Gardner Denver GD PILOT TS Series Translation Of The Original Operating Instructions
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Gardner Denver GD PILOT TS Series Translation Of The Original Operating Instructions

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Translation of the original operating
instructions
Compressor control
GD PILOT TS / L series
USA
ZS1133369 / 00 - January 2015

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Summary of Contents for Gardner Denver GD PILOT TS Series

  • Page 1 Translation of the original operating instructions Compressor control GD PILOT TS / L series ZS1133369 / 00 - January 2015...

  • Page 2: Table Of Contents

    Table of Contents TABLE OF CONTENTS Operation..........41 Operating Modes........41 Foreword............3 Stop the compressor.......41 Operation Monitoring......41 About these operating instructions....3 Intended use..........3 Clearing a fault..........43 Foreseeable misuse........3 Checklist for clearing faults..... 43 Service............3 Structure of fault and warning codes..43 Safety requirements........4 Troubleshooting........44 Labeling of safety instructions....4...

  • Page 3: Foreword

    Foreseeable misuse speed control Any changes to the software or hardware of the (A) (air); for air-cooled compressors controller must be approved by Gardner Denver. (W) (water); for water-cooled compressors Service All entries shown (parameters, settings, and con- figurations) are examples and do not apply to spe- If you have any questions about or problems with cial applications.

  • Page 4: Safety Requirements

    SAFETY REQUIREMENTS Components of safety instructions Hazard (consequences of hazard): The hazard Gardner Denver takes no responsibility for prop- sequence tells the type of hazard. erty damage or injuries that result from failure to Description of the hazard (hazard source ): The follow the safety requirements hazard source indicates the cause of the hazard.
  • Page 5 Safety requirements Safety symbol Meaning Use / Behaviour Do not operate with open It is not permitted to run the compressor with open doors doors or loose enclosure or loose enclosure panels, except for test runs. High panels. sound pressure level, risk of injury! Normal operation requires the enclosure to be closed.
  • Page 6 Safety requirements Safety symbol Meaning Use / Behaviour Warning of hand injuries Hazard that the hands may be crushed, drawn in, or oth- erwise injured. Keep clear. Warning of automatic In normal operation the compressor can start automati- start-up cally at any time. Operational readiness of the compres- sor is indicated by the green LED on the control panel.
  • Page 7 Safety requirements Safety symbol Meaning Use / Behaviour Electrical voltage Warning against dangerous electrical voltage. Residual voltage on the Warning of electrical energy stores in the form of capaci- capacitors tors. They carry deadly electrical voltage. Do not open the electrical switch cabinet (RS compres- sor) for 10 minutes after disconnecting the compressor.

  • Page 8: Control Panel And Controller

    Control panel and controller CONTROL PANEL AND Selection CONTROLLER If only certain defined values are available for an input, appropriate selection input menus are dis- played. Control Operating Mode Continuous Operation Automatic Operation Fig. 3-1: Control panel Touchscreen Display Start-Taste < I > Stopp-Taste <...
  • Page 9 Control panel and controller Parameters Access Code When parameters must be entered, an appropriate keyboard appears on the screen. The allowable Input Access Code range is displayed next to the entry for the para- meter that is being changed. Control Status: User Settings - Max.

  • Page 10: Menus

    Menus MENUS Menu structure Home (1) Home Date and Time / Language Selection Operating Display (Pictogram with Setpoints and Measured Values) Status / message area Hours Run / Service hours Status of switch-on functions On-Load 0rpm Hours Run Remote Start Enabled Hours On-load Timer Start Enabled Auto.
  • Page 11 Menus Home On-Load 3450rpm Remote Start Enabled Hours Run Timer Start Enabled Hours On-load Auto. Restart Enabled Hours to Next Service Fig. 4-2: "Home" menu Date and Time Status / message area Direct access <"Language Selection"> Status of switch-on functions Volumetric flow rate Register cards Network pressure...
  • Page 12 Menus "p1" is the normal pressure band that is used as Remote Start Enabled standard. Timer Start Enabled "p2" is a second pressure band that can be used if Auto. Restart Enabled a different line pressure is required. The integrated timer control (see the chapter "Timer Control Op- [7.1] Status Remote Start Enabled eration") or an external contact (see the chapter...
  • Page 13 Menus [9] Service information Symbol Designation Description The following service information is displayed: Normal operating <Home> Hours Run display. Hours On-load Hours to Next Service Displays various <Trends> statistics or ten- [9.1] Hours Run dencies of the Displays hours that the drive motor has run. compressor over a specified time [9.2] Hours On-load...

