Spirax Sarco GS25039-1-10-1810-FC Process Controller

Бренд: Spirax Sarco

Belongs to the GS-X series new-generation PID контроллер процесса (steam dedicated), used for closed-loop PID control of temperature, pressure and level in steam systems, supporting Industry 4.0 / IIoT and Ethernet communication. No official public document provides a full decoding table for this complete part number. GS25039 is the base material number. The subsequent -1-10-1810-FC stands for custom options, ввод/вывод, выход, firmware version and certification suffix, which are internal order codes. You need to submit the full model number to Spirax Sarco China channels to obtain the original factory selection sheet.Input accuracy: 0.1% ФС, high stability for temperature / pressure measurement, suitable for steam, горячая вода, heat exchange station, sterilization and clean steam applications

Heat exchange stations, steam desuperheating and pressure reduction, clean steam, стерилизаторы, hot water temperature control, boiler TDS / blowdown control, condensate recovery system regulation.

Spirax Sarco GS25039 (GS-X Series, Document Reference: TI-P794-01 / IM-P794-03)

Важное примечание: GS25039-1-10-1810-FC is a factory pre-configured FC version. Terminal layout follows the general GS-X base board, while I/O modules (-1, -10) are order-selected options. Always refer to the terminal label printed on the back of the controller itself for on-site wiring. The general terminal definitions below shall not replace the nameplate of this unit.

Standard Terminal Wiring Definition (General GS-X)

Силовые терминалы

л / Н: AC power supply 100–240 V AC wide range

Protective earth PE: Instrument shield ground. Connect the shield of sensor cable only to this terminal at the controller side; do not ground both ends.

Предупреждение: Low voltage sensor loops (ПТ100, 4–20 мА) must not be connected with 220 V AC and shall be isolated.

Sensor Input (IP1 Primary Input, IP2 Auxiliary Input)

ПТ100 (3-wire RTD, most common for temperature)

IP1+, IP1-, IP1-R: 3-wire RTD. Use shielded instrument cable for long runs and keep wire resistance balanced.

4–20 mA transmitters (давление / уровень)

IP1+ / IP1-: Текущий сигнал. The controller provides isolated 24 V DC transmitter supply (SU+, SU-) and can directly power Spirax Sarco pressure / датчики температуры.

Термопара: IP1+, IP1-. Cold junction compensation parameters need to be set.

Digital DI (DIO1, DIO2)

Dry contact digital input (valve feedback, external interlock, remote start/stop), passive contact with internal pull-up.

Выход управления (OP1 / OP2 for main PID output, OP3 alarm relay)

Суффикс -10 in your model typically means isolated 4–20 mA analogue output (Д1) for driving valve positioners such as SP7.

OP1+ / OP1-: 4–20 mA control output (изолированный), connected to valve positioner

OP3 (КОМ / НЕТ / Северная Каролина): C-type alarm relay for high/low limit alarm and fault interlock

Other optional output types: Реле (Р), bidirectional thyristor (Т), logic output (л), determined by order code.

Коммуникация

RS485: А / Б, Модбус РТУ

Ethernet RJ45 port: Native high-speed Ethernet for iTools configuration, SCADA and IIoT upload. FC pre-configured units usually come with preset IP address.

Wiring Specification Notes

Separate sensor cables and power cables in different cable trays to avoid interference.
Shield cable rule: Shield grounded only at the controller end; leave the sensor end floating.
Момент затяжки клемм: 0.4 Н·м, conductor cross-section: 0.5–1.5 mm²
Power off before wiring. Verify I/O configuration and rear label before power-on. FC factory-configured units may differ from standard templates.
Troubleshooting Checklist for GS-X Steam PID Controller

Предоперационная подготовка: Back up parameters first. Use Spirax iTools software for backup to avoid configuration loss.

