Gardner Denver GD Connect 12, Manual

Page 1: ...GD Connect 12 Intelligent interconnected control GB USA Id Nr ZS1060097 00 ...

Page 2: ...Basis German operating instructions ZS1060096 00 Valid for software versions 2 0x Subject to technical change without notice ...

Page 3: ...lly those with safety implications must be rectified immediately The control is designed exclusively for regulating systems which generate compressed air Using the control for any other purpose is contrary to its intended use The manufacturer supplier cannot be held responsible for damage resulting from such use The risk of such misuse lies solely with the user Operation of the control within the ...

Page 4: ...ions for the prevention of accidents which apply in the country and place of operation of the control the generally accepted technical rules for safe and proper working must also be observed Guarantee Operate the control only if you have familiarized yourself with the control and these operating instructions Gardner Denver cannot be held responsible for the safe operation of the control if it is u...

Page 5: ... 4 1 Functions 12 4 2 Overview 13 4 3 Example of a compressed air station with GD Connect 12 14 4 4 Technical data for the GD Connect 12 16 4 5 Scope of delivery 17 4 6 System components 17 5 Operation 19 5 1 First commissioning 19 5 2 Main display 20 5 3 Compressor information 21 5 4 SD card 21 5 5 Air station information 22 5 6 Controlling the air station 23 5 7 Settings 25 5 8 Messages 28 5 9 C...

Page 6: ...very 39 8 4 Connection to the GD Connect 12 40 8 5 Connection of external signals 40 9 Webserver module 42 9 1 Function 42 9 2 Technical data 42 9 3 Scope of delivery 42 9 4 Connection to the GD Connect 12 43 9 5 Connection to the net work 43 9 6 Access via browser 43 9 7 Configuration 43 Annex 44 Annex A Wiring diagrams 44 Annex B Module settings 49 Annex C Technical data of the line pressure sen...

Page 7: ...2 Table of contents 7 ...

Page 8: ...cation in relation to internal factors for example regarding work organization sequences of operations duties and responsibilities shall be maintained in addition to the operating instructions Personnel asked to work on the machine must have read the operating instructions and in particular the chapter on safety instructions before starting work Reading the instructions after work has begun is too...

Page 9: ...a control cabinet suitable lifting gear must be used which meets local safety regulations All loose or slewable parts must be safely fixed before the unit can be lifted It is strictly prohibited for personnel to remain within the danger zone of a lifted load The correct method of lifting according to the operating instructions of the load suspension device must be ensured If a remote control is us...

Page 10: ...f the system and of measures to avoid them personnel must observe all measures for safety at work Safety equipment for the prevention or elimination of danger must be maintained regularly and its function checked at least once a year Faults observed must be rectified immediately and or reported to the responsible person Only use original spare parts Only carry out maintenance and repair work when ...

Page 11: ...them in addition to insulating adjacent live parts and elements The electrical equipment of the control must be inspected and checked at regular intervals Defects such as loose connections or scorched cables must be rectified immediately Necessary work on live parts and elements must be carried out in the presence of a second person who can cut off the power supply in case of danger by operating t...

Page 12: ... input Current station status display Touch controls can display further information about the station i e statistics events etc Current compressor status display Touch controls can display further information about each compressor i e operating hours events etc Programmable inputs and outputs Programmable inputs and outputs can be used to control the stations and or output status messages to the ...

Page 13: ...twisted pair and screened 100003989 GD Pilot Standard or half full compressor Speed regulated compressor Three phase asynchronous motor with max 500A rating current Compressor module STD ZS1060046 Compressor module VSD ZS1060136 RS485 3 Customer SD card 100016138 Extension module 230V 50 60Hz ZS1060138 110V 50 60Hz ZS1060139 Digital inputs DI 1 8 Digital outputs DO 1 2 Analog inputs AI 1 2 Digital...

Page 14: ... input DI 1 RS485 2 Selection switch to activate a profile RS485 3 or digital I O ModBus RTU PROFIBUS optional Customer PLC to read datas Line pressure sensor RS485 1 Selection switch to activate a profile Dig input GD Connect 12 Compressor 1 Compressor 2 Compressor 3 Recevier Dryer Filter RS485 Dig Input Dig input Extension module ...

