Gardner Denver GD PILOT TS Original Operating Instructions
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Gardner Denver GD PILOT TS Original Operating Instructions

Gardner Denver GD PILOT TS Original Operating Instructions

Electronic controller for stationary screw compressors enviroaire 15- 37, enviroaire vs 15- 37
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Original Operating Instructions
GD PILOT TS
Electronic Controller
for Stationary Screw Compressors
EnviroAire 15 – 37
EnviroAire VS 15 – 37
GB
Id. No. ZS1091777 – 04/2012

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Summary of Contents for Gardner Denver GD PILOT TS

  • Page 1 Original Operating Instructions GD PILOT TS Electronic Controller for Stationary Screw Compressors EnviroAire 15 – 37 EnviroAire VS 15 – 37 Id. No. ZS1091777 – 04/2012...

  • Page 2: Table Of Contents

    Menu Access Security .............................. 13     Unlocking and Locking the User Settings ......................13     Configuration of the GD Pilot TS controller ......................14     Language Selection ............................14     Setting the current date and time ........................14  ...
  • Page 3 Gardner Denver Table of Contents     10.2 Conditions Associated With Programmable Inputs ..................... 39     10.3 Programmable Outputs ............................39     Setting Up Timer Control Operation ........................41     11.1 Timer-Controlled Starting and Stopping ......................41  ...
  • Page 4 1 Foreword Gardner Denver...

  • Page 5: Foreword

    This manual valid from software version Intended Use DXL-DH(RS)-1.xx. The installed GD PILOT TS controller is only designed for use with the Gardner Denver D range of compressors.

  • Page 6: Safety

    2 Safety Gardner Denver 2 Safety Safety Instructions Gardner Denver is not liable for any damage or injury Electrical Warning resulting from the non-observance of these safety instructions or negligence of the usual care and attention required during handling, operation,...
  • Page 7 Gardner Denver 2 Safety 2.3.2 Caution Operations or operational procedures marked by the word Caution are actions which, if incorrectly followed, may cause possible damage to the unit. 2.3.3 Notes The sections marked with the word Note indicate procedures which facilitate the job, as well as points...

  • Page 8: Control Panel And Display

    3Control panel and display Gardner Denver 3 Control panel and display SM 1763_GD GD PILOT TS Fig. 1 The GD PILOT TS control panel Touchscreen display – Yellow LED Overview & menu access (Flashing slowly) – Maintenance required Start button – Starts the compressor Green LED Stop button –...

  • Page 9: Accessing Display

    Fig. 2 Home page (normal operating display) The Home page is the default screen which is displayed Current volume flow during normal running. If the GD PILOT TS is left This is continuously calculated based on the unattended on a different screen, it will automatically rotational speed of the motor and known delivery revert back to this screen after 5 minutes.
  • Page 10 3 Control panel and display Gardner Denver P1 Target Pressure/P2 Target Pressure 22) Pictogram (see next section for more details) Air pressure which controller attempts to maintain. = Disabled = Enabled P1 Cut-In Point/P2 Cut-In Point Air pressure at which controller switches the compressor to on-load operation.

  • Page 11: Pictogram

    Gardner Denver 3 Control panel and display Pictogram page Home Cleaning the touch screen Switch off the compressor and isolate it from the power supply. The touch screen must be off. Use a soft and slightly moistened cloth to clean the touch screen without excessive pressure.

  • Page 12: Status Messages Table

    3 Control panel and display Gardner Denver Status messages table Status messages table Fault Xnnn: <Fault text> A fault has been detected and the machine has shut down. See the compressor's “Fault History” for more details (X=”F”, “E” or “A”; nnn = fault number) Ready to start The compressor is ready to start.

  • Page 13: Menu Access Security

    Gardner Denver 4 Menu Access Security A padlock displayed alongside a menu item as shown 4 Menu Access Security below indicates that the value cannot be changed because Unlocking and Locking the User  either the user settings are still locked or Settings ...