Симптом неисправности	Возможные причины	Действия по устранению неполадок
① No display when powered on	1. Loss of supply, напряжение ниже 90 ВАК; 2. Перегорел внутренний предохранитель; 3. Loose power terminals; 4. Poor panel cable connection	Measure L-N AC voltage with multimeter; check terminals after power-off; inspect internal fuse; confirm it is not a 24 V DC model mistakenly wired to AC supply
② “OPEN / SENSOR” sensor break alarm	Broken RTD, open 4–20 mA loop, обратная полярность, no transmitter supply, excessive wire resistance	1. Disconnect sensor and simulate signal at input terminal (PT100 resistance / 4 mA signal); 2. Check SU+ 24 В выход; 3. Verify three-wire resistance balance for 3-wire PT100; 4. Inspect cable damage
③ Unstable reading, drifting or fluctuating PV	Incorrect shield grounding, parallel routing with power cable, unstable transmitter supply, aged sensor, окисленные клеммы	Separate power and signal cables; correct single-point grounding; подтянуть клеммы; replace sensor for comparison test
④ PID no output, valve stays idle, PV/SV normal	Wrong output mode (руководство / auto / locked), hardware-output mismatch, open output loop, faulty positioner, triggered DI interlock	Switch to manual mode and force output to check 4–20 mA; verify output type in configuration; measure current at OP terminals; check DI interlock status; test valve positioner independently
⑤ Temperature / pressure hunting, нестабильное управление	Mismatched PID parameters, auto-tune not performed, large valve dead band, long steam loop lag, too small PV filter	Run Auto-tune first; increase integral time appropriately; check valve for sticking; increase PV filter; use Spirax Sarco native steam algorithm for steam systems
⑥ OP3 alarm relay continuously energized / false alarm	Wrong alarm threshold, incorrect alarm logic (высокий / low / sensor fault), DI interlock alarm, latched alarm not reset	Enter alarm menu and read alarm code; confirm alarm latch status; check PV range; clear alarm latch
⑦ Communication failure (RS485 / Ethernet)	Mismatched IP / адрес станции, inconsistent baud rate, поврежденный кабель, перепутанная проводка A/B, firewall / switch isolation, iTools password lock	Check communication parameters; fit termination resistor for RS485 bus; ping Ethernet; FC factory-configured units have OEM encryption and firmware flash is not allowed
⑧ Panel keys no response	Keylock enabled, damaged panel, firmware exception	Unlock keypad; цикл мощности; read firmware status via iTools; do not flash generic firmware for FC custom firmware
⑨ Parameters lost after reboot	Configuration not saved, failed internal backup battery, flash memory fault	Save after every modification and back up via iTools; return for repair if parameter loss recurs

Steam-Specific Troubleshooting for GS-X
Desuperheating / heat exchange: PV fluctuation should first check blocked sampling pipe, condensate accumulation and sampling point in turbulent zone, not controller fault.
Valve position feedback: If valve position feedback is fitted, check 4–20 mA feedback loop; broken feedback will trigger valve position fault alarm.
FC = Factory Configured: Steam dedicated logic preloaded at factory. Do NOT reset to factory default, otherwise custom steam control logic will be lost and only Spirax Sarco can reissue configuration file.
Safe Maintenance Sequence
Isolate power, apply lockout-tagout
Визуальный осмотр (терминалы, кабели, конденсация; high humidity in steam room easily causes terminal corrosion)
Continuity and insulation test
Inject simulated signal separately to distinguish sensor fault or controller body fault
Read alarm logs via iTools (alarm log is the most reliable fault source)
Check alarm code table first if alarm code exists

Spirax Sarco Full Product List (Sorted by Category, including GS-X)

Application scope: Complete steam & condensate system products, including steam trapping, pressure reducing, regulating, heat exchange, metering, автоматизация, clean steam, boiler auxiliary and compressed air products, для выбора, spare part lookup and replacement reference.

