Ingersoll Rand System Automation User Manual
Ingersoll Rand System Automation
ENGLISH
FRENCH
GERMAN
DUTCH
PRINT LANGUAGE
ITALIAN
SPANISH
IX IntelliFlow
Operator’s Manual
80445570
Revision D
January 2012
DE
Bedienungshandbuch
EN
Operator’s Manual
ES
Manual De Operadores
FR
Manuel De L’utilisateur
IT
Manuale D’uso
NL
Gebruiksaanwijzingen
Save These Instruction
SECTION 1 TABLE OF CONTENTS
Section 1 - table of contentS .............................2
DeclaRation of confoRMitY ...............................3
Section 3 - intRoDUction ......................................4
Section 4 - SafetY ....................................................4
SAFETY PRECAUTIONS .............................................4
SHIPMENT INSPECTION / PREINSTALLATION CHECK 4
INSTALLATION .............................................................................4
OPERATION ...................................................................................4
MAINTENANCE AND REPAIR .................................................5
Section 5 - connection anD contRol .............6
OPERATING MODES .................................................................6
Section 6 - inStallation .........................................8
IX INTELLIFLOW TECHNICAL DATA .....................................8
IX INTELLIFLOW INSTALLATION ...........................................9
IX BOX POWER SUPPLY ..........................................................10
IX INTELLIFLOW VALVE CONTROLLER CONNECTION
AND SENSOR ARRANGEMENT ............................................10
IX BOX RS485 NETWORK .......................................................11
Section 7 - DiSPlaY anD MenU oPeRation ....12
Section 8 - coMMiSSioninG .................................14
Section 10 - DiaGnoSticS .....................................21
DIAGNOSTIC MENU 5 .............................................................21
Section 11 - faUlt coDeS ......................................22
Section 12 - iX intellifloW contRolleR PaRt
liSt ..................................................................................23
Section 13 - iX intellifloW contRolleR
tecHnical Data .........................................................23
Section 14 - iX intellifloW contRolleR
WiRinG DiaGRaM .......................................................24
ENCLOSURE MOUNTING .......................................................26
Section 15 - iX intellifloW contRolleR
ReMote inPUtS ..........................................................27
IX BOX INPUT FUNCTIONS ...................................................27
VIRTUAL RELAY AUTOMATION ...........................................27
Section 16 - iX intellifloW contRolleR RS485
MoDbUS ReGiSteRS ...................................................28
Section 17 - iX intellifloW DiGital
PoSitioneR ..................................................................29
IX INTELLIFLOW DIGITAL POSITIONER SETUP
PROCEDURE ...............................................................................29
Section 18 - iX intellifloW actUatoR fail
oPen to fail cloSeD ................................................39
PHYSICAL CHECKS ...................................................................14
PRESSURE DISPLAY .................................................................14
OPERATING MODE ...................................................................14
PRESSURE SET POINTS ...........................................................14
IX BOX OPTIONAL FEATURES AND FUNCTIONS .........14
IX INTELLIFLOW STARTUP ...................................................14
SETTING THE TUNING PARAMETERS ................................15
Section 9 - SYSteM confiGURation .................16
DISPLAY AND MENU OPERATION......................................16
ACCESSING THE IX CONFIGURATION SCREENS ...........16
CONFIGURATION MENU OVERVIEW ................................17
USER CONFIGURATION MENU 1 ........................................18
PRESSURE TARGET MENU 2 .................................................20
SENSOR CALIBRATION MENU 3 ..........................................20
RELAY CONFIGURATION MENU 4 ......................................20
Section 19 - iX intellifloW aSSeMblY
oVeRVieW DRaWinG .................................................40
Section 20 - iX intellifloW aSSeMblY
DiMenSionS “incHeS” ..............................................41
Section 21 - iX intellifloW aSSeMblY
DiMenSionS “MilliMeteR” ......................................43
Section 22 - iX intellifloW aSSeMblY SPaRe
PaRtS liSt .....................................................................45
REFER TO SECTION INDICATED
NOTE
IMPORTANT OR CAUTION, SAFETY
2 Ingersoll Rand System Automation IX Intelliow
ingersollrandproducts.com
DECLARATION OF CONFORMITY
(ES) DECLARACIÓN DE CONFORMIDAD (FR) CERTIFICAT DE CONFORMITÉ (IT) DICHIARAZIONE DI CONFORMITÀ
(DE) KONFORMITÄTSERKLÄRUNG (NL) SCHRIFTELIJKE VERKLARING VAN CONFORMITEIT (DA) FABRIKATIONSERKLÆRING
(SV) FÖRSÄKRAN OM ÖVERENSSTÄMMELSE (NO) KONFORMITETSERKLÆRING (FI) VAKUUTUS NORMIEN TÄYTTÄMISESTÄ
(PT) DECLARAÇÃO DE CONFORMIDADE (EL) ΗΛΣΗ ΑΝΑΓΝΡΙΣΗΣ (SL) IZJAVA O SKLADNOSTI (SK) PREHLÁSENIE O
ZHODE (CS) PROHLÁŠENÍ O SHODĚ (ET) VASTAVUSDEKLARATSIOON (HU) MEGFELELŐSÉGI NYILATKOZAT (LT) ATITIKTIES
PAREIŠKIMAS (LV) ATBILSTĪBAS DEKLARĀCIJA (PL) DEKLARACJA ZGODNOŚCI
Ingersoll Rand 1302 GOSHEN PARKWAY, WEST CHESTER, PA 19380
DECLARE THAT UNDER OUR SOLE RESPONSIBILTY FOR MANUFACTURE AND SUPPLY, THE PRODUCT(S),
IX-050, IX-080, IX-100, IX-150, IX-200, IX-050HT, IX-080HT, IX-100HT, IX-150HT, IX-200HT
(ES) Declaramos que, bajo nuestra responsabilidad exclusiva, el producto: (FR) Déclarons sous notre seule responsabilité que le produit:
(IT) Dichiariamo sotto la nostra unica responsabilità che il prodotto: (DE) Erklären hiermit, gemäß unserer alleinigen Verantwortung, daß
die Geräte: (NL) Verklare n, onder onze uitsluitende aansprakelijkheid, dat het produkt: (DA) Erklærer som eneansvarlig, at nedenstående
produkt: (SV) Intygar härmed, i enlighet med vårt fullständiga ansvar, att produkten: (NO) Erklærer som eneansvarlig at produktet:
(FI) Vakuutamme ja kannamme yksin täyden vastuun siitä, että tuote: (PT) Declaramos sob a nossa exclusiva responsabilidade que o
produto: (EL) ηλώνουε ότι ε δική α ευθύνη το προϊόν: (SL) Pod polno odgovornostjo izjavljamo, da se izdelek: (SK) Prehlasujeme na
svoju zodpovednost’, že produkt: (CS) Prohlašujeme na svou zodpovědnost, že výrobek: (ET) Deklareerime oma ainuvastutusel, et toode:
(HU) Kizárólagos felelősségünk tudatában kijelentjük, hogy a termék: (LT) Prisiimdami atsakomybę pareiškiame, kad gaminys:
(LV) Uzņemoties pilnīgu atbildību, apliecinām, ka ražojums: (PL) Oświadcza, że ponosi pełną odpowiedzialność za to, że produkt:
To which this declaration relates, is in compliance with provisions of Directive(s): 97/23/EC., 93/68/EEC, 2004/108/EC, 2006/95/EC
(ES) a los que se reere la presente declaración, cumplen con todo lo establecido en las directivas: (FR) objet de ce certicat, est conforme
aux prescriptions des Directives: (IT) a cui si riferisce la presente dichiarazione è conforme alle normative delle direttive: (DE) auf die sich
diese Erklärung bezieht, den Richtlinien: (NL) waarop deze verklaring betrekking heeft overeenkomt met de bepalingen van directieven:
(DA) som denne erklæring vedrører, overholder bestemmelserne i følgende direktiver: (SV) som detta intyg avser, uppfyller kraven i
Direktiven: (NO) som denne erklæringen gjelder for, oppfyller bestemmelsene i EU-d irektivene: (FI) johon tämä vakuutus viittaa, täyttää
direktiiveissä: (PT) ao qual se refere a presente declaração, está de acordo com as prescrições das Directivas: (EL) τα οποία αφορά αυτή
η δήλωση‚ είναι σύφωνα ε τι προβλέψει των Eντολών: (SL) Na katerega se ta izjava o skladnosti nanaša, sklada z določili smernic:
(SK) Ku ktorému sa toto prehlásenie vzt’ahuje, zodpovedá ustanoveniam smerníc: (CS) Ke kterým se toto prohlášení vztahuje, odpovídají
ustanovením směrnic: (ET) Mida käesolev deklaratsioon puudutab, on vastavuses järgmis(t)e direktiivi(de) sätetega: (HU) Amelyekre ezen
nyilatkozat vonatkozik, megfelelnek a következő irányelv(ek) előírásainak: (LT) Kuriems taikomas šis pareiškimas, atitinka šios direktyvos
nuostatas: (LV) Uz kuru šī deklarācija attiecas, atbilst direktīvas(u) nosacījumiem: (PL) Do których ta deklaracja się odnosi, są zgodne z
postanowieniami Dyrektywy (Dyrektyw):
By using the following Principle Standards: ASME B31.1, EN61000-6-2:2001, EN61000-6-4:2001, EN60204-1:1997