  • Page 14: Configuration Of The Gd Pilot Ts Controller

    Fig. 8 Setting Date and Time Adjust the values using the + and - buttons. Fig. 7 Language selection, Step 2 Since the GD Pilot TS is continuously being improved, the language selection shown above is purely an example. Fig. 9 Date and Time keypad...

  • Page 15: Selecting Measurement Units

    Gardner Denver 5 Configuration of the GD Pilot TS controller Selecting Measurement Units Note Ensure that the user settings are unlocked (see Chapter 4). 5.3.1 Temperature Unit Touch: Settings > Configuration > Temperature Unit. Select °F or °C. Confirm the entry by pressing OK.

  • Page 16: Setting The Pressure Bands

    Regulated Speed Models and the compressor will go back on-load, delivering full output again. On VS models, software in the GD Pilot TS controller varies the motor speed to exactly match the demand for Setting the p1 Pressure Band compressed air.

  • Page 17: Setting The P2 Pressure Band

    Gardner Denver 6 Setting the pressure bands Setting the p2 Pressure Band Touch Settings >, then p2 > Control or p2 Cut-In Point Target Pressure Use the keypad which will appear to enter your desired setting (the permissible pressure limits are displayed on the keypad screen).

  • Page 18: Menu Structure

    7 Menu Structure Gardner Denver 7.1.1 Volume Flow, Line Pressure and Motor 7 Menu Structure Speed Graphs The graphs for Volume Flow, Line Pressure and Motor “Trends” Tab Speed are line graphs that take the following form: There are 4 trend graphs available to the user (5 if you have a machine).

  • Page 19: Settings" Tab

    Gardner Denver 7 Menu Structure 7.1.2 Statistics On-Load Hours 7.1.4 Statistics Weekly Profile Fig. 11 Statistic On-Load Hours ( Fig. 13 Statistics Weekly Profile This graph shows the number of hours that the This graph shows the average volume flow over an 8- compressor has been operating at various volume flows day period.
  • Page 20 7 Menu Structure Gardner Denver 7.2.1 Maintenance and Hour Meters 7.2.2 Control The Maintenance Meters menu Hour Touch the buttons to scroll up and down indicates: through the various settings. For more details, see Chapter 8.5.1, Chapter 11 and Chapter 12.
  • Page 21 Control Menu. For more details, see Chapter 14.6. 7.2.8 SD Card The GD Pilot TS is fitted with a data recording function (data logger) which can be used to assist maintenance personnel. For more details, see Chapter 14.8. 7.2.9...

  • Page 22: Fault History" Tab

    7 Menu Structure Gardner Denver After the cause of the alarm has been rectified, touch “Fault History” Tab button to reset the controller. The controller memorises the last 64 alarms (both faults Once this has been done, the flashing alarm symbol will and warnings) which have occurred.

  • Page 23: Overview Of Menu Structure

    Gardner Denver 7 Menu Structure Overview of Menu Structure...

  • Page 24: Starting And Operating

    8 Starting and Operating Gardner Denver 8 Starting and Operating SM 1763_GD GD PILOT TS Fig. 22 The GD Pilot TS control panel Touchscreen Display – Overview & Menu Access Yellow LED Start Button – Starts the compressor (Flashing slowly) – Maintenance required Stop Button –...

  • Page 25: Start Inhibits

    (Fault History > button 8.3.4 Dryer pre-run If the compressor controls a dryer, the GD Pilot TS can be programmed to start the dryer xx minutes before starting the compressor in order for it to reach its optimum...

  • Page 26: During Operation

    Ready to Start, and the flashing green LED will switch off. Continuous operation (drive motor runs continuously) Also in Continuous Operation the GD Pilot TS controls the on-load/off-load operation in response to the demand for air. If the compressor goes into off-load mode, the motor will not be stopped (Settings >...

  • Page 27: Warnings/Faults/Power Failures

    Gardner Denver 8 Starting and Operating Warnings/Faults/Power Failures 8.8.1 Warnings – machine will continue to run These are messages which are displayed when a monitored parameter is exceeded but not by enough to warrant shutting down the compressor. For example, if the compression temperature should reach 59°C, a flashing warning symbol (...

