X Series InterconnectGuide Non-IR Compressors

Ingersoll Rand
X-Series System Automation

Interconnect Guide
Non-Ingersoll Rand Compressors
Before installing or starting this unit for the first

time, this manual should be studied carefully to
obtain a working knowledge of the unit and/or the
duties to be performed while operating and
maintaining the unit.
RETAIN THIS MANUAL WITH UNIT. This Technical
manual contains IMPORTANT SAFETY DATA and
should be kept with the unit at all times.
C.C.N. : 80444466
More Than Air. Answers. REV. : C
Online answers: http://www.air.irco.com DATE : MAY 2008
1
SECTION 1 — TABLE OF CONTENTS
SECTION 1 — TABLE OF CONTENTS.................................2
SECTION 2 — INTRODUCTION.........................................3
SECTION 3 — SAFETY......................................................3
INSTALLATION ................................................................3
OPERATION.....................................................................3
MAINTENANCE AND REPAIR ............................................4
SECTION 4 — X4I SYSTEM OVERVIEW ..............................5
SECTION 5 — X8I SYSTEM OVERVIEW ..............................6
SECTION 6 — VSD OVERVIEW ..........................................7
SECTION 7 — ASSISTANCE ..............................................8
SECTION 8 — INTERCONNECT DRAWINGS .......................8
APPENDIX A — ir-PCB Interconnect Drawings To
Non-Ingersoll Rand Compressors .............................9
APPENDIX B — VSD Box Interconnect Drawings To
Ingersoll Rand Non-Nirvana VSD Compressors .......46
2
SECTION 2 — INTRODUCTION
The X - SERIES AUTOMATION is a family of specialized X8I
controllers designed to provide safe, reliable, and
The X8I is an advanced system controller designed to
energy-efficient control of your compressed air system.
provide safe, reliable, and energy-efficient management
X4I of your compressed air system. The X8I is capable of
controlling up to eight (8) positive displacement air
The X4I is capable of controlling positive displacement
compressors. The compressors may be fixed speed,
air compressors. The compressors may have electro-
variable speed or multi-step and have electro-pneumatic
pneumatic or microprocessor based controls. The X4I is
or microprocessor based controls. The X8I is uniquely
completely customizable to meet the specific needs of
configurable and customizable to meet the specific
your compressed air system.
needs of some of the most complex compressed air
system. Additionally, the X8I control network can expand
to include monitoring and control of various compressed
air system components.
SECTION 3 — SAFETY
access without obstruction or hazard
! WARNING : Risk of Danger and to allow clear visibility of indicators
at all times.
WARNING : Risk of Electric Shock • If raised platforms are required to
provide access to the X-Series
Automation System, they must not
WARNING : Risk of High Pressure interfere with normal operation or
! obstruct access. Platforms and stairs
should be of grid or plate construction
WARNING : Consult Manual with safety rails on all open sides.
• Before installing or operating the X- OPERATION

Series Automation System, take time to
carefully read all the instructions • The X-Series Automation System must
contained in this manual, all compressor only be operated by competent
manuals, and all manuals of any other personnel under qualified supervision.
peripheral devices that may be installed • Never remove or tamper with safety
or connected to the unit. devices, guards or insulation materials
• Electricity and compressed air have the fitted to the X-Series Automation System.
potential to cause severe personal injury • The X-Series Automation System must
or property damage. only be operated at the supply voltage
• The operator should use common sense and frequency for which it is designed.
and good working practices while • When main power is switched on, lethal
operating and maintaining this system. voltages are present in the electrical
All applicable codes should be strictly circuits and extreme caution must be
adhered to. exercised whenever it is necessary to
• Maintenance must be performed by carry out any work on the unit.
adequately qualified personnel that are • Do not open access panels or touch
equipped with the proper tools. electrical components while voltage is
applied unless it is necessary for
INSTALLATION measurements, tests or adjustments.
Such work should be carried out only by
• Installation work must only be carried a qualified electrician equipped with the
out by a competent person under correct tools and wearing appropriate
qualified supervision. protection against electrical hazards.
• A fused isolation switch must be fitted • All air compressors and/or other
between the main power supply and the equipment connected to the unit should
X-Series Automation System. have a warning sign attached stating
“THIS UNIT MAY START WITHOUT
• The X-Series Automation System should WARNING” next to the display panel.
be mounted in such a location as to
allow operational and maintenance
3
• If an air compressor and/or other on electrical power or attempt to
equipment connected to the unit is to be start the X-Series Automation
started remotely, attach two warning System if such a warning label is
signs to the equipment stating “THIS attached.
UNIT CAN BE STARTED REMOTELY”.
• Make sure that all instructions
Attach one sign in a prominent location
concerning operation and maintenance
on the outside of the equipment, and
are strictly followed and that the
the other sign inside the equipment
complete unit, with all accessories and
control compartment.
safety devices, is kept in good working
order.
MAINTENANCE AND REPAIR
• The accuracy of sensor devices must be
• Maintenance, repairs or modifications checked on a regular basis. They must
must only be carried out by competent be calibrated when acceptable tolerances
personnel under qualified supervision. are exceeded. Always ensure any
pressure within the compressed air
• If replacement parts are required, use system is safely vented to atmosphere
only genuine parts from the original before attempting to remove or install a
equipment manufacturer, or an sensor device.
alternative approved source.
• The X-Series Automation System must
• Carry out the following operations only be cleaned with a damp cloth, using
before opening or removing any access mild detergents if necessary. Avoid the
panels or carrying out any work on the use of any substances containing
X-Series Automation System: corrosive acids or alkalis.
i. Isolate the X-Series Automation • Do not paint the control faceplate or
System from the main electrical obscure any indicators, controls,
power supply. Lock the isolator instructions or warnings.
in the “OFF” position and remove
the fuses.
ii. Attach labels to the isolator
switch and to the unit stating
“WORK IN PROGRESS - DO NOT
APPLY VOLTAGE”. Do not switch
4
SECTION 4 — X4I SYSTEM OVERVIEW
It is recommended that installation and commissioning be carried out by an authorized and trained product supplier.
Ingersoll Rand Automation
Model X4I
SPECIFICATIONS The Maximum Number of Compressors Controlled By The X4I Is Four (4).
Dimensions 11.45” x 9.45” x 6.0”
The Maximum Number Of Direct ir-PCB Connections To The X4I is Four (4).
291mm x 241mm x 152mm
Weight 14lb (6.4kg)
Mounting Wall, 4 x screw fixings
Enclosure IP65, NEMA 4
Supply 230Vac +/- 10%, 50 Hz
115Vac +/- 10%, 60 Hz
Power 50VA
Temperature 32°F to 115°F
(0°C to 46°C)
Humidity 0% to 95% RH
(non-condensing)
Supply ir-PCB COMPRESSOR CONTROL CABLE

