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1. Actual values 01 02 gt gt Imot Motor current in A Tc Discharge pressure in C R dPoil Differential oil pressure in bar Slide position Slide position Suction press Suction press bar a Motor current Motor current A lt lt Actual values 01 02 gt gt Chap 1 6 510116E_chapter1 doc Disch press Discharge pressure bar a Oil press Oil pressure bar a Filter press Oil filter pressure bar a lt lt Actual values 01 02 gt gt 07 09 2006 Rev 1 rr LL Grasso Refrigeration Division Oil diff press Fit diff press Oil temp lt lt Actual values 01 02 gt gt Disch temp Suction temp External temp lt lt Actual values 01 02 gt gt Suct press C R Disc press C R Chill inlet C lt lt Actual values 01 02 gt gt ECO press ECO temp lt lt Actual values 01 02 gt gt Start to start Stop to start Motor feedback lt lt Actual values 01 02 gt gt Slide to min Pump by itself Auto start dly lt lt Actual values 01 02 gt gt Run hours lt lt Actual values 01 02 07 09 2006 Rev 1 Oil diff press Fit diff press Oil temp Discharge temp Suction temp External temp Suct press C R Disc press C R Chill inlet C ECO press ECO temp Start to start Stop to start Motor feedback Slide to min Pump by itself
2. be transferred to the C7 CPU or be amended there PG gt C7 Note 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 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 Note 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 P Note see also Item 1 2 12 11 2004 Rev 2 510116E_chapter4 doc Chap 4 3 rr B Grasso Refrigeration Division 4 4 Installation of the memory card EPROM 4 4 1 Description of the memory card used The PLC Siemens C7 633 P uses the following standard memory card Technical data Daten 5V Flash 12
3. Check the external software Alarm 38 High liquid level This alarm is activated if the input signal E 1 1 separator liquid level equals 0 and the Lad level dly timer has expired The level in the refrigerant separa tor is too high The level sensor is defective The terminal connections have become loose The wire is broken The time setting Lad level dly is too short Digital input module defective Reduce the level in the refrigerant separator Replace the level sensor Check the terminal connections Replace the wire Increase the time setting Iqd level dly Replace the digital input module 22 05 2008 Rev 1 510116_chapter6 doc Kap 6 9 rr ed Grasso Refrigeration Division Display message Explanation Alarm 40 Low oil pressure This alarm is activated if the differ ence between the oil pressure and discharge pressure is less than the Oil diff min limit value and the de lay time has expired Alarm 41 Oil filter blocked This alarm is activated if the differ ence between the discharge pressure and the Oil filter pressure is larger than the Filt diff press high alarm limit value and the time delay has expired Alarm 42 Bus Communication This alarm is activated at the slave GSC if the sequence control has been activated and the slave GSC is not connected to the master GSC via the MIPI
4. J PRCE gt m au tu V O stor DHAL Al LED not applicable LED off LED on LED flashes quickly nu yu H a EL R C aE lA N i b 3 1 i SEB 7 2 Restart following Alarms Alarms and warnings are signalled as follows a The alarm relay is de energised only for alarm conditions not for warning conditions b The red indicator light Alarm flashes at the control cabinet for alarms the yellow indicator light flashes for warnings 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 i e the applications program continues to run 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 6 3 2 This list includes troubleshooting and fault correction information e The alarm or warning is acknowledged by pressing the alarm acknowledgement key ACK 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 f Ifa flashing alarm text is not displayed and the alarm LED lights up
5. lt lt l The alarm and warning numbers are unique and are displayed in the alarm histogram E see Chapter 1 2 3 5 6 2 2 List of all alarms and warnings ME All alarm and warning messages of the 2 compressor marked with 2 E All not explained message numbers are provided as reserve 001 Alarm 1 Broken wire suction pressure sensor 097 002 Alarm 2 Broken wire oil pressure sensor 098 003 Alarm 3 Broken wire discharge pressure sensor 099 O 004 R tempersture senor wo 005 Alar roken wie ol temperature sensor go 005 Alar 61 roken wie side postion senor w C os Alarms Broken wire ertemaltemperauresansar 105 Kap 6 2 510116_chapter6 doc 22 05 2008 Rev 1 re GRASSO SYSTEM CONTROL ud Grasso Refrigeration Division 02 22 Alarm 22 Slide to min time too long 023 Alarm 11 Difference oil pressure discharge pressure too high 024 Alarm 24 Difference between both discharge pressures was too high Alarm 25 Low external temperature 03 Alarm 31 Motor speed too low 32 Alarm 32 Motor speed too high 34 Alarm 34 Comp motor or freq ctrl protection device active 04 42 Alarm 42 Bus Communikation 43 Alarm 43 Refrigerant leak detected Warning 1 Suction pressure is too low 0 Warning 3 Discharge pressure is too high 36 Alarm 36 Start procedure too long 037 Alarm 37 Feedback from motor starter missing 052 Warning 4 Discharge temperature is too high
6. Auto start dly Run hours 510116E_chapter1 doc GRASSO SYSTEM CONTROL Value calculated from the oil pressure minus discharge pressure in bar Value calculated from the discharge pressure minus the oil filter pressure in bar in C C ge External temperature If unit is configured for chiller this value is the chiller outlet temperature in C Suction pressure displayed as temperature Discharge pressure displayed as temperature Chiller inlet temperature in C Economiser pressure in bar a Economiser temperature in C Remaining time between two starts of the compressor drive motor in secs Remaining time between stop and next start of the compressor drive motor in secs Remaining time for motor running feedback signal from compressor drive motor starter Remaining time for capacity slide to return to its minimum position after stopping the compressor Remaining time the oil pump can run by itself without initialising an oil drain Remaining time for automatic start delay Number of operating hours Chap 1 7 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 1 2 3 2 Control settings menu 10 Control settings Set Point 1 Set Point 1 First Set Point for the controlled parameter C Set Point 2 Set Point 2 Second Set Point for the controlled parameter C Active SP Active SP Active Set Point in C lt lt Control 01 02 gt gt 2 different set point values can be entered The
7. Psuc low alarm Low warning Limit values 01 02 gt gt qa Page on using the key Adjust the limit values to the suit the refrigeration plant 3 4 Adjusting the control settings Press Select the main menu 10 Control settings The following selection appears on the display Q Set Point 1 Set Point 2 Active SP Control 01 02 gt gt Page on using the key Adjust the control parameters to suit the refrigeration plant 3 5 Check the compressor unit s wiring Remove each compressor unit 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 fthe alarm message appears even though no connector has been removed check the wiring to the sensor or if the sensor is not mounted then make sure it has not been configured Chap 3 4 510116E_chapter3 doc 12 11 2004 Rev 0 rr L 1 Grasso Refrigeration Division 4 System description GSC 4 1 Explanation of the system LED 4 2 C7 CPU Selection of the operating mode 4 3 Meaning of the key operated switches 4 4 Installation of the memory card EPROM 4 4 1 Description of the memory card used 4 4 2 Installation of the Siemens SIMATIC C7 memory card 4 5 Adjusting the date time 4 6 Changing the language 12 11 2004 Rev 0 510116E_chapter4 doc GRASSO SYSTEM CONTROL
8. Running This indicator lamp flashes slowly when the compressor unit 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 Detection of this warning can be acknowledged at the operator panel Warnings are automatically reset after the cause has gone The flashing light changes over to a steady light This 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 compressor unit 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
9. SHIFT Line Profibus use the pe and Y keys to select whether the process data via profibus DP is to be transferred to a master control system If No they can only be read via the MPI bus SHIFT v Line Economiser use the pe and keys to select whether an economizer is installed l SHIFT Line Eco sensor use the and to the economizer keys to select whether pressure and temperature sensors are fitted gt gt Press once The following selection appears on the display Sensor Psuc AmA equals 0 20mA equals 70 lt lt Configuration 01 gt gt SHIFT Line Sensor use the pur and Y 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 ti gt gt Press once The following selection appears on the display Configuration accept save ok ok l lt lt Accept the configuration with the wl key Use the E key to permanently save the configuration on the EPROMI of the CPU 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 Chap 3 2 510116E_chapter3 doc 12 11 2004 Rev 0 rr GRASSO SYSTEM CONTROL La 4 Grasso Gesch ftsbereich K ltetechnik 3 2 Parameterise options Press Select the main
10. Starting conditions fulfilled Output oil pump ON Energise the capacity control solenoids Y2 amp Y3 Output oil pump ON Pump by itself timer active Feedback Oil diff press okay Capacity slide position Minimum 1 Pump by itself timer not elapsed Output compressor motor ON Output compressor motor ON Motor feedback timer active Motor feedback signal equals 1 De energise the capacity control solenoids Y2 amp Y3 Release the capacity control system 510116_chapter2 doc Kap 2 5 Gesch ftsbereich K ltetechnik GRASSO SYSTEM CONTROL Grasso 2 5 Switch off sequence 2 5 1 Switching off sequence in the normal case and in case of slide failure Feedback compressor motor ON Output oil pump motor ON Energise capacity control Capacity slide at Minimum 1 position Slide to min timer active If 1 gt Then 4 gt Then 6 If 4 Or If 6 and 5 gt Then 7 gt Then Kap 2 6 Stop command solenoids Y2 amp Y3 Alarm A B A Normal case Capacity slide returns to Minimum 1 compressor and oil pump are stopped B Slide failure Capacity slide not returned to Minimum 1 before slide min timer expired compressor and oil pump are stopped and Alarm is generated see 2 5 2 3 Stop command Energise capacity control solenoids Y2 amp Y3 Slide to min timer active Energise capacity co
11. at least one alarm or warning is still active 07 09 2006 Rev 1 510116E_chapter7 doc Kap 7 1 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division g Press SHIFT and K6 keys to get into Status display mode where the current status is displayed h By pressing the cursor key down or the key up you can now view the still active alarms or warnings scroll L 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 j Information about alarm clearance is explained in Item 7 3 k 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 A key Display the signal states of digital and analogue signals in the display with the keys and Kap 7 2 510116E_chapter7 doc 07 09 2006 Rev 1 re GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division After pressing the ACK key the alarm is acknowledged at the PLC The alarm message is deleted in the display The main menu appears in the display Possibility 1 Possibility 2 LED A red ON LED A red OFF The cause of the alarm Cause of the alarm still exists has already been removed Remove cause of the alarm Restore operation mode active before B alarm occured by pressing
12. sensor P amp ID position no 100 Alarm 2 Broken wire oil pressure sensor The GSC has detected a loose wire or short circuit in the oil pressure sensor P amp ID position no 110 Alarm 3 Broken wire discharge pressure sensor The GSC has detected a loose wire or short circuit in the discharge pressure sensor P amp ID position no 105 Alarm 4 Broken wire discharge Temperature sensor The GSC has detected a loose wire or short circuit in the discharge tem perature sensor P amp ID position no 120 Kap 6 4 The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective A a a Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The anal
13. so maions sik sooo no mwone i x 100 ao onrterairereniatpresure dT Sid SS naaa tr ooo dT SCS Then warning o oo ao SSCS Taranis o ionam fo dT SCS se pios SR maan aa BEE BEE BE A f l on TSC eow a omw o f eons ST omw s 7 Chapter 9 8 510116E_chapter9 doc 12 11 2004 Rev 0 rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division Title Standard HotKey e Time settings me Parameters for timer values Range Default setting Project setting A A Tran ann senos f 90 oo _ fours fs asis wo _ our ss ow o _ fone its o oo 0 _ omwen fs oan e sms ooo sta vo min e f T ooo woo motorteestoce e so 20 Trust IC A ICI IR Pump feedback remanso foram sts so mo C ornes its soo 10 A Ba a BE PD BE reumas Jo J wo le Unit options ME Parameters for optional values Default setting Project setting Values Parameter Sequence Control Value Parameter Economiser Values Parameter DX Control Selftuner Control Condenser Values Parameter 12 11 2004 Rev 0 510116E_chapter9 doc Chapter 9 9 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division Title Standard HotKey ee Configuration ae Parameters for configuration values Default setting Project setting A anan Tae O O O oo EEE Tee O TE SSS Taren BEE BEE EEG S C woe H H
14. 1 Values Parameter Actual value Parameter Actual value Parameters Values Parameter 510116E_chapter1 doc GRASSO SYSTEM CONTROL Jump to display of sequence control values Jump to sequence control parameters Jump to display of Vi values Jump to Vi parameters Jump to display of economiser values Jump to economiser solenoid control parameters Jump to condensor values Jump to condensor parameters Chap 1 13 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 1 2 3 8 Configuration menu 50 Configuration PLC version PLC version Display of the PLC program version used OP version OP version Display of the operater panel version used Configuration gt gt Refrigerant Refrigerant Select R717 R22 R134a R404a R290 R507 or R1270 Comp type Compressor type Select the compressor type C up to XD Vi code Vi code Select fixed 51 52 or 53 lt lt Configuration gt gt Select using and a or 7 Confirm the selection with Oil filt sensor Oil filter sensor Select Yes or No Sensor position Sensor position Select 395 or 495 These numbers are position numbers referred to on the P amp ID drawing supplied with the lt lt Configuration gt gt compressor Select using S and a or 7 Confirm the selection with Oil level high Oil level high Select Yes if sensor mounted otherwise No Oil level low Oil level l
15. 2 8 4 Parameterisation of the sequencing control at the operator terminal 29 2 9 Restarting performance following power supply failure 30 2 10 Turn on Turn off solenoid valves 505 and 510 31 2 11 Chiller functions 32 2 11 1 Start up 32 2 11 2 Oil draining and return 32 21 05 2008 Rev 2 510116_chapter2 doc L GRASSO SYSTEM CONTROL ed Grasso Gesch ftsbereich K ltetechnik MENU 15 OPERATION MODES Remote HW Loc SP Local set point 7 Remote HV4Rem SP ai Control via GSC buttons Oil by itself Manual Manual ee manual auto auto Control via digital analogue signals 4 Remote HW co nt Eten Ext continuo us 5 Remote HW pulse ica Ext pulses E een Remote set point 8 Remote Net cont Rete Net continuous Remote Net pulse Pan Net pulse Ne two rk 10 Remote Net Loc SP Local set point Ne two rk Network set point 11 Remote Net Net P u 510116_chapter2 doc Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control Stop Start control Capacity control 21 05 2008 Rev 2 rr ud Grasso Gesch fts
16. 6 Fixed oil pressure safety delay active If 6 Fixed oil pressure safety delay elapsed and If 2 Oil diff press not OK gt Then 7 Low oil pressure alarm Kap 2 12 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL La Z Grasso Gesch ftsbereich K ltetechnik 2 7 2 Oil system monitor of the large screw compressor packages The oil system monitor is responsible for monitoring the oil system The package is switched off if alarms occur The difference between the oil pressure and the discharge pressure is monitored 2 7 2 1 Switching sequence in the normal case Start conditions fulfilled Output oil pump ON Oil diff press OK Oil diff start timer active Oil diff run timer active Low oil pressure alarm A B A During start up B Brief lowering of the oil differential pressure during running If 1 Start conditions fulfilled Then 2 Output oil pump ON If 2 Output oil pump ON gt Then 4 Oil diff start timer active If 3 Oil diff press not OK and e If 4 Oil diff start timer elapsed gt Then 5 Oil diff run timer active If the oil differential pressure is OK again within the appropriate delay time there is no alarm shutdown 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 13 r ed Grasso Gesch ftsbereich K ltetechnik GRASSO SYSTEM CONTROL 2 7 2 2 Switching sequence in the case of a
