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

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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
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

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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

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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

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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

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5. Right Arrow Button
The Right Arrow button is used to navigate horizontally to the next Operational or Adjustment menu.
6. Up Arrow Button
The Up Arrow button is used to navigate vertically to the next item inside a menu.
7. Down Arrow Button
The Down Arrow button is used to navigate vertically to the next item inside a menu.
8. Plus Button
The Plus button is used increment the value of a selected parameter while in the edit mode.
9. Minus Button
The Minus button is used decrement the value of a selected parameter while in the edit mode.

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3 Quick Start Guide
Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run
button to start the compressor, no other settings are required. The Target Pressure comes preset
to 100 PSI from the factory. The Unload Pressure is preset to 110 PSI. If a different pressure setting is
desired, the following steps can be used as a guide.
3.1 Setting the Target Pressure
The Target Pressure setting is used to set the operating point of the compressor. To make any
adjustments in the operation of the compressor, the machine must be stopped and in the Ready
mode. Stop the compressor by pressing the Stop/Reset button. The front panel display
should read “READY” on line 3.
Next, press the Enter button to access the Adjustment Menu tree
Since the Target Pressure setting is under the Operation Adjustment menu, press Enter
again to access that sub-menu
The Target Pressure is the second item in the Operation Adjustment sub-menu so press the Down
button to navigate to the Target Pressure setting.
0 PSI 75°F
10 HRS AUTOMATIC
READY
NO SERVICE ADVISORY
ADJUSTMENT MENU
OPERATION ADJUSTMENT
(SELECT SUB MENU)
OPERATION ADJUSTMENT
LANGUAGE-LANGUAGE
ENGLISH (US)
(SELECT PARAMETER)
OPERATION ADJUSTMENT
TARGET PRESSURE
100 PSI
(SELECT PARAMETER)

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To change the Target Pressure, press the Enter button to edit the value.
A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the
Plus and Minus buttons to change its value. Use the Right and Left buttons to
move the cursor to other digits in the Target Pressure value. When the desired Target Pressure
value is displayed, press the Enter button to save the new value. Pressing the Stop/Reset
button will abort the change and restore the previous value.
In order to save the changes made to parameters, press the Stop/Reset button to go back to the
heading of the current menu and then press the Stop/Reset button again. If parameter changes have
been made, the following screen will appear.
To permanently save the changes that were made, press the Enter button. If the Stop/Reset
button is pressed, the parameter changes will be lost the next time the compressor power is turned
off.
3.2 Setting the Load and Unload Pressure
After setting the Target Pressure, set the Unload and Load Pressures values in a similar fashion. The
Unload pressure is the third item in the Operation Adjustment sub-menu so press the Down
button to navigate to the Unload Pressure setting. The Unload Pressure will control at which
pressure the compressor unload and stops.
The Load pressure is the fourth item in the Operation Adjustment sub-menu so press the Down
button to navigate to the Load Pressure setting. The Load Pressure will control at which pressure the
compressor will startup again after unloading.
OPERATION ADJUSTMENT
TARGET PRESSURE
100 PSI
(EDIT PARAMETER)
STORE MODIFIED
PARAMETERS?
STOP = NO
ENTER = YES
OPERATION ADJUSTMENT
UNLOAD PRESSURE
110 PSI
(SELECT PARAMETER)
OPERATION ADJUSTMENT
LOAD PRESSURE
100 PSI
(SELECT PARAMETER)

