VILTech micro-controller
Operation and service manual
Important Note:
Before applying power to the control panel, all wiring to the panel should be per NEC. Specifically check for
proper voltage and that the neutral is grounded at the source. An equipment ground should also be ran to
the panel.
*See Wiring Instructions and Diagrams before proceeding.
Before start-up, enter all system values and options. See section on Setpoint Values.
3
Table of Contents
Important Note: ...................................................................................................................................................................... 3
Domestic Terms and Conditions .......................................................................................................................................... 10
Export Terms and Conditions ............................................................................................................................................... 12
Chapter 1 ......................................................................................................................................................... 11
Spare Parts List .................................................................................................................................................................... 12
Pre-Startup Check List ......................................................................................................................................................... 13
Retrofit Kit Instructions ....................................................................................................................................................... 14
Operating Procedures .......................................................................................................................................................... 19
Definitions ........................................................................................................................................................................... 19
Keypad Functions ............................................................................................................................................................... 20
Main Screen Overview ......................................................................................................................................................... 22
Screen Types ....................................................................................................................................................................... 23
Menu Screens ...................................................................................................................................................................... 23
Menu Option Selection ........................................................................................................................................................ 24
Data Entry Screens .............................................................................................................................................................. 24
Cursors ................................................................................................................................................................................ 25
Data Entry Procedures ......................................................................................................................................................... 25
Data Screen Keys................................................................................................................................................................. 25
Field Types .......................................................................................................................................................................... 26
Selectable Fields .................................................................................................................................................................. 26
Numerical Data Input Fields ................................................................................................................................................. 26
Absolute Pressure Fields ..................................................................................................................................................... 27
Time Fields ........................................................................................................................................................................... 27
Date Fields ........................................................................................................................................................................... 27
String Fields ......................................................................................................................................................................... 28
Telephone Number Field ...................................................................................................................................................... 28
Hexadecimal Fields ............................................................................................................................................................... 28
Status Screens ..................................................................................................................................................................... 30
Confirmation Screens ........................................................................................................................................................... 31
Confirmation Screen Procedures .......................................................................................................................................... 31
Momentary Screens ............................................................................................................................................................. 32
Information Screens ............................................................................................................................................................. 33
Access Screens.................................................................................................................................................................... 34
Log Screens ......................................................................................................................................................................... 35
Alarms & Failures ................................................................................................................................................................ 36
Modes Of Operation ............................................................................................................................................................ 39
Chapter 2 .........................................................................................................................................................39
Compressor Controls ........................................................................................................................................................... 39
Starting the Compressor ...................................................................................................................................................... 40
Manual Start ........................................................................................................................................................................ 40
Automatic Start .................................................................................................................................................................... 40
Remote/Auto Remote Start .................................................................................................................................................. 41
I/O Control ........................................................................................................................................................................... 41
Network Control ................................................................................................................................................................... 41
Sequenced Start ................................................................................................................................................................... 41
Stopping the Compressor .................................................................................................................................................... 42
Manual Stop ........................................................................................................................................................................ 42
Automatic Stop .................................................................................................................................................................... 42
Remote/Auto Remote Stop .................................................................................................................................................. 42
I/O Control ........................................................................................................................................................................... 42
Network Control ................................................................................................................................................................... 42
Sequenced Stop ................................................................................................................................................................... 42
4
Capacity Control .................................................................................................................................................................. 43
Manual Capacity Control ..................................................................................................................................................... 43
Automatic Capacity Control ................................................................................................................................................ 43
Control Groups .................................................................................................................................................................... 44
Cut-Out Setpoint .................................................................................................................................................................. 44
Cut-In Setpoint .................................................................................................................................................................... 44
Control Setpoint................................................................................................................................................................... 44
LowAlarm/Failure Setpoints ................................................................................................................................................ 44
Time Proportional Control Strategy ..................................................................................................................................... 44
Control Deadband................................................................................................................................................................ 44
Normal Bandwidth ............................................................................................................................................................... 44
Normal Stage Delay . ............................................................................................................................................................ 44
Fast Stage Delay - ................................................................................................................................................................ 44
Difference Above Setpoint .................................................................................................................................................. 45
Load Bandwidth ................................................................................................................................................................... 45
Unload Bandwidth ............................................................................................................................................................... 45
Difference Below Setpoint ................................................................................................................................................... 45
Remote Capacity Control ..................................................................................................................................................... 45
Auto-Remote Capacity Control............................................................................................................................................ 45
Sequenced Capacity Control ............................................................................................................................................... 46
LowAlarm and Failure Setpoints ......................................................................................................................................... 46
Running in Trim Mode ......................................................................................................................................................... 46
Running in Full Load Mode ................................................................................................................................................. 47
Anti-Cycle in Sequenced Mode........................................................................................................................................... 47
Forced Unloading & Limiting............................................................................................................................................... 47
Ramp Start ............................................................................................................................................................................ 47
Capacity Ramp Start Limiting ............................................................................................................................................... 48
Staging Setup....................................................................................................................................................................... 49
Minimum Capacity ............................................................................................................................................................... 49
Setpoint Scheduling............................................................................................................................................................. 50
Daily Schedules .................................................................................................................................................................. 50
Weekly Schedule ................................................................................................................................................................. 50
Oil Pressure Computation ................................................................................................................................................... 50
Oil Temperature Regulation.................................................................................................................................................. 50
Anti-Cycle Timer .................................................................................................................................................................. 51
Power Fail Restart ................................................................................................................................................................ 51
Process Temperature Control (Option) ................................................................................................................................ 51
Two Stage Configuration (Option) ....................................................................................................................................... 51
Operational Procedures........................................................................................................................................................ 52
Status Screens ..................................................................................................................................................................... 54
Compressor Main Status Screen .......................................................................................................................................... 54
Status Banner....................................................................................................................................................................... 55
Current System State ........................................................................................................................................................... 56
CURRENTSTATE DESCRIPTION ....................................................................................................................................... 56
Mode Area ........................................................................................................................................................................... 56
MODEDESCRIPTION ......................................................................................................................................................... 56
Alarm & FailureArea ........................................................................................................................................................... 57
ALARM SYSTEMS STATUS .............................................................................................................................................. 57
MESSAGE ............................................................................................................................................................................ 57
Operating Hours Screen....................................................................................................................................................... 57
TERM DEFINITION ............................................................................................................................................................. 57
Active Alarms & Failures Status Screen .............................................................................................................................. 58
ActiveAlarms & Failures Status Screen Definitions ........................................................................................................... 58
Active Alarms & Failures Status Screen .............................................................................................................................. 58
Auto-Start Warning Screen.................................................................................................................................................. 59
5
SETPT Hot Key.................................................................................................................................................................... 59
AUTO Start Warning Screen............................................................................................................................................... 59
SETPT Hot Key Screen ....................................................................................................................................................... 59
Setpoints ............................................................................................................................................................................. 60
Pressure Setpoints ............................................................................................................................................................... 61
Suction Pressure Control Groups......................................................................................................................................... 61
High Suction Pressure Setpoints ......................................................................................................................................... 63
Discharge Pressure Setpoints .............................................................................................................................................. 64
Oil Pressure Setpoints.......................................................................................................................................................... 65
Intermediate Pressure Setpoints (Two Stage only) Option .................................................................................................. 66
Temperature Setpoints ......................................................................................................................................................... 67
Discharge Temperature Setpoints ........................................................................................................................................ 67
Oil Temperature Setpoints .................................................................................................................................................... 68
Process Temperature Control Group .................................................................................................................................... 69
High Process Temperature Setpoints ................................................................................................................................... 70
Note Page............................................................................................................................................................................. 71
Capacity Setpoints ............................................................................................................................................................... 72
Scheduling ........................................................................................................................................................................... 73
Control ................................................................................................................................................................................. 73
Active Group ....................................................................................................................................................................... 74
Active Schedule................................................................................................................................................................... 74
Weekly Schedule ................................................................................................................................................................. 75
Daily Schedule ..................................................................................................................................................................... 75
CAP Control ......................................................................................................................................................................... 77
Suction Pressure Control Setpoints ..................................................................................................................................... 77
Process Temperature Control Setpoints............................................................................................................................... 78
MISC Control ....................................................................................................................................................................... 79
LOGS Hot Key ..................................................................................................................................................................... 80
MENUS Hot Key ................................................................................................................................................................. 80
Chapter 3 .........................................................................................................................................................81
Logging Functions Technical overview............................................................................................................................... 81
Logging Functions .............................................................................................................................................................. 81
Trend Log ............................................................................................................................................................................ 82
Alarm Log ............................................................................................................................................................................ 82
Failure Log ........................................................................................................................................................................... 82
User Log .............................................................................................................................................................................. 82
Logging Functions Operating Procedures ........................................................................................................................... 83
Operations and Trend Logs ................................................................................................................................................. 84
Alarm and Failure Logs ........................................................................................................................................................ 85
User Log .............................................................................................................................................................................. 86
Clear Logs ............................................................................................................................................................................ 86
ClearAll Logs....................................................................................................................................................................... 87
Set Log Rate ......................................................................................................................................................................... 87
Logon User .......................................................................................................................................................................... 89
Logoff User .......................................................................................................................................................................... 89
Automatic Log Off ............................................................................................................................................................... 89
Chapter 4 .........................................................................................................................................................89
Menu Functions .................................................................................................................................................................. 89
Set-up Menu ........................................................................................................................................................................ 91
Set Clock .............................................................................................................................................................................. 91
6
Calibrate Sensors ................................................................................................................................................................. 91
Dynamic Sensor Calibration ................................................................................................................................................. 91
Static Sensor Calibration ...................................................................................................................................................... 91
Passwords ............................................................................................................................................................................ 92
Adding/Deleting Users ........................................................................................................................................................ 92
Screen Access Levels .......................................................................................................................................................... 92
Initialization.......................................................................................................................................................................... 92
Power Fail Reset ................................................................................................................................................................... 92
Set Factory Configuration.................................................................................................................................................... 93
Configuration ....................................................................................................................................................................... 93
Display ................................................................................................................................................................................. 93
Communication .................................................................................................................................................................... 93
Set Operating Status ............................................................................................................................................................ 93
Staging Configuration.......................................................................................................................................................... 93
Control Configuration .......................................................................................................................................................... 93
Adjust Contrast ................................................................................................................................................................... 93
Operational Procedures........................................................................................................................................................ 94
Logon User .......................................................................................................................................................................... 95
Logoff User .......................................................................................................................................................................... 95
Diagnostics .......................................................................................................................................................................... 96
System Information .............................................................................................................................................................. 96
View Discrete I/O ................................................................................................................................................................. 97
ViewAnalogs ....................................................................................................................................................................... 98
Communication Status ....................................................................................................................................................... 100
Override Discrete I/O ......................................................................................................................................................... 101
Set-up................................................................................................................................................................................. 102
Set Clock ........................................................................................................................................................................... 102
Calibrate Sensors ............................................................................................................................................................... 103
Dynamic Sensor Calibration ............................................................................................................................................... 104
Static Sensor Calibration .................................................................................................................................................... 105
Password Control............................................................................................................................................................... 106
Password Control Screen ................................................................................................................................................... 106
Add/Delete User ................................................................................................................................................................ 107
Access Levels.................................................................................................................................................................... 108
Initialization........................................................................................................................................................................ 109
Power Fail Reset ................................................................................................................................................................. 109
Set Factory Config ............................................................................................................................................................. 110
Setpoint Save/Restore ....................................................................................................................................................... 110
Save/Restore Status........................................................................................................................................................... 110
Configuration ..................................................................................................................................................................... 111
Display ............................................................................................................................................................................... 111
Comm Setup ....................................................................................................................................................................... 112
Set Op Stats ....................................................................................................................................................................... 113
Setup Stages ...................................................................................................................................................................... 114
Control Configuration ........................................................................................................................................................ 115
Adjust Contrast ................................................................................................................................................................. 115
Variable Frequency Drive Option ....................................................................................................................................... 116
Sequencer Control........................................................................................................................................118
Sequencer Technical Section ............................................................................................................................................. 118
Sequencer System Control Parameters .............................................................................................................................. 119
Sequencer Staging Control ................................................................................................................................................ 119
Difference Above Setpoint ................................................................................................................................................ 120
7
Load Bandwidth ................................................................................................................................................................. 120
Unload Deadband .............................................................................................................................................................. 120
Unload Bandwidth ............................................................................................................................................................. 120
Sequencing Commands...................................................................................................................................................... 120
System Control Parameter and Setpoint Communication ................................................................................................... 120
Sequencer Operations........................................................................................................................................................ 121
Sequencer Lead List ........................................................................................................................................................... 121
Enabling and Disabling the Sequencer .............................................................................................................................. 124
Sequencer Control Groups ................................................................................................................................................. 124
Sequencer Setpoint Scheduling ......................................................................................................................................... 124
Alarm and Failure Setpoints............................................................................................................................................... 125
Setting up VILTech Panels for Sequencing ........................................................................................................................ 125
Sequencer Operating Procedures....................................................................................................................................... 126
Sequencer Status Screen ................................................................................................................................................... 126
SEQ Hot Key ...................................................................................................................................................................... 127
LEAD LIST ........................................................................................................................................................................ 127
CNTRLGROUPSELECT .................................................................................................................................................... 127
SCHEDULING .................................................................................................................................................................... 127
SCHEDULESETUP ............................................................................................................................................................ 127
DAILYSCHEDULE ............................................................................................................................................................ 127
SCHEDULE01 .................................................................................................................................................................... 127
SCEHDULE02 .................................................................................................................................................................... 127
SCHEDULE07 .................................................................................................................................................................... 127
HIGHALARM ................................................................................................................................................................... 127
LEAD LISTA ..................................................................................................................................................................... 127
LEAD LIST B ..................................................................................................................................................................... 127
CURRENTACTIVELEADLIST ........................................................................................................................................ 131
Control Group Select .......................................................................................................................................................... 132
CONTROLSETPT .............................................................................................................................................................. 132
LOWALARM .................................................................................................................................................................... 132
LOWFAILURE .................................................................................................................................................................. 133
Schedule Setup .................................................................................................................................................................. 133
Daily Schedules ................................................................................................................................................................. 134
SCHEDULEDTIME ........................................................................................................................................................... 134
SELECTEDGROUP ............................................................................................................................................................ 134
SELECTEDLEAD .............................................................................................................................................................. 134
LIST ................................................................................................................................................................................... 134
HighAlarm ......................................................................................................................................................................... 135
Addendum for Pump Down Program for VILTech .............................................................................................................. 136
APPENDIX A ............................................................................................................................................... 139
Alarm and Failure Data ...................................................................................................................................................... 139
AnalogAlarms ................................................................................................................................................................... 139
High Suction Pressure ....................................................................................................................................................... 139
Low Suction Pressure ........................................................................................................................................................ 139
High Discharge Pressure ................................................................................................................................................... 139
High Oil Temperature ......................................................................................................................................................... 139
Low Oil Pressure ................................................................................................................................................................ 139
Low Intermediate Temp(Two Stage) ................................................................................................................................... 139
High Process Temperature(Option).................................................................................................................................... 139
Low Process Temperature(Option) .................................................................................................................................... 139
High Intermediate Pressure (Two Stage) ............................................................................................................................ 140
8
Low Intermediate Pressure (Two Stage) ............................................................................................................................. 140
DiscreteAlarms .................................................................................................................................................................. 140
APPENDIX B ............................................................................................................................................... 141
Analog and Discrete I/O .................................................................................................................................................... 141
Analog Inputs.................................................................................................................................................................... 141
APPENDIX C ............................................................................................................................................... 143
Communication Protocols .................................................................................................................................................. 143
Introduction ....................................................................................................................................................................... 143
Applicable Documents ...................................................................................................................................................... 143
Hardware Interface Description ......................................................................................................................................... 144
Hardware Requirements ..................................................................................................................................................... 144
Interface Connections........................................................................................................................................................ 144
Pin Name ............................................................................................................................................................................ 144
Message Addressing ......................................................................................................................................................... 146
Software Interface Description .......................................................................................................................................... 148
Protocol Overview ............................................................................................................................................................. 148
Status Only or Status and Control Options ....................................................................................................................... 148
Message Categories .......................................................................................................................................................... 148
MODBUS Protocol Description ......................................................................................................................................... 149
Preset Single Register ........................................................................................................................................................ 150
Preset Multiple Registers ................................................................................................................................................... 150
Error Messages .................................................................................................................................................................. 151
Data Formats ...................................................................................................................................................................... 151
Status Message Description .............................................................................................................................................. 152
Analog Input and Computed Parameters ........................................................................................................................... 152
Discrtete Input and Outputs .............................................................................................................................................. 153
Alarm and Failure Data ...................................................................................................................................................... 154
Equipment Data.................................................................................................................................................................. 157
Alarm Status Table ............................................................................................................................................................. 157
Compressor Mode Table .................................................................................................................................................... 157
Compressor State Table ..................................................................................................................................................... 158
Last RECIP Start Status Table ............................................................................................................................................ 160
Control Message Description ............................................................................................................................................ 160
Network in Control Command ............................................................................................................................................ 161
Compressor Start/Stop ....................................................................................................................................................... 161
Set Comressor Capacity Command .................................................................................................................................... 162
Change Compressor Mode Command ............................................................................................................................... 162
Acknowledg/ClearActiveAlarm Command ....................................................................................................................... 163
Change Current Setpoint Group Command ........................................................................................................................ 163
Change Control Type Command ........................................................................................................................................ 163
Auto Start/Stop Contol Command ..................................................................................................................................... 163
Suction Pressure Setpoint Message Description............................................................................................................... 164
Process Temperature Setpoint Message Description ........................................................................................................ 165
APPENDIX D ............................................................................................................................................... 166
Condensor Control ............................................................................................................................................................ 166
9
Notes Page
10
11
Spare Parts List
QNTY Part#
Item
1
1
1
1
1
1
2
2
1
1
1
1
1
1
2
3400A
3400B
3400C
3400CG
3400F
400K
3400M
3400N
3400R
3400Y
2611N
2611P
Microcontroller Board
I/O (Digital andAnalog) Board
Display Interface Board
240x128 Liquid Crystal Display
Controller Fuse Pack Consisting of 1-15amp main, 3-5amp I/O
Controller Power Supply
120VAC Solid State Output Module
120VAC Solid State Input Module
EEPROM
Cable Kit (incl display cable, p.s. to main, p.s. to I/O bd)
DETECTOR -58/122DEG TEMP RESIST 4-20MA
DETECTOR 32/392DEG TEMP RESIST 4-20MA
TRANSDUCERAKS33 0-414.5PSIA4-20MAOUT
TRANSDUCERAKS33 0-200PSIA4-20MAOUT
CORDSET RK4T-4/S618 TURCK
2783D2
2783D4
3122B
12
Chapter 1
Pre-Startup Check List
Pre-Wired done at factory. The necessary field wiring connections are described below.
1. Connect power (L1) to e-stop at terminal #2. Then neutral is connected on TB5 to the
middle terminal labeled “N”. Last connect ground on TB5 at the right end terminal
labeled “G”.
2. Connect the Compressor Motor to Channel 1, the hot lead connects to terminal 4 and
the neutral end to terminal 1.
3. Connect the Motor StarterAUX to Channel 9. The hot side of the dry contact to
terminal 34. The neutral side of the dry contact to terminal 35.
4. At this time connectAUX #1,AUX #2, Remote Start/Stop, or water solenoid that
may have shipped loose per the wiring diagram.
5. First, press “Menu” key then press “#1” then next press “clear” now enter the pass-
word “999999”. Then enter setpoints by pushing “SETPT” key then #2 for Setpoints.
Now go through each screen for 1.Pressure, 2.Temperature, and 3.Capacity. Use the
“QUIT” or “SAVE” button to go to previous screen.
6. Still under “Setpt” screen setup Capactiy Control by pressing #4 and Misc Control by
pressing #5. If multiple control setpoints are going to be used then setup a Schedule by
pressing #3, please read the manual for more information.
7. Now press the “Menu” button then press #4 “System Setup” then #5 “Configure
Hardware” then #4 “Staging Configuration”, now on this screen please make sure that
the correct steps of unloading are shown on the right side of the screen, if the steps are
not correct then look in the manual or call Electrical Engineering atVilter Manufactur-
ing LLC. Now to get out of this screen press “Quit” key if no changes were done
otherwise press “Save” to get to the previous screen.
8. Next press #5 “Control Configuration” and verify the refrigerant and enable/disable
any options that are needed or not.
13
Chapter 1
Retrofit Kit Instructions
Belt Drive
Direct Drive
Mount Suction Side of Unit
14
WARNING
Do not bring in or run any
wiring on top of panel.
Do not run DC voltage on
the sam e side as the
AC Volta ge.
All 120V wires must enter
the lowe r right corner of
panel or all warranties
will be void.
DONOTRUNAC and DCwires
TOGETHER!!!
15
16
NOTES:
1) CONNECT ALL SENSOR DRAIN WIRES AT THIS
LOCATION.
2) DOTTED WIRING REPRESENTS FIELD WIRING
3) DOTTED COMPONENTS NOT BY VILTER
4) FOR NEMA 3, 3R, 4 & 12 PANELS, ALL OPENINGS TO
BE GASKETED.
5) MOTOR STARTER WIRING WILL VARY. REFER TO
STARTER MANUFACTURER‘S DIAGRAM FOR ACTUAL
WIRING.
6) ALL CONDUIT CONNECTIONS TO THE PANEL MUST
BE MADE WITH FLEXIBLE CONDUIT.
7) FUSE 5 AMP FAST BLOW.
8) ONLY (4) FOUR INCHES OF SIGNA WIRES SHOULD
BE UNSHIELDED AT SENSOR END.
