Ingerso/J Rand

XI Series Control Philosophy and Expectations

January 18, 2008
Revision C
Industrial Technologies Air Solutions
Davidson NC
 Table of Contents

1.0 Introduction 3
2.0 Tolerance and Damping 5
3.0 Sequencing Algorithms 9
4.0 Ancillary Functions 30
5.0 Accessory Boxes 32
6.0 Multi-485 35
7.0 Compressor Expectations 37
8.0 Revision History 39

.,
1.0 Introduction

The contents of this document are intended to provide a deeper understanding of how the
software in the X41, X81, and X 121operates without delving too deeply into the
algorithms and equations that form the heart of the controllers.

The most important thing to note about the new family of system controllers is that the
logic at the heart of the X41, X81, and XI 21 units is essentially the same. That is, the
logic that tells the system when to load the next compressor is shared among the family of
controllers. The only real differences come when you look at the extra features and the
methods in which the controller determines which compressor to load next. AIso
important to note is that the X81 and the X 121are essentially the same. The X8I has been
restricted to 8 compressors, 2 110 boxes, and a more limited suite of features artificially.
The software is all there; it is just turned off and hidden from view. This makes future
tweaking ofwhich features are avai1able very possible.

From a high level there are basically three layers of software which operate the XI
controllers.

• First, there is the innermost level which consists of the tolerance and damping
algorithms. As noted aboye, these algorithms tell the controller when to load the
next compressor; they have nothing to do with determining which compressor
will be utilized.
• Second, there are the sequencing algorithms. Once the controller has determined
that a compressor needs to be loaded it then needs to determine "well, which one
do I need?" The user is presented with multiple choices in this circumstance; they
can choose from First In last Out, Equal Hours Run, First In First Out, Variable
Energy Control, Energy Control, all dependant on which controller they have
installed. Priority and zoning would be inc\uded in this sequencing layer.
• Lastly, there are the ancillary functions which add extra usability to the controller.
Functions like lntelliflow control, System Prefill, Start Feedback, Pressure
Balancing, Pressure Schedule, etc. provide value to the customer but do not effect
the basic system control.

The X81 and X121 controllers also can make use ofancillary boxes such as the EXP, EX,
DX, CX, VSD, and 110 boxes. These do not directly affect the control of the system but
allow for an extension of this control. There will be a more detailed section in this
document to outline the use of each box. Please note that the TX box that is used with
the visualization aspect of the project is outside the scope of this document.

Also important in the functioning of the X81 and X 121controllers is the Multi-485 serial
network. This is CMes proprietary protocol that is run on a standard two wire RS-485
network. It has the same physical limits as Modbus or any other RS-485 serial network.
Multi-485 is, however, a multi-master network which makes a more efficient use of the
serial bus lo provide robust and timely control lo a compresscd air system. Mulli-485
will be discussed al the end of this document.

This document is meant lo go into more dctail than thc manual about certain subjects (i.c.
tolerance and damping and Multi-485) but in cases where the manual has thorough
information it will be noted.

4
2.0 Tolerance and Damping

As noted in the introduction to this document, Tolerance and Damping form the heart of
the XI series of system controllers. Having a common method of determining when to
load the compressors is very valuable when it comes to understanding system dynamics.
There are essentially only two parameters that need to be adjusted to obtain the system
performance that is needed.

• Tolerance (TO) is expressed in PSI (or Bar) and denotes a band below the Load
Setpoint (PL) where the algorithms will be in control and calculating when lo load
the next compressor for optimal efficiency. Tolerance defaults to 3.0 PSI and
ranges from 1.4 PSI lo 29 PSI. The step size for adjusting the tolerance is
dependent on the range of the installed pressure transducer. The size of the
tolerance band must always be equal to or larger than the size ofthe dead band
and larger than the space between PH and PM or PL and Pm. AII four tables are
taken into account when calculating these minimum and maximum tolerance
values.

• Damping (DA) is a unitless number ranging from 0.1 to 10.0 with a default of
1.0. Damping controls how quickly the algorithms will react to a falling pressure
and also how long the system will let a stable pressure that is below the load
setpoint exist before driving system pressure back up into the dead bando A
setting of 0.1 will react 10 times fas ter than default and a setting of 10.0 will react
10 times slower than the default.

These parameters interact with the pressure band as shown in Figure 1 below. Note that
the only time and load or unload decision will be made is when the system pressure falls
outside of the Deadband demarked below in blue. PH denotes the High Pressure
Setpoint, when an unload decision will take place and PL denotes the Low Pressure
Setpoint, when a load decision will take place.
PH + TO = 99 psi

PH=96PSI ~ - , ,

Deadband
PL = 92 PSI L~~~~ _ --- -----~ -

TO = 3 PSI
PL - TO = 89 PSl

Figure 1 - XI controJler pressure band

The tolerance setting defines the pressure range where the XI controller is allowed to
make decisions as to when is the appropriate time to start andlor load a compressor.
Please note that an XI controller will always load or unload one compressor when the PL
or PH setpoints are initially crossed. Ifsystem pressure remains outside ofthe dead band
the XI controller will make decisions based on the system pressure rate of change. If

5
system pressure stabilizes or begins to head back toward the dead band, the Xl controller
will take a "wait and see" approach. If system prcssurc continues to move away from the
dead band the XI willload compressors in an increasingly urgent manner proportional to
deviation from thc dead bando This logic all takes place in the "Controlled Rcaction
Regions" that are shown below in figure 2.

PM = 105 PSI
'Panic' Reaction - Stop all Compressors
102 PSI
HastenedReaction Reglan
PH + TO = 99 PSI f
Controlled Reaction Region
PH = 96 PSI ~. ---1

Deadband
PL= 92PSI L.

Controlled Reaction Region TO=3PSI

PL TO= 89PSI

Haslened Reacllon Region

86PSI,

"Panic" Reaclion - Start all Compressors

Pm =83PSI
Figure 2 - Tolerance in relation to the dead band

If system pressure continues to move farther from the dead band it may en ter the
"Hastened Reaction Region." This hastened reaction region is essentially a second
tolerance band that is the same size as the inner tolerance band, defined by TO. When
system pressure enters this region the response of the XI continues to increase
exponentially. This increase in response is continuous from the controlled reaction
region, but happens in an exponentially increasing manner. Please note that the response
curve for loading a compressor is not identical to the response curve for unloading a
compressor.

If system pressure still continues to move farther from the dead band it will eventually
reach a point that is 2 times the tolerance away from the dead bando At this point the XI
controller abandons all energy efficient decisions and will start all compressors as quickly
as possible. The XI controller will only wait for the start time of each compres sor before
starting the next machine in the sequence. When the XI controller has reached this region
it will start compressors until it sees a positive rate of change in the system pressure.
Once a positive rate of change is seen the hastened reaction aIgorithms will be in control

Note - The XI controllers need to know the start or star-delta time of each
compressor in arder to properly control the system. As soon as a compressor starts,
the tolerance and damping algorithm is put on hold until the start time elapses, or a
load feedback signal is received from the compressor. This allows the XI to see the

6
effect the comprcssor is having on the systcm bcforc dcciding to start a second
comprcssor.

