Gardner Denver GD PILOT TS Original Operating Instructions Download

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Original Operating Instructions

GD PILOT TS

Electronic Controller

for Stationary Screw Compressors

EnviroAire 15 – 37

EnviroAire VS 15 – 37

Id. No. ZS1091777 – 04/2012

Summary of Contents for GD PILOT TS

Page 1: ...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...

Page 2: ...Speed Models 16 6 3 Fixed Speed Models 16 6 4 Setting the p1 Pressure Band 16 6 5 Setting the p2 Pressure Band 17 7 Menu Structure 18 7 1 Trends Tab 18 7 2 Settings Tab 19 7 3 Fault History Tab 22 7 4...

Page 3: ...up Code and Compressor Data Reference Number 48 14 Maintenance Level Functions 50 14 1 Access Security Levels 50 14 2 Unlocking and Locking the Maintenance Level 50 14 3 Additional maintenance level v...

Page 4: ...1 Foreword Gardner Denver 4...

Page 5: ...s valid from software version DXL DH RS 1 xx 1 2 Selection and Qualification Of Personnel Basic Responsibilities Work on with the machine must be carried out by reliable personnel only Statutory minim...

Page 6: ...ns of the manual 2 3 Safety Instructions Gardner Denver is not liable for any damage or injury resulting from the non observance of these safety instructions or negligence of the usual care and attent...

Page 7: ...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 facil...

Page 8: ...the EnviroAire 15 37 and EnviroAire 15 37 range of compressors Compressors can also be supplied with further options that are not included in the standard package 3 2 About the controller This control...

Page 9: ...ess this screen touch the Home tab 18 Items displayed on the Home page 1 Page name Name of the page currently displayed 2 Current date time See Chapter 5 2 3 Language select button See Chapter 5 1 4 C...

Page 10: ...Status and Faults 10c Warning messages 11 Remote Start Status Must be enabled before the remote start stop function can operate 12 Timer Start Control Status Must be enabled before timer control can...

Page 11: ...to the next water change 8 Water change symbol Flashes when the water change stage is active 9 Water level minimum 10 Pressure tank 11 Screw air end 12 Main drive motor 13 Motor speed Current motor sp...

Page 12: ...r has been activated and the compressor will switch to stand by mode in x seconds Attention Start by Remote Control Attention This Compressor can start up at any time via remote control Attention Star...

Page 13: ...he entry by pressing the button When the access code is entered an unlocked padlock will appear The user setting are now unlocked You can implement any changes required A padlock displayed alongside a...

Page 14: ...the various language options Note Language can also be selected via the Settings Configuration Language tabs 5 2 Setting the current date and time Note Ensure that the user settings are unlocked see C...

Page 15: ...perature Unit 1 Touch Settings Configuration Temperature Unit 2 Select F or C 3 Confirm the entry by pressing OK 5 3 2 Pressure Unit 1 Touch Settings Configuration Pressure Unit 2 Select bar or psi 3...

Page 16: ...pressure of 10 0 bar due to no or low air demand the compressor will go off load and the run on timer is activated 6 3 Fixed Speed Models On fixed rotational speed models there are also two pressure s...

Page 17: ...he keypad screen 3 Confirm the entry by pressing OK The display will revert to the previous screen 4 Touch p2 Cut Out Point Note The upper pressure setting must be at least 0 3 bar higher than the low...

Page 18: ...ndicate that it is showing BLS Group data Volume Flow BLS Statistics Weekly Profile BLS 7 1 1 Volume Flow Line Pressure and Motor Speed Graphs The graphs for Volume Flow Line Pressure and Motor Speed...

Page 19: ...nce the statistics button was last reset It also shows the average volume flow since this time 7 1 4 Statistics Weekly Profile Fig 13 Statistics Weekly Profile This graph shows the average volume flow...

Page 20: ...ious settings For more details see Chapter 8 5 1 Chapter 11 and Chapter 12 Fig 16 Control Menu 7 2 3 Timer Control In the Timer Control Menu you can set the current date and time establish a Start Sto...

Page 21: ...ressor settings programmed into the controller at the factory and cannot be changed by the user Touch the and buttons to scroll up and down through the various settings Fig 18 Factory Settings Menu Th...

