3211566B Operation Secuence

CONTROL SYSTEMS AND SERVICES
105 RANDON DYER ROAD, ROSENBERG, TX 77471

TEL. (281) 633-4500, FAX (281) 633-4588
EXTERRAN
Operation Sequence
52-32-11566
Rev B
UNIT(S)
US-123106-01
Waukesha L5774LT ESM Driven

2 Stage / 4 Throw
Ariel JGK Compressor
DRAWING: # 52-29-11566
# 52-30-11566
SEQUENCE: # 52-32-11566
PROGRAM: # 52-34-11566
52-32-11566 Rev A 1/24/2019
TABLE OF CONTENTS:
1.0 TYPE OF SYSTEM ............................................................................................................................. 3

2.0 CONTROL PANEL POWER ON ......................................................................................................... 3
3.0 WAUKESHA ESM OPERATION NOTE ............................................................................................. 4
4.0 FIXED / VARIABLE ESM ENGINE SPEED CONTROL MODE ......................................................... 4
5.0 UNIT NOT READY TO START ........................................................................................................... 4
6.0 UNIT READY TO START .................................................................................................................... 4
7.0 COMPRESSOR & ENGINE PRELUBE .............................................................................................. 5
8.0 ENGINE START .................................................................................................................................. 6
9.0 UNIT READY TO LOAD ...................................................................................................................... 7
10.0 UNIT RUNNING – LOAD CONTROL ENABLED ................................................................................ 8
11.0 ENGINE SPEED CONTROL ............................................................................................................... 9
12.0 1ST STAGE RECYCLE VALVE CONTROL ..................................................................................... 10
13.0 2ND STAGE RECYCLE VALVE CONTROL .................................................................................... 10
14.0 UNIT NORMAL STOP ....................................................................................................................... 11
15.0 UNIT SHUTDOWN ............................................................................................................................ 12
16.0 UNIT EMERGENCY STOP ............................................................................................................... 13
17.0 GENERAL VALVE OPERATION ...................................................................................................... 14
18.0 WAUKESHA ESM AND RED LION RTU COMMUNICATIONS FAILURE....................................... 14
19.0 TEST MODE ..................................................................................................................................... 15
20.0 PLC I/O FORCING (MANUAL OVERRIDE) ..................................................................................... 15
21.0 ROD LOAD CALCULATIONS ........................................................................................................... 16
22.0 ALARM AND SHUTDOWN FUNCTIONS ......................................................................................... 17
23.0 CONFIGURABLE PROCESS VARIABLES (adjustable via the HMI/MMI) ....................................... 23
24.0 PASS CODE ACCESS ..................................................................................................................... 26
25.0 COMMUNICATION CONFIGURATION ............................................................................................ 26
26.0 MODBUS/PLC CONTROLLER TAGS DCS/SCADA DATA MAP .................................................... 27
29.0 WAUKESHA ESM MAP .................................................................................................................... 39
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1.0 TYPE OF SYSTEM
1.1 The control system consists of an Allen-Bradley CompactLogix PLC (1769-L36ERM). An Allen-Bradley
PanelView Plus 10” color touchscreen will provide the HMI/MMI (Human Machine Interface) between the
PLC and the operator. The HMI will display all active alarm or shutdown conditions on the Active Alarm
Display screen. A History of the last 1000 alarm or shutdown conditions in chronological order on the
Alarm History screen. A First Out Shutdown banner is located on the Active Alarm Display and Alarm
History screens to display the annunciation of the first out shutdown event.
1.2 The Communication between the PLC, HMI and remote devices is available via the 5-port RJ45 Ethernet
switch. Remote Modbus communication is available via Modbus RTU and Modbus TCP/IP protocols
using the Red Lion (with XCRS expansion card) DSPLE001. An XCRS expansion card with additional
RS485 and RS232 ports is included to assist with additional communication requirements.
1.3 The control system is powered by user-supplied 110-130VAC, 50/60 Hz @ 20A. The power feed
supplies power to two power supplies PSU1 and PSU2. The power supply PSU1 provides 24VDC @
20A for use by the PLC and associated I/O, HMI, RTU and Ethernet Switch. The power supply PSU2 and
provides 24VDC @ 20A for use by the Waukesha ESM.
NOTE: Throughout this document, it is understood that when a digital output is acted upon to be
Energized or De-Energized, it will remain in that state until described otherwise due to a process
requirement, a Unit Normal Stop, a Unit Shutdown, or a Unit ESD condition. Also, various setpoints
discussed throughout the document are adjustable via ‘Timers & Miscellaneous Setpoints’ HMI/MMI
screens unless described otherwise (Please refer Section 23.0 for further details).
2.0 CONTROL PANEL POWER ON
2.1 When the Main Power ON/OFF selector switches (SW1) is turned to the ‘ON’ position; the PLC, HMI/MMI,
Waukesha engine, Panel Power On and Engine Power On pilot lights (PL1 and PL2) will power ‘ON’. The
PLC program will begin executing, all the I/O will be scanned and the HMI/MMI will display any alarms
and/or shutdowns that may exist.
NOTE: All PLC controlled local indication lights with the exception of the ‘POWER ON’ lights can be
tested for failure by pressing and holding the ‘LAMP TEST’ HMI touch button located on the Alarm History
and Alarm Display HMI screens.
2.2 While the panel power is ‘ON’, when the Panel Light ON/OFF selector switch (SW3) is turned to the ‘ON’
position, the LED panel light(s) will power ‘ON’.
2.3 The HMI/MMI has a status banner at the top of every page which shows the current operational status of
the unit.
2.4 While the system is powered ‘ON’, the PLC Communication and I/O modules will be monitored for loss of
communication with the processor. If any Communication and/or I/O modules lose communication with
the processor, the unit will fault for the respective module fault. See section 22.0 for more detail.
2.5 If a Non-ESD Class shutdown exists, the status banner will display “UNIT SHUTDOWN – CHECK
ACTIVE ALARM DISPLAY / HISTORY FOR REASON OF FAILURE”. (SEQ_STEP=10)
2.6 When a Class ESD type shutdown condition exists, the status banner will display “UNIT ESD –
EMERGENCY STOP CONDITION EXISTS”. (SEQ_STEP=0)
2.7 An ESD type shutdown will occur under any of the following conditions:
 Local Emergency Stop digital input is De-Energized

 Remote Emergency Stop digital input is De-Energized
 High Engine Speed From ESM OP1 Shutdown
 Engine Speed From ESM OP1 Out of Range Shutdown
 The Unit Fail To Stop Timer expires (See Section 14.0)
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 ANY I/O Module Fault exists
2.8 To clear a shutdown condition in the system, the operator must first correct the identified fault and then
press the ‘LOCAL RESET’ pushbutton to clear the fault condition from the system. When all shutdown
conditions have been cleared, the sequence will advance to Unit Ready to Start (Section 6.0).
3.0 WAUKESHA ESM OPERATION NOTE
3.1 WAUKESHA ESM COOL DOWN TIME: In order for this system to shutdown properly, no cool down time
should be programmed into the Waukesha ESM ignition system. Cool down cycles will be controlled by
the PLC. The Waukesha ESM will be shutdown using the normal stop input, unless the shutdown cause
is an ESD condition. This prevents backfiring of the engine, delays the grounding of the ignition by the
ESM, and allows the engine to post-lube under non-ESD type fault conditions and normal stop cycles.
4.0 FIXED / VARIABLE ESM ENGINE SPEED CONTROL MODE
4.1 There are two modes of Fixed/Variable ESM engine speed control, 1) IDLE / RATED Speed Control (via
PLC digital output) and 2) REMOTE VARIABLE Speed Control (via PLC analog output 4-20mA),
selectable via the ‘IDLE / RATED’ and ‘REMOTE VARIABLE’ HMI/MMI touchbuttons.
NOTE: The engine speed control mode is selected before the unit is started.
4.2 When IDLE / RATED Speed Control is selected and the unit is NOT in the load control enabled state, the
Engine Idle/Rate Speed Setting to ESM and the Remote Speed Setting Enable to ESM digital outputs will
be De-Energized. The engine will ramp to its IDLE speed setting (configurable in the ESM via the ESP
software; reference ESP software, this is a user defined setting).
4.3 When IDLE / RATED Speed Control is selected and the unit is in the load control enabled state, the
Engine Idle/Rate Speed Setting to ESM digital output will be Energized and the Remote Speed Setting
Enable to ESM digital output will be De-Energized. The engine will ramp to its RATED speed setting
(configurable in the ESM via the ESP software; reference ESP software, this is a user defined setting).
4.4 When REMOTE VARIABLE Speed Control is selected, the Engine Idle/Rate Speed Setting to ESM
digital output will be De-Energized, the Remote Speed Setting Enable to ESM digital output will be
Energized and the Fixed/Variable ESM Speed Control To ESM 4-20mA analog output will be controlled
via Compressor Loading (CV) output Low Select Comparator 0-100% value. The Fixed/Variable ESM
Speed Control philosophy is further defined in sections 10.0 and 11.0 NOTE: Even though the speed
control selection may be continuously controlled via the Remote Variable Speed Control selection, the
ESM must be programmed such that the LOW IDLE and HIGH IDLE settings are set to safe mode
operation as defined in the ESM manual; reference ESP software, these are user defined settings.
5.0 UNIT NOT READY TO START
5.1 When all shutdown conditions have been cleared and a Unit Reset is performed by the Operator, or if no
shutdown conditions are present upon powering ‘ON’ the control panel and the Local Stop digital input is
De-Energized for a fixed 3 seconds, a unit start will be prohibited and the status banner will display
“UNIT NOT READY TO START – LOCAL STOP INPUT DE-ENERGIZED”. (SEQ_STEP=20)
6.0 UNIT READY TO START
NOTE: A complete Manual Purge will be required and verified by the Operator before starting the unit.
No Hold Points / Interlocks / Indications or Banners are included in the sequence to confirm a successful
manual purge.
6.1 When all shutdown conditions have been cleared and a Unit Reset is performed by the Operator, or if no
shutdown conditions are present upon powering ‘ON’ the control panel and the Local Stop digital input is
Energized, the unit will be considered Ready To Start and the status banner will display “UNIT READY
TO START | PRESS ‘LOCAL START’ PUSH BUTTON TO START THE UNIT”. (SEQ_STEP=30)
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6.2 In any case listed above including Unit Not Ready To Start section, the PLC outputs will be driven to the
following states:
 Unit Running – Remote Indication = De-Energized

