Gardner Denver AIRSMART User manual

13-17-613
Version: 01
March 1, 2017
AirSmartä
CONTROLLER
2nd GENERATION
USER’S
MANUAL
(Compressor
Application)

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WARNING –PROHIBITION –MANDATORY LABEL INFORMATION
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled
manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care
in its operation and maintenance. This book is written to give the operator and maintenance department
essential information for day-to-day operation, maintenance and adjustment. Careful adherence to these
instructions will result in economical operation and minimum downtime.
Boxed text formats are used, within this manual, to alert users of the following
conditions:
Safety Labels are used, within this manual and affixed to the appropriate areas of the
compressor package, to alert users of the following conditions:
Indicates a hazard with a high level of risk, which if not avoided, WILL result in death
or serious injury.
Equipment Starts Automatically Health Hazard –Explosive Release of Pressure
Cutting of Finger or Hand Hazard –Rotating
Impeller Blade
High Voltage –Hazard of Shock, Burn or Death
Present Until Electrical Power is Removed
Cutting of Finger or Hand Hazard –Rotating Fan
Blade Entanglement of Fingers or Hand –Rotating Shaft

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Indicates a hazard with a medium level of risk, which if not avoided, COULD result in death
or serious injury.
Asphyxiation Hazard –Poisonous Fumes or Toxic Gas in Compressed Air
Indicates a hazard with a low level of risk, which if not avoided, MAY result in a minor or
moderate injury.
Burn Hazard –Hot Surface
PROHIBITION - MANDATORY ACTION REQUIREMENTS
Do Not Operate Compressor with Guard
Removed
Lockout Electrical Equipment in De-Energized
State
Do Not Lift Equipment with Hook –No Lift Point Loud Noise Hazard –Wear Hearing Protection
Handle Package at Forklift Points Only Read the Operator’s Manual Before Proceeding
with Task

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SAFETY PRECAUTIONS
The following text presents common safety issues of which the user should be aware. Though the list below
includes unit and supporting equipment dangers present, the user must also be vigilant to other hazards
introduced in an industrial environment, and ensure they have received the necessary safety training.
Failure to observe these notices could result in injury to or death of personnel.
·Keep fingers and clothing away from rotating fan, drive coupling, etc.
·Disconnect the compressor unit from its power source, lockout and tagout before working on
the unit –this machine is automatically controlled and may start at any time.
·Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostatic mixing valve
or break any connections, etc., in the compressor air or oil system until the unit is shut down
and the air pressure has been relieved.
·Electrical shock can and may be fatal.
·Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any
applicable local electrical codes. Wiring and electrical service must be performed only by
qualified electricians.
·Open main disconnect switch, lockout and tagout before working on the control, wait 10
minutes and check for voltage.
Failure to observe these notices could result in damage to equipment.
·Stop the unit if any repairs or adjustments on or around the compressor are required.
·Do not use the air discharge from this unit for breathing –not suitable for human
consumption.
·An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch
inside diameter (OSHA Regulation, Section 1926.302).
·Do not exceed the rated maximum pressure values shown on the nameplate.
·Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.

