Ingersoll Rand X8I Operator’s Manual
Ingersoll Rand
Operator’s Manual
System Automation
X8I
Before installing or starting this unit for the first
time, this manual should be studied carefully to
obtain a working knowledge of the unit and or the
duties to be performed while operating and
maintaining the unit.
RETAIN THIS MANUAL WITH UNIT. This Technical
manual contains IMPORTANT SAFETY DATA and
should be kept with the unit at all times.
More Than Air. Answers.
Online answers: http://www.air.irco.com
C.C.N. : 80444060
REV. : B
DATE : MAY 2008
SECTION 1 TABLE OF CONTENTS
SECTION 1 TABLE OF CONTENTS ..........................2
CTION 2 INTRODUCTION
SE
...................................3
SECTION 3 SAFETY ....................................................3
INSTALLATION .............................................................................3
OPERATION
MAINTENANCE AND REPAIR
.................................................................................. 3
.................................................3
SECTION 4 COMPRESSOR CONNECTION AND
CONTROL ........................................................................5
COMPRESSOR CONNECTION AND CONTROL ..............5
OPTIONAL CONNECTION METHODS
PRESSURE DETECTION AND CONTROL
X8I MAIN DISPLAY
....................................................................7
.................................5
............................6
SECTION 5 INSTALLATION OVERVIEW ................. 8
INSTALLATION .............................................................................9
PRESSURE DISPLAY
X8I QUICK SETUP CONFIGURATION
OPTIONAL FEATURES AND FUNCTIONS.........................26
.................................................................26
...............................26
SECTION 9 SYSTEM CONFIGURATION ...............27
DISPLAY ITEM STRUCTURE...................................................27
NORMAL OPERATIONAL DISPLAY MENU PAGE P00
ACCESSING THE X8I CONFIGURATION SCREENS
USER LEVEL MENUS ................................................................29
SERVICE LEVEL MENUS ..........................................................30
X8I CONFIGURATION SCREENS
X8I COMPRESSOR CONNECTIVITY AND FUNCTIONAL
SETTINGS
.....................................................................................41
.........................................31
27
........27
SECTION 10 FAULT CODES ....................................46
X8I COMPRESSOR FAULT INDICATIONS, TYPES, AND
CODES: ..........................................................................................46
UNIT LOCATION
POWER SUPPLY
PRESSURE SENSOR LOCATION
PRESSURE SENSOR CONNECTION
IRPCB INTERFACE MODULE ................................................10
IR485 AND IRV485 GATEWAY MODULE........................11
IR485 COMMUNICATION PROTOCOL ...............................11
RS485 NETWORK
..........................................................................9
........................................................................... 9
.............................................9
....................................10
......................................................................11
SECTION 6 CONTROL FEATURES AND
FUNCTIONS ...................................................................13
STANDARD CONTROL FEATURES AND
FUNCTIONALITY .......................................................................13
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
ALTERNATE CONTROL FEATURES AND
FUNCTIONALITY
.......................................................................15
.......................................................................18
SECTION 11 — PARTS LIST….. ...............................48
SECTION 12 — DIAGRAMS…... ...............................49
WIRING DIAGRAM……….…….....................................49
CONNECTION DIAGRAM……... ...................................50
XPM-TAC24...................................... ...................................51
X8I COMMISSIONING FORM… ...............................52
SECTION 7 DISPLAY AND MENU OPERATION ..20
INDICATORS ...............................................................................23
SECTION 8 COMMISSIONING ...............................26
PHYSICAL CHECKS ...................................................................26
2
SECTION 2 INTRODUCTION
!
!
The X8I is an advanced system controller designed to
provide safe, reliable, and energy-efficient management
of your compressed air system. The X8I is capable of
controlling up to eight (8) positive displacement air
compressors. The compressors may be fixed speed,
variable speed or multi-step and have electro-pneumatic
SECTION 3 SAFETY
WARNING : Risk of Danger
WARNING : Risk of Electric Shock
WARNING : Risk of High Pressure
WARNING : Consult Manual
Before installing or operating the X8I, 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 X8I.