Steam Traps
Float type F series: FT14, FT44, FT47, FT57, FTS14, FTC series
Thermodynamic TD series: TD32, TD42, TD52, TD32F, BTD52, UTD26
Thermostatic BT/MST series: MST21, BT6-B, BT6-M (hygienic clean steam), BTM7, BTS7
Pressure balanced: BP series
Насос & trap integrated automatic pump: APT14, APT14HC, PPC series
Trap station assembly: STS17.2, 4-bolt integrated trap station
Pressure Reducing Valves & Self-acting Control Valves
Direct acting pressure reducing valves: SRV461S, SRV463S, BRV, DRV series
Pilot operated pressure reducing valves: 25П, 26П, 44, DP27, DP143, CP30, PRV series
Self-acting temperature control valves: ТВ, TS series (no controller required for steam heat exchange temperature control)
Desuperheating & pressure reducing assembly DS series, injection desuperheater, venturi desuperheating module
Электрический / Pneumatic Control Valves, Приводы & Positioners
Valve bodies

Spira-trol K/L 2-way valves (KE71/KE73/LE43/LE63/KE61)

QL series 3-way valves (смешивание / diverting)

85, 86, 89 micro-flow, 1000 ряд, 900 3-способ, 2003 high-pressure PRV, Revel high differential pressure labyrinth valve

STERI-TROL hygienic clean steam valves SAE6/SHE6/SQL6 (pharmaceutical clean steam)

Pneumatic actuators: PN9000, PN5700/6700, TN2000
Electric actuators: AEL5, AEL6, EL4600
Valve positioners: SP7 (Smart HART), EP500 (Electro-pneumatic positioner)
PID Controllers, Instruments & Monitoring Systems (GS-X included)
GS-X series (GS25039 is this series, new steam dedicated PID with Ethernet IIoT)
SPC3x single-loop PID controller (simplified version)
Flow computer M850
Spiratec on-line steam trap monitoring system
B850 boiler house energy monitor
SIMS system management software (iTools configuration tool)
Level switch, magnetic level gauge, температура / pressure transmitters
Flow Meters
Gilflo ILVA, ILVA20 differential pressure steam flowmeter
VIM20, VLM30 Food+ hygienic vortex flowmeter
RIM20 insertion variable area flowmeter
TVA/TFA target flowmeter
ELM electromagnetic flowmeter
MVT10 flow acquisition system
Condensate Recovery, Насос & Flash Systems
FREME flash recovery system
EVC exhaust condenser (waste heat recovery)
Pressure powered condensate pump: P series, APT pump trap
Boiler feed tank system, blowdown system BBV bottom blowdown valve
Condensate heat unit EasiHeat DHW / EasiHeat HTG (hot water package)
Heat Exchangers
Turflow corrugated tube heat exchanger
SC20 sample cooler (boiler water sampling)
Clean steam heat exchanger, sterilization heat exchange module
Safety Valves, Isolation Valves & Pipe Fittings
Safety relief valve SV series, SRV safety relief valve
Bellows seal globe valve BSA3BD, SafeBloc DBB3 double block and bleed valve
Check valve CV, CVS10M hygienic check valve
Ball valve M10s, Y-filter, basket filter, clean steam filter FS-HC
Air vent AE30, air vent for water system
Trap test valve, isolation valve set, sampling valve set
Clean Steam / Hygienic Range (Фармацевтический, Bio, Еда)

BT6-B / BT6-M hygienic steam trap

STERI-TROL control valve

CVS10M hygienic check valve

VLM30 food grade vortex flowmeter

Clean steam filter station, pure steam sampling module

Compressed Air Products (Spirax-Monnier sub-brand)

MF micro filter, ML3 oil mist separator, IL1 lubricator, air regulator, dryer accessories

Boiler Auxiliary & Water Treatment Monitoring

Boiler blowdown valve, TDS blowdown control module

Turbidity monitoring system, feedwater chemical dosing package

B850 boiler energy monitor

Steam Humidifiers & Steam Injection Systems

Steam humidifier, injection humidification module, venturi steam injector

Quick Index Guide

Prefix GS → GS-X controller (GS25039)

Prefix TD → Thermodynamic trap; FT → Float trap; BT → Hygienic thermostatic trap

AEL → Electric actuator; SP7 / EP500 → Positioner

ILVA / VIM / VLM → Flow meter

KE/LE/QL → Spira-trol control valve body

Spirax Sarco GS-X Series Controller List (TI-P794-01 Official Reference)

GS-X includes three main hardware platforms: GS-X1 / GS-X2 / GS-X3. Your GS25039 is the GS-X3 base part number. Suffixes are extended order codes for I/O, коммуникация, firmware and factory configuration and are not independent hardware part numbers.

