Ingersoll Rand System Automation Operator's Manual X8I: More Than Air. Answers

Ingersoll Rand
System Automation
X8I
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.
More Than Air. Answers. C.C.N. : 80444060

Online answers: http://www.air.irco.com
REV. : B
DATE :
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SECTION 1 — TABLE OF CONTENTS
SECTION 1 — TABLE OF CONTENTS...........................2 PRESSURE DISPLAY..................................................................26
SECTION 2 — INTRODUCTION....................................3 X8I QUICK SET-UP CONFIGURATION................................26
OPTIONAL FEATURES AND FUNCTIONS.........................26

SECTION 3 —safety.....................................................3
SECTION 9 — SYSTEM CONFIGURATION................27
INSTALLATION..............................................................................3
DISPLAY ITEM STRUCTURE...................................................27
OPERATION ..................................................................................3
NORMAL OPERATIONAL DISPLAY (MENU PAGE P00) 27
MAINTENANCE AND REPAIR..................................................3
ACCESSING THE X8I CONFIGURATION SCREENS.........27
SECTION 4 — COMPRESSOR CONNECTION AND
CONTROL .........................................................................5 USER Level Menus.................................................................29
COMPRESSOR CONNECTION AND CONTROL...............5 SERVICE Level Menus...........................................................30
OPTIONAL CONNECTION METHODS..................................5 X8I CONFIGURATION SCREENS ..........................................31
PRESSURE DETECTION AND CONTROL.............................6 X8I COMPRESSOR CONNECTIVITY AND FUNCTIONAL

SETTINGS......................................................................................41
X8I MAIN DISPLAY .....................................................................7
SECTION 10 — FAULT CODES.....................................46
SECTION 5 — INSTALLATION OVERVIEW..................8
X8I COMPRESSOR FAULT INDICATIONS, TYPES, AND
INSTALLATION..............................................................................9 CODES:...........................................................................................46
UNIT LOCATION...........................................................................9 SECTION 11 — PARTS LIST….. ...............................48
POWER SUPPLY............................................................................9 SECTION 12 — DIAGRAMS…..................................49
PRESSURE SENSOR LOCATION..............................................9 WIRING DIAGRAM……….…….....................................49
PRESSURE SENSOR CONNECTION.....................................10 CONNECTION DIAGRAM……... ...................................50

XPM-TAC24...................................... ...................................51
ir-PCB INTERFACE MODULE.................................................10
X8I COMMISSIONING FORM… ...............................52
ir-485 AND irV-485 GATEWAY MODULE........................11
ir485 COMMUNICATION PROTOCOL................................11
RS485 NETWORK.......................................................................11
SECTION 6 — CONTROL FEATURES AND

FUNCTIONS....................................................................13
STANDARD CONTROL FEATURES AND

FUNCTIONALITY........................................................................13
STANDARD CONTROL FEATURES AND

FUNCTIONALITY........................................................................15
ALTERNATE CONTROL FEATURES AND

FUNCTIONALITY........................................................................18
SECTION 7 — DISPLAY AND MENU OPERATION...20
INDICATORS................................................................................23
SECTION 8 — COMMISSIONING................................26
PHYSICAL CHECKS....................................................................26

SECTION 2 — INTRODUCTION
The X8I is an advanced system controller designed to or microprocessor based controls. The X8I is uniquely
provide safe, reliable, and energy-efficient management configurable and customizable to meet the specific needs
of your compressed air system. The X8I is capable of of some of the most complex compressed air system.
controlling up to eight (8) positive displacement air Additionally, the X8I control network can expand to
compressors. The compressors may be fixed speed, include monitoring and control of various compressed air
variable speed or multi-step and have electro-pneumatic system components.
SECTION 3 —safety
OPERATION
! WARNING : Risk of Danger
• The X8I must only be operated by competent
personnel under qualified supervision.
WARNING : Risk of Electric Shock • Never remove or tamper with safety devices, guards
or insulation materials fitted to the X8I.
WARNING : Risk of High Pressure • The X8I must only be operated at the supply voltage
! and frequency for which it is designed.
• When main power is switched on, lethal voltages are
WARNING : Consult Manual present in the electrical circuits and extreme caution
must be exercised whenever it is necessary to carry
out any work on the unit.
• Before installing or operating the X8I, take time to
carefully read all the instructions contained in this • Do not open access panels or touch electrical
manual, all compressor manuals, and all manuals of components while voltage is applied unless it is
any other peripheral devices that may be installed or necessary for measurements, tests or adjustments.
connected to the unit. Such work should be carried out only by a qualified
electrician equipped with the correct tools and
• Electricity and compressed air have the potential to wearing appropriate protection against electrical
cause severe personal injury or property damage. hazards.
• The operator should use common sense and good • All air compressors and/or other equipment
working practices while operating and maintaining connected to the unit should have a warning sign
this system. All applicable codes should be strictly attached stating ‘THIS UNIT MAY START WITHOUT
adhered to. 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 warning signs to the equipment stating ‘THIS
INSTALLATION UNIT CAN BE STARTED REMOTELY’ in a prominent
location, one on the outside of the equipment, the
• Installation work must only be carried out by a other inside the equipment control compartment.
competent person under qualified supervision.
MAINTENANCE AND REPAIR
• A fused isolation switch must be fitted between the
main power supply and the X8I. • Maintenance, repairs or modifications must only be
carried out by competent personnel under qualified
• The X8I should be mounted in such a location as to supervision.
allow operational and maintenance access without
obstruction or hazard and to allow clear visibility of • If replacement parts are required use only genuine
indicators at all times. parts from the original equipment manufacturer, or
an alternative approved source.
• If raised platforms are required to provide access
to the X8I they must not interfere with normal • Carry out the following operations before opening or
operation or obstruct access. Platforms and stairs removing any access panels or carrying out any work
should be of grid or plate construction with safety on the X8I:
rails on all open sides. i. Isolate the X8I from the main electrical power
supply. Lock the isolator in the ‘OFF’ position
and remove the fuses.

ii. Attach a label to the isolator switch and to the • The X8I must only be cleaned with a damp cloth,
unit stating ‘WORK IN PROGRESS - DO NOT using mild detergents if necessary. Avoid the use of
APPLY VOLTAGE’. Do not switch on electrical any substances containing corrosive acids or alkalis.
power or attempt to start the X8I if such a
• Do not paint the control faceplate or obscure any
warning label is attached.
indicators, controls, instructions or warnings.
• 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.

SECTION 4 — COMPRESSOR CONNECTION AND CONTROL
COMPRESSOR CONNECTION AND
CONTROL
irV- 485
Each air compressor in your system must be interfaced to
the X8I. Interface methods may vary depending on the
compressor type and/or local control configuration. The
following are main methods for interfacing compressors The irV-485 Gateway interface module is installed within
to the X8I: the compressor control cabinet and connected to the X8I
1) The ir-PCB Interface module that is designed to using Belden 9841 or equivalent RS485 cable.
interface to any positive displacement air compressor Nirvana 7.5 to 15HP (5.5 to 11KW) connect via the
(regardless of make or manufacturer) with an available ir- PCB using seven (7)-wire cable.
control voltage of 12-250V (either 50Hz or 60Hz).
4) Direct Connect via RS485 to any Ingersoll Rand
compressor that has an integrated RS485 network port
utilizing the ir485 protocol. The X8I communicates to
these compressors via a two wire, RS485 network. The
compressor is connected to the X8I using Belden 9841 or
equivalent RS485 cable.
4) Special Application Interface uses integration boxes
The ir-PCB interface module is installed within the designed to accommodate various types of compressor
compressor control area and connected to the X8I using and regulation methods and system monitoring.
a six (6) wire cable, (seven (7)-wire cable for Nirvana 7.5 to
15HP (5.5 to 11KW). OPTIONAL CONNECTION METHODS
Each air compressor must be equipped with an online/ Expansion Module: EXP Box (Option)
offline pressure regulation system capable of accepting a As standard the X8I has four direct connect ‘ir-PCB’
remote load/unload signal through a volt-free switching terminal connections. This capability can be extended
contact or a single electro-mechanical pressure switch. with the use of an optional EXP Box. The EXP Box will add
Consult the air compressor manual or your air another four direct connect ‘ir-PCB’ connection terminals.
compressor supplier/specialist for details before installing This would allow a total of 8 compressors to connected
the X8I. and controlled via ‘ir-PCB’ integration.
2) The ir-485 Gateway Interface module that is designed Compressors 1-4 connect via the X8I and Compressors 5-8
to interface to any Ingersoll Rand Intellisys controlled connect via the EXP Box
(Non-Nirvana) compressor. The X8I communicates to the The EXP Box is suitable for wall mounting and must be
ir-485 Gateway via a two wire, RS485 network utilizing the located adjacent to the X8I unit (max 33ft or 10m).
ir485 protocol. All IR compressors equipped with Intellisys
controllers (Non-Nirvana) require this interface. Ingersoll Rand
102 psi
1 1 2 3 4
18:35 #2
All Nirvana Compressors, 20 HP (15KW) and above

CAP
5 6 7 8
require the irV-485 Gateway.
ir-485
The EXP Box connects to the X8I controller via a two wire,
The ir-485 Gateway interface module is installed within dedicated RS485 network
the compressor control cabinet and connected to the X8I Use Belden 9841 or Equivalent In Grounded Conduit
using Belden 9841 or equivalent RS485 cable. No Greater Than 33ft (10m)
3) The irV-485 Gateway Interface module that is Up to four air compressors can be connected to the EXP
designed to interface to any Ingersoll Rand Nirvana Box using a 6 or 7 wire cable and a compressor interface
compressor. The X8I communicates to the irV-485 ir-PCB (330ft (100m) max). The ‘ir-PCB’ connections are
Gateway via a two wire, RS485 network utilizing the ir485 identical to the X8I.
protocol. All Nirvana Compressors, 20 HP (15KW) and
above, require this interface.

Remote Compressor Management; EX Box (option) The VSD Box connects to the X8I controller via a two wire,
RS485 network utilizing the ir485 protocol
The EX Box is an ‘EXtension’ to the X8I providing
additional ‘ir-PCB’ connectivity. Each air compressor in a system, that requires VSD Box
integration, must be equipped with an individual VSD
The EX Box will typically be used to provide ‘ir-PCB’
Box. Multiple VSD Boxes can be connected to the X8I as
connectivity at a remote location beyond the maximum
long as the number of compressors does not exceed the
distance specification of compressors that require ‘ir-PCB’
maximum number of compressors (8).
type connection; 330ft (100m). This effectively expands
the hardwire connection scheme of the ‘ir-PCB” to the full Remote Input & Output: I/O Box (option)
RS485 distance specification.
An I/O Box provides additional general purpose I/O
The EX box is suitable for wall mounting and can be (input/output) for a system enhancing monitoring
located up to 4000ft (1219m) from the X8I unit. capabilities and providing distributed system automation.
4000ft (1219m) max Up to two I/O Boxes can be connected to the X8I
controller. Each I/O Box features:
Ingersoll Rand
102
1
psi
1 2 3 4
8 Digital Inputs
18:35 #2
CAP
5 Analog Inputs
5 6 7 8
6 Relay Outputs
4000ft (1219) max
Ingersoll Rand
102 psi
1 1 2 3 4
18:35 #2
CAP
5 6 7 8
The EX Box connects to the X8I controller via a two wire,

RS485 network utilizing the IR485 protocol
Use Belden 9841 or Equivalent In Grounded Conduit
No Greater Than 4000ft (1219m)
One (1) or two (2) air compressors can be connected
to the EX Box using a 6-wire cable and a compressor
interface ir-PCB (330ft (100m) max). The ‘ir-PCB’
connections are identical to the X8I.
The I/O Box connects to the X8I controller via a two wire,
The EX Box also provides optional ‘local pressure sensor’ RS485 network utilizing the ir485 protocol
connections. The compressor delivery pressure, local
system pressure and air treatment differential pressure Digital inputs can be used to monitor switching contact
can be displayed. devices. Each input can be set to act as an Alarm or
High Level Alarm input. Digital inputs can also be used
Multiple EX Boxes can be connected to the X8I as long for metering (for example m3, ft3, kWh) providing an
as the number of compressors does not exceed the accumulative count of pulses from a metering device.
maximum number of compressors (8).
Analog inputs can be used to monitor sensor devices (for
Bolt-On VSD Control Integration: VSD Box (optional) example: pressure differential, temperature, dewpoint,
The VSD Box is intended to provide a method of flow, current, power, bearing condition). Each input is
system integration for a VSD (Variable Speed Drive) air equipped with adjustable high or low level detection that
compressor that is not equipped with any accessible can be used to activate an Alarm or High Level Alarm.
means of remote connectivity (such as IR- Nirvana). The Relay outputs use ‘Virtual Relay Automation’ technology
VSD Box will provide required functionality to enable and are totally configurable with duel input logic
system integration and efficient control using the X8I functions. Relay functions can be assigned utilizing any
automation system. status or condition information available on a system
network from any compatible unit connected to the
network.
30ft PRESSURE DETECTION AND CONTROL

max
The X8I utilizes the signal from a 4-20 ma pressure sensor
that is mounted remotely from the X8I in a suitable
ir-PCB location in the compressed air system.
Ingersoll Rand
102 psi
1 1 2 3 4
18:35 #2
The factory default settings for the pressure sensor is

CAP
5 6 7 8
From VSD Pressure Transducer 0–232 PSI (16 bar), but the X8I can accept any pressure
To VSD Pressure Transducer Input
sensor with a 4–20 ma output and a range of up to 8700
PSI (600 bar).

