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The Service Switch on VSD units

1. Compressor control philosophy on VSD units

In general, a VSD driven compressor is controlled by two devices:

` The Elektronikon controller

` The VSD control system

In order to make the two systems working together, a number of interfaces are created
between these two devices.

` The control functions

This is an interface between the control functions of the Elektronikon and the
VSD

` The shutdown function

This is a hardwire signal, coming from the Elektronikon to the VSD, in order to
shutdown the VSD in case of a shutdown initiated by the Elektronikon. This
function is also called “the Run-Enable” signal

` The service switch

This service switch is a tool created for service people and only to use for
trouble shooting. Detailed description is handled further in this document

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2. Description

2.1 The shutdown function

The output from Elektronikon (K05) is used to shutdown the VSD in case of compressor
problems.

K05 : Contact is closed in normal operation

Contact is open in case of shutdown order

2.2 Purpose of the Service Switch

The service switch is intended to be used for fault tracing purposes. In case the frequency
converter is not responding to the commands of the Elektronikon or when a failure
indication is present on the converter display, the service switch can be used to trace
what component (Elektronikon, wiring, frequency converter, …) is causing the
malfunction.

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2.3 Functionality of the Service Switch

In normal operation, the Elektronikon is controlling the complete compressor. This means
that on one side, it will give commands to the frequency converter(s) related to start, stop,
Run-Enable, etc. On the other side, the Elektronikon will monitor the sensor values and
determine whether the machine should stop or not (based on eg element outlet
temperature).

Important to know, is that there is a hard-wired link between the Elektronikon and the
frequency converter(s). This link is called the “Run-Enable”. This Run-Enable is a digital
output (K05) of the Elektronikon and will be a digital input for the frequency converter(s).
Whenever this digital input is active (Run-Enable is present), the frequency converter can
be started (by the Elektronikon or directly on the converter display, depending on the
position of the Service Switch).
When something happens on the compressor side (eg too high temperature), the
Elektronikon with de-activate the Run-Enable and the frequency converter(s) will stop the
drive motor.

The basic idea of the Service Switch is to isolate both Elektronikon and frequency
converter(s) from each other. This means that no communication will be present between
the Elektronikon controller and any frequency converter(s) present in the compressor.
Whenever the Service Switch is active, the Run-Enable signal coming from the
Elektronikon is bypassed. At the same time, a different set of parameter values are used.
This other set of parameter values will allow to start the frequency converter / motor on
the converter display and run the motor at a fixed speed (predefined at the minimum
speed of the compressor). Be aware that in this situation the compressor is no longer
protected by the Elektronikon.

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When you take a look at the service diagram, then this Service Switch is represented as
follows (2 different examples) :

The simplified representation is shown like :

Converter Service Switch Elektronikon

DIN A

DIN B

K05
S10

24V out

Attention - DANGER:
The Service Switch is used to by-pass the Run-Enable (K05). This means that whenever
a potentially dangerous situation is present in the compressor (eg high temperature) the
machine will keep on running !

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3. Activating the Service Switch

Activating the Service Switch is rather easy to do, but a little bit different depending on the
brand of frequency converter. What is mentioned in this chapter is a short summary on
how to activate the Service Switch.

3.1 Siemens frequency converter

Compressor types with this kind of converter are:

` ZR160 VSD
` ZR315 VSD
` ZE4 VSD
` GA132 VSD
` GA180 VSD

The Service Switch itself is located on the mounting rail in the Elektronikon cubicle. This
switch needs to be shifted to activate the Service Switch functionality. When the Service
Switch is activated, the converter / motor can be started and stopped on the display of the
converter.

S10

START
STOP

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3.2 ABB converter

Compressor types with this kind of converter are:

` ZR132 VSD / ZT132 VSD

` ZR160 VSD (Z-Modular) / ZT160 VSD
` ZR250 VSD / ZT250 VSD
` ZR315 VSD (Z-modular) / ZT315 VSD
` ZR90 VSD / ZT90 VSD

The Service Switch itself is located on the mounting rail in the Elektronikon cubicle. This
switch needs to be shifted to activate the Service Switch functionality. When the Service
Switch is activated, the converter / motor can be started and stopped on the display of the
converter. In order to be able to start and stop the main converter, you must be sure that
the display is connected to the RMIO print.

