INGERSOLL RAND Fixed Speed/Variable Speed Conversion COMMISSIONING AND OPERATION MANUAL

Transcription

1 INGERSOLL RAND Fixed Speed/Variable Speed Conversion COMMISSIONING AND OPERATION MANUAL Before installing or starting this unit for the first time, this manual should be studied carefully to obtain a working knowledge of the unit and/or the duties to be performed while operating and maintaining the unit. RETAIN THIS MANUAL WITH UNIT. This Technical manual contains IMPORTANT SAFETY DATA and should be kept with the unit at all times. More Than Air. Answers. Online answers: C.C.N. : REV. D DATE: Sept. 2011

2 TABLE OF CONTENTS TABLE OF CONTENTS... 2 SECTION 1 INTRODUCTION... 3 SECTION 2 FIELD CONVERSION... 3 SECTION 3 SAFETY AND PRECAUTIONS... 4 SECTION 4 CONTROL FEATURES AND FUNCTIONS... 5 SECTION 5 DISPLAY AND MENU OPERATION SECTION 6 COMMISSIONING SECTION SERIES VFD PARAMETER SETTINGS SECTION 8 - SPEED TABLES CONTACT COOLED SECTION 9 - SPEED TABLES OIL FREE SECTION 10 FAULT AND WARNING CODES SECTION 11 - MAINTENANCE AND REPAIR SECTION 12 PART NUMBER INDENTIFICATION SECTION 13 VFD TECHNICAL DATA SECTION 14 VFD WIRING DIAGRAM

3 SECTION 1 INTRODUCTION The purpose of this manual is to provide instructions needed to program the Ingersoll Rand 302 series Variable Speed Drive (VFD) and commission the completed compressor conversion. Only those Ingersoll Rand compressors listed in the Conversion Manual are authorized for the fixed speed to variable speed conversion. Refer to the Conversion Manual for all electrical connections, electrical installation and electrical wiring schematics required for this conversion. The Operators/Instruction Manual supplied with the compressor and this Instruction Manual supplied with the Ingersoll Rand 302 Series VFD should be referenced for more detailed instructions regarding each of these components. The Ingersoll Rand 302 Series VFD will maintain a constant pressure in compressed air systems by adjusting the compressor motor s speed to match the compressed air usage. Depending on the application and air demand profile, the Ingersoll Rand 302 Series VFD system can achieve 25-35% energy savings. Smooth start-up, reduced machine cycling, lower noise, and monitoring energy parameters are other benefits from an Ingersoll-Rand compressor equipped with Ingersoll Rand 302 Series VFD. WARNING: Risk of Danger WARNING: Risk of Electric Shock WARNING: Risk of High Pressure Before proceeding with the installation, take time to carefully read all the instructions contained in this manual, all compressor manuals, and all manuals of any other peripheral devices that may be installed or connected to the unit. Strict adherence to all National and Local electrical wiring and electrical safety procedures are required along with all National and Local safety standards for compressors. References Used Throughout This Manual: Note Important or Caution, Safety SECTION 2 FIELD CONVERSION For field conversions contact your local Ingersoll Rand distributor or air center to ensure that the motor is suitable for VFD operation, controls are appropriate and to determine the proper speed range of your compressor. Conversion to an SG Controller may be required in some applications to avoid operation problems. Check with your Ingersoll Rand representative. The Ingersoll Rand 302 Series VFD option can be supplied as a factory option or as a field conversion kit(s) for an existing compressor. The field kit includes the additional pressure transducer, terminals, and three relays required to convert to Ingersoll Rand 302 Series VFD operation. On Sierra machines, this kit also includes an additional electric-driven oil pump and all of its mounting and piping to provide constant oil pressure for the inlet valve's hydraulic cylinder. The factory option has all of the necessary components already installed into the compressor with the exception of the drive and pressure transducer. For a field installation of an existing compressor, the additional components for the VFD must be installed. The terminals, relays, and manual motor starter (for Sierra only) must be installed into the starter panel box per the assembly drawing. The electric-driven oil pump and its components (for Sierra only) must be installed per the assembly drawing specified. Refer to the Ingersoll Rand Conversion Manual for all electrical connections. See Compressor Schematics in the Conversion Manual. Wiring must be exactly as outlined on the schematics in the Conversion Manual. DO NOT make an alterations or omissions as this could void the package warranty. Prime the Sierra oil pump by filling suction hose with oil BEFORE applying power to compressor. Once filled with oil, quickly start and stop compressor until pump and associated hose are free of vibrations. The compressor should not be started and stopped in this manner more than 3 times. Pump seals may fail if pump runs dry. Once primed, there should be no need to prime pump again unless compressor has sat idle for extended time. If Sierra oil pump was not installed at factory, check for proper pump rotation. Ensure pump rotates counter-clockwise while viewing pump from behind motor. 3

