Gardner Denver GD Connect 12 User manual

GD Connect 12
Intelligent interconnected control
GB USA Id. Nr. ZS1060097 / 00

Basis: German operating instructions ZS1060096 / 00
Valid for software versions 2.0x
Subject to technical change without notice.

1. Foreword
3
1.Fore w or d
1.1 Intended use
The control has been designed in accordance with good
engineering practice and accepted safety standards.
Nevertheless, its use may constitute a risk to the health
and safety of users or to third parties or cause damage
to the machine or to other items, if
it is not used for the purpose for which it was
intended
it is operated by untrained personnel
it is improperly modified or changed
the safety instructions are not observed.
Therefore, any person entrusted with the operation,
maintenance or repair of the machine must read and
observe the safety instructions. This must be confirmed
by signature if required.
In addition:
applicable accident prevention regulations,
generally accepted safety rules and
national regulations
must be observed.
The control must only be used in full working order and
in accordance with its intended use and the instructions
set out in the operating manual. All operators must be
fully aware of the risks involved in operating the control
and must observe all safety instructions. Any functional
defects, especially those with safety implications, must
be rectified immediately.
The control is designed exclusively for regulating
systems which generate compressed air. Using the
control for any other purpose is contrary to its intended
use. The manufacturer/supplier cannot be held
responsible for damage resulting from such use. The
risk of such misuse lies solely with the user.
Operation of the control within the limits of its intended
use also includes observation of the operating
instructions and compliance with the inspection and
maintenance instructions.
1.2 Maintenance
Servicing
Please contact your authorized Gardner Denver dealer
in the event of a fault or for spare parts. In case of
damage, our fully trained personnel will ensure that a
quick and proper repair is carried out using original
Gardner Denver spare parts. Original Gardner Denver
spare parts are manufactured using state-of-the-art
technology, thereby guaranteeing the continued reliable
operation of the unit.
In case of queries
Please note the data on the typeplate of your control.
For queries or spare parts orders, please state the
compressor type indicated on the nameplate, the
identification no. and the year of construction. This
information will ensure that you receive the right
information or required spare part.

1. Foreword
4
1.3 Notes
General
These operating instructions are intended to familiarize
the user with the control and its intended use. The
instructions contain important notes on how to operate
the control safely, properly and cost effectively.
Observing these instructions helps to avoid risks, to
reduce repair costs and downtimes and to increase the
reliability and service life of the control.
The operating instructions apply in addition to
applicable national rules and regulations regarding the
prevention of accidents and environmental protection.
They must be kept available at all times at the place of
use of the control. The operating instructions must be
read and observed by any person carrying out work in
connection with the control, e.g. operation, including
setting up, fault-finding during operating cycles,
disposal of production waste, care, service, and
disposal of waste fuels and consumables, upkeep
(maintenance, inspection, repair), transport.
In addition to the operating instructions and the binding
regulations for the prevention of accidents which apply
in the country and place of operation of the control, the
generally accepted technical rules for safe and proper
working must also be observed.
Guarantee
Operate the control only if you have familiarized
yourself with the control and these operating
instructions.
Gardner Denver cannot be held responsible for the safe
operation of the control if it is used in a manner which
does not correspond to the intended use, or for
applications other than those mentioned in these
instructions.
Warranty claims will not be accepted in the case of:
Operating errors
Use of spare parts other than Gardner Denver
original spare parts
Modifications and changes to the installation.
The above exclusions do not extend the scope of the
warranty and liability conditions of the general terms
and conditions of Gardner Denver.
Any unauthorized changes to the control or the
installation of components not approved by the
manufacturer will result in the withdrawal of the CE
mark. As a consequence, any liability and warranty
claims will not be accepted by the manufacturer.
Safety instructions
Danger
The safety instructions in chapter 3 of the operating
instructions must be strictly observed.

