Ingersoll Rand X8I Operator’s Manual

Page 1

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

Page 2

SECTION 1  TABLE OF CONTENTS

SECTION 1  TABLE OF CONTENTS ..........................2

CTION 2  INTRODUCTION

...................................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 SETUP 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

SECTION 10  FAULT CODES ....................................46

X8I COMPRESSOR FAULT INDICATIONS, TYPES, AND

CODES: ..........................................................................................46

UNIT LOCATION

POWER SUPPLY

PRESSURE SENSOR LOCATION

PRESSURE SENSOR CONNECTION

IRPCB INTERFACE MODULE ................................................10

IR485 AND IRV485 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

Page 3

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

supply. Lock the isolator in the ‘OFF’ position and remove the fuses.

Page 4

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.

Page 5

SECTION 4  COMPRESSOR CONNECTION AND CONTROL

ir-485

irV-485

Ingersoll Rand

102

psi

1 3

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.

Page 6

Remote Compressor Management; EX Box (option)

Ingersoll Rand

102

psi

CAP

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

CAP

18:35 #2

5 7

6 8

4000ft (1219) max

Ingersoll Rand

102

psi

1 3

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).

Page 7

X8I MAIN DISPLAY

Ingersoll Rand

102

psi

A: 85%

CAP

102

PSI

d e

17:30 #1

a b c

CAP

a b c

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

Page 8

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

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

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)

Ingersoll Rand

102 psi

ir-485

Direct To

Ingersoll

Rand

102 psi

Ingersoll

Rand

102 psi

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

Page 9

INSTALLATION

XPM-TAC24

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 2 3 4

N L E

X04

X01

X04

Power Supply Terminals

2 3 4

VOLTAGE SELECT

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.

Page 10

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

IRPCB 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.

Page 11

IR485 AND IRV485 GATEWAY MODULE

ir-485

irV-485

X06

Ingersoll Rand

102

psi

1 2 3 4

CAP

18:35 #2

5 7

6 8

4000ft (1219m) max

I/O

Ingersoll

Rand

102 psi

Ingersoll Rand

102

psi

CAP

5263748

18:35 #2

1 2

Ingersoll

Rand

102 psi

Ingersoll

Rand

102 psi

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

RS485

L L1

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.

Incorrect RS485 Network Example

Page 12

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).

Page 13

SECTION 6  CONTROL FEATURES AND FUNCTIONS

PH + TO

PL - 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.

Page 14

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)

Page 15

Example 1: Find Required Storage Volume in Ft3 and US

20%

40%

80%

100%

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

Page 16

In another example, there is a four compressor system

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

A B C D A C B D A B C D A C B D

1 2 2 3

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

Page 17

Changing Target Pressures

! X

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.

Page 18

The ‘Insuﬃcient Capacity’ advisory alarm is intended as an

CAP

1 2 3 4

A B C D D A B C C D A B B C D A

advanced warning and is not recorded in the fault history log but is included as a Group Alarm (Warning), or Group Fault item.

‘Insuﬃcient Capacity’ is available as a dedicated data communications item.

ALTERNATE CONTROL FEATURES AND FUNCTIONALITY

Energy Control Mode (ENER) is the STANDARD control mode of the X8I. Alternate control strategies of the X8I are the basic FILO (First in / Last Out) and EHR (Equal Hours Run) EHR

The ‘Insuﬃcient Capacity’ advisory alarm function

can be de-activated. In this instance the unit’s Alarm indicator will still illuminate but no group alarm, group fault, or a remote indication is generated.

Restricted Capacity Alarm

The X8I is equipped with a dedicated ‘Restricted Capacity’ Advisory Alarm (Warning) indication.

This indication will ﬂash if all available compressors are loaded and further capacity is required but one or more, compressors are: 21

a) inhibited from use in a ‘Table’ priority setting

b) inhibited from use by the short-term Service/ Maintenance function

c) inhibited from use in the long term maintenance menu.

FILO: TIMER ROTATION MODE

The primary function of Timer Rotation mode is to eﬃciently operate a compressed air system consisting of ﬁxed capacity output compressors. The routine rotation assignments can be modiﬁed using ‘Priority’ settings to accommodate for a diﬀerentially sized or variable capacity output compressor(s).

Rotation:

Each time the rotation interval elapses, or the rotation time is reached, a sequence rotation occurs and the sequence assignment for each compressor is re-arranged. The compressor that was assigned for duty (A) is reassigned as last standby (D) and all other compressor assignments are incremented by one.

The ‘Restricted Capacity’ advisory alarm is intended to indicate that all available compressors are already loaded and further capacity is required but one or more, system compressor(s) have been restricted from use.

The ‘Restricted Capacity’ advisory alarm is not recorded in the fault history log but is included as a Group Alarm (Warning), or Group Fault item.

‘Restricted Capacity’ is available as a dedicated data communications item.

The ‘Restricted Capacity’ advisory alarm function can be de-activated. In this instance the unit’s Alarm indicator will still ﬂash but no group alarm, group fault, or a remote indication is generated.

The sequence assignment pattern can be modiﬁed by ‘Priority’ settings.

Tables; Priority Settings

Control:

Compressors are utilized, in response to changing demand, using a ‘FILO’ (First In, Last Out) strategy.

The ‘duty’ compressor (A) is utilized ﬁrst followed by (B) if demand is greater than the output capacity of (A). As demand increases (C) is utilized followed by (D) if demand increases further.

As demand reduces (D) is the ﬁrst compressor to be unloaded, followed by (C) and then (B) if demand continues to reduce.

The last compressor to be unloaded, if demand reduces signiﬁcantly, is (A). The compressor assigned as (A) in the sequence is the ﬁrst to be loaded and the last to be unloaded.

Page 19

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.

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 the rotation interval elapses, or the rotation time is reached, the sequence order of compressors is reviewed and re-arranged dependant on the running hours recorded for each compressor. The compressor with the least recorded running hours is assigned as the ‘duty’ compressor, the compressor with the greatest recorded running hours is assigned as the ‘last standby’ compressor. For systems with more than two compressors, the remaining compressor(s) are assigned in accordance with there recorded running hours in the same way.

If a compressor is operated independently from the X8I 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.

Control:

Compressors are utilized, in response to changing demand, using a ‘FILO’ (First In, Last Out) strategy. The ‘duty’ compressor (A) is utilized ﬁrst followed by (B) if demand is greater than the output capacity of (A).

As demand increases (C) is utilized followed by (D) if demand increases further. As demand reduces (D) is the ﬁrst compressor to be unloaded, followed by (C) and then (B) if demand continuous to reduce.

The last compressor to be unloaded, if demand reduces signiﬁcantly, is (A). The compressor assigned as (A) in the sequence is the ﬁrst to be loaded and the last to be unloaded.

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 X8I continuously monitors the running status of each compressor and calculates the accumulated running hours. These readings are viewable and adjustable in the X8I C01 setting screens. The X8I will use these values during EHR mode. The running hours on the X8I should be routinely checked to see that they match the compressors’ local calculations, and adjusted if necessary.

Page 20

SECTION 7  DISPLAY AND MENU OPERATION

Ingersoll Rand

102

psi

A: 85%

CAP

102

PSI

d e

17:30 #1

a b c

CAP

a b

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

The Main Display and the keypad and navigation buttons on the X8I are depicted below and provide the following functionality:

Page 21

2 3

Unit Functions:

The following Icons are used by the X8I to display the Controller Active Functions.

EHR - Equal Hours Run

Increasing to normal operational levels (Preﬁll, target pressure change or at system start)

Below the active lower, or load, pressure set point

Above the upper, or unload, active pressure set point

The following Icons are used by the X8I to display the Controller Status.

