Ingersoll-Rand X8I Operator's Manual

Document

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 200 8

SECTION 1 — TABLE OF CONTENTS

SECTION 1 — TABLE OF CONTENTS ..........................2

PRESSURE DISPLAY .................................................................26

SECTION 2 — INTRODUCTION ...................................3

X8I QUICK SET-UP CONFIGURATION ...............................26

OPTIONAL FEATURES AND FUNCTIONS.........................26

SECTION 3 —SAFETy ....................................................3

SECTION 9 — SySTEM CONFIGURATION ...............27

INSTALLATION .............................................................................3

OPERATION ..................................................................................3

DISPLAY ITEM STRUCTURE...................................................27

MAINTENANCE AND REPAIR .................................................3

NORMAL OPERATIONAL DISPLAY (MENU PAGE P00) 27

ACCESSING THE X8I CONFIGURATION SCREENS ........27

SECTION 4 — COMPRESSOR CONNECTION AND

CONTROL ........................................................................5

USER LEVEL MENUS ................................................................29

COMPRESSOR CONNECTION AND CONTROL ..............5

SERVICE LEVEL MENUS ..........................................................30

OPTIONAL CONNECTION METHODS .................................5

X8I CONFIGURATION SCREENS .........................................31

PRESSURE DETECTION AND CONTROL ............................6

X8I COMPRESSOR CONNECTIVITY AND FUNCTIONAL

SETTINGS .....................................................................................41

X8I MAIN DISPLAY ....................................................................7

SECTION 10 — FAULT CODES ....................................46

SECTION 5 — INSTALLATION OVERVIEW .................8

INSTALLATION .............................................................................9

X8I COMPRESSOR FAULT INDICATIONS, TYPES, AND

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

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

SECTION 11 — PARTS LIST….. ...............................48

SECTION 12 — DIAGRAMS…... ...............................49

WIRING DIAGRAM……….…….....................................49

CONNECTION DIAGRAM……... ...................................50

XPM-TAC24...................................... ...................................51

X8I COMMISSIONING FORM… ...............................52

IR485 COMMUNICATION PROTOCOL ...............................11

RS485 NETWORK ......................................................................11

SECTION 6 — CONTROL FEATURES AND

FUNCTIONS ...................................................................13

STANDARD CONTROL FEATURES AND

FUNCTIONALITY .......................................................................13

STANDARD CONTROL FEATURES AND

FUNCTIONALITY .......................................................................15

ALTERNATE CONTROL FEATURES AND

FUNCTIONALITY .......................................................................18

SECTION 7 — DISPLAy AND MENU OPERATION ..20

INDICATORS ...............................................................................23

SECTION 8 — COMMISSIONING ...............................26

PHYSICAL CHECKS ...................................................................26

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

OPERATION

WARNING : Risk of Danger

• The X8I must only be operated by competent personnel under qualified supervision.

WARNING : Risk of Electric Shock • Never remove or tamper with safety devices, guards or insulation materials fitted to the X8I.

•

WARNING : Risk of High Pressure

WARNING : Consult Manual

Before installing or operating the X8I, take time to carefully read all the instructions contained in this manual, all compressor manuals, and all manuals of any other peripheral devices that may be installed or connected to the unit.

Electricity and compressed air have the potential to cause severe personal injury or property damage.

The operator should use common sense and good working practices while operating and maintaining this system. All applicable codes should be strictly adhered to.

Maintenance must be performed by adequately qualified personnel that are equipped with the proper tools.

INSTALLATION

• Installation work must only be carried out by a competent person under qualified supervision.

•

A fused isolation switch must be fitted between the main power supply and the X8I.

The X8I should be mounted in such a location as to allow operational and maintenance access without obstruction or hazard and to allow clear visibility of indicators at all times.

If raised platforms are required to provide access to the X8I they must not interfere with normal operation or obstruct access. Platforms and stairs should be of grid or plate construction with safety rails on all open sides.

•

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.

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102 psi

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CAP

1 2 3 4

5 6 7 8 irV- 485

The irV-485 Gateway interface module is installed within the compressor control cabinet and connected to the X8I using Belden 9841 or equivalent RS485 cable.

Nirvana 7.5 to 15HP (5.5 to 11KW) connect via the ir- PCB using seven (7)-wire cable.

4) Direct Connect via RS485 to any Ingersoll Rand compressor that has an integrated RS485 network port utilizing the ir485 protocol. The X8I communicates to these compressors via a two wire, RS485 network. The compressor is connected to the X8I using Belden 9841 or equivalent RS485 cable.

4) Special Application Interface uses integration boxes designed to accommodate various types of compressor and regulation methods and system monitoring.

OPTIONAL CONNECTION METHODS

Expansion Module: EXP Box (Option)

As standard the X8I has four direct connect ‘ir-PCB’ terminal connections. This capability can be extended with the use of an optional EXP Box. The EXP Box will add another four direct connect ‘ir-PCB’ connection terminals.

This would allow a total of 8 compressors to connected and controlled via ‘ir-PCB’ integration.

Compressors 1-4 connect via the X8I and Compressors 5-8 connect via the EXP Box

The EXP Box is suitable for wall mounting and must be located adjacent to the X8I unit (max 33ft or 10m).

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.

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

Ingersoll Rand

102 psi

18:35 #2

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1 2 3 4

5 6 7 8

The VSD Box connects to the X8I controller via a two wire,

RS485 network utilizing the ir485 protocol

Each air compressor in a system, that requires VSD Box integration, must be equipped with an individual VSD

Box. Multiple VSD Boxes can be connected to the X8I as long as the number of compressors does not exceed the maximum number of compressors (8).

Remote Input & Output: I/O Box (option)

An I/O Box provides additional general purpose I/O

(input/output) for a system enhancing monitoring capabilities and providing distributed system automation.

Up to two I/O Boxes can be connected to the X8I controller. Each I/O Box features:

8 Digital Inputs

5 Analog Inputs

6 Relay Outputs

4000ft (1219) max

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1 2 3 4

5 6 7 8

Ingersoll Rand

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1 2 3 4

5 6 7 8

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 IR- Nirvana). The

VSD Box will provide required functionality to enable system integration and efficient control using the X8I automation system. ir-PCB

From VSD Pressure Transducer

To VSD Pressure Transducer Input

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

d e

1 a

102 b

PSI

17:30 #1 c

User Interface : a) b) c) d) e)

System Pressure Value

System Pressure Units

Unit Status

Unit Active Functions

User Menu Item a b c

CAP

System Alarms (Warning) : a) b)

Unit Run Indicator (green LED)

Unit Alarm Indicator (Red LED)

System Alarms (Warning) : a) Group Compressor Fault b) c)

Insuﬃcient Capacity Alarm (Warning)

Restricted Capacity Alarm (Warning)

Ingersoll Rand

102

A: 85% psi f a g h b c e d

CAP

1 2 3 4

5 6 7 8 a b c 1

Keypad and Navigational Keys Functionality d) e) f) g) h) a) b) c)

Start

Reset

Stop

Enter

Escape

Up (Plus)

Down (minus)

Compressor Status Indicators : a) Load Status b) c)

Run Status

Compressor Availability

SECTION 5 — INSTALLATION OVERVIEW

SPECIFICATIONS

Dimensions 13.4” x 9.45” x 6.0”

340mm x 241mm x 152mm

Weight 16.5lb (7.5kg)

Mounting Wall, 4 x screw fixings

Enclosure IP65, NEMA 4

Supply 230Vac +/- 10%, 50 Hz

115Vac +/- 10%, 60 Hz

Power 100VA

Temperature 32°F to 115°F

(0°C to 46°C)

Humidity 0% to 95% RH

(non-condensing)

Local Disconnect (Breaker) Box

Fused for 100VA

Power Cable

3 conductor (N, L, E)

(Sized in accordance with local electrical and safety regulations).

Ingersoll Rand Automation

Model X8I

Ingersoll Rand

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On/Off

Switch

Supply Voltage Cable

Pressure Transducer Cable

CAP

1 2 3 4

5 6 7 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.

EXP

OPTIONAL

EXP RS485 Network Cable

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)

The EXP Will Add Another (4)

Direct ir-PCB connections. This

Would Allow A Total Of (8)

Compressors To Be Connected

And Controlled Via The ir-PCB.

PRESSURE TRANSDUCER CABLE

2 Conductor Cable, 18 Gauge Stranded

Earth Shielded

No Greater Than 330FT (100M)

24VDC Control Voltage

X8I X05 CONNECTOR

PT CONNECTOR

+VDC Pin #3

26 Signal Pin #1

Reference X8I Operations Manual for Pressure

Sensor Connection Details

PRESSURE TRANSDUCER

To Plant Air

System

RECEIVER ir-PCB ir-PCB

DRIP LEG

From Air

Compressors

Ir-PCB Compressor #1

Control Cable

Reference X8I Application and Interconnect Guide For

Wiring Connections Between The X8I, The ir-PCB, and The Compressor

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)

24VAC Control Voltage

Reference X8I Application and Interconnect Guide For

Wiring Connections Between The X8I, The ir-485 or irV-

485 Gateway and The Compressor, S3 Direct Connects, and

Optional Special Application Interface Boxes

The RS485 Network is a Serial, Point to Point

Communication Network Refer to the X8I Application and

Interconnect Guide For Wiring Details and Connectivity.