Note that the XI controllers sample the system pressure every 35 ms and perform a
smoothing operation on the signa!. The master pressure signal must always come from a
transducer that is connected to the X8I or X 121. Also note that tolerance is necessary to
te1Ithe controller when to abandon energy efficient control and keep the system air
pressure in operating range at all costs. This means that a fixed tolerance setting is not
feasible and it must be an adjustable parameter.

Tolerance is the setting that is used to control at what pressures the increasing response to
pressure changes will occur, but damping affects just how quick the response is.
Damping is essentially a coefficient that ranges from 0.1 to 10.0 and is used to multíply
the rate of change calculations. Having a damping of 0.1 will cause the XI controller to
respond 10 times faster than the default setting of 1.0 and having a damping of 10.0 will
cause the XI controller to respond 10 times slower than the default setting.

Damping also performs one more important function that can arise in a system with one
or more variable speed compressors. When the system pressure achieves stability in a
position that may be outside of the dead band but inside the "Controlled Reaction
Region" it will be allowed to rema in in this situation for a predefined amount oftime.
This time limit depends on how far away from the dead band the system pressure has
stabilized. Stabilized pressure in this case means that there are no deviations greater than
+/- 10 mbar. This time limit is calculated as 30 min times the damping constant at the top
of the tolerance band and as 1 min times the damping constant at the bottom of the
tolerance band. This time limit decreases exponentially as system pressure finds a
stability point lower in the band. Once system pressure enters the "Hastened Reaction
Region" it is not aIlowed to find a stability point until it retums to the "Controlled
Reaction Regíon" or the dead band.

:: I Deadband (Nol lo Scale)

30 min x DamponJ
29_min , Eain~n_i
E. min x~m.E'''!I.
~ min x ~ampong
20 min x Oamping
15 min x Oamping
~ mlnx~mEi,;g
~ min J( ~am__E_i~
1 min x DamEI~
1 men JI. Oam~:)I
PL- TO
Figure 3 - System pressure stabiJity time limits (load side)

Please note that these numbers are just examples and not precisely indicative of the actual
response curve in the XI controllers.

7
When tuning the XI controller on a new air systern it is recommended that the tolerancc
setting be adjusted first. The damping setting should be left al default scttings unless
thcre is no margin for increasing the tolerance. This situation would most likely occur in
a systern with inadequate storage volumc. Increasing the damping setting increases the
chances that the systern will overreact to any change in system pressure and drastically
reduce energy efficiency. Increasing the tolerance setting gives the XI controller more
time to cope with changcs in demand and can maintain energy efficiency.
3.0 Sequencing Algorithms

Once the tolerance and damping algorithms have determined that a compressor is needed
to load or unload to sustain system pressure in the deadband the controller then needs to
determine which compressor it needs to use next. The XI control1crs have a variety of
algorithms that can be chosen by the user and each one offers its own advantages and
disadvantages to each unique system. The algorithms are explained below. Not al1
algorithms are available in every XI controlIer. Please note that in all examples below,
compressor A refers to the first compressors in the sequence, Compressor B is the second
compressor in the sequence and so on.

First In Last Out (FILO - X4I, X8I, X12I)

FILO control is the usual "rotary" sequencing algorithm that is currently implemented in
the 4Logic, ISM, and lEO products. This is a simple aIgorithm that will try and keep the
compressors at the beginning of the sequen ce loaded for long periods of times. This
allows the compressor(s) at the end ofthe sequence to be the ones to bear the load/unload
stress and act as trim units.

The XI series of controllers accomplishes this by assigning each compressor a letter that
designates its place in the sequence. The first compressor to load will always be "A," the
second compressor "B," and so on. When the XI is told to load a compressor via the
tolerance and damping algorithms it will choose the letter closest to "A" that is running
unloaded. The XI will give no priority to compressors whose motors are already running
in order to preserve efficiency, but last compressor to unload will be the next one chosen
to load and will be the compressor most likely to still have its motor running.

An example follows:

9
 PH + TO - - - - - - - - - - - - - - - - - - - - - - - --

PH
5/\ \_
7
..,
"1J
ro
(J)
(J)
1 e
..,
4 ro
PL~
2
3

PL-TO - - - - - - - - - - - - - - - - - - - - - - - --

Time

Figure 4 - Example system pressure and XI response in FILO

In the sample system prcssure graph shown above, assumc an air system consisting of
four identical output comprcssors: CO1, C02, C03, and C04. At point I the compressor
sequence looks like this, with COI and C02 loaded:

A B e o
EJ!!!I EJ!!!I E:!I ~
~ ., ~ .,

C01 C02 C03 C04

~ = Loaded
D = Unloaded
Figure 5 - Comprcssor sequcnce at point I

After a ccrtain period of time, the plant requircs more air than can be supplied by
compressors COI and C02. Systcm pressure begins to decay until it hits PL at point 2.
The XI controller responds by loading compressor C03.

10
 A B
,.,.------ -
e o
E::!!I E:!I E:!!!!I
'" ... '"
C01 C02 C03 C04

= Loaded
D = Unloaded
Figure 6 - Compressor sequence at point 2

After C03 is told to load, the XI controller must wait for the user adjustable start timer to
elapse before it is allowed to act again by loading another compressor. Altematively, the
start timer can be aborted when a load signal is received back from compressor C03. C03
begins to contribute air to the system at point 3 and system pressure rises back into the
dead band and no further action is necessary.

Systcm pressure continues to rise slowly until point 4. At point 4, plant demand lessens
and system pressure begins to rise more rapidly until it hits PH at point 5. At point 5 the
XI controller unloads the last compressor that was loaded, which in this case is
compressor C03.

A B e o
E:!! E:!!!!I ~ ~
'" '" '" '"
I C01 C02 ¡ C03 C04

= Loaded
D = Unloaded
Figure 7 - Comprcssor sequence at point 5

In this example, demand continues to lessen and system pressure continues to rise
through the tolerance bando At point 6 the XI controller decides that another compressor
needs to be unloaded to bring system pressure back into the dead bando The XI controller
will then unload the compressor that was the last to load. In our example this would be
compressor 2, in the B position.

11
 A B e D

EJ!!!I EJ!!J EJ!!!I

.. .. ..
I C01 C02 C03 C04

D = Loaded
D = Unloaded
Figure 8 - Compressor sequence al point 6

System pressure then stabilizes at point 7 and the XI controller takes no further action.

When using FILO control it is use fui to be able lo change the sequencing ofthe
compressors in order to balance the running hours among the compressors. Keep in mind
that balancing the running hours is not the primary function of FILO. EHR is the
algorithm that places equalizing running hours as the highest priority.

Rotation of the sequence can be initiated manually, based on the time ofday and day of
week, or periodically throughout the day. A more detailcd explanation of all FILO
options can be found in any of the XI controller manuals.