2. Table of contents
5
2.Ta ble of co nt e nts
1.Foreword ...................................................................................................................................................... 3
1.1 Intended use ........................................................................................................................................... 3
1.2 Maintenance............................................................................................................................................ 3
1.3 Notes....................................................................................................................................................... 4
2. Table of contents ......................................................................................................................................... 5
3. Safety regulations........................................................................................................................................ 8
3.1 Identification of safety instructions .......................................................................................................... 8
3.2 General safety instructions ..................................................................................................................... 8
3.3 Changes and modifications..................................................................................................................... 9
3.4 Installation and normal operation............................................................................................................ 9
3.5 Special work/maintenance .................................................................................................................... 10
3.6 Warning of special risks ........................................................................................................................ 11
4. Features of the system.............................................................................................................................. 12
4.1 Functions............................................................................................................................................... 12
4.2 Overview ............................................................................................................................................... 13
4.3 Example of a compressed air station with GD Connect 12 .................................................................. 14
4.4 Technical data for the GD Connect 12.................................................................................................. 16
4.5 Scope of delivery................................................................................................................................... 17
4.6 System components.............................................................................................................................. 17
5. Operation.................................................................................................................................................... 19
5.1 First commissioning .............................................................................................................................. 19
5.2 Main display .......................................................................................................................................... 20
5.3 Compressor information........................................................................................................................ 21
5.4 SD card ................................................................................................................................................. 21
5.5 Air station information ........................................................................................................................... 22
5.6 Controlling the air station ...................................................................................................................... 23
5.7 Settings ................................................................................................................................................. 25
5.8 Messages.............................................................................................................................................. 28
5.9 Codes.................................................................................................................................................... 29
6. Compressor module (STD) ....................................................................................................................... 30
6.1 Functions............................................................................................................................................... 30
6.2 Technical data....................................................................................................................................... 30
6.3 Scope of delivery................................................................................................................................... 30
6.4 Connection to the GD Connect 12 ........................................................................................................ 31
6.5 Connection to the compressor .............................................................................................................. 31
6.6 Parameters............................................................................................................................................ 33

2. Table of contents
6
7. Compressor module (VSD)....................................................................................................................... 34
7.1 Functions............................................................................................................................................... 34
7.2 Technical data....................................................................................................................................... 34
7.3 Scope of delivery................................................................................................................................... 35
7.4 Connection to the GD Connect 12 ........................................................................................................ 35
7.5 Connection to the compressor .............................................................................................................. 35
7.6 Parameters............................................................................................................................................ 38
8. Extension module...................................................................................................................................... 39
8.1 Function ................................................................................................................................................ 39
8.2 Technical data....................................................................................................................................... 39
8.3 Scope of delivery................................................................................................................................... 39
8.4 Connection to the GD Connect 12 ........................................................................................................ 40
8.5 Connection of external signals.............................................................................................................. 40
9. Webserver module..................................................................................................................................... 42
9.1 Function ................................................................................................................................................ 42
9.2 Technical data....................................................................................................................................... 42
9.3 Scope of delivery................................................................................................................................... 42
9.4 Connection to the GD Connect 12 ........................................................................................................ 43
9.5 Connection to the net work ................................................................................................................... 43
9.6 Access via browser ............................................................................................................................... 43
9.7 Configuration......................................................................................................................................... 43
Annex .............................................................................................................................................................. 44
Annex A: Wiring diagrams............................................................................................................................ 44
Annex B: Module settings ............................................................................................................................ 49
Annex C: Technical data of the line pressure sensor .................................................................................. 55
Annex D: Drill templates for mounting ......................................................................................................... 56
Annex E: Spare parts and accessories........................................................................................................ 58

