Gardner Denver AIRSMART User Manual Download

Page: 1 / 80

13-17-613

Version: 01

March 1, 2017

AirSmart

CONTROLLER

GENERATION

USER’S
MANUAL

(Compressor
Application)

Summary of Contents for AIRSMART

Page 1: ...13 17 613 Version 01 March 1 2017 AirSmart CONTROLLER 2nd GENERATION USER S MANUAL Compressor Application...

Page 2: ...mical 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...

Page 3: ...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 Elec...

Page 4: ...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 a...

Page 5: ...3 2 Setting Target Pressure 20 3 3 Setting Unload Pressure 22 3 4 Setting Load Pressure 23 3 5 Setting to Automatic Mode 24 3 6 Menu Structure at a Glance 24 4 Air Compressor Control 26 4 1 Variable...

Page 6: ...O Mapping Diagnostics 56 5 4 8 Multi Machine Sequencing 61 5 4 9 Oil Control Setup 63 5 4 10 Control Pressure 64 5 4 11 Motor Jog 65 5 5 Alarm History 65 6 Error Management 66 6 1 Advisory Faults 66 6...

Page 7: ...story and Software Compatibility Version Date Notes Current AirSmart G2 Firmware Version 00 January 27 2014 First release Supports fixed speed packages 1 0 2 01 February 20 2017 Supports VS and variab...

Page 8: ...needs of large compressor packages Three 4 20 mA analog inputs in support of analog pressure transducers Up to five additional 4 20 mA inputs available on I O expansion Three analog RTD inputs in sup...

Page 9: ...rve system status using its 320x240 color pixel display two status LED indicators seven navigational buttons and two control buttons 2 1 2 Emergency Stop Button The Emergency Stop button when pressed...

Page 10: ...n Figure 2 1 Button A1 will navigate to the Distributor Information screen Button A2 will navigate the user to the Notices screen Button A3 will navigate the user to the Maintenance screen and Button...

Page 11: ...rence for cooling control and some temperature based safety actions Operating mode reflects the current operating mode setting of the controller This will be one of Automatic Low Demand Constant Seque...

Page 12: ...s the blowdown timer to start The compressor will transition to loaded if delivery pressure falls below the Load Pressure setting or to blowdown state if the blowdown timer expires Blowdown The compre...

Page 13: ...he machine by displaying a different icon if any faults or advisories are active on the system The button next to this icon is used to navigate to the notice history screen See section 2 3 3 for more...

Page 14: ...con will navigate back to the home screen Pressing the button next to the Trend button will navigate to the trend history of this sensor reading recorded over time as described in section 2 3 2 2 2 3...

Page 15: ...in readings in one location These screens can be accessed immediately from the home screen by pressing the Previous button An example of the sensor summary screen is shown in Figure 2 6 and an example...

Page 16: ...ibutor information screens to display distributor contact information and consumable part numbers Regardless of the state of the machine pressing the button to the right of the status icon will naviga...

Page 17: ...he percentage of life remaining on the timer For example a maintenance timer with a 1000 hour interval and 500 running hours since the last change would display at 50 life indicated by the Half label...

Page 18: ...case this is due to the timer being disabled on this package by setting the Motor Lube Timer Interval to 0 hours If an interval is set to 0 hours no maintenance advisory will be triggered based on th...

Page 19: ...e 2 13 The Select User menu will appear as shown in Figure 2 14 Figure 2 13 Main Menu Figure 2 14 Select User Screen 3 Use the navigational buttons to choose the appropriate user level Maintenance Dis...

Page 20: ...en complete or simply press the Enter button to apply the code 5 The interface will automatically navigate to the Select User screen if the code is accepted If the code is not accepted the user interf...

Page 21: ...guide to quick starting the unit 3 1 Applying Machine Power 1 Apply power to the compressor 2 The AirSmart G2 controller will automatically boot to the default Home screen as shown in Figure 3 1 Boot...

