@ CAMERON Maestro Legend Initial Startup Guide Engineering Data Release: EDR-K-055 Rev. 1: 1930081 08/28/03, cl Rev. 2 05/03/06 PB Quality from Compression SystemsMaestro Legend — Initial Startup Guide INTRODUCTION The following document is intended to assist factory trained and authorized service personnel in the initial startup of Cooper Compression compressors equipped with a Maestro Legend (formerly Vantage 5) control panel, The main purpose of the document is serve as a guide in the proper field set up of the Maestro Legend control panel. Some ‘compressor commissioning information is included, but this is not all that is required, Each authorized service representative must follow the proper compressor commissioning procedures as well DESCRIPTION When performing a compressor startup with a Maestro Legend operating system you will need to have a portable computer loaded with the Vantage Desktop software, and a proper PC to Maestro legend communication cable. You will also need to have a valid User ID and Password to access the Online Support feature of the vantage-solution.com website NOTE: All Cooper and authorized distributor service personnel need to be registered to the Vantage-Solution WEB site for configuration archiving and easy access to the latest versions of the software and documentation. BEFORE TRAVELING TO THE JOB SITE To properly commission a compressor with Maestro Legend control, be sure to have the following items © PC (Windows NT 4.0/95/98/2000/ME/XP) w/Vantage Desktop Software installed. © RS-485 to RS-232 communication adapter and cable* to connect PC to panel, © Compressor Model and Serial Number (if possible) © Acopy of the as-shipped Maestro Legend configuration, if possible. © Maestro Legend License No, _- - - andKeyCode __- __, if possible. “The panel communicates with the PC through a RS-485 port. Therefore, the connecting cable must have an RS-485 connector on one end (for the panel), and the proper connector for the PC's com port on the other. if the PC has an RS-232 port, a RS-232 to RS-485 converter is required. If the PC has a USB port, an isolated USB to RS-485 converter is required *PC to Maestro Legend Connector Information: L Type Cooper Part No. Manufacturer Manufact. Part No, RS-232 to RS-485 | _ AAA3794960-00667 B&B Electronics 485SD9TB (with cable & 485 connector) USB to RS-232_ Not Available B&B Electronics 301-1001-15 EDR-K.055 Rev2 Page 2Maestro Legend — Initial Startup Guide AT SITE, BEFORE APPLYING POWER TO THE PANEL, Upon reaching th for a new compressor startup, follow Cooper's required compressor commissioning procedures, which include instructions for checking and setting up the Maestro Legend panel. An important part of this is to perform the following checks before first applying power to the panel: © Check that the isolating Block Valve is closed © Verify that the customer supplied control panel power is correct Verify the proper earth grounding of the panel © Check wiring for correctness, loose wires © Check the location of the system pressure transmitter © Check motor starter interface wiring from the panel © Check Main motor and auxiliary oil pump overload settings APPLY POWER TO THE PANEL Perform the following checks, after applying power to the panel for the first time. Make sure that the isolating block valve is fully closed before applying power. Note that the panel will be in the “Stopping” mode when initially powered up. © Verify proper AUX oil pump operation © Check the status of all Monitoring Points and correct any faults. © Verify the proper operation of the compressor inlet and discharge valves. ©. Input the correct Equipment Settings and Set Point values. SAVE THE EXISTING CONFIGURATION FROM THE MAESTRO LEGEND TO YOUR PC Saving the configuration synchronizes the PC files with the existing panel configuration Connect your PC to the panel and run the Vantage Desktop program. From the menus select File>New. Then enter the license number and press Next. The license number is found by selecting ‘Information’ in the View menus. V Software License Number ‘The contol stern scars erst separate fr each Vaniagecorl ster, Each contol stam identified th a uriqueHeerew nurboe composed ef