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Ingersoll Rand
System Automation
X8I
Operator’s Manual
Before installing or starting this unit for the first time, this manual should be studied carefully to obtain a working knowledge of the unit and or the duties to be performed while operating and maintaining the unit.
RETAIN THIS MANUAL WITH UNIT. This Technical manual contains IMPORTANT SAFETY DATA and should be kept with the unit at all times.
More Than Air. Answers.
Online answers: http://www.air.irco.com
C.C.N. : 80444060 REV. : B
DATE : MAY 2008
SECTION 1 — TABLE OF CONTENTS
SECTION 1 — TABLE OF CONTENTS........................... |
2 |
SECTION 2 — INTRODUCTION.................................... |
3 |
SECTION 3 —safety..................................................... |
3 |
INSTALLATION.............................................................................. |
3 |
OPERATION .................................................................................. |
3 |
MAINTENANCE AND REPAIR.................................................. |
3 |
SECTION 4 — COMPRESSOR CONNECTION AND |
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CONTROL ......................................................................... |
5 |
COMPRESSOR CONNECTION AND CONTROL............... |
5 |
OPTIONAL CONNECTION METHODS................................. |
5 |
PRESSURE DETECTION AND CONTROL............................. |
6 |
X8I MAIN DISPLAY ..................................................................... |
7 |
SECTION 5 — INSTALLATION OVERVIEW................. |
8 |
INSTALLATION.............................................................................. |
9 |
UNIT LOCATION........................................................................... |
9 |
POWER SUPPLY........................................................................... |
9 |
PRESSURE SENSOR LOCATION.............................................. |
9 |
PRESSURE SENSOR CONNECTION..................................... |
10 |
ir-PCB INTERFACE MODULE................................................ |
10 |
ir-485 AND irV-485 GATEWAY MODULE........................ |
11 |
ir485 COMMUNICATION PROTOCOL............................... |
11 |
RS485 NETWORK....................................................................... |
11 |
SECTION 6 — CONTROL FEATURES AND |
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FUNCTIONS.................................................................... |
13 |
STANDARD CONTROL FEATURES AND |
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FUNCTIONALITY....................................................................... |
13 |
STANDARD CONTROL FEATURES AND |
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FUNCTIONALITY....................................................................... |
15 |
ALTERNATE CONTROL FEATURES AND |
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FUNCTIONALITY....................................................................... |
18 |
SECTION 7 — DISPLAY AND MENU OPERATION...20 |
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INDICATORS................................................................................ |
23 |
SECTION 8 — COMMISSIONING............................... |
26 |
PHYSICAL CHECKS................................................................... |
26 |
PRESSURE DISPLAY.................................................................. |
26 |
X8I QUICK SET-UP CONFIGURATION................................ |
26 |
OPTIONAL FEATURES AND FUNCTIONS......................... |
26 |
SECTION 9 — SYSTEM CONFIGURATION................ |
27 |
DISPLAY ITEM STRUCTURE................................................... |
27 |
NORMAL OPERATIONAL DISPLAY (MENU PAGE P00)27 |
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ACCESSING THE X8I CONFIGURATION SCREENS......... |
27 |
USER Level Menus................................................................. |
29 |
SERVICE Level Menus........................................................... |
30 |
X8I CONFIGURATION SCREENS .......................................... |
31 |
X8I COMPRESSOR CONNECTIVITY AND FUNCTIONAL |
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SETTINGS..................................................................................... |
41 |
SECTION 10 — FAULT CODES.................................... |
46 |
X8I COMPRESSOR FAULT INDICATIONS, TYPES, AND |
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CODES:.......................................................................................... |
46 |
SECTION 11 — PARTS LIST….. ...............................48 |
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SECTION 12 — DIAGRAMS…..................................49 |
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WIRING DIAGRAM……….…….....................................49 |
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CONNECTION DIAGRAM……... ...................................50 |
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XPM-TAC24......................................................................... |
51 |
X8I COMMISSIONING FORM…............................... |
52 |
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
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.
SECTION 3 —safety
!WARNING : Risk of Danger
WARNING : Risk of Electric Shock
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WARNING : Risk of High Pressure |
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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.
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:
i.Isolate the X8I from the main electrical power supply. Lock the isolator in the ‘OFF’ position and remove the fuses.
ii.Attach a label to the isolator switch and to the unit stating ‘WORK IN PROGRESS - DO NOT APPLY VOLTAGE’. Do not switch on electrical power or attempt to start the 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.
SECTION 4 — COMPRESSOR CONNECTION AND CONTROL
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.
