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Ingersoll-Rand Xe-145M, Pocket Manual

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Ingersoll-Rand Xe-145M Pocket Manual Download Page 2

1 

 

                            

About this Pocket Guide 

 

This pocket guide was created to assist Field 
Service Technicians when troubleshooting

 warnings, 

alarms 

within the R-Series/RS-Series machines.  

 
For detailed information of the controller, such as: 
navigation keys, controller display layout, installation 
info, and basic operation download in Passport the 
following PDF files:  
 
Product information manuals:  
 
R37-160kW: CCN 80446164 
 
RS30-37IE: CCN 80448830 

      

 

RS200-355I/IE:

 CCN 

80449028 

 
*For Engineering Data, P&ID, and Electrical 
Schematics visit 

Sales Library

 (website not 

available on tablets)  
                   

 
 
 

                                                

  

Summary of Contents for Xe-145M

Page 1: ...Control Systems Xe 90M 145M R RS Series Fixed Speed Technician s Pocket Guide...

Page 2: ...ailed information of the controller such as navigation keys controller display layout installation info and basic operation download in Passport the following PDF files Product information manuals R37...

Page 3: ...0 P1 Triac Outputs 11 30 P2 Relay Outputs 31 32 P3 Digital Inputs 33 38 P4 Outputs Digital Analog Outputs 39 40 P5 Analog Pressure Sensor Inputs 41 48 P6 Analog Temp Sensor Inputs 49 56 P7 USB Service...

Page 4: ...ies This microprocessor based controller uses a finger touch membrane for operation of the compressor and setting control parameters Information about the programming and operating status is available...

Page 5: ...es make up the instrumentation that provides feedback to the controller Operating and navigating the controller is easy and intuitive through a series of folders and pages within the graphical user in...

Page 6: ...nt drawn by the machine can be several times greater than the full load rating See the Engineering Data sheets in Sales Library for fuse and cable size recommendations Main Fuse Protection not shown i...

Page 7: ...Fast Acting Class J fuses protect the Fan Drive FD in single stage units For 2 Stage units the machine is designed with two Fan Drives FD1 FD2 The second Fan Drive FD2 is mentioned below FU1 2 3 R Ser...

Page 8: ...Acting Class J fuses protecting FD2 are FU4 5 6 FU7 8 9 R Series Dryer Fuses S S Fuses are required when the Dryer option is installed FU7 8 9 RS Series Fuses Low Ambient 2 S A three phase auto trans...

Page 9: ...ls suitable for use with the Xe control system The reduced voltage sources are called secondary circuits The secondary circuit is rated at 115Vac 1 phase 60Hz and is used to energize solenoid valves a...

Page 10: ...dent on machine configuration as defined in the electrical schematic and label on the back of the controller cover Caution should be used to ensure each plug is properly inserted into the correct rece...

Page 11: ...plugs Ensure cables are properly installed in the terminals before replacing components Perform a quick test with a paper clip if faulty signals are suspected Replace quick disconnect plug if the ten...

Page 12: ...cting to P1 1 and the Neutral wire connecting to P1 10 Triac output information can be found on the back of the controller What is a Triac It is a three terminal electronic device that conduct current...

Page 13: ...12 R Series P1 Triac...

Page 14: ...13 RS Series P1 Triac 115VAC...

Page 15: ...P1 3 Fan Motor Contact KM4 P1 4 P1 4 Load Solenoid 1SV P1 5 P1 6 Modulation Solenoid 5SV P1 6 P1 7 Isolation Solenoid Valve 7SV N A P1 6 Moisture Separator Drain Valve 9SV P1 7 P1 8 Dryer Filter Drai...

Page 16: ...minals causing the contactor to pull in creating the path of electricity to the main motor Auxiliary contacts KM1 1 KM3 1 and KM3 2 provide full control of the Star Delta starting circuit Contactor KM...

Page 17: ...r starting circuit The Fan Motor Protection FMP is explained next FMP Fan Motor Protection The Fan Motor Protection overload is a normally open contact that closes when the Fan Motor Protection is on...

Page 18: ...closed de energize when the machine is unloaded auto restart or OFF 5SV Modulation Solenoid Valve Connected to P1 the controller provides power to the 5SV modulation solenoid valve when the controlle...

Page 19: ...oid This allows the inlet valve load cylinder to begin opening the butterfly valve of the inlet valve assembly 4SV Water Shut Off Solenoid W C only 4SV is connected to the main contactor KM1 aux conta...

Page 20: ...onditions Note CDE2 CDE3 No loss condensate drains are also connected in the Triac and P3 digital inputs for Dryer option only Condensate Drain Valves 9SV 10SV 11SV Connected to P1 the controller prov...

