-
7/23/2019 Performance Controler IM302
1/186
U
4725 121st Str
Des Moines, Iowa 50323, U.S
Phone: (515) 270-0
Fax: (515) 270-1
GLOBAL
SUPPLIERS
OF
TURBINE
AND
COMPRESSOR
CONTROL
SYSTEMS
Web: www.cccglobal.c
A/D
RAM
PID
ID
F
IM302
Series 3 Plus
Performance Controller
for Axial and CentrifugalCompressors
Publication IM302 (6.0.1)
Product Revision: 956-001
February 2001
http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/http://www.cccglobal.com/
-
7/23/2019 Performance Controler IM302
2/186
1987-1999, Compressor Controls Corporation. All rights
reserved.
This manual is for the use of Compressor Controls Corporation
and isnot to be reproduced without written permission.
The impeller and TTC logos, Total Train Control, TTC, Recycle
Trip,Safety On, Air Miser, TrainView, and WOIS are registered
trademarks;
and the Series 5 logo, Reliant, Vanguard, TrainTools,
TrainWare,SureLink, Guardian, and COMMAND are trademarks of
CompressorControls Corporation. Other product and company names
used herein
are trademarks or registered trademarks of their respective
holders.
The control methods and products discussed in this manual may
be
covered by one or more of the following patents, which have
beengranted to Compressor Controls Corporation by the United
StatesPatent and Trademark Office:
4,486,142 4,494,006 4,640,665 4,949,2765,347,467 5,508,943
5,599,161 5,609,465
5,622,042 5,699,267 5,743,715 5,752,3785,879,133 5,908,462
5,951,240 5,967,742
6,116,258
Many of these methods have also been patented in other
countries,and additional patent applications are pending.
The purpose of this manual is only to describe the configuration
and
use of the described products. It is not sufficiently detailed
to enableoutside parties to duplicate or simulate their
operation.
The completeness and accuracy of this document is not
guaranteed,and nothing herein should be construed as a warranty or
guarantee,express or implied, regarding the use or applicability of
the described
products. CCC reserves the right to alter the designs or
specificationsof its products at any time and without notice.
-
7/23/2019 Performance Controler IM302
3/186
Series 3 Plus Performance Controller
3
IM302 (6.0.1)
Document Scope
This manual tells how to configure, tune, and operate a Series 3
Plus PerformanceController. It does not tell how to install or
maintain it (see the Series 3 Plus Hard-ware Reference
[IM300/H]), nor how to program a host computer or DCS to use
its
Modbus interface (see the Series 3 Plus Modbus Reference
[IM300/M]).Chapter 1 summarizes this controllers applications
and features.
Chapter 2 describes the operation of the Performance
Controller.
Chapter 3 tells how to configure the analog and discrete inputs
and outputsand serial communication ports.
Chapter 4 tells how the Performance Controller calculates its
performancecontrol variables and describes its fallback
strategies.
Chapter 5 tells how to configure the PID loops and explains how
the perfor-mance control response is selected from their
actions.
Chapter 6 tells how to coordinate a Performance Controllers
actions with othercontrollers regulating the same compressor.
Chapter 7 tells how to configure the compressor load-sharing
algorithms.
Chapter 8 tells how the intended valve position and actuator
control signal arecalculated from the performance control
response.
Chapter 9 tells how to set up the Performance Controllers
automatic sequenc-ing, manual override, and redundant control
features.
Appendix A describes each Performance Controller configuration
parameter.
Appendix B describes the controller test procedures that can be
executed fromthe Engineering Panel.
Glossary/Index lists, summarizes, and directs you to the manual
sections that pro-vide more complete information on various
topics.
Finally, the following supporting documents are included at the
back of this manual:
DS302/M lists this controllers Modbus coils, discrete bits, and
registers.
DS302/O describes the controllers Front-Panel operator
interface.
DS302/V describes the changes in each standard release of the
PerformanceController software.
FM302/C lists the configuration and tuning parameters by key
sequence,organized by data group and page.
FM302/L lists the configuration and tuning parameters by name,
groupedaccording to the associated controller feature.
http://im300h.pdf/http://im300h.pdf/http://im300h.pdf/http://im300m.pdf/http://im300m.pdf/http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302V.pdfhttp://../Forms/FM302C.pdfhttp://../Forms/FM302L.pdfhttp://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302M.pdfhttp://im300m.pdf/http://im300h.pdf/http://im300h.pdf/http://../Forms/FM302L.pdfhttp://../Forms/FM302C.pdfhttp://../DataSheets/DS302O.pdf
-
7/23/2019 Performance Controler IM302
4/186
4
Contents
February 2001
The document title appears in the header of each
odd-numberedpage, while the chapter or appendix title appears in
the header ofeven-numbered pages. Odd-page footers list the
document number
and revision level [IM302 (6.0.1)], while even-page footers
providethe publication date (February 2001).
Acronyms are defined in the sections of this manual that discuss
thecorresponding subjects, by placing them in parentheses
followingthe spelled-out terms they represent. As an example, a
three-letteracronym (TLA) is a way to represent a three-word
subject by com-bining and capitalizing the initial letters of those
three words. Mostare also listed under Symbols and Acronymson page
11.
Cross-references to other documents specify a section and
chapter,while cross-references between chapters of this document
specify apage number. References that do not specify a location are
internalto the chapter in which they appear. In computerized
versions of thismanual, all such references are hot-linked to their
target locationsand appear in green. Entries in the tables of
contents, illustrationand table lists, and index are also
hot-linked but are not green.
The Titles
of other documents are italicized. In cross-references,double
quotation marks are used to delineate section headings (forexample,
see Document Scopeon page 3).
Attention may be drawn to information of special importance
byusing this text stylingor one of the following structures:
Note:
Notes contain important information that needs to be
emphasized.
Caution:
Cautions contain instructions that, if not followed, could lead
to irre-versible damage to equipment.
Warning!
Warnings contain instructions that, if not followed, could
leadto personal injury.
Document Conventions
-
7/23/2019 Performance Controler IM302
5/186
Series 3 Plus Performance Controller
5
IM302 (6.0.1)
Table of Contents
Document Scope . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 3Document Conventions . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Table of
Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 5List of Figures. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9List of
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 9Symbols and Acronyms . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1 Overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 15
Applications . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 15Major Features . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 20
Capacity Control Variable. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 22Set Points. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Capacity
Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 22Recycle Limiting . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 22Load Sharing . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 22
Fallback Strategies. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 23Loop Decoupling . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 23Speed
Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 23Automatic Sequencing . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 23Automatic or Manual
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
24Redundant Controller Tracking . . . . . . . . . . . . . . . . . .
. . . . . . . . . 24Hardware Configurations . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 24Analog and Discrete I/O .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24Control Element Features . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 25Serial Communication . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 25Configuration and
Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 25
Chapter 2 Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 27
Operator Interfaces . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 27Continuous Operation . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Stand-Alone Controller . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 28Control Element Position . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 28Capacity Control .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 28Alternate Control. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 29Capacity Limiting . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Station Controller . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 30Automatic Suspension . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 31
Load-Sharing Controller . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 32Primary Capacity Control . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 32Load Balancing. . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 32Load-Sharing Fallback . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 32
Sequencing Operation . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 33Shutdown . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34Stop/Idle State . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 34Startup . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
Load-Sharing Startups . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 35
-
7/23/2019 Performance Controler IM302
6/186
6
Contents
February 2001
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .36Initiating Manual. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.37Restoring Automatic . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 37Manual Override . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .39Tracking States . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.41
Speed or Output Tracking . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .41Redundant Control. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .42
Chapter 3 Input/Output Features
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .43
Hardware Options . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .43Disabling Input Signals . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .44Analog-to-Digital Variables .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.45Transmitter Testing . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .45Signal Variables. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.45Process Variables . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .46
Measured Variables. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .46Analog Outputs . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Split
Range Output . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .48Output Loopback Test . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .49Valve Position Test .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .50
Discrete Inputs. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .51Discrete Outputs . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.52
Fault Relays. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .52External Alarms . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.52
Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .55ID Numbers . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.56
Serial Communication Formats . . . . . . . . . . . . . . . . . .