X8I MAIN DISPLAY
a b User Interface :
102
PSI a) System Pressure Value
c b) System Pressure Units
d 1 c) Unit Status
d) Unit Active Functions
e
17:30 #1 e) User Menu Item
System Alarms (Warning) :

a) Unit Run Indicator (green LED)
b) Unit Alarm Indicator (Red LED)
a System Alarms (Warning) :

a) Group Compressor Fault
b CAP
b) Insufficient Capacity Alarm (Warning)
c c) Restricted Capacity Alarm (Warning)
Ingersoll Rand
a
102 psi
1 2 3 4
b
1
A: 85% c 1
CAP
5 6 7 8
Compressor Status Indicators :

a) Load Status
b) Run Status
c) Compressor Availability
Keypad and Navigational Keys Functionality
a) Start
b) Reset
a b c
c) Stop
g
d) Menu
e) Enter
f d
f) Escape
g) Up (Plus)
h e
h) Down (minus)

SECTION 5 — INSTALLATION OVERVIEW
Ingersoll Rand Automation

Model X8I
SPECIFICATIONS The Maximum Number of Compressors Controlled By
Dimensions 13.4” x 9.45” x 6.0” Ingersoll Rand
The X8I Is Eight (8).
340mm x 241mm x 152mm The Maximum Number Of Direct ir-PCB Connections
Weight 16.5lb (7.5kg) 102 psi
1 1 2 3 4 To The X8I is Four (4).
Mounting Wall, 4 x screw fixings 18:35 #2 Any Combination Of Compressor Connection Methods
Enclosure IP65, NEMA 4 CAP
5 6 7 8 May Be Used As Long As the Maximum Number Of

Supply 230Vac +/- 10%, 50 Hz Compressors (8) Is Not Exceeded.
115Vac +/- 10%, 60 Hz
Power 100VA
Temperature 32°F to 115°F
(0°C to 46°C) The EXP Will Add Another (4)
Humidity 0% to 95% RH Direct ir-PCB connections. This
(non-condensing) Would Allow A Total Of (8)
Compressors To Be Connected
EXP And Controlled Via The ir-PCB.
Local Disconnect (Breaker) Box OPTIONAL
On/Off Supply Voltage Cable EXP RS485 Network Cable
Fused for 100VA
Switch
Power Cable EXP RS485 NETWORK CABLE
3 conductor (N, L, E) Belden 9841 or Equivalent
(Sized in accordance with local In Grounded Conduit
electrical and safety regulations). Pressure Transducer Cable No Greater Than 33FT (10)
RS485 Network Cable
PRESSURE TRANSDUCER CABLE RS485 NETWORK CABLE

2 Conductor Cable, 18 Gauge Stranded
Belden 9841 or Equivalent
Earth Shielded
In Grounded Conduit
No Greater Than 330FT (100M)
No Greater Than 4000FT (1219M)
24VDC Control Voltage
X8I X05 CONNECTOR PT CONNECTOR

25 +VDC Pin #3
26 Signal Pin #1
Reference X8I Operations Manual for Pressure ir-PCB ir-PCB
Sensor Connection Details
PRESSURE TRANSDUCER
To Plant Air
System
RECEIVER
Ir-PCB Compressor #1 Ir-PCB Compressor #2
Control Cable Control Cable
ir-PCB COMPRESSOR CONTROL CABLE

7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
OR
DRIP LEG Reference X8I Application and Interconnect Guide For Single Conductor Wire, 18 Gauge Stranded, Quantity (7)
Wiring Connections Between The X8I, The ir-PCB, In Grounded Conduit No Greater Than 330FT (100M)
and The Compressor 24VAC Control Voltage
From Air Reference X8I Application and Interconnect Guide For

Compressors The RS485 Network is a Serial, Point to Point
Wiring Connections Between The X8I, The ir-485 or irV-
Communication Network Refer to the X8I Application and
485 Gateway and The Compressor, S3 Direct Connects, and
Interconnect Guide For Wiring Details and Connectivity.
Optional Special Application Interface Boxes
ir-485 Gateway
Ingersoll
Ingersoll Ingersoll Ingersoll
Rand Rand Rand Rand
102 psi 102 psi 102 psi
ir-485
For All 102 psi
IR (Non- Nirvana) Compressors

IntelliSys “Red Eye”, SG and SE
I/O ir-485 VSD OR EX
From VSD Pressure
Direct To Transducer
S3 irV-485 Gateway
To VSD Pressure
Transducer Input For All
irV-485 Nirvana Compressors
20HP (15KW) and Above
1
2D
LE
D
LE
ir-PCB

INSTALLATION Dry side pressure will be lower than the system
It is recommended that installation and pressure due to pressure differential losses across air
commissioning be carried out by an authorized and treatment equipment. The nominal system pressure will
trained product supplier. reduce as the air treatment differential pressure increases.
UNIT LOCATION DEMAND (DRY) SIDE PRESSURE CONTROL
The X8I can be mounted on a wall using conventional

bolts. The X8I can be located remotely from the P P
1
compressors as long as it is within 330 feet (100 meters)
of cable length when connecting compressors directly
with ir-PCB’s. When connecting the X8I over the RS485
communication network the distance is up to 4000 feet 2
(1219 meters) The X8I must be located within 330 feet
(100 meters) of the system pressure transducer.
Pressure Sensor Located After Shared Cleanup
POWER SUPPLY Equipment
P P
A fused switching isolator must be installed to the main
incoming power supply, external to the X8I. The isolator
must be fitted with a properly sized fuse to provide 1
adequate protection to the power supply cable used (in
P
accordance with local electrical and safety regulations).
XPM-TAC24 2
1 2 3 4 1 2 3 4
X04
VOLTAGE SELECT
Pressure Sensor Located After Individual Cleanup
X01 230Vac Equipment
1 2 3 4
N LE X04
VOLTAGE SELECT
Ensure each compressor is equipped with
independent excess pressure shutdown. An increase in
115Vac
pressure differential across air treatment equipment can
result in excess compressor discharge pressure.
Power Supply Terminals
Regular routine monitoring of pressure differential

Ensure that the voltage select input is properly
across air treatment equipment is recommended.
jumpered for the incoming power. Default voltage
configuration is 230Vac.
PRESSURE SENSOR LOCATION

The system pressure sensor (P) must be located where
it will see the air pressure that is common to all of the
compressors.
SUPPLY (WET) SIDE PRESSURE CONTROL
P
1 P
Pressure Sensor Located Before Cleanup Equipment

PRESSURE SENSOR CONNECTION For each compressor utilizing an ir-PCB, connection to
the X8I the signal wires must be made to the correct
The pressure sensor connects to terminal X05 of the X8I X8I terminals for that compressor number. Compressor
terminal PCB using a shielded 18 AWG maximum 2- 1 should be wired to terminal X01 on the terminal PCB,
conductor cable no more than 330 feet (100 meters) in Compressor 2 should be wired to terminal X02 on the
length. The transducer threads are BPT. It is the equivalent terminal PCB, etc.
of ¼” NPT.
Cable Earth Shield
ir-PCB Interface Module

Wire polarity is important. 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.
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 X8I providing protection and voltage isolation.
Consult the X8I Interconnect and Application Guide

prior to the installation of the X8I and the ir-PCB to the air
compressor.
Pressure Sensor Wiring and Location

ir-PCB INTERFACE MODULE
The ir-PCB is designed to interface a compressor with
the X8I using a seven (7)-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.
10

ir-485 AND irV-485 GATEWAY MODULE RS485 NETWORK
The ir-485 and irV-485 Gateways are designed to The X8I is equipped with an RS485 network
interface the Intellisys Controller on the Ingersoll Rand communications capability using the ir485 protocol. This
Compressors and the Nirvana compressors, 20 HP (15KW) facility can be used for remote connectivity to optional
and above, with the X8I via the RS485 Network utilizing networked units and modules with ir485 communications
the ir485 protocol. The ir-485 and irV-485 Gateways capabilities or compressor controllers equipped with the
are DIN Rail mounted and can be located within the ir485 capability.
compressor control gear enclosure or remotely within a
separately enclosure. X06
L2 30 L2
L1 29 L1
28 RS485
ir-485 irV- 485 27
The RS485 Network is a Serial, Point to Point

Communication Network. Refer to the X8I Application
ir-485 Gateway irV-485 Gateway and Interconnect Guide For Wiring Details and
The cable used between the X8I and the ir-485 and irV- Connectivity.
485 Gateways is Belden 9841 (or equivalent). It should be The following example details the “correct” method of
run in grounded conduit and should not be greater than wiring the RS485 Network
4000 feet (1219 meters) in length.
4000ft (1219m) max
The cable used between the ir-485 Gateway and irV-485
Gateways and the Intellisys Controller is included with the Ingersoll Rand
102 psi
Installation Kit
1 1 2 3 4
18:35 #2
CAP
5 6 7 8
The cable used between the ir-485 Gateway and the

Intellisys Controller is included with the Installation Kit
Consult the X8I Interconnect and Application Guide

and the ir-485 or irV-485 Gateway Manual prior to the Correct RS485 Network Example
installation of the X8I and the Compressor Gateway to the The following example details the “incorrect” method of
air compressor. wiring the RS485 Network
ir485 COMMUNICATION PROTOCOL
ir485 is a unique communication protocol designed Ingersoll
Rand
102 psi
Ingersoll
Rand
102 psi
specifically for Compressor and Air System control. ir485

is a Multi-Master vs. a Master–Slave protocol that enables I/O EX
faster, more effective control of network components.
ir485 also features distributed control capabilities and has
inherent resistance to communication faults due to noise
Ingersoll Rand
102 psi
1 1 2 3 4
18:35 #2
CAP
5 6 7 8
Note: Follow RS485 Network installation

recommendations.
1 2
Ingersoll
Ingersoll
Rand
Rand
102 psi 102 psi
EX I/O
Incorrect RS485 Network Example
11

c) Where possible, never route an RS485 or signal cable
RS485 data communications and other low near to equipment or devices that may be a source of
voltage signals can be subject to electrical interference. electrical interference (for example: 3-phase power
This potential can result in intermittent malfunction supply transformer, high voltage switchgear unit,
or anomaly that is difficult to diagnose. To avoid this frequency inverter drive module, radio communications
possibility always use earth shielded cables, securely antenna).
bonded to a known good earth at one end. In addition,
give careful consideration to cable routing during
installation.
a) Never route an RS485 data communications or low
voltage signal cable alongside a high voltage or 3-phase
power supply cable. If it is necessary to cross the path of a
power supply cable(s), always cross at a right angle.
b) If it is necessary to follow the route of power
supply cables for a short distance (for example: from a
compressor X8I to a wall along a suspended cable tray)
attach the RS485 or signal cable on the outside of an
earthed cable tray such that the cable tray forms an
earthed electrical interference shield.
12

SECTION 6 — CONTROL FEATURES AND FUNCTIONS
STANDARD CONTROL FEATURES AND ANTI-CYCLING CONTROL
FUNCTIONALITY The most efficient way to utilize most air compressors is
PRESSURE CONTROL either fully loaded or off, with the exception of variable
Pressure control is achieved by maintaining the system pressure speed compressors which can operate efficiently at
within an acceptable range, or pressure band, which is defined and reduced loading. Compressor cycling (start-load-unload-
programmed by the user. Pressure will rise in the band when system stop, etc.) is essential to maintain pressure control.
demand is less than the loaded compressor’s output. Pressure will Excessive cycling, however, can result in poor compressor
fall in the band when system demand is greater than the loaded
compressor’s output.
efficiency as well as increased maintenance.
Simply stated, pressure control is achieved by unloading and Anti-cycling control is incorporated to help ensure
loading compressors to closely match compressor output with that only the compressors that are actually required
system demand within a specified pressure band defined by PL and
are started and operating while all others are kept off.
PH. See Figure 1.
Variable speed compressors also operate within the pressure band
Anti-cycling control includes a pressure tolerance range
and actively match compressor output with system demand by or band, defined by the user, which is outside of the
speeding up and slowing down around a target pressure defined by primary pressure band. Inside the tolerance band, an
the exact midpoint of the pressure band defined by PT. See Figure 2. 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
a
PH
band settings and algorithm processing time (Damping).
PT
PL
TOLERANCE
b
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 X8I from overcompensating in the event of
a temporary significant increase or decrease in system
Figure 1 — Typical System Pressure vs. Time demand.
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 TO
PH + TO
point “b” is reached. Once point “b” is reached, the X8I will PH
load the next compressor in the sequence to match the PT

air demand. This cycle will repeat as long as the X8I is able
to keep the system air pressure between PH and PL. TO
PL
PL - TO
PH
PT
Figure 3 — Tolerance in Relation to PH and PL
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
X8I will continuously calculate the moment at which
Figure 2 — Typical VSD Pressure Control vs. Time compressors will be loaded or unloaded based on the rate
The variable speed compressors in the system will run of change of system pressure. When the system pressure
on their target pressure and smooth out the variations in strays outside of the tolerance band, the X8I will abandon
system pressure. This assumes that system demand does energy efficiency and begin to protect the system air
not vary more than the capacity of the variable speed pressure by loading or unloading the compressors.
compressor. Loading will be delay controlled.
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.
13

