LCO Technologies CROSSFIRE User manual

The CROSSFIRE
Ultra-Low Power Instrument Air Compressor
Installation and Operations Manual

CROSSFIRE Installation & Operations Manual
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© 2018, LCO Technologies LTD. All rights reserved.
Table of Contents
CSA Requirements and Installation Requirements ................................................................................3
CROSSFIRE Installation Guide .............................................................................................................7
CROSSFIRE Compressor Start Up...................................................................................................... 11
Software Interface Guide..................................................................................................................... 12
Interface Overview ........................................................................................................................... 12
Main menu....................................................................................................................................... 13
Connect to Controller: ...................................................................................................................... 13
Disconnect from Controller:.............................................................................................................. 13
Configuration Panel –Operator configuration................................................................................... 14
Motor Control Panel ......................................................................................................................... 15
Configuration Panel –System setup ................................................................................................ 16
Configuration Panel –I/O config....................................................................................................... 18
Configuration Panel –Advanced Automation ................................................................................... 19
Configuration Panel –Terminal............................................................................................................ 20
Configuration Panel –System status................................................................................................ 21
Possible Fault Codes ....................................................................................................................... 22
Controller Troubleshooting............................................................................................................... 24
CROSSFIRE Maintenance .................................................................................................................. 26
CROSSFIRE Technical Drawings........................................................................................................ 28
Assembled CROSSFIRE Instrument Air Compressor with Fan Cover:............................................. 28
Assembled CROSSFIRE Instrument Air Compressor with No Fan Cover: ....................................... 29
LCO-COMP Top Works Replacement Kit:........................................................................................ 30
CROSSFIRE Compressor Troubleshooting......................................................................................... 31
CROSSFIRE Return and Repairs........................................................................................................ 34
Repairs............................................................................................................................................. 34
Return Procedure............................................................................................................................. 34

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CSA Requirements and Installation Requirements
IMPORTANT SAFETY CONSIDERATIONS
WARNING
AVERTISSEMENT
EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS
MAY IMPAIR SUITABILITY FOR INSTALLATION IN HAZARDOUS LOCATIONS
RISQUE D'EXPLOSION - LA SUBSTITUTION DE COMPOSANTS
PEUT RENDRE CE MATÉRIEL INACCEPTABLE POUR LES
EMPLACEMENTS DANS DES ENDROITS DANGEREUX (CLASSE 1, DIVISION 2).
WARNING
AVERTISSEMENT
EXPLOSION HAZARD - DO NOT REPLACE COMPONENTS
UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS
KNOWN TO BE NON-HAZARDOUS.
RISQUE D'EXPLOSION - COUPER LE COURANT OU
S'ASSURER QUE L'EMPLACEMENT EST DÉSIGNÉ NON
DANGEREUX AVANT DE REMPLACER DES COMPOSANTS.
WARNING
AVERTISSEMENT
EXPLOSION HAZARD - DO NOT CONNECT OR DISCONNECT EQUIPMENT
UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS
KNOWN TO BE NON-HAZARDOUS.
RISQUE D'EXPLOSION - AVANT DE DÉBRANCHER
L'ÉQUIPEMENT, COUPER LE COURANT OU S'ASSURER
QUEL'EMPLACEMENT EST DÉSIGNÉ NON DANGEREUX
WARNING
AVERTISSEMENT
THE CONTROLLER ASSEMBLY IS FOR USE IN CLASS I, DIVISION 2, GROUPS C AND D, AND OR
NONHAZARDOUS LOCATIONS ONLY.
L’APPAREIL DU CONTRÔLEUR CONVIENT À L’UTILISATION DANS LES EMPLACEMENTS
DE CLASSE 1, DIVISION 2, GROUPES C ET D, OU NE CONVIENT
QU’A L’UTILISATION DANS DES EMPLACEMENTS DÉSIGNÉS NON DANGEREUX.
WARNING
AVERTISSEMENT
THE MOTOR ASSEMBLY IS FOR USE IN CLASS I, DIVISION 1, GROUPS C AND D, AND OR
NONHAZARDOUS LOCATIONS ONLY.
L’APPAREIL DU MOTEUR CONVIENT À L’UTILISATION DANS LES EMPLACEMENTS
DE CLASSE 1, DIVISION 1, GROUPES C ET D, OU NE CONVIENT
QU’A L’UTILISATION DANS DES EMPLACEMENTS DÉSIGNÉS NON DANGEREUX.

