fans or pumps controls the operation by manually stepping using an on off toggle button at each step Step Control The Step Control allows the operator to setup the man ner in which Fans Pumps amp VFD will be turned on off Fans amp Pumps are connected on digital outputs Out 1 to Out 4 VFD Fan is connected on Analog Output Each step can have maximum of five outputs connected to it Each step can be opted in or out depending on enabling of checkbox see Figure 11 2 Step Control Screen When Run Mode is Auto and condenser pressure rises above upper deadband condenser step gets incremen tal from Step 1 to Step 5 and hence switching on off Pumps Fans amp VFD connected on outputs This holds true for decremented of steps from Step 5 to Step 1 when condenser pressure falls below lower deadband Step Delay Allows operator to set time delays between condens er steps Condenser Pressure must be outside upper or lower deadband continuously for delay
170. y a pressure ratio is created across the compressor to ensure adequate lubrication of the compressor and also that the com pressor does not experience high discharge super heat conditions Since compressor lubrication is of great importance all load limiting is disabled when auto load is engaged e Auto Load at Start Defines the value at which Compressor ca pacity slide should be loaded and maintained at start if Auto Load is enabled Capacity Slide Volume Slide 0 0 Suction Press Control Setpoint 20 0 Psig Suction Press emp 61 0 Psig 42 7 F Discharge Press emp 145 3 Psig 84 3 F all values in mA Oil Filter Diff 0 4 Psig Sep Temp 113 7 F PressRatio 2 1 Superheat 1 8 F User 01 03 2002 03 03 33 42 Motor mperage 0 0 Amps Run Hours Figure 25 2 Cool Compression Control Functions Screen 25 2 Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 25 Cool Compression Control e Auto Load Timer his timer defines the maximum time that the Auto Load operation will be engaged After the timer expires Auto Load will be disengaged Auto load will be disengaged when one of the follow ing conditions occur e Pressure ratio reaches a value of 2 0 or greater Compressor has been running for 10 minutes defined by Auto Load Timer e Suction pressure setpoint has been reached
171. ystem s sensitivity to small discharge temperature fluctuations and the tendency to hunt Integral reset e This parameter integrates the error over time to ac count for a small error that has persisted for a long time This quantity is used for fine adjustment This setpoint is used to smooth out discharge tempera ture variations This setpoint should be set high enough to prevent hunting but not too high or it will cause control system overshoot D Derivative rate e This parameter accounts for how fast the error is changing positively or negatively Minimum Valve Open e When enabled this is the valve position used when ever the control variable drops below Liquid inj Setpoint 1 Use only if the compressor is tripping off for low oil temperature due to large overshoots and all other tuning methods have failed Avg with Oil Manifold Temperature e When enabled averages the Oil manifold tempera ture and the discharge temperature This creates a more stable control variable and should result in more stable control Vission 20 20 Operation and Service Manual Vilter Emerson 35391SC 1 8 5153 Section 7 Alarms and Trips Overview The Alarms and Trips screen allows the operator to view and adjust settings for compressor safety and alarm set tings see Figure 7 1 Alarms and Trips Screen Vission 20 20 uses Alarms as a way to notify the operator of running parameters that if left unchecked co

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