Ingersoll Rand X12I 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
hould be kept with the unit at all times. s
More Than Air, Answers.
Online answers: http://www.air.irco.com
Ingersoll Rand
System Automation
X12I
Operator’s Manual
C.C.N. : 80445075
REV. A
DATE DECEMBER 2008
TABLE OF CONTENTS
TABLEOFCONTENTS..................................................2
SECTION1—INTRODUCTION....................................3
SECTION2—SAFETYPRECAUTIONS...........................3
INSTALLATION.................................................................3
OPERATION....................................................................3
SERVICEMAINTENANCEANDREPAIR...................................4
SECTION3—COMPRESSORCONNECTIONAND
CONTROL...................................................................5
COMPRESSORCONNECTION..............................................5
STANDARDCONNECTIONMETHODS...................................5
OPTIONALCONNECTIONMETHODS....................................6
PRESSUREDETECTIONANDCONTROL.................................10
X12IMAINDISPLAYOVERVIEW.........................................11
X12ISYSTEMOVERVIEW.................................................12
X12IINSTALLATIONOVERVIEW.........................................13
SECTION4—INSTALLATION....................................14
UNITLOCATION............................................................14
POWERSUPPLY.............................................................14
PRESSURESENSORLOCATION..........................................15
PRESSURESENSORCONNECTION......................................15
IR‐485ANDIRV‐485GATEWAYMODULE.........................16
IR485COMMUNICATIONPROTOCOL.................................16
RS485NETWORK.........................................................16
COMPRESSORINTERFACEIR‐PCB.....................................18
IR‐PCBEXPBOX(OPTION).............................................18
ONBOARDI/OOPTIONS..................................................19
SECTION5—CONTROLFEATURESANDFUNCTIONS.21
PRESSURECONTROL.......................................................21
ANTI‐CYCLINGCONTROL..........................................21
TOLERANCE..............................................................22
DAMPING.................................................................22
SYSTEM
VOLUME......................................................23
SEQUENCECONTROLSTRATEGIES.....................................24
S
TANDARDCONTROLFEATURESANDFUNCTIONALITY..........24
ALTERNATECONTROLSTRATEGIES.....................................28
ADDITIONALCONTROLFEATURESANDFUNCTIONALITY..........29
SECTION6—DISPLAYANDMENUOPERATION........31
SERMENU.................................................................33
U
NFORMATIONDISPLAYS.................................................34
I
INDICATORLED’S..........................................................36
COMPRESSORIDENTIFICATION.........................................37
X12ICONTROLKEYPADFUNCTIONS.................................37
SECTION8—SYSTEMCONFIGURATION...................40
DISPLAYITEMSTRUCTURE................................................40
ACCESSINGTHEX12ICONFIGURATIONSCREENS....................40
USERLEVELMENUS.......................................................42
SERVICELEVELMENUS(0021)........................................43
HIGHLEVELMENUS(0032)............................................44
X12ICONFIGURATIONSCREENS.........................................45
X12ICOMPRESSORCONNECTIVITYANDFUNCTIONALSETTINGS
..................................................................................56
SECTION9‐VIRTUALRELAYAUTOMATION..............59
VIRTUALRELAYCONFIGURATION......................................62
FUNCTIONLISTS.............................................................67
VIRTUALRELAYAUTOMATIONEXAMPLES...........................71
SECTION10—DIAGNOSTICS....................................73
SECTION11—X12IFAULTINDICATIONS..................77
ERRORLOG...................................................................77
FAULTCODES.................................................................78
INTERNALCONTROLLERFAULT‘E’CODES.............................79
SECTION12—PARTSLIST........................................80
SECTION13—TECHNICALDATA..............................80
SECTION14—WIRINGDIAGRAM............................81
X12ISCHEMATIC...........................................................81
X12IXPM‐AI4&XPM‐DI8R4......................................82
X12ITERMINALPCB.....................................................83
XPM‐TAC24...............................................................84
SECTION15—COMMISSIONINGFORM...................85
NOTES.....................................................................91
Refer to Section Indicated
Note
Important or Caution, Safety
SECTION7—COMMISSIONING................................39
PHYSICALCHECKS..........................................................39
PRESSUREDISPLAY........................................................39
X12IQUICKSET‐UPCONFIGURATION...............................39
OPTIONALFEATURESANDFUNCTIONS...............................39
2
SECTION 1 — INTRODUCTION
The X12I is an advanced system controller designed to
provide safe, reliable, and energy-efficient management
of your compressed air system. The X12I is capable of
controlling up to twelve (12) positive displacement air
compressors. The compressors may be fixed speed,
variable speed or multi-step and have electro-pneumatic
or microprocessor based controls.
SECTION 2 — SAFETY PRECAUTIONS
ALWAYS EMPLOY SAFE WORKING PRACTISE
AND PROCEDURES
WARNING: Risk of Danger
WARNING: Risk of Electric Shock
WARNING: Risk of High Pressure
WARNING: Consult Manual
Before installing or operating the product, 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.
When installing, commissioning, operating or carrying out
service or maintenance on a product, personnel must use
safe working practice and observe all relevant local
health and safety requirements and regulations.
Electricity and compressed air have the potential to
Lethal voltages are used within the product. Use extreme
caution when carrying out electrical checks. Isolate the
power supply before starting any maintenance work.
Maintenance must be performed by adequately qualified
personnel that are equipped with the proper tools. If the
user employs an operating procedure, an item of
equipment, or a method of working which is not
specifically recommended, the user must ensure the
product will not be damaged or made unsafe and that
there is no risk to persons or property.
It is not possible to anticipate every circumstance that
might represent a potential hazard. Failure to observe
safety precautions or implement safe working practices
may be considered dangerous practice or misuse of the
roduct. p
ere personal injury or property damage cause sev
The X12I is uniquely configurable and customizable to
meet the specific needs of some of the most complex
compressed air system. Additionally, the X12I control
network can expand to include monitoring and control of
arious compressed air system components. v
INSTALLATION
Installation work must only be carried out by a competent
n under qualified supervision. perso
A fused isolation switch must be fitted between the main
wer supply and the product. po
The product should be mounted in such a location as to
allow operational and maintenance access without
obstruction or hazard and to allow clear visibility of
ators at all times. indic
If raised platforms are required to provide access to the
product they must not interfere with normal operation or
obstruct access. Platforms and stairs should be of grid or
late construction with safety rails on all open sides. p
OPERATION
The product must only be operated by competent
nnel under qualified supervision. perso
Never remove or tamper with safety devices, guards or
nsulation materials fitted to the unit. i
The product must only be operated at the supply voltage
and frequency for which it is designed.
When mains 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. This
work must only be carried out by a qualified electrician or
technician equipped with the correct tools and
appropriate protection against electrical hazards.
All air compressors and/or other machine equipment
connected too, and controlled by, the product should
have a warning sign attached stating ‘THIS UNIT MAY
ART WITHOUT WARNING' next to the display panel. ST
If an air compressor and/or other machine equipment
connected too, and controlled by, the product is to be
started remotely, attach warning signs to the machine
stating ‘THIS UNIT CAN BE STARTED REMOTELY’ in a
prominent location, one on the outside of the machine,
he other inside the machine control compartment. t
3
SERVICE MAINTENANCE AND REPAIR
Service, maintenance, repairs or modifications must only
be carried out by competent personnel under qualified
supervision.
