Ingersoll Rand X41 Operator’s Manual

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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.

Ingersoll Rand

X41 System Automation

Operator’s Manual

C.C.N. : 80443617

More Than Air. Answers.

Online answers: http://www.air.irco.com 1

REV. : A

DATE : APRIL 2007

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SECTION 1 — TABLE OF CONTENTS

SECTION 1 — TABLE OF CONTENTS................................ 2

SECTION 2 — INTRODUCTION........................................ 4

SECTION 3 — SAFETY..................................................... 4

INSTALLATION ............................................................ 4

OPERATION................................................................. 4

MAINTENANCE AND REPAIR ........................................ 5

SECTION 4 — COMPRESSOR CONNECTION & CONTROL.. 6

PRESSURE DETECTION AND CONTROL......................... 6

SECTION 5 — DISPLAY AND MENU OPERATION .............. 7

DISPLAY ITEM STRUCTURE .......................................... 9

NORMAL OPERATIONAL DISPLAY (MENU PAGE P00)..... 9

INFORMATION DISPLAYS ............................................. 9

Status Display.......................................................... 9

Sequence Rotation................................................. 10

OPERATIONAL FUNCTIONS........................................ 11

STOP ..................................................................... 11

START ................................................................... 11

POWER FAILURE AUTO-RESTART ............................ 11

FAILURE MODE....................................................... 11

RESET .................................................................... 11

SECTION 6 — CONTROL FEATURES AND FUNCTIONS.... 12

STANDARD CONTROL FEATURES AND FUNCTIONS.... 12

PRESSURE CONTROL .............................................. 12

ANTI-CYCLING CONTROL ....................................... 13

TOLERANCE ........................................................... 13

DAMPING............................................................... 13

SYSTEM VOLUME ................................................... 14

STANDARD SEQUENCE CONTROL STRATEGY.......... 15

FIRST IN LAST OUT MODE (FILO) ............................ 15

SEQUENCE ROTATION EVENTS ............................... 15

ADVANCED CONTROL FEATURES AND FUNCTIONS ... 16

ADVANCED SEQUENCE CONTROL STRATEGIES ....... 16

Variable Energy Control Mode (VEC) ...................... 16

Priority Settings ..................................................... 16

Tables and the Pressure Schedule.......................... 17

Pressure Schedule ................................................. 18

Pre-fill.................................................................... 18

ALTERNATE CONTROL FEATURES AND FUNCTIONS... 20

Equal Hours Run Mode .......................................... 20

First In First Out Mode (FIFO) ................................. 20

SECTION 7 — INSTALLATION ........................................22

Unit Location .............................................................22

Power Supply .............................................................22

Pressure Sensor Location ...........................................22

Generation Side Pressure Control ...........................22

System (Demand Side) Pressure Control .................23

Pressure Sensor Connection ......................................23

IR-PCB Interface Module.............................................23

Input Functions .........................................................24

Ready Input ............................................................24

Ready Input, Alternative Connection Method ..........25

Run Input ...............................................................26

Warning Input (optional).........................................27

Output Functions.......................................................27

Pressure Switch Regulation.....................................28

Digital Regulation Control Terminal C01 ................29

Service Maintenance Switch ....................................30

Auxiliary Input (Option)..........................................30

Auxiliary Output (Option) .......................................31

RS485 Communications .........................................31

SECTION 8 — FAULT CODES..........................................32

X4I Compressor Fault Indications, Types, and Codes:32

Alarm (Warning) .....................................................32

Not Available..........................................................32

Compressor Inhibited, Removed From Service........33

Service/Maintenance ..............................................33

Communications Disruption ...................................33

Special Controller Fault Codes................................33

Error Log ................................................................33

SECTION 9 — Commissioning .......................................35

Physical Checks .........................................................35

Pressure Display ........................................................35

X4I Quick Set-up Configuration..................................35

SECTION 10 — System Configuration............................36

Accessing the X4I Configuration Screens ...................36

User Configuration: Tab S01......................................37

Real Time Clock Settings ........................................37

Pressure Schedule Settings.....................................38

Auto Restart Settings..............................................39

Rotation Interval Settings .......................................40

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Table Select Settings ............................................. 41

Backlight Adjust Settings ....................................... 42

User Configuration: Tab S02..................................... 42

Units Settings ........................................................ 43

Number of Compressors Settings .......................... 43

Maximum Pressure Alarm Settings ........................ 44

Stop Control Settings............................................. 45

Tolerance Settings ................................................. 46

Damping Settings .................................................. 47

Pressure Change Settings ...................................... 47

Auxiliary Input Settings ......................................... 48

Auxiliary Output Settings ...................................... 49

Error Log Reset...................................................... 50

User Configuration: Tab S03..................................... 50

Pressure Sensor – Offset ........................................ 51

Pressure Sensor – Range Settings .......................... 51

Compressor Configuration: Tab C01 ........................ 52

Compressor Run Hours ......................................... 53

Compressor Configuration: Tab C02 ........................ 53

Compressor Connection Method ........................... 54

Compressor Table Configuration: Tab T01 ............... 57

High Pressure Setpoint Settings............................. 57

Low Pressure Setpoint Settings .............................. 58

Minimum Pressure Alarm Settings ..........................58

Sequence Strategy Settings.....................................59

Compressor #1 Priority Settings .............................60

Compressor #2 through 4 Priority Settings.............60

Pressure Schedule Configuration P01 Tab Screen ......61

Pressure Schedule Settings.....................................61

Pre-fill Configuration P02 Tab Screen .....................62

Pre-fill Function Settings.........................................63

Pre-fill Time Settings ..............................................64

Pre-fill Pressure Settings.........................................65

Pre-fill Compressor #1 Settings ..............................65

Pre-fill Compressor #2 through 4 Settings..............66

Diagnostics D01 Tab Screen ......................................67

Diagnostics Settings...............................................67

X4I Controller Diagnostics......................................68

Digital Inputs .........................................................68

Relay Outputs.........................................................68

Analog Inputs.........................................................69

Analog Output........................................................69

Total Unit Reset and Default Values........................69

Parts List.......................................................................73

Technical Data ..............................................................74

Diagrams ......................................................................75

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SECTION 2 — INTRODUCTION

The X4I is a specialized controller designed to provide safe, reliable, and energy-efficient control of your compressed air system. The X4I is capable of controlling up to four positive displacement air compressors. The compressors may have electro-pneumatic or microprocessor based controls. The X4I is completely customizable to meet the specific needs of your compressed air system.

SECTION 3 — SAFETY

WARNING :

• Before installing or operating the X4I, take time to carefully read all the instructions contained in this

manual, all compressor manuals, and all manuals of any other peripheral devices that may be installed or connected to the unit.

• Electricity and compressed air have the potential to cause severe personal injury or property damage.

• The operator should use common sense and good working practices while operating and maintaining this

system. All applicable codes should be strictly adhered to.

• Maintenance must be performed by adequately qualified personnel that are equipped with the proper

tools.

INSTALLATION

• Installation work must only be carried out by a competent person under qualified supervision.

• A fused isolation switch must be fitted between the main power supply and the X4I.

• The X4I 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 X4I, 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

OPERATION

• The X4I must only be operated by competent personnel under qualified supervision.

• Never remove or tamper with safety devices, guards or insulation materials fitted to the X4I.

• The X4I 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

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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 only be carried out by competent personnel under qualified

supervision.

• If replacement parts are required, use only genuine parts from the original equipment manufacturer, or an

alternative approved source.

• Carry out the following operations before opening or removing any access panels or carrying out any work

on the X4I:

i. Isolate the X4I from the main electrical power supply. Lock the isolator in the “OFF” position and

remove the fuses.

ii. 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 X4I 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 X4I 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.

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SECTION 4 — COMPRESSOR CONNECTION AND CONTROL

Each air compressor in your system can be interfaced to the X4I using the included IR-PCB interface modules. Any compressor with an available control voltage of 12-250V (either 50Hz or 60Hz) can be controlled by the X4I.

The interface module is mounted inside the compressor’s starter panel and connected to the X4I by using a shielded 7conductor cable, or individual cables run through conduit.

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 switch.

Consult the air compressor manual or your air compressor supplier/specialist for details before installing the X4I.

PRESSURE DETECTION AND CONTROL

The X4I utilizes the signal from a 4-20 ma pressure sensor that is mounted remotely from the X4I in a suitable location in the compressed air system.

The factory default settings for the pressure sensor is 0–232 PSI (16 bar), but the X4I can accept any pressure sensor with a 4–20 ma output and a range of up to 8700 PSI (600 bar).

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SECTION 5 — DISPLAY AND MENU OPERATION

The Main Display and the keypad and navigation buttons on the X4I are depicted below and provide the following functionality:

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DISPLAY ITEM STRUCTURE

Operational system status and values are accessible from the normal user display. To view status or values that are not normally visible on the default screen, press UP or DOWN. All standard user display items are viewable only and cannot be adjusted. The standard user display items are regarded as “Menu Page 00” items.

All adjustable value, parameter or option item displays are grouped into “menu mode” lists. Items are assigned to a list according to type and classification. Item lists are identified by page number (or menu number). All adjustable parameters and options are assigned to menu mode pages “P01” or higher.

NORMAL OPERATIONAL DISPLAY (MENU 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 three seconds before initialization is complete and the normal operating display (“Page P00”) is shown. In normal operational display mode, the main display will continuously show the detected system pressure and the Item display will show the first item of the “Page 00” 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 be shown. 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 and can be viewed by pressing UP or DOWN. The most recent “active” fault will be at the top of the list.

Main Status Screen

INFORMATION DISPLAYS

To view detailed information applicable to the selected User menu display item press the ENTER button:

STATUS DISPLAY

P00

Status Display Screen

18:00 T02

102 98 80

psi psi psi

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If the ‘Pressure Schedule’ feature is active; shows the day of the week (#1), the time of day (18:00) and the table to be

used (T02) of the next scheduled instruction to be executed.

The current active ‘Table’ (T01)

Upper, or unload, pressure setpoint

Lower, or load, pressure setpoint

Minimum pressure Alarm (Warning)

Press the ESCAPE

SEQUENCE ROTATION

button to return to the normal operational display screen.

P00

#4 18:00

18 / 05 / 2006

A B C D

Sequence Rotation Display Screen

Day of the week (#4: Thursday), the time of day (18:00) and the date (18/05/2006) of the next automated sequence rotation event.

The active ‘mode’ of operation

ABCD The current active rotation sequence assignment.

Press the ESCAPE

button to return to the normal operational display screen.

NOTE: The sequence assignment can be manually rotated at any time. When viewing the “Sequence Rotation” information

screen press the ENTER button. The manual rotation symbols will appear and flash. Press the ENTER

button to execute a manual rotation or the ESCAPE button to abandon the manual rotation.

Automated sequence rotation is not disrupted by a manual rotation; the next scheduled automated sequence rotation event will still occur.

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OPERATIONAL FUNCTIONS

STOP

To stop the X4I, press STOP. Dependent on the setup and configuration of the X4I, the compressors will function as follows:

• If parameter PC=0, then pressure regulation control is automatically transferred back to each compressor.

The compressor(s) will continue to operate using the pressure settings programmed or set in the individual compressor controller(s).

• If parameter PC=1, then the X4I will hold each compressor in an offload state. If the compressor is

equipped with a main motor run-on-time function, the compressor will run offload for a period of time and then stop into a “standby” or “auto restart” state.

The design of some air compressor control systems may inhibit automatic transfer of pressure regulation control to local operation mode. In this instance, the compressor will not continue production of compressed air. Consult the air compressor manual or your air compressor supplier/specialist for details before installing the X4I.

START

To start the X4I, press START. If the pre-fill function is enabled, and system pressure is below the set pre-fill pressure, the system will enter pre-fill mode for the set pre-fill time.

See the section on pre-fill for more information.

To manually skip the pre-fill function, press and hold START for several seconds. When pre-fill is complete, if applicable, the X4I will enter normal operating mode. The X4I will operate in accordance with the parameters and options set in the active “table”.

See the section on tables for more information.

Each compressor in the system must be started (running or in a standby or auto restart condition) before X4I control of the compressor can be established. The X4I will not start a compressor that is in a stopped condition.

POWER FAILURE AUTO-RESTART

If the power failure auto-restart function is enabled, the X4I will automatically start when power is restored after a disruption or failure, if the X4I was in a “started” state when the power disruption or failure occurred.

NOTE: The X4I will not automatically restart if the X4I was in a stopped state when the power disruption or failure occurred.

FAILURE MODE

If the X4I experiences a disruption to normal control, or an X4I shutdown fault occurs, pressure regulation control is automatically transferred back to each compressor. The compressor(s) will continue to operate using the pressure settings programmed or set in the individual compressor controller(s).

RESET

To reset an X4I alarm (warning) or shutdown condition, press RESET. Compressor alarm (warning) conditions are automatically reset when the condition has been resolved and reset on the compressor. “Compressor not available” (shutdown, trip) conditions are automatically reset when the condition has been resolved and reset on the compressor and the compressor has been restarted.

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SECTION 6 — CONTROL FEATURES AND FUNCTIONS

STANDARD 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 compressor’s output.