When the compressed air system storage is relatively SYSTEM VOLUME
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 and slower, the tolerance band can be reduced to
improve pressure control and maintain energy efficient
- +
operation.
The factory default setting for tolerance is 3.0 PSI (0.2Bar). Assorted Receiver Tanks
This setting is user adjustable. System volume defines how fast system pressure will rise
DAMPING or fall in reaction to either increased/decreased demand
or increased/decreased supply. The larger the system
Any time the pressure is within the Tolerance band the volume, the slower the pressure changes in relation to
Anti-Cycling algorithm is active, sampling the rate of increased/decreased demand or supply. Adequate system
pressure change and calculating when to load or unload volume enables effective pressure control and avoids
the next compressor. The damping (DA) setting is a user system over-pressurization in response to abrupt pressure
adjustable setpoint that determines how quickly the fluctuations. Adequate system volume is created by
controller samples and recalculates, effectively speeding correctly sizing and utilizing air receivers.
up or slowing down the reaction time.
The most accurate way to determine the size of air
The X8I’s factory default DA setting of “1” is adequate for receivers or the additional volume required would
the majority of compressed air systems but may need be to measure the size and duration of the largest
to be adjusted in the following circumstances involving demand event that occurs in the system, then size the
aggressive and disproportionate system pressure volume large enough to ride through the event with
changes: an acceptable decrease in system pressure. Sizing the
• Inadequate air storage volume for the worst event will ensure system stability
and effective control over all other normal operating
• High pressure differential across the air conditions.
treatment equipment
If measurement is not available, then estimating the
• Incorrectly sized piping largest event is a reasonable alternative. For example,
• Slow or delayed compressor response assume that the largest demand event could be equal to
the loss of the largest operating air compressor. System
In these circumstances, the X8I may overreact and
volume would be sized to allow time for a back-up
attempt to load additional compressors that may not
compressor to be started and loaded with an acceptable
be necessary if the system was given time to allow the
decrease in pressure.
system pressure to stabilize after the initial compressor
is given time to load. If the tolerance has already been The following formula determines the recommended
increased and the X8I is still overreacting, then increasing minimum storage volume for a compressed air system:
the damping factor is the next step.
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 times faster than the default and a factor of 10 is a
reaction time 10 times slower than the default.
V — “Volume of Required Storage” (Gal, Ft3, m3, L)
NOTE: There are many variables that go into deter-
mining the stability and control of the system pres- T — “Time to Start Back-up Compressor” (Minutes)
sure, only some of which are able to be controlled by C — “Lost Capacity of Compressed Air” (CFM, m3/min)
the X8I. System storage, air compressor capacity, and
air demand all need to be analyzed by experienced Pa — “Atmospheric pressure” (PSIa, BAR)
professionals to determine the best installation for ΔP — “Allowable Pressure Drop” (PSI, BAR)
your system. Tolerance (TO) and damping (DA) can be
used for minor tuning of the system.
14

Example 1: Find Required Storage Volume in Ft3 and US Control and Rotation:
Gal. Compressor control and utilization is dynamically
(4) - 100 Hp Compressors at 450 CFM (12.7 m3) each / automated with adaptive control logic and therefore
15 seconds to start and load a compressor. 5PSIG is the does not follow pre-determined schedules, rotation
maximum allowable pressure drop. configurations or time intervals. Energy Control mode
can, however be operator influenced by the Priority
T=15 Seconds (.25 minute)
functionality which is discussed later in this manual.
C=450 ft3
Energy Control mode is enabled by the ability of the
Pa = 14.5 PSI X8I to process individual compressor capacity, variable
Delta P = 5 PSI capacity capabilities, and changes in system pressure to
dynamically implement and continuously review ‘best fit’
V = [.25 x (450 x 14.5)]/5
configurations as demand variations occur.
V = (.25 x 6525)/5
100%
V = 1631/5
80%
V = 326 Ft3
2
1 ft3 = 7.48 Gal
40%
Gal= 326 Ft3 x 7.48
Gal = 2440 20%
Example 2: Find Required Storage Volume in m3 and L. 0%

0% 1 100%
(4) - 100 Hp Compressors at 450 CFM (12.7 m3) each / 15
seconds to start and load a compressor. 0.34 BAR is the 1: Demand
maximum allowable pressure drop.
2: Supply
T=15 Seconds (.25 minute)
PRIORITY SETTINGS
C=12.7 m3
The sequence assignment pattern can be modified by
Pa = 1BAR using the priority settings.
Delta P = .34 BAR Priority settings can be used to modify the rotation
V = [.25 x (12.7 x 1)]/.34 sequence assignments. Compressors can be assigned
a priority of 1 to 8, where 1 is the highest priority. Any
V = (.25 x 12.7)/.34
compressor can be assigned any priority and any number
V = 3.2/.34 of compressors can share the same priority.
V = 9.33m3 Priorities allow you to set up rotation groups. All
1m3 = 1000 L compressors that have the same priority number will
rotate inside their own group. The group with the highest
L= 9.33 m3 x 1000
priority will always be in the front of the sequence.
L = 933
For example, in a four compressor system including one
STANDARD CONTROL FEATURES AND variable speed compressor in the compressor 1 position
FUNCTIONALITY you may want the variable speed compressor to always
STANDARD SEQUENCE CONTROL STRATEGIES
be in the Lead position. By assigning compressor 1 a
priority of 1 and the other three compressors a priority
The standard configuration of the X8I provides ENER of 2, the variable speed compressor will always remain at
(Energy Control) sequence control strategy, Priority the front of the sequence:
Settings, Table Selection, Pressure Schedule, and Pre-fill
operation. 1 2 3 4
ENER: Energy Control Mode

1 2 2 2
The primary function of Energy Control mode is to:
#1 A B C D
1/ Dynamically match compressed air supply with
compressed air demand. #2 A C D B
2/ Utilize the most energy efficient set/combination of air #3 A D B C

compressors to achieve 1/. #4 A B C D
Energy Control mode is designed to manage systems that
include compressors of different capacities and different Compressor 1 has priority 1, all other compressors have
air compressor types (fixed speed, variable speed and priority 2
variable capacity) in any combination or configuration.
15

In another example, there is a four compressor system
that includes a compressor in the compressor 4 spot Priority control will also work with ENER control
that is used only as an emergency backup compressor. mode. Recall that ENER control automatically selects
To accomplish this, simply assign compressor 4 a lower the most efficient set of compressors to dynamically
priority than any other compressor in the system: match compressed air demand. Priority will force the
X8I controller to select from all “priority 1” compressors
1 2 3 4
and make sure that they are loaded in the sequence
before utilizing any priority 2 compressors. All priority
1 1 1 2 2 compressors must be utilized before priority 3
compressors can be loaded and so on. Priority allows
#1 A B C D a system to be segregated to backup and primary use
compressors when using ENER control.
#2 B C A D
Note: Using the Priority function with ENER Control can
#3 C A B D
affect system efficiency.
#4 A B C D TABLES AND THE PRESSURE SCHEDULE
Compressor 4 has priority 2, all other compressors have T01

priority 1 PH
PL
----
----
Pm ----
SQ ----
In a third example, there is a four compressor system The X8I operates based on settings that are
that includes a variable speed compressor designated configured into one of three tables. Each table defines
compressor 1 and a fixed speed compressor that is an the operational settings and sequence control mode
emergency backup assigned as compressor 4. To ensure of the X8I. The X8I can be instructed to change among
that compressor 1 is always at the front of the sequence the tables at any time based on the configuration of the
and compressor 4 is always at the end of the sequence, pressure schedule.
set the priority as shown below:
This functionality allows the X8I to switch among
multiple different system configurations without any
1 2 3 4
disruption to control. This is particularly useful in the case
of shift changes, or weekends when the system is to be
1 2 2 3
deactivated.
#1 A B C D Each table consists of the following parameters which can
be set independently in each table:
#2 A C B D
• PH – High Pressure Setpoint
#3 A B C D
• PL – Low Pressure Setpoint
#4 A C B D
• Pm – Minimum pressure warning level
Compressor 1 has priority 1, compressor 4 has priority 3 • SQ – Sequence Rotation Strategy
and all other compressors have priority 2
• 01 – Compressor 1 Priority
A last example involves another four compressor system
that will be assigned into two independently rotation • 02 – Compressor 2 Priority
groups. Compressors 1 and 2 are given priority 1 and • 03 – Compressor 3 Priority
compressors 3 and 4 are given priority 2. This results in
the rotation sequence shown below: • 04 – Compressor 4 Priority
The “maximum” pressure fault level and the rotation
1 2 3 4 interval, or rotation time, are set independently in a
configuration menu and are unchanging regardless of the
1 1 2 2 table selected.
#1 A B C D
When the X8I is instructed to change between tables,
it will not abruptly change the system operating
#2 B A D C parameters. The X8I will adjust the system target pressure
upward or downward to the next table’s settings.
#3 A B C D
This transition will occur gradually to preserve energy
#4 B A D C efficiency and safe, reliable control:
Two independently rotating compressor groups
16

At system start (manual start or automated start from
1 2 standby) the X8I will only load compressors that have
been pre-determined for prefill operation, for a pre-set
period of time. The prefill 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 prefill time expiring.
PC
If normal operational pressure is reached prior to the
Changing Target Pressures set prefill time, the prefill function will automatically
cease and normal operational control begin. If normal
The time the system is allotted to change the target
operational pressure is not reached by the end of
pressure is known as the Pressure Change Time (PC). This
the prefill time the P4 will utilize as many available
is a value that is adjustable in the system settings screen.
compressors as required to achieve normal operational
See the Quick Setup Manual.
pressure as quickly as possible. Normal operational
If the X8I is able to complete the transition in less time control will then begin.
than is allotted without threatening energy efficiency
Three prefill modes are available. ‘Backup’ and ‘Standard’
then PC will be automatically shortened.
modes require compressor pre-selection and function in
the same way; differing only in response to a failure, or
loss, of a prefill compressor. Automatic mode requires no
An aggressively short time setting will compromise
compressor pre-selection.
energy efficiency.
Backup Mode: Compressor(s) can be pre-selected
as ‘Primary Prefill’ compressor(s) or ‘Backup Prefill’
PRESSURE SCHEDULE compressor(s). If a primary prefill compressor experiences
a shutdown, or is stopped, a pre-defined backup
The X8I is equipped with a real-time clock feature compressor replaces it and prefill continues.
and pressure schedule functionality. The pressure
schedule function can be used to provide enhanced ! X Standard Mode: If one or more of the pre-
system automation.
defined prefill compressors experiences a shutdown, or
The pressure schedule consists of 28 individual settings is stopped, the prefill function is cancelled and normal
that instruct the system to change from one table to operation begins.
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 A Automatic Mode: No Prefill compressor
23:59 hours on Sunday (day #7) each calendar week. selection is necessary; any selection set is ignored. The
The pressure schedule has the capability of changing management unit automatically selects compressor(s)
tables based on the time of day, once each day, or once dynamically to achieve pressure in accordance with
each day except weekends. Please see the Quick Setup the set Prefill time. If a compressor is stopped, or shuts
Manual for detailed information on how to configure the down, it is automatically substituted with an alternative
pressure schedule. compressor.
The Prefill feature provides a controlled and energy To manually skip Prefill mode, press and hold Start
efficient method of increasing pressure to normal for several seconds.
operating levels at system start. This feature avoids the Insufficient Capacity Alarm
inefficient potential for all available system compressors
to start and load before pressure reaches the normal
operating level.
CAP
The X8I is equipped with a dedicated ‘Insufficient

Capacity’ Advisory Alarm (Warning) indication.
This indication will illuminate if all available compressors
are loaded and system pressure is continuing to decrease.
The indication will generally occur prior to any set low
pressure Alarm (Warning) and is intended to provide an
advanced warning of a potential ‘Low Pressure’ situation.
17

The ‘Insufficient Capacity’ advisory alarm is intended as an ALTERNATE CONTROL FEATURES AND
advanced warning and is not recorded in the fault history FUNCTIONALITY
log but is included as a Group Alarm (Warning), or Group
Fault item. Energy Control Mode (ENER) is the STANDARD control
mode of the X8I. Alternate control strategies of the X8I are
‘Insufficient Capacity’ is available as a dedicated data the basic FILO (First in / Last Out) and EHR (Equal Hours
communications item. Run) EHR
The ‘Insufficient Capacity’ advisory alarm function FILO: TIMER ROTATION MODE
can be de-activated. In this instance the unit’s Alarm
indicator will still illuminate but no group alarm, group
fault, or a remote indication is generated. The primary function of Timer Rotation mode is to
efficiently operate a compressed air system consisting of
Restricted Capacity Alarm fixed capacity output compressors. The routine rotation
assignments can be modified using ‘Priority’ settings
to accommodate for a differentially sized or variable
capacity output compressor(s).
CAP Rotation:
Each time the rotation interval elapses, or the rotation
time is reached, a sequence rotation occurs and the
sequence assignment for each compressor is re-arranged.
The X8I is equipped with a dedicated ‘Restricted Capacity’ The compressor that was assigned for duty (A) is re-
Advisory Alarm (Warning) indication. assigned as last standby (D) and all other compressor
assignments are incremented by one.
This indication will flash if all available compressors are
loaded and further capacity is required but one or more,
compressors are: 21 1 2 3 4
a) inhibited from use in a ‘Table’ priority setting

#1 A B C D
b) inhibited from use by the short-term Service/
Maintenance function #2 D A B C
c) inhibited from use in the long term maintenance menu. #3 C D A B
The ‘Restricted Capacity’ advisory alarm is intended to
indicate that all available compressors are already loaded
#4 B C D A
and further capacity is required but one or more, system
The sequence assignment pattern can be modified by
compressor(s) have been restricted from use.
‘Priority’ settings.
The ‘Restricted Capacity’ advisory alarm is not recorded
in the fault history log but is included as a Group Alarm
(Warning), or Group Fault item. Tables; Priority Settings
‘Restricted Capacity’ is available as a dedicated data Control:
communications item.
Compressors are utilized, in response to changing
demand, using a ‘FILO’ (First In, Last Out) strategy.
The ‘Restricted Capacity’ advisory alarm function can The ‘duty’ compressor (A) is utilized first followed by (B)
be de-activated. In this instance the unit’s Alarm indicator if demand is greater than the output capacity of (A). As
will still flash but no group alarm, group fault, or a remote demand increases (C) is utilized followed by (D) if demand
indication is generated. increases further.
As demand reduces (D) is the first compressor to be
unloaded, followed by (C) and then (B) if demand
continues to reduce.
The last compressor to be unloaded, if demand reduces
significantly, is (A). The compressor assigned as (A) in
the sequence is the first to be loaded and the last to be
unloaded.
18

