Gardner Denver AUTO SENTRY-ES+ Service manual

GARDNER DENVER®
13-9-653
Version: 02
April 23, 2002
AUTO SENTRY- ES+ CONTROLS
OPERATING AND
SERVICE MANUAL

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TABLE OF CONTENTS
Index..................................................................................................................................................ii
List Of Illustrations .............................................................................................................................iii
Section 1, Auto Sentry Es+ Controller...................................................................................................1
Section 2, Remote-Mounted Main Motor Starters ................................................................................29
Section 3, Remote Cooling Module Starters........................................................................................31
Section 4, Service And Field Modification ...........................................................................................33

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INDEX
Advisory Troubleshooting Guide....................22
Auto Sentry Es+ Control Display ......................3
Auto Sentry Es+ Controller
Section 1.....................................................1
Auto Sentry Es+ Operation..............................1
Automatic Mode...........................................2
Constant Run Mode.....................................2
Low Demand Mode......................................2
Sequence Mode ..........................................2
Connection To External Controls....................14
Alarm Relay ..............................................14
Remote In/Off............................................14
Serial Communications ..............................14
Wiring Diagrams........................................14
Controls Troubleshooting Guide.....................27
Display Modes..............................................21
Establishing The Initial Sequence...................12
General Description........................................1
Other Control Features....................................9
Auto Restart After Power Failure.................10
Current Limiting.........................................10
Modulating Load/Unload..............................9
Programming And Setup .................................5
Configuration Adjustments ...........................8
Main Adjustments Menu...............................6
Maintenance Adjustments............................7
Operation Adjustments.................................6
Sequence Adjustments................................7
Unit Setup Adjustments................................8
Protective Shutdowns......................................4
Amp Sensor Failure.....................................4
Connection Failure.......................................5
Emergency Stop..........................................4
External Device...........................................4
High Pressure.............................................4
High Temperature........................................4
Low Sump Pressure.....................................4
Motor Protective Devices .............................4
Other Shutdowns.........................................5
Power Failure..............................................4
Separator Differential Pressure.....................4
Remote – Mounted Main Motor Starters .........29
Connection................................................29
Remote Cooling Module Starters ...................31
Connection................................................31
Controls Checkout .....................................32
Controls Connections.................................31
Installation And Wiring...............................31
Section 3...................................................31
Starter.......................................................31
Remote Mounted Main Motor Starters
Controls Checkout .....................................29
Controls Connections.................................29
Installation And Wiring...............................29
Section 2...................................................29
Starter.......................................................29
Sequence System Operation.........................12
Sequenced System Checkout........................12
Automatic Rotation....................................13
Other Sequencing Features........................13
Sequencing Compressors .............................10
Compressor System..................................11
General.....................................................10
Sequencing Installation..............................11
Service Advisories ..........................................3
Service And Field Modification.......................33
Controller Replacement..............................33
Controller Upgrades...................................33
Pc Software...............................................33
Section 4...................................................33
Shutdown Troubleshooting Guide ..................23

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LIST OF ILLUSTRATIONS
Figure 1-1 – Auto Sentry Es+ Display...................................................................................................1
Figure 1-2 – Flow Chart.......................................................................................................................5
Figure 1-3 – Wiring Diagram..............................................................................................................15
Figure 1-4 – Wiring Diagram..............................................................................................................17
Figure 1-5 – Wiring Diagram..............................................................................................................19