  • Page 14: Pictogram

    Menus Pictogram Fig. 4-4: Pictogram Drive motor Compressed air outlet temperature Compressor stage Pressure in pressure vessel Pressure vessel Temperature at outlet from compressor stage [10] Pressure retention and check valve Drive motor speed (graphical and numerical) (only for speed-controlled compressor systems) Aftercooler [11]...
  • Page 15 Menus This bar chart shows how many hours the RS Volume flow compressor has been operated at various volume Trends flow rates. It also shows the average total volume flow since the last time it was reset. Volume Flow Trends Statistics On-Load Hours Hours Run Hours On-load...

  • Page 16: Settings" Menu

    Menus Scaling the X-axis Motor Speed (RS) Adjust the width of the chart. Trends 1 Press the <Button> of the X-axis. Motor Speed – The "Trend Time Axis" input menu appears. 2 Press the desired option. – The input is accepted. 3 Press the <OK>...
  • Page 17 Menus The arrow keys can be used to scroll down to view "Configuration..."; for setting up compressor additional items. data, language, etc. "p1 Cut-Out Point"; here the pressure band "Factory Settings..."; view for factory customer service can be set. See chapter "Configuration / Set Pressure bands".
  • Page 18 Menus The "Programmable Inputs and Outputs" menu is Timer Control used to assign the inputs and outputs. For details Timer Control on setting up the inputs and outputs, see chapter "Configuration / Programming Inputs and Outputs". Select a Setting Date and Time Communication Timer Start/Stop Display / Adjust...
  • Page 19 Menus The arrow keys can be used to scroll down to view "Language"; for setting the display language. additional items. See chapter "Configuration / Choose Lan- guage". "Compressor Rated Pressure"; Nominal operat- "Temperature Unit"; for setting the unit of tem- ing pressure the compressor can generate.

  • Page 20: Fault History" Menu

    Menus The <i> button at the right side of the menu line SD-Card displays the measured values captured at the SD-Card time of the alarm, in addition to further information about each alarm. Record Data Fault History State of SD-Card Ready Fault E400: Power Supply Failure...
  • Page 21 Menus NOTE The Service level is disabled automatically af- ter five minutes; the controller automatically acti- vates the user level. Inputting and using access codes 1 Press <Access Code> tab. – The "Access Code" input dialog appears. 2 Press <numeric keys> to enter the appropriate access code.

  • Page 22: Configuration

    Configuration CONFIGURATION Settings Choose Language Select Menu . Hour Meters... Configuration... 1 Press the <Globe Symbol> in the "Home" menu. Control... Factory Settings... – The "Choose Language" menu appears. Timer Control... SD-Card... Choose Language Programmable Inputs and Outputs... Communication... Fig. 5-2: "Settings" menu 2 Press the <Timer Control...>...

  • Page 23: Setting Units Of Measure

    Configuration 4 Set the Date and Time using the <+> and <-> 2 Press the <Configuration> button. buttons. – The "Configuration" menu appears. – As soon as a button is pressed, the <OK> button is displayed. Configuration Select a Setting Date and Time Language Adjust Time...
  • Page 24 Configuration Set the Volume Flow unit Settings 1 Press the register card <Settings>. Select Menu – The "Settings" appears. . Hour Meters... Configuration... Settings Control... Factory Settings... Select Menu Timer Control... SD-Card..Hour Meters... Configuration... Programmable Inputs and Outputs... Factory Settings...