9) CABLE FOR ANALOG DEVICES UNLESS SHOWN
OTHERWISE IS BELDEN #9533 OR EQUIVALENT. 24
AWG, 3 CONDUCTOR, SHIELDED WITH DRAIN WIRE,
RUN IN SEPARATE CONDUIT FROM POWER WIRING.
MAX WIRE SIZE FOR TERMINAL IS #14AWG. USE
COPPER CONDUCTORS ONLY WITH TEMPERATURE
RATING 60°C OR HIGHER. TIGHTENING TORQUE 4 LB-
IN.
10) MAXIMUM TOTAL SENSOR DRAW IS 2 AMPS. IF
GREATER THAN 2 AMPS IS REQUIRED CUSTOMER
SUPPLIED POWER SUPPLY IS REQUIRED. CONSULT
MANUFACTURER FOR DETAILS.
11) MAX WIRE SIZE FOR I/O BOARD TERMINAL IS
#12AWG. USE COPPER CONDUCTORS ONLY WITH
TEMPERATURE RATING 60°C OR HIGHER. TIGHTEN-
ING TORQUE 4 LB-IN MAXIMUM CURRENT FOR FORM
C RELAY IS 4 AMPS MAXIMUM CURRENT FOR SOLID
STATE OUTPUT MODULE IS 1.5 AMPS.
12) DRAWING IS SHOWN WITH INTERNALLY SUPPLIED
POWER ALTHOUGH IT IS CONFIGURABLE TO CUS-
TOMER SUPPLIED POWER.
13) 120 VAC OUTPUTS MAX. LOAD: 1.5 AM RUNNING,
30 AMPS INRUSH.
14) MAX WIRE SIZE FOR INPUT POWER TERMINAL IS
#10AWG. USE COPPER CONDUCTORS ONLY WITH
TEMPERATURE RATING 60°C OR HIGHER. TIGHTEN-
ING TORQUE 4.4-5.3 LB-IN.
15) CABLE FOR COMMUNICATION BETWEEN PANELS
OR COMPUTER IS BELDEN #9843, OR EQUIVALENT. 24
AWG, 6 CONDUCTOR, TWISTED PAIR SHIELDED WITH
DRAIN WIRE, RUN IN SEPARATE CONDUIT FROM
POWER WIRING.
17
18
Chapter 1
General Operating Procedures
Definitions
Cursor is a field indicator used on data entry screens. There are four possible cursor types:
* represents a number field input
> represents a selectable field
“ represents a string field
X represents a hexadecimal field
The cursor shows the user which fields are changeable on a data entry screen.
DisplayArea is the part of the LCD display that shows system information. The display area will
vary in size depending on whether a large character or small character screen is being viewed.
Fields are places where the user enters control parameters.
Highlight is when the letters appear light on a dark background instead of dark on a light back-
ground. The highlighted area may flash from light to dark to stress its importance and to gain the
user’s immediate attention.
Hot Keys are the top-level system functions and menus. The hot keys are located in a column to the
left of the Display area.
Large Character Screens are screens that use large, double high characters and also contain the
title banner and hot keys.
Main Status Screen is a large character status screen, which is considered the main system status
screen. This screen will also contain the alarm status, mode, and state of the system.
Parameter is a system control value, which is displayed by the system or input by the user.
Examples are suction pressure and high suction pressure alarm setpoint.
Screen is a method of displaying information to the user. The system contains eight types of
possible screens: menu screens, data entry screens, status screens, confirmation screens, momen-
tary screens, information screens, access screens, and log screens
Small Character Screens utilize the entire LCD display and use small characters to show system
information. These screens do not display the system hot keys.
Toggle is the process of moving from one selectable choice to the next by using the ENTER key.
User is an individual or group of individuals who will use the system. A user is identified by a user
number ranging from 1 to 10. The user may also be referred to as the operator in this document.
19
Keypad Functions
The following is a brief summary of the Viltech keypad along with a description of its individual keys. Below
is a drawing of the Viltech keypad layout.
Keypad Diagram
20
STOP The red STOP key causes an immediate and orderly shutdown of a compressor. This key
usually has no effect on master panels.
0 – 9
The NUMBER keys select menu or hot key options. On data entry screens the number keys
are used to enter numerical data.
•
The DOT key allows decimal point entry on data entry screens. This key also permits the
user to page forward one full screen at a time on log and status screens.
_
The MINUS key allows negative number entry on data entry screens. This key also permits
the user to page back one full screen at a time on log or status screens.
On data entry or menu screens, the UPARROW key moves the cursor up to the next item on the
screen.
On data entry or menu screens, the DOWN ARROW key moves the cursor down to the next item on
the screen.
On data entry or menu screens, the LEFTARROW key moves the cursor left to the next item on the
screen. This key also permits the user to page forward one full screen at a time on log and status
screens.
On data entry or menu screens, the RIGHTARROW key moves the cursor right to the next item on
the screen. This key also permits the user to page back one full screen at a time on log and status
screens.
PGUP The PG UP key is used to page back one full screen at a time for status screens or to page up
to more current data on log screens.
PGDN The PG DN key is used to page forward one full screen at a time for status screens or to page
down to older data on log screens.
QUIT The QUIT key exits the current screen and displays the previous screen. Pressing the QUIT
key to exit from a data entry screen will result all changed data being lost.
SAVE The SAVE key is used with data entry screens to save any changed information. It also exits
the current screen and displays the previous screen.
CLEAR The CLEAR key within data entry screens will erase the current number field. On the main
status or alarm status screen it acknowledges and clears alarms and failures.
ENTER The ENTER key is used within data entry screens on a number field to accept numerical data
or on a selectable field to toggle through the available choices. On menu screens, the ENTER key will
select the highlighted menu item. The ENTER key may also be used to scroll forward through the
status screens.
21
Main Screen Overview
The MAIN SCREEN is the name for a set of features common to all large character screens.
The Main screen is broken down into two areas: the Display Area, and the Title Banner.
The following drawing shows a representation of the main screen layout and labels each of
its various areas.
Title Banner
Display Area
Main Screen Layout
Title Banner -The top highlighted bar contains the Vilter logo and the current time of day and
may only be found on large character screens.
DisplayArea -Contains all of the detailed screen information. Large character screens will use
only the designated display area, while small character screens use the entire LCD display.
22
Screen Types
Viltech information is presented to the operator using eight different types of screens. The
different SCREEN TYPES each use specific data entry and control procedures. The screen
types let the user know which screen type heading to refer to for information on the specific
screens’ procedures. The following is a list of the eight different screen types.
Menu Screen - displays a numbered list of options.
Data Entry Screen - used to modify system control parameters.
Status Screen - displays real-time system summary data.
Confirmation Screen - used for verification, gives a choice for a yes or no option.
Momentary Screen - displays a message for three seconds.
Information Screen - used to display system information
Access Screen -a menu type screen with an number input field.
Log Screen - displays a record of system parameters and actions.
Menu Screens
The MENU screen is used to present the user with choices for various system
operations. Menu screens are found throughout the Viltech system. The following is
an example of a menu screen.
Menu Screen
23
The following table contains a list of the active keys on a menu screen and their function.
KEYS
FUNCTION
NUMBER
KEYPAD
ENTER
Used to choose a selection number.
Used to choose the selection number that is highlighted.
UP/DOWN
ARROW
QUIT
Moves the cursor from one selection to the next either up or down.
Exits from current screen to the previous screen.
Menu Screen Keys Table
Menu Option Selection -Use the number keys corresponding to the desired menu item
or the arrow keys and press ENTER to select the desired menu item.
Data Entry Screens
DATA ENTRY SCREENS are user interactive screens, which allow the user to change
or input system data. These screens contain a special cursor to signify the field type
at the cursor location. The cursor can be moved throughout the screen to indicate
each field location.
NOTE: Data entry screens may also contain information for reference purposes that is
not changeable. The following is an example of a data entry screen.
Data Entry Screen
24
The following table contains a list of the active keys on a data entry screen and their function.
KEYS
FUNCTIONS
NUMBER
KEYPAD
ENTER
Used to enter numerical data.
Toggles through the available choices on a selectable field. On a number field the
ENTER key is used to accept entered data and move to next field.
ARROWKEYS Moves the cursor from one field to the next either up, down, left or right. Any of the
arrow keys can also be used to accept the data entered on a number field.
CLEAR
Will clear the current numerical field. The CLEAR key is not active on selectable
fields.
SAVE
QUIT
Exits from the current screen and all new data is saved.
Exits from the current screen and all new data is lost.
Data Screen Keys
A data entry screen may contain both numerical input and selectable fields, which are identified by
different cursors as shown in the following table.
Cursors
>
*
Selectable cursor, indicated a selectable field.
Numerical input cursor, indicates a number field.
Data Entry Screen CursorTable
Data Entry Procedures
1. Verify Screen Type - One of the special cursors must appear on the screen. If
the cursor did not appear you are not on a data entry screen.
2. Change Fields - Use the arrow keys to move the cursor to the desired field.
3. Enter Data - Enter the desired numerical data or select the desired selectable
depending on field type.
4. SAVE OR QUIT - Upon completing the changing of data the user may press
SAVE to save all newly entered data and return to the previous screen. If the user
presses QUIT the entered data will not be saved. After pressing QUIT,
confirmation screen will ask the user to verify the desire to lose all changes
entered.
25
Field Types
This section discusses the procedures used to work with each of the FIELD TYPES as well as the general
procedures that apply to all number entry fields. The following information applies to any field when entering
numerical data:
Decimal Number Entry -If the data you wish to enter has a zero in the decimal place there is no need to enter “0.”
Simply enter the whole number value.
Arrow Keys - The arrow keys will accept the entered data and move the cursor to the next field.
Errors - The flashing error message tells the user that the entered data is not within an acceptable range for the
field. The user must clear the error before proceeding. To clear an error message the operator presses the CLEAR
key.
Restoring Valid Data -The user can clear and re-enter data from any field prior to leaving the field. If the arrow key
or the ENTER key is used to move off the field after it has been cleared, the previously entered valid data will be
restored to the field.
Selectable Fields
A SELECTABLE FIELD gives the user a choice of inputs from which to toggle
through and is recognized by the “>” cursor preceding it.
1. Verify Cursor Type - locate the “>” selection cursor.
2. ENTER Key - cycles the user through the available selections.
3. Arrow Keys - move to the next field and accept the selection.
Numerical Data Input Fields
A numerical field is used to enter control data and is recognized by the “*”
cursor preceding it.
1. Verify Cursor Type - locate the “*” numeric input cursor.
2. Number Keypad - press the number keys that correspond to the number you wish displayed. Use the
decimal and minus keys where applicable. Each field will limit the user to a maximum number of whole and
decimal numbers for that specific field.
3. ENTER/Arrow Keys -move to the next field and accept the entered number.
4. Verify Cursor Type - Upon pressing the ENTER or DOWNARROW key, if the cursor moves across to
the units column and changes to the “>” selectable cursor, the user is in a suction pressure field which is
described in the next section.
26
Absolute Pressure Fields
This field is actually a combination of numerical and selectable fields. The selectable or units section of the
field allows the user to adjust the units to select vacuum or non-vacuum ranges.
1. Verify Cursor Type - locate the “*” numeric input cursor.
2. Number Keypad - press the number keys that correspond to the number you wish displayed. Use the
decimal and minus keys where applicable. If the numeric field already has the correct data and only the
units need to be adjusted, re-enter the existing numerical data and press ENTER.
3. ENTER/Arrow Keys - locks in the numerical data and moves the cursor across to the units section of
the field.
4. Verify Cursor Type - locate the “>” selection cursor next to the units section.
5. ENTER - cycles between possible units selections.
6. Arrow Keys - move to the next field and accept the entered data.
7. Errors -If an error occurs because the value entered is out of range the CLEAR key will clear the field
and return the user to the number portion of the field.
Time Fields
The TIME FIELD is a special case numerical field used to enter time data.
1. Verify Cursor Type - locate the “*” numeric input cursor.
2. Number Keypad - use the number keys to enter the time you wish displayed. For example, to input the
time 5:59 press 0559, the system automatically moves from hours to the minutes. The “:” is automatically
entered in a time field. This field will allow for whole number acceptance. For example to set the time 8:00
the user may type 08 and press ENTER. The time on the screen will appear as 08:00.
NOTE:Time fields may be entered in 12-hour or 24-hour format depending on the system configuration. If the system
is in 12-hour format the user will be prompted to select “AM” or “PM” using a selectable field after a
number is entered.
3. Arrow Keys - move to the next field and accept the entered time.
Date Fields
The DATE FIELD is a special case numerical entry field used o enter the date.
1. Verify Cursor Type - locate the “*” numeric input cursor.
2. Number Keypad - use the number keys to enter the date you wish displayed. For example, to enter the
date 1/1/91 the user would type in 010191, the system automatically moves from the month to the day and
then to the year. The “/” slash symbol is entered for you.
3. Arrow Keys - move to the next field and accept the entered date.
27
String Fields
The STRING FIELD is a special case alpha-numeric entry field. It is similar to a selectable field but each character
in the string may be selected from the list of all possible letters, numbers, and special characters.
1. Verify Cursor Type - locate the “ “ “ string input cursor.
2. Enter Key - Pressing the ENTER key first will clear the current contents and start entering characters.
The ENTER key is primarily used to cycle through the available selections for the current character
positions.
3. “+” Key - Selecting the Positive (.) key puts the field into edit mode and allows the current contents of
the field to be entered.
4. Arrow Keys -Allows you to move within a field to different characters.
5. Number Keys - These keys are used to enter numbers into a character.
6. Clear Key - This key is used to clear the content of the entire field.
7. Entering a space - If a space is allowed in the field, an “_” will be available in the character list.
Selecting this character will result in a space being inserted in the string. All trailing spaces are eliminated.
Telephone Number Field
The TELEPHONE NUMBER FIELD is a special case alpha-numeric entry field. It is similar to a string field but only
allows numbers and several special characters required for telephone numbers.
1. Verify Cursor Type - locate the “ “ “ string input cursor.
2. Enter Key - Pressing the ENTER key first will clear the current contents and start entering characters.
The ENTER key is primarily used to cycle through the available selections for the current character
positions.
3. “+” Key - Selecting the Positive (.) key puts the field into edit mode and allows the current contents of
the field to be entered.
4. Arrow Keys -Allows you to move within a field to different characters.
5. Number Keys - These keys are used to enter numbers into a character.
6. Clear Key - This key is used to clear the content of the entire field.
7. Entering a space - If a space is allowed in the field, an “_” will be available in the character list.
Selecting this character will result in a space being inserted in the string. All trailing spaces are eliminated.
Hexadecimal Fields
The HEXADECIMAL FIELD is a special case alpha-numeric entry field. It is similar to a string field but only allows
numbers and several special characters required for hexadecimal numbers.
1. Verify Cursor Type - locate the “ “ “ string input cursor.
2. Enter Key - Pressing the ENTER key first will clear the current contents and start entering characters.
The ENTER key is primarily used to cycle through the available selections for the current character
positions.
3. “+” Key - Selecting the Positive(.) key puts the field into edit mode and allows the current contents of
the field to be entered.
4. Arrow Keys -Allows you to move within a field to different characters.
5. Number Keys - These keys are used to enter numbers into a character.
6. Clear Key - This key is used to clear the contents of the entire field.
7. Entering a space - If a space is allowed in the field, an “_” will be available in the character list.
Selecting this character will result in a space being inserted in the string. All trailing spaces are eliminated.
28
29
Status Screens
STATUS SCREENS are used to display a summary of significant system information. The
Main Status screen in a system is usually a large character text screen or graphics screen
and is the default screen displayed on the LCD. The Main Status screen will be replaced by
the Active Alarm and Failure screen when a new alarm or failure exists or by the Auto-Start
Warning screen if the compressor is online and ready to start.
The operator may view each of the system’s available status screens by scrolling through
using the ENTER, PG UP, PG DN, RightArrow, or LeftArrow keys. The number of status
screens on a system will vary depending upon the individual system’s configuration.
Another feature of the system is that it will automatically return to the main status screen
after 10 minutes of no keyboard activity. Below is an example of a Status screen.
Status Screen
The following table contains a list of the active keys on a status screen and their function.
KEY
FUNCTION
ENTER
Scrolls through the set of available status screens.
PG UP/PG DN
RIGHT/LEFT
ARROWS
QUIT
Pages forward or back through the available status screens.
Returns the user to the main status screen.
Status Screen Keys
30
Confirmation Screens
A CONFIRMATION SCREEN is used to ask the user to confirm a selection by answering a
question. This screen usually appears after the user has altered system parameters and
then presses the QUIT key or to verify a system control request. Below is an example of a
confirmation screen.
Confirmation Screen
The following table contains a list of the active keys on a confirmation screen and their
function.
KEYS
FUNCTION
NUMBER
KEYPAD
ENTER
Used to select a response number
Used to select the highlighted response number.
UP/DOWN
ARROWS
QUIT
Moves the cursor from one selection to the next, either up or down.
Exits from the current screen to the pervious screen. Same as selecting
NO for most screens or YES when quitting from a data entry screen after
making changes.
Confirmation Screen Keys
Confirmation Screen Procedures
Number Keypad -Use the keypad to match your response with the numerical choices shown
on the screen or press QUIT to exit the screen.
31
Momentary Screens
The MOMENTARY SCREEN is used to verify certain user selections by displaying an
informative message for three seconds. Rather than waiting for the entire three second time to
elapse, the operator may press the QUIT key to end viewing of the message. The following is
an example of a momentary screen.
Momentary Screen
The following table contains a list of the active keys on a momentary screen and their function
KEY
QUIT
.
FUNCTION
Stops display of the message before the three second time limit expires.
Momentary Screen Keys
32
Information Screens
INFORMATION SCREENS are used to display system data to the user. The information on
these screens may be real-time data, or a snapshot of data at the time the screen is first
displayed.
Information Screen
The following table contains a list of the active keys on an information screen and their
function.
KEY
FUNCTION
QUIT
Exits from current screen to the previous screen.
Information Screen Keys
33
Access Screens
The ACCESS SCREEN is used to index the user into a larger set of screens. This screen is
typically used in cases where more than eight screens are available for a particular option.
The access screen will perform error checking on the number entered. For example, if the
screen is used to access the daily schedules and the number eight is entered, the input area
will flash error since there are only seven possible schedules. The user will be required to
clear the error and enter a correct value. The data entry process is described in more detail in
the data entry section. The following is an example of an access screen.
Access Screen
The following table contains a list of the active keys on an access screen and their function.
KEYS
FUNCTION
NUMBER
KEYPAD
ENTER
QUIT
Used to enter a number selection.
Used to accept the selection number that is entered.
Exits from current screen to the previous screen.
Access Screen Keys
34
Log Screens
LOG SCREENS are used to view recorded system information. The width and length of the
log screens may be wider and longer than allowed by the LCD display area. The arrow and
page keys can then be used to view the entire log. All systems are configured with the
following logs: Operation Log, Trend Log, Alarm Log, Failure Log, and User Log. Other
log types may also be included, depending on system options. Below is an example of a
log screen.
Log Screen
The following table contains a list of the active keys on a log screen and their function.
KEY
FUNCTION
PGUP
PGDN
Allows the user to page forward and back through the log entries.
PG UP shows more recent log entries and PG DN shows older log
entries.
UP/DOWN
ARROWS
Scrolls line by line through the information. The Up arrow shows
more recent log entries and the Down arrow shows older log
entries.
RIGHT/LEFT
ARROWS
CLEAR
Scrolls to additional log pages while maintaining the same time and
date for log entries.
Returns the user to the beginning of the log.
Exits from current screen to the previous screen.
QUIT
Log Screen Keys
35
Alarms & Failures
The Viltech continually monitors the system parameters and compares them to ALARM AND FAILURE setpoints
to inform the operator of the system status. An alarm is intended to alert the operator that an undesirable
condition exists. A failure is an indication that a more severe system condition exists and may cause the system or
component to shutdown. The system parameters are compared to both operator-defined setpoints and Vilter
Manufacturing, LLC. safety setpoints. An alarm or failure is detected when a system parameter is outside the
acceptable range of the setpoints.
Certain alarms and failures may also be suppressed under specific conditions. For example, the low oil pressure
alarm is suppressed when the compressor is not running. Additionally, the detection of certain alarms and failures
can be delayed. For example, the low suction pressure failure is delayed for 10 seconds, in other words the suction
pressure must be below the low failure setpoint for 10 consecutive seconds before the system is shutdown.
Some alarm and failure setpoints are assigned factory default values, which may not be changed by the operator.
These are called OEM safety setpoints and typically indicate a condition that may cause damage to the equipment.
A detailed list of all system alarms and failures can be found in Appendix A.
When an alarm or failure is detected the sequence of operations is as follows:
The equipment controlled by the Viltech may be stopped, as in the case of a compressor, when a failure occurs.
The alarm or failure is entered into the active alarm and failure list and the current status screen on the
display is replaced with the active alarm and failure screen.
An entry is made in the appropriate alarm or failure log.
A special entry is made in the operation and trend logs listing the parameter values at the time of the alarm or
failure.
The current alarms and failures present on a system can be viewed on the active alarms & failures status screen.
The operator must acknowledge and clear alarms/failures from this screen or the main status screen using the
procedures covered in this section.
When a new alarm or failure becomes active, the Active Alarm & Failure status screen will be displayed as the
default status screen. The user can view all of the active alarms by scrolling through the alarms using the up and
down arrow keys. An example of the alarm & failure status screen is shown on the next page.
36
Active Alarms & Failures Status Screen
The active function keys for this screen are described in the following table.
KEY
FUNCTION
UP/DOWN
ARROWS
CLEAR
Scrolls line by line through the information.
The CLEAR key is used to acknowledge and clear alarms/failures as well
as to silence the alarm horn.
Alarms & Failures Screen Keys
Use the following steps to acknowledge and clear any alarms & failures.
1. Verify Screen Type - The Alarm & Failure status screen or the Main Status
screen should be displayed.
