Gardner Denver AIRSMART User manual

13-17-600
Version: 04
August 18, 2014
AIRSMART
CONTROLLER
USER’S
MANUAL
(Compressor
Application)

13-17-600 Page 1
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

13-17-600 Page 2
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

13-17-600 Page 3
SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or
circumstances cannot always be predicted and covered by established rules. Therefore, use your past
experience, watch out for safety hazards and be cautious. Some general safety precautions are given below:
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.................................................................................................................................... 5
1.1 AirSmart Controller Features................................................................................................................. 5
1.2 Control Panel Features.......................................................................................................................... 5
2Controller Operation................................................................................................................................... 6
2.1 Compressor Front Panel........................................................................................................................ 6
2.2 Control Panel Four-Line Display............................................................................................................ 7
2.3 Control Panel Indicator Functions.......................................................................................................... 8
2.4 Control Panel Button Functions............................................................................................................. 9
3Quick Start Guide..................................................................................................................................... 11
3.1 Setting the Target Pressure................................................................................................................. 11
3.2 Setting the Load and Unload Pressure................................................................................................ 12
4Air Compressor Control............................................................................................................................ 13
4.1 Variable Speed Compressors.............................................................................................................. 13
4.2 Variable Flow Compressors................................................................................................................. 13
4.3 Fixed Speed Compressors .................................................................................................................. 14
5AirSmart Controller Menus....................................................................................................................... 15
5.1 Operational Menus............................................................................................................................... 15
5.2 Adjustment Menus ............................................................................................................................... 38
6Error Management.................................................................................................................................... 65
6.1 VS Limiters........................................................................................................................................... 65
6.2 Advisory Faults..................................................................................................................................... 67
6.3 Shutdown Faults .................................................................................................................................. 70
6.4 Transducer Locations........................................................................................................................... 77
7Auxiliary Inputs and Outputs .................................................................................................................... 78
7.1 Operating Device Addresses ............................................................................................................... 78
7.2 Digital Input/Output Functions.............................................................................................................. 79
7.3 Analog Input/Output Functions ............................................................................................................ 81
7.4 Example “RUN” Digital Output Signal.................................................................................................. 82
8Technical Data.......................................................................................................................................... 85
8.1 All-In-One AirSmart Controller............................................................................................................. 85
8.2 Full-Sized AirSmart Controller............................................................................................................... 86
8.3 Agency Certifications ........................................................................................................................... 87
8.4 Environmental Ratings......................................................................................................................... 87
8.5 Electrical Ratings ................................................................................................................................. 87
Appendix A - Remote Mounted Main Motor Starters........................................................................................ 88
Appendix B - Remote Cooling Module Starters................................................................................................ 90

13-17-600 Page 5
1 General Information
The AirSmartController was designed specifically for use in the Gardner Denver Global Line of variable
speed, rotary screw air compressors. The AirSmartController is also capable of controlling fixed speed air
compressors which use traditional motor starters. The microprocessor-based unit can control up to three
Variable Frequency motor Drives (VFDs) while monitoring 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 Controller Features
Microprocessor controlled
Low voltage 24 VDC operation
Supports up to thee VFDs via Modbus link
Compressor air regulation via PID control
Can control variable speed or fixed speed compressors.
Intelligent limiting for operation in extreme environmental conditions
Feature rich error handling for safe machine operation
Expandable to meet the I/O needs of large compressor packages
Up to five pressure transducer inputs
Up to five temperature transducer inputs
Up to three discrete inputs for user control
Up to two discrete outputs for user status
Sequence capability for control of up to eight compressors (w/ opt. Communications Module)
RS-232 Serial communications for local monitoring (w/ opt. Communication Module)
Ethernet communications for remote monitoring (w/ opt. Communications Module)
1.2 Control Panel Features
4 x 20 Character LCD display with LED back lighting is easy to read in all lighting conditions.
9 Buttons for easy compressor control and menu navigation
4 status LEDs for “at-a-glance” compressor status
Password protection of setup parameter menus
Multiple language support

13-17-600 Page 6
2 Controller Operation
2.1 Compressor Front Panel
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 four-line LCD display, four status LED indicators and
nine buttons.
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/RESET button on the Control/Display Panel to clear the Emergency Stop fault.
Control Panel
Emergency
Stop Button

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2.2 Control Panel Four-Line Display
1. Line 1
The first line of the display is used to show the package pressure and temperature while the
compressor is operating. When editing parameters in the Adjustment Menus, the first line is used to
show the menu heading.
2. Line 2
The second line of the display is used to show the total operating hours and operating mode while the
compressor is running. The second line is also used to show Shutdown fault information. When
editing parameters in the Adjustment Menus, the second line is used to show the parameter heading.
3. Line 3
The third line of the display is used to show the state of the compressor while it is operating. The
third line is also used to show additional Shutdown fault information. When editing parameters in the
Adjustment Menus, the third line is used to show the parameter value.
4. Line 4
The fourth line of the display is used to show Service Advisory fault information and the Operational
Menus. When editing parameters under the Adjustment Menus, the fourth line is used to show the
editing mode.
0 PSI 75°F
125 HRS AUTOMATIC
READY
NO SERVICE ADVISORY
Line 1
Line 2
Line 3
Line 4

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2.3 Control Panel Indicator Functions
1. Shutdown LED Indicator (red)
The Shutdown LED indicates a shutdown fault in the compressor. The type of shutdown fault will be
shown in the four-line display. When the Shutdown LED is flashing, the shutdown fault condition is
active. When the Shutdown LED is on steady, the shutdown fault condition no longer exists, but the
fault has not been acknowledged. To acknowledge a shutdown fault and reset the compressor, press
the STOP/RESET button on the Control Panel.
Pressing the STOP/RESET button will not clear an active shutdown fault. The shutdown fault
condition must be removed before it can be reset.
2. Service LED Indicator (yellow)
The Service LED indicates a service advisory fault in the compressor. The type of service advisory
fault will be shown in the four-line display. When the Service LED is on steady, the advisory fault
condition is active, but the fault has not been acknowledged. To acknowledge an advisory fault,
press the ENTER button on the Control Panel.
If the service advisory fault condition has not been cleared before it is acknowledged, the advisory
fault indication will occur again in a short period of time.
3. Automatic LED Indicator (green)
The Automatic LED indicates that the compressor capable of starting automatically.
4. Power LED Indicator (white)
The Power LED indicates that power has been applied to the compressor.
0 PSI 75°F
125 HRS AUTOMATIC
READY
NO SERVICE ADVISORY
Shutdown
Service
Automatic
Power

13-17-600 Page 9
2.4 Control Panel Button Functions
1. RUN Button
The RUN button is used to start the compressor.
2. STOP/RESET Button
The STOP/RESET button is used to stop and blowdown the compressor. The STOP/RESET button
is also used to acknowledge and reset shutdown faults or exit from the Adjustment Menu tree.
3. ENTER Button
The ENTER button is used to acknowledge a service advisory fault. The ENTER button is also used
to enter the Adjustment Menu tree, select a parameter for editing or save an edited parameter.
4. Left Arrow Button
The Left Arrow button is used to navigate horizontally to the next Operational or Adjustment menu.
0 PSI 75°F
125 HRS AUTOMATIC
READY
NO SERVICE ADVISORY Plus
Minus
Stop/Reset
Up
Down
Run
Left RightEnter