SEQUENCE ROTATION EVENTS
If a compressor is operated independently from

A sequence rotation event can be triggered in the the X8I the running hours record may not be accurately
following ways: a periodic interval, a pre-determined updated.
time each day, or a pre-determined time day and time
each week. Please refer to the Quick Setup Manual to
The running hours meter display on most
determine how to configure the rotation events.
compressors are intended for approximate service
interval indication only and may deviate in accuracy over
EQUAL HOURS RUN MODE a period of time.
Control:
The primary function of EHR mode is to keep the
running hours of all compressors in the system as close Compressors are utilized, in response to changing
as possible. This provides the opportunity to service demand, using a ‘FILO’ (First In, Last Out) strategy. The
all of the compressors at the same time, given that the ‘duty’ compressor (A) is utilized first followed by (B) if
expected service interval for the compressors is similar. demand is greater than the output capacity of (A).
As demand increases (C) is utilized followed by (D) if
demand increases further. As demand reduces (D) is the
EHR is not an energy efficient focused mode of first compressor to be unloaded, followed by (C) and then
operation. (B) if demand continuous to reduce.
Each time the rotation interval elapses, or the rotation The last compressor to be unloaded, if demand reduces
time is reached, the sequence order of compressors is significantly, is (A). The compressor assigned as (A) in
reviewed and re-arranged dependant on the running the sequence is the first to be loaded and the last to be
hours recorded for each compressor. The compressor with unloaded.
the least recorded running hours is assigned as the ‘duty’
compressor, the compressor with the greatest recorded
running hours is assigned as the ‘last standby’ compressor.
For systems with more than two compressors, the
remaining compressor(s) are assigned in accordance with
there recorded running hours in the same way.
Example: The compressors in a four compressor system
have the following recorded running hours when a
rotation event occurs:
• Compressor 1 = 2200 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 X8I continuously monitors the running status of each
compressor and calculates the accumulated running
hours. These readings are viewable and adjustable
in the X8I C01 setting screens. The X8I will use these
values during EHR mode. The running hours on the X8I
should be routinely checked to see that they match the
compressors’ local calculations, and adjusted if necessary.
19

SECTION 7 — DISPLAY AND MENU OPERATION
The Main Display and the keypad and navigation buttons on the X8I are depicted below and provide the following
functionality:
a b User Interface :
102
PSI a) System Pressure Value
c b) System Pressure Units
d 1 c) Unit Status
d) Unit Active Functions
e
17:30 #1 e) User Menu Item
System Alarms (Warning) :

a) Unit Run Indicator (green LED)
b) Unit Alarm Indicator (Red LED)
a System Alarms (Warning) :

a) Group Compressor Fault
b CAP
b) Insufficient Capacity Alarm (Warning)
c c) Restricted Capacity Alarm (Warning)
Ingersoll Rand
a
102 psi
1 2 3 4
b
1
A: 85% c 1
CAP
5 6 7 8
Compressor Status Indicators :

a) Load Status
b) Run Status
Keypad and Navigational Keys Functionality
a) Start
b) Reset
a b c
c) Stop
g
d) Menu
e) Enter
f d
f) Escape
g) Up (Plus)
h e
h) Down (minus)
20

Unit Functions:
The following Icons are used by the X8I to
display the Controller Active Functions.
Operating Mode :
EHR - Equal Hours Run
FILO - Timer Rotation
ENER - Energy Control
Active Functions :
Power Failure Auto-Restart
1 Table #1 System Pressure Status :
Increasing to normal operational levels (Prefill,
2 Table #2 target pressure change or at system start)
3 Table #3 Below the active lower, or load, pressure set point
4 Table #4 Between the lower, or load, and upper, or unload,
active pressure set points
Standby Mode Active Above the upper, or unload, active pressure set point
Prefill Function
Pressure Schedule
Function Inhibited (Manual Override)
Remote Manual Override
System Pressure Value

System Pressure Units
Units Status :
The following Icons are used by the X8I to
display the Controller Status.
Stopped
Standby
Started and Running
Alarm (Warning)
Shutdown (Trip)
Real Time Clock Day of the week

24 Hour Format #1 = Monday
#2 = Tuesday
#3 = Wednesday
#4 = Thursday
#5 = Friday
#6 = Saturday
#7 = Sunday
21

Main Manu
Real Time Clock
17:30 #1
17.30 (24r system)
# 1 = Monday to # 7 = Sunday
Compressor Detailed Status:
User Manu
A number of User menu information displays are
1
A: 100%
available that can be accessed directly from the
front panel using the Up and Down navigation
buttons.
Compressor Status Symbols

Standby (or Auto restart)
Running Offload
Running Loaded
# Removed From Service in Table Priority Selection (# = Table Number)
Removed From Service in Long Term Maintenance Menu
Alarm (Warning) Standby (or Auto Restart)
Not Available(Stopped Shutdown, Trip Standby (or Auto Restart)
Network Communication Error (RS485 Connectivity Only)
Primary Detected Pressure
102 psi
The Pressure detected on the unit’s
primary pressure sensor.
Next Scheduled Sequence Rotation
00:00 #1
The next scheduled sequence rotation:
00 : 00 Time (24 hr system)
#1 Monday
A setting of zero hundred hours (00:00hrs)

on Monday (#1) equates to a sequence
rotation at one second past midnight on
Sunday.
22

INDICATORS ON – Loaded
Indicators b) Run Status
OFF – Not Running
The X8I indicators are as follows.
Off Slow Flash – The compressor has been requested
to load but is not running (blowdown delay or
On
other start delay)
Intermittent:
ON – Running
OFF – No Compressor Connected
1sec
Fast Flash – Not Available, Shutdown Fault or

Slow Flash:
Stopped
Slow Flash – Alarm (Warning)
Intermittent Flash – The compressor has been

1sec
intentionally removed from service.
Fast Flash: Available, OK

System Alarms (Warnings):
a
1sec
Unit Indicators b CAP

Unit Run Indicator (Green LED)
c
OFF – Not Active, Stopped
Slow Flash: Active, Standby Mode a) Group Compressor Fault
ON – Active, Running OFF – All Compressors OK
Fast Flash – One or more compressors Not

Unit Fault Indicator (Red LED) Available, Shutdown Fault or Stopped
Fast Flash: Shutdown (Trip) Slow Flash – One or more compressors Alarm
Slow Flash: Alarm (Warning) (Warning)
The X8I fault indicator does not indicate compressor
fault states; see Compressor Status Indicators. b) Insufficient Capacity Alarm (Warning)
Compressor Status Indicators: On – Insufficient Capacity
c) Restricted Capacity Alarm (Warning)
a Slow Flash – Restricted Capacity
b
c 1
Each compressor in the system has a set of dedicated
status indicators. The indicators will continuously show
the status of each compressor at all times.
a) Load Status
OFF – Not Loaded, Offload
Slow Flash – The compressor has been requested

to load but is not loaded (load or re-load delay
period)
23

Information Displays Primary Detected Pressure:
P00
To view detailed information applicable to the
selected User menu display item press Enter. 102 psi 2
1 1 98 psi 3
To view detailed information applicable to the
selected User menu display item press Enter. 80 psi 4
Real Time Clock:
P00 1: Active Table

2: Upper (Unload) Pressure Set Point
2 #1 18:30 3
3: Lower (Load) Pressure Set Point
T2 4
4: Minimum Pressure Alarm (Warning)
1 1 Sequence Rotation:
P00
Shows the next Pressure Schedule event.
#4 18:00
1: The Current Active Table
2: Day (#1=Monday, #7=Sunday)
18 / 05 / 2006
3: Time (24hr system) ABCD
4: Table
Items 2 and 3 show the day and time that the unit
will change to use the ‘Table’ shown in item 4.
Day of the week (#4: Thursday), the time of day
Compressor Status: (18:00) and the date (18/05/2006) of the next automated
sequence rotation event.
P00
3 IRV-485 4
The active ‘mode’ of operation
1 100 % 5 “ABCD” The current active rotation sequence assignment.
1 1
1 20 % 6 Manual Sequence Rotation:
2 30 % 7 The sequence assignment can be manually rotated at any

time. When viewing the ‘Sequence Rotation’ information
screen press Enter:
1: Compressor Number
2: Priority Setting
3: Zone Allocation Setting The manual rotation symbols will appear and
flash. Press Enter again to execute a manual rotation or
4: Compressor/Connection Type Escape to abandon the manual rotation.
5: Maximum Capacity % Setting
Automated sequence rotation is not disrupted by
6: Minimum Capacity % Setting a manual rotation; the next scheduled automated
7: Minimum Efficiency % Setting sequence rotation event will still occur.
Item values 6 and 7 are only shown if compressor Compressor Identification

type is IRV-485 (variable capacity/speed). Each compressor connected to the X8I will have a unique
assigned compressor identification number; starting at
compressor 1 increasing sequentially to the number of
compressors connected to the X8I.
24

Power Failure Auto-Restart
A: 85%
If the power failure auto-restart function is enabled

the X8I will automatically start, when power is restored
after a disruption or failure, if the X8I was in a ‘started’
state when the power disruption or failure occurred.
1 2 3 4
The X8I will not automatically restart if the X8I was in
a stopped state when the power disruption or failure
Stop:
occurred.
Failure Mode
To stop the X8I press Stop.
If the X8I experiences a disruption to normal control, or
The X8I will respond dependant on the setup of item ‘CF’ an X8I shutdown fault occurs, pressure regulation control
in menu S02: is automatically transferred back to each compressor. The
compressor(s) will continue to operate using the pressure
Pressure regulation control is automatically transferred
settings programmed or set in the individual compressor
back to each compressor. The compressor(s) will continue
controller(s).
to operate using the pressure settings programmed or set
in the individual compressor controller(s). Reset
The X8I will hold each compressor in an offload state.
If the compressor is equipped with a main motor run-on-
To reset an X8I Alarm (Warning) or Shutdown
time function the compressor will run offload for a period
condition press Reset.
of time and then stop in to 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 IAX4.
Start:
To start the X8I press Start.

If the Prefill function is enabled, and system pressure is
below the set prefill pressure, the system will enter Prefill
mode for the set Prefill time.
Prefill
To manually skip the Prefill function, press and hold
Start for several seconds.
When Prefill is complete, if applicable, the X8I will enter
normal operating mode.
The X8I will operate in accordance with the parameters
and options set in the active ‘Table’.
Tables
Each compressor in the system must be started
(running or in a standby or auto restart condition) before
X8I control of the compressor can be established. The X8I
will not start a compressor that is in a stopped condition.
25

SECTION 8 — COMMISSIONING
When commissioning the X8I, carry out the following PRESSURE DISPLAY
procedures before attempting to start.
Check the displayed system pressure. If the pressure is
incorrect, or inaccurate, check the type and range of the
It is recommended that an authorized and trained sensor and carry out the pressure sensor commissioning
service technician perform the commissioning. and calibration procedure. If the display shows an error,
this will need to be corrected before continuing. See the
PHYSICAL CHECKS Operator’s Manual for troubleshooting and correcting the
fault/error condition.
1. Before applying power to the X8I, ensure the
power supply connections are correct and secure X8I QUICK SET-UP CONFIGURATION
and the operating voltage selector is set correctly
for the power supply voltage in use (115Vac or Before successful basic operation can be established
230Vac (+-10%), 50/60Hz). specific parameters must be entered prior to startup.
Please refer to the X8I Quick Setup Manual for instruction
2. Open the front panel of the X8I and check the
to accomplish this.
location of the link wire(s) connected to the
“Voltage Selection” terminals of the power supply OPTIONAL FEATURES AND FUNCTIONS
PCB. If necessary, change the link wire locations to
Installation requirements may involve the
those illustrated for the voltage in use.
implementation of additional or optional functions and
features. Please refer to the appropriate Guide or Manual
See the section on Installation for more
as required.
information.
3. Switch on the power supply to the X8I.
4. The control program identification will be
displayed for a short period followed by the normal
operational user display.
26

SECTION 9 — SYSTEM CONFIGURATION
DISPLAY ITEM STRUCTURE ACCESSING THE X8I CONFIGURATION
Operational system status and values are accessible from SCREENS
the normal user display. To view status or values that are Access Code:
not normally visible on the default screen, press UP or
DOWN. All standard user display items are viewable only Access to adjustable menu page items is restricted by
and cannot be adjusted. The standard user display items access code. To access menu mode pages press MENU (or
are regarded as “Menu Page 00” items. UP and DOWN together); an access code entry display is
shown and the first code character will flash.
All adjustable value, parameter or option item displays
are grouped into “menu mode” lists. Items are assigned
to a list 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 “P01” or higher.
NORMAL OPERATIONAL DISPLAY (MENU

PAGE P00)
At controller initialization, all display elements and LED
indicators are switched on for three seconds and then the
normal operating display is shown. In normal operational Use UP(plus) or DOWN(minus) to adjust the value of the
display mode, the main display will continuously show first code character then press ENTER. The next code
the detected system pressure and the Item display will character will flash; use UP or DOWN to adjust then press
show the first item of the “Page 00” menu. User menu ENTER. Repeat for all four code characters.
“items” can be selected using the UP or DOWN buttons at If the code number is less than 1000 then the first code
any time. Pressing the ENTER button will lock any selected character will be 0(zero). To return to a previous code
item display and inhibit return to the default display. character press ESCAPE. When all four code characters
When an item display is locked, the “lock key” symbol have been set to an authorized code number press
will be shown. To unlock an item display, press UP or ENTER. An invalid code will return the display to normal
DOWN to view an alternative item display or press RESET operational mode; page ‘P00’.
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 Access Code Accepted
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.
Access Code Rejected
Access Code = 0032
Access Code Timeout:

When in menu mode, if no key activity is detected for
a period of time the access code is cancelled and the
display will automatically reset to the normal operational
display.
Menu Mode Navigation:
In menu mode the menu ‘page’ number will be
highlighted at the top of the display.
P00
To select a menu ‘page’ press UP or DOWN. To enter the
highlighted menu ‘page’ press ENTER; the first item of the
menu ‘page’ will be highlighted. Press UP or DOWN to
scroll though the selected menu ‘page’ items.
27

To select an item value or parameter for modification’
press ENTER; an adjustment screen for the item will be
displayed.
The value or option can now be modified by pressing
UP(Plus) or DOWN(Minus). To enter a modified value or
option in to memory press, ENTER.
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
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 0 Page 1
Page 2
Item 1 Value
All menu items have a unique reference consisting of the

menu page ID (a) and the menu page item number (b). Press and hold RESET for several seconds at any time
Each item in a menu also has a unique two alphanumeric to immediately exit menu mode and return to the normal
character code (c). All three references are visible at the operational display. Any value or option adjustment that
top of every menu item display. has not been confirmed and entered into memory will be
abandoned and the original setting maintained.
a b c
P01 01.02 AB The X8I will retain an ‘access code’ for a short period
after menu exit allowing the menu structure to be re-
Some menu items may consist of several individual entered without the need to re-enter the access code
settings. Each setting of the menu item is also referenced again. To immediately clear access code retention press
as a sub-item number. For example: P01-01.02 references and hold RESET for several seconds.
sub-item ‘02’ of menu item ‘01’ in menu page ‘P01’. Sub-
item settings, where applicable, are always displayed
together on the same ‘Item’ adjustment display screen. A ‘locked’ symbol displayed with any item indicates
Most menu items are single value or single option only the item is locked and cannot be modified. This will occur
in which case the single item is referenced as sub-item if the Item is view only (not adjustable) or in instances
number ‘01’ (for example: P01-01.01). where the item cannot be adjusted while the X8I is in an
operational state; stop the X8I first.
28

USER Level Menus
User Configuration
1
TABLE #1 S01
T01
01 Ct Real Time Clock Set
01 PH High Pressure Set Point 02 PS Pressure Schedule Enable
02 PL Low Pressure Set Point 03 AR Auto Restart Enable
03 Pm Minimum Pressure Alarm 04 RP Rotation Interval
04 SQ Sequence Algorithm 05 TS Default Table Select
05 01 Compressor #1 Priority 06 BL Display Backlit Adjust
to
12 08 Compressor #8 Priority
Compressor Running Hours
C01
TABLE #2 to #4 (as Table #1)
01 01 Compressor #1 Running Hours
to
Pressure Schedule
08 08 Compressor #8 Running Hours
P01
01 01 Schedule Setting #1
to Compressor Maintenance
28 28 Schedule Setting #28 C02
01 01 Compressor #1 Maintenance
to
08 08 Compressor #8 Maintenance
Prefill
P02
01 PF Prefill Function
02 PT Prefill Time Fault Log
03 PP Prefill Pressure E01
04 01 Compressor #1
to
01 01 Fault Log #1 (most recent)
11 08 Compressor #8
to
15 15 Fault Log #15
29

SERVICE Level Menus
High Level Menus
Configuration Diagnostic Menu 1
S02 D01
01 P> Pressure Units 01 D1 Digital Input #1 (Di 1)
02 NC Number Of Compressors to
03 PM Maximum Pressure Alarm 08 D8 Digital Input #8 (Di 8)
04 CF Stop Control Function 09 R1 Output Relay #1 (R1)
05 TO Tolerance to
06 DA Damping 14 R6 Output Relay #6 (R6)
07 PC Pressure Change Time 15 A1 Analog Input #1 (Ai1)
08 CA CAP Alarm Inhibit 16 A2 Analog Input #2 (Ai2)
09 MA Max Cap Restricted Alarm Inhibit 17 A3 Analog Input #3 (Ai3)
10 AI Auxiliary Input Function 18 Ao Analog Output (Ao)
11 AO Auxiliary Output Function
12 ER Error Log Reset
Diagnostic Menu 2
D02
01 SI Screen Invert
Auxiliary Box Monitoring 02 LT LED Panel Test
S03
01 01 Auxiliary Box #1 Enable D03 and D04

02 02 Auxiliary Box #2 Enable
03 BT RS485 Timeout Diagnostic menus D03 and D04 have no standard
function and are not shown.
Diagnostic Menu 5
Sensor Calibration
XPM Expansion Module C:5-8 Diagnostic Menu
S04
only available when applicable EXP Expansion Box is
01 1O Pressure Offset installed and registered (detected) by the X8I.
02 1R Pressure Range
D05
01 D1 Digital Input #1 (Di 1)
to
Compressor Configuration 08 D8 Digital Input #8 (Di 8)
09 R1 Output Relay #1 (R1)
C03
to
01 Compressor #1 Configuration 14 R6 Output Relay #6 (R6)
to 8 Compressor #8 Configuration 15 Ao Analog Output (Ao)
30

X8I CONFIGURATION SCREENS
If PL in Table 1 (T01) is set for 100 PSI and TO is set for 3.0
T01 PSI, then the highest Minimum Pressure setpoint would
08 04 1 04 be 94 PSI.
01 PH 102 psi T0# - SQ Sequence Strategy
02 PL 98 psi The sequence control strategy mode that will be used

when the table is active. The default setting for this
03 Pm 0 psi parameter is ENER.
04 SQ ENER (%)
The values for this parameter are:
ENER – Energy Control Mode. The Rotation and
Control functionality of the ENER mode is to achieve
Tables and maintain demand matched to optimum system
# = Table T01 to T04 efficiency.
T0# – PH High Pressure Set Point FILO – First In Last Out. The Rotation and Control
functionality of the FILO mode is the first compressor
The ‘upper’ or ‘unload’ pressure set point that will be loaded is the last compressor to be unloaded
used when the ‘Table’ is active. The default setting for this
parameter is 102 PSI. The values for this parameter are: EHR – Equal Hours Mode. The Rotation and Control
functionality of the EHR mode is to equalize the Run
The highest value for the High Pressure setpoint = PM Hours on all compressors
“Maximum Pressure Alarm” minus 2 times TO “Tolerance”.
T0# - 01 Compressor #1 Priority
If PM is set for 145 PSI and TO is set for 3.0 PSI, then the
The ‘priority’ setting for compressor number 1 that will be
highest value for the High Pressure setpoint would be 139
used when the table is active.
PSI.
T0# - 02 Compressor #2 Priority
The lowest value for the High Pressure setpoint = PL “Low
Pressure” setpoint plus TO “Tolerance” The ‘priority’ setting for compressor number 2 that will be
used when the table is active.
If PL is set for 98 PSI and TO is set for 3.0 PSI, then the
lowest value for the High Pressure setpoint would be 101 T0# - ‘n’ Compressor #’n’ Priority
PSI.
The ‘priority’ setting for compressor number ’n’ that will be
T0# - PL Low Pressure Set Point used when the table is active.
The ‘lower’ or ‘load’ pressure set point that will be used ‘n’ = number of compressors in the system. 8 is the
when the ‘Table’ is active. The default setting for this maximum number of compressors for the X8I
parameter is 98 PSI. The values for this parameter are:
The highest value for the Low Pressure setpoint = PH
Priority Settings:
“High Pressure” setpoint minus TO “Tolerance”.
: compressor(s) can be inhibited from use while a
If PH is set for 102 PSI and TO is set for 3.0 PSI, then the
table is active by selecting “X” priority. The compressor
highest value for the Low Pressure setpoint would be 99
will be held offload and will not be utilised under any
PSI.
circumstances.
The lowest value for the Low Pressure setpoint = Pm
“Minimum Pressure Alarm” setpoint plus 2 times TO
“Tolerance”
If Pm is set for 80 PSI and TO is set for 3.0 PSI, then the
lowest value for the Low Pressure setpoint would be 86
PSI...
T0# - Pm Minimum Pressure Alarm
The miniumum pressure ‘Warning’ or ‘Alarm’ level that will
be used when the ‘Table’ is active. The default setting for
this parameter is 80 PSI. The values for this parameter are:
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””
31

P01 P02
28 28 - . --:-- --- 11 08 X
01 01 - . --:-- --- 01 PF X
02 02 - . --:-- --- 02 PT - MIN
03 03 - . --:-- --- 03 PP 0 psi
04 04 - . --:-- --- 04 01 X
Pressure Schedule Prefill

P01 – 01 to 28 P02 - PF Prefill Function
The ‘Pressure Schedule’ items 01 to 28. The Pressure Determines the ‘Prefill’ strategy or function that will
Schedule consists of 28 individual settings that instruct be used at system startup. The default setting for this
the X8I to change from one Table to another, or put parameter is A .
the system into Standby mode, dependant on time of A (Represents the pre-fill function is in Automatic
day and day of the week. The default setting for this Mode)
parameter is -. --:-- - - - . (Represents the Pressure Schedule
is disabled) The values for this parameter are:
The values for this parameter are: (from left to right) = Prefill function OFF
Day of the Week. The values for this parameter are: “ ” = Prefill, Back-up Mode
“1” for Monday to “7” for Sunday (a specific day Compressor(s) can be pre-selected as ‘Primary
of the week) Pre-fill’ compressor(s) or ‘Backup Pre-fill’
compressor(s). If a primary pre-fill compressor
“8” for every working day of the week (every experiences a shutdown, or is stopped, it is
day, Monday through Friday, excluding replaced by a pre-defined backup compressor
Saturday and Sunday) and pre-fill continues.
“9’” for every working day of the week (every
day, Monday through Sunday) ! X = Prefill, Standard Mode
“–“ represents the Pressure Schedule is
If one or more of the pre-defined pre-fill
disabled.
compressors experiences a shutdown, or is
Hours (Military Time). The values for this parameter stopped, the pre-fill function is cancelled and
are: normal operation begins.
“00” to “23” the hours in a day
“–-“ represents the Pressure Schedule is A = Prefill, Automatic Mode
disabled.
No Prefill compressor selection is necessary;
Minutes. The values for this parameter are: any selection set is ignored. The management
unit automatically selects compressor(s)
“0” to “59”. the minutes in the hour
dynamically to achieve pressure in accordance
“__“ represents the Pressure Schedule is with the set Prefill time. If a compressor is
disabled. stopped, or shuts down, it is automatically
Table / Standby mode selection. This instructs the system substituted with an alternative compressor.
to change from one ‘Table’ to another, or put the system P02 - PT Prefill Time
in to ‘Standby’ mode for the Pressure Schedule. The values
The Pre-fill Time Setpoint (in minutes) sets the maximum
for this parameter are:
time allowed for a system to start and load the
“T01”, “T02”, “T03” or “T04” for the 4 different designated Compressor/s to increase system pressure
Tables to normal operational levels. The default setting for this
“– – “ for Standby Mode parameter is – . (Represents the Prefill is disabled)
“ __ “ represents the Pressure Schedule is The values for this parameter are:
disabled. “–” the Pre-fill Time is Off
“1 to 120” the number of minutes
32

P02 - PP Prefill Pressure
S01
The Pressure Setpoint used by the X8I to determine if the
Pre-fill Function is required at start up. If pressure is at, or 06 BL 5
above, this setting at system startup, the prefill function 08 Ct 1 . 18:00
will be abandoned immediately and normal pressure
control and sequence strategy will be implemented. This
08 PS X
setting is intended to inhibit ‘Prefill’ operation if pressure 08 AR
is already at an acceptible level at system startup. The 08 RP 1 . 00:00
default setting for this parameter is 0 PS.
0 to 232 (or the maximum scaled pressure Features and Functions
value used by the X8I if a different Pressure S01 - Ct Real Time Clock Set
Transducer range is used)” the PSI value for the
Pre-fill Pressure Adjustment for the internal real time clock.
P02 – 01 to ‘n’ Compressor 1 to ‘n’ (Hours, Minutes, Date, Month, Year)
‘n’ = number of compressors in the system. 8 is the The ‘Day of the Week’ (1= Monday to 7=Sunday) is
maximum number of compressors for the X8I automatically calculated and set in accordance with
the Day, Month and Year. The default setting for this
This parameter set the function of compressor 1 to ‘n’ parameter is - --.--. (Represents the clock has not been
during the ‘Prefill’ period. The default for this parameter is initialized))
. (Represents this compressor is not used by the The values for this parameter are:
Prefill Function) The values for this parameter are:
“1” to “7” the ‘Day of the Week’ (1= Monday to
“ ” for this compressor will not be used by the Pre- 7=Sunday) which is automatically calculated and set
fill Function in accordance with the Day, Month and Year entered.
“ ” for this compressor will be used as a primary “00” to “23” the Hour for the Real Time Clock.
compressor by the Pre-fill Function
“0” to “59” the Minutes for the Real Time Clock.
“!” for this compressor will be used as an emergency
Backup compressor by the Pre-fill Function “1” to “31” the Day for the Real Time Clock.
These settings are applicable to Prefill – Standard “1” to “12” the Month for the Real Time Clock.
and Prefill - Back-up modes only. In Automatic mode “2005” to “2100” the Year for the Real Time Clock.
the system management unit dynamically utilizes S01 - PS Pressure Schedule Enable
compressors as required.
This parameter enables or disables the Pressure Schedule
function in the X8I. The default setting for this parameter
Press and hold ‘Start’ for 5 seconds to manually skip is . (Represents the Pressure Schedule is disabled)
Prefill mode at start up.
= inhibit Pressure Schedule
“ ” = enable Pressure Schedule
S01 - AR Auto Restart Enable
This parameter enables or disables X8I restart function
after a power loss. When enabled, after a power
disruption or failure, the X8I will automatically restart
when power is restored if the X8I was in an operational
‘Started’ state when the power loss or disruption
occurred. The X8I will not automatically restart if the X8I
was in a “Stopped” state when the power disruption or
failure occurred. The default setting for this parameter is
. (Represents the Auto Restart is enabled)
= inhibit Power Failure Auto Restart
“ ” = enable Power Failure Auto Restart
33

