Emerson VSG User manual

VSG/VSSG compact logix PLC
Operation manual
FOR UNITS BUILT BEFORE JULY 1, 2013

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Important Note
Before applying power to the control panel, all wiring to the panel shall be installed per NEC. Specifically
check for proper voltage and that the neutral is grounded at the source. An equipment ground should also
be run to the panel.
*See Wiring Instructions and Diagrams before proceeding.
NOTES:
• Before start-up you need to enter all system values and options, see section on Setpoint Values.
• Power circuits entry on left side of enclosure
• Instrument circuits entry on right side of enclosure
Electrical installation shall be completed by a licensed electrician qualified in field wiring
located in Class 1 Div 2 Hazardous Locations per the National Electric Code (NEC).

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Important Note ................................................................................................. 3
VSG/VSSG STANDARD VILTER WARRANTY STATEMENT...................................... 6
Operational Flow Charts .................................................................................... 7
Main Screen..................................................................................................... 15
Log On Screen ................................................................................................. 16
Set Up Screen .................................................................................................. 17
Vilter Only Screen............................................................................................ 19
Menu Screen ................................................................................................... 20
Compressor Alarm and Trip ............................................................................. 24
Compressor Timer Setpoints ........................................................................... 26
Compressor Control Setpoints......................................................................... 28
Additional Compressor Controls...................................................................... 33
Compressor Setpoints and Alarms................................................................... 34
Motor Speed Setpoints & Control Screen ......................................................... 36
Diagnostics Force Output ................................................................................ 38
Instrument Calibration .................................................................................... 39
Oil Mixing Valve............................................................................................... 45
Unit Start Screen (Start / Stop Logic)................................................................ 48
Device Names.................................................................................................. 51
Calibration Procedure of Optical Actuators...................................................... 52
Calibration Procedure of Optical Actuators...................................................... 53
Calibration Procedure of Optical Actuators...................................................... 54
Installation Instructions For Replacement Of Optical Actuator ......................... 56
Slide Valve Actuator Theory of Operation ........................................................ 57
Slide Valve Actuator Troubleshooting Guide .................................................... 58
Command Shaft Rotation and Travel................................................................ 60
Safety Failure Message .................................................................................... 62
Version Screen................................................................................................. 65
Trend Charts.................................................................................................... 66
Captured Data at Shutdown ............................................................................ 69
Table of Contents

6VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
VSG/VSSG STANDARD VILTER WARRANTY STATEMENT
Seller warrants all new single screw gas compression units and bareshaft single screw compressors
manufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a period
of (a) eighteen (18) months from the date of shipment or (b) twelve (12) months from the date of
installation at the end user’s location, whichever occurs first.
If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product
shall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation
and Buyer’s exclusive remedy hereunder and shall be conditioned upon (a) Seller’s receiving written notice
of any alleged defect within ten (10) days after its discovery, (b) payment in full of all amounts owed by
Buyer to Seller and (c) at Seller’s option, Buyer shall have delivered such products to Seller, all expenses
prepaid to its factory. Expenses incurred by Buyer in repairing or replacing any defective product
(including, without limitation, labor, lost refrigerant or gas and freight costs) will not be allowed except by
written permission of Seller. Further, Seller shall not be liable for any other direct, indirect, consequential,
incidental, or special damages arising out of a breach of warranty.
This warranty is only applicable to products properly maintained and used according to Seller’s
instructions. This warranty does not apply (i) to ordinary wear and tear, damage caused by corrosion,
misuse, overloading, neglect, improper use or operation (including, without limitation, operation beyond
rated capacity), substitution of parts not approved by Seller, accident or alteration, as determined by Seller
or (ii) if the product is operated on a gas with an H2S level above 100 PPM. In addition, Seller does not
warrant that any equipment and features meet the requirements of any local, state or federal laws or
regulations. Products supplied by Seller hereunder which are manufactured by someone else are not
warranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products
that Seller may have from the original manufacturer. Labor and expenses for repair are not covered by
warranty.
THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND
WARRANTIES, EXPRESS OR IMPLIED, AND SELLER EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Any description of the products, whether in writing or made orally by Seller or Seller’s agents,
specifications, samples, models, bulletins, drawings, diagrams, engineering sheets or similar materials used
in connection with Buyer’s order are for the sole purpose of identifying the products and shall not be
construed as an express warranty. Any suggestions by Seller or Seller’s agents regarding use, application or
suitability of the products shall not be construed as an express warranty unless confirmed to be such in
writing by Seller.

