AirSmart Control Manual 002

AIRSMART™ CONTROLLER
QX189117
Firmware Version: 2.xx
Version: 002(1.01)
Date: Feb 2008
EN © 2007 Gardner Denver

Table of Contents
1. Introduction and Safety ........................................................................................................ 1

1.1 Storing the Books ......................................................................................................... 1
1.2 Safety ........................................................................................................................... 1
2. Operation ................................................................................................................................ 2
2.1 AirSmart™ Control Panel ............................................................................................. 2
2.2 Display.......................................................................................................................... 3
2.3 Button Functions .......................................................................................................... 4
2.4 Indicator Functions ....................................................................................................... 5
3. Operational Menus ................................................................................................................ 6

3.1 Maintenance Info Menu ............................................................................................... 8
3.2 Motor Information Menu * .......................................................................................... 11
3.3 Pressures and Temps Menu ..................................................................................... 12
3.4 Advisory and Shutdown History Menus ..................................................................... 14
3.5 Drive Information Menu * ........................................................................................... 15
3.6 Diagnostics Menu * ................................................................................................... 16
3.7 Operation Menu ......................................................................................................... 17
4. Adjustment Menus .............................................................................................................. 18

4.1 Operation Adjustment Menu ...................................................................................... 20
4.2 Maintenance Adjust Menu ......................................................................................... 24
4.3 Unit Setup Adjust Menu ............................................................................................. 25
4.4 Configuration Adjust Menu * ...................................................................................... 31
5. Error Management ............................................................................................................... 34

5.1 Advisory Alarms ......................................................................................................... 34
5.2 Shutdown Faults......................................................................................................... 37
5.3 Transducer Locations................................................................................................. 43
1. Introduction and Safety
1. Introduction and Safety
The AirSmart™ Controller is designed specifically for use in the Gardner Denver rotary screw air
compressors. This manual gives instructions on correct and safe operation of the AirSmart ™ controller.
For more information on operating the compressor, please refer to the operation and maintenance
instructions of the compressor.
Read these and other instructions delivered with the compressor carefully before taking your
screw compressor into use. This ensures correct preparations and use from the very beginning.
1.1 Storing the Books
All the instructions in this manual have been provided to guarantee a long life and reliable operation of your
screw compressor.
Always keep the manual available near the compressor. Make sure that the compressor is operated and
serviced according to the instructions.
1.2 Safety
Note! Always read also the safety instructions for transport, implementation, use and maintenance
presented in the operation and maintenance instructions of the compressor.
Always read the safety instructions before starting to work.
The instructions in this manual concerning safety are marked with this symbol.
In addition to these instructions, the local regulations in your country may impose additional requirements
that must be observed.
1
2. Operation
2. Operation
2.1 AirSmart™ Control Panel
The Control Panel is mounted on the compressor. It is used to operate the compressor and observe
system status by using the LCD display, status LED indicators and buttons.
The Control Panel displays a comprehensive overview of the compressor status and allows access to
operational parameters such as pressure set points, alarm set points and language selection.
AirSmart™ Control Panel
2
2. Operation
2.2 Display
Display
1. While the compressor is operating, the package pressure and temperature are shown on this
line. When editing parameters under the Adjustment Menus, the menu heading is shown here.
2. While the compressor is operating, the total operating hours and operating mode are shown
on this line. The shutdown fault information is also shown here. When editing parameters
under the Adjustment Menus, the parameter heading is shown here.
3. While the compressor is operating, it’s state is shown on this line. The additional shutdown
fault information is also shown here. When editing parameters under the Adjustment Menus,
the parameter value is shown here.
4. The Service Advisory fault information and the Operational Menus are shown on this line.
When editing parameters under the Adjustment Menus, the editing mode is shown here.
Note! The language of the text on the display varies depending on the language selection of the controller.
3
2. Operation
2.3 Button Functions
Button functions
1. Up Arrow button navigates vertically inside a menu. It scrolls through nonnumerical

parameters while in edit mode.
2. Down Arrow button navigates vertically inside a menu. It scrolls through nonnumerical
parameters while in edit mode.
3. RUN button starts the compressor.
4. ENTER button acknowledges a service advisory. It enters the Adjustment Menu tree and
selects a parameter for editing or saves an edited parameter.
5. Left Arrow button navigates horizontally to the next Operational or Adjustment menu.
6. Right Arrow button navigates horizontally to the next Operational or Adjustment menu.
7. Plus button increments the numerical value of a selected parameter while in the edit mode. It
scrolls through saved parameters while in Shutdown or Advisory history menus.
8. Minus button decrements the numerical value of a selected parameter while in the edit mode.
It scrolls through saved parameters while in Shutdown or Advisory history menus.
9. STOP/RESET button stops and blows down the compressor. It acknowledges and reset
shutdown faults and moves backwards from lower to higher level in the Adjustment Menu tree.
4
2. Operation
2.4 Indicator Functions
Indicator functions
1. Shutdown LED (red) indicates a shutdown fault in the compressor.
The type of the shutdown fault will be shown in the 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.
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 (yellow) indicates a service advisory fault in the compressor.
The type of the service advisory fault will be shown in the 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. If the service advisory fault condition
has not been cleared before it is acknowledged, the advisory fault indication will occur again in
short period of time.
3. Automatic LED Indicator (green) is lit, when the compressor is running or enabled to be started
by pressing the RUN button.
4. Power LED Indicator (white) indicates that power has been applied to the compressor.
5
3. Operational Menus
The AirSmart™ Controller has two sets of menus. 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 is Adjustment Menus, which are presented in the "Adjustment Menus" on page
18.
The Operational Menus are available at all times. The menus marked with * in the listings of this manual
are not available in all compressors. The menus available depend on the features and/or settings of the
compressor in question.
1. To enter the Operational Menu trees press the Right or Left Arrow buttons to access one of the
menus.
2. When the desired menu heading is shown in the fourth line of the display, use the Up and
Down Arrow buttons to access the individual items in the selected menu.
Note! If the Up or Down Arrow buttons are not pressed within five seconds of pressing the Right or Left buttons, the
display will return to its previous state.
3. It is not necessary to navigate back to the top of a particular menu in order to enter another
menu. Press the Right or Left buttons to go back to the heading of the current menu. Then use
the Right or Left buttons 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.
The AirSmart™ Operational Menus are presented on the next page.
6
Operational menus
Maintenance Motor Pressure Advisory Shutdown Drive

