Ingersoll Rand System Automation VSD V 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 V Box

Operator’s Manual

C.C.N. : 80444136 REV. A DATE DECEMBER 2008

TABLE OF CONTENTS

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

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

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

AFETYPRECAUTIONS.......................................................3

NSTALLATION.................................................................3

PERATION....................................................................3

AINTENANCEANDREPAIR..............................................4

SECTION3—COMPRESSORCONNECTIONAND

CONTROL...................................................................5

TANDARDCONTROLFEATURESANDFUNCTIONALITY............5

VBOXOPERATION...................................................6

VSD

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

NITLOCATION..............................................................7

OWERSUPPLY...............................................................7

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

RS485

VBOXANDPRESSURESENSORCONNECTIVITY...............8

VSD

RESSURESENSORCONNECTIONS.....................................10

ISCHARGE(DELIVERY)PRESSURESENSORINTERCONNECT....10

ISCHARGE(DELIVERY)PRESSURESENSORANDINTERNAL

PRESSURESENSORINTERCONNECT....................................11

COMPRESSORWITHPRESSURESWITCHREGULATED

VSD

COMPRESSORINTERCONNECT..........................................12

VANDIR‐PCBCOMPRESSORCONNECTIVITY...............13

VSD

COMPRESSORSTATUSMONITORING......................13

IR‐PCB

RESSURESWITCHREGULATIONCONTROL.........................15

SECTION5—DISPLAYANDMENUOPERATION........19

OPERATION...............................................................19

SECTION6—COMMISSIONING................................21

OMMISSIONINGPROCEDURE..........................................21

HYSICALCHECKS..........................................................21

OMPRESSORPRESSURESETPOINTS.................................21

VBOXCONFIGURATION..........................................22

VSD

RESSURESETPOINTS....................................................24

SECTION7—SYSTEMCONFIGURATION...................25

ISPLAYITEMSTRUCTURE...............................................25

CCESSINGTHEX12ICONFIGURATIONSCREENS.................25

ENUITEMSANDSETTINGS............................................27

SECTION8—DIAGNOSTICS.....................................31

SECTION9—FAULTCODES......................................32

SECTION10—VSDVBOXSTATUSBLOCKDIAGRAM 32

SECTION11—PARTSLIST........................................34

SECTION12—TECHNICALDATA..............................34

SECTION13—WIRINGDIAGRAM............................35

VSD

VBOXSCHEMATIC..................................................35

XPM‐TAC24 XPM‐V XPM‐PSU24

SCHEMATIC...............................................36

O2(+VDCANALOGOUTPUT)................................36

(24VACTO24VDC)....................................36

SECTION14—COMMISSIONINGFORM...................37

Refer to Section Indicated

Note

Important or Caution, Safety

SECTION 1 – INTRODUCTION

The VSD V (Voltage) Box is intended to provide a method of system integration for a VSD (Variable Speed Drive) air compressor equipped with a Voltage Pressure Sensor that is not equipped with any accessible means of remote connectivity (such as the Ingersoll Rand Nirvana).

SECTION 2 — SAFETY

SAFETY PRECAUTIONS

WARNING :

• Before installing or operating the VSD V 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 V Box.

• The VSD V 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 V 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

The VSD V Box will provide the required functionality to enable system integration and efficient control using the X8I or X12I Automation System.

OPERATION

• The VSD V 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 V Box.

• The VSD V Box must only be operated at the supply voltage and frequency for which it is designed.

• When main power is switched on, lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is necessary to carry out any work on the unit.

• Do not open access panels or touch electrical components while voltage is applied unless it is necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the correct tools and wearing appropriate protection against electrical hazards.

• All air compressors and/or other equipment connected to the unit should have a warning sign attached stating “THIS UNIT MAY START WITHOUT WARNING” next to the display panel.

• If an air compressor and/or other equipment connected to the unit is to be started remotely, attach two warning signs to the equipment stating “THIS UNIT CAN BE STARTED REMOTELY”. Attach one sign in a prominent location on the outside of the equipment, and the other sign inside the equipment control compartment.

MAINTENANCE AND REPAIR

• Maintenance, repairs or modifications must 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 V Box:

o Isolate the VSD V 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 V 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 V 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

SECTION 3 — COMPRESSOR CONNECTION AND CONTROL

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

The VSD V Box is intended to provide a method of system integration for 3 not equipped with any accessible means of remote connectivity. The VSD V Box is used to integrate with VSD Air Compressors that are controlled by Voltage Pressure Sensors.

Each air compressor in a system that requires VSD V Box integration must be equipped with an individual VSD V Box. Any number of VSD V 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 V Box will provide all required functionality to maximize the ENER, Energy Control Mode, in the X8I or X12I Automation System.

party air compressors that are

STANDARD CONTROL FEATURES AND FUNCTIONALITY

The air compressor must be equipped with a 0-5VDC, 15VDC or 0.5-4.5VDC type pressure sensor that is used for regulation control. For VSD type air compressors; the compressor must be equipped with a 0-5VDC, 1-5VDC or

0.5-4.5VDC type pressure sensor that is used for variable speed drive regulation. The VSD V Box will accommodate a pressure sensor range of 1.0bar to 600bar.

Various Compressor Configurations and Characteristics Can Be Accommodated by the VSD V Box. These include::

• Air compressors that are equipped with a package discharge (delivery) pressure sensor and a second internal pressure sensor. The internal pressure sensor is generally used for internal air/oil filtration differential pressure monitoring and/or internal pressure safety functions. The VSD V Box is able to accommodate this requirement without affecting functionality of the compressor control system internal pressure sensor feature(s).

• VSD air compressors that are equipped with t wo pressure sensors that both monitor package discharge (delivery) pressure. One sensor is dedicated to compressor control system basic regulation functions; the other is dedicated to variable speed drive unit regulation. The VSD V Box is able to accommodate this requirement without affecting compressor control system functionality.

