grasso system control - gea engineering for a better world documents/grasso gsc - rc... · 1...

Refrigeration / Grasso _853511_imm_gsc_ingenium_gbr_1_.doc 1

Grasso System Control for Grasso Ingenium, Ingenium Compact

User Manual

USER MANUAL GRASSO SYSTEM CONTROL FOR GRASSO INGENIUM

2 _853511_imm_gsc_ingenium_gbr_1_.doc Refrigeration / Grasso

COPYRIGHT

All Rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent of Grasso. This restriction also applies to the corresponding drawings and diagrams.

LEGAL NOTICE

This publication has been written in good faith. However, Grasso cannot be held responsible, neither for any errors occurring in this publication nor for their consequences.



SYMBOLS USED IN THIS MANUAL

Danger!

This is an important warning. Non-observance these warnings can cause accidents with relevant damages on persons or serious damages on the compressor or refrigerating plant.

Warning! Caution!

Attention! Caution! Important!

Hint!

Tip! Note!



PREFACE

Introduction

For several decades, Grasso has been producing refrigerating compressors and compressor sets for all kinds of different applications.

A new compressor controller has been developed for universal use based on our many years of operational experience.

The compressor control, type "GSC" (Grasso System Control) is a highly modern programmable controller, which is based on the Simatic C7-633 system.

The GSC is suitable for controlling and monitoring our company’s compressors.

Explanation of the abbreviations used

The following abbreviations are used in this manual.

Abbreviation Remark

GSC „Grasso System Control“ Type designation of the Grasso standard compressor control

CPU „Central Processing Unit“

DP „Decentralised Periphery“

Start to start „Starting frequency limiter“

EPROM „Erasable programmable read-only memory“

Ext. "external"

IM "Interface Modul"

HYS "Hysteresis"

RF "Refrigerant"

RF-separator "Refrigerant-separator"

LED „Light-emitting diode“

LIM „Limit“

MAX "Maximum"

MIN "Minimum"

MPI „Multi Point Interface“, Siemens internal, interface with multi-point capability on the GSC, used for communication between several controls

MRES „Memory Reset“

SV „Solenoidvalve“

LVS „Low Voltage switchgear“ – switchgear with power contactors for compressor motor, oil pump and oil heating

NZ "Neutralzone"

OP "Operator Panel"

PG „Programming device“

PLC „Programmable Logic Controller“

PV Process value



Abbreviation Remark

P & ID „Pipe and Instrumentation diagram“

SP Set point

SPC „Stored-program control

CDM „Compressor Drive Motor

General drawings

This drawing shows the general configuration of a Ingenium Type „Ingenium 350“.

The supplied model can deviate from this.

fig. 1: View of Ingenium 350

1 Drive motor

2 Reciprocating compressor

3 draining

4 Blow-off valve

5 GSC

6 Stop valve – discharge side

7 Condenser

8 Evaporator

9 stop valve – suction side



General Drawings Ingenium Compact


Fig. 2: Ingenium Compact

Fig. 3: Ingenium Compact

1 The supplied model can deviate from this.

2 Condenser

3 Evaporator

4 Electronic injection valve

5 Oil return system

6.1 Filling and draining valve

6.2 Ammonia liquid filter

7 Switch cabinet with control

8 Glycole cooler with cylinder head cooling

9 Inspection cover for filler vessel and expansion vessel

10 Cooling agent connections



General P & ID

This diagram is intended to give a general overview of the measuring points provided.


main switchgear cabinet main switchgear cabinet

additional input signals Emergency Stop External ON/OFF External ‘LESS’ External ‘MORE’ External "Start" External reset 2. set point Feedback of coolant pump Feedback of condenser unit Gas detection

additional output signals Ready Running No alarms Pump release Auxiliary output

fig. 2: P & ID



TABLE OF CONTENTS

1 Description of the Grasso System Control ........................................................................................... 17 1.1 Grasso System Control, general.............................................................................................. 17

1.1.1 View............................................................................................................................. 17 1.1.2 Lamps/ Push buttons .................................................................................................. 18

1.2 Operator terminal ................................................................................................................... 19 1.2.1 Key assignment ........................................................................................................... 20 1.2.2 Menu Structure ........................................................................................................... 22

1.2.2.1 Password level.............................................................................................. 22 1.2.2.2 General image format ................................................................................. 22 1.2.2.3 Open table of contents ............................................................................... 23

1.3 Status displays ......................................................................................................................... 47 2 Control sequence ................................................................................................................................. 50

2.1 Menu 15 “operation modes”................................................................................................... 50 2.2 Overview of the operating modes ......................................................................................... 51 2.3 Explanation of symbols and characters used ......................................................................... 52 2.4 General starting conditions .................................................................................................... 52

2.4.1 Start-to-start timer (anti-recycle timer) ...................................................................... 54 2.4.2 Stop to start timer ...................................................................................................... 55

2.5 Start up sequence - Chiller with reciprocating compressors .................................................. 56 2.6 Switching off behaviour.......................................................................................................... 57

2.6.1 Switching off sequence in the normal case - Chiller with reciprocating compressors 57 2.6.2 Switching off sequence in case of an alarm - Chiller with reciprocating compressors 58

2.7 Compressor control................................................................................................................. 59 2.7.1 Capacity control .......................................................................................................... 59 2.7.2 Function of the output controller .............................................................................. 60

2.8 Safety control (Alarms, warnings and limitations)................................................................. 63 2.8.1 Oil circuit monitoring - Chiller with reciprocating compressors................................. 64

2.8.1.1 Switching sequence in normal case............................................................. 64 2.8.1.2 Switching sequence in the event of a fault in operating state .................. 65

2.8.2 Compressor drive motor fault monitoring................................................................. 66 2.8.2.1 Fault case: compressor drive motor startup is too long ............................. 66 2.8.2.2 Switching sequence in case of fault feedback: "compressor motor feedback" fails ............................................................................................................. 67 2.8.2.3 Motor rated current limitation.................................................................... 67 2.8.2.4 Motor current alarm.................................................................................... 69 2.8.2.5 Suction pressure limitation .......................................................................... 70 2.8.2.6 Suction pressure alarm ................................................................................ 71 2.8.2.7 Limitation of the external temperature – refrigerant outlet temperature 73 2.8.2.8 Alarm: external temperature – refrigerant outlet temperature................ 75 2.8.2.9 Discharge pressure limitation ...................................................................... 77 2.8.2.10 Discharge pressure alarm .......................................................................... 79 2.8.2.11 Differential oil pressure alarm................................................................... 81 2.8.2.12 Suction gas overheating alarm.................................................................. 83 2.8.2.13 Discharge temperature limitation ............................................................. 85 2.8.2.14 Discharge temperature alarm ................................................................... 87 2.8.2.15 Start limitation based on too low oil temperature (optional) ................. 89 2.8.2.16 Oil temperature alarm (optional).............................................................. 90

2.8.3 Draining the oil ........................................................................................................... 92 2.8.3.1 Functional description ................................................................................. 92



2.8.3.2 Parameter .....................................................................................................92 2.8.4 Chiller Sequence Control (optional) ............................................................................93

2.8.4.1 Demands for the hydraulic System ..............................................................93 2.8.4.2 Description of the MPI communication and MPI Master............................94 2.8.4.3 Functional description ..................................................................................95 2.8.4.4 Parameter .....................................................................................................99 2.8.4.5 Actual values (Sequence info)....................................................................101

3 Initial start-up......................................................................................................................................102 3.1 Brief description for initial start-up .......................................................................................102 3.2 Compressor, refrigerant, and sensor selection .....................................................................103 3.3 Adjusting the control settings ...............................................................................................106 3.4 Call up operating mode setting ............................................................................................107 3.5 Adjusting the limit values ......................................................................................................107 3.6 Adjusting timer values ...........................................................................................................107 3.7 Parameterise options.............................................................................................................108 3.8 Saving the changes ................................................................................................................108 3.9 Check the chiller's wiring .......................................................................................................109

4 System description C7-633 ..................................................................................................................110 4.1 Explanation of the system LED..............................................................................................110 4.2 C7-CPU Selection of the operating mode .............................................................................111 4.3 Meaning of the key-operated switches ................................................................................112 4.4 Memory card (EPROM)..........................................................................................................114

4.4.1 Description of the memory card used.......................................................................114 4.4.2 Installation of the Siemens SIMATIC C7 memory card .............................................114

4.5 Adjusting the date/ time.......................................................................................................117 4.6 Changing the language .........................................................................................................117

5 Technical data .....................................................................................................................................118 5.1 Sensors - Types of sensors used.............................................................................................118 5.2 Terminal connection diagram ...............................................................................................119 5.3 Extended data communication (interfaces) .........................................................................119

5.3.1 Explanation of the MPI..............................................................................................119 6 Alarms .................................................................................................................................................122

6.1 General...................................................................................................................................122 6.1.1 Alarms ........................................................................................................................122 6.1.2 Warnings....................................................................................................................123 6.1.3 View active alarms and warnings..............................................................................123

6.2 Possible text displays for alarms and warnings.....................................................................123 6.2.1 General.......................................................................................................................123 6.2.2 List of all alarms and warnings..................................................................................124

6.3 Fault messages from the application program.....................................................................128 6.4 Description and diagnosis of warning messages ..................................................................147 6.5 No alarm signal and the compressor will not start...............................................................157

7 Acknowledging and resetting alarms and warnings .........................................................................158 7.1 Information about the status of the controls in case of an alarm/warning ......................158 7.2 Restart following Alarms .......................................................................................................159 7.3 Information from the controls in case of a system error (CPU)...........................................161

8 Service..................................................................................................................................................168 8.1 Damage Report (Fax) ............................................................................................................168 8.2 Special operating instruction for service staff.......................................................................170

8.2.1 Freeze Display ............................................................................................................171



8.2.2 Service menu ............................................................................................................. 172 8.2.3 "Service Mode" .......................................................................................................... 174

9 List of Parameters............................................................................................................................... 175



TABLE OF FIGURES

fig. 1: View of Ingenium 350.......................................................................................................................... 5 fig. 2: P & ID.................................................................................................................................................... 7 fig. 3: View of outside of power panel........................................................................................................ 17 fig. 4: View of inside of power panel .......................................................................................................... 18 fig. 5: GSC operator terminal ....................................................................................................................... 19 fig. 6: General image format........................................................................................................................ 22 fig. 7: Image format "menu" ........................................................................................................................ 23 fig. 8: Actual values, display 01.................................................................................................................... 24 fig. 9: Actual values, display 02.................................................................................................................... 24 fig. 10: Actual values, display 03.................................................................................................................. 24 fig. 11: Actual values, display 04.................................................................................................................. 25 fig. 12: Actual values, display 05.................................................................................................................. 25 fig. 13: Actual values, display 06.................................................................................................................. 25 fig. 14: Actual values, display 07.................................................................................................................. 25 fig. 15: Actual values, display 08.................................................................................................................. 26 fig. 16: Actual values, display 09.................................................................................................................. 26 fig. 17: Actual values, display 10.................................................................................................................. 26 fig. 18: Actual values, display 11.................................................................................................................. 26 fig. 19: Actual values, display 12.................................................................................................................. 27 fig. 20: Control parameter, display 01 ......................................................................................................... 27 fig. 21: Control parameter, display 02 ......................................................................................................... 27 fig. 22: Control parameter, display 03 ......................................................................................................... 28 fig. 23: Control parameter, display 04 ......................................................................................................... 28 fig. 24: Control parameter, display 05 ......................................................................................................... 28 fig. 25: Operating mode, display 01 ............................................................................................................ 29 fig. 26: Operating mode, display 02 ............................................................................................................ 29 fig. 27: Operating mode, display 03 ............................................................................................................ 29 fig. 28: Limit values, display 01 .................................................................................................................... 30 fig. 29: Limit values, display 02 .................................................................................................................... 30 fig. 30: Limit values, display 03 .................................................................................................................... 30 fig. 31: Limit values, display 04 .................................................................................................................... 31 fig. 32: Limit values, display 05 .................................................................................................................... 31 fig. 33: Limit values, display 06 .................................................................................................................... 31 fig. 34: Limit values, display 07 .................................................................................................................... 31 fig. 35: Limit values, display 08 .................................................................................................................... 32 fig. 36: Limit values, display 09 .................................................................................................................... 32 fig. 37: Limit values, display 10 .................................................................................................................... 32 fig. 38: Limit values, display 11 .................................................................................................................... 33 fig. 39: Limit values, display 12 .................................................................................................................... 33 fig. 40: Limit values, display 13 .................................................................................................................... 33 fig. 41: Limit values, display 14 .................................................................................................................... 33 fig. 42: Limit values, display 15 .................................................................................................................... 34 fig. 43: Limit values, display 16 .................................................................................................................... 34 fig. 44: Limit values, display 17 .................................................................................................................... 34 fig. 45: Limit values, display 18 .................................................................................................................... 35 fig. 46: Alarm Messages, display 01 ............................................................................................................. 35 fig. 47: Alarm Messages, display 02 ............................................................................................................. 35 fig. 48: Alarm Messages, display 03 ............................................................................................................. 35 fig. 49: Timer values, display 01 ................................................................................................................... 36 fig. 50: Timer values, display 02 ................................................................................................................... 36 fig. 51: Timer values, display 03 ................................................................................................................... 36



fig. 52: Timer values, display 04....................................................................................................................37 fig. 53: Timer values, display 05....................................................................................................................37 fig. 54: Timer values, display 06....................................................................................................................37 fig. 55: Timer values, display 07....................................................................................................................37 fig. 56: Options, display 01 ...........................................................................................................................38 fig. 57: Options, display 02 ...........................................................................................................................38 fig. 58: Sequence values, display 01 .............................................................................................................38 fig. 59: Sequence values, display 02 .............................................................................................................38 fig. 60: Sequence values, display 03 .............................................................................................................39 fig. 61: Sequence parameters, display 01.....................................................................................................39 fig. 62: Sequence parameters, display 02.....................................................................................................39 fig. 63: Sequence parameters, display 03.....................................................................................................40 fig. 64: Sequence parameters, display 04.....................................................................................................40 fig. 65: Option injection, injection value ......................................................................................................40 fig. 66: Option injection, injection parameters ............................................................................................41 fig. 67: Configuration, display 01 .................................................................................................................41 fig. 68: Configuration, display 02 .................................................................................................................41 fig. 69: Configuration, display 03 .................................................................................................................42 fig. 70: Configuration, display 04 .................................................................................................................42 fig. 71: Configuration, display 05 .................................................................................................................42 fig. 72: Configuration, display 06 .................................................................................................................43 fig. 73: Configuration, display 07 .................................................................................................................43 fig. 74: Configuration, display 08 .................................................................................................................43 fig. 75: Configuration, display 09 .................................................................................................................44 fig. 76: Configuration, display 10 .................................................................................................................44 fig. 77: Configuration, display 11 .................................................................................................................44 fig. 78: Configuration, display 12 .................................................................................................................45 fig. 79: Configuration, display 13 .................................................................................................................45 fig. 80: System menu, display 01 ..................................................................................................................46 fig. 81: System menu, display 02 ..................................................................................................................46 fig. 82: System menu, display 03 ..................................................................................................................46 fig. 83: System menu, display 04 ..................................................................................................................46 fig. 84: System menu, display 05 ..................................................................................................................47 fig. 85: "Status messages" display .................................................................................................................47 fig. 86: Explanation of symbols and characters used...................................................................................52 fig. 87: Time parameters, figure 05 ..............................................................................................................52 fig. 88: start-to-start timer (anti-recycle timer).............................................................................................54 fig. 89: Stop to start timer ............................................................................................................................55 fig. 90: Start up sequence .............................................................................................................................56 fig. 91: Time parameters, display 05.............................................................................................................57 fig. 92: Switching off sequence in the normal case ....................................................................................57 fig. 93: Switching off sequence in case of an alarm.....................................................................................58 fig. 94: Arrangement of capacity control calves ..........................................................................................59 fig. 95: Function of the output controller ....................................................................................................60 fig. 96: Determining the step times..............................................................................................................62 fig. 97: Graphic example of the formation of the limit value signals..........................................................63 fig. 98: Oil circuit monitoring in normal case ...............................................................................................64 fig. 99: Oil circuit monitoring in case of fault...............................................................................................65 fig. 100: Compressor drive motor fault monitoring.....................................................................................66 fig. 101: Compressor drive motor fault monitoring feedback.....................................................................67 fig. 102: Motor rated current limitation.......................................................................................................67 fig. 103: Determination of the forced adjustment factor for motor rated current limitation ...................68 fig. 104: Limit values, figure 15.....................................................................................................................68



fig. 105: Motor current alarm ...................................................................................................................... 69 fig. 106: Limit values, figure 14.................................................................................................................... 69 fig. 107: Suction pressure limitation ............................................................................................................ 70 fig. 108: Limit values, figure 02.................................................................................................................... 70 fig. 109: minimum suction pressure alarm................................................................................................... 71 fig. 110: Limit values, figure 01.................................................................................................................... 71 fig. 111: maximum suction pressure alarm.................................................................................................. 72 fig. 112: Limit values, figure 03.................................................................................................................... 72 fig. 113: Limit values, figure 04.................................................................................................................... 72 fig. 114: Limitation of the external temperature or refrigerant outlet temperature ................................ 73 fig. 115: Limit values, figure 17.................................................................................................................... 74 fig. 116: External temperature alarm .......................................................................................................... 75 fig. 117: Limit values, figure 16.................................................................................................................... 76 fig. 118: Discharge pressure limitation ........................................................................................................ 77 fig. 119: Actual values, figure 07 ................................................................................................................. 78 fig. 120: Discharge pressure alarm............................................................................................................... 79 fig. 121: Limit values, figure 06.................................................................................................................... 80 fig. 122: Differential oil pressure alarm ....................................................................................................... 81 fig. 123: Limit values, figure 10.................................................................................................................... 82 fig. 124: Time parameters, figure 05 ........................................................................................................... 82 fig. 125: Suction gas overheating alarm ...................................................................................................... 83 fig. 126: Limit values, display 05 .................................................................................................................. 84 fig. 127: Time parameters, figure 04 ........................................................................................................... 84 fig. 128: Discharge temperature limitation ................................................................................................. 85 fig. 129: Limit values, figure 07.................................................................................................................... 86 fig. 130: Discharge temperature alarm........................................................................................................ 87 fig. 131: Limit values, figure 08.................................................................................................................... 88 fig. 132: Start limitation based on too low oil temperature ...................................................................... 89 fig. 133: Limit values, figure 12.................................................................................................................... 89 fig. 134: Minimum oil temperature alarm ................................................................................................... 90 fig. 135: Limit values, figure 11.................................................................................................................... 90 fig. 136: Maximum oil temperature alarm .................................................................................................. 91 fig. 137: Limit values, figure 13.................................................................................................................... 91 fig. 138: Time parameters, figure 06 ........................................................................................................... 92 fig. 139: Time parameters, figure 07 ........................................................................................................... 92 fig. 140: Overview of the hydraulic system for the chiller sequence control ............................................ 93 fig. 141: Frontview MPI Master ................................................................................................................... 94 fig. 142: MPI network for 3 GSC systems with a MPI Master including the settings for the terminating resistor integrated in the MPI connector ................................................................................................... 94 fig. 143: Example of capacity increase with 3 chillers in sequence ............................................................. 97 fig. 144: Example of capacity decrease with 3 chiller units in sequence .................................................... 98 fig. 145: Bridge at the authorisation input (see chapter 5) ...................................................................... 111 fig. 146: Memory card................................................................................................................................ 114 fig. 147: Positioning of the memory card .................................................................................................. 115 fig. 148: Sequence of operation mode key state indication ..................................................................... 116 fig. 149: Overview of the interfaces, memory card placing and battery position ................................... 119 fig. 150: Interfaces C7-633, power supply and Author. connection ......................................................... 120 fig. 151: Bus cable connectors ................................................................................................................... 120 fig. 152: PG junction box........................................................................................................................... 120 fig. 153: Control cabinet with LED and indicator lights ............................................................................ 122 fig. 154: Display in case of an alarm .......................................................................................................... 158 fig. 155: Restart following Alarms ............................................................................................................. 160 fig. 156: Information from the controls - Possibility 1............................................................................... 162



fig. 157: Information from the controls - Possibility 2 ...............................................................................163 fig. 158: Information from the controls - Possibility 3 ...............................................................................164 fig. 159: Information from the controls - Possibility 4 ...............................................................................165 fig. 160: Information from the controls - Possibility 5 ...............................................................................166 fig. 161: Information from the controls - Possibility 6 ...............................................................................167 fig. 162: Freeze Display 01 ..........................................................................................................................171 fig. 163: Freeze Display 02 ..........................................................................................................................171 fig. 164: Freeze Display 03 ..........................................................................................................................171 fig. 165: Freeze Display 04 ..........................................................................................................................172 fig. 166: Freeze Display 05 ..........................................................................................................................172 fig. 167: Freeze Display 06 ..........................................................................................................................172 fig. 168: Service mode 01............................................................................................................................172 fig. 169: Service mode 02............................................................................................................................173 fig. 170: Service mode 03............................................................................................................................173 fig. 171: Service mode 04............................................................................................................................173 fig. 172: Service mode 05............................................................................................................................173



