Ingersoll Rand System Automation VSD B 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

Ingersoll Rand

System Automation

VSD B Box

Operator’s Manual

C.C.N. : 80445505
REV. A
DATE JANUARY 2009

TABLE OF CONTENTS

TABLE OF CONTENTS ................................................. 2

SECTION 1 – INTRODUCTION ..................................... 3

SECTION 2 — SAFETY ................................................ 3

SAFETY PRECAUTIONS...............................................3

INSTALLATION.............................................................3

OPERATION.................................................................3

MAINTENANCE AND REPAIR.......................................4

SECTION 3 — COMPRESSOR CONNECTION AND

CONTROL ...................................................................... 5

STANDARD CONTROL FEATURES AND

FUNCTIONALITY..........................................................5

VSD B BOX OPERATION............................................6

SECTION 4 — INSTALLATION ..................................... 7

UNIT LOCATION..........................................................7

POWER SUPPLY.........................................................7

RS485 NETWORK......................................................7

VSD B BOX AND X8I OR X12I CONNECTIVITY..........9

IR-5000 DISCHARGE (DELIVERY) PRESSURE

SENSOR INTERCONNECT..........................................10

IR-302 DISCHARGE (DELIVERY) PRESSURE SENSOR

INTERCONNECT.........................................................11

IR485 GATEWAY CONNECTION...............................12

SPEED MONITORING INPUT (OPTION)......................12

REMOTE OUTPUTS...................................................12

SECTION 5 — DISPLAY AND MENU OPERATION ... 13

OPERATION...............................................................13

SECTION 8 — DIAGNOSTICS ..................................... 23

SECTION 9 — FAULT CODES .................................... 23

SECTION 10 — VSD B BOX STATUS BLOCK

DIAGRAM ..................................................................... 24

SECTION 11 — PARTS LIST ....................................... 25

SECTION 12 — TECHNICAL DATA ............................ 25

SECTION 13 — WIRING DIAGRAM ............................ 26



VSD B BOX SCHEMATIC...........................................26



XPM-TAC24 SCHEMATIC........................................27

XPM-VO2 (+VDC ANALOG OUTPUT)......................27

XPM-PSU24 (24VAC TO 24VDC)...........................27

SECTION 14 — COMMISSIONING FORM ................... 28

Refer to Section Indicated

Note

SECTION 6 — COMMISSIONING ............................... 15

COMMISSIONING PROCEDURE.................................15

PHYSICAL CHECKS...................................................15

SELECTING VSD-B MODE:......................................15

COMPRESSOR PRESSURE SET POINTS...................15

VSD B BOX CONFIGURATION..................................16

TARGET PRESSURE SET POINT...............................17

SECTION 7 — SYSTEM CONFIGURATION ............... 18

DISPLAY ITEM STRUCTURE......................................18

ACCESSING THE VSD B BOX CONFIGURATION

SCREENS..................................................................18

MENU ITEMS AND SETTINGS....................................20

Important or Caution, Safety

2

SECTION 1 – INTRODUCTION

The VSD B Box is intended to provide a method of
system integration for an Ingersoll Rand Bolt-On VSD
(Variable Speed Drive) air compressor equipped with a
an Intellisys Controller. The VSD B Box will provide the

SECTION 2 — SAFETY

SAFETY PRECAUTIONS

WARNING :

!

WARNING :

WARNING :

!

WARNING :

• Before installing or operating the VSD B 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 com m on sense and
good working practices while operating and
maintaining this system. All applicable codes
should be strictly adhered to.

• Maintenance must be performed b y 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 VSD B Box.

• The VSD B 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 VSD B 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.

Risk of Danger

Risk of Electric Shock

Risk of High Pressure

Consult Manual

required functionality to enable system integration and
efficient control using the X8I or X12I Automation
System.

.

OPERATION

• The VSD B 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 VSD
B Box.

• The VSD B 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.

3

MAINTENANCE AND REPAIR

• Maintenance, repairs or modifications must onl y
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 VSD B Box:

o Isolate the VSD B Box from the main

electrical power supply. Lock the
isolator in the “OFF” position and
remove the fuses.

o 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 VSD B
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 VSD B 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

4

SECTION 3 — COMPRESSOR CONNECTION AND CONTROL

The VSD B Box is designed to connect to an X8I or X12I
Automation System unit, using a 2-wire RS485 data
cable.

The VSD B Box is intended to provide a method of
system integration Ingersoll Rand air compressors with
an Intellisys Controller equipped with a Bolt-On VSD.
The VSD B Box is used to integrate with VSD Air
Compressors that are controlled by Current Pressure
Sensors.