(ES) conforme a los siguientes estándares: (FR) en observant les normes de principe suivantes: (IT) secondo i seguenti standard:
(DE) unter Anlehnung an die folgenden Grundnormen entsprechen: (NL) overeenkomstig de volgende hoofdstandaards: (DA) ved at
være i overensstemmelse med følgende hovedstandard(er): (SV) Genom att använda följande principstandard: (NO) ved å bruke følgende
prinsipielle standarder: (FI) esitetyt vaatimukset seuraavia perusnormeja käytettäessä: (PT) observando as seguintes Normas Principais:
(EL) Χρησιοποιώντα ια παρακάτω κύρια πρότυπα: (SL) Uporabljeni osnovni standardi: (SK) Použitím nasledujúcich zákonných noriem: (CS) Použitím následujících zákonných norem: (ET) Järgmiste põhistandardite kasutamise korral: (HU) A következő elvi szabványok
alkalmazásával: (LT) Remiantis šiais pagrindiniais standartais: (LV) Izmantojot sekojošos galvenos standartus: (PL) Przy zastosowaniu
następujących podstawowych norm:
Date: May, 2010
(ES) Fecha: Mayo, 2010: (FR) Date: Mai, 2010: (IT) Data: Maggio, 2010: (DE) Datum: Mai, 2010: (NL) Datum: Mei, 2010:
(DA) Dato: Må, 2010: (SV) Datum: Maj, 2010: (NO) Dato: Mai, 2010: (FI) Päiväys: Toukokuu, 2010: (PT) Data: Maio, 2010:
(EL) Ηεροηνία: Μάιο, 2010: (SL) Datum: Maj, 2010: (SK) Dátum: Máj, 2010: (CS) Datum: Květen, 2010: (ET) Kuupäev: Mai, 2010: (HU) Dá-
tum: Május, 2010: (LT) Data: Gegužė , 2010: (LV) Datums: Maijs, 2010: (PL) Data: Maj, 2010
Approved By:
(ES) Aprobado por: (IT) Approvato da: (FR) Approuvé par: (DE) Genehmigt von: (NL) Goedgekeurd door: (DA) Godkendt af:
(SV) Godkänt av: (NO) Godkjent av: (FI) Hyväksytty: (PT) Aprovado por: (EL) Eγκρίθηκεαπό: (SL) Odobril: (SK) Schválil: (CS) Schválil: (ET)
Kinnitatud: (HU) Jóváhagyta: (LT) Patvirtinta: (LV) Apstiprināja: (PL) Zatwierdzone przez
H. MARK
H. MARK, ENGINEERING MANAGER
J. FARLEY, QUALITY ASSURANCE MANGER
J. FARLEY
ingersollrandproducts.com 3
SECTION 3 INTRODUCTION
!
!
IX IntelliFlow is an intermediate system controller that
controls the system air pressure. The IX IntelliFlow can
control the Demand Side, Supply Side, or a combination
of both using user selectable set-points.
SECTION 4 SAFETY
SAFETY PRECAUTIONS
WARNING : Risk of Danger
WARNING : Risk of Electric Shock
WARNING : Risk of High Pressure
WARNING : Consult Manual
Before installing or operating the IX IntelliFlow, take
•
time to carefully read all the instructions contained
in this manual, all compressor manuals, and all
manuals of any other peripheral devices that may be
installed or connected to the unit.
Electricity and compressed air have the potential to
•
cause severe personal injury or property damage.
The operator should use common sense and good
•
working practices while operating and maintaining
this system. All applicable codes should be strictly
adhered to.
Maintenance must be performed by adequately
•
qualied personnel that are equipped with the
proper tools.
SHIPMENT INSPECTION / PRE
INSTALLATION CHECK
The crating should be inspected for shipping
•
damage after the unit has arrived.
The lter regulator assembly is shipped loose
•
with the IX controller. The assembly is packaged
in a box that is stored underneath the controller
mounting bracket. Please notify the shipper if this
box is missing or if tampering has occurred with the
shipping crate.
After the unit has been removed from the crate,
•
re-tighten all bolt connections as required prior to
installation to the appropriate torque specication.
The IX IntelliFlow is equipped with a locally mounted
PID controller (IX Box) which modulates the valve to
maintain a constant pressure [+/- .75 psi (0.05 bar)]
given the application of appropriately sized storage.
INSTALLATION
Installation work must only be carried out by a
•
competent person under qualied supervision.
A fused disconnect / isolation switch must be
•
tted between the main power supply and the IX
IntelliFlow. This should be located in close proximity
to the controller. The power consumption of the
controller is listed in the IX IntelliFlow Controller
Technical Data section of this manual. The power
installation shall be performed in accordance to
locally and nationally recognized electrical codes.
The IX IntelliFlow should be mounted in such a
•
location as to allow operational and maintenance
access without obstruction or hazard and to allow
clear visibility of indicators at all times.
If raised platforms are required to provide access
•
to the IX IntelliFlow, they must not interfere with
normal operation or obstruct access.
OPERATION
The IX IntelliFlow must only be operated by
•
competent personnel under qualied supervision.
Never remove or tamper with safety devices, guards
•
or insulation materials tted to the IX IntelliFlow.
The IX IntelliFlow must only be operated at the
•
supply voltage and frequency for which it is
designed.
When main power is switched on, lethal voltages are
•
present in the electrical circuits and extreme caution
must be exercised whenever it is necessary to carry
out any work on the unit.
Do not open access panels or touch electrical
•
components while voltage is applied unless it is
necessary for measurements, tests or adjustments.
Such work should be carried out only by a qualied
electrician equipped with the correct tools and
wearing appropriate protection against electrical
hazards.
All air compressors and/or other equipment
•
connected to the unit should have a warning sign
attached stating “THIS UNIT MAY START WITHOUT
WARNING” next to the display panel.
4 ingersollrandproducts.com
If an air compressor and/or other equipment
•
connected to the unit is to be started remotely,
attach two warning signs to the equipment stating
“THIS UNIT CAN BE STARTED REMOTELY”. Attach
one sign in a prominent location on the outside
of the equipment, and the other sign inside the
equipment control compartment.
The IX IntelliFlow is designed for use on air piping
•
systems with a maximum pressure of 200 PSIG
(13.78 bar) at a maximum temperature of 150˚F
(65˚C).
Operation of equipment outside of stated
•
conditions may result in equipment damage or
injury. A eld supplied and installed pressure
limiting device (e.g. pressure relief valve) must be
installed in piping system.
MAINTENANCE AND REPAIR
Maintenance, repairs or modications must only
•
be carried out by competent personnel under
qualied supervision.
If replacement parts are required, use only genuine
•
parts from the original equipment manufacturer, or
an alternative approved source.
Make sure that all instructions concerning
•
operation and maintenance are strictly followed
and that the complete unit, with all accessories
and safety devices, is kept in good working order.
The accuracy of sensor devices must be checked
•
on a regular basis. They must be calibrated when
acceptable tolerances are exceeded. Always ensure
any pressure within the compressed air system is
safely vented to atmosphere before attempting to
remove or install a sensor device.
The IX IntelliFlow must only be cleaned with a
•
damp cloth, using mild detergents if necessary.
Avoid the use of any substances containing
corrosive acids or alkalis.
Do not paint the control faceplate or obscure any
•
indicators, controls, instructions or warnings.
Carry out the following operations before opening
•
or removing any access panels or carrying out any
work on the IX IntelliFlow:
i. Isolate the IX IntelliFlow from the main
electrical power supply. Lock the isolator in the
“OFF” position and remove the fuses.
ii. Attach labels to the isolator switch and to the
unit stating “WORK IN PROGRESS - DO NOT
APPLY VOLTAGE”. Do not switch on electrical
power or attempt to start the IX IntelliFlow if
such a warning label is attached.
ingersollrandproducts.com 5
SECTION 5 CONNECTION AND CONTROL
70
psi
80
90
100
110
120
130
140
150
160
P4
P3
Ao
105
P4 Target = 95
1
2
100%
0%
115
95
P3 P4
3
70
psi
80
90
100
110
120
130
140
150
160
P4
P3
Ao
100
110
1
P3 P4
P3 Target = 80
2
3
0%
100%
100
110
80
The IX IntelliFlow Air System Pressure/Flow Controller
can provide precise pressure control for Demand Side
(compressed air usage), Supply Side (compressed air
generation or Back Pressure control) applications as well
as a combination of Demand/Supply control applications.
OPERATING MODES
1) Demand Side or Forward Mode Pressure Control
This is the Default, As Shipped, from the Factory
Conguration
Used to accurately control Demand Side pressure (P4)
system using air from the Supply Side (P3).This mode of
operation is intended to ensure that a constant Demand
or Outlet side pressure is maintained.