1 DESCRIPTION OF THE GRASSO SYSTEM CONTROL

1.1 Grasso System Control, general

The GSC consists of the control unit with operator keypad and display unit, indicator lights for ”Running”, ”Warning” and ”Alarm”, emergency stop button, output relays etc.

The standard GSC is appropriate for directly mounting on the Chiller.

The GSC performs the following functions:

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

— Automatic start up and shut down of the INGENIUM and capacity regulation dependent on the following values:

— Suction pressure

— External temperature (value via analog input or network)

— inlet temperature

— outlet temperature

— condensing temperature (heat pump operation)

— discharge pressure (heat pump operation)

— Monitoring of all operating parameters.

— Compressor capacity limitation, in case the discharge pressure, discharge temperature, suction pressure, secondary refrigerant temperature or motor current limits are approached.

— Alarm memory with date and time.

— Wire failure detection of analogue input signals.

— Password protection for preventing unauthorised access to parameters.

— Program memory on EPROM.

— Control of the Chiller by a master controller via potential free contacts.

— MPI or Profibus-DP communication with a master controller.

— Freeze display for all actual values, existing directly before alarm shutoff.

1.1.1 View

fig. 3: View of outside of power panel



fig. 4: View of inside of power panel

1 PLC with analog subassemblies

2 Emergency stop relay

3 Power supply

4 Main fuses

5 Star/Delta contactors

6 Main switch

1.1.2 Lamps/ Push buttons

White indicator light (Running)

This indicator lamp flashes slowly when the INGENIUM is in the “Ready“ state.

This lamp flashes quickly during start up of the compressor.

Once the compressor has started, the light becomes steady.

This lamp flashes quickly during the shut down operation, until the compressor drive motor is switched off.

Yellow indicator light (Warning)

This lamp flashes if an operating condition reaches a preset value (Warning /Pre-alarm).

This state is signalled by a yellow flashing light.

After the warning has been acknowledged at the operator panel, this flashing light changes over to a steady light, as long as the warning condition remains.

All warnings are acknowledged automatically, which means that the indicator light switches off again when the operating conditions are back to normal.

Red indicator light (Alarm)

This lamp flashes if an operating condition exceeds its permitted value, the machine shuts down on alarm.

This state is signalled by a red flashing light.

After the alarm has been acknowledged at the operator panel, this flashing light changes over to a steady light, as long as the alarm condition remains.

Once the cause of the alarm has been corrected, this indicator light switches off (after it has been acknowledged).

Emergency Stop button

This red button can be used to switch the INGENIUM off at any time in case of an emergency.

The operator terminal controls remain functional.



1.2 Operator terminal

The operator terminal is the interface between the operator and the control unit.

All switching, operating and control actions are carried out via this operator terminal.

fig. 5: GSC operator terminal

A System LED’s B Function keys

C Soft keys

D CPU operating mode setting

E Digital keybord

F Cursor keys

G System keys

H System keys LED‘s

Hint!

See chapter "Explanation of the system LED"!



1.2.1 Key assignment

Key Function

+ Go to the menu item described

+ Back to previous display Move to next display

Switch on the INGENIUM, start enabled

Start 1st compressor (Press key for 5 sec. in operation mode ”Manual”) Increase capacity of 1st compressor (in case of manual capacity control only)

+ + without function

Call up display of actual values

Call up alarm signals

Lamp test

Switch off the INGENIUM, start disabled

Stop 1st compressor (Press key for 5 sec. in operation mode ”Manual”) Reduce capacity of 1st compressor (in case of manual capacity control only)

+ + without function

Call up controls – settings

Call up operating mode setting

Call up the menu overview

Return or cancel input

Acknowledge, reset alarm and warning

Confirm input

Press the button once for display of a help text.

Switch over to the 2nd keyboard level

Cursor keys



Functions for the F1 ... F4 buttons

These functions are only available if the symbols can be seen in the display.

Back to previous display

+ Go to the menu item described

Move to next display

Standard function of the shift key

+ or Change between the possible selections

+ Alter the display contrast

Special function of the shift key

+ Change to the ”Status display”

+ Change to the "Freeze display"

+ Change to the “Language selection” or “Contrast menu”

+

Change to the ”Transfer” menu.

Caution!

stop with

+ Change to the ”Digital inputs / outputs display”

+ Change to the "Password" menu

+ Change to the “Date, Time“ menu



1.2.2 Menu Structure

1.2.2.1 Password level

The access rights within the menu structure are protected by different passwords.

The operator is asked to enter a password when they try to enter a command.

Each password level has a different number allocated to it.

The passwords for Levels 1 to 8 can be freely allocated by the user.

Password level 0 doesn't need a password.

The password for the highest password level 9 is specified by Grasso on delivery and cannot be subsequently changed.

If a password is entered and then no key is used for a longer period (approx. 10 mins), the operator panel automatically logs out from the password level.

Caution!

The following password levels have been allocated:

Password level 0 Information level display function only, no parameter changes possible

Password level 1 Operator level in addition to level 0 Change to the set point values possible

Password level 2 for authorised persons only

in addition to level 1 changes to all limiting values/timers possible

Password level 8 Service level in addition to level 2 Changes in the configuration menu possible

Password level 9 for Grasso only in addition to level 9 System changes possible

1.2.2.2 General image format

The image format is identical in all the images

fig. 6: General image format

Depending on the menu, the actual or set point values are displayed in the 3 top rows.

The name of the selected menu is displayed again in the lowest row.



The double arrows or mean that you can move to the previous menu display or the next menu

display by pressing the key under this symbol.

If a menu is selected in which further branches are possible, the image format is as follows:

fig. 7: Image format "menu"

The current image name is displayed in the top row.

The keys under the symbols and are used to return to the previous menu display or to the next

menu display , and thus to further possible selections.

The described function is selected using the and keys under the symbols.

1.2.2.3 Open table of contents

To open the table of contents, please press the key. A list of the available menus is then displayed.

Number Heading Help text

05 Actual values Display of all INGENIUM's actual values

10 Control All control parameters can be changed here

15 Operating modes Selection of all possible operating modes

20 Limit values Enter the limit value parameters

25 Fault messages Fault messages + histogram

30 Time settings All time parameters can be changed here

35 Options All optional windows are selected from here

50 Configuration Enter: — Compressor type — Refrigerant — Number of cylinders — Sensor scaling

90 Main system menu



To open these views, position the cursor on this view (using the or key) and confirm with the key.

Danger!

Parameter changes in menu 20, 30, 35, 50 can cause serious damage to the INGENIUM!

1.2.2.3.1 Menu 05 "Actual values"

fig. 8: Actual values, display 01

PV: Process value (pressure or temperature) in °C

SP: Set Point in °C

Cap: Current capacity (for the low pressure stage) in %

Imot: Motor current in A

Tc: Discharge pressure in °C/R

dPoil: Oil differential pressure in bar


Capacity: Current capacity interval (for the low pressure stage) in %

Suction press: Suction pressure bar (a)

Disch press: Discharge pressure bar (a)


Oil diff press:

Value calculated from the oil pressure minus crankcase pressure in bar. If no crankcase pressure sensor is fitted then the suction pressure is used instead.

Oil press: Oil pressure bar (a)




Suction temp: Suction temperature °C

Disch temp: Discharge temperature °C

Oil temp: Oil temperature °C


Suc dif temp: Value calculated from the suction temperature minus suction pressure in K

Injection: Refrigerant injection in %


Suc press: Suction pressure in °C/R (refrigerant dependent)

Disc press: Discharge pressure in °C/R (refrigerant dependent)


Inlet temp: Cooling agent inlet temperature in °C

Outlet temp: Cooling agent outlet temperature in °C

Condenser temp: Condensing temperature in °C




Remote SP: External setpoint in °C

External temp: External temperature in °C


Motor current: Motor current in A


Start to start: Start to start – Remaining time between two starts of the compressor in sec.

Stop to start: Remaining time between stop and next start of the compressor in sec.


Unloaded start: Remaining time to unloaded start has been completed

Motor feedback: Remaining time to alarm "motor feedback too late"

Auto start dly: Remaining time for automatic start delay




Step time: Remaining time to next step

Limit time: Remaining time to limitation has been completed

Operating hours: Number of operating hours

1.2.2.3.2 Menu 10 Control Settings

fig. 20: Control parameter, display 01

1. Set Point: 1. 1st Set point in °C

2. Set Point: 2. 2nd Set point in °C

Active SP: Active set point in °C

The active set point value is displayed.

2 different set point values can be entered via the display.

The switchover between these 2 set points takes place due to a potential free contact or via BUS (MPI or Profibus-DP).

Furthermore, an external set point can be activated (analog input or Bus).

The switchover takes place due to the selection in the "Operating mode" menu. .


Active SP: Active set point in °C

Neutral zone: Neutral zone of capacity control in K

Prop zone: Proportional zone of capacity control in K




Cap inc min: Minimum step time to load compressor in secs

Cap inc max: Maximum step time to load compressor in secs

Cap dec min: Minimum step time to unload compressor in secs

Cap dec max: Maximum step time to unload compressor in secs


Auto start dly Length of delay in sec before automatic start up

Auto stop dly Length of delay in sec before automatic switch off


Dynamic SP: Temperature difference in K between in- and outlet temperature at the evaporator. This value is active in case of inlet temperature control only.

Cor P-zone: Correction of proportional zone in K. For capacity decreasing only (+ in set point direction / - from set point away).

Derative fact: Maximum temperature change in K within 5 secs (without forced temperature change). Enter 0.0 to switch off this function.



1.2.2.3.3 Menu 15 “Operating mode”

fig. 25: Operating mode, display 01

Operation mode selection

Select the operating mode using and or .

Confirm selection with


Control on:

Choose between "suction pressure", "external temperature", "inlet temperature", "outlet temperature", "discharge pressure", "condenser temperature" and "network temperature"

Sequence: Selection of the sequence control mode. Choose beween "OFF", "Master" and "Slave"




Power return:

Performance after connecting voltage. Choose between “Warning” (start released) and “Alarm” (start blocked)

Netw fault:

Performance after network failure. Choose between “Alarm” and one of the operating modes available after network failure.





1.2.2.3.4 Menu 20 Limit values

Caution!

1. line in display: display of current process variables only

2.+3. line in display: adjustable values

fig. 28: Limit values, display 01

Suction press: Actual suction pressure in bar (a)

Psuc low alarm: Alarm limit for minimum suction pressure in bar (a)

Low warning: Enter the warning value as an offset to the alarm value



Low limit: Begin of minimum suction pressure limitation. Enter value as an offset to the alarm value

Decr limit: Begin of forced capacity adjustment to minimum by too low suction pressure. Enter value as an offset to the alarm value



Psuc hi alm n1: Alarm limit for maximum suction pressure in bar (a) for low speed (n1)

Psuc hi alm n2: Alarm limit for maximum suction pressure in bar (a) for high speed (n2)





Psuc hi alarm: Current alarm limit for maximum suction pressure in bar (a)

High warning: Enter the warning value as an offset to the alarm value


Suct dif temp: Actual suction gas super heat in K

dT0 low alarm: Enter the alarm limit for minimum super heat in K



Disch press: Actual discharge pressure in bar (a)

Pdis hi alarm: Enter the alarm limit for maximum discharge pressure in bar (a)

High warning: Enter the warning value as an offset to the alarm value


Pdis hi Alarm: Alarm limit for maximum discharge pressure in bar (a)

High limit: Begin of max. discharge pressure limitation. Enter value as an offset to the alarm value

Decr limit: Begin of forced capacity adjustment to minimum by too high discharge pressure. Enter value as an offset to the alarm value




Disch temp: Actual discharge temperature in °C

Tdis hi alarm: Alarm limit for maximum discharge temperature in °C

High warning: Enter the warning value as an offset to the alarm value in K


Tdis hi Alarm: Alarm limit for minimum external temperature in °C

High limit: Begin of max. discharge pressure limitation. Enter value as an offset to the alarm value in K

Force limit: Begin of forced adjustment to maximum by too high discharge temperature. Enter value as an offset to the alarm value


Oil dif press: Actual oil differential pressure in bar

dPoil low alarm: Alarm limit for minimum pressure difference in bar





Oil temp: Actual oil temperature in °C

Toil low alarm: Alarm limit for minimum oil temperature in °C

Low warning: Enter the warning value as an offset to the alarm value in K



Low limit: Begin of start limitation at oil temperature too low. Enter value as an offset to the actual value

Oil press °C/R: Actual oil pressure in °C



Toil hi alarm: Alarm limit for maximum oil temperature in °C

High warning: Enter the warning value as an offset to the alarm value in K


Motor current: Actual motor current in A

Imot hi alarm: Alarm limit for maximum motor current in A

High warning: Enter the warning value in A as an offset to the alarm value




Imot hi alarm: Display of motor current alarm limitation in A

High limit: Begin the motor current limitation - enter value as an offset to the alarm value in A

Decr factor: Begin of forced adjustment to minimum by too high motor current. Enter value: 0% = OFF / 100% = motor current and compressor capacity are linearly dependent


External temp: Actual external temperature in °C

Text low alarm: Alarm limit for minimum external temperature in °C

Low warning: Enter the warning value as an offset to the alarm value in K


Text low alarm: Alarm limit for minimum external temperature in °C

Low limit: Begin the temperature limitation - Enter value as an offset to the alarm value in K

Decr limit: Begin of forced adjustment to minimum by too low temperature. Enter value as an offset to the alarm value in K




Capacity: Current capacity interval (for the low pressure stage) in %

Minimum: Minimum value in % to activate the auxiliary output in case of too low capaity (min-cap.)

Maximum: Maximum value in % to activate the auxiliary output in case of too high capaity (max-cap.)

1.2.2.3.5 Menu 25 Alarm Messages

fig. 46: Alarm Messages, display 01

View: The alarm No., date and time and status of the alarm are displayed. The status display has the following meaning: Q = when the alarm is acknowledged; K = is logged when the alarm first occurs; G = when the alarm condition has been

cleared. If the cursor is pointing to the alarm number, the alarm text can be displayed by pressing the key.

Print: no stored function


Number: Displays how many alarms have been stored and how many are still active

Delete: All the fault signals stored in the buffer can be deleted


Overflow: Enables a message to be displayed even if the fault buffer is full

Text: Display all possible alarm messages with alarm No.



1.2.2.3.6 Menu 30 Timer values

fig. 49: Timer values, display 01

Start to start: Delay between stop and next start in secs.

Stop to start: Delay between two starts of the compressor in secs


Oil dif start: Oil pressure alarm delay during start up in secs.

Oil dif run: Oil pressure alarm delay during running in secs.

Caution!

Summation of both times must never exceed the maximum value for selected compressor.


unloaded start: time in secs, which compressor runs unloaded during start-up

Motor feedback: Monitoring time until motor feedback in secs




dTo alarm dly: Monitoring time suction gas overheat in secs

Run hours: Operating hours in hours


Flow swtch dly: Length of delay of flow controller (sec. refr.) in sec

Cond. feedback: Length of delay condenser feedback in secs

Pump stop dly: Length of delay of coolant pump shut-down in secs


Oil drain: Draining – charging time in secs

Drain delay: Draining – pause after charging in secs


Oil return: Draining - draining time in secs

Return delay: Draining - Delay following oil return in sec.



1.2.2.3.7 Menu 35 Options

fig. 56: Options, display 01

Process value: Jump to display "Actual values" of sequence control

Parameter: Jump to display “Parameter“ of sequence control

fig. 57: Options, display 02

Process value: Jump to display "Actual calues" of refrigerant injection

Parameter: Jump to display “Injection“ to refrigerant injection parameters

Sequence values

fig. 58: Sequence values, display 01

Systems running: Number of systems with running compressors

start/stop sequence: Sequence of switching-ON and -OFF: left starts as 1st / stops as least, right start as least / stops as 1st


Start delay: Remaining time of start-stop delay in secs

Stop next dly: Remaining time of stop-start delay in secs

C.O.P. delay: Remaining time of C.O.P. optimisation delay in secs




Connected: Number of connected users (0: inactive, 1: active, MPI 1 – 2 = MPI 12)

Quality: Signal quality of MPI-communikation in %

100%: higly

< 20%: MPI-communikation without failures not guaranteed

Sequence Parameters

fig. 61: Sequence parameters, display 01

Operation:

Display Mode. The switchover takes place due to the selection in the "Operating mode" menu .