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Table of Contents
1General Information................................................................................................................................7
1.1 AirSmart™G2 Controller Features.................................................................................................7
1.2 Control Panel Features...................................................................................................................7
2Controller Operation...............................................................................................................................8
2.1 Compressor Front Panel ................................................................................................................8
2.1.1 AirSmart Controller Control Panel...............................................................................................8
2.1.2 Emergency Stop Button..............................................................................................................8
2.2 Control Panel Indicator and General Navigation Button Functions ..................................................9
2.2.1 LED Indicators and Stop Button..................................................................................................9
2.2.2 Button Navigation Functions.......................................................................................................9
2.3 Operating Screens.........................................................................................................................9
2.3.1 Home Screen........................................................................................................................... 10
2.3.2 Run Screens Carousel.............................................................................................................. 12
2.3.3 Notice History and Status Icon.................................................................................................. 15
2.3.4 Maintenance Timers Summary................................................................................................. 16
2.4 Login and Accessibility.................................................................................................................17
3Quick Start Guide................................................................................................................................. 20
3.1 Applying Machine Power.............................................................................................................. 20
3.2 Setting Target Pressure................................................................................................................ 20
3.3 Setting Unload Pressure............................................................................................................... 22
3.4 Setting Load Pressure..................................................................................................................23
3.5 Setting to Automatic Mode............................................................................................................ 24
3.6 Menu Structure at a Glance.......................................................................................................... 24
4Air Compressor Control ........................................................................................................................ 26
4.1 Variable Speed Compressors....................................................................................................... 26
4.2 Variable Flow Compressors.......................................................................................................... 27
4.3 Fixed Speed Compressors........................................................................................................... 27
5AirSmart Controller Menus.................................................................................................................... 28
5.1 Operational Settings..................................................................................................................... 28
5.1.1 Operating Mode........................................................................................................................ 30
5.1.2 Change Passwords .................................................................................................................. 30
5.1.3 Load/Unload Setpoints............................................................................................................. 31
5.1.4 Inlet Valve Control.................................................................................................................... 32
5.1.5 Timer Setpoints........................................................................................................................ 32
5.1.6 Current Date/Time.................................................................................................................... 35
5.1.7 Operating Limits....................................................................................................................... 35
5.1.8 AutoRun Scheduling................................................................................................................. 38
5.2 Maintenance ................................................................................................................................ 39
5.2.1 Counter/Timer Summary .......................................................................................................... 39
5.2.2 Maintenance Timers................................................................................................................. 40
5.2.3 Distributor Information.............................................................................................................. 42
5.2.4 Consumables........................................................................................................................... 43
5.2.5 Downloads ............................................................................................................................... 43
5.2.6 Diagnostics............................................................................................................................... 43
5.3 Display Options............................................................................................................................ 45
5.3.1 Display Language..................................................................................................................... 45
5.3.2 Pressure Units.......................................................................................................................... 45
5.3.3 Temperature Units.................................................................................................................... 45

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Table of Contents
5.4 Machine Configuration.................................................................................................................. 46
5.4.1 Compressor.............................................................................................................................. 46
5.4.2 Drive Train ............................................................................................................................... 47
5.4.3 Enclosure................................................................................................................................. 53
5.4.4 AirSmart Controller................................................................................................................... 54
5.4.5 Calibrate Sensor....................................................................................................................... 55
5.4.6 Communications....................................................................................................................... 55
5.4.7 I/O Mapping & Diagnostics....................................................................................................... 56
5.4.8 Multi-Machine Sequencing........................................................................................................ 61
5.4.9 Oil Control Setup...................................................................................................................... 63
5.4.10 Control Pressure................................................................................................................... 64
5.4.11 Motor Jog............................................................................................................................. 65
5.5 Alarm History ............................................................................................................................... 65
6Error Management................................................................................................................................ 66
6.1 Advisory Faults............................................................................................................................. 66
6.2 Shutdown Faults .......................................................................................................................... 67
7Data Logs............................................................................................................................................. 72
7.1 Format ......................................................................................................................................... 72
7.2 Information................................................................................................................................... 72
8Technical Data ..................................................................................................................................... 76
8.1 AirSmart Controller Dimensions.................................................................................................... 76
8.2 Agency Certifications.................................................................................................................... 76
8.3 Environmental Ratings................................................................................................................. 76
8.4 Electrical Ratings ......................................................................................................................... 76

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Revision History and Software Compatibility
Version
Date
Notes
Current AirSmart G2
Firmware Version
00 January 27, 2014 First release. Supports fixed speed packages. 1.0.2
01 February 20, 2017 Supports VS and variable capacity packages 2.32.0

