GAC Document No. GAC001-TG-4006-M24-0002 -01 PMC Doc. No.

A8GA-46900-55-EN-5400
Guinea Alumina Corporation S.A. Date 16-01-2018
Guinea Bauxite Export Project – Phase 1 Page 1 of 23
Contract A8GA

ANCILLARY BUILDING-MAINTENANCE FACILITIES-OPERATIONAL

PHILOSOPHY FOR COMPRESSED AIR SYSTEM FOR TRIP SERVICE &
LOCOMOTIVE WASH FACILITY AND WAGON MAINTENANCE AREA
GAC Document Number: GAC001-TG-4006-M24-0002 -01

PMC Document No: A8GA-46900-55-EN-5400

SPCPL Document No: SP-A8GA-46900-55-EN-5400

IR Document No: 16699120CP_L&W

This document has been revised as indicated below.

B 17.01.17 Issued for Squad Check

A 16th JAN 2017 Issued for SPCPL PRP PRP KBP KBP
review
Revision DD-MM-YY Status Name Name Name Name
Appr. By
Prepared Appr. By
Rev Date Description Checked By Discipline
By PEM
Lead Eng.

APPROVALS SIGNATURES DATE

Area Project
Manager:

Client
Representative:
ISSUED FOR : Design X Construction Other Review

Use same front size

SP-A8GA-46900-55-EN-5400
_RB Compressed Air System
 CONTROL PHILOSOPHY FOR
ROTARY COMPRESSOR

This document contains confidential and trade secret information, is the property of Ingersoll-Rand company, and is
given to the receiver in confidence. The receiver by reception and retention of the document accepts the document in
confidence and agrees that, except as authorized in writing by Ingersoll-Rand company, it will (1) not use the
document or any copy thereof or the confidential or trade secret information therein; (2) not copy the document; (3)
not disclose to others either the document or the confidential or trade secret information therein; and (4) upon
completion of the need to retain the document, or upon demand, return the document, all copies thereof, and all
material copied therefrom
Page 1 of 5
 CONTROL PHILOSOPHY FOR ROTARY COMPRESSOR

1.1 Start Sequence

The controller can receive a start command by the start button being pressed, by receiving a start command over
the com port, by the discharge pressure falling while the unit is stopped in auto restart, or the remote start contact
closing. When using the remote start input, the contact must be closed for 2 seconds before the controller will
issue a start command.

1.2.1Star-Delta

Once the start command has been received, the controller will begin the running hour timer and energize
the KM3 contactor followed, 50ms later, by the KM1 contactor. When the contactors pull in, the transition
timer will begin. At the end of the transition time, the KM3 contactor will be de-energized causing the KM2
contactor to pull in.

The transition time will consist of the star-delta time set by the operator. During this transition, the controller
will by-pass the trip logic for sensor 3APT. The logic by-pass will continue for the entire star-delta time plus
2 additional seconds. At the end of this transition period, the compressor will be able to load.

1.2 Load and Unload Sequence

Upon completion of the start sequence, the controller will wait 2 seconds and then automatically transition
to the selected mode of operation. All compressors will be able to operate in online/offline mode.

1.2.1Online/Offline Mode

In the on-line/off-line mode, the controller will monitor 4APT to determine whether or not to load
the compressor.

1.2.1.1 Load

If 4APT is less than or equal to the on-line set pressure, then the controller will load the unit. In
order to load the unit, the controller will energize 1SV. While the unit is loading, the trip logic for
3APT will be by-passed for 8 seconds. After the by-pass time, the controller will return to its
standard logic for operation.

1.2.1.2 Unload

If the 4APT reaches offline pressure the controller would unload the compressor. In order to unload
the unit, the controller will de-energize 1SV.

1.2.2 Unload Mode

Once the unload button is depressed, the compressor will run in an unloaded mode only. The
compressor must be running for the unload button to affect operation. Pressing the unload button
will be ignored if the compressor is stopped, except for when it is stopped in auto restart. When
the unload button is pressed and the unit is operating in an unloaded mode, the auto restart
function is disabled. The compressor cannot stop in auto restart. Also, the unit will not load if the
discharge pressure drops below the online set point and it will not accept a load command over
the communications port. To put the compressor back in a mode to load, the operator can press
the load button. Also, if the compressor is stopped (stop button or trip), the next time the
compressor starts, it will start in a condition that would allow it to load. One exception to note:
pressing the unload button while the compressor is stopped in auto restart will have the same

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 CONTROL PHILOSOPHY FOR ROTARY COMPRESSOR

effect as pressing the unloaded stop button. The compressor would remain stopped, but would
have to be restarted.

1.3 Stop Sequence

The compressor will be stopped by one of three methods; (1) shutdown due to trip, (2) unloaded stop,
and (3) emergency stop. An unloaded stop is initiated by pressing the stop key, receiving a stop
command over the comm. port, stopping in auto restart, and a remote stop contact opening. When using
the remote stop input, the contact must be opened for 0.3 seconds before the controller will issue a stop
command.

1.3.1 Shutdown Due to Trip

If a trip condition is met, the controller will first deactivate the compressor’s starter. Next, it will initiate the
unloading sequence and deactivate the running hour timer. It will then display the trip condition and retain
the last read values when the trip was encountered.

1.3.2 Unloaded Stop

For either loaded or unloaded stopping, the controller should not shut the unit down until it runs unloaded for stop
delay time.

Unit running loaded:

When the stop command is received, the unit will run unloaded for the delay stop time at which time the
Starter and the running hour timer will be deactivated. The controller will then by-pass all trip and warning
Logic for 9 seconds. After the 9 seconds, it will run the initial check sequence.

Unit running unloaded:

When the stop command is received or when stopped by the auto restart option, the controller will
deactivate the starter and the running hour timer. It will also by-pass all trip and warning logic for 9
seconds. After the 9 seconds, the controller will then run the initial check sequence. NOTE: When the
stop button is used to stop the compressor, if the unit has not been running unloaded for the delay stop time
period, the unit will continue to run unloaded for that length of time before stopping.

1.3.3 Emergency Stop

When the emergency stop button is pressed, the controller will de-energize the control voltage to all 110/120V
components. It will then display “Emergency Stop” (trip) on its screen. Once the emergency stop is disengaged
and the trip is reset, the controller will run the initial check sequence.

