Compressor Panel

Industrie Technofrigo Dell’Orto S.p.A.
Industrie TECHNOFRIGO DELL’ORTO S.p.A.

Via Matteotti 161 - 40013 Castel Maggiore BOLOGNA
Italy
Tel. 051-71.85.11 - Fax 051-71.42.61
OPERATOR'S MANUAL
TMP MKS
1
1. GENERAL SAFETY RECOMMENDATIONS ....................................................................................... 3

1.1. INSTALLATION ROOM RECOMMENDATIONS............................................................................ 4
1.2. PROHIBITED!...................................................................................................................................... 4
1.3. LIST OF SAFETY DEVICES INSTALLED ........................................................................................ 5
2. GENERAL DESCRIPTION ....................................................................................................................... 6
2.1. SYSTEM COMPOSITION ................................................................................................................... 6
2.2. PLC INPUT / OUTPUT LIST ............................................................................................................... 7
2.2.1. DIGITAL INPUTS:....................................................................................................................... 8
2.2.2. DIGITAL OUTPUTS:................................................................................................................... 8
2.2.3. ANALOGIC INPUTS:................................................................................................................... 9
2.3. SINGLE INPUT / OUTPUT SIGNAL DESCRIPTION...................................................................... 10
2.3.1. DIGITAL INPUT DESCRIPTION .............................................................................................. 10
2.3.2. DIGITAL OUTPUT DESCRIPTION .......................................................................................... 12
2.4. ANALOG INPUT DESCRIPTION..................................................................................................... 14
2.4.1. ANALOGIC INPUTS.................................................................................................................. 14
3. DESCRIPTION OF SETTINGS POSSIBLE FOR SYSTEM MANAGEMENT ................................ 16
4. COMPRESSOR OPERATING STATUS................................................................................................ 21
5. DESCRIPTION OF REGULATION ....................................................................................................... 23
5.1. MEANINGS OF PARAMETERS....................................................................................................... 24
6. SAFETY DEVICES................................................................................................................................... 29
7. ANOMALY MANAGEMENT ................................................................................................................. 31
8. OPERATOR'S PANEL ............................................................................................................................. 33
8.1. VIDEO PAGE DESCRIPTION .......................................................................................................... 34
8.2. MAIN PAGE....................................................................................................................................... 34
8.3. MANUAL COMMANDS................................................................................................................... 35
8.4. COMPRESSOR GENERAL VALUES (1) ......................................................................................... 36
8.4.1. COMPRESSOR GENERAL VALUES (2) ................................................................................... 37
8.5. SET POINT PAGES............................................................................................................................ 41
8.5.1. SET POINT PAGES 1A – 1B...................................................................................................... 41
8.5.2. SE T POINT PAGE 2.................................................................................................................. 42
8.5.3. SET POINT PAGES 3 - 4 ........................................................................................................... 43
8.5.4. SET POINT PAGE 5................................................................................................................... 44
8.5.5. SET POINT PAGE 6................................................................................................................... 45
8.6. LIMIT PARAMETERS PAGE ........................................................................................................... 47
8.7. BEFORE-ALARMS VALUES ........................................................................................................... 48
8.8. CONFIGURATION MENU ............................................................................................................... 49
8.9. CONFIGURATION............................................................................................................................ 50
8.10. SPECIAL PARAMETERS ONLY WITH PASSWORD ............................................................................ 51
8.10.1. IMPULSIVE LI-OC REGULATION........................................................................................... 51
8.10.2. ALARMS DELAYS SETTING ..................................................................................................... 52
8.11. DIGITAL INPUT/OUTPUT PAGE .................................................................................................... 54
8.12. ANALOGUE INPUT PAGE............................................................................................................... 55
8.13. SLIDE SETTINGS - OUTPUT FORCING PAGE.............................................................................. 56
8.14. SERVICE PAGE................................................................................................................................. 57
9. PASSWORD MANAGEMENT................................................................................................................ 57
10. GENERAL ELECTRIC SYSTEM CHARACTERISTICS ................................................................... 58
10.1. LIST OF ELECTRIC PANEL COMPONENTS ................................................................................. 59
2
1. GENERAL SAFETY RECOMMENDATIONS
TECHNOFRIGO machines and systems have been developed to strict safety standards rules in order
to safeguard operator safety (Italian D.P.R. 547 dated 27/04/55, Machinery Directive 89-392 and
amendments).
When connecting the machine for the first time, first make sure that it has been correctly connected to
your own productive unit grounding system.
Maintenance must only be performed specialised in order to avoid problems caused by incorrect
servicing.
Any modifications or additions to be made to the machine electric and/or control system must be
performed only by previously authorised and highly-specialised personnel using the right equipment
and taking all the right precautions in compliance with the machine operation manual, wiring
diagrams and other enclosed documentation.
For greatest safety, prior to performing any intervention on the electric system or equipment, contact
TECHNOFRIGO or one of its Technical Servicing centers, while bearing in mind that
TECHNOFRIGO cannot be held liable for any malfunctions caused by unauthorised client
modifications to the wiring diagram.
IMPORTANT!
The machine is provided with protective cases fastened by special screws in the areas most subject to
accidental contact. These cases must never be removed while the machine is running. After all
operations have been completed, thes cases must be replaced before the machine is started again.
3
1.1. INSTALLATION ROOM RECOMMENDATIONS
This machine requires no special precautions, and any room that complies with normal safety
standards for machine rooms can be used for the installation of the machine.
The presence of electronic components requires installation room temperature to be maintained

between 0°C - 40°C.
Make sure to provide adequate, obstacle-free, clean space for manoeuvre around the machine together
with adequate illumination.
1.2. PROHIBITED!
Never make electrical repairs while voltage is connected to the machine and always switch off the
power supply using the main power switch previously.
Never use the ground wire in place of the neutral wire in the electric connection, and always connect
two different and clearly marked wires to the respecting terminals in your own productive unit power
mains.
Whenever a motor thermal cut-out triggers and then triggers again after it has been rearmed when the
machine is switched on again, do not insisting on starting the machine and find the cause of motor
malfunction.
4
1.3. LIST OF SAFETY DEVICES INSTALLED
EMERGENCY
MUSHROOM-SHAPED
BUTTON
This emergency button is a "signal-stored" type: once pressed, it must be reset by pulling the red
mushroom head outward. When this switch is pressed, all power supply is disconnected from the
machine auxiliary relays and therefore all use/operation is blocked, while the respective alarm
message is shown on the display.
The electric box holds the main power switch with a door-lock mechanism: when the main power
switch is pressed (set on "1"), the electric box door is locked.
MAIN POWER SWITCH

WITH DOOR-LOCK
Yellow warning plates are positioned in the various parts of the machine to which the operators must
pay special attention.
These plates must be immediately replaced whenever they become worn out or illegible in order to
maintain the machine safety requisites.
Whenever a safety device is triggered, the respective message is shown on the operator's display.
5
2. GENERAL DESCRIPTION
The TMP MKS (Technofrigo Microprocessor Control) is a natural evolution of the previous versions
improved in order to adapt to the changing availability of electronic components in the market.
The system is based on a SIEMENS series S7–300 PLC equipped with an operator display for all
compressor control functions, including START–STOP functions and the regulation of the choke box.
The most important improvement offered by the latest version is that it can be used with both VITE
MYCOM and GRASSO screw compressors.
2.1. SYSTEM COMPOSITION
The control and the management of the TMP is executed from the Siemens S7-300 PLC (inside the
electric box).
The TMP control PLC is composed as follows:
• Central unit CPU313

• Analog signal amplifier module
• Profibus net board (optional)
Posto connettore = Connector position

Unità = Unit
Numero di ordinazione = Order Number
Indirizzo = Address
Conteggio = Count
UNIOP and TOP05 operator panel.

