Gardner Denver Governor TEN014980, User Manual

Page 1: ...1 1 1 13 17 621 Version 01 September 28th 2020 Governor Controller USER S MANUAL Rotary Screw Compressor Application ...

Page 2: ... operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety Labels are used within this manual and affixed to the appropriate areas of the compressor package to alert users of the following conditions Indicates a hazard with a high level of risk which if not avoided WILL result in death or serious injury Equipment Starts Automati...

Page 3: ... low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not Lift Equipment with Hook No Lift Point Handle Package at Forklift Points Only Lockout Electrical Equipment in De Energized State Loud Noise Hazard Wear Ear Protection Read the Operator s Manual Before ...

Page 4: ...m until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any applicable local electrical codes Wiring and electrical service must be performed only by qualified electricians Open main disconnect switch lockout and tagout and check for voltage before working on the contro...

Page 5: ...3 Scroll Elements 31 3 1 3 Settings and Input Elements 32 3 1 3 1 Dropdown Boxes 32 3 1 3 2 Value Settings 33 3 2 Home Screen 34 3 2 1 Screen Saver 36 3 3 Schematic Screen 37 3 4 Navigation Menu 40 3 5 Logging In 41 3 6 Setting Up 42 3 6 1 Controller Configuration 42 3 6 2 Control Settings 44 3 7 Clearing Alarms 45 3 8 Jogging the Motors 46 3 9 Operating the Compressor 47 3 9 1 Starting 47 3 9 2 R...

Page 6: ...7 4 7 1 8 Elevation 98 4 7 1 9 Total Hours 99 4 7 1 10 Loaded Hours 99 4 7 1 11 Brand 100 4 7 2 Operating Limits 100 4 7 2 1 Max Start Pressure 101 4 7 2 2 Heavy Startup 101 4 7 2 3 Minimum Start Temperature 101 4 7 2 4 Discharge Temperature Warning 101 4 7 2 5 Discharge Temperature Fault 102 4 7 2 6 Delivery Pressure Warning 103 4 7 2 7 Delivery Pressure Fault 103 4 7 2 8 Additional Operating Lim...

Page 7: ...SECTION 6 DIAGNOSTICS 164 6 1 Sequencing 164 6 2 Jog Motors 166 6 2 1 Jog Duration 166 6 2 2 Selected Motor 167 6 2 3 Jog Delay 167 6 3 IO 168 6 4 Controller 171 6 4 1 General 171 6 4 2 Logs 172 6 4 3 System 176 6 4 4 Update Software 181 6 4 5 Audit 181 6 4 6 Logger 182 6 4 7 Advanced 183 6 5 iConn 185 6 6 Communication 185 6 7 Remote Control 186 6 8 VFD Diagnostics 187 SECTION 7 TRENDS 189 SECTIO...

Page 8: ...13 17 621 Page 8 SECTION 1 REVISION HISTORY Version Date Notes 00 February 23rd 2019 First release 01 September 28th 2020 Added Sections and details to manual ...

Page 9: ...ribed briefly in this section 2 1 1 Display The display is the primary component that the user interacts with On the front of the display there is a color touchscreen interface The Start and Stop touch buttons are located directly below the screen The display houses the processor and memory for the system and interfaces with the other components through communications ports on the back side Figure...

Page 10: ...se values are monitored and controlled by the display to operate the compressor The IO module also contains RS485 communications ports for customer connection and sequencing with multiple machines Figure 2 IO Module The IO module is shown in Figure 2 above Note that depending on the type of compressor you have your IO module may have more or less inputs and outputs present on it indicated by the a...

Page 11: ...n to intelligently determine when the machine is operating normally and when it needs attention System inputs such as pressure and temperature are monitored individually and collectively to check for a variety of different system conditions When running the machine the controller ensures that the customer s pressure requirements are maintained After configuring and enabling the controller all oper...

Page 12: ...13 17 621 Page 12 Figure 4 Oblique View Figure 5 Rear View ...

Page 13: ...bit s Interface IF4 Type CAN bus Variant 3 pins of the 6 pin multipoint connector Bus terminating resistor 120 Ω can be switched using software Max distance 1000 m Interface IF5 Type RS485 Variant 3 pins of the 6 pin multipoint connector Max Distance 1200 m Transfer rate Max 115 2 kbit s Display Type TFT color Diagonal 7 0 Colors 16 7 million RGB 8 bits per channel Resolution WVGA 800 x 480 pixels...

Page 14: ...Figure 6 LEDs in Display Module Table 2 below explains the LEDs and their Color Codes Table 2 Display Module LED Diagnostic LED STATUS LED Color Status Description RDY F Yellow On Mode BOOT SERVICE or DIAGNOSIS Blinking LED R E blinks red and LED RDY F blinks yellow when there is a license violation R E Green On Mode RUN The application is running Red On Mode BOOT SERVICE or DIAGNOSIS Blinking LED...

Page 15: ...by Gardner Denver Service Location of reset button is shown just for reference purpose below in Figure 7 Figure 7 Reset Button 2 3 1 4 Connection Elements Below are the electrical connections available on the display unit in the Figure 8 Figure 8 Connection Elements CAN bus and RS485 Interface Figure 9 below shows the CAN bus and RS485 interface and Table 3 lists its pinouts Figure 9 CAN bus and R...

Page 16: ...D Receive Signal 2 RXD Received signal inverted 3 TXD Transmit signal 4 Termination Termination 5 Termination Termination 6 TXD Transmit signal inverted 7 Termination Termination 8 Termination Termination Diagnostic LED LED Color Status Description LNK Green On The link to the remote station is established ACT Orange On No Ethernet activity is taking place on the bus Blinking The link to the remot...

Page 17: ...odules based on machine configuration 2 3 2 1 Technical Data In the Table 7 below the technical data of the IO module is listed Table 7 IO Module Technical Data Model Number TEN014983 TEN014982 TEN014980 TEN014981 Short description I O Module digital inputs 6 analog inputs 12 digital outputs 2 analog outputs 9 PT1000 PTC 1 PWM output 8 digital inputs 6 analog inputs 8 digital outputs 1 analog outp...

Page 18: ... designation X11 Input 4 to 20 mA 2 wire connections Resistance measurement temperature inputs Quantity 8X PT1000 1X PTC 4X PT1000 2X PTC 2X PT1000 2X PTC Conn designation X12 X13 Input Resistance measurement for 2 wire connections Digital Output Quantity 12 8 12 8 Conn Designation X07 X08 X09 X07 X08 X07 X08 X09 X07 X08 Nominal Voltage 24 VDC PWM Output Quantity 1 Conn designation X08 Nominal vol...

Page 19: ...lded Lines A central ground connection is available to effectively deflect interference All cable shields must by connected to ground with good conductivity using a cable tie on the grounding plate or some other method Grounding The connection to ground potential must be as short as possible and sufficiently strong 4 mm Figure 13 explains the wiring diagram for the IO module The following should b...

Page 20: ...rt TEN014969 used for power supply connections and pinout to signal details Figure 15 Power Supply X01 Table 8 Power Supply X01 Power Supply Pin Signal 1 24 VDC 2 GND RS485 Interface X02 Only shielded cable must be used Figure 16 below shows the connector GD part TEN014970 used for RS485 connection and Table 9 for connector pin number to signal details Figure 16 RS485 Interface X02 ...

Page 21: ...AN bus connection Figure 18 below shows the connector GD part TEN014972 used for CAN bus connection and Table 10 for connector pin to signal details Figure 18 CAN bus X04 Table 10 CAN bus X04 CAN bus Connections Pin Signal Name 1 CAN_H 2 CAN_L 3 GND 2 3 2 5 Terminal Block Connections For all cables a mounting clip is provided on the left and right side of the housing for strain relief and shield c...

Page 22: ...rt TEN014974 used for X06 Digital Input connections and Table 12 for connector pin to signal details Figure 20 Digital Input X06 Table 12 DI X06 Digital Input X06 Connections Pin Signal Name 1 V or GND 2 DI05 3 DI06 4 DI07 5 DI08 Digital Outputs X07 Figure 21 below shows the connector GD part TEN014975 used for X07 Digital Output connections and Table 13 for connector pin to signal details Figure ...

