GEA Omni User manual

Control panel
GEA Omni™
Instruction Manual
E_806550_2

COPYRIGHT
All Rights reserved.
No part of this publication may be copied or pub-
lished by means of printing, photocopying, microfilm
or otherwise without prior written consent of
•GEA Refrigeration North America, Inc.
herein after called manufacturer. This restriction
also applies to the corresponding drawings and dia-
grams.
LEGAL NOTICE
This product information is a part of the documenta-
tion for the GEA Omni™ scope of delivery and
serves as product presentation and customer advi-
sory service. It contains important information and
technical data regarding the product.
The product information makes the technical, prod-
uct related and commercial information available to
the customer in detail before the sale of the product.
This product information serves as a support and
technical advisory service for our partners and cus-
tomers as well as for the marketing team. Apart from
serving as the medium for transfer of product know-
how, it also forms the basis for product demonstra-
tions, the organization and conduction of technical
seminars as well as the technical support at trade
fairs.
This product information should be supplemented
with the information about the industrial safety and
health related regulations at the site of installation of
the product. The regulations vary form place to place
as a result of the statutory regulations applicable at
the site of installation of the product and are there-
fore have not been considered in this product infor-
mation.
In addition to this product information and the acci-
dent prevention regulations applicable for the
respective country and area where the product is
used, the accepted technical regulations for safe and
professional work must also be observed.
This product information has been written in good
faith. However, the manufacturer cannot be held
responsible for any errors that this document may
contain or for their consequences.
The manufacturer reserves the right to make techni-
cal changes during the course of further develop-
ment of the GEA Omni™ shown in this product infor-
mation.
Illustrations and drawings in this product information
are simplified representations. As a result of the
improvements and changes, it is possible that the
illustrations do not exactly match the current devel-
opment status. The technical data and dimensions
are subject to change and claims can be made on
the basis of them.
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SYMBOLS USED IN THIS MANUAL
Danger!
Stands for an immediate danger which
leads to heavy physical injuries or to
the death.
Warning!
Stands for a possibly dangerous situa-
tion which leads to heavy physical
injuries or to the death.
Caution!
Stands for a possibly dangerous situa-
tion which could lead to light physical
injuries or to damages to property.
Hint!
Stands for an important tip whose
attention is important for the desig-
nated use and function of the device.
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TABLE OF CONTENTS
1 SAFETY AND CONFORMITY 13
1.1 Safety Instructions 13
1.2 Safety note concerning the connection of the GEA Omni™ with the starter panel 14
1.3 Conformity - CE marking (Europe) 15
1.4 Conformity - UL marking (USA, Canada) 15
2 USER INTERFACE 16
2.1 Menu Navigation 17
2.2 Status Bar 19
2.2.1 Logging In 19
2.2.2 Current State 21
2.2.3 Notifications, Warnings and Shutdowns 22
2.3 General Navigation 23
2.3.1 Tile Navigation 23
2.3.2 Grid and Chart Navigation 23
2.3.3 User Adjustable Fields 23
2.3.4 Keyboard 24
2.3.5 Keypad 25
2.3.6 User Non-Adjustable Fields 25
2.3.7 Drop Down Boxes and Text Edit 25
2.4 OmniView 26
2.4.1 Main Viewing Application 27
2.5 Compressor 29
2.5.1 Main Tab 31
2.5.2 Classic Tab 33
2.5.3 Vibration tab 33
2.5.4 Starter tab 36
2.6 Condenser 37
2.6.1 Overview tab (Condenser sequencer) 38
2.6.2 Main tab (Condenser sequencer) 39
2.6.3 Schedule tab 42
2.6.4 Main tab (Condenser water cooled) 46
2.7 Evaporator 46
2.7.1 Overview tab 47
2.7.2 Main tab 48
2.7.3 Evaporator for chiller 50
2.8 Sequencer 50
2.8.1 Overview tab 51
2.8.2 Main tab 53
2.8.3 Schedule Tab 55
2.9 OmniNet 58
2.9.1 OmniLink™ Tab 59
2.9.2 Modbus TCP Tab 60
2.10 History 61