. . . . . . . . . .56Serial Communication Errors. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .56Modbus Configuration . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.58
Chapter 4 Calculated Variables
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .59
Performance Control Variables . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .59Capacity Control Variable . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .59
Single Input Control . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 60Load Balancing and Cold-Recycle Control
. . . . . . . . . . . . . . . . .61Mass Flow Control . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
.61Compression Ratio Control . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .64
Fallback Control Variable. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .65Limiting Variables . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .65Pressure
Override Variable . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .65PV and SP Readouts. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .66Software Filters . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.66
Fallback Strategies . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .67Capacity Control Fallback . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Limiting
Control Fallback . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .68Pressure and Temperature Fallbacks . . . . . . . .
. . . . . . . . . . . . . . .68
-
7/23/2019 Performance Controler IM302
7/186
Series 3 Plus Performance Controller
7
IM302 (6.0.1)
Remote Set Point Fallback. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 68Load-Sharing Fallback . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 68
Chapter 5 Performance Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 69
General PID Algorithm . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 69Dead Zone . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Loop Direction . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 70Set Point Ramping . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Capacity
Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 72
CV1 Set Point. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 72Limiting Control . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73Alternate Capacity Control . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 74Performance Control Response. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 75
Chapter 6 Coordinated Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 77
Loop Decoupling . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 77Decoupling Gain Sign Conventions
. . . . . . . . . . . . . . . . . . . . . . . . 78
Antisurge from Performance. . . . . . . . . . . . . . . . . . .
. . . . . . . . . 79
Performance from Antisurge. . . . . . . . . . . . . . . . . . .
. . . . . . . . . 79Performance from Performance . . . . . . . . .
. . . . . . . . . . . . . . . . 79
Recycle Limiting. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 80Auxiliary Limiting Control . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80Pressure Override Response. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 81
Pressure Override Predictor . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 82Speed Tracking . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . 83
Serial Speed Tracking . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 85Analog Speed Tracking . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 86
Chapter 7 Load-Sharing Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 87
Load Distribution . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 87Primary Capacity Control . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Station Controller . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 89Load-Sharing Controller . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 89Antisurge
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 90Unit Controller. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 90
Load Balancing. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 91Parallel Load Balancing . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 92Series Load
Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 93
Load Limit Condition. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 95Load-Sharing Fallback . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . 96
Parallel Recycling. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 97Recycle Balancing . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97Cold-Recycle Control . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 98
Cold-Recycle Antisurge Control . . . . . . . . . . . . . . . . .
. . . . . . . . 99Cold-Recycle Performance Control . . . . . . . .
. . . . . . . . . . . . . . 99
Air Miser Control Systems . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 101Calculated Variable Displays . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 101
Measured Total Flow . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 102Available Flow . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 103
-
7/23/2019 Performance Controler IM302
8/186
8
Contents
February 2001
Summed Total Flow. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .104Total Drive Power . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .104System Efficiency. . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.104
Capacity Optimization . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .105Start Condition . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .105Stop
Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .105
Extraction Load Sharing . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .106
Chapter 8 Output Variables
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .107
Intended Valve Position. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .107Output Clamps. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .108Valve
Flow Characterization . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .110
Actuator Control Signal . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .111Valve Dead Band Compensation. . . .
. . . . . . . . . . . . . . . . . . . . . .111Display Output
Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .112
Chapter 9 States and Transitions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.113
Automatic Sequences . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .113
Operating State Request Signals . . . . . . . . . . . . . . . .
. . . . . . . . .114Check Valve. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .115Start-Up Sequence
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .116Shut-Down Sequence . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .117Coordinated Sequencing . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .117
Manual Override . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .119Alternate Parameter Sets . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
.119Redundant Tracking . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .120
Switching Conditions . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .120Alternate Control Strategies. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .120
Appendix A Configuration Parameters
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.121
Appendix B Controller Test Sequences
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Glossary/Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .165
-
7/23/2019 Performance Controler IM302
9/186
-
7/23/2019 Performance Controler IM302
10/186
10
Contents
February 2001
Symbols and Acronyms
A series load-sharing domain selection variable
ACS Actuator Control Signal
AD1 to AD8 Analog-to-Digital variables
CCC Compressor Controls Corporation
CH1 to CH8 analog input CHannels
CPU Central Processing Unit
CR
D
Derivative Control Response
CR
I
accumulated Integral Control Response
CR
I
Integral Control Response
CR
LD
Loop-Decoupling Control Response
CR
P
Proportional Control ResponseCR
PC
Primary Capacity Control Response
CRC Cyclic Redundancy Checksum
CRIC Cold-Recycle (flow) Indicating Controller
CR1 to CR5 Control Relays (discrete outputs)
CSP Computer Set Point
CV Control Variable or Check Valve
CV
b
load-balancing Control Variable
CV0 pressure override Control Variable
CV1 capacity Control Variable
CV2 higher priority limiting Control Variable
CV3 lower priority limiting Control Variable
DCS Distributed Control System
DEV antisurge control DEViation
DEV' parallel compressor load-balancing variable
DO1 to DO5 Discrete Outputs (control relays)DPT Differential
Pressure Transmitter
e error (control loop deviation)
EEPROM Electrically Erasable Programmable Read-Only Memory
Eff system Efficiency calculated variable
ESD Emergency ShutDown
fA Application function
-
7/23/2019 Performance Controler IM302
11/186
Series 3 Plus Performance Controller
11
IM302 (6.0.1)
FIC Flow Indicating Controller
FIOM Field Input/Output Module
FCV Fallback Control Variable
FT Flow Transmitter
FY Flow TransducerGTIC Gas Turbine (fuel) Indicating
Controller
I/O Input and Output circuits
I/P Current-to-Pneumatic signal converter
IT Current Transmitter
IFR Intended Flow Rate
IVP Intended Valve Position
J power
L series compressor load-balancing variable
LD Loop Decoupling
LED Light Emitting Diode
LodP Loaded Primary condition
LodS Loaded Secondary condition
LS Load-Sharing
LSIC Load-Sharing Indicating Controller (slave Performance
Controller)
LSP Local Set Point
M Molecular weight, occasionally Motor
MaxQ Available Mass Flow
N rotational speed (generally, the Number of revolutions per
unit time)
NO/NC Normally-Open/Normally-Closed
OP Operating Point
OutF Output Failure
OUT1 analog OUTput 1
OUT2 analog OUTput 2P Pressure
P
c
Pressure rise across a Compressor
P
c
Compensating Pressure for mass flows
P
d
Discharge Pressure
P
d,a
absolute Discharge Pressure
-
7/23/2019 Performance Controler IM302
12/186
12
Contents
February 2001
P
d,g
gauge Discharge Pressure
P
dh
Discharge Header Pressure
P
o
Pressure drop across an Orifice plate (flow measurement)
P
o,1
main flow measurement
P
o,2
second or sidestream flow measurementP
s
Suction Pressure
PCB Printed Circuit Board
PCR Performance Control Response
PI Proportional-Integral
PIC Pressure Indicating Controller
PID Proportional-Integral-Derivative
P&ID Piping and Instrumentation Diagram
POC Pressure Override Control
POP Pressure Override Predictor
POV Pressure Override Variable
Power total drive Power
psi pounds per square inch
PT Pressure Transmitter
PV1 to PV8 Process Variables
Q volumetric flow
q
s
reduced volumetric flow in Suction (preferred)
Q
s
volumetric flow in Suction
Q
s,red
reduced volumetric flow in Suction (alternate)
RAM Random Access Memory
R
c
Compression Ratio
RCS Redundant Control Selector
RFR Required Flow Rate
rpm revolutions per minuteRSP Remote Set Point
RT Recycle Trip
R
T
Temperature Ratio
RTL Recycle Trip Line
S proximity to the surge control line
-
7/23/2019 Performance Controler IM302
13/186
-
7/23/2019 Performance Controler IM302
14/186
14 Contents
February 2001
-
7/23/2019 Performance Controler IM302
15/186
-
7/23/2019 Performance Controler IM302
16/186
16 Chapter 1: Overview
February 2001
Figure 1-3 Compressor with multiple feeds and control
elements
Because it is far more efficient to regulate throughput by
adjustingthe compressor speed, the Performance Controller is often
used tomanipulate the set point of the drivers speed governor (if
that is a
turbine, integrated control can be obtained by combining the
Perfor-mance Controller with a Series 3 Plus Speed or Fuel
Controller). Ifthere are two throttling elements, a single
Performance Controllercan manipulate both for increased efficiency.