outmost Ihesidecnal numbers cepetated ty hyphens Urtinie AF for fr |r “The feense number shoud be provided ith the cont jslem Ceniac the supa of he ‘corte stem you ate unabie tor ct have quectons aba the icense EDR-K-055 Rev2 Page 3Maestro Legend ~ Initial Startup Guide In the Choose Configuration screen, select ‘Get from the Vantage Controller’. Press Next. i _ [Blew Contain Fs | codper Tutboceressor TA.2000 et Toco TA tno |GooveTurbocemeresser TAS) After the configuration is downloaded, the License Key Code dialog will be automatically filled in with the Key Code from the controller. When the upload completes, the ‘Configuration Created screen appears. Click Finish to complete the process. The entire configuration on your PC. © Review Configuration Use Vantage Desktop to review the entire configuration. Make any changes, and then be sure to send the final configuration back to the panel. Then, check in the revised configuration at vantage-solution.com when you have internet access. EDR-K.055 Rev2 Page 4Maestro Legend ~ Initial Startup Guide COMPLETE THE COMPRESSOR INSTALLATION REQUIREMENTS ‘Complete all of the compressor installation pre start requirements, as detailed in the compressor Handbook, and in Cooper's Startup checklist, and prepare for the initial run. PERFORM THE INITIAL COMPRESSOR START UP (TEST RUN) «Apply main power supply to the compressor and control panel. Be sure block valve is closed, AUX oil pump is on, and coolant supply is present. Turn on clean, dry air supply (if present) to air ejector. Be sure the condensate drain manual bypass valves are closed. START the compressor, and measure the acceleration time to full speed (in sec.) During acceleration, verify correct starter performance, and control panel messages. Make sure that the AUX pump shut off is at the correct time. Press UNLOAD immediately after the panel changes from Starting to Running status. Verify normal compressor operation. Continue running Unloaded at least 30 minutes. Check that the inlet valve unloaded position is correct. Make adjustments if needed Prepare for initial manual loading of the compressor. Do not run into the system yet. INITIAL COMPRESSOR LOADING + With the block valve closed, manually load the compressor, by first opening the inlet valve to Full Load amps, and then closing the blow-off valve to the System Pressure SP. + Allow the compressor to run loaded at least 60 minutes (to achieve thermal growth), and prepare to find the required surge point data. FIND THE REQUIRED SURGE POINTS, USING MANUAL VALVE OPERATION* Each surge point consists of a compressor discharge pressure, and the corresponding amperage when surge occurs at that pressure. The panel requires three surge points, and a fourth (Natural Surge) is required by Cooper's Startup Report. Perform the Natural Surge test, if possible, to document compressor capabilities + Perform the High Throttle Surge test, at a discharge pressure at least 5% above the System Pressure Offset setpoint, but below the Discharge Pressure Limit setpoint = Perform the Mid Throttle Surge test, at a discharge pressure equal to the customer selected System Pressure setpoint. Note that the surge amps found here will be the basis for the Surge Control Offset setpoint * Perform the Low Throttle Surge test, at a compressor discharge pressure approximately 15% below the System Pressure setpoint. + Enter the High, Mid, and Low Throttle surge point results into the control panel, Then, check the resulting Surge Line, and Surge Control Lines on the Performance screen for correctness. * Note: After the manual surge data is obtained, try to perform the 3 ‘automatic’ surge tests, as reference material. However, to do this, the compressor discharge valve must be the MBOV type. EDR-K-055 Rev 2 Page 5Maestro Legend ~ Initial Startup Guide PERFORM THE REQUIRED MAESTRO LEGEND CONTROL VALVE TUNING Note: Be sure to tune the control loops as taught, in the proper order. Do not run the compressor into the customer's system when tuning the first three loops. Tune the Inlet Maximum Load control loop first, at approximately Full Load amps Tune the Inlet Surge Control loop, at an amperage 5 to 10% greater than Surge Control