Spartan Controls Millennium Compressor Control Panel Operating Philosophy

Transcription

1 Project: Stock Revision 1 Page 1 Spartan Controls Millennium Compressor Control Panel Operating Philosophy Location: Stock Customer references: Vendor: Vendor document: Spartan Controls Ltd. Operating Philosophy Vendor project: Revision 0 1 Date September 23, 2004 June 2, 2006 Check PM AMB Review DOCUMENT ACCEPTANCE & APPROVAL Certification of acceptance and approval of Revision 0 of this document. Customer name signature: Date: Spartan Controls Ltd. signature: Date: Spartan Controls Ltd. without the prior consent of the Quality Manager of Spartan Controls.

2 Project: Stock Revision 1 Page 2 CUSTOMER SERVICES NETWORK Customer Millennium Operating Philosophy Revision 1 Spartan Controls Ltd. Company Confidential This document is the private property of Spartan Controls Ltd. and must be returned upon request. No part of this document shall be reproduced in any form and distributed outside the Customer Services Network without expressed written consent of Spartan Controls Ltd..

3 Project: Stock Revision 1 Page 3 TABLE OF CONTENTS 1. INTRODUCTION General Standard Base System Optional Functionality START-UP / SHUTDOWN SEQUENCING Compressor Cooldown Stop Alarm Stop (Optional) Engine / Compressor Shutdown Panel Emergency Shutdown (ESD) MANUAL LOADING CONTROL Manual Bypass Valve Control Manual Speed Control Manual Suction Valve Control AUTOMATIC LOADING CONTROL Automatic Speed Control Suction Discharge Automatic Bypass Valve Control Suction Discharge Automatic Suction Control Controlled Unload Blowdown Valve Control COMPRESSOR ROD LOAD CALCUATIONS LOW CLASS P DISCHARGE LOGIC MISCELLANEOUS Password Protection Verify Discrete Input / Outputs Service Mode... 19

4 Project: Stock Revision 1 Page Test Mode Run Time Hours Speed Output Actuator Adjustments MODBUS COMMUNICATIONS Local / Remote Mode APPENDIX A Input/Output List APPENDIX B Definitions... 21

5 Project: Stock Revision 1 Page 5 1. INTRODUCTION 1.1 General This document outlines the Millennium compressor control panel operating philosophy for Bidell Equipment Inc. A Millennium control system will be programmed to safely start, stop, and automatically sequence a two-stage four-cylinder reciprocating compressor with a gas engine driver. The automatic sequence has been designed based on practices and recommendations from Bidell Equipment Inc for control of a Caterpillar 3412 TA LE gas engine driver, and an Arial JGJ-4 reciprocating compressor. The display/control/communications control module (Head) contains the processing power in the form of a single board computer with support board, Vacuum Fluorescent Display (VFD), (which is a dot matrix alpha-numeric display in a 4 line by 20 character format), and 16 button keypad. The VFD displays first-in shutdowns, an alarm history, sequencing messages, and all process real-time data. A separate pushbutton mounted on the side of the panel is provided for ESD (Emergency Shutdown). This document covers both the standard base system, and several options summarized in the next sections. 1.2 Standard Base System The base system control logic functionality is listed below. These are covered in greater detail in later sections. Lube oil pump control (prelube and postlube) Engine Startup Cooldown stop sequencing Compressor shutdown logic Low class P discharge logic Rod load calculations Speed control Bypass control Suction valve control 1.3 Optional Functionality The optional system control logic functions are listed below. These are covered in greater detail in later sections. References to these control options throughout the philosophy are only valid if the options have been selected. Blowdown valve control

