Gardner Denver GD Pilot Product information sheet

GB Id. no. ZS1090606 / 01 -June 2014
1
Original User Manual
GD Pilot
Electronics for speed-controlled
stationary rotary screw compressor
VS 7 -VS 22

1
Attention:
Risk of electric shock from charged capacitors!
Always disconnect the system from the power supply
and then wait a further 10 minutes before touching
electrical components. The power capacitors take this
time to discharge.
Check the DC bus voltage at the system terminal strip
of the frequency converter by measuring this between
the +DC and -DC terminals (the exact position can
be found in the supplied operating manual of the
frequency converter), between the +DC terminal and
the chassis as well as between the -DC terminal and
the chassis. The voltage must read zero in the case
of all three measurements.
Basis: German manual ZS1090605 / 01
Valid as of software version DPro-LRS-1.xx
We reserve the right to modifications relating to
technical advances.

Contents
2
Contents
1Operator controls / arrangement ...................................................................................................................................... 3
1.1 Keys .............................................................................................................................................................................. 3
1.2 Status indicator (display / light signals)....................................................................................................................... 3
1.2.1 Speed indicator in the display .......................................................................................................................... 4
1.2.2 Status messages in display.............................................................................................................................. 4
1.3 Menu structure (values are examples)........................................................................................................................ 6
1.4 Displaying / changing values ....................................................................................................................................... 7
1.4.1 Selecting values................................................................................................................................................ 7
1.4.2 Changing values............................................................................................................................................... 7
2Default settings.................................................................................................................................................................... 8
2.1 Selecting language....................................................................................................................................................... 8
2.2 Setting line pressure..................................................................................................................................................... 8
2.3 Setting time/date (timer)............................................................................................................................................... 8
3Operations............................................................................................................................................................................ 9
3.1 Starting the unit ............................................................................................................................................................ 9
3.2 Emergency off button ................................................................................................................................................... 9
3.3 Switching off the unit .................................................................................................................................................... 9
3.4 On-load/off-load ............................................................................................................................................................ 9
3.5 Acknowledging warning/fault messages ..................................................................................................................... 9
3.5.1 Warning messages........................................................................................................................................... 9
3.5.2 Fault messages ................................................................................................................................................ 9
4Maintenance ([MAINTENANCE SCHED.] sub-menu) ................................................................................................... 10
4.1 Maintenance ............................................................................................................................................................... 10
4.2 Programming maintenance intervals......................................................................................................................... 10
4.3 Total/load hours counter ............................................................................................................................................ 10
5Extended functions........................................................................................................................................................... 11
5.1 [ CONTROL MENU ] sub-menu ............................................................................................................................... 11
5.1.1Operating modes ............................................................................................................................................ 11
5.1.2 Second pressure range (p2)........................................................................................................................... 11
5.1.3 Dryer pre-run................................................................................................................................................... 11
5.1.4 RS 485 communication .................................................................................................................................. 11
5.1.5 Automatic re-start ........................................................................................................................................... 12
5.1.6 Unlimited autom. re-start after power loss .................................................................................................... 12
5.2 [ FAULT MEMORY ] sub-menu .................................................................................................................................13
5.3 [ TIMER CONTROL ] sub-menu................................................................................................................................ 13
5.3.1 Setting for timer units...................................................................................................................................... 13
5.3.2 Pressure changeover setting ......................................................................................................................... 14
5.4 [Limit values] sub-menu ............................................................................................................................................. 15
5.5 [OPTIONAL IN-/OUTPUTS] sub-menu ..................................................................................................................... 16
5.5.1 Inputs............................................................................................................................................................... 16
5.5.2 Outputs............................................................................................................................................................ 16
5.6 Locking / unlocking code............................................................................................................................................ 17
5.7 Replacing the GD Pilot (SETUP-CODE)................................................................................................................... 18
5.8 Remote control ........................................................................................................................................................... 19
5.8.1 Remote control for pressure changeover...................................................................................................... 19
5.8.2 Enabling on-load operation ............................................................................................................................ 19
5.8.3 Remote start / stop ......................................................................................................................................... 20
6Error rectification .............................................................................................................................................................. 21
6.1 Safety regulations....................................................................................................................................................... 21
6.2 Warnings ..................................................................................................................................................................... 21
6.3 Faults........................................................................................................................................................................... 21
6.4 Checklist...................................................................................................................................................................... 21
6.5 Table of faults / warnings ........................................................................................................................................... 21

