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Gardner Denver Governor TEN014983, User Manual

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Gardner Denver Governor TEN014983 User Manual Download Page 158

 

 

13-17-621    Page 158 

a clamp on amp meter. Test motor insulation 
resistance. 

V1.13 

Warning 

VFD1 Drive 
Under Temp 
warning 

Ambient temperature is 
below the warning limit 
for the VFD 

Raise ambient temperature near the VFD and 
compressor package. 

V1.13 

Fault 

VFD1 Drive 
Under Temp 
fault 

Ambient temperature is 
below the fault limit for 
the VFD 

Raise ambient temperature near the VFD and 
compressor package. 

V1.14 

Warning 

VFD1 Drive 
Over Temp 
warning 

VFD is measuring 
internal temperatures 
above the warning 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. 

V1.14 

Fault 

VFD1 Drive 
Over Temp fault 

VFD is measuring 
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. 

V1.15 

Fault 

VFD1 Motor 
Stall fault 

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. 

V1.15 

Warning 

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 motor has been run 
in an overloaded 
condition for an extended 
time and is too 

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 

Fault 

VFD1 Motor 
Over Temp fault 

VFD has calculated that 
the motor has been run 
in an overloaded 
condition for an extended 
time and is too 

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. 

V1.19 

Fault 

VFD1 Power 
Board EEPROM 
fault 

VFD has detected 
internal memory error. 

Power cycle drive. Contact Gardner Denver 
service. 

V1.20 

Fault 

VFD1 RAM fault 

VFD has detected 
internal memory error. 

Power cycle drive. Contact Gardner Denver 
service. 

V1.21 

Warning 

VFD1 Serial 
Flash Warning 

VFD has detected 
internal memory error. 

Power cycle drive. Contact Gardner Denver 
service. 

V1.21 

Fault 

VFD1 Serial 
Flash Fault 

VFD has detected 
internal memory error. 

Power cycle drive. Contact Gardner Denver 
service. 

Summary of Contents for Governor TEN014983

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...

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 Li...

Page 4: ...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...

Page 5: ...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...

Page 6: ...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 Tempe...

Page 7: ...ECTION 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...

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: ...ibed 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...

Page 10: ...e 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 Figu...

Page 11: ...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...

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 can be switched using software Max distance 1000 m Interface IF5 Type RS485 Variant 3 pin...

Page 14: ...igure 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...

Page 15: ...y 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...

Page 16: ...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 Terminat...

Page 17: ...dules 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 TEN0149...

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 meas...

Page 19: ...ded 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...

Page 20: ...t 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...

Page 21: ...N 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 C...

Page 22: ...t 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...

Page 23: ...2 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 TEN0...

Page 24: ...odule 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 Conn...

Page 25: ...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...

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 PT...

Page 27: ...tails 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...

Page 28: ...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 p...

Page 29: ...reens 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 na...

Page 30: ...essed 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...

Page 31: ...e 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...

Page 32: ...m 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...

Page 33: ...ts 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 setti...

Page 34: ...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...

Page 35: ...ompressor 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 set...

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...

Page 37: ...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...

Page 38: ...ement 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...

Page 39: ...ellow 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 Eleme...

Page 40: ...scading 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 abou...

Page 41: ...iate 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 a...

Page 42: ...ord 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...

Page 43: ...rol 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...

Page 44: ...e 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 th...

Page 45: ...ding 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 b...

Page 46: ...e 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...

Page 47: ...n 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...

Page 48: ...reen 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...

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 t...

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 res...

Page 51: ...l 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...

Page 52: ...rs 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 6...

Page 53: ...nged 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 c...

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 t...

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 star...

Page 56: ...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 H...

Page 57: ...eters 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 A...

Page 58: ...r 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 m...

Page 59: ...e 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 variab...

Page 60: ...etween 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...

Page 61: ...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...

Page 62: ...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 Contr...

Page 63: ...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...

Page 64: ...ly 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...

Page 65: ...t 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...

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 pressur...

Page 67: ...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 F...

