INSTALLATION AND OPERATIONS MANUAL VERSION 3.1.2

Transcription

1 INSTALLATION AND OPERATIONS MANUAL VERSION 3.1.2

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3 This Manual is the intellectual property of Case Engineering inc. and is protected by U.S Copyright laws. You may not reproduce or alter this manual in any way. For inquiries please contact: Case Engineering inc. P.O. Box 6884 Evansville IN Tel (812) Fax (812)

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5 Chapter 1 Specifications... 1 This Manual... 3 What is AirLogix?... 3 Base System Definition... 4 Enclosure Specifications Front Panel Devices... 4 Allen Bradley CompactLogix Components... 4 Other System Components... 4 Electrical Requirements I/O... 5 Pre-lube/Auxiliary Oil Pump Circuitry... 7 Main Oil Pump Operation... 7 Auxiliary Air Oil Pump Circuitry... 7 Main Motor Circuitry... 7 Control Power Circuitry... 8 Emergency Stop Circuitry... 8 Common Options... 9 Control Component Upgrades... 9 Modem Connection... 9 Security Electrical Schematics Factory Testing Point to Point Test Lab Test Retrofit Options MP3 Retrofit Installation Chapter 2 Set-Up Procedures Verification of Main Power Connections Verification of Main Power Connections for the MP3-RetroFit Option Operation Parameters Control System Configuration Discrete Input Configuration Analog Input Configuration Oil Pump and Heater Configuration Motor Start and Stop Configuration Cooling Water Valve/Condensate Purge Configuration Condensate Purge Configuration AirWatch Setup Startup-Load/Unload Configuration Manual Valve Control Stroking the Analog Valves Stroking the DCAV Valves Stroking Discrete Bypass Valve Alternate Manual Valve Control Screen Testing the Pre-lube/Auxiliary Circuit PanelView Configuration Starting the Machine Chapter 3 Throttle Surge Procedure i

6 Inlet Starting Position Manual Valve Control Determining the Surge Line Throttle Surging Dynamic Throttle Limit (DTL) Manual Valve Control Trend Buttons Alternate Manual Valve Control Method Chapter 4 Valve Tuning What is a PID Loop? PID Screen Tuning Strategies: PID Tuning Methods Dynamic Throttle Limit PID Bypass Pressure PID Inlet Pressure PID DCAV Valve Tuning DCAV Valve Tuning Using Position Feedback Chapter 5 Operation Power On Common Start Permissives Starting the Compressor Stopping the Compressor Loading the Compressor Load and Throttle Sequence Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Unloading the Compressor Modifying the Pressure Set Point Status Screens Numeric Status Indicators Air End Status Screen Oil and Water Status Screen Motor Status Screen Discrete Status Screen Motor Status Screen... 1 Trend Screens User Defined Status Screen Misc Status Data Screen Resetting Hour Meters and Power Accumulators Peak Vibration Data Screen Peak Vibration During Startup Peak Vibration Running Peak Vibration During Coast Down Automatic Functions ii

7 Auto Start Auto Load Auto Unload Auto Stop Chapter 6 Troubleshooting: Modem Service Policy Warranty Service Non-Warranty Service Warning/Trip Descriptions Low/High Temperature Warnings/Trips Vibration Warnings/Trips TD01- Low Seal Air Pressure Trip TL05- Motor Current Low Trip TH05- Motor Current High Trip WH01 Machine Pressure High Warning TH01 - Machine Pressure High Trip WD16 Surge Warning WD17 Surge Line Indexed WD18 Non-Recoverable Surge Unload WD19 Auxiliary Oil Pump Running, Possible Mechanical Oil Pump Failure WD20- Processor Battery Low WD21- Motor Power Loss WD22 Performance Throttle Mode WD23 through 25 Slot # Analog Input Module Not Present WR00 through WR37 Signal Out Of Range Surging or Other Erratic Behavior Inlet air obstruction Discharge obstruction Valve Linkage Voltage Fluctuation Machine Wear Sensor Malfunction Abnormal PSI Setting Unable to Make Pressure Set-Point Max Motor Amp Limit Unable to Start the Machine Chapter 7 -AirMaster Operation Overview AirMaster Compressor Overview Enabling and Disabling AirMaster AirMaster Setup Parameters Auto Priority Rotation Setup iii

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9 Chapter 1 Specifications This Manual What is AirLogix? Base System Definition Pre-lube/Auxiliary Oil Pump Circuitry Main Oil Pump Operation Air Auxiliary Oil Pump Circuitry Main Motor Circuitry Control Power Circuitry Emergency Stop Circuitry Common Options Modem Connection Security Electrical Schematics Factory Testing Retrofit Options MP3 Retrofit Installation 1

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11 This Manual This manual is written as a guide to install, commission, and operate a Base System. Warning: Only qualified personnel should attempt to install and commission this product. Catastrophic failure can result from improper set up. If you need assistance, please call Case Engineering at (800) In the case of special logic for custom applications, an addendum to this manual is provided. Any information contained in the addendum supersedes anything stated in this manual. What is AirLogix? AirLogix is a PLC based control system for centrifugal compressors of all makes and models. It has been installed on Joy, Worthington, Elliott, Ingersoll-Rand, Clark ISOPAC, and other compressors. The PLC brings obvious advantages of flexibility, availability and serviceability by a number of resources. The copyrighted software or source code (part of which is known as ladder logic) is the property of Case Engineering Inc. It is licensed to users for installation and use on one centrifugal compressor per license. Case Engineering, Inc. also owns the copyright for this document. With the license for AirLogix, you have the right to copy this manual for use in the installation, operation and maintenance of a licensed AirLogix System. The AirLogix system is an evolving product with many features planned for future release. For this reason, each system manufactured ships with a version number. This number helps identify the features available in your system when contacting technical support. The AirLogix version number is found on the Case Controls screen. From the Main screen, press [F10], then select Case Controls from the navigation menu. The AirLogix version appears just below the AirLogix logo. Because of the unlimited variety of compressor applications and configurations, a Base System is defined as that which covers factors common to nearly all systems. The AirLogix software is developed and maintained for this Base System. It is important to understand that the Base System may not be appropriate for your application. This is where the flexibility of a PLC becomes invaluable. If your specific application requires instrumentation or procedures not common to the base system, custom software may be added to meet your specific needs. Some software units are modular and some are written specifically to your specifications. 3

12 Base System Definition AirLogix Base Systems with version numbers are shipped by default with the following hardware: Enclosure Specifications 1 NEMA 12, 36 high, 24 wide, 12 deep color: rough texture light gray weight: 166 lbs. Front Panel Devices color PanelView Plus 700 backlit LCD operator interface with sealed membrane keypad, Ethernet communications protocol and a flash memory card emergency stop push button (maintained position) 1 control power selector switch with indicator lamp 1 Allen Bradley CompactLogix Components (1) 1769-L32E Ethernet processor (750K) (1) 1769-ECR, Right End Cap (1) 1769-PA2, power supply (2) 1769sc-IF8U, eight analog inputs per module (1-5v or 4-20 ma current loop) (1) 1769-OF2, two analog outputs (4-20 ma current loop) (1) 1769-IA16, sixteen discrete inputs (120vac) (1) 1769-OW16, sixteen discrete relay outputs (120vac) Other System Components 120vac 10 amp circuit breaker 1 120vac surge protector AC fusing and terminals DC fusing and terminals 120vac 6 amp isolation relays for all discrete ouputs 1 120vac/24vdc Power Supply Allen Bradley Industrial Modem Hirschmann 5 port industrial ethernet switch Electrical Requirements 1 one 120vac, 10 amp circuit 1 Not part of the MP3-RetroFit option 4

13 I/O The AirLogix Base System includes logic to address the following common system variables: Analog Outputs Inlet valve Bypass valve Analog Inputs System Air Pressure 1 Machine Discharge Air Pressure Oil Temperature Discharge Air Temperature Oil Pressure Motor Current 2 Bearing Oil Pressure Pre-filter Oil Pressure Vibration (up to four stages) 3 Stage 1 Inlet Air Temperature Stage 2 Inlet/Stage 1 Discharge Air Temperature Stage 3 Inlet/Stage 2 Discharge Air Temperature Stage 4 Inlet/Stage 3 Discharge Air Temperature If 3 rd Analog Input Module is added: Stage 2 Inlet/Stage 1 Discharge Air Pressure Stage 3 Inlet/Stage 2 Discharge Air Pressure Stage 4 Inlet/Stage 3 Discharge Air Pressure Winding Temperature A Winding Temperature B Winding Temperature C Inlet Water Temperature Bull gear Vibration If the 4 th analog input module is added: Stage 5 Vibration Stage 5 Inlet/Stage 4 Discharge Air Temperature Stage 5 Inlet/Stage 4 Discharge Air Pressure Inboard Bearing Temperature Outboard Bearing Temperature Machine Air Flow Spare Spare 1 For best control the system air pressure instrument should be installed between eight and twenty feet from the machine discharge and between the check valve and the block valve. 2 The motor current CT is installed in the motor lead box on one leg of the motor leads. 3 Transmitters are required to convert the vibration probe outputs to 4-20ma analog current loop inputs. 5

14 Discrete Inputs Low Water Flow Low Seal Air High Inlet Filter D/P High Oil Filter D/P Low Oil Level High Condensate Level High Motor Temperature Emergency Stop Remote Stop Remote Start Remote Load/Unload Spares (5) Discrete Outputs Main Motor Start/Run Relay Main Motor Momentary Start/Wye-Delta Run Contact Main Motor Momentary Stop/Wye-Delta Shorting Relay Pre-lube/Auxiliary Oil Pump Alarm Fault Alarm or Fault Discrete Inlet Valve Close Discrete Inlet Valve Open Discrete Bypass Valve Open Discrete Bypass Valve Close Condensation Trap Purge Auxiliary Air Driven Oil Pump Water Control Valve Oil Heater Automatic Block Valve 6

15 Pre-lube/Auxiliary Oil Pump Circuitry By default, the AirLogix is designed to operate the pre-lube/auxiliary pump anytime seal air is present and the machine is off. Once the machine is running for X seconds as defined (see Chapter 2 Set up, Topic 3 Operation Parameters) the pre-lube/auxiliary pump is turned off. There is one 120vac, 6 amp, dry contact for a pre-lube pump motor starter. Motor starting equipment is not included with the base AirLogix system. However, this equipment can be provided upon request. Main Oil Pump Operation The main oil pump is common on Joy/Cooper and Clark ISOPAC compressors. The electric main oil pump starter coil may be wired to 120VAC or to a set of dry contacts designated for the main oil pump. The pump is designed to run anytime control power is on. However, if connected to the dry contacts, when the emergency stop is pressed the main oil pump will stop. Pressing the emergency stop to stop the compressor would allow the compressor to coast down without oil pressure. If a backup Air Auxiliary oil pump exists, connecting the main oil pump to the dry contacts prevents coast down without oil pressure. Auxiliary Air Oil Pump Circuitry The auxiliary air oil pump output is for air driven back up pumps. The output is energized to stop the pump and de-energized to run the pump. The pump is designed to run on loss of control power, or if the emergency stop is pressed, or if a low oil pressure trip occurs. If the compressor is running and a low oil pressure trip occurs, the output is de-energized causing the auxiliary oil pump to run. It will continue to run until the coast down timer is complete and the trip is acknowledged at the PanelView. The auxiliary oil pump solenoid should be wired to a normally open contact of the isolation relay. Main Motor Circuitry The AirLogix Base System main motor circuit consists of a single PLC output with a 120vac, 6 amp dry contact for starting the main motor. (This is not part of the MP3-RetroFit option.) The output is energized to run the motor and deenergized to stop it. Motor starting equipment is not included with the base AirLogix system. 7

16 Control Power Circuitry The Control Power switch on the enclosure door is not intended as a disconnect device. With the Control Power switch turned off, there may still be voltage points present in the enclosure. Emergency Stop Circuitry The Emergency Stop button disconnects all power to outputs thus disabling the main motor. Warning (systems with Pre-lube/Auxiliary Oil Pump) Because the pre-lube/auxiliary oil pump is wired in a fail-safe mode, the pre-lube may run even when the emergency stop is pressed. NOTE: The standard AirLogix installation reuses your existing motor starters, overloads and contactors. 8

17 Common Options Although the options for special logic for custom applications and additional variables are limitless, a few options are requested more often than others. Following are some examples: Mass Flow Bypass Flow Inter-stage Cooling Water Temperatures Cooling Water Flow Cooling Water Pressure Motor Winding Temperatures Motor Bearing Temperatures Additional Vibration Points Cooling water valve control De-mister control Control Component Upgrades Upgrade to ControlLogix platform Upgrade to larger PanelView Addition of redundant PanelView AirMaster (Load sharing of networked compressors) Remote monitoring of system Remote control of system Pre-programmed spare processors Spare parts kits Modem Connection Each location an AirLogix system is installed will have an Allen Bradley industrial 56K modem installed and tested. Typically, if a location has 1-2 AirLogix systems, a modem will be mounted with each system. If a location contains 3 or more AirLogix systems, one Allen Bradley Ethernet modem will be installed. Connection of a standard analog phone line allows for immediate technical support in the event of problems. Connection to a digital phone sytem can cause irrepairable damage to the modem. The modem provides the communication link for AirWatch, an invaluable tool for remote troubleshooting. The modem can be powered off and even unplugged for security. In the case of multiple machines, individual phone lines, or one shared phone line can be installed. 9

