Ingersoll-Rand Xe-145M User manual

80448905
Revision A
January 2016
Save These Instructions
Compressor Control System
Instruction Manual
Model Xe-145M Reciprocating Compressors
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EN
2 80448905 Rev A
SAFETYINFORMATION................................ 4
EXPLANATION OF SAFETY SIGNAL WORDS. . . . . . . . . . . . . . . 4
GENERAL WORKPLACE SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . 4
DOCUMENTATION, DECALS & TAGS. . . . . . . . . . . . . . . . . . . . . . 4
PERSONAL PROTECTIVE EQUIPMENT & ATTIRE . . . . . . . . . . . 4
OPERATION.............................................4
SAFETYINFORMATION................................ 5
SERVICE, MAINTENANCE, AND REPAIR . . . . . . . . . . . . . . . . . . . 5
INTERFACEDATA&KEYS.............................. 6
Xe-145M...............................................6
LEDSTATUSICONS......................................6
COMMANDKEYS .......................................6
NAVIGATIONKEYS......................................7
DISPLAYLAYOUT .......................................7
FOLDERNAVIGATION&ICONS...........................7
PAGENAVIGATION.......................................7
INTERFACEDATA&KEYS.............................. 7
ACCESSINGPARAMETERS................................8
DASHBOARDICONS.....................................8
DASHBOARD STATUS MESSAGES. . . . . . . . . . . . . . . . . . . . . . . . .8
HOMEFOLDER .........................................8
SYSTEMOVERVIEW......................................8
INTERFACEDATA&KEYS.............................. 8
COUNTERS..............................................9
ANALOGINPUTS ........................................9
RECIPROCATING COMPRESSORS. . . . . . . . . . . . . . . . . . . . . . . 9
OPERATOR SETTINGS FOLDER . . . . . . . . . . . . . . . . . . . . . . . . .10
OPERATORSETTINGS.................................. 10
OPERATOROPTIONS .................................. 11
CALIBRATESENSORS .................................. 12
EVENTSFOLDER.......................................12
ChangeInletFilter..................................... 12
OverPressure ......................................... 13
SensorFailure......................................... 15
InvalidCalibration..................................... 15
EmergencyStop....................................... 15
MainMotorOverload.................................. 15
StarterFault1SL(2SL) ................................. 15
RemoteStartFailure................................... 15
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RemoteStopFailure................................... 15
TripEventsList ........................................15
SensorFailure......................................... 17
StartInhibitList ....................................... 18
CheckSDCard ........................................ 18
TRIPHISTORY .........................................18
PAGES1TOAMAXOF3 ............................... 18
GRAPHINGFOLDER....................................18
PAGES 1 THRU 5 – INDIVIDUAL GRAPHS . . . . . . . . . . . . . . . . 18
PAGE 6 – GRAPHING SELECTIONS . . . . . . . . . . . . . . . . . . . . . . 19
MAINTENANCEFOLDER................................19
PAGE1–FILTERSTATUS ............................... 19
PAGE 2 – MAINTENANCE STATUS . . . . . . . . . . . . . . . . . . . . . . . 19
PAGE 3 - MAINTENANCE CONFIGURATION . . . . . . . . . . . . . . 19
GENERALSETTINGSFOLDER...........................19
PAGE 1 – LANGUAGE SELECTION . . . . . . . . . . . . . . . . . . . . . . . 19
PAGE 2 – UNITS OF MEASURE SETTINGS . . . . . . . . . . . . . . . . 20
PAGE 3 – HOME PAGE SELECTION . . . . . . . . . . . . . . . . . . . . . . 20
PAGE 4 – TIME & DATE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . 20
PAGE 5 – BACKLIGHT SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . 20
PAGE 6 - SERIAL PORT ADDRESS SETTINGS . . . . . . . . . . . . . 21
PAGES 7 AND 8 – ETHERNET SETTINGS . . . . . . . . . . . . . . . . . 21
PAGES 9 AND 10 OPTION MODULE INFORMATION . . . . . . 21
INTEGRAL SEQUENCING FOLDER . . . . . . . . . . . . . . . . . . . . . . .21
STATUSFOLDER.......................................22
PAGES 1 AND 2 – ANALOG INPUTS . . . . . . . . . . . . . . . . . . . . . 22
PAGE3–COMPRESSORDATA.......................... 23
