Spartan Controls Millennium Compressor Control Panel Operating Philosophy

Spartan Controls Ltd. Universal Comp.
Date: October 14, 2005
Project: Stock Revision 1 Page 1
Spartan Controls
Millennium Compressor Control Panel
Operating Philosophy
Location: Stock
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Vendor: Spartan Controls Ltd.
Vendor document: Operating Philosophy
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without the prior consent of the Quality Manager of Spartan Controls
Spartan Controls Ltd. Universal Comp. Date: October 14, 2005
CUSTOMER SERVICES NETWORK
Customer
Millennium
Operating Philosophy
Revision
1
Spartan Controls Ltd.
Company Confidential
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TABLE OF CONTENTS
1. INTRODUCTION........................................................................................................ 5
1.1 General ..................................................................................................................................... 5

1.2 Standard Base System.............................................................................................................. 5
1.3 Optional Functionality................................................................................................................ 5
2. START-UP / SHUTDOWN SEQUENCING ............................................................... 6
2.1 Compressor Cooldown Stop...................................................................................................... 8

2.2 Alarm Stop (Optional) ................................................................................................................ 9
2.3 Engine / Compressor Shutdown .............................................................................................. 10
2.4 Panel Emergency Shutdown (ESD)......................................................................................... 10
3. MANUAL LOADING CONTROL ............................................................................. 11
3.1 Manual Bypass Valve Control ................................................................................................. 11

3.2 Manual Speed Control............................................................................................................. 11
3.3 Manual Suction Valve Control ................................................................................................. 11
4. AUTOMATIC LOADING CONTROL....................................................................... 12
4.1 Automatic Speed Control......................................................................................................... 12

4.1.1 Suction ................................................................................................................................ 12
4.1.2 Discharge............................................................................................................................ 12
4.2 Automatic Bypass Valve Control ............................................................................................. 13
4.2.1 Suction ................................................................................................................................ 13
4.2.2 Discharge............................................................................................................................ 14
4.3 Automatic Suction Control ....................................................................................................... 15
4.4 Controlled Unload.................................................................................................................... 16
4.5 Blowdown Valve Control.......................................................................................................... 16
5. COMPRESSOR ROD LOAD CALCUATIONS ....................................................... 16
6. LOW CLASS P DISCHARGE LOGIC..................................................................... 17
7. MISCELLANEOUS .................................................................................................. 18
7.1 Password Protection ............................................................................................................... 18

7.2 Verify Discrete Input / Outputs................................................................................................. 19
7.3 Service Mode .......................................................................................................................... 19
7.4 Test Mode ............................................................................................................................... 19

7.5 Run Time Hours ...................................................................................................................... 19
7.6 Speed Output Actuator Adjustments ....................................................................................... 19
8. MODBUS COMMUNICATIONS .............................................................................. 20
8.1 Local / Remote Mode .............................................................................................................. 20
APPENDIX A .................................................................................................................. 21
Input/Output List................................................................................................................................... 21
APPENDIX B .................................................................................................................. 21
Definitions ............................................................................................................................................ 21
1. INTRODUCTION
1.1 General
This document outlines the Millennium compressor control panel operating

philosophy for Bidell Equipment Inc. A Millennium control system will be
programmed to safely start, stop, and automatically sequence a two-stage
four-cylinder reciprocating compressor with a gas engine driver. The
automatic sequence has been designed based on practices and
recommendations from Bidell Equipment Inc for control of a Caterpillar
3412 TA LE gas engine driver, and an Arial JGJ-4 reciprocating
compressor.
The display/control/communications control module (Head) contains the

processing power in the form of a single board computer with support board,
Vacuum Fluorescent Display (VFD), (which is a dot matrix alpha-numeric
display in a 4 line by 20 character format), and 16 button keypad. The VFD
displays first-in shutdowns, an alarm history, sequencing messages, and all
process real-time data. A separate pushbutton mounted on the side of the
panel is provided for ESD (Emergency Shutdown).
This document covers both the standard base system, and several options
summarized in the next sections.
1.2 Standard Base System
The base system control logic functionality is listed below. These are covered
in greater detail in later sections.
• Lube oil pump control (prelube and postlube)
• Engine Startup
• Cooldown stop sequencing
• Compressor shutdown logic
• Low class P discharge logic
• Rod load calculations
• Speed control
• Bypass control
• Suction valve control
1.3 Optional Functionality