1.4 Lead/Lag

When the compressor is set for lead operation, it will load when the package discharge pressure is less
than or equal to the online setting and will unload when the package discharge pressure is greater than or
equal to the offline setting. When the compressor is set for lag operation, it will load when the package
discharge pressure is less than or equal to the online setting minus the value of the lag offset and will
unload when the package discharge pressure is greater than or equal to the offline pressure minus the
lag offset. If the online pressure minus the lag offset is less than the online pressure minimum, the unit
will load at the online pressure minimum. Also, if the offline pressure minus the lag offset is less than the
offline pressure minimum, the unit will unload at the offline pressure minimum.

Note: To set a compressor for lead operation, the lead/lag set point must be set to lead and the remote
lead/lag digital input must be open. To set a compressor for lag operation, the lead/lag set point must be
set to lag or the remote lead/lag digital input must be closed.

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 CONTROL PHILOSOPHY FOR ROTARY COMPRESSOR

1.5 Condensate Solenoid Control

The condensate solenoid will be used to remove condensation from the compressor. When the
compressor is running, the condensate solenoid will open on a timed interval. The condensate solenoid
will remain open for the number of seconds in the condensate release set point and then close. The
condensate solenoid will also open after the start period for the condensate release time. The
condensate drain valve is normally closed. The controller will energize the solenoid to open the valve.

1.6 Auto Restart

For auto start/stop operation, the compressor must be operating in the online/offline mode. The auto
restart set point must be set to on. The auto restart function is disabled if the unit is operating in the
unload mode (the unload button has been pressed). The compressor will stop in auto start/stop if it has
been running for a total of 10 minutes (loaded or unloaded), is running unloaded, and has been running
unloaded for at least a period of time equal to the auto restart time. The compressor will remain stopped
until the conditions are right for restarting the unit. Once the conditions are right for restart the unit, the
start may be delayed if the auto restart delay time is set to a value other than 0 seconds. This set point
will delay starting the unit in auto restart. This is used to keep the unit from starting due to a momentary
drop in package discharge pressure. The auto restart delay is only used in normal operation or lead/lag.
The auto restart delay is not used with remote lead/lag and serial communications control. The following
sections will describe the conditions for starting and stopping the compressor in auto start/stop.

Note: The 10 minute minimum run timer is used to limit the number of starts to 6 per hour. Other
methods can be considered. This is how Intellisys controllers have limited the starts per hour.

1.6.1 Normal Operation

When the package discharge pressure (4APT) rises to the offline pressure setting, the
compressor will unload. The compressor will stop if it meets the conditions described in section
1.6 and the package discharge pressure stays above the online pressure setting. The
compressor will remain stopped until the package discharge pressure falls to the online pressure
set point. At this time the compressor will restart.

1.6.2 Lead/Lag

When using lead/lag, if the compressor is set for lead operation, it will operate exactly as
described in section 1.6.1 Normal Operation. However, if the compressor is set to lag operation,
the pressures that it will load and unload at will be lowered. A lag compressor will unload at the
offline pressure minus the lag offset. The lag compressor will stop if it meets the conditions
described in section 1.6 and the package discharge pressure stays above the online pressure
setting minus the lag offset. The lag compressor will remain stopped until the package discharge
pressure falls to the online pressure set point minus the lag offset. At this time the compressor
will restart. For example, if the lag offset is 5 psi, the offline pressure is 100, and the online
pressure is 90, a lag compressor would unload when the package discharge pressure reaches 95
psi. If it continues to run unloaded, meets the conditions described in section 1.6, and the
package discharge pressure stays above 85 (online pressure – lag offset), the lag compressor
will stop. Once the pressure falls to 85, the lag compressor will restart.

1.6.3 Remote Load/Unload

When the compressor is using the remote load/unload feature, the package discharge pressure
(4APT) is only used for compressor safety. While the remote load/unload enable input is closed,
the compressor will follow the remote load/unload input for loading and unloading instead of the

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 CONTROL PHILOSOPHY FOR ROTARY COMPRESSOR

package discharge pressure. The compressor will run unloaded while the remote load/unload
input is open. If this input remains open and the compressor meets the conditions described in
section 1.6, the unit will stop. The unit will remain stopped until the remote load/unload input
closes. At this time the compressor will restart. If the remote load/unload enable input opens, the
compressor will return to normal operation as described in section 1.6.1.

1.6.4 Serial Communications Control (X-series system controller)

When the compressor is being controlled by a host, the package discharge pressure (4APT) is
only used for compressor safety. The compressor will follow the load and unload commands
from the host for loading and unloading instead of the package discharge pressure. The
compressor will stop if the host issues an unload command and the unit meets the conditions
described in section. The compressor will remain stopped until the host issues a load command.
At this time the compressor will restart.

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OPERATING INSTRUCTIONS (XE-90M CONTROLLER)

 User Interface Icon Name Function
The standard user interface configuration of the controller consists of the
membrane and the LCD display. The membrane consists of five command
Start Starts the compressor.
keys (START, STOP, LOAD, UNLOAD, and RESET), four navigation keys (UP,
RIGHT, LEFT and DOWN), and an Edit mode selection key (ENTER). These keys,
the color graphics display and the LED icons make up the user interface to
the compressor. Stops the compressor. This button should be
Stop pressed instead of the E-Stop for normal stopping
Figure 7 : Xe-90M
operation.

Toggles the display between the Navigation mode

Enter
and the Edit mode.

NOTICE

The LOAD and UNLOAD keys are not used on variable speed
compressors.

 Navigation keys
There are four navigation keys (UP, RIGHT, DOWN and LEFT). While the ENTER
key is not considered a navigation key, it is used in conjunction with the
navigation keys to make or confirm a selection.
Figure 8 : Navigation Keys
 LED status icons
Three LED icons are used to indicate the current status of the control system
from a distance and are located on the upper left side of the user interface.
Table 4 : LED Status Icons

Icon Name Function

Illuminates when no Warnings or Trips are sensed.