  • Page 28: Faults And Warnings

    The following tables show details of possible warnings to a considerable number of fault displays. The faults and faults which may occur on the GD Pilot TS, with indicated, therefore, may frequently be attributed to their possible cause and suggested remedial action.

  • Page 29: Fault Numbers F000

    Fault Numbers F000 .. F399 (VSD- related) Fault F000... F399 is triggered by the VSD. Note If any Fxxx number error appears other than those listed in the table, contact Gardner Denver’s Technical Support. Fault Numbers F000 .. F399 Display Possible Cause...

  • Page 30: Fault Numbers E400

    9 Faults and Warnings Gardner Denver Fault Numbers E400 .. E495 (compressor-related) Fault Numbers E400 .. E495 Display Possible Cause Remedy Fault E400: Power failure. Find cause. Power Supply Failure Voltage dip. Find cause. Cabling damaged. Check, repair if necessary.
  • Page 31 Check, renew if necessary. defective. Cabling to sensor damaged. Check, renew if necessary. Fault E409: Controller hardware error. Renew GD Pilot TS Controller. Controller Hardware  Fan motor circuit breaker tripped. Fault E410: Check. Cooling  Resistances too high through Check, install auxiliary fan if necessary.
  • Page 32 9 Faults and Warnings Gardner Denver Display Possible Cause Remedy Fault E421: Recurring error during water change in Water change supply intake stage (warning A628 already activated): Poor supply of water for machine, water Check water pressure. pressure may be too low.

  • Page 33: Fault Numbers E500

    Check EM-Stop circuit. VSD EM-Stop Input only: This fatal fault cannot be reset. Re- While the GD Pilot TS controller has powering the compressor will run the detected a pressed Emergency Stop Setup Code procedure. See chapter 13. button there was no corresponding feedback from the VSD.

  • Page 34: Warning Numbers A600

    Warning A606: For more details, please refer to Line Pressure high section 12.5. Warning A607: Battery empty Renew battery: Gardner Denver Part No. Controller Battery empty 100016235 Warning A608: Alarm has been received from external See operating instructions for the dryer.
  • Page 35 Free. Warning A623: The SD card storage space is used up. Renew SD card. SD card full Gardner Denver Part No. ZS1067681 Warning A624: Water filter differential pressure too Check, renew water filter if necessary. Water Filter high. Warning A625:...

  • Page 36: Warning Numbers A700

    9 Faults and Warnings Gardner Denver Display Possible Cause Remedy Warning A627: Error during water change in discharge Water change drain phase: Solenoid valve for water outlet faulty. Check. Dirt trap in front of solenoid valve dirty. Check dirt trap.

  • Page 37: Programmable Inputs And Outputs

    A number of programmable inputs are available on the GD Pilot TS. The number of inputs can vary depending on how your compressor is set up. 10.1.3 Fault Dryer In this feature, the input would be connected to a dryer.
  • Page 38 10 Programmable Inputs and Outputs Gardner Denver 10.1.6 Warn. Condens. Drain 10.1.12 Pressure Band p2 This could be set to display a warning message (A609) This function switches the pressure band over to the if the water level in a condensate drain was close to full.

  • Page 39: Conditions Associated With Programmable Inputs

    10 Programmable Inputs and Outputs 10.2 Conditions Associated With 10.3 Programmable Outputs Programmable Inputs The following table lists certain timing and other conditions which must apply before the GD Pilot TS will trigger the event. Monitoring Condition External Fault Time > 1 s External Warning Time >...
  • Page 40 10 Programmable Inputs and Outputs Gardner Denver 10.3.5 Fault 10.3.11 Pressure Band p2 Activated when there has been a fault as a result of Indicates that the Controller is currently using Pressure which compressor shut down. This Band 2 either from the p2 Timer programmable output is normally closed and opens when a fault occurs.