18 Security The AirLogix system has several tiers of security passwords. The CompactLogix program is password protected to prevent unauthorized access via modem. Access to the initial machine set-up and commissioning screens is password protected. Electrical Schematics Each AirLogix system is shipped with electrical schematics. These drawings include all panel wiring and field devices specified (whether Base System or beyond) at the time of order. Auxiliary systems not connected to the control panel such as cooling water control, oil de-mister control, etc. are not included in the schematics. Piping and installation drawings may be provided by your installer but are not provided as part of the AirLogix system. Factory Testing Each AirLogix System is thoroughly tested prior to shipment. The checkout procedure used is documented and kept on file at Case Engineering. Point to Point Test After panel assembly is complete, each of the interconnected points is checked for continuity relative to the electrical schematics provided by the engineering department. Lab Test The point-to-point tested panel is delivered to our test lab where: a 48 hour hardware burn in is complete a simulator is connected power is applied to the system all programs are downloaded all screens are reviewed and each input and output is exercised by the simulator with run-like conditions visual inspection of workmanship is conducted 10

19 Retrofit Options Case Engineering offers multiple retrofits to replace existing OEM controls and utilize the existing enclosure/control panel, instruments and associated wiring. Installation and commissioning is reduced dramatically. This solution is ideal for replacing obsolete OEM controllers with a limited amount of compressor downtime. The following retrofits are offered: IR MP3 Retrofit IR CMC Retrofit Joy/Cooper QUAD III Retrofit Joy/Cooper QUAD 2000 Retrofit MP3 Retrofit Installation The MP3-RetroFit option is designed to provide a plug and play replacement for the obsolete Ingersol-Rand MP3 controller. Following are five steps for replacing the hardware. This typically requires less than 8 hours of downtime. It may be necessary to get set points from the old unit before powering it down. Installation of a machine discharge pressure sensor is required. Installation of the inlet temperature RTD/transmitter is optional, however, it is highly recommended to maximize compressor efficiency and protection from surge. Located just inside the enclosure door is the proprietary MP3 motherboard. There are five multiple conductor connections made to field wiring on the machine and to other devices within the enclosure. The cover is removed, the I/O connectors pulled off and the MP3 board removed from the enclosure. In its place is installed the AirLogix MP3 Interface Board with mating connectors that are mapped to the AirLogix system I/O. The interface board hosts certain transmitters for conversion to standard 4-20mA current loop inputs. 11

20 Some retrofits allow the PLC to be mounted on the interface board, however, there may be space inside the enclosure identified for installation of the Allen Bradley PLC, I/O hardware and pre-made cables to connect to I/O modules. Typical installation time is 30 minutes. If room is not available, Case can provide a satellite enclosure to be mounted near the machine. Please be sure to provide a cable length from the original panel to where the satellite will be located. The PanelView Plus 700 operator interface is then installed in place of the MP3 front panel leaving the MP3 push button interfaces to the new system. Typical installation time is one hour. 12

21 Chapter 2 Set-Up Procedures Verification of Main Power Connections Verification of Main Power Connections (MP3) Operation Parameters Control System Configuration Discrete Input Configuration Analog Input Configuration Oil Pump/Heater Configuration Motor Start/Stop Configuration Cooling Water Valve Configuration Condensate Purge Configuration Startup-Load/Unload Configuration Manual Valve Control Stroking the Analog Valves Stroking the DCAV Stroking the Discrete Bypass Alternate Manual Valve Control Screen Testing the Modem Connection AirWatch Operation Testing the Pre-lube/Auxiliary Oil Pump PanelView Setup Starting the Machine 13

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23 This chapter is intended to thoroughly assist an installation technician with the AirLogix setup. Verification of Main Power Connections WARNING: The Control Power switch on the enclosure door is not a disconnect device. Turning off the Control Power switch does not remove all power from the system. Use caution, remove power from an external disconnecting device and always check for voltages before performing any work inside the enclosure. Open all fuses and push red button on circuit breaker. Verify the E-stop push button is pressed before proceeding Located on the enclosure door, switch the Control Power switch to the ON position. Apply 120 volts AC to the panel. Verify voltage at ACCOM and the bottom side of the circuit breaker. If the voltage measures 120 volts AC, switch the circuit breaker on and close fuses FUCPU and FUPS located to the left of the circuit breaker. Verify that there is 24 volts DC between +24VDCF and DCCOM at the 24-volt power supply. Close fuses labeled FUPV, FUM, FUS, and FUIO located on the DC terminal strip. Check the PanelView to see that it is powered up and communicating to the processor. Check to see that there is a green light on the CompactLogix power supply and that the processor has a green RUN light. Verify that the processor key switch is in the REM mode. The processor should always remain in REM mode. 15

24 Verification of Main Power Connections for the MP3- RetroFit Option WARNING: Use caution, remove power from an external disconnecting device and always check for voltages before performing any work inside the enclosure. When installing the MP3-RetroFit option, the new replacement panel will receive its AC and DC power from the original terminal plugs and original DC power supply. Do not remove the original power supply or line filter. Be sure that the main motor is locked out before installing this unit. Before energizing the control power, verify seal air is present and check continuity at TS2-5 and TS2-6. This indicates the seal air pressure switch is closed. Turn the Control Power switch to the on position. Verify that there is 120VAC between terminals TS1-8 and TS1-10. Verify that there is 24VDC between terminals TS5-20 and TS5-19. Verify the prelube is running. Check the PanelView to see that it is powered up and communicating with the processor. If it is not, a blue diagnostic window will appear. Check to see that there is a green light on the CompactLogix power supply and that the processor has a green "RUN" light. Verify that the processor key switch is in the REM mode. The processor should always remain in REM mode. 16

25 Operation Parameters This screen contains the software version number and information to contact Case Engineering. The control panel temperature is also displayed on this screen. The temperature indication is taken from the first analog input module and may read slightly high due to module heat disipation. Press [F2] to navigate to the Main Screen. To begin the setup process from the Main screen, press [F10] to display the navigation menu. From the Navigation menu, use the up/down arrow keys to select General Setup and press [Enter]. The General Setup screen is designed to step the installation process along in a logical order. NOTE: All setup screens can be viewed by anyone. However, to modify a setup parameter an authorized user must log in. To log in, press [F10], and then press [F2]. If you do not know the correct user ID and password, contact Case Engineering. 17

26 Control System Configuration NOTE: To modify set points throughout the setup process, use the TAB keys. Use the TAB left [ ] and TAB right [ ] keys to place the green highlight on the desired entry point. The TAB keys are located just left of the shift key. The highlights may not be seen if the operator is not logged in as a setup technician. Also several entry points throughout the setup may require pressing a designated function key to change the field. Multiple presses of the function key will display all possible selections. Press [K1] to move to the Control System Configuration screen. Press [F1] to select the control system (AirLogix, MP3 Retrofit, QUAD 2000 Retrofit, or QUAD III Retrofit). Press [F2] to select the inlet valve control method (Analog or DCAV). DCAV inlet control refers to a Discretely Controlled Analog Valve with a motorized actuator. Press [F3] to select the bypass valve control method (Analog, DCAV, or Discrete). Discrete refers to a solenoid actuated valve that has no analogous positions. Press [F4] to select the bypass valve position reference. The bypass valve may be displayed as percent open or as percent closed. Press [F5] to select the compressor manufacturer (IR, Joy, Cooper, Worthington, Atlas Copco, FS-Elliott, Clark ISOPac, or Elliott). Enter the compressor ID/Name (15 character maximum). Enter the Number of Stages on the compressor. Enter the Design Capacity and Design Pressure. Enter the motor name plate full load amp (FLA) rating. Enter the Motor Voltage. Enter the motor name plate horse power (HP). 18

27 Press [F7] to modify the Units of Measure. Pressure selections are: psig, kpa, and bar Temperature selections include degrees Fahrenheit and degrees Celsius. Vibration selections include mils or microns. Note: Changing the units of measure does NOT automatically change the scaling and set points for monitored analog variables. The analog variables should be setup to the appropriate unit of measure during the commissioning process. Press [F10] to exit. Discrete Input Configuration From the General Setup screen, press [K2] to configure the discrete and analog inputs. For the discrete inputs, press the function key that corresponds to the discrete input which should be configured. Note: For each input there may be a green check mark or red X next to the Function Key assignment. indicates the input is enabled. indicates the input is disabled. Press [F1] to enable/disable the input. The indicator in the upper right-hand corner indicates if the condition is true or false. If necessary, modify the input ID. If the input is exercised and the indicator is incorrect, pressing [F2] will toggle between N/O (normally open) and N/C (normally closed). This should 19

28 correct the indicator. It is important that the input is exercised to determine the accuracy of the input. For example, to exercise the Low Water Flow switch, the water valve should be closed and opened to force the switch to change states. If the input should be a Start Permissive, press [F3]. The indicator determines whether the start permissive function is enabled or disabled. If the input should be a Warning, press [F4]. The indicator determines whether the warning function is enabled or disabled. There is also a Warning Time Dly associated with the discrete warning. To modify the delay timer, use the TAB left/right keys to highlight the timer and enter the new value. The unit for this quantity is seconds. If the input should be a Trip, press [F5]. The indicator determines whether the trip function is enabled or disabled. There is also a delay timer associated with the discrete trip. To modify the delay timer, use the TAB left/right keys to highlight the timer and enter the new value. After the input is configured, press [F9] to return to the discrete input module setup screen. Repeat the above process for all applicable discrete inputs. Analog Input Configuration From the Discrete Input Module Setup screen, press [F9] to navigate to the next screen to configure the analog inputs. For the analog inputs, press the function key that corresponds to the analog input to be configured. Note: For each input there may be a green check mark or red X next to the Function Key assignment. indicates the input is enabled. indicates the input is disabled. Press [F1] to enable/disable the input. The indicator in the upper right-hand corner indicates actual value after the input is enabled. 20

29 The input identification can be modified if necessary. Using the TAB left/right, highlight Input Scale High, and enter the appropriate range of the transmitter. Repeat for the Low value Enter the Start Permissive high and low set points if applicable. To utilize the high and/or low start permissive function, press the corresponding function key until the indicator states the function is Enabled. Enter the Warning Set Point high and low set points if applicable. To utilize the high and/or low warning function, press the corresponding function key until the indicator states the function is Enabled. The Warning Time Dly is a delay associated with the high and low warning functions. The input must cross the Warning Set Point for this length of time before a warning is issued. The unit for this quantity is seconds. Enter the Trip Set Point high and low set points if applicable. To utilize the high and/or low trip function, press the corresponding function key until the indicator states the function is Enabled. There is also a delay timer associated with the high and low trip functions. The unit for this quantity is also in seconds. The input signal type can be changed by pressing [K1]. There are two choices, 4-20mA and 1-5V input signals. If the input signal is set to 1-5V, the input jumper on the analog input module should also be changed for the corresponding input. By default, all inputs are set to 4-20mA. The input module must be removed to change the jumper. 21

30 The illustration above references module Cat#:1769sc-IF8u, P/N: , Series A. Contact Case Engineering for questions regarding other modules. 22

31 The Pos. # determines the location the analog input is displayed on the structured screens: Air End Status, Oil and Water Status, and Motor Status. The position should be set correctly from the factory, however, if it should be changed press [K3] to display the IO Map. Each position on the screen contains a number. This number should be entered by pressing [F10] to close the IO Map screen, highlighting the Pos # entry and entering the new position number. Note: It is possible to enter the same position number for multiple inputs. This will cause the position on the structured status screen to flicker. If this occurs, the input with a duplicate assignment should be located. Enter a position 40 to not display an input or correct a flickering numeric display. Note: It is possible to change the row labels on the Oil and Water Status screen. Press [F9] to return to the Analog Input Module screen. Repeat the above steps for each analog input the AirLogix control system will be monitoring. Upon completion of the analog input configuration, press [F10] to display the navigation menu. Using the up/down arrow keys, select General Setup and press the enter key. Oil Pump and Heater Configuration From the General Setup screen, press [K3] to open the Oil Pump Configuration screen. Press [F1], [F2], and [F3] depending on the oil pump(s) applicable to the compressor. YES indicates the pump exists and NO indicates the pump does not exist. Refer to page 6 for the various oil pump operations. Enter a value for the Prelube Off Timer. The Prelube Pump Off Timer" refers to the length of time that the auxiliary/prelube pump runs after the main motor is started. Adjust this timer value here. 23