2.10.1 Bottom Menu Navigation 61
2.10.2 RT-Trend Tab 64
2.10.3 Chart Tab 65
2.10.4 Annunciations Tab 66
2.10.5 Analysis Tab 68
2.10.6 Reporting Tab 69
2.11 Documentation 70
2.11.1 Documents Tab 70
2.11.2 Videos Tab 72
2.12 Service 73
2.12.1 I/O Status Tab 73
2.12.2 Maintenance Tab 76
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2.12.3 Activity Log Tab 80
2.12.4 Touch Panel Tab 82
2.12.5 Logic Tab 83
2.13 File Manager 84
2.13.1 Support Files 84
2.13.2 Documents Tab 87
2.13.3 Program Tab 89
2.13.4 System Tab 92
2.13.5 Apps Tab 94
2.14 Configuration 95
2.14.1 System Tab 95
2.14.2 Sensors Tab 96
2.15 Panel Settings 97
2.15.1 Localization Tab 97
2.15.2 Users Tab 98
2.15.3 Network Tab 100
2.15.4 Email Tab 102
2.16 Panel Info 103
3 CONTROL 104
3.1 Compressor Control Parameters 104
3.1.1 Capacity Control 104
3.1.2 Control 109
3.1.3 Variable Vi 113
3.1.4 Motor 114
3.1.5 Motor Power 115
3.1.6 Motor Current 116
3.1.7 Motor Interlock 118
3.1.8 Motor Speed 118
3.1.9 Motor Temperature 120
3.1.10 Oil Pump 122
3.1.11 Oil Pump Interlock 126
3.1.12 Oil Differential Pressure 126
3.1.13 Oil Filter Pressure 130
3.1.14 Oil Separator 132
3.1.15 Oil Temperature 134
3.1.16 Suction Pressure 135
3.1.17 Discharge Pressure 139
3.1.18 Discharge Temperature 142
3.1.19 Oil Cooling 143
3.1.20 Inlet Temperature 145
3.1.21 Outlet Temperature 145
3.1.22 Loss of Remote Start Signal 147
3.1.23 Power Failure Restart 147
3.1.24 Superheat 148
3.1.25 Economizer 150
3.1.26 Pump Down 151
3.1.27 Capacity Outputs 153
3.1.28 VTrac 154
3.1.29 Compressor Service 154
3.2 Oil Still Control Parameters 155
3.2.1 Oil Still 155
3.3 Condenser Sequencer Control Parameters 157
3.3.1 Schedule 157
3.3.2 Wet Bulb Control 158
3.3.3 Discharge Pressure 159
3.3.4 Condenser Control 160
3.3.5 Water Pump Lockout 161
3.4 Condenser Device Control Parameters 163
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3.4.1 Control 163
3.4.2 Variable Speed Fan/Variable Speed Pump 164
3.4.3 Water cooled condenser 164
3.5 Evaporator Control Parameters 165
3.5.1 Cooling 165
3.5.2 Fan Cycling 167
3.5.3 Defrost 167
3.5.4 Suction Valve Settings 170
3.5.5 Invert Solenoid Output 170
3.5.6 Evaporator for Chiller 171
3.6 Refrigerant Sensor Control Parameters 174
3.6.1 Refrigerant Sensor 174
3.7 Compressor Operating Data 176
3.7.1 Analog Inputs/ Outputs 177
3.7.2 Standard Calculated Values 178
3.7.3 Digital Inputs/ Outputs 179
3.8 Configuration 183
3.8.1 Panel Configuration 183
3.8.2 Compressor Configuration 187
3.9 Normal Operating States 197
3.9.1 Stopped Description 197
3.9.2 Starting Description 197
3.9.3 Running Description 198
3.9.4 Stopping Description 198
3.10 Additional Operating States 198
3.11 Screw Compressor Capacity Control 199
3.11.1 Forward and Reverse 199
3.12 Variable Vi 201
3.12.1 Operating Modes 201
3.12.2 Types of Vi Control Systems 202
3.12.3 Combined Vi Partial Load Control 202
3.13 Lubrication System 205
3.13.1 Full Time 205
3.13.2 Full Time with No Prelube 205
3.13.3 Startup 205
3.13.4 No Pump 206
3.14 IntelliSOC 206
4 ANNUNCIATIONS 207
4.1 Shutdowns 207
4.1.1 List and Description of Compressor Shutdowns 207
4.1.2 List and Description of Condenser Shutdowns 212
4.1.3 List and Description of Evaporator Shutdowns 213
4.1.4 List and Description of VTrac Shutdowns 213
4.1.5 List and Description of Refrigerant Sensor Shutdowns 213
4.1.6 List and Description of Drum Sequencer Shutdowns 213
4.1.7 List and Description of Other Shutdowns 214
4.2 Warnings 214
4.2.1 List and Description of Compressor Warnings 215
4.2.2 List and Description of Limitation Warnings 218
4.2.3 List and Description of Condenser Warnings 220
4.2.4 List and Description of Evaporator Warnings 220
4.2.5 List and Description of Profibus Gateway Warnings 221
4.2.6 List and Description of GEA BluAstrum Condenser Warnings 221
4.2.7 List and Description of VTrac Warnings 221
4.2.8 List and Description of Refrigerant Sensor Warnings 222
4.2.9 List and Description of Oil Still Warnings 222
4.2.10 List and Description of Other Warnings 222
4.3 Notifications 223
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4.3.1 List and Description of Compressor Notifications 223
4.3.2 List and Description of Condenser Notifications 223
4.3.3 List and Description of Other Notifications 224