Diagnostics Operation
Info Information and Temps History History Information
TOT HRS MTR1 CURRNT INLET TEMP ADVISORY #1 SHUTDOWN #1 V1 FRQ CMD V1 CALC MN TARGT PRES
LOAD HRS MTR2 CURRNT INTRSTG P ADVISORY #2 SHUTDOWN #2 V2 FRQ CMD V1 CALC MX UNLOD PRES
OIL FLTR IN MTR3 CURRNT INTRSTG T ADVISORY #3 SHUTDOWN #3 V3 FRQ CMD V2 CALC MN LOAD PRES
OIL CHNG IN TOT MTR CRNT DSCHRG TMP ADVISORY #4 SHUTDOWN #4 V1 DC V2 CALC MX OP MODE
OIL SEPR IN MTR 1 VOLTAGE RES PRES ADVISORY #5 SHUTDOWN #5 V2 DC TARGET TMP
AIR FLTR IN MTR 2 VOLTAGE DIF PRES ADVISORY #6 SHUTDOWN #6 V3 DC OIL VLV CMD
VOLT CTRL
NXT CBOX FLTR IN MTR 3 VOLTAGE SEP PRES V1 TEMP
FAN
MTR LUBE IN MTR1 POWER SEP TEMP V2 TEMP
START TIMER MTR2 POWER PLANT PRES V3 TEMP
DRIVE 1
BLOWDWN TIMER MTR3 POWER PLANT TEMP
FAULT
DRIVE 2
AUTO TIMER TOT MTR PWR DRYER TEMP
FAULT
DRIVE 3
AVG CAP X M3 MTR1 SPEED OIL PRES
FAULT
DRIVE
AVG CAP X % MTR2 SPEED
PARAMETERS
AVG PKG PWR MTR3 SPEED
ENERGY COST MTR1 FREQ
TOTAL COST MTR2 FREQ
FIRMWARE
MTR3 FREQ
VERSIONS
Note! Items and menus marked with grey filled boxes may not appear on the controller depending on the composition
and type of the compressor.
7
Maintenance Info Menu
3.1 Maintenance Info Menu
The Maintenance Info Menu gives access to the current status of all the maintenance counters and system
timers. The items under the Maintenance Info Menu are shown on the fourth line of the display.
0,0 BAR 25°C

125 HRS AUTOMATIC
READY
MAINTENANCE INFO
The items are presented on the following listing. The name of the item is followed by the text shown on the
display. The values are presented with x.
Total Hours, X TOT HOURS
• shows the total number of hours the compressor has been in operation
• shown also in the second line of the display during normal compressor operation
Loaded Hours, X LOAD HRS
• shows the number of hours the compressor has been loaded
Time To Next Oil Filter Change, OIL FLTR IN X H *
• shows the number of hours before the next oil filter change is needed
• change interval timer can be reset under the Maintenance Adjust menu in the Adjustment Menu
tree, see "Oil filter change timer, OIL FLTR IN X HRS *" on page 24
Time To Next Oil Change, OIL CHNG IN X H *
• shows the number of hours before the next oil change is needed
tree, see "Oil change timer, OIL CHNG IN X HRS *" on page 24
Time To Next Separator Element Change, OIL SEPR IN X H *
• shows the number of hours before the next separator element change is needed
tree, see "Oil separator element change timer, OIL SEPR IN X HRS *" on page 24
Time To Next Air Filter Change, AIR FLTR IN X H *
• shows the number of hours before the next air filter change is needed
tree, see "Air filter change timer, AIR FLTR IN X HRS *" on page 24
8
Time To Control Box Filter Change, NXT CBOX FLTR IN X H *
• shows the number of hours before the next control box filter change is needed
tree, see "Control box filter change timer, NXT CBOX FLTR IN X HRS *" on page 24
Time To Next Motor Lubrication, MTR LUBE IN X H *
• shows the number of hours before motor lubrication is needed

• lubrication interval timer can be reset under the Maintenance Adjust menu in the Adjustment
Menu tree, see "Motor lubrication timer, MTR LUBE IN X HRS *" on page 24
Start Timer, START TIMER X
• shows the current value of the Start Timer

• used to control the amount of time the compressor runs at minimum speed after the RUN
button has been pressed
• timer interval is set under the Operation Adjust menu in the Adjustment Menu tree, see "Start
Timer, START TIMER X SECONDS" on page 21
Blowdown Timer, BLOWNDWN TIMER X
• shows the current value of the Blowdown Timer

• used to control the amount of time the compressor runs unloaded before starting the blowdown
process
• timer interval is set under the Operation Adjust menu in the Adjustment menu tree, see "Stop
Timer, STOP TIMER X SECONDS" on page 22
Auto Timer, AUTO TIMER X
• shows the current value of the Auto Timer

• used to control the amount of time the compressor runs during the blowdown process
• timer interval is set under the Operation Adjust menu in the Adjustment menu tree, see "Auto
Timer, AUTO TIMER X MINUTES" on page 22
Average Capacity, AVG CAP X M3 *
• shows the Average Capacity of the compressor over the last hour of operation
Average Percent Capacity, AVG CAP X % *
• shows the Average Percent of the full capacity of the compressor over the last hour of operation
Average Package Power, AVG PKG PWR X KW *
• shows the Average Package Power of the compressor over the last hour of operation
9
Current Energy Cost, ENERGY COST X €/H *
• shows the cost of operating the compressor at the current power level
• number is based on the current package power output and the Energy Cost value
• Energy Cost value is set under the Configuration Adjust menu in the Adjustment Menu tree, see
"Energy Cost, ENERGY COST X €/KWH" on page 32
Cumulative Energy Cost, TOTAL COST X € *
• shows the Cumulative Energy Cost of operating the compressor

• can be reset under the Maintenance Adjust Menu in the Adjustment Menu tree, see "Total Cost,
TOTAL COST X €" on page 24
• value is based on Average Package Power and the Energy Cost value
• Energy Cost value is set under the Configuration Adjust menu in the Adjustment Menu tree
Firmware Versions, V1-V3 VERSION
Show the current versions of:
• Controller Firmware (CFW)

• Controller Model Table (CMT)
• Controller Language Table (CLT)
10
Motor Information Menu *
3.2 Motor Information Menu *
The Motor Information menu gives access to the current status of the VFD controlled motor(s) in the
compressor. The items under the Motor Information Menu are shown in the fourth line of the display.
7,0 BAR 70°C

125 HRS AUTOMATIC
LOADED 100%
MOTOR INFORMATION
Motor Current, MTR1-3 CURRNT X A, TOT MTR CRNT X A
• consumption value of each individual motor in the system and the total current consumption of
all the motors
• "MTR1" is followed by "MTR2" and "MTR3" depending on which motor is being observed
Motor Voltage, MTR1-3 VOLTAGE X V
• AC Voltage level being delivered by the VFD to each individual motor in the system
Motor Power, MTR1 POWER X KW, TOT MTR PWR X KW
• consumption value of each individual motor in the system and the total power consumption of
all the motors
Motor Speed, MTR1-3 SPEED X RPM
• Motor Speed value of each individual motor in the system

Motor Frequency, MTR1-3 FREQ X HZ
• Motor operating Frequency value of each individual motor in the system

11
Pressures and Temps Menu
3.3 Pressures and Temps Menu
The Pressures and Temps menu gives access to the current status of all pressure and temperature values
in the compressor. Only a maximum of five pressure values and five temperature values may be active at a
time.The items under the Pressures and Temps Menu are shown on the fourth line of the display.
7,0 BAR 70°C