• UNIOP and TOP05 Touch Screen operator panel
6
ELECTRIC BOX DOOR
TOUCH SCREEN
PANEL
2.2. PLC INPUT / OUTPUT LIST
DIGITAL INPUTS ANALOGIC ANALOGIC PROFIBUS

INPUTS INPUTS BOARD
(4-20 mA) (4-20 mA)
7
2.2.1. DIGITAL INPUTS:
SYMBOL ADDRESS TYPE DESCRIPTION
COMP.RUN E 124.0 BOOL COMPRESSOR ON

OIL P, RUN E 124.1 BOOL OIL PUMP ON
HIGH SPEED E 124.2 BOOL 0=SPEED LOW ; 1= SPEED HIGH
REM, STOP E 124.3 BOOL REMOTE STOP
SAFETY 1 E 124.4 BOOL SAFETY 1
EMERG.OK E 124.7 BOOL EMERGENCY MUSHROOM
REM. START E 125.0 BOOL REMOTE START
FREE E 125.1 BOOL FREE
REM. CHARGE E 125.2 BOOL EXTERN CHARGE
REM. DISCHA. E 125.3 BOOL EXTERN DISCHARGE
SLIDE BLOCK E 125.4 BOOL EXTERN SLIDE BLOCK
ELECT.P.OIL E 125.7 BOOL OIL PUMP PRESENCE
2.2.2. DIGITAL OUTPUTS:
SYMBOL ADDRESS TYPE DESCRIPTION
OIL HEATER A 124.0 BOOL OIL HEATER

COMP.START A 124.1 BOOL COMPRESSOR MOTOR
P.O. START A 124.2 BOOL OIL PUMP
EV CHARGE A 124.3 BOOL CHARGE
EV DISCHAR A 124.4 BOOL DISCHARGE
ALARMS A 124.5 BOOL ALARM
ECONOMIZER A 124.6 BOOL ECONOMIZER
OIL COOL. A 124.7 BOOL COOLING
SLIDE 0% A 125.0 BOOL SLIDE 0%
SLIDE 100% A 125.1 BOOL SLIDE 100%
EV BY-PASS A 125.2 BOOL BY PASS STARTING
EV DE-PRESS A 125.3 BOOL MINI-SCREW OIL LINE S.V.
AUTO.PRED. A 125.4 BOOL AUTOMATICALLY PRE-ARRANGED
EV OIL REC A 125.5 BOOL OIL RECOVERY S.V.
THERMOSTATICS DANFOSS OIL
EV EVAPORAT A 125.6 BOOL REFRIGERATION ALTERNATIVE
EV TER.LIOC A 125.7 BOOL VALVE LI-OC
8
2.2.3. ANALOGIC INPUTS:
SYMBOL SDDRESS TYPE DESCRIPTION
DISCHARGE
TEMPERATURE PEW 256 WORD DISCHARGE TEMPERATURE
OIL
TEMPERATURE PEW 258 WORD OIL TEMPERATURE
OIL SEPARATOR
TEMPER. PEW 260 WORD SEPARATOR OIL TEMPERATURE
PROCESS INLET
TEMPER. PEW 262 WORD IN. GLYCOL TEMPERATURE
FREE PEW 264 WORD FREE
SLIDE POSITION PEW 266 WORD SLIDE POSITION
MOTOR
CURRENT PEW 268 WORD MOTOR CURRENT
PEW270 PEW 270 WORD FREE
OIL PUMP
PRESSURE PEW 752 WORD OIL PRESSURE
OIL FILTER
PRESSURE PEW 754 WORD OIL FILTER PRESSURE
DISCHARGE
PRESSURE PEW 756 WORD DISCHARGE PRESSURE
SUCTION
PRESSURE PEW 758 WORD SUCTION PRESSURE
PROCESS
OUTLET TEMPER. PEW 760 WORD OUT GLYC. TEMPERATURE
9
2.3. SINGLE INPUT / OUTPUT SIGNAL DESCRIPTION
2.3.1. DIGITAL INPUT DESCRIPTION
INPUT E 124.0
Return and closing of the compressor motor magnetic switch.
After the triggering of the compressor motor control output, this input must be high.
Whenever this does not occur after the elapse of the period of time set in the special parameters, the
TMP generates the “COMPRESSOR DOESN’T START” error message and the machine comes to a
stop.
Similarly, when the compressor motor stops, the signal must be disabled.
Whenever the signal is not disabled (always after the time set has elapsed), the TMP generates the
“COMPRESSOR DOESN’T STOP” error message.
When the “COMPRESSOR RETURN” signal is given, the TMP keeps the oil pump running,
regardless of the condition of the machine.
INPUT E 124.1
Return and closing of the oil pump magnetic switch.
After the triggering of the oil pump control output, this input must be high.
Whenever this does not occur after the elapse of 5 seconds, the TMP generates the “OIL PUMP
DOESN’T START” error message and the machine comes to a stop.
When the pump stops, the signal must be disabled.
Whenever this does not occur, (always after the 5 second time set has elapsed), the TMP generates the
“OIL PUMP DOESN’T STOP” error message.
INPUT E 124.2
Twin-speed motor (low/high)
If the TMP is set to work with a “TWIN-SPEED MOTOR”, this input will utilise the absorption
control sets for high speed.
INPUT E 124.3
Stopping
This input is used only when IMPULSIVE DIGITAL INPUT starting has been selected.
In this situation, the operative logic is the following:
with the compressor stopped, the stop signal must be always enabled (high – input E124.3 = 1);
the start request must be made with an impulse that lasts at least one PLC cycle (1/10 second) always
with the signal stop enabled;
at this point, the compressor starts when all internal conditions permit and remains running for as long
as the stop signal stays high: the compressor will stop only following the absence of this signal.
Whenever any other type of starting is chosen, this input is not tested.
START
STOP
| STOP | RUN | STOP
10
INPUT E 124.4
Safety 1
Safety 1 input is a signal that comes from the system and therefore does not regard the machine.
Any one of the extremely important safety devices can be connected to this input, and most usually,
the cumulative of the compressor motor and oil pump thermal cutouts is connected. Whenever any of
these thermal cutouts is triggered, the TMP immediately stops the compressor.
INPUT E 124.5
Safety 2
The above holds true in this case as well, but with the following differences:
In the case above, the anomaly is always tested, but in this case it is tested only after the TMP has
received the order to START.
For this reason, this input is used as a “HIGH SEPARATOR LEVEL” input. It may occur - for
various reasons - that the level inside the separator rises while the compressor stops, and then returns
to normal level only after a relatively short time. If the anomaly is continuously tested, the compressor
is stopped for no reason and must be reset by the operator.
Whenever the anomaly remains or triggers while the machine is running, the compressor is
immediately switched off in order to avoid harmful suction of liquid.
INPUT E 124.6
Safety 3
The difference in the case of the Safety 3 is that it is tested by the TMP only 9 seconds after the
starting of the oil pump. It is therefore advised for the management of the safety concerning the
release of a safety flow switch on the gylcol circuit.
It sometimes happens in electro-mechanically systems that the control logic gives the start to both the
compressor and the glycol pump at the same time; a certain number of seconds is usually provided in
order to allow the above-mentioned flow-switch (most of which operate mechanically) the time to
open and stabilise for normal operation.
Whenever one of this signals is not present in the system or the decision is made to avoid using the
system in favour of another method of control, these inputs must be bridged or by-passed.
INPUT E 124.7
Emergency mushroom button. When this button is pressed, it stops the compressor and it is always
tested both when the machine is off and when it is running.
This button has two contacts: the first is used to inform the PLC of the fact that it has been pushed, the
second instead interrupts the power supply to the auxiliary relays in order to stop all the operation of
all users independently from the PLC and to increase the level of safety.
INPUT E 125.0
Remote start signal.
This remote start signal is managed by the PLC only if the start of the machine has been set as
“DIGITAL INPUT AT FRONT” or from “DIGITAL INPUT AT LEVEL”.
In the first case, the input must be of the impulsive type and least 1/10 second and must be used in
combination with the input E0.3 (STOP) as described above. In the second case, the PLC starts the
compressor when the signal is high and stops it when it is no longer enabled.
START
STOP | RUN | STOP
11
INPUT E 125.1 – FREE
INPUT E 125.2
Remote charge signal.
If the TMP has been set for regulation by “DIGITAL INPUT”, when this signal appears, and when
the compressor is running, the “SLIDE CHARGE” output is energised.
INPUT E 125.3
Remote discharge signal.
If the TMP has been set for regulation by “DIGITAL INPUT”, when this signal appears, and when
the compressor is running, the “SLIDE DISCHARGE” output is energised.
INPUT E 125.4 (Slide Block)

Slide block signal.
If slide block has selected by “DIGITAL INPUT” with "AUTOMATIC" regulation, the presence of
this signal in the input above forces the slide to move to its maximum permissible value. This signal is
ignored in all other cases and whenever “HIGH VOLTAGE” or “HIGH DISCHARGE PRESSURE”
occur.
INPUT E 125.7
This indicates the presence of the oil pump for Grasso-Small or Grasso-Medium compressors.
This input must be bridged or by-passed only if these types of compressor are equipped of pumps
with electric motors.
2.3.2. DIGITAL OUTPUT DESCRIPTION
OUTPUT A 124.0 (oil heating control)

This output is energised if the compressor is “NOT WORKING” and the temperature of the oil in the
separator is lower than the Set Point value set.
OUTPUT A 124.1
Compressor motor control.
OUTPUT A 124.2
Oil pump control.
OUTPUT A 124.3
Slide charge solenoid valve control.
12
OUTPUT A 124.4
Slide discharge solenoid valve control.
OUTPUT A 124.5 (Anomaly signal control)

