Gardner Denver Governor User Manual

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Version: 00
February 23rd, 2019
Governor™ Controller
USER’S MANUAL
Rotary Screw Compressor Application
WARNING – PROHIBITION – MANDATORY LABEL INFORMATION
Gardner Denver compressors are the result of advanced engineering and skilled manufacturing. To be
assured of receiving maximum service from this machine, the owner must exercise care in its operation
and maintenance. This book is written to give the operator and maintenance department essential
information for day-to-day operation, maintenance and adjustment. Careful adherence to these
instructions will result in economical operation and minimum downtime.
Boxed text formats are used, within this manual, to alert users of the following
conditions:
Safety Labels are used, within this manual and affixed to the appropriate areas of
the compressor package, to alert users of the following conditions:
Indicates a hazard with a high level of risk, which if not avoided, WILL result in death or serious
injury.
Equipment Starts Automatically
Health Hazard – Explosive Release of Pressure
Cutting of Finger or Hand Hazard – Rotating
Impeller Blade
High Voltage – Hazard of Shock, Burn, or Death
Present until Electrical Power is Removed
Cutting of Finger or Hand Hazard – Rotating Fan
Blade
Entanglement of Fingers or Hand/Rotating Shaft
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Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or
serious injury.
Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air
Indicates a hazard with 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
Lockout Electrical Equipment in De-Energized
State
Do Not Lift Equipment with Hook – No Lift Point
Loud Noise Hazard – Wear Ear Protection
Handle Package at Forklift Points Only
Read the Operator’s Manual Before Proceeding
with Task
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SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or
circumstances cannot always be predicted and covered by established rules. Therefore, use your past
experience, watch out for safety hazards and be cautious. Some general safety precautions are given
below:
Failure to observe these notices will result in injury to or death of personnel.

Keep fingers and clothing away from rotating fan, drive coupling/belting, etc.

Disconnect the compressor unit from its power source, lockout and tagout before working on the
unit – this machine is automatically controlled and may start at any time.

Do not loosen or remove the enclosure or belt covers, or break any connections, etc., in the
compressor air 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 applicable
local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.

Open main disconnect switch, lockout and tagout and check for voltage before working on the
control.
Failure to observe these notices could result in damage to equipment.

Stop the unit if any repairs or adjustments on or around the compressor are required.

Do not use the air discharge from this unit for breathing – not suitable for human consumption.

An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch
inside diameter (OSHA Regulation, Section 1926.302).

Do not exceed the rated maximum pressure values shown on the nameplate.

Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.
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TABLE OF CONTENTS
SECTION 1 REVISION HISTORY ................................................................................................................ 6
SECTION 2 GENERAL ................................................................................................................................. 7
2.1 Components and Layout ..................................................................................................................... 7
2.1.1 Display .......................................................................................................................................... 7
2.1.2 IO Module ..................................................................................................................................... 8
2.1.3 Cellular Module ............................................................................................................................. 9
2.2 Features and Method of Control .......................................................................................................... 9
SECTION 3 QUICK START ........................................................................................................................ 10
3.1
Common User Interface Elements ............................................................................................... 10
3.1.1 Common Navigation and Status Elements ................................................................................. 10
3.1.2 Buttons and Switches ................................................................................................................. 11
3.1.3 Scroll Elements ........................................................................................................................... 12
3.1.3 Settings and Input Elements ....................................................................................................... 13
3.1.3.1 Dropdown Boxes .................................................................................................................. 14
3.1.3.2 Value Settings ...................................................................................................................... 14
3.2
Home Screen ................................................................................................................................ 15
3.3
Schematic Screen......................................................................................................................... 18
3.4
Navigation Menu ........................................................................................................................... 21
3.5
Logging In ..................................................................................................................................... 22
3.6
Setting Up ..................................................................................................................................... 24
3.6.1
Controller Configuration ........................................................................................................ 24
3.6.2
Control Settings ..................................................................................................................... 26
3.7
Clearing Alarms ............................................................................................................................ 27
3.8
Jogging the Motors ....................................................................................................................... 28
3.9
Operating the Compressor ........................................................................................................... 28
3.9.1
Starting .................................................................................................................................. 28
3.9.2
Running ................................................................................................................................. 29
3.9.3
Stopping ................................................................................................................................ 30
3.9.4
Emergency Stop .................................................................................................................... 31
SECTION 4 SETTINGS .............................................................................................................................. 32
4.1
Settings Map ................................................................................................................................. 32
SECTION 5 TRENDS ................................................................................................................................. 34
SECTION 6 DIAGNOSTICS ....................................................................................................................... 38
6.1
Diagnostics Map ........................................................................................................................... 38
APPENDIX A ALARM CODES ................................................................................................................... 39
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SECTION 1
REVISION HISTORY
Version
00
Date
February 23rd, 2019
Notes
First release
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SECTION 2
GENERAL
The Gardner Denver Governor™ controller is an advanced electronic control system designed to provide
optimal operation of your Gardner Denver compressor. This manual describes the controller
specifications and operation on Gardner Denver rotary screw compressors.
2.1 Components and Layout
The Governor™ control system is made up of several different components, described 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 screen with touchscreen interface. The Start and Stop touch buttons are located directly below the
screen. The display houses the processor and memory for the system and interfaces with the other
components through communications ports.
Figure 1: Home Screen Display
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The display is shown above in Figure 1 with the Home screen visible. Note that the Start and Stop
buttons as shown in the image are active areas of the touchscreen rather than physical buttons.
2.1.2 IO Module
The IO module is mounted inside the compressor cabinet and connects to the display as well as all of the
digital and analog inputs and outputs on the system. These 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.
Figure 2: IO Module
The IO module is shown in Figure 2 above. Note that depending on the type of compressor you have,
your IO module may have more or less inputs and outputs present on it, indicated by the amount and size
of connectors on the board.
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2.1.3 Cellular Module
The Governor™ controller features a cellular module that is connected to the display by USB. This
connects into the iConn by Gardner Denver™ platform to provide machine health monitoring and
analysis.
Figure 3: Cellular Module
The cellular module is shown in Figure 3 above. It is mounted in the control cabinet and connected to an
antenna mounted on the top of the compressor package.
2.2 Features and Method of Control
The Governor™ controller is responsible for safe operation of the compressor package and optimal
operation under the customer’s parameters. The Governor™ controller utilizes Gardner Denver’s heritage
of compressor package design and operation to intelligently determine when the machine is operating
normally and when it needs attention. System inputs, such as pressure and temperature, are looked at
individually and collectively to check for a variety of different conditions.
When running the machine, the controller ensures that the customer’s pressure requirements are
maintained. After configuring and enabling the controller, all operation is automatic. The controller can be
set up to start / stop on a schedule and use two different pressure bands to more efficiently meet system
demand. Programmable inputs and outputs are available to interface to an array of external equipment.
Modbus and remote interfaces are provided to monitor the machine.
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SECTION 3
QUICK START
This section provides the basic information on the controller so that the user can understand how to
interact with and operate the machine. It focuses only on the common elements of the user interface and
the settings and actions that are required to get the compressor running and producing air.
3.1
Common User Interface Elements
The user interface has common elements that are shared across all screens in the system.
Understanding these elements will help improve interaction with the controller.
3.1.1 Common Navigation and Status Elements
Figure 4: Common Screen Elements
The common status and navigation elements are shown in Figure 4 above and described below.
1. The Menu bar expands when pressed and provides a cascading navigation for all screens on the
system.
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2. The Screen Title / Breadcrumbs shows your current location within the user interface structure
and also provides a navigation link back to the previous screen. For example, if the screen title
displayed Home > Dashboard, pressing Home would navigate back to the home screen.
3. The Login button in the Status Bar indicates what access level is currently logged in to the
system. Pressing it also provides a link to the Security screen, which is used to log in or out of the
system.
4. The Date and Time display in the Status Bar displays the current date and time set on the
controller. It is important to ensure that this is correct as it is used for several system functions
including logging, trends, and timer control.
5. The Status indicator in the Status Bar is a quick reference to the status of the machine from any
screen on the system. The status can take any of the following forms:
o
- This image indicates that the machine is enabled. If the image is stationary, it
indicates that the motor is not running, but could start at any time based on machine
configuration and conditions. If the image is rotating, it indicates that the motor is
currently running.
o
- This image indicates that the machine is ready to start with user input but not
enabled. The Start button must be pressed before the machine will be allowed to start.
o
- This image indicates that the machine is shut down due to a fault condition.
Refer to the Alarms system to determine the cause and resolve the fault condition.
6. The Gardner Denver Logo is present in the bottom right of every screen. Pressing this will
navigate back to the Home screen from any screen in the system.
3.1.2 Buttons and Switches
The user interface includes several types of buttons and switches that can be used to interact with the
system.
Figure 5: Button Styles
The various button and switch styles can be seen above in Figure 5 and are described in more detail
below:
 Primary buttons are displayed in dark blue, and indicate the default or most common action(s) for
the screen. For example, on a settings screen the Save button will be a primary button.
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
The Secondary buttons are outlined in blue with white fill. These buttons represent the less
common action(s) for a screen. For example, on a settings screen the Cancel button will be a
secondary button.