Ingersoll

Rand

102 psi

I/O

102 psi

Direct To

Ingersoll

Rand

102 psi

VSD

From VSD Pressure

Transducer ir-485

OR irV-485 ir-485 Gateway

For All

IR (Non- Nirvana) Compressors

IntelliSys “Red Eye”, SG and SE irV-485 Gateway

20HP (15KW) and Above

Ingersoll

Rand

102 psi

EX 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).

1 2 3

N L E

XPM-TAC24

X04

2 3 4

VOLTAGE SELECT

X01

1 2 3 4

X04

230Vac

VOLTAGE SELECT

115Vac

Power Supply Terminals

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

P P

Pressure Sensor Located After Shared Cleanup

Equipment

P P

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.

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

Pressure Sensor Located Before Cleanup Equipment

PRESSURE SENSOR CONNECTION

The pressure sensor connects to terminal X05 of the X8I terminal PCB using a shielded 18 AWG maximum 2conductor cable no more than 330 feet (100 meters) in length. The transducer threads are BPT. It is the equivalent of ¼” NPT.

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.

10 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.

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.

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 ir-485 irV- 485

RS485

1 ir-485 Gateway irV-485 Gateway

The cable used between the X8I and the ir-485 and irV-

485 Gateways is Belden 9841 (or equivalent). It should be run in grounded conduit and should not be greater than

4000 feet (1219 meters) in length.

The cable used between the ir-485 Gateway and irV-485

Gateways and the Intellisys Controller is included with the

Installation Kit

The cable used between the ir-485 Gateway and the

Intellisys Controller is included with the Installation Kit

The 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

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1 2 3 4

5 6 7 8

4000ft (1219m) max

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.

Correct RS485 Network Example

The following example details the “incorrect” method of wiring the RS485 Network

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Rand

102 psi

I/O

Ingersoll Rand

102 psi

18:35 #2

CAP

1 2 3 4

5 6 7 8

Ingersoll

Rand

102 psi

1 2

Ingersoll

Rand

102 psi

Ingersoll

Rand

102 psi

EX I/O

Incorrect RS485 Network Example

RS485 data communications and other low voltage signals can be subject to electrical interference.

This potential can result in intermittent malfunction or anomaly that is difficult to diagnose. To avoid this possibility always use earth shielded cables, securely bonded to a known good earth at one end. In addition, give careful consideration to cable routing during installation.

a) Never route an RS485 data communications or low voltage signal cable alongside a high voltage or 3-phase power supply cable. If it is necessary to cross the path of a power supply cable(s), always cross at a right angle. b) If it is necessary to follow the route of power supply cables for a short distance (for example: from a compressor X8I to a wall along a suspended cable tray) attach the RS485 or signal cable on the outside of an earthed cable tray such that the cable tray forms an earthed electrical interference shield. c) Where possible, never route an RS485 or signal cable near to equipment or devices that may be a source of electrical interference (for example: 3-phase power supply transformer, high voltage switchgear unit, frequency inverter drive module, radio communications antenna).

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.

ANTI-CyCLING CONTROL

The most efficient way to utilize most air compressors is either fully loaded or off, with the exception of variable speed compressors which can operate efficiently at reduced loading. Compressor cycling (start-load-unloadstop, etc.) is essential to maintain pressure control.

Excessive cycling, however, can result in poor compressor efficiency as well as increased maintenance.

Anti-cycling control is incorporated to help ensure that only the compressors that are actually required are started and operating while all others are kept off.

Anti-cycling control includes a pressure tolerance range or band, defined by the user, which is outside of the primary pressure band. Inside the tolerance band, an active control algorithm continually analyzes pressure dynamics to determine the last possible second to add or cycle another compressor into the system. This control is further enhanced by the ability to fine tune the tolerance band settings and algorithm processing time (Damping).

TOLERANCE

PL b

Tolerance is a user adjustable setting that determines how far above the PH setpoint and below the PL setpoint system pressure will be allowed to stray. Tolerance keeps the X8I from overcompensating in the event of a temporary significant increase or decrease in system demand.

Figure 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 + TO

PL - TO

Figure 2 — Typical VSD Pressure Control vs. Time

The variable speed compressors in the system will run on their target pressure and smooth out the variations in system pressure. This assumes that system demand does not vary more than the capacity of the variable speed compressor.

A variable speed compressor will be included in the load/unload sequence and be controlled exactly as a fixed speed machine with the exception of speed control to maintain target pressure.

Figure 3 — Tolerance in Relation to PH and PL

Tolerance (TO) is expressed as a pressure defining the width of the band above PH and below PL in which energy efficient control will be in effect.

When system pressure is in the tolerance band, the

X8I will continuously calculate the moment at which compressors will be loaded or unloaded based on the rate of change of system pressure. When the system pressure strays outside of the tolerance band, the X8I will abandon energy efficiency and begin to protect the system air pressure by loading or unloading the compressors.

Loading will be delay controlled.

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)

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%

40%

20%

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:

Compressor 1 has priority 1, all other compressors have priority 2

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

A B C D

B C A D

C A B D

A B C D

Priority control will also work with ENER control mode.

Recall that ENER control automatically selects the most efficient set of compressors to dynamically match compressed air demand. Priority will force the

X8I controller to select from all “priority 1” compressors and make sure that they are loaded in the sequence before utilizing any priority 2 compressors. All priority

2 compressors must be utilized before priority 3 compressors can be loaded and so on. Priority allows a system to be segregated to backup and primary use compressors when using ENER control.

Note: Using the Priority function with ENER Control can affect system efficiency.

TABLES AND THE PRESSURE SCHEDULE

Compressor 4 has priority 2, all other compressors have

A 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:

B C

C B

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:

T01

- - - -

- - - The X8I operates based on settings that are configured into one of three tables. Each table defines the operational settings and sequence control mode of the X8I. The X8I can be instructed to change among the tables at any time based on the configuration of the pressure schedule.

This functionality allows the X8I to switch among multiple different system configurations without any disruption to control. This is particularly useful in the case of shift changes, or weekends when the system is to be deactivated.

Each table consists of the following parameters which can be set independently in each table:

• PH – High Pressure Setpoint

•

PL – Low Pressure Setpoint

Pm – Minimum pressure warning level

•

SQ – Sequence Rotation Strategy

01 – Compressor 1 Priority

02 – Compressor 2 Priority

03 – Compressor 3 Priority

• 04 – Compressor 4 Priority

The “maximum” pressure fault level and the rotation interval, or rotation time, are set independently in a configuration menu and are unchanging regardless of the table selected.

When the X8I is instructed to change between tables, it will not abruptly change the system operating parameters. The X8I will adjust the system target pressure upward or downward to the next table’s settings.

This transition will occur gradually to preserve energy efficiency and safe, reliable control:

Two independently rotating compressor groups

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.

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 defined prefill compressors experiences a shutdown, or is stopped, the prefill function is cancelled and normal operation begins.

Standard Mode: If one or more of the pre-

Automatic Mode: No Prefill compressor selection is necessary; any selection set is ignored. The management unit automatically selects compressor(s) dynamically to achieve pressure in accordance with the set Prefill time. If a compressor is stopped, or shuts down, it is automatically substituted with an alternative compressor.

The Prefill feature provides a controlled and energy efficient method of increasing pressure to normal operating levels at system start. This feature avoids the inefficient potential for all available system compressors to start and load before pressure reaches the normal operating level.

To manually skip Prefill mode, press and hold Start for several seconds.

Insufficient Capacity Alarm

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.

The ‘Insufficient Capacity’ advisory alarm is intended as an advanced warning and is not recorded in the fault history log but is included as a Group Alarm (Warning), or Group

Fault item.

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

ALTERNATE CONTROL FEATURES AND

FUNCTIONALITy

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

Run) EHR

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

Restricted Capacity Alarm

CAP

The X8I is equipped with a dedicated ‘Restricted Capacity’

Advisory Alarm (Warning) indication.

This indication will flash if all available compressors are loaded and further capacity is required but one or more, compressors are: 21 a) inhibited from use in a ‘Table’ priority setting b) inhibited from use by the short-term Service/

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

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

The ‘Restricted Capacity’ advisory alarm is not recorded in the fault history log but is included as a Group Alarm

(Warning), or Group Fault item.

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

FILO: TIMER ROTATION MODE

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

Rotation:

Each time the rotation interval elapses, or the rotation time is reached, a sequence rotation occurs and the sequence assignment for each compressor is re-arranged.

The compressor that was assigned for duty (A) is reassigned as last standby (D) and all other compressor assignments are incremented by one.

The sequence assignment pattern can be modified by

‘Priority’ settings.

1 2 3 4

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

Tables; Priority Settings

Control:

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

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

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

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

SEQUENCE ROTATION EVENTS

A sequence rotation event can be triggered in the following ways: a periodic interval, a pre-determined time each day, or a pre-determined time day and time each week. Please refer to the Quick Setup Manual to determine how to configure the rotation events.

EQUAL HOURS RUN MODE

The primary function of EHR mode is to keep the running hours of all compressors in the system as close as possible. This provides the opportunity to service all of the compressors at the same time, given that the expected service interval for the compressors is similar.

EHR is not an energy efficient focused mode of operation.