• VSD air compressors that are equipped with a pressure switch dedicated to basic compressor control system load/unload regulation; and a pressure sensor dedicated to variable speed drive unit regulation. The VSD V Box is able to accommodate pressure switch regulation in conjunction with variable speed drive pressure sensor regulation without affecting compressor control system functionality.

VSD air compressor types that are unable to maintain maximum speed operation for a prolonged period of time. In these instances the controller may automatically reduce speed regardless of demand. The VSD V Box and management system unit will recognize this if it occurs and will, if necessary, utilize an additional compressor to meet demand.

VSD air compressor types are unable to maintain minimum speed operation for a prolonged period of time. In these instances the controller may automatically stop the compressor regardless of demand. The VSD V Box will recognize and accommodate this behavior. The management system unit will indicate and record the compressor status correctly without fault indication.

VSD V BOX OPERATION

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 V Box monitors the compressor pressure sensor as an input and simulates the pressure sensor signal as an output. The VSD V Box uses this method to modify the pressure signal and manipulate the behavior of the air compressor. In other words, the VSD V 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 V 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 V 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 V Box. The VSD V Box uses this information to calculate the difference between the compressor discharge pressure and the system ‘target’ pressure. The VSD V Box utilizes pressure signal manipulation to continuously re-align compressor output with system requirements.

This functionality also enables the VSD V 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.

VSD V 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 V 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 V 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 V 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.

VSD

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 V Box is wall or panel mounting using conventional screw fixings. The maximum distance between the X8I or X12I and the VSD V Box is 4000ft (1219 meters) of cable length. The VSD V Box must be located adjacent to the compressor unit within 6ft (2m) with total length of interconnecting cables not exceeding 10ft (3m).

POWER SUPPLY

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

N LE

XPM-TAC24

X01

X04

VOLTAGE SELECT

X04

VOLTAGE SELECT

234

230Vac

115Vac

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 V Box is equipped with an RS485 network communications capability using the ir485 protocol. The VSD V 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 V Box controller.

The cable used between the X8I or X12I and the VSD V 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 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).

Note: Polarity is important.

X07

L2 L1

VSD V BOX AND PRESSURE SENSOR CONNECTIVITY

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

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

Electrical Interference

0-5VDC, 1-5VDC, or 0.5-4.5VDC Pressure Sensors

Voltage sensors and cables carrying low voltage analog pressure signals are highly susceptible to interference.

C0 4

C0 2

C0 1

i-PCB

6ft,2m

max

LE D LE 2 D 1

C0 3

1 2 3

VSD Box

2 3

i-PCB

6wire : 18-20 Gau (1.0-1.5mm)ge Ground (earth) shielded

Delivery Pressure 2wire, twisted pair, 20 gauge

(0.5-1.0mm

Internal Pressure

2wire, twisted pair, 20 gauge

(0.5-1.0mm ) 2wire + Ground (earth)

115/230Vac, 5A

Ground (earth) shielded

)

Ground (earth) shielded

Cables identified as ‘3’ are only required for a two pressure sensor type compressor installation.

Always use shielded, braided (armored), foil

wrapped with a drain wire, 18 / 20 AWG (0.5-1.0mm) maximum, 2-conductor cable no more than 10 feet (3 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 V Box end only.

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

Compressor Ground (earth) Circuit Issues

An air compressor that uses an electrical induction main motor may experience voltage interference generated in the compressor’s ground (earth) circuits. An induction motor will generate induction currents in the ground (earth) circuit when changing state from loaded to unloaded, or vice versa, condition. Induction motors that are driven from a variable frequency drive will continuously induce ground (earth) currents during normal load and unload operation.

In some instances the induced current flow in the ground (earth) circuits may manifest as a small voltage difference between various parts of the compressor’s ground (earth) system.

Generally this has no consequence and can be ignored. As the compressor controller experiences minor ground (earth) reference fluctuations, all parts of the controller and control circuits will fluctuate with the same induced ground (earth) voltage simultaneously. The controller will be unaffected.

In the case of a low voltage signal that is referenced to a different ground (earth), remote from the compressor, the situation may represent an issue. As the compressor’s ground (earth) reference fluctuates the 0V reference for any voltage signal will also fluctuate. If a remotely generated voltage signal (from the VSD V Box for example) does not fluctuate in the same way simultaneously the compressor controller will detect a voltage difference in the signal. This will be seen as a fluctuating pressure display that will generally indicate a pressure that fluctuates to a lower pressure than actual.

To avoid this situation the VSD V Box must be securely bonded too, and referenced too, the same ground (earth) as the compressor controller.

If the VSD V Box is mounted remote from the compressor, and pressure signal fluctuations are experienced, the use of a length of ground (earth) cable, or the ground (earth) of a steel wire cable, will reduce, but may not resolve, the issue. Any length of conductive cable or cable screen will have a small resistance to high frequency current flow. This will generate a minor voltage differential alone the cable or cable screen resulting in a voltage difference between the two ends of the cable or cable screen. The pressure display may continue to fluctuate.

This situation can be avoided by mounting the VSD V Box on, or directly adjacent to, the compressor and connecting the VSD V Box ground (earth) to the compressor controller ground (earth) with a large cross section ground (earth) cable or braided conductor.

VSD Box

This action will ensure the VSD V Box experiences the same ground (earth) circuit fluctuations simultaneously with the compressor controller.

The necessity to avoid radiated electrical interference from the compressor still remains, particularly in the instance of a variable frequency drive. The use of twisted pair, ground (earth) shielded cable for low voltage signals internal to the compressor remains important.

PRESSURE SENSOR CONNECTIONS

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

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

2) Connect the VSD output pressure signal terminals to the compressor control system pressure sensor terminals as indicated on the following connection diagrams.

