chiller with 2 reciprocating compressors gsc tp documents/grasso... · the gsc tp consists of the...

GSC TPChiller with 2 Reciprocating Compressors

Product Information (Translation of the original text)E_891011_3

COPYRIGHTAll Rights reserved.No part of this publication may be copied or pub-lished by means of printing, photocopying, microfilmor otherwise without prior written consent of

• GEA Refrigeration Germany GmbHherein after called manufacturer. This restrictionalso applies to the corresponding drawings and dia-grams.

LEGAL NOTICEThis documentation has been written in all con-science. However, the manufacturer cannot be heldresponsible, neither for any errors occurring in thisdocumentation nor for their consequences.

Product Information | Chiller with 2 Reciprocating CompressorsGSC TP

2 GEA Refrigeration Germany GmbH | E_891011_3 | Generated 03.12.2014

SYMBOLS USED IN THIS MANUALDanger!

Stands for an immediate danger whichleads to heavy physical injuries or tothe death.

Warning!

Stands for a possibly dangerous situa-tion which leads to heavy physicalinjuries or to the death.

Caution!

Stands for a possibly dangerous situa-tion which could lead to light physicalinjuries or to damages to property.

Hint!

Stands for an important tip whoseattention is important for the designa-ted use and function of the device.


GEA Refrigeration Germany GmbH | E_891011_3 | Generated 03.12.2014 3

PREFACEFor several decades, Grasso has been producingrefrigerating compressors and compressor sets forall kinds of different applications.A new compressor controller has been developed foruniversal use based on our many years of opera-tional experience.This compressor controller Type GSC TP is a highlymodern controller based on a programmable controlsystem.The GSC TP is suitable for the control, monitoringand regulation of all chillers on the basis of recipro-cating compressors.For more detailed information on GSC TP, pleaserefer to the operating instructions.



TABLE OF CONTENTS1 DESCRIPTION OF THE GSC TP 9

1.1 Safety note concerning the connection of the controller with the power panel 91.2 GSC TP, general 9

1.2.1 View 101.2.2 Lamps/ Push buttons 11

1.3 Touch panel 132 CONTROL SEQUENCE 14

2.1 Overview of the operating modes 143 TECHNICAL DATA 16

3.1 Power panel 163.2 Sensors 173.3 Input and Output Signals 18

4 COMMUNICATION 214.1 Extended data communication (interfaces) 214.2 Explanation of the MPI 214.3 Explanation Modbus RTU 214.4 Profibus-DP Explanation 22

5 DOCUMENTATION 23



TABLE OF FIGURESfig. 1 Front view 10fig. 2 White indicator light (Running compressor 1) 11fig. 3 White indicator light (Running compressor 2) 11fig. 4 Yellow indicator light (Warning) 11fig. 5 Red indicator light (Alarm) 12fig. 6 Emergency stop button 12fig. 7 Touch panel, Grasso reciprocating compressor 13fig. 8 Bus cable connector with PG junction box 21fig. 9 Gateway 22



1 DESCRIPTION OF THE GSC TP

1.1 Safety note concerning the connection of the controller with the power panel

Hint!

It is not permitted to add an external controller between the controller and the power panel;this would extend the safety chain to be achieved. All control signals between the controllersand the power panel must be processed directly and must not flow indirectly via an externalcontroller. GEA Refrigeration Germany GmbH cannot otherwise guarantee the safe operationof the system.

1.2 GSC TP, general

The GSC TP consists of the control unit with operator and display unit, indicator lights for "Running", "Warning"and "Alarm", emergency stop button, output relays, power unit, main switch as well as the housing.The standard version of the GSC TP for Grasso chillers with reciprocating compressors is mounted directly onthe chiller.

The GSC TP performs the following functions as standard:

• Display of all important physical and technical parameters, e.g. pressure, temperature, capacity, number ofhours run, operating mode and status signals.