If a button is locked it will be shown as in the Primary Locked and Secondary Locked examples
above. This usually indicates that the appropriate access level is not currently logged in, but it
could also be locked because the current machine status does not allow the action, or the action
is not applicable to the machine configuration.

On / Off switches are used for settings that can be enabled / disabled. If the item is disabled, or
off, the switch will show “Off” in blue with a white background. If the item is enabled, or on, the
switch will show “On” in white with a green background. Pressing the switch will toggle it to the
opposite state.
Several screens on the system utilize tabs to organize and categorize the information. An example of
these tabs is shown in Figure 6 below.
Figure 6: Tabs Style
The currently active tab is shown with a white background and blue text while inactive tabs are shown
with blue background and white text. In the example above, “Digital Outputs” is the currently active tab.
Pressing on a tab will cause it to become the active tab if it is not currently selected.
3.1.3 Scroll Elements
The system uses two types of control for scrolling the values shown on a screen.
The first scroll element is shown in Figure 7 below. It operates much like a scroll bar on any other
application. Pressing the V on the bottom of the scroll bar will move the screen down. You can also drag
the scroll position indicator to move the position.
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Figure 7: Scroll Bar Example
The second type of scroll element is shown below in Figure 8. It is used for screens where there is a need
to move with more precision than with the scroll bar, for example when there is a long list of individual
elements. Pressing the single arrows will move the selection up or down one element. For example,
pressing the down arrow in the example below will select the next oldest entry in the Alarm History.
Pressing the double arrow buttons will jump down or up several selections to allow for quickly scrolling
multiple entries.
Figure 8: Scroll Button Example
3.1.3 Settings and Input Elements
The system uses several styles for elements that are used to show and change settings or other user
interface controls.
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3.1.3.1 Dropdown Boxes
Dropdown selections allow the user to select an item from a pre-defined list of available options. An
example is shown in Figure 9 below. To deploy the dropdown, press on the value that is shown
(Automatic in the example below). With the dropdown deployed, you can change the selection by
pressing on the option that you would like to select. Note that options that are not available for your
current configuration are shown in light gray as can be seen with the Low Demand setting in the
Operating Mode dropdown.
Figure 9: Dropdown Box
3.1.3.2 Value Settings
Value boxes display a numerical or text value. Pressing on the box will bring up a number or text entry
keypad. An example of a numerical value setting and keypad is shown below in Figure 10.
Figure 10: Number Keypad
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Keypad entry operation is described below:
 For inputs that have a maximum and minimum valid range, the keypad will display the valid input
range as shown in Figure 10.

To change the value, start typing a new value and it will overwrite the existing setting.

To commit changes and close the keypad, press

To close the keypad without saving changes, press
.