All Nirvana Compressors, 20 HP (15KW) and above require the irV-485 Gateway.
ir-485 |
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.
irV485 |
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 irPCB 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).
Ingersoll Rand
102 psi
1 
2 
3 
4
18:35 #2
5 
6 
7 
8
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.
Remote Compressor Management; EX Box (option)
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.
4000ft (1219m) max
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:
Ingersoll Rand
102 psi
1 
2 
3 
4
18:35 #2
5 
6 
7 
8
8 Digital Inputs
5 Analog Inputs
6 Relay Outputs
4000ft (1219) max
The EX Box connects to the X8I controller via a two wire, RS485 network utilizing the IR485 protocol
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 IRNirvana). The VSD Box will provide required functionality to enable system integration and efficient control using the X8I automation system.
30ft max
ir-PCB
Ingersoll Rand
102 psi
18:35 #2
From VSD Pressure Transducer
o VSD Pressure Transducer Input 
1 
2 
3 
4
5 |
6 |
7 |
8 |
Ingersoll Rand
102psi
1 
2 
3 
4
18:35 #2
5 
6 
7 
8
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).
X8I MAIN DISPLAY
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User Interface : |
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102 |
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PSI |
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System Pressure Value |
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System Pressure Units |
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Unit Status |
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17:30 |
#1 |
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Unit Active Functions |
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User Menu Item |
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System Alarms (Warning) : |
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Unit Run Indicator (green LED) |
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Unit Alarm Indicator (Red LED) |
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System Alarms (Warning) : |
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CAP |
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Group Compressor Fault |
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Insu cient Capacity Alarm (Warning) |
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c) |
Restricted Capacity Alarm (Warning) |
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Ingersoll Rand
102 psi |
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1 A: 85% |
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CAP |
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a
b
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Compressor Status Indicators :
a) |
Load Status |
b) |
Run Status |
c) |
Compressor Availability |
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Keypad and Navigational Keys Functionality |
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Start |
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Reset |
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Stop |
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d) |
Menu |
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Enter |
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Escape |
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g) |
Up (Plus) |
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Down (minus) |
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SECTION 5 — INSTALLATION OVERVIEW
Ingersoll Rand Automation
Model X8I
SPECIFICATIONS
Dimensions |
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13.4” x 9.45” x 6.0” |
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340mm x 241mm x 152mm |
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Weight |
16.5lb (7.5kg) |
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Mounting |
Wall, 4 x screw fixings |
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Enclosure |
IP65, NEMA 4 |
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Supply |
230Vac +/- 10%, 50 Hz |
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Power |
115Vac +/- 10%, 60 Hz |
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100VA |
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Temperature 32°F to 115°F |
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(0°C to 46°C) |
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Humidity |
0% to 95% RH |
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(non-condensing) |
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Ingersoll Rand
1021 |
psi |
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2 |
3 |
4 |
18:35 #2 |
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CAP |
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6 |
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8 |
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.
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The EXP Will Add Another (4) |
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Direct ir-PCB connections. This |
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Would Allow A Total Of (8) |
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Compressors To Be Connected |
EXP |
And Controlled Via The ir-PCB. |
Local Disconnect (Breaker) Box
Fused for 100VA
Power Cable
3 conductor (N, L, E) (Sized in accordance with local electrical and safety regulations).