Simply stated, pressure control is achieved by unloading and loading compressors to closely match compressor output with system demand within a specified pressure band.

Variable speed compressors also operate within the pressure band and actively match compressor output with demand by speeding up and slowing down around a target pressure defined by the exact midpoint of the pressure band.

Refer to the illustration below. The X4I functions by keeping the system pressure inside of an acceptable pressure range defined by the user. Compressors will load and unload in order to keep the pressure between the high pressure setpoint (PH) and the low pressure setpoint (PL), both of which are user adjustable. The pressure control algorithms will attempt to keep the pressure toward the midpoint of this pressure band. This midpoint is known as the system target pressure (PT).

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 X4I will load the next compressor in the sequence to match the air demand. This cycle will repeat as long as the X4I is able to keep the system air pressure between PH and PL.

When a compressed air system includes one or more variable speed compressors, each variable speed compressor must have its target pressure (on its local controller) set to the system target pressure.

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 speed compressor.

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.

Refer to the illustration below. If the system demand increases significantly or quickly and the capacity of the loaded compressor is insufficient to meet the demand, the system pressure will continue to decline at a slower rate. The X4I will then calculate the instant at which the next compressor is to be loaded. This instant, at point “c”, is dependent on the rate of change of the system pressure and the user adjustable anti-cycling control settings.

Compressor Supply is Insufficient to Maintain System Pressure

The same logic will come into effect if the system pressure rises above the PH setpoint due to a significant or abrupt reduction in demand.

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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 X4I. 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.

ANTI-CYCLING CONTROL

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-unload-stop, etc.) is essential to maintain pressure control. Excessive cycling, however, can result in poor compressor efficiency as well as increased maintenance.

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. Anti-cycling 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 ageratum 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 band settings and algorithm processing time (damping).

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 X4I from overcompensating in the event of a temporary significant increase or decrease in system demand.

PH + TO

PL - TO

Tolerance in Relation to PH and PL

Tolerance is expressed as a pressure defining the width of band above PH and below PL in which energy efficient control will still be in effect.

When system pressure is in the tolerance band, the X4I 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 X4I will abandon energy efficiency and begin to protect the system air pressure at all costs.

Tolerance will essentially calculate a new PH or PL setpoint based on the rate of change of the pressure and wait as long as possible to load or unload a compressor while still maintaining the integrity of the system pressure.

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 loaded just to be unloaded moments later.

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. This setting is user adjustable from 1.4 to 29.0 PSI.

DAMPING

When the X4I has loaded or unloaded a compressor in response to a pressure change, and the system pressure does not return to the pressure band between PH and PL, then the X4I needs to calculate how much time it has until it needs to load or unload an additional compressor. The damping (DA) setting is a user adjustable setpoint that determines how quickly or slowly the X4I will load or unload an additional compressor.

The X4I’s factory default setting for DA 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 changes:

• Inadequate air storage

• High pressure differential across the air treatment equipment

• Incorrectly sized piping

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• Slow or delayed compressor response

In these circumstances, the X4I 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 X4I is still overreacting, then increasing the damping factor is the next step.

Damping will control how quickly the tolerance algorithms recalculate the PH or PL setpoint in order to increase or decrease the response time of the system.

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 reaction time 10 times slower than the default.

SYSTEM VOLUME

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 air receivers.

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 conditions.

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.

The following formula determines the recommended minimum storage volume for a compressed air system:

V “volume required” = T “time of the event” (C “demand” x Pa “atmospheric pressure”)

Delta P “pressure drop”

Example: T=15 Seconds (.25 minute), C=92 ft

4 - 25 hp compressors at 92 CFM (2.6 m

, Pa = 14.5 PSI (1bar), Delta P = 5 PSI

) each / 15 seconds to start and load a compressor.

V = [.25 x (92 x 14.5)]/5

V = (.25 x 1334)/5

V = 333.5/5

V = 67

Gal = 67 x 7.48

Gal = 498.9

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STANDARD SEQUENCE CONTROL STRATEGY

The standard configuration of the X4I provides FILO (First In/Last Out) sequence control strategy.

The sequence control strategy consists of two components:

• The compressor rotation strategy

• The compressor load control strategy

The rotation strategy defines how the compressors are arranged in a new sequence whenever a rotation event occurs. Rotation events are triggered by a periodic rotation based on a set interval, a set time of day each day, or a set time of day once a week.

The compressor load control strategy defines when compressors load and unload based on system pressure variations and whether they run in fixed or variable speed modes.

Each compressor in a system will be assigned a permanent number based on where they are wired into the terminal PCB. Compressor 1 will always be wired into terminal X01; compressor 2 will always be wired into terminal X02, etc.

Each compressor will also be assigned a letter from A to D based on its location in the sequence:

• A = the base load compressor (the first compressor to be used).

• B = the first trim compressor (the second compressor to be used).

• C = the second trim compressor (the third compressor to be used).

• D = the third trim compressor (the last compressor to be used).

Compressor sequence assignments are reviewed and dynamically changed at a rotation event based on the sequencing strategy that is selected.

FIRST IN LAST OUT MODE (FILO)

The default configuration of the X4I provides FILO (First In/Last Out) sequence control strategy.

The primary function of FILO (First In/Last Out) mode is to efficiently operate a compressed air system consisting of fixed speed compressors. The standard FILO rotation assignments can be modified using priority settings, which are explained later in this section.

Whenever a rotation event occurs, the sequence assignment for each compressor is rearranged. The compressor that was assigned as the base load compressor (A) is reassigned to third trim compressor (D) and all other compressors are incremented by one.

1 2 3 4

ABCD

DABC

CDAB

BCDA

Sequence Rotation Table

SEQUENCE ROTATION EVENTS

A sequence rotation event can be triggered in the following ways: a periodic interval, a pre-determined time each day, or a pre-determined time day and time each week.

Please refer to the Quick Setup Manual to determine how to configure the rotation events.

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ADVANCED CONTROL FEATURES AND FUNCTIONS

ADVANCED SEQUENCE CONTROL STRATEGIES

The advanced configuration of the X4I provides VEC (Variable Energy Control) sequence control strategy, priority settings, table selection, and pre-fill operation.

VARIABLE ENERGY CONTROL MODE (VEC)

The primary function of VEC mode is to accommodate a variable speed compressor connected to the X4I using an IRV-PCB interface.

VEC mode utilizes the FILO sequencing and rotation strategy with the additional control philosophy needed to efficiently control variable speed compressors.

In any set rotation sequence, the variable speed compressor that is assigned closest to A will be utilized in trim mode and will be allowed to throttle based on its local target pressure setpoint and the variations in system pressure. Any other variable speed compressors in the system will be held in fixed speed mode to prevent multiple variable speed compressors from oscillating.

The compressor that is allowed to run in variable speed mode will be evaluated at each rotation event.

Compressors are brought on or offline in response to changing demand using the FILO strategy. The base load compressor (A) will be brought online first in the case of system pressure dropping below the low pressure setpoint. If pressure continues to drop, the first trim compressor (B) will also load. Compressors C and D will load in that order if needed. When system pressure rises above the high pressure setpoint, the last compressor to load will now be the first to be unloaded. Compressors C, B, and A will be unloaded, in that order, if system pressure continues to increase.

Compressor A will always be the first to be loaded and last to be unloaded.

PRIORITY SETTINGS

The sequence assignment pattern can be modified by using the priority settings.

Priority settings can be used to modify the rotation sequence assignments. Compressors can be assigned a priority of 1 to 4, 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 priority will always be in the front of the sequence.

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 base load 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

ABCD

ACDB

ADBC

ABCD

Compressor 1 has priority 1, all other compressors have priority 2

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:

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1 2 3 4

1112

ABCD

BCAD

CABD

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

ABCD

ACBD

ABCD

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:

1 2 3 4

1122

ABCD

BADC

ABCD

BADC

Two independently rotating compressor groups

T01

- - - -

TABLES AND THE PRESSURE SCHEDULE

- - - -

The X4I operates based on settings that are configured into one of three tables. Each table defines the operational settings and sequence control mode of the X4I. The X4I can be instructed to change among the tables at any time based on the configuration of the pressure schedule.

This functionality allows the X4I 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

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• PL – Low Pressure Setpoint

• Pm – Minimum pressure warning level

• SQ – Sequence Rotation Strategy

• 01 – Compressor 1 Priority

• 02 – Compressor 2 Priority

• 03 – Compressor 3 Priority

• 04 – Compressor 4 Priority

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.

When the X4I is instructed to change between tables, it will not abruptly change the system operating parameters. The X4I 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:

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. See the Quick Setup Manual.

If the X4I 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 X4I is equipped with a real-time clock feature and pressure schedule functionality. The pressure schedule function can be used to provide system automation.

The pressure schedule consists of 28 individual settings that instruct the system to change from one table to another, or put the system into standby mode dependent on the time of day and the 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 calendar week.

The pressure schedule has the capability of changing tables based on the time of day, once each day, and once each day except weekends. Please see the Quick Setup Manual for detailed information on how to configure the pressure schedule.

Changing Target Pressures

PRE-FILL

The pre-fill feature provides an energy efficient method of increasing pressure to normal operating levels upon system start. This feature avoids the inefficient potential for all compressors to start and load in an attempt to quickly get the system pressure up to normal levels:

System pressure during pre-fill

Page 19

At system start (manual start or automated start from standby), the X4I will only load compressors that have been pre-set for pre-fill operation, for a pre-set period of time. The pre-fill time (PT) can be adjusted to suit system characteristics. The aim is to increase pressure to normal operational levels, using only the pre-determined compressors, prior to the pre-fill time expiring.

If normal operational pressure is reached prior to the set pre-fill time, the pre-fill function will automatically cease and normal operational control will begin. If normal operational pressure is not reached by the end of the pre-fill time, the X4I will utilize as many available compressors as required to achieve normal operational pressure as quickly as possible. Normal operational control will then begin.

Two pre-fill modes are available. Both function in the same way but differ in response to a failure, or loss, of a pre-fill compressor.

•

Backup Mode: Compressor(s) can be pre-selected as “primary pre-fill” compressor(s) or “backup pre-fill” compressor(s). If a primary pre-fill compressor experiences a shutdown, or is stopped, it is replaced by a pre-defined backup compressor and pre-fill continues.

•

To manually skip pre-fill mode, press and hold START for several seconds.

! X

Standard Mode: If one or more of the pre-defined pre-fill compressors experiences a shutdown,

or is stopped, the pre-fill function is cancelled and normal operation begins.

Page 20

ALTERNATE CONTROL FEATURES AND FUNCTIONS

The alternate configuration of the X4I provides EHR (Equal Hours Run) and FIFO (First In/First Out) sequence control strategy.

EQUAL HOURS RUN MODE

The primary function of EHR mode is to keep the running hours of all compressors in the system as close as possible. This provides the opportunity to service all of the compressors at the same time, given that the expected service interval for the compressors is similar.

EHR is not an energy efficient focused mode of operation.

Each time a rotation event occurs, the compressor sequence is examined and will be rearranged based on the running hours recorded for each compressor. The compressor with the fewest running hours is assigned as the base load compressor and the compressor with the most running hours is assigned as the third trim compressor. For systems with more than two compressors, the compressors will be assigned from A to D in accordance with increasing running hours.

Example: The compressors in a four compressor system have the following recorded running hours when a rotation event occurs:

• Compressor 1 = 2200 hours

• Compressor 2 = 2150 hours

• Compressor 3 = 2020 hours

• Compressor 4 = 2180 hours

The new sequence order after the rotation event would be:

• Compressor 1 = D

• Compressor 2 = B

• Compressor 3 = A

• Compressor 4 = C

Compressor 3, which has the fewest running hours, will now be utilized more frequently in the new sequence, allowing running hours to accumulate at a faster rate.

The X4I continuously monitors the running status of each compressor and calculates the accumulated running hours. These readings are viewable and adjustable in the X4I C01 setting screens. The X4I will use these values during EHR mode. The running hours on the X4I should be routinely checked to see that they match the compressors’ local calculations, and adjusted if necessary.

If a compressor is operated independently from the X4I, 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 a period of time.

Compressors will be utilized following the FILO strategy.

FIRST IN FIRST OUT MODE (FIFO)

The primary function of FIFO mode is to keep a compressor loaded for the longest amount of time possible in order to minimize starts and stops on the motor. The compressors will continuously share pressure regulation.

FIFO is not an energy efficient focused mode of operation.

FIFO does not follow sequence rotation events. Compressors are rotated each time a compressor is loaded. The rotation strategy becomes the control strategy using the control mode.

When system pressure drops below the low pressure setpoint, compressor 1 (A) will be the first to load as usual. If system pressure continues to decrease, compressor 2 (B) will be loaded and be reassigned to (A) while compressor 1 is reassigned

Page 21

as (D). If this causes system pressure to rise above the high pressure setpoint, then compressor 1 (D) will be unloaded to allow compressor 2 (A) to maximize its run time. If system pressure decreases further, compressor 3 will be loaded and reassigned to (A) while Compressor 2 is reassigned to (D) and so on.

The most recently loaded compressor will always be assigned (A) and the longest running compressor will always be assigned (D).