The optional system control logic functions are listed below. These are
covered in greater detail in later sections. References to these control
options throughout the philosophy are only valid if the options have
been selected.
• Blowdown valve control
2. START-UP / SHUTDOWN SEQUENCING
The setpoint, and timer parameters discussed in this section can be accessed
from the setpoint screens. Please refer to the project IO list document for
setpoint / timer values, and locations.
The operator must ensure that all shutdowns have been cleared before a start
can be attempted. This may be confirmed by viewing the Millennium display.
Once all shutdowns have been cleared, a “STANDBY” message is displayed
on the ‘MAIN’ screen.
The ESD relay will energize, all other relays will remain off (Blowdown will
operate as required), and the Speed control will output the WARMUP RPM
setting. The Bypass Valve output will be at 0%.
If the Suction Valve control is in AUTO, the Suction Pressure will be

maintained at the START PRS setting. If the control is in MAN, the operator
can control the output using the MAN OUT setting.
Table 2-1 describes the start-up sequencing in detail.
Table 2-1: Start-Up Sequencing

Item Step Description
1 Press Initiates a start attempt. When the RUN/STOP button is pressed the Speed
RUN/STOP key. output is set to WARMUP RPM and the Bypass Valve will fully open to
0.0%. The Suction Valve output will be in control.
Each step through the start sequence will be displayed on the ‘HOME’ front
display screen on the “ST:” status line. When a shutdown occurs the status
will change to “SHUTDOWN”. The Event display will flash the ‘Alarm
Summary’ screen for details.
2 Prelube The Lube relay will energize and the PERMISS DLY timer will start. The
controller will monitor both compressor and engine oil permissive settings.
• If the compressor permissive pressure is not reached at the expiration of

the PERMISS DLY timer, the controller will signal “COMP OIL PERM
FAIL”. The Lube relay will turn off, and the controller will wait for a
RESET. The RUN/STOP button will have to be pushed to attempt
another start.
• If the engine permissive pressure is not reached at the expiration of the
PERMISS DLY timer, the controller will signal “ENGINE OIL PERM
FAIL”. The Lube relay will turn off, and the controller will wait for a
RESET. The RUN/STOP button will have to be pushed to attempt
another start.
When both permissives are met, the PERMISS DLY timer will zero, and
the PRELUBE DLY timer will start. The unit will continue prelubing for the
duration of the PRELUBE DLY timer.

3 Engine Start Following the completion of the PRELUBE DLY timer, the Lube relay will de-
energize and the crank sequence will initiate.
• The Ignition and Crank relays will energize. If the engine RPM does not
rise above 0 rpm at any time during the first crank attempt, the controller
will assume a problem with the unit and a “FAIL TO CRANK” shutdown
will occur.
• The CRANK DLY and PURGE DLY timers will start. The display will
change to “CRANKING”. The Crank relay will remain on for the duration
of the CRANK DLY or until the engine RPM rises above the CRANK DIS
(crank disconnect) RPM.
• When the PURGE DLY expires, the Fuel Valve relay will energize.
• If the speed does not reach the CRANK DIS RPM before the CRANK
DLY timer expires the Crank, Ignition, and Fuel Valve relays will de-
energize and the REST DLY timer will start. The display will change to
“RESTING”. When the REST DLY timer expires, the Crank and Ignition
relays will energize, the Fuel Valve relay will energize after the PURGE
DLY, and the crank attempt counter will increase by 1. If the engine
does not start when the actual crank attempts is equal to the CRANK
ATTEMPTS setpoint the controller will signal a “FAIL TO START” fault.
This fault must be RESET, and a new start attempt made.
NOTE: If the crank RPM falls below 50 rpm, after it has been above 50
RPM, the Crank relay will de-energize and the REST DLY timer will start.
The display will change to “RESTING”. When the REST DLY timer
expires the Crank relay will energize and the crank sequence will be
repeated.
4 Warm-up When the engine RPM rises above the CRANK DIS RPM, the crank
sequence will finish and the display will change to “WARMUP”. Automatic
loading of the unit is not permitted until the system has warmed up.
• The internal Run Hours will begin accumulating.
• The Class B1 and B2 timers will begin counting. When the timers expire
the Class B1 and B2 faults will be armed.
• The Status relay will energize at the expiration of the Class B1 timer.
• The WARMUP DLY timer is started. The Engine Jacket Water
Temperature, and Compressor Oil Temperature permissives are
monitored.
• After a 15 second delay the Suction Valve control setpoint will begin to
ramp from the START PRS setting to the MAINT SUC setting (if the
Suction Valve output is in AUTO) using the SUC STEP P, and ST RAMP
TIME settings (adjustable from the ‘SUCTION CNTL’ screen).
• If the engine RPM falls 50 RPM below the CRANK DIS RPM a “LOSS OF
SPEED SIGNAL” fault will occur immediately.
• The UNDERSPEED shutdown (Class C) will be armed when the engine
RPM rises above the UNDERSPEED setpoint.
• When the WARMUP DLY timer expires and the temperature
permissives are met the display will change to “READY TO LOAD”.
• The Speed output will increase to the IDLE RPM using the speed control
manual settings.
• The unit can be loaded by changing the first line of the ‘HOME’ front
display to “LOAD”. If the ‘HOME’ page is not displayed, the HOME key
can be repeatedly pressed until the page appears.
2.1 Compressor Cooldown Stop
Pressing the RUN/STOP button of the Millennium controller initiates a cooldown stop
sequence.
The Bypass Valve will begin ramping to 0% using the manual open bypass
settings. When the Bypass Valve position falls below the BYP P THR DWN (bypass
position for throttle down) setting, the Speed control output will begin ramping the
engine RPM to the Min RPM setting using the manual speed control settings. When
the Bypass Valve is at 0% and the speed control is at Min RPM, the Speed control
will decrease to the Warmup RPM setting. The status display will change to
“COOLDOWN”. The COOLDOWN DLY timer will begin counting. The unit can be
forced into an immediate stop by pressing the TIMER “0” key.
When the COOLDOWN DLY timer expires:

- The Fuel Valve relay will de-energize.
- The IGN KILL DLY timer is started.
- All Class B faults are locked out.
- The internal Run Hours stop counting.
- The Status relay will de-energize.
- The Suction Pressure will be controlled to the START PRS setting.
- When the IGN KILL DLY timer expires the Ignition relay will de-energize,
and the Lube relay will energize for the duration of the POSTLUBE DLY.
The display will change to “POSTLUBING”.
- When the postlube cycle is complete, the display will change to
“STANDBY”, and the unit will be ready for a start attempt.
NOTE: If the unit is restarted while the unit is postlubing, the postlube sequence will
stop and the start sequence will begin.
2.2 Alarm Stop (Optional)
An ALARM STOP is initiated when a parameter reaches an alarm setpoint. The unit
will complete a cooldown stop. The cooldown stop will help reduce engine
maintenance, rather than an always initiating an immediate stoppage.
The display will change to “SHUTDOWN”. The ‘FAULT SNAPSHOT’ page will record
the values of the process parameters. The 4-line fault message will appear in the
display. The Bypass Valve will begin ramping to 0% using the manual bypass
settings.
When the Bypass Valve position falls below the BYP P THR DWN (bypass position
for throttle down) setting, the Speed control output will begin reducing the engine
RPM to the Min RPM setting using the manual speed control settings. When the
Bypass Valve is at 0% and the Speed control is at Min RPM, the speed control will
decrease to the WARMUP RPM setting. The COOLDOWN DLY timer will begin
counting. The unit can be forced into an immediate stop by pressing the TIMER “0”
key.
When the COOLDOWN DLY expires:

- The Suction Valve will close completely (0%).
The unit must be reset to change the status to “STANDBY”, to allow another start
attempt.
The Alarm Stop option can be disabled by changing the COOLDOWN SELECT
option to NO (N) on the ‘MISC CAL’ setpoints screen.
2.3 Engine / Compressor Shutdown
A SHUTDOWN is initiated if a discrete shutdown switch trips, an analog shutdown

setpoint is exceeded, or an analog input sensor fails. This is deemed a point at
which catastrophic damage can occur, and the unit must be stopped immediately.
The display will change to “SHUTDOWN”. The ‘FAULT SNAPSHOT’ page will record
the values of the process parameters. The 4-line fault message will appear in the
display. The Suction Valve and, Bypass Valve outputs will immediately ramp to 0%.
The Speed output will ramp to the WARMUP RPM setting.
When a shutdown occurs:

- The Suction Valve will close completely (0%).
The unit must be reset to change the status to “STANDBY”, to allow another start
attempt. When the unit is reset the Suction Valve will start controlling to the START
PRS setting.
NOTE: If the fault condition is not cleared, and the RESET button is pushed the
‘FAULT SNAPSHOT’ page will be overwritten.
2.4 Panel Emergency Shutdown (ESD)
An ESD fault is initiated by pressing the ESD pushbutton mounted on the control
panel, opening the Remote ESD discrete input contact, or through Modbus.
When an ESD fault occurs:

− The Fuel and Ignition relays will de-energize.
− The Bypass valve will open.
− The Suction Valve will close completely (0%).
− The Blowdown valve will open to completely de-pressurize the unit
− The ESD relay will de-energize.
No compressor postlube cycle is performed.
3. MANUAL LOADING CONTROL

3.1 Manual Bypass Valve Control
Manual Bypass Valve control is only permitted when the unit has started, automatic
loading control has been initiated, and the engine speed has exceeded the engine
MIN RPM.
When the unit is in the ‘LOADED’ state, the Bypass Valve analog output can be
placed in manual mode from the ‘BYPASS CONTROL’ screen. In manual mode the
operator can select the desired bypass position using the keypad and changing the
MANUAL OUT setting. The output can only be changed between 0 and 100%. The
Bypass Valve output will ramp to the entered value using the OPEN % or CLOSE %
settings every second. If the AUTO/MAN button is toggled back and forth the MC
controller will track the auto setting so a bumpless transfer will occur.
The OPEN % and CLOSE % settings can be adjusted on the ‘MANUAL CONTROL’
setpoint screen (Login Access Level 4).
3.2 Manual Speed Control

The Speed analog output can be placed in manual mode from the ‘SPEED
CONTROL’ screen. In manual mode the operator can select the desired engine
RPM using the keypad and changing the MANUAL OUT setting. The RPM can only
be changed between the MIN RPM and MAX RPM settings. The Speed output will
ramp to the value using the INC RPM or DEC RPM settings every second. If the
AUTO/MAN button is toggled back and forth the MC controller will track the auto
setting so a bumpless transfer will occur.
The INC RPM and DEC RPM settings can be adjusted on the ‘MANUAL CONTROL’
3.3 Manual Suction Valve Control

In manual mode the operator can select the desired Suction Valve position using the
keypad and changing the MANUAL OUT setting from the ‘SUCTION CONTROL’
screen. This is only permitted when the controller is not in a shutdown condition.
The Suction Valve can only be changed between the 0 and 100%. The output will
ramp to the entered value using the OPEN % or CLOSE % settings every second.
The MC controller will track the auto setting so a bumpless transfer will occur. The
Suction Valve control can be placed in AUTO/MAN independent of the speed/bypass
control.
The OPEN % and CLOSE % settings can be adjusted on the ‘MANUAL CONTROL’
4. AUTOMATIC LOADING CONTROL
When a “READY TO LOAD” status is displayed the “LOAD” state can be selected.
From the ‘HOME’ screen the “STATE” line must be selected.
• Press the SETUP ENTER key.
• Press the UP ARROW key. This will change the “STATE” to “LOAD”.
• Press the SETUP ENTER key.
The Speed control will ramp up to the engine MIN RPM. Once the speed reaches
the MIN RPM, the Speed and Bypass outputs will be in Automatic control.
4.1 Automatic Speed Control
The lowest output signal from either the Suction or Discharge Speed Control is sent
to the Speed Control output.
4.1.1 Suction
If the Suction Pressure is above the MAINT SUC + SUC PRS DB (deadband), the
Speed control will increase by the INC RPM value at the UPDATE(ms) rate in an
attempt to reduce the pressure. If the Suction Pressure is below the MAINT SUC -
SUC PRS DB, the Speed control will decrease by the DEC RPM value at the
UPDATE(ms) rate in an attempt to increase the pressure. When the Suction
Pressure is within the deadband of the pressure setpoint no output change will
occur.
The SUC PRS DB, INC RPM, DEC RPM (Login Access Level 4), and UPDATE(ms)
(Login Access Level 3) parameters can be adjusted from the ‘SPD CTRL-SUC’
setpoint screen. The current Auto Mode (SUCTION/DISCHARGE) is also displayed
on this screen.
The MAINT SUC setting can be adjusted from the ‘SPEED CONTROL’ front display
screen (Login Access Level 5).
4.1.2 Discharge
If the Discharge Pressure is above the MAINT DIS + DIS PRS DB (deadband), the
Speed control will decrease by the DEC RPM value at the UPDATE(ms) rate in an
attempt to reduce the pressure. If the Discharge Pressure is below the MAINT DIS
– DIS PRS DB, the Speed control will increase by the INC RPM value at the
UPDATE(ms) rate in an attempt to increase the pressure. When the Discharge
Pressure is within the deadband of the pressure setpoint no output change will
occur.
The DIS PRS DB, INC RPM, DEC RPM (Login Access Level 4), and UPDATE(ms)
(Login Access Level 3) parameters can be adjusted from the ‘SPD CTRL-DIS’
setpoint screen. The current Auto Mode (SUCTION/DISCHARGE) is also displayed
on this screen.
The MAINT DIS setting can be adjusted from the ‘SPEED CONTROL’ front display
4.2 Automatic Bypass Valve Control