Page 21: ...mbalance The phase monitor is connected to the Incoming Power feed through circuit breaker MCB2 designated as K2 1 in the Electrical Schematic The phase monitor will open cables 102 and 105 K2 1 remov...

Page 22: ...r Drive Control Relay At startup the machine energizes K3 relay through P1 terminal closing the run signal for the Blower Drive FD terminals 12 18 and 27 K3 1 K3 1 run signal for the Blower Drive or D...

Page 23: ...ries machines with the Dryer option installed for RS Series the run signal of the Dryer energizes through K5 relay K5 Dryer Run relay for RS Series At start up the controller energize K5 relay closing...

Page 24: ...is an optional feature connected to the PSU Power supply 24VDC The main purpose is to monitor the temperatures of the motor bearings and the stator windings via the Modbus port in P9 7 8 The faults a...

Page 25: ...ower Outage Restart Option section PORO Power Outage Restart Option Option Only Connected to P1 Triac 115 VAC powers the PORO horn The PORO horn provides audible notice of a pending loss of Incoming P...

Page 26: ...in P4 terminal allowing P1 Triac voltage to energize the PORO horn K6 explain in this section PORO Field Installation Kit found in Passport MCB1 Main Circuit Breaker MCB1 is the schematic designation...

Page 27: ...transformer circuit to provide a degree of protection to the controller terminal P1 1 MCB4 Low Ambient option Main Circuit Breaker MCB4 protects the circuit for the thermostat and the temperature swit...

Page 28: ...n the contactor coils are energized If not installed the arc created by the coils can create nuisance faults in the 5 VDC circuits Refer to typical electrical schematics for location Emergency Stop Bu...

Page 29: ...d connects to terminal P1 1 ES 2 contact blue wires is located in the 24 VDC logic circuit at P3 7 8 for R Series or P3 1 2 for RS Series These contacts act in parallel to ensure power is removed from...

Page 30: ...h Note FR1 is normally closed and sends a trip signal to the controller P3 terminal opening the digital signal at cables 95 96 1ATS High Air Temperature Switch for RS A normally closed switch installe...

Page 31: ...rol Power Loss if Control Power Loss set point is enabled in Factory Settings Note A shorted 1ATS switch can cause the MCB3 breaker to open when power is applied to the machine or start button is pres...

Page 32: ...ts for remote warning and trip notification P2 contains 2 outputs rated at 250VAC 48 62Hz 3 Amps Relay outputs P2 information found on the back of the controller Electrical Schematic for R RS series P...

Page 33: ...contact The purpose is to close or open P2 terminals without changing the primary voltage applied to the controller allowing the customer to monitor the running status of the machine Why customers us...

Page 34: ...tal Inputs Terminal plug strip P3 is dedicated to digital inputs that provide remote control and feedback from various switches installed on the package like motor overload fan motor overload R Series...

Page 35: ...3 LED13 comes on if 5VDC is shorted out on any of the analog inputs It is visible through the hole between text P4 and text 1 of P4 Remove pressure transducer connections one at a time until the LED g...

Page 36: ...er High Pressure Switch DHP Option TAS Close P3 15 16 Close P3 21 22 Condensate Drain Error Signal Close P3 17 18 Close P3 17 18 Remote Stop Close P3 19 20 Close P3 7 8 Remote Start Open P3 21 22 Open...

Page 37: ...e the warning will occur However this switch is a locking switch The dryer high pressure switch must be reset contact closed before this warning can be reset If this warning is reset while the conditi...

Page 38: ...ed to start the compressor remotely The normally open momentary switch is connected to P3 terminal This is an option that can be installed by the customer Remote Lead Lag RLL The remote Lead Lag is a...

Page 39: ...rol the Load Unload function for the compressors from a remote location The normally closed contact is connected to the controller P3 terminal This is an option that can be installed by the customer A...

Page 40: ...or more outputs can be connected to the controller The controller has four digital and two analog outputs located at terminal plug strip P4 Digital Outputs Digital AO1 connected to P4 1 2 Digital AO2...

Page 41: ...40 Test on blower speed signal Tech Tube 10968 Machines with Low Ambient option installed...

Page 42: ...the beam The beam is attached to a strain gauge As pressure pushes the diaphragm the beam flexes and bends the strain gauge A continuous voltage is applied to the strain gauge assembly As the strain g...

Page 43: ...ing displayed load unload the compressor or possibly shut the compressor down If a pressure sensor is replaced it is important to calibrate the new sensor Calibration allows the controller to read the...