ABCD DABC DABC CDAB BCDA BCDA ABCDBCDA

FIFO Rotation

Page 22

SECTION 7 — INSTALLATION

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

UNIT LOCATION

The X4I can be mounted on a wall using conventional bolts. The X4I can be located remotely from the compressors as long as it is within 330 feet (100 meters) of cable length. The X4I must also be located within 330 feet (100 meters) of the system pressure transducer.

POWER SUPPLY

A fused switching isolator must be installed to the main incoming power supply, external to the X4I. 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).

1234

X01

LNE

XPM-TAC24

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.

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 compressors.

GENERATION SIDE PRESSURE CONTROL

Pressure Sensor Located Before Cleanup Equipment

Demand 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 increases.

Page 23

SYSTEM (DEMAND SIDE) PRESSURE CONTROL

Pressure Sensor Located After Shared Cleanup Equipment

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.

Regular routine monitoring of pressure differential across air treatment equipment is recommended.

PRESSURE SENSOR CONNECTION

The pressure sensor connects to terminal X05 of the X4I terminal PCB using a shielded 18 AWG maximum 2-conductor cable no more than 330 feet (100 meters) in length.

X05

26 25

Wire polarity is important.

Pressure Sensor Wiring and Location

4-20mA

IR-PCB INTERFACE MODULE

The IR-PCB is designed to interface a compressor with the X4I using a 7-conductor shielded cable no greater than 330 feet (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 operational reference.

For each compressor utilizing an IR-PCB, connection to the X4I the signal wires must be made to the correct X4I terminals for that compressor number. Compressor 1 should be wired to terminal X01 on the terminal PCB, Compressor 2 should be wired to terminal X02 on the terminal PCB, etc.

Page 24

IR-PCB Interface Module

The IR-PCB is a DIN rail mountable module designed to be installed within the compressor starter enclosure.

Each air compressor must be equipped with a load/unload regulation system and, if not regulated with a single electromechanical pressure switch, have a facility for a remote load/unload control with the ability to accept a volt-free switching contact input for remote load/unload.

For variable speed compressor(s) equipped with a “variable/fixed” digital input function, install a 7-conductor shielded cable from the IR-PCB to the X4I.

Consult the air compressor manual or your air compressor supplier/specialist for details before installing the X4I.

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 switch.

The IR-PCB accepts a 12V to 250V input voltage detection system and utilizes universal relay contact control outputs (250V “CE” / 115V “UL” @ 5A maximum) integrated directly into the circuits of an air compressor. The IR-PCB avoids the need for additional relays or remote inputs. The IR-PCB also acts as an electrical barrier between the compressor and the X4I providing protection and voltage isolation.

INPUT FUNCTIONS

The IR-PCB is fitted with a six-pin terminal, C04, for compressor monitoring. The IR-PCB uses two inputs, Ready and Run, to determine compressor status. An alarm input can be used if compressor warning indication is available and required. The alarm input is optional and is not necessary for system operation.

READY INPUT

The ‘Ready’ connection is intended to indicate that the compressor is in a “started” state, has no alarm condition that has shut down the compressor, and is ready to respond to X4I regulation without manual intervention.

Page 25

READY LAMP

ALARM

RUN

C04

READY

Typical Ready Input Wiring

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

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

This input must be connected to a circuit of the compressor control system that will be energized when the compressor is in a started (standby or running) condition. For example, locate the circuit across the ready or operating lamp as shown.

The voltage to this input must de-energize when the compressor is stopped and unavailable to produce air upon a load signal, or the emergency stop button is pressed, or when the compressor experiences a fault that prevents the compressor from running.

When the compressor ready lamp or other control circuit is energized, the IR-PCB will detect the voltage and signal the X4I that the compressor is ready and available to load and produce air when a load request signal is given.

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

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 voltage (12V to 250Vac or dc). This will signal the X4I that the compressor is ready and available at all times when power is applied to the compressor. The X4I has a built-in function to determine when a compressor is not responding, or is in a shutdown condition, even if the “ready” signal says otherwise. If the X4I requests a compressor to run/load, but fails to detect a RUN signal within 60 seconds, the X4I will regard the compressor as “not ready” and indicate the compressor as not available. If a RUN signal is reacquired at any time, the X4I will automatically reset the compressor “not ready” condition and re-establish control.

+Vac

0Vac

READY

Alternative Ready Signal Connection

Never connect the “Ready” input positive voltage 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.

Page 26

RUN INPUT

MAIN (LINE) CONTACTOR

READY

ALARM

RUN

C04

Run Signal Circuit

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

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.

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 X4I that the compressor is running.

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.

MAIN (LINE) CONTACTOR

AUXILIARY SWITCH

ALARM

RUN

C04

READY

Run Signal Circuit with Auxiliary Switch

In instances where a motor starter contactor is not available or accessible, any part of a compressor control circuit that is energized when the compressor is running can be monitored. For example: fan contactor or voltage signal to a remote starter.

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

Page 27

WARNING INPUT (OPTIONAL)

The IR-PCB is equipped with a warning input that can be used to detect warning conditions.

An alarm that stops the compressor, and/or prevents the compressor from running is determined from the “run” and “ready” inputs. Warning detection is optional and is not a requirement.

Alarm Lamp

Alarm Run Ready

C04

Warning Input Circuit

The warning input will accept 12V to 250V AC (50/60Hz) or DC.

Do not connect a voltage greater than 250Vac/DC to this input.

This input can be connected to the terminals of an alarm lamp or other accessible part of the control circuit that is energized when the compressor is in a warning condition.

If a warning condition is experienced the compressor warning lamp, or warning circuit, will energize. The IR-PCB will detect the voltage and signal the X4I that a warning has occurred. If the compressor has no accessible warning circuit, or this function is not required, the IR-PCB alarm terminals can be ignored.

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

OUTPUT FUNCTIONS

The X4I will control the IR-PCB load/unload relay outputs based on the active system load and unload pressure setpoints. The IR-PCB load/unload relay contacts can be used for compressor controllers that have electro-mechanical pressure switch load/unload regulation.

Page 28

OUT

VFD/Fixed

OUT

+VDC

Local/Remote

Load/Unload

IN NC

IN C

VFD

Relay

SEQ

Relay

1&2

LOAD Relay

C03

VFD

SEQ

CONT

LOAD

UNL

GND

+20VDI2DI1

135V246

24Vac

IR-PCB Internal Output Circuits

The C01 and C02 terminals of the IR-PCB are intended to control load and unload regulation of the compressor.

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 can be switched in and out of circuit automatically. If the X4I 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 local pressure settings of all compressors in the system should be set in a cascaded manner such that the system will operate normally in the event of X4I inoperability.

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.

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

LOAD

SOLENOID

OUT

C02

Two Wire Pressure Switch Connections

Page 29

LOAD

SOLENOID

RUN-ON

TIMER

CNC

OUT

C02

O N

Three Wire Pressure Switch Connections

DIGITAL REGULATION CONTROL TERMINAL C01

A 4-pin connector, C01, has been provided for air compressor controllers fitted with digital inputs allowing remote pressure regulation control.

This terminal provides volt free contact closure, referenced to a common terminal pin, for:

• Remote Load Enable (remote/local pressure regulation control)

• Remote Load (remote load/unload)

• Remote Variable Speed Regulation Inhibit (remote variable/fixed speed regulation control)

The “remote load enable” function provides the facility to change the compressor load regulation from internal control to a remote switching source (local/remote).

The “remote variable/fixed” function provides for multiple variable speed compressor regulation control on variable speed compressor(s) equipped with this facility.

When using the “Variable/Fixed” function, the “V” terminal of the IR-PCB must be connected to the appropriate “V” terminal of the X4I (according to compressor number) with an additional wire. Use a 7-conductor shielded cable in this instance.

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 X4I is stopped or experiences a fault or loss of power.

+VDC

VFD/Fixed Load Enable Load/Unload

+VDC

VFD/Fixed Load Enable Load/Unload

ir-PCB

Load, Sequence, and VFD Connections

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

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. 29

Page 30

For Example:

If the compressor controller “Local/Remote Pressure Control” input is a normally open type (local when open, 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

C NC NO

C NC

Local/Remote

common

Remote Load

common

Alternate Logic

Examine the “i-PCB” internal output circuit diagram to establish any desired switching logic that may differ from normal practice.

Do not attempt to utilize “Digital Pressure Regulation Control” (terminal C01) and the “Pressure Switch Control” (terminal C02) output connections at the same time for different products. These two output functions are internally connected and a short circuit condition and/or malfunction may result.

The IR-PCB connection examples shown in this manual are intended to provide a guide for the majority of compressor control systems in use. Some compressors have variations in operation and/or function; consult your compressor supplier/specialist for advice.

SERVICE MAINTENANCE SWITCH

The IR-PCB is equipped with a volt-free input (terminal C05) that can be used to remove the compressor from X4I control, without generating a fault condition, during short-term maintenance or servicing periods.

C05

Service Maintenance Switch Circuit

When the “Service Maintenance Switch” input terminal pins are connected together using a volt-free switching contact, the X4I will indicate that the compressor is not available but will not generate a warning, alarm, or shutdown condition. The X4I will also remove the compressor from the sequence strategy and substitute with an alternative available compressor if necessary. When the “Service Maintenance Switch” input circuit is open again, the compressor will automatically be accepted back in to the sequence strategy and will be utilized when next required.

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.

AUXILIARY INPUT (OPTION)

The X4I is equipped with an auxiliary input at terminals 31 and 32 (X07).

The function of the input is menu selectable and can be adapted for differing application requirements.

X07

32 31

Page 31

Auxiliary Input Circuit

The input is designed to detect a remote “volt-free” switching contact (rated for a minimum 24VDC @ 10mA).

AUXILIARY OUTPUT (OPTION)

The X4I is equipped with a remote relay contact output at terminals 33 and 34 (X08).

The function of the output is menu selectable and can be adapted for differing application requirements.

X08

Auxiliary Output Circuit

The remote output relay contacts are rated for 240V “CE” / 115V “UL” @ 5A maximum.

RS485 COMMUNICATIONS

The X4I is equipped with an RS485 network communications capability using the Multi485 protocol. This can be used for remote connectivity to optional networked units and modules with Multi485 communications capabilities.

X06

L1 L2

30 29 28

L1 L2

RS485

RS-485 Connection Circuit

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 shielded cables, securely bonded to a known ground at one end. In addition, give careful consideration to cable routing during installation.

• 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.

• If it is necessary to follow the route of power supply cables for a short distance (for example: from a

compressor to a wall along a suspended cable tray), attach the RS485 or signal cable on the outside of a grounded cable tray such that the cable tray forms a grounded electrical interference shield.

• 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.

Page 32

SECTION 8 — FAULT CODES

In the event of a unit or system “fault” the X4I will display a fault code. The fault code becomes an item in the user operational display menu. If more than one “active” fault occurs, each will be displayed as a separate item in the operational user menu. Press UP or DOWN to view all active fault codes or to view the normal status display.

Alarm (Warning)

Shutdown (Trip)

Fault codes are separated into unit faults (ERR) and system alarms (warning) (SYS).

Each fault type has a unique numeric code.

ERR.01

ERR.04

ERR.05 Emergency Stop

ERR.06

SYS.01

SYS.02

SYS.04

Compressor fault states are displayed as part of the normal operational status display and do not generate fault

codes. Examine the applicable compressor unit to establish the nature or description of the detected fault condition.

Pressure Sensor

Internal 24V Fault

Real Time Clock Error

Excess Pressure (PM)

Min Pressure (Pm)

Insufficient Capacity

X4I COMPRESSOR FAULT INDICATIONS, TYPES, AND CODES:

Compressor fault conditions are displayed on the user compressor status screen and are not regarded as X4I unit fault conditions.

Compressor fault conditions are displayed symbolically on the main User compressor status screen.

ALARM (WARNING)

• The Alarm input on the “ir-PCB” has been activated.

• The compressor, or remote compressor interface unit, is reporting a general or group alarm condition on

the RS485 network (RS485 network connectivity only).

The X4I fault LED will “slow flash”.

The alarm (warning) symbol will alternate with the normal compressor status symbol every two seconds.

NOT AVAILABLE

The compressor is reporting a general or group trip (shutdown) condition. The compressor has been stopped and taken out of service, power to the compressor has been isolated/lost or the compressor is not communicating.

• The ready input of the “ir-PCB” is no longer active.

• The run input of the “ir-PCB” is no longer active while the compressor is being requested to run loaded.

• The run input of the “ir-PCB” did not activate within 60 seconds of a load request.

• The compressor is reporting a general or group shutdown or stopped condition (RS485 network

connectivity only).

Page 33

• The remote compressor interface unit is in a shutdown condition (RS485 network connectivity only).

The X4I fault LED will “fast flash”.

The “not available” symbol will “slow flash”.

# COMPRESSOR INHIBITED, REMOVED FROM SERVICE

Set in the X4I active “table” (# = table number 1, 2 or 3) as inhibited from use.

In this condition, the status of the compressor is still monitored. The X4I fault LED will not illuminate or flash unless an actual alarm (warning) or trip (shutdown, not available) condition occurs.

The two symbols will alternate every two seconds.

SERVICE/MAINTENANCE

Inhibited from use by the user using the “ir-PCB” service/maintenance function.