The system shown inFigure 1-3uses analog signals to manipulate
inlet guide vanes anda speed governor. The system in Figure 1-4uses
serial communica-tion with Series 3 Plus Fuel Controllers to
regulate compressorsdriven by gas turbines, while the one in Figure
1-5uses Series 3Plus Speed Controllers to regulate
steam-turbine-driven units.
In addition to single-input variables like the discharge
pressure, the
Performance Controller can be configured to regulate the
compres-sion ratio or a pressure- and temperature-compensated mass
flow(also known as standard volumetric flow). If the total flow can
not bemeasured because there are multiple feed and discharge
streams,two flow measurements can be combined (see Figure 1-3).
FT TT PT
FT
FY
PIC Performance ControllerSIC Speed Controller
FT TT TTPT PT
UICPort 1
FY
TT PT
PIC
FY
SIC
UIC Antisurge Controller
N
SP
-
7/23/2019 Performance Controler IM302
17/186
-
7/23/2019 Performance Controler IM302
18/186
-
7/23/2019 Performance Controler IM302
19/186
-
7/23/2019 Performance Controler IM302
20/186
20 Chapter 1: Overview
February 2001
Major Features This software revision (956-001) offers the
following features: the Capacity Control Variablecan be any analog
input (usually
a pressure or flow measurement), a temperature and
pressure-compensated mass flow rate, the compression ratio, or a
load-sharing variable based on proximity to surge
bumpless switching between remote and local Set Points two
Capacity Limitingloops that can override the capacity con-
trol loop to maintain the analog inputs for any two
processvariables (such as drive-motor current or fluid
temperature)within safe or acceptable ranges
Recycle Limitingfeatures that use a companion Antisurge
Con-troller to help regulate throughput or a pressure
overridevariable.
Load Sharingfor compressors operating in series or in parallelor
for single-extraction steam turbines
Fallback Strategiesthat can provide continued control
whenotherwise required analog or serial communication inputs
fail
Loop Decouplingthat minimizes adverse interactions between
acompressors capacity and antisurge control loops
Speed Trackingfeatures that provide coordinated control
ofturbine-driven compressors
Automatic Sequencingof compressor startups and shutdowns
Automatic or Manual Operationfrom the Front Panel or a
hostcomputer or control system
Redundant Controller Trackingthat allows one
PerformanceController to serve as an on-line backup to another
Basic or Extended I/O Hardware Configurations
Analog and Discrete I/Oports that can be assigned
functionsappropriate to each application
Control Element Featuresthat adapt the analog output to
virtu-ally any final control element, allow both outputs to be used
tocontrol separate control elements, and test its accuracy
Serial Communicationwith companion Series 3 Plus Control-lers,
operator workstations, and Modbus host systems
Configuration and Tuningfrom either the Engineering Panel(from
which three alternate parameter sets can be stored andrecalled) or
from a computer workstation
Please refer to the Series 3 Plus Performance Controller
RevisionHistory[DS302/V]for information about previous
revisions.
http://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302V.pdfhttp://../DataSheets/DS302V.pdf
-
7/23/2019 Performance Controler IM302
21/186
Series 3 Plus Performance Controller 21
IM302 (6.0.1)
Figure 1-7 Performance Controller functional diagram
PI Algorithm
or
Display OutputReverse
Valve DeadBand Compensation
OUT Readout
IFR
IVP
e1
Loop Reverse 1
CV1
SP1
Application Function
Dead Zone
Output Clamps Speed TrackingManual
PCR
or
Limiting Control Response Selection
PID Algorithm
PID2PID1 PID3
e2
CV2
Disable/High/Low
Loop Decoupling
e3
CV3
Disable/High/Low
Valve Flow Characterizer
e0
Input Select
Loop Reverse 0
POV (CV0)
SP2
Analog Inputs
Loop Reverse 3Loop Reverse 2
Input Select Input Select
SP3orLSP
RSP
POC Predictor
I0P0
Relative POC SP
SP0
to Antisurge Controllers
OUT2OUT1
or Split Range Output
ACS
Primary Capacity
Control
Control Signal
Station Controller
PIDs & RTs
Interacting Loop
-
7/23/2019 Performance Controler IM302
22/186
-
7/23/2019 Performance Controler IM302
23/186
Series 3 Plus Performance Controller 23
IM302 (6.0.1)
Controller can regulate its compressor as a stand-alone
machine(see Load-Sharing Fallbackon page 96).
When two or more single-extraction steam turbines are
connectedto the same header, their total load can be distributed by
using aPerformance Controller to calculate the flow set points of
theirExtraction Controllers (see Extraction Load Sharingon page
106).
FallbackStrategies
If analog input or serial communication failures preclude
calculationor measurement of a capacity control or limiting
variable or set point,the controller can employ default values or
hold the performancecontrol signal constant (see Fallback
Strategieson page 67). In amultiple compressor application, it can
also switch to an alternatecontrol loop (see Load-Sharing
Fallbackon page 96).
Loop Decoupling The controller can counter the potentially
destabilizing effects thatcan result from interactions between the
various control loops regu-
lating a single compressor by adjusting its control response
inresponse to changes in the output signals of companion
controllers(see Loop Decouplingon page 77).
Speed Tracking If the performance control signal is used as the
remote set point of aturbine or motor speed governor, the capacity
control and limitingloops can be configured to avoid integral
windup when that governoris ignoring its remote set point, and to
bumplessly restore cascadespeed control when the governor resumes
using its remote set point(see Speed Trackingon page 83):
If the governor is a Series 3 Plus Speed or Fuel
Controller,speed tracking can be implemented via Port 1
serialcommunications.
Otherwise, speed tracking can be implemented using analogand
discrete signals.
AutomaticSequencing
The controller can be set up to automatically load and idle the
com-pressor in response to user-specified analog, discrete, and
serialcommunication signals (see Automatic Sequenceson page
113):
The start-up sequence loads the compressor by increasing the
performance control response until specified throttle control
ele-ment and recycle valve positions have been reached and anycheck
valve has opened (see Start-Up Sequenceon page 116).
The shut-down sequence idles the compressor by ramping
thethrottle control element to an idle level, where it is held
until theunit is loaded (see Shut-Down Sequenceon page 117).
-
7/23/2019 Performance Controler IM302
24/186
-
7/23/2019 Performance Controler IM302
25/186
Series 3 Plus Performance Controller 25
IM302 (6.0.1)
Control ElementFeatures
The actuator control signal can be clamped, adapted to a
director reverse, linear, quick-opening, or equal-percentage valve,
andcompensated for a deadband (see Output Variableson page 107).The
controller can also detect an excessive deviation of the
actuatorcontrol signal from its intended value (see Output Loopback
Testonpage 49) or of the control element from its intended position
(see
Valve Position Teston page 50).
When there are two control elements that affect the
compressorthroughput, they can be manipulated by defining both of
the control-lers analog output signals as separate functions of the
performancecontrol response (see Split Range Outputon page 48).
SerialCommunication
All Series 3 Plus Controllers are equipped with four serial
communi-cation circuits (see Serial Portson page 55):
Ports 1 and 2 are used to coordinate their actions with otherCCC
controllers (see Loop Decoupling, Speed Tracking, Load
Sharing, Automatic Sequencing, and Redundant
ControllerTracking).
Ports 3 and 4 are used for computer communication and
controlusing Modbus RTU commands (see Chapter 2and the Series 3Plus
Performance Controller Modbus Data Sheet[DS302/M]).This allows a
host control system or a computer running control-ler support
software (such as our COMMAND system) tomonitor or even control the
operation of your compressor. Someof our support programs can also
change the configuration andtuning of the controller.
Configuration andTuning
Each Performance Controller is adapted to its specific
application byassigning values to its configuration and tuning
parameters (seeAppendix A). This can be done from the Engineering
Panel or acomputer running one of our configuration programs.
If your application requires routine changes to a controllers
configu-ration or tuning, up to three sets of alternate parameter
values canbe stored. Engineering Panel procedures are provided for
definingthese alternate sets, determining which one is in use, and
switchingto a different one (see Alternate Parameter Setson page
119).
http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
26/186
26 Chapter 1: Overview
February 2001
-
7/23/2019 Performance Controler IM302
27/186
Series 3 Plus Performance Controller 27
IM302 (6.0.1)
IM302
Chapter 2 OperationThis chapter describes the operation of the
Performance Controller.
