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Page 5 

 

13-17-625 v00 

 

Table of Contents 

1. GENERAL INFORMATION ...................................................................................................................... 7

 

1.1

 

S

YSTEM 

D

ESIGN

 .................................................................................................................................... 7

 

1.2

 

H

ARDWARE

 ........................................................................................................................................... 7

 

1.3

 

S

OFTWARE

 ............................................................................................................................................ 8

 

1.4

 

S

YSTEM 

C

ONNECTIONS

 ......................................................................................................................... 8

 

2. SUPPORTED PROTOCOLS .................................................................................................................. 10

 

2.1

 

A

IR

S

MART 

P

ROTOCOL

 ......................................................................................................................... 10

 

2.3

 

D

ELCOS 

P

ROTOCOL

 ............................................................................................................................. 11

 

2.4

 

ES+

 

P

ROTOCOL

 .................................................................................................................................. 11

 

3. SEQUENCING USING 

THE AIRSMART™ PROTOCOL ...................................................................... 12

 

3.1

 

W

IRING 

C

ONNECTIONS

 ........................................................................................................................ 12

 

3.2

 

C

OMMUNICATION 

C

ONFIGURATION

 ....................................................................................................... 14

 

3.3

 

O

PERATING 

M

ODE 

S

ETTING

 ................................................................................................................. 16

 

3.4

 

S

EQUENCING 

S

ETTINGS

 ....................................................................................................................... 16

 

3.5

 

P

ROGRAMMABLE 

IO

 

C

ONFIGURATION

 ................................................................................................... 18

 

3.6

 

A

IR

S

MART 

S

YSTEM 

O

PERATION

 ........................................................................................................... 19

 

3.7

 

A

IR

S

MART 

S

EQUENCING 

D

IAGNOSTICS

 ................................................................................................. 20

 

4. SEQUENCING USING THE DELCOS PROTOCOL .............................................................................. 22

 

4.1

 

W

IRING 

C

ONNECTIONS

 ........................................................................................................................ 22

 

4.2

 

C

OMMUNICATION 

C

ONFIGURATION

 ....................................................................................................... 23

 

4.3

 

O

PERATING 

M

ODE 

S

ETTING

 ................................................................................................................. 24

 

4.4

 

S

EQUENCING 

S

ETTINGS

 ....................................................................................................................... 25

 

4.5

 

D

ELCOS 

S

EQUENCING 

S

YSTEM 

O

PERATION

 .......................................................................................... 27

 

4.6

 

D

ELCOS 

S

EQUENCING 

D

IAGNOSTICS

 .................................................................................................... 28

 

5. ES+ ......................................................................................................................................................... 32

 

T

HIS SECTION PROVIDES DETAILS ON CONFIGURATION AND OPERATION OF THE SYSTEM IN 

ES+

 SEQUENCING

.32

 

5.1

 

W

IRING 

C

ONNECTIONS

 ........................................................................................................................ 32

 

5.2

 

C

OMMUNICATION 

C

ONFIGURATION

 ....................................................................................................... 34

 

5.3

 

O

PERATING 

M

ODE 

S

ETTING

 ................................................................................................................. 35

 

5.4

 

S

EQUENCING 

C

ONFIGURATION

 ............................................................................................................. 36

 

5.4

 

ES+

 

S

YSTEM 

O

PERATION

 .................................................................................................................... 38

 

5.4.1 Establishing the Initial Sequence ............................................................................................... 38

 

5.4.2 How the ES+ Controls Pressure While Sequencing .................................................................. 39

 

5.5

 

S

EQUENCING 

D

IAGNOSTICS

 ................................................................................................................. 40

 

 

 

 

 

 

Summary of Contents for Governor

Page 1: ...13 17 625 Version 00 July 15 2020 Governor Controller MULTI MACHINE SEQUENCING MANUAL 7 4 3 Governor Compressor Applications...

Page 2: ...l 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 area...

Page 3: ...a 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...

Page 4: ...r system 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 app...

Page 5: ...9 3 7 AIRSMART SEQUENCING DIAGNOSTICS 20 4 SEQUENCING USING THE DELCOS PROTOCOL 22 4 1 WIRING CONNECTIONS 22 4 2 COMMUNICATION CONFIGURATION 23 4 3 OPERATING MODE SETTING 24 4 4 SEQUENCING SETTINGS 25...

Page 6: ...E 19 IO MODULE DIP SWITCH SETTINGS AT RS485 1 PORT 23 FIGURE 20 MENU NAVIGATION TO COMMUNICATIONS SCREEN 23 FIGURE 21 DELCO S COMMUNICATION CONFIGURATION SCREEN 24 FIGURE 22 MENU NAVIGATION TO CONTROL...

Page 7: ...ing dryers filters or other restrictions There should be no check valves or other devices which isolate a member from the air system During operation be sure that any unit is taken out of the sequence...

Page 8: ...ftware It is recommended that all machines in the sequenced network have the most up to date software available installed The most up to date software ensures that the machines have all of the latest...

Page 9: ...es running When using the Delcos protocol the master machine is dedicated and selected through the controller configuration For any Delcos network using a Governor controller a machine with a Governor...

Page 10: ...er Denver 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...

Page 11: ...sing Delcos protocol all the slave machines run off the master machine s delivery pressure sensor The master machine can be either fixed speed or variable speed but all slave machines must be the same...

Page 12: ...ller IO Module can be found in Figure 4 using the cable provided in the sequencing kit The compressor network may be comprised of any combination of Governor AirSmart and AirSmart G2 controlled machin...