If replacement parts are required use only genuine parts
from the original equipment manufacturer, or an
ative approved source. altern
Carry out the following operations before opening or
removing any access panels or carrying out any work on
• Isolate from the main electrical power supply. Lock
• Attach a label to the isolator switch and to the
Ensure that all instructions concerning operation and
maintenance are strictly followed and that the complete
product, 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 renewed when acceptable
tolerances are exceeded. Always ensure any pressure
within a compressed air system is safely vented to
atmosphere before attempting to remove or install a
The product must only be cleaned with a damp cloth,
using mild detergents if necessary. Avoid the use of any
Do not paint the control facial or obscure any indications,
controls, instructions or warnings.
uct:- the prod
the isolator in the 'OFF' position and remove the
fuses.
product stating ‘WORK IN PROGRESS - DO NOT
APPLY VOLTAGE'. Do not switch on electrical
power or attempt to start the unit if such a warning
label is attached.
evice. sensor d
ubstances containing corrosive acids or alkalis. s
4
SECTION 3 — COMPRESSOR CONNECTION AND CONTROL
COMPRESSOR CONNECTION
Each air compressor in your system must be interfaced
to the X12I. Interface methods may vary depending on
the compressor type and/or local control configuration.
The following are main methods for interfacing
ompressors to the X12I: c
1) The ir-PCB Interface
2) The ir-485 Gateway Interface
3) The irV-485 Gateway Interf
4) Direct Connect via RS485
5) Special Application Interface
Consult the air compressor manual or your air
compressor supplier/specialist for details before installing
he X12I. t
Consult the X12I Interconnect and Application
uide
G
ace
STANDARD CONNECTION METHODS
1) The ir-PCB Interface module that is designed to
interface to any positive displacement air compressor
(regardless of make or manufacturer) with an available
c
ontrol voltage of 12-250V (either 50Hz or 60Hz).
2) The ir-485 Gateway Interface
designed to interface to any Ingersoll Rand Intellisys
controlled (Non-Nirvana) compressor. The X12I
communicates to the ir-485 Gateway via a two wire,
RS485 network utilizing the ir485 protocol. All IR
compressors equipped with Intellisys controllers (Non-
irvana and Recips) require this interface.
N
All Nirvana Compressors, 20 HP (15KW) and
bove require the irV-485 Gateway.
a
The ir-485 Gateway interface module is installed within
the compressor control cabinet and connected to the
12I using Belden 9841 or equivalent RS485 cable.
X
ir-485 & irV485 Manual
3) The irV-485 Gateway Interface module that is
designed to interface to any Ingersoll Rand Nirvana
compressor. The X12I communicates to the irV-485
Gateway via a two wire, RS485 network utilizing the ir485
protocol. All Nirvana Compressors, 20 HP (15KW) and
above, and Recips, with Redeye and SG controllers,
equire this interface.
r
module that is
The ir-PCB interface module is installed within the
compressor control area and connected to the X12I using
a six (6) wire cable, (seven (7)-wire cable for Nirvana 7.5
o 15HP (5.5 to 11KW).
t
Each air compressor must be equipped with an
online/offline pressure regulation system capable of
accepting a remote load/unload signal through a volt-free
switching contact or a single electro-mechanical pressure
s
witch.
ir-PCB Manual
The irV-485 Gateway interface module is installed within
the compressor control cabinet and connected to the
12I using Belden 9841 or equivalent RS485 cable.
X
Nirvana 7.5 to 15HP (5.5 to 11KW) connect via the
-PCB using seven (7)-wire cable.
ir
ir-485 & irV485 Manual
4) Direct Connect via RS485
compressor (R-Series) that has an integrated RS485
network port utilizing the ir485 protocol. The X12I
communicates to these compressors via a two wire,
RS485 network. The compressor is connected to the
12I using Belden 9841 or equivalent RS485 cable. X
R-Series Manual
to any Ingersoll Rand
5
OPTIONAL CONNECTION METHODS
5) Special Application Interface uses integration boxes
designed to accommodate various types of compressor
nd regulation methods and system monitoring. a
Expansion Module: EXP Box (Option)
As standard the X12I has four direct connect ‘ir-PCB’
terminal connections. This capability can be extended
with the use of tw0 (2) optional EXP Boxes. Each EXP
Box will add another four direct connect ‘ir-PCB’
connection terminals. This would allow a total of 12
compressors to connected and controlled via ‘ir-PCB’
ntegration. i
Compressors 1-4 connect via the X12I
Compressors 5-8 connect via EXP Box #1
ompressors 9-12 connect via EXP Box #2 C
The EXP Box is suitable for wall mounting and must be
located adjacent to the X12I unit (max 33ft or 10m).
on) Remote Compressor Management; EX Box (opti
The EX Box is an ‘EXtension’ to the X12I providing
additional ‘ir-PCB’ connectivity.
The EX Box will typically be used to provide ‘ir-PCB’
connectivity at a remote location beyond the maximum
distance specification of compressors that require ‘irPCB’ type connection; 330ft (100m). This effectively
expands the hardwire connection scheme of the ‘ir-PCB”
o the full RS485 distance specification. t
The EX box is suitable for wall mounting and can be
cated up to 4000ft (1219m) from the X12I unit. lo
The EXP Box connects to the X12I controller via a two
ire, dedicated RS485 network w
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 33ft (10m)
Up to four air compressors can be connected to the EXP
Box using a 6 or 7 wire cable and a compressor interface
ir-PCB (330ft (100m) max). The ‘ir-PCB’ connections are
dentical to the X12I. i
EXP Box Manual
The EX Box connects to the X12I controller via a two
ire, RS485 network utilizing the ir485 protocol w
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 4000ft (1219m)
One (1) or two (2) air compressors can be connected to
the EX Box using a 6-wire cable and a compressor
interface ir-PCB (330ft (100m) max). The ‘ir-PCB’
onnections are identical to the X12I. c
The EX Box also provides optional ‘local pressure
sensor’ connections. The compressor delivery pressure,
local system pressure and air treatment differential
ressure can be displayed. p
Multiple EX Boxes can be connected to the X12I as long
as the number of compressors does not exceed the
maximum number of compressors (12).
EX Box Manual
6
Bolt-On VSD Control Integration: VSD Box (option)
The VSD Box is intended to provide a method of system
integration for a VSD (Variable Speed Drive) air
compressor that is not equipped with any accessible
means of remote connectivity (such as IR- Nirvana). The
VSD Box will provide required functionality to enable
system integration and efficient control using the X12I
utomation system.
a
Remote Compressor Management; CX Box (option)
The CX Box is intended to provide a method of system
integration for non-Ingersoll Rand air compressors that
are not equipped with any accessible means of remote
onnectivity. c
The CX Box provides advanced monitoring and control
unctionality for the following compressor types: f
• Load/Unloa•d
3-Step
• 5-Step
• Poppet Valve
• Modulation Valve
• Spiral Valve
• Variable Speed Inverter Drive
The VSD Box connects to the X12I controller via a two
ire, RS485 network utilizing the ir485 protocol w
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 4000ft (1219m)
Each air compressor in a system, that requires VSD Box
integration, must be equipped with an individual VSD
Box. Multiple VSD Boxes can be connected to the X12I
as long as the number of compressors does not exceed
he maximum number of compressors (12). t
VSD Box Manual
The CX Box connects to the X12I controller via a two
ire, RS485 network utilizing the ir485 protocol w
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 4000ft (1219m)
Each air compressor in a system that requires CX Box
integration must be equipped with an individual CX Box.