The IX IntelliFlow separates the supply side from the
demand side. By doing so, the supply side is not aected
by specic demand events. The IntelliFlow is able to
handle transient demand events without the need for
extra compression equipment to come on-line.
All IX IntelliFlow applications must include the
installation of the proper receiver volume.
2) Supply Side / Back Pressure or Backward Mode
Pressure Control
Used to protect the Inlet or Supply Side (P3) system from
pressure decay due to excess air usage from the Demand
Side (P4). This mode of operation is intended to ensure
that a minimum specied Supply or Inlet side pressure is
maintained.
If P3 remains above 95psi (6.55 bar):
P4 is maintained at P4 target:
If demand increases and P4 falls below 95psi (6.55 Bar):
Valve opens towards 100% (1)
If demand decreases and P4 increases above 95psi (6.55
Bar):
Valve closes towards 0% (2)
If P3 falls below 95psi (6.55 Bar):
Valve will open 100% and P4 pressure will equal
Valve remains fully open and P4 pressure will
equal P3 pressure (1).
If P3 falls to 80psi (5.51 bar):
P3 is protected from falling below 80psi:
If P3 falls below 80psi (5.51 bar):
Valve closes towards 0% (2)
If P3 increases above 80psi (5.51 bar):
Valve opens towards 100% (3) and P4 pressure
will equal P3 pressure.
P3 pressure (3).
The IX IntelliFlow is set to Fail Open by Default. To
If P3 remains above 80psi (5.51 bar):
The IX IntelliFlow is set to Fail Open by Default
6 ingersollrandproducts.com
change to Fail Closed, Please refer to Section 16
3) Combination Demand / Supply Side or Combination
70
psi
80
90
100
110
120
130
140
150
160
P4
P3
Ao
105
P3 Target = 80
P4 Target = 95
1
2
100%
0%
3
4
0%
100%
80
P3 P4
Mode Pressure Control
Used to accurately control pressure of the Demand Side
pressure (P4) system using air from the Supply Side (P3)
system while protecting the Supply Side (P3) system from
pressure decay due to excess air usage from the Demand
Side (P4) system
If P3 remains above 95psi (6.55 bar):
P4 is maintained at P4 target:
If demand increases and P4 falls below 95psi (6.55 bar)
Valve opens towards 100% (1)
If demand decreases and P4 increases above 95psi (6.55
bar):
Valve closes towards 0% (2)
If P3 falls below 95psi (6.55 bar) but remains above 80psi
(5.51 bar):
Valve will open 100% and P4 pressure will equal
P3 pressure.
If P3 falls to 80psi (5.51 bar):
P3 is protected from falling below 80psi (5.51
bar):
If P3 falls below 80psi (5.51 bar):
Valve closes towards 0% (3)
If P3 increases above 80psi (5.51 bar):
Valve opens towards 100% (4)
The IX IntelliFlow is set to Fail Open by Default. To
change to Fail Closed, Please refer to Section 16
ingersollrandproducts.com 7
SECTION 6 INSTALLATION
IX INTELLIFLOW TECHNICAL DATA
VALVE ASSEMBLY
Available in 2” to 8” (50 to 200mm) congurations.
•
Piping is A53, Grade B, Type E, Schedule 40 welded
•
steel.
Connections are ANSI / DIN Raised Face anges and
•
are design rated for 200 lb (13.87 Bar) ANSI / DIN.
The valve body material is cast iron ASTM A126 Class
•
B design.
The valve stem material is 416 stainless Steel ASTM
•
A582 Type 416 design.
The valve seat material is bonded Buna-N Food
•
Grade design.
The valve disc material is Nylon 11 coated ductile
•
iron ASTM A536 Gr.65-45-12 design.
Taps: 1 upstream of the valve for control air and
•
pressure transducer (P3), 1 downstream of the valve
for the pressure gage and pressure transducer (P4),
1 upstream & 1 downstream of the valve for drain
ports, 1 upstream & 1 downstream of the valve for
eld instruments.
Assemblies are assumed to be installed in a building
•
and thereby protected from the elements. Electrical
enclosures are designed to meet the requirements
for a NEMA 12 / IP54 rating. Assembly is CRN listed
Ambient Operating Conditions: between 35°F and
•
115°F (2°C and 46°C), humidity from 0-95% noncondensing and inlet pressures not to exceed
200 PSIG (13.78 bar).
Downstream set point should be at least 5 PSIG (0.3
•
bar) below minimum upstream pressure.
Pressure turndown typically ≤ 30% maximum.
•
The valve has no eld adjustments necessary to
•
maintain optimum eld performance.
Inlet air temperature to valve not to exceed 150°F
•
(66°C).
Minimum control supply pressure (upstream of
•
valve) of 80 PSIG (5.5 bar).
Nominal pressure drop should not exceed 1 PSIG
•
(0.06 bar) across entire assembly with valve fully
open.
The valve actuator is a direct mounted pneumatic,
•
rack & pinion actuator with spring return.
The valve positioner is a single acting type with
•
visual digital indicator.
The lter regulator assembly has a 5-micron rating.
•
The Bowl is metal with an adjustment knob and a
Sight Glass.
An Assembly mounted PID Controller is standard.
•
Control valve defaults open on loss of control signal
•
to provide maximum security to process.
Flow range on each size is based upon the ability of
•
the valve to maintain +/- 1.0 PSIG (0.05 bar) tolerance
at max. & min. ow conditions.
CONTROLLER ASSEMBLY
Forward, backpressure and combination control
•
4 Target Setpoints
•
6 Remote Input Functions
•
o Select 1 of 3 Target Pressure Setpoints
o Select Manual Mode
o Force Valve Open
o Force Valve Closed
2 Output Relays – Congurable via Virtual Relay
•
Programming
Dual pressure sensors - one for Inlet Pressure (P3)
•
and one for Outlet Pressure (P4)
Modbus RTU communications capabilities
•
Interfaces with a X8I or X12I system with
•
Visualization
Power supply input that will accept 100Vac to
•
240Vac, 50/60Hz
Enclosure is NEMA 12 / IP54 rated
•
Provided the application of a properly
sized receiver tank for system storage.
8 ingersollrandproducts.com
IX INTELLIFLOW INSTALLATION
B
A
B A BA
The IX IntelliFlow controller unit has been tested for
functionality and is ready for installation. Ingersoll
Rand recommends that a no-loss drain valve (CCN
38445920) be installed on the condensate drain valve
below the pressure transducer. (Other condensate drain
mechanisms can be installed/used. Consult Technical
Support or AfterMarket for assistance.) Inspect the unit
upon receipt. Immediately report any damage to the
shipping carrier.
FILTER INSTALLATION
The lter regulator assembly is shipped loose with
the IX controller. The assembly is packaged in a box
that is stored underneath the controller mounting
bracket. Please remove and mount as shown below
(A). The control air line for the lter assembly should be
connected to the tee tting connected to P3 (B).
MOUNTING POSITION & SUPPORT
The unit can be installed in any plane and is capable
of being installed vertically or horizontally. Additional
work is required when installing in the vertical mounting
position.
Horizontal Mounting
The unit is to be supported appropriately taking
into consideration the weight of the unit (reference
the respective drawings in the diagrams section for
approximate weights). Support should be provided
through:
The main piping (A) of the unit (not the control
A.
elements, the associated control piping, or valve
assemblies), and/or
The system piping (B).
B.
Consult Technical Support for further information.
•
Wire the unit in accordance with the wiring
•
schematic in the DIAGRAMS section of this manual.
Incoming power should be connected via the Gland
It may be necessary to add a drain line to the control
air lter to relieve buildup of condensate in the lter.
DIRECTION OF AIR FLOW
The unit has directional ow arrows. Orient the unit in
accordance with the compressed air ow system. The
factory unit is congured such that the air ows from
left to right when looking at the controller display. There
may be some cases when installing the IX IntelliFlow
unit where the air ows from right to left placing the
controller away from view. In these instances, re-mount
the bracket supporting the controller enclosure to the
opposite side of the IX IntelliFlow unit and rotate the
pressure gauge 180 degrees. Then mount the IntelliFlow
in the direction of the air ow (right to left). The air ow
will follow the air ow decals (entering on the P3 pressure
transducer side).
Holes using the necessary wire glands.
Fix any loose pre-wired connections.
•
Vertical Mounting
For vertical mounting, the pressure transducers and the
ltered pressure regulator are to be re-oriented 90˚.
The pressure transducers must be re-oriented such
•
that the body of the transducer is directed upwards.
The sensor cable should be on top of the sensor.
Additional elbows required to re-orient these devices
•
shall be eld supplied and installed.
o The ttings must be rated for 200 PSI (13.78
Bar) minumum.