  • Page 25: Additional Settings

    Configuration 4 Press the <cfm>, <m /h>, or <m /min> to se- Settings lect the Volume Flow unit. Select Menu 5 Press the <OK> button. . Hour Meters... Configuration... ✓ The Volume Flow unit has been set. Control... Factory Settings... Additional settings Timer Control...
  • Page 26 Configuration When the line pressure reaches the lower pres- NOTE sure limit value of 9.5 bar (Pressure Demand), the suction regulator opens and the compressor The difference between the upper and lower switches to On-Load mode, so that it provides pressure limits may not be less than 0.3 bar compressed air again.

  • Page 27: Program Inputs And Outputs

    Configuration 5.4.2 Program Inputs and Outputs Programmable Inputs and Outputs NOTICE Input 1 Oil Level Free Property damage External Fault Oil Temp. External Warning Oil Pressure Only potential-free contacts may be con- Fault Dryer Motor lubrication system nected to the terminal strip. Warning Dryer Override Timer Start Outside voltages can destroy the controller.
  • Page 28 Configuration Fault Dryer Oil level If the dryer connected to the input sends a fault This function, in combination with a level switch, message (contact opens in case of error), the checks the oil level during on-load phase. If the oil message "E413:Dryer"...
  • Page 29 Configuration 5.4.2.3 Programming inputs Enable Sensor B1 From the factory, the signal for switching the com- 1 Press the <Settings> tab. pressor between On-Load and Off-Load comes – The "Settings" menu appears. from the line pressure sensor B1. 2 Press the <Programmable Inputs and Out- If the input is open, the compressor is switched to puts>...
  • Page 30 Configuration 5.4.2.4 Programmable Outputs Off-Load The output is activated if the compressor is in Off- The controller has programmable outputs. The Load mode. number of outputs can vary according to the con- figuration of the compressor. See the electrical Fault schematic.

  • Page 31: Timer Control

    Configuration 2 Press <Program Inputs/Outputs> button. Programmable Inputs and Outputs – The "Program Inputs/Outputs" menu ap- Output 1 pears. Service Warning/Service Motor Running Programmable Inputs and Outputs Warn./Service/Fault Operating On-Load Ready for Rem. Start Select a Setting Off-Load Request for Start Input 1 Free Pressure Band p2...
  • Page 32 Configuration 5.4.3.2 Set the start and stop times for the Programming the compressor for the day compressor shift 1 Press the <Channel 1> button. The previous example is used to illustrate setting the starting and stopping times for the compres- –...
  • Page 33 Configuration Timer Start/Stop Timer Start/Stop Set Channel 2 Set Channel 3 Start Stop Start Stop Day of the Week Day of the Week Delete Channel Delete Channel Cancel Cancel Fig. 5-26: "Timer Start/Stop" input menu for Timer Con- Fig. 5-27: "Timer Start/Stop" input menu for Timer Con- trol Channel 2 (state after programming) trol Channel 3 (state after programming) 2 Press the <+>...
  • Page 34 Configuration – The "Home" menu shows that "Timer Start Timer Start/Stop Enabled" is activated. Start/Stop Schedule The Timer Control mode can be deactivated again with the <Off> button in the "Timer Start Enabled" menu. 7 Press the start button < I >. –...

  • Page 35: Programming The Dryer Pre-Run Time

    Configuration 5 Press the <+> and <-> buttons to set the start 5.4.3.5 Activating the Timer Control for oper- ation in pressure band p2 and end times. 6 Press the <Day of the Week> button to set the Activating Timer Control pressure band p2 Days of the Week for which the time settings 1 Press the register card <Settings>.

  • Page 36: Setting Rs485 Communication

    Configuration The minimum Pre-Run Time is indicated in the op- Operating: compressor and dryer are running. erating instructions for the dryer. Press the stop button < O >. 1 Press the register card <Settings>. – The compressor is stopped. 2 Press the <Control...> button. The relay output opens.

  • Page 37: Setting The Automatic Restart After Power Loss

    Configuration ✓ The address has been set. 5 Press the <On> button. – The "Communication" menu appears. The <Cancel> button can be used to cancel the enabling of the automatic restart. The previ- Set baud rate ously active setting is used. 1 Press the <Baud Rate>...

  • Page 38: Setting Remote Start/Stop

    Configuration 5.4.7 Setting remote start/stop DANGER DANGER Danger to life and limb In this Operating Mode, the compressor In this Operating Mode, the compressor can start up automatically at any time. can start automatically at any time and for an unlimited duration after a power Post warning signs on the compres- loss.