 Unit Alarm – Remote Indication = Energized (De-Energized on Alarm)
 Unit Shutdown – Remote Indication = Energized (De-Energized on Shutdown)
 Compressor Lube Solenoid = De-Energized
 Engine Start to ESM = De-Energized
 Engine Run/Stop to ESM = De-Energized
 Remote Speed Setting Enable to ESM = See Section 3.0
 Engine Idle/Rated Speed Setting to ESM = See Section 3.0
 ESD/Fault Shutdown to ESM = Energized (De-Energized on ESD condition)
 Alarm/Shutdown Strobe = De-Energized (Energized on AL and/or SD condition)
 Alarm/Shutdown Horn = De-Energized (Energized on AL and/or SD condition)
 Bypass Valves Solenoid = De-Energized (Closed)
 Blowdown Valve Solenoid = Energized (Closed)
 Unit Running – Local Indication = De-Energized
 Unit Alarm – Local Indication = De-Energized (Energized on Alarm)
 Unit Shutdown – Local Indication = De-Energized (Energized on Shutdown)
 Engine Speed Control to ESM = 4mA (0 %Load / Minimum Engine RPM)
 1st Stage Recycle Valve Control = 4mA (100.0 %Load / 0.0 %Open)
 2nd Stage Recycle Valve Control = 4mA (100.0 %Load / 0.0 %Open)
6.3 Once a Unit Start is initiated, the 1st Stage Bypass Valves Solenoid digital outputs will be Energized to
open the valve and the status banner will display “UNIT START INITIATED – OPENING BYPASS
VALVES | VALVE POSITION FAILURE IN: ### SECONDS”. (SEQ_STEP=40)
6.4 When the 1st Stage Bypass Valve is confirmed open via its limit switch status, the 1 st Stage Recycle
Control and 2nd Stage Recycle Control analog outputs will be ramped to 20mA (0 %Load / 100 %Open)
to open the valves and the status banner will display “UNIT START INITIATED – OPENING 1ST & 2ND
STAGE RECYCLE VALVES | 1ST & 2ND STG RECYCLE COMMAND: ### & ### %OPEN”.
(SEQ_STEP=50)
6.5 When both the 1st Stage Recycle Valve Control & 2nd Stage Recycle Valve Control analog outputs reach
the commanded 20mA (0 %Load / 100 %Open), the auto sequence will advance to Compressor &
Engine Prelube (Section 7.0).
7.0 COMPRESSOR & ENGINE PRELUBE
7.1 NOTE: A successful Engine Prelube is determined by the Waukesha ESM.
7.2 The Compressor Lube Solenoid digital output will be Energized to turn the lube pump ON and the
Compressor Oil Pressure will be compared to the Compressor Oil Pressure Prelube Permissive setpoint.
7.3 While the Compressor Oil Pressure remains less than the Compressor Oil Pressure Prelube Permissive
setpoint, the Compressor Prelube Permissive Fail Timer will begin counting down and the status banner
will display “UNIT START INITIATED – COMP OIL PRESS: ###.# psi(g) < COMP OIL PRESS
PRELUBE PERM SP: #### psi(g) | COMP PRELUBE PERMISSIVE FAIL SHUT DOWN IN: ####
SECONDS”. (SEQ_STEP=60)
7.4 If the Compressor Prelube Permissive Fail Timer expires while the Compressor Oil Pressure remains less
than the Compressor Oil Pressure Prelube Permissive setpoint, the unit will shut down for ‘SD:
Compressor Oil Pressure Prelube Permissive Failure’.
7.5 When the Compressor Oil Pressure exceeds the Compressor Oil Pressure Prelube Permissive setpoint
before the Compressor Prelube Permissive Fail Timer expires, the Compressor Post-Cooler Oil
Temperature will be compared to the Compressor Oil Temperature Prelube Permissive setpoint.
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7.6 While the Compressor Post-Cooler Oil Temperature remains less than the Compressor Oil Temperature
Prelube Permissive setpoint, the Compressor Prelube Permissive Fail Timer will continue counting down
and the status banner will display “UNIT START INITIATED – COMP POST-COOLER OIL TEMP: ###.#
Deg F < COMP OIL TEMP PRELUBE PERM SP: #### Deg F | COMP PRELUBE PERMISSIVE FAIL
SHUT DOWN IN: #### SECONDS”. (SEQ_STEP=70)
7.7 If the Compressor Prelube Permissive Fail Timer expires while the Compressor Post-Cooler Oil
Temperature remains less than the Compressor Oil Temperature Prelube Permissive setpoint, the unit
will shut down for ‘SD: Compressor Post-Cooler Oil Temperature Prelube Permissive Failure’.
7.8 When the Compressor Post-Cooler Oil Temperature exceeds the Compressor Oil Temperature Prelube
Permissive setpoint before the Compressor Prelube Permissive Fail Timer expires, the Compressor
Prelube Duration Timer will begin counting down, and the status banner will display “UNIT START
INITIATED – COMP OIL PRESS & TEMP PRELUBE PERMISSIVE MET | COMP PRELUBE
DURATION COMPLETE IN: #### SECONDS”. (SEQ_STEP=80)
7.9 Once the Compressor Prelube Duration Timer has begun counting down, throughout the starting of the
unit and while the subsequent Class B1 Lockout Delay Timer is counting down, if the Compressor Oil
Pressure falls below its Prelube Pressure Permissive setpoint, the unit will shut down for ‘SD:
Compressor Prelube Duration Failure - Unit Failed to Maintain Compressor Oil Pressure’.
7.10 Similarly, if the Compressor Post-Cooler Oil Temperature falls below its Prelube Temperature Permissive
setpoint, the unit will shut down for ‘SD: Compressor Prelube Duration Failure - Unit Failed to
Maintain Compressor Post-Cooler Oil Temperature’.
7.11 When the Compressor Prelube Duration has expired and Prelube Permissive has been met, the
sequence will advance to the Engine Start (Section 8.0).
8.0 ENGINE START
8.1 The Engine Run/Stop To ESM and the Engine Start To ESM digital outputs will be Energized and a fixed
5 second Engine Start Signal ON Timer will begin counting down.
NOTE: The Engine Run/Stop To ESM output serves two functions 1) During a normal stop, the output
will remain Energized until the compressor is unloaded and the 'Cooldown Duration' state has completed,
2) During a NON-ESD type shutdown, the output will be immediately De-Energized to stop the Engine
while allowing the ESM to initiate the engine post-lube.
8.2 Once the Engine Start to ESM ON Timer has expired, the Engine Start To ESM digital output will be De-
Energized, the Engine Start Fail Timer will begin counting down and the status banner will display “UNIT
START INITIATED – STARTING ENGINE | ENGINE SPEED: #### RPM < ENGINE RUNNING SP:
#### RPM – SHUTDOWN IN: #### SECONDS”. (SEQ_STEP=90)
8.3 If the Engine Speed (Current RPM) measured via ESM’s OP1, remains less than the Engine Running
Permissive setpoint and the Engine Start Fail Timer expires; the unit will shut down for ‘SD: Engine
Failed to Exceed Engine Running RPM Setpoint in Maximum Allowable Time’.
8.4 If the Engine Speed (Current RPM) measured via ESM’s OP1, is greater than or equal to the Engine
Running RPM Setpoint, the engine will be considered running and the Unit Running – Remote Indication
and Local Indication digital outputs will be Energized.
8.5 Once the engine is considered running, the Prelube Off Delay, Class B1 Shutdown Delay, Class B2
Shutdown Delay and the Minimum Warmup Duration Timers will begin counting down, the Internal Unit
Run Hour meter will begin to accumulate unit running hours and the status banner will display “UNIT
RUNNING UNLOADED – ENGINE SPEED GOVERNOR STABILIZATION IN PROGRESS | MINIMUM
WARMUP DURATION COMPLETE IN: #### SECONDS”. (SEQ_STEP=100)
8.6 When the Prelube Off Delay Timer expires, the Compressor Lube Solenoid digital output will be De-
Energized.
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8.7 When the Class B1 Shutdown Delay expires, all class B1 shutdowns and alarms become activated.
When the Class B2 Shutdown Delay expires, all class B2 shutdowns and alarms become activated.
8.8 If Remote Variable Speed Control is selected, the Engine Speed will ramp to the Engine Minimum Run
RPM setpoint. If Fixed Speed Control is selected, the Engine speed will maintain the LOW IDLE setting
programmed in the ESM.
8.9 Once the Minimum Warmup Duration Timer expires, the Engine Load Failure Timer will begin timing and
the sequence will advance to Unit Ready to Load (Section 9.0).
9.0 UNIT READY TO LOAD
9.1 The Engine Load Permissive Fail timer will begin counting down and the Engine Coolant Temperature
(analog input via OP3) and Engine Oil Temperature (via modbus communications) will be compared to
their respective load permissive setpoints.
9.2 While the Engine Coolant Temperature analog input (via OP3) remains less than the Engine Coolant
Temperature Load Permissive, the status banner will display “UNIT RUNNING UNLOADED – EJW
TEMP: ####.## Deg F < EJW TEMP LOAD PERM SP: ####.## Deg F | ENGINE LOAD PERMMISIVE
FAIL SHUT DOWN IN: #### SECONDS”. (SEQ_STEP=110)
9.3 If the Engine Coolant Temperature remains less than the Engine Jacket Water Temperature Load
Permissive Setpoint before the Engine Load Permissive Fail Timer expires, the unit will shut down for
‘SD: Time Exceeded for Engine to Run Unloaded - Engine Jacket Water Temperature Load
Permissive Failure’.
9.4 When the Engine Coolant Temperature exceeds the Engine Jacket Water Temperature Load Permissive
before the Engine Load Permissive Fail Timer expires, The Engine Oil Temperature will be examined.
9.5 While the Engine Oil Temperature (via Modbus) remains less than the Engine Oil Temperature Load
Permissive, the status banner will display “UNIT RUNNING UNLOADED – ENG OIL TEMP: ####.##
Deg F < ENG OIL TEMP LOAD PERM SP: ####.## Deg F | ENGINE LOAD PERMMISIVE FAIL SHUT
DOWN IN: #### SECONDS”. (SEQ_STEP=120)
9.6 If the Engine Oil Temperature exceeds the Engine Oil Temperature Load Permissive Setpoint before the
Engine Load Permissive Fail Timer expires, the unit will shut down for ‘SD: Time Exceeded for Engine
to Run Unloaded - Engine Oil Temperature Load Permissive Failure’.
9.7 If a communication failure occurs before the Engine Load Permissive are met, the status banner will
display “UNIT RUNNING UNLOADED – ENGINE LOAD PERMISSIVE TEMPS UNKNOWN / AWAITING
OPERATOR ACTION | ENGINE LOAD PERMISSIVE FAIL SHUT DOWN IN: #### SECONDS”.
(SEQ_STEP=130)
9.8 During a communication failure, the operator has the option to verify the temperatures manually (via
Temperature Indicators if installed) and acknowledge the permissive requirements via the ‘LOCAL
RESET’ pushbutton.
9.9 If the ‘LOCAL RESET’ pushbutton is pressed during the communication failure, the Engine Load
Permissive Temperature requirements will be ignored and the sequence will advance to the Compressor
Oil Temperature Load Permissive (Section 9.12).
9.10 If the Load Permissive Failure Timer expires while the engine load permissive temps are unknown and
the operator has NOT acknowledged via the ‘LOCAL RESET’ pushbutton, the unit will shut down for ‘SD:
Time Exceeded for Engine to Run Unloaded - Engine Parameters Unknown’.
9.11 Once the Engine Oil Temperature exceeds the Engine Oil Temperature Load Permissive before the timer
expires or the operator has acknowledged a communication failure and decided to proceed with loading;
the Compressor Post-Cooler Oil Temperature will be compared to the Compressor Oil Temperature Load
Permissive setpoint and the Unit Load Permissive Fail Timer will continue counting down.
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9.12 While the Compressor Post-Cooler Oil Temperature remains less than the Compressor Oil Temperature
Load Permissive Setpoint, the status banner will display “UNIT RUNNING UNLOADED – COMP POST-
COOLER OIL TEMP: ####.## Deg F < COMP OIL TEMP LOAD PERM SP: ####.## Deg F | ENGINE
LOAD PERMMISIVE FAIL SHUT DOWN IN: #### SECONDS”. (SEQ_STEP=140)
9.13 If the Engine Load Fail Timer expires before the Compressor Post-Cooler Oil Temperature exceeds the
Compressor Oil Temperature Load Permissive Setpoint, the unit will shut down for ‘SD: Time Exceeded
for Engine to Run Unloaded - Compressor Post-Cooler Oil Temperature Load Permissive Failure’.
NOTE: The operator must verify the OPEN position of both suction and discharge valves prior to
pressing the ‘PRESS TO LOAD’ touchbutton to load the unit.
9.14 When all engine and compressor Load Permissive Temperatures are satisfied before the Engine Load
Permissive Fail Timer expires, the status banner will display “UNIT RUNNING – READY TO LOAD /
OPERATOR ACTION REQUIRED – ‘PRESS TO LOAD’ | ENGINE LOAD PERMISSIVE FAIL SHUT
DOWN IN: #### SECONDS”. (SEQ_STEP=150)
9.15 If the Operator fails to press the ‘PRESS TO LOAD’ HMI/MMI touchbutton before the Load Permissive
Failure Timer expires, the Unit will shut down for ‘SD: Time Exceeded for Engine to Run Unloaded -
Operator Failed to Initiate Unit Loading’.
9.16 Once the operator presses the ‘PRESS TO LOAD’ HMI touchbutton, the Engine Speed Control analog
output will ramp to the Engine Minimum Load Speed and the status banner will display “UNIT RUNNING
– LOADING INITIATED / ENGINE SPEED: #### RPM < MIN LOAD RPM SP: #### RPM | ENGINE
LOAD PERMISSIVE FAIL SHUT DOWN IN: #### SECONDS”. (SEQ_STEP=160)
9.17 If Engine Speed From ESM OP1 analog input does not exceed -2% of the Engine Speed Min Load RPM
setpoint and the Load Permissive Failure Timer expires, the Unit will shut down for ‘SD: Time Exceeded
for Engine to Run Unloaded - Engine Failed to Reach Min Engine Load RPM Setpoint’
9.18 When the Engine Speed From ESM OP1 analog input is greater than -2% of the Engine Speed Min Load
RPM setpoint, the Bypass Valves Solenoid digital outputs will be De-Energized to close the valve and the
status banner will display “UNIT RUNNING – LOADING INITIATED / CLOSING BYPASS VALVES |
VALVE POSITION FAILURE IN: ### SECONDS”. (SEQ_STEP=170)
9.19 When the Bypass Valves are confirmed closed via its limit switch status, the sequence will advance to
Unit Running – Load Control Enabled (Section 10.0).
10.0 UNIT RUNNING – LOAD CONTROL ENABLED
10.1 While the Load Control Enabled state has been achieved, the Class P Load Delay Timer will begin
counting down and the status banner will display “UNIT RUNNING – LOAD CONTROL ENABLED | |
COMPESSOR LOADING OUTPUT: ###.# %CV”. (SEQ_STEP=180)
10.2 When the Class P Load Delay Timer expires, all class P and C/P shutdowns and alarms become
activated
10.3 While the Load Control Enabled state has been achieved, the compressor capacity loading shall be
accomplished via the Compressor Load (CV) Low Select Comparators.
10.4 The Compressor Load (CV) Low Select Comparator uses three possible controlling inputs to determine its
output value: 1) 1st Stage Suction Pressure PID 2) 2nd Stage Discharge Pressure PID and 3) Engine
Percent Load PID.
10.5 While the PID Control Loop algorithm configurations and may be ‘ENABLED’ or ‘DISABLED’ individually
via their respective HMI/MMI touch buttons; it is recommended that all PIDs be enabled to avoid nuisance
Low Suction and High Discharge Pressure shutdown conditions.
10.6 The 1st Stage Suction Pressure will provide the process variable (PV) for the 1st Stage Suction Pressure
PID.
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 When the 1st Stage Suction Pressure (PV) is LESS than the 1st Stage Suction Pressure PID
Setpoint (SP) minus the 1st Stage Suction Pressure PID Deadband (DB), the 1st Stage Suction
Pressure PID control variable (CV) output will DECREASE.
 When the 1st Stage Suction Pressure (PV) is GREATER than the 1st Stage Suction Pressure PID
Setpoint (SP) plus the 1st Stage Suction Pressure PID Deadband (DB), the 1st Stage Suction
Pressure PID control variable (CV) output will INCREASE.
10.7 The 2nd Stage Discharge Pressure will provide the process variable (PV) for the 2nd Stage Discharge
Pressure PID.
 When the 2nd Stage Discharge Pressure (PV) is LESS than the 2nd Stage Discharge Pressure
PID Setpoint (SP) minus the 2nd Stage Discharge Pressure PID Deadband (DB), the 2nd Stage
Discharge Pressure PID control variable (CV) output will INCREASE.
 When the 2nd Stage Discharge Pressure (PV) is GREATER than the 2nd Stage Discharge
Pressure PID Setpoint (SP) plus the 2nd Stage Discharge Pressure PID Deadband (DB), the 2nd
Stage Recycle Discharge Pressure PID control variable (CV) output will DECREASE.
10.8 The Engine Percent Load via ESM communication will provide the process variable (PV) for the Engine
Percent Load PID. In the event a communication failure occurs with the ESM, the PID will be Disabled
and updated via the Compressor Load (CV).
 When the Engine Percent Load (PV) is LESS than the Engine Percent Load PID Setpoint (SP)
minus the Engine Percent Load PID Deadband (DB), the Engine Percent Load PID control
variable (CV) output will INCREASE.
 When the Engine Percent Load (PV) is GREATER than the Engine Percent Load PID Setpoint
(SP) plus the Engine Percent Load PID Deadband (DB), the Engine Percent Load PID control
variable (CV) output will DECREASE.
10.9 The control variable output (CV) of all ‘ENABLED’ PID algorithms are compared with the lowest value
being passed to the Compressor Load (CV) low value select comparator output value.
10.10 Additionally, the low value select comparator maintains a maximum delta of a fixed 5% (CV) value to all
PIDs currently enabled by limiting each PID Loop’s Max (CV) to prevent PID windup. While at least one
of the compressor loading PID algorithms is ‘ENABLED’, any PID that is DISABLED will be continually
updated with the value of the Comp %Load (CV) to ensure if the disabled PID becomes enabled while
the unit is running loaded, the event will be bump-less.
11.0 ENGINE SPEED CONTROL
11.1 There are two Engine Speed Control To ESM analog output control modes available AUTO and
MANUAL. The Mode is selected via the HMI/MMI.
11.2 While AUTO control mode is selected, the Compressor Load (CV) output Low Select Comparator 0-
100% value will provide the input to be scaled between the Engine Speed Control To ESM Split Range
Min and Max (0-100 %Load) setpoints. The output of this scale block is then scaled between the Engine
Speed Control To ESM Min and Max Load RPM setpoints scaled as a percentage and directly applied to
the Engine Speed Control To ESM analog output.
11.3 While MANUAL control mode is selected, the Engine Speed Control To ESM analog output will be
controlled via the Engine Speed Control To ESM Manual RPM and Engine Speed Control To ESM 1%
Rate Of Change Timer setpoints adjustable via the HMI/MMI.
11.4 The transfer from AUTO to MANUAL control mode is bumpless. Once MANUAL control mode is
selected, the Engine Speed Control To ESM analog output Current RPM value is automatically copied
into the Engine Speed Control To ESM Manual RPM setpoint. The Engine Speed Control To ESM
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analog output may then be ramped to any value within a valid range between the Engine Speed Control
To ESM Min and Max Load RPM setpoints while the unit is running in either loaded or unloaded state.
11.5 The Engine Speed Control To ESM 1% Rate Of Change Timer setpoint will be used to determine the
length of time in milliseconds for the Engine Speed Control To ESM analog output to change 1% of its
total current speed span either loaded or unloaded.
11.6 The transfer from MANUAL to AUTO control mode is bumpless. Once AUTO control mode is selected,
the Engine Speed Control To ESM analog output will ramp using Stage Compressor Load (CV) output
Low Select Comparator. Once the Engine Speed Control To ESM analog output is equal to the
commanded value, the ramping effect will be terminated and the Engine Speed Control To ESM analog
output will change at the rate as defined by the tuning of the Compressor Load (CV) output Low Select
Comparator.
11.7 In the event the fail position of a valve or speed control device is incorrectly reported during the
programming development, an HMI/MMI touchbuttons has been provided on the HMI/MMI Analog Output
Manual Override Screen and is only visible while the User is logged ON. The touchbuttons, may be
toggled between the two following states:
 4mA = 0% Output | 20mA =100% Output (Where Output = Compressor Loading)

12.0 1ST STAGE RECYCLE VALVE CONTROL
12.1 There are two 1st Stage Recycle Valve Control analog output control modes available AUTO and
12.2 Auto mode compare 1st stage suction pressure and 1 stage discharge pressure and control recycle valve
based on what is most critical at any given time
12.3 While MANUAL control mode is selected, the 1st Stage Recycle Valve Control analog output will be
controlled via the 1st Stage Recycle Valve Control Manual %OPEN and 1st Stage Recycle Valve Control
1% Rate Of Change Timer setpoints adjustable via the HMI/MMI.
12.4 The transfer from AUTO to MANUAL control mode is bumpless. Once MANUAL control mode is
selected, the 1st Stage Recycle Valve Control analog output Current %OPEN value is automatically
copied into the 1st Stage Recycle Valve Control Manual %OPEN setpoint. The 1st Stage Recycle Valve
Control 4-20mA analog output may then be ramped to any value between 0-100% OPEN.
12.5 The 1st Stage Recycle Valve Control 1% Rate Of Change Timer setpoint will be used to determine the
length of time in milliseconds for the 1st Stage Recycle Valve Control analog output to change 1%.
12.6 The transfer from MANUAL to AUTO control mode is bumpless. Once AUTO control mode is selected,
the 1st Stage Recycle Valve Control analog output will ramp using 1st Stage Recycle Valve Control 1%
Rate Of Change Timer to the value currently commanded by the 1st Stage Recycle Valve output Low
Select Comparator. Once the 1st Stage Recycle Valve Control analog output is equal to the commanded
value, the ramping effect will be terminated and the 1st Stage Recycle Valve Control analog output will
change at the rate as defined by the tuning of the 1st Stage Recycle Valve output Low Select
Comparator.
programming development, an HMI/MMI touchbuttons has been provided on the HMI/MMI Analog Output
Manual Override Screen and is only visible while the User is logged ON. The touchbuttons, may be

13.0 2ND STAGE RECYCLE VALVE CONTROL
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13.1 There are two 2nd Stage Recycle Valve Control analog output control modes available AUTO and
13.2 Auto mode compare 2nd stage suction pressure and 2nd stage discharge pressure and control recycle
valve based on what is most critical at any given time
.
13.3 While MANUAL control mode is selected, the 2nd Stage Recycle Valve Control analog output will be
controlled via the 1st Stage Recycle Valve Control Manual %OPEN and 2 nd Stage Recycle Valve Control
1% Rate Of Change Timer set points adjustable via the HMI/MMI.
13.4 The transfer from AUTO to MANUAL control mode is bump less. Once MANUAL control mode is
selected, the 2nd Stage Recycle Valve Control analog output Current %OPEN value is automatically
copied into the 2nd Stage Recycle Valve Control Manual %OPEN set point. The 2nd Stage Recycle Valve
Control 4-20mA analog output may then be ramped to any value between 0-100% OPEN.
13.5 The 2nd Stage Recycle Valve Control 1% Rate Of Change Timer set point will be used to determine the
length of time in milliseconds for the 2nd Stage Recycle Valve Control analog output to change 1%.
13.6 The transfer from MANUAL to AUTO control mode is bump less. Once AUTO control mode is selected,
the 2nd Stage Recycle Valve Control analog output will ramp using 2 nd Stage Recycle Valve Control 1%
Rate Of Change Timer to the value currently commanded by the Compressor Load (CV) output Low
Select Comparator. Once the 2nd Stage Recycle Valve Control analog output is equal to the commanded
value, the ramping effect will be terminated and the 2nd Stage Recycle Valve Control analog output will
change at the rate as defined by the tuning of the Compressor Load (CV) output Low Select
Comparator.
programming development, an HMI/MMI touch buttons has been provided on the HMI/MMI Analog Output
Manual Override Screen and is only visible while the User is logged ON. The touch buttons, may be