RMIO

S10

START
STOP

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3.3 VACON CX converter

Compressor types with this kind of converter are:

` ZR500 VSD
` ZR900 VSD
` GA315 VSD

The Service Switch itself is located on the mounting rail in the Elektronikon cubicle. This
switch needs to be shifted to activate the Service Switch functionality. When the Service
Switch is activated, the converter / motor can be started and stopped on the display of the
converter.
Make sure to put the converter into “Panel control” first. To do this, following procedure
must be followed, after activating the Service Switch.

S10

START
STOP

` Go to the root menu of the parameter groups by pushing the left arrow
on the converter display until the text on the display remains the same.
` Use the up and down arrows to select Buttons
` Push the right arrow on the converter display to enter the menu
` Use the up and down arrows to select Panel control
` Press enter button to switch the panel control On

When this procedure is carried out, the drive motor can be started and stopped on the
converter display.
Deactivating the Service Switch automatically deactivates the Panel Control.

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3.4 VACON NX converter (ZB Compressor)

This type of converter is only used in the ZB compressors at this moment. Since this
compressor is a product with a high level of technology, there are certain steps to follow to
ensure a safe working in Service mode.

START
STOP

RS232 connection
Bearing Controller to PC

S10

Before starting the compressor

` Activate the Service Switch to by-pass the Elektronikon

` Connect the Bearing Controller to a PC (RS232)
` Run software “AMB-LINK” on the PC
` Clock on button “REMOTE COMMAND” (password = USER) and select
the control place “PC”. Click “SAVE” button
` Click the “MEASUREMENTS” button. You will see the mainscreen for
the Bearing Controller
` On the VACON display, got to menu “M3 KEYPAD CONTROL” and set
parameters according to
Ö P3.1 Control Place = KEYPAD REF
Ö P3.2 Keypad Reference = 100 Hz

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Starting the compressor

` With the PC, levitate the bearings manually by clicking on the “AMB-ON”
button in the measurements-screen
` On the keypad of the converter, press “RESET” button. Now the RED
LED (fault) should stop blinking and the GREEN LED (ready) should be
lit up. Now the converter is ready to start
` Press the “START” button on the keypad and the unit will run on the
frequency set in P3.2

Attention - DANGER:
When the Service Switch is activated and you start the compressor according to the
above mentioned procedure, then the cooling fans for the bearings are not running.

Resetting the compressor for normal operation

` Press “STOP” button to stop the compressor

` When the motor / impeller have come to a stop, delevitate the bearings
by clicking the “AMB-OFF” button
` Reset the “REMOTE COMMAND” back to “Customer Serial Link”
` Reset P3.1 of the converter back to “FIELDBUS”
` Deactivate the Service Switch

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4. When to use / remarks

As mentioned before in this document, the service switch will be used to by-pass the
Elektronikon controller. This means that all communication between converter and
Elektronikon will disappear whenever the Service Switch is activated.

This Service Switch is to be used when failures on communication between Elektronikon

and frequency converter(s) are experienced, or to test the converter whenever a failure
message is present of the converter display.
By activating the Service Switch, the compressor will be forced to run at a pre-
programmed fixed speed (minimum speed of the compressor).

Keep in mind that this is a potential unsafe situation for the compressor. When something
goes wrong with the compressor, the machine will keep on running as the Run-Enable
signal from the Elektronikon is by-passed with the Service Switch.

On ZB compressors, the cooling fans for the bearings are not running.

In general, whenever tests are done and the compressor will be running in Service
Switch mode, then you should be aware that damage can occur to the compressor.
Therefore it is recommended to minimize the time while the compressor is running
with Service Switch activated.

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