Grasso System Control

for two stage Chiller/ Packages with Screw

Compressors

Operating Instructions

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 OPERATING INSTRUCTIONS

GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

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.

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

SYMBOLS USED IN THIS MANUAL

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

Warning!
Attention! Caution! Important!

Hint!
Tip! Note!

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

TABLE OF CONTENTS
1 Start-up / Operation of GSC .................................................................................................................. 8
1.1 General Information ................................................................................................................. 8
1.2 Description of the Grasso System Control................................................................................ 8
1.2.1 View............................................................................................................................... 8
1.2.2 Lamps/ Push buttons .................................................................................................. 10
1.2.3 Operator terminal....................................................................................................... 11
1.2.3.1 Key assignment............................................................................................ 12
1.2.3.2 Call up table of contents ............................................................................. 14
1.2.4 Status displays ............................................................................................................. 15
1.3 System description GSC........................................................................................................... 18
1.3.1 Explanation of the system LED................................................................................... 18
1.4 Alarms ..................................................................................................................................... 19
1.4.1 View active alarms and warnings............................................................................... 19
1.4.2 No alarm signal and the compressor will not start.................................................... 19
1.4.3 Restart following Alarms ............................................................................................ 20

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

TABLE OF FIGURES
fig. 1: View of outside of switchgear cabinet................................................................................................ 8
fig. 2: View of inside of switchgear cabinet .................................................................................................. 9
fig. 3: GSC operator terminal ....................................................................................................................... 11
fig. 4: "Status messages" display................................................................................................................... 15
fig. 5: Restart following Alarms ................................................................................................................... 20

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 OPERATING INSTRUCTIONS

GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

1 START-UP / OPERATION OF GSC

1.1 General Information

Warning!
Read the ´Operating Instructions´ before starting the screw compressor unit/ chiller.
The ´Operating Instructions´ is an extract from the GSC User Manual, containing the most important
information for the operator.
The indexes are not identical with those of the GSC User Manual. The index [X.X.X.] under the
headings of this operating instruction refers to the matching chapter within the User manual.

For more specific information see GSC User Manual or press the key to obtain more
information about the selected parameter.
The GSC is supplied with text in native language.

1.2 Description of the Grasso System Control

1.2.1 View
[Chapter 1.1.1. in user manual]

fig. 1: View of outside of switchgear cabinet

A HP
B LP
C Warning
D Failure

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

fig. 2: View of inside of switchgear cabinet

1 Profibus DP/DP-coppler
2 Bus Terminal
3 Type of Power Supply
4 Emergency stop relay
5 Relays
6 Socket-outlet for service

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

1.2.2 Lamps/ Push buttons

[Chapter 1.1.2. in user manual]
White indicator light (Running HP compressor)
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.
White indicator light (Running LP compressor)
This lamp flashes during start up of the LP-compressor.
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.

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

1.2.3 Operator terminal

[Chapter 1.2. in user manual]
The operator terminal is the interface between the operator and the control unit.
All switching, operating and control actions are carried out via this operator terminal.

fig. 3: GSC operator terminal

A System LED’s
B Function keys
C soft keys
D CPU operating mode setting
E digital keybord
F cursor keys
G System keys
H System keys LED‘s

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 OPERATING INSTRUCTIONS

GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

1.2.3.1 Key assignment

[Chapter 1.2.1. in user manual]

Key Function

Go to the menu item described

+

Back to previous display

+ Move to next display

Switch on the compressor unit, start enabled

Start HP-compressor (Press key for 5 sec. in operation mode "Manual")

Increase capacity of HP-compressor (in case of manual capacity control only)

Start LP-compressor (Press key for 5 sec. in operation mode "Manual")

Increase capacity of LP-compressor (in case of manual capacity control only)

without function
+

Call up display of actual values

Call up alarm signals

Lamp test

Switch off the compressor unit, start disabled

Stop HP-compressor (Press key for 5 sec. in operation mode "Manual")

Reduce capacity of HP-compressor (in case of manual capacity control only)

Stop LP-compressor (Press key for 5 sec. in operation mode "Manual")