6 Project: Stock Revision 1 Page 6 2. START-UP / SHUTDOWN SEQUENCING The setpoint, and timer parameters discussed in this section can be accessed from the setpoint screens. Please refer to the project IO list document for setpoint / timer values, and locations. The operator must ensure that all shutdowns have been cleared before a start can be attempted. This may be confirmed by viewing the Millennium display. Once all shutdowns have been cleared, a STANDBY message is displayed on the MAIN screen. The ESD relay will energize, all other relays will remain off (Blowdown will operate as required), and the Speed control will output the WARMUP RPM setting. The Bypass Valve output will be at 0%. If the Suction Valve control is in AUTO, the Suction Pressure will be maintained at the START PRS setting. If the control is in MAN, the operator can control the output using the MAN OUT setting. Table 2-1 describes the start-up sequencing in detail. Table 2-1: Start-Up Sequencing Item Step Description 1 Press RUN/STOP key. Initiates a start attempt. When the RUN/STOP button is pressed the Speed output is set to WARMUP RPM and the Bypass Valve will fully open to 0.0%. The Suction Valve output will be in control. Each step through the start sequence will be displayed on the HOME front display screen on the ST: status line. When a shutdown occurs the status will change to SHUTDOWN. The Event display will flash the Alarm Summary screen for details. 2 Prelube The Lube relay will energize and the PERMISS DLY timer will start. The controller will monitor both compressor and engine oil permissive settings. If the compressor permissive pressure is not reached at the expiration of the PERMISS DLY timer, the controller will signal COMP OIL PERM FAIL. The Lube relay will turn off, and the controller will wait for a RESET. The RUN/STOP button will have to be pushed to attempt another start. If the engine permissive pressure is not reached at the expiration of the PERMISS DLY timer, the controller will signal ENGINE OIL PERM FAIL. The Lube relay will turn off, and the controller will wait for a RESET. The RUN/STOP button will have to be pushed to attempt another start. When both permissives are met, the PERMISS DLY timer will zero, and the PRELUBE DLY timer will start. The unit will continue prelubing for the

7 Project: Stock Revision 1 Page 7 duration of the PRELUBE DLY timer. 3 Engine Start Following the completion of the PRELUBE DLY timer, the Lube relay will deenergize and the crank sequence will initiate. The Ignition and Crank relays will energize. If the engine RPM does not rise above 0 rpm at any time during the first crank attempt, the controller will assume a problem with the unit and a FAIL TO CRANK shutdown will occur. The CRANK DLY and PURGE DLY timers will start. The display will change to CRANKING. The Crank relay will remain on for the duration of the CRANK DLY or until the engine RPM rises above the CRANK DIS (crank disconnect) RPM. When the PURGE DLY expires, the Fuel Valve relay will energize. If the speed does not reach the CRANK DIS RPM before the CRANK DLY timer expires the Crank, Ignition, and Fuel Valve relays will deenergize and the REST DLY timer will start. The display will change to RESTING. When the REST DLY timer expires, the Crank and Ignition relays will energize, the Fuel Valve relay will energize after the PURGE DLY, and the crank attempt counter will increase by 1. If the engine does not start when the actual crank attempts is equal to the CRANK ATTEMPTS setpoint the controller will signal a FAIL TO START fault. This fault must be RESET, and a new start attempt made. NOTE: If the crank RPM falls below 50 rpm, after it has been above 50 RPM, the Crank relay will de-energize and the REST DLY timer will start. The display will change to RESTING. When the REST DLY timer expires the Crank relay will energize and the crank sequence will be repeated. 4 Warm-up When the engine RPM rises above the CRANK DIS RPM, the crank sequence will finish and the display will change to WARMUP. Automatic loading of the unit is not permitted until the system has warmed up. The internal Run Hours will begin accumulating. The Class B1 and B2 timers will begin counting. When the timers expire the Class B1 and B2 faults will be armed. The Status relay will energize at the expiration of the Class B1 timer. The WARMUP DLY timer is started. The Engine Jacket Water Temperature, and Compressor Oil Temperature permissives are monitored. After a 15 second delay the Suction Valve control setpoint will begin to ramp from the START PRS setting to the MAINT SUC setting (if the Suction Valve output is in AUTO) using the SUC STEP P, and ST RAMP TIME settings (adjustable from the SUCTION CNTL screen). If the engine RPM falls 50 RPM below the CRANK DIS RPM a LOSS OF SPEED SIGNAL fault will occur immediately. The UNDERSPEED shutdown (Class C) will be armed when the engine RPM rises above the UNDERSPEED setpoint. When the WARMUP DLY timer expires and the temperature permissives are met the display will change to READY TO LOAD. The Speed output will increase to the IDLE RPM using the speed control manual settings.