OK
Can be in a Ready or Not Ready state. Pressing one of the navigation keys will lead the user down a navigation path.
Each time the key is pressed, another step in the path is taken. Once the end
Illuminates when an Warning (flashes) or Trip of a navigation path is reached, pressing the key one more time will bring the
Alert (constant ON) is sensed. Can be in a Ready user back to the beginning of the path. Pressing the opposite key, will move
(Warning) or Not Ready (Trip) state. the user through the navigation path in the opposite direction. Once the
beginning is reached, pressing the opposite key will take the user to the end
of the path.
Illuminates when the compressor stops in auto
Auto
restart.  Display layout
Figure 9 : Display Layout
 Command keys
These keys command the controller to perform actions as specified in the
following table. When any of these keys are pressed the action below will be
initiated and logged in the event log.
Table 5 : Command Keys

Icon Name Function

--- None

Puts the compressor into the selected mode of

Load operation. Unit will load if the pressure conditions
are right.
Table 6 : Display Layout

Puts the compressor into an unloaded state. Unit Key Name Description
Unload
will run unloaded. A Folder Bar Uses tabs to graphically identify each folder.
B Title Bar Identifies current folder and page (underlined).
C Page Content Content of the current page.
Clears Warnings and Trips once the condition is
Reset
corrected. D Dashboard Displays system status.

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 Folder navigation and icons Figure 10 : Numeric Entry Window

To move among the tabbed folders shown on the LCD display, press the
RIGHT and LEFT keys. The navigation rolls over from the last to the first folder
and vice-versa.
Table 7 : Folder Bar Icons

Folder
Icon Description
Name
System performance and status main
Home information. The first page of this folder is the
default page when the controller first powers up. NOTICE
Operator Not all pages have adjustable parameters. Some just have read-only
System options and configuration settings.
Settings information.

Events System events log.  Dashboard icons

The dashboard is intended to be a quick at-a-glance view of system status.
Trip History Details on the most recent trips. The following table lists standard dashboard icons and their definition.
Note that the color of these icons changes based on the state set by the
On-board graphing of system data. (Optional for application while running.
Graphing
some controllers)
Table 9 : Dashboard Icons
Status and notification setup for compressor
Maintenance
maintenance items. Name Icon Description
General General settings such as Language, Time, and Network
Network control is enabled.
Settings Units of Measure. Control

Service A service reminder is nearing or has expired

Integral Inter Module communication status and
Sequencing configuration. Required (i.e.: an air or oil filter needs to be changed).

Measurements or status from/of all analog and Unloaded Compressor is in the unloaded state.
Status
digital I/O. or
Factory Compressor tuning parameters. Also displays Loaded Compressor is in the loaded state.
Settings hardware and software versions.

 Page navigation  Folder Options (Fixed Speed)

Once the desired folder is selected, press the DOWN key to move to the page
selection area and then use the RIGHT and LEFT keys to select the desired  Home folder
page. Use the UP key to get back to the folder tabs.
Page 1: System Overview
Table 8 : Title Bar Page Icons
Figure 11 : Home Folder
Icon Description
Start of the page selection area.

Indicates that there are more pages available by navigating

right.

Indicates that there are more pages available by navigating

left.

 Accessing parameters
After the desired page is selected, the page’s parameters can be selected by
using the DOWN key. The cursor will move to the next parameter each time
the DOWN key is pressed. Use the UP key to go back to the previous one.
This is the factory default display after powering up the system.
The cursor rolls over, so once the last parameter is selected, pressing the
• Online Pressure Setpoint is indicated in the white box and by the white
DOWN key will navigate the cursor to the folder bar. If the first parameter is
arrow, which is always left of center on the gauge.
selected, pressing the UP key will move the cursor to the page selection area.
• Offline Pressure Setpoint is indicated in the white box and by the white
Once selected, access parameters by pressing the ENTER key. Make changes
arrow, which is always right of center on the gauge.
using the navigation keys and then enter the setting by pressing the ENTER
key again. After a parameter is accessed, pressing the ENTER key will enter • Package Discharge Pressure is indicated by the large numbers centered
the current setting into the control program and navigate the cursor back to below the gauge and by the red arrow.
the selected parameter on the page. • Pressure Unit of Measure is indicated below the Package Discharge
When the cursor is on a parameter that has an enabled/disabled box, Pressure. This is selectable from the General Settings folder.
pressing the ENTER key will cause the setting to toggle. • Airend Discharge Temperature is indicated by the numbers in the lower
This “X” icon appears on numeric entry windows as shown below. Placing the left of the display.
cursor on it and then pressing the ENTER key will cancel the entry and any • Temperature Unit of Measure is indicated to the right of the Airend
changes that were made. Discharge Temperature. This is selectable from the General Settings folder.

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• Run Hours indicate the number of hours the compressor has been • Coolant Filter Pressure Drop
running.
• Inlet Vacuum
• After-cooler Discharge Pressure (integrated dryer compressors only)
NOTICE
• Remote Pressure (optional)
The online and offline set points can be selected and modified on this
page. All other information on this page is read only.
 Operator settings folder
Page 2 : Counters Pages 1-2: Operator Settings
Figure 12 : Counters Figure 14 : Operator Settings

• Hour Meters indicate the hours that: the controller has been powered
Table 10 : Operator Settings
up, the compressor has been running, and the compressor has running
loaded.
Operator Selection Min. Max. Default Step Unit
• Starts indicate the number of times a start is attempted on the Settings
compressor.
Offline --- 75 Rated+10 Rated+10 1 psi
• Date & Time is adjustable and configurable in the General Settings folder. Pressure

Pages 3-4: Analog Inputs Online --- 65 Offline-10 Offline-10 1 psi

Pressure
Figure 13 : Analog Inputs
Lead/Lag Lead/Lag --- --- Lead --- ---
Lag Offset --- 0 45 0 1 psi
Mode of Mode --- --- ON/OFF --- ---
Operation line
Condensate --- 2 20 5 1 sec
Release
Condensate --- 90 270 180 1 sec
Interval
Stop Delay --- 10 30 10 1 sec
Time
Star-Delta --- 5 30 10 1 sec
Time / Start
Time
Pages 3-5: Operator Options
Icon Meaning Figure 15 : Operator Options
Pressure

Temperature

NOTICE

All information on these pages is read only.