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© 2018, LCO Technologies LTD. All rights reserved.
AGENCY
CERTIFICATION
Controller Assembly
(Must be placed in a Cabinet/Enclosure that provides a minimum Ingress Protection of NEMA
4/IP54)
Class 1, Division 2, Groups C and D, or nonhazardous.
Temperature Code: T4, Tamb: -40 to 60 Deg. C.
Suitable for Zone 2, IIB.
Motor Assembly
(Motor is for indoor or protected environment use only)
1
Class 1, Division 1, Groups C and D, or nonhazardous.
Temperature Code: T6, Tamb: -40 to 60 Deg. C.
Suitable for Zone 1, IIB.
Models:
Explosion Proof Motor Assembly Model LCOM-1000
Controller Model LCOC-1000-A and Model LCOC-1000-B
IMPORTANT: Conditions of Certification
✓The Controller must be installed within an enclosure suitable for the environment and requiring a
tool or key to open. Controller models LCOC-1000-A and LCOC-1000-B are intended for use in
a Pollution Degree 2 environment.
✓The RS232 connector must be retained with two screws on the mating connector.
✓The Ethernet RJ45 connector must be retained with its original locking tab to withstand a 15
Newton pull force once engaged.
✓Model LCOM-1000 and Model LCOC-1000 must be used together to form a Certified Brushless
DC (BLDC) Motor System. No substitutions of motor types are permitted.
Controller
The controller input voltage rating is 24 VDC. The battery power supply must be capable of supplying
24 VDC to ensure reliable operation and motor start-up. For average current draw based on application
and help with solar sizing, please contact LCO Technologies directly. Current draw on most
applications in steady state is around 0.7-2.0 A, however the rated maximum current draw for the
controller is 9.9A.
The Controller must be protected by external over current protection in keeping with CEC and NEC
practices supplied at the time of installation.
1
Note: Protected environment means the motor must be under a shelter and off the ground to protect the motor
from moisture (such as rain, snow, ice etc.)

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© 2018, LCO Technologies LTD. All rights reserved.
EXTERNAL CONNECTORS
The controller features several external connectors. These are labelled as followed:
•Power In: Connectors are used to connect the 24VDC power supply.
•To Motor: Connectors are used for Phase A, Phase B and Phase C of BLDC. These
connections are not phase sensitive.
Use only copper conductors on supply and motor load terminal blocks
“TIGHTEN TO 10.54 pound-inches (1.2 N•m)”. Or Equivalent
It is a CSA requirement to use #10 straight or ring lugs with 10 - 12 AWG wiring, when connecting to
the Power and Motor connectors. The Controller data connectors can accept 22 to 24 AWG stranded
wire.
All wiring and connections must be in line with accepted wiring practices as outlined by the Canadian
Electrical Code (Canada) and the National Electrical Code (USA) and installed by qualified personnel
only (use copper conductors only.)
There are two patterns of mounting holes on the Controller unit. The four corner mounting positions are
for a direct fastening to the enclosure using # 6 screws. The two patterns of 3 holes are for DIN Rail
mounting brackets. Installer must supply screws and brackets as applicable.

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Motor
Accurate mechanical lineup is essential for successful operation. Mechanical vibration and roughness
in running the motor may be an indication of poor alignment. It is recommended that the lineup be
checked when installed.
For direct coupled applications, use flexible couplings when possible. Use of a sealed fitting at the
motor wiring entrance point is required with a minimum of 5 full thread engagement to maintain the
Class I, Division1 rating of the motor when installed in a Hazardous Area.
The 3-Phase conductors and the Earth ground must be terminated in an approved Class I, Division 1
junction box. The green Earth lead must be grounded to the ground screw in the junction box.
WARNING: Motor, Control and Grounding must be in accordance with Canada - Canadian Electrical Code
and/or USA –National Electrical Code and consistent with Local requirements and practices. Use
Ground lug on exterior of Motor enclosure and Ground lead provided to ensure proper Grounding of the
Motor.
See below for Safe Operating Area Curves (SOAC) for the Motor
Figure 1: Safe Operating Area Curves (SOAC)

