Professional Documents
Culture Documents
FES CUSTOMER:.
REFRIGERATION & ENGINEERING SERVICE OF FLORIDA, INC.
SUNRISE, FL
END USER:
CENTRAL AMERICAN FISHERIES
REPUBLIC OF NICARAGUA
1. INSTALLATION
2. PACKAGE OPERATION
3. CONTROL PANEL OPERATION
4. COMPRESSOR STARTUP PROCEDURE
5. MAINTENANCE
6. COMPONENT LITERATURE
7. DATA SHEET/SPARE PARTS
8. DRAWINGS
GM SERIES SCREW
COMPRESSOR PACKAGES
Preface
This manual provides detailed instructions for the installation, operation and maintenance of
FES GM Series screw compressor packages. The compressor package will provide optimum
performance if applied to a properly designed refrigeration system. Specific questions
concerning these requirements can be answered by an FES certified representative or factory
personnel. Proper installation, operation and regular maintenance will provide the best and most
dependable equipment life.
GM Series packages are leak tested at the factory and are shipped with a holding charge of dry
nitrogen to prevent contamination from the atmosphere. During installation into the
refrigeration system, it is normally not necessary to leak test the compressor package on site
except when required by prevailing codes or standards. However, prior to charging the system
with refrigerant, the system, including the compressor package, should be evacuated in
compliance with site requirements or other recognized procedures outlined in documents such as
ANSI/IIAR, IIAR Bulletin 110, ASHRAE Handbook "Refrigeration" etc.
To ensure that the compressor is not exposed to liquid carryover in the suction gas, it is very
important to review piping layouts. The compressor is a vapor pump and can be damaged by
liquid refrigerant in the suction gas. Control schemes, accumulators, heat exchangers, defrost
cycles, etc. should be checked to ensure that only dry gas within the operating limits enters the
compressor suction.
The entering vapor temperature to the compressor should be 10°F superheated above the
refrigerant saturated suction temperature to ensure no liquid refrigerant is present in the suction
gas.
FES Systems Inc.
TABLE OF CONTENTS
PAGE
Introduction...........................................................................................................................1
Compressor Package Identification ....................................................................................1
Job Site Inspection and Damage Claims.............................................................................1
Foundation.............................................................................................................................1
Rigging, Moving, and Skid Removal...................................................................................1
Initial Installation .................................................................................................................2
Motor Mounting and Alignment for Field Mounted Motor .............................................2
Required Tools ......................................................................................................................2
Coupling Installation ............................................................................................................3
Coupling Removal.................................................................................................................4
Motor Mounting and Preliminary Alignment Procedure.................................................4
Shimless Motor Mounts........................................................................................................5
Coupling Final Alignment Procedure .................................................................................6
Storage and Holding Charge ...............................................................................................8
Compressor Oil .....................................................................................................................8
Oil Charge .............................................................................................................................8
Oil Heaters.............................................................................................................................9
Liquid Injection Oil Cooling ................................................................................................9
Thermosiphon Oil Cooling.................................................................................................12
Economizer ..........................................................................................................................15
Microprocessor Control Panel Installation Guide...........................................................15
Control Power Wiring .........................................................................................15
Control Power Supply .........................................................................................16
Grounding.............................................................................................................16
General..................................................................................................................16
GM SERIES SCREW Damage and shortage claims must be made by the
consignee and the carrier should be notified
COMPRESSOR PACKAGES immediately so that an inspection and claim form
can be completed. The FES Sales Administration
SECTION 1 INSTALLATION Department, York PA, should be notified of any
Introduction damage or shortage claim.
This section contains information and procedures Foundation
for installing the GM Series screw compressor GM Series screw compressor packages are
package. shipped mounted on wood skids, which must be
The GM Series screw compressor package is removed prior to installation. Since the screw
factory assembled, wired, and leak tested. compressor is internally balanced, no foundation
Installation consists primarily of establishing mass is required except that which is structurally
refrigerant, water and electrical services to the required to handle the package weight. A level
package. Rigging, installation, field wiring and mounting surface is required and the unit should
mounting of customer supplied motors, and field be bolted to this surface after installation.
piping are the responsibility of the contractor Grouting may be necessary to achieve
and/or customer. satisfactory results. Elevated housekeeping pads
Compressor Package Identification are a good practice but are not required.
Structural steel mounted units require grouting
The Model number is explained below: under the entire support base. Foundation floors
110 GM B or elevated structures should be evaluated to
determine that they do not have natural
Model frequencies coincident with compressor run speed
110, etc. or rotor pass gas pulsation frequencies. This is a
separate analysis from vibration transmission to
GM Series adjacent structures.
Note: If the package is to be installed on a non-
Duty rigid foundation, specific isolation may be
Blank – High Stage required.
B – Booster
E - Economized
Rigging, Moving and Skid Removal
The screw compressor package can be handled by
This information, along with the FES contract crane or similar lifting device by placing lifting
number, is contained on the data label mounted hooks into the four (4) lifting lugs provided on
on the inside of the control panel door. When the package. Adjustments to the rigging will be
parts or service information are needed, the data required to allow for the package center of
from this label should be included with the gravity, which can vary significantly if no motor
inquiry. There is a data plate located on the is provided on the package.
compressor that contains information pertaining The package can be moved by forktruck using
to the design of the compressor. forks to push against and under the skids. Under
no circumstances should the forks be used to push
Job Site Inspection and Damage Claims against the oil separator, piping, legs, or
Cartons, boxes and all exposed components compressor.
should be examined upon receipt at the job site. If the compressor package is lifted by crane the
The packing list should be checked to see that all skids can be unbolted and removed prior to
listed components have been received. setting the compressor on its foundation.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Document: GM-1
Revision: D
1 Effective: 09-04
If the package is to be skidded into position the coupling is shipped loose.
skids can be removed by using a 5 ton jack to lift Block and Shim Style Mount:
one end of the compressor package and unbolting
the skid on that end. The skids should then be The screw compressor package is shipped with
spread and the compressor package lowered. the motor support angles welded to the oil
Repeat this procedure for the other end. separator support plates. The motor mounting
blocks, shims, alignment bars with bolts, tie down
Initial Installation bolts, lock washers, flat washers, and shims are
After the compressor package is in place it must shipped loose. The motor mounting blocks are
be leveled by using a reliable bubble level on the drilled and tapped.
compressor mounting support angles to check The compressor hub of the coupling is mounted
both directions. This procedure was followed on the compressor shaft. The remainder of the
during the initial assembly at the factory, and it coupling is shipped loose.
will ensure the compressor package is properly
positioned.
Required Tools
The suction strainer and discharge connection The following tools are required in addition to
flanges are not to be used for leveling the common hand tools:
package. A. Dial indicator, accurate and readable to 0.001
Factory mounted motors have been aligned, but inches, with clamps for attaching the indicator
alignment must be checked at startup. to the coupling hubs.
B. Micrometer
Motor Mounting and Alignment for C. Feeler gauges
Field Mounted Motor D. Torque Wrench
E. Metric hex bit socket (6mm, 8mm & 10mm)
Shimless Motor Mount:
The screw compressor package is shipped with
the shimless motor mounts attached to the pre-
drilled support angles.
The compressor hub of the coupling is mounted
on the compressor shaft. The remainder of the
Coupling Removal
A. Remove bolts holding the disc packs to the
motor and compressor hubs.
B. Loosen the setscrew above keyway on motor
hub and slide hub back far enough so the
center member (with disc packs attached) can
be removed through the shaft ends. Once the Figure 1-3: B-LOC Assembly
center member is removed, the motor hub can
be removed though the shaft ends.
C. Extreme care must be used when removing Compressor Hub
Coupling
the compressor hub. Refer to Figure 1-3 for Size Shaft Dia. Thread TS
the following steps. mm DIN-912 (ft-lb)
D. Remove the tensioning screws from the B-
LOC locking assembly. Transfer the required 52-225 50 M6 X 35 11
number of screws into the jacking holes of the
clamp collar (Item 1). Table 1-3: Torque Specifications for
E. Some screws will contact the center collar Tensioning Screws
(Item 3) and will only go in half way. Other Coupling TB
screws will go in further and are used to Size (ft-lb)
release the inner clamping collar (Item 2).
52-225 25
F. Start by releasing collar (Item 1) by
progressively tightening the jacking screws Table 1-4: Torque Specifications for Coupling
that are in half way. The screws will appear Bolts
to be tight after only one pass of tightening
without any noticeable separation of the Motor Mounting and Preliminary
clamp collar. This is normal – continue to Alignment Procedure
apply torque in a clockwise or A. Mount all four mounting blocks on the motor
counterclockwise manner until the clamp feet with the tube sleeve spacer inserted as
collar springs loose. shown in Figure 1-5 or wrap the tie down
G. Release the center collar (Item 3) by repeating bolts with 0.0625 inch shim stock. Install a
procedure outlined above for item 1. The 0.25 inch shim pack as shown and snug the
screws for this procedure are the ones that tie-down bolt on each foot. Lift the motor
screw in deeper. and place it on the motor support angles.
H. Once the clamping collars are fully released
from the center collar, the coupling and B-
LOC assembly can be removed together
(There is no need to remove the B-LOC
cartridge from the coupling hub).
Document: GM-1
Revision: D
Effective: 09-04 4
to the motor support angle as shown in Figure
1-2. The alignment bracket will facilitate
positioning of the motor for angular
alignment. All motor assemblies must have
permanent means of jacking the motors into
position for vertical alignment.
E. Rough align for both parallel as well as
angular alignment by using a dial indicator.
F. Once rough alignment is complete, weld the
motor mounting blocks on the motor support
angle. Weld one block at the rear, then weld
Figure 1-5: Motor Foot Mounting Typical
the diagonally opposite block. Next weld the
B. Remove the center spacer from the other rear block and then the remaining front
compressor coupling, if mounted. Mount the block. Weld all four sides of the mounting
other coupling half on the motor shaft. If block, welding approximately one inch at the
difficulty is encountered while installing the corners. Weld one side at a time in the above
hub, check shaft and coupling hubs for burrs sequence as quickly as possible. The purpose
and fit key in both halves of the keyway. The of this procedure is to prevent distortion.
key must have a uniform tight fit in both the Allow to cool to room temperature.
shaft and coupling hub keyway. DO NOT Dowelling of the motor is not required.
ATTEMPT to drive either hub on either shaft G. Remove the tie down bolts and the tube
because serious damage to the ball bearings sleeve spacers or shim stock wrapping around
may result. the tie down bolts. Install the tie down bolts
C. Refer to Table 1-6 for motor and compressor again. Final alignment procedure must be
shaft gap requirements. If the lengths of the performed before the package is ready for
motor and compressor shafts are such that the operation.
center member can be removed at the shaft
gap shown in Table 1-6, the motor can be
Shimless Motor Mounts
mounted based on the shaft gap dimension. If Series compressor packages. Mounting is similar
the center member cannot be removed with to conventional block motor mounts except that
the gap shown, the motor must be positioned the shimless motor mounts are bolted to the
so that the coupling hubs can be moved on angle, not welded. Each shimless motor mount
their respective shafts to allow for removal of has provisions for jacking the motor horizontally
the center member without moving the and vertically.
compressor or motor. In such cases the shaft Horizontal adjustment is accomplished by turning
gap will be greater than the dimension shown the lateral adjustment bolts as required.
in Table 1-6. Minimum shaft engagement for Vertical adjustment is accomplished by first
the hubs must be at least 90% of hub length.
removing the top hold down nut, and loosening
Compressor Min. Shaft Gap the bottom. Once this is done, a metric wrench
Model (in.) can be applied to the top of the bolt. Turning the
110GM - 195GM 3 bolt clockwise will raise the motor, while turning
the bolt counter-clockwise will lower it. One-
Table 1-6: Required Motor to Compressor quarter turn will raise or lower the motor foot
Shaft Gap 0.010 inches.
D. Check motor height. If the motor is too high Note: An extension bar may be required for use
relative to the compressor, remove shims as on the wrench to exert enough force to raise the
required. Four alignment brackets with bolts motor.
are provided. The brackets should be welded
Document: GM-1
Revision: D
5 Effective: 09-04
Another check should be made after one week of
operation. The procedure used for final
alignment is as follows:
CAUTION: Before servicing the compressor or
any other moving parts, press the
compressor STOP button, then turn
off the control power and open
power disconnects to the
compressor and oil pump starter.
Tag and lock all disconnects in the
open position while conducting
service work.
A. Remove the coupling guard. Check the
runout of the compressor hub. With a dial
Figure 1-7: Shimless Motor Mounting (SMM) indicator base attached to the compressor, and
the dial indicator reading off the hub rim,
Coupling Final Alignment Procedure rotate the coupling assembly 180 degrees.
To ensure satisfactory performance and life from Note the runout. Rotate the assembly another
the compressor shaft seal and the motor and 180 degrees to the original position. Adjust
compressor bearings, a final alignment procedure the dial indicator to read the hub face. Rotate
must be performed. Whether the coupling was the assembly and note the runout. Repeat this
aligned at the factory or field installed, it must procedure for the motor hub. A runout in
have a final alignment done after the package is excess of 0.003 inches should be reported to
installed and piped. Improper piping procedures the FES factory.
can cause stress on the compressor casing making B. Check for motor soft feet. With the indicator
alignment impossible. The coupling must have a base attached to the motor support angles, and
final alignment check prior to start up and again the dial indicator reading off the top of a
after a few hours of operation. This "HOT" check motor foot, loosen the tie down bolt and note
after several hours of operation is required. the indicator reading. Any movement in
excess of 0.002 inches must be corrected a suitable place on the shaft. The shaft
using shims. Repeat this procedure with the must be held on its magnetic center
other three feet to ensure that each motor foot when aligning the motor. This can be
is in solid contact with the base. done by clamping the two hubs with a
NOTE: BE SURE TO MINIMIZE THE 5/8 inch diameter all thread rod and
AMOUNT OF SHIMS USED. double nuts.
Example: If a 0.005 inch, a 0.003 D. Align the motor so that the total indicator
inch, and a 0.002 inch were used, then reading (TIR) on the periphery and the face
replace them with one shim 0.010 inch does not exceed 0.002 inches misalignment.
thick. With reference to Figure 1-9, the following
C. With the coupling assembled, mount the dial applies to all screw compressor applications.
indicator on the compressor hub and take an 1. Align the motor first for angular in
indicator reading on the coupling hub as elevation. This alignment is adjusted with
shown in Figure 1-8. Due to the span of the shims to provide a maximum 0.002 inch
spacer coupling, indicator sag may be TIR at the top.
significant, and the indicator readings must be 2. Align the motor next for parallel in
corrected to include the sag. elevation. This alignment is also adjusted
1. To eliminate confusion, turn the coupling with shims and should be a maximum
in only one direction while taking 0.002 inch higher than the compressor.
readings. 3. Align the motor angular in plan next.
2. Take five readings, 0º, 90º, 180º, 270º, 4. Finally, align the motor parallel in plan.
and 360º on both the periphery (for
parallel) and face (for angular). The E. Record the alignment readings.
indicator should return to its original F. Verify that the distance between the coupling
position after the coupling has been hub faces ("C" from Figure/Table 1-2) is
rotated 360º. correct. Also the shaft gap should be checked
NOTE: Sleeve bearing motors or any motor to be in accordance with Table 1-6.
with measurable play must be NOTE: When the motor is field mounted
monitored with a dial indicator to the customer is responsible for aligning the
ensure that no motor shaft axial motor as prescribed on pages 2 through 7.
movement takes place when face The FES representative will check the final
readings are taken. If the motor is alignment before starting the compressor
fitted with sleeve bearings, the motor's package to ensure the motor was aligned
magnetic center must be determined properly.
from the manufacturer's G. Run the compressor at least two hours to
recommendations or by scribing the allow the package to reach its normal
uncoupled motor's running position at operating temperature. Stop the compressor
Document: GM-1
Revision: D
7 Effective: 09-04
and immediately check the alignment (keep 195GM. There are two methods for adding oil to
the coupling installed). The motor must be the oil separator. If the compressor package has
aligned so that the TIR on the periphery and had the refrigerant charge removed, the oil fill
face does not exceed 0.002 inch with the can be opened to atmosphere and oil poured or
package at its normal operating temperature. pumped into the oil separator. If the compressor
This check will be done by an authorized FES is charged with refrigerant, a pressure type pump
Service Representative at start up. must be used to add oil. This can be
H. Install the coupling guard. accomplished by attaching a refrigerant duty
pressure hose to the oil charging connection,
Storage and Holding Charge located on top of the oil separator, and using a
GM Series compressor packages are shipped with pressure type pump to pump oil into the
a holding charge of dry nitrogen to prevent separator.
contaminants from entering the package Devices used to trap and return oil must be filled
following the factory pressure test and with oil prior to compressor package operation.
evacuation. Since the package is sealed, it is The same pressure type pump and hose can be
suitable for short-term storage before installation. used for this.
Caution should be exercised when opening the The compressor package also has an oil level
package to safely release the nitrogen charge. sight glass located near the bottom of the
When packages are stored, they are to be kept in a separator on the discharge end of the package.
clean dry location. If packages are to be stored This sight glass should remain empty during
for prolonged periods of time the package should normal operation. If an oil level is observed
be checked to be sure a positive nitrogen pressure during operation, it is an indication of liquid
is maintained. The factory should be consulted refrigerant carryover or a malfunction in the line
for specific recommendations when extended returning oil to the compressor and primary side
storage (greater than two months) is expected. of the separator.
Care should also be used to protect the The approximate oil charge for the compressor
microprocessor and sensors from damage during packages is shown in Table 1-10 below.
storage.
Compressor Oil Oil Charge Oil Charge
Separator Size
The oil charge shipped with the compressor (LIQ. INJ.) (TSOC)
package was selected to meet the application 20" Dia. Separator 25 35
requirements as supplied at the time of order. 24" Dia. Separator 65 85
Questions concerning suitability can be answered
by referring to FES Document ENG-5 "FES Table 1-10: Approximate Oil Charge
Refrigeration Oils-Properties and Applications"
and Document ENG-6 "FES Recommended Oil
Specifications."
Oil Charge
GM Series compressor packages have sight
glasses for observing oil level. Models 110GM
through 160GM have one sight glass and normal
fill level is to the top of the sight glass. Model
195GM has two sight glasses and normal fill
level is to the top of the upper sight glass. The
normal operating level is to the center of the sight
glass on models 110GM through 160GM, and to
the center of the lower sight glass on model
Document: GM-1
Revision: D
Effective: 09-04 8
refrigerant supply is available for liquid injection
Oil Heaters feed.
Standard GM Series compressor packages are If the system condensing pressure is less than 100
equipped with 1200 watt oil heater(s) mounted on psig or greater than 225 psig the application
the oil sump on the oil sump (models 110GM should be referred to the FES factory.
through 160GM have one heater, model 195GM There are three suggested methods for meeting
has two). These heaters are sized to maintain a the criteria set forth in the proceeding paragraphs.
safe minimum oil temperature during a shut down The first of these is shown in Figure 1-11. This
cycle in normal indoor ambient conditions. If the arrangement uses a float switch to close the main
package is installed in an environment other than plant liquid solenoid valve if the receiver level
heated indoors, these heaters will not provide drops below the necessary level to supply the
sufficient heat to allow the oil to reach a safe compressor liquid injection feed requirements.
compressor start temperature. These low ambient
The second method utilizes a separate liquid
conditions require special consideration and the
injection receiver that has been sized to maintain
FES factory should be consulted before
a liquid level sufficient to maintain a five-minute
installation.
supply for compressor oil cooling. This method
The heaters operate only when the compressor is is illustrated in Figure 1-12.
in the off cycle. The heaters are thermostatically The third arrangement uses a receiver with a
controlled and are energized any time 120 volt second liquid injection feed dip tube, located
control voltage is applied to the package and the below the main plant supply dip tube. The
compressor is not operating. To prevent the compressor will receive a liquid injection supply
heaters from being energized, 15 amp circuit even after the main system supply is below its
breakers must be switched to the off position. minimum operating level. This arrangement is
NOTE: Do not apply control power without oil shown in Figure 1-13.
in the oil separator unless circuit The proper line size for delivery of the liquid
breakers are switched off. Failure to injection supply is very important. Also the
observe this precaution will result in liquid injection supply volume must be adequate.
the destruction of the heater elements. Table 1-14 provides the recommended supply
volume and line sizes. The supply volume is
Liquid Injection Oil Cooling
based on a nominal five minutes supply of liquid
High pressure oil is used in the screw compressor to the compressor. The liquid injection oil
to lubricate the bearings and to cool the cooling piping on the compressor package is self
compressor discharge gas. The oil also seals the contained and needs only to be connected to a
space between the rotors to prevent "blow-back" source of high pressure liquid as described in the
and provides muffling of the noise caused by proceeding paragraphs.
discharging gas. By injecting high pressure
refrigerant liquid into the compressor, the gas-oil
mixture is cooled by the latent heat of the
refrigerant liquid, thus omitting the need for a
separate externally cooled oil cooler.
The proper operation of liquid injection oil
cooling is dependent on having an uninterrupted
supply of high-pressure liquid refrigerant
available at all times. Several methods of
ensuring this are available. Whatever method is
used, the liquid refrigerant delivery line must be
adequately sized and the liquid source must retain
a reserve liquid supply beyond other system
needs so that an additional five minute liquid
Document: GM-1
Revision: D
9 Effective: 09-04
Figure 1-11: Liquid Injection Feed Arrangement Number 1
The specially charged thermostatic expansion gas is metered through the pressure regulator and
valve bulb must be installed in the thermowell returned to suction.
provided on the compressor discharge (being For dual high stage compressor packages, one
careful not to damage the connecting capillary outlet pressure regulator is used in conjunction
tube and sensing bulb). Refer to Figure 1-15 for with the two TX valves to provide a source of
typical compressor package liquid injection constant pressure at the TX valve equalizer port.
piping. Discharge gas is used in the same manner as on a
single high stage compressor package.
For booster applications, the high pressure gas
connection must be taken from a high side source.
It is the same as single high stage in all other
aspects.
For dual booster compressor arrangements, the
high pressure gas connection is taken from a high
side source. It is the same as dual high stage in
all of the aspects.
For two-stage compressor packages, only the high
stage compressor requires liquid injection. If the
booster can run by itself, liquid injection is
required for the booster.
NOTE: Some compressor sizes employ a dual
Figure 1-15: Typical Liquid Injection Piping TX valve arrangement for liquid
For single high stage compressor applications, the injection feed. This arrangement
thermal expansion valve is externally equalized to varies depending on compressor size.
a predetermined constant pressure intermediate to Piping schematics supplied with the
the discharge and suction pressure. This pressure compressor package, along with the
is maintained by the use of an outlet pressure Operation section of this manual,
regulating valve. A small amount of discharge should be referred to for operating
details
Document: GM-1
Revision: D
11 Effective: 09-04
Thermosiphon Oil Cooling cooler (400 psig DWP shell side and 300 psig
tube side). A typical arrangement for
Thermosiphon oil cooling utilizes liquid
thermosiphon oil cooling is shown in Figure 1-16.
refrigerant from the condenser to remove heat
from the oil. Liquid refrigerant is fed by gravity The following are general guidelines based on
to the oil cooler where it is vaporized by the good engineering practice and experience. Every
warm oil. The refrigerant vapor returns to the installation is unique and therefore will require
condenser where it is recondensed. The oil heat specific design consideration. It is the
is rejected directly to the condenser and therefore responsibility of the system designer and/or
requires no external cooling fluid or compressor installer to determine how these and other
capacity. guidelines shall apply.
Many variations are possible in constructing a NOTE: Refer to the FES Engineering Data
suitable thermosiphon oil cooling system, but the Sheet for the oil cooler heat of
basic system will always include a liquid rejection (OCHR) specific to the
refrigerant receiver or reservoir at condensing applicable model and design operating
temperature and pressure and a shell and tube oil conditions.
Document: GM-1
Revision: D
13 Effective: 09-04
R-717 OCHR R-22 OCHR E. Horizontal liquid supply lines to the
Pipe Size thermosiphon coolers shall be properly vented
(MBH) (MBH)
to allow generated gas to escape, or be
1-¼ 136 44 arranged to provide sewer flow into the cooler
1-½ 206 66 allowing generated gas to migrate back to the
liquid source without obstructing liquid flow.
2 400 128
F. R-717 systems require oil to be regularly
2-½ 638 204 drained from the lowest point of each system.
3 1128 361
NOTE: The thermostatic valve element is
4 2305 737
installed in the valve. The element is to
5 4114 1318 be immersed in oil for at least two
6 6651 2128 minutes prior to exposure to ammonia.
8 13615 4354
Based on 95°F Saturated Vapor
Table 1-19: Maximum Capacities for Vapor
Line from Receiver to Condenser
601 to 900 2 4
901 to 1500 3 5
1501 to 2700 3 6
2701 to 4800 4 8
Up to 60 1 2
61 to 300 2 3
301 to 600 3 4
R-22
601 to 900 4 6
901 to 1500 4 8
1501 to 2700 6 10
2701 to 4800 8 12
Based on 95°F Saturated Condensing Temperature
Table 1-20: Thermosiphon Line Sizes To and
From Oil Cooler
Document: GM-1
Revision: D
Effective: 09-04 14
Figure 1-21: Typical Economizer Arrangements
C. Grounding
On compressor packages, the compressor
motor must be grounded per FES Field
Wiring and Starter Specification ENG-3 using
a separate copper conductor sized in
accordance with all electrical codes applicable
to the job site. Conduit grounds are not
acceptable.
The oil pump motor must also be grounded
per FES Specification ENG-3 using a separate
copper conductor sized in accordance with all
applicable electrical codes. Conduit grounds Figure 1-22: MOV Installation
are not acceptable. All AC connections should enter the panel as
The microprocessor control panel must be close to their termination point as possible. AC
grounded to the same ground or to the voltage wiring must be prevented from making direct or
transformer using a separate single incidental contact with the circuit board or any of
uninterrupted copper conductor sized per the the low voltage connection cables. FES
power wiring guidelines listed above the microprocessor panels are designed with most, if
installed per the applicable FES field wiring not all, of the control voltage connections located
diagrams. Conduit grounds are not at the top of the panel. All field wiring should be
acceptable. contained in the top portion of the panel and away
The starter panel and the control voltage from potentially sensitive areas surrounding the
transformer must be grounded to a true earth microprocessor board.
ground (i.e. one supplied by the utility Any additional DC devices (e.g. process
company). A separate copper conductor is temperature input) must be connected using
recommended. shielded cable with the shield grounded at the
device end only.
NOTE: Refer to Figure 1-23 for the correct
grounding method. Figures 1-24 All pressure transducer should have their shield-
and 1-25 are examples of typical wire cut off.
improper grounding techniques.
Document: GM-1
Revision: D
Effective: 09-04 16
Figure 1-23: Proper Grounding
TABLE OF CONTENTS
PAGE
Introduction...........................................................................................................................1
Design Limitations ................................................................................................................1
Compressor............................................................................................................................2
Compressor Lubricating System .........................................................................................2
Compressor Oil Separating System ....................................................................................3
Compressor Oil Cooling Systems ........................................................................................3
Single Port Liquid Injection Oil Cooling ............................................................................3
Dual Port Liquid Injection Oil Cooling ..............................................................................5
Outlet Pressure Regulating Valve Adjustment ..................................................................5
Compressor Hydraulic System (Fixed VI) .........................................................................5
Compressor Hydraulic System (Variable VI) ....................................................................6
GM SERIES SCREW NOTE: This section must be read and
understood prior to startup or operation
COMPRESSOR PACKAGES of the package.
SECTION 2 PACKAGE OPERATION
Design Limitations
Introduction The GM Series screw compressor packages are
This section provides information for properly designed to operate within the limits shown below
operating the GM Series screw compressor in Table 2-1:
package. The package systems covered in this
section include the lubricating, oil separating, oil
cooling, and hydraulic systems.
Document: GM-2
Revision: B
1 Effective: 03-03
Compressor compressor shaft.
The FES GM Series screw compressor is a Compressor Lubricating System
positive displacement, helical-rotor axial flow The lubricating system of the GM Series
compressor designed for use with high pressure compressor package performs the following major
refrigerants. The compressor contains the functions:
following major features.
A. Provides lubrication to the bearing and
A. The compressor casting is high grade low mechanical shaft seal.
porosity cast iron precision machined for
minimal clearance about the periphery of the B. Provides motive force to move the unloader
rotors. piston.
B. Two intermeshing male and female rotors C. Provides oil to the balance piston which adds
machined from steel. The male rotor has five to the life of the bearings.
lobes and drives the female rotor which has D. Provides compressor cooling.
six lobes. E. Quiets compressor noise and reduces
C. Duplex angular contact ball bearings and a vibration.
balance piston are used to handle thrust loads. F. Creates an oil seal between the rotors
Radial bearings are cylindrical rolling element preventing rotor contact and gas bypassing.
bearings. R-717 Applications
D. The mechanical shaft seal is a single carbon GM Series compressors used in high stage
seal lubricated by supply oil which is cooled applications do not have an external oil pump.
and filtered. Injection oil (for cooling) and oil for the
E. Capacity control from 10% to 100% using a compressor bearings, balance piston, shaft seal,
slide valve assembly. and capacity control is supplied by positive gas
F. Shaft rotation is CLOCKWISE facing the differential pressure. A compressor internal oil
NOTE: One heater and one primary side sightglass is standard on the 110GM – 160GM.
Two heaters and two primary side sight glasses are standard on the 195GM.
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Revision: B
Effective: 03-03 6
MICRO CONTROL PANELS
SECTION 3 MICRO III OPERATION
FOR G SERIES COMPRESSORS
TABLE OF CONTENTS
PAGE
Introduction ....................................................................................................................................... 1
Keypad................................................................................................................................................ 2
Display Function Keys.................................................................................................................. 2
Data Entry Keys............................................................................................................................ 3
Alt Key.......................................................................................................................................... 3
Compressor Control Keys............................................................................................................. 3
Hardware ........................................................................................................................................... 5
Power Supply................................................................................................................................ 5
Processor Board Battery Requirements & Replacement .............................................................. 5
Display Contrast Adjustment........................................................................................................ 7
Communications Node ID ............................................................................................................ 7
Line Voltage Fuse F1.................................................................................................................... 7
Analog Over Current Reset........................................................................................................... 7
Analog Input Jumpers ................................................................................................................... 8
RS-232 / RS-422 Serial Communication Ports............................................................................. 8
Analog Output Configuration ....................................................................................................... 8
Dipswitch Settings ........................................................................................................................ 9
LED1 – LED6 ............................................................................................................................. 10
Displays............................................................................................................................................. 11
Operating Data ............................................................................................................................ 12
Analog Data ............................................................................................................................... 13
Analog Sensor Calibrations ........................................................................................................ 14
Digital Data ................................................................................................................................ 19
Shutdowns................................................................................................................................... 21
Alarms......................................................................................................................................... 25
Historical Data ............................................................................................................................ 27
Operating Parameters.................................................................................................................. 29
Alarm Parameters........................................................................................................................ 37
Compressor & Controls Data...................................................................................................... 39
Control.............................................................................................................................................. 42
Compressor Start Sequence of Operation ................................................................................... 42
Compressor Stop Sequence of Operation ................................................................................... 44
Suction Pressure / Process Temperature Capacity Control......................................................... 45
Low Suction Pressure Overload.................................................................................................. 46
Discharge Pressure Overload ...................................................................................................... 47
Motor Current Overload ............................................................................................................. 48
Compressor Lubrication System Control.................................................................................... 49
Compressor Slide Valve Control ................................................................................................ 51
Compressor Variable Vi Control ................................................................................................ 52
Communications Protocol............................................................................................................... 57
Addenda (when applicable)..................................................................................... following page 82
Diagnostics Operation MCP-144......................................................................... following Addenda
Introduction
This manual provides detailed information for operating the FES Micro III compressor control panel.
The FES Micro III control panel is a microprocessor based system that continuously monitors the
compressor package operation for optimum performance and reliability.
The front of the control panel contains a control power switch and a keypad/display overlay as standard.
The control power switch is used to completely disable the Micro III control panel and all outputs by
removing power from the panel. The control power switch should only be used in emergencies or
instances where the panel must be disabled to replace parts or make wiring additions.
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Keypad
The keypad is the user interface to the control panel. For discussion, it can be divided into three
sections: the Display Function keys, the Data Entry keys, and the Compressor Control keys.
CHANGE
DISPLAY ENTER
EDIT
CLEAR ALARM
OFF
COMPRESSOR CONTROL
ANTI-
REMOTE RECYCLE COND
START OIL LOAD 3 2 1
DRAIN A B C
ALT
NOTE: Keypad Lockout is available as an option for the Micro III. The Keypad Lockout option
provides a key switch to prohibit unauthorized changes to Micro III parameters, or totally disable
the Micro III keypad (dipswitch selection). The following examples assume that Keypad Lockout is
disabled or not installed.
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Keypad
To change an entry in a parameter display group, place the cursor on the appropriate entry and press
the [EDIT] key. Use the Data Entry keys to enter an appropriate value. If an error is made during
entry, press the [CLEAR] key to start entry again. Press [ENTER] after the entry is made. If the
new entry was within range limits, it will be accepted. If it was outside range limits, the last line of
the display will indicate 'Minimum=' or 'Maximum=' and the entry will be rejected. If the user
wishes to accept the old value, press the [EDIT] key again.
In the Shutdowns and Alarms Display Groups, the [CLEAR] key is used to remove individual
(acknowledge) shutdown and alarm messages once a resolution has been made. If an external
device like a siren or horn is connected to the panel, the [ALARM OFF] key is used to silence the
warning once the user has been alerted.
ALT KEY
Located in the lower right of the keypad/display overlay is the [ALT] key. The [ALT] key is used
to access any of the functions on the keypad that are in blue print, for example [A] – alternate
function to Data Entry key [1]. Pressing the [ALT] key will illuminate its LED. While the [ALT]
LED is illuminated, pressing any of the keys with blue print will take that action. For example, to
enter an alpha-numeric “A”, the [ALT] key would be pressed (LED illuminated) followed by the
[1] key. Note, the [ALT] LED will only stay illuminated until another key is pressed, 1 minute
passes before another key is pressed, or the [ALT] key is pressed again.
A motor driven oil pump is standard on GL Series Compressors but is an option on GM and GS
Series Compressors. The [OIL PUMP] key can be used to start the compressor oil pump, if so
equipped, and the compressor is stopped and in Service Mode (dipswitch SW6 #3 Closed). Press
the key once to start the oil pump, and again to stop it. This function is useful when setting oil
pump clearances or calibrating the slide valve. When started in this fashion for testing purposes,
the [OIL PUMP] LED will flash at a ¾ second on/off rate to indicate oil pump test mode. While
the Oil Pump is running, during normal compressor operation, the LED will be on steady. If the Oil
Pump is cycled off during the start-up period, the [OIL PUMP] LED will flash at a 1.5 second
on/off rate to indicate that the pump is off, but will be restarting within 10 seconds.
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Keypad
The [SHUTDOWNS] key will flash if a shutdown annunciation is present. Press the key to view
the Shutdowns Display. The [ALARMS] key functions in a similar fashion to access the Alarms
Display.
The [AUTO] key places the compressor in automatic capacity mode, where it will load and unload
its slide valve to maintain suction pressure or process temperature based on setpoints entered in
Operating Parameters. The [HOLD] key causes the compressor to maintain its current slide valve
position. The [LOAD] and [UNLOAD] keys force the slide valve to move manually. Pressing
[EXTERNAL] key allows an external device, like a programmable logic controller (PLC), to
control compressor capacity by energizing the optional External Load and Unload Inputs.
If compressor anti-recycle time or oil drain time has not expired, the [ANTI-RECYCLE/OIL
DRAIN] key’s LED will be lit steady1. The [OIL HEATER] key’s LED will be lit steady if the Oil
Heaters are energized. If the Micro III’s Power Fail Reset sequence has been activated by a power
loss, the [POWER FAIL RESET] key’s LED will be lit steady. Note that these keys are for status
only. Pressing the [ANTI-RECYCLE/OIL DRAIN], [OIL HEATER], or [POWER FAIL RESET]
keys will perform no control function.
1
Applies only to software Revision 4.0 or later. In previous versions this LED was illuminated only if anti-recycle
time had not expired. The only indication other than the time displayed on the Compressor & Controls screen was
that LED4 on the Micro III main board was illuminated.
2
Applies only to software Revision 5.9 or later.
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Hardware
POWER SUPPLY
The power supply has a +5VDC adjustable setting. Before adjusting the voltage, set the control
power switch to the off position. Next, unplug the power supply connector from the lower left of the
processor board. Set the control power switch to the on position. Because it has no load, the power
supply will "chirp" repeatedly.
Measure the +5VDC supply between the +5V and ground terminals on the power supply. Use a
small flat-blade screwdriver to adjust the voltage between 5.00 and 5.10 Volts DC.
Note that the power supply's "crowbar" protection will activate above 5.60 VDC, which
will cause it to shutdown. To reset the crowbar, turn the control power switch to the off
position and adjust the voltage potentiometer to its lowest setting.
Set the control power switch to the off position and plug the power supply connector into the
processor board. Turn the control power switch to the on position and verify the +5VDC, +12VDC,
-12VDC, and +24VDC power supply voltages. The +12VDC, -12VDC, and +24VDC supply
voltages are non-adjustable and should be within +5% of nominal (+11.4 to +12.6, -11.4 to -12.6,
+22.8 to +25.2, respectively). If they are not, replacement of the Micro III's power supply will be
necessary.
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Hardware
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Hardware
DISPLAY CONTRAST ADJUSTMENT
Due to differences in ambient lighting, it may be necessary to adjust the display's contrast once the
compressor package has been installed. This can be accomplished via the 'DISPLAY ADJ.'
potentiometer located on the upper right of the processor board, near the keypad/display ribbon
cable.
Communications NODE ID
Rotary switches SW4 and SW5 set the Node ID for ComMENT Network communications or Micro
III Direct communications. These rotary switches register the number or letter near the index mark
on the switch's base. The Node ID selection is read from the rotary switches during power up or
reset only. A Node ID of '05', for example, would be established by setting SW4 to '0' and SW5 to
'5'. Please refer to MCP-003 for a full explanation of the ComMENT Network and MCP-161 for
Micro III Direct Communications.
A Node ID of '00' is invalid and must not be used. When assigning Node ID's, remember that each
Communications Node must have its own unique ID.
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Hardware
ANALOG INPUT JUMPERS
The Micro III processor board has 16 channels of analog input. The factory-configuration defines
the purpose and scaling for each of these inputs. Each input has jumpers to make it electrically
compatible with 0-5V, 1-5V, 4-20mA, and ICTD (integrated-circuit temperature device) signals. In
addition to the these selections, channel 8 can be fitted to a potentiometer for slide valve indication
and channel 16 can be interfaced to a 0-5Amp current transformer.
To simplify sensor wiring, each input has terminals for analog power and ground. For the channels
1 through 6, J17 can be used to select an analog power supply of +5VDC for ratiometric pressure
transducers (J17 in upper position) or +24VDC (J17 in lower position). The analog power supply
for the remaining channels is fixed at +24VDC.
Channel Power Supply, Input, Ground Associated 0-5VDC or 1- 4-20mA ICTD Notes
Number Terminals Jumpers 5VDC Temperature
1 A1, A2, A3 J16, J14 J14 J16 J14
2 A4, A5, A6 J15, J13 J13 J15 J13
3 A7, A8, A9 J21, J19 J19 J21 J19
4 A10, A11, A12 J20, J18 J18 J20 J18
5 A13, A14, A15 J27, J23 J23 J27 J23
6 A16, A17, A18 J25, J22 J22 J25 J22
7 A19, A20, A21 J31, J29 J29 J31 J29
8 A22, A23, A24 for sensor J30, J28, J48 J28, J48 in J30, J48 in J28, J48 in J48 in upper
A25, A26, A27 for slide valve lower pos lower pos lower pos pos for slide
pot valve pot
9 A31, A32, A33 J35, J33 J33 J35 J33
10 A34, A35, A36 J34, J32 J32 J34 J32
11 A37, A38, A39 J39, J37 J37 J39 J37
12 A40, A41, A42 J38, J36 J36 J38 J36
13 A43, A44, A45 J43, J41 J41 J43 J41
14 A46, A47, A48 J42, J40 J40 J42 J40
15 A49, A50, A51 J47, J45 J45 J47 J45
16 A52, A53, A54 for sensor J46, J44, J49 J44, J49 in J46, J49 in J44, J49 in J49 in upper
A29, A30 for current input lower position lower position lower position position for
current input
Table of Processor Board Analog Input Terminals and Configuration
DIPSWITCH SETTINGS
Two banks of dipswitches, labeled SW6 and SW2, are located on the Micro III processor board.
They are used to select various operating modes of the control panel as described below:
DIPSWITCH SW6
SW6 #1, #2 – ComMENT Network Baud Rate
SW6 #1, #2 are used to set the Micro III's ComMENT Network baud rate for
communications. The selected baud rate must be the same as all other ComMENT devices
on the network.
SW6 #4 – spare
SW6 #7 – Spare
SW6 #8 – Spare
DIPSWITCH SW2
LED1 – LED6
LED’s located on the Micro III process board are provided to give indication of various
functions.
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Displays
The display used on the Micro III control panel is a 16 line by 26 character liquid crystal display with
LED backlighting. It provides an operator interface showing status, analog readings, and setpoints. The
operator interface is organized using Display Groups, with related information placed in the same group.
When control power is applied to the Micro III, the Opening Display appears briefly with the GEA logo.
Afterward, the Operating Data Display appears. The [CHANGE DISPLAY] key moves the user
through the following Display Groups in sequential order. The [ALT] key followed by the [CHANGE
DISPLAY] key will move the user to the previous Display Group1. Note that these are the standard
Display Groups, additional groups may be included, consult the addendum at end of Section 3 if the
Micro III has any special programming.
• Operating Data
• Analog Data
• Digital Data
• Shutdowns
• Alarms
• Historical Data
• Operating Parameters
• Alarm Parameters
• Compressor & Controls Data
Note that the Shutdowns Display cannot be accessed unless there is at least one shutdown annunciation
present. The Alarms Display cannot be accessed unless there is at least one alarm annunciation present.
1
Applies only to software Revision 5.9 or later.
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Displays
OPERATING DATA
The Operating Data Display shows important analog data and status information so the user can easily
monitor compressor operation. A typical Operating Data Display appears in the figure below. The
current suction pressure or process temperature is displayed with large numerals at the top of the
display. Slide valve load and unload activity is indicated with 'LD' and 'UL'. The first line of data
indicates the current setpoint, followed by pertinent analog data. An '*' will appear at the top center of
the display during ComMENT Network communication.
OPERATING DATA
* DIS LoS CUR
22.6
Suct 1 Setpnt 20.0 Psi
UL
While the compressor is operating, overload conditions are signaled by the appearance of 'DIS', 'LoS', or
'CUR' above the current suction pressure or process temperature. During an overload condition, the
compressor will automatically limit loading of the slide valve, or unload the slide valve, if necessary to
prevent a shutdown. 'DIS' will appear during a high discharge pressure overload. 'LoS' will appear
during a low suction pressure overload, while operating in process temperature control. 'CUR' will
appear during a high motor current overload.
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Displays
ANALOG DATA
The Analog Data Display shows the current readings from analog transducers located throughout the
compressor package. The [ ] and [ ] keys can be used to position the cursor and scroll the display to
view the following data. The [] and [ ] keys move the cursor down or up 8 lines at a time. If the
compressor is in Service Mode (dipswitch SW6 #3 Closed), then calibration of analog transducers can
be performed.
ANALOG DATA
Suction Pressure 41.1 Psi
Disch Pressure 162.1 Psi
Oil Diff Press 68.5 Psi
Oil Filter Diff 4.3 Psi
Oil Separator Tp 122.4 °F
Inlet Oil Temp 132.0 °F
Discharge Tmp 158.0 °F
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Displays
SV Voltage – Voltage from the output of the Slide Valve Position pot or indicator. Displayed in
Service Mode only. No calibration necessary.
Vi Scalc – Maximum primary slide valve position for GL series variable Vi compressors only.
See “Control” section of this manual for additional information.
Vi Vsopt – This is where the secondary slide it to be positioned to achieve the optimum Vi
setting for GM series compressors only. See “Control” section of this manual for additional
information.
Secondary Slide – Position of the Secondary Slide valve, for GM series variable Vi
compressors only. See “Control” section of this manual for additional information.
Secondary slide Voltage – Voltage from the output of the Secondary Slide Valve Position
indicator. For GM series Variable Vi compressors only and displayed only in Service Mode.
No calibration necessary.
Motor Current – Amps (RMS) flowing through the motor current CT (via Input P12).
kW Demand – Instantaneous energy usage calculated using the compressor motor current
transformer and kW Metering Ratio Operating Parameter. No calibration necessary.
kW Avg Usage – Average energy usage during the previous kilowatt hour Sampling Period.
No calibration necessary.
Volume Index – Calculated ideal volume index (from 1TD, 2TD). No calibration necessary.
Vi Viswitch – Vi position used by GS series compressors to switch between increasing or
decreasing Vi. For GS series variable Vi compressors only. See “Control” section of this
manual for additional information.
Line Voltage – Volts (RMS) powering the Micro III Processor Board (via Input P2). Reading
accurate within 1.5%. No calibration necessary.
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Displays
10. If the calibrated pressure is outside of range limits, a 'Minimum=' or 'Maximum=' warning
will appear on the last line of the display momentarily. Range limits are the current electrical
reading ±10% of the transducer's range. The need to calibrate a pressure transducer outside
the ±10% range limits is a sign that the transducer is damaged, miswired, or of the wrong
type.
Calibration of this pressure transducer is complete.
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Displays
CALIBRATION OF THE SLIDE VALVE FOR GM/GS COMPRESSORS W/O EXT. PUMP:
1. Ensure that the control panel is in Service mode (dipswitch SW6 #3 Closed) and the
compressor is Stopped.
2. Press the [CHANGE DISPLAY] key until the Analog Data Display appears.
3. Position the cursor on the 'Slide Valve %' entry using the [ ] and [ ] keys.
4. Verify that the compressor is physically fully unloaded as much as possible. The Micro III
will allow the compressor to start if it has a slide valve reading less than 70.0%. Otherwise,
the slide valve mechanism must be mechanically adjusted to less than 70% to allow the
Compressor to be initially started.
5. Start the Compressor and wait until.
6. Press the [UNLOAD] key. Wait until the slide valve reaches the fully unloaded position.
The 'SV Voltage' should stabilize once the compressor fully unloads.
7. Press the [EDIT] key and then the [0] key. Next, press [ENTER]. The corresponding slide
valve voltage has been recorded as the fully unloaded position.
8. Press the [LOAD] key. Wait until the slide valve reaches the fully loaded position. The 'SV
Voltage' should stabilize once the compressor fully loads.
9. Press the [EDIT] key and then the [1], [0], [0] keys. Next, press [ENTER]. The
corresponding slide valve voltage has been recorded as the fully loaded position.
10. Press the [UNLOAD] key again. The compressor should fully unload and the indicated Slide
Valve % should track with it. Press the [LOAD] key to fully load the compressor and
observe the Slide Valve %.
11. If the Slide Valve % appears to track with the mechanical indication (if equipped with this
feature), calibration is complete. Press the [OIL PUMP] key to terminate Oil Pump Test.
12. Otherwise, repeat the procedure. Ensure that the slide valve voltage changes smoothly
between full unload and full load.
13. Allow the compressor to remain stopped for several minutes so excess oil can drain.
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7. Put the hand-held clamp of an amprobe around every wire going through the compressor's
current transformer.
8. Adjust motor current span potentiometer R95 on the Micro III processor board until the 'Motor
Current' entry and the amprobe agree.
9. Press the [UNLOAD] key to unload the slide valve.
Additional Analog Points may be assigned for special applications, refer to the addendum at the end of
Section 3.
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Displays
DIGITAL DATA
The Digital Data Display shows the current state of the modules on the I/O rack(s). The [ ] and [ ] keys
can be used to scroll the display to view the data. The [] and [ ] keys move the cursor down or up 6
lines at a time.
DIGITAL DATA
Cmp Starter Off
Oil Pmp #1 Start Off
Cmp Interlock Off
Oil Pmp #1 Intlk Off
Oil Sep Heater On
Load Solenoid On
The following is a list of standard Digital Data Display entries, I/O Modules may not be installed in all
locations.
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A-R Timing Out – Anti-recycle Timing Output, On or Off. This output is energized when there
is anti-recycle time remaining for the Compressor Motor
Remote & Extl Out – Remote and External Out, On or Off. This output is energized when the
Micro III is place an External and Remote Modes
Sld Valve Out #1 – Slide Valve Output #1, On or Off. This output is energized or de-energized
based on user adjustable Operating Parameters, refer to DISPLAYS, OPERATING
PARAMETERS.
Sld Valve Out #2 – Slide Valve Output #2, On or Off. This output is energized or de-energized
based on user adjustable Operating Parameters, refer to DISPLAYS, OPERATING
PARAMETERS.
Shutdown Status – Shutdown Status Output, On or Off. Normally On, this output is de-
energized if there are any Shutdowns present.
Econ Suction Out – Economizer Suction Solenoid Output, On or Off.
Aux Alarm #1 In – Auxiliary Alarm #1 Input, OK or Alarm. When de-energized ‘Auxiliary
Alarm #1’ is annunciated immediately. This compressor motor is not stopped.
Alarm Status – Alarm Status Output, On or Off. Normally On, this output is de-energized if
there are any Alarms present.
Aux Shtdn #2 In – Auxiliary Shutdown #2 Input, OK or Shtdn(Shutdown). When de-energized
‘Auxiliary Shutdown #1’ is annunciated after a five second delay, the compressor motor is
stopped.
Low Oil Level In – Oil Separator Low Oil Level switch input, OK or Low. When de-energized
indicates a Low Oil Level condition in the Oil Separator, a shutdown will occur.
The following two modules are present on Variable Vi machines only.
Sec Slide Load – Secondary Slide Load Solenoid, On or Off.
Sec Slide Unload – Secondary Slide Unload Solenoid, On or Off.
Additional Digital I/O may be assigned for special applications, refer to the addendum at the
end of Section 3.
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Displays
SHUTDOWNS
The Shutdowns Display can be accessed only when a shutdown annunciation is present. The operator
can use the [CHANGE DISPLAY] key to locate the Shutdowns Display, or press the [SHUTDOWNS]
key to go directly to the display. This display group allows the operator to view the shutdown
annunciation, with the time and date (last line of display) at which the shutdown occurred, for as many
as 15 annunciations.
SHUTDOWNS
Low Suction Pressure
10:32 12/15/99
The Micro III will retain shutdown annunciations until manually cleared, even through power failures.
Note that all shutdown annunciations must be cleared to re-start the compressor. To clear a shutdown
annunciation, first resolve the source of the annunciation. Next, position the cursor on the shutdown to
be cleared using the [ ] and [ ] keys, then press the [CLEAR] key. The shutdown will re-appear if it has
not been properly resolved. The following is a list of possible shutdowns.
Hi Oil Separator Temp – Oil separator temperature exceeded the Oil Separator Upper
Operating Parameter while the compressor was Stopped or in the process of Starting.
Lo Oil Separator Temp – Oil separator temperature fell below the Oil Separator Lower
Operating Parameter while the compressor was in the process of Starting.
Auxiliary Shutdown #1, #2 – The appropriate Auxiliary Shutdown Input module was de-
energized for 5 continuous seconds during Stop, Startup, Run, or Shutdown. These inputs are
typically connected to external safety devices for the compressor package.
Compressor Start – The Compressor Interlock Input module failed to be energized or actual
motor current greater than 10% of the Motor Current Lower Operating Parameter was not
detected 8 seconds after the Compressor Start Output module was energized at Startup.
Loss of Compr Interlock – The Compressor Interlock Input module failed to be energized for at
least 1/2 second while the compressor was operating in Run.
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Loss of Compr Mtr Current – The motor current dropped below 10% of the Motor Current
Lower Operating Parameter while the compressor was operating in Run.
High Motor Current – The motor current exceeded the Motor Current Upper Operating
Parameter for 30 continuous seconds while the compressor was operating in Run.
Motor Current Overload – The motor current exceeded the Motor Current Upper Operating
Parameter, then remained above (Motor Current Upper - Motor Current Deadband Operating
Parameters) for 5 continuous minutes during Run.
Illegal Cmp Interlock – The Compressor Interlock Input module was energized for 5 seconds
while the compressor was Stopped, or remained energized 12 seconds after the compressor was
Shutdown.
Illegal Cmp Mtr Current – Actual motor current greater than 5 amps was detected for 5
seconds while the compressor was Stopped, or 12 seconds after the compressor was Shutdown.
High Discharge Pressure – The actual discharge pressure exceeded the Discharge Pressure
Maximum Operating Parameter during Run, or was within 10 PSI of the Discharge Pressure
Maximum Operating Parameter at Startup.
High Discharge Temp – The actual discharge temperature exceeded the Discharge Temperature
Upper Operating Parameter during Stop, Startup, Run, or Shutdown.
Operating Parameter # – The microprocessor detected an Operating Parameter outside its entry
limits. The number after the annunciation indicates which Operating Parameter is in error. In
the Operating Parameters Display, out-of-range parameters will flash until corrected. Refer to
the recommended settings (data sheets) that were included with the compressor package for the
proper entry. Note that this annunciation is active during Stop, Startup, Run, and Shutdown and
cannot be cleared until the error is corrected (valid Operating Parameter entered).
Discharge Press Overload – The actual discharge pressure exceeded (Discharge Pressure
Maximum - Discharge Pressure Prop Band Operating Parameters) for 5 continuous minutes
during Run.
Hi Oil Filter Differential – After a 90 second delay at Startup, the pressure drop across the oil
filter exceeded the Oil Filter Pressure Drop Operating Parameter for 30 seconds during Run.
This pressure drop is measured as the difference between the Oil Filter Inlet Pressure and the
Inlet Oil Pressure.
Low Line Voltage # – The line voltage powering the processor board dropped below the
factory-configured trip voltage. The number following the annunciation is the actual line voltage
at the time of the annunciation. Note that this shutdown is active only when the Power Fail
Reset option is disabled (dipswitch SW6 #6 Open).
Analog Calibration # – The microprocessor detected an Analog Calibration outside its entry
limits. The number after the annunciation indicates which analog channel's calibration is in
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error. Refer to Hardware's Table of Processor Board Analog Input Terminals and
Configuration. Note that this annunciation is active during Stop, Startup, Run, and Shutdown
and cannot be cleared until the error is corrected (channel re-calibrated).
Low Inlet Oil Temperature – After a 2 minute delay at Startup, the actual inlet oil temperature
fell below the Inlet Oil Temperature Lower Operating Parameter for 5 seconds during Run.
High Inlet Oil Temperature – After a 2 minute delay at Startup, the actual inlet oil temperature
exceeded the Inlet Oil Temperature Upper Operating Parameter for 2 minutes during Run.
Low Process Temperature – The compressor was operating in Process Temperature Control
Mode with the Low Process Temperature 0=Shutdn/1=Cycle Operating Parameter set to 0
(Shutdown). During Run, the actual process temperature fell below the Process Temperature
Lower Operating Parameter for the active Control Point (1 or 2).
Low Suction Pressure – While operating in Process Temperature Control Mode, the actual
suction pressure fell below the Process Temp Cntl Low Suction Shutdown Operating Parameter
for 10 continuous seconds during Run. Or while operating in Suction Pressure Control Mode
with the Low Suction Pressure Shutdn or Cycle Operating Parameter set to Shutdown, the actual
suction pressure fell below the Suction Pressure Lower Operating Parameter for the active
Control Point (1 or 2) during Run.
Low Suction Prs Overload – While operating in Process Temperature Control Mode, the actual
suction pressure remained below the Process Temp Cntl Low Suction Prop Band Operating
Parameter for 5 continuous minutes during Run.
Loss of Auxiliary Oil Pump Interlock or Loss of Oil Pump Interlock # – The Oil Pump
Interlock Input module was not energized within 5 seconds of the microprocessor running the oil
pump. This shutdown will only include the oil pump number (#) if the compressor packages is
equipped with dual oil pumps. This shutdown is only valid for compressors with external,
auxiliary oil pumps.
Illegal Auxiliary Oil Pump Interlock or Illegal Oil Pmp Interlock # – The Oil Pump Interlock
Input module remained energized for at least 5 seconds after the microprocessor stopped the oil
pump. This shutdown will only include the oil pump number (#) if the compressor packages is
equipped with dual oil pumps. This shutdown is only valid for compressors with external,
auxiliary oil pumps.
Low Auxiliary Oil Pump Pressure or Low Oil Pressure or Low Oil Pressure PMP # – The
Oil pressure failed to meet the minimum oil pressure requirements for five seconds. This
shutdown becomes active after the first 30 seconds of compressor operation. This shutdown will
only include the oil pump number ( PMP #) if the compressor packages is equipped with dual oil
pumps. The Low Auxiliary Oil Pump Press shutdown will only occur with GM or GS
compressors with external, auxiliary oil pumps.
High Oil Pressure – The actual inlet oil pressure exceeded maximum oil pressure limit for the
compressor during operation. Refer to the Control section of this manual for a detailed
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description of these limits based upon the compressor model and Operating Parameter - Control
settings.
Cmp Slide Valve Unload – The slide valve reading remained above 5.0% for 3 minutes of
unload during an attempted Startup.
Alarm Parameter # – The microprocessor detected an Alarm Parameter outside its entry limits.
The number after the annunciation indicates which Alarm Parameter is in error. In the Alarm
Parameters Display, out-of-range parameters will flash until corrected. Refer to the
recommended settings (data sheets) that were included with the compressor package for the
proper entry. Note that this annunciation is active during Stop, Startup, Run, and Shutdown and
cannot be cleared until the error is corrected (valid Alarm Parameter entered).
Low Oil Level – The Oil Level Input module was de-energized for 5 seconds while Stopped, or
for 3 minutes during Startup or Run.
Aborted Pwr Fail Reset – The power fail reset option was enabled (dipswitch SW6 #6 Close).
The microprocessor detected that incoming line voltage dropped below the factory-configured
limit and remained low longer than Abort Pwr Fail Reset After Operating Parameter.
Invalid Comp Model Sel – The compressor model selected on the Compressor & Controls Data
display is out of the range of valid entries. Please see the Compressor & Controls Data display
section of this manual to properly set the model. This shutdown is only valid for control panels
set to operate a compressor with continuous variable Vi control.
Oil Separator Temperature Probe Failure – The Oil Separator Temperature reading was
below –76.0 °F, indicating a Temperature Probe failure. While the temperature is below this
value, the Oil Heaters are de-energized. Refer to Analog Data section for information on the Oil
Separator Temperature.
Low Oil Press - Startup – This shutdown is issued after the 3rd start attempt of the oil pump to
build valid startup pressure.
Additional Shutdown Annunciations may be assigned for special applications, refer to the
addendum at the end of Section 3.
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ALARMS
The Alarms Display Group can be accessed only when an alarm annunciation is present. The operator
can use the [CHANGE DISPLAY] key to locate the Alarms Display, or press the [ALARMS] key to go
directly to the display. Operation of this display group is similar to the Shutdowns Display. This
display group allows the operator to view the alarm annunciation, with the time and date (last line of
display) at which the alarm occurred, for as many as 15 annunciations.
ALARMS
High Discharge Pressure
10:20 12/15/99
The Micro III will retain alarm annunciations until manually cleared, even through power failures. Note
that alarm annunciations are warnings and will not cause the compressor to shutdown. To clear an alarm
annunciation, first resolve the source of the annunciation. Next, position the cursor on the alarm to be
cleared using the [ ] and [ ] keys, then press the [CLEAR] key. The alarm will re-appear if it has not
been properly resolved. The following is a list of possible alarms.
Hi Oil Separator Temp – Actual oil separator temperature exceeded the Oil Separator Upper
Alarm Parameter while the compressor was Stopped or in the process of Starting.
Lo Oil Separator Temp – Actual oil separator temperature fell below the Oil Separator Lower
Alarm Parameter while the compressor was in the process of Starting.
Auxiliary Alarm #1 – The Auxiliary Alarm #1 Input module was de-energized during Stop,
Startup, Run, or Shutdown. This input is typically connected to external warning devices for the
compressor package.
High Motor Current – After a 2 minute delay at Startup, the actual motor current exceeded the
Motor Current Upper Alarm Parameter while the compressor was operating in Run.
High Discharge Pressure – The actual discharge pressure exceeded the Discharge Pressure
Maximum Alarm Parameter during Stop, Startup, Run, or Shutdown.
High Discharge Temp – The actual discharge temperature exceeded the Discharge Temperature
Upper Alarm Parameter during Stop, Startup, Run, or Shutdown.
Hi Oil Filter Differential – After a 2 minute delay at Startup, the pressure drop across the oil
filter exceeded the Oil Filter Pressure Drop Alarm Parameter during Run. This pressure drop is
measured as the difference between the Oil Filter Inlet Pressure and the Inlet Oil Pressure.
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Low Inlet Oil Temperature – After a 2 minute delay at Startup, the inlet oil temperature fell
below the Inlet Oil Temperature Lower Alarm Parameter during Run.
High Inlet Oil Temperature – After a 2 minute delay at Startup, the inlet oil temperature
exceeded the Inlet Oil Temperature Upper Alarm Parameter during Run.
Low Process Temperature – The compressor was operating in Process Temperature Control
Mode. After a 2 minute delay at Startup, the process temperature fell below the Process
Temperature Lower Alarm Parameter for the active Control Point (1 or 2).
Low Suction Pressure – While operating in Process Temperature Control Mode during Run, the
suction pressure fell below the Process Temp Cntl Low Suction Alarm Parameter after a 2
minute delay at Startup. While operating in Suction Pressure Control Mode during Run, the
actual suction pressure fell below the Suction Pressure Lower Alarm Parameter for the active
Control Point (1 or 2) after a 2 minute delay at Startup.
High Suction Pressure – While operating in Suction Pressure Control Mode, the suction
pressure rose above the Suction Pressure Upper Alarm Parameter for the active Control Point (1
or 2) after a 2 minute delay at Startup.
Low Line Voltage # – The line voltage powering the processor board dropped below the
factory-configured trip voltage. If the compressor was running, it was placed in Stop mode. The
number following the annunciation is the actual line voltage at the time of the annunciation.
