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Ingersoll Rand
System Automation X4I
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. : 80443617
REV.
: A
DATE : APRIL 2007
SECTION 1 — TABLE OF CONTENTS
SECTION 1 — TABLE OF CONTENTS ............................... 2
SECTION 2 — INTRODUCTION ....................................... 4
SECTION 3 — SAFETY .................................................... 5
INSTALLATION ........................................................... 5
OPERATION................................................................ 5
MAINTENANCE AND REPAIR........................................ 5
SECTION 4 — COMPRESSOR CONNECTION AND CONTROL... 7
COMPRESSOR CONNECTION AND CONTROL ............... 7
PRESSURE DETECTION AND CONTROL ........................ 7
X4I MAIN DISPLAY ...................................................... 8
SECTION 5 — INSTALLATION ......................................... 9
UNIT LOCATION ......................................................... 9
POWER SUPPLY ......................................................... 10
PRESSURE SENSOR LOCATION................................... 10
SUPPLY (WET) SIDE PRESSURE CONTROL ................ 10
DEMAND (DRY) SIDE PRESSURE CONTROL.............. 10
PRESSURE SENSOR CONNECTION .............................. 11
IR-PCB INTERFACE MODULE ..................................... 11
INPUT FUNCTIONS.................................................... 12
READY INPUT ........................................................ 12
READY INPUT, ALTERNATIVE CONNECTION METHOD... 12
RUN INPUT............................................................ 13
WARNING INPUT (OPTIONAL)................................. 13
OUTPUT FUNCTIONS ................................................ 14
PRESSURE SWITCH REGULATION ............................ 14
DIGITAL REGULATION CONTROL TERMINAL C01 ... 14
SERVICE MAINTENANCE SWITCH............................ 15
AUXILIARY INPUT (OPTION) ................................... 15
AUXILIARY OUTPUT (OPTION) ................................ 16
RS485 COMMUNICATIONS .................................... 16
SECTION 6 — CONTROL FEATURES AND FUNCTIONS ... 17
STANDARD CONTROL FEATURES AND FUNCTIONALITY... 17
PRESSURE CONTROL.............................................. 17
ANTI-CYCLING CONTROL...................................... 17
TOLERANCE .......................................................... 17
DAMPING .............................................................. 18
SYSTEM VOLUME................................................... 18
STANDARD CONTROL FEATURES AND FUNCTIONALITY .. 19
STANDARD SEQUENCE CONTROL STRATEGY ......... 19
FIRST IN LAST OUT CONTROL MODE (FILO) ........... 19
FIRST IN LAST OUT ROTATION MODE (FILO) .......... 19
SEQUENCE ROTATION EVENTS .............................. 20
ADVANCED CONTROL FEATURES AND FUNCTIONALITY... 20
ADVANCED SEQUENCE CONTROL STRATEGIES ...... 20
VARIABLE ENERGY CONTROL MODE (VEC) ............. 20
PRIORITY SETTINGS............................................... 20
TABLES AND THE PRESSURE SCHEDULE.................. 21
PRESSURE SCHEDULE............................................. 21
PRE-FILL ............................................................... 22
ALTERNATE CONTROL FEATURES AND FUNCTIONALITY .. 22
EQUAL HOURS RUN MODE..................................... 22
FIRST IN FIRST OUT MODE (FIFO)........................... 23
SECTION 7 — DISPLAY AND MENU OPERATION............ 24
DISPLAY ITEM STRUCTURE ....................................... 26
NORMAL OPERATIONAL DISPLAY (MENU PAGE P00) .. 26
INFORMATION DISPLAYS .......................................... 26
STATUS DISPLAY ................................................... 26
SEQUENCE ROTATION........................................... 26
OPERATIONAL FUNCTIONS ....................................... 27
STOP .................................................................... 27
START .................................................................. 27
POWER FAILURE AUTO-RESTART ........................... 27
FAILURE MODE...................................................... 27
RESET ................................................................... 27
SECTION 8 — COMMISSIONING ................................... 28
PHYSICAL CHECKS ................................................... 28
PRESSURE DISPLAY ................................................... 28
X4I QUICK SET-UP CONFIGURATION......................... 28
SECTION 9 — SYSTEM CONFIGURATION ...................... 29
ACCESSING THE X4I CONFIGURATION SCREENS ........ 29
USER CONFIGURATION: TAB S01 .............................. 29
REAL TIME CLOCK SETTINGS ................................. 30
PRESSURE SCHEDULE SETTINGS ............................. 30
AUTO RESTART SETTINGS ..................................... 31
ROTATION INTERVAL SETTINGS ............................ 31
TABLE SELECT SETTINGS ....................................... 32
BACKLIGHT ADJUST SETTINGS............................... 33
USER CONFIGURATION: TAB S02 .............................. 33
UNITS SETTINGS ................................................... 33
NUMBER OF COMPRESSORS SETTINGS ................... 34
2
MAXIMUM PRESSURE ALARM SETTINGS.................. 34
STOP CONTROL SETTINGS..................................... 35
TOLERANCE SETTINGS........................................... 35
DAMPING SETTINGS .............................................. 36
PRESSURE CHANGE SETTINGS ................................ 36
AUXILIARY INPUT SETTINGS................................... 36
AUXILIARY OUTPUT SETTINGS ............................... 37
ERROR LOG RESET................................................. 38
USER CONFIGURATION: TAB S03 .............................. 38
PRESSURE SENSOR – OFFSET .................................. 39
PRESSURE SENSOR – RANGE SETTINGS ................... 39
COMPRESSOR CONFIGURATION: TAB C01................. 40
COMPRESSOR RUN HOURS..................................... 40
COMPRESSOR CONFIGURATION: TAB C02................. 40
COMPRESSOR CONNECTION METHOD ................... 41
COMPRESSOR TABLE CONFIGURATION: TAB T01....... 42
HIGH PRESSURE SETPOINT SETTINGS ..................... 43
LOW PRESSURE SETPOINT SETTINGS ...................... 43
MINIMUM PRESSURE ALARM SETTINGS................... 44
SEQUENCE STRATEGY SETTINGS ............................ 44
COMPRESSOR #1 PRIORITY SETTINGS .................... 44
COMPRESSOR #2 THROUGH 4 PRIORITY SETTINGS.... 45
PRESSURE SCHEDULE CONFIGURATION P01 TAB SCREEN ... 45
PRESSURE SCHEDULE SETTINGS ............................. 46
PRE-FILL CONFIGURATION P02 TAB SCREEN.......... 46
PRE-FILL FUNCTION SETTINGS .............................. 47
PRE-FILL TIME SETTINGS ....................................... 47
PRE-FILL PRESSURE SETTINGS................................ 48
PRE-FILL COMPRESSOR #1 SETTINGS..................... 48
PRE-FILL COMPRESSOR #2 THROUGH 4 SETTINGS...... 48
DIAGNOSTICS D01 TAB SCREEN................................ 49
DIAGNOSTICS SETTINGS........................................ 49
X4I CONTROLLER DIAGNOSTICS ............................ 49
DIGITAL INPUTS .................................................... 50
RELAY OUTPUTS.................................................... 50
ANALOG INPUTS ................................................... 50
ANALOG OUTPUT.................................................. 50
TOTAL UNIT RESET AND DEFAULT VALUES ............ 50
SECTION 10 — DIAGNOSTIC FUNCTIONS IN THE X04
CONTROLLER ....................................................................... 54
IR-PCB (INGERSOLL RAND COMPRESSOR INTERFACE PCB)..... 54
CONNECTIVITY TO X4I AND DIAGNOSTIC LED
INDICATORS ............................................................ 54
‘IR-PCB’ PRESSURE REGULATION CONTROL INPUTS.. 55
VFD INPUT CONTROL DIAGNOSTIC INDICATOR ..... 55
SEQ (REMOTE PRESSURE REGULATION CONTROL)
INPUT DIAGNOSTIC INDICATOR ............................ 55
LOAD INPUT DIAGNOSTIC INDICATOR................... 55
‘IR-PCB’ STATUS MONITORING OUTPUTS .............. 55
READY SIGNAL DIAGNOSTIC INDICATOR ............... 55
RUN SIGNAL DIAGNOSTIC INDICATOR ................... 55
STATUS SIGNALS...................................................... 56
READY AND RUN STATUS SIGNALS ........................ 56
ALARM (WARNING) AND SERVICE/MAINTENANCE
FUNCTION STATUS SIGNALS.................................. 56
DETERMINING TERMINAL PCB TO CONTROLLER
I/O CONNECTIONS FROM THE X4I WIRING DIAGRAM
FOR USE WITH THE CONTROLLER DIAGNOSTIC TEST
FUNCTIONS.............................................................. 57
COMPRESSOR #1 DIAGNOSTICS ............................ 57
COMPRESSOR #2 DIAGNOSTICS ............................ 57
COMPRESSOR #3 DIAGNOSTICS ............................ 57
COMPRESSOR #4 DIAGNOSTICS ............................ 57
DIGITAL (SWITCHING) INPUT EXCEPTIONS................. 58
SECTION 11 — FAULT CODES ...................................... 59
X4I COMPRESSOR FAULT INDICATIONS, TYPES, AND CODES.. 59
ALARM (WARNING)............................................... 59
NOT AVAILABLE ................................................... 59
COMPRESSOR INHIBITED, REMOVED FROM SERVICE... 59
SERVICE/MAINTENANCE....................................... 59
COMMUNICATIONS DISRUPTION .......................... 59
SPECIAL CONTROLLER FAULT CODES .................... 60
ERROR LOG........................................................... 60
PARTS LIST.................................................................. 61
TECHNICAL DATA ....................................................... 62
DIAGRAMS .................................................................. 63
3
SECTION 2 — INTRODUCTION
The X4I is a specialized controller designed to provide safe, reliable, and energy-efficient control of your compressed air system. The X4I is capable of controlling up to four positive displacement air compressors. The compressors may have electro-pneumatic or microprocessor based controls. The X4I is completely customizable to meet the specific needs of your compressed air system.
4
SECTION 3 — SAFETY
!
W A R N IN G : R is k o f D a n g e r
W A R N IN G : R is k o f E le c tric S h o c k
W A R N IN G : R is k o f H ig h P re s s u re
!
W A R N IN G : C o n s u lt M a n u a l
•
•
•
•
Before installing or operating the X4I, 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
X4I.
The X4I 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 X4I, they must not interfere with normal operation or obstruct access.
Platforms and stairs should be of grid or plate construction with safety rails on all open sides.
OPERATION
•
•
•
•
•
•
•
The X4I must only be operated by competent personnel under qualified supervision.
Never remove or tamper with safety devices, guards or insulation materials fitted to the X4I.
The X4I 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 two warning signs to the equipment stating “THIS UNIT CAN
BE STARTED REMOTELY”. Attach one sign in a prominent location on the outside of the equipment, and the other sign inside the equipment control compartment.
MAINTENANCE AND REPAIR
•
•
•
Maintenance, repairs or modifications must only be carried out by competent personnel under qualified supervision.
If replacement parts are required, use only genuine parts from the original equipment manufacturer, or an alternative approved source.
Carry out the following operations before opening or removing any access panels or carrying out any work on the X4I:
5
• i. Isolate the X4I from the main electrical power supply. Lock the isolator in the “OFF” position and remove the fuses.
ii. Attach labels to the isolator switch and to the unit stating
“WORK IN PROGRESS - DO NOT
APPLY VOLTAGE”. Do not switch on electrical power or attempt to start the X4I 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 X4I 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.
6
SECTION 4 — COMPRESSOR CONNECTION AND CONTROL
COMPRESSOR CONNECTION AND CONTROL
Each air compressor in your system can be interfaced to the
X4I using the included IR-PCB interface modules. Any compressor with an available control voltage of 12-250V
(either 50Hz or 60Hz) can be controlled by the X4I.
The interface module is mounted inside the compressor’s starter panel and connected to the X4I by using a shielded
7-conductor cable or individual cables run through grounded conduit.
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 X4I.
PRESSURE DETECTION AND CONTROL
The X4I utilizes the signal from a 4-20 mA pressure sensor that is mounted remotely from the X4I 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 X4I can accept any pressure sensor with a 4–20 mA output and a range of up to 8700 PSI (600 bar).
7
X4I MAIN DISPLAY
d f g
1
A
h a b
1
2
B
PSI 102
10:35
3 4
C D
c e
12:00 #1 a b a) b) c) d) e) f) g) h)
User Interface
The User Interface display functiuonality is depicted below:
User Interface DisplayUser Interface
Display Functionality
System Pressure Value
System pressure Units
Unit Status
Unit Active Functions
Time
Compressor Number
Compressor Sequence Assignment
Compressor Status
To view the next automated Sequence
Rotation display, Press Down:
User Interface Display Functionality a) b)
Time of day (24hrs)
Day of the week
#1 = Monday to #7 = Sunday
Unit Run Indicator (Green LED)
OFF – Not Active, Stopped
Slow Flash: Active, Standby Mode
ON – Active, Running
Unit Fault Indicator (Red LED)
Fast Flash: Shutdown (Trip)
Slow Flash – Alarm (Warning) f a g b h e c d
8
The keypad and navigation keys on the X4I are depicted below and provide the following functionality.
Keypad and Navigational Keys Functionality e) f) g) h) a) b) c) d)
Start
Reset
Stop
Menu
Enter
Escape
Up (Plus)
Down (Minus)
SECTION 5 — INSTALLATION
It is recommended that installation and commissioning be carried out by an authorized and trained product supplier.
UNIT LOCATION
The X4I can be mounted on a wall using conventional bolts.
The X4I can be located remotely from the compressors as long as it is within 330 feet (100 meters) of cable length.
The X4I must also be located within 330 feet (100 meters) of the system pressure transducer.
SPECIFICATIONS
Dimensions 11.45” x 9.45” x 6.0”
291mm x 241mm x 152mm
Weight
Mounting
Enclosure
Supply
14lb (6.4kg)
Wall, 4 x screw fixings
IP65, NEMA 4
230Vac +/- 10%, 50 Hz
Power
115Vac +/- 10%, 60 Hz
50VA
Temperature 32°F to 115°F
Humidity
(0°C to 46°C)
0% to 95% RH
(non-condensing)
Ingersoll Rand Automation
Model X4I
COMPRESSOR CONTROL CABLE
7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
OR
Single Conductor Wire, 18 Gauge Stranded, Quantity (7)
In Grounded Conduit
No Greater Than 330FT (100M)
24VAC Control Voltage
Local Disconnect (Breaker) Box
Fused for 50VA On/Off
Switch Supply Voltage Cable
Power Cable
3 conductor (L, N, E)
(Sized in accordance with local electrical and safety regulations).
