Emerson Vilter PLC User manual

Blower Package PLC

Operation manual

Blower Package PLC Operation Manual •Vilter/Emerson • 35391BLP

Seller warrants all new assembled equipment 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 ex-

clusive 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 not approved by Seller. 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 ex-

penses 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 war-

ranty. 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.

Blower Packages - Standard Vilter Warranty Statement

ii Blower Package PLC Operation Manual •Vilter/Emerson • 35391BLP

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR BLOWER.

The following instructions have been prepared to assist in installation, operation and maintenance of Vilter blower

packages. Following these instructions will result in a long life of the package with satisfactory operation.

The entire manual should be reviewed before attempting to install, operate, service or repair any part of the

package.

A blower is a positive displacement machine. It is designed to compress gas. The blower must not be

subjected to liquid carry over. Care must be exercised in properly designing and maintaining the system

to prevent conditions that could lead to liquid carry over. Vilter Manufacturing is not responsible for the

system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing cannot warrant

equipment damaged by improperly protected or operating systems.

Vilter components are thoroughly inspected at the factory. However, damage can occur in shipment. For

this reason, the equipment should be thoroughly inspected upon arrival. Any damage noted should be re-

ported immediately to the Transportation Company. This way, an authorized agent can examine the unit,

determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays.

At the same time, the local Vilter representative or the home office should be notified of any claim made.

All inquires should include the Vilter sales order number, serial and model number. These can be found on the

nameplate on the blower.

All requests for information, services or parts should be directed to:

Vilter Manufacturing LLC

Customer Service Department

P.O. Box 8904

5555 South Packard Ave

Cudahy, WI 53110-8904 USA

Telephone: 1-414-744-0111

Fax:1-414-744-3483

E-mail: info.vilter@emerson.com

Equipment Identification Numbers:

Vilter Order Number: _______________________Blower Serial Number: _________________

Important Message

TOC - 1

Blower Package PLC Operation Manual •Vilter/Emerson • 35391BLP

Table of Contents

Section Title Section Number

Blower Packages - Standard Vilter Warranty Statement..........................................................................i

Important Message................................................................................................................................ii

Section 1 • General Information

How To Use This Manual.........................................................................................................................1-1

Glossary of Terms...................................................................................................................................1-2

Hardware Components..........................................................................................................................1-4

Wiring Requirements.............................................................................................................................1-6

VFD Installation Recommendations .......................................................................................................1-7

Section 2 • Operation Descriptions

Overview ...............................................................................................................................................2-1

Operational Descriptions and Diagrams.................................................................................................2-2

Configuration of the Blower Package .........................................................................................2-2

Starting of the Blower/Permissives.............................................................................................2-2

Anti-Recycle ..............................................................................................................................2-2

Automatic Speed Control...........................................................................................................2-2

Operating Modes.......................................................................................................................2-3

Load Limits and Forced Unloading..............................................................................................2-3

Safeties......................................................................................................................................2-3

Emergency Stop ........................................................................................................................2-5

Supplemental Blower Motor Protection .....................................................................................2-5

Air Cooled Oil Cooler Fan............................................................................................................2-6

External Electric Oil Pump..........................................................................................................2-6

Oil Pressure Safety Switch..........................................................................................................2-6

Air Cooled Aftercooler - Step Type..............................................................................................2-6

Air Cooled Aftercooler - VFD Type ..............................................................................................2-7

Water Cooled Gas Aftercooler....................................................................................................2-8

Gas Scrubbers............................................................................................................................2-9

Discharge Recycle Valve.............................................................................................................2-10

Section 3 • Overview Screens

Blower and System Overview Screens ....................................................................................................3-1

Section 4 • HMI Navigation

Main Menu Screen .................................................................................................................................4-1

HMI Security ..........................................................................................................................................4-2

Default .................................................................................................................................................4-2

OP1, OP2, OP3, OP4, OP5 (Operators) ...................................................................................................4-2

Super (Supervisor) .................................................................................................................................4-2

Logging In..............................................................................................................................................4-2

Section 5 • Configuration - Supervisor Level

Configuration Screen - Supervisor (SUPER) Level ....................................................................................5-1

Editing Device Names ............................................................................................................................5-4