S01 - RP Rotation Interval S01 - TS Default Table Select
The X8I provides a Timed rotation event that can be This parameter determines the ‘Table’ that will be used
automatically triggered on a routine basis using a by default when ‘Pressure Schedule’ is not active and no
pre-determined interval, a pre-determined time each table is selected remotely on a digital input. The default
day, or a pre-determined day and time each week. The setting for this parameter is T01.
default setting for this parameter is 1 00:00. (Represents a
rotation at Monday (1) at 00:00 hours)
“T01” for Table T01
“T02” for Table T02
“1” for Monday to “7” for Sunday (a specific day of the
week) “T03” for Table T03
“8” for every working day of the week (every day, “T04” for Table T04
Monday through Friday, excluding Saturday and S01 - BL Display Backlight Adjust
Sunday)
This parameter adjusts the backlight level for the display.
“9’” for every day of the week (every day, Monday The display will temporarily increase brightness by 2
through Sunday) levels when a key is pressed and return to normal setting
“t” for an interval of time (more than 1 or more after a period of no keypad activity. The default display
rotations per 24 hours) backlight level has been set to enable a ‘continuous use
service life’ in excess of 90000 hours while providing good
“–“ for disabling the Rotation Interval
readability in all ambient light conditions. LCD display
If the parameter chosen above is “1” to “9”, you will need ‘service life’ is defined as the time period before the
to set the time for the rotation to occur. It is in a Military backlight reduces to 50% of initial brightness. Typically
Time format. the display will remain usable for a much longer period
The values for this parameter are: of time. Adjusting the backlight to high levels will reduce
service life. The default setting for this parameter is 5. The
“00” to “23” the Hour values for this parameter are:
“0” to “59” the Minutes “1” to “7” 1 being the least amount of backlight and 7
“–“ the Rotation Interval is disabled. being the most.
If the parameter chosen above is “t”, you will need to
set the Interval Time. This sets the required number of
rotation events per day (1 to 96).
A value of 1 = rotate every 24 hours
A value of 24= rotate every 1 hours
A value of 48 = rotate every 30 minutes
“–“ the Rotation Interval is disabled.
34

S02 - CF Stop Control Function
S02 This parameter determines if the X8I maintains control of
12 ER X the compressors when the X8I is stopped. The default
01 P> psi setting for this parameter is . (Represents the
Stop Control Function is disabled) The values for this
02 NC 4 parameter are:
03 PM 145 psi = Stop: return pressure control to the
04 CF X compressors.
“ ” = Standby: maintain control and continouosly
hold compressors ‘off load’.
Pressure Control; Tables
S02 - TO Tolerance
S02 - P> Pressure Units
This parameter sets the pressure control ‘Tolerance’ band
This parameter selects the display and operating pressure setting. The Tolerance Band setting is a pressure band
units: The default setting for this parameter is PSI. The above and below the Load and Unload pressure band.
values for this parameter are: This accommodates for an instance of abrupt and/or
“PSI” significant increase or decrease in demand without
compromise to optimal energy efficient control. The X8I
“BAR” incorporates a Rate of Change algorithm in the Tolerance
“kPA” Band to determine when a compressor should be Loaded
S02 - NC Number of Compressors or Unloaded. The default setting for this parameter is 3.0
PSI (.2 Bar) The values for this parameter are:
This parameter sets the number of compressors “1.4 PSI (.1 Bar)” for the minimum Tolerance Band
connected to, and controlled by, the X8I. This value “29.0 PSI (2 Bar)” for the maximum Tolerance Band
must be set to match the system at commissioning. The
default setting for this parameter is 4. The values for this • If air system storage is generous, the rate of the
parameter are: pressure change is slow, and/or demand fluctuations
are insignificant and gradual, then the ‘Tolerance’
“1” for 1 compressor band can be decreased to improve pressure control
“2” for 2 compressors without compromise to optimum energy efficiency.
As the Tolerance Band is decreased, the Loading and
“3” for 3 compressors
Unloading of compressors while in the band is more
“4” for 4 compressors rapid.
To • If air system storage is inadequate, the rate of the
“8” for 8 compressors pressure change is fast, and/or demand fluctuations
are significantly large, the ‘Tolerance’ band can be
S02 - PM Maximum Pressure Alarm increased to maintain optimum energy efficiency,
This parameter sets the High pressure ‘Fault’ level. This and reduce over-reaction, during such transition
value remains active at all times and is the same for all periods. As the Tolerance Band is increased, the
‘Tables’. It should be set just below system pressure relief Loading and Unloading of compressors while in the
value(s) and below the maximum system pressure rating band is less rapid.
of all air system components. The default setting for this S02 - DA Damping
parameter is 145. The values for this parameter are:
This parameter sets the pressure control ‘Damping’
The highest value for the Maximum Pressure Alarm setting. Changing this parameter adjusts the time before
setpoint = “The maximum range of the pressure an additional compressor is loaded in accordance with
transducer used” the urgency of the situation to increase air system
The lowest value for the Maximum Pressure Alarm capacity further. The X8I has a dynamic reaction algorithm
setpoint = “The highest value from any Table “PH that is pre-set by default to accommodate for the majority
- Pressure High” Setpoint plus 2 times the “To of installation characteristics. If an increase or decrease in
– Tolerance” the Tolerance band is insufficient, the reaction response
If PH in Table 1 (T01) is set for 100 PSI, and PH can be influenced by increasing or decreasing the
in Table 2 (T02) is set for 110 and TO is set for ‘Damping’ factor. The default setting for this parameter is
3.0 PSI, then the lowest Maximum Pressure 1.0. The values for this parameter are: .1 TO 10
setpoint would be 116 PSI. “.1”, the fastest Damping reaction time (10 times faster
than the default of 1.0)
“10.0”, the slowest Damping reaction time (10 times
slower than the default of 1.0).
35

• If air system storage is generous and the rate of the S02 – CA Capacity Alarm Enable
pressure change is slow to rise, then the ‘Damping’
This parameter sets the functionality of the Capacity
can be increased to improve pressure control
Alarm. The default setting for this parameter is .
without compromise to optimum energy efficiency.
(Represents the Capacity Alarm is enabled) The values for
As the Dampening value is increased, the Loading of
this parameter are:
additional compressors is less rapid.
= inhibit Capacity Alarm
• If air system storage is inadequate and the rate of
the pressure change is fast to fall, then the ‘Damping’ = enable Capacity Alarm
can be decreased to improve pressure control
without compromise to optimum energy efficiency.
As the Damping value is decreased, the Loading of When inhibited the Capacity Alarm panel indication
additional compressors is more rapid. will still function; alarm code generation and remote
alarm indications are inhibited.
Damping also performs one more important function
that can arise in a system. When the system pressure S02 – MA Restricted Cap. Alarm Enable
achieves stability in a position that may be outside of This parameter sets the functionality of the Restricted
the dead band but inside the tolerance band it will Capacity Alarm. The default setting for this parameter is
be allowed to remain in this situation for a predefined
. (Represents the Restricted Capacity Alarm is enabled)
amount of time. This time limit depends on how far away
from the dead band the system pressure has stabilized.
This time limit is calculated as 30 min times the damping = inhibit Restricted Capacity Alarm
constant at the top of the tolerance band and as 1 = enable Restricted Capacity Alarm
min times the damping constant at the bottom of the
tolerance band.
S02 - PC Pressure Change Time When inhibited the Restricted Capacity Alarm panel
indication will still function; alarm code generation and
This parameter adjusts the time that the X8I will remote alarm indications are inhibited.
implement a smooth and controlled change from one
‘target’ pressure level to another when a table change is
made. The default setting for this parameter is 4 Min. The
values for this parameter are:
“1”, 1 minute between Table target pressure setpoint
changes
TO
“120”, 120 minutes between Table target pressure
setpoint changes.
36

S02 – AI Auxiliary Digital Input S02 – AO Auxiliary Output Function
S02 10.01 AI S02 11.01 AO
NO NO
01:D1 01:AF
The function of the Auxiliary input. The function of the Auxiliary output ‘volt-free’ relay
01:DI Digital Input contacts.
No defined function but status (0=normal, 01:AF Any Fault

1=activated) Any Alarm (Warning), Shutdown (Trip) or Compressor Not
02:T1 Override > Table 1 Available.
03:T2 Override > Table 2 02:AT Any Trip
04:T3 Override > Table 3 Any Shutdown (Trip) or Compressor Not Available.
05:T3 Override > Table 4 03:CF Compressor Fault
06:TS Override > Standby Any compressor Alarm (Warning), Shutdown (Trip) or Not
Available
07:AA Remote Alarm (always active)
04:CA Compressor Alarm
08:AR Remote Alarm (active when unit running,
inhibited when unit stopped or in Standby) Any compressor Alarm (Warning)
09:TA Remote Trip (always active) 05:CT Compressor Trip
10:TR Remote Trip (active when unit running, inhibited Any compressor Shutdown (Trip) or Not Available
when unit stopped or in Standby) 06:SF System Fault
11:SS Remote Start/Stop Any unit Alarm (Warning) or Shutdown (Trip)
NO (Normally Open) 07:ON System On
The selected function is activated when the input is Unit Started and Active, including Pre-Fill period and
closed circuit (input terminals are connected together by Standby mode (not active when unit stopped)
remote volt-free contacts)
08:SA System Active
NC (Normally Closed)
Unit Active, including Pre-Fill period (not active when unit
The selected function is activated when the input is open stopped or in standby mode)
circuit (input terminals are open circuit)
09:LP Low Pressure Alarm
10:HP High Pressure Alarm
11:PO Pressure Control Override
Normal, or Pressure Schedule’ operation is being manually
overriddenThe function of the Auxiliary output ‘volt-free’
relay contacts.
S02 - ER Error Log Reset
This parameter clears and resets the ‘Error Log’. The
default setting for this parameter is . (Represents the
Error Log Reset is disabled)
“ ” Error log reset is disabled
“ “ Error log reset enabled. Adjust the item setting to
‘ ’ and press ENTER. The display will return to the main
menu and all existing entries in the error log will be
permanently deleted.
37

The pressure transducer must be vented to
S03 atmosphere when setting the 0 or offset.
S04 - 1R Pressure Sensor Range
01 01 This parameter will be the maximum range of the
pressure transducer, 232 PSI, 16 BAR, or 1600 kPA. It can
02 02 also be used to create an ‘Offset’ if there is a difference in
03 BT 60 sec the range value being displayed. The default setting for
this parameter is 232 PSI. The values for this parameter
are:
S03 – 01/02 I/O Box Monitoring “232” when using the maximum value of the
This parameter determines if the X8I will monitor the pressure transducer range
selected I/O Box and display any ‘Fault’ detected on the A value greater than or less than 232 if the display
I/O Box inputs; dependant on I/O Box set-up. The default does not read 232.
setting for this parameter is . (Represents I/O Box The pressure transducer must have a known,
monitoring is disabled) The values for this parameter are: accurate pressure applied to it when changing
= Disabled this value to a value other than 232.
= Enabled Pressure Sensor Calibration Procedure:

a) Offset: Expose the sensor to atmosphere and adjust
the ‘offset’ setting (if necessary) until the detected
Refer to I/O Box manual for details. pressure display shows 0 PSI (0.0 BAR).
b) Range: Apply an accurately know pressure to the
S03 – BT Communications Timeout
pressure sensor and adjust the ‘Range’ setting until
This parameter determines the Communication Broadcast the detected pressure display matches the applied
Timeout between the X8I and the I/O box. If the I/O Box pressure. An applied pressure equal too, or greater
fails to communicate on the RS485 network within the than, the nominal system working pressure is
set ‘Communications Broadcast Timeout’ (BT), the X8I recommended.
will display an I/O Box RS485 communications Error.
The default setting for this parameter is 60 seconds. The The detected pressure is displayed with the
values for this parameter are: calibration menu item and will change to match the new
“10 to 300” the number of seconds calibration setting as the setting is adjusted.
The general operation of the selected I/O Box is also
monitored. There is no need for the applied pressure to be static;
it can be dynamic and changing. This enables calibration
S04 to be carried out on a fully operational system where
changing system pressure can be accurately verified from
another source.
01 1O 0 psi
02 1R 232 psi
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-
S04 - 1O Pressure Sensor Offset determined routine periodic basis.
This parameter 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 0
PSI. The values for this parameter are:
“0” when using the minimum value of the pressure
transducer range
A value greater than or less than 0 if the display
does not read 0 or when using an Offset pressure
transducer (an example of an Offset pressure
transducer would be one where the range was minus
PSI (-25) to a positive PSI (200).
38

C01
08 08 0 hrs
01 01 0 hrs
02 02 0 hrs
03 03 0 hrs
04 04 0 hrs
Control - Equal Hours Run Mode