5 SENSOR CALIBRATION 225
5.1 Pressure Transducer Calibration 225
5.2 ICTD Temperature Transducer Calibration 226
5.3 Capacity Slide Position Calibration 227
5.3.1 Compressor Capacity Slide Input Calibration with External Oil Pump 228
5.3.2 Compressor Capacity Slide Input Calibration without External Oil Pump 228
5.3.3 Calibration for Capacity Slide for Step Variable Vi Compressors 230
5.4 Volume Slide Position Calibration 231
5.5 Compressor Motor Current Calibration 232
5.6 Capacity Slide Sensor Calibration 232
5.6.1 Capacity Slide Calibration with External Oil Pump 232
5.6.2 Capacity Slide Calibration without External Oil Pump 233
6 LIST OF ABBREVIATIONS 235
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TABLE OF FIGURES
fig. 1 CE mark 15
fig. 2 UL mark 15
fig. 3 Initial Screen 16
fig. 4 Main menu bar 17
fig. 5 Default status bar 19
fig. 6 Expanded status bar 19
fig. 7 Default users 19
fig. 8 Remote Icon 20
fig. 9 User panel 20
fig. 10 Status panel 21
fig. 11 Annunciation icons 22
fig. 12 Annunciations panel 22
fig. 13 Sample Tile display 23
fig. 14 Keyboard display (Letters) 24
fig. 15 Keyboard Display (Numbers and symbols) 24
fig. 16 Keypad display 25
fig. 17 Main OmniView screen 26
fig. 18 Compressor tile 27
fig. 19 Condenser sequencer tile 27
fig. 20 Evaporator Tiles 28
fig. 21 Control level tile 28
fig. 22 Standard compressor buttons 29
fig. 23 Hold position options 30
fig. 24 Main tab display 31
fig. 25 Classic tab display 33
fig. 26 VTrac Damage view 34
fig. 27 VTrac Spectrum view 35
fig. 28 VTrac Options display 35
fig. 29 Starter tab display 36
fig. 30 Condenser overview tab 38
fig. 31 Condenser sequencer tile 38
fig. 32 Condenser fan tile 39
fig. 33 Condenser water pump tile 39
fig. 34 Main condenser tab (Condenser sequencer) 40
fig. 35 Main condenser tab (Condenser device) 41
fig. 36 Condenser schedule tab 42
fig. 37 Condenser schedule table 43
fig. 38 Condenser control buttons 44
fig. 39 Condenser timer control display 45
fig. 40 Condenser device control display 45
fig. 41 Main condenser tab (water cooled) 46
fig. 42 Evaporator Overview Tab 47
fig. 43 Zone Comparison Display 48
fig. 44 Evaporator Main Tab 49
fig. 45 Main evaporator for chiller 50
fig. 46 Sequencer overview tab 51
fig. 47 Control level tile 51
fig. 48 Compressor device tile 52
fig. 49 Add compressor display 52
fig. 50 Main sequencer tab (Control level) 53
fig. 51 Main sequencer tab (Compressor device) 54
fig. 52 Sequencer Schedule Tab 55
fig. 53 Sequencer Schedule Table 56
fig. 54 Sequencer Control Buttons 57
fig. 55 Sequencer Timer Control Display 58
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fig. 56 Compressor Device Control Display 58
fig. 57 OmniLink™ tab display 59
fig. 58 Modbus TCP tab display 60
fig. 59 The RT Trend button display 61
fig. 60 Edit view display 62
fig. 61 Chart tab button display 62
fig. 62 RT-Trend tab display (View - Graph) 64
fig. 63 RT-Trend tab display (View - Table) 64
fig. 64 Chart tab display (View - Graph) 65
fig. 65 Chart tab display (View - Table) 65
fig. 66 Annunciations tab display 66
fig. 67 Analysis tab display 68
fig. 68 Reporting tab display 69
fig. 69 Documents tile display 70
fig. 70 Sample document display 71
fig. 71 Videos tile display 72
fig. 72 Sample video display 72
fig. 73 I/O Status tab display 73
fig. 74 Sample digital input slice display 74
fig. 75 Sample digital output slice display 74
fig. 76 Compressor motor start notification 74
fig. 77 Sample analog input slice display 75
fig. 78 Sample analog output slice display 75
fig. 79 Maintenance tab display 76
fig. 80 Service task form display 77
fig. 81 Edit service tasks display 78
fig. 82 Service maintenance display 79
fig. 83 Activity log tab display 80
fig. 84 Touch panel tab display 82
fig. 85 Wash down icon 82
fig. 86 Logic diagram tab display 83
fig. 87 Support files tab display 84
fig. 88 Documents tab display 87
fig. 89 Program tab display 89
fig. 90 Update/Back up software display 90
fig. 91 Update/Back up configuration display 91
fig. 92 System tab display 92
fig. 93 Update/Back up system display 93
fig. 94 Factory default files display 93
fig. 95 Apps tab display 94
fig. 96 System tab display 95
fig. 97 Sensors tab display 96
fig. 98 Localization tab display 97
