PLC Manual
PLC Manual
PLC Manual
FRICK COMPANY 100 CV AVENUE P.O. BOX 997 WAYNESBORO, PA 17268-0997 PHONE (717-762-2121)
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1. 1. 2. TABLE OF CONTENTS
TABLE OF CONTENTS 2 4
Introduction and Purpose ____________________________________________________________ 4 Equipment Settings Grid ____________________________________________________________ 4 Recommended Spare Parts List ______________________________________________________ 4 Common Control Panel Equipment ____________________________________________________ 5
Bently Nevada Vibration Monitoring System _____________________________________________________________5 SPA2 Module _____________________________________________________________________________________7 HOA Switches ____________________________________________________________________________________7 Indicator Lights ___________________________________________________________________________________7 Pushbuttons______________________________________________________________________________________7 PLC Rack _______________________________________________________________________________________7
3.
GETTING STARTED
4.
STATUS SCREENS
15
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5.
PID SCREENS
23
PID Setpoints _____________________________________________________________________ 23 List of PID Loops __________________________________________________________________ 23 PID Loop Setpoints ________________________________________________________________ 23
Actual PV _______________________________________________________________________________________23 Setpoint SP _____________________________________________________________________________________23 Gain 23 Reset TI 24 Range 24 Output CV ______________________________________________________________________________________24
6.
27
7.
ALARM SCREENS
31
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Alarm Silence and Alarm Reset Buttons _______________________________________________ 33 New Alarm Banner_________________________________________________________________ 33 Active Alarms _____________________________________________________________________ 34 Alarms History ____________________________________________________________________ 35 First Out / Freeze __________________________________________________________________ 36
Freeze Screens __________________________________________________________________________________36
8.
TRENDING SCREENS
37
9.
38
10.
48
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The compressor is controlled by an Allen-Bradley processor, hereafter referred to as the controller or PLC. The controller continuously monitors compressor and system conditions and operation. This manual explains how the controller is used to control the refrigeration system. Operator interface is through a PanelView-Plus 1000 or 1250 Color, Touch Screen Operator Interface located on the front of the control panel. The interface is used for system monitoring, history, manual PID loop control, trending, and setpoint entry.
Please contact your Johnson Controls or York Process Systems Sales Representative to request a recommended spare parts list. Contact information can be found on the internet at www.jci.com or by calling Frick at (800)-ITSCOLD.
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Rack Interface Module This module is used for uploading / downloading / monitoring of the Bently Nevada system using the Bently Nevada Configuration Software. A laptop running the Rack Configuration software can communicate to the Rack using a standard RS232 cable (Null Modem). Relay Module This module is used to control the PLC interlocking signals. Proximotor Module Monitors the vibration transducers mounted on the compressor or motor. Keyphasor Module Monitors the keyphasors.
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RTD Module Monitors compressor, gear, and motor mounted RTDs. Communication Gateway Module Transfers Bently Nevada equipment status to the PLC using Modbus protocol.
SPA2 Module
The SPA or Site Programmable Alarm module is used for safety backup of transmitter data. The SPA2 module monitors a 4-20mA signal. When the signal falls above or below an alarm threshold, then a contact opens inside the SPA module which will cause the compressor to go into a shutdown condition. SPA2 modules are commonly used to monitor Discharge High Pressure and Compressor Journal Bearing Inlet Low Differential Pressure. SPA modules can also be used to retransmit a 4-20mA signal. SPA2 series module setpoints can be monitored and changed through a RS232 interface on the front of the module with the Moore Industries (www.miinet.com) SPA2 Configuration Software.
HOA Switches
The following are a list of standard HOA switches located on the electrical control panel: Compressor Aux Oil Pump (Auto / Manual) When in the Auto position, the PLC controls the oil pump. When in the Manual position, the pump will turn on immediately and run until the selector switch is returned to the auto position. Gear Aux Oil Pump (Auto / Manual) When in the Auto position, the PLC controls the oil pump. When in the Manual position, the pump will turn on immediately and run until the selector switch is returned to the auto position.