Alarm.
The output is high if the compressor is free of anomaly but drops low whenever the first anomaly that
affects the system arises.
OUTPUT A 124.6 (Economizer control)

This output is energised with the compressor running whenever the position of the choking box
exceeds the value set (a value that can be set from the operator panel on SETS POINT Page 4).
OUTPUT A 124.7 (Oil cooling ON/OFF solenoid valve control)

This output is energised (the solenoid valve opens) when the compressor is running.
OUTPUT A 125.0 (Slide at minimum)

This output is energised whenever the slide position valve is lower than the value set on “SLIDE
REGULATION SET POINTS Page 1”.
OUTPUT A 125.1 (Slide at maximum)

The output goes high if under the following conditions: if the compressor is running and the position
of the slide exceeds the value set on “SLIDE REGULATION SET POINTS Page 1”.
OUTPUT A 125.2 (By-pass solenoid valve control)

This output is energised only during the compressor starting phase (for around the 15 seconds that can
be set).
OUTPUT A 125.3 (Slide discharge forcing/de-pressurisation solenoid valve control)

MODE 1 Depressurisation machine (for LARGE MYCOM/GRASSO compressors).
This solenoid valve permits the balancing of the compressor pressure between the charging and
discharging pipes in two phases (Stopping and Running) for easier starting.
MODE 2 Discharging forcing (for MEDIUM GRASSO compressors)
This output is excited only during the compressor starting phase in order to allow the slide to move to
minimum level.
OUTPUT A 125.4 (Automatic operation preset control)

This is used for the presetting of the machine at the automatic working.
This output becomes enabled under the following conditions:
- no anomalies are present.
- the machine is not in anti-recycle
- if the type of starting has been selected by “DIGITAL INPUT” or by “SERIAL LAN”, the
regulation will be in “AUTOMATIC”
OUTPUT A 125.5 (Oil recovery solenoid valve control)

This output is enabled a determined number of minutes after the compressor has been running and
remains enabled for a certain number of seconds.
The values of these two periods of time can be set by the operator using the display panel on SET
POINT Page 5.
13
OUTPUT A 125.6 (Danfoss thermostat control)

This output is enabled for the operation of the Danfoss thermostat control unit (when present in the
panel).
OUTPUT A 125.7 (LIOC thermostat control)

This output is positioned on a static relay and controls the electronic injection valve, and is controlled
by jog pulses through a PID control that regulates the compressor oil temperature in order to keep the
temperature constantly near the set value set.
2.4. ANALOG INPUT DESCRIPTION
A total of 12 analog inputs divided as follows arrive from the compressor system:
No. 4 from pressure transmitters

No. 5 from temperature probes (two of which are optional)
No. 1 from slide position potentiometer
No. 1 of motor current (from the power panel)
No. 1 free
2.4.1. ANALOGIC INPUTS
The analog input board (sold by SIEMENS) is available in various models that are distinguished by
the type of input that can be configured.
PRESSURE
TRANSDUCER
The signal values (4 ÷ 20 mA)

come from pressure transducers.
PEW 758 Suction pressure Range: 0-16 absolute Bar
PEW 756 Discharge pressure * Range: 0-30 absolute Bar
PEW 752 Oil pressure * Range: 0-30 absolute Bar
PEW 754 Oil filter pressure * Range: 0-30 absolute Bar
14
PEW 256 Discharge Temperature Range -50 / + 100 °C TEMPERATURE PROBE

PT100
PEW 258 Heater control oil temperature Range -50 / + 100 °C
PEW 260 Oil temperature Range -50 / + 100 °C
PEW 262 Glycol inlet temperature Range -50 / + 100 °C
PEW 760 Glycol outlet temperature Range -50 / + 100 °C
PEW 266 Slide position Range 0 / 100 %
PEW 268 Motor current Range can be set from operator panel
PEW 264 Free
PEW 270 Free
15
3. DESCRIPTION OF SETTINGS POSSIBLE FOR SYSTEM

MANAGEMENT
The TMP has been designed for screw-type unit control in order to permit the management of both
STARTING and STOPPING and flexible regulation; in other words, it is possible to set a Manual
type of STARTING and Automatic regulation or vice versa.
Below, we provide all the possible configuration options available that can be set using the operator
panel on the compressor CONFIGURATION page.
The compressor will be subsequently managed according to the configuration set.
16
TYPES OF COMPRESSOR:
The operator can set a value from 1 to 4:

1 = MYCOM SCREW
2 = GRASSO SMALL
3 = GRASSO MEDIUM
4 = GRASSO LARGE
5 = MYCOM MINISCREW
It is therefore sufficient to select the type of respective compressor during the Starting phase in order
to obtain the correct type of management from the TMP.
TYPES OF REGULATION:
The operator can set a value from 1 to 4:

1 = AUTOMATIC
2 = KEYBOARD
3 = DIGITAL INPUT
4 = REMOTE CONTROL
When Option 1 – “AUTOMATIC” is selected, the TMP is set with an opportune algorithm to
regulate the choke slide as required by the suction pressure (or the temperature) and the set point that
has been set.
When Option 2 – “KEYBOARD” is selected, the manual regulation of the compressor is permitted
by using the respective buttons on the “MANUAL CONTROLS” page.
When Option 3 – “DIGITAL INPUT” is selected, the regulation of the slide through two digital
inputs is permitted. After selected this criteria, the TMP will energise the slide charge solenoid valve
if the digital input (CHARGE) has the right signal ( =1 ), while enabling discharge whenever the
signal is the present on the digital input (DISCHARGE).
When Option 4 – “REMOTE CONTROL” is selected, the operator has the opportunity to entrust
regulation at an external controller that communicates with the compressor PLC via PROFIBUS net.
After this option has been selected, with the entry of a value of 1 on the Bit linked to the LAN charge,
the charging solenoid valve will be energised; if a value of 0 is entered, on the other hand, de-
energising will be performed.
A similar setting must be made for discharging: the Bit linked to the slide discharge function give the
control for discharge when a value of 1 is entered, while discharge is disabled when a value of 0 is
entered. The mode is the same for both functions: the entry of a value of 1 energises the discharge
solenoid valve, while the entry of u 0 causes de-energising.
REGULATION MODE:
The operator can enter a value from 1 to 4:

1 = PRESSURE
2 = TEMPERATURE
3 = REMOTE SET (PRESS.)
4 = CHILLER
With the choice of Option 1, the machine regulates the pressure.
17
With the choice of Option 2, the machine regulates the temperature.

With the choice of Option 3, the machine performs regulation with a value that is set by an external
controller that enters such value in the internal register via Profibus net.
With the choice of Option 4, the machine regulates pressure or temperature automatically as
required by system conditions.
SLIDE REGULATION:

1 = PROPORTIONAL
2 = BY STEP
This configuration defines the mode in which the compressor will regulate the slide with the
REGULATION TYPE parameter set on AUTOMATIC.
TYPE OF START:

1 = PRESSURE / TEMPERATURE
2 = LOCAL/MANUAL
3 = DIGITAL INPUT AT LEVEL
4 = DIGITAL INPUT AT FRONT
5 = BY REMOTE
With the choice of Option 1, the TMP will start the compressor in such way that neither the pressure
value nor the temperature value will surpass the value set in SET POINTS Page 1.
The compressor will stop after the choke drawer reaches a value lower than the parameter set in SET
POINTS Page 1 as the “zero slide” value and will remain stopped for a period of time higher than the
respective value (set by the operator in SET POINTS Page 1).
For Starting, the TMP will use the temperature or pressure value defined by the type of parameter
chosen as the control parameter in “REGULATION MODE”.
With the choice of the Option 2, the compressor will start with the pressing of the START button
and stop by the pressing of the STOP button on the “MANUAL CONTROLS” page.
With the choice of the Option 3, the compressor will start with the presence of the corresponding
digital input and will remain running for as long as the input remains enabled (provided, of course,
that no anomalies arise in the meantime).
With the choice of the Option 4, the TMP starts the compressor following a pulse of opportune
duration on the assigned digital input (a duration of longer than 1/10 second), while making sure,
however, that the STOP signal is high before this signal is seen by the PLC and that it remains
running until the STOP signal goes to low level.
With the choice of the Option 5, Starting by REMOTE control permits an external device to start the
compressor by correctly entering a value of 1 on the respective internal Bit. The entry of 0 on this
register stops the compressor and keeps it stopped..
2 SPEED MOTOR:
The operator can set NO or YES to enable the respective motor start control desired.
18
NO = motor power absorption control is always made with the same parameters.
YES = control on the input assigned that discriminates between type of starting and the
consequent controls is enabled.
E 124.2 = 0 Low motor speed
E 124.2 = 1 High motor speed
SLIDE BLOCK:

1 = DIGITAL INPUT
2 = REMOTE
The slide block is a request that comes to the TMP from an external logic, following which the TMP
forces its slide to assume the maximum permissible value.
With the choice of Option 1 the situation also shows the presence of the signal from digital input E
125.4
With the choice of Option 2 this situation is created when the value of 1 is entered on the internal
register in combination with the slide block, while normal conditions are restored when a value of 0 is
entered on the register.
PROCESS OUTLET TEMPERATURE PRESENCE
The operator can enter YES or NO in order to enable or disable the control function (with the
respective alarms) of the analog input assigned to system process temperature.
PROCESS INLET TEMPERATURE PRESENCE
respective alarms) of the analog input assigned to system inlet temperature. In any case, the only
function of this probe is to help the operator supervise the system and has no effect on the machine
operating cycle.
TYPES OF COOLANT:
The operator can enter a value from 0 to 3. The parameters for the calculation of the system
saturation temperatures are modified according to the values set.
0 = R717
1 = R22
2 = R507
3 = R404A
ECON
Here, the operator must enter YES for the presence of the economizer.
The entry of YES controls the economizer solenoid valve when the compressor is running and
whenever slide capacity exceeds the economizer enabling value set on GENERAL SET POINTS
Page 3.
REC-OL
19
Here, the operator must enter YES for the presence of the oil recovery solenoid valve.
The entry of YES controls the opening or closing of the respective solenoid valve with 2 opening or
closing times set in the "OIL RECOVERY SV ON” and and “OIL RECOVERY SV OFF” parameters
set on “GENERAL SET POINTS” Page 5.
The valve is enabled only when the compressor is running and only after the passage of the period of
time defined “ENABLING DELAY AFTER COMPRESSOR RUN" set by the operator on
“GENERAL SET POINTS” Page 5.
P.D.
The entry of YES enables the compressor Pump-down function.
DEG.
The entry of YES enables the compressor gas vent function.
PROFIBUS DP CONNECTION:
respective alarms) of the data received from the PROFIBUS net.
20
4. COMPRESSOR OPERATING STATUS
In order to display this information, press the "MACHINE STATUS" button on the operator panel
main page.
The compressor may assume any of the following 4 states:
0 = STOPPED
1 = START
2 = RUN
3 = STOPPING
if the compressor is STOPPED, the following cases may be present:
1 = ANOMALY
2 = NOT AVAILABLE
3 = ANTI-RECYCLING
4 = NO ANOMALY
We provide descriptions of each of the cases above in the pages below.
STOPPED
With the machine in “STOPPED ”, the presence of any anomaly shifts the TMP into “ANOMALY"
status. In this situation, the TMP disables all the outputs and prevents the compressor from starting
and this is a condition from which the controller cannot emerge without the intervention of the
operator, who must first remove the causes of the situation and then reset the system for normal
operation.
Sometimes, the TMP might not be in ANOMALY status but the temperature of the separator oil is not
high enough to ensure the correct lubrication of the machine mechanical organs, or other times, not
enough time has passed since the last stopping of the motor (this parameter can be set by the
operator).
In any of these situations, even if the TMP does not shift into ANOMALY status and provide the
respective message, it will provide the “NOT AVAILABLE” message and will not permit the starting
of the screw unit.
The appearance of the “ANTI-RECYCLE” string indicates that not enough time has passed since the
last starting of the compressor motor (this time is generally 20 minutes and serves to guarantee that
the motor will not start beyond a certain number of times each hour).
Only whenever none of the conditions described above will the TMP be ready for operation and only
in this case will the START control be accepted.
STARTING
Once the START control has been accepted, the machine shifts from “STOPPED ” to “START ”
status. In this phase, the oil pump is immediately started (if present) and a check must be made in
order to make sure that it has really started or not.
If, in fact, 5 seconds after the corresponding output has been enabled the return of the magnetic switch
closed does not occur, the machine immediately shifts to “ANOMALY” status caused by the “OIL
PUMP FAILS TO START" anomaly. This state of anomaly also sends the TMP into “STOPPED ”
state regardless of the state in which it is in and the type of anomaly that has occurred.
21
At this point, the TMP must make sure that the pressure of the oil in the circuit reaches sufficient
pressure for correct lubrication. For this purpose, the machine waits for a period of time of around 9
seconds from the starting of the pump (in order to let the pressure stabilise) and the difference
between the pressure of the oil (after the filter) and the discharge pressure is calculated.
This difference must be greater than “MINIMUM OIL DIFFERENTIAL PRESSURE" parameter (to
be set by the operator).
It is very important to work on the differential pressure and not on the absolute pressure because
correct lubrication requires the oil to overcome the pressure of the gas in the discharge line, and this
would be impossible if both pressures were equal.
In this case as well, whenever this situation does not occur, the machine goes immediately into
malfunction due to a “MINIMUM OIL DIFFERENTIAL PRESSURE" anomaly.
Together with these checks, as soon as the machine shifts into “START ”status, the TMP makes sure
that the choke box is at its minimum level, and if it is not at such level, the discharge and de-
pressurisation solenoid valves are immediately energised until such situation is created, and only after
this situation has been created and in any case no sooner than 15 seconds after the starting of the oil
pump (a period of time necessary for the pre-lubrication of the screws prior to real running) will the
compressor start working and the wait for the return of the magnetic switch begins.
As soon as the right conditions have been created, the machine shifts from “START ” status to
"RUN" status. Whenever this magnetic switch fails to return within the time set on SPECIAL
PARAMETERS Page 2, the machine goes into "ANOMALY" status and the “COMPRESSOR
FAILS TO START” message is given .
RUN
After the machine has shifted into RUN, the TMP enables the regulation of the slide as required by
the operating status set and then performs all the safety management and optimisation functions
necessary. The compressor keeps running for as long as the request is enabled. As soon as the request
disappears, the machine shifts into “STOPPING ” status.
STOPPING
The first operation is the forcing of the discharge of the slide to its minimum value, and then a waiting
time known as “PARKING” (set by the operator) must be allowed to pass in order to make sure that
the request is a real and not a transitory request, and only after this period of time has passed will the
compressor motor switch off.
In this situation as well, the correct operation of the magnetic switch is managed. The waiting time
set on SPECIAL PARAMETERS Page 2 must be permitted to pass in order for the motor magnetic
switch return to disappear and if this does not occurs, the machine shifts to "ANOMALY" status
caused by the “COMPRESSOR NOT STOPPED” anomaly.
In a situation of this kind, the oil pump keeps running however in order to ensure the lubrication of
the compressor and to limit any possible damage.
The oil pump will switch off only after the opening of the compressor motor magnetic switch, and
after the TMP has effectively checked the opening of the respective magnetic switch, the machine will
shift from “STOPPING ” to “STOPPED ” status.
Also the opening of the pump magnetic switch provokes the management of the “OIL PUMP FAILS
TO STOP” anomaly that is triggered whenever the magnetic switch fails to open 5 seconds after the
disenergising of the respective output.
22
5. DESCRIPTION OF REGULATION
This chapter will deal only with “AUTOMATIC REGULATION” because all the other cases are
managed manually or by other devices external to the TMP:
The term "regulation" is intended to mean the shifting of the choke box through the energising or
disenergising of the CHARGING and DISCHARGING solenoid valves for the purpose of increasing
or decreasing the power of the compressor and in this way keeping the suction pressure stable and as
close as possible to the Set Point set.
On the basis of the suction pressure, the controller must calculate the position of the choke box and
position it appropriately, or in other words, closing it when it is excessively open or opening it
whenever it is excessively closed.
As we now begin our description, we begin with a list of the parameters that can be set on the
respective SET POINT page selected using the "Machine Status" button on the operator panel Main
Page. These are the necessary parameters for the correct operation of the regulation mechanism.
23
5.1. MEANINGS OF PARAMETERS

SET POINT, SUCTION PRESSURE or PROCESS TEMPERATURE
In case of pressure, it is the pressure that has been set, or in other words, the pressure at which the
circuit must is required to work. The same holds true for the process temperature.
DEAD BAND, SUCTION PRESSURE or PROCESS TEMPERATURE

