Danfoss Turbocor TT-300 Manuel utilisateur

SERVICE MONITOR USER MANUAL

Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1

TWIN-TURBINE CENTRIFUGAL

COMPRESSOR

MODEL TT-300

Contents

Danfoss Turbocor Compressors Inc. i

ECD-00007M Rev. 1

Introduction 1

System Requirements 2

Getting Started 3

Cable Connection 3

RS232 Connection 3

RS485 Connection 3

Monitor Program Installation 5

Starting the Monitor Program 5

User Interface 5

Monitor Program Toolbar 5

Entering User Input 6

Serial Port Connection 6

Compressor Configuration 7

Using the Setup Wizard 7

Start-up Settings 8

Electronics Valve Control 9

Analog Output Setup 11

Modbus Communications 12

Downloading and Saving Configuration Data 12

Using a Saved Configuration File 13

Controlling User Access 14

Starting and Stopping the Compressor 15

Analog Input 15

How to Start the Compressor 15

How to Stop the Compressor 15

Modbus Network 15

How to Start the Compressor 15

How to Stop the Compressor 16

Chiller Control 16

How to Start the Compressor 16

How to Stop the Compressor 16

Monitor Program Data and Controls 18

Main System 18

Bearing Calibration 20

Bearing Calibration Procedure 22

Calibration Data Interpretation 23

“Gain” Interpretation 23

“Offset” Interpretation 23

Compressor Control 23

Compressor Control Modes 26

Calibration 26

Manual Control 26

Analog Input 27

Modbus Network 27

Chiller Control 27

Compressor Faults/Alarms 27

Contents

ii Danfoss Turbocor Compressors Inc.

ECD-00007M Rev. 1

Motor Monitoring 28

Motor Monitoring Overview 28

Motor Faults / Alarms 30

Magnetic Bearing Monitoring 31

Bearing Monitoring Overview 31

Bearing Faults 33

Electronic Valve Data / Tuning 33

Chiller Control 36

System Information 38

Compressor Info 39

EEPROM Log Resets 39

EEPROM Settings 39

Compressor Controller Settings 40

Compressor Controller Alarms 41

Compressor Controller Fault Limits 43

Compressor Stepper Motor Settings 44

Stepper Motor Valve Controls 45

Analog Output Controls 47

Compressor Controller Impeller Specific Settings 49

Compressor Controller (CC) Critical Fault Lock Outs 50

Refrigerant 51

Compressor Event Log 51

History Data 52

Trending 53

Graphs 53

Trending & Data Acquisition 56

Compressor Map 57

Fault Captures 59

Data Capture 60

Appendix A: Determination of Actual Power Setting A-1

Service Monitor User Manual

Danfoss Turbocor Compressors Inc. 1

ECD-00007M Rev. 1

1 Introduction

The Turbocor Service Monitor program is a rich, user-

friendly, graphical user interface designed to control the

Turbocor compressor and to provide status information

about the compressor. Furthermore, it can be used as a tool

for troubleshooting purposes.

This manual describes the functions provided by the

Turbocor Service Monitor program.

System Requirements

2Danfoss Turbocor Compressors Inc.

ECD-00007M Rev. 1

2 System Requirements

The monitor program must be installed on a PC that meets

the minimum requirements specified in Table 1. For

optimum performance, a 533 MHz Pentium or higher CPU

with 128 MB RAM running Windows 2000 (SP4) or XP is

recommended.

The monitor program was developed for the .NET

Framework and requires the .NET Framework to be

installed on the PC where the program runs. Microsoft

provides a re-distributable installer, Dotnetfx.exe, that

contains the common language runtime and .NET

Framework components that are necessary to run the

monitor program. Before installing the monitor program,

the .NET framework 1.1 re-distributable must be installed.

This can be downloaded from the Microsoft website.

The latest Windows service packs and security updates

should also be installed on the PC.

Table 1: Minimum Requirements

Processor 533-MHz Intel Pentium-class processor

Operating System The .NET Framework 1.1 Re-distributable is supported on the following

platforms:

• Microsoft Windows® Server 2003 (.NET Framework 1.1 is installed as part

of the operating system)

• Windows XP Professional

• Windows XP Home Edition

• Windows 2000

• Windows Millennium Edition (Windows Me)

• Windows 98

• Microsoft Windows NT® 4.0 Service Pack 6a

The .NET Framework 1.1 Re-distributable cannot be installed on 64-bit

computers; Windows NT 4.0 Terminal Server is not supported

Memory 128 MB of RAM, 256 MB recommended

Hard Disk 110 MB of hard disk space required, 40 MB additional hard disk space

required for installation (150 MB total)

Display 800 x 600 or higher-resolution display with 256 colors

Input Device Microsoft mouse or compatible pointing device

Other Install the latest Windows service packs and critical updates from the

Windows Update site.

