Beruflich Dokumente
Kultur Dokumente
COPYRIGHT
All Rights reserved.
No part of this publication may be copied or pub-
lished by means of printing, photocopying, microfilm
or otherwise without prior written consent of
GEA Refrigeration Germany GmbH
herein after called manufacturer. This restriction
also applies to the corresponding drawings and dia-
grams.
LEGAL NOTICE
This documentation has been written in all con-
science. However, the manufacturer cannot be held
responsible, neither for any errors occurring in this
documentation nor for their consequences.
Warning!
Stands for a possibly dangerous situa-
tion which leads to heavy physical
injuries or to the death.
Caution!
Stands for a possibly dangerous situa-
tion which could lead to light physical
injuries or to damages to property.
Hint!
Stands for an important tip whose
attention is important for the designa-
ted use and function of the device.
TABLE OF CONTENTS
1 DESCRIPTION OF THE CONTROLLER 9
1.1 Safety note concerning the connection of the controller with the power panel 9
1.2 GSC TP, general 9
1.2.1 View 10
1.2.2 Lamps/ Push buttons 11
1.3 TouchPanel 13
1.3.1 General screen layout 13
1.3.2 Function key bar 14
1.3.3 Display and input boxes 15
1.3.3.1 Numerical value input 15
1.3.3.2 Selective list 17
1.3.3.3 Password level 18
1.3.4 Information bar 19
1.3.4.1 Status messages 19
1.3.4.2 Operation mode 21
1.3.5 Navigation bar 22
2 MAIN DISPLAY WITH SELECTION AREAS 24
3 INDICATION OF ACTUAL VALUES AND DELAY TIMES 25
4 CONTROL 28
4.1 Selective list "Operation mode" 28
4.2 Selective list "Control on" 30
4.3 Selective list "Power return" 31
4.4 Selective list "Network fault" 31
4.5 Control Parameters 32
5 COMPRESSOR SPEED CONTROL 34
6 TIMER SETTINGS 35
7 SENSOR VALUES (LIMIT VALUES AND SENSOR SCALING) 37
8 SEQUENCE CONTROL 45
8.1 Actual values 45
8.2 Settings 46
9 CONFIGURATION 48
9.1 Type 48
9.2 Refrigerant 49
9.3 Compressor 50
9.4 Coolant injection 51
9.5 Valve type 51
9.6 Motor valve suction line 51
9.7 Nominal speed 51
9.8 Auxiliary output 52
9.9 Frequency inverter 52
9.10 Motor current 52
9.11 Crankcase pressure 52
9.12 Suction temperature 52
9.13 Oil temperature 53
9.14 Oil separator temperature 53
9.15 Cooling agent inlet temperature 53
9.16 Cooling agent outlet temperature 53
9.17 Coolant inlet 53
9.18 Coolant out temp 53
9.19 External setpoint analog (HW) 54
9.20 External temperature 54
9.21 Communication 54
9.22 Thermomaster 54
9.23 Acknowledgement configuration 54
10 PASSWORD 55
11 DATE AND TIME 56
12 LANGUAGE 57
13 START UP MANAGER 58
14 ALARMS AND WARNINGS 59
14.1 Alarms 59
TABLE OF FIGURES
fig. 1 Front view 10
fig. 2 White indicator light (Running compressor) 11
fig. 3 Yellow indicator light (Warning) 11
fig. 4 Red indicator light (Alarm) 12
fig. 5 Emergency stop button 12
fig. 6 TouchPanel 13
fig. 7 General screen layout 13
fig. 8 Function key bar 14
fig. 9 Numeric input window 15
fig. 10 Selective list 17
fig. 11 Information bar 19
fig. 12 Navigation bar 22
fig. 13 Representation of the main process values 24
fig. 14 Indication of actual values and delay times 25
fig. 15 Input and selection areas 28
fig. 16 Setting the compressor speed control 34
fig. 17 Timer Settings 35
fig. 18 Sensor values 37
fig. 19 Sequence control settings 45
fig. 20 Configuration 48
fig. 21 Password 55
fig. 22 Date/Time 56
fig. 23 Language 57
fig. 24 Start up manager 58
fig. 25 Alarm report 59
fig. 26 Alarm overview 60
fig. 27 Alarm histogram 60
fig. 28 Warning message 64
fig. 29 Thermomaster (product-dependent variations possible) 67
fig. 30 Wire break (product-dependent variations possible) 68
fig. 31 Data at the time of the last failure (product-dependent variations possible) 68
fig. 32 Display of the maintenance intervals (product-dependent variations possible) 69
fig. 33 Average values (product-dependent variations possible) 69
fig. 34 History (product-dependent variations possible) 70
fig. 35 Maintenance settings (product-dependent variations possible) 71
1.1 Safety note concerning the connection of the controller with the power panel
Hint!