If the initial sequence was as follows:

A B e D

E::::!I E::::!I E::::!I ~

.. .. .. ..
C01 C02 C03 C04
Figure 9 - Initial FILO sequence

At the first rotation event the sequence would become:

A B e D

~ ~ ~ ~
.. .. .. ..
C04 C01 C02 C03
Figure 10 - FILO Sequence alter one rotation

The second rotation event would give the sequence:

12
 A B e o
E::!J EJ!!!J E:!l ~
... ... ... ...
C03 C04 C01 C02
Figure 11 - FILO sequencc after two rotatíons

This rotation would continue on indefinitely until the XI controllcrs paramcters were
changed by an operator.

Equal Hours Run (EHR - X41, X81, X121)

EHR mode is primarily concerned with keeping the running hours of al! compressors as
close as possiblc. The running hours of the machines are initially input into the XI
controller by the operator. As long as all Start and Run on times are correctly set in the
controller than the XI should keep an accurate count of running hours unless the
compressors are disconnected and run locally. The XI controller run hours are
incrcmcnted whenever a Run feedback signal is detected.

When EHR mode is active the XI will pcrforrn a comparison on the running hours at
every rotation interval. The rotation intervals are defined precisely the same as in FILO
control. The compressor with the least amount of running hours will be assigned lo "A"
in the sequence. The compressor with the second least amount ofrunning hours will be
assigned to "B" and so on. The sequence will not necessarily change unless there is a
new discrepancy in the running hours of the compressors.

For example, in an air system with four identical compressors: CO1, C02, C03, and C04
with running hours as shown bclow, the initial sequence would be:

A B e o
EJ!!!J EJ!!!J ~ ~
... ... ... ...
C01 C02 C03 C04
1000 Hours 1046 Hours 1073 Hours 1191 Hours
Figure 12 -Tnítial EHR sequence

Ifwe assume that the system requires compressors A and B to be running most of the
time, e to be running rarely, and O to be almost never utilized, then after a period of time
the accumulated running hours might look something like this:

13
 A B e D

~ E::!Il E::!Il ~
... .. ... ..
C01 C02 C03 C04
1128 Hours 1146 Hours 1122 Hours 1202 Hours
Figure 13 - Accumulatcd run hours before EHR rotatiun event

Once the rotation even occurs the comprcssors would be rearrangcd in the sequence so
that the compressors with the least hours are placed earliest in the scqucncc.

A B e D

E::!!!Il ~ ~ ~
... .. ... ..
C03 C01 C02 C04

1122 Hours 1128 Hours 1146 Hours 1202 Hours

Figure 14 - EHR rotation sequences cornprcssors bascd on running hours

This calculation would take place at every periodic or schcduled rotation event.

Variable Energy Control (VEC - X4I)

VEC mode is used in the X4I only when there is one or more variable speed drive (VSD)
comprcssors present in the systcm. Variable Energy Control uses the FILO algorithm
with one key difference; VEC will always keep the last variable speed compressor
running in the sequence in a full trim mode and any other variable speed compressors
will be allowed to run in a restricted trim mode where it can only vary from 75% to 100%
of its range. This method allows two variable speed compressors achieve a turndown that
is equal to that of one compressor.

In a system with two variable speed compressors, CO1 and C02, this means that when
only one machine is loaded it will be able to adjust its output throughout its full tumdown
range.

14
 A B
~I ~
.., ..
C01 VSD I C02 VSD
Capacity Range
25% - 100%

~ = Loaded
D = Unloaded
Figure 15 - Two VSD system with one compressor loaded

When the second compressor is loaded CO1's output range will be restricted to 75%-
100% of its capacity while C02 will be able to vary throughout its entire turndown range.

A B

~ ~
.. ..
C01 VSD C02 VSD
Capacity Range Capacity Range
75% - 100% 25% - 100%

= Loaded
D = Unloaded
Figure 16 - Two VSD system with both compressors loaded

The effect is the same whether or not there is a fixed speed machine in the sequence
between the YSD compressors:

A B C

E:!I EJ!!!I ~
.., .., ..
C01 VSD C02 C03 VSD
Capacity Range Fixed Capacity
25% -100% 0%

= Loaded
D = Unloaded

15
 A B C

~
..
C01 VSD C02 I C03 VSD
Capacity Range Fixed Capacity
25% - 100% 100%

= Loaded
D =Unloaded
Figure 17 - Loading a fixed speed comprcssor has no effcct on COI's range

CO1's Capacity Range wil! not be affected until the next YSD in the sequence is loaded.
In this case, the second YSD compressor is C03.

A B C

C01 VSD C02 ; C03 VSD

Capacity Range Fixed Capacity Capacity Range
75% - 100% 100% 25% - 100%

= Loaded
D = Unloaded
Figure 18 - Loading C03 immediatcly changes COI's range

Ifthere are more than two YSD compressors in a system only the last YSD compressor
in the sequen ce will be allowed to vary its capacity throughout its entire turndown range.
AH other YSD compressors \ViIIbe restricted to varying their capacities between 75%
and 10000.

YEC keeps most compressed air systems from getting into a situation where one YSD
compressor is not enough to maintain system pressure, but two YSD compressors
provides too much air and the second YSD compressor cycles on and off excessively.
This excessive cycling can cause a buildup of condensation in the oil ofthe compressor
which can lead to airend failure after sustained operation in this state.

YEC sequence rotation is defined in the same manner ad FILO and EHR sequence
rotation algorithms. YEC is most use fui when cornbined with priority. Priority allows
the variable speed compressors to always be place at the beginning ofthe sequence where
they can be of the most use (See Priority Discussion).

16
AH variable speed compressors running on an X4I must have their local target prcssures
set to a valid range that is inside the deadband on the systern controller. This target
pressure should usually be the midpoint between the XI controller's PH and PL
parameters.

First In First Out (FIFO - X4I)

FIFO control or "reciprocating logic" is used when the system is composed entirely of
reciprocating compressors. This mode attempts to keep each motor running for the
minimum amount oftime it can while still maintaining system pressure.

When FIFO control is active, the first compres sor to load is assigncd to sequence position
"A." If a second compressor is required lo load then it will be assigned position "A"
upon loading. Compressor 1 will then be assigned to letter "D." When the X4I decides
that a compressor needs lO be unloaded the compressor with the highest letter will be
unloaded. In this case, compressor 1 will unload since it has been assigned "D." In this
way running hours on the motors can be minimized to prolong the life of small
reciprocating compressors.

Using the same system pressure graph as in the FILO example, the XI sequencing would
behave as follows:

PH +TO - - - - - - - - - - - - - - - - - - - - - - - --
6

PH
..,
"O
CD
en
en
1 e
..,
CD

PL
3

PL-TO - - - - - - - - - - - - - - - - - - - - - - - --

Time

Figure 19 - Examplc system pressure and XI response in FIFO

Assuming that system pressure is stable at point 1 and we have four reciprocating
compressors, and starting with one compressor loaded we would have an initial sequence
as shown in Figure 20. Please note that as soon as a compressor is started it is assigned
the letter A.

