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

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January 2015

USA

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Summary of Contents for GD PILOT TS Series

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

Page 2: ...6 1 Stopping the compressor in case of emergency 40 6 2 Starting the compressor 40 6 3 Factors that inhibit starting 40 6 4 Operation 41 6 5 Operating Modes 41 6 6 Stop the compressor 41 6 7 Operatio...

Page 3: ...an authorized person For safety relevant changes to the compressor or its operating behavior the compressor must be stopped immediately and the fault must be re ported to the responsible area or pers...

Page 4: ...The protection against the hazard describes the measures for preventing the hazard Alert word The alert word classifies the severity of the hazard into four levels emphasized graphi cally with differ...

Page 5: ...cation of instructions where additional information can be found in the manufacturer s operating instruc tions Before the device is operated the user operator must have read and understood the operati...

Page 6: ...quip ment e g a machine or structural components e g covers enclosures guards fences during transport Working at the marked workstations requires increased vigilance Do not go stand beneath the load D...

Page 7: ...operating instructions for the fre quency converter Work on the electrical equipment of the compressor may be done only by an electrician in accordance with electri cal rules Spring tension Warning of...

Page 8: ...ault messages and automatic shut down when a fault occurs Data entry for adjustment of various operating parameters Keeping track of scheduled maintenance of the compressor 3 1 General operation Param...

Page 9: ...This page is to set the Timer Channel only The Timer for Compressor Start Stop or activating the second Pressure Band must be enabled within Setpoints Menu Fig 3 6 Menu with additional information Acc...

Page 10: ...ss Code 6 Base Load Sequencing optional 2 3 4 5 6 1 Date and Time Language Selection Operating Display Pictogram with Setpoints and Measured Values Status message area Hours Run Service hours Status o...

Page 11: ...See also the chapter Con figuration Set Language 3 Volume Flow Displays the current volume flow being supplied The current volume flow is calculated linearly from the motor speed RS and the supply rat...

Page 12: ...r is shown in defined status messages in the top line In the bottom line compressor warnings are dis played The potential status messages and explanations are summarized in a table in the appendix to...

Page 13: ...for entering the codes to enable certain settings Base Load Sequencing option Displays the menu for controlling the Base Load Sequencing func tion Chart 4 2 Tabs 9 Service information The following se...

Page 14: ...eed stopped idle max only for speed controlled compressor systems 6 Air supply 4 4 Trends menu The Trends menu consists of four trend charts FS or five trend charts RS The following trend charts are a...

Page 15: ...n operation total hours and On Load operation It also shows the average vol ume flow since the last time it was reset Statistics Weekly Profile Trends Average Volume Flow We Th Fr Sa Su Mo Tu We 20 Fe...

Page 16: ...the width of the chart 1 Press the Button of the X axis The Trend Time Axis input menu appears 2 Press the desired option The input is accepted 3 Press the OK button The X axis scale is adjusted acco...

Page 17: ...e set See chapter Configuration Set Pressure bands p1 Cut In Point FS p1 Target Pressure RS here the pressure band can be set See chapter Configuration Set Pressure bands p2 Cut Out Point here the sec...

Page 18: ...utputs submenu Programmable inputs can be used to monitor con nected devices or to set up functions that influ ence the operation of the compressor Programmable outputs can be used to transmit status...

Page 19: ...K Factory Settings Fig 4 18 Factory Settings submenu The Factory Settings menu shows the controller settings from the factory Some values can be changed at the service level see chapter Additional Ope...

Page 20: ...ight side of the menu line displays the measured values captured at the time of the alarm in addition to further information about each alarm Fault History Fault E400 Power Supply Failure When 29 Jan...

Page 21: ...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 3 Use the Back button to make corrections if required 4 Pr...

Page 22: ...en language has been preselected 5 Press the OK button The screen language is switched to the chosen language 5 2 Set the Date and Time 1 Press the register card Settings The Settings appears Hour Met...

Page 23: ...ng units of measure Set temperature unit 1 Press the register card Settings The Settings appears Hour Meters Control Timer Control Programmable Inputs and Outputs Communication Configuration Factory S...

Page 24: ...iguration Cancel OK 4 Press the bar or PSI button to select the pressure unit 5 Press the OK button The pressure unit has been set Set the Volume Flow unit 1 Press the register card Settings The Setti...

Page 25: ...e speed of the compressor varies between the minimum and the maximum in order to maintain the p1 Target Pressure of 9 5 bar When the line pressure reaches the upper pres sure value of 10 0 bar the com...

Page 26: ...switches to Off Load mode so that it no longer provides compressed air The run on timer is activated and the com pressor is switched to standby mode after the run on timer has expired When the line p...

Page 27: ...and Outputs menu for Input 1 RS Programmable Inputs and Outputs Input 1 Free External Fault External Warning Fault Dryer Warning Dryer Fault Condens Drain Warn Condens Drain Air filter Oil filter Mot...

