Ingersoll Rand

System Automation X4I

Operator’s Manual

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

More Than Air. Answers. REV. : A

Online answers: http://www.air.irco.com DATE : APRIL 2007

 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
2
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
 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
3
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
 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.

4
 SECTION 3 — SAFETY
W A R N IN G : R is k o f D an g e r
!
W A R N IN G : R is k o f E le ctric S h o c k
!
W A R N IN G : R is k o f H ig h P re s s u re
W A R N IN G : C o n s u lt M a n u a l
• 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.
5
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:
 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.
6
• 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.
 SECTION 4 — COMPRESSOR CONNECTION AND CONTROL

Consult the air compressor manual or your air

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.
compressor supplier/specialist for details before installing
the X4I.
PRESSURE DETECTION AND CONTROL
The X4I utilizes the signal from a 4-20 mA pressure 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 mA output and a range of up to 8700 PSI (600
bar).

7
X4I MAIN DISPLAY

User Interface
The User Interface display functiuonality is
depicted below:
a b User Interface DisplayUser Interface
Display Functionality

102
PSI
c a) System Pressure Value
b) System pressure Units
d 1 10:35 e c) Unit Status
d) Unit Active Functions
f 1 2 3 4 e) Time
g f) Compressor Number
A B C D g) Compressor Sequence Assignment
h) Compressor Status
h

To view the next automated Sequence

12:00 #1 Rotation display, Press Down:

User Interface Display Functionality

a b
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)

The keypad and navigation keys on the X4I are

depicted below and provide the following functionality.
a b c
Keypad and Navigational Keys Functionality
g a) Start
b) Reset
c) Stop
f d d) Menu
e) Enter
f) Escape
g) Up (Plus)
h e h) Down (Minus)

8
 SECTION 5 — INSTALLATION
It is recommended that installation and commissioning be UNIT LOCATION
carried out by an authorized and trained product supplier.

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.

SPECIFICATIONS Ingersoll Rand Automation

Dimensions 11.45” x 9.45” x 6.0”
291mm x 241mm x 152mm Model X4I
Weight 14lb (6.4kg) COMPRESSOR CONTROL CABLE
Mounting Wall, 4 x screw fixings 7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
Enclosure IP65, NEMA 4
Supply 230Vac +/- 10%, 50 Hz OR
115Vac +/- 10%, 60 Hz Single Conductor Wire, 18 Gauge Stranded, Quantity (7)
Power 50VA In Grounded Conduit
Temperature 32°F to 115°F No Greater Than 330FT (100M)
(0°C to 46°C) 24VAC Control Voltage
Humidity 0% to 95% RH
(non-condensing)

Compressor #4 Control Cable

Local Disconnect (Breaker) Box Compressor #3 Control Cable

Fused for 50VA On/Off
Switch Supply Voltage Cable Compressor #2 Control Cable
Power Cable
3 conductor (L, N, E) Compressor #1 Control Cable
(Sized in accordance with local
electrical and safety regulations). Reference X4I Compressor
Pressure Transducer Cable Compressor IR-PCB Interconnect and Application Guide
#1
For Connections Between The
PRESSURE TRANSDUCER CABLE Compressor #1 Control Cable Compressor And The IR-PCB
X4I X01 CONNECTOR IR-PCB CONNECTOR
2 Conductor Cable, 18 Gauge Stranded V1 V1
Earth Shielded 1 1
No Greater Than 330FT (100M) 2 2
3 3 Compressor IR-PCB
24VDC Control Voltage 4 4
5 5 #2
X4I X05 CONNECTOR PT CONNECTOR 6 6
Compressor #2 Control Cable
25 +VDC Pin #3 X4I X02 CONNECTOR IR-PCB CONNECTOR
26 Signal Pin #1 V3 V1
Reference X4I Operations Manual for Pressure 7 1
8 2
Sensor Connection Details 9 3
10 4
11 5
PRESSURE TRANSDUCER 12 6

Compressor IR-PCB
#3
RECEIVER
Compressor #3 Control Cable
X4I X03 CONNECTOR IR-PCB CONNECTOR
V3 V1
13 1
14 2
15 3
Compressor IR-PCB
16 4
17 5 #4
18 6
DRIP LEG Compressor #4 Control Cable
X4I X04 CONNECTOR IR-PCB CONNECTOR
V4 V1
19 1
20 2
21 3
22 4
23 5
24 6

9
POWER SUPPLY
DEMAND (DRY) SIDE PRESSURE CONTROL

A fused switching isolator must be installed to the main

incoming power supply, external to the X4I. The isolator P P
must be fitted with a properly sized fuse to provide 1
adequate protection to the power supply cable used (in
accordance with local electrical and safety regulations).

X PM -T AC 2 4 2
1 2 3 4 1 2 3 4
X04
Pressure Sensor Located After Shared Cleanup
L N E E VO L TAG E S E L E C T Equipment
X01 230Vac
1 2 3 4
L N E X04
P P
VO L TAG E S E L E C T

115Vac
1
P
Power Supply Terminals

Ensure that the voltage select input is properly 2

jumpered for the incoming power. Default voltage
configuration is 230Vac. Pressure Sensor Located After Individual Cleanup
Equipment
PRESSURE SENSOR LOCATION
Ensure each compressor is equipped with independent
The system pressure sensor (P) must be located where it excess pressure shutdown. An increase in pressure
will see the air pressure that is common to all of the differential across air treatment equipment can result in
compressors. excess compressor discharge pressure.

SUPPLY (WET) SIDE PRESSURE CONTROL Regular routine monitoring of pressure differential
across air treatment equipment is recommended.
P

P
1

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.

10
PRESSURE SENSOR CONNECTION

The pressure sensor connects to terminal X05 of the X4I

terminal PCB using a shielded 18 AWG maximum 2-
conductor cable no more than 330 feet (100 meters) in
length. The transducer threads are BPT. It is the equivalent
of ¼” NPT.

Pressure Sensor Wiring and Location

Wire polarity is important.

IR-PCB INTERFACE MODULE +VDC

C01 VFD/fixed
V V
Load Enable
The IR-PCB is designed to interface a compressor with the 1 SEQ CONT
Load/Unload
X4I using a 7-conductor shielded cable or individual wires 2 LOAD UNL

run through grounded conduit no greater than 330 feet 3 GND C03
NO
(100 meters) in length. 4 D11

OUT
5 D12 C
NC
Each compressor in the system must be assigned a unique 6 +20V C02
NO
identification number from 1 up to the number of LED 5 V C

IN
compressors in the system. The identification number LED 2 LOAD
NC
LED 1 SEQ
should be clearly indicated on each compressor for
operational reference.
READY
LED 4

ALARM
RUN
LED 3

For each compressor utilizing an IR-PCB, connection to the

C05
X4I the signal wires must be made to the correct X4I C04 RUN
terminals for that compressor number. Compressor 1 1

should be wired to terminal X01 on the terminal PCB, 2 READY

Compressor 2 should be wired to terminal X02 on the
terminal PCB, etc.

IR-PCB Interface Module

The IR-PCB is a DIN rail mountable module designed to be
installed within the compressor starter enclosure.
Each air compressor must be equipped with a load/unload
regulation system and, if not regulated with a single
electro-mechanical pressure switch, have a facility for a
remote load/unload control with the ability to accept a volt-
free switching contact input for remote load/unload. Each
air compressor must have Auto Restart capability.

V For variable speed compressor(s) equipped with a

“variable/fixed” digital input function, install a 7-conductor
shielded cable from the IR-PCB to the X4I.

11

Consult the air compressor manual or your air
compressor supplier/specialist for details before installing
the X4I.
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.
The IR-PCB accepts a 12V to 250V input voltage detection
system and utilizes universal relay contact control outputs
(250V “CE” / 115V “UL” @ 5A maximum) integrated directly
into the circuits of an air compressor. The IR-PCB avoids the
need for additional relays or remote inputs. The IR-PCB also
acts as an electrical barrier between the compressor and the
X4I providing protection and voltage isolation.
Consult the X4I Interconnect and Application Guide
prior to the installation of the X4I and the IR-PCB to the air
compressor.
INPUT FUNCTIONS
The IR-PCB is fitted with a six-pin terminal, C04, for
compressor monitoring. The IR-PCB uses two inputs, Ready
and Run, to determine compressor status. An alarm input
can be used if compressor warning indication is available
and required. The alarm input is optional and is not
necessary for system operation.
READY INPUT
The ‘Ready’ connection is intended to indicate that the
compressor is in a “started” state, has no alarm condition
that has shut down the compressor, and is ready to respond
to X4I regulation without manual intervention.
R EAD Y LAM P 0V
+V
ALARM RUN READY
C04
Typical Ready Input Wiring
The READY input will accept 12V to 250V ac (50/60Hz) or
dc.
Do not connect a voltage greater than 250Vac/dc to
this input.
This input must be connected to a circuit of the compressor
control system that will be energized when the compressor
is in a started (standby or running) condition. For example,
locate the circuit across the ready or operating lamp as
shown.
12
The voltage to this input must de-energize when the
compressor is stopped and unavailable to produce air upon
a load signal, or the emergency stop button is pressed, or
when the compressor experiences a fault that prevents the
compressor from running.
When the compressor ready lamp or other control circuit is
energized, the IR-PCB will detect the voltage and signal the
X4I that the compressor is ready and available to load and
produce air when a load request signal is given.
The IR-PCB common input terminal must always be
connected to the neutral, common or 0V line of the applied
input voltage.
READY INPUT, ALTERNATIVE CONNECTION METHOD
In instances where a convenient voltage signal for a
compressor ready condition is not available, the “ready”
input can be connected directly to a constant compressor
control voltage (12V to 250Vac or dc). This will signal the
X4I that the compressor is ready and available at all times
when power is applied to the compressor. The X4I has a
built-in function to determine when a compressor is not
responding, or is in a shutdown condition, even if the
“ready” signal says otherwise. If the X4I requests a
compressor to run/load, but fails to detect a RUN signal
within 60 seconds, the X4I will regard the compressor as
“not ready” and indicate the compressor as not available. If
a RUN signal is reacquired at any time, the X4I will
automatically reset the compressor “not ready” condition
and re-establish control.
+Vac
F1
0Vac
READY
Alternative Ready Signal Connection
Never connect the “Ready” input positive voltage
connection directly to the output of a control system
transformer. Always connect after a fuse or circuit breaker.
If a normally closed contact of an emergency stop button is
included in the compressor power supply circuit, connect
after the emergency stop button contacts. This will instantly
indicate a compressor “not ready” condition if the
emergency stop button is activated.
RUN INPUT
The IR-PCB input common terminal must always be
M A IN (LIN E ) C O N T A C T O R connected to the neutral, common or 0V line of the applied
0V input voltage.
+V
WARNING INPUT (OPTIONAL)
The IR-PCB is equipped with a warning input that can be
used to detect warning conditions.

An alarm that stops the compressor, and/or prevents

the compressor from running is determined from the “run”
and “ready” inputs. Warning detection is optional and is not
a requirement.
A LA R M RUN READY
C 04 A la rm L am p
0V
+V
Run Signal Circuit
The RUN input will accept 12V to 250V AC (50/60Hz) only.
DC cannot be used.

Do not connect a voltage greater than 250V to this

input.
12V to 250Vac must be applied to the “run” terminals when
the compressor motor is running.
This input can be connected to the control terminals A1 and
A2 (coil) of the main starter contactor of the compressor.
When the compressor control system energizes the main
contactor, the IR-PCB will detect the voltage across the
contactor coil terminals and signal the X4I that the
compressor is running.
Alternatively, if the main contactor coil voltage is greater
than 250Vac, a contactor auxiliary switch can be used to
apply a suitable voltage to the “run” input terminals.
M A IN (L IN E ) C O N T A C T O R
+V
0V
+V
0V
A U X IL IA R Y S W IT C H
A la rm R un R e ad y
C 04
Warning Input Circuit
The warning input will accept 12V to 250V AC (50/60Hz) or
DC.
Do not connect a voltage greater than 250Vac/DC to
this input.
This input can be connected to the terminals of an alarm
lamp or other accessible part of the control circuit that is
energized when the compressor is in a warning condition.
If a warning condition is experienced the compressor
warning lamp, or warning circuit, will energize. The IR-PCB
will detect the voltage and signal the X4I that a warning has
occurred. If the compressor has no accessible warning
circuit, or this function is not required, the IR-PCB alarm
terminals can be ignored.

ALAR M RUN READY The IR-PCB input common terminal must always be
C04 connected to the neutral, common or 0V line of the applied
input voltage.
Run Signal Circuit with Auxiliary Switch
In instances where a motor starter contactor is not available
or accessible, any part of a compressor control circuit that
is energized when the compressor is running can be
monitored. For example: fan contactor or voltage signal to a
remote starter.

13
OUTPUT FUNCTIONS
0V

+V
The X4I will control the IR-PCB load/unload relay outputs
based on the active system load and unload pressure LO A D
setpoints. The IR-PCB load/unload relay contacts can be S O LE N O ID
used for compressor controllers that have electro-
mechanical pressure switch load/unload regulation.

NC
NO
C

NC
NO
OUT IN
C 02

Two Wire Pressure Switch Connections

LO AD
S O L E N O ID

0V
+V

R U N -O N
T IM E R

IR-PCB Internal Output Circuits

NC
NO
C

NC
NO

The C01 and C02 terminals of the IR-PCB are intended to OUT IN

control load and unload regulation of the compressor. C 02

Three Wire Pressure Switch Connections

PRESSURE SWITCH REGULATION
For air compressors fitted with an electro-mechanical
pressure switch, a six-pin terminal C02 has been provided
to enable connection to a pressure switch that has a two-
wire or three-wire connection.
When connected, the pressure switch can be switched in
and out of circuit automatically. If the X4I is stopped or
experiences a failure or loss of power, pressure control will
automatically revert back to the pressure switch and the
compressor will continue to operate in “local” mode.
The local pressure settings of all compressors in the
system should be set in a cascaded manner such that the
system will operate normally in the event of X4I
inoperability.
The NC (normally closed) and NO (normally open)
terminal references of the IR-PCB are related to internal
connection functions and should not be referenced to the
connections of a compressor pressure switch, which will
generally be in reverse order.
Lethal voltages may be present on the terminals of the
air compressor pressure switch. Isolate the air compressor
power supply before starting any work.
DIGITAL REGULATION CONTROL TERMINAL C01
A 4-pin connector, C01, has been provided for air
compressor controllers fitted with digital inputs allowing
remote pressure regulation control.
This terminal provides volt free contact closure, referenced
to a common terminal pin, for:
• Remote Load Enable (remote/local
pressure regulation control)
• Remote Load (remote load/unload)
• Remote Variable Speed Regulation Inhibit
(remote variable/fixed speed regulation
control)
The “remote load enable” function provides the facility to
change the compressor load regulation from internal
control to a remote switching source (local/remote).
V The “remote variable/fixed” function provides for
multiple variable speed compressor regulation control on
variable speed compressor(s) equipped with this facility.
When using the “Variable/Fixed” function, the “V”
terminal of the IR-PCB must be connected to the
appropriate “V” terminal of the X4I (according to
compressor number) with an additional wire. Use a 7-
conductor shielded cable in this instance.

14

Compressors that use electronic pressure detection
but are not equipped with a remote pressure control enable
feature will not automatically revert to local control if the
X4I is stopped or experiences a fault or loss of power.
The IR-PCB connection examples shown in this manual are
intended to provide a guide for the majority of compressor
control systems in use. Some compressors have variations
in operation and/or function; consult your compressor
supplier/specialist for advice.

+VDC +VDC SERVICE MAINTENANCE SWITCH

V F D /F ixe d
The IR-PCB is equipped with a volt-free input (terminal
L o a d E n a b le C05) that can be used to remove the compressor from X4I
L o a d /U n lo a d V F D /F ixe d control, without generating a fault condition, during short-
term maintenance or servicing periods.
L o a d E n a b le
L o a d /U n lo a d 1
2
C05

ir-P C B

Service Maintenance Switch Circuit

Load, Sequence, and VFD Connections
Compressor controller inputs common voltage may be
0V or +V.
The local/remote pressure regulation input and/or remote
load input logic of some electronic pressure sensor type
controllers are reversed. In this instance, the “pressure
switch” outputs (terminal C02) can be used to establish
alternative logic control connections.
For Example:
If the compressor controller “Local/Remote Pressure
Control” input is a normally open type (local when open,
remote when closed), but the “Remote Load” input is a
normally closed type (load when open), the IR-PCB pressure
switch terminal contacts can be used to achieve the correct
switching logic.
When the “Service Maintenance Switch” input terminal pins
are connected together using a volt-free switching contact,
the X4I will indicate that the compressor is not available but
will not generate a warning, alarm, or shutdown condition.
The X4I will also remove the compressor from the sequence
strategy and substitute with an alternative available
compressor if necessary. When the “Service Maintenance
Switch” input circuit is open again, the compressor will
automatically be accepted back in to the sequence strategy
and will be utilized when next required.
The use of a “key switch” is recommended for this purpose
in order to prevent the switch contacts being inadvertently
left in the closed circuit condition after service maintenance
is complete.
DO NOT connect any external voltage source to the
pins of terminal C05.

