Gardner Denver GD Connect 12

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Overview

Function Description
Important Technical Specifications
GD Connect 12
Compressor module (STD)
Compressor module (VSD)
Extension module
Webserver module
Usage Features
Maintenance Features

The GD Connect 12 is an intelligent interconnected control system designed for managing up to 12 compressors in a pressurized air network, aiming for energy efficiency by maintaining a small pressure band. It features a color graphic display with touch functionality for optimal use and display of the compressor station and its states.

Function Description:

The core function of the GD Connect 12 is to control and optimize the operation of multiple compressors based on calculated air demand, maximizing energy efficiency. It acts as a central hub for managing the air station, allowing for various configurations and monitoring.

Key functions include:

Language Settings: Users can select their preferred language.
Guided Commissioning: A wizard guides users through the necessary steps for commissioning the station, individual compressors, or extension modules.
Compressor Connection: GD compressors can be directly connected via a data line (RS485 interface). For other compressors, specific compressor modules (STD for fixed speed/half/full load control, VSD for speed regulation) are used.
Compressor Control: The system switches compressors based on calculated air needs to ensure energy-efficient operation.
User-Defined Profiles: Up to 12 profiles can be defined, each containing a set of parameters (pressure band, compressor priorities) to match different operating requirements. These profiles can be activated by a timer control or a programmable digital input.
Status Display: Provides current status information for the station (statistics, events) and individual compressors (operating hours, events) via touch controls.
Programmable Inputs/Outputs: Allows for controlling the station and outputting status messages to the customer. The GD Connect 12 has 3 digital inputs (DI-1..3) and 2 digital outputs (DO-1..2).
SD Card Drive: Used for logging data from the compressed air station.
Battery Buffered Real-Time Clock: Ensures accurate timekeeping.
Code-Protected Menus: Secures parameter adjustments.
RS485 Interface: A separate RS485 interface (RS485-3) is available for customer communication, supporting ModBus-RTU protocol. An optional PROFIBUS module can be installed.
Extension Modules: Up to 4 extension modules can be added to expand the number of programmable inputs and outputs. Each extension module adds 8 digital inputs (DI-1..8), 2 digital outputs (DO-1..2), and 2 analog inputs (AI-1..2).
Help Functions: Provides access to wiring diagrams and necessary adjustments for compressor controls.
Webserver Module: Offers a web-based visualization interface for the GD Connect 12, accessible via web browser (e.g., Microsoft Internet Explorer, Mozilla Firefox with Adobe Flash Player installed). It allows for remote monitoring and configuration.

Important Technical Specifications:

GD Connect 12:

System Voltage: 100-240V +/-10%, 50/60Hz.
Power: 16VA.
Cable: 3 x 2.5 mm² / AWG 17..13, max. 10A fuse.
Display: Colour graphical display, resistive touch panel, QVGA (320x240) resolution.
Analog Inputs AI-1..2: 4..20mA input, 24VDC. Passive/Active dependent on connection.
Digital Inputs DI-1..3: Max. 20m wiring length, >20m use coupling relay.
Digital Outputs DO-1..2: Potential-free relay outputs (change-over contacts), max. 240VAC / 1A load.
RS485 Interface (GD Connect 12 to modules): 2x2x0.5..1.5mm² twisted pair and screened cable, max. 1200m wiring length. Max. 12 compressors.
Customer RS485 Interface (RS485-3): 2x2x0.5..1.5mm² twisted pair and screened cable, max. 1200m wiring length. ModBus-RTU protocol, 2400..38400 baudrate (adjustable).
Memory Card: SD card, max. Class 2, max. 2GB.
Ambient Temperature: Operation: 0..55°C, Storage: -25..75°C.
EMC Conformity: DIN EN 61000-6-3 (Immission), DIN EN 61000-6-2 (Immunity).
Dimensions (W x H x D): 380 x 300 x 155 mm.
Type of Construction/Protection: Steel plate housing / IP54.
Mounting: Wall mounting.
Weight: 11 kg / 24 lbs.

Compressor module (STD):

Electrical Connection: 110..230V AC/DC +/-10%, 1VA.
Digital Inputs: 24..230V AC/DC +/-10% for "Operation," "Motor," "Load" signals.
Digital Outputs: Potential-free relay outputs (change-over contacts) for "Remote load enable," "Remote load," "Remote half load," max. 240VAC / 1A.
RS485 Interface: 2x2x0.5..1.5mm² twisted pair and screened cable, max. 1200m. Address adjustable from 1..12 by DIP switches. Bus termination 120 Ohm (by DIP switches).
Ambient Temperatures: Operation: 0..55°C, Storage: -25..75°C.
Dimensions (W x H x D): 100 x 110 x 70 mm.
Type of Construction/Protection: Plastic housing / IP30.
Mounting: DIN rail TS35.