Stopped

Standby

Started and Running

Alarm (Warning)

Shutdown (Trip)

Day of the week #1 = Monday #2 = Tuesday #3 = Wednesday #4 = Thursday #5 = Friday #6 = Saturday #7 = Sunday

Between the lower, or load, and upper, or unload, active pressure set points

FILO - Timer Rotation

ENER - Energy Control

Active Functions :

Operating Mode :

System Pressure Status :

Units Status :

Power Failure Auto-Restart

Table #1

Table #2

Table #3

Table #4

Standby Mode Active

Preﬁll Function

Pressure Schedule

Function Inhibited (Manual Override)

Remote Manual Override

System Pressure Value System Pressure Units

Real Time Clock 24 Hour Format

Page 22

17:30 #1

A: 100%

102 psi

00:00 #1

Main Manu

Real Time Clock

Compressor Detailed Status:

Compressor Status Symbols

Primary Detected Pressure

Next Scheduled Sequence Rotation

The Pressure detected on the unit’s primary pressure sensor.

The next scheduled sequence rotation: 00 : 00 Time (24 hr system) #1 Monday

A setting of zero hundred hours (00:00hrs) on Monday (#1) equates to a sequence rotation at one second past midnight on Sunday.

17.30 (24r system) # 1 = Monday to # 7 = Sunday

Standby (or Auto restart)

Running Oﬄoad

Running Loaded

Removed From Service in Table Priority Selection (# = Table Number)

Removed From Service in Long Term Maintenance Menu

Alarm (Warning) Standby (or Auto Restart)

Not Available(Stopped Shutdown, Trip Standby (or Auto Restart)

Network Communication Error (RS485 Connectivity Only)

A number of User menu information displays are available that can be accessed directly from the front panel using the Up and Down navigation buttons.

User Manu

Page 23

INDICATORS

1sec

a b c

CAP

Indicators

The X8I indicators are as follows.

ON – Loaded

b) Run Status

OFF – Not Running

Oﬀ

Intermittent:

Slow Flash:

Fast Flash:

Unit Indicators

Unit Run Indicator (Green LED)

Slow Flash – The compressor has been requested to load but is not running (blowdown delay or other start delay)

ON – Running

c) Compressor Availability

OFF – No Compressor Connected

Fast Flash – Not Available, Shutdown Fault or Stopped

Slow Flash – Alarm (Warning)

Intermittent Flash – The compressor has been intentionally removed from service.

Available, OK

System Alarms (Warnings):

OFF – Not Active, Stopped

Slow Flash: Active, Standby Mode

ON – Active, Running

Unit Fault Indicator (Red LED)

Fast Flash: Shutdown (Trip)

Slow Flash: Alarm (Warning)

The X8I fault indicator does not indicate compressor

fault states; see Compressor Status Indicators.

Compressor Status Indicators:

Each compressor in the system has a set of dedicated status indicators. The indicators will continuously show the status of each compressor at all times.

a) Load Status

OFF – Not Loaded, Oﬄoad

a) Group Compressor Fault

OFF – All Compressors OK

Fast Flash – One or more compressors Not Available, Shutdown Fault or Stopped

Slow Flash – One or more compressors Alarm (Warning)

b) Insuﬃcient Capacity Alarm (Warning)

On – Insuﬃcient Capacity

c) Restricted Capacity Alarm (Warning)

Slow Flash – Restricted Capacity

Slow Flash – The compressor has been requested to load but is not loaded (load or re-load delay period)

Page 24

Information Displays

P00

#1 18:30

3 4

P00

IRV-485

100 %

20 %

30 %

5 6 7

1 1

P00

102 98

psi psi psi

2 3 4

P00

#4 18:00

18 / 05 / 2006

A B C D

To view detailed information applicable to the

selected User menu display item press Enter.

To view detailed information applicable to the

selected User menu display item press Enter.

Real Time Clock:

Shows the next Pressure Schedule event.

1: The Current Active Table

2: Day (#1=Monday, #7=Sunday)

3: Time (24hr system)

4: Table

Primary Detected Pressure:

1: Active Table

2: Upper (Unload) Pressure Set Point

3: Lower (Load) Pressure Set Point

4: Minimum Pressure Alarm (Warning)

Sequence Rotation:

Items 2 and 3 show the day and time that the unit

will change to use the ‘Table’ shown in item 4.

Compressor Status:

1: Compressor Number

2: Priority Setting

3: Zone Allocation Setting

4: Compressor/Connection Type

5: Maximum Capacity % Setting

6: Minimum Capacity % Setting

7: Minimum Eﬃciency % Setting

Item values 6 and 7 are only shown if compressor

type is IRV-485 (variable capacity/speed).

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.

Manual Sequence Rotation:

The sequence assignment can be manually rotated at any time. When viewing the ‘Sequence Rotation’ information screen press Enter:

The manual rotation symbols will appear and ﬂash. Press Enter again to execute a manual rotation or Escape 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.

Compressor Identiﬁcation

Each compressor connected to the X8I will have a unique assigned compressor identiﬁcation number; starting at compressor 1 increasing sequentially to the number of compressors connected to the X8I.

Page 25

1 2 3 4

A: 85%

Stop:

To stop the X8I press Stop.

The X8I will respond dependant on the setup of item ‘CF’ in menu S02:

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).

The X8I will hold each compressor in an oﬄoad state. If the compressor is equipped with a main motor run-ontime function the compressor will run oﬄoad for a period of time and then stop in to a ‘standby’ or ‘auto restart’ state.

Power Failure Auto-Restart

If the power failure auto-restart function is enabled the X8I will automatically start, when power is restored after a disruption or failure, if the X8I was in a ‘started’ state when the power disruption or failure occurred.

The X8I will not automatically restart if the X8I was in a stopped state when the power disruption or failure occurred.

Failure Mode

If the X8I experiences a disruption to normal control, or an X8I 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 X8I Alarm (Warning) or Shutdown

condition press Reset.

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 IAX4.

Start:

To start the X8I press Start.

If the Preﬁll function is enabled, and system pressure is below the set preﬁll pressure, the system will enter Preﬁll mode for the set Preﬁll time.

Preﬁll

To manually skip the Preﬁll function, press and hold

Start for several seconds.

When Preﬁll is complete, if applicable, the X8I will enter normal operating mode.

The X8I will operate in accordance with the parameters and options set in the active ‘Table’.

Tables

Each compressor in the system must be started

(running or in a standby or auto restart condition) before X8I control of the compressor can be established. The X8I will not start a compressor that is in a stopped condition.

Page 26

SECTION 8  COMMISSIONING

When commissioning the X8I, 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 X8I, 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 X8I 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 X8I.

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.

X8I QUICK SETUP CONFIGURATION

Before successful basic operation can be established speciﬁc parameters must be entered prior to startup. Please refer to the X8I Quick Setup Manual for instruction to accomplish this.

OPTIONAL FEATURES AND FUNCTIONS

Installation requirements may involve the implementation of additional or optional functions and features. Please refer to the appropriate Guide or Manual as required.

Page 27

SECTION 9  SYSTEM CONFIGURATION

Access Code Accepted

Access Code Rejected

Access Code = 0032

P00

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 and then the normal operating display 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.

ACCESSING THE X8I CONFIGURATION SCREENS

Access Code:

Access to adjustable menu page items is restricted by access code. To access menu mode pages press MENU (or UP and DOWN together); an access code entry display is shown and the ﬁrst code character will ﬂash.

Use UP(plus) or DOWN(minus) to adjust the value of the ﬁrst code character then press ENTER. The next code character will ﬂash; use UP or DOWN to adjust then press ENTER. Repeat for all four code characters.

If the code number is less than 1000 then the ﬁrst code character will be 0(zero). To return to a previous code character press ESCAPE. When all four code characters have been set to an authorized code number press ENTER. An invalid code will return the display to normal operational mode; page ‘P00’.

Access Code Timeout:

When in menu mode, if no key activity is detected for a period of time the access code is cancelled and the display will automatically reset to the normal operational display.

Menu Mode Navigation:

In menu mode the menu ‘page’ number will be highlighted at the top of the display.

To select a menu ‘page’ press UP or DOWN. To enter the highlighted menu ‘page’ press ENTER; the ﬁrst item of the menu ‘page’ will be highlighted. Press UP or DOWN to scroll though the selected menu ‘page’ items.