8 Project: Stock Revision 1 Page Compressor Cooldown Stop The unit can be loaded by changing the first line of the HOME front display to LOAD. If the HOME page is not displayed, the HOME key can be repeatedly pressed until the page appears. Pressing the RUN/STOP button of the Millennium controller initiates a cooldown stop sequence. The Bypass Valve will begin ramping to 0% using the manual open bypass settings. When the Bypass Valve position falls below the BYP P THR DWN (bypass position for throttle down) setting, the Speed control output will begin ramping the engine RPM to the Min RPM setting using the manual speed control settings. When the Bypass Valve is at 0% and the speed control is at Min RPM, the Speed control will decrease to the Warmup RPM setting. The status display will change to COOLDOWN. The COOLDOWN DLY timer will begin counting. The unit can be forced into an immediate stop by pressing the TIMER 0 key. When the COOLDOWN DLY timer expires: - The Fuel Valve relay will de-energize. - The IGN KILL DLY timer is started. - All Class B faults are locked out. - The internal Run Hours stop counting. - The Status relay will de-energize. - The Suction Pressure will be controlled to the START PRS setting. - When the IGN KILL DLY timer expires the Ignition relay will de-energize, and the Lube relay will energize for the duration of the POSTLUBE DLY. The display will change to POSTLUBING. - When the postlube cycle is complete, the display will change to STANDBY, and the unit will be ready for a start attempt. NOTE: If the unit is restarted while the unit is postlubing, the postlube sequence will stop and the start sequence will begin.

9 Project: Stock Revision 1 Page Alarm Stop (Optional) An ALARM STOP is initiated when a parameter reaches an alarm setpoint. The unit will complete a cooldown stop. The cooldown stop will help reduce engine maintenance, rather than an always initiating an immediate stoppage. The display will change to SHUTDOWN. The FAULT SNAPSHOT page will record the values of the process parameters. The 4-line fault message will appear in the display. The Bypass Valve will begin ramping to 0% using the manual bypass settings. When the Bypass Valve position falls below the BYP P THR DWN (bypass position for throttle down) setting, the Speed control output will begin reducing the engine RPM to the Min RPM setting using the manual speed control settings. When the Bypass Valve is at 0% and the Speed control is at Min RPM, the speed control will decrease to the WARMUP RPM setting. The COOLDOWN DLY timer will begin counting. The unit can be forced into an immediate stop by pressing the TIMER 0 key. When the COOLDOWN DLY expires: - The Fuel Valve relay will de-energize. - The IGN KILL DLY timer is started. - All Class B faults are locked out. - The internal Run Hours stop counting. - The Status relay will de-energize. - The Suction Valve will close completely (0%). - When the IGN KILL DLY timer expires the Ignition relay will de-energize, and the Lube relay will energize for the duration of the POSTLUBE DLY. The unit must be reset to change the status to STANDBY, to allow another start attempt. NOTE: If the unit is restarted while the unit is postlubing, the postlube sequence will stop and the start sequence will begin. The Alarm Stop option can be disabled by changing the COOLDOWN SELECT option to NO (N) on the MISC CAL setpoints screen.

