Ingersoll Rand

System Automation
DX Box
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. : 80445117
More Than Air. Answers. REV. A
Online answers: http://www.air.irco.com DATE: DECEMBER 2008
 TABLE OF CONTENTS

table Of Contents ....................................................... 2 
Section 1 — Introduction............................................ 3 
Section 2 — Safety ..................................................... 3 
Refer to Section Indicated
SAFETY PRECAUTIONS ....................................................... 3 
INSTALLATION ................................................................. 3 
OPERATION .................................................................... 3 
MAINTENANCE AND REPAIR .............................................. 4  Note

Section 3 — Compressor Connection And Control ....... 5 
STANDARD CONTROL FEATURES AND FUNCTIONALITY ............ 5  Important or Caution, Safety
COMPRESSOR OPERATION ................................................. 5 
SECTION 4 — INSTALLATION ...................................... 7 
UNIT LOCATION .............................................................. 7 
POWER SUPPLY ............................................................... 7 
RS485 NETWORK ........................................................... 7 
DX BOX AND IR‐PCB COMPRESSOR CONNECTIVITY ................ 8 
INPUT FUNCTIONS ........................................................... 8 
OUTPUT FUNCTIONS ...................................................... 10 
DX BOX AND PRESSURE SENSOR CONNECTIVITY .................. 12 
DX BOX AND I/O CONNECTIVITY ...................................... 13 
SECTION 5 — DISPLAY AND MENU OPERATION ........ 14 
SECTION 6 — COMMISSIONING ................................ 17 
PHYSICAL CHECKS .......................................................... 17 
X8I OR X12I AUTOMATION SYSTEM ................................. 17 
SECTION 7 —SYSTEM CONFIGURATION .................... 18 
MENU NAVIGATION ....................................................... 18 
ACCESSING THE DX CONFIGURATION SCREENS .................... 18 
MENU ITEMS AND SETTINGS ............................................ 20 
SECTION 8 —  DIAGNOSTICS ..................................... 27 
SECTION 9 — FAULT CODES ...................................... 28 
SECTION 10 — PART LIST .......................................... 29 
SECTION 11— TECHNICAL DATA ............................... 29 
SECTION 12— WIRING DIAGRAM ............................. 30 
XPM‐TAC24 ............................................................... 31 
SECTION 13— COMMISSIONING FORMS................... 32 

2
 SECTION 1 — INTRODUCTION
The DX Box is a dual unit extension to an X8I or X12I, together into one group that will then act as a single
Automation System. The DX Box provides the ability to multi-step air compressor.
group two individual Fixed Speed Air compressors

SECTION 2 — SAFETY
SAFETY PRECAUTIONS OPERATION
• The DX Box must only be operated by
! WARNING : Risk of Danger competent personnel under qualified
supervision.

WARNING : Risk of Electric Shock • Never remove or tamper with safety devices,
guards or insulation materials fitted to the DX
Box.
WARNING : Risk of High Pressure
! • The DX Box must only be operated at the
supply voltage and frequency for which it is
designed.
WARNING : Consult Manual
• When main power is switched on, lethal
voltages are present in the electrical circuits and
• Before installing or operating the DX Box, take
extreme caution must be exercised whenever it
time to carefully read all the instructions
is necessary to carry out any work on the unit.
contained in this manual, all compressor
manuals, and all manuals of any other • Do not open access panels or touch electrical
peripheral devices that may be installed or components while voltage is applied unless it is
connected to the unit. necessary for measurements, tests or
adjustments. Such work should be carried out
• Electricity and compressed air have the
only by a qualified electrician equipped with the
potential to cause severe personal injury or
correct tools and wearing appropriate protection
property damage.
against electrical hazards.
• The operator should use common sense and
• All air compressors and/or other equipment
good working practices while operating and
connected to the unit should have a warning
maintaining this system. All applicable codes
sign attached stating “THIS UNIT MAY START
should be strictly adhered to.
WITHOUT WARNING” next to the display panel.
• Maintenance must be performed by adequately
• If an air compressor and/or other equipment
qualified personnel that are equipped with the
connected to the unit is to be started remotely,
proper tools.
attach two warning signs to the equipment
stating “THIS UNIT CAN BE STARTED
INSTALLATION REMOTELY”. Attach one sign in a prominent
location on the outside of the equipment, and
• Installation work must only be carried out by a the other sign inside the equipment control
competent person under qualified supervision. compartment.
• A fused isolation switch must be fitted between
the main power supply and the DX Box.
• The DX Box 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 DX Box, 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.

3
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 DX Box:
i. Isolate the DX Box 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 CX Box if
such a warning label is attached.
• Make sure that all instructions concerning
operation and maintenance are strictly followed
and that the complete unit, with all accessories
and safety devices, is kept in good working
order.
• The accuracy of sensor devices must be
checked on a regular basis. They must be
calibrated when acceptable tolerances are
exceeded. Always ensure any pressure within
the compressed air system is safely vented to
atmosphere before attempting to remove or
install a sensor device.
• The DX Box 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.

