Xe-70M / Xe-90M / Xe-145M / Xe-300M
Xe replaced the long-running Intellisys SG/SGN in 2016+. If replacing an SGN with an Xe, confirm sensor wiring polarity (RTD vs thermistor) — cross-wiring shows up as immediate high-temp shutdown on start.
Manufacturer
Ingersoll Rand
Display
Xe-70M: 3.5" color; Xe-90M: 4.3" color; Xe-145M: 7" color touch; Xe-300M: 7" color touch with sequencing screens.
Years produced
~2016 – present. Replaced the long-running Intellisys SG/SGN family.
Power supply
24 VDC control from onboard PSU (120/230 VAC input). Battery-backed RTC.
Ambient range
0 – 46 °C. Xe-70M rated for enclosure ambient; Xe-145M/300M cabinet-mount.
Protection rating
IP54 front, IP20 rear.
Relay outputs
Configurable digital outputs for main / star / delta contactors, load solenoid, blowdown, alarm, dryer, remote-run.
Replaces
Intellisys SG, Intellisys SGN
Used on
- Ingersoll Rand R-Series RS 7.5–160 (contact-cooled)
- Ingersoll Rand R-Series RS 90n–160n Next-Gen
- Ingersoll Rand Nirvana / NirvanaXE (VSD)
- Retrofit for older Intellisys SG/SGN controllers
On AirCompDX
Features
- System Automation to sequence up to 4 (Xe-145M) or 12 (Xe-300M) units
- Progressive Adaptive Control (PAC) load management
- Multi-language interface, on-board trending (up to 30 days on Xe-300M)
- Integrated dryer control on TAS units
- PORO (Power-Out Restart Option) with configurable delay — safety-critical setting
Interfaces
- Ethernet (Modbus TCP, ICONS remote monitoring)
- USB service port
- Digital I/O for remote start/stop, load, ES
- Optional Modbus RTU, Profibus, EtherNet/IP gateway
Sensor inputs
- Airend discharge temperature (RTD)
- Package discharge temperature
- Sump pressure
- Line/system pressure
- Coolant filter ΔP (option)
- Separator ΔP (option)
- Motor winding temperature (thermistor input on n-series)
Common fault codes
First checks
- Check oil level and cooler cleanliness
- Verify oil thermostatic valve and cooler bypass
- Test airend discharge RTD
First checks
- Reset overload, check trip class vs FLA
- Verify voltage balance across all phases
- Confirm no airend seizure
First checks
- Release E-stop, check remote loop
- Verify 24 V on safety input
First checks
- Clean cooler; free fan blade; check bearings
- Verify fan contactor & OL setting
First checks
- Verify 24 VDC on remote stop input
- Check jumper on TB if not using remote
- Confirm run-permissive wiring integrity
First checks
- Check start-permissive chain
- Verify no active alarms
- Confirm mode = remote
First checks
- Check wiring polarity
- Compare RTD resistance to table
- Look for water intrusion at connector
First checks
- Change filter and verify O-ring
- Check for cold-start high ΔP masking real issue
- Sample oil for contamination
First checks
- Replace air filter
- Check inlet valve movement
- Verify vacuum switch calibration
First checks
- Change separator element as a full kit
- Check scavenge line
- Inspect fluid for foaming
First checks
- Check blowdown solenoid coil and orifice
- Inspect MPCV (min pressure check valve) for stuck poppet
- Verify inlet valve fully closes
First checks
- Check load/unload setpoints
- Verify inlet valve closes at unload
- Look for stuck-open bypass or MPCV
First checks
- Check inlet valve movement
- Look for large leak between airend and separator
- Verify blowdown closes
First checks
- Change Ultra Coolant / Ultra EL Coolant as set
- Sample old coolant for TAN & metals
- Reset timer only
First checks
- Verify ΔP before replacing (may still be good)
- Reset service counter
Fault list is non-exhaustive and firmware-dependent. Always confirm against the controller’s on-screen help or OEM manual.