125 HRS AUTOMATIC
LOADED 100%
PRESSURES AND TEMPS
Inlet Temperature, INLET TEMPX °C *
• reflects the current ambient temperature outside the compressor
Interstage Pressure, INTRSTG P X BAR *
• reflects the current air pressure inside the interstage pipe of a two-stage compressor
Interstage Temperature, INTRSTG T X °C *
• reflects the current temperature inside the interstage pipe of a two-stage compressor
Discharge Temperature, DSCHRG TMP X °C
• reflects the current temperature at the discharge of the air end but before the air-oil separator
• also shown in the first line of the display if there is no Plant Temperature transducer in the
system, see "Plant Temperature, PLANT TEMP X °C *" on page 13
Reservoir Pressure, RES PRES X BAR *
• reflects the current air pressure at the "wet side" of the air-oil separator
Differential Pressure, DIF PRES X BAR *
• reflects the current air pressure differential across the air-oil separator
• shows the positive difference between the Reservoir Pressure and the Plant Pressure
Separator Pressure, SEP PRES X BAR *
• reflects the current air pressure at the "dry side" of the air-oil separator
Separator Temperature, SEP TEMP X °C *
• reflects the current temperature at the "dry side" of the air-oil separator
12
Pressures and Temps Menu
Plant Pressure, PLANT PRES X BAR
• reflects the current air pressure at the package discharge port
Plant Temperature, PLANT TEMP X °C *
• reflects the current temperature at the compressor package discharge port
Dryer Temperature, DRYER TEMP X °C *
• reflects the current refrigerant temperature of the integrated dryer if present in the system
Oil Pressure, OIL PRES X BAR *
• reflects the current oil pressure at the oil manifold, which is the main distribution point for the oil
injection system
13
Advisory and Shutdown History Menus
3.4 Advisory and Shutdown History Menus
The Advisory History menu provides immediate access to the system status during the last advisory faults
in the compressor. The Shutdown History menu provides immediate access to the system status during
the last shutdown faults in the compressor. Navigating through the system status information is identical for
the menus.
0,0 BAR 25°C 0,0 BAR 25°C

125 HRS AUTOMATIC 125 HRS AUTOMATIC
READY READY
ADVISORY HISTORY SHUTDOWN HISTORY
Advisory/Shutdown #1-6, ADVISORY #1-6, SHUTDOWN #1-6
By using the Up and Down Arrow buttons, each of the advisories is shown in the fourth line of the display.
If there are less than six advisories/shutdown faults stored in the controller, the end of the list is indicated
with NO MORE HISTORY text.
0,0 BAR 25°C

125 HRS AUTOMATIC
READY
1 = HIGH DISCH TEMP
When the desired advisory is shown, use the Plus and Minus buttons to access the system status, which
was stored at the time of the advisory.
0,0 BAR 25°C

125 HRS AUTOMATIC
READY
ADVISORY # 3
The following status items are stored at the time of an Advisory or Shutdown fault:
Total machine hours Motor 1 frequency

Inlet temperature Motor 1 speed
Interstage pressure * Motor 1 current
Interstage temperature * Drive 1 temperature
Discharge temperature Drive 1 DC bus voltage
Reservoir pressure * Most recent Drive 2 fault value *
Separator pressure * Motor 2 frequency *
Separator temperature * Motor 2 speed *
Plant pressure Motor 2 current *
Plant temperature * Drive 2 temperature *
Most recent Drive 1 fault value Drive 2 DC bus voltage *
Note! Items marked with * appear only if the parameter is available in the compressor.
14
Drive Information Menu *
3.5 Drive Information Menu *
The Drive Information menu gives access to the current status of all the VFD’s in the compressor. The
items under the Drive Information Menu are shown on the fourth line of the display.
0,0 BAR 25°C

125 HRS AUTOMATIC
LOADED 100%
DRIVE INFORMATION
Commanded Motor Frequency, V1-3 FRQ CMD X HZ
• Commanded Motor Frequency value of each individual drive in the system

• indicates the frequency at which each VFD is commanded to run by the controller
• “V1" is followed by "V2" and "V3" depending on which drive is being observed
Drive DC Bus Voltage, V1-3 DC X V
• DC Bus Voltage value of each individual drive in the system

• "V1" is followed by "V2" and "V3" depending on which drive is being observed
Drive Temperature, V1-3 TEMP X °C
• VFD Heat Sink Temperature value of each individual drive in the system
• V1" is followed by "V2" and "V3" depending on which drive is being observed
Drive Fault, DRIVE 1-3 FAULT
• shows fault value of each individual drive in the system

• "DRIVE 1" is followed by "DRIVE 2" and "DRIVE 3" depending on which drive is being observed
• Note! See the appropriate VFD manual for fault values and their meanings.
Drive Parameters, V1-3 VERSION X, DRIVES NP VOLTS, DRIVES NP HZ, DRIVES NP FLA
• VFD parameters
• needed for maintenance purposes only
15
Diagnostics Menu *
3.6 Diagnostics Menu *
The Diagnostics Menu gives access to the current value of a number of calculated parameters used in
controlling the compressor. The items under the Diagnostics Menu are shown on the fourth line of the
display.
0,0 BAR 25°C

125 HRS AUTOMATIC
LOADED 100%
DIAGNOSTICS
Drive Calculated Frequency Limits, V1-2 CALC MN X HZ, V1-2 CALC MX X HZ
• calculated Drive Frequency Limits of each main motor drive in the system
• indicates the minimum and maximum speed of each VFD
• "V1 CALC MN" is followed by "V1 CALC MX", "V2 CALC MN" and ""V2 CALC MX"
depending on which drive is being observed
Target Temperature, TARGET TMP X °C
• Target discharge Temperature calculated by the oil flow algorithm

• discharge temperature of the compressor is automatically kept at or greater than the displayed
value to avoid water condensation
Oil Valve Command, OIL VLV CMD X %
• shows the current position of the Precision Oil Mixing Valve

• a value of 50 % indicates that equal amounts of oil are flowing through the oil cooler and the oil
cooler bypass line
Voltage Controlled Fan, VOLT CRTL FAN X V
• shows the speed command sent to the voltage controlled fan
16
Operation Menu
3.7 Operation Menu
The Operation Menu contains a group of parameters, which can be altered while the compressor is
running. The items under the Operation Menu are shown on the fourth line of the display.
0,0 BAR 25°C

125 HRS AUTOMATIC
LOADED 100%
OPERATION
The parameters are:
Target Pressure, TARGT PRES = X BAR
Unload Pressure, UNLOD PRES = X BAR
Load Pressure, LOAD PRES = X BAR
Operation Mode, OP MODE X
How to make changes to the parameters:
• use the Up and Down Arrow buttons to choose the parameter

