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

IR-5000 DISCHARGE (DELIVERY) PRESSURE SENSOR INTERCONNECT



1

1

A

A

N

N

A

A

-

+

10

IR-302 DISCHARGE (DELIVERY) PRESSURE SENSOR INTERCONNECT

1

1

A

A

N

N

A

A

-

+

11

IR485 GATEWAY CONNECTION

The VSD-B Box requires the use of an IR485
Compressor Gateway.

The IR485 Gateway must be connected to the same
RS485 management system network as the VSD-B Box
and management system unit. There is no requirement
to connect directly from the VSD-B Box to the IR485
Gateway. Both devices are autonomous and can be
regarded as individual components of the common X8I or
X12I Automation System network.

The IR485 Gateway must be set for the same

network address as the VSD-B Box; this will not
cause a network conflict in this instance.

The cable used between the X8I or X12I and the
IR485 Gateway is Belden 9841 (or equivalent). It should
be run in grounded conduit and should not be greater
than 4000 feet (1219 meters) in length.

Consult the IR485 & IRV485 Gateway Instruction
Manual prior to the installation of the VSD B Box and the
IR485 Gateway to the VSD and the compressor.

SPEED MONITORING INPUT (OPTION)

The VSD-B Box is equipped with a ‘speed detection’
input designed to function with an optional ‘VSD Speed
Monitoring Kit’ (available separately). This optional
feature will provide all required functionality to enable
total synergy with the energy control, VSD compressor
aware, functions of an X8I or X12I.

X05

2

2
1

2
0

2
9

1
8

1
7

1

rpm

+

REMOTE OUTPUTS

Compressor Running:
The VSD-B Box is equipped with a volt-free relay contact

output (R5) to indicate when the compressor is detected
as running. The output contacts will close when the
compressor is running.

Group Alarm:
The VSD-B Box is equipped with a volt-free relay contact

output (R6) to indicate Group Alarm. The Group Alarm
relay contacts are normally closed and will open in the
following conditions:-

1) VSD-B Box power failure

2) VSD-B Box internal fault condition

3) Input pressure sensor fault

4) Compressor ‘Not Ready’

X09

4

R6

R5

Relay contact rating:
CE: 250V @ 5A max
UL: 115V @ 5A max

3
3

3
2

3
1

3

X08

Group Alarm

Compressor
Running

12

SECTION 5 — DISPLAY AND MENU OPERATION

OPERATION

User Interface

a

b

c

g

f

h

a) START Button

b) RESET Button

c) STOP Button

d) MENU Button

e) ENTER Button

f) CANCEL Button

g) UP, Plus Button

h) DOWN, Minus Button
Display

The primary display value (A) will continuously show the
detected ‘Delivery’ pressure. The pressure is derived
from the compressor ‘Delivery’ pressure sensor and the
displayed value is not manipulated or adjusted.

The compressor controller ‘Pressure Display’ may
not represent the actual true local pressure(s) when VSD
B Box ‘Pressure Control’ is active. Use the VSD B Box
‘Input’ pressure display(s) for local pressure reference.

The ‘User Menu’ item display (B) will show the selected
user menu item. Press UP or DOWN to scroll through the
display ‘items’ list.

d

e

psi

Status Symbols

The Status display (C) will continuously show the current
state of the VSD B Box by using the following icons.

Power Failure Auto Restart (always on)
Communicating with System Management Unit

Flashing - No Communications System

Management Unit

Compressor Running

Compressor Loaded

Compressor Not Ready
Fault, Auxiliary Input Alarm/Trip

Pressure Control Active

Indicators

Run Indicator (Green LED)

OFF – Compressor stopped or not available.

Flashing - Compressor running

ON – Compressor loaded.

Fault Indicator (Red LED)
OFF – No fault

Flashing – VSD B Box Fault Condition

(see Fault Codes)
The VSD B Box will report that the compressor is ‘Not

Available’ to the system management unit when the VSD
B Box is in a stopped or fault condition.

Start

The START button has no function. All compressor
status data is derived from data received on the RS485
port.

The compressor must be in a started state (running
or in standby) before VSD B Box pressure control will
function.

When the compressor is running loaded, the VSD-B Box
will begin to manipulate the pressure signal to the
frequency inverter.

‘Pressure Control’ is active

Pressure Control will de-activate
automatically if communications with the system
management unit is disrupted or not connected; the
detected pressure from the pressure sensor(s) is re­transmitted to the compressor control directly.

When communications are re-established the
VSD B Box will automatically re-activate ‘Pressure
Control’.

