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How to Guide

Subject: SmartAir Master & GD Connect 12 Sequencer - Compressor Module (STD)

Date: June 2016

Compair Part Number - 100016166

Gardner Denver Part Number – ZS1060046

INTRODUCTION

The Compressor Module (STD) is used to link the Sequencer to any rotary screw compressor which
is not equipped with Modbus RS485 facility, regardless of manufacturer or model. The module
contains two inputs 110 to 230 or 24 to 48 voltage systems and uses universal relay contact control
outputs. Integrated directly into the circuits of an air compressor, the Compressor Module avoids
the need for additional relays or remote inputs.
The Compressor Module also acts as an electrical barrier between the compressor and the
sequencer to provide protection and voltage isolation. This document describes the function and
operation of the Compressor Module inputs and outputs and provides connection examples for
non-GD rotary screw compressors.

Technical Data

Dimensions: 100mm x 115mm x 65mm (above DIN rail)

Mounting: DIN rail (top hat, 35mm)
Power Supply: 110 to 230V AC/DC (50/60Hz) on to terminals 16 & 17
Interface: RS485
Cable type: 2x2x0.5 to 1.5mm² twisted pair and screened - Wiring length: max. 1200m
Address: Adjustable from 1 to 12 by DIP switches - Bus termination: 120 Ohm (by DIP switches)
Ambient temperatures - Operation: 0 to 55°C - Storage: -25 to 75°C
EMC conformity - Emission: DIN EN 61000-6-3 - Immunity: DIN EN 61000-6-2

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Compressor System Address

Each compressor in the system must be assigned an identification number from 1 up to the number
of compressors in the system. The identification number should be clearly marked on each
compressor for operational reference. This address number needs to be set at each module with
the dip switches .

Compressor Requirements

Each air compressor must be equipped with a load/unload regulation system and, if not regulated
with a single electro-mechanical pressure switch, have a facility for a remote load/unload control
with the ability to accept a volt free switching contact input for remote load/unload.

Compressor Module (STD)

The module uses a 24V minimum to 230V maximum ac (50/60Hz) or DC input voltage detection
system and universal relay contact control outputs (230Vac/dc @ 5A maximum).
Integrated directly into the circuits of an air compressor, the module avoids the need for additional
relays or remote inputs. The module also acts as an electrical barrier between the compressor and
the SmartAir providing protection and voltage isolation

Input Functions

The module uses three input terminals to determine the compressors status. :

 Operation ( Compressor is Available to Start)

 Motor ( Compressor is Running)
 Load (Compressor is On Load)

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Power Supply & Input Terminals

Inputs Power

Motor Input (Running)

9 10 or 11 9 10 or 11

The RUN input will accept 24 to 48V on terminal 6 & 8 or 110 to 230V on terminals 6 & 7, AC
(50/60Hz) only. Do not connect a voltage greater than 240V to these inputs.

The input can be connected to the control terminals A1 and A2 (coil) of the main starter contactor
of the compressor. When the compressor control system energises the main contactor, the module
will detect the voltage across the contactor coil terminals and signal the Sequencer that the
compressor is running.

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Alternatively, if the main contactor coil voltage is greater than 230Vac, a contactor auxiliary switch
can be used to apply a suitable voltage to the running input terminals.

In instances where a motor starter contactor is not available or accessible, any part of a compressor
control circuit that is energised when the compressor is running can be monitored. For example:
fan contactor or voltage signal to a soft-start or remote starter.

Operation Input (Available)

The OPERATION input will accept 24V minimum

to 230V maximum, ac (50/60Hz) or DC.
Do not connect a voltage greater than 240V to
this input.
The input must be connected to the terminals of a
‘ready’ or ‘operational’ lamp or other circuit of
the compressor control system that will be
energised when the compressor is in standby, 6 7 or 8
started or running condition. The voltage to this
input must de-energise when the compressor is stopped and unavailable to produce air upon a load
signal request or the Emergency Stop button is pressed or when the compressor experiences a fault
condition that prevents the compressor from running. When the compressor ready lamp, or other
control circuit, is energised the module will detect the voltage and signal the SmartAir that the
compressor is ready and available to load and produce air when a load request signal is given.

Operation Input (Available) - Alternative Connection Method:

In instances where a convenient voltage signal for a

compressor Operation condition is not available the
‘Operation’ input can be connected directly to a
constant compressor control system power supply
voltage (24V to 230Vac or dc). This will signal the
Sequencerr that the compressor is ready and available
at all times when power is applied to the compressor.
The Sequencerr has a built-in function to determine
when a compressor is not responding, or is in a
shutdown condition, regardless of the constant ready
signal. Operation

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Never connect the Operation input positive connection directly to the output terminal of a
control system transformer, always connect after a fuse or circuit breaker.