• values can be changed by using the Plus and Minus buttons
• to save the changes made, press ENTER button
Note! See the "Operation Adjustment Menu" on page 20 for more information on the parameters.
17
4. Adjustment Menus
4. Adjustment Menus
The Adjustment Menus 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.
The Adjustment Menus are only available when the compressor is stopped. The menus marked with * in
the listings of this manual are not available in all compressors. The menus available depend on the
features and/or settings of the compressor in question.
1. To enter the Adjustment Menu tree, press the ENTER button.
2. Press the Right or Left Arrow buttons to access one of the menus.
3. When the desired menu heading is shown in the second line of the display, press the ENTER
button to access the menu.
4. Use the Up and Down Arrow buttons to access the individual items in the selected menu.
5. Use the ENTER button to edit the selected parameter. To change the value, use Up and Down
Arrow buttons or Plus and Minus buttons.
6. To accept the changes made, press ENTER button. To disgard the changes, press STOP/
RESET button.
7. It is not necessary to navigate back to the top of a particular menu in order to enter another
menu. Press the STOP/RESET button to go back to the heading of the current menu. Then
use the Right or Left buttons to find the desired menu heading as described above.
8. To completely exit from the Adjustment menus, press the STOP/RESET button. If parameter
changes have been made, the following screen will appear.
STORE MODIFIED
PARAMETERS?
STOP = NO
ENTER = YES
9. To permanently save the changes that were made, press the ENTER button. If the STOP/
RESET button is pressed, the parameter changes that have been made are still valid but will
be lost the next time the controller is turned off.
The AirSmart™ Adjustment Menus are presented on the next page.
18
4. Adjustment Menus
Adjustment menus
Operation Adjustment Maintenance Adjust Unit Setup Adjust Configuration Adjust
LANGUAGE OIL FLTR IN UNIT PASSWORD COMPRESSOR MODEL
TARGET PRESSURE OIL CHNG IN OIL FILTER CHNG INT TOTAL RUN HOURMETER
UNLOAD PRESSURE OIL SEPR IN OIL CHANGE INTERVAL LOADED HOURMETER
LOAD PRESSURE AIR FLTR IN SEPARATOR CHNG INT REMOVE INTRSTG PRES
PRESSURE UNIT NXT CBOX FLTR IN AIR FILTER CHNG INT REMOVE RES PRES
TEMPERATURE UNIT MTR LUBE IN CTRL BOX FILTER INT REMOVE SEP PRES
OPERATING MODE TOTAL COST MOTOR LUBE INTERVAL REMOVE PLANT PRES
START TIMER HIGH PLANT PRES LIM REMOVE OIL PRES
STOP TIMER OVER TEMP LIMIT REMOVE SYSTEM PRES
BLOWDWN TIMER TEMP ALARM LIMIT DISTRIBUTOR INFO 1
BLOWDOWN COUNTER PLANT TEMP LIMIT DISTRIBUTOR INFO 2
AUTO TIME PLANT ALARM LIMIT ENERGY COST
REMOTE HALT DRYER TEMP LIMIT SYSTEM VOLTAGE
AUTO RESTART DRYER ALARM LIMIT ELEVATION
RESTART DELAY MIN TARGET TEMP INLET TEMP OFFSET
IDLE TIMER SELECT FAN TYPE INTRSTG TEMP OFFSET
MOTOR JOG? DISCHARGE TEMP OFFSET
DRAIN CLOSE INTERVAL SEP TEMP OFFSET
DRAIN OPEN INTERVAL PLANT TEMP OFFSET
LIMIT CAPACITY DRYER TEMP OFFSET
MIN TARGET PRESSURE OIL TEMP OFFSET
OIL TYPE
PP ADV TIMEOUt
SECONDARY PRESSURES
Note! Items and menus marked with grey filled boxes may not appear on the controller depending on the composition
and type of the compressor.
All the passwords are entered under the Unit Setup Adjust menu. The Configuration Adjust menu is shown
only if the passwords are entered.
19
4. Adjustment Menus
Operation Adjustment Menu
4.1 Operation Adjustment Menu
The Operation Adjustment menu provides access to the parameters that control the basic operation of the
compressor. The names of the items under the Operation Adjustment Menu are shown on the second line
of the display. The value of the item is shown on the third line of the display.
ADJUSTMENT MENU
OPERATION ADJUSTMENT
(SELECT SUB MENU)
Language, LANGUAGE-LANGUAGE
• can also be entered directly by holding down the STOP/RESET button for five seconds when
the compressor is stopped
• up to eight different language translations available at one time
Target Pressure, TARGET PRESSURE X BAR
• pressure set point of the compressor

• min value: min Target Pressure in Unit Setup adjustment Menu
• max value: High Plant Pressure Limit - 0,6 bar
• changing the Target Pressure affects also the Unload and Load pressures, for example:
Target pressure 7,0 bar → 7,2 bar

Unload pressure 7,5 bar → 7,7 bar
Load pressure 7,0 bar → 7,2 bar
Operation at excessive discharge air pressure can cause personal injury or damage to equipment. Do not
adjust the full discharge air pressure above the maximum stamped on the compressor name plate.
Unload Pressure, UNLOAD PRESSURE X BAR
• pressure value where the compressor unloads and stops

• Unload Pressure value can not be set lower than Target Pressure + 0,3 bar
• when the Target Pressure is changed, the Unload Pressure changes accordingly to keep the
difference between the pressures the same, see "Target Pressure, TARGET PRESSURE X
BAR" on page 20
• min value: Target Pressure + 0,3 bar
• max value: High Plant Pressure Limit - 0,3 bar
20
4. Adjustment Menus
Load Pressure, LOAD PRESSURE X BAR
• pressure value where the compressor loads again after an unload/stop sequence
• cannot be set higher than Target Pressure
• when the Target Pressure is changed, the Load Pressure changes accordingly to keep the
difference between the pressures the same, see "Target Pressure, TARGET PRESSURE X
BAR" on page 20
• min value: 2,0 bar
• max value: Target Pressure
Pressure Units, PRESSURE UNIT X
• determines how the pressure values will be displayed on the control panel
• pounds per square inch (PSI)
• bar (BAR)
• kiloPascals (KPA)
• kilograms per square centimeter (KGC)
Temperature Units, TEMPERATURE UNIT X
• determines how the temperature values will be displayed on the control panel
• Fahrenheit (°F)
• Celsius (°C)
Operating Mode, OPERATING MODE X
• Automatic: The compressor uses its internal modulation algorithms and the motor(s) will stop
after goes through the unload/blowdown process.
• Sequence: The compressor is part of a sequenced group of machines.
• Constant: The compressor operates only in loaded or unloaded state. It doesn’t stop or blow
down.
• Low demand: The compressor uses its internal modulation algorithms but motor(s) will NOT
stop after it goes through the unload/blowdown process.
Start Timer, START TIMER X SECONDS
• used to control how long the compressor runs at minimum speed before it is allowed to
modulate or run at maximum speed
• min value: 0 seconds
• max value: 600 seconds
21
4. Adjustment Menus
Stop Timer, STOP TIMER X SECONDS
• when the STOP/RESET button is pressed or a remote stop is activated, the compressors will
blow down and the motor(s) will run at minimum speed until this timer expires
Blowdown Timer, BLOWDWN TIMER X SECONDS
• used to control the amount of time the compressor runs unloaded before starting to blowdown
• min value: 1 second
Blowdown Counter, BLOWDOWN COUNTER X CYCLES
• used to control the number of unload/blowdown cycles the compressor can execute
• when the Blowdown Counter reaches zero, the compressor will skip the Unload State and go
directly to the Blowdown State
• reset to the programmed value when the compressor returns to the Modulation State from
either the Unload or Blowdown State
• min value: 0 cycles
• max value: 10 cycles
Auto Timer, AUTO TIMER X MINUTES
• used to control the amount of time the compressor will run (at minimum speed) during the
blowdown process
• when the Auto Timer expires, the compressor will stop provided the Operating Mode is set to
Automatic
• min value: 0 minutes
• max value: 20 minutes
Remote Halt, REMOTE HALT X
• controls how the compressor will stop if a Remote Halt signal is detected on one of the
controller's digital inputs
• refer to the appropriate compressor’s Electrical Drawings for connection of an external Remote
Halt signal
• Timed Unload: The compressor will stop after the Blowdown and Auto Timers have expired.
• Immediate: The compressor will stop according to the Stop timer.
22
4. Adjustment Menus
Auto Restart, AUTO RESTART X
• if auto restart is ON, the compressor will start up automatically after a power failure
• default value: OFF
Automatic restarting of the compressor can cause injury or death.
Restart Delay, RESTART DELAY X SECONDS *
• controls how long the compressor will wait to start after power has been restored
Idle Timer, IDLE TIMER X MINUTES
• used to control the blowdown of the ail/oil reservoir during long periods of compressor inactivity
• disabled when set to 0
• min value: 0 minutes
• max value: 120 minutes
23
4. Adjustment Menus
Maintenance Adjust Menu
4.2 Maintenance Adjust Menu
The Maintenance Adjust menu provides a means for resetting the maintenance timers after servicing the
compressor. The names of the items under the Maintenance Adjust Menu are shown on the second line of
the display. The value of the item is shown on the third line of the display.
ADJUSTMENT MENU
MAINTENANCE ADJUST
(SELECT SUB MENU)
The maintenance timers are:
Oil filter change timer, OIL FLTR IN X HRS *
Oil change timer, OIL CHNG IN X HRS *
Oil separator element change timer, OIL SEPR IN X HRS *
Air filter change timer, AIR FLTR IN X HRS *
Control box filter change timer, NXT CBOX FLTR IN X HRS *
Motor lubrication timer, MTR LUBE IN X HRS *
After the maintenance has been done:
• Select the appropriate timer and press the ENTER button to select timer reset. The default
timer intervals can be set in the Unit Setup Adjust menu, see "Unit Setup Adjust Menu" on page
25.
• Press the ENTER button again to reset the timer to the default value. The STOP/RESET button
will abort the timer reset.
Total Cost, TOTAL COST X €
• the total operating cost reset screen

