Ingersoll Rand X-Series System Automation Interconnect 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.

Ingersoll Rand

X-Series System Automation

Interconnect Guide

Ingersoll Rand Compressors

C.C.N. :

More Than Air. Answers.

Online answers: http://www.air.irco.com

REV. : A

DATE : APRIL 2007

1

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 ............................................4

SECTION 4 — X4I SYSTEM OVERVIEW ..............................5

SECTION 5 — X8I SYSTEM OVERVIEW ..............................6

SECTION 6 — VSD OVERVIEW ..........................................7

SECTION 7 — ASSISTANCE ..............................................8

SECTION 8 — INTERCONNECT DRAWINGS .......................8

INTELLISYS CONTROLLER E-PROM

RECOMMENDATIONS.......................................................8

INTELLISYS CONTROLLER INTERCONNECT

RECOMMENDATIONS.......................................................8

APPENDIX A — ir-485, irV-485, and RS485 Direct Interconnect Drawings To Ingersoll Rand Intellisys

Controlled Compressor ............................................9

APPENDIX B — ir-PCB Interconnect Drawings To Ingersoll Rand Intellisys Controlled And CMC Sierra

Compressors ..........................................................17

APPENDIX C — ir-PCB Interconnect Drawings To Ingersoll Rand Pressure Switch Controlled

Compressors ..........................................................51

APPENDIX D — VSD Box Interconnect Drawings To

Ingersoll Rand Non-Nirvana VSD Compressors .......92

2

SECTION 2 — INTRODUCTION

The X - SERIES AUTOMATION is a family of specialized controllers designed to provide safe, reliable, and energy-efficient control of your compressed air system.

X4I

The X4I is capable of controlling positive displacement air compressors. The compressors may have electropneumatic or microprocessor based controls. The X4I is completely customizable to meet the specific needs of your compressed air system.

SECTION 3 — SAFETY

WARNING :

!

WARNING :

!

WARNING :

INSTALLATION

Risk of Danger

Risk of Electric Shock

Risk of High Pressure

Consult Manual

• Before installing or operating the X-

Series Automation System, take time to carefully read all the instructions contained in this manual, all compressor manuals, and all manuals of any other peripheral devices that may be installed or connected to the unit.

• Electricity and compressed air have the

potential to cause severe personal injury or property damage.

• The operator should use common sense

and good working practices while operating and maintaining this system. All applicable codes should be strictly adhered to.

• Maintenance must be performed by

adequately qualified personnel that are equipped with the proper tools.

• Installation work must only be carried

out by a competent person under qualified supervision.

• A fused isolation switch must be fitted

between the main power supply and the X-Series Automation System.

• The X-Series Automation System should

be mounted in such a location as to allow operational and maintenance

X8I

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.

access without obstruction or hazard and to allow clear visibility of indicator at all times.

• orms are required to

If raised platf provide access to the X-Series Automation System, they must not interfere with normal operation or obstruct access. Platforms and stair should be of grid or plate construction with safety rails on all open sides.

OPERATION

• The X-Series Automation System must

only be operated by competent personnel under qualified superv

•

Never remove or tamper with safety devices, guards or insulation materia fitted to the X-Series Automation System

•

The X-Series Automation System 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.

• uch

Do not open access panels or to electrical components while voltage is applied unless it is necessary for measurements, tests or adjustment Such work should be carried out only b 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 s have a warning sign attached stating “THIS UNIT MAY START WITHOUT WARNING” next to the display pane

3

s

ision.

ls

.

s.

y

hould

l.

• If an air compressor and/or other

equipment connected to the unit is to be started remotely, attach two warning signs to the equipment stating “THIS UNIT CAN BE STARTED REMOTELY”. Attach one sign in a prominent location on the outside of the equipment, and the other sign inside the equipment control compartment.

MAINTENANCE AND REPAIR

• Maintenance, repairs or modifications

must only be carried out by competent personnel under qualified supervision.

• If replacement parts are required, use

only genuine parts from the original equipment manufacturer, or an alternative approved source.

• Carry out the following operations

before opening or removing any access panels or carrying out any work on the X-Series Automation System:

i. Isolate the X-Series Automation

System from the main electrical power supply. Lock the isolator in the “OFF” position and remove the fuses.

ii. Attach labels to the isolator

switch and to the unit stating “WORK IN PROGRESS - DO NOT APPLY VOLTAGE”. Do not switch

on electrical power or attempt to start the X-Series Automation System 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 X-Series Automation System must

only be cleaned with a damp cloth, using mild detergents if necessary. Avoid the use of any substances containing corrosive acids or alkalis.

• Do not paint the control faceplate or

obscure any indicators, controls, instructions or warnings.

4

SECTION 4 — X4I SYSTEM OVERVIEW

It is recommended that installation and commissioning be carried out by an authorized and trained product supplier.