Note that this alarm is active only when the Power Fail Reset option is enabled (dipswitch SW6
#6 Closed).
Real Time Clock Fault – A problem was detected with the Real Time Clock, this could indicate
a problem with the clock battery.
Additional Alarm Annunciations may be assigned for special applications, refer to the
addendum at the end of Section 3.
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HISTORICAL DATA
The Historical Data Display presents the Short-Term and Long-Term Historical Data in chronological
order for analysis. Data is arranged in a matrix format, with each row representing one data sample and
each column representing a particular piece of information, like Suction Pressure. The column headings
are abbreviations of the information presented in the Analog Data Display.
LONG-TERM HISTORICAL
SucP
SucP DisP
DisP OilP
OilP Fltr
Fltr SepT
SepT
41.1 162 184 4.3 106
40.8 163 186 4.3 106
38.4 160 180 4.2 106
40.1 164 188 4.2 104
42.2 164 189 4.2 108
Stop Unld Off Alarm
12/15/99 10:07:22
The last lines of the display indicate compressor status, time, and date when the data sample under the
flashing cursor was acquired. Press the [ ] and [] arrow keys to view other available information, and
press the [ ] and [ ] arrow keys to view other data samples. Data samples are presented in order (top to
bottom) from newest to oldest. To navigate through the matrix more quickly, press the [+/-SKIP] key. A
"+" will appear on the lower-left side of the display. The arrow keys will now move the cursor by an
entire screen width or height. Press the [+/-SKIP] key again to remove the "+" on the display and return
to incremental cursor movement.
The [. CHANGE] key can be used to reveal the unabbreviated description of the data under the flashing
cursor. If the data sample was the result of a shutdown or alarm (it will be flashing), press the [. CHANGE]
key again to reveal the shutdown or alarm annunciation. Press the [. CHANGE] key again to return to
compressor status.
The [ENTER] key is used to toggle between Long-Term and Short-Term Historical Data.
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OPERATING PARAMETERS
The Operating Parameters Display is used to enter setpoints that control or shutdown the compressor
package. Related parameters are presented as part of a group, which appears in all capital letters. The
Suction Pressure group is shown on the Example Operating Parameter Display. The operator can review
other Operating Parameters by pressing the [ ] arrow key to descend through the list, or the [ ] arrow
key to ascend. To quickly skip to the next group of parameters, press the [] arrow key, or the [ ] arrow
key for the previous group. If it is necessary to change an Operating Parameter, assure that the optional
Keypad
OPERATING PARAMETERS
SUCTION PRESSURE
Suction 1 Pressure
Set Point 40.0 Psi
Suction 1 Pressure
Upper 55.0 Psi
Suction 1 Pressure
Lower 30.0 Psi
Suction 1 Pressure
Prop Band 5.0 Psi
Suction 1 Pressure
Dead Band 5.0 Psi
Suction 2 Pressure
Set Point 40.0 Psi
Suction 2 Pressure
Upper 55.0 Psi
Lockout keyswitch is set to allow parameter changes. Next, position the cursor to the entry of interest.
Press the [EDIT] key and use the numeric keys to enter the new value. If a data entry error is made,
press the [CLEAR] key to remove the current entry. To return to the original entry, press the [EDIT]
key again. To accept the new entry, press the [ENTER] key. If the new entry is outside acceptable
range limits, a 'Minimum=' or 'Maximum=' message will appear on the last line of the display. Out-of-
range Operating Parameters will flash.
SUCTION PRESSURE
Two suction pressure setpoints are available for controlling the compressor package. Each of
the setpoints has its own set of parameters for complimentary functions.
Suction (1 or 2) Pressure Setpoint is the suction pressure to be maintained when the
compressor is in Auto capacity mode.
Suction (1 or 2) Pressure Upper is the suction pressure where a stopped compressor will
automatically startup if the ‘Low Suction Pres 0=Shutdn/1=Cycl Operating Parameter’ is set
to ‘1’ (Cycle). If it is set to ‘0’ (Shutdown), this parameter is not used
Suction (1 or 2) Pressure Lower is the suction pressure where a running compressor will
automatically stop. If the ‘Low Suction Pres 0=Shutdn/1=Cycl’ Operating Parameter is set
to ‘0’ (Shutdown), a shutdown will be annunciated. If it is set to ‘1’ (Cycle), it will cycle off
and re-start if the suction pressure rises above the Suction Pressure Upper Operating
Parameter. See 'Low Suction Pressure' Shutdown.
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Suction (1 or 2) Pressure Prop Band sets the width of the differential pressure band above
and below the Suction Pressure Dead Band used for proportionally loading and unloading the
compressor.
Suction (1 or 2) Pressure Dead Band sets the width of the pressure band, half above the
suction pressure setpoint and half below, where no capacity control adjustments are
performed.
Low Suction Pres 0=Shutdn/1=Cycl should be set to ‘0’ (Shutdown) if a shutdown
annunciation should be issued when the compressor encounters suction pressure lower than
the Suction Pressure Lower Operating Parameter. This selection should be set to ‘1’ (Cycle)
if the compressor should cycle off instead, and restart once the suction pressure exceeds the
Suction Pressure Upper Operating Parameter.
PROCESS TEMPERATURE
Two process temperature setpoints are available for controlling the compressor package.
Each of the setpoints has its own set of parameters for complimentary functions.
Process (1 or 2) Temperature Setpoint is the process temperature to be maintained when
the compressor is in Auto capacity mode.
Process (1 or 2) Temperature Upper is the process temperature where a stopped
compressor will automatically startup if the ‘Low Process Temp 0=Shutdn/1=Cycl’
Operating Parameter is set to ‘1’ (Cycle). If it is set to ‘0’ (Shutdown), this parameter is not
used.
Process (1 or 2) Temperature Lower is the process temperature where a running
compressor will automatically stop. If the ‘Low Process Temp 0=Shutdn/1=Cycl’ Operating
Parameter is set to ‘0’ (Shutdown), a shutdown will be annunciated after 10 continuous
seconds. If it is set to ‘0’ (Cycle), it will cycle off and re-start if the process temperature rises
above the Process Temperature Upper Operating Parameter. See 'Low Process Temperature'
Shutdown.
Process (1 or 2) Temperature Prop Band sets the width of the differential temperature
band above and below the Process Temperature Dead Band used for proportionally loading
and unloading the compressor.
Process (1 or 2) Temperature Dead Band sets the width of the temperature band, half
above the Process Temperature Setpoint Operating Parameter and half below, where no
capacity control adjustments are performed.
Low Process Temp 0=Shutdn/1=Cycl should be set to ‘0’ (Shutdown) if a shutdown
annunciation should be issued when the compressor encounters process temperature lower
than the Process Temperature Lower Operating Parameter. This selection should be set to
1(Cycle) if the compressor should cycle off instead, and restart once the process temperature
exceeds the Process Temperature Upper Operating Parameter.
Process Temp Control Lo Suct sets the lowest suction pressure allowable during process
temperature control. If suction pressure drops below this parameter during operation, a
shutdown will be annunciated. See 'Low Suction Pressure' Shutdown.
Process Temp Control Prop Band sets the suction pressure where proportional unloading
of the slide valve must take place to avoid a low suction pressure shutdown during process
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temperature control. If the suction pressure remains below this parameter for 5 continuous
minutes, a shutdown will be issued. See 'Low Suction Prs Overload' Shutdown.
Process Temp Control Ld Adjust sets the suction pressure where load pulses are
proportionally limited to avoid low suction pressure during process temperature control.
COMPRESSOR MOTOR
To avoid injury or damage to equipment, the parameters within this topic must be set
according to the motor manufacturer's recommendations.
Motor Current Upper should be set to Full Load Amps X Service Factor. If motor current
exceeds this parameter, the slide valve will be unloaded.
(484FLA)(1.15SF)=556.6 Amps
These proportional unload pulses will take place until motor current is reduced below (Motor
Current Upper - Motor Current Dead Band Operating Parameters). If motor current remains
above the Motor Current Upper Operating Parameter for 30 seconds, a shutdown will be
issued. See 'High Motor Current' Shutdown.
Motor Current Lower should be set to Full Load Amps. Once motor current rises above
this parameter, load pulses are proportionally limited as the current rises toward (Motor
Current Upper - Motor Current Dead Band Operating Parameters). In addition, motor
current in excess of 10% Motor Current Lower Operating Parameter must be detected within
8 seconds of Startup, or a shutdown will be issued. See 'Compressor Start' Shutdown.
Motor Current Dead Band should be set to at least Full Load Amps X Service Factor X
2%. This parameter is subtracted from the Motor Current Upper Operating Parameter to
form a dead band where no load pulses will be issued.
(484FLA)(1.15)(0.02)=11.1 Amps
If system conditions cause motor current to rise above the Motor Current Upper Operating
Parameter, then proportional unload pulses will take place until motor current is reduced
below the dead band. If motor current cannot be reduced below the dead band within 5
minutes, a shutdown will be issued. See 'Motor Current Overload' Shutdown.
Anti-Recycle Period establishes the minimum time that must elapse between compressor
starts.
Accumulated Cmp Runtime records the number of operating hours.
Motor Current CT Ratio sets the scaling ratio for the compressor motor current
transformer's primary. The scaling ratio entered for a 500:5 current transformer, for example,
would be 500. The secondary may be factory configured for 0-5 Amp or 0-1Amp.
INLET OIL
Oil Filter Pressure Drop, Max sets the tolerable drop across the oil filter. The pressure
drop is measured as the difference between the oil filter inlet and inlet oil pressures. If the
pressure drop exceeds this parameter for 30 seconds during Run after a 2 minute delay at
Startup, a shutdown will be issued. See 'Hi Oil Filter Differential' Shutdown.
Inlet Oil Temperature Upper sets the high temperature limit for the oil feeding the
compressor's inlet. If the inlet oil temperature exceeds this parameter for 2 minutes during
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Run after the 2 minute Startup delay, a shutdown will be issued. See 'Hi Inlet Oil
Temperature' Shutdown.
Inlet Oil Temperature Lower sets the low temperature limit for the oil feeding the
compressor's inlet. If the inlet oil temperature fails to exceed this parameter for 5 seconds
during Run after the 2 minute Startup delay, a shutdown will be issued. See 'Lo Inlet Oil
Temperature' Shutdown.
OIL SEPARATOR
Oil Separator Heater Setpoint is the temperature to be maintained in the oil separator by
the oil heaters. A fixed +1.5° hysteresis is used for control. Typically, the oil heater only
operates when the compressor is Stopped. Optionally, the oil heaters may be factory-
configured to operate when the compressor is Running for some refrigerants.
Oil Separator Temp Upper sets the high temperature limit for the oil separator. The oil
separator temperature is compared to this parameter when the compressor is Stopped, or
about to be Started. If the oil separator temperature exceeds this parameter, then a shutdown
will be issued. See 'Hi Oil Separator Temp' Shutdown.
Oil Separator Temp Lower sets the low temperature limit for the oil separator. The oil
separator temperature is compared to this parameter at startup. If the oil separator
temperature does not exceed this parameter, then a shutdown will be issued. See 'Lo Oil
Separator Temp' Shutdown.
DISCHARGE
Discharge Pressure Maximum establishes the upper limit for discharge pressure. If
discharge pressure exceeds this parameter at any time, a shutdown will be issued. Discharge
pressure must be at least 10 psi lower than this parameter to start the compressor, or a
shutdown will be issued. See 'High Discharge Pressure' Shutdown.
Discharge Pressure Prop Band sets the width of a pressure band below the Discharge
Pressure Maximum. If discharge pressure rises above (Discharge Pressure Maximum -
Discharge Pressure Prop Band Operating Parameters), then proportional unload pulses will
be issued. If discharge pressure does not fall below the pressure band within 5 minutes, a
shutdown will be issued. See 'Discharge Press Overload' Shutdown.
Discharge Temp Upper is the high temperature limit for the compressor's discharge. If the
discharge temperature exceeds this parameter at any time, a shutdown will be issued. See
'High Discharge Temp' Shutdown.
CONTROL
Control Mode 0=Press/1=Temp/2=DI determines whether the compressor controls capacity
based on suction pressure (0), or process temperature (1). Optionally, a factory-configured
digital input (Pressure/Temperature Input) may be used to make the selection (2).
Control Point 0=DI/1=PNT1/2=PNT2 determines which set of Suction Pressure or Process
Temperature Parameters is used to control capacity. An entry of 1 will utilize Suction 1
Parameters when the Control Mode is 0, or Process 1 Parameters when the Control Mode is
1. Optionally, a factory-configured digital input (PNT1/PNT2 Input) may be used to make
the selection (0).
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Capacity Load/Unload Period sets the maximum width of a capacity control pulse. All
proportional load or unload pulse calculations utilize this parameter.
Slide Valve Position Minimum keeps the compressor's slide valve loaded to at least this
parameter in Auto capacity mode.
Ld Lmt 0=None/1=Pulse/2=SP/3=SV selects the parameters used for Load Pulse Limiting.
‘Pulse’ limiting allows the operator to enter the maximum load pulse applied to the
compressor during pulldown. ‘SP’ or ‘Ramp to Suction Setpoint’ limiting limits loading to
bring the Suction pressure down at a rate determined by the operator. ‘SV’ or ‘Ramp to
Maximum Slide Valve’ sets the amount of time that the compressor will take to reach a fully
loaded condition.
Max Ld Pulse During Pulldown Displayed only when the ‘Ld Lmt’ parameter is set to ‘1’
for Pulse Limiting. This parameter sets the maximum load pulse that can be issued during
Load Limiting. Once Load Limiting is inactive, the compressor returns to normal loading.
To disable Load Limiting entirely, set this parameter to the same value entered into the
Capacity Load/Unload Period Operating Parameter. In addition, set the Allow Normal
Loading? 0=No/1=Yes Operating Parameter to 1 (Yes), and set the Allow Normal Loading
After % to 0%.
Allow Normal Loading? 0=No/1=Yes Displayed only when the ‘Ld Lmt’ parameter is set to
‘1’ for Pulse Limiting. This parameter forces the compressor to remain in Load Limiting,
regardless of slide valve position, with a ‘0’ (No) entry. With a ‘1’ (Yes) entry, Load
Limiting is active until the slide valve position exceeds the ‘Allow Normal Loading After’
operating parameter.
Allow Normal Loading After Displayed only when the ‘Ld Lmt’ parameter is set to ‘1’ for
Pulse Limiting. This parameter sets the slide valve position where Load Limiting is disabled
if the Allow Normal Loading? 0=No/1=Yes Operating Parameter is set to ‘1’ (Yes). If
Allow Normal Loading? 0=No/1=Yes is set to 0 (No), this parameter is not used.
Ramp to Suct Setpoint per Min Displayed only when the ‘Ld Lmt’ parameter is set to ‘2’
for Ramp to Suction Setpoint Limiting. This parameter sets the rate at which the Suction
Setpoint is reduced from the Suction Pressure measured at startup down to the Suction
Pressure Setpoint when ‘Ramp to Suction Setpoint’ is selected. The rate is set in pressure
units per minute.
Ramp to Max Slide Valve Over Displayed only when the ‘Ld Lmt’ parameter is set to ‘3’
for Ramp to Slide Valve Limiting. This parameter set the amount of time that it takes for the
slide valve to reach the fully loaded position. Time is set in minutes.
Booster/High Stage, 0=Bstr/1=HS/2=DI determines the operating mode of the compressor.
This parameter is displayed for GM, GS, and GL swing (booster/high stage) compressor
packages. Setting this parameter to a ‘0’ configures the compressor for booster operation.
Setting this parameter to a ‘1’ configures the compressor for high stage operation. Setting
the parameter to a ‘2’ configures the panel to examine the state of an input module to
determine the compressors operating mode. The input module is an option that must be
factory configured and it is used to alter oil pump operation for swing applications without
requiring the operator to change this parameter.
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Oil Pump Selection 0=Int/1=Ex/2=DI/3=Int+Ex determines the oil pump configuration that
is used on GM and GS Series compressor packages. This parameter is not displayed for GL
series compressor packages. Setting this parameter to a ‘0’ configures the compressor
without an external oil pump. Setting this parameter to a ‘1’ configures the compressor with
an external oil pump. Setting this parameter to a ‘3’ configures the compressor with both an
internal and an external oil pump. Setting the parameter to a ‘2’ configures the panel to
examine the state of an input module to determine the oil pump selection. The input module
is an option that must be factory configured and it is used to alter oil pump operation for
swing applications without requiring the operator to change this parameter.
ECONOMIZER
Economizer Solenoid On Above sets the slide valve position where the Economizer
Solenoid Output will be energized during compressor operation. The ‘On Above’ parameter
must be slightly greater than the ‘Off Below’ parameter to allow some hysteresis.
Economizer Solenoid Off Below sets the slide valve position where the economizer valve's
solenoid will be de-energized.
HISTORICAL DATA
Short-Term Sampling Period is the time interval (2-60 seconds) between data samples for
the Short-Term Historical Display. The Short-Term Historical Display records up to 60
samples while the compressor is running. This data is intended to provide a short history of
operation for assistance in troubleshooting or performance evaluation.
Long-Term Sampling Period is the time interval (1-120 minutes) between data samples for
the Long-Term Historical Display. The Long-Term Historical Display records up to 250
samples. A sample is recorded each time the Long-Term Sampling Period timer expires or
whenever a Shutdown or Alarm occurs. This data is intended to provide a record of
compressor and system activity.
Reset Short-Term Trend (0=No/1=Yes) can be used to clear all existing data samples from
the Short-Term Historical Display. Set this entry to a one, and it will return to a zero when
the data is cleared.
Reset Long-Term Trend (0=No/1=Yes) can be used to clear all existing data samples from
the Long-Term Historical Display. Set this entry to a one, and it will return to a zero when
the data is cleared.
VARIABLE Vi CONTROL
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Vi Operating Mode (0=Auto/1=Manual) is used to control the Vi operating mode for a
compressor equipped with variable Vi. This parameter is not displayed if the compressor is
fixed Vi. Setting this parameter to a ‘0’ selects automatic Vi control based on the current
operating conditions. Setting this parameter to a ‘1’ selects manual Vi control of the
compressor. In manual mode, the Vi is fixed at the value of the “Variable Vi Control,
Manual Vi control, Vi Setting” Operating Parameter.
Manual Vi Control Vi Setting represents the desired Vi setting when the Vi is being
controlled manually (Vi Operating Mode set to a ‘1’). This parameter is not displayed if the
compressor is fixed Vi . This parameter is not used when the Vi Control is in automatic
mode (Vi Operating Mode set to a 0).
RESET MEMORY
Reset Memory (0=No/1=Yes) can be used to clear the Micro III's battery-backed parameter
memory. This feature should be used with caution. All historical data will be deleted. All
parameters will be set to factory-default values, and all analog calibrations will be zeroed.
These factory-default values may or may not be correct for the user's application. The
defaults are only a starting point for re-configuration of the control panel. After using this
option, the user must consult the product's FES Data Sheets for proper parameter entries. Re-
calibrate all pressure and temperature transducers, including the slide valve.
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ALARM PARAMETERS
The Alarm Parameters Display is used to enter alarm points for the compressor package. These
parameters are used strictly for alarms; none of the Alarm Parameters will affect compressor operation.
ALARM PARAMETERS
SUCTION PRESSURE
Suction 1 Pressure
Upper 50.0 Psi
Suction 1 Pressure
Lower 32.0 Psi
Suction 2 Pressure
Upper 50.0 Psi
Suction 2 Pressure
Lower 32.0 Psi
PROCESS TEMPERATURE
Process 1 Temp
Upper 60.0 °F
Process 1 Temp
Lower 35.0 °F
The Micro III will only accept values with factory-configured range limits. If the user attempts to enter
a value outside the range limits, a 'Minimum=' or 'Maximum=' message will appear on the last line of
the display. Out-of-range Alarm Parameters will flash. The Alarm Parameters are grouped by topic
with related parameters.
SUCTION PRESSURE
Two suction pressure setpoints are available for controlling the compressor package. Each of
the setpoints has its own set of alarm parameters. These alarms are active only when the
Control Mode Operating Parameter is setup for Suction Pressure control.
Suction (1 or 2) Pressure Upper is the suction pressure where the 'High Suction Pressure'
alarm annunciation will occur.
Suction (1 or 2) Pressure Lower is the suction pressure where the 'Low Suction Pressure'
alarm annunciation will occur.
PROCESS TEMPERATURE
Two process temperature setpoints are available for controlling the compressor package.
Each of the setpoints has its own set of alarm parameters. These alarms are active only when
the Control Mode Operating Parameter is setup for Process Temperature control.
Process (1 or 2) Temperature Upper is the process temperature where the 'High Process
Temperature' alarm annunciation will occur.
Process (1 or 2) Temperature Lower is the process temperature where the 'Low Process
Temperature' alarm annunciation will occur.
Process Temp Control Lo Suct sets the lower limit for suction pressure before a 'Low
Suction Pressure' alarm annunciation will occur.
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COMPRESSOR MOTOR
Motor Current Upper should be set to Full Load Amps X (0.99).
(484 Amps)(0.99)=479.2 Amps
If motor current exceeds this parameter, the 'High Motor Current' alarm will be issued. This
alarm is active during Run only.
INLET OIL
Oil Filter Pressure Drop, Max sets the maximum drop across the oil filter before a 'Hi Oil
Filter Differential' alarm is annunciated. This alarm is active during Run only, after a 2
minute delay at Startup. The pressure drop is measured as the difference between the oil
filter inlet and inlet oil pressures.
Inlet Oil Temperature Upper sets the high temperature limit for the oil feeding the
compressor's inlet during Run. If the inlet oil temperature exceeds this parameter after a 2
minute delay at Startup, a 'Hi Inlet Oil Temperature' alarm will be issued.
Inlet Oil Temperature Lower sets the low temperature limit for the oil feeding the
compressor's inlet during Run. If the inlet oil temperature fails to exceed this parameter after
a 2 minute delay at Startup, a 'Low Inlet Oil Temperature' alarm will be issued.
OIL SEPARATOR
Oil Separator Temp Upper sets the high temperature limit for the oil separator. The oil
separator temperature is compared to this parameter when the compressor is being stopped,
or started. If the oil separator temperature exceeds this parameter, then a 'Hi Oil Separator
Temp' alarm will be issued.
Oil Separator Temp Lower sets the low temperature limit for the oil separator. The oil
separator temperature is compared to this parameter at startup. If the oil separator
temperature does not exceed this parameter, then a 'Lo Oil Separator Temp' alarm will be
issued.
DISCHARGE
Discharge Pressure Maximum establishes the warning point for high discharge pressure. If
discharge pressure exceeds this parameter at any time, a 'High Discharge Pressure' alarm will
be issued.
Discharge Temp Upper is the high temperature warning point for the compressor's
discharge. If the discharge temperature exceeds this parameter at any time, a 'High
Discharge Temp' alarm will be issued.
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Displays
COMPRESSOR & CONTROLS DATA
This screen provides the operator with information about compressor package status and controls
information. This screen is divided into groups, the operator can switch to the Controls Data by pressing
the [ ] key and back to the Compressor Data by pressing the [] key. In recent revisions, Current Time
and Date are present at the bottom of the screen.
COMPRESSOR DATA
This section consists of information pertaining to mechanical aspects of the compressor package.
The Compressor Series that the Micro III is configured to control is displayed. The Compressor
Series (GL, GM or GS) is fixed during the factory configuration of the program but the specific
model number for the compressor must be entered here if equipped with Variable Vi. The
compressor model number is obtained from the nameplate on the compressor. It is very important
Model Number
that the Micro III panel be configured for the exact model number of the compressor for proper
Variable Vi operation. The Micro III panel must be in the service mode to change the compressor
model number. Once the panel is in the service mode, a cursor will appear on the Compressor Data
display next to the model number. Pressing the [EDIT] key will change the cursor to an underline
indicating the compressor model number can be changed. Once the cursor is an underline, the
compressor model number is changed by pressing the [ ] or [ ] keys. The compressor model
number will change up or down one model number for each respective keystroke. When the correct
model number is displayed, pressing the [ENTER] stores the compressor model number in memory
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and returns the cursor to a block. Pressing the [EDIT] key a second time cancels the edit and
restores the previous compressor model number.
The amount of anti-recycle time remaining for the compressor motor and oil drain timers is also
displayed. Elapsed compressor motor run time and the kWh accumulated by the compressor motor
are monitored and displayed. The display also shows the refrigerant used for control panel
calculations.
The Operating Mode for the compressor is used to display the current compressor configuration
(booster or high stage). The next two items are the Vi control mode and fixed speed drive. Variable
Vi and variable speed Compressor Motor Drive are available as factory configured options.
The status of the Power Fail Reset is shown as the last item in this group. This is enabled or
disabled depending on the state of dipswitch SW6 #6, if this switch is open, Power Fail Reset is
disabled.
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CONTROLS DATA
This group displays data relating to the Micro III and its programs. The screen layout for a standard
program is shown below on the left. The ‘Program #’ is the FES part number for the program
currently running in the Micro III. The ‘Software Revision’ is the current revision of the operating
program in this Micro III. The ‘Utility Revision’ is for U10 on the Micro III, this chip contains the
downloading utilities and test routines. These numbers as well as the program number are
important when calling for service assistance.
The next lines show the state of the dip and rotary switches on the Micro III. The Node ID, for the
ComMENT network or Micro III Direct Communications, is displayed in both hexadecimal and
decimal formats. All communication traffic to be routed to this Micro III must reference this ID.
Dipswitch SW6 is shown (switches 1-8, left to right). Switches in the Open position are shown as
a ‘0’, and switches in the Closed position are shown as ‘1’. An indication is also given if Direct
Communications is enabled and the current baud rate.
The last line shows the current operating mode of panel, either ‘Normal Mode’ or ‘Service Mode’
as set by SW6 #3.
The figure on the right is a CONTROLS DATA group display for a special program. The ‘Contract #’
is the FES contract under which this unit was sold and is used to reference the special program. The
customer’s name is also shown. The ‘Factory Config Revision’ is for the special modifications made to
this system. Again, these numbers are important when calling for service assistance.
The figure on the right also shows the display if Micro III Direct Communications is enabled, showing
the baud rate that the port is configured. If Micro III Direct Communications is disabled, the entire line
will be missing as shown in the figure to the left. For a detailed description of MicroIII Direct
Communications, please refer to MCP-161 (Micro III Direct Communications).
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COMPRESSOR START SEQUENCE OF OPERATION
1. The start sequence begins with an examination of the compressor motor's Anti-Recycle Timer
and oil drain timers. If sufficient time has not elapsed since the last start of the compressor
motor, or oil drain time still exists, the control panel will wait until both timers have expired.
2a. If Suction Pressure Control is enabled and the Low Suction Pres 0=Shutdn/1=Cycl Operating
Parameter is set 1(Cycle), the control panel will wait until the actual suction pressure exceeds the
Suction Pressure (1 or 2) Upper Operating Parameter. The user can bypass this delay by
pressing the [LOCAL START] key a second time. If enabled in the factory configuration, an
external device can bypass this delay by energizing the Must Start Input module.
2b. If Process Temperature Control is enabled and the Low Process Temp 0=Shutdn/1=Cycl
Operating Parameter is set 1(Cycle), the control panel will wait until the actual process
temperature exceeds the Process Temperature (1 or 2) Upper Operating Parameter. The user can
bypass this delay by pressing the [LOCAL START] key a second time. If enabled in the factory
configuration, an external device can bypass this delay by energizing the Must Start Input
module.
3. The Ready to Start Output module will be energized.
4. The Permissive Start Input module will be examined. If enabled in the factory-configuration, the
control panel will wait for it to be energized. While waiting on the Permissive Start, the
[LOCAL START] or [REMOTE START] LED will be flashing.
5. The external oil pump will be started for GL series compressors or GM/GS series compressors
fitted with an external oil pump.
6. The unload solenoids will be energized.
7. If equipped with a Discharge Check Valve it will be opened. It must open completely within 30
seconds, or startup will be aborted.
8. The control panel will wait until the slide valve unloads to a position less than 5%. If it does not
unload within 3 minutes, startup will be aborted for all compressors equipped with an external oil
pump and a “Cmp Slide Valve Unload” shutdown will be issued. The GM and GS series
compressors with an internal pump (even if an external is also used) will be permitted to start if
the slide valve position is less than 70.0%. For GM and GS series compressors with or without
an external pump proceed to step #11. Note: The oil pressure built by the external oil pump is
monitored while trying to unload the slide valve to less than 5%. If valid oil pressure is not
established as explained in the next section, a “Low Oil Press – Startup” shutdown will be
initiated. If this occurs, the Oil pump will still operate for up to 3 minutes to unload the slide
valve.
9. After verifying that the slide valve is less then 5%, the Inlet Oil pressure is tested. The Oil
Pressure for machines equipped with an external oil pump must exceed discharge pressure + 14.2
psi (1 bar) within 8 seconds of the oil pump being started. If this pressure is not achieved within
8 seconds, the oil pump will be stopped for 10 seconds. The pump will be restarted 2 additional
times for 8 seconds with 10 second pauses between. If the pressure is still not achieved after the
last (3rd) pump start, a “Low Oil Press – Startup” shutdown will be issued. Note: During the
pump off cycles, the [OIL PUMP] LED will be flashing at a 1.5 second on/off rate.
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10. If the oil pump has been running longer than 10 seconds to unload the slide valve before the
compressor can be started, the startup will be delayed until the compressor has been given time
to drain the oil pumped into it during the startup process. Note: Any time the startup is delayed
in this manner, the oil drain timer will be set to 10 minutes and the compressor will remain in
LOCAL or REMOTE mode. The compressor will not be shutdown. The compressor will
automatically attempt to restart when the oil drain timer elapses. Oil drain time is displayed in
the Compressor Data display.
11. The compressor motor starter will be energized to begin operation of the compressor.
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COMPRESSOR STOP SEQUENCE OF OPERATION
1. The compressor motor starter will be de-energized to stop the compressor.
2. The compressor slide valve's unload solenoid will be energized.
3. The Ready to Start Output module will be de-energized.
4. The control panel will wait for the Compressor Interlock Input module to be de-energized, and
actual motor current to drop below 5 amps.
5. The external oil pump will continue to run until the compressor is unloaded for GL series
compressors or GM / GS series compressors fitted with an external oil pump. Stop sequence is
completed for GM / GS series compressors without an external oil pump or a combination of
internal and external oil pumps.
6. The control panel will wait until the slide valve unloads to a position less than 5%. If it does not
unload within 3 minutes, a “Cmp Slide Valve Unload” shutdown will be issued.
7. If the oil pump has been running longer than 10 seconds after the compressor has been
shutdown, the compressor will be issued oil drain time to allow the compressor to drain the oil
pumped into it during the shutdown process. Note: Any time the shutdown sequence is
extended such that the oil pump has been running 10 seconds without the compressor, the oil
drain timer will be set. The oil drain timer is set to 10 minutes and the compressor cannot be
restarted until the timer has elapsed. Oil drain time is displayed in the Compressor Data display.
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Control
SUCTION PRESSURE / PROCESS TEMPERATURE CAPACITY CONTROL
Continuous Load
LD
Proportional Band
½ Dead Band
Setpoint
½ Dead Band
Proportional Band
UL
Continuous Unload
Movement of the compressor slide valve and the resulting change in refrigeration capacity is done via a
time-proportioning scheme, as illustrated above.
The Control Mode Operating Parameter determines whether the compressor controls capacity based on
suction pressure, or process temperature (control variable). Additionally, the Control Point Operating
Parameter allows the operator to select between two setpoints, dead bands, and proportional bands.
The Capacity Control algorithms determine the proper load or unload pulse width based on the
relationship shown above. If the control variable is greater than [setpoint + 1/2 dead band +
proportional band], then a continuous load pulse will be used to move the slide valve. Conversely, a
continuous unload pulse will be used if the control variable is less than [setpoint - 1/2 dead band -
proportional band].
Proportional loading takes place when control variable is greater than [setpoint + 1/2 dead band ], but
less than [setpoint + 1/2 dead band + proportional band ]. Proportional unloading occurs when the
control variable is less than [setpoint - 1/2 dead band ], but greater than [ setpoint - 1/2 dead band -
proportional band].
If the control variable is only slightly above or below the setpoint [within setpoint + 1/2 dead band ], no
load or unload pulses will be issued.
The Micro III uses Overloads to consider situations where the slide valve position may impact the
compressor's safe area of operation. Overloads include those that monitor Motor Current, Low Suction
Pressure during Process Temperature Control, and Discharge Pressure. The final load or unload pulse
used to move the slide valve weighs these Overloads with Capacity Control.
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LOW SUCTION PRESSURE OVERLOAD
Normal Loading
Load Adjust
Suction Pressure
60.0 psig
Load Parameter
Limiting
55.0 psig Prop Band
Proportional Parameter
Unloading
50.0 psig Low Suction
Parameter
Time
The Low Suction Pressure Overload is a mechanism to unload the compressor to avoid extremely low
suction pressures during Process Temperature Control Mode. When this overload is active, 'LoS' will
appear on the upper right of the Operating Data Display.
For an example, a compact water-chilling system will be analyzed. R-717 (ammonia) will be used as
the refrigerant.
The Process Temperature Lo Suct Operating Parameter is set to the minimum pressure that the system
can tolerate, which is typically the pressure equivalent of the process fluid's freezing point. Pressure
drop between the heat exchanger and the compressor package must be considered if relevant. If the
suction pressure drops below this parameter, the compressor will be shutdown. Since the example
application's process fluid is water and the system is compact, 50.0 PSIG was chosen as the pressure
equivalent to the water's freezing point using R-717.
The Process Temperature Prop Band Operating Parameter is typically set slightly above the process
fluid's freezing point, causing the compressor to unload as the suction pressure drops close to the
pressure equivalent of the freezing point. This unloading is proportional between the Process
Temperature Prop Band and Lo Suct Operating Parameters. In the example, a 5.0 PSI proportional
unload band was chosen so the Process Temperature Prop Band Operating Parameter was set to 55.0
PSIG.
As the compressor's suction pressure nears the Process Temperature Prop Band Operating Parameter,
measures need be taken to slow loading of the compressor. Once the suction pressure drops below the
Process Temperature Ld Adjust Operating Parameter, the intended load pulses will be proportionally
reduced. Typically, the load adjustment (load limiting) band should be equal to or greater than the
proportional unload band, which was chosen to be 5.0 PSI. For the example, the Process Temperature
Ld Adjust Operating Parameter was set to 60.0 PSIG.
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DISCHARGE PRESSURE OVERLOAD
Discharge Pressure
Time
The Discharge Pressure Overload is a mechanism to unload a compressor experiencing high discharge
pressure, in order to avoid a shutdown. When this overload is active, 'DIS' will appear on the upper
right of the Operating Data Display.
At Startup, the compressor's discharge pressure must be at least 10.0 PSI lower than the Discharge
Pressure Maximum Operating Parameter, or the 'High Discharge Pressure' Shutdown will be
annunciated immediately.
Once in Run mode, the control panel monitors the compressor's discharge pressure continuously. A
proportional unload band is established between the Discharge Pressure Maximum and Discharge
Pressure Prop Band Operating Parameters (225.0 PSI and 10.0 PSI respectively for this example). If
actual discharge pressure rises into the proportional unload band, the compressor will be unloaded in an
attempt to avoid the 'High Discharge Pressure' Shutdown.
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MOTOR CURRENT OVERLOAD
Continuous Unload
556 A Motor Current Upper
Parameter
Motor Current
Time
The Motor Current Overload is designed to allow the compressor to utilize maximum motor
horsepower, without exceeding its thermal limitations. For an example, consider a motor with a Full
Load Amps (FLA) rating of 484 Amps. The motor has a 1.15 Service Factor.
The Motor Current Upper Operating Parameter represents the ultimate trip point for the 'High Motor
Current' Shutdown. This shutdown will be issued if the actual motor current remains above this
parameter for thirty continuous seconds. During the time delay, continuous unload pulses will be issued
to reduce the motor current. Typically, this parameter is set to Full Load Amps times Service Factor.
(484 FLA)(1.15SF)=556.6 Amps
The Motor Current Dead Band Operating Parameter establishes a band beneath the ultimate trip point
where no more loading is allowed. If system conditions cause the actual motor current to rise above the
ultimate trip point, proportional unload pulses will be used to reduce the motor current below (Motor
Current Upper - Dead Band Operating Parameters). If this cannot be done within 5 minutes, a 'Motor
Current Overload' Shutdown will be issued. This parameter must be set to at least 2% of the Full Load
Amps times Service Factor.
(484 FLA)(1.15)(0.02)=11.1 Amp
The Motor Current Lower Operating Parameter sets the point where proportional load limiting will
occur. Proportional load limiting causes the slide valve to load slowly once actual motor current has
exceeded this parameter, in an effort to avoid a high motor current trip. This parameter is typically set
to the Full Load Amps of the motor.
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COMPRESSOR LUBRICATION SYSTEM CONTROL
GL SERIES
The oil pump is started and pressure is established before the compressor is started. If at least 14.5 psi
(1 bar) of oil pressure is not established in 8 seconds, the oil pump will be stopped for 10 seconds. The
pump will be restarted 2 additional times for 8 seconds with 10 second pauses between. If the pressure
is still not achieved after the last (3rd) pump start, a “Low Oil Press – Startup” shutdown will be issued.
Note: During the pump off cycles, the [OIL PUMP] LED will be flashing at a 1.5 second on/off rate.
Once the compressor has been running for 15 seconds, the low oil pressure limit is lowered to discharge
+ 7.3 psi (0.5 bar). If the oil pressure falls below Discharge + 7.3 psi (0.5 bar) for greater than 6
seconds, a ‘Low Oil Pressure’ shutdown will be issued.
A ‘High Oil Pressure’ shutdown will be issued immediately if the oil pressure exceeds Discharge
pressure + 72.5 Psi (5 Bar) and the compressor has been running at least 30 seconds.
After a 90 second delay on startup, the pressure drop across the Oil Filter must be less than 20 psi or a
‘Hi Oil Filter Differential’ shutdown is issued after 30 seconds. There is also an alarm for this condition
that is enabled 2 minutes after startup. The oil pump will continue to run as long as the compressor is
running.
GM SERIES
The GM series can be configured with or without an external oil pump. The configuration of the oil
pump is based upon the “Oil Pump Selection” Operating Parameter located under the Control heading.
Setting this parameter to a ‘0’ configures the compressor without an external oil pump. Setting this
parameter to a ‘1’ configures the compressor with an external oil pump. Setting this parameter to a ‘3’
configures the compressor with both an internal and an external oil pump. Setting the parameter to a ‘2’
configures the panel to examine the state of an input module to determine the oil pump selection. The
input module is an option that must be factory configured and it is used to alter oil pump operation for
swing applications without requiring the operator to have access to change parameters to affect this
selection. The input module is typically wired to a selector switch located on the door of the panel to
simplify the internal / external oil pump - high stage/booster modes respectively.
When the GM series compressor is equipped with an external oil pump, the oil pump is started and will
continue to run as long as the compressor is running. Valid oil pressure is established before the
compressor is started. If at least 14.5 psi (1 bar) of oil pressure is not established in 8 seconds the oil
pump will be stopped for 10 seconds. The pump will be restarted 2 additional times for 8 seconds with
10 second pauses between. If the pressure is still not achieved after the last (3rd) pump start, a “Low Oil
Press – Startup” shutdown will be issued. Note: During the pump off cycles, the [OIL PUMP] LED
will be flashing at a 1.5 second on/off rate.
Once the compressor has been running for 15 seconds, the low oil pressure limit is lowered to discharge
+ 7.3 psi (0.5 bar). If the oil pressure falls below Discharge + 7.3 psi (0.5 bar) for longer than 6 seconds
a ‘Low Oil Pressure’ shutdown will be issued. If the Inlet Oil Pressure exceeds Discharge pressure +
58.0 psi (4.0 bar) Discharge after a 30 second delay at startup, a ‘High Oil Pressure’ shutdown will be
issued immediately.
When the GM series compressor is not equipped with an external oil pump, the compressor is permitted
to start without first establishing oil pressure. Once the compressor has reached RUN status for 30
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seconds, the inlet oil pressure to the compressor must exceed Discharge - 36.3 psi (-2.5 bar). If the oil
pressure falls below Discharge – 36.3 psi (-2.5 bar) for longer than 6 seconds, a ‘Low Oil Pressure’
shutdown will be issued. There is no high inlet oil pressure failure for GM series compressors without
an external oil pump.
After a 90 second delay on startup, the pressure drop across the Oil Filter must be less than 20 psi or a
‘Hi Oil Filter Differential’ shutdown is issued after 30 seconds. There is also an alarm for this condition
that is enabled 2 minutes after startup.
GS SERIES
The GS series can be configured with or without an external oil pump. The configuration of the oil
pump is based upon the “Oil Pump Selection” Operating Parameter located under the Control heading.
Setting this parameter to a ‘0’ configures the compressor without an external oil pump. Setting this
parameter to a ‘1’ configures the compressor with an external oil pump. Setting the parameter to a ‘2’
configures the panel to examine the state of an input module to determine the oil pump selection. The
input module is an option that must be factory configured and it is used to alter oil pump operation for
swing applications without requiring the operator to have access to change parameters to affect this
selection. The input module is typically wired to a selector switch located on the door of the panel to
simplify the internal / external oil pump - high stage/booster modes respectively.
When the GS series compressor is equipped with an oil pump, the oil pump is started and will continue
to run as long as the compressor is running. Valid oil pressure is established before the compressor is
started. If at least 14.5 psi (1 bar) of oil pressure is not established in 8 seconds the oil pump will be
stopped for 10 seconds. The pump will be restarted 2 additional times for 8 seconds with 10 second
pauses between. If the pressure is still not achieved after the last (3rd) pump start, a “Low Oil Press –
Startup” shutdown will be issued. Note: During the pump off cycles, the [OIL PUMP] LED will be
flashing at a 1.5 second on/off rate.
Once the compressor has been running for 15 seconds, the low oil pressure limit is lowered to Discharge
+ 7.3 psi (0.5 bar). If the oil pressure falls below Discharge + 7.3 psi (0.5 bar) for longer than 6 seconds
a ‘Low Inlet Oil Pressure’ shutdown will be issued. If the Inlet Oil Pressure exceeds Discharge pressure
+ 50.8 psi (3.5 bar) Discharge a ‘High Oil Pressure’ shutdown is issued immediately.
When the GS series compressor is not equipped with an oil pump, the compressor is permitted to start
without first establishing oil pressure. Once the compressor has reached RUN status for 15 seconds, the
inlet oil pressure sensed at the compressor must exceed Discharge – 43.5 psi (-3.0 bar). The 43.5 psi
limit includes drops through the strainer, oil filter and interconnecting piping. If the total pressure drop
across these components exceeds 43.5 psi, the inlet oil pressure at the compressor will be less than
Discharge – 43.5 psi (3.0 bar). If the inlet oil pressure fails to exceed this limit for 6 seconds, a ‘Low
Inlet Oil Pressure’ shutdown will be issued. There is no high inlet oil pressure failure for GS series
compressors without at external oil pump.
After a 90 second delay on startup, the pressure drop across the internal Oil Filter must be less than 30
psi or a ‘Hi Oil Filter Differential’ shutdown is issued after 30 seconds. There is also an alarm for this
condition that is enabled 2 minutes after startup.
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COMPRESSOR SLIDE VALVE CONTROL
Both the Slide Valve Load and Slide Valve Unload outputs from the Micro III are connected to dual
solenoid valves. The Slide Valve Load output is connected to solenoids Y1 and Y4. The Slide Valve
Unload output is connected to solenoids Y2 and Y3. Two additional solenoids are added on variable Vi
compressors to control the secondary slide. The secondary slide of a variable Vi compressor is loaded
by energizing solenoid Y5 and unloaded by energizing solenoid Y6. De-energizing both Y5 and Y6
lock the secondary slide in its’ current position.
The operation of the slide valve outputs when the compressor is not running is a function of which series
of compressor the panel is configured for. If the compressor is a GL series, both primary and secondary
slide valve outputs will be de-energized whenever the compressor is not running. For a GM and GS
series compressor, the presence/absence of the external oil pump will determine how the slide valve
outputs are controlled. If the GM or GS series compressor has an external oil pump or a combination of
internal and external oil pumps, the control of the slide valve outputs is identical to that of the GL series
machines. For GM and GS series not equipped with an external oil pump, both slide valve outputs will
be energized when the compressor is not running if the slide valve reading exceeds 5%. Both outputs
are energized to allow the pressure on either side of the slide valve piston to equalize thus allowing the
internal spring in the compressor to unload the machine.
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COMPRESSOR VARIABLE Vi CONTROL
G Series compressors offer continuous variable Vi control that is designed specifically for the model of
compressor that is being controlled. The variable Vi mechanism is unique to each compressor family
(GL, GM or GS) so different control philosophies are required for each compressor family. The
compressor family (GL, GM or GS) is fixed during the factory configuration but correct compressor
model number MUST be entered in the Compressor and Controls display for the Vi control to operate
properly. Please see Compressor and Controls display for instructions regarding setting this parameter.
The Vi control of the GL Series compressor is accomplished using two slides that operate in tandem
with one-another to simultaneously maintain the desired Vi and capacity of the compressor. To achieve
the desired Vi Setting, the primary slide is moved initially followed by the secondary slide. The Vi
position is infinitely variable (not stepped) using the two slides with the movement of the slides
determined by the current “Vi Mode” of the compressor. The Vi Mode (1, 2 or 3) determines which
slide is being moved to control capacity and which slide is being used to achieve the desired Vi setting.
The Vi Mode and Current Vi are displayed on the bottom line of the Operating Data display of the
Micro III.
Vi Mode #1
The primary slide is moved to control the capacity of the machine and the secondary slide is kept
unloaded. The Vi of the compressor in Vi Mode #1 is therefore a function of the movement of
the primary slide in order to maintain the desired suction pressure / process temperature setpoint.
The primary slide is used to control the capacity of the machine from completely unloaded up to
a position where the optimum Vi for the operating conditions is located. This positon is
displayed as “Vi SCALC” in the Operating Data Display. Loading the primary slide beyond the
value of Vi SCALC increases the Vi of the compressor beyond the calculated Vi Setting. If the
machine is attempting to load (increase capacity) and the primary slide reading approaches the
value of Vi SCALC, the primary slide will be locked at the value of Vi SCALC and a 2 second
transition timer is started. The 2 second timer will only time out when the load solenoid output
is energized, therefore; the actual duration of the transition timer is inversely proportional to the
duration of the load pulses. Continous load signals will transtion from Vi Mode #1 to Vi Mode
#2 in 2 seconds. Short load pulses will take significantly longer to transition because the time can
only accumulate based on the duration of the load pulses. Once the requests to load the
compressor accumulate 2 seconds of load pulses, the timer will elapse and the Vi Mode will
transition from Mode #1 to Vi Mode #2. If any type of unload signal is generated interupting the
2 second time transition timer, the unload signals will be issued and the 2 second timer will be
reset.
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Vi Mode #2
The primary slide is programmed to track the value of Vi SCALC and the secondary slide is
adjusted to maintain the suction pressure / process temperature setting. The value of Vi SCALC
is constantly being recalculated based on the current operating conditions. While in Vi mode #2,
the primary slide will only be moved to correct for changes in the value of Vi SCALC. There is
no positional feedback from the secondary slide, subsequently, there is no value for the
secondary slide valve position for GL Series compressors. In Vi Mode #2, the capacity of the
compressor lies between the value of SCALC and 100% and will be a calculated value based on
the following formula:
When the machine is attempting to load (increase capacity) and has initially entered Vi Mode #2
from Vi mode #1, a 30 second timer is started. This 30 second timer will only time out while the
load solenoid output is energized, therefore; the actual duration of the transition timer is
inversely proportional to the duration of the load signals. Continous load signals will transtion
from Vi Mode #2 to Vi Mode #3 in 30 seconds. Short load pulses will take a proportionally
longer time to transition because the timer is only permitted to time for the duration of each load
pulse. The slide valve reading will increase proportionally as this 30 second transition timer
accumulates. With this method, the accumulating load signals are used to alter the displayed
slide valve reading from the value of SCALC to 100%. The slide valve reading will be
approaching 99.9% just as the equivalent of 30 seconds of loading is accumulated. When the
timer has accumulated the full 30 seconds, the Vi Mode will transition from Mode #2 to Vi
Mode #3 locking the machine at 100%.
An unload signal that interupts the 30 second Vi Mode #2 to Vi Mode #3 transition timer will
automatically set the Mode #2 to Mode #1 transition timer with the equivalent amount of time
that the compressor has been loading in Mode #2. This method allows the microprocessor to
determine a relative “position” for the secondary slide based on the duration of load/unload
pulses. For example: If the compressor has accumulated 12 seconds of Load pulses in Vi Mode
#2, and begins unloading, 12 seconds of unload pulses must accumulate prior to returning toVi
Mode #1. In this example the slide valve reading would be displayed as 40% of the difference
between SCALC and 100% when the switch to unloading occurred using the formula above.
Similarly, if the machine is attempting to unload (decrease capacity) and has initially entered
Mode #2 from Mode #3, a 30 second unload timer is also started. This 30 second timer will only
time out while the unload solenoid output is energized, therefore; the actual duration of the
transition timer is inversely proportional to the duration of the unload signals. If a request to
unload the compressor continues for 30 continuous seconds, the Vi Mode will transition to Vi
Mode #1. A load signal that interupts the 30 second Vi Mode #2 to Vi Mode #1 transition timer
will automatically set the Mode #2 to Mode #3 transition timer with the equivalent amount of
time that the compressor has been unloading. This method allows the microprocessor to
determine a relative “position” for the secondary slide based on the duration of load/unload
pulses. For example: If the compressor has accumulated 18 seconds of Unload pulses in Vi
Mode #2, and begins loading, 18 seconds of load pulses must accumulate prior to returning to
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Vi Mode #3. The slide valve position that is displayed when transitioning from Mode #2 to
Mode #1 is directly proportional to the reaminging time on the transition timer using the
following formula.
This formula is different than the one used to transition between Modes #2 and Mode #3 because
the slide is operating in the opposite direction. The longer the secondary slide is
loaded/unloaded in Vi Mode #2, the equivalent time must elapse before the Vi mode can return
to the previous Vi Mode. This sequence of operation is used to approximate the operation of a
conventional slide valve assembly for a GL Series Variable Vi compressor.
Vi Mode #3
The primary slide continues to track the value of Vi SCALC and the secondary slide is placed in
load to force the compressor to maximum capacity. This arrangement ensures the maximum
capacity from the compressor while maintaining the optimum Vi setting for the current operating
conditions. The capacity of the compressor will always be displayed as 100% while operating in
Vi Mode #3. In Vi Mode #3, a 1 second timer will be started when the capacity control
generates an unload signal to decrease the capacity of the compressor. When the unload signal
accumulates the equivalent of 1 second of unload pulsess, the Vi Mode will transition to Vi
Mode #2. The Vi Mode will bypass the 1 second time delay and transition to Mode #2
immediately if the capacity control is placed in Manual Unload mode.
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Control
GM SERIES VARIABLE Vi CONTROL
The optimum Vi for the compressor is calculated based on the refrigerant, economizer activity and
current operating conditions using a proprietary algorithm. The optimum Vi setting produced by the
algorithm is displayed as “Vi Setting” on the Analog Data Display and “Volume Index” on the bottom
line of the Operating Data display of the Micro III.
The Vi control of the GM series compressor is accomplished using a series of two parallel slides that are
operated simultaneously maintain the desired Vi and capacity of the compressor. Each slide operates
independantly and has its’own position indicator and proportional controller mechanism.
The primary slide is used to adjust the capacity of the compressor to maintain the desired suction
pressure / process temperature setpoint and is completely independent of the secondary slide.
The secondary slide is used to maintain the optimum Vi for the current operating conditions. The
optimum position of the secondary slide is a calculated value that is a function of the current optimum
Vi setting and the current primary slide valve reading. The optimum position for the secondary slide is
displayed as “Vi VSOPT”. The physical position of the secondary slide is displayed as “Secondary
Slide”. Vi VSOPT and Secondary Slide position are both displayed on the Analog Data Display as
percentages (%). The Micro III is programmed to proportionally load or unload the secondary slide as
needed until its’ percentage matches the calculated Vi VSOPT percentage (+/- 1% deadband) when the
compressor is running. When the secondary slide matches Vi VSOPT +/- the deadband, the compresor
is operating at the optimum Vi Setting.
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GS SERIES VARIABLE Vi CONTROL
The optimum Vi for the compressor is calculated based on the refrigerant, economizer activity and
current operating conditions using a proprietary algorithm. The optimum Vi setting produced by the
algorithm is displayed as “VI Setting” on the Analog Data Display and “Volume Index” on the bottom
line of the Operating Data display of the Micro III.
The Vi control of the GS series compressor is accomplished using a series of two parallel slides that are
operated independantly to maintain the desired Vi and capacity of the compressor.
The primary slide is used to adjust the capacity of the compressor to maintain the desired suction
pressure / process temperature setpoint and is completely independent of the secondary slide.
The secondary slide is used to maintain the optimum Vi for the current operating conditions. The
secondary slide is loaded or unloaded based upon a calculated value that is a function of the current
optimum Vi setting and high / low Vi limits of the compressor. If the optimum Vi for the compressor is
below midpoint of the Vi range the secondary slide is unloaded. If the optimum Vi setting is above the
midpoint of the Vi range, the secondary slide is loaded. The secondary slide is loaded or unload in this
manner when the compressor is running. There is no positional feedback from the secondary slide,
subsequently, there is no value displayed value for the secondary slide valve on GS series compressors.
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Communications Protocol
The Micro III control panel has on-board ComMENT Network communications, allowing it to be
interfaced to a wide variety of communication devices with ease. Since the FES ComMENT Gateway
(optional) translates ComMENT Network transactions into Allen-Bradley DF1tm, GE SNPtm, or
Modicon Modbustm, off-the-shelf drivers can be used to interface PLC's, supervisory computers, or
building automatic systems. To an external device communicating with the Gateway, the Micro III's on
the FES ComMENT Network appear to be PLC's in a multi-drop configuration. FES document MCP-3
'ComMENT Network Installation & User's Manual' should be referenced for installation instructions.
The following table documents the data available at various registers within the Micro III's ComMENT
Network Database. Note that the data registers for all Micro III options are shown, but the options may
not be enabled in the factory.
The Micro III panel also has available direct communications. Please refer to MCP-161, Micro III
Direct Communications for a full description. Note that the data registers are the same for the
ComMENT Network or the Micro III Direct Communications.
The addresses shown are for G Series Compressor Panel Software Revision 6.6. All addresses may not
be present in earlier revisions.
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Panel Status
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Shutdown Codes
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Shutdown Flags
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Bit0=#1/Bit1=#2/Bit2=#3/
Bit3=#4/Bit4=#5/Bit5=#6/
Bit6=#7/Bit7=#8/Bit8=#9/
Bit9=#10/Bit10=#11/Bit11=#12/
Bit12=#13/Bit13=#14/Bit14=#15
N15: 41 542 Misc Parameter # R "
42 543 Sequencer Parameter # R "
43 544 Condenser Parameter # R "
44 545 Event Timer Parm # R "
45 546 Sequencer Timer # R "
46 547 Condenser Timer # R "
47 548 Loss of Aux Oil Pump Intlk R Bit15=1 Shutdown Present
48 549 Illegal Aux Oil Pump Intlk R “
49 550 Low Aux Oil Pump Press R “
50 551 Low Oil Pressure R “
51 552 Oil Sep Temp Probe Failure R “
52 553 Unused in G Series
53 554 Unused in G Series
54 555 Unused in G Series
55 556 Low Oil Press - Startup R Bit15=1 Shutdown Present
56 557 Low Differential Pressure R “
57 558 Low Auxiliary Suction Pressure R “
58 559 LifeTrac High Vibration R “
Alarm Codes
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Alarm Flags
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Compressor Commands
Operating Parameters
SUCTION
N20: 0 1001 Suction 1 Pressure Setpoint R/W Y
1 1002 Suction 1 Pressure Upper R/W Y
2 1003 Suction 1 Pressure Lower R/W Y
3 1004 Suction 1 Pressure Prop Band R/W Y
4 1005 Suction 1 Pressure Dead Band R/W Y
5 1006 Suction 2 Pressure Setpoint R/W Y
6 1007 Suction 2 Pressure Upper R/W Y
7 1008 Suction 2 Pressure Lower R/W Y
8 1009 Suction 2 Pressure Prop Band R/W Y
9 1010 Suction 2 Pressure Dead Band R/W Y
10 1011 Low Suction Pressure Shutdn or Cycle? R/W 0=Shutdown/1=Cycle
PROCESS
11 1012 Process 1 Temperature Setpoint R/W Y
12 1013 Process 1 Temperature Upper R/W Y
13 1014 Process 1 Temperature Lower R/W Y
14 1015 Process 1 Temperature Prop Band R/W Y
15 1016 Process 1 Temperature Dead Band R/W Y
16 1017 Process 2 Temperature Setpoint R/W Y
17 1018 Process 2 Temperature Upper R/W Y
18 1019 Process 2 Temperature Lower R/W Y
19 1020 Process 2 Temperature Prop Band R/W Y
20 1021 Process 2 Temperature Dead Band R/W Y
21 1022 Low Process Temperature Shutdn or Cycle? R/W 0=Shutdown/1=Cycle
22 1023 Process Temp Cntl Low Suction Shutdown R/W Y
N20: 23 1024 Process Temp Cntl Low Suction Prop Band R/W Y
24 1025 Process Temp Cntl Low Suction Load Adjust R/W Y
PUMP DOWN
25 1026 Pump Down Cycle On Setpoint R/W Y
26 1027 Pump Down Cycle Off Setpoint R/W Y
27 1028 Pump Down Cycle Once or Cycle On & Off? R/W 0=Cycle Once/1=Cycle On & Off
REMOTE SLIDE VALVE
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Alarm Parameters
SUCTION
N22: 0 1201 Suction 1 Pressure Upper R/W Y
1 1202 Suction 1 Pressure Lower R/W Y
2 1203 Suction 2 Pressure Upper R/W Y
3 1204 Suction 2 Pressure Lower R/W Y
PROCESS
4 1205 Process 1 Temperature Upper R/W Y
5 1206 Process 1 Temperature Lower R/W Y
N22: 6 1207 Process 2 Temperature Upper R/W Y
7 1208 Process 2 Temperature Lower R/W Y
8 1209 Process Temp Cntl Low Suction Alarm R/W Y
REMOTE SV
9 1210 Remote SV Cntl Low Suction Alarm R/W Y
COMPRESSOR MOTOR
10 1211 Motor Current Upper R/W Y
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INLET OIL
11 1212 Oil Filter Pressure Drop R/W Y
12 1213 Inlet Oil Temperature Upper R/W Y
13 1214 Inlet Oil Temperature Lower R/W Y
OIL SEPARATOR
14 1215 Oil Separator Heater Upper R/W Y
15 1216 Oil Separator Heater Lower R/W Y
DISCHARGE
16 1217 Discharge Pressure Maximum R/W Y
17 1218 Discharge Temperature Upper R/W Y
SUPERHEAT
18 1219 Suction Superheat Maximum R/W Y
19 1220 Suction Superheat Minimum R/W Y
20 1221 Discharge Superheat Maximum R/W Y
21 1222 Discharge Superheat Minimum R/W Y
SUCTION (continued from N22:03)
22 1223 Low Auxiliary Suction Setpoint R/W Y
N23: 0 1301 #1 Misc. Parameter R/W These values may be X1, X10 or X100
1 1302 #2 Misc. Parameter R/W Refer to job specific Addendum
2 1303 #3 Misc. Parameter R/W
| | | | |
99 1400 #100 Misc. Parameter R/W
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2=Next Step
3=Previous Step
4=@ Maximum Capacity
5=@ Minimum Capacity
6=Shutdown
15 2216 Timer Value R Seconds (Messages 1,2,3)
DISCHARGE
N32: 20 2221 Discharge 1 Pressure Setpoint R/W Y
21 2222 DIscharge 1 Pressure Upper R/W Y
22 2223 Discharge 1 Pressure Lower R/W Y
23 2224 Discharge 1 Pressure Next Step R/W Y
24 2225 Discharge 1 Pressure Previous Step R/W Y
25 2226 Discharge 2 Pressure Setpoint R/W Y
26 2227 DIscharge 2 Pressure Upper R/W Y
27 2228 Discharge 2 Pressure Lower R/W Y
28 2229 Discharge 2 Pressure Next Step R/W Y
29 2230 Discharge 2 Pressure Previous Step R/W Y
SAT LIQUID TEMP
30 2231 Saturated Liquid 1 Pressure Differential R/W 0-100.0 PSI Y
31 2232 Saturated Liquid 2 Pressure Differential R/W 0-100.0 PSI Y
CONTROL
32 2233 Control Mode Select R/W 0=Setpoint/1=Wet Bulb (Optional)
33 2234 Control Point Select R/W 0=DI/1=PNT1/2=PNT2
34 2235 Wet Bulb Setpoint Split Prs R/W 0 - 30.0 PSI Y
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Display Setup
N40: 0 3001 #1 Operating Parameter R 0=Disable/1=Enable/2=Out of Range
| | |
99 3100 #100 Operating Parameter R "
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| | |
99 3400 #100 Miscellaneous Parameter R “
N44: 0 3401 #1 Event Timer R "
| | |
95 3496 #96 Event Timer R "
N45: 20 3501 #1 Internal Sequence Parameter R "
| | |
43 3524 #24 Internal Sequence Parameter R "
N46: 20 3601 #1 Internal Condenser Parameter R "
| | |
34 3615 #15 Internal Condenser Parameter R "
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MICRO III DIAGNOSTICS OPERATION
Introduction ......................................................................................... 2
Diagnostic Tests
Warning Display................................................................................................ 3
Micro III Utility Home Screen ............................................................................ 5
Test # 1 – Keypad Test..................................................................................... 6
Test # 2 – Display / LED Test ........................................................................... 7
Test # 3 – Network Diagnostics Test................................................................ 8
Test # 4 – Input / Output Test ......................................................................... 12
Test # 5 – Analog Converters Test................................................................. 13
Test # 6 – 4-20 mA Analog Output Test ......................................................... 15
Test # 7 – RS-232 / RS-485 Communication Test ......................................... 16
Test # 8 – Line Voltage Test........................................................................... 17
Test # 9 – Motor Current & Slide Valve Test .................................................. 18
Test # 10 – Battery-Backed RAM Test ........................................................... 20
Test # 11 – DIP Switch Test ........................................................................... 21
Test # 12 – Rotary Switch Test....................................................................... 22
Test # 13 – Real Time Clock Test .................................................................. 23
Test # 14 – High Speed Counter Test ............................................................ 24
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Introduction
On-board diagnostic capabilities exist in most Micro-III panels via the keypad and display. To determine
if a Micro-III control panel has this feature, examine the U10 chip label, for panels with the optional Micro-
III I/O Expander Board or Rack Expander Board installed, removal of this board will be necessary to
examine the U10 chip label. If the label says, “Download” it does not have this capability; if the label says
“Utility” this function is supported. If you have a Rack Expander Board installed and the Revision on U10
is 5.0 or lower please contact FES to obtain an updated U10. Please note that some functions listed in
revision B are not available in program revisions prior to 5.1. These diagnostic tests can be accessed by
the following procedure:
• Locate jumper J6 on the Micro-III processor board. This jumper is located between the two square
(approximately 1-3/8”) chips near the top right-hand side of the main processor board. The label to
the right of this jumper is “CSSWP”.