1. Operator controls / arrangement
3
1 Operator c on trols / arr an geme nt
1st row / 2nd row / 3rd row
1.1 Keys

ISwitch on unit

Switch 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


Switch to next sub-menu / menu item,
or reduce a value


Switch to previous sub-menu / menu item,
or increase a value
Acknowledgement key,
if you are in a menu / sub-menu, the
acknowledgement key functions as an
Enter key [↵].
1.2 Status indicator (display / light
signals)
The control system is fitted with a three-row display.
1st row:
The final compression temperature, final compression -
pressure and line pressure are permanently displayed
here.
Final compression temperature: is the temperature
measured downstream of the compressor stage.
Final compression pressure: is the pressure measured
downstream of the compressor stage.
Line pressure: is the pressure within the system
connected downstream of the compressor.
The following symbols may also be used in the 1st row:
p2 Second pressure range
Remote start / stop activated
2nd row:
The second row shows the current engine speed.
The operating menus are also displayed there.
For this the speed display is faded out.
3rd row:
The third row shows status, fault and warning -
messages.
Light signals
The GD Pilot is fitted with two light signals (red, green).
Red light signal:
Flashing slowly: warning, maintenance due
Flashing rapidly: fault, unit is stopped until fault has
been rectified
The red light signal only goes out once the warning 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 RUNNING 4711h
ON-LOAD

1. Operator controls / arrangement
4
1.2.1 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:
[ _________❚___ ] 3290rpm
Speed in controlled range.
[ ❚____________ ] 1300rpm
Speed in lower controlled range,
minimum speed not yet reached.
[ |___________ ] 1280rpm
Minimum speed reached.
[ ___________| ] 3650rpm
Maximum speed reached.
1.2.2 Status messages in display
The status messages are shown 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 switched
on. The control system is being initialised and is setting
up communication to the frequency converter (VSD).
READY TO START
The unit is ready to start and can be switched on
(see section 3.1).
WARNING START WITH ...
alternating with
... PRESSURE REQUIREMENT
The unit has been switched on and is ready. The unit
starts automatically following the pressure requirement
from your system.
WARNING START AFTER ...
alternating with
... DE-PRESSURISE
The unit has been switched on and is ready. However
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 with
... TIMER CONTROL
The unit has been switched on and is ready. The
compressor is now waiting for start approval from the
timer (see section 5.3)
WARNING START BY ...
alternating with
... REMOTE OPERATION
The unit has been switched on and is ready. Remote
unit operations have been activated in the control menu.
The unit starts via a remote signal (see section 5.8).
WARNING START IN xxs
alternating with
... AFTER POWER LOSS
A power loss has caused the unit to shut down. The
'automatic restart' function has been selected in the
control menu. The unit now starts automatically after a
previously set time (see section 5.1.5)
WARNING START IN
alternating with
... AFTER DRYER PRE-RUN
The unit has been switched on and is ready. The unit
starts automatically after the dryer pre-run (see section
5.1.3).
MOTOR START PHASE
The unit has been switched on and the motor is starting

1. Operator controls / arrangement
5
ON-LOAD 2.8 m3/min
Machine is running on-load. The delivery rate is
2.8 m3/min (see section 3.4).
ON-LOAD 170 m3/h
Machine is running on-load. The delivery rate is
170 m3/h (see section 3.4).
OFF-LOAD
Machine is running off-load (see section 3.4).
OFF-LOAD XXs
Machine is running off-load and will shut down in
XX seconds (see section 3.4).
SOFT STOP TIME in xxs
The system has been switched off. The unit stops after
the soft-stop time of xx seconds.
FAULT: <fault text>
The unit has been shut down due to a fault. You will
find explanations of the fault texts in section 6.
WARNING <warning text>
There is a warning in place. Ignoring a warning may
result in a fault and shut down the compressor. You will
find explanations of the warning texts in section 6.
MAINTENANCE ELAPSED
A maintenance interval is about to lapse or has already
done so, you will find more details in section 4.

