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
TABLEOFCONTENTS..................................................2
SECTION1–INTRODUCTION......................................3
SECTION2—SAFETY.................................................3
S
AFETYPRECAUTIONS.......................................................3
NSTALLATION.................................................................3
I
PERATION....................................................................3
O
AINTENANCEANDREPAIR..............................................4
M
SECTION3—COMPRESSORCONNECTIONAND
CONTROL...................................................................5
S
TANDARDCONTROLFEATURESANDFUNCTIONALITY............5
VBOXOPERATION...................................................6
VSD
SECTION4—INSTALLATION......................................7
U
NITLOCATION..............................................................7
OWERSUPPLY...............................................................7
P
NETWORK...........................................................7
RS485
VBOXANDPRESSURESENSORCONNECTIVITY...............8
VSD
RESSURESENSORCONNECTIONS.....................................10
P
ISCHARGE(DELIVERY)PRESSURESENSORINTERCONNECT....10
D
ISCHARGE(DELIVERY)PRESSURESENSORANDINTERNAL
D
PRESSURESENSORINTERCONNECT....................................11
COMPRESSORWITHPRESSURESWITCHREGULATED
VSD
COMPRESSORINTERCONNECT..........................................12
VANDIR‐PCBCOMPRESSORCONNECTIVITY...............13
VSD
COMPRESSORSTATUSMONITORING......................13
IR‐PCB
RESSURESWITCHREGULATIONCONTROL.........................15
P
SECTION5—DISPLAYANDMENUOPERATION........19
OPERATION...............................................................19
SECTION6—COMMISSIONING................................21
C
OMMISSIONINGPROCEDURE..........................................21
HYSICALCHECKS..........................................................21
P
OMPRESSORPRESSURESETPOINTS.................................21
C
VBOXCONFIGURATION..........................................22
VSD
RESSURESETPOINTS....................................................24
P
SECTION7—SYSTEMCONFIGURATION...................25
D
ISPLAYITEMSTRUCTURE...............................................25
CCESSINGTHEX12ICONFIGURATIONSCREENS.................25
A
ENUITEMSANDSETTINGS............................................27
M
SECTION8—DIAGNOSTICS.....................................31
SECTION9—FAULTCODES......................................32
SECTION10—VSDVBOXSTATUSBLOCKDIAGRAM 32
SECTION11—PARTSLIST........................................34
SECTION12—TECHNICALDATA..............................34
SECTION13—WIRINGDIAGRAM............................35
VSD
VBOXSCHEMATIC..................................................35
XPM‐TAC24
XPM‐V
XPM‐PSU24
SCHEMATIC...............................................36
O2(+VDCANALOGOUTPUT)................................36
(24VACTO24VDC)....................................36
SECTION14—COMMISSIONINGFORM...................37
Refer to Section Indicated
Note
Important or Caution, Safety
2
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 :
!
WARNING :
WARNING :
!
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.
3
MAINTENANCE AND REPAIR
• Maintenance, repairs or modifications must onl y
be carried out by competent personnel under
qualified supervision.
• If replacement parts are required, use only
genuine parts from the original equipment
manufacturer, or an alternative approved
source.
• Carry out the following operations before
opening or removing any access panels or
carrying out any work on the VSD 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
4
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.
rd
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.
5
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.
PC
PS
VSD
PD
P
PN
6
SECTION 4 — INSTALLATION
It is recommended that installation and commissioning be
carried out by an authorized and trained product supplier.
Information regarding the compressor control system,
method of operation and regulation settings, is required.
Knowledge of VSD compressor regulation methods,
experience working with compressor control systems and
basic principle knowledge of compressed air systems, is
also required to be able to successfully install and
commission this product.
Dependent on compressor type and installation
environment additional fixings, wiring, cabling,
terminations and terminals will be required for installation.
UNIT LOCATION
The VSD 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
L
N
N LE
XPM-TAC24
EE
X01
X04
VOLTAGE SELECT
X04
VOLTAGE SELECT
1
234
1
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).
L2
L1
Note: Polarity is important.
X07
L2
L1
7
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
1
2
3
4
i-PCB
6wire : 18-20 Gau (1.0-1.5mm)ge
Ground (earth) shielded
Delivery Pressure
2wire, twisted pair, 20 gauge
#1
(0.5-1.0mm
?
Internal Pressure
2wire, twisted pair, 20 gauge
#2
(0.5-1.0mm )
2wire + Ground (earth)
115/230Vac, 5A
2
2
,
Ground (earth) shielded
)
2
,
Ground (earth) shielded
Cables identified as ‘3’ are only required for a two
pressure sensor type compressor installation.
4
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.
8
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
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.
9
PRESSURE SENSOR CONNECTIONS
Pressure sensor connectivity is dependent on
compressor and control system type.
21
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
1
n
2
L
e
L
e
r
X05
c
s
C
X01
D
V
4
2
+
RS485
X04
V
0
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
#1
+VDC(1)
X02
21
+VDC(2)
-
+
2
2
A
A
X03
#2
N
N
A
A
Vo2
1
1
A
A
N
N
A
A
-
+
+
-
IP = 0
1
+VDC
1
VSD Box
IC = 1 0 to 5VDC
IC = 2 1 to 5VDC
IC = 3 0.5 to 4.5VDC
X07
26 28
25 27
29
30
+VDC
+
-
XPM-Vo2
#1
X02
+VDC
signal
0VDC
+
v
-
Delivery
Pressure
Sensor
1
+
-
+VDC
signal
0VDC
+VDC
signal
0VDC
+
v
-
Delivery
Pressure
Sensor
10
DISCHARGE (DELIVERY) PRESSURE SENSOR AND INTERNAL PRESSURE SENSOR
INTERCONNECT
Internal = Sump
+VDC
1
+VDC
2
1
IP = 1
+
-
+
-
2
VSD Box
X07
25
26
IC = 1 0 to 5VDC
IC = 2 1 to 5VDC
IC = 3 0.5 to 4.5VDC
l
y
r
a
e
n
v
r
i
l
e
t
e
n
I
D
28 30
27 29
#1
+VDC
+
+VDC
signal
0VDC
+VDC
signal
0VDC
XPM-Vo2
+
v
-
+
v
-
Delivery
Pressure
Sensor
Internal
Pressure
Sensor
#2
+VDC
-
X02
-
+
X03
1
+
-
+
-
+VDC
signal
0VDC
+VDC
signal
0VDC
+VDC
signal
0VDC
+VDC
signal
0VDC
+
v
-
+
v
-
Delivery
Pressure
Sensor
Internal
Pressure
Sensor
2
11
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
1
+
-
IC = 1 0 to 5VDC
IC = 2 1 to 5VDC
IC = 3 0.5 to 4.5VDC
1
4-20mA
P
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
29
+VDC
30
XPM-Vo2
-
+
#1
X02
1
+VDC
signal
0VDC
+VDC
signal
0VDC
+
v
-
Delivery
Pressure
Sensor
P
Delivery
i-PCB
LED 1 LED 2
Pressure
Switch
12
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