Indicator Lights
The following are a list of standard indicator lights that are located on the electrical control panel: Compressor AOP Running The compressor AOP running light is an indicator of the status of the auxiliary input for the motor. The indicator is illuminated when the auxiliary input to the controller is energized. Gear AOP Running The compressor AOP running light is an indicator of the status of the auxiliary input for the motor. The indicator is illuminated when the auxiliary input to the controller is energized. Compressor Running The compressor running light is an indicator of the status of the auxiliary input for the motor. The indicator is illuminated when the auxiliary input to the controller is energized.
Pushbuttons
The following pushbuttons are located on the control cabinet door. Compressor Start Press to locally start the compressor. Please refer to the System Startup Procedures before pressing this button. Compressor Stop - Press to locally stop the compressor. Please refer to the System Shutdown Procedures before pressing this button. Emergency Stop Pull to immediately shutdown the compressor. Push to unlatch and allow the operator to restart the compressor.
PLC Rack
The following are a list of modules that can be found mounted in the PLC rack.
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Power Supply The power supply is used to supply power to the PLC backplane for use by the PLC cards. Processor The PLC processor is the decision making unit and is generally referred to as the controller. This system utilizes the 1756-L61 CPU. The PLC program is loaded into the processor via RS232 or Ethernet interface. The processor scans the status of the I/O cards and sends command signals to the outputs. Analog Input Card Analog input cards monitor the 4-20mA signals supplied from transmitter devices. The transmitter devices, typically Rosemount or similar, can be compressor mounted, package mounted, or from customer supplied equipment panels. Examples of typical 4-20mA analog inputs would be pressures, levels, motor current, and in some cases temperatures. Analog Output Card Analog output cards supply a variable 4-20mA control signal to modulating valves (typically Fisher or Hanson style) and variable frequency drives. Example of typical 4-20mA analog outputs would be PRV position control, pressure control valves, level control valves, and temperature control valves. Discrete Input Discrete input cards monitor the 120VAC or 24VDC signal supplied from a discrete switch or contact. Discrete devices are those that have an on or off state. Example of discrete input devices would be a level switches, pressure switches, thermostats, and auxiliary contacts. Discrete Output Discrete output cards are used to control 24VDC or 120VAC devices. Examples of discrete output devices would be solenoids and relays. RTD Module RTD input cards monitor the temperature of an RTD (resistive temperature device). Ethernet Module The Ethernet card is used for downloading a PLC program into the PLC processor, monitoring the PLC status via laptop, monitoring the system status via PanelView plus, and for DCS communications. A category 5 (Cat-5) cable connects the Ethernet card to a switch for interface with all Ethernet compatible devices on the system. ProSoft Modbus Module A ProSoft Modbus Card ( 1756-MNETR) is used to connect modbus capable devices to the PLC. The ProSoft configuration is handled by the PLC program & the Prosoft Configuration Builder Program (www.prosofttechnology.com). The ProSoft Modbus module is used to monitor Bently Nevada vibration information and can also be used for DCS communications.
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GETTING STARTED
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The Current User indicator is displayed in the upper left hand side of all screens. The indicator uses the format of CURRENT USER: with the username of the current user below. Default is displayed when no user is logged in.
Refer to the section User Level Security for more information on the Current User indicator.
The Alarm Status indicator is located in the upper right hand corner of all screens. The background color of the indicator is red for shutdowns and Yellow for alarms. The following are the status conditions that can be displayed: No Alarms or Shutdowns No active alarms or shutdowns exist in the controller. New Alarm Exists (Blinking Yellow) Displayed when an unacknowledged alarm exists in the controller.
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New Shutdown Exists (Blinking Red) Displayed when an unacknowledged shutdown exists in the controller. Alarm Exists Displayed when an acknowledged alarm exists in the controller. Shutdown Exists Displayed when an acknowledged shutdown exists in the controller.
Common Colors
The following are common colors that are used throughout the HMI: Yellow Alarm condition, or warning indication. Red Shutdown condition or high alert indication. Green On or Active. On setpoint entry boxes, green indicates that the user has the necessary security level to change the setpoint. Grey Off Blue Touch sensitive box Orange Used on setpoint entry boxes to indicate that the user does not have the necessary security level to change the setpoint.