Each time the rotation interval elapses, or the rotation time is reached, the sequence order of compressors is reviewed and re-arranged dependant on the running hours recorded for each compressor. The compressor with the least recorded running hours is assigned as the ‘duty’ compressor, the compressor with the greatest recorded running hours is assigned as the ‘last standby’ compressor.

For systems with more than two compressors, the remaining compressor(s) are assigned in accordance with there recorded running hours in the same way.

Example: The compressors in a four compressor system have the following recorded running hours when a rotation event occurs:

•

Compressor 1 = 2200 hours

Compressor 2 = 2150 hours

Compressor 3 = 2020 hours

Compressor 4 = 2180 hours

The new sequence order after the rotation event would be:

•

Compressor 1 = D

Compressor 2 = B

•

Compressor 3 = A

Compressor 4 = C

Compressor 3, which has the fewest running hours, will now be utilized more frequently in the new sequence, allowing running hours to accumulate at a faster rate.

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

If a compressor is operated independently from the X8I the running hours record may not be accurately updated.

The running hours meter display on most compressors are intended for approximate service interval indication only and may deviate in accuracy over a period of time.

Control:

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

‘duty’ compressor (A) is utilized first followed by (B) if demand is greater than the output capacity of (A).

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

(B) if demand continuous to reduce.

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

SECTION 7 — DISPLAy AND MENU OPERATION

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

1 a

102 b

PSI

17:30 #1 c

User Interface : a) System Pressure Value b) c) d) e)

System Pressure Units

Unit Status

Unit Active Functions

User Menu Item a b c

CAP

System Alarms (Warning) : a) b)

Unit Run Indicator (green LED)

Unit Alarm Indicator (Red LED)

System Alarms (Warning) : a) b) c)

Group Compressor Fault

Insuﬃcient Capacity Alarm (Warning)

Restricted Capacity Alarm (Warning)

Ingersoll Rand

102

A: 85% psi f a g h b c e d

CAP

1 2 3 4

5 6 7 8 a b c 1

Keypad and Navigational Keys Functionality e) f) g) h) a) b) c) d)

Start

Reset

Stop

Enter

Escape

Up (Plus)

Down (minus)

Compressor Status Indicators : a) b) c)

Load Status

Run Status

Compressor Availability

Unit Functions:

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

Operating Mode :

EHR - Equal Hours Run

FILO - Timer Rotation

ENER - Energy Control

Active Functions :

Power Failure Auto-Restart

Table #1

Table #2

Table #3

Table #4

Standby Mode Active

Prefill Function

Pressure Schedule

Function Inhibited (Manual Override)

Remote Manual Override

System Pressure Value

System Pressure Units

Real Time Clock

24 Hour Format

System Pressure Status :

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

Below the active lower, or load, pressure set point

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

Above the upper, or unload, active pressure set point

Day of the week

#1 = Monday

#2 = Tuesday

#3 = Wednesday

#4 = Thursday

#5 = Friday

#6 = Saturday

#7 = Sunday

Units Status :

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

Stopped

Standby

Started and Running

Alarm (Warning)

Shutdown (Trip)

Main Manu

Real Time Clock

17:30 #1

17.30 (24r system)

# 1 = Monday to # 7 = Sunday

Compressor Detailed Status:

A: 100% User Manu

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

Compressor Status Symbols

Standby (or Auto restart)

Running Oﬄoad

Running Loaded

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

Removed From Service in Long Term Maintenance Menu

Alarm (Warning) Standby (or Auto Restart)

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

Network Communication Error (RS485 Connectivity Only)

Primary Detected Pressure

102 psi

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

Next Scheduled Sequence Rotation

00:00 #1

The next scheduled sequence rotation:

00 : 00 Time (24 hr system)

#1 Monday

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

Sunday.

INDICATORS

Indicators

The X8I indicators are as follows.

Off

Intermittent:

Slow Flash:

Fast Flash:

1sec

ON – Loaded b) Run Status

OFF – Not Running

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

ON – Running c) Compressor Availability

OFF – No Compressor Connected

Fast Flash – Not Available, Shutdown Fault or

Stopped

Slow Flash – Alarm (Warning)

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

Available, OK

System Alarms (Warnings):

1sec

Unit Indicators

Unit Run Indicator (Green LED)

OFF – Not Active, Stopped

Slow Flash: Active, Standby Mode

ON – Active, Running a b c

CAP a) Group Compressor Fault

OFF – All Compressors OK

Unit Fault Indicator (Red LED)

Fast Flash: Shutdown (Trip)

Slow Flash: Alarm (Warning)

The X8I fault indicator does not indicate compressor fault states; see Compressor Status Indicators.

Compressor Status Indicators: a b c 1

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

a) Load Status

OFF – Not Loaded, Offload

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

Fast Flash – One or more compressors Not

Available, Shutdown Fault or Stopped

Slow Flash – One or more compressors Alarm

(Warning) b) Insufficient Capacity Alarm (Warning)

On – Insufficient Capacity c) Restricted Capacity Alarm (Warning)

Slow Flash – Restricted Capacity

Information Displays

To view detailed information applicable to the selected User menu display item press Enter.

Real Time Clock:

P00

2 #1 18:30

Shows the next Pressure Schedule event.

1: The Current Active Table

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

3: Time (24hr system)

4: Table

Items 2 and 3 show the day and time that the unit will change to use the ‘Table’ shown in item 4.

Compressor Status:

P00

1 1

IRV-485

100 %

20 %

30 %

1: Compressor Number

2: Priority Setting

3: Zone Allocation Setting

4: Compressor/Connection Type

5: Maximum Capacity % Setting

6: Minimum Capacity % Setting

7: Minimum Efficiency % Setting

Item values 6 and 7 are only shown if compressor type is IRV-485 (variable capacity/speed).

Primary Detected Pressure:

P00

102

80 psi psi psi

1: Active Table

2: Upper (Unload) Pressure Set Point

3: Lower (Load) Pressure Set Point

4: Minimum Pressure Alarm (Warning)

Sequence Rotation:

P00

#4 18:00

18 / 05 / 2006

A B C D

Day of the week (#4: Thursday), the time of day

(18:00) and the date (18/05/2006) of the next automated sequence rotation event.

The active ‘mode’ of operation

“ ABCD ” The current active rotation sequence assignment.

Manual Sequence Rotation :

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

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

Escape to abandon the manual rotation.

Automated sequence rotation is not disrupted by a manual rotation; the next scheduled automated sequence rotation event will still occur.

Compressor Identification

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

Power Failure Auto-Restart

A: 85%

Stop:

1 2 3 4

To stop the X8I press Stop.

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

Pressure regulation control is automatically transferred back to each compressor. The compressor(s) will continue to operate using the pressure settings programmed or set in the individual compressor controller(s).

The X8I will hold each compressor in an offload state.

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

The design of some air compressor control systems may inhibit automatic transfer of pressure regulation control to local operation mode. In this instance the compressor will not continue production of compressed air – consult the air compressor manual or your air compressor supplier / specialist for details before installing the IAX4.

Start:

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

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

Failure Mode

If the X8I experiences a disruption to normal control, or an X8I shutdown fault occurs, pressure regulation control is automatically transferred back to each compressor. The compressor(s) will continue to operate using the pressure settings programmed or set in the individual compressor controller(s).

Reset

To reset an X8I Alarm (Warning) or Shutdown condition press Reset.

To start the X8I press Start.

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

Prefill

To manually skip the Prefill function, press and hold

Start for several seconds.

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

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

Tables

Each compressor in the system must be started

(running or in a standby or auto restart condition) before

X8I control of the compressor can be established. The X8I will not start a compressor that is in a stopped condition.

SECTION 8 — COMMISSIONING

When commissioning the X8I, carry out the following procedures before attempting to start.

PRESSURE DISPLAy

It is recommended that an authorized and trained service technician perform the commissioning.

PHySICAL CHECKS

Check the displayed system pressure. If the pressure is incorrect, or inaccurate, check the type and range of the sensor and carry out the pressure sensor commissioning and calibration procedure. If the display shows an error, this will need to be corrected before continuing. See the

Operator’s Manual for troubleshooting and correcting the fault/error condition.

1. Before applying power to the X8I, ensure the power supply connections are correct and secure and the operating voltage selector is set correctly for the power supply voltage in use (115Vac or

230Vac (+-10%), 50/60Hz).

2. Open the front panel of the X8I and check the location of the link wire(s) connected to the

“Voltage Selection” terminals of the power supply

PCB. If necessary, change the link wire locations to those illustrated for the voltage in use.

X8I QUICK SET-UP CONFIGURATION

Before successful basic operation can be established specific parameters must be entered prior to startup.

Please refer to the X8I Quick Setup Manual for instruction to accomplish this.

OPTIONAL FEATURES AND FUNCTIONS

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

See the section on Installation for more information.

3. Switch on the power supply to the X8I.

4. The control program identification will be displayed for a short period followed by the normal operational user display.

SECTION 9 — SySTEM CONFIGURATION

DISPLAy ITEM STRUCTURE ACCESSING THE X8I CONFIGURATION

SCREENS

Operational system status and values are accessible from the normal user display. To view status or values that are not normally visible on the default screen, press UP or

DOWN. All standard user display items are viewable only and cannot be adjusted. The standard user display items are regarded as “Menu Page 00” items.

Access Code:

Access to adjustable menu page items is restricted by access code. To access menu mode pages press MENU (or

UP and DOWN together); an access code entry display is shown and the first code character will flash.