1. Operator controls / arrangement
6
1.3 Menu structure (values are examples)

+

INPUT 1: FREE
:
OUTPUT 4 OFF
DESIGN PRESS 13.0bar
START PROTECT 0.8bar
EXT. LIMIT 3650RPM
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-1.00
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









+


+














+










+










+






+






1. Operator controls / arrangement
7
1.4 Displaying / changing values
1.4.1 Selecting values
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 switch between the
following 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.
1.4.2 Changing values
Enter the sub-menu and then the menu item containing
the value you wish 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.

2. Default settings
8
2 Defaultset tin gs
2.1 Selecting language
You can change the language by pressing the + 

or + 
keys. Press these keys at the same time until
the right language appears.
2.2 Setting line pressure
Speed is controlled with the aid of a PI controller
implemented in the software and is matched to the
demand for compressed air. In the [CONTROL MENU ]
menu you have to set the maximum line pressure
switching point (CUT-OUT POINT) and the TARGET
PRESSURE.
When the maximum line pressure switching point is
reached, the machine switches to off-load.
In the range between TARGET PRESSURE and CUT-
OUT POINT the speed of the machine is regulated
according to the compressed air requirement.
Example:
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
switches 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 switch 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 whether 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 wear, the difference
between 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-LOAD
Fig. 1 Block diagram
2.3 Setting time/date (timer)
The GD Pilot accumulator can bridge a loss of power -
lasting between around two to three weeks. If power 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
following format:
TU 30.10.07 12:10:34
If you press the key, the left-hand value (day of the
week) 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
twice pressing the 
+
keys at the same time.

3. Operations
9
3 Operatio ns
3.1 Starting the unit
Danger
If the unit is ready, i.e. the green LED is flashing,
the compressor may automatically start at any time.
Use the main switch to switch the unit on.
If warning 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.
3.2 Emergency off button
The EMERGENCY-stop button is situated next to the
GD Pilot. It is used to immediately shut down the unit.
Only use the emergency off button to shut down the
unit in emergencies. When shutting down normally,
always use the 
key.
3.3 Switching off the unit
The unit is switched off by pressing the 
key on the
GD Pilot. However the unit will only stop after a 30-
second soft-stop.
The soft-stop is preset to protect the compressor.
Note
The unit may only be shut down using the emergency
off button in real emergencies. When shutting down
normally, please use the 
key.
3.4 On-load/off-load
Descriptions of the CONTINUOUS OPERATION and
AUTOMATIC OPERATION modes can be found in
section 5.1.1.
OFF-LOAD:
If there is no line pressure requirement from the
compressed air system and the unit is in
CONTINUOUS OPERATION, it switches 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 switches to OFF-LOAD. The unit is switched
off after a run-on time that is shown on the display. If there
is another pressure requirement during the run-on time,
the unit is automatically switched on.
ON-LOAD:
If the unit is in ON-LOAD, air is pumped into the
compressed air system.
3.5 Acknowledging warning/fault
messages
Warning and fault messages are shown in the third row
of the display. The red light signal flashes at the same
time.
You will find a table containing the messages and -
suggestions for how to remedy them in section 6.5.
3.5.1 Warning messages
When there are warnings, the red light signal flashes
slowly. The unit does not automatically shut down when
there are warnings. However ignored warnings may
cause faults.
Rectify what is causing the warning and press the
key to hide the warning.
3.5.2 Fault messages
Fault messages result in the unit automatically shutting
down or do not permit the unit to be started.
Once you have rectified the problem, you still have to
confirm by pressing the key.

4. Maintenance ([MAINTENANCE SCHED.] sub-menu)
10
4 Main te na nce ([ MA INTE NA NCE SCHED.] sub-menu)
4.1 Maintenance
The maintenance intervals are preset when the
compressor is supplied. You will find more information
in the unit's overall operating instructions.
It may however be necessary for 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 allows the operator to program various
maintenance intervals (see section 4.2).
If there is a maintenance interval at 200h (hours), the
compressor is not automatically shut down. The
MAINTENANCE ELAPSED message appears on the
display.
If you want the compressor to automatically shut
down when 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 down when
the –100h maintenance interval is displayed.
Once maintenance has been carried out, the
maintenance interval should be reprogrammed. The
maintenance message can be acknowledged using the
key.
4.2 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 with the key.
If you do not want 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 shown are examples only. The values used
in your unit may be different.
4.3 Total/load hours counter
You will find 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 which your
unit has been in on-load and off-load.
The load hours counter states the time for which your
unit has been in on-load.
Note
The total and load hours are lost when the GD Pilot is
replaced.