TOC - 2 Blower Package PLC Operation Manual •Vilter/Emerson • 35391BLP

Table of Contents

Section Title Section Number

Section 6 • Instrument Calibration

Calibration Main Screen .........................................................................................................................6-1

Pressure Calibration Screen....................................................................................................................6-2

Calibrate Pressure Instrument....................................................................................................6-3

Calibrate Transducer to a Known Pressure..................................................................................6-3

Temperature Calibration Screen.............................................................................................................6-4

Calibrate Temperature Instrument.............................................................................................6-4

Other Analog Calibration Screen ............................................................................................................6-5

Calibrate an Additional Instrument ............................................................................................6-5

Section 7 • Blower Configuration and Control Setpoints

Setpoints and Control Screens ...............................................................................................................7-1

Changing Setpoints ...................................................................................................................7-1

Blower Configuration Screen..................................................................................................................7-2

Blower Control Setpoints - Suction Pressure...........................................................................................7-3

Blower Control Setpoints - Discharge Pressure .......................................................................................7-5

Section 8 • Alarm and Trip Setpoints

Alarm and Trip Setpoints........................................................................................................................8-1

Alarm and Trip Setpoints - Page 1...........................................................................................................8-1

Alarm and Trip Setpoints - Page 2...........................................................................................................8-2

Section 9 • Step and PID Device Control Screens

Aftercooler Screens................................................................................................................................9-1

Aftercooler (VFD Type) Setpoints...............................................................................................9-1

Aftercooler (Step Type) Setpoints ..............................................................................................9-2

Water Cooled Aftercooler Setpoints...........................................................................................9-3

Discharge Recycle Valve Screen..............................................................................................................9-4

Discharge Recycle Valve Setpoints .............................................................................................9-4

Start Menu Popup Screen.......................................................................................................................9-5

Section 10 • Diagnostic Screens

IO/Comms Diagnostics Screen...............................................................................................................10-1

Event List Screen ....................................................................................................................................10-2

Diagnostics Forced Outputs Screen........................................................................................................10-3

Captured Data at Shutdown Screen .......................................................................................................10-4

Initial Baseline Running Data Screen.......................................................................................................10-5

TOC - 3

Blower Package PLC Operation Manual •Vilter/Emerson • 35391BLP

Section 11 • Alarms, Trips, Status Information

and Troubleshooting

Alarm and Trips......................................................................................................................................11-1

Alarm Listing..........................................................................................................................................11-2

Trip Listing .............................................................................................................................................11-9

Status Messages and Blower State Indicator...........................................................................................11-18

Troubleshooting ....................................................................................................................................11-22

If the Blower Will Not Start.........................................................................................................11-22

If Control Power Will Not Turn On ..............................................................................................11-22

Section 12 • Central Controller Communications

Communication with a Central Controller/DCS ......................................................................................12-1

VPN Access ................................................................................................................................12-1

Setting Up Communications......................................................................................................12-1

Watchdog Timer........................................................................................................................12-1

Data that can be Read from the Blower PLC ............................................................................................12-1

Live Instrument Data .................................................................................................................12-1

Alarm and Trip Data ...............................................................................................................................12-8

Status Data ............................................................................................................................................12-17

States of Discrete I/O .............................................................................................................................12-21

Blower State Indicator............................................................................................................................12-25

Data that can be Written to the Blower PLC............................................................................................12-26

Discrete Blower Commands.......................................................................................................12-26

Section Title Section Number

Table of Contents

TOC - 4 Blower Package PLC Operation Manual •Vilter/Emerson • 35391BLP

List of Tables and Figures

Table/Figure Section Number

Tables

Table 11-1. Alarm Listing........................................................................................................................11-2

Table 11-2. Trip Listing ...........................................................................................................................11-9

Table 11-3. Status Listing .......................................................................................................................11-16

Table 12-1. Engineered Units Value Interpretation (INT_OUT[x]) ...........................................................12-2

Table 12-2. Live Instrument Data............................................................................................................12-2

Table 12-3. Alarm Data...........................................................................................................................12-8

Table 12-4. Trip Data ..............................................................................................................................12-12

Table 12-5. Status Data ..........................................................................................................................12-17

Table 12-6. Discrete Input States............................................................................................................12-21