PRESSURE TRANSDUCER CABLE
2 Conductor Cable, 18 Gauge Stranded
Earth Shielded
No Greater Than 330FT (100M)
24VDC Control Voltage
X4I X05 CONNECTOR
25
26
PT CONNECTOR
+VDC Pin #3
Signal Pin #1
Reference X4I Operations Manual for Pressure
Sensor Connection Details
Pressure Transducer Cable
Compressor
#1
IR-PCB
Compressor #1 Control Cable
X4I X01 CONNECTOR
V1
1
2
5
6
3
4
IR-PCB CONNECTOR
V1
1
2
5
6
3
4
PRESSURE TRANSDUCER
Compressor #4 Control Cable
Compressor #3 Control Cable
Compressor #2 Control Cable
Compressor #1 Control Cable
Reference X4I Compressor
Interconnect and Application Guide
For Connections Between The
Compressor And The IR-PCB
Compressor
#2
IR-PCB
Compressor #2 Control Cable
X4I X02 CONNECTOR
V3
7
8
9
10
11
12
IR-PCB CONNECTOR
V1
1
2
5
6
3
4
RECEIVER
DRIP LEG
Compressor
#3
IR-PCB
Compressor #3 Control Cable
X4I X03 CONNECTOR
V3
13
14
15
16
17
18
IR-PCB CONNECTOR
V1
1
2
5
6
3
4
Compressor
#4
IR-PCB
Compressor #4 Control Cable
X4I X04 CONNECTOR
V4
19
20
21
22
23
24
IR-PCB CONNECTOR
V1
1
2
5
6
3
4
9
POWER SUPPLY
A fused switching isolator must be installed to the main incoming power supply, external to the X4I. The isolator must be fitted with a properly sized fuse to provide adequate protection to the power supply cable used (in accordance with local electrical and safety regulations).
1 2 3 4
X P M -T AC 2 4
1
X 0 4
L N E E
X 0 1
L N E
X 0 4
1
2 3
VO L TAG E S E L E C T
2 3
4
4
2 3 0 V a c
VO L TAG E S E L E C T
1 1 5 V a c
Power Supply Terminals
Ensure that the voltage select input is properly jumpered for the incoming power. Default voltage configuration is 230Vac.
PRESSURE SENSOR LOCATION
The system pressure sensor (P) must be located where it will see the air pressure that is common to all of the compressors.
SUPPLY (WET) SIDE PRESSURE CONTROL
P
1 P
DEMAND (DRY) SIDE PRESSURE CONTROL
1 P P
2
Pressure Sensor Located After Shared Cleanup
Equipment
P P
1
P
2
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.
2
Pressure Sensor Located Before Cleanup Equipment
Dry side pressure will be lower than the system pressure due to pressure differential losses across air treatment equipment. The nominal system pressure will reduce as the air treatment differential pressure increases.
10
PRESSURE SENSOR CONNECTION
The pressure sensor connects to terminal X05 of the X4I 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.
Pressure Sensor Wiring and Location
Wire polarity is important.
IR-PCB INTERFACE MODULE
The IR-PCB is designed to interface a compressor with the
X4I using a 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.
For each compressor utilizing an IR-PCB, connection to the
X4I the signal wires must be made to the correct X4I 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.
C05
1
2
2
3
4
V
1
5
6
V
SEQ CONT
LOAD UNL
C03 GND
D11
D12
+20V
LED 5 V
LED 2 LOAD
LED 1 SEQ
+VDC
C01 VFD/fixed
Load Enable
Load/Unload
C02
NO
C
NC
NO
C
NC
ALARM
C04 RUN
READY
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 voltfree switching contact input for remote load/unload. Each air compressor must have Auto Restart capability.
V
For variable speed compressor(s) equipped with a
“variable/fixed” digital input function, install a 7-conductor shielded cable from the IR-PCB to the X4I.
11
Consult the air compressor manual or your air compressor supplier/specialist for details before installing the X4I.
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.
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
X4I providing protection and voltage isolation.
The voltage to this input must de-energize when the compressor is stopped and unavailable to produce air upon a load signal, or the emergency stop button is pressed, or when the compressor experiences a fault that prevents the compressor from running.
When the compressor ready lamp or other control circuit is energized, the IR-PCB will detect the voltage and signal the
X4I that the compressor is ready and available to load and produce air when a load request signal is given.
The IR-PCB common input terminal must always be connected to the neutral, common or 0V line of the applied input voltage.
Consult the X4I Interconnect and Application Guide prior to the installation of the X4I and the IR-PCB to the air compressor.
INPUT FUNCTIONS
The IR-PCB is fitted with a six-pin terminal, C04, for compressor monitoring. The IR-PCB uses two inputs, Ready and Run, to determine compressor status. An alarm input can be used if compressor warning indication is available and required. The alarm input is optional and is not necessary for system operation.
READY INPUT
The ‘Ready’ connection is intended to indicate that the compressor is in a “started” state, has no alarm condition that has shut down the compressor, and is ready to respond to X4I regulation without manual intervention.
+ V
R E A D Y L A M P 0 V
READY INPUT, ALTERNATIVE CONNECTION METHOD
In instances where a convenient voltage signal for a compressor ready condition is not available, the “ready” input can be connected directly to a constant compressor control voltage (12V to 250Vac or dc). This will signal the
X4I that the compressor is ready and available at all times when power is applied to the compressor. The X4I has a built-in function to determine when a compressor is not responding, or is in a shutdown condition, even if the
“ready” signal says otherwise. If the X4I requests a compressor to run/load, but fails to detect a RUN signal within 60 seconds, the X4I will regard the compressor as
“not ready” and indicate the compressor as not available. If a RUN signal is reacquired at any time, the X4I will automatically reset the compressor “not ready” condition and re-establish control.
+ V a c
F 1
0 V a c
A L A R M R U N R E A D Y
C 0 4
Typical Ready Input Wiring
The READY input will accept 12V to 250V ac (50/60Hz) or dc.
Do not connect a voltage greater than 250Vac/dc to this input.
This input must be connected to a circuit of the compressor control system that will be energized when the compressor is in a started (standby or running) condition. For example, locate the circuit across the ready or operating lamp as shown.
R E A D Y
Alternative Ready Signal Connection
Never connect the “Ready” input positive voltage connection directly to the output of a control system transformer. Always connect after a fuse or circuit breaker.
If a normally closed contact of an emergency stop button is included in the compressor power supply circuit, connect after the emergency stop button contacts. This will instantly indicate a compressor “not ready” condition if the emergency stop button is activated.
12
RUN INPUT
+ V
M A IN (L IN E ) C O N T A C T O R
0 V
0 V
0 V
The IR-PCB input common terminal must always be connected to the neutral, common or 0V line of the applied input voltage.
WARNING INPUT (OPTIONAL)
The IR-PCB is equipped with a warning input that can be used to detect warning conditions.
An alarm that stops the compressor, and/or prevents the compressor from running is determined from the “run” and “ready” inputs. Warning detection is optional and is not a requirement.
A la rm L a m p
0 V
+ V
A L A R M R U N R E A D Y
C 0 4
Run Signal Circuit
The RUN input will accept 12V to 250V AC (50/60Hz) only.
DC cannot be used.
Do not connect a voltage greater than 250V to this input.
12V to 250Vac must be applied to the “run” terminals when the compressor motor is running.
This input can be connected to the control terminals A1 and
A2 (coil) of the main starter contactor of the compressor.
When the compressor control system energizes the main contactor, the IR-PCB will detect the voltage across the contactor coil terminals and signal the X4I that the compressor is running.
Alternatively, if the main contactor coil voltage is greater than 250Vac, a contactor auxiliary switch can be used to apply a suitable voltage to the “run” input terminals.
M A IN (L IN E ) C O N T A C T O R
+ V
+ V
A U X IL IA R Y S W IT C H
A L A R M R U N R E A D Y
C 0 4
Run Signal Circuit with Auxiliary Switch
In instances where a motor starter contactor is not available or accessible, any part of a compressor control circuit that is energized when the compressor is running can be monitored. For example: fan contactor or voltage signal to a remote starter.
A la rm R u n
C 0 4
R e a d y
Warning Input Circuit
The warning input will accept 12V to 250V AC (50/60Hz) or
DC.
Do not connect a voltage greater than 250Vac/DC to this input.
This input can be connected to the terminals of an alarm lamp or other accessible part of the control circuit that is energized when the compressor is in a warning condition.
If a warning condition is experienced the compressor warning lamp, or warning circuit, will energize. The IR-PCB will detect the voltage and signal the X4I that a warning has occurred. If the compressor has no accessible warning circuit, or this function is not required, the IR-PCB alarm terminals can be ignored.
The IR-PCB input common terminal must always be connected to the neutral, common or 0V line of the applied input voltage.
13
OUTPUT FUNCTIONS
The X4I will control the IR-PCB load/unload relay outputs based on the active system load and unload pressure setpoints. The IR-PCB load/unload relay contacts can be used for compressor controllers that have electromechanical pressure switch load/unload regulation.
+ V
L O A D
S O L E N O ID
0 V
+ V
O U T
C 0 2
IN
Two Wire Pressure Switch Connections
L O A D
S O L E N O ID
0 V
R U N -O N
T IM E R
IR-PCB Internal Output Circuits
The C01 and C02 terminals of the IR-PCB are intended to control load and unload regulation of the compressor.
PRESSURE SWITCH REGULATION
For air compressors fitted with an electro-mechanical pressure switch, a six-pin terminal C02 has been provided to enable connection to a pressure switch that has a twowire or three-wire connection.
When connected, the pressure switch can be switched in and out of circuit automatically. If the X4I is stopped or experiences a failure or loss of power, pressure control will automatically revert back to the pressure switch and the compressor will continue to operate in “local” mode.
The local pressure settings of all compressors in the system should be set in a cascaded manner such that the system will operate normally in the event of X4I inoperability.
The NC (normally closed) and NO (normally open) terminal references of the IR-PCB are related to internal connection functions and should not be referenced to the connections of a compressor pressure switch, which will generally be in reverse order.
Lethal voltages may be present on the terminals of the air compressor pressure switch. Isolate the air compressor power supply before starting any work.
O U T
C 0 2
IN
Three Wire Pressure Switch Connections
DIGITAL REGULATION CONTROL TERMINAL C01
A 4-pin connector, C01, has been provided for air compressor controllers fitted with digital inputs allowing remote pressure regulation control.
This terminal provides volt free contact closure, referenced to a common terminal pin, for:
•
Remote Load Enable (remote/local pressure regulation control)
•
•
Remote Load (remote load/unload)
Remote Variable Speed Regulation Inhibit
(remote variable/fixed speed regulation control)
The “remote load enable” function provides the facility to change the compressor load regulation from internal control to a remote switching source (local/remote).
V
The “remote variable/fixed” function provides for multiple variable speed compressor regulation control on variable speed compressor(s) equipped with this facility.
When using the “Variable/Fixed” function, the “V” terminal of the IR-PCB must be connected to the appropriate “V” terminal of the X4I (according to compressor number) with an additional wire. Use a 7conductor shielded cable in this instance.
14
Compressors that use electronic pressure detection but are not equipped with a remote pressure control enable feature will not automatically revert to local control if the
X4I is stopped or experiences a fault or loss of power.
+ V D C
V F D /F ixe d
L o a d E n a b le
L o a d /U n lo a d
+ V D C
V F D /F ixe d
L o a d E n a b le
L o a d /U n lo a d
The IR-PCB connection examples shown in this manual are intended to provide a guide for the majority of compressor control systems in use. Some compressors have variations in operation and/or function; consult your compressor supplier/specialist for advice.
SERVICE MAINTENANCE SWITCH
The IR-PCB is equipped with a volt-free input (terminal
C05) that can be used to remove the compressor from X4I control, without generating a fault condition, during shortterm maintenance or servicing periods.
C05
1
2 ir-P C B
Load, Sequence, and VFD Connections
Compressor controller inputs common voltage may be
0V or +V.
The local/remote pressure regulation input and/or remote load input logic of some electronic pressure sensor type controllers are reversed. In this instance, the “pressure switch” outputs (terminal C02) can be used to establish alternative logic control connections.
For Example:
If the compressor controller “Local/Remote Pressure
Control” input is a normally open type (local when open, remote when closed), but the “Remote Load” input is a normally closed type (load when open), the IR-PCB pressure switch terminal contacts can be used to achieve the correct switching logic.
N O
O U T C
N C
N O
IN
C
N C
C 0 2
L o c a l/R e m o te c o m m o n
R e m o te L o a d c o m m o n
Service Maintenance Switch Circuit
When the “Service Maintenance Switch” input terminal pins are connected together using a volt-free switching contact, the X4I will indicate that the compressor is not available but will not generate a warning, alarm, or shutdown condition.
The X4I will also remove the compressor from the sequence strategy and substitute with an alternative available compressor if necessary. When the “Service Maintenance
Switch” input circuit is open again, the compressor will automatically be accepted back in to the sequence strategy and will be utilized when next required.
The use of a “key switch” is recommended for this purpose in order to prevent the switch contacts being inadvertently left in the closed circuit condition after service maintenance is complete.
DO NOT connect any external voltage source to the pins of terminal C05.
AUXILIARY INPUT (OPTION)
The X4I is equipped with an auxiliary input at terminals 31 and 32 (X07).
The function of the input is menu selectable and can be adapted for differing application requirements.
X07
32
31
Alternate Logic
Examine the “i-PCB” internal output circuit diagram to establish any desired switching logic that may differ from normal practice.
Do not attempt to utilize “Digital Pressure Regulation
Control” (terminal C01) and the “Pressure Switch Control”
(terminal C02) output connections at the same time for different products. These two output functions are internally connected and a short circuit condition and/or malfunction may result.
Auxiliary Input Circuit
The input is designed to detect a remote “volt-free” switching contact (rated for a minimum 24VDC @ 10mA).
15
AUXILIARY OUTPUT (OPTION)
The X4I is equipped with a remote relay contact output at terminals 33 and 34 (X08).
The function of the output is menu selectable and can be adapted for differing application requirements.
X08
R6
34
33
Auxiliary Output Circuit
The remote output relay contacts are rated for 240V “CE” /
115V “UL” @ 5A maximum.
RS485 COMMUNICATIONS
The X4I is equipped with an RS485 network communications capability using the proprietary Multi485 protocol.
This can be only used for remote connectivity to optional X4I expansion networked units and modules with proprietary Multi485 communications capabilities.
X06
L1
L2
30
29
28
27
RS485
L1
L2
RS-485 Connection Circuit
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 shielded cables, securely bonded to a known ground at one end. In addition, give careful consideration to cable routing during installation.
•
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.
•
•
If it is necessary to follow the route of power supply cables for a short distance
(for example: from a compressor to a wall along a suspended cable tray), attach the
RS485 or signal cable on the outside of a grounded cable tray such that the cable tray forms a grounded electrical interference shield.
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.
16
SECTION 6 — CONTROL FEATURES AND FUNCTIONS
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
PRESSURE CONTROL
Pressure control is achieved by maintaining the system pressure within an acceptable range, or pressure band, which is defined and programmed by the user. Pressure will rise in the band when system demand is less than the loaded compressor’s output. Pressure will fall in the band when system demand is greater than the loaded compressor’s output.
Simply stated, pressure control is achieved by unloading and loading compressors to closely match compressor output with system demand within a specified pressure band defined by PL and PH. See Figure 1.
Variable speed compressors also operate within the pressure band and actively match compressor output with system demand by speeding up and slowing down around a target pressure defined by the exact midpoint of the pressure band defined by PT. See Figure 2.
a b
PH
PT
PL
When a compressed air system includes one or more variable speed compressors, each variable speed compressor must have its target pressure (on its local controller) set to the system target pressure.
The variable speed compressors in the system will run on their target pressure and smooth out the variations in system pressure. This assumes that system demand does not vary more than the capacity of the variable speed compressor.
A variable speed compressor will be included in the load/ unload sequence and be controlled exactly as a fixed speed machine with the exception of speed control to maintain target pressure.
ANTI-CYCLING CONTROL
The most efficient way to utilize most air compressors is either fully loaded or off, with the exception of variable speed compressors which can operate efficiently at reduced loading. Compressor cycling (start-load-unload-stop, etc.) is essential to maintain pressure control. Excessive cycling, however, can result in poor compressor efficiency as well as increased maintenance.
