Emerson VISSION 20/20 manual

1 Control P anel Operation and Ser vice Manual[...]

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3 Impor tant Note Befor e applying po wer to the control pane l, all wiring to the panel should be per NEC. Specifically check for proper voltage and th at the neutr al is grounded at the source . An equipment ground should also be run to the panel. *See Wiring Instruc tions and Di agrams bef ore proceeding. Before start-up y ou need to enter all s[...]

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5 T able of Contents Impor tant Note ........................................................................................... 3 Standard Vilter W arranty ............................................................................ 7 Operational Flo w Char ts .............................................................................. 9 Install[...]

6 Digital & Analog Boards ............................................................................. 66 Digital Outpu t #1 .................................................................................. 67 Digital Outpu t #2 .................................................................................. 68 Digital Input ...............[...]

7 Standard Vilter W arranty Seller warrants the p roduc ts it manufac tures to be f ree from defects i n material and workmanship for a period of eight een (18) months from the date of shipme nt from Seller’s manu facturing plant or t welve (12) months from date of ins tallation at the initial end users location, whichev er occurs first. In addit[...]

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9 Operational Flo w Char ts[...]

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1 1 Installation Rec ommendations Proper Wire Si zing • As a minimum, always siz e wire gauges a s specified b y the National Electrical Code (NE C) for electronic con- trol devic es. • For impro ved noise immunit y , inst all one size l arger wire g auge than the NE C requirement t o assure ample curren t -carr ying capabilit y • Ne[...]

12 V oltage Source • Connecting the Vilter Vission 20/20 to breake r panels and centr al control transforme rs exposes the Vission 20/20 to large amounts of electromagnetic inte r fere nce (EMI) emitted from the other devices connected to the second ar y terminals of the tr ansformer . This prac tice should be av oided if possible.[...]

13 Grounding • Continuou s grounds must be run from the po wer c ompany gr ound to the Vission 20/20. • Grounds must be c opper or aluminum wire . • Neve r use c onduit grounds.[...]

14 Mixing V oltages • Separ ate diff eren t voltagesfrom e ach othe r and separate A C from DC. • Each voltage lev el mu st be run in separa te conduit: • 460 V AC • 230 V AC • 120 V AC • 24 V AC • DC signals • If your pl ant ha s wire-ways or conduit tr ays, dividers mu st be installed bet ween the diff ere [...]

15 Wiring Methods • Don’t “D aisy-Chain ” contr ol powe r for Vission 20/20 pane ls.[...]

16 DO: • K eep AC wires aw ay from circ uit boards. • Alwa ys run conduit into the bott om or sides of an enclosure . • If the conduit must be placed in the top of an enclosure , use a water -tight conduit fit - ting to k eep water from ent ering the enclosure . • The Vission 20/20 is supplied with pre -punched conduit holes. Us[...]

17 Vission 20/20 Architecture The Vission 20/20 contr ol panel utili zes X -86 PC technology with a Linux Operating syste m. The V ission 20/20 has the f ollowing attributes : • Low pow er , Industri al rated X -86 CPU. • 15” XGA , high resolution L CD display . (Outdoor viewable L CD optional). • 8-wire touch scree n opera tor int[...]

18 BO ARD I/O # DESCRIPTION T YPE # 1 1 Compressor S t ar t OUTPUT 1 2 Oil Pump Start OUTPUT 1 3 Capacity Increase OUTPUT 1 4 Capacity Decrease OUTPUT 1 5 V olume Increase OUTPUT 1 6 V olume Decrease O UTPUT 1 7 Oil Sump Heate r OUTPUT 1 8 Alarm OUTPUT 2 9 Slide V alve Set point #1 (E conomiz er) OUTPUT 2 10 Slide V alve Set point #2 (Ho t Gas) OUT[...]

19 CAP ACITY INCREASE OUTPUT – This output is only ac tive when the c ompressor is running. Whe n the Vission 20/20 dete rmines that the c ompressor should incre ase capac it y by moving the sli de valve to a highe r perc ent - age, this o utput is ene rgiz ed. Once the slide valv e reache s 100%, this output will not e nergiz e. CAP ACITY DE CRE[...]

20 VRS OIL SOLENOID OUTPUT – U sed in VR S retrofit applica tions where an oil sole noid is installed in the oil line. COMP M OT OR ST ARTER AUXILIAR Y CONT ACT – This input looks for a feedback sign al from the compres sor star ter , confirming th at the compre ssor star ter is e nergiz ed. HIGH LEVEL SHUTDO WN INPUT – This input must be e n[...]