4
 SECTION 3 — COMPRESSOR CONNECTION AND CONTROL
The DX Box is designed to connect two load/unload air
compressors to an X8I or X12I, using a 2-wire RS485
data cable.
Ingersoll Rand
102 psi
A: 85%
DX
3 50%
1 2 #1
The DX Box is designed to allow two fixed speed
online/offline air compressors to be seen as one
compressor by the X8I or X12I. The DX Box provides for
two ‘ir-PCB’ connections.
The DX Box can also be used to provide ‘ir-PCB’
connectivity at a remote location beyond the maximum
distance specification of direct X8I or X12I connection.
STANDARD CONTROL FEATURES AND
FUNCTIONALITY
When two compressors of the same capacity are
connected to the DX Box the X8I or X12I sees the DX
box as one 3-step compressor that can provide 0%, 50%,
or 100% of capacity.
When two compressors of different capacities are
connected to the DX box the X8I or X12I sees the DX
box as one 4-step compressor. For example, if two
compressors are connected to the DX box, one with a
relative capacity of 25% and another with relative
capacity of 75%, the available load steps would be 0%,
25%, 75%, and 100%.
This functionality provides the ability to:
a) Group two adjacent air compressors together as
a single coherent unit.
b) Combine two similar capacity compressors
together to form a three-step variable output
group acting as a single coherent variable
output unit.
c) Take advantage of a small or minimal capacity
compressor, grouped together with a medium or
higher capacity compressor, to form a high
capacity, variable output, group acting as a
single variable output ‘top-up’ compressor.
Two single pressure switch control type air compressors
can be connected to the DX Box using a 6-wire cable and
an ir-PCB.
The DX Box also provides optional local pressure sensor
connections. The compressor discharge pressures, local
system pressure and air treatment differential pressures
can be displayed. The monitored local pressure is
available on the system network and can be utilized by
an X8I or X12I for advanced pressure related functions.
Any number of DX Boxes can be connected to an X8I or
X12I as long as the total number of single compressors
and/or groups does not exceed eight compressors for the
X8I or twelve compressors for the X12I.
COMPRESSOR OPERATION
Timer Rotation Mode (Tr)
A #1 B #2
50% = 100%
#2
1 A B
2 B A
Timer Rotation should be used when the two
compressors have the same (50%:50%), or very similar,
output capacity. The DX Box will assign one compressor
as base load and the other as trim.
The base load compressor will always be loaded first and
the trim compressor used as and when required to meet
demand. The base load and trim assignment will be
changed periodic intervals (user adjustable).
Automatic Mode (Ar)
A #1 B #2
75% 25% = 100%
0% - -
25% - B
75% A -
100% A B
Automatic mode can be used when the compressor
capacities are different. The DX Box will utilize each
compressor as required to match output to demand. This
mode enables the compressor ‘group’ to behave in the
same manner as a single (multiple step) variable output
unit.
The set interval time is ignored in this mode, the DX Box
will continuously evaluate utilization to match demand.
For example:
If demand can be satisfied by the smaller of the two
compressors (demand < 26%) the DX Box will utilize the
lower capacity compressor (B). If demand increases
above the output capacity of the smaller compressor, but
within the capacity of the larger capacity compressor, the
DX Box will utilize the larger capacity compressor (A). If
demand exceeds to capacity of the larger capacity
compressor the DX Box will load the larger compressor
continuously and utilize the smaller capacity compressor
to regulate as required.
5
X8I or X12I Integration
When integrated with an X8I or X12I the DX Box
compressor group will respond in trim mode or base load
mode as dictated by the X8I or X12I. The assigned mode
of response will change from time-to-time dependent on
the set sequencing mode of the X8I or X12I.
In trim mode the DX Box will allow variable capacity
control (as described above) dependent on demand.
Percentage Capacity
The capacity of each compressor is expressed, and set,
as a percentage of the combined output capacity of both
compressors.
For example:
If the larger compressor #1 (A) has an output capacity of
325cfm, and the smaller #2 (B) compressor an output
capacity of 175cfm, the total combined output of the DX
Box ‘group’ equates to 500cfm.
Total Capacity (500cfm) = 100%
Compressor #1 (A, 325cfm) = 65%
Compressor #2 (B, 175cfm) = 35%
Compressor Failure Mode
If one compressor in the DX Box ‘group’ suffers a
shutdown failure, or is manually stopped, the DX Box will
indicate an Alarm (Warning) condition. The remaining
compressor will continue to function and the DX Box will
continue to operate at reduced capacity.
If both compressors suffer a shutdown failure, or are
manually stopped, the DX Box will indicate a Trip
(shutdown) condition.
In base-load mode the DX Box will fully load both
compressors to provide full base-load capacity output.
The DX Box ‘group’ unit should be set as a variable
output unit on the X8I or X12I. The X8I or X12I will fully
utilize the variable output capacity capability of the DX
Box ‘group’ and report the percentage of utilization of the
‘group’ in the same manner as a single variable output
compressor.

6
 SECTION 4 — INSTALLATION
It is recommended that installation and commissioning be
carried out by an authorized and trained product supplier. The cable used between the X8I or X12I and the DX
Box is Belden 9841 (or equivalent). It should be run in
grounded conduit and should not be greater than 4000
UNIT LOCATION feet (1219 meters) in length.
The DX Box is wall mounted using conventional
screws/bolts. The maximum distance between the X8I or RS485 data communications and other low voltage
X12I and the DX Box is 4000ft (1219 meters) of cable signals can be subject to electrical interference. This
length. The maximum distance between the DX Box and potential can result in intermittent malfunction or anomaly
each compressor is 330ft (100 meters) of cable length that is difficult to diagnose. To avoid this possibility
and within 330ft (100 meters) of cable length from any always use earth shielded cables, securely bonded to a
pressure sensor option (if applicable). known good earth at one end. In addition, give careful
consideration to cable routing during installation.
POWER SUPPLY a) Never route an RS485 data communications or low
voltage signal cable alongside a high voltage or 3-phase
A fused switching isolator must be installed to the main power supply cable. If it is necessary to cross the path of
incoming power supply, external to the DX Box. The a power supply cable(s), always cross at a right angle.
isolator must be fitted with a properly sized fuse to
provide adequate protection to the power supply cable b) If it is necessary to follow the route of power supply
used (in accordance with local electrical and safety cables for a short distance (for example: from a
regulations). compressor X8I to a wall along a suspended cable tray)
attach the RS485 or signal cable on the outside of an
XPM-TAC24 earthed cable tray such that the cable tray forms an
1 2 3 4 1 2 3 4 earthed electrical interference shield.
X04
c) Where possible, never route an RS485 or signal cable
N L E E VOLTAGE SELECT near to equipment or devices that may be a source of
X01 230Vac electrical interference (for example: 3-phase power
1 2 3 4 supply transformer, high voltage switchgear unit,
N L E frequency inverter drive module, radio communications
X04
antenna).
VOLTAGE SELECT

115Vac

Power Supply Terminals

Ensure that the voltage select input is properly

jumpered for the incoming power. Default voltage
configuration is 230Vac.

RS485 NETWORK
The DX Box is equipped with an RS485 network
communications capability using the IR485 protocol. The
DX Box is intended to operate as part of the X8I and X12I
automation systems.
Connection to the automation network is two-wire,
twisted pair, earth shielded RS485 data cable. Connect
the RS485 data cable wires to terminal X07 located on
the rear of the DX Box main controller.

X07
L1 30 L1
L2 29 L2
28 RS485
27

Polarity is important.

7
DX BOX AND ir-PCB COMPRESSOR
CONNECTIVITY
The ir-PCB is designed to interface a compressor with
the DX Box using a 6-conductor shielded cable or
individual wires run through grounded conduit no greater
than 330 feet (100 meters) in length.
Each compressor in the system must be assigned a
unique identification number from 1 up to the number of
compressors in the system. The identification number
should be clearly indicated on each compressor for
operational reference. All compressors connected to the
DX box are assigned the same identification number.
The DX box compressors will also be assigned a
secondary identification number, either 1 or 2, to indicate
position on the DX box.
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 alarm 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 and has no fault
condition inhibiting operation and is ready to respond to
DX regulation without manual intervention.
READY LAMP 0V
+V

For each compressor connected to the DX utilizing an ir-

PCB, the signal wires must be connected to the DX
terminals dedicated for the assigned compressor
reference number.
The ir-PCB is a DIN rail mountable module designed to
be installed within the compressor starter enclosure.
ALARM RUN READY
C04

The READY input will accept 12V to 250V ac (50/60Hz)

or dc.
C01 C02 C04
Do not connect a voltage greater than 250Vac/dc to
ir-PCB #1 this input.
This input must be connected to the terminals of a ready
C03
V 1 2 3 4 5 6 C05 or ‘operational’ lamp, or other circuit of the compressor
control system, that will be energized when the
compressor is in a started (auto-restart or running)
LED 1LED 2
condition.
The voltage to this input must de-energize when the
V compressor is stopped via local stop button and unable
to produce air, or if the Emergency Stop button is
X01
pressed, or when the compressor experiences a fault that
prevents the compressor from running.
V1 1 2 3 4 5 6 When the compressor ready lamp, or other control circuit,
is energized the ir-PCB will detect the voltage and signal
the DX that the compressor is ready and available to
ir-PCB Interface Module produce air when a load request signal is given.
Each air compressor must be equipped with a
load/unload regulation system and, if not regulated with a The ir-PCB input common terminal must always be
single electro-mechanical pressure switch, have a facility connected to the neutral, common, or 0V line of the
for a remote load/unload control with the ability to accept applied input voltage.
a volt-free switching contact input for remote load/unload.