OperatorInterfaces
This section summarizes the controller features that can be
oper-ated via its front-panel, remote I/O, and Modbus
interfaces.
The front-panel keys, LEDs, and readouts can be used to
selectmanual or automatic operation, switch between the local and
remoteset point, raise or lower the local set point, and manually
vary thecontrol response, as described in the Series 3 Plus
PerformanceController Operator Interface Description[DS302/O].
The controllers remote I/O features (see Chapter 3) are
primarily forintegration with other devices. Discrete inputs can be
used to selectthe operating state or to trigger alternate capacity
control. Discreteoutputs can be used to implement external alarms
and indicators forvarious operating conditions. Process variable
analog inputs can bemonitored directly, while some internal
variables can be monitoredvia analog outputs.
The Modbus interface can be used to monitor the operation of
thecompressor and controller, select automatic or manual
operation,set either the remote or local capacity control set point
and switchbetween them, change the limiting control thresholds, and
manuallyset the intended control valve position, as described in
the Series 3Plus Performance Controller Modbus Data
Sheet[DS302/M].
Note: Because all three interfaces are always active, the
compressor canbe monitored and controlled using any combination of
their features.
http://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302O.pdf
-
7/23/2019 Performance Controler IM302
28/186
28 Chapter 2: Operation
February 2001
ContinuousOperation
The operation of a Performance Controller depends on whether it
isa Stand-Alone Controllerthat regulates a pressure or flow by
manip-ulating the throughput of a single compressor, a Station
Controllerthat regulates the throughput of a series or parallel
compressornetwork, or a Load-Sharing Controllerthat regulates the
throughputof one compressor in such a network.
In any of these applications, a Performance Controller will
select itsRun state when its loading sequence terminates, and will
remain inthat state until the operator initiates the idling
sequence or a drivershutdown (see Sequencing Operationon page 33).
The operatingstate will display as Status RUN and the Modbus
Startedand Star-tup Donediscretes and any Run relays will be
set.
Stand-AloneController
When a single-compressor Performance Controller is
operatingautomatically in its Run state, it varies its Control
Element Positionto satisfy its Capacity Controland Capacity
Limitingobjectives.
Control ElementPosition
The throughput of a stand-alone or load-sharing compressor can
becontrolled by varying the speed set point of a speed controller
orgovernor or the position of its guide vanes or throttle
valve.
In any case, the position of that control element can be
monitoredvia the OUT readout, Modbus Displayed OUTregister, or
analogoutput OUT1. Analog output OUT2 (and the Analog Output
2regis-ter) can also be configured to transmit that signal.
The Modbus High Clampor Low Clampdiscrete bit will be set if
thecontrol response equals the corresponding clamp.
If the controller has been configured to use both analog outputs
tomanipulate control elements (see Split Range Outputon page
48),both analog outputs are calculated as configurable functions of
theperformance control response, so that the displayed OUT
signalremains an essentially linear indication of overall
performance orthroughput. This feature can be used to regulate both
the rotationalspeed or a throttling valve and the guide vane
position.
Capacity Control The controller can regulate either a
single-input variable (usually aflow or pressure signal), a
compression ratio calculated from twopressure inputs, or a mass
flow rate calculated from flow, pressure,
and temperature inputs for either one or two streams (see
CapacityControl Variableon page 59). The PV and SP readouts
normallydisplay the value and set point for this variable, which a
Modbushost can monitor via the Displayed PVand Displayed
SPregisters.OUT2 (and the Analog Output 2register) can also be
configured totransmit either signal. The controllers individual
analog inputs canbe monitored via the front-panel AUXiliary readout
Measured Vari-ablesmenu or Modbus Channel #registers.
http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS301M.pdfhttp://../DataSheets/DS301M.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
29/186
Series 3 Plus Performance Controller 29
IM302 (6.0.1)
Depending on how the set point is set up (see CV1 Set
Pointonpage 72), it can be controlled either by a remote device or
from theFront Panel:
Pressing the Raise key while the controller is operating
auto-matically increases the local set point, while pressing the
Lowerkey reduces it.
If the Computer Remote Set Pointis disabled, the local set
pointcan also be changed by writing to the Capacity SPregister
andthe remote set point (if enabled) is controlled via an
analoginput. Depending on your application, that signal might be
con-trolled by a remote device or a potentiometer on an
auxiliarycontrol panel.
If the Computer Remote Set Pointis enabled, the remote setpoint
can be changed only via the Capacity SPregister and thelocal set
point can only be changed from the Front Panel.
If the local and remote set point are both enabled, you can
switchbetween them by pressing the REMOTE/LOCAL key or setting
andclearing the Remotecoil. When you do so, the actual set point
doesnot change because the newly selected set point is initialized
to thecurrent value of the previously selected set point. However,
a newlyselected analog remote set point will then ramp to the most
recentvalue sent by the remote device.
When the remote set point is selected, the Remote LED is lit
andany Remoterelays and the Modbus Remotecoil and discrete areset.
When the local set point is selected, the Local LED is lit and
theremote indicators are cleared.
Alternate Control The controller can be configured to switch to
local set point controlof an alternate process variable when
discrete input D6 is asserted(see Alternate Capacity Controlon page
74). The PV and SP read-outs and registers then display the
alternate variable and set point,while the Local LED flashes to
alert the operator. A Modbus hostcan detect this condition by
monitoring the sixth DO Statebit.
The local set point for this variable can then be varied by
pressingthe front-panel Raise and Lower keys. When D6 is cleared,
CV1control is restored and its selected set point is ramped from
thatvariables current value to its previous local or current remote
value.
Note: If necessary, a Modbus host should select the set point it
controlsbefore writing to the Primary SP register.
http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
30/186
30 Chapter 2: Operation
February 2001
Capacity Limiting A stand-alone or load-sharing Performance
Controller can also beset up to limit either of two capacity
limiting variables if they movebeyond prescribed high or low
control thresholds. In that event, theLimit LED will light, any
Limitrelays and the Modbus Limitdiscretewill be set, and the
capacity control (or load-balancing) variable maydeviate
significantly from its set point.
Pressing the DISPLAY LOOP 2 or DISPLAY LOOP 3 key will
tem-porarily display the corresponding limiting variable and its
controlthreshold in the PV and SP readouts. A Modbus host can
monitorthese variables via the corresponding Channel #register, and
canmonitor or vary their set points via the Limiting SP2and
LimitingSP3registers.
Station Controller In a Series 3 Plus Control System for
load-sharing compressors, amaster Performance Station
Controllerregulates a header flow rateor pressure by indirectly
manipulating the individual compressor
throughput and recycle (or blow-off) rates. This is accomplished
bybroadcasting changes in its control response to the Antisurge
andLoad-Sharing Controller, which then manipulate their control
ele-ments to efficiently and safely satisfy the station control
objective.
A Station Controller operates just like a Stand-Alone
Controller,except that its station control signal (SCS) is a serial
transmission tocompanion controllers rather than an analog signal
to a valve orguide vane actuator or speed governor. Because those
companionsrespond to changes in the SCS, its actual value has no
physical sig-nificance. It is usually configured as though it is
manipulating asignal-to-close valve. If its value falls below its
low clamp or risesabove its high clamp, it is simply reset to 50
percent.
The SCS can be monitored via the Station Controllers OUT
read-out, Displayed OUT register, or OUT1. Its OUT2 (and Analog
Output2register) can also be configured to transmit that
signal.
If Station Controller needs to but cannot increase the
throughput ofits compressor network because all of its Load-Sharing
Controllers
are load-limited or fail to respond to queries, it will set any
LoadedPrimary(LodP) relays and its Modbus Loaded Primarydiscrete
bit.In addition, an Automatic Suspensionis triggered if no
Load-SharingController is available to help control the primary
capacity variable.
In a system utilizing Dual-Loop A/P Unit Controllers, various
systemperformance variables calculated by the Station Controller
(see Cal-culated Variable Displayson page 101) can be monitored via
theCalculated Variablesmenu and the corresponding Modbus
registers(Efficiency, Flow, MaxQ, Power, and UsrQ).