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Operational Flow Charts
Volume and
Capacity slides are
less than 5 %.
Requirements to Start Compressor
Oil Separator Temp
> Oil Sep Start Trip
Setpt.
Filter Diff Press <
Start Filter Diff
Trip Setpt
Oil Pump On: Prelub Oil Press is > Prelub Oil
Press Reset Setpt for “Min Compressor Prelub
Timer” setting (Default 7 Seconds)
Start Compressor
Critical Compressor Run Logic @ Compressor Start
Is
Run Oil Press >
Run Oil Press
Reset setpt?
(Default 40 PSI)
Run Oil Press Failure
“Filter Diff Press Safety
Changeover” timer expires
(60 sec after start).
Is
Filter Diff < Hi Filter
Diff Press Run Trip
setpt?
Oil Separator Temp
Safety Changeover
Timer expires. (5 min
after start)
Is
Oil Sep Temp > Lo
Oil Sep Run Reset
setpt:?
Run
Run Filter Diff Press Failure Lo Run Oil Sep Temp Failure
No
Yes
No
Yes Yes
No
Yes
Compressor Amperage Load Limiting High Disch Pressure Load Limit
Is
Motor Amps >
FLA (ON)
Setpt?
Is
Motor Amps >
Max (OFF)
Setpt?
Normal Loading &
Unloading
Capacity Decrease
until Amps < FLA x
1.0625
Normal Loading &
Unloading
Capacity Decrease until
DischPress < ON Setpt x
1.0625
Is
Disch Press >
Cutin (ON)
Setpt?
Is
Disch Press >
Cutout (OFF)
Setpt?
No
Yes
Yes
No
No
Yes
Yes
No
Capacity INC Disabled Capacity INC Disabled
Start
Compressor
Prelube 5
Seconds
Satified Oil
Pressure
Compressor
Start Mode
Is Run Oil Press >
Run Oil Press setpt? Yes

8VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Suction Pressure Control
Is
Suction Press >
Suct Press Cap Inc
Setpt?
Is
Suction Press <
Suct Press Cap
Dec Setpt?
Reset Cap Inc Timers
Is
Suction Press <
Suct Press Alarm
Setpt?
Lo Suction Press
Alarm
Is Cap Inc ON Timer
Timed Out?
Is Cap Inc OFF Timer
Timed Out?
Capacity Inc WAIT
Capacity Dec
Is Cap Dec. ON Timer
Timed Out?
Is Cap Dec. OFF Timer
Timed Out? Reset Cap Dec Timers
Yes Yes Yes
No No
No
No
Yes Yes Yes
No
Suction Pressure Safety
No
Is
Suction Press <
Suct Press Trip
Setpt?
Lo Suction Press
Failure
Yes
Yes
No
No
Operational Flow Charts

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Oil Cooler Fan Control
(Selectable Control Optional)
Increase Speed
Decrease Speed
Unit Start
30 sec
delay
Yes
Yes
Oil Cooler
outlet temp >
set pt?
Oil Cooler
outlet temp <
set pt?
NoNo
Oil Temperature Control Valve
Modulate valve
Modulate valve
Unit Start
30 sec
delay
Yes
Yes
Oil injection
temp > set pt?
Oil injection
temp < set pt?
No No
PID Control
PID Control
Operational Flow Charts