Sequence No: Selection of the fixed sequence number (range 1 through 9).


Minimum: Enter minimum capacity of selected system in %

Part load: Enter part-load capacity of selected system in %

Maximum: Enter maximum capacity of selected system in %




Use fixed seq.: Select fixed sequence due to defined sequence numbers (“yes”) or select sequence due to compensation of hours of operation (“no”).

C.O.P. Logic: Select if the C.O.P. (Coefficiency Of Performance) logic is active ("yes" or "no")

neutral zone: Enter the neutral zone of the master in K

Select using and or



Start delay: Enter start delay of the next system in secs

Stop delay: Enter stop delay of the next system in secs

C.O.P. delay: Enter C.O.P. optimisation delay in secs

Menu Option injection - Injection actual value

fig. 65: Option injection, injection value

Suct dif temp: Value calculated from the suction temperature minus suction pressure in K

Injection Refrigerant injection in %

See Menu Actual values .



Menu Option injection - Injection parameters

fig. 66: Option injection, injection parameters

Selftuner: Status display of self-optimized controller

Inj. value: Display and enter the memorizing value of controller

Hint!

The self-optimizing of a capacity step can be re-started by pressing the F2 key.

1.2.2.3.8 Menu 50 Configuration

fig. 67: Configuration, display 01

SP: Display of the PLC program version used.

OP: Display of the operater panel version used

MPI: Display of the operater panel version /PLC MPI-address used

HW: Display of the hard ware version used


Refrigerant: Select Refrigerant (R717; etc.)

Comp Type: Select the compressor type (Grasso7S; Grasso7SW; etc.)

Select using and or Confirm selection with




LP cylinders: Enter number of LP cylinders

Min capacity: Enter minimum capacity in %



Additional cap: Select "yes" (for existing additional capacity steps), otherwise "no" (standard compressor).



Inject control: Select "no" for mechanic injection, otherwise "GSC" for electronic injection.

AKVA type: Select AKVA type (“no”, “10-1” to “20-5”)





Nom speed: Enter nominal speed in min-1

Aux output: Select function of the auxiliary output



Motor curr: Select “without” or “with” (sensor mounted)

Inlet temp: Select “without” or “with” (sensor mounted)



Oil temp: Select “without” or “with” (sensor mounted)

Outlet temp: Select “without” or “with” (sensor mounted)

Cond temp.: Select “without” or “with” (oil separator mounted)





Remote SP: Select “without” or “with” (sensor mounted)

Ext temp.: Select “without” or “with” (sensor mounted)


not valid for temperature sensors:


Sensor: Select the sensor type e.g. “suction pressure”, “discharge pressure”, etc.

4mA equals: Start of measuring range of the sensor selected; e.g. 0 bar

20mA equals: End of measuring range of the sensor selected; e.g. 21 bar

for temperature sensors only:


Offset (K): Offset of the sensor selected; e.g. 0 K

Range (%): Range of the sensor selected; e.g. 0 %





Accept: Store the set configuration in the main memory (program works with the new values, but these are not yet saved in the EPROM).

Save: Saves the set configuration in the EPROM.

Warning message during "Save"


Caution!

• For config settings to take effect choose "Accept" and "Save" before ESC!

• Press the key to exit the configuration menu without "Accept" and "Save".

• If a change has been made, the display shows “?”.

The "?" changes into "ok" after successful confirmation of “Accept” and “Save”.

• Limit values, timer values and control settings will be overwrited with standard values by confirming the "Accept" key for each change in the configuration menu with changes of compressor type and/or refrigerant.

It is therefore recommended to check the limit values, timer values and control settings after confirming the "Accept" key and change them before saving the configuration by confirming the "Save" key.

• During "Save" the CPU changes automatically to STOP and after 1 to 2 minutes back to RUN.

This procedure can be performed when the PLC is in RUN only (see 4.3), otherwise the following system message is displayed: “$369 S7 command error 20”.

During this time it is impossible to operate the GSC.

• Don't press any key or don't switch off before the CPU is in RUN again, otherwise all information saved on the EPROM will get lost!



1.2.2.3.9 Menu 90 System menu

fig. 80: System menu, display 01

Events: "Status messages" - further submenus: “View”, “Print”, “Number”, “Delete”, “Overflow”, “Text” Alarms: "Alarm messages" - further submenus “View”, “Print”, “Number”, “Delete”, “Overflow”, “Text”


Screens: Further submenus: “Edit”, “Print” Records: Further sub menus: “Edit”, “Print”, “Carry”


StatVAR: Status variables, control variables (values) can be displayed in this menu

ForceVAR: Control variables, control variables (values) can be altered


System: System settings, Further submenus “OPMode”, “DispMsg”, “SysMsg”, “Language”, “Dat/Time”, “Printer”, “IF1”, “IF2” Password: Further sub menus: “Login”, “Logout”, “Edit”




DI/DO: Display the control input and output assignments

RAM -> ROM:

Saves the set configuration in the EPROM. (see "Configuration menu", screen „safe“)

1.3 Status displays

Open the "status messages" display, press the key several times, or press the key and then .

This display shows all of the information shown in the first actual values screen plus the status of the INGENIUM.

fig. 85: "Status messages" display

PV: Actual value (pressure or temperature) display always in °C

SP: Set Point display in °C

Cap: Current capacity interval (for the low pressure stage) in %

Imot: Motor current in A

Tc: Discharge pressure in °C/R

dPoil: Oil differential pressure in bar

Hint!

See menu 05 actual values

The operating status provides information about the INGENIUM.



The following status messages are possible:

Initialisation Initialisation of the controller after swithing on the power supply or after saving the configuration (RAM → ROM)

Start to start A starting frequency limiter of the compressor drive motor is still active.

Stop to start 01 Start delay after each stop

External start 01 The controller is waiting for an external signal to enable the start of the unit

Standby 01 INGENIUM ready for switching on, but one or more starting conditions are still not fulfilled e.g. process variable still below set point

Low oil temp 01 Oil temperature too low, compressor start disabled.

Low suc press 01 Suction pressure too low, compressor start disabled.

High disch press 01 Discharge pressure too high, compressor start disabled.

Motor feedback 01 Compressor motor has been started but the switchover in "delta" has not yet taken place of the startup has not yet been completed.

Sec refr pump No feedback "Sec refr pump" (secondary refrigerant pump)

Condenser feedback No "Condenser feedback"

Starting 01 Compressor motor has been started, but compressor runs unloaded (1stage or 2stage) resp. the LP cylinders are not yet activated (2stage only).

Running 01 Compressor running in "delta" or startup has finished, the uINGENIUM is in operation.

Limit suct press 01 A capacity limitation is active (suction pressure too low). Capacity can't be increased and will be decreased in case of increasing suction pressure.

Limit disch press 01 A capacity limitation is active (discharge pressure too high). Capacity can't be increased and will be decreased in case of increasing discharge pressure.

Limit disch temp 01 A capacity limitation is active (discharge temperature too high). Capacity can't be decreased and will be increased in case of increasing discharge temperature.

Limit mot current 01 A capacity limitation is active (motor current too high). Capacity can't be increased and will be decreased in case of increasing motor current.

Limit ext temp 01 A capacity limitation is active (external temperature too low). Capacity can't be increased and will be decreased in case of decreasing external temperature.

Limit timer Delay following limitation is active.

Stopping 01 The INGENIUM has received a shutdown command, the capacity is moved towards its minimum.

Compressor off 01 Switch off the INGENIUM, start disabled.

Limit oil temp 01 Oil temperature too high, "refrigerant injection" is released (optional).

Failure 01 A failure has occurred, which is still active.

Main failure A failure has occurred, which is still active.

italic lettering Text display flashes

Normal lettering Text appears as static text



The status of the whole INGENIUM is displayed with the LEDs in and .

Key Colour Status Explanation

Green Flashing The INGENIUM is switched on.

The compressor could start any moment now.

Green Continuous light The INGENIUM is switched on.

The compressor is running.

+ without OFF

The INGENIUM is malfunctioning. The compressor is not running. The (red) indicator light ‘Collective fault’ flashes or is permanently lit.

red Continuous light The INGENIUM is switched off.

The compressor is not running.



2 CONTROL SEQUENCE

2.1 Menu 15 “operation modes”



2.2 Overview of the operating modes

Operation modes Signal for ...

Name Explanation Start/Stop Capacity +/-

0 Service Compressor motor blocked

1 manual + manual

Manueal control via OP (min. pause between capacity steps 15 secs)

manual manual

2 manual + auto Manual Start/Stop via OP and full automatic local capacity 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 GSC derives from the continuous +/- signals the pulses for controlling the slide position (indirect).

external external continous

5 Remote + HW (pulse)

Start/stop and capacity demand via digital contacts (Hardware) from a remote Master controller. The Master also generates the +/- signals as pulses for controlling the slide position directly. (min. pause between capacity steps 15 secs)

external external pulses

6 Remote + HW-Loc. SP

Start/stop via digital contacts (Hardware) from a remote Master controller. The capacity control is based on the local set point (OP).

external Local set point

7 Remote + HW-Rem. SP

Start/stop via digital contacts (Hardware) from a remote Master controller. The capacity control is based on the remote set point (analogue input).

external Remote set point

8 Remote + Net (cont)

Start/stop and capacity demand via network (MPI or Profibus-DP) from a remote Master controller. The GSC derives from the continuous +/- signals the pulses for controlling the slide position (indirect).

Network Network continous

9 Remote + Net (pulse)

Start/stop and capacity demand via network (MPI or Profibus-DP) from a remote Master controller. The Master also generates the +/- signals as pulses for controlling the slide position directly. (min. pause between capacity steps 15 secs)

Network Network pulses

10 Remote + Net-Loc. SP

Start/stop via network (MPI or Profibus-DP) from a remote Master controller. The capacity control is based on the local set point (OP).

Network Local set point

11 zentral + Net-Net SP

Start/stop via network (MPI or Profibus-DP) from a remote Master controller. The capacity control is based on a remote set point that is sent via the network also.

Network Network set point



2.3 Explanation of symbols and characters used

Progression of a signal with time or information

Progression of a signal with time or information, the pre-event history is irrelevant

Progression of a signal with time or information, the future is irrelevant

Time at which a cause or condition begins (in text „• if ...“)

Effect (in text „• then ...“)

fig. 86: Explanation of symbols and characters used

2.4 General starting conditions

Chiller's basic switching on procedure:

1. The switching on command for the chiller sets output A1.6 "release refrigerant pump / condenser". Coupling relays connected to these can release the plant's condenser system.

Within a fixed and a parameterisable time ("Condenser feedback") the GSC expects feedback that these systems are in operation at the inputs E1.6 "refrigerant feedback" (25 seconds fixed) and E1.5 "heat transfer medium feedback“ (parameterisable).

If no feedback is received within this time the GSC switches to warning state and the chiller does not start up.

2. If the GSC is in the above warning state and feedback is subsequently received the warnings are automatically acknowledged and switching on of the chiller continues.

3. If the feedback is received promptly the chiller continues to be switched on without warnings.

The parameter for setting the times is located in the main menu 30 "Timer Values" figure 5.

fig. 87: Time parameters, figure 05

Flow switch delay: Length of delay of refrigerant flow monitor in secs

Cond. feedback: Length of delay for condenser feedback in secs

Pump stop delay: Length of delay of refrigerant pump shut-down in secs



The following conditions have to be fulfilled to begin start up:

• If Start command

and

• If the input "refrigerant feedback" is active

and

• If the input "heat transfer medium feedback" is active

and

• If no start-to-start delay of the compressor motor is active

and

• If no stop-to-start timer of the compressor motor is active

and

• If no stop-to-start delay of oil temperature, suction pressure and final pressure is active

and

• If the input "compressor startup release" is active

and

• If no alarm is active

Then switching on conditions are fulfilled



2.4.1 Start-to-start timer (anti-recycle timer)

As electric motors are particularly highly loaded during the start up process, it is important to comply with the manufacturer’s requirements regarding the allowed number of start per hour.

These include protection for maintaining the thermal and mechanical loading within limits.

The ‘start-to-start’ timer fulfils the following function:

• Limitation of the number of starts per unit time (directly consecutive starts).

The permissible number of starts per hour is based on the motor manufacturer’s values for the operating mode and insulation class.

fig. 88: start-to-start timer (anti-recycle timer)

1 Compressor motor ON

2 ‘start-to-start’ timer active - Time

3 Compressor motor start not allowed

A ... The compressor motor ran longer than the ‘start-to-start’ timer, next start allowed immediately.

• If (1) Request to start the compressor motor is no longer active

and (2) start-to-start time is no longer active,

Then (3) compressor motor's stop-to-start delay is inactive

B ... The compressor motor ran less than the ‘start-to-start’ timer, the next start is not allowed until the remaining ‘start-to-start’ time has expired.

• If (1) Request to start the compressor motor is no longer active

and (2) start-to-start time is still active,

Then (3) the compressor motor's stop-to-start delay is active



2.4.2 Stop to start timer

A minimum time difference is required between a stop and the next start of the compressor motor.

At the same time, the switching device contacts have to open correctly for the compressor motor time!

fig. 89: Stop to start timer

1 Request to start the compressor motor

2 Feedback - compressor motor ON

3 Stop to start delay active

• If (1) Request to start the compressor motor not active anymore

and (2) no feedback compressor motor ON,

Then (3) Stop to start delay active



2.5 Start up sequence - Chiller with reciprocating compressors

fig. 90: Start up sequence

1 Starting conditions fulfilled


3 Feedback: "Motor in delta connection"

4 "Motor feedback" timer active

5 Unloaded start-up

6 Release of the capacity control system

• If (1) Starting conditions fulfilled

Then (2) Output „Compressor motor ON“

Then (4) ‘Motor feedback’ timer active

Then (5) Output „Unloaded start-up“

• If (3) Motor feedback signal equals 1

Then (4) Reset ‘Motor feedback’ timer

• If (5) „Unloaded start-up“

Then (4) Release of the capacity control system



2.6 Switching off behaviour

Chiller's basic switching off procedure:

1. After the compressor has stopped the refrigerant pump and the condenser system continue to run.

Output A 1.6 "Release refrigerant pump / condenser" remains set until the "pump switch off delay" delay time has expired.

2. In the event of a fault the output A1.6 is immediately deactivated and there is no pump coasting.

The parameter for setting the coasting time is located in the main menu 30 "Timer Values" figure 5.

fig. 91: Time parameters, display 05

Flow switch delay: Length of delay of refrigerant flow controller in secs

Cond. feedback: Length of delay condenser feedback in secs

Pump stop delay: Length of delay of coolant pump shut-down in secs

2.6.1 Switching off sequence in the normal case - Chiller with reciprocating compressors

fig. 92: Switching off sequence in the normal case

1 Stop command


3 Energise capacity solenoids to min

4 Capacity at "Minimum 1" position

• If (1) Stop condition fulfilled

Then (3) Output "Capacity to min"

• If (4) Capacity at "Minimum 1" position

Then Reset the actuating signals (2) and (3)



2.6.2 Switching off sequence in case of an alarm - Chiller with reciprocating compressors

fig. 93: Switching off sequence in case of an alarm

1 Alarm generated


3 Capacity control solenoids energised

• If (1) Alarm generated

Then (2) Reset output – compressor motor ON

Then (3) Capacity control solenoids de-energised



2.7 Compressor control

2.7.1 Capacity control

All reciprocating compressors of INGENIUM Series are equipped with a variable capacity control system in the geometric range (0 ... 100%).

An outlet temperature, an inlet temperature (option), an external temperature (option) or the suction pressure, can be selected as the controlled variable.

The capacity is adjusted using capacity control solenoids, thus connecting or dis-connecting cylinders.

The definitive number of operating cylinders for the compression process is thus altered.

The capacity adjustment is controlled via 1 to 5 solenoid valves, which are situated together in a block.

Number of control valves depends on the compressor type.

fig. 94: Arrangement of capacity control calves

C.. Compressor

V.. Solenoid valve block

SV0.. Solenoid valve for unloaded start-up (NO)

SV1.. Solenoid valve for capacity change NC




SV5.. Solenoid valve for "Fast Pull Down"



2.7.2 Function of the output controller

The output regulator is based on a three-point controller.

The reciprocating compressor's output is increased or lowered depending on the process value, setpoint, neutral zone, proportional zone and "step down correction" factor.

If the process value is above the "setpoint + ½ neutral zone" limit the output is increased.

If the process value is below the "setpoint - ½ neutral zone" limit the output is reduced.

fig. 95: Function of the output controller

PV Process or control variable or actual value

SP set point

Neutral zone neutral zone

PZ.. proportional zone

SDC.. "Step Down Correction" factor or P-zone correction

A.. PV variation with time

B.. variation of 3-point controller outputs with time

C.. Pulse generator variation with time (step time)

D.. Compressor drive motor variation with time



proportional zone The step time is calculated within this zone depending on the process value and setpoint. The zone is symmetrical about the setpoint. The value range is 2.0 to 50.0 K. The value must be larger than the neutral zone.

neutral zone

As soon as the process value is within this zone the compressor output is not changed. The output can only change if an output limiter is active. The zone is symmetrical about the setpoint. The value range is 0.1 to 10.0 K. The value must be smaller than the proportional zone.

P-zone correction or "step down correction"

The "step down correction" factor enables the lower limit (setpoint – ½ proportional zone) to be set higher, if this limit is below the "suction pressure too low" fault limit. The controller can be blocked if an output limiter which prevents the output from being lowered is active and the output is to be lowered on the basis of a process value. In this case the compressor switches off immediately as soon as the process value falls below the "setpoint – ½ proportional zone + SDC" limit. This limit must be higher than the suction pressure fault, otherwise a compressor shutdown on faults occurs. A positive value changes the "setpoint – ½ proportional zone +SDC" limit in the direction of the setpoint. A negative value changes this limit in a direction away from the setpoint. The value range is -10.0 to +10.0 K. The value may not be set so that the "setpoint – ½ proportional zone + SDC" limit is above the "setpoint – ½ neutral zone".

When the output is increased or lowered the output controller uses a step time to prevent the compressor output from being changed too quickly.