Page 44: ...43 Pressure Transducer Voltage Signals Note The signal terminal takes the DC feedback from the pressure transducer and calculates the corresponding psi bar value to be shown on the controller display...

Page 45: ...Bar Sump Pressure P5 4 5 6 P5 7 8 9 4APT 0 225 PSIG 15 51 Bar Package Discharge Pressure P5 7 8 9 P5 10 11 12 5CPT 0 225 PSIG 15 51 Bar Coolant Filter In Pressure P5 10 11 12 P5 13 14 15 6CPT 0 225 PS...

Page 46: ...i 0 1 03 Bar The output signal to the controller is 0 5 VDC at 0 psi 0 Bar and 4 5 VDC at 15 psi 1 03 Bar Inlet vacuum differential pressure is monitored to ensure the inlet air filter health and the...

Page 47: ...eeds 75 psi 5 17 Bar 2APT has an output signal range of 0 psi 0 Bar at 0 5 VDC to 225 psi 15 51 Bar at 4 5 VDC 3APT Sump Pressure Sump pressure is monitored for several reasons including a comparison...

Page 48: ...t signal range of 0 psi 0 Bar at 0 5 VDC to 225 psi 15 51 Bar at 4 5 VDC 5CPT Injected Coolant Pressure Mounted before the coolant filter to measure the inlet pressure coming from the sump 5CPT has an...

Page 49: ...ir pressure entering the dryer 7APT has an output signal range of 0 psi 0 Bar at 0 5 VDC to 225 psi 15 51 Bar at 4 5 VDC 10APT Remote System Pressure Option Mounted in the air system downstream of the...

Page 50: ...y a corresponding amount As the output voltage varies due to the temperature changes the voltage signal is processed by an analog to digital converter within the controller The Xe controller uses Nega...

Page 51: ...tor in cold water of known temperature and take an Ohm reading across the 2 wires Do the same with hot water and compare the 2 values with the Thermistor Resistance Chart If the thermistor Ohm value d...

Page 52: ...ature P6 17 18 P6 1 2 2ATT Air End Discharge Temperature P6 3 4 P6 3 4 2CTT Injected Coolant Temperature P6 1 2 P6 5 6 3CTT Oil Cooler Out Temp Option P6 7 8 N A 4 ATT Package Discharge Temperature P6...

Page 53: ...25988 113 4276 185 1014 50 20244 122 3507 194 865 2 59 15889 131 2894 203 741 68 12562 140 2400 212 636 9 77 10000 149 2001 221 549 7 86 8013 158 1677 230 476 1 95 6461 167 1412 239 413 9 Chart not a...

Page 54: ...53 5DTT and 6DTT option...

Page 55: ...o monitor the temperature of the air coolant mixture as it leaves the Air End discharge port 2ATT has a range between 10 F 23 3 C and 250 F 121 1 C The output voltage is 0 5 volts DC at 0 F to 4 5V DC...

Page 56: ...a range between 10 F 23 3 C and 250 F 121 1 C The output voltage is 0 5 volts DC at 0 F 17 8 C to 4 5V DC at 246 F 118 9 C 4ATT Package Discharge Temperature Sensor Mounted at the package discharge ne...

Page 57: ...moisture separator of the dryer 5DTT monitors the dew point of the dryer 5DTT has a range between 10 F 23 3 C and 250 F 121 1 C The output voltage is 0 5 volts DC at 0 F 17 8 C to 4 5V DC at 246 F 118...

Page 58: ...rt that provides access to the file system and allows programming through the Field Service Tool Controller Connection Electrical Schematic Terminal A standard USB Type A to B cable commonly a USB pri...

Page 59: ...through a Modbus TCP type system controller Settings are available through the controller UI to configure the Ethernet port as needed Note 1 Additional settings are required to allow remote control of...

Page 60: ...addition to USB and Ethernet communication the Xe has four RS 485 serial ports located at terminal plug strip P9 COM1 Airbus RS485 1 Network P9 3 L1 P9 4 L2 COM2 Modbus P9 1 L1 P9 2 L2 COM3 VSD Nirvan...

Page 61: ...ame speed or be speaking the same language If any one component wired in does not use the same protocol it can cause communication difficulties RS 485 data communications and other low voltage signals...

Page 62: ...c display analog and digital signals P10 2 Negative P10 1 Positive Supply Input P10 10 9 26 4 VDC at 0 45 Amps Electrical Schematic R RS Series Both machines require an external DC voltage source to p...

Page 63: ...Software Logic for R RS machines W Will occur if 1AVPT sensor is greater than 0 7 psi 05 Bar vacuum or 1 3 psi 09 Bar vacuum if the high dust filter option is enabled and the compressor has been loade...

