Ingersoll Rand System Automation VSD mA Box Operator
Ingersoll Rand
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.
Instruction Manual
System Automation
VSD mA Box
More Than Air. Answers.
Online answers: http://www.air.irco.com
C.C.N. : 80444128
REV. : C
DATE : MARCH 2009
SECTION 1 TABLE OF CONTENTS
Section 1 - tABLe oF contentS .............................3
Section 2 - intRoDUction ...................................... 4
Section 3 - SAFety ......................................................4
INSTALLATION .............................................................................4
OPERATION
MAINTENANCE AND REPAIR
..................................................................................4
.................................................4
Section 4 - coMPReSSoR connection AnD
contRoL .........................................................................5
COMPRESSOR CONNECTION AND CONTROL ................5
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
VSD BOX OPERATION
.........................................................................5
...............................................................6
Section 5 - inStALLAtion .........................................7
UNIT LOCATION ..........................................................................7
POWER SUPPLY
RS485 NETWORK
...........................................................................7
........................................................................7
Section 12 - PARtS LiSt .......................................... 25
IR VSD BOX .................................................................................25
Section 13 - tecHnicAL DAtA ............................... 25
VSD BOX ...................................................................................... 25
Section 14 - WiRinG DiAGRAM ............................. 26
Section 15 - coMMiSSioninG FoRM .................. 28
Refer to Section Indicated
Note
Important or Caution, Safety
PRESSURE SENSOR CONNECTIONS
VSD AND IRPCB COMPRESSOR CONNECTIVITY ..........9
IRPCB COMPRESSOR CONTROL ..........................................9
IRPCB COMPRESSOR STATUS MONITORING .................9
.............................................................................................9
READY
RUNNING
LOADED
.................................................................................... 10
......................................................................................10
....................................8
Section 6 - VSD BoX HARDWARe
conFiGURAtion ........................................................ 12
Section 7 - inGeRSoLL RAnD to VSD BoX
inteRconnect ........................................................... 13
Section 8 - coMMiSSioninG ................................. 15
Section 9 - DiSPLAy AnD MenU oPeRAtion .... 17
MENU NAVIGATION ............................................................... 17
Section 10 - DiAGnoSticS ..................................... 22
Section 11 - oPeRAtion ......................................... 23
KEYPAD ........................................................................................23
DISPLAY ....................................................................................... 23
INDICATORS ..............................................................................23
USER MENU ITEMS.................................................................. 24
POWER FAILURE AUTORESTART ...................................... 24
3
SECTION 2 INTRODUCTION
The VSD Box is intended to provide a method of
system integration for a VSD (Variable Speed Drive) air
compressor that is not equipped with any accessible
means of remote connectivity (such as the Ingersoll
SECTION 3 SAFETY
WARNING : Risk of Danger
WARNING : Risk of Electric Shock
WARNING : Risk of High Pressure
WARNING : Consult Manual
Before installing or operating the VSD 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 VSD BOX.
The VSD 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 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 VSD 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 BOX.
Rand Nirvana). The VSD Box will provide the required
functionality to enable system integration and efficient
control using the X8I Automation System.
The VSD 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, one on the outside of
the equipment, and the other 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 VSD BOX:
Isolate the VSD BOX from the main electrical
i.
power supply. Lock the isolator in the ‘OFF’
position and remove the fuses.
Attach a label 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 VSD 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.
4
5
1
2
1
2
1
2
The accuracy of sensor devices must be checked
• The VSD BOX must only be cleaned with a damp
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.
•
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.
SECTION 4 COMPRESSOR CONNECTION AND CONTROL
COMPRESSOR CONNECTION AND CONTROL
The VSD BOX is designed to connect to an X8I
Automation System unit, using a 2-wire RS485 data cable.
The VSD Box is intended to provide a method of system
integration for the Ingersoll Rand Bolt-On VSD’s as well
as other 3rd party air compressors that are not equipped
with any accessible means of remote connectivity.
Each air compressor in a system that requires VSD Box
integration must be equipped with an individual VSD
Box. Any number of VSD 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.
In conjunction with a ‘speed monitoring kit’ (available
separately) the VSD Box will provide all required
functionality to maximize the ENER, energy control mode,
in the X8I or X12I Automation System
3) 3rd party integrated VSD air compressors that are
equipped with a single package discharge pressure
sensor (1).