Page 22: ...gure 3 3 Figure 3 3 Operational Settings Menu 5 From the Operational Settings menu use the navigational buttons and select Load Unload Setpoints 6 Press the Enter button The Load Unload Setpoints menu...

Page 23: ...f the value is not accepted the number will turn red momentarily and the value displayed on the keypad will revert back to the current setting If this occurs check the value entered against the Min an...

Page 24: ...ious screen The Load Unload Setpoints menu will be displayed 2 From the Load Unload Setpoints use the navigational buttons and select Load Pressure 3 Press the Enter button The Load Pressure numeric k...

Page 25: ...ng the navigational buttons to choose the appropriate setting Press the Enter button to apply Automatic Mode Automatic will now be displayed in the gray area at the top of the screen 5 Press the Back...

Page 26: ...13 17 613 Page 25 Figure 3 9 Overall Menu Structure...

Page 27: ...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 com...

Page 28: ...the turn valve is in the fully closed state As the air demand decreases The AirSmart G2 Controller will open the turn valve to decrease the capacity of the airend to match the demand and keep the Plan...

Page 29: ...structure MAINTENANCE DISTRIBUTOR and FACTORY Before the description of each of the screens in the following section there is an accessibility chart that shows the read write access of each of the use...

Page 30: ...Menu button Figure 5 1 Home Screen 2 Log in to the system using the steps below See section 2 4 for more detail a Press the Login button to load the Select User screen Use the navigational buttons to...

Page 31: ...machines Refer to the AirSmart G2 Sequencing Manual 13 17 615 for information on operation in Sequenced mode Connect 12 The connect 12 operation of the compressor is similar to Sequenced mode Refer t...

Page 32: ...ue is the pressure set point of the compressor Min Value Load Pressure setting Max Value Unload Pressure setting 5 PSI 0 3 bar Default Value Package dependent 5 1 2 2 Unload Pressure Accessibility Mai...

Page 33: ...item is only available on machines that have inlet modulation capability It allows the user to change the control of the inlet valve on the compressor to either Load Unload or Modulation When set to...

Page 34: ...compressor will run during the blowdown process Min Value 0 seconds Max Value 1800 seconds Default Value 600 seconds fixed speed units 5 1 4 4 Idle Timer Accessibility Maintenance Distributor Factory...

Page 35: ...has been restored This parameter is only available if the Auto Restart feature is enabled Min Value 5 seconds Max Value 300 seconds Default Value 10 seconds 5 1 4 8 Start Timer Accessibility Maintenan...

Page 36: ...ngs screen Then select Edit Time or Edit Date This will trigger a numeric keypad set to enter a value in date or time format 2 Select CLR to clear the current value and begin entering the desired sett...

Page 37: ...s also shown above the keypad when a limit option is selected 5 1 6 3 Control Box Temperature Accessibility Maintenance Distributor Factory The Control Box Temperature option under the Operating Limit...

Page 38: ...that do not utilize a Precision Oil Mixing Valve 5 1 6 1 Minimum Target Pressure Accessibility Maintenance Distributor Factory The Minimum Target Pressure setting under the Operational Limits menu se...

Page 39: ...ssibility Maintenance Distributor Factory The Enable AutoRun menu allows the user to enable or disable the AutoRun functionality When AutoRun is enabled each timer in the AutoRun Schedule will be eval...

Page 40: ...cess the distributor contact information and document numbers pertaining to the unit Diagnostics screens are also provided for access to machine sensor readings and setpoints The Maintenance menu stru...

Page 41: ...r may reset the timer after performing required maintenance 5 2 2 1 Air Filter Change Timer Accessibility Maintenance Distributor Factory The first item in the Maintenance Timers menu is the Air Filte...

Page 42: ...in the Maintenance Timers menu is the Oil Filter Change Timer This value sets the default oil filter change countdown timer value Setting this parameter to zero will disable the timer and its associat...