To delete the most recently entered number, press
.
.
An example of a text entry keypad is shown in Figure 11 below. The operation of this keypad and its
controls are identical to the number keypad described above.
Figure 11: Text Keypad
3.2
Home Screen
The Home screen is the primary screen for operation of the machine. It displays machine status
messages, pressure and temperature readings, essential settings, and maintenance status. Figure 12
below shows the Home screen with each element defined.
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Figure 12: Home Screen Elements
Additional details on each of the home screen elements are provided below:
1. The Delivery Pressure gauge shows the current pressure as well as the currently active pressure
band used for control. The color of the gauge and pressure display also changes to indicate the
region that the pressure is currently in.
o
If the pressure is below the load pressure setting, it will be displayed in blue:
o
If the pressure is above the Load pressure and less than the Warning pressure setting, it
will be displayed in green:
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o
If the pressure is between the Warning and Fault pressure settings, it will be displayed in
yellow:
o
If the pressure is above the Fault pressure setting, it will be displayed in red:
2. The Discharge Temperature gauge shows the compressor airend discharge temperature.
o
If the temperature is below the Minimum Start Temperature setting, it will be displayed in
red.
o
If the temperature is between the Minimum Start Temperature setting and 3 ℃ (5.4 ℉)
above the Minimum Start Temperature, it will be displayed in yellow.
o
If the temperature is above the Minimum Start Temperature plus 3 ℃ (5.4 ℉) and below
the Warning temperature setting, it will be displayed in green.
o
If the temperature is above the Warning temperature setting and below the Fault
temperature setting, it will be displayed in yellow.
o
If the temperature is above the Fault temperature setting, it will be displayed in red.
3. The View Schematic button is used to navigate to the Schematic screen. This provides a
graphical representation of the machine operation and status.
4. The Control Settings Indicators area of the screen shows the current status of the control settings
that control machine operation and starting / stopping. Pressing anywhere within this area of the
screen will navigate to the Control Settings screen which can be used to adjust these settings.
o
Remote Halt: The Remote Halt indicator reflects the setting of Remote Halt Mode on the
control settings screen. If the Remote Halt Mode is Disabled, the indicator will show Off. If
the remote halt mode is Timed or Immediate, the indicator will show On.
o
Timer Control: The Timer Control indicator reflects the setting of Timer Start Enable on
the Control Settings screen.
o
Auto Restart: The Auto Restart indicator reflects the setting of Auto Restart Enable on
the Control Settings screen.
5. The Status Message Bar displays information about the current machine status. If a fault or
warning is active, red or yellow attention indicators will illuminate on the bar.
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6. The View Hours button links to the Service Dashboard screen, which can be used to view,
configure, and reset all of the maintenance timers on the system
7. The Total / Loaded hours display shows the current total and loaded hours of the machine.
8. The Hours Left to Service bar graph indicates the value of the minimum service timer. The colors
and fill of the graph change to give a visual indication of the length of time until next service as
described below:
3.3
o
100% service life, timers just reset:
o
Service life greater than 350 hours:
o
Service life of 350 hours or less:
o
Service life of 175 hours or less:
Schematic 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 13 below shows the
main Schematic screen view with a summary of the elements.
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Figure 13: Schematic View
The main elements of the schematic view are described below:
1. The View Home button returns the user to the Home screen.
2. The Delivery pressure is shown in large text on the right of the screen in the default view.
3. The estimated Volume Flow is shown below the discharge pressure on the default view.
4. The current pressure setpoints for Load and Unload pressure are shown below the Volume Flow
on the right side of the default view.
5. The Delivery Pressure is shown to the right of the Cooler element on the schematic.
6. The readings between the Airend and the Reservoir show the Reservoir Pressure and Discharge
Temperature of the machine.
7. On variable speed machines, the Motor RPM is displayed below the Motor element.
8. The Snapshot button is visible when logged in as Technician or Factory. Pressing this button
causes an entry to be added to the Alarm History log for a manual snapshot event. Use this
feature to capture readings for later analysis using the Info button on the Alarm History screen.
Each of the bold items on the schematic can be pressed to display more information about the element.
For example, pressing on the Airend will display the airend discharge temperature and inlet valve state
as shown in Figure 14 below.
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Figure 14: Airend Focus View
If an element of the machine is in a warning or fault state, the element will be highlighted in yellow or red
accordingly. For example, in Figure 15 below, the air filter service timer has expired, so the Air Filter
element is highlighted in yellow. Pressing the Air Filter element on the screen shows the value of the
service timer highlighted in yellow since it is the source of the warning.
Figure 15: Air Filter Focus with Warning
The values available at each element on the schematic are shown below in Table 1.
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Table 1: Values for Schematic Elements
Air Filter
Air Filter
Hours
Airend
Discharge
Temperature
Motor
State (FS)
Reservoir
Reservoir
Pressure
Inlet State
Motor RPM
(RS)
Motor Hz
Differential
Pressure
Separator
Change
Hours
Cooler
Delivery
Pressure
Oil Cooler
None on
current
machine
Oil Filter
Oil Filter
Hours
Oil Change
Hours
Motor
Current (RS)
Heatsink
Temp (RS)
DC Bus
Volts (RS)
Motor Lube
Hours
3.4
Navigation Menu
The Menu provides quick access to all screens on the system. Subcategories of the Menu will expand
when selected if there are multiple screens available.
Pressing the Menu button
in the upper left corner of the screen will deploy the Menu, as shown in
Figure 16 below. With the Menu deployed, press the X at the top of the Menu to hide the Menu.
Figure 16: Menu Deployed
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The following screens and categories are available through the Menu:
 Home: This button links to the Home screen.

Settings: Deploys cascading Settings Menu structure to view or modify any setting on the
system.

Alarms: Deploys cascading Alarms Menu with links to the Active Alarms and Alarm History
views.

Diagnostics: Deploys the cascading Diagnostics Menu structure. This area of the user interface
allows viewing information about the operation of the controller and the machine for technical and
troubleshooting use.

Trends: This button links to the Trends screen, which allows viewing graphs of the machine
operation over time.