The lowest output signal from either the Suction or Discharge Bypass PID is sent to
the Bypass Control output.
4.2.1 Suction
If the Suction Pressure is above the MAINT SUC + SUC PRS DB (deadband), the
Bypass control will increase (closing valve) in an attempt to reduce the pressure. If
the Suction Pressure is below the MAINT SUC - SUC PRS DB, the Bypass control
will decrease (opening valve). When the Suction Pressure is within the deadband of
the pressure setpoint no output change will occur.
The MAINT SUC setting can be adjusted from the ‘BYPASS CONTROL’ front display
The ‘BYP CTRL-SUC’ setpoint screen contains the following parameters and
displays:
SUC PRS DB: Deadband - No output change when pressure is within the range
of MAINT SUC +/- SUC PRS DB. (Login Access Level 4)
PROP COEF: Proportional Coefficient * – (Login Access Level 3)
INT COEF: Integral Coefficient * – (Login Access Level 3)
DERV COEF: Derivative Coefficient * – (Login Access Level 3)
PID UPDATE(ms): Update * - (Login Access Level 3)
P I D Display of the Proportional / Integral / Derivative weights.

E LE Display of the PID error / Last PID error.
BYPASS OUT: Display of Bypass output percentage.
S1 SUC PRS: Display of the current Suction Pressure.
AUTO MODE: Display of the current loop in control of the valve
(Suction/Discharge).
* Refer to Appendix B for detailed descriptions.
4.2.1.1 Gain Multiplier

If the Suction Pressure falls below the SUC BYP THR (suction bypass threshold)
setting it may be due to a condition where the Bypass Valve cannot react fast
enough to avoid a low-pressure shutdown (“pigging” for example). An additional
gain multiplier (BYP GAIN MULT) is used to open the valve faster when the pressure
is below this threshold.
The SUC BYP THR, and BYP GAIN MULT settings can be adjusted from the ‘MISC
SETTINGS’ setpoint screen (Login Access Level 3).
4.2.2 Discharge
If the Discharge Pressure rises above the MAINT DISC + DIS PRS DB, the Bypass
control will decrease (opening valve) in an attempt to reduce the pressure. If the
Discharge Pressure is below the MAINT DIS - DIS PRS DB, the Bypass control will
increase (closing valve). When the Discharge Pressure is within the deadband of
the pressure setpoint no output change will occur.
The MAINT DIS setting can be adjusted from the ‘BYPASS CONTROL’ front display
The ‘BYP CTRL-DIS’ setpoint screen contains the following parameters and
displays:
DIS PRS DB: Deadband - No output change when pressure is within the range
of MAINT DIS +/- DIS PRS DB. (Login Access Level 4)