If a normally closed contact of an Emergency Stop button is included in the compressor power
supply circuit, connect after the Emergency Stop button contacts. This will instantly indicate a
compressor not available condition if the Emergency Stop button is activated

Load Input

The LOAD input will accept 24 to 48V on terminal 12

& 13 or 110 to 230V on terminals 12 & 14, ac
(50/60Hz) or DC.
Do not connect a voltage greater than 230V to this
input.
The input can be connected to the terminals of an
Load solenoid valve or other circuit of the compressor
that is energised when the compressor is on load.
The module will detect the voltage and signal the 12 13 or 14
SmartAir that the compressor is loaded.

Output Function Terminals

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Relay Outputs

Compressor Module Output Functions

The output function of the Module is used to control the loading and unloading regulation of the
compressor.

The Module outputs are not intended to stop and start a compressor.

For air compressors fitted with an electromechanical pressure switch

A link is added between terminals 23 and 26.

When connected the pressure switch remains in circuit. If the SmartAir is stopped or experiences a
failure or loss of power, pressure control will automatically revert back to the pressure switch and
the compressor will continue to operate.

Two Wire Pressure Switch Connections:

Link

21 22 23 26 28

Note:
The pressure switch settings of all compressors in the system should be set in a cascaded sequence
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manner such that the system will operate normally in the event of Sequencer inoperability.

Danger:
Lethal voltages may be present on the terminals of the air compressor pressure switch while the
compressor is under Sequencerr control. Isolate the air compressor power supply
Before starting any work.

Electronic Pressure Sensor Type Control

For air compressors fitted with electronic pressure

detection, which are equipped with a remote input
enabling remote load/unload regulation to be
achieved.

This terminal provides volt free contact closure for load

control and also provides a volt free contact closure for
remote load control enable
(Local/Remote Regulation Control). A remote load
enable input provides the facility to change the
26 28 21 23
compressor load regulation from internal control to a
remote switching source.

Note: Compressors that use electronic pressure detection but are not equipped with a remote load
enable (local/remote) feature will not automatically revert to local control if the Sequencer is
stopped or experiences a fault or loss of power.

Note: Compressor controller inputs common voltage may be 0V or +V.

Note: The local/remote pressure regulation input and/or remote load input logics of some
electronic pressure sensor type controllers are reversed, in this instance the ‘Normally closed’
contact can be used to establish the correct logic control connections.

NOTE:
The Compressor Module connections shown in this document are intended to provide a guide for
the majority of compressor control systems in use. Some compressors have variations in
operation and/or function.

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Diagnostics - Compressor Module

The module is equipped with 6 LED indicators.

Command signals from the Sequencer

Remote Load enable (sequence control)

Will illuminate when Sequencer has regulation switched on and has energized the remote load
enable relay within the module, The remote Load enable signal is used to switch the compressor
from local to remote pressure control configuration.

Remote Load (load request)

Will illuminate when Sequencer is requesting the compressor to load.

Monitoring signals from compressor:

Operation (Available input)

Will illuminate when there is a voltage greater than 24Vac/dc on the ‘operation’ terminals of the
module.

Motor (Motor Running input)

Will illuminate when there is a voltage greater than 24Vac/dc on the ‘motor’ terminals of the
module.

Load (Onload input)

Will illuminate when there is a voltage greater than 24Vac/dc on the ‘onload’ terminals of the
module

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Safety Considerations

Danger!!
When carrying out work on any compressed air equipment, you will come across many hazards.

Work on any part of a compressor system should only be carried out by authorised service
personnel who are fully trained and competent.

You are obliged by law to understand any national or local safety rules and regulations.

 Electricity – Always Lock Off, Tag Out & Prove Isolation of Mains Supply
 Air Mains System - Always Lock Off, Tag Out & Depressurize
 Always use Calibrated Test Equipment
 Beware of Hot Surfaces & Liquids
 Beware of Pressurised Gases & Systems – Observe Regulations
 High Noise Levels – Use Hearing Protection
 Heavy Assemblies – Use correct Manual Handling & Certified Lift Equipment
 Moving Parts – Do Not Remove Guards
 Chemical Safety – Observe COSHH Regulations
 Use of Correct PPE
 Observe all Warning Labels
 Observe all Posted Signs and Notices

Any questions regarding this Bulletin can be emailed to:

technicalsupport.uk@gardnerdenver.com