Common Terms
ALARM - An alarm setpoint has been reached or exceeded and the compressor will continue to run. AOP - Auxiliary oil pump (also referred to as Lube Oil Pump). AUTO (Automatic) - The device is being controlled from the Allen-Bradley Processor. I/P Current (milliamps DC) / Pneumatic (PSIA) MAN (Manual) - The device is being controlled from the PanelView 1000 . PID (Proportional, Integral, Derivative) This references the loops used to control the current to pneumatic (I/P) valves. PLC Refers to the Allen Bradley SLC or ControlLogix processor that is installed in the control panel. Recycle Delay - this message indicates that the compressor has started and has shut down within the delay time that has been set to prevent the compressor from starting again. Recycle delay is intended to prevent damage to the compressor motor from successive restarts. SHUTDOWN - A critical safety limit has been reached or exceeded and the compressor has been shutdown.
Figure 6 Setpoint Entry Box. The highlighted color reflects the users security level. Green = access allowed, Orange = access denied.
Setpoint entry boxes are used by the operator to enter setpoints that are used by the controller to define parameters such as alarm delays, shutdown delays, PID gains and setpoints, control setpoints, etc. Setpoint Entry boxes have a raised border style, and are characterized by either a bright orange (access denied), or bright green (access allowed) outline. A user must be logged in with the correct security level to change setpoints.
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Value Display boxes show controller values such as temperatures, pressures, valve positions, and I/O status. Value Display boxes have an inset border style.
Figure 8 User Action Button (No highlight indicates that all user levels can access this button)
User Action Buttons are used by the operator to reset alarms, go to screens, and change system modes. User Action boxes are blue and, when applicable, have either a bright orange (access denied), or bright green (access allowed) outline. A user must be logged in with the correct security level to change setpoints.
User security is used to prevent unauthorized users from changing setpoints or controller modes. The user security system is similar in setup to the Frick Quantum LX controller.
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STATUS SCREENS
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The System Overview screen 1 is the default HMI startup display. This screen is an overview of the entire system based on the P&I Diagram (659D2149). It consists of a general diagram of the critical components of the refrigeration system as well as motor status, analog inputs, RTD inputs, modulating valve positions, and information displays. System Overview 2 (659D2147) supplies a more detailed view of the gearbox & motor. Finally Stem Overview 3 (659D2146) supplies a more detailed look of the Compressor.
Compressor Status
The compressor status is shown with respect to the running status of the compressor: ON = Green OFF = Grey
ON =
OFF =
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Modulating Valves
The modulating valve position is shown to the lower center of the valve box. Some limited function valve indicators will have a BV (Block Valve) or HV (Hand Valve) in the top left of the valve box. Block valve body and handle will turn green when the solenoid is energized. Hand valves have no solenoid so the image has no handle but the body turns green when the valve position is above 95%. Listed below are the different states of the valve indicator:
The green handle indicates the solenoid for the valve is energized
The green valve body indicates the valve is more than 95% open (adjustable 95 to 100%)
Transmitter Indicator
The Transmitter indicator can be used for Temperature, Flow, Current, Pressure, & Differential Pressure. This example is of a normal reading transmitter
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Figure 13 Above PT-1231A9 the SyncFault is active otherwise this space is empty Comparator Compares Local (PT-1231A0) & Common Header Suction Pressure (PT-1231A9). The Comparator uses the Common Header Suction pressure unless the Delta PSI differs by more than the Setpoint default of 2 (0-10 adjustable) then it uses the Local Pressure.
Digital Indicators
Figure 14 Above is an examples of digital alarm indicators The digital alarm indicator are used for level swithces and SPA2 module alarm conditions. Normal State Level switch in alarm SPA2 signal in shutdown (Same for Level Switch)
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Figure 15 Above is an examples of two Quick Link Buttons The blue Quick Link Buttons are on each of the Overview Screens to aid in moving between frequently used screens.
