13-17-616

Version: 00
November 18, 2014

Software Update Procedure

AirSmartä G2 Controller

INSTALLATION MANUAL
 MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER® COMPRESSOR PARTS AND SUPPORT SERVICES

Gardner Denver® Compressor genuine parts, manufactured to design tolerances, are developed for optimum
dependability – specifically for Gardner Denver compressor systems. Design and material innovations are the result
of years of experience with hundreds of different compressor applications. Reliability in materials and quality
assurance is incorporated in our genuine replacement parts.

Your authorized Gardner Denver Compressor distributor offers the entire backup you’ll need. A network of
authorized distributors provides the finest product support in the air compressor industry.

Your authorized distributor can support your Gardner Denver air compressor with these services:

1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. Factory warranted new and remanufactured rotary screw airends. Most popular model remanufactured
airends are maintained in stock at the factory, for purchase on an exchange basis with liberal core credit
available for the replacement unit.
3. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver
compressors.
4. Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.

Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They
are ready to respond and assist you by providing fast, expert maintenance and repair services.

To Contact Gardner Denver or locate your local distributor:

Visit: www.contactgd.com/compressors
Or
Call: (217)222-5400

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Compressor MODEL, Method of Cooling, HORSEPOWER and SERIAL NUMBER (see
nameplate on unit). The Airend Serial Number is also stamped on top of the discharge bearing carrier casting.

All orders for Parts should be placed with the nearest authorized distributor.

Where NOT specified, quantity of parts required per compressor or unit is one (1); where more than one is required
per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED.

DO NOT ORDER BY SETS OR GROUPS.

To determine the Right-Hand and Left-Hand side of a compressor, stand at the motor end and look toward the
compressor. Right-Hand and Left- Hand are indicated in parenthesis following the part name, i.e. (RH) and (LH),
when appropriate.

13-17-616 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 High Voltage – Hazard of Shock, Burn, or Death
Impeller Blade Present until Electrical Power is Removed

Cutting of Finger or Hand Hazard – Rotating Fan Entanglement of Fingers or Hand/Rotating Shaft
Blade

13-17-616 Page 2
Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or
serious injury.

Asphyxiation Hazard – Poisonous Fumes or Toxic Gases 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 Ear Protection

Handle Package at Forklift Points Only Read the Operator’s Manual Before Proceeding
with Task

13-17-616 Page 3
 SAFETY PRECAUTIONS

Safety is everybody’s business and is based on your use of good common sense. All situations or
circumstances cannot always be predicted and covered by established rules. Therefore, use your past
experience, watch out for safety hazards and be cautious. Some general safety precautions are given
below:

Failure to observe these notices will 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 and check for voltage before working on the
control.

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.

13-17-616 Page 4
 TABLE OF CONTENTS

List of Illustrations .................................................................................................................................... 6

SECTION 1, General Information............................................................................................................. 7
SECTION 2, Procedure ........................................................................................................................... 7
APPENDIX A, Loading Software onto an SD Card ................................................................................. 12

13-17-616 Page 5
 LIST OF ILLUSTRATIONS

Figure 1: AirSmart G2 SD Card Location ................................................................................................. 8

Figure 2: SD Card Orientation.................................................................................................................. 9
Figure 3: AirSmart Configuration Screen ................................................................................................ 10
Figure 4: System Update Screen ........................................................................................................... 10
Figure 5: SD Card Drive Letter............................................................................................................... 12
Figure 6: Extract Compressed Folders Dialog ........................................................................................ 13
Figure 7: SD Card Contents................................................................................................................... 13
Figure 8: Safely Remove SD Device ...................................................................................................... 14

13-17-616 Page 6
SECTION 1
GENERAL INFORMATION

This manual covers the process of performing a software update on the Gardner Denver AirSmart G2
controller. The AirSmart G2 is capable of loading software updates through an SD card that contains the
desired software. A software update may be required to change the configuration of a controller or to
realize software enhancements that are released as part of a continuous improvement development.

Software is distributed on an SD card pre-programmed from Gardner Denver, or in certain circumstances

the software may be distributed electronically as a zip archive, to be loaded onto an SD card in the field.
A single programmed SD card can be used to update any number of AirSmart G2 controllers with the
same software.

Loading invalid or improperly configured software or other files to the controller will render the controller
unusable and require factory reprogramming.
· Do not attempt to modify any files on the SD card
· Do not open any files on the SD card with an application on a PC or other device
· Only update software under direction from Gardner Denver service or engineering
· Software updates may only be performed by authorized technicians

SECTION 2
PROCEDURE

Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout power
supply to the starter before removing valves, caps, plugs, fittings, bolts and
filters. Do not open the control panel until the Lockout/Tagout procedure is
complete.

Setup:

1. Note that updating software may result in a reset of the machine to the default configuration.
Before continuing, make note of individual settings, including pressure and temperature set
points, operating modes, timer settings, and maintenance timers / intervals to ensure that the
machine can be properly configured following the software update.

2. Ensure that electrical power has been removed from the system and the Lockout/Tagout
procedure is complete.

13-17-616 Page 7
3. Open the control panel door and locate the SD card slot on the AirSmart G2 controller. The
slot is on the lower right side of the controller as shown in Figure 1.

4. The SD card socket is spring-loaded. Using your finger tip, press in on the SD card and
release, then remove the card once it has been ejected from the socket.