2. Table of contents
7

3. Safety instructions
8
3.Safetyregulations
3.1 Identification of safety instructions
Gardner Denver cannot be held liable for any damage
or injury resulting from of the failure to observe these
safety instructions or negligence of the usual care and
attention required during handling, operation,
maintenance or repair, even if this is not explicitly
mentioned in these operating instructions.
If any of the regulations contained in these instructions -
especially with regard to safety – does not correspond
to the local legal provisions, the stricter of the two shall
prevail.
These safety instructions are general in nature and
apply to various types of machines and equipment.
Therefore some references may not apply to the unit(s)
described in these instructions.
Danger
Passages marked with this sign indicate a risk of
injury to personnel.
Important
Passages marked with this sign indicate a risk of
damage to machinery or parts of machinery.
Note
Passages marked with this sign provide technical
information on an optimal cost-effective use of the
machine.
3.2 General safety instructions
Organizational measures
The operating instructions must be kept available at all
times at the place of use of the control (in the tool
compartment or box provided for such a purpose). In
addition to the operating instructions, other generally
applicable legal and other mandatory regulations
relating to accident prevention and environmental
protection must be observed. Such compulsory
regulations may also cover the handling of hazardous
materials or the issuing/ wearing of personal protective
equipment, or traffic regulations.
Instructions regarding supervisory responsibility and
duty of notification in relation to internal factors, for
example regarding work organization, sequences of
operations, duties and responsibilities, shall be
maintained in addition to the operating instructions.
Personnel asked to work on the machine must have
read the operating instructions and in particular the
chapter on safety instructions before starting work.
Reading the instructions after work has begun is too
late. This applies in particular to persons working only
occasionally on the machine, e.g. for setting up or
maintenance.
Regular checks must be made to ensure that personnel
are observing the operating instructions and in
particular the safety requirements
For safety reasons, long hair must be tied back or
otherwise secured, garments must be close-fitting and
no jewellery must be worn. Injury may result from being
caught up in the machinery or from rings catching on
moving parts. As necessary or as required by
regulations, personal protective equipment should be
used.
Observe all safety and warning notices attached to the
control.
Ensure that safety instructions and warnings attached
to the control are always complete and perfectly legible.
If changes to the machine/unit or its operating
behaviour which could have safety implications are
observed, stop the control immediately and report the
fault to the appropriate department/person.
Spare parts must comply with the technical
requirements specified by the manufacturer. This is
ensured by the use of original spare parts.
Follow the prescribed intervals or those specified in the
operating instructions for routine checks and
inspections. For maintenance work, tools and
equipment appropriate to the task must be used.
Personnel must be made familiar with the location and
operation of fire extinguishers. Observe all fire-warning
and fire-fighting procedures. Limit values (pressures,
time settings, etc.) must be permanently displayed.

3. Safety instructions
9
Selection and training of personnel;
basic responsibilities
Work on/with the control must be carried out by reliable
personnel only. Statutory minimum age limits must be
observed.
Employ only trained or instructed personnel and clearly
set out individual responsibilities for operation, setup,
maintenance and repair.
Ensure that only authorized personnel work on or with
the machine.
Define the machine operator's responsibilities, giving
the operator the authority to refuse instructions by third
persons that are contrary to safety regulations.
Do not allow persons to be trained or instructed or
persons taking part in a general training course to work
on or with the control without being continuously
supervised by an experienced person.
Work on the electrical equipment of the control must be
carried out only by a skilled electrician in accordance
with electrical engineering rules and regulations.
3.3 Changes and modifications
Do not make any changes, modifications or
attachments to the control which could affect safety
without the supplier's prior permission.
Unauthorized changes to the unit are not permitted for
safety reasons.
Original parts were designed specifically for this unit.
We wish to point out that we have not approved and will
not approve parts and special accessories which have
not been supplied by us. The installation and/or use of
such products can therefore affect active and/or passive
safety.
The manufacturer cannot be held liable for damage
resulting from the use of non-original parts or special
accessories.
3.4 Installation and normal operation
Installation
In addition to general operating requirements laid down
by local authorities, the following specific instructions
must be observed.
For the lifting of a control cabinet, suitable lifting gear
must be used which meets local safety regulations. All
loose or slewable parts must be safely fixed before the
unit can be lifted. It is strictly prohibited for personnel to
remain within the danger zone of a lifted load.
The correct method of lifting (according to the operating
instructions of the load suspension device) must be
ensured.
If a remote control is used, the system must carry a
clearly visible notice as follows: Attention: This system
is operated by remote control and can start up without
prior warning!
As an additional safety measure, persons who start
remotely controlled systems must take adequate safety
precautions to ensure that nobody is checking or
working on the system. A label with a corresponding
warning notice must be attached to the remote control
equipment.
If a system comprises several compressors, hand-
operated isolator valves must be installed in order to be
able to shut off each machine individually. When
working with pressure systems, do not rely on the
effectiveness of check valves alone to isolate these
systems.
Safety equipment, protective covers or insulation must
not be removed or modified. Any pressure vessel which
is located outside the system, the permissible operating
pressure of which is higher than atmospheric pressure
and which is fitted with two or more pressure supply
lines, must be provided with additional safety equipment
that will automatically prevent the pressure from
exceeding the permissible operating pressure by more
than 10%.
Electrical connections must comply with local
regulations. Power units must be connected to earth
and protected from short-circuits by means of fuses.
Normal operation
Take all necessary precautions to ensure that the
system is used only when in a safe and reliable state.
Operate the system only when all protective equipment,
emergency shut-off equipment, soundproofing elements
and extraction devices are in place and in full working
order.