• reset to 0 by pressing the ENTER button twice
24
4. Adjustment Menus
Unit Setup Adjust Menu
4.3 Unit Setup Adjust Menu
The Unit Setup Adjust menu provides access to the parameters that control advanced operation of the
compressor. The parameters in the Unit Setup adjust menu can only be changed if the correct value has
been entered into the Unit Password menu item.The names of the items under the Unit Setup Adjust Menu
are shown on the second line of the display. The value of the item is shown on the third line of the display.
ADJUSTMENT MENU
UNIT SETUP ADJUST
(SELECT SUB MENU)
Unit Password, UNIT PASSWORD
• correct value entered here will allow the items in this menu and the Configuration Adjust menu
to be changed, see "Configuration Adjust Menu *" on page 31
Oil Filter Change Interval, OIL FILTER CHNG INT X HRS
• sets the default oil filter change countdown timer value

• the oil filter change timer can be reset under the Maintenance Adjust menu, see "Oil filter
change timer, OIL FLTR IN X HRS *" on page 24
• min value: 0 hours
• max value: 4000 hours
Oil Change Interval, OIL CHANGE INTERVAL X HRS
• sets the default oil change countdown timer value

• the oil change timer can be reset under the Maintenance Adjust menu, see "Oil change timer,
OIL CHNG IN X HRS *" on page 24
Separator Element Change Interval, SEPARATOR CHNG INT X HRS
• sets the default separator change countdown timer value

• the separator change timer can be reset under the Maintenance Adjust menu, see "Oil
separator element change timer, OIL SEPR IN X HRS *" on page 24
25
4. Adjustment Menus
Air Filter Change Interval, AIR FILTER CHNG INT X HRS
• sets the default air filter change countdown timer value

• the air filter change timer can be reset under the Maintenance Adjust menu, see "Air filter
change timer, AIR FLTR IN X HRS *" on page 24
Control Box Change Interval, CTRL BOX FILTER INT X HRS
• sets the default control box filter change countdown timer value
• the control box filter timer can be reset under the Maintenance Adjust menu, see "Control box
filter change timer, NXT CBOX FLTR IN X HRS *" on page 24
Motor Lubrication Interval, MOTOR LUBE INTERVAL X HRS
• sets the default motor lubrication countdown timer value

• the motor lubrication timer can be reset under the Maintenance Adjust menu, see "Motor
lubrication timer, MTR LUBE IN X HRS *" on page 24
High Plant Pressure Limit, HIGH PLANT PRES LIM X BAR
• sets the maximum internal pressure limit where the compressor will shut down
• sets also the limit for maximum unload pressure
• max value: 13,8 bar
• Note! The parameter affects the maximum target pressue value.
Operation of the compressor with improper High Plant Pressure Limit setting can cause personal injury or
damage to equipment. Do not adjust the High Plant Pressure Limit above the level of the pressure relief
valve or 13,8 bar.
26
4. Adjustment Menus
Over Temperature Shutdown Limit, OVER TEMP LIMIT X °C
• sets the maximum internal temperature limit where the compressor will shut down
• min value: 79°C
• max value: 115°C
Operation of the unit at excessive high temperatures can cause personal injury or damage to equipment. Do
not adjust the Over Temperature Shutdown Limit above 115°C.
Temperature Alarm Limit, TEMP ALARM LIMIT X °C
• sets the internal temperature limit at which the compressor will give an advisory alarm
Plant Temperature Shutdown Limit, PLANT TEMP LIMIT X °C
• sets the maximum package discharge temperature limit where the compressor will shut down
Plant Temperature Alarm Limit, PLANT ALARM LIMIT X °C
• sets the package discharge temperature limit at which the compressor will give an advisory
alarm
Dryer Temperature Shutdown Limit, DRYER TEMP LIMIT X °C
• sets the dryer's maximum coolant temperature limit where the compressor will shut down
Dryer Temperature Alarm Limit, DRYER ALARM LIMIT X °C
• sets the dryer coolant's temperature limit at which the compressor will give an advisory alarm
Minimum Target Temp, MIN TARGET TEMP X °C
• sets the minimum temperature reference point for the oil-mixing valve
27
4. Adjustment Menus
Select Fan Type, SELECT FAN TYPE X
• alerts the controller as to which type of fan is being used with the air/oil cooler
• Single Speed Fan: The air/oil cooler fan uses a standard fixed speed motor.
• Two Speed Fan: The air/oil cooler fan uses a dual winding motor.
• Variable Speed Fan: The air/oil cooler uses a VFD to control fan speed based on the
discharge temperature of the compressor.
• Water Cooled: This is used in watercooled compressors.
• Variable Speed Fan (V1 Power): The air/oil cooler uses a VFD to control fan speed based on
the output power from the main motor.
Motor Jog, MOTOR JOG? X SECONDS
• cause all of the motors in the compressor to run for the programmed amount of time when the
ENTER button is pressed
• used to check the rotation of the motors after the main power has been connected to the
compressor
• min value: 0,1 seconds
• max value: 2,0 seconds for VFD compressors and 0,5 seconds for fixed speed compressors
Do not operate the compressor with the fan or coupling guard removed. Exposed fan and couplings may
cause personal injury.
The air end's direction of rotation must be checked every time the compressor is reconnected to the power
supply.
Drain Close/Open Intervals, DRAIN CLOSE INTERVAL X SECONDS, DRAIN OPEN INTERVAL X SECONDS
• used to control a solenoid operated drain valve in a water separator or integrated dryer
• Drain Close Interval, in variable speed compressors, is variable and dependant upon the speed
of the main motor
• setting the Drain Open Interval to 0 disables the water drain function
• Drain Close min value: 1 second
• Drain Close max value: 180 seconds
• Drain Open min value: 0 seconds
• Drain Open max value: 10 seconds
• Actual Drain Close Time (in VS compressors) = Drain Close Interval / (% of full speed/100).
Drain Close Interval Calculation Example:
Speed of main motor: 80%
Drain Close Interval setting: 30 seconds
30
Actual Drain Close Time = -------------------- = 37 ,5 sec
80 ⁄ 100
28
4. Adjustment Menus
Limit Capacity, LIMIT CAPACITY X %
• controls the maximum speed of a variable speed compressor

