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Gardner Denver AUTO SENTRY RS2000 Operating And Service Manual
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Gardner Denver AUTO SENTRY RS2000 Operating And Service Manual

Gardner Denver AUTO SENTRY RS2000 Operating And Service Manual

Airpilot + controller
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GARDNER DENVER
13-8-623
®
Version: 04
September 13, 2004
AUTO SENTRY
RS2000
AIRPILOT +
CONTROLLER
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver AUTO SENTRY RS2000

  • Page 1 GARDNER DENVER 13-8-623 ® Version: 04 September 13, 2004  AUTO SENTRY RS2000 AIRPILOT + CONTROLLER OPERATING AND SERVICE MANUAL...
  • Page 2 Your local authorized distributor maintains a large inventory of genuine parts and he is backed up for emergency parts by direct access to the Gardner Denver Master Distribution Center (MDC) in Memphis, Tennessee.

  • Page 3: Table Of Contents

    Other Control Features..........................4 Section 3, RS2000 V4.xx Instructions......................5 Operating Modes ............................. 5 Programming And Setup For The "Auto Sentry RS2000" Controller ............. 6 Sequencing Compressors With The Auto Sentry RS2000 ..............11 Establishing The Initial Sequence ......................13 Auto Sentry RS2000 Sequence System Operation ................

  • Page 4: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 - Keypad..............................1 Figure 3-1 – Flow Chart For Setup Programming – V4.xx ................. 7 Figure 3-2 – Typical Wiring Diagram – V4.xx ................... 17 Figure 4-1 – Flow Chart For Setup Programming – V6.xx ............... 21 Figure 4-2 –...
  • Page 5 SECTION 1 GENERAL INFORMATION GENERAL DESCRIPTION The rotary screw compressor is prewired 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).

  • Page 6: Section 2, Auto Sentry Operation

    SECTION 2 AUTO SENTRY OPERATION OPERATING THE COMPRESSOR The two keys on the left side of the keypad control the operation of the controls. Prior to starting, press the [STOP/RESET] key to place the controller into its READY state (as indicated on the display). Press the [RUN] key to start compressor operation.

  • Page 7: Service Advisories

    Service information may also be displayed while the compressor is running. Press the [+][-] keys to display the following: 1. Est. hours till next recommended oil change 2. Hours till next recommended oil filter change 3. List of any active advisory messages If no keys are pressed for 5 seconds, the display will revert to its normal mode.

  • Page 8: Other Control Features

    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 selecting the DIF PRES alternate display.

  • Page 9: Section 3, Rs2000 V4.Xx Instructions

    SECTION 3 RS2000 V4.xx INSTRUCTIONS OPERATING MODES Version 4 software provides four operating modes. These may be selected in the adjustments. While operating, the selected mode is displayed in the lower right corner of the message window. 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.

  • Page 10: Programming And Setup For The "Auto Sentry Rs2000" Controller

    [STOP/RESET] key to place the control in the "READY" state. Adjustments can also be performed from the "SHUTDOWN" state. After adjustments are completed, the "AUTO SENTRY RS2000" controller returns to this state until the cause is repaired and the controller is manually reset.
  • Page 11 300EBC1255-E (Ref. Drawing) Figure 3-1 – FLOW CHART FOR SETUP PROGRAMMING – V4.xx...
  • Page 12 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.
  • Page 13 "AUTO SENTRY RS2000" controllers. It should be noted that all controllers on the system must have the same number programmed here to operate correctly in SEQUENCE mode. Adjust as required, and press [ENTER] to proceed.
  • Page 14 3. In the top line, "TRANSFER INTERVAL" is displayed. The bottom line will indicate a number of hours in the range of 1 to 5000. It is factory set at 24. This is the number of hours that this machine will stay in the role of "lead"...

  • Page 15: Sequencing Compressors With The Auto Sentry Rs2000

    Unit Setup Adjustments 1. In the top line, "OIL CHANGE INTERVAL" is displayed. The bottom line will indicate a time interval of 1000 to 12000 hours. After the machine has run for the programmed setting, an advisory will be displayed, requesting an oil change. Adjust as desired and press [ENTER] to proceed. 2.
  • Page 16 The "AUTO SENTRY RS2000" controller is designed for systems of two through eight compressors piped into a common air receiver for distribution to the plant. In any such system, the receiver is an important part of the application; it supplies air to the plant and allows compressor units to be unloaded and stopped.