Page 23: ...22 Digital Output X08 Table 14 DO X08 Digital Output X08 connections Pin Signal Name 1 V 2 GND 3 DO05 PWM output 4 DO06 5 DO07 6 DO08 Digital Outputs X09 This option is available only in IO Module TEN014983 TEN014980 Figure 23 below shows the connector GD part TEN014976 used for X09 digital output connections and Table 15 for connector pin to signal details Figure 23 Digital Output X09 Table 15 DO...

Page 24: ...Module TEN014982 Figure 24 Analog Output X10 Table 16 AO X10 Analog Output X10 Connections Pin Signal Name 1 AO01 2 AO01 3 AO02 4 AO02 Figure 25 Analog Output X10 Table 17 AO X10 Analog Output X10 Connections Pin Signal Name 1 AO01 2 AO01 Analog Inputs X11 Only shielded cables must be used for analog input signals Following are the details for analog inputs connection for 3 available options of 6 ...

Page 25: ...e connector GD part TEN014965 and Table 19 connector pin to signal details for 4 analog input designs Figure 27 Analog Input X11 Table 19 AI X11 Analog Input X11 Connections Pin Signal Name 1 24 V_AI 2 AI01 3 24 V_AI 4 AI02 5 24 V_AI 6 AI03 7 24 V_AI 8 AI04 3 Analog Input Configuration Available with IO Module part number TEN014981 Figure 28 below shows the connector GD part TEN014964 and Table 20...

Page 26: ... numbers TEN014982 TEN014983 Figure 29 shows the connector GD part TEN014968 used and Table 21 have the connector pin to signal details Figure 29 PT1000 PTC Inputs X12 Table 21 PT1000 PTC X12 PT1000 PTC X12 Connections Pin Signal Name 1 PT1000 01 2 PT1000 01 3 PT1000 02 4 PT1000 02 5 PT1000 03 6 PT1000 03 7 PT1000 04 8 PT1000 04 9 PT1000 05 10 PT1000 05 11 PT1000 06 12 PT1000 06 13 PT1000 07 14 PT...

Page 27: ...etails Figure 31 PT1000 PTC Inputs X12 Table 23 PT1000 PTC X12 PT1000 PTC X12 Connections Pin Signal Name 1 PT1000 01 2 PT1000 01 3 PT1000 02 4 PT1000 02 PT1000 PTC Inputs X13 Only shielded cable must be used for PT1000 PTC inputs Based on the system design there are three types of connections used for PT1000 PTC input signals X13 Following are the details Available with IO Module part numbers TEN...

Page 28: ...e connector pin to signal details Figure 33 PT1000 PTC Inputs X13 Table 25 PT1000 PTC X13 PT1000 PTC X13 Connections Pin Signal Name 1 PTC 01 2 PTC 01 3 PT1000 08 4 PT1000 08 Available with IO Module part number TEN014980 Figure 34 shows the connector GD part TEN014962 used and Table 26 have the connector pin to signal details Figure 34 PT1000 PTC Inputs X13 Table 26 PT1000 PTC X13 PT1000 PTC X13 ...

Page 29: ...creens in the system Understanding these elements will help improve interaction with the controller 3 1 1 Common Navigation and Status Elements Figure 35 Common Screen Elements The common status and navigation elements are shown in Figure 35 above and described below 1 The Menu bar expands when pressed and provides a cascading navigation for all screens on the system 2 The Screen Title Breadcrumbs...

Page 30: ...ressed before the machine will be allowed to start o This image indicates that the machine is shut down due to a fault condition Refer to the Alarms system to determine the cause and resolve the fault condition 6 The Gardner Denver Logo is present in the bottom right of every screen Pressing this will navigate back to the Home screen from any screen in the system 3 1 2 Buttons and Switches The use...

Page 31: ...ve tab pressing on a tab will cause it to become the active tab if it is not currently selected 3 1 3 Scroll Elements The system uses two types of control for scrolling the values shown on a screen The first scroll element is shown in Figure 38 below It operates much like a scroll bar on any other application Pressing the V on the bottom of the scroll bar will move the screen down You can also dra...

Page 32: ...em from a pre defined list of available options An example is shown in Figure 40 below To deploy the dropdown press on the value that is shown Automatic in the example below With the dropdown deployed you can change the selection by pressing on the option that you would like to select Note that options that are not available for your current configuration are shown in light gray as can be seen wit...

Page 33: ...uts that have a maximum and minimum valid range the keypad will display the valid input range as shown in Figure 41 To change the value start typing a new value and it will overwrite the existing setting To commit changes and close the keypad press To close the keypad without saving changes press To delete the most recently entered number press An example of a text entry keypad is shown in Figure ...

Page 34: ...e status Figure 43 below shows the Home screen with each element defined Figure 43 Home Screen Elements Additional details on each of the home screen elements are provided below 1 The Delivery Pressure gauge shows the current machine delivery pressure as well as the currently active pressure band used for control The color of the gauge and pressure display also changes to indicate the region that ...

Page 35: ...compressor airend discharge temperature o If the temperature is below the Minimum Start Temperature setting it will be displayed in red o If the temperature is between the Minimum Start Temperature setting and 3 5 4 above the Minimum Start Temperature it will be displayed in yellow o If the temperature is above the Minimum Start Temperature plus 3 5 4 and below the Warning temperature setting it w...

Page 36: ... yellow attention indicators will illuminate on the bar 6 The View Hours button links to the Service Dashboard screen which can be used to view configure and reset all of the maintenance timers on the system 7 The Total Loaded hours display shows the current total and loaded hours of the machine 8 The Hours Left to Service bar graph indicates the value of the minimum service timer The colors and f...

Page 37: ...c Screen The Schematic screen shows a graphical summary of the machine operation status and data It is accessed from the Home screen by pressing the View Schematic button Figure 45 below shows the main Schematic screen view with a summary of the elements ...

Page 38: ...lement on the schematic 6 The readings between the Airend and the Reservoir show the Reservoir Pressure and Discharge Temperature of the machine 7 On variable speed machines the Motor RPM is displayed below the Motor element 8 The Snapshot button is visible when logged in as Technician or Factory Pressing this button causes an entry to be added to the Alarm History log for a manual snapshot event ...

Page 39: ...yellow since it is the source of the warning Figure 47 Air Filter Focus with Warning The values available at each element on the schematic are shown below in Table 27 Table 27 Values of Schematic Elements Air Filter Airend Motor Reservoir Cooler Oil Cooler Oil Filter Air Filter Hours Discharge Temperature State FS Reservoir Pressure Delivery Pressure None on current machine Oil Filter Hours Inlet ...

Page 40: ...ascading Alarms Menu with links to the Active Alarms and Alarm History views Diagnostics Deploys the cascading Diagnostics Menu structure This area of the user interface allows viewing information about the operation of the controller and the machine for technical and troubleshooting use Trends This button links to the Trends screen which allows viewing graphs of the machine operation over time La...

Page 41: ...riate access level The current access level is indicated by the User button on the Status Bar in the bottom left of the screen as shown in Figure 50 below The text of the button indicates the current access level Figure 50 Login Button Pressing this button will navigate to the Security screen as shown in Figure 51 below Figure 51 Security Screen ...

Page 42: ...word should only be required under unusual circumstances and must be provided by Gardner Denver Technical Support Note that the passwords can be changed from the default using the Adjustments button on the left of the screen once logged in After logging in press the Close button to return to the previous screen 3 6 Setting Up Before running the machine there are several basic configuration setting...

Page 43: ...trol trends etc Setting the time zone properly ensures that daylight savings time adjustments will be accounted for automatically The Date and Time Configuration screen is shown in Figure 54 Figure 54 Date and Time Configuration To set the time zone click on the Timezone box and use the selector dialog that appears to select the appropriate time zone for your region as shown in Figure 55 ...

Page 44: ...he default settings of the machine are acceptable for most installations However if the Pressure Band displayed on the gauge on the Home screen does not match the desired pressure range for the site the Pressure Band must be adjusted To adjust the Pressure Band navigate to Settings Control as shown in Figure 56 Then press the Adjust button next to p1 Pressure Band Figure 56 Control Settings ...