10 Project: Stock Revision 1 Page Engine / Compressor Shutdown A SHUTDOWN is initiated if a discrete shutdown switch trips, an analog shutdown setpoint is exceeded, or an analog input sensor fails. This is deemed a point at which catastrophic damage can occur, and the unit must be stopped immediately. The display will change to SHUTDOWN. The FAULT SNAPSHOT page will record the values of the process parameters. The 4-line fault message will appear in the display. The Suction Valve and, Bypass Valve outputs will immediately ramp to 0%. The Speed output will ramp to the WARMUP RPM setting. When a shutdown occurs: - The Fuel Valve relay will de-energize. - The IGN KILL DLY timer is started. - All Class B faults are locked out. - The internal Run Hours stop counting. - The Status relay will de-energize. - The Suction Valve will close completely (0%). - When the IGN KILL DLY timer expires the Ignition relay will de-energize, and the Lube relay will energize for the duration of the POSTLUBE DLY. The unit must be reset to change the status to STANDBY, to allow another start attempt. When the unit is reset the Suction Valve will start controlling to the START PRS setting. NOTE: If the unit is restarted while the unit is postlubing, the postlube sequence will stop and the start sequence will begin. NOTE: If the fault condition is not cleared, and the RESET button is pushed the FAULT SNAPSHOT page will be overwritten. 2.4 Panel Emergency Shutdown (ESD) An ESD fault is initiated by pressing the ESD pushbutton mounted on the control panel, opening the Remote ESD discrete input contact, or through Modbus. When an ESD fault occurs: The Fuel and Ignition relays will de-energize. The Bypass valve will open. The Suction Valve will close completely (0%). The Blowdown valve will open to completely de-pressurize the unit The ESD relay will de-energize. No compressor postlube cycle is performed.

11 Project: Stock Revision 1 Page MANUAL LOADING CONTROL 3.1 Manual Bypass Valve Control Manual Bypass Valve control is only permitted when the unit has started, automatic loading control has been initiated, and the engine speed has exceeded the engine MIN RPM. When the unit is in the LOADED state, the Bypass Valve analog output can be placed in manual mode from the BYPASS CONTROL screen. In manual mode the operator can select the desired bypass position using the keypad and changing the MANUAL OUT setting. The output can only be changed between 0 and 100%. The Bypass Valve output will ramp to the entered value using the OPEN % or CLOSE % settings every second. If the AUTO/MAN button is toggled back and forth the MC controller will track the auto setting so a bumpless transfer will occur. The OPEN % and CLOSE % settings can be adjusted on the MANUAL CONTROL setpoint screen (Login Access Level 4). 3.2 Manual Speed Control The Speed analog output can be placed in manual mode from the SPEED CONTROL screen. In manual mode the operator can select the desired engine RPM using the keypad and changing the MANUAL OUT setting. The RPM can only be changed between the MIN RPM and MAX RPM settings. The Speed output will ramp to the value using the INC RPM or DEC RPM settings every second. If the AUTO/MAN button is toggled back and forth the MC controller will track the auto setting so a bumpless transfer will occur. The INC RPM and DEC RPM settings can be adjusted on the MANUAL CONTROL setpoint screen (Login Access Level 4). 3.3 Manual Suction Valve Control In manual mode the operator can select the desired Suction Valve position using the keypad and changing the MANUAL OUT setting from the SUCTION CONTROL screen. This is only permitted when the controller is not in a shutdown condition. The Suction Valve can only be changed between the 0 and 100%. The output will ramp to the entered value using the OPEN % or CLOSE % settings every second. The MC controller will track the auto setting so a bumpless transfer will occur. The Suction Valve control can be placed in AUTO/MAN independent of the speed/bypass control. The OPEN % and CLOSE % settings can be adjusted on the MANUAL CONTROL setpoint screen (Login Access Level 4).