2. Acknowledging anAlarm or Failure - Press the CLEAR button. When the
CLEAR button is pressed the previously flashing ALARM or FAIL in the lower
right-hand corner of the screen will stop flashing and go to a constant highlight.
This action will also deactivate the alarm or failure discrete output. When multiple
alarms are active the acknowledging function operates on the entire set of active
alarms or failures.
3. Correct Problem -The operator must now correct the problem causing the alarm
or failure. This may be a control parameter that is out of range, or various other
conditions which should be familiar to the operator.
4. ClearAlarm or Failure - Once the problem is rectified press the CLEAR button
on the keypad. The Alarm & Failure status area should become non-highlighted
and display the word NORM, the entry in the active alarm list will also be removed.
The clearing of each alarm is processed when the conditions causing the alarm are
acceptable.
37
38
Chapter 2
Compressor Controls
The following sections discuss the standard and optional features contained in the Viltech RECIP
package.
Modes Of Operation
The RECIP Compressor package has several modes of operation. The mode is changed by using the
MODE key and making a selection from the Operation mode menu. The modes of operation are as
follows:
1. Manual - Starting, Stopping and Capacity Control are all performed manually.
2. Automatic - Starting and Stopping can be performed manually or automatically based on Suction
Pressure or Process Temperature. Capacity Control is performed automatically to maintain a specific
control setpoint.
3. Remote - Starting, Stopping and Capacity Control in the Remote mode can only be performed from a
remote computer.
4. Auto-Remote - Similar to theAutomatic mode except starting and stopping are performed using the
external Remote Start/Stop input or messages from a remote computer. The setpoint group can only be
selected from a remote computer.
5. Sequenced - This mode is utilized when two or more compressors are being used to control the same
load.
NOTE: The Remote, Auto-Remote, and Sequenced modes are available as system options.
39
Starting the Compressor
The sequence that the RECIP compressor goes through during a start is as follows.
1. A five second minimum start delay timer is started. During this time, the capacity stages are unloaded,
the logs are enabled, and any discrete I/O overrides are cleared. The compressor is now in the
STARTING state.
2. After the five second timer expires, the motor is started, the Cooling Control output is energized, and a
15 second up-to-speed timer is started. The user-programmable anti-recycle timer is also started at this
time.
3. If the motor starter auxiliary contact closes within 15 seconds, the starting sequence will continue.
Otherwise, the compressor will be shutdown. Also, low oil pressure alarms will be inhibited within the 25
seconds, pressure failure will be inhibited within 30 seconds.
4. When the 15 second up-to-speed timer expires, the compressor will be loaded to a point greater than or
equal to the Minimum Capacity setpoint using the Fast Stage Delay Time between stages.
5. Once the compressor has loaded to minimum, the compressor transitions to the RUNNING state.
Normal capacity control can now begin.
The RECIP Compressor can be started manually, automatically, or remotely based on the operating mode chosen.
The compressor will not start in any mode if a failure condition exists.
Manual Start
MANUAL START is accomplished by selecting the MAN key. Amanual start is used in Manual
mode.
Automatic Start
In AUTOMATIC START the compressor can be started automatically based on suction pressure or
process temperature. Automatic Starting is enabled on the Miscellaneous Control screen under the
SETPT hot key. Once the Auto Start/Stop feature is enabled, the operator must place the compressor
on-line using the Auto key. If the compressor is not needed at that time, it will immediately go to the
Cut-Out state and will start automatically whenever required. If the control parameter is already
above the Cut-In set-point, the compressor will start immediately. Afailure or manual stop will take
the compressor off-line.
40
Remote/Auto Remote Start
I/O Control
The REMOTE START/STOP input is used to start and stop the RECIP compressor in the Auto-Remote
mode only. The compressor must first be placed on-line by the operator through the use of the RMT hot
key. Once the compressor is on-line, the Remote Start/Stop input may be energized to start the
compressor. When the input is de-energized, the compressor will stop but remain on-line. A failure or
manual stop command will stop the compressor and force it off-line.
NOTE:
Before the remote location can control the system, the user must set the operating mode, and place the RECIP
compressor on-line using the RMT hot key. Then, and only then, is the system ready to accept remote control
signals.
Network Control
When the NETWORK CONTROL option is enabled, starting in the Remote or Auto-Remote mode is
performed using messages from a remote computer. It is required that the compressor be placed on-line
via the keypad or using an on-line message. For more information on Network Operation, please refer
toAppendix C.
Sequenced Start
In SEQUENCED START, the compressor takes commands from an Viltech Master Sequencer Control Panel.
The Sequenced mode can be selected from the operating modes. Once this mode is selected the RECIP
compressor must be placed on-line by using the SEQ hot key. Only when the RECIP compressor is placed on-
line will the Viltech respond to control signals from the master sequencer.
Sequenced in Remote Start
The VILTech panel can be controlled remotely and also be in sequence with other VILTech panels. In the
Sequencer Setup screens, this option can be enabled in the Control screen by choosing “Automatic”.
Once this mode is selected the RECIP compressor must be placed on-line by using the SEQ hot key. Now
all other panels in the sequence must be placed on-line by using the SEQ hot key otherwise the master
panel will not be able to communicate to the slave panels.
41
Stopping the Compressor
The stopping sequence is as follows:
1. The Motor is stopped, the capacity stages are unloaded, and Cooling Control outputs are de-
energized.
2. When the motor starter auxiliary contact opens within 15 seconds, the compressor will transition to the
STOPPED state.
3. Once the compressor is stopped, oil temperature regulation may begin using the Oil Heater output and
Oil Temperature input.
The RECIP compressor can be stopped manually or automatically depending on the operating mode. Any failure
will automatically stop the compressor.
Manual Stop
A MANUAL STOP is accomplished by using the stop button on the Viltech panel. The stop button
is active on all screens and causes an immediate shutdown of the motor. Use of the manual Stop
button will also take the compressor off-line.
Automatic Stop
When the AUTO START/STOP feature is enabled and the compressor is in the Automatic mode, the
compressor will stop automatically when the control parameter falls below the cut-out setpoint.
Remote/Auto Remote Stop
I/O Control
When remote operation is desired using discrete I/O signals, the Remote Start/Stop input signal is used to stop the
compressor for the Auto-Remote mode. When the Remote Start/Stop input is de-energized, the compressor will
stop but remain on-line. Afailure or manual stop command will stop the compressor and force it off-line.
Network Control
When the NETWORK COMMUNICATIONS option is enabled, stopping in the Remote andAuto-Remote modes is
performed using messages from a remote computer. Separate messages are available to stop the compressor and
leave it on-line, or to stop the compressor and force it off-line. For more information on network operation, please
refer toAppendix C.
Sequenced Stop
When the STOP command is received from the master sequencer, the Viltech will stop the RECIP
compressor automatically and leave it on-line for sequenced operation. While stopped on-line, the
compressor is available for sequencing and in standby waiting for commands.
42
Capacity Control
CAPACITY CONTROL on a RECIP compressor is performed by adding or removing stages. Loading the
compressor adds stages which increases the compressor capacity and Unloading the compressor
removes stages which decreases the compressor capacity. A stage can consist of one or more Loaders
which energize to add pistons, or Unloaders which de-energize to remove pistons. Capacity Control can
be performed manually or automatically depending on the mode of operation.
CAPACITY SETPOINTS there is a Max Time at 0% capacity which is a timer that is intended to NOT
allow the compressor to run too long at 0% capacity. The timer is activated in automatic and remote
modes. If the compressor runs at 0% capacity longer than the allowed time then the compressor will
perform a “Normal” stop and a log entry will be documented. When Auto Start/Stop is enabled then the
compressor will restart when the suction pressure rises above the cut-in setpoint. The compressor may
restart immediately, when two cases occur. Case #1- When the capacity ramp start delay is programmed
lengthy and a low max time is at 0% capacity, it is possible that the Max 0% capacity timer will expire
before the capacity ramp allows the machine to load. If, the suction pressure is above the cut-in setpoint
and auto start/stop is enabled, compressor will restart immediately. Case #2- When the suction pressure
is above cut-in and discharge pressure is above the limit/unload may be holding the compressor at 0%
capacity so the 0% capacity timer will expire and the compressor will restart immediately.
Manual Capacity Control
In MANUAL mode, the capacity is adjusted using the keypad on the Viltech. The up-arrow is used
to add stages and the down-arrow is used to remove stages. Each time an arrow key is hit, one
stage is added or removed until the compressor is fully loaded or unloaded. Manual capacity
control can only be performed when viewing the Main Status screen.
Automatic Capacity Control
AUTOMATIC CAPACITY CONTROL is accomplished by adding or removing stages to load and
unload the compressor in response to changes in the control parameter (suction pressure or process
temperature). Capacity changes are achieved using a time proportional control strategy with
setpoints for Control Deadband, Normal Bandwidth, Normal Stage Delay, and Fast Stage Delay.
Separate setpoints are provided for loading and unloading the compressor so that the operator may
tune the system differently for increasing or decreasing load conditions.
The operator can also define up to four Control Groups which consist of Cut-In, Cut-Out, Control,
Low Alarm, and Low Failure setpoints. The active control group can either be selected manually by
using the active group screen or automatically through setpoint scheduling. The operator can also
define a minimum capacity value which is used to limit capacity changes at the lower limit.
43
Control Groups
Four groups of control setpoints can be defined for use with automatic capacity control. Each setpoint group
consist of a Cut-In, Cut-Out, Control, LowAlarm, and Low Failure setpoint.
Cut-Out Setpoint -The Viltech will stop the compressor when the suction pressure or process temperature goes
below the cut-out setpoint.
Cut-In Setpoint - The Viltech will start the compressor when the suction pressure or process temperature goes
above the cut-in setpoint.
Control Setpoint -The Viltech will change the capacity in an attempt to maintain the suction pressure or process
temperature at the control setpoint.
LowAlarm/Failure Setpoints -These are the low suction pressure or process temperature alarm and failure
values associated with the control setpoint. In Sequenced Mode, the local setpoints are replaced by the Sequencer
low alarm and failure set-points transmitted by the master sequencer controller.
Time Proportional Control Strategy
For automatic capacity control, the amount of time between stage changes is a function of how far the Control
Parameter is from the Control Setpoint and how long the Control Parameter remains outside the Control Deadband.
A separate set of control parameters is defined for increasing or decreasing load conditions.
Control Deadband - When the difference between the Control Setpoint and the Control Parameter is less than the
deadband value capacity changes will take place. If the Control Deadband values are too small, the capacity may
increase and decrease excessively causing fluctuations in the Control Parameter. If the Control Deadband are too
large, the compressor may not hold the Control Parameter close enough to the Control Setpoint resulting in
inefficient capacity control.
Normal Bandwidth - If the difference between the Control Setpoint and the Control Parameter is between the
Control Deadband value and the Normal Bandwidth value, the Normal Stage Delay timer will be used to determine
when a stage will be added or removed.
If the difference between the Control Setpoint and the Control Parameter is greater than the Normal Bandwidth
value, the Fast Stage Delay timer will be used to determine when a stage will be added or removed. This ensures
that capacity changes will occur more quickly when the Control Parameter is far from the Control Setpoint.
If the Normal Bandwidth values are too small, the compressor will respond too quickly to small load changes and
may constantly overshoot the optimal position. If the Normal Bandwidth values are too large, the compressor will
react too slowly to load changes.
Normal Stage Delay - This is the amount of time used between stage changes when the Control Parameter is
between the Control Deadband and the Normal Bandwidth. This value should be greater than the Fast Stage Delay
time. If the Normal Stage Delay time is too small, then capacity changes will occur too often, possibly not allowing
the affects of the previous change to take effect.
Fast Stage Delay - This is the amount of time used between stage changes when the Control Parameter is outside
the Normal Bandwidth. This value should be less than the Normal Stage Delay time. If the Fast Stage Delay time is
too large, then capacity changes will not occur often enough, possibly allowing the system to exceed safe limits.
44
The relationship of these parameters can be seen in the time proportional control strategy diagrams shown below:
DifferenceAbove Setpoint
Stages added using the fast delay timer
LoadBandwidth
Stages added using the normal delay timer
LoadDeadband
No stages added or removed
Control Setpoint
No stages added or removed
UnloadDeadband
UnloadBandwidth
Stages added using the fast delay timer
Difference Below Setpoint
Stage Control Safety
Remote Capacity Control
When the Network Communications option is enabled, and the compressor is in the Remote mode, capacity
control is performed using load and unload messages from a remote computer. For more information on network
operation, please refer to Appendix C.
Auto-Remote Capacity Control
When the Network Communications option is enabled, and the compressor is in the Auto-Remote mode, capacity
control is performed using AUTOMATIC CAPACITY CONTROL. The control setpoint is selected using setpoint
messages from a remote computer.
45
Sequenced Capacity Control
While in the SEQUENCED mode, Automatic Capacity Control is used to adjust the capacity as documented
above. This is also true for Sequenced mode in Remote control. The master panel will wait for a remote indication
to start and according to the parameter setpoints in the sequencer setpoints screen then the master will turn on
and off the slave panels. If the master panel receives a remote indication to stop then the master panel will
sequentially communicate to the other panels to unload and all the panels will stay on-line.
When a sequenced compressor is on-line, one of the following three commands will be sent from the master
sequencer controller.
• Trim When the trim command is sent from the master sequencer, the Viltech will start the RECIP
compressor. The Control Parameter and Control Setpoint will be also be sent from the master, and the
compressor will begin making capacity adjustments using Automatic Capacity Control. Once the
compressor is started, the status area will display RUN-TRIM indicating that the trim command was
received.
• Full Load When the Full Load command is sent from the Master Sequencer, the Viltech will force and
hold the compression at full capacity. When the Full Load command has been received the status area
will display FULL LOAD.
• Seq-Stop When the Seq Stop command is received from the master sequencer the Viltech will stop the
RECIP compressor automatically and leave it on-line for sequenced operation.
LowAlarm and Failure Setpoints
When Sequenced mode is enabled and the compressor is online or running, the local low alarm and failure
setpoints are replaced by the Sequencer low alarm and failure setpoints. This is true for both Suction
Pressure and Process Temperature operation. The local sensor is still used to generate the alarm or failure
condition.
Running in Trim Mode
When the TRIM command is sent from the master sequencer the Viltech receives the System Control
Parameter, System Control Setpoint, and the sequencer load and unload deadband and bandwidth
parameters. These new control parameters are used instead of those defined on the Viltech itself. The
compressor’s local Normal Stage delay and Fast Stage delay are used for capacity changes.
The main status page will identify the control setpoint group as SY indicating that it is the System Control
Setpoint. Automatic Capacity Control is used to adjust the capacity while in Sequenced mode. The
System Control Parameter, System Control set-points, and Low Alarm and Failure setpoints are sent to the
compressor periodically by the master sequencer to ensure that the compressor is always using current
data. All automatic starting and stopping of the RECIP compressor is controlled by the master sequencer.
The local RECIP’s Cut-In and Cut-Out controls are also disabled. When the RECIP compressor is fully
loaded, limited, or forced to unload due to high process temp or suction pressure, the VILTech informs the
master sequencer that no further capacity increases are possible and additional compressors may be
needed.
46
Running in Full Load Mode
When the FULL LOAD command is received the Viltech disables all capacity control and locks the
compressor at the fully loaded position. However, normal limiting and unloading functions will still be active.
Anti-Cycle in Sequenced Mode
While in the SEQUENCED mode the anti-cycle time takes on a new role. If the master sequencer requests a
RECIP compressor to stop but time is still remaining on the anti-cycle timer, the compressor will not stop. The
compressor will remain running, until the anti-cycle timer expires. This procedure ensures that the compressor
is always available for the next sequenced start. If the compressor should be stopped manually, or due to a
failure, with time remaining on the anti-cycle timer it would then be unavailable for sequencing until the timer
expires.
Forced Unloading & Limiting
FORCED UNLOADINGAND LIMITING are performed to protect the system under extreme conditions or to slow-
down the rate of capacity increase. The Viltech may unload the compressor or limit loading of the compressor due
to high discharge and suction pressure. In the Manual mode of operation and forced unloading is enabled.
Forced Unloading and Limiting will cancel any ongoing capacity control changes. If a parameter exceeds the high
limit setpoint the compressor will be limited (not allowed to load). If a parameter exceeds the high unload setpoint
the compressor will be forced to unload until the parameter is reduced.
Ramp Start
RAMP START adjusts the forced unloading and limiting setpoints during a period of time after the compressor is
started. Ramp start is used to reduce the demand power requirements during compressor startup. Each high
unload and high limit setpoint has associated with it a similar ramp unload and ramp limit setpoint. Also associated
with each different parameter is a ramp duration time. After the compressor has started, the forced unloading and
limiting setpoints are gradually changed from the ramp setpoints to the high setpoints during the ramp duration
time. The Discharge Pressure Ramp Start parameters are set-up on the Discharge Pressure Setpoints screen under
the SETPT hot key.
The relationship of the ramp start feature to unloading and limiting can be seen in the following figure.
47
Capacity Ramp Start Limiting
The CAPACITY RAMP START feature has been provided to limit capacity increases after the
compressor starts. The operator can define the total time to limit capacity increases from the minimum
capacity to 100% capacity. Once the compressor has started and the minimum capacity has been
achieved, the capacity ramp timer is started, and further capacity increases will be limited. The
maximum allowable capacity will be gradually increased from the minimum capacity to 100% over the
ramp duration. When the capacity is limited due to this feature, the RECIP state will display
“LIMIT:CAP”. Unlike other limiting and unloading, the compressor is not considered fully loaded
when in this state.
The Capacity Ramp Start feature is available in Automatic, Auto-Remote and Sequenced mode.
When in Sequenced mode, capacity changes are limited when the compressor is a Fully Loaded
machine. If a fully loaded compressor is forced to unload for any reason, the capacity ramp will
engage from the current capacity position once the limiting condition has gone away. The Capacity
Ramp Start parameters are set-up on the Capacity set-point screen.
48
Staging Setup
The Viltech controller can be configured to operate on any compressor that performs capacity control in discrete
steps. The Controller supports up to six (6) capacity steps. Each capacity step is configured to energize to unload
(Unloader). Also, each capacity step can be assigned a percentage associated with that level of capacity. A
capacity percentage is also assigned to the fully unloaded position. The staging configuration is accessed from
the configuration menu (MENU >SYSTEM SETUP-> CONFIGURE HARDWARE -> STAGING
CONFIGURATION). To avoid possible damage to the compressor, it is important that the capacity configuration
be setup to match the compressor configuration when the controller is initially installed.
Minimum Capacity
Certain compressors should not operate below a minimum capacity value under normal operations. The compres-
sor starts fully unloaded and then must be staged up to the minimum immediately. Once the compressor has
started and the “Up to Speed” delay has expired, the compressor will be staged up to the minimum capacity
position using the load fast stage delay. Once the minimum capacity has been reached, the compressor will
transition into the running state. Under normal capacity control, the compressor will never unload beyond this
value. Please check the compressor manufactures documentation to verify if this is required for your unit.
49
Setpoint Scheduling
SETPOINT SCHEDULING is the automatic switching of Suction Pressure or Process Temperature control
setpoint groups based on time of the day and day of the week. The operator can define up to seven (7)
different daily time schedules and one weekly schedule. Schedule events can be manually overridden
and scheduling can be enabled or disabled by the operator. Setup of schedules and control of the
scheduling is performed from the Scheduling menu under the SETPT hot key.
Daily Schedules
Each DAILY SCHEDULE consists of up to eight (8) different time-of-day slots. For each time-of-day
slot the operator can define the time (either in 12 or 24 hour mode, depending on system clock mode
selected) and the desired setpoint group number. Unused time slots are ignored and the schedule
may be entered in any order. When the schedule is saved it is reordered chronologically. Each daily
schedule is identified by a schedule name (SCH1 - SCH7).
Weekly Schedule
The WEEKLY SCHEDULE allows the operator to assign different daily schedules to each day of the
week. A new day begins and schedules change at midnight. The current daily schedule or control
group may be overridden by the operator at anytime. Any item which has been manually overridden
will be changed when the next schedule change occurs.
Oil Pressure Computation
The oil pressure for a RECIP compressor is computed as follows:
Oil Pressure = Oil Pressure Sensor - Suction Pressure
The actual sensor value can be viewed on the Calibration and View analog screens. All other screens
display the computed value.
Oil Temperature Regulation
The OIL TEMPERATURE in the crankcase is regulated when the RECIP compressor is stopped. The temperature is
maintained above the oil heater setpoint with a deadband of +5 degrees. When the compressor is stopped, and
the Oil Temperature falls below the Heater Control Setpoint, the Oil Heaters will be turned on. When the Oil
Temperature rises 5 degrees above the Heater Control setpoint, the oil heaters will be turned off. The Heater
Control Set-point may be found on the Oil Temperature Setpoints screen under the SETPT hot key.
50
Anti-Cycle Timer
The ANTI-CYCLE TIMER is used to avoid repeated start attempts within a user programmable period of
time. The Anti-Cycle timer is started with the motor and must completely count down before the motor
can be started again. The duration of the Anti-Cycle timer can be adjusted from the Miscellaneous
Controls.
Power Fail Restart
The operator can define a POWER FAIL RESTART time from the miscellaneous controls screen. If the
Viltech is reset manually or due to a loss of power the down time is calculated and compared to this
setpoint. If power was off longer than the power fail restart time a failure is reported. If the power loss
was less than the setpoint no failure is reported and the compressor remains on-line and is allowed to
automatically restart if required.
Process Temperature Control (Option)
When the PROCESS TEMPERATURE option is enabled, the RECIP compressor capacity is adjusted to
maintain the outlet temperature of a product or process instead of suction pressure
(e.g. chiller outlet temperature control). The control strategy is documented in the Capacity Control
section above.