This step time is calculated and lies between a maximum and minimum limit.

This calculation takes place within the proportional zone only.

The more the process value differs from the setpoint the shorter the step time.

The closer the process value gets to the setpoint the longer the step time becomes.

The following figure helps with the controller adjustment.



fig. 96: Determining the step times

PV Process or control variable or actual value

SP set point

Neutral zone

neutral zone

PZ.. proportional zone

SDC.. "Step Down Correction" factor or "P-zone correction"

t1.. minimum step time to load compressor in secs

t2.. maximum step time to load compressor in secs

t3.. maximum step time to unload compressor in secs

t4.. minimum step time to unload compressor in secs

Example

The process value is 8.0°C, the corresponding step time can be determined as follows:

Search for the intersection between the process value and time line t1..t2 (or t3..t4) and read off the step time from the time axis.

Result: t = 75 seconds.

Hint!

The minimum pause between two output steps is always 15 seconds.



2.8 Safety control (Alarms, warnings and limitations)

The following types of alarms will activate the alarm output signal:

• Oil system alarms

• Minimum / Maximum limits reached

• Compressor and oil pump motor’s start equipment alarms

• Hardware or sensor failures

• Safety timers exceeded

The formation of a limit value signal is illustrated in the following figure.

fig. 97: Graphic example of the formation of the limit value signals

A.. Variation of process variable over time

V.. Forced adjustment

B.. Limitation active

T.. Limitation time is active; after this time has expired the output controller for the direction for which the limitation was active is released and the compressor output can be changed once more

IL W.. Switching on signal "Warning"

IL A.. Switching on signal "Fault"

AL.. parameterised limit value for start of the alarm

+ Offset.. parameterised positive offset from the limit value for start of the warning

- Offset.. parameterised negative offset from the limit value for start of the warning

W.. Limit value for start of the warning (= AL + Offset W)

b.. Limit value for start of the limitation (= AL + Offset b)

f.. Limit value for start of the forced adjustment (= AL + Offset f)

3.. Acknowledgement of the alarm message



Caution!

A limitation time is activated to prevent the compressor output from being changed in the direction of the limitation immediately after the limitation.

This limitation time ensures that, for a minimum time, the compressor output cannot be changed in the direction for which the limitation was active.

The limitation time is restarted after the time has expired and as long as the limitation is active.

2.8.1 Oil circuit monitoring - Chiller with reciprocating compressors

The task of the oil circuit monitoring is to monitor the function of the oil system.

The INGENIUM is switched off if faults occur.

The pressure difference between the oil pressure and suction pressure is monitored.

2.8.1.1 Switching sequence in normal case

fig. 98: Oil circuit monitoring in normal case

1 Switching on condition

2 Unloaded start-up

3 Compressor drive motor on

4 Differential oil pressure OK

5 "Oil monitoring start" delay time

6 "Oil monitoring operation" initial delay

7 Oil circuit fault

A.. Switching-on procedure

B.. Short lowering of the differential oil pressure (e.g. t < 6 s) in operating state



• If (1) switching on condition

Then (2) formation of the unloaded startup actuating signal

Then (3) formation of the compressor drive motor ON actuating signal

• If (3) Compressor drive motor on actuating signal value "1"

Then (5) oil circuit monitoring delay time starts

• If (4) Differential oil pressure OK signal value "0"

and

• If (5) delay time has expired

Then (6) oil circuit monitoring initial delay starts

If the differential oil pressure OK signal takes up the signal state "1" again within, e.g. 6 s there is no shutdown on faults.

2.8.1.2 Switching sequence in the event of a fault in operating state

fig. 99: Oil circuit monitoring in case of fault


2 Differential oil pressure OK

3 Oil circuit initial delay

4 Oil circuit fault

• If (1) compressor drive motor on

and

• If (2) differential oil pressure OK signal value "0"

Then (3) oil circuit initial delay starts

• If (3) oil circuit initial delay has expired

and

• If (2) differential oil pressure OK signal value "0"

Then (4) oil circuit fault



2.8.2 Compressor drive motor fault monitoring

2.8.2.1 Fault case: compressor drive motor startup is too long

fig. 100: Compressor drive motor fault monitoring


2 Feedback: "Compressor motor in delta"

3 Start monitoring time: "Start up compressor motor"

4 Alarm generated

A.. normal switching on procedure of the compressor drive motor

B.. There is no prompt feedback from the element starting up during the switching on procedure


Then (3) start initial delay: "Start up compressor motor"


and

If (2) feedback: "Compressor motor in delta"

and

If (3) start initial delay: "Start up compressor motor" expired

Then (4) alarm



2.8.2.2 Switching sequence in case of fault feedback: "compressor motor feedback" fails

fig. 101: Compressor drive motor fault monitoring feedback


2 Feedback: "Compressor motor in delta"

3 Alarm generated


and

• If (2) feedback: "compressor motor in delta" no longer ok

Then (3) alarm

2.8.2.3 Motor rated current limitation

The rated current limitation should prevent overloading of the compressor drive motor.

It does not become effective until the startup procedure has been completed.

If the calculated motor current reaches the initial limitation value for the next output level (e.g. 105% of the rated current Imotor = 1.05 Irated), a further increase in compressor output is blocked.

If the current motor current reaches this limit value the compressor output is directly reduced by one step.

The signal is dominant compared to the output adjustment and remains effective until the motor current is back below its initial limitation value and the limitation time has expired.

The formation of the adjusting signal is illustrated in the following figure.

fig. 102: Motor rated current limitation



Imot Compressor motor current

A.. variation in motor current over time: 1 = current value // 2 = calculated value for the next output level

V.. Forced adjustment in direction of minimum for motor current limitation

B.. Motor current limitation is active

T.. Limitation time is active; after this time has expired the output controller is released and the compressor output can be increased once more

b.. Limit value for start of limitation (calculated value 2) and limit value for forced adjustment (current value 1)

W.. Limit value for start of the warning

AL.. Limit value for start of the alarm

fig. 103: Determination of the forced adjustment factor for motor rated current limitation


Cap.. Output level of the capacitor in %

A.. theoretical change in the motor current if output increase 1 = current value // 2 = calculated value for the next output level

f.. Forced adjustment factor in %; at 0 % the calculated value for the next level equals the current value. At 100% the ratio is linear with the output change. The forced adjustment factor changes the gradient (increase) of line 3. Line 1 –2 is parallel to line 3.

b.. Limit value for start of the limitation and limit value for forced adjustment

fig. 104: Limit values, figure 15

Imot Alarm: display of motor current alarm limitation in A

Low limit: Start of motor current limitation, enter value in A as an offset to the alarm value

Forced adjustment factor: Calculated value for calculating from the start of forced adjustment in direction of minimum - value input 0 – 100 %



2.8.2.4 Motor current alarm

fig. 105: Motor current alarm


A.. Motor current variation with time 1 = current value // 2 = calculated value for the next output level

B.. Motor current limitation is active

V.. Forced adjustment in direction of minimum for motor current limitation

b.. Limit value for start of limitation (calculated value 2) and limit value for forced adjustment (current value 1)



IL W.. Warning message

IL A.. Alarm message



Motor curr: Display of the current motor current in A

Alarm (max): Alarm limit for maximum motor current in A

Warning: Enter the warning value in A as an offset to the alarm value



2.8.2.5 Suction pressure limitation

The suction pressure limitation should prevent a fault if the suction pressure is too low.

Further increase in the compressor output is blocked if the suction pressure reaches its initial limitation value.

The compressor output is immediately reduced by one step if the forced adjustment value is reached.

The signal is dominant compared to the output adjustment and remains effective until the suction pressure is back below its initial limitation value and the limitation time has expired.


fig. 107: Suction pressure limitation

Psuc Psuc

A.. Suction pressure variation with time

V.. Forced adjustment in direction of minimum for suction pressure limitation

B.. Suction pressure limitation is active


b.. Limit value for start of the limitation

f.. Limit value for forced adjustment




Psuc low alarm: Alarm limit display for suction pressure too low in bar (a)

Low limit: Start of minimum suction pressure limitation, enter value in bar as an offset to the alarm value

Forced adjustment: Start of forced adjustment in direction of minimum, enter value in bar as an offset to the alarm value



2.8.2.6 Suction pressure alarm

The suction pressure is monitored in two directions.

A fault occurs if the suction pressure is too high or too low.

Both faults do not become effective until the startup procedure has been completed.

In addition there is a fixed blocking time of 5 minutes for the maximum limit which becomes active after the compressor drive motor has started.

The formation of the adjusting signal if the suction pressure is too low is shown in the following figure.

fig. 109: minimum suction pressure alarm

Psuc Psuc


V.. Forced adjustment in direction of minimum for suction pressure limitation

B.. Suction pressure limitation is active















The formation of the adjusting signal if the suction pressure is too high is shown in the following figure.

fig. 111: maximum suction pressure alarm

Psuc Psuc









Alarm (max) n1: Enter the "maximum suction pressure" alarm limit in bar (a) for lower speed

Alarm (max) n2: Enter the "maximum suction pressure" alarm limit in bar (a) for higher speed



Psuc hi alarm: Display of the current "maximum suction pressure" alarm limit in bar (a) - speed dependent!




2.8.2.7 Limitation of the external temperature – refrigerant outlet temperature

This limitation is only active for refrigerant outlet temperature if the refrigerant outlet temperature sensor is installed.

Otherwise this limitation is always active for the external temperature if this temperature sensor is installed.

Further increase of the compressor output is blocked if the external temperature (or the refrigerant outlet temperature) reaches its initial limitation value.


The signal is dominant compared to the output adjustment and remains effective until the external temperature or refrigerant outlet temperature is back above its initial limitation value and the limitation time has expired.

This limitation is intended to prevent the chiller's compressor from freezing.


fig. 114: Limitation of the external temperature or refrigerant outlet temperature

Text External temperature

A.. variation in external temperature with time

V.. Forced adjustment in direction of minimum for temperature limitation

B.. Temperature limitation is active









ext temp. alarm: Alarm limit for minimum external temperature in °C

Low limit: Start of temperature limitation, enter value in K as an offset to the alarm value

Forced adjustment: Start of forced adjustment in direction of minimum, enter value in K as an offset to the alarm value



2.8.2.8 Alarm: external temperature – refrigerant outlet temperature

This limit value is used if a chiller is used to prevent the compressor from freezing.


fig. 116: External temperature alarm

Text External temperature

A.. variation in external temperature with time

V.. Forced adjustment in direction of minimum for temperature limitation

B.. Temperature limitation is active












External temp.: Display of the current temperature in °C

Alarm (min): Enter "minimum external temp" alarm limit in °C

Warning: Enter the warning value as an offset to the alarm value in K



2.8.2.9 Discharge pressure limitation

The discharge pressure limitation is intended to prevent a discharge pressure fault.

Further increase in the compressor output is blocked if the discharge pressure reaches its initial limitation value.


The signal is dominant compared to the output adjustment and remains effective until the discharge pressure is back below its initial limitation value and the limitation time has expired.


fig. 118: Discharge pressure limitation

Pdis Discharge pressure

A.. Variation of discharge pressure with time

V.. Forced adjustment in direction of minimum for discharge pressure limitation

B.. Discharge pressure limitation is active








fig. 119: Actual values, figure 07

Pdis Alarm: Alarm limit for maximum discharge pressure in bar (a)

Low limit: Start of discharge pressure limitation, enter value in bar as an offset to the alarm value

Forced adjustment: Start of forced adjustment in direction of minimum, enter value in bar as an offset to the alarm value



2.8.2.10 Discharge pressure alarm


fig. 120: Discharge pressure alarm

Pdis Discharge pressure

A.. Variation of discharge pressure with time

V.. Forced adjustment in direction of minimum for discharge pressure limitation

B.. Discharge pressure limitation is active












Discharge pressure: Actual discharge pressure in bar (a)

Alarm (max): Enter the alarm limit for maximum discharge pressure in bar (a)

Warning: Enter the warning value as an offset to the alarm value



2.8.2.11 Differential oil pressure alarm

The differential oil pressure is monitored.

A fault results if the difference is too small.

It does not become effective until the starting procedure has finished and two adjustable blocking times have ended.

The first blocking time "start oil monitoring" is active only immediately after the compressor drive motor starts.

The second blocking time "operational oil monitoring" becomes active as soon as the differential pressure becomes too low during operation and the first blocking time is inactive.

See chapter: "chiller with reciprocating compressor oil circuit monitoring".

Formation of the adjusting signal for the case when the differential oil pressure is too low is shown in the following figure.

fig. 122: Differential oil pressure alarm

Δ Poil Differential oil pressure

A.. Variation of differential oil pressure with time





T1 Oil circuit monitoring time at start "start oil monitoring"

T2.. Oil monitoring time during operation "operational oil monitoring"





Diff oil press: Display of the current differential oil pressure in bar

Alarm (min): Enter the alarm limit for "minimum differential oil pressure" in bar

Warning: Enter the warning value as an offset to the alarm value


Oil monitoringstart: Oil pressure alarm delay during start up in secs.

Oil monitoring run: Oil pressure alarm delay during running in secs.

Caution!

The sum of both times must not exceed the maximum allowed time of the differential oil pressure monitoring for the selected compressor type.



2.8.2.12 Suction gas overheating alarm

Suction gas overheating is monitored.

A fault results if the overheating is too small.

It does not become effective until the starting procedure has finished and an adjustable blocking time has ended.

The blocking time "Po overheat delay" becomes active as soon as the suction gas overheating becomes too low during operation.

Formation of the adjusting signal for the case when the suction gas overheating is too low is shown in the following figure.

fig. 125: Suction gas overheating alarm

Δ To Suction gas overheating

A.. Variation of suction gas overheating over time





T1 Suction gas overheating monitoring time during operation "Po overheat delay"





Suction gas overheat:

Display of current suction gas overheating in K

Alarm (min): Enter the alarm limit for "minimum suction gas overheating" in K

Warning: Enter the warning value in K as an offset to the alarm value


Po overheat delay: Monitoring time suction gas overheating in secs

Pz overheat delay: Monitoring time interim gas overheating in secs

Operating hours: Operating hours in h

Caution!

The following settings are recommended if the GSC controls refrigerant injection at the evaporator:

Limit values: Alarm (min) = 0.8 K / warning = 0.0 K

Time values: Po overheat delay = 40 secs



2.8.2.13 Discharge temperature limitation

The discharge pressure limitation is intended to prevent a discharge pressure fault.

Further reduction of the compressor's output is blocked if the discharge temperature reaches its initial limitation value.

The compressor output is immediately increased by one step if the forced adjustment value is reached.

The signal is dominant compared to the output adjustment and remains effective until the discharge temperature is back below its initial limitation value and the limitation time has expired.

Formation of the adjusting signal is illustrated in the following figure.

fig. 128: Discharge temperature limitation

Tdis Discharge temperature

A.. Variation of discharge temperature over time 1 = calculated value for the next output level (this line is above the current value if output is lowered) // 2 = current value

V.. Forced adjustment in direction of minimum for discharge temperature limitation

B.. Discharge temperature limitation is active

T.. Limitation time is active; after this time has expired the output controller is released and the compressor output can be reduced once more








Discharge temp Alarm:

Alarm limit display in °C

Limitation: Start of discharge temperature limitation, enter value in K as an offset to the alarm value

Forced adjustment: Start of forced adjustment in direction of maximum, enter value in K as an offset to the alarm value



2.8.2.14 Discharge temperature alarm


fig. 130: Discharge temperature alarm

Tdis Discharge temperature

A.. Variation of discharge temperature over time 1 = calculated value for the next output level (for output increase below the current value) // 2 = current value

V.. Forced adjustment in direction of minimum for discharge temperature limitation

B.. Discharge temperature limitation is active

T.. Limitation time is active; after this time has expired the output controller is released and the compressor output can be reduced once more











Discharge temp: Display of the current discharge temperature in °C

Alarm (max): Enter the alarm limit for "maximum discharge temperature" in °C




2.8.2.15 Start limitation based on too low oil temperature (optional)

The start limitation should prevent the compressor from starting if refrigerant is still dissolved in the oil.

Start of the compressor is blocked if the calculated oil temperature limit value reaches its initial limitation value.

This ensures that the compressor cannot start if refrigerant is still dissolved in the oil.

A compressor start with refrigerant dissolved in the oil can damage the compressor and should always be avoided.

The signal is dominant compared to the output controller and remains effective until the calculated oil temperature limit value is once more above its initial limitation value.


fig. 132: Start limitation based on too low oil temperature

Toil Oil temperature

A.. Variation with time.. 1 = current oil temperature // 2 = calculated oil temperature limit value

b.. Start limitation value

Poil [°C].. Variation with time of the oil's saturation temperature in the crankshaft housing. This value forms the limit value for start of the limitation and warning.

B.. Start limitation and warning are active



Low limit: Enter the start limitation value - enter value in K as an offset to the current oil temperature

Oil press °C: Display the oil pressure in the crankshaft housing in °C (refrigerant dependent)



2.8.2.16 Oil temperature alarm (optional)

The oil temperature is monitored in two directions.

If the temperature becomes too low a fault results as if the oil temperature is too low its viscosity is too high and good lubrication cannot be ensured.

A fault also occurs if the oil temperature is too high.

Formation of the adjusting signal for the case when the oil temperature is too low is shown in the following figure.

fig. 134: Minimum oil temperature alarm


A.. Variation of oil temperature with time








Alarm (min): Enter the alarm limit for "minimum oil temperature" in °C


Formation of the adjusting signal for the case when the oil temperature is too high is shown in the following figure.



fig. 136: Maximum oil temperature alarm


A.. Variation of oil temperature with time








Alarm (min): Enter the alarm limit for "maximum oil temperature" in °C




2.8.3 Draining the oil

Ingenium series chillers have an oil return from the condenser.

2 solenoid valves enable the oil to be drained from the condenser.

2.8.3.1 Functional description

The oil draining consists of the following phases:

1. After the compressor has started and the "draining pause phase" has ended a "charging phase" takes place, the solenoid valve 2305 opens for the "oil draining-charging" duration.

2. After the "charging" a "charging pause phase" takes place, the solenoid valve 2305 closes and a pause "Pause after charging" takes place.

3. After the "charging pause phase" the "draining phase" takes place, solenoid valve 2310 opens for the "draining" duration.

4. After the "draining" a "draining pause phase" takes place, the solenoid valve 2310 closes and a pause "Pause after draining" takes place.

The oil draining is inactive while the compressor is at a standstill.

As soon as the compressor is started up the oil draining starts in the phase it was in before the compressor motor was switched off.