It is not permitted to add an external controller between the controller and the power panel;
this would extend the safety chain to be achieved. All control signals between the controllers
and the power panel must be processed directly and must not flow indirectly via an external
controller. GEA Refrigeration Germany GmbH cannot otherwise guarantee the safe operation
of the system.
Hint!
Some parameters will be hidden if not used.
Automatic startup and shutdown of the chiller as well as capacity control depending on the following values:
Suction pressure
Inlet temperature
External temperature (value via MPI network)
Outlet temperature (option)
Monitoring of all operating parameters
Compressor capacity limitation if the measured discharge pressure, discharge temperature, motor current
(optional) or suction pressure indicate an overload
Fault memory with date and time
Wire failure detection for analogue input signals
Password protection for preventing unauthorised access to important parameters
Control of the chiller by a master controller via potential free contacts
Possibility of communication via MPI or Modbus RTU with master controller or building management system.
(The MPI communication is not recommended when using a successor model)
10-minute trend display with display of all actual values which existed just before alarm shutdown
Remote maintenance via Ethernet connection (TCP/IP)
The GSC TP optionally performs the following functions:
Frequency-controlled compressor drive motor
Motor current sensor
Outlet temperature sensor
Winter mode to protect the secondary cooling agent against freezing (evaporator block by motor valves) -
only Ingenium Compact.
Electronic flow switch for refrigerant circuit
Electronic flow switch for heating agent circuit
Remote setpoint adjustment (analogue signal)
Profibus DP communication
1.2.1 View
1.3 TouchPanel
The TouchPanel is the interface between the man and the machine.
All switching, operating and control actions are carried out via this TouchPanel.
The TouchPanel is available in different languages.
fig.6: TouchPanel
Hint!
Coloured highlighted buttons can be operated.
Grey marked push buttons can't be activated, a finger touch will not initiate any action.
1 Information bar
2 Navigation bar with "Pull down" menus
3 Main display with selection areas
4 Function key bar
Only push buttons on a coloured background can also be operated. Grey push buttons are not active.
Pushing the buttons gives a visual feedback, a colour change to "light green".
Key Function
Start
Switch off compressor (press key for 5 sec. in "Manual" operation mode)
Reduce output of compressor
(in case of manual capacity control only)
Hint!
As an additional feature, the control deviation is displayed within the push buttons for manual
output control as a simulated LED.
Example:
The push buttons and have a key characteristic, e.g. as long as touched by a finger.
If an active input box has been actuated, the numeric input window opens.
Use the keypad to enter values. All inputs will be acknowledged by pressing the button. The
button will only become active when the value is changed.
The actual value as well as the minimum and maximum limits are displayed in addition to the input value.
Press the button to quit the numerical value input window without changes.
The buttons and can be used to leaf through the list here. The active selection has a green
Press the button to quit the list selection and the entry window will close.
Hint!
Changing parameters without entering a password is not possible!
Password at
Delivery
1 Status
2 Selected operation mode
INITIALISATION Initialisation of the control after switching on the power supply or before the trans-
fer of the new settings.
COMPRESSOR OFF The compressor is switched off and the start is disabled.
EXTERNAL START The controller is waiting for an external signal to enable the start of the unit.
START TO START A starting frequency limiter of the compressor drive motor is still active.
BOOSTER WAIT The booster compressor will start as soon as the suction pressure drops below the
"Booster pressure". After achieving booster pressure the compressor will be
approved for starting.