Each air compressor in a system that requires VSD B
Box integration must be equipped with an individual VSD
B Box and the IR485 Gateway. Any number of VSD B
Boxes can be connected to the Automation System unit
as long as the total number of compressors does not
exceed the total number of compressors for the
Automation System model.

The VSD-B Box also monitors the compressor status, as
it is reported to the X8I or X12I Automation System unit,
by the IR485 Gateway. This function enables the VSD-B
Box to simulate all features of a standard X8I or X12I
network compressor integration.

In conjunction with a ‘speed monitoring kit’ (available
separately) the VSD B Box will provide all required
functionality to maximize the ENER, Energy Control
Mode, in the X8I or X12I Automation System.

STANDARD CONTROL FEATURES AND
FUNCTIONALITY

The IR Bolt-On VSD must be equipped with a 4-20mA
pressure sensor that is used for variable speed drive
regulation or compressor pressure regulation control. A
VSD B Box will accommodate a pressure sensor range of

14.5 psi (1.0bar) to 8702 psi (600bar). A VSD-B box also
requires the use of an “IR485 Gateway” compressor
device.

Compressor Configurations and Characteristics That Can
Be Accommodated by the VSD B Box:

• Ingersoll Rand air compressors with a Bolt-On VSD
that are equipped with two pressure sensors that
both monitor package discharge (delivery) pressure.
One sensor is dedicated to Intellisys compressor
controller for basic regulation functions; the other is
dedicated to variable speed drive unit regulation.
The VSD B Box is able to accommodate this
requirement without affecting compressor control
system functionality.

5

VSD B BOX OPERATION

All air compressors are equipped with a method of
sensing pressure. An air compressor regulates using the
compressor package delivery pressure as the control
variable.

4-20mA

IR air compressors equipped with a Bolt-On VSD use two
independent pressure sensors. The first provides the
normal fixed speed compressor Intellisys Controller with
pressure information for load/unload regulation and
safety features. The second provides the VSD with
pressure information for main motor variable speed
regulation.

The VSD-B Box monitors the VSD pressure sensor as an
input and simulates the pressure sensor signal as an
output. The VSD-B Box uses this method to modify the
pressure signal and manipulate the speed behavior of the
VSD. The VSD-B Box becomes the Bolt-On VSD
pressure sensor.

This functionality enables the management system to
utilize the compressor in a coherent manner and optimize
total system efficiency and maintain air quality.

VSD B Box Operation Example:

If the Automation System unit is detecting a network air
pressure (PN) of 100psi (6.9bar), and the system target
pressure requirement (P) is 103psi (7.1bar), the VSD B
Box will immediately calculate that a pressure rise of 3psi
(0.2bar) is required to achieve and maintain system
target pressure (P). Due to pressure differential across a
local compressed air treatment system (PD) the
compressor is currently operating at 107psi (7.4bar). The
VSD B Box will manipulate the compressor pressure
signal (PS) to cause the compressor to increase
discharge (delivery) pressure (PC) to 110psi (7.6bar).
This action will increase system pressure to the required
target pressure. The VSD B Box will continuously re­calculate and manipulate the compressor pressure signal
(PS) to accommodate changes in demand and
compensate for any local or compressed air network
pressure differentials.

PC

PS

VSD

PD

P

PN

VSD Box

4-20mA

The VSD-B Box also monitors compressor status, as it is
reported to the management system (Ready, Run, and
Load/Unload), by the IR485 Gateway device. This
function enables the VSD-B Box to simulate all features
of a standard X8I or X12I network compressor
integration.

Actual System pressure and Automation System ‘target’
pressure information is routinely transmitted from the X8I
or X12I to the VSD-B Box. The VSD-B Box uses this
information to calculate the difference between the
compressor delivery pressure and the system ‘target’
pressure. The VSD B Box utilizes pressure signal
manipulation to continuously re-align compressor output
with system requirements.

This functionality also enables the VSD B Box to
continuously compensate for any pressure differential
that may occur across local air treatment, along air pipe
work or between different locations in a compressed air
network.

6

SECTION 4 — INSTALLATION

It is recommended that installation and commissioning be
carried out by an authorized and trained product supplier.

Information regarding the compressor control system,
method of operation and regulation settings, is required.
Knowledge of VSD compressor regulation methods,
experience working with compressor control systems and
basic principle knowledge of compressed air systems, is
also required to be able to successfully install and
commission this product.

Dependent on compressor type and installation
environment additional fixings, wiring, cabling,
terminations and terminals will be required for installation.

UNIT LOCATION

The VSD B Box is wall or panel mounting using
conventional screw fixings. The maximum distance
between the X8I or X12I and the VSD B Box is 4000ft
(1219 meters) of cable length. The VSD B Box must be
located adjacent to the compressor unit within 330ft
(100m) of cable length from the VSD.