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1 General Information
The AirSmartäGeneration 2 (G2) controller was designed specifically for use in Gardner Denver rotary screw
air compressors and is capable of controlling fixed speed air compressors which use traditional motor starters
as well as variable speed and modulating compressors. The microprocessor-based unit monitors all
necessary temperature and pressure points within the compressor in order to safely operate the machine and
satisfy user air demand. The Control Panel displays a comprehensive overview of the compressor status and
allows easy access to operational parameters such as pressure set points, alarm set points and language
selection.
1.1 AirSmart™G2 Controller Features
üMicroprocessor controlled
üLow voltage 24 VDC operation
üIntelligent limiting for operation in extreme environmental conditions
üFeature rich error handling for safe machine operation
üExpandable to meet the I/O needs of large compressor packages
üThree 4-20 mA analog inputs in support of analog pressure transducers
üUp to five additional 4-20 mA inputs available on I/O expansion
üThree analog RTD inputs in support of PT1000 temperature transducers
üUp to five additional analog RTD inputs available on I/O expansion
üUp to six contact closure sensing discrete inputs for user control
üUp to six additional discrete inputs available on I/O expansion
üUp to six 24VDC discrete outputs for user status (800mA per channel)
üUp to six additional discrete outputs available on I/O expansion
üUp to two normally-open SPST Relay outputs
üUp to one additional SPST Relay output available on I/O expansion
üUp to two 4-20 mA analog outputs available for feedback and control on I/O expansion
üSD Card slot (32 Gigabyte max) for data logging
1.2 Control Panel Features
ü320x240 color pixel display with LED back lighting is easy to read in all lighting conditions.
ü7 navigational Buttons for easy compressor control and menu navigation
ü2 status LEDs for “at-a-glance”compressor status
üPassword protection of setup parameter menus
üMultiple language support

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2 Controller Operation
2.1 Compressor Front Panel
2.1.1 AirSmart Controller Control Panel
The Control Panel is mounted on the front panel of the compressor and is used to operate the
compressor and observe system status using its 320x240 color pixel display, two status LED
indicators, seven navigational buttons, and two control buttons.
2.1.2 Emergency Stop Button
The Emergency Stop button, when pressed, will immediately shut down the compressor. To reset the
compressor after an Emergency Stop, pull the Emergency Stop button out and then press the STOP
button on the Control/Display Panel to clear the Emergency Stop fault.

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2.2 Control Panel Indicator and General Navigation Button Functions
Figure 2-1: Control Panel Indicator and General Navigation Button Functions
2.2.1 LED Indicators and Stop Button
The Automatic LED (green) indicates that the compressor is capable of starting automatically, while the
Power LED (white) indicates that power has been applied to the compressor. The STOP button clears
a fault condition if the fault is not still active.
2.2.2 Button Navigation Functions
The display is controlled by seven navigation buttons. Four of these buttons are located to the right of
the display and three are located beneath it. The navigational buttons correspond to the functions
closest to them. For the example shown in Figure 2-1, Button A1 will navigate to the Distributor
Information screen, Button A2 will navigate the user to the Notices screen, Button A3 will navigate the
user to the Maintenance screen, and Button A4 will navigate the user to the Menu screen. The buttons
below the display (A5 and A6 for the example) will navigate to the Previous and Next pages,
respectively. Each screen will have unique navigational controls as labeled by the display text.
Figure 2-1 shows an example of the Home screen display.
2.3 Operating Screens
The AirSmart G2 controller features a set of easily-accessible screens providing run-time information
about the machine's operating state and condition. These are available from the home screen without
logging in to the system and include sensor readings, gauges, notice history, and maintenance timer
information. This section describes the operating screens in detail.
Power
Automatic
A1
A2
A3
A4
A5
A6
A7