Installation of the .NET Framework 1.1 is split into two parts: the core

and language packs. The core contains everything you need to run .NET

Framework applications; all dialog boxes and error messages will be in

English. If you want dialog boxes and error messages in another

language, you must also install the corresponding language pack. For

more information, see the .NET Framework Downloads page.

Service Monitor User Manual

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ECD-00007M Rev. 1

3 Getting Started

3.1 Cable Connection

The monitoring program communicates with the

compressor via the Modbus* protocol using either the

RS232 or RS485 connection at the Chiller Interface

module. RS485 communication requires an RS485/RS232

adapter (user-supplied). RS232 communication is

recommended for cable lengths not exceeding 15 meters

(50 feet) between the PC and compressor. For cables that

run up to 100 meters (328 feet), use the RS485

communication line. Always use shielded, twisted-pair

cable for data communications

*The Modbus protocol was originally developed to exchange information

between products on the factory floor. This protocol has become a de facto

standard for exchanging data and control between PLC systems. Modbus is

a registered trademark of Modicon Corp.

3.1.1 RS232 Connection

1. Connect one end of the RS232 cable (user-supplied) to

the DB9 connector on the Chiller Interface module; see

Figure 1.

2. Connect the other end of the cable to an available COM

port on the PC.

3. Confirm that jumpers JP2 and JP7 are in proper

positions before starting.

JP2 is the Modbus termination jumper. Install the

jumper if the Modbus connection is at the end of a

cable run.

Remove JP7 to enable RS-232 communication with the

PC.

3.1.2 RS485 Connection

1. Connect the RS485/RS232 adapter directly onto the PC

COM port.

Connect the other side of the adapter to the Modbus. Figure

2 shows the PC and adapter connections to the Modbus for

a single compressor application. Ensure that the termination

jumper (JP2) on the Chiller Interface module is installed.

Figure 3 shows the PC and adapter connections to the

Modbus for a multiple compressor application. In this case,

set the termination jumper only on the Chiller Interface

module that is connected at the end of the Modbus cable

run.

Figure 1 RS232 Connector - Chiller Interface

Module

Getting Started

4Danfoss Turbocor Compressors Inc.

ECD-00007M Rev. 1

Figure 2 PC to Modbus Connection (single compressor with > 10 m cable length)

Figure 3 PC to Modbus Connection (multiple compressors with > 10 m cable length)

Service Monitor User Manual

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ECD-00007M Rev. 1

3.2 Monitor Program Installation

The monitor program is installed on the PC and

communicates with the compressor using the ModBus

protocol over a RS-232 or RS-485 serial link. Administrator

privileges may be required to install and remove software

on the PC.

NOTE:

If a previous version of the monitor program is already

installed on the PC, it must be uninstalled before proceeding

with the current installation. To uninstall the monitor

program: from the “Start” menu, select “Settings” →

“Control Panel”. Double-click “Add/Remove Programs”.

From the list, select “Danfoss Turbocor Service Monitoring

Tool” and then click the “Remove” button.

Installation Procedure:

1. Insert the monitor program CD into the drive.

2. In Windows Explorer, navigate to the

Turbocor_Service_Tool_Setup.msi file. Double-click

the file to launch the setup wizard.

3. Follow the instructions provided by the wizard to

complete the installation.

4. Click the Close button to exit the setup wizard.

3.3 Starting the Monitor Program

To start the monitor program: from the “Start” menu, select

“Programs” →“Danfoss Turbocor Monitoring Tool”.

3.4 User Interface

3.4.1 Monitor Program Toolbar

The toolbar (located under the menu bar) provides the user

with easy access to the monitoring windows. Table 2

provides details for each icon on the toolbar.

NOTE:

Up to three windows can be displayed at one time. If three

windows are already open, one must be closed before

another window can be opened.

Table 2 Monitor Program Toolbar Icons

Icon Name Description

Serial Port Connection Clicking on the “Serial Port Connection” icon opens the “Serial Port

Connection” window. Refer to section 3.5 "Serial Port Connection"

on page 6.

Compressor Controller

Parameters Clicking on the “Compressor Controller Parameters” icon opens

the “Compressor Controller” window. Refer to section 6.3

"Compressor Control" on page 23.

Motor Monitor Clicking on the “Motor Monitor” icon opens the “Variable Speed

Permanent Magnet Motor Monitoring” window. Refer to section

6.4 "Motor Monitoring" on page 28.