Page 15: ... can be used to set a selection switch for example for switching to a different profile e g for pressure reduction The RS485 3 interface allows the customer to read data from the GD Connect 12 e g the status of the compressors and to activate a profile or reset a statistics counter for example The data is transmitted via the ModBus protocol An optional PROFIBUS interface can be retrofitted if requ...

Page 16: ...puts change over contacts Load max 240V 1A Connection of compressors Interface RS485 1 Cable type 2x2x0 5 1 5mm twisted pair and screened Wiring length max 1200m Devices max 12 compressors Connection of extension modules Interface RS485 2 Cable type 2x2x0 5 1 5mm twisted pair and screened Wiring length max 1200m Devices max 4 extension modules Customer interface Interface RS485 3 Cable type 2x2x5 ...

Page 17: ...onnect the analog inputs can be found in the annex General information on connecting compressors Compressors are connected to the GD Connect 12 via the RS485 1 interface only The RS485 interfaces of the GD Connect 12 and the compressor controls should form a bus structure i e all compressors are connected in series starting from the GD Connect 12 Fig 3 shows examples of correct and incorrect wirin...

Page 18: ... the current operating status of the GD Connect 12 RS485 3 The ModBus RTU protocol is implemented as standard Details of the protocol and the addresses can be found in a separate document GD Connect 12 Programmer guide ModBus RTU To enable the GD Connect 12 to be connected to a PROFIBUS network an optional PROFIBUS module can be installed in the GD Connect 12 control cabinet For the PROFIBUS modul...

Page 19: ...the wizard to help with commissioning The wizard automatically prompts you to set the necessary parameters Before starting this wizard the GD Connect 12 can show you the list of parameter settings required Once commissioning has been completed the main screen comes up and the GD Connect 12 switches off i e it shows the status of the compressors but does not control them This is also indicated by t...

Page 20: ... for compressors with speed regulation or half full load control Off load The compressor motor is running but the compressor does not produce compressed air Blow down Symbol flashing The value of the final pressure as the value of the start protection Standby The compressor is at standstill is ready and can be started by the GD Connect 12 when pressure is required Switched off The compressor is at...

Page 21: ... The appropriate symbol is shown on the compressor key see Fig 6 the compressor is not loaded and is taken out of the sequence by the GD Connect 12 Warnings and fault messages that are received are not displayed and are not listed in the event list for the compressor Service on is displayed in the list of events for this compressor Once servicing has been completed the compressor can be brought ba...

Page 22: ...sensor The event list can be deleted in the Adjustments GD Connect 12 menu Measured values The line pressure and volume flow values can be shown here as diagrams Operating hours The distribution of the compressor operating hours is shown here rather than in the compressor information There are two types of operating hours Absolute operating hours These are the total and loaded hours as listed in t...

Page 23: ...ctive Channel 3 Sat 0 24h Profile 2 active Sun 0 24h Station off If no profile is active for a particular time range on Sunday in this example the station stays off i e the compressors remain on standby but are not loaded b Activation by digital inputs or interface A profile can also be activated by programmable inputs or the serial customer interface The digital inputs can be located on the GD Co...

Page 24: ...h the same FAD could be switch the compressor with the lowest number of total hours will be loaded first In addition to the listed criteria the following parameters are relevant for the switching of compressors Switch on and switch off delay If a compressor is to be loaded or unloaded a timer is started with the appropriate adjusted time If the timer runs out and conditions for switching the compr...

Page 25: ...pressor is unloaded Compens total hours In this parameter the customer can set how the GD Connect 12 compensates the total hours of the compressors Relative setting The operating hours are compensated with the relative operating hours Absolute setting The operating hours are compensated with the absolute operating hours The meaning of absolute and relative operating hours is explained in section 5...

Page 26: ... to an individual priority Events Statistics Here the various statistics counters and event lists can be reset or deleted Inputs Outputs Here the inputs and outputs can be assigned to various functions Programmable functions of digital inputs DI 1 3 No use Activate profile 1 2 12 Warning Dryer 1 4 Warning Filter 1 4 Warning Bekomat 1 4 Warning Dew point Warning External In addition two further par...

Page 27: ...gs cannot be changed because they are automatically set to the requirements of the PROFIBUS module Adjustments Compressors The various compressor settings can be defined here and new compressors can be added or existing compressors deleted Adjustments extension modules The extension module parameters can be set here Language The flag on the key shows the current language setting Touching this key ...