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
The Bolt-On VSD or the VSD equipped air compressor
must be equipped with a 4-20mA pressure sensor or a
0.5V to 4.5VDC a pressure sensor that is used for variable
speed drive regulation or compressor pressure regulation
control. A VSD Box will accommodate a pressure sensor
range of 14.5 psi (1.0bar) to 8702 psi (600bar).
Various Compressor Configurations and Characteristics
Can Be Accommodated by the VSD Box. These include:
1) Bolt-On VSD air compressors that are equipped with
two pressure sensors (1 and 2) that both monitor
package discharge pressure. One sensor is dedicated
to the compressor control system for load/unload
regulation functions and the other pressure sensor
is dedicated to the VSD for variable speed drive
regulation.
2) Bolt-On VSD air compressors that are equipped with
a package discharge pressure switch (1) dedicated
to the compressor control system for load/unload
regulation and a pressure sensor (2) dedicated to the
VSD for variable speed drive regulation.
4) 3rd party integrated VSD air compressors that are
equipped with a package discharge pressure sensor
(1) and a second internal pressure sensor (2). The
internal pressure sensor is generally used for internal
air/oil filtration differential pressure monitoring and/
or internal pressure safety functions.
NOTE: There are VSD air compressors that are unable
to maintain maximum speed operation for a prolonged
period of time. In these instances, the compressor control
system may automatically reduce speed regardless
of demand. The VSD Box and Automation System will
recognize this, and if necessary, utilize an additional
compressor to meet demand.
NOTE: There are VSD air compressors that are unable
to maintain minimum speed operation for a prolonged
period of time. In these instances, the compressor control
system may automatically stop the compressor regardless
of demand. The VSD Box will recognize and accommodate
this behavior. The Automation System will indicate and
record the compressor status correctly without fault
indication.
VSD BOX OPERATION
From VSD Box
To ir-PCB
To Intellisys Controller
From VSD Box
To ir-PCB
To 1PS Pressure Switch
From Pressure Transducer
To VSD Box
From VSD Box
To IR-5000 Pressure Transducer Input
From Pressure Transducer
To VSD Box
From VSD Box
To IR-5000 Pressure Transducer Input
All air compressors are equipped with a method of
sensing pressure. An air compressor regulates using the
compressor package discharge pressure as the control
variable.
The VSD Box monitors the compressor pressure sensor
as an input and simulates the pressure sensor signal as
an output. The VSD Box uses this method to modify the
pressure signal and manipulate the behavior of the air
compressor. In other words, the VSD Box becomes the air
compressor pressure sensor. This functionality enables
the Automation System unit to utilize the compressor
effectively and optimize total system efficiency and
maintain air quality.
The VSD Box also monitors compressor status (Ready,
Run, and Load/Unload) and continuously reports this
information to the Automation System unit. This function
enables the VSD Box to simulate all features of a standard
X8I or X12I network compressor integration.
Actual System pressure and the Automation System
‘target’ pressure information is routinely transmitted
from the X8I or X12I to the VSD Box. The VSD Box uses
this information to calculate the difference between
the compressor discharge pressure and the system
‘target’ pressure. The VSD Box utilizes pressure signal
manipulation to continuously re-align compressor output
with system requirements.
This functionality also enables the VSD 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
7
1
VOLTAGE SELECT
2 3 4
X04
1
VOLTAGE SELECT
2 3 4
X04
230Vac
115Vac
XPM-TAC24
SECTION 5 INSTALLATION
It is recommended that installation and commissioning
be carried out by an authorized and trained product
supplier.
UNIT LOCATION
The VSD Box is wall mounted using conventional screws/
bolts. The maximum distance between the X8I or X12I
and the VSD Box is 4000ft (1219 meters) of cable length.
The maximum distance between the VSD Box and
each compressor is 330ft (100 meters) of cable length
and within 330ft (100 meters) of cable length from any
pressure sensor option (if applicable)..
POWER SUPPLY
A fused switching isolator must be installed to the
main incoming power supply, external to the VSD 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 3 4
L
N
N L E
EE
X01
RS485 data communications and other low
voltage signals can be subject to electrical interference.