PAGES 4 THRU 5 – DIGITAL INPUTS . . . . . . . . . . . . . . . . . . . . . 23
PAGES 6 AND 7 – DIGITAL OUTPUTS . . . . . . . . . . . . . . . . . . . . 23
FACTORYSETTINGSFOLDER ...........................24
PAGE1–PASSWORD .................................. 24
PAGES 2 THRU 3 – FACTORY SETTINGS. . . . . . . . . . . . . . . . . . 24
PAGES4–FACTORYSETTINGS ......................... 24
COMMISSIONING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . .25
WEBACCESS ........................................25
CONNECTINGTOAPC .................................26
ETHERNETCONFIGURATION ...........................30
LOGINPROCESS.......................................31
DEFAULTACCOUNTS...................................33
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CONTENTS

EN
80448905 Rev A 3
NAVIGATION...........................................34
TABNAVIGATION ......................................34
COMMANDBUTTONS..................................34
DASHBOARDICONS ...................................35
HOMEPAGE...........................................36
EVENTLOGUTILITY....................................37
PERFORMANCELOGUTILITY...........................39
GRAPHINGUTILITY ....................................41
INSPECTIONLOGUTILITY..............................44
COMPRESSORINFORMATION ..........................46
COMPRESSOR IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . .46
EMAIL(SMTP)SETTINGS ...............................47
COMPRESSORDETAILS.................................48
UNITTYPE.............................................48
ACCOUNTMANAGEMENT..............................49
MODBUS CONNECTION AND CONTROL . . . . . . . . . . . . . . . 53
MODBUSTABLE .....................................54
CONTENTS CONTD..

EN
4 80448905 Rev A
Only allow Ingersoll Rand trained technicians to perform
maintenance on these products. For additional information
contact Ingersoll Rand or nearest Distributor.
The use of other than genuine Ingersoll Rand replacement
parts may result in safety hazards, decreased performance,
and increased maintenance and will invalidate all warranties.
“Original instructions are in English. Other languages are a
translation of the original instructions.”
Refer all communications to the nearest Ingersoll Rand
Oce or Distributor.
SAFETY INFORMATION
EXPLANATION OF SAFETY SIGNAL WORDS
Throughout this manual there are steps and procedures
which, if not followed, may result in a hazard. The following
signal words are used to identify the level of potential hazard.
DANGER
Indicates an imminently hazardous
situation which, if not avoided, will
resulting death or serious injury.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury or
property damage.
NOTICE
Indicates information or a company
policy that relates directly or
indirectly to the safety of personnel
or protection of property.
Note: Important Information
GENERAL WORKPLACE SAFETY
The information presented in this manual should
be used in conjunction with your workplace safety
program.
It is the responsibility of each individual to ensure that
they work in a safe manner and in compliance with any
local law or site regulations.
Keep the work area clear of hazards.
Assess hazards, make a list, and discuss with appropriate
personnel.
Know how to quickly contact emergency assistance.
DOCUMENTATION, DECALS & TAGS
Read and understand this manual before handling and
installing this product.
Locate, read and understand all hazard alert symbols,
text decals and tags which point out items of extreme
importance to personal safety.
It is your responsibility to make this information
available to others.
Failure to observe these safety guidelines could expose
personnel to potentially hazardous situations which, if
not avoided, could result in death or serious injury.
If you have any questions about safety or procedures not
included in this manual, ask your supervisor or contact
any Ingersoll Rand oce or qualied Ingersoll Rand
distributor.
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PERSONAL PROTECTIVE EQUIPMENT & ATTIRE
Wear personal protective equipment that is appropriate
for the task (i.e. safety glasses with side shields,
respirator, hearing protection, cut resistant gloves and
safety shoes) at all times.