  • Page 17: Establishing The Initial Sequence

    Each controller circuit board has two modular jacks which accept RJ-12 telephone plugs. One jack is vacant, the other has a short pigtail plugged into it. To interconnect two compressors, plug the cable into the vacant jack on each controller. For installations of more than two units, the pigtail plug must be disconnected on all controllers except the two at each end of the communications line.

  • Page 18: Auto Sentry Rs2000 Sequence System Operation

    AUTO SENTRY RS2000 SEQUENCE SYSTEM OPERATION Each member compressor in the system operates similarly to the Automatic mode of operation. It will start, load, unload, blowdown, and automatically stop as necessary to meet system demand for air. There are several differences, however, when running in the Sequence mode.

  • Page 19: Connection To Other "Auto Sentry" Controlled Compressors

    CONNECTION TO OTHER "AUTO SENTRY" CONTROLLED COMPRESSORS The controller offers capabilities to communicate with other Gardner Denver compressors in a sequenced system. Although the system ideally consists of a group of identical machines, there are some instances where a mixed group may provide acceptable service.
  • Page 20 The air compressor will operate normally in its selected mode whenever this contact is closed (turned on). Note that the keypad is always the master control; the operating mode must be selected at the keypad, and the remote is not capable of starting a unit after the [STOP/RESET] key has been pressed to place the controller in the READY state.
  • Page 21 300EFC546-A (Ref. Drawing) Page 1 of 2 Figure 3-2 – TYPICAL WIRING DIAGRAM – V4.xx...
  • Page 22 WIRING DIAGRAM 300EFC546-A (Ref. Drawing) Pag 2 of 2...

  • Page 23: Section 4, Version V6.Xx Instructions

    SECTION 4 VERSION 6.xx INSTRUCTIONS OPERATING MODES Version 6 software provides two operating modes, suitable for internal or remote control of compressor delivery. While operating, the active mode is displayed in the lower right corner of the message window. Automatic Mode Operation - This mode provides automatic start and timed stop. It provides fast response for small air systems, or power savings in applications with long unloaded periods and adequate storage to allow the compressor to be stopped for periods of light demands.
  • Page 24 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. Adjustments can also be performed from the "SHUTDOWN" state. After adjustments are completed, the controller returns to this state until the cause is repaired and the controller is manually reset.
  • Page 25 300EFD1255-C (Ref. Drawing) Figure 4-1 – FLOW CHART FOR SETUP PROGRAMMING – V6.xx 8. In the top line, "REMOTE HALT" is displayed. The bottom line indicates either "TIMED" or "IMMEDIATE". Refer to the description of "Load/Unload" later in this section for additional details. Select the desired response to the remote input and press [ENTER] to proceed.
  • Page 26 2. The top line displays "NEXT OIL CHANGE" and the estimated hours remaining are displayed on the bottom line. The actual time will be affected by operating conditions which affect oil life. Press the [+] or [-] keys to switch to the oil change interval (see UNIT SETUP) if service was performed early. Press again to change back to remaining time.

  • Page 27: Connection To External Controls

    Obviously, pressure measurement errors will be encountered if 'zeroing' is done with pressure at the transducer. If large errors are detected, the controller will demand that the transducer be checked. 3. In the top line, "REMOVE RES PRESS" is displayed. The bottom line displays the current pressure being sensed in the reservoir.
  • Page 28 Local/Master - Remote control enabling of the compressor requires only a simple two-wire control, with an isolated contact suitable for 120 volts, 1 amp. This may be a switch, a relay contact, or a PLC output. To connect, simply run the two wires to the control enclosure, and connect the two wires to terminals 6 and 9.
  • Page 29 Wiring Diagrams - The following wiring diagrams show connections in typical units. Refer to the wiring diagram shipped with the compressor unit for actual connections. 13-8-623 Page 25...
  • Page 30 303EFC546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-2 – TYPICAL WIRING DIAGRAM – V6.xx...
  • Page 31 303EFC546-A (Ref. Drawing) Page 2 of 2...

