Microprocessor Control System

Microprocessor
Control System
Keeping You
In “Touch” With
Your Refrigeration
System...
...and providing
new tools for
effectively
managing your
energy usage
Refrigeration Technologies/ GEA FES, Inc.
GEA FES, Inc., the first
compressor package manufacturer
to provide microprocessor-based
control for screw compressor
packages and systems, continues
to enhance the GForce™ control
panel, the most operator-friendly,
practical, and easy-to-use control
panel in the industry.
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The GForce™ Panel can
do the following:
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Screw compressor control
Rotary/Reciprocating compressor control
Centrifugal compressor control
Compressor sequencing
Condenser fan/pump sequencing
Air unit cooling & defrost control
Vessel & Pump package control
Chiller control
Refrigerant leak detection
kW limiting/load shedding
All of these functions and many more are
possible in a single, or distributed across
multiple, GForce™ panels.
GForce™ Panels to replace existing controls are
available for, and have been installed on the
following compressors: All types of FES packages,
Grasso, Mycom, Howden WRV & XRV, Dunham-Bush,
Kobe, Sullair, Frick, Stal and Sabroe twin screws;
Vilter and Hall single-screws; single and compound
recips manufactured by Grasso, Vilter, Mycom, Sabroe
& Frick/York; and York and Carrier Centrifugals.
Easy Ethernet Communications
The GForce™ Ethernet port makes the panel highly
compatible with outside communications. Through a
secure Ethernet network, new or existing, a remote
user is able to view and access the panel as if standing
right in front of it. Free FES supplied software or any
Java-enabled web browser can be used; no additional
software is needed.
A dedicated network can be built using only an
Ethernet switch and standard Ethernet CAT5 cable
running to each GForce™ panel and to the remote
viewing computer. It’s as simple as that!
The GForce™ panel’s Ethernet Port also supports
Modbus/TCP/IP industry standard protocols as well as
Ethernet/IP protocol for providing access to an FES
MicroLINK SCADA System, a PLC, the plant’s DCS, or
any other supervisory system.
Existing ComMENT Network?
A ComMENT Network interface option available for
GForce™ panels makes new FES compressors
backward compatible with existing Micro-III based
sequencing via the FES ComMENT Network.
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General Description
Reliable & Secure
Built on an industrial processor
hardware platform and utilizing
the proven Microsoft Windows®
XP Embedded operating system
software, the GForce™ Panel
provides the reliability required
by the Industry.
Industrial Processor Assembly
Three levels of “watchdog” protection are
designed into the panel hardware and software to ensure that the compressor (or
other equipment) is only driven when the
panel is working properly. Even the inside
I/O Interface Board
panel temperature is monitored, and will
Want more details on its
generate an alarm if too high. Each I/O
reliability and construction?
Interface Board provides up to 16 analog inputs (16-bit
The GForce™ industrial processor is made for tough
resolution) and now up to 12 analog outputs (previenvironments and is designed for control purposes,
ously 4).
not for a desktop PC. It is based on an Intel processor
that is currently used in many products. And
Rounding out the hardware is the I/O Rack connected
obsolescence is not a concern—the GForce ™ panel
to the I/O Interface Board. Each rack has space for
design allows for future replacement of a malfunc24 I/O modules configured as inputs or outputs by
tioning processor with a newer processor that is
the panel program. The industry standard modules
available, extending the panel’s useful life.
with fuse and LED indicator are available with a
built-in H-O-A toggle switch. Each I/O rack includes
Programs and data are stored on a “disk on chip”
a fuse tester and spare fuse.
type flash memory. The GForce™ mass storage
media will provide reliable data storage for many
And the Software?
years.
