Ingersoll Rand X8I,X12I Quick Setup Guide
Before installing or starting this unit for the first
time, this manual should be studied carefully to
obtain a working knowledge of the unit and or the
duties to be performed while operating and
maintaining the unit.
RETAIN THIS MANUAL WITH UNIT. This Technical
manual contains IMPORTANT SAFETY DATA and
should be kept with the unit at all times.
More Than Air. Answers.
Online answers: http://www.air.irco.com
Ingersoll Rand
System Automation
X8I & X12I
Quick Setup Guide
C.C.N. : 80445067
REV. : A
DATE : DECEMBER 2008
SECTION 1 — TABLE OF CONTENTS
SECTION1—TABLEOFCONTENTS.....................................1
SECTION2—INTRODUCTION.............................................2
SECTION3—SAFETY..........................................................2
INSTALLATION...........................................................................2
OPERATION..............................................................................2
MAINTENANCEANDREPAIR........................................................2
SECTION4—SYSTEMOVERVIEW.......................................4
SECTION5—INSTALLATIONOVERVIEW.............................5
SECTION6—BEFOREYOUSTART.......................................6
CHECKLIST..............................................................................6
CHECKLISTGUIDANCE...............................................................6
ASSISTANCE..............................................................................7
INTELLISYSCONTROLLERE‐PROMREFERENCELIST...........................7
SECTION7—MENUNAVIGATION......................................8
X8IUSERINTERFACE.................................................................8
X8IINFORMATIONDISPLAYS.....................................................11
X12IUSERINTERFACE.............................................................12
USERMENU...........................................................................14
X12IINFORMATIONDISPLAYS...................................................15
X8IANDX12IINDICATORS.......................................................18
COMPRESSORIDENTIFICATION...................................................19
X8I&X12ICONTROLKEYPADFUNCTIONS..................................19
SECTION8—QUICKSETUPCOMMISSIONING...................21
SECTION10WIRINGDIAGRAMS........................................28
X8I,EXP,EX,VSDMA,VSDV,I/O,CX,DX,SMGPOWERSUPPLY
CONNECTION.........................................................................28
X12IPOWERSUPPLYCONNECTION............................................28
X8I,X12IPRESSURETRANSDUCERCONNECTION..........................28
X8I,X12IRS485CONNECTION................................................29
EXBOXRS485CONNECTION...................................................29
VSDMA,VSDVBOXRS485CONNECTION................................29
I/OBOXRS485CONNECTION..................................................29
CXBOXRS485CONNECTION...................................................29
DXBOXRS485CONNECTION...................................................29
X8ITOEXPRS485CONNECTION..............................................29
X12ITOEXPRS485CONNECTION............................................29
IR485,IRV485GATEWAYCONNECTION.....................................30
IR‐485GATEWAYSWITCHSETTINGS..........................................31
IRV‐485GATEWAYSWITCHSETTINGS........................................32
IRPCBCONNECTION................................................................33
SMGBOXRS485CONNECTION................................................33
VXBOXCONNECTION..............................................................34
PHYSICALCHECKS....................................................................21
PRESSUREDISPLAY..................................................................21
QUICKSET‐UPCONFIGURATION................................................21
OPTIONALFEATURESANDFUNCTIONS........................................21
SECTION9—SYSTEMCONFIGURATION............................22
X8IORX12ICONFIGURATIONSCREENS......................................22
X8IORX12ICOMPRESSORCONNECTIVITYANDFUNCTIONALSETTINGS
............................................................................................25
Refer to Section Indicated
Note
Important or Caution, Safety
1
SECTION 2 — INTRODUCTION
This manual is intended as a quick reference to establish
basic sequence control of the compressors with the X8I
or X12I. This document details the minimum required
hardware setup process for the product. Please refer to
the Operator’s Manual for complete setup and operating
SECTION 3 — SAFETY
WARNING :
!
WARNING :
WARNING :
!
WARNING :
• Before installing or operating the X8I or X12I,
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
product.
• 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.
Risk of Danger
Risk of Electric Shock
Risk of High Pressure
Consult Manual
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 or X12I.
• The X8I or X12I 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 or X12I 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.
instructions. If you have any questions regarding the X8I
or X12I, please contact your local authorized and trained
Ingersoll Rand Service Center or contact Technical
Support Services at 800-820-0308 to speak one of our
Technical Support Engineers.
OPERATION
• The X8I or X12I 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 or
X12I.
• The X8I or X12I 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 or X12I:
• Isolate the X8I or X12I from the main electrical
power supply. Lock the isolator in the 'OFF'
position and remove the fuses.
2
• 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 or X12I 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 or X12I 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.
3
SECTION 4 — SYSTEM OVERVIEW
Refer to the X8I or X12I Operator’s Manual and the
Interconnect and Application Guide for installation
details.
4
SECTION 5 — INSTALLATION OVERVIEW
Refer to the X8I or X12I Operator’s Manual and the
Interconnect and Application Guide for installation
details.
