v-plus ac manual - xa

8/2/2019 V-Plus AC manual - XA

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VPN 35391XAJuly 2005 Rev.00Price $45.00


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READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR UNIT.

The following instructions have been prepared to assist in installation, operation V-Plus unit. Following theseinstructions will result in a long life of the compressor with satisfactory operation.

The entire manual should be reviewed before attempting to install, service or repair any part of your unit.

Please refer to your operation manuals for trouble shooting, servicing and maintaining your compressor. Also refer

to the Vission Vantage manual for the microprocessor.

The V-PLUS pump is the heart of the system. The pump draws the liquid refrigerant from the receiver and injects

it directly into the compressor discharge line. This is accomplished by developing a pressure difference between the

receiver and the compressor discharge line.

Vilter screw compressor components are thoroughly inspected at the factory, assuring the shipment of a me-chanically perfect piece of equipment. Damage can occur in shipment, however. For this reason, the units

should be thoroughly inspected upon arrival. Any damage noted should be reported immediately to theTransportation Company. This way, an authorized agent can examine the unit, determine the extent of dam-age and take necessary steps to rectify the claim with no serious or costly delays. At the same time, the local

Vilter representative or the home office should be notified of any claim made.

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

the compressor name plate on the compressor.

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

Vilter Manufacturing Corporation

Customer Service Department5555 South Packard Ave

P.O. Box 8904

Cudahy, WI 53110-8904 USA

Telephone: 1-414-744-0111

Fax:1-414-744-3483

e-mail: [email protected]

IMPORTANT NOTE


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The procedure described is a general recommendation for extended storage (over one month of no operation) of

Vilter Manufacturing packages and compressors. While this procedure is intended to cover most of the commonly

encountered situations, it is the responsibility of the installation firm and end user to address any unusual condi-

tions. We suggest using the accompanying Long Term Storage Log sheet for recording purposes to validate the

appropriate procedures.

Prior to start-up, Vilter recommends that a complete system pressure check be performed. Upon verification of the

system integrity, a comprehensive evacuation procedure should be completed to ensure a dry system before refriger-

ant is introduced. The oil circuit of any compressor is to be primed at initial start-up through the oil gauge connec-

tion on reciprocating compressors and the pre-lube oil pump on screw compressors.

Warranty of the system remains in effect as described in Section 5, Product Warranty and Procedures.

* If the unit is designed for indoor duty, it must be stored in a heated building.

If the unit is designed for outdoor duty, and is to be stored outdoors, a canvas tarp is recommended for protection

until installation is imminent. Adequate drainage should be provided, by placing wood blocks under the base

skid, so that water does not collect inside the base perimeter or low spots in the tarp.

* All compressor stop valves are to be closed to isolate the compressor from the remainder of the system. All

other valves, except those venting to atmosphere, are to be open. It is essential that the nitrogen holding charge

integrity be maintained.

* Cover all bare metal surfaces (coupling, flange faces, etc.) with rust inhibitor.

* Desiccant is to be installed in the control panel. If the panel is equipped with a space heater, it is to beenergized. If the panel does not have a space heater, use a thermostatically controlled 50-watt light bulb. Use

an approved electrical spray-on corrosion inhibitor for panel components (relays, switches, etc.)

* All pneumatic controllers and valves (Fisher, Taylor, etc.) are to be covered with plastic bags and sealed with

desiccant bags inside.

* System and compressor pressures (unit is shipped with dry nitrogen holding charge approximately 5 psi above

atmospheric pressure) are to be monitored, on a regular basis, for leakage. It will be necessary to add a gauge

to monitor the system holding charge pressure. If a drop in pressure occurs, the source of leakage must be found

and corrected. The system must be evacuated and recharged with dry nitrogen to maintain the package integ-

rity.

* Motors (NOTE: The following are general recommendations. Consult the manufacturer of your motor forspecific recommendations.)

Long Term Storage

Requirements


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Long Term Storage

Requirements

1) Remove the condensation drain plugs from those units equipped with them and insert silica-gel into the open-

ings. Insert one-half pound bags of silica-gel (or other desiccant material) into the air inlets and outlets of drip-

proof type motors.

NOTE: The bags must remain visible, and tagged, so they will be noticed and removed when the

unit is prepared for service.

2) Cover the unit completely to exclude dirt, dust, moisture, and other foreign materials.

3) If the motor can be moved, it is suggested that the entire motor be encased in a strong, transparent plastic bag.

Before sealing this bag, a moisture indicator should be attached to the side of the motor and several bags of

silica-gel desiccant put inside the bag, around the motor. When the moisture indicator shows that the desiccant

has lost its effectiveness, as by a change in color, the bag should be opened and fresh replacement desiccantsinstalled.

Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10F above

the ambient temperature.

NOTE: There is a potential for damage by small rodents and other animals that will inhabit

motors in search of warm surroundings or food. Due to this, a possibility of motor

winding destruction exists. Sealing motor openings should restrict access to the motor.

4) Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate flat spots on

the bearing surfaces. If the compressor unit is installed, wired and charged with oil, open all oil line valves and

run the oil pump for 10 seconds prior to rotating the compressor shaft. Continue running the oil pump while the

compressor shaft is being turned to help lubricate the surfaces of the shaft seal.