21 BO ARD I/O DESCRIPTION T YPE # 6 1 Motor C urrent 4-20 mA, 0-5A 6 2 Suction Pressure 0-5V , 1-5 V , 0-10V , 4-20 mA 6 3 Dischar ge Pressure 0-5V , 1-5 V , 0-10V , 4-20 mA 6 4 Oil Filter Pres sure 0-5V , 1-5 V , 0-10V , 4-20 mA 6 5 Oil Manif old Pressure 0-5V , 1-5 V , 0-10V , 4-20 mA 6 6 VRS Oil Injection Pressure 0-5V , 1-5 V , 0-10V , 4-20 mA [...]

22 OIL MANIFOLD P RESSURE - Defa ult signal is 4-20Ma. Oil mani fold pres sure transduce r range and calibration is set in the calibration scree n. VRS OIL INJE CTION PRESSURE – Default sign al is 4-20Ma. VR S oil injection pressure transduce r range and calibra - tion is set in the calibration s creen. % SLIDE V AL VE POSI TION – R eads the 0-[...]

23 BO ARD I/O # DESCRIPTION TYPE # 10 1 Compressor VFD 4-20 mA 10 2 Condens er VFD 4-20 mA 10 3 % Slide V alve Positi on 4-20 mA 10 4 Motoriz ed Valv e (Cool Compression or Liqui d Injection), V+ 4-20 mA 10 5 Profile Coole r VFD (Profile only) 4-20 mA 10 6 10 7 10 8 COMP RESSOR VFD – 4-20mA outpu t to contr ol compressor mo tor speed with a V ari[...]

24 Main Screen The main screen gives the operator an ove rall view of operating parameters affecting the compressor package. This screen is display ed when mainten ance items and set -points items are not being per formed. The data on the screen is c ontinuously upd ated. Menu Butt on Navig ates t o the menu scree n for the f ollowing selections: ?[...]

25 L OG ON BUT TON Navig ates to the log on scree n which allo ws the ope rator t o ha ve acc ess t o system set -points, based on his le vel of security . LANGU AGE BUTTON Selects the prefe rred language f or all screens. HELP BUTTON Provide s help file not es for v arious screens and s ettings. STOP BUTTON Stop s the compres sor . ALARM RESET BUT[...]

26 COMP RESSOR CONTR OL - Na vigat es to the c ompressor contr ol screen where the ope rator can set the variou scom - pressor c ontrol parame ters. ALARMS AND TRIPS - Naviga tes to the alarms and trips screen w here the operator can set the various alarm and trip paramete r s. TIMERS - Navig ates to the time r screen where the ope rator can set th[...]

27 SLIDE CALIBRA TION - Navig ates to the slide calibration screen where the operat or can calibrate the slide and volume actuators. TREND CHART - Navig ates to the tre nd ch ar t screen where the operat or can select up to four paramete r s for histori- cal data trend ing. T rend c har ts are updat ed continuou sly . EVEN T LI ST - N avi ga te s t[...]

28 This screen allo ws the operat or to view and adjust s ettings tha t affect compres sor capacity control. COMPRESS OR CONTROL • Pressure/T empera ture contr ol setpoints • Auto-c ycle c ontrol points • VFD contr ol set -points • Pump -down con trol setpoin ts • Pull-down control s etpoints The Vision 20/20 comes preconfi[...]

29 TIME PROPORTIONING CONTR OL Assume tha t Suction Press ure is the se lected param ete r to co ntr ol c ompre sso r cap acity . Time pro portionin g co ntr ol is the method used t o control the c ompressor slide valve positi on in response to a se tpoint. The setpoints are ; • Pressure Con trol Setpoint (This is the targe t set -point.) •?[...]

30 • 3.5 second pulse = suction pressure is in the propor tional band regi on and is > 70% and < 80% from the dead- band region. • 4 second pulse = suction pressure is in the proportional band region and is > 80% and < 90% from the dead- band region. • 4.5 second pulse = suc tion pressure is in the propor tional band regi[...]

31 OTHER SETPOINTS THA T MIGHT BE REQUIRED FOR MO TOR PID CONTR OL • Max Change Rate = The VFD motor PID output is limited by this paramete r to preven t large instantaneous change s to the motor speed . • Dead-band = used to establish a range on eithe r side of the set -point in which no capacity con trol action will occur . Initial Se t[...]

32 (For F uture Sof t ware Re leases) Pump -down • The Pump -down set -points define a method of “pumping” down a chiller , which is to draw off refrigerant from the chiller . The purpose is to preve nt liquid refrige rant from dev eloping in the chiller during an off cycle , and then being drawn into the compressor when it restar ts. This[...]