It may be necessary to add a eld installed drain
connected at the bottom piping run to allow for proper
drainage of condensate that may collect in the piping.
ingersollrandproducts.com 9
IX BOX POWER SUPPLY
X02 X01
X03
P4
P3
Ao
4-20m
A
100m (330ft) max
2
1
X01
+C
A
i1
P4
4-20mA
100m (330ft) max
2
1
X02
+C
A
i2
P3
4-20mA
100m (330ft) max
2
1
X03
Ao
A-GND
The IX IntelliFlow Controller Unit is equipped with a
power supply input that will accept 100Vac to 240Vac,
50/60Hz.
Before applying power to the IX IntelliFlow Controller
unit ensure that the power supply connections are
correct and secure and that the supply voltage is 100Vac
to 240Vac (+-10%), 50/60Hz.
Wiring run through the enclosure must be made
using Type 12 UL rated ttings which are eld provided.
pressure, Demand side or outlet side, of the IX IntelliFlow
Valve assembly. Use shielded (earth screened), twoconductor (2 core), 20 gauge (0.5mm2 CSA) minimum,
cable no greater than 330ft (100m) in length.
Connection polarity is important.
For ‘Backward’ mode it is not necessary to connect a
‘P4’ pressure sensor.
For ‘Forward’ or ‘Combination’ Modes a ‘P4’ sensor
must be connected.
Re-use electrical ttings provided for pressure
transducer wiring.
P3 Pressure Sensor, 4-20mA: For Supply Side / Back
Pressure / Backward Mode or Combination Demand /
Supply Side / Combination Mode Pressure Control.
IX INTELLIFLOW VALVE CONTROLLER
CONNECTION AND SENSOR ARRANGEMENT
The IX IntelliFlow assembly ships with both the P3 and
the P4 pressure transducers installed and prewired to
the IX controller inputs. The control valve positioner
is also prewired to the controller output.
P3 Supply Side, High Pressure Side (IX IntelliFlow
Inlet) pressure transducer.
P4 Demand Side, Low Pressure Side (IX IntelliFlow
Outlet) pressure transducer.
Ao Analog output to the IX Control Valve positioner.
If it is necessary to remote mount the IX
IntelliFlow controller, the following diagrams depict
the electrical connections between the controller, the
pressure transducers, and the control valve positioner.
P4 Pressure Sensor, 4-20mA: For Demand Side /
Forward Mode Pressure Control (Factory Default) or
Combination Demand / Supply Side / Combination
Mode Pressure Control (Optional)
Pressure Sensor ‘P3’ must be installed on the High
Pressure or inlet side, of the IX IntelliFlow Valve assembly.
Use shielded (earth screened), two-conductor (2 core),
20 gauge (0.5mm CSA) minimum, cable no greater than
330ft (100m) in length.
Connection polarity is important.
For ‘Forward’ mode it is not necessary to connect a ‘P3’
pressure sensor.
For ‘Backward’ or ‘Combination’ Modes a ‘P3’ sensor
must be connected.
Re-use electrical ttings provided for pressure
transducer wiring.
Valve Control Analog Output, 4-20mA: For Control of
the Control Valve Positioner
Connect the controller ‘Ao’ 4-20mA control output to the
valve 4-20mA input. Use shielded (earth screened), twoconductor (2 core), 20 gauge (0.5mm2 CSA) minimum,
cable no greater than 330ft (100m) in length.
The ‘Ao’ 4-20mA output is active at a voltage of 24VDC
(+-2VDC) and is intended for connection to devices with a
‘loop powered’ 4-20mA input.
Connection polarity is important.
Re-use electrical ttings provided for pressure
transducer wiring.
Pressure Sensor ‘P4’ must be installed on the Low
10 ingersollrandproducts.com
IX BOX RS485 NETWORK
2
1
+L1 (A)
RS485
-L2 (B)
+L1 (A)
-L2 (B)
X13
Modbus RTU or IRBus/RS485
The IX IntelliFlow Valve Controller is equipped with an
RS485 network communications capability using Modbus
RTU or being connected to the X-Series compressor
control products.
The cable used should be Belden 9841 (or equivalent).
It should be run in grounded conduit and should not be
greater than 4000 feet (1219 meters) in length.
Connection polarity is important.
Wiring run through the enclosure must be made
using Type 12 UL rated ttings which are eld provided.
Menus and Menu Items
RS485 data communications and other low voltage
signals can be subject to electrical interference. This
potential can result in intermittent malfunction or
anomaly that is dicult to diagnose. To avoid this
possibility always use earth shielded cables, securely
bonded to a known good earth at one end. In addition,
give careful consideration to cable routing during
installation.
a) Never route an RS485 data communications or
low voltage signal cable alongside a high voltage
or 3-phase power supply cable. If it is necessary
to cross the path of a power supply cable(s),
always cross at a right angle.
b) If it is necessary to follow the route of power
supply cables for a short distance, attach
the RS485 or signal cable on the outside of a
grounded (earthed) cable tray such that the
cable tray forms a grounded (earthed) electrical
interference shield.
c) Where possible, never route an RS485 or signal
cable near to equipment or devices that may be
a source of electrical interference (for example:
3-phase power supply transformer, high voltage
switchgear unit, frequency inverter drive module,
radio communications antenna).
ingersollrandproducts.com 11
Keypad:
a
f
e
d
c
b
A
B
i
SECTION 7 DISPLAY AND MENU OPERATION
Press UP or DOWN to view other user menu
items.
The display will remain on the selected ‘User’ menu item
indenitely.
At power-up, or reset, the display will default to the rst
user menu list item.
Status Symbols:
ON/ON Operating
ON/Flash Manual Mode
Flash/OFF Forced Open/Closed
OFF/OFF Fault Shutdown
Reset
a)
Menu
b)
Enter
c)
Down (Minus)
d)
Up (Plus)
e)
Escape (Cancel)
f)
Display
Pressure = Main Display Pressure
% = Valve percentage open (0-100%)
The main display pressure is dependent on the Operating
mode or the Combi. Mode Display Pressure (1.dP) setting.
The Main Display Pressure will display the pressure value
as follows:
Forward Mode = P4 Pressure
Backwards Mode = P3 Pressure
Combination Mode = menu 1.dP setting
Manual Mode = menu 1.dP setting
Flash Fault
Status:
‘A’ = Active Target Pressure Setting
1, 2, 3 or 4 (1 = default)
Manual Mode = “-“(dash)
‘B’ = Mode
Forward Mode
Backward Mode
Combination Mode
Manual Mode
or Forced Closed
or Forced Open
see ‘Status Symbols’
12 ingersollrandproducts.com
Press UP or DOWN to view other user menu
items.
P3 High Pressure, Generation Side, Inlet:
Only shown in ‘Forward’ mode if P3 sensor tted.
P4 Low Pressure, Demand Side, Outlet:
Only shown in ‘Backwards’ mode if P4 sensor tted.
Network Address (IRBUS Mode):
B01 = Network I/O Box number
In IRBUS Mode the IX Box simulates a network I/O Box.
For networks that have I/O Box(s) ensure the I/O Box
number is unique.
When the unit is detecting valid IRBUS
communications from the XI management system unit
the communications indicator symbol will show:
Network Address: Modbus Mode
Modbus Address – decimal 01 to 99
The communications indicator symbol will not show
in Modbus mode.
Active ‘High Target’ Pressure:
In accordance with the active target pressure H1, H2, H3
or H4
Not shown in Forward or Manual Mode.
Active ‘Low Target’ Pressure:
In accordance with the active target pressure L1, L2, L3 or
L4
Not shown in Backwards or Manual Mode.
Valve Control Output (4-20mA):
Example: 12.0 Ao = 12.0mA, 50%
ingersollrandproducts.com 13
SECTION 8 COMMISSIONING
When commissioning the IX Box, carry out the following
procedures before attempting to start.
Menus and Menu Items
It is recommended that an authorized and trained
service technician perform the commissioning.
PHYSICAL CHECKS
1. Before applying power to the IX Box, ensure the
power supply connections are correct and secure
(115Vac or 230Vac (+-10%), 50/60Hz).
2. Open the front panel of the IX Box and ensure all
pressure sensor, RS485, and other connections are
correctly installed and secure.
See the section on Installation for more
information.
3. Close the front panel of the IX Box.
4. Switch on the power supply to the IX Box.
5. The control program identication will be displayed
for a short period followed by the normal operational
user display.
PRESSURE DISPLAY
Check the displayed delivery pressure. If the pressure is
incorrect, or inaccurate, check the type and range of the
sensor and carry out the pressure sensor commissioning
and calibration procedure.
3.3o P4 Outlet Pressure Oset
3.3r P4 Outlet Pressure Range
3.4o P3 Inlet Pressure Oset
3.4r P3 Inlet Pressure Range
User Conguration Menu 1
PRESSURE SET POINTS
Set the Forward Mode Target pressure set point to suit
system requirements in the appropriate control menu:
2.L1 Low Target Pressure #1
Menus and Menu Items
Target Conguration Menu 2
IX BOX OPTIONAL FEATURES AND
FUNCTIONS
Installation requirements may involve the
implementation of additional or optional functions and
features.
As default, additional optional functions and features
are deactivated or inhibited.