32 Enter the Prelube Recovery Pressure. The Prelube Recovery Pressure is the oil pressure set point that the prelube will resume operation. This set point should be set equal to or greater than the low oil pressure warning. This feature becomes active once the compressor is started and the Prelube Off Timer has expired. If the oil pressure falls equal to or less than the Prelube Recovery Pressure set point, the prelube will resume operation and the following alarm message is generated: Auxiliary Oil Pump Running, Possible Mechanical Oil Pump Failure. This condition will remain active until the compressor is stopped. It is designed to allow temporary operation of the compressor in the event of a mechanical oil pump failure. Zero may be entered to disable this function. Press [F4] to enable the oil heater output. Enter the Oil Heater On Temperature and Oil Heater Off Temperature set points. A minimum difference of 5 degrees F is required between the Off and On set points. The Oil Change Hour Meter may be used to create an oil change reminder or maintenance schedule. To enable the Warning, press [F6]. Once enabled, the ability to enter the warning set point will appear. Press [F5] to reset the hour meter. The hour meter accumulates anytime the compressor is running. Note: If the Oil Change Warning occurs and it is acknowledged, the warning will reoccur every week (168 hours) until the oil change hour meter is reset. Press [F10] to return to the General Setup screen. Motor Start and Stop Configuration From the General Setup screen, press [K4] to open the Motor Configuration screen. Press [F1] to configure the start/stop input signals By default, PanelView start/stop will be enabled. The ability to enable communication, discrete input or automatic start/stop is available. Examples of each of the other options are listed below. 24

33 Communication: remote start/stop from the customer s DCS or a remote operator interface. Discrete input: remote start/stop from motor switch-gear pushbuttons, control room pushbuttons, or pressure switches. Automatic: automatically starts/stops the compressor based on system pressure and time. If the system pressure falls below the auto start pressure set point for the duration of the auto start timer, the compressor will auto start. If the compressor runs unloaded for the duration of the auto stop timer, the compressor will stop. Press [F5] to configure a Start Sequence. The start sequence is designed to start the pre-lube/auxiliary oil pump prior to starting the compressor, and allow for oil pressure/temperature inputs to stabilize prior to starting the main motor. It will also stop the oil pump after the compressor has been stopped for a predetermined period of time. The Oil Pressure Timer is the amount of time allowed for oil pressure to reach the low start permissive set point. When this timer is done, if oil pressure is not above the low start permissive set point, the start sequence will abort. The Oil Temperature Timer is the amount of time allowed for oil temperature to reach the low start permissive set point. When this timer is done, if oil temperature is not above the low start permissive set point, the start sequence will abort. The Oil Pump Run After Stop Time indicates the amount of time the oil pump will run after the compressor has been stopped. This will also allow the oil pump to run after a start sequence has been initialized and aborted due to one or more start permissives not satisfied. Press [F10] to return to the Motor Configuration screen. Press [F2] to enable/disable the Momentary Start output and enter the momentary start time. When a start is initialized, the momentary start output is energized for the period of the momentary start time preset. Press [F3] to enable/disable the Momentary Stop output and enter the momentary stop time. When a stop is initialized, the momentary stop output is de-energized for the duration of the momentary stop time preset. This circuit should be wired fail-safe to a normally closed contact on the momentary stop relay. 25

34 Press [F4] to enable/disable the Wye-Delta start outputs and enter the shorting relay time duration. Note: The maximum motor current scale may have to be multiplied by 1.73 on an MP3-RetroFit with a "panel installed" wye-delta starter. This is because the CT is installed on the motor lead instead of the panel lead. The Main Motor Coastdown time preset will need to be modified after a motor coast down time is determined. Enter the number of starts allowed per time frame. Please refer to the motor manufacturer for this information. Enter the Run Hours, if desired. This may apply if the customer maintains a strict compressor maintenance schedule. Press [F10] to return to the General Setup screen. Cooling Water Valve/Condensate Purge Configuration From the General Setup screen, press [K5] to go to the Cooling Water Valve Configuration screen. Close Fuse ORF12 to allow operation of the Cooling Water Valve output. Press [F1] to enable/disable the Cooling Water Valve output. Press [F2] to determine whether to Energize Output To OPEN the water valve or Energize Output To Close the water valve. Enter the Post Shutdown Timer duration. This time determines the length of time the cooling water valve will remain open after the compressor is stopped. The water valve can be placed in Manual Mode by pressing [F3]. When in manual mode, the valve can be opened or closed by pressing [F4]. To protect the compressor, the cooling water valve cannot be closed when the compressor is running. By default, the cooling water valve will open when the compressor is started. An 26

35 indicator exists below the Auto/Manual mode indicate indicating the current state of the valve. Press [F10] to exit and return to the General Setup screen. Condensate Purge Configuration Close Fuse ORF10 to allow operation of the condensate purge output. Press [F1] to enable/disable the Condensate Purge [F1] output. Enter the Purge Interval. This is the amount of time between purges. Enter the Purge Duration. This is the length of time the output is energized. Pressing [F2], manually forces a purge cycle for the length of the purge duration timer. Press [F10], to exit and return to the General Setup screen AirWatch Setup From the General Setup screen, Press [K7] to display the AirWatch Configuration screen. AirWatch provides notification indicating the compressor has surged, is operating in a warning condition, or has shutdown to protect the compressor. The AirLogix controller is an client that uses a mail relay server to send . The CompactLogix controller can execute a message that sends an message to a SMTP mail relay server using the standard SMTP protocol. Some mail relay servers require a domain name be provided during the initial handshake of the SMTP session. For these mail relay servers, make sure you specify a domain name when you configure the network settings in the Ethernet module configuration. Press [F1] to Enabled/Disabled AirWatch. 27

36 Press [F2] to Enter the Company Name. This text will be used in the subject and body of the . Press [F3] to Enter the location. This text will be used in the subject and body of the . Press [F4] to enter the SMTP server. Press [F5] to enter the destination. Only one address may be entered. Rules with the mail client may be used to automatically forward the s to other addresses. Press [F6] to enter a text string for testing purposes. Press [F7] to test the functionality. Press [K1], [K2], or [K3] to select the events to send s. Startup-Load/Unload Configuration From the General Setup screen, Press [K8] to display the Startup-Load/Unload Configuration screen. Press [F1] to configure the load/unload input signals. By default, PanelView load/unload will be enabled. The ability to enable communication, discrete input or automatic load/unload is available. A description of each of the other options are listed below. Communication: remote load/unload from customer s DCS or a remote operator interface. Discrete input: remote load/unload from control room pushbuttons, or pressure switches. Automatic: automatically load/unload the compressor based on system pressure, discharge pressure and time. If the system pressure falls below the auto load pressure set point for the duration of the auto load timer, the 28

37 compressor will auto load. The compressor will auto unload if the machine pressure falls below the system pressure for the duration of the auto unload timer OR if the system pressure is greater than the unload pressure set point for the duration of the unload timer. Pressing [F10] will return to the Startup- Load/Unload Configuration screen. The General Start Override refers to a timer that starts timing when the main motor starts. This timer does not allow the variables other than vibration to issue a warning or trip until it is done. Adjust this timer value here. The Motor Current Start Override refers to a timer that starts timing when the main motor starts and does not allow the motor current to trigger a high warning or high trip until the timer is done. This time should be greater than the motor current inrush time. Adjust this timer value here. The Vibration Start Override refers to a timer that starts timing when the main motor starts. While the vibration start override timer is timing, or the coast down timer is timing, vibration warnings and trips are triggered using the warning and trip set points multiplied by the Vibration Multiplier (see below). After the vibration start override timer is complete, the original warning and trip set points are utilized. Adjust this timer value here. The Vibration Multiplier is used to create elevated vibration warning and trip set points during compressor spin up and coast down. Press [F2] to enable/disable the function. When the multiplier is disabled, vibration warnings and trips cannot trigger while the vibration start override timer or coast down timer is timing. For example, if the stage 1 vibration warning set point is.80 and the vibration multiplier is enabled and set to 2.0, then stage 1 vibration must exceed 1.60 during spin up or coast down to trigger a high stage 1 vibration warning. The Ready to Load timer refers to the length of time that must pass between starting the motor and allowing the compressor to be loaded. This time should be greater than the amount of time it takes the main motor to come up to speed. Adjust this timer value here. 29

38 The Set Point Ramp Up Rate refers to the amount the PID set point is incremented each time the time cycle is completed. When the compressor is loaded, this "steps" the PID set point up to the pressure set point entered on the main screen at a metered rate. The timer is shared with the ramp down function which is used when unloading the machine. Adjust these settings here. The Set Point Ramp Down Rate refers to amount the PID set point is decremented each time the time cycle is completed. When the compressor is unloaded, this "steps" the PID set point down to a pre-determined percentage of the pressure set point at a metered rate. The timer is shared with the ramp up function, which is used when loading the machine. Adjust these settings here. The Set Point Ramp Time sets the cycle time for the set point ramp up and set point ramp down rates. Press [F10] to exit and return to the General Setup screen. Manual Valve Control There are six different valve combinations possible with the AirLogix control system. They are: Analog Inlet/Analog Bypass Analog Inlet/Discrete Bypass Analog Inlet/DCAV Bypass DCAV Inlet/Analog Bypass DCAV Inlet/Discrete Bypass DCAV Inlet/DCAV Bypass The manual valve control screen may appear different for each combination of valves. The following sections demonstrate an example of each type of valve. The valve combination configured during the control system configuration step may require that the operator follow a portion of both of the following procedures for the particular valve set. If the compressor is not running, the manual valve control screens are not protected by security. If the compressor is running, login is required to operate the valves in manual mode. Also, each valve must be in Auto mode to start the compressor. Stroking the Analog Valves From the General Setup screen, press [K9] to display the Manual Valve control screen. Check the inlet & bypass valves for proper calibration. 30

39 The actual calibration of the valves or the current to pressure (I/P) transducers is not part of the scope of this document. Complete the procedure for the inlet valve before proceeding to the bypass valve Press [F6] to toggle the inlet valve between Auto/Manual Mode. The valve must be in manual mode to complete this procedure. Press [F8], to toggle the bypass valve between Auto/Manual Mode. The valve must be in manual mode to complete this procedure. Using the TAB left/right keys, move the cursor to the numeric data entry object, located directly above the [F2]: OPEN button ([F4]: CLOSE button for the bypass valve), and enter a value of "0". Verify that the actual inlet valve position is fully closed. Enter a value of "5.0". Verify that the actual valve position is approximately 5% open. The valve should show movement between the "0" and "5.0" setting. NOTE: The actual valve position is referencing the physical valve position, not the indicators on the PanelView screen. Enter a value of "25.0". Verify that the actual valve position is approximately 25% open. Enter a value of "50.0". Verify that the actual valve position is approximately 50% open. Enter a value of "75.0". Verify that the actual valve position is approximately 75% open. Enter a value of "100.0". Verify that the actual valve position is 100% open. Enter a value of "95.0". Verify that the actual valve position is 95% open. The valve should show movement between the "100.0" and "95.0" setting. Set the valve back to the "Auto" position with the [F6] button for the inlet valve or [F8] button for the bypass valve. 31

40 Repeat the above steps for the bypass valve. The bypass valve position will be inversely proportional to the inlet valve position (where the inlet valve is 25% open the bypass valve will be 25% closed). The trend display can be modified to enhance the data displayed in the trend. Pressing [K1] and [K2], modifies the trend Maximum and Minimum scale respectively. Pressing [K3] and [K4] allow the trend viewer to move back and forth in time to analyze data. Pressing [K5] will display the data logged currently. Approximately 3 hours of data is stored. This data is continually logged at one second intervals and can be viewed at anytime. Stroking the DCAV Valves From the General Setup screen, press [K9] to display the Manual Valve control screen. Close Fuses ORF06, ORF07, ORF08, and ORF09 for inlet and bypass discrete outputs. Press [F6] to toggle the inlet valve between Auto/Manual Mode. Or Press [F8], to toggle the bypass valve between Auto/Manual Mode. The valve must be in manual mode to complete this procedure. Press [K12] to display the DCAV valve configuration. Set the Inlet Speed to 100. Do not adjust the speed cycle time at this point. Press [F10] to return to the Manual Valve Control screen. Make sure that the valve that you are calibrating is fully retracted (not the valve position indicator on the screen). If it is not, press and hold the appropriate button on the manual valve control screen until both the valve and the position indicator are indicating 0%. While watching the appropriate valve position indicator, press and hold the open button just until the valve reaches the fully open position. The valve and indicator should both reach the same position at approximately the same time. If this is not the case adjust the Extend Position Constant value located on the DCAV setup screen. Increase the value if you want the PanelView indicator to reach position sooner and decrease the value to if you want the indicator to reach the value later. 32

41 Repeat the previous two steps to adjust for indicator error in the retract direction, making necessary adjustments to the Retract Position Constant and Extend Position Constant. These steps may need to be repeated several times to achieve the desired results. Repeat the procedure above for a DCAV bypass if necessary. The inlet and/or bypass indicated positions are set using the steps above. However, it is important to note, over time, accumulated error may allow the actual and indicated position to be erroneous. The indicated positions are not used in any control algorithm. They are for operator reference only. Accumulated error is reset each time the compressor is unloaded, or the inlet reaches 100% open, or the inlet reaches, 0%. Stroking Discrete Bypass Valve If the discrete bypass control was selected during the control system configuration, then Press [F4] to close the discrete bypass valve and press [F9] to open the discrete bypass. Verify the bypass valve is closing completely. Adjusting the flow control on the solenoid can increase or decrease the speed the valve opens or closes. Alternate Manual Valve Control Screen An additional Manual Valve control popup screen exists. It may be useful for viewing the vibrations while opening the inlet valve. From the Navigation Menu, select Manual Valve Control. Each valve control screens has obvious advantages. 33