Page 28

To select an item value or parameter for modiﬁcation’

Page 3

Page 2

Page 1

Item 1 Value Item 2 Value Item 3 Value Item 4 Value Item 5 Value

Page 0

Item 1 Value Item 2 Value Item 3 Value Item 4 Value Item 5 Value Item 6 Value

Page 5

Page 4

Page 3

Page 2

Page 1

Item 1 Value Item 2 Value Item 3 Value Item 4 Value Item 5 Value

Page 0

Item 1 Value Item 2 Value Item 3 Value Item 4 Value Item 5 Value Item 6 Value

Page 5

Page 4

P01

01.02 AB

a b c

press ENTER; an adjustment screen for the item will be displayed.

The value or option can now be modiﬁed by pressing UP(Plus) or DOWN(Minus). To enter a modiﬁed value or option in to memory press, ENTER.

Press ESCAPE at any time in menu mode to step backwards one stage in the navigation process. Pressing ESCAPE when the page number is ﬂashing will exit menu mode and return the display to normal operational mode.

All menu items have a unique reference consisting of the menu page ID (a) and the menu page item number (b). Each item in a menu also has a unique two alphanumeric character code (c). All three references are visible at the top of every menu item display.

Some menu items may consist of several individual settings. Each setting of the menu item is also referenced as a sub-item number. For example: P01-01.02 references sub-item ‘02’ of menu item ‘01’ in menu page ‘P01’. Subitem settings, where applicable, are always displayed together on the same ‘Item’ adjustment display screen. Most menu items are single value or single option only in which case the single item is referenced as sub-item number ‘01’ (for example: P01-01.01).

Press and hold RESET for several seconds at any time to immediately exit menu mode and return to the normal operational display. Any value or option adjustment that has not been conﬁrmed and entered into memory will be abandoned and the original setting maintained.

The X8I will retain an ‘access code’ for a short period after menu exit allowing the menu structure to be reentered without the need to re-enter the access code again. To immediately clear access code retention press and hold RESET for several seconds.

A ‘locked’ symbol displayed with any item indicates the item is locked and cannot be modiﬁed. This will occur if the Item is view only (not adjustable) or in instances where the item cannot be adjusted while the X8I is in an operational state; stop the X8I ﬁrst.

Page 29

USER LEVEL MENUS

TABLE #1

T01

TABLE #2 to #4 (as Table #1)

Pressure Schedule

P01

Prefill

P02

User Configuration

S01

Compressor Running Hours

C01

Compressor Maintenance

C02

Fault Log

E01

01 PH High Pressure Set Point

02 PL Low Pressure Set Point

03 Pm Minimum Pressure Alarm

04 SQ Sequence Algorithm

05 01 Compressor #1 Priority

12 08 Compressor #8 Priority

01 Ct Real Time Clock Set

02 PS Pressure Schedule Enable

03 AR Auto Restart Enable

04 RP Rotation Interval

05 TS Default Table Select

06 BL Display Backlit Adjust

01 01 Schedule Setting #1

28 28 Schedule Setting #28

01 PF Preﬁll Function

02 PT Preﬁll Time

03 PP Preﬁll Pressure

04 01 Compressor #1

11 08 Compressor #8

01 01 Compressor #1 Running Hours

08 08 Compressor #8 Running Hours

01 01 Compressor #1 Maintenance

8 08 Compressor #8 Maintenance

01 01 Fault Log #1 (most recent)

15 15 Fault Log #15

Page 30

SERVICE LEVEL MENUS

Configuration

S02

Auxiliary Box Monitoring

S03

Sensor Calibration

S04

Compressor Configuration

C03

Diagnostic Menu 1

D01

Diagnostic Menu 2

D02

D05

High Level Menus

01 P> Pressure Units

02 NC Number Of Compressors

03 PM Maximum Pressure Alarm

04 CF Stop Control Function

05 TO Tolerance

06 DA Damping

07 PC Pressure Change Time

08 CA CAP Alarm Inhibit

09 MA Max Cap Restricted Alarm Inhibit

10 AI Auxiliary Input Function

11 AO Auxiliary Output Function

12 ER Error Log Reset

01 01 Auxiliary Box #1 Enable

02 02 Auxiliary Box #2 Enable

03 BT RS485 Timeout

01 D1 Digital Input #1 (Di 1)

08 D8 Digital Input #8 (Di 8)

09 R1 Output Relay #1 (R1)

14 R6 Output Relay #6 (R6)

15 A1 Analog Input #1 (Ai1)

16 A2 Analog Input #2 (Ai2)

17 A3 Analog Input #3 (Ai3)

18 Ao Analog Output (Ao)

01 SI Screen Invert

02 LT LED Panel Test

D03 and D04

Diagnostic menus D03 and D04 have no standard

function and are not shown.

01 1O Pressure Oﬀset

02 1R Pressure Range

01 Compressor #1 Conﬁguration

to 8 Compressor #8 Conﬁguration

Diagnostic Menu 5

XPM Expansion Module C:5-8 Diagnostic Menu

only available when applicable EXP Expansion Box is

installed and registered (detected) by the X8I.

01 D1 Digital Input #1 (Di 1)

08 D8 Digital Input #8 (Di 8)

09 R1 Output Relay #1 (R1)

14 R6 Output Relay #6 (R6)

15 Ao Analog Output (Ao)

Page 31

X8I CONFIGURATION SCREENS

T01

02 03 04

PL Pm S

psi psi

ENER ( % )

01 PH psi102

Tables

# = Table T01 to T04

T0# – PH High Pressure Set Point

The ‘upper’ or ‘unload’ pressure set point that will be used when the ‘Table’ is active. The default setting for this parameter is 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”.

If PM is set for 145 PSI and TO is set for 3.0 PSI, then the highest value for the High Pressure setpoint would be 139 PSI.

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

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.

T0# - PL Low Pressure Set Point

If PL in Table 1 (T01) is set for 100 PSI and TO is set for 3.0 PSI, then the highest Minimum Pressure setpoint would be 94 PSI.

T0# - SQ Sequence Strategy

The sequence control strategy mode that will be used when the table is active. The default setting for this parameter is ENER.

The values for this parameter are:

ENER – Energy Control Mode. The Rotation and Control functionality of the ENER mode is to achieve and maintain demand matched to optimum system eﬃciency.

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

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

T0# - 01 Compressor #1 Priority

The ‘priority’ setting for compressor number 1 that will be used when the table is active.

T0# - 02 Compressor #2 Priority

The ‘priority’ setting for compressor number 2 that will be used when the table is active.

T0# - ‘n’ Compressor #’n’ Priority

The ‘priority’ setting for compressor number ’n’ that will be used when the table is active.

The ‘lower’ or ‘load’ pressure set point that will be used when the ‘Table’ is active. The default setting for this parameter is 98 PSI. The values for this parameter are:

The highest value for the Low Pressure setpoint = PH “High Pressure” setpoint minus TO “Tolerance”.

If PH is set for 102 PSI and TO is set for 3.0 PSI, then the highest value for the Low Pressure setpoint would be 99 PSI.

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

If Pm is set for 80 PSI and TO is set for 3.0 PSI, then the lowest value for the Low Pressure setpoint would be 86 PSI...

T0# - Pm Minimum Pressure Alarm

The miniumum pressure ‘Warning’ or ‘Alarm’ level that will be used when the ‘Table’ is active. The default setting for this parameter is 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” minus 2 times TO “Tolerance””

‘n’ = number of compressors in the system. 8 is the maximum number of compressors for the X8I

Priority Settings:

: compressor(s) can be inhibited from use while a table is active by selecting “X” priority. The compressor will be held oﬄoad and will not be utilised under any circumstances.

Page 32

P01

02 03 04

- . - - : - - - - -

01 01 - . - - : - - - - -

Pressure Schedule

P02

02 03 04

PT PP 01

MIN psi

01 PF X

! X

P01 – 01 to 28

The ‘Pressure Schedule’ items 01 to 28. The Pressure Schedule consists of 28 individual settings that instruct the X8I to change from one Table to another, or put the system into Standby mode, dependant on time of day and day of the week. The default setting for this parameter is -. --:-- - - - . (Represents the Pressure Schedule is disabled)

The values for this parameter are: (from left to right)

Day of the Week. 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)

“–“ represents the Pressure Schedule is disabled.