The following inputs are displayed in this section:

• Package Discharge Pressure
• Sump Pressure
• Airend Discharge Temperature
• Injected Coolant Temperature
• After-cooler Discharge Temperature
• Separator Pressure Drop

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Table 11 : Operator Options

Operator Options Selection Min. Max. Def. Step Unit Installed option
required?
Enable Auto Restart ON/OFF --- --- OFF --- --- No
Auto Restart Time --- 2 60 10 1 Min No
Auto Restart Delay --- 0 60 0 1 Sec No
Comm Control ON/OFF --- --- OFF --- --- No
Remote Start/Stop ON/OFF --- --- OFF --- --- No
Power Out Restart ON/OFF --- --- OFF --- --- Yes
Power Out Restart Time --- 10 600 10 1 Sec Yes
Low Ambient Temp* --- 30 60 35 1 Deg F No
Lead/Lag Cycle Time** --- 0 750 0 1 Hours No
Scheduled Start - Day --- Day Day Sun 1 Day Yes
Scheduled Start --- 00:00 23:59 00:00 1 Time Yes
Scheduled Stop - Day --- Day Day Sun 1 Day Yes
Scheduled Stop --- 00:00 23:59 00:00 1 Time Yes
High Dust Filter ON/OFF --- --- OFF --- --- Yes
Remote Sensor ON/OFF --- --- OFF --- --- Yes
* The low ambient temperature is only adjustable if the low ambient factory set point is on.
** A value of 0 will disable the lead/lag cycle time feature.
Pages 6-7: Sensor Calibration
Figure 16 : Sensor Calibration  Events folder
Pages 1-42 (max.)
Figure 17 : Events Folder

Sensor calibration can only take place when the compressor is stopped.
There should be no pressure on a sensor when it is calibrated. Calibration
only needs to take place after a sensor is replaced, the controller is replaced,
or the operator suspects the sensor reading is in error. Calibrate a sensor by The pages in the Events folder document up to the last 250 events that the
selecting the checkbox beside the sensor name. controller has experienced, and time stamps each. The events are recorded
in sequence, with number one being the newest and 250 being the oldest.
Each of the sensors listed below can be calibrated: When a new event occurs, it becomes number one and all others are shifted
• Inlet Vacuum (1AVPT) up in number.
• Sump Pressure (3APT) The page numbers in the Title Bar are used to scroll through the events, with
• Package Discharge Pressure (4APT) each page displaying up to seven. Page one displays events one through six,
page two displays seven through twelve, and so on.
• Coolant Filter Inlet Pressure (5CPT)
The following items will generate an event:
• Coolant Filter Outlet Pressure (6CPT)
• Power ON
• Remote Pressure (10APT) – Only on compressors with the remote sensor
option • Power OFF

• Interstage Pressure (2APT) – Only on 2-stage compressors • Press the Start Key

• After-cooler Discharge Pressure (7APT) – Only on compressors with • Press the Stop Key
integrated dryer • Press the Load Key
Please note that if a sensor is currently reading a value that is +/- 10% of • Press the Unload Key
its range from zero, the sensor will not be able to be calibrated. Please • Warning
make sure the sensor is being exposed to atmosphere before attempting
calibration. • Trip
• Start Inhibit

Active Warnings will be highlighted in amber while cleared Warnings will

have amber text.

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Active Trips will be highlighted in red while cleared Trips will have red text. equal to the service time period set point. However, 100 hours before this
a “100 HOURS TO SERVICE” warning will occur. This warning can be reset
Active Start Inhibits will be listed in the Event log, but not highlighted. The
the same as any other warning. One hundred hours later the “SERVICE
display will indicate the compressor is not ready to start if a start inhibit is
REQUIRED” warning will occur. This warning can be reset the same as any
active.
other warning, however this warning will return in 24 hours if the service
See the following lists for details about messages in each type of event. complete factory set point has not be set. If the service complete has not
been set, 100 hours later, the “ALARM – SERVICE REQUIRED” warning will be
Warning Events List issued. This warning can only be cleared by the service complete factory
Change Inlet Filter set point. Once the service complete factory set point is set, indicating the
service is completed, the time for the next “SERVICE REQUIRED” warning will
Will occur if 1AVPT is greater than 0.7 psi vacuum (or 1.3 psi vacuum if the be calculated by adding the service time period to the total hours value, with
high dust filter option is enabled) and the compressor has been loaded for at the “100 HOURS TO SERVICE” warning occurring 100 hours before and the
least 8 seconds. This condition must exist for 3 seconds before the warning “ALARM – SERVICE REQUIRED” warning occurring 100 hours after that time.
is issued.
Communication Failure
Change Coolant Filter
This will occur if the compressor is the lead compressor in integral
This will occur if the compressor has been running loaded for at least 8 sequencing and is unable to communicate with another compressor.
seconds, is warmed up, and the coolant filter pressure drop (5CPT - 6CPT)
is greater than 25 psi. This condition must exist for 3 seconds before the Sensor Failure 10APT – Remote Sensor
warning is issued. This will occur if the remote sensor option is ON and the remote sensor
Sensor Failure is recognized as missing or broken. If this occurs, the compressor will
automatically start using 4APT for loading and unloading the compressor.
This will occur whenever sensors 4ATT, 5DTT, 6DTT, and 7APT are recognized Units equipped with an integrated dryer cannot have a remote pressure
as missing or broken. The sensor failure message shall follow the following sensor. This condition must exist for 3 seconds before the warning is issued.
format: SENSOR FAILURE 4ATT. The 5DTT, 6DTT, and 7APT sensor failures will
be shown only when the integrated dryer is installed (accessed in the factory High Discharge Pressure
settings menu). This condition must exist for 3 seconds before the warning Will occur if the compressor is using a remote sensor or is under the control
is issued. of an external device, such as an 8XI, is loaded, and the discharge pressure
Change Separator Element (4APT) is greater than the maximum offline pressure. This condition must
exist for 3 seconds before the warning is issued. If this condition occurs, the
Will occur if the compressor is loaded, the compressor is warmed up (the compressor will automatically unload. The compressor will be available to
injected coolant temperature is at least 120 °F), the package discharge reload once the discharge pressure falls to the rated pressure value.
pressure is at least 90 psi, and the separator pressure drop is greater than
12 psi. This condition must exist for 3 seconds before the warning is issued. Condensate Drain Error