42 Testing the Pre-lube/Auxiliary Circuit Pull the Emergency Stop out and close Fuse ORF03 to test the Prelube/Auxiliary oil pump. Depending on the compressor type, seal air may be a permissive to run the pump. Refer to drawings ES01 and ES03 for wiring details. The pump should now be running. If not, trouble-shoot the wiring. After the pump is running, verify the oil pressure. PanelView Configuration There are set up parameters exclusively for the PanelView that may be accessed. To access the PanelView configuration screen, from the Main screen, press [F10]. Using the Up/Down arrow keys, select Case Controls and press enter. Pressing [F5] will close the PanelView program and open the configuration screen. Pressing [F4] from the configuration screen will permit terminal setting modifications. The most common adjustments to these settings are: Contrast Date and Time Back lighting Screen Saver ON/OFF Reference the PanelView Plus 700 manual (not provided) or contact Case Engineering for specific details regarding the PanelView Plus 700 configuration settings. Many of the settings could result in making the PanelView unresponsive to the system. For this reason it is suggested that anyone unfamiliar with the operation of a PanelView Plus 700 exercise great care while navigating the PanelView Configuration screens. 34

43 Starting the Machine If you have followed the steps above thoroughly and each start permissive is satisfied, you should now be ready to start the machine. You may need to remove the lockout from the main motor before continuing. Verify all auto functions are disabled. Close all remaining fuses. Push the [F6] button to start. The motor should start and the inlet valve move to its start position while the bypass valve remains fully open. Once you have determined the machine is stable, press [F10] to begin stepping through each status screen and verify that all instrumentation is reading properly. Once you have determined that all instrumentation is operating properly, you are ready to move on to the next chapter, THROTTLE SURGE PROCEDURE, to determine the surge data. 35

44 36

45 Chapter 3 Throttle Surge Procedure Inlet Starting Position Manual Valve Control Determining the Surge Line Throttle Surging Dynamic Throttle Limit(DTL) Manual Valve Control Trend Buttons Alternate Manual Valve Control Method 37

46 38

47 This chapter is intended for use by set-up personnel and provides a procedure for surging the machine under normal conditions. Note: This chapter assumes the machine is running. Inlet Starting Position From the General Setup screen, press [K9] to navigate to the Manual Valve Control screen. You must log in to take manual control of the valves when the compressor is running. If the inlet valve type is analog, adjust the "Start Pos." value so that stage 1 discharge/stage 2 inlet air pressure is approximately 3 psi. If this point is monitored by the AirLogix system, it can be viewed by pressing [F10] and selecting Air End Status from the Navigation menu. If this point is not monitored by the AirLogix system, use a gauge to determine this pressure. NOTE: For a DCAV inlet valve, this entry point will not be displayed. Finite position control cannot be achieved with a DCAV type valve actuator. Manual Valve Control CAUTION: Manually controlling a centrifugal compressor safely, requires a thorough understanding of compressor operation and should only be performed by trained personnel. For safety reasons, the compressor must be in the unloaded state as indicated on the Main screen, before the valves can be placed in manual. The valve control indicator must indicate "Manual Mode" to have manual control of the valve. The indicators and controls for each valve are grouped together with the inlet valve on the left and bypass valve on the right. These valve controls are as follows: F6: INLET MODE - Press this button to toggle the inlet valve between Auto/Manual modes. Note: Actual valve control state is reflected in the indicator immediately above the button indicator. 39

48 F2: OPEN.1% - Each time [F2] is pressed, the valve will open.1%. Holding the button does not provide continuous action. The button must be released and repressed in order to repeat the action. F7: CLOSE.1% - Each time [F7] is pressed, the valve will close.1%. Holding the button does not provide continuous action. The button must be released and repressed in order to repeat the action. NOTE: For a DCAV inlet valve, the valve will continue to move as long as the button is pressed at a rate set by the valve speed entered on the DCAV Setup screen. The cursor point numeric data entry object located above the Open button is used to move the valve to a percent open position for an analog inlet valve. Data entered has one decimal place for tenths of percent. If the inlet valve control type is DCAV, this will be a valve position display only. F8: BYPASS MODE - Press this button to toggle the bypass valve between Auto/Manual modes. Note: Actual valve control state is reflected in the indicator immediately above the button indicator. F4: CLOSE.1% - Each time F4 is pressed, the valve will close.1%. Holding the button does not provide continuous action. The button must be released and repressed in order to repeat the action. NOTE: For a DCAV bypass valve, the valve will continue to move as long as the button is pressed at a rate set by the valve speed set on the DCAV Setup screen. F9: OPEN.1% - Each time F9 is pressed, the valve will open.1%. Holding the button does not provide continuous action. The button must be released and repressed in order to repeat the action. NOTE: For a DCAV bypass valve, the valve will continue to move as long as the button is pressed at a rate set by the valve speed set on the DCAV Setup screen. 40

49 The cursor point numeric data entry object located above the F4 Close Button is used to move the valve to a percent closed position. If the bypass valve control type is DCAV or Discrete, this will be a valve position display only. F5: E-OPEN: Anytime a surge occurs the bypass should be immediately opened to prevent machine damage. Press this button to open the bypass valve at the fastest possible rate. IMPORTANT NOTE: Before attempting to throttle surge the compressor, it is important to understand the proper use of the data collection tools provided by AirLogix. Data is continually collected by two methods. The first is the trend on the Manual Valve Control screen. The second is by the processor, which collects the data at a much faster rate than the trend. The data collected by the processor is discharge pressure, motor current, inlet temperature, peak motor current change, and peak discharge pressure change. Pressing the F5: E-OPEN button, stops the data collection. This allows you to maintain the peak changes caused by the surge without recording subsequent peaks that may occur during unloading. The surge data for the two most recent surges, or E- Open presses, is kept on file. This data can be viewed by returning to the General Setup screen, pressing [K9] to go to Surge Parameters, then [F9] to View the Surge Data. Determining the Surge Line The objective is to establish the surge line for the compressor. This requires a high and low surge point. First, determine the pressure set point the compressor will be operating. Add 10% to the expected operating pressure set point to determine the high pressure surge point. Subtract 10% to determine the low pressure surge point. For example, if the compressor is intended to run at 100 psi, the high pressure surge point is 110 psi and the low pressure surge point is 90 psi. Warning: Never exceed the design pressure of the piping. Close the block valve so that the compressor can build pressure without affecting the system. 41

50 Slowly open the inlet valve until you reach the full load motor current or 100% open. The bypass valve should be completely open during this adjustment. Warning: Operating the motor above motor nameplate FLA may decrease the life expectancy of the motor. After reaching FLA or 100% open, begin closing the bypass valve until the desired discharge pressure is made or the machine surges. If the machine surges during this process, press [F5] immediately to open the bypass and alleviate the surge condition. This suggests that mechanical problems may exist. Contact your service technician. Let the machine run at this point until the air temperatures and pressures stabilize. Throttle Surging The objective is to cause a surge at the desired discharge pressure by adjusting both valves as needed in small increments until a throttle surge is accomplished. Determine the high pressure throttle surge point first. If DCAV valve control was selected, set the DCAV speed to 5 to move the valve(s) in the smallest increments. Example: Desired pressure is 110 psi. Close the bypass to reach 112 psi Then close the inlet to reach 110 psi Repeat these steps until the machine surges. Warning: When a surge occurs, immediately press [F5] to open the bypass. Repeat the throttle surge process again for the low pressure surge. As long as the high pressure surge was done first, the inlet should be in safe position to start the low pressure surge. Navigate to the Surge Parameters screen by pressing [K10] on the General Setup screen. Press [F9] to view the surge data collected from the two prior throttle surges. Record this data in the table below. Throttle Surge Data Newest Oldest Discharge Pressure Motor Current Inlet Temp Current Change Pressure Change 42

51 Press [F10] to close the Surge Data screen. Using the TAB Left/Right keys, enter the data recorded for the High Pressure Surge in the Surge Pressure and Surge Amps entry fields. Enter the data recorded for the Low Pressure Surge in the Surge Pressure and Surge Amps entry fields. If you wish to extend the surge line to a lower or higher pressure, the values can be calculated by pressure [F8] Calculator. Enter the throttle surge results in the upper section, and then enter the high and low pressure points needed to provide adequate throttle range for the compressor. Note the new pressure and amp set points and enter them on the surge parameters screen. Enter the surge line offset. This offset determines the minimum throttle point for the compressor when loaded. This offset is typically set to 7% when Inlet Air Temperature is utilized. If inlet air temperature is not utilized, use 10% for the Surge Line Offset. Press [F6] to reset the DTL to the new set points. Enter the lowest inlet temperature captured in the surge data recorded above. This establishes a base line for the Dynamic Throttle Point (DTL). As the inlet temperature changes, the surge line for the compressor will change. In cooler temperatures, additional turn down and reduced energy consumption is achieved. During warmer temperatures, the compressor is better protected while still providing the maximum turndown. If inlet air temperature is not monitored, enter 999 in this field. Enter the Motor Amp Index Per Surge. This value should be set approximately 1% of FLA. Each time a surge is detected, the surge line is shifted by the amount entered. The indexed surge parameters are displayed in the Amps Indexed column. If indexing is not desired, enter zero in this field. Accumulated indexes may be removed by pressing [F6] Reset DTL. Enter the Maximum Motor Amps (FLA). The motor nameplate FLA rating is recommended. Any set point higher than nameplate FLA may result in reduced motor life due to increased heat buildup. 43

52 Enter the Surge Detect Time. This determines the time span that both radical motor current and radical pressure must occur in order to detect surge. This is typically set to 2 seconds. A larger time entry will increase surge detection sensitivity, while a smaller value will decrease sensitivity. Enter the Radical Motor Current and Radical Discharge Pressure. The values entered should be 70% of the lowest pressure and current data recorded in the table above. Enter the number of surges allowed per given time frame. When this number is exceeded, the compressor unloads and remains unloaded until an operator acknowledges the alarm at the PanelView and presses the load button. The default values are 3 surges in 1 hour. Dynamic Throttle Limit (DTL) DTL is used to protect the compressor from surge and maintain the maximum inlet turndown to reduce energy consumption during low air demand periods. DTL is determined by the discharge pressure and inlet air density. The surge line is continously calculated based on these variables. The previous procedures determine the parameters for this algorithm. The surge point, or minimum throttle point, vary depending on machine discharge pressure and inlet conditions. A fixed "throttle limit" (illustrated by the vertical MIN AMPS line) leaves much of the throttle range available at lower pressures and/or lower temperatures unused. The DTL (Dynamic Throttle Limit) feature takes advantage of that additional throttle range by continuously calculating the surge line from two separate surge points performed during the throttle surge procedure. 44

53 Manual Valve Control Trend Buttons The data displayed on the trend can be modified to view the data in a way preferred by the technician. The data line colors correspond to the text color in the legend located above the trend. For example, the system pressure is the yellow line. Press [K1] to modify the Y-axis maximum scale. Press [K2] to modify the Y-axis minimum scale. Using [K1] and [K2] allows the technician to zoom in or out on the data available for display on the trend. Press [K3] to scroll the trend back and view data prior to the data currently shown on the screen. Press [K4] to scroll the trend forward in time to show data that is more current. Press [K5] to resume viewing live data collection. Alternate Manual Valve Control Method Another method of manually controlling the valves exists. The data is collected regardless which screen is displayed and can be viewed at any time. This method is a popup screen and may be most useful on the Main screen to allow the technician to view vibrations while the valves are in manual mode. From the Main screen, press [F10] to view the screen selection. Using the Up/Down arrow keys, select Manual Valve Control and press Enter. CAUTION: Manually controlling a centrifugal compressor safely, requires a thorough understanding of compressor operation and should only be performed 45

54 by trained personnel. For safety reasons, the compressor must be in the unloaded state as indicated on the Main screen, before the valves can be placed in manual. The valve control indicator must indicate "MANUAL MODE" to have manual control of the valve. The indicators and controls for each valve are grouped together with the inlet valve on the left and bypass valve on the right. These valve controls are as follows: F1: INLET MODE - Press this button to toggle the inlet valve between Auto/Manual modes. Note: Actual valve control state is reflected in the indicator immediately above the button indicator. F2: OPEN.1% - Each time [F2] is pressed, the valve will open.1%. Holding the button does not provide continuous or repetitive action. The button must be released and repressed in order to repeat the action. F7: CLOSE.1% - Each time [F7] is pressed, the valve will close.1%. Holding the button does not provide continuous or repetitive action. The button must be released and repressed in order to repeat the action. NOTE: For a DCAV inlet valve, the valve will continue to move as long as the button is pressed at a rate set by the valve speed entered on the DCAV Setup screen. The cursor point numeric data entry object located above the Open button is used to move the valve to a percent open position for an analog inlet valve. Data entered has one decimal place for tenths of percent. If the inlet valve control type is DCAV, this will be a valve position display only. F3: BYPASS MODE - Press this button to toggle the bypass valve between Auto/Manual modes. Note: Actual valve control state is reflected in the indicator immediately above the button indicator. F4: CLOSE.1% - Each time F4 is pressed, the valve will close.1%. Holding the button does not provide continuous or repetitive action. The button must be released and repressed in order to repeat the action. NOTE: For a DCAV bypass valve, the valve will continue to move as long as the button is pressed at a rate set by the valve speed set on the DCAV Setup screen. F9: OPEN.1% - Each time F9 is pressed, the valve will open.1%. Holding the button does not provide continuous or repetitive action. The button must be released and repressed in order to repeat the action. 46