fig. 99 Users tab display 98
fig. 100 Network tab display 100
fig. 101 Email tab display 102
fig. 102 Panel info tab display 103
fig. 103 Estimated power demand , calculation formula 116
fig. 104 Project details options 183
fig. 105 Panel details options 185
fig. 106 Package details options 187
fig. 107 Oil system details options 191
fig. 108 Motor options 193
fig. 109 Remote Set Point Options 195
fig. 110 Suction options 195
fig. 111 Discharge options 196
fig. 112 Economizer details options 196
fig. 113 Forward acting capacity control 200
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fig. 114 Reverse acting capacity control 201
fig. 115 Pressure Sensor Calibration Pad 225
fig. 116 Temperature Probe Calibration Pad 226
fig. 117 Capacity Slide Calibration Pad 227
fig. 118 Capacity Slide Calibration Pad (Step Variable Vi) 230
fig. 119 Volume Slide Calibration Pad 231
fig. 120 Motor Current Calibration Pad 232
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1 SAFETY AND CONFORMITY
1.1 Safety Instructions
The GEA Omni™ is reliable in operation if used as specified.
Hint!
Read the safety instructions in the GEA Omni™ operating manual before startup.
The intended use includes the observance and compliance of
•all notices regarding hazard to persons and damage to property in the operating instructions,
•the country-specific standards and safety regulations,
•the instruction for installation, operation and maintenance,
•the details of certificates,
•the requirements for personnel,
•the obligation to exercise due care.
Only compliance with all provisions and guidelines will enable optimum protection of the personnel as well as
dangers to the environment and the safe and smooth operation of the GEA Omni™.
Warning!
GEA Omni™ can cause hazard in case of improper or unintended use. A malfunction indica-
tion on the touch screen cannot be ignored.
A personal injury or damage to the machine or plant can be the result.
For precautions to prevent danger see safety instructions in the operating manual.
Warning of electric shock!
Danger of electric shock exists.
More than one switch-disconnect may be necessary to isolate all electrical components.
Before maintenance work on the control panel, make sure that all electrical components are
switched off.
Danger!
It should be ensured at any time that all are necessary processes for compressor cooling and
lubrication in operation as long as the compressor is in operation.
This applies esprecially for the case where the compressor is unintentionally in operation. The
unintentionally compressor operation can be determined by observation of the compressor
motor feedback, the motor current or the motor speed.
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Safety and Conformity
Safety Instructions
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Hint!
To minimize the possibility of interference from electromagnetic signals in the operation of the
ICTD temperature converters, the following wiring guidelines must be observed:
•The signal cables should be two conductor shielded cable. Twisted pair cable is preferable.
•The signal cables should be run in conduits which do not contain any AC wiring.
•The signal cables should not be run in parallel or in close proximity to VFD power cables.
•All VFD equipment in the facility must be solidly grounded.
•If the ICTD sensors are not mounted on the skid or compressor package, the convertor should be
mounted at the probe location.
•Operation of some high-powered radio or microwave communications equipment in close proxim-
ity to the ICTD temperature converters, ICTD sensors, or interconnecting wiring may result in
inaccurate readings for the associated temperature(s).
1.2 Safety note concerning the connection of the GEA Omni™ with the starter panel
Hint!
It is not permitted to add an external controller between the GEA Omni™ and the power panel;
this would compromise the safety interlocks designed for protecting personnel and equip-
ment. All control signals between the GEA Omni™ and the starter panel must be processed
directly and must not flow indirectly via an external controller. GEA Refrigeration North Amer-
ica, Inc. cannot otherwise guarantee the safe operation of the system.