Page 45: ...nding to save Hit the Save button at bottom to implement the changes and the will go away when changes are confirmed 3 7 Clearing Alarms If there are any faults present on the machine they must first be cleared to allow the machine to be started If the machine has been powered on recently and Auto Restart is not enabled a Power Loss fault will be present If a fault is active on the machine the Act...

Page 46: ...he desired jog duration and select Compressor Motor or Fan Motor from the dropdown as shown You will need to jog both individually to verify correct rotation The Jog Delay field allows you to delay the start of the jog from the time that you press the Start Jog button This is to allow you time to get into a position to view the rotation before the motor is started Note that the controller will onl...

Page 47: ...en running under the Automatic Operating Mode and control settings compressor operation will continue as described below The controller will attempt to keep the pressure within the set pressure band If the machine is a variable speed system the motor speed will be adjusted to attempt to keep the delivery pressure at the target pressure setting If the delivery pressure exceeds the unload pressure s...

Page 48: ...creen The machine will go through a soft stop process where it is depressurized before stopping When the Stop button is pressed the inlet valve will close immediately if the machine is currently loaded and the Message Status Bar will display that the controller is stopping as shown in Figure 62 Figure 62 Home Screen Stopping ...

Page 49: ... PSI The motor will be stopped when both the time and pressure requirements have been met or a maximum time of 120 seconds if the machine does not fully vent After stopping the display will return to the Ready state 3 9 4 Emergency Stop The Emergency Stop button is located on the front door of the control panel close to the display and is identified by a red button with a yellow background The Eme...

Page 50: ... two sub menus labeled Dashboard and Distributor Info Table 30 below summarizes the information that can be seen on these menus This is an important menu for the service technician who will need to reset the status of certain machine elements that have a life expectancy and require changing after a certain number operating hours Table 30 Service Settings Service Settings Setting Sub Menu Section B...

Page 51: ...ll be seen here are detailed below Use the scroll up and down buttons to bring the desired parameter on screen to view select or edit it The Air Filter timer is shown below The information shown on the bar is the time left for next service change of the air filter As shown below 2000 hours or 5 months 23 days indicates left until the next service The color of the bar will adapt dynamically based o...

Page 52: ...ers can be selected at a time Once a box is checked the Reset option will be enabled at the bottom of the screen Refer to Figure 65 below with Air Flow Oil Filter and Separator Change selected Figure 65 Select all option Pressing the Reset button will bring up another screen as shown in Figure 66 confirming that system is resetting the time left to Service to its default values Hit the Close butto...

Page 53: ...anged by selecting the box the Set Interval screen will come up as shown in below Figure 67 The values for hours and calendar time may not exceed the factory default values for the machine In certain circumstances it may desirable to set the interval below the factory default For example in a very dusty environment it may be necessary to change the air filter at a shorter interval Once the interva...

Page 54: ... need to be changed To change the current value of a timer press anywhere on the bar which will bring up another screen called New Service Times which displays the Hours Left to Service and Time Left to Service shown in Figure 69 below Only users with the technician or factory login credentials can create new service timers Figure 69 New Service Time The service timers can be manually adjusted by ...

Page 55: ... again 4 1 2 Distributor Info The Distributor Info screen is shown below in Figure 71 It includes information such as the Distributor s Name phone number website and Email address This is the best starting point when needing a resource for information about the particular compressor Figure 71 Distributor Info Values for Distributor name Phone Website and Email can be changed by touching the text b...

Page 56: ...a timer or control input 4 2 4 IV Control Mode Change how the Inlet Valve is controlled On machines that have inlet modulation this allows the mode to be set to load unload or modulation 4 2 5 Remote Halt Mode Remote Halt mode can be set between the available options of Timer Immediate and Disabled 4 2 6 Timer Start Enable Enable or disable starting and stopping the machine under timer control 4 2...

Page 57: ...meters to change edit or save 4 2 1 Operating Mode The Operating Mode drop down menu will show the options available in that particular package configuration In general there are four operating modes Automatic Constant Low Demand and Sequencing Refer to Figure 74 below Figure 74 Operating Mode By Default Automatic mode will be set However it can be changed between the available options at any time...

Page 58: ...ir storage and there are unloaded periods during the day but frequent motor starting and stopping is undesirable This mode is identical to constant mode during periods of moderate to high demand This mode of operation might not be available in all the machine configurations It is available in systems where the compressor uses the two valve load unload solenoid system This option cannot be selected...

Page 59: ...he pressure set point of the compressor This is the pressure that the compressor attempts to maintain throughout daily operation This is typically a value between the load and unload pressure On variable speed machines the motor speed will be controlled to match this pressure set point On machines with inlet and turn valve modulation the machine will modulate to match this set point Unload pressur...

Page 60: ...between the primary pressure and secondary pressure screen with the button available on the bottom of the Pressure Band Setting screen The p1 Pressure Band screen has a button called View p2 to jump to p2 pressure band screen 4 2 3 p2 Pressure Band The p2 Pressure Band defines alternative pressure set points that can be activated by a timer or control input This band can be used for when the compr...

Page 61: ...d unload the inlet valve will open at the load set point and close at the unload set point but will not modulate to the target pressure set point While in modulation mode the compressor will attempt to modulate the inlet valve and maintain the target pressure set point 4 2 5 Remote Halt Mode There are three options for Remote Halt Mode operation The modes are Timed Immediate and Disabled These can...

Page 62: ...p button has been pressed on the controller Disabled mode is used when there are no remote halt signals programmed to a digital input or when this function needs to be switched off for any reason Control will continue locally at the machine controller in this mode 4 2 6 Timer Start Enable Timer Start Enable allows the user to enable or disable the starting and stopping of the machine under timer c...

Page 63: ...s timer is set under the Timer Control Settings page When p2 Timer Enable is set to on the pressure set point will be automatically adjusted based on the schedule Refer to Figure 82 below Figure 82 p2 Timer Enable 4 2 9 Max Power Loss Time The Max Power Loss defines the maximum duration of a power failure event that will still allow a restart of the machine Values can be set between 1 and 999 seco...

Page 64: ...lly return the machine to the operating state it was in prior to the power failure With this setting off the machine will need to be started again manually A power failure event will cause a warning to be entered in the alarm history when auto restart is enabled but it will not be treated as a fault Figure 84 Auto Restart Enable 4 2 12 Dryer Pre Run Time The Dryer Pre Run Time is the time in minut...

Page 65: ...ot related to the control of the machine Table 32 Configuration Setting Configuration Settings Setting Sub Menu Short Description Configuration 4 3 1 Locale The User can see and set the Pressure Units Temperature Units Flow Units and Language under this section 4 3 2 Date Time The User can set the time date and time zone 4 3 3 Communication The User can set or edit the following parameters Etherne...

Page 66: ... Locale configuration menu the user can select the units used for different machine data such as the pressure temperature and flow Pressure Units With the drop down menu the user can select the pressure units between bar and psi as shown in Figure 87 below Figure 87 Pressure Units ...

Page 67: ...s The User can set the temperature units to either C or F as shown in Figure 88 below Figure 88 Temperature Units Flow Units The User can set the flow units between m 3 min m 3 hr and cfm as shown in Figure 89 below Figure 89 Flow Units ...

Page 68: ...set before editing the other Date Time settings Figure 90 Date Time Each parameter has a min and max value that may be entered Year can be selected from 2018 to 2106 Month can be entered between 1 to 12 Day between 1 to 31 Hour between 0 to 23 Minute between 0 to 59 and second between 0 to 59 Figure 91 below shows an example for setting the hours on the keypad When the Timezone is set correctly th...

Page 69: ... will not be able to set the other values and the IP addresses that are acquired will be shown in the respective fields Figure 92 Ethernet RS485 0 Communication Mode can be selected between Disabled Sequence AirSmart Sequence Delcos Sequence ES Modbus Master and Modbus Slave from drop down menu Figure 93 below shows the mode selection drop down menu options Table 33 Communication Modes Communicati...

