Gardner Denver GD Pilot Original User Manual
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Gardner Denver GD Pilot Original User Manual

Electronics for speed-controlled stationary rotary screw compressor
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Original User Manual
GD Pilot
Electronics for speed-controlled
stationary rotary screw compressor
GB
Id. no. ZS1090606 / 02 - October 2020
1

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Summary of Contents for Gardner Denver GD Pilot

  • Page 1 Original User Manual GD Pilot Electronics for speed-controlled stationary rotary screw compressor Id. no. ZS1090606 / 02 - October 2020...
  • Page 2 Attention: Risk of electric shock from charged capacitors! Alw ays disconnect the system from the pow er supply and then w ait a further 10 minutes before touching electrical components. The pow er capacitors take this time to discharge. Check the DC bus voltage at the system terminal strip of the frequency converter by measuring this betw een the +DC and -DC terminals or at the -DC and P2 terminals (the exact position can be found in the...

  • Page 3: Table Of Contents

    6.5.1 Inputs ................................17 6.5.2 Outputs ................................17 6.6 Locking / unloc king code ............................18 6.7 Replac ing the GD Pilot (SETUP- CODE) ........................19 6.8 Remote control ................................20 6.8.1 Remote control for pressure changeover ...................... 20 6.8.2 Enabling on- load operation..........................

  • Page 4: Identification Of Safety Guidelines

    1. Identification of safety guidelines I d e n t i f i c a t i o n o f s a f e t y g u i d e l i n e s Warning indicates a potentially dangerous situation which, if not protected against, could result in death or serious (irreversible) injuries.

  • Page 5: Operator Controls / Arrangement

    Sw itch to next sub-menu / menu item, messages. or reduce a value Light signals The GD Pilot is fitted w ith tw o light signals (red, green).   Sw itch to previous sub-menu / menu item, Red light signal:...

  • Page 6: Speed Indicator In The Display

    2. Operator controls / arrangement 2.2.1 Speed indicator in the display WARNING START AFTER ... The engine speed is displayed in the 2nd row of the alternating w ith display..DE-PRESSURISE If the menu navigation is displayed, the speed display is The unit has been sw itched on and is ready.
  • Page 7 2. Operator controls / arrangement ON-LOAD 2.8 m3/min Machine is running on-load. The delivery rate is 2.8 m /min (see section 4.4). ON-LOAD 170 m3/h Machine is running on-load. The delivery rate is 170 m /h (see section 4.4). OFF-LOAD Machine is running off-load (see section 4.4).

  • Page 8: Menu Structure (Values Are Examples)

    2. Operator controls / arrangement Menu structure (values are examples)    +  [MAINTENANCE SCHED.] TOTAL RUNNING 12345h LOADED HOURS 10987h    +   AIR FILTER IN 2000h   OIL FILTER IN 2000h  ...

  • Page 9: Displaying / Changing Values

    2. Operator controls / arrangement Displaying / changing values 2.4.1 Selecting values You can display values, e.g. total hours, and set the control system, e.g. cut-in and cut-out times, in the sub- menu.   To reach the main menu, you must press the ...

  • Page 10: Default Settings

    Setting time/date (timer) Max. line pressure: The GD Pilot accumulator can bridge a loss of pow er - The max. line pressure is set in the [ CONTROL MENU ]- lasting betw een around tw o to three w eeks. If pow er is ...

  • Page 11: Operations

     time. GD Pilot. How ever the unit w ill only stop after a 30- second soft-stop. You w ill find a table containing the messages and - suggestions for how to remedy them in section 7.5.

  • Page 12: Maintenance ([Maint Enance Sched.] Sub-Menu)

    If there is a maintenance interval at 200h (hours), the compressor is not automatically shut dow n. The Note MAINTENANCE ELAPSED message appears on the The total and load hours are lost w hen the GD Pilot is display. replaced. If you w ant the compressor to automatically shut dow n w hen a maintenance interval is due, you have to set this function.

  • Page 13: Extended Functions

    The compressor stage now runs continually menu items are of relevance. in off-mode w hen there is no need for pressure. The GD Pilot has a serial RS485 interface. This interface uses the ModBus RTU protocol. 6.1.2 Second pressure range (p...

  • Page 14: Automatic Re-Start

    Always fit the compressor with warning automatic re-start by entering a code. signs, lock the room containing the Please request the required code from Gardner Denver compressor and instruct your staff. customer service. Fit the main switch specified by EN60204 - Warning and fit the appropriate warning signs on it.