Hours (Military Time). The values for this parameter are:

“00” to “23” the hours in a day

Preﬁll

P02 - PF Preﬁll Function

Determines the ‘Preﬁll’ strategy or function that will be used at system startup. The default setting for this parameter is A .

(Represents the pre-ﬁll function is in Automatic

Mode)

The values for this parameter are:

= Preﬁll function OFF

“ ” = Preﬁll, Back-up 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.

= Preﬁll, 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.

“–-“ represents the Pressure Schedule is disabled.

Minutes. The values for this parameter are:

“0” to “59”. the minutes in the hour

“__“ represents the Pressure Schedule is disabled.

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”, “T03” or “T04” for the 4 diﬀerent Tables

“–

– “ for Standby Mode

“ __ “ represents the Pressure Schedule is disabled.

= Preﬁll, 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.

P02 - PT Preﬁll Time

The Pre-ﬁll Time Setpoint (in minutes) sets the maximum time allowed for a system to start and load the designated Compressor/s to increase system pressure to normal operational levels. The default setting for this parameter is – . (Represents the Preﬁll is disabled)

The values for this parameter are:

“–” the Pre-ﬁll Time is Oﬀ

“1 to 120” the number of minutes

Page 33

P02 - PP Preﬁll Pressure

S01

08 08 08

1 . 00:00

08 Ct 1 . 18:00

The Pressure Setpoint used by the X8I to determine if the Pre-ﬁll Function is required at start up. If pressure is at, or above, this setting at system startup, the preﬁll function will be abandoned immediately and normal pressure control and sequence strategy will be implemented. This setting is intended to inhibit ‘Preﬁll’ operation if pressure is already at an acceptible level at system startup. The default setting for this parameter is 0 PS.

The values for this parameter are:

0 to 232 (or the maximum scaled pressure value used by the X8I if a diﬀerent Pressure Transducer range is used)” the PSI value for the Pre-ﬁll Pressure

P02 – 01 to ‘n’ Compressor 1 to ‘n’

‘n’ = number of compressors in the system. 8 is the

maximum number of compressors for the X8I

This parameter set the function of compressor 1 to ‘n’ during the ‘Preﬁll’ period. The default for this parameter is

. (Represents this compressor is not used by the

Preﬁll Function) The values for this parameter are:

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

“ ﬁll Function

” for this compressor will be used as a primary

“ compressor by the Pre-ﬁll Function

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

These settings are applicable to Preﬁll – Standard and Preﬁll - Back-up modes only. In Automatic mode the system management unit dynamically utilizes compressors as required.

Press and hold ‘Start’ for 5 seconds to manually skip Preﬁll mode at start up.

Features and Functions

S01 - Ct Real Time Clock Set

Adjustment for the internal real time clock.

(Hours, Minutes, Date, Month, Year)

The ‘Day of the Week’ (1= Monday to 7=Sunday) is automatically calculated and set in accordance with the Day, Month and Year. The default setting for this parameter is - --.--. (Represents the clock has not been initialized))

The values for this parameter are:

“1” to “7” 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.

“00” to “23” the Hour for the Real Time Clock.

“0” to “59” the Minutes for the Real Time Clock.

“1” to “31” the Day for the Real Time Clock.

“1” to “12” the Month for the Real Time Clock.

“2005” to “2100” the Year for the Real Time Clock.

S01 - PS Pressure Schedule Enable

This parameter enables or disables the Pressure Schedule function in the X8I. The default setting for this parameter

. (Represents the Pressure Schedule is disabled)

The values for this parameter are:

= inhibit Pressure Schedule

“ ” = enable Pressure Schedule

S01 - AR Auto Restart Enable

This parameter enables or disables X8I restart function after a power loss. When enabled, after a power disruption or failure, the X8I will automatically restart when power is restored if the X8I was in an operational ‘Started’ state when the power loss or disruption occurred. The X8I will not automatically restart if the X8I was in a “Stopped” state when the power disruption or failure occurred. The default setting for this parameter is

. (Represents the Auto Restart is enabled)

The values for this parameter are:

= inhibit Power Failure Auto Restart

“ ” = enable Power Failure Auto Restart

Page 34

S01 - RP Rotation Interval

S01 - TS Default Table Select

The X8I 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. The default setting for this parameter is 1 00:00. (Represents a rotation at Monday (1) at 00:00 hours)

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

If the parameter chosen above is “1” to “9”, you will need to set the time for the rotation to occur. It is in a Military Time format.

The values for this parameter are:

“00” to “23” the Hour

“0” to “59” the Minutes

“–“ the Rotation Interval is disabled.

This parameter determines the ‘Table’ that will be used by default when ‘Pressure Schedule’ is not active and no table is selected remotely on a digital input. The default setting for this parameter is T01.

The values for this parameter are:

“T01” for Table T01

“T02” for Table T02

“T03” for Table T03

“T04” for Table T04

S01 - BL Display Backlight Adjust

This parameter adjusts the backlight level for the display. The display will temporarily increase brightness by 2 levels when a key is pressed and return to normal setting after a period of no keypad activity. The default display backlight 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. LCD display ‘service life’ is deﬁned as the time period before the backlight reduces to 50% of initial brightness. Typically the display will remain usable for a much longer period of time. Adjusting the backlight to high levels will reduce service life. The default setting for this parameter is 5. The values for this parameter are:

“1” to “7” 1 being the least amount of backlight and 7 being the most.

If the parameter chosen above is “t”, you will need to set the Interval Time. This sets the required number of rotation events per day (1 to 96).

The values for this parameter are:

A value of 1 = rotate every 24 hours

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

“–“ the Rotation Interval is disabled.

Page 35

S02

02 03 04

NC PM CF

psi

145

01 P>

psi

S02 - CF Stop Control Function

This parameter determines if the X8I maintains control of the compressors when the X8I is stopped. The default

Pressure Control; Tables

S02 - P> Pressure Units

This parameter selects the display and operating pressure units: The default setting for this parameter is PSI. The values for this parameter are:

“PSI”

“BAR”

“kPA”

S02 - NC Number of Compressors

This parameter sets the number of compressors connected to, and controlled by, the X8I. This value must be set to match the system at commissioning. The default setting for this parameter is 4. The values for this parameter are:

“1” for 1 compressor

“2” for 2 compressors

“3” for 3 compressors

“4” for 4 compressors

“8” for 8 compressors

S02 - PM Maximum Pressure Alarm

This parameter sets the High pressure ‘Fault’ level. This value remains active at all times and is the same for all ‘Tables’. It should be set just below system pressure relief value(s) and below the maximum system pressure rating of all air system components. The default setting for this parameter is 145. 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”

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

setting for this parameter is Stop Control Function is disabled) The values for this parameter are:

= Stop: return pressure control to the

compressors.

” = Standby: maintain control and continouosly

“ hold compressors ‘oﬀ load’.

S02 - TO Tolerance

This parameter sets the pressure control ‘Tolerance’ band setting. 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 X8I incorporates a Rate of Change algorithm in the Tolerance Band to determine when a compressor should be Loaded or Unloaded. The default setting for this parameter is 3.0 PSI (.2 Bar) The values for this parameter are:

“1.4 PSI (.1 Bar)” for the minimum Tolerance Band “29.0 PSI (2 Bar)” for the maximum Tolerance Band

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.

S02 - DA Damping

This parameter sets the pressure control ‘Damping’ setting. Changing this 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 X8I 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. The default setting for this parameter is

1.0. The values for this parameter are: .1 TO 10

“.1”, the fastest Damping reaction time (10 times faster

than the default of 1.0)

“10.0”, the slowest Damping reaction time (10 times

slower than the default of 1.0).

. (Represents the

Page 36

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.