Consult the X Series Interconnect and Application

Guide prior to the installation of the DX Box and the ir-
PCB to the air compressor.
The ir-PCB uses a 12V to 250V input voltage detection
system and universal relay contact control outputs (240V
‘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 DX providing protection and voltage isolation.

8
Ready Input, Alternative Connection Method: Run Input:
In instances where a convenient voltage signal for a
compressor ready condition is not available, the Ready MAIN (LINE) CONTACTOR
input can be connected directly to a constant compressor
0V
control system power supply voltage (12V to 250Vac or
dc). This will signal the DX that the compressor is ready +V
and available at all times when power is applied to the
compressor. The DX has a built-in function to determine
when a compressor is not responding, or is in a
shutdown condition, regardless of a constant ready
signal. If the DX requests a compressor to run/load, but
fails to detect a RUN signal within 60 seconds, the DX
will regard the compressor as ‘not ready’ and indicate the
compressor as not available. If a RUN signal is detected
at any time, the DX will automatically reset the
ALARM RUN READY
compressor ‘not ready’ condition and re-establish control. C04

+Vac The Run input will accept 12V to 250V ac (50/60Hz) only
(DC cannot be used).
F1

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
0Vac 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
READY DX that the compressor is running.

Never connect the Ready input positive
connection directly to the output of a control system
transformer, always connect after a fuse or circuit
breaker.
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.
MAIN (LINE) CONTACTOR

If a normally closed contact of an Emergency Stop button

is included in the compressor power supply circuit, +V
0V
connect after the Emergency Stop button contacts. This
+V
will instantly indicate a compressor ‘not ready’ condition if 0V
the Emergency Stop button is activated. AUXILIARY SWITCH

ALARM RUN READY

C04

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, a fan contactor or a
voltage signal to a remote starter can be used.

The ir-PCB input common terminal must always be

connected to the neutral, common or 0V line of the
applied input voltage.

9
Alarm Input (optional):
OUTPUT FUNCTIONS
The ir-PCB is equipped with an alarm (warning) input
that can be used to detect alarm (warning) conditions. The DX will control the ir-PC’ load/unload relay outputs in
accordance with the active system load and unload
A fault, that stops the compressor, and/or prevents pressure set points. The ir-PCB load/unload relay
the compressor from running, is determined from the Run contacts can be used for compressor controllers that
and Ready inputs; Alarm detection is optional and is not have pressure switch load/unload regulation.
a requirement. ir-PCB Internal Output Circuits
Alarm Lamp
0V C
+V OUT
1
NO Load

Seq

IN
OUT NO
C
IN
3
C
OUT
2 IN
NC
NC

Alarm Run Ready

SEQ LOAD Contacts :-
C04 Relay Relay 250Vac/dc @ 5A
1&2 3 maximum
The Alarm input will accept 12V to 250V ac (50/60Hz) or
dc.
C03
Do not connect a voltage greater than 250Vac/dc to
this input.
SEQ LOAD GND DI1 DI2 +20V
This input can be connected to the terminals of an alarm CONT UNL

lamp or other accessible part of the control circuit that is

energized when the compressor is in an alarm condition.
If an alarm condition is experienced the compressor
alarm lamp, or alarm circuit, will energize. The ir-PCB will
detect the voltage and signal the DX that an alarm has
occurred. If the compressor has no accessible alarm
circuit, or this function is not required, the ir-PCB alarm
terminals can be ignored.
The ir-PCB input common terminal must always be
connected to the neutral, common or 0V line of the
applied input voltage.
24Vac
The C01 and C02 terminal functions of the ir-PCB are
intended to control load and unload regulation of the
compressor.
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 DX 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 DX
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.

10
Two Wire Pressure Switch Connections: C01: Load and Sequence Connection:

0V

+V +VDC +VDC
VFD/Fixed
LOAD
SOLENOID Load Enable
Load/Unload
Load Enable
Load/Unload

ir-PCB
NO

NC
C
NO

NC

OUT IN
C02

Three Wire Pressure Switch Connections:

The VFD/Fixed Output terminal is not applicable for
LOAD
SOLENOID
CX Box connections.

0V
+V Compressors that use electronic pressure detection
but are not equipped with a remote pressure control
enable feature will not automatically revert to local control
RUN-ON
TIMER
if the DX is stopped or experiences a fault or loss of
power.

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
C
NO

NC
C

NC
NO

OUT IN
alternative logic control connections.
C02
For Example:
If the compressor controller ‘Local/Remote Pressure
Digital Regulation Control Terminal C01:
Control’ input is a normally open type; remote when
Remote Load/Unload Regulation: closed, but the ‘Remote Load’ input is a normally closed
type; load when open, the ir-PCB pressure switch
A 4-pin connector C01 has been provided for air terminal contacts can be used to achieve the correct
compressor controllers fitted with digital inputs for switching logic.
‘Remote/Local Pressure Regulation’ providing remote
pressure regulation control. C02
This terminal provides volt free contact closure, NO Local/Remote
referenced to a common terminal pin, for: OUT C common
a) Remote Load Enable (remote/local pressure NC
Remote Load
regulation control) NO
b) Remote Load (remote load/unload) common
IN C
The ‘remote load enable’ function provides the facility to
change the compressor load regulation from internal NC

control to a remote switching source (local/remote).

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 CX is stopped or experiences a fault or loss of
power.

11
Examine the ir-PCB internal output circuit diagram to
establish any desired switching logic that may differ from
normal practice.
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.
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.
Service Maintenance Switch:
The ir-PCB is equipped with a volt-free input (terminal
C05) that can be used to remove the compressor from
automation control, without generating a fault condition,
during short-term maintenance or servicing periods.
1 length.
2
C05
DX BOX AND PRESSURE SENSOR
CONNECTIVITY
System Pressure Sensor
Required for DX Box operation.
A pressure sensor input is available for monitoring local
‘system’ or ‘dry-side’ pressure downstream of local air
treatment or other potential restrictions to air flow. This
input is intended for a 4-20mA type pressure sensor.
The pressure sensor should be installed in such a
manner as to be able to sample atmospheric pressure
during routine calibration procedures. It is recommended
that a valve be used that will allow the sensor to be
removed without de-pressurization of the air system.
Connect the pressure sensor to the ‘System’ (REF)
pressure sensor input terminals of the DX Box.
The pressure sensor must be connected to the DX box
using an earth screened, two-core (20 AWG, 0.5mm2
CSA minimum), cable no greater than 330ft (100m) in
- -
26
+
25
+

