GD Pilot TS / AirSmart
Pilot TS is the current-generation controller; AirSmart is the earlier text-based system. On EnviroAire oil-free machines the controller also sequences the intercooler condensate drains — verify drain function during PM.
Manufacturer
Gardner Denver
Display
GD Pilot TS: 5.7" TFT color touch; AirSmart: 4-line VFD monochrome (older).
Years produced
Pilot TS ~2013 – present; AirSmart 2000s – 2013.
Power supply
24 VDC control power from onboard PSU. Battery-backed RTC.
Ambient range
0 – 50 °C.
Protection rating
IP54 front / IP20 rear.
Relay outputs
Configurable — main, star, delta, blowdown, dryer, alarm, remote-run, service.
Replaces
AirSmart, Auto Sentry ES (legacy)
Used on
- Gardner Denver EnviroAire T-Series (oil-free)
- Gardner Denver VS / VST rotary screws
- Gardner Denver L-Series (LC / LS)
- Gardner Denver ELECTRA-SAVER II retrofit
On AirCompDX
Features
- Sequencing up to 12 units on Pilot TS
- iConn cloud monitoring
- Fine-grained pressure band control
- Compressor + integrated dryer control on single HMI
- Trend log to internal memory / USB export
Interfaces
- Ethernet Modbus TCP / Profinet
- RS-485 Modbus RTU
- USB service port
- Digital I/O 24 VDC
- iConn cloud gateway (add-on)
Sensor inputs
- Airend discharge temp (T2)
- Package discharge pressure
- Sump pressure
- Separator ΔP
- Coolant filter ΔP (option)
- Ambient temp (option)
Common fault codes
First checks
- Check coolant level and cooler condition
- Verify thermostatic mixing valve
- Test T2 sensor resistance
First checks
- Replace separator element and fluid filter
- Check scavenge line for clog
- Change coolant if past hours
First checks
- Change fluid filter
- Sample coolant
First checks
- Check unload setpoint
- Verify inlet valve closes
- Inspect MPCV
First checks
- Swap any two incoming phases at disconnect
- Confirm arrow on airend matches
- Check phase monitor relay module
First checks
- Release E-stop
- Check remote loop
First checks
- Reset overload
- Verify FLA and voltage balance
- Inspect for airend drag or oil starvation
First checks
- Clean cooler / fan
- Check bearings & OL setting
First checks
- Read drive keypad F-code
- Check drive cabinet cooling filter
- Verify DC bus discharged before service
First checks
- Check RS-485 wiring & termination
- Verify addresses & baud
- Reboot iConn gateway
First checks
- Perform kit A/B/C service
- Reset counter in Service menu
Fault list is non-exhaustive and firmware-dependent. Always confirm against the controller’s on-screen help or OEM manual.
Wiring notes
- 24 VDC control from onboard PSU; expansion modules on internal RS-485
- Pilot TS supports both Y-Δ and VFD control heads with same HMI
- Sensor cabling shielded, single-point ground at controller
Terminal & connector map
Pinouts distilled from OEM wiring diagrams. Exact silk-screen labels and pin numbering vary by hardware revision and package options — always confirm against the machine’s as-built wiring diagram before landing a wire.
Connectors to the controller
- X1 – 24 VDC power in (screw terminals)
- X2 – RJ45 Ethernet (Modbus TCP / iConn cloud)
- X3 – RS-485 (Modbus RTU sequencer, up to 8 units)
- X4 – RTD block, airend & aftercooler
- X5 – 4–20 mA transducer block (line, sump, ΔP filter, ΔP separator)
- X6 – digital I/O to starter + dryer + drain solenoids
- USB port behind door – firmware update & trend export
X1 – PowerControl power
| Pin | Signal | Type | Connects to |
|---|---|---|---|
| + | +24 VDC | 24 VDC | Control transformer + |
| − | 0 V | 24 VDC ret. | Control transformer − |
| PE | PE | PE | Cabinet ground |
X4 – TemperatureRTDs
| Pin | Signal | Type | Connects to |
|---|---|---|---|
| 1 / 2 / 3 | Airend discharge | PT100 3-wire | Airend sensor |
| 4 / 5 / 6 | Aftercooler out (option) | PT100 3-wire | Aftercooler sensor |
X5 – Pressure & ΔP4–20 mA transducers
| Pin | Signal | Type | Connects to |
|---|---|---|---|
| PL +/− | Line pressure | 4–20 mA | Line transducer |
| PS +/− | Sump pressure | 4–20 mA | Sump transducer |
| ΔF +/− | Fluid filter ΔP | 4–20 mA | Filter ΔP transducer |
| ΔS +/− | Separator ΔP | 4–20 mA | Sep ΔP transducer |
X6 – Digital I/OStarter / drains / remote
| Pin | Signal | Type | Connects to |
|---|---|---|---|
| 1M / 1S / 1D | Star-delta contactor coils | 24 VDC out | Contactors |
| Y-BD | Blowdown solenoid | 24 VDC out | Blowdown solenoid |
| Y-DR1/2 | Intercooler / aftercooler drain solenoids (EnviroAire) | 24 VDC out | Drain solenoids |
| RS+/RS− | Remote start | dry contact in | Customer PLC |
| CT | Common trouble relay | relay out | Master alarm |
Known issues & field notes
- iConn cloud sync drops on stringent firewalls — whitelist connect.gardnerdenver.com
- Touchscreen dead pixels on early revs — replace HMI module, keep configuration on USB
Retrofit notes
AirSmart → Pilot TS retrofit exists for many EnviroAire and VS units; sensor loom is compatible but connector genders vary.
Manuals & literature
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