High Airend Discharge Temperature This will occur if the compressor is running, the package discharge pressure is
over 50 psi, and the condensate drain error contact closes for at least
Will occur if the compressor is running and 2ATT is greater than 221 °F (97% 240 seconds. This warning will be ignored for 4.5 minutes after starting.
of 228) and the compressor is running. This condition must exist for
3 seconds before the warning is issued. Freeze Warning

High Sump Pressure This will occur if the evaporator sensor has a value of 687 (about 0.5 C)
or below (low temp) while the dryer is running, on compressors with the
If the compressor is running loaded, has been loaded for at least 8 seconds integrated dryer. This is a dryer fault. If this happens, the compressor will
and the sump pressure is more than 25 psi above the rated pressure for the continue to run, but the dryer will stop. The condition must exist for at least
compressor. If this warning occurs, the online and offline pressures will be 180 seconds before the warning will occur. NOTE: If this warning is reset
reduced. For example, a rated pressure of 100 psi would have a maximum while the conditions for running the dryer exist, the dryer can restart. Also the
offline pressure of 110 psi. This warning would occur if the sump pressure dryer can restart if the evaporator value rises to 709 (about 5 C). However the
goes above 125 psi in this example. This condition must exist for 3 seconds warning will still be displayed.
before the warning is issued.
Dryer High Pressure
Auxiliary 1
On compressors with the integrated dryer, this will occur if the dryer high
This will occur if auxiliary input 1 closes. The contact must be closed for at pressure switch opens while the dryer is running. This is a dryer fault. If this
least 3 seconds before the warning will occur. happens, the compressor will continue to run, but the dryer will stop. The
contact must be open for at least 3 seconds before the warning will occur.
Auxiliary 2
If this warning is reset while the conditions for running the dryer exist, the
This will occur if auxiliary input 2 closes. The contact must be closed for at dryer can restart. However, this switch is a locking switch. The switch must be
least 3 seconds before the warning will occur. reset before the dryer can run. Resetting the warning on the display does not
reset the switch.
Service
Condenser Temperature High
Service warnings occur when the compressor has operated a certain number
of hours, based on the total hours. Service warnings can have multiple This will occur if the condenser sensor has a value above high temperature
levels, depending on the service level selection. A service level selection of 0 threshold while the dryer is running, on compressors with the integrated
disables service warnings. dryer. This is not a dryer fault. If this happens, the compressor and dryer will
continue to run. The condition must exist for at least 180 seconds before the
Service Level 1 warning will occur.
If service level 1 has been selected for the compressor, a “SERVICE REQUIRED” Condenser Temperature Low
warning will be issued on hour intervals equal to the service time period set
point. This warning can be reset the same as any other warning. This will occur if the condenser sensor has a value below the low temperature
threshold while the dryer is running, on compressors with the integrated
Service Level 2 dryer. This is not a dryer fault. If this happens, the compressor and dryer will
If service level 2 has been selected for the compressor, the service complete continue to run. The condition must exist for at least 180 seconds before the
factory set point will be used to clear a level 2 service warning and reset warning will occur.
the service time or date. The service complete can be reset before a service Change HE Filter
warning occurs.
The HE filter is located between the after-cooler discharge and the inlet to
The initial “SERVICE REQUIRED” warning will occur at total hour intervals the dryer and is only on compressors with an integrated dryer. The drop

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across the HE filter is measured by subtracting the package discharge this fault occurs, the operator can reset it and start the compressor. This fault
pressure from the after-cooler discharge pressure. If the compressor is will be logged in the trip history to indicate that the compressor is being
running, the measured drop across the HE filter is at or above 10 psi (0.7 started in low ambient conditions.
bar), the compressor is hot (injected coolant temp above 120 °F), and the
package discharge pressure (4APT) is above 90 psi, this warning can occur. High Interstage Pressure
The condition must exist for at least 3 seconds before the warning will occur. This will occur if the compressor is running and the interstage pressure
This is not a dryer fault. If this happens, the warning will be displayed, but the (2APT) is greater than 75 psi. This trip will only occur in 2 stage compressors.
dryer will continue to run.
Invalid Calibration
Trip Events List
Will occur if the sensor zero value is +/- 10% of its scale. This will only occur
Low Sump Pressure when a sensor is calibrated.
Will occur if the compressor is running unloaded or loaded and 3APT is less Start Inhibit List
than 13 psi for 15 seconds.
High Airend Discharge Temperature
High Airend Discharge Temperature
This will occur if 2ATT is greater than 95% of 228 °F.
This will occur if 2ATT is greater than 228 °F and the compressor is running.
High Sump Pressure
Check Motor Rotation
This will occur if the sump pressure (3APT) is 25 psi or higher than the rated
This will occur if 3APT is less than 1 psi on a compressor, 3 seconds after pressure of the compressor.
starting (6 seconds if the compressor is equipped with a soft starter or airend
discharge temperature is less than 50 °F). This condition can be caused by
the motor running in reverse. Once correct motor rotation is established, this  Trip history
trip will not be checked again unless power is removed from the controller.
Pages 1-4 (max.)
Main Motor Overload
Figure 18 : Trip History
This will occur if the motor overload relay contact opens. The contact must
be open for at least 3 seconds before the trip will occur.
Fan Motor Overload
Will occur if a fan motor overload relay contact opens. The contact must be
open for at least 3 seconds before the trip will occur.
Remote Stop Failure
Will occur if the remote start/stop option is enabled, the remote stop button
remains open and either start button is pressed.
Remote Start Failure
Will occur if the remote start/stop option is enabled, the compressor is
started by the remote start button, and the button stays closed for 7 seconds
after the compressor starts.
Sensor Failure The pages in the Trip History folder document up to the last 15 trips that the
This will occur when a sensor is recognized as missing or broken. The sensors controller has experienced, and time stamps each. The trips are recorded in
affected by this trip are 1AVPT, 3APT, 4APT, 5CPT, 6CPT, 2APT (if 2 stage sequence, with number one being the newest and 15 being the oldest. When
compressor), 2CTT, and 2ATT. The sensor should be displayed along with the a new trip occurs, it becomes number one and all others are shifted up in
sensor failure message. The sensor failure message shall follow the following number.
format: SENSOR FAILURE 1AVPT. The page numbers in the Title Bar are used to scroll through the events, with
Emergency Stop each page displaying up to seven. Page one displays events one through five,
page two displays six through ten, and so on.
This will occur when the emergency stop button is engaged.
The following items will generate an event.
High Sump Pressure
• Power ON
This will occur if the compressor is running loaded for at least 8 seconds, and • Power OFF
any one of the 3 following conditions exist. (1) The sump pressure is above
the rated pressure by 35 psi. (2) The separator pressure drop is measured to • Press the Start Key
be more than 25 psi and the package discharge pressure at least equal to the • Press the Stop Key
minimum online set point value. (3) The sump pressure is above 165 psi if the
rated pressure is less than 190 psi or the sump pressure is above 220 if the • Press the Load Key
rated pressure is 190 psi. • Press the Unload Key
High Coolant Filter Pressure Drop • Warning
This will occur if the compressor has been running loaded for at least 8 • Trip
seconds, is warmed up, already has a change coolant filter warning, and the
• Start Inhibit
coolant filter pressure drop (5CPT - 6CPT) is greater than 35 psi.
High Inlet Vacuum Active Trips will be highlighted in red while cleared Trips will have red text.