When the Service Maintenance Switch input terminal

pins are connected together, using a volt-free switching X05
contact, the DX will indicate that the compressor is not
available but will not generate an Alarm, Trip or
Shutdown condition. The automation system will remove
the compressor from the sequence strategy and Polarity is important.
substitute with an alternative available compressor if
necessary. When the Service Maintenance Switch inputs
Some types of pressure sensor are not suitable for
are open circuit again the compressor will automatically
direct exposure to water (e.g. rain, condensate, steam or
be accepted back in to the sequence strategy and will be
excess moisture) or direct sunlight. In this instance the
utilized as and when next required.
sensor must be protected from the environment if it is to
The use of a key switch is recommended for this purpose be mounted in a location exposed to climatic or adverse
in order to prevent the switch contacts being conditions.
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

12
Discharge Pressure Sensor (optional)
DX BOX AND I/O CONNECTIVITY
The compressor discharge pressure option can provide
local over-pressure protection and air treatment Auxiliary Fault Inputs (Option)
differential monitoring.
The DX Box is equipped with two auxiliary fault inputs,
P1 one dedicated to each compressor. The input(s) can be
used to detect a compressor ‘Alarm’ or ‘Shutdown Trip’
Ps condition. The input(s) can also be used to detect a fault
#1 condition of auxiliary equipment associated with the
compressor.
DP#1 The function of each fault input can be selected in the DX
P2 Box menu:
1: Alarm (Warning)

#2 The system management unit will display the fault as a

compressor ‘Alarm’ condition; the compressor will
DP#2 continue to run and be utilized as required.

Compressor Discharge Pressure: 2: Trip

A pressure sensor input is available for each compressor The system management unit will display the fault as a
connected to the DX Box. This input is intended for a 4- compressor ‘Shutdown Trip’ condition; the compressor
20mA type pressure sensor that is installed to monitor will be removed from sequence and will not be utilized.
the discharge pressure of the applicable compressor.
It is recommended the pressure sensor should be X04
installed up-stream of (before) any isolation valve and in
18
such a manner as to be able to sample atmospheric #2 Fault Comp #1
17
pressure during routine calibration procedures.
16
#1 Fault Comp #2
Connect the pressure sensor to the correct DX Box 15
terminals for the applicable compressor.
As default the auxiliary fault input(s) are normally open,
The pressure sensor must be connected to the DX box
Fault on closed circuit condition. If required this can be
using an earth screened, two-core (20 AWG, 0.5mm2
reversed in the DX Box menu to be normally closed,
CSA minimum), cable no greater than 330ft (100m) in
Fault on open circuit.
length.
- The maximum cable length for an Auxiliary ‘Fault’
X05 input is 330ft (100m).
+
- Remote Output (Option)
24 #2
+
#2
23 Remote Output R4
- -
22
#1 + The DX Box is equipped with a remote relay contact
21
+ output; terminal X03. The function of the output can be
defined in the DX Box menu. The contacts of the remote
#1 relay output can be used to switch an external device or
signal a remote condition or fault condition.

X03
Polarity is important. 14
R2
13

The remote relay contacts are rated for 24Vac/dc @ 5A

maximum.

13
 SECTION 5 — DISPLAY AND MENU OPERATION
OPERATION Press UP and DOWN to view the status, ‘Delivery’
pressure (if enabled) and ‘Differential’ pressure (if
Keypad applicable) for each compressor in the ‘group’.

a b c
g

f d

h e
a) Start
b) Reset
c) Stop
d) Menu
e) Enter
f) Escape (Cancel)
g) Up (Plus)
h) Down (Minus) When viewing the status or pressure information for a
compressor the ‘network address’ and DX Box
Display identification will be show on the upper display (for
example, “C.03.1” indicates that the compressor is
connected to the DX Box as compressor #1 and the DX
Box is represented on the system management unit as
compressor number “03”). The status of the compressor
will also be show using the ‘Run’ and ‘Load’ symbols.

Main Screen
The primary display value (A) will continuously show the
detected ‘System’ pressure. The pressure is derived
If the discharge pressure sensor option for a compressor
from the System Pressure sensor. The lower display (B)
has not been enabled the lower display line will not be
will show the percentage load of the DX Box ‘group’.
shown and the differential pressure item will not be
User Menu Items available.
To view the ‘User Menu Items’ (B), Press UP or DOWN.
The ‘Item’ display value will scroll through the available
items.

P.-C>: System pressure and % Output

C#1-P>: Compressor #1 Discharge Pressure
C#1- P: Compressor #1 Differential Pressure
C#2-P>: Compressor #2 Discharge Pressure
C#2- P: Compressor #2 Differential Pressure

14
Status Symbols Indicators
The Status display will continuously show the current Run Indicator (Green LED)
state of the DX Box (C) by using the following icons.
OFF DX Box Fault condition
Power Failure Auto Restart (always on)
ON Active
Communicating with the X8I or X12I (DX Box is in Fault Indicator (Red LED)
Remote Mode)
OFF – No fault
Flashing - No Communications with the X8I or
X12I (DX Box is in Local Mode) Slow Flash:

One, or both, Compressors are loaded 1: Compressor Alarm

One, or both, compressors are switched to service
maintenance mode.
One, or both, compressors have exceeded the set
pressure limit
1: Compressor Alarm
2: Auxiliary Alarm input active
3: Discharge Pressure Sensor fault
2: Pressure Sensor fault (display “- - - -“)
Fast Flash:
1: Any Compressor Not Available
Compressor Identification
Each compressor connected to the DX Box will have an
assigned compressor identification number #1 or #2.
Ingersoll Rand

102 psi

(display “- - - -“) A: 85%

1: Compressor Not Available DX

2: Auxiliary Trip input active

1 2 #1
3 #2
Compressor Status:

Compressor Running
Compressor Loaded
Flashing – Compressor Not Responding,
Compressor not running after a load signal has
been sent.
Service Maintenance function active
Pressure Limit Exceeded
1: Compressor Alarm
2: Auxiliary Alarm input active
3: Pressure Sensor fault (display “- - - -“)
The DX Box will also have an unique system address
identification and will be represented on the system
management unit as a single entity using the address
identification number. The identification number will be
unique in the system.
For example, “C.03.1” indicates that the compressor is
connected to the DX Box as compressor #1 and the DX
Box is represented on the system management unit as
compressor number “03”.
Operation
The DX Box is always active (started) and cannot be
stopped. The DX Box will automatically switch between
‘Remote’, when under X8I or X12I control, or ‘Local’
mode, when not under X8I or X12I control.
Power Failure Auto-Restart

1: Compressor Not Available The DX Box will always automatically start when power is
re-applied after a power supply disruption or failure.
2: Auxiliary Trip input active

15
Failure Modes
If communications with the X8I or X12I is disrupted, the
DX Box will switch to ‘Local’ mode and pressure
regulation control is maintained using the set pressure
set points.
The DX Box will automatically switch back to ‘Remote’
mode when communications with the X8I or X12I are re-
established, or the DX Box fault is reset.
If a fault occurs with the DX Box, or power to the DX Box
is disrupted, 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).

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 DX Box unit.
Compressor Fault
If a compressor fault condition is detected the ‘status’
display will show an ‘Alarm’ condition. The ‘status’ display
associated with the compressor will also indicate a fault
condition (see Status Symbols).
The DX Box ‘Fault’ indicator will flash to attract attention.
Compressor fault conditions will also be communicated to
the system management unit controller.