The X8I 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 X8I 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.
or microprocessor based controls. The X8I is uniquely
configurable and customizable to meet the specific needs
of some of the most complex compressed air system.
Additionally, the X8I control network can expand to
include monitoring and control of various compressed air
system components.
OPERATION
The X8I must only be operated by competent
•
personnel under qualified supervision.
Never remove or tamper with safety devices, guards
•
or insulation materials fitted to the X8I.
The X8I 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 warning signs to the equipment stating ‘THIS
UNIT CAN BE STARTED REMOTELY’ in a prominent
location, one on the outside of the equipment, the
other 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 X8I:
Isolate the X8I from the main electrical power
i.
supply. Lock the isolator in the ‘OFF’ position
and remove the fuses.
3
Attach a label to the isolator switch and to the
ii.
unit stating ‘WORK IN PROGRESS - DO NOT
APPLY VOLTAGE’. Do not switch on electrical
power or attempt to start the X8I 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 X8I must only be cleaned with a damp cloth,
•
using mild detergents if necessary. Avoid the use of
any substances containing corrosive acids or alkalis.
Do not paint the control faceplate or obscure any
•
indicators, controls, instructions or warnings.
4
SECTION 4 COMPRESSOR CONNECTION AND CONTROL
ir-485
irV-485
Ingersoll Rand
102
psi
1 3
1
2 4
CAP
18:35 #2
5 7
6 8
COMPRESSOR CONNECTION AND
CONTROL
Each air compressor in your system must be interfaced to
the X8I. Interface methods may vary depending on the
compressor type and/or local control configuration. The
following are main methods for interfacing compressors
to the X8I:
1) The ir-PCB Interface module that is designed to
interface to any positive displacement air compressor
(regardless of make or manufacturer) with an available
control voltage of 12-250V (either 50Hz or 60Hz).
The ir-PCB interface module is installed within the
compressor control area and connected to the X8I using
a six (6) wire cable, (seven (7)-wire cable for Nirvana 7.5 to
15HP (5.5 to 11KW).
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 X8I.
2) The ir-485 Gateway Interface module that is designed
to interface to any Ingersoll Rand Intellisys controlled
(Non-Nirvana) compressor. The X8I communicates to the
ir-485 Gateway via a two wire, RS485 network utilizing the
ir485 protocol. All IR compressors equipped with Intellisys
controllers (Non-Nirvana) require this interface.
The irV-485 Gateway interface module is installed within
the compressor control cabinet and connected to the X8I
using Belden 9841 or equivalent RS485 cable.
Nirvana 7.5 to 15HP (5.5 to 11KW) connect via the
ir- PCB using seven (7)-wire cable.
4) Direct Connect via RS485 to any Ingersoll Rand
compressor that has an integrated RS485 network port
utilizing the ir485 protocol. The X8I communicates to
these compressors via a two wire, RS485 network. The
compressor is connected to the X8I using Belden 9841 or
equivalent RS485 cable.
4) Special Application Interface uses integration boxes
designed to accommodate various types of compressor
and regulation methods and system monitoring.
OPTIONAL CONNECTION METHODS
Expansion Module: EXP Box (Option)
As standard the X8I has four direct connect ‘ir-PCB’
terminal connections. This capability can be extended
with the use of an optional EXP Box. The EXP Box will add
another four direct connect ‘ir-PCB’ connection terminals.
This would allow a total of 8 compressors to connected
and controlled via ‘ir-PCB’ integration.
Compressors 1-4 connect via the X8I and Compressors 5-8
connect via the EXP Box
The EXP Box is suitable for wall mounting and must be
located adjacent to the X8I unit (max 33ft or 10m).
All Nirvana Compressors, 20 HP (15KW) and above
require the irV-485 Gateway.
The ir-485 Gateway interface module is installed within
the compressor control cabinet and connected to the X8I
using Belden 9841 or equivalent RS485 cable.
3) The irV-485 Gateway Interface module that is
designed to interface to any Ingersoll Rand Nirvana
compressor. The X8I communicates to the irV-485
Gateway via a two wire, RS485 network utilizing the ir485
protocol. All Nirvana Compressors, 20 HP (15KW) and
above, require this interface.