In this condition, compressor fault conditions are ignored. The X4I fault LED will not illuminate or flash.

COMMUNICATIONS DISRUPTION

Network communications with the compressor have been disrupted/lost.

Note: only applicable where the compressor is integrated with the X4I using the RS485 communications network.

SPECIAL CONTROLLER FAULT CODES

• E0836 PLL Unlock Internal failure or excessively high external electrical interference

• E0866 Controller internal power supply fault

• E5000 Internal memory map error

• E5001 Internal memory failure

ERROR LOG

E01

- : - - - . - -

01 E : ERR . 01

02 03 04

The error log is presented in chronological order. Entry 01 is the most recent, whereas entry 15 is the oldest. Each error

log item will show the error code. To view details for the selected error log item, press the ENTER

E01

01.01

- : - - - . - -

Error Log Screen

button.

E: ERR.01

16/05/2006 14:25

First Error Log Information Screen

Page 34

The first error information display shows:

• The error code

• Error code symbols (if applicable)

• The date the error occurred

• The time the error occurred

• The active operational functions of the X4I at the time the error occurred; (see: X4I Status Display for

Icons)

To view the second error information screen, press the ENTER

press the ESCAPE

button.

E01

01.01

button. To return to the main error log menu screen,

1 2 3 4

Second Error Log Information Screen

The operational status of each compressor, at the time the error occurred, is displayed symbolically. See Compressor Status Displays for Icons.

To return to the first information screen press the ENTER

error log menu screen press the ESCAPE

button.

button or the ESCAPE button. To return to the main

Page 35

SECTION 9 — COMMISSIONING

When commissioning the X4I, carry out the following procedures before attempting to start.

It is recommended that an authorized and trained service technician perform the commissioning.

PHYSICAL CHECKS

1. Before applying power to the X4I, ensure the power supply connections are correct and secure and the operating

voltage selector is set correctly for the power supply voltage in use (115Vac or 230Vac (+-10%), 50/60Hz).

2. Open the front panel of the X4I and check the location of the link wire(s) connected to the “Voltage Selection”

terminals of the power supply PCB. If necessary, change the link wire locations to those illustrated for the voltage in use.

See the section on Installation for more information.

3. Switch on the power supply to the X4I.

4. The control program identification will be displayed for a short period followed by the normal operational user

display.

PRESSURE DISPLAY

Check the displayed system pressure. If the pressure is incorrect, or inaccurate, check the type and range of the sensor and carry out the pressure sensor commissioning and calibration procedure. If the display shows an error, this will need to be corrected before continuing. See the Operator’s Manual for troubleshooting and correcting the fault/error condition.

X4I QUICK SET-UP CONFIGURATION

Before successful basic operation can be established specific parameters must be entered prior to startup. Please refer to the X4I Quick Setup Manual for instruction to accomplish this.

Page 36

SECTION 10 — SYSTEM CONFIGURATION

ACCESSING THE X4I CONFIGURATION SCREENS

In order to change the configuration parameters you will first need to input the service access code. The service access code is 0032. Enter this code as follows:

1. Press the MENU

2. Adjust the first access code digit by using the scroll up (+)

the correct number shows press the ENTER right.

3. Adjust the remaining digits until the proper access code is shown on the screen. If for any reason you need to go

back to a previous digit press the escape

4. When you’ve adjusted the final digit to the correct number press the ENTER

animation of a key opening a lock. You are now able to access the configuration screens.

5. When in menu mode, if no button activity is detected for a period of time the access code is cancelled and the

display will automatically reset to the normal operational display

6. After successfully entering the access code you should see the screen shown below. The cursor will flash on the

button. This will display the Access Code Screen.

Access Code Screen

and scroll down (-) buttons. When

button. The cursor should then move to the next digit to the

button. This will back the cursor up one digit at a time.

button and you should see an

name of the current page (P00). You can scroll through the tabs by pressing the scroll up (+)

down (-)

buttons.

Default Configuration Screen

and scroll

Page 37

USER CONFIGURATION: TAB S01

1. Scroll up (+) or scroll down (-) until the S01 page is highlighted.

S01 Screen

2. Press the ENTER

REAL TIME CLOCK SETTINGS

1. From the S01 home screen scroll up (+)

(Real Time Clock).

button to confirm your selection. The cursor should be flashing on line 01 Ct.

User Configuration Home Screen

or scroll down (-) to move the cursor to highlight 01- Ct

Real Time Clock Setting

2. The default setting for this parameter is - --.--, which indicates the 24 Real Time Clock has not been initialized.

The format for the Real Time Clock is as follows.

• The ‘Day of the Week’ (1= Monday to 7=Sunday) which is automatically calculated and set in accordance

with the Day, Month and Year entered

• The Hours and Minutes (displayed in Military Time)

• The Day, Month, and Year

3. Press the ENTER

highlighting the Hours dash. This sets the Hour for the Real Time Clock. The values for this parameter are “00” to “23”.

button to display the Real Time Clock setup screen. The flashing cursor should be displayed

Page 38

4. Scroll up (+)

or scroll down (-) until the value is set for the correct Hour for the Real Time Clock.

Press the enter Minutes dash. This sets the Minutes for the Pressure Schedule. The values for this parameter are “0” to “59”.

5. Scroll up (+)

Clock. Press the ENTER the Day dash. This sets the Day for the Real Time Clock. The values for this parameter are “1” to “31”.

6. Scroll up (+)

Press the ENTER Month dash. This sets the Month for the Real Time Clock. The values for this parameter are “1” to “12”.

7. Scroll up (+)

Clock. Press the ENTER the Year dash. This sets the Year for the Real Time Clock. The values for this parameter are “2005” to “2100”.

8. Scroll up (+)

Press the ENTER just entered should appear next to the Ct parameter.

PRESSURE SCHEDULE SETTINGS

button to accept this parameter. The flashing cursor should be displayed highlighting the

or scroll down (-) until the value is set for the correct Minute for the Real Time

or scroll down (-) until the value is set for the correct Day for the Real Time Clock.

button to accept this parameter. The flashing cursor should be displayed highlighting the

or scroll down (-) until the value is set for the correct Month for the Real Time

or scroll down (-) until the value is set for the correct Year for the Real Time Clock.

button to accept this parameter. You should be returned to the S01 home screen and values

button to accept this parameter. The flashing cursor should be displayed highlighting

1. From the S01 home screen scroll up (+)

(Pressure Schedule).

Pressure Schedule Setting

2. The default setting for this parameter is

parameter enables or disables the Pressure Schedule Function in the X4I.

3. Press the ENTER

displayed highlighting the

• “

4. Scroll up (+)

” for the disabling the Pressure Schedule Function

” for enabling the Pressure Schedule Function

button to display the Pressure Schedule setup screen. The flashing cursor should be

. The values for this parameter are:

or scroll down (-) until the value is set for the mode of operation for your air

or scroll down (-) to move the cursor to highlight 02- PS

, which indicates the Pressure Schedule is turned off. This

system. Press the ENTER

5. You should be returned to the S01 home screen and values just entered should appear next to the PS parameter.

button to accept this parameter.

Page 39

AUTO RESTART SETTINGS

1. From the S01 home screen scroll up (+)

(Auto Restart).

2. The default setting for this parameter is

power disruption or failure, the X4I will automatically restart when power is restored if the X4I was in an operational ‘Started’ state when the power loss or disruption occurred. The X4I will not automatically restart if the X4I was in a “Stopped” state when the power disruption or failure occurred

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the

• “

” for the disabling the Auto Restart Function

button to display the Auto Restart setup screen.

or scroll down (-) to move the cursor to highlight 03- AR

Auto Restart Setting

. The indicates Auto Restart is turned on. When enabled, after a

. The values for this parameter are:

• “

5. Scroll up (+)

system. Press the ENTER

6. You should be returned to the S01 home screen and values just entered should appear next to the AR parameter.

” for enabling the Auto Restart Function

or scroll down (-) until the value is set for the mode of operation for your air

button to accept this parameter.

Page 40

ROTATION INTERVAL SETTINGS

1. From the S01 home screen scroll up (+)

(Rotation Interval).

Rotation Interval Setting

2. The default setting for this parameter is 9 00:00. The 9 00:00 indicates a daily rotation at 00:00 hours. The X4I

provides a Timed rotation event that can be automatically triggered on a routine basis using a pre-determined interval, a pre-determined time each day, or a pre-determined day and time each week.

3. Press the ENTER

4. The Rotation Interval setup screen should be displayed with a cursor highlighting the first dash after the #. This

sets the Rotation Interval. The values for this parameter are:

• “1” for Monday to “7” for Sunday (a specific day of the week)

• “8” for every working day of the week (every day, Monday through Friday, excluding Saturday and Sunday)

• “9’” for every day of the week (every day, Monday through Sunday)

• “t” for an interval of time (more than 1 or more rotations per 24 hours)

• “–“ for disabling the Rotation Interval

button to display the Rotation Interval setup screen.

or scroll down (-) to move the cursor to highlight 04- RP

5. Scroll up (+)

system. Press the ENTER

6. If the parameter chosen in 4.above is “a, b, or c”, the flashing cursor should be displayed highlighting the Hours

dash (Military Time). This sets the Hour for the Rotation Interval. The values for this parameter are:

• “00” to “23”

• “–“ represents the Rotation Interval is disabled.

7. Scroll up (+)

system. Press the ENTER

8. The flashing cursor should be displayed highlighting the Minutes dash. This sets the Minutes for the Rotation

Interval. The values for this parameter are:

• “0” to “59”

• “–“ represents the Rotation Interval is disabled.

9. Scroll up (+)

system. Press the ENTER

10. If the parameter chosen in 4.above is “d”, the flashing cursor should be displayed highlighting the Interval Time

selection. This sets 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. The values for this parameter are:

• A value of 1 = rotate every 24 hours

or scroll down (-) until the value is set for the Rotation Interval required for your air

button to accept this parameter.

or scroll down (-) until the value is set for the Rotation Interval required for your air

button to accept this parameter.

or scroll down (-) until the value is set for the Rotation Interval required for your air

button to accept this parameter.

Page 41

• A value of 2 = rotate every 12 hours

• A value of 3 = rotate every 8 hours

• A value of 4 = rotate every 6 hours

• A value of 6 = rotate every 4 hours

• A value of 8 = rotate every 3 hours

• A value of 12 = rotate every 2 hours

• A value of 24= rotate every 1 hours

• A value of 48 = rotate every 30 minutes

• A value of 72 = rotate every 20 minutes

• A value of 96 = rotate every 15 minutes

• “–“represents the Rotation Interval is disabled.

11. Scroll up (+)

system. Press the ENTER

12. You should be returned to the S01 home screen and values just entered should appear next to the RP parameter

TABLE SELECT SETTINGS

1. From the S01 home screen scroll up (+)

(Table Select).

2. The default setting for this parameter is T01. The T01 indicates Table T01 is selected. This parameter determines

which ‘Table’ will be used by default when the ‘Pressure Schedule’ is not active and when no table is selected remotely on a digital input.

or scroll down (-) until the value is set for the Rotation Interval required for your air

button to accept this parameter.

or scroll down (-) to move the cursor to highlight 05- TS

Table Select Settings

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the Table Select parameter. The values for this parameter

are:

• “T01” for Table T01

• “T02” for Table T02

• “T03” for Table T03

5. Scroll up (+)

air system. Press the ENTER

6. You should be returned to the S01 home screen and values just entered should appear next to the TS parameter.

button to display the Table Select configuration screen.

or scroll down (-) until the value is set for the Table Select setting required for your

button to confirm this selection.

Page 42

BACKLIGHT ADJUST SETTINGS

1. From the S01 home screen scroll up (+)

(Backlight Adjust).

2. The default setting for this parameter is 5. The 5 indicates the current level the backlight is set for. The default

display Backlight Setting level has been set to enable a ‘continuous use service life’ in excess of 90000 hours while providing good readability in all ambient light conditions. The display will temporarily increase brightness by 2 levels when a button is pressed and return to normal setting after a period of no keypad activity.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the Backlight Setting parameter. The values for this

parameter are “1” to “7” for 1 being the least amount of Backlight and 7 being the most.

5. Scroll up (+)

button to display the Backlight Setting configuration screen.

or scroll down (-) until the value is set for the Backlight Setting required for

or scroll down (-) to move the cursor to highlight 06- BL

Backlight Settings

visibility. Press the ENTER and values just entered should appear next to the BL parameter.

6. After you have completed adjusting the settings on the S01 screen press the ESCAPE

page selection screen.

button to confirm this selection. You should be returned to the S01 home screen

button to return to the

USER CONFIGURATION: TAB S02

1. After you have returned to the page selection screen, scroll up (+) or scroll down (-) until the S02

page is highlighted.

S02 Tab Screen

2. Press the ENTER

button to confirm your selection. The cursor should be flashing on 01 P>.

Page 43

UNITS SETTINGS

S021 Home Screen

1. From the S02 home screen scroll up (+)

(Units Settings).

