Gardner Denver GD Pilot Product information sheet

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

1
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
supplied operating man
ual of the frequency
converter).
The voltage must read zero.
Basis: German manual ZS1090605 / 02
Valid as of softw are version DPr o -LRS-1.09
We reserve the right to modifications relating to
technical advances.

Contents
2
Content s
1Identification of safety guidelines.....................................................................................................................................3
2Operator controls / arrangement......................................................................................................................................4
2.1 Keys ...............................................................................................................................................................................4
2.2 Status indicator (display / light signals)........................................................................................................................4
2.2.1 Speed indicator in the display ..........................................................................................................................5
2.2.2 Status messages in display ..............................................................................................................................5
2.3 Menu structure (values are examples) ........................................................................................................................7
2.4 Displaying / changing values ........................................................................................................................................8
2.4.1 Selecting values ................................................................................................................................................8
2.4.2 Changing values ...............................................................................................................................................8
3Default settings....................................................................................................................................................................9
3.1 Selecting language .......................................................................................................................................................9
3.2 Setting line pressure .....................................................................................................................................................9
3.3 Setting time/date (timer) ...............................................................................................................................................9
4Operations ..........................................................................................................................................................................10
4.1 Starting the unit ...........................................................................................................................................................10
4.2 Emergency off button..................................................................................................................................................10
4.3 Sw itching off the unit...................................................................................................................................................10
4.4 On-load/of f-load ..........................................................................................................................................................10
4.5 Acknow ledging w arning/fault messages ....................................................................................................................10
4.5.1 Warning messages .........................................................................................................................................10
4.5.2 Fault messages ...............................................................................................................................................10
5M aint e n an ce ( [M AINT ENA NC E SC HED.] s ub-menu)...................................................................................................11
5.1 Maintenance................................................................................................................................................................11
5.2 Programming maintenance intervals .........................................................................................................................11
5.3 Total/load hours counter .............................................................................................................................................11
6Extended functions ...........................................................................................................................................................12
6.1 [ CONTROL MEN U ] sub-menu ................................................................................................................................12
6.1.1 Operating modes.............................................................................................................................................12
6.1.2 Second pressure range (p2) ...........................................................................................................................12
6.1.3 Dryer pre-run ...................................................................................................................................................12
6.1.4 RS 48 5 communication...................................................................................................................................12
6.1.5 Automatic re-start............................................................................................................................................13
6.1.6 Unlimited autom. re-start af ter pow er loss.....................................................................................................13
6.2 [ FA UL T MEMORY ] sub-menu..................................................................................................................................14
6.3 [ TIMER CONTROL ] sub-me n u ................................................................................................................................14
6.3.1 Setting for timer units ......................................................................................................................................14
6.3.2 Pr essure changeover sett ing ..........................................................................................................................15
6.4 [Limit values] sub-me nu ..............................................................................................................................................16
6.5 [OPTIONAL IN-/OUTPUTS] sub-menu......................................................................................................................17
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 f or pressure changeover ......................................................................................................20
6.8.2 Enabling on-load operation.............................................................................................................................20
6.8.3 Remote start / stop..........................................................................................................................................21
7Error rectification...............................................................................................................................................................22
7.1 Safety regulations .......................................................................................................................................................22
7.2 Warnings .....................................................................................................................................................................22
7.3 Fau lts ...........................................................................................................................................................................22
7.4 Checklist ......................................................................................................................................................................22
7.5 Table of faults / w arnings............................................................................................................................................22

1. Identification of safety guidelines
3
1 I dent i f icat ionof safet yguidelines
Warning
indicates a potentially dangerous situation
which, if not protected against, could result
in death or serious (irreversible) injuries.
Important
Passages marked with this sign indicate a possible
danger to machines or part of machines.
Note
Passages marked w ith this sign provide technical
inf ormation on an optimal cost-effective use of the
machine.

2. Operator controls / arrangement
4
2 O pera t or contr ols/ arrange ment
1st row / 2nd row / 3rd row
2.1 Ke ys

ISw itch on unit

Sw itch off unit
The three keys on the right next to the display have a
dual function:

+ 

at the same
time
Call up or exit menu,
exit menu / sub
-menu


Sw itch to next sub
-menu / menu item,
or
reduce a value


Sw itch to previous sub
-menu / menu item,
or
increase a value
Acknow ledgement key,
if yo
u are in a menu / sub-menu, the
acknow ledgement key f unctions as an
Enter key [
↵].
2.2 Status indicator (display / light
signals)
The control system is fitted w ith a three-row display.
1s t r o w :
The final compression temperature, final compression -
pressure and line pressure are permanently displayed
here.
Final compression temperature: is the temperature
measured dow nstream of the compressor stage.
Final compression pressure: is the pressure measured
dow nstream of the compressor stage.
Line pressure: is the pressure w ithin the system
connected dow nstream of the compressor.
The follow ing symbols may also be used in the 1st row :
p2 Second pressure range
Remote start / stop activated
2nd row:
The second row show s the current engine speed.
The operating menus are also displayed there.
For this the speed display is faded out.
3rd row:
The third row show s status, fault and w arning -
messages.
Light signals
The GD Pilot is f itted w ith tw o light signals (red, green).
Red light signal:
Flashing slow ly: w arning, maintenance due
Flashing rapidly: fault, unit is stopped until fault has
been rectified
The red light signal only goes out once the w arning or
fault has been remedied properly.
Green light signal:
Flashing: system is ready, i.e. the motor
may start up automatically at any
time.
Lit up permanently: the drive motor is running
73ºC 10.4bar 10.3bar
TOTAL RU NN IN G 4711h
ON-LOAD