Compressor module (VSD):

Motor Type: Three-phase asynchronous motor, max. 500A rating current.
Electrical Connection: 110..230V AC/DC +/-10%, 1VA.
Digital Inputs: 24..230V AC/DC +/-10% for "Operation," "Warning," "Load" signals.
Digital Outputs: Optional use, potential-free relay outputs (change-over contacts) for "DO-1," "DO-2," max. 240VAC / 1A.
Analog Input AI-1: 4..20mA / 0..10V / 0..5V for line pressure detection.
Analog Output AO-1: 4..20mA / 0..10V / 0..5V for regulating compressor speed.
Analog Input AI-2: For speed detection, connected to a current transducer (LEM HTA500S, 500A measuring range).
RS485 Interface: 2x2x0.5..1.5mm² twisted pair and screened cable, max. 1200m. Address adjustable from 1..12 by DIP switches. Bus termination 120 Ohm (by DIP switches).
Ambient Temperatures: Operation: 0..55°C, Storage: -25..75°C.
Dimensions (W x H x D): 100 x 110 x 70 mm.
Type of Construction/Protection: Plastic housing / IP30.
Mounting: DIN rail TS35.

Extension module:

Electrical Connection: 230V AC +/-10% or 110V AC +/-10%.
Internal Fuses: F1 (Primary): T0.5A (5x20mm), F2 (Secondary): T0.5A (5x20mm).
Digital Inputs: 8 inputs, 24V DC input voltage.
Digital Outputs: 2 potential-free relay outputs (change-over contacts), max. 240V / 1A.
Analog Inputs: 2 inputs, 4..20mA type, 18V DC input voltage. Burden: max. 500m, >500m use amplifier.
RS485 Interface: 2x2x0.5..1.5mm² twisted pair and screened cable, max. 1200m. Address adjustable from 1..4 by DIP switches. Bus termination switchable by DIP switches.
Ambient Temperatures: Operation: 0..55°C, Storage: -20..70°C.
Dimensions (W x H x D): 180 x 180 x 74 mm.
Type of Construction/Protection: Plastic housing / IP64.
Mounting: Wall mounting.
Weight: 1.5 kg / 3.3 lbs.

Webserver module:

Electrical Connection: 230V AC +/-10% or 110V AC +/-10%.
Internal Fuses: F1 (Primary): T0.5A (5x20mm), F2 (Secondary): T0.5A (5x20mm).
RS485 Interface: 2x2x0.5..1.5mm² twisted pair and screened cable, max. 1200m. Bus termination switchable by jumper J1 and J2.
Network Connection: Ethernet, 10Base-TX / 100Base-TX, RJ45.
Ambient Temperatures: Operation: 0..55°C, Storage: -40..70°C.
Dimensions (W x H x D): 180 x 180 x 74 mm.
Type of Construction/Protection: Plastic housing / IP64.
Mounting: Wall mounting.
Weight: 1.5 kg / 3.3 lbs.

Usage Features:

Intuitive Operation: The color graphic display with touch function simplifies interaction and monitoring of the air station.
Flexible Control: Allows for activation of profiles via timer control, digital inputs, or a serial customer interface, enabling adaptation to varying production demands (e.g., normal production, weekend, retrofitting).
Remote Control Capability: The system can be operated remotely, with clear warnings required for safety.
Comprehensive Monitoring: Provides detailed information on compressor status, operating hours (absolute and relative), line pressure, volume flow, and events.
Data Logging: Logs compressor station data to an SD card in CSV format, compatible with MS Excel, for daily analysis.
Network Integration: The Webserver module enables access and configuration via a standard web browser, facilitating remote management and monitoring.
Scalability: Extension modules allow for expansion of inputs and outputs to accommodate larger or more complex air stations.
Security: Code-protected menus prevent unauthorized program changes and access to critical settings.

Maintenance Features:

Regular Checks: Emphasizes the importance of regular checks for protective equipment, fittings, electrical cables, and safety mechanisms.
Qualified Personnel: Maintenance and repair work must be carried out by skilled and authorized personnel.
Safety Precautions: Strict adherence to safety instructions, including disconnecting power, depressurizing components, and using appropriate tools, is required before any maintenance.
Original Spare Parts: Only original Gardner Denver spare parts should be used to ensure proper functioning and maintain warranty.
Fault Rectification: Faults must be rectified immediately and reported to the responsible person.
Software Updates: The system indicates when a software update is needed.
Event Logging: Records events and warnings, aiding in troubleshooting and maintenance planning.
Statistical Data: Provides statistical values (e.g., min/max line pressures) that can be reset, useful for performance tracking.
Bus Termination: DIP switches on compressor and extension modules allow for bus termination settings.
Current Transducer: For VSD modules, the current transducer for speed detection is designed for a maximum current of 500A, requiring careful attention during installation and operation.
Line Pressure Sensor: Technical data for the line pressure sensor is provided, including measuring range, output signal, supply voltage, and operating conditions.
Drill Templates: Detailed drill templates are provided for mounting the GD Connect 12, extension modules, and webserver modules.
Spare Parts and Accessories List: A comprehensive list of spare parts and accessories is provided for GD Connect 12, STD/VSD compressor modules, extension modules, and PROFIBUS modules, including ID numbers for easy ordering. This includes items like line pressure sensors, control units, batteries, circuit breakers, transformers, plugs, SD cards, current transducers, and various converters and sensors.