Page 28: ... signal Warning Filter 1 Filter 1 is indicating a warning signal Warning Bekomat 1 Bekomat 1 is indicating a warning signal Warning Temperature 1 max The temperature 1 has exceeded the programmed maximum limit Warning Temperature 1 min The temperature 1 has fall below the programmed minimum limit Warning Dew point A digital input has indicated that the dew point has been exceeded Warning Dew point...

Page 29: ...cked see section 5 7 Settings The Service status of a compressor to be switched on or off see section 5 3 Compressor information After the code is unlocked the code will be locked again automatically after 15min or by a power loss Code 7555 This code allows the Service status of a compressor to be switched on or off see section 5 3 Compressor information After the code is unlocked the code will be...

Page 30: ...ive fault signal Terminals 6 7 8 Motor Compressor motor is running Terminals 9 10 11 Load Compressor is on load Terminals 12 13 14 Digital outputs Remote load Remote load enable enable Terminals 21 22 23 Remote load Remote load Terminals 26 27 28 Remote half Remote half load load Terminals 31 32 33 Type Potential free relay outputs change over contacts Load max 240VAC 1A Connection to the GD Conne...

Page 31: ...ing diagrams with examples showing how to connect a compressor control to the module can be found in the annex Danger Switch off the power supply to the compressor before connecting the compressor module STD to the compressor control Digital inputs The module detects the compressor status via three digital inputs which are indicated via three LEDs on the module A voltage in the range from 24 to 23...

Page 32: ... load could also be used A parameter on the GD Connect 12 can be used to define whether or not a voltage at the input signals the compressor load Digital outputs Danger When a compressor module STD is installed the compressor s pressure switch can no longer provide over pressure protection For compressors that are not equipped with independent over pressure detection it is recommended that a press...

Page 33: ...total hours and loaded hours Type This menu item indicates whether the compressor is a standard or a half full load compressor Connection Invert signals This parameter specifies whether voltage at the corresponding inputs indicates a signal or not Full load command This parameter specifies how the compressor module STD sends a load command for standard compressors or full load command for half ful...

Page 34: ...ich terminals are used Operation Compressor available or collective fault signal Terminals 6 7 8 Warning Compressor sends a warning signal Terminals 9 10 11 Load Compressor is on load Terminals 12 13 14 Digital outputs DO 1 Optional use Terminals 1 2 DO 2 Optional use Terminals 3 4 Type Potential free relay outputs change over contacts Load max 240V 1A Analog input AI 1 Type 4 20mA 0 10V 0 5V depe...

Page 35: ...sor supplier specialist for advice Note The compressor module VSD can only be connected to compressors with a three phase asynchronous motor with a max rating current of 500A Wiring diagrams with examples showing how to connect a compressor control to the module can be found in the annex Danger Switch off the power supply to the compressor before connecting the compressor module VSD to the compres...

Page 36: ...ther or not a voltage at the input signals the compressor load Digital outputs The use of digital outputs is optional The status of these outputs is indicated via three LEDs These digital outputs are change over contacts and can be adapted to the requirements of the compressor control by selecting the appropriate terminals Wiring diagrams with examples showing how to connect a compressor control w...

Page 37: ...ng the speed of the compressor motor This is done by connecting the analog output to the analog input at the compressor control which is normally used to connect the line pressure sensor If the compressor module changes the signal of the analog output to reduce the line pressure the speed of the compressor will be increased and vice versa Fig 11 shows the relation between the analog inputs and out...

Page 38: ...responding compressor Safety pressure If the line pressure that is measured from the line pressure sensor of the compressor exceeds this value the load of the compressor will be interrupted and it will be switched over to internal regulation of the compressor so that the speed will be automatically reduced Off load pressure The line pressure value at which the compressor is switched to off load Th...

Page 39: ...age 24V DC Digital outputs Number 2 Type Potential free relay outputs change over contacts Load max 240V 1A Analog inputs Number 2 Type 4 20mA Input voltage 18V DC Type Passive Active depending on jumper Burden 100 Ohm Wiring length max 500m 500m use amplifier Connection to the GD Connect 12 Interface RS485 Cable type 2x2x0 5 1 5mm twisted pair and screened Wiring length max 1200m Address Adjustab...