This will occur if the compressor is running loaded and the inlet vacuum is The trip history also records compressor data at the time of the trip to assist
greater than 1.8 psi. If the compressor has a high dust filter, the trip threshold in diagnostics and troubleshooting. Navigating to the trip entry and hitting
for inlet vacuum is 2.4 psi. the enter button will bring up the trip history dialog box.

Unit Too Cold To Start

This will occur if the compressor does not have the low ambient option,
the airend discharge temperature (2ATT) is less than 35 °F, and the operator
attempts to start the compressor. This fault can only occur once a day. Once

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Figure 19 : Trip History Dialog Page 3: Maintenance Configuration

Figure 22 : Maintenance Configuration

While the dialog box is active, press the left and right keys in order to scroll
through the displayed data. The name of the trip will always be shown in
the title bar of the dialog box. Press enter when finished viewing the data to This page allows the user to set the service interval and to reset the counter
return to the trip history screen. after the service has been performed.

 Maintenance folder  General settings folder

Page 1: Filter Status
Figure 20 : Filter Status
NOTICE

All parameters in this folder are adjustable.

Page 1: Language Selection

Figure 23 : Language Selection

This page displays the following:

• Coolant Filter Status
• Separator Element Status
• Inlet Filter Status

Page 2: Maintenance Status Language is selectable from the following 30 choices:

Figure 21 : Maintenance Status • English (default) • Korean
• Bulgarian • Latvian
• Chinese, simplified • Lithuanian
• Croatian • Maltese
• Czech • Norwegian
• Danish • Polish
• Dutch • Portuguese
• Estonian • Romanian
• Finish • Russian
• French • Slovak
• German • Slovenian
• Greek • Spanish
This page displays the time until the compressor should be serviced. • Hungarian • Swedish
• Italian • Thai
• Indonesian • Turkish

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The controller will display all screens in the selected language and only one Pages 4-5: Time & Date Settings
language can be selected at a time.
Figure 26 : Time & Date Settings
Each language appears in its native translation.
Page 1: Units of Measure Settings
Figure 24 : Units of Measure Settings

All items are adjustable.

The following settings are displayed in this section:
The following compressors of measure settings are displayed in this section. Table 14 : Time & Date Settings
Table 12 : Units of Measure Settings
Display Text Description
Display Text Description Hours Allows the current hour to be set. The hours format is
Temperature Selectable between °F and °C. fixed on 24-hour.
Pressure Selectable among psi, kpa, bar, kg/cm2. Minutes Allows current minutes to be set.
Power Selectable between kW and HP. Seconds Allows current seconds to be set.
Page 3: Home Page Selection Year Allows current year to be set.
Figure 25 : Home Page Selection Month Allows current month to be set.
Day Allows current day to be set.
Date Format Selectable between dd/mm/yyyy (default) and mm/dd/
yyyy.
Confirm New Used to verify that changes to selections are desired. An
Time and Date “x” must appear in the checkbox before any changes will
take affect.
The controller will continue to display any changes, even when the selections
have not been confirmed and the user exits the page, then returns. Cycling of
the power returns all selections to their current settings.

NOTICE

The controller does not support Daylight Savings Time.

Table 13 : Home Page Selection Page 6: Backlight Settings

Figure 27 : Backlight Settings
Display Text Description
Auto Return to Enables the controller to return the display back to the
Home selected Home Page if there is no user activity for the
Delay Time shown. This is only enabled when an “x”
appears in the checkbox.
Delay Time Determines how many seconds of inactivity it will take
before the controller will return to the Home Page.
Select Home Used to select the Home folder.
Folder
Select Home Used to select the Home Page within the selected Home
Page folder.

The following settings are displayed in this section:

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Table 15 : Backlight Settings

 Status folder
Display Text Description
Backlight Adjusts the brightness of the display. NOTICE
Brightness
All information on these pages is read only.
Enable Backlight Enables the controller to shut-off the backlight if
Auto-Off there is no user activity for the delay time shown.
Pages 1-3: Analog Inputs
Backlight Auto-Off Determines how many seconds of inactivity it will
Delay Time take before the controller will shut-off the backlight. Figure 29 : Analog Inputs

NOTICE

The backlight will be switched ON whenever any of the controller’s

keys are pressed.
The START, STOP, LOAD, UNLOAD, RESET, and ACKNOWLEDGE keys on
the controller remain functional while the backlight is switched OFF. It
is recommended to press the ENTER key or one of the navigation keys
in order to switch the backlight ON.