13

Stop

The STOP button has no function. When the compressor
is stopped, unloaded or unavailable to the X8I or X12I,
the VSD-B Box will not manipulate or adjust the pressure
signal to the VSD; the detected pressure from the
pressure sensor is re-transmitted to the VSD directly.

Compressor Status

The detected status of the compressor is indicated by the
VSD B Box display status symbols (see Status Symbols)

VSD B Box Status

VSD B Box operation is indicated by the ‘Run’ LED
indicator (see Indicators). Pressure Control status is
indicated by the ‘pressure’ status symbols (see Status
Symbols).

User Menu Items

To view the ‘User Menu Items’, press UP or DOWN. The
‘Item’ display value will scroll through the available items.

P1 ‘Delivery’ output pressure transmitted to the

compressor controller.

SP* Percent motor speed
C> VSD B Box Status

(*) The percentage motor speed item is only shown if a
‘Speed Monitoring Kit’ is fitted and the function is
activated (Menu P08).

Delivery Output Pressure:

The delivery output pressure is manipulated during
‘Pressure Control’ and will differ from the actual ‘Input
Delivery’ pressure displayed as the main display value.
Pressure control function can be observed by comparing
the ‘Output’ discharge (delivery) pressure with the actual
detected ‘Input’ discharge (delivery) pressure. The two
pressures will be identical when ‘Pressure Control’ is not
active.

Percentage Motor Speed:

The percentage of detected motor speed compared to
maximum motor speed. This value provides a direct
indication of variable speed compressor output
regulation.

VSD B Box Status:

Power Failure Auto-Restart

Power failure auto restart is always active and cannot be
de-activated.

The VSD B Box will re-start if the VSD B Box was in an
operational started status before the break or failure of
the main power supply occurred.

The VSD B Box will not re-start if it was not in an
operational started status before the break or failure of
the main power supply occurred.

For Example:
Network Address = 1 (Compressor 1)

States = 5 (Ready)

The central ‘item’ display value (B) is the compressor
system identification number (network address number).
This is the same as the compressor system identification
number shown on the system management unit.

The ‘right hand’ display value indicates the VSD B Box
status condition (see Status Block Diagram).

4: Not Ready, Stopped, Not Available
5: Ready, motor not running
7: Running Offload
9: Running Onload; Pressure Control Active.

14

SECTION 6 — COMMISSIONING

COMMISSIONING PROCEDURE

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.

PHYSICAL CHECKS

Before applying power to the VSD B Box ensure that the
power supply connections are correct and secure and
that the operating voltage selector is set correctly for the
power supply voltage in use; 115Vac or 230Vac (+-10%),
50/60Hz; see ‘Installation’.

Check and ensure all pressure sensor, output pressure
signal and ir-PCB connections are correctly installed and
secure.

SELECTING VSD-B MODE:

IMPORTANT

If equipped with software version S1IRVSDC (E01 or
higher) the VSD mA box hardware can support two
different operating modes:

a) Standard “VSD-mA” mode (default)
b) VSD-B mode

The VSD B Box will be delivered in VSD mA mode as
default, it is important to select VSD-B mode prior to any
other configuration adjustments.

For standard VSD mA mode see VSD mA Box Operators
Manual

TO CHANGE MODE:

1) Enter access code “1215” and navigate to menu
‘PCt’.

2) Select “tYPE-b” from the ‘Ct’ menu item and
enter.

To change back to standard VSD mA mode set ‘Ct’ to
“tYPE-mA”.

When using the “1215” access code only the ‘PCt’ menu
is visible and accessible.

The ‘PCt’ menu is not visible, or accessible, when using
normal access code types.

VSD-B software ‘S1IRVSDC’ will not function with a

VSD Voltage Box.

COMPRESSOR PRESSURE SET
POINTS

Establish the following pressure set point values from the
compressor control system.

Establishing the correct compressor pressure set
point values is critical to successful VSD B Box
operation.

1) Compressor ‘Target’ pressure set point.

For VSD type compressors this is the pressure that the
variable speed drive is set to maintain.

For fixed speed compressors with the IR Bolt-On VSD,
the ‘target’ pressure can be set at the mid-point between
the Intellisys controller ‘load’ and ‘unload’ pressure set
points.

With the Bolt-ON VSD, the ‘target’ pressure is set
separately from the compressor controller (in the variable
speed drive controller menu or using a potentiometer
connected to the variable speed drive controller). In this
instance, the ‘target’ pressure may have to be
determined by observation and/or experiment.

COMPRESSOR

Pressure Set Points

Excess or Alarm Pressure

7psi (0.5bar) min

Unload Pressure

Pressure

Target Pressure

Load Pressure

If the compressor pressure set points have been set with
small differentials then the pressure set points of the
compressor will require adjustment before proceeding.