16
 SECTION 6 — COMMISSIONING
When commissioning the DX Box, 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 DX Box, 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 DX Box 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.
3. Check and ensure all pressure sensor, ir-PCB
and other connections are correctly installed
and secure.
4. Close the front panel of the DX Box.
5. Switch on the power supply to the DX Box.
6. The control program identification will be
displayed for a short period followed by the
normal operational user display.
X8I OR X12I AUTOMATION SYSTEM
Ensure the connection type for the DX Box compressor
address is defined as “IR-485” (RS485 network
communication) in the X8I or X12I configuration.
Each DX Box ‘group’ connected to an X8I or X12I must
be assigned a unique compressor identification number
(1 to the maximum number of compressors). This
number will be the ‘network address’ number for the DX
Box ‘group’. This number, and the DX Box identification
(‘1’ or ‘2’), should be clearly marked on the compressor
for identification purposes; for example ‘3(#1)’.
Ingersoll Rand
102 psi
A: 85%
DX
1 2 #1
3 #2
Indicate each compressor connected to the DX Box using
the DX Box compressor system identification number and
the compressors local reference number #1 or #2.
Example:
Compressor #1 = network address 3(#1)
Compressor #2 = network address 3(#2)
The local DX Box reference numbers (#1 and #2) have
no meaning for X8I or X12I identification and referencing;
it is not important for compressors to be connected to the
DX Box in numerical order or sequentially. The X8I or
X12I will indicate both compressors as a single unit with
one identification number.
17
 SECTION 7 —SYSTEM CONFIGURATION
MENU NAVIGATION
Display Item Structure:
All value, parameter or option selection displays are
grouped into menu lists. Items are assigned to a list
according to type and classification. Items that can be
used to select options or modify functions are assigned to
‘menu mode’ lists. Items that a User may require to view
during routine operation, detected pressure for example,
are assigned to the normal operational mode list. Lists
are identified by page number; the normal User display
list is page ‘P00’. All parameters and options are
assigned to menu mode pages ‘P01’ or higher. All Page
‘P00’ items are view only and cannot be adjusted.
Normal Operational Mode
(Page P00):
At controller initialization, all display elements and LED
indicators are switched on for three seconds, the display
will then show the software version code for a further 3
seconds before initialization is complete and the normal
operating display (Page P0) is shown. In page P00
‘normal operational display mode’ the main display will
continuously show the detected delivery pressure and the
Item display will show the first item of the ‘User’ menu.
User menu ‘Items’ can be selected using the Up or Down
buttons at any time. 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 slow flash. To unlock an Item display press
Up or Down to view an alternative Item display or press
Reset or Escape. No Item values, options or parameters
can be adjusted in page ‘P00’. If a fault condition occurs
the fault code becomes the first list item and the display
will automatically jump to display the fault code. More
than one active fault code item can exist at any one time.
Page 0
Item 1 Value
Item 2 Value
Item 3 Value
Item 4 Value
Item 5 Value
Item 6 Value
ACCESSING THE DX CONFIGURATION
SCREENS
Access Code:
Access to page list displays higher than page ‘P00’ is
restricted by access code. To access menu mode pages
press MENU, an access code entry display is shown and
the first code character will flash. Use PLUS or MINUS to
adjust the value of the first code character then press
ENTER. The next code character will flash; use UP or
DOWN to adjust then press ENTER. Repeat for all four
code characters.
If the code number is less than 1000 then the first code
character will be 0(zero). To return to a previous code
character press ESCAPE. When all four code characters
have been set to an authorized code number press
ENTER. An invalid code will return the display to normal
operational mode; page ‘P00’.
Access Code Timeouts:
When in menu mode, if no key activity is detected for a
period of time the display will automatically reset to the
normal operational display; Page ‘P00’.
Menu Mode Navigation:
In menu mode the main value display will flash and show
the Page number. To select a page press UP or DOWN.
For each page the display will show the first Item of the
page list. To view a page list press ENTER, the Page
number will stop flashing and the Item display will flash.
Press UP or DOWN to view the selected page list items.
To select an Item value for modification press ENTER,
the Item display will stop flashing and the Value display
will flash. The value or option can now be modified by
pressing UP(Plus) or DOWN(Minus). To enter a modified
value or option in memory press ENTER; alternatively the
modification can be abandoned, and the original setting
maintained, by pressing ESCAPE.
Page 1
Page 2
Page 3 Item 1 Value
Item 2 Value
Page 4
Item 3 Value
Page 5 Item 4 Value
Item 5 Value
18
Press ESCAPE at any time in menu mode to step
backwards one stage in the navigation process. Pressing
ESCAPE when the page number is flashing will exit
menu mode and return the display to normal operational
mode; page ‘P00’.

Page 0 Page 1

Page 2
Item 1 Value
Item 2 Value Page 3
Item 1 Value
Item 3 Value Item 2 Value
Page 4
Item 4 Value Item 3 Value
Item 5 Value Page 5 Item 4 Value
Item 6 Value Item 5 Value

Press and hold RESET for two seconds at any time

to immediately exit menu mode and return to the normal
operational mode display. Any value or option adjustment
that has not been confirmed and entered into memory will
be abandoned and the original setting maintained.

A flashing Key symbol displayed with any Item

indicates the Item is locked and cannot be modified. This
will occur if the Item is view only (non adjustable) or in
instances where the item cannot be adjusted while the
DX Box is in ‘Remote Mode’.

19
 Menu 1 – Compressor #1
MENU ITEMS AND SETTINGS
Menu items for compressor #1
Menu 1 – Comp #1 Settings Pc: Percent Capacity
1 Pc Comp #1 Percent Capacity Set to the percentage output compared to the total output
2 D3 ‘ir-PCB’ Alarm Input 0V/+V (Di3) of the DX Box ‘group’.

3 D6 Auxiliary Input (Di6) For example: If compressor #1 = 325cfm and compressor

#2 = 175cfm then the total output is 500 cfm.
Compressor #1 = 325cfm/500cfm = 65%
Menu 2 – Comp #2 Settings
D3: ir-PCB Alarm Input NO/NC
1 Pc Comp #2 Percent Capacity
ir-PCB Alarm input configuration for compressor #1.
2 D5 ‘ir-PCB’ Alarm Input 0V/+V (Di5)
As default the ir-PCB Alarm input (optional) will generate
3 D7 Auxiliary Input (Di7) an Alarm (Warning) condition when voltage (12V to
250V) is applied to the Alarm input terminals (‘no’).

Menu 3 – Configuration This configuration can be changed so that a constant

voltage can be applied to the Alarm input terminals and
1 Ad DX Box network Address an Alarm generated when the voltage is removed. (‘nc’).
2 Mo Mode ‘no’ (normally open) – default
3 Rt Rotation Interval time Alarm when voltage applied.
4 St Start Delay time ‘nc’ (normally closed)
5 P> Pressure display units Alarm when voltage removed.
6 R4 Auxiliary Output Function (R4)
Set to default ‘no’ if not used.
D6: Auxiliary Input
Menu 4 – Regulation Control
Selects the function and operation of the ‘Auxiliary Input’:
1 C> Control percent (view only)
Ano Alarm: (normally open) – default
2 Pf P Factor
Alarm when closed
3 If I Factor
Anc Alarm: (normally closed)
Alarm when open
Menu 5 – System Pressure Sensor
Tno Trip: (normally open)
2 Po Offset Calibration
Trip when closed
3 Pr Range Calibration
Tnc Trip: (normally closed)
Trip when open
Menu 6 – Comp #1 Pressure Sensor
1 PE Enable Set to default ‘Ano’ if not used.