17. All switching operating and control actions are carried out via this operator terminal System LED s function keys soft keys CPU operating mode setting G digital keybord cursor keys system keys system keys LED s Figure 1 3 GSC operator terminal E For detailed explanation of the system LEDs see Chapter 4 1 Chap 1 2 510116E_chapter1 doc 07 09 2006 Rev 1 rr GRASSO SYSTEM CONTROL L 1 Grasso Refrigeration Division 1 2 1 Key assignment Change to the next display window F2 F3 Go to the menu item described in the text display directly above a Switch on the compressor unit start enabled SE Start 1 compressor Press key for 5 sec in operation mode Manual Increase capacity of 1 compressor In case of manual capacity control only Start 2 compressor Press key for 5 sec in operation mode Manual Increase capacity of 2 compressor In case of manual capacity control only No function 4 Call up display of actual values SS Call up alarm signals Lamp test Switch off the compressor unit start disabled Stop 1 compressor Press key for 5 sec in operation mode Manual Reduce capacity of 1 compressor In case of manual capacity control only Stop 2 compressor Press key for 5 sec in operation mode Manual Reduce capacity of 2 compressor In case of manual capacity control only Bl 0 TS No function Call up controls settings
18. Attention 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 xx 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 E key The errors that have occurred can be viewed here with the date and time at which they occur For more detailed explanations for reading the error messages see Chapter 1 2 2 2 07 09 2006 Rev 1 510116E_chapter7 doc Kap 7 3 r GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 7 3 Information from the controls in case of a system error 7 3 1 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 e SPS hardware faults e Firmware errors e Program errors e Parameterising errors e Computational errors e Time errors e Faulty internal memory storage e Battery failure or the standby supply is missing while MAINS ON e 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 E There is no alarm message in the display If a system error occurs i
19. Call up operating mode setting Call up the menu overview Return or cancel input Acknowledge reset failure and warning Confirm input Press the button once for display of a help text In some screens two levels of help are available by pressing the button twice Switch over to the 2 keyboard level Cursor keys gt 07 09 2006 Rev 1 510116E_chapter1 doc Chap 1 3 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division S Functions for F1 F4 keys These functions are only available if the symbols can be seen in the display lt lt Back to previous display Go to the menu item described Ea gt gt Move to next display Standard function of the shift keys Change between the possible selections 1 or 2 compressor or Alter the display contrast E Special function of the shift key Change to the Status display Change to the Language selection or Contrast menu Change to the Digital inputs outputs display Change to the Transfer menu Attention stop with esc Change to the Password menu Change to the Date Time menu 1 2 2 1 Password level The access rights within the menu structure are protected by different passwords Hill 2 S E H R wA 15 sary 30 SHIFT g 1 2 2 Menu structure The operator is asked to enter a password when they try to enter a command The password consists
20. ESC Press key The following selection appears on the display Duopack Sequence control Limits Time set Press E once Select Timer settings The following selection appears on the display Start delay 120 Stop delay 120 Time Setting 1 2 gt gt Times valid for the 2 subsequent compressor only Depending on the requirements the default parameters for the plant conditions can be adjusted here gt gt Press once page forward to next image The following selection appears on the display Force start dly 600 Force stop dly 600 max hrs diff 99h lt lt Time Setting 1 2 Depending on the requirements the default parameters for the plant conditions can be adjusted here 2 9 Restarting performance following power supply failure e Following power failure the GSC requires a short time delay for self checking e During this delay the package cannot be started e When this timer has expired and no new alarms are present the alarm output is reset s Ifthe package is in remote control it cannot be requested to start until this timer has expired s Ifthe package is in control modes 1 2 or 3 it has to be started manually This prevents several packages starting together Start to start Stop to start Time Setting 01 gt gt Kap 2 30 510116_chapter2 doc 21 05 2008 Rev 2 SA ud Grasso Gesch ftsbereich K ltetechnik 2 10 Turn on Turn off sole
21. Enter the correct calibration value Replace sensor Alarm 19 Discharge pressure too high This alarm is activated if the dis charge pressure is higher than the Pdis hi alarm limit value Discharge pressure is too high Pdis hi alarm is set too low The sensor has not been correctly calibrated in the configuration menu Sensor defective Remove cause for the high dis charge pressure in the refrigerating plant Change Pdis hi alarm to a suitable value Enter the correct calibration value Replace sensor Alarm 20 Discharge temperature too high This alarm is activated if the dis charge temperature is higher than the Tdis hi alarm limit value Discharge temperature is too high Tdis hi alarm is set too low The sensor has not been correctly calibrated in the configuration menu Sensor defective Remove the cause for the high discharge temperature Change Tdis hi alarm to a suitable value Enter the correct calibration value Replace sensor Alarm 21 Oil temperature too high This alarm is activated if the oil tem perature is higher than the Toil hi alarm limit value Compressor oil temperature is too high The Toil hi alarm is set too low The sensor has not been correctly calibrated in the configuration menu Sensor defective Remove the cause for the high compressor oil temperature Change
22. Line Oil filt sensor use the and keys to select whether an oil filter pressure sensor is used SHIFT Line Sensor position Use the and 7 keys to select whether the oil filter pressure sensor is fitted at Pos 395 or 495 F gt gt Press once The following selection appears on the display Oil level high no Oil level low no lt lt Configuration gt gt SHIFT Line Oil level high use the and 7 keys to select whether an oil level sensor is installed for a too high level in the oil separator Y HIFT Line Oil level low use the and Y keys to select whether an oil level sensor is installed for a too low level in the oil separator F gt gt Press once page on to the next image The following selection appears on the display Unit type Package CH inlet sensor no lt lt Configuration gt gt 12 11 2004 Rev 0 510116E_chapter3 doc Chap 3 1 re GRASSO SYSTEM CONTROL La 4 Grasso Gesch ftsbereich K ltetechnik SHIFT Line Unit type use the and Y keys to select whether a compressor unit DX chiller or an FX chiller functionality is required SHIFT Line CH inlet sensor use the and Y keys to select whether a sensor is installed for the secondary refrigerant inlet temperature H gt gt Press once The following selection appears on the display Profibus no Economiser without Eco sensor no lt lt Configuration gt gt
23. Suitable cable connectors are required to connect the bus cable Within a Profibus network all configured stations have to be connected A two core double shielded bus cable is used as a connection cable between the individual bus stations The stations are connected to each other analogue to the MPI Bus The Profibus DP communication can be used by the customer for reading the following values out of the screw compressor package Chiller All analogue values pressures temperatures slide position etc Remaining waiting times Active warning and alarm messages Status messages Furthermore by sending control commands over the Profibus DP communication remote control of the screw compressor package Chiller is possible 64 Diagnose E customer Figure 5 4 DP DP Coupler and the DP address settings The slave address for the two slaves is set independent of each other with DIP switches that are located on the top side of the device The DP 1 address is for Grasso usage only The default setting for the DP1 address is 21 see figure 5 4 The customer must use the DP2 address for Profibus DP communication where the address can be set freely in accordiance of the customers network configuration Notice that the valid address range is 1 through 124 only Other addresses are not valid within a Profibus DP network A change of Profibus address becomes active after switching OFF ON the coupler first When adjusting th
24. aA no Pr RP WYN rr GRASSO SYSTEM CONTROL L 1 Grasso Refrigeration Division 4 SYSTEM DESCRIPTION GSC 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 1 2 Fig 1 3 Meaning of the status and error displays Display Meaning Explanation SF red C7 CPU centralised Lights up for fault Hardware errors Firmware errors Programming errors 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 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 Voltage supply S 5 green for C7 lights up if the internal DC 5V supply is OK FRCE Force application c SIE yellow Pe lights up if a force application is active RUN Operating state lights up if the C7 CPU application program is running green SNOT CRU 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 Operating state lights up if the C7 is not processing a CPU application program iat is Ad flashes
25. actual RPMs in the GSC see menu 50 configuration Adjust one of the timers accord ingly Adjust the scalings ranges of the inverter and the GSC accordingly Alarm 14 Virtual bushing position not reached Is for a SP Duo a virtual limitation bushing activated in the GSC see menu 10 figure 4 then the capac ity slide must reach this Limitation slide position within a certain moni toring time Movement of capacity slide is too slow Instead of the operation with a virtual limitation bushing the com pressor is equipped with a me chanical limitation bushing Check if oil diifferential pressure is sufficient for a proper slide move ment The function of the virtual limita tion bushing in the GSC must be deactivated contact Grasso Ser vice Kap 6 6 510116_chapter6 doc 22 05 2008 Rev 1 rr ud Grasso Refrigeration Division Display message Explanation Alarm 17 Suction pressure too low This alarm is activated if the suction pressure falls below the Psuc low alarm limit value Possible cause of the alarm Suction pressure is too low Psuc low alarm limit is set too high The sensor has not been correctly calibrated in the configuration menu Sensor defective GRASSO SYSTEM CONTROL Alarm clearance Remove cause of low suction pres sure in the refrigeration plant Change Psuc low alarm limit to a suitable value
26. 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 line termination resistance Figure 5 3 Bus cable connectors and PG junction box A two core double shielded bus cable is used as a connection cable between the individual bus users The MPI communication can be used by the customer for reading the following values out of the screw compressor package Chiller All analogue values pressures temperatures slide position etc Remaining waiting times Active warning and alarm messages Status messages Furthermore by sending control commands over the MPI communication remote control of the screw compressor package Chiller is possible 07 09 2006 Rev 6 637700E_chapter5 doc Kap 5 3 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 5 2 2 Explanation of the Profibus If the GSC is to be incorporated in a Profibus DP network this must be taken into consideration at the time of the order as additional modules have to be installed Profibus DP DP coppler The Profibus DP DP coppler consists of a 9 pin Sub D jack at the communications processor module
27. defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module Alarm 10 Broken wire oil pressure after oil filter sensor The GSC has detected a loose wire or short circuit in the oil filter pressure sensor P amp ID position no 395 or 495 The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module 22 05 2008 Rev 1 510116_chapter6 doc Kap 6 5 rr ed Grasso Refrigeration Division Display message Explanation Alarm 11 Difference oil pressure discharge pressure too high Remains during start up the differ encial pressure between oil filter pressure P amp ID position no 395 equivalent to pressure at balance piston and discharge pressure of the started compressor P amp ID position no 105 x equivalent to pressure at the face end of the rotor too high then there is the risk that the bal ance piston is overloaded and therefore the compressors gets damaged Therefor the start up is stopped after a cer
28. diff press OK Oil diff run timer active allowed Fixed oil pressure safety delay internal 2 3 4 5 6 T Low oil pressure alarm If 3 Energising of capacity control solenoids and If 2 Oil diff press not OK Then 4 Oil diff run timer active If 4 Oil diff run timer elapsed and If 2 Oil diff press not OK Then 6 Fixed oil pressure safety delay active Then 3 De energising of capacity control solenoids If 2 Oil diff press OK and If 6 Fixed oil pressure safety delay not elapsed Then 5 Energising of capacity control solenoids allowed 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 11 FA GRASSO SYSTEM CONTROL LL Grasso Gesch ftsbereich K ltetechnik 2 7 1 3 Switching sequence in case of too low oil differential pressure alarm during running For Small and Medium compressors with internal oil pump Feedback compressor motor ON Oil diff press OK Energising of capacity control solenoids Oil diff run timer active Energising of capacity control solenoids allowed Fixed oil pressure safety delay internal Low oil pressure alarm 7 If 3 Energising of capacity control solenoids and If 2 Oil diff press not OK gt Then 4 Oil diff run timer active If 4 Oil diff run timer elapsed and If 2 Oil diff press not OK gt Then
29. dly operates The parameters for oil draining and return are found in menu 30 Timer settings Oil return Return delay lt lt Time values CH Oil drain Drain delay lt lt Time values CH gt gt Kap 2 32 510116_chapter2 doc 21 05 2008 Rev 2 L GRASSO SYSTEM CONTROL EL Grasso Gesch ftsbereich K ltetechnik 3 INITIAL START UP 1 3 1 Compressor coolant and sensor selection 1 3 2 Parameterise options 3 3 Adjusting the limiting values 3 4 Adjusting the control values A A BR W 3 5 Check the generator unit sensor technology 12 11 2004 Rev 0 510116E_chapter3 doc rr GRASSO SYSTEM CONTROL La 4 Grasso Gesch ftsbereich K ltetechnik 3 INITIAL START UP 3 1 Compressor refrigerant and sensor selection Press Select the main menu 50 Configuration r F gt gt Press once The following selection appears on the display Refrigerant R717 Comp type P Vi code Fixed lt lt Configuration gt gt SHIFT Line Refrigerant select the refrigerant with the and Y keys Y Line Comp type select the compressor type with the and keys SHIFT Line Vi code read off the Vi code from the compressor rating plate and select here with the and Y keys gt Press once page down one image The following selection appears on the display Oil filt sensor yes Sensor position 395 lt lt Configuration gt gt SHIFT v
30. malfunction during the starting operation If gt Then If gt Then If and If gt Then If and If gt Then gt Then Kap 2 14 Start conditions fulfilled 1 Output oil pump ON Oil diff start timer active Oil diff run timer active Low oil pressure alarm 1 2 2 4 4 3 5 5 3 6 2 Oil diff press OK NE o A W IN O Start conditions fulfilled Output oil pump ON Output oil pump ON Oil diff start timer active Oil diff start timer elapsed Oil diff press not OK Oil diff run timer active Oil diff run timer elapsed Oil diff press not OK Low oil pressure alarm Reset of the output oil pump ON 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL La Z Grasso Gesch ftsbereich K ltetechnik 2 7 2 3 Switching sequence in the case of malfunction in the operating condition Output oil pump ON 1 Oil diff press OK Oil diff start timer active Oil diff run timer active a A W JN Output compressor motor ON Low oil pressure alarm O If 2 Oil diff press not OK gt Then 4 Oil diff run timer active If 4 Oil diff run timer elapsed and e If 2 Oil diff press not OK Then 6 Low oil pressure alarm Then Reset all actuating signals Ld 21 05 2008 Re
31. meaning No 24V supply voltage a 24V supply is applied and is OK o Device is running operation possible w The device is still in the initialisation phase Grave error in device exchange HW if necessary Operation is not possible o No messages are running on Network 1 T Messages are running on the PROFIBUS DP Network 1 w o fault o No messages are running on Network 2 E Messages are running on PROFIBUS DP Network 2 w o fault LED off LED on LED irrelevant Bo 07 09 2006 Rev 1 510116E_chapter7 doc Kap 7 7 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 7 3 3 Periphery bus coupler After switching on the bus coupler immediately checks the connected configuration During this self test all functions of the connected terminals and the communication with the input and output modules are tested During this phase the red I O LED flashes Error free start up is signalled by extinction of the red LED I O ERR Figure 2 Periphery bus coupler with system LEDs On the upper right hand side of the bus coupler are two more green LEDs that indicate the voltage supply The left hand LED indicates the 24V supply of the bus coupler The right hand LED signals the supply to the power contacts The system LEDs on the front side of the bus coupler have the following meaning RUN BF red DIA red Meaning green