Page 64: ...gic for R RS machines W Will occur if the compressor is loaded the compressor is warmed up the injected coolant temperature is at least 120 F the package discharge pressure is at least 90 psi 6 21 Bar...

Page 65: ...If one is turned on the other one needs to be set to off Is the dryer ON for a TAS unit If the machine has a dryer check the inline filter for obstructions Change Coolant Filter Xe Software Logic for...

Page 66: ...or foreign material Check piping and coolant filter housing for obstruction If the sensors are fluctuating when the machine is stopped the wiring is not connected properly or the wiring is touching an...

Page 67: ...eck connectors per Quick Disconnect Plugs Connector section of this manual If a Dryer TAS sensor failure is active ensure the machine has the option installed If the remote pressure set point is set t...

Page 68: ...is faulty the wire connection is incorrect or the sensor wire is close to an A C cable creating electrical noise Notes for Sensor Failure RS Series 1AVPT Inlet Vacuum This sensor failure is only check...

Page 69: ...ing is issued A This will occur if the compressor is running loaded for at least 8 seconds and any one of the 3 following conditions exist 1 the sump pressure is above the rated pressure by 35 psi 2 4...

Page 70: ...coolant thickness at start up Some cases the separator element will implode due to excessive thickness of the coolant when machine starts cold Check for use of OEM Ingersoll Rand Parts High Air End Di...

Page 71: ...degrees higher than the cooler in temperature Ensure the cooler temperature out is at least 30 F 1 11 C LESS than the cooler in when the machine is up to temperature Check TCV Check for piping obstru...

Page 72: ...shoot the warning Auxiliary 2 Xe Software Logic for R RS machines W This will occur if auxiliary input 2 closes The contact must be closed for at least 3 seconds before the warning will occur This wil...

Page 73: ...ic for R RS machines Service warnings occur when the compressor has operated a certain number of hours based on the total hours Service warnings can have multiple levels depending on the service level...

Page 74: ...g can be reset the same as any other warning Recommended Checks Add factory pass code to reset the alarm in factory settings Select service warnings according to customer needs options installed High...

Page 75: ...ning however this warning will return in 24 hours if the service complete factory set point has not be set If the service complete has not been set 100 hours later the ALARM SERVICE REQUIRED warning w...

Page 76: ...re Logic for R RS machines W This will occur if the compressor is the lead compressor in integral sequencing and is unable to communicate with another compressor Recommended Checks Be sure ISC is only...

Page 77: ...emote sensor option is on and the remote sensor is recognized as missing or broken If this occurs the compressor will automatically start using 4APT for loading and unloading the compressor Units equi...

Page 78: ...harge Pressure Xe Software Logic for R RS machines Will occur if the compressor is using a remote sensor or is under the control of an external device such as an 8XI is loaded and the discharge pressu...

Page 79: ...reading accurately If the sensor is installed before or after a dryer could it be freezing Is the sensor able to calibrate to 0 PSIG 0 Bar when the system pressure is bled down Condensate Drain Error...

Page 80: ...ergizes the drain to release the condensate water Is the drain or piping dirty A clogged pipe won t allow the drain to discharge causing an error in the condensate drain The drain is 120 VAC so it can...

Page 81: ...ded Checks Check temperature probe with a cup of ice Ensure metering device is not damaged Check refrigerant charge Calculate superheat and subcooling Dryer High Pressure Xe Software Logic for R RS ma...

Page 82: ...ecks High ambient temperature if air cooled Dirty condenser if water cooled High inlet air temperature High airflow rate Condenser fan operation Refrigerant charge Defective pressure sensor Condenser...

Page 83: ...operation Refrigerant charge Defective pressure sensor Condenser Temperature Low Xe Software Logic for R RS machines This will occur if the condenser sensor has a value below the low temperature thres...

Page 84: ...cross the HE filter is measured by subtracting the package discharge pressure from the aftercooler discharge pressure If the compressor is running the measured drop across the HE filter is at or above...

Page 85: ...loaded or loaded and 3APT is less than 13 psi 9 Bar for 15 seconds Recommended Checks Is the unloaded sump pressure 18 24 psi 1 24 1 65 Bar If not adjust inlet valve per Tech Note 1497 If the main mot...

Page 86: ...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...

Page 87: ...isconnect power to test the auxiliaries contact coils Ensure correct rotation of the motor Air End Is 2ATT reading more than 50 F 10 C when the Air End rotates Main Motor Overload Xe Software Logic fo...

Page 88: ...ing increase overload 5 amps and re test The Air End is the load Are SPM readings high or oil samples flagged A damaged bearing in the Air End can increase the amps in the induction motor opening the...