Voltage 7 Conductor Cable, 18 Gauge, Stranded, Earth Shielded
Local Disconnect (Breaker) Box OR
On/Off Cable
Fused for 50VA Single Conductor Wire, 18 Gauge Stranded, Quantity (7)
Switch
In Grounded Conduit No Greater Than 330FT (100M)
Power Cable 24VAC Control Voltage
3 conductor (N, L, E) Pressure
(Sized in accordance with local Transducer
electrical and safety regulations). Cable
PRESSURE TRANSDUCER CABLE

2 Conductor Cable, 18 Gauge Stranded
Earth Shielded
No Greater Than 330FT (100M)
24VDC Control Voltage
X4I X05 CONNECTOR PT CONNECTOR

25 +VDC Pin #3
26 Signal Pin #1
Reference X4I 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
DRIP LEG
ir-PCB ir-PCB
From Air
Compressors

Reference X4I Application and Interconnect Guide For
Wiring Connections Between The X4, The ir-PCB, and
The Compressor
5
SECTION 5 — X8I SYSTEM OVERVIEW
Model X8I
SPECIFICATIONS The Maximum Number of Compressors Controlled By The X8I Is Eight (8).
Dimensions 13.4” x 9.45” x 6.0” The Maximum Number Of Direct ir-PCB Connections To The X8I is Four (4).
340mm x 241mm x 152mm Any Combination Of Compressor Connection Methods May Be Used As Long As
Weight 16.5lb (7.5kg) the Maximum Number Of Compressors (8) Is Not Exceeded.
Mounting Wall, 4 x screw fixings
Enclosure IP65, NEMA 4
Supply 230Vac +/- 10%, 50 Hz
115Vac +/- 10%, 60 Hz
Power 100VA The EXP Box Will Add Another
Temperature 32°F to 115°F (4) Direct ir-PCB connections.
(0°C to 46°C) The X8I Supports 1 EXP Box.
Humidity 0% to 95% RH
This Would Allow A Total Of (8)
(non-condensing)
Compressors To Be Connected
And Controlled Via The ir-PCB.
Supply
Voltage
Local Disconnect (Breaker) Box OPTIONAL
On/Off Cable EXP RS485 Network Cable
Fused for 100VA
Switch
Power Cable EXP RS485 NETWORK CABLE
3 conductor (N, L, E) Pressure Belden 9841 or Equivalent
(Sized in accordance with local Transducer In Grounded Conduit
electrical and safety regulations). 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
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 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
Ingersoll
Rand ir-485 Gateway
102 psi
For All
ir-485 IR (Non- Nirvana) Compressors
IntelliSys “Red Eye”, SG and SE
ir-485 OR
Direct To
S3 irV-485 Gateway
From VSD Pressure For All
Transducer
irV-485 Nirvana Compressors
To VSD Pressure
Transducer Input 20HP (15KW) and Above
1
2D
LE
D
LE
3 4
ir-
PCB
6
SECTION 6 — VSD OVERVIEW
VSD Box
From VSD Box

To ir-PCB
To Intellisys Controller
LE
LE
D
2D
1
ir-PCB
1 > Intellisys Discharge

Pressure Transducer
1 2
2 > VSD Discharge
Pressure Transducer
From Pressure Transducer

To VSD Box
From VSD Box

To IR-5000 Pressure Transducer Input
LE
LE
D
2D
1
7
SECTION 7 — ASSISTANCE
Contacting Technical Support Services or Service Bulletins listed on the IR ServiceNet can provide further assistance if there
are other questions or concerns during Installation and Start-up. Also, additional Application and Compressor Interconnect
Guides will be posted and available on the IR ServiceNet as they are developed and created.
SECTION 8 — COMPRESSOR INTERCONNECT DRAWINGS