  • Page 39: Remote On-Load And Off-Load (Fs)

    Configuration Remote start function after power loss As long as the function "Enable Remote Load" is activated, the On-Load / Off-Load command is After a power loss, the remote switch must be given exclusively by the remote load input. All in- switched to OFF and back to ON so that the com- ternal pressure target values are ignored.

  • Page 40: Operating

    Operating OPERATING No Pressure Requirement If there is no Pressure Requirement when the Stopping the compressor in Start button < I > is pressed, the compressor case of emergency switches to standby mode. The green LED flashes and the message "Attention:Start with Pressure Emergency stop Requirement..."...

  • Page 41: Operation

    Operating Start by external Start Requ. Approval To change the Operating Mode: If a programmable input has been activated with 1 Press the register card <Settings>. the function "Start Requ. Approval", the controller 2 Press the <Control...> button. waits for the external start requirement approval. 3 Press the <Operating Mode>...
  • Page 42 Operating When the problem has been eliminated and the temperature drops, the warning message will con- tinue to be displayed. The warning symbol, the LED, and the symbol on the <Fault History> regis- ter card continue to flash until the warning is reset. The warning can be reset regardless of whether the compressor is stopped or running.

  • Page 43: Clearing A Fault

    Do not run any internally integrated measure- Acknowledge alarm ment instruments outside of the compressor. After the cause of the alarm has been corrected, Use only original Gardner Denver replacement the alarm must be reset in the controller. parts. 1 Correct the cause of the alarm.

  • Page 44: Troubleshooting

    Faults triggered by the frequency converter (F000 - F399) (RS) Display Potential root cause Remedy The converter has detected a Contact Gardner Denver service. Fault VSD Fxxx fault with fault number xxx, which is not listed below. Low voltage of the frequency Check power supply.
  • Page 45 Clearing a fault Display Potential root cause Remedy Output phase loss of the fre- Check the wiring of the frequency Fault VSD F021 quency converter. converter to the drive motor. Check all connection terminals and plugs for secure seating and tighten if needed.
  • Page 46 Clearing a fault Display Potential root cause Remedy Intake temperature too high. Check the cooling air supply, improve if necessary. Insufficient cooling. Check cooling air or cooling water infeed, and improve if nec- essary. System operated with the guard Close the enclosure. enclosure open.
  • Page 47 Clearing a fault Display Potential root cause Remedy Hardware error at the controller Replace the Delcos controller E409 Controller Hardware Air-cooled systems: E410 Cooling 1 Fan motor circuit breaker 1 Check it. tripped 2 Check, and install additional 2 Resistances too high in the fans if necessary.
  • Page 48 Pre-Adjustment (replacement device), so that it had to be reprogrammed by the GD Pilot TS. Error while programming the fre- Contact Gardner Denver service. E502: quency converter. VSD Locked Error while programming the fre- Contact Gardner Denver service.
  • Page 49 For more information, see "Con- A906: figuration / expanded settings / Line Pressure high remote load and idle operation" Battery dead Replace battery: Gardner Denver A607: Part No. 100016235 Controller Battery empty Chart 7-5: Warnings triggered by the compressor (A600 - A695) January 2015...
  • Page 50 Clearing a fault Display Potential root cause Remedy Fault of integrated or external See the chapter on the integrated A608 dryer. dryer in the compressor operating Dryer instructions. (compressor without speed con- trol) Fault from external dryer. Check and look for root cause. A608 Dryer (compressor with speed control)
  • Page 51 Clearing a fault Display Potential root cause Remedy Storage space on the SD card Replace SD card. Gardner Den- A623: has been used up. ver part no. ZS1067681 SD-Card full Chart 7-5: Warnings triggered by the compressor (A600 - A695) System-specific setting.

  • Page 52: Additional Controls

    Additional controls ADDITIONAL CONTROLS Trends Maintenance level Line Pressure Parameters locked at user level can be modified by the local maintenance personnel at mainte- nance level. In addition, more trend charts and se- lections are available. Enabling and locking the maintenance level 1 Press <Access Code>...