12 Project: Stock Revision 1 Page AUTOMATIC LOADING CONTROL When a READY TO LOAD status is displayed the LOAD state can be selected. From the HOME screen the STATE line must be selected. Press the SETUP ENTER key. Press the UP ARROW key. This will change the STATE to LOAD. Press the SETUP ENTER key. The Speed control will ramp up to the engine MIN RPM. Once the speed reaches the MIN RPM, the Speed and Bypass outputs will be in Automatic control. 4.1 Automatic Speed Control The lowest output signal from either the Suction or Discharge Speed Control is sent to the Speed Control output Suction If the Suction Pressure is above the MAINT SUC + SUC PRS DB (deadband), the Speed control will increase by the INC RPM value at the UPDATE(ms) rate in an attempt to reduce the pressure. If the Suction Pressure is below the MAINT SUC - SUC PRS DB, the Speed control will decrease by the DEC RPM value at the UPDATE(ms) rate in an attempt to increase the pressure. When the Suction Pressure is within the deadband of the pressure setpoint no output change will occur. The SUC PRS DB, INC RPM, DEC RPM (Login Access Level 4), and UPDATE(ms) (Login Access Level 3) parameters can be adjusted from the SPD CTRL-SUC setpoint screen. The current Auto Mode (SUCTION/DISCHARGE) is also displayed on this screen. The MAINT SUC setting can be adjusted from the SPEED CONTROL front display screen (Login Access Level 5) Discharge If the Discharge Pressure is above the MAINT DIS + DIS PRS DB (deadband), the Speed control will decrease by the DEC RPM value at the UPDATE(ms) rate in an attempt to reduce the pressure. If the Discharge Pressure is below the MAINT DIS DIS PRS DB, the Speed control will increase by the INC RPM value at the UPDATE(ms) rate in an attempt to increase the pressure. When the Discharge Pressure is within the deadband of the pressure setpoint no output change will occur.

13 Project: Stock Revision 1 Page 13 The DIS PRS DB, INC RPM, DEC RPM (Login Access Level 4), and UPDATE(ms) (Login Access Level 3) parameters can be adjusted from the SPD CTRL-DIS setpoint screen. The current Auto Mode (SUCTION/DISCHARGE) is also displayed on this screen. The MAINT DIS setting can be adjusted from the SPEED CONTROL front display screen (Login Access Level 5). 4.2 Automatic Bypass Valve Control The lowest output signal from either the Suction or Discharge Bypass PID is sent to the Bypass Control output Suction If the Suction Pressure is above the MAINT SUC + SUC PRS DB (deadband), the Bypass control will increase (closing valve) in an attempt to reduce the pressure. If the Suction Pressure is below the MAINT SUC - SUC PRS DB, the Bypass control will decrease (opening valve). When the Suction Pressure is within the deadband of the pressure setpoint no output change will occur. The MAINT SUC setting can be adjusted from the BYPASS CONTROL front display screen (Login Access Level 5). The BYP CTRL-SUC setpoint screen contains the following parameters and displays: SUC PRS DB: Deadband - No output change when pressure is within the range of MAINT SUC +/- SUC PRS DB. (Login Access Level 4) PROP COEF: Proportional Coefficient * (Login Access Level 3) INT COEF: Integral Coefficient * (Login Access Level 3) DERV COEF: Derivative Coefficient * (Login Access Level 3) PID UPDATE(ms): Update * - (Login Access Level 3) P I D Display of the Proportional / Integral / Derivative weights. E LE Display of the PID error / Last PID error. BYPASS OUT: Display of Bypass output percentage. S1 SUC PRS: Display of the current Suction Pressure. AUTO MODE: Display of the current loop in control of the valve (Suction/Discharge). * Refer to Appendix B for detailed descriptions.