5. If the software update has been provided on a programmed SD card directly from Gardner
Denver, locate and use this SD card for the remaining steps. If the software update has been
provided electronically, follow the procedure in Appendix A to create a programmed SD card.
The SD card on the AirSmart controller may be used to create the programmed SD card if
desired.

6. Carefully insert the SD card containing the desired software update. Make sure that the gold
plated fingers are facing away from the control panel door, as shown in Figure 2.

7. Close the control panel door and press the EMERGENCY-STOP button on the control panel
door.

Figure 1: AirSmart G2 SD Card Location

13-17-616 Page 8
 Figure 2: SD Card Orientation

Install Software Update:

Note: Depending on the circumstances, a particular software update may require a full reload of all of the
software components on the system, or it may only require an update to certain components, such as the
firmware, screens, or configuration. While the Update All option may be used to load all software
components, it may often be advisable to load each component individually as described below.

1. Reconnect power to the machine and allow the controller to boot completely to the home
screen.

2. Access the Main Menu and log in with a distributor level passcode as described in the
AirSmart G2 User’s Manual 13-17-613.

3. Navigate to Machine Configuration -> AirSmart Controller and press button next to the
Bootloader icon in the upper right corner of the screen as shown in Figure 3 to access the
System Update screen.

4. From the System Update screen, press the button corresponding to the component that you
would like to update. The Status line on the display will indicate success, failure, and ready
status after loading each component. Note that certain components (particularly the screens)
will take several minutes to complete. The recommended order of update is listed below:

a. Press Screens: This option loads all user interface screens and images to the
controller. Wait for the Status line to return to “Select Update Option” before
continuing.

b. Press Config: This option loads the configuration and language files to the controller.
Wait for the Status line to return to “Select Update Option” before continuing.

c. Press Fonts: This option loads the all fonts to the controller. Wait for the Status line to
return to “Select Update Option” before continuing.

d. Press Runtimes: This option loads the display application to the controller. Wait for
the Status line to return to “Select Update Option” before continuing.

13-17-616 Page 9
 e. Press Firmware: This option loads the primary controller firmware. Note: The
controller will automatically reboot following a firmware load.

Figure 3: AirSmart Configuration Screen

Figure 4: System Update Screen

Verification and Configuration:

1. Wait for the controller to boot completely following the firmware update.

2. Log in to the controller with the distributor passcode and navigate to

Machine Configuration -> AirSmart Controller -> Controller Firmware Version(s). Verify that
the firmware version listed now matches the version of the software update that was installed.

3. Review the applicable settings on the controller and verify against the previous settings
recorded before the software update. Make any necessary changes to match the machine
and customer configuration.

4. Remove electrical power from the system and follow Lockout/Tagout procedures.

5. Open the control panel and remove the SD card from the controller.

13-17-616 Page 10
6. Insert the original SD card that was in the controller prior to the software update. Be sure to
carefully insert the card as shown in Figure 2.

7. Close the control panel and restore electrical power to the machine.

8. Reset the EMERGENCY-STOP button and verify correct operation of the machine.

13-17-616 Page 11
APPENDIX A
LOADING SOFTWARE ONTO AN SD CARD

This section describes the process of loading software onto an SD card in the event that the update is
provided electronically in the form of a zip file rather than on a pre-programmed SD card.

The following materials will be required to perform this process:

1. Approved SD card compatible with the AirSmart G2 Controller. Gardner Denver part number
24CA7342.

2. Computer or other device with Zip archive utilities.

3. SD Card reader – This may be external (i.e. USB) or internal to the device used for accessing
the SD Card.

4. AirSmart G2 software archive from Gardner Denver. This will be delivered with the file name
of the software part number represented by the archive. For example, CC1120690.zip

Once all of the required materials have been acquired, follow the procedure below to load the software.
Note: The instructions below assume the use of a Microsoft Windows –based computer. Other operating
systems may be used to achieve the same result.

1. Download / save the software archive to a location on the computer that will be used to
program the SD card.

2. Insert the SD card into the card reader and note the drive letter that is assigned using
Windows Explorer as shown in Figure 5. The SD card is drive letter E: in this example.

Figure 5: SD Card Drive Letter

3. Extract the archive onto the SD card as follows:

a. Right click on the archive in Windows Explorer and select Extract All…

b. Enter the root of the SD card for the destination folder to extract the files. For
example, enter E:\ if the SD card has been assigned drive letter E: as determined in
step 2. See Figure 6.

13-17-616 Page 12
 Figure 6: Extract Compressed Folders Dialog

c. Check the box next to Show extracted files when complete as shown in Figure 6.

d. Press Extract and wait for the process to complete.

4. A new window showing the contents of the SD card should now be shown with a file structure
as shown in Figure 7.

Figure 7: SD Card Contents

5. Close the file manager for the SD card and use the eject / safely remove utility to ensure that
all files have been written before removing the disk. This is generally found on the Windows
Task bar as shown in Figure 8.

13-17-616 Page 13
 Figure 8: Safely Remove SD Device

6. Remove the SD card from the reader.

7. Recommended: Place a label on the card with the software number and version that has
been loaded onto it.

13-17-616 Page 14
For additional information, contact your local representative or visit:
www.contactgd.com/compressors

©2014 Gardner Denver, Inc. Printed in U.S.A.