  • Page 53: Resetting Statistics On-Load Hours

    Additional controls Trends Trends VSD Output Current Statistics On-Load Hours Are you sure you want to re-set the Statistics Data? Fig. 8-3: "VSD Output Current" trend chart Fig. 8-5: Confirmation question "Are you sure you want to re-set the Statistics Data?" The chart shows the time curve of the output cur- rent of the frequency converter.

  • Page 54: Data Recording

    Additional controls Starting and stopping data recording Hour Meters Starting data recording Hrs to next Service 1 Press the <Settings> tab. 2 Press the <SD card> button. 3 Press the <Record Data> button. Setting Range 4 Select data recording option "3" or "60" sec- onds interval.
  • Page 55 The SD-Card should be formatted in FAT32. SD card driver compatibility cannot be guaranteed for any SD card other than the card with CompAir part number ZS1105017. Gardner Denver recommends using the GD PILOT TS SD-card reader. Part number ZS1069300. January 2015...

  • Page 56: Setting Up A Replacement Controller

    Setting Up a Replacement Controller SETTING UP A REPLACEMENT Setting up a replacement CONTROLLER controller Setup Code and Compressor Replacing the controller Reference Number DANGER NOTICE Electric shock Deadly electrical voltage Property damage Work on the electrical equipment Each compressor has a dedicated Setup Code may be performed by specialized and a dedicated Reference Number.
  • Page 57 Setting Up a Replacement Controller Setup Code Compressor Data Enter Setup Code 1 Enter Reference Number All System Settings will now be re-set to Default Values. Before re-starting please check that all settings within the Control Menu are at the required values. The Setup Codes are located on a label within the Controller Cabinet.
  • Page 58 Setting Up a Replacement Controller When the following request appears: Home Press the Emergency Stop Button to test Fig. 9-6: Request "Press the Emergency Stop Button to test" 1 Press the <Emergency stop> pushbutton. – The message "Emergency Stop Activated" appears on the display.

  • Page 59: Base Load Sequencing (Bls)

    Base Load Sequencing (BLS) 10 BASE LOAD SEQUENCING Supported compressor group configurations (BLS) Type Description / Requirement The following chapter mainly describes the master FS Master An FS master can control up to 3 controller in Base Load Sequencing mode. FS slaves.

  • Page 60: Base Load Sequencing" Menu

    The software version can be viewed in the con- troller menu structure. For more information, see the operating instructions for each controller. If a software update is required, please consult Gardner Denver. 60 / 80 January 2015...
  • Page 61 Base Load Sequencing (BLS) 10 1 Press the <OK> button to confirm the message. Symbol Meaning – The message is closed. Base Load Sequencing is switched off. – The "Base Load Sequencing (BLS)" menu All compressors run, independently of appears. each other, according to their individual settings.

  • Page 62: Compressor Status Messages

    10 Base Load Sequencing (BLS) Pressing a <Compressor> button opens an infor- Symbol Meaning mation menu for the compressor with the option of no sym- Compressor not defined setting compressor data. See the chapter "Com- pressor Settings and Information". Compressor in Off-Load [2] Volume Flow Displays the current volume flow being supplied by Compressor in On-Load (FS)

  • Page 63: Compressor Settings And Information

    Base Load Sequencing (BLS) 10 Messages that are displayed if a compressor Description is not available Compressor 1 If a compressor is not available, this is indicated by a flashing alarm symbol on the <Base Load Se- Select a Setting Compressor 1 quencing>...

  • Page 64: Base Load Sequencing Settings

    10 Base Load Sequencing (BLS) If the compressor is connected via the STD mod- Description ule, the actual hours run for the compressor can- Settings not be read serially. In this case, there is a button for setting the hours run. After pressing the but- ton, an input menu appears for inputting the actual Base Load Sequencing hours run for the compressor.
  • Page 65 Base Load Sequencing (BLS) 10 Switch Off Delay (RS) p1 Cut-In Point The minimum line pressure at which the BLS When the master calculates that the compressed switches on the next available compressor. air demand in the network has dropped sufficiently to switch off one slave, a delay time (called the p2 Cut-Out Point Switch Off Delay) is activated.