The GForce™ Panel’s operating application software
was developed directly from the FES Micro-III panel,
The GForce™ Panel screen is weather and chemical
providing functionality that has been well-tested and
resistant, and it can withstand even a high-speed
proven reliable since the mid 1990’s. This application
impact from a blunt object. The display’s backlight
software interfaces to Microsoft’s Windows® XP
will last tens of thousands of hours; the panel’s
Embedded operating system, custom tailored for the
screen saver feature makes sure these are hours of
GForce™ panel hardware. Windows® XP Embedded
real use.
and software tools used to develop the GForce™
application software are in use by many companies
Integral to the monitoring and control provided by
and in many, many products operating throughout
the GForce™ panel is an I/O Interface Board customthe world. By using proven operating system and
designed by GEA FES, Inc. for interfacing directly to
development tools, the FES GForce™ development
the field devices. The processor accesses all field
team has been able to concentrate on implementing
devices via a robust RS485/Modbus network connecand testing the control and monitoring of the comtion to this I/O interface board, a very reliable means
pressor and other refrigeration equipment. All helpfor reading the state of the inputs and directing the
ing to ensure reliable GForce™ panel
outputs.
software.
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The I/O Interface Board, with its own microprocessor,
can override the main processor and shut off the
outputs for failsafe operation if it detects a problem.
It will direct all control outputs to their safe state.
Is it Secure?
The GForce™ panel has 3 levels of security—Basic,
User, and Service—each with increased capabilities
and each accessible via unique password entry.
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Easy to Operate & View
The GForce™ Control Panel display is clear, crisp,
and easy to view. Utilizing a large 15” diagonal,
full 32-bit-color, LCD display with 1024 x 768 pixel
resolution and a 120° viewing angle, the GForce™
provides high resolution color images, making even
very detailed screens appear with superior clarity.
Navigating from screen to screen is so easy it is almost
natural. A touch of the Suction Pressure Display area
near the compressor’s suction inlet will bring up a
screen with all Suction Pressure parameters —control,
alarm & shutdown. Access of all panel information is
one or two screen touches away!
The GForce™ display is also a resistive touch screen
with active touch areas clearly indicated. The screen
can sense a stylus or a bare, oil-covered, or even
gloved finger.
Multi-language support is included for standard screens
—English, German, French, Spanish, and Chinese are
standard. Further customization is available; the
GForce™ is adaptable for almost any language.
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Easy to Maintain & Update
An ordinary USB Flash Memory Device plugged into
the GForce™ Panel’s USB port is the means for transferring data to and from the panel. The transfer
capabilities are simple and versatile—operating program,
parameters, historical trend data, alarm history—all
can be transferred from the GForce™ memory and
archived or used for analysis. Manuals and drawings,
even a User’s document or picture in PDF format (SOP’s,
equipment service photos, etc.) can be loaded into
the panel’s memory and viewed on the panel display.
Program updates are easy—the update is e-mailed
from FES and transferred to the GForce™ processor in
the field through this same USB port.
For cleaning the screen, a Washdown mode is included.
After cleaning, a series of touches in sequence at
specific points on the screen will return the screen to
its normal operational mode.
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The GForce™ Maintenance Scheduler lists tasks with
time interval between service operations, time
stamping when
service is done,
and tracking of
time remaining
(in Run-time hours)
until due.
The GForce™
Maintenance Log
provides a date
and time-stamped
log of activities
and a way for
Users to enter
maintenance
records and/or
notes for the next
shift Users to view.
Easy to Support
The GForce™ Panel can now generate its own startup
record document which lists current values of all analog
and digital points and all adjustable parameter settings.
When trouble-shooting a problem, the refrigeration technician can quickly look at diagnostic utility screens, onscreen manuals, drawings and trouble-shooting guides.
Also capturing “Rx-Trend” historical data, the technician
can quickly display all analog and digital status with the
capability of e-mailing the data for diagnosis.
all analog and digital control signals recorded for the
10 minutes prior to the shutdown. Analyzing this display or comparing the data to data still retained in
panel's memory from earlier failures may help indicate
the source of the problem.
• To get additional help, the “Rx-Trend” data transferred to a USB flash memory drive can be e-mailed to
the servicing contractor or FES for analysis and support
assistance.