10 VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Shutdown due to
Operational
Failure
Delayed Lockout Timers
WARNING: FOR THE FOLLOWING SHUTDOWNS, A DELAYED RESTART MAY OCCUR:
High Discharge Pressure Failure
High Compressor Discharge Temp Failure
High Package Outlet Temp Failure
High Oil Injection Temp Failure
Is
Shutdown Value
Below Reset
Value?
1 min Delay
Have
There Been 3 Shutdowns of “Any
of the Above Failure Conditions”
in H2 Hours
Auto Restart if All Other Values
Are In Range
Lockout
Requires
Manual Restart
Has
It been *H1
Hours Since
Shutdown?
H1= Timer Set Between .5-6 Hours.
Default Value= .5 Hours
H2= Timer Set Between 4-100 Hours.
Minimum and Default Value= 4 Hours
H2 must be equal to or greater than 4 x H1
Yes
Yes
No
No
Yes
No
Shutdown Due
to Power Failure
1 min Delay Have
There Been 3 Shutdowns
of This Same Condition
in H4 Hours
Auto Restart if All Other Values
Are In Range
Lockout
Requires
Manual Restart
Has
It been *H3
Hours Since
Shutdown?
H3= Timer Set Between .5-6 Hours.
Default Value= .5 Hours
H4= Timer Set Between 4-100 Hours.
Minimum and Default Value= 4 Hours
H4 must be equal to or greater than 4 x H3
Yes Yes
No
Yes
Yes
No
Power Re-
establishing
WARNING: INCASE OF A POWER FAILURE A DELAYED RESTART MAY OCCUR:
Was Compressor
Running During Power
Failure?
No
No
Operational Flow Charts

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Start
Has
Decrease at Start
(Expired 15
sec.)
Wait
Are Motor
Amps >
Motor Amps Load
Limit ON Setpt?
(Time Delay
10 sec)
Disable Cap Inc
Are Motor
Amps >
Motor Amp Load Limit
OFF Setpt?
Dec Cap
(Timer)
Is Disch
Press > High Disch
Press Unload
OFF Setpt?
Is Capacity
> Min Run Cap
OFF Setpt?
Is Suct
Press > Cap Inc
ON Setpt?
Inc Cap
(Timer)
Disable Cap Inc Increase Cap
(Timer)
Is Suct Press< Cap
Dec ON Setpt?
No
Yes No No Yes Yes
Yes Yes No No
Yes
Yes
Is Disch
Press > High Disch
Press Unload
ON Setpt?
Dec Cap
(Timer)
Yes
No
Capacity Control Using Suction Pressure Control Setpoints
Dec Cap
(Timer)
No Change No Change
Operational Flow Charts

12 VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Start
Has
Decrease at Start
(Expired 15 sec.)
Wait
Is Disch Press > Cap
Dec ON Setpt?
Is Disch Press < Cap
Inc ON Setpt
No
Yes Yes
No
Dec Cap
(Timer)
Inc Cap
(Timer)
Yes
No
change
No
Capacity Control Using Discharge Pressure Control Setpoints
Are Motor
Amps >
Motor Amps Load
Limit ON Setpt?
(Time Delay
10 sec)
Are Motor
Amps >
Motor Amp Load Limit
OFF Setpt?
Dec Cap
(Timer)
Yes
Yes
Disable Cap Inc
No
No
Change)
No
Operational Flow Charts

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Compressor Operation with VFD Drive
Start
Compressor
Start VFD at
Minimum Speed
(30 Hz Typ.)
Is Control Press.
Within Setpt
Deadbands?
Increase or Decrease the
Compressor Capacity Slides to
Match Setpoints
Is Capslide @
100%
Increase or Decrease the
Compressor Capacity Slides to
Match Setpoints
Increase or Decrease Motor Speed
@ Rate Defined by VFD PID
Parameters
Is Control Press @
Setpoint?
Is Motor Speed @
Min?
No
Yes
No
Yes
No
No
Check/Adjust Capacity Slide
Check/Adjust VFD
Yes
Operational Flow Charts

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Main Screen
This screen contains buttons to navigate to setpoint
setup screens.
Status information on the compressor, oil pump,
oil heater and run mode.
Start/Stop buttons.
Hour meter.
Motor amperage.
Compressor operating conditions.
Main Screen
This screen has been designed to give the operator
an overall view of all operating parameters affect-
ing the compressor package. This screen should
always be displayed when maintenance items and
setpoint items are not being performed.
Status information such as Alarms and Trips are
displayed on the screen.

16 VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Log On Screen
Press Log on Button and the below screen will ap-
pear. When altering setpoints, log on is necessary.
Select appropriate user name and enter password
to change/access setpoints.
To Log On: Enter your User Name (case sensitive)
and Password (case sensitive) then touch the <_|
enter key.
To Log Off: Touch the Log Off button. This will return
to the DEFAULT low-level user. The DEFAULT user
may navigate to most screens but cannot change
settings.
Log On or Off
Note: An operator will be automatically
logged off after 10 minutes of inactivity.
Note: The machine can be run and moni-
tored without logging on. To change the
setup or parameters of the machine, the
operator must log on.