Long hair must be tied back or otherwise secured.
Clothing must be close-tting.
Do not wear jewelry.
OPERATION
This product must only be operated by trained (or
qualied) personnel.
Never remove or tamper with safety devices, guards or
insulation materials tted to the unit.
The product must only be operated at the supply
voltage and frequency for which it is designed.
If the user employs an operating procedure, an item
of equipment, or a method of working which is not
specically recommended, the user must ensure the
product will not be damaged or made unsafe and that
there is no risk to persons or property.
When the 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. This
work must only be carried out by a qualied electrician
or technician equipped with the correct tools and
appropriate protection against electrical hazards.
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80448905 Rev A 5
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SAFETY INFORMATION
SERVICE, MAINTENANCE, AND REPAIR
Repairs should be made only by authorized trained
personnel. Consult your nearest Ingersoll Rand
authorized service provider.
Lethal voltages are used within the product. Use
extreme caution when carrying out electrical
checks. Isolate the power supply before starting any
maintenance work.
If replacement parts are required, use only genuine
Ingersoll Rand parts.
Ensure that all instructions concerning operation and
maintenance are strictly followed and that the complete
product, with all accessories and safety devices, is kept
in good working order.
The accuracy of sensing devices must be checked on a
regular basis. They must be calibrated or replaced when
acceptable tolerances are exceeded. Always ensure any
pressure within a compressed air system is safely vented
to atmosphere before attempting to remove or install a
sensing device.
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The product 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 any of the Xe-145M modules or obscure
any indicators, instructions, warnings, or data labels.
Battery may explode if mistreated. Do not recharge,
disassemble, or subject to re.
The battery used in controller model Xe-145M must be
replaced at an Ingersoll Rand service center or by an
authorized Ingersoll Rand service technician.
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6 80448905 Rev A
INTERFACE DATA & KEYS
Xe-145M
The standard user interface conguration of the controller
consists of the membrane and the LCD display. The
membrane consists of ve command keys (Start, Stop, Load,
Unload, and Reset), four navigation keys (Up, Right, Left and
Down), and an Edit mode selection key (Enter). These keys,
in conjunction with the color graphics display and the LED
icons, make up the user interface to the compressor.
Figure : Xe-145M
LED STATUS ICONS
Three LED icons are used to indicate the current status of the
control system from a distance and are located on the upper
left side of the user interface.
Icon Name Function
OK
Illuminates when no
Warnings or Trips are sensed.
Can be in a Ready or Not
Ready state. This icon will
ash when the machine is
Running Unloaded
Alert
Illuminates when an Warning
(ashes) or Trip (constant on)
is sensed. Can be in a Ready
(Warning) or Tripped state.
Auto
Illuminates when the
compressor stops in auto
restart.
COMMAND KEYS
These keys command the controller to perform actions as
specied in the following table. When any of these keys are
pressed the action below will be initiated and logged in the
event log.
Key Name Function
--- None
Load
Puts the compressor into the
selected mode of operation.
Unit will load if the pressure
conditions are right.
Unload
Puts the compressor into an
unloaded state. Unit will run
unloaded indenitely.
Reset
Clears Warnings and Trips
once the condition is
corrected.
Start Starts the compressor.
Stop
Stops the compressor. This
button should be pressed
instead of the E-Stop for
normal stopping operation.
Enter
Toggles the display between
the Navigation mode and the
Edit mode.
Xe-145M Command Keys

80448905 Rev A 7
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NAVIGATION KEYS
There are four navigation keys (UP, RIGHT, DOWN and LEFT).
While the ENTER key is not considered a navigation key, it
is used in conjunction with the navigation keys to make or
conrm a selection.
Xe-145M Navigation Keys
The navigation keys roll over. Pressing one of the navigation
keys will lead the user down a navigation path. Each time
the key is pressed, another step in the path is taken. Once
the end of a navigation path is reached, pressing the key one
more time will bring the user back to the beginning of the
path. Pressing the opposite key will move the user through
the navigation path in the opposite direction. Once the
beginning is reached, pressing the opposite key will take the
user to the end of the path.