It is recommended that the pressure differential between
the ‘load’ and ‘unload’ (or ‘target’ and ‘controlled stop’)
pressures is a minimum of 7psi (0.5bar).

It is recommended that the pressure differential between
the ‘unload’ and ‘excess’ (or ‘controlled stop’ and
‘immediate stop’) pressures is a minimum of 7psi
(0.5bar).

7psi (0.5bar) min

15

VSD B BOX CONFIGURATION

If the VSD-B Box automatically starts (the green started
indicator illuminates or flashes) stop the compressor. The
VSD-B is then ready for configuration and pressure input
and output calibration.

VSD B Box Network Address

Each VSD compressor connected to the Automation
System unit must be assigned a unique compressor
identification number (1 to the maximum number of
compressors support by the X-Series controller). This
number will be the ‘network address’ number for the
compressor. The number should be clearly marked on
the compressor for identification purposes.

When connecting a compressor(s) to the VSD B Box,
always use the Automation System unit’s unique
identification number as the compressor ‘network
address’ number.

Using the VSD B Box menu routines, set the ‘Ad’
(Network Address) in menu P03 to the Automation
System unit’s compressor identification number.

The VSD-B and the associating IR485 Gateway
must be set to the same system network address
(compressor number).

Input Pressure Sensor(s)

The offset and range of the pressure sensor(s) used on
the compressor must be established for VSD B Box
pressure sensor calibration. Generally this information is
indicated on the pressure sensor label.

The majority of pressure sensor(s) have a minimum
pressure (offset) of 0(zero) bar gauge with a ‘range’
applicable to the application. For example 0 to 232 psi
(0.0 to 16.0 bar) - where 0(zero) psi (0.0(zero) bar) is the
‘offset’ minimum and 232 psi (16.0 bar) is the ‘range’ or
maximum.

Some pressure sensor(s) have non-zero offset. For
example -14.5 psi (minus -14.5), (-1.0 bar) (minus 1bar)
to 218 psi, 15bar; this type of pressure sensor can
measure negative or vacuum pressure. In this instance
the ‘offset’ is -14.5 psi (minus -14.5), (-1.0 bar) (minus
1bar)) and the ‘range’ is 232 psi (16.0 bar). Remember
the ‘range’ is the difference between the minimum and
maximum values and not the maximum value referenced
to 0(zero) bar ‘atmospheric’.

The correct ‘offset’ and ‘range’ values of each pressure
sensor are required for VSD B Box ‘input’ pressure
sensor calibration.

The main value display should show a pressure value; for
example 0 psi (0.0 bar).

If the display shows dashes (- - - -) check the ‘Delivery‘
pressure sensor connections.

At this stage the displayed pressure values will probably
be incorrect; this is normal.

Calibrate the input ‘Delivery’ pressure sensor, and input
‘Internal’ pressure sensor if used, following the input
‘Pressure Sensor Calibration’ procedure below:

Input and Output pressure calibration is critical for

successful VSD B Box operation.

Input Pressure Sensor Calibration

Using the VSD B Box menu navigation procedure, select
menu page P04 (Input Pressure Calibration). The ‘items’
of this menu enable calibration of the pressure sensor(s)
connected to the VSD B Box.

Enter the ‘OFFSET’ value for the ‘Delivery’ pressure
sensor in the ‘Do’ menu item.

For example: if the VSD pressure sensor is 0 tom 200 psi
(0 to 13.79 bar), enter 0 psi (0.0 bar) as the offset value.

Enter the ‘RANGE’ value for the ‘Delivery’ pressure
sensor in the ‘Dr’ menu item.

For example: if the VSD pressure sensor is 0 tom 200 psi
( 0 to 13.79 bar) enter 200 psi (13.79 bar) as the range
value.

When the ‘Delivery’ pressure sensor offset and range
menu items are selected the menu page display value
will change to show the actual detected ‘Delivery’
pressure measurement. This value can be used to
compare with a ‘known’ pressure applied to the ‘Delivery’
pressure sensor for accurate calibration purposes. An
independent and accurate means of measuring the
applied pressure is required.

1) Subject the ‘Delivery’ pressure sensor to atmosphere
(0bar).

2) Adjust the ‘Do’ pressure ‘offset’ value until the
‘Delivery’ pressure displayed by the VSD B Box sho ws
0(zero) bar.

3) Apply a known pressure to the ‘Delivery’ pressure
sensor. It is recommended that the applied pressure is
representative of normal working pressure levels. It is not
important if the applied pressure is static or continuously
fluctuating.

4) Adjust the ‘Dr’ pressure ‘range’ value until the
‘Delivery’ pressure displayed by the VSD B Box sho ws
the same as the ‘known’ applied pressure.