Damping also performs one more important function that can arise in a system. When the system pressure achieves stability in a position that may be outside of the dead band but inside the tolerance band it will be allowed to remain in this situation for a predeﬁned amount of time. This time limit depends on how far away from the dead band the system pressure has stabilized. This time limit is calculated as 30 min times the damping constant at the top of the tolerance band and as 1 min times the damping constant at the bottom of the tolerance band.

S02 - PC Pressure Change Time

This parameter adjusts the time that the X8I will implement a smooth and controlled change from one ‘target’ pressure level to another when a table change is made. The default setting for this parameter is 4 Min. The values for this parameter are:

“1”, 1 minute between Table target pressure setpoint

changes TO “120”, 120 minutes between Table target pressure

setpoint changes.

S02 – CA Capacity Alarm Enable

This parameter sets the functionality of the Capacity Alarm. The default setting for this parameter is (Represents the Capacity Alarm is enabled) The values for this parameter are:

= inhibit Capacity Alarm

= enable Capacity Alarm

When inhibited the Capacity Alarm panel indication will still function; alarm code generation and remote alarm indications are inhibited.

S02 – MA Restricted Cap. Alarm Enable

This parameter sets the functionality of the Restricted Capacity Alarm. The default setting for this parameter is

. (Represents the Restricted Capacity Alarm is enabled)

The values for this parameter are:

= inhibit Restricted Capacity Alarm

= enable Restricted Capacity Alarm

When inhibited the Restricted Capacity Alarm panel indication will still function; alarm code generation and remote alarm indications are inhibited.

Page 37

S02 – AI Auxiliary Digital Input

S02

10.01

01:D1

S02

11.01

01:AF

S02 – AO Auxiliary Output Function

The function of the Auxiliary input.

01:DI Digital Input

No deﬁned function but status (0=normal, 1=activated)

02:T1 Override > Table 1

03:T2 Override > Table 2

04:T3 Override > Table 3

05:T3 Override > Table 4

06:TS Override > Standby

07:AA Remote Alarm (always active)

08:AR Remote Alarm (active when unit running,

inhibited when unit stopped or in Standby)

09:TA Remote Trip (always active)

10:TR Remote Trip (active when unit running, inhibited

when unit stopped or in Standby)

11:SS Remote Start/Stop

NO (Normally Open)

The selected function is activated when the input is closed circuit (input terminals are connected together by remote volt-free contacts)

NC (Normally Closed)

The selected function is activated when the input is open circuit (input terminals are open circuit)

The function of the Auxiliary output ‘volt-free’ relay

contacts.

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 unit Alarm (Warning) or Shutdown (Trip)

07:ON System On

Unit Started and Active, including Pre-Fill period and

Standby mode (not active when unit stopped)

08:SA System Active

Unit Active, including Pre-Fill period (not active when unit

stopped or in standby mode)

09:LP Low Pressure Alarm

10:HP High Pressure Alarm

11:PO Pressure Control Override

Normal, or Pressure Schedule’ operation is being manually

overriddenThe function of the Auxiliary output ‘volt-free’

relay contacts.

S02 - ER Error Log Reset

This parameter clears and resets the ‘Error Log’. The

default setting for this parameter is

Error Log Reset is disabled)

The values for this parameter are:

” Error log reset is disabled

“

“ “ Error log reset enabled. Adjust the item setting to

‘ ’ and press ENTER. The display will return to the main

menu and all existing entries in the error log will be

permanently deleted.

. (Represents the

Page 38

S03

020302

01 01

sec

S03 – 01/02 I/O Box Monitoring

S04

02 1R psi232

01 1O psi0

This parameter determines if the X8I will monitor the selected I/O Box and display any ‘Fault’ detected on the I/O Box inputs; dependant on I/O Box set-up. The default

setting for this parameter is monitoring is disabled) The values for this parameter are:

= Disabled

= Enabled

Refer to I/O Box manual for details.

S03 – BT Communications Timeout

This parameter determines the Communication Broadcast Timeout between the X8I and the I/O box. If the I/O Box fails to communicate on the RS485 network within the set ‘Communications Broadcast Timeout’ (BT), the X8I will display an I/O Box RS485 communications Error. The default setting for this parameter is 60 seconds. The values for this parameter are:

“10 to 300” the number of seconds

. (Represents I/O Box

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

S04 - 1R Pressure Sensor Range

This parameter 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. The default setting for this parameter is 232 PSI. 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.

The pressure transducer must have a known, accurate pressure applied to it when changing this value to a value other than 232.

Pressure Sensor Calibration Procedure:

a) Oﬀset: Expose the sensor to atmosphere and adjust

the ‘oﬀset’ setting (if necessary) until the detected pressure display shows 0 PSI (0.0 BAR).

b) Range: Apply an accurately know pressure to the

pressure sensor and adjust the ‘Range’ setting until the detected pressure display matches the applied pressure. An applied pressure equal too, or greater than, the nominal system working pressure is recommended.

The detected pressure is displayed with the calibration menu item and will change to match the new calibration setting as the setting is adjusted.

The general operation of the selected I/O Box is also monitored.

S04 - 1O Pressure Sensor Oﬀset

This parameter 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. The default setting for this parameter is 0 PSI. 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).

There is no need for the applied pressure to be static; it can be dynamic and changing. This enables calibration to be carried out on a fully operational system where changing system pressure can be accurately veriﬁed from another source.

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 predetermined routine periodic basis.

Page 39

C01

02 03 04

hrs

hrs hrs

hrs

0 0

01 01 0 srh

Control - Equal Hours Run Mode

C02

02 03 04

03 04

01 01

C01 – 01 to C01 – ‘n’ Run Hours’

‘n’ = number of compressors in the system. 8 is the

maximum number of compressors for the X8I

This parameter is set to match the running hours of each compressor. Record of detected ‘running’ hours for each compressor. The run hours value can be manually adjusted, at any time, to match the running hours meter/ display value of each compressor. The default setting for this parameter is 0 hours. The values for this parameter are:

“0 to x” where x = the actual run hours for the compressor

C02 – 01 to C02 – ‘n’ Compressor Maintenance

‘n’ = number of compressors in the system. 8 is the

maximum number of compressors for the X8I

This parameter is set for a compressor(s) that is unavailable for use for a prelonged period for time due to maintenance or repair. The compressor will not be utilised under any circumtances; any Alarm (Warning) or Trip (shutdown) fault will be ignored. The default setting

for this parameter is available) The values for this parameter are:

= Remove compressor from operation

= Compressor can be utilised

. (Represents the compressor is

Page 40

C03

02 03 04

ir-PCB

08 08 ir-PCB

ir-PCB ir-PCB

01 01 ir-PCB

Installation – Compressor Connections

ir-PCB:

C03

01.01

IR-PCB

100 %

+V=!

10 s

IRV-PCB:

C03

01.01 01

IRV-PCB

100 %

10 s

+V=!

IR-485:

C03

01.01

IR-485

100 %

10 s

IR V- 485:

C03

01.01

IRV-485

100 %

10 s

60 %

50 %

C03 – 01 to C03 – ‘n’ Compressor Connection’

‘n’ = number of compressors in the system. 8 is the

maximum number of compressors for the X8I

This parameter sets the type, method of connection, and the control functionality, of each compressor connected to the X8I.

Dependant on the regulation and connection type selected the set-up screen will change to show applicable settings.

Page 41

X8I COMPRESSOR CONNECTIVITY AND

FUNCTIONAL SETTINGS

For ‘ir-PCB’ connectivity applications the voltage detection function for the ‘ir-PCB’ Alarm (Warning) input can be inverted.

Compressor Connectivity:

ir-PCB Fixed speed, load/unload; connected to X8I using

‘ir-PCB’ module using 6-wire method.

(0/100%) 0% or 100% regulation

IRV-PCB Variable Speed; connected to X8I using ‘ir-PCB’

module using the 7-wire ‘V’ terminal method.

(variable speed regulation)

IR-485

Fixed speed, load/unload; connected to X8I on

IR485 network.

(0/100%) 0% or 100% regulation

IRV-485

Variable Capacity/Speed; connected to X8I on

IR485 network.