• min value: 50 %
• max value: 100 %
Minimum Target Pressure, MIN TARGET PRESSURE X BAR
• sets the lower limit for the Target Pressure parameter in the Operation Adjustment menu, see
"Target Pressure, TARGT PRES = X BAR" on page 17
• should be set equal to or greater than the minimum pressure valve setting
• max value: 7,0 bar
Oil Type, OIL TYPE X
• determines how fast the Oil Change Timer will count down as the compressor discharge
temperature rises
• Standard: The Oil Change Timer counts down with normal aging rate at higher temperatures.
Use with AEON 3000 (type F 2105) or AEON 9000SP lubricants.
• High Temp: The Oil Change Timer counts down with slower aging rate at higher temperatures.
Use with AEON 9000TH lubricant.
• Food Grade: The Oil Change Timer counts down as with Standard Oil. Use with AEON
6000FG.
Oil type selections
Oil aging clock Standard/Food Grade High Temp oil

multiplier oil temp break points break points
X1 < 82 °C < 98 °C
X 1,3 82 - 87 °C 98 - 103 °C
X2 88 - 92 °C 104 - 108 °C
X4 93 - 102 °C > 109 °C
X8 103 - 112 °C
X 16 > 113 °C
Plant Pressure Advisory Timeout, PP ADV TIMEOUT X MINUTES
• sets the time interval after which the plant pressure advisory is given if the plant pressure stays
continually below the target pressure setting
• if the value is set to zero, the plant pressure advisory is disabled
• min value: 0 min
• max value: 30 min
29
4. Adjustment Menus
Secondary Pressures, SECONDARY PRESSURES X BAR
• when corresponding digital input is activated or the function is activated through the week clock,
the controller adds secondary pressures’ value to the present Target, Load and Unload
pressures
• min value: - 4,1 bar
• max value: + 2,1 bar
• for example:
Secondary pressure - 1,5 bar

Target pressure 7,0 bar → 5,5 bar
Unload pressure 7,5 bar → 6,0 bar
Load pressure 7,0 bar → 5,5 bar
30
4. Adjustment Menus
Configuration Adjust Menu *
4.4 Configuration Adjust Menu *
The Configuration Adjust menu also provides access to the parameters that control advanced operation of
the compressor. The parameters in the Configuration Adjust menu are not visible unless the correct value
has been entered into the Unit Password menu item in the Unit Setup Adjust menu. The names of the
items under the Configuration Adjust Menu are shown on the second line of the display. The value of the
item is shown on the third line of the display.
ADJUSTMENT MENU
CONFIGURATION ADJUST
(SELECT SUB MENU)
Compressor Model, COMPRESSOR MODEL X
Note! Selecting a compressor model from the Model Table will reset all of the adjustable parameters to the factory set
default values.
Selecting an incorrect Model Type can cause personal injury or damage the equipment.
Total Run Hourmeter, TOTAL RUN HOURMETER X HRS
• records the number of hours the compressor‘s main motor has been running
• value shown in the second line of the normal display as well as under the Maintenance Info
menu in the Operational Menu tree, see "Total Hours, X TOT HOURS" on page 8
• cannot be changed and will not appear in the menu tree unless the current value is zero
Loaded Hourmeter, LOADED HOURMETER X HRS
• records the number of hours that the compressor has been loaded
• value shown under the Maintenance Info menu in the Operational Menu tree, see "Loaded
Hours, X LOAD HRS" on page 8
• cannot be changed and will not appear in the menu tree unless the current value is zero
31
4. Adjustment Menus
The pressure transducer zero sets are:
Interstage Pressure, REMOVE INTRSTG PRES X VOLT
Reservoir Pressure, REMOVE RES PRES X VOLT
Oil Separator Pressure, REMOVE SEP PRES X VOLT
Plant Pressure (compressor discharge), REMOVE PLANT PRES X VOLT
Oil Pressure, REMOVE OIL PRES X VOLT
System Pressure, REMOVE SYSTEM PRES X VOLT
• used for setting the zero point of the pressure transducers in the compressor
• After all pressure has been removed from the system, navigate to the appropriate transducer
and press the ENTER button to select the zero pressure point. With zero pressure, the display
should read 0,50 Volts +/- 0,05 Volts.
• Pressing the ENTER button again will accept the displayed voltage as the zero pressure value.
The STOP/RESET button will abort the set point process.
Distributor Information #1, DISTRIBUTOR INFO 1 X
• used to set up a contact name

• appears in the display when a service item such as an air filter or oil change is needed
Distributor Information #2, DISTRIBUTOR INFO 2 X
• used to set up a contact number

• appears in the display when a service item such as an air filter or oil change is needed
Energy Cost, ENERGY COST X €/KWH
• should be set equal to the cost of each kWH that appears in the power bill
• used to calculate the Current Energy Cost and Cumulative Energy Cost values under the
Maintenance Info menu in the Operational Menu tree, see "Current Energy Cost, ENERGY
COST X €/H *" on page 10 and "Cumulative Energy Cost, TOTAL COST X € *" on page 10
• min value: 0,001
• max value: 65,000
System Voltage, SYSTEM VOLTAGE X V
• should be set to line voltage value present at the installation site

• controls the protective voltage limiter used in variable speed compressor applications
• failure to set this parameter to the correct value may limit the maximum running speed of the
unit
• min value: 115 Volts
• max value: 1000 Volts
32
4. Adjustment Menus
Elevation, ELEVATION X M
• should be set equal to the elevation above sea level at the compressor site
• used to de-rate the compressor drive system at higher elevations where heat dissipation is less
effective
• no de-rating performed at elevations below 1000 m (3300 feet)
• min value: 0 meters
• max value: 9144 meters
The temperature offset settings are:
Inlet Temperature Offset, INLET TEMP OFFSET X °C
Interstage Temperature Offset, INTRSTG TEMP OFFSET X °C
Discharge Temperature Offset, DISCHARGE TEMP OFFSET X °C
Separator Temperature Offset, SEP TEMP OFFSET X °C
Plant Temperature Offset, PLANT TEMP OFFSET X °C
Dryer Temperature Offset, DRYER TEMP OFFSET X °C
Oil Temperature Offset, OIL TEMP OFFSET X °C
• can be used to fix the offset on different temperatures

• min value: - 4 °C
• max value: + 5 °C
33
5. Error Management
5. Error Management
The AirSmart™ Controller can control up to three variable speed motor drives. It can read more than ten
analog inputs with expansion board and a host of digital I/O in order to achieve system objectives. There
are numerous tests that are performed every second by the controller in order to determine the state of the
compressor system. Many of those tests are designed to check, if certain parameters have been exceeded
so that action can be taken to protect the compressor.
5.1 Advisory Alarms
The advisory alarms alert the user of needed service or that certain parameters may be approaching their
shutdown level. Advisory alarms can be reset while the compressor is running or stopped by pressing the
ENTER button. If the error condition still exists after resetting the advisory alarm, the advisory alarm will
occur again. The status of the compressor at the time of the last six advisories is stored in nonvolatile
memory, which can be accessed through the Advisory History menu.
Advisory alarm information scrolls in the fourth line of the control panel display.
7,0 BAR 70°C