The EXP Box connects to the X8I controller via a two wire,
dedicated RS485 network
Use Belden 9841 or Equivalent In Grounded Conduit
No Greater Than 33ft (10m)
Up to four air compressors can be connected to the EXP
Box using a 6 or 7 wire cable and a compressor interface
ir-PCB (330ft (100m) max). The ‘ir-PCB’ connections are
identical to the X8I.
5
Remote Compressor Management; EX Box (option)
Ingersoll Rand
102
psi
1
CAP
1
5
2
6
3
7
4
8
18:35 #2
4000ft (1219m) max
From VSD Pressure Transducer
30ft
max
ir-PCB
o VSD Pressure Transducer Input
Ingersoll Rand
102
psi
1 3
2 4
1
CAP
18:35 #2
5 7
6 8
4000ft (1219) max
Ingersoll Rand
102
psi
1 3
1
2 4
CAP
18:35 #2
5 7
6 8
The EX Box is an ‘EXtension’ to the X8I providing
additional ‘ir-PCB’ connectivity.
The EX Box will typically be used to provide ‘ir-PCB’
connectivity at a remote location beyond the maximum
distance specification of compressors that require ‘ir-PCB’
type connection; 330ft (100m). This effectively expands
the hardwire connection scheme of the ‘ir-PCB” to the full
RS485 distance specification.
The EX box is suitable for wall mounting and can be
located up to 4000ft (1219m) from the X8I unit.
The EX Box connects to the X8I controller via a two wire,
RS485 network utilizing the IR485 protocol
The VSD Box connects to the X8I controller via a two wire,
RS485 network utilizing the ir485 protocol
Each air compressor in a system, that requires VSD Box
integration, must be equipped with an individual VSD
Box. Multiple VSD Boxes can be connected to the X8I as
long as the number of compressors does not exceed the
maximum number of compressors (8).
Remote Input & Output: I/O Box (option)
An I/O Box provides additional general purpose I/O
(input/output) for a system enhancing monitoring
capabilities and providing distributed system automation.
Up to two I/O Boxes can be connected to the X8I
controller. Each I/O Box features:
8 Digital Inputs
5 Analog Inputs
6 Relay Outputs
Use Belden 9841 or Equivalent In Grounded Conduit
No Greater Than 4000ft (1219m)
One (1) or two (2) air compressors can be connected
to the EX Box using a 6-wire cable and a compressor
interface ir-PCB (330ft (100m) max). The ‘ir-PCB’
connections are identical to the X8I.
The EX Box also provides optional ‘local pressure sensor’
connections. The compressor delivery pressure, local
system pressure and air treatment differential pressure
can be displayed.
Multiple EX Boxes can be connected to the X8I as long
as the number of compressors does not exceed the
maximum number of compressors (8).
Bolt-On VSD Control Integration: VSD Box (optional)
The VSD Box is intended to provide a method of
system integration for a VSD (Variable Speed Drive) air
compressor that is not equipped with any accessible
means of remote connectivity (such as IR- Nirvana). The
VSD Box will provide required functionality to enable
system integration and efficient control using the X8I
automation system.
The I/O Box connects to the X8I controller via a two wire,
RS485 network utilizing the ir485 protocol
Digital inputs can be used to monitor switching contact
devices. Each input can be set to act as an Alarm or
High Level Alarm input. Digital inputs can also be used
for metering (for example m3, ft3, kWh) providing an
accumulative count of pulses from a metering device.
Analog inputs can be used to monitor sensor devices (for
example: pressure differential, temperature, dewpoint,
flow, current, power, bearing condition). Each input is
equipped with adjustable high or low level detection that
can be used to activate an Alarm or High Level Alarm.
Relay outputs use ‘Virtual Relay Automation’ technology
and are totally configurable with duel input logic
functions. Relay functions can be assigned utilizing any
status or condition information available on a system
network from any compatible unit connected to the
network.