• “CSSWP”. If you have a panel with the optional Micro-III I/O Expander Board installed, jumper J6
should be permanently removed so that jumper J1 on the expander board can perform the same
function. The same applies if there is a Rack Expander installed. If both an I/O Expander and Rack
Expander are installed J1 on the Rack Expander should be removed and J1 on the I/O Expander will
be used to switch modes of operation.
• Remove this jumper and reset the panel by either the reset button, SW1; I/O expander board reset
button, SW1; rack expander reset button, SW1 or the control panel power switch. NOTE: When this
mode is entered, normal control functions of this panel will cease to operate. A running
compressor MUST be properly stopped before performing this procedure! If this is a Micro-III
System Panel, any interlocks or controlled devices (high level shutdowns, alarming,
condenser fans/pumps, pump packages, ammonia (NH3) detection, etc.) will also cease to
function. Take appropriate precautions prior to entering this mode of operation.
• The display screen will reappear with two choices. To enter the test routine mode, press the [2]
button on the keypad. This will display a list of thirteen or fourteen test routines, which can be
accessed from the control panel.
• For information on option 1 (Download Mode) please refer to MCP-125. Note: Unless you are
downloading a new software revision into this panel DO NOT SELECT OPTION 1. If you
choose Option 1, you will be asked to confirm continuing and your existing program will be
erased. If this occurs, there is no remedy except to replace the existing program chip or
download a valid program to it. The downloading routines were changed to allow the baud rate to
be selected between 2400 and 38400 in revision 5.1.
1. Download Mode
2. Test Routines
Selection:
08:23:40 08/18/04
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Warning Display
The diagnostics software continuously checks the Micro III board and if supplied, the optional
Micro III expander board for failures of critical components. If a failure is detected, the Micro III
will halt operation of the panel and give a display indication of the problem. When halted, a
description message will flash on the display along with all of the Keypad LED’s. During this
WARNING
ADC #1 FAILURE -- The microprocessor detected that the 1st Analog to Digital
Converter on the main processor board did not properly come out of reset. Note, a reset
is performed before every acquisition of Analog Data, not just on initial power-up.
Contact FES for assistance on this problem.
ADC #2 FAILURE -- The microprocessor detected that the 2nd Analog to Digital
Converter on the main processor board did not properly come out of reset. Note, a reset
is performed before every acquisition of Analog Data, not just on initial power-up.
Contact FES for assistance on this problem.
EXPANSION ADC #1 FAILURE -- The microprocessor detected that the 1st Analog to
Digital Converter on the I/O expander board did not properly come out of reset. Note, a
reset is performed before every acquisition of Analog Data, not just on initial power-up.
Contact FES for assistance on this problem.
EXPANSION ADC #2 FAILURE -- The microprocessor detected that the 2nd Analog to
Digital Converter on the I/O expander board did not properly come out of reset. Note, a
reset is performed before every acquisition of Analog Data, not just on initial power-up.
Contact FES for assistance on this problem.
EXPANSION ADC #3 FAILURE -- The microprocessor detected that the 3rd Analog to
Digital Converter on the I/O expander board did not properly come out of reset. Note, a
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Warning Display
reset is performed before every acquisition of Analog Data, not just on initial power-up.
Contact FES for assistance on this problem.
RACK EXPANDER FAILURE – (rev 5.1 or later) The microprocessor was previously
communicating to the Micro III rack expander board and is no longer able to. Please
check that the rack expander board is firmly attached to the Micro III main board and that
all of the standoffs are in place. If the above checks did not fix the problem, please
contact FES for assistance.
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Home Screen
When the Test Routine mode is selected by entering a [2] from the Initial Screen (Figure 1), the Micro-III
Utility Home Screen will be displayed. Depending on the expansion options installed thirteen or fourteen
test routines will be shown (Figures 3A or 3B) on this screen. To select a test routine, press the number
of the desired test(rev 5.1 or later) or press the [ ] and [ ] keys on the keypad until the cursor is at the
test you wish to run and press the [ENTER] button. When this is done, the appropriate Test Routine
screen will be displayed. To access Tests 10-14 press [ALT] A-E (rev 5.1 or later).
MICRO III UTIL VER x.y MICRO III UTIL VER x.y
1. Keypad 1. Keypad
2. Display/Led1-Led6 2. Display/Led1-Led11
3. Network Diagnostics 3. Network Diagnostics
4. Input/Output 4. Input/Output
5. Analog Converters 5. Analog Converters
6. 4/20 mA Output 6. 4/20 mA Output
7. RS232/RS485 Comm. 7. RS232/RS485 Comm.
8. Line Voltage 8. Line Voltage
9. Mtr Amp/Slide Valve 9. Mtr Amp/Slide Valve
10. BBRAM Test 10. BBRAM Test
11. Dip Switch 11. Dip Switch
12. Rotary Switches 12. Rotary Switches
13. Real Time Clock 13. Real Time Clock
14. Counters
Please Select Test Routine Please Select Test Routine
Figure 3A – Micro-III Utility Home Screen Figure 3B – Micro-III Utility Home Screen
with no expansion boards installed with I/O expander board installed
See the index for a list and location of each of the individual Test Routines described in this manual. All
of the individual test routines have a description at the bottom of the screen explaining how to exit the test
and return to the Micro III Utility Home Screen.
After ending each Test Routine, the software will return to this screen. Each test routine that has been
accessed during the current test session will display a check mark in the box to the left of the selection.
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Keypad Test
The Keypad Test allows you to test the functionality of each key on the control panel. This test is useful
to determine if any of the keys are malfunctioning. As each of the Display Control Keys ([CHANGE
DISPLAY], [ENTER], etc.) or Numeric Keys ([7], [8], [9], etc.) are pressed the key will be listed on the
screen.
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Display / LED Test
The Display / LED test screen is used to test the functionality of both the display screen and the status
LED’s on the main processor board, I/O expander board and rack expander boards.
Press the [ENTER] key on the keypad to again view the Micro-III Utility Home Screen Menu.
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Network Diagnostics Test
The Network Diagnostics Test provides the user with four useful tools for determining the integrity of a
ComMENT network. Select the desired tool by depressing the number that precedes it. A
recommended order of utilizing these tools would be to perform the RECON test followed by Map the
Network, followed by Node to Node test. At each step, you should stop to fix problems and advance
only when any problems which are encountered are resolved. The function of each choice is as
follows:
NETWORK DIAGNOSTICS
1. Wake up COM20020
2. Node to Node Comm.
3. Network Recon Activity
4. MAP Network
Enter # of test:
WAKE UP COM20020
WAKING UP COM20020….
COM20020 Passed!
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Network Diagnostics Test
2. Node to Node Communication will prompt the user for the two-digit hexadecimal Node ID of
another ComMENT Network Board. To enter the Node ID, press the [EDIT] key, which will change
the first digit of the Node ID to a 0. To change this digit to any other number, the [ ] & [ ] keys will
increment or decrement (respectively) the digit. After the desired digit is displayed, the [ENTER]
key will accept the digit and move to the next. On newer Micro III panels the exact number can be
entered and on panels with extended keypads, numbers greater than 9 (A-F) can be entered using
TRIED:
ACK’D:
RECON: 0
MYRECON: 0
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Network Diagnostics Test
normal network activity, a RECON or network reconfiguration, will occur. If the Micro-III Node
called for the RECON, it will be indicated by MYRECON. Using these two statistics, network
stability can be assessed. Four RECONs during a minute, for example, would not be unacceptable
for a communication system through an industrial environment. Frequent RECONs are not
acceptable and measures should be taken to investigate their source. Any RECONs will cause a
temporary loss of data which may be unacceptable to some customers. Press the [] key to again
view the Network Diagnostics Menu.
4. Map Network causes the Micro-III to interrogate each of the 255 possible Node ID’s, searching for
available Nodes. Properly configured Nodes will respond by identifying the node ID and chipset of
their local micro panel, along with the chipsets revision. The screen will pause once all Nodes have
been interrogated. If there are more nodes than can fit on one screen, a reverse video bar will
appear on the first node of the map and can be moved by pressing the [ ] or [ ] key to view nodes
past the bottom of the screen. Press the [] key to again view the Network Diagnostics Menu.
Other responses that could occur are:
NETWORK MAPPING
Enter=Net MAP Clear=reset
& scroll thru Net MAP.
<< Map Of Network nodes >>
02 MII Dual Scr # 1 TPDEL
03 MII Twin Scr # 3 TPSER
04 MIIe M,H,D-B # 4 M2E0G
05 MMst Twn Scr # 5 TP3R
06 MIII System # 6
07 Protocol Translator.
08 Unrecognized Panel #
09 MIII System # 8
20 MII Head Prs #898 CPNEK
22 Attached to Network.
30 MIIe Evap #999 DEF2A
Press key for Main menu
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Network Diagnostics Test
• Unrecognized Panel Type – This will result when the program type of the responding device is
not in the database of the node performing the network map. This can be solved by obtaining
an updated copy of the utility chip for the panel performing the network map or any other panel
that will be used for network mapping in the future. This response does not indicate that there
are any faults in the network and will not cause any network problems. The updated utility chip
program will only fix the display of the unrecognized panels.
Press the [ENTER] key on the keypad to again view the Micro-III Utility Home Screen Menu.
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Input / Output Test
The Input/Output Test is used to test the functionality of each of the I/O racks. When this test is run the
LED next to each output module will sequentially turn on, beginning at module #1 and continuing to
module #40. In revisions prior to 5.1 the display will differ slightly from figures 12A and 12B.
Figure 12A – I/O Test Routine Screen Figure 12B – I/O Test Routine Screen
no expansion boards installed with expansion boards installed
PLEASE NOTE: EXTREME CAUTION MUST BE USED WHEN RUNNING THIS TEST. SINCE THIS
TEST WILL TURN ON EVERY OUTPUT MODULE ON THE I/O RACK AS PART OF THIS TEST THE
FOLLOWING PROCEDURE MUST BE FOLLOWED EXACTLY TO PREVENT HARM TO THE
EQUIPMENT AND/OR OPERATING PERSONNEL. FES WILL NOT BE HELD LIABLE FOR INJURY
TO EQUIPMENT OR PERSONNEL AS A RESULT OF IMPROPER EXECUTION OF THIS TEST.
To run this test, follow these steps:
• Turn off all breakers providing power to the control panel and verify that power has been removed
from the Micro-III I/O racks, especially externally powered devices.
• While the power is turned off, unplug all field wired connectors from the I/O rack. This MUST be
done to ensure that no external devices can be energized during this test. This will also prevent
damage to the I/O modules installed on the rack. DO NOT CONTINUE THIS TEST UNTIL THIS
STEP HAS BEEN PERFORMED. Ensure that the terminal blocks that are unplugged are not
touching any device that would be harmed by the voltage present.
• Restore power to the control panel and turn the panel on.
• Press and hold the AR Switch (SW3) on the main processor board during the entire test. If this
switch is released at any time during the test, the test will be cancelled and the screen will return to
the Micro-III Utility Home Screen Menu.
• Follow directions on the screen to run this test. These directions are also shown in Figure 12A or
12B above.
• You can only change racks by pressing [+/-] when no rack LED’s are on.
• Upon completion of the test, turn off all power provided to the control panel as done previously.
• Return all connectors to their original positions and restore power to the panel.
Press the [ENTER] key on the keypad or release the AR Switch (SW3) to again view the Micro-III
Utility Home Screen Menu.
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Page 12 of 24 Effective: 8-2004
Analog Converters Test
The Analog Converter Test is used to confirm that the signal present at the terminals of the analog
input terminal strip is also sensed and properly interpreted by the microprocessor. Each ADC converts
8 channels of data, the channel number and data are displayed in the table. This value will be shown as
a range of 0 to 4095 regardless of the range of the analog input device. Press the [CHANGE DISPLAY]
ADC #1
CH01 CH02 CH03 CH04
208 3804 277 4050
CH05 CH06 CH07 CH08
18 577 831 1957
Measured Pressure(Psig)
∗ Voltage Range of Transducer + VoltageOffset = Theorectical Output
Transducer Range (Psig)
Using the above equation, a 0-500 PSIG, 1-5 volt transducer with a 185 PSIG pressure applied to it
would output the following theoretical voltage:
185.0 Psig
∗ 4Volts + 1Volt = 2.48 Volts, DC
500 Psig
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Revision: B
Page 13 of 24 Effective: 8-2004
Analog Converters Test
If the theoretical voltage does not match the voltage appearing at the output of the transducer within
several millivolts, a faulty transducer should be suspected. The above equations can also be modified
to work with other transducers. For example, if the sensor is a 4-20 mA type, the range of the sensor is
16.0 mA with an offset at minimum range of 4.0 mA.
Press the [ENTER] key on the keypad to again view the Micro-III Utility Home Screen Menu.
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Revision: B
Page 14 of 24 Effective: 8-2004
4-20 mA Output Test
The 4-20 mA Analog Output Test is used to test the functionality of the Digital to Analog Converters
(DAC) installed on the main microprocessor board. These chips are located on the lower right hand
corner of the microprocessor board in locations U22 through U25. On the I/O expander they are in
locations U12 through U19. In revisions prior to 5.0 the display will differ from Figure 13.
Figure 14A - Analog Output Test Screen Figure 14B - Analog Output Test Screen
no expansion board installed I/O expander installed
Note:
• All Micro-III control panels are not supplied with these chips installed. These chips are used to
provide a 4-20 mA output signal to an external control device such as a variable frequency drive
(VFD), modulating valve, DCS system interface, etc.
• These chips will be supplied only in the quantity required by the application. If one channel is
required, there will be a chip installed in U22. If two channels are required, U22 and U23 will both
have chips and so forth. For example, if VFD control is required (3rd channel) but slide valve and
motor current outputs (1st and 2nd channels) are not required, U22 and U23 must be installed for
U24 to operate for VFD control. This also applies to the I/O expander, the chips must be installed in
order from U12 to U19
• For any of the channels to work, two 8-pin HP 2231 chips must be installed in the sockets directly
to the left of chip U22. On some older Micro III boards, the HP 2231 chips were mounted onto
adapter boards. To determine if your Micro III board requires the adapter board on the HP 2231
chips, please contact FES. These chips are soldered directly in the I/O expander.
To test the output of these chips, place an ammeter in series with the device being controlled or remove
the devices wires and place the ammeter directly across the channels outputs and run the test using
the directions shown on the screen. If a reading is shown when directly across the outputs but not
when in series with the device, it can be assumed that the device is “open”. Also, if testing is done in
series with the device, the device will be actuated which may not be desirable in all situations. The
output of each of these chips will be a minimum of 4 mA and a maximum of 20 mA. Adjustment of the
4mA and the 20 mA settings are adjustable via potentiometers on the main microprocessor board.
These adjustments are factory set and normally require no adjustment.
Press the [ENTER] key on the keypad to again view the Micro-III Utility Home Screen Menu.
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Revision: B
Page 15 of 24 Effective: 8-2004
RS-232/RS-485 Test
The RS-232 / RS-485 Communication Test is used to test the functionality of the RS-232 or the RS-485
port. The RS-232 port is currently only used for program downloads to the microprocessor panel. This
test should be performed to troubleshoot any problems that occurred while trying to download a
program to the panel. The RS-485 port is used to talk Modbus (MCP-161), with Utility 5.1 or later baud
rate can be selected by pressing the AR switch.
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Revision: B
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Line Voltage Test
The Line Voltage Test is used to display the current line voltage as detected by the microprocessor.
This voltage is detected from the two terminal connections on the lower left side of the main
microprocessor board (P2). The other components in this circuit include the glass fuse (F1) located
next to these terminals and the square transformer located immediately above the terminals.
118 Vlts, AC
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Revision: B
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Motor Current/Slide Valve Test
The Motor Current & Slide Valve Test is used to display the current reading for the motor current input
and to test the slide valve circuitry.
2.891 Amps, AC
SLIDE VALVE TEST
1.001 Vlts, DC
Range:Max=1.029,Min=0.931
For the values shown in Figure 17, the displayed Motor Current Test reading is 2.891 Amps, AC. If the
current transformer ratio (CT) for this particular application were 500:5, the actual motor current would
be:
2.891 Amps
∗ 500 = 289.1 Amps, AC
5 Amps
Calibration of this motor current reading is done via potentiometer R95. This potentiometer is factory
set and should not need adjustment. If adjustment is needed, it should be done via the Analog data
screen and the known Motor Current from the starter panel. If an accurate 0 – 5 Amp, AC source is
known, this diagnostics screen can be used to calibrate the microprocessor board.
If a proper motor current reading cannot be obtained, please contact FES for further assistance.
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Revision: B
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Motor Current/Slide Valve Test
Slide Valve
The slide valve test voltage displayed is the DC voltage signal from the slide valve input on the main
processor board. With a slide valve potentiometer attached to the inputs, it should read approximately
the voltage at the slide valve input with respect to ground (wiper of the potentiometer). This testing is
meant for troubleshooting problems with a potentiometer type slide valve input. For other types of slide
valve input, for example 4-20 mA, please refer to the Analog Converters Test section. Also, for this test
to work, Jumper J48 must be in the lower two positions.
To test the circuitry, the slide valve potentiometer wiring will need to be removed from the Analog
Terminal Strip (P9) and all three input connections shorted together. With these inputs shorted, the
reading should be between the minimum and maximum limits as shown on the screen. If it is not within
this range, “****OUT OF RANGE****” message will appear on the screen. This test verifies the current
and offset resistor used in the slide valve circuitry. If a proper reading cannot be obtained, please
contact FES for further assistance.
Press the [ENTER] key on the keypad to again view the Micro-III Utility Home Screen Menu.
Document: MCP-144
Revision: B
Page 19 of 24 Effective: 8-2004
Battery-Backed Ram Test
The Battery-Backed RAM Test is used to test the integrity of the Battery-Backed RAM (U11) chip. This
chip contains all user-entered parameters such as setpoints, parameter limits, calibration values, etc.
for the control panel. This test will not erase any of these setpoints. Each location of the Battery-
Backed RAM is stored before it is tested and then is restored after testing is complete. Utility 5.0 or
earlier can only test a 1 Meg BBRAM and the display differs from Figure 18.
Document: MCP-144
Revision: B
Page 20 of 24 Effective: 8-2004
Dip Switch Test
The DIP Switch Test is used to confirm that both positions of all 8 switches in switch pack SW6 are
detected by the control panel. Before making any changes to the dip switch positions, please note their
positions and return them before ending this test. Failure to do so will result in unexpected changes to
the operation of the control panel. As you change the settings of these switches, the display will move
the blacked out section to correspond to the pressed in position of the actual switch. If this does not
occur, please contact FES for further assistance.
OPEN
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Rotary Switch Test
The Rotary Switch Test is used to confirm that the control panel detects all positions of these switches.
Before making any changes to the rotary switches, please note their positions and return them before
ending this test. Failure to do so will result in unexpected changes to the operation of the network. As
you change the settings of these switches, the display should also change to always reflect the current
position. If this does not occur, please contact FES for further assistance.
SW4
0123456789ABCDEF
1
SW5
0123456789ABCDEF 2
Press Enter key to exit
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Revision: B
Page 22 of 24 Effective: 8-2004
Real Time Clock Test
The Real Time Clock Test allows you to view and set the current settings for time and date in this
control panel. To change a setting, use the arrow keys to position the cursor next to the selection you
wish to change. Press the [EDIT] key followed by the key(s) for the number you wish to enter and
press the [ENTER] key. Repeat these steps until all entries are correct. For each selection on the
screen the range of valid entries is shown in parenthesis. An invalid entry will be flagged with “??” and
discarded.
16:16:31 3
FRI SEP 22, 0
HR (0-23) DOW(1-7)
MIN(0-59) MTH(1-12)
SEC(0-59) DOM(1-31)
TNS(0-99) YR(0-99)
Change Display key to exit
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Revision: B
Page 23 of 24 Effective: 8-2004
High Speed Counter Test
The high speed counters are part of the I/O expander board, they are typically used for
tachometer inputs or pulse flow meter inputs. Connect a frequency generator to the counter inputs
set the amplitude between 4 and 12 volts peak to peak. The frequency can range from 10 Hz to
65,500 Hz. The frequency will be displayed on the Micro III screen. Utility Revision 5.0 or later
COUNTER TEST
The counter values will
Display the frequency of
The signals present at the
CNT1IN and CNT2IN inputs.
Min frequency = 10 Hz.
Counter #1 Frequency
550
Counter #2 Frequency
0
Press the [ENTER] key on the keypad to again view the Micro-III Utility Home Screen Menu.
Document: MCP-144
Revision: B
Page 24 of 24 Effective: 8-2004
GM SERIES SCREW
COMPRESSOR PACKAGES
SECTION 4 COMPRESSOR STARTUP PROCEDURE
TABLE OF CONTENTS
PAGE
Introduction...........................................................................................................................1
Pre Startup Requirements ...................................................................................................1
Required Actions-Installing Mechanic ...............................................................................1
Required Services-FES Startup Representative ................................................................1
Initial Start Sequence ...........................................................................................................2
Parameter Setup....................................................................................................................3
Normal Shutdown Sequence ................................................................................................4
Normal Startup Procedure...................................................................................................4
GM SERIES SCREW may have moved to the secondary side of the
separator during shipment. Shipping
COMPRESSOR PACKAGES documents should be checked to find if an
initial oil charge was installed.
SECTION 4 COMPRESSOR
F. Do not turn on the oil heater(s) prior to the
STARTUP PROCEDURE
arrival of the FES startup representative.
Introduction G. Do not energize motor circuits for rotation
check prior to the arrival of the FES
This section contains information for conducting
startup representative.
initial startup, normal operational startup, and
restart after power failure. CAUTION: The oil pump (if provided),
compressor, and microprocessor
Pre Startup Requirements are to be initially started only
Initial startup must be supervised by an FES under the direct supervision of the
authorized startup representative. Failure to have FES startup representative.
this person present will void the compressor
package warranty. This section should be Required Services-FES Startup
carefully read and understood to prevent damage Representative
to the compressor or system. A. Verify that all electrical connections are
correct.
Required Actions-Installing Mechanic
B. Check the function and settings of all
A. Make all refrigerant piping connections.
electrical and mechanical controls of the
B. Provide liquid refrigerant line for liquid screw compressor package.
injection or thermosiphon oil cooling.
C. Verify the alignment of the compressor and
Provide water piping if water cooled oil
compressor motor.
cooler is used. A high pressure refrigerant
gas line must be provided for liquid injection D. Instruct the operating personnel in the
cooled booster compressors for external operation and maintenance of the GM Series
equalizing of the liquid injection expansion compressor package.
control valve. Compressor package drawings E. Inspect the system for obvious faults or
supplied with the package will show defects which may damage the compressor.
compressor connections. After the initial checkout procedures are
C. Pressure test all refrigerant connections, completed, the compressor startup will proceed as
before insulation is applied, and charge the described below in "Initial Startup Sequence".
system with refrigerant. After as many hours as possible (at least three
D. Connect all power, control and auxiliary hours), but before the FES Startup Representative
equipment. Do not energize control (120 or leaves the job, the customer must inspect and
220 volt) power supply to the clean the oil pump suction screen (if provided),
microprocessor. and compressor suction strainer screen. If the oil
filter pressure drop is 15 psid the oil filter should
E. Fill the oil separator with the initial charge of
be changed at this time. Otherwise, the spare
oil to top of the sightglass (one primary side
filter should be kept for future use.
sightglass) or to the middle of the top
sightglass (two primary side sightglasses).
Some packages are precharged with oil but
the oil may not be visible since some of it
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Document: GM-3
Revision: A
1 Effective: 09-01
8. If this is a liquid injection cooled
Initial Startup Sequence compressor, open the liquid supply to the
After the prestartup checks have been conducted feed station. If this is an externally cooled
for a new installation or for restart after compressor, the water feed valves or
maintenance or service shutdown, the following refrigerant supply valves should be open.
procedure should be observed when starting the 9. If economized, the economizer supply
compressor: should be closed. It should be opened
A. Check the oil level in the primary side of the slowly after initial compressor operation
oil sump. If there is one primary side is confirmed.
sightglass, the oil level during shutdown 10. Refer to the compressor schematic
should be at the top of the sightglass. When supplied with package and set any other
the compressor is operating, the oil level valves to the position for normal
should not be below the sightglass. If there operation.
are two primary side sightglasses, the oil level
during shutdown should be at the middle of C. Set the CONTROL POWER ON switch to the
the top sight glass. When the compressor is on position.
operating, the oil level will drop but should D. Close oil heater circuit breakers so power will
not be below the lower sight glass. be applied to oil heaters. Power should be
B. Check for the correct position of all valves as applied 24 hours prior to compressor startup
shown below: or as required to attain a minimum oil
temperature of 90°F.
1. Compressor suction valve should be open.
E. Ensure the disconnect to the compressor
2. Compressor discharge valve should be motor is open.
open.
3. The main oil injection metering valve NOTE: Some starters do not have a separate
should be fully open. Throttling the main motor and control voltage disconnect,
oil injection valve may be required to in which case the motor leads must be
reduce noise or vibration caused by disconnected from the starter.
excessive oil flow. If the package is This is necessary only if this is the initial start
supplied with an auxiliary main oil up or the motor or the wiring to the motor has
injection valve, this valve should be been changed.
opened only as required to maintain an
acceptable discharge temperature. NOTE: For a high stage application (no
external oil pump) , skip steps F. & G.
4. Open all valves feeding transducers on the
microprocessor control panel. Be sure the F. Close dipswitch SW6 #3 for service mode.
vent and purge valves are closed. Start the oil pump by pressing the OIL PUMP
5. Open the oil filter service valve(s). pushbutton. Allow the oil pump to run for
approximately 30 seconds to lubricate the
NOTE: If dual oil filters are supplied the compressor bearings. Stop the oil pump by
standby oil filter supply service valves pressing the OIL PUMP button.
will be closed, and the outlet valve must
be open. G. Close the disconnect or reconnect the motor
leads to the compressor motor. See step E
6. Open the secondary oil return metering above.
valve 1 turn open. The service stop valves
should be fully open. H. Check compressor rotation. Facing the
compressor shaft, the rotation should be
7. Open the service valve from the oil CLOCKWISE. To check rotation, start the
differential relief regulator (if applicable). oil pump and after going through the normal
Document: GM-3
Revision: A
Effective: 09-01 2
starting sequence, the compressor will start. the time that the oil pump has run will be
As soon as the direction of rotation is examined. If the oil pump has run more
confirmed, stop the compressor motor by than 10 seconds to establish oil pressure
pressing the STOP button. This check is only and/or unload the compressor, the startup
necessary if this is the initial startup or the is delayed for the oil drain timer period.
motor or wiring has been changed. The oil drain timer is set to 10 minutes,
I. Enter variable setpoints into the which must elapse before the compressor
microprocessor. will be started. Once the oil drain timer
has elapsed, the startup sequence will be
J. Depress the AUTO capacity control restarted at step #2. Otherwise proceed to
pushbutton or the EXTERNAL pushbutton, if step #7.
controlled by a sequencer. This will allow the
6. Compressors without an external oil pump
machine to control capacity.
must be unloaded to less than 70% in
K. Press the LOCAL START pushbutton, or if order to be started immediately. The
the compressor is to be sequenced by an compressor can still be started if the slide
auxiliary control, push the REMOTE START valve reading is less than 70% within
pushbutton (the LED of the key selected will three minutes of attempting to start the
be illuminated, and the OIL HEATER LED compressor. If the slide valve reading is
will go out). This will enable the compressor greater than 70% after the three-minute
to start depending on set up. From this point period, the startup is terminated.
the startup sequence will be automatic and the 7. The compressor will start.
following will occur:
a. A loss of oil pressure below the
1. If the compressor was started previously minimum allowable oil pressure for 30
within the anti-recycle time delay period, seconds is allowed at this time.
the LED on the ANTI-RECYCLE key
b. There will be a 15 second delay before
will be illuminated. The compressor start
the compressor begins to load.
will be delayed until the anti-recycle timer
has completed its timing cycle. c. The elapsed time meter will start
timing to display compressor
2. The microprocessor examines the position
operating hours as soon as the
of Dipswitch SW#6 switch #6 to
compressor starts.
determine if the GM series compressor
has an external auxiliary oil pump. If the The compressor will now operate automatically.
compressor does not have an external oil The capacity controller will cause the compressor
pump, proceed to step 6. A compressor slide valve to load and unload to maintain the
that is equipped with an external oil pump desired system pressure or temperature.
will start the oil pump and wait for it to
establish pressure and unload the Parameter Setup
compressor. Once the compressor conditions have stabilized
3. If the auxiliary oil pump fails to build and normal suction and discharge conditions have
adequate pressure in 10 seconds, the been reached, there are several compressor
startup sequence will terminate. operating parameters that must be set. The
settings and adjustments that must be made are as
4. If the slide valve does not move to less follows:
than the unloaded position for three
minutes, the startup sequence will also A. Adjust the liquid injection oil cooling. Refer
terminate. to Section 2, Figure 2-2 for system
explanation and schematics. Adjust the outlet
5. Once the compressor has been unloaded pressure regulating valve (OPRV) per
and the oil pressure has been established,
Document: GM-3
Revision: A
3 Effective: 09-01
instructions in Section 2 to maintain the oil Normal Shutdown Sequence
temperature listed in Table 2-1. Allow the
It is recommended that the compressor is first
compressor to run for several hours to observe
unloaded before shutdown. The normal
any changes in oil temperature. If the oil
shutdown sequence is initiated by pressing the
temperature should drop more than 5°F below
STOP pushbutton. This will cause the following:
the recommended limits, adjust the OPRV for
a higher pressure, which will reduce the High Stage Application (no external oil pump)
refrigerant flow for oil cooling. If the oil A. The compressor will stop immediately and the
temperature should increase more than 5°F STOP LED will be illuminated.
above the recommended limits, adjust the
B. The compressor internal oil pump will stop
OPRV for a lower pressure, which will
with the compressor. The slide valve tension
increase refrigerant flow for oil cooling. Do
spring will unload the compressor below 70%
not adjust the thermal expansion valve (#5 or
slide valve position (maximum slide valve
#10) to control oil temperature. After system
position allowable when starting the
equilibrium is obtained, the liquid injection
compressor).
oil cooling system will operate automatically
without manual adjustment. Booster Application (external oil pump)
B. For a booster application (with external oil A. The compressor will stop immediately and the
pump) - Once the oil temperature has reached STOP LED will be illuminated.
operating temperature, some drop in oil B. The oil pump will continue to run until the
pressure may be experienced. The oil slide valve moves to the less than 5% position
pressure should be adjusted to the or for a minimum of 5 seconds, and then it
requirements given in Table 2-1. Oil pressure shuts down.
is adjusted by changing the setting of the "v"
ported plug type regulating valve in the oil Normal Startup Procedure
bypass line to the separator. This valve is A. Ensure that system conditions will allow a
adjusted by removing the top cover and safe startup.
turning the stem clockwise to raise oil
B. Depress the AUTO capacity control button
pressure and counterclockwise to decrease oil
(or external if controlled by an auxiliary
pressure. The oil pressure of a high stage
controller).
compressor (no external oil pump) is not
adjustable. C. Press the LOCAL START, or if the
C. When oil pressure and temperature are stable, compressor is controlled by an auxiliary
adjust the compressor slide valve load and control press the REMOTE START.
unload rate. GM Series compressor packages D. The start sequence will now be automatic.
employ a double hydraulic cylinder to operate
the slide valve as illustrated in Figure 2-4.
The rate of slide valve movement is adjusted
by means of the three needle check valve
settings (two for load, one for unload). The
load and unload valves are identified in
Figure 2-5. Closing the needle valves slows
the rate of slide valve movement. Set the
needle valves such that is takes 30 to 60
seconds to load or unload the compressor
from 0% to 100% and from 100% to 0%,
respectively.
Document: GM-3
Revision: A
Effective: 09-01 4
.
GM SERIES SCREW
COMPRESSOR PACKAGES
SECTION 5 MAINTENANCE
TABLE OF CONTENTS
PAGE
Introduction...........................................................................................................................1
Compressor Removal/Installation.......................................................................................1
A. Compressor Removal ............................................................................................1
B. Compressor Installation ........................................................................................1
Normal Maintenance ............................................................................................................1
A. Compressor Shutdown and Restart .....................................................................2
B. Oil Filters ................................................................................................................2
C. Oil Strainer .............................................................................................................3
D. Liquid Refrigerant Strainers ................................................................................3
E. General Component Replacement........................................................................4
F. Coalescer Filter Replacement ...............................................................................4
G. Replace Compressor Unit Oil ...............................................................................5
H. Motor Bearings ......................................................................................................5
I. Motor Alignment....................................................................................................5
J. Suction Strainer Service ........................................................................................5
Recommended Maintenance ................................................................................................6
A. Oil Quality and Analysis .......................................................................................6
B. Vibration Analysis .................................................................................................6
C. Maintenance Schedule ...........................................................................................6
D. Class A, B, & C Inspection Summary ..................................................................8
E. Operating Log ........................................................................................................9
Parts and Warranty Contact Information .......................................................................11
A. Warranty Return Material Procedure...............................................................12
B. Parts Warranty ....................................................................................................12
C. Restocking Policy .................................................................................................12
GM SERIES SCREW COMPRESSOR
REMOVAL/INSTALLATION
COMPRESSOR PACKAGES
In some instances, it may be necessary to remove
SECTION 5 MAINTENANCE the compressor for repair or replacement. The
following procedure must be followed in order to
INTRODUCTION remove and/or install the compressor without
damage to any components.
This section of the manual contains information
on maintenance, service, and troubleshooting for A. Compressor Removal
the GM Series compressor package. It is a. Shutdown the compressor and isolate the
organized into two sections, Normal Maintenance compressor package from the system. Refer
and Recommended Maintenance. to the Compressor Shutdown and Restart
procedure outlined on the following page. Be
IN ORDER TO PROPERLY AND SAFELY sure the compressor power supply disconnect
MAINTAIN THE GM SERIES COMPRESSOR, has been opened before working on the
THE INFORMATION CONTAINED IN THIS package.
SECTION MUST BE READ AND
b. Remove the coupling guard to gain access to
UNDERSTOOD. ALL MAINTENANCE ON
the coupling.
THE PACKAGE SHOULD BE PERFORMED
ONLY BY A TRAINED REFRIGERATION c. Remove the coupling. Refer to the Coupling
MECHANIC QUALIFIED TO WORK WITH Removal/Installation instructions in Section 1
THE SPECIFIC REFRIGERANT BEING USED. of this manual.
d. Disconnect all piping, tubing, and wiring that
When performing service or maintenance operations, attaches to the compressor.
care must always be exercised and safety precautions
obeyed or serious injury or damage could result. e. Attach a lifting sling to the compressor.
Therefore, before performing any work requiring the f. Unbolt the compressor feet and remove the
opening of refrigerant containing parts, servicing compressor from the package.
high voltage components, or working near or on
B. Compressor Installation
rotating components, obey the following precautions:
a. Lift the compressor into position on the
• Before servicing the compressor or any compressor package. Install the compressor
other moving parts, press the compressor mounting hardware, but do not tighten.
STOP button, then turn off the control b. Align the compressor shaft with a center line
power and open power disconnects to the established by the compressor/motor
compressor and oil pump starter. Tag and mounting angles. Fasten the compressor to
lock all disconnects in the open position the mounting angle.
while conducting service work. c. Reconnect all piping, tubing, and wiring.
• Be sure the working space is adequately d. To reinstall the coupling, follow the
ventilated. instructions for Motor Mounting and
• Wear protective clothing and gear as Alignment for Field Mounted Motor in
required. Section 1 of this manual.
• Obey safety guidelines for the refrigerant NORMAL MAINTENANCE
being used in the system.
• READ AND UNDERSTAND THE The Normal Maintenance section identifies those
MAINTENANCE SECTION OF THIS service tasks which are necessary for the proper
MANUAL. operation of the compressor package.
Document: GM-4
Revision: B
1 Effective: 09-04
A. Compressor Shutdown and Restart B. Oil Filters
All GM Series compressor packages are
When the compressor is shutdown for prolonged
furnished with one 15 micron high efficiency
periods such as seasonal shutdown, the following
spin-on oil filter. As an option, dual oil filters are
procedure should be followed:
available so that the compressor can continue to
a. Depress STOP to shutdown the compressor. operate while one filter is being changed (Only
one filter is used during operation, the second
b. Turn CONTROL POWER to the OFF serves as 100% backup).
position. Open oil heater circuit breakers.
c. Open disconnects to the compressor and oil UNLESS DUAL OIL FILTERS ARE
heaters. SUPPLIED, IT IS NECESSARY TO SHUT
DOWN THE COMPRESSOR BEFORE
d. Close the suction and discharge valves. If REPLACING FILTER ELEMENTS.
used, close liquid injection feed and
economizer feed valves. Attach CLOSED Filter elements should be changed when the
tags. pressure drop across the filter exceeds 15 psid or
e. If water cooled, close the water supply and yearly.
return valves and attach CLOSED tags.
The procedure for changing the main oil filter is
Provisions should be made to protect from
as follows:
rust and corrosion during shutdown.
Also, if the package will be exposed to below a. If a single oil filter was supplied, shut down
freezing temperatures during shutdown, the oil the package by depressing the STOP button
cooler and piping must be heated or drained. and open the disconnects to the compressor
and oil pump (if provided).
To restart after extended shutdown use the If dual oil filters were supplied, SLOWLY
following procedure: open the upstream service ball valve to the
a. If water cooled, take necessary action to filter not in use. The valve must be opened
return cooling water to the cooler. Open the slowly to prevent a sudden lowering of oil
supply and return valves and remove pressure.
CLOSED tags. b. Close the service ball valves to the filter that
b. Inspect the compressor for any damage or is being replaced.
corrosion that may have occurred during c. The pressure in the oil filter must now be
prolonged shutdown. relieved. Connect a hose to the vent valve
c. Open the compressor suction and discharge connection at the top of the filter. Insert the
valves, and if supplied, the liquid injection free end of the hose into a container to collect
feed stop valve. Remove CLOSED tags. If the oil, which is in the piping. Slowly open
economized, the supply valve will be opened the vent valve to relieve the pressure.
after startup. d. Unscrew and remove the oil filter cartridge.
d. Close disconnects to the compressor and oil Used filter cartridges can then be properly
pump. disposed. Be sure to clean sealing surfaces to
e. Turn the CONTROL POWER switch to the remove any gasket material from previous
ON position. Close the circuit breakers to the filter elements.
oil heaters. Allow the oil to warm to 90°F. e. Lubricate the gasket of the new filter cartridge
f. Proceed with the startup as described in with oil.
Section 4. f. Screw filter cartridges on until gasket makes
contact; then tighten one-half turn.
Document: GM-4
Revision: B
Effective: 09-04 2
g. Open the valves closed in step b. Close the the oil, which is in the piping. Slowly open
disconnects to the compressor and oil pump the vent valve to relieve the pressure.
motors (if provided). d. Open drain valve under the oil separator.
h. The filter is now ready to be placed in service Collect the oil in a container for disposal.
and the compressor is ready to be restarted. e. Unscrew and remove the strainer cover and
i. If a single oil filter was supplied, the filter is O-ring.
now ready to be placed in service and the f. Remove the strainer basket and wash in
compressor is ready to be restarted. solvent. Blow with air to dry and clean.
If a dual oil filter was supplied, this filter g. Wipe the inside of the strainer housing with a
becomes the back up and the inlet stop valve clean dry lint free cloth.
should be closed (outlet open) until the other
filter is changed. h. Replace the strainer basket and install the
strainer cover and O-ring.
C. Oil Strainer (If Applicable) i. Open the valves closed in step b. Close the
disconnects to the compressor and oil pump
Cleaning the oil strainer REQUIRES motors.
COMPRESSOR SHUTDOWN. To clean the
j. The compressor can now be restarted.
strainer use the following procedure:
NOTE: The Booster External Oil Cooled
a. Stop the compressor by depressing STOP.
Application also has an oil strainer in
Open the disconnects to the compressor and
the main oil injection line. To service
oil pump (if provided).
this strainer, follow the same steps as
b. The oil strainer must be isolated by closing all above. To isolate this strainer, close the
the necessary valves in the oil piping system. valve between the oil separator and oil
Please refer to your Piping Schematic and the strainer, the main oil injection
summary below to determine all valves that metering/stop valve, and the oil filter
must be closed for your application. outlet valve.
High Stage External Oil Cooled Application:
Close the valve between the oil separator and D. Liquid Refrigerant Strainers
oil strainer and the oil filter outlet valve.
A number of liquid refrigerant strainers may be
High Stage Liquid Injection Cooled used on the GM Series compressor depending on
Application: Not applicable - no oil strainer the type of oil cooling and other optional
required. equipment supplied. For this reason a general
Booster External Oil Cooled Application: procedure is given that can be used for the
Close the valve between the oil separator and equipment supplied. Refer to the equipment
oil strainer, the main oil injection schematic provided with the package to find
metering/stop valve, and the oil filter outlet specific locations of valves. The procedure is as
valve. follows:
Booster Liquid Injection Cooled Application: a. Stop the compressor by depressing STOP and
Close the valve between the oil separator and open the disconnects to the compressor and
oil strainer, the main oil injection motor.
metering/stop valve, and the oil filter outlet b. Close the liquid supply stop valve to the
valve. strainer and solenoid valve.
c. The pressure in the oil strainer and associated c. OPEN THE SOLENOID MANUALLY BY
piping, which has been isolated, must now be SCREWING IN THE VALVE STEM AT THE
relieved. Connect a hose to the vent valve BOTTOM OF THE VALVE. This will prevent
connection at the top of oil filter. Insert the
free end of the hose into a container to collect
Document: GM-4
Revision: B
3 Effective: 09-04
liquid from being trapped between the e. Close the compressor suction stop valve and
solenoid valve and the stop valve. the suction check valve bypass valve.
d. Allow time for the liquid refrigerant to f. Vent the oil separator using the oil fill
evaporate then close the stop valve connection to purge any remaining
immediately down stream of the solenoid refrigerant. Carefully handle and dispose of
valve. refrigerant as required by applicable safety
e. When it can be determined that there is no codes.
remaining refrigerant in the strainer body or g. Complete service repair or replacement.
basket, cautiously loosen the bolts holding the h. Evacuate package if required for refrigerant
strainer cover. type used.
f. Carefully remove the cover and strainer i. Return valves to their original operating
basket. positions following the previous procedure in
g. Wash the strainer basket in solvent and dry reverse. Conduct a leak test.
with compressed air. j. Close the compressor and pump motor
h. Reassemble the strainer. disconnects. Close the oil heater circuit
i. Open the stop valve downstream of the breakers.
solenoid valve and perform a leak check. k. The compressor is now ready for operation.
j. Unscrew the manual open stem at the bottom
of solenoid valve. F. Coalescer Filter Replacement
k. Slowly open the liquid supply stop valve. Coalescer filter elements should be replaced
l. Close the disconnects to the compressor and when the pressure drop across the elements
pump motors. The compressor is ready for exceeds 5 psid. The procedure for replacement is
operation. as follows:
a. Refer to "General Component Replacement"
E. General Component Replacement above and utilize steps a through f to prepare
for coalescer service.
When repairing or replacing components that can
not be individually isolated, the following b. Loosen the manway cover retainer bolts.
procedure should be used. Remove the retainer, manway cover and
cover gasket. Do not reuse the cover gasket.
a. Stop the compressor by depressing STOP.
Open the disconnects to the compressor and c. Remove and keep the two nuts and cover
pump motors. Open the oil heater circuit plate from each rod retaining coalescers.
breakers. Slide the coalescer elements off of rod and
properly dispose.
b. Close the compressor package discharge stop
valve. d. Install new coalescer elements by sliding
them one at a time over the rod until the first
c. If provided, close the liquid injection liquid element is against the rear baffle. The end of
feed stop valve and stop valve at compressor the coalescer with the larger diameter o-ring
port G and the economizer supply stop valve. (this end is stamped "B") should contact the
Close the high pressure gas supply stop valve oil separator baffle plate. All elements should
to the liquid injection oil cooling outlet touch each other.
pressure regulator (if liquid injection cooled).
e. Install the cover plates. Tighten the first nut
d. Open the compressor suction check valve to 35 ft-lb. and use the second nut to lock the
bypass valve to allow the refrigerant in the first nut in place.
compressor package to be transferred to the
system suction. f. Install the manway cover being sure to use a
new gasket.
Document: GM-4
Revision: B
Effective: 09-04 4
g. Tighten the manway bolts. Recheck bolts H. Motor Bearings
after applying pressure to the oil separator
since they may loosen. Refer to the motor manufacturer
h. Refer to "General Component Replacement" recommendations for maintenance.
above and use steps h through k to complete
I. Motor Alignment
this procedure.
If motor alignment needs to be checked or
G. Replace Compressor Unit Oil adjusted, it should be conducted in accordance
When it is necessary to change the compressor with the procedures in Section 1.
package oil charge, the compressor must be
J. Suction Strainer Service
shutdown. Oil filters must be drained and filter
elements replaced, along with all oil strainers The suction strainer protects the compressor from
being cleaned. The procedure is as follows: system debris that could damage the compressor.
It is integrated into compressor suction casing.
a. Refer to "General Component Replacement" This strainer would normally be cleaned as part
Section and follow steps a through f. of the initial startup procedure or if the
b. Vent the compressor using the oil fill refrigerating system has been opened up (i.e. for
connection leaving the valve open during the repairs, plant expansion, etc.) The procedure for
oil draining procedure. cleaning this strainer is as follows:
c. Drain the oil into a suitable container using a. Stop the compressor.
the oil filter drain valve and a hose connected b. Refer to "General Component Replacement"
to the oil filter drain valve. Open this valve to Section and utilize steps a through f to
drain the oil from the compressor. prepare for suction strainer inspection and
d. Change the oil filters and clean the oil strainer cleaning.
as previously described. c. Carefully loosen the bolts on the compressor
e. Once step d is complete, and the filters and suction strainer cover. When it is determined
strainer are reassembled, close the oil filter that refrigerant or pressure is not present,
drain valve. remove and retain the bolts and cover.
f. Add oil through the oil fill connection until Discard the cover o-ring.
the oil level reaches the middle of the top d. Remove and inspect the strainer basket.
sight glass on the oil separator. Clean by washing in solvent and drying with
g. The oil fill connection can be used to purge or dry compressed air. Replace the strainer o-
evacuate the oil separator as required. When ring.
complete, close the oil fill connection. The e. Install the strainer in the compressor.
approximate oil charge is given in Table 1-10. f. Using a new cover o-ring, install the cover
h. Refer to "General Component Replacement" with the original bolts.
Section and follow Steps h through k to g. Refer to "General Component Replacement"
complete this procedure. Section and use steps h through k to complete
the procedure.
Document: GM-4
Revision: B
5 Effective: 09-04
RECOMMENDED MAINTENANCE c. The FES service department can provide oil
analysis services if a local laboratory is
The compressor package can operate at peak
unavailable.
performance only when it is properly maintained
and serviced. To ensure dependable and long life B. Vibration Analysis
performance, a regular scheduled maintenance
program should be followed. The analysis of changes in vibration patterns and
An operating log should be kept showing when levels can provide valuable information on both
maintenance was performed as well as results machine and structural components. In order for
from machine inspections for leaks, vibration, the vibration analysis to provide useful data, the
noise, oil quality, etc. A reference point for following guidelines should be used.
inspections should be established when the a. Initial data should be taken at startup to use as
package is placed in operation. A check for a reference for later readings. Data should
unusual or abnormal conditions should be made include the location and orientation of each
on a daily basis. reading, the slide valve setting, the Vi setting,
and the main oil injection setting. Any future
A. Oil Quality and Analysis readings should be taken at these same
conditions.
The proper type and condition of refrigeration oil
is essential for maintaining compressor b. Vibration readings are most useful if
performance and useful life. Oil quality changes spectrum data is taken. This data shows both
rapidly and reflects both system and compressor the displacement and frequency of the
mechanical problems. Conditions such as bearing vibration.
wear, contaminants, excessive temperature, and c. Vibration data can be misleading if not
moisture are all indicated by oil condition. Use interpreted properly. Also, vibration can
the following recommendations to maintain the occur as a result of other nearby equipment or
required quality from the compressor oil. be amplified by structural resonance.
a. Use only the oil recommended by FES for the Questions concerning vibration data and its
refrigerant and duty specified. Contact the application should be referred to the FES
FES service department if there are any service department.
question concerning the proper oil to use.
C. Maintenance Schedule
b. At start up, take two 8 oz. oil samples and
place them in clean containers. One sample A recommended maintenance schedule for
should be used as a visual reference point to normal refrigeration duty is shown in Table 5-1
compare to later samples. Oil that appears on the following page. This program should be
murky, discolored, milky or markedly followed if maximum compressor package
different from the original sample indicates a performance and life is to be obtained.
possible problem requiring further analysis.
The second sample is to be sent to a
laboratory for analysis. The analysis should
show, as a minimum, wear particle analysis,
viscosity, contaminants (i.e. iron, copper,
etc.), and moisture content. The second
sample's laboratory report will then be the
reference point for future samples. Each time
the oil is changed new reference samples must
be taken.
Document: GM-4
Revision: B
Effective: 09-04 6
Item Service Intervals in Hours (Services shown are to be repeated at the same intervals beyond 20,000 hours)
Maintenance to be Performed
No. Startup 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
1 Class A Inspection X
2 Class B Inspection X X
3 Class C Inspection ---------- Every 30,000 - 35,000 Hours - High Stage; Every 35,000 - 40,000 Hours - Booster ----------
7
8 Check & Clean Oil Return Strainer X X X
10 Change Coalescers X X X
11 Check Coupling X X X
13 Clean Package X X X
14 Oil Analysis X X X X X X X X X X X
Document: GM-4
Revision: B
Effective: 09-04
15 Change Oil ------------------------------------------------ As Indicated by Item #14 ------------------------------------------------
Document: GM-4
Revision: B
Effective: 09-04 8
Class C Inspection E. Operating Log
Service Interval: 30,000 Hours - 35,000 Hours The operating log is an essential tool used to
(High Stage Application) understand and document the operating
Service Interval: 35,000 Hours - 40,000 Hours characteristics of a refrigeration system.
(Booster Application) Recording temperatures, pressures, and other
(or as required based on operating conditions, system data (refer to Table 5-2) allows one to be
vibration analysis and oil analysis) familiar with the system operation and to identify
any changes in the normal operating conditions.
Service Time Required: 40-48 Hours
DISASSEMBLE COMPRESSOR COMPLETELY FES recommends that readings be taken at
Thoroughly Inspect the following: intervals of 2-4 hours of compressor operation.
• Male and Female Rotors
• Shaft Journals
• Slide Valve
• Balance Piston
• Unloader Piston
• Radial Bearings
• Thrust Bearings
Carefully Inspect the Following Critical
Clearances:
• Slide Valve
Reassemble Compressor Using the Following
New Parts:
• Radial Bearings
• Thrust Bearings
• Gaskets (as required)
• O-Ring (as required)
• Shaft Seal Kit
DISMANTLE OIL PUMP (If Applicable)
Check Gear and Idler for Wear
Rebuild and Set Proper Clearances
PERFORM CLASS A INSPECTION
(AFTER COMPRESSOR IS INSTALLED
ON PACKAGE)
Document: GM-4
Revision: B
9 Effective: 09-04
Table 5-2: GM Series Compressor Operating Log
Document: GM-4
Revision: B
Effective: 09-04 10
Parts and Warranty Contact To order spare parts you should call FES York,
Information Stockton or Houston. Please have the following
available:
FES offers technical support to our customer over a. Your company name.
the telephone. To efficiently assist you when you
b. The name of the end user.
call, please have the following information
available: c. A telephone number and fax number for us to
contact you.
a. Your company name.
d. The contract number of the machine. Check
b. The name of the end user.
the inside of the control panel door or the
c. A telephone number and fax number for us to cover of the instruction manual.
contact you.
e. The model number and serial number of the
d. The contract number of the machine. Check machine you are working on.
the inside of the control panel door or the
f. A purchase order number.
cover of the instruction manual.
g. A ship to address and telephone number.
e. The model number and serial number of the
machine you are working on. h. Either a part number or a detailed description
of the part required.
f. The manual and drawings supplied with the
unit. i. Method of shipping.
g. An accurate description of the problem. j. For airfreight, details of your airfreight
account.
h. If applicable, the analog failure data and the
failure message from the failure annunciator. If your problem requires parts and is covered by
warranty, call FES York, Stockton or Houston. If
The FES York telephone number is (717) 767- you know the part you need and do not need any
6411. The FES Stockton phone number is (209) technical support, you may call the Warranty
931-3970. The FES Houston phone number is department directly. Please have the following
(281) 441-7655. Please ask for the service available and ask for the Warranty department.
department. a. Your company name.
Before scheduling a startup, we will forward b. The name of the end user.
some checklists. Complete these forms and c. A telephone number and fax number where
return them to FES. This insures that we are we can contact you.
aware of any outstanding work. If start-up is not
d. Contract number, model number and serial
included in the capital purchase, a purchase order
number of the unit.
number is required before a service technician is
scheduled. e. Description of problem.
f. Purchase order number to insure defective
If you have a technical question or need parts parts are returned.
after 5:00 PM EST, you can reach the FES
service & parts department in Stockton, CA until g. Ship to address and telephone number.
8:00 PM EST, or Houston until 6:00 PM EST.
FES also has an EMERGENCY after hours
service. Call FES York and the answering
service will take a message and have someone
call you.
Document: GM-4
Revision: B
11 Effective: 09-04
A. Warranty Return Material C. Restocking Policy
Procedure New/unused parts may be returned to FES by
Return authorization forms will be supplied with requesting a return material authorization from
replacement parts and an in-warranty invoice the Parts Department. A return authorization will
submitted. This invoice will be canceled with be issued upon providing FES the FES sales order
return of alleged defective parts providing there is and invoice number for which FES supplied the
no evidence of customer neglect. Prompt material.
payment of invoice is expected if parts are not Credit will be issued after inspection by the FES
returned within 30 days of date of shipment from Quality Assurance department for all material
the FES factory (90 days for international supplied from FES stores. Credit for new/unused
shipments). FES cannot be responsible for material is subject to a 20% restocking charge.
material returned to the factory without the proper Credit will be issued upon receipt of same for
Return Material Authorization Forms. All material purchased from outside vendors on
transportation charges to and from the factory behalf of FES customers subject to a minimum,
must be paid by the purchaser. but not limited to, a 20% restocking charge.
B. Parts Warranty
FES parts are shipped in new condition. FES will
supply warranty replacements for parts claimed
defective at the time of receipt. Claims against
damaged goods must be made directly with the
carrier. Parts claimed defective might be returned
for warranty consideration. Warranty
consideration will be at the discretion of the FES
Quality Assurance department after inspection of
the material. Warranty will not be considered for
defects resulting from mishandling, improper
installation, abuse, and/or unauthorized
modification.
A return material authorization form must
accompany all return material and will be issued
upon providing FES the sales order number and
invoice number under which FES supplied the
material. All warranty claims must be submitted
through the FES service department.
Document: GM-4
Revision: B
Effective: 09-04 12
Component Literature
GM Series
RediStart
Solid State Starter
Software Manual
Control
The Leader In
Solid State Motor Control
Technology
i
TRADEMARK NOTICE
ii
WARNING
1. This starter contains hazardous voltage that can cause electric shock
resulting in personal injury or loss of life.
2. Before servicing, be sure all AC power is removed from the starter and
the motor has stopped spinning
3. Wait at least 1 minute after turning off the AC power for the bus
capacitor to discharge on the control card.
4. Do not connect or disconnect the wires to or from the starter when
power is applied.
5. Ensure shielded cables are discharged.
WARNING
iii
TABLE OF CONTENTS
1 INTRODUCTION.....................................................................................................................................................................................1
1.1 U SING THIS MANUAL ...........................................................................................................................................................................2
1.2 CONTACTING BENSHAW .....................................................................................................................................................................4
1.3 INSPECTION ...........................................................................................................................................................................................5
1.4 GENERAL OVERVIEW OF A REDUCED VOLTAGE STARTER............................................................................................................6
2 CONTROL CARD ....................................................................................................................................................................................7
2.1 CONTROL CARD SETUP .......................................................................................................................................................................9
2.1.1 CT Ratio Scaling .........................................................................................................................................................................9
2.1.2 CT Polarity...................................................................................................................................................................................9
2.1.3 Confirm Switch Settings.............................................................................................................................................................9
2.1.4 Configuring the Analog Input ................................................................................................................................................ 11
2.1.5 Configuring the Analog Output ............................................................................................................................................. 11
2.2 BASIC CONTROL W IRING DRAWING ...............................................................................................................................................12
3 KEYPAD OPERATION....................................................................................................................................................................... 13
3.1 INTRODUCTION...................................................................................................................................................................................14
3.2 STANDARD KEYPAD AND DISPLAY .................................................................................................................................................14
3.2.1 Special Messages Displayed .................................................................................................................................................. 14
3.2.2 Viewing and Changing Parameters for the Standard Keypad ......................................................................................... 15
3.2.3 Display Output for the Standard Keypad............................................................................................................................. 15
3.2.4 Quick Meters............................................................................................................................................................................. 16
3.2.5 Restoring Factory Parameter Settings................................................................................................................................. 16
3.2.6 Resetting a Fault ...................................................................................................................................................................... 17
3.2.7 Emergency Thermal Reset....................................................................................................................................................... 17
3.3 2X16 LCD REMOTE KEYPAD ..........................................................................................................................................................17
3.3.1 Description of the LED's on the Keypad.............................................................................................................................. 17
3.3.2 Description of the Keys on the LCD Remote Keypad ........................................................................................................ 18
3.3.3 Alphanumeric Display............................................................................................................................................................. 18
3.3.4 Parameter Group Screens....................................................................................................................................................... 20
3.3.5 Meter Pages............................................................................................................................................................................... 20
3.3.6 Fault Log Screen ...................................................................................................................................................................... 21
3.3.7 Fault Screen .............................................................................................................................................................................. 21
3.3.8 Lockout Screen ......................................................................................................................................................................... 21
3.3.9 Alarm Screen............................................................................................................................................................................. 22
3.3.10 Procedure for Setting Data .................................................................................................................................................... 22
3.3.11 Jump Code................................................................................................................................................................................. 22
4 PARAMETERS....................................................................................................................................................................................... 25
4.1 INTRODUCTION...................................................................................................................................................................................26
4.2 LED AND LCD DISPLAY PARAMETERS CROSS REFERENCE ......................................................................................................26
4.3 LED DISPLAY PARAMETERS............................................................................................................................................................27
4.4 LCD DISPLAY PARAMETERS............................................................................................................................................................30
4.4.1 Quick Start Group.................................................................................................................................................................... 30
4.4.2 Control Function Group ......................................................................................................................................................... 30
4.4.3 Protection Group...................................................................................................................................................................... 31
4.4.4 I/O Group................................................................................................................................................................................... 32
4.4.5 Function Group ........................................................................................................................................................................ 33
4.4.6 Fault Group............................................................................................................................................................................... 34
5 PARAMETER DESCRIPTIONS ...................................................................................................................................................... 35
5.1 EXPLANATION OF PARAMETER DESCRIPTION ................................................................................................................................36
5.2 QUICK START GROUP ........................................................................................................................................................................37
5.3 CONTROL FUNCTION GROUP ............................................................................................................................................................44
5.4 PROTECTION FUNCTION GROUP ......................................................................................................................................................55
5.5 INPUT /OUTPUT GROUP ......................................................................................................................................................................65
iv
TABLE OF CONTENTS
5.6 FAULT LOG..........................................................................................................................................................................................82
6 APPLICATIONS .................................................................................................................................................................................... 83
6.1 A PPLICATION CONSIDERATION BETWEEN LINE CONNECTED AND INSIDE DELTA CONNECTED SOFT STARTER ................84
6.1.1 Line Connected Soft Starter.................................................................................................................................................... 84
6.1.2 Inside Delta Connection.......................................................................................................................................................... 85
6.2 OTHER APPLICATIONS USING THE MX CONTROL .........................................................................................................................85
6.2.1 Wye Delta................................................................................................................................................................................... 85
6.2.2 Phase Control ........................................................................................................................................................................... 87
6.2.3 Current Follower...................................................................................................................................................................... 87
6.2.4 Across The Line (Full Voltage Starter) ................................................................................................................................ 88
7 TROUBLESHOOTING........................................................................................................................................................................ 89
7.1 GENERAL TROUBLESHOOTING CHARTS..........................................................................................................................................90
7.1.1 Motor does not start, no output to motor............................................................................................................................. 90
7.1.2 During starting, motor rotates but does not reach full speed........................................................................................... 91
7.1.3 Acceleration not operating as desired.................................................................................................................................. 91
7.1.4 Deceleration not operating as desired ................................................................................................................................. 92
7.1.5 Motor stops unexpectedly while running ............................................................................................................................. 92
7.1.6 Metering incorrect ................................................................................................................................................................... 93
7.1.7 Other Situations........................................................................................................................................................................ 94
7.2 FAULT CODE TROUBLESHOOTING TABLE ......................................................................................................................................95
8 THEORY OF OPERATIO N.............................................................................................................................................................103
8.1 SOLID STATE MOTOR OVERLOAD PROTECTION .........................................................................................................................104
8.1.1 Overview ..................................................................................................................................................................................104
8.1.2 Setting up the MX Motor Overload.....................................................................................................................................104
8.1.3 Motor Overload Operation...................................................................................................................................................106
8.1.4 Current Imbalance / Negative Sequence Current Compensation ..................................................................................106
8.1.5 Harmonic Compensation ......................................................................................................................................................107
8.1.6 Hot / Cold Motor Overload Compensation .......................................................................................................................107
8.1.7 Separate Starting and Running Motor Overload Settings...............................................................................................108
8.1.8 Motor Cooling While Stopped..............................................................................................................................................109
8.1.9 Motor Cooling when Running..............................................................................................................................................110
8.1.10 Emergency Motor Overload Reset ......................................................................................................................................110
8.2 M OTOR SERVICE FACTOR...............................................................................................................................................................111
8.3 A CCELERATION CONTROL..............................................................................................................................................................112
8.3.1 Current Ramp Settings, Ramps and Times.........................................................................................................................112
8.3.2 Programming A Kick Current..............................................................................................................................................113
8.3.3 TruTorque Acceleration Control Settings and Times.......................................................................................................113
8.3.4 Power Control Acceleration Settings and Times ..............................................................................................................115
8.3.5 Open Loop Voltage Ramps and Times................................................................................................................................117
8.3.6 Dual Acceleration Ramp Control ........................................................................................................................................119
8.4 DECELERATION CONTROL ..............................................................................................................................................................121
8.4.1 Voltage Control Deceleration ..............................................................................................................................................121
8.4.2 TruTorque Deceleration .......................................................................................................................................................122
8.5 W YE-DELTA OPERATION ................................................................................................................................................................123
8.6 PHASE CONTROL ..............................................................................................................................................................................125
8.7 CURRENT FOLLOWER......................................................................................................................................................................127
8.8 A CROSS THE LINE / FULL VOLTAGE OPERATION .......................................................................................................................128
8.9 SIMPLIFIED I/O SCHEMATICS .........................................................................................................................................................129
8.10 U SING M ODBUS................................................................................................................................................................................130
9 TECHNICAL INFORMATION.......................................................................................................................................................133
9.1 GENERAL INFORMATION.................................................................................................................................................................134
9.2 ENVIRONMENTAL CONDITIONS......................................................................................................................................................134
9.3 A LTITUDE DERATING ......................................................................................................................................................................134
v
TABLE OF CONTENTS
9.4 A PPROVALS.......................................................................................................................................................................................134
9.5 CERTIFICATE OF COMPLIANCE .......................................................................................................................................................134
9.6 LIST OF MOTOR PROTECTION FEATURES.....................................................................................................................................134
9.7 MX CONTROL BOARD ....................................................................................................................................................................135
9.7.1 Terminal Points, Functions and Ratings............................................................................................................................135
9.7.2 Terminal Block Rating ..........................................................................................................................................................136
9.7.3 Connectors, Functions and Ratings....................................................................................................................................136
9.7.4 Measurements, Accuracy and Ratings................................................................................................................................136
10 APPENDIX.........................................................................................................................................................................................137
A PPENDIX A – CE M ARK ...........................................................................................................................................................................139
A PPENDIX B – FAULT CODES.....................................................................................................................................................................140
A PPENDIX C – A LARM CODES...................................................................................................................................................................141
A PPENDIX D – M ODBUS REGISTER M AP .................................................................................................................................................143
A PPENDIX E – PARAMETER TABLE...........................................................................................................................................................154
vi
1 Introduction
1 – INTRODUCTION
Layout
This manual is divided into 10 sections. Each section contains topics related to the section.