55 NOTE: For a DCAV bypass valve, the valve will continue to move as long as the button is pressed at a rate set by the valve speed set on the DCAV Setup screen. The cursor point numeric data entry object located above the F4 Close Button is used to move the valve to a percent closed position. If the bypass valve control type is DCAV or Discrete, this will be a valve position display only. F8: E-OPEN - Anytime a surge occurs the bypass should be immediately opened to prevent machine damage. Press this button to open the bypass valve at the fastest possible rate. Data capture is halted as defined in previously in this chapter. 47

56 48

57 Chapter 4 Valve Tuning What is a PID Loop? PID Screen Parameters PID Tuning Strategies DCAV Tuning Parameters 49

58 50

59 What is a PID Loop? The term PID is short for Proportional, Integral, and Derivative. The AirLogix uses a total of four PID loops to optimize the performance of a Centrifugal Air compressor. A PID loop is a complex method of controlling a process (in this case air pressure) using feedback. Simply put, the PID is constantly looking at a process variable (air pressure, motor current, etc.) and comparing the process variable (PV) to the process set point (SP). If the PID sees a mathematical difference between the two (%error), it will adjust the control variable (CV) or the Inlet or Bypass valve, to try and meet the process set point. Each element of the PID controller refers to a particular action taken on the error. Proportional: With the Allen-Bradley CompactLogix and many other controllers, this term is referred to as Gain. This element is the amplifier of the control loop and increases rise time. It takes the %error multiplied by the gain constant and directly applies it to the CV. Gain effects the amount of valve movement each time the PID updates. A gain too large will cause overshoot and PV oscillation, and a gain too small will cause a slow sluggish response possibly not allowing the controller to ever stabilize. Integral: This element is referred to as reset. It takes the responsibility of reducing overshoot and attempts to allow the gain to effect the PV before any other action is taken. Reset is a time constant measured in seconds. Simply put, when %error is calculated and the CV is adjusted accordingly, the reset determines the time span before another CV change is made (time elapsed per repeat). With the AirLogix the lower the integral value, the more frequently the CV will be updated. A value too low will result in overshoot because the controller did not allow for the CV to affect the PV. A value too high will make the process sluggish because too much time was allowed to pass before making another change. Derivative: This element is referred to as rate and attempts to reduce any lag that occurs in the process variable. Like integral, it is a time constant but looks to predict what is going to happen next by looking at the rate at which the PV is changing in time due to a change in the CV. It sounds very useful but can cause much grief and is commonly referred to as the VILLAIN of PID loop control. You can think of it as a weather forecaster with respect that they aren t always correct. Rate works fairly well when the fluctuations in demand amount are always the same (very rare), and when process variable lag times are relatively long. Good candidates might be temperature and level control. With compressed air, demand amounts are usually changing with short lag times, which reduce the need for any derivative action. In most situations, if not all, a properly set gain and reset will produce adequate results. 51

60 There are four PID control loops in the AirLogix. Following is a list of each PID and what dynamic elements are used for each. 1. Inlet DTL PID: PV = motor current CV = Inlet Valve %Error = (SP- PV)/SP %Error = MMA set point minus the actual motor current, divided by the MMA set point. 2. Bypass Pressure PID: PV = system air pressure CV = Bypass valve %Error = (SP - PV)/SP %Error = System pressure set point minus the actual system pressure divided by the System pressure set point. 3. Inlet Pressure PID: PV = system air pressure CV = Inlet valve %Error = (SP PV)/SP %Error = System pressure set point minus the actual system pressure divided by the System pressure set point. 4. Inlet Max Amp PID: PV = motor current CV = Inlet valve %Error = (SP PV)/SP %Error = Max. motor amp set point minus actual motor current divided by the Max. motor set point. PID Screen PID parameters may be adjusted from the PID screen. From the Main screen, press [F10] to display the navigation screen. Use the Up/Down Arrow keys to select PID Parameters and press Enter. You must be logged in to modify these parameters. Contact Case Engineering if the login name and password are not known. NOTE: If DCAV Inlet valve control is selected, the inlet PID parameters will not be visible. If DCAV or Discrete bypass valve control is selected, the PID parameters for the bypass will not be visible. For tuning DCAV valves, see Tuning DCAV Valves later in this chapter. 52

61 The "Machine PSI PID Offset" is defined as follows. When the system pressure exceeds the set point, the compressor will attempt to reduce pressure. When the compressor throttles back and the bypass opens to the point that the machine discharge pressure is less than the pressure set point by the entered value, the bypass valve PID is placed in manual mode. This difference indicates that the check valve is shut and the machine is no longer contributing to the system. By stopping the throttling action at this point, the machine is kept at a closer standby pressure so that when the system requires more pressure, the machine may respond much faster to that demand. Increasing this value, results in letting the machine pressure fall further below the pressure set point, trading response time for extra efficiency. Adjust this pressure here. The "Motor Current PID Offset" is the motor current offset (in amps), that is added to the "DTL set point," which defines the point where the "DTL PID" is turned on. The offset is also subtracted from the "maximum motor amps set point" to define the point where the "maximum motor amp PID" is turned on. This provides a smooth transition to the DTL or Max Amp PID and is designed to eliminate overshoot. This value is typically set 5% of FLA. Tuning Strategies: Under most circumstances, there will be preset values entered in the Gain, Reset, and Rate fields for all the PIDs. These values will be a relatively good starting point in most cases. Normally, you can make set point changes in order to cause upsets in the process. These set point changes should allow you to fine tune the PIDs. It is to your advantage to record all the data for the PIDs before you make any changes and to consistently record your changes as you proceed. If you keep a good record, you can always go back and start over. Slight changes may need to be made in order to optimize the controller. When tuning the PID, carefully consider the plant process. You may need to talk to an operator to find what demand fluctuations to expect. It is very important that you understand and anticipate the process reaction when making a change to the PID control loop. For example, if the gain is increased by 50%, the CV (valve output) will make larger increments proportional to the PV (pressure or motor current) toward the set point. This chapter is intended to give the operator a general idea of what to expect. Another thing to keep in mind is that only one PID can be tuned at a time. At this point, the assumption is being made that the machine is running, unloaded, and that all setup procedures have been completed 53

62 PID Tuning Methods Dynamic Throttle Limit PID When tuning this PID, the goal is to force the inlet valve to modulate to the dynamic throttle limit set point. In order to achieve this, the compressor set points will have to be manipulated. The actions taken may vary depending on the compressor size and application. 1. Place a 1.00 in the Gain field,.02 in the Reset field, and 0 in the Rate field for the Inlet DTL PID parameters. 2. Navigate to Main screen and load the compressor. Pay attention to the Inlet valve attempting to approach Dynamic Throttle Limit set point. Before making a change to the PID parameters, decide whether the AMOUNT (Gain) or the TIME (Reset) needs adjustment. Typically, Gain adjustments alone will satisfy the intended response. 3. Change only one parameter at a time. Once you have changed the parameter needed, do NOT change it again until enough time is allowed to see the effects. Keep in mind that small changes (1.00 to 1.05, for example) will not be visible. Any changes made, need to be at least a multiple of.5 (1.00 to 1.50). 4. Entering a set point less then the current system pressure reading and loading/unloading the compressor can test the change. Entering a low pressure set point prevents the bypass valve from closing and changing the DTL set point due to a rise in discharge pressure. 5. When satisfied with the Inlet DTL PID performance, the same values can be placed in the Max Motor Amp PID parameters. Bypass Pressure PID When tuning this PID, the goal is to force the bypass valve to modulate to the pressure set point, preferably in the 50-70% range of the valve. In order to achieve this, the compressor pressure set point will need to be manipulated. The actions taken may vary depending on the compressor size and application. 1. From the Main screen, enter a pressure set point equal to the current system pressure reading. 2. Place 1.00 in the Gain field,.02 in the Reset field, and 0 in the Rate field. 3. Load the compressor. The inlet valve will open until DTL set point is reached. The bypass valve should move very little due to the pressure set point being equal to the system pressure. 4. Increase the pressure set point by small increments to force the bypass to close to approximately 50% (.5 PSI increments should be sufficient). Be certain to wait until the valve stabilizes before incrementing the set point again. 54

63 5. When the bypass valve reaches the desired position, make a pressure set point change of approximately 5% (100 PSI to 105 PSI) or (100 PSI to 95 PSI). Observe the bypass close or open trying to meet the pressure set point. Before making a change to the PID parameters, decide whether the AMOUNT (Gain) or the TIME (Reset) needs adjustment. Typically, Gain adjustments alone will satisfy the intended response. 6. Change only one parameter at a time. Once you have changed the parameter needed, do NOT change it again until enough time is allowed to see the effects. Keep in mind that small changes (1.00 to 1.05) will not be visible. Any changes made need to be at least a multiple of.5 (1.00 to 1.50). 7. When satisfied with the Bypass Pressure PID performance, unload the compressor. 8. Change the pressure set point back to the desired system pressure. Inlet Pressure PID When tuning this PID, the goal is to force the inlet valve to modulate to the pressure set point, preferably in the 50-70% range of the valve. In order to achieve this, the compressor pressure set point will need to be manipulated. The actions taken may vary depending on the compressor size and application. 1. The DTL, Max Motor Amp, and Bypass Pressure PIDs should be tuned. 2. Place 1.00 in the Gain field,.02 in the Reset field, and 0 in the Rate field for inlet Pressure PID. 3. Go to the Main screen and press the load button. The inlet valve will open until the DTL set point is reached. The bypass valve will start closing to meet the system pressure set point. The goal is to close the bypass 100%, and start opening the inlet to achieve the pressure set point. The pressure set point may have to be increased in order to achieve this action. Caution will need to be taken. Do not exceed the system piping design pressure or the compressor natural surge pressure. Changing the pressure set point of an adjacent compressor may help accomplish this. 4. When the Inlet valve reaches the desired position, make a pressure set point change of approximately 5% (100 PSI to 105 PSI) or (100 PSI to 95 PSI). Observe the Inlet valve open or close, trying to meet the pressure set point. Before making a change to the PID parameters, decide whether the AMOUNT (Gain) or the TIME (Reset) needs adjustment. 5. Change only one parameter at a time. Once you have changed the parameter needed, do NOT change it again until enough time is allowed to see the effects. Keep in mind that small changes (1.00 to 1.05) will not be visible. Any changes made need to be at least a multiple of.5 (1.00 to 1.50). 55

64 6. When satisfied with the Inlet Pressure PID performance, unload the compressor. Bypass Pressure PID Gain Reset Rate Inlet DTL PID Gain Reset Rate Inlet Pressure PID Gain Reset Rate Inlet Max Amp PID Gain Reset Rate 56

65 DCAV Valve Tuning If DCAV inlet or bypass control is used, the tuning methods will vary. The following explains the tuning constants for a DCAV valve. From the Manual Valve Control screen, press [K12] to enter the DCAV setup screen. From the pop up Manual Valve control screen, press [F6] to enter the DCAV setup screen. When the valve is in manual mode, Manual Control Speed determines the duty cycle of the discrete output signal. The entry indicates the percent of the Speed Cycle Time the output is ON to move the valve in the intended direction. When throttle surging the compressor, it is necessary to lower this entry to 5 to move the valve the least amount each time the button is pressed. Unload Speed Control determines the duty cycle of the inlet valve s discrete output signal when the valve is unloading. The entry indicates the percent of the Speed Cycle Time the output is ON to move the valve in the unload direction. Speed Cycle Time works much like the reset in a PID Loop. This is typically set to 1 second, but may be modified to allow more or less time before making another valve adjustment. Extend Position Constant-for position indication only. Retract Position Constant- for position indication only. Pressure Dead-band establishes set points above and below the compressor operating pressure set point. If the system pressure is within the pressure dead-band, the valve will not make an adjustment open/close. This is to prevent the continuous pulsing of the DCAV motor. For example, if the pressure dead-band is 2.0 and pressure set point is 100, then the valve will not move as long as the system pressure is between 102 psi and 98 psi when controlling to pressure. This should be set to 1% of the pressure set point. Pressure Max Speed This set point determines the pressure error that the output will operate at 100% duty cycle or be on for the full duration of the Speed Cycle Time. The pressure error is the pressure set point minus the actual system pressure. Any error less than this set point results in a duty cycle less than 100%. This may have to be set relatively high (50-100) to get the intended response. 57

66 Motor Current Dead-band - establishes set points above the compressor DTL set point and below the Maximum Motor Amp set point. If the motor current is within the motor current dead-band, the valve will not make an adjustment open/close. This is to prevent the continuous pulsing of the DCAV motor. For example, if the motor current dead-band is 5.0 and the DTL set point is 100, then the valve will not move as long as the motor current is between 100 amps and 105 amps when controlling to DTL. This should be set to 5% of FLA. Motor Current Max Speed This set point determines the motor current error that the output will operate at 100% duty cycle or be on for the full duration of the Speed Cycle Time. The motor current error is the DTL set point minus the actual motor current or the Max Amp set point minus the actual motor current. Any error less than this set point results in a duty cycle less than 100%. This may have to be set relatively high (2-5 times FLA) to get the intended response. The above entry points apply to both the inlet and bypass except Motor Current Dead-band and Motor Current Max Speed. These only apply to the inlet valve. DCAV Valve Tuning Using Position Feedback If DCAV inlet or bypass control is used, the tuning methods will vary. The following explains the tuning constants for a DCAV valve using position feedback. From the Manual Valve Control screen, press [K12] to enter the DCAV setup screen. From the pop up Manual Valve control screen, press [F6] to enter the DCAV setup screen. When the valve is in manual mode, Manual Control Speed determines the duty cycle of the discrete output signal. The entry indicates the percent of the Speed Cycle Time the output is ON to move the valve in the intended direction. When throttle surging the compressor, it is necessary to lower this entry to 5 to move the valve the least amount each time the button is pressed. Unload Speed Control determines the duty cycle of the inlet valve s discrete output signal when the valve is unloading. The entry indicates the percent of the Speed Cycle Time the output is ON to move the valve to the closed position. If the compressor sounds as if it is surging when unloading, enter a lower value in 25% decrements until the compressor unloads as desired. 58