PRESSURE DETECTION AND CONTROL
The X8I utilizes the signal from a 4-20 ma pressure sensor
that is mounted remotely from the X8I 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 X8I can accept any pressure
sensor with a 4–20 ma output and a range of up to 8700
PSI (600 bar).
6
X8I MAIN DISPLAY
a
b
c
d
f
g
h
e
Ingersoll Rand
102
psi
A: 85%
1
CAP
1
5
2
6
3
7
4
8
102
PSI
1
a
b
c
d
e
17:30 #1
a
b
c
CAP
a
b
c
1
Keypad and Navigational Keys Functionality
a) Start
b) Reset
c) Stop
d) Menu
e) Enter
f) Escape
g) Up (Plus)
h) Down (minus)
Compressor Status Indicators :
a) Load Status
b) Run Status
c) Compressor Availability
System Alarms (Warning) :
a) Group Compressor Fault
b) Insufficient Capacity Alarm (Warning)
c) Restricted Capacity Alarm (Warning)
System Alarms (Warning) :
a) Unit Run Indicator (green LED)
b) Unit Alarm Indicator (Red LED)
User Interface :
a) System Pressure Value
b) System Pressure Units
c) Unit Status
d) Unit Active Functions
e) User Menu Item
7
SECTION 5 INSTALLATION OVERVIEW
DRIP LEG
PRESSURE TRANSDUCER
RECEIVER
PRESSURE TRANSDUCER CABLE
2 Conductor Cable, 18 Gauge Stranded
Earth Shielded
No Greater Than 330FT (100M)
24VDC Control Voltage
X8I X05 CONNECTOR
PT CONNECTOR
25 +VDC Pin #3
26 Signal Pin #1
Reference X8I Operations Manual for Pressure
Sensor Connection Details
RS485 Network Cable
Ir-PCB Compressor #1
Control Cable
Ir-PCB Compressor #2
Control Cable
Pressure Transducer Cable
SPECIFICATIONS
Dimensions
13.4” x 9.45” x 6.0”
340mm x 241mm x 152mm
Weight
16.5lb (7.5kg)
Mounting
Wall, 4 x screw fixings
Enclosure
IP65, NEMA 4
Supply
230Vac +/- 10%, 50 Hz
115Vac +/- 10%, 60 Hz
Power
100VA
Temperature 32°F to 115°F
(0°C to 46°C)
Humidity 0% to 95% RH
(non-condensing)
Model X8I
Ingersoll Rand Automation
Supply Voltage Cable
Local Disconnect (Breaker) Box
Fused for 100VA
Power Cable
3 conductor (N, L, E)
(Sized in accordance with local
electrical and safety regulations).
On/Off
Switch
From Air
Compressors
To Plant Air
System
ir-PCB COMPRESSOR CONTROL CABLE
7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
OR
Single Conductor Wire, 18 Gauge Stranded, Quantity (7)
In Grounded Conduit No Greater Than 330FT (100M)
24VAC Control Voltage
Reference X8I Application and Interconnect Guide For
Wiring Connections Between The X8I, The ir-PCB,
and The Compressor
EXP
EXP RS485 Network Cable
The Maximum Number of Compressors Controlled By
The X8I Is Eight (8).
The Maximum Number Of Direct ir-PCB Connections
To The X8I is Four (4)
.
Any Combination Of Compressor Connection Methods
May Be Used As Long As the Maximum Number Of
Compressors (8) Is Not Exceeded.
OPTIONAL
Ingersoll Rand
102
psi
1 3
2 4
1
CAP
18:35 #2
5 7
6 8
EXP RS485 NETWORK CABLE
Belden 9841 or Equivalent
In Grounded Conduit
No Greater Than 33FT (10)
RS485 NETWORK CABLE
Belden 9841 or Equivalent
In Grounded Conduit
No Greater Than 4000FT (1219M)
EX
Ingersoll
Rand
102 psi
ir-485
Direct To
S3
Ingersoll
Rand
102 psi
OR
Ingersoll
Rand
102 psi
LE
D
1
LE
D
2
ir-PCB
From VSD Pressure
Transducer
To VSD Pressure
Transducer Input
I/O
Ingersoll
Rand
102 psi
VSD
Reference X8I Application and Interconnect Guide For
Wiring Connections Between The X8I, The ir-485 or irV-
485 Gateway and The Compressor, S3 Direct Connects, and
Optional Special Application Interface Boxes
The EXP Will Add Another (4)
Direct ir-PCB connections. This
Would Allow A Total Of (8)
Compressors To Be Connected
And Controlled Via The ir-PCB.
