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Vission 20/20 Retrofit Instructions Table of Contents Sections 1.0 2.0 2.1 2.2 3.0 Page General Information ................................................................................................................ 3 Vission 20/20 Retrofit Instructions .......................................................................................... 4 Removal ................................................................................................................................. 4 Installation .............................................................................................................................. 5 Field Wiring Instructions ......................................................................................................... 9 Table/Figures Page Table 1. Torque Specifications .................................................................................................... 12 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. VSS Compressor Unit with Keypad Microprocessor ....................................................... 4 Block and Bleed Assembly ............................................................................................. 5 Vission 20/20 with Vibration Isolators .......................................................................... 6 Block and Bleed Assembly with Transducers .................................................................. 6 Compressor Unit RTD Locations .................................................................................... 7 Block and Bleed Assembly with Transducers and Cables ................................................ 8 RTD and Transducer Cable Routing ............................................................................... 8 Solenoid Cable Routing ................................................................................................. 9 MCC and Customer Control Center Interconnect Wiring ............................................... 10 Vission 20/20 Mircocontroller Diagram ......................................................................... 10 Vission 20/20 Terminal Blocks ....................................................................................... 11 1.0 General Information This procedure defines the steps required to replace a Vilter Keypad Microcontroller with the Vission 20/20 Microcontroller. It is highly recommended that the instructions be reviewed prior to retrofitting. Figures and tables are included to illustrate key concepts. Safety precautions are shown throughout the manual. They are defined as the following: WARNING - Warning statements are shown when there are hazardous situations, if not avoided, will result in serious injury or death. CAUTION - Caution statements are shown when there are potentially hazardous situations, if not avoided, will result in damage to equipment. NOTE - Notes are shown when there are additional information pertaining to the instructions explained. ViSSion® 20/20 Retrofit Instructions • 35391SCRF 3 2.0 Vission 20/20 Retrofit Instructions This procedure defines the steps required to replace a Vilter Keypad Microcontroller with the Vission 20/20 Microcontroller. 2.1 Step 1. Removal Safely shutdown and de-energize the compressor unit (1) and keypad microcontroller (2) adhering to safe practices including lock-out/tag-out procedures. Figure 1. VSS Compressor Unit with Keypad Microprocessor Step 2. Disconnect wiring from transducers. WARNING When handling microcontroller, use additional personnel or lifting device as required. Failure to comply may result in serious injury and/or damage to equipment. Step 3. With additional personnel or lifting device, remove hardware securing keypad microcontroller (2) to rails (4). Remove keypad mirocontroller. NOTE Some compressor units are equipped with transducers and RTDs, if equipped, continue to step 3. If not, continue to installation. 4 Step 4. Disconnect all associated pressure and temperature sensors from compressor unit (1) and existing block and bleed assembly (3), if present. Step 5. Remove the existing block and bleed assembly (3), if present. ViSSion® 20/20 Retrofit Instructions • 35391SCRF 2.2 Installation NOTE Torque all hardware according to torque table specifications, see Table 1. NOTE Modification to rails may be required to support and properly align Vission 20/20 microcontroller and block and bleed assembly. Follow standard practices for weldment and fabrication procedures. Step 5. Install new block and bleed assembly (4) on rails (3). Figure 2. Block and Bleed Assembly WARNING When handling microcontroller, use additional personnel or lifting device as required. Failure to comply may result in serious injury and/or damage to equipment. NOTE On smaller compressor units, ensure there is adequate clearance between Vission 20/20 