Symbols
There are 2 symbols used in this manual to highlight important information. The symbols appear as the following:
2
1 – INTRODUCTION
General Information
Start-Up Services
Benshaw technical field support personnel are available to do startup and conduct on-site training on the starter operations and
troubleshooting.
Benshaw technical field support personnel are available to conduct on-site training on the operations and troubleshooting.
Technical Support
Benshaw technical support personnel are available (at no charge) to answer customer questions and provide technical support over
the telephone. For more information about contacting technical support personnel, refer to Contacting Benshaw on page 4.
Documentation
On-line Documentation
Replacement Parts
Software Number
Publication History
3
1 – INTRODUCTION
Contacting Benshaw
Information about Benshaw products and services is available by contacting Benshaw at one of the following offices:
Benshaw West
7820 E. Evans Drive, Suite 900
Scottsdale, AZ 85260
United States of America
Phone: (480) 905-0601
Fax: (480) 905-0757
E –Mail: usatechsupport@benshaw.com
cantechsupport@benshaw.com
Technical support for MX Control Series is available at no charge by contacting Benshaw’s customer service department at one of
the above telephone numbers. A service technician is available Monday through Friday from 8:00 a.m. to 5:00 p.m. EST.
NOTE:
An on-call technician is available after normal business hours and on weekends by calling Benshaw and following the recorded
instructions.
To help assure prompt and accurate service, please have the following information available when contacting Benshaw:
• Name of Company
• Telephone number where the caller can be contacted
• Fax number of caller
• Benshaw product name
• Benshaw model number
• Benshaw serial number
• Name of product distributor
• Approximate date of purchase
• System Voltage
• FLA of motor attached to Benshaw product
• A brief description of the application
4
1 – INTRODUCTION
1.3 Inspection
Before storing or installing the RediStart starter with MX control, thoroughly inspect the device for possible shipping damage.
Upon receipt:
• Remove the starter from its package and inspect exterior for shipping damage. If damage is apparent, notify the shipping agent
and your sales representative.
• Open the enclosure and inspect the starter for any apparent damage or foreign objects. Ensure that all of the mounting hardware
and terminal connection hardware is properly seated, securely fastened, and undamaged.
• Read the technical data label affixed to the starter and ensure that the correct horsepower and input voltage for the application
has been purchased.
R __ __ __ __ __ __ __ A __ __ __
Enclosures
C = Open Chassis
Frame Size
Amp Rating, (0 – 999A )
Fault Level
S = Standard
H = High
Type of Bypass
0 = None (only available with RC)
1 = Integrated
2 = Separate, Definite Purpose (Only with 1000V Starter)
3 = Separate, ATL IEC AC3 Rated
4 = Separate, ATL NEMA Rated (AC4)
Type of Control
M = Micro II Control
X = MX Control
A RediStart starter with bypass, MX control, Integrated Bypass, Standard Fault, 361 Amp unit, Frame 14, open Chassis
5
1 – INTRODUCTION
General Overview
The RediStart MX motor starter is a microprocessor-controlled starter for single or three-phase induction motors. The starter can be
custom designed for specific applications. A few of the features are:
• Solid state design.
• Reduced voltage starting and soft stopping.
• Closed-loop motor current control, power control, torque control.
• Programmable motor protection.
• Programmable operating parameters.
• Programmable metering.
Each starter can operate within applied line voltage and frequency values of 100VAC to 600VAC (optional 1000VAC) and 23 to
72Hz.
The starter can be programmed for any motor FLA and all of the common motor service factors. It enables operators to control both
motor acceleration and deceleration. It can also protect the motor and its load from damage that could be caused by incorrect phase
order wiring.
The starter continually monitors the amount of current being delivered to the motor. This protects the motor from overheating or
drawing excess current. The starter will automatically stop the motor if the Phase to Phase line current is not within acceptable ranges
or if the current is lost in a line.
6
2 Control Card
7
2 – TECHNICAL INFORMATION
Control Card
BIPC 300050-00-01
SN
Serial
Number
120V
Control
SCR 1
Gnd
120V
Control
SCR 4
NO1
RC1
NC1
SCR 2
NO2
NO3
SCR 5
RC3
NC3
START
DI 1
SCR 3
S/DI
Digital Inputs COM Conn 3
Start, DI1, Terminating Conn 2
DI2
DI2, DI3 Resistor
DI3
Modbus
Serial Port
Reset
Button
Analog
Input
& Config
Jumper
CT Input
Shield Shield
Grounding Grounding
CT Burden
Selector Switch LED Display & Analog Output
Keypad & Config Jumper
Serial Port
8
2 – TECHNICAL INFORMATION
Control Card
The motor current signal scaling is set according to the motor size and the application specified when the starter is ordered. To ensure
accurate operation, the motor current signal must be correctly scaled for the motor (and its application) being controlled by the
starter. Motor current signal scaling may have to be changed if:
Motor current signal scaling is accomplished by verifying the current transformer ratio as supplied with the starter and then selecting
the correct DIP switch setting from the chart on the following page for the current transformer ratio. The DIP switches are:
NOTE: The applicable ratio is stamped on each CT. Adjust the DIP switches only when there is no current being supplied to the
motor, or the switches could be damaged.
2.1.2 CT Polarity
The CT has a polarity that must be correct for the starter to correctly measure Watts, kW Hours, Power Factor, and for the Power and
TruTorque motor control functions to operate properly.
Each CT has a dot on one side of the flat surfaces. This dot, normally white in color, must be facing in the direction of the line.
The CT can be placed either before or after the starter. In specific applications, like Inside Delta and a starter with a DC brake, the
CT’s must be before the starter.
CT1 must be on Line L1 (R), CT2 must be on Line L2 (S), CT3 must be on Line L3 (T).
• Compare the CT ratio stamped on each CT to the CT ratio listed on the wiring diagram supplied with the starter to ensure the
correct CTs are installed.
• Inspect the control card to ensure that the DIP switches are in the correct positions for the applicable CT ratio and the motor
full-load Amps (FLA).
9
2 – TECHNICAL INFORMATION
Control Card
Table 1 – CT Ratios and Burden Switch Settings
CT Ratio Minimum Maximum Switch 6 Switch 6
FLA (A rms) FLA (A rms) Position 1 Position 2
72 2 3 Off Off
(4 wraps 3 4 Off On
288:1) 4 9 On Off
9 16 On On
96 3 4 Off Off
(3 wraps 4 5 Off On
288:1) 5 12 On Off
12 21 On On
144 4 7 Off Off
(2 wraps 7 8 Off On
288:1) 8 18 On Off
18 32 On On
288 8 14 Off Off
14 16 Off On
16 32 On Off
36 64 On On
864 24 42 Off Off
42 50 Off On
50 108 On Off
108 190 On On
1320 37 64 Off Off
(2 wraps 64 76 Off On
2640) 76 165 On Off
165 290 On On
2640 73 128 Off Off
128 151 Off On
151 330 On Off
330 590 On On
2880 73 140 Off Off
140 165 Off On
165 361 On Off
361 640 On On
3900 105 190 Off Off
190 225 Off On
225 490 On Off
490 870 On On
5760 160 280 Off Off
280 330 Off On
330 720 On Off
720 1280 On On
8000 223 390 Off Off
390 465 Off On
465 1000 On Off
1000 1800 On On
14400 400 700 Off Off
Mult. 700 840 Off On
CT-CT 840 1800 On Off
Combinations 1800 3200 On On
28800 800 1400 Off Off
Mult. 1400 1680 Off On
CT-CT 1680 3600 On Off
Combinations 3600 6400 On On
10
2 – TECHNICAL INFORMATION
Control Card
2.1.4 Configuring the Analog Input
The analog input can be configured for Voltage or Current loop. The input is shipped in the Current Loop configuration unless
specified in a custom configuration. Next to the analog input terminal block is JP3. When the jumper is installed, the input is current
loop. When removed, it is a voltage input. The control is shipped with the jumper JP3 installed.
NOTE: The analog output signal common also serves as the analog input signal common.
NOTE: The analog input is a low voltage input, maximum of 15VDC. The input will be damaged if control power (115VAC) or line
power is applied to the analog input.
The analog output can be configured for Voltage or Current loop. The output is shipped in the Voltage configuration unless specified
in a custom configuration. Next to the analog output terminal block is JP1. When the jumper is installed, the output is Voltage. When
removed, it is a current loop output. The control is shipped with the jumper installed.
NOTE: The analog output single common also serves as the analog input single common.
11
2 – TECHNICAL INFORMATION
Control Card
Digital inputs DI1, DI2, DI3 and relay outputs R1, R2, R3 are pre-programmed. This wiring diagram illustrates a 3-wire start/stop
control by programming DI1 as a stop input. 2-wire start/stop control can be implemented by just using the start input. Refer to
sections 5 & 6 for configuring the Digital and Analog input and output in software.
12
3 Keypad Operation
13
3 – KEYPAD OPERATION
3.1 Introduction
The MX Control provides a comprehensive set of parameters to allow the use of the reduced voltage solid state starter in nearly any
industrial application. While the starter can meet the requirements of many applications right out of the box, customization of
parameter values to better suit your particular application is easily accomplished with the standard, on-board, 4-digit, 7-segment LED
display/keypad, a remote display/keypad, or via remote serial communication.
The MX control has two remote keypads and displays that are optional equipment; a remote 4-digit, 7-segment LED display and a
2x16-backlit LCD display. Both keypads have the same keys as the standard display with several additional keys including start and
stop keys for operation of the starter from the keypad. When the remote keypad is connected, the local keypad and display are
disabled.
The LED display provides information on starter operation and programming. The 4-digit, 7-segment display shows starter meter
outputs and programming data. Special symbols provide further information about the starter operation (see the following section).
RESET
The keypad's display may show special information under certain conditions.
14
3 – KEYPAD OPERATION
The display will output different information depending on the operation of the starter Table 2 – LED Special Characters Displayed.
3.2.3.1 Power Up
The software version will be displayed as a series of blinking digits once power has been applied to the MX control. If the parameters
were being reset on power up, “dFLt” will be flashed on the display for three seconds, then the software version will be displayed.
3.2.3.2 Stopped
When the starter is not in the run mode, the display will show the status condition of the starter, such as “rdY” (ready), “L OL”
(Overload Lockout), “noL” (No Line).
3.2.3.3 Running
When running, the display will show the user selected meter function. The following meters can be selected using the “Meter”
display parameter P69.
15
3 – KEYPAD OPERATION
When an alarm condition exists, the display alternates between displaying the selected meter and the alarm code. The alarm code is
displayed as “A XX”, where XX is the alarm code.
• When a thermal overload alarm condition exists, “A OL” will be displayed.
• When a no line alarm condition exists, “noL” will be displayed.
When the starter is stopped, the selected meter is not displayed.
When a lockout condition exists, the display shows the lockout code. The lockout code is displayed as “L XX: where XX is the
lockout code. Following are the defined lockout conditions and their codes:
• When a motor thermal overload lockout condition exists, “L OL” will be displayed.
• When a power stack thermal overload lockout condition exists, “L Ot” will be displayed.
• When a low control power lockout condition exists, “L CP” will be displayed.
When there are multiple lockout codes, each will be displayed at 2 second intervals.
When a fault condition exists, the display shows the fault code. The exceptions to this are as follows:
• When the fault is thermal overload trip, “F OL” will be displayed.
• When the fault is Instantaneous over current, ioc will be displayed.
Although any meter may be viewed by changing the meter parameter, there are 3 “Quick Meters” that are always available with a
single key press. When the starter is in the normal display mode, the display may be toggled between the information currently
displayed and the following quick meters.
Status Meter Toggle between the programmed meter display and the starter operational status display (rdY, run,
utS, dcL, etc) by pressing the ENTER key.
Overload Meter Toggle between the programmed meter display and the overload content by pressing the DOWN key.
The overload will be displayed as “oXXX” where XXX is the overload content. For example if the
overload content is 76 percent, it will be displayed as “o 76”.
Phase Order Meter Toggle between the programmed meter display and the phase order by pressing the UP key. The
phase order will be displayed as “AbC” or “CbA”.
To restore ALL parameters to the factory default settings, press and hold the PARAM and ENTER pushbutton switch on power up. The
display will blink “dFLt”. Parameters unique to the motor starter applications will need to be set again to appropriate values before
motor operation
16
3 – KEYPAD OPERATION
To perform an emergency thermal reset, press RESET and DOWN. This will set the motor thermal overload content to 0.
Like the standard keypad, the LCD remote keypad has the same basic functions with enhancements which allows using plain text
instead of codes and a menu structure instead of a straight line of parameters.
Additional keys have been added, such as “start”, “stop”, and a “left arrow” for moving the cursor around in the LCD display. Status
indicators have been added, providing additional information for the starter operation.
The remote keypad and display are connected to the MX control board via a 1 or 2 meter (3 or 6ft) cable. The remote keypad is
NEMA 1, 12, and 3R when mounted directly on a panel or the door of an enclosure with the correct gasket. If the bezel and keypad
are used a NEMA 4 rating can be obtained.
kW
ST
STOP
OP
V
% Hz ALARM
RM
Min A RU
RU N
stop
reset start menu
enter
Starters
The keypad provides three LED indicators in addition to the 2x16 character display. The LED's provide starter status information.
17
3 – KEYPAD OPERATION
The UP arrow, DOWN arrow, ENTER and MENU keys on the LCD keypad perform the same functions as the UP, DOWN, ENTER and
PARAM keys on the standard keypad. Three keys have been added, with one of the keys serving a dual function.
Start Key The START key allows the starter to be started from the keypad. In order for this key to work, the
Local Source parameter must be set to Keypad (as opposed to terminal). Refer to section 5,
Parameter Descriptions.
Stop/Reset Key When the starter is in a faulted condition, the STOP/RESET key is used to reset the fault. When the
starter is running, the STOP/RESET key causes the starter to stop.
Left Arrow When changing a numerical parameter, the LEFT arrow key can be pressed to move the cursor to the
next significant digit. When navigating through the parameter group screens, the MENU key
progresses to the next group and the LEFT arrow key moves back to the previous group.
start This key causes the starter to begin the start sequence. The direction is dependent on wiring and phase selection.
The LCD Remote keypad and display uses a 32-character alphanumeric LCD display. All starter functions can be accessed by the
keypad. The keypad allows easy access to starter programming with parameter descriptions on the LCD display.
18
3 – KEYPAD OPERATION
On power up, the software part number is displayed for a few seconds. Pressing any key will immediately change the display to the
operate screen.
Software PN
810018-01-00
NOTE: The software part number may be different than that shown above.
Operate Screen
The operate screen is the main screen. The Operate screen is used to indicate the status of the starter, if it’s running, what state it’s in,
and display the values of Meter 1 and Meter 2, which are user selectable.
SSAAAAAACCCCCCCC
BBBBBBBBDDDDDDDD
19
3 – KEYPAD OPERATION
From the operate screen, the parameter group screens are accessed by pressing either the MENU or the LEFT arrow keys. The
parameter group screens display the different parameter groups; QST, CFN, PFN, I/O, FUN, FL_.
MMM: PPPPPPPPPPP
MI VVVVVVVVVVV
Although any meter may be viewed by changing the two meter parameters, there are 11 “Meter Pages” that are easily accessed to
view all of the meter information. These meter pages are scrolled through by pressing the UP or DOWN arrows from the operate
screen.
Current I2= 0A
I1= 0 I3 0A
MWatt Hour= 1
kWatt Hour= 356
Motor PF =0.00
VARS = 0
Watts = 0
VA = 0
TruTorque = 0%
Power = 0%
Overload = 12%
Gnd Curr = 0%
Frequency =60.0H
Phase =AbC
Analog In = 0.0%
Analog Out= 0.0%
Starts =xxxxx
20
3 – KEYPAD OPERATION
Pressing the MENU or the LEFT arrow keys repeatedly cycles through all of the Parameter Groups either forward or reverse. More
information regarding each fault is available through the remote LCD display than is available through the standard or remote LED
displays.
FL_: Fault__
NNNNNNNNNNNNN
FL _: = Fault Log Number. FL1 is the most recent fault and FL9 is the oldest fault.
Fault _ _ = Fault Code
NNN… = Fault Name, or the condition when the fault occurred
Pressing the UP and DOWN keys navigates through older and newer faults in the log.
Repeatedly pressing the ENTER key rotates through the conditions the starter was in when the fault occurred.
Enter
Step
1 Fault Description
2 Status when the fault occurred, Run, Stopped, Accel, etc
3 The average current at the time of the fault
4 The average voltage at the time of the fault
5 The line frequency at the time of the fault
When a Fault occurs, the main screen is replaced with a fault screen. The screen shows the fault number and the name of the fault.
The main status screen will not be shown until the fault is reset.
Fault Number
Fault Name
When a lockout is present, the word “Lockout” is displayed on the operate screen. Pressing the ENTER key will display more
information about the Lockout.
Lockout
Overload = 115%
Lockout
Control Power
21
3 – KEYPAD OPERATION
When an alarm is present, the word “Alarm” is displayed on the operate screen. Pressing the ENTER key will display more
information about the alarm.
Alarm Number
Alarm Name
Select a parameter that is to be changed. To change Motor FLA from 10 Amps to 30 Amps:
Press MENU key and the display shows QST: (Quick Start) screen.
QST: Jump Code
00 1
Press ENTER key once, the cursor will start to flash in the one’s place.
Press LEFT key once, the cursor will flash in the ten’s place.
Press UP arrow to increase the value, for a value of 30, pressed twice.
At the beginning of each parameter group, there is a Jump Code parameter. By changing the value of this parameter and pressing
enter, you can jump directly to any parameter within that group.
22
3 – KEYPAD OPERATION
23
3 – KEYPAD OPERATION
24
4 Parameters
25
4 – PARAMETERS
4.1 Introduction
The MX Control incorporates a large number of parameters that allow you to configure the starter to meet the special requirements of
your particular application. The parameters are organized two ways, depending on the display being used. When an LED display is
used, the parameters are in a single group, P1, P2, P3…etc.
When using the LCD display, the parameters are divided into groups of related functionality, and within the groups the parameters
are identified by a short, descriptive name.
This chapter describes the available parameters, the groups in which they are located, and the values that may be assigned to them.
26
4 – PARAMETERS
27
4 – PARAMETERS
P39 DI 1 Configuration OFF: Off StOP 65
(Digital Input #1) StOP: Stop
P40 DI 2 Configuration FH: Fault High byP 65
(Digital Input #2) FL: Fault Low
P41 DI 3 Configuration Fr: Fault Reset FL 65
(Digital Input #3) byP: Bypass Cnfrm
EoLr: E OL Reset
L-r: Local/Remote
hdIS: Heat Disable
hEn: Heat Enable
rSEL Ramp Select
P42 R1 Configuration OFF: Off FLFS 66
(Relay #1) FLFS: Fault (fail safe)
P43 R2 Configuration (Relay #2) FLnF: Fault (non fail run 66
P44 R3 Configuration (Relay #3) safe) utS
run: Running 66
utS: UTS
AL: Alarm
rdyr: Ready
LOC: Locked Out
OC: Over Current
UC: Under Current
OLA: OL Alarm
ShFS: Shunt Trip (fail
safe)
ShnF: Shunt Trip (non
fail safe)
GfLt: Ground Fault
ES: Energy Saver
HEAt: Heating
P45 Analog Input Trip Type OFF: Disabled OFF 67
Lo: Low Level
Hi: High Level
P46 Analog Input Trip Level 0 – 100 % 50 67
P47 Analog Input Trip Delay Time 0.1 – 90.0 Seconds 0.1 67
P48 Analog Input Span 1 – 100 % 100 69
P49 Analog Input Offset 0 – 99 % 0 69
P50 Analog Output Function 0: OFF (no output) 0 69
1: 0 – 200% Curr
2: 0 – 800% Curr
3: 0 – 150% Volt
4: 0 – 150% OL
5: 0 – 10 kW
6: 0 – 100 kW
7: 0 – 1 MW
8: 0 – 10 MW
9: 0 – 100% Ain
10: 0 – 100% Firing
11: Calibration
P51 Analog Output Span 1 – 125 % 100 70
P52 Analog Output Offset 0 – 99 % 0 71
P53 In Line Configuration OFF, 1.0 –10.0 Seconds 3.0 71
P54 Bypass / 2M Confirm 0.1 – 5.0 Seconds 2.0 72
P55 Keypad Stop Disable Enabled, Disabled Enabled 72
P56 Reserved
P57 Reserved
P58 Miscellaneous Commands 0: None 0 80
1: Reset Run Time
2: Reset KWh/MWh
3: Enter Reflash mode
4 Store Parameters
5 Load Parameters
6: Factory Reset
28
4 – PARAMETERS
P59 Communication Timeout OFF, 1 – 120 Seconds OFF 78
P60 Communication Baud Rate 1.2, 2.4, 4.8, 9.6, 19.2 Kbps 9.6 78
P61 Communication Address 1 – 247 1 78
P62 Energy Saver OFF, On OFF 77
P63 Heater Level OFF, 1 – 25 %FLA OFF 77
P64 Starter Type nor: Normal nor 76
Id: Inside Delta
y-d: Wye-Delta
PctL: Phase Control
cFol: Current Follow
AtL: ATL
P65 Motor Rated Power Factor -0.01 (Lag)–1.00 (Unity) -0.92 75
P66 Rated RMS Voltage 100, 110, 120, 200, 208, 220, 230, RMS 480 75
240, 350, 380, 400, 415, 440, 460, Voltage
480, 500, 525, 575, 600, 660, 690,
1000, 1140, 2200, 2300, 2400,
3300, 4160, 4600, 4800, 6000,
6600, 6900, 10.00 (10000), 11.00
(11000), 11.50 (11500), 12.00
(12000), 12.47 (12470), 13.20
(13200), 13.80 (13800)
P67 Input Phase Sensitivity InS Insensitive InS 74
AbC ABC
CbA CBA
SPH Single Phase
P68 CT Ratio 72, 96, 144, 288, 864, 288 74
1320, 2640, 2880, 3900,
5760, 8000, 14.4 (14400), 28.8
(28800)
P69 Meter 0: Status 1 73
1: Ave Current
2: L1 Current
3: L2 Current
4: L3 Current
5: Curr Imbal
6: Ground Fault
7: Ave Volts
8: L1-L2 Volts
9: L2-L3 Volts
10: L3-L1 Volts
11: Overload
12: Power Factor
13: Watts
14: VA
15: VARS
16: kW hours
17: MW hours
18: Phase Order
19: Line Freq
20: Analog Input
21: Analog Output
22: Run Days
23: Run Hours
24: Starts
25: TruTorque %
26: Power %
P70 Starter Model Number Model Dependent 79
P71 Software Part Number Display Only 79
P72 Passcode Off 81
P73 Fault Log 82
29
4 – PARAMETERS
The 2x16 display has the same parameters available as the LED display, with the exception of two meter parameters instead of one
since two meters may be displayed on the main screen. The parameters are subdivided into five groups. The groups are QST (quick
start), CFN (Control Functions), I/O (Input/Output Functions), PFN (protection functions) and FUN (function),
The following shows the menu structure for the LCD display as well as the strings that will be displayed for the parameters on the
display.
30
4 – PARAMETERS
31
4 – PARAMETERS
32
4 – PARAMETERS
33
4 – PARAMETERS
Group Display Description Setting Range Units Default Page
FUN 12 Com Timeout Communication Timeout Off, 1 – 120 Seconds Off 78
FUN 13 Starter MN Starter Model Number Model Dependent 79
FUN 14 Software PN Software Part Number Display Only 79
FUN 15 Misc Miscellaneous Commands None None 80
Command Reset RT
Reset kWh
Reflash Mode
Factory Reset
Store Parameters
Load Parameters
FUN 16 Passcode Passcode Off 81
34
5 Parameter Descriptions
35
5-PARAMETER DESCRIPTIONS
LCD Display
MMM:Function
Name
MI Parameter
Value
MI = Menu Index
EEE Keypad
36
5-PARAMETER DESCRIPTIONS
5.2 Quick Start Group
LCD Display
QST: Motor FLA
01 10 Amp
LED Display P1
Description This parameter configures the motor full load amps, and is obtained from the nameplate on the
attached motor.
If multiple motors are connected, the FLA of each motor must be added together for this
value
NOTE: Incorrectly setting this parameter will affect proper operation of the motor overload
protection, motor over current protection, motor undercurrent protection, ground fault protection and
acceleration control.
LCD Display
QST: Motor SF
02 1.15
LED Display P2
Description The service factor parameter should be set to the service factor of the motor. The service factor is
used for the overload calculations. If the service factor of the motor is not known then the service
factor should be set to 1.00.
NOTE: The NEC (National Electrical Code) does not allow the service factor to be set above 1.40.
Check with other local electrical codes for their requirements.
The National Electrical Code, article 430 Part C, allows for different overload multiplier factors
depending on the motor and operating conditions. NEC section 430-32 outlines the allowable service
factor for different motors.
37
5-PARAMETER DESCRIPTIONS
LCD Display
QST: Running OL
03 10
LED Display P3
Description The running OLparameter sets the class for starting and running if the independent S/R OL
is set to OFF
The running overload parameter sets the class of the electronic overload when up to speed and
stopping. The starter stores the thermal overload value as a percentage value between 0 and 100%,
with 0% representing a “cold” overload and 100% representing a tripped overload. See section 8.1
Solid State Motor Overload Protection for the overload trip time versus current curves.
When the running overload is set to OFF, the electronic overload is disabled when up to speed and a
separate motor overload protection device must be supplied.
If separate starting versus running OL class are desired, see P35/PFN 12 and P36/PFN13.
For more information about overload class, see section 8, Theory of Operation, Motor Overload
NOTE: Care must be taken not to damage the motor when turning the running OL off or setting a
high value.
NOTE: Consult motor manufacturer data to determine the correct motor OL settings.
38
5-PARAMETER DESCRIPTIONS
LCD Display
QST:Local Src
04 Terminal
LED Display P4
Description The MX control can have three sources of start and stop control, Terminal, Keypad and Serial. Two
parameters, Local Source and Remote Source select the source of the start and stop control.
If a digital input is programmed as “L-r” (Local / Remote), then that input selects the control source.
When the input is low, the local source is used. When the input is high, the remote source is used. If
no digital input is programmed as “L-r”, then the local/remote bit in the starter control modbuss
register selects the control source. The default value of the bit is Local (0).
PAd Keypad When selected, the start/stop control is from the keypad,
tEr Terminal When selected, the start/stop control is from the terminal strip inputs.
SEr Serial When selected, the start/stop control is from the network.
NOTE: The Stop key is always active, regardless of selected control source unless it is dasabled
using P55/I/O 17, Keypad Stop Disable
39
5-PARAMETER DESCRIPTIONS
LCD Display
QST:Remote SRC
05 Terminal
LED Display P5
Description The MX control can have three sources of start and stop control, Terminal, Keypad and Serial. Two
parameters, Local Source and Remote Source select the source of the start and stop control.
If a digital input is programmed as “L-r” (Local / Remote), then that input selects the control source.
When the input is low, the local source is used. When the input is high, the remote source is used. If
no digital input is programmed as “L-r”, then the local/remote bit in the starter control modbuss
register selects the control source. The default value of the bit is Local (0).
PAd Keypad When selected, the start/stop control is from the keypad.
tEr Terminal When selected, the start/stop control is from the terminal strip inputs.
SEr Serial When selected, the start/stop control is from the network.
Local Source
• Keypad
• Terminal
• Serial
Starter
Source
Remote Source
• Keypad
• Terminal L-r Input, DI1-DI3,
• Serial configured by Parameter
P39,P40,P41/
I/O01, I/O02, I/O03
40
5-PARAMETER DESCRIPTIONS
LCD Display
QST: Init Cur 1
06 100 %
LED Display P6
Description The initial current 1 parameter is set as a percentage of the motor FLA parameter setting. The initial
current parameter sets the current that will initially be supplied to the motor when a start is
commanded. The initial current should be set to the level that allows the motor to begin rotating
within a couple of seconds of receiving a start command.
To adjust the initial current setting, give the starter a run command. Observe the motor to see how
long it takes before it begins rotating and then stop the unit. For every second that the motor doesn’t
rotate, increase the initial current by 20%. Typical loads will require an initial current in the range of
50% to 175%.
If the motor does not rotate within a few seconds after a start command, the initial current should be
increased. If the motor takes off too quickly after a start command, the initial current should be
decreased.
The initial current must be set to a value that is lower than the maximum current parameter setting.
Refer to section 8.3.1, Current Ramp Settings, Ramps and Times on page 112.
See Also Max Curr (P7/QST07/CFN04), Ramp Time (P8/QST08/CFN2), and Start Mode (P10/CFN01)
CFN 03 is the same as P6/QST06
LCD Display
QST: Max Cur 1
07 600 %
LED Display P7
Description The maximum current 1 parameter is set as a percentage of the motor FLA parameter setting. The
maximum current parameter performs two functions. It sets the current level for the end of the ramp
profile. It also sets the maximum current that is allowed to reach the motor after the ramp is
completed.
If the ramp time expires before the motor has reached full speed, the starter will hold the current at
the maximum current level until the UTS timer expires, the motor reaches full speed, or the overload
trips.
Typically, the maximum current is set to 600% unless the power system or load dictates the setting of
a lower maximum current.
Refer to section 8.3.1, Current Ramp Settings, Ramps and Times on page 112.
See Also Init Curr (P6/QST06/CFN03), Ramp Time (P10/CFN01), and Start Mode (P10/CFN01)
CFN 09 is the same as P7/QST07
41
5-PARAMETER DESCRIPTIONS
P8 QST 08 Ramp Time 1 (ramp time)
LCD Display
QST: Ramp Time 1
08 15 sec
LED Display P8
Description The ramp time is the time it takes for the starter to allow the current to go from the initial current to
the maximum current. To make the motor accelerate faster, decrease the ramp time. To make the
motor accelerate slower, increase the ramp time.
If the ramp time expires before the motor reaches full speed, the starter will maintain the set
maximum current level until either the motor reaches full speed, the UTS timer expires, or the motor
thermal overload trips.
NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor will take
this time to accelerate to full speed. The motor and load may achieve full speed before the ramp time
expires if the application does not require the set ramp time and maximum current to reach full speed.
Alternatively, the motor and load may take longer than the set ramp time to achieve full speed.
See Also Init Curr (P6/QST06/CFN03), Max Curr (P7/QST07/CFN04), and Start Mode(P10/CFN01)
42
5-PARAMETER DESCRIPTIONS
LCD Display
QST: UTS Time
09 20 sec
LED Display P9
Description The up-to-speed timer parameter sets the maximum acceleration time to full speed that the motor can
take. A stalled motor condition will be detected if the motor does not get up-to-speed before the up-
to-speed timer expires. This allows the programming of a maximum acceleration time for the motor.
The motor is considered up-to-speed once the current stabilizes below 175 percent of the FLA value
and the ramp time expires.
NOTE: During normal acceleration ramps, the up-to-speed timer has to be greater than the sum of
the highest ramp time in use and the kick time. The up-to-speed timer will not automatically change
to be greater than the ramp time. If a ramp time greater than the up-to-speed timer is set, the starter
will declare an up-to-speed fault every time a start is attempted.
NOTE: When the start mode (CFN01, P10) is set to Open-Loop Voltage Ramp, the UTS timer acts
as an acceleration kick. When the UTS timer expires, full voltage will be applied to the motor. This
feature can be used to reduce motor oscillations if they occur near the end of an open loop voltage
ramp start.
NOTE: When the starter type (FUN07, P64 ) is set to Wye-Delta, the UTS timer is used as the
transition timer. When the UTS timer expires, the transition from Wye starting mode to Delta
running mode will take place.
Fault Code 01 - Up to Speed Fault will be declared when a stalled motor condition is detected.
See Also Ramp Time (P8/QST08/CFN02), Kick Time (P14/CFN11), Start Mode (P10/CFN01)
43
5-PARAMETER DESCRIPTIONS
LCD Display
CFN: Start Mode
01 Current Ramp
Description The start mode parameter allows the selection of the optimal starting ramp profile based on the
application.
Curr: Current Ramp Current control acceleration ramp. The closed loop current control
acceleration ramp is ideal for starting most general-purpose motor
applications. Examples: crushers, ball mills, reciprocating compressors,
saws, centrifuges, and most other applications.
tt: TT Ramp TruTorque control acceleration ramp. The closed loop TruTorque control
acceleration ramp is suitable for applications that require a minimum of
torque transients during starting or for consistently loaded applications
that require a reduction of torque surges during starting. Examples:
centrifugal pumps, fans, and belt driven equipment.
Pr: Power Ramp Power (kW) control acceleration ramp. The closed loop power control
acceleration ramp is ideal for starting applications using a generator or
other limited capacity source.
See Also Initial Current (P6/QST06/CFN03), Max. Current (P7/QST07/CFN04), Ramp Time
(P8/QST08/CFN02), Kick Level (P13/CFN10), Kick Time (P14/CFN11), Initial
Voltage/Torque/Power (P11/CFN08)
44
5-PARAMETER DESCRIPTIONS
CFN 02 Ramp Time 1(ramp time) Same as P8, QST 08
LCD Display
CFN: Ramp Time 1
02 15 sec
LED Display P8
Description The ramp time is the time it takes for the starter to allow the current to go from the initial current to
the maximum current. To make the motor accelerate faster, decrease the ramp time. To make the
motor accelerate slower, increase the ramp time.
If the ramp time expires before the motor reaches full speed, the starter will maintain the set
maximum current level until either the motor reaches full speed, the UTS timer expires, or the motor
thermal overload trips.
NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor will take
this time to accelerate to full speed. The motor and load may achieve full speed before the ramp time
expires if the application does not require the set ramp time and maximum current to reach full speed.
Alternatively, the motor and load may take longer than the set ramp time to achieve full speed.
See Also Init Curr 1 (P6/QST/CFN03), Max Curr 1 (P7/QST07/CFN04), and Start Mode (P10/CFN01)
LCD Display
CFN: Init Cur 1
03 100 %
LED Display P6
Description The initial current parameter is set as a percentage of the motor FLA parameter setting. The initial
current parameter sets the current that will initially be supplied to the motor when a start is
commanded. The initial current should be set to the level that allows the motor to begin rotating
within a couple of seconds of receiving a start command.
To adjust the initial current setting, give the starter a run command. Observe the motor to see how
long it takes before it begins rotating and then stop the unit. For every second that the motor doesn’t
rotate, increase the initial current by 20%. Typical loads will require an initial current in the range of
50% to 175%.
If the motor does not rotate within a few seconds after a start command, the initial current should be
increased. If the motor takes off too quickly after a start command, the initial current should be
decreased.
The initial current must be set to a value that is lower than the maximum current parameter setting.
Refer to section 8.3.1, Current Ramp Settings, Ramps and Times on page 112.
See Also Max Curr 1 (P7/QST07/CFN04), Ramp Time 1 (P8/QST08/CFN02), and Start Mode (P10/CFN01)
45
5-PARAMETER DESCRIPTIONS
CFN 04 Max Cur 1 (maximum motor current) Same as P7, QST 07
LCD Display
CFN: Max Cur 1
04 600 %
LED Display P7
Description The maximum current parameter is set as a percentage of the motor FLA parameter setting. The
maximum current parameter performs two functions. It sets the current level for the end of the ramp
profile. It also sets the maximum current that is allowed to reach the motor after the ramp is
completed.
If the ramp time expires before the motor has reached full speed, the starter will hold the current at
the maximum current level until the UTS timer expires, the motor reaches full speed, or the overload
trips.
Typically, the maximum current is set to 600% unless the power system or load dictates the setting of
a lower maximum current.
Refer to section 8.3.1, Current Ramp Settings, Ramps and Times on page 112.
See Also Init Curr 1 (P6/QST06/CFN03), Ramp Time 1 (P8/QST08/CFN02), and Start Mode (P10/CFN01)
46
5-PARAMETER DESCRIPTIONS
P11 CFN 08 Init V/T/P (Initial Voltage/Torque/Power)
LCD Display
CFN:Init V/T/P
08 25 %
Description Start Mode (CFN01, P10) set to Open Loop Voltage Acceleration:
When the Start Mode is set to open-loop voltage acceleration, this parameter sets the starting point
for the voltage acceleration ramp profile. A typical value is 25%. If the motor starts too quickly or
the initial current is too high, reduce this parameter. If the motor does not start rotating within a few
seconds after a start is commanded, increase this parameter.
Not Used when the Start Mode is set to Current control acceleration. Refer to Initial Current
(QST06, CFN03, P6) to set the initial current level.
When the Start Mode is set to TruTorque acceleration, this parameter sets the initial torque level that
the motor will produce at the beginning of the starting ramp profile. A typical value is 10% to 20%.
If the motor starts too quickly or the initial torque level is too high, reduce this parameter. If the
motor does not start rotating within a few seconds after a start is commanded, increase this parameter.
If the value is set too low a “No Current at Run” fault may occur during acceleration.
Note: It is important that the Motor Rated PF parameter (FUN06, P65) is set properly so that the
actual initial torque level is the value desired.
When the Start Mode is set to Power controlled acceleration, this parameter sets the initial motor
power (KW) level that will be achieved at the beginning of the starting ramp profile. A typical value
is 10% to 30%. If the motor starts too quickly or the initial power level is too high, reduce this
parameter. If the motor does not start rotating within a few seconds after a start is commanded,
increase this parameter. If the value is set too low a “No Current at Run” fault may occur during
acceleration.
Note: It is important that the Motor Rated PF parameter (FUN06, P65) is set properly so that the
actual initial power level is the value desired.
47
5-PARAMETER DESCRIPTIONS
LCD Display
CFN:Max T/P
09 105 %
Description Start Mode (CFN01, P10) set to Open Loop Voltage Acceleration:
Not Used when the Start Mode is set to open-loop voltage acceleration. When in open loop voltage
acceleration mode, the final voltage ramp value is always 100% or full voltage.
Not Used when the Start Mode is set to Current control acceleration mode. Refer to Maximum
Current (QST07, CFN04, P7) to set the maximum current level.
When the Start Mode is set to TruTorque acceleration, this parameter sets the final or maximum
torque level that the motor will produce at the end of the ramp time during acceleration. For a loaded
motor the maximum torque value initially should be set to 100% or greater. If the maximum torque
value is set too low, the motor may not produce enough torque to reach full speed and may stall. On
lightly loaded motors, this parameter may be reduced below 100% to produce smoother starts.
Note: It is important that the Motor Rated PF parameter (FUN06, P65) is set properly so that the
desired maximum torque level is achieved.
When the Start Mode is set to Power controlled acceleration, this parameter sets the final or
maximum power (KW) consumption level that will be achieved at the end of the ramp time. For a
loaded motor the maximum power value initially should be set to 100% or greater. If the maximum
power level is set too low, the motor may not produce enough torque to reach full speed and may
stall. On lightly loaded motors, this parameter may be reduced below 100% to provide for smoother
starts.
Note: It is important that the Motor Rated PF parameter (FUN06, P65) is set properly so that the
actual maximum power level is achieved.
48
5-PARAMETER DESCRIPTIONS
P13 CFN 10 Kick Lvl 1 (kick level)
LCD Display
CFN: Kick Lvl 1
10 Off
Description The kick level 1 parameter sets the current level that preceedes the current ramp when a start is first
commanded. The kick current is only useful on motor loads that are hard to get rotating but then are
much easier to move once they are rotating. An example of a load that is hard to get rotating is a ball
mill. The ball mill requires a high torque to get it to rotate the first quarter turn (90°). Once the ball
mill is past 90° of rotation, the material inside will begin tumbling and it is easier to turn.
The kick current parameter is usually set to a low value and then the kick time is adjusted to get the
motor rotating. If the kick time is set to more than 2.0 seconds without the motor rotating, increase
the kick current by 100% and re-adjust the kick time.
LCD Display
CFN: Kick Time 1
11 1.0 sec
Description The kick time 1 parameter sets the length of time that the kick current level is applied to the motor.
The kick time adjustment should begin at 0.5 seconds and be adjusted by 0.1 or 0.2 second intervals
until the motor begins rotating. If the kick time is adjusted above 2.0 seconds without the motor
rotating, start over with a higher kick current setting.
NOTE: The kick timer adds to the total start time and must be accounted for when setting the UTS
time.
See Also Kick Level 1 (P14/CFN10), Start Mode (P10/CFN01), UTS timer (P4/QST09)
49
5-PARAMETER DESCRIPTIONS
LCD Display
CFN: Stop Mode
14 Coast
Description The Stop Mode parameter allows for the most suitable stop of the motor based on the application.
CoS Coast Coast: A coast to stop should be used when no special stopping
requirements are necessary; Example: crushers, balls mills, centrifuges,
belts, conveyor. In Low Voltage systems, the bypass contactor is
opened before the SCRs stop gating to reduce wear on the contactor
contacts. (Default)
SdcL Voltage Decel Voltage Decel: In this mode, the starter will linearly phase-back the
SCRs based on the parameter settings Decel Begin Level, Decel End
Level, and Decel Time
tdcL TT Decel TruTorque Decel: In this mode, the starter will linearly reduce the
motor torque based on the Decel End Level and Decel Time.
Refer to section 8.4 Deceleration Control for more information, Page 121.
See Also Decel Begin Level (P16/CFN15), Decel End level (P17/CFN16), Decel Time (P18/CFN17)
50
5-PARAMETER DESCRIPTIONS
LCD Display
CFN:Decel Begin
15 40 %
The voltage deceleration profile utilizes an open loop S-curve voltage ramp profile. When the stop
mode is set to Voltage Decel, the decel begin level parameter sets the initial or starting voltage level
when transferring from running to deceleration. The deceleration beginning level is not a precise
percentage of actual line voltage but defines a point on the S-curve deceleration profile.
A typical voltage decel begin level setting is between 30% and 40%. If the motor initially surges
(oscillates) when a stop is commanded, decrease this parameter value. If there is a sudden drop in
motor speed when a stop is commanded, increase this parameter value.
Not Used when the stop mode is set to TruTorque Decel, the decel begin level has no effect on the
deceleration profile. The TruTorque beginning deceleration level is automatically calculated based
on the motor load at the time the stop command was given.
Note: It is important that the Motor Rated PF parameter (FUN06, P65) is set properly so that the
actual deceleration torque levels are the levels desired.
Refer to section 8.4 Deceleration Control for more information, page 121.
See Also Stop Mode (P15/CFN14), Decel End Level (P17/CFN16), Decel Time (P18/CFN17)
51
5-PARAMETER DESCRIPTIONS
LCD Display
CFN: Decel End
16 20 %
The voltage deceleration profile utilizes an open loop S-curve voltage ramp profile. When the stop
mode is set to Voltage Decel, the decel end level parameter sets the ending voltage level for the
voltage deceleration ramp profile. The deceleration ending level is not a precise percentage of actual
line voltage but defines an ending point on the S-curve deceleration profile.
Note: The deceleration end level can not be set greater than the decel begin level.
A typical voltage decel end level setting is between 10% and 20%. If the motor stops rotating before
the deceleration time has expired increase this parameter value. If the motor is still rotating when the
deceleration time has expired, decrease this parameter value. If the value is set too low a “No
Current at Run” fault may occur during deceleration.
When the stop mode is set to TruTorque Decel, the decel end level parameter sets the ending torque
level for the TruTorque deceleration ramp profile.
A typical TruTorque decel end level setting is between 10% and 20%. If the motor stops rotating
before the deceleration time has expired increase this parameter value. If the motor is still rotating
when the deceleration time has expired, decrease this parameter value.
See Also Stop Mode (P15/CFN14), Decel Begin Level (P16/CFN15), Decel Time (P18/CFN17)
52
5-PARAMETER DESCRIPTIONS
LCD Display
CFN: Decel Time
17 15 sec
Description The decel time parameter sets the time that the deceleration profile is applied to the motor and sets
the slope of the deceleration ramp profile. When in voltage decel mode, this time sets the time
between applying the initial decel level to the application of the final decel level.
Note: If the motor was not up to speed when a stop was commanded, the voltage decel profile will
begin at the lower of either the decel begin level setting or at the motor voltage level when the stop
was commanded. Although the profile may be adjusted, the deceleration time will remain the same.
When in the TruTorque deceleration mode, the decel time sets the time between the motor torque
level when stop was commanded is applied and when the decel end torque level is applied.
If the motor stops rotating before the decel time has expired, decrease the decel time parameter. If
the motor is still rotating when the decel time expires, increase the decel time parameter.
Note: Depending on the motor load and the decel parameter settings, the motor may or may not be
fully stopped at the end of the deceleration time.
See Also Stop Mode (P15/CFN14), Decel Begin Level (P16/CFN15), Decel End Level (P17/CFN16)
LCD Display
CFN: Init Cur 2
06 100 %
Description The initial current 2 parameter is set as a percentage of the motor FLA parameter setting. when the
second ramp select is active. Refer to P6 / QST 06 or CFN 03 for description of operation.
53
5-PARAMETER DESCRIPTIONS
P20 CFN 07 Max Cur 2 (maximum motor current)
LCD Display
CFN: Max Cur 2
07 600 %
Description The maximum current 2 parameter is set as a percentage of the motor FLA parameter setting, when
the second ramp select is active. Refer to P7 / QST 07 or CFN 04 for description of operation.
LCD Display
CFN: Ramp Time 2
05 15 sec
Description The ramp time is the time it takes for the starter to allow the current to go from the initial current to
the maximum current when the second ramp select is active. Refer to P8 / QST 08 or CFN 02 for
description of operation.
LCD Display
CFN: Kick Lvl 2
12 Off
Description The kick level 1 parameter sets the current level that preceedes the current ramp when a start is first
commanded when the second ramp select is active. Refer to P13 / CFN 10 for description of
operation.
LCD Display
CFN: Kick Time 2
13 1.0 sec
Description The kick time 2 parameter sets the length of time that the kick current level is applied to the motor
when the second ramp select is active. Refer to P14 / CFN 11 for description of operation.
54
5-PARAMETER DESCRIPTIONS
5.4 Protection Function Group
LCD Display
PFN:Over Cur Lvl
01 Off
Description If the starter detects a one cycle, average RMS current that is greater than the level defined, an
overcurrent alarm condition exists and the alarm relay will energize if defined. The over current
timer P15/PFN 02 will start a delay time. If the overcurrent still exists when the delay timer expires,
the starter will Over Current Trip (F31) and the fault relay will de-energize.
The Over Current Trip is only active in the UTS state, Energy Saver state, Current follower or while
in the Phase Control mode.
See Also R1-R3 Config (P42-44/ I/O 04-06), Over current Time (P25/PFN02)
Alarm Fault
% Current Condition Trip
Motor FLA
QST 01/P1
Time
Delay
PFN 02/P25
LCD Display
PFN:Over Cur Tim
02 0.1 sec
Description The Over Current Timer parameter sets the period of time that the motor current must be greater than
the over current level (P24/PFN 01) before an over current fault and trip will occur.
If OFF is selected, the over current timer will not operate and the starter will not trip. Itwill
energizeany relayset to Overcurrent until the current drops or the starter trips on O/L
A shear pin function can be implemented by setting the delay to its minimum value.
55
5-PARAMETER DESCRIPTIONS
P26 PFN 03 Undr Cur Lvl (under current level)
LCD Display
PFN:Undr Cur Lvl
03 Off
Description If the controller detects a one cycle, average RMS calculated current that is less than the level
defined, an under current alarm condition exists and the alarm relay will energize, if defined. The
under current timer PFN 04/P27 will start a delay time. If the under current still exists when the delay
times expires, the starter will Under Current Trip (F34) and the fault relay will de-energize.
The Under Current Trip will only be active in the UTS state, Energy Saver state, Current follower or
while in the Phase Control mode.
Alarm Fault
Condition Trip
% Current
Motor FLA
QST 01/P1
Time
Delay
PFN 04/P27
LCD Display
PFN:Undr Cur Tim
04 0.1 sec
Description The Under Current Timer parameter sets the period of time that the motor current must be less than
the under current level (P26/pfn03) before an under current fault and trip will occur.
If OFF is selected, the under current timer will not operate and the starter will not trip. It
will energize any relay set to Undercurrent until the current rises.
56
5-PARAMETER DESCRIPTIONS
P28 PFN 05 Cur Imbl Lvl (current imbalance trip level)
LCD Display
PFN:Cur Imbl Lvl
05 15%
Description The current imbalance level parameter sets the imbalance that is allowed before the starter will shut
down. The current imbalance must exist for 10 seconds before a fault will occur.
At average currents less than or equal to full load current (FLA), the current imbalance for each phase
is calculated as the percentage difference between the phase current that has the maximum deviation
from the average current (Imax) and the FLA current.
(I ave - I max )
% imbalance = x 100%
FLA
At average currents greater than full load current (FLA), the current imbalance for each phase is
calculated as the percentage difference between the phase current that has the maximum deviation
from the average current (Imax) and the average current (Iave).
The equation for the current imbalance if running at current > FLA:
(I ave - I max )
% imbalance = x 100%
I ave
If the highest calculated current imbalance is greater than the current imbalance level for 10 seconds,
the starter will shut down the motor and declare a fault 37 = current imbalance.
Alarm Fault
Condition Trip
% Imbalance
Time
Delay
(Fixed 10 Seconds)
57
5-PARAMETER DESCRIPTIONS
P29 PFN 06 Gnd Flt Lvl (ground fault trip level)
LCD Display
PFN:Gnd Flt Lvl
06 Off
Description The ground fault parameter sets a ground fault current trip or indicate level that can be used to protect
the system from a ground fault condition. The starter monitors the instantaneous sum of the three line
currents to detect the ground fault current.
The ground fault current has to remain above the ground fault level for 3 seconds before the starter
will recognize a ground fault condition. Once the starter recognizes a ground fault condition, it will
shut down the motor and declare a Fault 38-Ground Fault.
If a programmable relay is set to ground fault (GND), the starter will energize the relay when the
condition exists.
A typical value for the ground fault current setting is 10% to 20% of the full load amps of the motor.
Alarm Fault
Condition Trip
% Current
Time
Delay
(Fixed 3 seconds)
NOTE: This is often referred to as residual ground fault protection. This type of protection is meant
to provide machine ground fault protection only. It is not meant to provide human ground fault
protection.
NOTE: The MX residual ground fault protection function is meant to detect ground faults on solidly
grounded systems. Use on a high impedance or floating ground power system may impair the
usefulness of the MX residual ground fault detection feature.
NOTE: Due to uneven CT saturation effects and motor and power system variations, there maybe
small values of residual ground fault currents measured by the MX controller during normal
operation.
58
5-PARAMETER DESCRIPTIONS
P30 PFN 07 Over Vlt Lvl (over voltage trip level)
LCD Display
PFN:Over Vlt Lvl
07 Off
Description If the controller detects for one cycle of any of the individual input phase voltages (rms) is above the
overvoltage level, the over/under voltage alarm will be shown and the Voltage Trip timer will begin
counting. The delay time must expire before the starter will fault. The over voltage condition and the
phase that it occurred on is displayed.
NOTE: For the over voltage protection to operate correctly, the Rated RMS Voltage
parameter (FUN 05, P66) must be set correctly.
NOTE: The voltage level is only checked when the starter is running.
See Also Rated RMS Voltage (P66/FUN05), Voltage Trip Delay Timer (P32/PFN09)
LCD Display
PFN:Undr Vlt Lvl
08 Off
Description If the controller detects for one cycle of any of the individual input phase voltages (rms) is below the
undervoltage level, the over/under voltage alarm will be shown and the Voltage Trip timer will begin
counting. The delay time must expire before the starter will fault. The over voltage condition and the
phase that it occurred on is displayed.
NOTE: For the under voltage protection to operate correctly the Rated RMS Voltage
parameter (FUN 05, P 66) must be set correctly.
NOTE: The voltage level is only checked when the starter is running.
See Also Rated RMS Voltage (P66/FUN05), Voltage Trip Delay Timer (P32/PFN09)P32PFN 09
59
5-PARAMETER DESCRIPTIONS
P32 PFN 09 Vlt Trip Tim (over/under voltage trip delay time)
LCD Display
PFN:Vlt Trip Tim
09 0.1 sec
Description The Voltage Trip Timer parameter sets the period of time that either an overvoltage or undervoltage
condition must exist before a fault will occur.
See Also Over Voltage Trip Level (P30/PFN07), Under Voltage Trip Level (P31/PFN08)
LCD Display
PFN: Auto Reset
10 Off
Description The Auto Reset timer, sets the time delay after a fault occurred and before the starter can
automatically resets the faults. For the list of auto resettable faults, refer to the Appendix B, Fault
List.
NOTE: A start command will need to be initiated once the timer resets the fault.
LCD Display
PFN:Ctrl Flt En
11 On
Description If a fault condition occurs that permits a Controlled Fault Stop and the Controlled Fault Enable
parameter is ON, then a controlled fault stop will occur. During a controlled fault stop, the selected
stop mode CFN 14 (P 15) action is performed before the starter is tripped. This prevents the
occurrence of water hammer etc. in sensitive systems when a less than fatal fault occurs.
NOTE: All relays except the UTS relay are held in their present state until the stop mode action has
been completed.
NOTE: Only certain faults can initiate a controlled fault stop. Some faults are considered too
critical and will cause the starter stop immediately regardless of the Controlled Fault Enable
parameter.
Refer to Appendix B, Fault List to determine if a fault may perform a controlled stop.
60
5-PARAMETER DESCRIPTIONS
LCD Display
PFN:Indep S/R OL
12 Off
Description If “OFF”
When this parameter is “OFF” the running OL (overload) is active in all states
If “ON”
When this parameter is “ON”, the Starting and Running OL are separate with each having
their own settings. The Starting OL value is used during motor acceleration and
acceleration kick. The Running OL value is used during all other modes of operation.
If both the run OL and the start OL are set to OFF, then the existing accumulated motor OL% will be
erased and no motor OL will be calculated in any state.
If the start OL is set to OFF and the run OL is set to On, then the I2t motor OL will NOT accumulate
during acceleration kick and acceleration ramping states. However, the existing accumulated OL%
will remain during starting and the exponential heating and cooling will function during all other
states. However, the OL% will be capped at 99% during starting.
Although there is really no reason to do so, the start OL could be set to ON and the run OL set to
OFF.
See Also Motor O/L class Running (P3/QST03/PFN14), Motor O/L class Starting (P36/PFN13)
61
5-PARAMETER DESCRIPTIONS
P36 PFN 13 Starting OL (motor overload class starting)
LCD Display
PFN:Starting OL
13 10
Description The Starting overload parameter sets the class of the electronic overload when starting. The starter
stores the thermal overload value as a percentage value between 0 and 100%, with 0% representing a
“cold” overload and 100% representing a tripped overload. See section 8.1 for the overload trip time
versus current curves.
The Starting OL is active during Kicking and Ramping when the Independent Start/Run OL
parameter (PFN12/P35) is set “ON.
When the Starting overload is set to OFF, and the independent Start/Run OL parameter os “ON”, the
electronic overload is disabled when starting the motor.
NOTE: Care must be taken not to damage the motor when turning the starting OL off or setting to a
high value.
NOTE: Consult motor manufacturer data to determine the correct motor OL settings.
LCD Display
PFN: Running OL
14 10
LED Display P3
Description The running overload parameter sets the class of the electronic overload when up to speed and
stopping. The starter stores the thermal overload value as a percentage value between 0 and 100%,
with 0% representing a “cold” overload and 100% representing a tripped overload. See section 8.1 for
the overload trip time versus current curves.
When the running overload is set to OFF, the electronic overload is disabled when up to speed and a
separate motor overload protection device must be supplied.
NOTE: Care must be taken not to damage the motor when turning the running OL off or setting a
high value.
NOTE: Consult motor manufacturer data to determine the correct motor OL settings.
62
5-PARAMETER DESCRIPTIONS
LCD Display
PFN:OL H/C Ratio
15 60 %
Description The Motor Overload Hot/Cold Ratio parameter defines the steady state overload content (OLss) that is
reached when the motor is running with a current less than full load current (FLA) * Service Factor
(SF). This provides for accurate motor overload protection during a “warm” start.
Current 1
OLss = OL H/C Ratio × ×
FLA Current Imbalance Derate Factor
The rise or fall time for the overload to reach this steady state is defined by the overload cooling time
parameter.
See section 8.1.4 page number 106 for a description of the Current Imbalance Derate Factor.
The default value of 60% for the OL H/C Ratio parameter is typical for most motors. A more
accurate value can be derived from the hot and cold locked rotor times that are available from most
motor manufacturers using the following formula.
NOTE: Consult motor manufacturer data to determine the correct motor OL settings.
63
5-PARAMETER DESCRIPTIONS
P38 PFN 16 OL Cool Tim (motor overload cooling time)
LCD Display
PFN:OL Cool Tim
16 30.0 min
Description The motor overload cooling time parameter is the time to cool from 100% to less than (<) 1%. When
the motor is stopped, the overload content will be exponentially reduced based on the OL cooling
time parameter.
5
t
OL Content = OL Content wh en Stopped * e CoolingTime
So, a motor with a set cooling time of 30 minutes (1800 sec) with 100% accumulated OL content will
cool to <1% OL content in 30 minutes.
NOTE: Consult motor manufacturer data to determine the correct motor OL setting.
64
5-PARAMETER DESCRIPTIONS
LCD Display
I/O:DI 1 Config
01 Stop
I/O:DI 2 Config
02 Bypass Cnfrm
I/O:DI 3 Config
03 Fault Low
Description I/O parameters 1 – 3 configure which functions are performed by the D1 to D3 terminals.
StOP Stop Command a Stop to remove the software seal in for 3-wire control
(Default DI 1)
FH Fault High Fault High, Fault when input is asserted, 120V applied.
FL Fault Low Fault Low, Fault when input is de-asserted, 0V applied (Default DI 3)
Fr Fault Reset Fault Reset, Reset when input asserted, 120V applied.
byP Bypass Cnfrm Bypass/2M, bypass contactor feedback, 2M contactor feedback in full
voltage or Wye-delta (Default DI 2), See P54/I/O 16
EoLr EOL Reset Emergency Motor Overload content reset. After an OL trip has occured
Reset when input asserted, 120V applied.
L-r Local/remote Local/Remote control source, Selects whether the Local source
parameter or the Remote Source parameter is the control source. Local
source is selected when input is de-asserted, 0V applied. Remote source
selected when input asserted, 120V applied. See QST 4, QST5, P4, P5)
hdIS Heat Disable Heat Disable, Heater disabled when input asserted, 120V applied.
SeeP63, FUN 08
hEn Heat Enabled Heat Enabled, Heater enabled when input asserted, 120V applied.
SeeP63, FUN 08
rSEL Ramp Select Ramp 2 selection, Ramp 2 is enabled when input asserted, 120V
applied.