All adjustable value, parameter or option item displays are grouped into “menu mode” lists. Items are assigned to a list according to type and classification. Item lists are identified by page number (or menu number). All adjustable parameters and options are assigned to menu mode pages “P01” or higher.

NORMAL OPERATIONAL DISPLAy (MENU

PAGE P00)

At controller initialization, all display elements and LED indicators are switched on for three seconds and then the normal operating display is shown. In normal operational display mode, the main display will continuously show the detected system pressure and the Item display will show the first item of the “Page 00” menu. User menu

“items” can be selected using the UP or DOWN buttons at any time. Pressing the ENTER button will lock any selected item display and inhibit return to the default display.

When an item display is locked, the “lock key” symbol will be shown. To unlock an item display, press UP or

DOWN to view an alternative item display or press RESET or ESCAPE. No item values, options or parameters can be adjusted in “Page P00”. If a fault condition occurs, the fault code becomes the first list item and the display will automatically jump to display the fault code. More than one active fault code item can exist at any one time and can be viewed by pressing UP or DOWN. The most recent

“active” fault will be at the top of the list.

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

ENTER. Repeat for all four code characters.

If the code number is less than 1000 then the first code character will be 0(zero). To return to a previous code character press ESCAPE. When all four code characters have been set to an authorized code number press

ENTER. An invalid code will return the display to normal operational mode; page ‘P00’.

Access Code Accepted

Access Code Rejected

Access Code = 0032

Access Code Timeout:

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

Menu Mode Navigation:

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

P00

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

To select an item value or parameter for modification’ press ENTER; an adjustment screen for the item will be displayed.

The value or option can now be modified by pressing

UP(Plus) or DOWN(Minus). To enter a modified value or option in to memory press, ENTER.

Page 0

Item 1 Value

Item 2 Value

Item 3 Value

Item 4 Value

Item 5 Value

Item 6 Value

Page 1

Page 2

Page 3

Page 4

Page 5

Item 1

Item 2

Item 3

Item 4

Item 5

Value

Press ESCAPE at any time in menu mode to step backwards one stage in the navigation process. Pressing

ESCAPE when the page number is flashing will exit menu mode and return the display to normal operational mode.

Page 0

Item 1 Value

Item 2 Value

Item 3 Value

Item 4 Value

Item 5 Value

Item 6 Value

Page 1

Page 2

Page 3

Page 4

Page 5

Item 1

Item 2

Item 3

Item 4

Item 5

Value

All menu items have a unique reference consisting of the menu page ID (a) and the menu page item number (b).

Each item in a menu also has a unique two alphanumeric character code (c). All three references are visible at the top of every menu item display.

a b

P01 01.02

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

Most menu items are single value or single option only in which case the single item is referenced as sub-item number ‘01’ (for example: P01-01.01).

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

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

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

USER LEVEL MENUS

TABLE #1

T01

01 PH High Pressure Set Point

02 PL Low Pressure Set Point

03 Pm Minimum Pressure Alarm

04 SQ Sequence Algorithm

Compressor #1 Priority 05 01 to

12 0 8 Compressor #8 Priority

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

P01

Pressure Schedule

01 01 to

28 28

Schedule Setting #1

Schedule Setting #28

P02

Prefill

01 PF

02 PT

03 PP

04 01 to

11 0 8

Prefill Function

Prefill Time

Prefill Pressure

Compressor #1

Compressor #8

S01

User Configuration

01 Ct

02 PS

03 AR

04 RP

05 TS

06 BL

Real Time Clock Set

Pressure Schedule Enable

Auto Restart Enable

Rotation Interval

Default Table Select

Display Backlit Adjust

C01

Compressor Running Hours

01 01 to

08 08

Compressor #1 Running Hours

Compressor #8 Running Hours

C02

Compressor Maintenance

01 01 to

0 8 08

Compressor #1 Maintenance

Compressor #8 Maintenance

E01

Fault Log

01 01 to

15 15

Fault Log #1 (most recent)

Fault Log #15

SERVICE LEVEL MENUS

Configuration

S02

01 P>

02 NC

Pressure Units

Number Of Compressors

03 PM Maximum Pressure Alarm

04 CF Stop Control Function

05 TO

06 DA

07 PC

08 CA

Tolerance

Damping

Pressure Change Time

CAP Alarm Inhibit

09 MA Max Cap Restricted Alarm Inhibit

10 AI

11 AO

12 ER

Auxiliary Input Function

Auxiliary Output Function

Error Log Reset

Auxiliary Box Monitoring

S03

01 01

02 02

03 BT

Auxiliary Box #1 Enable

Auxiliary Box #2 Enable

RS485 Timeout

S04

01 1O

02 1R

Sensor Calibration

Pressure Offset

Pressure Range

01 to 8

C03

Compressor Configuration

Compressor #1 Configuration

Compressor #8 Configuration

High Level Menus

Diagnostic Menu 1

D01

01 D1 to

08 D8

09 R1 to

14 R6

15 A1

16 A2

17 A3

18 Ao

Digital Input #1 (Di 1)

Digital Input #8 (Di 8)

Output Relay #1 (R1)

Output Relay #6 (R6)

Analog Input #1 (Ai1)

Analog Input #2 (Ai2)

Analog Input #3 (Ai3)

Analog Output (Ao)

Diagnostic Menu 2

01 SI

02 LT

D02

Screen Invert

LED Panel Test

D03 and D04

Diagnostic menus D03 and D04 have no standard function and are not shown.

Diagnostic Menu 5

XPM Expansion Module C:5-8 Diagnostic Menu

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

D05

01 to

09 to

Digital Input #1 (Di 1)

Digital Input #8 (Di 8)

Output Relay #1 (R1)

Output Relay #6 (R6)

Analog Output (Ao)

X8I CONFIGURATION SCREENS

01 PH

T01

102

04 psi psi psi

ENER ( % )

Tables

# = Table T01 to T04

T0# – PH High Pressure Set Point

The ‘upper’ or ‘unload’ pressure set point that will be used when the ‘Table’ is active. The default setting for this parameter is 102 PSI. The values for this parameter are:

The highest value for the High Pressure setpoint = PM

“Maximum Pressure Alarm” minus 2 times TO “Tolerance”.

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

PSI.

The lowest value for the High Pressure setpoint = PL “Low

Pressure” setpoint plus TO “Tolerance”

If PL is set for 98 PSI and TO is set for 3.0 PSI, then the lowest value for the High Pressure setpoint would be 101

PSI.

T0# - PL Low Pressure Set Point

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

The highest value for the Low Pressure setpoint = PH

“High Pressure” setpoint minus TO “Tolerance”.

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

PSI.

The lowest value for the Low Pressure setpoint = Pm

“Minimum Pressure Alarm” setpoint plus 2 times TO

“Tolerance”

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

PSI...

T0# - Pm Minimum Pressure Alarm

The miniumum pressure ‘Warning’ or ‘Alarm’ level that will be used when the ‘Table’ is active. The default setting for this parameter is 80 PSI. The values for this parameter are:

The lowest Minimum Pressure Alarm setpoint = “The minimum range of the pressure transducer used.“

The highest Minimum Pressure Alarm setpoint = “The value from the Table PL – Low Pressure Setpoint” minus 2 times TO “Tolerance””

If PL in Table 1 (T01) is set for 100 PSI and TO is set for 3.0

PSI, then the highest Minimum Pressure setpoint would be 94 PSI.

T0# - SQ Sequence Strategy

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

The values for this parameter are:

ENER – Energy Control Mode. The Rotation and

Control functionality of the ENER mode is to achieve and maintain demand matched to optimum system efficiency.

FILO – First In Last Out. The Rotation and Control functionality of the FILO mode is the first compressor loaded is the last compressor to be unloaded

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

Hours on all compressors

T0# - 01 Compressor #1 Priority

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

T0# - 02 Compressor #2 Priority

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

T0# - ‘n’ Compressor #’n’ Priority

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

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

Priority Settings:

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

28 28

01 01

P01

- . - - : - - - - -

01 PF

P02

MIN psi

Pressure Schedule

P01 – 01 to 28

The ‘Pressure Schedule’ items 01 to 28. The Pressure

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

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

Day of the Week. The values for this parameter are:

“1” for Monday to “7” for Sunday (a specific day of the week)

“8” for every working day of the week (every day, Monday through Friday, excluding

Saturday and Sunday)

“9’” for every working day of the week (every day, Monday through Sunday)

“–“ represents the Pressure Schedule is disabled.

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

“00” to “23” the hours in a day

“–-“ represents the Pressure Schedule is disabled.

Minutes. The values for this parameter are:

“0” to “59”. the minutes in the hour

“__“ represents the Pressure Schedule is disabled.

Table / Standby mode selection. This instructs the system to change from one ‘Table’ to another, or put the system in to ‘Standby’ mode for the Pressure Schedule. The values for this parameter are:

“T01”, “T02”, “T03” or “T04” for the 4 different

Tables

“– – “ for Standby Mode

“ __ “ represents the Pressure Schedule is disabled.

Prefill

P02 - PF Prefill Function

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

(Represents the pre-fill function is in Automatic

Mode)

The values for this parameter are:

= Prefill function OFF

“ ” = Prefill, Back-up Mode

Compressor(s) can be pre-selected as ‘Primary

Pre-fill’ compressor(s) or ‘Backup Pre-fill’ compressor(s). If a primary pre-fill compressor experiences a shutdown, or is stopped, it is replaced by a pre-defined backup compressor and pre-fill continues.