Wire polarity is important.

16

Output Pressure Signal Calibration

Using the VSD B Box menu navigation procedure, select
menu page P05 (Output Pressure Calibration). The
‘items’ of this menu enable calibration of the pressure
signal(s) transmitted to the compressor controller.

Enter the ‘OFFSET’ value for the ‘Delivery’ pressure
signal in the ‘Do’ menu item. Set this value will to same
as the initial ‘Delivery’ pressure sensor input ‘offset’.

Enter the ‘RANGE’ value for the ‘Delivery’ pressure
signal in the ‘Dr’ menu item. Set this value to the same as
the initial ‘Delivery’ pressure sensor input ‘range’.

When the output ‘Delivery’ pressure signal offset and
range menu items are selected the menu page display
value will change to show the actual detected input
‘Delivery’ pressure measurement. This value represents
the pressure the VSD B Box is attempting to transmit to
the compressor controller and can be used to compare
with the compressor controller’s displayed pressure
value.

1) Subject the input ‘Delivery’ pressure sensor to
atmosphere (0bar).

2) Adjust the ‘Do’ pressure signal ‘offset’ value until the
compressor controller’s discharge (delivery) pressure
display value shows 0(zero) bar.

3) Apply a known pressure to the input ‘Delivery’
pressure sensor. It is recommended that the applied
pressure is representative of normal working pressure
levels. It is not important if the applied pressure is static
or continuously fluctuating.

4) Adjust the ‘Dr’ pressure signal ‘range’ value until the
compressor controller’s discharge (delivery) pressure
display value shows the same as the VSD B Box
discharge (delivery) pressure.

TARGET PRESSURE SET POINT

Establishing and implementing the correct target
pressure set point is critical for successful VSD-B Box
operation.

Using VSD-B Box menu navigation, select menu page
P01 (Target Pressure Set Point).

Set the ‘Pt’ (Target) pressure set point to exactly match
the ‘target’ pressure setting established for the
compressor’s VSD.

It is recommended that Input and Output pressure
calibration is examined, and adjusted if necessary, on a
routine periodic basis.

17

SECTION 7 — SYSTEM CONFIGURATION

DISPLAY ITEM STRUCTURE

All value, parameter or option selection displays are
grouped into menu lists. Items are assigned to a list
according to type and classification. 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. Lists
are identified by page number; the normal User display
list is page ‘P00’. All parameters and options are
assigned to menu mode pages ‘P01’ or higher. All Page
‘P00’ items are view only and cannot be adjusted.

Normal Operational Mode (Page P00)

At controller initialization, all display elements and LED
indicators are switched on for three seconds, the display
will then show the software version code for a further 3
seconds before initialization is complete and the normal
operating display (Page P0) is shown. In page P00
‘normal operational display mode’ the main display will
continuously show the detected discharge (delivery)
pressure and the Item display will show the first item of
the ‘User’ menu. User menu ‘Items’ can be selected
using the Up or Down buttons at any time. Pressing the
Enter button will lock any selected Item display and
inhibit return to the default display. When an Item display
is locked the lock key symbol will slow flash. To unlock
an Item display press Up or Down to view an alternative
Item display or press Reset or Escape. No Item values,
options or parameters can be adjusted in page ‘P00’. If a
fault condition occurs the fault code becomes the first list
item and the display will automatically jump to display the
fault code. More than one active fault code item can exist
at any one time.

ACCESSING THE VSD B BOX
CONFIGURATION SCREENS

Access Code

Access to page list displays higher than page ‘P00’ is
restricted by access code. To access menu mode pages
press UP and DOWN together, an access code entry
display is shown and the first code character will flash.
Use PLUS or MINUS to adjust the value of the first code
character then press ENTER. The next code character
will flash; use UP or DOWN to adjust then press ENTER.
Repeat for all four code characters.

If the code number is less than 1000 then the first code
character will be 0(zero). To return to a previous code
character press ESCAPE. When all four code characters
have been set to an authorized code number press
ENTER. An invalid code will return the display to normal
operational mode; page ‘P00’.

Access Code Timeout

When in menu mode, if no key activity is detected for a
period of time the display will automatically reset to the
normal operational display; Page ‘P00’.

Menu Mode Navigation

In menu mode the main value display will flash and show
the Page number. To select a page press UP or DOWN.
For each page the display will show the first Item of the
page list. To view a page list press ENTER, the Page
number will stop flashing and the Item display will flash.
Press UP or DOWN to view the selected page list items.
To select an Item value for modification press ENTER,
the Item display will stop flashing and the Value display
will flash. The value or option can now be modified by
pressing UP(Plus) or DOWN(Minus). To enter a modified
value or option in memory press ENTER; alternatively the
modification can be abandoned, and the original setting
maintained, by pressing ESCAPE.