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SECTION 1
AUTO SENTRY – ES+ CONTROLLER
GENERAL DESCRIPTION
The Gardner Denver rotary screw compressor isprewired with all controls, motor, and starter for the voltage and
horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply
and to the shop air line (and to the appropriate water supply if water cooled). A standard compressor unit consists of
the compressor, oil reservoir, oil cooling system and filter, motor type as specified, NEMA 12 starter / control box, and
control components as described in the package instruction manual.
This compressor unit features the Auto Sentry ES+ Controller, which integrates all the control functions under
microprocessor control. Its functions include safety and shutdown, compressor regulation, operator control, and
advisory / maintenance indicators. The keypad and display provide the operator with a logical and easily operated
control of the compressor and indication of its condition.
AUTO SENTRY®-ES+ OPERATION
Operation of the controller is dependent on selection of an operating mode (described below) from the controller
keypad. Prior to starting, the [STOP/RESET] key must be pressed to place the controller into its READY state (as
indicated on the display). Compressor operation may then be started by pressing an operating mode key. Once
operating, the mode may be changed at any time by pressing a key, and the selected mode will be displayed in the
lower right corner of the message window. Press the [STOP/RESET] key at any time to stop the compressor under
normal conditions. If the compressor has been running, the reservoir will first be relieved of pressure before stopping
the motor. The display will count down to zero during the normal stop.
WARNING
Automatic restarting or electrical shock can cause injury or death. Open and lock main
disconnect and any other circuits before servicing unit.
If any alternate display is on, press the operating mode key to return to the "normal" display. While operating and
running, the unit may be manually unloaded by pressing and holding the operating mode key. This unloads a running
compressor after several seconds, and will prevent loading while the key is held down. When the key is released, the
control will resume its normal operation as required.
An optional control may be wired into the controller to interrupt and restart the unit based on controls by others.
When stopped by these controls, the display indicates"REMOTE HALT".
In any mode, the compressor will start only if reservoir pressure is below 5 psig. The display will indicate if the control
is waiting for a reservoir blowdown, along with the remaining pressure. The controls also delay initial loading of the
compressor until a startup delay has been completed.
Figure 1-1– AUTO SENTRY ES+ DISPLAY

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Constant run mode operation - This mode is best used in applications where there are no long periods of unloaded
operation, or for minimum response time to sudden demands. The compressor unit will start and run continuously,
using its modulation controls to match delivery to demand.
As demand falls below the compressor capacity, the pressure will rise to thesetpoint of the control. When the
pressure reaches thesetpoint, the controller operates the solenoid valvesTVO (TurnValve open), TVC (TurnValve
close), IVO (inlet valve open) andIVC (inlet valve close) to control the CFM of the compressor to match the CFM
demand of the air system. As the demand changes, the controller will continue adjustment for the best compressor
operation. At moderate to heavy demand, the inlet will be held open, and theTurnValve will control delivery. At
lighter demands, theTurnValve will be fully open, and the inlet valve will control capacity. At very light demand, the
compressor will unload, but will not blow down the reservoir. It will reload just below the set pressure. The controller
will thus maintain the pressure within a few psi of the set pressure.
On compressor units without TurnValve, the controller operates valvesIVO and IVC to position the inlet valve. This
continuously adjusts delivery to match demand.
If the controller is programmed for "load-unload" operation, the controller will deliver full capacity until the system
pressure reaches the set pressure. It will then unload (but not blow down) and will not deliver any air to the system.
When the system pressure falls to halfway between the set and reset pressure the controller again fully loads the
compressor.
When first starting, the controller will keep the compressor fully unloaded and blown down until the system pressure
drops below the reset pressure. Once loaded, the reservoir will remain fully charged, regardless of demand.
Responses to demand are thus immediate, as soon as system pressure drops below thesetpoint.
Low demand mode operation - The low demand mode reduces power consumption by relieving pressure in the
reservoir during unloaded operation. This mode is best used where there is moderate air storage and there are
unloaded periods during the day, but frequent motor starting and stopping is undesirable. During periods of moderate
to high demands, this mode is identical to the constant-run mode described above.
During low demand periods, the controller will open the blowdown valve and fully close the inlet valve to minimize the
motor load. A timer is reset when this occurs. While in this state, control air pressure is supplied from the plant air
system (as are any plant loads). When the system air pressure drops to the reset pressure due to increased
demand, the blowdown valverecloses and the controls resume their normal modulation to maintain the system
pressure near the set pressure.
Subsequent blowdown periods are not allowed until the timer has completed its cycle. This cycle eliminates frequent
blowdowns during moderate loads, and the energy required torepressurize the reservoir. It also eliminates the
problems of oil foaming and carryover that can occur if the oil reservoir of an oil-flooded compressor is blown down
too often. The timer is adjustable from 1 to 20 minutes.
Automatic mode operation - This mode provides automatic start and timed stop, and is best used in applications
with long unloaded periods (e.g. idle shifts or weekends) and adequate storage to allow the compressor to be
stopped for periods of light demands. Operation during periods of moderate to heavy demands are identical to the
lowdemand mode.
The automatic time delay is adjustable from 1 to 20 minutes. If the controller operates unloaded for this period with
no demand, the compressor drive motor is halted to eliminate its power consumption. The controls will remain in this
state until demand is again indicated by a drop in pressure.
This is the most common selected mode of operation, as it automatically will operate the compressor unit in the most
efficient manner for the demand of the air system.
Sequence mode operation - This mode provides for communication between controllers, operating only as many as
are required for economical operation. This is best used on applications with large storage capacity and diverse
loads. The lead unit will operate identically to the automatic mode; operation will be automatically staged for each lag
unit (up to 8 total). For more information, refer to the sequencing instructions later in this chapter.
Communication between controllers is achieved by interconnection of a communications cable to circuit board
connectors. A "unit number" must be assigned to each unit in this mode, but the display will indicate the unit's actual
operating ranking.