Page 40: ...he annex After connecting an extension module the inputs and outputs can be programmed in the Adjustments Extension module menu Digital inputs Programmable functions of digital inputs DI 1 8 No use Activate profile 1 2 12 Warning Dryer 1 4 Warning Filter 1 4 Warning Bekomat 1 4 Warning Dew point Warning External In addition two further parameters are programmable for the digitial inputs to each fu...

Page 41: ...ors which are connected at analog inputs AI 1 or AI 2 of the GD Connect 12 For the connection of a volume flow meter applies Detection of the volume flow and subsequent switching of the compressors can also be done from a sensor which is connected to an analog input of an extension module The values measured at the analog inputs of an extension module can therefore only be used for monitoring Eith...

Page 42: ...m F2 Secondary T0 5A 5x20mm Connection to the GD Connect 12 Interface RS485 Cable type 2x2x0 5 1 5mm twisted pair and screened Wiring length max 1200m Bus termination 120 Ohm Switchable by jumper J1 and J2 Connection to the network Interface Ethernet 10Base TX 100Base TX Connection RJ45 Ambient temperatures Operation 0 55 C Storage 40 70 C EMC conformity Immission DIN EN 61000 6 3 Immunity DIN EN ...

Page 43: ... and the locking lugs of the plug are not damaged For longer distances the cable should be removed and an appropriate cable is to create To ensure the continued water protection the cable must be leaded through a suitable M20 gland before the assembly 9 6 Access via browser Within the Webserver module a HTTP Server is integrated which can be accessed via web browser Suitable are inter alia the cur...

Page 44: ...DI 3 16 COM 17 NO 18 Digital output DO 1 NC 19 COM 20 NO 21 Digital output DO 2 NC Terminal strip X1 Function 1 GND 2 B 3 A 4 RS485 1 Compressors PE Terminal strip X2 Function 1 GND 2 B 3 A 4 RS485 2 Extension modules PE Terminal strip X3 Function 1 GND 2 B 3 A 4 RS485 3 Customer PE Terminal strip X4 Function 1 GND 2 B 3 A 4 24V AC 5 0V AC 6 PE 7 PROFIBUS module PE Connections on control transform...

Page 45: ...ranslations Compressor module STD Operation 6 7 110 230VUC 6 8 24 48VUC Load 12 13 110 230VUC 12 14 24 48VUC Motor 9 10 110 230VUC 9 11 24 48VUC Supply 16 17 110 230VUC Line contactor Regulation valve Operation or Collective fault signal Supply voltage Compressor module STD Remote load enable Remote half load Remote load 21 23 26 28 31 33 Digital input Remote load enable Digital input Remote load ...

Page 46: ...s recommended that a pressure switch be incorporated in the compressor fault circuit s such that any local over pressure condition will stop the compressor independently from the GD Connect 12 Compressor module STD Remote load enable Remote load P Pressure switch High press prot P Compressor Press switch V 21 22 23 26 27 28 Regul valve Regul valve Compressor module STD Remote load enable Remote lo...

Page 47: ...r speed detection Translations Danger The current transducer supplied is designed for a maximum current of 500A Ensure that the current flowing through the current transducer does not exceed 500A Regulation valve Compressor module VSD Operation 6 7 110 230VUC 6 8 24 48VUC Load 12 13 110 230VUC 12 14 24 48VUC Warning optional 9 10 110 230VUC 9 11 24 48VUC Supply 16 17 110 230VUC Operation or Collec...

Page 48: ... pressure condition will stop the compressor independently from the GD Connect 12 Compressor module VSD Analog input AI 1 Analog output AO 1 Compressor control Analog input Line pressure sensor Compressor Line pressure sensor Type adjustment AI 1 AO 1 4 20mA Jumper 21 22 0 10V Jumper 22 23 0 5V Jumper 24 23 Internal relay AI 1 with AO 1 short circuits terminals 25 28 Compressor module VSD 28 IN AI...

Page 49: ...te load enable NO 26 COM 27 NC 28 Digital output Remote load NO 29 COM 30 NC 31 Digital output Remote half load NO Address The following table shows the necessary DIP switch settings Address DIP switches 1 2 3 4 5 1 1 0 0 0 0 2 0 1 0 0 0 3 1 1 0 0 0 4 0 0 1 0 0 5 1 0 1 0 0 6 0 1 1 0 0 7 1 1 1 0 0 8 0 0 0 1 0 9 1 0 0 1 0 10 0 1 0 1 0 11 1 1 0 1 0 12 0 0 0 1 0 Baudrate Protocol No adjustments necess...