This potential can result in intermittent malfunction
or anomaly that is difficult to diagnose. To avoid this
possibility always use earth shielded cables, securely
bonded to a known good earth at one end. In addition,
give careful consideration to cable routing during
installation.
a.
Never route an RS485 data communications or low
voltage signal cable alongside a high voltage or 3phase power supply cable. If it is necessary to cross
the path of a power supply cable(s), always cross at a
right angle.
b.
If it is necessary to follow the route of power supply
cables for a short distance (for example: from a
compressor X8I to a wall along a suspended cable
tray) attach the RS485 or signal cable on the outside
of an earthed cable tray such that the cable tray
forms an earthed electrical interference shield.
c.
Where possible, never route an RS485 or signal cable
near to equipment or devices that may be a source
of electrical interference (for example: 3-phase
power supply transformer, high voltage switchgear
unit, frequency inverter drive module, radio
communications antenna).
Power Supply Terminals
Ensure that the voltage select input is properly
jumpered for the incoming power. Default voltage
configuration is 230Vac.
RS485 NETWORK
The VSD Box is equipped with an RS485 network
communications capability using the ir485 protocol.
The VSD 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, earth
shielded, RS485 data link. Connect the RS485 data
cable wires to terminal X07 located on the VSD Box ‘S1’
controller.
Note: Polarity is important.
The cable used between the X8I and the VSD 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.
PRESSURE SENSOR CONNECTIONS
Consult the X8I Interconnect and Application Guide
prior to the installation of the VSD Box to the pressure
sensor on the VSD and the compressor.
Pressure sensor connectivity is dependant on compressor
and control system type.
Electrical Interference
0.5 to 4.5VDC Pressure Sensors
Voltage sensors and cables carrying low voltage analog
signals are highly susceptible to interference.
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 Box end only.
Always use shielded, braided, foil wrapped with a
drain wire, 18 AWG maximum, 2-conductor cable no
more than 330 feet (100 meters) in length. Ensure the
braided steel wire is securely connected to a known
good earth ground at both ends. Ensure the internal
drain wire is securely connected to a known good
earth ground at the VSD Box end only.
Failure to protect low voltage pressure signals between
the compressor and VSD Box will result in unstable and/or
erratic pressure readings; resulting in unstable and/or
erratic compressor regulation behavior.
8
9
VSD AND IRPCB COMPRESSOR
ir-PCB
LED 1LED 2
C01 C02 C04
C03
2 4 61 3 5
X01
2 4 61 3 5
#1
V
C05
0V
+V
READY LAMP
RUN
READY
ALARM
C04
CONNECTIVITY
IRPCB COMPRESSOR STATUS MONITORING
An ir-PCB is a requirement for a VSD Box installation.
The ir-PCB is a DIN rail mountable unit designed to be
installed within the compressor control or switchgear
area and connected to the VSD Box using a six-wire cable.
The ir-PCB is used for compressor status monitoring and
in some installations, for remote load/unload or pressure
switch regulation control.
Consult the X8I Interconnect and Application Guide
prior to the installation of the VSD Box and the ir-PCB to
the air compressor.
Consult the X8I Interconnect and Application Guide
prior to the installation of the VSD Box and the ir-PCB to
the air compressor.
The ir-PCB is fitted with a six-pin terminal C04 for
compressor monitoring. The ir-PCB uses three inputs
(Ready, Run and Loaded) to determine compressor status.
All three status-monitoring input signals are required.
READY
The ‘Ready’ connection is intended to indicate that the
compressor is in a ‘started’ state, has no operational
inhibiting fault condition and is ready to respond to VSD
Box regulation without manual intervention.
Ready Input
The ir-PCB uses a 12V to 250V ac/dc input voltage
detection system and universal relay contact control
outputs (250Vac/dc @ 5A maximum). Integrated directly
into the circuits of an air compressor, the ir-PCB avoids
the need for additional relays or remote inputs. The ir-PCB
also acts as an electrical barrier between the compressor
and the VSD Box providing protection and voltage
isolation.
IRPCB COMPRESSOR CONTROL
Consult the X8I Interconnect and Application Guide
prior to the installation of the VSD Box and the ir-PCB to
the air compressor.