  • Page 15: Fault Memory ] Sub-Menu

    6. Extended functions [ FAULT MEMORY ] sub-menu   To access this information please use to go to   the w arning message or fault that you are interested in Warning messages and faults are stored in the fault in the fault memory.

  • Page 16: Pressure Changeover Setting

    6. Extended functions 6.3.2 Pressure changeover setting Once the last unit of the sw itch-out point has been confirmed, the w hole timer unit is activated. Please go to the [ TIMER CONTROL ] sub-menu. There   The next step is to go to the [ CONTROL MENU ] sub- you can use to select betw een various timer ...

  • Page 17: Limit Values] Sub-Menu

    6. Extended functions When the is pressed, the first underscore _ starts to ... DE-PRESSURISE  flash. You can now use the key to set the first day of  c) If an input is programmed on the function [ EXT. the w eek (Sunday).

  • Page 18: Optional In-/Outputs] Sub-Menu

    Input is not assigned (programmed). outputs (relay contacts) are 4,5A / 240V. EXT FAULT The GD Pilot has four programmable outputs. Output 1 If the contact is opened, the EXT FAULT fault message is a relay w ith changeover contact and output 2..4 are appears on the display and the unit is shut dow n relays w ith NO contact.

  • Page 19: Locking / Unlocking Code

    6. Extended functions Locking / unlocking code When supplied, output 1 is programmed w ith the 'FAULT' function. The outputs 2..4 are not programmed upon delivery. Each of the outputs can be programmed Settings (sub-menus) can be locked using a code to w ith any of the functions listed below .

  • Page 20: Replac Ing The Gd Pilot (Setup- Code)

    6. Extended functions Sticker Replacing the GD Pilot (SETUP- CODE) Once the new GD Pilot has been fitted in your compressor, sw itch the main sw itch back on. The follow ing now appears on the display: PLEASE ENTER SETUP-CODE 1: 0000 You w ill find the setup codes on a sticker (see Fig.

  • Page 21: Remote Control

    But you can also activate the second pressure range Fig. 6 On-load/off-load remote control circuit diagram remotely. This is done using a digital input (input X in Fig. 5) on the GD Pilot (see section 6.5.1 and circuit diagram). In the [OPTIONAL IN-/OUTPUTS] menu you have to...

  • Page 22: Remote Start / Stop

    6. Extended functions The GD Pilot control system allow s the operator to Please connect the potential-free contact that you need sw itch the compressor into off-load from a remote point for the remote start / stop function to the corresponding through the connection of a potential-free contact.

  • Page 23: Error Rectification

    Warning messages are show n in the 3rd display row . 9. Do not connect up extra sw itching or measurement - The red light signal on the GD Pilot also flashes slow ly. devices w ithout the consent of Gardner Denver.
  • Page 24 7. Error rectification [Indication] / Problem Possible cause Rem edy FAULT POWER LOSS Pow er loss Find cause Voltage dip Find cause Cabling damaged Check, repair if necessary Loose terminals Check that all connecting terminals and plugs are tight, retighten if necessary FAULT EM-STOP Emergency off is being/has been activated Unlock...
  • Page 25 The frequency converter w as faulty or not as an emergency remedy: enter setup parameterized (replacement device) and has codes, check all settings and reset if (2)(3)(4)(5) to be parameterized again by the GD Pilot. necessary Enter setup codes, check all settings (2)(3)(4)(5) and reset if necessary...
  • Page 26 The red Stop button on the frequency Alw ays sw itch the compressor off via converter (VSD) w as pressed w hile the the GD Pilot. compressor w as running. FAULT VSD FAULT xx The frequency converter (VSD) detected a...
  • Page 27 The frequency converter w as faulty or not FAULT E500 FAULT E501 programmed (replacement device), so it had to be reprogrammed from the GD Pilot. FAULT E502 An error occurred w hile the frequency Notify Gardner Denver Service FAULT E503 converter w as being programmed.
  • Page 28 7. Error rectification The electronics recognized that an This fatal error cannot be reset. FAULT E506 emergency stop button w as pressed but no Disconnect the compressor from the corresponding feedback w as received from electrical supply and check the the converter.
  • Page 29 NOTES:...
  • Page 30 NOTES:...
  • Page 31 NOTES:...
  • Page 32 Gardner Denver Compressor Division, 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Fax: (217) 224-7814 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Deutschland Tel. ++49 (0)6761 832-0 Fax ++49 (0)6761 832-409...

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