Page 70: ...assigned as a Master in the sequence Modbus Slave The machine will be assigned as a Salve in the sequence Figure 93 RS485 0 Mode Baud Rate This is the bit rate the system will be using for data transfer The available options in the drop down menu are 1200 9600 19200 38400 57600 and 115200 Figure 94 RS485 0 Baud Rate shows the Baud Rate selection drop down menu option Note only the baud rates compa...

Page 71: ...n be managed or changed for a specific user level Note that a User level login won t see this option This is available when there is Maintenance Technician or Factory login and only Technician and Maintenance login password change is allowed Figure 95 below is the Security screen The password for the current level user and any lower level user may be changed For example Maintenance may only change...

Page 72: ... hits the Reset Password button the password will be reset to the factory default password values for the Technician and Maintenance login 4 3 5 Advanced This option is available only with Technician and Factory level logins Logging Level There are three logging levels Low Medium and High These logging levels the level of info included in the system logger which is valuable for engineering level d...

Page 73: ... either enabled or disabled with the toggle button Figure 99 below shows the Firewall Enable status There are specific communication instances where the firewall will need to be disabled on the controller to provide the required access for qualified personnel The firewall will revert to enabled when the controller is rebooted Do not change this setting unless directed by Gardner Denver service or ...

Page 74: ...e 34 Sequencing Settings Sequencing Settings Setting Sub Menu Short Description Sequencing 4 4 1 Sequencing Types Gives Information about the different Sequencing Types 4 4 2 AirSmart Protocol Summary of AirSmart Protocol Sequencing Settings 4 4 3 Delcos Protocol Summary of Delcos Protocol Sequencing Settings 4 4 1 Sequencing Types Figure 100 outlines the Sequencing settings home screen for the ES...

Page 75: ...r compressors with these controllers the AirSmart protocol should be used to allow for direct and optimal sequencing control The AirSmart protocol is uniquely designed to handle sequencing and load sharing of variable speed compressors or a mix of up to 8 variable speed and fixed speed machines It also features the ability to use a dedicated system pressure input to sample a true network delivery ...

Page 76: ...ws the compressor operation to be modified based on a time schedule There are two schedules available one to control starting and stopping of the machine and another to activate the secondary pressure band Table 35 below lists the timer control settings available under this menu Table 35 Timer Control Timer Control Setting Setting Sub Menu Short Description Timer Control Set Date Time and Time Zon...

Page 77: ...5 below all the channels are set to off We can set up to 8 different sets of time and days labeled as channels Each timer control channel controls a compressor switch on time and a compressor switch off time that can be set for one or more days of the week Figure 105 Timer Start Stop To configure one of the channels hit the button labeled Off next to the channel you want to set If the channel has ...

Page 78: ...day for example Once changed the screen will look like Figure 107 below Figure 107 Set Channel 2 Once saved it will bring the user back to the Timer Config Screen Channel 2 is set to On now as shown in Figure 108 below To turn off the timer channel press the Delete Channel Button on the bottom left of this screen this will delete all the values and bring the user back to the Timer Config screen wi...

Page 79: ... current schedule of operation The green areas shown on the schedule screen are the times when the compressor will be active shown in Figure 109 below Figure 109 Schedule View 4 5 2 Press Band p2 Timer The Press Band p2 button on the bottom left side of the Timer Control Screen will bring the user to the Timer Config screen this button is shown in Figure 110 below ...

Page 80: ...beled as channels Each timer control channel controls a compressor switch on time and a compressor switch off time that can be set for one or more days of the week Figure 111 Timer Pressure Band p2 To configure one of the channels hit the button labeled Off next to the channel you want to set If the channel has already been configured the button will be labeled On This will navigate you to the Cha...

Page 81: ...urday for example Once changed the screen will look like Figure 113 below Figure 113 Set Channel 2 Once saved it will bring the user back to the Timer Config Screen Channel 2 is set to On now as shown in Figure 114 below To turn off the timer channel press the Delete Channel Button on the bottom left of this screen this will delete all the values and bring the user back to the Timer Config screen ...

Page 82: ... the schedule screen are the times when the compressor will be active shown in Figure 115 below Figure 115 Schedule View 4 6 Programmable I O The Programmable I O settings menu allows the user to assign different digital and analog inputs and outputs to any free physical input or output connection on the controller This is categorized into four sections Digital Inputs Digital Outputs Temperature I...

Page 83: ...o available channels Table 36 above lists the sub menus of the Programmable I O sections 4 6 1 Digital Inputs The Digital Input tab lists 14 parameter settings and each can be assigned a channel based on their position on the IO module Figure 116 below shows the screen for the Digital Inputs Next to each signal name there is an input box to set the channel value and a toggle to set the signal as h...

Page 84: ...re is a positive voltage on the input An Active Low signals means the function that is assigned to the pin will be active if there is a low voltage on the input For example with the Remote Halt signal shown above configured as active low Remote Halt will be on when there is zero volts on input number 5 and will be off when there is 24VDC on input number 5 Table 37 below lists the signals available...

Page 85: ...ionality if active and the machine will run in load unload mode If assigned to an input and not active the inlet valve will be allowed to modulate Secondary Pressure Band This function enables the secondary P2 pressure band when it is active Timer Start Override This function is used to override the Timer Start Stop functionality For example if a machine is set to start at 6AM but needs to be star...

Page 86: ...te a clogged or defective filter Oil Temperature Warning If this digital input is active an oil temperature warning will be triggered Oil Temperature Fault If this digital input is active an oil temperature fault will be triggered Oil Pressure Warning If this digital input is active an oil pressure warning will be triggered Oil Pressure Fault If this digital input is active an oil pressure fault w...

Page 87: ...but is not running the motor Automatic Operation This signal indicates that the machine is enabled and the motor may be stopped or running The machine can start up at any time Motor Running This signal indicates that the main motor is running Loaded State This signal indicates that the compressor is loaded and producing air inlet valve is open Unloaded State This signal indicates that the compress...

Page 88: ...top Valve This function is used to control a water valve on water cooled machines Depending on the configuration of the machine the water stop valve may be controlled continuously or through a thermostatic algorithm based on the discharge temperature of the compressor Condensate Drain This function is used to control a condensate drain An internal timer and additional logic is used to activate the...

Page 89: ...mperature values can be set on the Settings Advanced Operating Limits page Enclosure Temperature This temperature signal monitors the temperature of the package enclosure for warning or fault When this function is assigned additional temperature values can be set on the Settings Advanced Operating Limits page 4 6 4 Analog Inputs The Analog Inputs settings page allows the user to configure optional...

Page 90: ...duce motor current for example if a turn valve is present 4 6 5 Analog Outputs The Analog Outputs tab consists of five signal settings which are shown below in Figure 122 Here the user can assign channels to various analog outputs on the compressor Figure 122 Analog Outputs Table 41 below lists the signals available on the Analog Outputs Signals screen and a brief description of their function Tab...

Page 91: ...p the Model Name Serial Number Design Pressure Max Volume Flow Oil Type System Voltage Motor SFA Elevation Total Hours Loaded Hours and Brand 4 7 2 Operating Limits The User can set the operating limits for Max Start Pressure Heavy Startup Minimum State Temperature Discharge Temperature Warning Delivery Pressure Warning Discharge Temperature Fault and Delivery Pressure Fault 4 7 3 Control Default ...

Page 92: ...own in Figure 123 Advanced Setup above The Model selection screen that comes up is shown in Figure 124 below A combination of two configuration files are used to configure the controller for a particular machine model The first file that must be loaded is the Machine Definition file this specifies the type of machine the IO mapping and the features of the machine The second file that is loaded is ...

Page 93: ...s or Machine Config Files depending on which is selected from the drop down menu Figure 125 Model Setting The bottom right text box will show the currently used file for each of the respective selections With the up and down scroll buttons users can browse through the list of files Figure 126 below shows the list of available Machine Definition Files Figure 127 below shows the list of available Ma...

Page 94: ...s loaded the user can confirm from the bottom right message box that the correct file is loaded Once the file is loaded to the machine successfully press the Restart button The controller will re boot with the new configuration and definition files for the machine Hit the Refresh Button available on bottom to refresh the list of available files Hit the Cancel Button to cancel this setting and exit...