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Table of Contents

Important Messagae ............................................................................................................................................................. 3

Long Term Storage Requirements ....................................................................................................................................... 4

DOMESTIC TERMS and CONDITIONS........................................................................................................................... 8

EXPORT TERMS and CONDITIONS .............................................................................................................................. 10

STANDARD VILTER WARRANTY STATEMENT ............. .............. ............... .............. ............... .............. .............. ..... 12

Symbols and Meanings ...................................................................................................................................................... 13

Introduction/Installation ............................................................................................ 14

THEORY ............................................................................................................................................................................ 14

CLEANLINESS ................................................................................................................................................................. 15

GAS PURGING FLOAT VALVE ...................................................................................................................................... 15

LUBRICATION LINE........................................................................................................................................................ 15

LIMITATIONS ................................................................................................................................................................... 16

Prior to Start-Up ............................................................................................................................................................... 17

Set-Up.......................................................................................................................... 18

Two Methods of Oil Temperature Control ............. ............. .............. .............. .............. .............. ............... .............. .......... 18

OTC-1VISSION CONTROLLED ..................................................................................................................................... 18

A-B VFD SETUP ............................................................................................................................................................. 18

V-Plus AC Setup Sheet..................................................................................................................................................... 18

OTC-2 VFD Controlled ..................................................................................................................................................... 20

A-B VFD SETUP ............................................................................................................................................................. 20

Motor Documentation ........................................................................................................................................................ 22

Motor Documentation ........................................................................................................................................................ 22Motor Drawing ................................................................................................................................................................... 23

Motor Wiring...................................................................................................................................................................... 24

Motor Electrical Design /Curves ....................................................................................................................................... 25

Recommended Spare Parts List For AC Drive.............................................................................................................. 26AC Drive Specifications..................................................................................................................................................... 26

AC Drive Specifications..................................................................................................................................................... 27

Electrical Wiring Diagram ................................................................................................................................................. 28

Electrical Wiring Diagram ................................................................................................................................................. 30

V-Plus w/ 2hp Motor .......................................................................................................................................................... 30

V-Plus ................................................................................................................................................................................. 30

Control Panel Assembly ..................................................................................................................................................... 31

HMI Overview .................................................................................................................................................................... 32

External Connections ......................................................................................................................................................... 32HMI LCD Display Elements .............................................................................................................................................. 33

HMI Menu Structure .......................................................................................................................................................... 34

HMI Viewing/Editing Parameters................. .............. .............. .............. ............. .............. ............... .............. .............. ..... 36

HMI Linking Parameters ................................................................................................................................................... 37

HMI Removing/Installing .................................................................................................................................................. 39


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Installation .................................................................................................................. 40

I/O Wiring .......................................................................................................................................................................... 40

I/O Control Cassette ........................................................................................................................................................... 41Terminal Designations ....................................................................................................................................................... 42

Encoder Terminal Block/ ................................................................................................................................................... 43

Hardware Enabler Circuitry ............................................................................................................................................... 43

Wiring Examples ................................................................................................................................................................ 44

Start-Up ...................................................................................................................... 46

Check List........................................................................................................................................................................... 46

Status Indicators ................................................................................................................................................................. 47

Frequently Used Parameters ............................................................................................................................................... 48

Parameters .......................................................................................................................................................................... 48

Frequently Used Parameters ............................................................................................................................................... 49

Troubleshooting.................................................................................................................................................................. 55

Manually Clearing Faults ................................................................................................................................................... 57

Start-up ............................................................................................................................................................................... 58

Start-up Routines ................................................................................................................................................................ 60

Recommended Spare Parts Lists .................................................................................................................................... 62

Drawings ..................................................................................................................... 63

Purge Float Valve Drawing ................................................................................................................................................ 63

ISO/Standard Drawings ..................................................................................................................................................... 64

P&I Standard Drawings ..................................................................................................................................................... 65

Pump Info ........................................................................................................................................................................... 67


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Exclusivity. Sellers acceptance of Buyers order is expressly conditional upon Buyers agreement to these terms and

conditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly re-

jected, and do not form a part of this Agreement unless Seller agrees to such terms in writing.

Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bind

Seller unless this Agreement and any purported change are signed by a home office Officer of Seller.

Prices and Payments. Prices are exclusive of taxes and may be modified at any time prior to Seller receiving Buyers

binding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unless

agreed otherwise in writing, all payments are due in full within 30 days of Seller shipping the products or providing

the services. All overdue amounts will incur finances charge of the lesser of (a) 1 % per month and (b) the

maximum allowed by law.

Security Agreement. This Agreement shall be considered a security agreement to the maximum extent allowed by

law. Seller shall have, retain, and possess a security interest in all products sold to Buyer until Seller is paid in full.

Buyer grants to Seller a power of attorney to complete, sign on Buyers behalf, and file all forms reasonably necessaryto perfect Sellers security interest. If Buyer defaults, or Seller deems itself insecure of receiving payment, the full

unpaid balance shall become immediately due and payable at the option of the Seller, and Seller may retake posses-

sion of the products without Court order.

Delivery. Seller shall not be liable for delivery delays beyond its control, including delays caused by its suppliers. All

delivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Sellers

Order Acknowledgment, all shipments are F.O.B. Sellers factory. Seller reserves the rights to make installment

deliveries.

Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for a

period of eighteen (18) months from the date of shipment from Sellers manufacturing plant or twelve (12) months

from date of installation at the initial end users location, whichever occurs first. In addition, Seller provides the

following extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal

rotating parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and recip-

rocating compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties

do not apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or

regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product contains

all features necessary to safely perform in Buyers and its customers plants and operations. Buyer must notify Seller

of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such claim.

