Ingersoll-Rand X41 User Manual
Application & Compressor Interconnect Guide
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
System Automation X4I
C.C.N. : 80443864
More Than Air. Answers.
Online answers: http://www.air.irco.com
REV. : A
DATE : APRIL 2007
SECTION 1 — TABLE OF CONTENTS
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SECTION 1 — TABLE OF CONTENTS................................ 2
SECTION 2 — INTRODUCTION........................................ 4
SECTION 3 — SAFETY..................................................... 4
INSTALLATION ............................................................... 4
OPERATION.................................................................... 4
MAINTENANCE AND REPAIR ........................................... 4
SECTION 4 — INSTALLATION ......................................... 6
Unit Location ................................................................. 6
Power Supply ................................................................. 7
Pressure Sensor Location ............................................... 7
SUPPLY (WET) Side Pressure Control ........................ 7
DEMAND (DRY) Side Pressure Control ...................... 7
Pressure Sensor Connection........................................... 8
IR-PCB Interface Module ................................................. 8
Input Functions.............................................................. 9
Ready Input ............................................................. 9
Ready Input, Alternative Connection Method ........... 9
Run Input .............................................................. 10
Warning Input (optional)........................................ 10
Output Functions ......................................................... 11
Pressure Switch Regulation.................................... 11
Digital Regulation Control Terminal C01 ............... 11
Service Maintenance Switch ................................... 12
Auxiliary Input (Option) ......................................... 12
Auxiliary Output (Option) ...................................... 13
RS485 Communications ........................................ 13
SECTION 5 — ASSISTANCE ........................................... 13
SECTION 6 — X4I Overview and Interconnect Drawings 13
X4I Overview................................................................ 11
X4I Interconnect To Ingersoll Rand Unigy &
Nirvana 15 - 30KW (20-40HP) Compressors ................. 15
Unigy 1 1of2 ......................................................... 11
Unigy 1 2of2 ......................................................... 11
Unigy 2/3 1of2...................................................... 11
Unigy 2/3 2of2...................................................... 11
Nirvana 15 - 30KW (20-40HP) 1of2 ........................ 20
Nirvana 15 - 30KW (20-40HP) 2of2 ........................ 21
X4I Interconnect To Ingersoll Rand Intellisys Redeye
Controlled Compressors ...............................................22
SSR Redeye 1of3.....................................................23
SSR Redeye FV 2of3 ................................................24
SSR Redeye SD 3of3 ...............................................25
X4I Interconnect To Ingersoll Rand Intellisys SE
Controlled Compressors ...............................................26
SE UP 1of2..............................................................27
SE UP 2of2..............................................................28
SE ESA 1of2 ............................................................29
SE ESA 2of2 ............................................................30
SE DSA 1of2 ...........................................................31
SE DSA 2of2 ...........................................................32
X4I Interconnect To Ingersoll Rand Intellisys SG
Controlled Compressors ...............................................33
SG SSR 1of2............................................................34
SG SSR 2of2............................................................35
SG Sierra 1of2 ........................................................36
SG Sierra 2of2 ........................................................37
X4I Interconnect To Ingersoll Rand Pressure Switch
Controlled Compressors ...............................................38
SSR UP5 11-22 SD 1of2 ..........................................39
SSR UP5 11-22 SD 2of2 ..........................................40
SSR UP5 22-37 SD 1of2 ..........................................41
SSR UP5 22-37 SD 2of2 ..........................................42
SSR UP6 15-30 FV 1of2...........................................43
SSR UP6 15-30 FV 2of2...........................................44
SSR UP6 15-30 SD 1of2 ..........................................45
SSR UP6 15-30 SD 2of2 ..........................................46
SSR UP6 40-50 FV 1of2...........................................47
SSR UP6 40-50 FV 2of2...........................................48