Multiple CX Boxes can be connected to the X12I as long
as the number of compressors does not exceed the
aximum number of compressors (12). m
CX Box Manual
7
tion) Remote Compressor Management; DX Box (op
The DX Box is designed to allow two fixed speed
online/offline air compressors to be seen as one
ompressor by the X12I. c
This c fun tionality provides the ability to:
a) Group two adjacent air compressors together as
a single coherent unit.
b) Combine two similar capacity compressors
together to form a three-step variable output
group acting as a single coherent variable
output unit.
c) Take advantage of a small or minimal capacity
compressor, grouped together with a medium or
higher capacity compressor, to form a high
capacity, variable output, group acting as a
single variable output ‘top-up’ compressor.
The DX Box also provides optional local pressure sensor
connections. The compressor discharge pressures, local
system pressure and air treatment differential pressures
can be displayed. The monitored local pressure is
available on the system network and can be utilized by
he X12I for advanced pressure related functions. t
Remote Input & Output: I/O Box (option)
An I/O Box provides additional general purpose I/O
(input/output) for a system enhancing monitoring
apabilities and providing distributed system automation. c
Up to twelve I/O Boxes can be connected to the X12I
ontroller. Each I/O Box features: c
• 8 Digital Inputs
• 5 Analog Inputs
• 6 Relay Outputs
The I/O Box connects to the X12I controller via a two
ire, RS485 network utilizing the ir485 protocol w
The DX Box connects to the X12I controller via a two
ire, RS485 network utilizing the ir485 protocol w
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 4000ft (1219m)
The DX Box provides for two ‘ir-PCB’ connections. The
DX Box can also be used to provide ‘ir-PCB’ connectivity
at a remote location beyond the maximum distance
pecification of direct X12I connection. s
Multiple DX Boxes can be connected to the X12I as long
as the number of compressors does not exceed the
aximum number of compressors (12). m
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 4000ft (1219m)
Digital inputs can be used to monitor switching contact
devices. Each input can be set to act as an Alarm or High
Level Alarm input. Digital inputs can also be used for
metering (for example m
ccumulative count of pulses from a metering device. a
Analog inputs can be used to monitor sensor devices (for
example: pressure differential, temperature, dewpoint,
flow, current, power, and bearing condition). Each input is
equipped with adjustable high or low level detection that
an be used to activate an Alarm or High Level Alarm. c
Relay outputs use ‘Virtual Relay Automation’ technology
and are totally configurable with duel input logic
functions. Relay functions can be assigned utilizing any
status or condition information available on a system
network from any compatible unit connected to the
etwork. n
I/O Box Manual
3
, ft3, kWh) providing an
DX Box Manual
8
Visualization: VX Box (Option)
The VX Box provides “visualization” of the X12I
Automation System. The VX Box incorporates hardware
and software to allow monitoring of the X12I Automation
system and equipment in a simple format. To access the
application running in the VX Box, simply connect via a
Web Browser from any PC using an Ethernet connection.
he PC can be local “stand alone” or part of a LAN. T
Once logged into the VX Box, the following items are
vailable to the user: a
System status & control
g System performance reportin
Equipment status monitoring
heduler Equipment maintenance sc
ding tools Graphing & Tren
Reporting tools
monitoring Warning & Alarm
SMS messaging
Email messaging
The VX Box is fully field configurable using standard
creen templates. s
System Modbus Gateway: SMG Box (Option)
The SMG Box is designed to provide a RS485 Modbus
connection to the X12I Automation System. This allows
a customer’s computer, PLC, or DCS to connect to,
monitor, and control the X12I Automation System from a
emote location. r
The SMG Box connects to the X12I controller via a two
ire, RS485 network utilizing the ir485 protocol w
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 4000ft (1219m)
The SMG Box communicates to the customer’s
computer, PLC, DCS via a two wire, RS485 network
tilizing the Modbus protocol. u
The VX Box connects to the X12I controller via a two
ire, RS485 network utilizing the ir485 protocol w
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 4000ft (1219m)
The VX Box connects to the customer’s PC or LAN via
Ethernet, using a RJ45 connector, Cat5e 10/100BaseT
cable.
VX Box Manual
Use Belden 9841 or Equivalent In Grounded
Conduit No Greater Than 4000ft (1219m)
Ethernet to RS485 Converter:
Lantronix XSDRIN-02 Xpress-DR-IAP or equivalent
Serial to RS485 Converter:
&B Electronics 4WSD9OTB or equivient B
SMG Box Manual
9
PRESSURE DETECTION AND CONTROL
The X12I utilizes the signal from an electronic pressure
sensor that can be mounted remotely from the X12I in a
suitable location in the compressed air system.
The default setup of the X12I is for operation with a
232psi (16bar) 4-20ma pressure sensor. The X12I can
accept an input from any 4-20mA type pressure sensor
ith a range from 14.5psi (1bar) up to 8700psi (600bar). w
Consult the Pressure Sensor Calibration Procedure
for information regarding the use and setup of the
ressure sensor. p
Pressure Sensor Calibration Procedure
10
X12I MAIN DISPLAY OVERVIEW
a
b
PSI
102
d
1
c
e
17:30 #1
a
b
CAP
c
a
b
c
a
f
b
g
h
c
d
e
1
11
X12I SYSTEM OVERVIEW
12
X12I INSTALLATION OVERVIEW
Dimensions 13.4” x 9.45” x 6.0”
Weight 16.5lb (7.5kg)
Mounting Wall, 4 x screw fixings
Enclosure IP54, NEMA 12
Supply 230Vac +/- 10%, 50 Hz
Power 100VA
Temperature 32°F to 115°F
Humidity 0% to 95% RH
Local Disconnect (Breaker) Box
(Sized in accordance with local
electrical and safety regulations).
X12I X05 CONNECTOR
Reference X12I Operations Manual for Pressure
SPECIFICATIONS
340mm x 241mm x 152mm
115Vac +/- 10%, 60 Hz
(0°C to 46°C)
(non-condensing)
Fused for 100VA
Power Cable
3 conductor (N, L, E)
PRESSURE TRANSDUCER CABLE
2 Conductor Cable, 20 Gauge Stranded
Earth Shielded
No Greater Than 330FT (100M)
24VDC Control Voltage
25 +VDC Pin #3
26 Signal Pin #1
Sensor Connection Details
To Plant Air
System
PT CONNECTOR
PRESSURE TRANSDUCER
RECEIVER
On/Off
Switch
Ingersoll Rand Automation
Supply
Voltage
Cable
Pressure Transducer
Cable
PRESSURE TRANSDUCER THREADS
Model X12I
ir-PCB
ir-PCB Compressor Control Cable
BPT G1/4” DIN3852,
Form E, Inox 1, 4305 STainless
Equivalent of ¼” NPT.
EXP RS485 Network Cable
EXP RS485 NETWORK CABLE
Belden 9841 or Equivalent
In Grounded Conduit
No Greater Than 33FT (10)
RS485 Network Cable
RS485 NETWORK CABLE
Belden 9841 or Equivalent
In Grounded Conduit
No Greater Than 4000FT (1219M)
ir-PCB COMPRESSOR CONTROL CABLE
7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
Single Conductor Wire, 20 Gauge Stranded, Quantity (7) In
Grounded Conduit No Greater Than 330FT (100M)
Reference X12I Application and Interconnect Guide For
Wiring Connections Between The X12I, The ir-PCB, and The
OR
24VAC Control Voltage
Compressor
DRIP LEG
I l
ngersol
Rand
From Air
Compressors
Reference X12I Application and Interconnect Guide For
Wiring Connections Between The X12I, The ir-485 or irV-
485 Gateway and The Compressor, S3 Direct Connects, and
Optional Special Application Interface Boxes
From VSD Pressure
Transducer
ir-PCB
To VSD Pressure
Transducer Input
The RS485 Network is a Serial, Point to Point
Communication Network Refer to the X12I Application and
Interconnect Guide For Wiring Details and Connectivity.
ir-485
irV-485
13
SECTION 4 — INSTALLATION
It is recommended that installation and
commissioning be carried out by an authorized and
trained product supplier.
