Gardner Denver GD PILOT TS Series Quick guide

USA ZS1133369 / 00 - January 2015
Translation of the original operating
instructions
Compressor control
GD PILOT TS / L series

Table of Contents
TM
2 / 80 USA January 2015
TABLE OF CONTENTS
1 Foreword........................................................ 3
1.1 About these operating instructions............3
1.2 Intended use............................................. 3
1.3 Foreseeable misuse..................................3
1.4 Service...................................................... 3
2 Safety requirements......................................4
2.1 Labeling of safety instructions...................4
2.2 Safety symbols..........................................4
3 Control panel and controller........................8
3.1 General operation / Parameter entry.........8
4 Menus........................................................... 10
4.1 Menu structure........................................ 10
4.2 "Home" menu..........................................10
4.3 Pictogram................................................ 14
4.4 "Trends" menu........................................14
4.5 "Settings" menu...................................... 16
4.6 "Fault History" menu.............................. 20
4.7 "Access Code" menu............................... 20
5 Configuration...............................................22
5.1 Choose Language...................................22
5.2 Set the Date and Time............................22
5.3 Setting units of measure......................... 23
5.4 Additional settings...................................25
5.4.1 Setting pressure bands........................... 25
5.4.2 Program Inputs and Outputs...................27
5.4.3 Timer Control.......................................... 31
5.4.4 Programming the Dryer Pre-Run
Time........................................................ 35
5.4.5 Setting RS485 communication................36
5.4.6 Setting the automatic restart after power
loss.......................................................... 37
5.4.7 Setting remote start/stop.........................38
5.4.8 Remote On-Load and Off-Load (FS).......39
6 Operating..................................................... 40
6.1 Stopping the compressor in case of
emergency...............................................40
6.2 Starting the compressor..........................40
6.3 Factors that inhibit starting......................40
6.4 Operation.................................................41
6.5 Operating Modes.................................... 41
6.6 Stop the compressor...............................41
6.7 Operation Monitoring.............................. 41
7 Clearing a fault............................................ 43
7.1 Checklist for clearing faults..................... 43
7.2 Structure of fault and warning codes.......43
7.3 Troubleshooting.......................................44
8 Additional controls..................................... 52
8.1 Maintenance level................................... 52
8.2 Additional trend charts at the maintenance
level......................................................... 52
8.3 Resetting Statistics On-Load Hours........ 53
8.4 Set the Service interval...........................53
8.5 Data Recording....................................... 54
9 Setting Up a Replacement Controller........56
9.1 Setup Code and Compressor Reference
Number....................................................56
9.2 Setting up a replacement controller........ 56
10 Base Load Sequencing (BLS)....................59
10.1 Base Load Sequencing...........................59
10.2 Supported slave controllers.................... 59
10.3 "Base Load Sequencing" menu............... 60
10.4 Compressor status messages................ 62
10.5 Compressor Settings and Information.....63
10.6 Base Load Sequencing Settings.............64
10.7 BLS Functional Description.....................66
10.8 Trend and History Charts........................67
10.9 Installing the RS485:3 module................ 68
10.10 Installing the compressor module
(STD).......................................................69
11 Appendix...................................................... 74
11.1 Status messages.................................... 74
11.2 Settings................................................... 75