C01 – 01 to C01 – ‘n’ Run Hours’
‘n’ = number of compressors in the system. 8 is the
maximum number of compressors for the X8I
This parameter is set to match the running hours of
each compressor. Record of detected ‘running’ hours for
each compressor. The run hours value can be manually
adjusted, at any time, to match the running hours meter/
display value of each compressor. The default setting for
this parameter is 0 hours. The values for this parameter
are:
“0 to x” where x = the actual run hours for the
compressor
C02
08 08
01 01
02 02
03 03
04 04
C02 – 01 to C02 – ‘n’ Compressor Maintenance
‘n’ = number of compressors in the system. 8 is the
This parameter is set for a compressor(s) that is
unavailable for use for a prelonged period for time due to
maintenance or repair. The compressor will not be utilised
under any circumtances; any Alarm (Warning) or Trip
(shutdown) fault will be ignored. The default setting
for this parameter is . (Represents the compressor is
available) The values for this parameter are:
= Remove compressor from operation
= Compressor can be utilised
39

ir-PCB:
C03
08 08 ir-PCB C03 01.01 01
01 01 ir-PCB 1 100 % 5
02 02 ir-PCB
03 03 ir-PCB 1 IR-PCB +V=! 4
04 04 ir-PCB
2 10 s
Installation – Compressor Connections

C03 – 01 to C03 – ‘n’ Compressor Connection’ IRV-PCB:
‘n’ = number of compressors in the system. 8 is the C03 01.01 01

This parameter sets the type, method of connection, and 1 100 % 5
the control functionality, of each compressor connected
to the X8I. 1 IRV-PCB +V=! 4
Dependant on the regulation and connection type 2 10 s 10 s 3

selected the set-up screen will change to show applicable
settings.
IR-485:
C03 01.01 01
1 100 % 5
1 IR-485
2 10 s
IRV-485:
C03 01.01 01
1 100 % 5
1 IRV-485 50 % 6
2 10 s 60 % 7
40

X8I COMPRESSOR CONNECTIVITY AND For ‘ir-PCB’ connectivity applications the voltage
FUNCTIONAL SETTINGS detection function for the ‘ir-PCB’ Alarm (Warning) input
can be inverted.
+V=! An Alarm (Warning) condition is generated if the ‘ir-
1
Compressor Connectivity: PCB’ Alarm input detects a voltage between 12-250Vac/dc
ir-PCB Fixed speed, load/unload; connected to X8I using (default).
‘ir-PCB’ module using 6-wire method. 0V=! An Alarm (Warning) condition is generated if the ‘ir-
(0/100%) 0% or 100% regulation PCB’ Alarm input detects no voltage.
IRV-PCB Variable Speed; connected to X8I using ‘ir-PCB’
module using the 7-wire ‘V’ terminal method. 5
% Maximum Output Capacity
(variable speed regulation) The maximum output capacity of each compressor must
IR-485 Fixed speed, load/unload; connected to X8I on be set as a percentage with reference to the highest
IR485 network. output capacity (the largest) compressor in the system.
The highest output capacity compressor must be
(0/100%) 0% or 100% regulation
assigned with 100% capacity. Equal capacity (equal sized)
IRV-485 Variable Capacity/Speed; connected to X8I on compressors should be assigned the same % capacity
IR485 network. value. Calculate the output capacity of compressor(s) that
(0 . . 100%) variable %Load regulation are smaller than the largest in the system as a percentage
2
of the largest in the system.
Compressor Start Sequence Time:
For example:
Set to match the time that the compressor takes to
start it’s main motor and load. This time will typically be Compressor 1 700 cfm 100%
equivalent to the compressors ‘Star/Delta’ time. Compressor 2 700 cfm 100%
If unknown, the time can be established by experiment; Compressor 3 420 cfm 60%
manually start the compressor, from a stopped condition,
and determin the time from pressing the start button Compressor 4 420 cfm 60 %
until the compressor loads and contributes capacity Compressor 5 350 cfm 50%
output to the system.
Compressor 6 175 cfm 25%
This time is used by the unit for ‘staggered starting’ of 6
% Minimum Output Capacity
multiple compressors and other operational calculations.
An accurate time is important for successful unit Only applicable for a variable output compressor
operation. (IRV-485). Not shown for other types.
3
Compressor Run-On Stop Time: The minimum output capacity of a variable output
compressor must be set as a percentage of the
compressor’s maximum output scaled in accordance
This setting is only applicable to ‘IRV-PCB’ with the % maximum capacity output value. Minimum
connectivity and is not displayed for other connectivity output capacity is regarded as the output capacity at the
options. lowest possible speed (variable speed compressor) or the
The time that the compressor main motor will continue to minimal output achievable (stepping or other variable
run when the compressor is offload (main motor run-on- regulation control).
time). For example 1:
If unknown, the time can be established by experiment; For a variable speed compressor that has been assigned
start and load the compressor then arrange a condition a maximum capacity output percentage of 100%, and is
that will unload the compressor for a period of time. able to reduce speed to 30% of maximum speed:
Determine the time from the moment the compressor
Minimum Output Capacity = 30% (related to the largest
unloads until the main motor stops and the compressor
capacity)
enters a ‘Standby’ or ‘Auto Restart’ condition.
Example Compressor 1 is a VSD:
This time is used by the X8I for accurate recording
of ‘run hours’ (EHR mode), operational calculations and Max CFM = 700
other data recording applications. An accurate time is
Max Output Capacity 700/700 = 100%
important for successful X8I operation.
4 Min CFM = 210 (30% or 700 x .30)
ir-PCB Alarm (Warning) Input:
Min Output Capacity 210/700 = 30% (or 30% x 100% =
Only applicable for ir-PCB connectivity. Not shown
30%)
for ‘485’ network types.
41

For example 2: The intent of this feature is to always operate the smallest,
most efficient compressor and to prevent a variable
For a variable speed compressor that has been assigned a
output capacity compressor operating at minimal
maximum capacity output percentage of 60% (related to
speed, or minimal output, for prolonged periods of time.
the largest capacity), and is able to reduce speed to 30%
Generally a variable output compressor operating at
of maximum speed:
minimal capacity is less efficient than a smaller capacity
Example Compressor 4 is a VSD: compressor that is able to achieve the same output at
higher, or maximum, output capacity.
Max CFM = 420
Min CFM = 127 (30% or 420 x .30)
18%)
For example 3:
For a 3-step (0/50/100%) reciprocating compressor
that has been assigned a maximum capacity output
percentage of 60%, the minimum output capacity is the
half-output regulation step:
Minimum Output Capacity = 30%
7
% Minimum Efficiency
Only applicable for a variable output compressor

(IRV-485). Not shown for other types.
The minimum efficiency point is regarded as the speed, or
step, below which another smaller capacity compressor
in the system could achieve the equivalent output at a
higher efficiency.
The percentage value is directly related, and scaled, to the
maximum and minimum output percentage values.
For example:
Example: A Compressor is a VSD: Max CFM = 420 (Largest
Compressor is 700 CFM)
Min CFM = 127 (30% or 420 x .30)
18%)
If another compressor in the system is able to provide
40% of the compressor’s full speed output more
efficiently, set the % Minimum Efficiency value to 24%
(40% x 60%). This percentage value represents 40% of
the full speed output of the compressor scaled to System
capacity.
When the compressor is detected as operating below the
% Minimum Efficiency value for a period of time the X8I
will immediately re-evaluate utilization and re-configure,
if possible, to utilize a the smaller capacity, more efficient
compressor, or combination of compressors. This process
is automatic and executed dynamically in accordance
with prevailing operational conditions at the time. The
ENER control mode algorithms will eventually conclude
the best compressor fit without this parameter; the %
Minimum Efficiency input will speed up this process.
42

To return to the main error log menu screen press the
E01 ESCAPE button.
15 -: --- . -- To view the second information screen press ENTER.

button
01 E : ERR . 01
02 -:--- . -- E01 01.01
03 -:--- . -- 1 2 3 4
04 -:--- . --
E01 – 01 to 15 The operational status of each compressor, at the time the
error occurred, is displayed symbolically. See Compressor
The error log is presented in chronological order. Entry 01 Status Displays for Icons.
is the most recent, whereas entry 15 is the oldest. Each
error log item will show the error code. To view details for To return to the first information screen press ENTER
the selected error log item, press the ENTER button. button or the ESCAPE.button. To return to the main error
log menu screen press the ESCAPE button.
E01 01.01
E: ERR.01
16/05/2006 14:25
1
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 X8I at the
time the error occurred; (see: X8I Status Display for
Icons)
43

D01 Diagnostics - Controller Relay Outputs:
Each relay output can be energized and de-energized
D01 manually by selecting the item. Use Up(plus) and
18 Ao 4.00 mA Down(minus) to adjust and Enter.
01 D1 0 Analog Inputs:
02 D2 0 The Analog Inputs will alternate between the detected
value and the electrical measurement on the controller
03 D3 1 input terminals. An independent measuring device can
04 D4 2 be used to check the displayed electrical measurement.
The X8I is equipped with comprehensive diagnostic A1: System Pressure, 4-20mA
functions. Each input can be examined individually and A2: Digital: ir-PCB #4 – Alarm/Serv.
each output can be manually activated or manipulated
individually. A3: Digital: Auxiliary Input (D1)
X8I Controller Diagnostics: Analog Output:
D1 Digital Input 1 The analog output can be manually adjusted. Use

Up(plus) and Down(Minus) to adjust and Enter. The
D2 Digital Input 2 ON output will return to normal operational value upon
D3 Digital Input 3 menu exit.
D4 Digital Input 4 OFF The analog output is utilized on the Terminal PCB to
switch the ir-PCB V outputs. Set the analog output to the
D5 Digital Input 5 Pulsing following to switch each ‘V’ output as required.
D6 Digital Input 6 4.0mA All ‘V’ outputs OFF
D7 Digital Input 7 7.0mA V1 = ON; V2, 3 and 4 = OFF
------------------------------------------------------------- 15.0mA V3 = ON; V1, 2 and 4 = OFF
R1 Relay Output 1 19.0mA V4 = ON; V1, 2 and 3 = OFF
R2 Relay Output 2 OFF
R3 Relay Output 3 D02 Diagnostics – LED Panel
R4 Relay Output 4 ON
D02
R5 Relay Output 5
R6 Relay Output 6
01 SI 0
-------------------------------------------------------------
02 LT 00
A1 Analog Input 1 bar <> mA
A2 Analog Input 2 v
A3 Analog Input 3 v
------------------------------------------------------------- SI: Screen Invert
Ao Analog Output 0.0 to 20.0mA LT: LED Panel Test
Digital Inputs: 0 = on test
OFF (open circuit) 1 = all on
ON (closed circuit) 2 = control test
Pulsing D03 and D04
The pulse signal from an ‘ir-PCB’ is 0V to 24VDC at

50/60Hz. A typical DC voltage meter, or multimeter, will Diagnostic menus D03 and D04 have no standard
detect this as 12VDC +-4V. function and are not shown.
44

Relay Outputs:
D05 Each relay output can be energized and de-energized
manually by selecting the item. Use Up(plus) and
15 Ao 4.00 mA Down(minus) to adjust and Enter.
01 D1 0
02 D2 0 Ao: Analog Output:
03 D3 1 The analog output can be manually adjusted. Press
04 D4 2 Up(plus) and Down(Minus) to adjust and Enter. The
output will return to normal operational value upon
menu exit.
Diagnostics: XPM Expansion Module C:5-8 The analog output is utilized on the Terminal PCB to
switch the ir-PCB V outputs. Set the analog output to the
following to switch each ‘V’ output as required.
o only available when applicable EXP Expansion Box
is installed and registered (detected) by the X8I.
X8I Controller Diagnostics: 4.0mA All ‘V’ outputs OFF
D2 Digital Input 2 ON 11.0mA V2 = ON; V1, 3 and 4 = OFF
D5 Digital Input 5 OFF
D6 Digital Input 6 Pulsing
D7 Digital Input 7
D8 Digital Input 8
-------------------------------------------------------------
R1 Relay Output 1
R2 Relay Output 2
R3 Relay Output 3 OFF
R4 Relay Output 4
R5 Relay Output 5 ON
R6 Relay Output 6
----------------------------------------------------------
Ao Analog Output 0.0 to 20.0mA
Digital Inputs:
OFF (open circuit)
ON (closed circuit)
Pulsing
45

SECTION 10 — FAULT CODES
X8I COMPRESSOR FAULT INDICATIONS, Trip (Shutdown):
TYPES, AND CODES:
In the event of a unit or system “fault” the X8I will display
a fault code. The fault code becomes an item in the user
1sec
operational display menu. If more than one “active” fault
occurs, each will be displayed as a separate item in the The Fault LED will ‘fast flash’ to indicate a Trip (Shutdown)
operational user menu. Press UP or DOWN to view all condition. A Trip (Shutdown) condition will stop normal
active fault codes or to view the normal status display. operation of the X8I. Pressure regulation control will
Alarm (Warning) automatically revert to the individual compressors that
will continue to operate using the pressure settings for
their own control systems. All Trip (Shutdown) conditions
Shutdown (Trip) are registered in the X8I Error Log. All Trip (Shutdown)
conditions must be manually reset.
Fault codes are separated into unit faults (ERR) and
system alarms (warning) (SYS). Fault Codes:
Compressor Alarm (Warning) conditions are automatically Each individual fault has a unique numeric code.
reset when the condition has been resolved and reset on ERR.01 Pressure Sensor Fault
the compressor.
The signal from the control pressure sensor is out-of-
Compressor Not Available (Shutdown, Trip) conditions are range (<3.5mA or >21.8mA).
automatically reset when the condition has been resolved
and reset on the compressor; and the compressor has ERR.04 Internal 24V Fault
been restarted. The 24VDC power supply, internal to the unit’s controller,
Compressor fault conditions are displayed by the is below 19.2V (internal controller fault)
compressor indicators and in the user menu status screen. ERR.05 Emergency Stop
Compressor fault conditions are not regarded as X8I unit
fault conditions. The wire link between terminals ‘+C’ and ‘C1’ of the unit’s
controller is open circuit. These terminals are permanently
connected together on the X8I Terminal PCB: this error
Compressor Status Sysmbols and Comressor Status will never occur in normal operational circumstances.
Indicators ERR.06 Real Time Clock Error
Fault Codes The Real Time Clock device, internal to the unit’s
Fault codes are separated in to unit faults ‘ERR’ and system controller, has failed.
Alarms (Warning) ‘SYS’. ERR.07 XPM-LED Module Error
ERR: Unit faults are errors with the X8I controller itself and Data communications with the internal XPM-LED (Status
are all conditions that prevent normal operation from LED Display) module have been disrupted or lost.
continuing.
ERR.12 ir-PCB Expansion Module C5-8
SYS: System faults are items that arise from conditions
external to the X8I controller; the X8I itself continues to Data communications with the external ir-PCB Expansion
function correctly. module ‘C:5-8’ have been disrupted or lost.
There are two types of Fault condition: ERR.13 ir-PCB Expansion Module C5-8
Alarm (Warning): Short Circuit condition detected on external ir-PCB