125 HRS AUTOMATIC
LOADED 100 %
ADVISORY # 302
The scrolling text indicates:
1. advisory number
2. short description of the fault (advisory text)
3. if service is necessary, the information adjusted in the Distributor Info 1 and 2 menus
See the following table for advisory alarms that can occur in the controller.
Advisory alarms
Advisory Advisory text Description Action
Differential pressure > 0,5

# 301 CHANGE SEPARATOR Change separator element
Bar
Vacuum switch on package

# 302 CHANGE AIR FILTER Change air filter
inlet has tripped
Maintenance timer for air

# 303 CHANGE AIR FILTER Change air filter and reset timer
filter change has expired
Maintenance timer for oil

# 304 CHANGE OIL FILTER Change oil filter and reset timer
filter change has expired
34
5. Error Management
Advisory alarms
Maintenance timer for oil

# 305 CHANGE OIL Change oil and reset timer
change has expired
Locate compressor to area

Package discharge (Plant)
# 306 LOW AMB TEMP A where ambient temperature >
temperature < 4°C
0°C
Locate compressor to area

Separator temperature <
# 307 LOW AMB TEMP B where ambient temperature >
4°C
0°C
Check oil cooler system

Temperature in separator >
# 308 HIGH SEP TEMP functionality or reduce package
(Preset Value)
power
Temperature at package Check air cooler functionality or

# 309 HIGH PLANT TEMP
discharge > (Preset Value) reduce package power
Temperature at package
inlet > 45°C. On some Wait for ambient temperature to
# 310 HIGH INLET TEMP
models, this may trigger at cool
40°C
Maintenance timer for

Change separator element and
# 315 CHANGE SEPARATOR separator element change
reset timer
has expired

Temperature at airend
# 316 HIGH DISCH TEMP functionality or reduce package
discharge > (Preset Value)
power
Temperature in interstage Check oil cooler system

HIGH INTERSTG
# 317 pipe > 110°C (two-stage functionality or reduce package
TEMP
package only) power
Digital input programmed for

# 318 OPTIONAL ALARM Check device connected to input
Optional Alarm has tripped
Pressure switch in oil filter

# 320 CHANGE OIL FILTER Change oil filter
assembly has tripped

# 321 LOW VOLTAGE Check line voltage
Low Voltage has tripped
Digital input programmed for Check main motor(s)

# 322 MOTOR OVERTEMP Motor Over Temperature temperature or reduce package
has tripped power

# 323 WATER PRESSURE Check water pressure
Water Pressure has tripped

# 324 HIGH VIBRATION Check for source of vibration
High Vibration has tripped
35
5. Error Management
Advisory alarms
Temperature at airend
# 325 LOW DISCH TEMP discharge < 85°C (two-stage
functionality
package only)
Temperature at dryer > Integrated dryer may have shut

# 326 HIGH DRYER TEMP
(Preset Value) down, check dryer functionality
CHANGE MOTOR Motor lubrication interval Lubricate motor(s) and reset

# 327
LUBE timer has expired timer.
Compressor is unable to
# 328 PLANT PRESSURE maintain target pressure Reduce demand on compressor
setting
Oil pressure has dropped

below (Interstage Pressure Change oil filter or check for oil
# 329 LOW OIL PRESSURE
+ 0,3 Bar) in two-stage system leaks or plugs.
compressor
Check if control box air has

Main drive heatsink
# 330 V1 MAX SINK TEMP become clogged or ambient
temperature > 76°C
temperature too high
Check if control box air has

Second stage drive heatsink
# 331 V2 MAX SINK TEMP become clogged or ambient
temperature > 76°C
temperature too high
CHNG CTRL BOX Control box filter change Change or clean control box air
# 332
FILTER interval timer has expired filter element
Integrated dryer has shut

# 333 DRYER ALARM Check dryer functionality
down.
36
5. Error Management
5.2 Shutdown Faults
The shutdown faults in the controller are designed to protect the compressor from component failure or
extreme environmental conditions. Shutdown faults can be reset by pressing the STOP/RESET button
after the compressor has been stopped. If the error condition still exists, the shutdown fault can not be
reset. Error condition is indicated by a blinking Shutdown LED.
The status of the compressor at the time of the last six advisories is stored in nonvolatile memory. It can be
accessed through the Advisory History menu. The shutdown number is shown in the second line. A short
description of the fault is shown in the third line.
0,0 BAR 115°C

SHUTDOWN # 128
HIGH DISCH TEMP
NO SERVICE ADVISORY
See the following table for shutdown faults that can occur in the AirSmart™ Controller.
Shutdown faults
Shutdown Shutdown text Description Action
Check fan motor and

# 101 FAN FAULT Cooler or vent fan fault
associated fuses and wiring.
Main motor VFD has shut Check main motor VFD

# 102 DRIVE 1 FAULT
down operation
Main motor VFD #2 has

Check main motor VFD #2
# 103 DRIVE 2 FAULT shut down (two-stage
operation
package only)
Cooler fan motor VFD has

Check cooler fan motor VFD
# 104 DRIVE 3 FAULT shut down (when
operation
equipped)
Compressor stopped
Turn Emergency Stop button
# 105 EMERGENCY STOP using Emergency Stop
to its normal position
button
Check wiring between

Connection to pressure
# 106 OPEN XDUCER XD5 pressure transducer XD5 and
transducer XD5 is open
controller
Pressure at package
Check for sources of high
# 107 HIGH PLANT PRES discharge > (Preset
system pressure
Value)

# 108 SHORTED XDUCER XD5 pressure transducer XD5 and
transducer XD5 is shorted
controller

controller
37
5. Error Management
Shutdown faults
Pressure in separator tank Check for sources of high

# 110 HIGH SEP PRES
> (Preset Value) system pressure

controller

controller
Pressure at airend
Check for sources of high
# 113 HIGH RESVR PRES discharge > (Preset
system pressure
Value)

controller

controller
Pressure in interstage Check for sources of high

# 116 HIGH INT PRES
pipe > (Preset Value) system pressure

controller

controller

controller
Connection to thermistor Check wiring between

# 121 OPEN THERM T5
T5 is open thermistor T5 and controller
Check air cooler functionality
# 122 HIGH PKG DISCH TMP discharge > (Preset
or reduce package power
Value)

# 123 SHORTED THERM T5
T5 is shorted thermistor T5 and controller

# 124 OPEN THERM T4

Temperature in separator
# 125 HIGH SEP TEMP functionality or reduce
> (Preset Value)
package power
38
5. Error Management
Shutdown faults


# 127 OPEN THERM T3
Temperature at airend Check oil cooler system

# 128 HIGH DISCH TEMP discharge > (Preset functionality or reduce
Value) package power


# 130 OPEN THERM T2
Temperature in interstage Check oil cooler system

# 131 HIGH INTERSTG TMP pipe > (Preset Value) functionality or reduce
(two-stage package only) package power


# 133 OPEN THERM T1
Ambient temperature too

# 134 HIGH INLET TEMP high for safe compressor
inlet > 45°C
operation

Fan Aux input does not

Check fan contactor
# 138 FAN STARTER match Cooler Start digital
operation
output
Main motor VFD start Check main motor VFD