BYPASS OUT: Display of Bypass output percentage.
DIS PRS: Display of the current Discharge Pressure.
AUTO MODE: Display of the current loop in control of the valve
(Suction/Discharge).
4.3 Automatic Suction Control
The MC controller will control the Suction Valve output based on a pressure setpoint.
If the suction pressure is above the setpoint, the valve will close. If the suction
pressure is below the setpoint, the valve will open. When the Suction Pressure is
within the deadband of the pressure setpoint, no output change will occur.
When the unit is in AUTO and at a STANDBY condition, the Suction Pressure will be
controlled to the START PRS setting. This setting is lower than the normal loaded
Suction Pressure. This will ensure that a minimum load is applied during the engine
start sequence.
Fifteen seconds after the CRANK DIS RPM has been reached, the Suction Pressure
setpoint will start ramping to the MAINT SUC setpoint using two settings: suction
step pressure (SUC STEP P) and start ramp time (ST RAMP TIME). The suction
step pressure is the amount of pressure increase that will be added to the current
suction pressure setpoint. This increase will occur every time the start ramp time
expires. The pressure will be controlled to the MAINT SUC PRS until the unit is
stopped manually or a shutdown occurs. When a shutdown occurs the Suction
Valve will close completely to 0%, until the condition is reset. The control will then
restart using the START PRS setting.
The MAINT SUC, and START PRS settings can be adjusted from the ‘SUCTION
CONTROL’ front display screen (Login Access Level 5).
The ‘SUCTION CNTL’ setpoint screen contains the following parameters, and
displays:
SUC PRS DB: Deadband - No output change when pressure is within the range
of MAINT SUC +/- SUC PRS DB. (Login Access Level 4)
SUCTION OUT: Display of Suction output percentage.
S1 SUC PRS: Display of the current Suction Pressure.
SUC STEP P: Setpoint ramp step size. (Login Access Level 3)
ST RAMP TIME: Time between setpoint ramp steps. (Login Access Level 3)
4.4 Controlled Unload

A controlled unload can be initiated from the ‘Home’ front display screen. The
Bypass Valve will start ramping open to 0% using the manual output settings. The
Speed control will remain in its current position until the Bypass Valve is open to the
BYP P THR DWN position (bypass position for throttle down). The Speed control
will then start decreasing to MIN RPM using the manual DEC RPM settings. When
the Bypass Valve is at 0% and the Speed output is at MIN RPM, the Speed output
will be reduced to the IDLE RPM. The unit will run in this position until a reload, or a
stop is initiated. When a stop is requested, the controller will reduce the RPM to the
Warmup RPM setting. The Cooldown Timer will start and the controller will initiate a
stop after the timer expires.
The BYP P THR DWN setting can be adjusted from the ‘MISC SETTINGS’ setpoint
4.5 Blowdown Valve Control

The MC controller is equipped with automatic blowdown logic. If the Suction
Pressure is above the BD VLV OPEN setpoint, the Blowdown Valve output will de-
energize to open the valve, and reduce the pressure. When the Suction Pressure
falls below the BD VLV CLS setpoint the Blowdown Valve output will energize to
close the valve. The logic is only active when the MC is in the “STANDBY” or
“SHUTDOWN” condition. If the unit is started while in the “BLOWDOWN” state, the
relay will energize, and the start sequence will begin.
The BD VLV OPEN/CLS settings can be adjusted from the ‘MISC SETTINGS’
5. COMPRESSOR ROD LOAD CALCUATIONS
Compressor stage differential pressure alarm/shutdown calculations are based on

the specific cylinder characteristic curves.
The rod-loading calculations are based on the compressor suction and discharge
pressures, in conjunction with a Rod-Loading formula.
When doing calculations for stage 2, and stage 3 (as applicable) the previous stages
discharge value will be used as the setpoint value for PS.
6. LOW CLASS P DISCHARGE LOGIC
Low class P discharge logic is provided for each compressor discharge stage. A
CLASS P Timer will start once the Bypass Valve reaches the BYP POS P LK preset
position. The Class P functions are armed once the CLASS P Timer expires. The
shutdown will disarm when the Bypass Valve position falls below the BYP POS P LK
preset position.
The CLASS P Timer, and BYP POS P LK setting can be adjusted from the ‘TIMERS’
7. MISCELLANEOUS
7.1 Password Protection
The parameters that are adjustable from the screens are grouped into different
access levels. A login code is required to access each level. Login level (5) is the
default level.
The Login entry is located in the ‘SETUP MENU’ screen. To Login with a higher-
level code, the cursor must be placed on the Login line, and then the SETUP ENTER
key must be pressed. The cursor will move over the zero displayed on the right side
of that line. A level pass-code can now be entered. There are four access levels
ranging from level (4), the lowest privilege level up to level (1), the highest privilege
level.
• Level (1) - called the Administrator level. Complete access. The Project, and
or Application can be deleted, outputs can be forced off and on, a Remote
Debugger can be run, the administrator menu is available, and the real time
clock can be set.
• Level (2) – access to input calibrations, and SERVICE MODE forcing of
outputs.
• Level (3) – access to settings that could cause improper operation of the
machine.
• Level (4) - access to settings that will not cause improper operation of the
machinery.
All login levels have a common timer that starts to count down after each key press.
If there are no key presses for the length of the Inactive/AutoLogout Delay, then the
Login level will revert to the base Login level (5).
7.2 Verify Discrete Input / Outputs

