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M&M RWB series User Manual

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M&M Refrigeration, Inc.
Computer Control System
Screw Compressor Control
RWB Series
Retro Fit Panel
&

Table of Contents

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M&M RWB series Specifications

General IconGeneral
BrandM&M
ModelRWB series
CategoryController
LanguageEnglish

Summary

CHAPTER 1 CCS Introduction

Associated Documents

Lists related M&M documents for reference.

Applicable Compressor Models

Identifies the M&M RWB Compressor retrofit this document covers.

CHAPTER 2 General Operating Overview

Definitions

Defines key terms and concepts used in the CCS.

Keypad Functions

Explains the function of each key on the CCS keypad.

Main Screen Overview

Describes the layout of the main screen, including display area, hot keys, and title banner.

Hot Key Selection

Details how to select options using the system's hot keys.

Screen Types

Lists and describes the eight different types of screens used by the CCS.

Menu Screens

Explains the purpose and function of menu screens.

Data Entry Screens

Describes user-interactive screens for changing system data.

Data Entry Procedures

Provides step-by-step instructions for entering data.

Field Types

Details the procedures for working with various field types.

Status Screens

Explains how status screens display system information.

Confirmation Screens

Describes screens used to confirm user selections.

Momentary Screens

Explains screens that display temporary informative messages.

Information Screens

Describes screens used to display system data.

Access Screens

Explains screens used to navigate to a larger set of options.

Log Screens

Details how log screens are used to view recorded system information.

Alarms & Failures

Explains how the CCS monitors and reports system alarms and failures.

CHAPTER 3 Compressor Controls

Modes Of Operation

Describes the different operational modes of the screw compressor.

Lubrication System

Explains the self-lubricating design and oil pump requirements.

Oil Pump Configuration

Details the configuration options for pre-lube, cycling, and full lube oil pumps.

Oil Pressure Calculations

Provides formulas for calculating oil pressure and oil filter pressure.

Oil Level Indication

Explains the oil level indicator switch function.

Starting the Screw Compressor

Details the sequence and conditions for starting the compressor.

Manual Mode

Describes how to start the compressor in Manual mode.

Automatic Mode

Explains automatic starting based on suction pressure or process temperature.

Remote/Auto Remote Mode

Details starting/stopping using external signals or remote computer.

Sequenced Mode

Explains operation when controlled by a master sequencer.

Stopping the Screw Compressor

Details the sequence for stopping the compressor manually or automatically.

Remote Mode

Describes remote control for starting, stopping, and capacity.

Capacity Control

Explains how slide valve position controls compressor capacity.

Control Groups

Defines setpoint groups for automatic capacity control.

Time Proportional Control Strategy

Explains how time proportional control determines slide valve movement.

Remote Capacity Control

Details capacity control via discrete I/O or network messages.

Auto-Remote Capacity Control

Explains capacity control using automatic settings in Auto-Remote mode.

Sequenced Capacity Control

Describes capacity control adjustments via master sequencer commands.

Low Alarm and Failure Setpoints

Explains how Sequencer setpoints replace local ones in Sequenced mode.

Running in Trim Mode

Details control parameters received from the master sequencer.

Running in Full Load Mode

Explains how full load mode disables capacity control but keeps limiting active.

Anti-Cycle in Sequenced Mode

Describes the role of the anti-cycle timer in Sequenced mode.

Forced Unloading & Limiting

Explains protection mechanisms against extreme system conditions.

Ramp Start

Details how ramp start adjusts setpoints to reduce power demand.

Slide Valve Position Ramp Start Limiting

Explains how slide valve position ramp start limits capacity increases.

Unload Solenoid Configuration

Describes configuration options for the unload solenoid.

Setpoint Scheduling

Explains automatic switching of setpoints based on time and day.

Daily Schedules

Details how to define time-of-day slots for daily schedules.

Weekly Schedule

Explains how to assign daily schedules to each day of the week.

Variable Vi Slide Stop Control

Describes how Vi slide stop adjusts discharge port size for efficiency.

Vi Adjustments

Explains how Vi slide stop is adjusted based on pressure ratio.

Manual Vi Adjustment

Details how to force a Vi adjustment from the Vi status screen.

Vi Slide Stop and Capacity Slide Valve Interference

Explains how Vi slide stop affects capacity slide valve travel.

VI Position Correction

Describes how sensor values are corrected for Vi position display.

Oil Temperature Regulation

Explains oil temperature control when the compressor is stopped.

Liquid Injection Oil Cooling (Option)

Details setpoints for liquid injection cut-in and cut-out.

Single Port Liquid Injection

Describes single port liquid injection operation.

Dual Port Liquid Injection

Describes dual port liquid injection operation.

Anti-Cycle Timer

Explains the timer used to avoid repeated start attempts.

Power Fail Restart

Explains how the system restarts after a power failure.

Remote Status Information

Lists discrete outputs for remote status information.

Process Temperature Control (Option)

Explains slide valve adjustment based on outlet temperature.