DISCHARGE PRES-
The discharge pressure is too high. The compressor is not allowed to start.
SURE TOO HIGH
STANDBY Product ready for switching on, but one or more starting conditions are still not ful-
filled e.g. process variable still below set point.
MOTOR FEEDBACK Compressor drive motor has been started, however the running feedback signal
from the starter panel has not yet been received or the start-up is not yet complete.
STARTING Compressor drive motor has been started, but the compressor still runs without
load (one and two-stage compressor) or the low pressure cylinder is still not active
(only two-stage compressors)
STARTING PULL DOWN More capacity is needed, but the next capacity steps are blocked due to high suc-
tion pressure. Low pressure cylinders are still not activated (two-stage compres-
sors only)
RUNNING The compressor drive motor is running in the starter panel or start-up has been
completed, product is in operation.
RUNNING PULL DOWN The compressor drive motor is running in the starter panel or start-up has been
completed. Product is in operation and more capacity is needed. However, the
next capacity steps are blocked due to high suction pressure (two-stage compres-
sors only).
SUCTION PRESSURE A capacity limitation is active (suction pressure too low). The capacity cannot be
LIM increased. In case the suction pressure increases, the capacity will be decreased.
DISCHARGE PRES- A capacity limitation is active (discharge pressure too high). The capacity cannot
SURE LIM be increased. In case the discharge pressure increases, the capacity will be
decreased.
DISCHARGE TEMPERA- A capacity limitation is active (discharge temperature too high). The capacity can-
TURE LIMITATION not be decreased or increased. In case the discharge temperature increases, the
capacity will be increased or decreased.
EXTERNAL TEMPERA- A capacity limitation is active (external temperature or outlet temperature too low).
TURE LIMITATION The capacity cannot be increased. In case the external temperature decreased,
the capacity will be decreased.
MOTOR CURRENT LIMI- A capacity limitation is active (motor current too high). The capacity cannot be
TATION increased. In case the motor current increases, the capacity will be decreased.
PUMP DOWN Before starting and stopping the compressor, the suction pressure is decreased
until the "Stop pressure" is reached (if the pump down sequence is activated only).
STOPPING The product has received a shut-down command, the capacity is decreased to a
minimum.
1 Navigation bar
Key Function
Key Function
Symbol Remark
Symbol Remark
Condenser temp.
Condenser temperature in C
(up to TP Version 7.2.0)
Injection Injection in %
Start to start Start to start, remaining time between two starts of the compressor in sec.
Auto start delay Remaining time for auto start delay in sec.
Symbol Remark
4 CONTROL
Hint!
A numerical value input or a selective list opens after pressing the push button if the opera-
tion of the input and selection areas are possible.
Password
Remark
level
Manual + Auto (2) Manual start/stop via display and full automatic local
capacity control
Auto + Auto (3) Full automatic start/stop and local capacity control
Remote + HW (cont) (4) Start/stop and capacity demand via digital contacts
(hardware) from a remote master controller. The
control derives from the continuous +/- signals the
pulses for capacity (indirect).
Remote + HW (pulse) (5) 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 capacity directly.
Remote + HW (loc. SW) (6) Start/Stop from a remote master controller via digital
contacts (hardware). The control adjusts the output
depending on a local setpoint (display) and from this
setpoint also automatically switches the product ON/
OFF.
Password
Remark
level
Remote + HW (ext. SW) (7) Start/Stop from a remote master controller via digital
contacts (hardware). The control adjusts the output
depending on an external setpoint (analog input)
and from this setpoint also automatically switches
the package ON/OFF.
Remote + Net (cont) (8) Start/stop and capacity demand via network from a
remote master controller. The control derives from
the continuous +/- signals the pulses for controlling
the capacity (indirect).
Remote + Net (pulse) (9) 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.
Remote + Bus (loc. SW) (10) Start/stop from a central master controller via a bus
signal. The control adjusts the output depending on
a local setpoint (display) and from this setpoint also
automatically switches the product ON/OFF.
Remote + Bus (net. SW) (11) Start/stop from a central master controller via a bus
signal. The control adjusts the output depending on
an external setpoint sent externally via the network
and from this setpoint also automatically switches
the package ON/OFF.