14 Project: Stock Revision 1 Page Gain Multiplier If the Suction Pressure falls below the SUC BYP THR (suction bypass threshold) setting it may be due to a condition where the Bypass Valve cannot react fast enough to avoid a low-pressure shutdown ( pigging for example). An additional gain multiplier (BYP GAIN MULT) is used to open the valve faster when the pressure is below this threshold. The SUC BYP THR, and BYP GAIN MULT settings can be adjusted from the MISC SETTINGS setpoint screen (Login Access Level 3) Discharge If the Discharge Pressure rises above the MAINT DISC + DIS PRS DB, the Bypass control will decrease (opening valve) in an attempt to reduce the pressure. If the Discharge Pressure is below the MAINT DIS - DIS PRS DB, the Bypass control will increase (closing valve). When the Discharge Pressure is within the deadband of the pressure setpoint no output change will occur. The MAINT DIS setting can be adjusted from the BYPASS CONTROL front display screen (Login Access Level 5). The BYP CTRL-DIS setpoint screen contains the following parameters and displays: DIS PRS DB: Deadband - No output change when pressure is within the range of MAINT DIS +/- DIS PRS DB. (Login Access Level 4) PROP COEF: Proportional Coefficient * (Login Access Level 3) INT COEF: Integral Coefficient * (Login Access Level 3) DERV COEF: Derivative Coefficient * (Login Access Level 3) PID UPDATE(ms): Update * - (Login Access Level 3) P I D Display of the Proportional / Integral / Derivative weights. E LE Display of the PID error / Last PID error. BYPASS OUT: Display of Bypass output percentage. DIS PRS: Display of the current Discharge Pressure. AUTO MODE: Display of the current loop in control of the valve (Suction/Discharge). * Refer to Appendix B for detailed descriptions.

15 Project: Stock Revision 1 Page Automatic Suction Control The MC controller will control the Suction Valve output based on a pressure setpoint. If the suction pressure is above the setpoint, the valve will close. If the suction pressure is below the setpoint, the valve will open. When the Suction Pressure is within the deadband of the pressure setpoint, no output change will occur. When the unit is in AUTO and at a STANDBY condition, the Suction Pressure will be controlled to the START PRS setting. This setting is lower than the normal loaded Suction Pressure. This will ensure that a minimum load is applied during the engine start sequence. Fifteen seconds after the CRANK DIS RPM has been reached, the Suction Pressure setpoint will start ramping to the MAINT SUC setpoint using two settings: suction step pressure (SUC STEP P) and start ramp time (ST RAMP TIME). The suction step pressure is the amount of pressure increase that will be added to the current suction pressure setpoint. This increase will occur every time the start ramp time expires. The pressure will be controlled to the MAINT SUC PRS until the unit is stopped manually or a shutdown occurs. When a shutdown occurs the Suction Valve will close completely to 0%, until the condition is reset. The control will then restart using the START PRS setting. The MAINT SUC, and START PRS settings can be adjusted from the SUCTION CONTROL front display screen (Login Access Level 5). The SUCTION CNTL setpoint screen contains the following parameters, and displays: SUC PRS DB: Deadband - No output change when pressure is within the range of MAINT SUC +/- SUC PRS DB. (Login Access Level 4) PROP COEF: Proportional Coefficient * (Login Access Level 3) INT COEF: Integral Coefficient * (Login Access Level 3) DERV COEF: Derivative Coefficient * (Login Access Level 3) PID UPDATE(ms): Update * - (Login Access Level 3) P I D Display of the Proportional / Integral / Derivative weights. E LE Display of the PID error / Last PID error. SUCTION OUT: Display of Suction output percentage. S1 SUC PRS: Display of the current Suction Pressure. SUC STEP P: Setpoint ramp step size. (Login Access Level 3) ST RAMP TIME: Time between setpoint ramp steps. (Login Access Level 3) * Refer to Appendix B for detailed descriptions.