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2.3.1 Home Screen
The home screen is the primary source of basic system status and operation. It includes plant delivery
pressure and discharge temperature readings, a status indicator icon, operating mode, total and loaded
hours, control state, and other dynamic information. Navigational links are provided to allow the user to
access other operating screens and system menus. An annotated image of the home screen is shown
in Figure 2-2.
Figure 2-2: Home Screen at a Glance
The items labeled in Figure 2-2 are described in more detail below:
·Plant Delivery Pressure is the largest piece of information on the home screen. This value reflects
the current air pressure at the compressor discharge port and is used to control compressor loading
and unloading.
·Discharge Temperature indicates the airend discharge temperature of the compressor and is used
as the control reference for cooling control and some temperature-based safety actions.
·Operating mode reflects the current operating mode setting of the controller. This will be one of
Automatic, Low Demand, Constant, Sequence, or Connect 12.
·The Hours line on the display shows the current Total (left of screen) and Loaded (right of screen)
hours on the package. These values are updated in real-time. The Total Hours will increment any
time the main motor is being driven. The Loaded Hours value will increment any time that the
compressor is producing air.
·Control State indicates the current state of the controller state machine and can be useful for quick
reference as well as diagnostics. A definition of the available control states that may be displayed is
provided in Table 2-1.
Plant Delivery
Pressure
Operating Mode
Discharge
Temperature
Total and Loaded
Hours
Control State
Dynamic
Information
Run Carousel Navigation
Navigate to Main
Menu
Navigate to
Maintenance Timer
Status Screen
Status Icon and
Navigate to Notice
History Screen
Clear Advisory and
Navigate to the
Distributor
Information screens

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Table 2-1: Control State Definitions
Control State Definition
Reset The controller is resetting
Auto Restart Auto Restart is enabled and active. The compressor will transition states at the expiration of the Auto Restart Timer.
Shutdown A shutdown fault is active.
Ready The compressor is healthy and ready to be enabled.
Remote Halt The compressor has been halted by a remote signal.
Ask to Start The compressor is attempting to start. Prolonged time in this state indicates that a precondition to starting the compressor has not been met.
Enabled The compressor is enabled and may start automatically when all starting conditions, such as pressure setpoints, have been met.
Ask to Load The compressor is attempting to load.
Pre-Wye Initiating wye-delta start
Wye Motor contactors have been engaged in the Wye (Start) connection.
Delta Motor contactors have transitioned to delta connection.
Start Themotor has been started andthe compressor is beginning the loading process
Pause
The motor has been started and the inlet valve has been opened but the controller is waiting on a
condition to be met before transitioning to the loaded state. Dwelling in this state may be due to low
reservoir pressure or the start timer.
Loaded The compressor is loaded and operating, and will unload once the Unload Pressure has been reached.
Unload
The compressor is in the unloaded state. Transition into this state triggers the blowdown timer to
start. The compressor will transition to loaded if delivery pressure falls below the Load Pressure
setting or to blowdown state if the blowdown timer expires.
Blowdown
The compressor is in the blowdown state. Pressure will be relieved from the air/oil reservoir.
Transition into this state triggers the auto timer to start. The compressor will transition to loaded if
delivery pressure falls below the Load Pressure setting, or to enabled if the auto timer expires.
Normal Stop The controller is executing the normal stop sequence. The motor will continue to run during this state until all conditions for stopping have been met, including the stop timer.
·The Dynamic information line on the home screen is used for various informational messages
depending on the state and condition of the compressor. If no other information is being displayed,
this line will show the current date and time setting on the controller. Table 2-2 describes the various
information that will be displayed here:
Table 2-2: Dynamic Information
Condition
Text Description (Left)
Value (Right)
Auto Restart in progress Auto Restart Timer Timer value (hh:mm:ss)
Waiting on AutoRun schedule Start Time Absolute start time (hh:mm:ss)
Waiting for blowdown to
complete Not Blown Down Reservoir pressure value
Waiting for reservoir pressure to
exceed control pressure setting Building Control Pressure Reservoir pressure value
Start Timer active Start Timer Timer value (hh:mm:ss)
Blowdown timer active Blowdown Timer Timer value (hh:mm:ss)
Auto timer active Auto Timer Timer value (hh:mm:ss)
Stop timer active Stop Timer Timer value (hh:mm:ss)