C 02
AUXILIARY INPUT (OPTION)
NO L oca l/R em ote
The X4I is equipped with an auxiliary input at terminals 31
OUT C co m m o n and 32 (X07).
NC

NO
R e m o te Lo a d The function of the input is menu selectable and can be
co m m o n adapted for differing application requirements.
IN C
NC
X07
32
Alternate Logic 31

Examine the “i-PCB” internal output circuit diagram to

establish any desired switching logic that may differ from Auxiliary Input Circuit
normal practice.
The input is designed to detect a remote “volt-free”
switching contact (rated for a minimum 24VDC @ 10mA).
Do not attempt to utilize “Digital Pressure Regulation
Control” (terminal C01) and the “Pressure Switch Control”
(terminal C02) output connections at the same time for
different products. These two output functions are
internally connected and a short circuit condition and/or
malfunction may result.

15
AUXILIARY OUTPUT (OPTION) potential can result in intermittent malfunction or anomaly
that is difficult to diagnose. To avoid this possibility, always
The X4I is equipped with a remote relay contact output at use shielded cables, securely bonded to a known ground at
terminals 33 and 34 (X08). one end. In addition, give careful consideration to cable
The function of the output is menu selectable and can be routing during installation.
adapted for differing application requirements. • Never route an RS485 data
communications or low voltage signal
X08 cable alongside a high voltage or 3-phase
34 power supply cable. If it is necessary to
R6 cross the path of a power supply cable(s),
33
always cross at a right angle.

Auxiliary Output Circuit • If it is necessary to follow the route of

power supply cables for a short distance
The remote output relay contacts are rated for 240V “CE” / (for example: from a compressor to a wall
115V “UL” @ 5A maximum. along a suspended cable tray), attach the
RS485 or signal cable on the outside of a
grounded cable tray such that the cable
RS485 COMMUNICATIONS tray forms a grounded electrical
The X4I is equipped with an RS485 network interference shield.
communications capability using the proprietary Multi485 • Where possible, never route an RS485 or
protocol. signal cable near to equipment or devices
that may be a source of electrical
interference. For example: 3-phase power
This can be only used for remote connectivity to
supply transformer, high voltage
optional X4I expansion networked units and modules with
switchgear unit, frequency inverter drive
proprietary Multi485 communications capabilities.
module, radio communications antenna.
X06
L1 30 L1
L2 29 L2
28 RS485
27

RS-485 Connection Circuit

RS485 data communications and other low voltage

signals can be subject to electrical interference. This

16
 SECTION 6 — CONTROL FEATURES AND FUNCTIONS
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
PRESSURE CONTROL
Pressure control is achieved by maintaining the system
pressure within an acceptable range, or pressure band,
which is defined and programmed by the user. Pressure will
rise in the band when system demand is less than the
loaded compressor’s output. Pressure will fall in the band
when system demand is greater than the loaded
compressor’s output.
Simply stated, pressure control is achieved by unloading
and loading compressors to closely match compressor
output with system demand within a specified pressure
band defined by PL and PH. See Figure 1.
Variable speed compressors also operate within the
pressure band and actively match compressor output with
system demand by speeding up and slowing down around a
target pressure defined by the exact midpoint of the
pressure band defined by PT. See Figure 2.
a
PH
PT
b
PL
Figure 1 — Typical System Pressure vs. Time
As pressure rises to point “a”, the compressor will unload
based on the sequencing algorithm. System pressure is
then allowed to decrease due to the drop in supply until
point “b” is reached. Once point “b” is reached, the X4I will
load the next compressor in the sequence to match the air
demand. This cycle will repeat as long as the X4I is able to
keep the system air pressure between PH and PL.
PH
PT
PL
Figure 2 — Typical VSD Pressure Control vs. Time
17
When a compressed air system includes one or more
variable speed compressors, each variable speed
compressor must have its target pressure (on its local
controller) set to the system target pressure.
The variable speed compressors in the system will run on
their target pressure and smooth out the variations in system
pressure. This assumes that system demand does not vary
more than the capacity of the variable speed compressor.
A variable speed compressor will be included in the load/
unload sequence and be controlled exactly as a fixed speed
machine with the exception of speed control to maintain
target pressure.
ANTI-CYCLING CONTROL
The most efficient way to utilize most air compressors is
either fully loaded or off, with the exception of variable
speed compressors which can operate efficiently at reduced
loading. Compressor cycling (start-load-unload-stop, etc.)
is essential to maintain pressure control. Excessive cycling,
however, can result in poor compressor efficiency as well as
increased maintenance.
Anti-cycling control is incorporated to help ensure that only
the compressors that are actually required are started and
operating while all others are kept off. Anti-cycling control
includes a pressure tolerance range or band, defined by the
user, which is outside of the primary pressure band. Inside
the tolerance band, an active control algorithm continually
analyzes pressure dynamics to determine the last possible
second to add or cycle another compressor into the system.
This control is further enhanced by the ability to fine tune
the tolerance band settings and algorithm processing time
(Damping).
TOLERANCE
Tolerance is a user adjustable setting that determines how
far above the PH setpoint and below the PL setpoint system
pressure will be allowed to stray. Tolerance keeps the X4I
from overcompensating in the event of a temporary
significant increase or decrease in system demand.
PH + TO
TO
PH
PT
PL
TO
PL - TO
Figure 3 — Tolerance in Relation to PH and PL
Tolerance (TO) is expressed as a pressure defining the
width of the band above PH and below PL in which energy
efficient control will be in effect.
When system pressure is in the tolerance band, the X4I will system. Tolerance (TO) and damping (DA) can be used
continuously calculate the moment at which compressors for minor tuning of the system.
will be loaded or unloaded based on the rate of change of
system pressure. When the system pressure strays outside
SYSTEM VOLUME
of the tolerance band, the X4I will abandon energy
efficiency and begin to protect the system air pressure by
loading or unloading the compressors. Loading will be
delay controlled.
When the compressed air system storage is relatively small
compared to the system demand, and fluctuations are large
and quick, the tolerance band setting should be increased
to maintain energy efficient operation and avoid a situation
in which multiple compressors are loaded just to be
unloaded moments later.
- +
When the compressed air system is relatively large
compared to system demand and fluctuations are smaller Assorted Receiver Tanks
and slower, the tolerance band can be reduced to improve
System volume defines how fast system pressure will rise or
pressure control and maintain energy efficient operation.
fall in reaction to either increased/decreased demand or
The factory default setting for tolerance is 3.0 PSI (0.2Bar). increased/decreased supply. The larger the system volume,
This setting is user adjustable. the slower the pressure changes in relation to increased/
decreased demand or supply. Adequate system volume
enables effective pressure control and avoids system over-
DAMPING pressurization in response to abrupt pressure fluctuations.
Any time the pressure is within the Tolerance band the Adequate system volume is created by correctly sizing and
Anti-Cycling algorithm is active, sampling the rate of utilizing air receivers.
pressure change and calculating when to load or unload the The most accurate way to determine the size of air receivers
next compressor. The damping (DA) setting is a user or the additional volume required would be to measure the
adjustable setpoint that determines how quickly the size and duration of the largest demand event that occurs
controller samples and recalculates, effectively speeding up in the system, then size the volume large enough to ride
or slowing down the reaction time. through the event with an acceptable decrease in system
The X4I’s factory default DA setting of “1” is adequate for pressure. Sizing the volume for the worst event will ensure
the majority of compressed air systems but may need to be system stability and effective control over all other normal
adjusted in the following circumstances involving operating conditions.
aggressive and disproportionate system pressure changes: If measurement is not available, then estimating the largest
• Inadequate air storage event is a reasonable alternative. For example, assume that
• High pressure differential across the air the largest demand event could be equal to the loss of the
treatment equipment largest operating air compressor. System volume would be
sized to allow time for a back-up compressor to be started
• Incorrectly sized piping and loaded with an acceptable decrease in pressure.
• Slow or delayed compressor response
The following formula determines the recommended
In these circumstances, the X4I may overreact and attempt minimum storage volume for a compressed air system:
to load additional compressors that may not be necessary if
the system was given time to allow the system pressure to
stabilize after the initial compressor is given time to load. If
the tolerance has already been increased and the X4I is still
overreacting, then increasing the damping factor is the next
step.
V — “Volume of Required Storage” (Gal, Ft3, m3, L)
Damping is adjustable and is scaled from 0.1 to 10 with a
factory default of 1. A factor of 0.1 is a reaction time 10 T — “Time to Start Back-up Compressor” (Minutes)
times faster than the default and a factor of 10 is a reaction
C — “Lost Capacity of Compressed Air” (CFM, m3/min)
time 10 times slower than the default.
Pa — “Atmospheric pressure” (PSIa, BAR)
NOTE: There are many variables that go into
determining the stability and control of the system P — “Allowable Pressure Drop” (PSI, BAR)
pressure, only some of which are able to be controlled
by the X4I. System storage, air compressor capacity, and
air demand all need to be analyzed by experienced
professionals to determine the best installation for your

18
Example 1: Find Required Storage Volume in Ft3 and US Gal. based on a set interval, a set time of day each day, or a set
time of day once a week.
(4) - 25 Hp Compressors at 92 CFM (2.6 m3) each / 15
seconds to start and load a compressor. 5PSIG is the
The compressor load control strategy defines when
maximum allowable pressure drop.
compressors load and unload based on system pressure
T=15 Seconds (.25 minute) variations and whether they run in fixed or variable speed
modes.
C=92 ft3
Each compressor in a system will be assigned a permanent
Pa = 14.5 PSI number based on where they are wired into the terminal
Delta P = 5 PSI PCB. Compressor 1 will always be wired into terminal X01;
compressor 2 will always be wired into terminal X02, etc.
V = [.25 x (92 x 14.5)]/5
Each compressor will also be assigned a letter from A to D
V = (.25 x 1334)/5 based on its location in the sequence:
V = 333.5/5 • A = the base load compressor (the first
compressor to be used).
V = 67 Ft3
• B = the first trim compressor (the second
1 ft3 = 7.48 Gal compressor to be used).
• C = the second trim compressor (the third
Gal= 67 Ft3 x 7.48 compressor to be used).
Gal = 498.9 • D = the third trim compressor (the last
compressor to be used).
Example 2: Find Required Storage Volume in m3 and L.
Compressor sequence assignments are reviewed and
(4) - 25 Hp Compressors at 92 CFM (2.6 m3) each / 15 dynamically changed at a rotation event based on the
seconds to start and load a compressor. 0.34 BAR is the sequencing strategy that is selected.
maximum allowable pressure drop.
T=15 Seconds (.25 minute)
FIRST IN LAST OUT CONTROL MODE (FILO)
3
C=2.6 m
Compressor load sequence will be A, B, C, D and
Pa = 1BAR
Unload sequence D, C, B, A
Delta P = .34 BAR
V = [.25 x (2.6 x 1)]/.34 FIRST IN LAST OUT ROTATION MODE (FILO)
V = (.25 x 2.6)/.34 The default configuration of the X4I provides FILO (First In/
Last Out) sequence control strategy.
V = .65/.34

V = 1.91 m3 The primary function of FILO (First In/Last Out) mode

3 is to efficiently operate a compressed air system consisting
1m = 1000 L
of fixed speed compressors. The standard FILO rotation
L= 1.91 m3 x 1000 assignments can be modified using priority settings, which
are explained later in this section.
L = 1910
Whenever a rotation event occurs, the sequence assignment
STANDARD CONTROL FEATURES AND for each compressor is rearranged. The compressor that
was assigned as the base load compressor (A) is reassigned
FUNCTIONALITY
to third trim compressor (D) and all other compressors are
incremented by one.
STANDARD SEQUENCE CONTROL STRATEGY
1 2 3 4
The standard configuration of the X4I provides FILO (First
In/Last Out) sequence control strategy.
#1 A B C D
The sequence control strategy consists of two components:
• The compressor rotation strategy #2 D A B C
• The compressor load control strategy #3 C D A B

The rotation strategy defines how the compressors are #4 B C D A

arranged in a new sequence whenever a rotation event
occurs. Rotation events are triggered by a periodic rotation Sequence Rotation Table

19
SEQUENCE ROTATION EVENTS
A sequence rotation event can be triggered in the
following ways: a periodic interval, a pre-determined time
each day, or a pre-determined time day and time each
week.
Please refer to the Quick Setup Manual to determine how to
configure the rotation events.
ADVANCED CONTROL FEATURES AND
FUNCTIONALITY
ADVANCED SEQUENCE CONTROL STRATEGIES
The advanced configuration of the X4I provides VEC
(Variable Energy Control) sequence control strategy, Priority
Settings, Table Selection, and Pre-fill operation.
VARIABLE ENERGY CONTROL MODE (VEC)
The primary function of VEC mode is to accommodate
a variable speed compressor connected to the X4I using an
IRV-PCB interface.
VEC mode utilizes the FILO sequencing and rotation
strategy with the additional control philosophy needed to
efficiently control variable speed compressors.
Compressor A will always be the first to be loaded and last
to be unloaded.
PRIORITY SETTINGS
The sequence assignment pattern can be modified by using
the priority settings.
Priority settings can be used to modify the rotation
sequence assignments. Compressors can be assigned a
priority of 1 to 4, where 1 is the highest priority. Any
compressor can be assigned any priority and any number of
compressors can share the same priority.
Priorities allow you to set up rotation groups. All
compressors that have the same priority number will rotate
inside their own group. The group with the highest priority
will always be in the front of the sequence.
For example, in a four compressor system including one
variable speed compressor in the compressor 1 position
you may want the variable speed compressor to always be
in the Lead position. By assigning compressor 1 a priority of
1 and the other three compressors a priority of 2, the
variable speed compressor will always remain at the front of
the sequence:
1 2 3 4
1 2 2 2

In any set rotation sequence, the variable speed compressor #1 A B C D

that is assigned closest to A will be utilized in trim mode
and will be allowed to vary its speed based on its local #2 A C D B
target pressure setpoint and the variations in system #3 A D B C
pressure. If there are additional variable speed
compressors in the system, each subsequent variable speed #4 A B C D
compressor to load will be placed into variable speed mode
and the previous variable speed compressor will be Compressor 1 has priority 1, all other compressors have
switched and held in fixed speed mode. This will prevent priority 2
multiple variable speed compressors from oscillating. An
example would be if 1 and 2 are both variable speed In another example, there is a four compressor system that
compressors, when the load drops outside the pressure includes a compressor in the compressor 4 spot that is
band, 1 will load first as a variable speed compressor. If the used only as an emergency backup compressor. To
pressure continues to drop, then 2 will load as a variable accomplish this, simply assign compressor 4 a lower
speed compressor and 1 will be switched to fixed speed. priority than any other compressor in the system:

The compressor that is allowed to run in variable speed 1 2 3 4

mode will be evaluated at each rotation event.
When a compressed air system includes one or more 1 1 1 2
variable speed compressors, each variable speed
compressor must have its target pressure (on its local #1 A B C D
controller) set to the system target pressure. #2 B C A D
Compressors are brought on or offline in response to
#3 C A B D
changing demand using the FILO strategy. The base load
compressor (A) will be brought online first in the case of #4 A B C D
system pressure dropping below the low pressure setpoint.
If pressure continues to drop, the first trim compressor (B) Compressor 4 has priority 2, all other compressors have
will also load. Compressors C and D will load in that order if priority 1
needed. When system pressure rises above the high
pressure setpoint, the last compressor to load will now be
the first to be unloaded. Compressors C, B, and A will be
unloaded, in that order, if system pressure continues to
increase.