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4 Air Compressor Control
The AirSmart Controller has been successfully implemented in a wide variety of compressor types within
the Gardner Denver product line from large variable speed, multi-stage, rotary screw compressors to
small fixed speed models. Each type of machine requires a certain amount of complexity for control and
the AirSmart Controller can employ everything from PID control loops with specialized I/O down to
simple binary (on/off) control. The following paragraphs present a brief description of how the AirSmart
Controller regulates pressure depending on machine type
4.1 Variable Speed Compressors
A variable speed compressor employs a Variable Frequency Drive (VFD) to regulate the airflow by
speeding up or slowing down the main motor which is directly connected to the airend. The Gardner
Denver VS and VST line of compressors are variable speed machines. The TARGET PRESSURE
setting is used to generate a difference value (error value) when compared to the package discharge
or PLANT PRESSURE signal. The TARGET PRESSURE setting is compared to the air storage
receiver or SYSTEM PRESSURE signal on units with the optional communications module that are
run in Sequence mode of operation. The error value is fed into a PID (Proportional, Integral and
Derivative) algorithm in the AirSmart Controller which produces an appropriate command for the VFD
to change the speed of the main motor thereby increasing or decreasing the pressure so that the
PLANT PRESSURE value will match the TARGET PRESSURE value. In a two-stage, variable speed
compressor, a second PID algorithm is used to match the power output from the second stage VFD
to that of the first stage VFD. PID control algorithms require tuning in order to function correctly
without losing control of the machine. The PID algorithms in the AirSmart Controller were carefully
tuned for each compressor model during the product development process and do not require any
further adjustment by the end user.
During normal operation, as the demand for air increases, the speed of the compressor will also
increase to meet the demand. When the speed of the compressor reaches the set maximum value
for the given the TARGET PRESSURE setting, it will not increase any further. As the demand for air
decreases, the speed of the compressor will decrease down to the set minimum value for the given
TARGET PRESSURE setting. If the demand for air continues to decrease, the PLANT PRESSURE
value will increase until it reaches the UNLOAD PRESSURE value programmed into the AirSmart
Controller at which time the compressor will unload and the main motor will stop. The compressor
will start again when PLANT PRESSURE falls below the LOAD PRESSURE setting. The minimum
and maximum motor speeds are fixed in the controller for each compressor model to ensure that the
motor and VFD current limits are not exceeded at any given TARGET PRESSURE setting.
4.2 Variable Flow Compressors
A variable flow compressor can be defined as a machine which uses a fixed speed motor (with a
traditional full voltage or wye-delta starter) but can regulate the air flow by using mechanical devices
such as a turn valve to change the size of the compression chamber in the airend or a variable inlet
valve to restrict the intake of air. The Gardner Denver Electra-Saver line of compressors are an
example of variable flow machines. In the case of a compressor with an inlet valve and a turn valve,
two separate PID algorithms are used which control each device based on the package discharge
pressure, that is, PLANT PRESSURE is compared to TARGET PRESSUE. So that the two
independent algorithms do not attempt to cancel or fight each other, each is used in succession while
the compressor is operating in different flow regions. The TARGET PRESSURE setting is compared
to the air storage receiver or SYSTEM PRESSURE signal on units with the optional communications
module that are run in Sequence mode of operation. In a typical Gardner Denver machine, the turn
valve is used to control the flow between 100% and typically 40% of full capacity while the inlet valve

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is used to control the flow at even lower capacity levels. The AirSmart Controller can also be
programmed to use only the inlet valve for flow control over the full capacity range of the machine.
At full capacity, the inlet valve is fully open and the turn valve is in the fully closed state. As the air
demand decreases, the AirSmart Controller will open the turn valve to decrease the capacity of the
airend to match the demand and keep the PLANT PRESSURE value at the TARGET PRESSURE
setting. When the turn valve is fully open and as the demand continues to decrease, the AirSmart
Controller will begin to close the inlet valve to further decrease the air flow after PLANT PRESSURE
has risen to TARGET PRESSURE + 3 PSI. The 3 PSI offset helps keep the two PID controllers from
interfering with each other. Decreasing the demand for air from this point will cause either the inlet
valve to fully close or the pressure to rise to the UNLOAD PRESSURE setting both of which will
cause the compressor to unload. If the demand increases the inlet valve will open followed by the
closing of the turn valve to meet the new demand. If the demand does not increase, the compressor
package will eventually stop. The compressor will start again when the PLANT PRESSURE value
falls below the LOAD PRESSURE setting.
4.3 Fixed Speed Compressors
A fixed speed compressor is the simplest type of machine in the Gardner Denver product line and
uses a fixed speed motor along with a binary inlet valve (open or closed) for flow control. The Integra
compressor series offered by Gardner Denver are representative of this type of machine. In a simple
fixed speed compressor, the TARGET PRESSURE setting in the AirSmart Controller is ignored due
to the fact that there is no way to partially restrict the air flow. The controller loads (starts) and
unloads (stops) the compressor based only on the LOAD PRESSURE and UNLOAD PRESSURE
settings. The LOAD PRESSURE and UNLOAD PRESSURE settings are compared to the air storage
receiver or SYSTEM PRESSURE signal on units with the optional communications module that are
run in Sequence mode of operation.

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5 AirSmart Controller Menus
The AirSmart Controller has two sets of menus that serve as a window into the operation of the
compressor. The first set is the Operational Menus, which allow the user to observe the current status of
various parts of the compressor like the motor(s) or the air-oil separator. The second set of menus are
the Adjustment Menus, which allow the user to change the operating parameters of the compressor such
as the plant pressure set point and the high temperature alarm limit. The default values for the adjustable
parameters are determined by the Controller Model Table stored in the controller’s memory.
5.1 Operational Menus
The Operational Menus are available at all times - while the compressor is running, stopped or even
while in a fault condition. To enter the Operational Menu trees press the Right or Left
buttons to access one of eight different menus. Once the desired menu heading is shown in the
fourth line of the display, use the Up and Down buttons to access the individual items in
the selected menu, which are also shown in the fourth line of the display. If the Up or Down buttons
are not pressed within five seconds of pressing the Right or Left buttons, the fourth line of the display
will return to its previous state.
It is not necessary to navigate back to the top of a particular menu in order to enter another menu.
Simply press the Right or Left buttons to go back to the heading of the current menu and
then use the Right or Left buttons again to find the desired menu heading as described above.
Note: Advisory fault information is also shown in the fourth line of the display. If an advisory is
active and the fault condition has not been cleared, the Operational Menu text will be periodically
replaced by the advisory text.