SSR UP6 40-50 SD 1of2 ..........................................49
SSR UP6 40-50 SD 2of2 ..........................................50
UP6 5-15 FV 1PH 60Hz 1of2...................................51
UP6 5-15 FV 1PH 60Hz 2of2...................................52
UP6 5-15 FV 3PH 60Hz 1of2...................................53
UP6 5-15 FV 3PH 60Hz 2of2...................................54
UP6 5-15 SD 3PH 60Hz 1of2 ..................................55
UP6 5-15 SD 3PH 60Hz 2of2 ..................................56
UP6 5-15 FV 3PH 50Hz 1of2...................................57
UP6 5-15 FV 3PH 50Hz 2of2...................................58
2
X4I Interconnect To Ingersoll Rand Pressure Switch
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Controlled Compressors .................................. Continued
UP6 5-15 SD 3PH 50Hz 1of2.................................. 59
UP6 5-15 SD 3PH 50Hz 2of2.................................. 60
SSR M15-22c 20-30HP XF EP HP HXP
50-60Hz 1of2 ........................................................ 61
SSR M15-22c 20-30HP XF EP HP HXP
50-60Hz 2of2 ........................................................ 62
M37-50 1of2 ......................................................... 64
M37-50 2of2 ......................................................... 65
EP 20-30 ESP FV 1of2............................................. 66
EP 20-30 ESP FV 2of2............................................. 67
EP 20-30 ESP SD 1of2 ............................................ 68
EP 20-30 ESP SD 2of2 ............................................ 69
X4I Interconnect To Ingersoll Rand Intellisys SGN / SGNe
Controlled Compressors .............................................. 70
Nirvana SGN/SGNe 1of3 ........................................ 71
Nirvana SGN/SGNe 2of3 ........................................ 72
Nirvana SGN/SGNe 3of3 ........................................ 73
SI1 Interface to Redeye, SE, SG Controllers ............ 73
X4I Interconnect To Ingersoll Rand Intellisys S3 ........... 74
Intellisys S3 1of2 ................................................... 75
Intellisys S3 2of2 ................................................... 76
X4I Interconnect to Ingersoll Rand Small Reciprocating
Air Compressors ......................................................... 77
UP6RE 7.5–15 175, UP6RX 7.5–15 175 1of3 .......... 78
UP6RE 7.5–15 175, UP6RX 7.5–15 175 2of3 .......... 79
UP6RE 7.5–15 175, UP6RX 7.5–15 175 3of3 .......... 80
Models 2340, 2475, 2545, 7100,
15T & 3000 10f3................................................... 81
Models 2340, 2475, 2545, 7100,
15T & 3000 20f3................................................... 82
Models 2340, 2475, 2545, 7100,
15T & 3000 30f3................................................... 83
Excessive Pressure Shutdown Switch Example Before
Installation .................................................................. 84
Excessive Pressure Shutdown Switch Example After
Installation .................................................................. 85
3
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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
SECTION 3 — SAFETY
WARNING :
!
WARNING :
WARNING :
!
WARNING :
INSTALLATION
Risk of Danger
Risk of Electric Shock
Risk of High Pressure
Consult Manual
• 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 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.
compressors may have electro-pneumatic or
microprocessor based controls. The X4I is completely
customizable to meet the specific needs of your
compressed air system.
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 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.
4
• Carry out the following operations
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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.
5
www.air.irco.com X4I System Automation
SECTION 4 — INSTALLATION
It is recommended that installation and commissioning
be carried out by an authorized and trained product
supplier.
Dimensions 11.45” x 9.45” x 6.0”
291mm x 241mm x 152mm
Weight 14lb (6.4kg)
Mounting Wall, 4 x screw fixings
Enclosure IP65, NEMA 4
Supply 230Vac +/- 10%, 50 Hz
115Vac +/- 10%, 60 Hz
Power 50VA
Temperature 32°F to 115°F
(0°C to 46°C)
Humidity 0% to 95% RH
(non-condensing)
electrical and safety regulations).
X4I X05 CONNECTOR
SPECIFICATIONS
Local Disconnect (Breaker) Box
Fused for 50VA
Power Cable
3 conductor (L, N, E)
(Sized in accordance with local
PRESSURE TRANSDUCER CABLE
2 Conductor Cable, 18 Gauge Stranded
Reference X4I Operations Manual for Pressure
Earth Shielded
No Greater Than 330FT (100M)
24VDC Control Voltage
25
26
PT CONNECTOR
+VDC Pin #3
Signal Pin #1
Sensor Connection Details
PRESSURE TRANSDUCER
RECEIVER
Ingersoll Rand Automation
Model X4I
On/Off
Switch
Pressure Transducer Cable
DRIP LEG
Supply Voltage Cable
Compressor #1 Control Cable
X4I X01 CONNECTOR
V1
1
2
3
4
5
6
Compressor #3 Control Cable
X4I X03 CONNECTOR
V3
13
14
15
16
17
18
Compressor
#1
IR-PCB CONNECTOR
Compressor
#3
IR-PCB CONNECTOR
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.