microcontroller and volume slide actuator. Adjust location of microcontroller as required by modifying support structure. Step 6. Make sure Vission 20/20 microcontroller will install onto existing rails. Measure mounting holes on rails (3) and Vission 20/20 microcontroller (6), taking into consideration dimension of mounting holes of vibration isolators (5). Step 7. Modify structure of rails (3) if required. Follow standard welding and fabrication procedures. ViSSion® 20/20 Retrofit Instructions • 35391SCRF 5 Step 8. Install hardware to secure new vibration isolators (5) to mounting holes of Vission 20/20 microcontroller (6). Figure 3. Vission 20/20 with Vibration Isolators Step 10. With additional personnel or lifting device, install hardware to secure Vission 20/20 microcontroller (6) with vibration isolators (5) to rails (3). NOTE Ensure to use correct transducers because transducers have different pressure ranges. Suction manifold uses 0-200 psia transducer, discharge manifold and oil filter inlet uses 0-414.5 psia transducer. Step 9. Install transducers (7) on block and bleed assembly (4). Figure 4. Block and Bleed Assembly with Transducers 6 ViSSion® 20/20 Retrofit Instructions • 35391SCRF NOTE Stainless steel tubing is not provided in a retrofit kit. Step 10. Route stainless steel tubing from suction manifold, discharge manifold and oil filter inlet lines. If existing tubing is not reusable then cables can be secured to block and bleed assembly (4). NOTE Wells are also provided in retrofit kit. Install new wells as required. Step 11. Install RTDs (8) on suction manifold (9), discharge manifold (11), oil separator (12) and inlet oil line (14) or oil manifold (13), if equipped. Figure 5. Compressor Unit RTD Locations Step 12. Connect cables (10) to RTDs (8). ViSSion® 20/20 Retrofit Instructions • 35391SCRF 7 Step 12. Connect cables (10) to transducers (7). Figure 6. Block and Bleed Assembly with Transducers and Cables Step 13. Route cables (10) from RTDs (8) and transducers (7) through bottom right side of Vission 20/20 microcontroller (6). Figure 7. RTD and Transducer Cable Routing 8 ViSSion® 20/20 Retrofit Instructions • 35391SCRF CAUTION Do not route A/C and D/C wires together, this will cause Electromagnetic Interferance. Failure to comply may result in damage to equipment. Step 14. If equipped with solenoids (15) (i.e. Danfoss Motorized Valve), route cables (16) from solenoids through bottom left side of Vission 20/20 microcontroller (6). Figure 8. Solenoid Cable Routing Step 15. To make following connections according to supplied wiring diagram, refer to Section 3.0 Field Wiring Instructions. 3.0 Field Wiring Instructions NOTE This procedure defines steps required to wire Vission 20/20 microcontroller for the following items: Compressor Motor Starter Auxiliary Contact, High Level Shutdown, Oil Separator Heater(s), Oil Pump Start and Compressor Starter. General figures, Figures 9, 10 and 11 are used for purposes of explanation, follow supplied wiring diagram for detailed wiring. Step 1. Control power of 115 VAC 50/60 HZ must be wired to left side of terminal blocks inside the Vission 20/20 cabinet. Line power (1A) shall be connected to 15-amp circuit breaker, CB1. Neutral (1N) is connected to any N terminal blocks. Number of line power feeds required to panel is dependent upon number supplied on compressor. Line power feeds for oil heaters are brought to additional 15-amp circuit breakers, CB2A, CB2B, CB2C and CB2D. Neutrals for circuits (2N, 3N, 4N, and 5N) are connected to terminal blocks labeled HTN2, HTN3, HTN4, and HTN5. Units with V-PLUS® oil cooling, L1 must connected to fuse in V-PLUS panel, and L1A must be connected to terminal 2B. ViSSion® 20/20 Retrofit Instructions • 35391SCRF 9 VISSION 2020 ON COMPRESSOR SKID CUSTOMER MCC PANEL (REFERENCE MCC OR STARTER DRAWING FOR DETAILED WIRING) #12AWG THHN (MINIMUM) CB1 TB1-1A CUSTOMER SUPPLIED VISSION POWER CIRCUIT VISSION 20/20 POWER TB1-N N AUX MS1 TB-1 COMPRESSOR MOTOR STARTER AUX CONTACT TB1-18 COMPRESSOR MOTOR STARTER AUX CONTACT TB1-4 TB-31 TB-11 TB1-11 COMPRESSOR START COMMAND OIL PUMP START TB-12 TB1-12 OIL PUMP START COMMAND OIL SEPARATOR HEATER START TB-17 TB1-17 OIL SEPARATOR HEATER START COMMAND COMPRESSOR START Figure 9. MCC and Customer Control Center Interconnect Wiring Step 2. An auxiliary contact from compressor motor starter is required. Connect isolated contact to terminal blocks 1 and 31. CONTROL POWER DISCONNECT AND BRANCH CIRCUIT PROTECTION TO BE SIZED PER THE NATIONAL ELECTRIC CODE. INCOMING POWER SUPPLIED FROM REMOTE CUSTOMER SUPPLIED UL LISTED FUSED DISCONNECT OR BREAKER 1A 1 N1 FROM LINE 31 35 2 RS50-24 DC POWER SUPPLIES 36 37 OUTPUT 24 COM 39 8 OUTPUTS DIGITAL OUTPUT: BOARD #1 PLUG X1 10 11 12 13 1 3 4 12A N COMPRESSOR CR CMP STARTER 70 N OIL PUMP STARTER CR OP 73 BLUE 13 A1 *SEE NOTE 10 BLACK N CAPACITY INCREASE/DECREASE ACTUATOR 14 