2 PL Pressure Limit
3 Po Offset Calibration
4 Pr Range Calibration

Menu 7 – Comp #2 Pressure Sensor

1 PE Enable
2 PL Pressure Limit
3 Po Offset Calibration
4 Pr Range Calibration

Menu 8 - Diagnostics
See ‘Diagnostics’

Access Code = 0021

20
Menu 2 – Compressor #2
Menu items for compressor #2
Pc: Percent Capacity
Set to the percentage output compared to the total output
of the DX Box ‘group’.
For example: If compressor #1 = 325cfm and compressor
#2 = 175cfm then the total output is 500cfm:
Compressor #2 = 175cfm/500cfm = 35%
D5: ‘ir-PCB’ Alarm Input NO/NC
‘ir-PCB’ Alarm input configuration for compressor #2.
As default the ‘ir-PCB’ Alarm input (optional) will generate
an Alarm condition when voltage (12V to 250V) is applied
to the Alarm input terminals (‘no’).
This configuration can be changed so that a constant
voltage can be applied to the Alarm input terminals and
an Alarm generated when the voltage is removed. (‘nc’).
‘no’ (normally open) – default
Alarm when voltage applied.
‘nc’ (normally closed)
Alarm when voltage removed.

Set to default ‘no’ if not used.

D7: Auxiliary Input
Selects the function and operation of the ‘Auxiliary Input’:
Ano Alarm: (normally open) – default
Alarm when closed
Anc Alarm: (normally closed)
Alarm when open
Tno Trip: (normally open)
Trip when closed
Tnc Trip: (normally closed)
Trip when open

Set to default ‘Ano’ if not used.

21
Menu 3 – Configuration R4: Auxiliary Output Function
DX Box configuration items Selects the function of the auxiliary relay contact output
R4
Ad: Network Address
Fno: Compressor Fault N/O
The DX Box network address must be set to the
compressor identification number used by the system The output is energized if a compressor Alarm or
management unit controller for the DX Box ‘group’ (1 to Trip fault is detected.
12). Each DX Box and/or compressor in a system must
have a unique identification number. Fnc: Compressor Fault N/C

Note: The DX Box network address number must be The output is de-energized if a compressor Alarm
unique and must not be set the same as any other or Trip fault is detected.
compressor or DX Box in a system. C1r: Compressor #1 Running
Mo: Mode (see: Operation) The output is energized when compressor #1 is
0: Timer Rotation detected as running.

1: Automatic (default) C2r: Compressor #2 Running

Rt: Rotation Interval Time The output is energized when compressor #2 is

detected as running.
1 to 24 Hours (24hrs default)
Crr: Compressor Running
The time interval between Trim and Base-Load rotation
of the compressors connected to the DX Box. The output is energized if compressor #1 and/or
compressor #2 is detected as running.
Note: Only applicable in Timer Rotation mode.
On: X8I or X12I On
St: Start Delay Time
The output is energized when the X8I or X12I is
If it is necessary for the DX Box to start the motors of regulating to achieve or maintain pressure (The
both compressors together, compressor #2 will not be output is off when the X8I or X12I is in standby or
started until the start delay time has expired after stopped).
compressor #1 has been started. Set this parameter to
the star/delta time of the largest compressor in the group. AC: X8I or X12I Active

P>: Pressure Units The output is energized when the X8I or X12I is
actively maintaining control of compressors,
Selects the display pressure units: inclusive of Standby (The output is off when
stopped; unless the X8I or X12I is set to force
0: bar (default) compressors to unload when stopped)
1: psi rPC: Remote Pressure Control
2: kPa The output is energized when in ‘Remote Mode’
i.e. X8I or X12I control.
CS: Compressor(s) in Maintenance Mode
The output is energized when one, or both,
compressors have been switched to
Service/Maintenance mode.

22
Menu 4 – Regulation Control
C>: Control percent (view only)
The DX Box uses a P&I pressure control algorithm to
determine compressor utilization. The control algorithm
produces a percentage value that is compared to the
percentage settings of each compressor. This control
percentage will increase and decrease in response to
changes in local system pressure ‘SP’. When the DX Box
is operating in conjunction with an X8I or X12I the
algorithm target response is automatically manipulated to
match the system requirements.
Pf: Proportional Factor (default 40)
If: Integral Factor (default 30)
Example % Control Functions:
The following graph shows the control percentage when
two equal sized compressors are connected to the DX
box. This gives the DX box the capabilities of a 3-step
compressor with steps of 0%, 50%, and 100%.
The next graph illustrates the control percentage when
two compressors of different capacities are connected to
the DX box. This gives the DX box the capabilities of a
4-step compressor with steps of 0%, 35%, 65%, and
100% of capacity.
When the control percentage is rising and calculated to
be less than 50% the DX box will load the smaller
compressor. If the control percentage continues to rise
to 82.5% the DX box will unload the smaller compressor
and load the larger compressor. If the control percentage
continues to rise to 100% the DX box will load both
compressors.
If the control percentage is falling and reaches 50% and
both compressors are loaded, the DX box will unload the
smaller compressor and keep the larger compressor
loaded. If the control percentage continues to fall to
17.5% the DX box will unload the larger compressor and
load the smaller compressor. If the control percentage
continues to fall to 0% the DX box will unload both
compressors.

When the control percentage is rising and calculated to 65:35%

Control
be less than 75% the DX box will load the first
100.0
compressor and when the control percent reaches 100%
the second compressor will load. %
90.0 ‘x’
If the control percentage is falling and reaches 25% and 82.5%
both compressors are loaded, compressor #2 will unload. 80.0
If the control percentage continues to fall compressor #1
‘x’
will unload at 0% control percentage. 70.0
65%
50:50%
Control 60.0
‘y’
100.0
50.0%
% 50.0
90.0 ‘x’ ‘y’
40.0
35%
80.0
75.0%
30.0
70.0 ‘z’

20.0 17.5%
‘x’
60.0
10.0 ‘z’
50%
50.0
0.0
40.0 A B A+B
‘y’ Display: 35% 65% 100%
30.0
25.0%
Do not adjust the ‘P’ and/or ‘I’ factor setting(s) unless
20.0 you are familiar with the P&I control response and the
function of these settings within the P&I control algorithm.
‘y’
10.0

0.0
A A+B
Display: 50% 100%

23
Menu 5 – System Pressure Sensor
The (Ps) System Pressure Sensor is a requirement
of DX Box operation and must be installed and
commissioned.
The System pressure sensor (Ps) input is intended for
monitoring system, or dry-side pressure downstream of
local air treatment or other potential airflow restriction that
may cause a pressure differential.
P1
Po Offset Calibration
The value can be adjusted between -15 and +22psi (–
1.5bar and +1.0bar).
Default = 0psi (0.0 bar)
The offset value can be used for atmospheric (0psig/bar-
g) calibration; expose the sensor to atmosphere and
adjust until the display pressure shows 0psi (0.0 bar).
The main display value will show the actual detected
pressure when this menu item is selected.