Page 22: ...ist one screen at a time 8 alarms Fig 19 Fault History Menu Touch the button on the right of each menu line for further information about that particular alarm Fig 20 Alarm information screen After th...

Page 23: ...Gardner Denver 7 Menu Structure 23 7 5 Overview of Menu Structure...

Page 24: ...y at any time 8 1 Stopping the Compressor in an Emergency Caution Use this method of stopping the machine in an emergency only as damage to the compressor could result 1 Press the Emergency Stop butto...

Page 25: ...lt 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 i...

Page 26: ...Automatic Level Control The water quantity can increase or decrease during operation water input through condensate at high atmospheric humidity water output through low remaining water quantity in co...

Page 27: ...ically These are messages which are displayed when a monitored parameter is exceeded by enough to warrant shutting down the compressor automatically for safety reasons or to prevent damage to the mach...

Page 28: ...expected 7 When retro fitting switchgear the control power transformers must not under any circumstances be tapped as they could be overloaded 8 Only use genuine Gardner Denver replacement parts 9 Do...

Page 29: ...re Check filters of switch gear cabinet and renew if necessary Ensure that electric motor driven switch gear cabinet fans if any and frequency converter fans are working correctly Check frequency conv...

Page 30: ...ure sensor defective indication too high Check renew if necessary Fault E404 Low Start Temperature Start attempt at too low temperature 1 Heat up compressor room R2 temperature sensor defective indica...

Page 31: ...se Fault E416 Heavy Startup Discharge compression pressure too high during motor start phase Check that intake regulator is closed and is sealing correctly Fault E417 Water Level Sensor B10 Faulty wat...

Page 32: ...ivated Poor supply of water for machine water pressure may be too low Check water pressure Water treatment unit faulty Check Solenoid valve for water inlet faulty Check Faulty water level sensor B10 C...

Page 33: ...erter VSD was pressed while the compressor was running Always switch the compressor off via the GD PILOT controller Fault E506 VSD EM Stop Input Compressors with PowerFlex 75x VSD only While the GD Pi...

Page 34: ...rature too high Improve Inadequate cooling Improve Unit being operated with enclosure open Close enclosure R2 temperature sensor defective indication too high Check renew if necessary Warning A603 Not...

Page 35: ...stion 4 Warning A621 Input 5 The programmable digital input 5 has been energized but is programmed as Free 4 Check the assignment of the input in question 4 Warning A622 Input 6 The programmable digit...

Page 36: ...k filters of switch gear cabinet and renew if necessary Ensure that electric motor driven switch gear cabinet fans if any and frequency converter fans are working correctly Check frequency converter f...

Page 37: ...been allocated to this input the message Input x will appear on the screen This indicates that a programmable input has been detected x is the number of the relevant programmable input but the control...

Page 38: ...u see chapter 11 3 this function will override the timer and start the compressor as long as the input is activated This allows the machine for example to be started by maintenance personnel during a...

Page 39: ...available on the controller They can be used for example to activate a warning light in a control centre or activate another device when the appropriate output terminals are closed Note A certain num...

Page 40: ...a service is due see above for details This programmable output is normally closed and opens when a warning service event occurs 10 3 9 Warn Service Fault Activated when a warning or fault occurs or a...

Page 41: ...7 50 and stop it at 16 10 The GD Pilot TS could then re start the compressor at 16 50 in readiness for the evening shift It could then stop the compressor again at 01 10 after the end of the late shif...

Page 42: ...cover the period 00 00 to 01 10 each morning a third timer channel would need to be set as shown below 4 Programme the additionally required third channel Key in the settings and confirm your entry by...

Page 43: ...ve to the example used above reduced pressure is to be maintained instead of completely shutting down the station between 16 10 4 10 pm and 16 50 4 50 pm The p2 timer would be set up as follows 1 Touc...

Page 44: ...nd ending at 01 10 Fig 37 Overview of Modified Timer Settings 11 6 Enabling Timer Control Operation for p2 Pressure Band If timer control using pressure band p2 is required p2 timer operation must als...

Page 45: ...ic Restart After Power Loss Danger In this operating mode the compressor may start up automatically at any time Fit the compressor with warning signs lock the room containing the compressor and instru...