ir-PCB ir-PCB
The RS485 Network is a Serial, Point to Point
Communication Network Refer to the X8I Application and
Interconnect Guide For Wiring Details and Connectivity.
ir-485 Gateway
For All
IR (Non- Nirvana) Compressors
IntelliSys “Red Eye”, SG and SE
irV-485 Gateway
For All
Nirvana Compressors
20HP (15KW) and Above
irV-485
ir-485
8
INSTALLATION
XPM-TAC24
1
P
P
2
1
P
2
P
1
P
2
P
P
It is recommended that installation and
commissioning be carried out by an authorized and
trained product supplier.
UNIT LOCATION
The X8I can be mounted on a wall using conventional
bolts. The X8I can be located remotely from the
compressors as long as it is within 330 feet (100 meters)
of cable length when connecting compressors directly
with ir-PCB’s. When connecting the X8I over the RS485
communication network the distance is up to 4000 feet
(1219 meters) The X8I must 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 X8I. The isolator
must be fitted with a properly sized fuse to provide
adequate protection to the power supply cable used (in
accordance with local electrical and safety regulations).
1
1 2 3 4
N L E
X04
X01
X04
Power Supply Terminals
2 3 4
VOLTAGE SELECT
1
2 3 4
VOLTAGE SELECT
230Vac
115Vac
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.
DEMAND (DRY) 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.
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
Pressure Sensor Located Before Cleanup Equipment
Regular routine monitoring of pressure differential
across air treatment equipment is recommended.
9
PRESSURE SENSOR CONNECTION
Cable Earth Shield
The pressure sensor connects to terminal X05 of the X8I
terminal PCB using a shielded 18 AWG maximum 2conductor cable no more than 330 feet (100 meters) in
length. The transducer threads are BPT. It is the equivalent
of ¼” NPT.
Wire polarity is important.
For each compressor utilizing an ir-PCB, connection to
the X8I the signal wires must be made to the correct
X8I 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.
Pressure Sensor Wiring and Location
IRPCB INTERFACE MODULE
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.
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 X8I providing protection and voltage isolation.
Consult the X8I Interconnect and Application Guide
prior to the installation of the X8I and the ir-PCB to the air
compressor.
The ir-PCB is designed to interface a compressor with
the X8I using a seven (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.
10
IR485 AND IRV485 GATEWAY MODULE
ir-485
irV-485
28
30
27
29
X06
Ingersoll Rand
102
psi
1 2 3 4
1
CAP
18:35 #2
5 7
6 8
4000ft (1219m) max
I/O
Ingersoll
Rand
102 psi
Ingersoll Rand
102
psi
1
CAP
1
5263748
18:35 #2
1 2
Ingersoll
Rand
102 psi
EX
Ingersoll
Rand
102 psi
EX
I/O
Ingersoll
Rand
102 psi
RS485 NETWORK
The ir-485 and irV-485 Gateways are designed to
interface the Intellisys Controller on the Ingersoll Rand
Compressors and the Nirvana compressors, 20 HP (15KW)
and above, with the X8I via the RS485 Network utilizing
the ir485 protocol. The ir-485 and irV-485 Gateways
are DIN Rail mounted and can be located within the
compressor control gear enclosure or remotely within a
separately enclosure.
ir-485 Gateway irV-485 Gateway
The cable used between the X8I and the ir-485 and irV485 Gateways is Belden 9841 (or equivalent). It should be
run in grounded conduit and should not be greater than
4000 feet (1219 meters) in length.