Products supplied by Seller which are manufactured by others are not warranted by Seller, but rather Seller merely

passes through the manufacturers warranty to Buyer. SELLER EXPRESSLY DISCLAIMS ALL OTHER WAR-RANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MER-

CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Unless otherwise agreed in writing, Buyers

sole remedy for breach of warranty is, at Sellers option, the repair of the defect, the correction of the service, or the

providing a replacement part FOB Sellers office. Seller will not be responsible for costs of dismantling, lost refrig-erant, reassembling, or transporting the product. Further, Seller will not be liable for any other direct, indirect,

consequential, incidental, or special damages arising out of a breach of warranty. THESE WARRANTY REM-EDIES ARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED. Products orparts for which a warranty claim is made are to be returned transportation prepaid to Sellers factory. Any improper

use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved by Seller, or any

alteration or repair by others which, in Sellers judgment, adversely affects the Product, shall void all warranties and

warranty obligations. Further, Seller shall not be liable under the above warranties should Buyer be in default of its

payment obligations to Seller under this Agreement or any credit agreement.

DOMESTIC TERMS and

CONDITIONS


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Changes, Cancellations, and Returns. Buyer will pay reasonable charges and all associated costs and damages

arising from canceling or changing this Agreement. No returns shall be allowed other than with Sellers express

permission, and such returns shall include a reasonable restocking charge to the extent permitted by law.

Resellers and Distributors. Should Buyer resell the product to a third party, then Buyer agrees to provide a copy of

these Terms and Conditions to such third party prior to the sale, and obtain such third partys agreement to be

bound by the relevant provisions including, but not limited to, the Warranties Section and the Limitation of

Liability Section. Buyer agrees to indemnify Seller against any and all claims, damages, or liability (including

reasonable attorney fees) arising from Buyers breach of the obligations set forth in this Section.

Proprietary Rights. All designs and information provided by Seller remain its property, and Buyer shall honor all

proprietary legends.

Limitation of Liability. The Sellers price is based on the enforceability of this limitation of liability, and the Buyer

understands that the price would be substantially higher without this limitation. SELLER SHALL HAVE NO

LIABILITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARYOR INCIDENTAL DAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PRODUCT

LIABILITY OR OTHERWISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN ADVANCE.

IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER INEXCESS OF THE CONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTY

REMEDY FAILS OF ITS ESSENTIAL PURPOSE, OR IS HELD TO BE INVALID OR UNENFORCE-ABLE FOR ANY REASON, IN CONSIDERATION OF THE OTHER PROVISIONS OF THIS AGREE-MENT, THE PARTIES AGREE THAT ALL LIABILITY LIMITATIONS WILL NEVERTHELESS RE-

MAIN IN EFFECT.

Governing Law. This Agreement shall be governed by the internal laws of the State of Wisconsin, without resort

to conflicts of law analysis.

Attorney fees, Collection Costs, and Indemnification. Buyer agrees to defend and indemnify Seller against any

claims, damages, or liability (including attorney fees) arising out of Buyers violation of any law or breach of its

obligations under this Agreement including, but not limited to, personal injury, death, or property damage. In

addition, Buyer shall reimburse Seller all reasonable attorney fees and collection costs incurred by Seller to enforce

its rights against Buyer under this Agreement.

Manuals and Brochures. Buyer shall communicate to Seller any special needs, pictorials, labels, warning signs,

instructions, or language required for the manuals and brochures used for the products. Buyer agrees to pay a

reasonable surcharge for additional manuals, special manuals, and brochures.

Severability. Any legally unenforceable provision may be severed from this Agreement, and the remaining terms

and conditions will be enforced as a whole as if such provision had not be inserted herein.

Waiver, Entire Agreement. No waiver by either party of a right under this Agreement shall waive any other rights.

These terms and conditions and any other writing signed by Seller constitute the entire agreement, and may not be

modified other than in writing signed by Seller.

DOMESTIC TERMS and

CONDITIONS


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Exclusivity. Sellers acceptance of Buyers order is expressly conditional upon Buyers agreement to these terms and

conditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly rejected,and do not form a part of this Agreement unless Seller agrees to such terms in writing.

Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bind

Seller unless this Agreement and any purported change are signed by a home office Officer of Seller.

Prices and Payments. Prices are exclusive of taxes and may be modified at any time prior to Seller receiving Buyers

binding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unless

agreed otherwise in writing, all payments are due in full upon receipt of order or Vilters receipt of an acceptable letter

of credit. All overdue amounts will incur finances charge of the lesser of (a) 1 % per month and (b) the maximum

allowed by law.

Export Transactions. If the products provided under this Agreement are to be shipped or used outside of the United

States, then the following terms apply unless otherwise agreed by Seller in writing: (1) Buyer shall be responsible for

all export and import scheduling and financial arrangements, (2) Buyer shall be responsible for compliance with all

export and import laws and shall comply, and shall cause its agents to comply, with the Foreign Corrupt Practices Act,

(3) the United Nations Convention on the International Sale of Goods shall not apply or govern the transaction, (4)

Buyer accepts all responsibility for the products complying with any non-United States based laws, regulations, and

other legal requirements, and (5) Seller shall be entitled to condition any shipment upon Buyer obtaining an acceptable

Letter of Credit in Sellers favor confirmed at a United States based bank of Sellers choosing.