Password
Remark
level
Password
Remark
level
Password
Remark
level
Remote + HW (loc. SW) (6) If a network fault occurs the operation mode is
switched to "6"
Remote + HW (ext. SW) (7) If a network fault occurs the operation mode is
switched to "7"
Password
Compressor Remark Unit Range
level
Inlet/outlet diff. SW1 Temperature difference between inlet and K 0.0 ... 30.0 2
outlet temperatures at 100% capacity for the
1st setpoint
Inlet/outlet diff. SW2 Temperature difference between inlet and K 0.0 ... 30.0 2
outlet temperatures at 100% capacity for the
2nd setpoint
Capacity incr. min. minimum step time to increase capacity s 15 ... 600 1
Capacity incr. max. maximum step time to increase capacity s 15 ... 600 1
Capacity decr. min. minimum step time to decrease capacity s 15 ... 600 1
Capacity decr. max. maximum step time to decrease capacity s 15 ... 600 1
Auto start delay Length of delay in sec before automatic start s 1 ... 1800 1
up
Auto stop delay Length of delay in sec before automatic s 1 ... 1800 1
switch off
Password
Compressor Remark Unit Range
level
Stop pressure After reaching this pressure the compressor bar (a) 0.3 ... 51.0 2
will be stopped.
To call up this screen press the button + select "Compressor speed control".
Password
Title Remark Unit Range
level
Ti 0.01 ...
I-factor of speed controller 2
320.00
Step Speed control step size at manual operation rpm 1 ... 500 2
6 TIMER SETTINGS
Hint!
Password
Title Remark Unit Range
level
Stop to start Delay between stop and next start s 300A 1800 2
Oil diff. start Oil circuit alarm delay during start up s 1 ... 30 2
Oil diff. run Oil circuit alarm delay during running s 1 ... 30 2
Password
Title Remark Unit Range
level
Pump stop delay Stop delay of secondary refrigerant pump s 1 ... 21600 2
Hint!
Press the button "Actual values" to display all remaining times of elapsed timers.
All values that can be assigned to a sensor can be set or changed in this screen.
Warning levels, limitations and injection level values must be entered as an offset to the alarm value without any
sign.
Password
Sensor Remark Unit Range
level
Suction Low alarm Alarm limit for minimum suc- bar (a) 0.30A ... 10.0A 3
pressure tion pressure
Password
Sensor Remark Unit Range
level
Suction Alarm (max) n1 Input alarm limit for "maxi- bar (a) 0.30A ... 10.0A 3
pressure mum suction pressure" for
low speed
Alarm (max) n2 Input alarm limit for "maxi- bar (a) 0.30A ... 10.0A 3
mum suction pressure" for
high speed
Suction gas Low alarm Input alarm limit for "minimum K 0.0A 25.0 3
superheat suction superheat"
Interm. gas Low alarm Input alarm limit for "minimum K 0.0 ... 25.0 3
superheat Intermediate superheat
(two-stage alarm"
compressors
only)
Password
Sensor Remark Unit Range
level
Discharge High alarm Input alarm limit for "maxi- bar (a) 3.0 ... 51.0A 3
pressure mum discharge pressure"
Password
Sensor Remark Unit Range
level
Discharge High alarm Alarm limit for "maximum dis- C 0 ... 170A 3
temperature charge temperature"
Oil diff. pres- Low alarm Input alarm limit for "minimum bar 1.3A 10.0A 3
sure oil differential pressure"
Password
Sensor Remark Unit Range
level
Oil tempera- Low alarm Input alarm limit for "minimum C 10A 90A 3
ture oil temperature"
Motor cur- High alarm Input alarm limit for "maxi- A 0 ... 1500 3
rent mum motor current"
Password
Sensor Remark Unit Range
level
Motor speed Low alarm Input alarm limit for "minimum min-1 400A 1800A 3
motor speed"
High alarm Input alarm limit for "maxi- min-1 400A 1800A 3
mum motor speed"
Password
Sensor Remark Unit Range
level
External tem- Low alarm Alarm limit for "minimum C -65.0 ... 65.0 3
perature or external temperature"
outlet tem-
perature Warning Input warning value "mini- K 0.0 ... 10.0 3
mum external temperature"
as an offset to the alarm
value
Password
Sensor Remark Unit Range
level
8 SEQUENCE CONTROL
Hint!