14.0 UNIT NORMAL STOP
14.1 When a Unit Stop is initiated before the unit is considered running, the sequence will revert to Unit Ready
to Start (Section 6.0).
14.2 When a Unit Stop is initiated once the unit is considered running, the Engine Idle/Rate Speed Setting to
ESM digital output will be De-Energized and the Engine Speed Control To ESM 4-20mA analog output
will be ramped to (a) the Engine Speed Min Load RPM setpoint while REMOTE VARIABLE Speed is
selected or (b) to the ESM controlled LOW IDLE setting programmed in the ESM if IDLE/RATED Speed
is selected, the 1st Stage Recycle Valve Control and 2nd Stage Recycle Valve Control analog outputs will
be ramped to 4mA (100 %Load / 0%Open) to close the recycle valves and the status banner will display
“UNIT NORMAL STOP INITIATED – REDUCING ENGINE SPEED & CLOSING 1ST & 2ND STG RECY
VLV(S) | ENG SPD: #### RPM > MIN LOAD RPM SP: #### RPM / 1ST & 2ND STG RECY VLV: ### &
### %OPEN”. (SEQ_STEP=190)
14.3 When the Engine Speed is Less Than the Engine Minimum Load RPM setpoint plus 2% or if the Engine
Speed Control is in Manual or Fixed Speed is selected and both the 1st Stage Recycle Valve Control & 2nd
Stage Recycle Valve Control analog outputs have reached their commanded 4mA (100 %Load /
0%Open), the Cooldown Duration timer will begin counting down and the status banner will display
“UNIT NORMAL STOP INTIATED – ENGINE TEMPERATURE STABILIZATION IN PROGRESS
ENGINE COOLDOWN DURATION COMPLETE IN: #### SECONDS”. (SEQ_STEP=200)
14.4 When the Cooldown Duration Timer expires, the Engine Run/Stop To ESM output will be De-Energized
to stop the engine, the Engine Stop Fail Timer will begin counting down and the status banner will display
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“UNIT NORMAL STOP INITIATED – ENGINE RUN COMMAND DE-ENERGIZED | ENGINE SPEED:
#### RPM > 10 RPM – EMERGENCY SHUT DOWN IN: ##### SECONDS”. (SEQ_STEP=210)
14.5 If the Engine Speed remains greater than 10 RPM and the Engine Stop Fail Timer expires, the ESD/Fault
Shutdown to ESM digital output will be De-Energized, and the unit will ESD-type shut down for ‘SD:
Engine Failed to Achieve Engine Stop Conditions via Engine Run/Stop To ESM Digital Output De-
Energized’.
14.6 If the Engine Speed drops below 10 RPM before the timer expires (NOT ESD), the Engine Post Lube
Duration Timer will begin counting down, the PLC outputs listed below will be driven to the following
states and the status banner will display “UNIT STOPPED – ENGINE CONTROLLED POSTLUBE IN
PROGRESS | ENGINE POSTLUBE DURATION COMPLETE IN: #### SECONDS”. (SEQ_STEP=220)
NOTE: The engine’s post lube sequence is controlled by the engine. The Post Lube Duration Timer
should be set to at least as long as the engine’s for proper operation and synchronization with the HMI
status banner.

 Unit Shutdown – Remote Indication = Energized (De-Energized on Shutdown)
 Compressor Lube Solenoid = De-Energized (Energized if tied with Engine Lube System)
 Engine Idle/Rated Speed Setting to ESM = De-Energized
 Alarm/Shutdown Strobe = De-Energized (Energized on AL and/or SD condition)
 Alarm/Shutdown Horn = De-Energized (Energized on AL and/or SD condition)
 Unit Shutdown – Local Indication = De-Energized (Energized on Shutdown)
14.7 When the Post Lube Duration Timer has expired, the sequence will revert to Unit Ready To Start (Section
6.0)
15.0 UNIT SHUTDOWN
15.1 When a NON-ESD type shutdown occurs before the unit is considered running, the PLC Outputs will be
driven to the following states and the status banner will display “UNIT SHUTDOWN – CHECK ACTIVE
ALARM DISPLAY / HISTORY FOR REASON OF FAILURE”. (SEQ_STEP=10)

 Unit Shutdown – Remote Indication = De-Energized
 Alarm/Shutdown Strobe = Energized (Energized on AL and/or SD condition)
 Alarm/Shutdown Horn = Energized (Energized on AL and/or SD condition)
 Bypass Valves Solenoid = Energized (Closed)
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 Unit Shutdown – Local Indication = Energized (Energized on Shutdown)
15.2 When a NON-ESD type shutdown occurs once the unit is considered running, the Cooldown sequence
will be skipped, the Engine Run/Stop To ESM output will be De-Energized and the Engine Stop Fail
Timer will begin counting down. The status banner will display “UNIT NON-ESD SHUTDOWN
INITIATED – ENGINE RUN COMMAND DE-ENERGIZED | ENGINE SPEED: #### RPM > 10 RPM –
EMERGENCY SHUT DOWN IN: ##### SECONDS”. (SEQ_STEP=215)
15.3 If the Engine Speed remains greater than 10 RPM and the Engine Stop Fail Timer expires, the ESD/Fault
Shutdown To ESM output will be De-Energized to cause an ESD-type shutdown for ‘ESD: Engine
Failed to Achieve Engine Stop Conditions via Engine Run/Stop To ESM Digital Output De-
Energized’.
15.4 When the Engine Speed drops below 10 RPM before the timer expires (NOT ESD), the Engine Controlled
Post Lube Sequence will be initiated and the Post Lube Duration Timer will begin counting down. The
PLC outputs listed below will be driven to the following states and the status banner will display “UNIT
SHUTDOWN – ENGINE CONTROLLED POSTLUBE IN PROGRESS | ENGINE POSTLUBE
DURATION COMPLETE IN: #### SECONDS”. (SEQ_STEP=225)
NOTE: The engine’s post lube sequence is controlled by the engine. The Post Lube Duration Timer
should be set to at least as long as the engine’s for proper operation and synchronization with the HMI
status banner.

 Alarm/Shutdown Strobe = Energized (Energized on AL and/or SD condition)
 Alarm/Shutdown Horn = Energized (Energized on AL and/or SD condition)
 Unit Shutdown – Local Indication = Energized (Energized on Shutdown)
15.5 When the Post Lube Duration Timer has expired, the status banner will display “UNIT SHUTDOWN –
CHECK ACTIVE ALARM DISPLAY / HISTORY FOR REASON OF FAILURE”. (SEQ_STEP=10)
15.6 When the Non-Class ESD shutdown condition has been cleared and a Unit Reset is performed, the
sequence will revert to Unit Ready To Start (Section 6.0).
16.0 UNIT EMERGENCY STOP
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16.1 If an ESD type shutdown condition exists at any time during operation, the ESD/Fault Shutdown to ESM
output will be De-Energized and the Postlube sequence will be skipped. The PLC outputs listed below
will be driven to the following states and the status banner will display “UNIT ESD – EMERGENCY
SHUTDOWN CONDITION EXISTS”. (SEQ_STEP=0)

 Unit Alarm – Remote Indication = De-Energized
 Remote Speed Setting Enable to ESM = De-Energized
 Engine Idle/Rated Speed Setting to ESM = De-Energized
 ESD/Fault Shutdown to ESM = De-Energized
 Alarm/Shutdown Strobe = De-Energized
 Alarm/Shutdown Horn = De-Energized
 Blowdown Valve Solenoid = De-Energized (Open)
 Unit Alarm – Local Indication = De-Energized
 Unit Shutdown – Local Indication = Energized
16.2 When the Class ESD shutdown condition has been cleared and Unit Reset performed by the operator,
the sequence will revert to Unit Ready To Start (Section 6.0).
17.0 GENERAL VALVE OPERATION
17.1 All PLC controlled process valves are considered spring return type (open or close) with either one or two
solenoids to control and maintain activation.
17.2 When the control sequence commands a particular valve to activate, the control output(s) will be
Energized and the valve open or close fail timer will start to time. If the correct limit switch status is not
achieved before the fail timer times out, the unit will shut down on the valve open or close failure.
17.3 When the control sequence commands the valve to de-activate, the control output will be De-Energized
and the valve close or open fail timer will start to time. If the correct limit switch status is not achieved
before the fail timer times out, the unit will shut down on the corresponding valve close or open failure.
17.4 Nuisance valve position shutdowns, due to a momentary disruption of control air, are avoided via a
secondary fixed 2 second de-bounce timer. If a valve’s position remains in a failed state and its fixed 2
second de-bounce timer expires, the unit will shut down on the relevant open or close position failure.
17.5 See Alarm & Shutdown Functions (Section 22.0) for a list of valve limit switch failures.
18.0 WAUKESHA ESM AND RED LION RTU COMMUNICATIONS FAILURE
18.1 If a communications failure, i.e. disconnected/improperly connected communication cable, ESM/ESM

display loss of power, etc., exists between the Waukesha ESM and the PLC for longer than 10 seconds,
the unit will alarm for ‘AL: Communication Failure Between Engine ECM and RTU’ and all data
displayed on the HMI/MMI will be replaced with ‘COMM FAILURE’.
18.2 If a communications failure, i.e. disconnected/improperly connected communication cable, Red Lion loss
of power, etc., exists between the Red Lion DSP and the PLC for longer than 10 seconds, the unit will
alarm for ‘AL: Communication Failure Between PLC and RTU’ and all data displayed on the HMI/MMI
will be replaced with ‘COMM FAILURE’.
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19.0 TEST MODE
19.1 While the unit is running, it may be put in test mode by pressing the ‘START INDIVIDUAL TEST MODE’
or ‘START GLOBAL TEST MODE’ HMI/MMI touchbutton. Once either mode is selected the Test Mode
Timer will start counting down and all shutdowns identified as Class A, B1, B2, C, C/P and S may be
tested without shutting the unit down and the alarm history will log, ‘TIMESTAMP: Test Mode Enabled’.
Some shutdown functions may be designated as Class ESD or A/S which will not be locked out in the test
mode and are therefore NOT testable. See Section 22.0 for testable alarm and shutdown functions.
19.2 If Individual Test Mode is selected, the technician must individually select each end device to be tested by
toggling that end device’s disable touchbutton from yellow (Cautionary) to red (Disabled) state as
appropriate on the HMI/MMI.
19.3 If Global Test Mode is selected, the aforementioned shutdown functions in Section 22.0 are disabled and
available for test as indicated by that end device’s disable touchbutton automatically toggling red. Once
Global test mode is selected, the operator may de-select (enable) individual end devices by toggling them
back to their yellow (Cautionary State).
19.4 Test Mode will end if the Test Mode Timer expires or the ‘STOP TEST MODE’ HMI/MMI touchbutton is
pressed. Once Test Mode is disabled, all disabled shutdowns will be re-enabled and will have to be
disabled again if necessary during the next test mode session. When less than one minute of Test Mode
time remains, the unit will alarm on ‘AL: Warning! Less Than 60 Seconds Test Mode Time
Remaining’.
19.5 If more time is needed for testing, the Test Mode Timer can be reset by depressing the ‘LOCAL RESET’
pushbutton, or by pressing either the ‘START INIDIVIDUAL TEST MODE’ or ‘START GLOBAL TEST
MODE’ HMI/MMI touchbuttons.
NOTE: When the system is in Test Mode, typically only Class ESD and A/S shutdowns will cause an
actual shutdown. All shutdowns of other classes will be displayed but will NOT cause an actual unit
shutdown. When a shutdown condition is active, it must be cleared by pressing the ‘LOCAL RESET’
pushbutton before the Test Mode is disabled or an actual unit shutdown will occur. While a shutdown
condition is active, the HMI/MMI will display ‘Shutdown Condition Active – Press Reset To Clear
Fault’ on all applicable setpoint pages.
20.0 PLC I/O FORCING (MANUAL OVERRIDE)
20.1 When a Non-ESD shutdown condition exists or if the unit is in the ‘READY TO START’ state, the user has
the ability to manually force both digital and analog outputs via the MANUAL OVERRIDE screens on the
HMI/MMI. The user must be logged on to access this feature. Refer to Section 24.0 to complete the
Login procedure.
20.2 All digital outputs are selected to the Forced OFF state by default, the operator may choose to toggle the
state of each digital output between ‘Forced OFF’ and ‘Forced ON’.
20.3 The operator may set the desired 4-20mA value for each analog output as required via its respective
HMI/MMI setpoint touchbutton, and then toggle the state of each analog output’s respective manual
override touchbutton between ‘Forced OFF’ and ‘Forced ON’.
20.4 When the operator has selected the desired forcing state of each output, pressing the ‘ENABLE PLC
OUTPUT FORCING’ HMI/MMI touchbutton will enable all PLC I/O Forcing both digital and analog; the
HMI/MMI will display “OUTPUT LOGIC FORCING ACTIVATED – UNIT AUTO SEQUENCE DISABLED |
OUTPUT FORCING AUTO TERMINATES IN: ##### SECONDS”. (SEQ_STEP=15)
20.5 When PLC I/O forcing is enabled, the fixed 900 second PLC Output Forcing Disable Timer will begin
timing. Once initiated, if more time is required, pressing the (ADD TIME) RESET FORCE TIMER
HMI/MMI touchbutton will reset this timer to the full 900 seconds.
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20.6 PLC I/O Forcing will be immediately disabled if the ‘DISABLE OUTPUT FORCING’ HMI/MMI touchbutton
is pressed or the Output Forcing Disable Timer expires. Once PLC I/O Forcing is disabled, all outputs
will be driven to their automatic sequence controlled states.
20.7 When PLC I/O Forcing is enabled, a Class ESD type shutdown will immediately disable PLC I/O Forcing.
21.0 ROD LOAD CALCULATIONS
21.1 Compressor rod load under the Ariel calculation method is determined using the following data and
formulas:
Double Acting Cylinders
RLc   Ahe  pdi    Ace  psi    Arod  patm 

RLt   Ace  pdi    Ahe  psi    Arod  patm 
Single Acting Crank-End Cylinders
RLc  Ahe  pdi , he    Ace  psi    Arod  patm 

RLt   Ace  pdi   Ahe  psi, he    Arod  patm 
Tandem Cylinders – High Pressure Cylinder Outboard
RLc  Ahe ,HP  pdi ,HP   Ahe ,LP  Ahe ,HP  psf lg, LP  Ace ,LP  psi ,LP    Arod  patm 
RLt  Ace ,LP  pdi ,LP   Ahe ,LP  Ahe ,HP  psf lg, LP  Ace ,HP  psi ,HP    Arod  patm 
Tandem Cylinders – High Pressure Cylinder Inboard
RLc  Ahe ,LP  pdi ,LP   Ahe ,LP  Ahe ,HP  psf lg, LP  Ace ,HP  psi ,HP    Arod  patm 
RLt  Ace ,HP  pdi ,HP   Ahe ,LP  Ahe ,HP  psf lg, LP  Ace ,LP  psi ,LP    Arod  patm 
where:
RLc = internal compression gas rod load, lbf

RLt = internal tension gas rod load, lbf
   Dcyl2 
 
Ahe = head end area,  4  , in in2, where D cyl is the cylinder diameter, in inches
 
Ace = crank end area,  Ahe  Arod  , in in . 2
   Drod
2

Arod = rod area,   , in in2, where Drod is the rod diameter, in inches
 4
 
LP = designation for low pressure cylinder or stage
HP = designation for high pressure cylinder or stage
PLs = suction pressure loss, in %
PLd = discharge pressure loss, in %
psflg = flange suction pressure, in psia
pdflg = flange discharge pressure, in psia
 100  PLs 
psi = internal suction pressure, psf lg    , in psia
 100 
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 100  PLd 
pdi = internal discharge pressure, pdf lg    ,in psia
 100 
patm = atmospheric pressure, in psi
21.2 High alarm and shutdown functions are provided for rod load in compression, tension and total, which is
compression and tension combined. See Section 22.0 for more details.
22.0 ALARM AND SHUTDOWN FUNCTIONS
Alarm/Shutdown Type Legend