Anti-cycling control is incorporated to help ensure that only the compressors that are actually required are started and operating while all others are kept off. Anti-cycling control includes a pressure tolerance range or band, defined by the user, which is outside of the primary pressure band. Inside the tolerance band , an active control algorithm continually analyzes pressure dynamics to determine the last possible second to add or cycle another compressor into the system.
This control is further enhanced by the ability to fine tune the tolerance band settings and algorithm processing time
(Damping).
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 X4I will load the next compressor in the sequence to match the air demand. This cycle will repeat as long as the X4I is able to keep the system air pressure between PH and PL.
TOLERANCE
Tolerance is a user adjustable setting that determines how far above the PH setpoint and below the PL setpoint system pressure will be allowed to stray. Tolerance keeps the X4I from overcompensating in the event of a temporary significant increase or decrease in system demand.
PH
PT
PL
TO
TO
PH + TO
PH
PT
PL
PL - TO
Figure 2 — Typical VSD Pressure Control vs. Time
17
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 X4I 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 X4I 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 X4I’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 X4I 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 X4I 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 X4I. 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
utilizing air receivers.
operating conditions.
+
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 overpressurization in response to abrupt pressure fluctuations.
Adequate system volume is created by correctly sizing and
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
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, Ft
3
, m
3
, L)
T — “Time to Start Back-up Compressor” (Minutes)
C — “Lost Capacity of Compressed Air” (CFM, m
3
/min)
Pa — “Atmospheric pressure” (PSIa, BAR)
P — “Allowable Pressure Drop” (PSI, BAR)
18
Example 1: Find Required Storage Volume in Ft
3 and US Gal.
(4) - 25 Hp Compressors at 92 CFM (2.6 m
3
) each / 15 seconds to start and load a compressor. 5PSIG is the maximum allowable pressure drop.
T=15 Seconds (.25 minute)
C=92 ft
3
Pa = 14.5 PSI
Delta P = 5 PSI
V = [.25 x (92 x 14.5)]/5
V = (.25 x 1334)/5
V = 333.5/5
V = 67 Ft
3
1 ft
3
= 7.48 Gal
Gal= 67 Ft
3
x 7.48
Gal = 498.9
Example 2: Find Required Storage Volume in m
3 and L.
(4) - 25 Hp Compressors at 92 CFM (2.6 m
3
) each / 15 seconds to start and load a compressor. 0.34 BAR is the maximum allowable pressure drop.
T=15 Seconds (.25 minute)
C=2.6 m
3
Pa = 1BAR
Delta P = .34 BAR
V = [.25 x (2.6 x 1)]/.34
V = (.25 x 2.6)/.34
V = .65/.34
V = 1.91 m
3
1m
3
= 1000 L
L= 1.91 m 3 x 1000
L = 1910
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
STANDARD SEQUENCE CONTROL STRATEGY
The standard configuration of the X4I provides FILO (First
In/Last Out) sequence control strategy.
The sequence control strategy consists of two components:
•
The compressor rotation strategy
•
The compressor load control strategy
The rotation strategy defines how the compressors are arranged in a new sequence whenever a rotation event occurs. Rotation events are triggered by a periodic rotation based on a set interval, a set time of day each day, or a set time of day once a week.
The compressor load control strategy defines when compressors load and unload based on system pressure variations and whether they run in fixed or variable speed modes.
Each compressor in a system will be assigned a permanent number based on where they are wired into the terminal
PCB. Compressor 1 will always be wired into terminal X01; compressor 2 will always be wired into terminal X02, etc.
Each compressor will also be assigned a letter from A to D based on its location in the sequence:
•
A = the base load compressor (the first compressor to be used).
•
•
•
B = the first trim compressor (the second compressor to be used).
C = the second trim compressor (the third compressor to be used).
D = the third trim compressor (the last compressor to be used).
Compressor sequence assignments are reviewed and dynamically changed at a rotation event based on the sequencing strategy that is selected.
FIRST IN LAST OUT CONTROL MODE (FILO)
Compressor load sequence will be A, B, C, D and
Unload sequence D, C, B, A
FIRST IN LAST OUT ROTATION MODE (FILO)
The default configuration of the X4I provides FILO (First In/
Last Out) sequence control strategy.
The primary function of FILO (First In/Last Out) mode is to efficiently operate a compressed air system consisting of fixed speed compressors. The standard FILO rotation assignments can be modified using priority settings, which are explained later in this section.
Whenever a rotation event occurs, the sequence assignment for each compressor is rearranged. The compressor that was assigned as the base load compressor (A) is reassigned to third trim compressor (D) and all other compressors are incremented by one.
1 2 3 4
#1
#2
#3
#4
A B C D
D A B C
C D A B
B C D A
Sequence Rotation Table
19
SEQUENCE ROTATION EVENTS Compressor A will always be the first to be loaded and last to be unloaded.
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.
ADVANCED CONTROL FEATURES AND
FUNCTIONALITY
ADVANCED SEQUENCE CONTROL STRATEGIES
The advanced configuration of the X4I provides VEC
(Variable Energy Control) sequence control strategy, Priority
Settings, Table Selection, and Pre-fill operation.
VARIABLE ENERGY CONTROL MODE (VEC)
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 4, where 1 is the highest priority. Any compressor can be assigned any priority and any number of compressors can share the same priority.
Priorities allow you to set up rotation groups. All compressors that have the same priority number will rotate inside their own group. The group with the highest priority will always be in the front of the sequence.
For example, in a four compressor system including one variable speed compressor in the compressor 1 position you may want the variable speed compressor to always be in the Lead position. By assigning compressor 1 a priority of
1 and the other three compressors a priority of 2, the variable speed compressor will always remain at the front of the sequence:
The primary function of VEC mode is to accommodate a variable speed compressor connected to the X4I using an
IRV-PCB interface.
VEC mode utilizes the FILO sequencing and rotation strategy with the additional control philosophy needed to efficiently control variable speed compressors.
In any set rotation sequence, the variable speed compressor that is assigned closest to A will be utilized in trim mode and will be allowed to vary its speed based on its local target pressure setpoint and the variations in system pressure. If there are additional variable speed compressors in the system, each subsequent variable speed compressor to load will be placed into variable speed mode and the previous variable speed compressor will be switched and held in fixed speed mode. This will prevent multiple variable speed compressors from oscillating. An example would be if 1 and 2 are both variable speed compressors, when the load drops outside the pressure band, 1 will load first as a variable speed compressor. If the pressure continues to drop, then 2 will load as a variable speed compressor and 1 will be switched to fixed speed.
The compressor that is allowed to run in variable speed mode will be evaluated at each rotation event.
When a compressed air system includes one or more variable speed compressors, each variable speed compressor must have its target pressure (on its local controller) set to the system target pressure.
Compressors are brought on or offline in response to changing demand using the FILO strategy. The base load compressor (A) will be brought online first in the case of system pressure dropping below the low pressure setpoint.
If pressure continues to drop, the first trim compressor (B) will also load. Compressors C and D will load in that order if needed. When system pressure rises above the high pressure setpoint, the last compressor to load will now be the first to be unloaded. Compressors C, B, and A will be unloaded, in that order, if system pressure continues to increase.
20
#1
#2
#3
#4
1 2 3 4
1 2 2 2
A B C D
A C D B
A D B C
A B C D
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:
#3
#4
#1
#2
1
1
A
B
C
A
2
1
B
C
A
B
3
1
C
A
B
C
4
2
D
D
D
D
Compressor 4 has priority 2, all other compressors have priority 1
In a third example, there is a four compressor system that includes a variable speed compressor designated compressor 1 and a fixed speed compressor that is an emergency backup assigned as compressor 4. To ensure that compressor 1 is always at the front of the sequence and compressor 4 is always at the end of the sequence, set the priority as shown below:
#3
#4
#1
#2
1 2 3 4
1 2 2 3
A B C D
A C B D
A B C D
A C B D
Compressor 1 has priority 1, compressor 4 has priority
3 and all other compressors have priority 2
A last example involves another four compressor system that will be assigned into two independently rotation groups. Compressors 1 and 2 are given priority 1 and compressors 3 and 4 are given priority 2. This results in the rotation sequence shown below:
#1
#2
#3
#4
1
1
A
B
A
B
2 3 4
1 2 2
B C D
A D C
B C D
A D C
Two independently rotating compressor groups
TABLES AND THE PRESSURE SCHEDULE
T01
PH
PL
Pm
SQ
- - - -
- - - -
- - - -
- - - -
The X4I operates based on settings that are configured into one of three tables. Each table defines the operational settings and sequence control mode of the X4I. The X4I can be instructed to change among the tables at any time based on the configuration of the pressure schedule.
This functionality allows the X4I 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 X4I is instructed to change between tables, it will not abruptly change the system operating parameters. The
X4I 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:
1 2
PC
Changing Target Pressures
The time the system is allotted to change the target pressure is known as the Pressure Change Time (PC). This is a value that is adjustable in the system settings screen. See the Quick Setup Manual.
If the X4I 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 X4I 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.
21
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.
ALTERNATE CONTROL FEATURES AND
FUNCTIONALITY
The alternate control strategies of the X4I provides EHR
(Equal Hours Run) and FIFO (First In/First Out) sequence control strategy.
PRE-FILL
The pre-fill feature provides an energy efficient method of increasing pressure to normal operating levels upon system start. This feature avoids the inefficient potential for all compressors to start and load in an attempt to quickly get the system pressure up to normal levels:
System pressure during pre-fill
At system start (manual start or automated start from standby), the X4I will only load compressors that have been pre-set for pre-fill operation, for a pre-set period of time.
The pre-fill 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 pre-fill time expiring.
If normal operational pressure is reached prior to the set pre-fill time, the pre-fill function will automatically cease and normal operational control will begin. If normal operational pressure is not reached by the end of the prefill time, the X4I will utilize as many available compressors as required to achieve normal operational pressure as quickly as possible. Normal operational control will then begin.
Two pre-fill modes are available. Both function in the same way but differ in response to a failure, or loss, of a pre-fill compressor.
•
•
Backup 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
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.
To manually skip pre-fill mode, press and hold START for several seconds.
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 a rotation event occurs, the compressor sequence is examined and will be rearranged based on the running hours recorded for each compressor. The compressor with the fewest running hours is assigned as the base load compressor and the compressor with the most running hours is assigned as the third trim compressor. For systems with more than two compressors, the compressors will be assigned from A to D in accordance with increasing running hours.
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 X4I continuously monitors the running status of each compressor and calculates the accumulated running hours.
These readings are viewable and adjustable in the X4I C01 setting screens. The X4I will use these values during EHR mode. The running hours on the X4I 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
X4I, the running hours record may not be accurately updated.
22
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.
Compressors will be utilized following the FILO strategy.
FIRST IN FIRST OUT MODE (FIFO)
The primary function of FIFO mode is to minimize the utilization on any one compressor. This control strategy is commonly used with air cooled reciprocating compressors.
FIFO is not designed as an energy efficient mode of operation.
FIFO does not follow sequence rotation events.
Compressors are rotated each time a compressor is loaded.
The rotation strategy becomes the control strategy using the control mode.
When system pressure drops below the low pressure setpoint, compressor 1 (A) will be the first to load as usual.
If system pressure continues to decrease, compressor 2 (B) will be loaded and be reassigned to (A) while compressor 1 is reassigned as (D). If this causes system pressure to rise above the high pressure setpoint, then compressor 1 (D) will be unloaded to allow compressor 2 (A) to maximize its run time. If system pressure decreases further, compressor
3 will be loaded and reassigned to (A) while Compressor 2 is reassigned to (D) and so on.
The most recently loaded compressor will always be assigned (A) and the longest running compressor will always be assigned (D).
3
4
1
2
ABCD DABC DABC CDAB BCDA BCDA BCDA ABCD
FIFO Rotation
23
SECTION 7 — DISPLAY AND MENU OPERATION
The Main Display and the keypad and navigation buttons on the X4I are depicted below and provide the following functionality: d f g
1
A h a b
1
2
B
PSI 102
10:35
3
C
4
D c e d) e) f) a) b) c) g) h)
User Interface
The User Interface display functiuonality is depicted below:
User Interface DisplayUser Interface
Display Functionality
System Pressure Value
System pressure Units
Unit Status
Unit Active Functions
Time
Compressor Number
Compressor Sequence Assignment
Compressor Status
12:00 #1 a b
To view the next automated Sequence
Rotation display, Press Down:
User Interface Display Functionality a) Time of day (24hrs) b) Day of the week
#1 = Monday to #7 = Sunday
Unit Run Indicator (Green LED)
OFF – Not Active, Stopped
Slow Flash: Active, Standby Mode
ON – Active, Running
Unit Fault Indicator (Red LED)
Fast Flash: Shutdown (Trip)
Slow Flash – Alarm (Warning) f a g b h e c d
24
The keypad and navigation keys on the X4I are depicted below and provide the following functionality.
Keypad and Navigational Keys Functionality e) f) g) h) a) b) c) d)
Start
Reset
Stop
Menu
Enter
Escape
Up (Plus)
Down (Minus)
Unit Functions:
The following Icons are used by the X4I to display the Controller Active Functions.
Operating Mode:
EHR- Equal Hours Run
FIFO – First In First Out
FILO –
First In Last Out
VEC – Variable Speed Energy Control
Active Functions:
Power Failure Auto-Restart
Table #1
1
2
3
Table #2
Table #3
Remote Manual Override
Prefill Function
Pressure Schedule
Function Inhibited (manual override)
System Pressure Value
System Pressure Units
System Pressure Status:
The following Icons are used by the X4I to display the 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
Unit Status:
The following Icons are used by the X4I to display the Controller Status.
Stopped
Standby
Started and Running
Compressor Status:
The following Icons are used by the X4I to display the Compressor/s Status.
Stopped
Standby (or Auto Restart)
Service Maintenance Active
Alarm (Warning)
Running Offload
Running Loaded
Not Available (Stopped, Shutdown, Trip)
Inhibited from use in Table
25
Real Time Clock
24 Hour Format
DISPLAY ITEM STRUCTURE
Operational system status and values are accessible from the normal user display. To view status or values that are not normally visible on the default screen, press UP or
DOWN. All standard user display items are viewable only and cannot be adjusted. The standard user display items are regarded as “Menu Page 00” items.
All adjustable value, parameter or option item displays are grouped into “menu mode” lists. Items are assigned to a list according to type and classification. Item lists are identified by page number (or menu number). All adjustable parameters and options are assigned to menu mode pages
“P01” or higher.
NORMAL OPERATIONAL DISPLAY (MENU
PAGE P00)
At controller initialization, all display elements and LED indicators are switched on for three seconds and then the normal operating display is shown. In normal operational display mode, the main display will continuously show the detected system pressure and the Item display will show the first item of the “Page 00” menu. User menu “items” can be selected using the UP or DOWN buttons at any time.
Pressing the ENTER button will lock any selected item display and inhibit return to the default display. When an item display is locked, the “lock key” symbol will be shown.
To unlock an item display, press UP or DOWN to view an alternative item display or press RESET or ESCAPE. No item values, options or parameters can be adjusted in “Page
P00”. If a fault condition occurs, the fault code becomes the first list item and the display will automatically jump to display the fault code. More than one active fault code item can exist at any one time and can be viewed by pressing UP or DOWN. The most recent “active” fault will be at the top of the list.