  • Page 41: Setting Up Timer Control Operation

    5 pm (17:00) and finish at 1 am (01:00). There is no weekend work. The GD Pilot TS could then be programmed to start the compressor at 07:50 and stop it at 16:10. The GD Pilot TS could then re-start the compressor at 16:50 in Fig.
  • Page 42 11 Setting Up Timer Control Operation Gardner Denver Programme the compressor for the morning shift. Touch Channel 1 button to set the times and days of the week for the morning shift. Confirm the entry by pressing OK. Fig. 29 Setting Channel 3 The channel display will finally be: Fig.

  • Page 43: Enabling Start/Stop Timer Control Operation

    Gardner Denver 11 Setting Up Timer Control Operation 11.4 Enabling Start/Stop Timer Control 11.5 Setting Timer for p2 Pressure Band Operation (Alternative Pressure) Operation After setting up the timer/s, timer control operation must As an alternative to the example used above, reduced then be enabled in Settings >...

  • Page 44: Enabling Timer Control Operation For P2 Pressure Band

    11 Setting Up Timer Control Operation Gardner Denver Touch Settings > Timer Control > Timer 11.6 Enabling Timer Control Operation for Pressure Band p2 > Start/Stop Schedule p2 Pressure Band to see an overview of p2 timer settings. If timer control using pressure band p2 is required, p2 timer operation must also be enabled in Settings >...

  • Page 45: Advanced Settings

    “Operating”, you can  In this operating mode, the compressor may programme the GD Pilot TS to start the dryer a few start up automatically at any time. minutes before starting the compressor so that it can ...

  • Page 46: Remote Start / Stop

    For this to be done, you must have read the following safety notices and authorise the unlimited automatic restart by entering an authorisation code. In this operating mode, the compressor may start Please request the required code from Gardner Denver up automatically at any time. Technical Support. Danger Caution ...

  • Page 47: Remote On-Load/Off Load

    Enable Remote Load function and another output for the Remote Load function. Fig. 41 “Remote Start Enabled Activated” indication For example: The “Start” and “Stop” buttons on the GD Pilot TS will no longer have any effect but the emergency stop The Enable Load function could be Remote button still remains operational.

  • Page 48: Setting Up A Replacement Controller

    Enter the 16-character code you made a note of earlier. Touch the OK button to confirm your entry. Fig. 44 Warning – Resetting to Defaults Caution Always check all GD PILOT TS settings before starting compressor after installing replacement controller. Restore your own specific settings.
  • Page 49 Due to the nature of the controller on some models, you may then see the following prompt: Press Emergency Stop Button To Test. This is to check that both the VSD and the GD Pilot TS have correctly recognised their Emergency Stop input. Fig. 45 Testing the Emergency Stop functions...

  • Page 50: Maintenance Level Functions

    14 Maintenance Level Functions Gardner Denver 14 Maintenance Level Functions 14.3 Additional maintenance level views In Trends menu 14.1 Access Security Levels Heatsink Temperature The menu structure is arranged so that there are two VSD Output Current levels of access security.

  • Page 51: Re-Set Statistics On-Load Hours

    Gardner Denver 14 Maintenance Level Functions 14.5 Reset Service Interval Re-set Statistics On-Load Hours 14.4 Touch the Re-Set Statistics button in the Note Trends > Statistics On-Load Hours The yellow LED on the panel will start to flash slowly Menu.

  • Page 52: Vs Setting Or Limiting The Rated Pressure

    This cycle time is already pre-set for your compressor. Note Never change the cycle time without first consulting Gardner Denver Technical Support. 14.7.2 Remaining change time Setup The current remaining time until the next water change can be modified if required, e.g. in order to initiate or delay a water change cycle.

  • Page 53: Data Recording Using The Sd Card

    Recording. 14.8.1 The Data Recording Feature GD PILOT TS is fitted with a data recording function (data logger). This function can be used to monitor and store various compressor parameters. Data created in the process can be stored on an SD card. This can assist maintenance personnel in monitoring compressor performance.
  • Page 54 When the recording session is ended by the user, a second “Settings file” containing the settings and configuration details of the GD Pilot TS at the end of the recording session is written to the SD card. This file name contains the date and is also suffixed with an “S00”...