Page 43: ...eset according to the same procedure described in section 5 2 2 1 for the Air Filter Change Timer 5 2 2 3 Motor Lubrication Timer Accessibility Maintenance Distributor Factory The next item in the Mai...

Page 44: ...ble documents that may be available include the operations manual controller manual wiring diagrams parts lists and the startup checklist Note Downloadable content is machine specific and may differ b...

Page 45: ...the min and max frequencies of the drivetrain motor frequency motor speed etc The second page shows the voltage current power etc of the motor The third page shows other various information of the com...

Page 46: ...take place immediately after the desired language is selected 5 3 2 Pressure Units Accessibility Maintenance Distributor Factory The next item in the Display Options menu is the Pressure Units which w...

Page 47: ...f usage The screens available for this submenu are detailed below 5 4 1 1 Compressor Model Accessibility Maintenance Distributor Factory Compressor Model informs user of the compressor model number de...

Page 48: ...Use with AEON 6000FG or similar lubricant Table 5 1 Oil Change Multipliers Oil Aging Clock Multiplier Standard Food Grade Oil Temperature Break Points High Temp Oil Temperature Break Points X 1 180 F...

Page 49: ...a specified capacity when the inlet temp of the compressor reads a value that is less than 50 degrees Fahrenheit 5 4 2 2 2 Cold Start Capacity Accessibility Maintenance Distributor Factory The next i...

Page 50: ...volt factor setting This will engage the voltage factor limiter to reduce system load This should be set to the default value of 87 5 4 2 2 6 Lag Pressure Accessibility Maintenance Distributor Factor...

Page 51: ...s in the machine none AB PF400 AB PF70 and AB PF700 5 4 2 2 9 2 Nominal Current Accessibility Maintenance Distributor Factory The next item in the VFD 1 menu is Nominal Current The Nominal Current set...

Page 52: ...e controller 5 4 2 2 10 VFD 2 Accessibility Maintenance Distributor Factory The next item in the VFD menu is the VFD 2 menu The VFD 2 menu allows the user to configure the settings of VFD 2 Refer to t...

Page 53: ...ccessibility Maintenance Distributor Factory The next item in the Drive Train menu is the Motor Current consumption value of each individual motor in the system Note This information is not populated...

Page 54: ...5 4 3 Enclosure Accessibility Maintenance Distributor Factory The next item on the Machine Configuration menu is Enclosure The Enclosure menu allows the user to select the cooler fan type after cooler...

Page 55: ...screen is shown in Figure 5 10 Figure 5 10 AirSmart Controller Versions Screen The top right button on the AirSmart Controller screen allows the distributor level user to update the screens configurat...

Page 56: ...on the controller will cause the current value shown on Core PIN 1 to be stored as the new PIN 1 Zero value The second button down from the upper right on the controller will do the same for pressure...

Page 57: ...s the user to directly map the analog inputs Ain digital inputs Din analog outputs Aout and digital outputs Dout through this menu The function in each set has an address which directs the correspondi...

Page 58: ...ut sub menus as well as the first Digital input Due to the number of functions available for mapping most I O types are divided into several menus as seen by the three different Ain Address options be...

Page 59: ...Machine Data Pressures Figure 5 17 Machine Data Pressures Continued The drivetrain data allows the user to review the minimum maximum command and current motor frequency as well as the motor speed al...

Page 60: ...13 17 613 Page 59 Figure 5 18 Drivetrain Data Page 1 Figure 5 19 Drivetrain Data Page 2 Figure 5 20 Drivetrain Data Page 3...

Page 61: ...Figure 5 21 Hardware Tests The Core DOUT tests are accomplished by pressing the perimeter buttons which correspond to the digital outputs 1 6 or the 2 available relay connections which are mapped to...