65
5-PARAMETER DESCRIPTIONS
P42 – P44 I/O 04 – 06 R1 – R3 Config (digital relay output)
LCD Display
I/O: R1 Config
04 Fault FS
I/O: R2 Config
05 Running
I/O: R3 Config
06 UTS
Description I/O parameters 1 – 3 configure which functions are performed by the R1 to R3 relays
OFF Off OFF, Not Assigned, Output has no function or may be controlled over
Modbus
FLFS Fault FS Faulted – Energized when no faults present, de-energized when faulted
(Default R1)
FLnF Fault NFS Faulted – De-energized when no faults present, energized when faulted
run Running Running, starter running, voltage applied to motor (Default R2)
rdyr Ready Ready, starter ready for start command, See P53, I/O15
OC Over Current Over Current Alarm, overcurrent condition detected ,See P24 & 25,
PFN 01 & 02
UC Under Current Under Current Alarm, undercurrent condition detected See P26 & 27,
PFN 03 & 04
ShFS Shunt FS Shunt Trip Relay – Fail Safe operation, energized when no shunt trip
fault present, de-engerized on shunt trip fault (See Appendix B for
faults that result in a shunt trip command)
ShnF Shunt NFS Shunt Trip Relay – Non Fail Safe operation, de-energized when no
shunt trip fault present, energized on shunt trip fault (See Appendix B
for faults that result in a shunt trip command)
GfLt Ground Fault A Ground Fault trip has occured, See P29, PFN 06
66
5-PARAMETER DESCRIPTIONS
LCD Display
I/O:Ain Trp Type
07 Off
Description This parameter allows the user to set a high or low comparator based on the analog input. If the type
is set to LOW, then a fault will occur if the analog input level is below the trip level for longer than
the trip delay time. If the type is set to HIGH, then a fault will occur if the analog input level is above
the trip level for longer than the trip delay time. This function is only active when the MX controller
is running.
This feature can be used to detect an open 4-20mA loop by setting the Ain Trip Type
(I/O07, P45) to LOW and setting the Ain Trip Level (I/O08, P46) to a value less than (<)
20%.
Lo Low Level Low, Fault if input signal below preset trip level
Hi High Level High, Fault if input signal above preset trip level
See Also Ain Trip Level (P46/ I/O 08, Ain Trip Time (P47/ I/O 09)
LCD Display
I/O:Ain Trp Lvl
08 50 %
This feature can be used to detect an open 4-20mA loop by setting the Ain Trip Type
(I/O07, P45) to LOW and setting the Ain Trip Level (I/O08, P46) to a value less than (<)
20%.
Note: The analog input trip level is NOT affected by the Analog Input Offset (I/O 11, P49) or
Analog Input Span (I/O 10, P48) parameter settings. Therefore if a trip level of 10% and a trip LOW
condition is set, the analog input will fault if the input signal level is less than (<) 1V or 2mA
independent of what the Analog Input Offset and Analog Input Span parameters values are set to.
See Also Ain Trip Type (P45/ I/O 07), Ain Trip Time (P47/ I/O 09)
67
5-PARAMETER DESCRIPTIONS
P47 I/O 09 Ain Trp Time (analog input trip time)
LCD Display
I/O:Ain Trp Tim
09 0.1 sec
Description Sets the length of time the analog input trip level must be reached before a trip will occur.
See Also Ain Trip Type (P45/ I/O 07), Ain Trip Level (P46/ I/O 08)
LCD Display
I/O: Ain Span
10 100 %
Description The analog input can be scaled using the “Analog Input Span” parameter.
Examples:
For a 0-10V input or 0-20mA input, a 100% Analog Input Span setting will result in a 0% input
reading with a 0V input and a 100% input reading with a 10V input.
For a 0-5V input, a 50% Analog Input Span setting will result in a 0% input reading with a 0V input
and a 100% input readings with a 5V input.
For a 4-20mA input, a 80% Analog Input Span setting and a 20% Analog Input Offset setting will
result in a 0% input reading at 4mA and a 100% input reading at 20mA.
Analog Input
Reading %
100%
0%
68
5-PARAMETER DESCRIPTIONS
P49 I/O 11 Ain Offset (analog input offset)
LCD Display
I/O:Ain Offset
11 0 %
Description The analog input can be offset so that a 0% reading can occur when a non-zero input signal is being
applied.
Example: Input level of 2V (4mA) => 0% input. In this case the Analog Input Offset
parameter should be set to 20% so that the 2v (4mA) input signal will result in a 0% input reading.
NOTE: For a 4-20mA input, set the Analog Input Span to 80% and the Analog Input Offset to 20%.
LCD Display
I/O: Aout Fctn
12 0
Description The “Analog Output Function” is selected from a list of possible output values. The available analog
output function selections and output scaling are shown below: The analog output is updated every
25msec.
Options
LED LCD Display
0 OFF OFF, Disabled (Default)
1 0 – 200% Curr Based on per cycle RMS values
2 0 – 800% Curr Based on per cycle RMS values
3 0 – 150% Volt Based on per cycle RMS values
4 0 – 150% OL Motor Thermal Overload
5 0 – 10 kW Based on filtered V and I values
6 0 – 100 kW Based on filtered V and I values
7 0 – 1 MW Based on filtered V and I values
8 0 – 10 MW Based on filtered V and I values
9 0 – 100% Ain The output value takes into
account the inputs span and offset
settings
10 0 – 100% Firing Output Voltage to Motor, based
on SCR firing angle
11 Calibration Calibration, full (100%) output
69
5-PARAMETER DESCRIPTIONS
LCD Display
I/O: Aout Span
13 100 %
Description The analog output signal can be scaled using the “Analog Output Span” parameter. For a 0-10V
output or 0-20mA output, a 100% scaling will output the maximum voltage (10V) or current (20mA)
when the selected output function requests 100% output. A scale of 50% will output 50%
voltage/current when the analog output function requests a 100% output.
NOTE: For a 4-20mA output, set the Analog Output span to 80% and the Analog Output Offset to
20%.
Analog
Output
10V /
20mA
Aout Span =
80%
70
5-PARAMETER DESCRIPTIONS
LCD Display
I/O:Aout Offset
14 0 %
Description The analog output signal can be offset using the “Analog Output Offset” parameter. A 50% offset
will output a 50% output (5v in the 10V case) when 0% is commanded. If the selected variable
requests 100% output, the span should be reduced to (100 minus offset) so that a 100% output request
will cause a 100% output voltage (x% offset + (100-x)%span)=100%.
NOTE: For a 4-20mA output, set the Analog Output Span to 80% and the Analog Output Offset to
20%
LCD Display
I/O:Inline Confg
15 3.0 sec
Description The Inline Configuration parameter controls the behavior of the No Line warning, No Line fault, and
the Ready relay function.
If the Inline Configuration parameter is set to Off, then the control assumes that there is no Inline
contactor and that line voltage should be present while stopped. If no line is detected, then a No Line
alarm condition will exist and the ready condition will not exist. If a start is commanded, then a No
Line fault will be declared.
If the Inline Configuration parameter is set to a time delay, then the control assumes that there is an
Inline contactor and that line voltage need not be present while stopped. If no line is detected, then
the No Line alarm condition will not exist and the ready condition will exist. If a start is commanded
and there is no detected line voltage for the time period defined by the Inline Configuration
parameter, then a “noL (No Line) fault will be declared.
NOTE: This fault is different than over/under voltage since it detects the presence of NO line.
71
5-PARAMETER DESCRIPTIONS
LCD Display
I/O:Bpas Fbk Tim
16 2.0 sec
Description The programmable inputs DI 1, DI 2 or DI 3 may be used to monitor an auxiliary contact from the
bypass contactor(s) or in the case of a wye-delta starter the 2M contactor. The digital input is
expected to be in the same state as the UTS relay. If it is not, the control will trip on Fault 48 –
Bypass Fault.
The Bypass Confirmation input must be different from the UTS relay for the time period specified by
the Bypass Confirm Time before a fault is declared. There is no alarm associated with this fault.
NOTE: A digital input needs to be programmed to Bypass/2M for this function to operate. See I/O
01 (P39), I/O 02 (P40), I/O 03 (P41) for more information.
LCD Display
I/O:Kpd Stop Dis
17 Enabled
Description If “Disabled”
When this parameter is “Disabled”, the keypad Stop button is de-activated. This should be
done with caution as the STOP will not stop the starter.
If the keypad is selected as local or remote control sources, the “STOP” key cannot be
disabled.
If “Enabled”
Option
LED LCD Display
Off Disabled Keypad Stop will not stop the starter
On Enabled Keypad Stop will stop the starter (Default
Enabled
72
5-PARAMETER DESCRIPTIONS
LCD Display
FUN: Meter 1
01 Ave Current
FUN: Meter 2
02 Ave Volts
Description For the LCD display, parameters FUN 1and 2 configure which meters are displayed on the two lines
of the main display screen. For the LED display, parameter P69 configures which single meter is
displayed on the main screen.
Options
LED LCD Display
0 Status Running State (LED meter only)
1 Ave Current Average current (Default meter 1)
2 L1 Current Current in phase 1
3 L2 Current Current in phase 2
4 L3 Current Current in phase 3
5 Cur Imbal Current Imbalance %
6 Ground Fault Residual Ground Fault % FLA
7 Ave Volts Average Voltage L-L RMS (Default meter 2)
8 L1-L2 Volts Voltage in, L1 to L2 RMS
9 L2-L3 Volts Voltage in, L2 to L3 RMS
10 L3-L1 Volts Voltage in, L3 to L1 RMS
11 Overload Thermal overload in %
12 Power Factor Motor power factor
13 Watts Motor real power consumed
14 VA Motor apparent power consumed
15 VARS Motor reactive power consumer
16 kW hours Kilo-watt-hour used by the motor, wraps at
1,000
17 MW hours Mega-watt-hour used by the motor, wraps at
10,000
18 Phase Order Phase Rotation
19 Line Freq Line Frequency
20 Analog Input Analog Input %
21 Analog Output Analog Output %
22 Run Days Running time in days, wraps at 2,730 days
23 Run Hours Running time in Hours and Minutes, wraps at
24:00
24 Starts Number of Starts, wraps at 65,536
25 TruTorque % TruTorque %
26 Power % Power %
73
5-PARAMETER DESCRIPTIONS
LCD Display
FUN: CT Ratio
03 288
Range 72, 96, 144, 288, 864, 1320, 2640, 2880, 3900, 5760, 8000, 14.4K, 28.8K (Default 288)
Description The CT ratio must be set to match the CTs (current transformers) supplied with the starter. This
allows the starter to properly calculate the current supplied to the motor.
Only Benshaw supplied CTs can be used on the starter. The CTs are custom 0.2 amp secondary CTs
specifically designed for use on the MX starter. The CT ratio is then normalized to a 1A secondary
value. The supplied CT ratio can be confirmed by reading the part number on the CT label. The part
number is of the form BICTxxx1M, where xxx is the CT primary and the 1 indicates the normalized
1 amp.
NOTE: It is very important that the CT ratio and burden switches are set correctly. Otherwise,
many starter functions will not operate correctly.
LCD Display
FUN:Phase Order
04 Insensitive
Description The Phase order parameter sets the phase sensitivity of the starter. This can be used to protect the
motor from a possible change in the incoming phase sequence. If the incoming phase sequence does
not match the set phase rotation, the starter will display an Alarm while stopped and will fault if a
start is attempted.
74
5-PARAMETER DESCRIPTIONS
P66 FUN 05 Rated Volts (rated rms voltage)
LCD Display
FUN:Rated Volts
05 480 Vlt
Range 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 500, 525, 575, 600, 660,
690, 1000, 1140, 2200, 2300, 2400, 3300, 4160, 4600, 4800, 6000, 6600, 6900, 10.00K, 11.00K,
11.50K, 12.00K, 12.47K, 13.20K, 13.80K (Default 480)
Description The Rated Voltage parameter sets the line voltage that is used when the starter performs Over and
Under line voltage calculations. This value is the supply voltage; NOT the motor utilization voltage.
When applied to medium voltage, (2200 and above) the voltage must be set correctly for the starter to
function properly.
LCD Display
FUN:Rated PF
06 -0.92
Description The motor rated power factor value sets the motor power factor value that is used by the MX starter
for TruTorque and Power control calculations and metering calculations.
If the motor rated Power Factor (PF) is not available, from either the motor nameplate or the motor
manufacture, the value can be obtained by viewing the power factor meter, providing an approximate
value for the MX control.
With the motor running at full name plate current, view the PF meter either by setting meter 1 (P69)
to 12 with the LED display, or by pressing ? until the Motor PF meter is displayed using the LCD
display.
75
5-PARAMETER DESCRIPTIONS
LCD Display
FUN:Starter Type
07 Normal
Description The MX control has been designed to be the controller for many control applications;Solid State
Starter, both Normal (outside Delta) and Inside Delta, and electromechanical starters, Wye Delta,
Across the line full voltage starter, Phase Control/Voltage Follower, Current Follower. In each case,
the MX control is providing the motor protection and the necessary control for these applications.
nor Normal Normal (Outside Delta), Reduced Voltage Soft Starter RVSS (Default)
PctL Phase Control Open Loop Phase control / voltage follower using external input
reference, Refer to Section 1.1
cFol Current Follow Closed Loop Current follower using external input reference. Refer to
Section 8.7 Current Follower
76
5-PARAMETER DESCRIPTIONS
LCD Display
FUN:Heater Level
08 Off
Description The heater level parameter sets the level of D.C. current that reaches the motor when the motor
winding heater/anti-windmilling brake is enabled. The motor winding heater/anti-windmilling brake
can be used to heat a motor in order to prevent internal condensation or it can be used to prevent a
motor from rotating.
NOTE: The motor can still slowly creep when the anti-windmilling brake is being used. If the motor
has to be held without rotating, a mechanical means of holding the motor must be used.
The motor winding heater/anti-windmilling brake operation may be controlled by a digital input and
by a heater disable bit in the starter control modbus register. There are two methods using the digital
inputs, either the input is an enable or disable.
Enabled: When the DI 1, DI 2 or DI 3 inputs are programmed as Heat Enable Inputs, the input may
be used to control when heating/anti-windmilling is applied. The Heater / Anti-Windmill Level
parameter must be set, the starter stopped and this input must be high for heating to occur.
Disabled: When the DI 1, DI 2 or DI 3 inputs are programmed as Heat Disable Inputs, the input may
be used to control when heating/anti-windmilling is applied. The Heater / Anti-Windmill Level
parameter must be set and this input must be low for heating to occur.
If no digital inputs are programmed as heater enabled or disabled, the heater will be applied at
all times when the motor is stopped.
The level of DC current applied to the motor during this operation needs to be monitored to ensure
that the motor is not overheated. The current level should be set as low as possible and then slowly
increased over a long period of time. While this is being done, the temperature of the motor should be
monitored to ensure it is not overheating.
LCD Display
FUN:Energy Saver
09 Off
77
5-PARAMETER DESCRIPTIONS
Range On – Off (Default OFF)
Description The energy saver will lower the voltage applied to a lightly loaded motor. It will continue to lower
the voltage until it finds the point where the current reaches its lowest stable level and then regulate
the voltage around this point. If the load on the motor increases, the starter will immediately return
the output of the starter to full voltage.
NOTE: This function will not operate if a bypass contactor is used once the motor is up to speed.
NOTE: In general, Energy Saver can save approximately 1000 watts per 100 HP.
LCD Display
FUN: Com Drop #
10 1
Description The Com Drop parameter sets the starter address when using RS-485 communications. The
equipment that is communicating with the control must use the same address.
LCD Display
FUN:Com Baudrate
11 9600
LCD Display
FUN:Com Timeout
12 Off
Description The communication timeout sets the time that the starter will stay running without receiving a valid
communications request. If a valid serial communications request is not received for the time that is
set, the starter will declare a F82, Modbus Time out. The starterwill do a controlled stop.
78
5-PARAMETER DESCRIPTIONS
LCD Display
FUN: Starter MN
13 None
Description The starter model number sets the thermal protection of the starter power stack. This information is
useful for future service reasons. If calling Benshaw for service, this number should be recorded so it
can be provided to the service technician.
LCD Display
FUN:Software PN
14 810018-01-xx
Description The software part number is useful for future service reasons. If calling Benshaw for service, this
number should be recorded so it can be provided to the service technician.
On power up with an LED display, the software version is flashed one character at a time on the least
significant digit. With an LCD display, the software PN is fully displayed on power up.
79
5-PARAMETER DESCRIPTIONS
LCD Display
FUN:Misc Command
15 None
Range 0 – 3 (Default 0)
The Reset Run Time command will reset the user run time meters back to zero (0).
The Reset kWh command will reset the accumulated kilowatt-hour and megawatt-hour meters back
to zero (0).
The Reflash mode command will put the MX control board into a reflash program memory mode.
The reflash mode can only be entered if the MX starter is idle. When the reflash mode is entered, the
MX control will be waiting to be programmed. The onboard LED display will show the “flsh”. The
remote displays will be disabled after entering reflash mode. The starter will not operate normally
until reflash mode is exited. Reflash mode may be exited by either pressing the on-board RESET
button or cycling control power.
The Store command allow the user to copy the parameters into non-volatile memory as a backup. If
changes are being made, store the old set of parameters before any changes are made. If the new
settings do not work, the old parameter values can be loaded back into memory.
The Load command loads the stored parameters into active memory.
The Factory Reset command will restore all parameters to the factory defaults. These can be found
section 4.
Options
LED LCD Display
0 None No commands
1 Reset Run Time Reset Run Time Meter
2 Reset kWh/MWh Reset kWh/MWh Meters
3 Reflash Mode Activate Reflash Mode
4 Store Parm The current parameter values are stored in non-volatile memory
5 Load Parm All parameter are retrieved from non-volatile memory
6 Factory Rst All parameters are restored to the factory defaults
80
5-PARAMETER DESCRIPTIONS
P72 FUN 16 Passcode (passcode)
LCD Display
FUN: Passcode
16 Off
Description The MX control supports a 4-digit passcode. When the passcode is set, parameters may not be
changed.
When a passcode is set and an attempt is made to change a parameter through the display/keypad, the
UP and DOWN keys will simply have no effect. When a passcode is set and an attempt is made to
change a parameter through Modbus, the control will return an error response with an exception code
of 03 (Illegal Data Value) to indicate that the register may not be changed.
The following steps must be performed to set a passcode using the LED Display:
1. At the default meter display, press the PARAM key to enter the parameter mode.
2. Press the UP or DOWN keys to get to the passcode parameter.
3. Press the ENTER key. “Off” will be displayed to indicate that no passcode is currently set.
4. Press the UP or DOWN keys and ENTER for each digit to be defined, select a value from 0000 to
9999 starting at the most significant digit.
5. Press the ENTER key to set the passcode.
The following steps must be performed to clear a passcode.
1. At the default meter display, press the PARAM key to enter the parameter mode.
2. Press the UP or DOWN keys to get to the passcode parameter.
3. Press the ENTER key. “On” will be displayed to indicate that a passcode is presently set.
4. Press the UP or DOWN keys and ENTER after each digit to select the previously set passcode
value.
5. Press the ENTER key. The passcode is then cleared.
The following steps must be performed to set a passcode using the LCD Display:
1. At the default meter display, press the MENU key to enter the Menu mode.
2. Press the UP or DOWN keys to get to the FUN parameters.
3. Press the ENTER key
4. Press the UP or DOWN keys to get to the FUN 16.
5. Press the ENTER key. “Off ” will be displayed to indicate that no passcode is currently set.
6. Press the UP or DOWN keys and ENTER for each digit to be defined, select a value from 0000 to
9999 starting at the most significant digit Press the ENTER key to set the passcode.
The following steps must be performed to clear a passcode.
1. At the default meter display, press the MENU key to enter the menu mode.
2. Press the UP or DOWN keys to get to the FUN parameter.
6. Press the ENTER key
7. Press the UP or DOWN keys to get to the FUN 16.
3. Press the ENTER key. “On” will be displayed to indicate that a passcode is presently set.
4. Press the UP or DOWN keys and ENTER after each digit to select the previously set passcode
value.
5. Press the ENTER key. The passcode is then cleared.
NOTE: To re-establish password protection after it has been cleared, the password must be entered
again.
81
5-PARAMETER DESCRIPTIONS
5.6 Fault Log
LCD Display
FL1:Last Fault #
Fault Name
Range 1–99
Description When a fault occurs, the fault number is logged in non-volatile memory. The most recent fault will be
in FL1 location and the oldest fault will be in FL9.
Refer to section 7, Troubleshooting or Appendix B for the fault codes and their descriptions.
If the starter is equipped with an LCD display, pressing “ENTER” will toggle through the Starter
Conditions, Avg. Line Current, Avg. Line Voltage, and Line Frequency at the time of the fault.
82
6 Applications
83
6-APPLICATIONS
6.1 Application Consideration between Line Connected and Inside Delta Connected Soft Starter
There are differences between a line connected soft starter as shown in Figure 8 and the inside delta connected soft starter as shown
in Figure 9 that need to be understood.
By observation of Figure 9, access to all six stator-winding terminals is required for an inside delta application. In the line connected
soft starter of Figure 8, access to only three leads of the stator windings of the motor is required. For a 12-lead motor, all 12 stator
terminals must be accessible.
One failed SCR on any phase of the inside delta soft starter will result in a single-phase condition. A shunt trip circuit breaker is
recommended to protect the motor in this case. A programmable relay can be configured as a shunt trip relay and can be used to trip
the breaker. When certain faults occur, the shunt trip relay energizes. Refer to Appendix B for those faults that cause a shunt trip.
The SCR control for an inside delta application is different than the SCR control for a standard soft starter. The starter type
(parameter FUN 07 or P64) needs to be properly set so that the SCRs are gated correctly.
If a circuit breaker is the only means to disconnect the soft starter and motor from the line, then one leg of the motor leads in the
inside delta soft starter is always electrically live when the circuit breaker is closed. This requires caution to ensure these leads of the
motor are not exposed to personnel.
In Figure 8, the power poles of the soft starter are connected in series with the line. The starter draws line current (L1 ,L2 ,L3 ).
6
L1
3 T1
5 T2
L2 Motor
2
T3
4
L3
1
84
6-APPLICATIONS
An inside delta soft starter is shown in Figure 9, where the power poles are connected in series with the stator windings of a delta
connected motor.
L3
3 T6 T3
1
6
4
Motor
T1 T5
L1 T4 T2
5 L2
For an Inside Delta connected motor, the inside windings average SCR current is less than that of the outside average line current by
a factor of 1.55 (FLA/1.55). By comparison of Figure 8 and Figure 9, the most obvious advantage of the inside delta starter is the
reduction of current seen by the soft starter. The soft starter current rating can be downsized by a factor of 1.55, providing significant
savings in cost and size of the starter.
An inside delta soft starter can also be considered for motors with more than 6 leads, including 12 lead dual voltage motors.
NEMA and IEC use different nomenclature for motor terminal markings, for 3 and 6 leaded motors.
NEMA labels motors leads, 1,2,3,4,5,6,
IEC labels motor leads, U1, V1, W1, U2, V2, W2
The MX control has been designed to be the controller for other motor control applications, such as Wye Delta, Across the line full
voltage starter, Phase Control/Voltage Follower and Current Follower. In each case, the MX control is providing the motor
protection and the necessary control for these applications.
When the MX control is set to Wye-Delta (FUN 07, P64, Starter Type parameter), the MX control is configured to operate an
electromechanical Wye-Delta (Star-Delta) starter. When in Wye-Delta mode, all MX motor and starter protective functions, except
bad SCR detection and power stack overload, are available to provide full motor and starter protection. The UTS / Transition Time
parameter (QST 09, P9) sets the time when the Wye to Delta transition occurs during starting.
The MX control can operate two configurations of Wye-Delta starters, open transition and closed transition.
An open transition starter momentarily disconnects the motor from the input line during the transition from Wye to Delta
operating mode.
A closed transition starter uses resistors that are inserted during the transition so that the motor is never completely
disconnected from the input line.
85
6-APPLICATIONS
The presence of these resistors in a closed transition starter smoothes the transition from Wye to Delta operation mode. A typical
closed transition Wye-Delta starter schematic is shown in Figure 10 – Wye Delta Motor Connection to the MX Control
L1 L2 L3
To TB 3, C 1+ (White Wire )
To TB3 , C 1- (Black Wire)
To TB3, C 2+ ( White Wire) Current Feedbacks
To TB3, C 2- (Black Wire) to MX
To TB3, C 3+ ( White Wire)
To TB3, C 3- (Black Wire)
To TB6 (SCR 2) K2
To TB8 (SCR 3) K3
To TB4 (SCR 1) K1
1M 2S 2M
Resistor
Resistor
Voltage &
Frequenc
y to MX
Line
Resistor
T3 T6 1S
T2 T5
T1 T4
Control Power
2M Confirm
Input Common
2M MX
2S
UTS
MX
1S
Run 2M 2S
MX Mechanical
1M Interlock
1S
2M
1M 1S
For the Wye-Delta starter mode to operate properly, one output relay needs to be programmed to the RUN output function and
another output relay needs to be programmed to the UTS output function. (Refer to parameters I/0 04-06, P42-44 for more
information).
For operation of the Wye-Delta and its transitions from a start to a completed run, refer to Section 8.5 Wye-Delta Operation.
The closed transition resistors generally are sized to be in the circuit for a short period of time. To protect the resistors from over
heating, one input should be programmed as a Bypass/2M contact feedback input and the Bypass/2M confirm parameter must be set.
86
6-APPLICATIONS
When the MX control Starter Type parameter (FUN 07, P64) is set to Phase Control, the MX control is configured to operate as a
phase controller / voltage follower. This is an open loop control mode. The firing angles of the SCRs are directly controlled based on
voltage or current applied to the Analog Input. A reference-input value of 0% will result in no output. A reference-input value of
100% will result in full (100%) output voltage. The actual voltage or current input that results in a given output can be adjusted
through the use of the Analog Input Offset (I/O 11, P49 ) and Analog Input Span (I/O 10, P48) user parameters. The Phase Control
mode has many uses. Two typical applications are use in master/slave starter configurations and as a basic phase controller.
Phase Controller:
When in Phase Control mode, the MX controller can function as a general phase controller. Phase control can be used to directly
control the voltage applied to motors, resistive heaters, etc. When in Phase Control mode, the phase angle of the SCRs and hence the
voltage applied is directly controlled based on the measured analog input signal. The MX controllers reference command can be
generated from any 0-10V, 0-20mA, 4-20mA source such as a potentiometer, another MX controller, or an external controller such as
a PLC.
The Phase control mode can only be used on continuous/fan cooled starters. The bypassed starter does not have the thermal capacity
to continuously operate at rated amps in phase control mode and the bypass contactor is not used. Use the RC power stack.
In the master / slave configuration, one “master” starter can directly control the output of one or more slave starters. To utilize the
master / slave configuration, one starter needs to be defined as the “master” starter. The Starter Type parameter (FUN 07, P64) of the
“master” starter should be configured appropriately as a Soft Starter (normal or ID), Phase Control, or Current Follower. If
configured as a soft starter, the acceleration and deceleration profiles will need to be configured for proper operation.
The analog output of the “master” starter should be set to 0-100% firing and connected to the analog input of the following starter(s).
“Slaves” should have FUN 07, P64 starter type set to Phase control.
Note: The power stack must be rated for continuous non-bypassed duty in order to properly operate in Phase Control mode.
When the MX control Starter Type parameter (FUN07, P64) is set to Current Follower, the MX control is configured to operate as a
Closed Loop current follower. Current Follower mode can be used to control the current applied to motors, resistive heaters, etc.
The Current Follower mode uses the analog input to receive the desired current command and controls the SCRs to output the
commanded current. The MX controllers reference command can be generated from any 0-10V, 0-20mA, 4-20mA source such as a
potentiometer, another MX controller, or an external controller such as a PLC. When a start command is given, the RUN
programmed relay output will energize and the SCRs will be gated on.
A reference-input value of 0% will result in no output. A reference-input value of 100% will result in a current output equal to the
FLA setting (QST1, P1). The actual voltage or current input that results in a given output can be adjusted through the use of the
Analog Input Offset (I/O 11, P49) and Analog Input Span (I/O 10, P48) user parameters.
Note: The power stack must rated for continuous non-bypassed duty be used. in order to operate in Current Follower mode.
87
6-APPLICATIONS
When the MX control is set to ATL (FUN 07, P64 Starter Type parameter), the MX control is configured to operate an
electromechanical full voltage or across-the-line (ATL) starter.
In the ATL configuration, the MX controller expects that the motor contactor (1M) will be directly controlled by a digital output
relay that is programmed for the RUN function. Therefore, when a start command is given, the RUN programmed relay will energize
the motor contactor, which will apply power to the motor. When the MX controller has determined that the motor has reached full
speed, the up-to-speed (UTS) condition will be indicated by energizing the UTS programmed relays. When configured as an ATL
starter, all MX motor and starter protective functions, except bad SCR detection and power stack overload, are available to provide
full motor and starter protection.
L1 L2 L3
To TB6 (SCR 2) K2
To TB8 (SCR 3) K3
1M
Voltage &
Frequenc
y to MX
Line
T2
T1 T3
MOTOR
Control Power
DIN#2 DIN#2
Input Common
1M MX
1M
Run
MX
Note: When in ATL mode, the acceleration ramp, kick, and deceleration parameter settings have no effect on motor operation.
Note: When in ATL mode, the SCR gate outputs are disabled.
88
7 TroubleShooting
89
7-TROUBLESHOOTING
The following troubleshooting charts can be used to help solve many of the more common problems that may occur.
90
7-TROUBLESHOOTING
7.1.2 During starting, motor rotates but does not reach full speed
91
7-TROUBLESHOOTING
7.1.4 Deceleration not operating as desired
92
7-TROUBLESHOOTING
93
7-TROUBLESHOOTING
7.1.7 Other Situations
94
7-TROUBLESHOOTING
7.2 Fault Code Troubleshooting Table
The following is a list of possible faults that can be generated by the MX starter control.
95
7-TROUBLESHOOTING
Fault Code Description Detailed Description of Fault / Possible Solutions
F14 Input power not single Three-phase power has been detected when the starter is expecting single-
phase phase power.
Verify that input power is single phase.
Verify that single-phase power is connected to the L1 and L2 inputs.
Correct wiring if necessary.
Verify that the SCR gate wires are properly connected to the MX control
board.
F15 Input power not three Single-phase power has been detected when the starter is expecting three-
phase phase power.
Verify that input power is three phase. Correct wiring if necessary.
Verify that the SCR gate wires are properly connected to the MX control
board.
On medium voltage systems, verify wiring of the voltage feedback
measurement circuit.
F21 Low Line L1-L2 Low voltage below the Undervoltage Trip Level parameter setting (PFN
08, P31) was detected for longer than the Over/Under Voltage Trip delay
time (PFN 09, P32).
Verify that the actual input voltage level is correct.
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Check input supply for open fuses or open connections.
On medium voltage systems, verify wiring of the voltage measurement
circuit.
F22 Low Line L2-L3 Low voltage below the Undervoltage Trip Level parameter setting (PFN
08, P31) was detected for longer than the Over/Under Voltage Trip delay
time (PFN 09, P32).
Verify that the actual input voltage level is correct.
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Check input supply for open fuses or open connections.
On medium voltage systems, verify wiring of the voltage feedback
measurement circuit.
F23 Low Line L3-L1 Low voltage below the Undervoltage Trip Level parameter setting (PFN
08, P31) was detected for longer than the Over/Under Voltage Trip delay
time (PFN 09, P32).
Verify that the actual input voltage level is correct.
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Check input supply for open fuses or open connections.
On medium voltage systems, verify wiring of the voltage feedback
measurement circuit.
F24 High Line L1-L2 High voltage above the Over voltage Trip Level parameter setting (PFN
07, P30) was detected for longer than the Over/Under Voltage Trip delay
time (PFN 09, P32).
Verify that the actual input voltage level is correct.
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Line power quality problems/ excessive line distortions.
96
7-TROUBLESHOOTING
Fault Code Description Detailed Description of Fault / Possible Solutions
F25 High Line L2-L3 High voltage above the Over voltage Trip Level parameter setting (PFN
07, P30) was detected for longer than the Over/Under Voltage Trip delay
time (PFN 09, P32).
Verify that the actual input voltage level is correct.
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Line power quality problems/ excessive line distortions.
F26 High Line L3-L1 High voltage above the Over voltage Trip Level parameter setting (PFN
07, P30) was detected for longer than the Over/Under Voltage Trip delay
time (PFN 09, P32).
Verify that the actual input voltage level is correct.
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Line power quality problems/ excessive line distortions.
F27 Phase Loss The MX control has detected the loss of one or more input or output
phases when the starter was running. Can also be caused by line power
dropouts.
Check input supply for open fuses.
Check power supply wiring for open or intermittent connections.
Check motor wiring for open or intermittent connections.
On medium voltage systems, verify wiring of the voltage feedback
measurement circuit.
Check Gate and Cathode connections to MX board
F28 No Line No input voltage was detected for longer than the Inline Configuration
time delay parameter setting (I/O 15, P53) when a start command was
given to the starter.
If an inline contactor is being used, verify that the setting of the Inline
Configuration time delay parameter (I/O 15, P53) allows enough time for
the inline contactor to completely close before the No Line fault occurs.
Check input supply for open disconnects, open fuses, open circuit
breakers, or disconnected wiring.
Verify that the SCR gate wires are properly connected to the MX control
board.
On medium voltage systems, verify wiring of the voltage feedback
measurement circuit.
F30 I.O.C. During operation, the MX controller detected a very high level of current
in one or more phases.
(Instantaneous
Overcurrent Current) Check motor wiring for short circuits or ground faults.
Check motor for short circuits or ground faults.
Check if power factor or surge capacitors are installed on the motor side
of the starter.
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and
burden switch settings are correct.
F31 Overcurrent Motor current exceeded the Over Current Trip Level setting (PFN 01,
P24) for longer than the Over Current Trip Delay Time setting (PFN 02,
P25).
Check motor for a jammed or an overload condition.
97
7-TROUBLESHOOTING
F34 Undercurrent Motor current dropped under the Under Current Trip Level setting (PFN
03, P26) for longer than the Under Current Trip Delay time setting (PFN
04, P27).
Check system for cause of under current condition.
F37 Current Imbalance A current imbalance larger than the Current Imbalance Trip Level
parameter setting (PFN 05, P28) was present for longer than ten (10)
seconds.
Check motor wiring for cause of imbalance. (Verify dual voltage and 6
lead motors for correct wiring configuration).
Check for large input voltage imbalances that can result in large current
imbalances.
Check motor for internal problems.
F38 Ground Fault Ground current above the Ground Fault Trip level setting (PFN 06, P29)
has been detected for longer than 3 seconds.
Check motor wiring for ground faults.
Check motor for ground faults.
Megger motor and cabling (disconnect from starter before testing).
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and
burden switch settings are correct.
Verify that the CTs are installed with all the White dots towards the input
line.
In Single phase applications, verify that only two CTs are being used; that
they are installed with all the White dots or Xs in the correct direction;
and that the CTs are connected to the L1 and L3 CT inputs on the MX
control card.
F39 No Current at Run Motor current went below 10% of FLA while the starter was running.
Verify Motor Connections.
Verify the CT wiring to the MX control board.
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and
burden switch settings are correct.
Check if load is still connected to starter
Check if motor may have been driven by the load (a regeneration
condition)
Check Gate and Cathode connections to MX for loose connections.
Check for inline contactor or disconnect.
F40 Shorted / Open SCR A shorted or open SCR condition has been detected.
Verify that all SCR gate leads wires are properly connected at the SCR
devices and the MX control board.
Check all SCRs with ohmmeter for shorts.
Verify that the Input Phase Sensitivity parameter setting (FUN 04, P67) is
correct.
Verify that the Starter Type parameter setting (FUN 07, P64) is correct.
Verify the motor wiring. (Verify dual voltage motors for correct wiring
configuration).
98
7-TROUBLESHOOTING
F41 Current at Stop Motor current was detected while the starter was not running.
Examine starter for shorted SCRs.
Examine bypass contactor (if present) to verify that it is open when starter
is stopped.
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and
burden switch settings are correct.
F47 Stack Protection Fault The MX electronic power stack OL protection has detected an overload
(stack thermal overload) condition.
Check motor for jammed or overloaded condition.
Verify Starter Model Number parameter setting (FUN 13, P70) is correct
(if available).
Verify that the CT ratio (FUN 03, P68) and burden switch settings are
correct.
Motor load exceeds power stack rating. Consult factory
F48 Bypass /2M Contactor A digital input has been programmed as a Bypass/2M Contactor Feedback
Fault input and an incorrect bypass feedback has been detected for longer than
the Bypass Confirm time parameter setting (I/O 16, P54).
Verify that the bypass/2M contactor coil and feedback wiring is correct.
Verify that the relay output that is connected to the bypass/2M contactor(s)
is programmed to the UTS function.
Verify that the bypass/2M contactor power supply is present.
Verify that the appropriate Digital Input Configuration parameter has been
programmed correctly.
Verify that the bypass contactor(s) are actually not damaged or faulty.
F50 Control Power Low Low control power (below 90V) has been detected while running, by the
MX controller.
Verify that the control power input level is correct especially during
starting when there may be significant line voltage drop.
Check control power transformer tap setting (if available).
Check control power transformer fuses (if present).
Check wiring between control power source and starter.
F51 Current Sensor Offset Indicates that the MX control board self-diagnostics have detected a
Error problem with one or more of the current sensor inputs.
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and
burden switch settings are correct.
Verify that no actual current is flowing through any of the starter’s CTs
when the starter is not running.
Consult factory if fault persists.
F52 Burden Switch Error The burden switch settings were changed when starter was running. Only
change burden switches when starter is not running.
F60 External Fault on DI#1 DI#1 has been programmed as a fault type digital input and the input
Input indicates a fault condition is present.
Verify that the appropriate Digital Input Configuration parameter has been
programmed correctly.
Verify wiring and level of input.
99
7-TROUBLESHOOTING
F61 External Fault on DI#2 DI#2 has been programmed as a fault type digital input and input indicates
Input a fault condition is present.
Verify that the appropriate Digital Input Configuration parameter has been
programmed correctly.
Verify wiring and level of input.
F62 External Fault on DI#3 DI#3 input has been programmed as a fault type digital input and input
input indicates a fault condition is present.
Verify that the appropriate Digital Input Configuration parameter has been
programmed correctly.
Verify wiring and level of input.
F71 Analog Input Level Fault Based on the Analog Input parameter settings, the analog input level has
Trip. either exceeded or dropped below the Analog Input Trip Level setting (I/O
08, P46) for longer than the Analog Input Trip Delay time (I/O 09, P47).
Measure value of analog input to verify correct reading.
100
7-TROUBLESHOOTING
F95 CPU Error – Parameter The non-volatile user parameter values have been found to be corrupted.
EEPROM Checksum Typically occurs when the MX control is re-flashed with new software.
Fault
Perform a Factory Parameter reset and then properly set all user
parameters before resuming normal operation.
If fault persists after performing a Factory Parameter reset, consult
factory.
F96 CPU Error The MX control has detected an internal CPU problem. Consult factory.
F97 CPU Error – SW The MX control has detected an internal software problem. Consult
Watchdog Fault factory.
F98 CPU Error The MX control has detected an internal CPU problem. Consult factory.
F99 CPU Error – Program The non-volatile program memory has been corrupted.
EPROM Checksum Fault
Consult factory. Control software will need to be reloaded in to the MX
control card before normal operation can resume.
101
7-TROUBLESHOOTING
102
8 Theory of Operation
103
8– THEORY OF OPERATION
Motor Overload
8.1.1 Overview
The MX control contains an advanced I2t electronic motor overload (OL) protection function. For optimal motor protection, the MX
control has forty standard NEMA style overload curves (in steps of one) available for use. Separate overload classes can be
programmed for acceleration and for normal running operation and individually or completely disabled if necessary. The MX motor
overload function also implements a NEMA based current imbalance overload compensation, user adjustable hot and cold motor
compensation, and user adjustable exponential motor cooling.
CAUTION: If the MX motor overload protection is disabled during any mode of operation, external motor overload protection must
be provided to prevent motor damage and/or the risk of fire in the case of a motor overload.
Motor overload protection is easily configured through seven user parameters (please refer to the descriptions of each parameter in
section 5 of this manual for additional parameter information):
1. Motor Full Load Current (P1 / QST 01)
2. Motor Service Factor (P2 / QST 02)
3. Motor OL Class Running (P3 / QST 03)
4. Motor OL Class Starting (P36 / PFN 13)
5. Independent Start / Run OL (P35 / PFN12)
6. Motor Hot/Cold Ratio (P37 / PFN 15)
7. Motor Cooling Time (P38 / PFN 16)
The Motor FLA and Service Factor parameter settings define the motor overload “pickup” point. For example, if the motor service
factor is set to 1.00, the motor overload will begin accumulating or incrementing when the measured motor current is >100% FLA
(100% * 1.00). The overload will NOT trip if the motor current is <100%. If the motor service factor is set to 1.15, the overload will
start accumulating content when the motor current >115% FLA (100% * 1.15). The overload will NOT trip if the measured motor
current is <115% of rated FLA.
The available overload classes are based on the trip time when operating at 600% of rated motor current. For example, a Class 10
overload will trip in 10 seconds when the motor is operating at 600% rated current; a Class 20 overload will trip in 20 seconds when
the motor is operating at 600% rated current.
The equation for the MX standard overload curves after the “pick-up” point has been reached is:
35 seconds * Class
Time to Trip (seconds) = 2
1
Measured Current *
Current Imbal Derate Factor − 1
Motor FLA
104
8– THEORY OF OPERATION
Motor Overload
10000
1000
Seconds to Trip
100
Class 40
Class 30
Class 20
10 Class 15
Class 10
Class 5
1
100 150 200 250 300 350 400 450 500 550 600 650 700 750 800
Current % (FLA)
NOTE: In some cases the power stack rating may determine what motor overload settings are available. Each power stack is designed to
support specific motor overload classes. The RBX power stack is designed for class 10 duty without derating. Refer to section 2.5.7 for the
specifics of the RBX overload capabilities. Also, in certain heavy duty DC braking applications, the overload settings may be limited to
protect the motor from potential damage during braking.
105
8– THEORY OF OPERATION
Motor Overload
Overload Heating
When the motor is operating in the overloaded condition (motor current greater than FLAxSF), the motor overload content will
accumulate based on the starter’s operating mode at a rate established by the overload protection class chosen. The accumulated
overload content can be viewed on the display or over the communications network.
Overload Alarm
When the accumulated motor overload content reaches 90%, an overload alarm condition will be declared. A relay output can be
programmed to change state when a motor overload alarm condition is present to warn of an impending motor overload fault.
Overload Trip
When the motor overload content reaches 100%, the MX starter will trip protecting the motor from damage. If the controlled fault
stop feature of the MX control is enabled, the starter will first perform the defined deceleration or DC braking profile before stopping
the motor. The motor overload trip time accuracy is ± 0.2 seconds or ± 3% of total trip time.
After tripping on an overload, restarting will be prevented and the starter will be “locked out” until the accumulated motor overload
content has cooled below 15%.
The MX motor overload calculations automatically compensate for the additional motor heating which results from the presence of
unbalanced phase currents. When a current imbalance is present, there can be significant negative sequence currents present in the
motor. These negative sequence currents have a rotation opposite the motor rotation and are typically at two times the line
frequency. Due to the negative sequence currents opposite rotation and higher frequency, these currents can cause a significant
increase in rotor heating.
The overload curves provided by a motor manufacturer are based on balanced motor operation. Therefore, if a current imbalance is
present, the MX motor overload will compensate for the additional heating effect by accumulating overload content FASTER and
tripping sooner to protect the motor. The current imbalance compensation also adjusts the Hot / Cold motor protection as described
below in section 8.1.6 Hot / Cold Motor Overload Compensation. The MX control’s derating factor is based on NEMA MG-1 14.35
specifications and is shown in the following Figure 12 – Overload Derated for Current Imbalance.
106
8– THEORY OF OPERATION
Motor Overload
Figure 12 – Overload Derated for Current Imbalance
0.95
Derating Factor
0.9
0.85
0.8
0.75
0 5 10 15 20 25 30
Current imbalance %
The MX motor overload calculation automatically compensates for the additional motor heating that can result from the presence of
harmonics. Harmonics can be generated by other loads connected to the supply such as DC drives, AC variable frequency drives, arc
lighting, uninterruptable power supplies, and other similar loads.
If a motor has been in operation for some time, it will have heated up to some point. Therefore, there is typically less overload
content available in the case where a motor is restarted immediately after it has been running when compared to the situation where a
motor has been allowed to cool down before restarting. The MX control provides adjustable hot motor overload compensation to
fully protect the motor in these cases.
If the hot and cold maximum locked rotor times are provided, the MX Hot/Cold Ratio parameter value can be calculated as follows:
If no motor information is available, a Hot/Cold ratio value of 60% is usually a good starting point.
The MX control will adjust the actual motor overload content based on the programmed Hot/Cold Ratio set point and the present
running current of the motor so that the accumulated motor overload content will accurately track the thermal condition of the motor.
If the motor current is constant, the overload content will eventually reach a steady state value. This value is derived as follows:
Current 1
OLss = OL H/C Ratio × ×
FLA Current Imbalance Derate Factor
The running OL content is also adjusted based on the derating factor due to the presence of any current imbalances and or harmonics.
If the existing motor overload content is less than the calculated running OL content, the motor overload will exponentially increase
the overload content until the appropriate running overload content level is achieved. If the existing motor overload content is greater
than the calculated running OL content level, the overload will exponentially cool down or decrease to the appropriate running
107
8– THEORY OF OPERATION
Motor Overload
overload content level. The rate of the running motor overload heating or cooling is controlled by the Motor Cooling Time
parameter.
The following diagram illustrates how the current and the OL H/C Ratio parameter determine the steady state overload content. It
assumes there is no current imbalance.
100%FLA
Motor
50%FLA
Current
0%FLA
80 %
OL H/C
Ratio
30 %
0 %
80 %
Motor
Overload 40 %
Content 30 %
15 %
0 %
T0 T1 T2 T3
At time T0, the motor current is 100%FLA and the OL H/C Ratio is set at 30%. It is assumed that the motor has been running for
some time and the motor overload content has reached a steady state value of 30% (30% H/C Ratio x 100% FLA = 30%).
At time T1, the motor current drops to 50%FLA. The motor overload content exponentially cools to a new steady state value of 15%
(30% H/C Ratio x 50% FLA = 15%).
At time T2, the OL H/C Ratio is set to 80%. The motor overload content exponentially rises to a new steady state value of 40% (80%
H/C Ratio x 50% FLA = 40%).
At time T3 the motor current rises back up to 100%FLA. The motor overload content exponentially rises to a new steady state value
of 80% (80% H/C Ratio x 100% FLA= 80%).
If desired, separate overload classes can be programmed for use during starting and during running. The motor overload protection
may also be disabled during starting or during normal running. In order to enable separate overload settings the Independent Start /
Run OL parameter needs to be set on to allow independent overload operation. Once set to independent “ON”, the individual Start
and Run OL class parameters can be set to either off or the desired overload class settings.
The Starting OL parameter value is used for the motor overload calculations when the starter is starting the motor (kick mode,
acceleration, and running before up-to-speed has been declared). Once the motor has reached full speed and during deceleration or
braking, the Running OL class is used for the motor overload calculations. As the motor protection curves shift from the acceleration
curve to the running curve, the accumulated overload content will be retained to provide a seamless transition from one mode of
operation to the other.
Disabling the Starting OL function or using a higher OL class for the Starting OL can be useful on extremely high inertial loads such
as large centrifuges or high friction loads that require very long starting periods.
108
8– THEORY OF OPERATION
Motor Overload
NOTE: When Independent Start/Stop OL is set “OFF”, the running OL is used at all times.
NOTE: When one or the other overload is disabled, the Hot/Cold motor compensation is still active. Therefore the motor overload
content may still slowly increase or decrease depending on the measured motor current. However if the motor overload is disabled in
one of the operating modes, the motor overload content will be limited in that mode to a maximum of 99%. Therefore a motor
overload trip can not occur.
CAUTION: When both overloads are disabled, the accumulated overload content will be set to zero (0%) and the starter will
provide no motor overload protection. External motor overload protection must be provided to prevent motor damage and/or the risk
of fire in the case of a motor overload.
The Motor Cooling Time parameter is used to adjust the cooling rate of the motor overload. When the motor is stopped and cooling,
the accumulated motor overload content is reduced in an exponential manner.
5
t
OL Content = OL Content wh en Stopped * e CoolingTime
When the motor is stopped, the motor overload will cool as shown in the following figure.
100
90
80
70
Remaining OL Content %
60
12 min
15 min
50
20 min
30 min
40
30
30 min
20
12 min
10
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800
Time (sec)
If the motor manufacturer does not specify the motor cooling time, the following approximations for standard TEFC cast iron motors
based on frame size can be used:
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8– THEORY OF OPERATION
Motor Overload
For motors less than 300hp, another approximation based on allowable motor starts per hour can also be used to set an initial value of
the Motor Cooling Time parameter:
60 minutes
Motor Cooling Time (minutes) ≈
Starts per hour
The MX’s Cooling Time parameter is defined as the time that it takes for the motor to cool from 100% overload content to less than
1% overload content. Sometimes a motor manufacturer may provide a cooling time constant (τ or tau) value. In these cases, the MX
motor cooling time parameter should be set to five (5) times the specified time constant value.
When the motor is running, the Motor Cooling Time parameter and the H/C Ratio parameter settings control the motor OL content.
If the motor overload content is above the steady state OL running level (See section 8.1.6 Hot/Cold Motor Compensation for more
details) the motor OL will exponentially cool to the appropriate steady state OL level. When the motor is running, the cooling time
will be adjusted based on the measured current level and current imbalance level that the motor is operating at.
In all cases, the running motor cooling time will be shorter (motor will cool faster) than when the motor is stopped. The faster cooling
results because it is assumed that when a motor is running, cooling air is being applied to the motor.
The MX control has an emergency motor overload reset feature that allows the user to override the overload starter lockout.
To perform an emergency overload reset, simultaneously press the RESET and DOWN buttons on the keypad. An emergency overload
reset may also be performed by applying 120 Volts to a digital input that is configured as an emergency overload reset input or by
setting the emergency overload reset bit in the stator control modbus register
CAUTION: This feature should only be used in an emergency. Before an emergency reset is performed the cause of the motor
overload should be investigated to ensure that the motor is capable of restarting without causing undesired motor or load damage.
When the emergency motor overload reset is used, the accumulated motor overload content will be reset back to zero (0%).
Therefore the MX’s motor protection functions may not be able to fully protect the motor from damage during a restart after
performing an emergency motor overload reset.
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8 – THEORY OF OPERATION
General The motor service factor parameter should be set to the service factor of the motor. The service factor
is used to determine the “pick up” point for the overload calculations. If the service factor of the
motor is not known then the service factor should be set to 1.00.
NOTE: The NEC (National Electrical Code) does not allow the service factor to be set above 1.40.
Check with other local electrical codes for their requirements.
The National Electrical Code, article 430 Part C, allows for different overload multiplier factors
depending on the motor and operating conditions. NEC section 430-32 outlines the allowable service
factor for different motors as follows:
Example: If a motor operates at 0°C, then a 1.36 correction factor could be applied to the overload
multiplier. This could give a theoretical overload multiplier of 1.36 x 1.25 or 1.70. The highest legal
NEC approved value of overload multiplier is 1.40, so this could be used.
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8 – THEORY OF OPERATION
Acceleration Control
General The current ramp sets how the motor accelerates. The current ramp is a linear increase in current
from the initial setting to the maximum setting. The ramp time sets the speed of this linear current
increase. The following figure shows the relationships of these different ramp settings.
Current
Max
Current
Start command
Kick
Current
Initial
Current
Motor FLA
Time
Kick Time Ramp Time
Up To Speed Timer
Initial Current The initial current should be set to the level that allows the motor to begin rotating within a couple of
seconds of receiving a start command.
To adjust the initial current setting, give the starter a run command. Observe the motor to see how
long it takes before it begins rotating and then stop the unit. For every second that the motor doesn’t
rotate, increase the initial current by 20%. Typical loads will require an initial current in the range of
50% to 175%.
Maximum Current For most applications, the maximum current can be left at 600%. This will ensure that enough current
is applied to the motor to accelerate it to full speed.
The maximum current can also be set to a lower current limit. This is usually done to limit the
voltage drop on the power system or to limit the torque the motor produces to help prevent damage to
the driven load.
NOTE: The motor may achieve full speed at any time during the current ramp. This means that the
maximum current setting may not be reached. Therefore, the maximum current setting is the most
current that could ever reach the motor, and not necessarily the maximum current that will reach the
motor.
NOTE: When setting a current limit, the motor must be monitored to ensure that the current is high
enough to allow the motor to reach full speed under worst case load conditions.
Ramp Time The ramp time is the time it takes for the current to go from the initial current to the maximum
current. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate
slower, increase the ramp time.
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8 – THEORY OF OPERATION
Acceleration Control
If the ramp time expires before the motor reaches full speed, the starter will maintain the set
maximum current level until either the motor reaches full speed, the Up to Speed time expires, or the
motor thermal overload trips.
NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor will take
this time to accelerate to full speed. The motor and load may achieve full speed before the ramp time
expires if the application does not require the set ramp time and maximum current to reach full speed.
Alternatively, the motor and load may take longer than the set ramp time to achieve full speed.
General The kick current sets a constant current level that is applied to the motor before the ramp begins. The
kick current is only useful on motor loads that are hard to get rotating but then are much easier to
move once they are rotating. An example of a load that is hard to get rotating is a ball mill. The ball
mill requires a high torque to get it to rotate the first quarter turn (90°). Once the ball mill is past 90°
of rotation, the material inside will begin tumbling and it is easier to turn.
Kick Level The kick current parameter is usually set to a low value and then the kick time is adjusted to get the
motor rotating. If the kick time is set to more than 2.0 seconds without the motor rotating, increase
the kick current by 100% and re-adjust the kick time.
Kick Time The kick time adjustment should begin at 0.5 seconds and be adjusted by 0.1 or 0.2 second intervals
until the motor begins rotating. If the kick time is adjusted above 2.0 seconds without the motor
rotating, start over with a higher kick current setting.
General TruTorque acceleration control is a closed loop torque based control. The primary purpose of
TruTorque acceleration control is to smoothly start motors and to reduce the torque surge that can
occur as an AC induction motor comes up to speed. This torque surge can be a problem in
applications such as pumps and belt driven systems. In pumping applications, this torque surge can
result in a pressure peak as the motor comes up to speed. In most situations this small pressure peak
is not a problem. However in selected cases, even a small pressure rise can be highly undesirable. In
belt driven applications, TruTorque can prevent the slipping of belts as the motor reaches full speed.
Motor
Torque
Max Torque
Motor Running
Torque
Start command
Optional Kick
Current
Initial Torque
Time
Kick Time Ramp Time
Up To Speed Timer
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8 – THEORY OF OPERATION
Acceleration Control
TruTorque acceleration control can be very useful for a variety of applications. However it is best
used to start centrifugal pumps, fans, and other variable torque applications. TruTorque generally
should not be used in applications where the starting load varies greatly during the start such as with
a reciprocating compressor, where the starting load is very low, or where the starting load varies
greatly from one start to another. TruTorque control is not recommended for the starting of AC
synchronous motors.
Initial Torque This parameter sets the initial torque level that the motor will produce at the beginning of the starting
ramp profile. A typical value is 10% to 20%. If the motor starts too quickly or the initial torque level
is too high, reduce this parameter. If the motor does not start rotating within a few seconds after a
start is commanded, increase this parameter. If the value is set too low a “No Current at Run” fault
may occur.
Maximum Torque This parameter sets the final or maximum torque level that the motor will produce at the end of the
ramp time during acceleration. For a loaded motor, the maximum torque value initially should be set
to 100% or greater. If the maximum torque value is set too low, the motor may not produce enough
torque to reach full speed and may stall. On lightly loaded motors, this parameter may be reduced
below 100% to produce smoother starts.
If the motor can be started by using the default TruTorque acceleration parameter values or another
ramp profile, the Maximum Torque level can be determined more precisely so that the motor will
come up to speed in approximately the preset ramp time. In this case, while the motor is running
fully loaded, display the TruTorque percent (TT%) meter on the display. Record the value displayed.
The Maximum Torque level should then be set to the recorded full load value of TT% plus an
additional 10%. Restart the motor with this value to verify correct operation.
Note: When setting the Maximum Torque value the motor must be monitored to ensure that the
torque level is high enough to allow the motor to reach full speed under worst case load conditions.
Note: Depending on loading, the motor many achieve full speed at any time during the TruTorque
ramp. This means that the Maximum Torque level many never be achieved. Therefore, the
maximum torque level is the maximum TruTorque level that will be permitted. However the motor
torque may not necessarily reach this value during all starts.
Ramp Time When in TruTorque acceleration mode, the ramp time setting is the time it takes for the torque to go
from the initial torque setting to the maximum torque setting. To make the motor accelerate faster,
decrease the ramp time. To make the motor accelerate slower, increase the ramp time.
If the ramp time expires before the motor reaches full speed, the starter will maintain the Maximum
Torque level until either the motor reaches full speed, UTS timer expires, or the motor thermal
overload protection trips.
Note: Setting the ramp time to a specific value does not necessarily mean that the motor will take
that exact amount of time to accelerate to full speed. The motor and load may achieve full speed
before the ramp time expires if the load does not require the set ramp time or set torque level to reach
full speed. Alternately, the motor and load may take longer than the set ramp time to achieve full
speed depending on the parameter settings and load level.
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8 – THEORY OF OPERATION
Acceleration Control
General Power control is a closed loop power based acceleration control. The primary purpose of Power
controlled acceleration is to control and limit the power (kW) drawn from the power system and to
reduce the power surge that may occur as an AC induction motor comes up to speed. This power
surge can be a problem in applications that are operated on generators or other limited or “soft”
power systems. Power control also reduces the torque surge that can also occur as an AC induction
motor comes up to speed.
Motor Input
Power
Max Power
Motor Running
Power Level
Start command
Optional Kick
Current
Initial Power
Time
Kick Time Ramp Time
Up To Speed Timer
Power control acceleration can be very useful for a variety of applications. Power control generally
should not be used in applications where the starting load varies greatly during the start such as with
a reciprocating compressor. Power control is not recommended for starting of AC synchronous
motors.
Initial Power This parameter sets the initial power level that the motor will draw at the beginning of the starting
ramp profile. A typical value is usually 10% to 30%. If the motor starts too quickly or the initial
power level is too high, reduce this parameter. If the motor does not start rotating within a few
seconds after a start is commanded, increase this parameter. If this value is set too low a “No Current
at Run” fault may occur.
Maximum Power This parameter sets the final or maximum power level that the motor will produce at the end of the
ramp time during acceleration. For a loaded motor, the maximum power level initially should be set
to 100% or greater. If the maximum power level value is set too low, the motor may not produce
enough torque to reach full speed and may stall. On lightly loaded motors, this parameter may be
reduced below 100% to produce smoother starts.
If the motor can be started by using the default Power acceleration parameter values or the Current
control ramp, the Maximum Power level can be determined more precisely so that the motor will
come up to speed in approximately the preset ramp time. In this case, while the motor is running
fully loaded, display the Power percent (KW%) meter on the display. Record the value displayed.
The Maximum Power level should then be set to the recorded full load value of KW% plus an
additional 5% to 10%. Restart the motor with this value to verify correct operation.
Note: When setting the Maximum Power level, the motor must be monitored to ensure that the
starting power is high enough to allow the motor to reach full speed under worst case load conditions.
Note: Depending on loading, the motor may achieve full speed at any time during the Power ramp.
This means that the Maximum Power level may not be reached. Therefore, the maximum power
115
8 – THEORY OF OPERATION
Acceleration Control
level is the maximum power level that will be permitted. However, the motor power may not
necessarily reach this value during all starts.
Ramp Time When in Power acceleration mode, the ramp time setting is the time it takes for the power to go from
the initial power setting to the maximum power setting. To make the motor accelerate faster,
decrease the ramp time. To make the motor accelerate slower, increase the ramp time.
If the ramp time expires before the motor reaches full speed the starter will maintain the Maximum
Power level until either the motor reaches full speed, the UTS timer expires, or the motor thermal
overload protection trips.
Note : Setting the ramp time to a specific value does not necessarily mean that the motor will take
that exact amount of time to accelerate to full speed. The motor and load may achieve full speed
before the ramp time expires if the load does not require the set ramp time or set power level to reach
full speed. Alternately, the motor and load may take longer than the set ramp time to achieve full
speed depending on the parameter settings and load level.
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8 – THEORY OF OPERATION
Acceleration Control
General The open loop voltage ramp provides soft starting of a motor by increasing the voltage applied to motor from the Initial
Voltage setting to full (100%) line voltage. The ramp time sets the speed at which the voltage is increased. Because this
is an open loop control profile the motor current during starting will tend to be reduced; however, the current will not be
limited to any particular level. This starting mode it is not commonly used except in special circumstances. In most
applications, the use of one of the other closed loop starting profiles is recommended
Voltage
Full Voltage
Start
command
Optional Kick
Current
Initial Voltage
Time
Kick Time Ramp Time
Initial Voltage This parameter sets the initial voltage level that is applied to the motor. To adjust the starting voltage level, give the
starter a run command and observe the motor operation. If the motor starts too quickly reduce the initial voltage level. If
the motor does not start rotating immediately or starts too slowly then increase the initial voltage level until the motor just
starts to rotate when a start command is given. If the initial voltage level is set too low a Fault 39 – No Current at Run
may occur. In this case increase the initial voltage level to permit more current to initially flow to the motor.
Ramp Time The ramp time setting is the time that it takes for the applied voltage to go from the initial voltage level to the full voltage
(100%) level. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower
increase the ramp time.
Note: Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate
to full speed. The motor and load may achieve full speed before the ramp time expires if the application does not require
the set ramp time and/or voltage to reach full speed. Alternatively, the motor and load may take longer than the set ramp
time to achieve full speed.