This is the value expressed in Bar (or in degrees for the temperature) that the operator wants the PLC
to add to and to subtract from the Set Point value in order to create a surrounding area in which the
controller will not perform any regulation.
If, for example, the Set Point value is set at 2.5 Bar and the dead band is set at 0.5 Bar, there will be a
neutral area between 2.0 Bar and 3.0 Bar, and this neutral area must remain the same in both the high
zone and the low zone.
HIGH - LOW ZONE BAND SUCTION PRESSURE or PROCESS TEMPERATURE

to add to and subtract from the Set Point value in order to create a surrounding area in which the
controller allows the operator to establish the real distance from the set point value that has been set.
PRESSURE OR TEMPERATURE FOR COMPRESSOR START:

This is the process value requested that permits the automatic starting of the compressor if it is preset
for such type of operation.
MINIMUM TEMPERATURE FOR COMPRESSOR ALARM:

If the control of the “PROCESS OUTLET TEMP.” has been set on the “CONFIGURATION” page, a
check will also be performed on the minimum alarm temperature (MINIMUM TEMPERATURE
ALARM) set on the SET POINTS page.
If this is lower than the time set in the “MINIMUM TEMPERATURE ALARM DELAY” parameter,
the machine generates an alarm and then stops for anomaly.
24
STOP SLIDE POSITION

If the compressor has reached the Set-Point value set, this is the position of the slide beneath which
the STOP SLIDE POSITION DELAY switch-off time starts elapsing.
MINIMUM SLIDE REGULATION

This is the value of the slide beneath which the slide can be considered discharged.
MAXIMUM SLIDE REGULATION

This is the value of the slide above which the slide can be considered completely charged.
MINIMUM SLIDE AUTOMATIC STOP DELAY

This is the delay taken by the compressor when it is in minimum slide condition and when the set
point has been reached before comes to a stop.
CHARGE INHIBITION TIME AT STARTING

This is the delay taken by the compressor after it has started and the slide ha reached the SLIDE
CHARGE INHIBITION POS. value before automatic regulation begins. Following a stopping of
the compressor even for a short period of time, the suction pressure can run to even fairly high values.
As a result, in its attempt to lower suction pressure rapidly, the compressors might run to higher
capacity values than strictly necessary and then reach the condition in which lowering must be
performed drastically, accompanied by the risk of hunting.
OUT 0% IF SLIDE POS. < :

OUT 100% IF SLIDE POS. > :
These indicates the slide two limit values. When these limits are exceeded, the capacity digital outputs
are raised to 0% and 100% capacity, and this is useful when working with more compressors
operating in sequence.
The regulation of the slide in the TMP has been designed to operate in two different modes, in order
to make the machine more versatile and suitable to the different conditions of the systems in which
they are installed.
25
SET PRESSURE/TEMPERATURE FOR OUT 100% :

This indicates the upper pressure or temperature limits above which (when permitted by slide
conditions) Digital Output A 125.1 lights up, and is useful when working with more compressors
operating in sequence.
STEP SLIDE REGULATION

This is used in systems in which the request for cold is fairly stable, and an immediate reaction to the
system is not required.
With this regulation, the controller increases or decreases the position of the slide every (x) seconds
set in the CHOKE CONTROL CYCLE TIME parameter.
At each control cycle, the machine checks the difference between the process variable and the set
point, and whenever such difference is within the range of the proportional band set in the previous
pages, the percentage of the slide movement is given by the IN PROPORTIONAL BAND parameter.
If such difference is not within the range of the proportional band set value set, the percentage of the
slide movement is given by the OUT PROPORTIONAL BAND parameter.
For further clarification, we provide an example that comes quite close to many real working
situations, by hypothesising the setting of the following parameters:
Set Pressure 2.5 Bar

Dead band 0.5 Bar
Band Regulation 1 Bar
In Band Regulation 1%
Out Band Regulation 5 %
Control cycle time 10 sec
As soon as the machine starts running, the PLC begins continuously calculating the following values:
PSET + BM, PSET – BM , PSET + BP and PSET – BP, which in our case are respectively 3 Bar, 2
Bar, 3.5 Bar and 1.5 Bar.
26
At this point, at regular 10 second intervals, the TMP will perform the following checks in the
pressure. There are five different cases possible:
1) Suction pressure > 2 Bar and < 3 Bar :

- in this case, the controller does not perform any type of calculation.
2) Suction pressure > 3 Bar and < 3.5 Bar

- In this case, the position of the slide is increased by 1%
3) Suction pressure < 2 Bar and > 1.5 Bar:

- In this case, the position of the slide is decreased by 1%
4) Suction pressure > 3.5 Bar :

- In this case, the position of the slide is increased by 5%
5) Suction pressure < 1.5 Bar :

- In this case, the position of the slide is decreased by 5%
PROPORTIONAL SLIDE REGULATION

This regulation is used in systems in which the request for cold is fairly unstable and subject to rapid
variation; for this reason, there is a request for a rapid reaction by the system.
With this regulation, the controller increases or decreases the position of the slide every (x) seconds
set in the BREAK TIME WITHIN 2 PULSES parameter.
At each check cycle, the controller checks the difference between process variable and set-point, and
uses this difference to calculate how long the discharge or charge solenoid valve energising pulse
must be. The duration of the pulse therefore depends on the proportional band value set and the
MAXIMUM SLIDE PULSE TIME parameter (Out Proportional band process variable).
During first starting after an extended pause, the pressure might be very high. In order to prevent the
compressor from reaching the maximum charge value too quickly, a gradual approach (0,5 Bar) to the
27
set-point is made. The NEW SET SETTING DELAY parameter indicates how much time must pass
from when the provisory set point has been reached before the setting of the next set point. Once the
provisory set point becomes less than or equal to the set point value that has been set, the compressor
brings the gradual approach phase to an end until the next time the system is started.
For further clarification, we provide an example that comes quite close to many real working
situations, by hypothesising the setting of the following parameters:
Set Pressure 2.5 Bar

Dead band 0.5 Bar
Band Regulation 2 Bar
Max. Pulse Duration 3 Sec
Break Time within 2 Pulses 10 Sec
As soon as the machine starts running, the PLC begins continuously calculating the following values:
PSET + BM, PSET – BM , PSET + BP and PSET – BP, which in our case are respectively 3 Bar, 2
Bar, 4.5 Bar and 0.5 Bar.
At this point, at regular 10 second intervals, the TMP will calculate the duration of the pulse
necessary.
Some of the cases possible are as follows:

1) Suction pressure > 2 Bar and < 3 Bar :
- The controller does not make any calculation and the solenoid valves are not energised.
2) Suction pressure = 5 Bar (Out Proportional Band).

- The charging solenoid valve is energised for 3 seconds.
3) Suction pressure = 3.5 (In proportional band)

- The charging solenoid valve is energised for 1.5 seconds.
The other parameters that can be set by the operator will be described in greater detail in the chapter
on the operator panel.
28
6. SAFETY DEVICES
The safety devices that intervene on the regulation logic are: excessive motor current absorption, high
discharge pressure, and minimum suction pressure (see the LIMIT PARAMETER Setting Page).
As regards current absorption, 2 current limits can be set, which we will call CURRENT STEP 1 and
CURRENT STEP 2.
For the max. discharge pressure value, three limits can be set: PRESSURE DISCHARGE G1 -
PRESSURE DISCHARGE G2 – PRESSURE DISCHARGE G3.
CURRENT STEP 1 (Motor current alarm - high)

This safety device inhibits slide charging.
This situation is maintained for a period of time equal to 30 seconds, after the anomaly disappears.
CURRENT STEP 2 (Motor current alarm - very high)

This safety device, in addition to performing all the operation described for CURRENT STEP 1, also
forces the discharge. Normal conditions are restored only 30 seconds after the CURRENT STEP 1
anomaly disappears.
CURRENT STEP 3 (Motor current alarm step 3)

This safety device trigger the immediate stopping of the compressor for “HIGH ABSORPTION”
anomaly.
DISCHARGE PRESSURE STEP 1 (Discharge pressure alarm - high)

This safety device inhibits slide charging.
29
This situation is maintained for a period of time equal to 30 seconds, after the anomaly disappears.
DISCHARGE PRESSURE STEP 2 (Discharge pressure alarm - very high)

This safety device, in addition to performing all the operation described for PRESSURE
DISCHARGE G1, also forces the discharge. Normal conditions are restored only 30 seconds after the
PRESSURE DISCHARGE G1 anomaly disappears.
DISCHARGE PRESSURE STEP 3 (Discharge pressure alarm step 3)

This safety device triggers the immediate stopping of the compressor for “HIGH DISCHARGE
PRESSURE” anomaly.
30
7. ANOMALY MANAGEMENT
The TMP manages the following anomalies:
NUMBER ADDRESS DESCRIPTION
1 M 140.0 GENERAL EMERGENCY (MUSHROOM SHAPED)