Page 95: ... Pressure set to 130 psi Note that setting the design pressure to a value that does not match the machine capabilities may allow dangerous operation of the compressor The warning and fault pressure band settings will be limited based off the design pressure setting Figure 128 Design Pressure 4 7 1 4 Max Volume Flow The Max Volume Flow setting is used on fixed speed machines it should be set to the...

Page 96: ...s should be set to match the type of oil used in the machine Figure 130 shows the drop down menu of Oil Type Figure 130 Oil Type Each of the Oil Types use a specific aging algorithm to determine the oil change interval The multipliers for the oil aging can be seen in Table 43 below The Oil Type selections are the following Standard Oil Change Timer counts down normally at high temperature Use with...

Page 97: ...4 7 1 6 System Voltage Each system is designed to operate at a certain voltage and in some cases a range of voltages The User can configure the operating voltage by touching the voltage value and enter the System Voltage on the number pad Figure 131 below shows setting the System Voltage to 460V Figure 131 System Voltage 4 7 1 7 Motor SFA The Motor Service Factor Amperage value is the amount of cu...

Page 98: ... above sea level of the geographical location where this unit compressor motor is installed Figure 133 below shows the Elevation setting This value is used on variable speed machines to ensure that the variable speed drive performance is de rated according to the elevation Figure 133 Elevation ...

Page 99: ...roller Figure 134 shows setting the Total Hours to 100h Figure 134 Total Hours 4 7 1 10 Loaded Hours The Loaded Hours are the hours run hours during which the machine was loaded and producing air One thing to note the Loaded Hours maximum allowed value will be equal to Total Hours As shown in Figure 135 The loaded hours must be set to match the actual loaded hours on the machine when installing a ...

Page 100: ...at the brand may only be set once by the technician level access and then only changed by the factory level thereafter Figure 136 Brand 4 7 2 Operating Limits On the advanced Operating Limits menu the user can set the machine operating pressures and temperatures warning and fault set points This option is available only to Technician and Factory level logins Figure 137 below represents the Operati...

Page 101: ...exceeded a heavy startup fault will occur 4 7 2 3 Minimum Start Temperature The Minimum Start Temperature setting is the temperature the compressor needs to be at before the motor will start Figure 138 below shows the setting of Minimum Start Temperature as 39 F Figure 138 Minimum Start Temperature 4 7 2 4 Discharge Temperature Warning The Discharge Temperature Warning setting defines the temperat...

Page 102: ...t setting defines the temperature where an over temperature fault will be triggered in the controller The technician may set the value of the Discharge Temperature Fault lower than the factory default but not above Figure 140 below shows the setting of Discharge Temperature Fault as 240 F Figure 140 Discharge Temperature Fault ...

Page 103: ...controller Figure 141 below shows setting the Delivery Pressure Warning to 127 psi Figure 141 Delivery Pressure Warning 4 7 2 7 Delivery Pressure Fault The Delivery Pressure Fault defines the pressure where an over pressure fault is triggered in the controller Figure 142 below shows setting the Delivery Pressure Fault to 137 psi Figure 142 Delivery Pressure fault ...

Page 104: ...er each of these tabs the user can set warning and fault limits for each of the additional temperature sensors on the machine There are min and max values for each entry as explained previously for the other settings An example of the Enclosure Temperature tab settings and the other possible tabs are shown below in Figure 143 Figure 143 Enclosure Temperature Limits 4 7 3 Control Default The Contro...

Page 105: ...ing Automatic Stop Time to 5 min 0 Sec Figure 145 Automatic Stop Time 4 7 3 2 Rotation Direction Check The Rotation Direction Check setting can be set to either On or Off by using the On Off toggle Button When the Rotation Direction Check is enabled the controller will for pressure to be built in the reservoir immediately following the motor starting if adequate pressure is not detected the unit w...

Page 106: ... the minimum amount of time that the compressor motor will run after pressing the stop button which starts the depressurization process Figure 147 shows setting the Minimum Stop Time as 30 seconds Figure 147 Min Stop Time 4 7 3 4 Minimum Run Time The Minimum Run Time setting is defines the amount of time that the compressor must be running before it will be allowed to stop automatically This setti...

Page 107: ...Motor failure as it provides a smooth loading of the Compressor On machines with a wye delta starter the acceleration time will start after the wye delta transition To extend the time before the compressor is loaded after the wye delta transition set the acceleration time to the desired value On machines with a full voltage soft starter or remote starter the acceleration time will start after the ...

Page 108: ... to accelerate to full speed before transitioning to delta Figure 150 show the setting of Star Delta Time to 5 Seconds Figure 150 Star Delta Time 4 7 4 Control Variable Speed The Control Variable Speed settings are related to the operation of the variable frequency drive on compressor packages that have a VFD Figure 151 below shows the home screen for Control Variable Speed settings under the adva...

Page 109: ... min is set to 30 the machine would not be allowed to modulate the speed below 30 when the External Speed Limit input was active If the Ext Speed Limit min is set to 15 on this same machine the machine would still not be allowed to run below its minimum of 21 regardless of the state of the input Figure 152 Ext Speed Limit min 4 7 4 2 Ext Speed Limit max The Ext Speed Limit max is a percentage of t...

Page 110: ...value the controller will use its internal algorithms based on the system configuration to control the speed of the motor and attempt to maintain pressure control When the speed control source is set to Remote the analog input for Remote Speed Control will be used to control the speed of the motor between the allowable minimum and maximum speeds for the current operating point When the Speed Contr...

Page 111: ...etting may be used in cases where a temporary power limitation or other condition presents a need to limit the maximum power or flow of the machine Figure 155 Capacity Limit 4 7 4 5 Cold Start Time The Cold Start Time setting allows the user to specify a time delay for the motor to warm up in cold weather before allowing to start and run fully loaded This setting has a maximum time setting of 15 m...

Page 112: ...nt conditions less than 50 degrees Fahrenheit Figure 157 Cold Start Limit 4 7 4 7 Manual Speed The Manual Speed setting allows the user to manually set the speed of the VFD output to the motor based on a percentage of the full speed This speed is active when the Speed Control Source is set to Manual The compressor will still load and unload based on the operating settings of the machine but the mo...

Page 113: ...ow represents the Cooling settings screen Figure 159 Cooling 4 7 5 1 Cooling Type There are two options to select for Cooling Type Air Cooled and Water Cooled Before making any change to this parameter one should know what cooling type the machine uses this value should generally not be changed in the field Figure 160 below shows the selection between Air Cooled and Water Cooled from drop down men...

Page 114: ...d on thermal sensor feedback If the temperature goes up beyond a set limit then the controller will turn on the cooling fan and will turn off if the temperature goes below the set limit Figure 161 Fan Control 4 7 5 3 Fan Shutoff Delay The Fan Shutoff Delay is a time delay setting for the fan to continue running for a set period after the main motor has been shut off for additional machine cooling ...

Page 115: ...he factory settings are optimized for the machine and will perform well for almost all applications Only make adjustments to these values if directed by Gardner Denver Figure 163 PID Tuning 4 7 7 Backup Restore The Backup Restore settings allow the user to save the current configuration restore an already saved configuration or restore the system to factory default Figure 164 below shows the Backu...

Page 116: ...tings and parameter values by selecting the Restore User Configuration option This option will only work when there is a stored configuration Press the Restore button and a dialogue box will confirm the changes as shown in Figure 166 below Figure 166 Restore User Configuration Once you hit the Save Button the controller will reboot to implement the changes Restore Factory Default The Restore Facto...

Page 117: ...ken immediately to protect the machine operators and the facility The controller home page includes a banner near the bottom of the screen which highlights the current status of the machine and alerts the user of any alarms Figure 168 below shows the home screen of controller with the machine in the enabled state This means the machine is ready to run and there are no current system alarms indicat...

Page 118: ...o navigate to this screen is through the main menu selecting the Alarms sub menu As you can see in the Figure 170 below the Alarm menu has two sub options Active Alarm and Alarm History Figure 170 Alarms Menu Selection 5 1 Active Alarm The Active Alarm page lists all the alarms which are currently active on the machine Figure 171 below shows the Active Alarm page with a few different alarms listed...