3213

X05

X01

D V

RS485

X04

Pressure signal output terminals are located on the XPMVo2 module within the VSD Voltage Box.

These terminals are not located on the main terminal

PCB of the VSD V Box

DISCHARGE (DELIVERY) PRESSURE SENSOR INTERCONNECT

1 D E L

+VDC(1)

X02

+VDC(2)

X03

Vo2

IP = 0

+VDC

VSD Box

IC = 1 0 to 5VDC IC = 2 1 to 5VDC IC = 3 0.5 to 4.5VDC

X07

26 28

25 27

+VDC

XPM-Vo2

X02

+VDC signal

0VDC

+ v

Delivery Pressure Sensor

+VDC

signal

0VDC

+VDC

signal 0VDC

+ v

Delivery Pressure Sensor

DISCHARGE (DELIVERY) PRESSURE SENSOR AND INTERNAL PRESSURE SENSOR INTERCONNECT

Internal = Sump

+VDC

IP = 1

VSD Box

X07

IC = 1 0 to 5VDC IC = 2 1 to 5VDC IC = 3 0.5 to 4.5VDC

28 30

27 29

+VDC

signal

0VDC

+VDC

signal

0VDC

XPM-Vo2

+ v

Delivery Pressure Sensor

Internal Pressure Sensor

+VDC

X02

X03

+VDC

signal 0VDC

+VDC

signal

0VDC

+VDC signal

0VDC

+VDC signal

0VDC

+ v

Delivery Pressure Sensor

Internal Pressure Sensor

VSD COMPRESSOR WITH PRESSURE SWITCH REGULATED COMPRESSOR INTERCONNECT

Compressor controller loads and unloads using a pressure switch; VSD unit regulates using +VDC discharge (delivery) pressure sensor.

See “i-PCB” Interface Connection

IC = 1 0 to 5VDC IC = 2 1 to 5VDC IC = 3 0.5 to 4.5VDC

4-20mA

Delivery Pressure Switch

+VDC

signal

0VDC

+ v

Delivery Pressure Sensor

VSD Box

6 5 4

1 0 X

3 2 1

IP = 0

VSD Box

25 27

X07

26 28

+VDC

XPM-Vo2

X02

+VDC

signal 0VDC

+VDC signal

0VDC

+ v

Delivery Pressure Sensor

Delivery

i-PCB

LED 1 LED 2

Pressure Switch

VSD V AND IR-PCB COMPRESSOR CONNECTIVITY

ir-PCB COMPRESSOR STATUS MONITORING

An ir-PCB is a requirement for a VSD V 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 V 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.

C01 C02 C04

i-PCB

C03

246135

LED 1 LED 2

X01 VSD Box

246135

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 irPCB also acts as an electrical barrier between the compressor and the VSD V Box providing protection and voltage isolation.

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 V Box regulation without manual intervention.

Ready Input

READY LAMP

READY

RUN

ALARM

C04

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-energies 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 V Box that the compressor is ready and available to load and produce air when a load request signal is given.

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:

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 V 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 V Box requests a compressor to run/load, but fails to detect a RUN signal within 60 seconds, the VSD V 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 V Box will automatically reset the compressor ‘not ready’ condition and re-establish control.

+Vac

0Vac

READY

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

MAIN (LINE) CONTACTOR

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 V Box that the compressor is running.

MAIN (LINE) CONTACTOR

AUXILIARY SWITCH

ALARM

RUN

C04

READY

Alternatively, if the main contactor coil voltage is greater than 250Vac, a contactor auxiliary switch 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.

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.

The ir-PCB input common terminal must always be connected to the neutral, common or 0V line of the applied input voltage.

READY

RUN

ALARM

C04

The RUN input will accept 12V to 250V ac (50/60Hz) only (DC cannot 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.

LOADED

ALARM = LOAD

The VSD V 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 V Box. An auxiliary ‘Alarm’ input terminal within the VSD V Box is available.

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.

LOAD SOLENOID

PRESSURE SWITCH REGULATION

CONTROL

In ‘Pressure Control’ mode the VSD V Box will also control the ir-PCB load/unload relay outputs in accordance with the set load and unload pressure set points. The ir-PCB load/unload relay contacts can be used for compressor controllers that have ‘pressure switch’ load/unload regulation (fixed speed and variable speed types).

ir-PCB Internal Output Circuits

OUT

C Load C

Seq

IN NO

IN C

IN NC

READY

ALARM

RUN

C04

The LOAD input will accept 12V to 250V ac (50/60Hz) or dc.

Caution: Do not connect a voltage greater than 250Vac/dc to this input.

The ‘Load’ input can be connected to the terminals of the compressor’s load solenoid; or other accessible part of the control circuit that is energized when the compressor is loaded.

The ir-PCB input common terminal must always be connected to the neutral, common or 0V line of the applied input voltage.

For a compressor that is not equipped with a load solenoid (a compressor that is loaded at all times while running) the ‘Load’ input can be connected to the ‘Run’ input.

Running 0v

Contacts :-

SEQ

Relay

1&2

LOAD Relay

250Vac/dc @ 5A maximum

C03

GND

LOAD

SEQ

UNL

CONT

24Vac

The C01 and C02 terminal functions of the ir-PCB are intended to control load and unload regulation of the compressor.

+20VDI2DI1

ALARM

RUN

C04

READY

Pressure Switch Regulation:

For air compressors fitted with an electro-mechanical pressure switch a six-pin terminal C02 has been provided to enable connection to a pressure switch that has a two wire or three-wire connection.

When connected the pressure switch remains in circuit. If the VSD V Box is stopped or experiences a failure or loss of power, pressure control will automatically revert back to the pressure switch and the compressor will continue to operate in ‘Local’ mode.

The NC (normally closed) and NO (normally open) terminal references of the ir-PCB are related to internal connection functions and should not be referenced to the connections of a compressor pressure switch (which will generally be in reverse order).