33 • Stop Delay = delays the compressor from s topping when the suc tion pressure is equal to or less than the stop pressure . • Minimum Slide Position = The minimum capacity slide position that the c ompressor is allo wed to r un at. By forc ing the compressor capac it y to operate a t a value above minimum, we insure tha t the suc tion [...]

34 Misc. Control • Control Mode = Drop-down bo x allow s selection of current operating mode, from the list of allowable modes. • High Motor Amps (Unloading) = This contr ol fea ture will limit the c ompressor capacity whe n the c ompressor motor amps re aches these load limiting set -points. When the set -points are set properly , this c[...]

35 • Sto p Load = pre ven ts the compre ssor from loading whe n the set -point is re ached. Set this set -point abov e nor ma l di sc har ge op er at ing con dit ion s. This set -po int shoul d on ly beco me activ e if nor ma l c ond en se r con trol is not functioning properly , which will cause disc harge pre ssure to become abnorm ally high[...]

36 • Current T ransformer Ratio : The value ente red must agree with the Curren t T ransforme r Ratio label on the curren t transformer being used. The current transformer is mounted in the compress or motor conduit box. The r atio is stated in te rms o f “Primary amps : Second ar y amps ”. The secondary value is always “5” amps. The p[...]

37 This screen allo ws the operat or to view and adjust s ettings f or compres sor safety and alarm settings. Alarms and T r ips defined are : • Low Suction Pressure set -points • High Dischar ge Pressure set -points • High Proce ss T e mperature s et -points • Low Proc ess T empera ture set -points • Low Suction T empe rat[...]

38 • Low Suction Pressure Alarm and T rip = This is the low suction pressure safe t y . This safety is active in both tempe rature and pressure control modes. An alarm or tr ip will be ac tive on a drop in suction pressure at or below the s et -point value. • High Disc harge Pressure Alarm and T rip = This is the high dischar ge pres sure[...]

39 • Low Suction T emperature = This is the low suction tempe rature safety . The alarm or tr ip will be ac tive if the suction temper ature should drop to a value th at is at or be low the set -point value . • High Discharge T emperature : This is the high dischar ge tempe rature safe t y . The alarm or trip will be ac tive if the disch [...]

40 Pre-lube Oi l Pressure = This is the pre-lube oil pump failure saf ety. If the pre-lube oil pre ssure does not rise abov e the alarm setting f or a time exc eeding the Minimum Pre-lube Time and the pump run runs longer than the Pre-lube Pump Time Limit, an alarm or trip will occur . These time limits are set on the Time r menu scree n. Pre- lube[...]

41 This screen allo ws the operat or to view and adjust time r settings assoc iated with c ompressor operation. Timers defined are : • Capacity Increase S tar t Delay • Minimum Compressor Pr e lube Time • Low Oil Pressur e Safety Changeo ver • High Filter Diff erenti al Pressure Saf ety Changeov er • Low Oil Se parator Le v[...]

42 • Low Oil Pressure Safet y Changeov er = This is the length of time in which the normal Low (Run) Oil Pressure set -points will be mas saged by the values of the Pre lube Oil Pressure set -points. Af ter the timer has expired, the normal Low Oil Pre ssure set -points become active . • High Filter Differential Pressure Safet y Changeove[...]

43 • T rue Anti-R ec yc le Timer = Once the compre ssor turns off , this timer will ke ep the compre ssor o ff for the settin g of the T rue Anti -Recycle Time r . This timer is used t o preve nt short c ycling of the c ompressor . • Accumulativ e Anti-Recycle Tim er = This timer also f orces a specified time bet ween compress or star ts.[...]

44 This screen allo ws the operat or to forc e digital outputs ON for di agnostic purpose s. If yo u choo se to exit this menu while an output is still for ced on, the output will be “unf orc ed” be fore the menu exits. Note : The forc ing of the compressor output will be limited to a “bump” for the purposes of dete rmining motor rotation d[...]

45 Instrument Calibration[...]

46 Vilte r Slide V alve A ctuator C alibration Procedure for Opti cal Style Mot ors Assuming that the ACTUA T OR motors hav e not been calibrated, the transmitter output of the ACTUA TOR motor will fluctuat e wildly until they are calibra ted. T o prev ent d amage to A C TUA T OR motors, do no t c onnect the P owe r Cable (Y ellow TURCK cable) or t[...]