5
SECTION 6 — BEFORE YOU START
CHECK LIST
Prior to attempting installation and commissioning of the
X8I or X12I please review the following check list:
o Quick Set Up Manual is available and has been
reviewed
o Application Guide is available and the correct
diagrams have been identified
o If the specific diagrams are not in the Application
Guide the specific compressor control wiring
schematic will be required to define the correct
interconnection
o Operator’s Manual is available and has been
reviewed
o Compressors to be connected can accept remote
load / unload commands
o Compressors to be connected have automatic
Start / Stop capability
o Correct compressor controller EPROM is installed
or available to allow Remote Control and Auto
Start/Stop (SE Controller) See Reference Table
Below.
o The correct wire is available to connect the X8I
or X12I with the Compressor / ir-PCB interface
o The correct wire is available to connect the X8I
or X12I with the Compressor / ir-485 and/or irV485 Gateway.
o The correct wire is available to connect the X8I
or X12I with the Optional Integration boxes
o The correct wire is available to connect the X8I
or X12I with the pressure sensor/transducer
o The X8I or X12I can be located within 330ft
(100m) of each compressor using the ir-PCB.
o The EXP must be located within 33ft (100m) of
X8I or X12I
o The EXP can be located within 330ft (100m) of
each compressor using the ir-PCB.
o The X8I or X12I can be located within 4000ft
(1219m) of each compressor using the ir-485
and/or irV-485 Gateway or Optional Integration
boxes. (The exception to this is connecting the
Optional EXP box to the X8I or X12I. The
maximum distance is 33ft (10m) in length.)
o The Pressure sensor/transducer can be located
appropriately within 330ft (100m) for the X8I or
X12I Controller
CHECK LIST GUIDANCE
o Electrical Drawing For Each Compressor: It is
important to have the Electrical drawing for each
compressor so that the correct interconnect
drawing can be referenced from the Interconnect
and Application Guide
o Types of Compressors To Be Sequenced: Refer
to the Interconnect and Application Guide for
specific details on the types of compressors that
can be sequenced and their individual
requirements such as Auto Restart, Intellisys
Software, etc.
o ir-PCB and ir-485 and/or irV-485 Gateway
Mounting: The ir-PCB and the Gateway module
is designed to be installed within the compressor
starter enclosure. The mounting location of the
ir-PCB should be away from any high voltage
connections, contactors, or transformers.
o ir-PCB, ir-485 and/or irV-485 Gateway and
Compressor Interconnections: Refer to the
Interconnect and Application Guide for specific
drawings for various compressors and the X8I or
X12I. If there is not a specific drawing available
for the compressor being sequenced at the site,
please contact Technical Support Services for
assistance.
o ir-PCB, ir-485 and/or irV-485 Gateway and
Compressor Interconnection Wire: The X8I or
X12I Installation kit contains 330 Ft (100m) of 18
gauge stranded wire (Orange) to use for the
connections between the ir-PCB and the
compressor. In most cases, this is sufficient for
most installations. If additional wire is required,
any 18 gauge stranded wire can be used in lieu
of the wire provided in the kit.
X8I or X12I Installation kit also contains an
interconnect cable for the connection between
the ir-485 Gateway and the Intellisys Controller.
o X8I or X12I, EXP, EX and ir-PCB Interconnect Wire:
The cable used between the X8I or X12I and the
compressor ir-PCB interconnection is designed to
use 7-conductor shielded cable or individual
wires run through earthed/grounded metal
conduit/tubing. (18 gauge wire).
o The cable used between the X8I or X12I, EXP, ir-
485 and/or irV-485 Gateway or any Optional
Integration Boxes 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 exception to this is connecting the
Optional EXP box to the X8I or X12I. The
maximum distance is 33ft (10m) in length.)
6
o X8I or X12I and Pressure Transducer Wire: The
X8I or X12I and the pressure transducer
interconnection is designed to use 2-conductor
shielded cable. (18gauge)
o All external wiring to the X8I or X12I should be
made through the holes (grommets are provided)
in the X8I or X12I enclosure (8 in total). Drilling
or tapping additional holes in the enclosure can
result metal shavings making contact with the
circuit boards. Damage due to metal shavings in
the circuit boards is not covered by warranty.
o Power / Local Disconnect (Breaker): Incoming
power (115VAC/230VAC, single phase) should
be fused (100VA) and a local disconnect
provided. The power source should be regulated
and noise free. The use of a power supply
regulator might be required in applications
where unregulated power is an issue
o Confirm that all electrical connections are made
properly and tightened and conform to local
standards.
o Common Receiver: The X8I or X12I must have
its pressure transducer located in a common
receiver for proper Wet Side or Dry Side System
pressure control.
Pressure Transducer Installation: The pressure
transducer threads are BPT G1/4” DIN3852, Form
E, Inox 1, 4305 stainless. It is the equivalent of
¼” NPT.
ASSISTANCE
o Contacting Technical Support Services or Service
Bulletins listed on the IR ServiceNet can provide
further assistance if there are other questions or
concerns prior to Installation and Start-up.
INTELLISYS CONTROLLER E-PROM REFERENCE LIST
Minimum Recommended E-prom Levels - IntelliSys Controllers
IntelliSys - First Generation "Redeye"
SSR 50 - 450HP 1 & 2 stg 2.4
Sierra 100 - 200HP 2.7
Recip 1.62
IntelliSys - Second Generation "SG" IntelliSys - Second Edition "SE"
SSR 50 - 450 1 & 2 stg 1.5 SSR 15 - 100HP 1.75
SSR 75 - 350kW ESA
Sierra 125-400HP 1.35 SSR 22 - 150kW ESA
Recip 1.28 Sierra 50 - 100HP 1.3
IntelliSys - Nirvana "SGN"
Nirvana CC 100 - 200HP 1.45
IntelliSys - Nirvana "SGNe"
Nirvana CC 50 - 300HP 2.4
1.5 SSR - UP (Pegasus) 1.23
1.93
Nirvana OF 50 - 200HP 1.2
7
SECTION 7 — MENU NAVIGATION
The Main Display and the keypad and navigation buttons
on the X8I or X12I are depicted below and provide the
following functionality:
X8I User Interface
d
e
1
17:30 #1
a
102
b
PSI
c
a
Ingersoll Rand
1
102
A: 85%
b
c
psi
CAP
a
b
1
CAP
5
3
2
6
4
7
8
c
1
a
b
c
g
f
h
d
e
8
1
2
3
4
9
17:30 #1
1
#
A: 100%
102 psi
00:00 #1
10
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