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GSC TPfor single stage Chiller/ Packages with Screw Compressors

Product Information (Translation of the original text)E_941011_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 product information is a part of the documenta-tion for the Grasso scope of delivery and serves asproduct presentation and customer advisory service.It contains important information and technical dataregarding the product.The product information makes the technical, prod-uct related and commercial information available tothe customer in detail before the sale of the product.This product information serves as a support andtechnical advisory service for our partners and cus-tomers as well as for the marketing team. Apart fromserving as the medium for transfer of product know-how, it also forms the basis for product demonstra-tions, the organisation and conduction of technicalseminars as well as the technical support at tradefairs.This product information should be supplementedwith the information about the industrial safety andhealth related regulations at the site of installation ofthe product. The regulations vary form place to placeas a result of the statutory regulations applicable atthe site of installation of the product and are there-fore have not been considered in this product infor-mation.In addition to this product information and the acci-dent prevention regulations applicable for therespective country and area where the product isused, the accepted technical regulations for safe andprofessional work must also be observed.This product information has been written in goodfaith. However, GEA Refrigeration Germany GmbHcannot be held responsible for any errors that thisdocument may contain or for their consequences.GEA Refrigeration Germany GmbH reserves theright to make technical changes during the course offurther development of the equipment covered bythis product information.Illustrations and drawings in this product informationare simplified representations. As a result of theimprovements and changes, it is possible that the

illustrations do not exactly match the current devel-opment status. The technical data and dimensionsare subject to change. No claims can be made onthe basis of them.

Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP

2 GEA Refrigeration Germany GmbH | E_941011_3 | Generated 21.03.2014

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_941011_3 | Generated 21.03.2014 3

PREFACEFor several decades, GEA Refrigeration Germanyhas been producing refrigerating compressors andcompressor sets for all 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 an established industrialprogrammable control system.This compressor controller Type GSC TP is a highlymodern controller based on an established industrialprogrammable control system.For more detailed information on GSC TP, pleaserefer to the operating instructions.



TABLE OF CONTENTS1 DESCRIPTION OF THE CONTROLLER 9

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

1.2.1 View 101.2.2 Lamps/ Push buttons 11

1.3 TouchPanel 131.3.1 General screen layout 13

2 CONTROL SEQUENCE 142.1 Overview of the operating modes 15

3 TECHNICAL DATA 173.1 Switching Cabinet 173.2 Sensors 183.3 Input and Output Signals 19

4 COMMUNICATION 224.1 Extended data communication (interfaces) 224.2 Explanation of the MPI 224.3 Profibus-DP Explanation 224.4 Explanation Modbus RTU 234.5 Explanation Modbus TCP 24

5 DOCUMENTATION 25



TABLE OF FIGURESfig. 1 Control, front view 10fig. 2 Control integrated in low-voltage switchgear, front view 10fig. 3 White indicator light (Running compressor) 11fig. 4 Yellow indicator light (Warning) 11fig. 5 Red indicator light (Alarm) 12fig. 6 Emergency stop button 12fig. 7 TouchPanel 13fig. 8 General screen layout 13fig. 9 Bus cable connector with PG junction box 22fig. 10 Profibus DP/DP-coppler 23fig. 11 Modbus RTU and Profibus DP interfaces 23fig. 12 Modbus RTU and Modbus TCP interfaces 24



1 DESCRIPTION OF THE CONTROLLER

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 Controls, general

The control consists of the control unit with operator keypad and display unit, indicator lights for "Running","Warning" and "Alarm", the emergency stop button, the output relays and the casing.The control is directly mounted to the product.The control can also be placed in a control centre. (does not apply to the Grasso BluAstrum Series)

The following features are fitted as standard:

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

Hint!

Some parameters will be hidden if not used.

• Automatic start-up and shut-down as well as capacity control depending on the controlled variables

• Monitoring of all operating parameters

• Compressor capacity limitation, in case the measured discharge pressure, suction pressure, cooling agenttemperature or motor current indicate overload

• Fault memory with date and time

• Wire failure detection for analogue input signals

• Password protection for preventing unauthorised access to important parameters

• Non-volatile saving of program

• Control by a master controller via potential-free contacts

• Possibility of communication with master controller via MPI(optionally via Profibus-DP, Modbus RTU or Modbus TCP)The MPI communication is not recommended when using a successor module.