Features and Functions; Menu Items
IX INTELLIFLOW STARTUP
1. At initial start-up, begin with the bypass open.
2. Set the controller setpoint to a pressure at
the bottom of the Existing Upstream pressure
bandwidth. This will provide a changing system to
manually tune the control variables (proportional
pressure and integral time) and verify stable control.
See the Setting the Tuning Parameters section
for a description of how these values aect the
control system.
Menus and Menu Items
Sensor Calibration Menu 3
OPERATING MODE
Set the operating mode for the IX Box to Forward Mode in
the appropriate control menu:
1.oP Operating Mode
0: Forward Mode
This is the Default, As Shipped from the Factory,
Conguration
Set the Tuning Parameters for Forward Control mode in
the appropriate control menu:
1.3P P4 Proportional Pressure
Default is 20
1.3I P4 Integral Time
Default is 10
3. Slowly close the bypass.
4. Monitor the system and validate stable control. If
stable control is not achieved, open the bypass,
adjust control variables, and return to step 3.
Otherwise, continue to step 5.
5. Once stable control has been achieved, gradually
lower the setpoint until the optimal value has been
reached.
EXAMPLE:
Existing Upstream Pressure: 100-110 psi (6.9 to 7.6 bar)
Critical Pressure (minimum): 85 psi (5.8 bar)
1. Begin with the bypass valve fully open.
2. Set the controller setpoint to 100 psi (6.9 bar).
3. Slowly close the bypass valve.
4. If the control is not stable (valve is overshooting the
correct position or the setpoint is not being reached),
open the bypass, adjust the control variables, and
return to Step 3. If the control is stable, continue to
step 5.
14 ingersollrandproducts.com
5. Gradually lower the setpoint (pausing to verify that
the control is still stable) until the optimal setpoint
has been reached.
In this example, the optimal setpoint might be 90 psi (6.2
bar) with the downstream pressure uctuating between
89.25 psi (6.1 bar) and 90.75 psi (6.25 bar) in regular
operation. This would provide a 5 psi (0.3 bar) safety that
would prevent the downstream pressure from going
below 85 psi (5.8 bar) in the event of a sudden change in
air demand or supply.
SETTING THE TUNING PARAMETERS
1.3P P4 Proportional Pressure
Default is 20
1.3I P4 Integral Time
Default is 10
PROPORTIONAL PRESSURE
Proportional control varies the signal sent to the valves
as a linear response to the dierence between the actual
system pressure and the system pressure setpoint. Valve
responsiveness can be adjusted through the IntelliFlow
Controller with the proportional pressure (1.3P.), setpoint.
This scaling factor is the amount of change in the input
variable (actual minus setpoint pressures) to cause a full
scale change in the output variable (valve position).
In other words, if the pressure in the air system uctuates
frequently, it would be prudent to set the proportional
pressure to a low value (a value / number greater than
the factory default of 20) to keep up with those system
changes. Otherwise, if the system is very stable, it would
be prudent to set the proportional pressure to a high
value (a value / number less than the factory default
of 20) to keep up with those system changes. The
proportional pressure is directly related to valve life and
indirectly related to valve cycling; so, as band decreases,
valve life decreases and cycling increases.
As stated earlier, the IntelliFlow Controller uses a
proportional plus integral control algorithm. The
result of proportional only control is oset from the
controlled variable discharge pressure. This means that
if the setpoint pressure is 100, the actual pressure may
only be 95. The value of this oset depends upon the
proportional pressure value.
What is the valve response when the dierence between
actual and setpoint pressures is zero? There is no
response. Proportional control only functions when a
dierence or error exists. Design discharge pressure could
not be attained in a proportional only control system.
Therefore, an integral control algorithm is added to
achieve the desired discharge pressure.
INTEGRAL TIME
The oset produced by the proportional control
algorithm could be eliminated by manually readjusting
the system pressure setpoint. Using the example above,
the setpoint could be reset to 105 to obtain the 100
desired. Manually resetting the setpoint would be
required as the system demand uctuated. Integral
control, also known as reset control, automatically resets
the desired system pressure setpoint. For the IntelliFlow
controller, the rate at which the controller resets the
system pressure setting is known as Integral Time, (1.3I.),
and is expressed in minutes between reset.
If precise control of the specied discharge pressure is
required, the Integral Time setpoint should be set for a
fast value. In other words, if the pressure in the air system
uctuates frequently, it would be prudent to set the
Integral Time to a high value (a value / number greater
than the factory default of 10) to keep up with those
system changes. Otherwise, if the system is very stable,
it would be prudent to set the Integral Time to a low
value (a value / number less than the factory default of
10) to keep up with those system changes. It is directly
related to valve life and inversely related to valve cycling,
so, as Integral Time increases, the valve life increases and
cycling decreases.
When band is low and Integral Time is fast, valve activity
is signicant in both magnitude and frequency to obtain
the desired setpoint. The other scenario, band is high and
Integral Time is slow, has relatively little valve activity, and
may never reach the setpoint position.
Proportional pressure and Integral Time are variables
used internally by the control system to determine
valve response and direction for a given compressed
air system. Each has an optimum value based upon the
system’s characteristics. Determining these optimum
values is a trial and error exercise. These setpoints should
be re-evaluated any time there is a major change in the
compressed air system.
ingersollrandproducts.com 15
SECTION 9 SYSTEM CONFIGURATION
DISPLAY AND MENU OPERATION
All value, parameter or option selection displays are
grouped into menu lists. Items are assigned to a list
according to type and classication. Items that can be
used to select options or modify functions are assigned to
‘menu mode’ lists. Items that a User may require to view
during routine operation, detected pressure for example,
are assigned to the normal operational mode list.
Each menu has a unique access code. Only one menu can
be entered at a time.
ACCESSING THE IX CONFIGURATION
SCREENS
To access a menu press MENU.
The display will show four “0” characters;
the rst character will ash.
Press Up or Down to adjust the rst
character to match the rst character of the required
access code. If the access code number is ess than ‘1000’
the rst character will be ‘0’. Press Enter to increment to
the second code character.
code is incorrect the display will return to the normal
operational display.
To select a menu item for adjustment press
Up or Down until the menu item is displayed.
To adjust an item setting press Enter, the value or
option will ash.
Press Up or Down to adjust as required.
Press Enter to store in memory.
To exit the menu routine and return to the normal
operational display, at any time, press Cancel. The
display will return to the normal operational view. Any
adjustment that has not be entered to memory will be
abandoned and the previous setting maintained.
Menu codes are listed next to each Menu. See
Conguration Menu Overview for codes
When all four access code
characters have been set, and the last code character
is ashing, press Enter. If the access code is correct for
access to one of the accessible menus the rst menu item
of the appropriate menu will be displayed. If the access
16 ingersollrandproducts.com
CONFIGURATION MENU OVERVIEW
1. - -
2. - -
3. - -
4. - -
5. - -
Each menu is accessed individually using the access
codes show.
User Conguration Menu 1
Menu Access Code ‘0011’
1.oP Operating Mode
1.3P P4 Proportional Pressure
1.3I P4 Integral Time
1.4P P3 Proportional Pressure
1.4I P3 Integral Time
1.bA Backwards Mode Algorithm
1.Po Manual Mode %Open
1.SP Maximum %Change/Second
1.LP Valve %Open Low Level
1.HP Valve %Open High Level
1.SF Control Pressure Fault Response
1.CF Communication Fault Response
1.Ad Network Address
1.Pd Pressure Display Unit
1.dP Combi. Mode Display Pressure
Target Conguration Menu 2
Menu Access Code ‘0021’
2.L1 Low Target Pressure #1 (default)
2.H1 High Target Pressure #1 (default)
2.L2 Low Target Pressure #2
2.H2 High Target Pressure #2
2.L3 Low Target Pressure #3
2.H3 High Target Pressure #3
2.L4 Low Target Pressure #4
2.H4 High Target Pressure #4
Relay Functions R1 to R6
Menu Access Code ‘0041’ (R1) to ‘0046’ (R6)
4.F1 Input Function #1 (A, b and C)
4.F2 Input Function #2 (A, b and C)
4.Fu Logic Function
4.on On Delay Time
4.oF O Delay Time
4.St Normal State
4.CF RS485 Failure Response
Diagnostic Menu 5
Menu Access Code ‘0051’
5.d1 Digital Input #1 (Di 1)
5.d2 Digital Input #2 (Di 2)
5.d3 Digital Input #3 (Di 3)
5.d4 Digital Input #4 (Di 4)
5.d5 Digital Input #5 (Di 5)
5.d6 Digital Input #6 (Di 6)
5.r1 Output Relay #1 (R1)
5.r2 Output Relay #2 (R2)
5.A1 Analog Input #1 (Ai1)
5.A2 Analog Input #2 (Ai2)
5.Ao Analog Output (Ao)
Sensor Calibration Menu 3
Menu Access Code ‘0031’
3.3o P4 Outlet Pressure Oset
3.3r P4 Outlet Pressure Range
3.4o P3 Inlet Pressure Oset
3.4r P3 Inlet Pressure Range
ingersollrandproducts.com 17
USER CONFIGURATION MENU 1
1.oP – Operating Mode
There are 5 Operating Modes for the IX IntelliFlow control.