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4.1.1 Operation Menu
The Operation Menu gives the user the ability to change the pressure set points and the operating
mode while the compressor is running or stopped. While in the Operation menu, small incremental
changes can be made to the parameter values using the Plus and Minus buttons. When
changing parameters, the “=” character will change to “->” to show that the value has been changed.
Pressing the Enter button will apply the change.
1. Target Pressure
The first item in the Operation menu is the Target Pressure. This value is the pressure set point
of the compressor. When the Target Pressure is changed, the Unload Pressure and the Load
Pressure values are also changed by the same amount as the Target Pressure. If this action is
not desired, the Unload and Load Pressure values may be changed individually. The Target
Pressure can also be changed inside the Operation Adjustment menu.
Min Value: Min Target Pressure in Unit Setup Adjustment menu
Max Value: 181 PSI (12.5 bar)
Default Value: 100 PSI (7 bar)
2. Unload Pressure
The next item in the Operation menu is the Unload Pressure. This pressure value is where the
compressor will unload and begin the unload/stop sequence. The Unload Pressure value cannot
be set any lower than [Target Pressure + 5 PSI].
Min Value: Target Pressure + 5 PSI (0.3 bar)
Max Value: 185 PSI (12.8 bar)
Default Value: 110 PSI (7.5 bar)
0 PSI 75°F
125 HRS AUTOMATIC
READY
OPERATION
0 PSI 75°F
125 HRS AUTOMATIC
READY
TARGT PRES=100PSI
0 PSI 75°F
125 HRS AUTOMATIC
READY
UNLOD PRES = 110 PSI

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3. Load Pressure
The next item in the Operation menu is the Load Pressure. This pressure value is where the
compressor will load again after an unload/stop sequence. The Load Pressure value cannot be
set any higher than Target Pressure.
Min Value: 30 PSI (2 bar)
Max Value: Target Pressure
Default Value: 100 PSI (7 bar)
4. Operating Mode
The next item in the Operation menu is the Operating Mode. The controller can be set to one of
four operational modes; Automatic, Sequence, Low Demand and Constant.
AUTOMATIC: (Default mode) the compressor uses its internal modulation algorithms and the
motor(s) will stop after it goes through the timed unload/blowdown sequence using the Blowdown
and Auto Timers.
SEQUENCE: The compressor is part of a sequenced group of machines. Refer to Gardner
Denver document 13-17-604 for further details about sequencing with the AirSmart Controller.
LOW DEMAND: The compressor uses its internal modulation algorithms but motor(s) will NOT
stop after it goes through the timed unload/blowdown sequence. The Blowdown Timer is used,
however, the Auto Timer is ignored in Low Demand mode.
CONSTANT: The compressor uses its internal modulation algorithms but motor(s) will NOT stop
and the compressor will NOT blowdown after it unloads. The Blowdown and Auto Timers are
both ignored in Constant mode.
0 PSI 75°F
125 HRS AUTOMATIC
READY
LOAD PRES = 100 PSI
0 PSI 75°F
125 HRS AUTOMATIC
READY
OP MODE = AUTOMATIC

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4.1.2 Maintenance Info Menu
The Maintenance Menu gives the user access to the current status of all the maintenance counters
and system timers.
1. Total Hours
The first item in the Maintenance Info menu is the total number of hours the compressor has been
in operation. This information is also available in the second line of the display during normal
compressor operation.
2. Loaded Hours
The next item in the Maintenance Info menu is the number of hours the compressor has been
loaded.
3. Time To Next Oil Filter Change
The next item in the Maintenance Info menu is the number of hours before the next oil filter
change is needed. The Oil Filter Change Interval Timer can be reset under the Maintenance
Adjust menu. The Oil Filter Change Interval Time can be changed under the Unit Setup Adjust
menu
0 PSI 75°F
125 HRS AUTOMATIC
READY
MAINTENANCE INFO
0 PSI 75°F
125 HRS AUTOMATIC
READY
125 TOT HRS
0 PSI 75°F
125 HRS AUTOMATIC
READY
120 LOAD HRS
0 PSI 75°F
125 HRS AUTOMATIC
READY
OIL FLTR IN 1000 H