DISPLAY LAYOUT
Xe-145M Display Layout
Folder Bar: Uses tabs to graphically identify each
folder.
Title Bar: Identies current folder and page
(underlined).
Page
Content:
Content of the current page.
Dashboard: Displays system status.
FOLDER NAVIGATION & ICONS
To move among the tabbed folders shown on the LCD display,
press the RIGHT and LEFT keys. The navigation rolls over from
the last to the rst folder and vice-versa.
Folder
Name Icon Description
Home
System performance and status
main information. The rst page
of this folder is the default page
when the controller rst powers
up.
Operator
Settings
System options and conguration
settings.
Events System events log.
Trip History Details on the most recent trips.
Graphing On-board graphing of system
data. (Xe-145M Only)
Maintenance Status and notication setup for
compressor maintenance items.
General
Settings
General settings such as
Language, Time, and Units of
Measure.
Integral
Sequencing
Intergral Sequencing
communication status and
conguration.
Status Measurements or status from/of
all analog and digital I/O.
Factory
Settings
Compressor tuning parameters.
Also displays hardware and
software versions.
Folder Bar Icons
PAGE NAVIGATION
Once the desired folder is selected, press the DOWN key to
move to the page selection area and then use the RIGHT and
LEFT keys to select the desired page. Use the UP key to get
back to the folder tabs.
Icon Description
Start of the page selection area.
Indicates that there are more pages available
by navigating right.
Indicates that there are more pages available
by navigating left.
Title Bar Page Icons
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INTERFACE DATA & KEYS

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8 80448905 Rev A
ACCESSING PARAMETERS
After the desired page is selected, the page’s parameters can
be selected by using the DOWN key. The cursor will move to
the next parameter each time the DOWN key is pressed. Use
the UP key to go back to the previous one.
The cursor rolls over, so once the last parameter is selected,
pressing the DOWN key will navigate the cursor to the Folder
Bar. If the rst parameter is selected, pressing the UP key will
move the cursor to the page selection area.
Once selected, access parameters by pressing the ENTER key.
Make changes using the NAVIGATION keys and then enter the
setting by pressing the ENTER key again. Note that the LEFT
ARROW key is used to select a digit to adjust. The UP ARROW
and DOWN ARROW keys are used to set the digit higher and
lower. Pressing the RIGHT ARROW key will highlight the
cancel button.
When the cursor is on a parameter that has an enabled/
disabled box, pressing the ENTER key will cause the setting to
toggle.
The icon appears on numeric entry windows (see gure
below). Placing the cursor on it and then pressing the ENTER
key will cancel the entry and any changes that were made.
Not all pages have adjustable parameters. Some just
have read-only information.
DASHBOARD ICONS
The dashboard is intended to be a quick at-a-glance view of
system status. The following table lists standard dashboard
icons and their denition. Note that the color of these icons
changes based on the state set by the application while
running.
Name Icon Description
Remote
Control
Remote control is enabled. This
can be Remote Start/Stop, COM
Control, Integral Sequencing or
Web Control.
Service
Required
A service reminder is nearing or
has expired (i.e.: an air or oil lter
needs to be changed).
Unloaded
or
Loaded
Compressor is in the unloaded
state.
Compressor is in the loaded state.
Xe-145M Dashboard Icons
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DASHBOARD STATUS MESSAGES
The dashboard also displays the current operating state of the
compressor. The following states can be encountered during
machine operation:
Ready to Start - – The compressor currently has no trip
or start inhibit conditions present. The machine can be
started by pressing the start button at any time
Starting – A start command has been given to the
compressor and the start sequence is being performed.
The time period for this state can vary depending on the
starter type of the machine.
Load Delay – The compressor is waiting for a small
period of time after starting before allowing the machine
to load. This ensures the machine is at operating
conditions before loading
Running Loaded – The compressor is operating and
producing air. The inlet valve is open and the blowo
valve is closed.
