Ingersoll-Rand X4I User manual

Ingersoll Rand
System Automation X4I
Operator’s Manual
More Than Air. Answers.
Online answers: http://www.air.irco.com
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
C.C.N. : 80443617
REV. : A
DATE : APRIL 2007

2
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

3
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

4
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.

5
SECTION 3 — SAFETY
•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:
!
!
WARNING : Risk of Danger
WARNING : Risk of Electric Shock
WARNING : Risk of High Pressure
WARNING : Consult Manual

6
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.

7
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 mApressure 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 mAoutput and a range of up to 8700 PSI (600
bar).

8
X4I MAIN DISPLAY
abc
d
f
g
he
The keypad and navigation keys on the X4I are
depicted below and provide the following functionality.
Keypad and Navigational Keys Functionality
a) Start
b) Reset
c) Stop
d) Menu
e) Enter
f) Escape
g) Up (Plus)
h) Down (Minus)
12:00 #1
ab
10:35
102
PSI
1
A
2
B
3
C
4
D
1
ab
c
e
h
d
f
g
User Interface
The User Interface display functiuonality is
depicted below:
User Interface DisplayUser Interface
Display Functionality
a) System Pressure Value
b) System pressure Units
c) Unit Status
d) Unit Active Functions
e) Time
f) Compressor Number
g) Compressor Sequence Assignment
h) Compressor Status
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)

9
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.
Compressor
#1
IR-PCB
DRIP LEG
PRESSURE TRANSDUCER
RECEIVER
Compressor
#3
IR-PCB
Compressor
#4
IR-PCB
Compressor
#2
IR-PCB
PRESSURE TRANSDUCER CABLE
2ConductorCable
,18 Gauge Stranded
Earth Shielded
No GreaterT han 330FT( 100M)
24VDCControlVoltage
X4I X05 CONNECTOR PT CONNECTOR
25 +VDC Pin #3
26 Signal Pin #1
Reference X4I Operations Manual for Pressure
Sensor Connection Details
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
Compressor #4 Control Cable
Compressor #3Control Cable
Compressor #2 Control Cable
Compressor #1 Control Cable
Pressure Transducer Cable
Compressor #2 Control Cable
X4I X02 CONNECTOR IR-PCBCONNECTOR
V3 V1
71
8 2
9 3
10 4
11 5
12 6
Compressor #3Control Cable
X4I X03 CONNECTOR IR-PCB CONNECTOR
V3 V1
13 1
14 2
15 3
16 4
17 5
18 6
Compressor #4 Control Cable
X4I X04 CONNECTOR IR-PCB CONNECTOR
V4 V1
19 1
20 2
21 3
22 4
23 5
24 6
Compressor #1Control Cable
X4I X01 CONNECTOR IR-PCB CONNECTOR
V1 V1
1 1
2 2
3 3
4 4
5 5
6 6
Reference X4I Compressor
Interconnect and Application Guide
For Connections Between The
Compressor And The IR-PCB
SPECIFICATIONS
Dimensions 11.45” x 9.45” x 6.0”
291mm x 241mm x 152mm
Weight 14lb (6.4kg)
Mounting Wall, 4 x screw fixings
Enclosure IP65, NEMA 4
Supply230Vac +/- 10%,50H
z
115Vac +/- 10%, 60 Hz
Power50VA
Temperature 32°F to 115°F
(0°C to 46°C)
Humidity 0% to 95% RH
(non-condensing)
Ingersoll Rand Automation
Model X4I
Supply Voltage Cable
Local Disconnect (Breaker) Box
Fused for 50VA
Power Cable
3c
onductor (L, N, E)
(Sized inaccordance with local
electrical and safety regulations).
On/Off
Switch

10
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).
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
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.
DEMAND (DRY) SIDE PRESSURE CONTROL
Pressure Sensor Located After Shared Cleanup
Equipment
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.
1
VOLTAGE SELECT
23 4
X04
1
VOLTAGE SELECT
23 4
X04
230Vac
115Vac
EE
N
L
LNE
X01
1234
XPM-TAC24
1
P
P
2
1P
2
P
1
P
2
P
P