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© 2018, LCO Technologies LTD. All rights reserved.
CROSSFIRE Installation Guide
Step 1: Open Shipment
−Confirm the following parts are present
oLCOD-COMPRESSOR Package
▪LCOD-Compressor mounted on an accumulator volume bottle, complete with
pressure transmitter and other accessories ordered
▪Complete with tubing from the compressor to the accumulator volume bottle
oSmart Controller: Part Number # LCOC-1000-B
▪Shipped loose or pre-installed in a C1D2 panel as per customer requirement
−Check to ensure no parts were damaged during shipment
oContact the shipment carrier and file a claim if any damage has been identified
oIf replacement parts are required, please contact your supplier
−Familiarize yourself with all parts and pieces
Step 2: Mount the compressor
−Find a desired location for installation
oA location that can accommodate compressor package dimensions
oEnsure the compressor is in a protected environment and out of the elements
▪For example, inside the skid building
oAvoid direct exposure to catalytic heaters if present in the building
▪The compressor generates its own heat and will run more efficiently when cool
oInstall near the utility gas distribution system
−Set the compressor package down
oRecommendation: Secure the compressor package to the floor; use prefabricated holes
in the base frame to bolt down or weld to attach materials
Figure 2: CROSSFIRE Compressor Package

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Warning: The Compressor is mounted and attached on top of the air accumulator
volume bottle to ensure any moisture present at discharge flows into the accumulator
and not back towards the compressor valves. In addition, the tubing from the
compressor outlet to the accumulator is completed already to ensure moisture can easily
drain. Do not adjust this set up or configuration. Any modifications may affect
compressor performance and will impact product warranty.
Step 3: Tube the compressor
−Remove the air filter and female connector fitting (PFC-06-08-SS) from the LCOD-Compressor
inlet
oKeep the filter attached to the PFC-06-08-SS
−Tube the attached filter and PFC-06-08-SS outside the skid building
oTube the filter out the top of the building so it is outside of the C1D1 environment
▪Confirm the air intake is from a fresh air source and located away from any fuel
gas or combustible gas lines that may be venting
oEnsure the filter is under the building overhang to protect from rain or snow
accumulation
oFace the filter downwards at a 45-degree angle.
Warning: Filter must be protected from rain and snow accumulation and installed at a 45-
degree angle. If insufficient cover from building overhang, water and liquids will be
introduced to the compressor and may affect compressor performance.
−Tube a “dirt pocket”into the system in between the filter and the compressor inlet to allow for
dirt and moisture capture. Attach a ball valve or mini valve or solenoid or back pressure
regulator for control.
−Tube a “dirt pocket”on the accumulator tank outlet and then tube to instruments
Tube provided filter for
the compressor inlet
above and outside of
the building at a 45-
degree angle
Figure 3: CROSSFIRE Compressor Installation P&ID
4-20 mA or 0-5 V Output
Supplied
Relief
Valve
Dirt Pocket
Dirt Pocket
Tube Air Output to
Instrument Header
(Regulate if
Required)
Accumulator
Bottle

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© 2018, LCO Technologies LTD. All rights reserved.
Step 4: Install the Smart Controller (LCOC-1000-B)
−Mount the Controller in a Nema 4 Enclosure as per CSA requirements (page 2 to 6)
−Wire the controller to a 24 VDC power supply
oConnect the 2 conductors, 10 gauge tech cables with appropriate environmental and
classification seals to the controller
−Attach the three conductor cables from the motor to the controller. The green ground wire can
be terminated at any ground. The conductor cables must be terminated in a Class 1, Division 1
junction box at the motor.
oThe three conductor cables will be terminated in the controller at termination points
marked phase A, phase B, and phase C (PH A, PH B, PH C)
oThe wires must be attached in a specific order to ensure the fan spins in the correct
direction. Attach the red wire to PH A, the black wire to PH B,and the yellow wire to
PH C.
oCables are gauge 10 and can be a maximum length of 60 ft
Warning: If the resistance in the gauge 10 wires does not meet AWG standards, the
distance must be reduced proportionately.
Warning: All conductor cables must be attached with proper end ferrule connectors and
clamped down properly with the appropriate tools. Double check that all screw terminals
are tightened down to avoid any electrical connection issues. Similarly, if two wires must
be spliced together, please use a proper splicer connector, clamp down sufficiently, and
do not use electrician twist caps.
Step 5: Install Pressure Transmitter
−A pressure transmitter is already installed on the volume accumulator bottle with the
compressor package. This transmitter allows the CROSSFIRE smart controller to automatically
control the motor speed to maintain a set pressure in the accumulator bottle to maximize energy
efficiency
−Wire in your pressure transmitter to the AI1 port on the CROSSFIRE smart controller according
to the wiring diagrams below
oUse Gauge 20-22 AWG Tech Cable for the AI1 Terminal