Ingersoll Rand Automation

Model X4I

Dimensions 11.45” x 9.45” x 6.0” 291mm x 241mm x 152mm Weight 14lb (6.4kg) Mounting Wall, 4 x screw fixings Enclosure IP65, NEMA 4 Supply 230Vac +/- 10%, 50 Hz 115Vac +/- 10%, 60 Hz Power 50VA Temperature 32°F to 115°F (0°C to 46°C) Humidity 0% to 95% RH (non-condensing)

Local Disconnect (Breaker) Box

electrical and safety regulations).

X4I X05 CONNECTOR

SPECIFICATIONS

Fused for 50VA

Power Cable

3 conductor (N, L, E)

(Sized in accordance with local

PRESSURE TRANSDUCER CABLE

2 Conductor Cable, 18 Gauge Stranded

Reference X4I Operations Manual for Pressure

Earth Shielded

No Greater Than 330FT (100M)

24VDC Control Voltage

25 +VDC Pin #3 26 Signal Pin #1

Sensor Connection Details

PT CONNECTOR

On/Off Switch

Supply

Voltage

Cable

Pressure

Transducer

Cable

ir-PCB ir-PCB

The Maximum Number of Compressors Controlled By The X4I Is Four (4).

The Maximum Number Of Direct ir-PCB Connections To The X4I is Four (4).

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)

OR

24VAC Control Voltage

PRESSURE TRANSDUCER

To Plant Air

System

Reference X4I Application and Interconnect Guide For Wiring Connections Between The X4, The ir-PCB, and

RECEIVER

Compressors

The Compressor

DRIP LEG

From Air

Ir-PCB Compressor #1

Control Cable

ir-PCB ir-PCB

Ir-PCB Compressor #4

Control Cable

Ir-PCB Compressor #2

Control Cable

Ir-PCB Compressor #3

Control Cable

5

SECTION 5 — X8I SYSTEM OVERVIEW

It is recommended that installation and commissioning be carried out by an authorized and trained product supplier.

Ingersoll Rand Automation

Model X8I

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)

electrical and safety regulations).

X8I X05 CONNECTOR PT CONNECTOR

SPECIFICATIONS

Local Disconnect (Breaker) Box

Fused for 100VA

Power Cable

3 conductor (N, L, E)

(Sized in accordance with local

PRESSURE TRANSDUCER CABLE

2 Conductor Cable, 18 Gauge Stranded

Reference X8I Operations Manual for Pressure

Earth Shielded

No Greater Than 330FT (100M)

24VDC Control Voltage

25 +VDC Pin #3 26 Signal Pin #1

Sensor Connection Details

On/Off

Switch

Supply

Voltage

Cable

Pressure

Transducer

Cable

ir-PCB ir-PCB

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.

The EXP Box Will Add Another (4) Direct ir-PCB connections. The X8I Supports 1 EXP Box. This Would Allow A Total Of (8) Compressors To Be Connected And Controlled Via The ir-PCB.

EXP RS485 Network Cable

EXP RS485 NETWORK CABLE Belden 9841 or Equivalent In Grounded Conduit No Greater Than 33FT (10)

OPTIONAL

RS485 Network Cable

RS485 NETWORK CABLE Belden 9841 or Equivalent In Grounded Conduit No Greater Than 4000FT (1219M)

To Plant Air

System

PRESSURE TRANSDUCER

RECEIVER

DRIP LEG

From Air

Compressors

Ingersoll

Rand

102 psi

ir-485

Direct To

S3

Ir-PCB Compressor #1

Control Cable

Reference X8I Application and Interconnect Guide For

Wiring Connections Between The X8I, The ir-PCB,

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

and The Compressor

Optional Special Application Interface Boxes

From VSD Pressure

Transducer

To VSD Pressure Transducer Input

1 D 2 LE D LE

ir-

PCB

ir-485

irV-485

Ir-PCB Compressor #2

Control Cable

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)

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- Nirva na ) Comp res so rs

IntelliSys “Red Eye”, SG and SE

OR

irV-485 Gateway

For All

Nirvana Compressors

20HP (15KW) and Above

OR

24VAC Control Voltage

34

6

SECTION 6 — VSD OVERVIEW

It is recommended that installation and commissioning be carried out by an authorized and trained product supplier.

Ingersoll Rand Automation

VSD Box

From VSD Box

To ir-PCB

LED 1

LED 2

ir-PCB

1 > Intellisys Discharge Pressure Transducer

2 > VSD Discharge Pressure Transducer

To Intellisys Controller

1

From Pressure Transducer

2

To VSD Box

From VSD Box

To IR-5000 Pressure Transducer Input

7

SECTION 7 — ASSISTANCE

Contacting Technical Support Services or Service Bulletins listed on the IR ServiceNet can provide further assistance if there are other questions or concerns during Installation and Start-up. Also, additional Application and Compressor Interconnect Guides will be posted and available on the IR ServiceNet as they are developed and created.

SECTION 8 — COMPRESSOR INTERCONNECT DRAWINGS

The following Appendix’s contain reference drawings designed to assist with the connection of the X – Series Automation System to Ingersoll Rand Air Compressors as well as Non-Ingersoll Rand Air Compressors. These drawings are for Guidance Only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to be used in conjunction with the compressor’s original control circuit diagram.