Caution: Lethal voltages may be present on the terminals of the air compressor pressure switch. Isolate the air compressor power supply before starting any work.

Two Wire Pressure Switch Connections:

Remote Load/Unload Regulation:

For air compressors fitted with a ‘Remote/Local Pressure Regulation’ and a ‘Remote Load/Unload’ digital input a four-pin terminal C01 has been provided.

This terminal provides volt free contact closure for load control and also provides volt free contact closure for remote pressure control enable.

A remote load enable input provides the facility to change the compressor load regulation from internal control to a remote switching source.

Compressors that use electronic pressure detection but are not equipped with a remote pressure control enable feature will not automatically revert to local control if the VSD V Box is stopped or experiences a fault or loss of power.

Load and Sequence Connection:

COMPRESSOR CONTROLLER

INPUTS

LOAD

SOLENOID

OUT

C02

Three Wire Pressure Switch Connections:

SOLENOID

RUN-ON

LOAD

TIMER

Remote Load

Local/Remote or

Inputs Common

Remote Load Enable

C01

E S

O L

Compressor controller inputs common voltage may be 0V or +V.

OUT

C02

The local/remote pressure regulation input and/or remote load input logic of some electronic pressure sensor type controllers are reversed, in this instance the ‘pressure switch’ outputs (terminal C02) can be used to establish alternative logic control connections.

For Example: If the compressor controller ‘Local/Remote Pressure

Control’ input is a normally open type; Remote when closed, but the ‘Remote Load’ input is a normally closed type; load when open, the ir-PCB pressure switch terminal contacts can be used to achieve the correct switching logic.

C02

OUT

Examine the ir-PCB internal output circuit diagram to establish any desired switching logic that may differ from normal practise.

Do not attempt to utilise the Load/Seq ‘Electronic Pressure Control’ (terminal C01) and the ‘Pressure Switch Control’ (terminal C02) output connections at the same time. These two output functions are internally connected and a short circuit condition and/or malfunction may result.

Service Maintenance Switch:

(Optional - dependant on management system controller model)

The ir-PCB is equipped with a volt-free input (terminal C05) that can be used to remove the compressor from management system control, without generating a fault condition, during maintenance or servicing periods.

C05

When the ‘Service Maintenance Switch’ input terminal pins are connected together, using a volt-free switching contact, the management unit will indicate that the compressor is not available but will not generate an Alarm, Trip or Shutdown condition. The management unit will also remove the compressor from the sequence strategy and substitute with an alternative available compressor if necessary. When the ‘Service Maintenance Switch’ inputs are open circuit again the compressor will automatically be accepted back in to the sequence strategy and will be utilized as and when next required.

Local/Remote

common

Remote Load

common

The use of a ‘key switch’ is recommended for this purpose in order to prevent the switch contacts being inadvertently left in the closed circuit condition after service maintenance is complete.

DO NOT connect any external voltage source to the

pins of terminal C05.

This function is only available with management system unit models equipped with ‘Service Maintenance Switch’ functionality. For management units that do not provide this function the pins of terminal C05 must not be utilized. Activating the ‘Service Maintenance Switch’ function with a management unit not equipped for the function will disrupt the ‘Compressor Loaded’ detection facility.

Auxiliary Alarm Input (Option)

The VSD V Box is equipped with an auxiliary ‘Alarm’ input. This input can be used to detect a compressor ‘Warning’ or ‘Alarm’ condition. The input can also be used to detect an ‘Alarm’ condition of auxiliary equipment associated with the compressor.

The management system unit will regard the alarm as a compressor alarm.

X04

1 5

1 4

1 3

Aux Alarm

As default the auxiliary ‘Alarm’ input is normally open, Alarm on closed circuit condition. If required this can be reversed in the VSD V Box setup menu to be normally closed, alarm on open circuit.

Auxiliary Trip Input (Option)

The VSD V Box is equipped with an auxiliary ‘Trip’ input. The input can be used to detect a compressor shutdown trip condition. The input can also be used to monitor other auxiliary equipment associated with the compressor and initiate a compressor trip condition.

The management system unit will regard the trip as a compressor shutdown trip and will remove the compressor from sequence; the compressor will run-on for the compressor controller’s set run-on time and stop.

X04

6 1

5 1

4 1

3 1

Aux Trip

As default the auxiliary ‘Trip’ input is normally open, Trip on closed circuit condition. If required this can be reversed in the VSD V Box setup menu to be normally closed, trip on open circuit.

The maximum cable length for Auxiliary ‘Alarm’ or ‘Trip’ inputs is 100m.

Speed Monitoring Input (Option)

The VSD V Box is equipped with a ‘speed detection’ input designed to function with a ‘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 the management system unit.

X05

2 1

2 0

2 9

1 8

1 7

rpm

Remote Outputs

Compressor Running: The VSD V 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 V 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 V Box power failure

2) VSD V Box internal fault condition

3) Input pressure sensor fault

4) Compressor ‘Not Ready’

X09

3 3

3 2

3 1

X08

Group Alarm

Compressor Running

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

SECTION 5 — DISPLAY AND MENU OPERATION

OPERATION

User Interface

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

Status Symbols

The Status display will continuously show the current state of the VSD Box (C) 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

psi

Flashing - Not Responding, Compressor Not

Running When Required

Flashing - Not Responding, Compressor Not

Loading When Required

Service Maintenance function active

Discharge (delivery) pressure or Internal

Pressure has exceeded the maximum set limit

Compressor Not Ready Fault, Auxiliary Input Alarm/Trip

Pressure Control OFF or inhibited Load Request to compressor Unload Request to compressor

Pressure Control Active

Indicators

Run Indicator (Green LED) OFF - Pressure Control Off, Stopped

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 V Box ‘Pressure Control’ is active. Use the VSD V 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.

