Ingersoll Rand
System Automation
System Modbus Gateway Box
Operator’s Manual
Before installing or starting this unit for the first
time, this manual should be studied carefully to
obtain a working knowledge of the unit and or the
duties to be performed while operating and
maintaining the unit.
RETAIN THIS MANUAL WITH UNIT. This Technical
manual contains IMPORTANT SAFETY DATA and
should be kept with the unit at all times.
More Than Air. Answers.
Online answers: http://www.air.irco.com
C.C.N. : 80444557
REV. : C
DATE : MARCH 2009
SECTION 1 TABLE OF CONTENTS
Section 1 - tABLe oF contentS .............................2
Section 2 - intRoDUction ...................................... 3
Section 3 -SAFety ....................................................... 3
INSTALLATION .............................................................................3
OPERATION
MAINTENANCE AND REPAIR
.................................................................................. 3
.................................................3
Section 4 - coMPReSSoR connection AnD
contRoL .........................................................................5
SYSTEM MODBUS GATEWAY BOX .......................................6
UNIT LOCATION
POWER SUPPLY
MODBUS RS485 CONNECTION TO REMOTE MODBUS
DEVICE CUSTOMER COMPUTER, PLC. DCS
IR485 CONNECTION TO XSERIES AUTOMATION
SYSTEM NET WORK
OPERATIONAL INDICATIONS
..........................................................................6
........................................................................... 6
.................. 7
.................................................................... 7
................................................. 8
Refer to Section Indicated
Note
Important or Caution, Safety
RS485 NETWORK
SYSTEM MODBUS GATEWAY OVERVIEW
........................................................................ 8
.......................... 9
Section 5 - PARtS LiSt ..............................................10
Section 6 - technicAL DAtA ..................................10
WIRING DIAGRAM ....................................................................11
2
SECTION 2 INTRODUCTION
!
!
The System Modbus Gateway (SMG) Box is designed to
provide a RS485 Modbus connection to the X8I or X12I
Automation System.
SECTION 3 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 SMG 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
•
competent person under qualified supervision.
A fused isolation switch must be fitted between the
•
main power supply and the SMG Box.
The SMG 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 SMG 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 SMG 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 SMG Box.
The SMG 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.
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 SMG Box.
Isolate the SMG Box from the main electrical
i.
power supply. Lock the isolator in the “OFF”
position and remove the fuses.
3
4
Attach labels to the isolator switch and to the
ii.
unit stating “WORK IN PROGRESS - DO NOT APPLY
VOLTAGE”. Do not switch on electrical power or
attempt to start the SMG 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 SMG 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 warning.
PLC
DCS
ir -485
Direct To
S3
From VSD Pressure
To VSD Pressure
Transducer
Transducer input
OR
ir-485 Gateway
irV-485 Gateway
For All
For All
IR (Non-Nirvana) Compressors
Intellisys “Red Eye”,SG and SE
Nirvana compressors
20 HP (15 KW) and Above
or
CUSTOMER COMPUTER
Ethernet to RS485
RS232 to RS485
Converter
Converter
Computer
RS 485
RS 485
Ethernet
RS 232
Ingersoll Rand
102
psi
1
CAP
1
5
2
6
3
7
4
8
18:35 #2
Ir-PCB Compressor #1
Control Cable
Pressure Transducer Cable
Supply Voltage Cable
EXP RS485 Network Cable
OPTIONAL
RS485 Network Cable
RS485 NETWORK CABLE
Belden 9841 or Equivalent
in Grounded Conduit
No Greater Than 4000FT (1219M)
EXP RS485 NETWORK CABLE
Belden 9841 or Equivalent
in grounded Conduit
No Greater Than 33FT (10)
The EXP Box Will Add Another (4)
Direct ir-PCB connections.
This X8I Supports 1 EXP box
Would Allow A Total Of (8)
Compressors To Be Connected
And Controlled Via The ir-PCB.
The Maximum Number of Compressors Controlled By
The X8I Is Eight (8).
The Maximum Number Of Direct ir-PCB Connections
To The X8I is Four (4).
Any Combination Of Compressor Connection Methods
May Be Used As Long As the Maximum Number Of
Compressors (8) Is Not Exceeded.