BROWN H LOW OIL LEVEL LS1 1 1 32 2 33 3 34 4 COMPRESSOR MOTOR STARTER AUXILIARY CONTACT HIGH LEVEL SHUTDOWN OPTIONAL OIL LEVEL FLOAT SWITCH #1 OPTIONAL OIL LEVEL FLOAT SWITCH #2 41 42 43 44 N N INPUTS N N 1 35 5 1 36 6 1 37 7 1 38 8 OPTIONAL CAPACITY CONTROL SELECT 1/2 OPTIONAL REMOTE START/STOP OPTIONAL REMOTE CAPACITY INCREASE OPTIONAL REMOTE CAPAPCITY DECREASE 45 46 47 14 OUTPUTS 1 16 17 18 19 48 H DIGITAL OUTPUT: BOARD #1 PLUG X2 15 2 11A 1 HL SHUTDOWN AUX 31 38 40 1 1 AUX MS1 +24VDC 7 9 INPUTS 1 DIGITAL INPUT: BOARD #3 PLUG X2 RD35-A +5VDC +12VDC 5/12 COM TO CPU BASEBOARD 6 33 34 LINE LOAD 1C 5 N DIGITAL INPUT: BOARD #3 PLUG X1 1B EMI FILTER 4 GND OUTPUT 1 DOOR GND LUG N GND SW 1 E-STOP INPUT CB 1 15 AMPS INPUT 3 FROM LINE 31 32 115VAC / 60HZ 2 GND 5 BLUE A2 *SEE NOTE 10 15 BLACK 6 16 7 17 49 N VOLUME INCREASE/DECREASE ACTUATOR BROWN 8 18 A1 CRH N A2 H OUTPUT CAN ALSO BE USED WITH AN INDICATING LIGHT, HORN, OR PLC INPUT (CUSTOMER SUPPLIED) N OIL SEPARATOR HEATER START 74, 78 OPTIONAL TRIP INDICATION 50 51 52 53 54 Figure 10. Vission 20/20 Mircocontroller Diagram Step 3. 10 A dry contact from control relay CR11 must be wired to compressor motor starter coil. This dry contact is wired to terminal blocks according to supplied drawing. Control power for this coil should come from a source, which will be de-energized with compressor disconnect. ViSSion® 20/20 Retrofit Instructions • 35391SCRF Step 4. A dry contact from control relay CR12 must be wired to oil pump motor starter coil. This dry contact is wired to two terminal blocks according to supplied drawing. Control power for this coil should come from a source, which will be de-energized with compressor disconnect. Step 5. An auxiliary safety cutout is available to shut down compressor package. A dry contact must be supplied and wired to terminal blocks 1 and 32. The jumper installed on terminal blocks must be removed to use this cutout. If contact is closed, it will allow compressor to run. If contact opens at any time, compressor will shut down. CB2C 15 A CB2C 15 A CB2C 15 A GND GND GND HT-N1 HT-N2 X1 X3 X4 ANALOG INPUT BOARD #6 DIGITAL OUTPUT BOARD #1 X2 X5 CB2C 15 A CB2C 15 A CB2C 15 A X1 GND GND GND HT-N1 HT-N2 X4 X5 ANALOG OUTPUT BOARD #10 OPEN 1 2 3 4 5 C5 CUSTOMER ANALOG WIRING C4 DIGITAL INPUT BOARD #3 1 1 1 1 1 1B N N N N N 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 28 31 32 33 34 35 36 37 38 45 46 47 48 DIGITAL WIRING CUSTOMER DIGITAL WIRING CB 1 15 A CB 1 15 A 1 1 1 1 1B N N N N N X3 ANALOG INPUT BOARD #7 DIGITAL OUTPUT BOARD #2 X2 Figure 11. Vission 20/20 Terminal Blocks Step 6. Indication of compressor shutdown status is also available. There is an output on terminal blocks 18 and N where a relay coil can be wired. For output, an energized state represents a “safe” condition. A deenergized state indicates a loss of voltage to relay coil or a “failure” has occurred. Step 7. Current transformer supplied in compressor motor conduit box should be checked to insure that motor leads of one leg are pulled through the transformer. Note, there is a dot on one side of the current transformer. This dot must face away from the motor. Typically, a wye delta started motor should have leads 1 and 6 pulled through this transformer for a 6 lead motor. However, this should always be checked as different motors and starting methods will require different leads to be used. ViSSion® 20/20 Retrofit Instructions • 35391SCRF 11 Table 1. Torque Specifications Torque Specifications (ft-lbs) Type Bolt Head Markings SAE Grade 2 Coarse (UNC) SAE Grade 5 Coarse (UNC) SAE Grade 5 Coarse (UNC) SAE Grade 8 Coarse (UNF) Nominal Size Numbers or Inches #10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 - 5 10 18 29 44 63 87 155 150* - 8 16 28 44 68 98 135 240 387 - - 18 - - - - - - - - 11 22 39 63 96 138 191 338 546 5 13 26 46 73 112 115 215 380 614 Socket Head Cap Screw (ASTM A574) Coarse (UNC) 1) Torque values in this table are not to override other specific torque specifications when supplied. 2) When using loctite, torque values in this table are only accurate if bolts are tightened immediately after loctite is applied. * The proof strength of Grade 2 bolts is less for sizes 7/8 and above and therefore the torque values are less than smaller sizes of the same grade. Torque Specifications for 17-4 Stainless Steel Fasteners (ft-lbs) Type Bolt/Nut Nominal Size Numbers or Inches Head Markings #10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 Hex & Socket Head Cap Screws 3 8 14 25 40 60 101 137 245 Nut - 8 - 25 - - - - - NOTE: Continue use of red loctite #271 (VPN 2205E) on currently applied locations. Use blue loctite #243 (VPN 2205F or 2205G) on all remaining locations. 12 ViSSion® 20/20 Retrofit Instructions • 35391SCRF 35391SCRF Rev. 1 (4/13) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. © 2012 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.