  • Page 32: Section 5, Troubleshooting

    SECTION 5 TROUBLESHOOTING AUTO SENTRY CONTROLLER DISPLAY MODES The normal display indicates the package service pressure, the airend discharge temperature, the total running hours, and one of the following operating modes. The green run light will be on for any operating mode, whether the compressor is running or not.

  • Page 33: Advisory Troubleshooting Guide

    ADVISORY TROUBLESHOOTING GUIDE All advisories are indicated on the keypad by a yellow indicator in the Status area, and one of the following messages alternating with the normal lower line display. Perform service or maintenance as indicated, then clear the advisory as instructed in the operating instructions. Message Action Needed CHECK COMM...

  • Page 34: Shutdown Troubleshooting Guide

    SHUTDOWN TROUBLESHOOTING GUIDE All shutdowns are indicated on the keypad by the word "SHUTDOWN" on the top line of the display, and one of the following messages on the lower line of the display. The red indicator in the Status area will be steadily lit while the condition exists, and will flash after the condition has been corrected.
  • Page 35 Message Action Needed HIGH RESVR Pressure in excess of the programmed high pressure limit has been detected. This PRESS shutdown will occur if a loss of pneumatic controls occurs. Check the inlet valve, all control piping, solenoid valves, and all other control devices to find the cause for the inlet valve not closing.
  • Page 36 Message Action Needed MOTOR 120 volts has been removed from terminal 6 of the terminal strip. This is normally OVERTEMP shipped jumpered directly to terminal 9, but the jumper may be removed to add a field installed shutdown switch. Reset the external switch. (V4.xx only) OPEN THERM The controller has detected an open connection to thermistor: (A) airend discharge or (B) separator.

  • Page 37: Controls Troubleshooting Guide

    CONTROLS TROUBLESHOOTING GUIDE The following are recommended service actions. Observe all instructions noted elsewhere in this manual. All electrical service is to be performed only by a qualified electrician. Symptom Recommended Action No display, Check incoming power to the compressor unit. Ensure that the disconnect is on compressor and that fuses have not blown (or circuit beaker tripped).
  • Page 38 Sympton Recommended Action Erractic pressures The sequencing system transmits low-level signals between units to communicate in SEQUENCE pressures. Units must be properly grounded to a good ground system, The only sequencing system transmits low-level signals between units to communicate pressures. Units must be properly grounded to a good ground system, The communications cable should use only appropriate quality cable, and the cable should be run in its own conduit.

  • Page 39: Section 6, Accessories

    301EFD566 - V6.xxEF Airpilot+ control software, English – French 302EFD566 - V6.xxES Airpilot+ control software, English – Spanish V4.xx RS2000 software is optimized for use with other Gardner Denver screw compressors with RS2000 or ES+ controllers. RS2000 does not provide the Local/Master input, Load/Unload input, and Compressor Available relay output.

  • Page 40: Section 7, Connection Of Remote-Mounted Main Motor Starters To Auto Sentry Control Systems

    SECTION 7 CONNECTION OF REMOTE-MOUNTED MAIN MOTOR STARTERS TO AUTO SENTRY CONTROL SYSTEMS The majority of our rotary screw compressor packages feature starters completely wired and tested at the factory. Some special applications and large units, however, do not have the main motor starter mounted on the package.

  • Page 41: Controls Checkout

    CONTROLS CHECKOUT Lock the disconnect switch for the starter in the open position. Energize the compressor package control panel. If the display indicates "SHUTDOWN - MAIN STRT CONTCT", the starter auxiliary contact is misconnected. Remove all power and correctly wire as indicated above. If the package has a separate fan motor, enter the adjustments menu and perform a jog to check for proper fan rotation.
  • Page 42 For additional information contact your local representative or Gardner Denver Compressor and Pump Division, 1800 Gardner Expressway, Quincy, Illinois 62301 Customer Service Department Telephone: (800) 682-9868 FAX: (217) 224-7814 Sales and Service in all major cities. Specifications subject to change without notice.

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