2 M 140.1 PUMP FAILS TO START ANOMALY
3 M 140.2 PUMP NOT STOPPED ANOMALY
4 M 140.3 COMPRESSOR FAILS TO START ANOMALY
5 M 140.4 COMPRESSOR NOT STOPPED ANOMALY
6 M 140.5 SLIDE NOT WORKING ANOMALY
7 M 140.6 HIGH DISCHARGE PRESSURE ANOMALY
8 M 140.7 LOW SUCTION PRESSURE ANOMALY
9 M 141.0 DISCHARGE TEMP. ANALOG ANOMALY
10 M 141.1 OIL COLLECTOR ANALOG. ANOMALY
11 M 141.2 OIL SEPARATOR ANALOG ANOMALY.
12 M 141.3 SUCTION TEMP. ANALOG ANOMALY
13 M 141.4 OIL PRESSURE ANALOG ANOMALY
14 M 141.5 OIL PRESSURE AFTER FILTER ANALOG ANOMALY
15 M 141.6 DISCHARGE PRESSURE ANALOG ANOMALY
16 M 141.7 SUCTION PRESSURE ANALOG ANOMALY .
17 M 142.0 SLIDE POSITION ANALOG ANOMALY
18 M 142.1 MOTOR CURRENT ANALOG ANOMALY .
19 M 142.2 SAFETY DEVICE 3 ANOMALY (PRE-SET)
20 M 142.3 SUPERVISION PC EMERGENCY
21 M 142.4 PROCESS TEMPERATURE ANALOG ANOMALY
22 M 142.5 LOW PROCESS TEMPERATURE ANOMALY
23 M 142.6 HIGH ABSORPTION ANOMALY (GREATER THAN STEP 3)
24 M 142.7 NO COMMUNICATION ANOMALY
25 M 143.0 HIGH DISCHARGE TEMP. ANOMALY
26 M 143.1 FILTER DIFF. HIGH PRESSURE ANOMALY
27 M 143.2 DISCHARGE OIL MIN. DIFF. ANOMALY
28 M 143.3 OIL SEPARATOR LOW TEMP. ANOMALY.
29 M 143.4 OIL COLLECTOR HIGH TEMP. ANOMALY
30 M 143.5 MIN. GAS PRESS. DIFF. ANOMALY (MINIV)
31 M 143.6 SAFETY DEVICE 1 ANOMALY
32 M 143.7 SAFETY DEVICE 2 ANOMALY
33 M 144.0 FREE
34 M 144.1 FREE
35 M 144.2 FREE
36 M 144.3 FREE
37 M 144.4 FREE
38 M 144.5 FREE
39 M 144.6 FREE
40 M 144.7 FREE
31
All the anomalies must be reset manually and any anomaly triggers the stopping of the compressor for
malfunction.
In addition to triggering the immediate stopping of the compressor, the appearance of one or more
malfunctions displays the Alarm Acceptance Page and triggers the flashing of the red l.e.d. positioned
at the upper right of the Operator's Panel to indicate the presence of an alarm.
Pressing the QUIT key gives confirmation to the TMP to accept the alarm, and then the operator can
return to the other video pages. In order to return to the Alarms Page, press the button with the symbol
“?” positioned at the upper right of the Operator's Panel.
The use of ALARM RESET permits the resetting of the alarm after his disappearance.
The anomaly will no longer interrupt the operation of the compressor only after it has been reset
regardless of the fact of whether or not it has been recognised (always provided that no other
anomalies are present).
The Operator's Panel returns to normal display mode only after ALL the alarms have been recognised.
The compressor can be started again if no more alarms are present or all alarms present have been
reset.
32
8. OPERATOR'S PANEL
The Operator's Panel with display is used for interface between the operator and the PLC.
The panel is equipped with a text-type display and designed for the display of all process parameters,
all the parameters that have been set, the status of the users, and all the alarms.
This Operator's Panel is a TOUCH-SCREEN type, meaning that the screen is sensitive to the touch,
and the operator only has to touch the right area of the screen in order to scroll pages, change
parameters or give commands to the compressor.
33
8.1. VIDEO PAGE DESCRIPTION

If no alarms are present, when the machine is switched on, the TMP Technofrigo page with the menus
for all the work pages will be displayed.
We provide the contents of the various video pages below.
8.2. MAIN PAGE
This is the Operator Panel Main Page. The use of the respective buttons grants access to the panel
various pages, while the type of compressor that has been selected and the type of operation adopted
(Control via NET or LOCAL) are also displayed.
Pressing the date and hour grants access to the Operator Panel System Page that permits the setting of
the Operator Panel and PLC date and hour.
34
8.3. MANUAL COMMANDS
This page permits the operator to command the manual starting and stopping of the compressors with
the respective buttons, provided that the START TYPE has first been configured in “Local/Manual”.
Charging and discharging can also be configured manually using the respective buttons, provided that
the type of regulation has been set in manual.
35
8.4. COMPRESSOR GENERAL VALUES (1)

This page is accessed by touching the “MACHINE STATUS” button.
36
8.4.1. COMPRESSOR GENERAL VALUES (2)
Pages 1 and 2 of “COMPRESSOR GENERAL VALUES ” display in numerical format all the
pressure and temperature values necessary for the monitoring of machine operation as well as the
percentage of opening of the oil cooling valve.
37
All the parameters on this page are read-only and for such reason cannot be changed.
This page displays the status of the compressor and the various strings that may assume different
values depending on the state of the compressor (ready, anti-recycle, run, anomaly, etc…)
38
This page displays the status of the compressor and the various strings that may assume different
values depending on the state of the compressor (CURRENT PRE-ALARM, ANTI-RE-CYCLING,
LOW OIL SEPARATOR TEMPERATURE).
39
This page displays the status of the various signals that the compressors receives from the network.
This page will be displayed only if operation via network has been enabled from the
CONFIGURATION page (see Page 18).
40
8.5. SET POINT PAGES

Use the WORK PARAMETERS button key to access the first of the SET POINT PAGES.
In order to change any value desired, touch the area of the screen in which it appears and a keyboard
will appear that permits the modification of the value.
8.5.1. SET POINT PAGES 1A – 1B
41
SUCTION PRESSURE or PROCESS TEMPERATURE SET POINT

In case of pressure, it is the pressure has been set, or in other words, the pressure at which the circuit
must work. The same description also applies to the temperature.
DEAD BAND, SUCTION PRESSURE or PROCESS TEMPERATURE

to add to and to subtract from the Set Point value in order to create a surrounding area in which the
controller will not perform any regulation.
If, for example, the Set Point value is set at 2.5 Bar and the dead band is set at 0.5 Bar, there will be a
neutral zone between 2.0 Bar and 3.0 Bar, and this neutral zone must remain the same in both the high
zone and the low zone.
HIGH - LOW ZONE BAND

to add to and subtract from the Set Point value in order to create an a surrounding area in which the
controller allows the operator to establish the real distance from the set point value that has been set.
PRESSURE OR TEMPERATURE FOR COMPRESSOR START:

This is the process value requested that permits the automatic starting of the compressor if it is preset
for such type of operation.
STOP SLIDE POSITION

If the compressor has reached the Set-Point value set, this is the position of the slide beneath which
the STOP SLIDE POSITION DELAY switch-off time starts elapsing
This page will be displayed only if the compressor is configured for normal operation
8.5.2. SE T POINT PAGE 2
42
MINIMUM SLIDE REGULATION

This is the value of the slide beneath which the slide can be considered discharged.
MAXIMUM SLIDE REGULATION

This is the value of the slide above which the slide can be considered completely charged.
MINIMUM SLIDE AUTOMATIC STOP DELAY

This is the delay taken by the compressor when it is in minimum slide condition and when the set
point has been reached before comes to a stop.
CHARGE INHIBITION DELAY

This is the delay for which the compressor waits before beginning the automatic regulation of the
slide. Following a stopping of the compressor even for a short period of time, the suction pressure
can run to even fairly high values. As a result, in its attempt to lower suction pressure rapidly, the
compressors might run to higher capacity values than strictly necessary and then reach the condition
in which lowering must be performed drastically, accompanied by the risk of hunting.
OUT 0% IF POS. SLIDE < :

OUT 100% IF POS. SLIDE < :
These indicates the slide two limit values. When these limits are exceeded. the digital outputs A125.0
and 125.1 are raised, and this is useful when working with more compressors operating in sequence.
SET PRESSURE/TEMPERATURE FOR OUT 100% :

This indicates the upper pressure or temperature limits above which (if these conditions remain for a
time equal to DELAY FOR OUT 100% and the slide has reached the 100% position) Digital Output
A 125.1 lights up, and this is useful when working with more compressors operating in sequence.
8.5.3. SET POINT PAGES 3 - 4
The Operator's Panel will display one or the other page depending on the type of slide regulation
selected on the CONFIGURATION page.
For the meaning of the parameters, see Chapter 4, Pages 24-27.
43
8.5.4. SET POINT PAGE 5
OIL HEATERS SET POINT Oil separator temperature Set Point.