Page 46: ...signs on it To authorise the unlimited automatic restart proceed as follows 1 Enter the code on the Access Code tab 2 Set Settings Control Max Power Loss Time to unlimited by entering 0 s Fig 40 Sett...

Page 47: ...automatically at any time Caution Only potential free contacts may be connected to the terminal strip External voltages will destroy the GD Pilot TS The potential free contacts must not be more than 2...

Page 48: ...irst be asked to select your preferred language 1 Touch the appropriate button to select the language then confirm your selection with OK An on screen keypad will then appear on the display 2 Enter th...

Page 49: ...e of the controller on some models you may then see the following prompt Press the Emergency Stop Button To Test This is to check that both the VSD and the GD Pilot TS have correctly recognised their...

Page 50: ...in the maintenance level code In this instance the padlock symbol on the tab does not change to an unlocked padlock but instead a small figure 2 will appear beside it This happens regardless of whethe...

Page 51: ...Note The yellow LED on the panel will start to flash slowly if there are 200 hours or less to the next service You will also see the corresponding message in the status line 1 Touch the Hours to next...

Page 52: ...enu In addition to this there are more display and control elements on the Home page Note The water treatment unit can only provide a limited amount of water per time unit Too frequent water intake sh...

Page 53: ...maintenance level see chapter 14 1 1 Touch the Settings SD Card Record Data tab The default setting is OFF The options which are displayed when you touch the Record Data button allow you to record da...

Page 54: ...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 c...

Page 55: ...ollowing compressor group configurations are supported Supported group configurations Type Description FS The fixed speed master can control up to 3 slaves The rated volume flow of each compressor wit...

Page 56: ...as they are not connected See chapter 15 13 If you select the Base Load Sequencing BLS page before any slave compressors have been defined or with the BLS feature switched off an appropriate message...

Page 57: ...ion such as On Off remaining sequence change time timer controlled start time etc 6 Compressor button The compressor number name actual operating hours the running hours BLS if applicable for more inf...

Page 58: ...ng on the slave controller type some data are read out by the slave while others have to be set manually Therefore an appropriate button is provided instead of a simple indication Note Correct compres...

Page 59: ...Gardner Denver 15 Base Load Sequencing BLS Optional 59 15 9 Overview of BLS Menu Structure...

Page 60: ...er Start Stop settings to start or stop the whole BLS group e g at the weekend 6 p2 Timer Enabled On Off Enables the scheduled BLS timer settings for pressure band p2 to activate the 2nd pressure sett...

Page 61: ...nected to the master 2 Speed Regulated Slaves Yes No Select whether the slaves are rotational speed regulated or not Note All slaves must be of the same type 3 Transfer Interval Use this area to defin...

Page 62: ...e asynchronous until the compressor has achieved its minimum or maximum rotational speed limit 15 11 2 Establishing a new Sequence based on Operating Hours BLS Whenever the transfer interval period ha...

Page 63: ...he provided socket Ensure that all pins are in the socket and not beside it 6 Close the cover install all connectors and switch on the power supply 15 13 2 Activation Activate the Base Load Sequencing...

Page 64: ...her marking on the slaves The following image shows examples of all supported hardware models The GD Pilot TS can control up to a maximum of 3 slaves Fig 62 Circuit diagram SM 1946_gd Signal leads Mus...

Page 65: ...ts RS485 interface In addition commands for the control of the compressor are transmitted from the master to the compressor module via the RS485 interface and are executed by the digital outputs Order...

Page 66: ...e coil of the regulation valve the compressor module detects the voltage over the coil and notifies the master that the motor is on load Any output which indicates that the compressor is on load could...

Page 67: ...g a compressor with line pressure switch example Danger When a compressor module STD is installed the compressor s pressure switch can no longer provide over pressure protection For compressors that a...

Page 68: ...0 4 0 0 1 0 0 0 0 0 0 0 1 On up 0 Off down 15 14 4 Terminal Designations Terminal Designations Terminal Function 1 2 3 Not used 4 5 6 COM 7 Digital input Operation 110 230 V UC 8 24 48 V UC 9 COM 10 D...

Page 69: ...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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