The cable used between the ir-485 Gateway and irV-485
Gateways and the Intellisys Controller is included with the
Installation Kit
The cable used between the ir-485 Gateway and the
Intellisys Controller is included with the Installation Kit
The X8I is equipped with an RS485 network
communications capability using the ir485 protocol. This
facility can be used for remote connectivity to optional
networked units and modules with ir485 communications
capabilities or compressor controllers equipped with the
ir485 capability.
L2
L
1
RS485
L
L1
2
The RS485 Network is a Serial, Point to Point
Communication Network. Refer to the X8I Application
and Interconnect Guide For Wiring Details and
Connectivity.
The following example details the “correct” method of
wiring the RS485 Network
Consult the X8I Interconnect and Application Guide
and the ir-485 or irV-485 Gateway Manual prior to the
installation of the X8I and the Compressor Gateway to the
air compressor.
The following example details the “incorrect” method of
wiring the RS485 Network
Correct RS485 Network Example
IR485 COMMUNICATION PROTOCOL
ir485 is a unique communication protocol designed
specifically for Compressor and Air System control. ir485
is a Multi-Master vs. a Master–Slave protocol that enables
faster, more effective control of network components.
ir485 also features distributed control capabilities and has
inherent resistance to communication faults due to noise
Note: Follow RS485 Network installation
recommendations.
11
Incorrect RS485 Network Example
RS485 data communications and other low
voltage signals can be subject to electrical interference.
This potential can result in intermittent malfunction
or anomaly that is difficult to diagnose. To avoid this
possibility always use earth shielded cables, securely
bonded to a known good earth at one end. In addition,
give careful consideration to cable routing during
installation.
a) Never route an RS485 data communications or low
voltage signal cable alongside a high voltage or 3-phase
power supply cable. If it is necessary to cross the path of a
power supply cable(s), always cross at a right angle.
b) If it is necessary to follow the route of power
supply cables for a short distance (for example: from a
compressor X8I to a wall along a suspended cable tray)
attach the RS485 or signal cable on the outside of an
earthed cable tray such that the cable tray forms an
earthed electrical interference shield.
c) Where possible, never route an RS485 or signal cable
near to equipment or devices that may be a source of
electrical interference (for example: 3-phase power
supply transformer, high voltage switchgear unit,
frequency inverter drive module, radio communications
antenna).
12
SECTION 6 CONTROL FEATURES AND FUNCTIONS
PH
PL
PT
a
b
PH
PL
PT
PH
PT
PL
PH + TO
PL - TO
TO
TO
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
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 defined by PL and
PH. See Figure 1.
Variable speed compressors also operate within the pressure band
and actively match compressor output with system demand by
speeding up and slowing down around a target pressure defined by
the exact midpoint of the pressure band defined by PT. See Figure 2.
Figure 1 — Typical System Pressure vs. Time
As pressure rises to point “a”, the compressor will unload
based on the sequencing algorithm. System pressure is
then allowed to decrease due to the drop in supply until
point “b” is reached. Once point “b” is reached, the X8I will
load the next compressor in the sequence to match the
air demand. This cycle will repeat as long as the X8I is able
to keep the system air pressure between PH and PL.
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-unloadstop, 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 algorithm continually analyzes pressure
dynamics to determine the last possible second to add or
cycle another compressor into the system. This control is
further enhanced by the ability to fine tune the tolerance
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 X8I from overcompensating in the event of
a temporary significant increase or decrease in system
demand.
Figure 2 — Typical VSD Pressure Control vs. Time
The variable speed compressors in the system will run
on their target pressure and smooth out the variations in
system pressure. This assumes that system demand does
not vary more than the capacity of the variable 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.
Figure 3 — Tolerance in Relation to PH and PL
Tolerance (TO) is expressed as a pressure defining the
width of the band above PH and below PL in which
energy efficient control will be in effect.
When system pressure is in the tolerance band, the
X8I 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 X8I will abandon
energy efficiency and begin to protect the system air
pressure by loading or unloading the compressors.
Loading will be delay controlled.
13
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 (0.2Bar).
This setting is user adjustable.