3. Safety instructions
10
Make regular checks to ensure that:
all means of protection are correctly fitted
and fixed,
all fittings are firmly tightened,
all electrical cables are connected correctly and are
in good condition,
the safety mechanisms are in full working order.
Avoid any working practices which may compromise
safety. Access panels, etc. must be kept closed during
operation. If a fault occurs, stop the machine/unit
immediately and lock it. Have any defects rectified
immediately.
Observe the start-up and stopping procedures and the
control displays according to the operating instructions.
Before starting up or setting the machine in motion,
ensure that nobody is at risk.
3.5 Special work/maintenance
Precautions
Observe the adjusting, maintenance and inspection
activities and intervals set out in the operating
instructions, including information on the replacement of
parts and equipment. These activities may be carried
out by skilled personnel only.
Brief the operating personnel prior to starting special
operations or maintenance work. Appoint a person to
supervise the activities.
Maintenance and repair work may only be carried out
under the supervision of a person who is qualified for
this work.
If the machine/unit is completely shut down for
maintenance and repair work, it must be secured to
prevent inadvertent restart:
•Lock the main command elements and remove the
key and/or
•Attach a warning sign to the main switch.
Always use the correct tools for maintenance and repair
work.
Never use inflammable solvents or carbon tetrachloride
to clean parts. Take precautions against toxic vapours
from cleaning agents.
In any work concerning the operation, conversion or
adjustment of the control and its safety devices or any
work related to maintenance, inspection and repair,
always observe the start-up and shutdown procedures
set out in the operating instructions and the information
on maintenance work.
Ensure that the maintenance area is adequately
secured.
Maintenance/rectification of faults
The employer must inform personnel of the dangers
possibly arising during the repair and maintenance of
the system and of measures to avoid them; personnel
must observe all measures for safety at work. Safety
equipment for the prevention or elimination of danger
must be maintained regularly and its function checked
at least once a year. Faults observed must be rectified
immediately and/or reported to the responsible person.
Only use original spare parts.
Only carry out maintenance and repair work when the
system is not in operation and the power supply
disconnected. Ensure that the power unit cannot be
switched on inadvertently.
Before removing or opening pressurized components,
positively isolate any source of pressure and
depressurize the entire system.
If work which produces heat, flames or sparks has to be
carried out on a machine, the adjacent components
must be protected by means of non-inflammable
material.
Before releasing the system for operation after
maintenance or overhaul, check that the operating
pressures, temperatures and time settings are correct
and that the regulating and shutdown equipment is
working properly.
Motor, air filter, electrical components and regulating
equipment must be protected from the ingress of
humidity, e.g. when cleaning the system by means of a
steam jet.
Never use etching solvents which could attack the
materials used.
Check the accuracy of the pressure indicator at regular
intervals. When the permissible tolerance limits are
exceeded, these devices must be replaced.
The fastening of loads and the instructing of crane
operators should be entrusted to experienced persons
only. The person giving the instructions must be within
sight or voice contact with the operator. For carrying out
overhead assembly work always use specially designed
safety ladders and working platforms. Never use
machine parts as a climbing aid. Wear a safety harness
when carrying out maintenance work at elevated
heights.
Keep all steps, handles, handrails, platforms, landings
and ladders free from dirt, snow and ice. Always re-
tighten screwed connections which have been loosened
for maintenance and repair work. If the setup,
maintenance or repair requires the removal of safety
equipment, this equipment must be remounted and
checked immediately after completion of these
activities.
Ensure that consumables and replacement parts are
disposed of in a safe and environmentally friendly
manner.