32. of a 4 figure number Each password level has a different number allocated to it The passwords for Levels 1 to 8 can be freely allocated by the user 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 Chap 1 4 510116E_chapter1 doc 07 09 2006 Rev 1 re GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division E The following password levels have been allocated Password level 1 Operator level Change to the set point values possible Password level 2 Only for authorised persons Changes to all limiting values timers possible in addition to Level 1 Password level 9 Service level Changes in the configuration menu possible in addition to level 2 1 2 2 2 General image format The image format is identical in all the images parameter text 1 parameter text 2 parameter text 3 Menu title 01 gt Back next Depending on the menu the actual or set point values are displayed in the 3 top rows The names of the selected menu and of the selected compressor 1 or 2 are displayed again in the lowest row 4 i gt The double arrows Fe or mean that you can move to the previous menu display E lt or the next menu gt display by pressing the key under this symbol If a menu is selected
33. off m LEDon m LED flashing slowly gt LED flashing quickly a LED additional information 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 Item 4 2 07 09 2006 Rev 1 510116E_chapter7 doc Kap 7 5 FEA GRASSO SYSTEM CONTROL Lh Y Grasso Refrigeration Division Option 4 The SE RUN and BATF LEDs are alight The alarm signal LED is flashing The application program continues to run the compressor is not switched off A warning message appears in the display 2 warning message identification of 2 compressor Fault The program battery is flat Fault correction Replace the battery FI H lt lt gt gt E LED irrelevant LED off LED on gt m LED flashing slowly m LED flashing quickly a LED additional information Bo Kap 7 6 510116E_chapter7 doc 07 09 2006 Rev 1 rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division 7 3 2 Profibus DP DP coupler Figure 1 Profibus DP DP coupler The LEDs on the front side of the DP DP coupler have the following
34. required when outside these operating limits 5 1 Types of sensors used Pressure transducer Passive electrical 2 wire measuring transducers with a output signal of 4 20 mA are used to measure all pressures Pt100 with top assembly sensor transmitters are used to measure temperatures Temperature detectors The passive 2 wire measuring transducers located in the connection head of the Pt 100 supply an output signal of 4 20 mA Position sensor Type HDT The position sensor Type HDT is an active pick up which produces an output signal of 4 20 mA Motor current An active 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 An active or passive current signal of 4 20 mA is required to evaluate an external value temperature value Scaling the range limits see Chapter 3 For description of the components used see separate documentation 07 09 2006 Rev 6 637700E_chapter5 doc Kap 5 1 r GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 5 2 Extended data communication interfaces The GSC is equipped with an MPI interface as a standard This interface can be used to connect up to 32 users to each other As this interface is an internal Siemens interface with multi point capability it can only be used b
35. switched off Stop to start 01 02 Start delay between stop and next start is active Failure 01 02 A failure has occurred which is still active italic writing Text display flashes Normal writing Text display is static 07 09 2006 Rev 1 510116E_chapter1 doc Chap 1 17 pead GRASSO SYSTEM CONTROL Lh Y Grasso Refrigeration Division The overall status of the compressor unit is displayed with the LEDs in and ro Key Colour Status Explanation gt The Grasso SPduo has received a start request Green Flashing One compressor may start One compressor is running The Grasso SPduo is switched off there is an alarm active The alarm light on the cabinet is active Red Continuous light The Grasso SPduo is switched off Chap 1 18 510116E_chapter1 doc 07 09 2006 Rev 1 re GRASSO SYSTEM CONTROL ud Grasso Gesch ftsbereich K ltetechnik 2 Control sequence 1 2 1 Overview of the operating modes 1 2 2 Explanation of symbols and characters used 2 2 3 General starting conditions 2 2 3 1 Start to start timer anti recycle timer 3 2 3 2 Stop to start timer 3 2 4 Start up sequence 4 2 4 1 Small and Medium Screw Compressor Packages 4 2 4 2 Large Screw Compressor Packages 5 2 5 Switch off sequence 6 2 5 1 Switching off sequence in the normal case and in case of slide failure 6 2 5 2 Switching off sequence in case of an alarm small and medium screw compressor packages 7 2 5 3 Switching off sequence in ca
36. switchover takes place due to a potential free contact The active set point value is displayed Active SP Active SP Active set point in C Neutral Zone Neutral Zone Neutral zone of the automatic capacity regulation in K Hysteresis Hysteresis Hysteresis of the automatic capacity regulation in K lt lt Control 01 02 gt gt Load pulse Load pulse Length of pulse to load compressor in secs Unload pulse Unload pulse Length of pulse to unload compressor in secs Pulse interval Pulse interval Interval between pulses to load or unload the compressor lt lt Control 01 02 gt gt in secs Auto start dly Auto start dly Length of delay in sec before automatic start up Auto stop pos Auto stop pos Compressor stops when capacity slide is below this position in automatic control lt lt Control 01 02 1 2 3 3 Operating mode menu 15 Operating modes 01 Manual Manual Switchover operating modes Manual Start Stop T Operating mode gt gt Select the operating mode using and or Confirm selection with era Example shown is operating mode type 01 Manual stop start and manual capacity control Please refer to section 2 1 Control on Control on Choose between Press and Temp Direction Direction Choose between Cooling and Heating lt lt Operating mode a v Select the operating mode using and or Confirm selection with ere C
37. the Toil hi alarm to a suit able value Enter the correct calibration value Replace sensor Alarm 22 Slide to min time too long This alarm is activated if the capacity slide does not reach its Minimum position after the strt stop signal within the setted time 22 05 2008 Rev 1 The Slide to min timer setting parameter is too short The capacity control solenoids for capacity reduction are not energis ing Oil pressure too low The throttle screws for adjusting the setting speed are closed 510116_chapter6 doc Set the Slide to min timer setting to 180 sec Check the function of the capacity control solenoids both electrically and mechanically Correctly set the oil pressure in accordance with the operating instructions for the compressor unit Correctly adjust the throttle screws in accordance with the operating instructions for the compressor unit Kap 6 7 rr ed Grasso Refrigeration Division Display message Explanation Possible cause of the alarm The capacity slide is sticking GRASSO SYSTEM CONTROL Alarm clearance Check the capacity slide change the seal s Alarm 23 High motor current This alarm is activated if the motor current is higher than the Imot high alarm limit value Motor current too high The Imot high alarm is set too low The sensor has not been correctly calibrated in the config
38. the alarm is acknowledged and 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 Not used Displays how many alarms have been stored and how many are still active All the alarm signals stored in the buffer can be deleted When switched off it enables a new alarm message to be displayed even if the fault buffer is full Display of all possible alarm messages with alarm number see section 6 for details of possible alarms Chap 1 11 re B Grasso Refrigeration Division 1 2 3 6 30 Timer Settings Timer Settings menu Start to start Stop to start Time Setting 01 02 gt gt Oil diff start Oil diff run Oil level dly lt lt Time Setting 01 02 gt gt Pump by itself Oil drain lt lt Time Setting 01 02 gt gt Slide to min Motor feedback Lad level dly lt lt Time Setting 01 02 gt gt Pump feedback Flow swtch dly lt lt Time setting CH gt gt Oil drain Drain delay lt lt Time values CH gt gt Oil return Return delay lt lt Time values CH Chap 1 12 Start to start Stop to start Oil diff start Oil diff run Oil level dly Pump by itself Oil drain Slide to min Motor feedback Lad level dly Pump feedback Flow swtch dly Oil drain Drain delay Oil r
39. 0 0 0 0 0 5 0 038 Alarm 38 High liquid level Alarm 40 Low oil pressure Alarm 41 Oil filter blocked 0 z 0 c 0 f 0 0 0 3 0 1 Alarm 23 High motor current 5 1 035 Alarm 35 Emergency switch or safety chain has responded 1 1 5 1 L 0 Warning 5 Oil temperature is too high Warning 13 Broken wire ECO temperature 062 Warning 14 Broken wire Chiller inlet temperature Warning 7 High motor current Warning 12 Broken wire ECO pressure 5 5 5 l 5 S 5 6 6 6 Warning 15 Broken wire Frequency value Warning 16 Oil separator level too high 065 Warning 17 Pre alarm oil filter 22 05 2008 Rev 1 510116_chapter6 doc Kap 6 3 Alarm 44 Flow switch secondary refrigerant circuit has responded rr ed Grasso Refrigeration Division GRASSO SYSTEM CONTROL 066 Warning 18 No feedback from refrigerant pump motor Chiller only 067 Warning 19 No feedback from condenser system fans or pumps 069 Warning 21 Program buffer battery empty 070 Warning 22 Oil separator level too low 66 071 072 6 3 Warning 23 Broken wire motor current transformer Warning 24 Broken wire suction temperature sensor e O Description and diagnosis of alarm messages 167 2 Identification of alarm messages and warning massages of the 2 compresso Alarm 1 Broken wire suction Pressure sensor The GSC has detected a loose wire or short circuit in the suction pressure
40. 60 395 400 01 02 MAIN SWITCHGEAR CABINET Additional output signals Start motor Start oil pump Ready Running No alarms Explanation Discharge temperature sensor Oil temperature sensor HP switch KP7 ABS Minimum oil level switch Oil heater Oil pressure after filter sensor Maximum oil level switch Compressor 1 Compressor 2 510116E_foreword doc ae Figure 0 2 P amp ID Foreword 3 rr L 1 Grasso Refrigeration Division 1 DESCRIPTION OF THE GRASSO SYSTEM CONTROL 1 1 Grasso System Control General 1 1 1 View 1 1 2 Lamps Push buttons 1 2 Operator terminal 1 2 1 Key assignment 1 2 2 Menu structure 1 2 2 1 Password level 1 2 2 2 General image format 1 2 3 Call up table of contents 1 2 3 1 Actual values menu 1 2 3 2 Control settings menu 1 2 3 3 Operating mode menu 1 2 3 4 Limit values menu 1 2 3 5 Alarm menu 1 2 3 6 Timer Settings menu 1 2 3 7 Unit options menu 1 2 3 8 Configuration menu 1 2 3 9 Main system Menu 1 3 Status display 07 09 2006 Rev 1 510116E_chapter1 doc GRASSO SYSTEM CONTROL WO GO GO Gn A n E A WN FA GRASSO SYSTEM CONTROL La 1 Grasso Refrigeration Division 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 direc
41. 8 kByte 8 bit Memory card 6ES7 951 0KG00 0AA0 Capacity 4 4 2 Installation of the Siemens SIMATIC C7 memory card The memory card is installed by carrying out the following steps Step Procedure 1 Turn off the power of the PLC This can be done by unplugging connector X1 on the PLC Placement of the Author connection Bridge connections A and AE on connector X1 see Figure 4 1 Bridge at the authorisation input 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 like shown in Figure 4 3 Positioning of the memory card 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 Figure 4 4 Furthermore the PLC will show message 551 SPS Adresse 2 nicht vorhanden or AS address 2 not possible Chap 4 4 510116E_chapter4 doc GRASSO SYSTEM CONTROL Ansicht
42. A Time characteristic of PV B Time characteristic of the 3 point controller outputs C Time characteristic of the pulse t generator D Time characteristic of the pulsed outputs to the capacity control solenoid valves TERR Bani ooo A O ON 2 7 Safety control Alarms warnings and limitations The following types of alarms will activate the alarm output signal e Oil system alarms e Minimum Maximum limits reached e Compressor and oil pump motor s start equipment alarms e Hardware or sensor failures e Safety timers exceeded The formation of a limit value signal is illustrated in the following diagram PV A Time characteristic of the process value B Warning output Offset C Alarm output A Lim Alarm limit of the process Lim value PV Process value B Offset Warning limit C 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 9 FA GRASSO SYSTEM CONTROL LL Grasso Gesch ftsbereich K ltetechnik 2 7 1 Oil system monitor of the small and medium screw compressor packages The oil system monitor is responsible for monitoring the oil system The package is switched off if alarms occur The difference between the oil pressure and the discharge pressure is monitored 2 7 1 1 Switching sequence in the normal case Capacity slide in Minimum 1 position Output compressor motor ON If gt Then If gt Then If and If gt Then Start conditions fulfilled Oil diff star
43. Bewer 15 3 881715 is dd 16 Contacts ve vd on ov mo s 17 a 38 18 Wids 18 g Hie 24V DC Top View Contact Assembly Connection Figure 5 6 Digital input terminal with 8 channels 07 09 2006 Rev 6 637700E_chapter5 doc Kap 5 5 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 5 3 3 Analogue input terminals The GSC is equipped with several types of analogue input terminals The standard input signals use 4 20mA signals The KL3054 terminal is used for the 4 20mA signals The job of the analogue input terminal with sensor supply is to supply power to measuring transducers located in the field and to transmit analog measurement signals with electrical isolation to the automation device The voltage for the sensors is supplied to the terminals via the power contacts The input electronics is independent of the supply voltage of the power contacts The 0 V rail is the reference potential for the inputs The RUN LEDs give an indication of the data exchange with the Bus Coupler The error LEDs indicate an overload condition and a broken wire The KL3054 version combins 4 channels in one housing RR Error LED1 eo e Error LED2 Error LEDI t eo I e Error LEDS ka HO N ze imputt___ RR 1 Input 2 elite TE Z EE y Ground EE Ground olla input3_ H I A ur a wi ms Ground ly Ba lt Ground oa u 2 Top view Contact assembly Connection Figure 5 10 Analogue input termina
44. CA ed Grasso Gesch ftsbereich K ltetechnik 2 7 3 8 LOW external temperature alarm GRASSO SYSTEM CONTROL Text External temperature T ext b Text limit begin e Text limit end W Text low warning Al Text low alarm V Capacity control solenoids Y2 amp Y3 energised ML W Warning message ML A Alarm message V A Text limitation effective ML W B Text low warning C Text low alarm ML_A D No alarm generated A B C D External temp Text low alarm Low warning lt lt Limit values 01 gt gt Kap 2 22 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 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL La Z Grasso Gesch ftsbereich K ltetechnik 2 7 3 9 High discharge pressure limitation The discharge pressure limitation is intended to prevent a high discharge pressure alarm It does not become effective until the start up process has been completed If the discharge pressure reaches its initial limitation value the capacity of the compressor is reduced by energising capacity control solenoids Y2 amp Y3 The signal dominates compared to the capacity control and is effective until the discharge pressure has reached the end of the limit
45. HT EEE HET e EEE sensor postion a Potes O e EEE Potente BEE BEE BE e EEE a CH inlet sensor ss Dem E e Bu Een a ES Taa SI Configuration Ta Parameters for configuration values Rane Default _ Default setting _ Project setting setting Sensor a Suction ae Sensor Psuc Sensor scaling Oil os pF Sensor Sensor scaling ee press PF Sensor ae AA ERRE A mea oor a H Chapter 9 10 510116E_chapter9 doc 12 11 2004 Rev 0 rr GRASSO SYSTEM CONTROL L 1 Grasso Refrigeration Division Title Standard HotKey ee Configuration a Parameters for configuration values Range Default setting Project setting Sensor Eee ee temp 20mA equals a a 100 200 Sensor scaling Oil Sensor Toil se be ee E S Poms ea 0 00 200 Sensor scaling Slide a 20mA 20mAequals B00 Sensor scaling a_i current Sensor mot a Ama equals CC Sensor e Suction a Sensor Tue Sensor BE External On Sensor ret se ee E S om eno e ET FE Sensor scaling Oil filter ee HS a a mea oar oo fa H 12 11 2004 Rev 0 510116E_chapter9 doc Chapter 9 11 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division Title Standard HotKey et Configuration Seel Parameters for configuration values Range Default setting Project setting Sensor Vi position pf Sensor ff Vis l _ _ e ee O Eco pressure Sensor Peco me ten ee om caus b