UNIT LOCATION
The X12I can be mounted on a wall using conventional
bolts. The X12I can be located remotely from the
compressors as long as it is within 330 feet (100 meters)
of cable length when connecting compressors directly
with an ir-PCB. When connecting the X12I over the
RS485 communication network the distance is up to
4000 feet (1219 meters) The X12I must be located within
30 feet (100 meters) of the system pressure transducer. 3
POWER SUPPLY
A fused switching isolator must be installed to the main
incoming power supply, external to the X12I. The isolator
must be fitted with a fuse of the correct rating to provide
adequate protection to the power supply cable used (in
ccordance with local electrical and safety regulations). a
XPM-TAC24
1
X04
X04
23 4
VOLTAGE SELECT
1
23 4
VOLTAGE SELECT
230Vac
115Vac
If it is necessary to adjust the link wires access to the link
terminals can be achieved by temporarily removing the
C Power supply unit (DC) located on the main DIN Rail. D
B
DC
A
C
A) Push the DIN Rail mount button located at the bottom
of the DC Power supply unit. This action can be
achieved by hand; no tooling is required.
B) Remove the DC power supply unit from the DIN Rail
and carefully maneuver to the left. There is no need
to disconnect any wiring.
C) Click the DC power supply unit back in place when
voltage select link adjustment is complete.
The DC power supply unit is mounted in an
inverted orientation on the DIN Rail; this is an
intentional design feature.
Connect the incoming power supply wires to the
power supply terminal blocks located on the main
DIN Rail.
Ensure that the voltage select input is properly
jumpered for the incoming power. Default voltage
onfiguration is 230Vac. c
14
PRESSURE SENSOR LOCATION
The system pressure sensor (P) must be located where it
will see the air pressure that is common to all of the
ompressors. c
SUPPLY (WET) Side Pressure Control
P
1
P
2
Pressure Sensor Located Before Cleanup Equipment
Dry side pressure will be lower than the system
pressure due to pressure differential losses across air
treatment equipment. The nominal system pressure will
reduce as the air treatment differential pressure
ncreases. i
DEMAND (DRY) Side Pressure Control
PRESSURE SENSOR CONNECTION
The pressure sensor must be connected to terminal X05
of the X12I Terminal PCB using a shielded (earth
screened), two-conductor (2 core), 20 gauge (0.5mm2
CSA minimum), cable no greater than 330ft (100m) in
ngth. le
X05
26
25
+
Wire polarity is important.
-
+
4-20mA
1
P
P
2
Pressure Sensor Located After Shared Cleanup
Equipment
P
P
1
P
2
Pressure Sensor Located After Individual Cleanup
Equipment
Ensure each compressor is equipped with
independent excess pressure shutdown. An increase in
pressure differential across air treatment equipment can
result in excess compressor discharge pressure.
Pressure Sensor Wiring and Location
The pressure transducer threads are BPT G1/4”
DIN3852, Form E, Inox 1, 4305 stainless. It is the
quivalent of ¼” NPT. e
Regular routine monitoring of pressure differential
across air treatment equipment is recommended.
15
IR-485 AND IRV-485 GATEWAY
MODULE
The ir-485 and irV-485 Gateways are designed to
interface the Intellisys Controller on the Ingersoll Rand
Compressors and the Nirvana compressors, 20 HP
(15KW) and above, with the X12I via the RS485 Network
utilizing the ir485 protocol. The ir-485 and irV-485
Gateways are DIN Rail mounted and can be located
within the compressor control gear enclosure or remotely
within a separately enclosure.
irV-485
ir-485 Gateway irV-485 Gateway
The cable used between the X12I and the ir-485 and irV485 Gateways is Belden 9841 (or equivalent). It should
be run in grounded conduit and should not be greater
than 4000 feet (1219 meters) in length.
The cable used between the ir-485 Gateway and irV-485
Gateways and the Intellisys Controller is included with
the Installation Kit
Consult the X12I Interconnect and Application
Guide and the ir-485 or irV-485 Gateway Manual prior to
the installation of the X12I and the Compressor Gateway
to the air compressor.
IR485 COMMUNICATION PROTOCOL
ir485 is a unique communication protocol designed
specifically for Compressor and Air System control. ir485
is a Multi-Master vs. a Master–Slave protocol that
enables faster, more effective control of network
components. ir485 also features distributed control
capabilities and has inherent resistance to
ommunication faults due to noise c
RS485 NETWORK
The X12I is equipped with an RS485 network
communications capability using the ir485 protocol. This
facility can be used for remote connectivity to optional
networked units and modules with ir485 communications
capabilities or compressor controllers equipped with the
485 capability. ir
X06
L2
L1
The RS485 Network is a Serial, Point to Point
Communication Network. Refer to the X12I Application
and Interconnect Guide For Wiring Details and
onnectivity. C
The following example details the “correct”
iring the RS485 Network w
The following example details the “incorrect” method of
iring the RS485 Network w
30
29
28
27
RS485
method of
Correct RS485 Network Example
L2
L1
ir-485
Follow RS485 Network installation
recommendations
Incorrect RS485 Network Example
16
S485 Installation ConsiderationsR
RS485 data communications and other low voltage
signals can be subject to electrical interference. This
potential can result in intermittent malfunction or anomaly
that is difficult to diagnose. To avoid this possibility
always use earth shielded cables, securely bonded to a
known good earth at one end. In addition, give careful
onsideration to cable routing during installation. c
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
power supply cable(s), always cross at a right angle. a
b) If it is necessary to follow the route of power supply
cables for a short distance (for example: from a
compressor X12I to a wall along a suspended cable tray)
attach the RS485 or signal cable on the outside of an
earthed cable tray such that the cable tray forms an
earthed electrical interference shield.
c) Where possible, never route an RS485 or signal cable
near to equipment or devices that may be a source of
electrical interference (for example: 3-phase power
supply transformer, high voltage switchgear unit,
frequency inverter drive module, radio communications
ntenna). a
17
COMPRESSOR INTERFACE IR-PCB
The ‘ir-PCB’ is designed to interface a compressor with
the X12I using a 6-core (or 7-core for IRV-PCB
operation), earth shielded, cable no greater than 330ft
100 meters) in length. (
Each compressor in the system must be assigned a
unique identification number from 1 up to the number of
compressors in the system. The identification number
should be clearly indicated on each compressor for
perational reference. o
For each compressor connected to the X12I utilizing an
‘ir-PCB,’ the signal wires must be connected to the X12I
terminals dedicated for the assigned compressor
eference number. r
C01 C02 C04
i-PCB
C03
V
24613 5
#1
C05
IR-PCB EXP BOX (OPTION)
As standard the X12I has four direct connect ‘ir-PCB’
terminal connections. This capability can be extended
with the use of optional ir-PCB EXP Box(s). Each box
adds another four direct connect ‘ir-PCB’ terminals. Up to
two ir-PCB EXP Boxes can be connected to the X12I to
provide a maximum of 12 direct connect ‘ir-PCB’
erminals. t
The ir-PCB EXP Box is wall mounting and must be
located adjacent to the X12I unit. The distance between
the X12I and the ir-PCB EXP Box is no greater than 33ft
10m). (
LED 1 LED 2
V
X01
246135
V1
The ‘ir-PCB’ is a DIN rail mountable module designed to
be installed within the compressor control or switchgear
rea. a
Each air compressor must be equipped with a
load/unload regulation system and, if not regulated with a
single electro-mechanical pressure switch, have a facility
for a remote load/unload control with the ability to accept
volt-free switching contact input for remote load/unload. a
V
For variable speed compressor(s) equipped with a
‘variable/fixed’ digital input function; Install a 7-core cable
from the ‘ir-PCB’ to the X12I.