Page 13: ...6 Figure 6 IO Module DIP Switch Settings at RS485 1 Port Figure 7 shows the RJ 45 adapter PN 24CA7402 used on existing AirSmart G2 control systems which use an RJ45 connector for the sequencing networ...

Page 14: ...RS485 GND Orange is RS485 White is RS485 3 2 Communication Configuration In order to set up communication between the machines the RS485 communications will need to be configured on the controller Ai...

Page 15: ...connections on the machine Figure 9 Menu navigation to communications screen Please note that the controller may prompt the user to reboot following the mode change of the communication parameters Sel...

Page 16: ...encing Settings Next navigate to the sequencing settings menu as shown in Figure 13 Figure 14 shows the sequencing settings screen and all of the different settings that can be configured Table 2 at t...

Page 17: ...onstant For AirSmart mode the master slave designation can change based on the capacity and total machine run hours for priority of master control Figure 13 Menu navigation to sequencing screen Figure...

Page 18: ...ame capacity when the difference between the run hours of the two machines is equal to the Transfer Interval Fault Action Local This value may be set to Local or Wait Indicates what a slave compressor...

Page 19: ...following conditions 1 A new master capable machine with larger capacity comes online 2 The run hours of the master machine exceeds the run hours of a slave machine of equal capacity by more than the...

Page 20: ...the master will unload Note that only variable speed machines can accept a speed command from the master Also a fixed speed master cannot send a speed command other than 100 to slave machines If there...

Page 21: ...nostics Page The machine shown with the blue border around its information is the current master of the network Each compressor detected will have a status icon on the tile according to the legend in...

Page 22: ...c for each machine in the sequenced group The Delcos RS485 connections are located on the IO Module at X02 in the control cabinet Depending on the machine configuration RS485 2 at X03 on the IO module...

Page 23: ...iguration and then Communication shown in Figure 20 Select the RS485 1 tab and then change the mode to Sequence Delcos Machines which have RS485 2 at X03 populated will show an additional tab called R...

Page 24: ...Mode Setting Next the operating mode for machine control needs to be configured Navigate to the control settings menu following Figure 22 by selecting menu settings and then control Change the operat...

Page 25: ...f this section outlines the settings associated with the Delcos sequencing protocol in more detail and lists all default parameters that are set in the controller The parameter settings are different...

Page 26: ...17 625 v00 Figure 24 Menu Navigation to Sequencing Screen Figure 25 Delcos Sequencing Settings Screen Table 4 below outlines each of the Delcos protocol settings in detail and their corresponding defa...

Page 27: ...k using the remaining slaves As soon as the pressure is above the Unload Pressure setting the compressor to the far right in the sequence is switched off When the Unload Pressure is exceeded additiona...

Page 28: ...for the first time Defining a new sequence based on Hours Run BLS When the Transfer Interval has expired the master defines a new sequence based on the Hours Run BLS of the compressors The compressor...

Page 29: ...enabled machine This page gives an overview of the sequencing settings for the machine The compressor name run hours BLS run hours operating pressure and pressure bands is also shown on this page for...

Page 30: ...ssor or the BLS Run Hours for a master machine the user will need to be signed in as a technician and click on the box shown in Figure 29 that says Master or 0 for BLS Run Hours on the sequencing diag...

Page 31: ...Page 31 13 17 625 v00 Figure 29 Delcos Keyboard to Change Name of Master Machine Figure 30 Delcos Change BLS Run Hours...

Page 32: ...display at RS485 IF5 in the control cabinet as shown in Figure 32 Figure 31 ES RS485 Communication Wiring Schematic Figure 32 below shows how to connect a legacy ES machine to the Governor controller...

Page 33: ...e connected to the ES controller The signal pinout for this board will be as follows Pin 1 RS485 GND Pin 2 RS485 Pin 3 RS485 Use a communications cable such as 97J93 to wire from these terminals to th...

Page 34: ...ail Mounted 2 Amp 120 Volt 1 24CA3404 CRIMPING TOOL 1 5 2 Communication Configuration Next configure the RS485 communications under the Communications Configuration page ES sequencing requires a speci...

Page 35: ...elect OK and allow the controller to reboot before continuing with the additional settings Figure 35 ES Communications Configuration Screen 5 3 Operating Mode Setting Next the operating mode for machi...

Page 36: ...te to the sequencing settings menu Figure 39Figure 38 shows the sequencing settings screen and all of the different settings that can be configured Table 6 at the end of this section outlines the sett...

Page 37: ...13 17 625 v00 Figure 38 Menu Navigation to Sequencing Screen Figure 39 ES Sequencing Settings Screen The below table outlines each of the ES protocol settings in detail and their corresponding default...

Page 38: ...ion is received it will assume position three and again wait for communications If a compressor with a lower rotation number is not detected it assumes position two Subsequently it assumes position on...

Page 39: ...must operate 21 PSI below the desired operating point when all compressors are running This is where the dynamic setpoint control takes over Whenever the system pressure is below the programmed Load P...

Page 40: ...in the sequence rotation The values are averaged and all compressors lead and lag then compare their local pressure reading to the average and adjust their Target by the amount of error The effect is...

Page 41: ...Page 41 13 17 625 v00 the name of the machine run hours load hours operation mode and the sequence number unit number Figure 41 ES Sequencing Diagnostics Page for a Master Slave...

Page 42: ...Page 42 13 17 625 v00 NOTES...

Page 43: ...Page 43 13 17 625 v00 NOTES...

Page 44: ...For additional information contact your local representative or visit www contactgd com compressors 2020 Gardner Denver Inc Printed in U S A...

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