  • Page 66: Bls Functional Description

    Display / Adjust Timer Pressure Band p2 In case of questions, consult Gardner Denver. This page is to set the Timer Channel only. The Timer for Configuration Sequencing Start/Stop or activating the second Pressure Band must be enabled within Setpoints Menu.

  • Page 67: Trend And History Charts

    Base Load Sequencing (BLS) 10 In the event of a line pressure sensor fault (Fault Example 1 E406:Sensor B1 (Line Press.)), the master can no Compressor 1 Compressor 2 longer control the group and shuts off the BLS until the fault is removed and reset. If the master 1000 h Hours Run compressor switches itself off because a different...

  • Page 68: Installing The Rs485:3 Module

    10 Base Load Sequencing (BLS) This chart shows the Volume Flow curve for the DANGER Base Load Sequencing group over a defined pe- riod of time. Electric shock Statistics Weekly Profile (BLS) Deadly electrical voltage Work on the electrical equipment Trends may be performed by specialized Statistics Weekly Profile (BLS)

  • Page 69: Installing The Compressor Module (Std)

    Base Load Sequencing (BLS) 10 Setting up the communication parameters of the slave compressor controller Master For proper operation, the required minimum soft- ware version must be installed on the controllers. Slave Slave Slave Correct See the table "Required Software Versions". Set the communication parameters on the slave controllers as follows: Master...
  • Page 70 10 Base Load Sequencing (BLS) Part Value Supply voltage 110..230 V AC/DC ±10 % Power consump- 1 VA tion Digital Inputs 24..230 V AC/DC ±10 % Digital outputs Potential-free relay outputs, max. 240 V AC / 1 A Ambient tempera- Operation from 0 to 55 °C ture (32 °F to 131 F)
  • Page 71 Base Load Sequencing (BLS) 10 "Motor" digital input NOTE Contacts A1 and A2 of a main contactor coil can be connected directly to this input. The connection of the compressor module (STD) shown in these operating instructions is If the compressor controller energizes the coil of the main contactor, the compressor module de- suitable for most compressor control systems.
  • Page 72 10 Base Load Sequencing (BLS) "Remote On-Load" digital output Compressor status messages Do not use this output to switch the compressor on and off. Compressor module (STD) This output switches the compressor to On-Load. This remote On-Load signal should be active Power supply Operating Motor...
  • Page 73 Base Load Sequencing (BLS) 10 Compressor module (STD) Enable Remote Remote On-Load On-Load 21 22 26 27 Pressure switch (Overpressure protection) Compressor Control valve Pressure switch Press. switch Compressor module (STD) Enable Remote On-Load Remote On-Load enable 21 22 23 26 27 28 Pressure switch (Overpressure...

  • Page 74: Appendix

    11 Appendix APPENDIX 11.1 Status messages Display Explanation A fault has been detected and the compressor has Fault <Fault number>:<Fault message> been switched off. See the chapter "Troubleshoot- ing". The compressor is ready to start. Ready to start The drive motor is starting. Motor starting…...

  • Page 75: Settings

    Appendix 11 Display Explanation Caution: The compressor is started automatically Caution: Start after pressure relief... as soon as the internal pressure in the compressor stage has fallen below the start enable value. If a programmable input has been activated with Caution: Start with external start approval…...
  • Page 76 11 Appendix Parameter Number / Setting Parameter Number / Setting Channel 1 Compressor Rated Pressure Channel 2 Start Protection Channel 3 Heavy Startup (FS) Channel 4 Discharge Temp. Warn- Channel 5 Channel 6 Discharge Temp. Fault Channel 7 Minimum Start Tem- perature Channel 8 Run-On Time...
  • Page 77 Appendix 11 Parameter Number / Setting Configuration Number of Slaves Transfer Interval Chart 11-3: Setting values Depends on the version; see the compres- sor operating instructions January 2015 77 /80...
  • Page 78 78 / 80 January 2015...
  • Page 79 January 2015 79 /80...
  • Page 80 Gardner Denver Compressor Division, 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Fax: (217) 224-7814...

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