17
 A B e o
~ E::!l E:::!I ~
~ .. ~ ~
C01 C02 C03 C04
Figure 20 - Initial FIFO sequcnce

Whcn systern pressurc rcaches PL at point 2, the Xl loads a second compressor, C02. At
this point COI is assigned scquence letter D sincc it has been running the longest and
needs to be the next to shut down. C02 is assigncd letter A since it has been running the
least amount of time. C03 and C04 are assigned B and C sequentially since they don 't
yet have a history.

A B e o

..
E:!l
..
E::!l
~I
C02 C03 C04 C01 I
Figure 21 - C02 is loaded and assigncd to A while COI is assigned to D

The XI controller must wait for C02's start timer to e1apse before making any decisions,
as usual, and during that time the pressure stabilizes and begins to recover at point 3. The
XI controller does not need to rnake any more decisions at this time. However, if the
pressure had continued to decay, C03 would be loaded and assigned to position A and the
sequence would've lookcd like this:

A B e o
~I
I

I E::!l ~
.. I
.. ..
C03 ¡ C04 I C02 C01
Figure 22 - C03 would load ir pressurc conCinucd te dccay

Continuing on from point 3, ifpressure rises up to PH as it does at point 5, the

compressor that is in the O position will be unloaded, but the sequence does not change.

A B e o
~ ~ ~
.. .. ..
¡ C02 C03 C04 C01
Figure 23 - COI unloads at PH

18
System pressure continues to increase until at point 6 the XI controller decides it needs to
unload another compressor. Since C02 is now the only compressor running, it is
unloaded and no compressors are needed. Pressure stabilizes at point 7.

A B C o
~ ~ ~ E:J!!II
-
C02
- C03
-
C04
-
C01
Figure 24 - Prcssure stabilized and the sequence remains the same

This control mode is self rotating so there is no need for a scheduled or periodic rotation
such as is used for FILO and VEC control modes.

Energy Control Mode (ENER - X81, X12I)

Encrgy control mode is meant to be a generic algorithm that can adapt to any system and
provide efficient control without having to go through painstaking setup and tuning
processes.

ENER mode needs to know the relative flow capacities of the compressors that are
installed in the system in arder to function properly. These capacities are expressed as a
percentage of the capacity of the largest compressor in the system. For example, if you
have a three compressor system with COI having a capacity of 500 CFM, C02 having a
capacity of 250 CFM, and C03 having a capacity of 100 CFM then the relative capacities
would be expressed as CO1 = 100%, C02 ce 50° 0, and C03 20%. -r;

EJ!!!I ~ E:::!I

- C01
-
C02
...
C03
Capacity 500 cfm Capacity 250 cfm Capacity 100 cfm
100% 50% 20%
Figure 25 - 3 Fixed speed compressor system

Upon system startup, the XI controller will choose the smallest compressor available, in
this case compressar C03 with 20% relative capacity. If C03 is unable to bring system
pressure up into the dead band then the XI will start the next smallest compressor which
would be C02. It will go through this process until it has exhausted its supply of
compressors or the system pressure is brought into the deadband. During this type of
startup energy efficiency is not the primary concem, getting the pressure into the proper
range is the goal.

19
 PH -------------------------------r4~----------------
PL -----------------------------+--------------------
"1J
...,
ro
VI
VI
c=
...,
ro

Time

Figure 26 - System startup with ENER active

In the example system pressure graph shown aboye the XI controller is activated and
system pressure is zero. At point I in Figure 26 C03, the smallest compressor, is loaded.
C03's start timer begins to count and pressure slowly begins to rise.

A B C

~ EJ!Il
.., ..,

C03 : C02 C01

Capacity 100 cfm Capacity 250 cfm Capacity 500 cfm
20% 50% 100%

= Loaded
D = Unloaded
Figure 27 - Sequencc at point I

After C03's start timer elapses (or a load feedback is received from C03), the XI
controller then loads the second smallest compressor, C02. C02's start timer begins
counting and when C02 begins contributing air to the systern, pressure begins lo rise
more rapidly.

20
 A B e

...
E::!!I i
I
~l ...
E::!!'!l

C03 ... c021 C01

Capacity 100 cfm Capacity 250 cfm Capacity 500 cfm
20% 50% 100%

= Loaded
D = Unloaded
Figure 28 • Sequence al polnt 2

Now C02's start timer has to elapse (or a load feedback has to be received frorn C02) and
then the XI controlIer wilI load the final, largest compressor.

A B C

...
E:!!I I

...
E::!!I
...
~¡
C03.! C02 C01 I
Capacity 100 cfm Capacity 250 cfm Capacity 500 cfm
20% 50% 100%

= Loaded
D = Unloaded
Figure 29 - Sequen ce al point 3

At this point, the energy control algorithm is not in control of the decision making
process. Energy control is activated when system pressure hits the PH setting, as in point
4 in Figure 26, and needs to unload a compressor. For the first unload, the energy control
algorithm does not have enough infonnation to change the sequence so it will simply
unload the last compressor to load. This will be the largest running compressor, in our
example this would be COl. Once the compressor is unloaded it will look at the rate of
change of system pressure and how long pressure takes to fall to PL and load another
compressor.

21
 PH + TO - - - - - - - - - - - - - - - - - - - - - - - --

PH
..,
\)
ro
(J)
(J)
e
..,
ro
PL
5

PL - TO - - - - - - - - - - - - - - - - - - - - - - - - -

Time

A B C
-
EJ!!!I
..
C03 I C02 C01
Capacity 100 cfm Capacity 250 cfm Capacity 500 cfm
20% 50% 100%

= Loaded
D = Unloaded
Figure 30 - COI unloads at point 4

Once PL is reached the XI controller will load CO I again and look at the rate of change of
system pressure.
 A B C

E:::!I ~ E:::!I
.. I
... ..
C03 C02 C01
Capacity 100 cfm Capacity 250 cfm Capacity 500 cfm
20% 50% 100%

= Loaded
D = Unloaded
Figure 31 - COI is reloadcd al point 5

When system pressure reaches PH again the XI controller will try to unIoad a compressor
that is the next size smaIler, in this case C02. 1f system pressure remains in the dead band
and the rate of change is sIow, the XI controller will know the approximate amount of
flow needed to meet demand and can then begin to look for more efficient ways of
managing the system.

PH + TO - - - - - - - - - - - - - - - - - - - - - - - --

PH
...,
"U
ro
C/l
C/l
c::
...,
ro
PL
5

PL-TO - - - - - - - - - - - - - - - - - - - - - - - --

Time
 A B C

~
..
C01 C02
Capacity 100 cfm Capacity 500 cfm Capacity 250 cfm
20% 100% 50%

= Loaded
D = Unloaded
figure 32 - C02 is unloadcd at point 6, system pressure rate of change slows to an acccptablc levcl

If, however, system pressure rate of change is still relatively fast, at the next cycle the XI
controller willload compressor C03 again instead ofC02.

Picase note that at each decision point the XI controller will calculate the entire sequencc.
The sequence should be looked al skeptically since it is liable to change al the next
decision making point.