2. Operator controls / arrangement
5
2.2.1 Speed indicator in the display
The engine speed is displayed in the 2nd row of the
display.
If the menu navigation is displayed, the speed display is
faded out.
Examples of speed displayed:
[ _________ζ___ ] 3290rpm
Speed in controlled range.
[ ζ____________ ] 1300rpm
Speed in low er controlled range,
minimum speed not yet reached.
[ |___________ ] 1280rpm
Minimum speed reached.
[ ___________| ] 3650rpm
Maximum speed reached.
2.2.2 Status messages in display
The status messages are show n in the 3rd row of the
display. With longer texts, the indication may 'alternate'.
Status messages:
INITIALIZATION VSD...
The compressor's supply voltage has been sw itched
on. The control system is being initialised and is setting
up communication to the frequency converter ( V SD).
READY TO START
The unit is ready to start and can be sw itched on
(see section 4.1).
WARNING START WITH ...
alternating w ith
... PRESSURE REQUIREMENT
The unit has been sw itched on and is ready. The unit
starts automatically follow ing the pressure requirement
from your system.
WARNING START AFTER ...
alternating w ith
... DE-PRESSURISE
The unit has been sw itched on and is ready. How ever
the internal unit pressure is above the start-up
protection level. Once the unit has been de-
pressurised, the compressor starts automatically.
WARNING START WITH ...
alternating w ith
... TIMER CONTROL
The unit has been sw itched on and is ready. The
compressor is now w aiting for start approval from the
timer (see section 6.3)
WARNING START BY ...
alternating w ith
... REMOTE OPERATION
The unit has been sw itched on and is ready. Remote
unit operations have been activated in the control menu.
The unit starts via a remote signal (see section 6.8).
WARNING START IN xxs
alternating w ith
... AFTER POWER LOSS
A pow er loss has caused the unit to shut dow n. The
'automatic restart' function has been selected in the
control menu. The unit now starts automatically after a
previously set time (see section 6.1.5)
WARNING START IN
alternating w ith
... AFTER DRYER PRE-RUN
The unit has been sw itched on and is ready. The unit
starts automatically after the dryer pre-run (see section
6.1.3).
MOTOR START PHASE
The unit has been sw itched on and the motor is starting

2. Operator controls / arrangement
6
ON-LOAD 2.8 m3/min
Machine is running on-load. The delivery rate is
2.8 m3/min (see section 4.4).
ON-LOAD 170 m3/h
Machine is running on-load. The delivery rate is
170 m3/h (see section 4.4).
OFF-LOAD
Machine is running off-load (see section 4.4).
OFF-LOAD XXs
Machine is running off-load and w ill shut dow n in
XX seconds (see section 4.4).
SOFT STOP TIME in xxs
The system has been sw itched off. The unit stops after
the soft-stop time of xx seconds.
FAULT: <fault text>
The unit has been shut dow n due to a fault. You w ill
find explanations of the fault texts in section 7.
WARNING <warning text>
There is a w arning in place. Ignoring a w arning ma y
result in a fault and shut dow n the compressor. You w ill
find explanations of the w arning texts in section 7.
MAINTENANCE ELAPSED
A maintenance interval is about to lapse or has already
done so, you w ill f ind more details in section 5.

2. Operator controls / arrangement
7
2.3 Menu structure (values are examples)

+ 
INPUT 1: FREE
:
OUTPUT 4 OFF
DESIGN PRESS 13.0bar
START PROTECT 0.8bar
EXT. LIMIT MAX. 3650RPM
EXT. LIMIT MIN. 800RPM
FINAL TEMP WARN 110ºC
FINAL TEMP MAX 120ºC
MIN START TEMP 1ºC
RUN-ON TIME 90s
SOFT STOP 30s
VOL.MAX. 2.8m3/min
VOL.MIN. 1.0m3/min
SOFTWARE: DPro-LRS-1.09
TH 08.02.07 13:55:41
1 ____________ 00:00 00:00
:
7 ____________ 00:00 00:00
:
p21 __________ 00:00 00:00
:
p27 00:00 00:00
02!EM-STOP 12345h
01!EM-STOP 12300h
:
:
CUT-OUT POINT 13.0bar
TARGET PRESSURE 12.5bar
p2CUT-OUT POINT 10.5bar
p2TARGET PRESSURE 10.0bar
AUTOMATIC OPERATION
DISPLAY UNITS m3/min
ENABLE REMOTE-START OFF
TIMER CONTROL OFF
p2TIMER CONTROL OFF
AUTO RESTART OFF
POWER LOSS TIME 2s
START-UP DELAY 5s
DRYER PRE-RUN 0min
RS485-PROTOCOL ModBus
RS485-BAUDRATE 19200
RS485-ADDRESS 1
[MAINTENANCE SCHED.]
[ TIMER CONTROL ]
[ FAULT MEMORY ]
[ CONTROL MENU ]
[OPTIONAL IN-/OUTPUTS]
[ LIMIT VALUES ]
TOTAL RUNNING 12345h
LOADED HOURS 10987h
AIR FILTER IN 2000h
OIL FILTER IN 2000h
SEPARATOR IN 4000h
OIL CHANGE IN 4000h
SHUTDOWN OFF