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"AUTO SENTRY®-ES+" CONTROL DISPLAY
The display above the keypad is used to provide operating information to the user. If a shutdown has occurred, the
display will indicate the cause.
During normal operation, the display will show the system (plant) pressure, compressor discharge temperature, total
running hours, and operation mode. Alternate displays are available by pressing the keys on the diagram or the [<][>]
keypad keys, and will be identified on the display. These include:
1. Air/oil reservoir pressure
2. Separator differential pressure
3. Air/oil reservoir & separator temperature
4. System discharge pressure
5. Airend discharge temperature
6. Remaining blowdown time
7. Remaining auto time
8. Total runninghourmeter
9. Loaded operationhourmeter
Remaining blowdown andauto times are only available in Low Demand, Automatic, and Sequence modes, as
appropriate.
Service information may also be displayed while the compressor is running. Press the [+][-] keys to display the
following:
1. Main motor current (optional)
2. Est. hours till next recommended oil change
3. Hours till next recommended oil filter change
4. List of any active advisory messages
If no keys are pressed for 5 seconds, the display will revert to its normal mode.
The display is also used as a service reminder for normal maintenance items. If service is recommended, the yellow
advisory light will be on, and a message will alternate with the normal lower line display. Yellow lights on the diagram
also indicate the area needing service. These messages are intended to advise of conditions which may lead to a
shutdown.
If a protective shutdown occurs, the red shutdown light will be on and the top line of the display will indicate
"SHUTDOWN". The lower line will indicate the cause of the shutdown. A red indicator on the diagram indicates the
areaneeding service.
SERVICE ADVISORIES
The controller turns on an advisory when it detects operation which needs service attention, but does not warrant
shutting down the compressor. Some of these are normal maintenance procedures, and are intended to serve as a
reminder to perform routine service. Others are conditions which can reduce the maximum compressor performance.
It will remain in effect until reset. Check the display during routine inspections, and perform maintenance as
suggested. Refer to the troubleshooting section for detailed information about each advisory.
Temperature advisories may be cleared while the unit is running by simply pressing the [ENTER] key. To reset the
service advisories, press the [STOP/RESET] key to stop operation of the compressor. After it has stopped,
disconnect power and service as required. After servicing, restore power and reset the board as indicated in the
programming / maintenance section below.