Pages 7-8: Ethernet Settings

Figure 28 : Ethernet Settings

The following inputs are displayed in this section:

• Package Discharge Pressure
• Sump Pressure
• Airend Discharge Temperature
• Injected Coolant Temperature
• After-cooler Discharge Temperature
• Separator Pressure Drop
• Coolant Filter Pressure Drop
• Inlet Vacuum
• After-cooler Discharge Pressure (integrated dryer compressors only)
• Remote Pressure (optional)
Table 16 : Ethernet Settings • Coolant Filter Inlet Pressure
Display Text Description • Coolant Filter Outlet Pressure
Enable Ethernet Allow connection by users to utilize the • Interstage Pressure (2-stage compressors only)
network enabled functionality of the controller • Evaporator
Enable DHCP Allow the controller to automatically receive an • Condenser
IP address from the Local Area Network (LAN)
Page 4: Compressor Data
IP Address Setting When DHCP is not enabled, this setpoint sets
the IP address of the controller. Figure 30 : Compressor Data
IP Address Actual This will match the IP address setting when
DHCP is not enabled. If DHCP is enabled
this will display the address assigned to the
controller by the DHCP server.
MAC Address This is the unique hardware MAC address for
the controller. This can not be changed.
Subnet Mask Setting Setpoint for the subnet mask
Subnet Mask Actual Current reading/setting for the subnet mask
Default Gateway Setting Setpoint for the default gateway.
Default Gateway Actual Current reading/setting for the default gateway.
Accept After editing the desired setpoint navigate
to the accept setting and press enter in order
for the values in the setting variables to be
confirmed by the controller.
Cancel Discard any changes made to the Ethernet The following data are displayed in this section:
settings. • Power ON Hours
• Running Hours
• Loaded Hours
• Real Time Clock

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Pages 5-6: Digital Inputs Page 9: Analog Outputs

Figure 31 : Digital Inputs Figure 33 : Analog Outputs

The value for the analog outputs will be in mA.

A marked checkbox beside a digital input indicates that the input is in its
TRUE state. For example, Starter Feedback is TRUE when its input is in the • VSD Blower Output
high state, where as, E-Stop is TRUE when its input is at 0Vdc. • Analog Output 2
• Emergency Stop
• Main Motor Overload NOTICE
• Fan Motor Overload (RO) indicates read-only values.
• Condensate Drain Error
• Remote Stop
• Remote Start  Factory settings folder
• Remote Lead/Lag This folder is for factory and service personnel. A password must be entered
• Remote Load Enable on page one in order to adjust values in this folder. This folder is used for
setting parameters that are specific to that compressor and displaying
• Remote Load/Unload software information for the controller.
• Auxiliary Input 1 Page 1: Password
• Auxiliary Input 2 Figure 34 : Password
• Dryer High Pressure

Pages 7-8: Digital Outputs

Figure 32 : Digital Outputs

Table 17 : Password

Display Text Description

Password Provides access to enter a valid password to gain access
A marked checkbox beside a digital output indicates that it is energized. to password protected parameters. The password is
entered by scrolling down to the password value and
• Starter Contact 1 • PORO Horn pressing the RETURN key.
• Starter Contact 2 • Trip Relay Password This checkbox will indicate a valid password has been
• Fan Starter Contact • Warning Relay entered entered. If this checkbox is blank, a valid password has
not been entered or it has timed out. This is read only.
• Blowdown Solenoid • Low Voltage Output 1
Password Checking this box will enable the password time feature.
• Modulation Solenoid • Low Voltage Output 2
timeout
• Condensate Drain • Low Voltage Output 3 enable
• Dryer Run / Fan Run • Low Voltage Output 4 Password This timeout along with the password timeout enable
timeout allows the user to set an adjustable amount of time
to require a valid password to be re-entered. Once
NOTICE
this timeout is reached re-entry of a valid password is
(RO) indicates read-only values. required.

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Pages 2-3: Factory Settings

Figure 35 : Factory Settings

These pages are used for setting parameters that are specific to the
compressor. All of the factory settings that are adjustable are listed below.
All settings on these pages are password protected.
Rated Pressure (psi – 100, 115, 135, 190)
Enable Two Stage (ON/OFF)
Starter Type (Star-delta, Remote Starter, Soft Starter)
Service Level (0, 1, or 2)
Service Time Period (1000 – 8000, in increments of 1000 hours)
Enable Modulation (ON/OFF)
Enable PAC (ON/OFF)
Enable Dryer (ON/OFF)
Running Hours (adjustable)
Loaded Hours (adjustable)
VSD Blower (ON/OFF)
Enable Low Ambient (ON/OFF)

Pages 4-5: Factory Settings

Figure 36 : Factory Settings

EN-22 80447204 Rev B

 MODBUS CONNECTION AND CONTROL
Connection to the Modbus Network
The Xe-90M and Xe-145M controllers are designed to interface to any Modbus master capable device using Belden
9841 or equivalent RS-485 cable. In order to connect to the network, the cable must be connected to port COM2 on
the controller as shown in the diagrams below:

RS-485 NETWORK

RS-485 data communications and other low voltage signals can be subject to electrical interference. This
potential can result in intermittent malfunction or anomaly that is difficult to diagnose. To avoid this possibility always
use earth shielded cables, securely bonded to a known good earth at one end. In addition, give careful consideration
to cable routing during installation.

1) Never route an RS-485 data communications or low voltage signal cable alongside a high voltage 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.

2) If it is necessary to follow the route of power supply cables for a short distance (for example: from a compressor
unit to a wall along a suspended cable tray) attach the RS-485 or signal cable on the outside of an earthed cable tray
such that the cable tray forms an earthed electrical interference shield.

3) Where possible, never route an RS-485 or signal cable near to equipment or devices that may be a source of
electrical interference (for example: 3-phase power supply transformer, high voltage switchgear unit, frequency
inverter drive module, radio communications antenna).

1
MODBUS ADDRESS SELECTION
Each compressor connected to the MODBUS network will have a unique assigned address, starting at compressor 1
increasing sequentially to the number of compressors connected to the MODBUS network.