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·The Run Carousel Navigation buttons are labeled Previous and Next. These are used to navigate
through the run screens carousel. See section 2.3.2 for more information.
·Main Menu Navigation is triggered by the button labeled Menu. The menu structure and operation
are described in the subsequent sections.
·Maintenance Timer Summary Navigation is triggered by the button labeled Timers and will take the
user to the maintenance timer summary screens which provide a graphical overview of the
maintenance timers. See section 2.3.4 for more detail.
·The Status Icon provides a graphical indication of the status of the machine by displaying a different
icon if any faults or advisories are active on the system. The button next to this icon is used to
navigate to the notice history screen. See section 2.3.3 for more detail.
2.3.2 Run Screens Carousel
The run screens carousel is a set of informational screens set up in a loop that may be accessed in any
direction from the home screen using the Previous and Next buttons. This set of screens includes
graphical gauges displaying sensor readings as well as sensor and drivetrain summary screens. Trend
logging for each sensor may be accessed from the respective gauge.
Figure 2-3: Run Screens Carousel
2.3.2.1 Gauges
Pressing the Next button from the home screen will take the user to the Plant Delivery Pressure
gauge. This screen is show in Figure 2-4.
Figure 2-4: Plant Delivery Pressure Gauge

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The position of the needle on the gauge indicates the current pressure reading as displayed in the
digital value in the center of the gauge. The yellow region on the right of the gauge begins at the
current setting for the Unload Pressure and the red region on the right of the gauge begins at the
Pressure Fault setting. The scale of the gauge and location of the yellow and red zones will change
dynamically according to the configuration of the system.
The Discharge Temperature and Reservoir Pressure gauges are formatted in a very similar fashion
to the Plant Delivery Pressure gauge, with yellow and red zones configured as noted in Table 2-3.
Table 2-3: Gauge Classifications
Gauge
Lower (left)
Red Zone
Upper (right) Yellow
Zone
Upper (right) Red
Zone
Plant Delivery
Pressure 0 PSI
Unload Pressure
Plant Pressure
Fault
Discharge
Temperature 0 °C
Discharge
Temperature Advisory
Discharge
Temperature Fault
Reservoir
Pressure 0 PSI
Plant Pressure
Advisory
Plant Pressure
Fault
From each gauge screen, pressing the button next to the Home icon will navigate back to the home
screen. Pressing the button next to the Trend button will navigate to the trend history of this sensor
reading recorded over time as described in section 2.3.2.2.
2.3.2.2 Trend Graphs
The readings from the primary sensors on the system are logged at a fixed interval during
compressor operation and may be displayed on the screen by navigating to the Trend screen from
the respective gauge. An image of the Discharge Temperature Trend screen is shown in Figure 2-5.
Figure 2-5: Discharge Temperature Trend
Trend data files are loaded one date at a time. The x-axis across the bottom of the screen indicates
the hours in the day based on the current date and time setting of the controller. The current date
loaded is shown in the bar at the bottom of the screen, and the data scale is indicated on the y-axis.
Pressing the right arrow will load the next day in the log history, the left arrow will load the
previous day in the history. If a log is requested for a date when the compressor was not powered,
either in the past or in the future, a message will be displayed indicating that no log is available.
Pressing the double left arrow will navigate back to the respective gauge screen regardless of
what date has been loaded.

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2.3.2.3 Sensor Summary Screen
The final two screens in the carousel are the sensor summary and drivetrain summary screens.
These screens provide a convenient display of all the sensor readings and drivetrain readings in one
location. These screens can be accessed immediately from the home screen by pressing the
Previous button. An example of the sensor summary screen is shown in Figure 2-6 and an example
of the drivetrain summary is shown in Figure 2-7. Note that the Drivetrain Summary screen is only
visible on units equipped with a variable speed drive.
Figure 2-6: Sensor Summary Screen
Figure 2-7: Drivetrain Summary Screen