The following Appendix’s contain reference drawings designed to assist with the connection of the X – Series Automation
System to Ingersoll Rand Air Compressors as well as Non-Ingersoll Rand Air Compressors. These drawings are for
Guidance Only; connections may differ with date, model, type, variant, special, custom or concession builds. This
information is intended to be used in conjunction with the compressor’s original control circuit diagram.
8
APPENDIX A
ir-PCB TO NON-INGERSOLL RAND
COMPRESSOR INTERCONNECT DRAWINGS
Atlas Copco Pre-Elektronikon Compressors.................. A1 CompAir – Cyclon 105 to 475 with Control Card
C20605-50 / -160 Compressors .................................A23
Atlas Copco Elektronikon MK1 Compressors................ A2
CompAir – 6000N Series with MK2/MK3 SureScan
Atlas Copco Elektronikon MK2 and MK3
Controller C20606-60 / -120 Compressors.................A24
Compressors ............................................................... A3
CompAir – 6000F Series with MK2/MK3 SureScan
Atlas Copco Elektronikon I (MK4) GA11 to GA55C
Controller C20606-60 / -120 Compressors.................A25
Compressors ............................................................... A4
CompAir – 6000F Series with Controller C20605-150
Atlas Copco Elektronikon II (MK4) GA55 And Above
Compressors ..............................................................A26
Compressors ............................................................... A5
CompAir – 6000N/F Series with MK1 SureScan Controller
Atlas Copco Elektronikon II (MK4) ZT75
C20606-30 / -40 Compressors ...................................A27
Compressors ............................................................... A6
CompAir Demag – Delcos 3000 Compressors.............A28
Atlas Copco Elektronikon MK3 ZT145
Compressors ............................................................... A7 CompAir Demag – Delcos 1000 Compressors.............A29
Atlas Copco Elektronikon II (MK4) ZT160 CompAir Demag – Delcos SL Slave Compressors.........A30
Compressors ............................................................... A8
CompAir Demag – Delcos SL Master Compressors ......A31
Atlas Copco Elektronikon II (MK4) GA75VSD-FF
CompAir – Hydrovane 68 Series and Similar
Compressors ............................................................... A9
Compressors ..............................................................A32
Boge – Ratiotronic (S Series) (with Pressure Switch)
CompAir – Hydrovane 128 – 218 Series
Compressors ............................................................. A10
Compressors ..............................................................A33
Boge – Ratiotronic (S Series) (with Pressure Sensor)
CompAir – Hydrovane RS Speed Regulated
Compressors ............................................................. A11
Compressors ..............................................................A34
Boge – Supertronic (SF Series – Frequency Inverter Drive)
Worthington Creyssensac – Rollair 50 to 125
Compressors ............................................................. A12
Compressors ..............................................................A35
ECOAIR D31-D102 (EcoControl) Compressors ............ A13
Sullair – LS12/16 MFV EMCTL Comprssors..................A36
HPC – KAESER DSB Series Compressors...................... A14
HPC – KAESER DS/FS Series Compressors................... A15
HPC – KAESER AS/SK Series Compressors .................. A16
HPC – KAESER (Sigma Control) Compressors .............. A17
CompAir – RA Series Compressors............................. A18
CompAir – 6000 Series with Control Card
C20605-30 / -360 Compressors ................................ A19
CompAir – 6000E/6040N-6050N Series
with Control Card C20605-100 / -360 . -120 / -310
Compressors 1 of 2 ................................................... A20
with Control Card C20605-100 / -360 . -120 / -310
Compressors 2 of 2 ................................................... A21
with Pressure Switch Relay e5 Control Card C20605-100
/ -360 . -120 / -310 Compressors .............................. A22
9
Atlas Copco - Pre Elektronikon
+Vac
IR-PCB
Emergency Stop
C01 (not fitted to all models)
S3
C
LOAD
C K1
11
SEQ CONT
blocking
11 relay
C02
OUT NO
OUT C
11
OUT NC Pressure
PSR
Switch
IN NO 14
13
IN C
IN NC
C04
ALARM
COMPRESSOR
CONTROL
K23 PCB
RUN
READY
S3
C03 A1 Line Y1 Loading

K21 Contactor Solenoid
Valve
A2 Coil
To X-Series Automation 0Vac 12
CAUTION
Wires with the same identification number as the pressure switch wires also appear in different parts of the
circuit. Do not rely on wire numbering only, ensure that the correct wires are identified by following the wires
directly from the pressure switch.
Guidance only; connections may differ with date, model, type, variant, special, custom or concession builds
This information is intended to be used in conjunction with the compressor’s original control circuit diagram
Appendix A Page A1
Atlas Copco - Elektronikon Mk1
NOTE: Look for REMOTE LOAD and REMOTE CONFIG digital inputs on the rear label of the
controller. Some Mk1 controllers have dryer inputs instead of remote pressure control inputs -
if remote pressure control inputs do not exist the Electronikon controller will need to be
replaced with a remote pressure control version in order to connect to an X4I.
Connection is not possible to an Electronikon with dryer monitoring inputs
IR-PCB Elektronikon Controller

C01
C common
LOAD remote load/unload
C
SEQ CONT ! remote/local config
C02
DIGITAL INPUTS
OUT NO
Emergency
OUT C S3
Stop
OUT NC
IN NO K1 Blocking
Relay
IN C
IN NC
C04 24Vac/dc min

! 250Vac/dc max
ALARM
RUN
A1
Line
K21 Contactor
READY Coil
A2
1X1 1X1
C03
To X-Series Automation
IMPORTANT: Mk1 Elektronikon

The state of the '
Remote/Local Pressure Sensing'input is only detected at compressor start. If sequencer
control is manually stopped, or automatically removed in the event of a failure, the compressor will not revert
to local pressure control until the compressor is stopped and re-started. To put the compressor under
sequencer control, ensure the sequencer is activated and running before the compressor start button is
pressed - check that the Elektronikon ' Remote'indicator is illuminated.
Appendix A Page A2
Atlas Copco - Elektronikon Mk2 and 3
Note: Elektronikon digital inputs common