Economizer Control (Option)

Details control of the economizer solenoid based on mode and setpoints.

Power Assist (Option)

Explains power assist for check valve closure in booster applications.

Operational Procedures

Introduces operating procedures using LCD and keypad hot keys.

START Hot Key

Initiates the compressor start sequence and online status.

STATS Hot Key

Allows quick return to the main status screen.

Compressor Main Status Screen

Shows a summary of compressor analog and state parameters.

Status Banner

Displays system state, operating mode, and alarm/failure status.

System Current State

Details the current state of the system.

Mode Area

Displays the general operating mode of the system.

Alarm & Failure Area

Shows the system's current alarms and failures.

Compressor Graphics Screen

Presents compressor information in a graphical format.

Energy Status Screen

Displays motor current and energy consumption information.

Operating Hours Screen

Allows viewing of compressor running hours and start counts.

Variable VI Status Screen

Displays information pertaining to the Variable Vi Control option.

Economizer Status Screen (Option)

Shows information for the Economizer Control option.

Active Alarms & Failures Status Screen

Displays the system's current alarms and failures.

Auto-Start Warning Screen

Warns when the screw may be automatically started.

MODE Hot Key

Allows selection of the system's operational mode.

Local Mode

Allows service personnel to operate or lock out equipment.

Manual Mode

Used for startup and diagnostic purposes, with keypad control.

Automatic Mode

Primary configuration for stand-alone compressors, automatic capacity adjustment.

Remote Mode

External control system responsible for start, stop, and capacity.

Auto-Remote Mode

External control for start/stop, but not direct capacity control.

Sequenced Mode

Control by a master sequencer for multiple compressors.

SETPT Hot Key

Accesses menu options to set system setpoints.

Pressure Setpoints

Allows adjustment of pressure-related setpoints.

Suction Pressure Control Groups

Sets control values for four suction pressure control groups.

Suction Pressure Control Data Entry Screen

Details data entry fields for suction pressure setpoints.

High Suction Pressure Setpoints

Sets active alarm and failure setpoints for high suction pressure.

Discharge Pressure Setpoints

Sets discharge pressure control parameters for alarm, limiting, and ramp.

Oil Pressure Setpoints

Allows setting acceptable ranges for oil pressure parameters.

Oil Filter Pressure Setpoints

Allows setting acceptable ranges for oil filter pressure.

Temperature Setpoints

Allows setting temperature-related setpoints.

Discharge Temperature Setpoints

Sets acceptable ranges for discharge temperature.

Oil Temperature Setpoints (without Liquid Injection)

Sets oil temperature and sump temperature regulation ranges.

Oil Temperature Setpoints ( with Liquid Injection)

Adds setpoints for liquid injection cut-in and cut-out.

Process Temperature Control Group

Sets process temperature control parameters when enabled.

High Process Temperature Selection

Sets setpoints for high process temperature when enabled.

Motor Current Setpoints

Sets motor current parameters for alarm, limiting, and ramp.

Slide Valve Setpoints

Sets acceptable ranges for minimum slide valve position.

SCHED Hot Key

Allows creating and modifying schedules for setpoint control.

Control

Determines if equipment operation is controlled by predefined schedules.

Active Group

Allows selection of the current active group for control.

Active Schedule

Allows changing the current active daily schedule.

Weekly Schedule

Defines daily schedule assignments for each day of the week.

Daily Schedules

Defines times to change setpoints for daily schedules.

Schedule 1 To Schedule 7

Standard format for selecting up to 8 schedule changes per day.

CNTRL Hot Key

Accesses menu options to set system control features.

Suction Pressure Control Setpoints

Sets load/unload controls for automatic capacity control.

Process Temperature Control Setpoints

Sets load/unload controls for automatic capacity control.

Economizer Control Setpoints (Option)

Sets parameters for Economizer Control when enabled.

Variable VI Setpoints (Option)

Provides setpoints for Vi Control.

MISC Hot Key

Accesses miscellaneous control screens for system parameters.

LOGS Hot Key

Accesses logging functions described in Chapter 4.

MENUS Hot Key

Accesses miscellaneous screens not under other hot keys.

CHAPTER 4 Logging Functions

Logging Functions Technical Overview

Discusses the overall function of standard and optional logs.

Operations Log

Records system operating conditions and events.

Trend Log

Records periodic data with user-defined intervals.

Alarm Log

Records the last 100 system alarms.

Failure Log

Records the last 100 system failures.

User Log

Records the last 50 user logons to the system.

KW Log (Optional)

Records daily, weekly, monthly, yearly KW usage and demand.

System Log (Optional)

Tracks and accumulates all system data for PC Monitor analysis.

Logging Functions Operating Procedures

Explains how to access and use the system's available logs.

Operations and Trend Logs

Details parameters and data descriptions for Operations and Trend logs.

Alarm and Failure Logs

Describes data content for alarm and failure log entries.

Clear Logs

Explains how to erase data from system logs.