5. Extended functions
11
5 Extendedf unctions
5.1 [ CONTROL MENU ] sub-menu
The most important parameters of the [CONTROL MENU ]
menu have already been explained in section 2Default
settings. This section simply contains an overview and
explanation of additional (extended) functions.
5.1.1 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
switch to CONTINUOUS OPERATION. Confirm a set
value by pressing the key.
You can choose from two 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 down after the RUN-ON TIME. The control system
automatically recognises when compressed air is
needed again. The unit then starts up straight away.
CONTINUOUS OPERATION
CONTINUOUS OPERATION is only needed for some
special applications. When in this operating mode, the
motor is not shut down if there is no longer any need for
pressure. The compressor stage now runs continually
in off-mode when there is no need for pressure.
5.1.2 Second pressure range (p2)
The range between the maximum pressure and the
target pressure is called the pressure range. The
second pressure range function allows you to use
another pressure range in addition to the pressure
range already set (see section 2.2). This could be used
to for example implement night-time lowering.
You will find 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 switching 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 5.5).
Section 5.3.2 contains a description of how to set the
timer for the second pressure range.
Note
The values shown are examples only. The values used
in your unit may be different.
5.1.3 Dryer pre-run
If you are using an external dryer, you can provide the
dryer with a specified pre-run time. The compressor is
then only started after 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 want. Then confirm your entry
using the key.
5.1.4 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 interface. This
interface uses the ModBus RTU protocol.
ModBus interfaces and drivers are available from many
of the well-known manufacturers of programmable logic
controllers (PLC).
You can set the baud rate you want in the RS485-
BAUDRATE menu item.
You can set the participant number you want in the
RS485-ADDRESS menu item.
Note
The values shown are examples only. The values used
in your unit may be different.

5. Extended functions
12
5.1.5 Automatic re-start
Danger
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.
After a power 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 which a power loss may last
and after which the compressor is to automatically start
up in the POWER LOSS TIME menu item. The time can
be set within a period of 3 -999 seconds. If the power
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 power supply
is not loaded unnecessarily.
5.1.6 Unlimited autom. re-start after
power loss
The control system can perform an automatic re-start
after any power loss period.
For this to be done, you must have read the following
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.
Danger
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
follows:
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
After approval, the menu item for the max. power 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 will find more details about the code in section 5.6

5. Extended functions
13
5.2 [ FAULT MEMORY ] sub-menu
Warning messages and faults are stored in the fault
memory. The last warning message or fault recorded is
always at the top. In order to distinguish between faults
and warning messages, faults are marked with a !.
You can use 
or 
to switch between the individual
memory areas in the fault memory.
The faults are displayed as follows:
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 off
button being pressed.
d) Fault occurred at 100 running hours.
03 HIGH TEMP 000100h
a) b) c)
a) The same warning has occurred three times.
b) Warning resulting from final compression
temperature being too high
c) Warning occurred at 100 running hours.
The last eight warning messages or faults recorded are
displayed in the fault memory. All messages/faults
occurring before that are however retained in the long-
term memory. The frequency with which a warning or
fault occurs is therefore always recorded.
However you can access more detailed information on
warning messages and faults that have been recorded -
in the fault memory. The following are saved for every
warning message/fault 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 warning message or fault that you are interested in
in the fault 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.
5.3 [ TIMER CONTROL ] sub-menu
Danger
When programming in standby, the machine may
start up at any time.
The timer allows you to switch the machine on and off
at permanently set (programmed) times. You can also
change over the pressure level (e.g. night-time
lowering).
5.3.1 Setting for timer units
You will have already set the time and date as
described in section 2.3. 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
where you can use 
or 
to select from seven
different timer units. The status line of each switching
unit is as follows:
a) b) c) d)
1 _______ 00:00 00:00
a) Unit no.
b) Days of the week [SMTWTFS] = Sunday, Monday ..
c) Switch-in point
d) Switch-out point
If there are no days of the week selected in the
switching unit line, the switching unit is not active. The
switching unit only becomes active when the day of the
week is set. When the is pressed, the first
underscore _ starts to flash. You can now use the 

key to set the first day of the week (Sunday). Then use
the key to confirm the day of the week. The next
underscore _ then starts to flash. If you do not want to
confirm a day of the week as set, please immediately
press . You can run through all seven days of the
week in this way. Once you have confirmed the last day
of the week (Saturday), the first unit of the switch-in -
point starts to flash. You can either set this using 
or

.