2. The default setting for this parameter is PSI. The PSI indicates the pressure units selected for X4I. This parameter

determines the X4I display and operating units.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the Units parameter. The values for this parameter are:

• “PSI”

• “BAR”

• “kPA”

button to display the Units configuration screen.

or scroll down (-) to move the cursor to highlight 01- P>

Units Settings

5. Scroll up (+)

system. Press the ENTER

6. You should be returned to the S02 home screen and values just entered should appear next to the P> parameter.

NUMBER OF COMPRESSORS SETTINGS

1. From the S02 home screen scroll up (+)

NC (Number of Compressors).

or scroll down (-) until the value is set for the Units setting required for your air

button to confirm this selection.

or scroll down (-) to move the cursor to highlight 02-

Page 44

Number of Compressors Settings

2. The default setting for this parameter is 4. The 4 indicates the number of compressors the X4I is configured for

and the number of compressors that will be sequenced by the X4I. This value must be set to match the system at commissioning.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the Number of Compressor parameter. The values for this

parameter are:

• “1” for 1 compressor

• “2” for 2 compressors

• “3” for 3 compressors

• “4” for 4 compressors

5. Scroll up (+)

wired into the controller. Press the ENTER

6. You should be returned to the S02 home screen and values just entered should appear next to the NC parameter.

MAXIMUM PRESSURE ALARM SETTINGS

1. From the S02 home screen scroll up (+)

PM (Number of Compressors).

button to display the Number of Compressor configuration screen.

or scroll down (-) until the value matches the number of compressors that you have

button to confirm your selection.

or scroll down (-) to move the cursor to highlight 03-

Maximum Pressure Alarm Settings

2. The default setting for this parameter is 145. The 145 indicates the value used for the High pressure ‘Fault’ level.

This value remains active at all times regardless of which ‘Table’ is active. It should be set at a level just below the system pressure relief value(s) and below the maximum system pressure rating of all air system components

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the Maximum Pressure Alarm parameter. The values for this

parameter are:

• The highest value for the Maximum Pressure Alarm setpoint = “The maximum range of the pressure

transducer used”

• The lowest value for the Maximum Pressure Alarm setpoint = “The highest value from any Table “PH -

Pressure High” Setpoint plus 2 times the “To – Tolerance”

i. If PH in Table 1 (T01) is set for 100 PSI, and PH in Table 2 (T02) is set for 110 and TO is set for 3.0

5. Scroll up (+)

system requirements. Press the ENTER

6. You should be returned to the S02 home screen and values just entered should appear next to the PM parameter.

button to display the Maximum Pressure Alarm configuration screen.

PSI, then the lowest Maximum Pressure setpoint would be 116 PSI.

or scroll down (-) until the value is set to a pressure that is just below your air

button to confirm your selection.

Page 45

STOP CONTROL SETTINGS

Stop Control Settings

1. From the S02 home screen scroll up (+)

(Stop Control Function Settings).

2. The default setting for this parameter is

determines what state the compressors will revert to when the X4I controller is stopped.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the

• “

” for Stop: return pressure control to the compressors

” for Standby: maintain control and continuously hold compressors an unloaded state

button to display the Stop Control configuration screen.

or scroll down (-) to move the cursor to highlight 04- CF

Stop Control Settings

. This indicates the Stop Control is turned off. This parameter

. The values for this parameter are:

5. Scroll up (+)

system. Press the ENTER

6. You should be returned to the S02 home screen and values just entered should appear next to the CF parameter.

or scroll down (-) until the value is set for the mode of operation for your air

button to confirm your selection.

Page 46

TOLERANCE SETTINGS

1. From the S02 home screen scroll up (+)

TO (Tolerance Settings).

2. The default setting for this parameter is 3.0 PSI. This is the width of the Tolerance Band for the X4I. The

Tolerance Band setting is a pressure band above and below the Load and Unload pressure band. This accommodates for an instance of abrupt and/or significant increase or decrease in demand without compromise to optimal energy efficient control. The X4I incorporates a Rate of Change algorithm while in the Tolerance Band to determine when a compressor should be Loaded or Unloaded.

• If air system storage is generous, the rate of the pressure change is slow, and/or demand fluctuations are

insignificant and gradual, then the ‘Tolerance’ band can be decreased to improve pressure control without compromise to optimum energy efficiency. As the Tolerance Band is decreased, the Loading and Unloading of compressors while in the band is more rapid.

• If air system storage is inadequate, the rate of the pressure change is fast, and/or demand fluctuations are

significantly large, the ‘Tolerance’ band can be increased to maintain optimum energy efficiency, and reduce over-reaction, during such transition periods. As the Tolerance Band is increased, the Loading and Unloading of compressors while in the band is less rapid.

or scroll down (-) to move the cursor to highlight 05-

Tolerance Settings

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 3.0. The values for this parameter are:

• “1.4” for the minimum Tolerance Band

• “29.0” for the maximum Tolerance Band

5. Scroll up (+)

of for your air system. Press the ENTER

6. You should be returned to the S02 home screen and values just entered should appear next to the TO parameter.

button to display the Tolerance Settings configuration screen.

or scroll down (-) until the number is set to the value required to maintain control

button to confirm your selection.

Page 47

DAMPING SETTINGS

1. From the S02 home screen scroll up (+)

DA (Damping Settings).

2. The default setting for this parameter is 1.0. The parameter adjusts the time before an additional compressor is

loaded in accordance with the urgency of the situation to increase air system capacity further. The rate of pressure change may be aggressive and disproportionate. In such instances the X4I may over-react and attempt to load an additional compressor that may not be necessary once the initial compressor is running, loaded, and able to contribute adequate additional generation capacity. The X4I has a dynamic reaction algorithm that is pre-set by default to accommodate for the majority of installation characteristics. If an increase or decrease in the Tolerance band is insufficient, the reaction response can be influenced by increasing or decreasing the ‘Damping’ factor.

• If air system storage is generous and the rate of the pressure change is slow to rise, then the ‘Damping’

can be increased to improve pressure control without compromise to optimum energy efficiency. As the Dampening value is increased, the Loading of additional compressors is less rapid.

• If air system storage is inadequate and the rate of the pressure change is fast to fall, then the ‘Damping’

can be decreased to improve pressure control without compromise to optimum energy efficiency. As the Damping value is decreased, the Loading of additional compressors is more rapid.

or scroll down (-) to move the cursor to highlight 06-

Damping Settings

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 1.0. The values for this parameter are “.1” for the fastest

Damping reaction time (10 times faster than the default of 1.0) through “10.0” for the slowest Damping reaction time (10 times slower than the default of 1.0).

5. Scroll up (+)

of for your air system. Press the ENTER

6. You should be returned to the S02 home screen and values just entered should appear next to the DA parameter.

PRESSURE CHANGE SETTINGS

1. From the S02 home screen scroll up (+)

(Pressure Change Settings).

2. The default setting for this parameter is 4 Min. The 4 minutes is the time the X4I will use implement a smooth and

controlled change from one ‘target’ pressure level to another when a Table change is made.

button to display the Dampening Settings configuration screen.

or scroll down (-) until the number is set to the value required to maintain control

button to confirm your selection.

or scroll down (-) to move the cursor to highlight 07- PC

Pressure Change Settings

Page 48

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 4. The values for this parameter are “1” for 1 minute

between Table target pressure setpoint changes through “120” for 120 minutes between Table target pressure setpoint changes.

button to display the Pressure Change Settings configuration screen.

5. Scroll up (+)

for your air system. Press the ENTER

6. You should be returned to the S02 home screen and values just entered should appear next to the PC parameter.

AUXILIARY INPUT SETTINGS

1. From the S02 home screen scroll up (+)

(Auxiliary Input Settings).

2. The default setting for this parameter is 05:SS NO. With this setting, the function for the Auxiliary Input for X4I is

set to Remote Start/Stop. The function of the Auxiliary Input as well as the state of the contacts controlling the Auxiliary Input can be changed.

or scroll down (-) until the number is set to the value required maintain control of

button to confirm your selection.

or scroll down (-) to move the cursor to highlight 08- AI

S01 S03

PC 4 Min

AI 05:SS NO

AO 07:ON NO

ER X

P> PSI

Auxiliary Input Settings

S02

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 05:SS parameter. The values for this parameter are:

• “01:T1” Override > Use Table 1

• “02:T2” Override > Use Table 2

• “03:T3” Override > Use Table 3

• “04:TS” Override > Place the X4I in Standby

• “05:SS” Remote Start/Stop (Default)

• “06:AA” Remote Alarm (always active)

• “07:AR” Remote Alarm (active when X4I is running, inhibited when the X4I is stopped or in Standby

• “08:TA” Remote Trip (always active)

• “08:TA” Remote Trip (active when X4I is running, inhibited when the X4I is stopped or in Standby

5. Scroll up (+)

ENTER

6. The flashing cursor should be displayed highlighting the NO. The values for this parameter are:

• “NO” for the function is activated when the input terminals are a closed set of dry contacts

• “NC“ for the function is activated when the input terminals are an open set of dry contacts

button to confirm your selection.

button to display the Auxiliary Input Settings configuration screen.

or scroll down (-) until you have selected the input function desired. Press the

7. Scroll up (+)

button to confirm your selection.

or scroll down (-) to select the appropriate input selection. Press the ENTER

Page 49

8. You should be returned to the S02 home screen and values just entered should appear next to the AI parameter.

AUXILIARY OUTPUT SETTINGS

1. From the S02 home screen scroll up (+)

AO (Auxiliary Output Settings).

Auxiliary Output Settings

2. The default setting for this parameter is 07:ON NO. With this setting, the function for the Auxiliary Output for X4I

is set to the X4I is Active. The function of the Auxiliary Output as well as the state of the contacts controlling the Auxiliary Input can be changed. If it is determined this value requires a change, then this will need to be modified.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 05:SS parameter. The values for this parameter are:

• “01:AF Any Fault” Any Alarm (Warning), Shutdown (Trip) or Compressor Not Available.

• “02:AT Any Trip” Any Shutdown (Trip) or Compressor Not Available.

• “03:CF Compressor Fault” Any compressor Alarm (Warning), Shutdown (Trip) or Not Available

• “04:CA Compressor Alarm” Any compressor Alarm (Warning)

• “05:CT Compressor Trip” Any compressor Shutdown (Trip) or Not Available

• “06:SF System Fault” Any X4I Alarm (Warning) or Shutdown (Trip)

• “07:SA System Active” X4I is Active, including pre-fill period (not active when the X4I is stopped or in

standby

• “08:SP System Pressure Control Active” X4I is Active excluding pre-fill (not active when the X4I is stopped,

or in standby, or in pre-fill mode

• “09:LP Low Pressure Alarm”

• 10:HP High Pressure Alarm

• 11:PO Pressure Control Override Normal, or Pressure Schedule operation is being manually overridden

button to display the Auxiliary Output Settings configuration screen.

or scroll down (-) to move the cursor to highlight 09-

5. Scroll up (+)

ENTER

6. The flashing cursor should be displayed highlighting the NO. The values for this parameter are:

• “NO” for the auxiliary output relay contacts are normally open and will close when the set function is

• “NC“ for the auxiliary output relay contacts are normally closed and will open when the set function is

7. Scroll up (+)

the ENTER

8. You should be returned to the S02 home screen and values just entered should appear next to the AO parameter.

button to confirm your selection.

active or true

active or true; or in the event of a X4I shutdown or loss of power

or scroll down (-) until you have selected the output function desired. Press the

or scroll down (-) to select the appropriate setting for your output selection. Press

button to confirm your selection.

Page 50

ERROR LOG RESET

1. From the S02 home screen scroll up (+)

(Error Log Reset).

2. The default setting for this parameter is

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the

• “

5. Scroll up (+)

” for not resetting the Error log

“ for resetting the Error log

button to display the Error Log Reset configuration screen.

or scroll down (-) to select the function you want to perform. Note: If you select

or scroll down (-) to move the cursor to highlight 10- ER

Error Log Reset

. This parameter Clears and resets the ‘Error Log’ in the X4I

. The values for this parameter are:

the

to reset the Error Log, the .will revert back to the after selecting the ENTER button. Press the

ENTER

6. You should be returned to the S02 home screen and the

7. After you have completed adjusting the settings on the S02 screen press the ESCAPE

page selection screen.

button to confirm your selection.

should appear next to the ER parameter.

button to return to the

USER CONFIGURATION: TAB S03

1. After you have returned to the page selection screen, scroll up (+) or scroll down (-) until the S03

page is highlighted

S03 Tab Screen

2. Press the ENTER

button to confirm your selection. The cursor should be flashing on 01 01.

Page 51

PRESSURE SENSOR – OFFSET

S02 C01

1O 0 PSI

1R 232 PSI

S03 Home Screen

S03

1. From the S03 home screen scroll up (+)

1O (Pressure Sensor 1 Offset Settings).

S02 C01

1O 0 PSI

1R 232 PSI

Pressure Sensor Offset Settings

2. The default setting for this parameter is 0 PSI. In most applications, this value 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.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 0. 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).

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

button to display the Pressure Sensor Offset Settings configuration screen.

or scroll down (-) to move the cursor to highlight 01-

S03

5. Scroll up (+)

ENTER

6. You should be returned to the S03 home screen and values just entered should appear next to the 1O parameter.

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 pre-determined routine periodic basis

PRESSURE SENSOR – RANGE SETTINGS

1. From the S03 home screen scroll up (+)

(Pressure Sensor Range Settings).

button to confirm your selection.

or scroll down (-) to change the value until the display indicates 0 PSI. Press the

or scroll down (-) to move the cursor to highlight 02- 1R

Page 52

S02 C01

1R 232 PSI

1O 0 PSI

Pressure Sensor Range Settings

2. The default setting for this parameter is 232 PSI. In most applications, this 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.