Consult the air compressor manual or your air
compressor supplier/specialist for details before installing
the X12I.
Consult the X-Series Interconnect and Application
Guide prior to the installation of the X12I and the ir-PCB
to the air compressor.
C: 5 - 8
Consult the air compressor manual or your air
compressor supplier/specialist for details before installing
the X12I.
Consult the X12I Interconnect and Application
Guide prior to the installation of the X12I and the ir-PCB
to the air compressor.
Consult the EXP Box Instruction Manual for
information regarding the use of the EXP Box.
EXP Box Instruction Manual
Consult the ir-PCB Instruction Manual for
information regarding the use of the ir-PCB.
ir-PCB Instruction Manual
18
ON BOARD I/O OPTIONS
DIGITAL INPUTS (OPTIONS)
T he X12I is equipped with ten auxiliary inputs.
Each input is designed to detect a remote ‘volt-free’
switching contact (rated for a minimum 24VDC @ 10mA)
ith a cable length of 330ft (100m) maximum. w
D i1: Digital Input 1, Menu Configurable
X07
32
31
Menu Items – S02:D1
he functions of Di2 to Di10 are fixed. T
ange Di2: Force Sequence Ch
Di3: Remote Start/Stop
Di4: Standby Override
Di5: Table 1 Override
Di6: Table 2 Override
Di7: Table 3 Override
Di8: Table 4 Override
Di9: Table 5 Override
i10: Table 6 Override D
XPM-Ai4
X03
Di1
Di2: Force Sequence Change
Initiates an immediate change/review of the compressor
sequence assignment. The input must be activated for a
minimum of two second. Routine scheduled sequence
change events are not disrupted and will still occur as
ormal. n
Di3: Remote Start/Stop
A start command is generated when the input changes
state from open to closed. The input must remain closed
while running. A stop command is generated when the
put changes state from closed to open. in
Local and Communications Start and Stop remain
active. If the Stop button is pressed while this input is
eld closed, the unit will stop. h
Di4: Standby Override
All compressors are unloaded and continuously held
offloaded. Any active ‘Table’ override input has priority
ver the standby override input. o
Di5 to Di10: Table 1 to 6 Override
The X12I will select the applicable ‘Table’ when a table
input is activated. The X12I will return to normal table
selection, in accordance with pressure schedule or menu
etting, when no table input is activated. s
When a table override input is activated the display
will show a manual table override symbol adjacent to the
able’ symbol. ‘t
If more than one table override input is activated at the
same time the X12I will give priority to the lowest table
number. For example: If table 2 and 3 override inputs are
activated at the same time the X12I will use table 2.
0VDC
Ai4
7
8
Di2
XPM-Di8R4
X03
1
Di1
2
3
Di2
4
5
Di3
6
7
Di4
8
9
Di5
10
11
Di6
12
13
Di7
14
15
Di8
16
Di3
Di4
Di5
Di6
Di7
Di8
Di9
Di10
19
DIGITAL OUTPUTS (OPTIONS)
The X12I is equipped with five remote relay contact
utput. o
Remote output relay contacts are rated for 240V
‘CE’ / 115V ‘UL’ @ 4A maximum.
1: Relay Output 1, Menu Configurable R
X08
36
35
34
33
R1
R2: Relay Output 2, Menu Configurable
R3: Relay Output 3, Menu Configurable
R4: Relay Output 4, Menu Configurable
5: Relay Output 5, Menu Configurable R
XPM-Di8R4
X03
1
R1
2
3
R2
4
5
R3
6
7
R4
8
R2
R3
R4
R5
P2+>DP: Pressure Differential Mode
P1P2 DP
The second pressure sensor can be used to monitor
pressure downstream, or upstream, of air treatment
equipment. The pressure differential (DP) between the
primary control pressure sensor (P1) and the second
pressure sensor (P2) can be displayed on the screen. A
pressure differential Alarm (Warning) level can also be
set to indicate when differential pressure exceeds the set
mit. li
Airflow Sensor Monitoring
The X12I is equipped with a 4-20mA input dedicated for
optional airflow sensor monitoring. Any airflow sensor,
that is equipped with a ‘loop powered’ 4-20mA output,
can be connected to the X12I. The airflow sensor value
can be displayed on the X12I screen and is available on
emote communications. r
Dewpoint Sensor Monitoring
The X12I is equipped with a 4-20mA input dedicated for
optional dewpoint sensor monitoring. Any dewpoint
sensor, that is equipped with a ‘loop powered’ 4-20mA
output, can be connected to the X12I. The dewpoint
sensor value can be displayed on the X12I screen and is
available on remote communications.
Virtual Relay Automation – R1 to R5
ANALOG INPUTS (OPTIONS)
Second Pressure Sensor:
The X12I is equipped with a 4-20mA input dedicated for
n optional second pressure sensor. a
The second pressure sensor (P2) can be utilized for one
f two available functions: o
1<>P2: Redundant Pressure Transducer ModeP
P1
P2
If the primary control pressure sensor (P1) fails the
management unit will automatically switch to the ‘backup’
ressure sensor (P2). p
20
SECTION 5 — CONTROL FEATURES AND FUNCTIONS
PRESSURE CONTROL
Pressure control is achieved by maintaining the system
pressure within an acceptable range, or pressure band,
which is defined and programmed by the user. Pressure
will rise in the band when system demand is less than
the loaded compressor’s output. Pressure will fall in the
band when system demand is greater than the loaded
ompressor’s output. c
Simply stated, pressure control is achieved by unloading
and loading compressors to closely match compressor
output with system demand within a specified pressure
and defined by PL and PH. See Figure 1. b
Variable speed compressors also operate within the
pressure band and actively match compressor output
with system demand by speeding up and slowing down
around a target pressure defined by the exact midpoint of
the pressure band defined by PT. See Figure 2.
a
b
PH
PT
PL
PH
PT
PL
Figure 2 — Typical VSD Pressure Control vs. Time
The variable speed compressors in the system will run on
their target pressure and smooth out the variations in
system pressure. This assumes that system demand
does not vary more than the capacity of the variable
peed compressor. s
A variable speed compressor will be included in the
load/unload sequence and be controlled exactly as a
fixed speed machine with the exception of speed control
to maintain target pressure.
ANTI-CYCLING CONTROL
Figure 1 — Typical System Pressure vs. Time
As pressure rises to point “a”, the compressor will unload
based on the sequencing algorithm. System pressure is
then allowed to decrease due to the drop in supply until
point “b” is reached. Once point “b” is reached, the X12I
will load the next compressor in the sequence to match
the air demand. This cycle will repeat as long as the X12I
is able to keep the system air pressure between PH and
PL.
The most efficient way to utilize most air compressors is
either fully loaded or off, with the exception of variable
speed compressors which can operate efficiently at
reduced loading. Compressor cycling (start-load-unloadstop, etc.) is essential to maintain pressure control.