amps. Tune the Blow-Off Discharge Pressure control loop’, at a discharge pressure about 5% above the Blow Off System Pressure setpoint When finished with the above tuning, Unload the compressor. The above tuning data is automatically saved by the panel. Next, open the block valve and run the unit in the Automatic control mode. Tune the Inlet System Pressure control loop while running into the system Tune the Blow-Off System Pressure control loop* while running into the system. Enter the final tuning parameters into the panel Observe compressor operation through several load cycles (if existing) to verify the correct performance of all control loops. If any changes are required, repeat the tuning for those loops. “Note: Blow —Off control loops can only be tuned if the compressor discharge valve is the modulating blow-off type. If the compressor discharge valve is the Bypass type, Blow-Off tuning is not required COMPLETE THE MAESTRO LEGEND CONTROL CONFIGURATION Caution: Do not use the Desktop wizard to make configuration changes after surge tests and tuning, It will set incorrect values and the unit will not run proper Set the Operator, and Equipment Settings at the panel Set the Control Parameters and Commissioning Settings at the panel Enter access codes for Commissioning and Tools screens, if required. Save the final Maestro Legend configuration to your laptop, and then be sure to send it to the vantage-solution.com website. TRAIN THE CUSTOMER ON ALL USER ACCESSIBLE FEATURES Before completing the start up service call, be sure to train the customer on the basic functions of the control (view screens, control modes, etc.) The best way to do this is the ‘walk him through’ the control section in the compressor handbook EDR-K-055 Rev2 Page 6@ CAMERON Compression Systems ROUTINE COMPRESSOR OPERATION TYPICAL ROUTINE START UP PROCEDURE level in the oil tank. 5),.Close condensate drain manual bypa 1) Verify the correct s valves. 3) Open the main coolant supply and return valves. 4) Adjust air ejector regulator supply pressure to obtain the required gear box vacuum, 5) Rack in the main power to the compressor and driver. 6) Apply panel power and verify operation of the AUX oil pump. 7) Verify correct oil pressure, and check for water and oil leaks. 8) Open the isolating discharge block valve (if non-automatie). 9) Verify that the control panel’s starting sequence parameters are met. 10) Press the Start key and observe the successful completion of the start sequence. 11) Observe the unit accelerate (o full speed, and verify the tuming off of the aux pump. 12) Observe the unit loading into the plant air system when it is called upon, (OTE: No matter what type of drain control device is used, a manual bypass should be included in the condensate piping. Prior to any compressor shutdown, the bypass valves around the control | device should be opened and not closed again until the compressor is ready to be put back in | operation. These open drains prevent any water accumulation in the compressor from excess condensate or failure of an intercooler tube. J This document end al information therein is the property of and confidential lo Cameron Compression Systems. I must Not be made public or copied. tis loaned subject to return upon demand. It is not to be used directly or indirectly in any \way detrimental tothe interests of Cameron Compression Systems. -@ CAMERON Compression Systems Tra ROUTINE COMPRESSOR OPERATION TYPICAL ROUTINE SHUTDOWN PROCEDURE NOTE: If another compressor will be run to supply the plant system when this compressor is shut| down, be sure to that the replacement compressor has been started and loaded into the system before shutting down this unit, 1, Press STOP key and observe the automatic unloading of the compressor. When unloaded, the control will drop out the power to the drive motor, stopping the compressor. WARNING: Never attempt a restart until the compressor has completely stopped rotating. Close the air system isolating block valve (if non-automatic). Open the condensate drain bypass valves (Close again before the unit is put back into service). Allow the lube oil and cooling water to circulate fora minimum of 30 minutes to remove