Reduce capacity of LP-compressor (in case of manual capacity control only)

without function
+

Call up controls – settings

Call up operating mode setting

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

Key Function

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

Switch over to the 2nd keyboard level

Cursor keys

Functions of the F1 ... F4 buttons

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

Back to previous display

Go to the menu item described

Move o next display

Standard functions of the Shift button

Change between the possible selections

+ or

Alter the display contrast

+

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

Special function of the shift key

Change to the Status display

+

Change to the "Language selection + Contrast" menu

+

Change to the "Digital inputs / outputs" display

+

Change to the "Transfer" menu

+
stop with

Change to the "Password" menu

+

Change to the "Date, Time" menu

+

1.2.3.2 Call up table of contents

[Chapter 1.2.3. in user manual]

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

Number Title Help text

05 Actual values Display of all unit’s actual values

10 Control settings Display and set up of all control parameters

15 Mode Selection of operation mode

20 Limit values Set up of alarm, warning and limitation parameters

25 Fault messages Display of current and previous alarms

30 Timer settings Set up of timers

35 Options Selection of unit option menus

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

Number Title Help text

50 Configuration Enter:
— Refrigerants
— SC-Type
— Code
— - with/ without economiser
— - scaling of the sensors

90 Main system menu

To get to these menus, position the cursor on the menu name (using the or key) and confirm with the

key.

Danger!
Parameter changes in menu 20, 30, 35, 50 can cause serious damage to the screw compressor
unit or chiller!

1.2.4 Status displays

[Chapter 1.3. in User Manual]

To get to the "status display" views, 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.

fig. 4: "Status messages" display

AV-LP: Actual value (pressure or temperature) always displayed in °C

SP: Set Point display in °C
Pos LP: Current slide position in %
dPoil: Differential oil pressure in bar
Tc: Condensation temperature in °C
dOilf: Differential oil filter pressure in bar

Hint!
See menu 05 actual values

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS
The operating status provides information about the compressor unit.
The following status messages are possible:

Initialisation Initialisation of the control after switching on the power supply or after saving the
settings (RAM → ROM)

Start to start HP A switch on frequency limitation of the HP compressor drive motor is still active

Oil drain A switch on block period is active, the oil pump has run too long by itself
(Minimum position was not reached during start or stop procedure)

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

No start release The controller is waiting for an external signal to enable the start of the unit

Force to Min HP Starting procedure issued, slide moves to minimum position (HP)

Starting HP Compressor motor has been started, but the switchover to "Delta" has not yet taken
place or the startup has not yet been completed.

Running Compressor motor running in "Delta" or startup has been completed. Package/ Chiller
in operation.

Psuc Limitation A capacity limitation is active (suction pressure too low), "reduce output" solenoid
valve is opened.

Pdis Limitation A capacity limitation is active (discharge pressure too high), "reduce output" solenoid
valve is opened.

Imot Limitation HP A capacity limitation is active (HP motor current too high), "reduce output" solenoid
valve is opened.

Text Limitation A capacity limitation is active (external temperature too low), "reduce output"
solenoid valve is opened.

Toil Limitation Oil temperature too high, "refrigerant injection" is enabled (optional)

Stopping HP The compressor unit/ chiller has received a shutdown command, the capacity slide is
moved towards its minimum position (HP)

Compressor off The compressor has switched off

Stop to start timer Start delay after each stop

Failure A failure has occurred, which is still active.

Pump by itself The minimum position was not reached during switch on or off procedure. The oil
pump continues to try to adjust the control slide in the min direction. After the oil
pump run by itself the oil block period becomes active.

Pull down Pinterm The intermediate pressure is drawn off down to the switch on pressure (release of
the LP compressor)

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

Start to start LP A switch on frequency limitation of the LP compressor drive motor is still active

Imot Limitation LP A capacity limitation is active (LP motor current too high), "reduce output" solenoid
valve is opened.

