Gardner Denver Governor User manual

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Version: 00
February 23rd, 2019
Governor™Controller
USER’S MANUAL
Rotary Screw Compressor Application

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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
Cutting of Finger or Hand Hazard –Rotating
Impeller Blade
Cutting of Finger or Hand Hazard –Rotating Fan
Blade
Health Hazard –Explosive Release of Pressure
High Voltage –Hazard of Shock, Burn, or Death
Present until Electrical Power is Removed
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
Do Not Lift Equipment with Hook –No Lift Point
Handle Package at Forklift Points Only
Lockout Electrical Equipment in De-Energized
State
Loud Noise Hazard –Wear Ear Protection
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
Date
Notes
00
February 23rd, 2019
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 Von 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.
oIf the pressure is below the load pressure setting, it will be displayed in blue:
oIf the pressure is above the Load pressure and less than the Warning pressure setting, it
will be displayed in green:

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oIf the pressure is between the Warning and Fault pressure settings, it will be displayed in
yellow:
oIf 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.
oIf the temperature is below the Minimum Start Temperature setting, it will be displayed in
red.
oIf the temperature is between the Minimum Start Temperature setting and 3 ℃(5.4 ℉)
above the Minimum Start Temperature, it will be displayed in yellow.
oIf the temperature is above the Minimum Start Temperature plus 3 ℃(5.4 ℉) and below
the Warning temperature setting, it will be displayed in green.
oIf the temperature is above the Warning temperature setting and below the Fault
temperature setting, it will be displayed in yellow.
oIf 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.
oRemote 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.
oTimer Control: The Timer Control indicator reflects the setting of Timer Start Enable on
the Control Settings screen.
oAuto 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:
o100% service life, timers just reset:
oService life greater than 350 hours:
oService life of 350 hours or less:
oService life of 175 hours or less:
3.3 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.