To call up this screens press the button + select "Options" and "Sequence control".
Auto start delay Remaining time, start delay for next machine s
Auto stop delay Remaining time, stop delay for last machine s
8.2 Settings
Pass-
Title Remark Unit Range word
level
Auto start Auto start delay for the subsequent compressor (control devia- s 1 ... 1
delay tion larger than neutral zone) 3600
Switch delay Switch delay of control routine, e.g. forced adjustment to part s 1 ... 1
load or switching not required load off 1800
Pass-
Title Remark Unit Range word
level
Auto stop delay Auto stop delay for the last current compressor (control devia- s 1 ... 1
tion smaller than neutral zone) 3600
Neutral zone Neutral zone for switching the next compressor on/ off. K 0 1 ... 1
Value must be equal or larger than the value of the local control 10.0
neutral zone, setted in the "Control" menu.
9 CONFIGURATION
Hint!
fig.20: Configuration
Hint!
The configutation is carried during the installation of the refrigerating plant only.
9.1 Type
9.2 Refrigerant
9.3 Compressor
Password
Value Remark Selection
level
Password
Value Remark Selection
level
9.21 Communication
9.22 Thermomaster
(from TP Version 7.0.0)
10 PASSWORD
Hint!
See chapter "Password level".
fig.21: Password
(from TP version 6.2.0, figure varies)
3 Service ****
4 Administrator ******
The password levels are hierarchically structured. The password level "4 (Administrator)" is the highest level.
Change passwords of lower levels by using the active password level and pressing the "Edit" button.
The padlock symbol indicates the active password level.
Defined settings are released or blocked for each password level.
After 10 minutes of inactivity an automatic log-out is performed.
Pressing the button returns to the previous screen (from TP version 6.2.0).
fig.22: Date/Time
Date and time are required to display alarm messages in the alarm histogram correctly.
Applying the new values cause the automatic transfer of date and time to the control.
Confirm by pressing the display area "accept".
12 LANGUAGE
Hint!
fig.23: Language
All screens are multilingual. The screen can be displayed in native language as required.
Switching over between the blue coloured language selection is possible. The flag symbol identifies the activated
language.
Hint!
Changing the language does not require a restart of the display, except for the Chinese and
Japanese languages.
13 START UP MANAGER
When the power is switched on, the Touch Panel starts and the "Start up manager" screen appears for approx.
10 seconds.
After that, the screen changes into the first screen layout of the project.
Hint!
Push "Select" "Browse" to start the project manually in case the project doesn't start
automatically.
If so, please contact GEA Refrigeration Germany GmbH, Service department!
14.1 Alarms
14.1.1 Alarm window
Hint!
If an impermissible operating status occurs, the product is stopped immediately. The display
will have an alarm window with report on the cause of the stop.
The alarm banner displays the cause for the alarm as well as the total number of active warn-
ings and alarms. The banner closes after pressing the red button, but the alarm is not yet
acknowledged!
At the same time a red LED will appear in the event push button in the navigation bar .
The LED provides the same function like the red indicator light at the control cabinet.
An alarm switches off the system.
The alarm overview will be shown automatically after closing the alarm banner.
This screen shows all active alarms and warnings. Press the button to acknowledge (reset) alarms and
warnings. The border of the button flashes until an alarm or a warning is acknowledged.
If an alarm is acknowledged all inactive alarms and warnings will be deleted out of the list. Following only active
alarms and warnings will be displayed in the alarm overview.
The button appears instead of the button when switching to the alarm overview by closing the alarm
window.
Press the button to return to the previous screen (from TP version 6.2.0)
This screen shows the last 255 alarms and/or warnings with alarm numbers and matching date/ time information.
To see the plain text of the alarm number, select the alarm by finger touch directly on the item and press the
button then.
Hint!
The alarm RESET and alarm OFF will always appier together within several seconds. This is
normal.