Page 0

Item 1 Value
Item 2 Value
Item 3 Value
Item 4 Value
Item 5 Value
Item 6 Value

Page 1

Page 2

Page 3

Page 4

Page 5

Item 1 Value
Item 2 Value
Item 3 Value

Item 4 Value

Item 5 Value

18

Press ESCAPE at any time in menu mode to step
backwards one stage in the navigation process. Pressing
ESCAPE when the page number is flashing will exit
menu mode and return the display to normal operational
mode; page ‘P00’.

Page 0

to immediately exit menu mode and return to the normal
operational mode display. Any value or option adjustment
that has not been confirmed and entered into memory will
be abandoned and the original setting maintained.

indicates the Item is locked and cannot be modified. This
will occur if the Item is view only (non adjustable) or in
instances where the item cannot be adjusted while the
VSD B Box is in the operational STARTED state.

Item 1 Value

Item 2 Value
Item 3 Value
Item 4 Value
Item 5 Value
Item 6 Value

Press and hold RESET for two seconds at any time

A flashing Key symbol displayed with any Item

Page 1
Page 2

Page 3
Page 4
Page 5

Item 1 Value
Item 2 Value
Item 3 Value
Item 4 Value
Item 5 Value

19

MENU ITEMS AND SETTINGS

MENU P00 - User
1 P1 Discharge Pressure - Output (view only)
2 SP Percent Speed (view only)

MENU P01 - Pressure Set Points
1 Pt Target Pressure

MENU P02 – Error Log
1 Hr VSD B Box Operating Hours
2 01 Error Log #1

to

16 15 Error Log #15

MENU P03 - Configuration
1 P> Pressure Units Select
2 Ad Network Address (Compressor No.)
3 PA Pressure Averaging Factor

MENU P04 – Input Pressure Calibration
1 Do Discharge Pressure ‘Offset’
2 Dr Discharge Pressure ‘Rang e’

MENU P05 – Output Pressure Calibration
1 Do Discharge Pressure ‘Offset’
2 Dr Discharge Pressure ‘Rang e’

MENU P06 / Diagnostics

See ‘Diagnostics’

MENU P08 – Speed Monitoring
1 FL Frequency at Minimum Speed
2 FH Frequency at Maximum Speed
3 C> Control Percentage (view only)

MENU P10 – Unit Configuration
1 Er Error Log Reset
2 Hr VSD B Box Operating Hours Adjust

MENU P16 – Analog Output Diagnostic

See ‘Diagnostics’

Note: Menus P07, 9 and 11 to 15 are not used.

Access Code = 0021

MENU P01 - Pressure Set Points

Pt: Target Pressure

Compressor ‘Target’ pressure set point. For VSD type
compressors this is the pressure that the variable speed
drive is set to maintain. Set the ‘Pt’ (Target) pressure set
point to the ‘target’ pressure setting established for the
compressor.

Establishing and maintaining the correct pressure
set point values ( Pt ) is critical to the successful
operation of VSD B Box control functions.
See ‘Commissioning - Pressure Set Points’

MENU P02 - Error Log

The first item of the log error menu is the VSD B Box
operational hours (Hr). This is an indication of the
accumulated hours the VSD B Box has been operational
and is used to time-stamp fault codes in the error log.
The hours counter has no other function.

The VSD B Box operating hours counter is NOT
intended as a measure of compressor operation or
running hours; the hours counter will differ from, and
operate independently from, the compressor hours
counter.

Each error log item will show the fault code alternating
with the VSD B Box operational hours when the fault
occurred. The error log stores the last 15 faults in
chronological order; item ‘01’ is the most recent fault.

MENU P03 – Configuration
P>: Pressure Units Select

Selects the display pressure units (bar, psi or kPa)

Ad: Net work Address

Network address; must be set to the compressor
identification number used by the Automation System
unit for the compressor (1 to the maximum number of
compressors). Each compressor in a system must have a
unique identification number.

PA: Pressure Averaging Factor

Pressure corrections supplied by the Automation System
unit are averaged to prevent abrupt changes and enable
smooth and controlled pressure adjustments. The
Automation System updates pressure information
approximately every two seconds. The ‘Pressure
Averaging Factor’ is the number of previous pressure
corrections that are used for averaging. For example: a
factor of ‘2’ will average the most recent pressure
correction value received with the previous two values
received.