Note: Do not be alarmed if the OUT display of a Station
Controller sud-denly jumps from 00.0 or 99.9 to a value near
50.0.
http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
31/186
-
7/23/2019 Performance Controler IM302
32/186
32 Chapter 2: Operation
February 2001
Load-SharingController
When a Load-Sharing Controller is operating automatically in
itsRun state, it varies its Control Element Positionto satisfy its
PrimaryCapacity Controland Load Balancingor Capacity
Limitinggoals.
Such a Performance Controller sets any Loaded
Secondary(LodS)relays and its Modbus Loaded Secondarydiscrete bit
when it cannot increase its compressors performance in response to
a risingstation control signal. In addition, its Load-Sharing
Fallbackwill betriggered if communication with the Station
Controller breaks down.
Primary CapacityControl
If the network throughput needs to be reduced and the
compressorsare already operating near their surge control limits,
the AntisurgeControllers will provide that reduction by increasing
their recycle orblow-off rates, as described in the Load
Sharingsection in Chapter2 of IM301. Otherwise, the Load-Sharing
Controllers will reduce net-work performance by closing their
control elements or reducing theirspeed set points in response to a
declining station control signal.
Load Balancing Load-Sharing Controllers use their capacity
control loops to distrib-ute the total load among all operating
compressors in the network(except when overridden by a limiting
control loop):
For compressors operating in series, the overall load
distributionis balanced by equalizing a load-balancing variable
based ondistance-from-surge, recycle flow, and speed or
compressionratio.
For machines operating in parallel, load-balancing equalizesonly
the compressors distances from surge. If desired, a sepa-rate
recycle balancing algorithm can be used to evenly
distribute the total load when the compressors are
recycling.
Whenever a Load-Sharing Controller is operating automatically
withits remote set point selected, it calculates this balancing
variable forits own compressor and compares it to an average-value
set pointreceived from the Station Controller. Those two variables
are dis-played by the PV and SP readouts (and can be monitored via
theModbus Displayed PVand Displayed SPregisters). The
balancingresponse calculated from the resulting deviation is added
to thePrimary Capacity Controlresponse.
Load-SharingFallback
If communication with the Station Controller is disrupted, that
con-troller selects its Capacity Control Fallback(see page 67), or
the D6input is asserted, a Load-Sharing Controller can fall back to
local setpoint control of its compressors throughput (see
Load-Sharing Fall-backon page 96). The front-panel Remote LED then
goes out, theLocal LED starts flashing, the Fallback LED lights
(unless D6 trig-gered this condition), and the Modbus
Fallbackdiscrete is set. Loadsharing will then be automatically
resumed when the condition thattriggered the fallback is
corrected.
http://../DataSheets/DS302M.pdfhttp://im301.pdf/http://im301.pdf/http://im301.pdf/http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://im301.pdf/http://im301.pdf/http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
33/186
-
7/23/2019 Performance Controler IM302
34/186
34 Chapter 2: Operation
February 2001
Shutdown If a Performance Controller is operating in its Run
state (see Contin-uous Operationon page 28), it will assume the
compressor is beingshut down when a designated analog input falls
below its start-upthreshold or the stop discrete input is asserted.
In practice, this usu-ally means the driver is either being shut
down or a stop or idleswitch has been set.
A Performance Controller that is coordinating its sequences
withthose of a Series 3 Plus Speed or Fuel Controller will idle its
com-pressor (and signal its companions that it has done so) when
thatcontrollers shut-down sequence is initiated, unless it has
alreadybeen initiated by a switch.
Any Run relays and the Modbus Startup Donediscrete are
thencleared and the control response is ramped downward at a
constantrate until it reaches its stop/idle level. While it is
ramping down, theAUXiliary readout displays the operating state as
Status RAMP.When that ramp concludes, that readout changes to
Status STOP.
If the compressors Antisurge Controller has been configured
toparticipate in automatic startups and shutdowns, it will either
rampits valve open or open it as quickly as possible as soon as the
Per-formance Controller initiates its shut-down ramp (see the
Shutdownsection in Chapter 2 of IM301).
Stop/Idle State After a Shutdownhas finished ramping the control
response, a Per-formance Controller will operate in its stop/idle
state as long as anystop or idle request is set. In practice, this
usually means the driveris either stopped or a stop or idle switch
is set.
This operating state displays as Status STOP and clears the
Mod-bus Starteddiscrete unless the compressor is idling. The
controlresponse is held at its stop/idle level, which is often
zero. If used toposition a throttling valve, that signal would then
hold the valve fullyclosed to prevent back-flow through the
compressor.
If the compressors Antisurge Controller has been configured to
par-ticipate in automatic startups and shutdowns, it will hold its
controlvalve fully open (to allow any unintended flow to bypass the
com-pressor). If its purge response is triggered, however, it will
fully closethat valve so purge gas can be forced through the
compressor (see
the Stop Statesection in Chapter 2 of IM301).
http://../DataSheets/DS302M.pdfhttp://im301.pdf/http://im301.pdf/http://im301.pdf/http://../DataSheets/DS302M.pdfhttp://im301.pdf/http://im301.pdf/http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://im301.pdf/http://im301.pdf/http://im301.pdf/
-
7/23/2019 Performance Controler IM302
35/186
Series 3 Plus Performance Controller 35
IM302 (6.0.1)
Startup If a Performance Controller is operating in its
Stop/Idle State, astartup will be initiated as soon as all
stop/idle requests are cleared.In practice, this usually means the
driver is running and any stop oridle switches are cleared or in
their run positions. A PerformanceController that is coordinating
its sequences with those of a Series 3Plus Speed or Fuel Controller
will load its compressor only after the
turbine controllers start-up sequence has been completed.
The operating state display then changes to Status RAMP andany
Run relays and the Modbus Starteddiscrete are set. After ashort
delay, the controller signals its companions that it has
selectedits Run state, and the control response starts to rise at a
constantrate. During this ramp, the local set point can be varied
(if selected)from either the Front Panel or a Modbus host. When the
controlresponse reaches its minimum operating level, closed-loop
controlis initiated, the status display changes to Status RUN, and
theStartup Donediscrete is set.
If the compressors Antisurge Controller has been configured to
par-ticipate in automatic startups and shutdowns, it will initiate
closed-loop control when its inputs indicate the compressor is
running andits specified companion selects its Run state. It will
then slowly closethat valve until it is fully shut or the minimum
safe recycle or blow-offflow rate is reached (see the
Startupsection in Chapter 2 of IM301).
Load-SharingStartups
The sequencing features of a parallel compressor networks
StationController are usually disabled, as it will simply suspend
its controlactions (see Automatic Suspensionon page 31) when all of
thecompressors are idled or shut down. As the first compressor
is
brought on-line, load sharing is initiated when its startup
sequenceterminates. As subsequent compressors are loaded, their
startupswill not terminate until their check valves open (see Check
Valveonpage 115), at which point the CV Opendiscretes of their
Load-Shar-ing Controllers are set.
In a system employing Dual-Loop A/P Unit Controllers, special
sig-nals are provided to indicate when additional compressors
shouldbe idled or loaded. The operation of such systems are
described inthe Load-Sharing Sequencessection in Chapter 2 of
IM303.
http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://im301.pdf/http://im301.pdf/http://../DataSheets/DS302M.pdfhttp://im303.pdf/http://im303.pdf/http://im303.pdf/http://../DataSheets/DS302M.pdfhttp://im301.pdf/http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
36/186
-
7/23/2019 Performance Controler IM302
37/186
Series 3 Plus Performance Controller 37
IM302 (6.0.1)
Initiating Manual Manual operation can be selected at any time
unless the controlleris configured for Auxiliary Limiting
Control(see page 80). However:
If Speed or Output Trackingis active, the operator cannotchange
the control signal (the governors remote speed setpoint) until that
controller resumes remote set point speedcontrol.
In a Redundant Controlsystem, only the active controller can
bemanually operated (the backup will track that selection).
Manual is selected by pressing the AUTO/MAN key while the
greenAuto LED is lit or clearing the Modbus Automaticcoil. The
ManualLED then lights and the Auto LED, any Auto relays, and the
Auto-maticcoil and discrete bit all clear. The Remote or Local LED
willremain lit to indicate the selected set point. The operating
state willthen display as either Run or Stop, depending on whether
the com-pressor is running.