Figure 16 Motor indiactors The motor will indicate running when the motor aux contact is made. The alarm states are tripped from the GE Multilin MIF II Digital Feeder Relay. The following are the trip states: Differential Current Phase Trip Differential Current Ground Trip
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The Compressor Start Summary Screen displays information regarding the Startup sequence and anything inhibiting the compressor from starting.
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The Electric Motor Inhibits and Runtimes screen displays information regarding motor protection and motor runtimes. When anti-Recycle is active the compressor is prevented from starting. Anti-recycle is used to prevent excessive starting of the compressor to avoid damage to the motor.
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Motor Runtimes
The Motor Runtimes section displays run time information and number of start counts for the compressor motor and auxiliary oil pump motors. The last compressor start is logged on this display with the date and time being displayed
2 Minute Delay
Indicates two minute start inhibit delay time. Compressor startup will be permitted when this value is zero
FLA Setpoint
Enter the motor AMP Setpoint to be used as the 100% load value.
Actual FLA %
The current Motor Amps usage as a percentage of Full Load Amp draws.
Stop Load
When the motor FLA reaches or exceeds this setpoint, the pre-rotation vanes are prohibited from opening any further. Range (0 110%)
Force Unload
When the motor FLA reaches or exceeds this setpoint, the pre-rotation vanes are ramped closed at a rate of 10% per second. The ramp time is adjustable and can be changed via the Motor Current Force Unload setpoint in the System Setup page accessed via the System Setup Menu. Range (0 103%)
Number of Starts
The total number of starts for each motor.
Runtimes
The total running hours for each motor.
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5. PID Setpoints
PID SCREENS
Setpoint SP
Enter the setpoint of the desired temperature, pressure, level, or flow to be maintained. The PID loop will equalize the process variable around this setpoint based on the gain, reset, and rate (not adjustable on the display). (See explanations of each below)
Gain
This is the Proportional Gain, ranging from .001 to 20. Gain acts directly on the change in error since the last scan (error is the setpoint (SP) minus the control variable (CV) value). Therefore, in the case of steady-state error, gain alone has no effect on the output. For this reason, gain cannot be used alone.
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Gain is also used as a multiplier on the integral and derivative. A rule of thumb is to set this gain to one half the value needed to cause the output to oscillate when the reset is set to zero. Too much gain results in output oscillation (overshooting). Too little gain results in very slow performance UPPER Gain - This setpoint will be used when the process variable is above the loop setpoint. LOWER Gain - This setpoint will be used when the process variable is below the loop setpoint. Adjusting Gain Values Increasing gain causes a FASTER response (valve ramps in larger increments). Decreasing gain causes a SLOWER response (valve ramps in smaller increments)
Reset TI
Reset is the Integral gain, adjustable from 0.001 to 20. This term acts only on the current error. It is used to reduce the current error to zero. Note that during steady-state conditions, integral multiplied by current error multiplied by gain is the only thing affecting the output. A rule of thumb is to set the reset as low as needed to prevent over-shooting. UPPER Reset - This setpoint will be used when the process variable is above the loop setpoint LOWER Reset - This setpoint will be used when the process variable is below the loop setpoint Adjusting Reset Values - Increasing reset causes a SLOWER response. Decreasing reset causes a FASTER response.
Range
The range is used to set minimum and maximum control values for the modulating valve. An example would be a minimum value of 20% for a pressure control valve that should never close to less than 20%.
Output CV
This displays the current control output in % open. NOTE: When the valve is in manual
mode, this value will represent the PID Loop control position if the valve were still in auto mode, and not the physical position of the valve.
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Command Position
The Command Position represents the percentage location of the valve. 0% represents fully closed, 100% represents fully open. When the valve is in manual mode in can be ramped open and close using 2 different methods, by touching on the Command box and entering a command value, or by touching the blue ramp up or ramp down arrows.
NOTE: If a valve is left in manual mode, and the current user logs out, the valve mode status will show Valve in Manual Mode Login to Change.