The open (0) or closed (X) status of each discrete input, and the off (0) or on (X)
status of each discrete output can be viewed from the HMI ‘INPUTS’ front display
screen.
7.3 Service Mode

The unit is equipped with a “SERVICE MODE”. The technician can use this mode to
force relay outputs and analog outputs to ensure proper operation of connected
devices. When the unit is in a “STANDBY” or “SHUTDOWN” state press the FN key,
confirm “Fn Key Activated” is displayed, and then press the TEST key.
When the timeout expires the unit will switch back to STANDBY or SHUTDOWN
mode. All relay outputs will turn off when in the SERVICE MODE. When the service
mode is exited normal panel operation will start. Login level (2) is required to enter
this mode.
Note: The ESD relay will be de-energized when in the SERVICE MODE.
7.4 Test Mode

The unit is equipped with a TEST mode for testing discrete input functionality.
Analog values are not normally tested, due to the ability to read the actual value of
the parameter. Pressing the TEST key activates the TEST mode. The preferred
display page is D-3 as the test timer and status can be observed. When a switch is
faulted, a 4-line alarm message will appear. No parameters are logged in the
snapshot page or the EVENT history.
7.5 Run Time Hours

The engine Run Time Hours can be viewed from the HMI ‘HOME’ screen. Run Time
Hours can be reset on the ‘RPM SETTINGS’ setpoint screen.
7.6 Speed Output Actuator Adjustments

The THR OUT MIN, and THR OUT MAX settings can be used to match the controller
output to the resulting engine speed. The THR OUT MIN is the RPM value when
4mA is applied, and the THR OUT MAX is the RPM value when 20mA is applied.
Some extrapolation may be required if 4mA is lower than the actual minimum speed
output, or if maximum speed is achieved with less than 20mA.
The THR OUT MIN, and THR OUT MAX settings can be adjusted from the ‘MISC
CAL’ setpoint screen (Login Access Level 2).
8. MODBUS COMMUNICATIONS
This panel will be provided with MODBUS functionality. The following points will be
available for read-only access:
• All Analog Input Readings
• All Analog Output Values (percent)
• Speed Output (RPM) Reading
• All Thermocouple Input Readings
• All Discrete Input Open/Closed Status
• All Discrete Output On/Off Status
• Engine Run Time Hours
• Alarm and Shutdown Event Codes
The following points will be available for read/write access:

• Remote Start
• Remote Stop
• Remote Reset
• Remote Engine Maximum Load Speed Setpoint
• Remote PID Control Setpoints
• Load / Unload
• Alarm / Shutdown setpoints
Note: A complete address list will be provided in the Event List and Modbus
Map document for this project.
8.1 Local / Remote Mode

The Local and Remote Stop, Start and Reset commands are active at all
times.
APPENDIX A
Input/Output List
See project I/O list provided separately.
APPENDIX B
Definitions
Table B-1: Alarm/Shutdown Classification, and PID Definitions
Class Description
Class A Class A alarm/shutdown functions are always enabled. All Class A shutdowns must
be cleared before the unit can be started.
Examples: Engine Oil Level, Cylinder Discharge Temperature
Class B1 Class B1 alarm/shutdown functions are disabled until the B1 Timer expires.
Examples: Low Comp Oil Pressure
Class B2 Class B2 alarm/shutdown functions are disabled until the B2 Timer expires.
Examples: Compressor Rod Reversal
Class C Class C alarm/shutdown functions are disabled until the unit is running. Class C
functions are then individually monitored. When a Class C function becomes healthy
it is enabled, and will cause an alarm/shutdown if it then goes unhealthy.
Class P Class P alarm/shutdown are armed once the bypass valve reaches a preset position
and a P timer expires. The shutdown will disarm when the bypass valve position falls
below the preset position.
Prop Coef The Proportional coefficient for the PID loop. This is a multiplier for the error (PV
minus setpoint) and will determine how the error will directly affect the amount of
change in output. Too low a number here will result in sluggish action of the PID
loop. Too high a number here will result in overshoot and oscillation of the PID loop.
Int Coef The Integral coefficient for the PID loop. This is a multiplier for the amount of time the
error (PV minus setpoint) has been above or below setpoint. The more time that
passes before the loop reaches its setpoint, will directly affect the amount of change
in output. Use this number to balance out overshoot caused by the Proportional part
of the PID loop. Too low a number here will take out the Integral part of control of the
PID loop. Too high a number here will result in oscillation of the PID loop.
Derv Coef The Derivative coefficient for the PID loop. This is a multiplier for how fast the error
(PV minus setpoint) is changing. The faster the PV or setpoint changes will directly
affect the amount of change in output. Use this number to catch spikes in pressure.
Too low a number here will take out the Derivative part of control of the PID loop.
Too high a number here will result in oscillation of the PID loop.
PID Update Set the delay in milliseconds for the PID loop calculation to allow the PV readings to
(ms) update and stabilize to the changing conditions caused by the PID loop. Too fast an
update time will result in oscillation of the PID loop. Too slow an update time will
result in a sluggish PID loop.
PLEASE APPROVE AND RETURN.
Comments: ________________________________________________________
__________________________________________________________________
__________________________________________________________________
Approved by: ________________________ Approval date: _________________
END DOCUMENT