46. Limit values 01 02 Toil hi alarm Inject begin Inject end lt lt Limit values 01 02 Fit diff press High alarm High warning lt lt Limit values 01 02 Oil diff press Low alarm lt lt Limit values 01 02 Chap 1 10 Text low alarm Limit begin Limit end Disch temp Tdis hi alarm High warning Tdis hi alarm Inject begin Inject end Oil temp Toil hi alarm High warning Toil hi alarm Inject begin Inject end Fit diff press High alarm High warning Oil diff press Low alarm 510116E_chapter1 doc GRASSO SYSTEM CONTROL Alarm limit for minimum external temperature in C Begin the temperature limitation enter value as an offset to the alarm value in K End the temperature limitation enter value as an offset to the alarm value in K Actual discharge temperature in C Alarm limit for maximum discharge temperature in C Enter the warning value as an offset to the alarm value inK Alarm limit for maximum discharge temperature in C Begin injection cooling if mounted enter value as an offset to the alarm value in K End injection cooling if mounted enter value as an offset to the alarm value in K Actual oil temperature in C Alarm limit for maximum oil temperature in C Enter the warning value as an offset to the alarm value inK Display the alarm limit in C Begin injection cooling if mounted
47. List of parameters see chapter 9 12 11 2004 Rev 0 510116E_chapter8 doc Chapter 8 3 rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division LIST OF PARAMETERS COMPRESSOR 1 Title Standard HotKey Actual values ACTUAL values of compressor unit data remaining times for timers eae Range Default setting Project setting Pema ls o seo A A Default setting Project setting ee cometas SS SS mes TE A Range Default setting Project setting A a l an a gang pseiom atom bart osons a0 towwerning tar gt aor ao0 oso imita i bar oono sos A ae A a ee AO Tem end f ao a0 if CS 12 11 2004 Rev 0 510116E_chapter9 doc Chapter 9 1 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division Title Standard HotKey APP ATA Range Default setting Project setting O mooramene O mapan aan fa 90 ao rwm a to o SS imita fa l oo o S Tm a S to s 7 Tei EEE SSCS Treo m re on ao roman gt 00 100 roo imita EK ooo io Tin TK ooo Taa temperature O O dT SCS O rimae O aoe oo S Ten warning e oeo so T e rono sso i monea i x soo oo Tamers i SR anaa pre oa mo CS wish warning e mao so maions sik sooo no mwone i x 100 ao onrterairereniatpresure dT Sid SS naaa tr ooo dT SCS Then warning o oo ao SSC
48. M CONTROL ed Grasso Gesch ftsbereich K ltetechnik 2 6 Compressor control 2 6 1 Capacity control All screw compressors from Grasso are equipped with an infinitely variable capacity control system in the geometric range 0 100 An external temperature or the suction pressure can be selected as the controlled variable The capacity is adjusted using a hydraulically adjustable regulating capacity slide adjustment of which results in a reduction in the effective rotor length of the compressor The definitive length of the rotor for the compression process is thus altered The position of the capacity slide is measured by a position sensor HDT path sensor The hydraulic adjustment of the capacity slide is controlled via 4 solenoid valves which are situated together in a block C Compressor mvy1 Mvy2 Lo V Solenoid valve block ers HDT HDT Path sensor controller a l C slider van 87 u lt a 4 ES PI The solenoid valves for capacity adjustment are operated in pulses by the GSC control and are switched in pairs Solenoid valve Y2 Energised Solenoid valve Y3 Energised Solenoid valve Y4 De energised Kap 2 8 510116_chapter2 doc 21 05 2008 Rev 2 A GRASSO SYSTEM CONTROL 4 Grasso Gesch ftsbereich K ltetechnik 2 6 2 Mode of operation of the capacity controller and of the subsequent solenoid valve pulses PV Process value SP Set point value NZ Neutral zone HYS Hysteresis
49. S Taranis o ionam fo dT SCS se pios SR maan aa BEE BEE BE A f l on TSC eow a omw o f eons ST omw s 7 Chapter 9 2 510116E_chapter9 doc 12 11 2004 Rev 0 rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division Title Standard HotKey e Time settings me Parameters for timer values Range Default setting Project setting A A Tran ann senos f 90 oo _ fours fs asis wo _ our ss ow o _ fone its o oo 0 _ omwen fs oan e sms ooo sta vo min e f T ooo woo motorteestoce e so 20 Trust IC A ICI IR Pump feedback remanso foram sts so mo C ornes its soo 10 A Ba a BE PD BE reumas Jo J wo le Unit options ME Parameters for optional values Default setting Project setting Values Parameter Sequence Control Value Parameter Economiser Values Parameter DX Control Selftuner Control Condenser Values Parameter 12 11 2004 Rev 0 510116E_chapter9 doc Chapter 9 3 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division Title Standard HotKey ee Configuration ae Parameters for configuration values Default setting Project setting A anan Tae O O O oo EEE Tee O TE SSS Taren BEE BEE EEG S C woe H H HT EEE HET e EEE sensor postion a Potes O e EEE Potente BEE BEE BE e EEE a CH inlet sensor ss Dem E e Bu Een a ES Taa SI Configuration Ta Parameters for configu
50. SIEMENS 20 MECO CAPO TASH 19 HR 3 RBT ric itar come C e Figure 4 2 Memory card MC 951 64 kB 5V FLASH 6ES7 951 0KF00 0AA0 alx ES Figure 4 3 Positioning of the memory card RUN H stop RUN Operation Figure 4 4 STOP 12 11 2004 Rev 0 rr GRASSO SYSTEM CONTROL L 1 Grasso Refrigeration Division Procedure Use the key in order to reset the memory a v 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 NI 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 S M g v 0 a Furthermore for a few seconds the STOP indicator will blink yellow 0 5Hz Subsequently this indicator will light yellow continuously Figure 4 4 Now the PLC operation mode key state S equals the actual PLC mode indicated by the STOP indicator D v 0 2 Figure 4 5 Sequence of operation mode key state indication Change the operation mode to RUN By using the upper key button the PLC operation mode H run can be changed into RUN Figure 4 5 STOP For a few seconds the RUN indicator will blink g
51. The wire is broken Digital input module defective Replace defective parts Reset the gas alarm system Check the terminal connections Replace the wire Replace the digital input module 510116_chapter6 doc 22 05 2008 Rev 1 rr ud Grasso Refrigeration Division Alarm 44 Flow switch secondary Refrigerant circuit has responded This alarm is activated if the input signal E 12 2 secondary refrigerant flow OK equals 0 and the time set ting Flow swtch dly has expired 22 05 2008 Rev 1 Secondary refrigerant pump is not running The flow sensor is defective The terminal connections have become loose The wire is broken The time setting Flow swtch dly is too short Digital input module defective GRASSO SYSTEM CONTROL A a a Start up the secondary refrigerant pump Replace the flow sensor Check the terminal connections Replace the wire Increase the time setting Flow swtch dly to a suitable value Replace the digital input module 510116_chapter6 doc Kap 6 11 rr ed Grasso Refrigeration Division 6 4 WET MS Warning 1 Suction pressure is too low This warning is activated if the suc tion pressure is less than Psuc lo alarm plus Low warning limit val ues Description and diagnosis of warning messages Possible cause Suction pressure is too low Psuc lo alarm plus Low warning s
52. are not yet saved in the EPROM Save Saves the set configuration in the EPROM For configuration settings to take effect you must choose both accept and save before escaping from this menu With save the configuration data is stored on the EPROM 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 510116E_chapter1 doc Chap 1 15 re B Grasso Refrigeration Division 1 2 3 9 Main system Menu 90 Main system Main system Events Alarms gt gt Main system Screens Records lt lt gt Main system StatVAR ForceVAR lt lt gt gt Main system System Password lt lt gt gt Main system menu DI DO RAM gt ROM lt lt Chap 1 16 Events Alarms Screens Records StatVAR ContrVAR System Password DI DO RAM gt ROM 510116E_chapter1 doc GRASSO SYSTEM CONTROL nu Further submenus View Print Number Delete Overflow Text Further submenus View Print Number Delete Overflow Text Further submenus Edit Print Further sub menus Edit Print Carry Status variables control variables values can be displayed in this menu Control variables control variables values can be altered in th
53. arning message ML A Alarm signal Imot limitation effective B High motor current warning Cc High motor current alarm D No alarm generated Motor current Imot high alarm High warning lt lt Limit values 01 gt gt Warning Kap 2 18 Motor current Alarm max GRASSO SYSTEM CONTROL V ET ML W ML A Actual motor current in A Alarm limit for maximum motor current in A Enter the warning value as an offset to the alarm value inA 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL hw Y Grasso Gesch ftsbereich K ltetechnik 2 7 3 5 LOW suction pressure limitation The suction pressure limitation attempts to prevent a low suction pressure alarm It does not become effective until the start up process has been completed If the suction pressure reaches its initial limitation value the capacity of the compressor is reduced by energising capacity control solenoids Y2 amp Y3 The signal dominates compared to the capacity control is effective until the suction pressure reaches the end of the limitation The suction pressure limitation function is illustrated in the following diagram Pi Suction pressure Psuc V Capacity control solenoids Y2 amp Y3 energised b Psuc low limit begin e Psuc low limit end W Psuc low warning Al Psuc low alarm A Start up N B Short
54. asso 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 GSC cP CPU DP Eco EPROM Ext HDT RF RF separator LED MAX MIN MPI MRES SV LVS OP PG PLC Slide Seq Slide Pos P amp ID sc SCP SC Type Description I Grasso System Control Type designation of the Grasso standard compressor control Communication processor Central processing unit Decentralised periphery Economizer Erasable programmable read only memory External Hermetically sealed differential transformer Refrigerant Refrigerant separator Light emitting diode Maximum Minimum Multi Point Interface Siemens internal interface with multi point capability on the GSC used for communication between several controls Memory Reset Solenoid valve Low Voltage switchgear switchgear with power contactors for compressor motor oil pump and oil heating i Operator panel control and display device Programming device Programmable logic controller Primary slide position in the sequencing control Primary slide position Pipe and instrumentation diagram Screw Compressor Scre
55. at 1 second intervals if C7 CPU general reset MRES is required SF IM red Switching module lights up if the connection between C7 and the extension rack is centralised fault interrupted A red Alarm active lights up if a malfunction has been confirmed but is still active flashes if a further malfunction has been activated Hep Help textavellable lights up if a help text is available green shift Wih veka lights up if the SWITCHOVER function is active green function active 12 11 2004 Rev 2 510116E_chapter4 doc Chap 4 1 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division Display elements for Profibus BUSF Meaning green On Bus error physical defect Check the bus cable for a short circuit or breakage DP interface error for various baud Analyse diagnosis if necessary replan the rates in multimaster mode project or correct error On Flashes Station failure Check the bus cable for correct connection short circuit or breakage At least one of the allocated slaves Wait until the C7 has completed the start up cannot be contacted if the flashing doesn t stop check the DP slaves and analyse diagnosis Missing or faulty DP project Analyse diagnosis if necessary replan the planning event is CPU has not been project or correct error parameterised as the DP master No error 4 2 C7 CPU Selection of the operating mode Change the C7 CPU operating mode The CPU ope
56. ation The discharge pressure limitation function is illustrated in the following diagram Pas Discharge pressure Pdis V Capacity control solenoids Y2 amp Y3 energised b Pdis limit begin b Pdis limit end W Pdis high warning Al Pdis high alarm y A Start up A B C D B Short term limitation C Intermittent limitation D Shut down procedure no limitation Pdis high alarm Pdis high alarm Alarm limit for maximum discharge pressure in bar a Limit begin Limit begin Begin the discharge pressure limitation Limit end enter value as an offset to the alarm value in bar lt lt Limit values 01 gt gt Limit end End the discharge pressure limitation enter value as an offset to the alarm value in bar 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 23 FA GRASSO SYSTEM CONTROL LL Grasso Gesch ftsbereich K ltetechnik 2 7 3 10 High discharge pressure alarm Pais Discharge pressure Pdis b Imot limit begin e Imot limit end 4 2 a W Imot high warning b J l Al Imot high alarm l i V Energise capacity control solenoids Y2 amp Y3 MLW Warning signal y O ML A Alarm signal E A Pdis limitation effective ML W BE 8 B High discharge pressure warning ML A na Ci High discharge pressure alarm A B C D No alarm generated Disch pressure Disch pressu
57. bereich K ltetechnik 2 CONTROL SEQUENCE 2 1 Overview of the operating modes Name Explanation GRASSO SYSTEM CONTROL Start Stop Capacity Service Oil pump by itself Compressor motor blocked Manual Manual Manual control via OP Manual Manual Manual Auto Manual Start Stop via OP and full automatic local capacity control Manual Auto Auto Auto Full automatic Start Stop and local capacity control Auto Auto 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 continuous 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 External External pulses 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 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 Remote Net cont Start stop and capacity demand via
58. bus Possible cause of the alarm Oil pressure is too low The Oil diff min limit value is set too high The sensor has not been correctly calibrated in the configuration menu Sensor defective The delay time is too short Discharge pressure is too high GRASSO SYSTEM CONTROL Alarm clearance Remove the cause for the low oil pressure at the compressor Reduce the Oil diff min limit to a suitable value Enter the correct calibration value Replace sensor Increase the time setting Oil diff start for the start up phase or Oil diff run for the running phase Remove the cause for the high dis charge pressure at the compressor Oil filter is blocked The Fit diff press hi alarm limit value is set too low The sensor has not been correctly calibrated in the configuration menu Sensor defective The delay time Oil diff run or Oil diff start is too short Replace the oil filter cartridge Increase the alrm limit to a suitable value Enter the correct calibration value Replace sensor Increase the time setting Oil diff run or Oil diff start to a suitable value Alarm 43 Refrigerant leak detected This alarm is activated if the input signal E 1 2 gas sensor equals 0 Kap 6 10 Bus cable broken or plug in connec tor defective Gas alarm system is active The terminal connections have become loose
59. cases this value is neglected 3 In case of motor current limitation and 1 compressor running only the next compressor is forced to start after start delay time fixed additional time 90 sec 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 25 FA GRASSO SYSTEM CONTROL LL Grasso Gesch ftsbereich K ltetechnik CAPACITY INCREASE NORMAL SITUATION 1000 kw Capacity demand 500 kw O Kw stan delay MAX sow Comp 1 Inverter MED x MED ECO Nmin D KW MAX 1400 kw Comp 2 PS 100 Nmax Switch delay Switch delay 0 KW O PS MED PS 100 Diagram 1 Capacity increase normal situation 0 Start compressor 1 equipped with frequency inverter at minimum speed and control slide up to 100 Next activate economizer 1 Increase compressor capacity by increasing the motor speed up to maximum speed 2 Wait until start delay has elapsed and start 2 compressor without frequency inverter 3 The 2 compressor is forced to Part load regardless of set point and process value During this time compressor 1 is in control a If less capacity is needed compressor 1 will reduce capacity b If more capacity is needed compressor 1 will stay at 100 with maximum speed 4 After that compressor 2 has reached the desired Part load for more than switch delay time compressor 1 is forced to reduce capacity part load and compressor 2 takes over control 5 As soon as com
60. cess value This situation equals points 7 and 8 at capacity increase normal situation Capacity demand decreases and compressor 2 decreases capacity during the time that compressor 1 is forced to Part load As long as the capacity of compressor 2 is more than the Part load nothing special happens This situation is equal to points 5 and 6 of capacity increase normal situation or points 2 and 3 of capacity decrease normal situation Capacity demand decreases dramatically and compressor 2 decreases capacity below the Part load before or after compressor 1 has reached the Part load In this case compressor 2 will be shut off after stop delay time and this situation equals points 4 5 and 6 of capacity decrease normal situation Kap 2 28 510116_chapter2 doc 21 05 2008 Rev 2 re GRASSO SYSTEM CONTROL ud Grasso Gesch ftsbereich K ltetechnik 2 8 2 Determination of the starting sequence The screw compressors are switched on or off according to a fixed starting sequence The start sequence 1 gt 2 or 2 gt 1 is defined at the terminal Menu 35 Duopack sequence control limits If a compressor fails another automatically takes up its function if available The compressor start sequence within the sequencing control plays a major role It determines the order in which the sequencing control logic selects the compressor for power adjustment or for switching on and off A start se
