Ingersoll-Rand Xe-90M User manual

Control Systems
Xe-90M/145M
R & RS Series
Fixed Speed
Technician’s Pocket Guide

1
About this Pocket Guide
This pocket guide was created to assist Field
Service Technicians when troubleshooting warnings,
alarms within the R-Series/RS-Series machines.
For detailed information of the controller, such as:
navigation keys, controller display layout, installation
info, and basic operation download in Passport the
following PDF files:
Product information manuals:
R37-160kW: CCN 80446164
RS30-37IE: CCN 80448830
RS200-355I/IE: CCN 80449028
*For Engineering Data, P&ID, and Electrical
Schematics visit Sales Library (website not
available on tablets)

2
Table of Contents
Description
Pages
Controller Introduction
3-4
Main Customer’s Power Supply
5
Fuse Designation for R & RS-Series
6-7
T1 Transformer & Control Voltage 115 VAC
8
Quick Disconnect Plugs/Connectors
9-10
P1 Triac Outputs
11-30
P2 Relay Outputs
31-32
P3 Digital Inputs
33-38
P4 Outputs Digital-Analog Outputs
39-40
P5 Analog Pressure Sensor Inputs
41-48
P6 Analog Temp Sensor Inputs
49-56
P7 USB Service Tool
57
P8 RJ45 Ethernet Port
58
P9 RS485 Communication (COM1‐4)
59-60
P10 24VDC Power Supply
61
Warnings & Alarms Troubleshooting Tips
62-107
Start Inhibit Trip Guide
108
Tips To Test The Triac (P1 Terminal)
109-115

3
CONTROLLER INTRODUCTION
The Xe-90M/145M control system provides
efficient and reliable compressor operation. The
controller supports thirty languages,
independently configurable units of measure as
well as enhanced network and communication
capabilities.
This microprocessor-based controller uses a
finger touch membrane for operation of the
compressor and setting control parameters.
Information about the programming and
operating status is available on a Liquid Crystal
Display (LCD) from a system of Folders and
Pages.
The controller monitors compressor health and
should any pre-programmed limit be exceeded
the controller automatically displays a warning
or issues a trip to shut the compressor down.

4
The major components of the control system
include the controller, voltage transformer, and
solenoid valves to control compressor
operation.
A series of pressure sensors, temperature
sensors, relays, and switches make up the
instrumentation that provides feedback to the
controller.
Operating and navigating the controller is easy
and intuitive through a series of folders and
pages within the graphical user interface (GUI).
The following explanation introduces and
describes the major components that make up
the Xe control system. Always refer to the
drawings and schematics for your specific
compressor or application.

5
Customer’s Main Power Supply
The customer is responsible for correctly sizing and
installing the Main Fuse Protection. This is intended to
protect the machine during an overcurrent condition.
These fuses should be time-delay in order to
accommodate the inrush current at machine startup.
For an instant, the inrush current drawn by the machine
can be several times greater than the full-load rating.
*See the Engineering Data sheets in Sales Library for
fuse and cable size recommendations.
*Main Fuse Protection not shown in Electrical
Schematic.
Important note: Ingersoll Rand (IR) recommends
fuses and cable size in the Engineering Data Sheet to
facilitate the electrical installation of the machine.
IR is not responsible of customer’s power supply,
electrical installation outside the air compressor, nor
size fuses/cable gage for the customer.

6
Fuse Designation for R & RS-Series
Always use local electrical code or National
Electrical Code manual (NEC) to size fuses.
FU 1, 2, 3 RS-Series Fan Drive Fuses
Fuses are required when the Low ambient option is
installed in the machine. FU1, 2, & 3 Fast Acting Class-
J fuses protect the Fan Drive (FD) in single stage units.
For 2-Stage units, the machine is designed with two
Fan Drives FD1 & FD2. The second Fan Drive (FD2) is
mentioned below.
FU1, 2, 3 R-Series Fan Drive
Fuses are required when the Low ambient option is
installed. The Fan Drive is called FD.
FU4, 5, 6 Fuses for New RS-Series Single & 2-Stage
RS30-37ie FU 4, 5, 6: A three-phase auto-transformer
is required for water cooled units (W/C) at

7
575VAC/60Hz. Dryer option at 208VAC/60HZ and
575VAC/60Hz.
RS200-250kW FU 4, 5, 6: This machine uses two Fan
Drives FD1 and FD2 when the Low Ambient Option is
installed. The Fast Acting Class-J fuses protecting FD2
are FU4, 5, 6.
FU7, 8, 9 R-Series Dryer Fuses (S-S)
Fuses are required when the Dryer option is installed.
FU7, 8, 9 RS-Series Fuses Low Ambient (2-S)
A three-phase auto-transformer is required with the
Low Ambient option at 575VAC/60HZ.
FU10, 11 Fuses
Fuses 10 and 11 are an acceptable alternative to
MCB1 and required when line power is 575VAC/60HZ

8
T1 Transformer & Control Voltage 115 VAC
T1 - Control Transformer
T1 is the schematic designation
of the control transformer. A
step-down transformer (T1)
reduces the incoming line
voltage to levels suitable for use
with the Xe control system. The
reduced voltage sources are
called secondary circuits.
The secondary circuit is rated at
115Vac, 1 phase, 60Hz and is
used to energize solenoid valves and starter coils. The
“hot” connection is X1 and the neutral connection, X3,
is grounded to the starter chassis.
Ensure transformer is grounded according to the
electrical schematic of the machine.

9
Quick Disconnect Plugs/Connectors
*Also known as Phoenix
connector
A group of differently sized terminal plugs is used to
connect control and instrument wires to the controller.
These connectors are female Phoenix type (5.08mm
spacing) and plug into matching male receptacles on
the controller. Devices and instrumentation connected
through each plug are dependent on machine
configuration as defined in the electrical schematic and
label on the back of the controller cover. Caution
should be used to ensure each plug is properly
inserted into the correct receptacle.
Always refer to the compressor electrical schematic.
These plugs are designed to be inserted in one
direction only. The wiring schematic identifies the
proper terminal plug for each connected device or
instrument.
For example, the 115VAC circuit passes through a
circuit breaker and Emergency Stop switch with the
“hot” connected to P1-1 and neutral P1-10.