On/O
Switch
Ir-PCB Compressor #2
Control Cable
ir-PCB
ir-PCB
From Air
Compressors
Reference X8I Application and Interconnect Guide For
Wiring connections Between The X8I, The ir-485 or irV-485
Gatewayand The Compressor, S3 Direct Connects,
and Optional Special Application interface Boxes
The RS485 Network is a Serial, Point to Point
Communication Network Refer to the X8I Application and
Interconnect Guide For Wiring Details and Connectivity.
ir-PCB COMPRESSOR CONTROL CABLE
7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
OR
Single Conductor Wire, 18 Gauge Stranded, Quantity (7)
In grounded Conduit No Greater Than 330FT (100M)
24VAC Control Voltage
Reference X8I Application and Interconnect Guide For
Wiring connections Between The X8I, The ir-PCB,
and The Compressor
PRESSURE TRANSDUCER CABLE
2 Conductor cable, 18 Gauge Stranded
Earth Shielded
No Greater Than 330 FT (100M)
24VDC Control Voltage
Power Cable
3 conductor (N, L, E)
(Sized in accordance with local
electrical and saftey regulations).
Local Disconnect (Breaker) Box
Fused for 100 VA
Dimensions 13.4” x 9.45” x6.0”
340 mm x 241mm x 152 mm
Weight 16.5LB (7.5kg)
Mounting Wall, 4 x screw xings
Enclosure IP65, NEMA 4
Supply 230 Vac ± 10%, 50 Hz
115Vac ± 10%, 60 Hz
Power 100VA
Temperature 32°F to 115°F
(0°C to 46°C)
Humidity 0% to 95% RH
(non-condensing)
SPECIFICATIONS
Ingersoll Rand Automation
Model X8I
Reference X8I Operations Manual for Pressure
Sensor Connection Details
X8I X05 CONNECTOR
25
26
PT CONNECTOR
+ VDC Pin #3
Signal Pin #1
To Plant Air
System
DRIP LEG
PRESSURE TRANSDUCER
RECEIVER
OR
PCB
VSD
SMG
I/O
EX
X8I
SECTION 4 COMPRESSOR CONNECTION AND CONTROL
5
6
SYSTEM MODBUS GATEWAY BOX
XPM-TAC24
X03
1 2
24Vac
0Vac
X01
1 2
42CAT-MPX
System Modbus Gateway
POWER SUPPLY
The System Modbus Gateway (SMG) Box is designed
to provide a RS485 Modbus connection to the X8I or X12I
Automation System.
The X8I or X12I Automation System communicates to the
SMG Box via a two wire, RS485 network utilizing the ir485
protocol.
The SMG Box communicates to the customer’s computer
via a two wire, RS485 network utilizing the Modbus
protocol.
X01
12 13 23
3
1
n
2
L
e
L
e
r
c
X05
ir485
s
c
d
/
c
c
a
/d
c
V
a
4
2
V
+
0
1 2
2
X04
#
#
D
D
E
E
L
L
System Modbus Gateway
SW1 SW2 SW3
1
#
1
2
D
E
ON
L
OFF
9
8
7
6
#
#
#
#
D
D
D
D
E
E
E
E
L
L
L
L
4
7
5
6
3
12 13 23
4
5
1
n
2
#
#
D
D
E
E
L
L
8
9
MODBUS
L
e
L
e
r
c
X03
s
1
0
1
1
X02
2
1
A fused switching isolator must be installed to the main
incoming power supply, external to the SMG 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).
1
1 2 3 4
2 3 4
X04
VOLTAGE SELECT
N L E
X01
X04
1
2 3 4
VOLTAGE SELECT
230Vac
115Vac
Power supply Terminals
Ensure that the voltage select input is properly
jumpered for the incoming power. Default voltage
configuration is 230Vac.
UNIT LOCATION
The SMG Box is wall mounted using conventional
screws/bolts. The maximum distance between the X8I
and the SMG Box is 4000ft (1219 meters) of cable length.
The maximum distance between the SMG Box and the
customer’s computer is 4000ft (1219 meters) of cable
length.
Avoid mounting the SMG Box near high voltage
cables or high voltage devices or equipment.
24Vac (+-15%) @ 35mA, 50/60Hz.
wire polarity is important if 0Vac is earthed.
Never use the same 24Vac power supply, derived
from the same transformer secondary winding, as used
for other devices/controllers connected to the RS485
network - this may result in permanent damage to the
RS485 communications port.
MODBUS RS485 CONNECTION TO REMOTE
50ms
4
5
2
3
SW1 SW2 SW3
MODBUS DEVICE
CUSTOMER COMPUTER, PLC, DCS
IR485 CONNECTION TO XSERIES
AUTOMATION SYSTEM NETWORK
X02
3
2
1
L2
L1
MODBUS
RS485
L2
L1
(B)
(A)
Wire polarity is important
Use 2-wire, 24 gauge (Belden 9841 or equivalent), twisted
pair, earth shielded, data cable with a total system
network length no greater than 4000ft (1219m).