2.8.3.2 Parameter

The parameters are located in the main menu 30 "time values" from figure 6 and 7.


Oil drain-charge: Oil draining – charging time in secs

Pause after filling: Oil draining – pause after charging in secs


Drain: Oil draining - draining time in secs

Pause after draining:

Oil draining - pause after draining in sec.



2.8.4 Chiller Sequence Control (optional)

The GSC can organise a sequence control between several GSC control systems.

To do so, an additional PLC is installed, the so called MPI Master. This PLC handles the MPI communication between the GSC systems.

To ensure a correct functioning of the chiller sequence control the hydraulic system must meet with certain demands.

Only if these demands are fulfilled the sequence control will function properly.

In case the hydraulic system does not fulfil these demands the customer can organise a sequence control by himself using the standard MPI communication signals or potential free contacts.

The additional MPI Master from Grasso is not needed.

2.8.4.1 Demands for the hydraulic System

To ensure a correct functioning of the chiller sequence control the hydraulic system has to meet with the following demands:

— Each chiller is equipped with a secondary coolant pump with a constant flow.

— Each chiller controls on its outlet temperature.

— All chiller’s hydraulic are installed in parallel. The pressure losses are equal.

Between chillers and customer devices a buffer tank is installed (see figure).

— The system volume must be at least 20 l/kW total cooling capacity.

In case water is cooled with an outlet temperature of +1.0°C the system volume must be at least 30 l/kW total cooling capacity.

— The fluid quantity of each circuit related to the cooling capacity of each chiller must be equal, i.e. for equal type of chiller equal pump loads have to be installed.

— The total liquid flow through the secondary circuit , customer circuit) has to be less or equal to the total

liquid flow through the primary circuit , chiller circuit).

— If the chiller is stopped the flow through the chiller must be blocked, i.e. the pump must be stopped and the flow over the evaporator must be interrupted

except for the leading chiller, which pump must be running to ensure a correct measurement of the coolant temperature that is used as signal for the capacity control of the chiller unit.

fig. 140: Overview of the hydraulic system for the chiller sequence control



2.8.4.2 Description of the MPI communication and MPI Master

The sequence control uses the standard integrated MPI port of the GSC for communication.

Each GSC has got 2 MPI addresses: the 1st for the display and the 2nd for the PLC.

Each address within an MPI network must be unique.

Grasso has defined the following MPI addresses for the GSC:

GSC 1: MPI adresses 1 and 11

GSC 2: MPI adresses 2 and 12

GSC 3: MPI adressea 3 and 13, etc. through 8 and 18

All GSC systems that are part of the same sequence control circuit must be connected with the same MPI network.

The additional PLC, the MPI Master, that handles the MPI communication can be placed within an electrical cabinet of one of the chillers. This PLC is also connected to the same MPI network.

It has got the fixed MPI address 10.

The position of the MPI Master does not affect the Master/Slave setting of the chillers.

As an option a memory card (MMC) can be installed to store the MPI Master program. This option is needed in case the MPI Master is not supplied with power for several months. Under normal circumstances the program is preserved and the memory card is not needed.

fig. 141: Frontview MPI Master

fig. 142: MPI network for 3 GSC systems with a MPI Master including the settings for the terminating resistor integrated in the MPI

connector



2.8.4.3 Functional description

Master/ Slave

First the terms “Master“ and “Slave“ have to be defined.

The GSC where all sequence control parameters are set as well as the operation mode is selected and if necessary all external signals are linked to is called the “Master”.

The selection “Master” does not influence the start and stop sequence of the chillers and is also not linked to the position of the MPI Master.

All other GSC that are part of the sequence control circuit are defined as “Slave” automatically.

In case a slave is set as “Master” the old master will be set as slave automatically.

In this way it is ensured that only 1 master is active at the same time.

The setting “Master/Slave” can be changed via the display.

Control

The capacity of each chiller is controlled by the local GSC.

The local capacity control is described in the GSC manual.

As default the local coolant outlet temperature is used as control signal for the chiller.

The set point set at the master is sent to all slaves automatically.

It is possible to control on the local inlet temperature as well. However, for a correct function of the sequence control all chillers have to use the same control signal.

If the master receives a remote set point via an analogue input and the corresponding operation mode is activated on the master this signal is also sent to all slaves.

The process value however is the local coolant temperature. There is one situation where the process value of the master can differ from its local process value. If all chillers are switched off and the leading chiller is a slave only the pump of this chiller will run. Now the sequence control logic cannot use the local process value of the master to determine if capacity is needed. So the local process value of the slave with the running pump will be sent to the master to ensure that the sequence logic receives a valid signal.

The following operation modes are possible in combination with the sequence control:

— 03 Auto + Auto

— 04 remote + HW (cont)

— 06 remote + HW local SP

— 06 remote + HW ext. SP SP

— 08 remote + network (cont)

— 10 remote + network local SP

— 11 remote + network SP

All other operation modes are blocked.

The MPI Master derives the start/stop sequence based on the sequence control settings from the master and the status of all chillers that are part of the sequence control circuit.

The neutral zone used by the local capacity control must be less than the neutral zone for the sequence control set at the master (see “parameters” for more information).

The MPI Master monitors the total capacity of all chillers and takes action if due to local limitations the chiller capacity does not respond on the capacity demand based on set point and process value.

For instance if the local capacity of a chiller is reduced by an active limitation and capacity is needed the MPI Master will start the next available chiller after a fixed delay.



Due to the fact that the chillers are running in parallel more than one chiller will run in part load if less capacity is needed.

To ensure that only those chillers are running that are necessary to cover the load demand the sequence control logic derives which chillers can be switched off.

The time before these chillers are switched off can be adjusted in the sequence control parameter menu.

The sequence control logic can handle a system with different type of chillers.

In all situations it should be considered that the different chiller types match with their capacity.

If the maximum capacity of the smallest chiller is less than the minimum capacity of the largest chiller the function of the logic is not guaranteed.

Control of the coolant pump and condenser unit

If all chillers are not active, i.e. the compressors are switched off, then at least one coolant pump must be active to ensure the correct measurement by the master of the coolant temperature. The MPI Master handles this.

Each chiller unit has got a digital output relay (A 1.6) that is activated in case the coolant pump and condenser unit have to be activated by the customer.

The customer has to process this signal correctly to ensure the function of the sequence control.

As soon as this digital output is activated the chiller unit expects two feedback signals from the customer:

1. Coolant pump running / flow OK (E1.6)

2. Condenser unit active (E1.5)

After that these two feedback signals are set the chiller will continue the start-up procedure.

If one of the feedback signals is not set within an adjustable delay a warning with a corresponding text is activated.

After that the compressor is stopped a stop delay for both coolant pump and condenser unit is activated.

First after this delay the pump and condenser unit are stopped.

If no delay is needed a time value of 1 second can be entered.

Explanation of the start up and capacity increase logic

The next figure shows the start procedure of the sequence control with 3 chillers.

As soon as the MPI Master releases the 1st chiller the corresponding coolant pump and condenser unit are enabled by digital output A.

First after time Tx (customer) the feedback signals (E) are activated the compressor can start.

Based on the local set point and local process value the “Auto start delay” time (T1) is activated.

If this time has elapsed the compressor starts up and the capacity is increased (T2, local step time for increasing the capacity).

The capacity control of the compressor is based on the local control settings.

If chiller 1 has reached its maximum and more capacity is needed and the process value exceeds above the set point + ½ neutral zone (sequence) the “Start delay” time (T4) is activated. (T4).

If this time has elapsed the 2nd chiller is enabled and the start procedure like that of chiller 1 is repeated.

In case the capacity demand becomes negative, like in this example, chiller 2 would increase its capacity up to the minimum value set in the sequence parameter menu.

In this way it is ensured that running chiller will never run below the set minimum.

Only for the last running chiller this rule is not active.

The start of chiller 3 is released after that both chillers 1 and 2 have reached their maximum and the “Start delay” time (T4) has elapsed and still more capacity is needed.



fig. 143: Example of capacity increase with 3 chillers in sequence

Explanation of the stop and capacity decrease logic

The next figure shows the stop procedure for a sequence control with 3 chillers.

If less capacity is needed all chillers will decrease their capacity in parallel based on the local capacity control settings (T3, step time for capacity decrease).

The capacity control of the compressor is based on the local control settings.

If the total capacity of all running chillers, which are part of the sequence control circuit, becomes so low that 1 or more chillers can be stopped the “C.O.P. delay” (T5) is activated.

f this time has elapsed the MPI Master will disable chiller 3.

After that chiller 3 has stopped chillers 1 and 2 keep running.

After a short period where the capacity is increased again the capacity is decreased further.

This time the capacity is decreased so fast that chiller 2 reaches its minimum without the C.O.P. logic to become active.

Now the “Stop delay” time (T6) is activated. After this time the chiller is stopped by the MPI Master. In the end chiller 1 is stopped based on its local capacity control (T3, step time for capacity decrease).



The MPI Master does not disable chiller 1.

However, due to the active block time for chiller 1 (“Stop to start”) this chiller is not available for the sequence control to start directly. As a result this chiller is disabled and the coolant pump is stopped.

To ensure a correct measurement of the process value the next available chiller, in this case chiller 3, is enabled.

The coolant pump and condenser unit are enabled (output A) and the system waits for the customer feedback signals (E).

After these feedback signals are received the compressor can start and the capacity can be controlled based on the local capacity control settings.

fig. 144: Example of capacity decrease with 3 chiller units in sequence



2.8.4.4 Parameter

All parameters of the sequence control are found in menu 35 „Options“, „Sequence control“, „Parameters“.

Below all parameters are explained in detail.

Operation mode

Indication of the selected operation mode (OFF, MASTER or SLAVE).

This parameter can be changed in menu 15 “Operation mode” . For both master as slave this parameter must be set correctly.

Sequence number

Selection of the fixed sequence number (range 1 through 9). If the sequence order is not determined by the running hours this value determines the actual order for starting and stopping the chillers. Number 1 has got the highest priority, i.e. will start first and stop last. Number 9 has got the lowest priority. Parameter “Fixed sequence” (see below) is used to select which method should be used for the start/stop order. The sequence number has to be set at both master and slave. In case the sequence number is not unique the MPI address will determine which chiller has got the highest priority. MPI address 1/11 has got highest priority. MPI address 8/18 has got lowest priority.

Minimum %

Enter the minimum capacity value for this chiller in %. If the actual capacity is below this value the chiller may stop if it is the last running chiller else the local capacity control will increase the capacity automatically for as long no capacity limitation is active. In this way the chiller will not run with a capacity lower then this minimum value. The minimum capacity has to be set at both master and slave.

Part load % This parameter has no influence on the chiller sequence control.

Maximum %

Enter the maximum capacity value for this chiller in %. This parameter has to be set at both master and slave. As soon as the chiller capacity exceeds this value and the average process value of all running chillers lies above the neutral zone set at the master the start delay for the next chiller will become active. This neutral zone value differs from the neutral zone value set for the local control (menu 10

"Control" ).

Fixed sequence

Selection of the sequence order to use. If “yes” then the sequence order is based on the sequence numbers else (“no”) the order is based on the running hours. Due to interference by the C.O.P. logic the actual switch off order can differ from the expected order. Set for the master only.

C.O.P.

This parameter is used to activate the C.O.P. (Coefficiency Of Performance) logic (“yes”). If not active “no” has to be selected. As default this logic should be activated. Only in case of problems with the stopping order this logic can be switched off. Due to the fact that the chillers are running in parallel more than one chiller will run in part load if less capacity is needed. The C.O.P. logic prevents that several chiller units are running in part load for longer time. The advantage is that with active C.O.P. logic the chillers that are not needed to cover the capacity demand will be stopped more quickly in compared to the default capacity decrease logic. Set for the master only.



neutral zone

Enter the neutral zone for the sequence control master in K. This value should always be more than the value entered for the local capacity control. (menu

10 "Control" ). Otherwise the correct function of the sequence control cannot be guaranteed. Reason is that only if this setting is correct it is ensured that the next chiller is not started before all other running chillers have reached their maximum capacity value. Set for the master only.

Start delay

Enter the start delay for the next chiller to start in s. Before the start of the next chiller this delay is activated. In case the start condition for the next chiller is not fulfilled this delay is stopped and restarts as soon as the condition is fulfilled again. First after that this delay has elapsed the next chiller can start. Set at the master only.

Stop delay

Enter the stop delay for the next chiller to stop in s. In case the stop condition is not fulfilled this delay is stopped and restarts as soon as the stop condition is fulfilled again. First after this delay has elapsed the chiller is stopped. Set at the master only.

C.O.P. delay

Enter the delay for the C.O.P. logic in s. After that the logic has detected a situation where a chiller can be switched off this delay will become active. As soon as this condition is not fulfilled anymore the delay is stopped and restarts as soon as the condition is fulfilled again. First after that this delay has elapsed a chiller will be stopped by the logic. Set at the master only.



2.8.4.5 Actual values (Sequence info)

All actual values of the sequence control are found in menu 35 "Options", "Sequence control", "Actual values".

Below an explanation of these values is given.

Running systems Indication of all chiller that are part of the sequence control circuit with running compressors. (active systems of sequence control only)

Start/stop sequence

List of sequence numbers sorted in the actual start/stop order: chiller to start 1st and stop last is listed at the left hand side, chiller to start last and stop 1st is listed at the right hand side. The sequence numbers of all chillers that are not available for the sequence control are replaced by zeros and listed to the most right hand side. Example with 5 chillers (sequence numbers 1 through 5) with fixed sequence order:

Both chillers with sequence number 2 and 3 are running. The chillers with sequence numbers 1 and 5 are standing still and are available for the sequence control. Chiller 1 is the next chiller to start. The position in the list is cause by a system stop due to an active alarm on this unit. The alarm is reset and the unit is available again. However it is not started after that the alarm is reset. The sequence order is restored after that the chiller is started. In case less capacity is needed chiller 3 will be stopped first. Chiller 4 is listed because it is not available for the sequence control (there are a few reasons thinkable for this, for example an active alarm or start to start time).

Start delay Remaining time of start delay in s.

Stop delay Remaining time of stop delay in s.

C.O.P. delay Remaining time of the C.O.P. logic delay in s

Connected

Indication of the active systems on the MPI network. Only MPI devices that are equipped with a GSC are listed. Example:

The MPI devices (chillers) with MPI addresses 11, 12, 13 and 16 are available on the MPI network.

Caution!

In case other MPI devices are used with addresses in the range of 11 through 18 communication can become instable or fail completely. The MPI Master is programmed in such a way that it will look for table number 19 (DB19) within the MPI device.

If this table is found it will build-up communication with this MPI device else it will not send any data to the device.

So make sure that other MPI device do not have table 19 or have MPI addresses in another range.

Quality

Signal quality of the MPI communication in % (0…100%). > 70% : very good 20...70% : good < 20% : poor, MPI-communikation without failures cannot be guaranteed.



3 INITIAL START-UP

This chapter describes the most important steps during initial start-up.

This information can be useful for system changes in the future.

3.1 Brief description for initial start-up



3.2 Compressor, refrigerant, and sensor selection

Press once.

Select the main menu 50 "Configuration".

Caution!

Confirm each selection with .

Press once (move to next display).

The following selection appears on the display:

Line: "Refrigerant" select the refrigerant with the and keys.

Line: "Comp type" select the compressor type with the and keys.



Line: "LP cylinders" enter number of LP cylinders.

Line: "Capacity min" Enter the capacity min. value (standard = 0%).



Line: "Capacity +" select with and keys, if a solenoid for an additional capacity step is mounted.





Line: "Ref Injection" select with and key, if the refrigerant injection should be controlled by GSC.

Line: "AKVA Type" select with and the mounted AKVA type valve for refrigerant injection.



Line: "Nom Speed" Enter the nominal speed.

Line: "Aux. output" Select with and key the function of the auxiliary output

Possible function of the auxiliary output:

Function Description

the digital output „Aux. output“ is active if...

Warning ... a warning is active

More cap ... more output (refrigeration capacity) is required

Standby ... the 1st compressor is operational

Starting ... the 1st compressor is starting

Limitation ... A capacity limitation is active

min. cap. ... The 1st compressor has reached the adjustable limit value for minimum capacity

max. cap. ... The 1st compressor has reached the adjustable limit value for maximum capacity

neutral ... The process value lies within the neutral zone





Line: "Motor curr" Use the and keys to select whether an motor current sensor is installed.



Line: "Oil temp" Use the and keys to select whether an oil temperature sensor is installed.

Line: "Outlet temp" Use the and keys to select whether an outlet temperature sensor is installed.

Line: "Cond. temp" Use the and keys to select whether an condensing temperature sensor is installed.



Line: "Remote SP" Use the and keys to select whether an external setpoint sensor is installed as analogue input signal.

Line: "ext temp" Use the and keys to select whether an external temperature sensor is installed.



Line: "Sensor:" Use the and keys to select the sensor to be scaled.

Line: “4mA equals“ Enter the selected sensor’s minimum value (when its output is 4 mA).

Line: "20mA equals" Enter the selected sensor’s maximum value (when its output is 20 mA).



Caution!

Please note for temperature sensors: instead of “4mA equals“ is displayed "Offset (K)" and instead of "20mA equals" is displayed "Range %".



Accept the configuration with the "accept" key.

Caution!

Press the key to exit the configuration menu without "Accept" and "Save".

Limit values, timer values and control settings will be overwrited with standard values by confirming the "Accept" key for each change in the configuration menu with changes of compressor type and/or refrigerant.

It is therefore recommended to check the limit values, timer values and control settings after confirming the "Accept" key and change them before saving the configuration by confirming the "Save" key.

"Save" finally to store all settings in the EPROM memory card (see chapter "Brief description for initial start-up").

3.3 Adjusting the control settings

Press . Select the main menu 10 "Control Settings".


Page on using the key.

Adjust the control parameters to suit the refrigeration plant.



3.4 Call up operating mode setting

Press . Select the main menu 15 "Operation modes".



Adjust all operation parameters to the suit the refrigeration plant.

3.5 Adjusting the limit values

Press . Select the main menu 20 "Limit values".



Adjust the limit values to the suit the refrigeration plant.

3.6 Adjusting timer values

Press . Select the main menu 30 "Timer values".



Adjust the timer values to the suit the refrigeration plant.



3.7 Parameterise options

Press . Select the main menu 35 "Options".


Use the key to select the sequence control parameter list.

Use the key to select the actual values of the master and slave.

Press once.


Use the key to select the "Injection"-parameter list.

Use the key to select the actual values of the injection.