When connecting to an VSD, the VSD Box will control the
ir-PCB load/unload relay outputs (terminals C01 and C02)
in accordance with the VSD Box load and unload pressure
set points. The ir-PCB load/unload relay contacts can be
used for compressor that have pressure switch load/
unload regulation as well as those that have digital inputs
for load/unload regulation.
The READY input will accept 12V to 250V ac (50/60Hz) or
dc.
Caution: Do not connect a voltage greater than 250Vac/
dc to this input.
This input must be connected to the terminals of a ‘ready’
or ‘operational’ lamp, or other circuit of the compressor
control system, that will be energized when the
compressor is in started (standby or running) condition.
The voltage to this input must de-energize when the
compressor is stopped and unavailable to produce air
upon a load signal or the Emergency Stop button is
pressed or when the compressor experiences a fault that
prevents the compressor from running.
When the compressor ready lamp, or other control circuit,
is energized the ir-PCB will detect the voltage and signal
the VSD Box that the compressor is ready and available to
load and produce air when a load request signal is given
Note: The ir-PCB input common terminal must always
be connected to the neutral, common or 0V line of the
applied input.
Ready Input, Alternative Connection Method:
F1
+Vac
0Vac
READY
0V
RUN
READY
ALARM
+V
MAIN (LINE) CONTACTOR
C04
0V
+V
MAIN (LINE) CONTACTOR
0V
+V
AUXILIARY SWITCH
RUN
READY
ALARM
C04
In instances where a convenient voltage signal for a
compressor ready condition is not available the ‘Ready’
input can be connected directly to a constant compressor
control system power supply voltage (12V to 250Vac or
dc). This will signal the VSD Box that the compressor is
ready and available at all times when power is applied
to the compressor. The VSD has a built-in function to
determine when a compressor is not responding, or is
in a shutdown condition, regardless of a constant ready
signal. If the VSD Box requests a compressor to run/load,
but fails to detect a RUN signal within 60 seconds, the
VSD Box will regard the compressor as ‘not ready’ and
indicate the compressor as not available. If a RUN signal is
detected at any time, the VSD Box will automatically reset
the compressor ‘not ready’ condition and re-establish
control.
For a fixed speed air compressor this input can be
connected to the control terminals A1 and A2 (coil) of
the main starter contactor of the compressor. When the
compressor control system energizes the main contactor,
the ir-PCB will detect the voltage across the contactor coil
terminals and signal the VSD Box that the compressor is
running
Alternatively, if the main contactor coil voltage is greater
than 250Vac, a contactor auxiliary relay can be used to
apply a suitable voltage to the ‘Run’ input terminals.
For a ‘Variable Speed’ air compressor alternative methods
of determining a running condition may have to be
established.
Safety: Never connect the READY input positive
connection directly to the output of a control system
transformer; always connect after a fuse or circuit breaker.
If a normally closed contact of an Emergency Stop button
is included in the compressor power supply circuit,
connect after the Emergency Stop button contacts. This
will instantly indicate a compressor ‘not ready’ condition if
the Emergency Stop button is activated
RUNNING
The majority of VSD compressors are fitted with a
single main motor contactor but in most instances this
contactor energizes at compressor initialization and
remains energized regardless of motor running. The
following alternative signals may be used to indicate
motor running in most cases:-
1) The ‘Fan’ contactor – in instances where the cooling
fan energizes and de-energizes in conjunction with
the main motor.
2) The compressor controller ‘run’ signal to the ‘Inverter
Drive Unit’; an interface relay may be required.
Note: The ir-PCB input common terminal must always
be connected to the neutral, common or 0V line of the
applied input voltage.
LOADED
ALARM = LOAD
The VSD Box uses the ir-PCB ALARM input to detect the
load condition of the compressor. There is no Alarm
input facility on the ir-PCB when used with a VSD Box.
An auxiliary ‘Alarm’ input terminal within the VSD Box is
available.
The RUN input will accept 12V to 250V ac (50/60Hz) only
(DC can not be used).
Caution: Do not connect a voltage greater than 250V to
this input.
12V to 250Vac must be applied to the ‘Run’ terminals
when the compressor motor is running.
Note: A fault that stops the compressor, and/or prevents
the compressor from running, is determined from the
‘Run’ and ‘Ready’ inputs; Alarm detection is optional and is
not a requirement.
10
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