Page 68: ...et 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 1...

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 Se...

Page 70: ...ssigned 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 transfe...

Page 71: ...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 Main...

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 a...

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 control...

Page 74: ...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...

Page 75: ...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 sha...

Page 76: ...s 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...

Page 77: ...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 of...

Page 78: ...ay 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...

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...

Page 80: ...eled 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...

Page 81: ...rday 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...

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 assig...

Page 83: ...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...

Page 84: ...e 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...

Page 85: ...onality 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 seco...

Page 86: ...e 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 temper...

Page 87: ...ut 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...

Page 88: ...op 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 thermost...

Page 89: ...perature 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...

Page 90: ...uce 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 chann...

Page 91: ...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 limit...

Page 92: ...wn 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 particul...

Page 93: ...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 selectio...

Page 94: ...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...

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 ban...

Page 96: ...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 oi...

Page 97: ...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...

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...

Page 99: ...oller 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 t...

Page 100: ...t 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...

Page 101: ...xceeded 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...

Page 102: ...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...

Page 103: ...ontroller 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...

Page 104: ...r 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...

Page 105: ...ng 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 But...

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 Figu...

Page 107: ...otor 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 compre...

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...

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...

Page 110: ...alue 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 t...

Page 111: ...tting 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...

Page 112: ...t 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...

Page 113: ...w 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...

Page 114: ...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...

Page 115: ...e 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 Backu...

Page 116: ...ings 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 th...

Page 117: ...en 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...

Page 118: ...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 Alar...

Page 119: ...ms 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 Timesta...

Page 120: ...w 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 p...

Page 121: ...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 fi...

Page 122: ...r 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 U...

Page 123: ...age 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 ab...

Page 124: ...ogs 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 communic...

Page 125: ...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...

Page 126: ...et 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...

Page 127: ...al 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 Outpu...

Page 128: ...orcing 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...

Page 129: ...ound 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 pi...

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 outpu...

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...

Page 132: ...e 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...

Page 133: ...ipe 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 expo...

Page 134: ...shot recording completed successfully Informational Snapshot recording process was successful No action needed C 124 Warning Snapshot recording interrupted and aborted Snapshot recording was interrupt...

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 per...

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 ma...

Page 137: ...ult 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 adj...

Page 138: ...ng 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...

Page 139: ...1 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 a...

Page 140: ...ck 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...

Page 141: ...s 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 fau...

Page 142: ...ault 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...

Page 143: ...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...

Page 144: ...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 Fau...

Page 145: ...he 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 i...

Page 146: ...ibration 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 fau...

Page 147: ...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...

Page 148: ...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 Dry...

Page 149: ...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...

Page 150: ...epair 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 limi...

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...

Page 152: ...re 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 meas...

Page 153: ...ct 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 Chec...

Page 154: ...d 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 oi...

Page 155: ...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 instr...

Page 156: ...r 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 co...

Page 157: ...ulation 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 v...

Page 158: ...FD1 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 volta...

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...

Page 160: ...r 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 th...

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 c...

Page 162: ...larm 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 Tabl...

Page 163: ...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 Ala...

Page 164: ...l 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 fr...

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

Page 166: ...mage 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 Dur...

Page 167: ...re 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...

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 Digit...

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 pr...

Page 170: ...w 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 Out...

Page 171: ...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 sel...

Page 172: ...ation 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 down...

Page 173: ...91 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...

Page 174: ...6_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...

Page 175: ...ted 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...

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...

Page 177: ...s 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...

Page 178: ...thin 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 vari...

Page 179: ...en 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 se...

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...

Page 181: ...ottom 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...

Page 182: ...on 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...

Page 183: ...nd 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 l...

Page 184: ...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 confirmatio...

Page 185: ...r 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...

Page 186: ...t 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 rega...

Page 187: ...meters 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 Communicati...

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 sh...

Page 190: ...ted 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 ba...

Page 191: ...wn 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...

Page 192: ...ser 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 pres...

Page 193: ...13 17 621 Page 193 Page left blank intentionally...

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...

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