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8 – THEORY OF OPERATION
Acceleration Control
UTS Timer When the start mode is set to open-loop voltage ramp acceleration the UTS Timer acts as an acceleration kick. When the
UTS timer expires full voltage will be applied to the motor. This feature can be used to reduce motor surging that may
occur near the end of an open loop voltage ramp start. If a surge occurs near the end of the ramp set the UTS timer to
expire at this time and restart the motor. If the surge still occurs set the UTS time to a lower time until the surging
subsides. If motor surging continues to be a problem it is recommended that one of the other standard MX closed-loop
starting profiles be used.
Voltage
Full Voltage
Start
command
Optional Kick
Current
Initial Voltage
Time
Kick Time Ramp
Time
UTS Time
118
8 – THEORY OF OPERATION
Acceleration Control
General Two independent current ramps and kick currents may be programmed. The use of two different
starting profiles can be very useful with applications that have varying starting loads such as
conveyors that can start either loaded or unloaded.
The Current Ramp 1 profile is programmed using the parameters Initial Current 1, Maximum
Current 1, and Ramp Time 1. The Current Ramp 2 is programmed using the parameters Initial
Current 2, Maximum Current 2, and Ramp Time 2. Kick Current 1 profile is programmed using the
parameters Kick Level 1 and Kick Time 1. Kick Current 2 profile is programmed using the
parameters Kick Level 2 and Kick Time 2.
Acceleration Ramp Selection Current Ramp 2 and Kick Current 2 starting profiles are selected by programming a digital input to
the Ramp Select function and then energizing that input by applying 120 Volts to it. When a digital
input is programmed to Ramp Select, but de-energized, Current Ramp 1 and Kick Current 1 are
selected. When no digital inputs are programmed to the Ramp Select function the Ramp 1 profile is
used.
The Ramp Select input only affects the starting profile when using a current ramp profile and during
a kick. The Ramp Select input does not affect the TruTorque ramp, Power ramp, or the Voltage ramp
profile (unless kicking is enabled at the beginning of those ramps).
The following table summarizes which parameters affect the starting profile when a digital input is
programmed to the Ramp Select function and that input is either energized or de-energized.
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8 – THEORY OF OPERATION
Acceleration Control
Changing Ramp Profiles The selected ramp profile may be changed during starting by changing the Ramp Select input. When
the Ramp Select input changes during ramping, control switches to the other profile as if it were
already in progress. It does not switch to the beginning of the other profile. Refer to the following
example below:
Note: Once the motor has achieved an up-to-speed status (UTS), changes to the Ramp
Select input will have no effect on the motor operation.
Ramp Profile 1
Kick Level 1
Maximum Current 1
Initial Current 1
Ramp Time 1
Kick Time 1
Ramp Profile 2
Maximum Current
2
Kick Level 2
Initial Current 2
Ramp Time 2
Kick Time 2
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8– THEORY OF OPERATION
Deceleration Control
Overview The deceleration control on the MX control uses an open loop voltage ramp. The control will ramp
the voltage down to decelerate the motor. The curve shows the motor voltage versus the decel setting.
Beginning Level This sets the starting voltage of the deceleration ramp. Most motors require the voltage to drop to
around 60% or lower before any significant deceleration is observed. Therefore, a good first setting
for this parameter is 35%.
To adjust this parameter, it is necessary to observe the motor operation as soon as a stop is
commanded. If the motor hunts (speed oscillations) at the beginning of the deceleration, then lower
the parameter by 5%. If the motor has a big drop in speed as soon as a stop is commanded, then raise
the parameter by 5%.
Some motors are very sensitive to the adjustment of this parameter. If a 5% adjustment changes the
motor from hunting to dropping in speed, then a smaller change of 1% or 2% may be necessary.
Ending Level This sets the final voltage for the deceleration ramp. In most cases, this parameter can be set to 10%
and the decel time can be used to adjust the deceleration rate. If the motor is coming to a stop too
quickly or if the starter continues to apply current to the motor after the motor has stopped, this
parameter can be increased in 5% increments to fix this.
Decel Time The decel time sets how quickly the motor decelerates. Usually a time of 30 seconds is a good
starting point. To make the motor take longer to decelerate, increase this parameter or to make the
motor decelerate quicker, decrease this parameter.
Note: Deceleration control will provide a smoother stop, however the motor will take longer to stop
than if it was just allowed to coast to stop.
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8 – THEORY OF OPERATION
Deceleration Control
8.4.2 TruTorque Deceleration
Overview TruTorque deceleration control is a closed loop deceleration control. This allows TruTorque
deceleration to be more consistent in cases of changing line voltage levels and varying motor load
conditions. TruTorque deceleration is best suited to pumping and compressor applications where
pressure surges, such as water hammer, must be eliminated. The MX controller will linearly reduce
the motor’s torque to smoothly decelerate the motor and load. TruTorque deceleration is very easy to
use with only two parameters to set.
Motor
Torque
Stop command
Motor Torque
Before Stop
Command
End Torque
Level
Time
Decel Time
Beginning Level TruTorque deceleration control automatically calculates the motor loading when the stop command
was given and uses this value as the beginning level for the TruTorque deceleration ramp. Therefore
there is no user parameter to set and the calculated beginning torque value provides a very smooth
transition from running to deceleration.
Ending Level The decel end level parameter sets the ending torque level for the TruTorque deceleration ramp
profile.
A typical TruTorque decel end level setting is between 10% and 20%. If the motor stops rotating
before the deceleration time has expired, increase this parameter value. If the motor is still rotating
when the deceleration time has expired, decrease this parameter value.
Decel Time The decel time sets the ramp time between the motor torque level when stop was commanded and the
decel end torque level.
If the motor stops rotating before the decel time has expired, decrease the decel time parameter. If
the motor is still rotating when the decel time expires, increase the decel time parameter.
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8– THEORY OF OPERATION
When the MX control Starter Type parameter (FUN 07, P64) is set to Wye-Delta, the MX control is configured to operate an
electromechanical Wye-Delta (Star-Delta) starter. When in Wye-Delta mode, all MX motor and starter protective functions except
bad SCR detection and power stack overload, are available to provide full motor and starter protection
The MX control utilizes an intelligent Wye to Delta transition algorithm. If during starting the measured motor current drops below
85% of FLA and more than 25% of the UTS / Transition Time (QST 09, P9) has elapsed then a Wye to Delta transition will occur.
The intelligent transition algorithm prevents unnecessarily prolonged motor starts thereby reducing motor heating. If a Wye to Delta
transition has not already occurred, a transition will always occur when the complete UTS / Transition Time (QST 09, P9) expires.
The MX control can operate two configurations of Wye-Delta starters, open transition and closed transition. An open transition
starter momentarily disconnects the motor from the input line during the transition from Wye to Delta operating mode. A closed
transition starter uses resistors that are inserted during the transition so that the motor is never completely disconnected from the input
line. The presence of these resistors in a closed transition starter smoothes the transition from Wye to Delta operating mode. A
typical closed transition Wye-Delta starter schematic is shown in Figure 10.
For the Wye-Delta starter mode to operate properly, one output relay needs to be programmed to the RUN output function and
another output relay needs to be programmed to the UTS output function. (Refer to parameters I/0 04-06, P42-44 for more
information)
Based on the typical closed transition schematic shown in Figure 10 – Wye Delta Motor Connection to the MX Control, when a start
command is given the starter will enter the Wye starting mode by energizing the relay programmed as RUN.
or
The measured motor current is less than 85% of FLA and at least 25% of the Transition Time (QST 09, P9) has elapsed.
3. A fault occurs.
When the Transition Time (QST 09, P9) expires, the starter will change from Wye starting mode to the Delta or normal running
mode by energizing the relay programmed as UTS. In Delta mode, the RUN and UTS relays are both energized and the motor is
connected in the normal running Delta configuration.
or
The measured motor current is less than 85% of FLA and at least 25% of the Transition Time (QST 09, P9) has elapsed.
5. When the 2M contactor is pulled in, feedback can be sent to the MX control board to confirm that the transition sequence
to Delta is complete.
The starter will remain in the Delta or running mode until the start command is removed or a fault occurs.
Usually the MX intelligent Wye to Delta transition algorithm provides an optimal transition point that minimizes the transient current
and torque surges that can occur. However sometimes, based on the motor and loading, the Wye to Delta transition will occur only
after the Transition Time has expired. In order to reduce the current surge that can take place during the transition from Wye to Delta
mode, the Transition Time parameter (QST 09, P9) should be adjusted so that the transition occurs as close to full speed as possible
within the constraints of the load. If the transition time is set too short, a large current and torque surge may occur during the
transition. If the transition time is set too long, the motor may not have sufficient torque to continue accelerating when in Wye mode
and may stop accelerating at a low speed until the transition to Delta mode occurs. If this occurs, the start is unnecessarily prolonged
and motor heating is increased.
A typical closed transition Wye-Delta starting current profile is shown in Figure 23.
600%
500%
% Full 400%
Load
Motor
Current 300%
200%
100%
0% 100 %
% speed
A digital input (I/O 01-03, P39-41) can be programmed as a 2M contactor feedback input. This input provides verification that the
2M contactor has fully closed preventing operation when the transition resistors are still connected in the motor circuit. The use of
this feedback is recommended to prevent the overheating of the transition resistors if the 2M contactor does not close properly. The
2M confirmation trip time can be adjusted by modifying the Bypass / 2M Confirm parameter (I/O 16, P54).
Note: When in Wye-Delta mode, the acceleration ramp, kick, and deceleration settings have no effect on motor operation.
Note: When in Wye-Delta mode, the SCR gate outputs are disabled.
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8– THEORY OF OPERATION
Phase Control
When the MX control Starter Type parameter (FUN 07, P64) is set to Phase Control, the MX control is configured to operate as a
phase controller or voltage follower. This is an open loop control mode. When a start command is given, the RUN programmed
relays outputs will energize. The firing angles of the SCRs will be directly controlled based on voltage or current applied to the
Analog Input.
100
90
80
70
SCR phase angle (%)
60
SCR phase
angle
50 command
40
30
20
10
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Analog Input (%)
A reference input value of 0% will result in no output. A reference input value of 100% will result in full (100%) output voltage.
The actual input voltage / current that results in a given output can be adjusted through the use of the Analog Input Offset (I/O 11,
P49) and the Analog Input Span (I/O 10, P48) parameters.
The Phase Control mode has many uses. Two typical applications are use in master/slave starter configurations and as a basic phase
controller.
Phase Controller:
When in Phase Control mode, the MX controller can function as a general phase controller. Phase control can be used to directly
control the voltage applied to motors, resistive heaters, etc. When in Voltage Control mode, the phase angle of the SCRs and hence
the voltage applied is directly controlled based on the measured analog input signal. The MX controller’s reference command can be
generated from any 0-10V, 0-20mA, or similar sources such as a potentiometer, another MX controller, or an external controller
such as a PLC.
In the master / slave configuration, one “master” starter can directly control the output of one or more slave starters. To utilize the
master / slave configuration, one starter needs to be defined as the “master” starter. The Starter Type parameter (FUN 07, P64) of the
“master” starter should be configured appropriately as a Soft Starter (normal or ID), Phase Controller, or Current Follower. If
configured as a soft starter, the acceleration and deceleration profiles will need to be configured for proper operation.
1. The analog output of the master MX control card needs to be connected to the analog input(s) of the slave card(s).
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8 – THEORY OF OPERATION
Phase Control
2. The master MX control card’s analog output needs to be configured. Set the Analog Output Function parameter (I/O 12,
P50) to option 10 or “0 – 100% firing”. The analog output span parameter (I/O 13, P51) should be set to provide a 0 –
10V or 0-20 milliamp output to the slave starter(s). Adjust analog output jumper (JP1) to provide either a voltage or a
current output.
Set the slave MX control card’s Starter Type parameter (FUN 07, P64) to Phase Control and verify that the Analog input
offset (I/O 11, P49) and span (I/O 10, P48) parameters are set to accept the master signal.
3. The slave MX control cards need to be provided with a start command from the master MX card. A RUN programmed
relay from the master MX controller can be used to provide the start command to the slave controllers. The slave card(s)
Control Source parameter settings need to be set appropriately.
4. The slave MX control card analog input(s) need to be configured for the appropriate voltage or current input signal type.
Set the analog input jumper (JP3) to the desired input type.
Note: The power stack must be rated for continuous non-bypassed duty in order to operate in Phase Control mode
continuously, NO BYPASS.
Note: When operating in Phase Control mode, the acceleration ramp, kick, and deceleration settings have no effect on
operation.
Note: When in Phase Control mode the following motor / starter protective functions are available:
- Current Imbalance
- Over Current
- Under Current
- Over Voltage
- Under Voltage
- Over Frequency
- Under Frequency
- Phase Loss
- Phase Rotation
- Motor OL
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8 – THEORY OF OPERATION
Current Follower
When the MX control Starter Type parameter (FUN07, P64) is set to Current Follower, the MX control is configured to operate as a
Closed Loop current follower. Current Follower mode can be used to control the current applied to motors, resistive heaters, etc.
The Current Follower mode uses the analog input to receive the desired current command and controls the SCRs to output the
commanded current. The MX controllers reference command can be generated from any 0-10V, 0-20mA, 4-20mA source such as a
potentiometer, another MX controller, or an external controller such as a PLC. When a start command is given, the RUN
programmed relay output will energize and the SCRs will be gated.
100
90
80
70
Current Output (% FLA)
60
Current
Output
50
40
30
20
10
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Analog Input (%)
A reference input value of 0% will result in no output. A reference input value of 100% will result in a current output equal to the
FLA setting (QST1, P1). The actual voltage or current input that results in a given output can be adjusted through the use of the
Analog Input Offset (I/O 11, P49) and Analog Input Span (I/O 10, P48) user parameters.
Note: The power stack must be rated for continuous non-bypassed duty in order to operate in Current Follower mode continuously.
Note: When operating in Current Follower mode, the acceleration ramp, kick, and deceleration settings have no effect on operation.
Note: When in Current Follower mode the following motor / starter protective functions are available:
127
8– THEORY OF OPERATION
When the MX control Starter Type parameter (FUN 07, P64) is set to ATL, the MX control is configured to operate an
electromechanical full voltage or across-the-line (ATL) starter.
In the ATL configuration, the MX controller expects that the motor contactor (1M) will be directly controlled by a digital output
relay that is programmed for the RUN function. Therefore, when a start command is given, the RUN programmed relay will energize
the motor contactor, which will apply power to the motor. When the MX controller has determined that the motor has reached full
speed, the up-to-speed (UTS) condition will be indicated by energizing the UTS programmed relays. When configured as an ATL
starter, all MX motor and starter protective functions except bad SCR detection and power stack overload are available to provide full
motor and starter protection.
L1 L2 L3
To TB6 (SCR 2) K2
To TB8 (SCR 3) K3
1M
Voltage &
Frequenc
y to MX
Line
T2
T1 T3
MOTOR
Control Power
DIN#2 DIN#2
Input Common
1M MX
1M
Run
MX
Note: When in ATL mode, the acceleration ramp, kick, and deceleration settings have no effect on motor operation.
Note: When in ATL mode, the SCR gate outputs are disabled.
128
8 – THEORY OF OPERATION
15.0K O
D2
475 O
D2/D3
Com
15.0K O
1M O
AIN+
499 O
JP 3
AIN-
1M O
20.0K O
20.0K O
365 K O
+ 15V
0.1 ?f
1KO
36.0K O 10 O
10 K O 0.1 ?f AOUT
499 O
JP 1
COM
129
8-THEORY OF OPERATION
Modbus Register Addresses The Modbus specification defines holding registers to begin at 40001 and input registers to begin at
30001. Holding registers may be read and written. Input registers may only be read.
In the MX Control, the register maps are identical for both the holding registers and the input
registers. For example, the Motor FLA parameter is available both in holding register 40050 and in
input register 30050. This is why the register addresses in the appendix are listed with both numbers
(e.g. 30050/40050).
Cable Specifications Good quality twisted, shielded communications cable should be used when connecting to the Modbus
port on the MX Control. The cable should contain two twisted pairs and have an overall shield. Use
one pair of conductors for the A(-) and B(+) signals. Use the other pair of conductors for the
Common signal. The cable should adhere to the following specifications.
• Conductors: 2 twisted pair
• Impedance: 100 Ohm to 120 Ohm
• Capacitance: 16 pF/ft or less
• Shield: Overall shield or individual pair shields
Examples of cables that meet these specifications are Belden part number 9842 and Alpha Wire part
number 6412.
Terminating Resistors The MX Control contains a jumper site (JP2) located next to the Modbus connection terminals for
installing a 120 Ohm impedance matching terminating resistor. Installing a jumper on JP2 connects a
120 Ohm resistor between the RS-485 A(-) and B(+) lines.
The purpose of terminating resistors is to eliminate signal reflections that can occur at the end of a
network trunk line. In general, terminating resistors are not needed unless the bit rate is very high, or
the network is very long. In fact, terminating resistors place a large load on the network and may
reduce the number of drops that may be placed on the network.
The maximum baud rate of 19,200 supported by the MX Control is not high enough to warrant a
terminating resistor unless the network is extremely long (3,000 feet or more). A jumper should only
be installed on the MX if signal reflection is known to be a problem and only if the MX Control is at
the end of the network. Terminating resistors should never be installed on nodes that are not at the
end of the network.
Grounding RS-485 buses with isolated nodes are most immune to noise when the bus is not connected to earth
ground at any point. If electrical codes require that the bus be connected to earth ground, then the
Common signal should be connected to earth ground at one point and one point only. If the Common
signal is connected to earth ground at more than one point, then significant currents can flow through
the Common signal when earth ground potentials are different at those points. This can cause damage
to devices attached to the bus.
Shielding The shield should be continuous from one end of the trunk to the other. The shield must be tied to the
RS-485 Common signal at one point and one point only. If the shield is not tied to Common at any
point or is tied to Common at more than one point, then its effectiveness at eliminating noise is
greatly reduced.
130
8 – THEORY OF OPERATION
Starter
Controller
or
Computer
The terminating resistors in many cases are not required. If there is a lot of noise on the line or the line is several hundred (100) feet
long or greater, then the terminating resistors may be required. The resistor is 120 ohm ¼ Watt in size.
The shield, which is not shown, is connected to ground at one end of the line, not at each device. If connected at each device,
ground loops may be induced in the starters.
IMPORTANT
DO NOT CREATE STUBS
CABLES MUST GO TO
EACH STARTER
Right
Wrong
131
8-THEORY OF OPERATION
132
9 Technical Information
133
9-TECHNICAL INFORMATION
Technical Specifications
The physical specifications of the starter vary depending upon its configuration. The applicable motor current determines the
configuration and its specific application requirements.
This document covers the control electronics and several power sections:
• MX control board
• RB Power Stacks with Bypass, Integral and Separate
• RC Power Stacks, Continuous operation, NO bypass
Benshaw’s starters are capable of operating at altitudes up to 3,300 feet (1000 meters) without requiring altitude derating. provides
the derating percentage to be considered when using a starter above 3,300 feet (1000 meters).
9.4 Approvals
CE Mark
134
9-TECHNICAL INFORMATION
Technical Specifications
9.7 MX Control Board
Table 9 – Terminals
Function Terminal Number Description
TB1
Control Power Input N, neutral 96 – 144V AC input
L, line 45VA current requirements
G, ground Line Frequency, 23 to 72Hz
Relay Output R1 NC1: Normally Closed Relay Output, SPDT form C
RC1:Common 5 Amp, 125VAC, resistive
NO1:Normally Open 1 Amp, 125VAC, 0.4PF
100VA Inrush
Relay Output R2 & R3 NC2, RC2, NO2 Relay Output, SPDT form C
NC3, RC3, NO3 16 Amp, 250VAC, resistive
8 Amp, 250VAC, 0.4PF
2000VA Inrush
TB2
Digital Inputs Start, DI1, S/DI1 Com 120V AC digital input, 2500V optical isolation, 4mA cur. draw
Start & DI1 Off = 0 to 35 VAC, On = 60 to 120VAC
See Figure 26 – Digital Input Simplified Schematic
Digital Inputs DI2, DI3, 120V AC digital input, 2500V optical isolation, 4mA cur. draw
DI2 & DI3 DI2/DI3 Com Off = 0 to 35 VAC, On = 60 to 120V AC
Serial Comm. (Slave) SA-, SB+, SCOM, Modbus slave serial communication port.
SHLD RS485 interface, SHLD is chassis ground
Data Rates; 19.2k baud maximum Modbus RTU
2500V Optical Isolation
Serial Comm MA-, MB+, MCOM, Factory Use Only, not isolated
SHLD
TB12
Analog Output AOUT, COM, SHLD Voltage or Current Output, selectable by JP1
Voltage; 0-10VDC (20mA Maximum),
Current; 0-20mA, Software scalable, 500ohm load max.
Accuracy ±1.5% Full Scale
Update rate: 25msec.
See Figure 28 – Analog Output Simplified Schematic
TB13
Analog Input AIN+, ANI-, SHLD Voltage or Current Input, selectable by JP3
Voltage; 0-10VDC, 1 Meg. impedance
Current; 0-20mA, 499 ohm impedance, Software scalable,
Accuracy ± 3% of full scale
See Figure 27 – Analog Input Simplified Schematic
Reference Supply AIN PWR 10V DC (4 mA Maximum) Reference Source
Jumpers
JP1 Analog Output Voltage output when installed, Current loop removed
JP3 Analog Input Current input when installed, Voltage input removed
JP0, JP2,JD3 Factory Use Only
135
9-TECHNICAL INFORMATION
Technical Specifications
The terminals can support 1- 14 AWG wire or 2-16 AWG wires or smaller.
The terminals on the control board have a torque rating of 3.5-inch lb. or 0.4nm. This MUST be followed or damage will occur to
the terminals.
Table 10 - Connectors
Connectors Description
Aux Power TB0 120V AC, 5 amps, Aux. Connector for control voltage
Current Transformers TB3 CT connection for CT1, CT2 and CT3
(CT) Molex Connector: #39-01-2065
Connection Molex Connector Pins: #39-00-0090 crimp,
SCR Connection TB4 Cathode and Gate for SCR # 1
SCR Connection TB5 Cathode and Gate for SCR # 4
SCR Connection TB6 Cathode and Gate for SCR # 2
SCR Connection TB7 Cathode and Gate for SCR # 5
SCR Connection TB8 Cathode and Gate for SCR # 3
SCR Connection TB9 Cathode and Gate for SCR # 6
Molex Connector for gates: #39-01-3028
Molex Connector pins: #39-00-0056 crimp,
Remote Display Conn 3 Remote Display or Option Board Interface
TB10, Conn 4 Factory Use Only
Table 11 – Accuracy
Internal Measurements
CT Inputs Conversion; True RMS, Sampling @ 1.562kHz
Line Voltage Inputs Conversion; True RMS,
Range; 100VAC to 600VAC ± 10%
Metering
Current 0 – 40,000 Amps ± 3%
Voltage 0 – 660 Volts ± 3%
Watts 0 – 9,999 MW ± 5%
Volts-Amps 0 – 9,999 MVA ± 5%
Watt-Hours 0 – 10,000 MWh ± 5%
PF -0.01 to +0.01 (Lag & Lead) ± 5%
Line Frequency 23 – 72 Hz ± 0.1 Hz
Ground Fault 5 – 100% FLA ± 5% (Machine Protection)
Run Time ± 3 seconds per 24 hour period
Analog Input Accuracy ± 3% of full scale
Analog Output Accuracy ±1.5% of full scale
Note: Percent accuracy’s are percent of full scale of the given ranges, Current = Motor FLA Full
Range, Voltage = 660V, Watts/Volts-Amps/Watt-Hours = Motor & Voltage range
136
10 Appendix
137
10-APPENDIX
List of Tables
Table 1 – CT Ratios and Burden Switch Settings.................................................................................................................................................10
Table 2 – LED Special Characters Displayed......................................................................................................................................................14
Table 3 – 2x16 Remote Keypad LED Functions .................................................................................................................................................17
Table 4 – Description of the Keys on the LCD Remote Keypad.........................................................................................................................18
Table 5 – Operate Screen Section A.....................................................................................................................................................................19
Table 6 – Operate Screen Section B .....................................................................................................................................................................19
Table 7 – Operate Screen Section SS....................................................................................................................................................................19
Table 8 – Environmental Ratings .......................................................................................................................................................................134
Table 9 – Terminals ............................................................................................................................................................................................135
Table 10 - Connectors.........................................................................................................................................................................................136
Table 11 – Accuracy ...........................................................................................................................................................................................136
List of Figures
Figure 1 – Control Board Layout ...........................................................................................................................................................................8
Figure 2 – CT Inputs and CT switches ...................................................................................................................................................................9
Figure 3 – MX Control Board Analog Jumper Placement ...................................................................................................................................11
Figure 4 – Basic Wiring Diagram.........................................................................................................................................................................12
Figure 5 – Standard Keypad and Display.............................................................................................................................................................14
Figure 6 – LCD Remote Keypad..........................................................................................................................................................................17
Figure 7 – Local Remote Source...........................................................................................................................................................................40
Figure 8 – Typical Motor Connection..................................................................................................................................................................84
Figure 9 – Typical Inside Delta Motor Connection..............................................................................................................................................85
Figure 10 – Wye Delta Motor Connection to the MX Control ............................................................................................................................86
Figure 11 – A typical ATL starter schematic to the MX Control ........................................................................................................................88
Figure 12 – Overload Derated for Current Imbalance........................................................................................................................................107
Figure 13 – Motor Overload H/C Ratio Example...............................................................................................................................................108
Figure 14 – Motor Cooling While Stopped Curves............................................................................................................................................109
Figure 15 – Current Ramp ..................................................................................................................................................................................112
Figure 16 – TruTorque Ramp .............................................................................................................................................................................113
Figure 17 – Power Ramp ....................................................................................................................................................................................115
Figure 18 – Voltage Ramp..................................................................................................................................................................................117
Figure 19 - Effect of UTS Timer on Voltage Ramp ...........................................................................................................................................118
Figure 20 - Ramp Select Change During Start ...................................................................................................................................................120
Figure 21 – Motor Voltage Versus Decel Level.................................................................................................................................................121
Figure 22 – TruTorque Deceleration ..................................................................................................................................................................122
Figure 23 – Wye Delta Profile............................................................................................................................................................................124
Figure 24 – Phase Control Mode........................................................................................................................................................................125
Figure 25 – ATL Starter Schematic....................................................................................................................................................................128
Figure 26 – Digital Input Simplified Schematic.................................................................................................................................................129
Figure 27 – Analog Input Simplified Schematic ................................................................................................................................................129
Figure 28 – Analog Output Simplified Schematic..............................................................................................................................................129
138
10-APPENDIX
Appendix A – CE Mark
Model Numbers:
Model Number Model Number Model Number Model Number
RBX-1-S-027A-11C RBX-1-S-240A-15C RCX-1-S-027A-11C RCX-1-S-240A-15C
RBX-1-S-040A-11C RBX-1-S-302A-15C RCX-1-S-040A-11C RCX-1-S-302A-15C
RBX-1-S-052A-12C RBX-1-S-361A-16C RCX-1-S-052A-12C RCX-1-S-361A-16C
RBX-1-S-065A-12C RBX-1-S-414A-17C RCX-1-S-065A-12C RCX-1-S-414A-17C
RBX-1-S-077A-13C RBX-1-S-477A-17C RCX-1-S-077A-13C RCX-1-S-477A-17C
RBX-1-S-096A-13C RBX-1-S-515A-17C RCX-1-S-096A-13C RCX-1-S-515A-17C
RBX-1-S-125A-14C RBX-1-S-590A-18C RCX-1-S-125A-14C RCX-1-S-590A-18C
RBX-1-S-156A-14C RBX-1-S-720A-19C RCX-1-S-156A-14C RCX-1-S-720A-19C
RBX-1-S-180A-14C RBX-1-S-838A-20C RCX-1-S-180A-14C RCX-1-S-838A-20C
RBX-1-S-180A-15C RCX-1-S-180A-15C
The before mentioned products comply with the following EU directives and Standards:
Safety: UL 508 Standard for Industrial Control Equipment covering devices for starting, stopping, regulating,
controlling, or protecting electric motors with ratings of 1500 volts or less.
The products referenced above are for the use of control of AC motors.
The use in residential and commercial premises (Class B) requires an optional EMC series filter.
Via internal mechanisms and Quality Control, it is verified that these products conform to the
requirements of the Directive and applicable standards.
139
10-APPENDIX
Appendix B – Fault Codes
140
10-APPENDIX
Appendix C – Alarm Codes
The following is a list of all MX alarm codes. The alarm codes correspond to associated fault codes. In general, an alarm indicates a
condition that if continued, will result in the associated fault.
142
10-APPENDIX
Following is the Modbus Register Map. Note that all information may be accessed either through the Input registers (30000
addresses) or through the Holding registers (40000 addresses).
Modbus Registers
Absolute Register Description R/W Range Units
Address
30020/40020 Starter Control R/W Bit 0: Run/Stop -
Bit 1: Fault Reset
Bit 2: Emergency overload rset
Bit 3: Local/Remote
Bit 4: Heat Disable
Bit 5: Ramp Select
Bit 13: Relay 3
Bit 14: Relay 2
Bit 15: Relay 1
30021/40021 Starter Status R Bit 0: Ready -
Bit 1: Running
Bit 2: UTS
Bit 3: Alarm
Bit 4: Fault
Bit 5: Lockout
30022/40022 Input Status R Bit 0: Start -
Bit 1: DI 1
Bit 2: DI 2
Bit 3: DI 3
30023/40023 Alarm Status 1 R Bit 0: “A OL” – Motor overload -
Bit 1: “A 10” – Phase rotation not ABC
Bit 2: “A 11” – Phase rotation not CBA
Bit 3: “A 12” – Low Line Frequency
Bit 4: “A 13” – High Line Frequency
Bit 5: “A 14” – Phase rotation not SPH
Bit 6: “A 15” – Phase rotation not 3 Phase
Bit 7: “A 21” – Low line L1-L2
Bit 8: “A 22” – Low line L2-L3
Bit 9: “A 23” – Low line L3-L1
Bit 10: “A 24” – High line L1-L2
Bit 11: “A 25” – High line L2-L3
Bit 12: “A 26” – High line L3-L1
Bit 13: “A 27” – Phase loss
Bit 14: “noL” – No line
Bit 15: Reserved
30024/40024 Alarm Status 2 R Bit 0: “A 31” – Overcurrent -
Bit 1: “A 34” – Undercurrent
Bit 2: Reserved
Bit 3: Reserved
Bit 4: “A 37” – Current imbalance
Bit 5: “A 38” – Ground fault
Bit 6: “A 47” – Stack overload
Bit 7: Reserved
Bit 8: “A 71” – Analog Input Trip
Bit 9: Reserved
30025/40025 Lockout Status R Bit 0: “L OL” – Motor overload -
Bit 1: “L Ot” – Stack overload
Bit 2: “L CP” – Control power
30026/40026 Present Fault Code R See Appndix B for list of codes
30027/40027 Average Current R Arms
30028/40028 L1 Current R Arms
30029/40029 L2 Current R Arms
30030/40030 L3 Current R Arms
30031/40031 Current Imbalance R 0.1 %
143
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30032/40032 Residual Ground Fault R %FLA
Current
30033/40033 Average Voltage R Vrms
30034/40034 L1-L2 Voltage R Vrms
30035/40035 L2-L3 Voltage R Vrms
30036/40036 L3-L1 Voltage R Vrms
30037/40037 Motor Overload R %
30038/40038 Power Factor R -99 – +100 0.01
(in 16-bit two’s compliment signed format)
30039/40039 Watts (lower 16 Bits) R (in 32 bit unsigned interger format) kW
30040/40040 Watts (upper16 Bits)
30041/40041 VA (lower 16 Bits) R (in 32 bit unsigned interger format) kVA
30042/40042 VA (upper 16 Bits)
30043/40043 VARS (lower 16 Bits) (in 32 bit two’s compliment signed interger
30044/40044 VARS (uper 16 Bits) format)
30045/40045 kW hour (lower 16 Bits) R 0 – 999 kWh
30046/40046 KW hours (upper 16 Bits)
30047/40047 Phase Order R 0: no line -
1: ABC
2: CBA
3: SPH
30048/40048 Line Frequency R 230 – 720, 0.1 Hz
or 0 if no line
30049/40049 Analog Input R -1000 – +1000 0.1 %
(in 16-bit two’s compliment signed format)
30050/40050 Analog Output R 0 – 1000 0.1%
Running Time R 0 – 65535 Hours
Running Time R 0 – 59 Minutes
Starts R 0 – 65535 -
TruTorque % R %
Power % R %
30101/40101 Motor FLA R/W 1 – 6400 Arms
30102/40102 Motor Service Factor R/W 100 – 199 0.01
30103/40103 Independent Start/Run R/W 0: Disabled -
Motor Overloads 1: Enabled
30104/40104 Motor Overload Running R/W 0: Disabled -
Enable 1: Enabled
30105/40105 Motor Overload Running R/W 1 – 40 -
Class
30106/40106 Motor Overload Starting R/W 0: Disabled -
Enable 1: Enabled
30107/40107 Motor Overload Starting R/W 1 – 40 -
Class
30108/40108 Motor Overload Hot/Cold R/W 0 – 99 %
Ratio
30109/40109 Motor Overload Cooling R/W 1 – 9999 0.1 Min
Time
30110/40110 Local Source R/W 0: Keypad -
1: Terminal
2: Serial
30111/40111 Remote Source R/W 0: Keypad -
1: Terminal
2: Serial
30112/40112 Start Mode R/W 0: Open Loop Voltage Ramp -
1: Closed Loop Current Ramp
2: TruTorque Ramp
3: Power Ramp
30113/40113 Initial Motor Current 1 R/W 50 – 600 % FLA
144
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30114/40114 Maximum Motor Current R/W 100 – 800 % FLA
1
30115/40115 Ramp Time 1 R/W 0 – 300 Sec
30116/40116 Initial Motor Current 2 R/W 50 – 600 % FLA
30117/40117 Maximum Motor Current R/W 100 – 800 % FLA
2
30118/40118 Ramp Time 2 R/W 0 – 300 Sec
30119/40119 UTS Time R/W 1 – 900 Sec
30120/40120 Initial V/T/P R/W 1 – 100 %
30121/40121 Maximum V/T R/W 10 – 325 %
30122/40122 Stop Mode R/W 0: Coast -
1: Voltage Decel
2: TruTroque Decel
30123/40123 Decel Begin Level R/W 100 – 1 %
30124/40124 Decel End Level R/W 99 – 1 %
30125/40125 Decel Time R/W 1 – 180 Sec
30126/40126 Kick Enable 1 R/W 0: Disabled -
1: Enabled
30127/40127 Kick Current Level 1 R/W 100 – 800 % FLA
30128/40128 Kick Time 1 R/W 1 – 100 100 mSec
30129/40129 Kick Enable 2 R/W 0: Disabled -
1: Enabled
30130/40130 Kick Current Level 2 R/W 100 – 800 % FLA
30131/40131 Kick Time 2 R/W 1 – 100 100 mSec
145
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30132/40132 Rated RMS Voltage R/W 0: 100 Vrms
1: 110
2: 120
3: 200
4: 208
5: 220
6: 230
7: 240
8: 350
9: 380
10: 400
11: 415
12: 440
13: 460
14: 480
15: 500
16: 525
17: 575
18: 600
19: 660
20: 690
21: 1000
22: 1140
23: 2200
24: 2300
25: 2400
26: 3300
27: 4160
28: 4600
29: 4800
30: 6000
31: 6600
32: 6900
33: 10000
34: 11000
35: 11500
36: 12000
37: 12470
38: 13200
39: 13800
30133/40133 Input Phase Sensitivity R/W 0: Ins -
1: ABC
2: CBA
3: SPH
30134/40134 Motor Rated Power R/W 1–100 -
Factor
30135/40135 Overcurrent Enable R/W 0: Disabled -
1: Enabled
30136/40136 Overcurrent Level R/W 50 – 800 % FLA
30137/40137 Overcurrent Delay Time R/W 0: Disabled -
Enable 1: Enabled
30138/40138 Overcurrent Delay Time R/W 1 – 900 100 mSec
30139/40139 Undercurrent Trip Enable R/W 0: Disabled -
1: Enabled
30140/40140 Undercurrent Trip Level R/W 5 – 100 % FLA
30141/40141 Undercurrent Delay Time R/W 0: Disabled -
Enable 1: Enabled
30142/40142 Undercurrent Trip Delay R/W 1 – 900 100 mSec
Time
146
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30143/40143 Current Imbalance Trip R/W 0: Disabled -
Enable 1: Enabled
30144/40144 Current Imbalance Trip R/W 5 – 40 %
Level
30145/40145 Ground Fault Trip Enable R/W 0: Disabled -
1: Enabled
30146/40146 Ground Fault Trip Level R/W 5 – 100 % FLA
30147/40147 Over Voltage Trip Enable R/W 0: Disabled -
1: Enabled
30148/40148 Over Voltage Trip Level R/W 1 – 40 %
30149/40149 Under Voltage Trip R/W 0: Disabled -
Enable 1: Enabled
30150/40150 Under Voltage Trip Level R/W 1 – 40 %
30151/40151 Over/Under Voltage R/W 1 – 900 100 mSec
Delay Time
30152/40152 Auto Fault Reset Enable R/W 0: Disabled -
1: Enabled
30153/40153 Auto Fault Reset Delay R/W 1 – 900 100 mSec
Time
30154/40154 Controlled Fault Stop R/W 0: Disabled -
1: Enabled
30155/40155 DI 1 Configuration R/W 0: Off -
30156/40156 DI 2 Configuration 1: Stop
30157/40157 DI 3 Configuration 2: Fault High
3: Fault Low
4: Fault Reset
5: Bypass / 2M Feedback (F48)
6: Emergency Motor OL Reset
7: Local / Remote Control Source
8: Heat Disable
9: Heat Enable
10: Ramp Select
30158/40158 R1 Configuration R/W 0: Off -
30159/40159 R2 Configuration 1: Fault (fail safe)
30160/40160 R3 Configuration 2: Fault (non fail safe)
3: Running
4: Up To Speed
5: Alarm
6: Ready
7: Locked Out
8: Over Current Alarm
9: Under Current Alarm
10: Overload Alarm
11: Shunt Trip (fail safe)
12: Shunt Trip (non fail safe)
13: Faulted on Ground Fault
14: In Energy Saver Mode
15: Heating
30161/40161 Analog Input Trip Enable R/W 0: Disabled -
1: Enabled
30162/40162 Analog Input Trip Type R/W 0: Low – Fault below preset level -
1: High – Fault above preset level
30163/40163 Analog Input Trip Level R/W 0 – 100 %
30164/40164 Analog Input Trip Delay R/W 1 – 900 100 mSec
Time
30165/40165 Analog Input Span R/W 1 – 100 %
30166/40166 Analog Input Offset R/W 0 – 99 %
147
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30167/40167 Analog Output Function R/W 0: Off (no output) -
1: Ave. Current (0 – 200% FLA)
2: Ave. Current (0 – 800% FLA)
3: Ave. Voltage
(0 – 150% Rated)
4: Thermal Overload %
5: kW (0 – 10kW)
6: kW (0 – 100kW)
7: kW (0 – 1MW)
8: kW (0 – 10MW)
9: Analog Input
10: Output Voltage to Motor (based on
firing angle)
11: Calibrate (full 100% output)
30168/40168 Analog Output Span R/W 1 – 125 %
30169/40169 Analog Output Offset R/W 0 – 99 %
30170/40170 Inline Enable R/W 0: Disabled -
1: Enabled
30171/40171 Inline Delay Time R/W 10 – 100 100 mSec
30172/40172 Bypass Feedback Time R/W 1 – 50 100 mSec
30173/40173 Keypad Stop Disable R/W 0: Disabled -
1: Enabled
30174/40174 Reserved
30175/40175 Reserved
30176/40176 Reserved
30177/40177 Modbus Timeout Enable R/W 0: Disabled -
1: Enabled
30178/40178 Modbus Timeout R/W 1 – 120 Sec
30179/40179 CT Ratio (x:1) R/W 0: 72:1 -
1: 96:1
2: 144:1
3: 288:1
4: 864:1
5: 1320:1
6: 2640:1
7: 2880:1
8: 3900:1
9 5760:1
10: 8000:1
11: 14.4K:1
12: 28.8K:1
30180/40180 Energy Saver Enable R/W 0: Disabled
1: Enabled
30181/40181 Heater / Anti-Windmill R/W 0: Disabled -
Enable 1: Enabled
30182/40182 Heater / Anti-Windmill R/W 1 – 25 % FLA
Level
30183/40183 Starter Type R/W 0: Normal (Outside Delta) -
1: Inside Delta
2: Wye-Delta
3: Phase Controller
4: Current Follower
5: Across the Line (Full Voltage)
148
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30184/40184 LED Display Meter R/W 0: Status -
1: Ave Current
2: L1 Current
3: L2 Current
4: L3 Current
5: Current Imbalance %
6: Ground Fault
7: Ave. Volts
8: L1-L2 Volts
9: L2-L3 Volts
10: L3-L1 Volts
11: Overload
12: Power Factor
13: Watts
14: VA
15: VARS
16: kW hours
17: MW hours
18: Phase Order
19: Line Frequency
20: Analog Input
21: Analog Output
22: Running Days
23: Running Hours
24: Starts
25: TruTorque %
26: Power %
30185/40185 LCD Display Meter 1 R/W Same as above but without 0 Status -
30186/40186 LCD Display Meter 2 R/W Same as above but without 0 Status -
30187/40187 Custom Stack Enable R/W 1: Disabled -
0: Enabled
30188/40188 Starter Model Number R/W 0: None -
30189/40189 Misc Commands R/W 0: None -
1: Reset Run Time
2: Reset kWh
3: Enter Reflash Mode
4 Store Parameters
5 Load Parameters
6 Factroy Reset
30301/40301 Fault Code – R See the fault table in Appendix B -
Most Recent Fault Log
Entry
30302/40302 Fault Code – R -
2nd Most Recent Fault
Log Entry
30303/40303 Fault Code – R -
3rd Most Recent Fault
Log Entry
30304/40304 Fault Code – R -
4th Most Recent Fault
Log Entry
30305/40305 Fault Code – R -
5th Most Recent Fault
Log Entry
30306/40306 Fault Code – R -
6th Most Recent Fault
Log Entry
30307/40307 Fault Code – R -
7th Most Recent Fault
Log Entry
149
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30308/40308 Fault Code – R -
8th Most Recent Fault
Log Entry
30309/40309 Fault Code – R -
9th Most Recent Fault
Log Entry
30311/40311 System State – R 0: Initializing -
Most Recent Fault Log 1: Locked Out
Entry 2: Faulted
3: Stopped
4: Heating
5: Kicking
6: Ramping
7: Jogging
8: Not UTS
9: UTS
10: Phase Controlling / Current
Following
11: Decelling
12: Braking
13: Wye
14: PORT
30312/40312 System State – R -
2nd Most Recent Fault
Log Entry
30313/40313 System State – R -
3rd Most Recent Fault
Log Entry
30314/40314 System State – R -
4th Most Recent Fault
Log Entry
30315/40315 System State – R -
5th Most Recent Fault
Log Entry
30316/40316 System State – R -
6th Most Recent Fault
Log Entry
30317/40317 System State – R -
7th Most Recent Fault
Log Entry
30318/40318 System State – R -
8th Most Recent Fault
Log Entry
30319/40319 System State – R -
9th Most Recent Fault
Log Entry
30321/40321 Current – R Arms
Most Recent Fault Log
Entry
30322/40322 Current – R Arms
2nd Most Recent Fault
Log Entry
30323/40323 Current – R Arms
3rd Most Recent Fault
Log Entry
30324/40324 Current – R Arms
4th Most Recent Fault
Log Entry
150
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30325/40325 Current – R Arms
5th Most Recent Fault
Log Entry
30326/40326 Current – R Arms
6th Most Recent Fault
Log Entry
30327/40327 Current – R Arms
7th Most Recent Fault
Log Entry
30328/40328 Current – R Arms
8th Most Recent Fault
Log Entry
30329/40329 Current – R Arms
9th Most Recent Fault
Log Entry
30331/40331 Voltage – R Vrms
Most Recent Fault Log
Entry
30332/40332 Voltage – R Vrms
2nd Most Recent Fault
Log Entry
30333/40333 Voltage – R Vrms
3rd Most Recent Fault
Log Entry
30334/40334 Voltage – R Vrms
4th Most Recent Fault
Log Entry
30335/40335 Voltage – R Vrms
5th Most Recent Fault
Log Entry
30336/40336 Voltage – R Vrms
6th Most Recent Fault
Log Entry
30337/40337 Voltage – R Vrms
7th Most Recent Fault
Log Entry
30338/40338 Voltage – R Vrms
8th Most Recent Fault
Log Entry
30339/40339 Voltage – R Vrms
9th Most Recent Fault
Log Entry
30341/40341 Line Period – R micro-
Most Recent Fault Log seconds
Entry
30342/40342 Line Period – R micro-
2nd Most Recent Fault seconds
Log Entry
30343/40343 Line Period – R micro-
3rd Most Recent Fault seconds
Log Entry
30344/40344 Line Period – R micro-
4th Most Recent Fault seconds
Log Entry
30345/40345 Line Period – R micro-
5th Most Recent Fault seconds
Log Entry
30346/40346 Line Period – R micro-
6th Most Recent Fault seconds
Log Entry
151
10-APPENDIX
Modbus Registers
Absolute Register Description R/W Range Units
Address
30347/40347 Line Period – R micro-
7th Most Recent Fault seconds
Log Entry
30348/40348 Line Period – R micro-
8th Most Recent Fault seconds
Log Entry
30349/40349 Line Period – R micro-
9th Most Recent Fault seconds
Log Entry
Starter Control Register:
Bit 0 – Run/Stop 0 Stop
1 Start
Bit 1 – Fault Reset 0 No action
1 Fault Reset
Bit 2 –Emergency Overload 0 No action
Reset 1 Emergency Overload Reset
Bit 3 –Local/Remote 0 Local
1 Remote
Bit 4 –Heat Disabled 0 Heater Enabled
1 Heater Disabled
Bit 5 –Ramp Select 0 Ramp 1
1 Ramp 2
Bit 13 – Relay 3 0 Engerized (d)
1 De-engerized (d)
Bit 14 – Relay 2 Same as above
Bit 15 – Relay 1 Same as above
The control source must be serial for the starter to be started through Modbus. The Run/Stop bit must transition from 0
to 1 for a start to occur. If the starter stops due to a fault, the Run/Stop bit must be set back to a 0 before another start
can occur.
The fault reset bit must transition from 0 to 1 for a fault to be reset.
If any of the programmed digital inputs are programmed as Local/Remote inputs, then the local/Remote bit has no
effect.
The Relay Bits may be written to in order to control the relays, if the relays are programmed as “OFF”. If the relays are
programmed for any function other than “OFF” ( Fault, Run, UTS for example), then the relay bits may be read to
determine the state of the relays.
These meter registers presenta 32 bit meter in two consecutive 16 bit registers. The least significent 16 bits are te first
register followed by the most significent 16 bit register.
Reading the least significent register laches data into the most significent register so that the data remains synhronized
betweenthe two.
152
10-APPENDIX
Starter Status Register:
Bit 0 – Ready 0– Initializing or
Faulted and Decelling or
Faulted and Braking or
Faulted and Stopped or
Lockout
1– Otherwise
Bit 1 – Running 0– Not Running
1– Running
Bit 2 – UTS 0– Not UTS
1– UTS
Bit 3 – Alarm 0– No alarm conditions
1– 1 or more alarm conditions
Bit 4 – Fault 0– No Fault Condition
1– Fault Condition
Bit 5 – Lockout 0– Start or Fault Reset not locked out.
1– Start or Fault Reset locked out. Possible causes are:
Overload Lockout State
153
10-APPENDIX
Following is the parameter table for both the LED and LCD Display.
154
10-APPENDIX
Protection Function Group Cont.
P27 PFN 04 Undr Cur Tim Under Current Trip Delay Off, 0.1 – 90.0 Seconds 0.1 56
Time
P28 PFN 05 Cur Imbl Lvl Current Imbalance Trip Off, 5 – 40 % 15 57
Level
P29 PFN 06 Gnd Flt Lvl Ground Fault Trip Level Off, 5 – 100 % FLA Off 58
P30 PFN 07 Over Vlt Lvl Over Voltage Trip Level Off, 1 – 40 % Off 59
P31 PFN 08 Undr Vlt Lvl Under Voltage Trip Level Off, 1 – 40 % Off 59
P32 PFN 09 Vlt Trip Tim Over/Under Voltage Trip 0.1 – 90.0 Seconds 0.1 60
Delay Time
P33 PFN 10 Auto Reset Auto Fault Reset Time Off, 1 – 900 Seconds Off 60
P34 PFN 11 Ctrl Flt En Controlled Fault Stop Off, On On 60
P35 PFN 12 Indep S/R OL Independent Off, On Off 61
Starting/Running Overload
P36 PFN 13 Starting OL Motor Overload Class Off, 1 – 40 10 62
Starting
P3 PFN 14 Running OL Motor Overload Class Off, 1 – 40 10 62
Running
P37 PFN 15 OL H/C Ratio Motor Overload Hot/Cold 0 – 99 % 60 63
Ratio
P38 PFN 16 OL Cool Tim Motor Overload Cooling 1.0 – 999.9 Minutes 30.0 64
Time
P55 PFN 17 Reserved Reserved
P57 PFN 18 Reserved Reserved
I/O Group
Group Display Description Setting Range Units Default Page User
Settings
I/O 00 Jump Code Jump to parameter 1 – 17 1
P39 I/O 01 DI 1 Config DI 1 Configuration Off Stop 65
(Digital Input #1) Stop
P40 I/O 02 DI 2 Config DI 2 Configuration Fault High Bypass
(Digital Input #2) Fault Low Cnfrm
P41 I/O 03 DI 3 Config DI 3 Configuration Fault Reset Fault Low
(Digital Input #3) Bypass Cnfrm
E OL Reset
Local/Remote
Heat Disable
Heat Enable
Ramp Select
P42 I/O 04 R1 Config R1 Configuration Off Fault FS 66
(Relay #1) Fault FS
P43 I/O 05 R2 Config R2 Configuration Fault NFS Running
(Relay #2) Running
P44 I/O 06 R3 Config R3 Configuration UTS UTS
(Relay #3) Alarm
Ready
Locked Out
Overcurrent
Undercurrent
OL Alarm
Shunt Trip FS
Shunt Trip NFS
Ground Fault
Energy Saver
Heating
P45 I/O 07 Ain Trp Type Analog Input Trip Type Off Off 67
Low Level
High Level
P46 I/O 08 Ain Trp Lvl Analog Input Trip Level 0 – 100 % 50 67
155
10-APPENDIX
I/O Group Cont.
P47 I/O 09 Ain Trp Tim Analog Input Trip Delay 0.1 – 90.0 Seconds 0.1 68
Time
P48 I/O 10 Ain Span Analog Input Span 1 – 100 % 100 68
P49 I/O 11 Ain Offset Analog Input Offset 0 – 99 % 0 69
P50 I/O 12 Aout Fctn Analog Output Function Off Off 69
0 – 200% Curr
0 – 800% Curr
0 – 150% Volt
0 – 150% OL
0 – 10 kW
0 – 100 kW
0 – 1 MW
0 – 10 MW
0 – 100% Ain
0 – 100% Firing
Calibration
P51 I/O 13 Aout Span Analog Output Span 1 – 125 % 100 70
P52 I/O 14 Aout Offset Analog Output Offset 0 – 99 % 0 71
P53 I/O 15 Inline Confg In Line Configuration Off, 1.0 – 10.0 Seconds 3.0 71
P54 I/O 16 Bypas Fbk Tim Bypass / 2M Confirm 0.1 – 5.0 Seconds 2.0 72
P55 I/O 17 Kpd Stop Dis Keypad Stop Disable Enabled, Disabled Enabled 72
Function Group
Group Display Description Setting Range Units Default Page
FUN 00 Jump Code Jump to parameter 1 – 16 1
P69 FUN 01 Meter 1 Meter 1 Ave Current Ave 73
L1 Current Current
NA FUN 02 Meter 2 Meter 2 L2 Current Ave Volts
L3 Current 73
Curr Imbal
Ground Fault
Ave Volts
L1-L2 Volts
L2-L3 Volts
L3-L1 Volts
Overload
Power Factor
Watts
VA
VARS
kW hours
MW hours
Phase Order
Line Freq
Analog Input
Analog Output
Run Days
Run Hours
Starts
TruTorque %
Power %
P68 FUN 03 CT Ratio CT Ratio 72, 96, 144, 288, 864, 288 74
1320, 2640, 2880, 3900,
5760, 8000, 14400, 28800
P67 FUN 04 Phase Order Input Phase Sensitivity Insensitive Insens. 74
ABC
CBA
Single Phase
156
10-APPENDIX
Function Group Cont.
P66 FUN 05 Rated Volts Rated RMS Voltage 100, 110, 120, 200, 208, RMS 480 75
220, 230, 240, 350, 380, Voltage
400, 415, 440, 460, 480,
500, 525, 575, 600, 660,
690, 1000, 1140, 2200,
2300, 2400, 3300, 4160,
4600, 4800, 6000, 6600,
6900, 10000, 11000,
11500, 12000, 12470,
13200, 13800
P65 FUN 06 Motor PF Motor Rated Power Factor -0.01 (Lag) – 1.00 (Unity) -0.92 75
P64 FUN 07 Starter Type Starter Type Normal Normal 76
Inside Delta
Wye-Delta
Phase Ctl
Curr Follow
ATL
P63 FUN 08 Heater Level Heater Level Off, 1 – 25 %FLA Off 77
P62 FUN 09 Energy Saver Energy Saver Off, On Off 77
P61 FUN 10 Com Drop # Communication Address 1 – 247 1 78
P60 FUN 11 Com Baudrate Communication Baud Rate 1200 bps 9600 78
2400
4800
9600
19200
P59 FUN 12 Com Timeout Communication Timeout Off, 1 – 120 Seconds Off 78
P70 FUN 13 Starter MN Starter Model Number Model Dependent 79
P71 FUN 14 Software PN Software Part Number Display Only 79
P58 FUN 15 Misc Miscellaneous Commands None None 80
Command Reset RT
Reset kWh
Reflash Mode
Store Parameters
Load Parameters
Factory Reset
P72 FUN 16 Passcode Passcode Off 81
Fault Group
Group Description Setting Range Display
FL1 Last Fault (newest) Display Only Fault #
FL2 Previous Fault Display Only Fault #
FL3 Previous Fault Display Only Fault #
FL4 Previous Fault Display Only Fault #
FL5 Previous Fault Display Only Fault #
FL6 Previous Fault Display Only Fault #
FL7 Previous Fault Display Only Fault #
FL8 Previous Fault Display Only Fault #
FL9 Previous Fault (oldest) Display Only Fault #
157
10-APPENDIX
Revision History
158
10-APPENDIX
159
10-APPENDIX Sales and Service
United States
BENSHAW PRODUCTS Pittsburgh, Pennsylvania
Dayton, Ohio
Syracuse, New York
Boston, Massachusetts
Wilmington, Delaware
Low Voltage Solid State Reduced Charlotte, North Carolina
Jacksonville, Florida
Voltage Starters Birmingham, Alabama
- RSD/RSM6 – SSRV Non or Separate Bypass Los Angeles, California
- RDB/RMB6 – SSRV Integral Bypass Detroit, Michigan
- RSM7 – SSRV + DC Injection Braking LaCrosse, Wisconsin
- RSM10 – SSRV + Reversing Chicago, Illinois
- RSM11 – SSRV + DC Injection Braking + Reversing St. Louis, Missouri
- RSM10/12TS – SSRV Two Speed Phoenix, Arizona
- WRSM6 – SSRV Wound Rotor Seattle, Washington
- SMRSM6 – SSRV Synchronous Denver, Colorado
- DCB3 – Solid State DC Injection Braking Houston, Texas
- RBX/RBM – SSRV with integral or separate Bypassed,
- RCX/RCM – SSRV with no bypass Canada
Listowel, Ontario
Toronto, Ontario
Medium Voltage Solid State Reduced Montreal, Quebec
Calgary, Alberta
Voltage Starters
South America
- 5kV – Induction or Synchronous to 10,000HP
Sao Paulo, Brazil
- 7.2kV – Induction or Synchronous to 10,000HP
Santiago, Chile
- 15kV – Induction or Synchronous to 60,000HP
Singapore
160
Bulletin T479d
March, 2002
Specifications, Applications,
Service Instructions & Parts
ST
STRAINERS
(FILTERS)
WARRANTY
Hansen strainers and valves are guaranteed against
L3 R defective materials or workmanship for one year
F.O.B. our plant. No consequential damages or field
labor is included.
Screen Area
CAT NO. H1 H2 L1 L3 R W
in ² (c m ²)
ST050
3.32 0.68 2.03 1.38 3.00 2.03 5.40 REPLACEMENT SCREEN KITS
(84) (17) (52) (35) (76) (52) (35)
D E S C R IP T IO N QTY PART NO.
5.15 1.56 3.75 4.59 3.00 4.59 63.00
ST100
(130) (40) (95) (117) (76) (117) (407) Screen Kit for ST050 Consists of: 7 8 -1 0 0 1
5.34 2.79 9.88 4.25 4.00 4.58 84.50 Screen Assembly 1 78-0005
ST200
(136) (71) (251) (108) (102) (116) (545) Bottom Cap Gasket 1 78-0016
Screen Kit for ST100
ST250
6.10 3.62 9.88 5.38 4.50 5.62 134.50 7 8 -1 0 0 3
(155) (92) (251) (137) (114) (143) (868) (standard) Consists of:
Screen Assembly 1 78-0028
6.56 4.06 12.25 5.38 4.75 6.50 134.50
ST300 Bottom Cover Gasket 1 78-0026
(167) (103) (311) (137) (121) (165) (868)
Screen Kit for ST100
7.38 4.73 14.12 6.75 5.75 8.06 219.00 7 8 -1 0 1 3
ST400
(187) (120) (359) (171) (146) (205) (1413) (optional, heavy duty) Consists of:
Screen Assembly 1 78-0135
14.34 6.40 20.40 12.75 8.00 12.75 536.50
STW500
(364) (163) (518) (324) (203) (324) (3462)
Bottom Cover Gasket 1 78-0026
Screen Kit for ST200 Consists of: 7 8 -1 0 0 5
14.34 6.40 20.40 12.75 8.00 12.75 536.50
STW600 Screen Assembly 1 78-0052
(364) (163) (518) (324) (203) (324) (3462)
Bottom Cover Gasket 1 75-0196
W = Maximum width of strainer body
R = Clearance for screen assembly removal Screen Kit for ST250 Consists of: 7 8 -1 0 0 6
Screen Assembly 1 78-0040
SERVICE AND MAINTENANCE Bottom Cover Gasket 1 75-0128
Repeated inspection of strainers during system Screen Kit for ST300 Consists of: 7 8 -1 0 0 7
start-up or repairs is essential for optimum benefit. Screen Assembly 1 78-0054
Before opening a strainer or any other component, Bottom Cover Gasket 1 75-0128
be sure it is isolated from the system, and all Screen Kit for ST400 Consists of: 7 8 -1 0 0 8
refrigerant is removed (pumped out to zero pressure). Screen Assembly 1 78-0057
The ¾" through 6" strainers have a drain plug in the Bottom Cover Gasket 1 75-0234
bottom cover for connecting a drain valve and hose Screen Kit for STW500 & STW600 7 8 -1 0 0 9
for proper and safe removal of any trapped liquid Screen Assembly 1 78-0071
refrigerant. Bottom Cover O-Ring, Inner 1 75-0605
Screen Removal and Cleaning: Be careful to Bottom Cover O-Ring, Outer 1 75-0606
avoid any refrigerant which may still be in the strainer.
For the ½" strainer, slowly remove the hex bottom
cap, then remove the screen assembly. For ¾" through ISO 9002
6" strainers, loosen the bottom cover bolts and bottom Hansen Technologies Corp.
Burr Ridge, IL Cert. # 000472
Orlando, FL Cert. # 001523
cover, check for refrigerant presence, and then remove
the bolts, cover, and screen assembly. Clean the
screen assembly with a good solvent, blow dry, and HANSEN TECHNOLOGIES
inspect. If the screen is damaged or sediment cannot CORPORATION
be removed from the screen, replace the screen 6827 High Grove Boulevard
assembly. Carefully align the screen assembly in Burr Ridge, Illinois 60527 USA
the center of the strainer body and replace the bottom E-mail: info@hantech.com Web site: www.hantech.com
cover. Pressure test for leaks before returning to Telephone: 630-325-1565 FAX: 630-325-1572
service. Toll-free: 800-426-7368
© 2000 Hansen Technologies Corporation Printed in U.S.A.
2
THREE-WAY DUAL
SHUT-OFF VALVES
Features:
✔ Bodies: 92 Series: forged brass; through the valve regardless of stem position, assuring maxi-
802 series: forged steel; painted mum protection. Furthermore, this design provides for convenient
✔ Maximum working pressure: 450 PSI (31.5 Kg/cm2) parallel mounting of the two relief valves and fulfills the require-
ment set forth in the ANSI/ASHRAE 15.
✔ Temperature rating: -20°F (-29°C) to +300°F (+149°C)
“No stop valve shall be located between any automatic pressure
✔ Recommended for use with relief valve types
relief device or fusible plug and the part or parts of the system
✔ 802A Series is suitable for refrigerants including protected thereby, except when the parallel relief devices are so
ammonia and other industrial fluids non-corrosive to steel arranged that only one can be rendered inoperative at a time for
On all vessels 10 ft3 and larger when relief valves are used as test or repair purposes.”
the over pressure protective device, a dual relief valve assembly Two three-way valves, installed in a drier bypass arrangement,
is required. permit installation or removal of service drier without air, dirt,
Three-Way Dual Shut-off Valve inlets are shown at the bottom of or moisture entering line.
the illustration. Tight shut-off can be obtained at either extreme of
stem position, closing off either the left or right outlet port. The
system should not be run with the valve stem in the center position.