LOGIC: Alarm, shutdown or indication is determined by a certain process condition.
DISCRETE: Alarm, shutdown or indication is associated with a discrete input.
4-20 mA: Alarm, shutdown or indication is associated with a 4-20mA analog input.
TC: Alarm, shutdown or indication is associated with a thermocouple input.
RTD: Alarm, shutdown or indication is associated with an RTD input.
Range (AI)/Type (DI) Legend
N/A: Not applicable
N/C: Normally closed discrete input
N/O: Normally open discrete input
MIN-MAX: Analog input scaled value range
TYPE J: Type J thermocouple range
TYPE K: Type K thermocouple range
100 Ω Pt: 100 Ω platinum RTD range
AL/SD/IND/CTL Legend
AL: Alarm
SD: Shutdown
IND: Indication (value display only)
CTL: Control
Class Legend
ESD: Monitored at all times. Class ESD shutdowns remain active at all times.
A: Monitored at all times. Class A shutdown remains active all times except while disabled in Test
Mode.
B1: Monitored after the Class B1 Lockout Delay expires. The Class B1 Lockout Delay starts counting
down once the main drive motor or engine is confirmed running. Once expired, it will remain
armed until the unit is stopped.
B2: Monitored after the Class B2 Lockout Delay expires. The Class B2 Lockout Delay starts counting
down once the main drive motor or engine is confirmed running. Once expired, it will remain
armed until the unit is stopped.
C: Monitored after the process variable being protected exceeds the respective low alarm or low
shutdown setpoint for at least 2 seconds. Once armed, it will remain armed until the control panel
power is removed and the PLC is restarted.
P: Monitored once the unit is running under load control.
C/P: Monitored as a Class C while the unit is running under load control only.
S: Monitored when a certain process condition is satisfied.
VIBR: Monitored at all times but with hardcoded 2-5 second Vibration Debounce Timer. Class VIBR
shutdown remains active all times except while disabled in Test Mode.
Factory Setpoint Legend
↑: Value must exceed this setpoint.
↓: Value must fall below this setpoint.
Non-Configurable Setpoints
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All High Scrubber Liquid Level assigned digital inputs utilize a fixed 5 second trip debounce timer
to alleviate nuisance shutdowns due to the possibility of turbulence through the scrubber at high
flow rates. All remaining Non-ESD assigned digital fault inputs have a fixed two second trip
debounce timer unless otherwise specified, i.e. motor run failures, etc.
NOTE: FW Murphy Control Systems and Services are not responsible for the accuracy or completeness of these setpoints.
CALIBRATED
PRE-
KEY END DEVICE RANGE (AI) FAULT
DESCRIPTION / ANNUNCIATION TYPE FUNCTION COMMISSIONED
ID# TAG HEALTHY CLASS
SETPOINT
STATE (DI)
SD: Compressor Oil Pressure Prelube Permissive
1 N/A LOGIC N/A SD S See Section 7.4
Failure
SD: Compressor Oil Temperature Prelube
Permissive Failure
SD: Compressor Prelube Duration Failure - Unit
Failed to Maintain Compressor Oil Pressure
SD: Compressor Prelube Duration Failure - Unit
Failed to Maintain Compressor Oil Temperature
SD: Engine Failed to Exceed Engine Running RPM
Setpoint in Maximum Allowable Time
SD: Time Exceeded for Engine to Run Unloaded -
6 Engine Jacket Water Temperature Load Permissive N/A LOGIC N/A SD S See Section 9.3
Failure
Engine Oil Temperature Load Permissive Failure
8 N/A LOGIC N/A SD S See Section 10
Engine Parameters Unknown
9 Compressor Oil Temperature Load Permissive N/A LOGIC N/A SD S See Section 9.13
Failure
Operator Failed to Initiate Unit Loading
11 Engine Failed to Exceed Engine Minimum Load N/A LOGIC N/A SD S See Section 9.17
RPM Setpoint
SD: Engine Failed to Achieve Engine Stop
See Section 14.5
12 Conditions via Engine Run/Stop To ESM Digital N/A LOGIC N/A SD ESD
& 15.3
Output De-Energized
13 SD: R1S01 Module Faulted N/A LOGIC N/A SD ESD See Section 2.7
AL: Warning! Less Than 60 Seconds of Test Mode
29 N/A LOGIC N/A AL S See Section 19.4
Time Remaining
AL: Engine Communication Failure Between
30 N/A LOGIC N/A AL S See Section 18.2
Waukesha ESM and RTU
31 TIMESTAMP: Test Mode Enabled N/A LOGIC N/A IND S See Section 19.1
32 SD: Local Emergency Stop N/A DISCRETE ON SD ESD N/A
33 TIMESTAMP: Local Start N/A DISCRETE OFF IND N/A N/A
34 TIMESTAMP: Local Stop N/A DISCRETE ON IND N/A N/A
35 TIMESTAMP: Local Reset N/A DISCRETE OFF IND N/A N/A
36 AL: Engine Alarm from ESM N/A DISCRETE OFF AL A N/A
37 SD: Engine Shutdown from ESM N/A DISCRETE OFF SD A N/A
38 SD: Remote Emergency Stop N/A DISCRETE ON SD ESD N/A
39 SD: Lubricator No-Flow Left Bank FSLL-2126 DISCRETE ON SD B2 N/A
40 SD: Lubricator No-Flow Right Bank FSLL-2127 DISCRETE ON SD B2 N/A
41 SD: Low Engine Oil Level LSLL-2022 DISCRETE ON SD A N/A
42 SD: Low Engine Jacket Water Level LSLL-4100 DISCRETE ON SD A N/A
43 SD: Low Engine Auxiliary Water Level LSLL-4101 DISCRETE ON SD A N/A
44 SD: Low Compressor Oil Separator Level LSLL-2023 DISCRETE ON SD A N/A
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CALIBRATED
PRE-
SETPOINT
STATE (DI)
45 SD: High 1st Stage Suction Scrubber Liquid Level LSHH-1500 DISCRETE ON SD A N/A
46 SD: High 2nd Stage Suction Scrubber Liquid Level LSHH-1501 DISCRETE ON SD A N/A
47 SD: High Discharge Scrubber Liquid Level LSHH-1502 DISCRETE ON SD A N/A
48 SD: High Cooler Fan Vibration VSHH-8350 DISCRETE ON SD A N/A
49 SD: Bypass Valve Open ZSO-1041 DISCRETE ON SD S N/A
50 SD: Bypass Valve Closed ZSC-1041 DISCRETE ON SD S N/A
51 SD: Bypass Valve Open ZSO-1040 DISCRETE ON SD S N/A
52 SD: Bypass Valve Closed ZSC-1040 DISCRETE ON SD S N/A
53 SD: Blowdown Valve Open ZSO-1037 DISCRETE ON SD S N/A
54 SD: Blowdown Valve Closed ZSC-1037 DISCRETE ON SD S N/A
55 AL: Low Panel Purge Pressure Alarm N/A DISCRETE ON AL A N/A
56 SD: Low Compressor Oil Pressure SD B1 45 PSIG ↓
57 AL: Low Compressor Oil Pressure AL B1 50 PSIG ↓
PIT-2103 4-20mA 0 - 400 PSIG
3.6mA ↓
58 SD: Compressor Oil Pressure Out of Range Failure SD A
20.5mA ↑
59 AL: Low Compressor Oil Filter Differential Pressure AL B1 30 mm W.C.↓
60 AL: High Compressor Oil Filter Differential Pressure -1000 – 1000 mm AL A 140 mm W.C.↑
DPIT-2057 4-20mA
SD: Compressor Oil Filter Differential Pressure Out W.C. 3.6mA ↓
61 SD A
of Range Failure 20.5mA ↑
62 SD: Low 1st Stage Suction Pressure SD P 7 PSIG ↓
63 AL: Low 1st Stage Suction Pressure AL P 10 PSIG ↓
64 AL: High 1st Stage Suction Pressure AL S 19 PSIG ↑
PIT-1520 4-20mA 0 - 100 PSIG
65 SD: High 1st Stage Suction Pressure SD S 22 PSIG ↑
SD: 1st Stage Suction Pressure Out of Range 3.6mA ↓
66 SD A
Failure 20.5mA ↑
67 SD: Low 1st Stage Discharge Pressure SD C/P 45 PSIG ↓
68 AL: Low 1st Stage Discharge Pressure AL C/P 50 PSIG ↓
69 AL: High 1st Stage Discharge Pressure AL A 75 PSIG ↑
PIT-1521 4-20mA 0 - 400 PSIG
70 SD: High 1st Stage Discharge Pressure SD A 80 PSIG ↑
SD: 1st Stage Discharge Pressure Out of Range 3.6mA ↓
71 SD A
Failure 20.5mA ↑
72 SD: Low 2nd Stage Suction Pressure SD C/P 40 PSIG ↓
73 AL: Low 2nd Stage Suction Pressure AL C/P 45 PSIG ↓
74 AL: High 2nd Stage Suction Pressure AL A 75 PSIG ↑
PIT-1522 4-20mA 0 - 400 PSIG
75 SD: High 2nd Stage Suction Pressure SD A 80 PSIG ↑
SD: 2nd Stage Suction Pressure Out of Range 3.6mA ↓
76 SD A
Failure 20.5mA ↑
77 SD: Low 2nd Stage Discharge Pressure SD C/P 205 PSIG ↓
78 AL: Low 2nd Stage Discharge Pressure AL C/P 215 PSIG ↓
79 AL: High 2nd Stage Discharge Pressure AL A 260 PSIG ↑
PIT-1523 4-20mA 0 - 400 PSIG
80 SD: High 2nd Stage Discharge Pressure SD A 270 PSIG ↑
SD: 2nd Stage Discharge Pressure Out of Range 3.6mA ↓
81 SD A
Failure 20.5mA ↑
AL: High Engine Intake/Manifold Pressure from
82 AL A 70 in-hg Abs. ↑
ESM (OP4)
SD: High Engine Intake/Manifold Pressure from
83 PI-8100 4-20mA 0-149 in-hg Abs. SD A 80 in-hg Abs. ↑
ESM (OP4)
SD: Engine Intake/Manifold Pressure from ESM 3.6mA ↓
84 SD A
(OP4) Out of Range Failure 20.5mA ↑
AL: High Engine Coolant Temperature from ESM
85 AL A 190 DEG F ↑
(OP3)
SD: High Engine Coolant Temperature from ESM
86 TI-8101 4-20mA 32-320 DEG F SD A 200 DEG F ↑
(OP3)
SD: Engine Coolant Temperature from ESM (OP3) 3.6mA ↓
87 SD A
Out of Range Failure 20.5mA ↑
88 SD: Low Engine Oil Pressure from ESM (OP2) SD B1 30 PSIG ↓
89 AL: Low Engine Oil Pressure from ESM (OP2) AL B1 35 PSIG ↓
PI-8102 4-20mA 0-100 PSIG
SD: Engine Oil Pressure from ESM (OP2) Out of 3.6mA ↓
90 SD A
Range Failure 20.5mA ↑
91 SD: Low Engine Speed from ESM (OP1) SD B2 800 RPM ↓
92 AL: Low Engine Speed from ESM (OP1) AL B2 850 RPM ↓
93 AL: High Engine Speed from ESM (OP1) AL A 1200 RPM ↑
SI-8160 4-20mA 0-2016 RPM
94 SD: High Engine Speed from ESM (OP1) ESD A 1210 RPM ↑
SD: Engine Speed from ESM (OP1) Out of Range 3.6mA ↓
95 ESD A
Failure 20.5mA ↑
96 AL: High Engine Vibration AL A 0.45 IPS ↑
VT-8251 4-20mA 0 – 1.0 IPS
97 SD: High Engine Vibration SD A 0.50 IPS ↑
19
52-32-11566 Rev A 1/24/2019
CALIBRATED
PRE-
SETPOINT
STATE (DI)
3.6mA ↓
98 SD: Engine Vibration Out of Range Failure SD A
20.5mA ↑
99 AL: High Compressor Vibration AL A 0.45 IPS ↑
100 SD: High Compressor Vibration SD A 0.50 IPS ↑
VT-8250 4-20mA 0 – 1.0 IPS
3.6mA ↓
101 SD: Compressor Vibration Out of Range Failure SD A
20.5mA ↑
102 Suction Flow IND IND N/A
FIT-1500 4-20mA 0 – 7.0 MMSCFD 3.6mA ↓
103 AL: Suction Flow Out of Range Failure AL A
20.5mA ↑
104 Interstage Flow IND IND N/A
FIT-1501 4-20mA 0 – 2.0 MMSCFD 3.6mA ↓
105 AL: Interstage Flow Out of Range Failure AL A
20.5mA ↑
106 Discharge Flow IND IND N/A
FIT-1502 4-20mA 0 – 10.0 MMSCFD 3.6mA ↓
107 AL: Discharge Flow Out of Range Failure AL A
20.5mA ↑
AL: High Compressor Cylinder #1 Discharge
108 AL A 103 °F ↑
Temperature A
SD: High Compressor Cylinder #1 Discharge 100 ohm Pt
109 TE-1631A -328.0 – 1562.0 °F SD A 108 °F ↑
Temperature A RTD
SD: Compressor Cylinder #1 Discharge -328.0 °F ↓
110 SD A
Temperature A Out of Range Failure 1562.0 °F ↑
111 AL A 103 °F ↑
Temperature B
112 TE-1631B -328.0 – 1562.0 °F SD A 108 °F ↑
Temperature B RTD
113 SD A
Temperature B Out of Range Failure 1562.0 °F ↑
114 AL A 213 °F ↑
Temperature
115 TE-1632 -328.0 – 1562.0 °F SD A 223 °F ↑
Temperature RTD
116 SD A
Temperature Out of Range Failure 1562.0 °F ↑
117 AL A 103 °F ↑
Temperature A
118 TE-1633A -328.0 – 1562.0 °F SD A 108 °F ↑
Temperature A RTD
119 SD A
Temperature A Out of Range Failure 1562.0 °F ↑
120 AL A 103 °F ↑
Temperature B
121 TE-1633B -328.0 – 1562.0 °F SD A 108 °F ↑
Temperature B RTD
122 SD A
Temperature B Out of Range Failure 1562.0 °F ↑
123 AL A 213 °F ↑
Temperature
124 TE-1634 -328.0 – 1562.0 °F SD A 223 °F ↑
Temperature RTD
125 SD A
Temperature Out of Range Failure 1562.0 °F ↑
126 AL: High Compressor Suction Gas Temperature AL A 19 °F ↑
127 SD: High Compressor Suction Gas Temperature SD A 23 °F ↑
TE-1630 Type-K TC -454.0 – 2482.0 °F
SD: Compressor Suction Gas Temperature Out of -454.0 °F ↓
128 SD A
Range Failure 2482.0 °F ↑
129 AL: High Compressor Post-Cooler Oil Temperature AL A 180 °F ↑
130 SD: High Compressor Post-Cooler Oil Temperature SD A 190 °F ↑
TE-2059 Type-K TC -454.0 – 2482.0 °F
SD: Compressor Post-Cooler Oil Temperature Out -454.0 °F ↓
131 SD A
of Range Failure 2482.0 °F ↑
132 AL: High Compressor Bearing #1 Temperature AL A 210 °F ↑
133 SD: High Compressor Bearing #1 Temperature SD A 220 °F ↑
TE-8200A Type-K TC -454.0 – 2482.0 °F
SD: Compressor Bearing #1 Temperature Out of -454.0 °F ↓
134 SD A
TE-8200B Type-K TC -454.0 – 2482.0 °F
137 SD A
TE-8200C Type-K TC -454.0 – 2482.0 °F
20
52-32-11566 Rev A 1/24/2019
CALIBRATED
PRE-
SETPOINT
STATE (DI)
140 SD A
TE-8200D Type-K TC -454.0 – 2482.0 °F
143 SD A
AL: High Compressor Packing Cylinder #1
144 AL A 240 °F ↑
Temperature
SD: High Compressor Packing Cylinder #1
145 TE-8201A Type-K TC -454.0 – 2482.0 °F SD A 250 °F ↑
Temperature
SD: Compressor Packing Cylinder #1 Temperature -454.0 °F ↓
146 SD A
Out of Range Failure 2482.0 °F ↑
147 AL A 240 °F ↑
Temperature
148 TE-8201B Type-K TC -454.0 – 2482.0 °F SD A 250 °F ↑
Temperature
149 SD A
150 AL A 240 °F ↑
Temperature
151 TE-8201C Type-K TC -454.0 – 2482.0 °F SD A 250 °F ↑
Temperature
152 SD A
153 AL A 240 °F ↑
Temperature
154 TE-8201D Type-K TC -454.0 – 2482.0 °F SD A 250 °F ↑
Temperature
155 SD A
156 AL: High Engine Cylinder #1L Temperature AL A 1200 °F ↑
157 SD: High Engine Cylinder #1L Temperature SD A 1250 °F ↑
TE-8121A Type-K TC -454.0 – 2482.0 °F
SD: Engine Cylinder #1L Temperature Out of -454.0 °F ↓
158 SD A
TE-8122A Type-K TC -454.0 – 2482.0 °F
161 SD A
TE-8123A Type-K TC -454.0 – 2482.0 °F
164 SD A
TE-8124A Type-K TC -454.0 – 2482.0 °F
167 SD A
TE-8125A Type-K TC -454.0 – 2482.0 °F
170 SD A
TE-8126A Type-K TC -454.0 – 2482.0 °F
173 SD A
174 AL: High Engine Cylinder #1R Temperature AL A 1200 °F ↑
175 SD: High Engine Cylinder #1R Temperature SD A 1250 °F ↑
TE-8121B Type-K TC -454.0 – 2482.0 °F
SD: Engine Cylinder #1R Temperature Out of -454.0 °F ↓
176 SD A
TE-8122B Type-K TC -454.0 – 2482.0 °F
179 SD A
TE-8123B Type-K TC -454.0 – 2482.0 °F
182 SD A
TE-8124B Type-K TC -454.0 – 2482.0 °F
21
52-32-11566 Rev A 1/24/2019
CALIBRATED
PRE-
SETPOINT
STATE (DI)
185 SD A
TE-8125B Type-K TC -454.0 – 2482.0 °F
188 SD A
TE-8126B Type-K TC -454.0 – 2482.0 °F
191 SD A
192 AL: High Engine Main Bearing #1 Temperature AL A 225 °F ↑
193 SD: High Engine Main Bearing #1 Temperature SD A 250 °F ↑
TE-8101 Type-K TC -454.0 – 2482.0 °F
SD: Engine Main Bearing #1 Temperature Out of -454.0 °F ↓
194 SD A
TE-8102 Type-K TC -454.0 – 2482.0 °F
197 SD A
TE-8103 Type-K TC -454.0 – 2482.0 °F
200 SD A
TE-8104 Type-K TC -454.0 – 2482.0 °F
203 SD A