If system volume is large and/or pressure variations are
slow a higher ‘Pressure Averaging Factor’ can be used to
dampen response and smooth control pressure changes.
If system volume is small and/or pressure variations are
fast a lower ‘Pressure Averaging Factor’ should be used
to enable a faster response. In some instances pressure
differential across air treatment and/or small diameter
pipe work can result in sudden and abrupt changes in
detected pressure.

A higher ‘Pressure Averaging Factor’ can be used to
dampen this effect.

20

MENU P04 – Input Pressure Calibration
Do: Discharge Pressure Offset

This parameter will be the minimum value of the pressure
transducer, 0 PSI, 0 BAR, or 0 kPA. It can also be used
to create an ‘Offset’ if there is a difference in the zero
value being displayed. The default setting for this
parameter is 0 PSI. The values for this parameter are:

“0” when using the minimum value of the pressure
transducer range

A value greater than or less than 0 if the display does not
read 0 or when using an Offset pressure transducer (an
example of an Offset pressure transducer would be one
where the range was minus PSI (-25) to a positive PSI
(200).

The pressure transducer must be vented to atmosphere
when setting the 0 or offset.

Dr: Discharge Pressure Range

This parameter will be the maximum range of the
pressure transducer, 232 PSI, 16 BAR, or 1600 kPA. It
can also be used to create an ‘Offset’ if there is a
difference in the range value being displayed. The
default setting for this parameter is 232 PSI. The values
for this parameter are:

“232” when using the maximum value of the
pressure transducer range

A value greater than or less than 232 if the display
does not read 232.

The pressure transducer must have a known, accurate
pressure applied to it when changing this value to a value
other than 232.

Calibration Checks

When the ‘Discharge’ pressure sensor offset and range
menu items are selected the menu page display value
will change to show the actual detected ‘Discharge’
pressure measurement. This value can be used to
compare with a ‘known’ pressure applied to the
‘Discharge’ pressure sensor for accurate calibration
purposes. An independent and accurate means of
measuring the applied pressure is required.

1) Subject the ‘Discharge’ pressure sensor to
atmosphere 0psi (0bar).

2) Adjust the ‘Do’ pressure ‘offset’ value until the
‘Discharge’ pressure displayed by the VSD B Box shows
0psi ((0) bar.

3) Apply a known pressure to the ‘Discharge’ pressure
sensor. It is recommended that the applied pressure is
representative of normal working pressure levels. It is not
important if the applied pressure is static or continuously
fluctuating.

4) Adjust the ‘Dr’ pressure ‘range’ value until the
‘Discharge’ pressure displayed by the VSD B Box shows
the same as the ‘known’ applied pressure.

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
verified 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 pre­determined routine periodic basis.

Input and Output pressure calibration is critical to the
successful operation of VSD B Box functions and must
be examined, and adjusted if necessary, periodically on a
routine basis.

MENU P05 – Output Pressure Calibration
Do: Discharge Pressure Offset

Enter the ‘OFFSET’ value for the ‘Discharge’ pressure
signal in the ‘Do’ menu item. Set this value will to same
as the initial ‘Discharge’ pressure sensor input ‘offset’.

Dr: Discharge Pressure Range

Enter the ‘RANGE’ value for the ‘Discharge’ pressure
signal in the ‘Dr’ menu item. Set this value to the same as
the initial ‘Discharge’ pressure sensor input ‘range’.

Calibration Checks

When the output ‘Discharge’ pressure signal offset and
range menu items are selected the menu page display
value will change to show the actual detected input
‘Discharge’ pressure measurement. This value
represents the pressure the VSD B Box is attempting to
transmit to the compressor controller and can be used to
compare with the compressor controller’s displayed
pressure value.

1) Subject the input ‘Discharge’ pressure sensor to
atmosphere 0psi (0bar).

2) Adjust the ‘Do’ pressure signal ‘offset’ value until the
compressor controller’s discharge pressure display value
shows 0psi (0) bar.

3) Apply a known pressure to the input ‘Discharge’
pressure sensor. It is recommended that the applied
pressure is representative of normal working pressure
levels. It is not important if the applied pressure is static
or continuously fluctuating.

4) Adjust the ‘Dr’ pressure signal ‘range’ value until the
compressor controller’s discharge pressure display value
shows the same as the VSD B Box discharge pressure.

Input and Output pressure calibration is critical to the
successful operation of VSD B Box functions and must
be examined, and adjusted if necessary, periodically on a
routine basis.

21

FL: Frequency at Minimum Speed

set to 0(zero) if speed detection is not in use.

Intended for VSD type compressors.

The VSD output frequency at the compressor’s minimum
operating speed.

When this menu item is selected the menu page number
display will change to show the actual detected
frequency. By restricting the output air from the
compressor the compressor VSD can be forced to
minimum speed. Set the value to the lowest frequency
detected.