Language: This button provides one-click access to the Menu for setting the Language on the
controller. This prevents the need to navigate to the appropriate settings screen if the controller is
set to a language that the user cannot read.
As you navigate through the system, the Menu will cascade to the right to indicate your current position.
For example, Figure 17 below shows the view of the Menu after selecting Settings, then Configuration.
Figure 17: Menu Cascade
3.5
Logging In
Before making any changes to the settings on the controller, you must log in with an appropriate 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 18 below. The text of the button indicates the current access level.
Figure 18: Login Button
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Pressing this button will navigate to the Security screen as shown in Figure 19 below.
Figure 19: Security Screen
To log in, select the desired access level from the User dropdown, enter the password into the Password
field, and press the Log In button.
The available access levels and default passwords are shown below in Table 2 below.
Table 2: Access Levels
User Level
User
Maintenance
Default Password
None
407
Technician
8412
Factory
Contact Gardner
Denver
Description
Default level, limited access
End user. Basic settings access and ability to reset service
timers.
Advanced access targeted towards distributors and service
technicians.
Full access to all settings and features. The password
rotates automatically throughout the life of the machine. It
may not be changed. This password should only be required
under unusual circumstances and must be provided by
Gardner Denver Technical Support.
Note that the passwords can be changed from the default using the Adjustments button on the left of the
screen once logged in.
After logging in, press the Close button to return to the previous screen.
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3.6
Setting Up
Before running the machine, there are several basic configuration settings that may need to be changed.
3.6.1 Controller Configuration
Basic controller configuration is located under the Settings -> Configuration menu as shown in Figure 20.
Figure 20: Configuration Menu
First, ensure that the units are set as desired by selecting the Locale link from the Configuration menu.
The Pressure, Temperature, and Flow Units can be set individually as shown in Figure 21. If the
Language needs to be changed, it may be changed by selecting the Language button below the units.
Figure 21: Locale Configuration
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It is important to verify that the Date, Time, and Timezone are set properly for the site. The date and time
are relied on for logs, timer control, trends, etc. Setting the timezone properly ensures that daylight
savings time adjustments will be accounted for automatically. The Date and Time Configuration screen is
shown in Figure 22.
Figure 22: Date and Time Configuration
To set the timezone, click on the Timezone box and use the selector dialog that appears to select the
appropriate timezone for your region as shown in Figure 23.
Figure 23: Timezone Selection
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3.6.2 Control Settings
The settings under the Control Menu determine how the machine operates to match the process
requirements of the customer. The default settings of the machine are acceptable for most installations.
However, if the Pressure Band displayed on the gauge on the Home screen does not match the desired
pressure range for the site, the Pressure Band must be adjusted.
To adjust the Pressure Band, navigate to Settings -> Control as shown in Figure 24. Then, press the
Adjust button next to p1 Pressure Band.
Figure 24: Control Settings
The p1 Pressure Band Setting screen is shown in Figure 25 below. The bar graph gives a visual
indication of the pressure band settings. Press the numerical value boxes to make adjustments as
needed. Note that the minimum and maximum values that will be allowed for each box will change
dynamically based on the design pressure of the machine as well as the values of the other settings. For
example, to increase the Load pressure to 126 PSI in Figure 25, the Unload pressure and Target
pressure would first need to be increased.
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Figure 25: Primary Pressure Band Setting
Once you are satisfied with the pressure band settings, press the Save button to commit the changes.
3.7
Clearing Alarms
If there are any faults present on the machine, they must first be cleared to allow the machine to be
started. If the machine has been powered on recently and Auto Restart is not enabled, a Power Loss fault
will be present.
If a fault is active on the machine, the Active Alarms screen can be accessed by pressing on the Alarm
triangle on the Message Status Bar on the Home screen, or by navigating to Alarms -> Active Alarms
through the Menu. The Active Alarms screen is shown in Figure 26.
Figure 26: Active Alarms Screen
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If the alarm icon in the Alarm column is an outline, as shown in Figure 26, the alarm is no longer active
and may be reset. If the alarm icon is solid (
resolved before it can be cleared.
), the fault is still active and the condition must be
Once all faults have been resolved, press the Reset All button, which will move the alarms to the Alarm
History screen. Once all faults have been reset, return to the Home screen.
3.8
Jogging the Motors
If this is the first time that the machine has been started after being connected to power, the motors must
be jogged to verify correct rotation. To do this, you must be logged in as a Technician. After logging in,
navigate to Diagnostics -> Jog Motors. The Jog Motors screen is shown in Figure 27.
Figure 27: Jog Motors Screen
Select the desired jog duration and select Compressor Motor or Fan Motor from the dropdown as shown.
You will need to jog both individually to verify correct rotation. The Jog Delay field allows you to delay the
start of the jog from the time that you press the Start Jog button. This is to allow you time to get into a
position to view the rotation before the motor is started. Note that the controller will only allow one jog
every 10 seconds and will disable the Start Jog button during this time period.
After correct rotation has been verified, return to the Home screen and proceed to operate the
compressor.
3.9
Operating the Compressor
The compressor is now ready to operate. This section gives a basic overview of how to operate the
machine.
3.9.1 Starting
From the home screen, the Message Status Bar should display “Ready to Start” as shown in Figure 28.
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Figure 28: Home Screen Ready to Start
Press the Start button
on the display directly below the screen. If the delivery pressure is below
the load pressure setting, the compressor will start and accelerate the motor, then open the inlet valve
and begin building pressure. If this is the first time that the compressor has been started, make sure that
all systems are working properly (refer to the machine service manual for more information).
3.9.2 Running
When running under the Automatic Operating Mode and control settings, compressor operation will
continue as described below:
 The controller will attempt to keep the pressure within the set pressure band.