(0 . . 100%) variable %Load regulation

Compressor Start Sequence Time:

Set to match the time that the compressor takes to

start it’s main motor and load. This time will typically be

equivalent to the compressors ‘Star/Delta’ time.

If unknown, the time can be established by experiment;

manually start the compressor, from a stopped condition,

and determin the time from pressing the start button

until the compressor loads and contributes capacity

output to the system.

This time is used by the unit for ‘staggered starting’ of multiple compressors and other operational calculations. An accurate time is important for successful unit operation.

+V=! An Alarm (Warning) condition is generated if the ‘irPCB’ Alarm input detects a voltage between 12-250Vac/dc (default).

0V=! An Alarm (Warning) condition is generated if the ‘irPCB’ Alarm input detects no voltage.

% Maximum Output Capacity

The maximum output capacity of each compressor must be set as a percentage with reference to the highest output capacity (the largest) compressor in the system. The highest output capacity compressor must be assigned with 100% capacity. Equal capacity (equal sized) compressors should be assigned the same % capacity value. Calculate the output capacity of compressor(s) that are smaller than the largest in the system as a percentage of the largest in the system.

For example:

Compressor 1 700 cfm 100%

Compressor 2 700 cfm 100%

Compressor 3 420 cfm 60%

Compressor 4 420 cfm 60 %

Compressor 5 350 cfm 50%

Compressor 6 175 cfm 25%

% Minimum Output Capacity

Only applicable for a variable output compressor

(IRV-485). Not shown for other types.

Compressor Run-On Stop Time:

This setting is only applicable to ‘IRV-PCB’ connectivity and is not displayed for other connectivity options.

The time that the compressor main motor will continue to run when the compressor is oﬄoad (main motor run-ontime).

If unknown, the time can be established by experiment; start and load the compressor then arrange a condition that will unload the compressor for a period of time. Determine the time from the moment the compressor unloads until the main motor stops and the compressor enters a ‘Standby’ or ‘Auto Restart’ condition.

This time is used by the X8I for accurate recording of ‘run hours’ (EHR mode), operational calculations and other data recording applications. An accurate time is important for successful X8I operation.

ir-PCB Alarm (Warning) Input:

Only applicable for ir-PCB connectivity. Not shown

for ‘485’ network types.

The minimum output capacity of a variable output compressor must be set as a percentage of the compressor’s maximum output scaled in accordance with the % maximum capacity output value. Minimum output capacity is regarded as the output capacity at the lowest possible speed (variable speed compressor) or the minimal output achievable (stepping or other variable regulation control).

For example 1:

For a variable speed compressor that has been assigned a maximum capacity output percentage of 100%, and is able to reduce speed to 30% of maximum speed:

Minimum Output Capacity = 30% (related to the largest capacity)

Example Compressor 1 is a VSD:

Max CFM = 700

Max Output Capacity 700/700 = 100%

Min CFM = 210 (30% or 700 x .30)

Min Output Capacity 210/700 = 30% (or 30% x 100% = 30%)

Page 42

For example 2:

For a variable speed compressor that has been assigned a maximum capacity output percentage of 60% (related to the largest capacity), and is able to reduce speed to 30% of maximum speed:

Example Compressor 4 is a VSD:

Max CFM = 420

Max Output Capacity 420/700 = 60%

Min CFM = 127 (30% or 420 x .30)

Min Output Capacity 127/700 = 18% (or 30% x 60% = 18%)

For example 3:

For a 3-step (0/50/100%) reciprocating compressor that has been assigned a maximum capacity output percentage of 60%, the minimum output capacity is the half-output regulation step:

Minimum Output Capacity = 30%

% Minimum Eﬃciency

The intent of this feature is to always operate the smallest, most eﬃcient compressor and to prevent a variable output capacity compressor operating at minimal speed, or minimal output, for prolonged periods of time. Generally a variable output compressor operating at minimal capacity is less eﬃcient than a smaller capacity compressor that is able to achieve the same output at higher, or maximum, output capacity.

Only applicable for a variable output compressor

(IRV-485). Not shown for other types.

The minimum eﬃciency point is regarded as the speed, or step, below which another smaller capacity compressor in the system could achieve the equivalent output at a higher eﬃciency.

The percentage value is directly related, and scaled, to the maximum and minimum output percentage values.

For example:

Example: A Compressor is a VSD: Max CFM = 420 (Largest Compressor is 700 CFM)

Max Output Capacity 420/700 = 60%

Min CFM = 127 (30% or 420 x .30)

Min Output Capacity 127/700 = 18% (or 30% x 60% = 18%)

If another compressor in the system is able to provide 40% of the compressor’s full speed output more eﬃciently, set the % Minimum Eﬃciency value to 24% (40% x 60%). This percentage value represents 40% of the full speed output of the compressor scaled to System capacity.

When the compressor is detected as operating below the % Minimum Eﬃciency value for a period of time the X8I will immediately re-evaluate utilization and re-conﬁgure, if possible, to utilize a the smaller capacity, more eﬃcient compressor, or combination of compressors. This process is automatic and executed dynamically in accordance with prevailing operational conditions at the time. The ENER control mode algorithms will eventually conclude the best compressor ﬁt without this parameter; the % Minimum Eﬃciency input will speed up this process.

Page 43

E01

02 03 04

- : - - - . - -

01 E : ERR . 01

- : - - - . - -

E01

01.01

E: ERR.01

16/05/2006 14:25

To return to the main error log menu screen press the

E01

01.01

1 2 3 4

ESCAPE button.

To view the second information screen press ENTER. button

E01 – 01 to 15

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 button.

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 X8I at the

•

time the error occurred; (see: X8I Status Display for Icons)

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 ENTER button or the ESCAPE.button. To return to the main error log menu screen press the ESCAPE button.

Page 44

D01 Diagnostics - Controller

D01

02 03 04

D2 D3 D4

0 1 2

01 D1 0

18 Ao 00.4 Am

D02

02 LT 0

01 SI

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.

Analog Inputs:

The Analog Inputs 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.

The X8I is equipped with comprehensive diagnostic functions. Each input can be examined individually and each output can be manually activated or manipulated individually.

X8I Controller Diagnostics:

D1 Digital Input 1

D2 Digital Input 2 ON

D3 Digital Input 3

D4 Digital Input 4 OFF

D5 Digital Input 5 Pulsing

D6 Digital Input 6

D7 Digital Input 7

D8 Digital Input 8

-------------------------------------------------------------

R1 Relay Output 1

R2 Relay Output 2 OFF

R3 Relay Output 3

R4 Relay Output 4 ON

A1: System Pressure, 4-20mA

A2: Digital: ir-PCB #4 – Alarm/Serv.

A3: Digital: Auxiliary Input (D1)

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.

The analog output is utilized on the Terminal PCB to switch the ir-PCB V outputs. Set the analog output to the following to switch each ‘V’ output as required.

4.0mA All ‘V’ outputs OFF

7.0mA V1 = ON; V2, 3 and 4 = OFF

11.0mA V2 = ON; V1, 3 and 4 = OFF

15.0mA V3 = ON; V1, 2 and 4 = OFF

19.0mA V4 = ON; V1, 2 and 3 = OFF

D02 Diagnostics – LED Panel

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.

SI: Screen Invert

LT: LED Panel Test

0 = on test

1 = all on

2 = control test

D03 and D04

Diagnostic menus D03 and D04 have no standard

function and are not shown.

Page 45

D05

02 03 04

D2 D3 D4

0 1 2

01 D1

4.00

Diagnostics: XPM Expansion Module C:5-8

o only available when applicable EXP Expansion Box is installed and registered (detected) by the X8I.

X8I Controller Diagnostics:

D1 Digital Input 1

D2 Digital Input 2 ON

D3 Digital Input 3

D4 Digital Input 4

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.

Ao: Analog Output:

The analog output can be manually adjusted. Press Up(plus) and Down(Minus) to adjust and Enter. The output will return to normal operational value upon menu exit.

The analog output is utilized on the Terminal PCB to switch the ir-PCB V outputs. Set the analog output to the following to switch each ‘V’ output as required.