Once system pressure has stabilizcd inside of the dead band the XI controller will start to
look for ways to improve system efficiency. Maybe two small compressors can be
rcplaccd with a largcr compressor with approxirnately the same flow capacity. To make
these decisions, the XI controller will look at the 3 previous load/un load cycles and
determine how long these cycles take to occur and the effect on the system pressure rate
of change. The XI controller can then manipulate the sequence as it sees fit to achieve
higher efficiency.

A couple general points:

When ENER is given a choice whether to start a compressor from a stopped condition or
load a compressor that is currently running unloadcd, it will always choose the
compressor that has its motor already running.

In a system with compressors that are all identical ENER will revert to using FILO
sequencing. When two or more compressors are identical to each other but different
from the rest ofthe group, ENER \ViIIsequence the identical compressors together as sort
of an automatic priority mode.

For example, if the system pressure is maintained with C03 in position "A" and C02 in
position "B" but C02 is cycling fairly quickly, the XI controller \ViIItry and rotate C02
into position A because it knows that compressor C03 is not providing enough air but
C02 and C03 is providing too much air. Cycling the smaller pressure will cause far less
drastic changes in system pressure.
When variable speed comprcssors are added to the system, ENER mode becomes more
use fuI. In a system with variable specd compressors, the XI controller will first try to
start the smallest variable speed comprcssor and when all variable speed compressors are
started it will then go to start the smallest fixed speed compressor. When variable speed
compressors are present the XI needs to be told the maximum capacity of the compressor
(expressed as a percentage relative to the capacity of the largest compressor), the
minimum capacity of the compressor, (relative to the largest compressor) and the point at
which running below will be an inefficient situation. In figure 33 below, both VSD
compressors have a range of32%-100% ofcapacity. C02's range is displayed relative ro
the sizes of all compressors

A BCD E

IIcoJ:I,111co;1v:IJ II t:I,111 t:I,111 t:11

Capacity 500 cfm Capacity 250 cfm Capacity 500 cfm Capacity 250 cfm Capacity 100 cfm
32% - 100% 16% - 50% 100% 50% 20%
Figure 33 - 5 compressor systcm including 2 VSD comprcssors

The last point determines when the XI should try to add another fixed speed compressor
or replace smaller VSD compressors with one larger one to improve efficiency.

PH --------------------------------------~------------
---4
PL -----------------------------r----------------------
"U
<Ti
en
en
e
al

Time

Figure 34 - System startup with ENER active, including VSD compressors

In the example system pressure graph shown above the XI controller is aetivated and
system pressure is zero. At point l in Figure 26 C02, the smallest VSD compressor, is
loaded. Since C02 is the first VSD in the sequenee it is designated as the trim machine
and its target pressure is set to the midpoint between PL and PH. Since system pressure
is much lower than this target pressure, C02 immediately proceeds to full speed. C02's
start timer begins to eount and pressure slowly begins to risco

25
 A BCD E

, C02 V:! 1,1c01-1v:I,111 -1c:I,111 -1c:IJ ij -1c:I,1

Capacity 250 cfm Capacity 500 cfm Capacity 500 cfm Capacity 250 cfm Capacity 100 cfm
16% - 50% 32% - 100% 100% 50% 20%
= Loaded
CJ = Unloaded
Figure 35 - Sequence at point I

After C02's start timer elapses (or a load feedback is received from C02), the XI
controller then loads the second smallest VSD compressor, COl. COl ' s start timer begins
counting and when C02 begins contributing air to the system, pressure begins to rise
more rapidly. Since CO1 is not the first VSD in the sequence its target pressure is set to
the midpoint ofPH and PL plus 3 PSI. This 3 PSI offset is so that the first VSD
compressor in the sequcnce is given time to throttle back before any other VSD throttles
back. Multiple VSDs throttling at the same time can cause oscillations in the system.
System pressure is significantly lower than this pressure so COl immediately proceeds to
maximum speed.

A B
-

C01 VSD
Capacity 250 cfm Capacity 500 cfm Capacity 500 cfm Capacity 250 cfm Capacity 100 cfm
16% - 50% 32% - 100% 100% 50% 20%

= Loaded
CJ = Unloaded
Figure 36 - Scqucncc at point 2

After all VSD compressors in a system are loaded, the XI controller will then attempt to
load the smallest fixed speed compressor. In our example, system pressure continues to
rise but COl 's start time has elapsed. The XI controller then starts the smallest fixed
speed compressor, which is C05.

26
 A BCD E

C02v: ~c01-1v:ll -1 c:lll -1 c:llll

Capacity 250 cfm Capacity 500 cfm Capacity 100 cfm Capacity 250 cfm Capacity 500 cfm
-1 c:ll
16% - 50% 32% - 100% 20% 50% 100%

= Loaded
CJ = Unloaded
Figure 37 - Sequence at point 3

In our example in Figure 34 system pressure reaches target and C02 begins lo throttle
back. This throttling is sufficient to keep system pressure within the dead bando As was
noted previously, the system pressure has to reach PH before the energy control
algorithm is activated. The XI controller, however, knows that there are YSD
compressors in the system and begins to look at the stability ofthe system pressure. Ifa
certain period of time elapses and system pressure is still stable within the dead band the
XI controller will go ahead and activate energy control to try and optimize the sequence.

In addition to the efficiency decisions the XI can make with replacing fixed speed
compressors, the XI can also make the decision to add a fixed speed compressor to
replace a variable speed compressor. In order for this decision to be made the XI must
determine that the fixed speed compressor will be able to maintain the supply. For
example, if a variable speed compressor eo l is varying from 23% lo 30° o of relative
capacity and you have a fixed speed compressor with 25% relative capacity available it
would not be the best option to replace the variable speed since the fixed speed would not
be able to cover the demand swing. However, ifthe variable speed compressor was
varying from 20% to 23% it would then make sense as the fixed speed compressor could
cover the entire range.

A B C
1I
~ ~I ~
... .. ..
C01 VSD C02 VSD C03
Capacity 250 cfm Capacity 500 cfm Capacity 125 cfm
16%-50% 32% - 100% 25%

= Loaded
D = Unloaded
COl Throttle Range
C02 Throttle Range
23-30%
100%
Figure 38 - e03 is unable to provide 30% relative capaclty to replnce COI

27
Howevcr, if the variable speed compressor was varying from 200 oto 23% it would then
rnake sense as the fixed speed compressor could cover the entire range. C03 would then
be loaded and ca I would be unloaded once pressurc reaches PH. Note that C02 moves
into the A position to havc a VSD compressor in the lead position. C02 is now able to
trim back since C03 provides (minimal) extra capacity.