+



+















+











+











+







+







2. Operator controls / arrangement
8
2.4 Displaying / changing values
2.4.1 Selectingvalues
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 
+ 
keys at the same time.
You can use the 
or  keys to sw itch betw een the
follow ing sub-menus:
[MAINTENANCE SCHED.]
[CONTROL MENU ]
[FAULT MEMORY ]
[TIMER CONTROL ]
[LIMIT VALUES ]
[OPTIONAL IN-/OUTPUTS]
Enter a sub-menu by pressing the key.
Again here you can use the 
or  keys to go to a
menu item.
To exit the sub-menu, you must press the 
+  keys
at the same time.
To then fully exit the main menu, you must again press
the 
+  keys at the same time.
2.4.2 Changing values
Enter the sub-menu and then the menu item containing
the value you w ish to change.
Then press the key, the value flashes. You can now
press 
or  to change the value. You must then
press the key again to confirm the value.

3. Default settings
9
3 Defaul t settings
3.1 Se le cting language
You can change the language by pressing the + 

or + 
keys. Press these keys at the same time until
the right language appears.
3.2 Setting line pressure
Speed is controlled w ith the aid of a PI controller
implemented in the sof tw are and is matched to the
demand for compressed air. In the [CONTROL MENU ]
menu you have to set the maximum line pressure
sw itching point (CUT-OUT POINT) and the TARGET
PRESSURE.
When the maximum line pressure sw itching point is
reached, the machine sw itches to of f-load.
In the range betw een TARGET PRESSURE and CUT-
OUT POINT the speed of the machine is regulated
according to the compressed air requirement.
Exam ple:
CUT-OUT POINT 10.0bar
TARGET PRESSURE 9.5bar
The speed of the machine is regulated according to the
need for compressed air so that the set pressure of
9.5 bar is maintained.
When the line pressure reaches 10.0 bar, the machine
sw itches to off-load.
Max. line pressure:
The max. line pressure is set in the [CONTROL MENU ]-
sub-menu. The 
+ keys have to be pressed at the
same time to do this. You are then taken to the main
menu. Use 
to sw itch to the [CONTROL MENU ]sub-
menu. Then please press the key.
The CUT-OUT POINT menu item now appears on the
display. Again pressing the 
–key causes the value to
flash. You can now correct (increase or decrease) this
value using 
or  . Then confirm the value set by
pressing the key.
Note
The control system checks w hether the value set can
be used. The maximum line pressure CUT-OUT POINT
must be at least 0.2 more than the TARGET
PRESSURE.You may therefore have to first set the
TARGET PRESSURE. To prevent your compressor
suffering from excess w ear, the difference betw een the
CUT-OUT POINT and TARGET PRESSURE should not
be too small.
Target pressure:
In the [ CONTROL MENU ] sub-menu please use 
to
go to the TARGET PRESSURE menu item.
Pressing the key causes the value to flash.
You can now correct (increase or decrease) this value
using 
or  . Then confirm the value set by pressing
the key.
CUT-OUT POINT
TARGET PRESSURE
ON-LOA D
Fig. 1 Block diagram
3.3 Setting time/date (timer)
The GD Pilot accumulator can bridge a loss of pow er -
lasting betw een around tw o to three w eeks. If pow er is
lost for longer periods, the timer's time and date are lost
and have to be entered anew .
Press the 
+ keys at the same time. Use  to go
to the [TIMER CONTROL ] sub-menu and press the
key. The date and time are displayed there in the
follow ing format:
TU 30.10.07 12:10:34
If you press the key, the left-hand value (day of the
w eek) starts to flash. You can now use the 
or  
keys to set this. Then confirm the value by pressing the
key.
All values can now be set in succession using this
procedure. When the last value (seconds) has been
set, the timer is fully set and you can exit the menu by
tw ice pressing the 
+ keys at the same time.