Set Log Rates

Allows setting the rate for data collection in minutes.

CHAPTER 5 Menu Functions

Logon User

Describes the process of logging onto the system with a password.

Logoff User

Explains how to log off from the system.

Automatic Log Off

Details automatic logoff after a period of inactivity.

Diagnostics Menu

Permits viewing basic system information for troubleshooting.

System Information

Displays system options and software configuration status.

View Discrete I/O

Displays discrete input/output information from the unit.

View Analogs

Displays analog signal information, including values and units.

View Dip Switches

Shows the position of dip switches on the microprocessor board.

View Network Comm

Monitors the status of system communication links.

Override Discrete I/O (Option)

Allows simulating discrete inputs/outputs for diagnostics.

Setup Menu

Allows performing miscellaneous setup changes to configure the system.

Set Date and Time

Allows changing the system date, clock mode, or time of day.

Calibrate Sensors

Allows adjustment of sensor input ranges using Dynamic or Static calibration.

Dynamic Sensor Calibration

Adjusts sensor readings to remove small inaccuracies.

Static Sensor Calibration

Resets or restores sensor calibration values after changes.

Password Control

Assigns user passwords, screen access levels, and requirements.

Adding/Deleting Users

Allows system manager to add or delete users.

Screen Access Levels

Assigns read/write access levels to restrict user access to screens.

Initialization

Resets the system or restores factory setpoints.

Power Fail Reset

Restarts software using current setpoints as if a power failure occurred.

Set Factory Configuration

Resets the system to factory default values.

Configuration

Sets basic system parameters for display and operation.

Display Setup

Configures display units, default status screen, and compressor model.

Communication

Sets hardware communication parameters for protocols.

Motor Configuration

Sets CT size, motor voltage, and power factor.

Set Operating Status

Resets total runtime hours and start counts.

Operational Procedures

Diagram of screens available under the MENUS Hot Key.

APPENDIX A Alarm and Failure Data

Analog Alarms

Describes analog alarms, their levels, default setpoints, and comments.

Discrete Alarms

Lists discrete alarms, their levels, and associated comments.

APPENDIX B Analog and Discrete I/O

Analog Inputs

Identifies channel assignments for sensor inputs.

Discrete I/O RACK 1

Details discrete input/output assignments for Rack 1.

APPENDIX C Communication Protocols

Introduction

Defines hardware and software protocols for serial communications.

Applicable Documents

Lists recommended documents for familiarity.

Hardware Interface Description

Details hardware requirements and interface connections.

Hardware Requirements

Specifies the hardware needed for Modbus and DF1 communications.

Interface Connections

Shows physical connections for Modbus and DF1 ports.

Software Interface Description

Describes the request-response communication basis.

Protocol Overview

Explains the communication structure between master and slave.

Status Only or Status and Control Options

Details options for responding to status or control messages.

Message Categories

Lists supported message categories for communication.

MODBUS Protocol Description

Details Modbus RTU transmission mode and default configuration.

Read Holding Registers

Explains how to read controller registers using Function Code 0x03.

Preset Single Register

Explains how to change single register contents using Function Code 0x06.

Preset Multiple Registers

Explains how to change multiple registers using Function Code 0x10.

Error Messages

Describes Modbus error codes returned for data errors.

DF1 Protocol Description

Details DF1 transactions and default software configuration.

Protected Typed Logical Read

Explains reading registers using DF1 Protected Typed Logical Read.

Protected Typed Logical Write

Explains writing data using DF1 Protected Typed Logical Write.

Word Range Read

Explains reading register blocks using PLC-5 Logical ASCII Addressing.

Word Range Write

Explains writing register blocks using PLC-5 Logical ASCII Addressing.

Data Formats

Describes data representation for DF1, Modbus, and Discrete I/O.

Status Message Description

Explains read-only status messages containing analog, discrete, alarm data.

Analog Inputs and Computed Parameters

Lists analog inputs and computed parameters with their addresses.

Discrete Input and Outputs

Lists discrete I/O assignments and active states.

Alarm and Failure Data

Provides a table of alarm and failure parameters and their levels.

Equipment Data

Lists equipment parameters and their corresponding formats.

Control Message Description

Describes read/write messages for compressor control.

Network In Control Command

Allows network to enable or disable system control.

Compressor Start/Stop Command

Controls compressor start, stop, and online status.

Set Compressor Mode Command

Changes the current active mode of the compressor.

Change Compressor Capacity Command

Forces the compressor to load or unload.

Acknowledge/Clear Active Alarm Command

Silences alarms and clears active alarms from the display.

Change Current Setpoint Group Command

Changes the current active setpoint of the system.

Set Economizer Mode Command

Changes the current active mode of the economizer.

Auto Start/Stop Control Command

Allows compressor to start/stop based on setpoints.

Suction Pressure Setpoint Message Description

Displays or changes suction pressure control group setpoints.

Process Temperature Setpoint Message Description

Displays or changes process temperature control group setpoints.