If the machine is a variable speed system, the motor speed will be adjusted to attempt to keep
the delivery pressure at the target pressure setting.

If the delivery pressure exceeds the unload pressure setting, the controller will close the inlet
valve and the Status Message Bar will display information about the new running state.

If the pressure remains above the load pressure with the inlet valve closed for a set amount of
time based on the machine design, the controller will stop the motor until the delivery pressure
falls back below the Load pressure. While in this state, the Status Message Bar will indicate that
the machine is enabled and will start when the pressure requirement is met as shown in Figure
29.
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Figure 29: Home Screen Enabled
3.9.3 Stopping
To stop the machine, press the Stop button
directly below the screen. The machine will go
through a soft stop process where it is depressurized before stopping. When the Stop button is pressed,
the inlet valve will close immediately (if the machine is currently loaded) and the Message Status Bar will
display that the controller is stopping as shown in Figure 30.
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Figure 30: Home Screen Stopping
The progress of the stopping process is shown on the Message Status Bar. The time value shown (for
example, “20 seconds”), is the time remaining on the minimum stop timer. The pressure value shown is
the amount of pressure in the reservoir that must be vented for the system to be depressurized, or blowndown, to the appropriate value for the machine. For example, if the machine is designed to vent to 25 PSI
in the reservoir and the reservoir currently has 85 PSI during the stopping process, the Message Status
Bar would display 60 PSI. The motor will be stopped when both the time and pressure requirements have
been met, or a maximum time of 120 seconds if the machine does not fully vent.
After stopping, the display will return to the Ready state.
3.9.4 Emergency Stop
The Emergency Stop button is located on the front door of the control panel close to the display and is
identified by a red button with a yellow background. The Emergency Stop cuts power to outputs on the
controller immediately and stops the machine abruptly. This should only be used in case of emergency
where the machine must be stopped immediately.
Regular use of the Emergency Stop will cause damage to the machine. Always use the Stop
button as described above to stop the machine under normal operation.
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SECTION 4
SETTINGS
This section describes the settings available on the controller.
4.1
Settings Map
The complete map of settings available on the controller is shown in Figure 31 below. Note that items in
dashed boxes are not shown if they do not apply to the machine.
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Service
Control
Configuration
Distributor Info
Date & Time
Locale
Operating Mode
Ethernet
Date
Pressure Units
P1 Pressure Band
RS485-0
Time
Temp Units
IV Cntrl Mode
RS485-1
Time Zone
Flow Units
P2 Press Band
Dashboard
Communication
Timer Start Stop
Seq Type
Press Band P2
Analog Inputs
Remote Halt Mode
Language
Timer Start Enable
Restart Delay Time
P2 Timer Enable
Dryer pre-run time
Loaded Hours
Auto Restart Enable
Total Hours
Panel Temp Fault
Max Power Loss
Elevation
Panel Temp Warn
Manual Speed
Page 33
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Sequencing
Timer Control
Temp Inputs
Del Press Fault
Digital Outputs
Del Press Warn
Star/Delta Time
Digital Inputs
Disch Temp Fault
Acceleration Time
Cold Start Limit
Programmable I/O
Disch Temp Warn
Min Run Time
Cold Start Time
Motor SFA
Min Start Temp
Min Stop Time
Capacity Limit
System Voltage
Heavy Startup
Rot Dir Check
Speed Source
Oil Type
Max Start Press
Auto Stop Time
Ext Speed Max
Max Flow
Default
Ext Speed Min
Fan Off Delay
Design Pressure
VFD
Fan Control
Factory Defaults
Serial Number
Cooling Type
Restore Config
Model
Operating Limits
Control
Cooling
Save User Config
Setup
Advanced
PID Tuning
Backup/Restore
Figure 31: Settings Map
SECTION 5
TRENDS
The Trends screen on the controller shows data on the operation of the machine over time. The main
Trends screen is shown in Figure 32.
Figure 32: Trends Display
The graph allows you to display any two available parameters by changing the selection in the dropdown
boxes. The left dropdown changes the left y-axis of the graph and the right dropdown changes the right yaxis on the graph. The value shown next to the dropdown box is the live value of the parameter. The
available parameters for each dropdown are shown in Figure 33 and Figure 34 below. Note that
selections that do not apply to the machine configuration will be disabled (as shown with Fan Motor
Speed in the examples).
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Figure 33: Trend Left Dropdown
Figure 34: Trend Right Dropdown
The trends on the controller keep up to 30 days of date. To examine historical readings, press anywhere
within the graph window, and a cursor will be activated for History View. This is shown in Figure 35.
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Figure 35: Trend History View
While History view is activated, you can use the arrows to scroll forward and backward in time. The black
vertical bar on the display shows the current position and the readings just above the graph show the
values at the location of the bar. Press Return to Current to return to the Live Data view.
Additional configuration of the graph can be done by pressing the Graph Setup button. This will bring up
a configuration popup as shown in Figure 36.
 The upper and lower limits of each axis can be configured to change the scale of the graph.