Safety and Conformity
Safety note concerning the connection of the GEA Omni™ with the starter panel
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1.3 Conformity - CE marking (Europe)
The CE marking of the GEA Omni™ takes place according to the Low Voltage Directive 73/23/EEC and the
EMC Directive 89/336/EEC.
By affixing the CE mark, the manufacturer confirms the conformity of the product with the applicable EC Direc-
tives and compliance with the principle requirements stipulated within them.
The CE mark is affixed in the cabinet.
fig.1: CE mark
1.4 Conformity - UL marking (USA, Canada)
The UL marking of the GEA Omni™ takes place according to the UL certification process and confirms the com-
pliance with national standards in the United States and Canada.
With affixing the UL marking, the manufacturer confirms the GEA Omni™ is built to the guidelines of UL.
The UL mark is affixed in the cabinet.
fig.2: UL mark
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Safety and Conformity
Conformity - CE marking (Europe)
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2 USER INTERFACE
The screen shown below will appear when the GEA Omni™ panel is powered on.
The central portion of the screen will change depending on the current display of the panel.
The menu bar on the left displays options used for navigation between displays or interfaces. The status bar at
the bottom displays important information regarding the status of the panel and its devices. Both the menu bar
and the status bar will remain visible at all times.
fig.3: Initial Screen
User interface
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2.1 Menu Navigation
fig.4: Main menu bar
The menu bar is used to navigate through the various user interfaces available on the GEA Omni™ panel. Each
option will display a new screen on the panel. For full information on a given option, see the associated section
of the document.
The options and their corresponding sections are shown in the list below.
OmniView Section 2.4, Page 26
Compressor Section 2.5, Page 29
Condenser Section 2.6, Page 37
Evaporator Section 2.7, Page 46
Sequencer Section 2.8, Page 50
OmniNet Section 2.9, Page 58
History Section 2.10, Page 61
Documentation Section 2.11, Page 70
Service Section 2.12, Page 73
File Manager Section 2.13, Page 84
Configuration Section 2.14, Page 95
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User interface
Menu Navigation
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Panel Settings Section 2.15, Page 97
Panel Info Section 2.16, Page 103
User interface
Menu Navigation
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2.2 Status Bar
fig.5: Default status bar
The status bar is displayed along the bottom of the panel display and will be visible regardless of which screen is
currently open on the panel. It displays the current user, the status of certain devices controlled by the panel, any
notifications, warnings or shutdowns that have been annunciated and the current date and time.
fig.6: Expanded status bar
Touching anywhere on the status bar will bring up the sub-screen displayed above. The expanded status bar
may be used to make changes to the user level, view detailed status information regarding controlled devices, or
acknowledge and clear annunciations.
2.2.1 Logging In
fig.7: Default users
The bottom left corner of the panel displays the user who is currently logged in. The icon is also color coded to
indicate the permissions each user has access to. When no user is logged in, this section will display Logged
Out and the user icon will be red. Once a user has logged in, the name of the user will be displayed and the icon
will change to green if the user’s access level is Operator or Service, or yellow if the user’s access level is
Admin.
Hint!
Admin level is only for use by GEA certified technicians.
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User interface
Status Bar
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fig.8: Remote Icon
Additionally, if the panel is currently being viewed remotely through OmniLink, the bottom left hand corner of the
display will blink back and forth between the icon for the current user and the remote icon shown above. The
remote icon is always colored blue and displays how many remote devices are currently viewing the panel dis-
play.
fig.9: User panel
The section shown to the far left of the sub-screen when the status bar is clicked displays a list of all users cur-
rently associated with the panel. For more information on adding or deleting users, refer to Instruction Manual
Section 2.15.2, Page 98.
If the user selected in the list is the one that is currently logged in, the Logout button will be enabled, which will
cause the panel to display the Logged Out message until another user is logged in. The Login button will be
enabled whenever a user account other than the one that is currently logged in is selected.
When a user not currently signed in is selected, the Login button will be enabled. Touching it will bring up a
numeric keypad which will allow the user to enter their password. If the correct password is entered, the selected
user will be signed in on the panel. If another user is already logged in, logging in as a different user will result in
them being signed out.
The default passwords for the Operator, Service and Admin access levels are displayed in the table shown to
the below. It is advisable to change these passwords once startup is completed.
Access level Default password
Operator 1
Service 123654
Admin 1236547890
User interface
Status Bar
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