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PROTECTIVE SHUTDOWNS
The controller will shut down the unit following any fault detected in the following devices. Long-term problems will
have a brief blowdown period before fully shutting down. Following a shutdown, a message will be displayed, with
the top line indicating"SHUTDOWN" and the lower line indicating the cause. The shutdown light will be steadily lit if
the cause still exists, or will flash if the cause has been cleared. Refer to the troubleshooting section for detailed
information about each shutdown. To resume operation, the cause of the shutdown must be corrected and the
controller reset by pressing the [STOP/RESET] key.
Motor protective devices - Overload heaters are furnished for the starter in the voltage range specified. There are
three (3) overloads in the starter of proper size for the starter and its enclosure. Note that motor nameplate current
must be multiplied by 0.577 for wye-delta starters. The display will indicate that an overload relay has tripped. The
overload relay is reset by pressing the button on the relay itself, then the controller may be reset. Motor current
(amps) and voltage must be measured in the affected motor wiring to locate the cause for high current. Overload
relays provided in standard units are sensitive to both overload and phase imbalance for improved motor protection.
Proper starter coil and contact action is also monitored and errors in operation will cause a shutdown with the cause
displayed as a starter or starter contact error.
High temperature - The compressor is protected from high discharge temperature by athermistor probe located in
the compressor discharge elbow. This controller will shut the compressor down if temperature exceeds 225°F (or as
set in setup adjustments) or if rapid temperature rise is detected. Reservoir / separator temperature is also
monitored, and will provide high temp shutdowns. The location of the temperature fault will be displayed. Thermistor
probes are also checked for open or shorted circuits, and the display will indicate the location of the defective probe.
CAUTION
Machine damage will occur if compressor is repeatedly restarted after high temperature stops
operation. Find and correct the malfunction before resuming operation.
Separator differential pressure - The pressure drop across the separator is continually monitored by the controller.
The unit will be shut down at a differential pressure of approximately 15 psid.
The pressure drop can be monitored at any time by pressing the separator key on the diagram twice. This should be
checked while the compressor is delivering at full capacity. A service advisory comes on to recommend maintenance
prior to this shutdown.
High pressure - The controller will first attempt to unload and blow down the unit if excessive pressures are detected
in the reservoir or the plant system. If unsuccessful, a shutdown will occur. Shutdown will also occur if a defective
transducer is detected, or improper zero adjustments are detected. The display will indicate the location of the high
sensed pressure or transducer (xducer) error. Check that all adjustments have been properly made, and all
connectionsare secure.
Low sump pressure - The controller will shut down the unit if inadequate oil reservoir pressure is detected after
loading the compressor. If this occurs, check the wiring and piping to the solenoid valves.
Emergency stop - Press the emergency stop button to shut down the unit and the controller. To restart, pull the
button out to its normal position and reset the controller. This should be used for emergency purposes only - use the
keypad [STOP/RESET] for normal controlled stopping.
Power failure - Following power interruptions, the controller will remain in a shutdown state (unless programmed for
auto restart).
External device - This input is provided for user- or dealer- installed devices needed by specific applications. Other
shutdown field selectable messages include: high vibration, phase relay, low voltage relay, water press, and motor
overtemp.
Amp sensor failure - The optional current sensor used with the controller is used for operational tuning and advisory
purposes only. The only shutdown functions are those when the controller senses improper operation. These may
be disabled if no sensor is installed.

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Connection failure - The controller checks input connectors and will shutdown if they become unplugged.
Other shutdowns - The controller runs continuous diagnostic checks of its own operation and the sensors to which it
is connected. Refer to the service section for a complete listing of shutdowns and remedial actions.
PROGRAMMING AND SETUP FOR THE "AUTO SENTRY®-ES+" CONTROLLER
Programming and setup is accomplished with the PROGRAM keys. Seefigure 1-1. In all steps, the [ENTER] key
enters the displayed value into memory and advances to the next programming function. The plus [+] and minus [-]
keys will increase and decrease displayed numeric values, or step through menu selections. During numeric
adjustments, the left [<] and right [>] arrow keys, move the cursor (flashing digit) to the position desired. Use the
[+] and [-] keys to change the number at the cursor. At any point in the programming and setup routine, the
[STOP/RESET] key can be pressed to exit the adjustment mode without altering the adjustment. In all steps of the
programming routine, the top line of the display will give a description of the parameter to be programmed, while the
bottom line shows the variable that may be altered or stored.
The following is a step by step guide to programming the controller. Remember, between each step, it is necessary
to press the [ENTER] key to store the new value and advance to the next step.
Figure 1-2– FLOW CHART
302EAU1255-B
(Ref. Drawing)