Elektronikon Controller
is +Vdc on Mk3 units or 0Vdc on Mk2 units
- never use Earth or Ground for digital
input common connection. 2X4
1 digital inputs
common
1X1
IR-PCB
30
C01
C
remote
LOAD 6
load/unload (5)
C
7 remote/local
SEQ CONT
pressure sensing (4)
C02
OUT NO Emergency
S3
Stop 2X2
OUT C
OUT NC 14
K01 blocking relay
IN NO 15
IN C
IN NC
C04
24Vac/dc min
! 250Vac/dc max
ALARM
RUN
A1
Line
K21 Contactor
READY Coil
A2
1X1 1X1
C03
IMPORTANT: Mk2 Electronikon Only

The state of the '
Remote/Local Pressure Sensing'input (2X4-7) is only detected during controller initialisation
which occurs when power is applied to the compressor. If sequencer control is manually stopped, or
automatically removed in the event of a failure, the compressor will not revert to local pressure control until
the power to the compressor is removed and re-applied. To put the compressor under sequencer control,
ensure the sequencer is activated and running before power is applied to the compressor.
Appendix A Page A3
Atlas Copco - Elektronikon I (Mk4)
GA11 to GA55C
IR-PCB
C01
Elektronikon I
C
LOAD
C
SEQ CONT
C02
OUT NO
OUT C
OUT NC
IN NO
IN C
IN NC
C04
ALARM
RUN
There is no known method of
READY connecting any non OEM remote
sequence control device to an
C03 Elektronikon I (Mk4) at this time
Appendix A Page A4
Atlas Copco - Elektronikon II (Mk4)
GA55 >>
IR-PCB Elektronikon II
1X6 2X9
C01
30 13
C
LOAD
34 5
C
F1 F2 F3
SEQ CONT
35 6
C02
OUT NO
OUT C 1X6 - 30 common +VDC
1X6 - 34 remote load/unload
OUT NC 1X6 - 35 remote pressure sensing
IN NO
IN C
IN NC 1X4
5
C04 5
24Vac/dc min
ALARM ! 250Vac/dc max
blocking
K01
relay
RUN
READY 1X4
6
K22 K21
C03
11
A1
Line
K21 Contactor
Coil
A2
2 2 2
1X4
Appendix A Page A5
ZT75
1X5 2X9
C01
53 13
C
LOAD
56 5
C
F1 F2 F3
SEQ CONT
57 6
C02
OUT NO
IN NO
IN C
IN NC
24Vac/dc min
! 250Vac/dc max
C04
1X7 24Vac
ALARM
1X7 7
0Vac
6
RUN 1X7 1X7
Compressor Running
17 18
READY 1X7 1X7
Automatic Operation
11 12
C03 Elektonikon Relay
Contact Outputs
Appendix A Page A6
Atlas Copco - Elektronikon Mk3
ZT145
IR-PCB Elektronikon Mk3

1X1
2X9
C01 common +VDC
53 1
C
2X6
LOAD remote load/unload
58 4
C
2X6
SEQ CONT remote pressure sensing
59 5
C02
OUT NO
OUT C
OUT NC
IN NO
IN C
IN NC
24Vac/dc min
! 250Vac/dc max
C04
24Vac
ALARM ?
0Vac
?
RUN
Compressor Running
? ?
READY
Automatic Operation
? ?
Contact Outputs
Appendix A Page A7
ZT160
1X5 2X9
C01
53 13
C
LOAD
57 5
C
F1 F2 F3
SEQ CONT
58 6
C02
OUT NO
IN NO
IN C
IN NC
24Vac/dc min
! 250Vac/dc max
C04
1X7 24Vac
ALARM
1X7 7
0Vac
6
RUN 1X7 1X7
Compressor Running
19 20
READY 1X7 1X7
Automatic Operation
11 12
Contact Outputs
Appendix A Page A8
GA75VSD-FF
1X6 - 30 common +VDC

1X6 2X9
C01
30 13
C
LOAD
34 5
C
F1 F2 F3
SEQ CONT
C02
OUT NO
OUT C
Automatic
OUT NC Operation
IN NO
IN C 24Vac/dc min
! 250Vac/dc max 2X12 3 2
IN NC
C04
1X4 1X4
ALARM 5
5
RUN 2X10-9
Emergency
S3
Stop
READY
2X10-8
4
C03 A1 1X4
Fan
K15 Contactor 5
Coil
A2
To X-Series Automation 2
Caution
The VSD Elektonikon Mk4 controller is not equipped with a ' Remote Pressure Sensing'input. If sequencer
control is manually stopped, or automatically removed in the event of a failure, the compressor will not revert
to local pressure control until the Elektonikon '
Remote Pressure Sensing'setting is manually adjusted to
local pressure control.
Appendix A Page A9
Boge - Ratiotronic (S Series) fitted with Pressure Switch
IR-PCB
C01 terminal numbers: x(y) Ratiotronic Controller

x = S30 to S220 (SG101 to SG340)
C y = S6 to S29
LOAD
17
C
20 19 18 18
SEQ CONT (10) (19)(18)
21(11) 31(29)
C02
OUT NO
OUT C
original connection
OUT NC 17
IN NO
20 19 18 18
IN C 21 (10) (19) (18)
IN NC (11) 31(29)
control
pressure switch
24Vac/dc min
! 250Vac/dc max
X2-1 230Vac
C04 S1 Emergency Off
Without r1
ALARM 27 230Vac
READY relay
X2-2 X3-1
33 Ready for
RUN With READY relay Operation
34
X3-2
X2-4
READY 24 Circuit
Contactor
A1
C03 K2 Circuit
Contactor
A2
0Vac
X2-8 41 44
(39)
Appendix A Page A10