The frequency setting must represent the lowest VSD
output frequency that will occur in normal operation.

FH: Frequency at Maximum Speed

Used for optional ‘Speed Monitoring Kit’ if fitted. Must be
set to 0(zero) if speed detection is not in use. Intended
for VSD type compressors.

The VSD output frequency at the compressor’s maximum
operating speed.
When this menu item is selected the menu page number
display will change to show the actual detected
frequency. By creating a demand for air the compressor
VSD can be forced to maximum speed. Set the value to
the highest frequency detected.

The frequency setting must represent the maximum
(100%) VSD output frequency that will occur in normal
operation.

C>: Control Percentage

This menu item value is view only and cannot be
adjusted. The value represents the variation in VSD
output frequency; where 0% is minimum speed and
100% is maximum speed.

Note: The ‘Control Percentage’ value represents the
percentage of speed variation from minimum speed to
maximum speed and differs from the ‘User’ menu percent
motor speed value. This value is used internally by the
VSD B Box for Automation System unit functions and is
only active when an optional ‘Speed Monitoring Kit’ is
installed.

Er: Error Log Reset MENU P08 – Speed Monitoring

Adjust to ‘RST’ and press ENTER to clear and reset the
‘Error Log’ menu.
Used for optional ‘Speed Monitoring Kit’ if fitted. Must be

Hr: VSD B Box Operating Hours Adjust

Allows adjustment of the VSD B Box operating hours
counter. The accumulated hours counter is used for
‘Error Log’ time-stamp only and has no other function.

22

SECTION 8 — DIAGNOSTICS

The VSD B Box controller is equipped with
comprehensive diagnostic functions. Each input can be
examined individually and each output can be manually
activated or manipulated individually.

MENU P06 / Diagnostics

Controller Diagnostics:

MENU P06 / 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
D7 Digital Input 7
D8 Digital Input 8

-------------------------------------------------------------

R1 Relay Output 1
R2 Relay Output 2

OFF

R3 Relay Output 3
R4 Relay Output 4
R5 Relay Output 5

ON

R6 Relay Output 6

-------------------------------------------------------------

A1 Analog Input 1 psi (bar) <> mA
A2 Analog Input 2 psi (bar) <> mA
A3 Analog Input 3 psi (bar) <> +VDC

-------------------------------------------------------------

Ao Analog Output 4.0 to 20.0mA

Digital Inputs:

D4 is the only digital input that will detect a pulsing signal.
(in case speed monitoring kit is installed and compressor
is running).

The pulse signal is 24VDC at 50/60Hz. A DC voltage
meter will detect this as 12VDC +-4V.

Relay Outputs:

Each relay output can be energized and de-energized
manually by selecting the item. Use PLUS and MINUS to
adjust and ENTER.

Analog Inputs:

The item will alternate between the detected value and
the electrical measurement on the input terminals. An
independent measuring device can be used to check the
displayed electrical measurement.

A1: Delivery Pressure 4-20mA
A2: Internal Pressure 4-20mA
A3: Discharge (delivery) pressure 0.5-4.5VDC

Analog Output:

The output can be manually adjusted by selecting the
item. Use PLUS and MINUS to adjust and ENTER. The
output will return to normal operational value upon menu
exit.

XPM-Ao2 Module Diagnostics:

MENU P16 / XPM-Ao2 Diagnostics
A1 Analog Output 1 4-20mA #1
A2 Analog Output 2 4-20mA #2
A3 Analog Output 3 0.5-4.5VDC

Analog Outputs:

Each output can be manually adjusted by selecting the
item. Use PLUS and MINUS to adjust and ENTER. The
output will return to normal operational value upon menu
exit.

A1: Discharge (delivery) pressure +VDC Output
A2: Internal Pressure +VDC Output
A3: Delivery Pressure 0.5-4.5VDC

SECTION 9 — FAULT CODES

If a VSD B Box fault, or auxiliary input fault, occurs the
‘Item’ display will show a fault code:

0115E 4-20mA Delivery P. Sensor Fault
0821E Short Circuit Condition Detected

Check all inputs and outputs.
0845E S1 Controller Communications with XPM-

Ao2 unit disrupted

Press RESET to reset the fault code display when the
fault condition is resolved.

23

SECTION 10 — VSD B BOX STATUS BLOCK DIAGRAM

The VSD B Box User menu ‘Status’ display item (C>)
continuously shows the network address and the VSD B
Box status block number.

For Example:
Network Address = 1 (Compressor 1)
State Block = 3 (Ready To Start)
The ‘status block number’ enables VSD B Box

operational status to be established from the status block
diagram.

.