4. Operations
10
4 O pera t ions
4.1 Starting the unit
Warning
If the unit is ready, i.e. the green LED is
flashing, the compressor may automatically
start at any time.
Use the main sw itch to sw itch the unit on.
If w arning or fault messages appear in the third row of
the display, these first have to be rectified and
confirmed using the key.
Then start the unit by pressing the 
Ikey on the GD
Pilot.
4.2 Emergency off button
The EMERGENCY-stop button is situated next to the
GD Pilot. It is used to immediately shut dow n the unit.
Only use the emergency off button to shut dow n the
unit in emergencies. When shutting dow n normally,
alw ays use the 
key.
4.3 Switching off the unit
The unit is sw itched off by pressing the 
key on the
GD Pilot. How ever the unit w ill only stop after a 30-
second soft-stop.
The soft-stop is preset to protect the compressor.
Note
The unit may only be shut dow n using the emergency
off button in real emergencies. When shutting dow n
normally, please use the 
key.
4.4 On-load/off-load
Descriptions of the CONTINUOUS OPERATION and
AUTOMATIC OPERATIONmodes can be f ound in
section 6.1.1.
OFF-L OAD:
If there is no line pressure requirement from the
compressed air system and the unit is in
CONTINUOUS OPERATION, it sw itches to OFF-LOAD.
This means that the motor and compressor stage run
but no air is pumped into the compressed air system.
The unit behaves differently if in AUTOMATIC OPERATION
mode. If there is no line pressure requirement, the
compressor sw itches to OFF-LOAD. The unit is sw itched
off af ter a run-on time that is show n on the display. If there
is another pressure requirement during the run-on time,
the unit is automatically sw itched on.
ON-L OAD:
If the unit is in ON-LOAD, air is pumped into the
compressed air system.
4.5 Acknowledging warning/fault
me ssages
Warning and fault messages are show n in the third row
of the display. The red light signal flashes at the same
time.
You w ill f ind a table containing the messages and -
suggestions for how to remedy them in section 7.5.
4.5.1 Warning messages
When there are w arnings, the red light signal flashes
slow ly. The unit does not automatically shut dow n w hen
there are w arnings. How ever ignored w arnings may
cause f aults.
Rectify w hat is causing the w arning and press the
key to hide the w arning.
4.5.2 Fault messages
Fault messages result in the unit automatically shutting
dow n or do not permit the unit to be started.
Once you have rectified the problem, you still have to
confirm by pressing the key.

5. Maintenance ([MAINTENANCE SCHED.] sub-menu)
11
5 M ai nt e nance ([ MAINT ENANCES CHED.] sub -m enu)
5.1 Maintenance
The maintenance intervals are preset w hen the
compressor is supplied. You w ill find more information
in the unit's overall operating instructions.
It may how ever be necessary f or the maintenance -
intervals to be adjusted individually to your ambient
conditions. For example, the air filter's level of
contamination depends on the compressor's intake
conditions.
The GD Pilot allow s the operator to program various
maintenance intervals (see section 5.2).
If there is a maintenance interval at 200h (hours), the
compressor is not automatically shut dow n. The
MAINTENANCE ELAPSEDmessage appears on the
display.
If you w ant the compressor to automatically shut
dow n w hen a maintenance interval is due, you have
to set this function. To do this, please go to the
[MAINTENANCE SCHED.] sub-menu. Go to the last
SHUTDOWN OFF menu item. Now press the key. The
OFF value now starts to flash. By pressing the 
key
you can change the value to ON. Finally you need to
confirm using .
The compressor now automatically shuts dow n w hen
the –100h maintenance interval is displayed.
Once maintenance has been carried out, the
maintenance interval should be reprogrammed. The
maintenance message can be acknow ledged using the
key.
5.2 Programming maintenance intervals
To program a maintenance interval, please go to the
[MAINTENANCE SCHED.] sub-menu. Here you can
program the maintenance intervals for:
AIR FILTER IN 2000h
OIL FILTER IN 2000h
SEPARATOR IN 4000h
OIL CHANGE IN 4000h
Go to the menu item required. Please press the key.
The value then starts to flash. You can use 
or  to
now set the value to an interval of 0….9999. Confirm
your entry w ith the key.
If you do not w ant the maintenance intervals to be
monitored, program the intervals to more than 9999
hours in the various menu items. ---- appears on the
display. The maintenance interval is then blocked.
Note
The values show n are examples only. The values used
in your unit may be diff erent.
5.3 Total/load hours counter
Y ou w ill f ind the total/load hours counters in the
[MAINTENANCE SCHED.] sub-menu. To do this,
please press the 
+ keys at the same time. You
are then taken to the main menu. Then please press
the key. You are now in the
[MAINTENANCE SCHED.] sub-menu. You can use the

or  keys to now go to the various menu items.
The total hours counter states the time for w hich your
unit has been in on-load and off -load.
The load hours counter states the time f or w hich your
unit has been in on-load.
Note
The total and load hours are lost w hen the GD Pilot is
replaced.

6. Extended functions
12
6 Exte nded functions
6.1 [ CONTROL M ENU ] sub-menu
The most important parameters of the [CONTROL MENU ]
menu have already been explained in section 3 Def ault
settings. This section simply contains an overview and
explanation of additional (extended) functions.
6.1.1 Operating modes
Go to the [CONTROL MENU ]sub-menu and use the 