Flashing - Pressure Control ON, waiting for

compressor to respond

ON - Pressure Control On, Started Fault Indicator (Red LED)

OFF – No fault

Flashing – VSD V Box Fault Condition

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

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

Start

Press START to activate VSD V Box pressure control. The run indicator will illuminate or flash.

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

When started the VSD V Box will begin to manipulate the pressure signal(s) to the compressor controller – ‘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 V Box will automatically re-activate ‘Pressure Control’.

Stop

Press STOP to de-activate VSD V Box pressure control. The run indicator will extinguish.

When stopped the VSD V Box will not manipulate or adjust the pressure signal(s) to the compressor controller; the detected pressure from the pressure sensor(s) is re-transmitted to the compressor control directly.

The VSD V Box will report that the compressor is ‘Not Available’ to the system management unit when the VSD V Box is in a stopped condition.

During compressor service or routine maintenance the VSD V Box can be stopped to return the compressor to normal local pressure regulation.

Compressor Status

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

VSD V Box Status

VSD V 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. P2* ‘Internal’ output pressure transmitted to the compressor controller.

SP** Percent motor speed C> VSD V Box Status

(*) The ‘Internal’ output pressure item is only shown if the ‘Internal’ pressure control function is activated (IC = 2). (**) 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.

Internal Output Pressure:

The internal output pressure is manipulated during ‘Pressure Control’ to simulate and maintain the actual detected differential between the ‘Input’ discharge (delivery) pressure and the ‘Input’ Internal pressure. This functionality allows compressor controller differential pressure monitoring functions to be maintained regardless of VSD V Box output pressure signal manipulation.

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 V Box Status:

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 V Box status condition (see Status Block Diagram).

Power Failure Auto-Restart

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

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

The VSD V 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.

SECTION 6 — COMMISSIONING

COMMISSIONING PROCEDURE

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

PHYSICAL CHECKS

Before applying power to the VSD V 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.

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 V Box operation.

1) Compressor ‘Load’ pressure set point. The pressure at which the compressor will start/load. On fully integrated VSD compressor controllers this value

may be represented as the ‘Target Pressure’ level.

2) Compressor ‘Unload’ pressure set point. The pressure at which the compressor will stop/offload. On fully integrated VSD compressor controllers this value

may be represented as the ‘Controlled Stop Pressure’ level.

3) Compressor ‘Target’ pressure set point. For VSD type compressors this is the pressure that the

variable speed drive is set to maintain. This value will generally be the same as the ‘load’

pressure set point for variable speed compressors that have fully integrated VSD control systems. For variable speed compressors that do not have fully integrated control systems this value will generally be the mid-point between the ‘load’ and ‘unload’ pressure set points.

If the variable speed ‘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), then the compressor controller is not a fully integrated type. In this instance the ‘target’ pressure may have to be determined by observation and/or experiment.

For fixed speed compressors the ‘target’ pressure can be set at the mid-point between the compressor ‘load’ and ‘unload’ pressure set points.

4) The maximum Discharge (delivery) pressure level (and maximum Internal pressure level if used) set in the compressor controller. This value will be the Excess or High pressure Alarm safety level. On fully integrated VSD compressor controllers this value may be represented as the ‘Immediate Stop Pressure’ level.

COMPRESSOR

Pressure Set Points

Excess or Alarm Pressure

7psi (0.5bar) min

Unload Pressure

Pressure

Target Pressure

Load Pressure

7psi (0.5bar) min

COMPRESSOR

Pressure Set Points

Immediate Stop Pressure

7psi (0.5bar)) min

Controlled Stop Pressure

Pressure

Target Pressure

7psi (0.5bar) min

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).

VSD V BOX CONFIGURATION

Apply power to the VSD V Box. If the VSD V Box automatically starts (the green started

indicator illuminates or flashes) press the STOP button. Using the VSD V Box menu routines, set the ‘IC’ (I/O

Configuration - Type) item of menu P03 to the correct setting for the pressure sensor input/output configuration. See Menu Items and Settings.

VSD V 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 Box, always use the Automation System unit’s unique identification number as the compressor ‘network address’ number.

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

Input Pressure Sensor(s)

The offset and range of the pressure sensor(s) used on the compressor must be established for VSD V 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 V 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.

Wire polarity is important. If an ‘Internal’ pressure sensor is in use press DOWN to

view the ‘P2’ pressure value in the User menu ‘items’ display. The ‘P2’ value display should show a pressur e value; for example 0 psi (0.0 bar). If the display shows dashes (- - - -) check the ‘Internal‘ 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:

In many instances where a 0 to 5VDC pressure sensor is indicated or specified the actual operation is 1 to 5VDC. Request conformation from the compressor supplier or manufacturer.

Input and Output pressure calibration is critical for successful VSD V Box operation.

Input Pressure Sensor Calibration

Using the VSD V 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 V Box.

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

For example: if the pressure sensor is 0 tom 232 psi (0 to

16.0 bar), enter 0 psi (0.0 bar) as the offset value; if the pressure sensor is -14.5 to 218 psi, (–1.0 to 15 bar) enter

-14.5 psi (minus -14.5), (-1.0 bar) (minus 1bar) as the offset value.

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

For example: if the pressure sensor is 0 tom 232 psi ( (0 to 16.0 bar) enter 232 psi (16.0 bar) as the range value; if the pressure sensor is -14.5 to 218 psi, (–1.0 to 15 bar) then the range value is also 232 psi (16.0 bar).

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 V 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 V Box sho ws the same as the ‘known’ applied pressure.

If an ‘Internal’ pressure sensor is also in use, follow the same procedure described above applying adjustments to the ‘Io’ (Internal offset) and ‘Ir’ (Internal range) menu items. When these menu items are selected the menu page display value will change to show the actual detected ‘Internal’ pressure measurement.