INFORMATION DISPLAYS
To view detailed information applicable to the selected User menu display item press the ENTER button:
STATUS DISPLAY
P00
1
#1 18:00 T02
102
98
80 psi psi psi
Status Display Screen
If the ‘Pressure Schedule’ feature is active; shows the day of the week (#1: Monday), the time of day (18:00) and the table to be used (T02) of the next scheduled instruction to be executed.
1
The current active ‘Table’ (T01)
Upper, or unload, pressure setpoint
Lower, or load, pressure setpoint
Minimum pressure Alarm (Warning)
Main Status Screen
Press the ESCAPE button to return to the normal operational display screen.
SEQUENCE ROTATION
P00
#4 18:00
18 / 05 / 2006
A B C D
ABCD
Sequence Rotation Display Screen
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
The current active rotation sequence assignment.
26
Press the ESCAPE button to return to the normal operational display screen.
NOTE: The sequence assignment can be manually rotated at any time. When viewing the “Sequence Rotation” information screen press the ENTER button. The manual rotation symbols the ENTER
will appear and flash. Press
button to execute a manual rotation or
START
To start the X4I, press START. If the pre-fill function is enabled, and system pressure is below the set pre-fill pressure, the system will enter pre-fill mode for the set pre-fill time.
See the section on pre-fill for more information.
To manually skip the pre-fill function, press and hold
START for several seconds. When pre-fill is complete, if applicable, the X4I will enter normal operating mode. The
X4I will operate in accordance with the parameters and options set in the active “table”.
See the section on tables for more information.
the ESCAPE tion.
button to abandon the manual rota-
Automated sequence rotation is not disrupted by a manual rotation; the next scheduled automated sequence rotation event will still occur.
OPERATIONAL FUNCTIONS
Each compressor in the system must be started
(running or in a standby or auto restart condition) before
X4I control of the compressor can be established. The X4I will not start a compressor that is in a stopped condition.
STOP
To stop the X4I, press STOP. Dependent on the setup and configuration of the X4I, the compressors will function as follows:
•
If parameter CF=X, then 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).
•
If parameter CF= and If parameter PC=1, the X4I will hold each compressor in an offload state. If the compressor is equipped with a main motor run-on-time function, the compressor will run offload for a period of time and then stop into 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 X4I.
POWER FAILURE AUTO-RESTART
If the power failure auto-restart function is enabled, the X4I will automatically start when power is restored after a disruption or failure, if the X4I was in a “started” state when the power disruption or failure occurred.
NOTE: The X4I will not automatically restart if the X4I was in a stopped state when the power disruption or failure occurred.
FAILURE MODE
If the X4I experiences a disruption to normal control, or an
X4I 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 X4I alarm (warning) or shutdown condition, press RESET. 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.
27
SECTION 8 — COMMISSIONING
When commissioning the X4I, carry out the following procedures before attempting to start.
It is recommended that an authorized and trained service technician perform the commissioning.
PHYSICAL CHECKS
1. Before applying power to the X4I, 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 X4I and check the location of the link wire(s) connected to the
“Voltage Selection” terminals of the power supply
PCB. If necessary, change the link wire locations to those illustrated for the voltage in use.
See the section on Installation for more information.
3. Switch on the power supply to the X4I.
4. The control program identification will be displayed for a short period followed by the normal operational user display.
PRESSURE DISPLAY
Check the displayed system pressure. If the pressure is incorrect, or inaccurate, check the type and range of the sensor and carry out the pressure sensor commissioning and calibration procedure. If the display shows an error, this will need to be corrected before continuing. See the
Operator’s Manual for troubleshooting and correcting the fault/error condition.
X4I QUICK SET-UP CONFIGURATION
Before successful basic operation can be established specific parameters must be entered prior to startup.
Please refer to the X4I Quick Setup Manual for instruction to accomplish this.
28
SECTION 9 — SYSTEM CONFIGURATION
ACCESSING THE X4I CONFIGURATION
SCREENS
In order to change the configuration parameters you will first need to input the service access code. The service access code is 0032. Enter this code as follows:
1. Press the MENU
Access Code Screen.
button. This will display the
Default Configuration Screen
USER CONFIGURATION: TAB S01
1. Scroll up (+) or scroll down (-) until the S01 page is highlighted.
Access Code Screen
2. Adjust the first access code digit by using the scroll up (+) and scroll down (-) buttons. When the correct number shows press the
ENTER button. The cursor should then move to the next digit to the right.
3. Adjust the remaining digits until the proper access code is shown on the screen. If for any reason you need to go back to a previous digit press the escape button. This will back the cursor up one digit at a time.
4. When you’ve adjusted the final digit to the correct number press the ENTER button and you should see an animation of a key opening a lock.
You are now able to access the configuration screens.
5. When in menu mode, you must press the escape
button until you are returned to the Main menu. If you do not, the X4I remains in the menu mode
6. After successfully entering the access code you should see the screen shown below. The cursor will flash on the name of the current page (P00). You can scroll through the tabs by pressing the scroll up (+) buttons.
and scroll down (-)
29
S01 Screen
2. Press the ENTER button to confirm your selection. The cursor should be flashing on line 01
Ct.
User Configuration Home Screen
REAL TIME CLOCK SETTINGS
1. From the S01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 01- Ct (Real Time Clock).
or the Month for the Real Time Clock. The values for this parameter are “1” to “12”.
6. Scroll up (+) or scroll down (-) until the value is set for the correct Month for the
Real Time Clock. Press the ENTER button to accept this parameter. The flashing cursor should be displayed highlighting the Year dash. This sets the Year for the Real Time Clock. The values for this parameter are “2005” to “2100”.
Real Time Clock Setting
1. The default setting for this parameter is - --.--, which indicates the 24 Real Time Clock has not been initialized. The format for the Real Time
Clock is as follows.
•
•
•
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
The Hours and Minutes (displayed in
Military Time)
The Day, Month, and Year
2. Press the ENTER button to display the Real
Time Clock setup screen. The flashing cursor should be displayed highlighting the Hours dash.
This sets the Hour for the Real Time Clock. The values for this parameter are “00” to “23”.
3. Scroll up (+) or scroll down (-) until the value is set for the correct Hour for the
Real Time Clock. Press the enter button to accept this parameter. The flashing cursor should be displayed highlighting the Minutes dash. This sets the Minutes for the Real Time Clock. The values for this parameter are “0” to “59”.
4. Scroll up (+) or scroll down (-) until the value is set for the correct Minute for the
Real Time Clock. Press the ENTER button to accept this parameter. The flashing cursor should be displayed highlighting the Day dash. This sets the Day for the Real Time Clock. The values for this parameter are “1” to “31”.
5. Scroll up (+) or scroll down (-) until the value is set for the correct Day for the Real
Time Clock. Press the ENTER button to accept this parameter. The flashing cursor should be displayed highlighting the Month dash. This sets
7. Scroll up (+) or scroll down (-) until the value is set for the correct Year for the
Real Time Clock. Press the ENTER button to accept this parameter. You should be returned to the S01 home screen and values just entered should appear next to the Ct parameter.
PRESSURE SCHEDULE SETTINGS
1. From the S01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 02- PS (Pressure Schedule).
or
Pressure Schedule Setting
2. The default setting for this parameter is , which
indicates the Pressure Schedule is turned off.
This parameter enables or disables the Pressure
Schedule Function in the X4I.
3. Press the ENTER button to display the Pressure
Schedule setup screen. The flashing cursor should be displayed highlighting the . The values for this parameter are:
•
•
“ ” for the disabling the Pressure
Schedule Function
“ ” for enabling the Pressure Schedule
Function
4. Scroll up (+) or scroll down (-) until the value is set for the mode of operation for your air system. Press the ENTER accept this parameter.
button to
30
5. You should be returned to the S01 home screen and values just entered should appear next to the
PS parameter.
AUTO RESTART SETTINGS
1. From the S01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 03- AR (Auto Restart).
or
ROTATION INTERVAL SETTINGS
1. From the S01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 04- RP (Rotation Interval). New Picture
Below
or
Auto Restart Setting
2. The default setting for this parameter is . The indicates Auto Restart is turned on. When enabled, after a power disruption or failure, the X4I will automatically restart when power is restored if the
X4I was in an operational ‘Started’ state when the power loss or disruption occurred. The X4I will not automatically restart if the X4I was in a “Stopped” state when the power disruption or failure occurred
3. Press the ENTER
Restart setup screen.
button to display the Auto
4. The flashing cursor should be displayed highlighting the . The values for this parameter are:
•
“ ” for the disabling the Auto Restart
Function
•
“ ” for enabling the Auto Restart Function
5. Scroll up (+) or scroll down (-) until the value is set for the mode of operation for your air system. Press the ENTER accept this parameter.
button to
6. You should be returned to the S01 home screen and values just entered should appear next to the
AR parameter.
Rotation Interval Setting
2. The default setting for this parameter is 1 00:00.
The 1 00:00 indicates a rotation at Monday (1) at
00:00 hours. The X4I 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 predetermined day and time each week.
3. Press the ENTER
Interval setup screen.
button to display the Rotation
4. The Rotation Interval setup screen should be displayed with a cursor highlighting the first dash after the #. This sets the Rotation Interval. 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
5. Scroll up (+) or scroll down (-) until the value is set for the Rotation Interval required for your air system. Press the ENTER button to accept this parameter.
6. The flashing cursor should be displayed
highlighting the Hours dash (Military Time). This
sets the Hour for the Rotation Interval. The values
for this parameter are:
•
“00” to “23”
•
“–“ represents the Rotation Interval is
disabled.
31
7. Scroll up (+) or scroll down (-) until the value is set for the Rotation Interval required for your air system. Press the ENTER button to accept this parameter.
8. The flashing cursor should be displayed highlighting the Minutes dash. This sets the
Minutes for the Rotation Interval. The values for this parameter are:
•
•
“0” to “59”
“–“ represents the Rotation Interval is disabled.
9. Scroll up (+) or scroll down (-) until the value is set for the Rotation Interval required for your air system. Press the ENTER button to accept this parameter.
10. If the parameter chosen in 4.above is “t”, the flashing cursor should be displayed highlighting the Interval Time selection. This sets the required number of rotation events per day (1 to 96). The hour and minutes display will now show the interval time between each rotation event. 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
“–“represents the Rotation Interval is disabled.
11. Scroll up (+) or scroll down (-) until the value is set for the Rotation Interval required for your air system. Press the ENTER button to accept this parameter.
12. You should be returned to the S01 home screen and values just entered should appear next to the
RP parameter
TABLE SELECT SETTINGS
1. From the S01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 05- TS (Table Select).
or
2. The default setting for this parameter is T01. The
T01 indicates Table T01 is selected. This parameter determines which ‘Table’ will be used by default when the ‘Pressure Schedule’ is not active and when no table is selected remotely on a digital input.
3. Press the ENTER button to display the Table
Select configuration screen.
4. The flashing cursor should be displayed highlighting the Table Select parameter. The values for this parameter are:
•
•
•
Table Select Settings
“T01” for Table T01
“T02” for Table T02
“T03” for Table T03
5. Scroll up (+)
TS parameter.
or scroll down (-) until the value is set for the Table Select setting required for your air system. Press the ENTER button to confirm this selection.
6. You should be returned to the S01 home screen and values just entered should appear next to the
32
BACKLIGHT ADJUST SETTINGS
1. From the S01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 06- BL (Backlight Adjust).
or
USER CONFIGURATION: TAB S02
1. After you have returned to the page selection screen, scroll up (+) or scroll down (-)
until the S02 page is highlighted.
Backlight Settings
2. The default setting for this parameter is 5. The 5 indicates the current level the backlight is set for.
The default display Backlight Setting 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. The display will temporarily increase brightness by 2 levels when a button is pressed and return to normal setting after a period of no keypad activity.
3. Press the ENTER button to display the
Backlight Setting configuration screen.
4. The flashing cursor should be displayed highlighting the Backlight Setting parameter. The values for this parameter are “1” to “7” for 1 being the least amount of Backlight and 7 being the most.
S02 Tab Screen
2. Press the ENTER button to confirm your selection. The cursor should be flashing on 01 P>.
S021 Home Screen
5. Scroll up (+) or scroll down (-) until the value is set for the Backlight Setting required for visibility. Press the ENTER button to confirm this selection. You should be returned to the S01 home screen and values just entered should appear next to the BL parameter.
6. After you have completed adjusting the settings on
UNITS SETTINGS
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 01- P> (Units Settings).
or the S01 screen press the ESCAPE return to the page selection screen.
button to
33
Units Settings
2. The default setting for this parameter is PSI. The PSI indicates the pressure units selected for X4I. This parameter determines the X4I display and operating units.
3. Press the ENTER configuration screen.
button to display the Units
4. The flashing cursor should be displayed highlighting the Units parameter. The values for this parameter are:
•
•
•
“PSI”
“BAR”
“kPA”
5. Scroll up (+) or scroll down (-) until the value is set for the Units setting required for your air system. Press the ENTER confirm this selection.
button to
6. You should be returned to the S02 home screen and values just entered should appear next to the
P> parameter.
NUMBER OF COMPRESSORS SETTINGS
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 02- NC (Number of Compressors).
or
MAXIMUM PRESSURE ALARM SETTINGS
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 03- PM (Maximum Pressure Alarm).
or
Number of Compressors Settings
2. The default setting for this parameter is 4. The 4 indicates the number of compressors the X4I is configured for and the number of compressors that will be sequenced by the X4I. This value must be set to match the system at commissioning.
3. Press the ENTER button to display the Number of Compressor configuration screen.
4. The flashing cursor should be displayed highlighting the Number of Compressor parameter.
The values for this parameter are:
•
•
•
•
“1” for 1 compressor
“2” for 2 compressors
“3” for 3 compressors
“4” for 4 compressors
5. Scroll up (+) or scroll down (-) until the value matches the number of compressors that you have wired into the controller. Press the
ENTER button to confirm your selection.
6. You should be returned to the S02 home screen and values just entered should appear next to the
NC parameter.
Maximum Pressure Alarm Settings
2. The default setting for this parameter is 145. The
145 indicates the value used for the High pressure
‘Fault’ level. This value remains active at all times regardless of which ‘Table’ is active. It should be set at a level just below the system pressure relief value(s) and below the maximum system pressure rating of all air system components
3. Press the ENTER button to display the
Maximum Pressure Alarm configuration screen.
4. The flashing cursor should be displayed highlighting the Maximum Pressure Alarm parameter. 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” i. 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.
5. Scroll up (+) or scroll down (-) until the value is set to a pressure that is just below your air system requirements. Press the ENTER
button to confirm your selection.
6. You should be returned to the S02 home screen and values just entered should appear next to the
PM parameter.
34
STOP CONTROL SETTINGS TOLERANCE SETTINGS
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 05- TO (Tolerance Settings).
or
Stop Control Settings
1. From the S02 home screen scroll up (+) or scroll down (-) to move the cursor to highlight 04- CF (Stop Control Function Settings).
•
•
Stop Control Settings
2. The default setting for this parameter is . This indicates the Stop Control is turned off. This parameter determines what state the compressors will revert to when the X4I controller is stopped.
3. Press the ENTER button to display the Stop
Control configuration screen.
4. The flashing cursor should be displayed highlighting the . The values for this parameter are:
“ ” for Stop: return pressure control to the compressors
“ ” for Standby: maintain control and continuously hold compressors an unloaded state
5. Scroll up (+) or scroll down (-) your air system. Press the ENTER confirm your selection.
button to until the value is set for the mode of operation for
6. You should be returned to the S02 home screen and values just entered should appear next to the
CF parameter.
Tolerance Settings
2. The default setting for this parameter is 3.0 PSI.
This is the width of the Tolerance Band for the X4I.