! X

= Prefill, Standard Mode

If one or more of the pre-defined pre-fill compressors experiences a shutdown, or is stopped, the pre-fill function is cancelled and normal operation begins.

= Prefill, Automatic Mode

No Prefill compressor selection is necessary; any selection set is ignored. The management unit automatically selects compressor(s) dynamically to achieve pressure in accordance with the set Prefill time. If a compressor is stopped, or shuts down, it is automatically substituted with an alternative compressor.

P02 - PT Prefill Time

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

The values for this parameter are:

“–” the Pre-fill Time is Off

“1 to 120” the number of minutes

P02 - PP Prefill Pressure

The Pressure Setpoint used by the X8I to determine if the

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

The values for this parameter are:

0 to 232 (or the maximum scaled pressure value used by the X8I if a different Pressure

Transducer range is used)” the PSI value for the

Pre-fill Pressure

P02 – 01 to ‘n’ Compressor 1 to ‘n’

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

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

. (Represents this compressor is not used by the

Prefill Function) The values for this parameter are:

“ ” for this compressor will not be used by the Prefill Function

“ ” for this compressor will be used as a primary compressor by the Pre-fill Function

“!” for this compressor will be used as an emergency

Backup compressor by the Pre-fill Function

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

Press and hold ‘Start’ for 5 seconds to manually skip

Prefill mode at start up.

08 Ct

S01

1 . 18:00

1 . 00:00

Features and Functions

S01 - Ct Real Time Clock Set

Adjustment for the internal real time clock.

(Hours, Minutes, Date, Month, Year)

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

The values for this parameter are:

“1” to “7” the ‘Day of the Week’ (1= Monday to

7=Sunday) which is automatically calculated and set in accordance with the Day, Month and Year entered.

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

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

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

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

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

S01 - PS Pressure Schedule Enable

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

is . (Represents the Pressure Schedule is disabled)

The values for this parameter are:

= inhibit Pressure Schedule

“ ” = enable Pressure Schedule

S01 - AR Auto Restart Enable

This parameter enables or disables X8I restart function after a power loss. When enabled, after a power disruption or failure, the X8I will automatically restart when power is restored if the X8I was in an operational

‘Started’ state when the power loss or disruption occurred. The X8I will not automatically restart if the X8I was in a “Stopped” state when the power disruption or failure occurred. The default setting for this parameter is

. (Represents the Auto Restart is enabled)

The values for this parameter are:

= inhibit Power Failure Auto Restart

“ ” = enable Power Failure Auto Restart

S01 - RP Rotation Interval

The X8I provides a Timed rotation event that can be automatically triggered on a routine basis using a pre-determined interval, a pre-determined time each day, or a pre-determined day and time each week. The default setting for this parameter is 1 00:00. (Represents a rotation at Monday (1) at 00:00 hours)

The values for this parameter are:

“1” for Monday to “7” for Sunday (a specific day of the week)

“8” for every working day of the week (every day,

Monday through Friday, excluding Saturday and

Sunday)

“9’” for every day of the week (every day, Monday through Sunday)

“t” for an interval of time (more than 1 or more rotations per 24 hours)

“–“ for disabling the Rotation Interval

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

Time format.

The values for this parameter are:

“00” to “23” the Hour

“0” to “59” the Minutes

“–“ the Rotation Interval is disabled.

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

The values for this parameter are:

A value of 1 = rotate every 24 hours

A value of 2 = rotate every 12 hours

A value of 3 = rotate every 8 hours

A value of 4 = rotate every 6 hours

A value of 6 = rotate every 4 hours

A value of 8 = rotate every 3 hours

A value of 12 = rotate every 2 hours

A value of 24= rotate every 1 hours

A value of 48 = rotate every 30 minutes

A value of 72 = rotate every 20 minutes

A value of 96 = rotate every 15 minutes

“–“ the Rotation Interval is disabled.

S01 - TS Default Table Select

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

The values for this parameter are:

“T01” for Table T01

“T02” for Table T02

“T03” for Table T03

“T04” for Table T04

S01 - BL Display Backlight Adjust

This parameter adjusts the backlight level for the display.

The display will temporarily increase brightness by 2 levels when a key is pressed and return to normal setting after a period of no keypad activity. The default display backlight level has been set to enable a ‘continuous use service life’ in excess of 90000 hours while providing good readability in all ambient light conditions. LCD display

‘service life’ is defined as the time period before the backlight reduces to 50% of initial brightness. Typically the display will remain usable for a much longer period of time. Adjusting the backlight to high levels will reduce service life. The default setting for this parameter is 5. The values for this parameter are:

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

01 P>

S02

X psi

145

X psi

Pressure Control; Tables

S02 - P> Pressure Units

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

“PSI”

“BAR”

“kPA”

S02 - NC Number of Compressors

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

“1” for 1 compressor

“2” for 2 compressors

“3” for 3 compressors

“4” for 4 compressors

“8” for 8 compressors

S02 - PM Maximum Pressure Alarm

This parameter sets the High pressure ‘Fault’ level. This value remains active at all times and is the same for all

‘Tables’. It should be set just below system pressure relief value(s) and below the maximum system pressure rating of all air system components. The default setting for this parameter is 145. The values for this parameter are:

The highest value for the Maximum Pressure Alarm setpoint = “The maximum range of the pressure transducer used”

The lowest value for the Maximum Pressure Alarm setpoint = “The highest value from any Table “PH

- Pressure High” Setpoint plus 2 times the “To

– Tolerance”

If PH in Table 1 (T01) is set for 100 PSI, and PH in Table 2 (T02) is set for 110 and TO is set for

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

S02 - CF Stop Control Function

This parameter determines if the X8I maintains control of the compressors when the X8I is stopped. The default setting for this parameter is . (Represents the

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

= Stop: return pressure control to the compressors.

“ ” = Standby: maintain control and continouosly hold compressors ‘off load’.

S02 - TO Tolerance

This parameter sets the pressure control ‘Tolerance’ band setting. The Tolerance Band setting is a pressure band above and below the Load and Unload pressure band.

This accommodates for an instance of abrupt and/or significant increase or decrease in demand without compromise to optimal energy efficient control. The X8I incorporates a Rate of Change algorithm in the Tolerance

Band to determine when a compressor should be Loaded or Unloaded. The default setting for this parameter is 3.0

PSI (.2 Bar) The values for this parameter are:

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

“29.0 PSI (2 Bar)” for the maximum Tolerance Band

• If air system storage is generous, the rate of the pressure change is slow, and/or demand fluctuations are insignificant and gradual, then the ‘Tolerance’ band can be decreased to improve pressure control without compromise to optimum energy efficiency.

As the Tolerance Band is decreased, the Loading and

Unloading of compressors while in the band is more rapid.

• If air system storage is inadequate, the rate of the pressure change is fast, and/or demand fluctuations are significantly large, the ‘Tolerance’ band can be increased to maintain optimum energy efficiency, and reduce over-reaction, during such transition periods. As the Tolerance Band is increased, the

Loading and Unloading of compressors while in the band is less rapid.

S02 - DA Damping

This parameter sets the pressure control ‘Damping’ setting. Changing this parameter adjusts the time before an additional compressor is loaded in accordance with the urgency of the situation to increase air system capacity further. The X8I has a dynamic reaction algorithm that is pre-set by default to accommodate for the majority of installation characteristics. If an increase or decrease in the Tolerance band is insufficient, the reaction response can be influenced by increasing or decreasing the

‘Damping’ factor. The default setting for this parameter is

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

“.1”, the fastest Damping reaction time (10 times faster than the default of 1.0)

“10.0”, the slowest Damping reaction time (10 times slower than the default of 1.0).

•

If air system storage is generous and the rate of the pressure change is slow to rise, then the ‘Damping’ can be increased to improve pressure control without compromise to optimum energy efficiency.

As the Dampening value is increased, the Loading of additional compressors is less rapid.

If air system storage is inadequate and the rate of the pressure change is fast to fall, then the ‘Damping’ can be decreased to improve pressure control without compromise to optimum energy efficiency.

As the Damping value is decreased, the Loading of additional compressors is more rapid.

Damping also performs one more important function that can arise in a system. When the system pressure achieves stability in a position that may be outside of the dead band but inside the tolerance band it will be allowed to remain in this situation for a predefined amount of time. This time limit depends on how far away from the dead band the system pressure has stabilized.

This time limit is calculated as 30 min times the damping constant at the top of the tolerance band and as 1 min times the damping constant at the bottom of the tolerance band.

S02 - PC Pressure Change Time

This parameter adjusts the time that the X8I will implement a smooth and controlled change from one

‘target’ pressure level to another when a table change is made. The default setting for this parameter is 4 Min. The values for this parameter are:

“1”, 1 minute between Table target pressure setpoint changes

“120”, 120 minutes between Table target pressure setpoint changes.

S02 – CA Capacity Alarm Enable

This parameter sets the functionality of the Capacity

Alarm. The default setting for this parameter is .