47 button in the ce nter of the photo chopper to release the brake , and thereby release the tension on the ac tuator motor . Then use the “+” button to pulse the mo tor so that the capacity slide is “just off” of its minimum position and there is no te nsion on the motor shaft. 7. Quickly press and re l ea se the BLUE CALIBRA TION BUT TON [...]

48 NO TES: The manual operating shaft on the gear motor should be turned the opposite direction of the desired comm and shaft rotation. The capacity and volume control motors are equipped with a brake , if it is necessar y to opera te the con trol mo tors manu ally , the brak e must be dise ngaged. The brake can be dise ngaged by p ushing on the mo[...]

49 Slide V alve Operation The slide valve actuat or is a gear -motor with a po si- tion sensor . The motor is powered in the for ward and reverse directions from the main comput er in the con trol pane l. The position se nsor te lls the main comput er the position of the slide valve . The main co mput er uses the posit ion and proc ess inf orm atio[...]

50 The ac tuat or cannot be cali- brat ed The a c tu ato r g oe s in to cali - bration m ode spo ntan eou sly Th e act ua to r g oe s in to c al ib ra- tio n mod e eve r y tim e po we r is restored a f te r a powe r los s Dir t or debris is blocking one or both opt ocouple r slots The photochoppe r fence ex tends less than about half way into the o[...]

51 T h e m ot o r w as m a n ua l l y m o ve d while the position sensor was n ot powe red. The motor brake is not working properly The position sensor’s EEPROM memory has failed The photochopper is misaligned with the slotted op tocouple rs The pho toch opp er is posi tio ned too low on the mot or shaft. A motor be aring has f ailed There is a l[...]

52 Bad therm al switch Any of the reasons listed in “The m o t o r w i l l n o t m o ve i n ei t h e r direction” St r i p p e d ge a r s i n s i d e t h e ge a r motor or the arm ature has come un - pr e ss e d f ro m th e a r ma tu r e shaft Re place the actuator . See abov e. Re place the actuator . The mo tor runs s poradic ally Th e mo t o[...]

53 This screen allo ws the operat or to view and adjust s ettings f or the trend ch ar t. The tre nd ana lysis scre en sho ws rec orded data for proble m analy sis or tuning impro ve men ts. A loggin g buff er holds 30 minute s of data f or 13 vari ables sampled at 10 sec ond intervals. Whe n the logging buffe r fills with 30 minute s of data, it i[...]

54 This scree n is designed t o displ ay c ompressor ev ents, in chronological or der and time stamped. The top o f the list shows the most rec en t eve nt follo wed by olde r events. E vent List Screen[...]

55 This screen allows showing of “Live Data” of all analog points and digital points being monitored, or of “Fr oze n Data ”. F roz en data is a snapsho t of the values of the analog points and digital points at the time in which the c om- pressor last shutdown, eithe r by normal shut down me thods or vi a a f ault condition. The Live D ata[...]

56 Configuration Screens[...]

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59 MA Log on and check off e ach item as c ompleted at the listed service inte r val. Maintenanc e Screen[...]

60 This menu allo ws the operat or to assign u ser acc ounts. The 20/20 will be shipped with a Lev el 3 ope rator and passw ord pre-assigned to the installing c ontractor . He can then assi gn all lower le ve l securities as needed. The procedure t o assign acc ess lev els is to first press the logon butt on. The logon screen will appe ar with the [...]

61 Screen to Add U sers[...]

62 Lev el 1 View Only No pa ssword as socia ted with this leve l Lev el 2 Operat or Leve l Limited acc ess Lev el 3 F ull Acces s Super visor Page Use r Lev el Note E ven t list Lev el 1 Input/output state s Leve l 1 T rend c hart Level 1 Slide calibration Level 3 Instrument calibra tion Lev el 3 Service options Leve l 3 Condens er con trol Lev el [...]

63 Suction Pressure SP#1 F ail - This mes sage wi ll appe ar when the suction pressure falls be low the sa fety se tting o f the Low Suc tion Pres- sure T rip Setp oint No.1. In addi tion, this mess age will appear when the suction pre ssure read ing rise s abo ve 300 PSI, indicating an ope n transduce r or bad analog channel. Suction Pressure SP#2[...]

64 Low S tart Oil Pressure Fail – This me ssage will appear with the Prelub Oil Pressure (Manifold minus Discharge) has remained below the Prelub Oil Pressure Reset setpoint. The Prelub Oil Pressure must be above the Prelub Oil Pressure for a time period of the Minimum Compressor Prelub time . It will continue to tr y to do this for a time period[...]