COMPRESSOR CONTROL CABLE
V1
1
2
3
4
5
6
V1
1
2
3
4
5
6
IR-PCB
IR-PCB
Compressor #2 Control Cable
Compressor #1 Control Cable
Compressor #2 Control Cable
X4I X02 CONNECTOR
V3
7
8
9
10
11
12
Compressor #4 Control Cable
X4I X04 CONNECTOR
V4
19
20
21
22
23
24
7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
Single Conductor Wire, 18 Gauge Stranded, Quantity (7)
No Greater Than 330FT (100M)
Compressor #3 Control Cable
Reference X4I Compressor
Interconnect and Application Guide
For Connections Between The
Compressor And The IR-PCB
Compressor
#2
IR-PCB CONNECTOR
V1
1
2
3
4
5
6
Compressor
#4
IR-PCB CONNECTOR
V1
1
2
3
4
5
6
OR
In Grounded Conduit
24VAC Control Voltage
Compressor #4 Control Cable
IR-PCB
IR-PCB
6
POWER SUPPLY
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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).
DEMAND (DRY) SIDE PRESSURE CONTROL
1
P
P
1234
XPM-TAC24
EENL
X01
LNE
X04
X04
1
234
VOLTAGE SELECT
1
234
VOLTAGE SELECT
230Vac
115Vac
Power Supply Terminals
Ensure that the voltage select input is properly
jumpered for the incoming power. Default voltage
configuration is 230Vac.
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.
SUPPLY (WET) SIDE PRESSURE CONTROL
P
2
Pressure Sensor Located After Shared Cleanup
Equipment
P
P
1
P
2
Pressure Sensor Located After Individual Cleanup
Equipment
Ensure each compressor is equipped with
independent excess pressure shutdown. An increase in
pressure differential across air treatment equipment can
result in excess compressor discharge pressure.
Regular routine monitoring of pressure differential
across air treatment equipment is recommended.
1
P
2
Pressure Sensor Located Before Cleanup Equipment
Dry side pressure will be lower than the system
pressure due to pressure differential losses across air
treatment equipment. The nominal system pressure will
reduce as the air treatment differential pressure
increases.
7
PRESSURE SENSOR CONNECTION
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The pressure sensor connects to terminal X05 of the X4I
terminal PCB using a shielded 18 AWG maximum 2-
Pressure Sensor Wiring and Location
Wire polarity is important.
IR-PCB INTERFACE MODULE
conductor cable no more than 330 feet (100 meters) in
length. The transducer threads are BPT. It is the
equivalent of ¼” NPT.
The IR-PCB is designed to interface a compressor with
the X4I using a 7-conductor shielded cable or individual
wires run through grounded conduit 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.
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 electro-mechanical 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. Each air compressor must have Auto
Restart capability.
V
For variable speed compressor(s) equipped with a
“variable/fixed” digital input function, install a 7conductor shielded cable from the IR-PCB to the X4I.
8
Consult the air compressor manual or your air
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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.
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.
Consult the X4I Interconnect and Application Guide
prior to the installation of the X4I and the IR-PCB to the
air compressor.
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.
READY LAMP
+V
0V
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
F1
0Vac
READY
Alternative Ready Signal Connection
Never connect the “Ready” input positive voltage
READY
ALARM
RUN
C04
Typical Ready Input Wiring
The READY input will accept 12V to 250V ac (50/60Hz)
or dc.
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
Do not connect a voltage greater than 250Vac/dc to
if the emergency stop button is activated.
this input.
This input must be connected to a circuit of the
compressor control system that will be energized when
9
RUN INPUT
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MAIN (LINE) CONTACTOR
The IR-PCB input common terminal must always be
connected to the neutral, common or 0V line of the
applied input voltage.
0V
+V
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
+V
+V
AUXILIARY SWITCH
0V
0V
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
+V
0V
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 IRPCB 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.
ALARM
RUN
C04
READY
The IR-PCB input common terminal must always be
connected to the neutral, common or 0V line of the
applied input voltage.