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 X4I incorporates a Rate of Change algorithm while in the Tolerance Band to determine when a compressor should be Loaded or Unloaded.
•
•
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.
3. Press the ENTER button to display the
Tolerance Settings configuration screen.
4. The flashing cursor should be displayed highlighting the 3.0. The values for this parameter are:
•
•
“1.4” for the minimum Tolerance Band
“29.0” for the maximum Tolerance Band
5. Scroll up (+) or scroll down (-) until the number is set to the value required to maintain control of for your air system. Press the
ENTER button to confirm your selection.
35
6. You should be returned to the S02 home screen and values just entered should appear next to the
TO parameter.
DAMPING SETTINGS
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 06- DA (Damping Settings).
S01 S02 S03
or
05 TO
06 DA
07 PC
08 AI
09 AO
3.0 PSI
1.0
4 Min
05:SS NO
07:ON NO
5. Scroll up (+) or scroll down (-) until the number is set to the value required to maintain control of for your air system. Press the
ENTER button to confirm your selection.
6. You should be returned to the S02 home screen and values just entered should appear next to the
DA parameter.
PRESSURE CHANGE SETTINGS
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 07- PC (Pressure Change Settings).
S01 S02 S03
06 DA
07 PC
08 AI
09 AO
10 ER
1.0
4 Min
05:SS NO
07:ON NO
X
or
Damping Settings
2. The default setting for this parameter is 1.0. The 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 rate of pressure change may be aggressive and disproportionate. In such instances the X4I may over-react and attempt to load an additional compressor that may not be necessary once the initial compressor is running, loaded, and able to contribute adequate additional generation capacity. The X4I 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.
•
•
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.
3. Press the ENTER button to display the
Dampening Settings configuration screen.
4. The flashing cursor should be displayed highlighting the 1.0. The values for this parameter are “.1” for the fastest Damping reaction time (10 times faster than the default of 1.0) through “10.0” for the slowest Damping reaction time (10 times slower than the default of 1.0).
Pressure Change Settings
2. The default setting for this parameter is 4 Min. The
4 minutes is the time the X4I will use implement a smooth and controlled change from one ‘target’ pressure level to another when a Table change is made.
3. Press the ENTER button to display the Pressure
Change Settings configuration screen.
4. The flashing cursor should be displayed highlighting the 4. The values for this parameter are “1” for 1 minute between Table target pressure setpoint changes through “120” for 120 minutes between Table target pressure setpoint changes.
5. Scroll up (+) or scroll down (-) until the number is set to the value required maintain control of for your air system. Press the
ENTER button to confirm your selection.
6. You should be returned to the S02 home screen and values just entered should appear next to the
PC parameter.
AUXILIARY INPUT SETTINGS
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 08- AI (Auxiliary Input Settings).
or
36
S01
07 PC
08 AI
09 AO
10 ER
01 P>
S02 S03
4 Min
05:SS NO
07:ON NO
X
PSI
Auxiliary Input Settings
2. The default setting for this parameter is 05:SS NO.
With this setting, the function for the Auxiliary
Input for X4I is set to Remote Start/Stop. The function of the Auxiliary Input as well as the state of the contacts controlling the Auxiliary Input can be changed.
3. Press the ENTER button to display the
Auxiliary Input Settings configuration screen.
4. The flashing cursor should be displayed highlighting the 05:SS parameter. The values for this parameter are:
•
•
•
•
“01:T1”Override > Use Table 1
“02:T2”Override > Use Table 2
“03:T3”Override > Use Table 3
“04:TS”Override > Place the X4I in Standby
•
•
•
•
•
“05:SS”Remote Start/Stop (Default)
“06:AA”Remote Alarm (always active)
“07:AR”Remote Alarm (active when X4I is running, inhibited when the X4I is stopped or in Standby
“08:TA”Remote Trip (always active)
“09:TR”Remote Trip (active when X4I is running, inhibited when the X4I is stopped or in Standby
5. Scroll up (+) or scroll down (-) until you have selected the input function desired.
Press the ENTER selection.
button to confirm your
6. The flashing cursor should be displayed highlighting the NO. The values for this parameter are:
•
“NO” for the function is activated when the input terminals are a closed set of dry contacts
•
“NC“ for the function is activated when the input terminals are an open set of dry contacts
7. Scroll up (+) or scroll down (-) select the appropriate input selection. Press the
to
ENTER button to confirm your selection.
8. You should be returned to the S02 home screen and values just entered should appear next to the
AI parameter.
AUXILIARY OUTPUT SETTINGS
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 09- AO (Auxiliary Output Settings).
S01 S02 S03
or
08 AI
09 AO
10 ER
01 P>
02 NC
05:SS NO
07:ON NO
X
PSI
3
Auxiliary Output Settings
2. The default setting for this parameter is 07:ON NO.
With this setting, the function for the Auxiliary
Output for X4I is set to the X4I is Active. The function of the Auxiliary Output as well as the state of the contacts controlling the Auxiliary Output can be changed. If it is determined this value requires a change, then this will need to be modified.
3. Press the ENTER button to display the
Auxiliary Output Settings configuration screen.
4. The flashing cursor should be displayed highlighting the 05:SS parameter. The values for this parameter are:
•
•
“01:AFAny Fault”Any Alarm (Warning),
Shutdown (Trip) or Compressor Not
Available.
“02:ATAny Trip”Any Shutdown (Trip) or
Compressor Not Available.
•
•
•
“03:CFCompressor Fault”Any compressor
Alarm (Warning), Shutdown (Trip) or Not
Available
“04:CACompressor Alarm”Any compressor
Alarm (Warning)
“05:CTCompressor Trip”Any compressor
Shutdown (Trip) or Not Available
•
•
•
•
•
“06:SFSystem Fault”Any X4I Alarm
(Warning) or Shutdown (Trip)
“07:SASystem Active”X4I is Active, including pre-fill period (not active when the X4I is stopped or in standby
“08:SPSystem Pressure Control Active”X4I is Active excluding pre-fill (not active when the X4I is stopped, or in standby, or in pre-fill mode
“09:LPLow Pressure Alarm”
10:HPHigh Pressure Alarm
37
•
11:POPressure Control OverrideNormal, or
Pressure Schedule operation is being manually overridden
5. Scroll up (+) or scroll down (-) until you have selected the output function desired.
Press the ENTER selection.
button to confirm your
6. The flashing cursor should be displayed highlighting the NO. The values for this parameter are:
•
•
“NO” for the auxiliary output relay contacts are normally open and will close when the set function is active or true
“NC“ for the auxiliary output relay contacts are normally closed and will open when the set function is active or true; or in the event of a X4I shutdown or loss of power
4. The flashing cursor should be displayed highlighting the . The values for this parameter are:
•
“ ” for not resetting the Error log
•
“ “ for resetting the Error log
5. Scroll up (+) or scroll down (-) to select the function you want to perform. Note: If you select the to reset the Error Log, the .will revert back to the after selecting the ENTER button. Press the ENTER your selection.
button to confirm
6. You should be returned to the S02 home screen and the should appear next to the ER parameter.
7. After you have completed adjusting the settings on
7. Scroll up (+) or scroll down (-) select the appropriate setting for your output
to selection. Press the ENTER your selection.
button to confirm
8. You should be returned to the S02 home screen and values just entered should appear next to the
AO parameter.
ERROR LOG RESET
1. From the S02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 10- ER (Error Log Reset).
S01 S02 S03
or
09 AO
10 ER
01 P>
02 NC
03 PM
07:ON NO
X
PSI
3
145 PSI the S02 screen press the ESCAPE return to the page selection screen.
USER CONFIGURATION: TAB S03
button to
1. After you have returned to the page selection screen, scroll up (+) or scroll down (-)
until the S03 page is highlighted
Error Log Reset
2. The default setting for this parameter is . This parameter Clears and resets the ‘Error Log’ in the
X4I
3. Press the ENTER button to display the Error
Log Reset configuration screen.
S03 Tab Screen
2. Press the ENTER button to confirm your selection. The cursor should be flashing on 01 01.
S02 S03 C01
01 1O
02 1R
0 PSI
232 PSI
S03 Home Screen
38
PRESSURE SENSOR – OFFSET
1. From the S03 home screen scroll up (+) scroll down (-) to move the cursor to highlight 01- 1O (Pressure Sensor 1 Offset
Settings).
S02 S03 C01
or
PRESSURE SENSOR – RANGE SETTINGS
1. From the S03 home screen scroll up (+) or scroll down (-) to move the cursor to highlight 02- 1R (Pressure Sensor Range Settings).
S02 S03 C01
01
02
1O
1R
0 PSI
232 PSI
02 1R
01 1O
232 PSI
0 PSI
Pressure Sensor Offset Settings
2. The default setting for this parameter is 0 PSI. In most applications, this value 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.
3. Press the ENTER button to display the Pressure
Sensor Offset Settings configuration screen.
4. The flashing cursor should be displayed highlighting the 0. 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).
i. The pressure transducer must be vented to atmosphere when setting the 0 or offset.
Pressure Sensor Range Settings
2. The default setting for this parameter is 232 PSI. In most applications, this 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.
3. Press the ENTER button to display the Pressure
Sensor Range Settings configuration screen.
4. The flashing cursor should be displayed highlighting the 232. 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.
i. The pressure transducer must have a known, accurate pressure applied to it when changing this value to a value other than 232.
5. Scroll up (+) or scroll down (-) to change the value until the display indicates 0 PSI.
Press the ENTER selection.
button to confirm your
6. You should be returned to the S03 home screen and values just entered should appear next to the
1O parameter.
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 pre-determined routine periodic basis
5. Scroll up (+) or scroll down (-) change the value until the display indicates the
to correct PSI. Press the ENTER confirm your selection.
button to
6. You should be returned to the S03 home screen and values just entered should appear next to the
1R parameter.
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 pre-determined routine periodic basis
After you have completed adjusting the settings on the S03 screen press the ESCAPE selection screen.
button to return to the page
39
COMPRESSOR CONFIGURATION: TAB C01
1. After you have returned to the page selection screen, scroll up (+) or scroll down (-)
until the C01 page is highlighted.
C01 Tab Screen
2. Press the ENTER button to confirm your selection. The cursor should be flashing on line 01
01.
S03 C01 C02
01
02
03
04
01
02
03
04
0 hrs
0 hrs
0 hrs
0 hrs
3. Press the ENTER button to display the
Compressor Run Hours setup screen for compressor #1
4. The flashing cursor should be displayed highlighting the 0. The values for this parameter are “0 to x” where x = the actual run hours for the compressor connected to the #1 control channel.
5. Scroll up (+) or scroll down (-) to change the value to match the run hours on compressor #1. Press the ENTER confirm your selection.
button to
6. You should be returned to the C01 home screen and the value entered should appear next to the
01-01 parameter.
7. Repeat this by scrolling up (+) or scrolling down (-) to move the cursor to highlight the remaining compressors and set the run hours to match each of the other compressors.
8. You should be returned to the C01 home screen and values just entered should appear next to the
01 parameter. Once all run hours have been entered for all compressors, you should be returned to the C01 home screen and all values entered should appear next each compressor parameter.
9. After you have completed adjusting the settings on
C01 Home Screen
COMPRESSOR RUN HOURS
1. From the C01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 01- 01 (Compressor 1 Run Hours).
S03 C01 C02
or the C01 screen press the ESCAPE return to the page selection screen.
button to
COMPRESSOR CONFIGURATION: TAB C02
1. After you have returned to the page selection screen, scroll up (+) or scroll down (-)
until the C02 page is highlighted.
01
02
03
04
01
02
03
04
0 hrs
0 hrs
0 hrs
0 hrs
Compressor Run Hours Settings
2. The default setting for this parameter is 0 hours.
This value can be manually set to match the running hours of each compressor. When using the
EHR (Equal Run Hours) Sequence mode, the X4I uses these values to maintain equal run hours among all compressors.
C02 Tab Screen
2. Press the ENTER button to confirm your selection. The cursor should be flashing on line 01
01.
40
C02 Home Screen
COMPRESSOR CONNECTION METHOD
1. From the C02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 01- 01 (Compressor 1 Connection
Settings).
or
Compressor Connection Settings
2. The default setting for this parameter is I-PCB.
This setting is used for the type, method of connection, and the control functionality, of each compressor connected to the X4I. Each air compressor in the system is integrated with the X4I using an interface module.
3. Press the ENTER button to display the
Compressor Connection setup screen for compressor #1
4. The flashing cursor should be displayed highlighting the I-PCB. The values for this parameter are:
•
•
•
•
“IR-PCB” for Fixed speed, load/unload; connected to X4I using ‘ir-PCB’ module using 6-wire method.
“IRV-PCB” for Variable Speed; connected to
X4I using ‘ir-PCB’ module employing the
7-wire ‘V’ terminal method
“I-485” for Fixed speed, load/unload; connected to X4I on Multi485 network.
“V-485” for Variable Capacity/Speed; connected to X4I on Multi485 network
5.
IR-PCB Setup : Scroll up (+) or scroll down (-)
Press the ENTER selection.
to change the value to IR-PCB.
button to confirm your
41
6. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time.
The Default setting for this parameter is 10 Sec.
This is the time required to start the motor and then load the compressor. The values for this parameter are “0” to “60” seconds.
7. Scroll up (+) or scroll down (-) to change the value to the time required. Press the
ENTER button to confirm your selection.
8. The flashing cursor should be displayed highlighting the ‘i-PCB’ Alarm (Warning) Input. The
Default setting for this parameter is +V=!. If the ‘i-
PCB’ Alarm input detects a voltage between 12-
250VAC/DC, an alarm (Warning) condition is generated. The values for this parameter are:
•
•
+V=! for an Alarm (Warning) condition is generated if the ‘ir-PCB’ Alarm input detects a voltage between 12-250Vac/dc
(default)
0V=! for an Alarm (Warning) condition is generated if the ‘ir-PCB’ Alarm input detects no voltage.
9. Scroll up (+) or scroll down (-) to change the value for the Alarm condition required for your application. Press the ENTER button to confirm your selection.
10. You should be returned to the C02 home screen and ‘ir-PCB’ should appear next to the 01-01 parameter.
11.
IRV-PCB Setup : Scroll up (+) or scroll down (-) to change the value to IRV-PCB.
Press the ENTER selection.
button to confirm your
12. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time.
The Default setting for this parameter is 10 Sec.
This is the time required to start the motor and then load the compressor. The values for this parameter are “0” to “60” seconds.
13. Scroll up (+) or scroll down (-) to change the value to the time required. Press the
ENTER
•
button to confirm your selection.
14. The flashing cursor should be displayed highlighting the ‘i-PCB’ Alarm (Warning) Input. The
Default setting for this parameter is +V=!. If the ‘i-
PCB’ Alarm input detects a voltage between 12-
250VAC/DC, an alarm (Warning) condition is generated. The values for this parameter are:
+V=! for an Alarm (Warning) condition is generated if the ‘ir-PCB’ Alarm input detects a voltage between 12-250Vac/dc
(default)
•
0V=! for an Alarm (Warning) condition is generated if the ‘ir-PCB’ Alarm input detects no voltage.
15. Scroll up (+) or scroll down (-) to change the value for the Alarm condition required for your application. Press the ENTER button to confirm your selection.
16. The flashing cursor should be displayed highlighting the Compressor Run-On Stop Time.
The Default setting for this parameter is 0 Sec.