Page 28: ...il Filter if the differential pressure switch on the oil filter indicates that it needs to be replaced Oil level This function in combination with a level switch checks the oil level during on load ph...

Page 29: ...ime 30 s Air filter Time 30 s Oil filter Time 30 s Oil Level Time 60 s only during the load phase Oil Temp Time 30 s Oil Pressure Time 30 s only during the load phase Chart 5 1 Conditions linked to pr...

Page 30: ...ng as there is no fault The output is deactivated if a fault has occurred Warning The output is activated as long as there is no warning The output is deactivated if a warning has occurred Service The...

Page 31: ...ts menu for Output 1 5 Press the button for the desired output func tion The Cancel button can be used to cancel the selection of the output function The function previously assigned to the output is...

Page 32: ...ing The shows an overview of the Timer Control chan nels Each Timer Control channel controls a compres sor switch on time and a compressor switch off time that can be set for one or more Days of the W...

Page 33: ...ed time period from 12 00 midnight to 1 10 a m 1 Press the Channel 3 button The input menu for setting the start time end time and Day of the Week appears Timer Start Stop Set Channel 3 Start OK Mo Tu...

Page 34: ...bled is activated The Timer Control mode can be deactivated again with the Off button in the Timer Start Enabled menu 7 Press the start button I The compressor is switched ON set in op eration The com...

Page 35: ...in pressure band p2 Activating Timer Control pressure band p2 1 Press the register card Settings 2 Press the Control button 3 Press the Arrow Key until the p2 Timer En abled button is visible 4 Press...

Page 36: ...eration The external dryer is switched off when the com pressor taken out of operation Press the start button I The relay output closes The dryer connected to the relay output is switched on and runs...

Page 37: ...mpressors a staged start up can be set up by assigning start up delays Activate automatic restarting 1 Press the register card Settings 2 Press the Control button 3 Press the Arrow Key until the Auto...

Page 38: ...button The start up delay is set The Control menu is displayed The delay time setting now appears on the Restart delay button 5 4 7 Setting remote start stop DANGER In this Operating Mode the compress...

Page 39: ...0204 and post a warning sign on it NOTICE Property damage Only potential free contacts may be con nected to the terminal strip Outside voltages can destroy the controller The potential free contacts m...

Page 40: ...tart with Pressure Requirement appears on the display The compressor starts automatically if the lower pressure limit is reached The ambient temperature is below the permis sible minimum starting temp...

Page 41: ...f Load there is no Run On Time and the drive motor is not switched off Changing the Operating Mode The compressor is set to Automatic Operation at the factory as standard To change the Operating Mode...

Page 42: ...con troller switches the compressor off A flashing fault symbol appears on the display with a correspond ing message The symbol on the Fault History register card flashes the red LED flashes quickly...

Page 43: ...the electrical enclosure Prior to commissioning and after performing maintenance work ensure that the screws on all connections are tight and that all plugs are properly seated The cables for the powe...

Page 44: ...for compressors with PowerFlex 400 converters Check all connection terminals and plugs for secure seating and tighten if needed Fault VSD F008 Over temperature of the fre quency converter Check the c...

Page 45: ...l root cause Remedy Power failure Look for root cause Voltage drop Look for root cause Damaged cables wiring Check cables wiring and repair if needed E400 Power Supply Failure Loose terminals Check al...

Page 46: ...line pressure values too high 3 External pressure demand too high 4 Suction regulator does not close 5 Pressure sensor B1 or B2 de fective incorrect display 1 Check and look for root cause 2 Correct i...

Page 47: ...and look for root cause E412 External Fault Deactivation by an external device3 Check and look for root cause E413 Dryer compressor without speed con trol Fault of integrated or external dryer 3 See t...

Page 48: ...VSD EM Stop Input Only for compressors with Pow erFlex 75x converter While the GD Pilot TS has detected that an emergency stop button has been pressed no cor responding feedback has been received from...

Page 49: ...fective incorrect display Check and look for root cause Correct it Check remote load idle switching points Check and look for root cause Check and replace if neces sary Final compression temperature...

Page 50: ...an external device 3 Check and look for root cause A616 Lubrication System A fault has occurred in the motor lubrication system or the LC unit is empty 3 See the chapter on the motor lubrication syst...

Page 51: ...ventilation of the electrical switch cabinet and the frequency converter fans work properly Check the inlet and outlet of the cooling air supply to the fre quency converter for blockages and dirty coo...

Page 52: ...ds menu on the mainte nance level Setpoints Targets button on the Line Pres sure trend chart VSD Heatsink Temperature RS VSD Output Current RS Discharge Pressure Discharge temperature Line pressure Se...

Page 53: ...Press the Re Set Statistics button The confirmation question Are you sure you want to re set the Statistics Data ap pears Trends Statistics On Load Hours No Yes Are you sure you want to re set the St...