Wire polarity is important.

Output Pressure Signal Calibration

Using the VSD V 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 V 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 V Box discharge (delivery) pressure.

If an ‘Internal’ pressure sensor is also in use, follow the same procedure described above applying adjustments to the ‘Io’ (Internal offset) and ‘Ir’ (Internal range) pressure output signal menu items. When these menu items are selected the menu page display value will change to show the actual detected ‘Internal’ pressure measurement.

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

PRESSURE SET POINTS

Establishing and implementing the correct pressure set points is critical for successful VSD V Box operation.

Using VSD V Box menu navigation, select menu page P03 (Configuration).

1) Set the ‘Dm’ Discharge (delivery) pressure Maximum Limit) to the compressor’s ‘Excess Discharge (delivery) pressure Alarm’ or ‘Immediate Stop’ pressure setting.

2) If an ‘Internal’ pressure sensor is in use set the ‘Im’ (Internal Pressure Maximum Limit) to the compressor’s ‘Excess Internal Pressure Alarm’ pressure setting. Typically this value will be at least 12psi (0.8bar) above the excess or alarm ‘delivery’ pressure limit.

Using VSD V Box menu navigation, select menu page P01 (Pressure Set Points).

1) Set the ‘Pu’ (Unload) pressure set point to the compressor’s ‘Unload’ or ‘Controlled Stop’ pressure set point value.

2) Set the ‘Pt’ (Target) pressure set point to the ‘target’ pressure setting established for the compressor.

3) Set the ‘PL’ (Load) pressure set point to the compressor’s ‘Load’ or ‘Target’ pressure set point value.

VSD V Box Pressure Set Point Control: When the VSD V Box ‘loads’ the compressor it will force

the output ‘Delivery’ pressure signal to a pressure value 3psi (0.2bar) below the set ‘Unload’ pressure set point. This manipulation will force the compressor to respond to the low pressure value and the compressor will load. When the VSD V Box detects the compressor has loaded the pressure signal is returned to normal active ‘pressure control’ values.

When the VSD V Box ‘unloads’ the compressor it will force the output ‘Delivery’ pressure signal to a pressure value 3psi (0.2bar) above the set ‘Load’ pressure set point. This manipulation will force the compressor to respond to the high pressure value and the compressor will unload. The VSD V Box will hold this pressure value to maintain offload operation regardless of actual discharge (delivery) pressure fluctuations.

COMPRESSOR

Pressure Set Points

Excess or Alarm Pressure

Unload Pressure

r u

s e

Target Pressure

Load Pressure

COMPRESSOR

Pressure Set Points

Immediate Stop Pressure

Controlled Stop Pressure

r P

Target Pressure

Pressure Set Points

- Unload Pressure

- Target Pressure

- Load Pressure

Pressure Set Points

- Unload Pressure

- Target Pressure

PT & PL - Load Pressure

VSD Box

Pu +0.2bar

Pu -0.1bar

PL -0.2bar

Pu +0.2bar

Pu -0.1bar

PL -0.2bar

VSD Box

Control Pressures

Unload Request Pressure

Max Control Pressure Limit

Load Request Pressure

VSD Box

Control Pressures

Unload Request Pressure

Max Control Pressure Limit

Load Request Pressure

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 X12I 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

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 V 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

MENU ITEMS AND SETTINGS

MENU P00 - User 1 P1 Discharge Pressure - Output (view only) 2 P2 Internal Pressure - Output (view only) 3 SP Percent Speed (view only)

MENU P01 - Pressure Set Points 1 Pu Unload Pressure 2 Pt Target Pressure 3 PL Load Pressure

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

16 15 Error Log #15

MENU P03 - Configuration 1 P> Pressure Units Select 2 Ad Network Address (Compressor No.) 3 PA Pressure Averaging Factor 4 IC I/O Configuration (Type) 5 IP Internal Pressure Enable 6 Dm Discharge Pressure Maximum Level 7 Im Internal Pressure Maximum Level

MENU P04 – Input Pressure Calibration 1 Do Discharge Pressure ‘Offset’ 2 Dr Discharge Pressure ‘Range’ 3 Io Internal Pressure ‘Offset’ 4 Ir Internal Pressure ‘Range’

MENU P05 – Output Pressure Calibration 1 Do Discharge Pressure ‘Offset’ 2 Dr Discharge Pressure ‘Range’ 3 Io Internal Pressure ‘Offset’ 4 Ir Internal Pressure ‘Range’

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 D7 Aux Alarm Input Configuration 2 D8 Aux Trip Input Configuration 3 SQ ir-PCB Sequence control hold 4 Ao Analog Output Function (4-20mA) 5 Er Error Log Reset 6 Hr VSD 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

Pu: Unload Pressure

Compressor ‘Unload’ pressure set point: The pressure at which the compressor will stop/unload. On fully integrated VSD compressor controllers this value may be represented as the ‘Controlled Stop Pressure’ level. Set the ‘Pu’ (Unload) pressure set point to the compressor’s ‘Unload’ or ‘Controlled Stop’ pressure set point value.

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.

PL: Load Pressure

Compressor ‘Load’ pressure set point: The pressure at which the compressor will start/load. On fully integrated VSD compressor controllers this value may be represented as the ‘Target Pressure’ level. Set the ‘PL’ (Load) pressure set point to the compressor’s ‘Load’ or ‘Target’ pressure set point value.

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

MENU P02 - Error Log

The first item of the log error menu is the VSD Box operational hours (Hr). This is an indication of the accumulated hours the VSD 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 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 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.

IC: I/O Configuration (Type)

Determines the pressure detection and pressure output signal configuration.