key to go to the AUTOMATIC OPERATION menu item. If
you press the key, the AUTOMATIC OPERATION
value starts to flash. You can use the 
key to now
sw itch to CONTINUOUS OPERATION. Confirm a set
value by pressing the key.
You can choose f rom tw o operating modes:
AUTOMATIC OPERATION
AUTOMATIC OPERATION
is the most economical of
your compressor's operating modes. If there is no need
for compressed air in your system, the compressor is
shut dow n af ter the RUN-ON TIME. The control system
automatically recognises w hen compressed air is
needed again. The unit then starts up straight aw ay.
CONT INUO U S OP ERA T I O N
CONTINUOUS OPERATION is only needed for some
special applications. When in this operating mode, the
motor is not shut dow n if there is no longer any need for
pressure. The compressor stage now runs continually
in of f-mode w hen there is no need for pressure.
6.1.2 Second pressure range (p2)
The range betw een the maximum pressure and the
target pressure is called the pressure range. The
second pressure range function allow s you to use
another pressure range in addition to the pressure
range already set (see section 3.2). This could be used
to for example implement night-time low ering.
You w ill f ind the settings for the second pressure range
function in the [CONTROL MENU ]sub-menu. The
relevant menu items there are:
p2CUT-OUT POINT 10.5bar
p2TARGET PRESSURE 10.0bar
p2TIMER CONTROL OFF
You can use p2CUT-OUT POINT and p2TARGET
PRESSURE to set the line pressure sw itching points.
Use the p2TIMER CONTROL On menu item to activate
the timer for the second pressure range.
You also can activate / deactivate the second pressure
range using an external potential-free contact (see
section 6.5).
Section 6.3.2 contains a description of how to set the
timer for the second pressure range.
Note
The values show n are examples only. The values used
in your unit may be diff erent.
6.1.3 Dryer pre-run
If you are using an external dryer, you can provide the
dryer w ith a specified pre-run time. The compressor is
then only started af ter this pre-run time.
To set the pre-run time, please go to the
[CONTROL MENU ]sub-menu. From there use the 

key to go to the DRYER PRE-RUN 0min menu item.
Once you have pressed the key, the 0min value
starts to flash. You can now use the 
or  keys to
set the pre-run time you w ant. Then confirm your entry
using the key.
6.1.4 RS 485 communication
You can perform the settings for RS 485
communication in the [CONTROL MENU ]sub-menu.
The
RS485-PROTOCOL ModBus
RS485-BAUDRATE 19200
RS485-ADDRESS 1
menu items are of relevance.
The GD Pilot has a serial RS485 interf ace. This
interf ace uses the ModBus RTU protocol.
ModBus interfaces and drivers are available from many
of the w ell-know n manufacturers of programmable logic
controllers (PLC).
You can set the baud rate you w ant in the RS485-
BAUDRATE menu item.
You can set the participant number you w ant in the
RS485-ADDRESS menu item.
Note
The values show n are examples only. The values used
in your unit may be diff erent.

6. Extended functions
13
6.1.5 Automatic re-start
Warning
In this operating mode, the compressor may
start automatically at any time and after an
unlimited length of power loss.
Always fit the compressor with warning
signs, lock the room containing the
compressor and instruct your staff.
Fit the main switch specified by EN60204 -
and fit the appropriate warning signs on it.
Af ter a pow er loss that has not exceeded the preset
time, the unit can re-start automatically.
The settings needed must be undertaken in the
[CONTROL MENU ] sub-menu. The relevant menu
items are:
AUTO RESTART OFF
POWER LOSS TIME Xs
START-UP DELAY Xs
Use the AUTO RESTART ON menu item to activate the
automatic re-start.
You can state the time for w hich a pow er loss may last
and after w hich the compressor is to automatically start
up in the POWER LOSS TIME menu item. The time can
be set w ithin a period of 3 - 999 seconds. If the pow er
loss lasts longer than the time you have set, the unit
does not automatically re-start. The POWER LOSS. fault
message then appears on the display
You can also program a start-up delay of 1 – 60 seconds.
This is set in the START-UP DELAY menu item and
ensures a staggered start-up if the unit features several
compressors. This in turn ensures that the pow er supply
is not loaded unnecessarily.
6.1.6 Unlimited autom. re-start after
power loss
The control system can perform an automatic re-start
after any pow er loss period.
For this to be done, you must have read the follow ing
safety notices and submit the approval for the unlimited
automatic re-start by entering a code.
Please request the required code from Gardner Denver
customer service.
Warning
In this operating mode, the compressor may
start automatically at any time and after an
unlimited length of power loss. Check the
safety notices (e.g. EN1012-1, EN60204) that
apply in your country to find out whether
you can run an unlimited autom. re-start and
what safety precautions must be taken.
Always fit the compressor with warning
signs, lock the room containing the
compressor and instruct your staff.
Fit the main switch specified by EN60204 -
and fit the appropriate warning signs on it.
To approve the unlimited automatic restart, proceed as
f ollow s :
1. Press the key for 5 seconds.
2. Use the 
or  keys to enter the code
3. Press the key to transfer the set code
Af ter approval, the menu item for the max. pow er loss
time can also be programmed to [POWER LOSS TIME –
s]. This is the setting for an unlimited automatic re-
start.
If you re-enter the code, you cancel the approval.
Note
You w ill f ind more details about the code in section 6.6