A
A dual relief valve installation consists of one three-way shut-off
valve and two relief valves so arranged that both relief valves
cannot be shut off from the protected pressure vessel at the
same time. This permits safe removal of either relief valve for C
repair or replacement, while the vessel is protected and under D
pressure. Each relief valve must have sufficient capacity to pro- INLET
USA: (800) 262-4332 or (408) 747-0550, Western Canada: (888) 578-9988 or Eastern Canada (888) 317-4332 D-11
Relays RH Series
Part Numbers
Internal Circuit
1 4 1 2 4 1 2 3 4
1
5 8 5 6 8 5 6 7 8
5
9 12 9 10 12 9 10 11 12
9
13 14 13 14 13 14
13 14
D-12 USA: (800) 262-4332 or (408) 747-0550, Western Canada: (888) 578-9988 or Eastern Canada (888) 317-4332
Relays RH Series
Ratings
Coil Ratings
Rated Current ±15% at 20°C
Rated Voltage Coil Resistance ±15% at 20°C
60Hz 50Hz
SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT
6V 150mA 200mA 280mA 330mA 170mA 238mA 330mA 387mA 18.8Ω 9.4Ω 6.0Ω 5.4Ω
12V 75mA 100mA 140mA 165mA 86mA 118mA 165mA 196mA 76.8Ω 39.3Ω 25.3Ω 21.2Ω
AC 24V 37mA 50mA 70mA 83mA 42mA 59.7mA 81mA 98mA 300Ω 153Ω 103Ω 84.5Ω
120V* 7.5mA 11mA 14.2mA 16.5mA 8.6mA 12.9mA 16.4mA 19.5mA 7,680Ω 4,170Ω 27,70Ω 22,20Ω
240V† 3.2mA 5.5mA 7.1mA 8.3mA 3.7mA 6.5mA 8.2mA 9.8mA 3,1200Ω 15,210Ω 12,100Ω 91,20Ω
SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT
6V 128mA 150mA 240mA 250mA 47Ω 40Ω 25Ω 24Ω
12V 64mA 75mA 120mA 125mA 188Ω 160Ω 100Ω 96Ω
DC 24V 32mA 36.9mA 60mA 62mA 750Ω 650Ω 400Ω 388Ω
48V 18mA 18.5mA 30mA 31mA 2,660Ω 2,600Ω 1,600Ω 15,50Ω
110V‡ 8mA 9.1mA 12.8mA 15mA 13,800Ω 12,100Ω 8,600Ω 7,340Ω
* For RH2 relays = 110/120V AC. D
† For RH2 relays = 220/240V AC.
‡ For RH2 relays = 100/110V DC.
Contact Ratings
Resistive Inductive Motor Load
Voltage Rating SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT SPDT DPDT
28V DC UL 10A 10A 10A 10A 7.5A — — 7.5A — —
UL — 7A — —
— —
30V DC CSA 10A 10A 10A 7A — —
10A 7.5A
Nominal 7.5A 7.5A — —
110V DC Nominal 0.5A 0.5A 0.5A 0.5A 0.3A 0.3A 0.3A 0.3A — —
UL — 1/6 1/6
7.5A —
120V AC CSA 10A 10A 10A 10A 7.5A
7.5A — —
Nominal 7A 7.5A
UL * 1/3 1/3
10A 10A — 7.5A 7A 7A
240V AC CSA 7A 5A
— —
Nominal 7A 7.5A 7.5A 4.5A 5A 5A 5A
1. * 6.5A/pole, 20A total.
2. Inductive load cos ø = 0.3, L/R = 7ms.
AC Load DC Load
5000 5000
Life (x 10,000 operations)
Life (x 10,000 operations)
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Load Current (A) Load Current (A)
USA: (800) 262-4332 or (408) 747-0550, Western Canada: (888) 578-9988 or Eastern Canada (888) 317-4332 D-13
FES
GM SERIES
MECHANICAL SHAFT SEAL
REPLACEMENT PROCEDURE
Introduction holes of the seal housing cover until it releases
from the rotor body. Remove the seal housing
This procedure is designed to provide guidance cover (Figure 1). The stationary carbon ring
for replacing the mechanical shaft seal in the GM and O-ring will come out with the seal housing
Series compressors. In some cases the cover.
replacement seals will differ from that which was
originally supplied. In these cases, the difference
merely represents an improvement in the seal
design.
Required Tools
In addition to ordinary hand tools, the following
items are required:
Manufacturer reserves the right to discontinue, or change at any time, specification or designs without notice and without incurring obligations.
P/N 037-000018-000
3. Replace the seal housing cover O-ring (Figure
6) and install the seal housing cover (Figure 7).
Torque the socket head screws progressively to
125 ft-lbs. using a cross diagonal pattern.
Figure 3
Assembly
1. Lubricate the shaft and the seal with an
acceptable refrigeration oil. Install the
Figure 6
mechanical shaft seal. Push the seal onto the
shaft so that the dowel pin hole on the seal is
inserted into the dowel pin located in the shaft
(Figure 4).
Figure 7
4. P ressurize the compressor to 40 psig with
refrigerant from the system and check for
Figure 4 leaks. Also, check the shaft to see it is free to
rotate.
2. Install the new stationary ring with O-ring into
the seal housing cover, lubricating the parts 5. Install the coupling guard ring onto the seal
with oil (Figure 5). Note that the O-ring is housing cover.
installed on the side of the carbon with the 6. Install the compressor hub and center member
larger land and that the carbon is installed into per the instructions in the Installation,
the seal housing cover with the O-ring side Operation and Maintenance Manual.
down.
7. Install the coupling guard.
8. Restart the compressor and check for leaks.
Figure 5
P/N 037-000018-000
Rev. Date: 11/00
IAC/OAC
IDC/ODC
Input/Output Modules
Ordering Information
3. Options:
Blank = IAC Type — 120VAC/VDC input (90-140VAC/VDC) * *
IDC Type — 3.3-32VDC input * *
OAC Type — 3A, 24-280VAC, zero voltage turn-on output
ODC Type — 3A, 3-60VDC output
A = IAC Type — 240VAC/VDC input (180-280VAC/VDC) * *
OAC Type — 3A, 24-280VAC, zero voltage turn-on output
ODC Type — 1A, 3-250VDC output
IDC Type — 10-60VDC input * *
E = IAC Type — 18-36VAC/VDC input * *
F = IDC Type — 4-32VDC input & fast turn-on & turn-off times * *
H = OAC Type — 5A, 24-280VAC, zero voltage turn-on output
R = OAC Type — 5A, 12-280VAC, random voltage turn-on output
Stock Items – The following items are normally maintained in stock for immediate delivery.
IAC-5 IDC-24 OAC-24A
IAC-5A OAC-5 ODC-5
IAC-5E OAC-5A ODC-5A
IAC-15 OAC-5H ODC-15
IAC-24 OAC-15 ODC-15A
IDC-5 OAC-24 ODC-24
IAC
AC Input Modules
Input Specifications
IAC-5 IAC-15 IAC-5A IAC-15A IAC-5E IAC-15E
IAC-24 IAC-24A IAC-24E
Parameter Conditions Units Min. Typ. Max. Min. Typ. Max. Min. Typ. Max.
Control Voltage Range VIN VAC/VDC 90 120 140 180 240 280 18 24 36
Must Operate Voltage VIN(OP) VAC/VDC 90 180 18
Must Release Voltage VIN(REL) VAC/VDC 20 20 3
Max. Input Current @VIN=Max. mA 6 6 18
Input Resistance Ohms 28K 75K 2K
OAC
AC Output Modules
Input Specifications
OAC-5 OAC-5A OAC-15 OAC-15A OAC-24 OAC-24A
OAC-5H OAC-5R OAC-15H OAC-15R OAC-24H OAC-24R
Parameter Conditions Units Min. Typ. Max. Min. Typ. Max. Min. Typ. Max.
Control Voltage Range VIN VDC 3 5 8 9 15 18 18 24 32
Must Operate Voltage VIN(OP) VDC 3 9 18
Must Release Voltage VIN(REL) VDC 1 1 1
Maximum Input Current @VIN=Nominal mADC 20 16 13
Input Resistance RIN Ohms 220 1000 2000
PIN-3 must be positive with respect to PIN-4 for correct operation.
* Nominal Turn-On and Turn-Off times for IDC5A, IDC15A & IDC24A are 5 ms.
ODC
DC Output Modules
Input Specifications
1 1
INPUT OUTPUT ZERO OR
RANDOM
2 2 VOLTAGE
CIRCUIT
R IN
+VCC 3 + 3
SCHMIDT INPUT
OUTPUT 4 TRIGGER – 4
COMMON 5
EQUIVALENT EQUIVALENT
CIRCUIT ONLY CIRCUIT ONLY
+ +
1 + 1
INPUT OUTPUT
2 – 2
AMPLIFIER
+ + RC
+VCC 3 + 3
SCHMIDT INPUT
OUTPUT 4 TRIGGER – 4
COMMON 5
EQUIVALENT EQUIVALENT
CIRCUIT ONLY CIRCUIT ONLY
Outline Dimensions
0.6
1.25 .270
(15.2) 0.1
(38.10) (6.85 ) .30 (2.54)
(7.62)
0.3
(7.62)
0.7
1
1.0 (17.8)
1.0
(25.4) (25.4)
1.2
1.7 (30.5)
2
(43.18) 1.4
(35.6)
1.6
CAPTIVE (40.6)
#4-40 PHILLIPS
3
HEAD HOLD
5 4
DOWN SCREW
.042 DIA.TYP.
(1.067 )
ra
ke
ISO 9001
tion
Par
CERTIFIED
SAFETY PROCEDURES REFRIGERATING SPECIALTIES DIVISION
io n
Ref
FOR REFRIGERATING SPECIALTIES SAFETY BULLETIN RSBCV
s
r ig
iv i
ra D
e
ti ng S ialties
p ec
REFRIGERATION CONTROL VALVES
INTRODUCTION HAND VALVES
This bulletin is a summary of safety procedures for the proper selection, instal- All hand valves that could trap liquid when closed must be marked with a
lation, use and maintenance of Refrigerating Specialties Division industrial warning against accidental closing. The liquid refrigerant must be removed
refrigerant control valves. Additional free copies are available and should be before the hand valves are closed on both sides of a control valve or any other
distributed to all concerned personnel. This bulletin is intended to help you component. Also, liquid must be removed before a hand valve is closed at the
protect your personnel, product and plant. Because of space limitations, this inlet of a solenoid valve or a regulator with positive electric shut-off, or some
bulletin must be supplemented by accepted and known industry safety prac- outlet pressure regulators, or at the outlet of a check valve, unless these
tices and local code requirements. valves are manually open.
Refrigerating Specialties Division control valves are designed and built to the Caution: To protect personnel, product and plant, remove all liquid from the
highest standards of the refrigeration industry. However, for proper perfor- section to be isolated before hand valves are closed. Make sure the control
mance the valves must be correctly chosen, properly installed and periodically valves are open when removing the liquid. See Service and Maintenance
serviced. Because safe operation is of primary concern, this bulletin empha- Instructions before attempting to take any valve apart.
sizes suggestions for the safe installation and maintenance of Refrigerating
RELIEF DEVICES
Specialties Valves. Read this information carefully before installing a valve or
Relief devices or relief methods should be used in all parts of a refrigeration
working on one already installed; also, use it to review all previous installations.
system where liquid can be trapped and liquid expansion could take place.
All personnel working on valves must be qualified to work on refrigeration Under no circumstances should R/S Pressure Regulators be used as a relief to
systems. Any person intending to service a valve should completely read this the atmosphere, R/S Type H Safety Relief valves should be used instead.
bulletin and the product bulletin describing the particular valve and its opera-
tion before any work begins. If there are any questions, contact Refrigerating SELECTION AND APPLICATION
Specialties before proceeding with the work. A control valve must be selected only by a person having adequate knowl-
edge of the system and of the valve to be chosen. Any Refrigerating Special-
RECEIVING AND UNPACKING
ties Division control valve must be used only as specifically stated in Refriger-
All control valves are packed for maximum protection. Unpack carefully. Flange
ating Specialties Division Catalogs or Bulletins for normal refrigeration applica-
bolts are packed in cotton bags and coils are packed loose. Check the carton
tions unless otherwise approved in writing by Refrigerating Specialties Divi-
to make sure all flanges and other items are unpacked and in agreement with
sion.
the packing slip. Save the enclosed instructions for the installer and eventual
user. Do not remove the protective covering from the inlet and outlet of the The valves are designed to operate with ammonia and/or halocarbon refriger-
control valve until the valve is ready to be installed. ants. Valves using flanges with copper connections must not be used with
ammonia refrigerant. Unless authorized by the factory, Refrigerating Special-
Caution: Do not, at any time, make any alteration or modifications to any
ties valves should not be used for refrigerants or fluids not mentioned on the
Refrigerating Specialties Division valves or regulators without the express and
nameplate or in the pertinent bulletin.
written approval of this company. Threaded parts should not be subjected to
excessive torque by use of an oversized wrench, wrench extension or by INSTALLATION
impacting the wrench handle. Where specified in the individual bulletin, ob- Installation must be done according to all applicable Safety Codes and Stan-
serve the torque requirements for bolts, screws and other threaded parts. dards, and by personnel qualified to install refrigeration systems. Refrigerating
Contact the factory for torque values not furnished in current literature. Specialties Division control valves must be installed according to the
For extensive repairs on valves or regulators, especially those more than three manufacturer’s instructions, this bulletin, and the generally known safety prac-
years old, the valves or regulators should be returned to the factory for thor- tices.
ough inspection and rebuilding. Spare parts should be checked for corrosion
before installation. In addition, part numbers should be checked against the MOUNTING
latest assembly bulletin to be sure current parts are being used. ASTM A307 Grade A square headed bolts should be used to mount flanged
If a valve or regulator has failed under circumstances which caused, or could body valves. They assure the maximum bolt surface and flange engagement.
have caused, injury to personnel or damage to property, a replacement valve For all lug mounted valves, flange bolts should be inserted in a direction
should not be installed until the reason for the previous failure is determined pointing toward the valve body. The bolt should pass first through the mount-
and corrected. Adequate protection should be taken to prevent both liquid ing flange before engaging the valve flange. Allow proper space for installing
shock and suction shock both upstream and downstream of the valve or the valve. Do not use the valve to “stretch” or “align” the pipe. Using flange bolts
regulator. to close a large gap can distort the valve or at least stress it unduly, and
possibly cause it to malfunction, or the bolts may be damaged or stripped.
LIQUID EXPANSION (See table below for proper torque requirements). For proper sealing the
In liquid lines, or lines that might contain substantial amounts of liquid refri- gaskets should be lightly oiled and all bolts must be tightened evenly. Make
gerant, certain precautions must be taken to avoid damage due to liquid sure the flange tongues are properly aligned with the grooves in the valve
expansion when a section of line is isolated by positive shut off valves. This body. Where necessary, support the valve by brackets or hangers to avoid
condition may occur whenever the ambient temperature could be higher than overstressing the pipe or valve.
the liquid temperature. This could even occur in a refrigerant or oil line other When mounting weld-end valves: welding procedures for all steel pipe and
than a “liquid” line. fitting need to conform to all requirements of the ASME IX and other Pressure
Temperature increase in a section with trapped liquid can cause extremely Pipe welding standards. In all cases where valves are installed without disas-
high pressures due to the expanding liquid and possibly rupture a gasket, sembly, they should be manually opened.
pipe, or valve. When low temperature liquid lines are used, as in a liquid
overfeed (recirculation) system, and the lines or control valves may be ex- TORQUE REQUIREMENTS FOR FLANGE BOLTS
posed to warm ambient conditions, particular care must be taken; liquid expan- Bolt Diameter Used on Valve Port Size Torque
sion can occur very rapidly. 7/16" (11 mm)* 5-13 mm (3/16" - 1/2") 3.9 mkg (28 ft. lb.)
CHECK VALVES 20-25 mm (3/4" - 1")
5/8" (16 mm) 11.8 mkg (85 ft. lb.)
Check valves must never be installed at the inlet of either a solenoid valve, or 32-50 mm (1-1/4" - 2")
a regulator with an electric solenoid pilot shut-off feature. Also, the check valve 3/4" (19 mm) 65-75 mm (2-1/2" - 3") 14.5 mkg (105 ft. lb.)
should not be installed at the inlet of an outlet pressure regulator in a system 7/8" (22 mm) 100 mm (4") 22.1 mkg (160 ft. lb.)
where liquid may be trapped between the two valves. If a check valve is
needed, install it on the outlet side of such valves. Most solenoid valves and *All A2 direct operated regulators, and AFR-3 and FFR flow regulators use
regulators will permit reverse flow if the outlet pressure is greater than inlet 7/16" diameter bolts.
pressure. If at any time, such reverse pressure conditions are possible and
reverse flow is unacceptable a check valve should be installed at the control
valve outlet.
FEATURES
• Pilot operated characterized Modulating
Plug for precise control
• Suitable for all common refrigerants and oil
• 400 psig (27.6 bar) Design Pressure
(MRP)
• Flanges for threaded or welded steel pipe
and copper tube (copper not for ammonia)
• Unique Modular construction
• Interchangeable parts
• Easy to Service
• Close coupled strainers, optional
• Many control variations are possible with the
March 2002
use of a few modules and kits.
Installation, Service and Parts Information
• Stainless Steel Diaphragm
• Manual Opening Stem Description:
These compact, heavy duty, pilot operated, iron alloy
(ASTM A126 Class B) Differential Pressure Regulators
are suitable for Ammonia, R22, R134a, R404a, R507 and
other common refrigerants and fluids approved for use in
FLANGE RING TUBE refrigeration systems.
ASSEMBLY
ADJUSTING STEM
All A4AL Regulators are pilot operated using upstream
pressure for the opening force and require a minimum 2
psi (0.14 bar) pressure drop to fully open.
POWER PISTON
These valves are generally ordered with close coupled
upstream strainer to prevent entrance of foreign material
into the valve and the rest of the system.
Purpose:
MODULATING Modulates flow of refrigerant liquid or gas to maintain a
PLUG constant set-for pressure differential between regulator
inlet and regulator outlet.
CLOSING SPRING
Regulator applications are as follows: As a relief valve
from pump outlet to accumulator of a liquid recirculating
MANUAL OPENING STEM pump system to prevent pump overload or dry pumping
when evaporator liquid solenoid valves are closed. Dif-
ferential pressure will not vary despite fluctuating accu-
mulator pressures. As a gas or liquid pressure regulator
whenever it is desired to maintain a set-for pressure
A4AL difference between regulator inlet and outlet.
Fig 1 The fluid temperature range for the A4AL Series of
Regulators is -50F to 220F (-45C to 105C).
050453
A4AL PARTS KITS REFERENCE
ITEM DESCRIPTION PORT SIZE
3/4 1 1-1/4 1-5/8 2 2-1/2 3 4
1, 2 Cap Kit, Seal 202110 202110 202110 202110 202110 202110 202110 202110
3-5 Packing Kit, Stem 202100 202100 202100 202100 202100 202100 202100 202100
4-6 Stem Kit 202120 202120 202120 202120 202120 202120 202120 202120
Spring Stem Kit Rng A 202006 202006 202006 202006 202006 202006 202006 202006
3-5, 6, 12-16
Spring Stem Kit Rng D 202007 202007 202007 202007 202007 202007 202007 202007
8 Bonnet Kit *** *** *** *** *** *** *** ***
Spring Kit Rng A 202481 202481 202481 202481 202481 202481 202481 202481
12-14, 16
Spring Kit Rng D 202482 202482 202482 202482 202482 202482 202482 202482
Diaphragm Kit Rng A 200770 200770 200770 200770 200770 200770 200770 200770
16, 17, 19
Diaphragm Kit Rng D 200771 200771 200771 200771 200771 200771 200771 200771
16-19 Seat Kit 202002 202002 202002 202002 202002 202003 202003 202003
27 Plug Pkg, Pipe 202552 202552 202552 202552 202552 202552 202552 202552
19, 28, 29 Adapter Kit 200703 200703 200700 200725 200725 200685 200713 200716
20, 45 Flange Ring Tube 200439 200439 200441 200443 200443 200445 200447 200449
29, 30 Piston Kit 200760 200760 200767 200389 200389 200391 200393 200227
34-37 Spring Kit, Closing 202300 202300 202301 202302 202302 202303 202304 202305
Plug Kit, Full Capacity 202021 202022 202023 202024 202025 202026 202027 202028
Plug Kit, 50% Capacity 202029 * NA NA NA NA NA NA
33-37, 40-42
Plug Kit, 35% Capacity NA NA 202031 202032 ** 202033 202034 202035
Plug Kit, 17% Capacity 202030 * NA NA NA NA NA
37, 38, 40, 41 Bottom Cover Kit 200761 200761 200761
40-42 Packing Kit, Stem 202100 202100 202100 202100 202100 202100 202101 202101
43, 44 Cap Kit, Seal 202110 202110 202110 202110 202110 202110 202111 202111
Bottom Kit, Full Cap 202010 202011 202012 202013 202014 202015 202016 202017
33-38, 40-44 Bottom Kit, 50% Cap 202347 * NA NA NA NA NA NA
Bottom Kit, 17% Cap 202346 * NA NA NA NA NA NA
(All Seals) Gasket / O-Ring Kit 202112 202112 202113 202114 202114 202115 202116 202117
11 (Qty 8) Bolt Pkg, Bonnet 202246 202246 202246 202246 202246 202246 202246 202246
31 (Qty 8) Bolt Pkg, Adapter 202248 202248 202249 202249 202249 202249 202250 202250
39 (Qty 6) Bolt Pkg, Bottom Cap NA NA NA 202251 202251 202251 202252 202252
(*)
All Plug Kits and Bottom Assembly Kits for 3/4" Port Size Valves can be used in the 1" Port Size
Valves for reducing capacity.
(**)
All Plug Kits and Bottom Assembly Kits for 1-5/8" Port Size Valves can be used in the 2" Port Size
Valves for reducing capacity.
(***)
See Industrial List Price Schedule for PK-1 Pneumatic Bonnet Kit.
A4AL
Fig 2
FPT 3/4 229 9.0 1-1/4 269 10.6 1-1/2 318 12.5 2-1/2 343 13.5 3 401 15.8 4 462 18.2
D PIPE 1 229 9.0 1-1'2 269 10.6 2 318 12.5
SIZE 1-1/4 229 9.0
SW 3/4 229 9.0 1-1/4 269 10.6 1-1/2 318 12.5 2-1/2 343 13.5 3 401 15.8 4 462 18.2
E PIPE 1 229 9.0 1-1/2 269 10.6 2 318 12.5
SIZE 1-1/4 229 9.0
WN 3/4 267 10.5 1-1/4 312 12.3 1-1/2 376 14.8 2-1/2 414 16.3 3 490 19.3 4 584 23.0
F PIPE 1 274 10.8 1-1/2 318 12.5 2 384 15.1
SIZE 1-1/4 274 10.8
ODS 1-1/8 300 11.8 1-3/8 338 13.3 1-5/8 427 16.8 2-5/8 445 17.5 3-1/8 508 20.0 4-1/8 625 24.6
G TUBE 1-3/8 297 11.7 1-5/8 339 13.8 2-1/8 417 16.4 3-1/8 480 18.9 3-5/8 554 21.8
SIZE 1-5/8 313 12.3 2-1/8 384 15.1 2-5/8 442 17.4
H (ALL) 117 4.6 117 4.8 140 5.5 159 6.3 176 7.0 222 8.8
J (ALL) 98 3.9 178 7.0 251 9.9 314 12.4 314 12.4 363 14.3
Instructions
_______________________________________________________________________
Induction Motors
143-449 Frame
TABLE OF CONTENTS
INSPECTION 4
STORAGE 4
INSTALLATION 4
OPERATION 5
VOLTAGE REGULATION 6
MAINTENANCE
l BEARING LUBRICATION 7
l INSULATION RESISTANCE 7
l CLEANING 8
VERTICAL MOTOR THRUST BEARINGS 8
SERVICE 8
The contents of this instruction manual shall not become part of or modify any
prior or existing agreement, commitment or relationship. The sales contract
contains the entire obligation of Siemens. The warranty contained in the contract
between the parties is the sole warranty of Siemens. Any statements contained
herein do not create new warranties or modify the existing warranty.
INDUSTRIAL MOTOR DIVISION
INTRODUCTION
THIS EQUIPMENT CONTAINS HAZARDOUS VOLTAGES, ROTATING PARTS AND HOT SURFACES.
SEVERE PERSONAL INJURY OR PROPERTY DAMAGE CAN RESULT IF SAFETY INSTRUCTIONS
ARE NOT FOLLOWED. ONLY QUALIFIED PERSONNEL SHOULD WORK ON OR AROUND THIS
EQUIPMENT AFTER BECOMING THOROUGHLY FAMILIAR WITH ALL WARNINGS, SAFETY
NOTICES, AND MAINTENANCE PROCEDURES CONTAINED HEREIN. THE SUCCESSFUL AND
SAFE OPERATION OF THIS EQUIPMENT IS DEPENDENT UPON PROPER HANDLING,
INSTALLATION, OPERATION AND MAINTENANCE.
QUALIFIED PERSON
For the purpose of this manual and product labels, a qualified person is one who is
familiar with the installation, construction and operation of the equipment, and the
hazards involved. In addition, he has the following qualifications:
a) Is trained and authorized to energize, de-energize, clear, ground and tag circuits and
equipment in accordance with established safety practices.
b) Is trained in the proper care and a use of protective equipment such as rubber
gloves, hard hat, safety glasses or face shields, flash clothing, etc., in accordance
with established safety practices.
DANGER
For the purpose of this manual and product labels, DANGER indicates death, severe
personal injury or substantial property damage will result if proper precautions are not
taken.
WARNING
For the purpose of this manual and product labels, WARNING indicates death, severe
personal injury or substantial property damage can result if proper precautions are not
taken.
CAUTION
For the purpose of this manual and product labels, CAUTION indicates minor personal
injury or property damage can result if proper precautions are not taken.
INSPECTION
Care is taken at the factory to assure that the motor arrives at its destination in first
class condition. If there is evidence of rough handling or damage in shipping, file a
claim at once with the carrier and notify your Siemens Sales Office.
Examine the outside of the motor carefully for damage, with particular attention to
conduit box, fans, and covers. Inspect and tighten all hardware and accessories which
may have become loosened during shipping and handling. Turn the shaft by hand to be
sure that it rotates freely. If the motor has been mishandled sufficiently to break
external parts, the end shield should also be removed to check for internal damage
unless the motor is explosion-proof. See warning below on explosion proof motors.
WARNING
Explosion-proof motors - these motors are constructed to comply with the U.L. Label
Service Procedure Manual. When repairing and reassembling a motor that has an
under-writer’s label, it is imperative that the unit be reinspected and:
STORAGE
Motors must be stored in a clean, dry, well ventilated location free from vibration and
rapid or wide temperature variations. If the unit is to be stored longer than three
months, consult factory. Ball bearing motors are shipped from the factory properly
lubricated and ready to operate. When in storage, the motor shaft must be turned
several rotations every month and the bearing relubricated every year. On non-
explosion-proof TEFC motors, a removable plug in the bottom of the frame or housing
permits removal of accumulated moisture. Drain regularly if storage atmosphere results
in formation of condensation.
INSTALLATION
Installation must be handled by qualified service or maintenance personnel. The motor
foundation must rigidly support all four feet in the same plane. Place shims under the
motor feet, as required, so they will not be pulled out of plane when mounting bolts are
tightened. All wiring to the motor and control must be in accordance with the National
Electrical Code and all local regulations. Before drive is connected, momentarily energize
motor to check that direction of rotation is proper. For direct drive, accurate alignment
is 0.004 inch/ft. (radius to dial indicator = one foot.)
Any change in shims requires rechecking alignment. When alignment is within limits,
dowel two feet of each unit. When installing flat belt pulley, V-belt sheave, spur or
helical pinion or chain drives, be certain that they are within NEMA limitations. Refer to
NEMA motor and general standards, MG-1 14.07 and 14.42.
OPERATION
Repeated trial starts can overheat the motor and may result in motor burnout
(particularly for across the line starting). If repeated trial starts are made, allow
sufficient time between trials to permit heat to dissipate from windings and rotor to
prevent overheating. Starting currents are several times running currents, and heating
varies as the square of the current.
After installation is completed, but before motor is put in regular service, make an initial
start as follows:
1. Check motor starting and control device connections against wiring diagrams.
2. Check voltage, phase, and frequency of line circuit (power supply) against motor
nameplate.
3. If possible, remove external load (disconnect drive) and turn shaft by hand to
ensure free rotation. This may have been done during installation procedure; if
so, and conditions have not changed since, this check may not be necessary.
b. If drive is not disconnected, interrupt the starting cycle after motor has
accelerated to low speed. Carefully observe for unusual conditions as motor
coasts to a stop.
4. When checks are satisfactory, operate at minimum load and look for unusual
condition. Increase load slowly to maximum. Check unit for satisfactory
operation.
CAUTION
Electric motors operating under normal conditions become quite warm. Although some
places may feel hot to the touch, the unit may be operational within limits. Use a
thermo-couple to measure winding temperature when there is any concern.
The total temperature, not the temperature rise, is the measure of safe operation.
Investigate the operating conditions if the total temperature measured by a
thermocouple placed on the winding exceeds:
Motors will operate successfully under the following conditions of voltage and frequency
variation, but not necessarily in accordance with the standards established for operation
under rated conditions:
a. When the variation in voltage does not exceed 10% above or below normal,
with all phases balanced.
b. When the variation in frequency does not exceed 5% above or below normal.
c. When the sum of the voltage and frequency does not exceed 10% above or
below normal (provided the frequency variation does not exceed 5%).
MAINTENANCE
Failure to properly maintain the equipment can result in severe personal injury and
product failure. The instructions contained herein should be carefully reviewed,
understood and followed. The following maintenance procedures should be performed
regularly:
1. Bearing lubrication
3. Cleaning
This checklist does not represent an exhaustive survey of maintenance steps necessary
to ensure safe operation of the equipment. Particular applications may require further
procedures. Should further information be desired or should particular problems arise
which are not covered sufficiently for the purchaser’s purposes, the matter should be
referred to the local Siemens Sales Office.
Dangerous voltages are present in the equipment which can cause severe personal
injury and product failure. Always de-energize and ground the equipment before
maintenance. Maintenance should be performed only by qualified personnel.
The use of unauthorized parts in the repair of the equipment, tampering by unqualified
personnel, or removal or alteration of guards or conduit covers will result in dangerous
conditions which can cause severe personal injury or equipment damage. Follow all
safety instructions contained herein.
BEARING LUBRICATION
CAUTION
Do not lubricate motor while in operation, since excess grease will be forced through
the bearings and into the motor before it will force its way out of the drain plug.
Excess grease accumulation on windings reduces insulation life.
Prior to shipment, motor bearings are lubricated with the proper amount and grade to
provide six months of satisfactory service under normal operation and conditions.
For best results, grease should be compounded from a polyurea base and a good grade
of petroleum oil. It should be of No. 2 consistency and stabilized against oxidation.
Operating temperature range should be from -15ºF to +250ºF for class B insulation,
and to +300ºF for class F and H. Most leading oil companies have special bearing
greases that are satisfactory.
Relubricate bearings every six months (more often if conditions require), as follows:
4. Add grease to inlet with hand gun until small amount of new grease is forced
out of drain.
5. Remove excess grease from ports, replace inlet plugs, and run motor 1/2 hour
before replacing drain plug.
INSULATION RESISTANCE
This formula is satisfactory for most checks. For more information, see IEEE Standard
No. 43, “Recommended Practice for Insulation Resistance Testing of AC Rotating
Machinery”.
Siemens Energy &
Automation, Inc.
Motors and Drives Division
14000 Dineen Drive
Little Rock, Arkansas 72206
CLEANING
WARNING
Do not attempt to clean motor while it is operating. Contact with rotating parts can cause
severe personal injury or property damage. Stop the motor and lock out switch before
cleaning.
The motor exterior must be kept free of oil, dust, dirt, water, and chemicals. For fan cooled
motors, it is particularly important to keep the air intake openings free of foreign material. Do
not block air outlet or inlet.
On non-explosion-proof TEFC motors, a removable plug in the bottom center of the motor
frame or housing permits removal of accumulated moisture. Drain regularly.
Top bearings – high external thrust from the driven unit is usually carried by the top bearing
or bearings. If replacement is necessary, the new bearing must be the same size and type as
the original. Duplex bearings must also be the same type and mounted in an identical manner.
When angular contact type bearings are replaced, the new bearing must have the same thrust
capacity.
Bottom bearings – grease lubricated lower bearings are adequately lubricated at the factory
for at least three months operation. The relubrication procedure is the same as outlined above
under “Bearing Lubrication”. It is important to maintain the lower cavity full of grease at all
times.
The correct replacement bearings are given on the nameplate by AFBMA (Anti-Friction Bearing
Manufacturers Association) number.
SERVICE
For immediate action on your motor problems call your certified service center or contact your
nearest Siemens District Office.
___________________________________________________________________________________
Bulletin IMD 1000 1OM 10/92 Tl Printed in U.S.A. ©1990 Siemens Energy & Automation, Inc.
October 2003 / BULLETIN 10-11
Thermostatic
Expansion Valves
Installation, Field Service, and Assembly
Installation While not always convenient or possible, valve Types BI, F, FB, and
O are easier to service if mounted in a vertical and upright position.
Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
If mounted in a horizontal position, the internal parts must be
Solder Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
carefully reassembled to prevent damage to them. Also, some consid-
Bulb Location and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
eration should be taken in mounting larger sized expansion valves.
External Equalizer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
They must be adequately supported since system vibration and the
Driers, Strainers, and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 4
weight of the valve may cause valve connections to fracture.
Test Pressures and Dehydration Temperatures . . . . . . . . . . . . . . . 4
Expansion Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
If a hand valve is located on the outlet side of the TEV it should have
How to Determine Superheat Correctly . . . . . . . . . . . . . . . . . . . . 5
a full sized port. No restrictions should appear between the TEV and
How to Change the Superheat Setting . . . . . . . . . . . . . . . . . . . . . 5
the evaporator, except a refrigerant distributor if one is used.
For peak performance, it is important to select a Sporlan Occasionally, TEVs are located in corrosive atmospheric conditions
Thermostatic Expansion Valve (TEV) with correct capacity, selective that can damage the valve and/or the element assembly. Due to this
charge, external or internal equalizer, etc. See Bulletins 10-9 and 10-10 possibility, the valve must be protected with appropriate materials to
for complete application information. Equally important is the proper prevent premature failure. Consult specialists in protective coatings.
installation, which can determine the success or failure of the entire
system.
Precautions:
When the evaporator and TEV are located above the
Valve Location receiver, there is a static pressure loss in the liquid line. This is due
TEVs may be mounted in any position, but they should be installed to the weight of the column of liquid refrigerant, and this weight may
as close to the evaporator as possible. If a refrigerant distributor is be interpreted in terms of pressure loss in pounds per square inch as
used with the expansion valve, best performance is obtained if the shown in Table 3, Bulletin 10-9. If the vertical lift is great enough,
distributor is mounted directly to the valve outlet. If the distributor vapor or flash gas will form in the liquid line causing a serious
cannot be mounted directly to the valve outlet, the distance between reduction in the capacity of the TEV.
the valve outlet and distributor should not exceed 24 inches or refrig-
erant distribution problems may occur. Also, the tube connecting the When an appreciable vertical lift is unavoidable, precautions should
valve outlet and distributor can be sized smaller to maintain refrig- be taken to prevent the accompanying pressure loss from producing
erant velocity and better distribution. Elbows located between the liquid line vapor. This can be accomplished by providing enough
expansion valve and distributor will hinder proper distribution and subcooling to the liquid refrigerant, either in the condenser or after
therefore, are not recommended. the liquid leaves the receiver. Subcooling is determined by
subtracting the actual liquid temperature from the condensing
Best distribution is usually obtained if the expansion valve feeds temperature (corresponding to the condensing pressure). A
vertically up or down into the distributor. System manufacturers, subcooling calculation example is provided in the "subcooling"
however, have successfully applied distributors in other orientations. section of Bulletin 10-9.
This precaution will prevent overheating the valve body which could
damage the superheat spring and result in flood back problems. In
addition, the Type O, EBF/SBF, and EBS valve contain synthetic
parts which can be damaged due to overheating, resulting in poor
valve performance.
Receiver
Main Suction Line Accepted principles of good suction line piping should be followed
to provide a bulb location that will give the best possible valve
To Compressor control. When system manufacturers have piping recommendations
that differ from the general industry recommendations and Sporlan’s
Figure 1 suggestions shown in this section, those recommendations should be
used. When specific recommendations are not available, the sugges-
Ordinarily the conventional suction-liquid heat exchanger is installed tions below should be used.
near the evaporator, where the suction vapor is the coldest, to re-
condense any vapor in the liquid line. When the primary purpose of The bulb should be attached to a horizontal suction line at the
the heat exchanger is to prevent the formation of flash gas – particu- evaporator outlet (See Figures 3, 4, and 5) If the bulb cannot be
larly on systems that have a long liquid line or excessive vertical lift located in that manner, it may be located on a descending vertical
– install the heat exchanger near the receiver before the vertical line only (as shown in Figure 5 for “pumpdown control”). The bulb
lift occurs. (This also applies to the special devices described in should never be located in a trap or downstream of a trap in the
Method 3). Because vapor in the liquid line considerably increases suction line. Liquid refrigerant or mixture of liquid refrigerant and oil
friction losses, the total pressure drop available across the expansion boiling out of the trap will falsely influence the temperature of the
device on these types of systems is reduced. Also, the suction line and bulb and result in poor valve control.
liquid line should be carefully insulated to minimize heat gain if
subcooled below ambient temperature. On suction lines 7/8” OD and larger, the surface temperature may
vary slightly around the circumference of the line. On these lines, it
Important is generally recommended that the bulb be installed at 4 or 8 o’clock
Preventing the formation of vapor in liquid lines having high pressure on the side of the horizontal line, and parallel with respect to the
losses does not eliminate the requirement that an adequate pressure direction of flow. On smaller lines the bulb may be mounted at any
drop must be available across the TEV. The capacity tables show point around the circumference, however locating the bulb on the
valve capacities at pressure drops lower than normal. For TEV bottom of the line is not recommended as an oil-refrigerant mixture
application data and capacities at pressure drops below those listed, is generally present at that point. Certain conditions peculiar to a
consult Sporlan Valve Company. particular system may require a different bulb location than normally
BULLETIN 10-11 / Page 3
On brine tanks and water coolers, the bulb should be below the liquid
Short as possible to minimize amount of oil. surface where it will be at the same temperature as the evaporator
during the off-cycle. When locating the bulb in a brine tank, paint it
and the capillary tubing with pitch or other corrosion resistant paint.
Figure 3
recommended. In these cases the proper bulb location may be If, for practical reasons, the bulb must be located where its tempera-
determined by trial. ture will be higher than the evaporator during the off-cycle, a
solenoid valve must be used ahead of the TEV.
For satisfactory expansion valve control, good thermal contact
between the bulb and suction line is essential. The bulb should be
securely fastened with two bulb straps, supplied with each expansion Compressor BELOW
valve, to a clean straight section of the suction line.
Evaporator
Recommended suction line piping usually includes a horizontal line
leaving the evaporator to which the TEV bulb is attached. This line is Without
pitched slightly downward, and when a vertical riser follows, a short Pumpdown
trap is placed immediately ahead of the vertical line, see Figure 3.
The trap will collect any liquid refrigerant or oil passing through the
suction line and prevent it from influencing the bulb temperature.
Multiple Evaporators
Pumpdown
Above and Below Main Suction Line Control
Figure 5
Free draining. The equalizer connection should be made at a point that will most
accurately reflect the pressure existing in the suction line at the bulb
location. See Figure 6. Generally, the connection is immediately
downstream of the bulb. However, equipment manufacturers
Figure 4 sometimes locate them in return bends or suction headers that are
Page 4 / BULLETIN 10-11
Excessive test pressures can shorten the life of the TEV diaphragm.
Table 1 lists the maximum pressure that can safely be applied with
the expansion valve connected to the evaporator. These maximum
pressures are well above the minimum field leak test pressures for
low sides, listed by the ANSI/ASHRAE Standard 15-2001 or latest
revision.
It must be connected - NEVER CAPPED!
Must be free of crimps, solder, etc. The external equalizer line should be disconnected if there is any
possibility of exceeding the recommended maximum pressures
listed below.
Figure 6
If elevated temperatures are used to assist in dehydrating the system,
compatible with their specific design requirements. The difference
the TEV should not be exposed to temperatures exceeding those
between the pressure at the equalizer connection and the suction
shown in Table 2.
pressure at the bulb location should not exceed reasonable pressure
drop values. The values shown in Table 1 of Bulletin 10-9 can be Table 2 refers to the maximum dehydration temperatures when the
used as a guide in determining the value. bulb and valve body are subjected to the same temperature. On L, C,
Z, and X charges, 250°F maximum valve body temperature is
If any evaporator pressure or temperature control valves are located permissible if the bulb temperature does not exceed those
in the suction line at or near the evaporator outlet, the equalizer must shown in the table.
be connected on the evaporator side of these valves.
Table 2
Maximum Dehydration Temperatures – Degrees F
Figure 7 Thermostatic Charge
Refrigerant
L C Z X VGA P Type, ZP Series
Moisture and smaller particles of foreign materials are equally
harmful to the system and must be removed for peak system perfor- 12, 134a 190 190 250 ---
mance. Field experience has proven that, without a doubt, most 22 160 160 185 210 250 250
expansion valve failures are due to the presence of dirt, sludge, and
404A, 502, 507 150 150 170 ---
moisture in the system. Furthermore, the performance and life of
other system components are also seriously affected by these foreign 717 (Ammonia) 150 190 235 --- --- ---
materials. The Sporlan Catch-All Filter-Drier® removes dirt,
moisture, acids, and sludge, and insures the circulation of clean, dry
refrigerant through the system at all times.
Expansion Valve Adjustment
For all refrigeration and air conditioning applications we recommend Each Sporlan TEV is thoroughly tested and set at the factory before
that a Sporlan Catch-All Filter-Drier be installed in the liquid line shipment. This factory superheat setting will be correct and no
ahead of the TEV. See Bulletin 40-10 for complete Catch-All Filter- further adjustment is required for the majority of applications.
Drier specifications. However, there are many factors which can affect the performance of
a TEV. These factors are independently variable and all of them
Further system protection is easily and inexpensively provided with cannot be compensated for in the design of a valve. When the
the installation of a Sporlan See-All®. The See-All is a combination application or operating conditions require a different valve setting
liquid and moisture indicator that visually indicates if there is a due to one or more of the factors listed below, the valve may be
shortage of refrigerant in the liquid line, or if the moisture content of adjusted to obtain the required operating superheat. Therefore, an
the refrigerant is at a dangerous level. See Bulletin 70-10 for adjusting stem is provided on all standard valves. The valve should
complete See-All specifications. be set with the system as near as possible to design conditions.
BULLETIN 10-11 / Page 5
Factors which affect valve performance and may make it necessary the estimated pressure drop will equal the approximate
to adjust the valve are: suction line pressure at the bulb.
1. Low temperature difference (TDs) between the refrigerant and 3. Convert the pressure obtained in 2a or 2b above to saturated
the air evaporator temperature by using a temperature-pressure chart.
2. TEV bulb location 4. Subtract the two temperatures obtained in 1 and 3 – the differ-
3. Balance between compressor and evaporator ence is superheat.
4. Ratio of load to TEV capacity Figure 8 illustrates a typical example of superheat measurement on
5. Condenser capacity an air conditioning system using Refrigerant 22. The temperature of
6. Operation of several fixtures on multiple installation the suction line at the bulb location is read at 52°F. The suction
pressure at the compressor is 66 psig and the estimated suction line
7. Seasonal variation in head pressure caused by extreme changes in pressure drop is 2 psi …66 psig + 2 psig = 68 psig at the bulb, which
ambient air temperature. is equivalent to a 40°F saturation temperature. (Use dew point
temperature for refrigerant blends.) 40°F subtracted from 52°F =
Note: Valve Types F, (E)BF/SBF, Q, A, M, V, K, and W have non- 12°F superheat.
rising adjusting stems and a change in adjustment does not change
the stem position. Note: Refrigerated case manufacturers frequently use a “tempera-
ture difference” method to approximate superheat. This procedure
When setting valves on multi-evaporator refrigeration systems with consists of measuring the temperature of a location on the evaporator
pressure or temperature sensitive evaporator control valves, the which is representative of saturated vapor temperature; and, then
following procedure is recommended: subtracting that temperature from the outlet evaporator temperature
1. Evaporator Pressure Regulating Valve (ORI Type): the ORI valve which is measured at the bulb location.
is set first at the minimum load condition. Then, if necessary, the
expansion valve is adjusted to the desired superheat setting while While this method of reading “superheat” is acceptable on those
under the normal operating load condition. manufacturer’s cases where the pressure drop through the evaporator
is low, Sporlan does not recommend the “temperature difference”
2. Temperature Sensitive Evaporator Regulating Valves (CDS
method for other types of systems.
Type): The CDS valve is forced into a fully open position first.
Then the expansion valve is adjusted to the desired superheat
setting at full load condition. Finally, the controller for the CDS
is set to the desired temperature. Contact Sporlan Valve
Company, or the case manufacturer, for additional details on What's Your
setting the CDS controller. Superheat?
When the adjustment is completed on the TEV, always tighten the
adjusting stem packing nut and replace the seal cap tightly.
Temperature
Many expansion valves are made non-adjustable for use on here reads
Original Equipment Manufacturer’s units, particularly those valves 52°
used on residential air conditioning and heat pump systems. These
valves are set at a superheat predetermined by the manufacturer’s OBTAIN SUCTION PRESSURE 40°
laboratory tests and cannot be adjusted in the field. 68 PSIG (at bulb) 12°
SUPERHEAT
Some non-adjustable models are modifications of standard
adjustable type valves. This is done by using a solid bottom cap
instead of one equipped with an adjusting stem and seal cap. These
valves can be identified by an N preceding the standard valve designa-
tion. Adjustable bottom cap assemblies are available for converting
most non-adjustable valves to the adjustable type. However, this is Figure 8
rarely required. If symptoms indicate that a valve adjustment is
needed, carefully check the other possible causes of incorrect
superheat, pages 6 through 10, before attempting an adjustment. How to Change the Superheat
Setting
How to Determine Superheat Note: There are some valve bodies (G, EG, C, S, EBS
and EMC) that have a packing nut around the adjust-
Correctly ment stem. It may be necessary to loosen the packing
1. Measure the temperature of the suction line at the bulb location. nut slightly to turn the adjusting stem. Do not forget
2. Obtain the suction pressure that exists in the suction line at the to retighten the nut after the superheat is set.
bulb location by either of the following methods:
a. If the valve is externally equalized, a gauge in the external To reduce the superheat, turn the adjusting stem counter-
equalizer line will indicate the desired pressure directly and clockwise. To increase the superheat, turn the adjusting stem
accurately. clockwise. When adjusting the valve, make no more than one turn
b. Read the gauge pressure at the suction valve of the of the stem at a time and observe the change in superheat closely to
compressor. To the pressure add the estimated pressure drop prevent over-shooting the desired setting. As much as 30 minutes
through the suction line between bulb location and may be required for the new balance to take place after an adjust-
compressor suction valve. The sum of the gauge reading and ment is made.
Page 6 / BULLETIN 10-11
If in doubt about the correct superheat setting for a particular system, The primary cause of difficulty with either the BP or RPB feature is
consult the equipment manufacturer. As a general rule, the proper dirt and other foreign materials that restrict or plug them. And if the
superheat setting will depend on the amount of temperature differ- system purpose intended for either feature is not being satisfied, the
ence (TD) between refrigerant temperature and the temperature of the valve probably needs cleaning or replacing.
air or other substance being cooled. Where high TD’s exist, such as
on air conditioning applications, the superheat setting can be made as As stated in Bulletin 10-9, the RPB type valve is not to be applied on
high as 15°F without noticeable loss in evaporator capacity. Where systems using high starting torque compressors or “hard-start”
low TD’s exist, such as in low temperature blower coil applications, electrical components, on outdoor coils of heat pumps, or on any
a superheat setting of 10°F or below is usually recommended for refrigeration system, and it should not be used to replace BP type
maximum evaporator capacity. It is these applications that the TEV valves that are applied on those types of systems. On systems other
will more than likely need to be adjusted. than those described above, the RPB type valve can replace the BP
type valve when necessary. Usually it is advisable to replace a valve
For the correct valve setting on factory built equipment, manufac- with one of the same specification unless advised differently. Consult
turers’ recommendations should be followed. Some manufacturers with the system manufacturer for assistance.
specify the superheat directly; others may recommend valve adjust-
ment to a given suction pressure at certain operating conditions, or
until a certain frost line is observed. Such recommendations, however
they are stated, represent the results of extensive laboratory testing to
Complaint "A"
determine the best possible operation. “Valve does not feed enough refrigerant.”
SYMPTOMS:
■ Load temperature (air or water leaving
* When system has some form of capacity reduction — cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEV
performance, a better analysis is possible when these devices are locked out or shut off so the suction pressure will respond to variations in load or valve feed.
BULLETIN 10-11 / Page 7
3. Wax — Certain systems are contaminated with small amounts 7. Insufficient pressure drop across valve — One of the
of wax which will precipitate at low temperatures in systems factors that influence expansion valve capacity is the pressure
with Refrigerants 22 or 502. Since the TEV represents the first drop that exists between the inlet and outlet. Anything
cold point in the refrigeration cycle, wax is most likely to form contributing to a reduction in this pressure drop will reduce valve
at the valve port. capacity. Abnormally low condensing pressures, excessive liquid
It is sometimes difficult to observe the wax in a valve because it line pressure losses (even with adequate subcooling), undersized
may exist in solid form only at very low temperatures. By the distributor nozzle or distributor tubes may also be responsible for
time the valve has been taken apart, the temperature has a very low net pressure drop across the valve port.
increased enough to cause the wax to melt and thus become Remedy — Remove source of pressure loss, or install valve
difficult to detect. When wax is suspected, it can usually be with adequate capacity at the reduced pressure drop. If inlet
detected on the pin and seat by packing the valve in dry ice pressure to valve is low due to low condensing pressure, raise
while disassembling. pressure.
Remedy — Clean the valve with solvent before reassembling If the refrigerant distributor nozzle is undersized replace with
the valve. The Sporlan HH style Catch-All Filter-Driers have a correct size. See Bulletin 20-10.
special activated charcoal desiccant that is designed to remove
wax in the liquid line before it causes trouble. Therefore, to 8. Dead thermostatic element or wrong thermo-
prevent wax problems, use these HH style driers (e.g., C-415- static charge — If the element has partially or completely
S-HH) on all low temperature systems using Refrigerants 22 or lost its thermostatic charge, the valve will be unable to feed
502. sufficient refrigerant or will remain closed. A wrong charge may
cause insufficient feed also.
4. Refrigerant shortage — See•All or sight glass in the Remedy — Replace the element if it is dead. If charge is
liquid line will show bubbles when the system is short of refrig- incorrect, replace with proper selective charge. See Bulletin 10-9.
erant charge. Before adding more refrigerant however, be sure
the bubbles are not produced by other causes (See Paragraphs 9. Charge migration (CP series, ZP series, and VGA
A-2 and A-5). charges only) — In order for valves with these charges to
A lack of refrigerant charge may also be detected by a hissing maintain control at the bulb, the bulb must be kept at a lower
sound at the TEV. Some systems not equipped with a liquid line temperature than the element (diaphragm case). If the thermo-
sight glass will have test cocks or other devices for checking the static charge does migrate to the element because of a lower
refrigerant level in the receiver. element temperature, the valve will throttle.
Remedy — Add enough refrigerant to obtain desired result. Detection — Warm the element with a cloth saturated with
hot water. If this produces more refrigerant feed and reduces the
5. Gas in the liquid line — As explained in Paragraphs A-2 superheat to normal, charge migration is responsible for the
and A-4, liquid line vapor can be produced by a partially starved evaporator.
plugged strainer or drier and by a shortage of refrigerant charge. Causes —
In addition, gas in the liquid line can be caused by air or other ■ Insufficient pressure drop between the valve outlet and bulb
non-condensable gases in the system or by excessive pressure location, possibly due to an oversized distributor nozzle or no
losses in the liquid line as a result of: nozzle at all.
■ Long or undersized line. ■ Excessive pushrod leakage, which allows the leaking refrig-
■ Liquid line vertical lift. erant to cool the diaphragm case before passing into the
Remedy — Verify the correct liquid line size for the equiva- equalizer line. This is a rare occurrence and should be
carefully checked before arriving at this conclusion.
lent length and system tonnage. Consult liquid line sizing data
■ Cold location of TEV, or condensate drippage on the
published in many manufacturers’ catalogs and in textbooks. If
diaphragm case.
undersized, repipe with the correct size.
Remedies —
Determine amount of vertical lift, and obtain the resulting
■ Install distributor nozzle correctly sized in accordance with
pressure loss from Table 3, Bulletin 10-9. Using the subcooling
calculation example provided in the "subcooling" section of nozzle sizing procedure given in Sporlan Bulletin 20-10.
■ On valves with packed pushrod construction, remove element
Bulletin 10-9, find required subcooling necessary to prevent
gasification with the existing pressure losses. Provide the and tighten the pushrod packing nuts.
■ Relocate the TEV away from cold outlet air, or condensate
necessary subcooling by using one of the methods described on
Page 1. drippage.
flowing through the evaporator, check the piping for possible Disassemble the valve to be certain that dirt or foreign material
refrigerant flow from another evaporator affecting the bulb. Re- is not responsible (see B-2). If the pin and seat are worn or
pipe if necessary. See Figure 4. damaged and an internal parts kit is available, replace the parts.
When parts are not available, the valve must be replaced.
13. High pressure drop through evaporator
Remedy — Check the pressure at the evaporator inlet and 4. Oversized valve — Check valve ratings considering all the
outlet with gauges. If pressure difference is greater than the factors which affect its capacity. See Page 16, Bulletin 10-9, or
values shown in Table 1, Bulletin 10-9, use an externally Page 3, Bulletin 10-10.
equalized valve. Remedy — Install correctly sized valve.
14. Restricted, plugged, or capped external equalizer — 5. Incorrect bulb installation — The bulb should be securely
If the pressure under the diaphragm builds up due to pushrod fastened to a straight, clean, section of the suction line using two
leakage and cannot escape through the external equalizer line, bulb straps for good thermal contact. Also, the temperature of the
the valve will remain closed. bulb should not be influenced by ambient temperature — an
Remedy — Check the external equalizer line to be sure it is external heat source such as a steam pipe or heating coil.
open or not capped. Remedy — Install bulb correctly. See Bulb Location and
Installation, Page 2.
for this purpose. Another corrective measure is to install a suction 3. Low load— Low evaporator load may be caused by insuffi-
line solenoid valve that is de-energized during the off-cycle. cient air over the coil as a result of an undersized blower, dirty
air filters, or an obstruction in the air stream. In addition, frost
3. Restricted or plugged external equalizer — A formation on the coil or low entering air temperatures will
momentary flood can occur when the load increases suddenly, reduce the evaporator load.
such as at start-up because the higher suction pressure cannot
Remedy — Correct the condition responsible.
reach the underside of the diaphragm and help close the valve.
If the pressure under the diaphragm increases due to any
4. Flow from one coil affecting TEV bulb of another
pressure leakage around the pushrods, the valve will eventually
(Multiple evaporator systems only) — The tempera-
throttle.
ture of the bulb may be falsely influenced by flow from another
Remedy — Remove the restriction or plugged portion of the evaporator usually because of incorrect piping.
external equalizer.
Remedy — Correct the piping. See Figure 4, Page 3.
4. Liquid line solenoid valve seat leak or interrupted
5. Improper compressor-evaporator balance — If the
pumpdown — Liquid refrigerant can continue to feed the
compressor is too large for the load and evaporator capacity, the
TEV and/or remain in evaporator upon shut-down causing
low suction pressure which results will cause poor system
flood-back to the compressor upon start-up.
performance.
Remedy — Disassemble and clean solenoid valve and/or
Remedy — Consult with the manufacturer or consulting
replace damaged internal parts if seat leakage is the problem. If
engineer, or the ASHRAE Handbook on component balancing.
the pumpdown cycle isn’t completed before the compressor
cycles off, or the thermostat calls for cooling and reopens the If necessary, change or correct the improperly sized component.
liquid line solenoid before the evaporator has been properly Hot gas bypass may be used to balance properly.
evacuated, check the low pressure cut-off setting or the
electrical controls for possible causes. 6. Evaporator oil-logged — Poor heat transfer occurs and
unpredictable performance takes place. If erratic performance is
observed over a period of time, and other causes are omitted
from consideration, review the amount of oil in the system.
Complaint "D" Turbulent compressor oil level with little or no return to the
“Valve doesn't feed properly.” compressor sump indicates oil problems.
SYMPTOMS: Remedy — Remove excessive oil from evaporator and
■ Poor system performance. connecting piping. Many times the evaporator temperature will
■ Superheat normal or lower than normal. be too low for the oil to be removed. Therefore, the system must
■ Suction pressure lower than normal with be allowed to warm sufficiently to get cold oil to drain. Analyze
compressor unloaders locked out or hot gas system components for possible causes of oil problem before
bypass shut off.* restarting the system. Consult with the compressor manufacturer
for specific details on their compressor.
enter the suction line and throttle the valve. This will cause ■ Superheat fluctuates.
normally loaded circuits to be deprived of their share of ■ Valve does not feed enough, and then too much
* When system has some form of capacity reduction — cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEV
performance, a better analysis is possible when these devices are locked out or shut off so the suction pressure will respond to variations in load or valve feed.
Page 10 / BULLETIN 10-11
tions are not necessary. If hunting is severe with floodback to 5. System is hunting or cycling. See Section E on Page 9.
the compressor, check the possible remedies shown in
paragraphs below. 6. The TEV has been physically abused in an effort
to make the valve work properly. This is usually the
2. Valve size — An over-sized valve usually aggravates hunting. result of a mistaken analysis. It is frequently assumed that if a
Carefully check the valve rating considering all the factors valve does not feed properly, it is stuck (either opened or
affecting its capacity. See Bulletin 10-9, or Bulletin 10-10. closed). Beating the valve body with a hammer will only distort
Remedy — Replace valve with one correctly sized. On the body and make it impossible for the valve to work once the
multiple circuit evaporators using a refrigerant distributor, the real cause is determined.
capacity of the valve can be reduced, within certain limits, by If a valve “sticks,” it is usually due to moisture freezing in the
installing a smaller distributor nozzle. See Bulletin 20-10. port, dirt and other foreign material restricting or plugging the
internal parts, wax forming on the internal parts at low temper-
3. Bulb location — If the bulb is located in a suction line trap, atures, or the valve has been physically abused so it cannot
its temperature will be affected by liquid oil and refrigerant function.
alternately collecting and evaporating at this point. This Remedy — Inspect the valve and its internal parts, including
condition frequently results in severe hunting. the inlet strainer. If plugged or restricted in any way, clean the
Remedy — As a temporary measure relocate the bulb away parts thoroughly, oil the parts with a good grade of refrigerant
from the trap, and any turbulent areas created by elbows, tees, oil, and reassemble the parts. Complete details on this subject
etc. Also remove the bulb from the air stream or insulate. Re- are found on Pages 10 through 12.
pipe if necessary. Sometimes another position around the If the valve is beyond normal cleaning processes, or if it is
circumference of the suction line will minimize hunting. Follow physically damaged in any way, replace the valve with its proper
the Bulb Location and Installation instructions given on Page 2 replacement model.
for the best TEV control.
Seat
Complaint "F"
Pin Carrier
“System won't perform properly.”
SYMPTOM:
■ Cannot get valve to react or regulate at all. Spring
Spring Guide
THE CAUSE MAY BE: Bottom Cap
1. No refrigerant being fed to evaporator. See Section Assembly
A on Pages 6 & 7.
Note: These Field Assembly Instructions apply in part to all Sporlan exerting too much pressure in tightening the element or in
TEVs. See Figure 9 for an “exploded” view of those models that can clamping the body in the vise. Also, do not use a wrench on the
be completely disassembled. When a TEV is to be disassembled for outer welded edge of the element.
inspection and cleaning, or for replacement of the thermostatic
element or the internal parts, the following information should be 4. Inspect parts, element, and body for any foreign materials or
reviewed for assistance. physical damage.
Types F dated approximately C84 or earlier and Types I, BI, NI, RI, 5. On valves with replaceable elements and/or internal parts,
FB manufactured prior to 1994 do not have replaceable elements nor replace any items that appear damaged.
internal parts kits, but can be disassembled for inspection and
cleaning. Type F dated D84 or later, Type S valves dated B69 or later, 6. Clean all parts with solvent, preferably by applying and then
Type C valves dated C70 or later, and ALL Type G, X, (E)BF/SBF blowing off with clean dry compressed air.
and EBS valves employ packless pushrod construction and internal
parts are NOT available for use with them. However, their elements
can be replaced and they can be disassembled for inspection and
cleaning. Due to the single pushrod construction of the Type RIGHT WRONG
(E)BF/SBF and EBS valves, only the bottom cap assembly, pin
guide, and superheat spring may be removed for inspection and
cleaning.
SOLENOID VALVES
Installation and Servicing Instructions
■ When changing from the old KC model coils to the current Types B6, B9, B10, B14, B19, B25 Series (Brass Connections)
MKC molded model coils, discard the coil housing, coil 1. Remove the coil assembly, enclosing tube and nut, all internal
housing bottom plate, two coil sleeves (not used with KC-1 parts, and manual lift stem assembly.
coil) AND THE SPACER. 2. Locate the word IN or the directional arrow on the valve body.
3. Place the valve in the line in the proper direction of flow and
■ The OMKC-2 coil fits the OB9, OE9, OB10, OE10, OB14, OE14, solder.
OB19, OE19, OB25, OE25, OB33, OE33, OE34, OE42 series
normally open solenoid valves and the XRN, XRM, XPO
series rapid cycle solenoid valves.
■ Figure 1
Enclosing
■ Other Sporlan Valve products using a molded coil are as Tube Locknut
follows: Enclosing Tube
MKC-1 — OM-1, SORIT, 8D, 12D, 10G, SORIT-PI, 5D, SHGB(E)-8. Enclosing
MKC-2 — 16D, DDR-20, SHGB(E)-15, OLDR-15 and OLDR-20. Kickoff Spring Tube Gasket
OMKC-2 — LDR-15, LDR-20, XTM and XTO. Stem and Plunger
To insure peak performance, solenoid valves must be selected and Valve Body Seat Disc
applied correctly; however, proper installation procedures are equally
important. The following instructions list the essential points for
correct installation.