VSD B Box Status Block Diagram

VSD Box

VSD Box

Fault

Fault State

1

No Fault

PRESSURE CONTROL:

The compressor is running loaded and the VSD-B Box is
regulating the frequency inverter pressure signal.

If communications with the management system are
disrupted, or lost, the VSD-B Box will not manipulate the
pressure signal. The detected pressure is transmitted
directly to the frequency inverter.

If the appropriate compressor status signals are re­established the VSD-B Box will automatically reset the
‘not available’ condition and pressure control will resume.
The management system unit will automatically reset and
accept the compressor back into sequence.

Power On

2

Initialise

Initialisation
Complete

NO RESPONSE

Ready

= False

No RUN

STOP

Ready

= False

Run

= False

Response

No LOAD

STOP

Response

STOP

STOP

Ready = True

Run Response Timeout

No Load

6

Request

Run = True

STOP

Ready

Load Response Timeout

AND

No Load

8

Request

Load = True

Run = True

STOP

Ready

To Start

Compressor

NOT READY

Ready

= False

Compressor

READY

Run

= False

Compressor

RUNNING

Load

= False

Compressor

LOADED

Start

OR

AutoStart

Ready
= True

Ready = True

Run = True

Ready = True

Run = True

Load = True

3

4

PRESSURE

CONTROL

5

AND

7

Ready = False

AND

AND

9

Ready = False

STARTED

Run
= False

24

SECTION 11 — PARTS LIST

VSD B Box

Item Part No. Description

- 23410780 VSD B Box Kit

- 23242225 VSD mA / B Box Unit

- 80444086 Manual, User CD

1 42659490 Controller, VSD mA / B
2 42659284 Unit, XPM-PSU24
3 23242282 Unit, XPM-Ao2
4 39265913 Unit, XPM-TAC24
5 23242993 PCB, Terminal VSD
6 38036703 Gland, Set - Pg13.5
7 39266085 KIT, ir485 Gateway

Optional Accessories:

Item Part No. Description
6 39265939 Sensor, Pressure

4-20mA, 0-16.0bar

20mm

IEC

5mm

Qty Part No. Description
10 39265962 IEC Fuse T1.0A

10 39265970 IEC Fuse T1.6A
10 39265988 IEC Fuse T3.15A

X

P

M

-

XPM-Ao2

XPM-PSU24

TA

3

4

C

2

4

5
2
1

6

7

IR485

SECTION 12 — TECHNICAL DATA

Dimensions 291mm x 241mm x 152mm

11.45” x 9.45” x 6.0”
Weight 6.5kg (14Ib)
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

24mm

188mm

Mounting Dimensions:

24mm

8mm Ø

238mm

236mm

286mm

25

SECTION 13 — WIRING DIAGRAM

VSD B BOX SCHEMATIC

26

XPM-TAC24 SCHEMATIC

T3.15A

FH5

IEC

5x20mm

BLUE

T1.6A

BROWN

RED

FH4

X03

2 1 2

24Vac/2
earthed

GREEN

T1.6A

24Vac/1

isolated

BLACK

ORANGE

WHITE

VIOLET

1

2 3 4

X04

T1.0A

FH2FH3

1 2 3 4

X02

L

N

N L E

VOLTAGE SELECT

T1.0A

X01

EE

230V
115V

FH1

1 2 3 4

230V +-10%

115V +-10%

XPM-VO2 (+VDC ANALOG OUTPUT)



21

3213

1

n

2

L

e

L

e

r

X05

c

s

C

X01

D
V
4
2
+

RS485

X04

V
0

21

1
D
E

L

+

3
A
N
A

#1

4-20mA(1)



ACTIVE

C03

-

+

PASSIVE

X02

4-20mA(1)

21

VDC

-

3
A
N
A

+

2
A
N
A

4-20mA(2)

-

2
A

X03X06

N
A

#2

Ao2

1

1

A

A

N

X02

N

A

A

-

+

X03

4-20mA(2)

-

+

ACTIVE

PASSIVE

C010

XPM-PSU24 (24VAC TO 24VDC)

32

1

c

c

a

a

V

V

X01

0

4

ACTIVE MODE

-

500R
max

+

+24VDC

2

C
D
V
4
2

X02

X03

1

0VDC

+24VDC

2

X04

PASSIVE MODE

+

+- +- +-

2

1

XPM-Ao2

+

-

­+

1

+12-30VDC

500R

X05

C
D
V
0

1
D
E

L

2

1

-

max

0VDC

PSU24

C

C

D

D

V

V

8

0

+

2

+-

D
E

L

2

LED 1

LED 2

27

SECTION 14 — COMMISSIONING FORM

28