Delivery. Seller shall not be liable for delivery delays beyond its control, including delays caused by its suppliers. All

delivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Sellers

Order Acknowledgment, all shipments are F.O.B. Sellers factory. Seller reserves the rights to make installment

deliveries.

Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for a

period of eighteen (18) months from the date of shipment from Sellers manufacturing plant or twelve (12) months

from date of installation at the initial end users location, whichever occurs first. In addition, Seller provides the

following extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal

rotating parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and recipro-

cating compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties do

not apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or

regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product contains

all features necessary to safely perform in Buyers and its customers plants and operations. Buyer must notify Seller

of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such claim.

Products supplied by Seller which are manufactured by others are not warranted by Seller, but rather Seller merely

passes through the manufacturers warranty to Buyer. SELLER EXPRESSLY DISCLAIMS ALL OTHER WAR-

RANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MER-CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Unless otherwise agreed in writing, Buyerssole remedy for breach of warranty is, at Sellers option, the repair of the defect, the correction of the service, or the

providing a replacement part FOB Sellers office. Seller will not be responsible for costs of dismantling, lost refriger-

ant, reassembling, or transporting the product. Further, Seller will not be liable for any other direct, indirect, conse-

quential, incidental, or special damages arising out of a breach of warranty. THESE WARRANTY REMEDIESARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED.

EXPORT TERMS and

CONDITIONS


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Products or parts for which a warranty claim is made are to be returned transportation prepaid to Sellers factory.

Any improper use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approvedby Seller, or any alteration or repair by others which, in Sellers judgment, adversely affects the Product, shall void

all warranties and warranty obligations. Further, Seller shall not be liable under the above warranties should Buyer

be in default of its payment obligations to Seller under this Agreement or any credit agreement.

Changes, Cancellations, and Returns. Buyer will pay reasonable charges and all associated costs and damages

arising from canceling or changing this Agreement. No returns shall be allowed other than with Sellers express

permission, and such returns shall include a reasonable restocking charge to the extent permitted by law.

Proprietary Rights. All designs and information provided by Seller remain its property, and Buyer shall honor all

proprietary legends.

Limitation of Liability. The Sellers price is based on the enforceability of this limitation of liability, and the Buyer

understands that the price would be substantially higher without this limitation. SELLER SHALL HAVE NOLIABILITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARY

OR INCIDENTAL DAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PRODUCTLIABILITY OR OTHERWISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN ADVANCE.

IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER INEXCESS OF THE CONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTYREMEDY FAILS OF ITS ESSENTIAL PURPOSE, OR IS HELD TO BE INVALID OR UNENFORCEABLE

FOR ANY REASON, IN CONSIDERATION OF THE OTHER PROVISIONS OF THIS AGREEMENT,THE PARTIES AGREE THAT ALL LIABILITY LIMITATIONS WILL NEVERTHELESS REMAIN IN

EFFECT.

Governing Law and Dispute Resolution. This Agreement shall be governed by the internal laws of the State of

Wisconsin, U.S.A. without resort to conflicts of law analysis. The parties agree the State courts located in Milwau-

kee, Wisconsin, U.S.A. shall have exclusive venue for any dispute concerning the enforceability, interpretation, or

termination of this Agreement, and agree to bring any such action in this venue. The parties further agree to per-

sonal jurisdiction in such courts for any such dispute.

Attorney fees, Collection Costs, and Indemnification. Buyer agrees to defend and indemnify Seller against any

claims, damages, or liability (including attorney fees) arising out of Buyers violation of any law or breach of its

obligations under this Agreement including, but not limited to, personal injury, death, or property damage. In

addition, Buyer shall reimburse Seller all reasonable attorney fees and collection costs incurred by Seller to enforce

its rights against Buyer under this Agreement.

Manuals and Brochures. Buyer shall communicate to Seller any special needs, pictorials, labels, warning signs,

instructions, or language required for the manuals and brochures used for the products. Buyer agrees to pay a

reasonable surcharge for additional manuals, special manuals, and brochures.

Severability. Any legally unenforceable provision may be severed from this Agreement, and the remaining terms

and conditions will be enforced as a whole as if such provision had not be inserted herein.

Waiver, Entire Agreement. No waiver by either party of a right under this Agreement shall waive any other rights.

These terms and conditions and any other writing signed by Seller constitute the entire agreement, and may not be

modified other than in writing signed by Seller.

EXPORT TERMS and

CONDITIONS


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STANDARD VILTER

WARRANTY STATEMENT

Seller warrants the products it manufactures to be free from defects in material and workmanship for a period of

eighteen (18) months from the date of shipment from Sellers manufacturing plant or twelve (12) months from date

of installation at the initial end users location, whichever occurs first. In addition, Seller provides the following

extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal rotating

parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and reciprocating

compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties do not

apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or

regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product con-

tains all features necessary to safely perform in Buyers and its customers plants and operations. Buyer must notify

Seller of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such

claim. Products supplied by Seller, which are manufactured by others, are not warranted by Seller, but rather Seller

merely passes through the manufacturers warranty to Buyer.

SELLER EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED,

INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-

LAR PURPOSE.