The GForce™ Panel has a minimal number of
components to change and a minimal number of connections between them, making troubleshooting &
repair easier. The main components are: Processor/
Touch Screen Assembly, I/O Interface Board, I/O Rack,
Power Supply, I/O Modules, relays, and fuses.
• Sensor or interface hardware failures can be
pinpointed using diagnostic screens available.
Using the diagnostic & support features of the GForce™
Panel, how can an Operator find out why
a compressor shut down unexpectedly?
• The Shutdown Failure annunciation shows the
actual shutdown condition.
• The “Rx-Trend” graphical screen displays the status of
• The repair can be logged into the panel’s own
User-customized, date-stamped Maintenance Log for
future reference.
• FES-supplied drawings, data sheets and parts lists
stored in the panel memory can be viewed to locate
the part that must be ordered, again right at the
GForce™ panel.
• Alarms & shutdowns can automatically cause an email
or text message to be sent to multiple levels of personnel with acknowledgement capability when message
is received.
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Screw
Compressor
Control
The Compressor view shows a
^
graphical representation of the
compressor and system components.
View it Your Way!
The GForce™ panel is
flexible. Operators can
view the compressor the
way they like to see it with
a choice of three main
operating screens.
The OmniView is a tabular display
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of everything you need to know
about the compressor on a single
screen, giving the ability to change
a parameter and watch the effect.
Many different tasks can
be done at the panel
while the compressor is
running—
parameter access; viewing
on-screen drawings and
manuals; maintenance
log and scheduler entries;
viewing historical trend
data and alarm history; etc.
The Classic view, a favorite of
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people who have worked with
refrigeration systems for a long time;
shows gauges, meters, lamps and
pushbuttons typical of an electromechanical panel.
System Control
A single GForce™ System Panel can be configured for
compressor sequencing, control and monitoring of
screw, reciprocating and rotary
vane compressors; control of
condenser fans and pumps;
control of air units; and other
refrigeration system functions
like vessel/pump package control,
refrigerant leak detection,
engine room ventilation, and
KW monitoring and load
shedding.
Panel Sizes and I/O
Capacity
Up to 48 Analog Inputs, now 36 Analog Outputs, and
120 Digital I/O in one panel; Remote I/O GForce™
panels expand these to 160 Analog
Inputs, 120 Analog Outputs, and 480
Digital I/O. GForce™ Remote I/O Panels
connect to their GForce™ Processor
Panel with a single, shielded, 3-wire,
communications cable, up to thousands
of feet in length.
GForce™ Main System Overview
Four panel sizes are currently available; all
are designed and built to meet UL/cUL
508A, Type 4 rating—22"H x 26"W x 8"D,
30”H x 26”W x 8”D, 40”H x 30”W x 10”D,
and 76”H x 36”W x 12”D.
Historical Trending
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Compressor Sequencing
The Compressor Sequencing function is an energy
management control method that maintains stable
refrigeration plant suction pressures on process
temperatures by coordinating the operation of multiple
screw, recip and rotary vane compressors in a system.
The function’s purpose is to utilize the plant’s compressor
capacity in the most energy efficient manner.
Features
• S equence up to 50 compressors—
GForce™-controlled via an Ethernet network;
FES Micro-III, Micro-II/IIE or MicroMASTER-controlled
and Frick’s Plus or Quantum-controlled (version 3 or
later) via the FES ComMENT network; electromechanically- controlled recip and rotary vane compressors via hard-wired digital I/O; on up to 4 suction air temperature levels.
•D
rum sequencer operation – a rise in suction pressure
above designated differential “moves” drum in
direction to increase capacity; drop in suction
pressure moves drum in decreasing capacity direction
and moving from step to step is governed by individual user-adjustable timers just for that step.
•E
ach step of sequencer has User-adjustable soak,
next step and previous step timers.
ach step has User•E
configurable operation—starting, stopping, loading, unloading or automatic
control—for each compressor individually.