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

The following features are added as optional extras:

• Frequency-controlled compressor drive motor

• Outlet temperature sensor

• Remote setpoint adjustment (analogue signal)


Description of the controller


1.2.1 View

fig.1: Control, front view

fig.2: Control integrated in low-voltage switchgear, front view

Description of the controller Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP


1.2.2 Lamps/ Push buttons

fig.3: White indicator light (Running compressor)

White indicator light (Running compressor)This indicator lamp flashes slowly when the compres-sor package/ chiller 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 apreset value (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 compressoroff at any time in case of an emergency.The operator terminal controls remain functional.

Description of the controller Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP


1.3 TouchPanel

The TouchPanel is the interface between the man and the machine.All switching, operating and control actions are carried out via this TouchPanel.The TouchPanel is available in different languages.

fig.7: TouchPanel

1.3.1 General screen layout

The image format is identical in all the images. The images shown are examples and can vary in the actualproject!

Hint!

Coloured highlighted buttons can be operated.Grey marked push buttons can't be activated, a finger touch will not initiate any action.

fig.8: General screen layout

1 Information bar

2 Navigation bar with "Pull down" menus

3 Main display with selection areas

4 Function key bar




2 CONTROL SEQUENCE

Control sequence Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP


2.1 Overview of the operating modes

Modes Signal for …

Name Remark Start/Stop Capacity +/-

0 Service Oil pump by itselfCompressor motor blocked

1 Manual+ Manual

Manual control via Touch Panel (TP) Manual Manual

2 Manual + Auto Manual Start/Stop via TP 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 GSCTP derives from the continuous +/- signals the pulsesfor capacity (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 TP controls the outputdepending on a local setpoint (TP) and from this set-point also automatically switches the product ON/OFF.

External+ setpointdeviation

LocalSetpoint

7 Remote+ HW (ext.SW)

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

External+ setpointdeviation

RemoteSetpoint

8 Remote+ Net (cont)

Start/stop and capacity demand via network from aremote master controller. The GSC TP derives fromthe continuous +/- 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


Modes Signal for …

10 Remote+ Bus (loc.SW)

Start/stop from a central master controller via a bussignal. The GSC TP controls the output depending ona local setpoint (TP) and from this setpoint also auto-matically switches the product ON/OFF.

Network+ setpointdeviation

LocalSetpoint

11 Remote+ Bus (net.SW)

Start/stop from a central master controller via a bussignal. The GSC TP controls the output depending onan external setpoint sent externally via the networkand from this setpoint also automatically switches theproduct ON/OFF.

Network+ setpointdeviation

NetworkSetpoint

Control sequence Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP


3 TECHNICAL DATA

3.1 Switching Cabinet

The technical data relates to the whole GSC power panel.

Operating voltage 100 to 240 V AC

Mains frequency 47 to 63 Hz

Power consumption max. 300 W

Control voltage 24 V DC

Protection class IP 23

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

Permissible ambient temperature (operation) +5°C to +40°C 1)

Maximum air humidity5 to 95 % at 25°C (no moisture condensa-tion) 1)

Dimensions / Weight ControllerWithout low-voltage switchgear

Width: 600 mmDepth: 210 mmHeight: 600 mm36 kg

ControllerWith low-voltage switchgear

Width: 1000 mm 2)

Depth: max. 800 mm 2)

Height: 2000 mm 2)

Weight dependent on dimensions

1) additional measures are required outside these operating limits2) dependent on driving power


Technical Data


3.2 Sensors

Types of sensors used

Sensor type Remark

Pressure transducer Passive electrical 2-wire measuring transducers with a output signal of 4...20 mAare used to measure all pressures.

Temperature sensor Pt100 with top assembly sensor transmitters are used to measure temperatures.The passive 2-wire measuring transducers located in the connection head of thePt 100 supply an output signal of 4...20 mA.

Position sensor Type LDS The position sensor Type LDS is an active pick-up, which produces an output sig-nal of 4...20 mA.

Motor current An active current signal of 4...20 mA is required to measure the power consump-tion of the compressor drive motor.

External setpoint value An active or a passive current signal of 4...20 mA is required to evaluate an exter-nal setpoint value.

External temperature An active or a passive current signal of 4...20 mA is required to evaluate an exter-nal temperature.

Hint!

Scaling the range limits, see parameter list.For description of the components used, see separate documentation.

Technical Data Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP


3.3 Input and Output Signals

Hint!

Not applicable if the low-voltage switchgear is included in the scope of supply.