Expansion module ‘C:5-8’.
SYS.01 Excess Pressure (PM)
Pressure has exceeded the set Maximum Pressure Limit.
1sec
SYS.02 Min Pressure (Pm)
The Fault LED will ‘slow flash’ to indicate an Alarm
Pressure has fallen below the set Minimum Pressure Limit
(Warning) condition. An Alarm (Warning) indicates that
(see ‘Tables’)
the X8I is continuing with normal operation but user
attention is required. All Alarm (Warning) conditions are SYS.04 Capacity Alarm (Warning)
registered in the X8I Error Log. All Alarm (Warning)
Insufficient Capacity; all available compressors are loaded
and pressure is still decreasing.
46

SYS.05 Remote Alarm (Warning) The controller’s main power supply must be removed and
re-applied to reset this condition.
Auxiliary Input Function ‘AA’
E5001: Internal memory failure
The auxiliary Input is set for ‘Alarm (always active)’
function and is in a Fault condition. The unit’s controller has detected disruption to the
internal permanent application memory storage (FLASH).
SYS.06 Remote Alarm (Warning)
The integrity of the FLASH memory contents is suspect.
Auxiliary Input Function ‘AR’ Re-load the main application software in the first
The auxiliary Input is set for ‘Alarm (active when unit instance; re-new the controller if the condition persists.
running)’ function and is in a Fault condition. The controller’s main power supply must be removed and
SYS.07 Remote Trip (Shutdown) re-applied to reset this condition.
Auxiliary Input Function ‘TA’ To Display the Software Version:
The auxiliary Input is set for ‘Trip/Shutdown (always Press and hold Reset then press Escape.
active)’ function and is in a Fault condition. The user menu display item will show the software
SYS.08 Remote Trip (Shutdown) version ID (example: “E01”).Fault Codes:
Auxiliary Input Function ‘TR’

The auxiliary Input is set for ‘Trip/Shutdown (active when
unit is running)’ function and is in a Fault condition.
Internal Controller Fault ‘E’ Codes:
‘E’ code errors are specific to the unit’s ‘internal to
controller’ digital logic circuits and will only occur in the
most exceptional of circumstances.
All ‘E’ code conditions are Trip (Shutdown) type faults.
The ‘Fault’ (red) LED will ‘fast flash’ and the condition is
registered in the Error Log. If an ‘E’ code fault condition
persists, consult your product supplier for advise or renew
the unit’s controller.
E0836: PLL Unlock; Internal failure or excessively high
external electrical interference detected.
The main timing circuit (processor clock) has been
disrupted and the processor is running on an ‘internal
to chip’ back-up clock. The back-up clock is intended to
keep the processor running, at a much slower processing
speed, to enable emergency actions to be taken. The
controller is unable to continue running the main
software application in this condition.
The unit will Shutdown; compressors will continue to
operate using local pressure regulation.
The controller’s main power supply must be removed and
re-applied to reset this condition.
E0866: Controller internal power supply fault
The low voltage logic processing power supply, internal
to the unit’s controller, is below minimum operational
levels; internal to controller fault. Renew the controller if
this fault condition persists. The Trip must be manually
reset from the keypad.
E5000: Internal memory map error
The unit’s controller has detected disruption to the
internal operational memory storage (RAM). The integrity
of the RAM memory contents are suspect; the controller
must be reset to clear and re-map the memory. Renew
the controller if this fault condition persists.
47

SECTION 11 — PARTS LIST
Item Part No. Description Item Part No. Description
- 42659250 X8I, Kit - 22194773 XI Installation Kit
- 23242159 Unit, X8I - 80444078 Quick Setup Guide
- 80444086 Manual, User CD
1 42659268 Unit, Controller
2 42659284 Unit, XPM-PSU24
3 39265913 Unit, XPM-TAC24
4 39265905 PCB, Terminal 3
5 42659276 Unit, XPM-LED
6 38036703 Gland, Set - Pg13.5
4
7 39265939 Sensor, Pressure
5
4-20mA, 232psi (16bar)
2
20mm
1
IEC 5mm 6
Item Part No. Description

7
10 39265962 IEC Fuse T1.0A
10 39265970 IEC Fuse T1.6A
10 39265988 IEC Fuse T1.6A
Mounting Dimensions:
TECHNICAL DATA
27mm 286mm
Dimensions 13.4” x 9.45” x 6.0”

27mm
340mm x 241mm x 152mm

Weight 16.5lb (7.5kg)
Mounting wall, 4 x screw fixings
Enclosure IP65, NEMA 4 188mm
Supply 230Vac +/- 10%

115Vac +/- 10%
Power 100VA 8mm Ø
Temperature 32°F to 115°F (0°C to 46°C)

Humidity 95% RH, non-condensing
48

SECTION 12 — DIAGRAMS
X8I
T1-46-321-R6-DiC-CG
Terminal PCB
4-20mA
33 34 35 36
X06
+VDC C03
Ai1 C04 C01
X08
C03
C05
X05
+VDC
C031 A-GND C04
4
Ai2 C06
C032 Ao +VDC C07 C05
3
C06
31 32
Ai3 C08 SEQ C08
X07
2
C07 C07
GND
X09
C08
1
C+ C019
27 28 29 30
C010
1 C020 C09
C09
X06
X08
XPM-LED
2 C021 C010
X02 3 C022
X04
4
L2 L1
C011
SEQ
1 C023
2 5 C024 C012
25 26
C04
X05
6 C025 C013 C03
7
XPM485
RS485#2
C026 C014 C019

8 C027
+
-
C015
V4 19 20 21 22 23 24
R-SEQ 10k
C016 C024
24Vac
C034
GND
150k
C017 C06
X04
C011 C018 150k
R5
C019 C012
C012
X02
24Vac
C020
C01/3 SEQ
C021
R6
L2 L1 RS485#1
C022
Multi485
C01/4
X07
C023
C024
10k
V3 13 14 15 16 17 18
C013
C09 R1 C025 C023
C014
GND
C010 C026 C027

R2
X03
C027
C015
X03
R3 C028 C018
C016
C029
C017 C030
24Vac
R4
X01
C018 C033
10k
V2 7 8 9 10 11 12
C034
2
1
C022
0VDC
C026
X02
C031
X02
XPM-TAC24
C016
-
C032 4-20mA
2
1
0Vac - earthed
+
NL E 24Vac
2 1 R-V4
X01
X03 10k
6
R-V3
C021
5
0Vac
C029 R-V2
C028 C025
X01
2 3 4
24Vac
R-V1
X01
XPM-PSU24
NL E C015
2 1 24Vac
230Vac 10%
V1 1
115Vac 10% X02 X03

24VDC 24VDC
1 2 1 2
XPM-LED X03
1 2
XPM485 X02
L1 1
1 1 L1
L2 2
2 2 L2
Wiring Diagram
49

Connection Diagram
Terminal PCB
33 34 35 36
115V 'UL' @ 5A maximum.
X08
R1 Auxiliary Output #1
31 32
Auxiliary Input #1
X07
D1
330ft (100m) max
L2 L2
27 28 29 30
L1
X06
L1
Multi485
L2
L1
330ft (100m) max
-
25 26
- Ai1 System
X05
Pressure
+ +
+20VDC 6 4-20mA
V4 19 20 21 22 23 24
Di5 Ready/Run
i-PCB 4
5
Ai2 Alarm/Serv. 4
X04
- GND 3
330ft (100m) max
R5 LOAD 2
R1 SEQ 1
4
V4 VFD V V
IR-PCB 6-core
IRV-PCB 7-core
+20VDC
V3 13 14 15 16 17 18
Di4 Ready/Run
i-PCB 3
Di8 Alarm/Serv. 4
X03
- GND 3 330ft (100m) max

R4 LOAD 2
R1 SEQ 1
3
V V
V3 VFD
IR-PCB 6-core
IRV-PCB 7-core
+20VDC 6
V2 7 8 9 10 11 12
Di3 Ready/Run
i-PCB 2
Di7 Alarm/Serv. 4
X02
- GND 3
330ft (100m) max
R3 LOAD 2
R1 SEQ 1
2
V2 VFD V V
IR-PCB 6-core
IRV-PCB 7-core
+20VDC 6
6
Di2 Ready/Run
i-PCB 1
5
5
Di6 Alarm/Serv. 4
X01
2 3 4
- GND 3
330ft (100m) max
R2 LOAD 2
R1 SEQ 1
1
V1 1
V1 VFD V V
IR-PCB 6-core
IRV-PCB 7-core
50

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
51

X8I 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 bar/psi
#1 kW VA Hz Comp #1 Full Load Capacity cfm
psi cfm
Comp #2 Model/Type
#2 kW VA Hz Comp #2 Working Pressure bar/psi
Comp #2 Full Load Capacity cfm
psi cfm Comp #3 Model/Type
#4 kW VA Hz
Comp #4 Working Pressure bar/psi
Comp #5 Model/Type
psi cfm Comp #5 Working Pressure bar/psi
#5 kW VA Hz
52

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 FILO ENERGY
T01 01 Comp #1 Priority



53

P02 PF Prefill Function !>X A
P02 PT Prefill Time Sec
P02 PP Prefill Pressure psi/bar
P02 - Primary Compressors 1 2 3 4 5 6 7 8 9 10 11 12
P02 - Backup Compressors 1 2 3 4 5 6 7 8 9 10 11 12
S01 PS Pressure Schedule

S01 AR Auto Restart
S01 RP Rotation Interval
S01 TS Default Table Select
S02 NC Number of Compressors 1 2 3 4 5 6 7 8 9 10 11 12

S02 PM Max 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
S02 AO Auxiliary Output
S02 CA Capacity Alarm
S02 MA Capacity Restricted Alarm
S03 01 Aux I/O Box #1

S03 02 Aux I/O Box #2
S03 BT RS485 Timeout sec
S04 1o Pressure OffsetA psi/bar

S04 1r Pressure Range psi/bar
54

C01 01 Compressor #1 Hours hrs
C03 01 Compressor #1 Type IR-PCB IRV-PCB IR-485 IRV-485

C03 - Start Time Sec
C03 - Max Capacity %
C03 - Min Capacity %
C03 - Min Efficiency %







55

Ingersoll Rand System Automation Operator's Manual X8I: More Than Air. Answers

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Ingersoll Rand System Automation Operator's Manual X8I: More Than Air. Answers

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Ingersoll Rand

Before installing or starting this unit for the first

More Than Air. Answers. C.C.N. : 80444060

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SECTION 2 — INTRODUCTION....................................3 X8I QUICK SET-UP CONFIGURATION................................26

OPTIONAL FEATURES AND FUNCTIONS.........................26

COMPRESSOR CONNECTION AND CONTROL...............5 SERVICE Level Menus...........................................................30

OPTIONAL CONNECTION METHODS..................................5 X8I CONFIGURATION SCREENS ..........................................31

PRESSURE DETECTION AND CONTROL.............................6 X8I COMPRESSOR CONNECTIVITY AND FUNCTIONAL

PRESSURE SENSOR CONNECTION.....................................10 CONNECTION DIAGRAM……... ...................................50

ir485 COMMUNICATION PROTOCOL................................11

SECTION 6 — CONTROL FEATURES AND

STANDARD CONTROL FEATURES AND

STANDARD CONTROL FEATURES AND

ALTERNATE CONTROL FEATURES AND

SECTION 7 — DISPLAY AND MENU OPERATION...20

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All Nirvana Compressors, 20 HP (15KW) and above

require the irV-485 Gateway.

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The EX Box connects to the X8I controller via a two wire,

30ft PRESSURE DETECTION AND CONTROL

The factory default settings for the pressure sensor is

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System Alarms (Warning) :

a System Alarms (Warning) :

Compressor Status Indicators :

Keypad and Navigational Keys Functionality

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Ingersoll Rand Automation

5 6 7 8 May Be Used As Long As the Maximum Number Of

RS485 Network Cable

PRESSURE TRANSDUCER CABLE RS485 NETWORK CABLE

X8I X05 CONNECTOR PT CONNECTOR

ir-PCB COMPRESSOR CONTROL CABLE

From Air Reference X8I Application and Interconnect Guide For

IR (Non- Nirvana) Compressors

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UNIT LOCATION DEMAND (DRY) SIDE PRESSURE CONTROL

The X8I can be mounted on a wall using conventional

Regular routine monitoring of pressure differential

PRESSURE SENSOR LOCATION

Pressure Sensor Located Before Cleanup Equipment

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Cable Earth Shield

ir-PCB Interface Module

Consult the X8I Interconnect and Application Guide

Pressure Sensor Wiring and Location

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The RS485 Network is a Serial, Point to Point

The cable used between the ir-485 Gateway and the

Consult the X8I Interconnect and Application Guide

specifically for Compressor and Air System control. ir485

Note: Follow RS485 Network installation

Incorrect RS485 Network Example

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Tolerance is a user adjustable setting that determines

load the next compressor in the sequence to match the PT

A variable speed compressor will be included in the

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