• Energy saving scheduler functions include:
• Enable/Disable of compressors
• Enable/Disable of sequencer
•C
hanging/Ramping suction pressure or process
temp setpoint
Benefits
•M
inimize horsepower consumption at partial plant
load.
•M
inimal installation costs using commonly-available
Ethernet switches and Ethernet CAT5 cable to the
GForce™ sequencing panel and to each of the
compressor panels.
•R
ecip and rotary vane compressors with electromechanical controls do not require replacement
of existing controls to be included in sequencing;
GForce™ panel is configured with the I/O needed
for each recip or rotary. Existing safety switches are
left intact.
•P
rovides cost effective and easily implemented
way of adding sequencing to existing compressor
installations.
•A
dding future GForce™ controlled compressors to
the sequencing on existing suction levels requires
no factory configuration changes, only Ethernet
wiring and User-adjustable addition of the compressor using the GForce™ panel’s touch screen.
he sequencing function can be either added into a
•T
compressor's GForce™ panel or in a GForce™ panel
remote from the compressors.
•T
ouch screen display of the sequencing GForce™
panel can be used to remotely view operation of
each compressor being sequenced.
• S equencer operates independently of the compressors;
therefore, it is unaffected by failed or marginallyoperating compressors.
he sequencing function is fully predictable as
•T
defined by the User’s setup.
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Condenser Control
Condenser Control maintains stable system discharge
pressure by providing automatic cycling of the fans
and water pumps of evaporative or air-cooled
condensers. The condenser sequencer’s purpose is to
utilize the plant’s evaporative condenser capacity in
the most energy efficient manner. Other features are
provided to compliment and enhance this control.
Features
•C
ontrols up to 50 devices on a common discharge
level. Factory configurable devices include any
combination of water pumps and single, dual, and
variable speed fans.
•M
anual override of automatic stepping by
touching HOLD, LOAD (one step) or UNLOAD
(one step) screen buttons
•D
rum sequencer operation - rise in discharge
pressure above designated differential “moves”
drum in direction to increase evaporative condenser
capacity; drop in pressure moves drum in decreasing
capacity direction.
•T
wo setup matrices exist so that two different fan/
pump sequences (example: winter/summer)
can be pre-programmed by the Operator. Matrix
selection is manual or can be factory configured
to change automatically based on ambient air
temperature or other system-defined function.
•A
condenser setup matrix allows the User to select
and change each step of the sequencer at any time:
•R
un time is accumulated and displayed for each
device.
•T
he operation of each device—starting, stopping,
high/low speed as well as automatic control for
variable speed fans
•U
ser-adjustable High-to-low spin down time for
2-speed fans
•“
Soak” time for system to respond to change in
condenser capacity
•U
ser-adjustable Proportional, Integral and
Derivative constants for PID loop controlled
variable speed fans
• Delay times for stepping forward and backward
• Energy saving scheduler functions include:
• The condenser setup matrix allows:
• enable/disable of fans and pumps
• Any combination of device starting sequences
• changing discharge pressure set point
• S ingle or multiple devices can be started or
stopped on the same step
• switching control from one matrix to the other
Optional Features
•A
utomatic water pump lockout on low ambient
air temperature with a high discharge pressure
override set point.
•M
onitoring of condensed refrigerant liquid
temperature and alarm when non-condensables
are in the system.
•W
et-bulb control—floating discharge pressure
control set point based on wet-bulb temperature
calculation using outside relative humidity and
ambient air temperature. This feature can help
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keep the discharge pressure as low as possible
while reducing wasted energy usage when ambient
outdoor conditions are not favorable for evaporative
condensing.
and-Off-Auto toggle switches in output modules
•H
for manual override of the condenser device control
outputs;
• Condenser sump monitoring/control
Air Unit Control
The Evaporator Control functions provide temperature monitoring and control for plant areas. Control outputs of the
GForce™ panel direct the opening and closing of valve station solenoid or modulating valves and the starting and
stopping or speed control of air unit fans, providing the
cooling and defrost functions for each evaporator zone.