67 Speed Cycle Time works much like the reset in a PID Loop. This is typically set to 1 second, but may be modified to allow more or less time before making another valve adjustment. Pressure Dead-band establishes set points above and below the compressor operating pressure set point. If the system pressure is within the pressure dead-band, the valve will not make an adjustment open/close. This is to prevent the continuous pulsing of the DCAV motor. For example, if the pressure dead-band is 2.0 and pressure set point is 100, then the valve will not move as long as the system pressure is between 102 psi and 98 psi when controlling to pressure. This should be set to 1% of the pressure set point. Pressure Max Speed This set point determines the pressure error that the output will operate at 100% duty cycle or be on for the full duration of the Speed Cycle Time. The pressure error is the pressure set point minus the actual system pressure. Any error less than this set point results in a duty cycle less than 100%. This may have to be set relatively high (50-100) to get the intended response. Motor Current Dead-band - establishes set points above the compressor DTL set point and below the Maximum Motor Amp set point. If the motor current is within the motor current dead-band, the valve will not make an adjustment open/close. This is to prevent the continuous pulsing of the DCAV motor. For example, if the motor current dead-band is 5.0 and the DTL set point is 100, then the valve will not move as long as the motor current is between 100 amps and 105 amps when controlling to DTL. This should be set to 5% of FLA. Motor Current Max Speed This set point determines the motor current error that the output will operate at 100% duty cycle or be on for the full duration of the Speed Cycle Time. The motor current error is the DTL set point minus the actual motor current or the Max Amp set point minus the actual motor current. Any error less than this set point results in a duty cycle less than 100%. This may have to be set relatively high (2-5 times FLA) to get the intended response. Press [F1] to enable Position Feedback. This function allows setup of an input to accurately display the position of the DCAV valve. Once enabled, the setup parameters will appear on the screen. Navigate to the Manual Valve control screen and command the valve closed until it is fully closed. The valve is fully closed when the actuator shaft stops moving while holding down the closed button. Return to the DCAV Setup screen. The Valve Position number is the raw input value from the position feedback instrument. The value can read between , where 0 indicates fully closed and indicates fully open. At this time the valve should be fully closed. If the Valve Position 59

68 indicates that the valve is fully open by displaying a number close to 16383, press [F2] to invert the signal. With the valve in the fully closed position, press [F3] to set the Zero Travel Position. Navigate to the Manual Valve control screen and command the valve open until it is fully open. The valve is fully open when the actuator shaft stops moving while holding down the open button. Return to the DCAV Setup screen. The Valve Position should indicate the valve is fully open. Press [F4] to set the Span Travel Position. 60

69 Chapter 5 Operation Power On Starting the Compressor Stopping the Compressor Loading the Compressor Load and Throttle Sequence Unloading the Compressor Modifying the Pressure Set Point Status screens Numeric Status Indicators Air End Status Screen Oil and Water Status Screen Motor Status Screen Discrete Status Screen Warning Banner/Event History Screen Trend Screens User Defined Status Screens Misc. Data Status Screen Peak Vibration Data Screens Automatic Functions This chapter is intended for use by the operator to provide a basic understanding of how to operate the machine under normal conditions. 61

70 62

71 Power On Turn on the main power source to the panel.. This will energize the processor and the PanelView Plus 700 operator interface. The PanelView will initialize and display the Case Controls startup screen. Press [F2] to move to the main screen. The Main screen provides an overview of the compressor. This screen is where the compressor is manually started, loaded, unloaded, and stopped. The pressure set point is also modified from this screen. 63

72 If the compressor is not ready to start, the Start Permissive Display on the main screen will indicate the reason. If more than one permissive is preventing a start, the messages will scroll every three seconds. Common Start Permissives Coast Down Timer E-Stop pressed Oil Temperature Oil Pressure Inlet and/or bypass valves in manual mode Unacknowledged Trips Low Seal Air Pressure Low Water Flow The [F6] button will indicate Not Ready To Start if a start permissive is preventing a start. If the compressor is ready to start, the Start Permissive Display will indicate Ready to Start and the [F6] button will indicate START. Starting the Compressor Press [F6] to start the compressor. The bar graph indicators and gauges on the main operator screen will be displaying real-time, system variable data. If a Trip occurs after the compressor has been started, it will stop the compressor and display the reason for the Trip. If a warning occurs, the compressor will continue to run, but will display the warning message. Upon starting the compressor, the inlet should immediately open to the inlet start position. This is also referred to as the unload position. 64

73 Stopping the Compressor To stop the compressor, press the [F9] button located on main screen. This will display a stop confirmation in the center of the screen. Press [F4] to stop the compressor. Press [F5] to continue running. After the compressor has been stopped for any reason, the coast down timer will initiate therefore inhibiting restarting for the preset number of seconds. When the coast down timer is done the inlet goes to 0%. The coast down timer is adjustable and should be set to prevent a start while the motor is rotating. Loading the Compressor After starting the motor, there is a Ready to Load delay time. This timer allows the compressor to stabilize before loading. While this timer is active, Not Ready to Load is displayed in the [F7] LOAD button. When the timer has completed, LOAD will display on the button. To initiate the load sequence, press the [F7] button. As the compressor loads the [F7] button indicator will read, "Loading". Once the compressor is Loaded, the [F7] button will indicate Loaded and the [F8] button will change from Unloaded to UNLOAD. NOTE: There are several interpretations of LOADED. For the AirLogix system, when the compressor is loading, the AirLogix processor is ramping the PID set point to the pressure set point indicated on the Main screen. This ramp time will vary depending on the relationship between the system pressure and the pressure set point. The PID pressure set point is first set equal to the current system pressure reading. Then it is ramped to the operating pressure set point at a rate determined by the set point ramp up rate entered during the commissioning process. When the PID pressure set point is equal to the pressure set point on the Main screen, the compressor is LOADED. 65

74 Load and Throttle Sequence The following explanations assume worst-case situations in order to explain everything that can happen during the automatic throttling of the valves. The valve throttling process occurs in steps. Steps 1-4 describe how the compressor loads into the system to achieve maximum output. Steps 5-8 describe how the compressor would reduce flow into the system due to a rise in system pressure. Ultimately, system air demand determines which step the compressor will operate. It is likely the compressor could stop at any step. Step 1: When the load button is pressed, the first step is to open the inlet valve until motor current reaches the Dynamic Throttle Limit (DTL) for the pressure set point. This step is designed to prevent the compressor from surging, assuming the surge parameters have been set properly. An indicator below the inlet valve position indicates which PID is currently active. During this step, the indicator should display Controlling to DTL. Step 2: Once the inlet reaches the DTL set point, the bypass will begin to close if system pressure is below the set point. An indicator below the bypass valve position indicates if the bypass PID is currently active. During this step, the indicator should display Controlling to Pressure. During this time, the bypass will modulate to system pressure and the inlet will continue throttling to DTL. Step 3: If system pressure remains below the pressure set point and the bypass valve closes to 100%, the inlet will switch to the pressure PID. Switching to the pressure PID will allow the inlet to open to create additional machine flow to increase pressure. An indicator below the inlet valve position indicates which PID is currently active. During this step, the indicator should display Controlling to 66

75 Pressure. At this point, the inlet will modulate to system pressure and the bypass will remain 100% closed. Step 4: If system pressure continues to remain below the pressure set point, the inlet will reach 100% open or the Maximum Motor Amp set point (FLA). If opening the inlet reaches the switching point for Maximum Motor Amp PID, the indicator will display Controlling to FLA. When the inlet valve is throttling to FLA or at 100% open, the compressor is fully loaded. Step 5: If the compressor is fully loaded, controlling to FLA and the system pressure begins to rise above the pressure set point, inlet control will switch back to pressure. Therefore, the indicator will be displaying Controlling to Pressure. As long as system pressure remains above the pressure set point and motor current above the DTL set point, the inlet will continue to throttle back/closed. Step 6: If the inlet is controlling to pressure and throttles back to the point motor current approaches the DTL set point, control will switch to the DTL PID. Therefore, the inlet valve indicator will be displaying Controlling to DTL. At this time, the bypass will begin throttling to the system pressure. Unloading the Compressor To initiate the unload sequence, press the [F8] UNLOAD button. When the unload sequence is initiated, the [F8] UNLOAD button indicator will read "Unloading" and the bypass valve will begin to open in a controlled manner. After the bypass valve reaches 0% closed, the inlet valve will move to the start position. When the bypass reaches 0% closed and the inlet reaches the inlet start position, the compressor is completely unloaded. The [F8] UNLOAD button indicator will change from "Unloading" to "Unloaded." The Main screen is the only screen where the compressor may be started, loaded, unloaded, and stopped. 67

76 The Retrofit options may use the original start/stop and load switches for the machine. However, for the original pushbuttons and switches to function, the proper Start/Stop and Load/Unload signal configuration must exist. Modifying the Pressure Set Point The pressure set point is displayed in the upper right-hand corner of the Main screen. To modify the pressure set point, simply enter the pressure set point using the numeric keypad. When the first number is pressed, the numeric pop-up keypad will be displayed. Enter the pressure set point and pressure the Enter key. Any mistakes may be corrected using the ESC or Back Space key. If the system is operating in AirMaster, the set point cannot be modified. AirMaster is the load management software to coordinate multiple compressors. All screens, including setup screens, in the PanelView may be viewed by the operator. However, to change any set point other than the pressure set point, an authorized user must login. Status Screens The status and informational screens for the compressor are divided into groups. These groups are: Air End Status Oil and Water Status Motor Status Discrete Status Event History Trends User Defined Status screens Misc Status Data Each of these screens can be accessed by pressing [F10] on the Main screen. Pressing [F10] brings up the Navigation menu. Use the Up/Down arrow keys to navigate the list and press Enter. A description of each of these screens is found below. The screens for each compressor may be slightly different depending on the IO monitored by AirLogix. 68

77 Numeric Status Indicators Each numeric display on the following status screens will change color if the variable crosses the start permissive or warning threshold. If the variable does not meet the start permissive criteria, the background color will blink green. It will continue to display this way until the variable returns to the safe starting condition. If the compressor is running and crosses the warning threshold, the background color will blink yellow. It will continue to display this way until the variable returns to the safe running condition. Air End Status Screen Selecting Air End Status from the Navigation menu displays one of the two following screens. The only difference is the reference for innerstage temperatures and pressures. Typically, IR refers to the inner-stage pressures and temperature by discharge while most other manufactures refer to these inputs by inlet. This Air End Status screen references inlet pressures and temperatures. This Air End Status screen reference discharge pressures and temperatures. 69

78 Oil and Water Status Screen The Oil and Water status displays all monitored analog oil and water pressures and temperatures. NOTE: Oil Filter DP is calculated. The Main Oil Pressure is subtracted from the Pre-filter Oil Pressure. Pressing [F6] or [F7] allow starting and stopping of the Pre-lube/Auxiliary oil pump. The AirLogix system prevents stopping the oil pump when the compressor is starting up or coasting down. If the compressor is running, pressing [F6] will start the oil pump. The oil pump will run for 10 seconds and automatically stop. Motor Status Screen This screen displays all monitored analog inputs regarding the main motor. NOTE: The kilowatt reading is calculated based on motor voltage, current, and 90% efficiency rating. A KW transmitter may be provided to improve the accuracy of this number. 70

79 Discrete Status Screen The Discrete Status screen shows the On/Off status of the compressor and any auxiliary systems. Yellow means the device should be On, Open, or Running. Black indicates the device is Off, Closed, or Not Running. For example, if the cooling water valve open indicator is yellow, the valve is open. If the indicator is black, the valve is closed. Discrete input status is also displayed. If the discrete input is setup as a warning or trip, then the color will be green (OK) or red (Not OK). If the discrete input is monitor only, then the color will be Yellow (On) or Black (Off). For discrete inputs, if the indicator is Green, the condition is good. If the indicator is blinking red, it indicates the condition is bad. For example, if low water flow is green, then it indicates water flow is present. Red indicates water flow does not exist. Warning Banner/Event History If the compressor is running and a warning or trip condition occurs, the warning banner will be displayed. Press F5, to acknowledge the warning/trip condition and clear the banner from the screen. If more than one condition exists, the oldest will appear first, followed by the newest or most recent. NOTE: Once a warning condition is acknowledged from the PanelView, the banner will not appear again until the variable resumes normal, safe operating state and rises above/below the warning threshold again. The Event History contains each acknowledged warning/trip and events as they occur on the compressor. 71