INTELLISYS CONTROLLER E-PROM ROMMENDATION REFERENCE LIST

Minimum Recommended E-prom Levels - IntelliSys Controllers

IntelliSys - Firs t Generation

SSR 50 - 450HP

Sierra 100 - 200HP

Recip

IntelliSys - Second Generation

SSR 50 - 450 (1 & 2 Stage)

SSR 75 - 350kW (ESA)

Sierra 125-400HP

Recip

Redeye SE

2.4 1.75

2.7 1.23

1.62 1.93

SG SGN

1.5 1.45

1.5 SGNe

1.35 2.4

1.28 1.2

IntelliSys - Second Edition

SSR 15 - 100HP (DSA)

SSR - UP (Pegasus)

SSR 22 - 150kW (ESA)

Sierra 50 - 100HP

IntelliSys - Nirvana

Nirvana CC 100 - 200HP

IntelliSys - Nirvana

Nirvana CC 50 - 300HP

Nirvana OF 50 - 200HP

1.3

INTELLISYS CONTROLLER INTERCONNECT RECOMMENDATION

When using the X8I Automation System, the ir-485 and irV-485 Gateway is the “recommended and preferred” method when interfacing and connecting to the FG (redeye), SG, SGN and SGNe, SE IntelliSys controlled compressors and Nirvana 1530KW (20-40HP) Compressors. See Appendix A for interconnect drawings for these applications

When using the X4I Automation System, the ir-PCB is the only method when interfacing and connecting to the FG (redeye), SG, SGN and SGNe, SE IntelliSys controlled compressors and Nirvana 15-30KW (20-40HP) Compressors. See Appendix B for interconnect drawings for these applications

8

APPENDIX A

ir-485, irV-485, and RS485 DIRECT TO INGERSOLL RAND

INTELLISYS AND NIRVANA 15-30KW (20-40HP)

COMPRESSOR INTERCONNECT DRAWINGS

IR-485, IRV-485, AND RS485 DIRECT to Ingersoll Rand

Intellisys and Nirvana 15-30kw (20-40hp) ................... A1

irV-485 Interconnect To Ingersoll Rand Intellisys SGN /

SGNe Controlled Compressors ..................................... A2

ir-485 Interconnect To Ingersoll Rand Intellisys SG

Controlled Compressors .............................................. A3

ir-485 Interconnect To Ingersoll Rand Intellisys SE

Controlled Compressors .............................................. A4

ir-485 Interconnect To Ingersoll Rand Intellisys Redeye

Controlled Compressors .............................................. A5

RS485 Direct Interconnect To Ingersoll Rand Intellisys S3

Controlled Compressors .............................................. A6

irV-485 Interconnect To Ingersoll Rand Nirvana 15-30kw

(20-40HP) .................................................................... A7

9

ir-485, irV-485, and RS485 DIRECT To Ingersoll Rand

Intellisys and Nirvana 15-30KW (20-40HP) Compressors

All Intellsys and Nirvana 15-30KW (20-40HP) Compressors

All compressors must have Automatic Start / Stop

ir-485

irV-485

No Modbus Functionality in Controller

Redeye Controller

Operates in irbus mode

Sequence Control Set To “ON”

Remote Start / Stop Set To “OFF”

SG Recip Controller

No Modbus Functionality in Controller

Operates in irbus mode

Sequence Control Set To “ON”

Remote Start / Stop Set To “OFF”

`SE Controller

No Modbus Functionality in Controller

Operates in irbus mode

Sequence Control Set To “ON”

Remote Start / Stop Set To “OFF”

SG Controller

Modbus Functionality in Controller

Set Modbus To ON

Set Modbus Address To Unique

Modbus Address

1-8 For X8I 1-12 For x12I

Sequence Control Set To “ON”

Remote Start / Stop Set To “OFF”

irV-485

RS485 Direct

From X8I or X12I

Automation

System

Modbus Functionality in Controller

SGN Controller

Set Modbus To ON

Set Modbus Address To Unique

Modbus Address

1-8 For X8I 1-12 For x12I

Sequence Control Set To “ON”

Remote Start / Stop Set To “OFF”

S3 Controller

Modbus Functionality in Controller

Set Modbus To ON

Set Modbus Address To Unique

Modbus Address

1-8 For X8I 1-12 For x12I

Remote Control Set To “ON”

Remote Start / Stop Set To “OFF”

Appendix A - Page A1

From Previous X8I or X12I

Automation Network

Component

irV-485 To INTELLISYS SGN / SGNe

RS485 RS485

X04

And

X02

X05

To Next

X8I or X12I Automation

Network Component

RJ11 Modbus Cable

Supplied With The

irV-485 Gateway

Modify As Shown By

Removing The RJ11 Plug.