Page 89: ...d causing an air restriction If the machine has a blower drive installed install an LCP or HIM to read the fault log of the drive Megger the motor Remote Stop Failure Xe Software Logic for R RS machin...

Page 90: ...ontroller is not receiving the signal from the remote stop switch Check wiring switch Remote Start Failure Xe Software Logic for R RS machines Will occur if the remote start stop option is enabled the...

Page 91: ...mergency stop button is engaged Recommended Checks The remote stop switch is a 24 VDC signal on P3 terminal in the controller An open switch will show this alarm Check for loose broken wiring Broken s...

Page 92: ...y there is a short ground or electrical noise from a power cable blower motor drain valve Take oil sample for contaminated environments Check wiring of the sensors in P5 terminal High Inlet Vacuum Xe...

Page 93: ...h Dust filter option selected in Factory settings Unit Too Cold To Start Xe Software Logic for R RS machines This will occur if the compressor does not have the low ambient option the Air End discharg...

Page 94: ...kits ensure the heat trace option is connected and the thermostat is set no less than 50 F For more info see Tech Note 7998 High Inter Stage Pressure Xe Software Logic for R RS 2 stage units This will...

Page 95: ...nes Will occur if the sensor zero value is 10 of its scale This will only occur when a sensor is calibrated Recommended Checks Ensure sensor part number matches with the machine Look in Passport or ca...

Page 96: ...ustomer air piping causing the compressor to cycle all the time Increase the air receiver capacity Verify that pressure sensors are reading correctly Install muffler Load Cycles Severe Xe Software Log...

Page 97: ...r Elevated Air End Discharge Temperature Xe Software Logic for R RS machines Will occur if the main motor is running and airend discharge temperature 215 F 101 7 C for 30 minutes Recommended Checks If...

Page 98: ...00 50 HZ or 60 HZ depending on the drive parameter motor data plate Is the coolant at least way full in the sump sight glass when the machine is running loaded Inspect free movement of the check valve...

Page 99: ...ON low ambient enable set point is OFF and the package inlet temperature is less than 40 F 4 44 C for a period of 30 minutes Will also occur if the Enable ambient Monitoring set point is ON low ambien...

Page 100: ...302 F 150 C Recommended Checks Check motor for dirt debris oil etc Clean accordingly Check for blockage of the cooling air path into and through the machine Is ductwork installed Improve airflow to th...

Page 101: ...gh Motor Bearing Temperature Xe Software Logic for RS machines Will occur if any enabled Motor Bearing RTD temperature reading exceeds 203 F 95 C Recommended Checks Check motor for dirt debris oil etc...

Page 102: ...rature if the corresponding Motor Temperature Enable set point is set to ON and the RTD monitor shows an open circuit condition for a given channel for 10 consecutive reads Recommended Checks Ensure t...

Page 103: ...d to the 24 VDC power supply and to the controller P9 COM3 Ensure all the 2 bearing temperature sensors are connected properly to the RTD monitor Check loose broken wire Motor Monitor Communications F...

Page 104: ...D monitor module is bad High Separator Delta P Xe Software Logic for R RS machines A Will occur if the controller has been in a Run Loaded state for 8 seconds Package Discharge Pressure 65 psi 4 48 Ba...

Page 105: ...er Control Type set point is set to Variable Speed and the Fan Motor Overload digital input opens for a period of 3 seconds The number of Blower Fault event occurrences may be recorded in controller m...

Page 106: ...rm Megger Milliohm on the blower motor P3 Terminal connection is the one receiving the drive status alarm Check for good connections Ensure the ductwork of the machine is properly sized not creating a...

Page 107: ...e airflow to package Check connection of the sensor according to Electrical Schematic Is it in the right P6 terminal Control Power Loss Xe Software Logic for R RS machines Will occur if Control Power...

Page 108: ...exception of the hot 120 VAC and ground cable Re connect the components to see which one is causing the trip troubleshoot by elimination technic E stop wiring needs to be close to allow control volta...

Page 109: ...f the sump pressure 3APT is 25 psi 1 72 Bar or higher than the rated pressure of the compressor Wait For Blowdown Will occur if the sump pressure is greater than 20 psi 1 38 Bar before the machine is...

Page 110: ...109 Tips to Test the Triac P1 Terminal Ensure to isolate a shorted grounded solenoid sensor or component before testing the Triac...

Page 111: ...110 Triac Test 1...

Page 112: ...111 Triac Test 2...

Page 113: ...112 Triac Test 3...

Page 114: ...113 Triac Test 4...

Page 115: ...114 Triac Test 5...

Page 116: ...115 Triac Test 6...

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