Boge - Ratiotronic (S Series) fitted with Pressure Sensor
IR-PCB
Ratiotronic must be setup to operate
C01 ! with remote pressure control input and Ratiotronic Controller
set to '
Remote'mode
C Fit Local/Remote switch, Option 40/4
LOAD
C
20Vdc
SEQ CONT
X2-
C02
18
OUT NO
OUT C 19
OUT NC
IN NO
IN C
IN NC
!
24Vac/dc min
! 250Vac/dc max
X2-1 230Vac
Without 27 230Vac
ALARM READY relay
X2-2 X3-1
33 Ready for
RUN With READY relay
Operation
34
X3-2
X2-4
READY 24 Circuit
Contactor
A1
C03 K2 Circuit
Contactor
A2
0Vac
X2-8 41 44
(39)
Local'control if the X-Series Automation is stopped or fails, switch to

Ratiotronic will not automatically revert to '
'
Local'mode ! to operate independantly of the X-Series Automation
Appendix A Page A11

Boge - Supertronic (SF Series - Frequency Inverter Drive)
Note: The Frequency Inverter control 'target'

IR-PCB pressure setting must be set so as to
maintain a pressure that is mid-way between
the upper and lower pressure set points of
C01 the X-Series Automation sequencer. Supertronic Controller
The X-Series Automation pressure sensor
C must be located to detect compressor discharge
LOAD pressure (a common ' wet-side'receiver
vessel) and not downstream of air treatment.
C
SEQ CONT X2-26
18
C02
X2-18
OUT NO
OUT C
Remote
OUT NC 17 Pressure
X2-19 Control
IN NO
Link
IN C
IN NC
24Vac/dc min
! 250Vac/dc max
X2-1 230Vac
r1
ALARM 27 230Vac
X2-2
19 33 Ready for
RUN Operation
34
20
READY 24 Fan
X2-4
A1
C03 K1 Fan
Contactor
A2
0Vac
Appendix A Page A12

ECOAIR D31-D102 (EcoControl)
IR-PCB
C01 ECOCONTROL
Controller PCB
C
LOAD
C
ensure base-load terminals X06-5
SEQ CONT ! are permanently wire linked Base - Load
X06-6
C02
OUT NO
OUT C X06-3 +12V
OUT NC 2
S17 P
IN NO 1
IN C X06-4 Pressure Switch
IN NC
C04
L1(220Vac)
X01-2 220Vac
ALARM
RUN
X01-1 Main Contactor
READY
A1
K1M
C03
A2
To X-Series Automation N (0Vac)
24Vac/dc min
! 250Vac/dc max
Appendix A Page A13

HPC - KAESER DSB series
IR-PCB
C01
C
LOAD
C
SEQ CONT
20
C02 C4
OUT NO
P
OUT C
OUT NC
IN NO 21
IN C
IN NC
d4
16 17 0Vac
24Vac/dc min
! 250Vac/dc max
C04
+Vac
C1
ALARM
RUN
6 22
READY
C03 Hours
Counter h
h3 MV3
To X-Series Automation 10 11 12 0Vac
Appendix A Page A14

HPC - KAESER DS/FS series
IR-PCB
C01 +V
C X1W-17
LOAD
C X1W-24
SEQ CONT Pressure
Switch 11
C02 -B1 P
14 12
OUT NO
X1W-19
OUT C
OUT NC X1W-23
IN NO
X11W-19 X1W-32W
IN C
X11W-32W
IN NC
X11W-18
-K1.2T
X1W-18
-K2 -K2M
Aux Contact
C04
24Vac/dc min
ALARM
! 250Vac/dc max +V
from E.Stop
RUN -X1-80
Door
Safety 11
READY Interlock
12
A1
MAIN -X1-81
C03 CONTACTOR
-K1M
A2
0Vac
To X-Series Automation Door
Safety 11
Interlock
12
if 3 door -X1-85
if 4 door -X1-87
Appendix A Page A15

HPC - KAESER AS/SK Series
IR-PCB
C01
C
LOAD
C
SEQ CONT
C02
17
OUT NO
OUT C
OUT NC
IN NO p1 11 Pressure
Switch
IN C
IN NC 12 14
18 19
!
24Vac/dc min
250Vac/dc max C04 220Vac
ALARM
1
RUN 13
Start Button
14
b2
READY
2
21
C03 c1
22 16 7
To X-Series Automation a1
Mains
h2 MV3 h3 Z c1
Relay
b1
0Vac
2 7 8 9
Appendix A Page A16

HPC - KAESER (Sigma Control) Note: The load/idling external input
! (DI8) must be enabled through the
compressor controller user interface,
see the Sigma control user manual.
Kaeser (Sigma) Controller

IR-PCB
mother board inputs
-X14 -X14
C01 DI8
P4
I 0.7
C
15 15 load/idling external
LOAD DI8
C
SEQ CONT Note: The X4I upper pressure
! setting P.High must be less than 7.25 PSI
C02 (0.5bar) above the Sigma control local upper
pressure set point to avoid '
remote
OUT NO overpressure'unloading.
OUT C
OUT NC
! -X2 13
IN NO -X02 13
wire link '
A'
IN C
S2 Emergency Stop
IN NC
-X02 14
C04 -X2 14
ALARM L02 (230Vac)
RUN
A1
Main/Line
K1M Contactor
READY Coil
A2
-X11
C03
N01 (0Vac)
PE
If the X-Series Automation is stopped, or experiences a power loss or failure, the compressor will automatically
revert to it'
s own internal pressure control '
remote overpressure'limit and continue to operate with
an upper pressure of 7.25 PSI (0.5bar) above the set local compressor upper pressure setting.
If it is desired that the compressor unloads (and runs offload for the set run-on time before stopping
! to standby) when the X-Series Automation is stopped, remove wire link ' A'between ' IN C'and 'IN NO'.
Note: In this condition the compressor will NOT automatically revert to it' s own internal pressure
control in the event of an X-Series Automation power loss or failure. The load/idling external input must be
disabled through the Sigma compressor controller user interface to enable the compressor to
operate in stand alone configuration.
Appendix A Page A17