The Modbus address for each compressor is set on the General Settings Tab, Page 7. The controller’s default
Modbus Address setting is 1

MODBUS MASTER SETTINGS

In order to communicate properly with the Xe-M controller, the Modbus master must be set to communicate with the
following configuration:

Baud Rate – 9600

Data Bits – 8
Stop Bits – 1
Parity – None

The following polling parameters are recommended for optimal system operation:

Polling Rate: Not less than 500 ms

Timeout: 500 ms
Retries: 2

2
 XE-90M MODBUS TABLE
R55 – R160 Fixed Speed Modbus Table

Register Variable Read/ Range Notes

(40XXX) Write
001 Status/Control R/W See FIGURE 1
003 Discharge Pressure R See Note 1
004 Sump Pressure R See Note 1
005 Inlet Vacuum R See Note 2
006 Injected Coolant Temperature R
007 Airend Discharge Temperature R
008 Aftercooler Discharge Temperature R
010 Separator Pressure Drop R See Note 1
011 Coolant Filter In Pressure R See Note 1
012 Coolant Filter Out Pressure R See Note 1
013 Coolant Filter Pressure Drop R See Note 1
014 Interstage Pressure R 2-Stage Units Only,
See Note 1
015 Remote Pressure R See Note 1
016 Aftercooler Discharge Pressure R See Note 1
064 Running Hours (hours) R
065 Loaded Hours (hours) R
098 Rated Pressure R
099 2-Stage R 0 = 1 Stage
100 Starter Type R 1-3 See FIGURE 2
101 Modulation Enabled R 0=Disabled
102 Service Level R 0-2 0=Level 0, 1=Level 1,
2=Level 2
103 Service Time Period R 1000 - 8000 Increments of 1000
104 Dryer Installed R 0=Off
112 Offline Pressure R/W 75 - (rated+10) rated = rated pressure
113 Online Pressure R/W 65-(offline-10) offline = offline pressure
114 Mode of Operation R/W 0–2 See FIGURE 2
115 Starter Time (seconds) R/W 5 – 30
116 Auto Start/Stop (AS/S) Time (seconds) R/W 120 – 3600
117 Auto Start/Stop (AS/S) On/Off R 0=Off
118 Communication Control On/Off R 0=Off
119 Remote Start/Stop Enable R 0=Off
120 Unused
121 Power Out Restart Option (PORO) Enable R 0=Off
122 PORO Time (seconds) R/W 10 - 120
123 Auto Start/Stop Delay Time (seconds) R/W 0 - 60
124 Low Ambient Temperature R/W 30 - 60 Degree F
125 Unloaded Stop Time R/W 10 - 60

3
 Register Variable Read/ Range Notes
(40XXX) Write
126 Low Ambient Option On/Off R 0=Off
127 High Dust Filter R 0=Off
128 Lead/Lag R/W 0=Lag
129 Lag Offset R/W 0 - 45 psi
130 Variable Frequency Drive R 0=Off
131 Lead/Lag Cycle Length (Hours) R/W 0 – 750
132 Scheduled Start (Day) R/W 0-9 See FIGURE 2
133 Scheduled Start (Hour) R/W 0 – 23
134 Scheduled Start (Minute) R/W 0 – 59
135 Scheduled Stop (Day) R/W 0-9 See FIGURE 2
136 Scheduled Stop (Hour) R/W 0 – 23
137 Scheduled Stop (Minute) R/W 0 – 59
138 Condensate Release Time R/W 2 - 20
139 Condensate Interval Time R/W 90 - 270
140 Remote Sensor R 0=Off
255 Warning Code R See FIGURE 4
256 Trip Code R See FIGURE 4

Note 1 - If unit of measure is bar or kgcm², divide by 10.

Note 2 - If unit of measure is bar or kgcm², divide by 100. If unit of measure is PSI, divide by 10.

4
 Bit 0: Host/Local (R/W) Bit 6: Alarm (R)
0 = Local 0 = No Alarms
1 = Host 1 = Alarms
Bit 1: Run/Stop (R/W) Bit 7: Warning (R)
0 = Stop 0 = No Warnings
1 = Run 1 = Warnings
Bit 2: Load/Unload (R/W) Bit 8: On/Off Line Mode (R)
0 = Unload 0 = Not in On/Off Line Mode
1 = Load 1 = On/Off Line Mode
Bit 3: Modulating (R) Bit 9: Mod/ACS or Mod Only (R)
0 = Not Modulating 0 = Not in Mod/ASC Mode
1 = Modulating 1 = Mod/ASC Mode
Bit 4: Unused Bits 10-12: Unused
Bit 5: Stopped in Auto Restart (R) Bits 13-15: Unit Type (R)
0 = Not Stopped in Auto Restart 001 = SSR controller
1 = Stopped in Auto Restart
FIGURE 1 XE-90M FIXED SPEED CONTROLLER REGISTER 01-STATUS/CONTROL

Register 100: Starter Type Register 114: Mode of Operation

1 = Star-Delta 0 = On/Off Line
2 = Remote Starter 1 = MOD/ACS
3 = Soft Starter 2 = Modulation Only

Registers 132, 135: Day

0 = Sunday 4 = Thursday 7 = Daily
1 = Monday 5 = Friday 8 = Weekdays
2 = Tuesday 6 = Saturday 9 = Weekends
3 = Wednesday

FIGURE 2 XE-90M FIXED SPEED CONTROLLER REGISTER CODES

5
 Code Description
01 Sensor Failure 1AVPT
02 Sensor Failure 3APT
03 Sensor Failure 4APT
04 Sensor Failure 5CPT
05 Sensor Failure 6CPT
06 Sensor Failure 10APT (Remote)
07 Sensor Failure 2APT
08 Sensor Failure 7APT
09 Sensor Failure 2CTT
10 Sensor Failure 2ATT
11 Sensor Failure 4ATT
12 Sensor Failure T4 (Spare)
13 Sensor Failure 5DTT
14 Sensor Failure 6DTT
15 Sensor Failure T7 (Spare)
16 Sensor Failure T8 (Spare)
17 High Inlet Vacuum
18 Motor Overload (Main)
19 Fan Motor Overload
22 Check Motor Rotation
25 Remote Stop Failure
26 Remote Start Failure
28 Low Sump Pressure
29 High Air Pressure
30 High Coolant Filter Pressure Drop
31 High A/E Discharge Temperature
32 Emergency Stop
33 Change Inlet Filter
34 Change Separator Element
35 Change Coolant Filter
36 Sensor Error (Calibration)
38 100 Hours To Service
39 Service Required
40 Alarm – Service Required
41 Auxiliary 2
42 Auxiliary 1
43 Condensate Drain Error
48 Unit Too Cold To Start
49 High Sump Pressure
50 High Interstage Pressure
51 Dryer High Pressure
52 Dryer Freeze Warning
53 Condenser Low (Dryer)
54 Condenser High (Dryer)
55 Change HE Filter (Dryer)
200 Check SD Card

FIGURE 4 XE-90M FIXED SPEED CONTROLLER TRIP & WARNING CODES