Page 50: ...Jumper 22 23 0 5V Jumper 24 23 25 OUT 26 Analog output AO 1 GND 27 15V 28 IN 29 Analog input AI 1 GND 30 Screen 31 15V 32 15V 33 SIGN 34 Analog input AI 2 GND Address The following table shows the necessary DIP switch settings Address DIP switches 1 2 3 4 5 1 1 0 0 0 0 2 0 1 0 0 0 3 1 1 0 0 0 4 0 0 1 0 0 5 1 0 1 0 0 6 0 1 1 0 0 7 1 1 1 0 0 8 0 0 0 1 0 9 1 0 0 1 0 10 0 1 0 1 0 11 1 1 0 1 0 12 0 0 0...

Page 51: ...1 NO 7 COM 8 Digital output DO 2 NO 9 GND 10 DI 1 11 DI 2 12 DI 3 13 DI 4 14 DI 5 15 DI 6 16 DI 7 17 DI 8 18 GND 19 24V DC 20 24V DC 21 24V DC 22 24V DC 23 24V DC 24 24V DC 25 24V DC 26 Digital inputs DI 1 8 24V DC 27 18VDC GND 28 AI 1 29 Analog input AI 1 Screen 33 18VDC GND 34 AI 2 35 Analog input AI 2 Screen 32 GND 36 Screen 37 B 38 RS485 A ...

Page 52: ...Annex 52 Drawing Jumper for analog inputs Analog Eingang AI 1 Terminal 27 J2 18V DC J2 GND Analog Eingang AI 2 Terminal 33 J1 18V DC J1 GND ...

Page 53: ...Adresse DIP Schalter 1 2 3 4 5 6 7 1 1 0 0 0 0 0 0 2 0 1 0 0 0 0 0 3 0 0 1 0 0 0 0 4 0 0 0 1 0 0 0 Baudrate DIP switch 8 to OFF bottom Protocol No adjustments necessary Bus termination Set jumpers J3 and J4 accordingly Bus termination on Bus termination off 1 ON oben 0 OFF unten ...

Page 54: ...Annex 54 Webserver module Terminals Terminal X1 Function 1 L1 2 N 3 Power supply 230V AC 50 60Hz 110V AC 50 60Hz PE Terminal X2 Function 1 5V 2 A 3 B 4 RS485 GND Drawing ...

Page 55: ...y of the GD Connect 12 Gardner Denver ID no 100003136 Technical data Measuring range 1 15bar Output signal 4 20mA Supply voltage 10 30V DC Current limitation 28 mA Polarity protected Media temperature 0 85 C Ambient temperature 0 85 C Operating pressure max 16 bar Testing pressure 24 bar ...

Page 56: ...Annex 56 Annex D Drill templates for mounting GD Connect 12 drill template Webserver module Weight 11 kg 24 lbs 260 mm 10 2 340 mm 13 4 260 mm 10 2 340 mm 13 4 ...

Page 57: ...Annex 57 Extension module drill template Weight 1 5 kg 3 3 lbs ...

Page 58: ...use T1A 250V 5x20mm 10000 4436 Compressor module VSD ZS1060136 Spare parts Fuse T1A 250V 5x20mm 10000 4436 Current transducer 10001 6223 Cable to connect current transducer to the compressor module 10001 6224 Extension module 230V 50 60Hz ZS1060138 Spare parts Fuse T0 16A 250V 5x20mm 10001 6883 Fuse T0 5A 250V 5x20mm A11270574 Cable to connect current transducer to the compressor module 10001 6227...

Page 59: ...00004858 USB RS232 converter Flash program adapter ZS1073178 Adapter for software update of compressor module STD or VSD ZS1047721 Key lock for GD Connect 12 ZS1049510 Volume flow sensor kit ZS1060132 Dew point sensor 4 20mA 10001 4803 Temperature sensor 4 20mA 10001 6229 ...

Page 60: ...60 Gardner Denver Deutschland GmbH Argenthaler Str 11 55459 Simmern Deutschland Tel 49 0 6761 832 0 www gardnerdenverproducts com e mail info tampere gardnerdenver com ...