TE-8105 Type-K TC -454.0 – 2482.0 °F
206 SD A
TE-8106 Type-K TC -454.0 – 2482.0 °F
209 SD A
TE-8107 Type-K TC -454.0 – 2482.0 °F
212 SD A
213 AL: High Engine Left Bank Turbo Temperature AL A 1200 °F ↑
214 SD: High Engine Left Bank Turbo Temperature SD A 1375 °F ↑
TE-8133 Type-K TC -454.0 – 2482.0 °F
SD: Engine Left Bank Turbo Temperature Out of -454.0 °F ↓
215 SD A
216 AL: High Engine Right Bank Turbo Temperature AL A 1200 °F ↑
217 SD: High Engine Right Bank Turbo Temperature SD A 1375 °F ↑
TE-8134 Type-K TC -454.0 – 2482.0 °F
SD: Engine Right Bank Turbo Temperature Out of -454.0 °F ↓
218 SD A
219 AL: High Engine Pre-Catalyst Temperature AL A 1100 °F ↑
220 SD: High Engine Pre-Catalyst Temperature SD A 1150 °F ↑
TE-7030 Type-K TC -454.0 – 2482.0 °F
SD: Engine Pre-Catalyst Temperature Out of -454.0 °F ↓
221 SD A
222 AL: High Engine Post-Catalyst Temperature AL A 1200 °F ↑
223 SD: High Engine Post-Catalyst Temperature SD A 1250 °F ↑
TE-7031 Type-K TC -454.0 – 2482.0 °F
SD: Engine Post-Catalyst Temperature Out of -454.0 °F ↓
224 SD A
225 AL: High Throw #1 Rod Load Compression AL A 36000 LBF↑
0-40000 LBF
226 SD: High Throw #1 Rod Load Compression SD A 38000 LBF↑
227 AL: High Throw #1 Rod Load Tension AL A 33300 LBF↑
N/A CALC 0-37000 LBF
228 SD: High Throw #1 Rod Load Tension SD A 35150 LBF↑
229 AL: High Throw #1 Rod Load Total AL A 66600 LBF↑
0-74000 LBF
230 SD: High Throw #1 Rod Load Total SD A 70300 LBF↑
0-40000 LBF
0-74000 LBF
22
52-32-11566 Rev A 1/24/2019
CALIBRATED
PRE-
SETPOINT
STATE (DI)
0-37000 LBF
0-74000 LBF
0-40000 LBF
0-74000 LBF
23.0 CONFIGURABLE PROCESS VARIABLES (adjustable via the HMI/MMI)
Setting Factory
Setting Description Range Setting
Time allowed to test shutdowns for associated end devices. The Test Mode
0-1800
Test Mode Timer Timer will start counting down when Test Mode is enabled. When the Test 900 secs
secs
Mode Timer expires, Test Mode will be disabled.
The minimum Compressor Oil Pressure required to satisfy compressor
Compressor Oil Pressure Prelube 30-50
prelube. Compressor Oil Pressure is compared with the prelube permissive 45 psi(g)
Permissive Setpoint psi(g)
until the Class B2 Shutdown Delay expires.
Compressor Oil Temperature The minimum Compressor Oil Temperature required to satisfy compressor 32-100
50 Deg F
Prelube Permissive setpoint prelube. Deg F
Compressor Prelube Permissive Time allowed for unit to meet prelube permissive setpoints (for both 0-300
30 secs
Fail Timer Compressor Oil Pressure and Compressor Oil Temperature) secs
Compressor Prelube Duration Time allowed for the Compressor Oil Pressure and Temperature to exceed 120-300
120 secs
Timer their prelube permissives. secs
Minimum Engine Speed required before Class B1/B2 & P timer start timing
Engine Running Permissive 0-500 300 RPM
down and Engine advanced to Minimum Warmup Timer.
30-300
Engine Start Fail Timer Time allowed to satisfy the Engine Running Speed Permissive. 120 secs
secs
Time given for the engine to run at its Engine Minimum Run Speed and for 10-120
Minimum Warmup Duration Timer 10 secs
the compressor to run unloaded after the unit is running. secs
Compressor prelube Off Delay Time allowed to continue operating the Prelube Pump after the Engine has 0-60
15 secs
Timer been started. secs
The amount of time allowed before Class B1 alarms and shutdowns are
10-30
Class B1 Lockout Delay Timer monitored. The Class B1 Alarm & Shutdown Delay begins counting down 10 secs
secs
once the unit is running.
The amount of time allowed before Class B2 alarms and shutdowns are
15-300
Class B2 Lockout Delay Timer monitored. The Class B2 Alarm & Shutdown Delay begins counting down 60 secs
secs
once the unit is running.
Engine Jacket Water Load The minimum Engine Jacket Water Outlet Temperature required to satisfy 100-200
140 Deg F
Permissive Temperature the load permissive. Deg F
Engine Oil Load Permissive The minimum Engine Oil Temperature required to satisfy the load 100-200
145 Deg F
Temperature permissive. Deg F
Compressor Oil Load Permissive The minimum Compressor Oil Temperature required to satisfy the load 70-200
86 Deg F
Temperature permissive. Deg F
Time allowed to satisfy the Engine Oil, Engine Jacket Water and 0-1800
Unit Load Permissive Fail Timer 1800 secs
Compressor Oil load permissives. secs
The amount of time allowed before Class P alarms and shutdowns are 10-60
Class P Load Delay Timer 10 secs
monitored. secs
st
The amount of time allowed before the 1 Stage Suction High Alarm &
1st Stage Suction High Alarm & 10-60
Shutdown are monitored. The 1st Stage Suction High Alarm & Shutdown 5 secs
Shutdown Arming Delay Timer secs
Delay begins counting down once the unit is running.
The local atmospheric pressure. This is required for calculating compressor 0-15
Atmospheric Pressure 14.468 psi
rod load. psi
The time allowed for the engine to run at its Engine Minimum Run Speed
0-900
Cooldown Duration Timer and for the compressor to run unloaded after a normal stop command is 20 secs
secs
initiated.
The time allowed for the engine speed to drop below 10 RPM before the unit 10-30
Engine Stop Fail Timer 10 secs
will ESD when the Initiate Start to CAT output is De-Energized. secs
0-900
Engine Postlube Duration Timer The time allowed for the unit to Postlube after the engine has stopped. 30 secs
secs
0-2 (N/C)
Compressor Lubricator No-Flow This is the period of time the lubricator no-flow digital input must transition 2 secs
3-300
Fail Timer within. Entering a 2 second or less will disable the pulse function and treat
(Pulse)
23
52-32-11566 Rev A 1/24/2019
Setting Factory
the input as a fail open digital input. Entering any other value of time within
the setpoint settable range will treat the input as a pulsed time input.
Time allowed for the Bypass Valve to move and activate its open position 0-120
Bypass Valves Open Fail Timer 10 secs
limit switch. secs
Time allowed for the Bypass Valve to move and activate its close position 0-120
Bypass Valves Close Fail Timer 10 secs
limit switch. secs
Time allowed for the Blowdown Valve to move and activate its open position 0-120
Blowdown Valve Open Fail Timer 10 secs
limit switch. secs
Time allowed for the Blowdown Valve to move and activate its close position 0-120
Blowdown Valve Close Fail Timer 10 secs
limit switch. secs
Engine Speed from ESM Control Minimum setpoint value used for scaling Engine Speed from ESM Control
0-100 0 %LOAD
Range Min analog output.
Engine Speed from ESM Control Maximum setpoint value used for scaling Engine Speed from ESM analog
0-100 60 %LOAD
Range Max output.
1st Stage Recycle Valve Control Minimum setpoint value used for scaling Recycle Valve Control analog
0-100 50 %LOAD
Range Min output.
1st Stage Recycle Valve Control Maximum setpoint value used for scaling Recycle Valve Control analog
0-100 100 %LOAD
Range Max output.
1st Stage Suction Pressure PID The target Suction Pressure needed to be maintained by the 1st Stage 0 - 200
133 psi(g)
Setpoint Suction Pressure PID. psi(g)
1st Stage Suction Pressure PID The Suction deadband for the 1st Stage Suction Pressure PID while it is in
0 – 20 psi(g) 1 psi(g)
Deadband Auto Mode.
The gain for the 1st Stage Suction Pressure PID. The gain determines the
1st Stage Suction Pressure PID
reaction of the output with respect to the current error (setpoint - process 0.1-20 1.0
Gain (P):
variable).
1st Stage Suction Pressure PID The reset for the 1st Stage Suction Pressure PID. The reset determines the
0.1-10 2.5 min/repeat
Reset (I): reaction of the output based a summation of previous errors.
1st Stage Suction Pressure PID The rate of the 1st Stage Suction Pressure PID. The rate determines the
0-1 0 min
Rate (D): reaction of the output based on the rate at which the error is changing.
2nd Stage Discharge Pressure The target Discharge Pressure needed to be maintained by the 2nd Stage 0 - 300
285 psi(g)
PID Setpoint Discharge Pressure PID. psi(g)
2nd Stage Discharge Pressure The Discharge deadband for the 2nd Stage Discharge Pressure PID while it
0 – 20 psi(g) 5 psi(g)
PID Deadband is in Auto Mode.
The gain for the 2nd Stage Discharge Pressure PID. The gain determines
2nd Stage Discharge Pressure
the reaction of the output with respect to the current error (setpoint - process 0.1-20 1.0
PID Gain (P):
variable).
2nd Stage Discharge Pressure The reset for the 2nd Stage Discharge Pressure PID. The reset determines
PID Reset (I): the reaction of the output based a summation of previous errors.
2nd Stage Discharge Pressure The rate of the 2nd Stage Discharge Pressure PID. The rate determines the
0-1 0 min
PID Rate (D): reaction of the output based on the rate at which the error is changing.
Compressor Load Engine Percent The target Engine Percent Load needed to be maintained by the Engine 0 - 100
105 %Load
Load PID Setpoint Percent Load Pressure PID. %Load
Compressor Load Engine Percent The Engine Percent Load deadband for the Engine Percent Load Pressure 0 - 100
0 %Load
Load PID Deadband PID while it is in Auto Mode. %Load
The gain for the Engine Percent Load Pressure PID. The gain determines
Compressor Load Engine Percent
the reaction of the output with respect to the current error (setpoint - process 0.1-20 1.0
Load PID Gain (P):
variable).
Compressor Load Engine Percent The reset for the Engine Percent Load Pressure PID. The reset determines
Load PID Reset (I): the reaction of the output based a summation of previous errors.
Compressor Load Engine Percent The rate of the Engine Percent Load Pressure PID. The rate determines the
0-1 0 min
Load PID Rate (D): reaction of the output based on the rate at which the error is changing.
Engine Speed Control To ESM
The target speed when Engine Speed Control is placed in Manual Mode. 800-1200 N/A
Panel Manual Speed
The amount of time for the Engine Speed Control output to change 1%. 10-1000 300 MSEC
Panel 1% Rate of Change Timer
The Engine Speed calibration when the Engine Speed Control output is at
Panel Engine Speed Calibration @ 0-2200 750 rpm
4mA.
4mA
This is the Engine Speed calibration when the Engine Speed Control output
Panel Engine Speed Calibration @ 0-2200 1206 rpm
is at 20mA.
20mA
Panel Minimum Engine Run The engine speed to be set when the unit is in Warmup or in Cooldown 750-1206 750 rpm
Speed
Panel Minimum Engine Load The minimum engine speed to be set when the unit is in load control. 750-1206 800 rpm
Speed
Panel Maximum Engine Load The maximum engine speed to be set when the unit is in load control. 750-1206 1206 rpm
Speed
24
52-32-11566 Rev A 1/24/2019
Setting Factory
1st Stage Recycle Control Valve The target % OPEN when 1st Stage Recycle Valve Control is placed in
0 - 100 N/A
Manual Target Setpoint Manual Mode.
1st Stage Recycle Control Valve The amount of time for the 1st Stage Recycle Valve Control output to change
10 - 1000 300 MSEC
1% Rate of Change Timer 1%.
2nd Stage Recycle Control Valve The target % OPEN when 2nd Stage Recycle Valve Control is placed in
0 - 100 N/A
Manual Target Setpoint Manual Mode.
2nd Stage Recycle Control Valve The amount of time for the 2nd Stage Recycle Valve Control output to change
10 - 1000 300 MSEC
1% Rate of Change Timer 1%.
Frame Selection Compressor Frame Type N/A JGK
Select Blank, Single Acting, Double Acting, Tandem (HP) Outboard, or
Throw #1 Configuration N/A Double Acting
Tandem (HP) Inboard
Select the correct stage assigned for Throw #1. When a Tandem
Throw #1 Assignment Stage (HP
configuration is selected, the text will change to Throw #1 Assignment HP
Stage when configured for 1-6 1
Stage and be used to select the correct stage assignment for the Tandem
Tandem)
High Pressure Cylinder.
When a Tandem Configuration is selected, the Throw #1 Assignment LP
Throw #1 Assignment LP Stage Stage selection will become available and used to select the correct stage 1-6 N/A
assignment for the Tandem Low Pressure Cylinder.
Throw #1 Rod Diameter Rod Diameter for Throw #1. 0.0-36.0 2.0
Throw #1 Cylinder Head End Diameter used for Area Calculation when
Throw #1 Cylinder Head End Single or Double Acting configuration is selected. When a Tandem
Diameter configuration is selected, the text will change to Throw #1 HP Cylinder Head
0.0-36.0 17.875
(HP Cylinder when configured for End Diameter and the Throw #1 LP Cylinder Head End Diameter will
Tandem) become available and used for the Head End Area Calculation of the
Tandem High Pressure Cylinder.
When a Tandem configuration is selected, the Throw #1 LP Cylinder Head
Throw #1 LP Cylinder Head End
End Diameter will become available and used for Head End Area Calculation 0.0-36.0 N/A inch
Diameter
of the Tandem Low Pressure Cylinder.
Tandem (HP) Inboard
Tandem)
0.0-36.0 14.125
Diameter
Tandem (HP) Inboard
Tandem)
0.0-36.0 17.875
Diameter
Tandem (HP) Inboard
25
52-32-11566 Rev A 1/24/2019
Setting Factory
Tandem)
0.0-36.0 14.125
(HP Cylinder when configured for
End Diameter and the Throw #4 LP Cylinder Head End Diameter will
Diameter
24.0 PASS CODE ACCESS
24.1 The setpoint adjustments that are available on the HMI/MMI are access protected with a username and
password. If the user attempts to make setpoint changes a login popup will appear. The user must login
before setpoints and configurable process variables can be modified.
24.2 The default login for this control panel is as follows:
Username: EXTERRAN
Password: 11566
25.0 COMMUNICATION CONFIGURATION
25.1 HMI:
Ethernet Port:
Protocol: AB Ethernet / IP
IP Address: 10.10.0.2
Subnet Mask: 255.255.255.0
25.2 PLC:
CPU Ethernet Port:

Protocol: AB Ethernet / IP
Subnet Mask: 255.255.255.0
25.3 RTU:
Ethernet Port:
Protocol 1: AB Ethernet / IP
Protocol 2: Modbus TCP / IP Slave
TCP Port: 502
Subnet Mask: 255.255.255.0
RS485 Port:
Protocol: Modbus RTU Slave
Baud Rate: 9600
Data, Stop, Parity: 8, 1, N
26
52-32-11566 Rev A 1/24/2019
Node / Drop Address: 1
XCRS RS485 Port:

Protocol: Modbus RTU Master
Baud Rate: 9600
Data, Stop, Parity: 8, 1, N
ESM Node / Drop Address: 1
26.0 MODBUS/PLC CONTROLLER TAGS DCS/SCADA DATA MAP

MODBUS MODBUS DATA UNITS OF BIT FUNCTION
DESCRIPTION PLC TAG
WORD BIT TYPE MEASURE INDICATION TYPICAL
0=HEALTHY
SD: Local Emergency Stop DCS_READ_INT[0].0 40001 BIT 0 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Engine Shutdown from ESM DCS_READ_INT[0].5 40001 BIT 5 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Remote Emergency Stop DCS_READ_INT[0].6 40001 BIT 6 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Lubricator No-Flow Left Bank (FSLL-2126) DCS_READ_INT[0].7 40001 BIT 7 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Lubricator No-Flow Right Bank (FSLL-2127) DCS_READ_INT[0].8 40001 BIT 8 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Low Engine Oil Level (LSLL-2022) DCS_READ_INT[0].9 40001 BIT 9 I16u 0/1 SD
1=FAULTED
SD: Low Engine Jacket Water Level (LSLL- 0=HEALTHY
DCS_READ_INT[0].10 40001 BIT 10 I16u 0/1 SD
4100) 1=FAULTED
SD: Low Engine Auxiliary Water Level (LSLL- 0=HEALTHY
4101) 1=FAULTED
SD: Low Compressor Oil Separator Level (LSLL- 0=HEALTHY
2023) 1=FAULTED
SD: High 1st Stage Suction Scrubber Liquid 0=HEALTHY
Level (LSHH-1500) 1=FAULTED
SD: High 2nd Stage Suction Scrubber Liquid 0=HEALTHY
Level (LSHH-1501) 1=FAULTED
SD: High Discharge Scrubber Liquid Level 0=HEALTHY
(LSHH-1502) 1=FAULTED
0=HEALTHY
SD: High Cooler Fan Vibration (VSHH-8350) DCS_READ_INT[1].0 40002 BIT 0 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Bypass Valve Open (ZSO-1041) DCS_READ_INT[1].6 40002 BIT 6 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Bypass Valve Closed (ZSC-1041) DCS_READ_INT[1].7 40002 BIT 7 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Bypass Valve Open (ZSO-1040) DCS_READ_INT[1].8 40002 BIT 8 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Bypass Valve Closed (ZSC-1040) DCS_READ_INT[1].9 40002 BIT 9 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Blowdown Valve Open (ZSO-1037) DCS_READ_INT[1].10 40002 BIT 10 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Blowdown Valve Closed (ZSC-1037) DCS_READ_INT[1].11 40002 BIT 11 I16u 0/1 SD
1=FAULTED
0=HEALTHY
AL: Engine Alarm from ESM DCS_READ_INT[16].4 40017 BIT 4 I16u 0/1 AL
1=FAULTED
0=HEALTHY
AL: Low Panel Purge Pressure Alarm DCS_READ_INT[17].15 40018 BIT 15 I16u 0/1 AL
1=FAULTED
0=HEALTHY
TIMESTAMP: Local Start DCS_READ_INT[32].1 40033 BIT 1 I16u 0/1 IND
1=FAULTED
0=HEALTHY
TIMESTAMP: Local Stop DCS_READ_INT[32].2 40033 BIT 2 I16u 0/1 IND
1=FAULTED
0=HEALTHY
TIMESTAMP: Local Reset DCS_READ_INT[32].3 40033 BIT 3 I16u 0/1 IND
1=FAULTED
SD: Low Compressor Oil Pressure Shutdown 0=HEALTHY
(PIT-2103) 1=FAULTED
SD: Low 1st Stage Suction Pressure Shutdown 0=HEALTHY
SD: Low 1st Stage Discharge Pressure 0=HEALTHY
Shutdown (PIT-1521) 1=FAULTED
SD: Low 2nd Stage Suction Pressure Shutdown 0=HEALTHY
SD: Low 2nd Stage Discharge Pressure 0=HEALTHY
SD: Low Engine Intake/Manifold Pressure from 0=HEALTHY
ESM (OP4) Shutdown (PI-8100) 1=FAULTED
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DESCRIPTION PLC TAG
SD: Low Engine Coolant Temperature from ESM 0=HEALTHY
(OP3) Shutdown (TI-8101) 1=FAULTED
SD: Low Engine Oil Pressure from ESM (OP2) 0=HEALTHY
Shutdown (PI-8102) 1=FAULTED
SD: Low Engine Speed from ESM (OP1) 0=HEALTHY
Shutdown (SI-8160) 1=FAULTED
0=HEALTHY
SD: Low Suction Flow Shutdown (FIT-1500) DCS_READ_INT[49].8 40050 BIT 8 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Low Interstage Flow Shutdown (FIT-1501) DCS_READ_INT[49].9 40050 BIT 9 I16u 0/1 SD
1=FAULTED
0=HEALTHY
SD: Low Discharge Flow Shutdown (FIT-1502) DCS_READ_INT[49].10 40050 BIT 10 I16u 0/1 SD
1=FAULTED
AL: Low Compressor Oil Pressure Alarm (PIT- 0=HEALTHY
DCS_READ_INT[58].0 40059 BIT 0 I16u 0/1 AL
2103) 1=FAULTED
AL: Low Compressor Oil Filter Differential 0=HEALTHY
Pressure Alarm (DPIT-2057) 1=FAULTED
AL: Low 1st Stage Suction Pressure Alarm (PIT- 0=HEALTHY
1520) 1=FAULTED
AL: Low 1st Stage Discharge Pressure Alarm 0=HEALTHY
AL: Low 2nd Stage Suction Pressure Alarm 0=HEALTHY
AL: Low 2nd Stage Discharge Pressure Alarm 0=HEALTHY
(PT-1523) 1=FAULTED
AL: Low Engine Intake/Manifold Pressure from 0=HEALTHY
ESM (OP4) Alarm (PI-8100) 1=FAULTED
AL: Low Engine Coolant Temperature from ESM 0=HEALTHY
(OP3) Alarm (TI-8101) 1=FAULTED
AL: Low Engine Oil Pressure from ESM (OP2) 0=HEALTHY
Alarm (PI-8102) 1=FAULTED
AL: Low Engine Speed from ESM (OP1) Alarm 0=HEALTHY
(SI-8160) 1=FAULTED
AL: High Compressor Oil Filter Differential 0=HEALTHY
Pressure Alarm (DPT-2057) 1=FAULTED
AL: High 1st Stage Suction Pressure Alarm (PIT- 0=HEALTHY
1520) 1=FAULTED
AL: High 1st Stage Discharge Pressure Alarm 0=HEALTHY
AL: High 2nd Stage Suction Pressure Alarm 0=HEALTHY
AL: High 2nd Stage Discharge Pressure Alarm 0=HEALTHY
AL: High Engine Intake/Manifold Pressure from 0=HEALTHY
ESM (OP4) Alarm (PI-8100) 1=FAULTED
AL: High Engine Coolant Temperature from ESM 0=HEALTHY
(OP3) Alarm (TI-8101) 1=FAULTED
AL: High Engine Oil Pressure from ESM (OP2) 0=HEALTHY
Alarm (PI-8102) 1=FAULTED
AL: High Engine Speed from ESM (OP1) Alarm 0=HEALTHY
(SI-8160) 1=FAULTED
0=HEALTHY
AL: High Engine Vibration Alarm (VT-8251) DCS_READ_INT[69].0 40070 BIT 0 I16u 0/1 AL
1=FAULTED
0=HEALTHY
AL: High Compressor Vibration Alarm (VT-8250) DCS_READ_INT[69].1 40070 BIT 1 I16u 0/1 AL
1=FAULTED
AL: Suction Flow Out of Range Failure (FIT- 0=HEALTHY
1500) 1=FAULTED
AL: Interstage Flow Out of Range Failure (FIT- 0=HEALTHY
1501) 1=FAULTED
AL: Discharge Flow Out of Range Failure (FIT- 0=HEALTHY
1502) 1=FAULTED
SD: High Compressor Oil Filter Differential 0=HEALTHY
Pressure Shutdown (DPIT-2057) 1=FAULTED
SD: High 1st Stage Suction Pressure Shutdown 0=HEALTHY
SD: High 1st Stage Discharge Pressure 0=HEALTHY
SD: High 2nd Stage Suction Pressure Shutdown 0=HEALTHY
SD: High 2nd Stage Discharge Pressure 0=HEALTHY
28
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
SD: High Engine Intake/Manifold Pressure from 0=HEALTHY
ESM (OP4) Shutdown (PI-8100) 1=FAULTED
SD: High Engine Coolant Temperature from 0=HEALTHY
ESM (OP3) Shutdown (TI-8101) 1=FAULTED
SD: High Engine Oil Pressure from ESM (OP2) 0=HEALTHY
Shutdown (PI-8102) 1=FAULTED
SD: High Engine Speed from ESM (OP1) 0=HEALTHY
Shutdown (SI-8160) 1=FAULTED
0=HEALTHY
SD: High Engine Vibration Shutdown (VT-8251) DCS_READ_INT[89].0 40090 BIT 0 I16u 0/1 SD
1=FAULTED
SD: High Compressor Vibration Shutdown (VT- 0=HEALTHY
8250) 1=FAULTED
SD: Compressor Oil Pressure Out of Range 0=HEALTHY
Failure (PIT-2103) 1=FAULTED
SD: Compressor Oil Filter Differential Pressure 0=HEALTHY
Out of Range Failure (DPIT-2057) 1=FAULTED
SD: 1st Stage Suction Pressure Out of Range 0=HEALTHY
SD: 1st Stage Discharge Pressure Out of Range 0=HEALTHY
Failure (PT-1521) 1=FAULTED
SD: 2nd Stage Suction Pressure Out of Range 0=HEALTHY
SD: 2nd Stage Discharge Pressure Out of 0=HEALTHY
Range Failure (PIT-1523) 1=FAULTED
SD: Engine Intake/Manifold Pressure from ESM 0=HEALTHY
(OP4) Out of Range Failure (PI-8100) 1=FAULTED
SD: Engine Coolant Temperature from ESM 0=HEALTHY
(OP3) Out of Range Failure (TI-8101) 1=FAULTED
SD: Engine Oil Pressure from ESM (OP2) Out of 0=HEALTHY
Range Failure (PI-8102) 1=FAULTED
SD: Engine Speed from ESM (OP1) Out of 0=HEALTHY
Range Failure (SI-8160) 1=FAULTED
SD: Engine Vibration Out of Range Failure (VT- 0=HEALTHY
8251) 1=FAULTED
SD: Compressor Vibration Out of Range Failure 0=HEALTHY
(VT-8250) 1=FAULTED
AL: High Compressor Cylinder #1 Discharge 0=HEALTHY
Temperature A Alarm (TE-1631A) 1=FAULTED
Temperature B Alarm (TE-1631B) 1=FAULTED
Temperature Alarm (TE-1632) 1=FAULTED
Temperature A Alarm (TE-1633A) 1=FAULTED
Temperature B Alarm (TE-1633B) 1=FAULTED
AL: High Compressor Suction Gas Temperature 0=HEALTHY
Alarm (TE-1630) 1=FAULTED
AL: High Compressor Post-Cooler Oil 0=HEALTHY
AL: High Compressor Bearing #1 Temperature 0=HEALTHY
Alarm (TE-8200A) 1=FAULTED
Alarm (TE-8200B) 1=FAULTED
Alarm (TE-8200C) 1=FAULTED
Alarm (TE-8200D) 1=FAULTED
AL: High Compressor Packing Cylinder #1 0=HEALTHY
Temperature Alarm (TE-8201A) 1=FAULTED
Temperature Alarm (TE-8201B) 1=FAULTED
Temperature Alarm (TE-8201C) 1=FAULTED
Temperature Alarm (TE-8201D) 1=FAULTED
AL: High Engine Cylinder #1L Temperature 0=HEALTHY
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52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
AL: High Engine Cylinder #1R Temperature 0=HEALTHY
AL: High Engine Main Bearing #1 Temperature 0=HEALTHY
AL: High Engine Left Bank Turbo Temperature 0=HEALTHY
AL: High Engine Right Bank Turbo Temperature 0=HEALTHY
AL: High Engine Pre-Catalyst Temperature 0=HEALTHY
AL: High Engine Post-Catalyst Temperature 0=HEALTHY
SD: High Compressor Cylinder #1 Discharge 0=HEALTHY
Temperature A Shutdown (TE-1631A) 1=FAULTED
Temperature B Shutdown (TE-1631B) 1=FAULTED
Temperature Shutdown (TE-1632) 1=FAULTED
Temperature A Shutdown (TE-1633A) 1=FAULTED
Temperature B Shutdown (TE-1633B) 1=FAULTED
SD: High Compressor Suction Gas Temperature 0=HEALTHY
Shutdown (TE-1630) 1=FAULTED
SD: High Compressor Post-Cooler Oil 0=HEALTHY
SD: High Compressor Bearing #1 Temperature 0=HEALTHY
Shutdown (TE-8200A) 1=FAULTED
Shutdown (TE-8200B) 1=FAULTED
Shutdown (TE-8200C) 1=FAULTED
Shutdown (TE-8200D) 1=FAULTED
SD: High Compressor Packing Cylinder #1 0=HEALTHY
Temperature Shutdown (TE-8201A) 1=FAULTED
30
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
Temperature Shutdown (TE-8201B) 1=FAULTED
Temperature Shutdown (TE-8201C) 1=FAULTED
Temperature Shutdown (TE-8201D) 1=FAULTED
SD: High Engine Cylinder #1L Temperature 0=HEALTHY
SD: High Engine Cylinder #1R Temperature 0=HEALTHY
SD: High Engine Main Bearing #1 Temperature 0=HEALTHY
SD: High Engine Left Bank Turbo Temperature 0=HEALTHY
SD: High Engine Right Bank Turbo Temperature 0=HEALTHY
SD: High Engine Pre-Catalyst Temperature 0=HEALTHY
SD: High Engine Post-Catalyst Temperature 0=HEALTHY
SD: Compressor Cylinder #1 Discharge 0=HEALTHY
Temperature A Out of Range Failure (TE-1631A) 1=FAULTED
Temperature B Out of Range Failure (TE-1631B) 1=FAULTED
Temperature Out of Range Failure (TE-1632) 1=FAULTED
Temperature A Out of Range Failure (TE-1633A) 1=FAULTED
Temperature B Out of Range Failure (TE-1633B) 1=FAULTED
Temperature Out of Range Failure (TE-1634) 1=FAULTED
SD: Compressor Suction Gas Temperature Out 0=HEALTHY
of Range Failure (TE-1630) 1=FAULTED
SD: Compressor Post-Cooler Oil Temperature 0=HEALTHY
Out of Range Failure (TE-2059) 1=FAULTED
SD: Compressor Bearing #1 Temperature Out of 0=HEALTHY
Range Failure (TE-8200A) 1=FAULTED
31
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
Range Failure (TE-8200B) 1=FAULTED
Range Failure (TE-8200C) 1=FAULTED
Range Failure (TE-8200D) 1=FAULTED
SD: Compressor Packing Cylinder #1 0=HEALTHY
Temperature Out of Range Failure (TE-8201A) 1=FAULTED
Temperature Out of Range Failure (TE-8201B) 1=FAULTED
Temperature Out of Range Failure (TE-8201C) 1=FAULTED
Temperature Out of Range Failure (TE-8201D) 1=FAULTED
SD: Engine Cylinder #1L Temperature Out of 0=HEALTHY
SD: Engine Cylinder #1R Temperature Out of 0=HEALTHY
SD: Engine Main Bearing #1 Temperature Out of 0=HEALTHY
Range Failure (TE-8101) 1=FAULTED
SD: Engine Left Bank Turbo Temperature Out of 0=HEALTHY
SD: Engine Right Bank Turbo Temperature Out 0=HEALTHY
of Range Failure (TE-8134) 1=FAULTED
SD: Engine Pre-Catalyst Temperature Out of 0=HEALTHY
SD: Engine Post-Catalyst Temperature Out of 0=HEALTHY
0=OFF
AL: High Throw #1 Rod Load Compression DCS_READ_INT[184].0 40185 BIT 0 I16u 0/1 AL
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
SD: High Throw #1 Rod Load Compression DCS_READ_INT[184].8 40185 BIT 8 I16u 0/1 SD
1=ON
32
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
0=OFF
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
AL: High Throw #1 Rod Load Tension DCS_READ_INT[185].0 40186 BIT 0 I16u 0/1 AL
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
SD: High Throw #1 Rod Load Tension DCS_READ_INT[185].8 40186 BIT 10 I16u 0/1 SD
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
AL: High Throw #1 Rod Load Total DCS_READ_INT[186].0 40187 BIT 0 I16u 0/1 AL
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
SD: High Throw #1 Rod Load Total DCS_READ_INT[186].8 40187 BIT 8 I16u 0/1 SD
1=ON
0=OFF
1=ON
0=OFF
1=ON
0=OFF
1=ON
SD: Compressor Oil Pressure Prelube 0=HEALTHY
Permissive Failure 1=FAULTED
SD: Compressor Oil Temperature Prelube 0=HEALTHY
Permissive Failure 1=FAULTED
SD: Compressor Prelube Duration Failure - Unit 0=HEALTHY
Failed to Maintain Compressor Oil Pressure 1=FAULTED
SD: Compressor Prelube Duration Failure - Unit 0=HEALTHY
Failed to Maintain Compressor Oil Temperature 1=FAULTED
SD: Engine Failed to Exceed Engine Running 0=HEALTHY
RPM Setpoint in Maximum Allowable Time 1=FAULTED
SD: Time Exceeded for Engine to Run Unloaded
0=HEALTHY
- Engine Jacket Water Temperature Load DCS_READ_INT[187].5 40188 BIT 5 I16u 0/1 SD
1=FAULTED
Permissive Failure
0=HEALTHY
- Engine Oil Temperature Load Permissive DCS_READ_INT[187].6 40188 BIT 6 I16u 0/1 SD
1=FAULTED
Failure
SD: Time Exceeded for Engine to Run Unloaded 0=HEALTHY
- Engine Parameters Unknown 1=FAULTED
0=HEALTHY
- Compressor Oil Temperature Load Permissive DCS_READ_INT[187].8 40188 BIT 8 I16u 0/1 SD
1=FAULTED
Failure
SD: Time Exceeded for Engine to Run Unloaded 0=HEALTHY
- Operator Failed to Initiate Unit Loading 1=FAULTED
0=HEALTHY
- Engine Failed to Exceed Engine Minimum Load DCS_READ_INT[187].10 40188 BIT 10 I16u 0/1 SD
1=FAULTED
RPM Setpoint
SD: Engine Failed to Achieve Engine Stop
0=HEALTHY
Conditions via Engine Run/Stop To ESM Digital DCS_READ_INT[187].11 40188 BIT 11 I16u 0/1 SD
1=FAULTED
Output De-Energized
0=HEALTHY
SD: R1S01 Module Faulted DCS_READ_INT[188].0 40189 BIT 0 I16u 0/1 SD
1=FAULTED
0=HEALTHY
1=FAULTED
33
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
0=HEALTHY
1=FAULTED
AL: Warning! Less Than 60 Seconds of Test 0=HEALTHY
Mode Time Remaining 1=FAULTED
AL: Engine Communication Failure Between 0=HEALTHY
Waukesha ESM and RTU 1=FAULTED
AL: Communication Failure Between PLC and 0=HEALTHY
RTU 1=FAULTED
0=HEALTHY
TIMESTAMP: Test Mode Enabled DCS_READ_INT[199].0 40200 BIT 0 I16u 0/1 IND
1=FAULTED
0=OFF INPUT
Local Emergency Stop DCS_READ_INT[200].0 40201 BIT 0 I16u 0/1
1=ON STATUS
0=OFF INPUT
Local Start DCS_READ_INT[200].1 40201 BIT 1 I16u 0/1
1=ON STATUS
0=OFF INPUT
Local Stop DCS_READ_INT[200].2 40201 BIT 2 I16u 0/1
1=ON STATUS
0=OFF INPUT
Local Reset DCS_READ_INT[200].3 40201 BIT 3 I16u 0/1
1=ON STATUS
0=OFF INPUT
Engine Alarm from ESM DCS_READ_INT[200].4 40201 BIT 4 I16u 0/1
1=ON STATUS
0=OFF INPUT
Engine Shutdown from ESM DCS_READ_INT[200].5 40201 BIT 5 I16u 0/1
1=ON STATUS
0=OFF INPUT
Remote Emergency Stop DCS_READ_INT[200].6 40201 BIT 6 I16u 0/1
1=ON STATUS
0=OFF INPUT
Lubricator No-Flow Left Bank (FSLL-2126) DCS_READ_INT[200].7 40201 BIT 7 I16u 0/1
1=ON STATUS
0=OFF INPUT
Lubricator No-Flow Right Bank (FSLL-2127) DCS_READ_INT[200].8 40201 BIT 8 I16u 0/1
1=ON STATUS
0=OFF INPUT
Low Engine Oil Level (LSLL-2022) DCS_READ_INT[200].9 40201 BIT 9 I16u 0/1
1=ON STATUS
0=OFF INPUT
Low Engine Jacket Water Level (LSLL-4100) DCS_READ_INT[200].10 40201 BIT 10 I16u 0/1
1=ON STATUS
0=OFF INPUT
Low Engine Auxiliary Water Level (LSLL-4101) DCS_READ_INT[200].11 40201 BIT 11 I16u 0/1
1=ON STATUS
Low Compressor Oil Separator Level (LSLL- 0=OFF INPUT
DCS_READ_INT[200].12 40201 BIT 12 I16u 0/1
2023) 1=ON STATUS
High 1st Stage Suction Scrubber Liquid Level 0=OFF INPUT
(LSHH-1500) 1=ON STATUS
High 2nd Stage Suction Scrubber Liquid Level 0=OFF INPUT
(LSHH-1501) 1=ON STATUS
High Discharge Scrubber Liquid Level (LSHH- 0=OFF INPUT
1502) 1=ON STATUS
0=OFF INPUT
High Cooler Fan Vibration (VSHH-8350) DCS_READ_INT[201].0 40202 BIT 0 I16u 0/1
1=ON STATUS
34
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
0=OFF INPUT
Spare DI_17 DCS_READ_INT[201].1 40202 BIT 1 I16u 0/1
1=ON STATUS
0=OFF INPUT
1=ON STATUS
0=OFF INPUT
1=ON STATUS
0=OFF INPUT
1=ON STATUS
0=OFF INPUT
1=ON STATUS
0=OFF INPUT
Bypass Valve Open (ZSO-1041) DCS_READ_INT[201].6 40202 BIT 6 I16u 0/1
1=ON STATUS
0=OFF INPUT
Bypass Valve Closed (ZSC-1041) DCS_READ_INT[201].7 40202 BIT 7 I16u 0/1
1=ON STATUS
0=OFF INPUT
Bypass Valve Open (ZSO-1040) DCS_READ_INT[201].8 40202 BIT 8 I16u 0/1
1=ON STATUS
0=OFF INPUT
Bypass Valve Closed (ZSC-1040) DCS_READ_INT[201].9 40202 BIT 9 I16u 0/1
1=ON STATUS
0=OFF INPUT
Blowdown Valve Open (ZSO-1037) DCS_READ_INT[201].10 40202 BIT 10 I16u 0/1
1=ON STATUS
0=OFF INPUT
Blowdown Valve Closed (ZSC-1037) DCS_READ_INT[201].11 40202 BIT 11 I16u 0/1
1=ON STATUS
0=OFF INPUT
1=ON STATUS
0=OFF INPUT
1=ON STATUS
0=OFF INPUT
1=ON STATUS
0=OFF INPUT
Low Panel Purge Pressure Alarm DCS_READ_INT[201].15 40202 BIT 15 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Unit Running-Remote Indication DCS_READ_INT[216].0 40217 BIT 0 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Unit Alarm-Remote Indication DCS_READ_INT[216].1 40217 BIT 1 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Unit Shutdown-Remote Indication DCS_READ_INT[216].2 40217 BIT 2 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Spare DO_03 DCS_READ_INT[216].3 40217 BIT 3 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Compressor Lube Solenoid (XY-2007) DCS_READ_INT[216].4 40217 BIT 4 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
Engine Start to ESM DCS_READ_INT[216].6 40217 BIT 6 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Engine Run/Stop to ESM DCS_READ_INT[216].7 40217 BIT 7 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Remote Speed Setting Enable to ESM DCS_READ_INT[216].8 40217 BIT 8 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Engine Idle/Rated Speed Setting to ESM DCS_READ_INT[216].9 40217 BIT 9 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
ESD/Fault Shutdown to ESM DCS_READ_INT[216].10 40217 BIT 10 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
Alarm/Shutdown Strobe DCS_READ_INT[216].14 40217 BIT 14 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Alarm/Shutdown Horn DCS_READ_INT[216].15 40217 BIT 15 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
Bypass Valve Solenoid (XY-1041) DCS_READ_INT[217].1 40218 BIT 1 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Bypass Valve Solenoid (XY-1040) DCS_READ_INT[217].2 40218 BIT 2 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Blowdown Valve Solenoid (XY-1037) DCS_READ_INT[217].3 40218 BIT 3 I16u 0/1
1=ON STATUS
35
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
1=ON STATUS
0=OFF OUTPUT
Unit Running-Local Indication DCS_READ_INT[217].13 40218 BIT 13 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Unit Alarm-Local Indication DCS_READ_INT[217].14 40218 BIT 14 I16u 0/1
1=ON STATUS
0=OFF OUTPUT
Unit Shutdown-Local Indication DCS_READ_INT[217].15 40218 BIT 15 I16u 0/1
1=ON STATUS
DECIMAL MACHINE
Auto Sequence Step DCS_READ_INT[224] 40225 WORD I16u N/A
VALUE STATE
0= CONVERT
Convert Engineering Units Status DCS_READ_INT[249].0 40250 BIT 0 I16u 0/1 ENGLISH UNITS
1 = METRIC STATUS
Compressor Oil Pressure Scaled Value (PIT- SCALED
DCS_READ_REAL[0] 40251 DWORD F32s IEEE754 N/A
2103) VALUE
Compressor Oil Filter Differential Pressure SCALED
Scaled Value (DPIT-2057) VALUE
1st Stage Suction Pressure Scaled Value (PIT- SCALED
1520) VALUE
1st Stage Discharge Pressure Scaled Value SCALED
(PIT-1521) VALUE
2nd Stage Suction Pressure Scaled Value (PIT- SCALED
1522) VALUE
2nd Stage Discharge Pressure Scaled Value SCALED
(PIT-1523) VALUE
SCALED
Spare AI_06 Scaled Value DCS_READ_REAL[6] 40263 DWORD F32s IEEE754 N/A
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
Engine Intake/Manifold Pressure from ESM SCALED
(OP4) Scaled Value (PI-8100) VALUE
Engine Coolant Temperature from ESM (OP3) SCALED
Scaled Value (TI-8101) VALUE
Engine Oil Pressure from ESM (OP2) Scaled SCALED
Value (PI-8102) VALUE
Engine Speed from ESM (OP1) Scaled Value SCALED
(SI-8160) VALUE
SCALED
Engine Vibration Scaled Value (VT-8251) DCS_READ_REAL[16] 40283 DWORD F32s IEEE754 N/A
VALUE
SCALED
Compressor Vibration Scaled Value (VT-8250) DCS_READ_REAL[17] 40285 DWORD F32s IEEE754 N/A
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
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52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
Suction Flow Scaled Value (FIT-1500) DCS_READ_REAL[24] 40299 DWORD F32s IEEE754 N/A
VALUE
SCALED
Interstage Flow Scaled Value (FIT-1501) DCS_READ_REAL[25] 40301 DWORD F32s IEEE754 N/A
VALUE
SCALED
Discharge Flow Scaled Value (FIT-1502) DCS_READ_REAL[26] 40303 DWORD F32s IEEE754 N/A
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
Compressor Cylinder #1 Discharge Temperature SCALED
A Scaled Value (TE-1631A) VALUE
B Scaled Value (TE-1631B) VALUE
Scaled Value (TE-1632) VALUE
A Scaled Value (TE-1633A) VALUE
B Scaled Value (TE-1633B) VALUE
SCALED
Spare TE_06 Scaled Value DCS_READ_REAL[166] 40583 DWORD F32s IEEE754 N/A
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
Compressor Suction Gas Temperature Scaled SCALED
Value (TE-1630) VALUE
Compressor Post-Cooler Oil Temperature SCALED
Compressor Bearing #1 Temperature Scaled SCALED
Value (TE-8200A) VALUE
Value (TE-8200B) VALUE
Value (TE-8200C) VALUE
Value (TE-8200D) VALUE
Compressor Packing Cylinder #1 Temperature SCALED
Scaled Value (TE-8201A) VALUE
Scaled Value (TE-8201B) VALUE
Scaled Value (TE-8201C) VALUE
Scaled Value (TE-8201D) VALUE
SCALED
VALUE
SCALED
VALUE
37
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
Engine Cylinder #1L Temperature Scaled Value SCALED
(TE-8121A) VALUE
(TE-8122A) VALUE
(TE-8123A) VALUE
(TE-8124A) VALUE
(TE-8125A) VALUE
(TE-8126A) VALUE
Engine Cylinder #1R Temperature Scaled Value SCALED
(TE-8121B) VALUE
(TE-8122B) VALUE
(TE-8123B) VALUE
(TE-8124B) VALUE
(TE-8125B) VALUE
(TE-8126B) VALUE
Engine Main Bearing #1 Temperature Scaled SCALED
Engine Left Bank Turbo Temperature Scaled SCALED
Engine Right Bank Turbo Temperature Scaled SCALED
Engine Pre-Catalyst Temperature Scaled Value SCALED
(TE-7030) VALUE
Engine Post-Catalyst Temperature Scaled Value SCALED
(TE-7031) VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
Engine Speed Control Scaled Value DCS_READ_REAL[272] 40795 DWORD F32s IEEE754 N/A
VALUE
1st Stage Recycle Valve Control Scaled Value SCALED
(PY-1046) VALUE
2nd Stage Recycle Valve Control Scaled Value SCALED
(PY-1047) VALUE
SCALED
Spare AO_03 Scaled Value DCS_READ_REAL[275] 40801 DWORD F32s IEEE754 N/A
VALUE
SCALED
Throw #1 Calculated Rod Load Compression DCS_READ_REAL[288] 40827 DWORD F32s IEEE754 N/A
VALUE
38
52-32-11566 Rev A 1/24/2019