65 Vission 20/20 T roubl eshooting Guide Before applying power to the V ission 20/20 control panel, all wiring to the panel should be per the National Electrical Code (NEC). Specifically check for proper voltage and that the n eutral is grounded at th e source. An equipment ground should also be run to the panel. In the eve nt of a problem with the[...]

66 The illustration above shows the position and t y pe of the digital and analog input/output (I/O) boards. It is im - por tant to install the bo ards a s shown in this illustration and configure them as show in the f ollowing illu strations. DIPSWIT CHES Each board has a dipswitch which sets its communications address so that it can communicate w[...]

67 Digital Outpu t #1 DIPSWIT CH POSITION 4 Open (right) 3 Open (right) 2 Open (right) 1 Closed (le f t)[...]

68 Digital Outpu t #2 DIPSWIT CH POSITION 4 Open (right) 3 Open (right) 2 Closed (le f t) 1 Open (right)[...]

69 Digital Input DIPSWIT CH POSITION 4 Open (right) 3 Open (right) 2 Closed (le f t) 1 Closed (le f t)[...]

70 Digital Input/O utput #1 DIPSWIT CH POSITION 4 Open (right) 3 Closed (le f t) 2 Open (right) 1 Open (right)[...]

71 Digital Input/O utput #2 DIPSWIT CH POSITION 4 Open (right) 3 Closed (le f t) 2 Open (right) 1 Closed (le f t)[...]

72 Analog Input #1 DIPSWIT CH POSITION 4 Open (right) 3 Closed (le f t) 2 Closed (le f t) 1 Open (right) JUMPER POS ITION JP-1 ON JP-4 ON JP-7 ON JP-10 ON JP-13 ON JP-16 ON JP-25 PO SITION-1 JP-26 PO SITION-1 JP-35 ON[...]

73 Analog Input #2 DIPSWIT CH POSITION 4 Open (right) 3 Closed (le f t) 2 Closed (le f t) 1 Closed (le f t) JUMPER POS ITION JP-16 ON JP-19 ON JP-22 ON JP-27 ON JP-28 ON JP-29 ON JP-30 ON JP-31 ON[...]

74 Analog Input #3 DIPSWIT CH POSITION 4 Closed (le f t) 3 Open (right) 2 Open (right) 1 Open (right) JUMPER POS ITION JP-1 ON JP-25 PO SITION-2 JP-26 PO SITION-2 JP-28 ON JP-29 ON JP-30 ON JP-31 ON[...]

75 Analog Input #4 DIPSWIT CH POSITION 4 Closed (le f t) 3 Open (right) 2 Open (right) 1 Closed (le f t) JUMPER POS ITION JP-25 PO SITION-2 JP-26 PO SITION-2 JP-31 ON JP-32 ON JP-33 ON JP-34 ON[...]

76 Analog Output DIPSWIT CH POSITION 4 Closed (le f t) 3 Open (right) 2 Closed (le f t) 1 Open (right)[...]

77 CHANNEL #1 SIGNAL JP-1 JP-2 JP-3 JP-27 JP -35 NO TE S Analog Input 1-A 0-5 AMP OUT OUT OUT OUT IN An alog 1-A For C urrent Analog Input 1-B 0-5 V olt OUT OUT OUT OUT OUT T ransf ormers 1-5 V olt OUT OU T OUT OU T OUT Onl y . 0-10 V olt OUT OUT IN OUT OUT 4-20 mA IN OUT OU T OUT OU T ICTD OUT IN OUT OUT OUT RTD OUT OUT OU T IN OUT CHANNEL #2 SIGN[...]

78 CHANNEL #6 SIGNAL JP-16 JP -17 JP18 JP-32 Analog Input 6 0-5 V olt OUT OUT OUT OU T 1-5 V olt OUT OU T OUT OU T 0-10 V olt OUT OUT IN OUT 4-20 mA IN OUT OU T OUT ICTD OUT IN OUT OUT RTD OUT OUT OU T IN CHANNEL #7 SIGNAL JP-19 JP -20 JP-21 JP-33 JP-25 Analog Input 7 0-5 V olt OUT OUT OUT OU T 2 1-5 V olt OUT OU T OUT OU T 2 0-10 V olt OUT OUT IN [...]

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80 Vilter Manufacturing LLC ar e trademarks of Emerson Electric Co. or one of its a ffi liated companie s. ©2010 Emerson Climate T echnoligies, Inc. All rights rese rved. Printed in the USA. 35391SC Rev 2.00 Vilter Manufacturing LLC P .O. Box 8904 Cudahy , WI 53110-8904 P 414 744 0111 F 414 744 1769 www .vilter .com EmersonClimate .com[...]