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System Automation I-O Accessory Box
User Manual
26 pgs2.51 Mb0

Ingersoll Rand System Automation I-O Accessory Box User Manual

Ingersoll Rand
System Automation
I/O Accessory Box
Operator’s Manual
More Than Air. Answers.
Online answers: http://air.ingersollrand.com
C.C.N. : 80444110
: A
REV. DATE : DECEMBER 2008
SECTION 1  TABLE OF CONTENTS
Section 1 - table of contentS .............................2
Section 2 - intRoDUction ......................................
Section 3 - Safety pRecaUtionS .........................
INSTALLATION .............................................................................3
OPERATION ...................................................................................3
MAINTENANCE AND REPAIR .................................................4
Section 4 - inStallation .........................................5
UNIT LOCATION ..........................................................................5
POWER SUPPLY ...........................................................................
RS485 NETWORK ........................................................................
I/O BOX ANALOG CONDITIONING MODULE................... 5
TO CHANGE AN ACM DEVICE: ............................................... 6
TO REMOVE AN ACM DEVICE: ............................................... 7
TO INSTALL AN ACM DEVICE: ...................................
ACM IDENTIFICATION ...............................................
6.5 OPERATION ............................................................
6.6 DIGITAL INPUT STATUS INDICATIONS ................
3
6.7 ANALOG INPUT DISPLAY .........................................
3
6.8 POWER FAILURE AUTORESTART ..........................
6.9 I/O BOX FAULT ..............................................................
6.10 SHUTDOWN FAULTS ...................................................
MANAGEMENT UNIT FAULT CODES .................................
Section 8 - paRtS liSt ..............................................20
Section 9 - technical Data ..................................
5
Section 10 - WiRing DiagRam ..............................
5
XPMTAC24 .................................................................................22
Refer to Section Indicated
7
7
Note
17
17
18
18
18
18
19
20
21
Section 5 - commiSSioning ....................................9
PHYSICAL CHECKS .....................................................................9
NETWORK ID ................................................................................
REFERENCE SYSTEM PRESSURE DISPLAY ......................... 9
I/O CONFIGURATION ................................................................9
VIRTUAL RELAY AUTOMATION .............................................9
Section 6 - DiSplay anD menU opeRation .....10
MENU NAVIGATION .................................................................10
MENU ITEMS AND SETTINGS ..............................................
MENU S01  CONFIGURATION ...............................
MENU D01 THROUGH D08  DIGITAL INPUTS .......
MENUS A01 THROUGH A04  ANALOG INPUTS ....
DIAGNOSTICS ............................................................................16
11
11
12
13
Section 7 - opeRation ............................................17
Important or Caution, Safety
9
6.1 USER INTERFACE .........................................................17
6.2 DISPLAY ..........................................................................
6.3 STATUS SYMBOLS ....................................................
6.4 INDICATORS ..................................................................
17
17
17
2
SECTION 2  INTRODUCTION
1 2
A: 85%
Ingersoll Rand
IO
Ab.01
Ingersoll Rand
IO
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An I/O Box provides additional general purpose I/O (input/output) for system enhancing monitoring capabilities and for providing distributed system automation via Virtual Relay.
More than one I/O Box can be installed in a system (up to a maximum of 2 on an X8I). Each I/O Box features:
8 Digital Inputs
5 4-20 mA Analog Inputs (1 is a dedicated
pressure input)
6 Relay Outputs
Digital inputs can be used to monitor switching contact devices. Each input can be set to act as an Alarm or Trip input or used for Virtual Relay Automation. Digital inputs can also be used for metering (for example m3, ft3, kWh) providing an accumulative count of pulses from a metering device.
Analog inputs can be used to monitor sensor devices (for example: pressure, differential pressure, temperature, dew point, flow, current, power, bearing condition). Each input is equipped with adjustable high or low level detection that can be used to activate an
Alarm or Trip or used for Virtual Relay Automation.
Relay outputs use the Virtual Relay Automation technology and are totally configurable with dual input logic functions. Relay functions can be assigned utilizing any status or condition information available on a system network from any compatible unit connected to the network.
The I/O Box is designed to connect to a management system using an industrial 2-wire RS485 data network,
with a total cable length up to 4000 ft (1219 m).
SECTION 3  SAFETY PRECAUTIONS
competent person under qualified supervision.
WARNING : Risk of Danger
WARNING : Risk of Electric Shock
WARNING : Risk of High Pressure
WARNING : Consult Manual
Before installing or operating the I/O Box, 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
•
qualified personnel that are equipped with the proper tools.
INSTALLATION
Installation work must only be carried out by a
•
A fused isolation switch must be fitted between the
•
main power supply and the I/O Box.
The I/O Box 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 I/O Box they must not interfere with normal operation or obstruct access. Platforms and stairs should be of grid or plate construction with safety rails on all open sides.
OPERATION
The I/O Box must only be operated by competent
•
personnel under qualified supervision.
Never remove or tamper with safety devices, guards
•
or insulation materials fitted to the I/O Box.
The I/O Box 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.
3
4
Such work should be carried out only by a qualified 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.
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.
MAINTENANCE AND REPAIR
Maintenance, repairs or modifications must only
•
be carried out by competent personnel under qualified supervision.