DESCRIPTION PLC TAG
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
Throw #1 Calculated Rod Load Tension DCS_READ_REAL[296] 40843 DWORD F32s IEEE754 N/A
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
Throw #1 Calculated Rod Load Total DCS_READ_REAL[304] 40859 DWORD F32s IEEE754 N/A
VALUE
SCALED
VALUE
SCALED
VALUE
SCALED
VALUE
29.0 WAUKESHA ESM MAP
PLC WORD MODBUS

BIT NAME DESCRIPTION ENGINEERING UNIT
PLC ADDRESS ADDRESS
FUNCTION CODE 01
BIT 0 Main Fuel Valve Status of the main fuel valve 1 = ON

0 = OFF
BIT 1 Pre-Chamber Fuel Valve Status of the pre-chamber 1 = ON
fuel valve (if applicable) 0 = OFF
BIT 2 Engine Running Whether the engine is running 1 = RUNNING
or not running 0 = OFF
BIT 3 Starter Motor Whether the starter motor is 1 = ENGAGED
engaged or not 0 = OFF
Whether the pre/post lube pump 1 = RUNNING
BIT 4 Pre/Post Lube
is running 0 = OFF
Whether a validated alarm is 1 = ON
BIT 5 Engine Alarm
active 0 = OFF
Whether the shutdown is active 1 = OK
BIT 6 Engine Shutdown
0 = SHUTDOWN
BIT 7 Engine Knocking Whether the engine is in 1 = ON
uncontrollable knock 0 = OFF
ESM_FC01_DATA[0] 00001 Whether the engine is 1 = NO SPARK
BIT 8 No Spark experiencing a no-spark 0 = OK
situation
BIT 9 Ignition Power Level Whether the ignition power 1 = HIGH
level is high or low 0 = LOW
Whether the ignition is enabled 1 = ON
BIT 10 Ignition Enabled
or not 0 = OFF
BIT 11 Not Used
BIT 12 Not Used
BIT 13 Not Used
BIT 14 Not Used
BIT 15 Not Used
PLC WORD MODBUS

PLC ADDRESS ADDRESS
FUNCTION CODE 02
Whether the start engine signal 1 = Start Engine Signal High
ESM_FC02_DATA[0] 10001 BIT 0 Start Engine Signal
is active 0 = Start Engine Signal Low
39
52-32-11566 Rev A 1/24/2019
PLC WORD MODBUS

PLC ADDRESS ADDRESS
FUNCTION CODE 02
BIT 1 Normal Shutdown Whether the normal 1 = Normal Shutdown

shutdown signal is active 0 = OK To Run
BIT 2 Emergency Shutdown Whether the emergency 1 = Emergency Shutdown
shutdown signal is active 0 = OK To Run
Whether the remote rpm 1 = Remote rpm Select Active
BIT 3 Remote rpm Select analog input is active or
inactive 0 = Remote rpm Select Inactive
BIT 4 Run High Idle Whether the run high-idle 1 = Run Engine At High Idle
digital input is active 0 = Run Engine At Low Idle
1 = Load Coming Digital Input
BIT 5 Load Coming Whether the load-coming Active
digital input is active 0 = Load Coming Digital Input
Inactive
1 = Alternate Gov Dynamics Is
BIT 6 Alternate Dynamics/ Whether the alternate Active
Synchronizer Mode governor dynamics is active 0 = Alternate Gov Dynamics Is
Inactive
Whether either the lockout
Lockout Button/Ignition button has been depressed 1 = Lockout Active
BIT 7
Module or the IPM-D has failed, or is 0 = Lockout Inactive
not powered
Whether user digital input 1 is 1 = User DIP 1 High
BIT 8 User Digital Input 1
high 0 = User DIP 1 Inactive
Whether the engine-driven 1 = Alternator OK
BIT 12 Alternator alternator is operating
correctly 0 = Alternator Not OK
AFR Manual/Automatic Whether the air/fuel ratio 1 = Automatic Mode