Two Stage Configuration (Option)
In a TWO STAGE CONFIGURATION, an intermediate pressure and temperature sensor are monitored. High Failure,
HighAlarm, LowAlarm and Low Failure setpoints are provided for each.
51
Operational Procedures
The operator interface for the RECIP compressor is performed using LCD, keypad, and the
following four hot keys:
STOP
SETPT
LOGS
MENU
The following sections will explain the operating procedures associated with each of these
hot keys.
Momentary Screen
The following table lists possible momentary screens associated with the START mode key function.
SCREEN
FUNCTION
STARTINGMANUALMODE
The compressor is starting in the Manual mode.
STARTINGAUTOMATICMODE The compressor is starting in the Automatic mode.
ON-LINEREMOTEMODE The compressor is on-line in the Remote mode and may be started by the
remote computer.
ON-LINEAUTO-REMOTEMODE The compressor is on-line in the Auto-Remote mode and may start,
depending on the state of the Remote Start/Stop input, or the remote
computer.
ON-LINESEQUENCEDMODE
The compressor is on-line in the Sequenced mode and may start,
depending on the master sequencer.
STARTDISABLEDALREADY
IN PROGRESS
STARTDISABLEDSYSTEM
RUNNING
The start function is disabled because the compressor is already in the
process of undergoing the start-up operation.
The start function is disabled because the compressor is already IS
running.
STARTDISABLEDANTI-CYCLE The compressor is delayed from starting. An anti-cycle timer has been
XX:XX
activated which prevents start-up until the time period has expired
(XX:XX is the time remaining). The screen will continue to be displayed
until the timer expires or the user presses the QUIT key.
STARTDISABLEDSYSTEM
ALARM/FAILURE
The start function is disabled due to a system alarm or ALARM/ failure.
52
53
Status Screens
The status of the compressor can be viewed from a group of status screens as described below. Consecutive uses
of the QUIT key will return the user to the main STATUS SCREEN.
Compressor Main Status Screen
The COMPRESSOR STATUS SCREEN shows a numerical summary of the compressor analog and state
parameters. The values are continuously updated in real-time to reflect the current state of the compressor.
For example, in the figure below, the current state of the system is STOP-ONLINE. The system’s mode of
operation is SEQ (Sequenced) and the alarm status of the system is NORM (normal). There are also two
system functions which may be performed from this screen: Capacity adjustment when in Manual mode and
the clearing of alarms and failures.
RECIP Status Screens
The following table lists the additional keys available on the RECIP status screen.
KEY
FUNCTION
UPARROW
Loads the compressor when RECIP is in Manual or Local mode. One stage is added each time
the UP arrow key is pressed.
DOWNARROW Unloads the compressor when RECIP is in Manual or Local mode, or if one stage is removed.
CLEAR
Stops manual capacity loading or unloading. Acknowledges alarms and failures and stops the
alarm horn from sounding.
RECIP Status Screen Keys
Manual Capacity changes are discussed in the Capacity Control section and Alarms and Failures are discussed in
theAlarm/Failure section of this manual.
54
The following table lists the various parameters displayed on the RECIP status screen.
PARAMETER
DESCRIPTION
S1-S4, P1-P4, SY
The active capacity control setpoint. S1-S4 indicate represent Suction
Pressure setpoints, P1-P4 represent Process Temperature setpoints, and SY
represents the Sequenced setpoint.
Suction Pressure
Discharge Pressure
Oil Pressure
Intermediate Pressure (two-stage machines only)
Capacity
SP
DP
OP
IP
CP
ST
DT
Suction Temperature
Discharge Temperature
OT
Oil Temperature
Status Banner
The STATUS BANNER is located at the bottom of the Compressor status screen, Active
Alarms & Failures screen, and Auto-Start Warning status screen. The Banner consists of
three highlighted sections which provide the user with the status of the following system
conditions.
Current System State
Current Operating mode
Alarm & Failure Status
55
Current System State
The left-most highlighted status banner section displays the CURRENT STATE of the system. The following is a
table with a brief description of possible system states.
CURRENT STATE DESCRIPTION
ACYCLE XX:XX
STOPPED
Anti-cycle count down timer has been activated to delay motor start. XX:XX is the time remaining.
Compressor is stopped.
STARTING
RUNNING
Starting sequence is in progress.
Compressor is running.
INCREASING
DECREASING
LIMIT:CAP
LIMIT:DP
UNLOAD:DP
STOPPING
FAILED
Capacity is increasing.
Capacity is decreasing.
Loading was stopped due to capacity
Loading was stopped due to high discharge pressure.
Forced unloading due to high discharge pressure.
Stopping sequence is in progress.
Compressor has failed.
RESET
The Viltech has been reset.
STOP-OFFLINE
STOP-ONLINE
Compressor is stopped and is off-line (not available for auto start).
Compressor is stopped and is on-line (available for auto start)
STOP CUT-OUT Compressor is stopped on cut-out pressure (or temperature)
RUN-TRIM
The compressor is running in Sequenced mode as the Trim machine.
FULL-LOAD
The compressor is running in Sequenced mode as a Fully Loaded machine.
System State
Mode Area
The middle highlighted status banner section displays the general operating mode of the system as shown in the
following table:
MODE
AUTO
MAN
DESCRIPTION
Automatic mode is selected.
Manual mode is selected.
Remote mode is selected.
RMT
SEQ
Sequenced mode is selected.
System Modes
56
Alarm & FailureArea
The right most highlighted status banner section displays the ALARM AND FAILURE
STATUS of the system. When a new alarm or failure occurs, this area will flash from
highlighted to non-highlighted to inform the operator. The area will stop flashing but
remain highlighted when the operator has used the CLEAR key to acknowledge the alarm or
failure. Once all alarm and failure conditions have be corrected the operator may again
press the CLEAR key to clear the alarm from the display. The following table lists the
various alarm/failure states and their meanings.
NOTE: If both an alarm and failure exist the failure state will be displayed as it has a
higher priority
ALARM
MESSAGE
NORM
SYSTEMS STATUS
No alarm or failure is active, the RECIP is operating normally.
An alarm is active on the RECIP.
ALARM
FAIL
A failure is active on the RECIP.
Alarm Status
Operating Hours Screen
The OPERATING HOURS STATUS screen allows the operator to view the compressor’s
current running hours since its last start and the total number of hours the system has been
in operation since installation In addition, the number of compressor starts is accumulated
for today, yesterday, and the overall total.
Operating Hours Status Screen
The following table lists the various parameters displayed on the screen.
TERM
RUNNING HOURS The number of successive motor running hours since the last start up.
TOTALHRS The motor’s total accumulated running hours.
STARTS TODAY The number of times the motor has been started since midnight.
DEFINITION
STARTS
The number of times the motor was started yesterday.
YESTERDAY
STARTS TOTAL The total number of times the motor has been started.
Operating Hours Status Definitions
57
ActiveAlarms & Failures Status Screen
The ACTIVE ALARMS & FAILURES STATUS screen displays the system’s currentAlarms/Failures. This screen
will be the initial screen displayed by the system when an alarm or failure first becomes active. The default status
screen can be reached by simply pressing the QUIT key. An example of the alarm screen is shown below.
ActiveAlarms & Failures Status Screen
The active function keys for this screen are described in the following table.
KEY
FUNCTION
SHIFT UP/
DOWNARROWS
Switches control between the display area and the hot keys. Scrolls line by line through the information.
CLEAR
The CLEAR key is used to acknowledge and clear alarms/failures as well as to silence the alarm horn.
ActiveAlarms & Failures Status Screen Definitions
58
Auto-Start Warning Screen
The AUTO-START WARNING screen is displayed anytime the RECIP may be automatically
started. The user can return to the system default status screen by pressing the QUIT key
or cycle through all the status screens using the ENTER key. The system will return to the
Auto-Start Warning screen after 10 minutes of keypad inactivity. An example of the screen
is shown below.
AUTO Start Warning Screen
SETPT Hot Key
The SETPT hot key allows the operator to select various systems options available. When the
SETPT key is selected, a menu screen displays the available options contained on the system.
SETPT Hot Key Screen
59
Setpoint
The SETPOINT option allows the user to access a set of menu options used to set the
systems various setpoints. SETPOINTS
1. PRESSURE
1. SUCTION CONTROL GROUP
2. HIGH SUCTION
3. DISCHARGE
4. OIL
5. INTERMEDIATE (Two stage only)
2. TEMPERATURE
1. DISCHARGE
2. OIL
3. PROCESS GRP
4. HIGH PROCESS
5. INTERMEDIATE (Two stage only)
3. CAPACITY
SETPT Menu Diagram
60
Pressure Setpoints
The Pressure Setpoints menu allows the user adjust the various pressure related setpoints
described in the following sections.
Suction Pressure Control Groups
This screen allows the user to set the control values for each of the RECIP’s four (4) control groups
which are used for Automatic Capacity control. An example of the screen is shown below.
Suction Pressure Control Data Entry Screen
61
The following table lists the data entry fields on the screen and a description of their purposes.
TERM
DEFINITION
RANGE
CUT-IN
Cut-in Setpoint. IfAutomatic orAuto-Remote mode is
selected, Auto Start/Stop is enabled, the compressor is
on-line, and the suction pressure rises above the Cut-in
Setpoint, the compressor will start.
29.9 INHG185.0 PSIG
29.9 INHG185.0 PSIG
CONTROL
CUT-OUT
Control Setpoint. In the Automatic or Auto-Remote
mode of operation the compressor is loaded or unloaded
as required to maintain the Control Set-point.
Cut-out Setpoint. IfAutomatic orAuto-Remote mode
is selected, Auto Start/Stop is enabled, the compressor is
running, and the suction pressure falls below the Cut-out
Setpoint, the compressor will stop.
The Suction Pressure value at which the Viltech should
report a Low Suction Pressure alarm to the operator
(for all modes except Sequenced).
29.9 INHG185.0 PSIG
29.9 INHG185.0 PSIG
29.9 INHG185.0 PSIG
LOWALARM
LOWFAILURE The Suction Pressure value at which the Viltech should
fail (stop) the compressor and report a failure to the
operator (for all modes except Sequenced).
Suction Pressure Control Data Definitions
Suction Pressure Active Group Control Screen
62
TERM
DEFINITION
RANGE
ACTIVEGROUP
There are four possible suction pressure control
groups, each with its own pressure parameters.
This field is used to manually select the active
setpoint group.
S1-S4
Suction Pressure Active Group Control Definitions
High Suction Pressure Setpoints
The HIGH SUCTION PRESSURE alarm and failure setpoints are not scheduled and are active
regardless of which group is in control.This screen also has the High Suction Limit & Unloading
for each step of CapacityControl
High Suction Pressure Setpoints Screen
The following table lists the data entry fields for the High Suction Pressure Set-points screen
TERM
DEFINITION
RANGE
HIGHFAILURE
The compressor is failed (stopped) when this
value is exceeded.
The Viltech reports an alarm to the operator when
this value is exceeded.
29.9INHG
-185 PSIG
29.9INHG
-185PSIG
HIGHALARM
High Suction Pressure Data Definitions
63
Discharge Pressure Setpoints
The DISCHARGE PRESSURE SETPOINTS screen is used to set the discharge pressure control parameters for
high alarm, limiting, and ramp conditions.
Discharge Pressure Setpoints Data Entry Screen
The following table lists the data entry fields for the Discharge Pressure Setpoints screen.
TERM
DEFINITION
RANGE
HIGHFAILURE
The compressor is failed (stopped) when this value is exceeded.
0 - 225 NH3 0
- 275 FREON
0 - 225 NH3 0
- 275 FREON
0 - 225 NH3 0
- 275 FREON
0 - 225 NH3 0
- 275 FREON
0 - 225 NH3 0
- 275 FREON
0 - 225 NH3 0
- 275 FREON
HIGHALARM
The Viltech reports an alarm to the operator when this value is exceeded.
The compressor is forced to unload when this value is exceeded.
The compressor is not allowed to load when this value is exceeded.
The starting value of the forced unload parameter used during ramp start.
The starting value of the limiting parameter used during ramp start.
HIGH UNLOAD
HIGH LIMITING
RAMP UNLOAD
RAMP LIMITING
RAMPSTART DELAY The time period after start used to ramp the forced unload and limiting
parameters from the ramp value to the normal value.
Allows Discharge Pressure Ramp start to be enabled or disabled.
0.1 - 60 Min
ENABLE/
RAMPSTART
ENABLE
DISABLE
Discharge Pressure Data Definitions
64
Oil Pressure Setpoints
The OIL PRESSURE SETPOINTS screen allows the operator to set acceptable ranges for the oil pressure
parameter to allow the Viltech to identify when the value is out of range. An example of the screen is shown
below.
Oil Pressure Setpoints Screen
The following table lists the data entry fields and a description of their purpose.
TERM
DEFINITION
RANGE
LOWALARM
The Viltech will report an alarm to the operator when
the Oil Pressure is below this value
The compressor will be failed (stopped) when the
20 - 200 PSIG
LOWFAILURE
Oil Pressure is below this value.
20 - 200 PSIG
Oil Pressure Setpoints Definitions
NOTE: The Oil Pressure on a RECIP Compressor is computed as the differential between the Oil Pressure Sensor and
Suction Pressure.
65
Intermediate Pressure Setpoints (Two Stage only) Option
The INTERMEDIATE PRESSURE SETPOINTS screen allows the operator to set acceptable ranges for the
intermediate pressure, and is only visible on the two stage compressor. An example of the screen is shown below.
Intermediate Pressure Setpoints
The following table lists the data entry fields and a description of their purposes.
TERM
HIGHFAILURE
DEFINITION
The compressor is failed (stopped) when the Intermediate
Pressure exceeds this value.
RANGE
0 - 225 PSIG
HIGHALARM
LOWALARM
LOWFAILURE
The Viltech reports an alarm to the operator when the
Intermediate Pressure exceeds this value.
The Viltech will report an alarm to the operator when the
Intermediate Pressure is below this value.
The compressor will be failed (stopped) when the
0 - 225 PSIG
0 - 225 PSIG
Intermediate Pressure is below this value.
0 - 225 PSIG
Intermediate Pressure Definitions
66
Temperature Setpoints
The TEMPERATURE SETPOINTS menu allows the user to set temperature related setpoints
described in the following sections.Discharge Temperature Setpoints
Discharge Temperature Setpoints
The DISCHARGE TEMPERATURE SETPOINTS screen allows the operator to set acceptable
ranges for the RECIP discharge temperatureand second discharge temperature (DT2) for 12 &
16 single stage compressors.
.
Discharge Temperature Setpoints Screen
The following table lists the data entry fields and a description of their purposes.
TERM
DEFINITION
RANGE
HIGH FAILURE The compressor is failed (stopped) when
the discharge temperature exceeds this value.
32-392 DEGF
Discharge Temperature Definitions
67
Oil Temperature Setpoints
The OIL TEMPERATURE SETPOINTS screen allows the operator to set acceptable ranges for the
RECIP oil temperature.
Oil Temperature Setpoints Screen
The following table lists the data entry fields and a description of their purposes.
TERM
DEFINITION
RANGE
HIGHFAILURE
The compressor will be failed (stopped) when
the oil temperature exceeds this value.
The Viltech will report an alarm to the operator
when the oil temperature exceeds this value
The temperature at which to maintain the oil in
the separator. The oil heater uses the Oil
Temperature sensor but only when the compressor
is stopped.
32-392 DEGF
32-392 DEGF
HIGHALARM
HEATERCONTROL
32-392 DEGF
32-392 DEGF
32-392 DEGF
LOWALARM
LOWFAILURE
The Viltech will report an alarm to the operator when
the Oil Temperature is below this value.
The compressor will be failed (stopped) when the
Oil Temperature is below this value.
Oil Temperature Definitions
68
Process Temperature Control Group
The PROCESS TEMPERATURE CONTROL GROUP screen is used to set-up the Process Temperature control
parameters when the Process Temperature Control option is enabled.
Process Temperature Control Group
TERM
DEFINITION
RANGE
CUT-IN
Cut-in Setpoint. IfAutomatic orAuto-Remote mode is selected,
Auto Start/Stop is enabled, the compressor is on-line, and the process
temperature rises above the Cut-in Setpoint, the compressor will start.
Control Setpoint. In the Automatic or Auto-Remote mode of operation
the compressor is loaded or unloaded as required to maintain the Control
Set-point.
Cut-out Setpoint. If Automatic or Auto-Remote mode is selected, Auto
Start/Stop is enabled, the compressor is running, and the process temperature
falls below the Cut-out Setpoint, the compressor will stop.
-58:122DEGF
-58:122DEGF
CONTROL
CUT-OUT
-58:122DEGF
-58:122DEGF
-58:122DEGF
LOWALARM An alarm is reported when the Process Temperature falls below the low
alarm setpoint.
LOWFAILURE A failure is reported and the compressor is shutdown when the Process\
Temperature falls below the low failure setpoint.
Process Temperature Definitions
69
Process Temperature Active Group Control Screen
TERM
DEFINITION
ACTIVEGROUP
There are four possible process temperature control groups, each with it’s own
temperature control parameters. This field is used to manually select the active
setpoints group.
Process Temperature Active Group Control Definitions
High Process Temperature Setpoints
The HIGH PROCESS TEMPERATURE SETPOINTS screen is only visible when the Process Temperature
Control option is enabled.
High Process Temperature Setpoints Screen
TERM
DEFINITION
RANGE
HIGHFAILURE
A failure is reported and the compressor is shutdown when
the Process Temperature rises above the High Failure setpoint -58:122DEGF
An alarm is reported when the Process Temperature rises
HIGHALARM
above the High Alarm setpoint.
-58:122DEGF
High Process Temperature Setpoint Definitions
70
Note Page
71
Capacity Setpoints
The CAPACITY SETPOINTS screen allows the operator to set acceptable ranges for minimum Capacity
and Ramp Start Parameters as shown in the following example.
Capacity Setpoint Screen
The following table lists the data entry fields and a description of their purposes.
TERM
DEFINITION
RANGE
MINIMUMCAPACITY
The minimum allowable capacity of the compressor when
running.
0-100 PCT
RAMPSTARTDELAY
The amount of time after startup that Capacity Limiting will
take place.
0-60MIN
ENABLE/
DISABLE
RAMPSTARTENABLE Allows Capacity Ramp Start to be enabled or disabled.
Capacity Setpoint Definitions
72
Scheduling
The SCHEDULING function allows the user to create and modify schedules to control the changing of Suction
Pressure or Process Temperature Setpoints based on the day of the week and time of day. The following sections
will describe the various screens associated with this function.
Scheduling
1. CONTROL
2. ACTIVE GROUP
3.ACTIVE SCHED
4.WEEKLYSCHED
5. DAILYSCHED
Control
The CONTROL screen allows the user to determine if equipment operation will be controlled by predefined schedules.
An example of this screen is shown below.
Scheduling Control Screen
The following table lists the data entry fields and a description of their purposes.
TERMS
DEFINITION
RANGE
SCHEDULING Allows the Setpoint Scheduling feature to be enabled or disabled
ENABLED/DISABLE
Scheduling Definition
73
Active Group
The ACTIVE GROUP screen allows the user to select the current active group. This setting will be active
until a scheduling change or the operator modifies it. An example of the screen is shown below.
Active Group Screen
The following table lists the data entry fields and a description of their purposes.
TERM
DEFINITION
RANGE
GROUPNUMBER
The active suction pressure control group for the system.
If Suction Pressure control is enabled, G1G4 correspond to
Suction Pressure control groups S1-S4. If Process
Temperature control is enabled, G1-G4 correspond to Process
Temperature control groups P1-P4.
G1-G4
Active Group Definitions
Active Schedule
The ACTIVE SCHEDULE screen allows the user to change the current active daily schedule. This setting
will be active until a scheduling change or the user modifies it. An example of the screen is shown below.
Active Schedule Screen
The following table lists the data entry fields and a description of their purposes.
TERM
DEFINITION
RANGE
DAILYSCHEDULE The current daily schedule used by the system.
SCH1 - SCH7
Active Schedule Definitions
74
Weekly Schedule
The WEEKLY SCHEDULE screen is used to define which of the seven available daily schedules is to be
assigned to each day of the week as shown in the following example screen.
Weekly Schedule Screen
The following table lists the data entry fields and a description of their purposes.
TERM
DEFINITION
RANGE
DAYSOFTHEWEEK
The daily schedule assigned to that specific day of the week. SCH1 - SCH7
Weekly Schedule Definitions
Daily Schedule
The DAILY SCHEDULE function is used to define the times at which to change control setpoints for
each of the seven available daily schedules. The first screen upon entering the Daily Schedule
function is an access screen, which prompts the user to enter a number from one to seven to view the
corresponding Daily Schedule.
Daily Schedule Screen
75
Schedule 1 To Schedule 7
The seven DAILY SCHEDULES all have a standard format allowing the user to select up to 8 schedule changes
per day. The following example shows the standard format for all seven of the daily schedules.
DAILYSCHEDULE
hh:mm:ss
GROUP
NUMBER
SCHEDTIME
1
2
3
4
5
6
7
8
XX:XX AM
XX:XX AM
XX:XX AM
XX:XX AM
XX:XX AM
XX:XX AM
XX:XX AM
XX:XX AM
G1
G2
G3
G4
G3
G2
G1
G1
Daily Schedule 1 Screen
76
The following table lists the data entry fields and a description of their purposes.
TERM
SCHEDTIME
GROUPS
DEFINITION
RANGE
ValidTime
G1-G4
The time of day the control group will be changed to the selected group.
The control group number to be used after the scheduled time occurs.