3.8 Saving the changes

Press and select menu 50 "Configuration".

Press until the following selection appears in the display:

Press "save" to store the configuration permanently in the EPROM memory card.

Caution!

During "Save" the CPU changes automatically to STOP and after 1 to 2 minutes back to RUN.

This procedure can be performed when the PLC is in RUN only (see chapter "Meaning of the key-operated switches"), otherwise the following system message is displayed: "$369 S7 command error 20".

During this time it is impossible to operate the GSC.

Don't press any key or don't switch off before the CPU is in RUN again, otherwise all information saved on the EPROM will get lost!



3.9 Check the chiller's wiring

• Remove each chiller sensor connector from its sensor and wait for an alarm message to appear.

If a 'Broken wire' alarm message does not appear for the disconnected sensor, then this sensor has not been configured in menu 50 'Configuration'.

• If the alarm message appears even though no connector has been removed, check the wiring to the sensor.

If the sensor is not mounted, then make sure it has not been configured!



4 SYSTEM DESCRIPTION C7-633

The system LEDs are located on the front of the GSC.

These system LEDs provide information about the status of the controller.

4.1 Explanation of the system LED

The position of the system LED is given in Chapter "Operator terminal".

Meaning of the status and error displays

Display Meaning Explanation

SF (red) C7-CPU-centralised fault Lights up for: — Hardware errors,

— Firmware errors,

— Programming errors,

— Parameterising errors,

— Computational errors,

— Time errors,

— Faulty internal memory storage,

— Battery failure or the standby supply is missing while MAINS ON,

— Peripheral error in the internal peripheral functions.

Further information about the malfunction that has occured can be read out of the diagnosis memory using the PG.

BATF (red) Battery error Lights up, if battery — does not have enough voltage,

— is defective,

— is missing.

DC5V (green) Voltage supply for C7 lights up, if the internal DC 5V supply is OK.

FRCE (yellow) Force application lights up, if a Force-order is active.

RUN (green) Operating state RUN of the C7-CPU

lights up, if the C7 CPU application program is running. flashes (2Hz) during the C7 CPU start up (the STOP lamps also lights up; after the STOP lights go off, the outputs are released).

STOP (yellow) Operating state STOP of the C7 CPU

lights up, if the C7 is not processing a CPU-application program. flashes at 1-second intervals, if C7 CPU general reset (MRES) is required.

SF-IM (red) Switching module - centralised fault

lights up, if the connection between C7 and the extension rack is interrupted.

(red) Alarm active lights up, if a malfunction has been confirmed, but is still active. flashes, if a further malfunction has been activated.

Help (green) Help text available lights up, if a help text is available.

Shift (green) Switch over function active lights up, if the SWITCHOVER function is active.



Display elements for Profibus

SF-DP

(red)

BUSF

(green) Meaning Remedy

Bus error (physical defect) Check the bus cable for a short circuit or breakage.

On On DP interface error for various baud rates in multimaster mode.

Analyse diagnosis, if necessary, replan the project or correct error.

Station failure Check the bus cable for correct connection, short circuit or breakage.

On Flashes At least one of the allocated slaves cannot be contacted.

Wait until the C7 has completed the start up. If the flashing doesn’t stop, check the DP slaves and analyse diagnosis.

On Off Missing or faulty DP project planning (event is CPU has not been parameterised as the DP master)

Analyse diagnosis, if necessary, replan the project or correct error.

Off Off No error

4.2 C7-CPU Selection of the operating mode

Change the C7-CPU operating mode

The CPU operating modes RUN-P, RUN, STOP and MRES are selected as follows:

The status of the CPU is changed each time the key is pressed.

The key must be pressed for at least 300 ms, so that the change takes place and the relevant LED lights up.

To prevent uncontrolled C7 CPU operating mode changes during the control mode, the key function can be activated or deactivated via an external authorisation input.

During the activated authorisation input, the operating mode selection is active and an LED displays the current CPU operating mode set.

If the authorisation input is deactivated, all status LEDs are off.

The authorisation input is located on the same connector as the C7 power supply.

fig. 145: Bridge at the authorisation input (see chapter 5)



4.3 Meaning of the key-operated switches

SF-DP

(red) Meaning Remedy

RUN-P (R-P)

The C7 CPU processes the application program. The programs and data can: — be read out of the C7 CPU using the PG (C7 PG)

— be transferred to the C7 CPU or be amended there (PG C7)

RUN-P (R)

or

The C7 CPU processes the application program. The programs and data can: — be read out of the C7 CPU using the PG (C7 PG)

— not be transferred to the C7 CPU or be amended there (PG C7)

STOP (S)

The C7 CPU does not edit the application program. Programs can: — be read out of the C7 CPU using the PG (C7 PG)

— be transferred to the C7 CPU or be amended there (PG C7)

Hint!

The Operating state STOP is only valid for the C7 CPU.

It does not apply for C7 OP.

It is possible to continue to work with the C7 OP.



SF-DP

(red) Meaning Remedy

MRES (M)

General reset The general reset of the C7-CPU (delete memory, reload the application program from the flash memory, where a memory card has been inserted) requires a special operating sequence of the operating modes STOP and MRES: — Select the operating mode STOP by pressing the DOWN key.

The key must be pressed for at least 300 ms, so that the change takes place.

The LED keys "S" and the CPU status LED "STOP" light up.

— Select the operating mode MRES by keeping the DOWN key pressed.

The LED key "M" lights up.

Directly after the CPU status LED "STOP" lights up for the second time, release the key for a moment and then press it again.

After flashing for a short while, the status LED "STOP" lights up again constantly.

The CPU is thus in the STOP status.

Hint!

If the data that the C7 OP project planning requires has been deleted during the general reset, a relevant error message appears for the C7-OP.

Hint!

See chapter "Operator terminal".



4.4 Memory card (EPROM)

4.4.1 Description of the memory card used

The PLC Siemens C7-633/P uses the following standard memory card:

Memory card (type): 6ES7 951-0KG00-0AA0

Capacity: 128 kB

Technical data: 5V Flash 128 kByte / 8 bit

fig. 146: Memory card

4.4.2 Installation of the Siemens SIMATIC C7 memory card

The memory card is installed by carrying out the following steps:

(1) Turn off the power of the PLC

This can be done by unplugging connector X1 on the PLC.

(2) Placement of the Author. connection

Bridge connections A+ and AE on connector X1

(see figure "Bridge at the authorisation input")

(3) Insert the memory card

The C7-633/P PLC is equipped with a memory card slot (X6) on one of its sides (see the back of the PLC for detailed information).

This slot has an identifying marking on the upper side (small opening).

The memory card also has an identifying mark (black dot).

These marks should be positioned at the same side when inserting the memory card (see figure).



fig. 147: Positioning of the memory card

(4) Turn on the power of the PLC

This can be done by reconnecting connector X1 on the PLC.

The PLC will restart.

Furthermore, on the left of the “key”, a green LED will indicate the current state of the operation mode key of the PLC.

During the restart the PLC will notice the memory card and this will cause the PLC to stop.

The STOP-indicator of the PLC will blink (1Hz) yellow.

STOP-indicator: (RUN = Operation)

Furthermore, the PLC will show message $551 "SPS-Adresse 2 nicht vorhanden" or "AS address 2 not possible".

(5) Use the “key” in order to reset the memory

The next step is to reset the PLC memory, so that the new program will be uploaded from the memory card.

In order to reset the memory, the PLC operation mode key state must be changed from "R" to "M".

This can be done by pressing the lower "key"-button until the green LED of the "M" lights.

After releasing the “key”-button, the green LED of the "S" will light indicating that the current PLC operation mode key state is STOP.

Furthermore, for a few seconds the STOP-indicator will blink yellow (0.5Hz).

Subsequently this indicator will light yellow continuously.

Now the PLC operation mode key state “S” equals the actual PLC mode indicated by the STOP-indicator.



fig. 148: Sequence of operation mode key state indication

(6) Change the operation mode to "R-P" (RUN)

By using the upper "key"-button, the PLC operation mode can be changed into RUN.

This can be done by pressing the "key"-button twice.

Caution!

The PLC operation mode must be changed into RUN, to realise the function "Save" in configuration menu.

For a few seconds the RUN-indicator will blink green (0,5Hz).

Subsequently this indicator will light green continuously.

RUN-indicator: (RUN = Operation)

(7) Remove the Author. connection

In order to disable the PLC operation mode key, the bridge between A+ and AE of connector X1 should be removed.

If not removed, unauthorised personal could stop the PLC or even reset the memory of the PLC.



4.5 Adjusting the date/ time

The current date and time can be adjusted at the OP, e.g. to correct for summer/winter time.

Any change made affects all the messages and images, in which a date/ time variable appears.

The display format for the date and time is specified in the project planning and cannot be changed at the OP.

1. The Date/Time sub-menu is called up by pressing the + key.

Move the cursor from the date field to the time field and back again using the cursor keys.

To move the cursor to the right or left within the date or time input field using the cursor keys, activate the shift lock switching so that the LED lights up.

Change the weekday by entering it symbolically.

The date and time are altered by entering numbers.

2. Confirm the entry with .

3. Quit the standard image with .

4.6 Changing the language

The project planning can be loaded on the OP in up to three languages simultaneously.

You can switch between the individual languages online at any time.

After switching over, all the language dependent texts are displayed in the new language.

1. Press the + key to select the contrast/ language sub-menu.

To switch over languages, enter the password required for this action.

Confirm it with .

2. Select the language required using a symbolic input.

The selection list only contains the languages that have been loaded onto the OP.

The OP restarts and displays all language-dependent texts in the new language.



5 TECHNICAL DATA

This technical data refers to the whole GSC control cabinet.

Operating voltage PLC components 100 up to 240 V AC / Power components 380 up to 420 V AC

Mains frequency 47 to 63 Hz

Control voltage 24V DC

Type of protection IP 54

Voltage level for solenoids 240 V AC (optional 115 V AC)

Permissible ambient temperature (storage)

-20 to +70 °C

Permissible ambient temperature (operation)

0 up to 50 °C 1

Maximum air humidity 5 to 95 % at 25 °C (no moisture condensation)1

Power consumption 30 kW 45 kW 55 kW 75 kW

Dimensions Width Depth Height

1,000 mm 210 mm 760 mm

1,000 mm 300 mm 760 mm

1,000 mm 300 mm 760 mm

1,000 mm 300 mm 800 mm

Weight 80 kg 90 kg 90 kg 110 kg

5.1 Sensors - Types of sensors used

Sensor type Description

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

Temperature detectors Pt1000-2L without top assembly sensor transmitters are used to measure temperatures.

Motor current An acive current signal of 4...20 mA is required to measure the power consumption of the compressor drive motor.

External set point value An active or passive current signal of 4...20 mA is required to evaluate an external set point value.

External temperature value An active or passive current signal of 4...20 mA is required to evaluate an external temperature value.

Hint!

Scaling the range limits, see chapter "Initial start-up".

For description of the components used, see separate documentation.

1 Additional measures required when outside these operating limitsh



5.2 Terminal connection diagram

Hint!

The terminal connection plan is a project-related document. See separate documentation.

5.3 Extended data communication (interfaces)

The GSC is equipped with an MPI interface as a standard.

As this interface is an internal Siemens interface with multi-point capability, it can only be used between Siemens controls (S7).

The MPI interface can be operated with a maximum transmission speed of 187.5 kBit/s, whereby the distance between 2 adjacent users must not exceed maximum 50 m.

Caution!

The precise bus structure and the transmission and receiving data protocol are described in more detail in the "MPI and Profibus" manual.

5.3.1 Explanation of the MPI

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

As the MPI interface is fed to the GSC on a 9-pin sub-D jack, suitable cable connectors are required.

fig. 149: Overview of the interfaces, memory card placing and battery position

1 IM

2 MPI

3 Memory Card

4 Analog inputs

5 Battery

Hint!

To access the battery remove this cover!



fig. 150: Interfaces C7-633, power supply and Author. connection

1 Digital inputs and outputs

2 Power supply and authorisation input

3 Programming interface for OP

The individual users can also be fitted with a bus cable connector.

This connector is inserted directly in the bus interface (9-pin sub-D jack).

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.

A two core, double shielded bus cable is used as a connection cable between the individual bus stations.

fig. 151: Bus cable connectors

fig. 152: PG junction box



The MPI communication can be used by the customer for reading the following values out of the INGENIUM:

— All analogue values (pressures, temperatures, motor current etc.)

— Remaining waiting times

— Active warning and alarm messages

— Status messages

Furthermore, by sending control commands over the MPI communication remote control of the INGENIUM is possible.



6 ALARMS

6.1 General

Caution!

Shut down on alarms are carried out to prevent the refrigeration equipment operating outside of design limits and do not represent a defect in the controls!

The alarm signals are divided into 2 groups:

fig. 153: Control cabinet with LED and indicator lights

1 Alarm

2 Warning

6.1.1 Alarms

Caution!

Alarms cause the compressor to switch off and prevent it from automatically switching back on.

Alarms are indicated by the indicator light (red) "Alarm", LED (red) and text message in the display.



6.1.2 Warnings

Caution!

Warnings do not cause the compressor to switch off, but could block it from being switched on.

Warnings are signalled optically by the indicator light (yellow) "Warning", LED (red) and text message in the display.

Warnings are automatically reset after the cause has gone.

6.1.3 View active alarms and warnings

The "Status mode" is displayed by pressing the key several times. The most important actual values are shown in the first three rows and in the 4th row the status message is shown.

By scrolling with the cursor keys and all active alarms and warnings are displayed.

6.2 Possible text displays for alarms and warnings

6.2.1 General

The GSC produces all the alarms and warnings listed in the following section.

All the warnings and alarms are stored in a history file for possible later analysis by the operator.

View The alarm No., date and time and status of the alarm are displayed. The status display has the following meaning: A = Acknowledged C = Come G = Gone If the cursor is pointing to the alarm number, the alarm text can be displayed by pressing

the key.

Print no stored function

Number Displays how many alarms have been stored and how many are still active.

Delete All the fault signals stored in the buffer can be deleted.



Overflow Enables a message to be displayed even if the fault buffer is full.

Text Display all possible alarm messages with alarm No.

The alarm and warning numbers are unique and are displayed in the alarm histogram.

Hint!

See chapter "Alarm menu".

6.2.2 List of all alarms and warnings

Alarm histogram number

Full Alarm text

002 Alarm Wire failure condenser temperature

(004) Alarm Evaporator refrigerant level too high

005 Alarm Refrigerant leak detected

008 Alarm Secondary refrigerant flow missing

010 Alarm Wire failure external temperature

011 Alarm Wire failure external set point

012 Alarm Wire failure evaporator outlet temperature

013 Alarm Wire failure evaporator intlet temperature

014 Alarm Wire failure ICM valve feedback signal

025 Alarm External temperature too low

029 Alarm MPI sequence control network comm. failure

030 Alarm MPI network comm. failure




Full Alarm text

031 Alarm PLC power supply interrupted

032 Alarm Refrigerant data not found. Please select other refr.

035 Warning Motor valve feedback too late

036 Warning ICM valve feedback too late

037 Warning Low external temperature

038 Warning Secondary refrigerant flow missing

039 Warning Condenser unit feedback missing

041 Warning PLC power supply interrupted

042 Warning Replace PLC battery

043 Warning PLC operation mode changed

044 Warning Selection not permitted. Please check input data.

045 Warning MPI network comm. failure

046 Warning MPI sequence control network comm. failure

049 Alarm Wire failure crankcase pressure

050 Alarm (01) Oil differential pressure too low

051 Alarm (01) Differential (Psuc and Pdis) pressure too high

052 Alarm (01) Differential ratio (Psuc and Pdis) too high

053 Alarm (01) Suction temperature too low

054 Alarm (01) Wire failure suction temperature

055 Alarm (01) Suction gas overheat too low

056 Alarm (01) Discharge temperature too high




Full Alarm text

057 Alarm (01) Suction pressure too low

058 Alarm (01) Suction pressure too high

059 Alarm (01) Wire failure suction pressure

060 Alarm (01) Discharge pressure too high

061 Alarm (01) Wire failure discharge pressure

064 Alarm (01) Wire failure oil pressure

065 Alarm (01) Motor current too high

066 Alarm (01) Wire failure motor current

070 Alarm (01) Emergency stop or HP-switch active

071 Alarm (01) Motor feedback too late

072 Alarm (01) Motor protection device active

073 Alarm (01) Wire failure discharge temperature

078 Alarm (01) Oil temperature too low

079 Alarm (01) Oil temperature too high

080 Alarm (01) Wire failure oil temperature

081 Alarm (01) Selected refrigerant not valid with selected compressor

082 Alarm (01) Compressor data not found. Please select other compr.

083 Alarm (01) Compressor configuration not valid

089 Alarm (01) Differential temp. (Tc – To) too high

(090) Alarm (01) Cylinder head temperature too high

091 Alarm (01) Motor feedback missing during operation




Full Alarm text

(092) Alarm (01) Liquid in compressor. Discharge temp too low

(093) Alarm (01) Compressor heating. Discharge temperature too high

097 Warning (01) Low suction gas overheat

098 Warning (01) High discharge temperature

101 Warning (01) Low oil temperature

102 Warning (01) High oil temperature

103 Warning (01) High motor current

105 Warning (01) Low suction pressure

106 Warning (01) High suction pressure

107 Warning (01) High discharge pressure

109 Warning (01) Low oil differential pressure

112 Warning (01) Low suction temperature

123 Warning (01) Differential temp. (Tc – To) too high

(124) Warning (01) Liquid in compressor. Discharge temp too low

(125) Warning (01) Compressor heating. Discharge temperature too high

Hint!

All not mentioned alarm numbers are provided as free space!



6.3 Fault messages from the application program

Hint!

Representation in this chapter:

Fault number

Figure = display of the control

— Possible cause of the fault

Remedy

002

— Terminal connection contact difficulties

Check the terminal connections at the GSC and at the sensor.

— Control cable between sensor and GSC is interrupted (cable break).

Replace control cable.

— The sensor is defective.

Replace the sensor.

— The electronic input at analogue module is defective.

Replace analogue module.

004

Hint!

This fault is activated if the input signal E 1.1 "refrigerant separator level" equals 0.

I.e., there is no electrical connection between the terminals of the input signal.

— The level in the refrigerant separator is too high.

Reduce the level in the refrigerant separator.


Check the terminal connections at the GSC and at the electric power panel.

— Level sensor is defective

Replace the level sensor

— Control cable between level sensor and GSC is interrupted (cable break).


— Electronic input at GSC is defective.