• Automatic start-up and shut-down of the chiller as well as capacity control depending on the following val-ues:

– Suction pressure

– Inlet temperature

– External temperature (value via MPI network)

– Outlet temperature (option)

• Monitoring of all operating parameters

• Compressor capacity limitation if the measured discharge pressure, discharge temperature, motor current(optional) or suction pressure indicate an overload

• Fault memory with date and time

• Wire failure detection for analogue input signals

• Password protection for preventing unauthorised access to important parameters

• Control of the chiller by a master controller via potential free contacts

• Possibility of communication via MPI or Modbus RTU with master controller or building management system.(The MPI communication is when using a sequence Grasso models not recommended)

• 10-minute trend display with display of all actual values which existed just before alarm switched off

• Remote maintenance via EtherNet connection (TCP/IP)

The GSC TP optionally performs the following functions:

• Frequency-controlled compressor drive motor

• Motor current sensor

• Outlet temperature sensor

• Electronic flow switch for secondary refrigerant circuit

• Electronic flow switch for heating agent circuit


Description of the GSC TP


• Remote setpoint adjustment (analogue signal)

• Profibus DP-communication

1.2.1 View

fig.1: Front view

Description of the GSC TP Product Information | Chiller with 2 Reciprocating CompressorsGSC TP


1.2.2 Lamps/ Push buttons

fig.2: White indicator light (Running compressor 1)

White indicator light (Running compressor 1)This indicator lamp flashes slowly, when the compres-sor 1 is in the "Standby" state.This lamp flashes quickly during start up of the com-pressor.Once the compressor has started, the light becomessteady.This lamp flashes quickly during the shut down opera-tion, until the compressor drive motor is switched off.

fig.3: White indicator light (Running compressor 2)

White indicator light (Running compressor 2)This indicator lamp flashes slowly, when the compres-sor 2 is in the "Standby" state.This lamp flashes quickly during start up of the com-pressor.Once the compressor has started, the light becomessteady.This lamp flashes quickly during the shut down opera-tion, until the compressor drive motor is switched off.

fig.4: Yellow indicator light (Warning)

Yellow indicator light (Warning)This lamp flashes, if an operating condition reaches acritical region (Warning /Pre-alarm).Detection of this warning can be acknowledged at theoperator panel. Warnings are automatically reset afterthe cause has gone.After the warning has been acknowledged at the oper-ator panel, this flashing light changes over to a steadylight, as long as the warning condition remains.




fig.5: Red indicator light (Alarm)

Red indicator light (Alarm)This lamp flashes, if an operating condition exceeds itspermitted value. The machine shuts down on alarm.This state is signalled by a red flashing light.After the alarm has been acknowledged at the opera-tor panel, this flashing light changes over to a steadylight, as long as the alarm condition remains.Once the cause of the alarm has been corrected, thisindicator light switches off (after it has been acknowl-edged).

fig.6: Emergency stop button

Emergency stop buttonThis red button can be used to switch the compressorunit off at any time in case of an emergency.The operator terminal controls remain functional.

Description of the GSC TP Product Information | Chiller with 2 Reciprocating CompressorsGSC TP


1.3 Touch panel

The touch panel is the interface between the operator and the control unit.All switching, operating and control actions are carried out via this touch panel. (Exception: emergency stop)The touch panel is language dependent.

fig.7: Touch panel, Grasso reciprocating compressorTouch panel with information bar (top), navigation bar (on the top, with "Pull down" menu), main display (central display and selection area)

and function key bar (bottom)




2 CONTROL SEQUENCE

2.1 Overview of the operating modes

Modes Signal for …

Name Remark Start/Stop Capacity +/-

0 Service Compressor motor blocked

1 Manual+ Manual

Manual control via display Manual Manual

2 Manual + Auto Manual start/stop via display and full automatic localcapacity control

Manual Auto

3 Auto + Auto Full automatic start/stop and local capacity control Auto Auto

4 Remote+ HW (cont)

Start/stop and capacity demand via digital contacts(hardware) from a remote master controller. The GSCderives from the continuous +/- signals the pulses forcapacity (indirect).

External Externalcontinuous

5 Remote+ HW (pulse)

Start/stop and capacity demand via digital contacts(hardware) from a remote master controller. The mas-ter also generates the +/- signals as pulses for control-ling the slide capacity directly.

External Externalpulses

6 Remote+ HW (loc.SW)

Start/Stop from a remote master controller via digitalcontacts (hardware). The GSC controls the outputdepending on a local setpoint (display) and from thissetpoint also automatically switches the package ON/OFF.

External+ setpointdeviation

LocalSetpoint

7 Remote+ HW (ext.SW)

Start/Stop from a remote master controller via digitalcontacts (hardware). The GSC controls the outputdepending on an external setpoint (analog input) andfrom this setpoint also automatically switches the pack-age ON/OFF.

External+ setpointdeviation

RemoteSetpoint

8 Remote+ Net (cont)

Start/stop and capacity demand via network from aremote master controller. The GSC derives from thecontinuous +/- signals the pulses for controlling thecapacity (indirect).