This is the time that the compressor main motor will continue to run when the compressor is unloaded. The time is from the moment the compressor unloads until the main motor stops and the compressor enters a ‘Standby’ or ‘Auto
Restart’ condition. This setting is only applicable to ‘IRV-PCB’ connectivity and is not displayed for other connectivity options. The values for this parameter are “0” to “999” seconds.
17. Scroll up (+) or scroll down (-) to change the value to the time required. Press the enter button to confirm your selection.
18. You should be returned to the C02 home screen and ‘irv-PCB’ should appear next to the 01-01 parameter.
24. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time.
The Default setting for this parameter is 10 Sec.
This is the time required to start the motor and then load the compressor. The values for this parameter are “0” to “60” seconds.
25. Scroll up (+) or scroll down (-) to change the value to the time required. Press the
ENTER button to confirm your selection.
26. You should be returned to the C02 home screen and ‘v-485’ should appear next to the 01-01 parameter.
27. Repeat this by scrolling up (+) or scrolling down (-) to move the cursor to highlight the remaining compressors and set the
Compressor Connection type and the Compressor
Connection parameters for each of the other compressors.
28. You should be returned to the C02 home screen and values just entered should appear next to the
01 parameter Once all values have been entered for all compressors, you should be returned to the C01 home screen and all ‘i-PCB’ values entered should appear next each compressor parameter.
29. After you have completed adjusting the settings on
19.
I-485 Setup : Scroll up (+) or scroll down
(-) to change the value to I-485. Press the ENTER button to confirm your selection.
20. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time.
The Default setting for this parameter is 10 Sec.
This is the time required to start the motor and then load the compressor. The values for this parameter are “0” to “60” Seconds.
the C01 screen press the ESCAPE return to the page selection screen.
button to
COMPRESSOR TABLE CONFIGURATION: TAB
T01
1. After you have returned to the page selection screen, scroll up (+) or scroll down (-)
until the T01 page is highlighted.
21. Scroll up (+) or scroll down (-) to change the value to the time required. Press the
ENTER button to confirm your selection.
22. You should be returned to the C02 home screen and ‘i-485’ should appear next to the 01-01 parameter.
23.
V-485 Setup : Scroll up (+) or scroll down
(-) the ENTER
to change the value to V-485. Press
button to confirm your selection.
T01 Tab Screen
42
2. Press the ENTER button to confirm your selection. The cursor should be flashing on line 01
PH.
5. Scroll up (+) or scroll down (-) until the number is set to the value required to maintain control of for your air system. Press the
ENTER button to confirm your selection.
6. You should be returned to the T01 home screen and values just entered should appear next to the
PH parameter.
LOW PRESSURE SETPOINT SETTINGS
T01 Home Page
HIGH PRESSURE SETPOINT SETTINGS
1. From the T01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 01- PH (High Pressure Setpoint).
P00 T01 T02
08 04
01 PH
02 PL
03 Pm
04 SQ
1
102 PSI
98 PSI
0 PSI
FILO ( )
or
1. From the T01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 02- PL (Low Pressure Setpoint).
P00 T01 T02
or
01 PH
02 PL
03 Pm
04 SQ
05 01
102 PSI
98 PSI
0 PSI
FILO ( )
1
High Pressure Setpoint Setting
2. The default setting for this parameter is 102 PSI.
The 102 PSI indicates the High Pressure Setpoint that is used to unload the compressor when the
Table is active.
3. Press the ENTER button to display the High
Pressure Setpoint setup screen.
4. The flashing cursor should be displayed highlighting the 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”.
i. 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” ii. 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.
Low Pressure Setpoint Setting
2. The default setting for this parameter is 98 PSI.
The 98 PSI indicates the Low Pressure Setpoint that used to load the compressor when the Table is active.
3. Press the ENTER button to display the Low
Pressure Setpoint setup screen.
4. The flashing cursor should be displayed highlighting the 98 PSI. The values for this parameter are:
•
The highest value for the Low Pressure setpoint = PH “High Pressure” setpoint minus TO “Tolerance”.
i. 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” ii. 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...
5. Scroll up (+) or scroll down (-) until the number is set to the value required to maintain control of for your air system. Press the
ENTER button to confirm your selection.
43
6. You should be returned to the T01 home screen and values just entered should appear next to the
PL parameter.
MINIMUM PRESSURE ALARM SETTINGS
Minimum Pressure Alarm Setting
2. The default setting for this parameter is 80 PSI.
The 80 PSI indicates the Minimum Low Pressure
Setpoint that is used to alarm if the pressure in the air system is low when the Table is active.
3. Press the ENTER button to display the
Minimum Low Pressure Setpoint setup screen.
4. The flashing cursor should be displayed highlighting the 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”” i. 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.
5. Scroll up (+) or scroll down (-) until the number is set to the value required to maintain control of for your air system. Press the
ENTER button to confirm your selection.
6. You should be returned to the T01 home screen and values just entered should appear next to the
Pm parameter.
SEQUENCE STRATEGY SETTINGS
P00
03 Pm
04 SQ
05 01
06
07
02
03
T01 T02
80 PSI
FILO ( )
1
1
1 1. From the T01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 03- Pm (Minimum Pressure Alarm).
P00 T01 T02
or
02 PL
03 Pm
04 SQ
05 01
06 02
90 PSI
80 PSI
FILO ( )
1
1
Sequence Strategy Setting
2. The default setting for this parameter is FILO. The
FILO indicates the Sequence Control Strategy mode used when the Table is active. Each sequence control strategy consists of two sub strategies. The
‘Rotation’ strategy defines how the compressors are re-arranged, or re-ordered, in to a new sequence at each routine ‘Rotation’ event. Rotation events are triggered by a cyclic interval time, a set time of day each day, or a set time of day once a week. The compressor load ‘Control’ strategy defines how the compressors are utilized in response to variations in system pressure
3. Press the ENTER button to display the
Sequence Strategy Setpoint setup screen.
4. The flashing cursor should be displayed highlighting the FILO. The values for this parameter are:
•
•
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
FIFO – First In First Out. The Rotation and
Control functionality of the FIFO mode is the first compressor loaded is the first compressor to be unloaded
•
•
VEC – Variable Energy Control. This uses the same Rotation and Control functionality of the FILO mode with the additional control required for variable speed compressor installations
EHR – Equal Hours Mode. The Rotation and
Control functionality of the EHR mode is to equalize the Run Hours on all compressors
5. Scroll up (+) or scroll down (-) until the control mode is set to the value required to maintain control of for your air system. Press the ENTER button to confirm your selection.
6. You should be returned to the T01 home screen and values just entered should appear next to the
SQ parameter
COMPRESSOR #1 PRIORITY SETTINGS
1. From the S01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 04- SQ (Sequence Strategy).
or
1. From the T01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 05- 01 (Compressor Priority).
or
44
P00
04 SQ
05 01
06 02
07 03
08 04
T01 T02
FILO ( )
1
1
1
1
COMPRESSOR #2 THROUGH 4 PRIORITY SETTINGS
1. Repeat Steps above for Compressor #2, #3, and #4
Priority settings. When complete, the ENTER button to confirm your selection. You should be returned to the T01 home screen
2. After you have completed adjusting the settings on
Compressor #1 Priority Setting
2. The default setting for this parameter is 1. The 1 indicates the Compressor Priority setting for compressor number #1 Any compressor can be assigned any priority or remove it from Sequence
Rotation and Control and any number of compressors can have the same priority. By changing the priority setting, it can be used to modify the ‘Rotation’ sequence assignment. For example: The air system configuration is a single variable speed compressor that should be always loaded first and act a trim compressor and 3 fixed speed compressors that should be rotated on an equal basis. You would assign the variable speed compressor a Priority of 1 and the 3 fixed speed compressors a Priority of 2. The variable speed compressor is always loaded first and the 3 fixed speed compressors would load and rotate based on the Sequence and Rotation setup.
#3
#4
#1
#2
1
1
A
A
A
A
2
2
B
C
D
B
3
2
C
D
B
C
4
2
D
B
C
D
Priority Example
3. Press the enter button to display the
Compressor Priority setup screen.
4. The flashing cursor should be displayed highlighting the 1. The values for this parameter are “1” for the highest priority through “4” for the lowest priority. Value “ ” indicates inhibit from use while a table is active. The compressor will be held unloaded and will not be utilized under any circumstances the T01 screen, press the ESCAPE return to the page selection screen.
button to
3. Repeat the T02 and T03 Tabs Screen if you will be using more than one Table in your application.
4. After you have completed adjusting the settings on the other T0x screens, press the ESCAPE button to return to the page selection screen.
PRESSURE SCHEDULE CONFIGURATION P01
TAB SCREEN
1. After you have returned to the page selection screen, such as in figure 3, scroll up (+) or scroll down (-) highlighted.
until the P01 page is
P01 Tab Screen
2. Press ENTER to confirm your selection. The cursor should be flashing on line 01 01.
5. Scroll up (+) or scroll down (-) until the number is set to the value required to maintain control of for your air system. Press the
ENTER button to confirm your selection.
6. You should be returned to the T01 home screen and values just entered should appear next to the
01 parameter.
P01 Home Screen
45
PRESSURE SCHEDULE SETTINGS this parameter are “0” to “59”. The value “–“ indicates the Pressure Schedule is disabled.
1. From the P01 home screen scroll up (+) scroll down (-) to move the cursor to highlight 01- 01 (Pressure Schedule).
or
9. Scroll up (+) or scroll down (-) until the value is set for the Pressure Schedule required for your air system. Press the ENTER button to accept this parameter.
10. The flashing cursor should be displayed highlighting the 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” or ‘T03” for the 3 different
Tables
•
•
“– – “ for Standby Mode
“–––“represents the Pressure Schedule is disabled.
Pressure Schedule Setpoints
2. The default setting for this parameter is -. --:-- -
- - . The -. --:-- - - - indicates the Pressure
Schedule is turned off. The Pressure Schedule consists of 28 individual settings that instruct the
X4I to change from one Table to another, or put the system into Standby mode, dependant on time of day and day of the week. T
3. Press the ENTER button to display the Pressure
Schedule setup screen.
4. The flashing cursor should be displayed highlighting the first dash after the #. This sets the
Day of the Week for the Pressure Schedule. 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)
“–“ for disabling the Pressure Schedule
11. Scroll up (+)
ENTER
or scroll down (-) until the value is set for the Pressure Schedule required for your air system. Press the ENTER button to accept this parameter.
12. You should be returned to the P01 home screen and values just entered should appear next to the
01 parameter.
13. Repeat Steps 5.1.A 1 to 12 if additional Pressure
Schedules are required. When complete, press the
button to confirm your selection.
14. You should be returned to the P01 home screen
15. After you have completed adjusting the settings on
5. Scroll up (+) or scroll down (-) until the value is set for the Pressure Schedule required for your air system. Press the ENTER button to accept this parameter.
6. The flashing cursor should be displayed highlighting the Hours dash (Military Time). This sets the Hour for the Pressure Schedule. The values for this parameter are “00” to “23”. The value “–“ indicates the Pressure Schedule is disabled.
the P01 screen, press the ESCAPE return to the page selection screen.
button to
PRE-FILL CONFIGURATION P02 TAB SCREEN
1. After you have returned to the page selection screen, such as in figure 3, scroll up (+) scroll down (-) highlighted.
until the P02 page is
or
7. Scroll up (+) or scroll down (-) until the value is set for the Pressure Schedule required for your air system. Press the ENTER button to accept this parameter.
8. The flashing cursor should be displayed highlighting the Minutes dash. This sets the
Minutes for the Pressure Schedule. The values for P02 Tab Screen
46
2. Press ENTER to confirm your selection. The cursor should be flashing on line 01 PF.
P01 P02 S01
06 03
01 PF
02 PT
03 PP
04 01
X
X
- MIN
0 PSI
X
Home Screen
PRE-FILL FUNCTION SETTINGS
1. From the P02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 01- PF (pre-fill function).
P01 P02 S01
06 03
01 PF
02 PT
03 PP
04 01
X
X
- MIN
0 PSI
X
or
•
“
! X
” for Pre-fill, Standard Mode ii. 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.
5. Scroll up (+) or scroll down (-) until the value is set for the Pre-fill Function required for your air system. Press the ENTER button to accept this parameter.
6. You should be returned to the P02 home screen and values just entered should appear next to the
PF parameter.
PRE-FILL TIME SETTINGS
1. From the P02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 02- PT (Pre-fill Time).
P01 P02 S01
01 PF
02 PT
03 PP
04
05
01
02
X
- MIN
0 PSI
X
X
or
Pre-fill Function Setpoint Screen
2. The default setting for this parameter is . The
indicates the pre-fill function is turned off. The pre-fill function 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.
3. Press the ENTER button to display the pre-fill function setpoint screen.
4. The flashing cursor should be displayed highlighting the . The values for this parameter are:
•
“ ” for the Pre-fill Function is Off
•
“ ” for Pre-fill, Back-up Mode i. Compressor(s) can be preselected as ‘Primary Pre-fill’ compressor(s) or ‘Backup Pre-fill’ compressor(s). If a primary prefill compressor experiences a shutdown, or is stopped, it is replaced by a pre-defined backup compressor and pre-fill continues.
Pre-fill Time Setpoint Setting
2. The default setting for this parameter is – MIN .
The – MIN indicates the Pre-fill Time is turned off.
The Pre-fill Time Setpoint (in minutes) determines the time the Pre-fill Function has to start and load the designated Compressor/s to increase system pressure to normal operational levels
3. Press the ENTER
Time Setpoint screen.
button to display the Pre-fill
4. The flashing cursor should be displayed highlighting the . The values for this parameter are:
•
“–” for the Pre-fill Time is Off
•
“1 to 120” for the number of minutes for the Pre-fill Time Setpoint
5. Scroll up (+) or scroll down (-) until the value is set for the Pre-fill Time required for your air system. Press the ENTER accept this parameter.
button to
6. You should be returned to the P02 home screen and values just entered should appear next to the
PT parameter.
47
PRE-FILL PRESSURE SETTINGS
1. From the P02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 03- PP (Pre-fill Pressure).
P01 P02 S02
02 PT
03 PP
04
05
06
01
02
03
- MIN
0 PSI
X
X
X
or
P01
03 PP
04
05
06
07
01
02
03
04
P02
0 PSI
X
X
X
X
S02
Pre-fill Pressure Setpoint Setting
2. The default setting for this parameter is 0 PS. The
0 PSI indicates the Pressure Setpoint used by the
X4I to determine if the Pre-fill Function is required at startup. If the system pressure is at, or above, this setting, the pre-fill function will be abandoned immediately and normal pressure control and sequence strategy will be implemented. This setting is intended to inhibit ‘Pre-fill’ operation if pressure is already at an acceptable level at system startup
3. Press the ENTER button to display the Pre-fill
Pressure Setpoint screen.
4. The flashing cursor should be displayed highlighting the 0. The values for this parameter are:
•
0 to 232 (or the maximum scaling used by the X4I if a different Pressure Transducer range is used)” for the PSI value for the
Pre-fill Pressure
5. Scroll up (+) or scroll down (-) until the value is set for the Pre-fill Pressure required for your air system. Press the ENTER button to accept this parameter.
6. You should be returned to the P02 home screen and values just entered should appear next to the
PP parameter.