Daily Schedule 1 Definitions
CAP Control
The CAP CONTROL option allows the user to access a set of menu options used to
set the systems control features. CAP CONTROL
CAP CONTROL
1. SUCT PRESS
2. PROC TEMP
Suction Pressure Control Setpoints
The SUCTION PRESSURE CONTROL SETPOINTS screen allows the user to set-up the Load and Unload Controls
for Automatic capacity control. The Normal Stage delay and Fast Stage Delay fields are also used for Capacity
changes in the Sequenced mode. Included on this screen is additional reference data to assist the operator when
setting-up the compressor. An example of the screen is shown below.
SUCTION PRESS CONTROL SETPTS
LOAD
hh:mm:ss
UNLOAD
NORMAL BANDWIDTH
CONTROLDEADBAND
NORMALSTAGE DELAY
FASTSTAGE DELAY
XX.X
XX.X
XX.X
XX.X
XX.X PSID
XX.X PSID
XX.XSEC
XX.XSEC
SETPOINT
MODE
STATE
S1
AUTO
FAILED
X.XPSIG
SP
CP
XX.X INHG
XX.X PCT
Suction Pressure Control Setpoints Screen
77
The following table lists the data entry and information fields on the screen and a description of their purposes.
PARAMETER DEFINITION
RANGE
NORMAL
Adjusts the sensitivity of the time proportional control routine.
0-20PSID
BANDWIDTH
CONTROL
DEADBAND
NORMAL
The capacity will not be adjusted if the suction pressure is within
the control deadband.
The Normal Stage Delay Timer starts when the Suction Pressure
0-20PSID
1-999 SEC
STAGEDELAY exceeds the Control Deadband. When it expires, a stage will be added
or removed as appropriate
FASTSTAGE
DELAY
SETPOINT
SUCTION
PRESSURE
CAPACITY
The Fast Stage Delay Timer starts when the Suction Pressure exceeds
the Normal Bandwidth.
The current control setpoint group and value (reference).
The current suction pressure (reference).
The current capacity (reference)
1-999 SEC
N/A
N/A
N/A
RECIPMODE The current compressor mode (reference).
RECIPSTATE The current compressor state (reference).
N/A
N/A
Suction Pressure Control Setpoints Definitions
Process Temperature Control Setpoints
The PROCESS TEMPERATURE CONTROL SETPOINTS screen allows the user to setup the Load and Unload
Controls for Automatic capacity control. The Normal Stage delay and Fast Stage Delay fields are also used for
Capacity changes in the Sequenced mode. Included on this screen is additional reference data to assist the
operator when setting-up the compressor. An example of the screen is shown below.
PROCESS TEMP CONTROL SETPTS
LOAD UNLOAD
XX.X XX.XDEG
hh:mm:ss
NORMAL BANDWIDTH
CONTROLDEADBAND
NORMALSTAGE DELAY
FASTSTAGE DELAY
XX.X XX.XDEG
XX.X XX.XSEC
XX.X XX.XSEC
SETPOINT
MODE
STATE
S1
AUTO
FAILED
X.XPSIG
PT
CP
XX.X DEGF
XX.X PCT
Process Temperature Setpoints Screen
78
The following table lists the data entry and information fields on the screen and a description of their purposes.
TERM
DEFINITION
RANGE
NORMAL
BANDWIDTH
CONTROL
DEADBAND
NORMAL
Adjusts the sensitivity of the time proportional control routine.
0 - 20 DEG
0-20DEG
The capacity will not be adjusted if the Process Temperature is within
the control deadband.
The Normal Stage Delay Timer starts when the Suction Pressure
STAGEDELAY exceeds the Control Deadband. When it expires, a stage will be added
or removed as appropriate
1-999 SEC
FASTSTAGE
DELAY
SETPOINT
The Fast Stage Delay Timer starts when the Suction
Pressure exceeds the Normal Bandwidth.
The current control setpoint group and value (reference).
1-999 SEC
N/A
PROCESSTEMPThe current Process Temperature value (reference)
CAPACITY The current Capacity (reference)
N/A
N/A
RECIPMODE The current compressor mode (reference).
N/A
RECIPSTATE The current compressor state (reference).
N/A
Process Temp Control Setpoints Definitions
MISC Control
The MISCELLANEOUS CONTROL screen provides setpoints and controls for various system parameters.
Miscellaneous Control Screen
79
The following table lists the data entry fields and a description of their purposes.
TERM
DEFINITION
RANGE
AUTO START/STOP
When Auto Start/Stop is Enabled, the compressor
will start and stop automatically in the Automatic and
Auto-Remote modes.
ENABLE/
DISABLE
POWERFAILRESART When Power Fail Restart is Disabled, the compressor
will be forced off-line after a power failure occurs.
ENABLE/
DISABLE
When Enabled, the compressor will be available to
auto-restart as long as the power has not been off for
longer than the Power Fail Restart Delay.
POWERFAILRESTART This is the maximum amount of time a compressor is
0 - 999 MIN
1-30MIN
DELAY
allowed to be without power before being allowed to
auto-restart when the power returns.
ANTI-CYCLETIME
This is the amount of time that the compressor will be
able to restart after the STOP hot key is pushed.
Miscellaneous Control Definitions
LOGS Hot Key
The LOGS hot key is fully described in Chapter 3, Logging Functions.
MENUS Hot Key
The MENUS hot key is fully described in Chapter 4, Menu Functions.
80
Chapter 3
Logging Functions
The Viltech records the systems parameters and conditions for later use in a set of logs. Each log has a
limit on the number of entries that it can store, so as the log fills-up the oldest entries are replaced by the
most recent ones. The system maintains the following standard logs.
• Operations Log
• Trend Log
• Alarm Log
• Failure Log
• User Log
Log screens usually contain more data than the LCD display area can show at one time. In order to view
the entire set of information the operator uses the function keys. For the specific working procedure of
log screens please refer to the log screen section in Chapter 1.
Logging Functions Technical overview
The following sections will discuss the overall function of each of the five standard logs.
Operations Log
The OPERATIONS LOG displays a list of the system operating conditions for the last hour at 30-
second intervals and has a limit of 255 recorded data entries. An extra entry is made to the Opera-
tions Log when special events occur, such as alarms, failures or system reset. When an alarm, failure,
or OEM failure occurs a special indicator is also placed next to the logged parameter causing the
problem. Typically the data recorded in this log will be the analog inputs, system state variables and
alarm information.
81
Trend Log
The format of the TREND LOG is identical to the operations log. The Trend Log allows the
user to define the recording interval (Default 15 minutes) and has a limit of 255 recorded data
entries. A special entry is made to the Trend Log when certain events occur similar to the
Operations Log. Indicators and highlighting are used to identify parameters causing alarms
or failures as in the Operations Log.
Alarm Log
The ALARM LOG is a record of the last 100 system alarms. When an alarm first occurs an
alarm entry is made in the log. The process is repeated until the maximum of 100 entries is
reached. Alarms previously logged are then replaced by more recent alarms detected.
Failure Log
The FAILURE LOG is a record of the last 100 failures. When a failure first occurs a failure
entry is made in the log. The process is repeated until the maximum of 100 entries is
reached. Failures previously logged are then replaced by more recent failures detected.
User Log
The USER LOG is a record of the last 50 users who logged on to the system. An entry is
made into this log when a user logs on to the system. The process is repeated until the
maximum of 50 entries is reached. Users previously logged on are then replaced by users
who have more recently logged on
82
Logging Functions Operating Procedures
The LOG FUNCTION is accessed by the operator through the LOGS hot key. This hot key allows
the user to view or erase any of the systems available logs. A diagram of the available menu
options under the LOGS hot key is shown below. The operator simply selects the menu item of
the log they wish to access using standard menu screen operating procedures.
LOGS
1. VIEWLOGS
1. OPERATIONS LOG
2. TRENDLOG
3.ALARM LOG
4. FAILURELOG
5. USERLOG
2. CLEAR LOGS
1. OPERATIONS LOG
2. TRENDLOG
3.ALARM LOG
4. FAILURE LOG
5. USERLOG
3. CLEARALLLOG
1. NO
2.YES
The following sections will provide an operating overview of the system logs.
83
Operations and Trend Logs
The OPERATIONSAND TREND LOGS typically store the same parameters. The only difference is the time
interval at which entries are made. The logs will also indicate which parameters have caused an alarm or failure by
placing an indicator next to the responsible parameter. The following table shows the indicators used for each of
the system alarm or failure states.
INDICATOR
STATE
Alarm State
Failure State
A
F
O
OEM Failure State
NOTE: The Operations and Trend Logs on compressors only accumulate data when the compressor is running.
However, alarm and failures will still be logged when the compressor is stopped.
The following is an example of the first page of the Operations Log. This particular log has 7 different pages to
display all the data.
PG 1/7 OPERATIONS LOG
hh:mm:ss
TYPE
TIME
DATE
HH:MM:SS AM
HH:MM:SS AM
HH:MM:SS AM
HH:MM:SS AM
HH:MM:SS AM
HH:MM:SS AM
MM:DD:YY
MM:DD:YY
MM:DD:YY
MM:DD:YY
MM:DD:YY
MM:DD:YY
MODES
MODES
MODES
MODES
MODES
MODES
HH:MM:SS AM
MM:DD:YY
MODES
Operations Log Page
The following data descriptions apply to the Operations and Trend Logs.
PARAMETER
TIME
DATE
DEFINITION
The time the problem occurred.
The date the problem occurred.
The type of log entry.
TYPE
ENTRY DESCRIPTION Description of the log entry if applicable.
ALARM LEVEL
DATA
The status level of the alarm/failure if one occurred.
The analogs and other data recorded for the system.
Operations Log Definitions
84
Alarm and Failure Logs
The ALARM AND FAILURE LOGS are records of the system alarm and failure conditions.
The screen format is the same for both logs, except for the TYPE column. The following is
an example of the first page of theAlarm log.
PG 1/2
TIME
ALARM LOG
DATE
hh:mm:ss
TYPE
HH:MM:SSAM
HH:MM:SSAM
HH:MM:SSAM
MM:DD:YY
MM:DD:YY
MM:DD:YY
ALARMS
ALARMS
ALARMS
Alarm Log Page
TheAlarm and Failure logs will contain the data described in the following table for each entry.
PARAMETER
TIME
DATE
DEFINITION
The time the problem occurred.
The date the problem occurred.
The type of problem that occurred.
TYPE
Alarm Log Definitions
85
User Log
The USER LOG is a record of the last 50 user logon’s for the system. The following is an example of the first page of
a typical User Log screen.
PG 1/2 USERLOG
hh:mm:ss
USER
TIME
DATE
hh:mm:ssAM
hh:mm:ssAM
hh:mm:ssAM
hh:mm:ssAM
hh:mm:ssAM
hh:mm:ssAM
hh:mm:ssAM
mm/dd/yy
mm/dd/yy
mm/dd/yy
mm/dd/yy
mm/dd/yy
mm/dd/yy
mm/dd/yy
01
01
01
01
01
01
01
User Log Page
The User log will contain the data described in the following table for each entry.
PARAMETER DEFINITION
TIME
DATE
USER
The time the user logged onto the system.
The date the user logged onto of the system.
User identification number.
User Log Definitions
Clear Logs
The CLEAR LOGS function is typically not available to the user. A special one-time password is required from
Vilter Manufacturing to access this function. Please contact the Vilter Manufacturing service department if you
desire to clear the logs.
86
ClearAll Logs
The CLEAR ALL LOGS menu entry provides a method of erasing all the data currently
contained in all the logs available on your system. After choosing to clear all logs the
user will be prompted by a confirmation screen to verify the selection. If the user
decides to continue with the clearing of the logs, a momentary screen will appear with a
message stating that the logs have been erased. The action of clearing the logs
requires a special password. The message “ACCESS DENIED” indicates that the user
does not have privilege to perform this function. If a standard user password will not
allow access to clear the logs, contact your control system provider for assistance.
Set Log Rate
The SET LOG RATES menu entry allows the user to set the rate in minutes for collection of
the logging data. The Trend Log Rate (standard) can be set to the rate in minutes which is
most desirable for your system and operational needs.
87
88
Chapter 4
Menu Functions
The MENUS hot key allows the user to access miscellaneous screens that do not fall under one of the other hot
key categories. The system supports the following four additional menus:
Logon User
Logoff User
Diagnostics
System Set-up
Technical Overview
Additional menus are available for system logon and logoff, basic system information for diagnostic purposes
and set-up of various system parameters, passwords, access levels and initialization sequences.
Logon User
To log onto the system the user selects the LOGON USER option and enters a numeric user
password assigned by the Viltech system manager. Once a password is accepted the system allows
access according to the preset restrictions set by the Viltech according to the access level. Please
review the Screen Access Levels section for an explanation of access levels.
Logoff User
To logoff of the system the user selects the LOGOFF USER menu option. The system then logs the
user off and changes the access levels to the default values. Please review the Screen Access Levels
section for an explanation of access levels.
Automatic Log Off
A user will be automatically logged off after a 10-minute period of no keyboard activity. The system automati-
cally returns to the main status screen.
89
Diagnostics Menu
The DIAGNOSTICS menu option permits the user to view basic information about the system. The information
can then be used to readily troubleshoot problems when they occur. Most of the screens available under this
menu option are view-only screens and information displayed cannot be changed by the user. There are a few
screens available which have selected parameters for which data entry is possible. The menu selections include
System Info, View Discrete I/O, ViewAnalogs, View Network Communications and Override Discrete I/O.
System Information
Selecting SYSTEM INFO will display the System Information screen. Information displayed includes the
dates for last memory initialization and system reset, status on system options such as modem
communications and frame statistics.
View Discrete I/O
The VIEW DISCRETE I/O screens display discrete Input and Output information from the unit. Channel
assignment, signal name, input/output designation and current state of the signal are displayed for discrete
I/O racks.
ViewAnalogs
The VIEW ANALOGS screens display analog signal information from the unit. Channel assignment, signal
name, current value, units of measurement and hexadecimal equivalent values are displayed.
View Network Comm
The VIEW NETWORK COMM selection displays the current communication status for various units
involved in system communication such as the modem, PC or other network connections. Current status, last
error, total error count and message count are examples of the parameters which may be displayed here.
Override Discrete I/O
The OVERRIDE DISCRETE I/O screen allows the user to set the state of certain discrete outputs. It also
allows the user to simulate certain discrete inputs to an active or inactive state. This feature is for diagnostics
purposes only and will only function if the system is off-line.
NOTE: The user is responsible for knowing the consequences of manual control actions. Please use with
caution.
90
Set-up Menu
The SET-UP menu allows the user to perform miscellaneous set-up changes, which are
used to configure the system.
Set Clock
The SET CLOCK screen allows the user to enter the current day and date. The system clock may be set
to a 12 or 24 hour mode.
The correct hour, minute and second for the current time must be entered as 24 hour time.
Calibrate Sensors
Two types of calibration can be accomplished using the Dynamic or Static Sensor Calibration options.
Dynamic Sensor Calibration is selected when the user wishes to change current sensor range values.
Static Sensor Calibration is selected to recall sensor calibration values after a return to factory
configuration or after a system software or hardware change, which would effect sensor calibration.
Dynamic Sensor Calibration
DYNAMIC SENSOR CALIBRATION is the process of adjusting the readings of the Viltech analog
sensors to remove small inaccuracies. The calibration process is performed from the Dynamic Sensor
Calibration screen. The approach used for dynamic calibration divides the sensor range into three
zones. When the value being calibrated is in the upper zone (above 66%) the upper range limit is
allowed to change by a maximum of 5% and the lower range limit remains constant. This is referred to
as a span change. When the value being calibrated is in the lower zone (below 33%) the lower range
is allowed to change by a maximum of 5% and the upper range remains constant. This is referred to
as an offset change. When the value being calibrated is in the middle zone (33% to 66%) both end
points are allowed to move a maximum of 5% (typical) resulting in both a span and offset change.
For best results calibration should be performed both at the operating value and at or near the lower
limit. Several calibration attempts may be required to zero-in on the correct values over the full
operating range.
Static Sensor Calibration
STATIC CALIBRATION is performed to reset or restore sensor calibration values after a hardware,
software or factory configuration change. The previous dynamic calibration results are shown on the
Static Sensor Calibration screen to allow the user to re-enter the values manually or perform a Restore
operation to reset the minimum and maximum range values for the previous calibration results.
Sensors should only be calibrated by qualified personnel and always against devices known to be
accurate. Refer to the information for the Calibrate Sensors screen in the Additional Menus Operating
Procedures section of this manual.
91
Passwords
The Viltech system manager will assign user numbers, passwords, screen read and write access levels and screen
access requirements for all users. A user is defined as an individual or group of individuals who will be using the
system. Each user of the Viltech can be assigned a numeric password to define their operating privileges. The
system manager’s password will initially be assigned by Vilter Manufacturing upon system configuration and may
be changed by the system manager if desired. All other users will be assigned a six digit password, which has an
associated read and write access level. A user must enter the numeric password to log onto the system to obtain
access beyond the basic system default access levels. Once a user is finished performing the task required, he may
then logoff manually. If the logoff option is not selected, logoff will occur automatically after a 10 minute period of
no keypad activity.
Adding/Deleting Users
The system manager is able to add or delete users from the Viltech by accessing the ADD/DELETE USER
screen. A user is added by defining a password, read access level and write access level. The higher the
access level the more privileges the individual will have on the system. Access levels will range from 0 to 9,
with the system manager being assigned 9 for full access. The read and write features will each have their
own access level with the left number being the read access level and the right number being the write access
level. The read access level defines the access level at which a user may view a screen. The write access level
defines the access level at which a user may change data on a screen. When a user is deleted this information
is removed from the list. The maximum number of users is 10. When the system is set to Factory
Configuration, User 01 is given a password of 999999 with full access. This should be changed after the
password system is set-up.
Screen Access Levels
The system manager can assign read and write access levels to groups of screens on the Viltech by
choosing the SCREENACCESS LEVEL menu selection. The specific screens available for protection will
vary depending on the system configuration. Some examples of screens which might be considered for
limited access are control, setpoint, calibration and initialization screens. Access for screens such as set date
and time and set log rate may be less restricted.
Initialization
The INITIALIZATION menu selection under the Set-up group allows the user to reset the system or restore
factory setpoints.
Power Fail Reset
Choosing Power Fail Reset causes the software to restart using current setpoints as if a power failure oc-
curred.
92
Set Factory Configuration
SET FACTORY CONFIG will initialize the system using the preset default factory configuration values. All
the system setpoints and calibration data should be recorded either manually or electronically prior to
performing a Factory Configuration.
Configuration
The CONFIGURATION menu contains menu items which need to be configured once at system startup or which
do not typically require modification.
Display
The DISPLAY set-up screen allows the user to set the units of measure and the
default display configuration.
Communication
The COMMUNICATIONS CONFIGURATION screen (optional) allows the user to set the hardware
communications parameters for the Modbus communications protocol.
Set Operating Status
The SET OPERATING STATUS screen allows the user to reset the runtime and startup information of the
compressor in the event that the data is lost due to a board change or factory configuration operation.
Staging Configuration
The SETUP STAGES screen allows the user to configure the capacity stages for the compressor. The operator can
assign the type of Stage and assign a capacity value for each stage. The type of stages that can be selected are:
None (not used), Loader (energize to load), or Unloader (energize to unload). A capacity value is also assigned to
the fully unloaded condition.
Control Configuration
The Control Configuration screen allows the operator to select refrigerants and enable Viltech options.
Adjust Contrast
The Adjust Contrast screen allows the user to adjust contrast to the display.
93
Operational Procedures
A diagram of the screens available under the MENUS hot key is shown below. Note that some screens are
optional and may not be accessible on all compressors.
MENUS
1. LOGON USER
2. LOGOFF USER
3. DIAGNOSTICS
1. SYSTEM INFO
2. VIEW DISC I/O
1. CHANNEL 1-8
2. CHANNEL 9-16
3. VIEWANALOGS CHANNEL1-8 CHANNEL9-16 (Two stage only)
1. CHANNEL 1-8
2. CHANNEL 9-16
4. COMMUNICATIONS STATUS
5. OVERRIDE 1/O
1. CHANNEL 1-8
2. CHANNEL 9-16
4. SET-UP
1. SET CLOCK
2. CALIBRATE
1. DYNAMIC SENSOR CALIB.
2. STATIC SENSOR CALIB.
3. PASSWORDS
1. ADD/DELETE USERS
2. SCREENACCESSLEVELS
4. INITIALIZATION
1. POWER FAILRESET
2. SETFACTORYCONFIG.
3. SETPOINTSAVE/RESTORE
4. SAVE/RESTORE STATUS
5. CONFIGURE HARDWARE
1. DISPLAY
2. COMMUNICATION
3. SET OPERATING STATUS
4. STAGING CONFIGURATION
5. CONTROL CONFIGURATION
6. ADJUST CONTRAST
Additional Menus Diagram
94
Logon User
To log onto the system the user selects the LOGON USER option and enters the appropriate
user password. Once a password is accepted the system allows access according to the
restrictions preset by the Viltech system manager. Below is an example of a logon.
Logon User Screen
The following table lists the data entry fields and a description of their purpose.
TERM
DEFINITION
RANGE
PASSWORD
The designated password for a particular user.
0-999999
Logon User Definitions
NOTE: The password is not displayed when typed. Instead, “*” characters are displayed to avoid
anyone overseeing the typed password.
Logoff User
To logoff of the system the user selects the LOGOFF USER menu option. A temporary
screen will then appear to signal the initiation of the logoff. The system then logs the
user off and changes the access levels to the default values. The system automatically
returns to the main status screen. A user will be automatically logged off after a 10
minute period of no keyboard activity.
95
Diagnostics
The DIAGNOSTICS menu option permits the user to view and in some cases alter basic information about the
system. The menu selections include viewing System Information, Viewing IO, Analogs; and viewing Network
Communications.
Diagnostics Screen
System Information
The SYSTEM INFORMATION screen is used to provide the user with the system options and software configuration
status. An example of a System Information screen is shown below.