CompAir - RA Series
NOTE : the example component and terminal identifications shown may differ according
to model and year of manufacture. The correct identification of the pressure switch
terminals, the control/start relay and the fault relay must be established from the wiring
diagram of the applicable compressor model.
Control 0Vac
Pressure
Switch Fault Relay
( eg : d4 )
P
(eg : 21 21A) (eg : 22A 22)
Control/Start
Relay
( eg : d1)
!
250V
maximum
Applicable to all RA Series models except RA30 ( F004-1001 to 1179 ) and RA40 ( F002-1001 to 1179 ).
Appendix A Page A18

CompAir - 6000 Series
Fitted with Control Card C20605-30 or C20605-360
Control Card Circuit Breaker

( PL1-3 ) E0 ( 110Vac )
Control Card C20605-30

or C20605-360
A1
PL2-20
2 x QM socket PL2-30
( size 16 )
PL2-29
A2
0V
see Outputs -
2 wire pressure
switch connections
Appendix A Page A19

CompAir - 6000E/6040N-6050N
Fitted with Control Card C20605-100 / -110 / -120 or -310
6000E
6040N / 6050N 18
C20605-100 17
C20605-110 Emergency
C20605-120 16 Stop Button
C20605-310 15
14
13
12
5
4
Main
3
Contactor
2 C1
control
1
transformer
N
L
1e0
see 6000E-40/50N 24Vac
Output Connections
Appendix A Page A20

CompAir - 6000E/6040N-6050N
Control Card C20605-100 / -110 / -120 or -310
6000E
6040N / 6050N 18
C20605-100 17
C20605-110
C20605-120 16
C20605-310 15
14
13
P
12
5
4
3
2
1
N
L
see 6000E-40/50N
Input Connections
Appendix A Page A21

CompAir - 6000E/6040N-6050N
Fitted with Pressure Switch Relay e5 Control Card C20605-100 / -110 / -120 or -310
6000E
6040N / 6050N 18
C20605-100 17
C20605-110
C20605-120 16
C20605-310 15
14
13
P
12
e5
5
4
3
2
control
1
transformer
N
L
1e0
24Vac
see 6000E-40/50N
Input Connections
Appendix A Page A22

CompAir - Cyclon 105 to 475
Fitted with Control Card C20606-50/160
SureScan Control Card C20606-50 or C20606-160
X01 X08
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12
110
X1/1
KM101
X1/2
X2/1 X1/2
Appendix A Page A23

CompAir - 6000N Series
Fitted with Mk2/3 SureScan Controller C20606-60/120
Mk2/3 SureScan Control Card C20606-60/-120
Note: Set the `Remote Control Config'option of the

`Commissioning Config'sub menu to Load/Unload option
X01 X08
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10
212
X2/1
X3/2
KM201
X2/2
X3/1 X2/2
Note: If an X-Series Automation fault or power failure occurs, set the `Remote Control Config'
option of the `Commissioning Config'sub menu to Disabled. This will allow the compressor to
operate using local pressure control. Pressure control will not automatically revert
to local compressor control.
Appendix A Page A24

CompAir - 6000F Series
Fitted with Mk2/3 SureScan Controller C20606-70/130
Extension Module Mk2/3 SureScan Control Card

C20774-1 C20606-70 or C20606-130
X01 X08
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10
212
X2/1
KM201
X2/2
X5/1 X2/2
Appendix A Page A25

CompAir - 6000F Series
Fitted with Controller C20605-150
Note:- Fit Control Program 98515-32-SV

Adjust compressor controller to PRESS SWITCH Mode
STARTER AREA TERMINALS
82
44
45
46
55
75
76
77
78
79
80
81
42
43
51
52
53
54
50
Install
Wire
Link
!
110Vac
Note: If an X-Series Automation fault or power failure occurs, set the compressor control mode
to TRANSDUCER. This will allow the compressor to operate using local pressure
control. Pressure control will not automatically revert to local compressor control.
Appendix A Page A26

CompAir - 6000N/F Series
Fitted with Mk1 SureScan Controller C20606-30/40
Input Contactor Output

Card 1 Card Card
98161-20 98161-22 98161-18
Available
I13 I12 C1 C5 A5 B5
X2/1
213
K201
X2/2
X2/4 X2/2
Appendix A Page A27

CompAir Demag - DELCOS 3000
Note: The DELCOS controller must be set for Remote Load/Unload Pressure control on Input 1.
Adjust Input 1 to B1 setting, do not adjust any setting in the remote control menu.
(See the compressor User Manual for menu setting procedures)
Remote DELCOS 3000 Fault

Load Relay
Remote
X3/23 24VDC
Control 3AO pin 52 46 47
X3/24 Load
Enable
X3/15
X3/18
52
230Vac
X3/5
230Vac
NC
A1 X3/35
24VDC Relay
3k3
+ - Line Contactor X3/36
A2 ensure connections to
controller are fitted
X3/4
0Vac
X1/5 X3/3
0VDC
!
230Vac
! IMPORTANT
Delco 3000 ' local'pressure control still remains active when in '
remote'control mode. If local detected
pressure falls below the lower '
local'pressure set point the compressor will start and/or load itself and will
local'upper presure set point is reached. This function prevents X-Series Automation
then remain onload until the '
system shutdown functions from operating (eg. put all compressors in standby when the X-Series Automation is
stopped or when the X-Series Automation timer or pressure schedule requests a system stop to standby).
Ensure the 'local'pressure set point is adjusted below the X-Series Automation operating pressure band inclusive of
the X-Series Automation Tolerance band setting.
Appendix A Page A28