3. Safety instructions
11
3.6 Warning of special risks
Electrical power
Attention: external voltage:
If external electrical circuits which cannot be cut out by
the main switch are connected to the control, these
external electrical circuits must be identified in
accordance with EN 60204. Warning signs must be
fixed near the main switch and near these electrical
circuits. In addition, these conductors must be laid
separately and/or colour-coded.
Use only original fuses with the specified current rating.
Switch off the control immediately if a fault occurs in the
electrical system.
Work on the electrical system or equipment may only
be carried out by a skilled electrician or by specially
instructed personnel under the control and supervision
of such an electrician and in line with the relevant
electrical engineering rules.
If regulations require, the power supply to parts of
machines and plants on which inspection, maintenance
and repair work is to be carried out must be cut off.
Before starting any work, check the de-energized parts
for the presence of power and earth or short-circuit
them in addition to insulating adjacent live parts and
elements.
The electrical equipment of the control must be
inspected and checked at regular intervals. Defects
such as loose connections or scorched cables must be
rectified immediately.
Necessary work on live parts and elements must be
carried out in the presence of a second person who can
cut off the power supply in case of danger by operating
the emergency shutdown or main power switch. Secure
the working area with a red-and-white safety chain and
awarning sign. Use insulated tools only.
Before starting work on high-voltage assemblies and
after having cut off the power supply, the feeder cable
must be earthed, and components such as capacitors
short-circuited with an earthing rod.
Gas, dust, steam, smoke
Carry out welding, flame-cutting and grinding work on
the control only if this has been expressly authorized,
as there may be a risk of explosion and fire.
Before carrying out welding, flame-cutting and grinding
operations, clean the control and its surroundings to
remove dust and inflammable substances and make
sure that the premises are adequately ventilated (risk of
explosion).
Adhere to the regulations in force for the place of
operation.
Observe any existing national regulations if work is to
be carried out in confined spaces.

4. Features of the system
12
4.Fe at ures of t he syst em
4.1 Functions
The GD Connect 12 is an intelligent interconnected
control for up to 12 compressors, which is responsible
for keeping a pressurized air network within a relatively
small pressure band in the interests of energy
efficiency.
An optimal use and display of the compressor station
and states is provided by the colour graphic display with
touch function.
The main functions and features of the GD Connect 12
are as follows:
Choice of language settings
Guided commissioning
The user is guided through the necessary steps for
commissioning a station, compressor or extension
module.
Connection of compressors
GD compressors are directly connectable via a
data line (see chapter 4.2).
For all other compressors, an appropriate
compressor module has to be used:
Compressor module (STD)
For connecting a compressor with fixed speed or
half/full load control.
Compressor module (VSD)
For connecting a compressor with speed
regulation.
Control of compressors
Switching of the compressor based on the
calculated air need to maximize the energy-efficient
operation of the compressors.
User-defined profiles
Aprofile is a set of parameters (i.e. pressure band
and compressor priorities) corresponding to
different operating requirements of the station.
Up to 12 profiles are definable and can be
activated by the timer control or a programmable
digital input.
Current station status display
Touch controls can display further information
about the station (i.e. statistics, events, etc.)
Current compressor status display
Touch controls can display further information
about each compressor (i.e. operating hours,
events, etc.)
Programmable inputs and outputs
Programmable inputs and outputs can be used to
control the stations and/or output status messages
to the customer.
SD card drive
to log data from the compressed air station.
Battery buffered real time clock
Code-protected menus
to adjust all necessary parameters.
RS485 interface
The customer can use a separate RS485 interface
to communicate with the GD Connect 12.
The ModBus-RTU protocol is implemented as
standard; an optional PROFIBUS module can be
installed if required.
Extension modules
Extension modules can increase the number of
programmable inputs and outputs. Up to 4
extension modules can be added to the GD
Connect 12.
Help functions
to show wiring diagrams and necessary
adjustments to the compressor controls for
operation via the GD Connect 12.
Abbreviations
In this document and in the display of the GD Connect
12, the following abbreviations are used:
AI-x = Analog input no. x
DI-x = Digital input no. x
DO-x = Digital output no. x
AC = Alternating current
DC = Direct current
UC = Universal current (AC or DC)
COM = Common connection e.g. at a
change-over contact.
STD = Standard
VSD = Variable Speed Drive
Overviews
Section 4.2 "Overview" shows all system components
with the appropriate order numbers.
Section 4.3 "Example of a compressed air station with
GD Connect 12" shows an example of an installation.