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.
10
OUTPUT FUNCTIONS
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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 electromechanical pressure switch load/unload regulation.
+V
LOAD
SOLENOID
C
C
C
O
N
N
OUT
C02
C
O
N
N
IN
Two Wire Pressure Switch Connections
SOLENOID
+V
RUN-ON
0V
LOAD
0V
TIMER
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.
OUT
N
C02
O
N
N
IN
O
N
C
C
C
C
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).
V
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
11
compressor number) with an additional wire. Use a 7-
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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.
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.
+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.
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
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.
1
C05
2
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.
OUT
NO
C
NC
NO
IN
C
NC
Local/Remote
common
Remote Load
common
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
Alternate Logic
Examine the “i-PCB” internal output circuit diagram to
establish any desired switching logic that may differ from
normal practice.
32
31
Auxiliary Input Circuit
The input is designed to detect a remote “volt-free”
Do not attempt to utilize “Digital Pressure
switching contact (rated for a minimum 24VDC @ 10mA).
Regulation Control” (terminal C01) and the “Pressure
Switch Control” (terminal C02) output connections at the
same time for different products. These two output
12
AUXILIARY OUTPUT (OPTION)
www.air.irco.com X4I System Automation
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
R6
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 proprietary
Multi485 protocol.
This can be only used for remote connectivity to
optional X4I expansion networked units and modules
with proprietary Multi485 communications capabilities.
X06
L1
L2
RS-485 Connection Circuit
30
29
28
27
34
33
L1
L2
RS485
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 3phase 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: 3phase power supply transformer, high
voltage switchgear unit, frequency
inverter drive module, radio
communications antenna.
RS485 data communications and other low voltage
signals can be subject to electrical interference. This
potential can result in intermittent malfunction or
SECTION 5 — ASSISTANCE
Contacting Technical Support Services or Service Bulletins listed on the IR ServiceNet can provide further assistance if there
are other questions or concerns during Installation and Start-up. Also, additional Application and Compressor Interconnect
Guides will be posted and available on the IR ServiceNet as they are developed and created.
SECTION 6 — X4I OVERVIEW AND INTERCONNECT DRAWINGS
The following pages are to assist with the connection of the X4I to variety of Ingersoll Rand Compressors. These drawings
are for
information is intended to be used in conjunction with the compressor’s original control circuit diagram.
Guidance Only; connections may differ with date, model, type, variant, special, custom or concession builds. This
13
Dimensions 11.45” x 9.45” x 6.0”
291mm x 241mm x 152mm
Weight 14lb (6.4kg)
Mounting Wall, 4 x screw fixings
Enclosure IP65, NEMA 4
Supply 230Vac +/- 10%, 50 Hz
115Vac +/- 10%, 60 Hz
Power 50VA
Temperature 32°F to 115°F
(0°C to 46°C)
Humidity 0% to 95% RH
(non-condensing)
SPECIFICATIONS
Local Disconnect (Breaker) Box
Fused for 50VA
Power Cable
3 conductor (L, N, E)
(Sized in accordance with local
electrical and safety regulations).