heat from the compressor. Close the cooling water supply valves, if desired. Tum off the electric AUX oil pump. if desired. ‘Tum off air supply to air ejector if desired. Pull the main power disconnect to the drive motor starter, if desired, Ps en (CAUTION: If the compressor is to be shut down for an extended period in a cold environment, drain all water from the system, or continue to maintain some water flow through all coolers. Even! small amounts of residual water can freeze and damage cooler tubes. {This document anc’ all information therein is the property of and confidential to Cameron Compression Systems. it must | not be made public or copied. It is loaned subject to return upon demand. Its not to be used directly or indirectly in any | way detrimental to the interests of Cameron Compression Systems.STD. COMPR. START-UP REPORT Compressor S/N: Model: ‘CUSTOMER: Location: SONTACT:, TITLE: PHONE SERVICE TECH: COMPANY: DATE: _ COMPRESSOR INFORMATION — DESIGN PRESSURE: DESIGN FLOW: DESIGN HP: CONTROL TYPE: VERSION CONTROL MODE, INLET YALVE TYPE: INLET VALVE ACTUATOR DISCHARGE VALVE TYPE DISCHARGE VALVE ACTUATOR: “MAIN DRIVE MOTOR /ST.ARTER INFORMATION MOTOR MFR, MOTOR FLA: AMPS STARTER MER MOTOR HP: __ | SERVICE FACTOR: STARTER TYPE MOTOR VOLTS: crRario, cTRATIO. (ENTERED) INLET FILTER PRESS. DROP AIR TEMPS C1STAGE 11 STAGE2 GISTAGES C1 DISCHARGE AIR OIL FILTER PRESS OROP NUMBER OF VIBRATION CHANNELS: CLMOTOR STATOR TEMPS, CI MOTOR BEARING TEMPS. | a MoToR vis, MONITOR ‘CONTROL PANEL OPTIONS: KEY.CONTROL SYSTEM SETPOIN Wax WOTOR LOAD’ SYSTEM PRESS. OFFSET i « SYSTEM PRESSURE [MAX DISCHARGE PRESS ° SURGE OFFSET SURGEWATCH: GAN Te See FINAL ALK ena SHAFT SEPARATION MOTOR INDICATOR —_ woTOR FLOAT;_ foales FINAL COMPRESSOR OPERATING DATA sySTEMPRESSURE ST61 VIBRATION / GAP AIR EJECTOR PRESSURE. DISCHARGE PRESSURE ST62 VIBRATION / GA. Ot FILTER PRESS. DROP. LOADED AMPS ST63 BRATION GAP INLET FILTER PRESS. ROP UNLOADED AMS, STAGE 2INLET TEMP TEMP. AT COMPRESSOR INLET MAIN OIL PRESSURE, STAGE 3 INLET TEMP. TEMP. AT MOTOR INLET. OIL TEMPERATURE. GEARBOX VACUUM MOTOR BRG TEMPS: SURGE POINT: DISCHARGE PRESSURE ‘AMES MOTOR STATOR: HIGH THROTTLE COOLANT TEMP. IN Mio THROTTLE “wat pressure SP) | COOLANT TEMP. OUT. Low THROTTLE: ‘ACCELERATION TIME SEC NATURAL SURGE PT: DISCH PRESS: AMPS: START UP COMPLETION DATE: OM TYPE: COOLANT TYPE: DRIVE COUPLING TYPE: COGEARED —GOISC PACK (COUPLING BOLT TORQUE ‘BOLTS LUBED FTLBS CO BOLTS NOT LUBED PAGE 1 OF 3STANDARD COMPRESSOR INSTALLATION CHECK LIST This check list must be completed and submitted with the start up report on all new installations. 1. INSTALLATION Machine level checked Anchor bolts tight INLET FILTER HOUSING ‘Housing cleaned and inspected Elements installed correetly/flow arrow verified Housing located away from contaminant sources, 3. INLET PIPING Inlet piping sized correctly Long radius elbows used Maintenance flange installed Expansion boot installed correctly Piping supported adequately Start up screen inspected and installed correctly Piping cleaned and inspected intemall 4. DISCHARGE PIPING Discharge piping sized correcth Long radius elbows used Expansion joint installed Isolating biock valve installed correctly Discharge check valve properly installed and low arrow correct Blow off valve pipe correct size and location (per CCS drawing) Minimum number of elbows in blow off line Silencer bolted directly to blow off valve Piping volume between discharge flange and discharge check vaive per drawing Instrument air and control tubing sized correctly and leak checked 5. COOLING WATER PIPING Water piping sized correctly Water in and water out piped correctly Condensate traps piped individually to open drains ‘Condensate trap bypass lines installed ‘Water throtile valve located on water out line Water shut off valves installed Maintenance flanges installed in water piping 6 OL SYSTEM. Electric pump rotation checked and correct ‘Cameron Compression Systems specified type and amount of oil installed Oil flush completed, for required number of hours Oil pressure regulating valves set. Oil filter changed after Nush completed Main drive motor bearings filled with correct type and amount of lubricant Oil