20
In a third example, there is a four compressor system that Each table consists of the following parameters which can
includes a variable speed compressor designated be set independently in each table:
compressor 1 and a fixed speed compressor that is an • PH – High Pressure Setpoint
emergency backup assigned as compressor 4. To ensure
• PL – Low Pressure Setpoint
that compressor 1 is always at the front of the sequence
and compressor 4 is always at the end of the sequence, set • Pm – Minimum pressure warning level
the priority as shown below: • SQ – Sequence Rotation Strategy
• 01 – Compressor 1 Priority
1 2 3 4
• 02 – Compressor 2 Priority
1 2 2 3 • 03 – Compressor 3 Priority

#1 A B C D • 04 – Compressor 4 Priority

#2 A C B D
The “maximum” pressure fault level and the rotation
#3 A B C D interval, or rotation time, are set independently in a
configuration menu and are unchanging regardless of the
#4 A C B D table selected.
When the X4I is instructed to change between tables, it will
Compressor 1 has priority 1, compressor 4 has priority
not abruptly change the system operating parameters. The
3 and all other compressors have priority 2
X4I will adjust the system target pressure upward or
A last example involves another four compressor system downward to the next table’s settings. This transition will
that will be assigned into two independently rotation occur gradually to preserve energy efficiency and safe,
groups. Compressors 1 and 2 are given priority 1 and reliable control:
compressors 3 and 4 are given priority 2. This results in the
rotation sequence shown below: 1 2
1 2 3 4

1 1 2 2

#1 A B C D PC
#2 B A D C Changing Target Pressures
#3 A B C D The time the system is allotted to change the target
pressure is known as the Pressure Change Time (PC). This is
#4 B A D C
a value that is adjustable in the system settings screen. See
the Quick Setup Manual.
Two independently rotating compressor groups
If the X4I is able to complete the transition in less time than
is allotted without threatening energy efficiency then PC will
be automatically shortened.
T01
PH ----
PL
Pm
----
---- An aggressively short time setting will compromise
SQ ----
TABLES AND THE PRESSURE SCHEDULE energy efficiency.

The X4I operates based on settings that are configured into

one of three tables. Each table defines the operational
settings and sequence control mode of the X4I. The X4I can
be instructed to change among the tables at any time based
on the configuration of the pressure schedule.
This functionality allows the X4I to switch among multiple
different system configurations without any disruption to
control. This is particularly useful in the case of shift
changes, or weekends when the system is to be
deactivated.
PRESSURE SCHEDULE
The X4I is equipped with a real-time clock feature and
pressure schedule functionality. The pressure schedule
function can be used to provide enhanced system
automation.
The pressure schedule consists of 28 individual settings
that instruct the system to change from one table to
another, or put the system into standby mode dependent
on the time of day and the day of the week. The pressure
schedule will cycle from 00:00 hours Monday (day #1) to
23:59 hours on Sunday (day #7) each calendar week.

21
The pressure schedule has the capability of changing tables
based on the time of day, once each day, or once each day
except weekends. Please see the Quick Setup Manual for
detailed information on how to configure the pressure
schedule.
PRE-FILL
The pre-fill feature provides an energy efficient method of
increasing pressure to normal operating levels upon system
start. This feature avoids the inefficient potential for all
compressors to start and load in an attempt to quickly get
the system pressure up to normal levels:
System pressure during pre-fill
At system start (manual start or automated start from
standby), the X4I will only load compressors that have been
pre-set for pre-fill operation, for a pre-set period of time.
The pre-fill time (PT) can be adjusted to suit system
characteristics. The aim is to increase pressure to normal
operational levels, using only the pre-determined
compressors, prior to the pre-fill time expiring.
If normal operational pressure is reached prior to the set
pre-fill time, the pre-fill function will automatically cease
and normal operational control will begin. If normal
operational pressure is not reached by the end of the pre-
fill time, the X4I will utilize as many available compressors
as required to achieve normal operational pressure as
quickly as possible. Normal operational control will then
begin.
Two pre-fill modes are available. Both function in the same
way but differ in response to a failure, or loss, of a pre-fill
compressor.
• Backup Mode: Compressor(s) can be
pre-selected as “primary pre-fill”
compressor(s) or “backup pre-fill”
compressor(s). If a primary pre-fill
compressor experiences a shutdown, or is
stopped, it is replaced by a pre-defined
backup compressor and pre-fill continues.
• ! X Standard Mode: If one or more
of the pre-defined pre-fill compressors
experiences a shutdown, or is stopped, the
pre-fill function is cancelled and normal
operation begins.
To manually skip pre-fill mode, press and hold START
for several seconds.
22
ALTERNATE CONTROL FEATURES AND
FUNCTIONALITY
The alternate control strategies of the X4I provides EHR
(Equal Hours Run) and FIFO (First In/First Out) sequence
control strategy.
EQUAL HOURS RUN MODE
The primary function of EHR mode is to keep the
running hours of all compressors in the system as close as
possible. This provides the opportunity to service all of the
compressors at the same time, given that the expected
service interval for the compressors is similar.
EHR is not an energy efficient focused mode of
operation.
Each time a rotation event occurs, the compressor sequence
is examined and will be rearranged based on the running
hours recorded for each compressor. The compressor with
the fewest running hours is assigned as the base load
compressor and the compressor with the most running
hours is assigned as the third trim compressor. For systems
with more than two compressors, the compressors will be
assigned from A to D in accordance with increasing running
hours.
Example: The compressors in a four compressor system
have the following recorded running hours when a rotation
event occurs:
• Compressor 1 = 2200 hours
• Compressor 2 = 2150 hours
• Compressor 3 = 2020 hours
• Compressor 4 = 2180 hours
The new sequence order after the rotation event would be:
• Compressor 1 = D
• Compressor 2 = B
• Compressor 3 = A
• Compressor 4 = C
Compressor 3, which has the fewest running hours, will
now be utilized more frequently in the new sequence,
allowing running hours to accumulate at a faster rate.
The X4I continuously monitors the running status of each
compressor and calculates the accumulated running hours.
These readings are viewable and adjustable in the X4I C01
setting screens. The X4I will use these values during EHR
mode. The running hours on the X4I should be routinely
checked to see that they match the compressors’ local
calculations, and adjusted if necessary.
If a compressor is operated independently from the
X4I, the running hours record may not be accurately
updated.

The running hours meter display on most compressors
are intended for approximate service interval indication
only and may deviate in accuracy over a period of time.
Compressors will be utilized following the FILO strategy.
FIRST IN FIRST OUT MODE (FIFO)
The primary function of FIFO mode is to minimize the
utilization on any one compressor. This control strategy is
commonly used with air cooled reciprocating compressors.
If system pressure continues to decrease, compressor 2 (B)
will be loaded and be reassigned to (A) while compressor 1
is reassigned as (D). If this causes system pressure to rise
above the high pressure setpoint, then compressor 1 (D)
will be unloaded to allow compressor 2 (A) to maximize its
run time. If system pressure decreases further, compressor
3 will be loaded and reassigned to (A) while Compressor 2
is reassigned to (D) and so on.
The most recently loaded compressor will always be
assigned (A) and the longest running compressor will
always be assigned (D).
1

FIFO is not designed as an energy efficient mode of 2

operation.
3
FIFO does not follow sequence rotation events.
4
Compressors are rotated each time a compressor is loaded.
The rotation strategy becomes the control strategy using ABCD DABC DABC CDAB BCDA BCDA BCDA ABCD
the control mode.
FIFO Rotation
When system pressure drops below the low pressure
setpoint, compressor 1 (A) will be the first to load as usual.

23
 SECTION 7 — DISPLAY AND MENU OPERATION
The Main Display and the keypad and navigation buttons on
the X4I are depicted below and provide the following
functionality:

User Interface
The User Interface display functiuonality is
depicted below:
a b User Interface DisplayUser Interface
Display Functionality

102
PSI
c a) System Pressure Value
b) System pressure Units
d 1 10:35 e c) Unit Status
d) Unit Active Functions
f 1 2 3 4 e) Time
g f) Compressor Number
A B C D g) Compressor Sequence Assignment
h) Compressor Status
h

To view the next automated Sequence

12:00 #1 Rotation display, Press Down:

User Interface Display Functionality

a b
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)

The keypad and navigation keys on the X4I are

depicted below and provide the following functionality.
a b c
Keypad and Navigational Keys Functionality
g a) Start
b) Reset
c) Stop
f d d) Menu
e) Enter
f) Escape
g) Up (Plus)
h e h) Down (Minus)

24
Unit Functions:
The following Icons are used by the X4I to
display the Controller Active Functions.

Operating Mode:

EHR- Equal Hours Run

FIFO – First In First Out

System Pressure Status:
FILO – First In Last Out The following Icons are used by the X4I to display the System
Pressure Status.
VEC – Variable Speed Energy Control
Increasing to normal operational levels (Prefill, target
Active Functions: pressure change or at system start)

Power Failure Auto-Restart Below the active lower, or load, pressure set point

1 Table #1 Between the lower, or load, and upper, or unload,

active pressure set points
2 Table #2
Above the upper, or unload, active pressure set point
3 Table #3

Remote Manual Override

Prefill Function

Pressure Schedule

Function Inhibited (manual override) System Pressure Value

System Pressure Units

Unit Status:
The following Icons are used by the X4I to
display the Controller Status.

Stopped

Standby

Started and Running

Real Time Clock

24 Hour Format

Compressor Status:
The following Icons are used by the X4I to display the Compressor/s Status.

Stopped Service Maintenance Active

Standby (or Auto Restart) Alarm (Warning)

Running Offload Not Available (Stopped, Shutdown, Trip)

Running Loaded Inhibited from use in Table

25
DISPLAY ITEM STRUCTURE INFORMATION DISPLAYS

Operational system status and values are accessible from To view detailed information applicable to the selected User
the normal user display. To view status or values that are
not normally visible on the default screen, press UP or menu display item press the ENTER button:
DOWN. All standard user display items are viewable only
and cannot be adjusted. The standard user display items
are regarded as “Menu Page 00” items. STATUS DISPLAY
All adjustable value, parameter or option item displays are
grouped into “menu mode” lists. Items are assigned to a list P00
according to type and classification. Item lists are identified
by page number (or menu number). All adjustable
parameters and options are assigned to menu mode pages
#1 18:00 T02
“P01” or higher.
102 psi
NORMAL OPERATIONAL DISPLAY (MENU 1 98 psi
PAGE P00) 80 psi
At controller initialization, all display elements and LED Status Display Screen
indicators are switched on for three seconds and then the
normal operating display is shown. In normal operational
display mode, the main display will continuously show the If the ‘Pressure Schedule’ feature is active; shows the
detected system pressure and the Item display will show the day of the week (#1: Monday), the time of day (18:00) and
first item of the “Page 00” menu. User menu “items” can be the table to be used (T02) of the next scheduled instruction
selected using the UP or DOWN buttons at any time. to be executed.
Pressing the ENTER button will lock any selected item
display and inhibit return to the default display. When an
item display is locked, the “lock key” symbol will be shown. The current active ‘Table’ (T01)
To unlock an item display, press UP or DOWN to view an 1
alternative item display or press RESET or ESCAPE. No item Upper, or unload, pressure setpoint
values, options or parameters can be adjusted in “Page
P00”. If a fault condition occurs, the fault code becomes the Lower, or load, pressure setpoint
first list item and the display will automatically jump to Minimum pressure Alarm (Warning)
display the fault code. More than one active fault code item
can exist at any one time and can be viewed by pressing UP
or DOWN. The most recent “active” fault will be at the top of
the list.

Press the ESCAPE button to return to the normal

operational display screen.

SEQUENCE ROTATION

P00

#4 18:00
Main Status Screen
18 / 05 / 2006
ABCD

Sequence Rotation Display Screen

Day of the week (#4: Thursday), the time of

day (18:00) and the date (18/05/2006) of
the next automated sequence rotation event.
The active ‘mode’ of operation

ABCD The current active rotation sequence

assignment.

26

Press the ESCAPE button to return to the normal
operational display screen.
NOTE: The sequence assignment can be manually rotated
at any time. When viewing the “Sequence Rotation” infor-
mation screen press the ENTER button. The manual
rotation symbols will appear and flash. Press
the ENTER button to execute a manual rotation or
the ESCAPE button to abandon the manual rota-
tion.
Automated sequence rotation is not disrupted by a man-
ual rotation; the next scheduled automated sequence
rotation event will still occur.
OPERATIONAL FUNCTIONS
STOP
To stop the X4I, press STOP. Dependent on the setup and
configuration of the X4I, the compressors will function as
follows:
• If parameter CF=X, then pressure
regulation control is automatically
transferred back to each compressor. The
compressor(s) will continue to operate
using the pressure settings programmed or
set in the individual compressor
controller(s).
• If parameter CF= and If parameter PC=1,
the X4I will hold each compressor in an
offload state. If the compressor is
equipped with a main motor run-on-time
function, the compressor will run offload
for a period of time and then stop into a
“standby” or “auto restart” state.
The design of some air compressor control systems
may inhibit automatic transfer of pressure regulation
control to local operation mode. In this instance, the
compressor will not continue production of compressed air.
Consult the air compressor manual or your air compressor
supplier/specialist for details before installing the X4I.
27
START
To start the X4I, press START. If the pre-fill function is
enabled, and system pressure is below the set pre-fill
pressure, the system will enter pre-fill mode for the set
pre-fill time.
See the section on pre-fill for more information.
To manually skip the pre-fill function, press and hold
START for several seconds. When pre-fill is complete, if
applicable, the X4I will enter normal operating mode. The
X4I will operate in accordance with the parameters and
options set in the active “table”.
See the section on tables for more information.
Each compressor in the system must be started
(running or in a standby or auto restart condition) before
X4I control of the compressor can be established. The X4I
will not start a compressor that is in a stopped condition.
POWER FAILURE AUTO-RESTART
If the power failure auto-restart function is enabled, the X4I
will automatically start when power is restored after a
disruption or failure, if the X4I was in a “started” state when
the power disruption or failure occurred.
NOTE: The X4I will not automatically restart if the X4I was
in a stopped state when the power disruption or failure
occurred.
FAILURE MODE
If the X4I experiences a disruption to normal control, or an
X4I shutdown fault occurs, pressure regulation control is
automatically transferred back to each compressor. The
compressor(s) will continue to operate using the pressure
settings programmed or set in the individual compressor
controller(s).
RESET
To reset an X4I alarm (warning) or shutdown condition,
press RESET. Compressor alarm (warning) conditions are
automatically reset when the condition has been resolved
and reset on the compressor. “Compressor not available”
(shutdown, trip) conditions are automatically reset when the
condition has been resolved and reset on the compressor
and the compressor has been restarted.
 SECTION 8 — COMMISSIONING
When commissioning the X4I, carry out the following
procedures before attempting to start.
It is recommended that an authorized and trained
service technician perform the commissioning.
PHYSICAL CHECKS
1. Before applying power to the X4I, ensure the power
supply connections are correct and secure and the
operating voltage selector is set correctly for the
power supply voltage in use (115Vac or 230Vac (+-
10%), 50/60Hz).
2. Open the front panel of the X4I and check the
location of the link wire(s) connected to the
“Voltage Selection” terminals of the power supply
PCB. If necessary, change the link wire locations to
those illustrated for the voltage in use.
See the section on Installation for more
information.
28
3. Switch on the power supply to the X4I.
4. The control program identification will be displayed
for a short period followed by the normal
operational user display.
PRESSURE DISPLAY
Check the displayed system pressure. If the pressure is
incorrect, or inaccurate, check the type and range of the
sensor and carry out the pressure sensor commissioning
and calibration procedure. If the display shows an error,
this will need to be corrected before continuing. See the
Operator’s Manual for troubleshooting and correcting the
fault/error condition.
X4I QUICK SET-UP CONFIGURATION
Before successful basic operation can be established
specific parameters must be entered prior to startup.
Please refer to the X4I Quick Setup Manual for instruction to
accomplish this.
 SECTION 9 — SYSTEM CONFIGURATION

ACCESSING THE X4I CONFIGURATION

SCREENS

In order to change the configuration parameters you will

first need to input the service access code. The service
access code is 0032. Enter this code as follows:

1. Press the MENU button. This will display the

Access Code Screen. Default Configuration Screen

USER CONFIGURATION: TAB S01

1. Scroll up (+) or scroll down (-)

until the S01 page is highlighted.

Access Code Screen

2. Adjust the first access code digit by using the scroll

up (+) and scroll down (-)

buttons. When the correct number shows press the

ENTER button. The cursor should then move

to the next digit to the right. S01 Screen

3. Adjust the remaining digits until the proper access

code is shown on the screen. If for any reason you 2. Press the ENTER button to confirm your
need to go back to a previous digit press the selection. The cursor should be flashing on line 01
Ct.

escape button. This will back the cursor up

one digit at a time.
4. When you’ve adjusted the final digit to the correct

number press the ENTER button and you

should see an animation of a key opening a lock.
You are now able to access the configuration
screens.
5. When in menu mode, you must press the escape
User Configuration Home Screen

button until you are returned to the Main

menu. If you do not, the X4I remains in the menu
mode
6. After successfully entering the access code you
should see the screen shown below. The cursor will
flash on the name of the current page (P00). You
can scroll through the tabs by pressing the scroll

up (+) and scroll down (-)

buttons.

29
REAL TIME CLOCK SETTINGS the Month for the Real Time Clock. The values for
this parameter are “1” to “12”.

1. From the S01 home screen scroll up (+) or

6. Scroll up (+) or scroll down (-)
until the value is set for the correct Month for the
scroll down (-) to move the cursor to
highlight 01- Ct (Real Time Clock).
Real Time Clock. Press the ENTER button to
accept this parameter. The flashing cursor should
be displayed highlighting the Year dash. This sets
the Year for the Real Time Clock. The values for
this parameter are “2005” to “2100”.