0: Forward Mode
P4 pressure sensor (Outlet, Low pressure, Demand Side) is
used for Control Pressure in accordance with active ‘Low
Target’ (2.L1 to 2.L4) pressure set point. The ‘High Target’
(2.H1 to 2.H4) pressure set points are inhibited and any P3
pressure sensor fault is ignored.
The valve will regulate using the P4 pressure in
accordance with the ‘1.4P’ proportional pressure and ‘1.4I’
integral time settings.
Forward Mode Control action is:
Target is 95psi (6.55 bar)
If P3 remains above 95psi (6.55 bar):
P4 is maintained at P4 target:
If demand increases and P4 falls below 95psi (6.55 Bar):
Valve opens towards 100%
If demand decreases and P4 increases above 95psi (6.55
Bar):
Valve closes towards 0%
If P3 falls below 95psi (6.55 Bar):
Valve will open 100% and P4 pressure will equal
P3 pressure
This mode of operation is intended to maintain a constant
Demand, or Outlet, side pressure where the Generation,
or Inlet, is at a higher pressure level.
1: Backward Mode
P3 pressure sensor (Inlet, High Pressure, Generation Side)
is used for Control Pressure in accordance with active
‘High Target’ (2.H1 to 2.H4) pressure set point. The ‘Low
Target’ (2.L1 to 2.L4) pressure set points are inhibited and
any P4 pressure sensor fault is ignored.
If ‘1.bA = 0’:
The ‘1.4P’ (P4 Proportional Pressure) and ‘1.4I’ (P4 Integral
Time) algorithm parameters are used.
If ‘1.bA = 1’:
The ‘1.3P’ (P3 Proportional Pressure) and ‘1.3I’ (P3 Integral
Time) algorithm parameters are used.
The valve will regulate using the P3 (Inlet, High Pressure,
Generation Side) pressure sensor in accordance with
the applicable ‘Proportional’ pressure and ‘Integral’ time
settings.
Backward Mode Control action is:
Target is 80psi (5.51 bar)
If P3 remains above 80psi (5.51 bar):
Valve remains fully open and P4 pressure will
equal P3 pressure.
If P3 falls to 80psi (5.51 bar):
P3 is protected from falling below 80psi:
If P3 falls below 80psi (5.51 bar):
Valve closes towards 0%
If P3 increases above 80psi (5.51 bar):
Valve opens towards 100% and P4 pressure will
equal P3 pressure.
This mode of operation is intended to ensure a minimum
specied Generation, or Inlet, side pressure is maintained
in instances where air demand from the Demand side,
or Outlet, becomes excessive and Demand side pressure
begins to decay.
2: Combination Mode
Both the P4 (Outlet, Low pressure, Demand Side) and the
P3 (Inlet, High Pressure, Generation Side) pressure sensors
are used for control. The ‘Forward’ mode and ‘Backwards’
mode control algorithms operate together at the same
time. Whichever control loop algorithm produces the
lowest %Open value will take priority; the valve will follow
the lowest %Open value.
In Combination mode, the operation and use of the valve
is dependent on the relationship between the set ‘Low
Target’ and ‘High Target’ pressure set points.
Backward Mode Control action is:
P4 target is 95psi (6.55 bar)
P3 target is 80psi (5.51 bar)
If P3 remains above 95psi (6.55 bar):
P4 is maintained at P4 target:
If demand increases and P4 falls below 95psi (6.55 bar)
Valve opens towards 100%
If demand decreases and P4 increases above 95psi (6.55
bar):
Valve closes towards 0%
If P3 falls below 95psi (6.55 bar) but remains above 80psi
(5.51 bar):
Valve will open 100% and P4 pressure will equal
P3 pressure.
If P3 falls to 80psi (5.51 bar):
P3 is protected from falling below 80psi (5.51
bar):
If P3 falls below 80psi (5.51 bar):
Valve closes towards 0%
If P3 increases above 80psi (5.51 bar):
Valve opens towards 100%
3: Manual Mode
The valve will open to the percentage open value
specied in ‘1.Po’. The valve will remain xed at this
%Open value regardless of target pressure set points,
variation in detected pressure, pressure sensor availability
or sensor fault state condition.
18 ingersollrandproducts.com
4: Forced Closed
The valve is forced ‘Closed’. P3 and P4 pressure sensor
faults are ignored. When ‘Force Closed’ is activated the
valve will close immediately in accordance with the set
‘1.SP’ percent change per second limit. The ‘1.SP’ setting
restricts how fast the valve will close.
1.LP Valve %Open Low Level
If valve %Open < set ‘1.LP’; then Ai#3 ‘S’ state is set to ‘1’.
Ai#3 ‘S’ state will return to ‘0’ if valve %Open >= ‘1.LP’.
This setting has no eect on valve operation or %Open
position but can be used in local and/or system wide
‘Virtual Relay’ automation.
5: Forced Open
The valve is forced ‘Open’. P3 and P4 pressure sensor
faults are ignored. When ‘Force Open’ is activated the
valve will open immediately in accordance with the set
‘1.SP’ percent change per second limit. The ‘1.SP’ setting
restricts how fast the valve will open.
1.3P P3 Proportional Pressure Factor
The pressure range, above and below the set ‘target’
pressure, where integral control will occur.
1.3I P3 Integral Time Factor
The time that the output will execute a full scale change
from 4mA to 20mA, 0-100% (or vice versa).
1.4P P4 Proportional Pressure Factor
The pressure range, above and below the set ‘target’
pressure, where integral control will occur.
1.4I P4 Integral Time Factor
The time that the output will execute a full scale change
from 4mA to 20mA, 0-100% (or vice versa).
1.bA Backwards Mode Algorithm
0 - The ‘1.4P’ (P4 Proportional Pressure) and ‘1.4I’
(P4 Integral Time) algorithm parameters are used
for ‘Backwards’ mode operation.
1 - The ‘1.3P’ (P3 Proportional Pressure) and ‘1.3I’ (P3
Integral Time) algorithm parameters are used
for ‘Backwards’ mode operation (default).
1.HP Valve %Open High Level
If valve %Open > set ‘1.HP’; then Ai#4 ‘S’ state is set to ‘1’.
Ai#4 ‘S’ state will return to ‘0’ if valve %Open <= ‘1.HP’.
This setting has no eect on valve operation or %Open
position but can be used in local and/or system wide
‘Virtual Relay’ automation.
1.SF Control Pressure Fault Response
If a fault with the ‘Control’ pressure sensor occurs, or any
pressure sensor in Combination Mode:
0 - Manual Mode
1 - Force Valve Open (default)
2 - Force Valve Closed
1.CF Communications Fault Response
If a fault with network communications occurs:
0 – Continue normally (default)
1 – Force Valve Open
2 – Force Valve Closed
Only applicable in IRBUS Communications Mode; always
‘0’ (continue normally) in Modbus Mode.
1.Ad Network Address
Modbus:
01 to 99 decimal (0 to 63 Hex)
IRBUS Mode:
b01 to b12 (I/O Box 1 to 12)
1.Po Manual Mode %Open Value
Manual Mode %Open value (0 to 100%)
refer to ‘Manual Mode’ (1.oP)
1.SP %Change/Second
Restricts how fast the valve will open, or close, when
pressure changes abruptly and/or a signicant
‘Target’ pressure change is made. If the applicable, or
predominate, target algorithm produces a change in
%Open that exceeds the ‘1.SP’ setting the change in valve
%Open is restricted to the maximum % change
determined by the ‘1.SP’ setting until the required valve
%Open position is reached.
The ‘1.SP’ setting is expressed in %Change per second
where a setting of 20% will restrict any change to a
maximum of 20%Open per second - the valve will change
from fully open (100%Open) to fully closed (0%Open) in
ve seconds if the required %Open value changes from
100%Open to 0%Open abruptly.
‘1.SP’ is always active in all modes.
IRBUS or Modbus mode is selected automatically
dependant on set address.
1.Pd Pressure Display Units
0 – bar
1 - psi (default)
1.dP Combi. Mode Display Pressure
Determines if the P3 or P4 pressure is displayed as the
‘Main Display Pressure’ when operating in Combination
mode.
0 – P4 (default)
1 – P3
ingersollrandproducts.com 19
PRESSURE TARGET MENU 2
2.L1 Low Target Pressure #1 (default)
Normal default outlet side target pressure when no
digital inputs are activated.
Active in ‘Forward’ and ‘Combination’ modes; not used for
‘Backwards’ mode.
2.H1 High Target Pressure #1 (default)
Normal default inlet side target pressure when no digital
inputs are activated.
Active in ‘Backwards’ and ‘Combination’ modes; not used
for ‘Forward’ mode.
2.L2 Low Target Pressure #2
Applicable when ‘Target Pressure Set 2’ digital input
activated.
Active in ‘Forward’ and ‘Combination’ modes; not used for
‘Backwards’ mode.
2.H2 High Target Pressure #2
Applicable when ‘Target Pressure Set 2’ digital input
activated.