S03

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 232. 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.

i. The pressure transducer must have a known, accurate pressure applied to it when changing this

5. Scroll up (+)

Press the ENTER

6. You should be returned to the S03 home screen and values just entered should appear next to the 1R parameter.

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 pre-determined routine periodic basis

After you have completed adjusting the settings on the S03 screen press the ESCAPE selection screen.

button to display the Pressure Sensor Range Settings configuration screen.

value to a value other than 232.

or scroll down (-) to change the value until the display indicates the correct PSI.

button to confirm your selection.

button to return to the page

COMPRESSOR CONFIGURATION: TAB C01

1. After you have returned to the page selection screen, scroll up (+) or scroll down (-) until the

C01 page is highlighted.

C01 Tab Screen

2. Press the ENTER button to confirm your selection. The cursor should be flashing on line 01 01.

Page 53

COMPRESSOR RUN HOURS

C01 Home Screen

1. From the C01 home screen scroll up (+)

01 (Compressor 1 Run Hours).

S03 C02

01 0 hrs

02 0 hrs

04 0 hrs

Compressor Run Hours Settings

2. The default setting for this parameter is 0 hours. This value can be manually set to match the running hours of

each compressor. When using the EHR (Equal Run Hours) Sequence mode, the X4I uses these values to maintain equal run hours among all compressors.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 0. The values for this parameter are “0 to x” where x =

the actual run hours for the compressor connected to the #1 control channel.

5. Scroll up (+)

Press the ENTER

6. You should be returned to the C01 home screen and the value entered should appear next to the 01-01 parameter.

button to display the Compressor Run Hours setup screen for compressor #1

or scroll down (-) to change the value to match the run hours on compressor #1.

button to confirm your selection.

or scroll down (-) to move the cursor to highlight 01-

C01

0 hrs

7. Repeat this by scrolling up (+)

remaining compressors and set the run hours to match each of the other compressors.

8. You should be returned to the C01 home screen and values just entered should appear next to the 01 parameter.

Once all run hours have been entered for all compressors, you should be returned to the C01 home screen and all values entered should appear next each compressor parameter.

9. After you have completed adjusting the settings on the C01 screen press the ESCAPE

page selection screen.

or scrolling down (-) to move the cursor to highlight the

button to return to the

COMPRESSOR CONFIGURATION: TAB C02

1. After you have returned to the page selection screen, scroll up (+) or scroll down (-) until the

C02 page is highlighted.

Page 54

C02 Tab Screen

2. Press the ENTER

COMPRESSOR CONNECTION METHOD

1. From the C02 home screen scroll up (+)

01 (Compressor 1 Connection Settings).

button to confirm your selection. The cursor should be flashing on line 01 01.

C02 Home Screen

or scroll down (-) to move the cursor to highlight 01-

Compressor Connection Settings

2. The default setting for this parameter is I-PCB. This setting is used for the type, method of connection, and the

control functionality, of each compressor connected to the X4I. Each air compressor in the system is integrated with the X4I using an interface module.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the I-PCB. The values for this parameter are:

• “IR-PCB” for Fixed speed, load/unload; connected to X4I using ‘ir-PCB’ module using 6-wire method.

• “IRV-PCB” for Variable Speed; connected to X4I using ‘ir-PCB’ module emplying the 7-wire ‘V’ terminal

method

• “I-485” for Fixed speed, load/unload; connected to X4I on Multi485 network.

• “V-485” for Variable Capacity/Speed; connected to X4I on Multi485 network

5. IR-PCB Setup: Scroll up (+)

button to confirm your selection.

button to display the Compressor Connection setup screen for compressor #1

or scroll down (-) to change the value to IR-PCB. Press the ENTER

Page 55

6. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time. The Default setting for

this parameter is 10 Sec. This is the time required to start the motor and then load the compressor. The values for this parameter are “0” to “60” seconds.

7. Scroll up (+)

button to confirm your selection.

8. The flashing cursor should be displayed highlighting the ‘i-PCB’ Alarm (Warning) Input. The Default setting for this

parameter is +V=1. If the ‘i-PCB’ Alarm input detects a voltage between 12-250VAC/DC, an alarm (Warning) condition is generated. The values for this parameter are:

• +V=1 for an Alarm (Warning) condition is generated if the ‘ir-PCB’ Alarm input detects a voltage between

12-250Vac/dc (default)

• +V=0 for an Alarm (Warning) condition is generated if the ‘ir-PCB’ Alarm input detects no voltage.

9. Scroll up (+)

application. Press the ENTER

10. You should be returned to the C02 home screen and ‘ir-PCB’ should appear next to the 01-01 parameter.

11. IRV-PCB Setup: Scroll up (+)

button to confirm your selection.

12. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time. The Default setting for

this parameter is 10 Sec. This is the time required to start the motor and then load the compressor. The values for this parameter are “0” to “60” seconds.

13. Scroll up (+)

button to confirm your selection.

14. The flashing cursor should be displayed highlighting the ‘i-PCB’ Alarm (Warning) Input. The Default setting for this

parameter is +V=1. If the ‘i-PCB’ Alarm input detects a voltage between 12-250VAC/DC, an alarm (Warning) condition is generated. The values for this parameter are:

• +V=1 for an Alarm (Warning) condition is generated if the ‘ir-PCB’ Alarm input detects a voltage between

12-250Vac/dc (default)

• +V=0 for an Alarm (Warning) condition is generated if the ‘ir-PCB’ Alarm input detects no voltage.

or scroll down (-) to change the value to the time required. Press the ENTER

or scroll down (-) to change the value for the Alarm condition required for your

button to confirm your selection.

or scroll down (-) to change the value to IRV-PCB. Press the ENTER

or scroll down (-) to change the value to the time required. Press the ENTER

15. Scroll up (+)

application. Press the ENTER

16. The flashing cursor should be displayed highlighting the Compressor Run-On Stop Time. The Default setting for

this parameter is 10 Sec. This is the time that the compressor main motor will continue to run when the compressor is unloaded. The time is from the moment the compressor unloads until the main motor stops and the compressor enters a ‘Standby’ or ‘Auto Restart’ condition. This setting is only applicable to ‘IRV-PCB’ connectivity and is not displayed for other connectivity options The values for this parameter are “0” to “999” seconds.

17. Scroll up (+)

button to confirm your selection.

18. You should be returned to the C02 home screen and ‘irv-PCB’ should appear next to the 01-01 parameter.

19. I-485 Setup: Scroll up (+)

button to confirm your selection.

20. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time. The Default setting for

this parameter is 10 Sec. This is the time required to start the motor and then load the compressor. The values for this parameter are “0” to “60” Seconds.

or scroll down (-) to change the value for the Alarm condition required for your

button to confirm your selection.

or scroll down (-) to change the value to the time required. Press the enter

or scroll down (-) to change the value to I-485. Press the ENTER

Page 56

21. Scroll up (+)

button to confirm your selection.

22. You should be returned to the C02 home screen and ‘i-485’ should appear next to the 01-01 parameter.

or scroll down (-) to change the value to the time required. Press the ENTER

23. V-485 Setup: Scroll up (+)

button to confirm your selection.

24. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time. The Default setting for

this parameter is 10 Sec. This is the time required to start the motor and then load the compressor. The values for this parameter are “0” to “60” seconds.

25. Scroll up (+)

button to confirm your selection.

26. You should be returned to the C02 home screen and ‘v-485’ should appear next to the 01-01 parameter.

27. Repeat this by scrolling up (+)

remaining compressors and set the Compressor Connection type and the Compressor Connection parameters for each of the other compressors.

28. You should be returned to the C02 home screen and values just entered should appear next to the 01 parameter

Once all values have been entered for all compressors, you should be returned to the C01 home screen and all ‘iPCB’ values entered should appear next each compressor parameter.

29. After you have completed adjusting the settings on the C01 screen press the ESCAPE

page selection screen.

or scroll down (-) to change the value to the time required. Press the ENTER

or scroll down (-) to change the value to IR-PCB. Press the ENTER

or scrolling down (-) to move the cursor to highlight the

button to return to the

Page 57

COMPRESSOR TABLE CONFIGURATION: TAB T01

1. After you have returned to the page selection screen, scroll up (+) or scroll down (-) until the

T01 page is highlighted.

T01 Tab Screen

2. Press the ENTER

HIGH PRESSURE SETPOINT SETTINGS

1. From the T01 home screen scroll up (+)

PH (High Pressure Setpoint).

button to confirm your selection. The cursor should be flashing on line 01 PH.

T01 Home Page

or scroll down (-) to move the cursor to highlight 01-

High Pressure Setpoint Setting

2. The default setting for this parameter is 102 PSI. The 102 PSI indicates the High Pressure Setpoint that is used to

unload the compressor when the Table is active.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 102 PSI. The values for this parameter are:

• The highest value for the High Pressure setpoint = PM “Maximum Pressure Alarm” minus 2 times TO

“Tolerance”.

i. If PM is set for 145 PSI and TO is set for 3.0 PSI, then the highest value for the High Pressure

• The lowest value for the High Pressure setpoint = PL “Low Pressure” setpoint plus TO “Tolerance”

button to display the High Pressure Setpoint setup screen.

setpoint would be 139 PSI.

Page 58

i. If PL is set for 98 PSI and TO is set for 3.0 PSI, then the lowest value for the High Pressure setpoint

would be 101 PSI.

5. Scroll up (+)

of for your air system. Press the ENTER

6. You should be returned to the T01 home screen and values just entered should appear next to the PH parameter.

LOW PRESSURE SETPOINT SETTINGS

1. From the T01 home screen scroll up (+)

(Low Pressure Setpoint).

2. The default setting for this parameter is 98 PSI. The 98 PSI indicates the Low Pressure Setpoint that used to load

the compressor when the Table is active.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 98 PSI. The values for this parameter are:

• The highest value for the Low Pressure setpoint = PH “High Pressure” setpoint minus TO “Tolerance”. i. If PH is set for 102 PSI and TO is set for 3.0 PSI, then the highest value for the Low Pressure

• The lowest value for the Low Pressure setpoint = Pm “Minimum Pressure Alarm” setpoint plus 2 times TO

“Tolerance”

i. If Pm is set for 80 PSI and TO is set for 3.0 PSI, then the lowest value for the Low Pressure setpoint

or scroll down (-) until the number is set to the value required to maintain control

button to confirm your selection.

or scroll down (-) to move the cursor to highlight 02- PL

Low Pressure Setpoint Setting

button to display the Low Pressure Setpoint setup screen.

setpoint would be 99 PSI.

would be 86 PSI...

5. Scroll up (+)

of for your air system. Press the ENTER

6. You should be returned to the T01 home screen and values just entered should appear next to the PL parameter.

MINIMUM PRESSURE ALARM SETTINGS

1. From the T01 home screen scroll up (+)

Pm (Minimum Pressure Alarm).

or scroll down (-) until the number is set to the value required to maintain control

button to confirm your selection.

or scroll down (-) to move the cursor to highlight 03-

Page 59

Minimum Pressure Alarm Setting

2. The default setting for this parameter is 80 PSI. The 80 PSI indicates the Minimum Low Pressure Setpoint that is

used to alarm if the pressure in the air system is low when the Table is active.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 80 PSI. The values for this parameter are:

• The lowest Minimum Pressure Alarm setpoint = “The minimum range of the pressure transducer used.“

• The highest Minimum Pressure Alarm setpoint = “The value from the Table “PL – Low Pressure Setpoint”

value minus 6 PSI if in PSI, .4 BAR if in BAR, 41 kPA if in kPA.”

i. If PL in Table 1 (T01) is set for 100 PSI, then the highest Minimum Pressure setpoint would be 94

5. Scroll up (+)

of for your air system. Press the ENTER

6. You should be returned to the T01 home screen and values just entered should appear next to the Pm parameter.

SEQUENCE STRATEGY SETTINGS

1. From the S01 home screen scroll up (+)

(Sequence Strategy).

button to display the Minimum Low Pressure Setpoint setup screen.

PSI.

or scroll down (-) until the number is set to the value required to maintain control

button to confirm your selection.

or scroll down (-) to move the cursor to highlight 04- SQ

Sequence Strategy Setting

2. The default setting for this parameter is FILO. The FILO indicates the Sequence Control Strategy mode used when

the Table is active. Each sequence control strategy consists of two sub strategies. 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 day, or a set time of day once a week. The compressor load ‘Control’ strategy defines how the compressors are utilized in response to variations in system pressure

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the FILO. The values for this parameter are:

• FILO – First In Last Out. The Rotation and Control functionality of the FILO mode is the first compressor

loaded is the last compressor to be unloaded

• FIFO – First In First Out. The Rotation and Control functionality of the FIFO mode is the first compressor

loaded is the first compressor to be unloaded

• VEC – Variable Energy Control. This uses the same Rotation and Control functionality of the FILO mode

with the additional control required for variable speed compressor installations

• EHR – Equal Hours Mode. The Rotation and Control functionality of the EHR mode is to equalize the Run

Hours on all compressors

5. Scroll up (+)

control of for your air system. Press the ENTER

6. You should be returned to the T01 home screen and values just entered should appear next to the SQ parameter

button to display the Sequence Strategy Setpoint setup screen.

or scroll down (-) until the control mode is set to the value required to maintain

button to confirm your selection.