0VDC

-V

NC

OUTPUT

idec

DC ON

V.ADJ

INPUT

100/240 VAC 0.17A

50/60HZ

L

L N G

From Compressor

110 / 230VAC

24VDC 0.3A

7.5

POWER SUPPLY

PS5R-A24

N

+24VDC

+V

WOUTPUT

SHIELD

L1L2

GROUND

SHIELD

SGN/SGNe

Mounting Bolt

GROUND

WIRE

2121

P10 P8

P7

Phoenix 6Pin CONNECTOR

6 5 43

21

L2

2

1

L1

SGN / SGNe

Phoenix 6Pin

COM PORT

On Right Side

As Viewed From

The Back

n

e

r

c

s

X01

+24VDC

0VDC

2 L

X05

123 123

1

L

c

d

/

c

d

a

/

V

c

4

a

2

V

+

0

1 2

1212

X04

ir485

irV-485

1 #

D E

L

ON

OFF

6

7

8

#

D

E

2

# D

E

L

SW1 SW2

E

3

L

# D

E

L

2

341

+24

0

V

DC

12

SGN / SGNe

As Viewed From

The Back Side Of

The Controller

4

# D

E

L

SW3

9

n

e

r

c

s

101

1

2 L

X03

2 1

123 123

1

L

X02

irbus /

Modbus

9

# D

E

5

L

# D

E

L

6

785

Place Ground

Wire Lug Behind

SGN/SGNe

Mounting Bolt

Appendix A - Page A2

From Previous X8I or X12I

Automation Network

Component

ir-485 To INTELLISYS SG

RS485 RS485

To Next

X8I or X12I Automation

Network Component

0VDC

-V

OUTPUT

idec

DC ON

V.ADJ

INPUT

100/240 VAC 0.17A

L

NC

24VDC 0.3A

7.5

POWER SUPPLY

PS5R-A24

50/60HZ

N

+24VDC

+V

WOUTPUT

SHIELD

X04

And

X02

X05

L1L2

RJ11 Modbus Cable

Supplied With The

irV-485 Gateway

GROUND

SHIELD

SG

Mounting Bolt

GROUND

WIRE

21

P10

n

e

r

c

s

X01

2

L

X05

123 123

1

L

c

d

/

c

d

a

/

V

c

4

a

2

V

+

0

1 2

X04

ir485

1 #

D E

L

ON

OFF

1212

6

# D

E

2

3

L

#

D

E

L

ir-485

SW1 SW2

2

341

4

# D

E

L

SW3

9

n

e

r

c

s

101

1

2 L

X03

2 1

123 123

1

L

8

9

7

#

D

E

5

L

# D

E

L

6

785

X02

irbus /

Modbus

12

SG

As Viewed From

The Back Side Of

The Controller

P7

P9

P8

SG

RJ11 COM PORT

On Right Side

As Viewed From

RJ11

The Back

L2 (4)

43 2

1

CONNECTOR

6 5

4

3

2

1

L1 (2)

L N G

From Compressor

110 / 230VAC

+24VDC

0VDC

+24

DC

Place Ground

Wire Lug Behind

0

V

DC

SG Mounting Bolt

Appendix A - Page A3

From Previous X8I or X12I

Automation Network

Component

ir-485 To INTELLISYS SE

RS485 RS485

To Next

X8I or X12I Automation

Network Component

0VDC

-V

OUTPUT

idec

DC ON

V.ADJ

INPUT

100/240 VAC 0.17A

L

NC

24VDC 0.3A

7.5

POWER SUPPLY

PS5R-A24

50/60HZ

N

SHIELD

+24VDC

+V

WOUTPUT

X04 And

X02

X05

L1L2

RJ11 Modbus Cable

Supplied With The

irV-485 Gateway

GROUND

SHIELD

SG

Mounting Bolt

GROUND

WIRE

n

e

r

c

s

X01

2 L

X05

123 123

1

L

c

d

/

c

d

a

/

V

c

4

a

2

V

+

0

1 2

X04

ir485

1 #

D E

L

ON

OFF

1212

6

# D

E

2

3

L

#

D

E

L

ir-485

SW1 SW2

2

341

RJ11

CONNECTOR

6 5

4

12

7

9

8

#

D

E

5

L

# D

E

L

123 123

SE

4

1

n

2

#

e

L

e

D

r

E

c

L

s

X03

X02

L

irbus /

Modbus

As Viewed From

The Back Side Of

The Controller

J8

3

2

1

RJ11 COM PORT

On Right Side

As Viewed From

The Back

SW3

2

1

101

6

785

9

J11

L2 (4)

L1 (2)

SE

L N G

From Compressor

110 / 230VAC

+24VDC

0VDC

+24

DC

Place Ground

Wire Lug Behind

0

V

DC

SE Mounting Bolt

Appendix A - Page A4

From Previous X8I or X12I

Automation Network

ir-485 To INTELLISYS REDEYE

Component

RS485 RS485

To Next

X8I or X12I Automation

Network Component

0VDC

-V

NC

OUTPUT 24VDC 0.3A

idec

DC ON

V.ADJ

INPUT

100/240 VAC 0.17A

L

7.5

POWER SUPPLY

PS5R-A24

50/60HZ

N

+V

W

SHIELD

+24VDC

OUTPUT

X04 And X05

L1L2

X02

L1L2

RJ11 Modbus Cable

Supplied With The

irV-485 Gateway

GROUND

SHIELD

GROUND

L2 (4)