7. Scroll up (+) or scroll down (-)

until the value is set for the correct Year for the

Real Time Clock. Press the ENTER button to

accept this parameter. You should be returned to
the S01 home screen and values just entered
Real Time Clock Setting should appear next to the Ct parameter.
1. The default setting for this parameter is - --.--,
which indicates the 24 Real Time Clock has not PRESSURE SCHEDULE SETTINGS
been initialized. The format for the Real Time
Clock is as follows.
• The ‘Day of the Week’ (1= Monday to 1. From the S01 home screen scroll up (+) or
7=Sunday) which is automatically
calculated and set in accordance with the scroll down (-) to move the cursor to
Day, Month and Year entered highlight 02- PS (Pressure Schedule).
• The Hours and Minutes (displayed in
Military Time)
• The Day, Month, and Year

2. Press the ENTER button to display the Real

Time Clock setup screen. The flashing cursor
should be displayed highlighting the Hours dash.
This sets the Hour for the Real Time Clock. The
values for this parameter are “00” to “23”.

Pressure Schedule Setting

3. Scroll up (+) or scroll down (-)
until the value is set for the correct Hour for the
2. The default setting for this parameter is , which
Real Time Clock. Press the enter button to indicates the Pressure Schedule is turned off.
accept this parameter. The flashing cursor should This parameter enables or disables the Pressure
be displayed highlighting the Minutes dash. This Schedule Function in the X4I.
sets the Minutes for the Real Time Clock. The
values for this parameter are “0” to “59”.
3. Press the ENTER button to display the Pressure
Schedule setup screen. The flashing cursor should
4. Scroll up (+) or scroll down (-)
until the value is set for the correct Minute for the be displayed highlighting the . The values for
this parameter are:
Real Time Clock. Press the ENTER button to
accept this parameter. The flashing cursor should • “ ” for the disabling the Pressure
be displayed highlighting the Day dash. This sets Schedule Function
the Day for the Real Time Clock. The values for this
parameter are “1” to “31”. • “ ” for enabling the Pressure Schedule
Function
5. Scroll up (+) or scroll down (-)
until the value is set for the correct Day for the Real 4. Scroll up (+) or scroll down (-)
until the value is set for the mode of operation for
Time Clock. Press the ENTER button to accept
this parameter. The flashing cursor should be your air system. Press the ENTER button to
displayed highlighting the Month dash. This sets accept this parameter.

30
 5. You should be returned to the S01 home screen ROTATION INTERVAL SETTINGS
and values just entered should appear next to the
PS parameter.
1. From the S01 home screen scroll up (+) or
AUTO RESTART SETTINGS
scroll down (-) to move the cursor to
highlight 04- RP (Rotation Interval). New Picture
1. From the S01 home screen scroll up (+) or Below

scroll down (-) to move the cursor to

highlight 03- AR (Auto Restart).

Rotation Interval Setting

2. The default setting for this parameter is 1 00:00.
The 1 00:00 indicates a rotation at Monday (1) at
Auto Restart Setting 00:00 hours. The X4I provides a Timed rotation
event that can be automatically triggered on a
routine basis using a pre-determined interval, a
2. The default setting for this parameter is . The
pre-determined time each day, or a pre-
indicates Auto Restart is turned on. When enabled,
determined day and time each week.
after a power disruption or failure, the X4I will
automatically restart when power is restored if the
X4I was in an operational ‘Started’ state when the 3. Press the ENTER button to display the Rotation
power loss or disruption occurred. The X4I will not Interval setup screen.
automatically restart if the X4I was in a “Stopped”
state when the power disruption or failure occurred 4. The Rotation Interval setup screen should be
displayed with a cursor highlighting the first dash
after the #. This sets the Rotation Interval. The
3. Press the ENTER button to display the Auto values for this parameter are:
Restart setup screen.
• “1” for Monday to “7” for Sunday (a specific
4. The flashing cursor should be displayed day of the week)
highlighting the . The values for this parameter • “8” for every working day of the week
are: (every day, Monday through Friday,
excluding Saturday and Sunday)
• “ ” for the disabling the Auto Restart • “9’” for every day of the week (every day,
Function Monday through Sunday)
• “t” for an interval of time (more than 1 or
• “ ” for enabling the Auto Restart Function more rotations per 24 hours)
• “–“ for disabling the Rotation Interval
5. Scroll up (+) or scroll down (-)
until the value is set for the mode of operation for
5. Scroll up (+) or scroll down (-)
your air system. Press the ENTER button to until the value is set for the Rotation Interval
accept this parameter.
required for your air system. Press the ENTER
6. You should be returned to the S01 home screen button to accept this parameter.
and values just entered should appear next to the
AR parameter. 6. The flashing cursor should be displayed
highlighting the Hours dash (Military Time). This
sets the Hour for the Rotation Interval. The values
for this parameter are:
• “00” to “23”
• “–“ represents the Rotation Interval is
disabled.

31
 TABLE SELECT SETTINGS
7. Scroll up (+) or scroll down (-)
until the value is set for the Rotation Interval
1. From the S01 home screen scroll up (+) or
required for your air system. Press the ENTER
button to accept this parameter. scroll down (-) to move the cursor to
highlight 05- TS (Table Select).
8. The flashing cursor should be displayed
highlighting the Minutes dash. This sets the
Minutes for the Rotation Interval. The values for
this parameter are:
• “0” to “59”
• “–“ represents the Rotation Interval is
disabled.

9. Scroll up (+) or scroll down (-)

until the value is set for the Rotation Interval
required for your air system. Press the ENTER
button to accept this parameter. 2.
10. If the parameter chosen in 4.above is “t”, the
flashing cursor should be displayed highlighting
the Interval Time selection. This sets the required
number of rotation events per day (1 to 96). The
hour and minutes display will now show the interval
time between each rotation event. The values for
this parameter are: 3.
• A value of 1 = rotate every 24 hours
4.
• A value of 2 = rotate every 12 hours
• A value of 3 = rotate every 8 hours
Table Select Settings
The default setting for this parameter is T01. The
T01 indicates Table T01 is selected. This
parameter determines which ‘Table’ will be used by
default when the ‘Pressure Schedule’ is not active
and when no table is selected remotely on a digital
input.
Press the ENTER button to display the Table
Select configuration screen.
The flashing cursor should be displayed
highlighting the Table Select parameter. The
values for this parameter are:

• A value of 4 = rotate every 6 hours • “T01” for Table T01

• A value of 6 = rotate every 4 hours • “T02” for Table T02

• A value of 8 = rotate every 3 hours • “T03” for Table T03

• A value of 12 = rotate every 2 hours

• A value of 24= rotate every 1 hours 5.
• A value of 48 = rotate every 30 minutes
• A value of 72 = rotate every 20 minutes
• A value of 96 = rotate every 15 minutes
6.
• “–“represents the Rotation Interval is
disabled.
Scroll up (+) or scroll down (-)
until the value is set for the Table Select setting
required for your air system. Press the ENTER
button to confirm this selection.
You should be returned to the S01 home screen
and values just entered should appear next to the
TS parameter.

11. Scroll up (+) or scroll down (-)

until the value is set for the Rotation Interval

required for your air system. Press the ENTER

button to accept this parameter.
12. You should be returned to the S01 home screen
and values just entered should appear next to the
RP parameter

32
BACKLIGHT ADJUST SETTINGS USER CONFIGURATION: TAB S02

1. From the S01 home screen scroll up (+) or 1. After you have returned to the page selection

scroll down (-) to move the cursor to screen, scroll up (+) or scroll down (-)
highlight 06- BL (Backlight Adjust).
until the S02 page is highlighted.

Backlight Settings
2. The default setting for this parameter is 5. The 5 S02 Tab Screen
indicates the current level the backlight is set for.
The default display Backlight Setting level has been
set to enable a ‘continuous use service life’ in 2. Press the ENTER button to confirm your
excess of 90000 hours while providing good selection. The cursor should be flashing on 01 P>.
readability in all ambient light conditions. The
display will temporarily increase brightness by 2
levels when a button is pressed and return to
normal setting after a period of no keypad activity.

3. Press the ENTER button to display the

Backlight Setting configuration screen.
4. The flashing cursor should be displayed
highlighting the Backlight Setting parameter. The
values for this parameter are “1” to “7” for 1 being
the least amount of Backlight and 7 being the most.
S021 Home Screen

5. Scroll up (+) or scroll down (-) UNITS SETTINGS

until the value is set for the Backlight Setting

required for visibility. Press the ENTER button 1. From the S02 home screen scroll up (+) or
to confirm this selection. You should be returned to
the S01 home screen and values just entered
should appear next to the BL parameter. scroll down (-) to move the cursor to
highlight 01- P> (Units Settings).
6. After you have completed adjusting the settings on

the S01 screen press the ESCAPE button to

return to the page selection screen.

Units Settings
2. The default setting for this parameter is PSI. The PSI
indicates the pressure units selected for X4I. This
parameter determines the X4I display and
operating units.

3. Press the ENTER button to display the Units

configuration screen.

33
 4. The flashing cursor should be displayed MAXIMUM PRESSURE ALARM SETTINGS
highlighting the Units parameter. The values for
this parameter are:
1. From the S02 home screen scroll up (+) or
• “PSI”
• “BAR” scroll down (-) to move the cursor to
• “kPA” highlight 03- PM (Maximum Pressure Alarm).

5. Scroll up (+) or scroll down (-)

until the value is set for the Units setting required

for your air system. Press the ENTER button to

confirm this selection.
6. You should be returned to the S02 home screen
and values just entered should appear next to the
P> parameter.

Maximum Pressure Alarm Settings

NUMBER OF COMPRESSORS SETTINGS
2. The default setting for this parameter is 145. The
145 indicates the value used for the High pressure
1. From the S02 home screen scroll up (+) or ‘Fault’ level. This value remains active at all times
regardless of which ‘Table’ is active. It should be
set at a level just below the system pressure relief
scroll down (-) to move the cursor to value(s) and below the maximum system pressure
highlight 02- NC (Number of Compressors). rating of all air system components

3. Press the ENTER button to display the

Maximum Pressure Alarm configuration screen.
4. The flashing cursor should be displayed
highlighting the Maximum Pressure Alarm
parameter. The values for this parameter are:
• The highest value for the Maximum
Pressure Alarm setpoint = “The maximum
range of the pressure transducer used”

Number of Compressors Settings • The lowest value for the Maximum

Pressure Alarm setpoint = “The highest
2. The default setting for this parameter is 4. The 4 value from any Table “PH - Pressure High”
indicates the number of compressors the X4I is Setpoint plus 2 times the “To – Tolerance”
configured for and the number of compressors that
will be sequenced by the X4I. This value must be i. If PH in Table 1 (T01) is set for
set to match the system at commissioning. 100 PSI, and PH in Table 2 (T02)
is set for 110 and TO is set for
3.0 PSI, then the lowest Maximum
3. Press the ENTER button to display the Number Pressure setpoint would be 116
of Compressor configuration screen. PSI.
4. The flashing cursor should be displayed
highlighting the Number of Compressor parameter. 5. Scroll up (+) or scroll down (-)
The values for this parameter are: until the value is set to a pressure that is just below
• “1” for 1 compressor your air system requirements. Press the ENTER

• “2” for 2 compressors button to confirm your selection.

• “3” for 3 compressors 6. You should be returned to the S02 home screen
• “4” for 4 compressors and values just entered should appear next to the
PM parameter.

5. Scroll up (+) or scroll down (-)

until the value matches the number of compressors
that you have wired into the controller. Press the

ENTER button to confirm your selection.

6. You should be returned to the S02 home screen
and values just entered should appear next to the
NC parameter.

34
STOP CONTROL SETTINGS TOLERANCE SETTINGS

1. From the S02 home screen scroll up (+) or

scroll down (-) to move the cursor to

highlight 05- TO (Tolerance Settings).

Stop Control Settings

1. From the S02 home screen scroll up (+) or

scroll down (-) to move the cursor to

highlight 04- CF (Stop Control Function Settings). Tolerance Settings
2. The default setting for this parameter is 3.0 PSI.
This is the width of the Tolerance Band for the X4I.
The Tolerance Band setting is a pressure band
above and below the Load and Unload pressure
band. This accommodates for an instance of abrupt
and/or significant increase or decrease in demand
without compromise to optimal energy efficient
control. The X4I incorporates a Rate of Change
algorithm while in the Tolerance Band to determine
when a compressor should be Loaded or Unloaded.
• If air system storage is generous, the rate
Stop Control Settings of the pressure change is slow, and/or
demand fluctuations are insignificant and
2. The default setting for this parameter is . This gradual, then the ‘Tolerance’ band can be
decreased to improve pressure control
indicates the Stop Control is turned off. This
without compromise to optimum energy
parameter determines what state the compressors
will revert to when the X4I controller is stopped. efficiency. As the Tolerance Band is
decreased, the Loading and Unloading of
compressors while in the band is more
3. Press the ENTER button to display the Stop rapid.
Control configuration screen. • If air system storage is inadequate, the rate
4. The flashing cursor should be displayed of the pressure change is fast, and/or
demand fluctuations are significantly large,
highlighting the . The values for this parameter the ‘Tolerance’ band can be increased to
are: maintain optimum energy efficiency, and
reduce over-reaction, during such
• “ ” for Stop: return pressure control to the transition periods. As the Tolerance Band
compressors is increased, the Loading and Unloading of
compressors while in the band is less
rapid.
• “ ” for Standby: maintain control and
continuously hold compressors an
unloaded state 3. Press the ENTER button to display the
Tolerance Settings configuration screen.
4. The flashing cursor should be displayed
5. Scroll up (+) or scroll down (-)
highlighting the 3.0. The values for this parameter
until the value is set for the mode of operation for
are:
your air system. Press the ENTER button to • “1.4” for the minimum Tolerance Band
confirm your selection.
• “29.0” for the maximum Tolerance Band
6. You should be returned to the S02 home screen
and values just entered should appear next to the
CF parameter. 5. Scroll up (+) or scroll down (-)
until the number is set to the value required to
maintain control of for your air system. Press the

ENTER button to confirm your selection.

35
 6. You should be returned to the S02 home screen
and values just entered should appear next to the
5. Scroll up (+) or scroll down (-)
TO parameter.
until the number is set to the value required to
maintain control of for your air system. Press the
DAMPING SETTINGS
ENTER button to confirm your selection.
6. You should be returned to the S02 home screen
1. From the S02 home screen scroll up (+) or and values just entered should appear next to the
DA parameter.
scroll down (-) to move the cursor to
highlight 06- DA (Damping Settings).
PRESSURE CHANGE SETTINGS
S01 S02 S03
1. From the S02 home screen scroll up (+) or
05 TO 3.0 PSI
06 DA 1.0 scroll down (-) to move the cursor to
07 PC 4 Min highlight 07- PC (Pressure Change Settings).
08 AI 05:SS NO
09 AO 07:ON NO S01 S03
S02

06 DA 1.0
Damping Settings 07 PC 4 Min
08 AI 05:SS NO
2. The default setting for this parameter is 1.0. The
09 AO 07:ON NO
parameter adjusts the time before an additional 10 ER X
compressor is loaded in accordance with the
urgency of the situation to increase air system
capacity further. The rate of pressure change may
be aggressive and disproportionate. In such
instances the X4I may over-react and attempt to Pressure Change Settings
load an additional compressor that may not be 2. The default setting for this parameter is 4 Min. The
necessary once the initial compressor is running, 4 minutes is the time the X4I will use implement a
loaded, and able to contribute adequate additional smooth and controlled change from one ‘target’
generation capacity. The X4I has a dynamic pressure level to another when a Table change is
reaction algorithm that is pre-set by default to made.
accommodate for the majority of installation
characteristics. If an increase or decrease in the
Tolerance band is insufficient, the reaction 3. Press the ENTER button to display the Pressure
response can be influenced by increasing or Change Settings configuration screen.
decreasing the ‘Damping’ factor.
4. The flashing cursor should be displayed
• If air system storage is generous and the highlighting the 4. The values for this parameter
rate of the pressure change is slow to rise, are “1” for 1 minute between Table target pressure
then the ‘Damping’ can be increased to setpoint changes through “120” for 120 minutes
improve pressure control without between Table target pressure setpoint changes.
compromise to optimum energy efficiency.
As the Dampening value is increased, the
Loading of additional compressors is less 5. Scroll up (+) or scroll down (-)
rapid. until the number is set to the value required
• If air system storage is inadequate and the maintain control of for your air system. Press the
rate of the pressure change is fast to fall,
then the ‘Damping’ can be decreased to ENTER button to confirm your selection.
improve pressure control without 6. You should be returned to the S02 home screen
compromise to optimum energy efficiency. and values just entered should appear next to the
As the Damping value is decreased, the PC parameter.
Loading of additional compressors is more
rapid.
AUXILIARY INPUT SETTINGS
3. Press the ENTER button to display the
Dampening Settings configuration screen. 1. From the S02 home screen scroll up (+) or
4. The flashing cursor should be displayed
highlighting the 1.0. The values for this parameter scroll down (-) to move the cursor to
are “.1” for the fastest Damping reaction time (10 highlight 08- AI (Auxiliary Input Settings).
times faster than the default of 1.0) through “10.0”
for the slowest Damping reaction time (10 times
slower than the default of 1.0).