Magnetic Bearings Clicking on the “Magnetic Bearings” icon opens the “Magnetic

Bearing Monitoring” window. Refer to section 6.5 "Magnetic

Bearing Monitoring" on page 31.

Getting Started

6Danfoss Turbocor Compressors Inc.

ECD-00007M Rev. 1

3.4.2 Entering User Input

When user input is required for the monitor program fields,

perform the following sequence:

1. Double-click the variable field. (This activates the field

for user input.)

2. Scroll or type in the new setting.

3. Press Enter. It is important to press Enter as this causes

the user input to be validated.

3.5 Serial Port Connection

The Serial Port Connection window contains fields that

must be filled in order to enable communication between

the monitor program and the compressor; refer to Figure 4.

The comm settings of the compressor must be known in

order for the monitor program to communicate with the

compressor.

To access the “Serial Port Connection” window, select

“Window”→ “Connection” from the menu bar, or click on

the “Serial Port Connection” icon located below the menu

bar.

The following paragraphs describe the dialog box fields.

Comm Port - Serial communication port that the computer

will use to connect to the compressor. Enter the COM port

number such as COM1 or COM2, etc.

Baud Rate -19,200 or 38,400 baud (38,400: default)

Stop Bits - 1 or 2. (1: default)

Slave Address - 1-63. (1: default)

Expansion Valves Clicking on the “Expansion Valves” icon opens the “Electronic

Valve / Data Tuning” window. Refer to section 6.6 "Electronic

Valve Data / Tuning" on page 33.

Event Log Clicking on the “Event Log” icon opens the “Compressor Event

Log” window. Refer to section 6.10 "Compressor Event Log" on

page 51.

EEPROM Settings Clicking on the “EEPROM Settings” icon opens the “EEPROM

Settings” window. Refer to section 6.9 "EEPROM Settings" on

page 39.

Load Profile Graphs Clicking on the “Load Profile Graphs” icon opens the “Compressor

History Data” window. Refer to section 6.11 "History Data" on page

52.

Fault Captures Clicking on the “Fault Captures” icon opens the “Fault Captures”

window. Refer to section 6.14 "Fault Captures" on page 59.

Trending Clicking on down arrow next to the “Trending” icon, and selecting

“Charts 1” opens the trending “Graphs” window; selecting on

“Charts 2” opens the “Trending and Data Acquisition” window.

Refer to section 6.12 "Trending" on page 53.

Chiller Control Clicking on the “Chiller Control” icon opens the “Chiller Control”

window. Refer to section 6.7 "Chiller Control" on page 36.

Compressor Envelope Clicking on the “Compressor Envelope” icon opens the

“Compressor Map” window. Refer to section 6.13 "Compressor

Map" on page 57.

Table 2 Monitor Program Toolbar Icons (Continued)

Icon Name Description

Service Monitor User Manual

Danfoss Turbocor Compressors Inc. 7

ECD-00007M Rev. 1

Access Code - The access code controls access to all

adjustable parameters. The default user access level on

power up is read only. Enter the code that corresponds to

the access level you require. Contact Turbocor Product

Support to obtain the required access code.

1. Once the serial port connection data has been set, click

the Connect button. At this point, connection status,

compressor details, and user access level appear in the

right-hand pane of the dialog box.

2. If necessary, change the access level. Enter the access

code in the “Access Code” parameter box, then click

“Change Access Level”. Confirm that the correct

access level has been set on the right-hand pane of the

dialog box.

NOTE:

The access level connection cannot be changed prior to a

establishing connection.

Entering the wrong access code more than 3 times will lock

out all communications until a cycle of the power is

performed.

3. Click the “OK to start monitoring” button.

4 Compressor Configuration

4.1 Using the Setup Wizard

The monitor program features a commissioning setup

wizard to guide the user through the complete compressor

configuration process.

1. To launch the commissioning setup wizard, select

“System Commissioning” from the “Advanced” menu

item. The introduction screen for the commissioning

setup wizard appears; refer to Figure 5. Click Next.

(To bypass the setup wizard and use a saved

configuration file to setup the compressor, check the

checkbox and click Next. Continue with 4.2 "Using a

Saved Configuration File" on page 13.)

2. Select the appropriate units of measurement (metric or

imperial). Refer to Figure 6.

3. Select the appropriate compressor control method.

There are three modes available:

• Analog Input: compressor loading controlled using

an analog demand signal of 0-10 VDC from an

external controller. The variable demand signal

corresponds to the range of 0-100% maximum

power available.

Figure 4 Serial Port Connection Dialog Box

Figure 5 Commissioning Set-up Wizard

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