Unless otherwise agreed in writing, Buyers sole remedy for breach of warranty is, at Sellers option, the repair of

the defect, the correction of the service, or the providing a replacement part FOB Sellers office. Seller will not be

responsible for costs of dismantling, lost refrigerant, reassembling, or transporting the product. Further, Seller will

not be liable for any other direct, indirect, consequential, incidental, or special damages arising out of a breach of

warranty. THESE WARRANTY REMEDIES ARE EXCLUSIVE AND ALL OTHER WARRANTY REM-EDIES ARE EXCLUDED. Products or parts for which a warranty claim is made are to be returned transportation

prepaid to Sellers factory. Any improper use, corrosion, neglect, accident, operation beyond rated capacity, substi-

tution of parts not approved by Seller, or any alteration or repair by others which, in Sellers judgement, adversely

affects the Product, shall void all warranties and warranty obligations. Further, Seller shall not be liable under the

above warranties should Buyer be in default of its payment obligations to Seller under this Agreement or any credit

agreement.


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Symbols and Meanings

Electrical Hazards........................................................

Misc. Hazards...............................................................

Mechanical Hazards.....................................................

Fire Hazards..................................................................

Heat/Hot Hazards...........................................................

Mandatory Action Sign/Verification -

Communicates an action to be taken toAVOID hazard......................................................

Prohibition Symbol......................................................

Note: The symbols that appear on this page, are used throughout the

manual to help identify any potential warnings, cautions or hazards and to

assist in avoidance of any accidents or injuries.


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THEORY

The V-PLUS (Vilter Pumped Liquid Unitary Sys-

tem) oil cooling system cools the oil in the screw

compressor unit by injecting high pressure liquid

refrigerant from the condenser into the hot screw

compressor discharge gas/oil stream AFTER com-

pression. As the liquid flashes (boils off) at con-

densing temperature, it cools both the gas/oil prior

to entry into the oil separator.

The V-PLUS pump draws liquid refrigerant from

the receiver and pumps it through a nozzle directly

into the discharge housing of the single screw com-

pressor, and into the discharge line on a twin screw

unit. The amount of liquid being injected by the V-

PLUS pump is controlled by changing the speed of

the pump with a variable speed AC motor controlled

by a VFD. The VFD controls the speed of the motor

to inject the proper amount of liquid to maintain an

oil manifold temperature of 130 F - 140 F.

Conventional liquid injection oil cooling systems

inject liquid into the compressor itself at some point

in the compression cycle. This results in flash gas

that the compressor must pump, requiring an in-

crease in compressor horsepower consumption rang-

ing from 5% at low pressure ratios to 25% at high

pressure ratios. By comparison the V-PLUS system

does NOT increase compressor horsepower because

the liquid is injected after compression.

INSTALLATION

Because the V-PLUS pump is supplied with satu-

rated liquid from the receiver, the pressure drop

in the liquid supply line to the pump must be kept

as low as possible to prevent flash gas formation

at the pump suction.

A dedicated liquid line from the receiver to the V-

PLUS pump is preferred, with a dip tube in the

receiver that extends below the dip tube for the

main liquid to the system. Note: Any

Thermosyphon, V-PLUS, liquid injection system

designs for a high pressure, should allow for a 10

minute supply of liquid. If a dedicated liquid source

in not available, the main liquid line can be used.

The Tee on the main liquid line must point down

so that the liquid source comes from the bottom of

the line to avoid pulling-in flash gas from the line.

The Tee MUST be full size with any line size re-

duction taking place after the Tee. The main liq-

uid line size to where the Tee is located should be

sized so that the liquid line velocity does not ex-

ceed 150 FPM. This will reduce flash gas result-

ing from pressure drop.

All liquid supply lines to the V-PLUS pump must

be schedule 80 pipe minimum. The 11 GPM re-

quires a 1 supply line with reduction to 1 at

the V-PLUS pump service valve. The 20 GPM

pump requires a 1 supply line and has a 1

service valve. The 30 GPM pump requires a 2

supply line and has a 2 service valve. Sizes are

Introduction/Installation


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recommended to minimize pressure drop in the

liquid line, although the actual pump size may be

larger or smaller.

See the piping drawings for proper liquid line in-

stallation. DO NOT add any stop valves beyond

the valves shown on the drawings. DO NOT add

any strainers in the liquid line prior to the V-PLUS

pump as this will create flash gas and cause pump

cavitation and loss of oil cooling.

CLEANLINESS

Care must be taken to clean all piping to the V-

PLUS pump to prevent any dirt, scale, or slag from

entering the pump during compressor operation

since no pump strainers are installed.

GAS PURGING FLOAT VALVE

Due to the pressure drop of the liquid through the

piping and valves, flash gas will be created in the

lines and at the inlet of the V-PLUS pump. This

gas must be purged from the vertical line prior to

the V-PLUS pump to prevent cavitation and loss

of oil cooling.

The Gas Purging Float Valve must be installed at

the highest elevation of the liquid supply line above

the V-PLUS pump. See the installation drawings

showing the proper location.

A 1/4 service valve for the bleed line and 1 1/2

isolation valve on the inlet (gas purge) is

recommended. The 3/8 bleed line from the float

should be piped into a suction trap or

recirculator vessel, if possible, otherwise it may

be piped into a suction header.