A B e
~
-
C03 C01 VSD
Capacity 500 CFM Capacity 125 cfm Capacity 250 cfm
32%-100% 25% 16%-50%

= Loaded
D = Unloaded
C02 Throttle Range
96-100%
Figure 39 - C03 is able to rcplace COI 's capacity, COZ is allowcd to throttle

In systems with multiple variable speed compressors the XI controller will keep track of
the current capacity of each compressor and do calculations to determine whether there
are too many variable speed compressors currently loaded. For example ifthere are three
variable speed compressors with ca 1 = 80%, C02 = 80%, and C03 = 20%, the system
knows that the total capacity of the running compressors is 180% and that 1\\'0
compressors would be able to cover the demando Since COI and C02 together have 40%
spare capacity, and dropping C03 would only result in a 10% increase to each
compressor, the XI will drop C03 from the sequence and allow ca 1 and C02 to cover the
demando

In the situation where three identically sized variable speed compressors are running at
capacities: COI _-40°0, C02:;: 100%, and C03:;: 100% the total capacity would be 240%
and ifC03 was dropped from the scquence there would be no spare capacity left. In this
case all three compressors would continue to runo However, if system pressure rises so
that the compressors are running at ca l = 25%, C02 = 60%, and C03 = 60% the total
used capacity is 14500 and could be easily covered with COI = 45% and C02 = 100%.
C03 could then be unloaded. This decision is made within 2-3 minutes of stable system
pressure.

If a variable speed machine is running at 100% as a base load machine, the XI can decide
lo bring a fixed speed machine to replace the variable speed machine as long as the
capacities are a close match.

28
Keep in mind that the XI will prefer to start a YSD machine over a fixed speed machine
by a factor of 2. This is due to the probability algorithm that is used in the adaptivc
control logic of ENER mode.

Priority Control (X4I, X81,X12I)

Priority control allows the user to fine tune where they want certain compressors to
appear in the sequence. When you assign a compressor a high priority (1 is the highest) it
will always appear in the beginning of the scquence. Priority with FILO, EHR, and YEC
is well defined in the X4I manual.

Priority control will also work with ENER control mode. Priority will force the XI
controller to look for all priority 1 compressors and make sure that they are loaded in the
sequence before it is allowed to use any priority 2 compressors. AlI priority 2
compressors must be used before priority 3 compressors can be loaded and so on.
Priority allows you to still have backup and primary use compressors regardless of the
sequencing algorithm that you are using. Priority can interfere with system efficiency.

Zone Control (X12I)

Zone control allows the user to group compressors based on physical location, or pressure
differential from the master transducer, or any other criteria that they want. Zone control
will attempt to keep at least one compressor from each zone running at all times. The
XI2I can use up to three different zones.

The X 12] will first look to zone 1 and start a compressor from that zone. When the next
compressor is needed it willlook to zone 2 and choose a compressor based on the current
sequencing algorithm. After a zone 2 compressor is used, the X 12] will finally look to
zone 3 for a compressor. The process will then repeat until all compressors are utilized
or system pressure is satisfied. Zone control essentially limits the choices that the X 12]
can make to certain compressors at each time. When used in conjunction with priority
the user can essentially fine tune the sequence to be precisely what they want at all times.
Zoning and priority can conflict with energy efficiency and work against the ENER
control algorithm. Zoning must be used with careo
4.0 Ancillary Functions

Prcssurc Balancing (X121)

The X 121 is capable of taking the inputs of up lo 3 pressure transduccrs and using thc
high signal, the low signal, or the average of the three signals in order to control the
system based on a balanccd pressure across the entire compressed air system.

The master pressure signal must always come from a transducer that is connected to the
X 121. The two secondary pressure signals can come from an l/O, EX, or DX box as well
as from any compressor in the system. Pressure signals received from an l/O box are
updatcd every 10 sec, or during a status change of any input, whichever is faster.
Pressure signals from EX, DX, or compressors are updated cvery 2 seconds. The master
pressure signal is updated evcry 35 milliseconds. Ifthe secondary pressure signals fail
the system will always default to using the master pressure signal.

There are safeties that are integral to the pressurc balancing algorithrn. Each secondary
transducer has a Deviation Allowance that is set by the user. These deviation allowances
essentially place an upper and lower limit on the pressure reading that is sent to the
master controller. For example, if D I is set ro +/- 5 PSI and the secondary pressure
transducers PI is sending a signal l08 PSI while the master pressure transducer is
sending a signal of 100 PSI, the signal from PI will be capped at 105 PSI by the X 121.
Each secondary pressure transducer has its own deviation allowance.

The next level of safety is the deviation limit. This is set for both secondary sensors
using the parameters D+ and D-. 1f either of the secondary pressure sensors exceeds the
readings of the master transducer by more than 0+ or D- then the offending sensor will
be ignored completely in the pressure balancing calculation.

When the controller is using the average of the pressures for control it will first average
the secondary pressure transducers together and then will average that result with the
master pressure transducer in order to obtain a control signal.

System Prefill (Standard and Backup - X41, X8I, X12I. Automatic - X8I, X12I)

System Prefill is used to bring a stopped and empty compressed air system up to
operational pressure in a controlled in efficient manner by using pre-selected
compressors. This prcvents the situation where all compressors load upon system start
because the system pressure is very far below the deadband. Oscillations can occur iftoo
many compressors are started to fill the system and the system pressure completely
overshoots the deadband and all compressors turn off. When the compressors tum off the
system pressure can then undershoot the deadband and this can continue for sorne time.

The Standard and Backup prefill modes are cxplained in detail in the X4I, X8I, and X 121
operator 's manuals.

30
Automatic Prefill Mode is exclusive to the X8I and X 121 controllers and utilizes the same
tolerance and damping logic that is at the heart of the controller.

When using automatic prefill, the load marks all start out at O PSI and will begin to rise at
arate that is determined by the pressure rise needed divided by the Prefill Time. This is a
simple linear formula. As the load marks rise the first compres sor will start when the
system pressure is below the first load mark. The second load mark will continue to rise
toward the deadband until the system pressure is below the second load mark. The
second compressor will then load. The compressors are chosen based on the Energy
Control AIgorithm. This process will repeat until all the eompressors are loaded or the
system pressure has reached the dead band or the Prefill Time has elapsed. After the
Prefill Time has elapsed the XI eontroller will convert to the normal sequeneing
algorithm selected.

Pressure Schedule (X41,X81,X12I)

The Pressure Schedule allows the user to set the XI controller to switch among its tables
(described in the manuals) and a stand by mode based on the time of day and the day of
week. The user can input up to 28 individual events that the controller will follow. The
pressure schedule is well defined in the manuals. The only portion that needs further
explanation is how the transition from one table to another oecurs.

When a Pressure Schedule event is reached the system is given a user defined time called
Pressure Change Time (PC) to adjust the pressure setpoints accordingly. At the time of
the event the High Pressure and Low Pressure setpoints are instantly adjusted. The load
marks defined by tolerance are not instantly adjusted. The load marks on the side of the
deadband that is in the direetion of the change (PL when pressure is lowered, PH when
pressure is raised) will change instantly. The load marks on the side opposite the change
will again adjust linearly based on the amount ofpressure change divided by the pressure
change time. The compressors will respond to these load/unload marks accordingly until
either the new operating pressure is reached or the Pressure Change time elapses. Ifthe
pressure change time elapses the system will revert to the normal control and do whatever
it can to get the system pressure inside of the deadband.