36
 8. You should be returned to the S02 home screen
S01 S02 S03 and values just entered should appear next to the
AI parameter.
07 PC 4 Min
08 AI 05:SS NO AUXILIARY OUTPUT SETTINGS
09 AO 07:ON NO
10 ER X
01 P> PSI
1. From the S02 home screen scroll up (+) or

scroll down (-) to move the cursor to

Auxiliary Input Settings highlight 09- AO (Auxiliary Output Settings).

2. The default setting for this parameter is 05:SS NO. S01 S03
S02
With this setting, the function for the Auxiliary
Input for X4I is set to Remote Start/Stop. The
function of the Auxiliary Input as well as the state 08 AI 05:SS NO
of the contacts controlling the Auxiliary Input can 09 AO 07:ON NO
be changed. 10 ER X
01 P> PSI
02 NC 3
3. Press the ENTER button to display the
Auxiliary Input Settings configuration screen.
4. The flashing cursor should be displayed
highlighting the 05:SS parameter. The values for Auxiliary Output Settings
this parameter are:
2. The default setting for this parameter is 07:ON NO.
• “01:T1”Override > Use Table 1 With this setting, the function for the Auxiliary
Output for X4I is set to the X4I is Active. The
• “02:T2”Override > Use Table 2 function of the Auxiliary Output as well as the state
• “03:T3”Override > Use Table 3 of the contacts controlling the Auxiliary Output can
be changed. If it is determined this value requires a
• “04:TS”Override > Place the X4I in Standby change, then this will need to be modified.
• “05:SS”Remote Start/Stop (Default)
• “06:AA”Remote Alarm (always active) 3. Press the ENTER button to display the
Auxiliary Output Settings configuration screen.
• “07:AR”Remote Alarm (active when X4I is
running, inhibited when the X4I is stopped 4. The flashing cursor should be displayed
or in Standby highlighting the 05:SS parameter. The values for
this parameter are:
• “08:TA”Remote Trip (always active)
• “01:AFAny Fault”Any Alarm (Warning),
• “09:TR”Remote Trip (active when X4I is Shutdown (Trip) or Compressor Not
running, inhibited when the X4I is stopped Available.
or in Standby
• “02:ATAny Trip”Any Shutdown (Trip) or
Compressor Not Available.
5. Scroll up (+) or scroll down (-) • “03:CFCompressor Fault”Any compressor
until you have selected the input function desired. Alarm (Warning), Shutdown (Trip) or Not
Available
Press the ENTER button to confirm your
selection. • “04:CACompressor Alarm”Any compressor
Alarm (Warning)

6. The flashing cursor should be displayed • “05:CTCompressor Trip”Any compressor

highlighting the NO. The values for this parameter Shutdown (Trip) or Not Available
are: • “06:SFSystem Fault”Any X4I Alarm
• “NO” for the function is activated when the (Warning) or Shutdown (Trip)
input terminals are a closed set of dry • “07:SASystem Active”X4I is Active,
contacts including pre-fill period (not active when
• “NC“ for the function is activated when the the X4I is stopped or in standby
input terminals are an open set of dry • “08:SPSystem Pressure Control Active”X4I
contacts is Active excluding pre-fill (not active when
the X4I is stopped, or in standby, or in
pre-fill mode
7. Scroll up (+) or scroll down (-) to
select the appropriate input selection. Press the • “09:LPLow Pressure Alarm”
• 10:HPHigh Pressure Alarm
ENTER button to confirm your selection.

37
 • 11:POPressure Control OverrideNormal, or 4. The flashing cursor should be displayed
Pressure Schedule operation is being
manually overridden highlighting the . The values for this parameter
are:

5. Scroll up (+) or scroll down (-) • “ ” for not resetting the Error log
until you have selected the output function desired.
• “ “ for resetting the Error log
Press the ENTER button to confirm your
selection.
6. The flashing cursor should be displayed 5. Scroll up (+) or scroll down (-) to
highlighting the NO. The values for this parameter select the function you want to perform. Note: If
are:
you select the to reset the Error Log, the .will
• “NO” for the auxiliary output relay contacts
are normally open and will close when the revert back to the after selecting the ENTER
set function is active or true
• “NC“ for the auxiliary output relay contacts button. Press the ENTER button to confirm
are normally closed and will open when the your selection.
set function is active or true; or in the 6. You should be returned to the S02 home screen
event of a X4I shutdown or loss of power
and the should appear next to the ER parameter.

7. Scroll up (+) or scroll down (-) to 7. After you have completed adjusting the settings on
select the appropriate setting for your output

selection. Press the ENTER button to confirm

your selection. the S02 screen press the ESCAPE button to
return to the page selection screen.
8. You should be returned to the S02 home screen
and values just entered should appear next to the
AO parameter.
USER CONFIGURATION: TAB S03

ERROR LOG RESET 1. After you have returned to the page selection

screen, scroll up (+) or scroll down (-)

1. From the S02 home screen scroll up (+) or
until the S03 page is highlighted
scroll down (-) to move the cursor to
highlight 10- ER (Error Log Reset).

S01 S02 S03

09 AO 07:ON NO
10 ER X
01 P> PSI
02 NC 3
03 PM 145 PSI

S03 Tab Screen

Error Log Reset

2. Press the ENTER button to confirm your
selection. The cursor should be flashing on 01 01.
2. The default setting for this parameter is . This
parameter Clears and resets the ‘Error Log’ in the
X4I S02 S03 C01

3. Press the ENTER button to display the Error

Log Reset configuration screen. 01 1O 0 PSI
02 1R 232 PSI

S03 Home Screen

38
PRESSURE SENSOR – OFFSET PRESSURE SENSOR – RANGE SETTINGS

1. From the S03 home screen scroll up (+) or 1. From the S03 home screen scroll up (+) or

scroll down (-) to move the cursor to scroll down (-) to move the cursor to
highlight 01- 1O (Pressure Sensor 1 Offset highlight 02- 1R (Pressure Sensor Range Settings).
Settings).
S02 S03 C01
S02 S03 C01

02 1R 232 PSI
01 1O 0 PSI 01 1O 0 PSI
02 1R 232 PSI

Pressure Sensor Range Settings

Pressure Sensor Offset Settings
2.
2. The default setting for this parameter is 0 PSI. In
most applications, this value will be the minimum
value of the pressure transducer, 0 PSI, 0 BAR, or 0
kPA. It can also be used to create an ‘Offset’ if
there is a difference in the zero value being
displayed.
The default setting for this parameter is 232 PSI. In
most applications, this will be the maximum range
of the pressure transducer, 232 PSI, 16 BAR, or
1600 kPA. It can also be used to create an ‘Offset’
if there is a difference in the range value being
displayed.

3. Press the ENTER button to display the Pressure

3. Press the ENTER button to display the Pressure Sensor Range Settings configuration screen.
Sensor Offset Settings configuration screen.
4. The flashing cursor should be displayed
4. The flashing cursor should be displayed highlighting the 232. The values for this parameter
highlighting the 0. The values for this parameter are:
are:
• “232” when using the maximum value of
• “0” when using the minimum value of the the pressure transducer range
pressure transducer range
• a value greater than or less than 232 if the
• a value greater than or less than 0 if the display does not read 232.
display does not read 0 or when using an
Offset pressure transducer (an example of i. The pressure transducer must
an Offset pressure transducer would be have a known, accurate pressure
one where the range was minus PSI (-25) to applied to it when changing this
a positive PSI (200). value to a value other than 232.

i. The pressure transducer must be

vented to atmosphere when 5. Scroll up (+) or scroll down (-) to
setting the 0 or offset. change the value until the display indicates the

correct PSI. Press the ENTER button to

5. Scroll up (+) or scroll down (-) to confirm your selection.
change the value until the display indicates 0 PSI.
6. You should be returned to the S03 home screen
Press the ENTER button to confirm your and values just entered should appear next to the
selection. 1R parameter.

6. You should be returned to the S03 home screen

and values just entered should appear next to the
1O parameter.
Correct pressure sensor set-up and calibration is critical
for successful system operation. It is recommended that
pressure sensor calibration is examined, and adjusted if
necessary, annually or a pre-determined routine periodic
basis
Correct pressure sensor set-up and calibration is
critical for successful system operation. It is recommended
that pressure sensor calibration is examined, and adjusted
if necessary, annually or a pre-determined routine periodic
basis
After you have completed adjusting the settings on the S03

screen press the ESCAPE button to return to the page

selection screen.

39
COMPRESSOR CONFIGURATION: TAB C01
3. Press the ENTER button to display the
Compressor Run Hours setup screen for
1. After you have returned to the page selection compressor #1
4. The flashing cursor should be displayed
screen, scroll up (+) or scroll down (-) highlighting the 0. The values for this parameter
are “0 to x” where x = the actual run hours for the
until the C01 page is highlighted. compressor connected to the #1 control channel.

5. Scroll up (+) or scroll down (-)

to change the value to match the run hours on

compressor #1. Press the ENTER button to

confirm your selection.
6. You should be returned to the C01 home screen
and the value entered should appear next to the
01-01 parameter.

C01 Tab Screen

7. Repeat this by scrolling up (+) or scrolling

2. Press the ENTER button to confirm your down (-) to move the cursor to highlight
selection. The cursor should be flashing on line 01 the remaining compressors and set the run hours
01. to match each of the other compressors.
8. You should be returned to the C01 home screen
S03 C01 C02 and values just entered should appear next to the
01 parameter. Once all run hours have been
entered for all compressors, you should be
01 01 0 hrs returned to the C01 home screen and all values
entered should appear next each compressor
02 02 0 hrs
parameter.
03 03 0 hrs
04 04 0 hrs 9. After you have completed adjusting the settings on

C01 Home Screen the C01 screen press the ESCAPE button to
return to the page selection screen.
COMPRESSOR RUN HOURS
COMPRESSOR CONFIGURATION: TAB C02
1. From the C01 home screen scroll up (+) or
1. After you have returned to the page selection

scroll down (-) to move the cursor to

highlight 01- 01 (Compressor 1 Run Hours). screen, scroll up (+) or scroll down (-)

S03 C01 C02 until the C02 page is highlighted.

01 01 0 hrs
02 02 0 hrs
03 03 0 hrs
04 04 0 hrs

Compressor Run Hours Settings

2. The default setting for this parameter is 0 hours.
This value can be manually set to match the
running hours of each compressor. When using the C02 Tab Screen
EHR (Equal Run Hours) Sequence mode, the X4I
uses these values to maintain equal run hours
among all compressors. 2. Press the ENTER button to confirm your
selection. The cursor should be flashing on line 01
01.

40
 6. The flashing cursor should be displayed
highlighting the Compressor Start Sequence Time.
The Default setting for this parameter is 10 Sec.
This is the time required to start the motor and
then load the compressor. The values for this
parameter are “0” to “60” seconds.

7. Scroll up (+) or scroll down (-)

to change the value to the time required. Press the

C02 Home Screen ENTER button to confirm your selection.

8. The flashing cursor should be displayed
highlighting the ‘i-PCB’ Alarm (Warning) Input. The
COMPRESSOR CONNECTION METHOD Default setting for this parameter is +V=!. If the ‘i-
PCB’ Alarm input detects a voltage between 12-
250VAC/DC, an alarm (Warning) condition is
1. From the C02 home screen scroll up (+) or generated. The values for this parameter are:
• +V=! for an Alarm (Warning) condition is
scroll down (-) to move the cursor to generated if the ‘ir-PCB’ Alarm input
highlight 01- 01 (Compressor 1 Connection detects a voltage between 12-250Vac/dc
Settings). (default)
• 0V=! for an Alarm (Warning) condition is
generated if the ‘ir-PCB’ Alarm input
detects no voltage.

9. Scroll up (+) or scroll down (-)

to change the value for the Alarm condition

required for your application. Press the ENTER

button to confirm your selection.

Compressor Connection Settings 10. You should be returned to the C02 home screen
and ‘ir-PCB’ should appear next to the 01-01
2. The default setting for this parameter is I-PCB. parameter.
This setting is used for the type, method of
connection, and the control functionality, of each
compressor connected to the X4I. Each air 11. IRV-PCB Setup: Scroll up (+) or scroll
compressor in the system is integrated with the X4I
using an interface module.
down (-) to change the value to IRV-PCB.

3. Press the ENTER button to display the Press the ENTER button to confirm your
Compressor Connection setup screen for selection.
compressor #1
12. The flashing cursor should be displayed
4. The flashing cursor should be displayed highlighting the Compressor Start Sequence Time.
highlighting the I-PCB. The values for this The Default setting for this parameter is 10 Sec.
parameter are: This is the time required to start the motor and
then load the compressor. The values for this
• “IR-PCB” for Fixed speed, load/unload; parameter are “0” to “60” seconds.
connected to X4I using ‘ir-PCB’ module
using 6-wire method.
• “IRV-PCB” for Variable Speed; connected to 13. Scroll up (+) or scroll down (-)
X4I using ‘ir-PCB’ module employing the to change the value to the time required. Press the
7-wire ‘V’ terminal method
ENTER button to confirm your selection.
• “I-485” for Fixed speed, load/unload;
connected to X4I on Multi485 network. 14. The flashing cursor should be displayed
highlighting the ‘i-PCB’ Alarm (Warning) Input. The
• “V-485” for Variable Capacity/Speed;
Default setting for this parameter is +V=!. If the ‘i-
connected to X4I on Multi485 network
PCB’ Alarm input detects a voltage between 12-
250VAC/DC, an alarm (Warning) condition is
generated. The values for this parameter are:
5. IR-PCB Setup: Scroll up (+) or scroll
• +V=! for an Alarm (Warning) condition is
generated if the ‘ir-PCB’ Alarm input
down (-) to change the value to IR-PCB.
detects a voltage between 12-250Vac/dc
(default)
Press the ENTER button to confirm your
selection.

41
 • 0V=! for an Alarm (Warning) condition is
generated if the ‘ir-PCB’ Alarm input
detects no voltage.
15. Scroll up (+) or scroll down (-)
to change the value for the Alarm condition
24. The flashing cursor should be displayed
highlighting the Compressor Start Sequence Time.
The Default setting for this parameter is 10 Sec.
This is the time required to start the motor and
then load the compressor. The values for this
parameter are “0” to “60” seconds.

required for your application. Press the ENTER 25. Scroll up (+) or scroll down (-)
button to confirm your selection. to change the value to the time required. Press the

16. The flashing cursor should be displayed
highlighting the Compressor Run-On Stop Time.
The Default setting for this parameter is 0 Sec.
This is the time that the compressor main motor
will continue to run when the compressor is
unloaded. The time is from the moment the
compressor unloads until the main motor stops
and the compressor enters a ‘Standby’ or ‘Auto
Restart’ condition. This setting is only applicable
to ‘IRV-PCB’ connectivity and is not displayed for
other connectivity options. The values for this
parameter are “0” to “999” seconds.
17. Scroll up (+) or scroll down (-)
to change the value to the time required. Press the
enter button to confirm your selection.
18. You should be returned to the C02 home screen
and ‘irv-PCB’ should appear next to the 01-01
parameter.
ENTER button to confirm your selection.
26. You should be returned to the C02 home screen
and ‘v-485’ should appear next to the 01-01
parameter.
27. Repeat this by scrolling up (+) or scrolling
down (-) to move the cursor to highlight
the remaining compressors and set the
Compressor Connection type and the Compressor
Connection parameters for each of the other
compressors.
28. You should be returned to the C02 home screen
and values just entered should appear next to the
01 parameter Once all values have been entered for
all compressors, you should be returned to the C01
home screen and all ‘i-PCB’ values entered should
appear next each compressor parameter.
29. After you have completed adjusting the settings on

19. I-485 Setup: Scroll up (+) or scroll down

the C01 screen press the ESCAPE button to

(-) to change the value to I-485. Press
return to the page selection screen.
the ENTER button to confirm your selection.
COMPRESSOR TABLE CONFIGURATION: TAB
20. The flashing cursor should be displayed
highlighting the Compressor Start Sequence Time.
T01
The Default setting for this parameter is 10 Sec.
This is the time required to start the motor and 1. After you have returned to the page selection
then load the compressor. The values for this
parameter are “0” to “60” Seconds.
screen, scroll up (+) or scroll down (-)

21. Scroll up (+) or scroll down (-) until the T01 page is highlighted.
to change the value to the time required. Press the

ENTER button to confirm your selection.