LUBRICATION LINE

A oil line is installed to supply oil from the

screw compressor unit to the V-PLUS pump bear-

ings and seal chamber. After the system has been

running for approximately one hour, the seal area

and supply and return oil lines of the pump should

be warm. This indicates oil flow. A check

valve is also installed in this line to prevent back

flow of the liquid refrigerant into the screw com-

pressor oil separator while the compressor is off.

WARNING: On a Single Screw Compressor

unit oil flows to the V-PLUS pump because dis-

charge pressure in the oil separator is slightly

higher than the liquid line pressure (12 psid).

The liquid refrigerant receiver MUST BE ON

THE SAME LEVEL AS THE COMPRESSOR

UNIT . The liquid refrigerant level in the re-

ceiver must not be more than 6 feet above oil

level in the compressor unit. At levels higher

than this, the pump will have a head and the

liquid line pressure will exceed discharge pres-

sure and oil will not flow to the pump. This will

result in V-PLUS pump bearing and seal fail-

ure.


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LIMITATIONS

Although the V-PLUS oil cooling system is well

engineered and can be of tremendous value when

used properly, the following limitations apply:

a) This discharge temperature should be set

no less than 10 F higher than the system con-

densing temperature and not above 140 F maxi-

mum temperature. This setting will enable all the

liquid refrigerant to evaporate before the gas/oil

mixture enters the oil separator.

b) The V-PLUS pump pressure differential

is limited to 25 psig on standard units. For units

in excess of 25 psig, consult the Home Office.

c) The V-PLUS is for use on systems with

standard high pressure liquid source, subcooled

to no lower than 20F. For control pressure re-

ceiver source, a special 2HP system is required.

Consult the Home Office for details.

d) The main liquid refrigerant receiver must

be on the same elevation as the screw compressor

unit.


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Special Note:

On all VSS and VSMs this valve needs to be fully open.

Prior to Start-Up


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18

V-Plus AC Setup Sheet

Two Methods of Oil Temperature Control

There are two methods for oil temperature control when using the AC drive:

OTC-1 Vission does temperature control and sends VFD a target speed.

OTC-2 Vission sends temperature to VFD which does the temperature control.

OTC-1 Oil Temperature Control - Method 1

The oil injection temperature and the compressor discharge temperature are monitored by the

Vission controller. Either of these temperatures or an average of the two can be used to control

the oil temperature. This is selectable on the HMI screen V Plus Control.

The Vission programming includes a PID loop which uses the temperature selected to set a target speed

for the VFD. This is shown on the V Plus Control screen as the Pump Output (% full speed).

The V-Plus pump speed will change as the VFD follows the target set by the Vission controller.

The setpoint is a parameter in the Vission controller, not in the VFD.

VISSION CONTROLLER SETUP

1.0 From the Menu screen, select V+ Control. Actual

2.0 From the V-Plus Control screen: Setting

2.1 Pump Control ParametersProportional Gain 3.0 ______

Reset Time (min) 4.0 ______

Rate Time (min) 0.0 ______

Pump On (F) 120 ______

Pump Off (F) 110 ______

2.2 Temperature Control By

Select Average Tdisch & Tinj.

2.3 Pump Control Variables ______

Temperature Setpoint 142F ______

3.0 The following data is accessible through the Raw Data Screen

3.1 G126 = 0 This is the toggle between control methods.

3.2 G318 = 1

A-B VFD SETUP

The following parameter settings must be entered into the VFD for proper operation.

This list shows the parameters settings that must be changed from the default values that are

present when the drive is shipped.

Enter Actual Settings Here


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Copy # Name Value Units Actual Value Default Min Max

42 Motor NP FLA 1.6Amps 8 0 3200

44 Motor NP RPM 1736RPM 1750 60 25200

45 Motor NP Power 1 0 0 1000

47 Motor OL Hertz 20Hz 0 0 24000

61 Autotune Ready Calculate Ready Calculate

62 IR Voltage Drop 26VAC 20 0 690

63 Flux Current Ref 0.81Amps 26 0.1 3200

69 Start/Acc Boost 13VAC 5 0 115

70 Run Boost 13VAC 0 0 24000

90 Speed Ref A Sel Analog In 1 Analog In 2 Analog In 1 Scale Block4

121 Slip RPM @ FLA 64RPM 30 0 1200

148 Current Lmt Val 3.2Amps 1.2 0.2 3200

148 Stop/Brk Mode A Coast Ramp Coast DC Brake

148 DC Brake Level 2.1Amps 0 0 3200

148 Direction Mode Reverse Dis Unipolar Unipolar Reverse Dis

148 Param Access Lvl Advanced Basic Basic Reserved320 Anlg In Config 11 10 -10 11

322 Analog In 1Hi 20 10 -10 20

323 Analog In 1 Lo 4 0 -10 20

361 Digital In1 Sel Run Stop - CF Not Used Fast Stop

362 Digital In2 Sel Not Used Start Not Used Fast Stop

363 Digital In3 Sel Not Used Auto/ Manual Not Used Fast Stop

542 Encdlss Vlt Comp 26VAC 20 0 690

Other parameter settings that should be verified, which are the defaults, are listed below:

55 Maximum Freq 130.0 Hz 1300 130.0 5.0 420.0

82 Maximum Speed 60.0 Hz 600 60.0 5.0 400.0

For this method of control, none of the VFD PI parameters are used. They remain set at the factory

defaults. The VFD will follow the target signal from the Vission controller.