Running Unloaded – The compressor is operating,
but not producing air. The inlet valve is closed and the
blowo valve is open.
Auto-Restart – The compressor has stopped due to
pressure rising above the oine or auto-stop setpoints
and auto-restart being enabled. The compressor will
automatically restart when pressure falls to the online or
target pressure setpoint.
Stopping – The compressor has received a stop
command and the stop sequence is being performed.
Blowdown – The compressor must wait for a brief period
of time after stopping its motor before it is allowed to
start again.
Not Ready – The compressor has detected a condition
that will not allow the compressor to start. The condition
must be cleared before a start is allowed, but does not
need to be acknowledged.
Tripped – The compressor has detected an abnormal
operational condition that has stopped the machine. A
trip must be acknowledged by hitting the reset button
before the compressor can start.
Processor Init – The controller is being initialized.
HOME FOLDER
SYSTEM OVERVIEW
This is the factory default display after powering up the
system.
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INTERFACE DATA & KEYS

80448905 Rev A 9
EN
Load Pressure - indicated in the white box and by the
white arrow, which is always left of center on the gauge. The
compressor will load when package discharge pressure falls
below this value.
Unload Pressure - indicated in the white box and by the
white arrow, which is always right of center on the gauge. The
compressor will unload when package discharge pressure
rises above this value.
Package Discharge Pressure - indicated by the large
numbers centred below the gauge and by the red arrow. This
is the air pressure that the compressor is supplying to the
plant.
Pressure Unit of Measure - indicated below the Package
Discharge Pressure. This is selectable from the GENERAL
SETTINGS folder.
Package Discharge Temperature - indicated by the numbers
in the lower right of the display. This is the temperature of the
compressed air/at the discharge of the compression module.
The Package Discharge Temperature is only displayed if the
Hot Discharge option is disabled.
Temperature Unit of Measure - indicated to the right of the
Airend Discharge Temperature. This is selectable from the
GENERAL SETTINGS folder.
Percent Load - Indicates the current capacity being delivered
by the compressor. Note that this will vary based on the load
control method of the compressor. Two step control will
show only 0% or 100%. Three step control will show 0%, 50%,
and 100%. Five step control will show 0%, 25%, 50%, 75%,
and 100%
Run Hours indicate the number of hours the compressor has
been running.
All information on this page is read only.
COUNTERS
Hour Meters - Indicates the hours that: the controller has
been powered up, the compressor has been running, and
the compressor has running loaded. at 100%, loaded at 75%,
loaded at 50%, or loaded at 25% capacity. Note that the
number of counters will vary depending on the compressor
type. Compressors with two step control will only display
100% Loaded Hours. Compressors with three step control will
display 100% and 50% Loaded Hours. Compressors with ve
step control will display 100%, 75%, 50%, and 25% Loaded
Hours.
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Starts - Indicates the number of times a start is attempted on
the compressor.
Date & Time – Indicates the current date and time. This is
adjustable and congurable in the GENERAL SETTINGS folder.
All information on this page is read only.
ANALOG INPUTS
Pressure is indicated by this icon.
Temperature is indicated by this icon.
Any sensor that is not installed or is reporting a failure will
show an X symbol.
All information on these pages is read only.
The following analog inputs are displayed in this section.
Frame Oil Pressure – The pressure of the oil being delivered
to the cylinder.
Water Inlet Pressure - The pressure of the cooling water at
the intake to the cooling system
Water Outlet Pressure - The pressure of the cooling water at
the discharge of the cooling system
Package Discharge Pressure - The pressure the compressor
is delivering to the plant
1st Stage Discharge Pressure - The pressure of the air at the
discharge of the rst stage of the compression module
2nd Stage Discharge Pressure - The pressure of the air at the
discharge of the second stage of the compression module
Suction Pressure - The pressure if the intake air to the
compressor when boosted from another compressor.