5. Extended functions
14
Once the last unit of the switch-out point has been
confirmed, the whole timer unit is activated.
The next step is to go to the [CONTROL MENU ]sub-
menu and then the TIMER CONTROL menu item. You
will 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 switched on.
To improve your understanding of this function, the
timer unit setting is explained below using various
examples.
Example 1:
Switching unit 1 not active:
1 _______ 00:00 00:00
Example 2:
The unit should run Monday to Friday between 7.30 am
and 4.15 pm.
2 _MTWTF_ 07:30 16:15
a) b) c)
a) Days of the week Monday to Friday
b) Switch-in point
c) Switch-off point
Example 3:
The unit is to run from Sunday 10 pm through
continuously to Saturday 2 pm. However during the
daily break (12 midday to 12.30 pm), the unit is to be
shut down.
You will now have to use various switching units. The
following settings would 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
5.3.2 Pressure changeover setting
Please go to the [TIMER CONTROL ]sub-menu. There
you can use 
or 
to select between various timer
units. The timer units of the 2nd (p2)pressure range are
in the menu under the normal timer units.
CUT-OUT POINT
TARGET PRESSURE
p2 CUT-OUT
p2 TARGET PRESSURE
p2 TIMER CONTROL
ON-LOAD
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 switching unit is active. The 1st row on the display
then shows the p2symbol behind the line pressure. If
the switching unit becomes inactive, the values for
CUT-OUT POINT and TARGET PRESSURE are again
used.
The status line of each switching unit is as follows:
a) b) c) d) e)
p21 _______ 00:00 00:00
a) 2nd pressure range
b) Unit no.
c) Days of the week [SMTWTFS] = Sunday, Monday...
d) Switch-in point
e) Switch-out point

5. Extended functions
15
When the is pressed, the first underscore _ starts to
flash. You can now use the 
key to set the first day of
the week (Sunday). Then use the key to confirm the
day of the week. The next underscore _ now flashes. If
you do not want to confirm a day of the week as set,
immediately press . You can run through all seven
days of the week in this way. Once you have confirmed
the last day of the week (Saturday), the first unit of the
switch-in point starts to flash. You can either set this
using 
or 
. Once the last unit of the switch-out
point has been confirmed, the whole switching unit is
activated.
Go to the [CONTROL MENU ]sub-menu and then the
p2TIMER CONTROL menu item. You will now see the
p2TIMER CONTROL OFF default setting. 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 switched on for the second pressure range. Please
refer to section 5.1.2 for how to set the parameters for
the 2nd pressure range.
5.4 [Limit values] sub-menu
In the sub-menu [LIMIT VALUES ]are the factory-
set and changeable parameters. These represent:
a) DESIGN PRESS 13.0bar
b) START ProTECT 0.8bar
c) EXT. LIMIT 2500RPM
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-1.00
Note
The values shown are examples only. The limit values
in your unit may be different.
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 when the compressor's internal
pressure is less than or equal to the set value. If the
compressor's internal pressure is higher when
starting up, the following appears in the display's
third row:
WARNING START AFTER ...
alternating with
... DE-PRESSURISE
c) If an input is programmed on the function [EXT.
RPM LIMIT ]and its contact is closed, the speed
of the plant will be restricted to the value set here.
d) If the final compression temperature reaches
110 °C, WARNING HIGH TEMP appears in the
display's third row.
e) If the final compression temperature reaches
120 °C, the compressor shuts down. 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. After the run-on time, the compressor
automatically shuts down and is ready to start
again.
h) In order to protect the compressor stage, once the

key (shut down system) has been pressed, the
compressor is only switched 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 software currently loaded on your
unit here.