16 Project: Stock Revision 1 Page Controlled Unload A controlled unload can be initiated from the Home front display screen. The Bypass Valve will start ramping open to 0% using the manual output settings. The Speed control will remain in its current position until the Bypass Valve is open to the BYP P THR DWN position (bypass position for throttle down). The Speed control will then start decreasing to MIN RPM using the manual DEC RPM settings. When the Bypass Valve is at 0% and the Speed output is at MIN RPM, the Speed output will be reduced to the IDLE RPM. The unit will run in this position until a reload, or a stop is initiated. When a stop is requested, the controller will reduce the RPM to the Warmup RPM setting. The Cooldown Timer will start and the controller will initiate a stop after the timer expires. The BYP P THR DWN setting can be adjusted from the MISC SETTINGS setpoint screen (Login Access Level 3). 4.5 Blowdown Valve Control The MC controller is equipped with automatic blowdown logic. If the Suction Pressure is above the BD VLV OPEN setpoint, the Blowdown Valve output will deenergize to open the valve, and reduce the pressure. When the Suction Pressure falls below the BD VLV CLS setpoint the Blowdown Valve output will energize to close the valve. The logic is only active when the MC is in the STANDBY or SHUTDOWN condition. If the unit is started while in the BLOWDOWN state, the relay will energize, and the start sequence will begin. The BD VLV OPEN/CLS settings can be adjusted from the MISC SETTINGS setpoint screen (Login Access Level 3). 5. COMPRESSOR ROD LOAD CALCUATIONS Compressor stage differential pressure alarm/shutdown calculations are based on the specific cylinder characteristic curves. The rod-loading calculations are based on the compressor suction and discharge pressures, in conjunction with a Rod-Loading formula. When doing calculations for stage 2, and stage 3 (as applicable) the previous stages discharge value will be used as the setpoint value for PS.

17 Project: Stock Revision 1 Page LOW CLASS P DISCHARGE LOGIC Low class P discharge logic is provided for each compressor discharge stage. A CLASS P Timer will start once the Bypass Valve reaches the BYP POS P LK preset position. The Class P functions are armed once the CLASS P Timer expires. The shutdown will disarm when the Bypass Valve position falls below the BYP POS P LK preset position. The CLASS P Timer, and BYP POS P LK setting can be adjusted from the TIMERS setpoint screen (Login Access Level 3).

18 Project: Stock Revision 1 Page MISCELLANEOUS 7.1 Password Protection The parameters that are adjustable from the screens are grouped into different access levels. A login code is required to access each level. Login level (5) is the default level. The Login entry is located in the SETUP MENU screen. To Login with a higherlevel code, the cursor must be placed on the Login line, and then the SETUP ENTER key must be pressed. The cursor will move over the zero displayed on the right side of that line. A level pass-code can now be entered. There are four access levels ranging from level (4), the lowest privilege level up to level (1), the highest privilege level. Level (1) - called the Administrator level. Complete access. The Project, and or Application can be deleted, outputs can be forced off and on, a Remote Debugger can be run, the administrator menu is available, and the real time clock can be set. Level (2) access to input calibrations, and SERVICE MODE forcing of outputs. Level (3) access to settings that could cause improper operation of the machine. Level (4) - access to settings that will not cause improper operation of the machinery. All login levels have a common timer that starts to count down after each key press. If there are no key presses for the length of the Inactive/AutoLogout Delay, then the Login level will revert to the base Login level (5).

19 Project: Stock Revision 1 Page Verify Discrete Input / Outputs The open (0) or closed (X) status of each discrete input, and the off (0) or on (X) status of each discrete output can be viewed from the HMI INPUTS front display screen. 7.3 Service Mode The unit is equipped with a SERVICE MODE. The technician can use this mode to force relay outputs and analog outputs to ensure proper operation of connected devices. When the unit is in a STANDBY or SHUTDOWN state press the FN key, confirm Fn Key Activated is displayed, and then press the TEST key. When the timeout expires the unit will switch back to STANDBY or SHUTDOWN mode. All relay outputs will turn off when in the SERVICE MODE. When the service mode is exited normal panel operation will start. Login level (2) is required to enter this mode. Note: The ESD relay will be de-energized when in the SERVICE MODE. 7.4 Test Mode The unit is equipped with a TEST mode for testing discrete input functionality. Analog values are not normally tested, due to the ability to read the actual value of the parameter. Pressing the TEST key activates the TEST mode. The preferred display page is D-3 as the test timer and status can be observed. When a switch is faulted, a 4-line alarm message will appear. No parameters are logged in the snapshot page or the EVENT history. 7.5 Run Time Hours The engine Run Time Hours can be viewed from the HMI HOME screen. Run Time Hours can be reset on the RPM SETTINGS setpoint screen. 7.6 Speed Output Actuator Adjustments The THR OUT MIN, and THR OUT MAX settings can be used to match the controller output to the resulting engine speed. The THR OUT MIN is the RPM value when 4mA is applied, and the THR OUT MAX is the RPM value when 20mA is applied. Some extrapolation may be required if 4mA is lower than the actual minimum speed output, or if maximum speed is achieved with less than 20mA. The THR OUT MIN, and THR OUT MAX settings can be adjusted from the MISC CAL setpoint screen (Login Access Level 2).