The PLC switches on the oil heaters whenever the temperature falls lower than the OIL HEATERS
DELTA SET-POINT and switches off when such SET-POINT is reached.
If the compressor is running, these heaters remain switched off.
OIL COOLING SET

If the compressor is running, the oil cooling solenoid valve enables oil cooling whenever the
temperature exceeds the SET-POINT + OIL COOLING DELTA value until the temperature falls
below the SET-POINT - OIL COOLING DELTA.
ECONOMISER S.V. Economiser solenoid valve enabling

ECONOMISER S.V. FOR SLIDE Economiser value (slide position) above which - with
the compressor running - the economiser solenoid
valve opens.
OIL RECOVERY S.V. Oil recovery solenoid valve enabling
When the compressor is running, this solenoid valve operates in pause-work mode.
OIL RECOVERY OFF Oil recovery solenoid valve closing time
OIL RECOVERY ON Oil recovery solenoid valve opening time
SUCTION SET POINT - REGULATION UNDER PRESSURE

This is the working set-point whenever regulation is made under pressure .
44
8.5.5. SET POINT PAGE 6
MAXIMUM PRE-LUBE TIME This is the maximum time for lubrication

during the starting phase (Oil Pump running),
after which the drain time is enabled.
DRAIN TIME When drainage is in progress, the compressor
is not enabled for starting.
PUMP DOWN CONTROL Enabling of Pump-Down control

PUMP-DOWN PRESSURE SET This is level to which the pressure must drop
after the machine has received a request for
stopping and has been brought to the
minimum level before definitively removing
the command to the compressor motor and
the oil pump.
MAX. PUMP-DOWN TIME This is the motor switch-off delay after the
correct pump-down pressure has been
reached.
PUMP-DOWN SLIDE POSITION This is the capacity set point that the
compressor must reach before starting the
pump-down phase.
DEPRESSURISING CONTROL Enabling of depressurising control

DE-PRESSURISING IN STOP This is the value that must be reached by the
discharge pressure with the machine stopped;
this de-pressurising is carried out with the de-
pressurising valve and is set with the
DISCHARGE PRESS.> DE-PRESS. IN
STOP + DE-PRESS. DP
45
DE-PRESSURISING IN START This is the value that must be reached by the

discharge pressure with the machine in
starting; this de-pressurising is set with the
DISCHARGE PRESS.> DE-PRESS. IN
START + DE-PRESS. DP
DE-PRESSURISING DP De-pressurising Start differential
46
8.6. LIMIT PARAMETERS PAGE

The LIMIT PARAMETERS button gives access to the first of the LIMIT PARAMETERS SET-
POINTS pages, which provides the values that stop the machine whenever they are exceeded with the
corresponding alarm status.
In order to change any value desired, touch the area of the screen in which it appears and a keyboard
will appear that permits the modification of the value.
The parameters of safety device CURRENT STEPS 1-2 and DISCHARGE PRESSURE STEPS 1-2-3
are described in Chapter 6 - SAFETY DEVICES
MIN. P. ASP. 1 Bar Minimum suction pressure
MAX. T. MAN. 80 C Maximum discharge temperature only with PASSWORD
MAX. P.D.F. 1.5 Bar Maximum oil filter diff. pressure
MIN. P. D. O. 1 Bar Minimum oil diff. pressure only with PASSWORD
MIN. T.. SEP. 25 °C Minimum oil separator temperature
MAX. T. OIL 80 °C Maximum oil collector temperature only with PASSWORD
MIN. P. D. G 3.5 Bar Minimum gas differential pressure only with PASSWORD
47
8.7. BEFORE-ALARMS VALUES

The Before-Alarms Values button is used to access the page with the respective information.
This video page displays the values (read-only values) of all the machine parameters as they were one
moment before the occurrence of any anomaly.
The display of these parameters helps identify the cause of any determined event.
These values cannot be modified by the operator because they are read-only and remain in memory
only until a new anomaly occurs, at which time the existing values are replaced with new ones.
48
8.8. CONFIGURATION MENU
Access to this page is granted by the “SPECIAL CONFIG.” button on the Main Menu, which contains
the buttons used to scroll the pages described below.
49
8.9. CONFIGURATION
“CONFIGURE COMP. TYPE” button
These parameters are described in Chapter 3.
50
8.10. SPECIAL PARAMETERS only with password

8.10.1. IMPULSIVE LI-OC REGULATION
“LI-OC SV PID” button
DISCHARGE TEMP. SET: this is the Set point for the temperature to be maintained
DEAD BAND: this is the value that is added to and subtracted from the set-point in
order to define a surrounding area inside of which the controller will not modify the output.
PROPORTIONAL BAND: this regulates the sensitivity of the calculation of the PID output
The energising time of the respective solenoid valve depends on the difference between the Set Point
and the temperature value measured and on the value set in the PROPORTIONAL BAND. The
INTEGRAL and DERIVATIVE TIMES are both standard values.
PULSE DURATION AND PERIOD TIME: Together with the proportional band, these values
regulate the cooling valve switch-on times.
COOLING PID: this is the PID regulation value expressed in percentage that
represents the opening of the cooling valve whenever an analogue signal for the control of opening
and closing is required.
Whenever the impulsive LI-OC valve is commanded by a digital signal, this value is converted into
time (closing/opening duration).
51
8.10.2. ALARMS DELAYS SETTING
“SPECIAL PARAMETERS” button
SLIDE NOT WORKING DELAY Delay caused by slide not working anomaly
DISCHARGE PRESSURE HIGH DELAY Delay caused by high discharge pressure anomaly
52
SUCTION PRESSURE LOW DELAY Delay caused by low suction pressure anomaly
DISCHARGE TEMP. HIGH DELAY Delay caused by high discharge temperature anomaly
OIL FILTER DIFF. PRESSURE DELAY Delay caused by high filter diff. pressure anomaly
OIL PUMP PRESSURE LOW DELAY Delay caused by low oil pump pressure anomaly
OIL SEPARATOR TEMP. LOW DELAY Delay caused by low oil separator temp. anomaly
OIL TEMPERATURE HIGH DELAY Delay caused by high oil temperature anomaly
GAS SUC.-DISCH. PRESS. LOW DELAY Delay caused by low gas diff. pressure anomaly
SAFETY DEVICE 1 DELAY Delay caused by safety device 1 anomaly
START AGAIN The minimum time interval between a STOP and the
next STARTING
ANTI-RECYCLING The minimum time interval between two startings
COMPRESSOR NOT RUNNING DELAY The max. delay time for the return of compressor
running (from the power board)
COMPRESSOR NOT STOPPING DELAY The max. delay time for the stopping of compressor
PUMP NOT RUNNING DELAY The max. delay time for the return of pump running
(from the power board)
PUMP NOT STOPPING DELAY The max. delay time for the stopping of pump
53
8.11. DIGITAL INPUT/OUTPUT PAGE

“PLC IN/OUT STATUS” button
54
8.12. ANALOGUE INPUT PAGE
This video page provides a list of the analogue inputs present in the system with the respective
matching EW and the engineering value of the analogue input executed in the software program.
All the parameters of this video page are read-only (and cannot be varied).
55
8.13. SLIDE SETTINGS - OUTPUT FORCING PAGE