Excessive cycling, however, can result in poor
ompressor efficiency as well as increased maintenance.
c
Anti-cycling control is incorporated to help ensure that
only the compressors that are actually required are
started and operating while all others are kept off. Anticycling control includes a pressure tolerance range or
band, defined by the user, which is outside of the primary
pressure band. Inside the tolerance band, an active
control algorithm continually analyzes pressure dynamics
to determine the last possible second to add or cycle
another compressor into the system. This control is
further enhanced by the ability to fine tune the tolerance
and settings and algorithm processing time (Damping). b
21
TOLERANCE
Tolerance is a user adjustable setting that determines
how far above the PH Setpoint and below the PL
Setpoint system pressure will be allowed to stray.
Tolerance keeps the X12I from overcompensating in the
event of a temporary significant increase or decrease in
system demand.
TO
TO
Figure 3 — Tolerance in Relation to PH and PL
Tolerance (TO) is expressed as a pressure defining the
width of the band above PH and below PL in which
energy efficient control will be in effect.
When system pressure is in the tolerance band, the X12I
will continuously calculate the moment at which
compressors will be loaded or unloaded based on the
rate of change of system pressure. When the system
pressure strays outside of the tolerance band, the X12I
will abandon energy efficiency and begin to protect the
system air pressure by loading or unloading the
ompressors. Loading will be delay controlled. c
When the compressed air system storage is relatively
small compared to the system demand, and fluctuations
are large and quick, the tolerance band setting should be
increased to maintain energy efficient operation and
avoid a situation in which multiple compressors are
oaded just to be unloaded moments later. l
When the compressed air system is relatively large
compared to system demand and fluctuations are smaller
and slower, the tolerance band can be reduced to
improve pressure control and maintain energy efficient
operation.
The factory default setting for tolerance is 3.0 PSI
0.2Bar). This setting is user adjustable. (
PH + TO
PH
PT
PL
PL - TO
DAMPING
Any time the pressure is within the Tolerance band the
Anti-Cycling algorithm is active, sampling the rate of
pressure change and calculating when to load or unload
the next compressor. The damping (DA) setting is a user
adjustable Setpoint that determines how quickly the
controller samples and recalculates, effectively speeding
p or slowing down the reaction time. u
The X12I’s factory default DA setting of “1” is adequate
for the majority of compressed air systems but may need
to be adjusted in the following circumstances involving
aggressive and disproportionate system pressure
hanges: c
• Inadequate air storage
• High pressure differential across the air
treatment equipment
• Incorrectly sized piping
• Slow or delayed compressor response
In these circumstances, the X12I may overreact and
attempt to load additional compressors that may not be
necessary if the system was given time to allow the
system pressure to stabilize after the initial compressor is
given time to load. If the tolerance has already been
increased and the X12I is still overreacting, then
creasing the damping factor is the next step. in
Damping is adjustable and is scaled from 0.1 to 10 with a
factory default of 1. A factor of 0.1 is a reaction time 10
times faster than the default and a factor of 10 is a
eaction time 10 times slower than the default. r
There are many variables that go into
determining the stability and control of the system
pressure, only some of which are able to be
controlled by the X12I. System storage, air
compressor capacity, and air demand all need to be
analyzed by experienced professionals to determine
the best installation for your system. Tolerance (TO)
and damping (DA) can be used for minor tuning of
the system.
22
SYSTEM VOLUME
torage Calculations:S
The following formula determines the recommended
inimum storage volume for a compressed air system: m
-
+
Assorted Receiver Tanks
System volume defines how fast system pressure will
rise or fall in reaction to either increased/decreased
demand or increased/decreased supply. The larger the
system volume, the slower the pressure changes in
relation to increased/decreased demand or supply.
Adequate system volume enables effective pressure
control and avoids system over-pressurization in
response to abrupt pressure fluctuations. Adequate
system volume is created by correctly sizing and utilizing
ir receivers. a
The most accurate way to determine the size of air
receivers or the additional volume required would be to
measure the size and duration of the largest demand
event that occurs in the system, then size the volume
large enough to ride through the event with an
acceptable decrease in system pressure. Sizing the
volume for the worst event will ensure system stability
and effective control over all other normal operating
onditions. c
If measurement is not available, then estimating the
largest event is a reasonable alternative. For example,
assume that the largest demand event could be equal to
the loss of the largest operating air compressor. System
volume would be sized to allow time for a back-up
compressor to be started and loaded with an acceptable
decrease in pressure.
V — “Volume of Required Storage” (Gal, Ft , m , L)
T — “Time to Start Back-up Compressor” (Minutes)
3 3
M, m
3
Pa — “Atmospheric pressure” (PSIa, BAR)
P — “Allowable Pressure Drop” (PSI, BAR) ∆
3
Ft
and US Gal.
(4) - 100 Hp Compressors at 450 CFM (12.7 m
Required Storage Volume in Example 1: Find
3
) each
15 seconds to start and load a compressor.
5PSIG pressure drop. is the maximum allowable
nds (.25 minute) T=15 Seco
C=450 ft
3
Pa = 14.5 PSI
Delta P = 5 PSI
.5)]/5 V = [.25 x (450 x 14
525)/5 V = (.25 x 6
V = 1631/5
V = 326 Ft
1 ft = 7.48 Gal
3
3
3
x 7.48 Gal= 326 Ft
Gal = 2440
: Find Required Storage Volume in Example 2
3
) each 4) - 100 Hp Compressors at 450 CFM (12.7 m
m
(
3
and L.
15 seconds to start and load a compressor.
0.34 B essure drop. AR is the maximum allowable pr
ds (.25 minute) T=15 Secon
C=12.7 m3
Pa = 1BAR
Delta P = .34 BAR
]/.34 V = [.25 x (12.7 x 1)
2.7)/.34 V = (.25 x 1
V = 3.2/.34
V = 9.33m
1m = 1000 L
3
3
3
x 1000 L= 9.33
m
L = 933
/min) C — “Lost Capacity of Compressed Air” (CF
23
SEQUENCE CONTROL STRATEGIES
The X12I provides three basic sequence control
strategies or modes. Each sequence control strategy
onsists of two sub strategies: c
1) The compressor ‘Rotation’ strategy
2) The compressor load ‘Control’ strategy
The ‘Rotation’ strategy defines how the compressors
are re-arranged, or re-ordered, in to a new sequence at
each routine ‘Rotation’ event. Rotation events are
triggered by a cyclic interval time, a set time of day each
ay, or a set time of day once a week. d
The compressor load ‘Control’ strategy defines how
the compressors are utilized in response to variations in
ystem pressure. s
ompressor Sequence Arrangements: C
Each compressor in a system is initially assigned to the
X12I with a fixed and unchanging number reference, 1 to
2. 1
The ‘duty’ that a compressor is assigned in any set
‘Rotation’ sequence arrangement is defined by a letter, A
o L. t
For example:
A = the ‘Duty’ compressor, the first to be utilized.
d. B = The ‘Standby’ compressor, the second to be utilize
C = The ‘Second Standby’ compressor, the third to be
utilized.
D = The ‘Third Standby’ compressor, the forth to be
tilized. u
Compressor ‘duty’ assignments are reviewed, and rearranged as appropriate in accordance with the selected
rotation strategy, at each rotation event.
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
The standard (default) configuration of the X12I provides
ENER (Energy Control) sequence control strategy,
Priority Settings, Table Selection, Pressure Schedule,
nd Pre-fill operation. a
ENER: ENERGY CONTROL MODE
he primary function of Energy Control mode is to: T
1/ Dynamically match compressed air supply with
compressed air demand.
