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.