CompAir Demag - DELCOS 1000
DELCOS 1000 Fault

Relay
X08-1
X01-1 X2-3 X08-2 230Vac X08-10
X08-9
4S5 A1
P 3k1
Line
A2
0Vac
X2-1
!
230Vac
Appendix A Page A29

CompAir Demag - DELCOS SL Slave
220Vac
Load Enable DELCOS SL
E04.1 E04.0 SLAVE NS E.Stop
17 2S70
X1-1
X6-1
(optional)
E.Stop
Remove connections 2S71
! to Master compressor
if fitted X1-2
A1
1 2
3k20
5S20 X6-2 Line/Net
A2 L4
1 Local
2 Remote
+24Vac 0Vac
!
220Vac
! Remove and discard any connections to Master compressor
Appendix A Page A30

CompAir Demag - DELCOS SL Master
DELCO SL controller program IC (chip)

! must be changed to 'Slave' type.
!
REMOVE WIRE
CONNECTION FROM
X1-25 to E13.2 220Vac
Enable Load DELCOS SL
E13.2 E13.2 E04.1 MASTER NS E.Stop
17 2S70
X1-1
(optional)
X1-25 E.Stop
1 Local
2S71
2 Remote 1 2
A1 X1-2
11S20
3k20
Line/Net
X1-26 A2 L4
0Vac
+24Vac
!
220Vac
! Remove and discard any connections to Slave compressors
Appendix A Page A31

CompAir Hydrovane (68 Series and similar) !
MAN
OFF AUTO NOTE: Compressor
must be operated in
AUTO control mode
IR-PCB
11
C01 21
C
d3 d2
LOAD
C 17 18
SEQ CONT 18
C02
17 Pressure Switch
OUT NO
OUT C
OUT NC 19
IN NO
d2
IN C
Load
17
IN NC Solenoid
SV d3 Run-On Timer
30
30
0v
24Vac/dc min
! 250Vac/dc max +V
11
C04
C1 C2
ALARM
RUN
13
READY
C2
C03 12 12
h C1 C3
30
To X-Series Automation 0v
CAUTION: All Hydrovanes have short timer delays (eg. 5sec) when responding to load and unload
requests. This function must be noted when adjusting the X-Series Automation unit pressure control settings
and will require a wider X-Series Automation '
Tolerance'presure control band than normal (eg. 0.5bar)
Appendix A Page A32

CompAir Hydrovane (128 - 218)
MAN
!
OFF AUTO NOTE: Compressor
must be operated in
IR-PCB AUTO control mode
C01
C
LOAD +V 30
C 36
SEQ CONT
d3 d4
C02
OUT NO 33 *(34)
OUT C 30 *(31) !
OUT NC Pressure
remove wire
Switch 2 33 (34) from
IN NO Pressure 32
Switch 1
terminal 33
IN C (34) and
34 *(35)
IN NC isolate wire
d4 d4 end to remove
31 *(37) pressure
switch 2 from
32 33 *(34) **(35) circuit
d3 d4 d5 Run-On Timer
(K6T) (K7T) (K8T)
24Vac/dc min
! 250Vac/dc max 40
0v
C04 !
+V 14
NOTE: Pressure switch circuit
ALARM voltage and motor contactor
control circuit voltage may be
different. This will not affect
D5 connection method.
RUN
15
READY
C3 C1 C2
C03
16 16
h C1
40
0v
CAUTION: All Hydrovanes have short timer delays (eg. 5sec) when responding to load and unload
requests. This function must be noted when adjusting the X-Series Automation unit pressure control settings
and will require a wider X-Series Automation '
Tolerance'presure control band than normal (eg. 0.5bar)
Appendix A Page A33

CompAir Hydrovane RS (speed regulated)
IR-PCB
X52
NOTE:
C01 Remove and discard link wire
between terminals X52 and X53
C X53
LOAD
C
C1 X51
SEQ CONT U1 - VSD
CMY
U1 - VSD
C02 B1
X52
OUT NO
OUT C
OUT NC X53
50
IN NO
S2A
IN C P24
IN NC U1 - VSD
X50 X50
link
0V
T1
24Vac/dc min F1F
110V
! 250Vac/dc max
11
C04 !
EMERGENCY
STOP Caution: ensure READY
connection is to 110V
ALARM SWITCH
circuit of Emergency Stop
Switch Contact (wire 41)
41
RUN
30
Over Temperature Control PCB

READY
10
C03
(A1)
K1M
X30 (A2)
30
0V
Appendix A Page A34

Worthington Creyssensac- Rollair 50 to 125
IR-PCB
C01 Interface
PCI 06
C
LOAD
C X2
SEQ CONT
012
C02 B7
12
OUT NO
Regulation
OUT C 12
Pressure
OUT NC Switch
IN NO
IN C
X4
IN NC
X4
24Vac/dc min Br5
! 250Vac/dc max
A1
Ventilator
KM4 X3
Contactor
C04 A2
ALARM Br6
RUN
PCI 06
READY
TA1 24Vac F2 Br14
C03 X3
0Vac Br15
Appendix A Page A35