Wiring notes
- 24 VDC control power from onboard PSU
- PORO (Power Out Restart Option) toggle in service menu — safety-critical (LOTO warning required)
- TAS integrated dryer wired to Xe I/O terminals; standalone dryers via digital in/out
- Modbus RTU on 2-wire RS-485; terminate 120 Ω at both ends of the daisy-chain
Terminal & connector map
Pinouts distilled from OEM wiring diagrams. Exact silk-screen labels and pin numbering vary by hardware revision and package options — always confirm against the machine’s as-built wiring diagram before landing a wire.
Connectors to the controller
- P1 – 24 VDC control power (screw terminals, top of controller)
- P2 – RS-485 X-Series sequencer bus (A/B/GND) — daisy-chain to lead controller
- P3 – RJ45 Ethernet (Modbus TCP)
- P4 – RTD sensor harness (keyed connector) to airend discharge / package discharge sensors
- P5 – 4–20 mA transducer harness (line pressure, sump pressure, sep ΔP)
- P6 – digital I/O to starter panel (star/delta, blowdown, remote start/stop, common trouble)
P1 – PowerControl power
| Pin | Signal | Type | Connects to |
|---|---|---|---|
| +24 | +24 VDC | 24 VDC | T1 secondary + |
| 0V | 0 V return | 24 VDC ret. | T1 secondary − |
| PE | Protective earth | PE | Panel ground bar |
P4 – RTD inputsAirend & package RTDs
| Pin | Signal | Type | Connects to |
|---|---|---|---|
| 1RTD 1/2/3 | Airend discharge (2ATT) | PT100 3-wire | 2ATT sensor at airend outlet |
| 2RTD 1/2/3 | Package discharge (3ATT) | PT100 3-wire | 3ATT sensor at aftercooler out |
| 3RTD 1/2/3 | Injection temp (option) | PT100 3-wire | Injection temp sensor |
Xe uses PT100 (SGN often thermistor) — verify sensor type before energizing.
P5 – Pressure4–20 mA transducers
| Pin | Signal | Type | Connects to |
|---|---|---|---|
| 1AVPT +/− | Package discharge pressure | 4–20 mA | 1AVPT transducer |
| 2AVPT +/− | Sump pressure | 4–20 mA | 2AVPT transducer |
| ΔP +/− | Separator ΔP | 4–20 mA | Sep ΔP transducer |
P6 – Digital I/OStarter, remote, alarm
| Pin | Signal | Type | Connects to |
|---|---|---|---|
| 1M | Main contactor coil (star/delta or ATL) | 24 VDC out | 1M main contactor |
| 1S | Star contactor coil | 24 VDC out | 1S star contactor |
| 1D | Delta contactor coil | 24 VDC out | 1D delta contactor |
| 1SV | Load / blowdown solenoid | 24 VDC out | 1SV load solenoid |
| RS+/RS− | Remote start (dry) | dry contact in | Customer PLC |
| RSt+/RSt− | Remote stop (dry) | dry contact in | Customer PLC |
| CT+/CT− | Common trouble relay | relay out | Master alarm / BMS |
Known issues & field notes
- PORO on by default from factory on some builds — verify with customer before commissioning
- USB firmware update fails on FAT32 sticks > 32 GB — use small industrial-grade stick
- Touchscreen unresponsive after long dwell — cold-cycle 24 V PSU
- MPCV false 'code 27' alarms on cold Ultra Coolant — recheck after 20 min run
Retrofit notes
SGN → Xe retrofit: sensor pinouts and RTD types differ. Wire per Xe wiring diagram, not old SGN loom. Confirm sump pressure sensor polarity.
Firmware notes
Xe firmware families are frame-specific — do not cross-flash between Xe-70M and Xe-145M without verified image.
Service level requires 4-digit PIN (dealer-set). Do not share OEM defaults publicly.
Manuals & literature
Ingersoll Rand — support portal
Customer Care → Manuals & Parts (login often required)
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