4. Features of the system
13
4.2 Overview
Fig. 1
For spare parts and
Accessories
see "Annex E"
RS485-2
ModBus
-
RTU
PROF
IBUS
-
module
(ZS1060052)
GD Connect 12 (ZS1060135)
Line pressure sensor (100003136)
Programmable (Line pressure / Volume flow / Temperature / Dew point)
Analog input AI
-1
Analog input AI
-2
RS485-1
2x2x0,5..1,5mm²
twisted pair and
screened
(100003989)
GD Pilot
Standard or
half/full
compressor
Speed regulated
compressor
(Three-phase asynchronous
motor with max. 500A rating
current)
Compressor
module (STD)
(ZS1060046)
Compressor
module (VSD)
(ZS1060136)
RS485-3
(Customer)
SD card
(100016138)
Extension
module
230V/50-60Hz
(ZS1060138)
110V/50-60Hz
(ZS1060139)
Digital inputs DI-1..8
Digital outputs DO-1..2
Analog inputs AI-1..2
Digital input
DI-1..3
Digital outputs
DO-1..2
GD Pilot MK
Webserver
module
230V/50-60Hz
(ZS1060148)
110V/50-60Hz
(ZS1060149)

4. Features of the system
14
4.3 Example of a compressed air station with GD Connect 12
Fig. 2
Analog input AI
-1
Dig. Eingang DI-2
Dig. input DI-1
RS485-2
Selection switch
to activate a profile
RS485-3
or digital I/O
ModBus-RTU
PROFIBUS (optional)
Customer PLC
to read datas
Line pressure
sensor
RS485-1
Selection switch
to activate a profile
Dig.input
GD Connect 12
Compressor 1 Compressor 2 Compressor 3 Recevier Dryer Filter
RS485
Dig. Input
Dig. input
Extension module

4. Features of the system
15
Fig. 2 shows an example of a compressed air station
with a GD Connect 12:
The connection of the compressors with GD Pilot is
directly via the RS485 interfaces.
The size of the compressed air receiver equals the
parameter "Receiver volume" that has to be set on
the GD Connect 12.
Aprogrammable digital input at the GD Connect 12
can monitor a warning or error message from a
dryer.
Afurther programmable digital input at the GD
Connect 12 can be used to set a selection switch,
for example, for switching to a different profile (e.g.
for pressure reduction).
The RS485-3 interface allows the customer to read
data from the GD Connect 12, e.g. the status of the
compressors, and to activate a profile or reset a
statistics counter, for example.
The data is transmitted via the ModBus protocol.
An optional PROFIBUS interface can be retrofitted
if required.
Communication to the customer is also provided by
digital inputs or outputs.
If the distance to further filters, dryers or selection
switches is too great or if the number of inputs and
outputs on the GD Connect 12 is too small, an
extension module can be added.