Active in ‘Backwards’ and ‘Combination’ modes; not used
for ‘Forward’ mode.
2.L3 Low Target Pressure #3
Applicable when ‘Target Pressure Set 3’ digital input
activated.
Active in ‘Forward’ and ‘Combination’ modes; not used for
‘Backwards’ mode.
2.H3 High Target Pressure #3
Applicable when ‘Target Pressure Set 3’ digital input
activated.
Active in ‘Backwards’ and ‘Combination’ modes; not used
for ‘Forward’ mode.
2.L4 Low Target Pressure #4
Applicable when ‘Target Pressure Set 4’ digital input
activated.
Active in ‘Forward’ and ‘Combination’ modes; not used for
‘Backwards’ mode.
2.H4 High Target Pressure #4
Applicable when ‘Target Pressure Set 4’ digital input
activated.
Active in ‘Backwards’ and ‘Combination’ modes; not used
for ‘Forward’ mode.
If more than one digital input is activated the
following priority will apply:
1: (highest priority) Force Closed
2: Force Open
3: Manual Mode
4: Target Set #2
5: Target Set #3
6: (lowest priority) Target Set #4
SENSOR CALIBRATION MENU 3
3.3o P3 Pressure Sensor Oset
3.3r P3 Pressure Sensor Range
P3 pressure sensor (Inlet, High pressure, Generation Side)
calibration settings.
See ‘Pressure Sensor Calibration Procedure’
3.4o P4 Pressure Sensor Oset
3.4r P4 Pressure Sensor Range
P4 pressure sensor (Outlet, Low pressure, Demand Side)
calibration settings.
see ‘Pressure Sensor Calibration Procedure’
Pressure Sensor Calibration Procedure:
1) Commissioning
Initially set the ‘Oset’ (minimum) to the minimum or
lowest pressure value for the sensor. Set the ‘Range’
(maximum) to the maximum or highest value for the
sensor.
For example:
If the pressure sensor is a 0 to 232psi (0 to 16.0bar)
type set the ‘oset’ to 0psi (0bar) and the ‘Range’ to
232psi (16.0bar).
Execute the calibration procedure.
2) Calibration Procedure
a) Oset: Expose the sensor to atmosphere and adjust
the ‘oset’ setting (if necessary) until the detected
pressure display shows 0psi (0bar).
b) Range: Apply an accurately know pressure to the
pressure sensor and adjust the ‘Range’ setting until
the detected pressure display matches the applied
pressure. An applied pressure equal too, or greater
than, the nominal system working pressure is
recommended.
The detected pressure is displayed with the
calibration menu item and will change to match the
new calibration setting as the setting is adjusted.
There is no need for the applied pressure to be
static; it can be dynamic and changing. This enables
calibration to be carried out on a fully operational
system where changing system pressure can be
accurately veried from another source.
Correct pressure sensor set-up and calibration
is critical for successful system operation. It is
recommended that pressure sensor calibration is
examined, and adjusted if necessary, annually or a
pre-determined routine periodic basis.
RELAY CONFIGURATION MENU 4
see ‘Virtual Relay Automation’
20 ingersollrandproducts.com
SECTION 10 DIAGNOSTICS
D1 Digital Input 1
D2 Digital Input 2
D3 Digital Input 3
D4 Digital Input 4
D5 Digital Input 5
D6 Digital Input 6
-------------------------------------------------------------
R1 Relay Output 1
R2 Relay Output 2
-------------------------------------------------------------
A1 Analog Input 1 psi <> mA
A2 Analog Input 2 psi <> mA
1: ON
0: OFF
OFF
ON
------------------------------------------------------------Ao Analog Output 0.0 to 20.0mA
DIAGNOSTIC MENU 5
The IX IntelliFlow Controller is equipped with
comprehensive diagnostic functions. Each input can be
examined individually and each output can be manually
activated or manipulated individually.
P2 Controller Diagnostics:
Reset All Settings To Default:
Enter an Access Code of ‘9750’; do not press enter when
the last character is ashing.
Press and hold CANCEL for 10 seconds; the controller will
reset and all settings will be reset to default. All previous
settings will be permanently lost.
Relay Outputs:
Each relay output can be energised and de-energised
manually by selecting the item. Use Up(plus) and
Down(minus) to adjust and Enter.
Analog Inputs:
The item will alternate between the detected value
and the electrical measurement on the controller input
terminals. An independent measuring device can be used
to check the displayed electrical measurement.
A1: P4 Outlet Pressure, 4-20mA
A2: P3 Inlet Pressure, 4-20mA
Analog Output:
The analog output can be manually adjusted to any
desired level. Press Enter then use Up (Plus) and Down
(Minus) to adjust and Enter. The output will return to
normal operational value upon menu exit.
ingersollrandproducts.com 21
SECTION 11 FAULT CODES
In the event of a IX IntelliFlow IX Box Fault, the IX Box
display a fault code. The fault code becomes an item
in the User operational display menu. If more than one
active fault occurs each will be displayed as a separate
item in the operational User menu; press Up or Down to
view all active fault codes or to view the normal status
display.
Fault codes are separated in to A: Alarm (Warning) and E:
Shutdown Trip.
Pressure Sensor Faults:
Reaction to a pressure sensor fault is dependent on the
sensor and mode. If the pressure sensor is being used for
‘Control Pressure’, or the unit is in ‘Combination Mode’, the
controller will shutdown.
If the sensor is not being used for ‘Control Pressure’, and
the unit is not in ‘Combination Mode’, the sensor fault will
be ignored and the associating pressure display will show
“- - - -“ (dashes).
Fault Codes:
E0115 P4 Pressure Sensor Fault
E0125 P3 Pressure Sensor Fault
The unit’s controller has detected disruption to the
internal operational memory storage (RAM). The integrity
of the RAM memory contents is suspect; the controller
must be reset to clear and re-map the memory. Renew
the controller if this fault condition persists.
The controller’s main power supply must be removed and
re-applied to reset this condition.
Remote XI Management System Fault Code Display:
When set for an I/O Box address (b01 to b12) the XI
management system can be set to monitor the unit for
fault conditions.
B’nn’57 ‘nn’ = IO Box number (01 to 12)
P4 Demand Side Pressure Sensor Fault when operating in
Forward or Combination mode.
B’nn’58 ‘nn’ = IO Box number (01 to 12)
P3 Generation Side Pressure Sensor Fault when operating
in Backwards or Combination mode.
B’nn’60 ‘nn’ = IO Box number (01 to 12)
General Trip (Shutdown)
B’nn’ - - ‘nn’ = IO Box number (01 to 12)
RS485 communications disruption or loss.
E0821 Short Circuit
Short Circuit condition detected on the main controller
unit (digital inputs)
E0866 DC Power Supply Low
Check voltage of main power supply.
E5000 Internal Memory Map Error
When in IR485 mode, and connected to a network,
the ‘B’ fault codes can be monitored and displayed by an
XI system management unit. The ‘B’ codes do not show on
the IntelliFlow display.
22 ingersollrandproducts.com
SECTION 12 IX INTELLIFLOW CONTROLLER PART LIST
3
20mm
5mm
IEC
1
253
160
90
2
A
B
205
253
4242
160 136
24
IX Box
Item Part No. Description
- 23451966 IX IntelliFlow
1 23451974 Unit, IX IntelliFlow
2 634067 Gland, Set - Pg13.5
- 80445588 Manual, User CD
ACCESSORIES:
Required For P3 and P4 System Pressure Transducers
Item Part No. Description
3 634065 Sensor, Pressure – Quantity (2)
4-20mA, 0-232 psi (0-16.0bar)
Item Part No. Description
2 634104 IEC Fuse T1.6A
SECTION 13 IX INTELLIFLOW CONTROLLER TECHNICAL DATA
Dimensions 10” x 6.3” x 3.6”
253 x 160 x 90mm
Weight 5.0lb (2.2kg)
Mounting wall, 2 x screw xings (8mm)
Enclosure IP54, NEMA 12
Supply 100 to 240Vac +/- 10%
Power 100VA
Temperature 32°F to 115°F (0°C to 46°C)
Humidity 95% RH, non-condensing
IX Box Technical Data
Mounting Dimensions (mm):
ingersollrandproducts.com 23
FH1
T1
.6
A
FH2
X10
T1
.6
A
PSU
IEC
20 x 5mm
LED1b
N
L
E
0VDC
+VDC
X09
X08
RL1
RL2
C01
Ai2
ACM
C018
RT1
X07
X06
X05
X04
X03
X02
X01
LCD
Ai2
C
Ai1
+C
Ao
A-GND
R1
R2
1
2
1
2
1
2
3
1
2
1
2
1
2
Di5
+C
Di6
D6
+C
+L1 (A)
RS
48
5
-L2 (B)
D5
2
1
2
1
2
1
4-20mA
4-20mA
4-20mA
Di4
GND
D4
+24 VDC
IR IntelliFlow Valv e
Control Unit - P2
100-240Vac
60VA
50/60Hz
1
2
3
4
E
L
N
X11
X12
X13
P2
4-20mA
LED2
LED1
+C
1
2
3
Di3
GND
D3
+24 VDC
+C
1
2
3
Di2
GND
D2
+24 VDC
+C
1
2
3
Di1
GND
D1
+24 VDC
+C
SECTION 14 IX INTELLIFLOW CONTROLLER WIRING DIAGRAM
24 ingersollrandproducts.com
4-20mA
100m (330ft) max
1
2
3
1
2
3
1
2
3
1
2
3
1
2
Ai2
+C
2
1
1
2
+L1
2
1
0VDC
+24VDC
D1
+L1 (A)
RS485
-L2 (B)
+L1 (A)
-L2 (B)
-L2
RS485
X13
X02
X04
X05
X06
X07
Di1
+C
0VDC
+24VDC
D2
0VDC
+24VDC
D3
0VDC
+24VDC
D4
+24VDC
Ai2
4-20mA
100m (330ft) max
1
2
Ai1
+C
2
1
X01
+24VDC
Ai1
P4
P3
Target 2
Target 3
Target 4
Outlet
Demand Side
Inlet
Supply Side
330ft (100m) max
IR IntelliFlow Valve
Control Unit - P2
GND
Pressure
Pressure
Modbus
P2
L NE
X10
1 2 3 4
4-20mA
100m (330ft) max
1
2
A-GND
Ao
2
1
X03
Ao
A-GND
IntelliFlow Valve
4-20mA Output
Ao
100-240Vac
100VA
50/60Hz
Virtual Relay
Configurable
240V 'CE ' / 115V 'UL ' @ 4A
maximum.