Pdis Limitation LP A capacity limitation as active (LP discharge pressure too high), "reduce output"
solenoid valve is opened

Psuc Limitation HP A capacity limitation as active (HP suction pressure too low), "reduce output" solenoid
valve is opened

Slide to min LP Starting command issued, control slide moves into the minimum position (LP)

Starting LP Compressor motor has been started, and the running feedback signal from the
starter panel has not yet been received (LP)

Stopping LP The compressor unit/ chiller has received a shutdown command, the capacity slide is
moved towards its minimum position (LP)

Italic lettering Text display flashes

Normal lettering Text appears as static text

The overall status of the compressor unit is displayed with the LEDs in and .

Key Colour Status Explanation

The unit/ chiller has received a start request. The

Green Flashing
compressor could start any moment now.

The unit/ chiller has received a start request. The

Green Continuous light
compressor is running.

The unit/ chiller is malfunctioning. The compressor is

None OFF not running. The (red) indicator light ‘Collective fault’
+ flashes or is permanently lit.

The unit/ chiller is switched off. The compressor is not

red Continuous light
running.

Display of the system deviation or the ext. actuating

Green Continuous light
pulses of the HP compressor (more output is required)

Display of the system deviation or the ext. actuating

Green Continuous light
pulses of the LP compressor (more output is required)

Display of the system deviation or the ext. actuating

Green Continuous light
pulses of the HP compressor (less output is required)

Display of the system deviation or the ext. actuating

Green Continuous light
pulses of the LP compressor (less output is required)

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

1.3 System description GSC

[Chapter 4. in user manual]
The system LEDs are located on the front of the GSC. These system LEDs provide information about the status of
the controller.

1.3.1 Explanation of the system LED

[Chapter 4.1. in User Manual]
The position of the system LED is given in Chapter figure 3, page 11.
Meaning of the status and error displays

Display Meaning Explanation

SF (red) C7-CPU-centralised fault Lights up for:

— Hardware errors,
— Firmware errors,
— Programming errors,
— Parameterising errors,
— Computational errors,
— Time errors,
— Faulty internal memory storage,
— Battery failure or the standby supply is missing while MAINS
ON,
— Peripheral error in the internal peripheral functions.
Further information about the malfunction that has occured can
be read out of the diagnosis memory using the PG.

BATF (red) Battery error Lights up, if battery

— does not have enough voltage,
— is defective,
— is missing.

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

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

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

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

SF-IM (red) Switching module - centralised lights up, if the connection between C7 and the extension rack
fault is interrupted.

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

Display Meaning Explanation

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

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

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

1.4 Alarms
[Chapter 6. in user manual]

1.4.1 View active alarms and warnings

[Chapter 6.1.3. in user manual]

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

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

1.4.2 No alarm signal and the compressor will not start

[Chapter 6.5. in user manual]
Compressor will not start, although there is no active alarm.

Key “ON” has been pressed and the LED K1 ”ON” is flashing.

Cause Remedy

No ‘start release’ signal The input ´start release´ is not Close input or install a link.
closed.

‘Auto Start dly’ active The time setting ‘Auto start dly’ in Wait until the delay time has
‘control settings menu’ has not yet expired.
expired.

‘Start to start’ delay active The time setting ‘Start to start’ in Wait until the delay time has
‘Timer settings’ menu has not yet expired.
expired.

actual value < (set point + ½ NZ) Check set point and neutral zone
NZ = neutral zone settings in ´Control settings´menu.
In case of suction pressure control
the set point value is entered in
degrees Celsius.

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

1.4.3 Restart following Alarms

[Chapter 7.2. in user manual]

fig. 5: Restart following Alarms

Caution!
It is not possible to restart the compressor as long as the cause of the alarm still exists!

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GRASSO SYSTEM CONTROL

FOR TWO STAGE CHILLER/ PACKAGES WITH SCREW
COMPRESSORS

Display of the cause(s) of the alarms after deleting the display on view (press the key) or in the case that
several alarms have occurred simultaneously:

Step Procedure

1
Call up the "Alarms" menu by pressing the key.

2
Select the "View" menu item for the alarms by pressing the key.
The errors that have occurred can be viewed here with the date and time at which
they occur.

Caution!
For more detailed explanations for reading the error messages, see Chapter 1.2.2.2. (GSC User
Manual).

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