Manual Lift Stem
An exploded view of a typical solenoid valve is illustrated in Figures (if required)
5, 5A and 6, page 4.
Position — All standard solenoid valves may be mounted 4. Re-assemble as follows, see Figures 1, 5, and 5A:
horizontal, on its side or in a vertical line with the exception of the a. Place the seat disc into the valve body with the smaller
following: A3 dated 6-86 or before, MA32, B33, OB33, MA42, diameter end facing up.
MA50, MA5A, MA17A, XWG, XUP, XRN, XRM and XPO series. b. Place the enclosing tube gasket onto the valve body above the
These valves MUST be installed in horizontal lines with the coil threads.
housing no more than 45° from vertical, see table on page 2. The c. Hold the plunger with one hand so that the pointed end is
direction of flow is indicated by an arrow or the word IN on the inlet resting in the pilot port of the disk. Make sure the small spring
of the valve body. For heat pump applications, valve types C(M)E is in place on the top of the plunger. (NOTE: Does not
and C(M)B are typically installed with the directional arrow pointing apply to normally open and rapid cycle series.)
toward the outdoor coil. Or, the IN connection toward the indoor coil. d. With the other hand, place the enclosing tube over the plunger,
making sure the enclosing tube gasket is in position.
NOTE: Solenoid valves having a type number starting with the letter e. Replace the enclosing tube locknut and tighten. (See
"X" are Special Solenoid Valves (non-standard). Contact Sporlan recommended torque in the table on page 2.) Do not over
Valve Company, Washington, MO if valve mounting is in question. tighten.
f. Replace manual lift stem. Tighten lift stem assembly and seal cap.
SOLDER CONNECTIONS g. Replace the coil assembly. (NOTE: For normally open and
Because of possible damage to valve components due to the high rapid cycle valves replace spacer and spacer cup
temperatures of soldering and brazing, "B" Series Solenoid Valves with coil assembly.)
with brass connections are shipped handtight to facilitate
disassembly, with the exception of the (M)B33S2 & OB33S2. It is NOTE: Excessive tightening of the enclosing tube locknut can
necessary to completely disassemble these valves before any heat is damage the valve body bore. Please observe the torques listed on
applied to the valve body. The following steps outline recommended page 2.
procedures when installing these valves.
Types: All E Series (Extended Copper Connections)
Soldering Precautions — Solder connections on Sporlan Solenoid Brazed into the line without disassembly because the valve contains
Valves are either copper or brass. Any of the commonly used types of extended connections. Use caution by placing a wet cloth or chill
solder are satisfactory with these materials. Regardless of the type of block on the extensions at the body to prevent excessive overheating.
solder used, it is important to avoid overheating the valve. Follow Type A3S1 installation instructions.
© COPYRIGHT 2003 BY SPORLAN VALVE COMPANY, WASHINGTON, MISSOURI
BULLETIN 30-11, AUGUST 2003 SUPERSEDES BULLETIN 30-11, NOVEMBER 2000 AND ALL PRIOR PUBLICATIONS.
Page 2 / BULLETIN 30-11
PIPE CONNECTIONS These valves have male flange connections on the inlet of the valve;
Types A3, W3, B6, W6, B9, B10, B14, W14, B19, W19, B25, therefore, the flange and bushing for the inlet must be the female pair.
W25, (K)(B)R183, (K)(B)R184, (K)(B)R246 Series
These valves can be installed without disassembly. Avoid excessive INSTALLATION—ALL VALVES
amounts of pipe sealing compounds. It will interfere with the valve Mounting — A Type 1216-1 universal mounting bracket, Figure 2,
operation if it comes in contact with the valve's internal parts. is available, when ordered. It fits all standard Sporlan Solenoid
Valves except the Types W3, MA32, B33, E33, E34, E42, MA42,
NOTE: When pipe type solenoid valves are installed with pipe to MA50, (K)(B)R183, (K)(B)R184, (K)(B)R246 series and the Type
ODF adaptors, the valve must be disassembled prior to brazing the 180 Solenoid Pilot Control. The slots in the bracket match the tapped
ODF adaptors. holes in the standard solenoid valves so that they may be secured by
two screws supplied with the bracket. A locknut is also furnished for
use with Types MA5A3 and MA17A3. Both types of installations are
FLANGED CONNECTIONS— shown in Figure 2. The manual lift stem seal cap is replaced after the
PIPE or SOLDER locknut is tightened against the bracket.
Solenoid valves with flanged connections may be installed without
disassembly. In most cases the flanges are packed disassembled from 1.50 1.50
the valve body. Therefore, they may be installed in the line before the ■ Figure 2 Hole through
which solenoid
valve is installed. Be certain that the correct flange is installed on the is screwed to
inlet line in order to properly match the flow direction of the valve. If bracket
1.75 2.16
the valve is installed backwards, it will not function properly.
1.16
Types MA5A3, MA17A3, MA32P3, MA42P3, MA50P3
1.
06
Coil
Plunger
Assembly
Enclosing
Tube
Spacer Diaphragm
(normally open & Assembly
Typical View of rapid cycle only) Enclosing
E34 & E42 Series Tube O-Ring
Solenoid Valves Enclosing Enclosing
Tube Tube O-Ring Plunger
Lock Nut Assembly
Pilot Assembly
Enclosing Tube Enclosing Tube Body
or (normally open & Body
(normally closed)
rapid cycle)
Body
(A & B Coil Housing
Series)
Body
(E Series)
Body
(E34 & E42 Coil Sleeve
Series)
Manual Lift Stem Assembly
(if required) Coil Spring
*Tetraseal
*B and E Series Solenoid Valves have been redesigned. The new design can be easily identified as a thin, synthetic Gasket
coated metal gasket, known as a Wolverine gasket. The old gasket is a thicker type of O-ring with a square cross or
section, known as a tetraseal. See the partial cross sections of the valve body at right. The gaskets and the
enclosing tubes of the two designs are not interchangeable. The new enclosing tube assembly is included in the
*Wolverine
Gasket Coil
replacement parts kits.
2.75 DIA.
7.18
2.50
3.38
5.06
Page 2
Actual system piping must be done so as to protect 80 psig. The valve setting should be selected to utilize
the compressor at all times. This includes protection evaporator surface effectively when the system load is
against overheating, slugging with liquid refrigerant, at a minimum to avoid the possibility of floodback to the
and trapping oil in various system locations. compressor during low load operation. When the load is
at a maximum, the increase in evaporator pressure will
Since the PDA-1-0/80 may be applied in a bypass line cause the valve to modulate to a more closed position.
between the discharge line and the low side of the sys- This prevents the pressure from rising further and over-
tem, the valve may be subjected to compressor vibra- loading the compressor.
tions which result from discharge pulses and inertia
forces associated with the moving parts. These pulses To adjust the PDA-1-0/80, remove the cap and turn the
and forces must be controlled by accepted industry adjustment nut with a 5/16" hex wrench. A clockwise
practices. rotation increases the setting and a counter clockwise
rotation decreases the setting. Replace the cap after com-
Strainer – The need for an inlet strainer is a function pleting the adjustment procedure.
of system cleanliness and proper installation proce-
dures. The PDA-1-0/80 is supplied automatically with Service Instructions – There are several possible causes
a cleanable internal strainer which is removable when for system malfunction when the PDA-1-0/80 is applied.
the inlet flange is removed. A Type XD-074 (1/2" FPT) As with any form of trouble shooting, it is essential to
strainer is available if an external, cleanable strainer know the symptoms or existing operating temperatures
is specified. and pressures for the type of application before the mal-
function can be determined. Once the actual malfunc-
Valve Setting and Adjustment – The PDA-1-0/80 can tion is pinpointed, it is easier to isolate the cause and
be set to maintain any downstream pressure from 0 to then take appropriate corrective action.
SPECIFICATIONS
NOMINAL PORT SIZE DISCHARGE ADJUSTMENT CONNECTIONS FLANGE RING
VALVE TYPE CAPACITY TUBE SIZE (Inches - FPT) SIZE (Approx.)
(Inches) RANGE (psig)
(Tons) (Inches) Inlet Outlet OD x ID (Inches)
PDA-1-0/80 1 1/16 1/32 0/80 1/4, 3/8, or 1/2 1.12 x 0.75
TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE REMEDY
1. Dirt or foreign material in valve. 1. Disassemble valve and clean.
Failure to Open
2. Inlet strainer plugged. 2. Clean strainer.
1. Dirt or foreign material in valve. 1. Disassemble valve and clean.
2. Diaphragm failure. 2. Replace element only.
Failure to Close
3. Equalizer passageway plugged. 3. Disassemble valve and clean.
4. Damaged internal parts. 4. Replace internal parts.
REPLACEMENT PARTS
VALVE TYPE REPLACEABLE ELEMENT KIT INTERNAL PARTS KIT
PDA-1-0/80 A-2-0/80 KP10-0010 *
*The PDA-1-0/80 internal parts kit is identical to the internal parts kit for the DA(E)-1 thermostatic expansion valve. However, the
pushrod height required for the PDA-1-0/80 is different than the pushrod height for the DA(E)-1. All DA(E) thermostatic expansion
valves use the #2 pushrod gauge (refer to the pushrod gauge included with the kit) which provides a pushrod height of 0.222". The
PDA-1-0/80 requires a pushrod height of 0.230". When sizing the PDA-1-0/80 pushrod height, use the #2 gauge and allow for an
additional 0.008”.
CONTENTS
Introduction 1
Special Information 2
Special Mechanical Seals 2
Maintenance 2
Disassembly 3
Assembly 5
Thrust Bearing Adjustment 7
Installation of Carbon Graphite Bushings 7 FIGURE 1
Pressure Relief Valve Instructions 7 GG. HJ and HL 4195 SERIES
Foot Type Unmounted Pump with Tapped
Ports
INTRODUCTION
The illustrations used in this manual are for identification
purposes only and cannot be used for ordering parts. Obtain
a parts list from the factory or a Viking® representative.
Always give complete name of part, part number and
material with model number and serial number of pump
w hen ordering repair parts. The unmounted pump or pump
unit model number and serial number are on the nameplate
secured to the pump.
In the Viking model number system, basic size letters are
combined with series number (4195 and 495), indicating both
the unmounted or mounted pump units.
This manual deals only with Series 4195 and 495 Heavy
Duty Pumps. Refer to Figures 1 thru 14 for general
configuration and nomenclature used in this manual. Pump
specifications and recommendations are listed in Catalog
Section 144, Series 4195 and 495 Heavy Duty Pumps.
FIGURE 4
VIKING PUMP INC. • AS, AK and AL SIZE 495 SERIES
Unmounted Pump with Tapped Ports
A Unit of IDEX Corporation •
SPECIAL MECHANICAL SEALS
SPECIAL INFORMATION
This bulletin illustrates the mechanical seal which is
standard in the catalog pump. A Seal Installation
DANGER Drawing will be furnished with a pump fitted with a non-
standard mechanical seal. Consult this Seal Installation
BEFORE OPENING ANY VIKING PUMP LIQUID Drawing before disassembling pump.
CHAMBER (PUMPING CHAMBER,
Modifications are required to install Teflon seals in
RESERVOIR, RELIEF VALVE ADJUSTING CAP
these pumps. Contact factory for specific information.
FITTING ETC.) BE SURE:
1. THAT ANY PRESSURE IN CHAMBER RELIEF VALVE ADJUSTING SCREW CAP
HAS BEEN COMPLETELY VENTED
THROUGH SUCTION OR DISCHARGE
LINES OR OTHER APPROPRIATE
OPENINGS OR CONNECTIONS.
2. THAT THE DRIVING MEANS (MOTOR,
TURBINE, ENGINE, ETC.) HAS BEEN SUCTION DISCHARGE
“LOCKED OUT” OR MADE NON -
OPERATIONAL SO THAT IT CANNOT BE
STARTED WHILE WORK IS BEING DONE
ON PUMP.
3.
THAT YOU KNOW WHAT LIQUID THE FIGURE 5
PUMP HAS BEEN HANDLING AND THE
PRECAUTIONS NECESSARY TO SAFELY MAINTENANCE
HANDLE THE LIQUID. OBTAIN A
MATERIAL SAFETY DATA SHEET Series 4195 and 495 pumps are designed for long, trouble-
free service life under a wide variety of application
(MSDS) FOR THE LIQUID TO BE SURE
conditions with a minimum of maintenance. The points
THESE INFORMATION
SPECIAL PRECAUTIONS ARE listed below will help provide long service life.
UNDERSTOOD.
CLEANING PUMP: Keep pump as clean as possible. This
FAILURE TO FOLLOW ABOVE LISTED will facilitate inspection, adjustment and repair work and
PRECAUTIONARY MEASURES MAY RESULT help prevent overlooking a dirt covered grease fitting.
IN SERIOUS INJURY OR DEATH.
STORAGE: If pump is to be stored, or not used for six
months or more, pump must be drained and a light coat of
non-detergent SAE 30 weight oil must be applied to all
ROTATION: Viking pumps operate equally well in a
internal pump parts. Lubricate fittings and apply grease to
clockwise or counterclockwise rotation. Shaft rotation
pump shaft extension. Viking suggests rotating pump shaft
determines which port is suction and which is discharge.
by hand one complete revolution every 30 days to circulate
Suction Port is where pumping elements (gear teeth) come
the oil.
out of mesh.
SUGGESTED REPAIR TOOLS: The following tools must
PRESSURE RELIEF VALVES: be available to properly repair Series 4195 and 495 pumps.
1. Viking pumps are positive displacement pumps and These tools are in addition to standard mechanics’ tools
must be provided with some sort of pressure protection. such as open end wrenches, pliers, screw drivers, etc.
Most of the items can be obtained from an industrial supply
This may be a relief valve mounted directly on the
pump, an inline pressure relief valve, a torque limiting house.
device or a rupture disk. 1. Soft Headed hammer
2. There are relief valve options available on those pump 2. A lIen wrenches (set screws & special mechanical seals)
models designed to accept a relief valve. Options may 3. Snap Ring Pliers
include a return to tank relief valve and a jacketed relief
INTERNAL – Viking Part No. 2-810-047-999
valve. Pumps equipped with a jacketed head plate are
GG-HJ-HL 4195-495
generally not available with a relief valve. EXTERNAL – Viking Part No. 2-810-029-375
3. If pump rotation is reversed during operation, pressure GG-HJ-HL 4195-495
protection must be provided on both sides of pump. 4. Mechanical Seal Installation Sleeve
4. Relief valve adjusting screw cap must always point 2-751-001-900 for 0.75 inch seal; GG 4195-495
towards suction side of pump. If pump rotation is 2-751-004-900 for 1.25 inch seal; AS-AL 4195-495
reversed, remove pressure relief valve and turn end for 5. Bearing Locknut Spanner Wrench
end. Refer to Figure 5. (Source: #471 J.H. Williams & Co. or equal)
5. Pressure relief valves should not be used to control 6. Spanner Wrench, adjustable pin type for use on bearing
pump flow or regulate discharge pressure. housing end cap.
(Source: #482 J.H. Williams & Co. or equal)
For additional information on pressure relief valves, refer to 7. Brass bar
Technical Service Manual TSM 000 and Engineering
8. Arbor press
Service Bulletin ESB-31.
2
DISASSEMBLY 1. Refer to figures 7 & 8 page 4 for model to be
disassembled and name of parts. Models 4195 & 495 are
disassembled and assembled the same. The difference
DANGER between these models is the casings.
2. Mark head and casing before disassembly to insure
BEFORE OPENING ANY VIKING PUMP LIQUID proper reassembly. The idler pin, which is offset in the
CHAMBER (PUMPING CHAMBER, pump head, must be positioned up an equal distance
RESERVOIR, RELIEF VALVE ADJUSTING CAP between port connections to allow for proper flow of liquid
FITTING ETC.) BE SURE: through the pump.
1. THAT ANY PRESSURE IN CHAMBER 3. Remove the head capscrews.
HAS BEEN COMPLETELY VENTED
NOTE: The four valve capscrews, valve and gasket must
THROUGH SUCTION OR DISCHARGE be removed from the GG 4195-495 model before the six
LINES OR OTHER APPROPRIATE head capscrews are removed.
OPENINGS OR CONNECTIONS.
4. Tilt top of head back when removing to prevent idler from
2. THAT THE DRIVING MEANS (MOTOR, falling off idler pin.
TURBINE, ENGINE, ETC.) HAS BEEN
“LOCKED OUT” OR MADE NON - 5. Remove idler and bushing assembly. If idler bushing
OPERATIONAL SO THAT IT CANNOT BE needs replacing, see “Installation of Carbon Graphite
STARTED WHILE WORK IS BEING DONE Bushings”, page 7.
ON PUMP. 6. Insert a brass bar or piece of hardwood in the port
opening and between the rotor teeth to keep the shaft
3. THAT YOU KNOW WHAT LIQUID THE from turning. Turn the locknut counterclockwise and
PUMP HAS BEEN HANDLING AND THE remove locknut. See Figure 9 or 10.
PRECAUTIONS NECESSARY TO SAFELY
HANDLE THE LIQUID. OBTAIN A 7. Loosen two setscrews in face of bearing housing and turn
MATERIAL SAFETY DATA SHEET thrust bearing assembly counterwise and remove from
(MSDS) FOR THE LIQUID TO BE SURE casing. See Figure 9 or 10.
THESE PRECAUTIONS ARE
8. GG, HJ, HL: Remove snap ring from shaft. See Figure 9.
UNDERSTOOD.
AS, AK, AL: Remove bearing spacer from shaft. See
FAILURE TO FOLLOW ABOVE LISTED Figure 10.
PRECAUTIONARY MEASURES MAY RESULT 9. Remove brass bar or piece of hardwood from port
IN SERIOUS INJURY OR DEATH. opening.
MECHANICAL SEAL
SHAFT
SNAP RINGS
IDLER PIN
CASING
HEAD GASKET
3
Modifications to pump casing and rotor are required for installation
of optional Teflon® Mechanical Seal. Consult the factory.
ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART
1 Locknut 7 Ball Bearing, Inner 12 Idler Bushing 18 Gasket for Relief Valve
2 Snap Ring, Outer 8 Casing (4195) 13 Idler and Bushing 19 Relief Valve
3 Ball Bearing, Outer 8A Casing (495) 14 Head Gasket 20 Capscrew for Valve
4 Snap Ring for Shaft * 9 Pipe Plug 15 Idler Pin
5 Bearing Housing 10 Mechanical Seal 16 Head and Idler Pin
6 Snap Ring, Inner 11 Rotor and Shaft 17 Capscrew for Head
ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART
4
INNER BALL BEARING
BALL BEARING
INNER SNAP RING
LOCKNUT
BEARING HOUSING
BALL BEARING
NYLON INSERT
END CAP
LIP SEAL
LOCKNUT
BEARING HOUSING
SETSCREW
10. The rotor and shaft can now be removed by tapping on 13. GG, HJ, HL: Remove inner snap ring and single row
end of shaft with a lead hammer or, if using a regular ball bearing from casing.
hammer, use a piece of hardwood between shaft and AS, AK, AL: Remove single row ball bearing from
hammer. The rotary member of the seal will come out casting.
with rotor and shaft.
14. Remove seal seat or stationary part of seal from casing.
11. AS,AK,AL: Remove bearing retainer w asher. The
washer may have stayed with Rotor and 15. Disassemble thrust bearing assembly.
Shaft when removed or is against ball GG, HJ, HL: Remove outer snap ring from bearing
bearing. See Figure 10. housing and remove ball bearing. See
12. Remove the mechanical seal rotary member and spring Figure 9.
from rotor and shaft assembly. AS, AK, AL: Loosen two set screws in flange outside
diameter. Rotate end cap and lip seal
counterclockwise and remove. Remove
ball bearing. See Figure 10.
5
The casing should be examined for wear, particularly in the SPRING
area between ports. All parts should be checked for wear MECHANICAL SEAL (ROTARY MEMBER)
before pump is put together.
When making major repairs, such as replacing a rotor and
shaft; it is advisable to also install a new mechanical seal,
head and idler pin, idler and bushing. See "Installation of
Carbon Graphite Bushings" page 7.
Clean all parts thoroughly and examine for wear or
damage. Check lip seals, ball bearings, bushing and idler
TAPERED SLEEVE
pin and replace if necessary. Check all other parts for
nicks, burrs, excessive wear and replace if necessary.
COAT WITH LIGHT OIL BEFORE ASSEMBLY
Wash bearings in clean solvent. Blow out bearings with
compressed air. Do not allow bearings to spin; turn them FIGURE 11
slowly by hand. Spinning bearings will damage race and
balls. Make sure bearings are clean, then lubricate with ROTOR HUB
non-detergent SAE 30 weight oil and check for roughness. SPRING
Roughness can be determined by turning outer race by MECHANICAL SEAL
hand. Replace bearings if bearings have roughness. (ROTARY MEMBER)
Be sure shaft is free from nicks, burrs and foreign particles SHAFT
that might damage mechanical seal. Scratches on shaft in
seal area will provide leakage paths under mechanical
seal. Use fine emery cloth to remove scratches or sharp
edges.
ASSEMBLY
Assembly Notes On Standard Mechanical Seal
(Synthetic Rubber Bellows Type)
FIGURE 12
READ CAREFULLY BEFORE REASSEMBLING PUMP
4. Place tapered installation sleeve on shaft, refer to Figure
The seal used in this pump is simple to install and good 11. Sleeve is furnished with GG, AS, AK and AL
performance will result if care is taken during installation. replacement mechanical seals. Coat rotor shaft, tapered
The principle of mechanical seal is contact between the installation sleeve and inner diameter of mechanical seal
rotary and stationary members. These parts are lapped to rotary member with a generous amount of non-detergent
SAE 30 weight oil. Petrolatum may be used but grease is
a high finish and their sealing effectiveness depends on
not recommended.
complete contact.
Prior to installing rotary portion of mechanical seal, prepare 5. Place seal spring on shaft against rotor hub. Refer to
and organize rotor shaft, head and idler assemblies and Figure 12.
appropriate gaskets for quick assembly. 6. Slide rotary member, lapped contact surface facing away
Once rotary portion of mechanical seal is installed on rotor from spring, over installation sleeve on shaft until just
shaft, it is necessary to assemble parts as quickly as contacting the spring. Do not compress spring. Remove
installation sleeve.
possible to insure the seal does not stick to shaft in wrong
axial position. The seat will stick to the shaft after several 7. Coat rotor shaft with non-detergent SAE 30 weight oil.
minutes setting time. Install shaft slowly pushing until the ends of rotor teeth
are just below the face of the casing.
Never touch sealing faces with anything except clean
hands or clean cloth. Minute particles can scratch the seal 8. Leave the rotor in this position. Withdrawal of rotor and
faces and cause leakage. shaft may displace the carbon seal rotating face and
1. Coat idler pin with non-detergent SAE 30 weight result in damage to the seal.
oil and place idler and bushing on idler pin in 9. Place O-ring gasket on head and install head and idler
head. If replacing a carbon graphite bushing, refer assembly on pump. Pump head and casing were marked
to Installation of Carbon Graphite Bushings, page before disassembly to insure proper reassembly. If not,
7. be sure idler pin, which is offset in pump head, is
2. Clean rotor hub and casing seal housing bore. positioned up and equal distance between port
Make sure both are free from dirt and grit. Coat connections to allow for proper flow of liquid through
pump.
outer diameter of seal seat and inner diameter of
seal housing bore with non-detergent SAE 30 10. Tighten head capscrews evenly.
weight oil.
11. If pump was equipped with a relief valve and was
3. Start seal seat in seal housing bore. If force is removed during disassembly, install on head with new
necessary protect seal face with a clean gaskets. Relief valve adjusting screw cap must always
cardboard disc and gently tap i1 in place with a point towards suction port. Refer to Figure 5 page 2. For
piece of wood. Be sure seal seat is completely relief valve repair or adjustments, see PRESSURE
seated in the bore. RELIEF VALVE INSTRUCTIONS, Page 7.
6
12. Pack inner ball bearing with multi-purpose grease, THRUST BEARING ADJUSTMENT
NLGI #2.
See Figures 9 and 10.
GG, HJ, HL: Install bearing in casing with sealed side
Loosen two screws in face of thrust bearing assembly.
towards head end of pump. Drive the
bearing into the bore. Tap the inner race If shaft cannot be rotated freely, turn thrust bearing
with a brass bar and lead hammer to assembly counterclockwise until shaft can be turned
position bearing.Install inner snap ring. easily.
AS, AK, AL: Install bearing retainer washer over the To set end clearance:
shaft before installing ball bearing. Install
ball bearing in casing with sealed side 1. While turning rotor shaft, rotate thrust bearing
towards head end of pump. Drive the assembly cloc kwise until noticeable drag occurs.
bearing into the bore. Tap the inner race This is zero end clearance.
with a brass bar and lead hammer to
2. Mark position of bearing housing with respect to the
position bearing.
casing.
13. GG, HJ, HL: Install shaft snap ring in groove in the
3. Rotate thrust bearing assembly counterclockwise the
shaft. See Figure 9. distance listed below as measured on outside of
AS, AK, AL: Install bearing spacer over shaft and bearing housing.
against single row ball bearing. See
4. Tighten two setscrews in face of bearing housing
Figure 10.
after adjustment is made to secure thrust bearing
14. Pack lubrication chamber between inner ball bearing assembly position.
and double row ball bearing in the thrust bearing
assembly approximately one-half full of multi-purpose For viscosities above 2500 SSU, add additional end
grease, NLGI #2. The thrust bearing assembly will take clearance (0.004” for GG, HJ and HL size pumps
the remaining space. See Figure 9 and 10. and 0.005” for AS, AK and AL size pumps).
15. Pack double row ball bearing with multi-purpose
grease, NLGI #2.
GG, HJ, HL: Install ball bearing into bearing housing
with shield side toward coupling end of shaft. See Distance In Inches On End
Pump Size O.D. Of Bearing Housing Clearance
Figure 9. Install snap ring into bearing housing to
retain ball bearing. This snap ring has a tapered edge GG 0.44” .003
to fit tapered groove in bearing housing. The tapered
HJ, HL 0.56” .003
edge is located away from ball bearing.
AS, AK, AL 0.5” .003
AS, AK, AL: Install ball bearing into bearing housing.
Install lip seal in bearing housing end cap. The lip
should face towards end of shaft. Put bearing spacer
collar in lip seal and install in bearing housing and
tighten set screws securely. See Figure 10.
16. Insert brass bar or hardwood through port opening
betw een rotor teeth to keep shaft from turning.
INSTALLATION OF CARBON
17. Start thrust bearing assembly into casing. Turn by
hand until tight. This forces rotor against head. GRAPHITE BUSHINGS
Replace and tighten locknut or shaft.
When installing carbon graphite bushings, extreme care
18. Remove brass bar or hardwood from port opening.
must be taken to prevent breaking. Carbon graphite is a
19. Adjust pump end clearance, refer to page 7. brittle material and easily cracked. If cracked, the bushing
will quickly disintegrate. Using a lubricant and adding a
chamfer on the bushing and the mating part will help in
installation. The additional precautions listed below must
be followed for proper installation:
DANGER 1. A press must be used for installation.
7
PRESSURE RELIEF VALVE DISASSEMBLY
INSTRUCTIONS
DANGER
BEFORE OPENING ANY VIKING PUMP LIQUID
CHAMBER (PUMPING CHAMBER,
RESERVOIR, RELIEF VALVE ADJUSTING CAP
FITTING ETC.) BE SURE:
1. THAT ANY PRESSURE IN CHAMBER
HAS BEEN COMPLETELY VENTED
THROUGH SUCTION OR DISCHARGE
LINES OR OTHER APPROPRIATE
OPENINGS OR CONNECTIONS.
2. THAT THE DRIVING MEANS (MOTOR,
TURBINE, ENGINE, ETC.) HAS BEEN
“LOCKED OUT” OR MADE NON -
OPERATIONAL SO THAT IT CANNOT BE
STARTED WHILE WORK IS BEING DONE
FIGURE 13 ON PUMP.
VALVE - GG, HJ, and HL SIZES
3. THAT YOU KNOW WHAT LIQUID THE
PUMP HAS BEEN HANDLING AND THE
VALVE - LIST OF PARTS PRECAUTIONS NECESSARY TO SAFELY
1. Valve Cap 6. Valve Body HANDLE THE LIQUID. OBTAIN A
2. Adjusting Screw 7. Valve Spring MATERIAL SAFETY DATA SHEET
3. Lock Nut 8. Poppet (MSDS) FOR THE LIQUID TO BE SURE
4. Spring Guide 9. Cap Gasket THESE PRECAUTIONS ARE
UNDERSTOOD.
5. Bonnet
FAILURE TO FOLLOW ABOVE LISTED
PRECAUTIONARY MEASURES MAY RESULT
IN SERIOUS INJURY OR DEATH.
FIGURE 14 ASSEMBLY
VALVE – AS, AK and AL SIZES
Reverse procedures outlined under Disassembly. If valve
is removed for repairs, be sure to replace in same
VALVE - LIST OF PARTS position. Relief valve adjusting screw cap must always
1. Valve Cap 6. Valve Body point towards suction side of pump. If pump rotation is
2. Adjusting Screw 7. Valve Spring reversed, remove relief valve and turn end for end. Refer
to Figures 5, page 2.
3. Lock Nut 8. Poppet
4. Spring Guide 9. Cap Gasket
5. Bonnet 10. Bonnet
8
TECHNICAL SERVICE MANUAL
SECTION TSM144
HEAVY DUTY PUMPS
PAGE 9
SERIES 4195 and 495
ISSUE B
SERIES GG - AL
DANGER
CONTENTS
out the discharge port. Reversing the rotation reverses
Installation, General Comments 1 the flow through the pump. When determining shaft
Foundation 2 rotation, always look from the shaft end of the pump.
Alignment 3 Unless otherwise specified, rotation is assumed to be
Piping 3 clockwise (CW), which makes the suction port on the
Start Up 4 right side of the pump. The idler pin, which is offset in the
Troubleshooting 5 pump head, should be properly positioned toward and
Preventative Maintenance 6 an equal distance between the port connections.
Rapid Wear 7
Do’s and Don’ts 7 DISCHARGE B
Warranty 8
INSTALLATION A
GENERAL
Before installation is started a few items of a general nature
should be considered. SUCTION
1. Location - always locate the pump as close as possible
to the supply of liquid to be pumped. Locate it below
the liquid supply if at all practical. Viking pumps are self IDLER PIN
priming but the better the suction conditions the better
the performance.
FIGURE 3
2. Accessibility - the pump should be located where it is 5. Pressure Protection - Viking pumps are positive
accessible for inspection, maintenance, and repair. For displacement. This means that when the pump is rotated,
large pumps, allow room to remove the rotor and shaft liquid will be delivered to the discharge side of the pump.
without removing the pump from the base. If there is no place for this liquid to go - discharge line is
blocked or closed - pressure can build up until the motor
3. Port Arrangement - since the pumps have different port stalls, the drive equipment fails, a pump part breaks or
arrangements depending on the model, port location ruptures, or the piping bursts. Because of this, some
should be checked before starting the installation. The form of pressure protection must be used with a positive
ports may be upright, opposite or at right angles to each displacement pump. This may be relief valve mounted
other, see Figure 1. The right angle ports are normally directly on the pump, an inline relief valve, a torque
right-hand, see Figure 2; some models are available with limiting device or a rupture disk
left-hand arrangements; still other models are available
with the right angle ports located in any one of eight
VALVE BODY (C) SPRING (A)
positions including right-hand and left-hand. CAP
POPPET (B) (SHOULD ALWAYS
POINT TOWARD
POINT (E) SUCTION PORT)
FIGURE 1
ADJUSTING
SCREW (D)
VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA
against the underside of the poppet at point (E). When the DISCHARGE
force exerted by the liquid under the poppet exceeds that
exerted by the spring, the poppet lifts and liquid starts to PUMP HEAD
flow through the valve. As the discharge pressure builds up,
more and more of the liquid flows through until a pressure
is reached at which all of the liquid being pumped is going
through the valve. This is pressure is the relief valve setting.
CAUTION !
SUCTION
Internal type relief valves mounted
RELIEF VALVE ADJUSTING
on Viking pumps should always have SCREW CAP(SHOULD ALWAYS POINT
the cap or bonnet pointed toward the TOWARD SUCTION PORT
suction side of the pump. Return-to- FIGURE 5A
INTERNAL PRESSURE RELIEF VALVE
tank-type relief valves should always
be mounted on the discharge side of DISCHARGE
the pump. If pump rotation is reversed,
change the relief valve. Turn the in- PUMP HEAD
1. Check pump ports to be sure they are square and in 1. Never use piping smaller than the pump port
proper position; shim or move pump as required. Do not connections.
force piping to line up with the ports.
2. Be sure the inside of the pipe is clean before hooking it
2. If the pump is driven by a flexible coupling(s) either direct up.
connected to the motor or through a reducer, remove
any coupling guards or covers and check alignment of 3. Foot valve - When pumping a light liquid with a suction
the coupling halves. A straightedge (a piece of key stock lift, a foot valve at the end of the suction piping or a
works nicely) across the coupling must rest evenly on check valve in the first horizontal run will hold the liquid
both rims at the top, bottom, and sides. See Figure 6. in the line and make it easier for the pump to prime.
Be sure the foot or check valve is big enough so that it
3. If the pump is driven by V-belts, check the alignment by doesn’t cause excessive line loss.
using a long straightedge or tightly drawn string across
the face of the sheaves. See Figure 6A.
FIGURE 9
WHEN SHEAVES ARE PROPERLY ALIGNED ALL POINTS A, B, C, D WILL
TOUCH STRING OR STRAIGHTEDGE. V-BELT DRIVE
FIGURE 6A
SECTION TSM 000 ISSUE E PAGE 3 OF 8
4. When approaching an obstacle in the suction or
discharge line, go around the obstacle instead of over it.
Going over it creates an air pocket. See Figure 10. NOT THIS
OBSTRUCTION OBSTRUCTION
GO AROUND THE
OBSTRUCTION ON
THE HORIZONTAL THIS
13. Now you are ready to push the “start” button - gently. 3. Fluttering, jumping, or erratic reading -
a). Liquid vaporizing.
If the pump begins to deliver liquid within 60 seconds, you’re b). Liquid coming to pump in slugs, possibly an air leak
in business. If it does not, push the “stop” button. Do not insufficient liquid above the end of the suction pipe.
run the pump longer than one minute without liquid in it; you c). Vibrating from cavitation, misalignment, or damage
may damage it. Review the steps just outlined, consider parts.
what the suction and discharge gauges indicate, see page
6; if everything appears to be in order, put some liquid in the Pressure Gauge - Discharge Port
pump, a lubricating liquid is best. This will help it prime. 1. High reading would indicate -
Push the “start” button again. If nothing is flowing within two a). High viscosity and small and/or long discharge line.
minutes, stop the pump. The pump is not a compressor, it will b). Gate valve partially closed.
not build up much air pressure; it may be necessary to vent c). Filter plugged.
the discharge line until liquid begins to flow. d). Vertical head did not consider a high specific gravity
liquid.
If the pump still does not deliver, the cause may be one or e). Line partially plugged from build up on inside of
more of the following: pipe.
1. Suction line air leaks; vacuum gauge reading should help f). Liquid in pipe not up to temperature.
determine if this is the problem. g). Liquid in pipe has undergone a chemical reaction
and has solidified.
2. End of suction pipe not submerged deep enough in h). Relief Valve set too high.
liquid.
3. Suction lift is too great or the suction piping is too small. 2. Low reading would indicate -
a). Relief valve set too low.
4. Liquid is vaporizing in the suction line before it gets to the b). Relief valve poppet not seating properly.
pump. c). Bypass around the pump partially open.
SECTION TSM 000 ISSUE E PAGE 5 OF 8
d). Too much extra clearance. E). Pump takes too much power.
e). Pump worn. 1. Running too fast - Is correct motor speed, reducer ratio,
sheave size, etc. being used?
3. Fluttering, jumping, or erratic reading -
2. Is liquid more viscous than unit sized to handle; heat the
a). Cavitation.
liquid, increase the pipe size, slow the pump down, or
b). Liquid coming to pump in slugs.
get a bigger motor.
c). Air leak in suction line.
3. Discharge pressure higher than calculated, check
d). Vibrating from misalignment or mechanical
with pressure gauge. Increase size or reduce length
problems.
of pipe, reduce speed (capacity), or get bigger
Some of the following may also help pinpoint the problem: motor.
4. Packing gland drawn down too tight.
A). Pump does not pump. 5. Pump misaligned.
1. Lost its prime - air leak, low level in tank, foot valve 6. Extra clearance on pumping elements may not be
stuck. sufficient for operating conditions. Check parts for
2. Suction lift too high. evidence of drag or contact in pump and increase
3. Rotating in wrong direction. clearance where necessary.
4. Motor does not come up to speed.
5. Suction and discharge valves not open. F). Rapid Wear.
6. Strainer clogged. On most applications the pump will operate for many
7. Bypass valve open, relief valve set too low, relief valve months or years before it gradually loses its ability to
poppet stuck open. deliver capacity or pressure. Examination of such a
8. Pump worn out. pump would show a smooth wear pattern on all parts.
9. Any changes in the liquid system, or operation that Rapid wear, occurring in a few minutes, hours or days,
would help explain the trouble, e.g. new source of shows up as heavy grooving, galling, twisting, breaking
supply, added more lines, inexperienced operators, etc. or similar severe signs of trouble. SEE CHART PAGE 7.
10. Too much end clearance.
11. Head position incorrect. See Fig. 3.
B). Pump starts, then loses its prime. PREVENTATIVE MAINTENANCE
1. Supply tank empty.
Performing a few preventative maintenance procedures will
2. Liquid vaporizing in the suction line.
extend the life of your pump and reduce the overall cost of
3. Air leaks or air pockets in the suction line; leaking air
ownership.
through packing or mechanical seal.
4. Worn out. A). Lubrication - Grease all grease fittings after every 500
hours of operation or after 60 days, whichever occurs
C). Pump is noisy. first. If service is severe, grease more often. Do it gently
1. Pump is being starved (heavy liquid cannot get to pump with a hand gun. Use a NLGI #2 grease for normal
fast enough). Increase suction pipe size or reduce applications. For hot or cold applications use appropriate
length. grease. See Engineering Service Bulletin ESB-515.
2. Pump is cavitating (liquid vaporizing in the suction line).
B). Packing Adjustment - Occasional packing adjustment
Increase suction pipe size or reduce length; if pump is
may be required to keep leakage to a slight weep; if
above the liquid, raise the liquid level closer to the pump;
impossible to reduce leakage by gentle tightening,
if the liquid is above the pump, increase the head of
replace packing or use different type. See Technical
liquid.
Service Manual on particular model series for details on
3. Check alignment.
repacking.
4. May have a bent shaft or rotor tooth. Straighten or
replace. C). End Clearance Adjustment - After long service the
5. Relief valve chatter; increase pressure setting. running clearance between the end of the rotor teeth and
6. May have to anchor base or piping to eliminate or reduce the head may have increased through wear to the point
vibration. where the pump is losing capacity or pressure. Resetting
7. May be a foreign object trying to get into the pump end clearance will normally improve pump performance.
through the suction port. See TSM on particular model series for procedure on
adjusting end clearance for pump involved.
D). Pump not up to capacity.
1. Starving or cavitating - increase suction pipe size or D). Examine Internal Parts - Periodically remove the head,
reduce length. examine idler and bushing and head and pin for wear.
2. Strainer partially clogged. Replacing a relatively inexpensive idler bushing and
3. Air leak in suction piping or along pump shaft. idler pin after only moderate wear will eliminate the
4. Running too slowly; is motor the correct speed and is it need to replace more expensive parts at a later date.
wired up correctly. See TSM on particular model series for procedure in
5. Bypass line around pump partially open. removing head of the pump. Be sure idler does not
6. Relief valve set too low or stuck open. slide off idler pin as head is removed and drop and hurt
7. Pump worn out. someone or damage the part.
8. Too much end clearance.
9. Head position incorrect. See Fig. 3. E). Cleaning the Pump - A clean pump is easier to inspect,
lubricate, adjust, and runs cooler; plus, it looks better.
ABRASIVES Gouges or marks made by large, hard particles; Flush the system with the pump removed. Install strainer
1.
a rapid wearing away of bushings from very small in suction line. Oftentimes after a system has run for a few
abrasives similar to pumice; or anything in between. cycles or a few days the dirt is pretty well cleaned out and
if the pump is rebuilt into good condition it will then last for
a long time.
CORROSION Rust, pitting or metal appears to be “eaten” away. Check the Viking General Catalog Liquid List for materials
2.
of construction recommendation. Consider whether all of
the materials used in pump construction were attacked;
consider other materials used in the system to determine
how they resisted the liquid. Check to see whether or not the
liquid has been contaminated to make it more corrosive than
anticipated.
EXCEEDING OPERATING Noisy operation, broken bushings, twisted shaft, Review General Catalog for operating limits on particular
3.
LIMITS parts show evidence of high heat (discoloration). model involved.
INSUFFICIENT EXTRA Pump may stall. Evidence of heavy contact between Increase end clearance and/or contact your distributor or
4.
CLEARANCE end of rotor teeth and head or other parts. the factory with details of the application so that information
regarding proper extra clearance may be provided.
LACK OF LUBRICATION Noisy bearings, localized heating at bearings or lip Be sure all grease fittings are greased before starting and
5.
seal, smoke, rapid bushing wear. instructions for lubrication of drive equipment are followed;
consider use of auxiliary lubricating equipment.
MISALIGNMENT Wear on only one part of a surface, e.g., one side Double check alignment of drive equipment and piping.
6.
of the casing, one side of the packing gland, only a Check the alignment under conditions as close to operating
portion of the face of the head. conditions as possible.
Pump stalls because parts have uneven expansion Be sure there is liquid in the system at the time of start up.
7. RUN DRY
caused by frictional heat; galling between surfaces Provide some kind of automatic alarm or shut-off if supply
having relative motion; seal seats and idler pins tank runs dry.
changing colour because of high heat.
.
PAGE 8 OF 8
INSTALLATION, START UP, TRUBLESHOOTING,
ISSUE E
PREVENTATIVE MAINTENANCE, DO’S & DON’TS
those shown in the catalog for your model. 9. Do have spare parts, pumps or standby units available,
particularly if the pump is an essential part of a key
3. Don’t operate pumps at temperatures above or below
operation or process.
limits shown in the catalog for your pump.
4. Don’t operate pumps without all guards being in place.
5. Don’t operate pump without a relief valve on the pump
or in the discharge piping; be sure valve is mounted and
set correctly.
6. Don’t exceed catalog limits for temperature and
pressures of fluids in jacketed areas of pump.
WARRANTY
7. Don’t use the pump in a system, which includes a steam
blow or an air or vapour blow or purge without provision Viking warrants all products manufactured by it to
for over-speed shutdown in case the pump starts to act be free from defects in workmanship or material for a
as a turbine and over-speeds the drive. period of one (1) year from date of startup, provided
that in no event shall this warranty extend more than
8. Don’t operate the pump with all of the liquid bypassing eighteen (18) months from the date of shipment from
through a pump mounted internal type relief valve or Viking. If, during said warranty period, any products
without any flow of liquid going through the pump for sold by Viking prove to be defective in workmanship
more than a couple of minutes. Operation under either or material under normal use and service, and if such
of these conditions may result in a heat build-up in products are returned to Viking’s factory at Cedar
the pump, which could cause hazardous conditions or Falls, Iowa, transportation charges prepaid, and if
the products are found by Viking to be defective in
happenings.
workmanship or material, they will be replaced or
repaired free of charge, FOB. Cedar Falls, Iowa.
MAINTENANCE - Viking assumes no liability for consequential
damages of any kind and the purchaser by acceptance
1. Do make sure any pump that has residual system of delivery assumes all liability for the consequences of
pressure in it or that has handled high vapour pressure the use or misuse of Viking products by the purchaser,
liquids, e.g., LP-gas, ammonia, Freons, etc. has been his employees or others. Viking will assume no field
vented through the suction or discharge lines or other expense for service or parts unless authorized by it in
openings provided for this purpose. advance.
Equipment and accessories purchased by Viking
2. Do make sure that if the pump is still hooked to the driver from outside sources which are incorporated into any
while maintenance is being performed that the driver Viking product are warranted only to the extent of and
has been “locked out” so that it cannot be inadvertently by the original manufacturer’s warranty or guarantee,
started while work is being done on the pump. if any.
3. Do make sure any pump that has handled a corrosive, THIS IS VIKING’S SOLE WARRANTY AND IS IN
flammable, hot, or toxic liquid has been drained, flushed, LIEU OF ALL OTHER WARRANTIES, EXPRESSED
vented and/or cooled before it is disassembled. OR IMPLIED, WHICH ARE HEREBY EXCLUDED,
INCLUDING IN PARTICULAR ALL WARRANTIES
4. Don’t drop parts during disassembly, e.g., idler can slip OF MERCHANTABILITY OR FITNESS FOR A
from the pin as the head is removed from the pump; PARTICULAR PURPOSE. No officer or employee of
it may drop on your foot, plus, it may get nicked or IDEX Corporation or Viking Pump, Inc. is authorized to
gouged. alter this warranty.
5. Don’t stick fingers in the ports of a pump! Serious injury
may result.
6. Don’t spin the idler on the idler pin! Fingers may be
jammed between teeth and crescent.
7. Do remember that a few simple preventative
maintenance procedures such as periodic lubrication,
adjustment of end clearance, examination of internal
parts, etc., will extend the service life of your pump.
8. Do obtain, read and keep maintenance instructions
furnished with your pump.
MODEL: 110GME
REFRIGERANT: R-22
TYPE OF COOLING: LIQUID INJECTION
APPLICATION: HIGH STAGE – FIXED VI
TYPE OF CONTROL: MICRO III
OPERATING CONDITIONS:
PACKAGE RATINGS:
CAPACITY 43.9 Tons
POWER 121.1 BHP
Ratings are for the complete package including losses for FES supplied suction and
discharge stop valves. Stop valves supplied by others may have losses slightly greater or
less than those used in the calculation.
PRECOOLER COMPONENTS
Strainer 370-007590-150 1
Temperature Probes
Separator Oil 715-00006A-001 1 1T
Inlet Oil 715-00006A-000 1 2T
Discharge 715-00006A-000 1 3T
Suction 715-00006A-001 1 4T
Pressure Transducers
Suction 745-001500-000 1 1TD, 0-100 psia
Discharge 745-001510-000 1 2TD, 0-500 psig
Inlet Oil 745-001510-000 1 3TD, 0-500 psig
Oil Filter Inlet 745-001510-000 1 4TD, 0-500 psig
ENCLOSURE: NEMA 4
UNITS: I-P
LANGUAGE: ENGLISH
ENVIRONMENT: NON-HAZARDOUS
Suction Pressure
Suction 1 Pressure Setpoint 4.9 psig
Suction 1 Pressure Upper 10.2 psig
Suction 1 Pressure Lower 0.5 psig
Suction 1 Pressure Proportional Band 4.0 psi
Suction 1 Pressure Dead Band 0.5 psi
Suction 2 Pressure Setpoint 4.9 psig
Suction 2 Pressure Upper 10.2 psig
Suction 2 Pressure Lower 0.5 psig
Suction 2 Pressure Proportional Band 4.0 psi
Suction 2 Pressure Dead Band 0.5 psi
Low Suction Pressure 0=Shutdown / 1=Cycle 0
Process Temperature
Process 1 Temperature Setpoint 0.0 °F
Process 1 Temperature Upper 0.0 °F
Process 1 Temperature Lower 0.0 °F
Process 1 Temperature Proportional Band 0.0 °F
Process 1 Temperature Dead Band 0.0 °F
Process 2 Temperature Setpoint 0.0 °F
Process 2 Temperature Upper 0.0 °F
Process 2 Temperature Lower 0.0 °F
Process 2 Temperature Proportional Band 0.0 °F
Process 2 Temperature Dead Band 0.0 °F
Low Process Temperature 0=Shutdown / 1=Cycle 0
Process Temperature Control Low Suction 0.0 psig
Process Temperature Control Proportional Band 0.0 psig
Process Temperature Control Load Adjust 0.0 psig
Compressor Motor
Motor Current Upper (FLA X SF) 193.2 A
Motor Current Lower (FLA X SF X 0.85) 164.2 A
Motor Current Dead Band (Nom. 10% FLA) 16.8 A
Anti-Recycle Period 20 min
Accumulated Compressor Runtime 0.0 hrs
Motor Current CT Ratio 300 :5
Inlet Oil
Oil Filter Pressure Drop Maximum 15.0 psid
Inlet Oil Temperature Upper 150.0 °F
Inlet Oil Temperature Lower 95.0 °F
Oil Separator
Oil Separator Heater Setpoint 115.0 °F
Oil Separator Temperature Upper 225.0 °F
Oil Separator Temperature Lower 75.0 °F
Discharge
Discharge Pressure Maximum 270.0 psig
Discharge Pressure Proportional Band 10.0 psi
Discharge Temperature Upper 225.0 °F
Control
Control Mode 0=Pressure / 1=Tempreature / 2=Digital Input 0
Control Point 0=Digital Input / 1=Point #1 / 2=Point #2 1
Capacity Load / Unload Period 4.0 s
Slide Valve Position Minimum 0.0 %
Load Limit 0=None / 1=Pulse / 2=Set Point / 3=Slide Valve 0
Economizer
Economizer Solenoid On Above % 40.0 %
Economizer Solenoid Off Below % 40.0 %
Slide Valve
Slide Valve Output #1 ON Position 0.0 %
Slide Valve Output #1 OFF Position 0.0 %
Slide Valve Output #2 ON Position 0.0 %
Slide Valve Output #2 OFF Position 0.0 %
Power Failure Reset
Reset to Mode? 1=Local / 2=Remote 1
Delay Before Power Fail Reset 10.0 s
Abort Power Fail Reset After 600.0 s
Power Monitoring
Demand Metering Ratio (CT)(Voltage)(.7)(1.732)/1000 167.3 kW
Kilo Watt Hour Sampling Period 5 min
Kilo Watt Hours Consumed 0.0 kWh
Historical Data
Short Term Sampling Period 2.0 s
Long Term Sampling Period 10 min
Reset Short Term Trend (0=No / 1=Yes) 0
Reset Long Term Trend (0=No / 1=Yes) 0
Real Time Clock
Hour (0-23)
Minute (0-59)
Second (0-59)
Day of Week (1=Sun / 7=Sat)
Month (1-12)
Day of Month (1-31)
Year (00-99)
Units
Temperature 0=°C / 1=°F 1
Pressure 0=kg/cm2 / 1=kPa / 2=psi / 3=Bar 2
Reset Memory
Reset Memory (0=No / 1=Yes) 0
ALARM PARAMETERS
Suction Pressure
Suction 1 Pressure Upper 9.0 psig
Suction 1 Pressure Lower 1.3 psig
Suction 2 Pressure Upper 9.0 psig
Suction 2 Pressure Lower 1.3 psig
Process Temperature
Process 1 Temperature Upper 0.0 °F
Process 1 Temperature Lower 0.0 °F
Process 2 Temperature Upper 0.0 °F
Process 2 Temperature Lower 0.0 °F
Process Temperature Control Low Suction 0.0 psig
Compressor Motor
Motor Current Upper (FLA X S.F. X 0.99) 191.2 A
Inlet Oil
Oil Filter Pressure Drop Maximum 10.0 psi
Inlet Oil Temperature Upper 145.0 °F
Inlet Oil Temperature Lower 102.0 °F
Oil Separator
Oil Separator Temperature Upper 210.0 °F
Oil Separator Temperature Lower 102.0 °F
Discharge
Discharge Pressure Maximum 250.0 psig
Discharge Temperature Upper 210.0 °F
Deg. F R-22 R-717 R-134a R-507 R-290 R-1270 Deg. F R-22 R-717 R-134a R-507 R-290 R-1270
-60 11.9 18.7 21.6 5.8 10.2 4.4 27 51.2 41.2 23.7 68.7 48.4 63.2
-55 9.2 16.7 20.2 2.2 7.4 0.8 28 52.4 42.4 24.5 70.2 49.5 64.6
-50 6.1 14.4 18.6 0.9 4.3 1.5 29 53.7 43.7 25.3 71.7 50.6 66.0
-45 2.7 11.8 16.7 3.1 0.9 3.6 30 54.9 44.9 26.1 73.3 51.7 67.3
-40 0.6 8.8 14.7 5.5 1.4 5.9 31 56.2 46.1 26.9 74.8 52.9 68.7
-35 2.6 5.5 12.3 8.2 3.4 8.4 32 57.5 47.4 27.8 76.4 54.0 70.1
-30 4.9 1.7 9.7 11.1 5.6 11.1 33 58.8 48.7 28.6 78.0 55.2 71.5
-25 7.5 1.2 6.8 14.9 8.1 14.1 34 60.2 50.0 29.5 79.6 56.4 72.9
-20 10.2 3.5 3.6 17.9 10.7 17.4 35 61.5 51.4 30.4 81.3 57.6 74.3
-18 11.4 4.5 2.2 19.3 11.8 18.8 36 62.9 52.7 31.3 82.9 58.8 75.8
-16 12.6 5.6 0.7 20.9 13.0 20.2 37 64.3 54.1 32.2 84.6 60.0 77.3
-14 13.9 6.7 0.4 22.5 14.1 21.6 38 65.7 55.5 33.1 86.3 61.3 78.8
-12 15.2 7.8 1.2 24.1 15.4 23.2 39 67.1 57.0 34.1 88.1 62.5 80.3
-10 16.5 9.0 2.0 25.9 16.7 24.7 40 68.6 58.4 35.0 89.8 63.8 81.9
-8 17.9 10.2 2.8 27.6 18.0 26.3 41 70.0 59.2 36.0 91.6 65.1 83.5
-6 19.4 11.5 3.7 29.4 19.3 28.0 42 71.5 61.4 37.0 93.3 66.4 85.0
-4 20.9 12.8 4.6 31.3 20.7 29.7 43 73.0 62.9 38.0 95.2 67.8 86.6
-2 22.4 14.2 5.5 33.2 22.2 31.4 44 74.5 64.5 39.0 97.0 69.1 88.2
0 24.0 15.6 6.5 35.3 23.6 33.2 45 76.1 66.1 40.0 98.9 70.5 90.1
1 24.8 16.4 7.0 36.2 24.4 34.1 46 77.6 67.6 41.1 100.8 71.8 91.5
2 25.7 17.1 7.5 37.3 25.2 35.1 47 79.2 69.3 42.2 102.7 73.2 93.2
3 26.5 17.9 8.0 38.3 26.0 36.0 48 80.8 70.9 43.2 104.6 74.6 94.9
4 27.4 18.7 8.6 39.4 26.7 37.0 49 82.4 72.6 44.3 106.6 76.0 96.6
5 28.3 19.5 9.1 40.5 27.6 38.0 50 84.1 74.3 45.4 108.6 77.5 98.3
6 29.1 20.3 9.7 41.6 28.4 39.0 55 92.6 83.2 51.2 118.9 84.9 107.2
7 30.0 21.1 10.2 42.7 29.2 40.0 60 101.6 92.6 57.4 129.8 92.8 116.7
8 31.0 22.0 10.8 43.8 30.0 41.0 65 111.3 102.8 64.0 141.4 101.2 126.7
9 31.9 22.8 11.4 45.0 30.9 42.0 70 121.5 113.8 71.1 153.6 110.0 137.2
10 32.8 23.7 12.0 46.2 31.7 43.1 75 132.2 125.5 78.7 166.6 119.3 148.3
11 33.8 24.6 12.6 47.3 32.6 44.1 80 143.7 138.0 86.7 180.3 129.1 159.9
12 34.8 25.5 13.2 48.5 33.5 45.2 85 155.7 151.4 95.2 194.9 139.4 172.2
13 35.8 26.4 13.8 49.8 34.4 46.3 90 168.4 165.5 104.3 210.2 150.2 185.1
14 36.8 27.4 14.4 51.0 35.3 47.4 95 181.9 180.6 113.9 226.4 161.6 198.6
15 37.8 28.3 15.1 52.3 36.2 48.6 100 196.0 196.7 124.1 243.6 173.6 212.8
16 38.8 29.3 15.7 53.5 37.2 49.7 105 210.8 213.3 134.9 261.6 186.1 227.7
17 39.9 30.3 16.4 54.8 38.1 50.9 110 226.4 231.8 146.4 280.7 199.2 243.2
18 40.9 31.3 17.1 56.1 39.1 52.0 115 242.8 251.0 158.4 300.8 213.0 259.5
19 42.0 32.4 17.7 57.4 40.1 53.2 120 260.0 271.1 171.1 322.0 227.4 276.5
20 43.1 33.4 18.4 58.8 41.1 54.4 125 278.1 292.5 184.5 344.3 242.5 294.2
21 44.2 34.5 19.2 60.1 42.1 55.6 130 297.0 314.9 198.7 367.8 258.2 312.8
22 45.3 35.5 19.9 61.5 43.1 56.9 135 316.8 338.8 213.5 392.7 274.7 332.1
23 46.5 36.6 20.6 62.9 44.1 58.1 140 337.5 363.5 229.2 418.8 291.9 352.3
24 47.6 37.7 21.4 64.3 45.2 59.4 145 359.5 390.2 245.6 446.3 309.8 373.3
25 48.8 38.8 22.1 65.8 46.2 60.6 150 381.7 417.4 262.8 475.3 328.5 395.2
26 50.0 40.0 22.9 67.2 47.3 61.9 155 405.4 447.0 281.0 505.8 348.0 418.1
COMPRESS0R PARTS
DESCRIPTION 110GM QTY. 125GM QTY. 160GM QTY. 195GM QTY.
KIT, MECHANICAL SHAFT SEAL 391-00451M-000 1 391-00451M-000 1 391-00452M-000 1 391-00452M-000 1
KIT INCLUDES:
SEAL, MECHANICAL SHAFT 390-004510-040 1 390-004510-040 1 390-004510-040 1 390-004510-040 1
O-RING, MECH. SEAL OUTER HUB 390-004510-041 1 390-004510-041 1 390-004200-066 1 390-004200-066 1
INSTRS., SEAL REPLACEMENT 037-000018-000 1 037-000018-000 1 037-000018-000 1 037-000018-000 1
ELEMENT, SUCTION STRAINER 390-004510-133 1 390-004510-133 1 390-004520-133 1 390-004520-133 1
KIT, SHAFT SEAL (HNBR) 391-N0451M-000 1 391-N0451M-000 1 391-N0452M-000 1 391-N0452M-000 1
PACKAGE COMPONENTS
COALESCER, OIL SEPARATOR 030-00613C-008 2 030-00613C-008 2 030-00613C-008 2 030-00613C-008 3
GASKET, MANWAY 030-00086C-000 1 030-00086C-000 1 030-00086C-000 1 030-00085C-000 1
OIL FILTER, SPIN ON 130-000910-002 1 130-000910-002 1 130-000910-002 1 130-000910-002 1
H.S. 370-007595-110 1 370-007595-110 1 370-007595-110 1 370-007840-002 1
ELEMENT, OIL STRAINER
BSTR. 370-007595-110 1 370-007595-110 1 370-007595-110 1 370-007595-110 1
COIL, SOLENOID VALVE (USED IN
390-004260-139 4 390-004260-139 4 390-004260-139 4 390-004260-139 4
LOAD/UNLOAD)
VALVE, RELIEF 250 PSIG R-717, H.S./BSTR. 370-016980-250 2 370-016980-250 2 370-016980-250 2 370-016980-250 2
R-22, H.S. 370-016980-300 1 370-016980-300 1 370-016980-300 1 370-016990-300 1
VALVE, RELIEF 300 PSIG
R-22, BSTR. 370-016980-300 1 370-016980-300 1 370-016980-300 1 370-016980-300 1
FLOAT SWITCH, LOW OIL LEVEL 745-001850-000 1 745-001850-000 1 745-001850-000 1 745-001850-000 1
KIT, MECHANICAL SHAFT SEAL
291-00012M-000 1 291-00012M-000 1 291-00012M-000 1 291-00012M-000 1
(EXTERNAL OIL PUMP)
SCREEN, MAIN OIL INJECTION STRAINER
370-007595-110 1 370-007595-110 1 370-007595-110 1 370-007595-110 1
(R-717/R-22 BSTR.; R-22 LIQ. INJ. H.S.)
VALVE, BALL 1” 360-000050-000 1 360-000050-000 1 360-000050-000 1 360-000050-000 1
VALVE, BALL 1-1/2” 360-001720-150 1 360-001720-150 1 360-001720-150 1 360-001720-150 1
VALVE, COMBO 370-005090-000 1 370-005090-000 1 370-005090-000 1 370-005090-000 1
VALVE, DRAIN 370-005130-000 1 370-005130-000 1 370-005130-000 1 370-005130-000 1
COOLING CONTROLS – LIQUID INJECTION OIL COOLING
VALVE, COIL (115V) SOLENOID 370-001860-000 1 370-001860-000 1 370-001860-000 1 370-001860-000 1
KIT, REPLACEMENT PARTS FOR TX VALVE:
R-717 HIGH STAGE 370-001880-020 1 370-001880-020 1 370-001880-020 1 370-001880-050 1
R-717 BOOSTER 370-001890-005 1 370-001890-005 1 370-001890-010 1 370-001890-010 1
R-22 HIGH STAGE 370-004000-016 1 370-004000-020 1 370-008080-000 1 370-008080-042 1
R-22 BOOSTER N/A (Replace Valve) N/A (Replace Valve) 370-004000-005 1 370-004000-005 1
VALVE, PRESSURE REDUCING (R-717) 370-000400-000 1 370-000400-000 1 370-000400-000 1 370-000400-000 1
VALVE, HOT GAS SOLENOID
BSTR. 370-007530-015 1 370-007530-015 1 370-007530-015 1 370-007530-015 1
(COMPLETE)
COIL ONLY BSTR. 370-007620-115 1 370-007620-115 1 370-007620-115 1 370-007620-115 1
* Use P/N 370-003290-000 for Type RF design – identified by an “-F” after the FES P/N on the nameplate.
The recommended spare parts listing represents those items FES believes to be prudent customer selections for continued operation with minimum
downtime during routine or emergency maintenance.