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OTC-2 Oil Temperature Control - Method 2

The oil injection temperature and the compressor discharge temperature are monitored by the

Vission controller. Either of these temperatures or an average of the two can be used to control

the oil temperature. This is selectable on the HMI screen V Plus Control.

The selected temperature is transmitted to the VFD from analog output K11.

The VFD programming includes a PID loop which uses the temperature input from the Vission

controller. The V-Plus pump speed will change in direct proportion to the deviation of the actual

temperature from the setpoint. The setpoint is a parameter in the VFD, not in the Vission controller.

VISSION CONTROLLER SETUP

1.0 From the Menu screen, select V+ Control.

2.0 From the V-Plus Control screen:

2.1 Pump Control Parameters

IGNORE - this function has been shifted to the VFD

2.2 Temperature Control By Actual Setting

Select Average Tdisch & Tinj.

2.3 Pump Control Variables

IGNORE - this function has been shifted to the VFD

3.0 The following data can be verified from the Raw Data Screen

3.1 G126 = 1 This is the toggle between control methods.

3.2 G318 = 1

These are program defaults.

A-B VFD SETUP

The following parameter settings must be entered into the VFD for proper operation.

This list shows the parameters settings that must be changed from the default values that are

present when the drive is shipped.


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Copy # Name Value Units Actual Value Default Min Max

42 Motor NP FLA 1.6Amps 8 0 3200

44 Motor NP RPM 1736RPM 1750 60 25200

45 Motor NP Power 1 0 0 1000

47 Motor OL Hertz 20Hz 0 0 2400061 Autotune Ready Calculate Ready Calculate

62 IR Voltage Drop 26VAC 20 0 690

63 Flux Current Ref 0.81Amps 26 0.1 32000

69 Start/Acc Boost 13VAC 5 0 115

70 Run Boost 13VAC 5 0 115

81 Minimum Speed 5 0 0 24000

90 Speed Ref A Sel Analog In 1 Analog In 2 Analog In 1 Scale Block4

121 Slip RPM @ FLA 64RPM 30 0 1200

124 PI Configuration 11 0 0 1111111111

125 PI Control 1 0 0 111

127 PI Setpoint 35% 50 -100 100

128 PI Feedback Sel Analog In 1 Analog In 2 Setpoint Scale Block4129 PI Integral Time 100Secs 2 0 100

130 PI Prop Gain 2.75 1 0 100

131 PI Lower Limit 0% -100 -800 800

139 PI BW Filter 1Rad 0 0 240

148 Current Lmt Val 3.2Amps 1.2 0.2 3200

155 Stop/Brk Mode A Coast Ramp Coast DC Brake

158 DC Brake Level 2.1Amps 0 0 3200

190 Direction Mode Reverse Dis Unipolar Unipolar Reverse Dis

196 Param Access Lvl Advanced Basic Basic Reserved

320 Anlg In Config 11 0 0 11

322 Analog In 1 Hi 20 10 -10 20

323 Analog In 1 Lo 4 0 -10 20

361 Digital In1 Sel Run Stop - CF Not Used Fast Stop

362 Digital In2 Sel Not Used Start Not Used Fast Stop

363 Digital In3 Sel Not Used Auto/ Manual Not Used Fast Stop

542 Encdlss Vlt Comp 26VAC 20 0 690

Other parameter settings that should be verified, which are the defaults, are listed below:

55 Maximum Freq 130.0 Hz 1300 130.0 5.0 420.0

82 Maximum Speed 60.0 Hz 600 60.0 5.0 400.0

132 PI Upper Limit 100 % 1000 100 -800 800

The following value shows the reaction of the drive to the PID loop tuning parameters P129 & 130.

137 PI Error Meter read only

137 PI Error Meter read only

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Motor Documentation

Product Details

Product:1329RS-ZA00118WVCDescription:AC Motor, 1 HP, 230/460V, 1800 RPM, TENV, C-Face Foot

Mounted, WC143TC Frame,1000:1 CT,Coupled or Belted Duty Per

Standard NEMA Limits

MOTOR CONFIGURATIONBulletin Number Bulletin 1329RSMotor Voltage 230/460VRating 1 HPBase Speed 1800 RPMMotor Enclosure TENV (Totally Enclosed Non-Ventilated, Vector Duty, Washdown,

Encoder Capable)Torque Type / Speed Range Constant Torque, 1000:1 (with Encoder, 120:1 without) Speed RangeMounting Options C-Face Foot MountedCoupling Coupled or Belted Duty Per Standard NEMA LimitsSeries/Version Series ACOMMENTSNotes This rating includes a NEMA C-Face with feet.Dimensions and WeightWeight (kg / lbs) 36.3 / 79.9


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Motor Drawing


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Motor Wiring


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Motor Electrical Design /Curves


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Product DetailsProduct:20BD2P1A3AYNANC0Description:PowerFlex700 AC Drive, 480 VAC, 3 PH, 2.1 Amps, 1 HP Normal Duty, 0.75 HP Heavy Duty,

IP20 / Type 1, LCD Display, Full Numeric Keypad, Brake IGBT Installed, Without Drive Mounted Brake

Resistor, Second Environment Filter per CE EMC directive (89/336/EEC), No Communication Module,Vector Control with 24V I/O, No Feedback