PRESSURE TRANSDUCER CABLE
2 Conductor Cable, 18 Gauge Stranded
Earth Shielded
No Greater Than 330FT (100M)
24VDC Control Voltage
On/O Supply Voltage Cable
Switch 
Pressure Transducer Cable
EXP RS485 Network Cable |
OPTIONAL |
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EXP RS485 NETWORK CABLE
Belden 9841 or Equivalent
In Grounded Conduit
No Greater Than 33FT (10)
RS485 Network Cable
RS485 NETWORK CABLE
Belden 9841 or Equivalent
In Grounded Conduit
No Greater Than 4000FT (1219M)
X8I X05 CONNECTOR |
PT CONNECTOR |
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25 |
+VDC Pin #3 |
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26 |
Signal Pin #1 |
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Reference X8I Operations Manual for Pressure |
ir-PCB |
ir-PCB |
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Sensor Connection Details |
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PRESSURE TRANSDUCER
To Plant Air
System
RECEIVER
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Ir-PCB Compressor #2 |
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Control Cable |
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ir-PCB COMPRESSOR CONTROL CABLE |
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7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded |
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DRIP LEG |
Reference X8I Application and Interconnect Guide For |
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OR |
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Single Conductor Wire, 18 Gauge Stranded, Quantity (7) |
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Wiring Connections Between The X8I, The ir-PCB, |
In Grounded Conduit No Greater Than 330FT (100M) |
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and The Compressor |
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24VAC Control Voltage |
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Reference X8I Application and Interconnect Guide For |
The RS485 Network is a Serial, Point to Point |
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Wiring Connections Between The X8I, The ir-485 or irV- |
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Communication Network Refer to the X8I Application and |
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485 Gateway and The Compressor, S3 Direct Connects, and |
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Interconnect Guide For Wiring Details and Connectivity. |
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Optional Special Application Interface Boxes |
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Ingersoll |
Ingersoll |
Ingersoll |
Rand |
Rand |
Rand |
102 psi |
102 psi |
102 psi |
I/O |
ir-485 |
VSD |
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Direct To |
From VSD Pressure |
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Transducer |
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S3 |
To VSD Pressure |
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Transducer Input |
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ir-485 Gateway |
Rand |
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For All |
Ingersoll |
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102 psi |
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ir-485 |
IR (NonNirvana) Compressors |
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IntelliSys “Red Eye”, SG and SE |
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OR |
EX |
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irV-485 Gateway |
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For All |
irV-485 |
Nirvana Compressors |
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20HP (15KW) and Above |
ir-PCB
INSTALLATION
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).
XPM-TAC24
1 |
2 |
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1 |
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4 |
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X04 |
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VOLTAGE SELECT |
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N L E |
X01 |
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230Vac |
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X04 |
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VOLTAGE SELECT
115Vac
Power Supply Terminals
Ensure that the voltage select input is properly jumpered for the incoming power. Default voltage configuration is 230Vac.
PRESSURE SENSOR LOCATION
The system pressure sensor (P) must be located where it will see the air pressure that is common to all of the compressors.
SUPPLY (WET) SIDE PRESSURE CONTROL
1 |
P |
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P |
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2 |
Pressure Sensor Located Before Cleanup Equipment
Dry side pressure will be lower than the system pressure due to pressure differential losses across air treatment equipment. The nominal system pressure will reduce as the air treatment differential pressure increases.
DEMAND (DRY) SIDE PRESSURE CONTROL
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P |
P |
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Pressure Sensor Located After Shared Cleanup
Equipment
P |
P |
1 |
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P |
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2 |
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Pressure Sensor Located After Individual Cleanup
Equipment
Ensure each compressor is equipped with independent excess pressure shutdown. An increase in pressure differential across air treatment equipment can result in excess compressor discharge pressure.
Regular routine monitoring of pressure differential across air treatment equipment is recommended.
PRESSURE SENSOR CONNECTION
The pressure sensor connects to terminal X05 of the X8I terminal PCB using a shielded 18 AWG maximum 2- conductor cable no more than 330 feet (100 meters) in length. The transducer threads are BPT. It is the equivalent of ¼” NPT.
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.
Cable Earth Shield
Wire polarity is important.
Pressure Sensor Wiring and Location ir-PCB INTERFACE MODULE
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.
ir-PCB Interface Module
The ir-PCB is a DIN rail mountable module designed to be installed within the compressor starter enclosure.
Each air compressor must be equipped with a load/ unload regulation system and, if not regulated with a single electro-mechanical pressure switch, have a facility for a remote load/unload control with the ability to accept a volt-free switching contact input for remote load/unload. Each air compressor must have Auto Restart capability.
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.
10
ir-485 AND irV-485 GATEWAY MODULE
The ir-485 and irV-485 Gateways are designed to interface the Intellisys Controller on the Ingersoll Rand Compressors and the Nirvana compressors, 20 HP (15KW) and above, with the 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 |
irV485 |
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
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.
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.
RS485 NETWORK
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.
|
X06 |
|
L2 |
30 |
L2 |
L1 |
29 |
L1 |
|
28 |
RS485 |
|
27 |
|
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
4000ft (1219m) max
102 psi
18:35 #2
Correct RS485 Network Example
The following example details the “incorrect” method of wiring the RS485 Network
Ingersoll |
Ingersoll |
Rand |
Rand |
102 psi |
102 psi |
I/O |
EX |
102 psi |
|
18:35 |
#2 |
1 |
2 |
|
Ingersoll |
Ingersoll |
|
Rand |
||
102 psi |
Rand |
|
102 psi |
||
|
||
EX |
I/O |
Incorrect RS485 Network Example
11
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).