BIT 13 control is in manual or
Status (Left Bank) automatic mode 0 = Manual Mode
AFR Manual/Automatic Whether the air/fuel ratio 1 = Automatic Mode

BIT 14 control is in manual or
Status (Right Bank) automatic mode 0 = Manual Mode
BIT 15 Reserved For Future Use
PLC WORD MODBUS

NAME ENGINEERING UNITS
PLC ADDRESS ADDRESS
FUNCTION CODE 03
ESM_FC03_DATA[00] 44001 Number of ESD fault codes 16-bit unsigned integer that goes from 0 to 5
16-bit unsigned integer that goes from 111 to
ESM_FC03_DATA[01] 44002 First ESD fault code to occur 555, excluding any values that contain zeros
(see Table 4.00-3 for ESD Fault Codes)
ESM_FC03_DATA[02] 40403 Second ESD fault code to occur 555, excluding any values that contain zeros
ESM_FC03_DATA[03] 44004 Third ESD fault code to occur 555, excluding any values that contain zeros
ESM_FC03_DATA[04] 44005 Fourth ESD fault code to occur 555, excluding any values that contain zeros
16-bit unsigned integer that goes from 111 to 555, excluding any
ESM_FC03_DATA[05] 44006 Fifth ESD fault code to occur values that contain zeros (see Table 4.00-3 for ESD Fault
Codes)
ESM_FC03_DATA[06] 44007 Number of ALM fault codes 16-bit unsigned integer that goes from 0 to 5
ESM_FC03_DATA[07] 44008 First ALM fault code to occur values that contain zeros (see Table 4.00-2 for ALM Fault
Codes)
ESM_FC03_DATA[08] 44009 Second ALM fault code to occur values that contain zeros (see Table 4.00-2 for ALM Fault
Codes)
40
52-32-11566 Rev A 1/24/2019
PLC WORD MODBUS

PLC ADDRESS ADDRESS
FUNCTION CODE 03
ESM_FC03_DATA[09] 44010 Third ALM fault code to occur values that contain zeros (see Table 4.00-2 for ALM Fault
Codes)
ESM_FC03_DATA[10] 44011 Fourth ALM fault code to occur values that contain zeros (see Table 4.00-2 for ALM Fault
Codes)
ESM_FC03_DATA[11] 44012 Fifth ALM fault code to occur values that contain zeros (see Table 4.00-2 for ALM Fault
Codes)
ESM_FC03_DATA[12]
44013
Engine operating hours (in seconds) of 32-bit unsigned integer – full range
ESM_FC03_DATA[13] most recent ESD fault code
44014
ESM_FC03_DATA[14]
44015
ESM_FC03_DATA[15] second most recent ESD fault code
44016
ESM_FC03_DATA[16]
44017
ESM_FC03_DATA[17] third most recent ESD fault code
44018
ESM_FC03_DATA[18]
44019
ESM_FC03_DATA[19] fourth most recent ESD fault code
44020
ESM_FC03_DATA[20]
44021
Engine operating hours (in seconds) of fifth 32-bit unsigned integer – full range
ESM_FC03_DATA[21] most recent ESD fault code
44022
ESM_FC03_DATA[22]
44023
ESM_FC03_DATA[23] most recent ALM fault code
44024
ESM_FC03_DATA[24]
44025
ESM_FC03_DATA[25] second most recent ALM fault code
44026
ESM_FC03_DATA[26]
44027
ESM_FC03_DATA[27] third most recent ALM fault code
44028
ESM_FC03_DATA[28]
44029
ESM_FC03_DATA[29] fourth most recent ALM fault code
44030
ESM_FC03_DATA[30]
44031
Engine operating hours (in seconds) of fifth 32-bit unsigned integer – full range
ESM_FC03_DATA[31] most recent ALM fault code
44032
ESM_FC03_DATA[32] 44033 Desired engine load 16-bit unsigned integer that goes from 0 to 2304 (0 – 112%)
ESM_FC03_DATA[33] 44034 Actual engine load 16-bit unsigned integer that goes from 0 to 2560 (0 – 125%)
ESM_FC03_DATA[34] 44035 Position of stepper motor 1 – left bank 16-bit unsigned integer that goes from 0 to 20,000
ESM_FC03_DATA[35] 44036 Position of stepper motor 2 – right bank 16-bit unsigned integer that goes from 0 to 20,000
ESM_FC03_DATA[36] 44037 Reserved For Future Use
ESM_FC03_DATA[40] 44041
Current engine operating hours (in
32-bit unsigned integer – full range
seconds)
ESM_FC03_DATA[42] 44042
41
52-32-11566 Rev A 1/24/2019
PLC WORD MODBUS

PLC ADDRESS ADDRESS
FUNCTION CODE 03
Rich stepper maximum motor limit of active
ESM_FC03_DATA[43] 44043 16-bit unsigned integer that goes from 0 to 20,000
fuel (left bank)
Lean stepper minimum motor limit of active
fuel (left bank)
Rich stepper maximum motor limit of active
fuel (right bank)
Lean stepper minimum motor limit of active
fuel (right bank)

Countdown in seconds until engine starts
once starter pressed
PLC WORD MODBUS

NAME SCALING ENGINEERING UNITS
PLC ADDRESS ADDRESS
FUNCTION CODE 04
16-bit unsigned integer that
ESM_FC04_DATA[0] 43001 Average rpm Average engine rpm * 4 goes from 0 to 8800 (0 –
2200 rpm)
ESM_FC04_DATA[1] 43002 Oil pressure Oil pressure * 2 in units of kPa gauge goes from 0 to 2204 (0 –
1102 kPa)
ESM_FC04_DATA[2] 43003 Intake manifold absolute Intake manifold pressure * 4 in units of kPa goes from 0 to 2304 (0 –
pressure absolute
576 kPa)
Throttle position in units of percent open * 16-bit unsigned integer that

ESM_FC04_DATA[4] 43005 Throttle position
20.48 goes from 0 to 2048 (0 –
100%)

ESM_FC04_DATA[7] 43008 Coolant outlet temperature (Coolant outlet temperature in C + 40) * 8 goes from 0 to 1520 (-40 –
150° C)
ESM_FC04_DATA[8] 43009 Spark timing 1 (Spark timing + 15) * 16 of 1st cylinder in the goes from 0 to 960 (-15 –
firing order
45° BTDC)
ESM_FC04_DATA[9] 43010 Spark timing 2 (Spark timing +15) * 16 of 2nd cylinder in the goes from 0 to 960 (-15 –
firing order
45° BTDC)
ESM_FC04_DATA[10] 43011 Spark timing 3 (Spark timing + 15) * 16 of 3rd cylinder in the goes from 0 to 960 (-15 –
firing order
45° BTDC)
ESM_FC04_DATA[11] 43012 Spark timing 4 (Spark timing + 15) * 16 of 4th cylinder in the goes from 0 to 960 (-15 –
firing order
45° BTDC)
firing order
45° BTDC)
firing order
45° BTDC)
firing order
45° BTDC)
firing order
45° BTDC)
42
52-32-11566 Rev A 1/24/2019
PLC WORD MODBUS

PLC ADDRESS ADDRESS
FUNCTION CODE 04
firing order
45° BTDC)
firing order
45° BTDC)
ESM_FC04_DATA[18] 16-bit unsigned integer that
43019 Spark timing 11 (Spark timing + 15) * 16 of 11th cylinder in the goes from 0 to 960 (-15 –
firing order
45° BTDC)
ESM_FC04_DATA[19] 16-bit unsigned integer that
43020 Spark timing 12 (Spark timing + 15) * 16 of 12th cylinder in the goes from 0 to 960 (-15 –
firing order
45° BTDC)
firing order
45° BTDC)
firing order
45° BTDC)
firing order
45° BTDC)
firing order
45° BTDC)
ESM_FC04_DATA[24] 43025 Desired spark timing (Spark timing + 15) * 16 goes from 0 to 960 (-15 –
45° BTDC)
ESM_FC04_DATA[25] 43026 Battery voltage Battery voltage * 16 goes from 0 to 640 (0 – 40
VDC)
ESM_FC04_DATA[26] 43027 Intake manifold air (Intake manifold air temperature in C + 40) * 8 goes from 0 to 1520 (-40 –
temperature (left bank)
150° C)
ESM_FC04_DATA[27] 43028 Oil temperature (Oil temperature in C + 40) * 8 goes from 0 to 2048 (-40 –
216° C)
ESM_FC04_DATA[28] 43029 First exhaust temperature (1st exhaust temperature in C + 40) * 2 (left goes from 0 to 1840 (-40 –
bank)
880° C)
ESM_FC04_DATA[29] 43030 Second exhaust temperature (2nd exhaust temperature in C + 40) * 2 (right goes from 0 to 1840 (-40 –
bank)
880° C)

Setpoint rpm * 4 16-bit unsigned integer that
ESM_FC04_DATA[32] 43033 Setpoint rpm Example: If register = 4400, then 4000/4 = goes from 0 to 8800 (0 –
1000 rpm 2200 rpm)
ESM_FC04_DATA[33] 43034 IMAP left bank/rear Intake manifold pressure * 4 in units of kPa goes from 0 to 2304 (0 –
absolute
576 kPa)
ESM_FC04_DATA[34] 43035 IMAP right bank/front Intake manifold pressure * 4 in units of kPa goes from 0 to 2304 (0 –
absolute
576 kPa)
ESM_FC04_DATA[36] 43037 Ambient temperature (Ambient temp. in Centigrade + 40) * 8 goes from 0 to 1120 (-40 –
100° C)
ESM_FC04_DATA[37]
43038
Digital input values
A 32-bit number representing the status of all 32-bit unsigned integer – full
ESM_FC04_DATA[38] of the 1XXXX messages range
43039
ESM_FC04_DATA[39]
43040
Digital output values
A 32-bit number representing the status of all 32-bit unsigned integer – full
ESM_FC04_DATA[40] of the 0XXXX messages range
43041
43
52-32-11566 Rev A 1/24/2019
PLC WORD MODBUS

PLC ADDRESS ADDRESS
FUNCTION CODE 04
ESM_FC04_DATA[43] 43044 Rich burn Lambda actual 1 Lambda * 4096 16-bit unsigned integer that
(left bank) goes from 0.9000 to 1.1000
ESM_FC04_DATA[44] 43045 Rich burn Lambda actual 1 Lambda * 4096 16-bit unsigned integer that
(right bank) goes from 0.9000 to 1.1000

ESM_FC04_DATA[47] 43048 WKI value (WKI -16) *16 goes from 0 to 2048 (16 –
144 WKI)

ESM_FC04_DATA[57] 43058 The ECU temperature (Temperature in Centigrade + 40) * 8 goes from 0 to 1120 (-40 –
100° C)
The voltage from the left 16-bit unsigned integer that
ESM_FC04_DATA[58] 43059 bank rich burn oxygen Volts * 1024 goes from 0 to 1536 (0 – 1.5
sensor VDC)
The voltage from the right 16-bit unsigned integer that
ESM_FC04_DATA[59] 43060 bank rich burn oxygen Volts * 1024 goes from 0 to 1536 (0 – 1.5
sensor VDC)
The rpm modification value 16-bit unsigned integer that
ESM_FC04_DATA[60] 43061 from a Woodward™ (rpm + 250) * 4 goes from 0 to 2000 (-250 –
Generator control 250 rpm)
16 bit unsigned integer that
ESM_FC04_DATA[61] 43062 Engine torque % * 20.48 goes from 0 to 2560 (0 to
125%)
16 bit unsigned integer that
ESM_FC04_DATA[62] 43063 Rated torque % * 20.48 goes from 0 to 2560 (0 to
125%)
Spark reference number cyl. 16-bit unsigned integer that
ESM_FC04_DATA[63] 43064 Value * 1
#1 in firing order goes from 0 to 255
44
52-32-11566 Rev A 1/24/2019
PLC WORD MODBUS

PLC ADDRESS ADDRESS
FUNCTION CODE 04
ESM_FC04_DATA[79] 43080 Rich burn setpoint Lambada Lambada * 4096
goes from 0.9000 to 1.1000

ESM_FC04_DATA[83] 43084 Oil Temperature Alarm Limit (Oil Temperature in C + 40) * 8 goes from 0 to 2048 (-40 to
216° C)
ESM_FC04_DATA[84] 43085 Oil Temperature Shutdown (Oil Temperature in C + 40) * 8 goes from 0 to 2048 (-40 to
Limit
216° C)
ESM_FC04_DATA[85] 43086 IMAT Alarm Limit (Intake manifold air temperature in C + 40) * 8 goes from 0 to 1520 (-40 to
150° C)
ESM_FC04_DATA[86] 43087 IMAT Shutdown Limit (Intake manifold air temperature in C + 40) * 8 goes from 0 to 1520 (-40 to
150° C)
ESM_FC04_DATA[87] 43088 Coolant Temperature Alarm (Coolant Temperature in C + 40) * 8 goes from 0 to 1520 (-40 to
Limit
150° C)
ESM_FC04_DATA[88] 43089 Coolant Temperature (Coolant Temperature in C + 40) * 8 goes from 0 to 1520 (-40 to
Shutdown Limit
150° C)
ESM_FC04_DATA[89] 43090 Gauge Oil Pressure Alarm Oil pressure * 2 in units of kPa gauge goes from 0 to 2204 (0 to
Limit
1102 kPa)
Gauge Oil Pressure
ESM_FC04_DATA[90] 43091 Oil pressure * 2 in units of kPa gauge goes from 0 to 2204 (0 to
Shutdown Limit
1102 kPa)
45

3211566B Operation Secuence

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3211566B Operation Secuence

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CONTROL SYSTEMS AND SERVICES

105 RANDON DYER ROAD, ROSENBERG, TX 77471

Waukesha L5774LT ESM Driven

1.0 TYPE OF SYSTEM ............................................................................................................................. 3

1.0 TYPE OF SYSTEM

2.0 CONTROL PANEL POWER ON

 Local Emergency Stop digital input is De-Energized

 ANY I/O Module Fault exists

3.0 WAUKESHA ESM OPERATION NOTE

4.0 FIXED / VARIABLE ESM ENGINE SPEED CONTROL MODE

5.0 UNIT NOT READY TO START

6.0 UNIT READY TO START

 Unit Running – Remote Indication = De-Energized

7.0 COMPRESSOR & ENGINE PRELUBE

7.1 NOTE: A successful Engine Prelube is determined by the Waukesha ESM.

8.0 ENGINE START

9.0 UNIT READY TO LOAD

10.0 UNIT RUNNING – LOAD CONTROL ENABLED

11.0 ENGINE SPEED CONTROL

 4mA = 0% Output | 20mA =100% Output (Where Output = Compressor Loading)

12.0 1ST STAGE RECYCLE VALVE CONTROL

 4mA = 0% Output | 20mA =100% Output (Where Output = Compressor Loading)

13.0 2ND STAGE RECYCLE VALVE CONTROL

 4mA = 0% Output | 20mA =100% Output (Where Output = Compressor Loading)

14.0 UNIT NORMAL STOP

 Unit Running – Remote Indication = De-Energized

15.0 UNIT SHUTDOWN

 Unit Running – Remote Indication = De-Energized

 Blowdown Valve Solenoid = Energized (Closed)

 Unit Running – Remote Indication = De-Energized

16.0 UNIT EMERGENCY STOP

 Unit Running – Remote Indication = De-Energized

17.0 GENERAL VALVE OPERATION

18.0 WAUKESHA ESM AND RED LION RTU COMMUNICATIONS FAILURE

18.1 If a communications failure, i.e. disconnected/improperly connected communication cable, ESM/ESM

19.0 TEST MODE

20.0 PLC I/O FORCING (MANUAL OVERRIDE)

21.0 ROD LOAD CALCULATIONS

Double Acting Cylinders

RLc   Ahe  pdi    Ace  psi    Arod  patm 

Single Acting Crank-End Cylinders

RLc  Ahe  pdi , he    Ace  psi    Arod  patm 

Tandem Cylinders – High Pressure Cylinder Outboard

Tandem Cylinders – High Pressure Cylinder Inboard

RLc = internal compression gas rod load, lbf

22.0 ALARM AND SHUTDOWN FUNCTIONS

Alarm/Shutdown Type Legend

23.0 CONFIGURABLE PROCESS VARIABLES (adjustable via the HMI/MMI)

24.0 PASS CODE ACCESS

24.2 The default login for this control panel is as follows:

25.0 COMMUNICATION CONFIGURATION

CPU Ethernet Port:

Node / Drop Address: 1

XCRS RS485 Port:

26.0 MODBUS/PLC CONTROLLER TAGS DCS/SCADA DATA MAP

MODBUS MODBUS DATA UNITS OF BIT FUNCTION

MODBUS MODBUS DATA UNITS OF BIT FUNCTION

MODBUS MODBUS DATA UNITS OF BIT FUNCTION

MODBUS MODBUS DATA UNITS OF BIT FUNCTION

MODBUS MODBUS DATA UNITS OF BIT FUNCTION

MODBUS MODBUS DATA UNITS OF BIT FUNCTION

MODBUS MODBUS DATA UNITS OF BIT FUNCTION

MODBUS MODBUS DATA UNITS OF BIT FUNCTION