Page 60

COMPRESSOR #1 PRIORITY SETTINGS

1. From the T01 home screen scroll up (+)

or scroll down (-) to move the cursor to highlight 05-

01 (Compressor Priority).

Compressor #1 Priority Setting

2. The default setting for this parameter is 1. The 1 indicates the Compressor Priority setting for compressor

number #1 Any compressor can be assigned any priority or remove it from Sequence Rotation and Control and any number of compressors can have the same priority. By changing the priority setting, it can be used to modify the ‘Rotation’ sequence assignment. For example: The air system configuration is a single variable speed compressor that should be always loaded first and act a trim compressor and 3 fixed speed compressors that should be rotated on an equal basis. You would assign the variable speed compressor a Priority of 1 and the 3 fixed speed compressors a Priority of 2. The variable speed compressor is always loaded first and the 3 fixed speed compressors would load and rotate based on the Sequence and Rotation setup.

1 2 3 4

1222

ABCD

ACDB

ADBC

ABCD

Priority Example

3. Press the enter

button to display the Compressor Priority setup screen.

4. The flashing cursor should be displayed highlighting the 1. The values for this parameter are “1” for the highest

priority through “4” for the lowest priority. Value “ ” indicates inhibit from use while a table is active. The compressor will be held unloaded and will not be utilized under any circumstances

5. Scroll up (+)

of for your air system. Press the ENTER

or scroll down (-) until the number is set to the value required to maintain control

button to confirm your selection.

6. You should be returned to the T01 home screen and values just entered should appear next to the 01 parameter.

COMPRESSOR #2 THROUGH 4 PRIORITY SETTINGS

1. Repeat Steps above for Compressor #2, #3, and #4 Priority settings. When complete, the ENTER

button to

confirm your selection. You should be returned to the T01 home screen

2. After you have completed adjusting the settings on the T01 screen, press the ESCAPE

button to return to the

page selection screen.

3. Repeat the T02 and T03 Tabs Screen if you will be using more than one Table in your application.

Page 61

4. After you have completed adjusting the settings on the other T0x screens, press the ESCAPE

to the page selection screen.

button to return

PRESSURE SCHEDULE CONFIGURATION P01 TAB SCREEN

1. After you have returned to the page selection screen, such as in figure 3, scroll up (+) or scroll down (-)

until the P01 page is highlighted.

P01 Tab Screen

2. Press ENTER

PRESSURE SCHEDULE SETTINGS

1. From the P01 home screen scroll up (+)

(Pressure Schedule).

to confirm your selection. The cursor should be flashing on line 01 01.

P01 Home Screen

or scroll down (-) to move the cursor to highlight 01- 01

Pressure Schedule Setpoints

2. The default setting for this parameter is -. --:-- - - - . The -. --:-- - - - indicates the Pressure Schedule is turned

off. The Pressure Schedule consists of 28 individual settings that instruct the X4I to change from one Table to another, or put the system into Standby mode, dependant on time of day and day of the week. T

3. Press the ENTER

button to display the Pressure Schedule setup screen.

Page 62

4. The flashing cursor should be displayed highlighting the first dash after the #. This sets the Day of the Week for

the Pressure Schedule. The values for this parameter are:

• “1” for Monday to “7” for Sunday (a specific day of the week)

• “8” for every working day of the week (every day, Monday through Friday, excluding Saturday and Sunday)

• “9’” for every working day of the week (every day, Monday through Sunday)

• “–“ for disabling the Pressure Schedule

5. Scroll up (+)

air system. Press the ENTER

6. The flashing cursor should be displayed highlighting the Hours dash (Military Time). This sets the Hour for the

Pressure Schedule. The values for this parameter are “00” to “23”. The value “–“ indicates the Pressure Schedule is disabled.

7. Scroll up (+)

air system. Press the ENTER

8. The flashing cursor should be displayed highlighting the Minutes dash. This sets the Minutes for the Pressure

Schedule. The values for this parameter are “0” to “59”. The value “–“ indicates the Pressure Schedule is disabled.

9. Scroll up (+)

air system. Press the ENTER

10. The flashing cursor should be displayed highlighting the Table / Standby mode selection. This instructs the

system to change from one ‘Table’ to another, or put the system in to ‘Standby’ mode for the Pressure Schedule. The values for this parameter are:

• “T01”, “T02” or ‘T03” for the 3 different Tables

• “–

• “–––“represents the Pressure Schedule is disabled.

– “ for Standby Mode

or scroll down (-) until the value is set for the Pressure Schedule required for your

button to accept this parameter.

or scroll down (-) until the value is set for the Pressure Schedule required for your

button to accept this parameter.

or scroll down (-) until the value is set for the Pressure Schedule required for your

button to accept this parameter.

11. Scroll up (+)

air system. Press the ENTER

12. You should be returned to the P01 home screen and values just entered should appear next to the 01 parameter.

13. Repeat Steps 5.1.A 1 to 12 if additional Pressure Schedules are required. When complete, press the ENTER

button to confirm your selection.

14. You should be returned to the P01 home screen

15. After you have completed adjusting the settings on the P01 screen, press the ESCAPE

page selection screen.

PRE-FILL CONFIGURATION P02 TAB SCREEN

1. After you have returned to the page selection screen, such as in figure 3, scroll up (+)

until the P02 page is highlighted.

or scroll down (-) until the value is set for the Pressure Schedule required for your

button to accept this parameter.

button to return to the

or scroll down (-)

Page 63

P02 Tab Screen

2. Press ENTER

PRE-FILL FUNCTION SETTINGS

1. From the P02 home screen scroll up (+)

(pre-fill function).

to confirm your selection. The cursor should be flashing on line 01 PF.

Home Screen

or scroll down (-) to move the cursor to highlight 01- PF

Pre-fill Function Setpoint Screen

2. The default setting for this parameter is

function 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 operating level.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the

• “

” for the Pre-fill Function is Off

” for Pre-fill, Back-up Mode

i. Compressor(s) can be pre-selected as ‘Primary Pre-fill’ compressor(s) or ‘Backup Pre-fill’

! X

button to display the pre-fill function setpoint screen.

compressor(s). If a primary pre-fill compressor experiences a shutdown, or is stopped, it is replaced by a pre-defined backup compressor and pre-fill continues.

” for Pre-fill, Standard Mode

. The indicates the pre-fill function is turned off. The pre-fill

. The values for this parameter are:

Page 64

i. If one or more of the pre-defined pre-fill compressors experiences a shutdown, or is stopped, the

pre-fill function is cancelled and normal operation begins.

5. Scroll up (+)

system. Press the ENTER

6. You should be returned to the P02 home screen and values just entered should appear next to the PF parameter.

PRE-FILL TIME SETTINGS

1. From the P02 home screen scroll up (+)

(Pre-fill Time).

2. The default setting for this parameter is – MIN . The – MIN indicates the Pre-fill Time is turned off. The Pre-fill

Time Setpoint (in minutes) determines the time the Pre-fill Function has to start and load the designated Compressor/s to increase system pressure to normal operational levels

or scroll down (-) until the value is set for the Pre-fill Function required for your air

button to accept this parameter.

or scroll down (-) to move the cursor to highlight 02- PT

Pre-fill Time Setpoint Setting

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the

• “–” for the Pre-fill Time is Off

• “1 to 120” for the number of minutes for the Pre-fill Time Setpoint

5. Scroll up (+)

system. Press the ENTER

6. You should be returned to the P02 home screen and values just entered should appear next to the PT parameter.

button to display the Pre-fill Time Setpoint screen.

. The values for this parameter are:

or scroll down (-) until the value is set for the Pre-fill Time required for your air

button to accept this parameter.

Page 65

PRE-FILL PRESSURE SETTINGS

1. From the P02 home screen scroll up (+)

(Pre-fill Pressure).

Pre-fill Pressure Setpoint Setting

2. The default setting for this parameter is 0 PS. The 0 PSI indicates the Pressure Setpoint used by the X4I to

determine if the Pre-fill Function is required at startup. If the system pressure is at, or above, this setting, the prefill function will be abandoned immediately and normal pressure control and sequence strategy will be implemented. This setting is intended to inhibit ‘Pre-fill’ operation if pressure is already at an acceptable level at system startup

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the 0. The values for this parameter are:

• 0 to 232 (or the maximum scaling used by the X4I if a different Pressure Transducer range is used)” for

the PSI value for the Pre-fill Pressure

button to display the Pre-fill Pressure Setpoint screen.

or scroll down (-) to move the cursor to highlight 03- PP

5. Scroll up (+)

system. Press the ENTER

6. You should be returned to the P02 home screen and values just entered should appear next to the PP parameter.

PRE-FILL COMPRESSOR #1 SETTINGS

1. From the P02 home screen scroll up (+)

(Pressure Schedule).

2. The default setting for this parameter is

The Pre-fill Time Setpoint (in minutes) determines the time the Pre-fill Function has to start and load the designated Compressor/s to increase system pressure to normal operational levels

or scroll down (-) until the value is set for the Pre-fill Pressure required for your air

button to accept this parameter.

or scroll down (-) to move the cursor to highlight 04- 01

Pre-fill Time Setting

. The indicates the Pre-fill Function for Compressor #1 s turned off.

3. Press the ENTER

4. The flashing cursor should be displayed highlighting the

• “

”” for this compressor will not be used by the Pre-fill Function

button to display the Pre-fill Time Setpoint screen.

. The values for this parameter are:

Page 66

• “

• “!” for this compressor will be used as an emergency Backup compressor by the Pre-fill Function

” for this compressor will be used as a primary compressor by the Pre-fill Function

5. Scroll up (+)

for your air system. Press the enter

6. You should be returned to the P02 home screen and values just entered should appear next to the 04 parameter.

PRE-FILL COMPRESSOR #2 THROUGH 4 SETTINGS

1. Repeat above steps for compressor #2, #3, and #4 Pre-fill Compressor settings. When complete, the ENTER

button to confirm your selection.

2. You should be returned to the P02 home screen

3. After you have been returned to the page selection screen, press the ESCAPE

screen.

or scroll down (-) until the value is set for the compressor Pre-fill Function required

button to accept this parameter.

button to return to the main

Page 67

DIAGNOSTICS D01 TAB SCREEN

1. After you have returned to the page selection screen, scroll up (+) or scroll down (-) until the

D01 page is highlighted.

D2 Tab Screen

2. Press ENTER

DIAGNOSTICS SETTINGS

1. From the D01 home screen scroll up (+)

D1 (Digital Input 1).

to confirm your selection. The cursor should be flashing on line 01 D1.

or scroll down (-) to move the cursor to highlight 01-

D01

20 Ao mA4.00

01 D1 0

Diagnostic Setting Screen

2. The X4I is equipped with comprehensive diagnostic functions. Each input can be examined individually and each

output can be manually activated or manipulated individually.

0 1 2

Page 68

X4I CONTROLLER DIAGNOSTICS

D1 Digital Input 1

D2 Digital Input 2

D3 Digital Input 3

D4 Digital Input 4

OFF Pulsing

D5 Digital Input 5

D6 Digital Input 6

D7 Digital Input 7

D8 Digital Input 8

D9 Digital signal detected on A2

DA Digital signal detected on A3

_____________________________________________________________________________________________

R1 Relay Output 1

R2 Relay Output 2

R3 Relay Output 3

OFF

R4 Relay Output 4

R5 Relay Output 5

R6 Relay Output 6

_____________________________________________________________________________________________

A1 Analog Input 1 bar <> mA

A2 Analog Input 2 v

A3 Analog Input 3 v

_____________________________________________________________________________________________

Ao Analog Output 0.0 to 20.0mA

DIGITAL INPUTS

OFF (open circuit)

ON (closed circuit)

Pulsing

The pulse signal from an “ir-PCB” is 0V to 24VDC at 50/60Hz. A typical DC voltage meter, or multimeter, will detect this as 12VDC +-4V.

RELAY OUTPUTS

Each relay output can be energized and de-energized manually by selecting the item. Use UP (plus) and DOWN (minus) to adjust and ENTER.

Page 69

ANALOG INPUTS

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

• A1: System Pressure, 4-20mA

• A2: Digital Input #9, voltage

• A3: Auxiliary Digital Input, voltage

Analog inputs 2 and 3 are equipped with ACM modules designed to conform to the standard specification for a

controller digital input. The inputs are utilized as digital inputs on this X4I.

ANALOG OUTPUT

The analog output can be manually adjusted. Use UP (plus) and DOWN (Minus) to adjust and ENTER. The output will return to normal operational value upon menu exit.

After you have completed adjusting the settings on the D01 screen press the ESCAPE selection screen.

After you have been returned to the page selection screen, press the ESCAPE

TOTAL UNIT RESET AND DEFAULT VALUES

If at any time there is a requirement to reset all the parameters and internal memory values to factory default, this can be accomplished by using the following procedure.