Page 54: ...ec onds interval 5 Press the OK button Data recording starts immediately The SD Card menu appears The notice Recording appears The file name of the data recording file is also shown Stopping data reco...

Page 55: ...e read from this settings file and entered in the Setting Values table in the ap pendix of these operating instructions All files are tsv tab separated values text format and can be imported and displ...

Page 56: ...ettings for the compressor are defined in the Setup Code The setup code consists of 16 characters The Setup Code is specified on a sticker inside the switch cabinet Compressor Reference Number The com...

Page 57: ...ase check that all settings within the Control Menu are at the required values OK Fig 9 4 Confirmation query Reset System Settings 8 Press the OK button All settings are reset to the basic factory set...

Page 58: ...pushbutton 3 Press the Fault History tab 4 Press the Reset button The symbol on the Fault History tab stops flashing The controller is ready for use Checking the settings NOTE All specific settings s...

Page 59: ...Requirement FS Master FS Slaves An FS master can control up to 3 FS slaves The rated volume flow for each compressor within the Base Load Sequencing group should be about the same as that of the mast...

Page 60: ...For more information see the operating instructions for each controller If a software update is required please consult Gardner Denver 10 3 Base Load Sequencing menu Activating and deactivating Base L...

Page 61: ...n defined yet Base Load Sequencing BLS On Load BLS is switched on Settings Switched off Standby Compressor 1 Compressor 2 Compressor 3 Compressor 4 On Load Next sequence transfer in 24h Base Load Sequ...

Page 62: ...s sor is the base load compressor the other com pressors are switched on in sequence from left to right if the demand for compressed air increases Status Display The status of the compressor is shown...

Page 63: ...oad Sequencing tab 2 Press the Compressor x button for the de sired compressor The Compressor Select a Setting menu appears Description Compressor Name Hours Run Hours Run BLS Maximum Volume Flow Line...

Page 64: ...ors that are controlled by the compressor module STD Software Version Display of the software version of the controller 10 6 Base Load Sequencing Settings Calling Up 1 Press the Base Load Sequencing t...

Page 65: ...r right of the BLS sequence is switched off and the remaining compressors cover the demand for compressed air If the compressed air demand rises again before the programmed switch off delay has elapse...

Page 66: ...nly The Timer for Sequencing Start Stop or activating the second Pressure Band must be enabled within Setpoints Menu Fig 10 12 BLS Timer Control BLS menu The Timer Control BLS menu can be used to chan...

Page 67: ...ous for a brief period until the compressor reaches its minimum or maximum speed limit for the first time Defining a new sequence based on Hours Run BLS Once the transfer interval period has elapsed t...

Page 68: ...485 3 module in order to install the RS485 3 module DANGER Electric shock Deadly electrical voltage Work on the electrical equipment may be performed by specialized electrical technicians only For spe...

Page 69: ...ave controller 2 Set the slave baud rate to 9600 See the op erating instructions for the slave controller 3 Set the RS485 address for the slave See the operating instructions for the slave controller...

Page 70: ...the compres sor electrical enclosure The DIP switches are located behind a cover on the right side of the module Address DIP switches 0 1 Address DIP switch 1 2 3 4 5 6 7 8 9 10 11 12 12 3 4 n a n a G...

Page 71: ...for the compressor This informs the GD PILOT TS master that there is no fault at the compressor Motor digital input Contacts A1 and A2 of a main contactor coil can be connected directly to this input...

Page 72: ...ting Load Motor Power supply Mains contactor Control valve Operating or Collective error signal Supply voltage 6 7 110 230 V UC 6 8 24 48 V UC 12 13 110 230 V UC 12 14 24 48 V UC 9 10 110 230 V UC 9 1...

Page 73: ...protection P Compressor Pressure switch V 21 22 23 26 27 28 Control valve Enable Remote On Load Remote On Load P Compressor Pressure switch Press switch V 21 22 23 26 27 28 P Pressure switch Overpress...

Page 74: ...ad in continuous operation at the lowest permis sible speed Off Load FS The compressor is currently running Off Load in continuous operation Off Load Run On Time x s FS The run on timer has been activ...

Page 75: ...itializing RS The converter is initialized VSD is setting parameters x RS Parameters are being sent to set up the con verter Chart 11 1 Status messages 11 2 Settings Compressor data The compressor ref...

Page 76: ...RS Ext Speed Limit min RS Ext Speed Limit max RS Factory Settings Chart 11 3 Setting values Parameter Number Setting Compressor Rated Pressure Start Protection Heavy Startup FS Discharge Temp Warn in...

Page 77: ...Appendix 11 January 2015 USA 77 80 Parameter Number Setting Configuration Number of Slaves Transfer Interval Chart 11 3 Setting values 1 Depends on the version see the compres sor operating instructio...

Page 78: ...TM 78 80 USA January 2015...

Page 79: ...TM January 2015 USA 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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Gardner Denver GD PILOT TS Series, Translation Of The Original Operating Instructions

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