22. You should be returned to the C02 home screen
and ‘i-485’ should appear next to the 01-01
parameter.

23. V-485 Setup: Scroll up (+) or scroll down

(-) to change the value to V-485. Press

T01 Tab Screen
the ENTER button to confirm your selection.

42
 2. Press the ENTER button to confirm your 5. Scroll up (+) or scroll down (-)
selection. The cursor should be flashing on line 01 until the number is set to the value required to
PH. maintain control of for your air system. Press the

ENTER button to confirm your selection.

6. You should be returned to the T01 home screen
and values just entered should appear next to the
PH parameter.

LOW PRESSURE SETPOINT SETTINGS

1. From the T01 home screen scroll up (+) or

T01 Home Page
scroll down (-) to move the cursor to
highlight 02- PL (Low Pressure Setpoint).
HIGH PRESSURE SETPOINT SETTINGS
P00 T01 T02
1. From the T01 home screen scroll up (+) or
01 PH 102 PSI
scroll down (-) to move the cursor to 02 PL 98 PSI
highlight 01- PH (High Pressure Setpoint). 03 Pm 0 PSI
04 SQ FILO ( )
P00 T01 T02 05 01 1

08 04 1
01 PH 102 PSI Low Pressure Setpoint Setting
02 PL 98 PSI
2. The default setting for this parameter is 98 PSI.
03 Pm 0 PSI The 98 PSI indicates the Low Pressure Setpoint that
04 SQ FILO ( ) used to load the compressor when the Table is
active.

High Pressure Setpoint Setting 3. Press the ENTER button to display the Low
2. The default setting for this parameter is 102 PSI. Pressure Setpoint setup screen.
The 102 PSI indicates the High Pressure Setpoint 4. The flashing cursor should be displayed
that is used to unload the compressor when the highlighting the 98 PSI. The values for this
Table is active. parameter are:
• The highest value for the Low Pressure
3. Press the ENTER button to display the High setpoint = PH “High Pressure” setpoint
Pressure Setpoint setup screen. minus TO “Tolerance”.
4. The flashing cursor should be displayed i. If PH is set for 102 PSI and TO is
highlighting the 102 PSI. The values for this set for 3.0 PSI, then the highest
parameter are: value for the Low Pressure
setpoint would be 99 PSI.
• The highest value for the High Pressure
setpoint = PM “Maximum Pressure Alarm” • The lowest value for the Low Pressure
minus 2 times TO “Tolerance”. setpoint = Pm “Minimum Pressure Alarm”
setpoint plus 2 times TO “Tolerance”
i. If PM is set for 145 PSI and TO is
set for 3.0 PSI, then the highest ii. If Pm is set for 80 PSI and TO is
value for the High Pressure set for 3.0 PSI, then the lowest
setpoint would be 139 PSI. value for the Low Pressure
setpoint would be 86 PSI...
• The lowest value for the High Pressure
setpoint = PL “Low Pressure” setpoint plus
TO “Tolerance”
5. Scroll up (+) or scroll down (-)
ii. If PL is set for 98 PSI and TO is set until the number is set to the value required to
for 3.0 PSI, then the lowest value maintain control of for your air system. Press the
for the High Pressure setpoint
would be 101 PSI. ENTER button to confirm your selection.

43
 6. You should be returned to the T01 home screen
and values just entered should appear next to the P00 T01 T02
PL parameter.
03 Pm 80 PSI
MINIMUM PRESSURE ALARM SETTINGS 04 SQ FILO ( )
05 01 1
06 02 1
1. From the T01 home screen scroll up (+) or 07 03 1

scroll down (-) to move the cursor to

highlight 03- Pm (Minimum Pressure Alarm). Sequence Strategy Setting
2. The default setting for this parameter is FILO. The
P00 T01 T02
FILO indicates the Sequence Control Strategy mode
used when the Table is active. Each sequence
02 PL 90 PSI control strategy consists of two sub strategies. The
03 Pm 80 PSI ‘Rotation’ strategy defines how the compressors
04 SQ FILO ( ) are re-arranged, or re-ordered, in to a new
05 01 1 sequence at each routine ‘Rotation’ event. Rotation
events are triggered by a cyclic interval time, a set
06 02 1 time of day each day, or a set time of day once a
week. The compressor load ‘Control’ strategy
defines how the compressors are utilized in
Minimum Pressure Alarm Setting response to variations in system pressure

2. The default setting for this parameter is 80 PSI.

The 80 PSI indicates the Minimum Low Pressure
Setpoint that is used to alarm if the pressure in the
air system is low when the Table is active.
3. Press the ENTER button to display the
Minimum Low Pressure Setpoint setup screen.
4. The flashing cursor should be displayed
highlighting the 80 PSI. The values for this
parameter are:
3. Press the ENTER button to display the
Sequence Strategy Setpoint setup screen.
4. The flashing cursor should be displayed
highlighting the FILO. The values for this
parameter are:
• FILO – First In Last Out. The Rotation and
Control functionality of the FILO mode is
the first compressor loaded is the last
compressor to be unloaded

• The lowest Minimum Pressure Alarm
setpoint = “The minimum range of the
pressure transducer used.“
• The highest Minimum Pressure Alarm
setpoint = “The value from the Table PL –
Low Pressure Setpoint” minus 2 times TO
“Tolerance””
i. If PL in Table 1 (T01) is set for
100 PSI and TO is set for 3.0 PSI,
then the highest Minimum
Pressure setpoint would be 94
PSI.
• FIFO – First In First Out. The Rotation and
Control functionality of the FIFO mode is
the first compressor loaded is the first
compressor to be unloaded
• VEC – Variable Energy Control. This uses
the same Rotation and Control
functionality of the FILO mode with the
additional control required for variable
speed compressor installations
• EHR – Equal Hours Mode. The Rotation and
Control functionality of the EHR mode is to
equalize the Run Hours on all compressors

5. Scroll up (+) or scroll down (-) 5. Scroll up (+) or scroll down (-)
until the number is set to the value required to until the control mode is set to the value required
maintain control of for your air system. Press the to maintain control of for your air system. Press

ENTER button to confirm your selection. the ENTER button to confirm your selection.

6. You should be returned to the T01 home screen 6. You should be returned to the T01 home screen
and values just entered should appear next to the and values just entered should appear next to the
Pm parameter. SQ parameter

SEQUENCE STRATEGY SETTINGS COMPRESSOR #1 PRIORITY SETTINGS

1. From the S01 home screen scroll up (+) or 1. From the T01 home screen scroll up (+) or

scroll down (-) to move the cursor to scroll down (-) to move the cursor to
highlight 04- SQ (Sequence Strategy). highlight 05- 01 (Compressor Priority).

44
 COMPRESSOR #2 THROUGH 4 PRIORITY SETTINGS
P00 T01 T02
1. Repeat Steps above for Compressor #2, #3, and #4
04 SQ FILO ( )
Priority settings. When complete, the ENTER
05 01 1
button to confirm your selection. You should be
06 02 1 returned to the T01 home screen
07 03 1
08 04 1 2. After you have completed adjusting the settings on

Compressor #1 Priority Setting the T01 screen, press the ESCAPE button to
return to the page selection screen.
2. The default setting for this parameter is 1. The 1
indicates the Compressor Priority setting for 3. Repeat the T02 and T03 Tabs Screen if you will be
compressor number #1 Any compressor can be using more than one Table in your application.
assigned any priority or remove it from Sequence
Rotation and Control and any number of 4. After you have completed adjusting the settings on
compressors can have the same priority. By
changing the priority setting, it can be used to
modify the ‘Rotation’ sequence assignment. For
example: The air system configuration is a single the other T0x screens, press the ESCAPE
variable speed compressor that should be always button to return to the page selection screen.
loaded first and act a trim compressor and 3 fixed
speed compressors that should be rotated on an PRESSURE SCHEDULE CONFIGURATION P01
equal basis. You would assign the variable speed
compressor a Priority of 1 and the 3 fixed speed TAB SCREEN
compressors a Priority of 2. The variable speed
compressor is always loaded first and the 3 fixed
1. After you have returned to the page selection
speed compressors would load and rotate based on
the Sequence and Rotation setup.
screen, such as in figure 3, scroll up (+) or
1 2 3 4

scroll down (-) until the P01 page is

1 2 2 2 highlighted.
#1 A B C D

#2 A C D B

#3 A D B C

#4 A B C D

Priority Example

3. Press the enter button to display the

Compressor Priority setup screen.
4. The flashing cursor should be displayed P01 Tab Screen
highlighting the 1. The values for this parameter
are “1” for the highest priority through “4” for the 2. Press ENTER to confirm your selection. The
lowest priority. Value “ ” indicates inhibit from cursor should be flashing on line 01 01.
use while a table is active. The compressor will be
held unloaded and will not be utilized under any
circumstances

5. Scroll up (+) or scroll down (-)

until the number is set to the value required to
maintain control of for your air system. Press the

ENTER button to confirm your selection.

6. You should be returned to the T01 home screen
and values just entered should appear next to the P01 Home Screen
01 parameter.

45
PRESSURE SCHEDULE SETTINGS
1. From the P01 home screen scroll up (+)
scroll down (-) to move the cursor to
highlight 01- 01 (Pressure Schedule).
Pressure Schedule Setpoints
2. The default setting for this parameter is -. --:-- -
- - . The -. --:-- - - - indicates the Pressure
Schedule is turned off. The Pressure Schedule
consists of 28 individual settings that instruct the
X4I to change from one Table to another, or put the
system into Standby mode, dependant on time of
day and day of the week. T
3. Press the ENTER button to display the Pressure
Schedule setup screen.
4. The flashing cursor should be displayed
highlighting the first dash after the #. This sets the
Day of the Week for the Pressure Schedule. The
values for this parameter are:
• “1” for Monday to “7” for Sunday (a specific
day of the week)
• “8” for every working day of the week
(every day, Monday through Friday,
excluding Saturday and Sunday)
• “9’” for every day of the week
(every day, Monday through Sunday)
• “–“ for disabling the Pressure Schedule
5. Scroll up (+) or scroll down (-)
until the value is set for the Pressure Schedule
required for your air system. Press the ENTER
button to accept this parameter.
6. The flashing cursor should be displayed
highlighting the Hours dash (Military Time). This
sets the Hour for the Pressure Schedule. The values
for this parameter are “00” to “23”. The value “–“
indicates the Pressure Schedule is disabled.
7. Scroll up (+) or scroll down (-)
until the value is set for the Pressure Schedule
required for your air system. Press the ENTER
button to accept this parameter.
8. The flashing cursor should be displayed
highlighting the Minutes dash. This sets the
Minutes for the Pressure Schedule. The values for
this parameter are “0” to “59”. The value “–“
indicates the Pressure Schedule is disabled.
or
9. Scroll up (+) or scroll down (-)
until the value is set for the Pressure Schedule
required for your air system. Press the ENTER
button to accept this parameter.
10. The flashing cursor should be displayed
highlighting the Table / Standby mode selection.
This instructs the system to change from one
‘Table’ to another, or put the system in to ‘Standby’
mode for the Pressure Schedule. The values for
this parameter are:
• “T01”, “T02” or ‘T03” for the 3 different
Tables
• “– – “ for Standby Mode
• “–––“represents the Pressure Schedule is
disabled.
11. Scroll up (+) or scroll down (-)
until the value is set for the Pressure Schedule
required for your air system. Press the ENTER
button to accept this parameter.
12. You should be returned to the P01 home screen
and values just entered should appear next to the
01 parameter.
13. Repeat Steps 5.1.A 1 to 12 if additional Pressure
Schedules are required. When complete, press the
ENTER button to confirm your selection.
14. You should be returned to the P01 home screen
15. After you have completed adjusting the settings on
the P01 screen, press the ESCAPE button to
return to the page selection screen.
PRE-FILL CONFIGURATION P02 TAB SCREEN
1. After you have returned to the page selection
screen, such as in figure 3, scroll up (+) or
scroll down (-) until the P02 page is
highlighted.
P02 Tab Screen
46
 2. Press ENTER to confirm your selection. The • “ ! X ” for Pre-fill, Standard Mode
cursor should be flashing on line 01 PF. ii. If one or more of the pre-defined
pre-fill compressors experiences
P01 P02 S01 a shutdown, or is stopped, the
pre-fill function is cancelled and
normal operation begins.
06 03 X
01 PF X
02 PT - MIN 5. Scroll up (+) or scroll down (-)
03 PP 0 PSI until the value is set for the Pre-fill Function
04 01 X
required for your air system. Press the ENTER
button to accept this parameter.
Home Screen 6. You should be returned to the P02 home screen
and values just entered should appear next to the
PF parameter.
PRE-FILL FUNCTION SETTINGS

PRE-FILL TIME SETTINGS

1. From the P02 home screen scroll up (+) or

1. From the P02 home screen scroll up (+) or

scroll down (-) to move the cursor to
highlight 01- PF (pre-fill function).
scroll down (-) to move the cursor to
P01 S01 highlight 02- PT (Pre-fill Time).
P02

P01 P02 S01

06 03 X
01 PF X
02 PT - MIN 01 PF X
03 PP 0 PSI 02 PT - MIN
04 01 X 03 PP 0 PSI
04 01 X
05 02 X

Pre-fill Function Setpoint Screen

2. The default setting for this parameter is . The Pre-fill Time Setpoint Setting
2. The default setting for this parameter is – MIN .
indicates the pre-fill function is turned off. The
The – MIN indicates the Pre-fill Time is turned off.
pre-fill function provides a controlled and energy
The Pre-fill Time Setpoint (in minutes) determines
efficient method of increasing pressure to normal
the time the Pre-fill Function has to start and load
operating levels at system start. This feature avoids
the designated Compressor/s to increase system
the inefficient potential for all available system
pressure to normal operational levels
compressors to start and load before pressure
reaches the normal operating level.
3. Press the ENTER button to display the Pre-fill
Time Setpoint screen.
3. Press the ENTER button to display the pre-fill
function setpoint screen. 4. The flashing cursor should be displayed
4. The flashing cursor should be displayed highlighting the . The values for this parameter
are:
highlighting the . The values for this parameter
are: • “–” for the Pre-fill Time is Off
• “1 to 120” for the number of minutes for
• “ ” for the Pre-fill Function is Off the Pre-fill Time Setpoint

• “ ” for Pre-fill, Back-up Mode

5. Scroll up (+) or scroll down (-)
i. Compressor(s) can be pre- until the value is set for the Pre-fill Time required
selected as ‘Primary Pre-fill’
compressor(s) or ‘Backup Pre-fill’
compressor(s). If a primary pre- for your air system. Press the ENTER button to
fill compressor experiences a accept this parameter.
shutdown, or is stopped, it is 6. You should be returned to the P02 home screen
replaced by a pre-defined backup and values just entered should appear next to the
compressor and pre-fill PT parameter.
continues.

47
PRE-FILL PRESSURE SETTINGS
P01 P02 S02

1. From the P02 home screen scroll up (+) or 03 PP 0 PSI

04 01 X
scroll down (-) to move the cursor to 05 02 X
highlight 03- PP (Pre-fill Pressure). 06 03 X
07 04 X
P01 P02 S02

02 PT - MIN Pre-fill Time Setting

03 PP 0 PSI
04 01 X 2. The default setting for this parameter is . The
05 02 X
06 03 X indicates the Pre-fill Function for Compressor
#1 s turned off. The Pre-fill Time Setpoint (in
minutes) determines the time the Pre-fill Function
has to start and load the designated Compressor/s
Pre-fill Pressure Setpoint Setting to increase system pressure to normal operational
levels
2. The default setting for this parameter is 0 PS. The
0 PSI indicates the Pressure Setpoint used by the
X4I to determine if the Pre-fill Function is required 3. Press the ENTER button to display the Pre-fill
at startup. If the system pressure is at, or above, Time Setpoint screen.
this setting, the pre-fill function will be abandoned
immediately and normal pressure control and 4. The flashing cursor should be displayed
sequence strategy will be implemented. This
setting is intended to inhibit ‘Pre-fill’ operation if highlighting the . The values for this parameter
pressure is already at an acceptable level at system are:
startup
• “ ”” for this compressor will not be used
by the Pre-fill Function
3. Press the ENTER button to display the Pre-fill
Pressure Setpoint screen.
• “ ” for this compressor will be used as a
4. The flashing cursor should be displayed primary compressor by the Pre-fill
highlighting the 0. The values for this parameter Function
are:
• “!” for this compressor will be used as an
• 0 to 232 (or the maximum scaling used by emergency Backup compressor by the Pre-
the X4I if a different Pressure Transducer fill Function
range is used)” for the PSI value for the
Pre-fill Pressure
5. Scroll up (+) or scroll down (-)
until the value is set for the compressor Pre-fill
5. Scroll up (+) or scroll down (-) Function required for your air system. Press the
until the value is set for the Pre-fill Pressure
enter button to accept this parameter.
required for your air system. Press the ENTER
6. You should be returned to the P02 home screen
button to accept this parameter.
and values just entered should appear next to the
6. You should be returned to the P02 home screen 04 parameter.
and values just entered should appear next to the
PP parameter.
PRE-FILL COMPRESSOR #2 THROUGH 4 SETTINGS
1. Repeat above steps for compressor #2, #3, and #4
PRE-FILL COMPRESSOR #1 SETTINGS
Pre-fill Compressor settings. When complete, the

1. From the P02 home screen scroll up (+) or ENTER button to confirm your selection.
2. You should be returned to the P02 home screen
scroll down (-) to move the cursor to 3. After you have been returned to the page selection
highlight 04- 01 (Pressure Schedule).

screen, press the ESCAPE button to return to

the main screen.