Inlet vacuum - The vacuum reading at the inlet valve
Frame Oil Temperature - The temperature of oil being
delivered to the cylinder
Water Inlet Temperature - The temperature of the cooling
water at the intake of the machine
2nd Stage Inlet Temperature - The temperature of the air at
the intake of the second stage of the airend.
3rd Stage Inlet Temperature - The temperature of the air at
the intake of the third stage of the airend.
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RECIPROCATING COMPRESSORS

EN
10 80448905 Rev A
Package Discharge Temperature - The temperature of the
air as delivered to the plant.
1st Stage Discharge Temperature - The temperature of the
air as it leaves the rst stage of the compression module.
2nd Stage Discharge Temperature- The temperature of the
air as it leaves the second stage of the compression module.
3rd Stage Discharge Temperature - The temperature of the
air as it leaves the third stage of the compression module.
1st Cylinder Discharge Temperature - The temperature
of the air as it leaves the rst compression module of a two
airend compressor
2nd Cylinder Discharge Temperature - The temperature of
the air as it leaves the second compression module of a two
airend compressor
OPERATOR SETTINGS FOLDER
OPERATOR SETTINGS
The below values are all setpoints.
Oine Pressure – The compressor will unload when package
discharge pressure rises above this value. Range (in PSI): 30 to
Rated Pressure
Online Pressure – The compressor will load when the
package discharge pressure falls below this value Range (in
PSI): 20 to Oine Pressure - 2
Starter Time – Time period that the compressor needs in
order to come up to operating speed after a start command
before being able to produce air.
Range (in seconds): 5 - 30.
Load Delay Time - Determines how long after the
compressor starts the machine must wait prior to
compressing air.
Range (in seconds): 15 - 60
High 1st Stage Discharge Temperature Trip - Determines
the trip point for the 1st Stage Discharge Temperature
reading.
Range (in degF): 150 - 500
Compressors Present: ESV Atmospheric, Two Stage
Atmospheric, Three Stage Atmospheric, ESV Booster
High 2nd Stage Discharge Temperature Trip - Determines
the trip point for the 2nd Stage Discharge Temperature
reading.
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Range (in degF): 150 - 500
Compressors Present: Two Stage Atmospheric, Three Stage
Atmospheric
High 3rd Stage Discharge Temperature Trip - Determines
the trip point for the 3rd Stage Discharge Temperature
reading.
Range (in degF): 150 - 500
Compressors Present: Three Stage Atmospheric
High 1st Cylinder Discharge Temperature Trip - Determines
the trip point for the 1st Cylinder Discharge Temperature
reading
Range (in degF): 150 - 500
Compressors Present: Two Airend Booster
High 2nd Cylinder Discharge Temperature Trip -
Determines the trip point for the 1st Cylinder Discharge
Temperature reading
Range (in degF): 150 - 500
Compressors Present: Two Airend Booster
High Frame Oil Temperature Trip - Determines the trip point
for the Frame Oil Temperature reading
Range (in degF): 120 - 210
Compressors Present: ALL
Low Water Inlet Temperature Trip - Determines the trip
point for the Water Inlet Temperature reading
Range (in degF): 20 - 50
Compressors Present: ALL
High Water Inlet Temperature Trip - Determines the trip
point for the Water Inlet Temperature reading
Range (in degF): 50 - 150
Compressors Present: ALL
High 2nd Stage Inlet Temperature Trip- Determines the trip
point for the 2nd Stage Inlet Temperature reading
Range (in degF): 80 - 160
Compressors Present: Two Stage Atmospheric, Three Stage
Atmospheric, Two Stage Booster
High 3rd Stage Inlet Temperature Trip - Determines the trip
point for the 3rd Stage Inlet Temperature reading
Range (in degF): 80 - 160
Compressors Present: Three Stage Atmospheric
High Package Discharge Temperature Trip - Determines the
trip point for the Package Discharge Temperature reading
Range (in degF): 80 - 500
Compressors Present: ALL
High 1st Stage Discharge Pressure Trip - Determines the
trip point for the 1st Stage Discharge Pressure reading
Range (in psi): 25 - 100
RECIPROCATING COMPRESSORS