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2.3.3 Notice History and Status Icon
The status icon on the home screen provides a clear indication of the status of the machine. The icon
will change according to the conditions described below:
·If no advisories or faults are currently active, a flag image will be displayed under the
Notices label.
·If a fault has occurred and is currently active, the status icon will change to a flashing red
triangle: .
·Once the fault condition has been resolved, for example a sensor reading has been lowered
below the fault level or a digital input trigger has been cleared, the fault icon will change from
flashing to solid. This indicates that the fault may be cleared by pressing the STOP button.
·If an advisory condition is currently active, a yellow triangle will be displayed: . To clear
an advisory, press the button to the right of the Gardner Denver logo . Note that
this will also navigate to the Distributor information screens to display distributor contact
information and consumable part numbers.
Regardless of the state of the machine, pressing the button to the right of the status icon will navigate
to the Notice History screen. This screen displays information about all faults and advisories logged on
the system. For example, Figure 2-8 illustrates the Notice History display for an Emergency Stop fault.
Figure 2-8: Notice History Fault Display
As shown in Figure 2-8, the following information is displayed for each event in the log:
·Type of notice (Fault / Advisory)
·Notice number (since commissioning)
·Date and Time of notice
·Notice description ("Emergency Stop" for example)
·Total hours at time of notice
·Sensor readings at time of the event
·Timeline of notices when they have occurred (Green section = last 24hr period, Blue section
= previous seven days, Black section = older than seven days). The yellow and red flags
represent either an advisory (yellow) or fault (red) condition and the location on the timeline
indicates when they occurred. The flag corresponding to the currently displayed event will
flash slowly.

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Pressing the Next button will load the next notice in the log (if one exists). Pressing the Previous button
will load the previous entry in the log (if one exists). The Back button will return to the home screen.
The display is very similar for advisory conditions, as shown in Figure 2-9.
Figure 2-9: Notice History Advisory Display
2.3.4 Maintenance Timers Summary
The Maintenance Timers Summary screens can be accessed by pressing the button labeled Timers on
the home screen. These screens provide bar graphs for a graphical representation of the maintenance
status of the package. For each bar in the graph, the height of the bar indicates the percentage of life
remaining on the timer. For example, a maintenance timer with a 1000 hour interval and 500 running
hours since the last change would display at 50% life, indicated by the Half label on the graph. At 10%
life remaining, the bar will turn yellow, followed by red at 5% and below. Once the timer has reached
0% remaining at the Expired label on the graph, it will begin counting in the opposite direction towards
the Critical label, which will be reached at 50% past the expiration point.
Note: Although the graph displays Critical at the -50% point, maintenance should be performed at or
before the timer reaches Expired.
The first screen in this set is shown in Figure 2-10 and shows the following timers:
·Air Filter change timer
·Control Box Filter change timer
·Oil Filter change timer
·Oil Separator change timer
Figure 2-10: Maintenance Timer Summary`

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From the first timer summary screen, pressing the right arrow will navigate to the second screen as
shown in Figure 2-11, which includes the following timers:
·Oil Sample timer
·Oil Change timer
·Motor Lube timer
Figure 2-11: Maintenance Timer Summary
Notice on Figure 2-11 that the Motor Lube timer is displayed at the Expired level. In this case, this is
due to the timer being disabled on this package by setting the Motor Lube Timer Interval to 0 hours. If
an interval is set to 0 hours, no maintenance advisory will be triggered based on this timer.
2.4 Login and Accessibility
The Login operation for menu access is found under the Main Menu. Logging in is required to access
any screens other than those described in the Operating Screens under section 2.3.
To access and operate the Login function:
1. From the Home screen, select the Menu button as shown in Figure 2-12.
Figure 2-12: Home Screen

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2. From the Main Menu, select the Login button as shown in Figure 2-13. The Select User menu
will appear as shown in Figure 2-14.
Figure 2-13: Main Menu
Figure 2-14: Select User Screen
3. Use the navigational buttons to choose the appropriate user level: Maintenance,
Distributor, or Factory. Press the Enter button . The Enter Passcode screen will appear.

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Figure 2-15: Passcode Entry Screen
4. Enter the passcode for the requested access using the navigational buttons to choose the
appropriate number. The Select button is used to enter the number. Navigate to and select
ENTER when complete, or simply press the Enter button to apply the code.
5. The interface will automatically navigate to the Select User screen if the code is accepted. If the
code is not accepted, the user interface will remain at the Enter Passcode keypad.
Note: The timeout for any active user is approximately six minutes from the last screen navigation.
When the timeout occurs, the user will be logged out and the unit will be reset to the Home page