RestoringAutomatic
Pressing the AUTO/MAN key while in manual or setting the
ModbusAutomaticcoil initiates a bumpless return to automatic
control. TheManual LED then clears and the Auto LED, any Auto
relays, and theAutomaticcoil and discrete bit all set.
To prevent sudden throttle movements, the effective values of
theCV1 set point and limiting control thresholds are initialized to
thecurrent values of their control variables. The limiting
thresholds arethen ramped to their parameter values, while the
behavior of theCV1 set point depends on which set point is
selected:
If the remote set point is selected, it is ramped from the
currentvalue of CV1 to the target value from the remote source.
If the local set point is selected and Local Set Point
Recallisenabled, it is ramped from the current value of CV1 to the
valuethat set point had when manual was initiated.
If the local set point is selected and Local Set Point Recallis
dis-abled, it remains at the current (or last good) CV1 value
untilyou specifically change it.
Either way, the initial PID error will be zero. The derivative
error isset to zero, and the accumulated integral response is set
equal to
the last back-calculated control response. Thus, restoring
automaticcontrol will not cause a sudden change in the performance
controlsignal unless it is above its high clamp or below its low
clamp, inwhich case it will jump back to that clamp. In addition,
the ValveDead Band Compensation(see page 111)feature will
rememberwhich direction the operator last moved the output while in
manualand resume operation accordingly.
http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
38/186
38 Chapter 2: Operation
February 2001
Manual Override Several parameters (see Manual Overrideon page
119) determinewhether or not manual control actions are ever
automatically termi-nated or restricted:
If the Capacity Manual Overrideis enabled, unrestricted
manualoperation will continue even if a stop or ESD request signal
isasserted or a limiting variable is beyond its control
threshold.This potential hazard is indicated by flashing the
front-panelManual LED when manual control is selected while this
parame-ter is On.
Otherwise, asserting a stop or ESD request will restore
auto-matic control (although manual could then be reselected
anddoing so would terminate the resulting shutdown) and each
lim-iting control loop can be independently configured to
overridemanual operation when its control variable reaches its
controlthreshold.
Regardless of all manual override settings, you cannot
manually
adjust the control response while Speed or Output
Trackingisactive.
The Limit LED will light whenever either capacity limiting
variable isat or beyond its defined limit, but automatic control is
temporarilyrestored (and the Limit relay and discrete bit are set)
only if that vari-ables manual override has been enabled. The
performance controlresponse can still be manually adjusted while a
limiting override isactive, but only in the direction that would
restore the out-of-rangevariable to an acceptable value.
Caution: We advise you not to permanently enable the Capacity
ManualOverrideparameter.
-
7/23/2019 Performance Controler IM302
39/186
Series 3 Plus Performance Controller 39
IM302 (6.0.1)
Fault Indicators In addition to a General Fault, which would be
indicated via the FaultLED and relays, the Performance Controller
can use front-panelLEDs, assignable relays, and Modbus discrete
bits to indicate SerialCommunication Errors, Analog Input or
Transmitter Failures, OutputFailures, and Valve Position Failures.
It will also indicate when itsBackup Inputis selected or a Fallback
Conditionis active due to
analog input or serial communication problems.
General Fault Each Series 3 Plus Controller has a watchdog
circuit that must beregularly reset by its control program. If it
does time out, it will de-energize the fault relay and reset the
CPU chip, thus causing thecontrol program to restart:
If that restart succeeds, it will reset the timer, clear the
relay,and temporarily set the Modbus Resetdiscrete. The
Engineer-ing Panel will beep and display Reset.
If it fails, the fault relay will remain de-energized and the
FrontPanel will light its Fault LED (and turn the other thirteen
off).
This can indicate either a software error or a hardware
problemthat prevents the control program from running.
If the fault relay has also been assigned a second function
(seeFault Relayson page 52), that condition will not light the
Fault LED.If that assigned function is one that has its own LED,
you can tellwhy the fault relay has tripped by looking at the Front
Panel.
Serial CommunicationErrors
When the controller fails to detect expected serial
transmissions, itwill light the ComErr LED and set any Serial
Communication Error(SerC) relays and the Modbus Port 1 Failor Port
2 Faildiscrete (seeSerial Communication Errorson page 56).
Because the exact meaning of these conditions depends on
whichfeatures have been enabled, their interpretation will be
highly sitespecific. Loss of Port 2 communications will disrupt
load-sharing andpressure override control. A Port 1 serial error
can also disrupt thosefeatures, as well as loop decoupling,
automatic sequencing andoperating state selection, and redundant
control.
Analog Input orTransmitter Failures
Whenever one or more analog inputs is beyond its valid range,
thecontroller lights its TranFail LED and sets any Transmitter
Failure(Tran) relays and the Modbus Tran Faildiscrete (see
TransmitterTestingon page 45).
This condition usually indicates a failure in the input loop
(transmit-ter, signal wire, and Analog PCB circuit), but might also
be used toalarm undesirable process conditions.
Caution:The controllers output signal is totally unpredictable
when a watch-dog fault is indicated. Process disruptions or
compressor damagecan result if it is not immediately disconnected
from your process.
http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
40/186
-
7/23/2019 Performance Controler IM302
41/186
Series 3 Plus Performance Controller 41
IM302 (6.0.1)
Tracking States The Performance Controller includes two features
that allow anexternal device to manipulate its actuator control
signal (ACS):
When Speed or Output Trackingis active, the ACS tracks ananalog
or serial signal from a remote device.
When Redundant Controlis active, it tracks the ACS of
another
Series 3 Plus Performance Controller.If either feature is
active, the Tracking LED will either light (redun-dant tracking) or
flash (speed tracking). Redundant tracking will alsodisplay as
Status TRACK and set the Modbus Trackingdiscrete.There are no relay
functions that indicate either of these states.
Speed or OutputTracking
The Performance Controller can be configured to coordinate
itsactions with a turbine (or other drivers) speed governor by
enablingeither of two speed tracking features:
Serial Speed Tracking(see page 85)configures a Performance
Controller to coordinate its actions with those of a Series 3
PlusSpeed or Fuel Controller.
Specifically, it will keep its ACS (which is the speed set
point)equal to the turbine speed whenever the turbine controller
stopsmaintaining its remote set point because it is being
manuallyoperated, is using a local set point, or has encountered a
limit-ing condition (for example, a temperature limit) that
prevents itfrom raising or lowering the rotational speed or drive
power.
If the capacity control loop pushes the turbine controller into
alimit condition, the controllers will normally resolve that
potential
impasse when conditions permit a reduction of the speed ordrive
power. If they dont, you can prompt them to do so byselecting
manual operation and pressing the Lower () key.
Analog Speed Tracking(see page 86)configures a Perfor-mance
Controller to keep its ACS equal to a specified analoginput when
the D4 discrete input is asserted.
This can be used to coordinate control with a speed governorfrom
some other supplier. A Performance Controller can then beconfigured
to request a lower speed when manual operation isselected and the
Lower () key is pressed. In such applications,this may be the only
way to break a speed-tracking deadlock,
which can occur if the Performance Controller raises the
speedset point high enough to create a speed limiting condition
andthen starts tracking that set point.
This feature can also be used to configure the
PerformanceController as a signal selector for its own output
signal and thatof another device. In this application, which is
referred to as out-put tracking, the desired control loop is
usually selected by acontrol panel switch or DCS discrete output
connected to D4.
http://../DataSheets/DS302M.pdfhttp://../DataSheets/DS302M.pdf
-
7/23/2019 Performance Controler IM302
42/186
42 Chapter 2: Operation
February 2001
If both features are enabled, analog tracking has priority and
will beinitiated whenever D4 is asserted, even if serial tracking
is active.
In any case, the controller will enter its speed tracking state
evenif Manual Operationis in effect. You can still switch between
theremote and local set points and change the local set point, but
suchactions will not take effect until automatic, remote set point
opera-tion of the speed controller is restored or D4 is
cleared.
RedundantControl
If one Performance Controller has been installed as an on-line
hotbackup to another (see Redundant Trackingon page 120), it will
useserial communications to track the operating state, set point
mode,set points (remote and local), and intended flow rate of the
activecontroller whenever its own D1 discrete input is cleared.
