Gardner Denver XMX Series User manual

XMX Series
Version 4.10
Demand Expander
INSTALLATION
INSTRUCTION
&
MAINTENANCE
MANUAL
Gardner Denver Inc.
1800 Gardner Expressway
Quincy, IL 62305
[phone]

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©Copyright 2005-2013
Gardner Denver Corporation
Version 4.10
Table of Contents
Introduction: ..................................................................................................................................... 3
Installation: ....................................................................................................................................... 3
Wiring (Stand-Alone with XMX-1V Controller): ............................................................................. 4
Placing the Unit into Service: ........................................................................................................... 5
Setting the Regulators: .............................................................................................................. 5
Electronic Controller ........................................................................................................................ 6
P3 Storage Pressure – .............................................................................................................. 6
P4 System Pressure – ............................................................................................................... 6
Valve Control – .......................................................................................................................... 6
Navigating through the LC Display .................................................................................................. 7
ESC – ......................................................................................................................................... 7
CURSER – ................................................................................................................................. 7
OK – ........................................................................................................................................... 7
Setting the Pressure Set Point ........................................................................................................ 7
PID Tuning: ...................................................................................................................................... 8
Proportional- .............................................................................................................................. 8
Integral- ...................................................................................................................................... 8
Derivative- .................................................................................................................................. 9
Optional Back Pressure Control: ..................................................................................................... 9
Setting the P3 and P4 Pressure Set Points ................................................................................... 10
Part Number Nomenclature ........................................................................................................... 10
Wiring (When connected to the Series 1000 Controller): .............................................................. 11
Demand Expander Screen: ..................................................................................................... 12
Operation: ...................................................................................................................................... 13
Maintenance: ................................................................................................................................. 14

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Gardner Denver Corporation
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Introduction:
The Gardner Denver XMX Controller is designed to operate in compressed air systems less than
150 PSIG. When properly placed in the compressed air supply, the controller will offer the
following results.
A. Separates the supply side from the demand side of the compressed air system
allowing each to operate independently.
B. Creates real storage from existing and added air receivers. Allows compressed
air to be stored at a higher pressure reserving energy for event changes in demand.
C. When used with good compressor control, the XMX can avert compressor motor
starts thus conserving energy. Allows the air compressors to operate at their most
efficient pressure converting as much horsepower into compressed air as possible.
D. Operates the demand side of the system at the lowest tolerable level with the
security of stored energy on the supply side in the air receivers. Eliminates artificial
demand by lowering the flow through all leaks and unregulated points of use.
E. Maintains a constant system pressure thus improving the quality and consistency
of plant products and services.
It is important to install the Gardner Denver XMX Controller properly in order to maximize the
benefits and effects of expansion.
Installation:
The controller is completely packaged, only requiring in-line installation and a 115 VAC power
source. However, it is important that the controller is placed in proper relationship with other
system components.
A. The controller must be placed in a common pipeline feeding the entire facility or
desired area of the facility. No other path can be allowed from supply to demand
side piping.
B. The controller must be placed downstream of all clean-up equipment (dryers,
aftercoolers, etc.) and all air receivers and storage tanks.
For operational and maintenance purposes, it is desired that the controller is placed at ground
level, therefore, if possible, overhead piping should be routed to the floor level and back up to the
ceiling after passing through the controller.

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©Copyright 2005-2013
Gardner Denver Corporation
Version 4.10
Left to Right configuration shown above. Right to Left configuration is also available
Since the controller has a built in by-pass, the unit can be simply placed in-line with no valving
requirements by the installer.
It is highly recommended that an automatic drain trap be placed on the outlet side controller
header at the point designated as “Drain”. A trap on the inlet header can be used as well if
desired. Place the factory provided pressure gauges on the inlet and outlet headers at the
indicated points.
Prior to pressurizing the unit, close all valves. Once pressure has been applied, and prior to
applying power, slowly open valve V1. The control valve is normally opened. Slowly open valve
V2, allowing air to flow from supply to demand side without control. Valve V3 (by-pass) should
now be opened and remain opened during the power up and initial tuning stages.
Wiring (Stand-Alone with XMX-1V Controller):
The controller requires a low current 115VAC supply, 2 amps. min. and two shielded and twisted
pairs of wires to the control valve and pressure transmitter located on the Demand Expander
assembly. Terminals L1 and L2 have been designated as the power input terminals and by using
the provided conduit opening, place the 115 VAC hot wire on L1 and the neutral on L2. Close the
cabinet door and apply the power. The display should be illuminated.
115 VAC POWER
L1 L2
Figure 1 - Connect 115 VAC Power to Terminals L1 & L2