Page 119: ...rms above is only showing faults A warning is alarm that needs to be addressed as soon as possible but the system can keep running in most cases It is shown with a yellow triangle Timestamp The Timestamp column shows the date and time when that particular alarm was triggered As you can see below M1 1 alarm was activated on 11th Apr 2020 at 14 35 45 Code Each alarm has a specific alarm code The ala...

Page 120: ...ow for a list of the all faults and warnings on the system This table has a full list of alarms with major minor format Note some alarms are specific to the machine configuration and sensors that are present Diagnose an Alarm The table below shows the possible root cause and first hand remedy for each alarm Note that if the remedy listed is not useful and the problem persists please contact the Ga...

Page 121: ...t the sensor may read within range at room temperature but still be faulty once exposed to an elevated temperature or vibration Replace or repair the wiring or sensor depending on the results of the findings A1 5 Fault Airend Discharge Temperature Input is below the Fault Limit Airend discharge temperature is too low to start or run the machine Check site conditions and increase the ambient temper...

Page 122: ...ir based on the results of the investigation A1 8 Fault Airend Discharge Temperature input is shorted check sensor wiring Discharge temperature sensor is faulty or the wiring to the sensor is shorted Using the wiring schematic for the machine locate the discharge temperature sensor connection to the controller Check for any shorted wires at the connector Inspect the cable for damage between the co...

Page 123: ...kage discharge pressure has exceeded the fault limit Inspect the oil level and condition Check the performance of the thermal mixing valve and oil cooler if equipped A1 15 Warning Discharge pressure above the Warning Limit The package discharge pressure has exceeded the warning limit and is approaching the fault limit Inspect the oil level and condition Check the performance of the thermal mixing ...

Page 124: ...logs from the controller and contact Gardner Denver service C 9 Warning Error on FX30 USB link task Internal error in communication with iConn module Check the iConn diagnostics page to verify communication between the iConn and controller Check USB cable between the iConn and controller and the power cable to the iConn If the problem persists export the logs from the controller and contact Gardne...

Page 125: ...e controller and contact Gardner Denver service C 19 Warning Error transferring logs to USB An error occurred while trying to export the logs to a USB device Remove and re insert the USB device and try to save the logs again Ensure that the USB device is formatted in a FAT16 format and make sure that it is not removed during the save operation Try a different USB device If the problem persist cont...

Page 126: ...set it low This indicates that the output pin is shorted to 24VDC C 51 Fault Digital Output 4 Short High The feedback value of Digital Output 4 is high while the controller is attempting to set it low This indicates that the output pin is shorted to 24VDC C 52 Fault Digital Output 5 Short High The feedback value of Digital Output 5 is high while the controller is attempting to set it low This indi...

Page 127: ...tal Output 13 is high while the controller is attempting to set it low This indicates that the output pin is shorted to 24VDC C 61 Fault Digital Output 14 Short High The feedback value of Digital Output 14 is high while the controller is attempting to set it low This indicates that the output pin is shorted to 24VDC C 62 Fault Digital Output 15 Short High The feedback value of Digital Output 15 is...

Page 128: ...forcing the value ON and OFF If shorted or overloaded the Feedback result will stay OFF regardless of the forced value 3 Remove any wires from the digital output at the IO module connection and see if the feedback begins to operate following the commanded value If the output operates correctly without anything connected to the module the problem is most likely with the wiring outside the controlle...

Page 129: ...round or the output is overloaded C 76 Fault Digital Output 9 Short Low The feedback value of Digital Output 9 is low while the controller is attempting to set it high This indicates that the output pin is shorted to ground or the output is overloaded C 77 Fault Digital Output 10 Short Low The feedback value of Digital Output 10 is low while the controller is attempting to set it high This indicat...

Page 130: ... ground or the output is overloaded C 83 Fault Digital Output 16 Short Low The feedback value of Digital Output 16 is low while the controller is attempting to set it high This indicates that the output pin is shorted to ground or the output is overloaded C 84 Fault Digital Output 17 Short Low The feedback value of Digital Output 17 is low while the controller is attempting to set it high This ind...

Page 131: ... the logs from the controller and contact Gardner Denver service C 94 Fault Controller Initialization Failed Internal software or hardware error or misconfiguration Reboot the controller If the problem persists export the logs from the controller and contact Gardner Denver service C 95 Fault Communications with VFD Cooling Lost Modbus communications lost with cooling fan VFD Check the connections ...

Page 132: ...ce C 103 Warning Machine Parameter recipe load failed An error occurred when the controller tried to read the machine parameter file The operation may have been interrupted Reboot the controller If the problem persists export the logs from the controller and contact Gardner Denver service C 104 Warning Machine Parameter recipe load partially failed An error occurred when the controller tried to re...

Page 133: ...cipe load partially failed An error occurred during an attempt to save the machine parameter file The operation may have been interrupted The controller was able to recover If the problem persists export the logs from the controller and contact Gardner Denver service C 113 Warning Permanent Variables recipe save failed An error occurred during an attempt to save the permanent variables file The op...

Page 134: ...pshot recording completed successfully Informational Snapshot recording process was successful No action needed C 124 Warning Snapshot recording interrupted and aborted Snapshot recording was interrupted Reboot the controller If the problem persists export the logs from the controller and contact Gardner Denver service C 125 Warning Snapshot value of a registered process variable has violated limi...

Page 135: ... contact Gardner Denver service C 136 Fault Error in IO Mapping task An error occurred in trying to load the IO map for the controller Possible misconfiguration Reboot the controller If the problem persists export the logs from the controller and contact Gardner Denver service C 137 Fault Internal Configuration Fault Bad VFD Address A misconfiguration was detected where one of the VFDs in the syst...

Page 136: ... An error was detected in serial communications on the IO Module serial port RS485 2 Check wiring and all devices connected to the RS485 2 port Check configuration of the devices to ensure that they match This problem is generally related to baud rate or other communication misconfigurations If the problem persists export the logs from the controller and contact Gardner Denver service C 147 Warnin...

Page 137: ...ault limit due to motor regen or high input voltage Verify supply voltage within tolerance Check if fan wheel is freewheeling when not running Fan deceleration may be too fast and require parameter adjustment contact Gardner Denver service FV1 3 Warning VFD Cooling Earth Warning The VFD has detected a high level of ground current Check wiring between motor and VFD for incorrect or loose connection...

Page 138: ...ing internal temperatures above the fault limit Confirm ambient temperature near the VFD is below 50C Check ventilation filters and fans mounted in the control panel for debris Check the VFD heat sink cooling fans for correct operation Clean cooling fans and heat sink fins with compressed air FV1 15 Fault VFD Cooling Motor Stall Fault Motor has stalled during start or run Check wiring between fan ...

Page 139: ...V1 39 Fault VFD Cooling Device Removed fault VFD has detected removal of an Option card Power cycle drive Contact Gardner Denver service FV1 40 Fault VFD Cooling Unknown Device fault VFD has detected and compatibility error between its control board and an option board Power down drive Check option card and ribbon cable are connected FV1 41 Fault VFD Cooling IGBT Temp fault VFD has detected that I...

Page 140: ...ock battery is depleted Replace the RTC battery FV1 65 Warning VFD Cooling Replace Fan Warning VFD has calculated that its cooling fan life is less than 2 months Inspect condition and operation of heat sink cooling fans Replace as needed FV1 65 Fault VFD Cooling Replace Fan Fault VFD has calculated that its cooling fan life is less than 2 months Inspect condition and operation of heat sink cooling...

Page 141: ...ts Internal software configuration issue Reboot the controller If the problem persists export the logs from the controller and contact Gardner Denver service Motor Alarms M1 0 Fault Motor Auxiliary fault The motor contactor or contactor coil has failed The wiring to the contactor coil or aux contact has failed Check wiring to the contactor coil and auxiliary contact Use the digital output IO diagn...