Sullair - LS12/16 MFV EMCTL
ELECTRO-MECHANICAL
COMPRESSOR
IR-PCB CONTROLLER
PSW1
C01
208 208 108 109
4 4
C
LOAD
208 208 PSW1 108 109 9
C
Line
SEQ CONT Pressure
Switch
C02
OUT NO
OUT C
OUT NC
IN NO
IN C
IN NC
24Vac/dc min
250Vac/dc max
C04 ALARM
102 5
0V 0V
102 105 10
1M Motor
RUN PB1 Starter
READY
PB1
117 3
316 315 203 206 202
PSW2 TSW1 2MOL 1MOL
PB1
117 315 3
316 203 206 202

C03
TSW1 2MOL 1MOL 13 K3
PSW2
14
Water Pressure Switch
Appendix A Page A36

APPENDIX B
ir-PCB TO NON-INGERSOLL RAND VSD
COMPRESSOR INTERCONNECT DRAWINGS
Atlas Cpco GA VSD .......................................................B1
Kaeser / HPC Cs121 SFC ...............................................B2
46
Atlas Copco GA VSD Variable Speed - Frequency Inverter Drive
VSD Volt Box

XPM-Vo2
Delivery
Internal
#1 #2
X07 +VDC +VDC
+
+
-
-
25 26 27 28 29 30
X02 X03
Elektronikon
Elektronikon
F1 F2 F3
0.5-4.5VDC
Delivery
Pressure +VDC +VDC
+ 1 V+
signal signal Delivery
2 sig
0VDC 0VDC Pressure
- 3 gnd
2X5
0.5-4.5VDC
Internal +VDC +VDC
Pressure + 4 V+
signal signal Internal
5 sig
0VDC 0VDC Pressure
- 6 gnd
2X5
24Vac
6-wire, earth shielded

100m (330ft) max
A1
+VDC
V
VFD/Fixed
C01 Fan H2
1 1 Load Enable
Load/Unload A2
2 2
3 3 C03 NO
2
4 4 OUT C
NC 0Vac
5 5 C02 NO
6 6
LED 1
IN C
NC F3 10 10
T1
Ingersoll Rand 24Vac
ir-PCB
LED 2
Alarm 4
General
Shutdown
C04 Run 2X7 2X7
K08 6
Ready
5
This information is intended to be used in conjunction with the compressor's original control circuit diagram
Appendix B Page B1
Kaeser / HPC CS121 SFC Variable Speed - Frequency Inverter Drive
VSD Box
XPM-Ao2
4-20mA(2) 4-20mA(1)
+ ANA1
+ ANA2
- ANA1
- ANA2
X07
25 26 27 28 29 30
#2 #1
X03 X02
Sigma
Controller
4-20mA +VDC +VDC

+ + Delivery
Delivery
Pressure - - Pressure
signal signal
4-20mA +VDC +VDC

+ + Internal
Internal
- - Pressure
Pressure signal signal
230Vac
Sigma Controller
6-wire, earth shielded I/O Periphery -X11-1
100m (330ft) max
0.5
Set to Load
X2.12 X2.11
+VDC
V
VFD/Fixed
1 1 C01 Load Enable
0.4
Load/Unload
2 2 Set to Run
3 3 C03 NO
X2.10 X2.9
4 4 OUT C
NC
5 5 C02 NO
S3.2
6 6
LED 1
IN C E-STOP
NC
Ingersoll Rand
ir-PCB
LED 2
Alarm
C04 Run
Ready
0Vac
-X11
This information is intended to be used in conjunction with the compressor's original control circuit diagram
Appendix B Page B2

X Series InterconnectGuide Non-IR Compressors

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Ingersoll Rand

X-Series System Automation

Before installing or starting this unit for the first

• Before installing or operating the X- OPERATION

Supply ir-PCB COMPRESSOR CONTROL CABLE

PRESSURE TRANSDUCER CABLE

X4I X05 CONNECTOR PT CONNECTOR

Ir-PCB Compressor #4 Ir-PCB Compressor #3

RS485 Network Cable

PRESSURE TRANSDUCER CABLE

X8I X05 CONNECTOR PT CONNECTOR

ir-PCB COMPRESSOR CONTROL CABLE

From Air Reference X8I Application and Interconnect Guide For

From VSD Box

1 > Intellisys Discharge

From Pressure Transducer

From VSD Box

SECTION 8 — COMPRESSOR INTERCONNECT DRAWINGS

C03 A1 Line Y1 Loading

To X-Series Automation 0Vac 12

IR-PCB Elektronikon Controller

C04 24Vac/dc min

IMPORTANT: Mk1 Elektronikon

Note: Elektronikon digital inputs common

IMPORTANT: Mk2 Electronikon Only

IR-PCB Elektronikon Mk3

1X6 - 30 common +VDC

C01 terminal numbers: x(y) Ratiotronic Controller

C04 S1 Emergency Off

Appendix A Page A10

C04 S1 Emergency Off

Local'control if the X-Series Automation is stopped or fails, switch to

Appendix A Page A11

Note: The Frequency Inverter control 'target'

C04 S1 Emergency Off

Appendix A Page A12

To X-Series Automation N (0Vac)

Appendix A Page A13

To X-Series Automation 10 11 12 0Vac

Appendix A Page A14

Appendix A Page A15

Appendix A Page A16

Kaeser (Sigma) Controller

ALARM L02 (230Vac)

Appendix A Page A17

Appendix A Page A18

Control Card Circuit Breaker

Control Card C20605-30

Appendix A Page A19

Appendix A Page A20

Appendix A Page A21

Appendix A Page A22

SureScan Control Card C20606-50 or C20606-160

Appendix A Page A23

Mk2/3 SureScan Control Card C20606-60/-120

Note: Set the `Remote Control Config'option of the

Appendix A Page A24

Extension Module Mk2/3 SureScan Control Card

Appendix A Page A25

Note:- Fit Control Program 98515-32-SV