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©Copyright 2005-2013
Gardner Denver Corporation
Version 4.10
Using Beldon 9363 or equivalent cable, connect the pressure transmitter mounted on the Demand
Expander assembly to terminals GND, A2+ and A2- as shown below. Also using the same wire
specification, wire the Demand Expander valve positioner to terminals O1+, O1-, and ground as
indicated below.
Placing the Unit into Service:
Prior to opening the controlled circuit and closing the by-pass, the desired setpoint and
preliminary tuning parameters need to be entered into the controller. The following steps are
necessary to achieve the above:
Setting the Regulators:
There is an air pressure regulator mounted and pre-piped on the assembly. It is
factory set, however should be confirmed prior to placing the unit into service.
The regulator, located on the right side of the control box is for the valve power. It is
factory set at 80 PSI and should be checked prior to start-up to assure its correct
setting. This regulator provides pneumotive power to move the valve in response to
the position signal. If an adjustment to the setpoint is required, turn the large knob on
Connect 4-20 mA signal wiring
Valve position signal
(Polarity is not critical)
GRD
A2+
A2-
O1+
GRD
O1-
SHD
Brown
Blue

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Gardner Denver Corporation
Version 4.10
the top of the regulator, clockwise to increase, or counter-clockwise to decrease,
while watching the gauge, until the proper setpoint valve is reached.
Electronic Controller
The Gardner Denver Version 2.0 XMX Demand Expander is provided with a controller using the
Allen Bradley MicroLogix programmable controller. This controller performs as a stand-alone
controller however when connected through its Ethernet port to the Series 1000 system
controller, performs under the control of the master control instructions.
The controller should be wall mounted at eye level in close proximity to the Demand Expander.
The controller has input and output ports for the following:
P3 Storage Pressure –
(Terminals A1+ and A1-) Used only when connected by Ethernet to the ESP 20/20 Series 1000
controller and provides the storage pressure upstream of the Demand Expander to the master
controller. This is not used when the controller is functioning as a stand-alone device.
P4 System Pressure –
(Terminals A2+ and A2-) wire to the downstream pressure transmitter mounted on the XMX
Demand Expander. Provides the control variable to the controller for valve control.
Valve Control –
(Terminals O1+ and O1-) connects to the valve positioner and provides the control to maintain
accurate system pressure.
Field Wiring Terminals
Shielded cables with twisted pairs should be used for the transmitter and valve control wiring.
Beldon catalog number 9363 or equal is recommended.
Once all of the power, signal and control wiring is in place, the unit can be energized with 115
VAC power and the processor will indicate the following screen on its LC display. Pressure and
valve position will reflect the actual values however.

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Gardner Denver Corporation
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Overview Screen
Navigating through the LC Display
The Allen Bradley MicroLogix controller has a liquid crystal display that allows values to be
viewed and set points to be entered by the operator. There are three buttons associated with
the display.
ESC –
The ESC button will return the screen to the main screen. If held for more than three seconds,
the ESC key will return the screen to the processor information menu. If this is inadvertently
done, use the menu to select USER DISPL. The main screen indicating the P4 pressure and
valve position will be displayed.
CURSER –
The diamond shaped curser control button in the middle will be used to advance numerical
values up or down as desired. When the set point screen is displayed, for example, the curser
up arrow will increase the set point and the curser down arrow will decrease the pressure set
point.
OK –
The OK button accepts the current value displayed on the input screens and advances the
screen to the next in the sequence.
Setting the Pressure Set Point
As a stand-alone controller, the set point is entered through the LC display by pressing the OK
button as described above. The set point entry screen will appear as follows:
REMOTE
XMX DEM EXP
P4 PRESS = 85
VALVE % = 92