61. ched on Warnings are signalled optically by the indicator light amber Warning LED red A and text message in the display Note Warnings are automatically reset after the cause has gone 6 1 3 View active alarms and warnings ESC 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 4 row the status message is shown By scrolling with the cursor keys a and M all active alarms and warnings are displayed 22 05 2008 Rev 1 510116_chapter6 doc Kap 6 1 rr GRASSO SYSTEM CONTROL ed Grasso Refrigeration Division 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 Alarms View The alarm No date and time and status of the alarm are di A Acknowledged C Come G Gone View Print s5 If the cursor is pointing to the alarm No the alarm text can Print no stored function Alarms Number Displays how many alarms have been stored and how many are still active Number Delete Delete All the fault signals stored in the buffer can be deleted folk lt lt I gt gt Alarms Overflow Enables a message to be displayed even if the fault buffer Text Display all possible alarm messages with alarm No Overflow Text
62. condary refrigerant pump and the condenser system are thus released The GSC at digital inputs E 12 0 and E 12 1 accepts feedback signals to ensure that these systems are in operation If no feedbacks are received within the set times the GSC passes into a warning condition and the package starts up 2 The GSC monitors the secondary refrigerant flow by means of o flow switch input E12 2 Once the secondary refrigerant pump has been released to start the GSC must receive this input within the timer setting Flow swtch dly If the input is not made within this time the GSC passes into an alarm condition and the unit stops Pump feedback Flow swtch dly lt lt Time setting CH gt gt 3 The start up procdure for the screw compressor package is not initiated until the flow in the secondary refrigerant cicruit is established 2 11 2 Oil draining and return The FX range of chillers have an oil return from the evapaorator The oil is returned to the comprerssor from the evaporator via 2 solenoid valves 1 After start up of the compressor an oil draining phase operates the solenoid valve position number 2305 opens for the duration Oil drain 2 After the oil draining phase the timer Oil drain dly operates 3 After the oil drain delay the oil return phase operates the solenoid valve position number 2310 opens for the duration Oil return 4 After the oil return phase the timer Oil return
63. e address pay attention to the writing on the body of the coupler 0 and 1 and do not pay attention to the writing on the DIP switches themselfs Ear more information see User Instruction MPI and Profibus and Profibus DP DP coupler available at Grasso Kap 5 4 637700E_chapter5 doc 07 09 2006 Rev 6 rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division 5 3 Description of the periphery modules The periphery modules are the link between the GSC the compressor unit the power panel and the customer 5 3 1 Periphery bus coupler As link between the PLC and periphery modules a periphery bus coupler is used see figure The address selector must be set to address 11 Power LEDs K Bus Fieldbus Connection Bus Coupler Supply Input for Power Address Selector Contacts Power Contacts Configuration Interface Figure 5 5 Beckhoff periphery bus coupler BK3120 5 3 2 Digital input terminal The KL1408 digital input terminal acquires the binary control signals from the process level and transmits them in an electrically isolated form to the higher level automation unit Each Bus Terminal contains eight channels which indicate their signal state by means of light emitting diodes Signal LED 1 4 Signal LED 2 Signal LED 3 _ Signal LED 4 Signal LED 5 lt Signal LED 6 Signal LED 7 lt Signal LED 8 U 11 LaS 612 11 12 E a 13 2 58 6 14 13 i i 14 A 24V DC E
64. enser outlet Tr 20mA 20mA equals C 100 200 100 200 200 Sensor scaling Condenser inlet Te Sensor Condin in a ee m IE aon aust oc 0000 wo if CS IU ION a IE AAA Chapter 9 6 510116E_chapter9 doc 12 11 2004 Rev 0 rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division LIST OF PARAMETERS COMPRESSOR 2 Title Standard HotKey Actual values ACTUAL values of compressor unit data remaining times for timers eae Range Default setting Project setting Pema ls o seo A A Default setting Project setting ee cometas SS SS mes TE A Range Default setting Project setting A AA pseiom atom bart omo ooo a0 C ionnam bar aor ao0 oso imita i bar oono roo A ae A a ee AO Tem end f owe nso a0 if CS 12 11 2004 Rev 0 510116E_chapter9 doc Chapter 9 7 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division Title Standard HotKey APP ATA Range Default setting Project setting O mooramene O mapan aan fa 90 ao rwm a to o SS imita fa l oo o S Tm a S to s 7 Tei EEE SSCS Treo m re on ao roman gt 00 100 roo imita EK ooo io Tin TK ooo Taa temperature O O dT SCS O rimae O aoe oo S Ten warning e oeo so T e rono sso i monea i x soo oo Tamers i SR anaa pre oa mo CS wish warning e mao
65. ensor pos 115 Kap 6 16 The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module 510116_chapter6 doc 22 05 2008 Rev 1 F SS GRASSO SYSTEM CONTROL ud Grasso Refrigeration Division 6 5 No alarm signal and the compressor will not start Compressor will not start although there is no active alarm Key O ON has been pressed and the LED K1 ON is flashing No start release signal The input start release is not Close input or install a link closed Auto Start dly active The time setting Auto start dly in Wait until the delay time has ex control settings menu has not yet pired expired Start to start delay active The time setting Start to start in Wait until the delay time has ex Time
66. enter value as an offset to the alarm value in K End injection cooling if mounted enter value as an offset to the alarm value in K Actual oil filter differential pressure in bar Alarm limit for maximum pressure differential in bar Enter the warning value as an offset to the alarm value in bar Actual oil differential pressure in bar Alarm limit for minimum pressure differential in bar 07 09 2006 Rev 1 rr LL Grasso Refrigeration Division Slide position Minimum 1 Minimum 2 lt lt Limit values 01 02 gt gt Slide position Eco begin Eco end lt lt Limit values 01 02 1 2 3 5 Alarm menu 25 Alarms Alarms View Print l l gt gt Alarms Number Delete lt lt gt gt Alarms Overflow Text lt lt l l 07 09 2006 Rev 1 Slide position Minimum 1 Minimum 2 Slide position Eco begin Eco end View Print Number Delete Overflow Text 510116E_chapter1 doc GRASSO SYSTEM CONTROL Actual slide position in Minimum slide position for starting stopping in 2 minimum slide position for starting in only for compressor type Small and Medium Actual slide position in Open economiser solenoid at this slide position Close economiser solenoid at this slide position The alarm number date time and status of the alarmare displayed Status K is logged when the alarm first occurs Q when
67. erto oe Sensor scaling Eco bb Sensor Teco me be ee E S om ra e oo Sensor scaling Chiller inlet A po AO E E me be ee E S nn Condenser outlet Tr 20mA 20mA equals C 100 200 100 200 200 Sensor scaling Condenser inlet Te Sensor Condin in a ee m IE aon aust oc 0000 wo if CS IU ION a IE AAA Chapter 9 12 510116E_chapter9 doc 12 11 2004 Rev 0 LA LY Grasso Refrigeration Division 02 04 Master_Backpage doc Grasso Products b v Parallelweg 27 P O Box 343 5201 AH s Hertogenbosch The Netherlands Phone 31 0 73 6203 911 Fax 31 0 73 6214 320 E Mail products grasso ni Grasso GmbH Refrigeration Technology Holzhauser Stra e 165 13509 Berlin Germany Phone 49 0 30 43 592 6 Fax 49 0 30 43 592 777 E Mail info grasso de Go L Grasso Refrigeration Division A company of mg technologies group
68. et too high The sensor has not been correctly calibrated in the configuration menu Sensor defective GRASSO SYSTEM CONTROL Warning clearance Remove the cause for low suction pressure in the refrigerating plant Change Psuc lo alarm and Low warning limits to suitable values Enter the correct calibration value Replace sensor Warning 3 Discharge pressure is too high This warning is activated if the dis charge pressure is higher than the Pdis hi alarm minus High warning limit values The discharge pressure is too high Pdis hi alarm minus High warning set too high The sensor has not been correctly calibrated in the configuration menu Sensor defective Remove the reason for the high discharge pressure in the refrigerat ing plant Change Pdis hi alarm and High warning limits to suitable values Enter the correct calibration value Replace sensor Warning 4 Discharge temperature is too high This warning is activated if the dis charge temperature is higher than the Tdis hi alarm minus High warn ing limit values The compressor discharge tempera ture is too high Tdis hi alarm minus High warning set too high The sensor has not been correctly calibrated in the configuration menu Sensor defective Remove the cause for high com pressor discharge temperature in the refrigerating plant C
69. etechnik 2 7 31 Low external temperature limitation GRASSO SYSTEM CONTROL This limitation is only active if the external temperature is selected as the controlled value This limitation is intended to prevent the evaporator from freezing It does not become effective until the start up process has been completed If the external temperature reaches its initial limitation value the capacity of the compressor is reduced by energising capacity control solenoids Y2 amp Y3 The signal dominates compared to the capacity control and is effective until the external temperature has reached the end of the limitation The low external temperature limitation is illustrated in the following diagram Tes External temperature T ext V Capacity control solenoids Y2 amp Y3 energised b Text low limit begin e Text low limit end W Text low warning Al Text low alarm A Start up B Short term limitation N C Intermittent limitation D Normal operation no limitation Text low alarm Text low alarm Limit begin Limit begin Limit end lt lt Limit values 01 gt gt Limit end 21 05 2008 Rev 2 Alarm limit for minimum external temperature in C Begin the temperature limitation enter value as an offset to the alarm value in K End the temperature limitation enter value as an offset to the alarm value in K 510116_chapter2 doc Kap 2 21
70. eturn Return delay 510116E_chapter1 doc GRASSO SYSTEM CONTROL Delay between two starts of the compressor in secs Delay between stop and next start in secs Oil pressure alarm delay during start up in secs Oil pressure alarm delay during running in secs Low oil level alarm delay in secs Maximum time the oil pump may run by itself without initialising an oil drain in secs Compressor oil drain time if Pump by itself expires in secs Maximum time for slide to return to its minimum position after compressor stops in sec Large series only After start output maximum time to allow feedback signal from start equipment in secs High liquid level alarm delay in secs Maximum time between pump start output and feedback signal from start equipment in secs No secondary refrigerant flow alarm delay in secs Time period during which oil is drained from the evaporator in secs Delay following oil drain Time period during which oil is returned to the compressor in sec Delay following oil return in sec 07 09 2006 Rev 1 re L 1 Grasso Refrigeration Division 1 2 3 7 Unit options menu 35 Unit Options DuoPack Sequence Control Values Parameter gt gt Unit options Vi Control Values Parameter lt lt gt Unit options Economiser Values Parameter lt lt gt Unit options Condenser Values Parameter lt lt l 07 09 2006 Rev
71. etween 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 As an option the GSC can also be fitted with a Profibus DP coupler Master Slave method This bus protocol is standardised and can also be interpreted by other controls With a Profibus up to 128 users can be operated together with a maximum transmission speed of 12 Mbit s whereby the maximum total length is between 100 m and 1200 m The maximum total length of the bus system is dependent on the number of users and the transmission speed The precise bus structure and the transmission and receiving data protocol are described in more detail in the MPI and Profibus manual 5 2 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 IM MPI I O interface Memory Card Battery To access the battery remove this cover Figure 5 1 Overview of the interfaces memory card placing and battery position Kap 5 2 637700E_chapter5 doc 07 09 2006 Rev 6 re GRASSO SYSTEM CONTROL La 4 Grasso Refrigeration Division Power supply and authorisation input Programming interface for OP Figure 5 2 Interfaces C7 633 power supply and Author connection The individual users can
72. g start or stop procedure Standby 01 02 Compressor unit ready for switching on but one or more starting conditions are still not fulfilled e g process variable still below set point External start 01 02 The controller is waiting for an external signal to enable the start of the unit Slide to min 01 02 Starting procedure commenced slide moving towards minimum position Starting 01 02 Compressor motor has been started and the running feedback signal from the starter panel has not yet been received Running 01 02 Running feedback signal from the starter panel has been received Unit in operation Limit suct press 01 02 A capacity limitation is active suction pressure too low capacity control solenoid to reduce capacity is opened Limit disch press 01 02 A capacity limitation is active discharge pressure too high capacity control solenoid to reduce capacity is opened Limit mot current 01 02 A capacity limitation is active motor current too high capacity control solenoid to reduce capacity is opened Limit ext temp 01 02 A capacity limitation is active external temperature too low capacity control solenoid to reduce capacity is opened Limit oil temp 01 02 A temperature limitation is active oil temperature too high refrigerant injection is enabled optional Stopping 01 02 The compressor unit has received a shutdown command the capacity slide is moved towards its minimum position Compressor off 01 02 The compressor is
73. gE o o Operation state RUN inputs are read and outputs are set 1 Bus activity but slave is not yet parameterised Possible cause E aor 2 no program available 2 Bus error in which the outputs become 0 o o c PLC is in STOP mode no exchange of data o E T No bus activity connection to PLC could not be established Cor W Bus error exchange of data between bus coupler and in and E B output modules is stopped The LED lights up in order to indicate fault free operation If the LED blinks an error in the area of the terminals is indicated o ORS The error code can be determined from the frequency and number of blinks o LED off m LEDon m LED flashing slowly Ww LED flashing quickly 7 3 4 Analogue incoming terminals The error LEDs indicate sensor faults e g a broken wire or an overload see chapter 5 4 4 Kap 7 8 510116E_chapter7 doc 07 09 2006 Rev 1 rr GRASSO SYSTEM CONTROL L 1 Grasso Refrigeration Division 8 DAMAGE REPORT 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 Stra e 165 13509 Berlin Germany Telephone 49 0 30 43 592 6 Fax 49 0 30 43 592 777 24 h Central Call Out Service Telephone 49 172 391 20 50 E Yo
74. hange Tdis hi alarm and High warning limits to suitable values Enter the correct calibration value Replace sensor Warning 5 Oil temperature is too high This warning is activated if the oil temperature is higher than the Toil hi alarm minus High warning limit values The compressor oil temperature is too high Toil hi alarm minus High warning set too high The sensor has not been correctly calibrated in the configuration menu Sensor defective Remove the cause for high com pressor oil temperature in the re frigerating plant Change Toil hi alarm and High warning limits to suitable values Enter the correct calibration value Replace sensor Kap 6 12 510116_chapter6 doc 22 05 2008 Rev 1 rr ud Grasso Refrigeration Division WEI MUERE Warning 7 High motor current This warning is activated if the Motor current input signal does not provide at least mA Possible cause No motor current sensor projected Faulty connected motor current sensor The analogue input module is de fective Sensor defective GRASSO SYSTEM CONTROL Warning clearance Order one at Grasso immediately Study circuit diagram Replace analogue module Replace sensor Warning 8 Broken wire ext Set point sensor This warning is activated if the Ext set point input signal in operation mode 7 Remo
75. hap 1 8 510116E_chapter1 doc 07 09 2006 Rev 1 rr LL Grasso Refrigeration Division 1 2 3 4 20 Limit values Limit values menu Suction pressure Psuc low alarm Low warning Limit values 01 02 gt gt Psuc low alarm Limit begin Limit end lt lt Limit values 01 02 gt gt Disch pressure Pdis high alarm High warning lt lt Limit values 01 02 gt gt Pdis high alarm Limit begin Limit end lt lt Limit values 01 02 gt gt Motor current Imot high alarm High warning lt lt Limit values 01 02 gt gt Imot high alarm Limit begin Limitend lt lt Limit values 01 02 gt gt External temp Text low alarm Low warning lt lt _ Limit values 01 02 07 09 2006 Rev 1 Suction pressure Psuc low alarm Low warning Psuc low alarm Limit begin Limit end Disch pressure Pdis high alarm High warning Pdis high alarm Limit begin Limit end Motor current Alarm max Warning Imot high alarm Limit begin Limit end External temp Text low alarm Low warning 510116E_chapter1 doc GRASSO SYSTEM CONTROL Actual suction pressure in bar a Alarm limit for minimum suction pressure in bar a Enter the warning value as an offset to the alarm value in bar Alarm limit for minimum suction pressure in bar a Begin the suction pressu