PRE-FILL COMPRESSOR #1 SETTINGS
1. From the P02 home screen scroll up (+) scroll down (-) to move the cursor to highlight 04- 01 (Pressure Schedule).
or
Pre-fill Time Setting
2. The default setting for this parameter is . The
indicates the Pre-fill Function for Compressor
#1 s turned off. The Pre-fill Time Setpoint (in minutes) determines the time the Pre-fill Function has to start and load the designated Compressor/s to increase system pressure to normal operational levels
3. Press the ENTER
Time Setpoint screen.
button to display the Pre-fill
4. The flashing cursor should be displayed highlighting the . The values for this parameter are:
•
•
•
“ ”” for this compressor will not be used by the Pre-fill Function
“ ” for this compressor will be used as a primary compressor by the Pre-fill
Function
“!” for this compressor will be used as an emergency Backup compressor by the Prefill Function
5. Scroll up (+) or scroll down (-) until the value is set for the compressor Pre-fill
Function required for your air system. Press the enter button to accept this parameter.
6. You should be returned to the P02 home screen and values just entered should appear next to the
04 parameter.
PRE-FILL COMPRESSOR #2 THROUGH 4 SETTINGS
1. Repeat above steps for compressor #2, #3, and #4
Pre-fill Compressor settings. When complete, the
ENTER button to confirm your selection.
2. You should be returned to the P02 home screen
3. After you have been returned to the page selection screen, press the ESCAPE the main screen.
button to return to
48
DIAGNOSTICS D01 TAB SCREEN
1. After you have returned to the page selection screen, scroll up (+) or scroll down (-)
until the D01 page is highlighted.
D2 Tab Screen
2. Press ENTER to confirm your selection. The cursor should be flashing on line 01 D1.
DIAGNOSTICS SETTINGS
1. From the D01 home screen scroll up (+) or scroll down (-) to move the cursor to highlight 01- D1 (Digital Input 1).
D01
20 Ao
01 D1
02
03
04
D2
D3
D4
4.00
0
0
1
2 mA
Diagnostic Setting Screen
2. The X4I is equipped with comprehensive diagnostic functions. Each input can be examined individually and each output can be manually activated or manipulated individually.
X4I CONTROLLER DIAGNOSTICS
D1Digital Input 1
D2Digital Input 2
D3Digital Input 3
D4Digital Input 4
D5Digital Input 5
D6Digital Input 6
D7Digital Input 7
D8Digital Input 8
D9Digital signal detected on A2
DADigital signal detected on A3
____________________________________________________
R1Relay Output 1
R2Relay Output 2
R3Relay Output 3
R4Relay Output 4
R5Relay Output 5
R6Relay Output 6
____________________________________________________
A1Analog Input 1bar <> mA
A2Analog Input 2v
A3Analog Input 3v
____________________________________________________
AoAnalog Output0.0 to 20.0mA
49
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 item 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 Input #9, voltage
A3:Auxiliary Digital Input, voltage
Analog inputs 2 and 3 are equipped with ACM modules designed to conform to the standard specification for a controller digital input. The inputs are utilized as digital inputs on this X4I.
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.
After you have completed adjusting the settings on the D01
Access Code Screen
2. Enter the access code “9750” but do not press the
ENTER button when the last access code character “0” is flashing.
3. When the flashing cursor is highlighting the last
“0”, press and hold the STOP button for
10 seconds. After 10 seconds, the controller will reset and re-initialize.
All parameters, values and options will be reset to default and the internal permanent memory will be cleared and reset.
screen press the ESCAPE selection screen.
button to return to the page
After you have been returned to the page selection screen, press the ESCAPE button to return to the main screen.
TOTAL UNIT RESET AND DEFAULT VALUES
If at any time there is a requirement to reset all the parameters and internal memory values to factory default, this can be accomplished by using the following procedure.
1. Press the MENU access code screen.
button. This will display the
50
The Default Parameters for all X4I settings are shown in the following lists.
ON
TABLE #1
T01
PHHigh Pressure Setpoint
Default Setting is: 102 PSI
PLLow Pressure Setpoint
Default Setting is: 98 PSI
PmMinimum Pressure Alarm
Default Setting is: 0 PSI
SQSequence Rotation Mode
Default Setting is: FILO
01Compressor #1 Priority
Default Setting is: 1
02Compressor #2 Priority
Default Setting is: 1
03Compressor #3 Priority
Default Setting is: 1
04Compressor #4 Priority
Default Setting is: 1
OFF
ON
OFF
Pulsing
TABLE #3
T03
PHHigh Pressure Setpoint
Default Setting is: 102 PSI
PLLow Pressure Setpoint
Default Setting is: 98 PSI
PmMinimum Pressure Alarm
Default Setting is: 0 PSI
SQSequence Rotation Mode
Default Setting is: FILO
01Compressor #1 Priority
Default Setting is: 1
02Compressor #2 Priority
Default Setting is: 1
03Compressor #3 Priority
Default Setting is: 1
04Compressor #4 Priority
Default Setting is: 1
TABLE #2
T02
PHHigh Pressure Setpoint
Default Setting is: 102 PSI
PLLow Pressure Setpoint
Default Setting is: 98 PSI
PmMinimum Pressure Alarm
Default Setting is: 0 PSI
SQSequence Rotation Mode
Default Setting is: FILO
01Compressor #1 Priority
Default Setting is: 1
02Compressor #2 Priority
Default Setting is: 1
03Compressor #3 Priority
Default Setting is: 1
04Compressor #4 Priority
Default Setting is: 1
Pressure Schedule
P01
01Schedule Setting #1 to
Default Setting is: -. - - : - - - - -
28Schedule Setting #28
Default Setting is: -. - - : - - - - -
51
P02
Pre-fill
PFPre-fill Function
Default Setting is: X
PTPre-fill Time
Default Setting is: - MIN
PPPre-fill Pressure
Default Setting is: 0 PSI
01Compressor #1
Default Setting is: X
02Compressor #2
Default Setting is: X
03Compressor #3
Default Setting is: X
04Compressor #4
Default Setting is: X
User Configuration
S01
CtReal Time Clock Set
Default Setting is: -. - - : - -
PSPressure Schedule Enable
Default Setting is: X
ARAuto Restart Enable
Default Setting is:
RPRotation Interval
Default Setting is: 1. 00:00
TSDefault Table Select
Default Setting is: T01
BLDisplay Backlit Adjust
Default Setting is: 5
Configuration
S02
P>Pressure Units
Default Setting is: PSI
NCNumber Of Compressors
Default Setting is: 4
PMMaximum Pressure Alarm
Default Setting is: 145 PSI
CFStop Control Function
Default Setting is: X
TOTolerance
Default Setting is: 3.0 PSI
DADamping
Default Setting is: 1.0
PCPressure Change Time
Default Setting is: 4 MIN
AIAuxiliary Input Function
Default Setting is: 05:SS NO
AOAuxiliary Output Function
Default Setting is: 07 ON NO
ERError Log Reset
Default Setting is: X
Sensor Calibration
S03
1OPressure Offset
Default Setting is: 0 PSI
1RPressure Range
Default Setting is: 232 PSI
52
Compressor Running Hours
C01
01Compressor #1 Running Hours
Default Setting is: 0 HRS
02Compressor #2 Running Hours
Default Setting is: 0 HRS
03Compressor #3 Running Hours
Default Setting is: 0 HRS
04Compressor #4 Running Hours
Default Setting is: 0 HRS
Compressor Configuration
C02
01Compressor #1 Configuration
Default Setting is: IR-PCB
02Compressor #2 Configuration
Default Setting is: IR-PCB
03Compressor #3 Configuration
Default Setting is: IR-PCB
04Compressor #4 Configuration
Default Setting is: IR-PCB
53
SECTION 10 — DIAGNOSTIC FUNCTIONS IN THE X04
CONTROLLER
In order to understand and utilize the functionality provided on the D01 diagnostics tab, you must first know how to troubleshoot the control signals between the X4I and the ir-PCB interface. The troubleshooting of the signals can then be used to understand the information displayed o the D01 diagnostic screen in the X4I.
IR-PCB (INGERSOLL RAND COMPRESSOR INTERFACE PCB)
C01 C02
ir-PCB
V 1 2
C03
3 4 5 6
C05
C04
LED 1 LED 2
C01 C02
ir-PCB
V 1 2
C03
3 4 5 6
C05
C04
LED 1 LED 2
V1 1 2 3 4 5 6
Wire Connections for IR-PCB Mode
6core, earth shielded, cable (330 ft max)
CONNECTIVITY TO X4I AND DIAGNOSTIC LED INDICATORS
V1 1 2 3 4 5 6
Wire Connections for IRV-PCB Mode
7core, earth shielded, cable (330 ft max)
NO C NC NO C NC
OUT
C02
IN
C01
ir-PCB
V 1 2
C03
3 4 5 6
Alarm Run Ready
C04
LED 5
LED 4
RUN
READY
LED 2
LED 5 LED 1
C05
VFD SEQ LOAD
GND D1 D2
+24VDC
VFD LOAD SEQ
X03-3 (GND) is 0Vac and 0VDC common. GND is also connected to ‘earth’ on the X4I Terminal PCB ( this is not a
‘Safety Earth’ connection and is used for “control” only ).
The ‘ir-PCB’ provides 3kV opto-coupled isolation between compressor circuit pressure regulation and monitoring inputs (X01, X02 and X04) and the low voltage connections to the X4I (X03).
54
‘IR-PCB’ PRESSURE REGULATION CONTROL INPUTS
On connector C03, the following connections provide the control to the compressor from the X4I to the ir-PCB.
V 1 2 3
V S E Q L O A D
0 Va c
G N D
2 4 Va c
C 0 3
VFD INPUT CONTROL DIAGNOSTIC INDICATOR
V 1 2 3 C 0 3
+ 2 4 Va c
V F D
0 Va c
L E D 5
V F D
2 4 Va c
0 Va c
G N D
When the X4I is set up for in VFD mode (IRV-PCB), the controller will send a signal to the VFD input (V) on the ir-
PCB. Its associated diagnostic LED 5 will be on indicating the presence of 24Vac.
SEQ (REMOTE PRESSURE REGULATION CONTROL)
INPUT DIAGNOSTIC INDICATOR
V 1
S E Q
2 4 Va c
2 3
0 Va c
G N D
C 0 3
+ 2 4 Va c
S E Q
0 Va c
L E D 1
When the X4I places a compressor into Sequence control, the controller will send a signal to the SEQ input (1) on the ir-PCB. Its associated diagnostic LED 1 will be on indicating the presence of 24Vac.
LOAD INPUT DIAGNOSTIC INDICATOR
V 1 2 3 C 0 3
+ 2 4 Va c
L O A D
0 Va c
L E D 2
L O A D
0 Va c
G N D
2 4 Va c
When the X4I initiates a Load command to the compressor, the controller will send a signal to the Load input (2) on the ir-PCB. Its associated diagnostic LED 2 will be on indicating the presence of 24Vac.
‘IR-PCB’ STATUS MONITORING OUTPUTS
On connector C03, the following connections provide the status of the compressor from the ir-PCB to the X4I.
C 0 3
3 4 5 6
0 V D C
G N D
D 1 D 2
+ 2 4 V D C
READY SIGNAL DIAGNOSTIC INDICATOR
1 2 -2 5 0 Va c o r D C
C 0 4
A L A R M
(W a rn in g )
R U N R E A D Y
+ V
R E A D Y
L E D 4
0 V
When the compressor is “on” and “ready” to be sequenced, there will be voltage present on the Ready connection on
C04. Its associated diagnostic LED 4 will be on indicating the presence of the signal.
RUN SIGNAL DIAGNOSTIC INDICATOR
C 0 4
1 2 -2 5 0 Va c
A L A R M
(W a rn in g )
R U N R E A D Y
R U N
+ V
L E D 3
0 V
When the compressor is “running”, there will be voltage present on the Run connection on C04. Its associated diagnostic LED 3 will be on indicating the presence of the signal.
55
STATUS SIGNALS
READY AND RUN STATUS SIGNALS
12-250V ac
12-250 V ac or DC
Po la r ity is n o t im p o r ta n t
Po la r ity is n o t im p o r ta n t
N O C N C N O C N C
O U T IN
C02
C01 ir-PC B
V 1 2
C03
3 4 5 6
A larm R un R eady
C04
C 0 5
R E A D Y
+ V
0 V
R U N
+ V a c
0 V a c
D 2
+ 2 4 V D C
0 V D C
D 2
P u ls e 5 0 /6 0 H z
1 2 -2 5 0 Va c
1 2 -2 5 0 Va c o r D C
D i2
+ 2 4 V D C
0 V D C
X 4 I
+ V D C
X 0 1
R e a d y/R u n
G N D
+ V
D 2
X 0 3
G N D
R u n
C 0 4
R e a d y ir-P C B
0 V D C
0V DC
D2
When the Ready and Run signals are present on C04, they can be monitored on connection C03 terminal 5 (D2).
Referring to the above graph, the signal (wave form) seen on D2 is shown.
Note: RUN input 12-250V’ac’ only. The ‘ac’ frequency is used to create the pulsing on the ‘D2’ (C03-3) output.
Note: If measured with a ‘typical’ DC voltage meter the
‘pulsing’ will appear as 10VDC (+-3V)
ALARM (WARNING) AND SERVICE/MAINTENANCE FUNCTION STATUS SIGNALS
12-250V ac or DC
Po la r ity is n o t im p o r ta n t
N O C N C N O C N C
O UT
C02
IN
C01 ir-PC B
V 1 2
C03
3 4 5 6
A larm R un R eady
C04
C0 5
A L A R M
+ V
0 V
S ervice
M a in te n an ce
D 1
+ 2 4 V D C
0 V D C
D 2
P u ls e 5 0 /6 0 H z
0V DC
D1
Se rv ic e
M a in t e n a n c e
When the Alarm or Service Maintenance signals are present on C04 or C05, they can be monitored on connection C03 terminal 5 (D1). Referring to the above graph, the signal
(wave form) seen on D1 is shown.
Pulses are generated by the ‘ir-PCB’ itself for the Service/
Maintenance ‘D1’ (C03-5) Signal.
Notice that the 10k pull-up resistor on the X4I Terminal PCB will hold the ‘D1’ signal at +24VDC. The Signal will go to
0VDC when there is an Alarm (Warning) input on the ‘ir-
PCB’. This functions in reverse to the way the ‘D2’ Ready/
Run signal, from the ‘ir-PCB’ to the X4I functions.
D i6
+ 2 4 V D C
0 V D C
X 4 I
1 0 k
1 2 -2 5 0 Va c o r D C
C 0 4
X 0 1
A la rm /S e rv.
G N D
X 0 3
D 1
G N D
A la rm ir-P C B
0 V D C
In addition, if the ‘D1’ wire connection from the X4I to the
‘ir-PCB’ is not connected the ‘D2’ output on the ‘ir-PCB’ pin will always measure 0VDC (no pull-up resistor connected).
A Service/Maintenance signal (pulsing) will mask any Alarm
(Warning) signal. This is not an issue because the X4I will ignore any compressor Alarm (Warning) or Trip (Shutdown) conditions in Service/Maintenance mode.
Note: If measured with a ‘typical’ DC voltage meter the
‘pulsing’ will appear as 10VDC (+-3V)
56
DETERMINING TERMINAL PCB TO CONTROLLER I/O CONNECTIONS FROM THE X4I WIRING
DIAGRAM FOR USE WITH THE CONTROLLER DIAGNOSTIC TEST FUNCTIONS
Example: ‘ir-PCB 1’ Ready/Run Signal to Controller Di2 (Digital Input 2) Terminal
Di2 ir- PCB
Ready/Run
C+
X04
1
2
3
4
5
6
7
8
C019
C020
C021
C022
C023
C024
C025
C026
C027
C015
C016
C017
C018
C019
C020
C021
C022
C023
C024
C025
10k
C021
C025
C015
6
5
4
3
2
1
V1
X01
C03
+
Di2
-
Di6
R2
R1
+20VDC 6
Ready/Run 5
Alarm/Serv
.