Page 142: ...Fault VFD Motor Speed Low fault VFD Actual Motor Speed is below the minimum speed limit set in the controller Typically this alarm will be accompanied by a VFD warning or fault See the actions for the associated VFD alarm Contact Gardner Denver service M1 13 Warning VFD Motor Speed Low warning VFD Actual Motor Speed is below the minimum speed limit set in the controller Typically this alarm will b...

Page 143: ...n compressor package area P 8 Warning Control box temperature limiter warning Control panel internal air temperature above the limiter set point Confirm ambient temp near the compressor package inlets is below the rating of the machine Check ventilation filters and fans mounted in the control panel for debris clean replace as needed P 9 Warning Cold start speed limiter warning Ambient temperature ...

Page 144: ...t oil level and condition Add oil as necessary P 26 Fault Oil Level 1 warning Programmable input for oil level 1 warning has been activated Inspect oil level and condition Add oil as necessary P 27 Fault Oil level 2 fault Programmable input for oil level 2 fault has been activated Inspect oil level and condition Add oil as necessary P 27 Fault Oil level 2 warning Programmable input for oil level 2...

Page 145: ...the connector Inspect the cable for damage between the controller and the sensor Remove the cable connector from the sensor and use a multi meter to check the resistance of the sensor and ensure that it is not shorted It is possible that the sensor may read within range at room temperature but still be faulty once exposed to an elevated temperature or vibration Replace or repair the wiring or sens...

Page 146: ...vibration Replace or repair the wiring or sensor depending on the results of the findings P 110 Fault Control Box temperature high fault Control panel internal air temperature has exceeded the high fault limit Confirm ambient temp near the compressor package inlets is below the rating of the machine Check ventilation filters and fans mounted in the control panel for debris clean replace as needed ...

Page 147: ...r and cooling fan for proper operation Clean the aftercooler if required P 115 Warning Plant delivery temperature high warning Plant delivery air temperature is approaching the high fault limit Inspect the aftercooler and cooling fan for proper operation Clean the aftercooler if required P 116 Fault Plant delivery temperature low fault Plant delivery air temperature is below the low fault limit Ch...

Page 148: ...f the dryer air temperature P 122 Fault Dryer temperature short fault Dryer temperature sensor is faulty or the wiring to the sensor is shorted Using the wiring schematic for the machine locate the Dryer temperature sensor connection to the controller Check for any shorted wires at the connector Inspect the cable for damage between the controller and the sensor Remove the cable connector from the ...

Page 149: ...g or sensor depending on the results of the findings P 133 Fault Oil Sump 1 temperature open fault Oil Sump 1 temperature sensor is faulty the wiring to the sensor is broken or the wiring or connector is disconnected Using the wiring schematic for the machine locate the Oil Sump 1 temperature sensor connection to the controller Check for disconnected wires plugs or loose connections Inspect the ca...

Page 150: ...repair the wiring or sensor depending on the results of the findings P 139 Fault Oil Injection Temperature rate fault Oil injection temperature is increasing at a rate above the rate of rise fault limit Inspect the oil level and condition Add oil as required Inspect the oil cooler and thermal mixing valve operation Clean the cooler as required P 140 Fault Oil Injection temperature high fault Oil i...

Page 151: ... Enclosure temperature has exceeded the high temp fault limit Check the site conditions and decrease the ambient temperature in the compressor enclosure P 160 Warning Enclosure temperature high warning Enclosure temperature is approaching the high temp fault limit Check the site conditions and decrease the ambient temperature in the compressor enclosure P 161 Fault Enclosure temperature low fault ...

Page 152: ...ure sensor connection to the controller Check for any shorted wires at the connector Inspect the cable for damage between the controller and the sensor Using a multi meter with process clamp meter measure the current mA in the signal wire between the sensor and controller The signal should be in the range of 4 20mA Replace or repair the wiring or sensor depending on the results of the findings P 2...

Page 153: ...ect inlet valve assembly for leaks and proper sealing during unloaded operation Confirm proper adjustment of control pressure regulator if equipped Confirm proper operation of the blowdown circuit Check MPV for proper operation Inspect aftercooler for blockages P 208 Fault Separator pressure short fault Separator pressure sensor is faulty or the wiring to the sensor is shorted Using the wiring sch...

Page 154: ...nd thermal mixing valve operation Confirm proper operation of the oil pump P 226 Fault Oil Injection pressure high fault Oil injection pressure has exceeded the high pressure fault limit Inspect the oil system pump and cooler for blockages Confirm proper operation of the oil pump P 226 Warning Oil Injection pressure high warning Oil injection pressure has exceeded the high pressure warning limit a...

Page 155: ...e change is complete S 4 Warning Oil sample maintenance warning Oil Sample Service required The service timer for taking an oil sample has expired Perform the Oil sample service following service instructions Reset the timer in the controller once the change is complete S 5 Warning Separator maintenance warning Separator service required The service timer for performing separator maintenance has e...

Page 156: ...or warning Problem with the communication wiring or connection to the controller Check the cable and wiring connection to the controller or IO brick depending on protocol to verify no loose wires or connectors Make sure each of the compressors in the sequence are wired properly and the controller sequencing settings are correct SQ 1 Warning Sequencing duplicate unit number warning The Unit number ...

Page 157: ...sulation resistance V1 5 Fault VFD1 Charging Circuit fault The VFD has detected that the charging circuit has faulted Verify package supply voltage within tolerance Check DC bus voltage with meter to verify voltage level approx 1 414 times AC Rms input voltage Reset and restart compressor If issue persists contact Gardner Denver service V1 6 Fault VFD1 Estop fault Emergency Stop Pressed E Stop dig...

Page 158: ...VFD1 Motor Stall warning Motor has stalled during start or run Check wiring between motor and VFD for incorrect or loose connections Check drive system for proper alignment and wear Verify supply voltage within tolerance Decouple compressor from drive motor and check for proper manual rotation Test motor insulation resistance V1 16 Warning VFD1 Motor Over Temp warning VFD has calculated that the m...

Page 159: ... insulation resistance V1 51 Warning VFD1 External Input warning VFD has detected external fault input active Check for any damage in external cable wirings and check if there is any loose connections or terminal V1 51 Fault VFD1 External input fault VFD has detected external fault input active Check for any damage in external cable wirings and check if there is any loose connections or terminal V...

Page 160: ...or proper alignment and wear Decouple compressor from drive motor and check for proper manual rotation Test motor insulation resistance V1 68 Warning VFD1 over Voltage limit warning VFD has detected that the DC bus voltage has risen above the warning limit due to motor regen or high input voltage Verify supply voltage within tolerance Motor deceleration may be too fast and require parameter adjust...

Page 161: ... with AC power lines and confirm cable shielding drains are terminated to ground terminals Water Pump Alarms WP 0 Fault Water Pump Auxiliary Input fault The contactor coil failed or the wiring to the coil or auxiliary contact is disconnected The contactor could be stuck in the open or closed position Check wiring to the contactor coil and auxiliary contact for the Water Pump Use the digital output...

Page 162: ...Alarm History page lists all the alarms the system has experienced in the order they occurred As shown in Figure 174 below the alarm column has various symbols that represent different alarm types Table 46 shows the possible symbols in the alarm column and a description for each Table 46 Alarm Symbols Alarm Symbols Alarm Description A yellow outlined triangle shows a warning alarm that is no longe...

Page 163: ...m History Page is the same as described in section 5 1 2 The Info button will be available for alarm and snapshot events but disabled for acknowledged events as shown in Figure 175 below The Active Alarms button takes the user back to the Active Alarms page Figure 175 Alarm History ...

Page 164: ...el s status can be seen here 6 7 Remote Control The current state of all remote control functions can be viewed from this page 6 8 VFD Diagnostics The user can see the information about the variable frequency drive used on this machine if applicable 6 1 Sequencing The Sequencing Diagnostics page gives an overview of the sequencing settings for the machine The compressor name run hours capacity and...

Page 165: ...13 17 621 Page 165 Figure 176 Sequencing Diagnostics ES Protocol Figure 177 Sequencing Diagnostics AirSmart Protocol ...