Display Remark
Alarm 026 Separator level too high. Please check the injection valve.
Display Remark
Display Remark
14.2 Warnings
14.2.1 Warning banner
Hint!
The warning banner appears after the occurrence of a warning. The banner displays the cause
for the warning. The banner displays the cause for the warning as well as the number of all
active warnings and alarms.
The window closes after pressing the yellow warning symbol, but the warning is not yet
acknowledged.
An alarm and warning overview (see alarms) is automatically displayed after closing the warn-
ing banner. The warning can be acknowledged in the alarm overview only.
All warnings are acknowledged automatically as soon as the cause for the warning not longer
exists.
At the same time a yellow LED will appear in the event push button in the navigation bar
.
The LED provides the same function like the yellow indicator light at the control cabinet.
A warning does NOT cause switching off the unit!
Display Remark
Warning 038 Feedback flow switch cooling agent circuit too late
Display Remark
15 THERMOMASTER
(from TP Version 6.1.0 / control for products with 2 reciprocating compressors)
(from TP Version 7.0.0 / control for products with 1 reciprocating compressor)
Hint!
To call up this screen press the button + select "Options" and "Thermomaster".
The "Thermomaster" button is only active in the options screen when activated in the Thermo-
master configuration menu (select "integrated).
The Thermomaster integrated in the GSC TP communicates with the GSC via Modbus RTU.
For the communication to work, the parameters for Modbus RTU communication must be configured in the serv-
ice menu as follows:
Parameter Value
Hint!
With a Thermomaster integrated in the GSC TP, external communication via Modbus RT is not
possible.
If the temperature of a cylinder exceeds the maximum temperature, the GSC TP goes into the failure condition.
The cylinder, whose temperature has caused the fault becomes red and remains red until the cylinder tempera-
ture falls below the maximum temperature.
If there is a wire break in a temperature sensor, the GSC TP goes into the failure condition. The cylinder in
whose sensor there is a wire break, becomes red and an icon representing wire break appears in place of the
current temperature.
If the "Alarm" button is pressed, the temperature at the time of the last Thermomaster failure are displayed
instead of the current temperatures.
The current temperatures are displayed again after 60 seconds or by pressing the "Current" button.
fig.31: Data at the time of the last failure (product-dependent variations possible)
A hint (in English only) regarding the communication between the Thermomaster and the GSC TP is displayed at
the bottom right in the "Thermomaster" figure. In case of a communication error, the GSC TP goes into fault con-
dition.
16 COMPRESSOR MAINTENANCE
(from TP Version 6.2.0 / control for products with 2 reciprocating compressors)
(from TP Version 9.0.0 / control for products with 1 reciprocating compressor)
The maintenance intervals are calculated only if "Grasso V-L" or Grasso "V-M" is selected as the compressor
frame size in the configuration menu.
Hint!
The is found on the Service 1 screen. If an inspection is due within the next 30 days, the
The run hours, the age of the compressor (time since commissioning) and the hours to the next inspection are
displayed.
The current and the average values over the last 10, 100,1000 and the total hours of the suction temperature
(Tsuc), discharge temperature (Tdis), oil temperature (Toil), speed (Rpm) and the number of compressor starts
(Starts) are displayed.
16.3 History
The history shows the inspections which have been carried out. The inspection of unit type 0 indicates the time
of start-up. If an inspection was not carried out then this is automatically entered into the history after 2000
hours. In the "type" column this inspection receives the "X" in addition (e.g: XA or XB).
The appearance of the button instead of the button indicates that an inspection is due within the next
button. A prompt appears as to whether the maintenance has actually been carried out. Confirming with
OK enters the maintenance in the history.
Press the button to go to the maintenance screen. (Only with a logged-in service password)
If the "Calculation active" parameter is deactivated then the calculation of service intervals will still be carried out.
However, there is no hint regarding an upcoming inspection and it is only possible to change over to the mainte-
nance menu with a logged-in service password.
16.5.1 Reset
If the compressor has been replaced, the average value must be set to 0 and the history deleted by pressing the
"Reset" button. The operating hours must also be set to 0.