76. he GSC has detected a loose wire or short circuit in the Economiser pres sure sensor The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module 22 05 2008 Rev 1 510116_chapter6 doc Kap 6 13 rr ed Grasso Refrigeration Division WET message Warning 13 Broken wire Eco temperature The GSC has detected a loose wire or short circuit in the Economiser tem perature sensor Possible cause The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective GRASSO SYSTEM CONTROL Warning clearance Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module Warning 14 Broken wire Chiller inlet temperature The GSC has detected a loose wire or short circuit in the chiller inlet tem perature sensor The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective T
77. he analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module Warning 15 Broken wire Frequency value This warning is activated if the Frequency value input signal does not provide at least 4mA while a frequency inverter operation is de fined in menu 50 No connection between inverter and GSC was projected The actual frequency of the in verter is not assigned to any ana logue output of the inverter The inverter does not have ana logue outputs to be scaled for the needed range 4 20 mA The digital input module is defec tive Project connection and refit if needed an additional analogue output card in the inverter Assign the actual frequency RPMs to an analogue output of the in verter in the menu of the inverter Insert a adequate anologue card in the inverter Replace digital input module Warning 16 Oil separator level too high This warning is activated if the input signal E 1 6 high level in oil separa tor equals 0 and the timer Oil level dly has expired The oil level in the oil separator is too high Level sensor is defective The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The timer setting Oil level dly is too shor
78. hen 3 Energise the capacity control solenoids Y1 amp Y4 gt Then 5 Slide to min timer active e 4 Feedback capacity slide below Minimum 1 position gt Then 6 Output compressor motor ON gt Then 5 Reset Slide to min timer gt Then 3 De energise the capacity control solenoids Y1 amp Y4 If 6 Output compressor motor ON gt Then 8 Motor feedback timer active e If 7 Motor feedback signal equals 1 gt Then 2 De energise the capacity control solenoids Y2 amp Y3 gt Then 8 Reset Motor feedback timer gt Then 10 Release of the capacity control system Kap 2 4 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL La Z Grasso Gesch ftsbereich K ltetechnik 2 4 2 Large Screw Compressor Packages Energise the capacity control solenoids Y2 amp Y3 If gt Then gt Then If gt Then If and If and If gt Then If gt Then If gt Then gt Then Feedback Oil diff press okay Capacity slide position Minimum 1 Output compressor motor ON Motor feedback signal equals 1 Motor feedback timer active Release the capacity control system 1 2 4 2 6 3 5 6 7 7 9 8 4 11 21 05 2008 Rev 2 Pump by itself timer active Starting conditions fulfilled Output oil pump ON Start up alarm
79. immediately Case 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 2 3 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 Request to start the compressor motor 1 Feedback compressor motor ON 2 Stop to start delay active 3 e If 1 Request to start the compressor motor not active anymore gt and 2 no feedback compressor motor ON gt Then 3 Stop to start delay active 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 3 FA GRASSO SYSTEM CONTROL LL Grasso Gesch ftsbereich K ltetechnik 2 4 Start up sequence 2 4 1 Small and Medium Screw Compressor Packages Starting conditions fulfilled 1 Capacity control solenoids Y2 amp Y3 energised dl IN O N EN Capacity control solenoids Y1 amp Y4 energised Capacity slide position below Minimum 1 Slide to min timer active 1 E Feedback compressor motor ON 6 Motor feedback signal equals 1 7 Motor feedback timer active 8 a Start up Alarm D 9 a Release of the capacity control system 10 EN If 1 Starting conditions fulfilled gt Then 2 Energise the capacity control solenoids Y2 amp Y3 gt T
80. in which further branches are possible the image format is as follows Menu title Select 1 select 2 lt lt gt gt back accept accept next select 1 select 2 The current image name is displayed in the top row gt gt The keys under the symbols E lt and are used to return to the previous menu display Fe or to the next gt gt menu display and thus to further possible selections The described function is selected using the E and E keys under the symbols 07 09 2006 Rev 1 510116E_chapter1 doc Chap 1 5 T u 1 Refrigeration Division GRASSO SYSTEM CONTROL Grasso 1 2 3 Call up table of contents To get to the table of contents press the key A list of the available menus is then displayed Help text 25 Alarms e Display of current and previous alarms a Timer settings Set up of timers Unit Options Selection of unit option menus Enter Refrigerant used Compressor type With without economiser Scaling of the sensors etc Configuration To get to these menus position the cursor on the menu name using the a or Y key and confirm with the key Parameter changes in menu 20 30 35 50 can cause serious damage to the screw compressor unit or chiller 1 2 3 1 Actual values menu 05 Actual values PV SP PV Process Variable display in C R pressure or C temp Pos Imot SP Set Point display in C C R Tc dPoil Pos Capacity slide position in
81. is in menu Further sub menus OPMode DispMsg SysMsg Language Dat Time Printer 1F1 IF2 Further sub menus Login Logout Edit Display the control input and output assignments Copies the contents of the main memory to the EPROM only possible if PLC is in Stop 07 09 2006 Rev 1 re GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division 1 3 Status display S To get to the status 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 compressor unit PV SP PV Process Value display in C R pressure or C temp Pos Imot SP Set Point display in C C R Tc Dpoil Pos Capacity slide position in Operating status Imot Motor current in A Tc Discharge pressure in C R dPoil Differential oil pressure in bar Operating status eg Running Off Slide to min Motor in Star etc The operating status provides information about the compressor unit The following status messages are possible Initialisation Initialisation of the controller after swithing on the power supply or after saving the configuration save RAM gt ROM Start to start 01 02 Start delay between two starts is active Oil drain 01 02 Oil drain delay is active the oil pump has run too long by itself Minimum slide position has not been reached durin
82. itch between the individual languages online at any time After switching over all the language dependent texts are displayed in the new language Procedure Press the shift K8 hey to select the contrast language sub menu To switch over languages enter the password required for this action Confirm it with ENTER 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 Chap 4 6 510116E_chapter4 doc 12 11 2004 Rev 0 I SS GRASSO SYSTEM CONTROL EL Y Grasso Refrigeration Division 5 Technical Data 1 5 1 Types of sensors used 1 5 2 Extended data communication interfaces 2 5 2 1 Explanation of the MPI 2 5 2 2 Explanation of the Profibus 4 5 3 Description of the periphery modules 5 5 3 1 Periphery bus coupler 5 5 3 2 Digital input terminal 5 5 3 3 Analogue input terminals 6 5 3 4 Bus end terminal 6 07 09 2006 Rev 6 637700E_chapter5 doc rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division 5 TECHNICAL DATA This technical data refers to the whole GSC control cabinet Permissible ambient temperature storage 20 to 70 C Permissible ambient temperature operation 0 to 50 C Maximum air humidity 5 to 95 at 25 C no moisture condensation Dimensions Width 600 mm Depth 210 mm Height 600 mm Weight Additional measures
83. librated in the configuration menu External temperature too low Remove cause for low external tem perature in the refrigerating plant Change the Text lo alarm limit to a suitable value Enter the correct calibration value Remove cause for low external tem perature in the refrigerating plant Alarm 31 Motor speed too low If a frequency inverter is used for compressor drive motor the actual motor speed must not fall below the minimum speed after start up menu 10 pict 5 Output scaling of actual frequency speed at frequency inverter does not communicate with GSC fre quency scaling menu 50 The values of minimum speed and starting speed are too similar The GSC as well as the frequency inverter must have identical ranges of scale The minimumm difference between both values should be gt 100 min Kap 6 8 510116_chapter6 doc 22 05 2008 Rev 1 rr ud Grasso Refrigeration Division Display message Explanation Alarm 34 Comp Motor or freq ctrl protection device active This alarm is activated if the digital input signal E 0 1 motor OK Equals 0 Possible cause of the alarm Motor protection has tripped contact open The terminal connections have become loose The wire is broken Digital input module defective GRASSO SYSTEM CONTROL Alarm clearance Investigate cause and possibly reset the motor protection Check the ter
84. ls with 4 channels 4 20mA 5 3 4 Bus end terminal At the end of the periphery terminals a bus end terminal KL9010 must be mounted otherwise the periphery bus coupler detects an error and no data will be send to the PLC Kap 5 6 637700E_chapter5 doc 07 09 2006 Rev 6 r_ ud Grasso Refrigeration Division 6 1 General 6 1 1 Alarms 6 1 2 Warnings 6 1 3 View active alarms and warnings 6 2 Possible text displays for alarms and warnings 6 2 1 General 6 2 2 List of all alarms and warnings 6 3 Description and diagnosis of alarm messages 6 4 Description and diagnosis of warning messages 6 5 No alarm signal and the compressor will not start 22 05 2008 Rev 1 510116_chapter6 doc GRASSO SYSTEM CONTROL Zo gt m N N Bb NNN d _ FA GRASSO SYSTEM CONTROL La 1 Grasso Refrigeration Division 6 1 General E Shut down on alarms are carried out to prevent the refrigeration equipment operating outside of de sign limits and do not represent a defect in the controls The alarm signals are divided into 2 groups Alarm Warning Figure 1 Control cabinet with LED and indicator lights 6 1 1 Alarms These 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 A and text message in the display 6 1 2 Warnings These do not cause the compressor to switch off and do not block it from being swit
85. mM A Ca LY Grasso Refrigeration Division Grasso System Control GSC DuoPack Units and Chiller with screw compressors User Manual 22 05 2008 _510116_um_gsc_spduo_gbr_rev2 Mm A C LY Grasso Refrigeration Division 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 2 _510116_um_gsc_spduo_gbr_ doc 12 11 2004 0 rr L 1 Grasso Refrigeration Division FOREWORD GRASSO SYSTEM CONTROL DESCRIPTION OF GRASSO SYSTEM CONTROL 1 CONTROL SEQUENCE 2 INITIAL START UP 3 SYSTEM DESCRIPTION 4 TECHNICAL DATA 5 ALARMS 6 TROUBLESHOOTING 7 SERVICE 8 APPENDICES 9 12 11 2004 0 510116E_contents doc 1 1 rr GRASSO SYSTEM CONTROL L 1 Grasso Refrigeration Division FOREWORD Introduction Grasso has been producing refrigerating compressors and compressor units for a wide range of different applications for several decades A new compressor control has been developed for universal use based on our many years operational experience The compressor control type GSC Gr
86. menu 35 Unit options The following selection appears on the display Y DuoPack Sequence Control Values Parameter lt lt gt gt Use the E key to select the sequence control parameter list Use the E key to select the actual values of the master and slave F gt gt Press once The following selection appears on the display Unit options Vi control Values Parameter lt lt gt gt Use the E key to select the Vi parameter list LZ Use the ee key to select the actual Vi values F gt gt Press once The following selection appears on the display Unit options Economiser Values Parameter lt lt gt Use the E key to select the economiser parameter list rn Use the Et key to select the actual economiser values Fa gt gt Press once The following selection appears on the display Unit options Condenser Values Parameter lt lt gt Use the E key to select the condenser parameter list Use the ri key to select the actual values for the condenser The actual values menu item is always quit by pressing the key 12 11 2004 Rev 0 510116E_chapter3 doc Chap 3 3 re GRASSO SYSTEM CONTROL La 4 Grasso Gesch ftsbereich K ltetechnik 3 3 Adjusting limiting values Press Select the main menu 20 Limit values The following selection appears on the display Q Suction press
87. minal connections Replace the wire Replace the digital input module Alarm 35 Emergency switch or safety chain has responded This alarm is activated if the input signal E 0 2 equals 0 The discharge pressure HP switch has activated The emergency stop button has been pressed The terminal connections have become loose The wire is broken Digital input module defective Reset the discharge pressure switch internal external reset Reset the emergency stop button Check the terminal connections Replace the wire Replace the digital input module Alarm 36 Start procedure too long This alarm is activated if the feed back signal digital input E 0 0 equals 1 from the compressor drive motor starter equipment takes longer than Motor feedback time setting Time setting Motor feedback too short Increase time setting Motor feed back to a suitable value Alarm 37 Feedback from motor starter missing This alarm is activated if the com pressor is running and the input signal E 0 0 compressor feedback equals 0 The feedback contactor is defective contact open Power failure due to tripped fuse The terminal connections have become loose The wire is broken The compressor motor feedback is faulty indicated by external control device Replace the feedback contactor Change fuse Check the terminal connections Replace the wire
88. ncy inverter a fixed sequence order is used This compressor will always start first and stop last Act seq order Actual active sequence DuoPack sequence control time settings menu 35 Unit options Start delay Start delay in sec to start the 2 compressor after 1 has reached maximum Stop delay Stop delay in sec to stop the 2 compressor as soon as it has reached middle position med position and the 1 compressor is running at middle position Force start dly Monitoring time for capacity increase in sec This time is not active if a limitation is active As soon as this time has elapsed the next step in the sequence will be forced Force stop dly Monitoring time for capacity decrease in sec This time is not active if a limitation is active As soon as this time has elapsed the next step in the sequence will be forced Max hrs diff Maximum number of running hours between both compressors As soon as the value is reached and both compressors are running then the sequence order will be changed automatically If one compressor is running only and the value is reached no forced change of the sequence order will be executed This parameter is not active if one of both compressors is equipped with a frequency inverter 1 These parameters must be set for each compressor individually All other parameters are equal for both compressors 7 The minimum load position is monitored if both compressors are running only In all other
89. 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 continuous 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 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 Remote 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 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 1 re GRASSO SYSTEM CONTROL ed Grasso Gesch ftsbereich K ltetechnik 2 2 Explanation of symbols and characters used Progression of a signal with time or information Progression of a signal with time or ME information the pre event history is irrelevant Progression of a signal with time or 1 information the future is irrelevant Time at which a cause or condition begins in text e f Effect in text gt then 2 3 General starting conditio
90. ng Pump fback dly is too short The digital input module is defec tive GRASSO SYSTEM CONTROL Warning clearance Change the oil filter cartridge soon Change Filt diff press hi alarm and Hi warning limits to a suitable value Enter the correct calibration value Replace sensor Change the timer setting Oil filt dly to a suitable value Switch on the secondary pump Replace the contact relay Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Change the timer setting Pump fback dly to a suitable value Replace digital input module Warning 19 No feedback from condenser system This warning is activated if the input signal E 12 1 feedback condenser equals 0 and the fixed delay timer has expired Condenser is not running The condensor feedback contact relay is defective The terminal connections have become loose or a wire is broken There is a short circuit in the sen sor relay wiring The delay time is too low The digital input module is defec tive Switch on the condenser Replace the contact relay Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Increase the t KT Pump feed back parameter in the time val ues menu time values chiller image Replace digi