Page 166: ...amage to the machine This function should be utilized anytime there is a risk that the AC power phases changed sequence such as on initial startup This page lists the following three parameters Jog Duration Selected Motor and Jog Delay 6 2 1 Jog Duration The Motor Jog Duration is the amount of time the motor will be run during the jog operation The shortest amount of time sufficient to turn the mo...

Page 167: ...ure 181 below shows the selection of compressor motor Figure 181 Selected Jog Motor 6 2 3 Jog Delay The Jog Delay setting allows the user to insert a delay between pressing the start job button and the start of the motor jog operation Figure 182 shows setting the Jog Delay with the keypad This allows the user time to get into a position where the motor can be viewed to observe rotation ...

Page 168: ... Diagnostics screen gives the status of IO signals for the Digital Inputs Digital Outputs Temperature Inputs Analog Inputs and Analog Outputs Digital Inputs Figure 183 below shows the tab for the Digital Inputs Each Input number represents the channel number of the input To see which parameter is assigned against each channel number you can refer to the Settings Programmable I O screen as well as ...

Page 169: ... the bottom right of the screen Note that any device connected to the output pin such as a motor or valve will be toggled based on the values that are set in this mode When output forcing is enabled pressing on the value column for a specific output will turn that output on or off Figure 184 Digital Output Temperature Inputs The Temperature Inputs tab shows the raw and scaled values for each of th...

Page 170: ...aw and scaled values for each of the analog sensors on the machine Figure 186 below shows the Analog Input screen Figure 186 Analog Inputs Analog Outputs Similar to the Analog Inputs tab the Analog Outputs tab lists the raw and scaled values for each of the analog sensors on the machine Figure 187 below shows the Analog Outputs screen ...

Page 171: ...n being used and update the controller software to the latest version 6 4 5 Audit The user can view a record of all the changes made to the system 6 4 6 Logger The user can view the system logs and select a specific logger 6 4 7 Advanced Lists files on the controller and the size of each folder in the structure 6 4 1 General Figure 188 below shows the Controller s General Info This includes Total ...

Page 172: ...uation of system performance and troubleshooting To save the Log to a flash drive first insert the USB drive into an open port on the controller and then press the Save button and the logs will be downloaded If there is no flash drive available then the system the Save button will be disabled and grayed out Figure 189 below shows what the page s like when a flash drive is connected hit the Save bu...

Page 173: ...191 below shows the files contained in the unzipped folder The folders and files contained here are explained in more detail below Figure 191 Log Folder Audit The Audit folder contains files which hold a record of the activities performed on the controller The Audit report are text files that may be opened with any text editor Figure 192 shows a typical view of Audit file opened on the computer Fo...

Page 174: ...16_30 csv contains the logs of the system after the previously generated log In this example it would include the logs between 30th April 11 16 05 to 1st May 08 16 30 Figure 194 below shows an example of the Data Recorder Log file Note that the parameters that are logged will change based on the configuration and features of the machine The entries in the data recorder files will be logged at diff...

Page 175: ...ated when a specific event occurred These files include the same information that is available in the Data Recorder files but at a higher resolution for a short period of time preceding a fault Entries in this file will be made every 500ms Each file will include several minutes worth of data Figure 195 below shows the Event Trace Folder containing various log files created with the name of Exporte...

Page 176: ... system dump files which can be used by Gardner Denver support for diagnostics If this file is requested please forward to Gardner Denver support Figure 198 shows the system dump file for this example Figure 198 System Dump File 6 4 3 System The Controller System screen gives information about the status of the controller and its operation The System menu has been distributed between 6 tabs Note u...

Page 177: ...ts the operational values time synchronization software versions and CPU configuration information Figure 200 below shows the System screen Figure 200 System Software The Software information page will list the software configuration Figure 201 shows the Software tab ...

Page 178: ...ithin the hardware tree It also have the Module Status and Module details Figure 202 below shows the hardware status with green tick marks Figure 202 Hardware Logger The Logger page lists logs for various machine modules The User can either view it right on the screen or save it see Figure 203 below ...

Page 179: ...een hit the View button Another screen with more details will show up as shown in Figure 204 below Figure 204 Logger Details Hit to return to previous screen of Logger Hit to refresh the page Hit to select how many pages show at a time It will be as shown in Figure 205 below ...

Page 180: ... level Diagnostic tool which keeps track of all the changes taking place with very fine level of details By default there will be default profiler running and keeping record of all the changes Note the user should not modify this page unless directed to by Gardner Denver Figure 206 Profiler ...

Page 181: ...bottom left of the screen Figure 207 below shows the Update Software Screen Figure 207 Update Software 6 4 5 Audit The Audit log is a record of all the changes made to the system This includes details such as changes to settings as well as resetting alarms Refer to Figure 208 below for an example of the Audit Log screen On the first line you can see that on 21th August 2020 at 11 33 11 PowerLossFa...

Page 182: ...ion 6 4 3 This screen facilitates the user to read the logs from a specific logger Figure 209 below represents the Logger screen Note that this page should be used only when directed by Gardner Denver service Figure 209 Logger To select a logger hit the Sel Logger button on the bottom right side It will open up the list of all the loggers the system created Refer Figure 210 below ...

Page 183: ...and it will take you to the Logger home screen It might take few minutes to load and display the data Left to the Sel Logger there is a Refresh button Hit the Refresh button if you want to update the log list note it will refresh the logs for the currently selected logger only 6 4 7 Advanced The Advanced screen of the controller lists the number of files and their sizes in kB for each folder Figur...

Page 184: ...s being used in the system In the above figure 18588 kB of system memory is used of the 162348 kB available To refresh the list hit the refresh button on the bottom right side of the page A confirmation dialogue box will show up displaying the total number of folders and their loading status Refer Figure 213 below Note the system will automatically manage the amount of free space available and del...

Page 185: ...or cellular signal can lead to connection loss with the iConn server Example Figure 214 shows an iConn connected to a machine but the cellular status is not connected Figure 214 iConn 6 6 Communication The Communication diagnostics screen displays the status of the RS485 1 RS485 2 channels As shown in Figure 215 below each RS485 network shows a Mode Rx Count Tx Bytes and Rx Tx toggle Status indica...

Page 186: ...ut is enabled if assigned and not active remote load input is ignored Remote Timer Override If assigned and active the timer start functionality will be overridden so that the machine will operate regardless of a start stop timer schedule Secondary Pressure Activate If active the secondary pressure band will be activated if not active the secondary pressure band is ignored Active Regulation If act...

Page 187: ...ameters If toggled ON it means the digital input assigned to this function is active Note that this could mean that the physical input is high or low depending on configuration of the input Communication Status The Communication Status is shown with either ON or OFF If toggled ON it indicates that the bit representing this function in the communication interface is active Figure 216 below shows an...

Page 188: ...13 17 621 Page 188 Figure 217 VFD Diagnostics Figure 218 VFD Diagnostics ...

Page 189: ... two available parameters by changing the selection in the two dropdowns The left dropdown changes the left y axis of the graph and the right dropdown changes the right y axis on the graph The value shown next to the dropdown box is the value of the currently selected parameter The available parameters for each dropdown are shown in Figure 220 and Figure 221 below Notice the selections that do not...

Page 190: ...ated for a History View This is shown in Figure 222 Figure 222 Trend History View While the History view is activated you can use the arrows to scroll forward and backward in time The black vertical bar on the display shows the current position of the cursor and the readings just above the graph show the values at the location of the cursor Press Return to Current to return to the Live Data view ...

Page 191: ...own can be used to change the scale of the time axis For example setting to 12 hours would scale the graph so that the full width of the window represents 12 hours of time To jump to a particular date and time in history view press the Edit button next to the Date Time and enter the date and time that you would like to view This can be more efficient than scrolling on the graph and allows precise ...

Page 192: ...wser with 81 at the end to specify port 81 The web interface will look like Figure 224 below As seen in the figure the web interface shows the user the pressure and temperature limits with current pressure and temperature readings on the gauges for the machine being monitored There is also a list of active alarms and alarm history for the machine The hours left to service loaded hours and total ru...

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Page 194: ...13 17 621 Page 194 For additional information contact your local representative or visit www contactgd com compressors 2019 Gardner Denver Inc Printed in U S A ...