TM
Foreword 1
January 2015 USA 3 /80
1 FOREWORD
1.1 About these operating
instructions
These operating instructions contain information
about controllers for fixed-speed or variable-speed
compressors, and for water-cooled or air-cooled
compressors.
Special sections are marked accordingly:
(FS) (fixed speed); for compressors with a fixed
speed
(RS) (regulated speed); for compressors with
speed control
(A) (air); for air-cooled compressors
(W) (water); for water-cooled compressors
All entries shown (parameters, settings, and con-
figurations) are examples and do not apply to spe-
cial applications. They are not specific values for a
particular model of compressor.
The controller type GD PILOT TS is intended
for use exclusively with compressors from the L
Series from Gardner Denver.
This operating instructions are valid for the con-
troller type GD PILOT TS with software versions
DXL-L(RS)-2.0x and higher.
Requirements for personnel
Only assigned personnel may work on the con-
troller and compressor. Personnel are trained and
instructed on the compressor.
The responsibilities of personnel for operation,
maintenance, and repair must be clearly defined.
The work of personnel should be checked regu-
larly to make sure that all work is done with the
personnel being aware of safety and hazard is-
sues.
Personnel in training, under instruction, being
taught, or taking part in a general training program
may work with the controller and compressor only
under the continuous supervision of an authorized
person.
For safety-relevant changes to the compressor
or its operating behavior, the compressor must
be stopped immediately and the fault must be re-
ported to the responsible area or person.
Faults, especially those that can compromise
safety, must be corrected immediately. Otherwise
the compressor must not be operated.
Work on electrical equipment may be performed
only by an appropriately qualified electrician, in ac-
cordance with electrical engineering regulations
and specifications.
Reference documents
These operating instructions only describe the
controller type GD PILOT TS.
In addition to these operating instructions, the op-
erating instructions for the compressor must be
followed.
1.2 Intended use
The installed controller type GD PILOT TS is in-
tended for use exclusively with compressors from
the L Series from Gardner Denver.
1.3 Foreseeable misuse
Any changes to the software or hardware of the
controller must be approved by Gardner Denver.
1.4 Service
If you have any questions about or problems with
the compressor please consult your Gardner Den-
ver representative.
Trained and specialized personnel provide fast,
technically accurate assistance.
In case of queries
If you have a query or wish to make a spare parts
order, please specify the model, the identification
number and year of manufacture as indicated on
the name plate. Providing these data ensures that
you will receive the correct information or spare
parts.
Your Gardner Denver representative
Please enter the details of your local Gardner
Denver agency in the following table.
Name:
Contact person:
Address:
Telephone
Fax
Email:
Chart 1-1: Local Gardner Denver representative

2 Safety requirements
TM
4 / 80 USA January 2015
2 SAFETY REQUIREMENTS
Gardner Denver takes no responsibility for prop-
erty damage or injuries that result from failure to
follow the safety requirements
In additional to these operating instructions, the
operating instructions for the compressor must be
followed.
2.1 Labeling of safety instructions
Safety instructions are used as special warning
notices in the operating instructions, using the fol-
lowing names and symbols.
These special warning notices serve to protect
against hazards and are close to the potential haz-
ard in space and time:
On the system, near the source of hazard
In the operating instructions, before a se-
quence of actions or activities to be performed
is described
Structure of safety instructions
The special warning notices in the operating in-
structions are structured as follows:
ALERT WORD
Safety
symbol
Hazard (consequences of haz-
ard)
Description of the hazard (source)
Protective measure (protection
against hazard)
Components of safety instructions
Hazard (consequences of hazard): The hazard
sequence tells the type of hazard.
Description of the hazard (hazard source ): The
hazard source indicates the cause of the hazard.
Protective measure (protection against haz-
ard): The protection against the hazard describes
the measures for preventing the hazard.
Alert word: The alert word classifies the severity
of the hazard into four levels, emphasized graphi-
cally with different colors. The alert word is used in
the safety instructions as described below.
DANGER Indicates an immediate dangerous sit-
uation that, if not prevented, will result in death or
extreme (irreversible) injury.
WARNING Indicates a potential dangerous situ-
ation that, if not prevented, can result in death or
extreme (irreversible) injury.
CAUTION Indicates a potential dangerous situa-
tion that, if not prevented, can result in slight or mi-
nor (reversible) injury.
CAUTION Indicates information or recommenda-
tions that directly or indirectly relate to the safety
of persons or equipment protection.
2.2 Safety symbols
The safety symbols (hazard warning signs) can be used in the operating instructions and in the environ-
ment around the compressor.
Safety symbol Meaning Use / Behaviour
General hazard Warning of a general hazard.
Observe the warning and proceed with the required cau-
tion (e.g., protective clothing) and care.
Slip hazard Warning of a slip hazard.
Use caution when walking, running, or climbing.
Component or system
under pressure
Identification of devices or areas in which the air pres-
sure is substantially higher than in the normal atmos-
phere.
Do not open devices or chambers until the pressure has
been equalized.
Chart 2-1: Safety symbol