91. nimum parameter is valid if both compressors are running As soon as the capacity of a running compressor is less than this value the capacity is increased In this way it is ensured that no compressor can run with less capacity than the Minimum value Furthermore the minimum value for the sequence control is always higher than the bushing limit for the local control So it also ensures that the compressor keeps running 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 27 lt A A GRASSO SYSTEM CONTROL LL Grasso Gesch ftsbereich K ltetechnik CAPACITY INCREASE DECREASE SPECIAL SITUATION ne Capacity demand 500 kW O kw ir Comp 1 Inverter O kw PS MED PS 100 Diagram 3 Capacity increase decrease special situation 0 PWN Compressor 1 increases capacity same as point 0 Capacity increase normal situation Failure shut down of compressor 1 Compressor 2 takes over capacity control Failure at compressor 1 acknowledged Compressor 1 standby Compressor 2 reaches maximum capacity After Start delay time compressor 1 is started and forced to Part load From now on 3 situations can occur 1 Capacity demand is so high that compressor 2 stays at maximum load As soon as compressor 1 has reached the Part load the switch delay timer starts After this time compressor 2 is forced to stay at maximum load Compressor 1 is controlling capacity based on set point and pro
92. noid valves 505 and 510 Duo Pack with external oil pump standard PS Pos Limit bushing DD RE SV MIN Kd SV Max ZA mz dPoil a EA Pfilt Pend lt 3bar 3 bar AAA Vt LET nap Diff Pdisc 1 2 lt 3 bar 1 I Start Vz WLLL Oil pump VM MM Ltt ae AAA AAA Motor badk sak TACA SV 505 Function oil 77 WLLL SV 510 Injection oil CHE SV Oil retum to oil sep RE pi pP E 3 Leni 3 7 Duo Pack with external pump with pressure failure PS Pos ume busting Do Dip a SV MIN WELLL Z SV Max Z pl dPoil A AZ Pfit Pend lt 3bar Be ATA Traer Diff Pdisc 1 2 lt 3 bar not Start TACA CCA Oil pump WM AT TT AA Motor control ATA Motor feedback UMMM SV 510 Injection oil Tho Be SV Oil retum to oil sep e T x 2 r e Bhi down 3 gl ae In HRL B 21 05 2008 Rev 2 510116_chapter2 doc GRASSO SYSTEM CONTROL WD lara TATI A Va ra s WL zz e Z B 7 OOO ls N HELL R LLL LLL LL VU ee UUM WL Le UZ VD 7 gt o Peg ve ETA 7 a_i TTD I oz EPOC OCC WM UL WM Ua aA a Fe u em if I ag y it a foi Ih EB woo Mi Kap 2 31 re GRASSO SYSTEM CONTROL ed Grasso Gesch ftsbereich K ltetechnik 2 11 Chiller functions The GSC can also form part of a chiller package control system 2 11 1 Start up The start up operation of a chiller package is as follows 1 The digital outputs A 12 0 and A 12 1 are energised following a start request The se
93. ns The following conditions have to be fulfilled to begin start up of the compressor unit e If Start command eg External on input equals 1 for operating mode 6 and If the Start to start timer is not active and If the Stop to start timer is not active and If the Oil drain timer is not active only applies to Large compressors and If the digital input start release equals 1 and If No alarms are active gt Then the starting conditions are fulfilled Kap 2 2 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL La Z Grasso Gesch ftsbereich K ltetechnik 2 3 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 e Limitation of the number of starts per unit time The permissible number of starts per hour is based on the motor manufacturer s values for the operating mode and insulation class Output compressor motor on 1 oo oO B u Start to start timer active 2 BA Compressor motor start not allowed 3 A B Case A The compressor motor ran longer than the Start to start timer next start allowed
94. ntrol solenoids Y2 amp Y3 Slide to min timer elapsed Capacity slide at Minimum 1 position not reached Alarm Reset the actuating signals 2 3 and 4 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL La Z Grasso Gesch ftsbereich K ltetechnik 2 5 2 Switching off sequence in case of an alarm small and medium screw compressor packages Alarm generated 1 Output compressor motor ON 2 Capacity control solenoids Y2 amp Y3 energised 3 A Capacity control solenoids Y1 amp Y4 4 energised Capacity slide Minimum 1 position 5 e If 1 Alarm generated gt Then 2 Reset output compressor motor ON gt Then 3 Capacity control solenoids Y2 amp Y3 energised gt Then 4 Capacity control solenoids Y1 amp Y4 energised If 5 Capacity slide Minimum 1 position Then 3 Capacity control solenoids Y2 8 Y3 de energised Then 4 Capacity control solenoids Y1 amp Y4 de energised Ld 2 5 3 Switching off sequence in case of an alarm large screw compressor packages Alarm generated 1 w Output compressor motor ON ES Output oil pump motor ON Capacity control solenoids Y2 amp Y3 energised KR O JIN If 1 Alarm generated gt Then 2 Reset output compressor motor ON gt Then 3 Reset output oil pump motor ON gt Then 4 Capacity control solenoids Y2 amp Y3 de energised 21 05 2008 Rev 2 510116_chapter2 doc re GRASSO SYSTE
95. ogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module 510116_chapter6 doc 22 05 2008 Rev 1 rr ud Grasso Refrigeration Division Possible cause of the alarm GRASSO SYSTEM CONTROL Alarm clearance Display message Explanation Alarm 5 Broken wire oil temperature sensor The GSC has detected a loose wire or short circuit in the oil pressure sensor P amp ID position no 125 The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module Alarm 6 Broken wire capacity slide position sensor The GSC has detected a loose wire or short circuit in the capacity slide sen
96. ow Select Yes if sensor mounted otherwise No lt lt Configuration gt gt a y Select using and or Confirm the selection with Unit type Unit type Select Package FX Chiller or DX Chiller CH inlet sensor CH inlet sensor Select Yes if sensor mounted otherwise No lt lt Configuration gt gt a v Select using and or Confirm the selection with ee Chap 1 14 510116E_chapter1 doc 07 09 2006 Rev 1 L 1 Grasso Refrigeration Division Profibus Economiser Eco sensors lt lt Configuration gt gt Sensor AmA equals 20mA equals lt lt Configuration gt gt Configuration Accept Save ok ok lt lt 07 09 2006 Rev 1 GRASSO SYSTEM CONTROL Profibus Select Yes if mounted otherwise No Economiser Select With and Without Eco sensors Select Yes if mounted otherwise No Select using and a or 7 Confirm the selection with Sensor Select the sensor type e g motor current external setpoint suction pressure discharge pressure etc 4mA equals Start of measuring range of the sensor selected e g 0 bar or 60 C 20mA equals End of measuring range of the sensor selected e g 21 bar or 140 C Select using and a or 7 Confirm the selection with Accept Store the set configuration in the main memory program works with the new values but these
97. pressor 1 has reached the Part load which is within the speed control area and above the minimum speed the capacity is fixed 6 Compressor 2 is controlled based on set point and process value by changing the slide position 7 As soon as compressor 2 has reached 100 slide position the economizer is activated and the capacity is fixed 8 From now compressor 1 takes over capacity control The speed can be increased or decreased down to minimum speed depending on the capacity demand Kap 2 26 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL La Z Grasso Gesch ftsbereich K ltetechnik CAPACITY DECREASE NORMAL SITUATION 1000 KW x Capacity demand MAX 500 KW Comp 1 Inverter 500 KW O Kw MED on OKW ea 100 y Nin MAX 1400 Kw MED O kW PS 100 PS MED Diagram 2 Capacity decrease normal situation Compressor 1 decreases capacity by reducing motor speed As soon as the Part load is reached and or below the switch delay is set After this delay compressor 2 takes over capacity control and Compressor 1 is forced to stay at Part load If compressor 2 runs below Part load the stop delay is started After the stop delay compressor 1 takes over capacity control and Compressor 2 is stopped Compressor 1 is running and controlled based on set point and process value If no capacity is needed compressor 1 is stopped also NS oe ee The Mi
98. quence canbe fixed automatically or manually If a parameterisable maximum difference in operating hours is exceeded and the start sequence mode is auto a forced changeover in the priorities takes place But no compressor is forced to start or stop 2 8 3 Fault handling Compressors under fault conditions are evaluated within the sequencing control as not being in the sequencing control mode If the malfunction is corrected the corresponding compressor is automatically included back in the sequencing control to previous position 2 8 4 Parameterisation of the sequencing control at the operator terminal 9 Press Select main menu 15 Operating modes SHIFT Use and Y to select Autotauto and Press pre Select main menu 35 Options and Press pre Y Duopack Sequence control Limits Time set Press E once Select Limits The following selection appears on the display The following selection appears on the display Maximum 95 Part load 65 Minimum 35 Duopack limits gt gt Depending on the requirements the default parameters for the plant conditions can be adjusted here Parameters valid for both compressors F gt gt Press The following selection appears on the display Neutral zone 4 Seq order auto Act seq order 1 2 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 29 re GRASSO SYSTEM CONTROL ed Grasso Gesch ftsbereich K ltetechnik
99. r settings menu has not yet pired expired PV lt SP 1 NZ Check set point and neutral zone settings in Control settings menu PV Process value SP Set point Attention NZ Neutral zone In case of suction pressure control the set point value is entered in degrees Celsius 22 05 2008 Rev 1 510116_chapter6 doc Kap 6 17 _ A L 1 Grasso Refrigeration Division 7 ACKNOWLEDGING AND RESETTING ALARMS AND WARNINGS 7 1 Information about the status of the controls in case of an alarm warning 7 2 Restart following Alarms 73 Information from the controls in case of a system error 7 3 1 7 3 2 7 3 3 7 3 4 07 09 2006 Rev 1 CPU Profibus DP DP coupler Periphery bus coupler Analogue incoming terminals 510116E_chapter7 doc GRASSO SYSTEM CONTROL oon A A rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division 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 At the control cabinet Signal lamp red Alarm signal lamp yellow Warning At the GSC display An alarm message appears in the display 2 alarm message identification of the 2 compressor The LED alarm signal flashes The application program continues to run The DC5V LED and the RUN LED light up O sr ha O Barr r gt mM ocs j R O
100. rating modes RUNP RUN STOP and MIRES are selected as follows Procedure The status of the CPU is changed each time the key is pressed Input 24V DC 1 0A X1 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 Figure 4 1 Bridge at the authorisation input see Figure 5 2 The authorisation input is located on the same connector as the C7 power supply Chap 4 2 510116E_chapter4 doc 12 11 2004 Rev 0 rr GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division 4 3 Meaning of the key operated switches The C7 CPU processes the application program The program and data can be read out of the C7 CPU with the PG C7 gt PG be transferred into the C7 CPU or be amended there PG gt C7 The C7 CPU processes the application program The programs and data can be read out from the C7 CPU using the PG C7 gt PG not be transferred to the C7 CPU or be amended there PG gt C7 The C7 CPU does not edit the application program Programs can be read out of the C7 CPU using the PG C7 gt PG
101. ration values Rane Default _ Default setting _ Project setting setting Sensor a Suction a Sensor Psuc Sensor scaling Oil E Sensor Sensor scaling ee press PF Sensor o a cr AA ERRE E A mea oor a H Chapter 9 4 510116E_chapter9 doc 12 11 2004 Rev 0 rr GRASSO SYSTEM CONTROL L 1 Grasso Refrigeration Division Title Standard HotKey ee Configuration a Parameters for configuration values Range Default setting Project setting Sensor Eee ee temp 20mA equals a a 100 200 Sensor scaling Oil Sensor Toil se be ee E S Poms ea 0 00 200 Sensor scaling Slide a 20mA 20mAequals B00 Sensor scaling a_i current Sensor mot a Ama equals CC Sensor e Suction a Sensor Tue Sensor BE External On Sensor ret se ee E S om eno e ET FE Sensor scaling Oil filter ee eT ae a 02 035 meo foarte oo fa H 12 11 2004 Rev 0 510116E_chapter9 doc Chapter 9 5 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division Title Standard HotKey et Configuration Seel Parameters for configuration values Range Default setting Project setting Sensor Vi position pf Sensor ff Vis l _ _ e ee O Eco pressure Sensor Peco me ten ee om caus berto oe Sensor scaling Eco bb Sensor Teco me be ee E S om ra e oo Sensor scaling Chiller inlet A po AO E E me be ee E S nn Cond
102. re Actual discharge pressure in bar a Pdis high alarm Pdis high alarm Alarm limit for maximum discharge pressure in bar a High warning High warning Enter the warning value as an offset to the alarm value lt lt Limit values 01 gt gt in bar Kap 2 24 510116_chapter2 doc 21 05 2008 Rev 2 re GRASSO SYSTEM CONTROL ud Grasso Gesch ftsbereich K ltetechnik 2 8 Internal DuoPack Sequence control This document describes the sequence control for a DuoPack The normal situations are described for increasing and decreasing capacity see diagram 1 and 2 Furthermore the special situation is described where compressor 1 trips on an alarm and is shut off see diagram 3 Only this situation is special because if compressor 2 trips on an alarm the sequence is not changed 2 8 1 GSC Parameters DuoPack sequence control limits menu 35 Unit options Minimum Minimum position in based on total swept volume Part load Part load med position in based on total swept volume Maximum Maximum position in based on total swept volume Neutral zone Neutral zone in K The 2 compressor may start as soon as the process value exceeds the set point 12 NZ Seq order Select the sequence order to use Auto Sequence order based on running hours 1 2 Compressor 1 will start first and stop last 2 1 Compressor 2 will start first and stop last Note If one of both compressors is equipped with a freque
103. re limitation enter value as an offset to the alarm value in bar End the suction pressure limitation enter value as an offset to the alarm value in bar Actual discharge pressure in bar a Alarm limit for maximum discharge pressure in bar a Enter the warning value as an offset to the alarm value in bar Alarm limit for maximum discharge pressure in bar a Begin the discharge pressure limitation enter value as an offset to the alarm value in bar End the discharge pressure limitation enter value as an offset to the alarm value in bar Actual motor current in A Alarm limit for maximum motor current in A Enter the warning value as an offset to the alarm value in A Alarm limit for maximum current in A Begin the motor current limitation enter value as an offset to the alarm value in A End of the motor current limitation enter value as an offset to the alarm value in A Actual external temperature in C Alarm limit for minimum external temperature in C Enter the warning value as an offset to the alarm value in K Chap 1 9 re B Grasso Refrigeration Division Text low alarm Limit begin Limit end lt lt Limit values 01 02 gt gt Disch temp Tdis hi alarm High warning lt lt Limit values 01 02 gt gt Tdis hi alarm Inject begin Inject end lt lt _ Limit values 01 02 Oil temp Toil hi alarm High warning lt lt
104. reen 0 5Hz Subsequently this indicator will light green RUN Operation continuously Figure 4 6 Figure 4 6 RUN indicator seeFigure 1 3 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 12 11 2004 Rev 2 510116E_chapter4 doc Chap 4 5 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 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 Step Procedure 1 The Date Time sub menu is called up by pressing the Shift K16 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 Confirm the entry with 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 sw
105. s not become effective until the start up process has been completed If the motor current reaches its initial limitation value e g 105 of the full load current the capacity of the compressor is reduced by energising capacity control solenoids Y2 amp Y3 The signal dominates compared to the capacity control and is effective until the motor current has reached the end of the limitation The motor current limitation function is illustrated in the following diagram Imo Motor current mot V Capacity control solenoids Y2 amp Y3 Al energised b Imot limit begin br e Imot limit end e Pj A Start up B Limitation during eg pull down y C Intermittent limitation x 7 7 BEER A B C D D Shut down procedure no limitation Imot high alarm Imot high alarm Alarm limit for maximum current in A Limit begin Limit begin Begin the motor current limitation Limitend enter value as an offset to the alarm value in A lt lt Limit values 01 gt gt Limit end End of the motor current limitation enter value as an offset to the alarm value in A 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 17 CA ed Grasso Gesch ftsbereich K ltetechnik 2 7 3 4 High motor current alarm I mot Motor current b Imot Limit begin e Imot Limit end W Imot high warning Al Imot high alarm V Capacity control solenoids Y2 amp Y3 energised ML W W