6. Extended functions
14
6.2 [ F AULT MEMORY] sub-menu
Warning messages and f aults are stored in the fault
memory. The last w arning message or fault recorded is
alw ays at the top. In order to distinguish betw een faults
and w arning messages, f aults are marked w ith a !.
You can use 
or  to sw itch betw een the individual
memory areas in the fault memory.
The faults are displayed as follow s:
03! EM-STOP 000100h
a) b) c) d)
a) The same fault has occurred three times.
b) This relates to a fault.
c) Fault has occurred as a result of the emergency of f
button being pressed.
d) Fault occurred at 100 running hours.
03 HIGH TEMP 000100h
a) b) c)
a) The same w arning has occurred three times.
b) Warning resulting from final compression
temperature being too high
c) Warning occurred at 100 running hours.
The last eight w arning messages or f aults recorded are
displayed in the f ault memory. All messages/faults
occurring before that are how ever retained in the long-
term memory. The f requency w ith w hich a w arning or
fault occurs is therefore alw ays recorded.
How ever you can access more detailed information on
w arning messages and f aults that have been recorded -
in the f ault memory. The follow ing are saved for every
w arning message/f ault recorded:
- time and date
- compressor status (e.g. on-load)
- speed
- final compression temperature, final compression
pressure and line pressure
When accessed, these values flash to clearly show
that they are not the current display values.
To access this information please use 
or  to go to
the w arning message or fault that you are interested in
in the f ault memory.
The information set out above relating to the status of
the compressor at the time of the fault can be called up
in turn by pressing the button several times.
6.3 [ TIM ER CONTROL ] sub-me nu
Warning
When programming in standby, the machine
may start up at any time.
The timer allow s you to sw itch the machine on and off
at permanently set (programmed) times. You can also
change over the pressure level (e.g. night-time
low ering).
6.3.1 Setting for timer units
You w ill have already set the time and date as
described in section 3.3. This setting serves as the
basis for accurate timer operations. If you have not yet
set the time and date, please do so now .
Please go to the [TIMER CONTROL ]sub-menu w here
you can use 
or  to select from seven different -
timer units. The status line of each sw itching unit is as
f ollow s :
a) b) c) d)
1 _______ 00:00 00:00
a) Unit no.
b) Days of the w eek [SMTWTFS] = Sunday, Monday ..
c) Sw itch-in point
d) Sw itch-out point
If there are no days of the w eek selected in the
sw itching unit line, the sw itching unit is not active. The
sw itching unit only becomes active w hen the day of the
week is set. When the is pressed, the f irst
underscore _ starts to flash. You can now use the 

key to set the first day of the w eek (Sunday). Then use
the key to confirm the day of the w eek. The next
underscore _ then starts to flash. If you do not w ant to
confirm a day of the w eek as set, please immediately
press . You can run through all seven days of the
w eek in this w ay. Once you have confirmed the last day
of the w eek (Saturday), the first unit of the sw itch-in -
point starts to f lash. You can either set this using 
or

.

6. Extended functions
15
Once the last unit of the sw itch-out point has been
confirmed, the w hole timer unit is activated.
The next step is to go to the [CONTROL MENU ]sub-
menu and then the TIMER CONTROL menu item. You
w ill now see the default setting TIMER CONTROL OFF.
If you press the key, the OFF value starts to flash.
You can now use the 
key to change the value to ON
. Then please press the key again to confirm the
entry. The timer is now sw itched on.
To improve your understanding of this function, the
timer unit setting is explained below using various
examples.
Exam ple 1:
Sw itching unit 1 not active:
1 _______ 00:00 00:00
Exam ple 2:
The unit should run Monday to Friday betw een 7.30 am
and 4.15 pm.
2 _MTWTF_ 07:30 16:15
a) b) c)
a) Days of the w eek Monday to Friday
b) Sw itch-in point
c) Sw itch-off point
Exam ple 3:
The unit is to run from Sunday 10 pm through
continuously to Saturday 2 pm. How ever during the
daily break (12 midday to 12.30 pm), the unit is to be
shut dow n.
You w ill now have to use various sw itching units. The
follow ing settings w ould be needed in this case:
1 S______ 22:00 00:00 a)
2 _MTWTFS 00:00 12:00 b)
3 _MTWTF_ 12:30 00:00 c)
4 ______S 12:30 14:00 d)
5 _______ 00:00 00:00
6 _______ 00:00 00:00
7 _______ 00:00 00:00
a) Start of operating period
b) Operating period up until lunch break
c) Start of operation after lunch break
d) End of operating period
6.3.2 Pressure changeover setting
Please go to the [TIMER CONTROL ]sub-menu. There
you can use 
or  to select betw een various t ime r
units. The timer units of the 2nd (p2) pressure range are
in the menu under the normal timer units.
CUT-OUT POINT
TARGET PR ESSU RE p2 CUT-OUT p2 TARGET PRESSURE
p2 TIMER CONTROL
ON-LOA D
Fig. 2 Pressure changeover block diagram
Seven timer units are again available here for the
setting (programming). The values that you have set for
the second pressure range supersede the values for
CUT-OUT POINT and TARGET PRESSURE as soon as a
sw itching unit is active. The 1st row on the display then
show s the p2symbol behind the line pressure. If the
sw itching unit becomes inactive, the values for CUT-
OUT POINT and TARGET PRESSURE are again used.
The status line of each sw itching unit is as follow s:
a) b) c) d) e)
p21 _______ 00:00 00:00
a) 2nd pressure range
b) Unit no.
c) Days of the w eek [SMTWTFS] = Sunday, Monday...
d) Sw itch-in point
e) Sw itch-out point