Power Out Restart (X41,X8I, X121)

Power Out Restart is well defined in the manuals.

Intelliflow Control (X12I)

Intellitlow control is nothing more than a PI loop that utilizes an analog input for the
lntellitlow Valve's pressure transducer and an analog output to control the position ofthe
valve based on a forward or backward tlow control algorithm. This is explained in the
X 121controller manual as well as in Ingersoll Rand's Intellitlow manual.

31
5.0 X81 and X 121 Acccssory Boxes

The X81 and X 121have a selection of acccssory boxes that can be used to enhance the
functionality of the product. These consist ofan EX box to extend the range ofIR-PCB
connected cornpressors, a DX box to allow two compressors lo be utilizcd as a single
compressor, a CX box which allows step control of compctitive reciprocating, poppit
valve, and other machinery, and an 1 O box which allows digital input/output control of
accessory c1eanup equipment as well as analog input readings from dew point rneters,
flow meters, and other such equipment.

EXP Box (X81, X12I)

The EXP box allows for connections of more than four IR-PCB connected compressors.
lt has an SI controller and a Terminal PCB lo accornrnodate the wires from these
compressors. The user simply selects whether the EXP box is being used to control
compressors 5 through 8 or compressors 9 through 12. The EXP box connects lo rhe X8I
or XI21 via a short distance (30 ft) XPM Bus. Compressors will behave as ifthey are
directly connected lo the X81 or X 121. Diagnostics for the EXP box will appear on the
X81 or X 121when the EXP box is detected. After connecting the EXP box, the X8I or
X 121will need to be rebooted in order to be detected.

EX Box (X8I, X121)

The EX box is used in a situation where a compressor that is connected through an IR-
PCB interface board is located more than 330 ft from the X81 or X 121controller. The EX
box connects via Multi-485 to the X81 or XI21 and extends the use fui distance from the
XI controller to a maximum of 4000 ft. Up to two compressors can be connected to the
EX box and these compressors do not have to be sequentially numbered in the system.
The user can select the compressor's number via the front panel. The EX box can
accommodate one pressure transducer from each compressor to be used in automatic
pressure correction plus one transducer to be used as a secondary signal for pressure
balancing on the X81 or XI 21.

The user can have as many EX boxes on the system as he/she desires as long as the total
of 8 compressors (X8I) or 12 compressors (X 121)is not exceeded.

A Note on Pressure Correction - Pressure correction takcs place in evcry

compressor gateway and in evcry interface box (EX, DX, CX, l/O). Pressure
correction essentially calculates the delta between the local prcssure transducer on a
compressor or interface box and the system pressure and adds a corresponding
offset to the compressor target pressure. This way any pressure drops across
external cleanup equipment can be automatically compensatcd foro

32
DX Box (X8I, X12I)

Thc DX box allows two compressors to behave as one compressor and be seen as a
variable speed compressor from the X81 or X 121. When selecting the comprcssor ID for
thc DX box the uscr only necds to select one ID number to cover both compressors.
Compressors connecting to a OX box must be IR-PCB connected machines and must not
be variable speed compressors in thcir own right. There is no V terminal on the OX box
to allow compressors to switch between restricted VFD and true VFD modes (se e VEC
modelo There is an optional secondary pressure transducer to be used in pressure
balancing on the X81 or X 121 controller. The pressure transducers on the compressors
must be connected to the OX box for it to work propcrly. The OX box is connected to
the X81 or X121 via Multi-485 and must not be located more than 4000 ft. from the XI
controller.

The compressors connected to the OX box are treated as a multi-step compressor by the
X81 or X121. For examp1e, ifyou have two compressors that are each 50% relative
capacity, then the XI controller will be able to step through the compressor as a 0-50°0-
100% compressor. Ifyou have two compressors ofvarying sizes, such as 80% and 20%
relative capacity then you will have a four step compressor which would be able to use 0-
20° 0-80° 0-1 00° o steps.

There is a PID algorithm running in the OX box to determine when to step the
compressors up or down. The OX box will always stagger the starts ofthe two
compressors connected to it in order to preserve energy efficiency.

ex Box (X81, X121)

The CX box is used to control a variable capacity compressor that does not have serial
interface capability. The most common use for the CX box will be in the case ofpressure
switch controlled reciprocating compressors. Any multi-step recip compressor up to 5
steps can be controlled by the CX box. The CX box interfaces with a compressor by
using up to 4 IR-PCBs, depending on the number of pressure switches the compressor
has. The CX box can also be used to control compressors utilizing poppet valves, or
variable speed compressors that have no serial connection and an available analog input
signal to control the drive throttle.

The CX box manual describes all possible compressor connections and functions in
detail.

l/O Box (X81, X121)

The l/O box is a generic multi-purpose box communicating on the Multi-485 network.
The l/O box has 8 volt free digital inputs, 6 relay outputs, 4 Analog Inputs, and 1
dedicated pressure input for pressure balancing. The X81 can connect to up to 2 I/O
boxes and the X 121can connect to up to 12 LO boxes.

33
The state of every input and output on the 10 boxes is placed onto thc Multi-485 network
upon a status change, or every 10 scconds at the latest. The infonnation will be placed on
the bus regardless of whether or nor the XI controllcr is set up lo monitor the box.
Therefore the infonnation on the bus is available to the Modbus systern gateway,
visualization, virtual relays, etc., at all times.

The l/O boxes on the network are labeled BO1 through B 12. 1 O boxes can freely share
infonnation with each other and do not necessarily need an XI controller to function. The
[/0 Box and Virtual Relay manuals describe the functions ofthe LO box in detail.

VSD Box (X8I, XI2I)

There are two VSD boxes that are available for use with an X81 or X 121 controller.
These VSD boxes utilize the pressure transducer inputs on a variable speed drive to
control the output ofthe compressor. The two available types ofVSD box are VSD mA
for 4-20 mA type pressure transducers, and the VSD Vo box for 0-5 VDC pressure
transducers.

The VSD boxes operate by adding a "bias" to the pressure signal that is being sent to the
drive. The VSD box calculates the pressure differential between the local discharge
pressure and the systcm pressure and willlower the pressure signal that the drive sees by
the same amount. In this way the drive is always aiming for the target pressure that is
being calculated by the X81 or X 121 controller. The drive's PID control is still active and
does all demand tracking. Ifthe VSD box compressor is being utilized as a base load
(fuI! output) unit, the pressure being sent over is biased lower until the drive reaches
100° o speed. Please note that in arder for the full effectiveness of the VSD box to be
reached the optional speed sensor kit needs lo be installed. The speed sensor kit includes
an appropriately sized current transducer as wcll as a signal processor that is mounted
inside the compressor starter encIosure. The signals from the processor are then sent to
the VSD box.