80 Press [F8] or the up arrow key on the key pad to move up through the event history. Press [F9] or the down arrow key on the key pad to move down through the event history. There are two sets of date/time registers. The first column indicates the date/time of the event occurrence. The second displays the date/time of the event acknowledgement. If a date/time does not appear in the acknowledge time column, the condition is not acknowledged. Press [F7] to acknowledge all unacknowledged conditions. If a date/time does not appear in the acknowledge time column, the condition is not acknowledged. Press [F6] to retrieve additional information for specific warnings/trips and troubleshooting assistance. Press [F2] and [F7] to scroll up/down through the list of alarms. Normal causes of each condition will be listed in the middle of the screen. Each message is prefixed by an alphanumeric code specific to each event. When contacting Case Engineering for support, the code may be much easier to remember than the message. Refer the Troubleshooting chapter for descriptions of various warnings and trips. EL## - Event Log for starts, stops, loads, unloads, etc. TH## - High analog input trips TL## - Low analog input trips TD## - Discrete trips WH## - High analog input warnings WL## - Low analog inputs warnings WD## - Discrete warnings WR## - Analog Input Signal Range warnings 72

81 Trend Screens The AirLogix system provides several trend screens that allow the operator or service technician to view historical data. Selecting Trend Selection from the Navigation menu displays a screen to select which data to view. Among these screens are: [F1] Vibrations [F2] Air Temperatures [F3] Air Pressures [F4] Motor Data [F5] Compressor Overview [F6]Oil and Water This screen illustrates the Compressor Overview. The following explanation of trend functionality and operation applies to all trend screens. The text color in the legend above the trend corresponds to the trend line colors. For example, System pressure is the yellow line. The data displayed in the trend is over a 15 minute time span. However, 2-3 hours of data is continuously logged at 1 second intervals. This data is kept on file in the PanelView and can be viewed using the trend function buttons. Press [F2] to view data prior the data currently viewed. Press [F4] to move forward in time. Press [F3] to resume to current live data. The Y-axis scale may also be adjusted. This provides the ability to set the minimum and maximum scale to best view the data collected. Press [F1] to change the Y-axis maximum scale. Press [F6] to change the Y-axis minimum scale. Pressing [F10] will return to the Trend Selection screen. 73

82 User Defined Status Screen The AirLogix system provides two screens that allow the user/operator to select the variables to view. This may be useful if there are inputs that do not appear on a structured status screen. Use the TAB left [ ] and TAB right [ ] keys to place the green highlight on the desired entry point. Use the UP/DN arrow keys to select the input to view and press Enter. The value for the selected analog input will not update until the Enter key is pressed. Misc Status Data Screen This screen provides miscellaneous status data on the compressor to assist in monitoring overall compressor performance and efficiency. There are five hour meters: 1. Run active anytime the compressor is running. 2. Loaded Active when compressor is running loaded. 3. Fully Loaded Active when the compressor is running fully loaded (inlet 100% open or throttling the FLA). 4. Performance Throttle Mode Active when operating in Performance Throttle Mode. Refer to the Troubleshooting chapter for additional information on this mode of operation. 5. Oil Change Active when the compressor is running. A warning may be enabled to assist in setting up a regular oil change interval. When the accumulated time reaches the warning set point, an alarm banner is displayed. The warning will retrigger every 7 days until the hour meter is reset. The warning set point and the reset button for the hour meter are located on the Oil System Configuration screen. 74

83 Power information is displayed on this screen. The kilowatt numeric display is estimated and calculated using the formula below. kw = (Motor Current x Motor Voltage x x 0.90)/1000 Motor Current is typically the only analog variable monitored by the AirLogix system. The motor voltage is entered on the control system configuration screen. The MegaWatt hour (MWh) "This Month" is reset to zero on the first day of each month. The MWh "This Year" is reset to zero on the first day of the year. Resetting Hour Meters and Power Accumulators Press [F6] to access the Screen Information. This screen provides the ability to reset each individual hour/power meter. However, you must be logged in to reset individual hour meters. The Oil Change Hour Meter does not require login. Peak Vibration Data Screen Press [F7] from the Misc Data screen to access the peak vibration data. This data may be useful for detecting vibration issues before a major problem arises. Peak Vibration Detection The AirLogix PLC is collecting peak vibration data throughout three different operational periods for the compressor. The data collected may be viewed in Bar Graph or numerical form. The selection is toggled by pressing [F6]. The most recent twenty events (1-20) are displayed. Event number 1 is the most recent and event 20 is the oldest. 75

84 The scale of the bar graph may be modified by pressing [F5] Screen Info and entering the desired maximum scale. Peak Vibration During Startup Press [F7] to view Peak Vibration During Startup. This is the peak vibration point detected after a start is initialized and the vibration inhibit timer is timing. Peak Vibration Running Press [F8] to view Peak Vibration while Running. This is the peak vibration point detected after the vibration inhibit timer is done and the compressor is running. Also, a new peak value is created every day at 12:00 AM. For example, if a compressor runs continuously 10 days, you will have at least 10 separate peak data points, one for each day. Peak Vibration During Coast Down Press [F9] to view Peak Vibration During Coast Down. This is the peak vibration point detected after a compressor stop is initialized and during the coast down time. Additional data is available not shown on the screen. This data includes oil temperature, oil pressure, and inlet valve position during each of the peak detected data points. Also, the AirLogix system contains 100 events, while the PanelView only displays the 20 most recent events. Please contact Case Engineering for additional information. 76

85 Automatic Functions Each AirLogix system has the ability to utilize automatic start/load/unload/stop functionality. To utilize these functions, select Auto Functions from the navigate menu. Each function may be enabled and disabled independently. NOTE: If AirMaster is utilized, see Chapter 7-AirMaster. The set points will be determined by AirMaster and cannot be modified on this screen. However, the ability to enable/disable each function still exists. Auto Start Enter the Pressure and Time delay to automatically start the compressor. If the system air pressure falls below the pressure set point for the length of time specified, the compressor will automatically start. Press [F1] to Enable/Disable the Auto Start Function. Auto Load Enter the Pressure and Time delay to automatically load the compressor. If the compressor is running unloaded and the system air pressure falls below the auto load pressure set point for the length of time specified, the compressor will auto load. Press [F2] to Enable/Disable the Auto Load Function. Auto Unload Enter the Time delay to automatically unload the compressor. If the compressor has a modulating bypass valve, the timer will start when the machine discharge pressure is less than the System air pressure by the machine pressure PID offset (typically 10 psi). This indicates the check valve is closed and the compressor is not contributing to the system. If the compressor has a discrete solenoid operated bypass valve, there will be a pressure set point entry point available. Press [F2] to Enable/Disable the Auto Unload Function. 77

86 Auto Stop Enter the Time delay to automatically stop the compressor. The auto stop timer will start when the compressor is unloaded. If the compressor runs unloaded continuously for the length entered, the compressor will automatically stop. Press [F2] to Enable/Disable the Auto Stop Function. 78

87 Chapter 6 Troubleshooting: Modem Service Policy Warranty Service Non-Warranty Service Warning/Trip Descriptions Surging or Other Erratic Behavior Unable to Make Pressure Set-Point Unable to Start the Machine Request for Remote Modem Service Fax 79

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89 Modem Service Policy Because of the critical nature of compressed air systems to the operation of a manufacturing plant or process, each AirLogix installation is shipped with at least one configured and pre-tested modem per location. A standard analog phone line connected to the modem will allow Case Engineering to connect to your machine and provide numerous diagnostic services. Qualified personnel are available 24 hours a day with software tools that make remote diagnostics safe, efficient and effective. Case Engineering is anxious to resolve your problem via modem or on-site if necessary. The average modem service call is 2-hours from initial contact. The average on-site time is 36 hours from initial contact depending on your location. Warranty Service In some cases, the diagnostic services may reveal an issue that is covered under our standard warranty, which expires 12 months from the date the system is shipped from our facility. Service calls considered warranty will not be billed to the customer. Non-Warranty Service The majority of the modem service calls result in diagnosis of a problem that is unrelated to any defect or error in the AirLogix system. For this reason, we provide the following basic troubleshooting guide for your convenience and efficiency. Please check each item. This may resolve the problem quickly without any service charges. If you are unable to resolve the problem in this manner, please contact Case Engineering at (812) day or night for modem service. 81

90 Warning/Trip Descriptions A wide variety of warnings and trips may occur on the AirLogix system. For each warning/trip, the compressor must be running or attempting to start. The follow is a compiled list of warnings and general descriptions of each. Each message is prefixed by an alphanumeric code specific to each event. When contacting Case Engineering for support, the code may be much easier to remember than the message. EL## - Event Log for starts, stops, loads, unloads, etc. TH## - High analog input trips TL## - Low analog input trips TD## - Discrete trips WH## - High analog input warnings WL## - Low analog inputs warnings WD## - Discrete warnings WR## - Analog Input Signal Range warnings Warnings or trips with code TH, TL, WH, or WL are associated with the analog inputs monitored on the compressor. Any associated Warning/Trip indicates the analog variable has exceeded the warning/trip threshold. However, there are warnings/trips that may not be obvious. The following may assist in troubleshooting the operation of the compressor. Low/High Temperature Warnings/Trips Most instances of temperature warnings/trips lead to air or oil cooler problems. However, it is possible the problem may lie in the instrumentation. The most common instrumentation problem is a loose wire where the RTD transmitter connects to the RTD element. An open RTD will read full scale resulting in a compressor warning/trip. Vibration Warnings/Trips Causes of vibration warnings/trips are numerous. The most common nuisance warnings/trips involve loose instrumentation wiring or cabling. Probe cables should be tightened 1/8 to ¼ turn past finger tight. Compressor Surge may also cause vibration warning/trips. Also, unlike other warnings/trips, vibration warnings/trips may occur during motor spin-up and coast down. The warning and trip thresholds are higher due to the vibration multiplier, but may indicate a possible problem. 82

91 TD01- Low Seal Air Pressure Trip Seal air isolates the lube oil side from the air compression side of the compressor on some machines. If the seal is not present, the machine will shut down and/or will not start until it is returned. If seal air is present, and the machine cannot be started or is shut down due to this trip then the switch should be checked for proper operation. TL05- Motor Current Low Trip This trip only occurs if a compressor start is attempted and motor current is not sensed. In most instances, motor switch-gear is the cause. It may also be an incorrectly wired or faulty current transmitter. TH05- Motor Current High Trip This trip should never occur if the compressor was initially set up correctly. A few causes may be the trip set point is set below the Max Amp PID (FLA) set point, an inlet valve stuck in the open position, or voltage drop to the main motor. WH01 Machine Pressure High Warning The most common cause is failure of the check valve stuck in the closed position. Another cause could be if the bypass valve failed in the closed position. It may also occur if the block valve is closed and the system pressure transmitter is located down stream of the block valve. TH01 - Machine Pressure High Trip The most common cause is failure of the check valve stuck in the closed position. Another cause could be if the bypass valve failed in the closed position. It may also occur if the block valve is closed and the system pressure transmitter is located down stream of the block valve. WD16 Surge Warning Indicates the air flow through the compressor has become unstable. When this condition occurs, the compressor unloads and reloads as long as the number of surges allowed over a specific time period has not been exceeded. If the recommended checks found on page 85 have been verified, contact Case Engineering for assistance. WD17 Surge Line Indexed After a surge warning is triggered, if surge line indexing is enabled, the surge line is indexed. The amount the surge line is indexed can be found on the Surge Parameters screen. The surge line will not index if the inlet valve is 100% open when the surge occurs. This is an indication of Natural Surge and the pressure set point may be lowered to prevent this from occurring. 83

92 WD18 Non-Recoverable Surge Unload This warning indicates the number of compressor surges has exceeded the number allowed over a preset given period of time. When this warning occurs, the compressor unloads and remains unloaded. When the warning is acknowledged, the compressor may be loaded by pressing [F7]. WD19 Auxiliary Oil Pump Running, Possible Mechanical Oil Pump Failure This warning indicates the oil pressure fell below the recovery pressure set point found on the Oil Pump/Configuration screen. It is only utilized when an auxiliary oil pump exists on the compressor. When this warning occurs, the auxiliary (prelube) pump is started to allow the compressor to continue to run until a standby can be started. The condition should be attended to immediately. WD20- Processor Battery Low Indicates the processor battery needs to be replaced. Turning control power off the panel for any extended period of time will result in program loss. Replace the battery as soon as possible. Case Engineering may provide this upon request. WD21- Motor Power Loss This warning indicates the motor lost power, thus shutting down. Although the compressor is not running after this alarm is issued, it was not shut down by the control system. The most common cause is power loss to the main motor, however, a remote Emergency stop circuit or motor starter safety circuit could result in the same condition. WD22 Performance Throttle Mode This condition occurs if the compressor is loaded, the inlet valve is 100% open, and unable to achieve the DTL set point for the operating pressure. When this condition is triggered, the AirLogix system calculates the safe operating pressure set point based on the amount of motor current draw when the inlet is 100% open. In some instances, the cause of this warning is an inlet valve problem. If the inlet valve is not calibrated correctly or is physically stopped due to mechanical wear or a lack of instrument air supply, the valve may not open to 100%. The valve position indicators on the PanelView screen indicate the intended position based on the output signal the AirLogix system is sending the valve. If the inlet valve appears to operating correctly, this alarm indicates the compressor is not capable of operating at the intended pressure and should be evaluated by a service technician. WD23 through 25 Slot # Analog Input Module Not Present Indicates an analog input was enabled on an analog module that does not exist. Case Engineering may provide additional analog input modules upon request. 84