L1 (2)

WIRE

Redeye

Starter Interface

Board

Mounting Bolt

X02

irbus /

Modbus

12

Test Port

1212

123 123

1

n

2

e

L

e

r

c

s

X05

X04

L

ir485

6

7

8

9

#

D

E

2

3

#

D

E

L

E

L

5

L

# D

E L

123 123

4

1

n

2

#

L

e

L

e

D

r

E

c

L

s

X03

ir-485

RJ11

CONNECTOR

J2

1

6235

4

Sequencer Port

Place Ground

Wire Lug Behind

Starter Interface

Board Mounting

Screw

J3

c

X01

d

/

c

a V

4

2 +

1 2

c

d

/

c a V

0

1

# D

E

L

ON

OFF

SW1 SW2

2

341

SW3

2

1

101

9

6

785

REDEYE STARTER

INTERFACE BOARD

RJ11 COM PORT

On Top Center

BTS

As Viewed Facing Board

L N G From Compressor

110 / 230VAC

+24VDC

0VDC

+24

DC

0

V

DC

REDEYE STARTER

INTERFACE BOARD

As Viewed Facing Board

Appendix A - Page A5

X01

X04

X02

X02 X03

X09

X07 X08

GND

Vcc

TxD RxD

1212

SHIELD

X03

X06 X05

X05X06X07 X08

IntelliSys S3

As Viewed From

The Back Side Of

The Controller

RS485 RS485

From Previous X8I or X12I

Automation Network

Component

RS485 To INTELLISYS S3

To Next

X8I or X12I Automation

Network Component

Appendix A - Page A6

From Previous X8I or X12I

Automation Network

irV-485 To NIRVANA 15-30KW (20-40HP)

Component

RS485 RS485

To Next

X8I or X12I Automation

Network Component

0VDC

-V

NC

OUTPUT 24VDC 0.3A

idec

DC ON

V.ADJ

INPUT

100/240 VAC 0.17A

L

7.5

POWER SUPPLY

PS5R-A24

50/60HZ

N

+V

W

SHIELD

+24VDC

OUTPUT

X04 And X05

L1L2

X02

L1L2

RJ11 Modbus Cable

Supplied With The

irV-485 Gateway

NIRVANA 15-30KW

(20-40HP)

SHIELD

GROUND

CONTROL BOARD

As Viewed Facing Board

GROUND

WIRE

n e

e

r

c

s

X01

2

L

X05

123 123

1 L

c

d

/

c

d

a

/

V

c

4

a

2

V

+

0

1 2

X04

ir485

1

# D

E

L

ON

OFF

1212

3

2

#

D

E

E L

L

ir-485

SW1 SW2

2

341

4

# D

E L

SW3

9

n e

e

r

c

s

101

1

2

L

X03

2

1

123 123

1 L

6

7

8

9

#

D

E

L

5

L

# D

E L

6

785

X02

irbus /

Modbus

12

NIRVANA

15-30KW

(20-40HP)

COM PORT

On Right

Side As

Viewed

From The

2 1

68 6961

L1

Back

68 6961

L2

L N G

From Compressor

110 / 230VAC

+24VDC

0VDC

+24

V

DC

0

V

Phoenix 3Pin CONNECTOR

Place Ground Wire Lug

Behind

NIRVANA 15-30KW

(20-40HP) Mounting Bolt

Appendix A - Page A7

APPENDIX B

ir-PCB TO INGERSOLL RAND INTELLISYS CONTROLLED

COMPRESSOR INTERCONNECT DRAWINGS

ir-PCB Interconnect Requirements For Ingersoll Rand

Unigy & Nirvana 15-30KW (20-40HP) Compressors .......B1

Unigy 1 1of2.................................................................B2

Unigy 1 2of2.................................................................B3

Unigy 2/3 1of2 ............................................................. B4

Unigy 2/3 2of2 ............................................................. B5

Nirvana 15-30KW (20-40HP) 1of2..................................B6

Nirvana 15-30KW (20-40HP) 2of2..................................B7

ir-PCB Interconnect Requirements For Ingersoll Rand

Intellisys Redeye Controlled Compressors ....................B8

SSR Redeye 1of3 ...........................................................B9

SSR Redeye FV 2of3 ....................................................B10

SSR Redeye SD 3of3 ....................................................B11

ir-PCB Interconnect Requirements For Ingersoll Rand

Intellisys SE Controlled Compressors .......................... B12

SE UP 1of2 ..................................................................B13

SE UP 2of2 ..................................................................B14

SE ESA 1of2 ................................................................B15

SE ESA 2of2 ................................................................B16

SE DSA 1of2................................................................B17

SE DSA 2of2................................................................B18

ir-PCB Interconnect Requirements For Ingersoll Rand

Intellisys SG Controlled Compressors..........................B19

SG SSR 1of2 ................................................................ B20

SG SSR 2of2 ................................................................ B21

SG Sierra 1of2.............................................................B22

SG Sierra 2of2.............................................................B23

ir-PCB Interconnect Requirements For Ingersoll Rand

Intellisys SGN / SGNe Controlled Compressors ........B24

Nirvana SGN/SGNe 1of3 .............................................. B25

Nirvana SGN/SGNe 2of3 .............................................. B26

Nirvana SGN/SGNe 3of3 .............................................. B27

SI1 Interface to Redeye, SE, SG Controllers.................. B28

ir-PCB Interconnect Requirements For Ingersoll Rand

Intellisys S3 ................................................................B29