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Gardner Denver Corporation
Version 4.10
Set Point Screen
By using the curser up or curser down key the value shown above as 85, can be adjusted
accordingly. Press the OK button to advance to the next screen.
PID Tuning:
Proportional-
PID tuning is accomplished through the next three displays. The first display is for adjusting the
Proportional Gain. This is the value that establishes the size of the response that the valve will
take as a result of a deviation from set point. The factory set point for this is 20 and is often times
perfect for good control. However, if the valve is oscillating or not maintaining set point this value
can be adjusted up or down by using the curser key. Generally, this will be moved lower if the
valve control is erratic.
Proportional Set Point Screen
Integral-
By pressing OK, the value will be accepted and the screen will advance to the INTEGRAL set
display. The integral is a value in times per minute that the deviation from set point is examined
and a bias affect is taken by the valve to drive the control variable to the set point. The display is
the actual value times 10, and is factory set to 1. This actually represents 0.1. This is generally a
perfect set point for the integral however if the valve is erratic, or the pressure is offset from the
set point, this may be increased.
Integral Set Point Screen
REMOTE
XMX DEM EXP
SETPOINT?
= 85
REMOTE
XMX DEM EXP
PROPORTIONAL
= 20
REMOTE
XMX DEM EXP
INTEGRAL
= 1

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©Copyright 2005-2013
Gardner Denver Corporation
Version 4.10
Derivative-
By pressing OK, the value is accepted and the screen advances to the DERIVATIVE set display.
It is not recommended that the derivative value is set to any value above zero. If the system has
wide swings in demand and the valve is not keeping up, the derivative function biases the control
based on the rate of pressure change. It can be increased slowly in order to assist with valve
control. This is very rare however.
Derivative Set Point Screen
When the OK button is again pushed, the screen will return to the overview display providing the
actual system pressure and valve position. The system is ready for operation.
Optional Back Pressure Control:
The standard controller has an optional software routine that will provide forward pressure control
with overriding back pressure protection. The Demand Expander must be order with a normally
closed valve. Both P3 and P4 pressures must be connected and set points for both forward
pressure and back pressure must be entered. When selected, by the installation of a jumper
between +24 VDC and I/1 on the processor’s input terminals, the software automatically adjusts
and the screen navigation reflects the added set point entry requirements and pressure displays.
Pressure will alternate between P3 and P4 pressure on the overview display and valve position
will reflect the actual valve output signal in percent.
Alternating Overview Screens
The main overview screen will alternate between the P3 and P4 pressure readings and provide
the valve position as calculated by the controller.
REMOTE
XMX DEM EXP
DERIVATIVE
= 0
REMOTE
XMX DEM EXP
P3 PRESS = 85
VALVE % = 92
REMOTE
XMX DEM EXP
P4 PRESS = 92
VALVE % = 92

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©Copyright 2005-2013
Gardner Denver Corporation
Version 4.10
Setting the P3 and P4 Pressure Set Points
As a stand-alone controller, the set point is entered through the LC display by pressing the OK
button as described above. The set point entry screen will appear as follows:
Upstream Set Point Screen
By using the curser up or curser down key the value shown above as 92, can be adjusted
accordingly. This set point represents the minimum pressure allowable on the high pressure side
of the Demand Expander. Press the OK button to advance to the next screen.
Downstream Set Point Screen
The same method is used on the next screen to set the control for the low pressure system. This
set point should represent the maximum allowable pressure on the low pressure side of the
valve. Press the OK button to advance to the next screen.
Part Number Nomenclature
XMX-1 00
Blank = Normally Open Valve, “C” = Normally Closed Valve
“R” = Discharge connection to the Right, “L” = Discharge
Connection to the Left
“L” = Inlet connection to the Left, “R” = Inlet Connection to the
Right
Valve Size, 1.5” through 8”
REMOTE
XMX DEM EXP
P3 SETPOINT?
= 92
REMOTE
XMX DEM EXP
P4 SETPOINT?
= 85