5. Extended functions
16
5.5 [OPTIONAL IN-/OUTPUTS] sub-menu
5.5.1 Inputs
Attention
Only potential-free contacts may be connected to
the terminal strip. External voltages will destroy the
GD Pilot.
The potential-free contacts must not be more than
20 metres away from the terminal strip. If necessary
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 functions are listed below. Each
input can be programmed with each function.
You can also find 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 want, this
has to be confirmed 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 down
(shutting down is delayed by 1sec.).
EXT WARNING
If the contact is opened, the EXT WARNING warning
message appears on the display (the indication is
delayed by 1sec.). This function does not result in the
unit shutting down.
DRYER FAULT
If the contact is opened, the DRYER FAULT fault
message appears on the display and the unit is shut
down (shutting down is delayed by 1sec.).
DRYER WARNING
If the contact is opened, the DRYER WARNING warning
message appears on the display (the indication is
delayed by 1 sec.). This function does not result in the
unit shutting down.
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 function results in the unit shutting
down.
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 function does not result in the unit
shutting down.
Ext. speed restriction (EXT. RPM LIMIT)
When the contact is closed the speed of the
compressor is restricted to the set speed 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 down 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 5.1.2.
ENAB.REM-START (enable remote-start)
For use, see section 5.8.3.
OPERATE_B1 (Enable B1)
For use, see section 5.8.2.
5.5.2 Outputs
Attention
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 with changeover contact and output 2..4 are
relays with NO contact. You can assign (program)
various functions 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 want, this
has to be confirmed using the key. The output is now
programmed.
You access the other programmable output by pressing
the 
key.

5. Extended functions
17
When supplied, output 1 is programmed with the
'FAULT' function. The outputs 2..4 are not programmed
upon delivery. Each of the outputs can be programmed
with any of the functions listed below. You can also find
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 when the compressor's
motor is switched on or when the compressor is ready.
ON-LOAD
The output (relay) is activated when the compressor is
in on-load.
OFF-LOAD
The output (relay) is activated when the compressor is
in off-load.
FAULT
The output (relay) is activated when there are no faults
on the compressor.
WARNING
The output (relay) is activated when there are no
warnings on the compressor.
Maintenance elapsed MAINT. ELAPSED
The output (relay) is activated when there are no
maintenance messages on the compressor.
Warning/Mainenance WARNING/MAINT.
The output (relay) is activated when there are no
warnings and no maintenance messages on the
compressor.
Warning/Mainenance/Fault WARN/MA/FAULT
The output (relay) is activated when there are no
warnings, no maintenance messages and no faults on
the compressor.
REM.STARTABLE
The output (relay) is activated when the compressor is
ready for the remote start.
RUNNING
The output (relay) is activated when the compressor's
motor is running (is switched on).
2nd PR. RANGE
The output (relay) is activated when the 2nd pressure
range is applicable.
TIMER
The output (relay) is activated when the compressor is
switched on by the internal timer.
5.6 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 for 5 seconds. The following
message then appears on the display:
CODE: UNLOCK (for 1 second)
CODE INPUT 0000 (0000 value flashes)
If the code: 3022 is entered, the following message
appears:
CODE: LOCK (for 1 second)
The sub-menus are now locked and cannot be
changed.
If the wrong code is entered, the following message
appears:
CODE: UNLOCK (for 1 second)
The display then automatically jumps back to where it
started from.
Unlocking
If the code is to be unlocked again, this either done by:
*pressing (for 5 seconds) the key when 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)
CODEINPUT 0000 (0000 value flashes)
Here you must enter the code: 3022.
If the code is entered correctly, the following message
appears:
CODE: UNLOCK (for 1 second)
If the code is entered incorrectly, the following message
appears:
CODE: LOCK (for 1 second)
The display then automatically jumps back to where it
started from.

5. Extended functions
18
5.7 Replacing the GD Pilot (SETUP-
CODE)
Once the new GD Pilot has been fitted in your
compressor, switch the main switch back on.
The following now appears on the display:
*** GARDNER DENVER ***
SETUP-CODE 1: 0000
You will find the setup codes on a sticker (see Fig. 3) in
the compressor switch panel (see Fig. 4). You can now
use the 
or 
keys to enter the first setup code.
Please confirm your entry using the key. The whole
process now has to be repeated twice 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
will have automatically been switched to its delivery
status.
The language has now been reset to English. If you
need a different language, please set this as described
in section 2.1.
You now have to set the maximum line pressure and
the target pressure. You will find 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 for this. It contains information about
how the inputs and outputs were programmed.
The Menu section [Option. inputs/outputs]
contains an accurate description of how to program
inputs and outputs.
Fig. 3 Setup code sticker
Fig. 4 Compressor with open switch panel
1 Sticker