48
DIAGNOSTICS D01 TAB SCREEN X4I CONTROLLER DIAGNOSTICS
D1Digital Input 1
1. After you have returned to the page selection D2Digital Input 2
D3Digital Input 3
screen, scroll up (+) or scroll down (-)
D4Digital Input 4
until the D01 page is highlighted. D5Digital Input 5
D6Digital Input 6
D7Digital Input 7
D8Digital Input 8

D9Digital signal detected on A2

DADigital signal detected on A3
____________________________________________________

D2 Tab Screen
R1Relay Output 1

2. Press ENTER to confirm your selection. The R2Relay Output 2

cursor should be flashing on line 01 D1. R3Relay Output 3
R4Relay Output 4
DIAGNOSTICS SETTINGS
R5Relay Output 5
R6Relay Output 6
1. From the D01 home screen scroll up (+) or
____________________________________________________
scroll down (-) to move the cursor to
highlight 01- D1 (Digital Input 1).
A1Analog Input 1bar <> mA

D01 A2Analog Input 2v

A3Analog Input 3v
20 Ao 4.00 mA
____________________________________________________
01 D1 0
02 D2 0
AoAnalog Output0.0 to 20.0mA
03 D3 1
04 D4 2
Diagnostic Setting Screen
2. The X4I is equipped with comprehensive diagnostic
functions. Each input can be examined individually
and each output can be manually activated or
manipulated individually.

49
DIGITAL INPUTS
OFF (open circuit)
ON (closed circuit)

Pulsing
The pulse signal from an “ir-PCB” is 0V to 24VDC at 50/
60Hz. A typical DC voltage meter, or multimeter, will detect
this as 12VDC +-4V.

RELAY OUTPUTS Access Code Screen

Each relay output can be energized and de-energized 2. Enter the access code “9750” but do not press the
manually by selecting the item. Use UP (plus) and DOWN
(minus) to adjust and ENTER. ENTER button when the last access code
character “0” is flashing.
ANALOG INPUTS 3. When the flashing cursor is highlighting the last
The item will alternate between the detected value and the
electrical measurement on the controller input terminals. “0”, press and hold the STOP button for
An independent measuring device can be used to check the 10 seconds. After 10 seconds, the controller will
displayed electrical measurement. reset and re-initialize.
• A1:System Pressure, 4-20mA
• A2:Digital Input #9, voltage All parameters, values and options will be reset to
default and the internal permanent memory will be cleared
• A3:Auxiliary Digital Input, voltage and reset.

Analog inputs 2 and 3 are equipped with ACM modules

designed to conform to the standard specification for a
controller digital input. The inputs are utilized as digital
inputs on this X4I.

ANALOG OUTPUT
The analog output can be manually adjusted. Use UP (plus)
and DOWN (Minus) to adjust and ENTER. The output will
return to normal operational value upon menu exit.
After you have completed adjusting the settings on the D01

screen press the ESCAPE button to return to the page

selection screen.
After you have been returned to the page selection screen,

press the ESCAPE button to return to the main screen.

TOTAL UNIT RESET AND DEFAULT VALUES

If at any time there is a requirement to reset all the
parameters and internal memory values to factory default,
this can be accomplished by using the following procedure.

1. Press the MENU button. This will display the

access code screen.

50
The Default Parameters for all X4I settings are shown in the following lists.

TABLE #1
T01
PHHigh Pressure Setpoint
Default Setting is: 102 PSI
PLLow Pressure Setpoint
Default Setting is: 98 PSI
PmMinimum Pressure Alarm
Default Setting is: 0 PSI
SQSequence Rotation Mode
Default Setting is: FILO
01Compressor #1 Priority
Default Setting is: 1
02Compressor #2 Priority
Default Setting is: 1
03Compressor #3 Priority
Default Setting is: 1
04Compressor #4 Priority
Default Setting is: 1
ON
OFF TABLE #3
Pulsing T03
PHHigh Pressure Setpoint
Default Setting is: 102 PSI
PLLow Pressure Setpoint
Default Setting is: 98 PSI
PmMinimum Pressure Alarm
Default Setting is: 0 PSI
SQSequence Rotation Mode
Default Setting is: FILO
01Compressor #1 Priority
Default Setting is: 1
OFF
02Compressor #2 Priority
ON Default Setting is: 1
03Compressor #3 Priority
Default Setting is: 1
04Compressor #4 Priority
Default Setting is: 1

TABLE #2
Pressure Schedule
T02
P01
PHHigh Pressure Setpoint
Default Setting is: 102 PSI 01Schedule Setting #1
PLLow Pressure Setpoint Default Setting is: -. - - : - - - - -
Default Setting is: 98 PSI to
PmMinimum Pressure Alarm 28Schedule Setting #28
Default Setting is: 0 PSI Default Setting is: -. - - : - - - - -
SQSequence Rotation Mode
Default Setting is: FILO
01Compressor #1 Priority
Default Setting is: 1
02Compressor #2 Priority
Default Setting is: 1
03Compressor #3 Priority
Default Setting is: 1
04Compressor #4 Priority
Default Setting is: 1

51
 Pre-fill
P02
PFPre-fill Function
Default Setting is: X
PTPre-fill Time
Default Setting is: - MIN
PPPre-fill Pressure
Default Setting is: 0 PSI
01Compressor #1
Default Setting is: X
02Compressor #2
Default Setting is: X
03Compressor #3
Default Setting is: X
04Compressor #4
Default Setting is: X
User Configuration
S01
CtReal Time Clock Set
Default Setting is: -. - - : - -
PSPressure Schedule Enable
Default Setting is: X
ARAuto Restart Enable
Default Setting is:
RPRotation Interval
Default Setting is: 1. 00:00
TSDefault Table Select
Default Setting is: T01
BLDisplay Backlit Adjust
Default Setting is: 5
52
Configuration
S02
P>Pressure Units
Default Setting is: PSI
NCNumber Of Compressors
Default Setting is: 4
PMMaximum Pressure Alarm
Default Setting is: 145 PSI
CFStop Control Function
Default Setting is: X
TOTolerance
Default Setting is: 3.0 PSI
DADamping
Default Setting is: 1.0
PCPressure Change Time
Default Setting is: 4 MIN
AIAuxiliary Input Function
Default Setting is: 05:SS NO
AOAuxiliary Output Function
Default Setting is: 07 ON NO
ERError Log Reset
Default Setting is: X
Sensor Calibration
S03
1OPressure Offset
Default Setting is: 0 PSI
1RPressure Range
Default Setting is: 232 PSI
 Compressor Running Hours

C01

01Compressor #1 Running Hours

Default Setting is: 0 HRS
02Compressor #2 Running Hours
Default Setting is: 0 HRS
03Compressor #3 Running Hours
Default Setting is: 0 HRS
04Compressor #4 Running Hours
Default Setting is: 0 HRS

Compressor Configuration

C02

01Compressor #1 Configuration
Default Setting is: IR-PCB
02Compressor #2 Configuration
Default Setting is: IR-PCB
03Compressor #3 Configuration
Default Setting is: IR-PCB
04Compressor #4 Configuration
Default Setting is: IR-PCB

53
 SECTION 10 — DIAGNOSTIC FUNCTIONS IN THE X04
CONTROLLER

In order to understand and utilize the functionality provided on the D01 the signals can then be used to understand the information displayed o
diagnostics tab, you must first know how to troubleshoot the control the D01 diagnostic screen in the X4I.
signals between the X4I and the ir-PCB interface. The troubleshooting of

IR-PCB (INGERSOLL RAND COMPRESSOR INTERFACE PCB)

C01 C02 C04 C01 C02 C04

ir-PCB ir-PCB
C03 C03
V 1 2 3 4 5 6 C05 V 1 2 3 4 5 6 C05

LED 1 LED 2 LED 1 LED 2

V1 1 2 3 4 5 6 V1 1 2 3 4 5 6

Wire Connections for IR-PCB Mode Wire Connections for IRV-PCB Mode
6core, earth shielded, cable (330 ft max) 7core, earth shielded, cable (330 ft max)

CONNECTIVITY TO X4I AND DIAGNOSTIC LED INDICATORS

Load/Unload
Load Enable
VFD/Fixed
+VDC

NO C NC NO C NC Alarm Run Ready

OUT IN
C02 C04

C01
ir-PCB
LED 5
RUN
C03
LED 4
READY
V 1 2 3 4 5 6

LED 2

LED 5 LED 1 C05

VFD SEQ LOAD +24VDC

VFD LOAD SEQ
GND D1 D2

X03-3 (GND) is 0Vac and 0VDC common. GND is also The ‘ir-PCB’ provides 3kV opto-coupled isolation between
connected to ‘earth’ on the X4I Terminal PCB (this is not a compressor circuit pressure regulation and monitoring
‘Safety Earth’ connection and is used for “control” only). inputs (X01, X02 and X04) and the low voltage connections
to the X4I (X03).

54
‘IR-PCB’ PRESSURE REGULATION CONTROL INPUTS
LOAD INPUT DIAGNOSTIC INDICATOR
On connector C03, the following connections provide the
control to the compressor from the X4I to the ir-PCB.
V 1 2 3 C 03 + 24Vac
L O AD
0Vac

V 1 2 3 0Vac
LED 2

GND
LO A D

24Vac
0Vac
GND
C 03
V S E Q LO A D
24Vac When the X4I initiates a Load command to the compressor,
the controller will send a signal to the Load input (2) on the
ir-PCB. Its associated diagnostic LED 2 will be on indicating
VFD INPUT CONTROL DIAGNOSTIC INDICATOR the presence of 24Vac.

V 1 2 3 C 03 + 24Vac ‘IR-PCB’ STATUS MONITORING OUTPUTS

VFD
0Vac

LED 5
On connector C03, the following connections provide the
0Vac
GND
status of the compressor from the ir-PCB to the X4I.
VFD
24Vac

3 4 5 6
When the X4I is set up for in VFD mode (IRV-PCB), the
controller will send a signal to the VFD input (V) on the ir-
PCB. Its associated diagnostic LED 5 will be on indicating C 03 0V D C +24 V D C
GND

the presence of 24Vac. D1 D2

SEQ (REMOTE PRESSURE REGULATION CONTROL) READY SIGNAL DIAGNOSTIC INDICATOR

INPUT DIAGNOSTIC INDICATOR

12-250Vac
V 1 2 3 C 03 + 24Vac or D C
SEQ +V
0Vac R E AD Y
C 04 0V
LED 1
0Vac
LED 4
GND
SEQ A LA R M RUN READY
(W arning)
24Vac

When the X4I places a compressor into Sequence control, When the compressor is “on” and “ready” to be sequenced,
the controller will send a signal to the SEQ input (1) on the there will be voltage present on the Ready connection on
ir-PCB. Its associated diagnostic LED 1 will be on indicating C04. Its associated diagnostic LED 4 will be on indicating
the presence of 24Vac. the presence of the signal.

RUN SIGNAL DIAGNOSTIC INDICATOR

12-250Vac

+V

C 04 RUN
0V

LED 3
A LA R M RUN READY
(W arning)

When the compressor is “running”, there will be voltage

present on the Run connection on C04. Its associated
diagnostic LED 3 will be on indicating the presence of the
signal.

55
STATUS SIGNALS

READY AND RUN STATUS SIGNALS

12-250 V ac
12-250V ac or DC

Po la r ity is n o t Po la r ity is n o t
im p o r ta n t im p o r ta n t

+V 12-250Vac
12-250Vac or D C
READY
0V
Load Enable
Load/Unload
VFD /Fixed
+ VDC

NO C NC NO C NC A larm R un R eady
OU T IN +Vac
C02 C04 RUN
C01 0V ac C 04
+V D C
ir-PC B +24 V D C +V R un R ead y
P u lse 5 0 /6 0 H z
C03
+24V D C
X 01
R ead y/R un
V 1 2 3 4 5 6 D2 D2 D i2 D2
0V D C X 03
0V D C 0V D C
C 05 GND GND

X 4I ir-P C B

0V DC
D2

When the Ready and Run signals are present on C04, they Note: RUN input 12-250V’ac’ only. The ‘ac’ frequency is
can be monitored on connection C03 terminal 5 (D2). used to create the pulsing on the ‘D2’ (C03-3) output.
Referring to the above graph, the signal (wave form) seen Note: If measured with a ‘typical’ DC voltage meter the
on D2 is shown. ‘pulsing’ will appear as 10VDC (+-3V)

ALARM (WARNING) AND SERVICE/MAINTENANCE FUNCTION STATUS SIGNALS

12-250V ac
or DC

Po la r ity is n o t
im p o r ta n t
12 - 250Vac
or D C
+V
ALARM
0V
VFD /Fixed
Load Enable
Load/U nlo ad
+VD C

N O C N C N OC N C A larm R un R eady
O UT IN
C02 C04
S ervice +24 V D C C 04
M ain ten an ce
C01
A larm
ir-PC B 10k A larm /S erv. D1
D i6
C03 P u lse 5 0 /6 0 H z
V 1 2 3 4 5 6 +24V D C X 01 X 03
D1 D2 0V D C 0V D C
0VD C GND GND
C0 5
X 4I ir-P C B

0V DC Se rv ic e
D1 M a int e na nc e

When the Alarm or Service Maintenance signals are present In addition, if the ‘D1’ wire connection from the X4I to the
on C04 or C05, they can be monitored on connection C03 ‘ir-PCB’ is not connected the ‘D2’ output on the ‘ir-PCB’ pin
terminal 5 (D1). Referring to the above graph, the signal will always measure 0VDC (no pull-up resistor connected).
(wave form) seen on D1 is shown.
A Service/Maintenance signal (pulsing) will mask any Alarm
Pulses are generated by the ‘ir-PCB’ itself for the Service/ (Warning) signal. This is not an issue because the X4I will
Maintenance ‘D1’ (C03-5) Signal. ignore any compressor Alarm (Warning) or Trip (Shutdown)
conditions in Service/Maintenance mode.
Notice that the 10k pull-up resistor on the X4I Terminal PCB
will hold the ‘D1’ signal at +24VDC. The Signal will go to Note: If measured with a ‘typical’ DC voltage meter the
0VDC when there is an Alarm (Warning) input on the ‘ir- ‘pulsing’ will appear as 10VDC (+-3V)
PCB’. This functions in reverse to the way the ‘D2’ Ready/
Run signal, from the ‘ir-PCB’ to the X4I functions.