1: 0.0VDC to 5.0VDC Pressure Sensor(s) 2: 1.0VDC to 5.0VDC Pressure Sensor(s) 3: 0.4VDC to 4.5VDC Pressure Sensor(s)

In some instances where a 0.0 to 5.0VDC pressure sensor is indicated or specified the actual operation is 1.0 to 5.0VDC. Always request conformation before commissioning.

IP: Internal Pressure Enable 0: No internal pressure sensor connected 1: Internal pressure function enabled

If the internal pressure sensor function is disabled (0), the second analog output will replicate the first analog output.

Dm: Discharge Pressure Maximum Level

If the detected Discharge pressure input exceeds this setting ‘Pressure Control’ is disabled and the detected Discharge pressure (and Internal pressure if in use) is transmitted directly to the compressor controller without alteration. This is intended as a safety feature that will allow the safety functions of the compressor controller to respond to excess pressure situations.

Im: Internal Pressure Maximum Level

If the detected Internal pressure input exceeds this setting ‘Pressure Control’ is disabled and the detected Discharge and Internal pressure is transmitted directly to the compressor controller without alteration. This is intended as a safety feature that will allow the safety functions of the compressor controller to respond to excess pressure situations.

Note: Internal compressor pressure will increase over time with an increase in air/oil separator element differential and will generally be 0.8bar (12psi) above discharge pressure.

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 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 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.

Io: Internal Pressure Offset

Use the same procedure as described for Do: to set the Offset for Io:

Ir: Internal Pressure Range

Use the same procedure as described for Dr: to set the Offset for Ir:

Follow the same procedure described above for Do: and Dr: Calibration Checks for applying adjustments to the ‘Io’ (Internal offset) and ‘Ir’ (Internal range).

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

MENU P04 – 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 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 Box discharge pressure.

Io: Internal Pressure Offset

Use the same procedure as described for Do: to set the Offset for Io:

Ir: Internal Pressure Range

Use the same procedure as described for Dr: to set the Offset for Ir:

Follow the same procedure described above for Do: and Dr: Calibration Checks for applying adjustments to the ‘Io’ (Internal offset) and ‘Ir’ (Internal range).

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

MENU P08 – Speed Monitoring MENU P10 – Unit Configuration FL: Frequency at Minimum Speed D7: Auxiliary Alarm Input Configuration

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

Intended for inverter drive variable speed type

compressors. The inverter drive 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 inverter drive can be forced to minimum speed. Set the value to the lowest frequency detected.

The frequency setting must represent the lowest inverter drive 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 inverter drive variable speed type compressors.

The inverter drive 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 inverter drive can be forced to maximum speed. Set the value to the highest frequency detected.

The frequency setting must represent the maximum (100%) inverter drive 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 inverter drive 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 Box for Automation System unit functions and is only active when an optional ‘Speed Monitoring Kit’ is installed.

Determines the input configuration for the auxiliary Alarm input:

‘0’ – Normally open, Alarm when closed ‘1’ – Normally closed, Alarm when open

D8: Auxiliary Trip Input Configuration

Determines the input configuration for the auxiliary Trip input:

‘0’ – Normally open, Trip when closed ‘1’ – Normally closed, Trip when open

SQ: ir-PCB Sequence Control Hold

If using the ir-PCB load relay output on a remote digital input pressure control, or pressure switch, type compressor controller, it may be desirable to maintain VSD Box load/unload control of the compressor when the VSD Box is stopped.

If this item is set to ‘1’ the VSD Box will continue to load and unload the compressor, in accordance with the set VSD Box ‘load’ and ‘unload’ pressure set points, at all times.

If set to ‘0’ (Default) the VSD Box will deactivate remote pressure control (SEQ) and/or re-introduce the pressure switch, when the VSD Box is stopped. The compressor will operate in ‘local’ pressure control mode.

Ao: Analog Output Function

The VSD Box controller is equipped with a 4-20mA auxiliary output. The output can be used to remotely signal the selected analog value.

‘0’ – Disabled ‘9’ – Detected Discharge pressure ‘10’ – Detected Internal pressure

Er: Error Log Reset

Adjust to ‘RST’ and press ENTER to clear and reset the ‘Error Log’ menu.

Hr: VSD Box Operating Hours Adjust

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

SECTION 8 — DIAGNOSTICS

The VSD V 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

R6 Relay Output 6

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

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

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

Ao Analog Output 4.0 to 20.0mA

Digital Inputs:

D2 and D6 (connected to the ‘ir-PCB) are the only digital inputs that will detect a pulsing signal.

D2: i-PCB Compressor Ready/Run Status

OFF Not Ready ON Ready Pulsing Running D6: i-PCB Compressor Load/Maintenance

OFF Loaded ON Not Loaded Pulsing Service Maintenance 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: not used A2: Internal Pressure +VDC Input A3: Discharge (delivery) pressure +VDC Input

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

A1: Discharge (delivery) pressure +VDC Output A2: Internal Pressure +VDC Output

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.

SECTION 9 — FAULT CODES

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

0080E Auxiliary Input Shutdown Tr ip 0115E +VDC Delivery P. Sensor Fault 0125E +VDC Internal P. Sensor Fault 0821E Short Circuit Condition Detected

Check all inputs and outputs. 0845E S1 Controller Communications with XPM-Vo2

unit disrupted 2070A Auxiliary Input Alarm Press RESET to reset the fault code display when the

fault condition is resolved.

SECTION 10 — VSD V BOX STATUS BLOCK DIAGRAM

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

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

operational status to be established from the status block diagram.

STARTED:

The VSD V Box is in a started state. The START button has been pressed or the Auto-Restart has started the VSD V Box. The ‘Active’ indicator will be illuminated or flashing.

PRESSURE CONTROL:

The VSD V Box is regulating the compressor. If communications with the management system exist the

VSD V Box will manipulate the pressure signal(s) and switch the ir-PCB load/unload relay contacts.