4. Features of the system
16
4.4 Technical data for the GD Connect 12
Electrical connection
System: 1~/N/PE
Voltage: 110/230V +/-10% 50/60Hz
Adjust control transformer accordingly
Power: 16VA
Cable: 1.0 .. 2.5 mm² / AWG 17..13
Fuse: max. 10A
Display
Type: Colour graphical display
Resistive touch panel
above the display
Screen size: 5.7" (diagonal)
Resolution: QVGA (320x240)
Analog inputs AI-1..2
Type: 4..20mA
Input voltage: 24VDC
AI-1: Passive / Active dep. on connection
AI-2: Passive / Active dep. on connection
Wiring length: max. 500m
>500m: use amplifier
Digital inputs DI-1..3
Wiring length: max. 20m
>20m: use coupling relay
Digital outputs DO-1..2
Type: Potential-free relay outputs
(change-over contacts)
Load: max. 240V / 1A
Connection of compressors
Interface: RS485-1
Cable type: 2x2x0.5..1.5mm²
twisted pair and screened
Wiring length: max. 1200m
Devices: max. 12 compressors
Connection of extension modules
Interface: RS485-2
Cable type: 2x2x0.5..1.5mm²
twisted pair and screened
Wiring length: max. 1200m
Devices: max. 4 extension modules
Customer interface
Interface: RS485-3
Cable type: 2x2x5..1.5mm²
twisted pair and screened
Wiring length: max. 1200m
Protocol: ModBus-RTU
PROFIBUS (optional)
Baudrate: 2400..38400 (adjustable)
Memory card
Type: SD card
Class: max. Class 2
Size: max. 2GB
Ambient temperature
Operation: 0..55°C
Storage: -25..75°C
EMC conformity
Immission: DIN EN 61000-6-3
Immunity: DIN EN 61000-6-2
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

4. Features of the system
17
4.5 Scope of delivery
After receipt, check the scope of delivery:
GD Connect 12 control cabinet
incl. cable glands
2coded plugs (4-pin)
for the RS485-1 and RS485-3 interfaces
Line pressure sensor
Plug kit to connect the compressor controllers
SD card
Wiring diagram
CD-ROM with manuals
Quick Start Guide incl. drill template for mounting
The drill template can also be found in the annex.
4.6 System components
Analog inputs
There are two analog inputs (4..20mA) on the GD
Connect 12:
Analog input AI-1
This is fixed assigned to the "Line pressure 1" function.
The scaling is adjustable in the menu "Adjustments GD
Connect 12 " menu, "Inputs/Outputs" sub-menu.
Either a passive or active 4..20mA sensor can be used.
Analog input AI-2
This input can be set to different functions and scalings
in the menu "Adjustments GD Connect 12" ,
"Inputs/Outputs" sub-menu.
Either a passive or active 4..20mA sensor can be used.
Information on how to connect the analog inputs can be
found in the annex.
General information on connecting compressors
Compressors are connected to the GD Connect 12 via
the RS485-1 interface only.
The RS485 interfaces of the GD Connect 12 and the
compressor controls should form a bus structure, i.e. all
compressors are connected in series, starting from the
GD Connect 12.
Fig. 3 shows examples of correct and incorrect wiring of
the compressor station.
C1 . .C3
Fig. 3 – Wiring of the compressor station
Connecting Gardner Denver compressors
GD compressors can be connected directly to the GD
Connect 12 via their RS485 interfaces.
Note
In order to operate correctly, the appropriate minimum
software version must be installed on the controllers.
The minimum software versions are listed in the
overview in section 4.2.
Note that the RS485 interfaces of the compressor
controls have been set to the correct values for
Protocol
Baudrate
Address
Further information on the connections (wiring diagrams
and compressor control settings) can be found in the
annex.
C1 C2 C3 Incorrect
GD
Conn.12
GD
Conn.12
C1 C2 C3 Correct
C1 C2 C3
GD
Conn.12
Incorrect
GD
Conn.12
C1 C2 C3 Correct