Ps For sensors with negative offset values any detected

pressure below 0psi/bar will be displayed, and
#1 transmitted on the network, as 0psi/bar.

DP#1 Pr Range Calibration

P2 The value can be adjusted for any sensor range between
15psi (1.0bar) and 9135psi (630 bar). Default = 232psi
(16.0 bar).

#2 If the sensor does not have a 0psi/bar offset, the range

value must be the same as the ‘maximum’ pressure
DP#2
value of the sensor.
For example: if the sensor is a –10psi (-0.69bar) to 200
psi (13.8 bar) type then:
P1 Offset = -10psi Range = 200psi
Ps
#1 The range value can be used for calibration: expose the
senor to a known accurate pressure and adjust the range
value until the display pressure matches the applied
pressure. The main display value will show the actual
detected pressure when this menu item is selected.

DP#1/2

#2
P2
The System pressure is broadcast on the network and
can be used for advanced X8I or X12I pressure control.

24
Menu 6 – Compressor #1 Pressure Sensor Po Offset Calibration

P1 The value can be adjusted between -15 and +22psi (–

#1
DP#1
The Compressor #1 pressure sensor (P1) input is
intended for monitoring the discharge pressure of
compressor #1 prior to any isolation valve and air
treatment or other potential air flow restriction that may
cause a pressure differential.
1.5bar and +1.0bar).
Default = 0psi (0.0 bar)
The offset value can be used for atmospheric (0psig/bar-
g) calibration; expose the sensor to atmosphere and
adjust until the display pressure shows 0psi (0.0 bar).
The main display value will show the actual detected
pressure when this menu item is selected.
For sensors with negative offset values any detected
pressure below 0psi/bar will be displayed, and
transmitted on the network, as 0psi/bar.

PE: Pressure Sensor Option Enable Pr Range Calibration

4-20mA auxiliary pressure sensor enable The value can be adjusted for any sensor range between
15psi (1.0bar) and 9135psi (630 bar). Default = 232psi
0: Disable (default) (16.0 bar).
1: Enable If the sensor does not have a 0psi/bar offset, the range
value must be the same as the ‘maximum’ pressure
A compatible ‘4-20mA’ type pressure sensor must be
value of the sensor.
connected to the DX Box compressor #1 pressure sensor
input. For example: if the sensor is a –10psi (-0.69bar) to 200
psi (13.8 bar) type then:
When enabled, the pressure will be displayed with
compressor #1 status. Offset = -10psi Range = 200psi
PL: Pressure Limit The range value can be used for calibration: expose the
senor to a known accurate pressure and adjust the range
When pressure detection is enabled, and the pressure
value until the display pressure matches the applied
sensor used to detected compressor discharge, or ‘wet-
pressure. The main display value will show the actual
side’ pressure, this function can be implemented. The
detected pressure when this menu item is selected.
maximum pressure limit function is intended to protect
the compressor from local excess pressure conditions
when pressure is being regulated remotely; for example,
from the system management unit that is using system,
or ‘dry-side’ pressure for regulation control. If the set
pressure limit is exceeded the compressor will be
unloaded, regardless of remote load command.
The compressor will be inhibited from loading again until
the detected pressure has reduced below the set limit,
and remains below the set limit, for longer than 10
seconds. If, after re-loading, pressure exceeds the limit
again, the cycle is repeated.
When pressure exceeds the set limit the excess pressure
symbol will flash in the appropriate compressor status
display. This indication will remain until manually reset.
To deactivate adjust to 0(zero) – default.

25
Menu 7 – Compressor #2 Pressure Sensor Po Offset Calibration

P2 The value can be adjusted between -15 and +22psi (–

#2
DP#1
The Compressor #1 pressure sensor (P1) input is
intended for monitoring the discharge pressure of
compressor #1 prior to any isolation valve and air
treatment or other potential air flow restriction that may
cause a pressure differential.
PE: Pressure Sensor Option Enable
4-20mA auxiliary pressure sensor enable
0: Disable (default)
1.5bar and +1.0bar).
Default = 0psi (0.0 bar)
The offset value can be used for atmospheric (0psig/bar-
g) calibration; expose the sensor to atmosphere and
adjust until the display pressure shows 0psi (0.0 bar).
The main display value will show the actual detected
pressure when this menu item is selected.
For sensors with negative offset values any detected
pressure below 0psi/bar will be displayed, and
transmitted on the network, as 0psi/bar.
Pr Range Calibration
The value can be adjusted for any sensor range between
15psi (1.0bar) and 9135psi (630 bar). Default = 232psi
(16.0 bar).

1: Enable If the sensor does not have a 0psi/bar offset, the range
value must be the same as the ‘maximum’ pressure
A compatible ‘4-20mA’ type pressure sensor must be value of the sensor.
connected to the DX Box compressor #1 pressure sensor
input. For example: if the sensor is a –10psi (-0.69bar) to 200
psi (13.8 bar) type then:
When enabled, the pressure will be displayed with
compressor #1 status. Offset = -10psi Range = 200psi

PL: Pressure Limit The range value can be used for calibration: expose the
senor to a known accurate pressure and adjust the range
When pressure detection is enabled, and the pressure value until the display pressure matches the applied
sensor used to detected compressor discharge, or ‘wet- pressure. The main display value will show the actual
side’ pressure, this function can be implemented. The detected pressure when this menu item is selected.
maximum pressure limit function is intended to protect
the compressor from local excess pressure conditions
when pressure is being regulated remotely; for example,
from the system management unit that is using system,
or ‘dry-side’ pressure for regulation control.
If the set pressure limit is exceeded the compressor will
be unloaded, regardless of remote load command.
The compressor will be inhibited from loading again until
the detected pressure has reduced below the set limit,
and remains below the set limit, for longer than 10
seconds. If, after re-loading, pressure exceeds the limit
again, the cycle is repeated.
When pressure exceeds the set limit the excess pressure
symbol will flash in the appropriate compressor status
display. This indication will remain until manually reset.
To deactivate adjust to 0(zero) – default.

26
 SECTION 8 — DIAGNOSTICS
Relay Outputs:
The DX Box controller is equipped with comprehensive Each relay output can be energized and de-energized
diagnostic functions. Each input can be examined manually by selecting the item. Use PLUS and MINUS to
individually and each output can be manually activated or adjust ‘on’ (1) or ‘off (0) and then ENTER.
manipulated individually.
Analog Inputs:
Menu 8 – Diagnostics
The item will alternate between the detected value and
DX Box Controller Diagnostics: the electrical measurement on the input terminals. An
independent measuring device can be used to check the
Menu P06 - Diagnostics displayed electrical measurement.
D1 Digital Input 1 A1: Compressor #1 Discharge Pressure 4-20mA
D2 Digital Input 2 ON A2: Compressor #2 Discharge Pressure 4-20mA
D3 Digital Input 3 A3: System Pressure 4-20mA
OFF
D4 Digital Input 4
D5 Digital Input 5 Pulsing

D6 Digital Input 6
D7 Digital Input 7
D8 Digital Input 8
-------------------------------------------------------------
R1 Relay Output 1
R2 Relay Output 2 OFF

R3 Relay Output 3
ON
R4 Relay Output 4
R5 Relay Output 5
R6 Relay Output 6
-------------------------------------------------------------
A1 Analog Input 1 bar <> mA
A2 Analog Input 2 bar <> mA
A3 Analog Input 3 bar <> mA

Digital Inputs:
D2, D3, D4 and D5 (connected to the ‘ir-PCB’s’) are the
only digital inputs that will detect a pulsing signal.
D2/4: ir-PCB Compressor Ready/Run Status
OFF Not Ready
ON Ready
Pulsing Running
D3/5: ir-PCB Compressor Load/Maintenance
OFF Alarm (unless reversed in menu)
ON OK (unless reversed in menu)
Pulsing Service Maintenance
The pulse signal is 24VDC at 50/60Hz. A DC voltage
meter will detect this as 12VDC +-4V.