The Time Span dropdown can be used to change the scale of the time axis. For example, setting
to 12 hours would scale the graph so that the full width of the window represents 12 hours of
time.

To jump to a particular date and time in history view, press the Edit button next to the Date / Time
and enter the date and time that you would like to view. This can be more efficient than scrolling
from the graph.
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Figure 36: Trend Graph Setup
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SECTION 6
DIAGNOSTICS
The controller provides a section of screens for diagnostics and troubleshooting.
6.1
Diagnostics Map
The complete map of diagnostics available on the controller is shown in Figure 37 below. Note that items
in dashed boxes are hidden on the user interface if they do not apply to the machine configuration.
Sequencing
System Overview
Jog Motors
Jog Duration
Selected Motor
Jog Delay
Start Jog
I/O
Digital Inputs
Digital Outputs
Temp Inputs
Analog Inputs
General
Motor Starts
Software Version
Logs
Save
Controller
System
Update Software
Audit
iConn
iConn Status
Communications
Remote Control
VFD
VFD Status
Figure 37: Diagnostics Map
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APPENDIX A
ALARM CODES
Each alarm in the system is assigned a code to indicate the exact condition. If a condition can cause both
a warning and a fault, they will share the same alarm code and the severity will be indicated by the alarm
type on the system. For example, a power loss fault is code P.0. If Auto Restart is enabled, power failures
will cause a warning P.0 to be triggered. However, if Auto Restart is disabled or the Maximum Power Loss
Time is exceeded, a fault P.0 will be triggered.
Alarm codes are set up in a major.minor format. The major portion of the code defines the component or
subsystem, and the minor code defines the specific condition. Table 3 below provides a definition of the
major codes and components.
Table 3: Alarm Major Codes
Major
Code
A1
Component
Description
Airend 1
P
Package
S
Service
M1
Motor
F1
Fan
C
Controller
V1
VFD
SQ
Sequencing
This major code indicates an issue related to the compressor airend, such as
high discharge temperature.
This category indicates an issue related to the compressor package, such as
separator and reservoir sensors.
This category indicates issues with service items, such as maintenance
timers and filter monitors.
This category indicates an issue with the main compressor motor, such as
over-temperature.
This category indicates an issue with the fan or fan motor, such as overtemperature.
This category indicates an issue with the controller, such as a configuration
error or hardware fault.
This category indicates an issue with the main compressor variable speed
drive.
This category indicates an issue with the sequencing communications
system, such as communication faults.
Refer to Table 4 below for a list of all faults and warnings on the system. Note that some alarms are
specific to the machine configuration and sensors that are present.
Table 4: Alarm Codes
Alarm Code
Major Minor
A1
0
A1
1
A1
3
A1
4
A1
5
A1
6
A1
7
A1
8
A1
9
A1
15
A1
16
A1
17
Alarm Name
Low Inlet Temperature
High Inlet Temperature
Inlet Temperature Sensor Shorted
Inlet Temperature Sensor Open
Low Discharge Temperature
High Discharge Temperature
High Discharge Temperature Rate of Rise
Discharge Temperature Sensor Shorted
Discharge Temperature Sensor Open
High Discharge Pressure
Discharge Pressure Sensor Shorted
Discharge Pressure Sensor Open
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Warning
✔
✔
✔
✔
✔
Severity
Fault
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Notice
Alarm Code
Major Minor
C
0
C
1