20 Project: Stock Revision 1 Page MODBUS COMMUNICATIONS This panel will be provided with MODBUS functionality. The following points will be available for read-only access: All Analog Input Readings All Analog Output Values (percent) Speed Output (RPM) Reading All Thermocouple Input Readings All Discrete Input Open/Closed Status All Discrete Output On/Off Status Engine Run Time Hours Alarm and Shutdown Event Codes The following points will be available for read/write access: Remote Start Remote Stop Remote Reset Remote Engine Maximum Load Speed Setpoint Remote PID Control Setpoints Load / Unload Alarm / Shutdown setpoints Note: A complete address list will be provided in the Event List and Modbus Map document for this project. 8.1 Local / Remote Mode The Local and Remote Stop, Start and Reset commands are active at all times.

21 Project: Stock Revision 1 Page 21 APPENDIX A Input/Output List See project I/O list provided separately. APPENDIX B Definitions Table B-1: Alarm/Shutdown Classification, and PID Definitions Class Class A Class B1 Class B2 Class C Class P Prop Coef Int Coef Derv Coef PID Update (ms) Description Class A alarm/shutdown functions are always enabled. All Class A shutdowns must be cleared before the unit can be started. Examples: Engine Oil Level, Cylinder Discharge Temperature Class B1 alarm/shutdown functions are disabled until the B1 Timer expires. Examples: Low Comp Oil Pressure Class B2 alarm/shutdown functions are disabled until the B2 Timer expires. Examples: Compressor Rod Reversal Class C alarm/shutdown functions are disabled until the unit is running. Class C functions are then individually monitored. When a Class C function becomes healthy it is enabled, and will cause an alarm/shutdown if it then goes unhealthy. Class P alarm/shutdown are armed once the bypass valve reaches a preset position and a P timer expires. The shutdown will disarm when the bypass valve position falls below the preset position. The Proportional coefficient for the PID loop. This is a multiplier for the error (PV minus setpoint) and will determine how the error will directly affect the amount of change in output. Too low a number here will result in sluggish action of the PID loop. Too high a number here will result in overshoot and oscillation of the PID loop. The Integral coefficient for the PID loop. This is a multiplier for the amount of time the error (PV minus setpoint) has been above or below setpoint. The more time that passes before the loop reaches its setpoint, will directly affect the amount of change in output. Use this number to balance out overshoot caused by the Proportional part of the PID loop. Too low a number here will take out the Integral part of control of the PID loop. Too high a number here will result in oscillation of the PID loop. The Derivative coefficient for the PID loop. This is a multiplier for how fast the error (PV minus setpoint) is changing. The faster the PV or setpoint changes will directly affect the amount of change in output. Use this number to catch spikes in pressure. Too low a number here will take out the Derivative part of control of the PID loop. Too high a number here will result in oscillation of the PID loop. Set the delay in milliseconds for the PID loop calculation to allow the PV readings to update and stabilize to the changing conditions caused by the PID loop. Too fast an update time will result in oscillation of the PID loop. Too slow an update time will result in a sluggish PID loop.

22 Project: Stock Revision 1 Page 22 PLEASE APPROVE AND RETURN. Comments: Approved by: Approval date: END DOCUMENT