PRESSURE TRANSDUCER CABLE
2 Conductor Cable, 18 Gauge Stranded
Earth Shielded
No Greater Than 330FT (100M)
24VDC Control Voltage
X4I X05 CONNECTOR PT CONNECTOR
25 +VDC Pin #3
26 Signal Pin #1
Reference X4I Operations Manual for Pressure
Sensor Connection Details
PRESSURE TRANSDUCER
RECEIVER
DRIP LEG
Ingersoll Rand Automation
Model X4I
On/Off
Switch
Pressure Transducer Cable
Supply Voltage Cable
Compressor
Compressor #1 Control Cable
X4I X01 CONNECTOR IR-PCB CONNECTOR
V1 V1
1 1
2 2
3 3
4 4
5 5
6 6
Compressor
Compressor #3 Control Cable
X4I X03 CONNECTOR IR-PCB CONNECTOR
V3 V1
13 1
14 2
15 3
16 4
17 5
18 6
#1
#3
IR-PCB
IR-PCB
Compressor #2 Control Cable
Compressor #1 Control Cable
Compressor #2 Control Cable
X4I X02 CONNECTOR IR-PCB CONNECTOR
V3 V1
7 1
8 2
9 3
10 4
11 5
12 6
Compressor #4 Control Cable
X4I X04 CONNECTOR IR-PCB CONNECTOR
V4 V1
19 1
20 2
21 3
22 4
23 5
24 6
7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
COMPRESSOR CONTROL CABLE
OR
Single Conductor Wire, 18 Gauge Stranded, Quantity (7)
In Grounded Conduit
No Greater Than 330FT (100M)
24VAC Control Voltage
Compressor #4 Control Cable
Compressor #3 Control Cable
Reference X4I Compressor
Interconnect and Application Guide
For Connections Between The
Compressor And The IR-PCB
Compressor
IR-PCB
#2
Compressor
IR-PCB
#4
X4I Overview Page 14
X4I Interconnect To Ingersoll Rand Unigy & Nirvana 20-40 HP Compressors
Refer to the X4I Overview Drawing for the X4I Compressor 2 through 4 X01 to IR-PCB terminal connections
For Unigy Compressors::
All Unigy Phase 1 compressors “MUST” be converted to Phase 2 or higher. Contact Technical Support Services for the CCN's required for this
conversion.
For Nirvana 20-40HP Compressors:
Remote Control “MUST” be set to on.
Check the Nirvana Software revision level. It “MUST” be updated to Version 1.10 or greater. Contact Technical Support Services to acquire the
update.
Drawing Notes For Unigy Phase 1 Machines:
Note: All Unigy Phase 1 compressors “MUST” be converted to Phase 2 or higher. Contact Technical Support Services for the CCN's required for this conversion. This Drawing on
Page 16 is a representation for “AFTER” the conversion is completed.
Note: The Unigy Target Pressure “MUST” be set equal to the “midpoint” of the X4I pressure control band.
Drawing Notes For Unigy Phase 2/3 Machines:
Note: The Unigy Target Pressure “MUST” be set equal to the “midpoint” of the X4I pressure control band.
Drawing Notes For Nirvana 20-40HP Machines:
Note: Remote Control “MUST” be set to on.
Note: The Nirvana Target Pressure “MUST” be set equal to the “midpoint” of the X4I pressure control band.
Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to
be used in conjunction with the compressor’s original control circuit diagram.
X4I Interconnect To Ingersoll Rand Unigy & Nirvana 20-40 HP Compressors Page 15
Unigy Phase 1
X4I
COMPRESSOR #1
X01 TERMINAL
V1
1
2
3
4
5
6
Refer to the X4I Overview Drawing
for the X4I Compressor 2 through 4
terminal connections
C05
V
1
SEQ CONT
LOAD UNL
2
GND
3
D11
4
D12
5
+20V
6
LED 5 V
LED 2 LOAD
LED 1 SEQ
READY
1
2
+VDC
VFD/fixed
V
C01
Load Enable
SA1
HATS
10
13
D13
+24VDC
Load/Unload
C03
NO
OUT
E-STOP
14
EN
C
IN
NC
NO
12
DI-4
C
C02
NC
+24VDC
DI-2
0V
LED 4
VFD/FIX
LED 3
RUN
ALARM
11
9
C04
RUN
READY
5
IR-PCB
17
NO
Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds.
This information is intended to be used in conjunction with th e co mpr esso r ’s or igin al control circuit diagram.
Unigy Phase 1 1of2 Page 16
Unigy 1
7.5 - 15 HP
5.5 – 11 kW
Unigy Phase 1
Unigy Phase 1 2of2 Page 17
Unigy Phase 2/3
X4I
COMPRESSOR #1
X01 TERMINAL
V1
1
2
3
4
5
6
Refer to the X4I Overview Drawing
for the X4I Compressor 2 through 4
terminal connections
C05
V
1
2
3
4
5
6
1
2
V
SEQ CONT
LOAD UNL
GND
C03
D11
D12
+20V
LED 5 V
LED 2 LOAD
LED 1 SEQ
LED 4
READY
D13
+24VDC
VFD/fixed
C01
Load Enable
+VDC
SA1
10
HATS
13
Load/Unload
E-STOP
NO
OUT
14
EN
C
IN
NC
NO
12
DI-4
C
C02
NC
VFD/FIX
LED 3
RUN
ALARM
11
9
C04
RUN
READY
5
+24VDC
DI-2
0V
IR-PCB
17
NO
Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds.