SYSTEM INFORMATION
hh:mm:ss
COPYRIGHT2001
VILTERMANUFACTURING, LLC.
VILTER Standard Recip:V1.00
BUILD DATE : day mm/dd/yy hh:mm:ss
INIT DATE :
day mm/dd/yy hh:mm:ss
RESETDATE : day mm/dd/yy hh:mm:ss
CURNT TIME : day mm/dd/yy hh:mm:ss
OPTIONS :
R22
SEQ
ARMT PT
NETW
TIMER STATUS :
USED X OF X
MAX XX
MAX: XXXX XXXX XXXX XXXX
AVG: XXXX XXXX XXXX XXXX
MIN: XXXX XXXX XXXX XXXX
System Information Screen
96
The following table lists the various parameters displayed on the screen.
PARAMETER
VILTER,INC.
DEFINITION
The name and version number of the installed software.
RECIP COMP.VO.XX
BUILDDATE
INITDATE
The date the system was last built.
The date the system was intiaited.
RESETDATE
CURNTTIME
OPTIONS
The date and time the system was last reset.
The current date and time for this panel.
The status of various options are shown on the lower section of the screen.
The number of timers currently being used, the total number of available timers,
TIMERSTATUS
and the maximum number of timers used since the last reset.
System Information Definitions
View Discrete I/O
The View Discrete I/O screens are information screens used for viewing purposes only as shown in the following
example.
NOTE: The I/O channels are used for optional equipment.
Discrete I/O Rack 1A Screen
97
Discrete I/O Rack 1B Screen
The following table lists the various parameters displayed on the screen.
PARAMETER
CH
DEFINITION
The discrete channel number
NAME
I/O
STATE
The name of the discrete signal.
Shows whether the discrete is an input or an output.
The current state of the discrete signal.
Discrete I/O Rack Definitions
ViewAnalogs
The VIEWANALOG Inputs screen can be viewed by the operator and will be displayed on a screen similar to the
following example.
Analog Inputs Screen (Channels 1-8)
98
The following table lists the various parameters displayed on the screen.
PARAMETER
CH
NAME
VALUE
HEX
DEFINITION
The analog channel number.
The name of the analog signal.
The decimal value of the analog input.
The hexidecimal value of the analog input.
Analog Input Definitions
99
Communication Status
The Communication Status screen allows the user to monitor the status of the system’s communication links. The
screen shown below is an example of a Communication Status screen.
COMMUNICATION STATUS
MODEM
hh:mm:ss
PC
FAIL
MASTR
FAIL
DF1
FAIL
STATUS
FAIL
LASTERR
TOTAL ERR
MSGCOUNT
XXXX
XXXX
XXXX
XXXX
XXXX
XXXX
XXXX
XXXX
VILTER
UNIT: X
DF1
UNIT: X
MODBUS
UNIT X
NETWORK
IN CTRL:NO
Communication Status Screen
The following table lists the various parameters displayed on the screen.
PARAMETER
STATUS
DEFINITION
The status of the link to a specific unit, either pass or fail. MODEM indicates
the status for the optional modem link, PC indicates the status for the optional
PC or Modbus connection, Master indicates the status for an optional.
The last error message received from each unit. The field is blank if no errors
have been received.
LASTERR
TOTALERR
A hexadecimal counter of the total number of errors received by each unit.
Time-out errors do not increase the total. The counter rolls over at FFFF.
A hexadecimal counter of the number of messages received by each unit. The
counter rolls over at FFFF.
MSGCOUNT
VILTERUNITNUMBER
The unit number for use when the compressor is communicating with a Vilter
master panel.
MODBUSUNITNUMBER
NETWORKINCONTROL
The Unit Number used when the compressor is communicating using the
Modbus communication protocol.
Indicates that the Network master is in control of the compressor.
Communication Status Definitions
100
Override Discrete I/O
The OVERRIDE DISCRETE I/O screens allow discrete Inputs and Outputs to be simulated whenever the
compressor is stopped (some channels are not assigned). Any overridden channels will be restored to normal
when the compressor is started.
Override Discrete I/O Rack 1A Screen
Override Discrete I/O Rack 1B Screen
The following table lists the various parameters displayed on the screen.
PARAMETER
CH
DEFINITION
The discrete channel number.
NAME
I/O
STATE
The name of the discrete signal.
Shows whether the discrete is an input or an output.
The current state of the discrete override. AUTO indicates the output is in automatic
control, OFF indicates that the output is de-energized, and ON indicates that the output
is energized.
Override Discrete I/O Rack Definitions
101
Set-up
The SET-UP menu allows the user to perform miscellaneous set-up changes, which are used to configure the
system. The menu selections include Set Time and Date, Calibrate Sensors, Password Control, Initialization, and
Configuration.
Set-up Menu Screen
Set Clock
The SET CLOCK screen allows the user to change the date, clock mode or time of day for the system. The
clock mode gives the user the ability to display time in 24 hour or 12 hour modes. An example of the screen
is shown below.
Set Time & Date Screen
102
The following table lists the data entry fields and a description of their purpose.
TERM
DAY
DEFINITION
The current day of the week.
RANGE
SUN - SAT
DATE
The current date entered as month, day, and year. All six
digits must be entered. For example, to set the date to
March 2nd, 2001, enter 03 02 01. The slash delimiter does
not need to be entered.
MM/DD/YY
24HOURTIME
The current time of day which must be entered in military
24 hour format. This field is initially blank. The user only
needs to enter enough digits to specify the required time.
All unused digits will be set to zero. The colon delimiter
does not need to be entered.
00:00:0023:59:59
CLOCKMODE
The time display mode for the system, either 12 or 24 hour
format.
12HOUR 24 HOUR
Set Time & Date Definitions
Calibrate Sensors
The CALIBRATE SENSORS menu allows the user to adjust the range of sensor inputs. There are two types of
calibration, Dynamic and Static. Dynamic calibration is used primarily for accurate calibration of sensor inputs
where the sensor is being compared to known system conditions. Static calibration is performed to reset or restore
sensor calibration values after a hardware, software or factory configuration change.
Calibrate Sensors Screen
103
Dynamic Sensor Calibration
DYNAMIC SENSOR CALIBRATION is described more fully on page 87 of this chapter.
DYNAMIC CALIBRATION
hh:mm:ss
CH
1
2
3
4
5
6
7
8
NAME
VALUE
SUCTIONPRESS
DISCHARGEPRESS
OILPRESS
DISCHARGETEMP
OIL TEMP
SUCTION TEMP
PRESS.2 OPTIONAL
PROCESSTEMP
XXX.XPSIG
XXX.XPSIG
XXX.XPSIG
XXX.XDEGF
XXX.XDEGF
XXX.XDEGF
XXX.XPSIG
XXX.XDEGF
SPAN CORRECTION 0.0
OFFSET CORRECTION 0.0
Dynamic Sensor Calibration Screen
The following table lists the data entry fields and a description of their purpose.
TERM
CH
DEFINITION
The discrete channel number
NAME
VALUE
UNIT
The name of the discrete signal.
Current dynamic value of the discrete signal.
The unit of measurement for the discrete signal value.
Dynamic Sensor Calibration Definitions
104
Static Sensor Calibration
STATIC SENSOR CALIBRATION is described more fully on page 87 of this chapter.
STATIC CALIBRATION
hh:mm:ss
CH
1
2
3
4
5
6
7
8
NAME
MIN
MAX
SUCTIONPRESS
DISCHARGEPRESS
OILPRESS
DISCHARGETEMP
OIL TEMP
SUCTION TEMP
PRESS2 OPTIONAL
PROCESSTEMP
XXX.X
XXX.X
XXX.X
XXX.X
XXX.X
XXX.X
XXX.X
XXX.X
XXX.X PSIA
XXX.X PSIG
XXX.X PSIA
XXX.X DEGF
XXX.X DEGF
XXX.X DEGF
XXX.X PSIG
XXX.X DEGF
SPANCORRECTION
0.0
OFFSETCORRECTION 0.0
Static Calibration Sensors Screen
The following table lists the data entry fields and a description of their purpose.
TERM
CH
DEFINITION
The discrete channel number
NAME
VALUE
UNIT
The name of the discrete signal.
Current dynamic value of the discrete signal.
The unit of measurement for the discrete signal value.
Static Calibration Definitions
105
Password Control
The Viltech system manager will assign each user a password to define their operating
privileges. The password sets privileges for screen read and write access. The read access
level defines the access level required to view a screen, while the write access level defines
the access level required to change data on a screen.
Each user can be assigned a six digit password, which has associated read and write access
levels. The higher the access level the more privileges the individual will have on the
system. Read and write privileges will each have their own access level. The system
manager can assign read and write access levels to numerous screens on the Viltech. The
Viltech password protection is controlled through two system screens, the Add Delete User
screen and the Screen Access Level screen which are discussed in the following sections.
Password Control Screen
106
Add/Delete User
The ADD/DELETE USER screen will allow for the addition or deletion of a user. This
function is performed by creating or deleting a password and corresponding access levels
for a particular user. An example of the screen is shown below.
ADD DELETE USERS
hh:mm:ss
LEVEL
LEVEL
R / W
XX
XX
XX
USER PASSWORD
R / W USER PASSWORD
1
2
3
4
5
XXXXXX
XXXXXX
XXXXXX
XXXXXX
XXXXXX
XX
XX
XX
XX
XX
6
7
8
9
XXXXXX
XXXXXX
XXXXXX
XXXXXX
XXXXXX
XX
XX
10
Add/Delete Screen
The following table lists the data entry fields and a description of their purpose.
TERM
DEFINITION
RANGE
PASSWORD
LEVEL
The desired password for each user.
The desired read and write levels for each
user. The first digit is the read level and the
second is the write level. The lowest level
of access is 0 and 9 is the highest level.
0-999999
0 - 9 (per digit)
Add/Delete User Definitions
107
Access Levels
Screen Access authorization levels are selected for various screen sections using the
SCREEN ACCESS LEVELS screen. This allows the system manager to restrict user access
to certain areas of the system. An example of a Screen Access Level screen is shown
below.
SCREENACCESSLEVELS
hh:mm:ss
LEVEL
R/W
XX
XX
XX
XX
XX
XX
XX
LEVEL
R/W
XX
XX
XX
XX
XX
XX
XX
FUNCTION
START
STOP / PC
STOP / MODEM
CHANGEMODES
SETPOINTS
CAPACITYCNTRL
SCHEDULING
FUNCTION
MISCCONTROL
SETDATE/TIME
CALIBRATION
CHNG PASSWORDS
INITIALIZATION
CONFIGURATION
SET LOG RATES
Screen Access Level
TERM
DEFINITION
RANGE
ACCESSLEVEL
READ/WRITE
The desired read and write levels for each
user. The first digit is the read level and the
second is the write level. The lowest level
of access is 0 and 9 is the highest level.
0 - 9 (per digit)
Screen Access Level Definitions
108
Initialization
The INITIALIZATION menu selection under the Set-up group includes Power Fail Reset, Setpoint Save/Restore, Save
Restore Status, and Set Factory Config. These screens are discussed further in the following sections.
Initialization Screen
Power Fail Reset
Selection of this initialization option causes the software to restart using the current setpoints as if a power failure
occurred. When the user selects POWER FAIL RESET, a confirmation screen will be displayed asking the user to
verify that he wishes to reset the system. If the user answers yes the system will restart as if a power failure
occurred.
Power Fail Reset Screen
109
1. Set Factory Config
This selection allows the user to reset the system to factory default values. When the user selects the SET
FACTORY CONFIG menu option a confirmation screen will be displayed asking the user to verify that he wishes
to reset the system to the original factory configuration. If the user answers yes the system will be reset and all
existing configuration changes will be lost. This includes all logs, set-points, controls, modes, etc. Do not use
this option without proper consideration of the results.
Set Factory Configuration Screen
2. Setpoint Save/Restore
This function is to be used to save a copy of setpoints from the Viltech to the eeprom of the microprocessor board.
Setpoints Save/Restore Screen
3. Save/Restore Status
This screen display will display that a save or a restore of a status has been made.
Save/Restore Status Screen
110
4. Configuration
The CONFIGURATION menu selection allows the user to set-up various basic system parameters
for the display and operation of the compressor. These parameters are usually set-up once and
never change.
Configuration Screen
Display
The DISPLAY SET-UP screen allows the user to configure the display units for all analog parameters
and panel name.
Display Screen
The following table list the data entry fields and a description of their purpose.
TERM
DEFINITION
RANGE
PRESSURE
UNITS
Selects the units of measure for pressure fields.
PSIG/KPAG/BAR
TEMPERATURE Selects the units of measure for temperature fields. DEGF/DEGC
UNITS
PANEL
NAME
Select panel name to change name of panel by
touching clear and using up down arrows to enter
letters or characters to name the panel
Display Definitions
111
Comm Setup
The following screen is a sample COMMUNICATIONS SET-UPscreen for Modbus Commu-
nications.
Communications Screen
The following table list the data entry fields and a description of their purpose.
TERM
DEFINITION
RANGE
BAUDRATE
DATABITS
Selects the baud rate for Modbus
serial communications.
Selects the number of Databits used for
communications.
2400/4800/ 9600/ 19200
7/8
PARITY
STOP BITS
Sets the Parity used for communications.
Sets the number of Stop Bits to be used
for communication.
None/Odd/Even
1/2
Communications Definitions
112
Set Op Stats
The SET OPERATING STATUS screen is used to reset the total runtime hours and number of
starts following a board change or software update.
Set Operating Status Screen
The following table list the data entry fields and a description of their purpose.
TERM
DEFINITION
RANGE
TOTAL
Sets the total runtime hours for the compressor.
0-999999.9 HRS
HOURS
STARTS
TODAY
Sets the total number of starts since midnight today. 0-999
STARTS
YESTERDAY
STARTS
TOTAL
Sets the total number of starts for yesterday.
Sets to total number of starts for the compressor.
0-999
0-999999
Operating Status Definitions
113
Setup Stages
The following is a sample STAGINGCONFIGURATION STATUS screen.
Staging Configuration Status Screen
The following table list is the data entry fields and a description of their purpose.
TERM
DEFINITION
RANGE
STAGENUMBER
This field displays the reference
number used to identify the state
number
STAGEOUTPUT
STATE
Specify if stage is an unloader
(open to load). Only list those
stages actually used.
ON/OFF
CAPACITYPCT
Selects the capacity for the stage 0-100%
number.
Staging Configuration Status Definitions
NOTE: Stages should be configured starting at Stage 1 and increasing based on the number of Capacity Control
Devices available.
114
Control Configuration
The following screen enables alarm and fail or fail out and selects the refrigerant.
Control Configuration Screen
Adjust Contrast
This screen allows you to change the contrast of the display.
Adjust Contrast Screen
115
Variable Frequency Drive Option
When VFD is enabled, a Proportional-Integral-Derivative (PID) algorithm is used to generate a 4-20mA control
signal to the VFD. The VFD in turn varies the frequency and voltage to the motor resulting in slower or faster
speeds.
The VFD option will only work when the option is enabled and the VFD single channel analog output board
(VPN-3400G) is connected to the microprocessor board. The analog output card is to be placed on the
microprocessor board towards the left-center, by four black “holes” and there is a connector labeled “J5
ANALOG OUTPUT.”
The VFD is enabled by pressing the “Menu” key then press the number 4 for “System Setup” then press
number 5 for “Configure Hardware” and then press number 5 for “Control Configuration”. After enabling the
VFD option, the configuration of the VFD can be located by pressing the “SETPT” key then press number 4
for “Capacity Control” and then press number 2 for “Motor Speed.”
Motor Control Screen
116
VFD Single ChannelAnalog Output Card and Jumper Settings.
Definitions of the terms used in the Motor Speed screen.
Term
Definition
Range
0:1000
Proportional
Constant
Adjusts the speed based on how far the control
parameter currently is from the control setpoint. A higher
P term causes a greater speed changes when far from the setpoint.
Integration Time
Derivative Time
Control Mode
Adjusts speed based on how rapidly the
0:1000 sec
0:1000 sec
control parameter should approach the setpoint. A higher
I term causes a slower approach to the setpoint when the
control parameter is not changing.
Adjusts the speed based on the past value
of the control parameter. Alarge D term may result in large
fluctuations in the speed.
Care must be taken to keep D as low as possible.
The control for the VFD.
Automatic/Manual/Tuning
Automatic lets the VILTech select proper speed.
Manual Speed
The VFD speed when Manual mode is selected.
50-100 PCT
VFD Control Type
The 4-20mA control signal may be set to direct or reverse.
When set to Direct, 4mA is low speed and 20mA is high speed.
When set to Reverse, 20mA is the low speed and 4mA is high speed.
Direct/Reverse
This control is useful for testing purposes.
117
Sequencer Control
The control function is responsible for the management of a group of compressors to control a refrigeration load.
The following sections will present the user with both a technical overview and the operating procedures for
sequencer control.
Sequencer Technical Section
In a typical refrigeration system several compressors may be used to provide the required tonnage to control the
refrigeration load. If the load is high all compressors may be needed. If the load is low only one compressor may be
needed. The sequencer automatically manages the starting and stopping of the compressors to maintain the system
control parameter at the desired setpoint. This process of starting and stopping compressors is referred to as staging
up or down compressors.
The order that the compressors are staged is defined by the operator in a lead list. The sequencer makes decisions
based on operator defined parameters and delay times which can be tailored to match the needs of the refrigeration
system. The sequencer continuously transmits the setpoint and system control parameter values to each compressor.
When a compressor is started by the sequencer it attempts to maintain the system control parameter at the defined
setpoint using its own automatic capacity control. The compressor that is making capacity adjustments in response
to load changes is referred to as the “Trim Machine.” Once the trim machine is fully loaded it informs the sequencer
that it can no longer increase capacity. If the load is still not under control the sequencer will inform the trim machine
to lock at full capacity and will start another compressor, if one is available. The newly started compressor is now the
trim machine. This process will continue until the load is under control or all compressors have been utilized. If the
load decreases to the point where the trim machine is no longer needed it will be stopped and control is passed back
to the previous compressor.
The staging up and down of compressors will be performed at different rates based on the difference between the
system control parameter and the setpoint. If the difference is large, fast staging is performed. If the difference is
small, normal staging is performed. This staging technique ensures that compressors are started when needed and at
the same time minimizes any unnecessary starting or stopping. Independent sets of operator defined parameters are
provided for both the loading and unloading conditions.
The refrigeration control may contain multiple sequencers depending on the configuration of the refrigeration
system. For example, if booster compressors are used to maintain one suction pressure level and high stage compressors
maintain a second pressure level the system would use two different sequencers. In many refrigeration systems a
compressor may be piped such that it can be used on more than one refrigeration load, this is referred to as a swing
machine. For example, using hand valves the operator can configure a compressor as a booster or a high stage
machine. This swing machine would be available to both the high stage and booster sequencers.
The sequencer allows a group of compressors to be used in an efficient manner without operator intervention. The
automatic starting and stopping of compressors ensures that power requirements and operational costs are kept to a
minimum.
118
Sequencer System Control Parameters
A sequencer uses a sensor value and compares this value to an operator defined setpoint to control the refrigera-
tion load. This system control parameter may be a suction pressure, a process temperature or any other reading
that provides an accurate indication of the required refrigeration load.
Sequencer Staging Control
The sequencer starts and stops compressors based on operator defined parameters. Independent parameters may
be defined for loading and unloading conditions. The control parameters described below are modified using the
sequencer setpoints and sequencer control group select screens.
Control Setpoint - The control setpoint defines the desired level for the system control parameter. The
sequencer will take action based on the difference between the system control parameter and the setpoint.
The setpoint value is also transmitted to the compressors to be used in automatic capacity control while in
the sequence mode.
Control Deadband - The load and unload deadbands define a zone around the control setpoint where no
staging actions will be taken. If the difference between the setpoint and the system control parameter is less
than the load or unload deadband, no staging will be performed. The deadband values for loading and
unloading are transmitted to the compressors to be used in automatic capacity control while in sequenced
mode.
Normal Bandwidth - The load and unload bandwidths are used to define the difference between normal
staging and fast staging. If the difference between the system control parameter and the setpoint is outside
the deadband but within the bandwidth the normal stage delay is used. If the difference is greater then the
bandwidth the fast stage delay time is used. The normal bandwidth values for loading and unloading are
transmitted to the compressors to be used in automatic capacity control while in sequenced mode.
Normal Stage Delay - The load and unload normal stage delays are used to reduce unnecessary compressor
stops or starts. The sequencer will delay this amount of time before taking action when the difference
between the system control parameter and the setpoint is outside the deadband but within the bandwidth
and the trim machine is fully loaded. Setting the normal stage delay to zero will disable normal stage delay
staging.
Fast Stage Delay - The load and unload fast stage delays are used to allow quick action to be taken when the
system control parameter is far above or below the setpoint. The sequencer will delay this amount of time
before taking action when the system control parameter is outside the bandwidth.
119
The relationship of these parameters can be seen in the sequencer control strategy diagram shown below.
DifferenceAbove Setpoint
Stages added using the fast delay timer
Stages added using the normal delay timer
LoadBandwidth
LoadDeadband
No stages added or removed
No stages added or removed
Control Setpoint
UnloadDeadband
UnloadBandwidth
Stages added using the fast delay timer
Difference Below Setpoint
Sequencer Control Strategy
Sequencing Commands
The sequencer controls compressors by sending sequencing commands. These commands are transferred locally
to compressors on the master or via the communications link to remotes. The commands and their function are as
follows:
SEQUENCE STOP- The SEQUENCE STOP command is sent to cause a compressor to form an
automatic stop. The compressor remains on-line and available for the nextsequencer operation. If
the anti-recycle timer on the compressor has not expired, the compressor will continue running in
the Hot Standby state at zero percent capacity.