IRV-485 Gateway (X8I, XI2I)

34
6.0 Multi-485

Multi-485 is CMC's proprietary RS-485 network that is used for all communication
between the XI controller and the boxes and gateways that use the network. Multi-485 is
a multi-rnaster protocol that is loosely based on modbus and has the following
characteristics:

• Operates al a speed of 9600 Baud

• Has a maximum number of nodes of 32 (per physical network, a radio modem
or other device can extend this)
• Double Checksum Protocol
• Daisy Chain or Star topology is acceptable, it is NOT a token ring network
• Maximum wire length of 4000 ft.

Communication on the bus works as follows: As every device on the network is a master
and all devices broadcast their dala a polling protocol would take an excessive amount of
time to transfer information. As such, each device has an internal random timer which
can very from 10ms lo 40ms and follows a bcll curve between those times. Whcnever a
devices random timer elapses it is allowed to place a message on the bus. Once the
message is on the bus the device does not nced to wait for a response before the ncxt
message is placed on the bus. The device wilI, however, remember that it needs to hear a
response and will wait for it. In the unlikely event that two devices' timers elapse at the
same time then both timers will restart and the timer that elapses first will then be
allowed to place its message on the bus.

After a command is sent to a compressor the device expects to receive an

acknowledgement of"O" back from the compressor within 10 ms. Ifthe
acknowledgement is not received within 12 ms it is noted but the system operation
continues on normally and the devicc will expect a response within lOs, as lOs is the
normal period between status updates. After the status update is received the controller
will again check for an acknowledgement. After 3 missed acknowledgements the XI will
register a communications error and the compressor will be taken out of sequence. The
XI wilI continue to listen for the compressor, however, and once a valid
acknowledgement is received the compressor will be weIcomed back into the sequence
automatically.

The X8I or XI2I's random timer will have a better statistical chance ofbeing lower than
any other device on the network to ensure that its broadcasts will be placed on the bus
promptly.

Modbus System Gateway

The system gateway will accept one request from a modbus master every 500 ms and
place the request on one of its two stacks. This stack will act as a buffer to make sure
that the system gateway does not flood the multi-485 network with requests. The second

35
stack stores all information that is broadcast over the Multi-485 network for instant
retrieval by any modbus master that is requesting this information.

There are two major rypes of modbus requests that the system gateway will accept: An
Advise request which rncans that the data is already being broadcast on the Multi-485
network and can be instantly retrieved from the system gateway's mernory, or a Get
requesl in which the systern gateway will take the request from the modbus master and
ask for the infonnation directly from the compressor. Advise data is generally preferable
as much of the important dala that is needed will already be placed on the bus and stored
on the system gateway, such as compressor pressures, status, sequence number, etc. The
full modbus list is available for all devices.

36
7.0 Compressor Expectations

Ingersoll Rand Pressure Switch Fixcd Speed Compressors

Ingersoll Rand compressors that are controlled via pressure switch are expectcd to be
controlled via the IR-PCB. It is expected that the pressure switch is accessible and is of a
two or three wire type. The motor running contactor needs to be accessible and have an
available auxiliary output so that the XI is able to determine the state of the motor.

The XI controllers need to know the start time for the compressor to begin producing air
as well as the flow capacity of the compressor relative to the flow capacity of the largest
compressor in the system.

Ingersoll Rand Intellisys Fixed Speed Compressors

In order to be connected to the Ingersoll Rand Automation X4I, electronically controlled

compressors must be able to accept digital inputs for remote control enable, load
command, and unload command. The same IR-PCB that is utilized to connect pressure
switch machines will be used to conneet Intellisys machines. The motor running
contaetor needs to be accessible and have an available auxiliary output so that the X41 is
able to determine the state ofthe motor. The X41 needs to know the start time for the
compressor to begin producing airo

In order to be connected to the Ingersoll Rand Automation X81 or X 121,Ingersoll Rand

fixed speed compressors with eleetronic controls are expected to be able to communicate
via either the MODBUS protocol, Multi-485 protocol, or the IRBUS-A protocol. The
eompressor must be able to accept write commands to its status word in order to be put
into remote control, and ro be loaded and unloaded by the X8I, or X 121. Thc system
controller needs to know the start time for the compressor to begin producing air as well
as the flow capacity of the compressor relative to the flow capacity of the largest
compressor in the system.

The fixed speed compressors should always have their local setpoints set so that the
machine will supply sufficient air should something happen to the system controller.

Ingersoll Rand Intellisys Variable Speed Compressors

In order to be connected to the Ingersoll Rand Automation X4I, Ingersoll Rand Nirvana
rotary compressors must be interfaced using an IR-PCB. The controller must accept
digital inputs for remote enable, load/unload, and VFD/Fixed Speed eommands. The
compressor will be expected to offer its own protection method for condensate buildup.

The Ingersoll Rand Nirvana 20hp 40hp product has a modified VFD. Fixed Speed
switch which is described in detail in the "Nirvana 20hp 40hp VFD Change Request"
document, Revision C. This decreases the amount of startlstop cycles that the
compressor experiences on a system with inadequate storage volume and a tight pressure

37
bando The compressor response time is to be around 20 seconds for the cornpressor to
ramp from a minimum to a maximum speed in order for the compressor to react promptly
to demand swings. The 20hp 40hp Nirvana will always run on its local target pressure
setpoint.

50hp or larger rotary Nirvanas are not intended to function with the X41, but will connect
serially to thc X8I and X 121 for additional energy cfficient control. The Nirvana
conlroller is expected to accept remote enable, load command, and unload comrnands, as
well as allow for manipulation of its target pressure. The compressors' local setpoints
should be adjusted for proper local control in the event that the system controller
malfunctions. The local setpoints will be ignored when in remote control except for the
immediate stop setpoint. The immediate stop setpoint will be used as a safety for the
compressor and must be set high enough that it does not interfere with the X81 or X 121's
control setpoints. In the case of pressure exceeding the immediate stop setpoint, the
compressor will un load and not reload until it has gone below the auto-stop setpoint. The
same 20 second response time as mentioned with the Nirvana 20hp 40hp applies to the
larger Nirvanas.

Competitor Comprcssors

Competitor air compressors will not likely be able to be communicated with using a serial
connection. The IR-PCB will be the interface method of choice. The compressor must
be pressure switch controlled, in which case all of the requirements for the Ingersoll Rand
pressure switch machine applies, or have an electronic controller that is capable of
receiving digital inputs to place the machine into remote control, load the machine, and
unload the machine. In this case it would be treated like an Ingersoll Rand fixed speed
machine that is under control of an X41.

Competitor variable speed machines will either need to have a YSD mA box or YSD Yo
box installed, or will only be able to run on their local target pressure setpoint and have
simple load/un load control from the Ingersoll Rand Automation unit.
Revision Author Date Comments
A Jason Roberge 6/18/2007 Inítial Release
B Jason Robergc 1/15/2007 Clarified TolerancclDampíng and Energy
Algorithm discussion based on training and
CMC N.V. Feedback. Addcd CX, EXP, and
VSD Box discussions
C Jason Roberge 1/18/2007 Added illustrations and examples to sections
2.0 and 3.0. Added placeholdcr for
forthcoming IRV-485 díscussion.

39