This information is intended to be used in conjunction with th e co mpr esso r ’s or igin al control circuit diagram.
Unigy Phase 2/3 1of2 Page 18
Unigy
7.5 - 15 HP
5.5 – 11 kW
Unigy Phase 2/3
Unigy Phase 2/3 2of2 Page 19
Nirvana 15 – 30KW
(20 – 40HP)
X4I
COMPRESSOR #1
X01 TERMINAL
V1
1
2
3
4
5
6
Refer to the X4I Overview Drawing
for the X4I Compressor 2 through 4
terminal connections
C05
V
1
2
3
4
5
6
1
2
V
SEQ CONT
LOAD UNL
GND
C03
D11
D12
+20V
LED 5 V
LED 2 LOAD
LED 1 SEQ
LED 4
READY
12
+24VDC
+VDC
VFD/fixed
C01
Load Enable
Load/Unload
18
32
33
NO
OUT
Remote
VFD / FIXED
Remote
LOAD ENABLE
Remote
LOAD / UNLOAD
C
IN
NC
NO
C
C02
NC
37
LED 3
RUN
ALARM
4
C04
RUN
READY
20
SAFE
C
COM
IR-PCB
6
NC
Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds.
This information is intended to be used in conjunction with th e co mpr esso r ’s or igin al control circuit diagram.
Nirvana 15 - 30KW (20-40HP) 1of2 Page 20
Nirvana
20 - 40 HP
15 – 30 kW
Nirvana 15 - 30KW
(20-40HP)
Nirvana 15 - 30KW (20-40HP) 2of2 Page 21
X4I Interconnect To Ingersoll Rand Intellisys Redeye Controlled Compressors
Refer to the X4I Overview Drawing for the X4I Compressor 2 through 4 X01 to IR-PCB terminal connections
For Redeye Intellisys Controlled Machines:
The ‘MASTER CONTROL’ setting of the Intellisys controller must be set to ‘ON’
The 'SEQUENCER' setting of the Intellisys controller must be set to 'ON'.
Auto Restart must be turned 'ON’ to allow the machines to stop in Auto restart when unloaded by the X4I.
The Intellisys must be run in the Online/Offline regulation mode. Do not use Modulation or ACS.
Check the Intellisys software revision level. Always update to the latest revision prior to operation.
For DSA Redeye Controllers, the 'SEQUENCER Option’ must be purchased. installed and then turned on.
CCN: 39225099
For ESA Redeye Intellisys Controllers, the SI1 interface (CCN: 42425710) must be used to allow the Redeye to be controlled by the X4I
For Sierra Redeye Intellisys Controllers, the SI1 interface (CCN: 42425710) must be used to allow the Redeye Controller to be sequenced/controlled
by the X4I
Drawing Notes For Redeye Intellisys Controlled Machines:
Note: For Star Delta starter wiring the X4I Run signal should be connected directly to the 1M coil.
Note: For Full voltage wiring the 1S (1Sb) interlock will not be used. The X4I Run signal can be connected directly to the Intellisys BTS1-28 terminal.
Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to be
used in conjunction with the compressor’s original control circuit diagram.
X4I Interconnect To Ingersoll Rand Intellisys Redeye Controlled Compressors Page 22
X4I
COMPRESSOR #1
X01 TERMINAL
V1
1
2
3
4
5
6
Refer to the X4I Overview Drawin g
for the X4I Compressor 2 through 4
terminal connections
C05
V
1
SEQ CONT
LOAD UNL
2
GND
3
D11
4
D12
5
+20V
6
LED 5 VFD
LED 2 LOAD
LED 1 SEQ
READY
1
2
SSR Redeye
Analog Barrier Board
BTS3-
11
+VDC
VFD/fixed
V
C03
LED 4
LED 3
RUN
C01
Load Enable
Load/Unload
C02
C04
IR-PCB
NO
OUT
NC
NO
IN
NC
ALARM
RUN
READY
C
C
0VAC
110VAC
E-STOP
1M
HATS
12
16
18
BTS1-
1
BTS1-
34
Remote Load/Unload
(was Remote Start)
Remote Load Enable
(was Remote Stop)
Guidance only; connections may differ with date, model, type, variant, special, cus tom or concession builds.