Intellisys S3 1of2 ........................................................B30

Intellisys S3 2of2 ........................................................B31

ir-PCB Interconnect Requirements For Ingersoll Rand CMC

Sierra 1of2.................................................................. B32

ir-PCB Interconnect Requirements For Ingersoll Rand CMC

Sierra 2of2.................................................................. B33

17

ir-PCB Interconnect To Ingersoll Rand

Unigy & Nirvana 20-40 HP Compressors

FOR UNIGY COMPRESSORS:

All Unigy Phase 1 compressors “MUST” be converted to Phase 2 or higher. Contact Technical Support Services for the CCN's required for this conversion.

FOR NIRVANA 20-40HP COMPRESSORS:

When using the X8I Automation System, the ir-485 and irV-485 Gateway is the “recommended and preferred” method when interfacing and connecting to the FG (redeye), SG, SGN and SGNe, SE IntelliSys controlled compressors and Nirvana 15-30KW (20-40HP) Compressors. See Appendix A for interconnect drawings for these applications

When using the X4I Automation System, the ir-PCB is the only method when interfacing and connecting to the FG (redeye), SG, SGN and SGNe, SE IntelliSys controlled compressors and Nirvana 15-30KW (20-40HP) Compressors. See Appendix B for interconnect drawings for these applications

Remote Control “MUST” be set to “ON”. Remote Start / Stop must be set to “OFF”. Check the Nirvana Software revision level. It “MUST” be updated to Version 1.10 or greater. Contact Technical Support

Services to acquire the update.

DRAWING NOTES FOR UNIGY PHASE 1 MACHINES:

Note: All Unigy Phase 1 compressors “MUST” be converted to Phase 2 or higher. Contact Technical Support Services for the CCN's required for this conversion. The Drawing “Unigy Phase 1 1of2” is a representation for “AFTER” the conversion is completed.

Note: The Unigy Target Pressure “MUST” be set equal to the “midpoint” of the X - Series Automation pressure control band.

DRAWING NOTES FOR UNIGY PHASE 2/3 MACHINES:

Note: The Unigy Target Pressure “MUST” be set equal to the “midpoint” of the X - Series Automation pressure control band.

DRAWING NOTES FOR NIRVANA 20-40HP MACHINES:

Note: Remote Control “MUST” be set to on. Note: The Nirvana Target Pressure “MUST” be set equal to the “midpoint” of the X - Series Automation pressure

control band.

Appendix B Page B1

Unigy Phase 1

X - SERIES AUTOMATION COMPRESSOR #1 X01 TERMINAL

V1

1 2 3 4 5 6

C05

V

1 2 3 4 5 6

1 2

V

SEQ CONT LOAD UNL GND

C03 D11 D12 +20V

LED 5 V LED 2 LOAD LED 1 SEQ

LED 4

READY

LED 3

RUN

C01

Load Enable

Load/Unload

C02

C04

IR-PCB

+VDC

VFD/fixed

NO

OUT

NC

NO

IN

NC

ALARM

RUN

READY

D13

+24VDC

SA1

HATS

10

13

E-STOP

14

EN

C

12

DI-4

C

VFD/FIX

11

9

5

17

+24VDC

DI-2

0V

NO

Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to be used in conjunction with the compressor’s original control circuit diagram.

Unigy 1

7.5 - 15 HP

5.5 – 11 kW

Appendix B Page B2

Unigy Phase 1

Appendix B Page B3

Unigy Phase 2/3

X - SERIES AUTOMATION COMPRESSOR #1 X01 TERMINAL

V1

1 2 3 4 5 6

C05

V

1

SEQ CONT LOAD UNL

2

GND

3

D11

4

D12

5

+20V

6

LED 5 V LED 2 LOAD LED 1 SEQ

READY

1 2

V

LED 4

C03

RUN

LED 3

C01

Load Enable

Load/Unload

C02

C04

IR-PCB

+VDC

VFD/fixed

NO

OUT

NC NO

IN

NC

ALARM

RUN

READY

D13

+24VDC

SA1

10

HATS

13

E-STOP

14

EN

C

12

DI-4

C

VFD/FIX

11

9

5

17

+24VDC

DI-2

0V

NO

Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to be used in conjunction with the compressor’s original control circuit diagram.