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Safety requirements 2
January 2015 USA 5 /80
Safety symbol Meaning Use / Behaviour
Do not operate with open
doors or loose enclosure
panels.
It is not permitted to run the compressor with open doors
or loose enclosure panels, except for test runs. High
sound pressure level, risk of injury!
Normal operation requires the enclosure to be closed.
Do not breathe in the
compressed air from this
unit
It is not permitted to use the compressed air produced by
this compressor for breathing. Indrawn materials can be
dangerous to health.
Do not use compressed air as breathing air.
Electrical voltage Warning against dangerous electrical voltage.
Work on the electrical equipment of the compressor may
be done only by an electrician in accordance with electri-
cal rules.
System continues to run After pressing the stop button <O>, the compressor runs
on for 30 seconds.
Do not open the compressor enclosure until the com-
pressor has stopped.
Follow the operating
instructions
Identification of instructions where additional information
can be found in the (manufacturer’s) operating instruc-
tions.
Before the device is operated, the user (operator) must
have read and understood the operating instructions
(manufacturer’s operating instructions).
Use hearing protection Identification of areas with increased sound pressure
level.
Enter the area only with suitable hearing protection.
Warning against indus-
trial trucks
Warning of industrial trucks traveling within the plant
(e.g., forklifts).
Do not perform any work in traffic lanes with limited visi-
bility that are not secured or blocked off. Use or crossing
of this traffic lane requires great caution.
Warning of suspended
loads
Warning of suspended loads being transported.
During transport, no person may be present in the haz-
ard area. In particular, do not reach in or allow the feet to
pass beneath the suspended compressor.
Warning of moving
machine parts.
When performing maintenance work, it is necessary to
check some functions with the enclosure open. Risk of
injury due to rotational or translational motion.
Maintenance work may be performed only by specially
trained technicians.
Chart 2-1: Safety symbol

2 Safety requirements
TM
6 / 80 USA January 2015
Safety symbol Meaning Use / Behaviour
Warning of hand injuries Hazard that the hands may be crushed, drawn in, or oth-
erwise injured.
Keep clear.
Warning of automatic
start-up
In normal operation the compressor can start automati-
cally at any time. Operational readiness of the compres-
sor is indicated by the green LED on the control panel.
Do not perform any work on the compressor when the
green LED is lit.
Warning of hot surfaces Parts of the compressor become very hot when in opera-
tion (up to 235 °C). Risk of injury from hot surfaces.
Before beginning maintenance and repair work, the com-
pressor must have cooled off sufficiently.
Warning of suffocation Suffocation hazard due to insufficient exhaust extraction
and ventilation of the compressor room.
The operator must provide sufficient exhaust extraction
and ventilation of the compressor room.
Warning of crushing haz-
ards
Warning of crushing hazards caused by a piece of equip-
ment (e.g., a machine) or structural components (e.g.,
covers, enclosures, guards, fences) during transport.
Working at the marked workstations requires increased
vigilance.
Do not go / stand
beneath the load
Do not go / stand beneath a suspended load. The driver
is not allowed to drive the industrial truck if there is a per-
son beneath the load. The driver must also make sure
that no one stands or walks under the load.
The load must be transported so that it is sufficiently
clear of the ground (max. 0.5 m above the ground).
(In Germany also refer to the law BGV D27 “Industrial
trucks”). The driver is responsible for all travel and load
movements of an industrial truck.
Lifting point Identification of lifting points.
Only the indicated lifting points may be used for trans-
port.
XX bar
Safety valve Opening pressure of safety valves (for value “xx” see the
label on the control panel).
Check connection ter-
minals and retighten if
needed. For additional
information, see the
operating instructions.
Warning of loosened clamp connections. Clamping pres-
sure can fade after some time.
Check the clamps regularly according to the safety
guidelines and retighten as needed.
Chart 2-1: Safety symbol

TM
Safety requirements 2
January 2015 USA 7 /80
Safety symbol Meaning Use / Behaviour
10 min
Electrical voltage
Residual voltage on the
capacitors
Warning against dangerous electrical voltage.
Warning of electrical energy stores in the form of capaci-
tors. They carry deadly electrical voltage.
Do not open the electrical switch cabinet (RS compres-
sor) for 10 minutes after disconnecting the compressor.
Check the DC bus voltage of the frequency converter
at the grid terminal strip of the frequency converter. The
exact position of the “DC+” and “DC-” terminals can be
found in the included operating instructions for the fre-
quency converter.
Work on the electrical equipment of the compressor may
be done only by an electrician in accordance with electri-
cal rules.
Spring tension Warning of springs under tension in the interior of the
suction regulator.
Before opening the suction regulator, read the repair
manual.
Bacterial contamination
hazard
Warning of the presence of Legionella in the cooling
water in an open-loop cooling water circuit
Continuous monitoring of the cooling water by mainte-
nance personnel.
Caution: hot liquid Warning of hot oil or hot coolant.
Allow the compressor to cool before opening the fluid cir-
cuit lines.
Chart 2-1: Safety symbol
NOTE
All hazard warning signs must be present and in legible condition.
Check regularly and replace when needed.