106. se of an alarm large screw compressor packages 7 2 6 Compressor control 8 2 6 1 Capacity control 8 2 6 2 Mode of operation of the capacity controller and of the subsequent solenoid valve pulses 9 2 7 Safety control Alarms warnings and limitations 9 2 7 1 Oil system monitor of the small and medium screw compressor packages 10 2 7 1 1 Switching sequence in the normal case 10 2 7 1 2 Switching sequence for capacity control solenoid valves 11 2 7 1 3 Switching sequence in case of too low oil differential pressure alarm during running 12 2 7 2 Oil system monitor of the large screw compressor packages 13 2 7 2 1 Switching sequence in the normal case 13 2 7 2 2 Switching sequence in the case of a malfunction during the starting operation 14 2 7 2 3 Switching sequence in the case of malfunction in the operating condition 15 2 7 3 Compressor motor alarms 16 2 7 3 1 Motor feedback alarm start up of compressor motor takes too long 16 2 7 3 2 Feedback from motor starter missing alarm 16 2 7 3 3 Motor current limitation 17 2 7 3 4 High motor current alarm 18 2 7 3 5 Low suction pressure limitation 19 2 7 3 6 Low suction pressure alarm 20 2 7 3 7 Low external temperature limitation 21 2 7 3 8 Low external temperature alarm 22 2 7 3 9 High discharge pressure limitation 23 2 7 3 10 High discharge pressure alarm 24 2 8 Internal DuoPack Sequence control 25 2 8 1 GSC Parameters 25 2 8 2 Determination of the starting sequence 29 2 8 3 Fault handling 29
107. sor P amp ID position no 011 The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module Alarm 7 Profibus DP Slave The GSC as Profibus DP Master has detected a failure at one of the Pro fibus DP Slaves The terminal connections have become loose or a wire is broken Faulty wiring between the GSC and slave modules The sensor is defective or in a fault state range Faulty settings of Profibus connec tors Check the terminal connections master and slaves for tightness and continuity of wiring Check the connection of A and B clamp wires of Master connector with the A B clamp wires of the slaves Replace slave module Profibus connectors with only one connected cable must be setted switch the DIP Button ON Profibus connectors with two con nected cables must not be setted switch the DIP Button OFF Alarm 9 Broken wire external Temperature sensor The GSC has detected a loose wire or short circuit in the external tempera ture sensor The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is
108. t The digital input module is defec tive Reduce the level in the oil separa tor Replace the level sensor Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Increase the timer setting Oil level dly Replace digital input module Kap 6 14 510116_chapter6 doc 22 05 2008 Rev 1 rr ud Grasso Refrigeration Division Warning message Warning 17 Pre alarm oil filter This warning is activated if the dif ference between the discharge pres sure and the Oil filter pressure is larger than the Filt diff press high alarm minus the high warning limit values and the fixed time delay has expired Possible cause Oil filter is slightly blocked Fit diff press Hi alarm minus Hi warning set too low The sensor has not been correctly calibrated in the configuration menu Sensor defective The timer setting Oil filt dly is too short Warning 18 No feedback from refrigerant pump motor Chiller only This warning is activated if the input signal E 12 0 feedback secondary pump equals O and the timer pump fback dly has expired The secondary pump is not run ning The pump s feedback contact re lay is defective The terminal connections have become loose or a wire is broken There is a short circuit in the sen sor relay wiring The timer setti
109. t timer active Oil diff run timer active Low oil pressure alarm 2 3 3 5 4 5 6 Oil diff press OK A B A During start up B Brief lowering of the oil differential pressure during running Capacity slide in Minimum 1 position Output compressor motor ON Output compressor motor ON Oil diff start timer active Oil diff press not OK Oil diff start timer elapsed Oil diff run timer active If the oil differential pressure is OK again within the appropriate delay time there is no alarm shutdown Kap 2 10 510116_chapter2 doc 21 05 2008 Rev 2 A ud Grasso GRASSO SYSTEM CONTROL Gesch ftsbereich K ltetechnik 2 7 1 2 Switching sequence for capacity control solenoid valves Energising of capacity control solenoids Energising of capacity control solenoids Ld The configuration of the oil cycle causes the oil pressure to drop when a solenoid valve is opened Actuating time monitoring is provided for the solenoid valves of the package to guarantee that the oil pressure is built up again The blocking of the actuating signals only takes place in the operating condition of the package compressor motor in delta and during the shutdown cycle A new capacity control pulse cannot be generated for a solenoid valve until the oil differential pressure has recovered Feedback compressor motor ON 1 u Oil
110. t can be signalled in one of the following possible ways Option 1 The SE and RUN LEDs are alight The application program continues to run The compressor is not switched off BATF DCS FRCE y H R LV RUN SS STOP E D Q SFM ld ld ms a I SF DP Buse LED irrelevant o LED off m LEDon w LED flashing slowly gt LED flashing quickly a LED additional information Kap 7 4 510116E_chapter7 doc 07 09 2006 Rev 1 r GRASSO SYSTEM CONTROL LL Grasso Refrigeration Division Option 2 The SE LED is alight and the STOP LED flashes slowly 1Hz the 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 U E tt R u D RUN lt lt gt gt m stor K Ls 4 i At pl A v a P T e Buse 7 Be MIS IA om LED irrelevant c LED off m LEDon 3w LED flashing slowly LED flashing quickly a LED additional information Option 3 The SE LED is alight and the STOP LED flashes slowly 1Hz the 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 E s BATF L DCSV O FRCE V S Be py py P t eX stor PaA gt DAAU Ie fa sror Y L eae E AAA AA K JF NE A 53 Ade JZ bs Baer LED irrelevant c LED
111. tain time value Possible cause of the alarm Sensors are defective The analogue input module is de fective Faulty oil circuit design GRASSO SYSTEM CONTROL Alarm clearance Check replace the sensors Replace analogue module Check revise the oil circuit design and or contact Grasso service de partment Alarm 12 Motor feedback too late During starting up of the compressor motor the GSC must receive withing a certain time the motor feedback digital input DI 0 0 The ramp time of the softstarter or the inverter does not match with the monitoring time for the motor feedback of the GSC The ramp time of the softstarter or the inverter leads to exceeded starting time of the motor The terminal connections have become loose Digital input module defective Compare and adjust the ramp time of softstarter inverter with the timer motor feedback in the GSC Adjust the ramp time of softstarter inverter accordingly Check the terminal connections Replace the digital input module Alarm 13 Start speed not reached In case of use of an inverter for the compressor motor the start speed adjustable parameter must be reached within a certain time ad justable parameter The ramp time of the inverter is not matching the monitoring time Tsar in the GSC Menu 30 The scaling of the output for the actual RPMs of the inverter is not matching the corresponding scaling for the
112. tal input module Warning 21 Program buffer battery empty This warning is activated if the bat tery is empty Battery is empty Replace battery 22 05 2008 Rev 1 510116_chapter6 doc Kap 6 15 rr ed Grasso Refrigeration Division WET MS Warning 22 Oil separator level too low This warning is activated if the input signal E 1 0 low level in oil separa tor equals O and the timer setting Oil level dly has expired Possible cause The oil level in the oil separator is too low The level sensor is defective The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The timer setting Oil level dly is too short The digital input module is defec tive GRASSO SYSTEM CONTROL Warning clearance Increase the oil level in the oil sepa rator Replace the level sensor Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Change the timer setting Oil level dly to a suitable value Replace digital input module Warning 23 Broken wire motor current transformer The GSC has detected a loose wire or short circuit in the motor current sensor pos 16 Warning 24 Broken wire suction temperature sensor The GSC has detected a loose wire or short circuit in thesuction tem perature s
113. te HW ext SW does not provide at least 4mA No external set point adjustment projected Faulty connected external set point adjustment The analogue input module is de fective Do never change to operation mode 7 07 Remote HW ext SW Study circuit diagram Replace analogue module Warning 9 Low external temperature This warning is activated if the ex ternal temperature is less than Text lo alarm plus Low warning limit values External temperature is too low Text lo alarm plus Low warning set too high The sensor has not been correctly calibrated in the configuration menu Sensor defective Remove the cause for low external temperature in the refrigerating plant Change Text lo alarm and Low warning limits to suitable values Enter the correct calibration value Replace sensor Warning 11 Broken wire Vi position sensor The GSC has detected a loose wire or short circuit in the Vi slide sensor P amp ID position no 052 2 The terminal connections have become loose or a wire is broken There is a short circuit in the sensor wiring The sensor is defective The analogue input module is de fective Check the terminal connections for tightness and continuity of wiring Check where short circuit has oc curred and rectify Replace the sensor Replace analogue module Warning 12 Broken wire Eco pressure T
114. term limitation C Intermittent limitation A B C D D Normal operation no limitation Psuc low alarm Psuc low alarm Alarm limit for minimum suction pressure in bar a Limit begin Limit begin Begin the suction pressure limitation Limit end enter value as an offset to the alarm value in bar lt lt Limit values 01 gt gt Limit end End the suction pressure limitation enter value as an offset to the alarm value in bar 21 05 2008 Rev 2 510116_chapter2 doc Kap 2 19 CA ed Grasso Gesch ftsbereich K ltetechnik GRASSO SYSTEM CONTROL 2 7 3 6 Low suction pressure alarm Pc Suction pressure Psuc b Psuc low limit begin e Psuc low limit end W Psuc low warning Al Psuc low alarm V Capacity control solenoids Y2 amp Y3 energised ML W Warning message ML A Alarm message N A Psuc Limitation effective B Low suction pressure warning SEN C Low suction pressure Alarm ML A D No alarm generated A B D Suction pressure Psuc low alarm Low warning Limit values 01 gt gt Kap 2 20 Suction pressure 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 in bar 510116_chapter2 doc 21 05 2008 Rev 2 A ud Grasso Gesch ftsbereich K lt
115. tly mounted on the compressor package unit However the GSC can also be located in a control centre 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 compressor unit and capacity regulation dependent on the suction pressure or an external temperature Monitoring of all operating parameters Compressor capacity limitation in case the discharge pressure 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 compressor unit by a master controller via potential free contacts MBI or Profibus DP communication with a master controller Sequence control of max 5 compressor package units via MPI 1 1 1 View 1 4 6 1 Power supply 4 Emergency stop relay 2 Profibus DP DP coppler 5 Relays 3 Socket outlet for service 6 Bus Terminal Figure 1 1 View of outside of switchgear cabinet Figure 1 2 View of inside of switchgear cabinet 07 09 2006 Rev 1 510116E_chapter1 doc Chap 1 1 re GRASSO SYSTEM CONTROL B Grasso Refrigeration Division 1 1 2 Lamps Push buttons white indicator light
116. ur nearest contact Fax muaa 24 h Central Call Out Service Telephone seene Please use the fax form on the back of this page to report your damage By submitting a complete damage report you ensure that the damage that has occurred can be repaired quickly 12 11 2004 Rev 0 510116E_chapter8 doc Chapter 8 1 rr B Grasso Refrigeration Division DAMAGE REPORT GRASSO GMBH REFRIGERATION TECHNOLOGY SERVICE Address of the owner operator Type and model number of the product Designation of the defective module Suspected cause of the damage Date damage occurred Operating hours of the module until damage occurred Software Version can be called up under the menu item Configuration Manufacturer s code SIEMENS see figure Tobe mat nn En 2 m CEG d Lee MECH GRBG PER SW 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 A 60 OFF ON Flashing 2Hz Functional Key LEDs LED K1 ON OFF ON Flashing LED K9 OFF OFF ON Additional Informations e Description of the symptoms e Owner operator requirements Chapter 8 2 510116E_chapter8 doc 12 11 2004 Rev 0 SA GRASSO SYSTEM CONTROL EL A Grasso Refrigeration Division e
117. uration menu Sensor defective Remove cause for high motor cur rent in the refrigerating plant Change the Imot high alarm limit to a suitable value Enter the correct calibration value Replace sensor Alarm 24 Difference between both discharge pressures was too high During start up of the second com pressor the discharge pressures Pos 105 1 und 105 2 of both compres sors are compared At a low pressure difference the standard start procedure is executed A remaining high pressure difference during start up is an indication that the started compressor is not devel oping pressure on the compressor outlet port To avoid overloading of the balance piston and a compressor damage the start procedure is stopped after a certain time Check why the discharge pressures values a differing strongly Check if both discharge sided check valves POS 185 1 and 185 2 are fully opened Discharge pressure sensors might cover different metering ranges but without any concordance with scaling ranges of the GSC Inspect the check valve function Set the scaling of both discharge pressure sensors to the actual me tering ranges menu 50 Alarm 25 Low external temperature This alarm is activated if the external temperature is lower than the Text lo alarm limit value External temperature too low The Text lo alarm is set too high The sensor has not been correctly ca
118. v 2 510116_chapter2 doc Kap 2 15 re GRASSO SYSTEM CONTROL ed Grasso Gesch ftsbereich K ltetechnik 2 7 3 Compressor motor alarms 2 7 3 1 Motor feedback alarm start up of compressor motor takes too long Output compressor motor ON 1 Motor feedback signal equals 0 2 Motor feedback timer active Time before motor feedback too long alarm generated A B A During start up B During the starting operation the motor feedback signal is delayed for too long If 1 Output compressor motor ON gt Then 3 Motor feedback timer active If 1 Output compressor motor ON and e If 2 Motor feedback signal equals 0 and If 3 Motor feedback timer elapsed gt Then 4 Time before motor feedback too long alarm generated 2 7 3 2 Feedback from motor starter missing alarm Output compressor motor ON 1 Motor feedback signal equals O 2 Feedback from motor starter missing 3 alarm generated If 2 Motor feedback signal equals 0 and e If 1 Output compressor motor ON gt Then 3 Feedback from motor starter missing alarm generated Kap 2 16 510116_chapter2 doc 21 05 2008 Rev 2 SA GRASSO SYSTEM CONTROL La Z Grasso Gesch ftsbereich K ltetechnik 2 7 3 3 Motor current limitation The motor current limitation prevents overloading of the compressor drive motor It doe
119. w Compressor Package Screw Compressor Type 12 11 2004 0 510116E_foreword doc Foreword 1 m GRASSO SYSTEM CONTROL La Grasso Refrigeration Division General drawings This drawing shows the general configuration of a screw compressor unit type Large The supplied model can deviate from this n m 111 Ir Ir y A t HB ue eee EN E lt ER es G N Cos T i i e aul l 4 AI H Left pet i Co A o Am H Fa HLS l Jl LL SR 2 YT J AA N pau 7 h 4 I D C i Figure 0 1 View of screw compressor unit type Grasso SP duo Medium Foreword 2 510116E_foreword doc 12 11 2004 0 rr LL Grasso Refrigeration Division General P amp ID GRASSO SYSTEM CONTROL This diagram is intended to give a general overview of the measuring points provided The supplied unit may deviate from this diagram MAIN SWITCHGEAR CABINET Input signals Motor feedback Motor thermal protection Emergency Stop External ON External LESS External MORE Start release External reset Liquid level switch Gas sensor Setpoint switch Pos 011 012 016 100 105 110 115 Explanation Capacity control solenoids Capacity slide position sensor Motor current sensor Suction pressure sensor Discharge pressure sensor Oil pressure sensor Suction temperature sensor 12 11 2004 0 Pos 120 125 350 355 3

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