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250 Ohm
Resistor
Pressure
Transmitter
0-50 PSI
4-20mA
AI1+
GND
CROSSFIRE Controller
(LCOC-1000-A or LCOC-1000-B)
Red
Black
24 V
-
+
Green
Note: Wiring diagrams are designed for the pressure transmitter that comes standard with the
Compressor Package (Rosemount 2088). Diagrams may be applied to other models requested outside
of the package, however LCO Technologies does not guarantee this. The use of other models may
affect compressor performance and is not recommended without the consultation of LCO Technologies.
Note: Please use Gauge 20, single strand wires for all terminals on the smart controller.
Figure 4: Wiring Diagram for 0-50 PSI, 4-20 mA Pressure Transmitter

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CROSSFIRE Compressor Start Up
Step 1: Download the configuration software
−Go to www.lcotechnologies.com
−Click on the resources tab
−Click on download button and follow all prompted instructions
−ZIP file password: crossfire2017
−The Interface is compatible with the following operating systems:
oWindows XP (32-bit)
oWindows 7
oWindows 8.1
oWindows 10
−Both the operator and technician tabs are password protected.
oOperator Password: Pristine
oTechnician Password: Automation
−Note: When using the Mobile Android or Apple App, the passwords are as follows:
oOperator Password: Pristine
oTechnician Password: Automatio
Step 2: Start the Compressor
−Connect an RS 232 cable to the controller and computer
−Ensure the acrylic top plate and fan enclosure are on the compressor
−Start up the compressor as per the operator interface instructions listed on page 13.
oSelect proportional control mode “36 psi” or “50 psi” based on your application
Warning: Pinch Hazard. Always keep the clear acrylic top plate and the fan cover on the
unit while the compressor is running
Step 3: Observe proper scaling of the pressure transmitter
−Once the compressor is running, isolate the instrument air distribution system and allow the
pressure in the accumulator tank to climb to the set maximum pressure.
oAs the pressure increases, the motor speed will decrease
−Open all valves connecting the compressor to the instruments on site and allow compressed air
to flow throughout the system.
−As instruments use the pressurized air, the compressor will automatically modulate the motor
speed up and down to maintain the set pressure in the accumulator bottle.
Optional Step –MODBUS Communications: The CROSSFIRE Compressor can be connected to a
local SCADA/RTU System and communicate via MODBUS. Consult LCO Technologies for the latest
MODBUS maps and for further instructions on integration.

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© 2018, LCO Technologies LTD. All rights reserved.
Software Interface Guide
The LCO Technologies CROSSFIRE Configuration Software is a tool used to easily monitor and
configure the controller that drives the CROSSFIRE pump and compressor with a RS232 serial
connection. Additionally, a mobile version of the software for cell phones and tablets is available using
Bluetooth Low Energy communications. For additional information on the Bluetooth communications
options, please visit www.lcotechnologies.com/resources.html and refer to the manual titled
“CROSSFIRE Bluetooth Adaptor Manual & Spec Sheet”.
There are two distinct logins for the interface –technician and operator. Operators only have access to
the operator config and system status panels. Technicians have access to all panels which includes
the more advanced automation features.
Interface Overview
The CROSSFIRE configuration software is divided into three regions:
Figure 5: CROSSFIRE Configuration Software main window
1) Main menu bar: Used to connect and disconnect from the CROSSFIRE controller
2) Configuration panel: Used to view and edit the configuration data stored on the CROSSFIRE
controller in addition to selecting compressor model configuration.
3) Motor control panel: Shows motor status and is used to start/stop the motor, and set motor
speed when in manual configuration
1
2
3

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Main menu
Connect to Controller:
The Start here menu is used to connect or disconnect from the CROSSFIRE controller. Select Connect
to controller and provide the following information:
1) Port: Select the number of the COM port that the RS232 serial cable or Bluetooth serial adapter
is connected (see: Troubleshooting –COM Port Issues)
2) Login as: Select operator, or technician. Operators only have access to the Operator config and
the System Status tab of the configuration panel; Technicians have access to all tabs including
ones with more advanced settings such as System setup and I/O config tabs.
3) Password: Enter the correct password to log in to the controller as operator or technician.
oOperator Password: Pristine
oTechnician Password: Automation
If connecting to the controller succeeds, the configuration and status panels will be enabled. If the
attempt to connect fails, an error message will be displayed (see: Troubleshooting –Connection Errors,
page 23-24).
Disconnect from Controller:
Select Disconnect from controller to log out from the CROSSFIRE controller and end device
connection. A pop-up message will be displayed to confirm successful device disconnection.
Figure 8: Successful disconnection
Figure 6: Main menu
Figure 7: Connection window