Features
•G
Force™ panels can provide up to 80 configured
evaporator zone control groups for control of valve
stations and air unit fans.
• Zone control groups are factory-configured to
provide monitoring of a zone temperature and control of fans and liquid, suction, soft hot gas, hot
gas, bleed, and humidity control solenoid valves.
• A
ll defrost cycle timers—pump down, soft hot gas,
hot gas, bleed, and fan delay—are easily adjustable.
• All zones have temperature alarm differential set
points above and below the current zone set point.
Benefits
•V
arious standard features that can be used to
minimize energy usage:
• Zone defrost cycles can be initiated by liquid
runtime set point, scheduler, or manual initiate.
• Zone defrost terminate on coil temperature or
other condition is possible through optional
factory configuration.
• Zone temperatures can be lowered during
lower-cost energy periods and raised during peak
energy periods.
• Ramping of zone temperatures is possible for
controlling temperature pull down and
temperature increase rates.
• Fan cycling feature can be enabled for stopping
the fans when the zone temperature is at set
point, another energy saving feature. Fans run
periodically for several minutes to agitate the air
in the room and to check the zone temperature.
• Automatically delayed startup of each zone stag-
es the turning on of zone fans to avoid power
spikes during power up.
• Defrost loops provide a means for avoiding simultaneous zone defrosts; if defrost is initiated for a second zone on a single loop, that zone’s defrost cycle
will be delayed until the first zone’s defrost is terminated.
• Easily-adjusted zone probe assignment is especially
useful for temporary re-assignment if a probe fails.
• Zone outputs may be controlled from GForce™
panel with processor or from a remote I/O GForce™
panel; remote I/O panel can be located closer to
valve stations to minimize field wiring.
• An extremely flexible Energy
Saving Scheduler is provided
for initiating defrosts, changing/ramping zone temperature setpoints, enabling/disabling individual zones, and
prohibiting individual zone defrosts;
all entries are user-defined.
Optional Features
•
Factory configurable functions:
• Humidity control (Reheat function)
• Variable-speed air unit fan control
• KW limiting/load shedding
• Heating control—hot gas or electric
• Defrost termination by coil temperature sensor or
other status
•H
and-Off-Auto toggle switches in zone output
modules provide means for manual override.
• Fan isolation relays can be included in panel for
zones with fan loads that exceed output module
current capacity.
• Zone can be configured for Glycol air unit control.
• Defrost cycle can include a water-wash step.
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Reciprocating and Rotary Vane
Compressor Control
Safety Monitoring and Capacity Control of reciprocating and rotary
vane compressors using direct, hard-wired I/O connections can be a
cost effective way of retrofitting existing instrumentation
or providing automated control for these compressors.
Features
•E
ach recip/rotary compressor can be factoryconfigured with up to 5 capacity solenoid outputs
and up to 10 capacity steps (including start).
For total replacement of existing sensors and controls:
• One GForce™ panel can accommodate up to four
reciprocating or rotary vane compressors with full
instrumentation.
• Capacity control of each compressor based on
compressor’s own suction pressure is included
with load limiter functions standard.
• Each compressor’s suction pressure, discharge
pressure, discharge temperature, oil pressure,
motor current and a miscellaneous temperature
(e.g., for oil temperature or coolant temperature)
are monitored with User-adjustable alarm and
safety shutdown set points provided.
• Unloaded Start and Oil Return outputs are available
•C
ontrol relay contacts are included for Oil Heater
and Oil Cooling control
• Panel E-Stop switch is included
For those who wish to keep existing safety switches
and devices, but still want sequencing of the compressor:
• A maximum of ten hard-wired compressors can be
configured in one GForce™ panel
• If more than 10 are needed, a second GForce™
panel can accommodate.
• Monitoring of safety shutdown input is included for
electro-mechanical safety annunciation.