Page 62: ...ement and sequence time offset See the AirSmart G2 Sequencing Manual 13 17 615 for detailed information on sequencing operation The Multi Machine Sequencing menu structure is organized as follows 5 4...

Page 63: ...which will increase its total hours Machine A will allow Machine B to become the leader only when it accumulates 101 hours of runtime then Machine B will become the leader and only allow Machine A to...

Page 64: ...thod allows the distributor and factory user to define one of the following for the oil control method none injection or delta T Depending on which method is defined there will be different parameters...

Page 65: ...Adjust Accessibility Maintenance Distributor Factory The Target temperature Adjust is a factory parameter used to change the scale for the target temperature calculation on machines using the delta T...

Page 66: ...capture of the Motor Jog screen Note that the compressor must be in the Ready state before motor jog will be allowed The Power LED should turn off upon loading the Motor Jog screen if all precondition...

Page 67: ...ripped Change air filter Air Filter Timer Maintenance timer for air filter change has expired Change air filter and reset timer Oil Filter Timer Maintenance timer for oil filter change has expired Cha...

Page 68: ...emperature Oil injection temperature is alarm set point Check oil temperature or reduce package power DIN Oil Level 1 Digital Input oil level 1 has tripped Check oil level 1 DIN Oil Level 2 Digital in...

Page 69: ...ut programmed for Water Pressure has tripped Check water pressure Emergency Stop Compressor stopped using Emergency Stop button Pull out Emergency Stop button to its normal position High Discharge Tem...

Page 70: ...Check controller for malfunction or damage SD Card Error SD card failure Check SD card is inserted into controller correctly Configuration Error Configuration failure Reload configuration files into c...

Page 71: ...pen EXP XD3 Connection to expansion module PIN3 is open Check wiring between expansion module PIN3 and controller Shorted EXP XD3 Connection to expansion module PIN3 is shorted Check wiring between ex...

Page 72: ...l 2 Oil sump level 2 alarm set point Oil level low add oil to sump 2 High Oil Level 1 Oil sump level 1 alarm set point Oil level high check oil in sump 1 High Oil Level 2 Oil sump level 2 alarm set po...

Page 73: ...was recorded Inside this folder are CSV files with naming convention as follows DataLog_xxxx_weekXX csv The xxxx is the year and XX is the week Each file contains one week of log data The following i...

Page 74: ...1 Auto Restart 10 Delta 2 Shutdown 11 Start 3 Ready 12 Pause 4 Remote Halt 13 Loaded 5 Ask to Start 14 Unload 6 Enabled 15 Blowdown 7 Ask to Load 16 Normal Stop 8 Pre Wye Table 7 2 Operating Modes Ope...

Page 75: ...gh Oil Temperature 1 5 Separator Change Timer 18 Low Ambient A 31 High Oil Temperature 2 6 Motor Lube Timer 19 High Plant Delivery Temperature 32 High Plant Delivery Pressure 7 Control Box Filter Time...

Page 76: ...Open Expansion XD2 15 Shorted TT2 47 High Plant Delivery Temperature 79 Shorted Expansion XD2 16 Open TT3 48 High Plant Temperature Rate 80 Open Expansion XD3 17 Shorted TT3 49 High Separator Tempera...

Page 77: ...ree 2 wire PT1000 inputs Up to five additional PT1000 inputs on I O Expansion Digital Outputs P8 and P6 on core board P2 and P4 on I O Expansion Six 0 to 24 VDC outputs 800mA per channel Up to six add...

Page 78: ...NOTES...

Page 79: ...NOTES...

Page 80: ...For additional information contact your local representative or visit www contactgd com blowers 2017 Gardner Denver Inc Printed in U S A...

Search results

Summary of Contents for AIRSMART

Reviews:

Related manuals for AIRSMART

Brands by name

Popular brands

Gardner Denver AIRSMART, User Manual

Search results

Summary of Contents for AIRSMART

Reviews:

Related manuals for AIRSMART

Brands by name

Popular brands