3 Control panel and controller
TM
8 / 80 USA January 2015
3 CONTROL PANEL AND
CONTROLLER
Fig. 3-1: Control panel
[1] Touchscreen Display
[2] Start-Taste < I >
[3] Stopp-Taste < O >
[4] rote LED
langsames Blinken: Warnung oder
Wartung
schnelles Blinken: Störung
[5] gelbe LED
langsames Blinken: Wartung erforderlich
[6] grüne LED
Dauerleuchten: Anlage in Betrieb
Blinken: Anlage in Standby (Bereitschaft)
[7] Taster <Not-Halt>
About the compressor controller
The controller is responsible for the following:
Starting and stopping the compressor
Compressor rotational speed control (RS) and
switching the compressor between load and
Off-Load operation in response to variations in
air demand
Monitoring of various operating parameters,
such as pressures and temperatures
Display of warnings and fault messages, and
automatic shut-down when a fault occurs
Data entry for adjustment of various operating
parameters
Keeping track of scheduled maintenance of the
compressor
3.1 General operation / Parameter
entry
Input menus
If parameters must be adjusted or other inputs
must be made in a menu, the appropriate input
menu appears in order to make the input.
The input menus are largely self-explanatory.
Selection
If only certain defined values are available for an
input, appropriate selection input menus are dis-
played.
Control
Operating Mode
OK
Continuous Operation
Cancel
Automatic Operation
Fig. 3-2: "Select” input menu, example: “Operating
Mode”
Control
Remote Start Enabled
OK
On
Cancel
Off
Fig. 3-3: “Select” input menu, example: “Remote Start
Enabled”
The input menus are enhanced with an explana-
tory text where needed.
Control
Periodic Start-Up
OK
Every 24 hours
Cancel
Never
Periodically starts the
motor for a few seconds.
Fig. 3-4: Input menu with explanatory text

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Control panel and controller 3
January 2015 USA 9 /80
Parameters
When parameters must be entered, an appropriate
keyboard appears on the screen. The allowable
range is displayed next to the entry for the para-
meter that is being changed.
Control
- Max. Power Loss Time
Setting Range
OK
Cancel
Fig. 3-5: Screen keyboard
Additional information
Instructions for the current menu are given wher-
ever needed.
Timer Control
Select a Setting
Date and Time
Timer Start/Stop
Timer Pressure Band p2
Display / Adjust
Display / Adjust
OK
This page is to set the
Timer Channel only. The Timer for
Compressor Start/Stop or activating the
second Pressure Band must be enabled
within Setpoints Menu.
Fig. 3-6: Menu with additional information
Access Code
Input menus for access codes always have a note
about the status of the current access authoriza-
tion.
Access Code
Input Access Code
Status:
User Settings
Unlocked
Fig. 3-7: Access code input menu
Arrow keys
If the menu contents do not fit on the display, ar-
row keys for scrolling through the menu contents
will appear.
Control
Select a Setting
OK
8.0 bar
Automatic Operation
Off
Off
Off
p2 Timer Enabled
Timer Control Enabled
Remote Start Enabled
p2 Target Pressure
Operating Mode
Fig. 3-8: Menu with arrow keys

4 Menus
TM
10 / 80 USA January 2015
4 MENUS
4.1 Menu structure
Home
On-Load 0rpm345
Hours Run
Hours On-load
Hours to Next Service
Remote Start Enabled
Timer Start Enabled
Auto. Restart Enabled
(1) Home
(2) Trends
Statistics On-Load Hours
Statistics Weekly Profile
Volumetric flow rate
Network pressure
Motor Speed (VS)
(3) Settings
Hour Meters
Controller
Timer Control
Programmable Inputs and Outputs
Communication
Configuration
Factory Settings
SD-Card
(4) Fault History
List of alarms, displaying
Alarm Details
(5) Access Code
Input menu
„
Input Access Code“
(6) Base Load Sequencing (optional)
2
3
4
5 6
1
Date and Time / Language Selection
Operating Display (Pictogram with
Setpoints and Measured Values)
Status / message area
Hours Run / Service hours
Status of switch-on functions
Turn on/off Base Load Sequencing
Settings:
- Setpoints
- Behavior
- Timer Control
- Configuration
Additions at the Service level:
Discharge pressure
- Output temperature
- Heatsink Temperature (VS)
- VSD Output Current (VS)
Base Load Sequencing additions:
- Volume Flow (BLS)
- Statistics Weekly Profile (BLS)
Fig. 4-1: Menu structure
4.2 "Home" menu
The "Home" menu is the basic screen that is shown during normal operation.
This menu is called up via the <Home> register card.
If there is no input for five minutes, this menu will appear automatically.