DAMPING
Any time the pressure is within the Tolerance band the
Anti-Cycling algorithm is active, sampling the rate of
pressure change and calculating when to load or unload
the next compressor. The damping (DA) setting is a user
adjustable setpoint that determines how quickly the
controller samples and recalculates, effectively speeding
up or slowing down the reaction time.
The X8I’s factory default DA setting of “1” is adequate for
the majority of compressed air systems but may need
to be adjusted in the following circumstances involving
aggressive and disproportionate system pressure
changes:
Inadequate air storage
•
High pressure differential across the air
•
treatment equipment
Incorrectly sized piping
•
Slow or delayed compressor response
•
In these circumstances, the X8I 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 X8I is still overreacting, then increasing
the damping factor is the next step.
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 in pressure.
The following formula determines the recommended
minimum storage volume for a compressed air 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.
NOTE: 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 X8I. 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.
V — “Volume of Required Storage” (Gal, Ft3, m3, L)
T — “Time to Start Back-up Compressor” (Minutes)
C — “Lost Capacity of Compressed Air” (CFM, m3/min)
Pa — “Atmospheric pressure” (PSIa, BAR)
∆P — “Allowable Pressure Drop” (PSI, BAR)
14
Example 1: Find Required Storage Volume in Ft3 and US
20%
40%
80%
100%
100%
0%
0%
2
1
1 2 3 4
#1
#2
#3
#4
A B C D
A C D B
A D B C
A B C D
1 2 2 2
Gal.
(4) - 100 Hp Compressors at 450 CFM (12.7 m3) each /
15 seconds to start and load a compressor. 5PSIG is the
maximum allowable pressure drop.
T=15 Seconds (.25 minute)
C=450 ft3
Pa = 14.5 PSI
Delta P = 5 PSI
V = [.25 x (450 x 14.5)]/5
V = (.25 x 6525)/5
V = 1631/5
V = 326 Ft3
1 ft3 = 7.48 Gal
Gal= 326 Ft3 x 7.48
Gal = 2440
Example 2: Find Required Storage Volume in m3 and L.
(4) - 100 Hp Compressors at 450 CFM (12.7 m3) each / 15
seconds to start and load a compressor. 0.34 BAR is the
maximum allowable pressure drop.
T=15 Seconds (.25 minute)
C=12.7 m3
Pa = 1BAR
Delta P = .34 BAR
V = [.25 x (12.7 x 1)]/.34
V = (.25 x 12.7)/.34
V = 3.2/.34
V = 9.33m3
1m3 = 1000 L
L= 9.33 m3 x 1000
L = 933
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
STANDARD SEQUENCE CONTROL STRATEGIES
The standard configuration of the X8I provides ENER
(Energy Control) sequence control strategy, Priority
Settings, Table Selection, Pressure Schedule, and Pre-fill
operation.
ENER: Energy Control Mode
Control and Rotation:
Compressor control and utilization is dynamically
automated with adaptive control logic and therefore
does not follow pre-determined schedules, rotation
configurations or time intervals. Energy Control mode
can, however be operator influenced by the Priority
functionality which is discussed later in this manual.
Energy Control mode is enabled by the ability of the
X8I to process individual compressor capacity, variable
capacity capabilities, and changes in system pressure to
dynamically implement and continuously review ‘best fit’
configurations as demand variations occur.
1: Demand
2: Supply
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 8, 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 Lead position. By assigning compressor 1 a
priority of 1 and the other three compressors a priority
of 2, the variable speed compressor will always remain at
the front of the sequence:
The primary function of Energy Control mode is to:
1/ Dynamically match compressed air supply with
compressed air demand.
2/ Utilize the most energy efficient set/combination of air
compressors to achieve 1/.
Energy Control mode is designed to manage systems that
include compressors of different capacities and different
air compressor types (fixed speed, variable speed and
variable capacity) in any combination or configuration.