This information is intended to be used in conjunction with the compressor’s original control circuit diagram.
SSR Redeye 1of3 Page 23
BTS2-
1
2
3
Starter Interface Board
SSR Redeye FV
SSR Redeye FV 2of3 Page 24
SSR Redeye SD
SSR Redeye SD 3of3 Page 25
X4I Interconnect To Ingersoll Rand Intellisys SE Controlled Compressors
Refer to the X4I Overview Drawing for the X4I Compressor 2 through 4 X01 to IR-PCB terminal connections
For All SE Intellisys Controlled Machines:
The 'SEQUENCER' setting of the Intellisys controller must be set to 'ON'.
Auto Restart must be turned 'ON’ to allow the machines to stop in Auto restart when unloaded by the X4I.
The Intellisys must be run in the Online/Offline regulation mode. Do not use Modulation or ACS.
Check the Intellisys software revision level. Always update to the latest revision prior to operation.
For UP SE Intellisys Controllers
Minimum Software Version 1.11
CCN: 39217047 (w/o PORO)
CCN: 39217039 (w PORO)
When installing the Sequence Option to enable Remote Load/Unload, the Remote Start Stop input terminals are now used for the Remote Load
I nputs. Remote Start Stop will no longer be functional. The SI1 interface (CCN: 42425710) can be used in place of the Sequence Option to allow
the SE controlled machines to function with both Remote Load Unload and Remote Start Stop.
Software Version 1.20 and Greater
The 'CONTACT SEQUENCE' setting of the Intellisys controller must be set to 'ON'.
Drawing Notes For UP SE Intellisys Controlled Machines:
Note: For Star Delta starter wiring the X4I Run signal should be connected directly to the 1M coil.
Note: For Full voltage wiring the 1S (1Sb) interlock will not be used. The X4I Run signal can be connected directly to the Intellisys J5-1 terminal.
Note: For Pegasus machines wiring may be factory installed connecting the Intellisys Alarm Relay J5-9, J5-10 and J5-11 to a terminal strip but unused. Remove any factory installed
wiring from the Intellisys Alarm Relay contacts and connect the X4I Interface board wiring directly to the Intellisys Alarm Relay terminals J5-9 and J5-10.
For ESA SE Intellisys Controllers, the 'SEQUENCER Option’ must be purchased. installed and then turned on.
Minimum Software Version 1.40
CCN: 39217047 (w/o PORO)
CCN: 39217039 (w PORO)
When installing the Sequence Option to enable Remote Load/Unload, the Remote Start Stop input terminals are now used for the Remote Load
I nputs. Remote Start Stop will no longer be functional. The SI1 interface (CCN: 42425710) can be used in place of the Sequence Option to allow
the SE controlled machines to function with both Remote Load Unload and Remote Start Stop.
Drawing Notes For ESA SE Intellisys Controlled Machines:
Note: For Star Delta starter wiring the X4I Run signal should be connected directly to the 1M coil.
Note: For Full voltage wiring the 1S (1Sb) interlock will not be used. The X4I Run signal can be connected directly to the Intellisys J5-1 terminal.
For DSA SE Intellisys Controllers, the 'SEQUENCER Option’ must be purchased. installed and then turned on.
CCN: 22179238
When installing the Sequence Option to enable Remote Load/Unload, the Remote Start Stop input terminals are now used for the Remote Load
inputs. Remote Start Stop will no longer be functional. The SI1 interface (CCN: 42425710) can be used in place of the Sequence Option to allow
the SE controlled machines to function with both Remote Load Unload and Remote Start Stop.
Drawing Notes For DSA SE Intellisys Controlled Machines:
Note: For Star Delta starter wiring the X4I Run signal should be connected directly to the 1M coil.
Note: For Full Voltage wiring, the 1S (1Sb) interlock will not be used. The X4I Run signal can be connected directly to the Intellisys terminal 42.
,
For Sierra SE Intellisys Controllers, the SI1 interface (CCN: 42425710) must be used to allow the SE Controller to be sequenced/controlled by the X4I
Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to be
used in conjunction with the compressor’s original control circuit diagram.
X4I Interconnect To Ingersoll Rand Intellisys SE Controlled Compressors Page 26
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