(Represents the Capacity Alarm is enabled) The values for this parameter are:

= inhibit Capacity Alarm

= enable Capacity Alarm

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

S02 – MA Restricted Cap. Alarm Enable

This parameter sets the functionality of the Restricted

Capacity Alarm. The default setting for this parameter is

. (Represents the Restricted Capacity Alarm is enabled)

The values for this parameter are:

= inhibit Restricted Capacity Alarm

= enable Restricted Capacity Alarm

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

S02 – AI Auxiliary Digital Input

S02 10.01

01:D1

NO

S02 – AO Auxiliary Output Function

S02 11.01

01:AF

NO

The function of the Auxiliary input.

01:DI Digital Input

No defined function but status (0=normal,

1=activated)

02:T1 Override > Table 1

03:T2 Override > Table 2

04:T3 Override > Table 3

05:T3 Override > Table 4

06:TS Override > Standby

07:AA Remote Alarm (always active)

08:AR Remote Alarm (active when unit running, inhibited when unit stopped or in Standby)

09:TA Remote Trip (always active)

10:TR Remote Trip (active when unit running, inhibited when unit stopped or in Standby)

11:SS Remote Start/Stop

NO (Normally Open)

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

NC (Normally Closed)

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

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

01:AF Any Fault

Any Alarm (Warning), Shutdown (Trip) or Compressor Not

Available.

02:AT Any Trip

Any Shutdown (Trip) or Compressor Not Available.

03:CF Compressor Fault

Any compressor Alarm (Warning), Shutdown (Trip) or Not

Available

04:CA Compressor Alarm

Any compressor Alarm (Warning)

05:CT Compressor Trip

Any compressor Shutdown (Trip) or Not Available

06:SF System Fault

Any unit Alarm (Warning) or Shutdown (Trip)

07:ON System On

Unit Started and Active, including Pre-Fill period and

Standby mode (not active when unit stopped)

08:SA System Active

Unit Active, including Pre-Fill period (not active when unit stopped or in standby mode)

09:LP Low Pressure Alarm

10:HP High Pressure Alarm

11:PO Pressure Control Override

Normal, or Pressure Schedule’ operation is being manually overriddenThe function of the Auxiliary output ‘volt-free’ relay contacts.

S02 - ER Error Log Reset

This parameter clears and resets the ‘Error Log’. The default setting for this parameter is . (Represents the

Error Log Reset is disabled)

The values for this parameter are:

“ ” Error log reset is disabled

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

‘ ’ and press ENTER. The display will return to the main menu and all existing entries in the error log will be permanently deleted.

01 01

S03

60 sec

S03 – 01/02 I/O Box Monitoring

This parameter determines if the X8I will monitor the selected I/O Box and display any ‘Fault’ detected on the

I/O Box inputs; dependant on I/O Box set-up. The default setting for this parameter is . (Represents I/O Box monitoring is disabled) The values for this parameter are:

= Disabled

= Enabled

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

S04 - 1R Pressure Sensor Range

This parameter will be the maximum range of the pressure transducer, 232 PSI, 16 BAR, or 1600 kPA. It can also be used to create an ‘Offset’ if there is a difference in the range value being displayed. The default setting for this parameter is 232 PSI. The values for this parameter are:

“232” when using the maximum value of the pressure transducer range

A value greater than or less than 232 if the display does not read 232.

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

Pressure Sensor Calibration Procedure: a) Offset: Expose the sensor to atmosphere and adjust the ‘offset’ setting (if necessary) until the detected pressure display shows 0 PSI (0.0 BAR).

b) Range: Apply an accurately know pressure to the pressure sensor and adjust the ‘Range’ setting until the detected pressure display matches the applied pressure. An applied pressure equal too, or greater than, the nominal system working pressure is recommended.

Refer to I/O Box manual for details.

S03 – BT Communications Timeout

This parameter determines the Communication Broadcast

Timeout between the X8I and the I/O box. If the I/O Box fails to communicate on the RS485 network within the set ‘Communications Broadcast Timeout’ (BT), the X8I will display an I/O Box RS485 communications Error.

The default setting for this parameter is 60 seconds. The values for this parameter are:

“10 to 300” the number of seconds

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

S04

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

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

01 1O

02 1R 232

0 psi psi

S04 - 1O Pressure Sensor Offset

This parameter will be the minimum value of the pressure transducer, 0 PSI, 0 BAR, or 0 kPA. It can also be used to create an ‘Offset’ if there is a difference in the zero value being displayed. The default setting for this parameter is 0

PSI. The values for this parameter are:

“0” when using the minimum value of the pressure transducer range

A value greater than or less than 0 if the display does not read 0 or when using an Offset pressure transducer (an example of an Offset pressure transducer would be one where the range was minus

PSI (-25) to a positive PSI (200).

Correct pressure sensor set-up and calibration is critical for successful system operation. It is recommended that pressure sensor calibration is examined, and adjusted if necessary, annually or a predetermined routine periodic basis.

C01

08 08

01 01

0 hrs h r s hrs hrs hrs

Control - Equal Hours Run Mode

C01 – 01 to C01 – ‘n’ Run Hours’

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

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

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

C02

08 08

01 01

C02 – 01 to C02 – ‘n’ Compressor Maintenance

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

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

(shutdown) fault will be ignored. The default setting

for this parameter is . (Represents the compressor is available) The values for this parameter are:

= Remove compressor from operation

= Compressor can be utilised

08 08

01 01

C03 ir-PCB ir-PCB ir-PCB ir-PCB ir-PCB

Installation – Compressor Connections

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

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

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

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

ir-PCB:

C03 01.01

IR-PCB

10 s

IRV-PCB:

C03 01.01

IRV-PCB

10 s

IR-485:

C03 01.01

IR-485

10 s

IRV-485:

C03 01.01

IRV-485

10 s

100 %

+V=!

50 %

60 %

100 % 5

100 %

+V=!

10 s

100 % 5

X8I COMPRESSOR CONNECTIVITy AND

FUNCTIONAL SETTINGS

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

‘ir-PCB’ module using 6-wire method.

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

IRV-PCB Variable Speed; connected to X8I using ‘ir-PCB’ module using the 7-wire ‘V’ terminal method.

(variable speed regulation)

IR-485 Fixed speed, load/unload; connected to X8I on

IR485 network.

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

IRV-485 Variable Capacity/Speed; connected to X8I on

IR485 network.

(0 . . 100%) variable %Load regulation

Compressor Start Sequence Time:

Set to match the time that the compressor takes to start it’s main motor and load. This time will typically be equivalent to the compressors ‘Star/Delta’ time.

If unknown, the time can be established by experiment; manually start the compressor, from a stopped condition, and determin the time from pressing the start button until the compressor loads and contributes capacity output to the system.

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

An accurate time is important for successful unit operation.

Compressor Run-On Stop Time:

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

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

If unknown, the time can be established by experiment; start and load the compressor then arrange a condition that will unload the compressor for a period of time.

Determine the time from the moment the compressor unloads until the main motor stops and the compressor enters a ‘Standby’ or ‘Auto Restart’ condition.

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

ir-PCB Alarm (Warning) Input:

Only applicable for ir-PCB connectivity. Not shown for ‘485’ network types.

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

+V=! An Alarm (Warning) condition is generated if the ‘ir-

PCB’ Alarm input detects a voltage between 12-250Vac/dc

(default).

0V=! An Alarm (Warning) condition is generated if the ‘ir-

PCB’ Alarm input detects no voltage.

% Maximum Output Capacity

The maximum output capacity of each compressor must be set as a percentage with reference to the highest output capacity (the largest) compressor in the system.

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

For example:

Compressor 1 700 cfm 100%

Compressor 2 700 cfm 100%

Compressor 3 420 cfm 60%

Compressor 4 420 cfm 60 %

Compressor 5 350 cfm 50%

Compressor 6 175 cfm 25%

% Minimum Output Capacity

Only applicable for a variable output compressor

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

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

For example 1:

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

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

Example Compressor 1 is a VSD:

Max CFM = 700

Max Output Capacity 700/700 = 100%

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

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

30%)

For example 2:

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

Example Compressor 4 is a VSD:

Max CFM = 420

Max Output Capacity 420/700 = 60%

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

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

18%)

For example 3:

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

Minimum Output Capacity = 30%

% Minimum Efficiency

The intent of this feature is to always operate the smallest, most efficient compressor and to prevent a variable output capacity compressor operating at minimal speed, or minimal output, for prolonged periods of time.

Generally a variable output compressor operating at minimal capacity is less efficient than a smaller capacity compressor that is able to achieve the same output at higher, or maximum, output capacity.

Only applicable for a variable output compressor

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

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

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

For example:

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

Compressor is 700 CFM)

Max Output Capacity 420/700 = 60%

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

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

18%)

If another compressor in the system is able to provide

40% of the compressor’s full speed output more efficiently, set the % Minimum Efficiency value to 24%

(40% x 60%). This percentage value represents 40% of the full speed output of the compressor scaled to System capacity.

When the compressor is detected as operating below the

% Minimum Efficiency value for a period of time the X8I will immediately re-evaluate utilization and re-configure, if possible, to utilize a the smaller capacity, more efficient compressor, or combination of compressors. This process is automatic and executed dynamically in accordance with prevailing operational conditions at the time. The

ENER control mode algorithms will eventually conclude the best compressor fit without this parameter; the %

Minimum Efficiency input will speed up this process.

E01

- : - - - . - -

E : ERR . 01

- : - - - . - -

E01 – 01 to 15

The error log is presented in chronological order. Entry 01 is the most recent, whereas entry 15 is the oldest. Each error log item will show the error code. To view details for the selected error log item, press the ENTER button.