If no communications with the management system exist the VSD V Box will not manipulate the pressure signal(s) but will switch the ir-PCB load/unload relay contacts. The detected pressure(s) are transmitted directly to the compressor controller.

NO RESPONSE:

The VSD V Box is attempting to run and load the compressor but the compressor is not responding. The ‘Active’ indicator will flash.

When the VSD V Box fails to detect the correct compressor ‘running’ and ‘loaded’ signals the ir-PCB load relay will pulse every 10 seconds. If the compressor fails to respond within 60 seconds the VSD V Box will regard the compressor as ‘not available’. The management system will indicate that the compressor is not available and will remove the compressor from sequence. The VSD V Box will continue to pulse the ir-PCB load relay every 10 seconds.

If the compressor was shutdown or stopped, and is manually re-started, the load pulses will cause the compressor to start and run. This action will automatically reset the ‘not available’ condition.

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

Some VSD air compressor types are unable to maintain minimum speed operation for a prolonged period of time and may stop regardless of demand or ‘load’ signal. The VSD V Box will accommodate this behavior without entering a ‘No Response’ state if the initial response to the VSD V Box ‘load’ request was successful and no other compressor fault condition is detected. The VSD V Box and management system status report will follow the actual compressor status regardless of continued ‘load’ request indications.

VSD V Box Status Block Diagram

Power On

VSD Box

Fault

NO RESPONSE

Ready

= False

STOP

Ready

= False

STOP

Run

= False

VSD Box

Fault State

No RUN

Response

No LOAD

Response

No Fault

STOP

Ready = True

Run Response Timeout

No Load

Request

Run = True

STOP

Ready Load Response Timeout

AND

No Load

Request

Load = True

Run = True

STOP

Initialise

Ready

To Start

Compressor

NOT READY

Ready

= False

Compressor

READY

Run

= False

Compressor

RUNNING

Load

= False

Compressor

LOADED

Initialisation Complete

Start

AutoStart

Ready = True

AND

Run = True

Ready = True

AND

Run = True

AND

Load = True

PRESSURE

CONTROL

Ready = False

Run

= False

Ready = False

STARTED

SECTION 11 — PARTS LIST

VSD V Box

Item Part No. Description

- 42659425 VSD V Box Kit

- 23242241 VSD V Box Unit

- 80444086 Manual, User CD

1 42659508 Controller, VSD V 2 42659284 Unit, XPM-PSU24 3 42659532 Unit, XPM-Vo2 4 39265913 Unit, XPM-TAC24 5 23242993 PCB, Terminal VSD 6 38036703 Gland, Set - Pg13.5 7 39265921 Unit, ir-PCB

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

XPM-Vo2

XPM-PSU24

3 2 1

ir-PCB

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

Mounting Dimensions:

24mm

188mm

8mm Ø

238mm

236mm

286mm

SECTION 13 — WIRING DIAGRAM

VSD V BOX SCHEMATIC

XPM-TAC24 Schematic

5x20mm

IEC

BLUE

BROWN

RED

GREEN

VIOLET

ORANGE

WHITE

BLACK

2 3 4

T3.15A

FH5

T1.6A

FH4

24Vac/2

earthed

T1.6A

X03

2 1 2

24Vac/1

isolated

T1.0A

FH2FH3

X02

VOLTAGE SELECT

1 2 3 4

T1.0A

N L E

X04

230V 115V

FH1

X01

1 2 3 4

230V +-10%

115V +-10%

XPM-VO2 (+VDC ANALOG OUTPUT)

3213

X01

D V 4 2 +

0.5-4.5VDC 0-5VDC1-5VDC

0.5-4.5VDC

RS485

X04X05

V 0

1 D E

+VDC(1)

0.5-4.5VDC 0-5VDC1-5VDC

1-5VDC 0-5VDC

X02

1 A N A

X03

1 A N A

+VDC(2)

Vo2

0.5-4.5VDC 0-5VDC1-5VDC

XPM-PSU24 (24VAC TO 24VDC)

X01

4 2

C D V 4 2

X02

X03

+- +- +-

X04

X05

PSU24

D E

LED 1

LED 2

SECTION 14 — COMMISSIONING FORM

VSD Voltage Commissioning Form

Customer

Installation/Site

Software

psi

** variable speed/regulaton

P01 Pu Unload Pressure Set Point psi/bar P01 Pt Load Pressure Set Point psi/bar P01 PL Load Pressure psi/bar

P03 P> Pressure Units P03 Ad Network Address (Compressor No.) P03 PA Pressure Averaging Factor P03 IC Input Configuration (Type) P03 IP Internal Pressure Sensor Enable P03 Dm Delivery Pressure Maximum Limit psi/bar P03 Im Internal Pressure Maximum Limit psi/bar

cfm

Contact

Phone

Ser No.

Manufacturer Model/Type Working Pressure psi/bar Full Load Capacity cfm Minimum Load Capacity** cfm Full Load Power Minimum Load Power** kW Voltage V Full Load Current (FLC) A Frequency Hz

Customer Ref:

Internal Ref:

Commission Date

Commission Engineer

bar psi

0.5-4.5V

1: 01

1-5V

0-5V

P04 Do Delivery Pressure 'Offset' psi/bar P04 Dr Delivery Pressure 'Range' psi/bar P04 Io Internal Pressure 'Offset' psi/bar P04 Ir Internal Pressure 'Range' psi/bar

P08 FL Frequency at Minimum Speed Hz P08 FH Frequency at Maximum Speed Hz

P10 D7 Auxiliary Alarm Input Configuration P10 D8 Auxiliary Trip Input Configuration P10 SQ 'i-PCB' Sequence Control Hold P10 Ao Analogue Output Function (4-20mA)

NO NC NO NC 01 0910

Ingersoll Rand System Automation VSD V Box Operator’s Manual

Specifications and Main Features

Frequently Asked Questions

User Manual