TRIM-The TRIM command is sent to the compressor that has been chosen to become the trim
machine. This compressor will make capacity adjustments to control the load using automatic
control. If the compressor is stopped and on-line, the TRIM command will perform a
sequenced start. Bandwidths and deadbands are sent to a compressor when the TRIM command
is sent. Also, all time proportional control parameters are transferred to recip compressors with
this command.
FULL LOAD - When FULL LOAD is received, a compressor will adjust to full
capacity and hold that condition. If a compressor is stopped and on-line, the
FULL LOAD command will perform a sequenced start.
120
System Control Parameter and Setpoint Communication
The sequencer continuously sends the setpoint and system control parameter to all the compressors in its lead
list. Sending the setpoint eliminates the need to setup every compressor individually and allows the sequencer to
schedule setpoint changes. Sending the system control parameter eliminates any piping losses and assures that
all compressors are working towards the same goal. When a compressor is using the sequencer setpoint and
control parameter the setpoint will be displayed and the setpoint group label will be displayed as “SY.”
Sequencer Operations
The current operational status of a sequencer is displayed on the sequencer status page. The sequencer may be
in any one of the following states :
DISABLED -The sequencer has been disabled and no staging will be performed.
HOLDING -The sequencer is enabled and the system control parameter is currently within the
deadband.
DECREASING -The sequencer is enabled and the system control parameter is below the unload
deadband. Stages will be removed based on the stage delay timers.
INCREASING -The sequencer is enabled and the system control parameter is above the load
deadband. Stages will be added based on the stage delay timers.
Sequencer Lead List
The compressors available to a sequencer and the order in which they are to be used are defined in the sequencer
lead list. The operator can modify the lead list from the sequencer lead list screen. The total list of compressors
available to the sequencer is pre-defined based on the piping of your refrigeration system.
Unused Compressors in the Lead List
If the operator determines that a particular compressor should not be used, a NONE may be selected in any
of the lead list slots.
Swing Machines
In many refrigeration systems a compressor may be piped such that it is allowed to be used on more than one
refrigeration load. For example, using hand valves the operator may configure a compressor as a booster or
a high stage machine. In such a system this swing machine may be available to two separate sequencers.
The operator should take precautions to ensure that the name of the swing machine appears in only one
sequencer lead list.
121
Lead list Processing
The sequencer processes through the lead list starting and stopping compressors as required. Lead list changes,
unavailable compressors, or a failure on one or more machines will cause special processing to be performed. This
special processing is described in the following sections:
Lead List Changes
When the operator changes the sequencer lead list, no compressors will be stopped or started immediately.
Instead, the compressors will be re-ordered and the last running compressor in the lead list will be given a
Trim command. The trim machine in the previous lead will be given a Full Load command. The standby
monitor timer is then started. When the standby monitor timer expires, the first compressor in Standby
which is above the new trim machine will be started with the Full Load command. The standby monitor timer
will then be restarted. The sequencer should now find a new operating condition which may result in the
current trim machine stopping. This process continues until all Standby machines above the trim machine
are started.
Unavailable Compressors
If a compressor in the lead list is not available when required it will be skipped and the next available machine
will be started. If the skipped compressor then becomes available it will be started immediately using the Full
Load command. The standby monitor timer will then be started, allowing the new configuration to find its
proper operating point. This process of starting a skipped compressor automatically maintains all running
compressors in the lead list order. It should be noted that a compressor becomes unavailable any time it is
stopped locally, not in sequenced mode or failed.
Trim Machine Failures
If the trim machine fails making it unavailable, two different scenarios can occur depending on the number of
compressors running. If the trim machine was the only compressor running the next available compressor in
the lead list is started immediately. If fully loaded compressors exist the previous compressor in the lead list
becomes the trim machine. Additional compressors may then be started using the normal staging process.
Fully Loaded Machine Failures
If a fully loaded machine fails making it unavailable, no immediate action is taken. Additional compressors
will be added through the normal staging process.
SequencerActionsAfter Power Failures
After a power failure to the master, the sequencer will send a sequence stop command to all compressors in its lead
list. The compressors will be restarted using the normal staging process. Compressors that have failed because
the power was off for more than their power fail reset time will be off-line and unavailable for sequencing.
122
Sequencer Status
Every compressor in a sequencer’s lead list is assigned a sequencer status which can be viewed on
the sequencer status page. The following list describes the possible status conditions. :
UNAVAIL -The compressor is not available to the sequencer.
STANDBY -The compressor is available to the sequencer. This compressor may be stopped
and on-line or be running with time remaining on its anti-cycle timer.
LOADED -The compressor is running and has been told to stay fully loaded
TRIM -The compressor is running and is the trim machine.
HOTSTBY -The Hot Standby state occurs when the compressor is running at zero percent
capacity due to time remaining on its anti-recycle timer. This compressor is available to be
restarted immediately if required by the sequencer.
FRCTRIM -The Force Trim state is an optional state used in two-stage refrigeration
systems. If the booster sequencer needs a compressor to start but none of the high stage
machines are currently running, the lead compressor in the high stage lead list will be forced
to start and run.
NO HSTG -The No High Stage state is an optional state used in two-stage refrigeration
systems. If the booster sequencer needs a compressor to start but all of the high stage
machines are failed or off-line, the booster compressors will not be allowed to start.
CompressorAvailability
The sequencer is continuously checking the status of all compressors in its lead list to determine their
availability. Unavailable compressors are marked with a sequencer status of UNAVAIL and are skipped
when sequencer actions are taken. A compressor must meet the following conditions to be available to a
sequencer:
COMMUNICATION WITH THE MASTER -The communications between the master and the
panel controlling the compressor must be operational. Compressors being controlled locally by
the master are not affected by communications.
SEQUENCED MODE -The compressor must be in sequenced mode.
ON-LINE -The compressor must have been placed on-line for sequenced operation.
NOTIME REMAININGONTHEANTI-CYCLE TIMER -If the compressor is stopped with time
remaining on the anti-cycle timer it will not be allowed to start. Therefore it is unavailable for
sequenced operation.
123
NO FAILURES -Afailure takes a compressor off-line and makes it unavailable for sequenced
operation.
When a compressor determines that it can no longer make capacity adjustments to reduce the system
control parameter it informs the sequencer that it is fully loaded. Compressors are fully loaded when all of
their stages are in use.
Enabling and Disabling the Sequencer
Each sequencer can be enabled or disabled from the sequencer control screen. When a sequencer is enabled or
disabled, all available compressors in the lead list will be sent a sequence stop command. If it is desired that the
compressors continue running, it is suggested that their mode be changed to AUTO before the sequencer is
disabled.
Sequencer Control Groups
A sequencer allows the operator to define up to four different control groups for the system control parameter.
Each control group consists of a control setpoint, a low alarm setpoint and a low failure setpoint. All four control
groups can be modified using the control group select screen.
Sequencer Setpoint Scheduling
Sequencer setpoint scheduling is the automatic switching of control groups based on time of day and day of the
week. Control setpoint groups and the selected lead list can be changed using scheduling. The operator can
define up to seven (7) different daily time schedules and one weekly schedule. Sequencer scheduling can be
enabled or disabled by the operator. All schedule changes are relayed to the compressors and take effect auto-
matically.
Daily Schedules
Each daily time schedule consists of up to eight (8) different time of day slots. For each time of day slot the
operator can define the time, desired setpoint group number, and the desired lead list. Unused time slots are
ignored and the schedule may be entered in any order. When the schedule is saved it is reordered
chronologically. Each daily schedule is identified by a schedule name (SCH1 - SCH7)
Weekly Schedule
The weekly schedule allows the operator to assign different daily schedules to each day of the week. Anew
day begins and schedules change at midnight. The sequencer weekly schedule is found on the schedule
setup screen.
Enabling / Disabling Scheduling
The operator may enable or disable setpoint scheduling from the schedule setup screen. When scheduling
is enabled the setpoints are changed to match those defined by the schedule. When scheduling is disabled
the setpoints must be changed manually.
124
Overriding ScheduleActions
Using the schedule setup screen the operator can temporarily override scheduling actions. The active lead
list, active schedule, and active group can be changed. Overrides may be altered after a schedule change
occurs but may only last until the next scheduled activity occurs.
Alarm and Failure Setpoints
The control parameter used to sequence compressors is monitored by the Viltech for alarm processing. High alarm
and high failure setpoints can be defined by the operator using the high alarm setpoint screen under the SEQ hot-
key. Low alarm and failure setpoints are set on the control group select screen and can be changed using schedul-
ing.
Setting Up VILTech Panels for Sequencing
Sequencing can be done using up to 8 VILTech panels. The VILTech panels are connected using a daisy chain
wired to COMM 0 in the VILTech panels, as shown in wiring diagram 682017. Each compressor in the sequence
must have the Sequence Option enabled in the “Control Configuration” screen that is found by pressing the
“Menu” hot key then press number 4 for “System Setup” then press number 5 for “Configure Hardware”. Now
setup the safety setpoints for each compressor. Next, the Dip switches on the microprocessor board must be
configured for the master and trim (slave) VILTech panels. The master VILTech panel will have the 8th dip switch in
the “ON” position, this identifies the panel as the master, and the rest of the dip switches will identify to the
master how many trim panels are in the sequence by putting the dip switch in the “ON” position for the correct
binary sum value that corresponds to that number of trim panels. Then the dip switches on the trim panels must be
set up sequentially in the order that each will turn on by the command of the master. For example, if there is a
master and 3 trim compressors then dip switch 1, 2, and 8 are in the “ON” position and the trim compressors will
have their own unique address starting with 1. Shown below is a chart on how this example would be set up. (If
there are more than 4 trim panels then those would be set up like it is shown below.)
Binary Value
Dip Switch
1
1
2
2
4
3
8
4
16
5
32
6
64
7
8
Master
Trim1
Trim2
Trim3
Trim4
Trim5
Trim6
Trim7
on
on
off
on
off
on
off
on
on
off
on
on
off
off
on
on
off
off
off
off
on
on
on
on
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
on
off
off
off
off
off
off
off
Now on the master panel the ON/OFF switch on the I/O board can be used to reboot the microprocessor. Next
press the SETPT key and press the number 6 for Sequencer. On the Sequencer screen, the Control screen has the
enable, disable, and automatic options. Disabling the sequencer will not allow the master to communicate with the
other trim panels even if the “SEQ” key is pressed. Enabling the sequencer will allow the master to communicate
with the trim compressors when the “SEQ” key is pressed. Now if the sequencer control is put to Automatic then a
remote signal tied into channel 12 will start/stop the master panel and then it will automatically control the other
trim panels according to capacity needs. When all the setpoints are configured then the panels can be put on-line
by pressing the “SEQ” button in the Mode section of the keypad.
125
Sequencer Operating Procedures
The sequencer function will use a SEQ hot key to allow the operator to adjust the controls for the various
sequencers contained in the system. The following sections describe the various procedures used in the
sequencer function.
Sequencer Status Screen
The presence of a SEQ hot key will add at least one sequencer status screen to the list of status screens.
The extra status screen appears when the user scrolls through the system status screens. Below is an
example of a sequencer status screen. Multiple sequencer status screens may be present depending on
the systems configuration.
Sequencer Status Screen
The following table lists the data entry and information fields on the screen and a description of their purpose.
TERM
DEFINITION
SEQUENCEOPERATION
The state of the sequencer (DISABLED, DECREASING, INCREASING,
HOLDING). Also shows the value of the staging timer.
The current value of the system suction pressure for system process
SUCTION PRESS
temperature.
GROUP
Shows the current control group being used.
SETPOINT
The current setpoint value utilized by the sequencer. Engineering units
will change to DEGF if Process Temperature is being used.
Shows the currently selected lead list number and the value of the
LEAD LIST(Status)
standby monitor timer.
LEAD LIST (Heading)
COMPRESSOR
STATUS
Shows the current order of compressors in the lead list.
Shows the names of the compressors in the lead list.
The current sequencer status of the compressors (UNAVAIL, STANDBY,
FULL LOAD, TRIM, HOTSTBY).
MODE
The current mode of each compressor.
STATE
The state of each compressor.
ANTICYCLE
The time remaining on each compressor’s anti-cycle timer.
Sequencer Status Screen Definitions
126
SEQ Hot Key
Following is a menu diagram for the SEQ hot key. This menu diagram is for a system with only one sequencer. If
the system has more than one sequencer, multiple sequencer setup selections will be available. Additional menu
selections for control setpoints, control groups, and high alarm setpoints are present if the system contains
multiple system control parameters.
SEQ
1. SEQUENCERCONTROL
2. SETPOINTS
3. LEAD LIST
4. CNTRLGROUPSELECT
5.SCHEDULING
1. SCHEDULESETUP
2. DAILYSCHEDULE
1. SCHEDULE01
2. SCEHDULE02
1. SCHEDULE07
6. HIGHALARM
SEQ Menu Diagram
127
Sequencer Control
The sequencer control screen allows the operator to enable or disable the sequencer. If process
temperature is an option, it may also be selected from this screen.
Sequencer Control Screen
Sequencer Setpoints
On the next page is an example of a sequencer control setpoints screen. If the sequencer can use
multiple system control parameters, a menu will allow selection of control setpoints for each param-
eter.
The standby monitor timer is used to limit compressor starts after lead list changes or when previously failed
compressors are brought back on-line. The Sequencer Control Setpoints screen is divided into four areas.
The Sequencer Controls section at the top controls how the sequencer decides when to start or stop
compressors. The Compressor Controls section in the center is passed to the Trim Compressor to allow it to
load and unload at a different rate than the Sequencer. At the bottom of the screen is the Standby Monitor
timer and an optional setpoint for use in two-stage refrigeration systems. The Reference Data on the right
is dynamically updated while the user if changing setpoints.
128
Sequencer Control Setpoints Screen
The following table lists the data entry fields and a description of their purposes. The ranges for these
parameters will vary based on the type of system control parameter used.
PARAMETER
DEFINITION
RANGE
SEQNORMALBANDWIDTH
The sequencer load and unload normal
bandwidth define when normal staging
stops and fast staging begins. If the
difference between the setpoint and
system control parameter is greater than
0 - 20 PSID
the bandwidth fast staging is performed.
The sequencer load and unload control
deadbands define a zone around the
setpoint where no staging action will be
taken.
SEQCONTROLDEADBAND
SEQNORMALSTAGEDELAY
0 - 20 PSID
0 - 99 MIN
The sequencer normal stage delay is
used to add or remove stages when the
difference between the system control
parameter and the setpoint is outside
the deadband but within the normal
bandwidth. Entering a zero for the load
or unload normal stage delay time
disables staging under these conditions.
SEQFASTSTAGEDELAY
The sequencer fast stage delay is used to 0.1 - 10 MIN
add or remove stages when the difference
between the system control parameter and
the setpoint is outside the normal
bandwidth.
Sequencer Control/Setpoints Screen Definitions
129
PARAMETER
DEFINITION
RANGE
COMPNORMALBANDWIDTH The compressor load and unload normal
bandwidth define when the compressor
will increase or decrease capacity. If the
difference between the setpoint and system
control parameter is greater than the
0 - 20 PSID
bandwidth the compressor will load or
unload continuously.
COMPCONTROLDEADBAND The compressor load and unload normal
deadband define a zone around the
0 - 20 PSID
setpoint where no loading or unloading
will be performed.
STANDBYMONITORTIMER
The standby monitor timer is used to limit 0.1 -99.9 MIN
compressor starts after lead list changes
or when previously failed compressors are
brought back on-line.
HSTG SUCT PRESS MIN SETPT This optional parameter may be used in
29.9 INHG – 185.3 PSIG
(OPTION)
the Booster stage of two-stage
refrigeration systems. The High Stage
Suction Pressure Minimum Setpoint is
used to ensure that the Suction Pressure
of the High Stage compressors is below a
minimum value before a Booster
compressor is allowed to start.
Sequencer Control/Setpoints Screen Definitions (Continued)
130
Lead List
The sequencer lead list defines the order that the compressors will be added or removed. The “NONE”
selection is used to allow the operator to remove a compressor from the lead list. The user should make sure
no duplicate entries exist in the lead list and that no two sequencers contain the same compressor at the
same time. Two lead lists are now provided as a standard in most new control systems. Lead ListAor B may
be selected manually or scheduled along with the sequencer control setpoint.
Sequencer Lead List Screen
The following table lists the various parameters displayed on the sequencers lead list screen.
TERM
DEFINITION
RANGE
LEADLISTA
LEAD LIST B
CURRENTACTIVE
LEADLIST
The order of compressors in the A lead list.
The order of compressors in the B lead list.
Allows the user to select the Lead List to be
used by the sequencer. The new lead list will
effect when the screen is saved.
Selectable
Selectable
Selectable
Sequencer Lead Screen Definitions
131
Control Group Select
The sequencer control group select screen permits the user to set the control, low alarm, and low
failure setpoints for the different control groups. Below is an example of a sequencer control group
select screen. If the sequencer contains multiple system control parameters, a menu will allow
selection of control groups for each parameter.
Sequencer Control Group Select Screen
The following table lists the various parameters displayed on the sequencer suction pressure control group
select screen. The range of these parameters will vary depending on the type of system control parameter
used.
TERM
DEFINITION
RANGE
CONTROLSETPT
The sequencer will add or remove compressors to
maintain the system control parameter at this
control setpoint.
29.9 INHG-
185.3 PSIG
LOWALARM
LOWFAILURE
An alarm is activated when the system control
parameter is below this value.
29.9 INHG-
185.3 PSIG
29.9 INHG-
185.3 PSIG
A failure is activated when the system control
parameter is below this value.
Sequencer Control Group Select Definitions
132
Schedule Setup
The schedule setup screen is used to enable/disable scheduling along with setting the weekly
schedules and performing scheduling overrides. An example of a schedule setup screen is shown
below.
Sequencer Schedule Setup Screen
The following table lists the various parameters displayed on the master sequencer setup screen.
TERM
DEFINITION
RANGE
SEQUENCER
SCHEDULING
CURRENTACTIVE
LEADLIST
Enables or disables scheduling.
Selectable
Overrides the current active lead list.
Overrides the current active group.
Selectable
Selectable
CURRENTACTIVE
GROUP#
CURRENTACTIVE
SCHEDULE#
Overrides the current active schedule.
Selectable
Selectable
WEEKLY
Allows one of the seven dailly schedules to each
day of the week.
SCHEDULE
Sequencer Schedule Setup Screen Definitions
133
Daily Schedules
The daily schedules are reached by entering the schedule number on the schedule access screen. Below is
an example of a daily schedule screen.
Sequencer Daily Schedule Screen
The following table lists the data entry fields and description of their purposes.
TERM
DEFINITION
RANGE
SCHEDULEDTIME
The time schedule change will take place
(entered in 12 or 24 hour mode.)
Valid Time of Day
SELECTEDGROUP
The control group number to be used at this Selectable
time.
SELECTEDLEAD
LIST
The lead list to be used at this time.
Selectable
Sequencer Daily Schedule Screen Definitions
134
HighAlarm
The high alarm setpoints screen allows the operator to adjust the high alarm and failure setpoints. If the
sequencer supports multiple system control parameters, a menu will allow selection of high alarm setpoints
for each parameter. An example of the high alarm setpoints screen is shown below.
SequencerHigh Alarm Screen
The following table lists the data entry fields and description of their purposes.
TERM
DEFINITION
HIGHFAILURE
If the system control parameter is above this value, a failure
will be reported.
HIGHALARM
If the system control parameter is above this value, an alarm
will be reported.
Sequencer High Alarm Screen Definitions
135
Addendum forPump Down Program forVILTech
The VILTech needs to be setup for Remote operation, Auto Start/Stop enabled, and Suction
Pressure control. The Process Temperature control is not an option for capacity control and
is used instead to control the Chiller Liquid Valve.
When the controller is On-Line, the Remote Start/Stop input energizes, and the Process Tem-
perature input is above the High Temperature Cut-In setpoint; the Chiller Liquid Valve will be
opened. Then when the Chiller Liquid Valve is open and the Suction Pressure rises above the
Cut-In setpoint, the compressor starts.
Note: that if the Process Temperature is not above the High Temperature setpoint or if the
compressor is not On-Line, the Chiller Liquid Valve will not be opened and the compressor
will not start even if the Suction Pressure is above the Cut-In setpoint.
As long as the Process Temperature remains above the Low Temperature setpoint, the com-
pressor will load, unload, cut-out, and cut-in normally based on the Suction Pressure control
setpoints. If the Process Temperature falls below a Low Temperature setpoint, the Chiller
Liquid Valve will be closed and the compressor should pump down and shutoff normally when
the Suction Pressure falls below the Cut-Out setpoint. But if the Remote Start/Stop input is de-
energized, the Liquid Valve will be closed right away but the compressor will be allowed to
pump down and shutoff normally when the Suction Pressure falls below the Cut-Out setpoint.
Other operations are still allowed likeAutomatic operation is permitted when using theAUTO
button on the panel. In this case, operation is the same except that the Remote Start/Stop input
is ignored. Manual operation is permitted when using the MAN button on the panel. In this
case, the compressor starts and the Chiller Liquid Valve opens and closes normally with
temperature but none of the time delays, cut-in, cut-out, or automatic capacity controls are
used. Manual capacity control is available.
A user-programmable time delay will be started anytime the compressor starts to prevent the
compressor from stopping due to the Cut-Out setpoint or a Low Suction Pressure Failure.
The default time delay is 90 seconds should be varied with each application. For example,
when using glycol, this time delay can be shortened to 5 seconds or less. High and Low
Suction Pressure alarms and failures will remain inhibited for the time delay period and when
the compressor is stopped.
136
The Process Temperature Cut-In/Cut-Out setpoints used for control are taken from the
setpoint group associated with the current Suction Pressure control group. For example,
if Suction Pressure Group 2 is currently selected for control, the Process Temperature
setpoints will also be taken from Group 2.