4.0mA All ‘V’ outputs OFF

7.0mA V1 = ON; V2, 3 and 4 = OFF

11.0mA V2 = ON; V1, 3 and 4 = OFF

15.0mA V3 = ON; V1, 2 and 4 = OFF

19.0mA V4 = ON; V1, 2 and 3 = OFF

D5 Digital Input 5 OFF

D6 Digital Input 6 Pulsing

D7 Digital Input 7

D8 Digital Input 8

-------------------------------------------------------------

R1 Relay Output 1

R2 Relay Output 2

R3 Relay Output 3 OFF

R4 Relay Output 4

R5 Relay Output 5 ON

R6 Relay Output 6

----------------------------------------------------------

Ao Analog Output 0.0 to 20.0mA

Digital Inputs:

OFF (open circuit)

ON (closed circuit)

Pulsing

Page 46

1sec

SECTION 10  FAULT CODES

X8I COMPRESSOR FAULT INDICATIONS, TYPES, AND CODES:

In the event of a unit or system “fault” the X8I 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).

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.

Compressor fault conditions are displayed by the compressor indicators and in the user menu status screen. Compressor fault conditions are not regarded as X8I unit fault conditions.

Compressor Status Sysmbols and Comressor Status

Indicators

Fault Codes

Fault codes are separated in to unit faults ‘ERR’ and system Alarms (Warning) ‘

ERR: Unit faults are errors with the X8I controller itself and are all conditions that prevent normal operation from continuing.

SYS: System faults are items that arise from conditions external to the X8I controller; the X8I itself continues to function correctly.

There are two types of Fault condition:

Alarm (Warning):

SYS’.

Trip (Shutdown):

The Fault LED will ‘fast ﬂash’ to indicate a Trip (Shutdown) condition. A Trip (Shutdown) condition will stop normal operation of the X8I. Pressure regulation control will automatically revert to the individual compressors that will continue to operate using the pressure settings for their own control systems. All Trip (Shutdown) conditions are registered in the X8I Error Log. All Trip (Shutdown) conditions must be manually reset.

Fault Codes:

Each individual fault has a unique numeric code.

ERR.01 Pressure Sensor Fault

The signal from the control pressure sensor is out-ofrange (<3.5mA or >21.8mA).

ERR.04 Internal 24V Fault

The 24VDC power supply, internal to the unit’s controller, is below 19.2V (internal controller fault)

ERR.05 Emergency Stop

The wire link between terminals ‘+C’ and ‘C1’ of the unit’s controller is open circuit. These terminals are permanently connected together on the X8I Terminal PCB: this error will never occur in normal operational circumstances.

ERR.06 Real Time Clock Error

The Real Time Clock device, internal to the unit’s controller, has failed.

ERR.07 XPM-LED Module Error

Data communications with the internal XPM-LED (Status LED Display) module have been disrupted or lost.

ERR.12 ir-PCB Expansion Module C5-8

Data communications with the external ir-PCB Expansion module ‘C:5-8’ have been disrupted or lost.

ERR.13 ir-PCB Expansion Module C5-8

Short Circuit condition detected on external ir-PCB Expansion module ‘C:5-8’.

The Fault LED will ‘slow ﬂash’ to indicate an Alarm (Warning) condition. An Alarm (Warning) indicates that the X8I is continuing with normal operation but user attention is required. All Alarm (Warning) conditions are registered in the X8I Error Log. All Alarm (Warning)

SYS.01 Excess Pressure (PM)

Pressure has exceeded the set Maximum Pressure Limit.

SYS.02 Min Pressure (Pm)

Pressure has fallen below the set Minimum Pressure Limit (see ‘Tables’)

SYS.04 Capacity Alarm (Warning)

Insuﬃcient Capacity; all available compressors are loaded and pressure is still decreasing.

Page 47

SYS.05 Remote Alarm (Warning)

Auxiliary Input Function ‘AA’

The auxiliary Input is set for ‘Alarm (always active)’ function and is in a Fault condition.

SYS.06 Remote Alarm (Warning)

Auxiliary Input Function ‘AR’

The auxiliary Input is set for ‘Alarm (active when unit running)’ function and is in a Fault condition.

SYS.07 Remote Trip (Shutdown)

Auxiliary Input Function ‘TA’

The auxiliary Input is set for ‘Trip/Shutdown (always active)’ function and is in a Fault condition.

SYS.08 Remote Trip (Shutdown)

Auxiliary Input Function ‘TR’

The auxiliary Input is set for ‘Trip/Shutdown (active when unit is running)’ function and is in a Fault condition.

Internal Controller Fault ‘E’ Codes:

‘E’ code errors are speciﬁc to the unit’s ‘internal to controller’ digital logic circuits and will only occur in the most exceptional of circumstances.

The controller’s main power supply must be removed and re-applied to reset this condition.

E5001: Internal memory failure

The unit’s controller has detected disruption to the internal permanent application memory storage (FLASH). The integrity of the FLASH memory contents is suspect. Re-load the main application software in the ﬁrst instance; re-new the controller if the condition persists.

The controller’s main power supply must be removed and re-applied to reset this condition.

To Display the Software Version:

Press and hold Reset then press Escape.

The user menu display item will show the software version ID (example: “E01”).Fault Codes:

All ‘E’ code conditions are Trip (Shutdown) type faults. The ‘Fault’ (red) LED will ‘fast ﬂash’ and the condition is registered in the Error Log. If an ‘E’ code fault condition persists, consult your product supplier for advise or renew the unit’s controller.

E0836: PLL Unlock; Internal failure or excessively high external electrical interference detected.

The main timing circuit (processor clock) has been disrupted and the processor is running on an ‘internal to chip’ back-up clock. The back-up clock is intended to keep the processor running, at a much slower processing speed, to enable emergency actions to be taken. The controller is unable to continue running the main software application in this condition.

The unit will Shutdown; compressors will continue to operate using local pressure regulation.

The controller’s main power supply must be removed and re-applied to reset this condition.

E0866: Controller internal power supply fault

The low voltage logic processing power supply, internal to the unit’s controller, is below minimum operational levels; internal to controller fault. Renew the controller if this fault condition persists. The Trip must be manually reset from the keypad.

E5000: Internal memory map error

The unit’s controller has detected disruption to the internal operational memory storage (RAM). The integrity of the RAM memory contents are suspect; the controller must be reset to clear and re-map the memory. Renew the controller if this fault condition persists.

Page 48

20mm

5mm

IEC

2 1

Mounting Dimensions:

27mm

286mm

27mm

188mm

8mm Ø

SECTION 11 — PARTS LIST

Item Part No.

Description

Item Part No. Description

- 42659250 X8I, Kit

- 23242159 Unit, X8I

- 80444086 Manual, User CD

1 42659268 Unit, Controller

2 42659284 Unit, XPM-PSU24

3 39265913 Unit, XPM-TAC24

4 39265905 PCB, Terminal

5 42659276 Unit, XPM-LED

6 38036703 Gland, Set - Pg13.5

7 39265939 Sensor, Pressure

4-20mA, 232psi (16bar)

Item Part No. Description

10 39265962 IEC Fuse T1.0A

10 39265970 IEC Fuse T1.6A

10 39265988 IEC Fuse T1.6A

TECHNICAL DATA

22194773 XI Installation Kit

80444078 Quick Setup Guide

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%

115Vac +/- 10%

Power 100VA

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

Humidity 95% RH, non-condensing

Page 49

SECTION 12 — DIAGRAMS

N L E

T1-46-321-R6-DiC-CG

A m

0 2

C031

C032

XPM-LED

X02

1 2

2 # 5 8 4 S

5 8

lt u

C09

C010

N L E

230Vac 10% 115Vac 10%

6 0

8 0

5 8 4

M P X

1 0

A-GND

9 0

1 L

2 L

1 # 5 8 4 S

1 L

c a

V 4 2

X8I

3 5

3 3

3 1

2 7

2 6

2 5

2 3

2 2

2 1

2 0

2 9

4 V

1 7

1 6

1 5

1 4

1 3

3 V

1 1

1 0

1 9

0 X

X 8 7

2 V

6 5 4

X 2 1

1 V

C029 C028

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

c a V 4 2

D N G

C01

4 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

C012

10k

C023 C027

C018

10k

C022 C026

4-20mA

R-V4

R-V3

R-V2

R-V1

C016

10k

C021 C025

C015

C03 C04 C05 C06 C07 C08

C019 C020 C021 C022 C023 C024 C025 C026 C027

C011

0 X

+VDC

Ai1

+VDC

Ai2

+VDC

Ai3

C+

4 0

1 2

3 4

5 6 7 8

2 0

C012

C01/3

C01/4

C013

R1 R2

0 X

C014

C015

C016

C017

C018

0VDC

C A

0Vac - earthed

1 0

2 U S

X02

24VDC

P X

24Vac

2 1

X03

X01

24Vac

X03

24VDC

0Vac 24Vac

XPM485

1 2

XPM-LED

X02

1 2

X03

1 2

Wiring Diagram

Page 50

Connection Diagram

Terminal PCB

3 5

3 3

3 1

0 X

115V 'UL' @ 5A maximum.