2/ Utilize the most energy efficient set/combination of air
ompressors to achieve 1/. c
Energy Control mode is designed to manage systems
that include compressors of different capacities and
different air compressor types (fixed speed, variable
speed and variable capacity) in any combination or
onfiguration. c
Energy Control Mode Control and Rotation:
Compressor control and utilization is dynamically
automated with adaptive control logic and therefore does
not follow pre-determined schedules, rotation
configurations or time intervals. Energy Control mode
can, however be operator influenced by the Priority
unctionality which is discussed later in this manual. f
Energy Control mode is enabled by the ability of the X12I
to process individual compressor capacity, variable
capacity capabilities, and changes in system pressure to
dynamically implement and continuously review ‘best fit’
onfigurations as demand variations occur. c
100%
80%
2
40%
20%
0%
0%
1: Demand
1
100%
2: Supply
PRIORITY SETTINGS
The sequence assignment pattern can be modified
y using the priority settings. b
Priority settings can be used to modify the rotation
sequence assignments. Compressors can be assigned a
priority of 1 to 12, where 1 is the highest priority. Any
compressor can be assigned any priority and any number
of compressors can share the same priority.
Priorities allow you to set up rotation groups. All
compressors that have the same priority number will
rotate inside their own group. The group with the highest
riority will always be in the front of the sequence. p
For example, in a four compressor system including one
variable speed compressor in the compressor 1 position
you may want the variable speed compressor to always
be in the Lead position. By assigning compressor 1 a
priority of 1 and the other three compressors a priority of
2, the variable speed compressor will always remain at
the front of the sequence:
1 2 3 4
1222
#1
ABCD
#2
ACDB
#3
ADBC
#4
ABCD
Compressor 1 has priority 1, all other compressors
have priority 2
24
In another example, there is a four compressor system
that includes a compressor in the compressor 4 spot that
is used only as an emergency backup compressor. To
accomplish this, simply assign compressor 4 a lower
priority than any other compressor in the system:
1 2 3 4
1112
#1
ABCD
#2
BCAD
#3
CABD
#4
ABCD
Compressor 4 has priority 2, all other
compressors have priority 1
In a third example, there is a four compressor system
that includes a variable speed compressor designated
compressor 1 and a fixed speed compressor that is an
emergency backup assigned as compressor 4. To ensure
that compressor 1 is always at the front of the sequence
and compressor 4 is always at the end of the sequence,
set the priority as shown below:
1 2 3 4
1223
#1
ABCD
#2
ACBD
#3
ABCD
#4
ACBD
Compressor 1 has priority 1, compressor 4 has
priority 3 and all other compressors have priority 2
A last example involves another four compressor system
that will be assigned into two independently rotation
groups. Compressors 1 and 2 are given priority 1 and
compressors 3 and 4 are given priority 2. This results in
the rotation sequence shown below:
Priority control will also work with ENER control
mode. Recall that ENER control automatically selects the
most efficient set of compressors to dynamically match
compressed air demand. Priority will force the X12I
controller to select from all “priority 1” compressors and
make sure that they are loaded in the sequence before
utilizing any priority 2 compressors. All priority 2
compressors must be utilized before priority 3
compressors can be loaded and so on. Priority allows a
system to be segregated to backup and primary use
ompressors when using ENER control. c
Using the Priority function with ENER Control can
affect system efficiency.
TABLES AND THE PRESSURE SCHEDULE
T01
- - - -
PH
- - - -
PL
- - - -
Pm
- - - -
SQ
The X12I operates based on settings that are
configured into one of six tables. Each table defines the
operational settings and sequence control mode of the
X12I. The X12I can be instructed to change among the
tables at any time based on the configuration of the
ressure schedule. p
This functionality allows the X12I to switch among
multiple different system configurations without any
disruption to control. This is particularly useful in the case
of shift changes, or weekends when the system is to be
deactivated.
Each table consists of the following parameters which
can be set independently in each table:
• PH – High Pressure Setpoint
• PL – Low Pressure Setpoint
• Pm – Minimum pressure warning level
• SQ – Sequence Rotation Strategy
• 01 – Compressor 1 Priority
• to
• 12 – Compressor 12 Priority
1 2 3 4
1122
#1
ABCD
#2
BADC
#3
ABCD
#4
BADC
Two independently rotating compressor groups
The “maximum” pressure fault level and the
rotation interval, or rotation time, are set independently
in a configuration menu and are unchanging regardless
of the table selected.
25
PRESSURE CHANGE TIME:
When the X12I is instructed to change between tables, it
will not abruptly change the system operating
parameters. The X12I will adjust the system target
pressure upward or downward to the next table’s
settings. This transition will occur gradually to preserve
energy efficiency and safe, reliable control:
Adjust the ‘day of the week’ sub-setting first and then
press Enter to increment to the next setting. Repeat until
all item sub-settings are entered. The complete ‘Pressure
Schedule’ item will not be set in X12I memory until the
last sub-setting is entered. Press Escape to step back
one sub-item if required.
SEQUENCE ROTATION:
1
The time the system is allotted to change the target
pressure is known as the Pressure Change Time (PC).
This is a value that is adjustable in the system settings
screen.
If the X12I is able to complete the transition in less time
than is allotted without threatening energy efficiency then
PC will be automatically shortened.
An aggressively short time setting will compromise
energy efficiency.
PRESSURE SCHEDULE:
The X12I is equipped with a real time clock feature
and pressure schedule facility. The ‘Pressure Schedule’
function can be used to provide automation of the
ystem. s
The pressure schedule consists of 28 individual settings
that instruct the system to change from one ‘Table’ to
another, or put the system in to ‘Standby’ mode,
dependant on time of day and day of the week. The
pressure schedule will cycle from 00:00 hours Monday
(day #1) to 23:59 hours on Sunday (day #7) each
alendar week. c
P01
01.0# 01
2
PC
Changing Target Pressures
A sequence ‘Rotation’ event can be automatically
triggered on a routine basis using a pre-determined
interval, a pre-determined time each day or a pre-
etermined day and time each week. d
S01
04.01 RP
#1 18:00
Enter the rotation period menu item (RP); the ‘day’
etting will flash. s
Select the ‘day’ or day function as required:
#1 = Monday to #7 = Sunday
#8 = each working day of the week, excluding Saturday
and Sunday
of the week. #9 = each working day
- (dash) = deactivate #
Select the required hour and minutes of the day(s) using
he same method. t
A day starts at 00:00hrs and ends at 23:59hrs (24hr
lock system). c
To define an interval time (more than one
rotation event a day) select ‘#t’ for the day function and
ress Enter: p
S01
04.02 RP
# - - - : - -
- - -
01 02 03040# =
01) Day of the Week
#1 = Monday to #7 = Sunday
#8 = every working day of the week; Monday to
ay. Friday, excluding Saturday and Sund
#9 = every working day of the week.
Select “-“ (dash) and enter to delete a setting from
he schedule. t
4hr format) 02) Hours; time of day (2
03) Minutes; time of day
04) The required table, T01 to T04, or
“-X-“ = Standby (unload all compressors).
# t 12:00
2
An ‘intervals per day’ value will appear and flash. Select
the required number of rotation events per day (1 to 96).
The hour and minutes display will now show the interval
time between each rotation event; 1 = every 24hrs to 96
every 15 minutes (example: 2 = every 12hrs). =
The first automated rotation event each day will
occur at 00:00hrs and then every set rotation interval
time throughout the day.