heater parameters properly set Tow oil pressure trip verified during motor uncoupled ran Air ejector air supply as required (clean, dry and correct amount) PAGE 2 0F 3STANDARD COMPRESSOR INSTALLATION CHECK LIST con’t. 7. WIRING Main drive motor and its starter wired correctly ‘All monitoring sensors (including C.T.) wired correcth Vibration cables connected in correct order: connectors properly tightened Start/Stop circuit verified Oil pump circuit verified Proper earth ground installed 8. CONTROL SYSTEM. Control system configured correct G.T. Seale factor correctly entered Vibration probes properly set ‘Compressor Inlet and Discharge valves both checked to verily proper srokes Discharge and System pressure sensor taps located correctly 9. STARTER, MAIN DRIVE MOTOR and COUPLING Motor Starter parameters properly set (if applicable) ‘Motor bearing Jubricant installed per manufacturer’ ‘Main driver rotation correct Soft foot checks completed and corrected if required Motor/Compressor axial shaft separation correct ("d" distance) Horizontal and vertical motor alignment complete and correct, Main drive coupling lubricated (if applicable) All drive coupling bolts properly torqued to specified values Motor floated with coupling installed Motor doweled as required by manufacturer Coupling guard installed Final motor alignment data (dial indicator readings) shown on Start-Up Report 10. COMPRESSOR OPERATION Surge tests completed / correct control set points entered Controls properly tuned with compressor at full operating temperature All measured levels acceptable (vibration, amps, pressures, temperatures) No oil leaks Il. CUSTOMER ORIENTATION Start up/ Shutdown procedures fully explained Operating training completed Routine maintenance training completed 12, DOCUMENTATION ‘Start-Lip Report completed in full, and copy left with customer Final control configuration sent to web site ‘Submit this final Start-Up Report electronically to: CTC-Warranty@e-a-m.com COMMENTS: SERVICE TECH SIGNATURE: PRINT: COMPANY: DATE: PAGE 3 OF 3| | @ CAMERON Compression Systems Training LOADING THE VANTAGE 5.0 PROGRAM INTO THE VANTAGE PANEL. The laptop must be powered up with the vantage desktop program displaying the 5.0 configuration for the compressor being worked on. PROCEDURE TO CONNECT THE LAPTOP Connect the Vantage-to-PC cable between an open serial communications port on the personal computer/laptop, and the C-Link communications port on the Vantage controller main logic module (MLM). The C-Link communications port is identified as “J2” on the main logic module and is located on the upper left corner of the module. If more than one main logic module is in use, connect to the master MLM. This is the MLM that is connected to the user interface module by a display cable. This cable will be connected to “J1” PROCEDURE TO ERASE THE MLM It is necessary to erase the MLM completely. To do this the following procedure is used: . Turn off the power to the controller. . Wait 2 seconds. ‘Turn power back on to the controller . When the first display appears, which shows the serial number, press the Set Points key within 3 seconds of the display appearing. If you do not press the key in time, start over, 5. When prompted, press the Enter key to erase the module. Use the Increase and Decrease keys to set the correct digit of your license number and press the Enter key when the correct digit is displayed. You will need to select each digit separately, a total of 8 digits, If you make a mistake, press the Back key to select the digit, and use the Increase and Decrease keys to change the displayed digit. Once the last digit is set, the license number is written into memory and the Vantage then begins to load the sofiware, and displays the progress using a progress bar on the main sereen. At this point the new 5.0 configuration is loaded and the new performance control sereen is displayed. This document and all information therein is the property of and confidential to Cameron Compression Systems. lt must ‘not be made public or copied. ts loaned subject to return upon demand. It is not to be used directly or indirectly in any way detrimental tothe interests of Cameron Compression Systems.