4. Features of the system
18
Connecting other compressors
Compressors from other manufacturers can be
connected to the GD Connect 12 via compressor
modules:
Compressor module (STD)
Compressors with fixed speed or half/full load
control can be connected with this module.
Compressor module (VSD)
Compressors with speed regulation can be
connected with this module.
Further information on the modules can be found in
chapter 6 "Compressor module (STD)" and chapter 7
"Compressor module (VSD)" respectively.
Programmable inputs and outputs
The GD Connect 12 has
3digital inputs (DI-1..3)
2digital outputs (DO-1..2)
These are routed to the terminal strip and can be
assigned to various functions.
Further information on programming can be found in the
description of the "Settings" menu in section 5.7.
ModBus-RTU / PROFIBUS interface
Aseparate RS485 interface is provided for customer
use to read the current operating status of the GD
Connect 12 (RS485-3).
The ModBus-RTU protocol is implemented as standard.
Details of the protocol and the addresses can be found
in a separate document ("GD Connect 12 Programmer
guide ModBus-RTU").
To enable the GD Connect 12 to be connected to a
PROFIBUS network, an optional PROFIBUS module
can be installed in the GD Connect 12 control cabinet.
For the PROFIBUS module too, details of the protocol
and the addresses can be found in a separate
document ("GD Connect 12 Programmer guide
PROFIBUS").
Extension modules
An extension module is used to expand the number of
programmable inputs and outputs of the GD Connect
12.
The RS485-2 interface of the GD Connect 12 can
connect a maximum of 4 extension modules.
The extension modules are available in two versions
which differ only in terms of their power supply:
Version 1: 230V AC / 50-60Hz
Version 2: 110V AC / 50-60Hz
An extension module adds
8digital inputs (DI-1..8)
2digital outputs (DO-1..2)
2analog inputs (AI-1..2)
to the GD Connect 12.
Further information can be found in chapter 8
"Extension modules".

5. Operation
19
5.Operation
5.1 First commissioning
Note
This section describes the behaviour of the control
when it is booted up for the first time after delivery.
After the first commissioning, this behaviour can be
initialized every time by entering a code (see section
5.9 "Codes”).
Note
Do not touch the display when switching on the power
supply, otherwise the GD Connect 12 will not start up
correctly.
After booting up, the language selection screen appears
(see Fig. 4).
Fig. 4 – Language selection
You can select the language by touching the
appropriate flag symbol.
After that you can decide whether to use the wizard to
help with commissioning. The wizard automatically
prompts you to set the necessary parameters.
Before starting this wizard, the GD Connect 12 can
show you the list of parameter settings required:
Once commissioning has been completed, the main
screen comes up and the GD Connect 12 switches off,
i.e. it shows the status of the compressors but does not
control them.
This is also indicated by the message "GD CONNECT
12 IS SWITCHED OFF"
To switch on the GD Connect 12, open the menu
"Adjustments GD Connect 12" menu. In the
"Regulation" sub-menu you can switch on the control.
(See also section 5.7 "Settings").
Note
In order to operate correctly, the appropriate minimum
software version must be installed on the GD Pilot and
GD Pilot MK. The minimum software versions are listed
in the overview in section 4.2.

5. Operation
20
5.2 Main display
The main display contains essential information about
the condition of the air station.
The individual elements of the main display are shown
in Fig. 5.
Fig. 5 – Main display
(1) Current line pressure
(2) Current pressure band
(3) Current volume flow
(4) Compressor switches showing the compressor
status (see Fig. 6).
(5) Status lines showing status, warnings and fault
indications.
(6) "Info" key to show information about the air
station.
(7) "Settings" key to change parameters.
(8) Current date and time
(9) "SD card" key
(10) "Reset" key to reset warnings and fault
messages.
The status of a compressor is indicated on the
compressor key as shown in the following table:
On load
Indication for compressors with fixed
speed.
On load + delivery rate
Indication for compressors with speed
regulation or half/full load control.
Off load
The compressor motor is running, but
the compressor does not produce
compressed air.
Blow down
(Symbol flashing)
The value of the final pressure as the
value of the start protection.
Standby
The compressor is at standstill, is ready
and can be started by the GD Connect
12 when pressure is required.
Switched off
The compressor is at standstill and no
fault is signalled, but it cannot be started
by the GD Connect 12.
Fault
The compressor is signalling a fault.
Service
The compressor is being serviced and is
therefore not available. Warnings and
fault messages will be ignored.
Fault communication
Serial communication to the compressor
control or to the compressor module has
failed.
Software update necessary
The software of the compressor
controller needs an update.
Warning / Service
The compressor indicates a warning or
requires servicing.
Fig. 6 – Compressor status
(1)
(2)
(3)
(6)
(4)
(5)
(7)
(8)
(9)
(10)