A tracking Performance Controller lights its Tracking LED
anddisplays its operating state as Status TRACK. Most of its
otherLEDs will duplicate those of the main controller.
In a typical redundant system, each pair of Performance
Controllersis interconnected via a Redundant Control Selector (RCS)
that mon-itors their fault relays, controls their D1 inputs, and
connects thevalve actuator to the selected controllers analog
output. If the maincontrollers fault relay de-energizes, the RCS
automatically transferscontrol of the recycle valve to the backup
controller (provided that ithas not faulted as well). That
controller then initiates control begin-ning from the last
conditions received from the main controller.
The RCS also indicates which controller is active by lighting
itsgreen MAIN or red BACK-UP LED, and you can manually select
the
active controller by pressing the Switch to Back-Up or Switch
toMain push-button.
Note:The RCS will not automatically return control of your
process to themain controller after a fault is cleared (this must
be done manually)and will never automatically or manually transfer
control to a control-ler that appears to have failed.
-
7/23/2019 Performance Controler IM302
43/186
Series 3 Plus Performance Controller 43
IM302 (6.0.1)
IM302
Chapter 3 Input/Output FeaturesThis chapter tells how to
configure the analog and discrete inputsand outputs and serial
communication ports.
Figure 3-1 ECC field terminals are provided by separately
mounted FIOM
HardwareOptions
The Performance Controller usually uses either the Basic
Compres-sor Controller (BCC) or Extended Compressor Controller
(ECC)hardware configuration, as described in Chapter 1 of
IM300/H.Either provides the following input and output
circuits:
eight Analog Inputs(CH1 to CH8),
two standard Analog Outputs(OUT1 and OUT2),
seven Discrete Inputs(D1 to D7),
five Discrete Outputs(CR1 to CR5), and
four Serial Ports(Port 1 to Port 4).When the ECC configuration
is used, all I/O terminals are providedon a separately mounted
Field Input/Output Module (FIOM, seeFigure 3-1), which is connected
to an Extended I/O Back Panel bya High-Density Interconnect Cable
(HDIC).
Disabling InputSignals
As an aid to developing and demonstrating Series 3 Plus
Perfor-mance Controllers, they include a CPU Inputs
Lockout[MODE:DLOCK 6]parameter that, when enabled, configures the
controller toignore its analog and discrete inputs (which can then
be updated via
the Port 3 or Port 4 Modbus serial link).
Caution: An installed controller should not be operated with
LOCK 6 enabled,as that would prevent it from receiving needed input
signals.
http://im300h.pdf/http://im300h.pdf/
-
7/23/2019 Performance Controler IM302
44/186
44 Chapter 3: Input/Output Features
February 2001
Figure 3-2 Analog input signal processing
Analog Inputs Each Series 3 Plus Controller is equipped with
eight analog inputs.As described in the Analog Input
Installationsection in Chapter 6 ofIM300/H, they are set up as
either 0 to 5 Vdc or 4 to 20 mA inputs byinstalling resistors on
either the Field Input/Output Module or setting
jumpers on the Analog PCB Assembly (if not using FIOMs).
In this manual, we will refer to both the input circuits and the
associ-ated analog signals as Channels 1 through 8 (CH1 to CH8)
themeaning in each case should be clear from its context.
The initial processing of these inputs and the terms used to
distin-guish their various intermediate values are illustrated by
Figure 3-2:
Step 1: The raw analog inputs are converted to equivalent
digitalvalues called Analog-to-Digital Variables(AD1 to AD8).
Step 2: Transmitter Testingcompares each AD variable against
itsindividual alarm limits.
Step 3: The AD variables are converted into percent-of-range
SignalVariables(SV1 to SV8).
Step 4: Gains and biases are then applied to obtain the
ProcessVariables(PV1 to PV8) used by the control calculations.
Step 5: The signal variables are also independently scaled to
obtainthe Measured Variables(MV1 to MV8) displayed by the
AUXil-iary readouts Analog In Menu.
AD (%)
PV = Bias +
SV (%)
(SV Gain)
PV (%)MV
MV = Min +(Span SV)
TEST 4
PV = Bias +
SV (%)
AN IN ON(e.g., 4 to 20 mA)
AN IN OFF(e.g., 0 to 10 V)
CH (V)
SV = AD
AD (%)
Failed if:
< AN IN LOW> AN IN HIGH
SV = 1.25 (AD - 20%)
Sampling
Hardware
CH (mA)
Failed if:
< AN IN LOW> AN IN HIGH
(SV Gain)
PV (%)MV
Sampling
Hardware
MV = Min +(Span SV)
TEST 4
SV (%)SV (%)
http://im300h.pdf/http://im300h.pdf/http://im300h.pdf/http://im300h.pdf/http://im300h.pdf/
-
7/23/2019 Performance Controler IM302
45/186
-
7/23/2019 Performance Controler IM302
46/186
46 Chapter 3: Input/Output Features
February 2001
Process Variables The analog inputs for some control
calculations must be convertedto absolute values. For example, the
pressure and temperatureinputs used to compute mass flow rates must
be scaled as percent-ages of the highest absolute pressure their
sensors can measure.These process variables are calculated by
applying appropriategains and biases to the corresponding signal
variables:
where:
Bias = (Offset 100) / Maximum
Gain = Range / Maximum
Maximum = absolute measurement corresponding to the
highestpossible transmitter signal. If there is more than
onetransmitter of a given type, this should be the largestsuch
value for the group
Offset = absolute measurement corresponding to lowest possi-ble
transmitter signal
PV = Process Variable, expressed as a percentage of abso-lute
maximum
Range = span of the transmitter in question
The gain and bias for each process variable must be assigned to
thecorresponding Process Variable Gain[COND:D GAIN #]and Pro-cess
Variable Bias[COND:D BIAS #]. For unused channels, set thegain to
1.000 (.A00) and the bias to 00.0.
MeasuredVariables
The AUXiliary Displays Analog In menu is used to display the
con-trollers eight signal variables, scaled to appropriate ranges,
alongwith descriptive labels of your choosing. For example, you
might dis-play an inlet temperature signal as:
The available choices are set up by each inputs five Measured
Vari-able [COND:D DISPLAY 0] parameters. For example, the DISPLAY0
1 parameters govern the display of signal variable SV1:
Each Measured Variable Display[COND:D DISPLAY 0 #]parameter
defines whether the corresponding variable can beviewed (SV1 can be
displayed only if DISPLAY 0 1 is On).
Each Measured Variable Label[COND:D DISPLAY 0 # ]parameter
defines the label that will precede the numeric valueof the input.
Each can be any combination of eight symbols fromTable 3-1. The
default labels [see page 3 of DS302/O], can berestored by entering
the COND:D DISPLAY 0 0 key sequence.
PV Gain SV Bias+=
TempIn: 400
http://../DataSheets/DS302O.pdfhttp://../DataSheets/DS302O.pdf
-
7/23/2019 Performance Controler IM302
47/186
Series 3 Plus Performance Controller
47
IM302 (6.0.1)
Each signal variables Measured Variable Minimum
[COND:DDISPLAY 0 # LOW]defines the digits shown when it is zero,
itsMeasured Variable Maximum
[COND:D DISPLAY 0 # HIGH]defines the digits shown when it is 100
percent, and its Mea-sured Variable Decimal
[COND:D DISPLAY 0 # ]defines thedecimal point position.
Mathematically, this can be stated as:
wheren
SV is the signal variables normalized value.
Because the decimal point is a character that requires one of
thefour display positions, only three digits can be displayed
unless thatparameter is disabled (Off). In other words, that
parameter identifiesthe digit the decimal should replace (that and
all less-significant dig-its are shifted one position to the
right). A value of one correspondsto the right-most,
least-significant digit, while four is the
left-most,most-significant digit. Thus, if DISPLAY 0 1 HIGH is
3210, the five
possible values of DISPLAY 0 1 would yield the following
displayswhen SV1 is 100 percent:
0: 3210 1: 321. 2: 32.1 3: 3.21 4: .321
To obtain the most precise possible readouts, you should
alwaysmake the DISPLAY HIGH parameters as large as possible.