6. Extended functions
16
When the is pressed, the first underscore _ starts to
flash. You can now use the 
key to set the first day of
the w eek (Sunday). Then use the key to confirm the
day of the w eek. The next underscore _ now flashes. If
you do not w ant to confirm a day of the w eek as set,
immediately press . You can run through all seven
days of the w eek in this w ay. Once you have confirmed
the last day of the w eek (Saturday), the first unit of the
sw itch-in point starts to flash. You can either set this
using 
or  . Once the last unit of the sw itch-out
point has been confirmed, the w hole sw itching unit is
activated.
Go to the [CONTROL MENU ]sub-menu and then the
p2TIMER CONTROL menu item. You w ill now see the
p2TIMER CONTROL OFF default setting. If you press the
key, the OFF value starts to f lash. You can now use
the 
key to change the value to ON. Then please
press the key again to confirm the entry. The timer is
now sw itched on for the second pressure range. Please
refer to section 6.1.2 for how to set the parameters for
the 2nd pressure range.
6.4 [Limit values] sub-menu
In the sub-menu [LIMIT VALUES ]are the factory-s et
and changeable parameters. These represent:
a) DESIGN PRESS 13.0bar
b) START ProTECT 0.8bar
c) EXT. LIMIT MAX. 2500RPM
c) EXT. LIMIT MIN. 800RPM
d) FINAL TEMP WARN 110°C
e) FINAL TEMP MAX 120°C
f) MIN START TEMP 1°C
g) RUN-ON TIME 90s
h) SOFT STOP 30s
i) VOL.MAX. 2.8m3/min
j) VOL.MIN. 1.0m3/min
k) SOFTWARE: DPro-LRS-1.09
Note
The values show n are examples only. The limit values
in your unit may be diff erent.
a) This is your unit's operating pressure. This is also
stamped on the compressor's name plate.
b) To protect the compressor stage, the compressor
only starts up w hen the compressor's internal
pressure is less than or equal to the set value. If the
compressor's internal pressure is higher w hen
starting up, the follow ing appears in the display's
third row :
WARNING START AFTER ...
alternating w ith
... DE-PRESSURISE
c) If an input is programmed on the f unction [EXT.
RPM LIMIT ]and its contact is closed, the speed of
the plant w ill be restricted to the values (max. and
min.) s et here.
d) If the f inal compression temperature reaches
110 °C, WARNING HIGH TEMP appears in the
display's third row .
e) If the f inal compression temperature reaches
120 °C, the compressor shuts dow n. FAULT
COMP TEMP then appears in the third row on the
display
f) If the final compression temperature is below 1 °C,
you cannot start the machine.
g) If the compressor is in automatic mode and there is
no line pressure requirement, the OFF-LOAD xxs
indication appears and the machine goes into off -
load.
Af ter the run-on time, the compressor automatically
shuts dow n and is ready to start again.
h) In order to protect the compressor stage, once the

key (shut dow n system) has been pressed, the
compressor is only sw itched off 30 seconds later.
If using the timer or the remote start / stop function,
the run-on time is also used.
i) The maximum volume flow that may be adjusted in
relation to the compressor is displayed here.
j) The minimum volume flow that may be adjusted in
relation to the compressor is displayed here
k) You can find the softw are currently loaded on your
unit here.

6. Extended functions
17
6.5 [OPTIONAL IN-/OUTPUTS] sub-menu
6.5.1 Inputs
Important
Only potential-free contacts m ay be connected to
the term inal strip. External voltages w ill destroy the
GD Pilot.
The potential-free contacts m ust not be more than
20 m etres aw ay from the terminal strip. If neces sary
coupling relays must be fitted in the control
cabinet.
The GD Pilot has five programmable inputs. These
inputs can be assigned (programmed) various
functions. The various f unctions are listed below . Each
input can be programmed w ith each function.
You can also f ind an overview of inputs and
corresoponding functions in the circuit diagram of the
machine.
The inputs are programmed in the [OPTIONAL IN-
/OUTPUTS] sub-menu. Please go to the
[OPTIONAL IN-/OUTPUTS] sub-menu. Then go to the

INPUT 1: FREE menu item.
If you press the key, the function starts to flash. By
pressing the 
or  key, you can now change the
function. Once you have set the function you w ant, this
has to be conf irmed using the key. The input is now
programmed.
You access all other programmable inputs by pressing
the 
or  key.
Explanation of functions:
FREE
Input is not assigned (programmed).
EXT FAULT
If the contact is opened, the EXT FAULT fault message
appears on the display and the unit is shut dow n
(shutting dow n is delayed by 1sec.).
EXT WARNING
If the contact is opened, the EXT WARNING w arning
message appears on the display (the indication is
delayed by 1sec.). This function does not result in the
unit shutting dow n.
DRYER FAULT
If the contact is opened, the DRYER FAULT fault
message appears on the display and the unit is shut
dow n (shutting dow n is delayed by 1sec.).
DRYER WARNING
If the contact is opened, the DRYER WARNING w arning
message appears on the display (the indication is
delayed by 1 sec.). This function does not result in the
unit shutting dow n.
BEKOMAT FAULT
If the line pressure is ≥1.0 bar and the contact is
opened for at least 250sec., BEKOMAT FAULT appears
on the display. This f unction results in the unit shutting
dow n.
BEKOMAT WARN.
If the line pressure is ≥1.0bar and the contact is
opened for at least 250sec., BEKOMAT WARN. appears
on the display. This f unction does not result in the unit
shutting dow n.
Ext. speed restriction (EXT. RPM LIMIT)
When the contact is closed the speed of the
compressor is restricted to the max. and min. set
speeds in the menu [LIMIT VALUES] in menu item
EXT. LIMIT.
RTC OVERRIDE
The timer can be overridden using this input.
Example: The compressor has been shut dow n by the
timer. If the contact is now closed, the compressor
starts up.
2nd PR. RANGE (2nd pressure range)
If the contact is closed, the system changes over to the
second pressure range. Also refer to section 6.1.2.
ENAB.REM-START (enable r e mo te -s tar t )
For use, see section 6.8.3.
OPERATE_B1 (Enable B1)
For use, see section 6.8.2.
6.5.2 Outputs
Important
The maximum connected loads for the programmable
outputs (relay contacts) are 4,5A / 240V.
The GD Pilot has four programmable outputs. Output 1
is a relay w ith changeover contact and output 2..4 are
relays w ith NO contact. You can assign (program)
various f unctions to the outputs.
The outputs are programmed in the [OPTIONAL IN-
/OUTPUTS] sub-menu. Please go to the
[OPTIONAL IN-/OUTPUTS] sub-menu. Then go to the