Wire polarity is important
Use 2-wire, 24 gauge (Belden 9841 or equivalent), twisted
pair, earth shielded, data cable with a total system
network length no greater than 4000ft (1219m).
Modbus Communication Indicators:
RX – Data Received:
A valid Modbus communication has just been
received from a remote source.
TX – Data Transmitted:
A Modbus message has just been sent to a remote
source.
Modbus Communications:
Baud Rate: 9600
Parity: None
Start Bit: 1
Stop Bit: 1
After power-up initialisation; allow a minimum of ten
(10) seconds for management system initialisation before
attempting to request Modbus information.
ir485 Protocol Communications:
RX – Data Received:
A valid Ir485 communication has just been
received from the management system network. In
normal operation this event should occur at least every
two seconds.
TX – Data Transmitted:
A ir485 message has just been sent to a
management system network device.
Selector Switches:
Ensure all System Modbus Gateway module selector
switches are set to the OFF position.
7
8
OPERATIONAL INDICATIONS
1s
6 7 8 9
6
7
8
9
At power on initialisation, or when power has
been removed, all operational indicators will fast flash for
several seconds.
Normal Operation Example:
Valid communications with compressor management
system network and remote Modbus device.
RS485 NETWORK
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.
1)
Never route an RS485 data communications or low
voltage signal cable alongside a high voltage 3phase power supply cable. If it is necessary to cross
the path of a power supply cable(s), always cross at
a right angle.
2)
If it is necessary to follow the route of power supply
cables for a short distance (for example: from
a compressor unit 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.
3)
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).
ir485 Communications
OFF
No valid communications with the
compressor management system network
ON; communicating
OFF; no function
OFF; no function
Modbus Communications
OFF
No valid communications with remote
Modbus device
ON; communicating
SYSTEM MODBUS GATEWAY OVERVIEW
9
10
SECTION 5 PARTS LIST
20mm
5mm
IEC
12 13 23
ir485
X05
12 13 23
MODBUS
X03 X02
X04
1 2
X01
ON
OFF
SW1 SW2 SW3
24mm
238mm
24mm
188mm
8mm Ø
236mm
286mm
ITEM PART NO. DESCRIPTION
- 39266093 KIT, System Modbus
Gateway
- 80444490 Manual Reference Sheet
1 42659359 Module, System Modbus
Gateway
2 39265913 Unit, XPM-TAC24
3 39036703 Gland, Set - Pg13.5
4 23243009 System Enclosure
ITEM PART NO. DESCRIPTION
10 39265962 IEC Fuse T1.0A
10 39265970 IEC Fuse T1.6A
10 39265988 IEC Fuse T3.15A
SECTION 6 TECHNICAL DATA
Module - System Modbus Gateway (42659359)
Dimensions 3.8” x 3.4” x 2.2”
96mm x 85mm x 55mm
Weight 0.6Ib (0.25kg)
Mounting DIN, 35mm
Enclosure IP20
Supply 24VDC/ac +/-15%
Power 1.0VA
Temperature 0°C to 46°C (32°F to 115°F)
Humidity 95% RH non-condensing
Box - System Modbus Gateway (30266093)
Dimensions 11.45” x 9.45” x 6.0”
291mm x 241mm x 152mm
Weight 14Ib (6.5kg)
Mounting wall, 4 x screw fixings
Enclosure IP54, NEMA 12
Supply 230Vac +/-10%
115Vac +/-10%
Power 50VA
Temperature 0°C to 46°C (32°F to 115°F)
Humidity 95% RH non-condensing
WIRING DIAGRAM
L
E
D
#
6
L
E
D
#
7
L
E
D
#
8
L
E
D
#
9
s
c
r
e
e
n
L
2
L
1
s
c
r
e
e
n
L
2
L
1
L
E
D
#
2
L
E
D
#
3
L
E
D
#
5
L
E
D
#
4
+
2
4
V
a
c
/
d
c
0
V
a
c
/d
c
L
E
D
#
1
2
3
4
1
6
7
8
5
1
0
1
1
1
2
9
BLÅ
BRUN
RØD
GRØN
VIOLET
HVID
ORANGE
SORT
SPÆNDINGSOMSKIFTER
System Modbus Gateway
11
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