  • Page 55: Base Load Sequencing (Bls) (Optional)

    15.2 System Requirements approximately the same as the master. A communication module (RS485:3 module) must be installed on the master GD Pilot TS controller, if it has 15.4 Supported slave controllers not been pre-installed ex-factory. For more information see chapter 15.13.

  • Page 56: Supported Slave Compressor Controllers And Required Software Versions

    Note Please contact your local Gardner Denver Technical Only configured slave compressors are shown. This Support if a software update is required. means that at the first activation (number of slaves = 0), only the master compressor is shown. The compressor 15.6 The Base Load Sequencing (BLS)

  • Page 57: Compressor Status Messages (Bls Group)

    Gardner Denver 15 Base Load Sequencing (BLS) (Optional) currently unloading. Sequence Status Load Slave has received a load Indicator Requested… request but hasn't started yet. If the BLS is turned on, this indication shows the current Not displayed for slaves controlled by the compressor sequence.

  • Page 58: Compressor Settings And Information Button

    15 Base Load Sequencing (BLS) (Optional) Gardner Denver 15.7.1 Messages displayed if a slave is not available: If a BLS group Slave is not available (indicated by the symbol on the “BLS” tab), one of the following alarm messages will be displayed:...

  • Page 59: Overview Of Bls Menu Structure

    Gardner Denver 15 Base Load Sequencing (BLS) (Optional) 15.9 Overview of BLS Menu Structure...

  • Page 60: Bls Settings Button

    15 Base Load Sequencing (BLS) (Optional) Gardner Denver Timer Start Enabled On/Off 15.10 BLS Settings Button Enables the scheduled BLS timer Start/Stop settings to Touch the Settings button to view and adjust the BLS start or stop the whole BLS group, e.g. at the weekend.

  • Page 61: Function Description

    Gardner Denver 15 Base Load Sequencing (BLS) (Optional) The master controller utilises this figure to perform Transfer Interval calculations while the line pressure is within the Use this area to define the time interval at which the pressure band. The figure is used to calculate whether...

  • Page 62: Bls Trend And Statistic Graphs

    15 Base Load Sequencing (BLS) (Optional) Gardner Denver In the event of a line pressure sensor fault (Fault E406), Example 1 the master can no longer control the group and shuts off the BLS until the fault is removed and reset.

  • Page 63: Installation And Activation - Rs485:3 Module

    GD Pilot TS. compressor controllers should form a bus structure, i.e. all compressors should be connected in series. The RS485:3 module extends the GD Pilot TS by an additional 3rd RS485 interface. The following image shows examples of correct and incorrect wiring of the compressor station.
  • Page 64 Pilot TS can control up to a maximum of 3 slaves. Signal leads. Must be wired as a twisted pair (TP) 4 3 2 1 Ground (GND) RS485:3 GD Pilot TS (Master) STD - Module GD Pilot TS RS485:1 GD Pilot 14 15 16...

  • Page 65: Installation - Compressor Module (Std)

    GD Pilot TS, GD Pilot The module detects the compressor status via three or GD Pilot MK to the GD Pilot TS master. The module digital inputs, which are indicated via three LEDs on the is connected to the master via the integrated RS485 module.
  • Page 66 The status of these outputs is indicated via three LEDs. This will indicate to the GD Pilot TS Master that there is no fault at the compressor. These digital outputs are change-over contacts and can be adapted to the requirements of the compressor Digital input “Motor”...
  • Page 67 GD Pilot TS Master.
  • Page 68 SM 1948 Fig. 66 Position of DIP switches Digital output “Remote half load” The following table shows the necessary and valid DIP switch settings for communicating with the GD Pilot TS master: Compressor module (STD) DIP Switch Settings Address DIP switch 1.2.3.4.5.6.7.8.9.10...
  • Page 69 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Germany Tel. ++49 (0)6761 832-0 Fax ++49 (0)6761 832-409 www.gardnerdenverproducts.com gdcompressors.eu@gardnerdenver.com...

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