C
2
C
3
C
4
C
6
C
7
C
8
C
13
C
14
C
15
C
18
C
19
C
20
C
21
F1
0
F1
1
M1
M1
M1
M1
M1
M1
0
1
2
6
7
8
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
0
1
2
3
4
5
6
7
8
20
21
22
22
29
29
30
100
101
102
Alarm Name
Warning
Network Error
Machine Configuration Task Error
Machine Definition Task Error
Date And Time Error
Valve Task Error
Oil Control Task Error
Manual Snapshot
Security Task Error
Alarm Task Error
Invalid Machine Configuration Parameter
IO Module Error
Backup System Error
USB Transfer Error
Software Installation Error
Audit Log Warning
Cooler Fan Aux Contact Fault
Cooler Fan Fault (Digital Input)
Motor Aux Contact Fault
Motor Fault (Digital Input)
Motor Temperature Fault
High Motor Current
Motor Current Sensor Shorted
Motor Current Sensor Open
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Page 40
Notice
✔
✔
✔
✔
✔
✔
✔
✔
Power Loss
Emergency Stop
Low DC Supply Voltage
Low Sump Pressure
Design Pressure Warning
No Start Pressure
Heavy Startup
Ambient Temperature Speed Limiter Active
Control Box Temperature Speed Limiter Active
Phase Monitor Fault (Digital Input)
Low Voltage Relay Warning (Digital Input)
High Vibration Fault (Digital Input)
High Vibration Warning (Digital Input)
External Fault (Digital Input)
External Warning (Digital Input)
Dryer Fault (Digital Input)
High Separator Temperature Rate of Rise
High Separator Temperature
Low Separator Temperature
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Severity
Fault
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Alarm Code
Major Minor
P
103
P
104
P
105
P
106
P
107
P
108
P
110
P
111
P
112
P
113
P
114
P
115
P
116
P
117
P
118
P
119
P
120
P
121
P
122
P
123
P
201
P
202
P
203
P
204
P
205
P
206
P
207
P
208
P
209
P
210
P
211
P
212
S
S
S
S
S
S
S
S
S
S
0
1
2
3
4
5
6
7
21
22
Alarm Name
Warning
Separator Temperature Sensor Shorted
Separator Temperature Sensor Open
High Ambient Temperature
Low Ambient Temperature
Ambient Temperature Sensor Shorted
Ambient Temperature Sensor Open
High Control Box Temperature
Low Control Box Temperature
Control Box Temperature Sensor Shorted
Control Box Temperature Sensor Open
High Plant Delivery Temperature Rate of Rise
High Plant Delivery Temperature
Low Plant Delivery Temperature
Plant Delivery Temperature Sensor Shorted
Plant Delivery Temperature Sensor Open
High Dryer Temperature Rate of Rise
High Dryer Temperature
Low Dryer Temperature
Dryer Temperature Sensor Shorted
Dryer Temperature Sensor Open
High Delivery Pressure
Delivery Pressure Sensor Shorted
Delivery Pressure Sensor Open
High Reservoir Pressure
Reservoir Pressure Sensor Shorted
Reservoir Pressure Sensor Open
High Separator Pressure
Separator Pressure Sensor Shorted
Separator Pressure Sensor Open
High System Pressure
System Pressure Sensor Shorted
System Pressure Sensor Open
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Service Due
Service Due: Air Filter
Service Due: Oil Filter
Service Due: Oil Change
Service Due: Oil Sample
Service Due: Separator
Service Due: Motor Lubrication
Service Due: Control Box Filter
Air Filter Warning (Digital Input)
Oil Filter Warning (Digital Input)
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✔
✔
Page 41
Severity
Fault
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Notice
Alarm Code
Major Minor
S
25
S
30
SQ
SQ
V1
V1
0
1
105
106
Alarm Name
Warning
Severity
Fault
External Maintenance Warning (Digital Input)
Change Separator
✔
✔
✔
Sequence Communications Warning
Sequence Duplicate Unit Number Warning
VFD Warning
VFD Fault
✔
✔
✔
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✔
Notice
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Page 43
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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