Replace input module



005

Hint!

This fault is activated if the input signal E 1.2 "gas sensor" equals 0.

I.e. there is no electrical connection between the terminals of the input signal.

— Gas warning system is active

Reset the gas warning system

— Terminal connection has contact difficulties

Check the terminal connections at the GSC and electric power panel.

— Check cable between gas warning system and GSC is interrupted (cable break)


— Electronic input at the GSC is defective.


008

Hint!

This fault is activated if the input signal E 1.6 "Refrigerant feedback" equals 0 and the delay period has expired.


— Refrigerant pump is not running.

Start up the refrigerant pump.

— The flow sensor is defective

Replace the flow sensor



— Control cable between flow sensor and GSC is broken (cable break).


— The delay time is too short.

Increase the "Flow switch delay" parameter in the “time values“ menu, “time values/chiller“ display.

— Electronic input at digital input/output module is defective

Replace the digital input/output module.



010

Hint!

The GSC has detected a cable break from "external temperature" sensor.






Replace the sensor.



011

Hint!

The GSC has detected a cable break from the "external setpoint" sensor.






Replace the sensor.





012

Hint!

The GSC has detected a cable break from the "outlet temperature" sensor






Replace the sensor.



013

Hint!

The GSC has detected a cable break from the "inlet temperature" sensor.






Replace the sensor.





014

025

Hint!

This fault is activated if the "external temperature" input signal is lower than the parameterised limit value.

— External temperature is too low.

Remove the cause for low external temperature in the refrigerating plant

— The parameterised limit value is set too high

Change the "Alarm (min) parameter in "external temperature" view of "Limit values" menu

— The sensor's measuring range does not match the parameterised value

In the "Configuration" menu, view: "Sensor: - external temperature" check and correct the "Start" and "End" parameters


Replace the sensor.

029

Hint!

This fault is activated at the slave machine if sequence control mode has been selected whereby data exchange takes place via the MPI bus and the slave machine is not connected to the master machine.

— MPI cable interrupted or plug-in connector is defective

Replace defective parts.

— The operating mode of the master machine (programmable controller) is "STOP"

Change the operating mode of the master machine to "RUN"

— The operating mode of the additional programmable controller (PCS) is "STOP"

Change the operating mode of the additional control PCS to "RUN"

— Incorrect setting of "Bus error" parameter

Check and correct the "bus error" parameter in the "operating modes" menu.



030

Hint!

This fault is activated at the slave machine if an operating mode has been selected whereby data exchange takes place via a bus (MPI) and the slave machine is not connected to the master machine.


Replace defective parts.

— The operating mode of the master machine (programmable controller) is "STOP"


— The "life-Bit" is not transferred by the master machine

Check and correct the master machine's program



031

Hint!

This fault is activated if the power supply to the PCS is interrupted



— Incorrect setting of "voltage on" parameter

Check and correct "Voltage on" parameter in "operating modes" menu

032

Hint!

This fault is activated if a refrigerant is selected during configuration which is not available at the EPROM



— Incorrect configuration

Check and correct the "Refrigerant" parameter in the "configuration" menu

— The refrigerant is not available at the EPROM

The EPROM must be replaced if the correct refrigerant has been selected and this message arrives, whereby the PCS does not display any other errors.

— Electronic input at analogue module is defective.


049

050

Hint!

This fault is activated if the calculated "differential oil pressure" value is lower than the parameterised limit value.

— Differential oil pressure is too low.

Remove the cause of the low oil pressure at the compressor.

— The parameterised limit value has been set too high

Change the "Alarm (min) parameter in the "diff oil press" view in the "limit values" menu

— Time parameter set too short.

Set higher "start oil monitoring" or "operational oil monitoring" parameter in the "time values"

051

Hint!

This fault is activated if the calculated "differential pressure" value is higher than the fixed limit value.

— Differential pressure is too high

Remove the cause of the high differential pressure in the refrigerating plant.




Check and correct the refrigerant and compressor type in the "configuration" menu

052

Hint!

This fault is activated if the calculated "pressure ratio" value is higher than the fixed limit value.

— Pressure ratio is too high

Remove the cause of the high pressure ratio in the refrigerating plant.



053

Hint!

This fault is activated if the "suction temperature" input signal is lower than the fixed limit value

— Suction temperature too low

Remove the cause of low suction temperature in the refrigerating plant

— The sensor's measuring range does not match the parameterised values

In the "Configuration" menu, view: "Sensor: - suction temperature" check and correct the "offset" and "range" parameters


Replace sensor.

054

Hint!

The GSC has detected a cable break from the "suction temperature" sensor








Replace sensor.



055

Hint!

This fault is activated if the calculated "suction gas overheating" value is lower than the parameterised limit value.

— Suction gas overheating too low

Remove the cause of low suction gas overheating in the refrigerating plant.


Change the "Alarm (min)" parameter in the "suction gas overheating" view in the "limit values" menu


Set the parameter "Po overheating delay" parameter in the "time values" menu to 40 secs



056

Hint!

This fault is activated if the "discharge temperature" input signal is higher than the parameterised limit value.

— Discharge temperature too high

Remove the cause of the high discharge temperature in the refrigerating plant.

— The parameterised limit value is set too low.

Change the "Alarm (max)" parameter in "discharge temperature" view in "limit values" menu




In the "Configuration" menu, view: "Sensor: - discharge temperature" check and correct the "offset" and "range" parameters


Replace sensor.

057

Hint!

This fault is activated if the "suction pressure" input signal is smaller than the parameterised limit value.

— Suction pressure too low

Remove the cause of low suction pressure in the refrigerating plant.


Change the "Alarm (min)" parameter in the "suction pressure" view in the " limit values" menu


In the "Configuration" menu, view: "Sensor: - suction pressure" check and correct the "start" and "end" parameters


Replace sensor.

058

Hint!

This fault is activated if the "suction pressure" input signal is higher than the parameterised limit value.

Caution!

The current motor speed is decisive in determining which limit is used!

— Suction pressure too high

Remove the cause of high evaporator pressure in the refrigerating plant.




In the "limit values" menu, "suction pressure" view, change the "Alarm (max)" parameter




Replace sensor.

059

Hint!

The GSC has detected a cable break from the "suction pressure" sensor.






Replace sensor.



060

Hint!

This fault is activated if the "discharge pressure" input signal is higher than the parameterised limit value.

— Discharge pressure is too high.

Remove the cause of the high condenser pressure in the refrigerating plant.


In the "limit values" menu, under "discharge pressure" view, change the "alarm (max)" parameter


In the "Configuration" menu, view: "Sensor: - discharge pressure" check and correct the "start" and "end" parameters




Replace sensor.

061

Hint!

The GSC has detected a cable break from the "discharge pressure" sensor






Replace sensor.



064

Hint!

The GSC has detected a cable break from the "oil pressure" sensor






Replace sensor.



065

Hint!

This fault is activated if the "motor current" input signal is higher than the parameterised limit value.

— Motor current is too high

Remove the cause of the high motor current in the refrigerating plant.


In the "limit values" menu, "motor current" view, change the "alarm (max)" parameter


In the "Configuration" menu, view: "Sensor: - motor current" check and correct the "start" and "end" parameters


Replace sensor.

066

Hint!

The GSC has detected a cable break from "motor current" sensor






Replace sensor.





070

Hint!

This fault is activated if the "safety chain ok" input signal E 0.2 equals 0.


— The emergency stop switch has been actuated.

Reset the emergency stop switch.

— The mechanical discharge pressure switch has opened.

Reset the discharge pressure switch at the outer/inner RESET switch.



— The control cable is broken.




071

Hint!

This fault is activated if the feedback from the motor is not received within the specified time.

I.e. the feedback from the delta contactor or the ramp up message, e.g. from the frequency converter (digital input E 0.0) is not available.


Increase the "motor feedback" parameter in the “time values“ menu



— Delta contactor is defective – contact open.

Replace the delta contactor.

— Power failure due to tripped fuse in electric power panel.

Replace the fuse





— Control cable between electric power panel and GSC is interrupted (cable break).


072

Hint!

This fault is activated if the "motor protection OK" input signal E 0.1 equals 0.


— Motor protection has tripped – contact open.

Acknowledge motor protection.







073

Hint!

The GSC has detected a cable break from the "discharge temperature" sensor






Replace the sensor.





078

Hint!

This fault is activated if the "oil temperature" input signal is lower than the parameterised limit value.

— Oil temperature too low

Remove the cause of the low oil temperature.


Change the "alarm (min)" parameter in the "limit values" menu, "oil temperature" view


In the "Configuration" menu, view: "Sensor: - oil temperature" check and correct the "offset" and "range" parameters


Replace the sensor.

079

Hint!

This fault is activated if the "oil temperature" input signal is higher than the parameterised limit value.

— Oil temperature too high

Remove the cause of the high oil temperature in the refrigerating plant.


Change the "alarm (max)" parameter in the "limit values" menu, "oil temperature" view




Replace the sensor.



080

Hint!

The GSC has detected a cable break from the "oil temperature" sensor






Replace the sensor.



081

Hint!

This fault is activated if a combination of refrigerant and compressor type is selected during configuration which is not permitted.


Check and correct the "Refrigerant" and "compressor type" parameters in the "configuration" menu

082

Hint!

This fault is activated if a compressor type is selected during configuration, which is not available at the EPROM




Check and correct the "Compressor type" parameter in the "configuration" menu

— The compressor type is not available on the EPROM

The EPROM must be replaced if the correct compressor type has been selected and this message appears, whereby the PCS does not display any other errors.

083

Hint!

This fault is activated if a compressor configuration is selected during configuration, which is not available on the EPROM


Check and correct the parameter "LP cylinders", "HP cylinders", "Fast Pull Down" and "Booster" parameters in the "configuration" menu

— The compressor configuration is not available on the EPROM

The EPROM must be replaced if the correct compressor configuration has been selected and this message appears and the PLC does not display any other errors.

089

Hint!

This fault is activated if the calculated "(Tk – To)" value is higher than the fixed limit value and a fixed delay time has expired.

— Temperature difference too high

Remove the cause of the high temperature difference at the compressor or in the refrigerating plant.

— The measuring ranges of the sensors (suction pressure and discharge pressure) do not match the parameterised values

In the "Configuration" menu, view: "Sensor: – Suction pressure" and "Sensor: - Discharge pressure" - check and correct the "4mA" and "20mA" parameters.

— Suction or discharge sensor defective

Replace sensor.



090

Hint!

This fault is activated if the "Cylinder head temperature protection OK" input signal E 1.3 becomes 0.


— Cylinder head temperature is too high

Remove the cause of the high cylinder head temperature at the compressor or in the refrigerating plant.

— Control cable interrupted between cylinder head temperature sensor and GSC (cable break).







Replace the sensor.

091

Hint!

This fault is activated if the motor feedback is (briefly) missing during operation.

I.e., the feedback from the delta contactor or the ramp up message from the frequency converter (digital input E 0.0) is no longer available after the startup phase.



— The delta contactor is defective, contact open.

Replace the delta contactor.

— Power failure due to tripped fuse in electric power panel.

Replace the fuse







092

Hint!

This fault is activated if the "discharge temperature" input signal is lower than a calculated value.

— Discharge temperature is too low

Remove the cause of the low discharge temperature in the refrigerating plant.

093

Hint!

This fault is activated if the "discharge temperature" input signal is higher than a calculated value.

— Discharge temperature is too high

Remove the cause of the high LP discharge temperature in the refrigerating plant.

6.4 Description and diagnosis of warning messages

Hint!

Representation in this chapter:

Warning number

Figure = display of the control

— Possible cause of the warning

Remedy

035



036

037

Hint!

This warning is activated if the "external temperature" input signal is lower than the parameterised limit value plus offset.

— External temperature is too low.

Remove the cause of the low external temperature in the refrigerating plant

— Parameterised limit value offset set too low.

Change "warning" parameter as an offset to the alarm value in the "limit values" menu, "external temp" view.


In the "Configuration" menu, view: "Sensor: - external temperature" check and correct the "start" and "end" parameters


Replace sensor.

038

Hint!

This warning is activated if the input signal E 1.6 "Refrigerant feedback" equals 0 and the fixed delay time has expired.


— Refrigerant pump is not running.

Start up the refrigerant pump.

— The flow sensor is defective.

Replace the flow sensor.


Check the terminal connections at the GSC and at the electric power panel.



— Control cable between flow sensor and GSC is interrupted (cable break).




039

Hint!

This warning is activated if the input signal E 1.5 ‘heat transfer medium feedback" equals 0 and the fixed delay time has expired.


— Condenser is not running.

Switch on the condenser.

— The contact (relay) is defective.

Replace the contact (relay).

— Control cable between relay contact and GSC is interrupted (cable break).


— The delay time is too short.

Increase the parameter "Condenser feedback" in the “time values“ menu, “time values/chiller“ image.



041

Hint!

This warning is activated if the PCS power supply is interrupted



— Incorrect setting of "voltage on" parameter

Check and correct "Voltage on" parameter in "operating modes" menu



042

Hint!

This warning is activated if the buffer battery is empty.

The "BATF" LED on the GSC also lights up.

— The buffer battery is flat.

Replace buffer battery.

043

Hint!

This warning is activated if the operating mode of the PCS is changed.

— This message appears during "Save" configuration after the backup procedure has finished.

no error

044

Hint!

This warning is activated if an invalid input has been entered.

— Input of a new value or a new selection is invalid.

Certain values can be changed automatically, to ensure valid input.

Check and correct all relevant parameters again.

045



Hint!

This warning is activated at the slave machine if an operating mode has been selected - whereby data exchange takes place via a bus (MPI) and the slave machine is not connected to the master machine.


replace all defective parts

— The operating mode of the master machine (PCS - programmable control system) is "STOP"


— The "life-Bit" is not transferred from the master machine

Check and correct the master machine's program



046

Hint!

This warning is activated at the slave machine if sequence control operating mode has been selected whereby data exchange takes place via the MPI bus and the slave machine is not connected to the master machine.


replace all defective parts

— The operating mode of the master machine (PCS - programmable control system) is "STOP"


— The operating mode of the additional PCS for sequence control is "STOP"

Change the operating mode of the additional PCS to "RUN"



097

Hint!

This warning is activated if the calculated "suction gas overheating" value is lower than the parameterised limit value plus offset.



— Suction gas overheating is too low

Remove the cause of low suction gas overheating in the refrigerating plant.

— The parameterised limit value offset is set too high.

Change "warning" parameter as offset to the alarm value in the "limit values" menu, "suction gas overheating" view.


Set the "Po overheating delay" parameter in the "time values" menu to 40 secs


Check and correct the compressor type, refrigerant and ECO System parameters in the "configuration" menu

098

Hint!

This warning is activated if the "discharge temperature" input signal is higher than the parameterised limit value minus offset.




Change "warning" parameter as offset to the alarm value in the "limit values" menu, "discharge temperature" view.


In the "Configuration" menu, view: "Sensor: - discharge temperature" check and correct the "offset" and "range" parameters


Replace sensor.

101

Hint!

This warning is activated if the "oil temperature" input signal is lower than the parameterised limit value plus offset.



— Oil temperature is too low

Remove the cause of the low oil temperature in the refrigeration plant.


Change "warning" parameter as an offset to the alarm value in the "limit value", "oil temperature" view.




Replace sensor.

102

Hint!

This warning is activated if the "oil temperature" input signal is higher than the parameterised limit value minus offset.

— Oil temperature too high

Remove the cause of the high oil temperature in the refrigerating plant.


Change "warning" parameter as an offset to the alarm value in the "limit values" menu, "oil temperature" view.




Replace sensor.

103

Hint!

This warning is activated if the "motor current" input signal is higher than the parameterised limit value minus offset.



— Motor current too high

Remove the cause of the high motor current in the refrigerating plant.

— Parameterised limit value offset set too low.

Change "warning" parameter as offset to the alarm value in the "limit values" menu, "motor current" view.


In the "Configuration" menu, view: "Sensor: - motor current" check and correct the "start" and "end" parameters


Replace sensor.

105

Hint!

This warning is activated if the "suction pressure" input signal is lower than the parameterised limit value plus offset.

— Suction pressure is too low.

Remove the cause of low evaporator pressure in the refrigerating plant.


Change "warning" parameter as an offset to the alarm value in the "limit values", "suction pressure" view.




Replace sensor.

106

Hint!

This warning is activated if the "suction pressure" input signal is higher than the parameterised limit value minus offset.



— Suction pressure too high

Remove the cause of high evaporator pressure in the refrigerating plant.


Change "warning" parameter as an offset to the alarm value in the "limit values", "suction pressure" view.




Replace sensor.

107

Hint!

This warning is activated if the "discharge pressure" input signal is higher than the parameterised limit value minus offset.

— Discharge pressure is too high.

Remove the cause of the high condenser pressure in the refrigerating plant.


Change "warning" as offset to the alarm value in the "limit values" menu, "discharge pressure" view.


In the "Configuration" menu, view: "Sensor: - discharge pressure" check and correct the "start" and "end" parameters


Replace sensor.

109

Hint!

This warning is activated if the calculated "differential oil pressure" value is lower than the parameterised limit value plus offset.

— Differential oil pressure is too low.

Remove the cause of low oil pressure in the refrigerating plant.




Change "warning" parameter as offset to alarm value in the "limit values" menu, "oil differential pressure" view.

112

Hint!

This warning is activated if the "suction temperature" input signal is lower than the fixed limit value

— Suction temperature is too low

Remove the cause of low suction temperature in the refrigerating plant


In the "Configuration" menu, view: "Sensor: - suction temperature" check and correct the "offset" and "range" parameters


Replace sensor.

123

Hint!

This warning is activated if the calculated "(Tk – To)" value is higher than the fixed limit value.

— Temperature difference is too high

Remove the cause of the high temperature difference in the refrigerating plant.

— The measuring ranges of the sensors (suction pressure and discharge pressure) do not match the parameterised values

In the "Configuration" menu, view: "Sensor: – Suction pressure" and "Sensor: - Discharge pressure" - check and correct the correct "4mA" and "20mA" parameters.

124



Hint!

This warning is activated if the "discharge temperature" input signal is lower than a calculated value.

— Discharge temperature is too low

Remove the cause of the low discharge temperature in the refrigerating plant.

125

Hint!

This warning is activated if the "discharge temperature" input signal is higher than a calculated value.



6.5 No alarm signal and the compressor will not start

Compressor will not start, although there is no active alarm.

Key “ON” has been pressed and the LED K1 ”ON” is flashing.

Cause Remedy

No"start release" signal The input "start release" is not closed.