56
DETERMINING TERMINAL PCB TO CONTROLLER I/O CONNECTIONS FROM THE X4I WIRING
DIAGRAM FOR USE WITH THE CONTROLLER DIAGNOSTIC TEST FUNCTIONS

Example: ‘ir-PCB 1’ Ready/Run Signal to Controller Di2 (Digital Input 2) Terminal

C015
C+ C019 C016

1 C020 C017
X01 C03
Di2 2 C021 C018
ir- PCB X04 3 C022
C019 10k 6 + +20VDC 6

Ready/Run 4 C023
C020 C021 5 Di2 Ready/Run 5
5 C024
C025 4 Di6 Alarm/Serv 4 ir-PCB 1
C021
6 C025
C022
3 - .GND 3
7 C026
C015 2 R2 LOAD 2
C023
8 C027
1 1
C024 R1 SEQ
V1 V
C025 V1 VFD

X04-3
(C2)
Di2

ir- PCB 1
Ready/Run

X4 I Controller C021 X01-5

Terminal PCB

COMPRESSOR #1 DIAGNOSTICS
• To view ‘ir-PCB’ #1 Ready/Run input in the controller’s Diagnostic menu select digital input ‘D2’ (Di2)
• To view ‘ir-PCB’ #1 Alarm/Serv input in the controller’s Diagnostic menu select digital input ‘D6’ (Di6)

COMPRESSOR #2 DIAGNOSTICS
• To view ‘ir-PCB’ #2 Ready/Run input in the controller’s Diagnostic menu select digital input ‘D3’ (Di3)
• To view ‘ir-PCB’ #2 Alarm/Serv input in the controller’s Diagnostic menu select digital input ‘D7’ (Di7)

COMPRESSOR #3 DIAGNOSTICS
• To view ‘ir-PCB’ #3 Ready/Run input in the controller’s Diagnostic menu select digital input ‘D4’ (Di4)
• To view ‘ir-PCB’ #3 Alarm/Serv input in the controller’s Diagnostic menu select digital input ‘D8’ (Di8)

COMPRESSOR #4 DIAGNOSTICS
• To view ‘ir-PCB’ #4 Ready/Run input in the controller’s Diagnostic menu select digital input ‘D5’ (Di5)
• To view ‘ir-PCB’ #4 Alarm/Serv input in the controller’s Diagnostic menu select digital input ‘A2’ (Ai2)

57
DIGITAL (SWITCHING) INPUT EXCEPTIONS

• ‘ir-PCB’ #4: The ‘Alarm/Service Note: A digital (switching) conditioning circuit is not
Maintenance’ digital input (X04-22) is employed on analog input 2 (‘ir-PCB’ #4 Alarm/Service
monitored by a DC voltage ‘Analogue’ Maintenance) because this input has a ‘pulsing’ state that
input (A2) on the unit’s controller. The the digital (switching) conditioning circuit is unable to
Terminal PCB has a 2x150k resistor and detect correctly; hence the DC voltage level detection to
capacitor circuit to condition the signal pick-up the ‘pulsing’ state.
from the ‘ir-PCB’. View analogue input ‘A2’
in the controller’s Diagnostic menu.
• Auxiliary Digital Input 1 (X07) is monitored
by ‘Analog’ input (A3) on the unit’s
controller. The analogue input has been
fitted with a digital (switching) conditioning
circuit and has the same characteristics as
a normal ‘Digital’ input. View analogue
input ‘A3’ in the controller’s Diagnostic
menu.

58
 SECTION 11 — FAULT CODES
In the event of a unit or system “fault” the X4I will display a The alarm (warning) symbol will alternate with the normal
fault code. The fault code becomes an item in the user compressor status symbol every two seconds.
operational display menu. If more than one “active” fault
occurs, each will be displayed as a separate item in the
operational user menu. Press UP or DOWN to view all active
fault codes or to view the normal status display. NOT AVAILABLE
The compressor is reporting a general or group trip
Alarm (Warning) (shutdown) condition. The compressor has been stopped
and taken out of service, power to the compressor has been
isolated/lost or the compressor is not communicating.
Shutdown (Trip)
• The ready input of the “ir-PCB” is no longer
Fault codes are separated into unit faults (ERR) and system active.
alarms (warning) (SYS).
• The run input of the “ir-PCB” is no longer
Each fault type has a unique numeric code. active while the compressor is being
requested to run loaded.
ERR.01 Pressure Sensor • The run input of the “ir-PCB” did not
activate within 60 seconds of a load
request.
ERR.04 Internal 24V Fault
• The compressor is reporting a general or
group shutdown or stopped condition
ERR.05 Emergency Stop (RS485 network connectivity only).
• The remote compressor interface unit is in
ERR.06 Real Time Clock Error a shutdown condition (RS485 network
connectivity only).
SYS.01 Excess Pressure (PM) The X4I fault LED will “fast flash”.
The “not available” symbol will “slow flash”.
SYS.02 Min Pressure (Pm)

SYS.04 Insufficient Capacity
Compressor fault states are displayed as part of the
normal operational status display and do not generate fault
codes. Examine the applicable compressor unit to establish
the nature or description of the detected fault condition.
X4I COMPRESSOR FAULT INDICATIONS,
TYPES, AND CODES:
#
COMPRESSOR INHIBITED, REMOVED FROM
SERVICE
Set in the X4I active “table” (# = table number 1, 2 or 3) as
inhibited from use.
In this condition, the status of the compressor is still
monitored. The X4I fault LED will not illuminate or flash
unless an actual alarm (warning) or trip (shutdown, not
available) condition occurs.
The two symbols will alternate every two seconds.

Compressor fault conditions are displayed on the user

compressor status screen and are not regarded as X4I unit
fault conditions.
Compressor fault conditions are displayed symbolically on
the main User compressor status screen.
SERVICE/MAINTENANCE
Inhibited from use by the user using the “ir-PCB” service/
maintenance function.
In this condition, compressor fault conditions are ignored.
The X4I fault LED will not illuminate or flash.

ALARM (WARNING)
• The Alarm input on the “ir-PCB” has been COMMUNICATIONS DISRUPTION
activated.
Network communications with the compressor have been
• The compressor, or remote compressor
interface unit, is reporting a general or disrupted/lost.
group alarm condition on the RS485
network (RS485 network connectivity only). Note: only applicable where the compressor is integrated
The X4I fault LED will “slow flash”. with the X4I using the RS485 communications network.

59
SPECIAL CONTROLLER FAULT CODES To view the second error information screen, press the
• E0836 PLL Unlock Internal failure or
excessively high external electrical ENTER button. To return to the main error log menu
interference
• E0866 Controller internal
power supply fault screen, press the ESCAPE button.
• E5000 Internal memory
map error E01 01.01
• E5001 Internal memory
failure 1 2 3 4

ERROR LOG Second Error Log Information Screen

The operational status of each compressor, at the time the
E01 error occurred, is displayed symbolically. See Compressor
Status Displays for Icons.
15 -: --- . --
To return to the first information screen press the ENTER
01 E : ERR . 01
02 -:--- . --
03 -:--- . -- button or the ESCAPE button. To return to the
04 -:--- . --
Error Log Screen
main error log menu screen press the ESCAPE button.
The error log is presented in chronological order. Entry 01
is the most recent, whereas entry 15 is the oldest. Each
error log item will show the error code. To view details for

the selected error log item, press the ENTER button.

E01 01.01

E: ERR.01
16/05/2006 14:25
1

First Error Log Information Screen

The first error information display shows:
• The error code
• Error code symbols (if applicable)
• The date the error occurred
• The time the error occurred
• The active operational functions of the X4I
at the time the error occurred; (see: X4I
Status Display for Icons)

60
 PARTS LIST
Item Part No. Description
- 39265889 X4I
2
- 80443617 Manual, User CD
1 39265897 Unit, Controller
2 39265913 Unit, XPM-TAC24
3 39265905 PCB, Terminal
4 38036703 Gland, Set - Pg11 3
5 39265921 Module, ir-PCB
6 39265939 Sensor, Pressure 1
4-20mA, 232psi (16bar) 4

5 i-PCB 6
20mm
IEC 5mm

Qty. Part No. Description

10 39265962 IEC Fuse T1.0A
10 39265970 IEC Fuse T1.6A
10 39265988 IEC Fuse T3.15A

61
 TECHNICAL DATA Mounting Dimensions:

Dimensions (HxWxD) 9.45” x 11.45” x 6.0” 24mm 238mm

241mm x 291mm x 152mm

24mm
Weight 14 lb (6.4 kg)
Mounting Wall, 4 x mounting screws
Enclosure IP65, NEMA 4
Power Supply 50VA 188mm 236mm

230Vac +/- 10% (50 Hz)

115Vac +/- 10% (60 Hz)
Control Power 24Vdc 8mm

Temperature 32°F to 115°F (0°C to 46°C)

Humidity 0% to 95% RH
286mm
non-condensing

62
 DIAGRAMS
Wiring Diagram
T 1-5 6-32 1 -R 6 -C G T erm in al P C B

33 34 35 36
C01

X08
C03

4-20m A

X 06

4
+VDC C03 C04

A i1 C04 C05

3
X 05

31 32
+VDC C05 C06

X07
C 031 A -G N D SEQ C08

2
A i2 C06 C07
GND C07
C 032 Ao

1
+VDC C07 C08
A i3 C08

27 28 29 30
C 010
C09

X06
C09
X 09

C 010
C+ C 019

SEQ
C 020 C 011
X 08

2 C 021

25 26
C 012 C04

X05
3 C 022
C 013
X 04

C03
L2 L1

4 C 023
C 014 C 019
5 C 024

+
-

V4 19 20 21 22 23 24
C 015 R -S E Q 10k
6 C 025
C 016 C 024

24 V ac
XPM 485
R S 485#2

GND
7 C 026
C 017
C 034 150k
C06

X04
8 C 027
C 018 150k
C 019 C 012
2 4V ac
C 020
C 011
SEQ
R5 C 021
X 02

C 012 C 022
C 023
C 0 1 /3
L2 L1 R S 485#1

C 024
R6

V3 13 14 15 16 17 18
1 0k
M ulti485

C 0 1 /4 C 025
X 07

C 023
GND

C 026 C 027

X03
C 013 C 027
C09 R1
C 014 C 028 C 018
C 010
R2 C 029
C 015
X 03

C 030
R3
C 016 C 033

9 10 11 12
1 0k
C 017 C 034
24V ac

C 022
R4
X 01

C 026

X02
C 018
2
1

C 031

8
-

C 016
0VDC
C 032 4 -20 m A

7
+

V2
C 029

C 028

R -V 4
6

R -V 3 1 0k
24 V ac
0V ac

C 021
5

R -V 2
C 025
X01
3 4
X 02

X P M -T A C 24

R -V 1
X03
2

C 015
2
1

1 2
2 4V ac
1
N
E
E
L

0 V a c - e a rth ed
V1
X 01

L N E
230V ac 1 0%
115V ac 1 0%

63
Connection Diagram

Terminal PCB
36
115V 'UL ' @ 5A maximum.
35 X08
34
33 Auxiliary Output #1

32 X07
31 Auxiliary Input #1
330ft (100m) max
30 L1
29 X06 L1
28 L2 Multi485 L2

27 L1
L2 330ft (100m) max
26 -
X05 - System
25
+ Ai1Pressure
+ +
24
+ +20VDC 6 4- 20mA

Di5 Ready/Run 5 ir-PCB4

23
22 X04
21 Ai2 Alarm/Serv. 4
20
- GND 3
330ft (100m) max

19
R5 LOAD 2

V4
R1 SEQ 1
4
V4 VFD V
IR- PCB 6- core
V
IRV- PCB 7-core

18
+ +20VDC 6 ir-PCB3
17
16 Di4 Ready/Run 5
X03
15 Di8 Alarm/Serv. 4
14
- GND 3 330ft (100m) max

13 R4 LOAD 2

R1 SEQ 1 3
V3
V V
V3 VFD IR- PCB 6- core
IRV- PCB 7-core
12
+ +20VDC 6
11 ir-PCB2
10
Di3 Ready/Run 5
X02
Di7 Alarm/Serv. 4
9 - GND 3 330ft (100m) max
8
R3 LOAD 2
7
V2
R1 SEQ 1
2
V2 VFD V IR- PCB 6- core
V
IRV- PCB 7-core

6 + +20VDC 6
5
Di2 Ready/Run 5 ir-PCB1
4 X01
3
Di6 Alarm/Serv. 4
2
- GND 3 330ft (100m)max

1
R2 LOAD 2

V1
R1 SEQ 1
1
V1 VFD V IR- PCB 6- core V
IRV- PCB 7-core

64
XPM-TAC24
Power Supply Module

83
89
6 12 mm
6

4 x 4.5mm

BLUE BLACK

BROWN ORANGE

RED WHITE
GREEN VIOLET

10 32
1 2 3 4
X04 1 2 3 4

FH5 FH4 FH3 FH2

VOLTAGE SELECT
230V +-10%

230V
T3.15A

T1.6A

T1.6A

T1.0A

115V
115V +-10%
IEC T1.0A FH1
5x20mm
1 2 3 4
X03 X02
2 1 2
X01 12 mm
141 L N E E
147
24Vac/2 24Vac/1
earthed isolated L N E

65
 X4I Commissioning Form
Customer Contact Customer Ref:

Phone Internal Ref:

Installation/Site Commission Date

Software Ser No. Commission Engineer

Comp #1 Manufacturer
Comp #1 Model/Type
psi cfm
Comp #1 Working Pressure psi/bar
#1 kW VA Hz
Comp #1 Full Load Capacity cfm

Comp #2 Manufacturer
cfm
Comp #2 Model/Type
psi
#2 kW VA Hz
Comp #2 Working Pressure psi/bar
Comp #2 Full Load Capacity cfm

Comp #3 Manufacturer
psi cfm Comp #3 Model/Type
#3 kW VA Hz Comp #3 Working Pressure psi/bar
Comp #3 Full Load Capacity cfm

Comp #4 Manufacturer
psi cfm Comp #4 Model/Type
#4 kW VA Hz Comp #4 Working Pressure psi/bar
Comp #4 Full Load Capacity cfm

T01 PH High Pressure Set Point psi/bar

T01 PL Low pressure Set Point psi/bar
T01 Pm Minimum Pressure Alarm psi/bar
T01 SQ Sequence Rotation Mode EHR FIFO TR VEC
T01 01 Comp #1 Priority
T01 02 Comp #2 Priority
T01 03 Comp #3 Priority
T01 04 Comp #4 Priority

T02 PH High Pressure Set Point psi/bar

T02 PL Low pressure Set Point psi/bar
T02 Pm Minimum Pressure Alarm psi/bar
T02 SQ Sequence Rotation Mode EHR FIFO TR VEC
T02 01 Comp #1 Priority
T02 02 Comp #2 Priority
T02 03 Comp #3 Priority
T02 04 Comp #4 Priority

T03 PH High Pressure Set Point psi/bar

T03 PL Low pressure Set Point psi/bar
T03 Pm Minimum Pressure Alarm psi/bar
T03 SQ Sequence Rotation Mode EHR FIFO TR VEC
T03 01 Comp #1 Priority
T03 02 Comp #2 Priority
T03 03 Comp #3 Priority
T03 04 Comp #4 Priority

66
S01 Ct Real Time Clock Set
S01 PS Pressure Schedule Enable
S01 AR Auto Restart Enable
S01 RP Rotation Interval or Time
S01 TS Default Table T01 T02 T03

S02 P> Pressure Units bar psi kPa

S02 NC Number of Compressors 1 2 3 4
S02 PM Maximum Pressure Alarm psi/bar
S02 CF Stop Control Function
S02 TO Tolerance
S02 DA Damping
S02 PC Pressure Change Time min
S02 AI Auxiliary Input Function
S02 AO Auxiliary Output Function

S03 1O Pressure Offset

S03 1R Pressure Range

P02 PF Prefill Function !>X

P02 PT Prefill Time sec
P02 PP Prefill Pressure psi/bar
P02 01 Compressor #1 Prefill Function !
P02 02 Compressor #2 Prefill Function !
P02 03 Compressor #3 Prefill Function !
P02 04 Compressor #4 Prefill Function !

C01 01 Compressor #1 Running Hours hrs

C01 02 Compressor #2 Running Hours hrs
C01 03 Compressor #3 Running Hours hrs
C01 04 Compressor #4 Running Hours hrs

C02 01 Compressor #1 Connection I-PCB V-PCB I-485 V-485

C02 Compressor #1 Start Time sec
C02 Compressor #1 Stop Time sec

C02 02 Compressor #2 Connection I-PCB V-PCB I-485 V-485

C02 Compressor #2 Start Time sec
C02 Compressor #2 Stop Time sec

C02 03 Compressor #3 Connection I-PCB V-PCB I-485 V-485

C02 Compressor #3 Start Time sec
C02 Compressor #3 Stop Time sec

C02 04 Compressor #4 Connection I-PCB V-PCB I-485 V-485

C02 Compressor #4 Start Time sec
C02 Compressor #4 Stop Time sec

67
Machine models represented in this manual may be used in various locations world-wide. Machines sold and
shipped into European Union Territories require that the machine display the EC Mark and conform to various
directives. In such cases, the design specification of this machine has been certified as complying with EC
directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking
being rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

93/68/EEC, 92/31/EEC, 89/336/EEC, 73/23/EEC

we,
Represented in EC by:

Ingersoll-Rand Company Ingersoll-Rand European Sales Limited

800A Beaty Street Swan Lane
P.O. Box 1600 Hindley Green
Davidson Wigan WN2 4EZ
North Carolina 28036 United Kingdom

declare that, under our sole responsibility for manufacture and supply,
the product(s)

X4I

to which this directive relates, is (are) in conformity with the provisions of the above directives using the following
principal standards.

EN61000-6-4, EN61000-6-2, EN60204-1

Issued at Hindley Green on 23/04/2007 by H. Seddon, Quality Assurance Manager.

H. Seddon