Compressor 1 has priority 1, all other compressors have
priority 2
15
In another example, there is a four compressor system
1 2 3 4
#1
#2
#3
#4
A B C D
B C A D
C A B D
A B C D
1 1 1 2
1 2 3 4
#1
#2
#3
#4
A B C D
A C B D
A B C D
A C B D
1 2 2 3
1 2 3 4
#1
#2
#3
#4
A B C D
B A D C
A B C D
B A D C
1 1 2 2
T01
PH
PL
Pm
SQ
- - - -
- - - -
- - - -
- - - -
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:
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:
Priority control will also work with ENER control
mode. Recall that ENER control automatically selects
the most efficient set of compressors to dynamically
match compressed air demand. Priority will force the
X8I controller to select from all “priority 1” compressors
and make sure that they are loaded in the sequence
before utilizing any priority 2 compressors. All priority
2 compressors must be utilized before priority 3
compressors can be loaded and so on. Priority allows
a system to be segregated to backup and primary use
compressors when using ENER control.
Note: Using the Priority function with ENER Control can
affect system efficiency.
TABLES AND THE PRESSURE SCHEDULE
The X8I operates based on settings that are
configured into one of three tables. Each table defines
the operational settings and sequence control mode
of the X8I. The X8I can be instructed to change among
the tables at any time based on the configuration of the
pressure schedule.
This functionality allows the X8I 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.
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:
Each table consists of the following parameters which can
be set independently in each table:
PH – High Pressure Setpoint
•
PL – Low Pressure Setpoint
•
Pm – Minimum pressure warning level
•
SQ – Sequence Rotation Strategy
•
01 – Compressor 1 Priority
•
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 X8I is instructed to change between tables,
it will not abruptly change the system operating
parameters. The X8I 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:
Two independently rotating compressor groups
16
PC
1
2
Changing Target Pressures
! X
A
CAP
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 X8I 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 X8I is equipped with a real-time clock feature
and pressure schedule functionality. The pressure
schedule function can be used to provide enhanced
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, or once
each day except weekends. Please see the Quick Setup
Manual for detailed information on how to configure the
pressure schedule.
At system start (manual start or automated start from
standby) the X8I will only load compressors that have
been pre-determined for prefill operation, for a pre-set
period of time. The prefill time (PT) can be adjusted to suit
system characteristics. The aim is to increase pressure to
normal operational levels, using only the pre-determined
compressors, prior to the prefill time expiring.
If normal operational pressure is reached prior to the
set prefill time, the prefill function will automatically
cease and normal operational control begin. If normal
operational pressure is not reached by the end of
the prefill time the P4 will utilize as many available
compressors as required to achieve normal operational
pressure as quickly as possible. Normal operational
control will then begin.
Three prefill modes are available. ‘Backup’ and ‘Standard’
modes require compressor pre-selection and function in
the same way; differing only in response to a failure, or
loss, of a prefill compressor. Automatic mode requires no
compressor pre-selection.
Backup Mode: Compressor(s) can be pre-selected
as ‘Primary Prefill’ compressor(s) or ‘Backup Prefill’
compressor(s). If a primary prefill compressor experiences
a shutdown, or is stopped, a pre-defined backup
compressor replaces it and prefill continues.
Standard Mode: If one or more of the predefined prefill compressors experiences a shutdown, or
is stopped, the prefill function is cancelled and normal
operation begins.
Automatic Mode: No Prefill compressor
selection is necessary; any selection set is ignored. The
management unit automatically selects compressor(s)
dynamically to achieve pressure in accordance with
the set Prefill time. If a compressor is stopped, or shuts
down, it is automatically substituted with an alternative
compressor.
The Prefill feature provides a controlled and energy
efficient method of increasing pressure to normal
operating levels at system start. This feature avoids the
inefficient potential for all available system compressors
to start and load before pressure reaches the normal
operating level.
To manually skip Prefill mode, press and hold Start
for several seconds.
Insufficient Capacity Alarm
The X8I is equipped with a dedicated ‘Insufficient
Capacity’ Advisory Alarm (Warning) indication.
This indication will illuminate if all available compressors
are loaded and system pressure is continuing to decrease.
The indication will generally occur prior to any set low
pressure Alarm (Warning) and is intended to provide an
advanced warning of a potential ‘Low Pressure’ situation.
17
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