Figure 20 Typical PRV Capacity Control Screen with Discharge Pressure Override
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Startup Setpoint
Default conditions will allow for the compressor to do a slow loading of the Pre Rotation Vanes according to setup parameters entered in the setup display section. This slow loading can be bypassed at any time of the startup procedure by pushing the Suction Slow Pulldown Enabled Press to Disable button. If the Slow Pulldown is disabled the pushbutton will display Suction Pulldown Disabled Press to Enable, this will disable all Slow Pulldown setpoints on startup.
Override Comparator
The Override Comparator is located in the lower right portion of the screen (box with < symbol). The lines to & from the comparator to the PRV PID will normally be black. When Discharge Override, Motor Current Stop / Force Unload are active the lines will turn green as in figure 20.
Sync Fault
Figure 20 shows PT-1231A0 with SyncFault active otherwise this space is empty A comparator compares Local (PT-1231A0) & Common Header Suction Pressure (PT-1231A9). The comparator uses the Common Header Suction pressure unless the Delta PSI differs by more than the Setpoint default of 2 (0-10 adjustable) then it uses the Local Pressure.
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The Digital Inputs and Digital Outputs screen displays the actual states of all digital inputs wired to the controller. The inputs and outputs are listed in order as wired to the digital input card.
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Analog Inputs
The Analog Inputs screen displays the scaled values of all analog transmitters wired to the controller. The inputs are listed in order as wired to the analog input card.
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RTD Inputs
The RTD Inputs screen displays the actual temperature of all RTDs wired to the controller. The RTDs are listed in order as wired to the RTD input card. Since the processor derives the temperature directly from the resistance sensed at the RTD, no scaling is required.
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Analog Outputs
The Analog Outputs screen displays the scaled (0 to 100%) values of all analog transmitters in the controller. The outputs are listed in order as wired to the analog input card.
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ALARM SCREENS
The analog Alarm Setpoint Entry Screens are used for entering in low alarm / shutdown, and high alarm / shutdown, setpoints and delays. The center value is the current reading of the analog input.
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The Digital Alarm setup page allows for limited adjustment of the alarm delay time.
Figure 27 Alarm Navigation Box found on Alarm History and Active Alarms Screen
The Alarm Navigation Box is used on the Alarms History and Active Alarms screen. Each screen is capable of storing up to 100 alarms, but only 15 can be displayed at a time. The buttons on the Navigation box are used to control a highlighter, which shows focus on an alarm. The Navigation box is broken down into 3 columns. The columns are used as follows: Column 1 These 2 buttons are used to move the highlighter to the top or the bottom of the alarm list. Column 2 These 2 buttons are used to move the highlighter up or down 1 page of alarms, or approximately 15 alarm messages. Column 3 These 2 buttons are used to move the highlighter up or down 1 alarm message.
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The New Alarm Banner is displayed at the top of the HMI display any time a new alarm or shutdown occurs. The New Alarm Banner is a Pop-Up style window and includes the ability to Silence or Reset Alarms. Analog Alarms and Shutdowns are displayed in the format: Tag, Description, Low / High Reading Alarm / Shutdown. Discrete Alarms and Shutdowns are displayed using a description of the alarm / shutdown and the tag if applicable.
Note: Active Alarms cannot be reset until the error or conditions that caused the alarm to occur have been corrected.
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Active Alarms
Figure 29 Active Alarms Screen showing alarms in yellow and shutdowns in red
The Active Alarms screen display all active, unacknowledged alarms and includes the ability to silence and reset alarms. Up to 100 unacknowledged alarms can be viewed using the alarm navigation box. Alarms and Shutdowns are displayed in the format: Alarm Date, Alarm Time, Tag ID, Description, Low/High Reading Alarm/Shutdown. Discrete Alarms and Shutdowns only display a tag ID when applicable.
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Alarms History
Figure 30 Alarms History Screen showing alarms in yellow and shutdowns in red
The Alarms History screen display all acknowledged alarms and includes the ability to silence and reset active alarms. Up to 100 acknowledged alarms can be viewed using the alarm navigation box. Alarms and Shutdowns are displayed in the format: Alarm Date, Alarm Time, Tag ID, Description, Low/High Reading Alarm/Shutdown. Discrete Alarms and Shutdowns only display a tag ID when applicable. The Clear History Button is used to clear all alarms from the Alarms History Display box.