Auxiliary Output #1

Auxiliary Input #1

330ft (100m) max

3 9

2 8

2 7

2 6

2 5

2 4

2 3

2 2

2 1

2 0

2 9

1 4

1 7

1 6

1 5

1 4

1 3

V 2

1 1

1 0

1 9

8 7 2

V 6

5 4

3 2 1 1

0 X

L2 L

Ai1

+20VDC Ready/Run

Di5

Alarm/Serv.

Ai2

GND LOAD

SEQ

VFD

+20VDC Ready/Run

Di4

Alarm/Serv.

Di8

GND LOAD

SEQ

VFD

+20VDC

Di3

Ready/Run Alarm/Serv.

Di7

GND LOAD

SEQ

VFD

+20VDC Ready/Run

Di2

Alarm/Serv.

Di6

GND

LOAD

SEQ

VFD

Multi485

System Pressure

330ft (100m) max

6 5

4 B

2 1

6 5

3 B

2 1

6 5

2 B

2 1

6 5

1 B

2 1

330ft (100m) max

IRV-PCB 7-core

330ft (100m) max

IRV-PCB 7-core

330ft (100m) max

IRV-PCB 7-core

330ft (100m) max

IRV-PCB 7-core

IR-PCB 6-core

4-20mA

L2 L

Page 51

XPM-TAC24

230V

115V

24Vac/1

isolated

24Vac/2

earthed

E E

N L E

BLUE

BROWN

RED

GREEN

VIOLET

WHITE

ORANGE

BLACK

FH1

FH2FH3FH4

FH5

VOLTAGE SELECT

2 3 4

X04

2 1 2

X03

X02

X01

T3.15A

T1.6A

T1.0A

1 2 3 4

115V +-10%

230V +-10%

1 2 3 4

IEC

5x20mm

Page 52

X8I COMMISSIONING FORM

psi

cfm

psi

cfm

psi

cfm

psi

cfm

psi

cfm

psi

cfm

psi

cfm

psi

cfm

Customer Contact Customer Ref:

Phone Internal Ref:

Installation/Site Commission Date

Software Ser No. Commission Engineer

Comp #1 Manufacturer

Comp #1 Model/Type Comp #1 Working Pressure bar/psi

Comp #1 Full Load Capacity cfm

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

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

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

Comp #5 Manufacturer Comp #5 Model/Type Comp #5 Working Pressure bar/psi Comp #5 Full Load Capacity cfm

Comp #6 Manufacturer Comp #6 Model/Type Comp #6 Working Pressure bar/psi Comp #6 Full Load Capacity cfm

Comp #7 Manufacturer Comp #7 Model/Type Comp #7 Working Pressure bar/psi Comp #7 Full Load Capacity cfm

Comp #8 Manufacturer Comp #8 Model/Type Comp #8 Working Pressure bar/psi Comp #8 Full Load Capacity cfm

Page 53

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 T01 01 Comp #1 Priority T01 02 Comp #2 Priority T01 03 Comp #3 Priority T01 04 Comp #4 Priority T01 05 Comp #5 Priority T01 06 Comp #6 Priority T01 07 Comp #7 Priority T01 08 Comp #8 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 T02 01 Comp #1 Priority T02 02 Comp #2 Priority T02 03 Comp #3 Priority T02 04 Comp #4 Priority T02 05 Comp #5 Priority T02 06 Comp #6 Priority T02 07 Comp #7 Priority T02 08 Comp #8 Priority

EHR FILO ENERGY

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 T03 01 Comp #1 Priority T03 02 Comp #2 Priority T03 03 Comp #3 Priority T03 04 Comp #4 Priority T03 05 Comp #5 Priority T03 06 Comp #6 Priority T03 07 Comp #7 Priority T03 08 Comp #8 Priority

T04 PH High Pressure Set Point psi/bar T04 PL Low pressure Set Point psi/bar T04 Pm Minimum Pressure Alarm psi/bar T04 SQ Sequence Rotation Mode T04 01 Comp #1 Priority T04 02 Comp #2 Priority T04 03 Comp #3 Priority T04 04 Comp #4 Priority T04 05 Comp #5 Priority T04 06 Comp #6 Priority T04 07 Comp #7 Priority T04 08 Comp #8 Priority

EHR FILO ENERGY

Page 54

P02 PF Preﬁll Function P02 PT Preﬁll Time Sec P02 PP Preﬁll Pressure psi/bar P02 - Primary Compressors P02 - Backup Compressors

!>X A

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

S01 PS Pressure Schedule S01 AR Auto Restart S01 RP Rotation Interval S01 TS Default Table Select

S02 NC Number of Compressors S02 PM Max 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 S02 AO Auxiliary Output S02 CA Capacity Alarm S02 MA Capacity Restricted Alarm

S03 01 Aux I/O Box #1 S03 02 Aux I/O Box #2 S03 BT RS485 Timeout sec

S04 1o Pressure OﬀsetA psi/bar S04 1r Pressure Range psi/bar

1 2 3 4 5 6 7 8 9 10 11 12

Page 55

C01 01 Compressor #1 Hours hrs C01 02 Compressor #2 Hours hrs C01 03 Compressor #3 Hours hrs C01 04 Compressor #4 Hours hrs C01 05 Compressor #5 Hours hrs C01 06 Compressor #6 Hours hrs C01 07 Compressor #7 Hours hrs C01 08 Compressor #8 Hours hrs

C03 01 Compressor #1 Type C03 - Start Time Sec C03 - Max Capacity % C03 - Min Capacity % C03 - Min Eﬃciency %

C03 02 Compressor #2 Type C03 - Start Time Sec C03 - Max Capacity % C03 - Min Capacity % C03 - Min Eﬃciency %

C03 03 Compressor #3 Type C03 - Start Time Sec C03 - Max Capacity % C03 - Min Capacity % C03 - Min Eﬃciency %

C03 04 Compressor #4 Type C03 - Start Time Sec C03 - Max Capacity % C03 - Min Capacity % C03 - Min Eﬃciency %

IR-PCB IRV-PCB IR-485 IRV-485

C03 05 Compressor #5 Type C03 - Start Time Sec C03 - Max Capacity % C03 - Min Capacity % C03 - Min Eﬃciency %

C03 06 Compressor #6 Type C03 - Start Time Sec C03 - Max Capacity % C03 - Min Capacity % C03 - Min Eﬃciency %

C03 07 Compressor #7 Type C03 - Start Time Sec C03 - Max Capacity % C03 - Min Capacity % C03 - Min Eﬃciency %

C03 08 Compressor #8 Type C03 - Start Time Sec C03 - Max Capacity % C03 - Min Capacity % C03 - Min Eﬃciency %

IR-PCB IRV-PCB IR-485 IRV-485

Ingersoll Rand X8I Operator’s Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 11 — PARTS LIST

SECTION 12 — DIAGRAMS

X8I COMMISSIONING FORM