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
From the Main screen, touch the Setup button. After
entering an authorized user name and password, the
screen pictured below will appear.
Pressure units,Temperature units and Suction/
Discharge Pressure control configurations are list
selectable.
To choose a configuration from a list: 1.) Touch the
list. 2.) Touch the Up or Down Arrow to move the
green cursor “>” along side of the desired configura-
tion. 3.) Touch the Enter button. This will highlight-
green the chosen configuration.
Set Up Screen
Touch Here

18 VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
· Setpoint #1/#2 Select – The operator can select
the compressor to run with setpoint #1 or #2
settings.
· Oil Pump Selection – The operator can select
the compressor to use either oil pump #1 or #2
when compressor has a second oil pump.
· Pressure Units – Select units of measure for pres-
sure readings. Choices are PSIG, PSIA, kPa [A],
kPa [G], kg/cm² [A], kg/cm² [G], Hg (vac) [G], WC
[A], WC [G], Bar [A], Bar [G], Torr [A], Torr [G].
· Temperature Units – Select units of measure
for temperature. Choices are Fahrenheit or Cel-
sius, Kelvin and Rankine.
· Anti-Recycle – The operator can select from the
following Anti-Recycle options: True, Accumula-
tive, Modified, or Hot Starts. These select the
strategy used to prevent excessive start/stop
cycles of the compressor. Timers and counters
used to enforce anti-recycling are adjusted and
monitored in the Compressor Timer Settings
screen, reached from the Menu screen. Help
for the Timer Settings screen explains how the
different settings and strategies operate.
· Compressor Control Via – Operator can choose
the method or mode of compressor control.
This determines which measured variable is used
in making loading (capacity control) decisions.
The choice selected here determines which
setpoints are made available for adjustment on
the Compressor Control Setpoints screen.
·Capacity & Volume Slide Non-Movement – Alarm
enable and disable buttons permit selecting
whether an alarm should be generated when
failure of slides to move is detected.
·Reset After Power Fail – When Auto is selected,
the compressor will attempt to restart on pow-
ering up if it was running in ‘Auto’ when powered
down and enabling conditions are met. When
‘Manual’ is selected, the compressor powers up
into the ‘Stop’ mode and an explicit command
to run is required from an operator or comms
channel.
·MinRunCapacity– When enabled, the Minimum
Run Capacity setting on the Addition Compres-
sor Setpoints screen operates as described in the
help for that screen. When multiple compressor
sequencing is used, selecting Disable here does
not interfere with use of the Min Run Capacity
setting in the sequencing logic.
·Oil Pump Option #1 – The operator can choose
the method the compressor oil pump operates.
·Suction Pressure Sensor Mode – The operator
can select local or remote sensor mode. Remote
sensor mode is typically used when compressors
are installed in parallel.
Set Up Screen

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VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
Vilter Only Screen
To synchronize the PanelView date and time to the Conrol Logix date and time:
1. Display the Vilter Only Screen (This screen has restricted access).
2. Touch the “Touch to Synchronize HMI Clock to PLC” button.

20 VSG/VSSG • Compact Logix PLC Manual •Vilter/Emerson • 35391CL
At the bottom of the Main screen touch the Menu button to bring up the screen shown in Figures below.
Use this screen to navigate to the other setpoint screens contained within the program. Each screen has a help
button to describe the function of the screen.
There are several buttons that are common for all menu screens:
Return to Menu – This button always returns you to the Menu screen
Log On – The user is allowed to view data at all screen levels but cannot edit data until a login has occurred.
Refer to the Log on/off Instructions on page 16.
Menu Screen
Touch Here
Set – To change a value, the operator must first press the SET button and then the text field of the value they
want to modify. A number pad will pop up for ease in entry.
Help – This screen will provide more information to the user about the operation of the microprocessor.
Event List – provides a chronological event listing.
Chart – Provides a line graph showing process values over a range of time.
Auto – Places the capacity slides into automatic mode. In automatic mode, the capacity slide moves according
to control setpoint information.
Manual – Places the capacity slides into manual mode. In manual mode, the capacity slide moves moves based
on input from the operator.