Documents: TI-P794-01 (Техническая спецификация), IM-P794-03 (Установка & Operating Manual)

Base Hardware Models (3 Types)

Базовая модель	Panel Size	Позиционирование	Main Hardware Features
GSX1	1/16 ОТ (45×45 mm)	Compact single loop	1 универсальный вход; optional output; optional transmitter supply; RS485 / Ethernet опционально; for small cabinet and simple heat exchange control
GSX2	1/8 ОТ (92×45 mm)	Standard single loop	1 main universal input, optional 2nd auxiliary input; изолированный 24 V transmitter supply; RS485 / Ethernet; richer I/O options than X1
GSX3	1/4 ОТ (92×92 mm)	Основная модель (GS25039 belongs here)	1 main universal input, optional 2nd auxiliary input; изолированный 24 В Вашингтоне; maximum I/O capacity; native Ethernet IIoT; steam dedicated PID, widely used for heat exchange, desuperheating & sterilization with large display

✅ GS25039 = GS-X3 base part number

Full order format:

GS25039 [InputCode] [OutputCode] [Прошивка] [Суффикс]

Пример: GS25039-1-10-1810-FC (FC = Factory Configured)

GS-X I/O Selection Order Codes (Обычно используется)

Coding rule: GSxxxx InputCode OutputCode Firmware Suffix

Input Code

1: Universal input (РТД / ТК / 4–20 мА / 0–10 В, наиболее распространенный, matches -1 in your model)

2: RTD dedicated version

3: Thermocouple dedicated version

4: Текущий / voltage dedicated version

Выходной код (твоя модель -10)

01: Релейный выход

02: Thyristor logic output

10: Isolated 4–20 mA analogue control output (for SP7 / EP500 valve positioner, mainstream for steam control valves)

11: 4–20 мА + alarm relay

12: Dual 4–20 mA

20: Двойное реле

30: Реле + thyristor mixed

Firmware 4-digit code (e.g.1810)

Internal factory firmware package: distinguish general PID, steam heat exchange, desuperheating, EasiHeat matched, sterilizer dedicated program. Cross-version firmware flashing is prohibited; FC pre-configured units are bound to firmware package.

Суффикс-код

ФК: Factory Configured (preloaded parameters, ПИД, диапазон, блокировка, ИП)

ФС: Factory Set (simple calibration, no complex logic)

АТЕХ: Explosion-proof version

HW: High humidity reinforced version (steam room)

FS-H: Food hygienic firmware

GSX Spare Parts & Аксессуары
GS-X-USB-CABLE: iTools configuration cable (USB to Ethernet / service port)
GS-X-BACKUP: Parameter backup package (free iTools software from Spirax Sarco website)
GS-X-PANEL-GASKET: Уплотнительная прокладка панели (пыль & water proof, recommended for steam room)
GS-X-TERMINAL-KIT: Replacement terminal block kit
Platform Comparison (to avoid confusion with old models)

GS-X: Новое поколение, native Ethernet IIoT, 0.1% точность, configured via iTools

SPC300 / SPC310: Previous generation single-loop controller (устаревший, replaced by GS-X)

SX80 / SX90: Low-cost basic temperature indicator, not GS-X series

Важные замечания
The manufacturer does not publish a complete list of all combinations. Many combinations are project-specific order codes only retrievable from Spirax Sarco internal selection system.
GS-X1/X2/X3 share the same software core and iTools compatibility, differing in terminal layout and I/O capacity.
Do NOT reset FC factory-configured units to factory default, custom steam logic will be lost and only the manufacturer can reissue configuration.
Поддерживаемые протоколы: Модбус РТУ (RS485), Модбус TCP (Ethernet), совместим со SCADA, BMS and iTools.