Forexample, if you want to display three digit numbers from 0 to
600,set DISPLAY HIGH to 6000 and DISPLAY to 1 (for a trailing
deci-mal). This will give more precise readouts than you would get
bysetting DISPLAY HIGH to 0600 and DISPLAY to 0.
If Auxiliary Display Reset
[MODE:D LOCK 9]is disabled, Measured
Variables will be displayed until another variable is selected.
Other-wise, the operating state display is restored 60 seconds
after theMENU or SCROLL key was last pressed.
Table 3-1 Available symbols for measured variable labels
MV Min SVn( ) Max Min( )+[ ] 10dec=
space
! " # $
% & ' ( ) * + , - . /
0 1 2 3 4 5 6 7 8 9 : ; < = > ? @A B C D E F G H I J K L M
N O P
Q R S T U V W X Y Z [ \ ] ^ _ `
a b c d e f g h i j k l m n o p
q r s t u v w x y z
-
7/23/2019 Performance Controler IM302
48/186
48
Chapter 3: Input/Output Features
February 2001
Analog Outputs
The Performance Controller has two standard analog outputs,
bothof which are generated as both 4 to 20 mA and 0 to 5 Vdc
signals(although only one of these signals can be used for each
output):
OUT1 is usually used to manipulate the compressors
throttlingelement (speed set point, flow valve, or guide vanes). It
can beused to drive an indicator for the intended throughput (see
Actu-ator Control Signalon page 111) even if its electrical signal
isnot used to manipulate a control element (for example, if
thethrottling element is a Speed Controller that obtains its set
pointfrom the Performance Controller via serial communication).
OUT 2 is generated as the equivalent of one of the
variableslisted in Table 3-2, as specified by the Second Output
AssignedVariable
[COND:D OUT 2]. Assigning that parameter the Spltvalue enables
the Split Range Output, which uses both outputsto drive control
elements. Otherwise, OUT2 can be used to drivean indicator for the
selected variable.
The Output Loopback Testcan be used to compare the actual
out-put signal to its intended value, while the Valve Position
Testcan beused to compare the measured and intended positions of
the finalcontrol element.
Table 3-2 Functions for OUT2
Split RangeOutput
The split range output calculates both analog outputs as
functions ofthe control signal. It is often used to regulate both
rotational speedor a throttling valve and the position of any guide
vanes. Alternately,it can be used to define custom characterizers
for both the final con-trol element and an external intended flow
indicator.
This feature is enabled by selecting Splt as the Second
Output
Assigned Variable[COND:D OUT 2]. The OUT1 Characterizer[COND:D
f(X) 1 # and X 1 #]and OUT2 Characterizer[COND:D f(X)2 # and X 2
#]then define those signals as independent functions ofthe control
signal, as shown in Figure 3-3. In addition, the resetrates for the
Capacity Controland Load-Sharing Fallbackor Alter-nate Capacity
Controlloops and the Primary Capacity Controlgainare all multiplied
by the OUT2 Gain Multiplier[COND:D Q 1]whenthe actuator control
signal is above the Split Point[COND:D LVL 1].
Code Signal
Out Actuator Control Signal(see page 111)
PV Capacity Control Variable(see page 59)
SP CV1 Set Point(see page 72)
Splt enables Split Range Output(see page 48)
-
7/23/2019 Performance Controler IM302
49/186
Series 3 Plus Performance Controller 49
IM302 (6.0.1)
Figure 3-3 Characterization of the split range output
signals
When using this feature, disable both the Valve Flow
Characterizer[MODE:P fC 8]and Display Output Reverse[MODE:P fD
1]andconfigure the control loops for a direct-acting control
element. Ifeither control element is reverse-acting, its output
characterizer canthen be defined as a decreasing function.
Independent outputclamps can also be built into each characterizer
(the coordinates ofany point serving as a clamp are its valve flow
and position limits).
If one of the control elements is a Series 3 Plus Speed
Controller, itshould be set up to use the corresponding Performance
Controlleranalog output as an analog remote set point (see the
Speed SetPointsection in Chapter 5 of IM307). However, serial
communica-tions can still be used to coordinate other aspects of
their operation(see Speed Trackingon page 83and Coordinated
Sequencingonpage 117).
Output LoopbackTest
The controller can be configured to energize one or more
discreteoutputs to indicate an excessive deviation between the
measuredand intended values of the actuator control signal.
This feature is set up by connecting OUT1 to analog input CH8,
asdescribed in the Analog Output Installationsection in Chapter 6
ofIM300/H. Any discrete output assigned the output failure
(OutF)
Control Signal (%)
OUT2(%)
100
COND:D X 2 n = CSn
COND:D f(X) 2 n = OUT1n
0
n = 0
n = 9
OUT1(%)
100
100
COND:D X 1 n = CSn
COND:D f(X) 1 n = OUT1n
0
n = 0
n = 9
0
Note:
When this feature is selected, the OUT readout will display the
value
of the actuator control signal.
http://im307.pdf/http://im307.pdf/http://im307.pdf/http://im300h.pdf/http://im300h.pdf/http://im300h.pdf/http://im307.pdf/http://im307.pdf/http://im300h.pdf/http://im300h.pdf/
-
7/23/2019 Performance Controler IM302
50/186
-
7/23/2019 Performance Controler IM302
51/186
Series 3 Plus Performance Controller 51
IM302 (6.0.1)
Discrete Inputs All Series 3 Plus Performance Controllers are
equipped with sevendiscrete inputs (D1 to D7) that can be used to
trigger the control fea-tures listed in Table 3-3. The threshold
level above or below whichthese inputs are asserted or cleared is
listed on the Series 3 PlusCompressor Controllers Hardware
Specifications[DS300/H]:
Check Valve The controller will assume there is a closed
discharge check valve ifD5 is set (see Check Valveon page 115).
Fallback Setting D6 will trigger the load-sharing capacity
control fallback (seeLoad-Sharing Fallbackon page 96) or alternate
capacity control, ifeither of those features is enabled (see
Alternate Capacity Controlon page 74).
Purge D3 can serve as the purge request for an Antisurge
Controller, asdescribed in the Operating State Request
Signalssection in Chapter9 of IM301.
Recall Setting D7 will recall the second alternate parameter set
and clear-
ing it will recall the first, provided that feature is enabled
(seeAlternate Parameter Setson page 119).
Speed Tracking Setting D4 will cause the control signal to track
the compressorspeed via a specified analog input, provided that
feature is enabled(see Analog Speed Tracking(see page 86)).
Stop Setting D2 will initiate the idle sequence, provided that
feature isenabled and configured to use D2 rather than an analog
input (seeOperating State Request Signalson page 114).
Tracking Setting D1 will cause this controller to track the
operation of a com-panion Performance Controller, provided that
feature is enabled
(see Redundant Trackingon page 120).
Table 3-3 Discrete input functions
Input Function
D1 Redundant Trackingrequest
D2 Stoprequest
D3 Purgerequest
D4 Speed Trackingrequest
D5 Check Valveclosed
D6 Fallbackrequest
D7 Recallalternate parameter set
http://../DataSheets/DS300H.pdfhttp://../DataSheets/DS300H.pdfhttp://../DataSheets/DS300H.pdfhttp://im301.pdf/http://im301.pdf/http://im301.pdf/http://im301.pdf/http://im301.pdf/http://../DataSheets/DS300H.pdfhttp://../DataSheets/DS300H.pdf
-
7/23/2019 Performance Controler IM302
52/186
-
7/23/2019 Performance Controler IM302
53/186
-
7/23/2019 Performance Controler IM302
54/186
-
7/23/2019 Performance Controler IM302
55/186
-
7/23/2019 Performance Controler IM302
56/186
-
7/23/2019 Performance Controler IM302
57/186
Series 3 Plus Performance Controller
57
IM302 (6.0.1)
The offending port can be determined and additional
diagnosticinformation obtained via the following Engineering Panel
tests:
The Serial Port 1 Test
[MODE COMM 3]indicates (by control-ler ID number) the
controllers from which Port 1 transmissionsare or are not being
received (regardless of whether or not suchtransmissions are needed
or expected). The status of control-lers that are transmitting will
display as Good, while the statusof controllers from which no
transmissions are being receivedwill display as Bad. A serial error
is indicated only if the statuso