If replacement parts are required, use only genuine
•
parts from the original equipment manufacturer, or an alternative approved source.
Carry out the following operations before opening
•
or removing any access panels or carrying out any work on the I/O Box:
i. Isolate the I/O Box from the main electrical power supply. Lock the isolator in the “OFF” position and remove the fuses. ii. Attach label 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 I/O Box if such a warning label is attached.
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 I/O Box 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.
1
VOLTAGE SELECT
2 3 4
X04
1
VOLTAGE SELECT
2 3 4
X04
230Vac
115Vac
EELN
NLE
X01
1 2 3 4
XPM-TAC24
26
28
25
27
X07
L1
L2
RS485
SECTION 4  INSTALLATION
It is recommended that installation and commissioning be carried out by an authorized and trained product supplier.
UNIT LOCATION
The I/O Box is wall mounted using conventional screws/ bolts. The maximum distance between the X8I and the I/O Box is 4000ft (1219 m) of cable length. The maximum distance between the I/O Box and each compressor is 330ft (100 m) of cable length and within 330ft (100 m) of cable length from any pressure sensor option (if applicable).
The cable used between the X8I and the I/O Box is Belden 9841 (or equivalent). It should be run in grounded conduit and should not be greater than 4000 feet (1219m) in length.
POWER SUPPLY
A fused switching isolator must be installed to the main incoming power supply, external to the I/O Box. The isolator must be fitted with a properly sized fuse to provide adequate protection to the power supply cable used (in accordance with local electrical and safety regulations).
Belden 9841 (or equivalent). It should be run in grounded conduit and should not be greater than 4000 feet (1219 m) in length.
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 difficult 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 (for example: from a compressor X8I to a wall along a suspended cable tray) attach the RS485 or signal cable on the outside of an earthed cable tray such that the cable tray forms an 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).
POWER SUPPLY TERMINALS
Ensure that the voltage select input is properly jumpered for the incoming power. Default voltage configuration is 230Vac.
RS485 NETWORK
The I/O Box is equipped with an RS485 network communications capability using the IR485 protocol. The I/O Box is intended to operate as part of the X8I Management System. Connection to the system management unit is two-wire, twisted pair, earth shielded, RS485 data link. Connect the RS485 data cable wires to terminal X07.
Note: Polarity is important.
The cable used between the X8I and the I/O Box is
5
6
I/O BOX ANALOG CONDITIONING MODULE
1
2
34
4 3 1
X04
XPM-Ai4
XPM-Ai4
1234
30X20X10X
X04
ACM
XPM-Ai4
1
34
4 3 2
Ai1
Ai2
Ai1
Ai2Ai3Ai4
12345678
Ai1
Ai2Ai3Ai4
XPM-Ai4
3338
X10
3437 3235
X09
3136
Ai1
Ai2Ai3Ai4
CAi1CAi2CAi3CAi4
X03
I/O Box
The electrical input characteristics of the four adjustable analog inputs can be individually altered to suit a sensor or signal type using Analog Conditioning Modules
(ACM).
ACM devices are hardware modules that plug in to the analog input circuit and condition the incoming signal.
For a particular sensor type the correct ACM device must be selected and fitted.
TO CHANGE AN ACM DEVICE:
Remove the power from the unit.
ACM devices for analog inputs 1 to 4 are located within the unit’s XPM-Ai4 module.
To gain access to the ACM devices remove the cover of the XPM-Ai4 module. The ACM devices can be removed and inserted by hand without the use of a tool.
TO REMOVE AN ACM DEVICE:
2
1
1 2 3
4
1
2
34
#
Ai4 Ai3 Ai2 Ai1
ACM
Never use a metallic tool (screwdriver tip for example)
to remove an ACM device.
TO INSTALL AN ACM DEVICE:
Antistatic Precaution
ACM devices contain electronic components; take all necessary antistatic precautions including:
Before handling an ACM device touch an exposed
1) earthed surface to discharge any body static.
Always store in an anti-static container or package;
2) never place on a non anti-static surface.
Handle the device by the edges; never touch the
3) electronic com[ponenets on the device.
ACM IDENTIFICATION
# ACM devices are classified by a number and can be
readily identified by color:
Any ACM type can be fitted to an analog input socket. ACM devices can be fitted in the XPM-Ai4 module in any required combination.
The I/O Box is shipped with four type 3 ACMs installed and two spare type 6 ACMs.
Example: for analog input 1 (Ai1):
Before inserting an ACM device check the pins of the ACM and the XPM-Ai4 socket.
ACM devices are designed to mount in the XPM-Ai4 socket at an angle. This is intended to retain the device securely in the socket in the instance of mechanical vibration.
When an ACM device is fitted the ‘AT: Input Type’ menu setting for the analog input must be adjusted to match the ACM type number.
Menu Items: Analog Inputs A01-A04
Digital Input:
Remote volt-free switching contact
Analog Signal:
DC Voltage or Current
wire polarity is important
Temperature Sensor
7
8
3: 0mA
0-20mA +24VDC
3: 4mA
4-20mA +24VDC
6: PT1
PT100
3
6
3
2
3
1
3
2
3
1
3
2
3
1
GREEN
RED (Blue)
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