POWER SUPPLY

A fused switching isolator must be installed to the main
incoming power supply, external to the VSD B 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 2 34

L

N

N L

XPM-TAC24

EE

X01

E

Power Supply Terminals

Ensure that the voltage select input is properly
jumpered for the incoming power. Default voltage
configuration is 230Vac.

X04

X04

1

3 4

2

VOLTAGE SELECT

1

3 4

2

VOLTAGE SELECT

230Vac

115Vac

The cable used between the X8I or X12I and the
VSD B Box is Belden 9841 (or equivalent). It should be
run in grounded conduit and should not be greater than
4000 feet (1219 meters) in length.

RS485 and Signal Cable Routing

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 ground (earth) shielded cables, securely
bonded to a known good ground (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
grounded (earthed) cable tray such that the cable tray
forms an 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).

RS485 NETWORK

The VSD B Box is equipped with an RS485 network
communications capability using the ir485 protocol. The
VSD B Box is intended to operate as part of the X8I or
X12I Automation System. Connection to the system
management unit is two-wire, twisted pair, ground (earth)
shielded, RS485 data link. Connect the RS485 data
cable wires to terminal X07 located on the VSD B Box
controller.

L2

L1

Note: Polarity is important.

X07

L2
L1

7

VSD B BOX HARDWARE
CONFIGURATION

VSD B Box Terminal PCB Type Selector

VSD B Box Terminal PCB has a jumper on it that
determines the type of control box the PCB is being used
in. Check to determine if jumper (J1), as shown below, is
placed in the correct position for a VSD B Box.

VSD/EX

J1

X01

1

246

X02

7

53

X03

119

8 10 12 1416 182022 24 26282930

XPM-Ao2 Module 4-20mA Output Mode Selectors

Remove the top cover of the XPM-Ao2 module and
check the 4-20mA output mode selectors are in the
‘PASSIVE’ mode position. (The default position as
shipped from the factory.)

KC-

18 17 16 15 14 13 12

KC-

X04

19171513

21

28

27 26 25 24 23 22 21

10

98765

11

23

X07X06X05

2725

43

X09

X08

31 32 33 34

20 19

21

R05

R06

21

3213

1

n

2

L

e

L
e

r

c

s

C

X01

D
V

4

2

+

RS485

X04X05

V

0

1
D
E
L

21

-

+

3

3

A

A

N

N

A

A

X02

#1

4-20mA(1)

VDC

1
A
N
A

-

21

+

2
A
N
A

1
A
N
A

+

4-20mA(2)

-

2
A

X03X06

N
A

Ao2

#2

X06 X03

4-20mA(2)

C010

PASSIVE MODE

C03

4-20mA(1)

X02

8

VSD B BOX AND X8I OR X12I
CONNECTIVITY

Consult the X8I OR X12I Interconnect and
Application Guide prior to the installation of the VSD B
Box to the pressure sensor on the VSD and the
compressor.

Pressure sensor connectivity is dependent on
compressor and control system type.

1

Gateway

1

2

IR485

RS485

VSD-B Box

Belden 9841

Or Equivilant

2 + Ground (Earth)
115/230Vac, 5A

2

PRESSURE SENSOR CONNECTIONS

Pressure sensor connectivity is dependent on
compressor and control system type.

1) Disconnect the VSD pressure sensor wires from the
VSD and connect to the VSD-B Box terminals as
indicated on the following connection diagrams.

2) Connect the VSD-B output pressure signal terminals to
the VSD pressure sensor terminals as indicated on the
following connection diagrams.

Pressure signal output terminals are located on the XPM­Ao2 module within the VSD-B Box. These terminals are
not located on the main terminal PCB of the VSD-B Box

21

3213

1

n

2

L

e

L
e

r

c

s

C

X01

D
V

4

2

+

RS485

X04X05

V

0

1
D
E
L

21

-

+

3

3

A

A

N

N

A

A

#1

4-20mA(1)

VDC

X02

1
A
N
A

-

21

+

2
A
N
A

1
A
N
A

+

4-20mA(2)

-

2
A

X03X06

N
A

Ao2

#2

Consult the X8I Interconnect and Application Guide

prior to the installation of the VSD B Box to the pressure
sensor on the VSD and the compressor.

Pressure sensor connectivity is dependent on
compressor and control system type.

Electrical Interference

Failure to protect low voltage pressure signals between
the compressor and VSD-B Box will result in unstable
and/or erratic pressure readings; resulting in unstable
and/or erratic compressor regulation behaviour.

4 to 20mA Pressure Sensors

Always use shielded, 18 gauge, 2-conductor

cable no more than 330 feet (100 meters) in length.
Ensure the shield wire is securely connected to earth
ground at the VSD B Box end only.

9