#139 DRIVE 1 STARTER
failure operation
Main motor VFD #2 start

Check main motor VFD #2
# 140 DRIVE 2 STARTER failure (two-stage package
operation
only)
Cooler fan motor VDF Check cooler fan motor VFD

# 141 DRIVE 3 STARTER
start failure operation
Loss of power to
# 142 POWER FAILURE Check line voltage
compressor package
Controller internal Replace controller, check

# 143 XB1 COMM ERROR
communications failure PIO settings for fault entries
Communications failure Check wiring or

# 144 DRIVE 1 COMM ERROR between controller and communications parameters
main motor VFD in main motor VFD
39
5. Error Management
Shutdown faults
Communications failure
Check wiring or
between controller and
# 145 DRIVE 2 COMM ERROR communications parameters
main motor VFD #2 (two-
in main motor VFD #2
stage package only)
Check wiring or
between controller and
# 146 DRIVE 3 COMM ERROR communications parameters
cooler fan motor VFD
in cooler fan motor VFD
(when equipped)
Digital input programmed

Check device connected to
# 147 OPTIONAL SHUTDOWN for Optional Shutdown
input
has tripped

# 148 LOW VOLTAGE for Low Voltage has Check line voltage
tripped

# 149 PHASE SEQUENCE for Phase Sequence has Check phase relay
tripped

Check main motor(s) or
# 150 MOTOR OVERTEMP for Motor Over
reduce package power
Temperature has tripped

# 151 WATER PRESSURE for Water Pressure has Check water pressure
tripped

# 152 HIGH VIBRATION for High Vibration has Check for source of vibration
tripped
Pressure transducer XD5

Zero pressure transducer
# 153 ZERO XDUCER XD5 not properly zeroed or
XD5 or remove vacuum
vacuum present in system




# 160 CONTROLLER ERROR Controller internal failure Replace controller
40
5. Error Management
Shutdown faults
Main parameter set in

# 161 EEPROM RESTORED nonvolatile memory No action required
restored with backup set
Valid compressor model

not selected during factory Select valid compressor
# 164 INVALID MODEL
setup or controller model from model table
replacement
24 VDC input to controller

# 165 DC POWER LOW Check 24 VDC power supply
< 20 VDC
Integrated dryer may have

Temperature at dryer >
# 166 HIGH DRYER TEMP shut down, check dryer
(Preset Value)
functionality

# 167 OPEN THERM T6

Model Table in memory

# 169 CM TABLE INVALID Load new Model Table values
has been corrupted
ACTUATOR COMM Check wiring or mixing valve
# 170 between controller and
ERROR operation
mixing valve
Oil pressure has dropped

below (Interstage Change oil filter or check for
# 171 LOW OIL PRESSURE
Pressure + 0,2 Bar) in oil system leaks or plugs.
two-stage compressor
Communications failure Remove and reconnect or

# 172 SEQUENCER COMM ERR between controller and replace communications
communications module module

communications module

#174 SHORTED XDUCER XD6 pressure transducer XD6 and


#176 OPEN XDUCER XD7 pressure transducer XD7 and
41
5. Error Management
Shutdown faults


#178 ZERO XDUCER XD7 not properly zeroed or
Pressure in reservoir < 1

# 201 LOW SUMP PRES Bar after one minute of Check inlet valve operation
compressor operation
Differential pressure > 1

# 202 CHANGE SEPARATOR Change separator element
Bar
42
5. Error Management
5.3 Transducer Locations
The Gardner Denver compressors with AirSmart™ controller can be equipped with a number of
temperature and pressure transducers to monitor status and control the compressor. See the table for
locations, where the transducers are typically used, depending on the version of the controller installed in
the compressor.
Locations of the transducers
AirSmart™ Controller with AirSmart™ Controller

AirSmart ™ Controller
Transducer Expansion Board P/N: Communications
P/N: 89864799
300ETK1173 Module P/N: 301ETK1173
T1 Discharge temperature Discharge temperature
T2 Inlet temperature Inlet temperature
T3 Plant temperature
T4 Separator temperature
T5 Interstage temperature
XD1 Plant pressure Plant pressure
XD2 Reservoir pressure Reservoir pressure
XD3 Separator pressure
XD4 Oil pressure
XD5 Interstage pressure
XD6 System pressure
XD7 Spare
43

AirSmart Control Manual 002

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AIRSMART™ CONTROLLER

EN © 2007 Gardner Denver

1. Introduction and Safety ........................................................................................................ 1

3. Operational Menus ................................................................................................................ 6

4. Adjustment Menus .............................................................................................................. 18

5. Error Management ............................................................................................................... 34

1. Introduction and Safety

1.1 Storing the Books

Always read the safety instructions before starting to work.

2.1 AirSmart™ Control Panel

AirSmart™ Control Panel

2.3 Button Functions

1. Up Arrow button navigates vertically inside a menu. It scrolls through nonnumerical

3. RUN button starts the compressor.

2.4 Indicator Functions

1. Shutdown LED (red) indicates a shutdown fault in the compressor.

2. Service LED (yellow) indicates a service advisory fault in the compressor.

The AirSmart™ Operational Menus are presented on the next page.

Maintenance Motor Pressure Advisory Shutdown Drive

MTR LUBE IN MTR1 POWER SEP TEMP V2 TEMP

START TIMER MTR2 POWER PLANT PRES V3 TEMP

AVG PKG PWR MTR3 SPEED

ENERGY COST MTR1 FREQ

TOTAL COST MTR2 FREQ

3.1 Maintenance Info Menu

0,0 BAR 25°C

Total Hours, X TOT HOURS

Loaded Hours, X LOAD HRS

• shows the number of hours the compressor has been loaded

Time To Next Oil Filter Change, OIL FLTR IN X H *

Time To Next Oil Change, OIL CHNG IN X H *

Time To Next Separator Element Change, OIL SEPR IN X H *

Time To Next Air Filter Change, AIR FLTR IN X H *

Time To Control Box Filter Change, NXT CBOX FLTR IN X H *

Time To Next Motor Lubrication, MTR LUBE IN X H *

• shows the number of hours before motor lubrication is needed

Start Timer, START TIMER X

• shows the current value of the Start Timer

Blowdown Timer, BLOWNDWN TIMER X

• shows the current value of the Blowdown Timer

Auto Timer, AUTO TIMER X

• shows the current value of the Auto Timer

Average Capacity, AVG CAP X M3 *

Average Percent Capacity, AVG CAP X % *

Average Package Power, AVG PKG PWR X KW *

Current Energy Cost, ENERGY COST X €/H *

Cumulative Energy Cost, TOTAL COST X € *

• shows the Cumulative Energy Cost of operating the compressor

Firmware Versions, V1-V3 VERSION

Show the current versions of:

• Controller Firmware (CFW)

3.2 Motor Information Menu *

7,0 BAR 70°C

Motor Current, MTR1-3 CURRNT X A, TOT MTR CRNT X A

Motor Voltage, MTR1-3 VOLTAGE X V

Motor Power, MTR1 POWER X KW, TOT MTR PWR X KW

Motor Speed, MTR1-3 SPEED X RPM

• Motor Speed value of each individual motor in the system

Motor Frequency, MTR1-3 FREQ X HZ