Optional features
•D
ual Discharge configuration monitoring
• 2-Stage reciprocating compressor control and
monitoring
Management of Energy Usage and
Other Refrigeration System Monitoring and Control Functions
Many other functions
normally needed in a
complete refrigeration
control system are also configurable in a GForce™ panel. These include, but are not limited to:
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•C
hiller system monitoring and control
• Monitoring of miscellaneous pressures, temperatures, levels and humidity with
alarm annunciations
• Monitoring and control for glycol and water system with single or multiple pumps
• Vessel and Pump Package monitoring and control with liquid level makeup control,
high and low liquid level alarms/shutdowns from level sensor and set points or float
switches, multiple pump lead/lag control with automatic switchover on loss of pump
run interlock, loss of pump pressure or seal oil level.
• Refrigerant Leak Detector monitoring, alarm annunciation and equipment shutdown
• Fail-safe Engine Room Exhaust Fan control for room temperature and refrigerant
leak detection
• kW Usage monitoring and kW limiting functions
• Underfloor heating system monitoring and control
• NEW Energy Saving Scheduler, with both proactive (kW demand control)
and reactive (kW limiting/load shed control) operation, will save energy costs!
GEA FES, Inc.
MicroLINK
Supervisory
Computer System
•A
full-function, desktop PC-Based
Supervisory Control & Data
Acquisition (SCADA) System for an
FES Refrigeration Control System
•A
ble to communicate with and
provide SCADA functions for any
combination of FES Micro Panels,
FES PLC Panels and even PLC Panels
and Micro Panels supplied by other
manufacturers
Satellite Panel
The FES GForce™ Satellite Panel is used to
display information from, and interact with,
multiple GForce™ compressor control and
system panels. The front of the control panel
features a 15” full color LCD with a resistive
touch screen as the user interface.
•G
Force™ panel dedicated to remote viewing
capability
• Includes Custom Overview screen
showing P&ID and overview status
of the refrigeration system
• Includes Custom Planview screen of
the facility showing location and
status of each air unit
single point of collection for all
•A
historical and alarm history data
rovides logging of supervisory
•P
operations and changes
ble to show any two screens
•A
selected by user at one time
•A
ble to remotely view information from, and
interact with, multiple GForce™ compressor and
system control panels
•V
iew up to four GForce™ panel screens at the
same time!
•P
rovides 15” full-color touch screen display, same
as all GForce™ panels
•P
rovides a cost-effective central HMI station
suitable for factory floor use; UL Type 4/Nema 4
enclosure rating standard, Nema 4X stainless or
fiberglass optional
•P
rovides a central location for documentation
storage/viewing and maintenance logging
•R
eplaceable processor/touch screen assembly
common for this panel and all other GForce™
panels
•A
vailable with mushroom-style Emergency-Stop
switch for common point of equipment shutdown
via hardwired connections to other GForce™
panels
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GEA FES, Inc.
Parts Centers
There are five strategically
located parts and compressor
rebuild centers in the United
States. Contact the nearest
center for certified FES parts.
GEA FES, Inc. Headquarters, York, Pennsylvania
Pennsylvania
Headquarters
GEA FES, Inc.
3475 Board Road
York, PA 17406
Phone: 717-767-6411
Fax: 717-764-3627
Texas
GEA FES, Inc.
18574 Van Road
Houston, TX 77049
Phone: 281-456-8500
Fax: 281-456-8504
California
GEA FES, Inc.
3210 North Ad Art Road
Unit B1
Stockton, CA 95205
Phone: 209-931-3970
Fax: 209-931-1710
Arkansas
GEA FES, Inc.
780 W. Randall Wobbe Lane
Springdale, AR 72764
Phone: 479-751-6440
Fax: 479-751-6448
Florida
GEA Refrigeration CNA
3038 N.W. 82nd Avenue
Miami, FL 33122
Phone: 305-913-7500
Fax: 305-913-7501
GEA FES, Inc.
3475 Board Road, York, Pennsylvania 17406
Ph: 717-767-6411 | Fax: 717-764-3627
Email: [email protected] | www.geafes.com
Form No. GForce 03-11