1. Press the MENU

button. This will display the access code screen.

Access Code Screen

button to return to the main screen.

button to return to the page

2. Enter the access code “9750” but do not press the ENTER

flashing.

3. When the flashing cursor is highlighting the last “0”, press and hold the STOP

After 10 seconds, the controller will reset and re-initialize.

All parameters, values and options will be reset to default and the internal permanent memory will be cleared and

reset.

button when the last access code character “0” is

button for 10 seconds.

Page 70

The Default Parameters for all X4I settings are shown in the following lists.

TABLE #1

T01

PH High Pressure Setpoint

Default Setting is: 102 PSI

PL Low Pressure Setpoint

Default Setting is: 98 PSI

Pm Minimum Pressure Alarm

Default Setting is: 0 PSI

SQ Sequence Rotation Mode

Default Setting is: FILO

01 Compressor #1 Priority

Default Setting is: 1

02 Compressor #2 Priority

Default Setting is: 1

03 Compressor #3 Priority

Default Setting is: 1

04 Compressor #4 Priority

Default Setting is: 1

TABLE #3

T03

PH High Pressure Setpoint

Default Setting is: 102 PSI

PL Low Pressure Setpoint

Default Setting is: 98 PSI

Pm Minimum Pressure Alarm

Default Setting is: 0 PSI

SQ Sequence Rotation Mode

Default Setting is: FILO

01 Compressor #1 Priority

Default Setting is: 1

02 Compressor #2 Priority

Default Setting is: 1

03 Compressor #3 Priority

Default Setting is: 1

04 Compressor #4 Priority

Default Setting is: 1

TABLE #2

T02

PH High Pressure Setpoint

Default Setting is: 102 PSI

PL Low Pressure Setpoint

Default Setting is: 98 PSI

Pm Minimum Pressure Alarm

Default Setting is: 0 PSI

SQ Sequence Rotation Mode

Default Setting is: FILO

01 Compressor #1 Priority

Default Setting is: 1

02 Compressor #2 Priority

Default Setting is: 1

03 Compressor #3 Priority

Default Setting is: 1

04 Compressor #4 Priority

Default Setting is: 1

Pressure Schedule

P01

01 Schedule Setting #1

Default Setting is: -. - - : - - - - -

28 Schedule Setting #28

Default Setting is: -. - - : - - - - -

Page 71

Pre-fill

P02

PF Pre-fill Function

Default Setting is: X

PT Pre-fill Time

Default Setting is: - MIN

PP Pre-fill Pressure

Default Setting is: 0 PSI

01 Compressor #1

Default Setting is: X

02 Compressor #2

Default Setting is: X

03 Compressor #3

Default Setting is: X

04 Compressor #4

Default Setting is: X

User Configuration

S01

Ct Real Time Clock Set

Default Setting is: -. - - : - -

PS Pressure Schedule Enable

Default Setting is: X

AR Auto Restart Enable

Default Setting is:

RP Rotation Interval

Default Setting is: 1. 00:00

TS Default Table Select

Default Setting is: T01

BL Display Backlit Adjust

Default Setting is: 5

Configuration

S02

P> Pressure Units

Default Setting is: PSI

NC Number Of Compressors

Default Setting is: 4

PM Maximum Pressure Alarm

Default Setting is: 145 PSI

CF Stop Control Function

Default Setting is: X

TO Tolerance

Default Setting is: 3.0 PSI

DA Damping

Default Setting is: 1.0

PC Pressure Change Time

Default Setting is: 4 MIN

AI Auxiliary Input Function

Default Setting is: 05:SS NO

AO Auxiliary Output Function

Default Setting is: 07 ON NO

ER Error Log Reset

Default Setting is: X

Sensor Calibration

S03

1O Pressure Offset

Default Setting is: 0 PSI

1R Pressure Range

Default Setting is: 232 PSI

Page 72

Compressor Running Hours

C01

01 Compressor #1 Running Hours

Default Setting is: 0 HRS

02 Compressor #2 Running Hours

Default Setting is: 0 HRS

03 Compressor #3 Running Hours

Default Setting is: 0 HRS

04 Compressor #4 Running Hours

Default Setting is: 0 HRS

Compressor Configuration

C02

01 Compressor #1 Configuration

Default Setting is: IR-PCB

02 Compressor #2 Configuration

Default Setting is: IR-PCB

03 Compressor #3 Configuration

Default Setting is: IR-PCB

04 Compressor #4 Configuration

Default Setting is: IR-PCB

Page 73

PARTS LIST

Item Part No. Description

- 39265889 X4I

- 80443617 Manual, User CD

1 39265897 Unit, Controller

2 39265913 Unit, XPM-TAC24

3 39265905 PCB, Terminal

4 38036703 Gland, Set - Pg11

5 39265921 Module, ir-PCB

6 39265939 Sensor, Pressure

4-20mA, 232psi (16bar)

20mm

IEC

Qty. Part No. Description

10 39265962 IEC Fuse T1.0A

10 39265970 IEC Fuse T1.6A

10 39265988 IEC Fuse T3.15A

5mm

i-PCB

Page 74

TECHNICAL DATA

Dimensions 9.45” x 11.45” x 6.0”

241mm x 291mm x 152mm

Weight 14 lb (6.4 kg)

Mounting Wall, 4 x mounting screws

Enclosure IP65, NEMA 4

Power Supply 50VA

230Vac +/- 10% (50 Hz)

115Vac +/- 10% (60 Hz)

Control Power 24Vdc

Temperature 32°F to 115°F (0°C to 46°C)

Humidity 0% to 95% RH

non-condensing

24mm

188mm

24mm

Mounting Dimensions:

238mm

236mm

8mm Ø

286mm

Page 75

DIAGRAMS

Wiring Diagram

C031

C032

C09

C010

T1-56-321-R6-CG

A-GND

0 X

u M

0 X

230Vac 10% 115Vac 10%

L 2

a V

0 X

+VDC

Ai1

+VDC

Ai2

+VDC

Ai3

0 X

2 C A

P X

C+

X03

1 2 3

4 5 6 7 8

0 C

a V

0Vac - earthed

0 C

C019 C020 C021 C022 C023 C024 C025 C026 C027

C013

C014

C015

C016

C017

C018

a V

24Vac

C03 C04 C05 C06 C07 C08

C011

C012

C01/3

C01/4

0VDC

Terminal PCB

C03

C04 C05 C06 C07 C08

C09

C010

C011

C012

C013 C014 C015

C016 C017 C018

C019 C020 C021 C022 C023 C024 C025 C026 C027

C028 C029

C030

C033 C034

C031 C032

a V

D N G

C01

6 3

5 3

SEQ

GND

Q E S

D N G

C034

24Vac

SEQ

R-SEQ

C06

C08 C07

C010

C09

C04 C03

C019

C024

10k

150k

150k C012

10k

C023 C027

C018

10k

C022 C026

3 3

2 3

1 3

0 3

9 2

8 2

7 2

6 2

5 2

4 2

3 2

2 2

1 2

0 2

9 1

4 V

8 1

7 1

6 1

5 1

4 1

3 1

3 V

2 1

1 1

0 1

R-V1

4-20mA

R-V2

R-V3

C016

R-V4

10k

C021 C025

C015

8 7 2

V 6

5 4

3 2

8 0 X

7 0 X

6 0 X

5 0 X

4 0 X

3 0 X

2 0 X

1 0 X

1 1

Page 76

Connection Diagram

Terminal PCB

6 3

5 3

4 3

3 3

2 3

1 3

0 3

9 2

8 2

7 2

6 2

5 2

4 2

3 2

2 2

1 2

0 2

9 1

4 V

8 1

7 1

6 1

5 1

4 1

3 1

3 V

2 1

1 1

0 1

9 8 7 2

V 6

5 4

3 2 1 1

115V 'UL' @ 5A maximum.

8 0 X

Auxiliary Output #1

7 0

Auxiliary Input #1

330ft (100m) max

0 X

L1 L2

5 0 X

4 0 X

3 0 X

2 0 X

1 0 X

Ai1

+20VDC Ready/Run

Di5

Alarm/Serv.

Ai2

GND

LOAD

SEQ

VFD

+20VDC Ready/Run

Di4

Alarm/Serv.

Di8

GND LOAD

SEQ

VFD

+20VDC Ready/Run

Di3

Alarm/Serv.

Di7

GND LOAD

SEQ

VFD

+20VDC Ready/Run

Di2

Alarm/Serv.

Di6

GND LOAD

SEQ

VFD

System Pressure

Multi485

L1 L2

330ft (100m) max

6 5

4 B

330ft (100m) max

2 1

6 5

3 B

2 1

6 5

2 B

2 1

6 5

1 B

2 1

I-PCB 6-core I-VFD 7-core

330ft (100m) max

I-PCB 6-core I-VFD 7-core

330ft (100m) max

I-PCB 6-core I-VFD 7-core

330ft (100m) max

I-PCB 6-core I-VFD 7-core

4-20mA

Page 77

XPM-TAC24

Power Supply Module

4 x 4.5mm

12 mm

BLACK

ORANGE

WHITE

234

VOLTAGE SELECT

T1.0A

EENL

X01

230V

115V

FH1

1234

230V +-10%

115V +-10%

12 mm

IEC

5x20mm

141

FH5

BLUE

3 T

BROWN

RED

GREEN

X03

212

X02

VIOLET

X04

FH2FH3FH4

1 T

1234

147

T1 S1

24Vac/2 earthed

24Vac/1

isolated

LNE

Page 78

Commissioning Form

Customer

Installation/Site

Software

psi

cfm

Contact

Phone

Ser No.

Customer Ref:

Internal Ref:

Commission Date

Commission Engineer

Comp #1 Manufacturer Comp #1 Model/Type Comp #1 Working Pressure psi/bar Comp #1 Full Load Capacity cfm

Comp #2 Manufacturer Comp #2 Model/Type Comp #2 Working Pressure psi/bar Comp #2 Full Load Capacity cfm

Comp #3 Manufacturer Comp #3 Model/Type Comp #3 Working Pressure psi/bar Comp #3 Full Load Capacity cfm

Comp #4 Manufacturer Comp #4 Model/Type Comp #4 Working Pressure psi/bar Comp #4 Full Load Capacity cfm

T01 PH High Pressure Set Point psi/bar T01 PL Low pressure Set Point psi/bar T01 Pm Minimum Pressure Alarm psi/bar T01 SQ Sequence Rotation Mode

EHR FIFO TR VEC

T01 01 Comp #1 Priority T01 02 Comp #2 Priority T01 03 Comp #3 Priority T01 04 Comp #4 Priority

T02 PH High Pressure Set Point psi/bar T02 PL Low pressure Set Point psi/bar T02 Pm Minimum Pressure Alarm psi/bar T02 SQ Sequence Rotation Mode

EHR FIFO TR VEC

T02 01 Comp #1 Priority T02 02 Comp #2 Priority T02 03 Comp #3 Priority T02 04 Comp #4 Priority

T03 PH High Pressure Set Point psi/bar T03 PL Low pressure Set Point psi/bar T03 Pm Minimum Pressure Alarm psi/bar T03 SQ Sequence Rotation Mode

EHR FIFO TR VEC

T03 01 Comp #1 Priority T03 02 Comp #2 Priority T03 03 Comp #3 Priority T03 04 Comp #4 Priority

Page 79

S01 Ct Real Time Clock Set S01 PS Pressure Schedule Enable S01 AR Auto Restart Enable S01 RP Rotation Interval or Time S01 TS Default Table

T01 T02 T03

S02 P> Pressure Units S02 NC Number of Compressors

bar psi kPa 1 2 3 4

S02 PM Maximum Pressure Alarm psi/bar S02 CF Stop Control Function S02 TO Tolerance S02 DA Damping S02 PC Pressure Change Time min S02 AI Auxiliary Input Function S02 AO Auxiliary Output Function

S03 1O Pressure Offset S03 1R Pressure Range

P02 PF Prefill Function

!>X

P02 PT Prefill Time sec P02 PP Prefill Pressure psi/bar P02 01 Compressor #1 Prefill Function P02 02 Compressor #2 Prefill Function P02 03 Compressor #3 Prefill Function P02 04 Compressor #4 Prefill Function

! !

C01 01 Compressor #1 Running Hours hrs C01 02 Compressor #2 Running Hours hrs C01 03 Compressor #3 Running Hours hrs C01 04 Compressor #4 Running Hours hrs

C02 01 Compressor #1 Connection

I-PCB V-PCB I-485 V-485

C02 Compressor #1 Start Time sec C02 Compressor #1 Stop Time sec

C02 02 Compressor #2 Connection

I-PCB V-PCB I-485 V-485

C02 Compressor #2 Start Time sec C02 Compressor #2 Stop Time sec

C02 03 Compressor #3 Connection

I-PCB V-PCB I-485 V-485

C02 Compressor #3 Start Time sec C02 Compressor #3 Stop Time sec

C02 04 Compressor #4 Connection

I-PCB V-PCB I-485 V-485

C02 Compressor #4 Start Time sec C02 Compressor #4 Stop Time sec

Ingersoll Rand X41 Operator’s Manual

Specifications and Main Features

Frequently Asked Questions

User Manual