26
PREFILL
The Prefill feature provides a controlled and energy
efficient method of increasing pressure to normal
operating levels at system start. This feature avoids the
inefficient potential for all available system compressors
to start and load before pressure reaches the normal
perating level. o
At system start (manual start or automated start from
standby) the X12I will only load compressors that have
been pre-determined for prefill operation, for a pre-set
period of time. The prefill time (PT) can be adjusted to
suit system characteristics. The aim is to increase
pressure to normal operational levels, using only the pre-
etermined compressors, prior to the prefill time expiring. d
If normal operational pressure is reached prior to the set
prefill time, the prefill function will automatically cease
and normal operational control begin. If normal
operational pressure is not reached by the end of the
prefill time, the X12I will utilize as many available
compressors as required to achieve normal operational
pressure as quickly as possible. Normal operational
ontrol will then begin. c
Three prefill modes are available. ‘Backup’ and
‘Standard’ modes require compressor pre-selection and
function in the same way; differing only in response to a
failure, or loss, of a prefill compressor. Automatic mode
equires no compressor pre-selection. r
Backup Mode: Compressor(s) can be pre-selected as
‘Primary Prefill’ compressor(s) or ‘Backup Prefill’
compressor(s). If a primary prefill compressor
experiences a shutdown, or is stopped, a pre-defined
ackup compressor replaces it and prefill continues. b
! X
Standard Mode: If one or more of the predefined prefill compressors experiences a shutdown, or is
stopped, the prefill function is cancelled and normal
peration begins. o
A
Automatic Mode: No Prefill compressor
selection is necessary; any selection set is ignored. The
management unit automatically selects compressor(s)
dynamically to achieve pressure in accordance with the
set Prefill time. If a compressor is stopped, or shuts
down, it is automatically substituted with an alternative
ompressor. c
To manually skip Prefill mode, press and hold Start
or several seconds. f
INSUFFICIENT CAPACITY ALARM
CAP
The X12I is equipped with a dedicated ‘Insufficient
Capacity’ Advisory Alarm (Warning) indication. This
indication will illuminate if all available compressors are
loaded and system pressure is continuing to decrease.
The indication will generally occur prior to any set low
pressure Alarm (Warning) and is intended to provide an
dvanced warning of a potential ‘Low Pressure’ situation. a
The ‘Insufficient Capacity’ advisory alarm is intended as
an advanced warning and is not recorded in the fault
history log but is included as a Group Alarm (Warning), or
roup Fault item. G
‘Insufficient Capacity’ is available as a dedicated data
communications item.
can be de-activated. In this instance the unit’s Alarm
indicator will still illuminate but no group alarm, group
fault, or a remote indication is generated.
RESTRICTED CAPACITY ALARM
The ‘Insufficient Capacity’ advisory alarm function
CAP
The X12I is equipped with a dedicated ‘Restricted
Capacity’ Advisory Alarm (Warning) indication. This
indication will flash if all available compressors are
loaded and further capacity is required but one or more,
ompressors are: c
a) inhibited from use in a ‘Table’ priority setting
b) inhibited from use by the short-term Service /
Maintenance function
) inhibited from use in the long term maintenance menu. c
The ‘Restricted Capacity’ advisory alarm is intended to
indicate that all available compressors are already loaded
and further capacity is required but one or more, system
ompressor(s) have been restricted from use. c
The ‘Restricted Capacity’ advisory alarm is not recorded
in the fault history log but is included as a Group Alarm
(Warning), or Group Fault item.
‘Restricted Capacity’ is available as a dedicated data
ommunications item. c
be de-activated. In this instance the unit’s alarm indicator
will still flash but no group alarm, group fault, or a remote
indication is generated.
The ‘restricted capacity’ advisory alarm function can
27
ALTERNATE CONTROL STRATEGIES
Energy Control Mode (ENER) is the STANDARD control
mode of the X12I. Alternate control strategies of the X12I
are EHR (Equal Hours Run) and the basic FILO (First in /
ast Out). L
EHR: EQUAL HOURS RUN MODE
The primary function of EHR mode is to maintain a close
relationship between the running hours of each
compressor in the system. This provides an opportunity
to service all compressors at the same time (providing
the service interval times for all compressors are the
ame or similar). s
EHR is not an energy efficient focused mode of
peration. o
EHR Rotation:
Each time the rotation interval elapses, or the rotation
time is reached, the sequence order of compressors is
reviewed and re-arranged dependant on the running
hours recorded for each compressor. The compressor
with the least recorded running hours is assigned as the
‘duty’ compressor, the compressor with the greatest
recorded running hours is assigned as the ‘last standby’
compressor. For systems with more than two
compressors, the remaining compressor(s) are assigned
in accordance with their recorded running hours in the
ame way. s
Example: The compressors in a four-compressor system
have the following recorded running hours at the
Rotation’ time. ‘
Compressor 1 = 2200 hrs
Compressor 2 = 2150 hrs
Compressor 3 = 2020 hrs
ompressor 4 = 2180 hrs C
The new sequence order arrangement after a rotation
vent would be: e
Compressor 1 = D
Compressor 2 = B
Compressor 3 = A
ompressor 4 = C C
Compressor 3, which has the least recorded running
hours, will now be utilized to a greater extent in the new
sequence arrangement; potentially increasing the running
ours at a faster rate. h
The X12I continuously monitors the running status of
each compressor and maintains a record of the
accumulated running hours. These are available, and
adjustable, in the X12I’s compressor running hour’s
menu. The X12I uses these values in EHR mode. The
X12I’s running hours record should be routinely checked,
and adjusted if necessary, to ensure a close match with
he actual run hours displayed on each compressor. t
If a compressor is operated independently from the
X12I the running hours record may not be accurately
updated.
The running hours meter display on most
compressors are intended for approximate service
interval indication only and may deviate in accuracy over
period of time. a
EHR Control:
Compressors are utilized, in response to changing
demand, using a ‘FILO’ (First In, Last Out) strategy. The
‘duty’ compressor (A) is utilized first followed by (B) if
demand is greater than the output capacity of (A). As
demand increases (C) is utilized followed by (D) if
demand increases further. As demand reduces (D) is the
first compressor to be unloaded, followed by (C) and then
(B) if demand continuous to reduce. The last compressor
to be unloaded, if demand reduces significantly, is (A).
The compressor assigned as (A) in the sequence is the
rst to be loaded and the last to be unloaded. fi
FILO: TIMER ROTATION MODE
The primary function of Timer Rotation mode is to
efficiently operate a compressed air system consisting of
fixed capacity output compressors. The routine rotation
assignments can be modified using ‘Priority’ settings to
accommodate for a differentially sized or variable
apacity output compressor(s). c
FILO Rotation:
Each time the rotation interval elapses, or the rotation
time is reached, a sequence rotation occurs and the
sequence assignment for each compressor is rearranged. The compressor that was assigned for duty (A)
is re-assigned as last standby (D) and all other
ompressor assignments are incremented by one. c
#1
#2
#3
#4
The sequence assignment pattern can be modified by
‘Priority’ settings.
Tables; Priority Settings
FILO Control:
Compressors are utilized, in response to changing
emand, using a ‘FILO’ (First In, Last Out) strategy. d
The ‘duty’ compressor (A) is utilized first followed by (B) if
demand is greater than the output capacity of (A). As
demand increases (C) is utilized followed by (D) if
emand increases further. d
As demand reduces (D) is the first compressor to be
unloaded, followed by (C) and then (B) if demand
continues to reduce.
The last compressor to be unloaded, if demand reduces
significantly, is (A). The compressor assigned as (A) in
the sequence is the first to be loaded and the last to be
unloaded.
1 2 3 4
ABCD
DABC
CDAB
BCDA
28
Loading...