OUTPUT 1: FAULT menu item
If you press the key, the function starts to flash. By
pressing the 
or 
key, you can now change the
function. Once you have set the function you w ant, this
has to be conf irmed using the key. The output is now
programmed.
You access the other programmable output by pressing
the 
key.

6. Extended functions
18
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
w ith any of the functions listed below . You can also f ind
an overview of outputs and corresoponding functions in
the circuit diagram of the machine.
Explanation of functions:
OFF
Output is not programmed.
OPERATING
The output (relay) is activated w hen the compressor's
motor is sw itched on or w hen the compressor is ready.
ON-LOAD
The output (relay) is activated w hen the compressor is
in on-load.
OFF-LOAD
The output (relay) is activated w hen the compressor is
in of f-load.
FAULT
The output (relay) is activated w hen there are no faults
on the compressor.
WARNING
The output (relay) is activated w hen there are no
w arnings on the compressor.
Maintenance elapsed MAINT. ELAPSED
The output (relay) is activated w hen there are no
maintenance messages on the compressor.
Warning/Mainenance WARNING/MAINT.
The output (relay) is activated w hen there are no
w arnings and no maintenance messages on the
compressor.
Warning/Mainenance/Fault WARN/MA/FAULT
The output (relay) is activated w hen there are no
w arnings, no maintenance messages and no faults on
the compressor.
REM.STARTABLE
The output (relay) is activated w hen the compressor is
ready for the remote start.
RUNNING
The output (relay) is activated w hen the compressor's
motor is running (is sw itched on).
2nd PR. RANGE
The output (relay) is activated w hen the 2nd pressure
range is applicable.
TIMER
The output (relay) is activated w hen the compressor is
sw itched on by the internal timer.
6.6 Locking / unlocking code
Settings (sub-menus) can be locked using a code to
prevent unauthorised programming.
Limit values cannot be changed by the operator.
Locking
If the code is to be locked, this is done using the key.
Please press this key f or 5 seconds. The follow ing
message then appears on the display:
CODE: UNLOCK (for 1 second)
CODE INPUT 0000 (0000 value f lashes)
If the code: 3022 is entered, the follow ing message
appears:
CODE: LOCK (for 1 second)
The sub-menus are now locked and cannot be
changed.
If the w rong code is entered, the follow ing message
appears:
CODE: UNLOCK (for 1 second)
The display then automatically jumps back to w here it
started from.
Unlocking
If the code is to be unlocked again, this either done by:
*pressing (for 5 seconds) the key w hen not in the
menu or
*attempting to change a protected value in a sub-
menu.
The code prompt then appears:
CODE: LOCK (for 1 second)
CODE INPUT 0000 (0000 value f lashes)
Here you must enter the code: 3022.
If the code is entered correctly, the follow ing message
appears:
CODE: UNLOCK (for 1 second)
If the code is entered incorrectly, the follow ing message
appears:
CODE: LOCK (for 1 second)
The display then automatically jumps back to w here it
started from.

6. Extended functions
19
6.7 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 f ind the setup codes on a sticker (see Fig. 3) in
the compressor sw itch panel (see Fig. 4). You can now
use the 
or 
keys to enter the first setup code.
Please conf irm your entry using the key. The w hole
process now has to be repeated tw ice for codes 2 and
3.
If you have entered a code incorrectly, the indication
immediately jumps back to code 1. You then have to re-
enter all three codes.
If you have correctly entered the codes, the machine
w ill have automatically been sw itched to its delivery
status.
The language has now been reset to English. If you
need a dif ferent language, please set this as described
in section 3.1.
You now have to set the maximum line pressure and
the target pressure. You w ill f ind the precise description
for this process in the Default settings section.
You then have to repeat the individual programming for
the inputs and outputs. Consult your compressor's
circuit diagram f or this. It contains information about
how the inputs and outputs w ere programmed.
The Menu section [Option. inputs/outputs]
contains an accurate description of how to program
inputs and outputs.
Fig. 3 Setup code sticker
Sticker
Fig. 4 Compressor w ith open sw itch panel