Low-voltage switchgear - GSC TP

from the low-voltage switchgear to theGSC TP - INPUTS

from the GSC TP to thelow-voltage switchgear OUTPUTS

Supply: 100 ... 240 V, 50/60 Hz

digital:

– Motor feedback

– Motor protection compressor

digital:

– Run compressor

– Run oil pump

analog (4 - 20 mA):

– Motor current compressor

– Speed1)

analog (4 - 20 mA):

– Motor speed set point1)

*1) Option, for operation with frequency inverter only

Remote controller or BMS (building management system) - GSC TP

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

from the GSC TP to the remote controller (BMS -building management system)OUTPUTS

digital:

– External ON/OFF

– External "MORE"

– External "LESS"

– External locking

– Remote alarm reset

– External set point switchover

digital:

– Signal "Ready for remote control"

– Signal "Compressor runs"

– Signal "Main fault"

– 1x free programmable output

analog (4 - 20 mA):

– Remote setpoint

analog (4 - 20 mA):

– PS position Compressor or compressor capacity


Technical Data


Refrigerating plant - GSC TP

from the refrigerating plant to the GSC TPINPUTS

from the GSC TP to the refrigerating plantOUTPUTS

digital:

– Emergency Stop

– Separator level too high1)

– Economizer level too high1)

– Gas alarm

digital:

– --

analog (4 - 20 mA):

– --

analog (4 - 20 mA):

– --

Technical Data Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP


Package/ chiller - GSC TP

from package/ chiller to GSC TPINPUTS

from the GSC TP to the package/ chillerOUTPUTS

digital:

– Discharge pressure safety switch

– Oil separator level too low1)

– Oil separator level too high1)

digital:

– Solenoid valve for increasing capacity (compres-sor)2)

– Solenoid valve for decreasing capacity (compres-sor)2)

– Solenoid valve, hot gas bypass1)

– Solenoid valve Vi-adjustment1) 2)

– Solenoid valve Eco1)

analog (4 - 20 mA):

– PS position compressor2)

– Suction pressure compressor

– Discharge pressure compressor

– Oil pressure

– Oil filter pressure2)

– Suction temperature

– Discharge temperature

– Oil temperature

– Eco temperature1)

– Eco pressure1)

– Vi-adjustment compressor1) 2)

analog (4 - 20 mA):

– --

1) Option/ 2) dependent on compressor type


Technical Data


4 COMMUNICATION

4.1 Extended data communication (interfaces)

The GSC TP is equipped with an MPI interface as a standard. A Profibus-DP, Modbus RTU or Modbus TCP canbe optionally used via a gateway (interface converter).

Hint!

The precise bus structure and the transmission and receiving data protocol are described ingreater detail in the "Communications Guideline". This guideline is also available from GEARefrigeration Germany if necessary.

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 TP 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 cables are connected in the socket.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 (see figure).

fig.9: Bus cable connector with PG junction box

The MPI bus 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 Package can be remotely controlled by transmitting commands over the MPI bus.

4.3 Profibus-DP Explanation

To set up a network with Profibus-DP, all users must be connected to each other with a bus cable.

Communication Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP


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 GEA Refrigeration Germany is to be used in the project planning.

fig.10: Profibus DP/DP-coppler

4.4 Explanation Modbus RTU

To set up a network with Modbus, all the users must be connected to each other with a bus cable.A gateway with a DE9 (D-SUB 9pole, RS485) interface is installed for the Modbus link.Data transmission is done by means of a Modbus RTU-Master-Slave-connection, with the Grasso control act-ing as the Modbus RTU-slave.An additional feature of the Modbus application is the advantage of freely selectable bus addresses.The bus settings for the communication between master and slave are preadjusted.

fig.11: Modbus RTU and Profibus DP interfaces

1 Modbus RTU interface

2 Address switches S4 and S5 for Modbus address

3 Profibus DP interface


Communication


4.5 Explanation Modbus TCP

To set up a network with Modbus, all the users must be connected to each other with a bus cable.A gateway with an Ethernet interface and the Modbus RTU gateway are installed for the Modbus link. Both gate-ways communicate with each other by use of the Modbus RTU interface.Data transmission is done by means of a Modbus TCP-Master-Slave-connection, with the Grasso control actingas the Modbus TCP-slave.An additional feature of the Modbus application is the advantage of freely selectable bus addresses. This isestablished by the use of the Modbus RTU gateway.The bus settings for the communication between master and slave are preadjusted.

fig.12: Modbus RTU and Modbus TCP interfaces

1 Modbus RTU interface

2 Address switches S4 and S5 for Modbus RTU address

3 Modbus TCP interface

Communication Product Information | for single stage Chiller/ Packages with Screw CompressorsGSC TP


5 DOCUMENTATION

The following documentation for the GSC TP is supplied to the customer with delivery of the Package:

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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