Unigy

7.5 - 15 HP

5.5 – 11 kW

Appendix B Page B4

Unigy Phase 2/3

Appendix B Page B5

Nirvana 15 – 30KW

(20 – 40HP)

X - SERIES AUTOMATION COMPRESSOR #1 X01 TERMINAL

V1

1 2 3 4 5 6

C05

V

1

SEQ CONT LOAD UNL

2

GND

3

D11

4

D12

5

+20V

6

LED 5 V LED 2 LOAD LED 1 SEQ

READY

1 2

12

+24VDC

+VDC

VFD/fixed

V

C01

Load Enable

Load/Unload

C03

NO

OUT

18

32

33

Remote

VFD / FIXED

Remote

LOAD ENABLE

Remote

LOAD / UNLOAD

C

IN

NC NO

C

C02

NC

SAFE

C

COM

LED 4

RUN

LED 3

C04

ALARM

RUN

READY

37

4

20

IR-PCB

6

NC

Alternate Connection Metthod For READY Input If Alarm Contacts Are Being Used

READY

Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to be used in conjunction with the compressor’s original control circuit diagram.

Nirvana

20 - 40 HP

15 – 30 kW

37

SAFE

Appendix B Page B6

Nirvana 15 - 30KW

(20-40HP)

Appendix B Page B7

ir-PCB Interconnect To Ingersoll Rand

First Generation IntelliSys “Redeye” Controlled Compressors

FOR REDEYE INTELLISYS CONTROLLED MACHINES:

When using the X8I Automation System, the ir-485 and irV-485 Gateway is the “recommended and preferred” method when interfacing and connecting to the FG (redeye), SG, SGN and SGNe, SE IntelliSys controlled compressors and Nirvana 15-30KW (20-40HP) Compressors. See Appendix A for interconnect drawings for these applications

When using the X4I Automation System, the ir-PCB is the only method when interfacing and connecting to the FG (redeye), SG, SGN and SGNe, SE IntelliSys controlled compressors and Nirvana 15-30KW (20-40HP) Compressors. See Appendix B for interconnect drawings for these applications

The ‘MASTER CONTROL’ setting of the Intellisys controller must be set to ‘ON’ The 'SEQUENCER' setting of the Intellisys controller must be set to 'ON'. Remote Start / Stop must be set to “OFF”. Auto Restart must be turned 'ON’ to allow the machines to stop in Auto restart when unloaded by the X - Series

Automation. The Intellisys must be run in the Online/Offline regulation mode. Do not use Modulation or ACS. Check the Intellisys software revision level. Always update to the latest revision prior to operation. FOR DSA REDEYE CONTROLLERS, the 'SEQUENCER Option’ must be purchased. installed and then turned on.

CCN: 39225099

FOR ESA REDEYE INTELLISYS CONTROLLERS, the SI1 interface (CCN: 42425710) must be used to allow the Redeye to be controlled by the X - Series Automation

FOR SIERRA REDEYE INTELLISYS CONTROLLERS, the SI1 interface (CCN: 42425710) must be used to allow the Redeye Controller to be sequenced/controlled by the X - Series Automation

DRAWING NOTES FOR REDEYE INTELLISYS CONTROLLED MACHINES:

Note: For Star Delta starter wiring the X - Series Automation Run signal should be connected directly to the 1M coil. Note: For Full voltage wiring the 1S (1Sb) interlock will not be used. The X - Series Automation Run signal can be

connected directly to the Intellisys BTS1-28 terminal.

Appendix B Page B8

X - SERIES AUTOMATION COMPRESSOR #1 X01 TERMINAL

V1

1 2 3 4 5 6

C05

V

1

SEQ CONT LOAD UNL

2

GND

3

D11

4

D12

5

+20V

6

LED 5 VFD LED 2 LOAD LED 1 SEQ

READY

1 2

SSR Redeye

Analog Barrier Board

BTS311

+VDC

VFD/fixed

V

C03

LED 4

RUN

LED 3

C01

Load Enable

Load/Unload

C02

C04

IR-PCB

NO

OUT

NC NO

IN

NC

ALARM

RUN

READY

C

0VAC

110VAC

E-STOP

1M

HATS

12

16

18

BTS1-

1

BTS1-

34

Remote Load/Unload

(was Remote Start)

Remote Load Enable

(was Remote Stop)

Alternate Connection Metthod For READY Input If Alarm Contacts Are Being Used

READY

Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to be used in conjunction with the compressor’s original control circuit diagram.

