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13-17-621 Page 156

maintenance
warning

compressor overhaul has
expired.

S.21

Warning

Air Filter
Warning

The digital input for the
air filter vacuum has
tripped. The air filter is
blocked and has created
excessive vacuum at the
inlet to the compressor

Change the air filter and reset the air filter
maintenance timer when the change is complete.

S.22

Warning

Oil Filter
Warning

The digital input for the
oil filter differential
pressure has tripped.
The oil filter is blocked or
defective.

Change the oil filter and reset the oil filter
maintenance timer when the change is complete.

S.25

Warning

External
maintenance
warning

The digital input
programmed for external
maintenance warning
has tripped.

Service the external device.

S.30

Fault

Change
Separator fault

The differential pressure
across the separator
element has exceeded
the fault limit. The
separator element needs
to be serviced.

Change the separator element and reset the
separator maintenance timer when the change is
complete.

S.30

Warning

Change
Separator
Warning

The differential pressure
across the separator
element has exceeded
the warning limit. The
separator element needs
to be serviced.

Change the separator element and reset the
separator maintenance timer when the change is
complete.

Sequencing Alarms

SQ.0

Warning

Sequencing
communication
error 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
assigned in the
sequencing menu is
identical to another
machine in the
sequence.

Change the unit number in the sequencing
settings menu of the device to an unused value,
either the next number in the sequence or the
missing number.

SQ.2

Warning

Sequencing no
Compressor
detected
warning

No available
compressors in
sequence. Connection
may have been disrupted
between compressors.

Check the communication wiring from the master
machine to each of the slaves to ensure
connection is secure and there are no loose
wires. Confirm the sequencing settings in the
controller. Refer to the sequencing manual for
more information. Power cycle controller if
connections and settings are correct.

VFD1 Alarms

V1.1

Warning

VFD1 Over
Current warning

VFD is measuring
excessive current to the
motor. Motor current is
approaching the fault
limit to run the
compressor.

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.

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Содержание Governor TEN014983

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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