BASE DRIVE INFORMATIONInput Voltage 480 VAC, 3 PHCurrent Rating 2.1 AmpsEnclosure IP20 / Type 1Frame Size Frame Size 0Output Current Information Output Amps: 2.1A Cont, 2.4A 1 Min, 3.2A 3 SecStock Product Program YesINSTALLED OPTIONSHuman Interface Module LCD Display, Full Numeric KeypadDocumentation User ManualBrake IGBT Brake IGBT InstalledBrake Resistor Without Drive Mounted Brake ResistorFilter Options Second Environment Filter per CE EMC directive (89/336/EEC)Internal Communication Module No Communication ModuleI/O Options Vector Control with 24V I/OFeedback Option No FeedbackDimensions and WeightWeight (kg / lbs) 2.37 / 5.21Recommended Spare PartsSK-G9-TB1-S1 1 PF700 Removable I/O Terminal BlockSK-G9-TB1-ENC1 1 PF700 Removable Encoder Terminal Block20-DA1-A0 1 PowerFlex 700 I/O Option, 24V AC/DC20-DA1-B0 1 PowerFlex 700 I/O Option, 115V AC20B-STD-N 1 Standard Control Cassette, no I/O20B-STD-A0 1 Standard Control Cassette, 24V I/O20B-STD-B0 1 Standard Control Cassette, 115V I/O20B-VECT-C0 1 Vector Control Cassette, 24V I/O, no FB20B-VECT-D0 1 Vector Control Cassette, 115V I/O, no FBSK-G9-FAN2-F0 1 Fan, Internal, Frame 0SK-G9-FAN1-F01 1 Fan, Heatsink, Frames 0 & 120BD-DB1-0 1 PowerFlex 700 DB Resistor, Internal, Frame 0, 400/480V, 115 ohm

AC Drive Specifications

Recommended Spare Parts List For AC Drive


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AC Drive Specifications


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Electrical Wiring Diagram


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V-Plus

V-Plus w/ 2hp Motor


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Control Panel Assembly

Item

Number Description Quantity Part

1 Control Panel 1 3029A

2 Terminal Block, 25 amp, 600V 12 3089A

3 Rail, Din, 35mm Slotted .500 3089H

4 Varistor, Metal Oxide 1 2533A

5 Relay, 115V/60H, Open, 2PDT 1 1537C *

6 Speed Control, 0-90VDC 1 2556A *

7 Temperature Controller 1 3014A *

8 Decal, V-PLUS Oil Cooling System 1 2461A

9 Label, x 1, Silver Component 1 2271D10 Fuseholder, 30 amp, 600V 3 3090BB

11 Fuse, 15 amp, 125V 3 3090X *

12 Socket, 11-Pin 1 3014B

13 Sticker, Conduit Instruction 1 3028A

14 Varistor, Metal Oxide 1 2533B

15 Network 2 3030B

16 Stop End, W Series 2 3089F

17 Marker, Blank, W Series 1 3089G

18 Circuit Sticker, Data 1 2124A


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HMI Overview

External Connections


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HMI LCD Display Elements


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HMI Menu Structure


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HMI Menu Structure


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HMI Viewing/Editing Parameters


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HMI Linking Parameters


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HMI Linking Parameters


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HMI Removing/Installing


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Installation

I/O Wiring


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I/O Control Cassette


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Terminal Designations


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Encoder Terminal Block/

Hardware Enabler Circuitry


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Wiring Examples


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Wiring Examples


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Start-Up

Check List

Using these toggle

buttons will allow

you to scroll from

screen to screen.

Note: These screen are capture from the Powerflex Manual. If you need

additional information please refer to the Power Flex User Manual.


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Status Indicators


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Parameters

Frequently Used Parameters


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Troubleshooting


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Troubleshooting


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Manually Clearing Faults


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Start-up


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Applying Power To The Drive


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Start-up Routines


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Running Smart Start or on Assisted Start


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Recommended Spare Parts Lists

Note: For Recommended Spare Parts Lists for the Vission/Vantage or

Compressor, please refer to the appropiate manual.

Component Component Description UM Quantity

A 27209AH PUMP 20GPM VPSTD 110V NEMA 1-4 HALO EA 1

1484C GLASS 1-1/2 CLEAR SIGHT EA 2

1726B NUT 5/16-18NC-2B HEX HVY PLAIN EA 4

1949A VALVE 1/4MPTX1/4PT ANG STL 7771 EA 1

2493A VALVE 1/40DT CHECK IN-LINE STN STL EA 1

2494A MOTOR 1HP 1800RPM TEFC 56C EA 1

2501A PUMP HV2657M LIQ AMM V-PLUS 1-1/2 EA 1

2540B THERMOCOUPLE TYPE J SENSOR B-C EA 1

2650DACCF VALVE SOL. 120V60H S7A PORT EA 1

2916CF VALVE ANG THRD SEAL CAP AT076C EA 1

A 14053B VALVE 1-1/2 STRT FLGD HALO EA 1

A 17326A NOZZLE V-PLUS LIQ INJECTION 3/32 EA 1

65544A GASKET 3-11/16X3-1/8 FLANGE FLOAT EA 1


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Purge Float Valve Drawing

Gasket: See recommended

Spare parts

Note: Orientation


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ISO/Standard Drawings

VSS

VSS / VSM SCREW

COMPRESSOR UNITRE

CEIVER

OILSEPARATOR

VSS IS SHOWN


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B

P&I Standard Drawings


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Assembly Drawings


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Viking Pump Info


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Viking Pump Info


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Viking Pump Info


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v-plus ac manual - xa

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