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SECTION 6 — CONTROL FEATURES AND FUNCTIONS
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.
a |
PH |
|
|
|
PT |
|
PL |
|
b |
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.
PH |
PT |
PL |
Figure 2 — Typical VSD Pressure Control vs. Time
The variable speed compressors in the system will run on their target pressure and smooth out the variations in system pressure. This assumes that system demand does not vary more than the capacity of the variable 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.
ANTI-CYCLING CONTROL
The most efficient way to utilize most air compressors is either fully loaded or off, with the exception of variable speed compressors which can operate efficiently at reduced loading. Compressor cycling (start-load-unload- stop, etc.) is essential to maintain pressure control. Excessive cycling, however, can result in poor compressor efficiency as well as increased maintenance.
Anti-cycling control is incorporated to help ensure that only the compressors that are actually required are started and operating while all others are kept off.
Anti-cycling control includes a pressure tolerance range or band, defined by the user, which is outside of the primary pressure band. Inside the tolerance band, an active control 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.
PH + TO |
TO |
PH |
PT |
PL |
TO |
PL - TO |
Figure 3 — Tolerance in Relation to PH and PL
Tolerance (TO) is expressed as a pressure defining the width of the band above PH and below PL in which energy efficient control will be in effect.
When system pressure is in the tolerance band, the 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.
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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.
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.
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:
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)
ΔP — “Allowable Pressure Drop” (PSI, BAR)
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Example 1: Find Required Storage Volume in Ft3 and US
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
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.
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.
100% 
80% |
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2 |
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40% |
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20% |
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0% |
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0% |
1 |
100% |
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:
|
1 |
2 |
3 |
4 |
|
1 |
2 |
2 |
2 |
#1 |
A |
B |
C |
D |
#2 |
A |
C |
D |
B |
#3 |
A |
D |
B |
C |
#4 |
A |
B |
C |
D |
Compressor 1 has priority 1, all other compressors have priority 2
15
In another example, there is a four compressor system that includes a compressor in the compressor 4 spot that is used only as an emergency backup compressor. To accomplish this, simply assign compressor 4 a lower priority than any other compressor in the system:
|
1 |
2 |
3 |
4 |
|
1 |
1 |
1 |
2 |
#1 |
A |
B |
C |
D |
#2 |
B |
C |
A |
D |
#3 |
C |
A |
B |
D |
#4 |
A |
B |
C |
D |
Compressor 4 has priority 2, all other compressors have priority 1
In a third example, there is a four compressor system that includes a variable speed compressor designated compressor 1 and a fixed speed compressor that is an emergency backup assigned as compressor 4. To ensure that compressor 1 is always at the front of the sequence and compressor 4 is always at the end of the sequence, set the priority as shown below:
|
1 |
2 |
3 |
4 |
|
1 |
2 |
2 |
3 |
#1 |
A |
B |
C |
D |
#2 |
A |
C |
B |
D |
#3 |
A |
B |
C |
D |
#4 |
A |
C |
B |
D |
Compressor 1 has priority 1, compressor 4 has priority 3 and all other compressors have priority 2
A last example involves another four compressor system that will be assigned into two independently rotation groups. Compressors 1 and 2 are given priority 1 and compressors 3 and 4 are given priority 2. This results in the rotation sequence shown below:
|
1 |
2 |
3 |
4 |
|
1 |
1 |
2 |
2 |
#1 |
A |
B |
C |
D |
#2 |
B |
A |
D |
C |
#3 |
A |
B |
C |
D |
#4 |
B |
A |
D |
C |
Two independently rotating compressor groups
•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:
16
1 |
2 |
|
PC |
Changing Target Pressures
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.
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.
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.
! X Standard Mode: If one or more of the predefined prefill compressors experiences a shutdown, or is stopped, the prefill function is cancelled and normal operation begins.
A Automatic Mode: No Prefill compressor selection is necessary; any selection set is ignored. The management unit automatically selects compressor(s) dynamically to achieve pressure in accordance with the set Prefill time. If a compressor is stopped, or shuts down, it is automatically substituted with an alternative compressor.
To manually skip Prefill mode, press and hold Start for several seconds.
Insufficient Capacity Alarm
CAP
The X8I is equipped with a dedicated ‘Insufficient Capacity’ Advisory Alarm (Warning) indication.
This indication will illuminate if all available compressors are loaded and system pressure is continuing to decrease. The indication will generally occur prior to any set low pressure Alarm (Warning) and is intended to provide an advanced warning of a potential ‘Low Pressure’ situation.
17
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