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Configuration Panel –Operator configuration
The Operator config tab is used to specify the physical setup and operational speed of the
CROSSFIRE platform. The CROSSFIRE can be configured either as a chemical injection pump, or an
instrument air compressor. The software is default to the chemical injection pump. Therefore, first
manually select that the CROSSFIRE is configured as an Instrument Air Compressor. Select the
“Compressor” drop down menu to indicate this configuration.
Figure 9: Operator config
Next, select either “stop when tank at 36 psi” or “stop when tank at 50 psi” to indicate which
proportional control reverse acting input curve to exercise. Please note that both curves will respond
appropriately to a 4-20 mA pressure transmitter when wired with a 250 Ohm resistor, or a 1-5 V
pressure transmitter. Refer to page 10 for wiring diagrams.
Note: Auto system restart function will be automatically enabled in Compressor proportional control
mode. If the system loses power, the system will auto-restart once 24 VDC of power is availible again.

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Figure 10: Save/Reload buttons
The Save to controller button saves any changes made to the settings and the configuration data saved
in the controller. Therefore, select Save to controller once the compressor mode and pressure control
mode has been selected.
The Reload from controller button reloads the saved configuration data from the controller. This
function can be used when connecting to a unit currently running on site to show the current
configuration and operation mode saved to the controller prior to making any changes.
Note: Any unsaved changes made to the settings will be lost.
Motor Control Panel
The motor control panel is used to configure and check the status of the system drive motor:
Figure 11–Motor control panel
When connected to the controller, the start/stop button will start or stop the motor when the controller is
connected and online.

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Configuration Panel –System setup
The System setup tab allows for setup and configuration of the advanced controller features and is
divided into two regions:
Figure 12: Technician config
1) System configuration
2) MODBUS configuration
The system behavior settings are used to reset and change controller behavior.
•Controller code can be used to assign a name or number to the controller (maximum 8
characters)
•Reset system time sets the controller’s system clock to the current date and time
•Gearbox ratio specifies the gear ratio of the installed gearbox on the motor (compressor ratio is
5:1)
•Reinitialize total stroke count will reset the system record of total strokes to zero.
1
2
5
5

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The MODBUS configuration panel is used to view and change the settings of the controller’s MODBUS
port, to properly integrate it with your SCADA system. Configurable options include MODBUS slave ID,
connection baud rate, and parity checking. Data bits and stop bits are determined by the selected parity
option, according to the MODBUS standard. The Save to controller and Reload from controller buttons
will save the settings to the controller and reload the configuration from the controller, respectively.
Warning: As pressing “reset system time” or “reset system total stroke count” has serious
consequences, a warning and confirmation window will appear to confirm action.
Figure 13: Reset stroke count warning

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Configuration Panel –I/O config
The Controller I/O panel is used to view the state of the controller’s discrete input, discrete output,
analogue input, and analogue output pins. Inputs will auto-populate when connected to the controller
however, all I/O configuration for outputs must be done in the terminal tab. Specific control applications
can be exercised under the Terminal tab, which will allow configuration of a wide variety of logic
parameters. Please contact LCO Technologies directly for assistance with I/O configuration.
Figure 14 - I/O config
Note: Monitored values are automatically updated in the interface every few seconds as they change
on the controller.

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Configuration Panel –Advanced Automation
The advanced automation tab is only available to Technicians. This allows selection between manual
control mode, and other proportional control modes. This tab is not required when setting the
compressor up as all functionality is on the operator config panel.
Figure 15- Proportional control

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Configuration Panel –Terminal
The Terminal tab is only available to technicians and allows users to by pass any software selections to
speak directly to the controller. This tab can be used for troubleshooting to determine if communication
errors exist on the controller or software and can also be used for more advanced configuration such as
I/O commands specific to applications. For a full list of applicable commands contact LCO
Technologies directly.
Figure 16- Terminal