GND
4
3
LOAD 2
SEQ 1
V
V1 VFD ir-PCB 1
X04-3
(C2)
Di2 ir- PCB 1
Ready/Run
X4 I Controller
C021 X01-5
Terminal PCB
COMPRESSOR #1 DIAGNOSTICS
• To view ‘ir-PCB’ #1 Ready/Run input in the controller’s Diagnostic menu select digital input ‘D2’ (Di2)
• To view ‘ir-PCB’ #1 Alarm/Serv input in the controller’s Diagnostic menu select digital input ‘D6’ (Di6)
COMPRESSOR #2 DIAGNOSTICS
• To view ‘ir-PCB’ #2 Ready/Run input in the controller’s Diagnostic menu select digital input ‘D3’ (Di3)
• To view ‘ir-PCB’ #2 Alarm/Serv input in the controller’s Diagnostic menu select digital input ‘D7’ (Di7)
COMPRESSOR #3 DIAGNOSTICS
• To view ‘ir-PCB’ #3 Ready/Run input in the controller’s Diagnostic menu select digital input ‘D4’ (Di4)
• To view ‘ir-PCB’ #3 Alarm/Serv input in the controller’s Diagnostic menu select digital input ‘D8’ (Di8)
COMPRESSOR #4 DIAGNOSTICS
• To view ‘ir-PCB’ #4 Ready/Run input in the controller’s Diagnostic menu select digital input ‘D5’ (Di5)
• To view ‘ir-PCB’ #4 Alarm/Serv input in the controller’s Diagnostic menu select digital input ‘A2’ (Ai2)
57
DIGITAL (SWITCHING) INPUT EXCEPTIONS
•
•
‘ir-PCB’ #4: The ‘Alarm/Service
Maintenance’ digital input (X04-22) is monitored by a DC voltage ‘Analogue’ input (A2) on the unit’s controller. The
Terminal PCB has a 2x150k resistor and capacitor circuit to condition the signal from the ‘ir-PCB’. View analogue input ‘A2’ in the controller’s Diagnostic menu.
Auxiliary Digital Input 1 (X07) is monitored by ‘Analog’ input (A3) on the unit’s controller. The analogue input has been fitted with a digital (switching) conditioning circuit and has the same characteristics as a normal ‘Digital’ input. View analogue input ‘A3’ in the controller’s Diagnostic menu.
Note: A digital (switching) conditioning circuit is not employed on analog input 2 (‘ir-PCB’ #4 Alarm/Service
Maintenance) because this input has a ‘pulsing’ state that the digital (switching) conditioning circuit is unable to detect correctly; hence the DC voltage level detection to pick-up the ‘pulsing’ state.
58
SECTION 11 — FAULT CODES
In the event of a unit or system “fault” the X4I 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).
Each fault type has a unique numeric code.
ERR.01
ERR.04
Pressure Sensor
Internal 24V Fault
ERR.05
ERR.06
SYS.01
SYS.02
SYS.04
Emergency Stop
Real Time Clock Error
Excess Pressure (PM)
Min Pressure (Pm)
Insufficient Capacity
Compressor fault states are displayed as part of the normal operational status display and do not generate fault codes. Examine the applicable compressor unit to establish the nature or description of the detected fault condition.
X4I COMPRESSOR FAULT INDICATIONS,
TYPES, AND CODES:
Compressor fault conditions are displayed on the user compressor status screen and are not regarded as X4I unit fault conditions.
Compressor fault conditions are displayed symbolically on the main User compressor status screen.
The alarm (warning) symbol will alternate with the normal compressor status symbol every two seconds.
NOT AVAILABLE
The compressor is reporting a general or group trip
(shutdown) condition. The compressor has been stopped and taken out of service, power to the compressor has been isolated/lost or the compressor is not communicating.
•
The ready input of the “ir-PCB” is no longer active.
•
•
The run input of the “ir-PCB” is no longer active while the compressor is being requested to run loaded.
The run input of the “ir-PCB” did not activate within 60 seconds of a load request.
•
•
The compressor is reporting a general or group shutdown or stopped condition
(RS485 network connectivity only).
The remote compressor interface unit is in a shutdown condition (RS485 network connectivity only).
The X4I fault LED will “fast flash”.
The “not available” symbol will “slow flash”.
#
COMPRESSOR INHIBITED, REMOVED FROM
SERVICE
Set in the X4I active “table” (# = table number 1, 2 or 3) as inhibited from use.
In this condition, the status of the compressor is still monitored. The X4I fault LED will not illuminate or flash unless an actual alarm (warning) or trip (shutdown, not available) condition occurs.
The two symbols will alternate every two seconds.
SERVICE/MAINTENANCE
Inhibited from use by the user using the “ir-PCB” service/ maintenance function.
In this condition, compressor fault conditions are ignored.
The X4I fault LED will not illuminate or flash.
ALARM (WARNING)
•
The Alarm input on the “ir-PCB” has been activated.
•
The compressor, or remote compressor interface unit, is reporting a general or group alarm condition on the RS485 network (RS485 network connectivity only).
The X4I fault LED will “slow flash”.
COMMUNICATIONS DISRUPTION
Network communications with the compressor have been disrupted/lost.
Note: only applicable where the compressor is integrated with the X4I using the RS485 communications network.
59
SPECIAL CONTROLLER FAULT CODES
•
•
E0836 PLL Unlock Internal failure or excessively high external electrical interference
Controller internal
•
E0866 power supply fault
E5000 map error
Internal memory
•
E5001 failure
Internal memory
ERROR LOG
15
01
02
03
04
E01
- : - - - . - -
E : ERR . 01
- : - - - . - -
- : - - - . - -
- : - - - . - -
Error Log Screen
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
E01 01.01
E: ERR.01
16/05/2006
1
14:25
button.
First Error Log Information Screen
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 X4I at the time the error occurred; (see: X4I
Status Display for Icons)
To view the second error information screen, press the
ENTER button. To return to the main error log menu screen, press the ESCAPE
E01 01.01
1 2
button.
3 4
Second Error Log Information Screen
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 the ENTER
button or the ESCAPE button. To return to the main error log menu screen press the ESCAPE button.
60
4
5
2
3
6
-
1
Item
-
Part No.
39265889
80443617
39265897
39265913
39265905
38036703
39265921
39265939
PARTS LIST
Description
X4I
Manual, User CD
Unit, Controller
Unit, XPM-TAC24
PCB, Terminal
Gland, Set - Pg11
Module, ir-PCB
Sensor, Pressure
4-20mA, 232psi (16bar)
20mm
IEC 5mm
10
10
10
39265962
39265970
39265988
Description
IEC Fuse T1.0A
IEC Fuse T1.6A
IEC Fuse T3.15A
1
4
5 i-PCB
6
2
3
61
TECHNICAL DATA
Dimensions (HxWxD) 9.45” x 11.45” x 6.0”
241mm x 291mm x 152mm
Weight
Mounting
14 lb (6.4 kg)
Wall, 4 x mounting screws
Enclosure
Power Supply
IP65, NEMA 4
50VA
230Vac +/- 10% (50 Hz)
115Vac +/- 10% (60 Hz)
Control Power
Temperature
Humidity
24Vdc
32°F to 115°F (0°C to 46°C)
0% to 95% RH non-condensing
24mm
24mm
Mounting Dimensions:
238mm
188mm
8mm
286mm
236mm
62
DIAGRAMS
Wiring Diagram
C 0 3 1
C 0 3 2
C 0 9
C 0 1 0
T 1 -5 6 -3 2 1 -R 6 -C G
A -G N D
A o
+ V D C
A i1
+ V D C
A i2
+ V D C
A i3
C +
4
5
6
7
8
R 1
R 2
R 3
1
2
3
R 5
R 6
R 4
X 0 3
1 2
2 4 V a c
0 V a c - e a rth e d
C 0 3
C 0 4
C 0 5
C 0 6
C 0 7
C 0 8
C 0 1 9
C 0 2 0
C 0 2 1
C 0 2 2
C 0 2 3
C 0 2 4
C 0 2 5
C 0 2 6
C 0 2 7
C 0 1 1
C 0 1 2
C 0 1 /3
C 0 1 /4
C 0 1 3
C 0 1 4
C 0 1 5
C 0 1 6
C 0 1 7
C 0 1 8
0 V D C
C 0 1 1
C 0 1 2
C 0 1 3
C 0 1 4
C 0 1 5
C 0 1 6
C 0 1 7
C 0 1 8
C 0 1 9
C 0 2 0
C 0 2 1
C 0 2 2
C 0 2 3
C 0 2 4
C 0 2 5
C 0 2 6
C 0 2 7
C 0 2 8
C 0 2 9
C 0 3 0
C 0 3 3
C 0 3 4
T e rm in a l P C B
C 0 1
C 0 3
C 0 4
C 0 5
C 0 6
C 0 7
C 0 8
S E Q
G N D
C 0 9
C 0 1 0
C 0 8
C 0 7
C 0 1 0
C 0 9
24V ac
C 0 3 4
R -S E Q
C 0 6
C 0 4
C 0 3
C 0 1 9
1 0 k
C 0 2 4
1 5 0 k
1 5 0 k
C 0 1 2
SE Q
1 0 k
C 0 2 3
C 0 2 7
C 0 1 8
1 0 k
C 0 2 2
C 0 2 6
C 0 3 1
C 0 3 2 4 -2 0 m A
C 0 1 6
R -V 1
R -V 2
R -V 3
R -V 4
1 0 k
C 0 2 1
C 0 2 5
C 0 1 5
L N E
2 3 0 V a c 1 0 %
1 1 5 V a c 1 0 %
63
Connection Diagram
Terminal PCB
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
V4
18
17
16
15
14
13
V3
12
11
10
9
8
7
V2
6
5
4
3
2
1
V1
115V ' UL ' @ 5A maximum.
X08
Auxiliary Output #1
X07
Auxiliary Input #1
330ft (100m) max
L1
X06
X05
L1
L2
L1
L2
Multi485
-
+
Ai1 System
Pressure
X04
+
+20VDC
Di5
-
Ai2
R5
R1
Ready/Run
Alarm/Serv.
4
GND
LOAD
SEQ
5
3
2
1
V4
VFD
6
+ ir-PCB4
V
330ft (100m) max
-
+
4- 20mA
330ft (100m) max
IR- PCB 6- core
IRV- PCB 7- core
L2
V
X03
X02
+
+20VDC
Di4
-
Di8
R4
R1
V3
Ready/Run
Alarm/Serv.
4
GND
LOAD
SEQ
VFD
5
3
2
1
6
+
+20VDC
Di3
-
Di7
Ready/Run
Alarm/Serv.
GND 3
5
4
R3
R1
V2
LOAD
SEQ
VFD
2
1
6
X01
+
+20VDC
Di2
-
Di6
R2
R1
V1
Ready/Run
Alarm/Serv.
4
GND
LOAD
SEQ
VFD
5
3
2
1
6 ir-PCB3
V ir-PCB2
V ir-PCB1
V
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
V
V
V
64
4
3
2
1
XPM-TAC24
Power Supply Module
6
4 x 4.5mm
12 mm
BLUE
BROWN
RED
GREEN
BLACK
ORANGE
WHITE
VIOLET
IEC
5x20mm
141
147
FH5 FH4 FH3
X03
2 1
X02
2
1 2 3 4
FH2
X04
VOLTAGE SELECT
230V
115V
T1.0A
1 2 3 4
X01
L N E E
FH1
24Vac/2 earthed
24Vac/1 isolated L N E
10
1 2 3 4
230V +-10%
32
115V +-10%
12 mm
65
Customer
Installation/Site
Software
#1 psi cfm kW VA Hz
#2 psi cfm kW VA Hz
#3 psi cfm kW VA Hz
#4 psi cfm kW VA Hz
01
02
03
04
PH
PL
Pm
SQ
PH
PL
Pm
SQ
01
02
03
04
01
02
03
04
PH
PL
Pm
SQ
T02
T02
T02
T02
T02
T02
T02
T02
T01
T01
T01
T01
T01
T01
T01
T01
T03
T03
T03
T03
T03
T03
T03
T03
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
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
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
Contact
Phone
X4I Commissioning Form
Customer Ref:
Internal Ref:
Commission Date
Commission Engineer 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 psi/bar cfm psi/bar cfm psi/bar cfm psi/bar cfm psi/bar psi/bar psi/bar
EHR FIFO TR VEC
EHR FIFO TR VEC
EHR FIFO TR VEC psi/bar psi/bar psi/bar psi/bar psi/bar psi/bar
66
C01
C01
C01
C01
C02
C02
C02
C02
C02
C02
C02
C02
C02
C02
C02
C02
S01
S01
S01
S01
S01
S02
S02
S02
S02
S02
S02
S02
S02
S02
S03
S03
P02
P02
P02
P02
P02
P02
P02
P>
NC
PM
CF
TO
DA
PC
AI
AO
1O
1R
Ct
PS
AR
RP
TS
PF
PT
PP
01
02
03
04
01
02
03
04
01
02
03
04
Real Time Clock Set
Pressure Schedule Enable
Auto Restart Enable
Rotation Interval or Time
Default Table
Pressure Units
Number of Compressors
Maximum Pressure Alarm
Stop Control Function
Tolerance
Damping
Pressure Change Time
Auxiliary Input Function
Auxiliary Output Function
Pressure Offset
Pressure Range
Prefill Function
Prefill Time
Prefill Pressure
Compressor #1 Prefill Function
Compressor #2 Prefill Function
Compressor #3 Prefill Function
Compressor #4 Prefill Function
Compressor #1 Running Hours
Compressor #2 Running Hours
Compressor #3 Running Hours
Compressor #4 Running Hours
Compressor #1 Connection
Compressor #1 Start Time
Compressor #1 Stop Time
Compressor #2 Connection
Compressor #2 Start Time
Compressor #2 Stop Time
Compressor #3 Connection
Compressor #3 Start Time
Compressor #3 Stop Time
Compressor #4 Connection
Compressor #4 Start Time
Compressor #4 Stop Time
T01 bar
1
T02 psi
2
T03 kPa
3 4
!>X
psi/bar min sec psi/bar
!
!
!
!
I-PCB V-PCB I-485
I-PCB V-PCB I-485
I-PCB V-PCB I-485
I-PCB V-PCB I-485
hrs hrs hrs hrs
V-485
sec sec
V-485
V-485
sec sec
V-485
sec sec sec sec
67
Machine models represented in this manual may be used in various locations world-wide. Machines sold and shipped into European Union Territories require that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid. A declaration of that conformity follows:
EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES
93/68/EEC, 92/31/EEC, 89/336/EEC, 73/23/EEC
we,
Represented in EC by:
Ingersoll-Rand Company
800A Beaty Street
P.O. Box 1600
Davidson
North Carolina 28036
Ingersoll-Rand European Sales Limited
Swan Lane
Hindley Green
Wigan WN2 4EZ
United Kingdom declare that, under our sole responsibility for manufacture and supply, the product(s)
X4
I to which this directive relates, is (are) in conformity with the provisions of the above directives using the following principal standards.
EN
61000-6-4, EN61000-6-2, EN60204-1
Issued at Hindley Green on
23
/0
4
/200
7
by H. Seddon, Quality Assurance Manager.
H. Seddon
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