Spartan Controls Millennium Compressor Control Panel Operating Philosophy

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Spartan Controls Millennium Compressor Control Panel Operating Philosophy

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Spartan Controls Ltd. Universal Comp.

Date: October 14, 2005

Project: Stock Revision 1 Page 1

Vendor: Spartan Controls Ltd.

Vendor document: Operating Philosophy

Date September 23, 2004 June 2, 2006

DOCUMENT ACCEPTANCE & APPROVAL

Certification of acceptance and approval of Revision 0 of this document.

Customer name signature: ______________________________ Date: ____________

Spartan Controls Ltd. signature: ______________________________ Date: ____________

Spartan Controls Ltd.

Project: Stock Revision 1 Page 2

CUSTOMER SERVICES NETWORK

Spartan Controls Ltd.

Project: Stock Revision 1 Page 3

1.1 General ..................................................................................................................................... 5

2. START-UP / SHUTDOWN SEQUENCING ............................................................... 6

2.1 Compressor Cooldown Stop...................................................................................................... 8

3. MANUAL LOADING CONTROL ............................................................................. 11

3.1 Manual Bypass Valve Control ................................................................................................. 11

4. AUTOMATIC LOADING CONTROL....................................................................... 12

4.1 Automatic Speed Control......................................................................................................... 12

5. COMPRESSOR ROD LOAD CALCUATIONS ....................................................... 16

6. LOW CLASS P DISCHARGE LOGIC..................................................................... 17

7.1 Password Protection ............................................................................................................... 18

Project: Stock Revision 1 Page 4

7.4 Test Mode ............................................................................................................................... 19

8. MODBUS COMMUNICATIONS .............................................................................. 20

8.1 Local / Remote Mode .............................................................................................................. 20

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This document outlines the Millennium compressor control panel operating

The display/control/communications control module (Head) contains the

1.2 Standard Base System

1.3 Optional Functionality

Project: Stock Revision 1 Page 6

2. START-UP / SHUTDOWN SEQUENCING

If the Suction Valve control is in AUTO, the Suction Pressure will be

Table 2-1 describes the start-up sequencing in detail.

Table 2-1: Start-Up Sequencing

• If the compressor permissive pressure is not reached at the expiration of

Project: Stock Revision 1 Page 7

duration of the PRELUBE DLY timer.

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2.1 Compressor Cooldown Stop

When the COOLDOWN DLY timer expires:

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2.2 Alarm Stop (Optional)

When the COOLDOWN DLY expires:

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2.3 Engine / Compressor Shutdown

A SHUTDOWN is initiated if a discrete shutdown switch trips, an analog shutdown

When a shutdown occurs:

2.4 Panel Emergency Shutdown (ESD)

When an ESD fault occurs:

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3. MANUAL LOADING CONTROL

3.2 Manual Speed Control

3.3 Manual Suction Valve Control

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4. AUTOMATIC LOADING CONTROL

4.1 Automatic Speed Control

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Customer name signature: __________________ Date:

Spartan Controls Ltd. signature: __________________ Date:

Approved by: ________ Approval date: _