110VAC

E-STOP

HATS

BTS2-

1 2 3

Starter Interface Board

BTS2 34

Appendix B Page B9

SSR Redeye FV

Appendix B Page B10

SSR Redeye SD

Appendix B Page B11

ir-PCB Interconnect To Ingersoll Rand

Second Edition Intellisys “SE” Controlled Compressors

FOR ALL SE INTELLISYS CONTROLLED MACHINES:

When using the X8I Automation System, the ir-485 and irV-485 Gateway is the “recommended and preferred” method when interfacing and connecting to the FG (redeye), SG, SGN and SGNe, SE IntelliSys controlled compressors and Nirvana 15-30KW (20-40HP) Compressors. See Appendix A for interconnect drawings for these applications

When using the X4I Automation System, the ir-PCB is the only method when interfacing and connecting to the FG (redeye), SG, SGN and SGNe, SE IntelliSys controlled compressors and Nirvana 15-30KW (20-40HP) Compressors. See Appendix B for interconnect drawings for these applications

The 'SEQUENCER' setting of the Intellisys controller must be set to 'ON'. Remote Start / Stop must be set to “OFF”. Auto Restart must be turned 'ON’ to allow the machines to stop in Auto restart when unloaded by the X - Series

Automation. The Intellisys must be run in the Online/Offline regulation mode. Do not use Modulation or ACS. Check the Intellisys software revision level. Always update to the latest revision prior to operation.

FOR UP SE INTELLISYS CONTROLLERS

Minimum Software Version 1.11 CCN: 39217047 (w/o PORO) CCN: 39217039 (w PORO)

When installing the Sequence Option to enable Remote Load/Unload, the Remote Start/Stop input terminals are now used for the Remote Load inputs. Remote Start Stop will no longer be functional. The SI1 interface (CCN: 42425710) can be used in place of the Sequence Option to allow the SE controlled machines to function with both Remote Load Unload and Remote Start Stop.

Software Version 1.20 and Greater

The 'CONTACT SEQUENCE' setting of the Intellisys controller must be set to 'ON'. DRAWING NOTES FOR UP SE INTELLISYS CONTROLLED MACHINES:

Note: For Star Delta starter wiring the X - Series Automation Run signal should be connected directly to the 1M coil. Note: For Full voltage wiring the 1S (1Sb) interlock will not be used. The X - Series Automation Run signal can be

connected directly to the Intellisys J5-1 terminal. Note: For Pegasus machines wiring may be factory installed connecting the Intellisys Alarm Relay J5-9, J5-10 and J5-11

to a terminal strip but unused. Remove any factory installed wiring from the Intellisys Alarm Relay contacts and connect the X - Series Automation Interface board wiring directly to the Intellisys Alarm Relay terminals J5-9 and J5-10.

FOR ESA SE INTELLISYS CONTROLLERS

Minimum Software Version 1.40 CCN: 39217047 (w/o PORO) CCN: 39217039 (w PORO)

When installing the Sequence Option to enable Remote Load/Unload, the Remote Start Stop input terminals are now used for the Remote Load inputs. Remote Start Stop will no longer be functional. The SI1 interface (CCN: 42425710) can be used in place of the Sequence Option to allow the SE controlled machines to function with both Remote Load Unload and Remote Start Stop. DRAWING NOTES FOR ESA SE INTELLISYS CONTROLLED MACHINES:

Note: For Star Delta starter wiring the X - Series Automation Run signal should be connected directly to the 1M coil. Note: For Full voltage wiring the 1S (1Sb) interlock will not be used. The X - Series Automation Run signal can be

connected directly to the Intellisys J5-1 terminal.

FOR DSA SE INTELLISYS CONTROLLERS

CCN: 22179238

When installing the Sequence Option to enable Remote Load/Unload, the Remote Start Stop input terminals are now used for the Remote Load inputs. Remote Start Stop will no longer be functional. The SI1 interface (CCN: 42425710) can be used in place of the Sequence Option to allow the SE controlled machines to function with both Remote Load Unload and Remote Start Stop. DRAWING NOTES FOR DSA SE INTELLISYS CONTROLLED MACHINES:

Note: For Star Delta starter wiring the X - Series Automation Run signal should be connected directly to the 1M coil. Note: For Full Voltage wiring, the 1S (1Sb) interlock will not be used. The X - Series Automation Run signal can be

connected directly to the Intellisys terminal 42.

,

, the 'SEQUENCER Option’ must be purchased. installed and then turned on.

FOR SIERRA SE INTELLISYS CONTROLLERS be sequenced/controlled by the X - Series Automation

, the SI1 interface (CCN: 42425710) must be used to allow the SE Controller to

Appendix B Page B12

SE UP

X - SERIES AUTOMATION COMPRESSOR #1 X01 TERMINAL

V1

1 2 3 4 5 6

C05

V

1

SEQ CONT LOAD UNL

2

GND

3

D11

4

D12

5

+20V

6

LED 5 VFD LED 2 LOAD LED 1 SEQ

READY

1 2

J1

+VDC

VFD/fixed

V

C03

LED 4

RUN

LED 3

C01

Load Enable

Load/Unload

C02

C04

IR-PCB

NO

OUT

NC NO

IN

NC

ALARM

RUN

READY

C

0VAC

110VAC

E-STOP

1M

11 12 13 14

J5

1

J5

7

J5

9 10 11

Remote Load/Unload

(was Remote Start)

Remote Enable

(was Remote Stop)

Intellisys SE

UP Series

Alternate Connection Metthod For READY Input If Alarm Contacts Are Being Used

READY

Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds. This information is intended to be used in conjunction with the compressor’s original control circuit diagram.

110VAC

E-STOP

J5

7

Appendix B Page B13