“FORCING” Button
56
8.14. SERVICE PAGE

“SERVICE” Button
This page is reserved exclusively to use by Technofrigo compressor maintenance personnel.
9. PASSWORD MANAGEMENT
The user is responsible for ensuring that the keyboard is accessed and used only be adequately trained
personnel.
The Operator's Panel can manage up to 8 different User password levels plus a 9th "Super-User" level
that is provided with universal access.
In our case, the parameters and the pages marked by the “only with password” message can be
accessed or modified only after entering the “Super User” password.
The first time that access to a protected page or parameter is requested, the Operator's Panel
automatically requests Log-in (the entry of the password - e.g. 1234 followed by "Enter"). Access
remains possible for 10 seconds before "Log-out" is automatically performed (e.g. the password is
disabled).
57
10. GENERAL ELECTRIC SYSTEM CHARACTERISTICS
The electric system has been designed and constructed in compliance with the international standards
in force and particular attention to the prescriptions contained in the technical specifications for
automatic machine electric equipment.
Mains voltage is connected to the machine electric equipment by the main power switch with a handle
outside the electric box door and equipped with door-lock mechanism: whenever the main power
switch has been switched on (turned to "1"), the electric box door is closed and locked.
The electrical equipment and the system are protected against overload, and the maximum is obtained
by providing fuses on the main power supply and automatic circuit breakers for the protection of the
auxiliary circuits and the PLC.
The operating voltage of the entire system is shown in the table below:
a) 380V, 50 Hz three-phase motor power supply line (this voltage is present

only in the power box)
b) 110V or 220V, 50 Hz one-phase electric control panel power supply line
c) 24V DC auxiliary circuit operating voltage
All the panel electric connections are made to terminal blocks with wires clamped to the terminals,
and each terminal is clearly marked with the indication of the wire to be connected.
The electrical equipment does not occupy all the space available in the panel contained inside the
electric box, and sufficient space remains for the installation of other equipment required by future
modification.
Each solenoid valve is protected against short-circuit by independent fuses built into the electric box
control panel terminal block.
The electric equipment used in the system, in the electric box, and in the pushbutton panel are all of
the highest quality and installed correctly in order to provide the highest guarantee for the
optimisation of compressor operation.
The emergency circuit is controlled by a PILZ safety device (Code PNOZ X7 24V DC/AC) for Risk
2 Class Emergency Circuits as per EN 60204, one channel connection with feedback circuit and
automatic reset.
These safety devices possess two release circuits (safety device circuits) as closing circuit. Two l.e.d.
signal the state of operation and function. When the emergency key is released, the correct operation
of the internal circuit of the safety device and the external contactors are checked. The conditions of
safety remain enabled even when the device malfunctions.
58
PILZ safety device
The compressor cycle is managed by a PLC that has been programmed to control and supervise all
compressor functions.
The compressor is equipped with an Operator's Panel; its many functions include message display that
informs the operator of the compressor working state and - in case the compressor automatically stops
- the cause of compressor stopping.
See Chapter 8 for more details on the Operator's Panel.
10.1. LIST OF ELECTRIC PANEL COMPONENTS
Name Type Description Manufacturer

6ES7331-1KF01- SM 331 8 Input Analogue Input Module (13 Bit
AI 0AB0 resolution) Siemens
6ES7392-1BM01- SM 331 8 Input Analogue Input Module (13 Bit
AI 0AA0 resolution) Siemens
6GK7342-5DA02-
CP 342-5 0XE0 Profibus DP Module SIEMENS
6ES7313-5BE01- CPU 313C with MPI 24DI/16DO/4AI/2AO/
CPU313C 0AB0 1PT100, Siemens
CPU 313C with MPI 24DI/16DO/4AI/2AO/
CPU313C 6ES7953-8LF11-0AA0 1PT100, Siemens
6ES7392-1BM01- CPU 313C with MPI 24DI/16DO/4AI/2AO/
CPU313C 0AA0 1PT100, Siemens
6ES7392-1BM01- CPU 313C with MPI 24DI/16DO/4AI/2AO/
6ES7390-1AE80- CPU 313C with MPI 24DI/16DO/4AI/2AO/
FSV1 Solenoid valve
FSV2 Solenoid valve
FSV3 Solenoid valve
FSV4 Solenoid valve
FSV6 Solenoid valve
FSV101 Solenoid valve
6ES7307-1EA00-
GD1 0AA0 One-phase power supply SIEMENS
KA00 OMRG2RN8811C Auxiliary relay coil OMRON
KA00 OMRP2R 6003H Auxiliary relay coil OMRON
59

KA17 OMRG3R 2091C Auxiliary relay coil OMRON
KA17 OMRP2R 6002M Auxiliary relay coil OMRON
PILPNOZ-
KA5-1 X724VAC/DC Safety device PILZ
PAN 6ZA1040-7BE10 Operator's Panel UNIOP
PAN 6ZA9387-7BE10 Operator's Panel UNIOP
6ES7972-0BB41-
PAN 0XA0 Operator's Panel SIEMENS
6ES7972-0BA12-
PAN 0XA0 Operator's Panel SIEMENS
PG1 RTA86624 Ring nuts RTA
PG2 REIST13,5 Cable clamps REITER
60

PG2 CEM1843 Cable clamps REITER
PT1 Pressure-switch
PT2 Pressure-switch
PT3 Pressure-switch
PT4 Pressure-switch
QF1 MEG24266 Two-pole automatic circuit breaker MERLIN GERIN
QG RIT1060500 PANEL RITTAL
QG RGHPANGEAMKS PRINTED PANEL STARGRAFIC
QSG BRELA2-16-1754 Two-pole manual knife-switch BRETER
QSG BRELFS2-G-6-175 Two-pole manual knife-switch BRETER
SBEG TELZB4BS844 Stable emergency button TELEMECANIQUE
SBEG TELZB4BZ102 Stable emergency button TELEMECANIQUE
ST1 Thermostat
TCV101 Solenoid valve
TE1 Variable resistor
XS1 VIM09967 Two-pole socket with ground VIMAR
X1 WAG281-611 Terminal with fuse WAGO
X1 WAG281-601 4 mm terminal WAGO
X1 WAG870-501 Double 2.5 mm2 terminal WAGO
61
62

Compressor Panel

Uploaded by

Copyright:

Available Formats

Compressor Panel

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Compressor Panel

Uploaded by

Copyright:

Available Formats

Industrie Technofrigo Dell’Orto S.p.A.

Industrie TECHNOFRIGO DELL’ORTO S.p.A.

1. GENERAL SAFETY RECOMMENDATIONS ....................................................................................... 3

1. GENERAL SAFETY RECOMMENDATIONS

1.1. INSTALLATION ROOM RECOMMENDATIONS

The presence of electronic components requires installation room temperature to be maintained

1.3. LIST OF SAFETY DEVICES INSTALLED

MAIN POWER SWITCH

2.1. SYSTEM COMPOSITION

The TMP control PLC is composed as follows:

• Central unit CPU313

Posto connettore = Connector position

UNIOP and TOP05 operator panel.

ELECTRIC BOX DOOR

2.2. PLC INPUT / OUTPUT LIST

DIGITAL INPUTS ANALOGIC ANALOGIC PROFIBUS

2.2.1. DIGITAL INPUTS:

SYMBOL ADDRESS TYPE DESCRIPTION

COMP.RUN E 124.0 BOOL COMPRESSOR ON

2.2.2. DIGITAL OUTPUTS:

SYMBOL ADDRESS TYPE DESCRIPTION

OIL HEATER A 124.0 BOOL OIL HEATER

2.2.3. ANALOGIC INPUTS:

SYMBOL SDDRESS TYPE DESCRIPTION

2.3. SINGLE INPUT / OUTPUT SIGNAL DESCRIPTION

2.3.1. DIGITAL INPUT DESCRIPTION

| STOP | RUN | STOP

STOP | RUN | STOP

INPUT E 125.1 – FREE

INPUT E 125.4 (Slide Block)

INPUT E 125.5 – FREE

INPUT E 125.6 – FREE

2.3.2. DIGITAL OUTPUT DESCRIPTION

OUTPUT A 124.0 (oil heating control)

OUTPUT A 124.5 (Anomaly signal control)

OUTPUT A 124.6 (Economizer control)

OUTPUT A 124.7 (Oil cooling ON/OFF solenoid valve control)

OUTPUT A 125.0 (Slide at minimum)

OUTPUT A 125.1 (Slide at maximum)

OUTPUT A 125.2 (By-pass solenoid valve control)

OUTPUT A 125.3 (Slide discharge forcing/de-pressurisation solenoid valve control)

OUTPUT A 125.4 (Automatic operation preset control)

OUTPUT A 125.5 (Oil recovery solenoid valve control)

OUTPUT A 125.6 (Danfoss thermostat control)

OUTPUT A 125.7 (LIOC thermostat control)

2.4. ANALOG INPUT DESCRIPTION

No. 4 from pressure transmitters

2.4.1. ANALOGIC INPUTS

The signal values (4 ÷ 20 mA)

PEW 758 Suction pressure Range: 0-16 absolute Bar

PEW 756 Discharge pressure * Range: 0-30 absolute Bar

PEW 752 Oil pressure * Range: 0-30 absolute Bar

PEW 754 Oil filter pressure * Range: 0-30 absolute Bar

PEW 256 Discharge Temperature Range -50 / + 100 °C TEMPERATURE PROBE

PEW 260 Oil temperature Range -50 / + 100 °C

PEW 262 Glycol inlet temperature Range -50 / + 100 °C

PEW 760 Glycol outlet temperature Range -50 / + 100 °C

PEW 266 Slide position Range 0 / 100 %

PEW 264 Free