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Main Adjustments Menu
1. The compressor must be stopped prior to making any adjustments. If the unit is running, press the
[STOP/RESET] key to place the control in the"READY" state.
2. Adjustments can also be performed from the"SHUTDOWN" state. After adjustments are completed, the
controller returns to the this state until the cause is repaired and the controller is manually reset.
3. Press the [ENTER] key to begin programming. This enters the adjustments menu. The adjustments are broken
into five groups as shown infigure 1-2. To select a group, press [+] or [-] until the desired group is shown on the
bottom line of the display. Press [ENTER] to proceed to the group adjustments detailed below.
Note: Configuration adjustments are normally required only at the time of assembly or after parts have been
replaced. Unit setup adjustments are normally required only at the time of unit installation. To prevent accidental
access, these will not be available if the "SET" switch is in the position closest to the corner. The "SET" switch is
located on the bottom of the controller chassis, on the side behind the program keypad area. If the switch is towards
the center of the controller, all five adjustment sections are accessible.
Operation Adjustments
1. In the top line, "LANGUAGE" is indicated. The bottom line will indicate"ENGLISH" or an alternate language for
display messages. Select the desired display language and press [ENTER] to proceed.
If a controller is set for another language, press the [STOP/RESET] key, press [ENTER] twice, and press the [+]
or [-] key to select ENGLISH at this step. Then press [ENTER] to select the language.
2. In the top line, "DISPLAY UNITS" is indicated. The bottom line will indicate"ENGLISH" (PSIG, Fahrenheit) or
"METRIC" (Bars, Celsius) units of measurement. Select the desired display units and press [ENTER] to
proceed.
3. In the top line, "START TIMER" is displayed. The bottom line will indicate a time between 3 and 10 seconds.
This is the time that the controller spends in the unloaded 'start' mode. This also controls the operation of
package-mounted wye-delta starters, if so equipped. Set this adjustment for the amount of time needed for the
motor to reach its highest speed while starting. This is typically 3 seconds for full-voltage starters, 7-9 seconds
for wye-delta starters.
If a remote-mounted, reduced voltage starter is used, set this adjustment 1-2 seconds longer than the starter's
internal timer.
4. In the top line, "SET PRESSURE" is displayed. The bottom line will indicate a pressure value. It is to be set at
the nameplate rating of the compressor for normal operation. Under NO circumstances, is this adjustment to
be set in excess of the compressor nameplate pressure. It may be set lower, if desired, to reduce pressure and
power consumption.
5. In the top line, "RESET PRESSURE" is displayed. The bottom line will indicate a pressure value. This setting
determines the point at which machine startup occurs in AUTO and SEQUENCE modes and when the
compressor will load up from the blown down condition. Note that RESET PRESSURE can be set up to 5 PSI
below SET PRESSURE. Set this lower to reduce compressor cycling. All sequenced machines must have the
same SET and RESET PRESSUREsetpoints.
6. In the top line,"BLOWDOWN TIME" is displayed. The bottom line will indicate a time between 1 and 20
minutes. It is factory set at 10 minutes. This is the minimum time interval betweenblowdowns. A longer
blowdown time minimizes wasteful dumping of compressed air when loading is likely to occur in a short time.
7. In the top line, "AUTO TIME" is displayed. The bottom line will indicate a time between 1 and 20
minutes. It too, is factory set at 10 minutes. Its function is to prevent too frequent motor starting, and
to allow the motor a 'cool-down' period before stopping.
8. "IV CONTROL MODE" is displayed on the top line. Select "MODULATING" for standard operation.
"LOAD-UNLOAD" may be selected for systems with large storage and wide pressure differential.
9. In the top line, "REMOTE HALT" is displayed. The bottom line indicates either "TIMED" or
"IMMEDIATE". Refer to the description of "Remote On / Off" later in this section for additional
details. Select the desired response to the remote input and press [ENTER] to proceed.