Table 12-7. Discrete Output States.........................................................................................................12-23

Table 12-8. State Indicator .....................................................................................................................12-25

Table 12-9. Blower Command (Real).......................................................................................................12-26

Table 12-10. Blower Command (Double Integer)....................................................................................12-26

Figures

Figure 2-1. Operational Diagram - Load Limits / Forced Unloading (Example) .........................................2-4

Figure 2-2. Control Panel Master Power and Emergency Stop Electrical Circuit .......................................2-5

Figure 2-3. Operational Diagram - Air Cooled Aftercooler (Step Type)..................................................... 2-6

Figure 2-4. Operational Diagram - Air Cooled Aftercooler (VFD Type) .....................................................2-7

Figure 2-5. Operational Diagram - Water Cooled Gas Aftercooler ...........................................................2-8

Figure 2-6. Operational Diagram - Discharge Recycle Valve ....................................................................2-10

Figure 3-1. Basic Blower Package Screen ................................................................................................3-1

Figure 4-1. Main Menu Screen................................................................................................................4-1

Figure 4-3. Login Popup Screen..............................................................................................................4-2

Figure 4-4. Login Screen Keyboard .........................................................................................................4-3

Figure 5-1. Configuration Screen - All Options Shown (Supervisor Level) ................................................5-1

Figure 5-2. Set Date/Time Pop-Up Screen - Supervisor Level...................................................................5-2

Figure 5-3. Change Password Pop-Up Screen - Supervisor Level..............................................................5-3

Figure 5-4. Define Device Names - Devices and Vessels (Supervisor Level) .............................................. 5-4

Figure 5-5. Define Device Names - Instrumentation (Supervisor Level)...................................................5-5

Figure 5-6. Define Device Names - Alarm and Trip 1 (Supervisor Level) (1 of 2) .......................................5-6

Figure 5-7. Define Device Names - Alarm and Trip 2 (Supervisor Level) (2 of 2) .......................................5-7

Figure 6-1. Instrument Calibration Overview Screen ..............................................................................6-1

Figure 6-2. Pressure Calibration Screen - 1 of 3.......................................................................................6-2

Figure 6-3. Pressure Calibration Screen - 3 of 3.......................................................................................6-3

Figure 6-4. Temperature Calibration Screen ...........................................................................................6-4

Figure 6-5. Other Analog Calibration Screen ..........................................................................................6-5

Figure 7-1. Numeric Entry Pop-up Screen...............................................................................................7-1

Figure 7-2. Blower Configuration Screen ................................................................................................7-2

Figure 7-3. Blower Control Screen - Suction Pressure..............................................................................7-4

Figure 7-4. Blower Control Screen - Discharge Pressure..........................................................................7-5

TOC - 5

Blower Package PLC Operation Manual •Vilter/Emerson • 35391BLP

Figure 8-1. Alarm and Trip Setpoints Screen - 1 of 2................................................................................8-1

Figure 8-2. Alarm and Trip Setpoints Screen - 2 of 2................................................................................8-2

Figure 9-1. Aftercooler (VFD Type) Screen..............................................................................................9-1

Figure 9-2. Aftercooler (Step Type) Screen .............................................................................................9-2

Figure 9-3. Water Cooled Aftercooler Screen..........................................................................................9-3

Figure 9-4. Discharge Recycle Valve Screen ............................................................................................9-4

Figure 9-5. Start Menu ...........................................................................................................................9-5

Figure 10-1. IO/Comms Diagnostics Screen...........................................................................................10-1

Figure 10-2. Event List Screen.................................................................................................................10-2

Figure 10-3. Diagnostics Forced Output Screen......................................................................................10-3

Figure 10-4. Captured Data at Shutdown Screen....................................................................................10-4

Figure 10-5. Initial Baseline Running Data Screen ...................................................................................10-5

Figure 11-1. Alarm/Trip/Status Bars (Main Menu Screen)........................................................................11-1

Figure 11-2. Alarm Popup Screen ...........................................................................................................11-1

Figure 11-3. Alarm/Trip/Status Bars (Main Menu Screen)........................................................................11-18

List of Tables and Figures

Table/Figure Section Number

Blank / TOC Blower Package PLC Operation Manual •Vilter/Emerson • 35391BLP

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