Network Networkcontinuous

9 Remote+ Net (pulse)

Start/stop and capacity demand via network from aremote master controller. The master also generatesthe +/- signals as pulses for controlling the capacitydirectly.

Network Networkpulses

Control sequence Product Information | Chiller with 2 Reciprocating CompressorsGSC TP


Modes Signal for …

10 Remote+ Bus (loc.SW)

Start/stop from a central master controller via a bus sig-nal. The GSC controls the output depending on a localsetpoint (display) and from this setpoint also automati-cally switches the package ON/OFF.

Network+ setpointdeviation

LocalSetpoint

11 Remote+ Bus (net.SW)

Start/stop from a central master controller via a bus sig-nal. The GSC controls the output depending on anexternal setpoint sent externally via the network andfrom this setpoint also automatically switches the pack-age ON/OFF.

Network+ setpointdeviation

NetworkSetpoint


Control sequence


3 TECHNICAL DATA

3.1 Power panel

The technical data relates to the whole GSC power panel.

Operating voltage 100 to 240 V AC

Mains frequency 47 to 63 Hz

Control voltage 24 V DC

Voltage for solenoid valves 240 V AC (optional 115 VAC)

Protection class IP 54

Permissible ambient temperature (storage) -20°C to +70°C

Permissible ambient temperature (operation) +5°C to +40°C*)

Maximum air humidity5 to 95 % at 25°C (no mois-ture condensation) *)

Power consumption According to the project

Dimensions

FX G

CW

WidthDepthHeightWeight

mmmmmmkg

According to the project

DX

FK

A

WidthDepthHeightWeight

mmmmmmkg

According to the project

*) Additional measures are required outside these operating limits

Technical Data Product Information | Chiller with 2 Reciprocating CompressorsGSC TP


3.2 Sensors

Types of sensors used

Sensor type Remark

Pressure transducer Passive electrical 2-wire measuring transducers with an output signal of4...20 mA are used to measure all pressures.

Temperature sensor Pt1000-2L without sensor head transmitters are used to measure tem-peratures.

Hint!

Scaling of the range limits: See parameter list!Description of the components used: see separate documentation!


Technical Data


3.3 Input and Output Signals

Low-voltage switchgear - GSC / chiller

from the low-voltage switchgear to the GSC /chillerINPUTS

from the GSC / chiller to the low-voltage switch-gearOUTPUTS

digital:

– Compressor drive motor feedback (compressor 1)

– Compressor drive motor feedback (compressor 2)

– Motor protection compressor (compressor 1)

– Motor protection compressor (compressor 2)

digital:

– Compressor drive motor control (compressor 1)

– Compressor drive motor control (compressor 2)

– Frequency converter alarm reset

analogue:

– Motor current (optional) (compressor 1)

– Motor current (optional) (compressor 2)

– Compressor drive motor speed (optional with useof a frequency converter) (compressor 1)

– Compressor drive motor speed (optional with useof a frequency converter) (compressor 2)

analogue:

– Compressor drive motor speed setpoint (optionalwith use of a frequency converter) (compressor 1)

– Compressor drive motor speed setpoint (optionalwith use of a frequency converter) (compressor 2)

Remote controller or control system - GSC / chiller

from the remote controller (BMS - building man-agement system) to the GSC / chillerINPUTS

from the GSC / chiller to the remote controller(BMS)OUTPUTS

digital:

– Remote on/Off

– Remote reduce power

– Remote increase power

– Remote start release

– Remote alarm reset

– 2. setpoint

– Safety control (Emergency stop)

– Remote 1st compressor blocked

– Remote 2nd compressor blocked

– Remote. only one compressor from both available

digital:

– Ready for remote control

– Running (compressor 1)

– Running (compressor 2)

– Main failure

– Coolant pump release / condenser release

– Failure (compressor 1)

– Failure (compressor 2)

analogue:

– External setpoint (optional)

analogue:

– capacity in %



Refrigeration plant / chiller - GSC / chiller

from the refrigeration plant / chiller to the GSC /chillerINPUTS

from the GSC / chiller to the refrigeration plant /chillerOUTPUTS

digital:

– Gas sensor

– Condenser feedback (optional)

– Flow switch feedback (optional)

– Service switch (compressor 1)

– Service switch (compressor 2)

– refrigerant-level low (Chiller FX GC)

– refrigerant-level high (Chiller FX GC)

– Oil Heating ok (Chiller FX GC)

– Separator level

– Antifreeze protection (optional)

digital:

– Solenoid valve, refrigerant injection (optional)

– Solenoid valve, oil drain (2310)

– Solenoid valve, oil drain (2335)

– Heating oil return (optional)

– Releasing refrigerant injection 1 (optional) (com-pressor 1)




analogue:

– Coolant inlet temperature

– Coolant outlet temperature (optional)

– Iinjection valve feedback (optional)

analogue:

– Control Iinjection valve (optional)

Compressor - GSC / chiller


Technical Data


from compressor to the GSC / chillerINPUTS

from the GSC / chiller to the compressorOUTPUTS

digital:

– Safety control (Emergency stop) (compressor 1)

– Safety control (Emergency stop) (compressor 2)

digital:

– Solenoid valve 1 (compressor 1)






– Solenoid valve 4 (optional) (compressor 1)




analogue:

– Suction pressur (compressor 1)

– Suction pressur (compressor 2)

– Suction temperature (compressor 1)

– Suction temperature (compressor 2)

– Discharge pressure (compressor 1)

– Discharge pressure (compressor 2)

– Discharge temperature (compressor 1)

– Discharge temperature (compressor 2)

– Oil pressure (compressor 1)

– Oil pressure (compressor 2)

– Oil temperature (compressor 1)

– Oil temperature (compressor 2)

– Crankcase pressure (optional) (compressor 1)

– Crankcase pressure (optional) (compressor 2)



4 COMMUNICATION

4.1 Extended data communication (interfaces)

The GSC is equipped with an MPI interface and Modbus RTU (RS485) as a standard.A Profibus-DP can be optionally used via a gateway (interface converter).The Communication can be used by the customer to read out the following values:

– All analogue values (pressures, temperatures, etc.)

– Remaining times

– Active warning and alarm messages

– Status messagesFurthermore, the chiller can be remotely controlled by transmitting commands over the Bus.

Hint!

The precise bus structure and the transmission and receiving data protocol are described indetail in the "Communications Guideline". This guideline is also available from Grasso if nec-essary.

4.2 Explanation of the MPI

To set up a network with MPI, all the users must be connected to each other with a bus cable.The MPI interface can be operated with a maximum transmission speed of 187.5 kbit/s, whereby the distancebetween two adjacent users must not exceed 50 m maximum.As the MPI interface is fed to the GSC on a 9-pin sub-D jack, suitable cable connectors are required.These connectors are inserted directly in the bus interface (9-pin sub-D jack).A two-core, double shielded bus cable is used as a connection cable between the individual bus devices.The incoming and outgoing bus cable is connected in the socket via 4 terminals.The line termination resistance integrated in the bus cable can be connected via a switch.This is required at both ends of a network.We recommend bus cable connectors with vertical outgoing feeder cables.

fig.8: Bus cable connector with PG junction box

4.3 Explanation Modbus RTU

To set up a network with Modbus RTU, all the users must be connected to each other with a bus cable.


Communication


The interface can be operated with a maximum transmission speed of 115,2 kbit/s, whereby the distancebetween two adjacent users must not exceed 50 m maximum.As the Modbus RTU interface is fed to the GSC on a 9-pin sub-D jack, suitable cable connectors are required.These connectors are inserted directly in the bus interface (9-pin sub-D jack).A two-core, double shielded bus cable is used as a connection cable between the individual bus devices.Die GSC s defined as slaveAn additional feature of the Modbus RTU application is the advantage of freely selectable bus addresses.The client can adjust the transmission speed and other Modbus RTU settings via the display from the GSC.

4.4 Profibus-DP Explanation

To set up a network with Profibus-DP, all users must be connected to each other with a bus cable.The notes in the "MPI Explanation" chapter must be noted and observed regarding the connectors and data.A gateway is installed for the Profibus-DP link. The gateway behaves like a Profibus-DP slave at the customerend.An additional feature of the Profibus-DP application is the advantage of freely selectable bus addresses.The transmission speed and other Profibus-DP settings are transferred from the Profibus-DP master (suppliedby the customer) to the gateway.The GSD file provided by Grasso is to be used in the project planning.

fig.9: Gateway

Communication Product Information | Chiller with 2 Reciprocating CompressorsGSC TP


5 DOCUMENTATION

The following documentation for the GSC is supplied to the customer with delivery of the liquid chiller:

Document Language (standard)

Operating manual National language

Quick reference card National language

Communication guideline German, English

Parameter list German, English, Russian *)

Electrical drawings German, English, Russian *)

*) other languages can be contractually agreed


Documentation


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