E01 01.01

E: ERR.01

16/05/2006

14:25

To return to the main error log menu screen press the

ESCAPE button.

To view the second information screen press ENTER.

button

E01 01.01

1 2 3 4

The operational status of each compressor, at the time the error occurred, is displayed symbolically. See Compressor

Status Displays for Icons.

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

The first error information display shows:

• The error code • Error code symbols (if applicable)

•

The date the error occurred

The time the error occurred

The active operational functions of the X8I at the time the error occurred; (see: X8I Status Display for

Icons)

D01 Diagnostics - Controller

D01

18 Ao

01 D1

4 .

0 0

2 m A

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

X8I Controller Diagnostics:

D1 Digital Input 1

ON D2 Digital Input 2

D3 Digital Input 3

D4 Digital Input 4

D5 Digital Input 5

OFF

Pulsing

D6 Digital Input 6

D7 Digital Input 7

D8 Digital Input 8

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

R1 Relay Output 1

R2 Relay Output 2

R3 Relay Output 3

OFF

R4 Relay Output 4

R5 Relay Output 5

R6 Relay Output 6

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

A1 Analog Input 1 bar <> mA

A2 Analog Input 2 v

A3 Analog Input 3 v

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

Ao Analog Output 0.0 to 20.0mA

Digital Inputs:

OFF (open circuit)

ON (closed circuit)

Pulsing

The pulse signal from an ‘ir-PCB’ is 0V to 24VDC at

50/60Hz. A typical DC voltage meter, or multimeter, will detect this as 12VDC +-4V.

Relay Outputs:

Each relay output can be energized and de-energized manually by selecting the item. Use Up(plus) and

Down(minus) to adjust and Enter.

Analog Inputs:

The Analog Inputs will alternate between the detected value and the electrical measurement on the controller input terminals. An independent measuring device can be used to check the displayed electrical measurement.

A1: System Pressure, 4-20mA

A2: Digital: ir-PCB #4 – Alarm/Serv.

A3: Digital: Auxiliary Input (D1)

Analog Output:

The analog output can be manually adjusted. Use

Up(plus) and Down(Minus) to adjust and Enter. The output will return to normal operational value upon menu exit.

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

4.0mA All ‘V’ outputs OFF

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

11.0mA V2 = ON;

15.0mA V3 = ON;

19.0mA V4 = ON;

V1, 3 and 4 = OFF

V1, 2 and 4 = OFF

V1, 2 and 3 = OFF

D02 Diagnostics – LED Panel

01 SI

02 LT

SI: Screen Invert

LT: LED Panel Test

0 = on test

1 = all on

2 = control test

D03 and D04

D02

Diagnostic menus D03 and D04 have no standard function and are not shown.

15 Ao

01 D1

D05

4.00

2 mA

Relay Outputs:

Each relay output can be energized and de-energized manually by selecting the item. Use Up(plus) and

Down(minus) to adjust and Enter.

Diagnostics: XPM Expansion Module C:5-8

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

X8I Controller Diagnostics:

D1 Digital Input 1

D2 Digital Input 2

D3 Digital Input 3

D4 Digital Input 4

D5 Digital Input 5

D6 Digital Input 6

D7 Digital Input 7

OFF

Pulsing

D8 Digital Input 8

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

R1 Relay Output 1

R2 Relay Output 2

R3 Relay Output 3

R4 Relay Output 4

R5 Relay Output 5

R6 Relay Output 6

OFF

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

Ao Analog Output 0.0 to 20.0mA

Digital Inputs:

Ao: Analog Output:

The analog output can be manually adjusted. Press

Up(plus) and Down(Minus) to adjust and Enter. The output will return to normal operational value upon menu exit.

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

4.0mA All ‘V’ outputs OFF

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

11.0mA V2 = ON;

15.0mA V3 = ON;

19.0mA V4 = ON;

V1, 3 and 4 = OFF

V1, 2 and 4 = OFF

V1, 2 and 3 = OFF

OFF (open circuit)

ON (closed circuit)

Pulsing

SECTION 10 — FAULT CODES

X8I COMPRESSOR FAULT INDICATIONS,

TyPES, AND CODES:

Trip (Shutdown):

In the event of a unit or system “fault” the X8I will display a fault code. The fault code becomes an item in the user operational display menu. If more than one “active” fault occurs, each will be displayed as a separate item in the operational user menu. Press UP or DOWN to view all active fault codes or to view the normal status display.

Alarm (Warning)

Shutdown (Trip)

Fault codes are separated into unit faults (ERR) and system alarms (warning) (SYS).

Compressor Alarm (Warning) conditions are automatically reset when the condition has been resolved and reset on the compressor.

Compressor Not Available (Shutdown, Trip) conditions are automatically reset when the condition has been resolved and reset on the compressor; and the compressor has been restarted.

Compressor fault conditions are displayed by the compressor indicators and in the user menu status screen.

Compressor fault conditions are not regarded as X8I unit fault conditions.

Compressor Status Sysmbols and Comressor Status

Indicators

Fault Codes

Fault codes are separated in to unit faults ‘ ERR ’ and system

Alarms (Warning) ‘ SyS’ .

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

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

There are two types of Fault condition:

Alarm (Warning):

1sec

The Fault LED will ‘slow flash’ to indicate an Alarm

(Warning) condition. An Alarm (Warning) indicates that the X8I is continuing with normal operation but user attention is required. All Alarm (Warning) conditions are registered in the X8I Error Log. All Alarm (Warning)

1sec

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

Fault Codes:

Each individual fault has a unique numeric code.

ERR.01 Pressure Sensor Fault

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

ERR.04 Internal 24V Fault

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

ERR.05 Emergency Stop

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

ERR.06 Real Time Clock Error

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

ERR.07 XPM-LED Module Error

Data communications with the internal XPM-LED (Status

LED Display) module have been disrupted or lost.

ERR.12 ir-PCB Expansion Module C5-8

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

ERR.13 ir-PCB Expansion Module C5-8

Short Circuit condition detected on external ir-PCB

Expansion module ‘C:5-8’.

SyS.01 Excess Pressure (PM)

Pressure has exceeded the set Maximum Pressure Limit.

SyS.02 Min Pressure (Pm)

Pressure has fallen below the set Minimum Pressure Limit

(see ‘Tables’)

SyS.04 Capacity Alarm (Warning)

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

SyS.05 Remote Alarm (Warning)

Auxiliary Input Function ‘AA’

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

SyS.06 Remote Alarm (Warning)

Auxiliary Input Function ‘AR’

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

SyS.07 Remote Trip (Shutdown )

Auxiliary Input Function ‘TA’

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

SyS.08 Remote Trip (Shutdown)

Auxiliary Input Function ‘TR’

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

Internal Controller Fault ‘E’ Codes:

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

All ‘E’ code conditions are Trip (Shutdown) type faults.

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

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

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

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

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

E0866: Controller internal power supply fault

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

E5000: Internal memory map error

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

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

E5001: Internal memory failure

The unit’s controller has detected disruption to the internal permanent application memory storage (FLASH).

The integrity of the FLASH memory contents is suspect.

Re-load the main application software in the first instance; re-new the controller if the condition persists.

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

To Display the Software Version:

Press and hold Reset then press Escape.

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

Item

Part No.

42659250

23242159

80444086

42659268

42659284

39265913

39265905

42659276

38036703

39265939

20mm

IEC

SECTION 11 — PARTS LIST

Description

X8I, Kit

Unit, X8I

Manual, User CD

Unit, Controller

Unit, XPM-PSU24

Unit, XPM-TAC24

PCB, Terminal

Unit, XPM-LED

Gland, Set - Pg13.5

Sensor, Pressure

4-20mA, 232psi (16bar)

Item

Part No.

22194773

80444078

5mm 6

Part No.

39265962

39265970

39265988

Description

IEC Fuse T1.0A

IEC Fuse T1.6A

Description

XI Installation Kit

Quick Setup Guide

Mounting Dimensions:

TECHNICAL DATA

Dimensions 13.4” x 9.45” x 6.0”

340mm x 241mm x 152mm

Weight 16.5lb (7.5kg)

Mounting wall, 4 x screw fixings

Enclosure IP65, NEMA 4

Supply 230Vac +/- 10%

115Vac +/- 10%

Power 100VA

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

Humidity 95% RH, non-condensing

27mm

188mm

27mm

8mm Ø

286mm

SECTION 12 — DIAGRAMS

C031

C032

XPM-LED

X02

T1-46-321-R6-DiC-CG

A-GND

+VDC

Ai1

+VDC

Ai2

+VDC

Ai3

C+

C09

C010

N L E

230Vac 10%

115Vac 10%

C013

C014

C015

C016

C017

C018

C011

C012

C01/3

C01/4

C03

C04

C05

C06

C07

C08

0VDC

0Vac - earthed

24Vac

X03

X02

24VDC

1 2

0Vac

24Vac

C029

C028

X01

24Vac

X03

24VDC

1 2

C019

C020

C021

C022

C023

C024

C025

C026

C027

C011

C012

C013

C014

C015

C016

C017

C018

C019

C020

C021

C022

C023

C024

C025

C026

C027

C028

C029

C030

C033

C034

Terminal PCB

C01

C03

C04

C05

C06

C07

C08

SEQ

GND

C09

C010

C08

C07

C010

C09

24Vac

C034

R-SEQ

C06

C04

C03

C019

10k

C024

150k

C012

SEQ

10k

C023

C027

C018

10k

C022

C026

C031

C032 4-20mA

C016

R-V2

R-V1

R-V4

R-V3

10k

C021

C025

C015

XPM-LED

XPM485

X02

X03

L1 1

L2 2

1 2

Wiring Diagram

X8I

Connection Diagram

Terminal PCB

115V ' UL ' @ 5A maximum.