1
2
1
2
R1
R2
X09
X08
Di6
+C
Di5
+C
1
2
1
2
+24VDC
D5
+24VDC
D6
X12
X11
Force Closed
Force Open
Manual Mode
X02 X01
X03
P4
P3
Ao
Di2
+C
GND
Di3
+C
GND
Di4
+C
GND
330ft (100m) max
330ft (100m) max
330ft (100m) max
330ft (100m) max
330ft (100m) max
ingersollrandproducts.com 25
ENCLOSURE MOUNTING
A B
A
B
1
2
Use correct size Torrex Screw Driver
Excessive localized loading or force may fracture the
enclosure:
1. Always use mounting washes provide.
2. Do not over tighten mounting xtures.
See ‘Technical Data’ for enclosure and mounting
dimensions.
26 ingersollrandproducts.com
Cable Installation and Wire Connections:
Invert and secure front panel to the rear enclosure
lower front panel xings.
SECTION 15 IX INTELLIFLOW CONTROLLER REMOTE INPUTS
1
2
3
1
2
3
1
2
3
1
2
3
0VDC
+24VDC
D1
X04
X05
X06
X07
Di1
+C
0VDC
+24VDC
D2
0VDC
+24VDC
D3
0VDC
+24VDC
D4
T2
T3
T4
GND
M
Di2
+C
GND
Di3
+C
GND
Di4
+C
GND
Di6
+C
Di5
+C
1
2
1
2
+24VDC
D5
+24VDC
D6
X12
X11
FC
FO
330ft (100m) max
Virtual Relay
'CE' 240V @ 4A
'UL' 115V @ 4A
1
2
1
2
R1
R2
X09
X08
1
2
R1
X08
1
2
3
0VDC
+24VDC
D4
X07
M
IX BOX INPUT FUNCTIONS
Remote ‘Volt-Free’ Switching Contact:
Use 20 gauge (0.5mm CSA) minimum, cable conductors
no greater than 330ft (100m) in length.
T2: Target Pressure Set Points #2
T3: Target Pressure Set Points #3
T4: Target Pressure Set Points #4
M: Manual Mode
FO: Force Open
FC: Force Closed
Remote inputs are intended for remote activation from a
‘volt-free’ switching contact, relay contact, PLC or other
remote logic device.
T2, T3 and T4:
When no ‘target pressure set’ digital inputs (Di1 to Di3) are
activated the controller will use ‘Target Pressure Set #1’.
VIRTUAL RELAY AUTOMATION
The target pressure set (2, 3 or 4), manual mode or force
closed/open selection inputs can also be activated by
the IntelliFlow ‘Virtual Relay’ automation functions by
connecting the appropriate ‘Virtual Relay’ output (R1 or
R2) to the required digital input.
For example:
Virtual Relay output R1 (X08) will activate Manual Mode
(X07).
Combinations of logic involving ‘Virtual Relay’ automation
output(s) and remote switching ‘volt-free’ contact(s) of
other third party devices can be implemented using this
methodology.
Remote Input Priority:
If more than one digital input is activated at the same
time the following priority will apply:
1 (highest priority): Force Closed
2: Force Open
3: Manual Mode
4: Target Set #2
5: Target Set #3
6: (lowest priority): Target Set #4
For example:
If the ‘Force Open’ and ‘Target Set #3’ inputs are both
activated together the unit will respond to the ‘Force
Open’ input.
ingersollrandproducts.com 27
SECTION 16 IX INTELLIFLOW CONTROLLER RS485 MODBUS REGISTERS
Modbus RTU Protocol @ 9600, N-8-1
Registers 400XX:
‘XX’ Item, Description
01 Status (R)
Bits:
0 - Forward Mode
1 - Backwards Mode
2 - Combination Mode
3 - Manual Mode
4 - Forced Closed
5 - Forced Open
6 - Control Sensor Fault
7 - General Fault Shutdown
(including control sensor fault)
02 P4 Outlet Pressure, psi (R)
03 P3 Inlet Pressure, psi (R)
04 Valve %Open x 100
0 to 10000 = 0 to 100% (R)
05 Ao - mA x 100
400 to 2000 = 4.0 to 20.0mA (R)
06 Mode (R/W)
0 - Forward Mode
1 - Backward Mode
2 - Combination Mode
3 - Manual Mode
4 - Force Closed
5 - Force Open
07 L1: Low Target #1, psi (R/W)
08 H1: High Target #1, psi (R/W)
09 L2: Low Target #2, psi (R/W)
10 H2: High Target #2, psi (R/W)
11 L3: Low Target #3, psi (R/W)
12 H3: High Target #3, psi (R/W)
13 L4: Low Target #4, psi (R/W)
14 H4: High Target #4, psi (R/W)
15 3P - P4 Proportional Pressure
mBar; 69mBar = 1psi (R/W)
16 3I - P4 Integral Time; secs (R/W)
17 4P - P3 Proportional Pressure (R/W)
mBar; 69mBar = 1psi (R/W)
18 4I - P3 Integral Time; secs (R/W)
19 BA - Backwards Mode Algorithm (0=3P/3I;
1=4P/4I) (R/W)
20 SP - Maximum %Change/Second
100 to 10000 = 1% to 100% (R/W)
21 LP - Valve %Open Low Level
0 to 10000 = 0% to 100% (R/W)
22 HP - Valve %Open High Level
0 to 10000 = 0% to 100% (R/W)
23 SF - Control Sensor Fault (R/W)
0 - manual mode
1 - force valve open
2 - force valve closed
24 CF - Comms Fault (R/W)
0 - continue operating
1 - force valve open
2 - force valve closed
25 Manual Mode %Open value, ‘Po’
0 to 10000 = 0% to 100% (R/W)
(R) = Read Only
(R/W) = Read/Write
Read - function 03Hex
“01 03 00 00 00 01” Status Register
‘XX’ Register address has a ‘1’ oset:
For ‘Status’ (register address 01) use Hex address “00 00”
Write - function 06Hex only (single register)
“01 06 00 05 00 02” set Mode to Combination
‘XX’ Register address has a ‘1’ oset:
For ‘Mode’ (register address 06) use Hex address “00 05”
Mode - Write:
If the ‘P4’ sensor is not tted, or in a fault state, the
controller will not accept a command to change to
‘Forward’ or ‘Combination’ modes; a Modbus exception
response will be returned.
If the ‘P3’ sensor is not tted, or in a fault state, the
controller will not accept a command to change to
‘Backwards’ or ‘Combination’ modes; a Modbus exception
response will be returned.
28 ingersollrandproducts.com
SECTION 17 IX INTELLIFLOW DIGITAL POSITIONER
The Digital I/P Positioner comes from the factory
pretested and fully calibrated and should not require
recalibration on new installations.
If the unit appears to need recalibration, please check
all pipe ttings and connections for air leaks prior to
performing the following calibration procedure.
IX INTELLIFLOW DIGITAL POSITIONER
SETUP PROCEDURE
Overview
Bray Series 6A (single-acting: only one output pressure)•
ingersollrandproducts.com 29
Feedback Angle Dial
Set to 90˚
•
o Rotate yellow outside c-ring clockwise until
center-mark is aligned with 90˚.
o The sticker below the dial indicates the correct
position for 90˚.
Transmission Ratio Push-Bar
Set to 90˚
•
o Push the Bar upwards from the bottom of the
unit.
o The sticker on top, by the display, indicates the
correct position for 90˚.
30 ingersollrandproducts.com
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