27
 SECTION 9 — FAULT CODES
In the event of a DX Box Fault, the DX will display a fault
code. The fault code becomes an item in the User
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.
Fault codes are separated in to A: Alarm (Warning) and
E: Shutdown Trip.

Compressor initiated fault states are displayed as

part of the normal operational status display and do not
generate fault codes. Examine the compressor unit to
establish the nature or description of the detected fault
condition.
DX Box Controller Fault Codes:
The DX Box has two Trip (shutdown) fault conditions:
E:0821

Short circuit condition detected, check all DX Box

controller inputs and outputs.
E:0115

PSI

System Pressure Sensor Fault

If one of these fault conditions occurs the DX Box will
switch off. The run indicator (9) will also switch off and
the fault indicator (10) will fast flash.
Pressure Sensor Fault (Option)
If a discharge pressure sensor fault is detected (if the
discharge pressure sensor option is enabled) the DX Box
will indicate a compressor alarm (warning) condition and
the associated pressure display will show “- - - -“ dashes.
The DX Box will continue to operate normally without
interruption.

28
 SECTION 10 — PART LIST
DX Box

Item Part No. Description

- 42659367 Unit, DX Box
- 23242175 Assembly, DX Box XPM
-TA
C24 2
- 80444086 Manual, User CD
- 80444490 Manual Reference Insert
1 42659441 Controller, S1 DX
2 39265913 Unit, XPM-TAC24
3 23242969 PCB, Terminal
3
4 38036703 Gland, Set - Pg13.5
1
Required For Each Compressor:
4
Item Part No. Description
5 39265905 Module, ir-PCB
5 ir-PCB 6
Accessories:
Required For System Pressure
(Optional For Compressor Discharge Pressure)

Item Part No. Description

6 39265939 Sensor, Pressure
4-20mA, 0-232 psi (0-16.0bar)
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

SECTION 11— TECHNICAL DATA

DX Box
24mm
Dimensions 11.45” x 9.45” x 6.0”   238mm

291mm x 241mm x 152mm 24mm

Weight 14Ib (6.5kg)

Mounting wall, 4 x screw fixings
Enclosure IP54, NEMA 12
188mm 236mm
Supply 230Vac +/- 10%
115Vac +/- 10%
Power 50VA
8mm Ø
Temperature 0°C to 46°C (32°F to 115°F)
Humidity 95% RH non-condensing
286mm

29
 SECTION 12— WIRING DIAGRAM

S1-10-R4-333
DX Box

C001
Controller
+VDC

29 30 31 32
C002
Ai1 C009 L1 Multi485
C003
X05
C010 L2

X07
+VDC C004
Ai2 C005
L1 Multi485
+VDC C006
L2
Ai3

27 28

X06
C007
C007
not used
X06

A-GND C008
C008
Ao

21 22 23 24 25 26
C006 - Ai3 4-20mA
RS485

C009
X07

L1 System Press.

+
C005
C010
L2 C004 - Ai2 4-20mA

X05
Pressure #2

+
8 7 6 5 4 3 2 1 C+

C011 C003
C012 C002 - Ai1 4-20mA

+
C013 C001 Pressure #1
C014

15 16 17 18 19 20
X04

C015 C011 +C
C016 C017 Di6 Aux Fault #1
C017

X04
+C
C018
C018 Di7 Aux Fault #2
C019
not used
C019
C028

C029

C026

C027
13 14

X03

C024
C020 R4 Aux Output
C025
R3 R2 R1

C021
C011
X03

10k
V2 7 8 9 10 11 12

C022 +20VDC 6

Di4 Ready/Run 5
i-PCB 2
C015
C023
X02

C016 Di5 Alarm/Serv. 4

C024 C031 - GND 3
24Vac

R4

C023 R3 LOAD 2
X01

C025
C021 1
R1 SEQ
2
1

C032
C029
+

+20VDC
2 3 4 5 6

10k 6
24Vac
XPM-TAC24

i-PCB 1

Di2 Ready/Run 5
X02

C013
X03

X01

C030
C014 Di3 Alarm/Serv. 4
1

- GND 3
C031
N

E
E
L

C022 R2 LOAD 2
X01

0Vac

V1 1

1
R1 SEQ
C027
N

E
L

230Vac 10%
115Vac 10%

30
XPM-TAC24

BLUE BLACK

BROWN ORANGE

RED WHITE
GREEN VIOLET

1 2 3 4 X04
T3.15A T1.6A T1.6A T1.0A 1 2 3 4

FH5 FH4 FH3 FH2 VOLTAGE SELECT

230V +-10%
230V

115V
115V +-10%
IEC T1.0A FH1
5x20mm
1 2 3 4
X03 X02
2 1 2 X01

N L E E

24Vac/2 24Vac/1
earthed isolated NL E

31
 SECTION 13— COMMISSIONING FORMS

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

P01 Pc Comp #1 Percent Capacity %

P01 D3 ‘i-PCB’ Alarm Input no nc
P01 D6 Auxiliary Input Ano Anc Tno Tnc

P02 Pc Comp #2 Percent Capacity %

P02 D5 ‘i-PCB’ Alarm Input no nc
P02 D7 Auxiliary Input Ano Anc Tno Tnc

P03 Ad Network Address 1 2 3 4 5 6 7 8 9 10 11 12

P03 Mo Mode Ar Tr
P03 Rt Rotation Time hrs
P03 St Start Delay Time sec
P03 P> Pressure Display Units bar psi
P03 R4 Auxiliary Output Function (R4) Fno Fnc C1r C2r Crr Eon Eac rPC CS

P04 Pf ‘P’ factor

P04 If ‘I’ factor

P05 Po System Pressure 'Offset' psi/bar

P05 Pr System Pressure 'Range' psi/bar

P06 PE Comp #2 Pressure Enable 0 1

P06 PL Comp #2 Pressure Limit psi/bar
P06 Po Comp #2 Pressure 'Offset' psi/bar
P06 Pr Comp #2 Pressure 'Range' psi/bar

P07 PE Comp #2 Pressure Enable 0 1

P07 PL Comp #2 Pressure Limit psi/bar
P07 Po Comp #2 Pressure 'Offset' psi/bar
P07 Pr Comp #2 Pressure 'Range' psi/bar

32