R1 Auxiliary Output #1

D1 Auxiliary Input #1

330ft (100m) max

Multi485

Ai1 System

Pressure

Di5

Ai2

+20VDC

Ready/Run

Alarm/Serv.

GND

LOAD

SEQ

V4 VFD

330ft (100m) max

IR-PCB 6-core

IRV-PCB 7-core

4-20mA

Di4

Di8

+20VDC

Ready/Run

Alarm/Serv.

GND

LOAD

SEQ

V3 VFD

Di3

Di7

+20VDC

Ready/Run

Alarm/Serv.

GND

LOAD

SEQ

V2 VFD

Di2

Di6

+20VDC

Ready/Run

Alarm/Serv.

GND

LOAD

SEQ

V1 VFD

330ft (100m) max

IR-PCB 6-core

IRV-PCB 7-core

330ft (100m) max

IR-PCB 6-core

IRV-PCB 7-core

330ft (100m) max

IR-PCB 6-core

IRV-PCB 7-core

XPM-TAC24

BLUE

BROWN

RED

GREEN

BLACK

ORANGE

WHITE

VIOLET

IEC

5x20mm

T3.15A T1.6A

FH5 FH4

X03

T1.6A

FH3

X02

1 2 3 4

X04

T1.0A

FH2

VOLTAGE SELECT

230V

115V

T1.0A

N L

2 3 4

X01

FH1

24Vac/2 earthed

24Vac/1 isolated N L E

1 2 3 4

230V +-10%

115V +-10%

Customer

Installation/Site

Software

#1 psi kW cfm

VA Hz

#2 psi kW cfm

VA Hz

#3 psi kW cfm

VA Hz

#4 psi kW cfm

VA Hz

#5 psi kW cfm

VA Hz

#6 psi kW cfm

VA Hz

#7 psi kW cfm

VA Hz

#8 psi kW cfm

VA Hz

Contact

Phone

Ser No.

Comp #1 Manufacturer

Comp #1 Model/Type

Comp #1 Working Pressure

Comp #1 Full Load Capacity

Comp #2 Manufacturer

Comp #2 Model/Type

Comp #2 Working Pressure

Comp #2 Full Load Capacity

Comp #3 Manufacturer

Comp #3 Model/Type

Comp #3 Working Pressure

Comp #3 Full Load Capacity

Comp #4 Manufacturer

Comp #4 Model/Type

Comp #4 Working Pressure

Comp #4 Full Load Capacity

Comp #5 Manufacturer

Comp #5 Model/Type

Comp #5 Working Pressure

Comp #5 Full Load Capacity

Comp #6 Manufacturer

Comp #6 Model/Type

Comp #6 Working Pressure

Comp #6 Full Load Capacity

Comp #7 Manufacturer

Comp #7 Model/Type

Comp #7 Working Pressure

Comp #7 Full Load Capacity

Comp #8 Manufacturer

Comp #8 Model/Type

Comp #8 Working Pressure

Comp #8 Full Load Capacity

X8I COMMISSIONING FORM

Customer Ref:

Internal Ref:

Commission Date

Commission Engineer bar/psi cfm bar/psi cfm bar/psi cfm bar/psi cfm bar/psi cfm bar/psi cfm bar/psi cfm bar/psi cfm

T04

T03

T02

T01

High Pressure Set Point

Low pressure Set Point

Minimum Pressure Alarm

Sequence Rotation Mode

Comp #1 Priority

Comp #2 Priority

Comp #3 Priority

Comp #4 Priority

Comp #5 Priority

Comp #6 Priority

Comp #7 Priority

Comp #8 Priority

High Pressure Set Point

Low pressure Set Point

Minimum Pressure Alarm

Sequence Rotation Mode

Comp #1 Priority

Comp #2 Priority

Comp #3 Priority

Comp #4 Priority

Comp #5 Priority

Comp #6 Priority

Comp #7 Priority

Comp #8 Priority

High Pressure Set Point

Low pressure Set Point

Minimum Pressure Alarm

Sequence Rotation Mode

Comp #1 Priority

Comp #2 Priority

Comp #3 Priority

Comp #4 Priority

Comp #5 Priority

Comp #6 Priority

Comp #7 Priority

Comp #8 Priority

High Pressure Set Point

Low pressure Set Point

Minimum Pressure Alarm

Sequence Rotation Mode

Comp #1 Priority

Comp #2 Priority

Comp #3 Priority

Comp #4 Priority

Comp #5 Priority

Comp #6 Priority

Comp #7 Priority

Comp #8 Priority

EHR FILO ENERGY psi/bar psi/bar psi/bar

EHR FILO ENERGY

EHR FILO ENERGY psi/bar psi/bar psi/bar psi/bar psi/bar psi/bar psi/bar psi/bar psi/bar

S03

S04

S02

S01

P02

Prefill Function

Prefill Time

Prefill Pressure

Primary Compressors

Backup Compressors

Pressure Schedule

Auto Restart

Rotation Interval

Default Table Select

Number of Compressors

Max Pressure Alarm

Stop Control Function

Tolerance

Damping

Pressure Change Time

Auxiliary Input

Auxiliary Output

Capacity Alarm

Capacity Restricted Alarm

Aux I/O Box #1

Aux I/O Box #2

RS485 Timeout

Pressure OffsetA

Pressure Range

!>X A

Sec psi/bar

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

1 2 3 4 5 6 7 8 9 10 11 12 psi/bar min sec psi/bar psi/bar

Compressor #1 Hours

Compressor #2 Hours

Compressor #3 Hours

Compressor #4 Hours

Compressor #5 Hours

Compressor #6 Hours

Compressor #7 Hours

Compressor #8 Hours

Compressor #1 Type

Start Time

Max Capacity

Min Capacity

Min Efficiency

Compressor #2 Type

Start Time

Max Capacity

Min Capacity

Min Efficiency

Compressor #3 Type

Start Time

Max Capacity

Min Capacity

Min Efficiency

Compressor #4 Type

Start Time

Max Capacity

Min Capacity

Min Efficiency

Compressor #5 Type

Start Time

Max Capacity

Min Capacity

Min Efficiency

Compressor #6 Type

Start Time

Max Capacity

Min Capacity

Min Efficiency

Compressor #7 Type

Start Time

Max Capacity

Min Capacity

Min Efficiency

Compressor #8 Type

Start Time

Max Capacity

Min Capacity

Min Efficiency

C03

C01

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

Sec

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

Sec

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

Sec

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

Sec

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

Sec

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

Sec

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

Sec

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

Sec

% hrs hrs hrs hrs hrs hrs hrs hrs

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System Automation

Operator’s Manual

More Than Air. Answers.

SECTION 1 — TABLE OF CONTENTS

SECTION 2 — INTRODUCTION

SECTION 3 —SAFETy

OPERATION

INSTALLATION

MAINTENANCE AND REPAIR

SECTION 4 — COMPRESSOR CONNECTION AND CONTROL

COMPRESSOR CONNECTION AND

CONTROL

OPTIONAL CONNECTION METHODS

PRESSURE DETECTION AND CONTROL

X8I MAIN DISPLAy

SECTION 5 — INSTALLATION OVERVIEW

INSTALLATION

UNIT LOCATION

POWER SUPPLy

PRESSURE SENSOR LOCATION

PRESSURE SENSOR CONNECTION

IR-PCB INTERFACE MODULE

IR-485 AND IRV-485 GATEWAy MODULE

RS485 NETWORK

IR485 COMMUNICATION PROTOCOL

SECTION 6 — CONTROL FEATURES AND FUNCTIONS

STANDARD CONTROL FEATURES AND

FUNCTIONALITy

STANDARD CONTROL FEATURES AND

FUNCTIONALITy

ALTERNATE CONTROL FEATURES AND

FUNCTIONALITy

SECTION 7 — DISPLAy AND MENU OPERATION

INDICATORS

SECTION 8 — COMMISSIONING

PRESSURE DISPLAy

PHySICAL CHECKS

X8I QUICK SET-UP CONFIGURATION

OPTIONAL FEATURES AND FUNCTIONS

SECTION 9 — SySTEM CONFIGURATION

DISPLAy ITEM STRUCTURE ACCESSING THE X8I CONFIGURATION

SCREENS

NORMAL OPERATIONAL DISPLAy (MENU

PAGE P00)

USER LEVEL MENUS

SERVICE LEVEL MENUS

X8I CONFIGURATION SCREENS

NO

NO

X8I COMPRESSOR CONNECTIVITy AND

FUNCTIONAL SETTINGS

E: ERR.01

SECTION 10 — FAULT CODES

X8I COMPRESSOR FAULT INDICATIONS,

TyPES, AND CODES:

SECTION 11 — PARTS LIST

SECTION 12 — DIAGRAMS

X8I COMMISSIONING FORM

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