The following Hardware needs to be installed for the Pump Down program to function:
•
•
•
•
Process Temperature input (Analog Channel 8) is the Alcohol Temperature
from another control system.
The Remote Start/Stop input from DCS is used to control enabling/disabling
the process when the RMT button on the panel is used to start the process.
Spare I/O Channel 16 will be fitted with a solid state output module to control
the Liquid Valve.
Software for the Pump Down Program installed.
137
138
APPENDIX A
Alarm and Failure Data
The Alarm and Failure Data Appendix provides a table which describes all of the analog
and discrete alarms in the system. The level column describes the type of alarm or failure
and the Default column lists the factory setpoint for analog alarms.
AnalogAlarms
No.
1.
2.
3.
4.
Parameter Name
Level Default Comments
Fail 70PSIG
Alarm 50PSIG
Alarm 28PSIG
High Suction Pressure
High Suction Pressure
Low Suction Pressure
Low Suction Pressure
Low Suction Pressure
High Discharge Pressure
Fail
OEM
OEM
29.9PSIG
29.9PSIG
5.
6.
225 PSIG for NH3
275 PSIG for R22
225 PSIG for NH3
275 PSIG for R22
7.
High Discharge Pressure
Fail
8.
9.
High Discharge Pressure
High Discharge Temperature
High Discharge Temperature
High Discharge Temperature
High Oil Temperature
High Oil Temperature
High Oil Temperature
Low Oil Pressure
Low Oil Pressure
Low Oil Pressure
Low Intermediate Temp(Two Stage)
Spare(One Stage)
High Process Temperature(Option)
High Process Temperature(Option)
Low Process Temperature(Option)
Low Process Temperature(Option)
High Intermediate Pressure(Two Stage)
Spare(One Stage)
Alarm 215DEGF
OEM 212DEGF
10.
11.
12.
13.
14.
15.
16.
17.
18.
Fail
212DEGF
Alarm 200DEGF
OEM 180DEGF
Fail
155DEGF
Alarm 140DEGF
Alarm 15PSIG
Fail
10PSIG
OEM 10PSIG
Fail
Fail
50DEGF
50DEGF
19.
20.
21.
22.
23.
Alarm 45DEGF
Alarm 30DEGF
Fail
Fail
25DEGF
103PSIG
24.
25.
26.
High Intermediate Pressure(Two Stage)
Spare(One Stage)
Low Intermediate Pressure(Two Stage)
Spare(One Stage)
Low Intermediate Pressure(Two Stage)
Spare(One Stage)
Alarm 58PSIG
Alarm 45PSIG
Fail
40PSIG
139
No.
Parameter Name
Level Default Comments
27. High Intermediate Pressure (Two Stage)
Spare (One Stage)
Alarm 58PSIG
28. Low Intermediate Pressure (Two Stage)
Spare (One Stage)
29. Low Intermediate Pressure (Two Stage)
Spare (One Stage)
Alarm
Fail
45PSIG
40PSIG
DiscreteAlarms
The Micro checks the state of the
Motor Output and Aux Input. To verify
correct operation Aux contact closed
indicates the motor is running. If
Motor is running when it should be off
the Micro will take the following
steps:(1) Failure signal is generated
to alert operator: (2) Capacity is
forced to a full unload condition.
140
APPENDIX B
Analog and Discrete I/O
The Analog and Discrete I/O section identifies the channel assignments for sensor
inputs, control outputs, and status inputs for various compressor models.
Analog Inputs
RECIP Compressor-Analog Inputs
TYPE
CHANNEL NAME
RANGE UNITS SENSORTYPE
Press
Press
Press
Well Temp
Well Temp
Well Temp
Press
1
2
3
4
5
6
7
Suction Press
Discharge Press
Oil Press
Discharge Temp
OilTemp
Suction Temp
Intermediate Press(Two Stage)
Spare(One Stage)-DP2
Process Temp or DT2
0:200 INGH 4-20 mA
0:500 PSIG
4-20 mA
0:500 INGH 4-20 mA
32: 392 DEGF 4-20 mA
32: 392 DEGF 4-20 mA
-58:122 DEGF 4-20 mA
0:500 PSIG
4-20 mA
Well Temp
8
-58:122 DEGF 4-20 mA
Discrete I/O RACK 1
TYPE
CHANNEL NAME
OFF STATE
Off
Off
Off
Off
Off
Off
Off
Norm
Open
Alarm
Alarm
Off
Open
Closed
Closed
Closed
ON STATE
On
On
On
On
On
On
On
Alarm
Closed
Norm
Norm
On
Closed
Open
Open
Open
NOTES
Output
Output
Output
Output
Output
Output
Output
Output
Input
1
2
3
4
5
6
Compressor Motor
Capacity Stage 1
Capacity Stage 2
Capacity Stage 3
Capacity Stage 4
Spare
7
Spare
8
9
Alarm/Failure
MotorAUX
1
3
3
Input
Input
10
11
13
12
14
15
16
AUX Shutdown
Safety Circuit
Crank Case Heater
Remote Start/Stop
Oil Return Solenoid
Cooling Control
Spare
Output
Input
Output
Output
Output
Notes:
1-Normally open contact with no power or level
2-Normally closed contact with no power or level
3-Normally closed contact open to fail
4-Energize for condition
5-De-energize for condition
6-Pilot driven-Energize to close
7-De-energize to turn via customer supplied relay
141
142
APPENDIX C
Communication Protocols
Introduction
The hardware interface and software protocol are defined for performing serial
communications with the Viltech using the Modbus RTU protocol. In this case, the
implementation of the protocol is limited to the sub-set of the complete set of possible
message types. Communications with one or more compressors is possible using a RS-
485 or RS-422 multi-drop interface.
NOTE: Modbus is a registered trademark of Modicon, Inc.
Real time monitoring of the following data is provided:
•
•
•
•
•
Analog input parameters
Discrete I/O parameters
Mode and State information
Computed parameters
Alarm Information
Real time control of the following parameters is provided:
•
•
Compressor Control including start/stop and mode changes
Compressor Capacity Control Setpoints
Applicable Documents
Familiarity with the following documents is highly recommended:
•
Modicon Modbus Protocol Reference Guide (PI-MBUS300)
143
Hardware Interface Description
Hardware Requirements
The Vilter 400 Series Compressor uses the on-board COMM 1 port for Modbus RTU communications. The hard-
ware configuration for both protocols is 5-volt RS-485 or RS422 multi-drop.
Interface Connections
Physical interface connections for Modbus communications are made at COMM 1 located on the left side of the
main microprocessor board next to the corner. The following table shows the pin-outs for the Viltech hardware for
COMM 1.
Pin
1
2
3
4
Name
TX+
TX-
GND
GND
RX-
Function
Transmit Data (Positive)
Transmit Data (Negative)
Ground
Ground
Receive Data (Negative)
5
6
RX+
Receive Data (Positive)
NOTE: For RS-485 communications, use Terminals 1 and 2 for the network connection and add a
jumper between Terminals 1-6 and 2-5.
The use of low capacitance twisted/shielded cable is required (e.g. Belden #9503 or eq.). The shields should be
grounded at the master computer end of the cable and floated at the microprocessor end.
Figure 1 shows the interface cabling connections for typical Modbus applications. Also shown are the
recommended shield grounding requirements for an in-line data path and a split data path. Other
controllers or PC configurations may be different.
NOTE: Since Modbus communications share a port with Viltech communications, The port must be
selected for Modbus operation on the Communications Setup screen.
144
145
Message Addressing
Each compressor is required to have a unique address referred to as the unit number. The unit number is initially
set using dip switch SW1 on the main microprocessor board. However, the actual unit number can be changed
through software by setting the Modbus unit number on the appropriate set-up screen on the controller. The
following table shows the dip switch settings for up to 31 individual RECIP compressors.
146
147
Software Interface Description
Protocol Overview
All communications with the Vilter Reciprocating Compressor Controller is on a request-response basis. The main
computer is the “master” and the Viltech controller is the “slave”. All messages will originate on the master with the
slave responding as required.
Status Only or Status and Control Options
The reciprocating compressor microprocessor communications supports two options. When configured for the
Status Only option, the Viltech will only respond to the status message but will not respond to any control or
setpoint messages. When configured for the Status and Control option, the Viltech will respond to all message
types. The Status and Control option is selected by enabling Modbus communications on the Communications
Setup screen. To allow setpoints to be changed, select Yes for the “Allow Network Control” selection. If network
control is not allowed, Status Only is selected and an error response will be returned whenever a control message is
attempted. When network control is allowed, Status and Control is selected and control messages may be used to
control the compressor. The Remote mode is the primary means of control when the Network Control Option is
enabled. Remote mode is enabled on the Control Configuration screen.
Message Categories
Several message categories are supported and described below:
•
•
•
•
Status Message
Compressor Control Message
Suction Pressure Setpoint Message
Process Temperature Setpoint Message (Optional)
148
MODBUS Protocol Description
All transactions will be performed using the Modbus RTU transmission mode. All messages will be terminated
with a two-byte CRC-16. The Modbus ASCII transmission mode is not supported.
The default software configuration for Modbus is shown below. Where a parameter can be changed, a range of
options is also shown. It is the responsibility of the user to ensure that the software configuration is the same for
both the master and slave controllers.
•
•
•
•
Baud rate:
Data bits:
Parity:
9600 bps
(2400/4800/9600/19200/38400/76800)
8
(7/8)
None
2
(None/Odd/Even)
(1/2)
Stop bits:
Currently there are only three Modbus message types supported by the Vilter protocol:
•
•
•
Function Code 03 (0x03): Read Holding Registers
Function code 06 (0x06): Preset Single Register
Function Code 16 (0x10): Preset Multiple Registers
Other Modbus message types may become available later or if the need arises. A brief description of the format
for each function code will be provided below. However, for a more thorough explanation, please refer to the
Modicon Modbus Protocol Reference Guide (PI-MBUS-300)
Read Holding Registers
The Read Holding Registers function code (0x03) is used to read the contents of one or more registers within
the Viltech controller. Registers within the Status Message, Control Message and Setpoint Messages may be
requested singularly or in groups as long as the number of registers requested does not extend beyond the
valid range.
The following table is an example of the use of the Read Holding Registers function code to request all 40
words in the Status Message.
149
Preset Single Register
The Preset Single Register function code (0x06) is used to change the contents of a single register within the
Viltech controller. Any register within the Control Message and Setpoint Messages may be changed as long as the
address and data are within the valid range.
The following table is an example of the use of the Preset Single Register function code for changing the value
of the S1 Suction Pressure Control Setpoint to 0 PSIG
(14.7 PSIA) using Modbus word address 40202.
Preset Multiple Registers
The Preset Multiple Registers function code (0x10) is used to change the contents of one or more registers within
the Viltech controller. Any group of registers within the Control Message and Setpoint Messages may be changed
as long as the number of registers addressed does not extend beyond the valid range.
The following table is an example of the use of the Preset Multiple Registers function code for changing the value
of the S1 Suction Pressure Control Setpoint to 0 PSIG
(14.7 PSIA) using Modbus word address 40202 (Viltech word address 201).
150
Error Messages
The Modbus protocol provides for the return of error codes in the event of a data error within a correctly
formatted message block. When the Viltech controller detects an error within a read or write message, the message
response will contain an error code instead of the expected data response.
The following example shows an error response to an illegal data value in a Preset Multiple Registers command.
NOTE: 0x80 has been added to the function code.
The following error codes are supported:
Data Formats
For Modbus communications, 16-bit messages are transmitted with the lower 8-bits first followed by
the upper 8-bits.
Real number data is represented in 16-bit signed integer format with one or less implied decimal points.
For example, the number 127.3 would be stored as 1273 decimal or 04F9 hex. Negative numbers are stored
in two’s complement form. For example, -237.4 would be stored as -2374 decimal or F6BAhex.
The Discrete I/O parameters are transmitted in a packed binary format where each bit represents an
individual input or output. Data marked as optional only applies to RECIP compressors with optional
equipment installed.
The Alarm data includes all alarm, failure, and OEM failure conditions currently active on the compressor. The
data is transmitted in a packed binary format where each bit represents an individual alarm. Each alarm is assigned
one of the following three levels:
•
•
•
Alarm -The parameter is outside of the normal operating range.
Fail - Similar to alarm but may cause RECIP to shutdown.
OEM -Afailure caused by parameters exceeding the manufacturer’s safety limits.
The Equipment data contains important information about the equipment on the microcontroller. This information
is packed into a data block which mixes several types and formats of data.
151
Status Message Description
The status message is a read-only message containing analog, discrete, alarm and state data.
NOTE: Some data in the status message may not apply to your particular compressor, depending on
optional equipment and features.
The Status Message includes the following types of data:
•
•
•
•
•
16-bit analog input parameters from sensors
16-bit derived or computed parameters
Discrete input and output data in packed bit format
Alarm data in packed bit format
Compressor mode and state data
Analog Inputs and Computed Parameters
414.5
414.5
PSIA
PSIA
152
153
Alarm and Failure Data
154
Alarm and Failure Data (Continued)
155
Alarm and Failure Data (Continued)
156
Equipment Data
Alarm Status Table
Bits 7 6 5 4 3 2 1 0
X X X X X X X X
AlarmActive
FailureActive
Alarm is Non-Fatal
Failure is Non-Fatal
AlarmAcknowledge
NewAlarmAcknowledge
New FailureAcknowledge
Not Used
Compressor Mode Table
157
Compressor State Table
158
Last RECIPStart Status Table
159
Control Message Description
The Control Message is a read/write message containing fields to start and stop the compressor, change the
compressor mode, and change the control setpoint group number.
The contents of the Control Message are shown in the following table and described further in the paragraphs
below.
NOTE: The Control Message may not be written unless the Allow Network Control selection is set to Yes.
Commands other than Network In Control can only be written once the Network In Control
Command has been issued.
NOTE:The data described by each register may be slightly different depending on if the register is being read or written.
160
Network In Control Command
The Network In Control command is used to allow the network to enable or disable
itself from controlling the system. When set to zero, the contents of the remainder of
the Control Message, the Suction Pressure Setpoint Message, and the Process
Temperature Set-point Message will be ignored. When read, the current value of the
Network In Control register will be returned.
Compressor Start/Stop Command
The Compressor Start/Stop command is used to start and stop the compressor or to
put the compressor Online, depending on the current mode. When set to 0, nothing
will occur. When set to 1, the compressor will stop (if running) but remain Online. A
value of 2 will start the compressor as long as the mode is Remote or Auto-Remote and
the compressor is Online. A value of 3 will stop the compressor with a failure indication
and take it Offline. This command is intended to be used by the master for system
safeties (High Level Shutdown, NH3 detection, etc.). A value of 4 will put the
compressor Online. The Start and Online commands are also used in conjunction with
the Auto Start/Stop Control to allow the compressor to Cut-In and Cut-Out by itself.
NOTE: After a failure or if an operator at the local panel hits the Stop pushbutton, the
compressor must be placed back online by the operator at the machine or through the Online
command. It is the responsibility of the system programmer to ensure that restarts after failures
are only allowed after the operator verifies the safety and integrity of the system. Also, the
Online command may result in the compressor starting immediately, depending on the value of
the control parameter.
The following table summarizes the actions taken for each mode.
161
Set Compressor Mode Command
The Set Compressor mode command is used to change the current active mode of the compressor. Normally,
only the Remote mode is used by the master. The SEQ, Sequence, mode is then automatically controlled by
setpoints and loaded and unloaded automatically. Auto-Remote mode allows the master to provide the
control setpoint and the compressor will load and unload to maintain the current active setpoint.
Change Compressor Capacity Command
The Change Compressor Capacity command allows the master to force the compressor to load or unload.
This command word is only processed when the compressor is in the Remote mode. When set to 1 or 2, the
compressor will load or unload respectively. Each time the command is written, a single stage will be added or
removed.
When read, the current value of the compressor capacity register will be returned (1 if the compressor is
loading, 2 if the compressor is unloading, and 0 if the compressor is neither loading or unloading).
162
Acknowledge/Clear Active Alarm Command
The Acknowledge/Clear Active Alarm command is used by the master computer to
silence the audible alarm horn and to clear alarms from the active alarm display. After
each new alarm or failure, the first control message received with this word set will only
silence the audible alarm horn. Subsequent alarm messages will clear any alarms which
are no longer active. This command is ignored when the compressor is in Local mode.
Change Current Setpoint Group Command
The Change Current Setpoint Group command is used to change the current active
set-point of the system (Groups 1-4).
When read, the currently selected setpoint group will be returned (0-3 for Suction Pres
sure Groups, 4-7 for Process Temperature Groups, and 8 for Sequenced)
NOTE: This may or may not actually affect the system capacity, depending on the current
mode of the compressor. For example, automatic capacity control is not
performed in the Manual Mode. Auto Start/Stop Control Command
Change Control Type Command
The Change Control Type Command is used to switch automatic control between
Suction Pressure and Process Temperature operation.
NOTE: The Process Temperature Control option must be enabled on the compressor
before this command may be issued.
When read, the current value of the control command will be returned.
Auto Start/Stop Control Command
The Auto Start/Stop Control command is used in the Automatic or Remote modes to
allow the compressor to start when the Cut-In setpoint is exceeded and to stop when
the Cut-Out setpoint is exceeded. When disabled, the compressor will run until
commanded to stop or a failure occurs.
When read, the current value of the Auto Start/Stop register will be returned.
163
Suction Pressure Setpoint Message Description
The Suction Pressure Setpoint message is a read/write message used to display or change the four
Suction Pressure control group setpoints. Suction Pressure setpoints may be read or written individually
or in groups. The master is responsible for setting the correct starting address, number of registers, and
the register data for the message block.
NOTE: Setpoints may not be changed unless the Allow Network Control selection is set to Yes, and the
Network In Control Command has been issued in the Control Message.
Note: DF1 is NOT used.
164
Process Temperature Setpoint Message Description
The Process Temperature Setpoint message is a read/write message used to display or change the four
Process Temperature control group setpoints. This command is only used if the Process Temperature
control option is enabled. Process Temperature setpoints may be read or written individually or in groups.
The master is responsible for setting the correct starting address, number of registers, and the register
data for the message block.
NOTE: Setpoints may not be changed unless the Allow Network Control selection is set to Yes, and the
Network In Control Command has been issued in the Control Message.
Note: DF1 is NOT used.
165
Appendix D - Condensor Control
(Important Note)
Main Screen
The main screen has been designed to give the operator an overall view of the
operating parameters. This screen should always be displayed when setpoint
and manual operation items are not being performed and contains buttons to
navigate to Auto Setpoints and Manual Operations.
This screen displays status information on the mode of the condenser con-
troller and the stage of the condenser.
Modes Of Operation
The Condenser Controller always starts in the OFF position. The Controller
has two modes of operation. The mode is changed by selecting the preferred
mode on the main screen. The modes of operation are as follows:
1. Automatic - Starting and Stopping will be performed automatically based
on Discharge Pressure.
2. Manual – In manual mode the user has two options. To increment the
stage one by one or to enter the Manual over ride screen.
166
Automatic Mode
To enter Automatic Mode touch the AUTO MODE button. The button will
light up and the words Aut will appear on the screen.
In Automatic mode the Stage operation will be selected automatically based
on the designated Discharge Pressure. To set these points see “Auto Setup
Screen” section of this manual.
Automatic Operation
In automatic mode the Condenser Controller will attempt to keep the Dis-
charge Pressure within the deadband range. Once the discharge pressure
moves outside the specified dead band range the Controller will wait the
specified amount of seconds and toggle the appropriate stage.
The Main Screen will state the appropriate stage. The picture below shows
the Controller in the second stage.
Auto Setup Screen
From the Main screen, touch the AUTO SETUP button.
To specify the setpoints for Pressure, Dead Band, or Timer touch the num-
ber inside the green rectangle to bring up a keypad, as shown below.
In this screen you can specify the appropriate value for the given parameter.
When finished touch the Ent button to return to the Auto Setup Screen.
Pressure value can not exceed three digits and should always stay within safe
operating conditions specified by the condenser manufacture.
Deadband value can not exceed three digits and should always stay within
safe operating conditions specified by the condenser manufacture.
Timer Set value can not exceed two digits and should stay within safe oper-
ating conditions specified by the condenser manufacture
To return to the Main Screen touch the MAIN button.
168
Manual Mode
To enter Manual Mode touch the MANUAL MODE button. The button will
light up and the words MAN will appear on the screen. Also the up and
down toggle arrows will appear.
From the main screen you can move up and down through the stages by
pressing the up or down toggle arrows.
Manual Override Screen
To enter the Manual Override Screen touch the MANUAL OVERRIDE but-
ton.
In the Manual Override Screen you can operate each stage individually. To
operate a given stage touch the corresponding toggle button. When the
specified stage is selected the light will become illuminated as well as the
toggle button itself and shut off a specified stage touch the corresponding
toggle button. When the specified stage is no longer running the light next to
said stage will read “OFF” and the light and toggle button will no longer be
illuminated.
169
Stages 1 and 3 are on as shown above.
IMPORTANT NOTE: THE OPERATOR SHOULD SHUT OFF ALL
STAGES BEFORE EXITING MANUAL OVERRIDE SCREEN.
Exiting the Manual Override screen will not change the status of the steps
selected. Entering into Auto Mode or Off Mode from the Main Screen will
shut off the stages until you enter Manual Mode again. When the operator
enters back into Manual Mode the stages selected in the Manual Override
screen will begin to run again.
Communication Failure
If the HMI looses communications with the Processor a “COM Port Open
Failed” message will appear on the screen, as shown below.
170
Condenser operation will no longer be controlled by the HMI. The operator
will have to control the stages at the motor starter by using either HAND or
OFF.
171
172
35391VT Rev. 4 (7/13) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. © 2012 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.
|