93 WR00 through WR37 Signal Out Of Range Indicates the input signal for an analog variable monitored on the compressor is not normal. The electrical input signal should typically be between 4-20mA for current devices or 1-5volts for voltage devices. Anytime the signal is outside this range and the compressor is running, the associated warning is triggered. The instrument should be bench calibrated or replaced. Surging or Other Erratic Behavior Following is a list of problems that are commonly blamed on controls when in reality they are mechanical in nature and are actually maintenance issues. Inlet air obstruction Dirty or frozen inlet air filters can cause many problems including surging due to the inability to get air flow through the machine. Discharge obstruction If a block valve is closed or even partially closed, the machine may not be able to achieve proper airflow to prevent a surge. A check valve which fails to open may force the compressor to surge. Valve Linkage Often, loose inlet or bypass valve linkage will cause unexplainable behavior or surging. The controls will command the valves to be in certain positions and then assume they made it there. If loose or broken valve linkage prevents the valve from actually moving the controls cannot correct that. Voltage Fluctuation If your plant voltage is significantly higher or lower than normal due to a plant shutdown or new process start-up, the current at which the compressor surges may have changed. In this case, the machine will need to be re-tuned to the new surge line. Machine Wear As a compressor ages, it wears, and its surge characteristics may change. The same applies to rebuilding a worn machine. In either case, the machine may need to be re-tuned to its new surge point. 85

94 Sensor Malfunction The AirLogix relies heavily upon its sensors for proper control of the machine, particularly the discharge air pressure, system air pressure and motor current transmitters. If any of these sensors are malfunctioning, they should be replaced. If they have recently been replaced, they may need to be scaled properly. Abnormal PSI Setting When the AirLogix is initially set-up, it s surge point is determined at certain operating pressure range. If you are operating outside of the normal pressure range for any reason, the system may need to be tuned to accommodate that. Unable to Make Pressure Set-Point Max Motor Amp Limit Each machine is configured with a maximum motor amp limit that is usually equal to the motors nameplate Full Load Amp (FLA) value. In some cases, you have requested that your machine be configured to run into the motor s service factor, which may be 10% to 15% more than FLA. In either case, if the motor current (as displayed on the AirLogix Main Screen) is running equal to the max motor amp setting, your machine may not be capable of making set-point pressure. This can happen when a motor is undersized, when the ambient air temperature is extremely high or when any of a host of mechanical issues exist such as a high inner stage air temperature possibly caused by a cooling water problem. Unable to Start the Machine Control Power - The control power switch on the front door must be in the on position. E-Stop Depressed - The Emergency stop button on the front door must be in a non-depressed position. Start Permissives - Each machine has numerous possible start permissive combinations. The following are a few of the most common: Seal air pressure switch must be made. Oil temperature must be within permissive range. Oil pressure must be within permissive range. 86

95 Existing Fault Condition - Any unacknowledged fault will prevent the machine from starting. Cycling power to the control panel should allow the operator to correct this condition. 87

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97 Chapter 7 AirMaster Operation Overview AirMaster is an optional software solution that resides in the AirLogix System for managing multiple compressors with the intent of meeting changing plant air demands while reducing overall energy consumption. Because each compressed air system has unique characteristics, some customization may be required. The load sharing process is achieved by sharing the load among two or more compressors, as they are needed. AirMaster utilizes the inlet throttle capacity of each compressor in order to minimize or eliminate bypass modulation and maintain a constant header pressure. AirMaster makes dynamic decisions about starting/stopping, loading/unloading and throttling machines based upon predetermined set-up parameters relative to current plant air demand as represented by system header pressure. It is important to understand the electronic hierarchy in AirMaster, which does not utilize or depend on a dedicated Master Controller. Redundant logic resides in each AirLogix Controller. This means that the loss of any networked machine leaves the entire AirMaster system functioning properly to maintain a constant header pressure with the greatest efficiency. AirMaster allows set-up personnel to select the lead-lag order and all system operating parameters for all machines from the front panel of any networked AirLogix and transmit these parameters to all machines on the network. Each controller then operates with the same logic to create a redundancy that is not dependent on a Master Controller. The following pages describe in detail how to configure AirMaster. 89

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99 AirMaster Compressor Overview AirMaster will be setup, enabled, and disabled from any networked PanelView with the following procedure. From the Main screen, press [F1] to display the AirMaster compressor overview screen. The AirMaster compressor overview may also be accessed from the Navigate menu. Press [F10]to display the navigation screen. Select AirMaster and press Enter or press. The first AirMaster screen contains status information for the first four units on the AirMaster network. If there are more than 4 units, pressing [F7] will display the status of the remaining compressors in the AirMaster network. For each unit listed, the following information is communicated across the AirMaster network. -Unit Identification -Operational Status -AirMaster Enabled/Disabled -Auto Rotation Enabled/Disabled -Unit Priority -Pressure Set Point -Inlet Position -Bypass Position -Motor Current -DTL Set Point 91

100 There are 11 possible operational states for each compressor. Each state will be preceded by the compressor ID (i.e. Unit 1 Not Ready). Not Ready - Either the unit doesn t have AirMaster enabled locally, or the start permissives for that compressor are not met. Ready to Start - AirMaster is enabled locally and the unit is ready to start. May Start In ### Seconds Indicates the unit may auto start. The timer must complete without interruption in order to auto start the compressor. In any auto start sequence, the software prevents simultaneous starts of two or more units. However, network communication must be active to accomplish this. Running Indicates the compressor is running Unloaded. May Load In ### Seconds Indicates the compressor auto load timer is timing. The timer must complete without interruption in order to auto load the compressor. Loaded Indicates the compressor is going through or completed the load sequence. Fully Loaded Indicates the compressor is operating at the maximum output. Maximum output is determined when the inlet valve is 100% open or the inlet valve is controlling to the FLA set point. May Unload In ### Seconds - Indicates the compressor has throttled back to the point to start the unload timer. When an analog bypass valve is used, the unload timer is started when the discharge pressure is less than the system pressure and the system pressure is greater than the pressure set point. This indicates the check valve is closed and the compressor is not contributing to the system. When a discrete bypass valve is used, the timer is started when the system pressure exceeds the unload pressure set point. The timer must complete without interruption in order to auto unload the compressor. May Stop In ### Minutes Indicates the compressor Auto stop timer is timing. The timer starts when the compressor is running unloaded. The timer must complete without interruption in order to auto stop the compressor. Tripped Indicates the compressor has shutdown due to a safety interlock (i.e. E-stop pressed). Not Found Indicates a communication loss to that controller. New AirMaster Parameters Received Indicates that the compressor received the parameters. Anytime new parameters are sent, this message will display for approximately 20 seconds. This allows the operator to return to the AirMaster overview screen and confirm each unit received the new parameters. 92

101 Enabling and Disabling AirMaster Enabling and Disabling AirMaster can be accomplished from this screen by pressing [F6]. This enables AirMaster only for the local compressor. If power is cycled on the control panel, AirMaster is automatically disabled. Therefore, when power is applied to the panel, AirMaster must be Enabled. Note: AirMaster must be enabled locally at each unit. The AirMaster status is also displayed on the main screen below the unit ID. In addition, the yellow pressure indicator will read System Pressure when AirMaster is disabled and AM System Pressure when AirMaster is enabled. AM System Pressure is the priority 1 or lead unit s system pressure transmitter. AirMaster Setup Parameters From the AirMaster compressor Overview screen, press [F6] to navigate to the AirMaster Setup screen. The priority is defined as the order or sequence in which the units will start, load, unload, and stop. Priority designation of 1 is the highest priority and also considered the Lead unit. The highest priority will be the first to start, followed by priority 2, priority 3, and so on. There are two columns for unit priority. The first column, labeled New, is used to make any necessary changes to the priority. The second column, labeled Current, displays the current priority designation for each compressor. 93

102 The priority is entered by scrolling to the desired compressor, using the left and right TAB keys, entering a value, and pressing enter. Each unit must have a different priority. If duplicate priorities are detected, the original values will be retained and the parameters are not sent. In order for any change to take place among the AirMaster network, [F6]-Send AirMaster Parameters must be pressed. When this key is pressed, the new priority will take effect. Pressing [F6] Send AirMaster Parameters transmits all AirMaster parameters to the other units on the network. When a parameter is modified, an indicator in the upper left hand corner of the screen will flash New AirMaster Set Point Detected. If the parameters are not sent within 5 minutes, the newly modified parameters will return to the current parameters. When new parameters are sent, the communication status of each compressor on the AirMaster network will indicate one of three states. The AirMaster Pressure Set Point is the pressure set point for the Priority 1 compressor. The Pressure Offset is the pressure difference between each compressor s set point. For example, if there are three compressors and the AirMaster pressure set point is 120 PSI and the pressure offset entered is 1.0 PSI, the first priority unit will have a pressure set point at 120 PSI. The second will have a 119 PSI set point and the third a 118 PSI set point. This set point is process specific and may have to be adjusted to maintain desired performance. The pressure set points are staggered to provide a sequential throttling action for each compressor. The Emergency Pressure set point is the minimum operating system pressure determined by the operator. This pressure establishes a pressure set point that immediately starts the next unit in priority when the system pressure drops below the emergency pressure. Not more than one unit can start at a time. If the system pressure remains below the emergency pressure set point, additional units will start once the previous priority compressor is loaded. The Low Pressure Timer is expressed in seconds. Once the system pressure has dropped below the unit s AirMaster pressure set point the timer is initialized. If the timer completes its timing sequence, the compressor will start and load into 94

103 the system. If the system pressure rises above the unit s pressure set point after the timer has started timing, the timer will reset. The Unload Timer is expressed in minutes and defines when to unload the compressor. When an analog bypass valve is used, the unload timer is started when the discharge pressure is less than the system pressure and the system pressure is greater than the pressure set point. This indicates the check valve is closed and the compressor is not contributing to the system. When a discrete bypass valve is used, the timer is started when the system pressure exceeds the unload pressure set point. The timer must complete without interruption in order to auto unload the compressor. The Shutdown Timer is expressed in minutes and defines the amount of time the compressor must be unloaded before the compressor shuts down. From the AirMaster Setup screen, Press [F8] to view the AirMaster auto function setup. The AirMaster Auto Function screen allows the operator to customize each compressor individually. Note: These functions are not sent to each unit on the AirMaster network when the AirMaster parameters are sent. These functions must be set at each compressor. Each function may be turned ON and OFF by pressing the corresponding function key. Emergency Auto Start is initiated by a system pressure below the emergency pressure set point. Auto Start is initiated by the low pressure timer. Auto Load Auto Unload Auto Stop The Bypass Pressure Offset is used to minimize bypass blow-off by utilizing the inlet turn down on other compressors running loaded in the system. This set point defines a pressure set point above the normal operating set point creating an increased pressure set point for the bypass valve. This is designed to allow for maximum air efficiency upon a decrease in plant air demand. If all prior priority compressors are fully loaded and the bypass is less than 100% closed, 95

104 the bypass pressure set point is incremented until equal to the pressure set point plus the bypass offset. This will cause other compressors on the AirMaster network to throttle back the inlet valve due to a rise in system pressure. For this function to work effectively, the bypass pressure set point (pressure set point plus the bypass offset) of the throttle compressor should be greater than the operating pressure set point of the Priority 1 unit. If it is not, then the lead unit will not be forced to throttle back due to a decrease in demand. This data entry is unit specific and is not transmitted when a SEND command is executed. However, by default, the bypass pressure is automatically calculated. The calculation is based on the AirMaster pressure offset and the number of compressor running loaded in the system. When AirMaster is disabled, the local system pressure at the unit is used. When AirMaster is enabled, the lead unit (Priority 1) system pressure signal is used. The only situations preventing this transmission are a faulted processor, loss of power or network failure. If this condition exists, the unit designated as priority 2 will take the lead. If communication is lost to the priority 1, 2, and 3 units, AirMaster is automatically disabled. AirMaster is also automatically disabled if the lead unit system pressure and the local system pressure difference is greater than 15%. Auto Priority Rotation Setup Auto Priority Rotation is designed to establish an automatic rotation of compressors based on unit priority in the AirMaster sequence and an elapsed time interval. Rotation of compressor priorities will take place in the event the rotation timer expires. The number one priority unit determines when an auto rotation cycle is executed. The auto rotation timer is enabled (timing) as long as AirMaster is enabled. Auto Rotation does not have to be enabled on the lead unit for the rotation to occur. If the number one unit has a faulted processor or loss of power, the number two unit will assume this responsibility. The rotation only affects the compressors with the Auto Rotation Function enabled. If auto rotation is disabled, no priority change will take place for that unit. When a rotation cycle occurs, the compressor with auto rotation enabled and the highest priority designation, will take the lowest priority unit with auto rotation enabled. If three compressors designated as priorities 1 through 3 have auto rotation enabled and a rotation is triggered, the number one in priority will shift to the third priority. The compressor currently number two in priority will shift to the number one position and the compressor currently number three will assume priority two. 96