Close input or install a link.

Start-stop delay in automatic mode active

The time setting "Auto start dly" in "control settings menu" has not yet expired.

Wait until the delay time has expired.

"Start to start" delay or "Stop to start" active

The time settings "Start to starty" and "Stop to start" in "Timer values menu" have not yet expired.

Wait until the delay time has expired.

A warning blocking the switch on is active Remove cause of the warning.

actual value < (set point + ½ NZ) NZ = neutral zone

Check set point and neutral zone settings in "Control settings" menu. Attention: In case of suction pressure control the set point value is entered in degrees Celsius.



7 ACKNOWLEDGING AND RESETTING ALARMS AND WARNINGS

7.1 Information about the status of the controls in case of an alarm/warning

The occurrence of an alarm/warning is signalled by

(1) At the control cabinet:

— Signal lamp (red) "Alarm"

— Signal lamp (yellow) "Warning"

(2) At the GSC display:

— An alarm message appears in the display

— The LED ”alarm signal” flashes

— The application program continues to run

The “DC5V“ LED and the “RUN“ LED light up.

fig. 154: Display in case of an alarm

LED irrelevant

LED off

LED on

LED flashing quickly



7.2 Restart following Alarms

Alarms and warnings are signalled as follows:

1. The compressor turns itself off or does not start up after the system is switched on.

2. The occured alarm is signalled by:

a.a The alarm relay is de-energised, potential free contact can be used by customer (only for alarm conditions – not for warning conditions).

a.b The red indicator light ‘Alarm’ flashes at the control cabinet for alarms, the yellow indicator light flashes for warnings.

a.c System LED check (left-hand side of display).

There is no system fault if only the green LEDs "DC5V" and "RUN" are lit up.

The applications program continues to run.

a.d Display check: A flashing text message is visible in the display, which describes the alarm or warning that has occurred.

In addition, the red LED on the right-hand of the display also flashes.

All possible text messages are listed in section (see chapter "Alarms").

This list includes troubleshooting and fault correction information.

a.e The alarm is acknowledged by pressing the alarm acknowledgement key .

The flashing text message disappears.

If the cause of the alarm still exists after acknowledgement, the red alarm LED changes from a flashing light to a steady light; otherwise it goes out.

The "warning" and "alarm" indicator lights also change over to a steady light or switch off after acknowledgement.

a.f If a flashing alarm text is not displayed and the alarm LED lights up; at least one alarm or warning is still active.

a.g The "Status mode" is displayed by pressing the key several times. The following text appears on the display: "...Compressor off".

By pressing the cursor key or the key you can now view the still active alarms or warnings (scroll).

a.h If only warning signals are still active, the compressor can be restarted, otherwise the cause for the still active alarm messages have to be corrected before the compressor can be restarted.

a.i Information about alarm clearance is explained in chapter " Information from the controls in case of a system error".

a.j The last 256 alarms/warnings, saved with their time and date, can be viewed in the menu item 25

"Alarms" or by calling them up directly using the key.

Hint!

Display the states of digital signals in the display with the keys and .



fig. 155: Restart following Alarms

Caution!

It is not possible to restart the compressor as long as the cause of the alarm still exists!



Display of the cause(s) of the alarms after deleting the display on view (press the key) or in the case that several alarms have occurred simultaneously:

Step Procedure

1

Call up the "Alarms" menu by pressing the key.

2

Select the "View" menu item for the alarms by pressing the key. The errors that have occurred can be viewed here with the date and time at which they occur.

Caution!

For more detailed explanations for reading the error messages, see chapter "General image format".

7.3 Information from the controls in case of a system error (CPU)

A system error is triggered by the Siemens system software, e.g. by the detection of an SPS hardware fault.

A system error is signalled by the “SE” LED.

System errors are:

— SPS hardware faults

— Firmware faults

— Program faults

— Parameterising errors

— Computational errors

— Time errors

— Faulty internal memory storage

— Battery failure or if standby supply missing for MAINS ON

— Peripheral error in the internal peripheral functions

A PG or a PC with the relevant software must be used to read out the diagnostics buffer for precise determination of the errors.

Hint!

There is no alarm message in the display!

If a system error occurs, it can be signalled in one of the following possible ways:



Possibility 1

The "SE" and "RUN" LEDs are alight.

The application program continues to run.

The compressor is not switched off.

fig. 156: Information from the controls - Possibility 1

LED irrelevant

LED off

LED on

LED flashing slowly LED flashing quickly

LED additional information



Possibility 2

The "SE" and "STOP" LEDs are alight.

"RUN" LED is off.

The application program is not running.

The compressor is switched off and the ‘alarm’ relay signals an alarm (relay has de-energised).


LED irrelevant

LED off

LED on





Possibility 3

The "SE" LED lights up and the "STOP" LED flashes slowly (1Hz).

"RUN" LED is off.




LED irrelevant

LED off

LED on



The flashing "STOP" LED signals that a general reset has been requested.

The cause for the CPU "general reset" request can only read from the diagnostics buffer using programming device; check any peripheral modules used that have "SE" LEDs.

General reset means that the main memory in the CPU is deleted and the application program is reloaded from the flash memory (EPROM).

For the actions required to carry out the general reset (MRES), see chapter "C7-CPU Selection of the operating mode".



Possibility 4

The "SE", "RUN" and "BATF" LEDs are alight.

The LED "alarm signal" flashes.

The application program continues to run.

The compressor is not switched off.

A warning message appears in the display.

Fault:The program battery is flat.

Fault correction: Replace the battery.


LED irrelevant

LED off

LED on





Possibility 5

The "SF" LED flashes. An alarm message appears in the display.




LED irrelevant

LED off

LED on



This system message is also active at possibility 3.

The display can't establish a connection to PLC because of a wrong MPI address.

The Alarm can be cancelled by a "General reset" in case the correct software is stored in the EPROM memory card.





Possibility 6

The "SF" LED flashes. An alarm message appears in the display.

The applications program continues to run.


LED irrelevant

LED off

LED on



This system message appears, if the display tries to use data, which are not available in the actual loaded applications program.

The Alarm can be cancelled by a "General reset" in case the correct software is stored in the EPROM memory card.





8 SERVICE

Caution!

The operator control actions of chapter "Special operating instruction for service staff" is only to be carried out by instructed and qualified personnel.

The Grasso System Control is a high quality product.

Nevertheless, damage or malfunctions during operation cannot be completely avoided.

Please direct any questions concerning malfunctions that occur to your Grasso supplier. Your contact in Germany:

Grasso GmbH Refrigeration Technology

Holzhauser Straße 165

13509 Berlin

Germany

Phone number: +49 (0)30 – 43 592 6

Number of Fax machine: +49 (0)30 – 43 592 777

24 h Central Call Out Service - Phone: +49 (0)172 – 391 20 50

Hint!

Please use the fax form on the back of this page to report your damage!

For custumers outside Germany: Please send an identical damage report to the Grasso office responsible for your area.

By submitting a complete damage report you ensure that the damage that has occurred can be repaired quickly.

8.1 Damage Report (Fax)

Hint!

Please print the form to fill it out and send it to Grasso GmbH RT via fax machine.

Address of the owner/operator:

Type and model number of the product:

Designation of the defective module

Suspected cause of the damage:

Date of the damaging event:



Operating hours of the module until damage occurred:

Software Version: (can be called up under the menu item “Configuration“)

Manufacturer's code:

Error message in display:

Row 1: Row 2: Row 3: Row 4:

Status and error displays

SF-LED OFF ON

BATF-LED OFF ON

DC5V-LED OFF ON

FRCE-LED OFF ON

RUN-LED OFF ON flashing (2Hz)

STOP-LED OFF ON flashing (1Hz)

SF-IM-LED OFF ON

SF-DP-LED OFF ON

BUSF-LED OFF ON flashing (2Hz)

-LED

OFF ON flashing (2Hz)



Functional Key LEDs

LED K1 "ON" OFF ON flashes

LED K9 "OFF" OFF ON

Additional Informations

— Description of the symptoms

— Owner/operator requirements

— List of parameters (see chapter 9)

8.2 Special operating instruction for service staff

Um dem Servicepersonal die Möglichkeit zu geben, Fehler schneller zu beseitigen, ist die GSC mit folgender ergän-zender Funktionalität ausgestattet:

Service-

function Operation Description

"Freeze display" Change to the menu by pressing +

Display for all actual values, existing directly before last alarm shutoff.

Service menu Change to the menu by pressing +

Digital inputs / outputs display, display of current, minimum and maximum capacity steps.

"Service Mode"

Select the operating mode using and

or in the "Operating mode" menu

Operating mode with blocked compressor motor. Digital outputs ca be activated manually.



8.2.1 Freeze Display

Freeze display for all actual values (pressures, temperatures and other process values), existing directly before alarm shutoff.

fig. 162: Freeze Display 01

Date display during alarm shutoff

Time display during alarm shutoff

Status of the compressor: Compressor status display during alarm shutoff

Hint!

Date and time match with alarm histogram in the "Alarms" menu .

Use the key to display alarm messages.


Run time: Run time after starting until alarm shutoff in h:mm:ss

Capacity LP: LP compressor capacity in %


Set Point: Set point in °C

Process value: Process value in °C

Motor curr: Motor current in A




Suction press: Suction pressure in bar (a)

Disch press: Discharge pressure in bar (a)

Disch temp: Discharge temperature in °C


Oil press: Oil pressure in bar (a)

Oil dif press: Oil difference pressure in bar

Suction temp: Suction temperature in °C


Oil temp: Oil temperature in °C

Suct dif temp:

Suction difference temperature in K

Motor speed:

Motor speed in min-1

8.2.2 Service menu

Inputs / outputs display, display of current, minimum and maximum capacity steps as well as of two-stage φ-value.

Unique digital outputs can be activated.

This can be done by selecting the "Service mode" (see chapter "Service mode").

fig. 168: Service mode 01

0.7 – 0.0: digital inputs 0.0 through 0.7 (0.0 rightmost)

1.7 – 1.0: digital inputs 1.0 through 1.7 (1.0 rightmost)




0.7 – 0.0: digital outputs 0.0 through 0.7 (0.0 rightmost)

Set: digital outputs 0.0 through 0.7 (0.0 rightmost)


1.7 – 1.0: digital outputs 1.0 through 1.7 (1.0 rightmost)

Set: digital outputs 1.0 through 1.7 (1.0 rightmost)


Step: Current capacity step (0…16)

Min: Minimum capacity step

Max: Maximum capacity step

Dn: Nearest lower capacity step

Up: Nearest higher capacity step


OK: Step release: 1 = releases (steps 1 through 16 from the right to the left)



8.2.3 "Service Mode"

Operating mode with blocked compressor control. Digital outputs ca be activated manually.

Caution!

The compressor motor outlet can be setted just as all other outputs.

This is allowed only to check the direction of rotation of compressor motor with removed coupling or if contactors are disabled.

Otherwise the compressor runs without protection by the GSC.

Press the key to select the "Operation menu" directly and select the "Service mode" with and or .



9 LIST OF PARAMETERS

05 Actual values

# Title Hot Key Parameter

05 Actual values

ACTUAL values of compressor unit data + remaining times for timers

10 Control settings

# Title Standard Hot Key

10 Control settings

Parameters for control values

Range Default setting Project setting

1. set point °C -65,0 ... +65,0 6,0

2. set point °C -65,0 ... +65,0 6,0

neutral zone K 0,1 ... 10,0 1,0

prop zone K 2,0 ... 50,0 15,0

capacity + (min) s 15 ... 600 30

capacity + (max) s 15 ... 600 120

capacity - (min) s 15 ... 600 20

capacity - (max) s 15 ... 600 90

Start dly auto s 15 ... 1800 30

Cor P-zone K -10,0 ... 10,0 0,0

Derative fact K 0,0 ... 10,0 1,0

15 Operating modes 01 Manual + Manual


15 Operating modes

Parameters for operating modes

Default setting Project setting

Operating mode 01 Manual + Manual

Controled value Psuc

Sequence OFF




Power return Alarm

Bus error Alarm

20 Limit values


20 Limit values

Parameters for limiting values

Psuc Range Default setting Project setting

Psuc low alarm bar (a) 0,30 ... ? 3,00

Warning bar + 0,00 ... 3,00 0,20

Limit bar + 0,00 ... 3,00 ,050

Decr limit bar + 0,00 ... 3,00 0,30

Psuc hi alm n1 bar (a) 0,30 ... ? 6,50

Psuc hi alm n2 bar (a) 0,30 ... ? 6,50

Warning bar - 0,00 ... 3,00 0,20

Suction gas overheat Range Default setting Project setting

Psuc low alarm K 0,0 ... 25,0 2,0

Warning K + 0,0 ... 10,0 0,0

Pdis Range Default setting Project setting

Pdis high alarm bar (a) 3,0 ... ? 17,0

Warning bar - 0,00 ... 5,00 0,5

Limit bar - 0,00 ... 5,00 1,5

Decr limit bar - 0,00 ... 5,00 0,5

Discharge temperature Range Default setting Project setting

Pdis high alarm °C 0 ... ? 150

Warning K - 0,00 ... 50,00 5,0

Limit K - 0,00 ... 50,00 15,0

Decr limit K - 0,00 ... 50,00 5,0

Oil differential pressure Range Default setting Project setting

Psuc low alarm bar 1,30 ... 10,00 1,5

Warning bar + 0,00 ... 5,00 0,2




Oil temperature Range Default setting Project setting

Psuc low alarm °C 10 ... ? 30,0

Warning K + 0,00 ... 30,00 1,0

Limit K - 5,00 ... 30,00 10,0

Pdis high alarm °C 10 ... ? 80,0

Warning K + 0,00 ... 30,00 1,0

Imot Range Default setting Project setting

Pdis high alarm A 0 ... 1500 150

Warning A - 0 ... 200 10

Limit A - 0 ... 200 10

Decr factor % 0 ... 100 80

External temperature Range Default setting Project setting

Psuc low alarm °C -65,0 ... +65,0 2,0

Warning K + 0,0 ... 10,0 1,0

Limit K + 0,0 ... 10,0 2,0

Decr limit K + 0,0 ... 10,0 1,0

Capacity Range Default setting Project setting

Minimum % 0 ... 100 0

Maximum % 0 ... 100 100

30 Timer values


30 Time settings

Parameters for timer values

Range Default setting Project setting

Start to start s 60 ... 1800 600

Stop to start s 60 ... 1800 180

Oil dif Start s 1 ... 60 20

Oil dif run s 1 ... 60 10

unloaded Starting s 5 ... 150 20

Motor feedback s 1 ... 60 10




Po dif dly s 5 ... 40 20

Run hours h 0 ... 99999999 0

Flow swtch dly s 1 ... 21600 25

Cond. feedback s 1 ... 21600 30

Pump stop dly s 1 ... 21600 60

Oil drain s 1 ...3600 120

Drain delay s 1 ... 21600 1200

Oil return s 1 ...3600 60

Return delay v 1 ... 21600 60

35 Unit Options


35 Unit options

Parameters for optional values

Sequence Control: Parameter Range Default setting Project setting

Sequence - 1 ... 9 1

Minimum % 0 ... 100 10

Part load % 0 ... 100 50

Maximum % 0 ... 100 100

Use fixed seq. - yes / no No

Master - yes / no No

neutral zone K 0,1 ... 15,0 3,0

Start delay s 1 ... 21600 300

Stop delay s 1 ... 21600 180

C.O.P. delay s 1 ... 21600 1200

Injection: Parameter

Inject begin: value - 0,001 ... 5 1

50 Configuration




50 Configuration

Parameters for configuration values

SW _____________ ___.___.___

OP MPI ____ /____ ___.___.___

HW ___ ___ - ___.___.___

Default setting Project setting

Refrigerant

Compressor

LP cylinders

Min capacity

add. capacity

Inject control

AKVA type

Nom speed

Aux output

Imot

Oil temperature

Outlet temp.

Cond temp.

Remote SP

external temp

50 Configuration


50 Configuration

Parameters for configuration values

Sensor scaling: Psuc Range Default setting Project setting

Sensor: Psuc

4mA equals bar (a) 0,0 ... 40,0 0,0

20mA equals bar (a) 0,0 ... 40,0 10,0




Sensor scaling: Pdis

Sensor: Pdis

4mA equals bar (a) 0,0 ... 40,0 0,0

20mA equals bar (a) 0,0 ... 40,0 25,0

Sensor scaling: Poil

Sensor: Poil

4mA equals bar (a) 0,0 ... 40,0 0,0

20mA equals bar (a) 0,0 ... 40,0 25,0

Sensor scaling: Suction temperature

Sensor: Suction temp

Offset (K) °C -10,0 ... 10,0 0,0

Range (%) °C -20,0 ... 20,0 0,0

Sensor scaling: Discharge temperature

Sensor: Tdis

Offset (K) °C -10,0 ... 10,0 0,0

Range (%) °C -20,0 ... 20,0 0,0

Sensor scaling: Oil temperature

Sensor: Toil

Offset (K) °C -10,0 ... 10,0 0,0

Range (%) °C -20,0 ... 20,0 0,0

Sensor scaling: Imot

Sensor: Imot

4mA equals A 0,0 ... 1500,0 0,0

20mA equals A 0,0 ... 1500,0 600,0

Sensor scaling: External temperature

Sensor: external temp

4mA equals °C -60,0 ... 140,0 -60,0

20mA equals °C -60,0 ... 140,0 140,0

Sensor scaling: Remote set point

Sensor: Remote set point




4mA equals °C -65,0 ... 65,0 -60,0

20mA equals °C -65,0 ... 65,0 60,0

Sensor scaling: inlet temperature

Sensor: SP output

Offset (K) °C -10,0 ... 10,0 0,0

Range (%) °C -20,0 ... 20,0 0,0

Sensor scaling: outlet temperature

Sensor: SP output

Offset (K) °C -10,0 ... 10,0 0,0

Range (%) °C -20,0 ... 20,0 0,0

Sensor scaling: Setpoint output

Sensor: SP output

4mA equals °C -65,0 ... 65,0 -60,0

20mA equals °C -65,0 ... 65,0 60,0

Sensor scaling: PV output

Sensor: PV output

4mA equals °C -65,0 ... 65,0 -60,0

20mA equals °C -65,0 ... 65,0 60,0

Sensor scaling: Cond. temp.

Sensor: SP output

Offset (K) °C -10,0 ... 10,0 0,0

Range (%) °C -20,0 ... 20,0 0,0

Configuration

Accept ok

Save ok

grasso system control - gea engineering for a better world documents/grasso gsc - rc... · 1...

Documents