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Figure 31 Compressor Shutdown First Out Screen with links to freeze screens at bottom
The first out screen identifies the specific fault that has shutdown the compressor. The fault description, tag number, and date / time stamp are displayed. The first out fault will not be reset until the shutdown has been reset from the active alarm screen.
Freeze Screens
On the lower half of the First-Out Screen are buttons to view instantaneous data captured at the moment of a system shutdown. This data is updated after every system shutdown. The values displayed on the Freeze Screens are in a format identical to the I/O data screens used for real time data.
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8. Purpose of Trending
TRENDING SCREENS
Trending screens are used to view historical data in a graphical format. The primary purpose(s) of viewing the trended information is troubleshooting machine events (alarms, shutdowns, etc), tuning PID Loops, and record keeping. All Analog Input, Analog Output, and RTD temperatures can be viewed. Trending snapshots are shown in a 10 minute format. Screen Features include the ability to go back in time several hours to view historical data, view up to 8 pens at a time, pause, and scale adjustment.
Trending Screen
Figure 32 Typical Trending Screen for 4-20mA transmitters, comments show location of buttons on screen
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Screen Protector
The screen protector is used to prevent screen burn, primarily on the overview screen. If the overview screen is active for the delay setpoint (30 300 minutes), a temporary logo screen will appear for 60 seconds, and then the overview screen will reappear. The screen protector feature can be disabled if desired.
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AOP Setpoints
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Run Comp AOP for xxx Min. Every xx Hours When Comp Not Running When the compressor is not running, these parameters define how frequent, and the length of time, that the compressor AOP will run to maintain adequate lube oil pressure to system components.
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Setup Page 1
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Add to Min PRV Bias After Each Surge - On the first event, the respective hot gas valve is opened to the preset value (default 25%) and the surge bias (see below) is added to the PRV Control Minimum. Surge Input Delay Timer Preset - This adjustable time setpoint defines the length of time in-between recorded surges. No matter how many times the surge input opens and closes during this time, only one surge event will be recorded. This prevents multiple surges from occurring due to chatter of the discrete surge input. (Default 10 seconds, adjustable 0-30 seconds) Surge Reset Timer Preset - This adjustable time setpoint defines the length of time to accumulate surge events. This timer is started with the first surge event. Subsequent surge events must occur before this preset time in order to count as a second or third surge. If this time expires, the surge counter will reset to zero. Any surge that takes place after this time expires will be counted as the first surge event. st Increase Hot Gas Valve at 1 Surge - After the first surge event the recycle gas valve is adjust this amount. nd Increase Hot Gas Valve at 2 Surge - After the second surge event the recycle gas valve is adjust this amount.
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Setup Page 2
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Setup Page 3
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Flash with new occurrence (YES) This option will open and close the relay repeatedly every second when a new alarm or shutdown occurs. When the alarm or shutdown is acknowledged the relay will be de-energized. This option can be enabled in order to differentiate between an existing and new alarm.
Note: The compressor shutdown light and alarm light will respond according to dry contact setup.
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Setup Page 4
Action
Determines the response of the PID loop. Forward action will be a direct action loop, if the pressure or temperature increases the output will increase. For Reverse acting as the pressure or temperature increases the value will decrease.
Direction
Determines the direction of the PID loop for the valve. If 4mA = 100% then the valve will be open at 4mA, if 20mA = 100% then the valve will be open at 20mA.
Operating Minimum
The Minimum the valve can be closed. Default 5% (adjustable 0 to 100%) see 669D0127 sheet 8
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Setup Page 5
Suction
The Suction Hot Gas Valve PR1, PR2 FLOMAX1, & FLOMIN1 are constants used in flow calculations. These values are located in a table on 669D0127 sheet 10.
Stage 2 & 3
The PR1, PR2 FLOMAX1, & FLOMIN1 are constants used in flow calculations. These values are located in a table on 669D0127 sheet 9.
Surge Bias
The Surge Bias is the percentage that is added to the Minimum Compressor Flow while in a surge condition. Default 5% (Adjustable 0 to 100%)
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10.