4 SECTION 3 SAFETY AND PRECAUTIONS Safety Precautions WARNING: Risk of Danger WARNING: Risk of Electric Shock WARNING: Risk of High Pressure WARNING: Consult Manual Before installing or operating the Ingersoll Rand 302 Series VFD, take time to carefully read all the instructions contained in this manual, all compressor manuals, and all manuals of any other peripheral devices that may be installed or connected to the unit. Also refer to the Conversion Manual for all electrical connections. Electricity and compressed air have the potential to cause severe personal injury or property damage. The operator should use common sense and good working practices while operating and maintaining this system. All applicable codes should be strictly adhered to. Maintenance must be performed by adequately qualified personnel that are equipped with the proper tools. WARNING: The Ingersoll Rand 302 Series VFD contains dangerous voltages when connected to line voltage. After disconnecting from the line wait at least 15 minutes before touching any electrical components. Also make sure that any other voltage inputs have been disconnected. Only a competent electrician should carry out the electrical installation. Improper installation of the Ingersoll Rand 302 VFD to the compressor control logic circuits and motor(s) may cause equipment failure, serious injury or death. Follow this manual along with National and Local Electrical Wiring Codes and all Safety Procedures. WARNING: Electrostatic Discharge (ESD) Precaution. Many electronic components are sensitive to static electricity. Voltages are so low that they cannot be felt, seen or heard, can reduce the life, affect performance, or completely destroy sensitive electronic components. When performing service, proper ESD equipment should be used to prevent possible damage from occurring. WARNING: It is the responsibility of the user or the person installing the Ingersoll Rand 302 Series VFD to provide proper grounding, as well as motor overload and branch circuit protection according to the National Electrical Code and local codes. Operational Safety The Ingersoll Rand 302 Series VFD must only be operated by competent personnel under qualified supervision. Never remove or tamper with safety devices, guards or insulation materials fitted to the Ingersoll Rand 302 Series VFD. The Ingersoll Rand 302 Series VFD must only be operated at the supply voltage and frequency for which it is designed. When main power is switched on, lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is necessary to carry out any work on the unit. Do not open access panels or touch electrical components while voltage is applied unless it is necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the correct tools and wearing appropriate protection against electrical hazards. All air compressors and/or other equipment connected to the unit should have a warning sign attached stating THIS UNIT MAY START WITHOUT WARNING next to the display panel. If an air compressor and/or other equipment connected to the unit is to be started remotely, attach two warning signs to the equipment stating THIS UNIT CAN BE STARTED REMOTELY. Attach one sign in a prominent location on the outside of the equipment, and the other sign inside the equipment control compartment. VFD Warnings and Precautions The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid electrical shock hazard, disconnect the frequency converter from the mains before carrying out maintenance. Before doing service on the frequency converter wait at least the amount of time indicated below: 4

5 o V kw 20 minutes kw 40 minutes o V kw 20 minutes kw 30 minutes The Stop/Reset key on the local control panel of the Ingersoll Rand 302 Series VFD DOES NOT disconnect the equipment from the AC line. DO NOT use the Stop/Reset key as a safety switch. The installer must supply correct protective grounding of the equipment. The user must be protected against supply voltage, and the motor must be protected against overload in accordance with National Electric Code and local codes. To avoid potential shock hazard when servicing a motor or Ingersoll Rand 302 Series VFD, remove all power to all drives with wiring that shares any conduit to be worked on. If that is not possible, remove power to the drive and ground the motor wires at the drive. When the work has been completed, remove the grounds before reapplying power to the drive. In general, a conduit should not contain power conductors for more than one PWM operated motor. VFD motor leads must be run in separate metallic conduit and if unavailable, shielded power cable must be used. VFD, compressor motor(s) and compressor cabinet must all be grounded per NEC electrical code. Special attention to ensuring one common ground point is established to minimize ground loops and prevent circulating currents within motor and motor bearings. Ensure a continuous ground from VFD cabinet to compressor cabinet exists. The earth leakage current from the frequency converter exceeds 3.5 ma. To ensure that the earth cable has a good mechanical connection to the earth connection (terminal 95), the cable cross section must be at least 10 mm 2 or 2 rated earth wires terminated separately. The Electronic Thermal Relay (ETR) in UL/cUL listed VFDs provides class 20 motor overload protection in accordance with the NEC in a single motor applications when parameter 1-40 is set for "TRIP" and parameter 1-24 is set for the nominal motor rated (nameplate) current. Protection against motor overload is NOT included in the factory setting. If this function is desired, set parameter to 1-40 to data value ETR trip or data value ETR warning. ETR function is initialized at 1.16 x rated motor current. Warning Against Unintended Start The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop, while the Ingersoll Rand 302 Series VFD is connected to the AC line. These stop functions are NOT sufficient to ensure that no unintended start occurs and should NOT be used for personal safety considerations. While parameters are being changed, the motor may start. Consequently, the Stop/Reset button must be enabled (Parameter 0-41) after which data can be modified. When the drive is in local stop the LCP will be flashing. Parameter 0-41 will be changed later during the startup procedure. WARNING: A motor that has been stopped may start if faults occur in the electronics of the Ingersoll Rand 302 Series VFD or if a temporary overload or a fault in the AC line supply or the motor connection clears. SECTION 4 CONTROL FEATURES AND FUNCTIONS The Ingersoll Rand 302 drive is an external device that is wired to the compressor s motors through the starter panel. The Intellisys controller on the compressor still starts and stops the compressor, while the Ingersoll Rand 302 Series VFD s controller varies the compressor s motor speed to regulate constant system pressure. The Ingersoll Rand 302 Series VFD operates in two different setups: 1) In Setup 1, the Ingersoll Rand 302 Series VFD runs at constant minimum speed and the compressor is unloaded. 2) In Setup 2, the Ingersoll Rand 302 Series VFD regulates a constant pressure and the compressor is loaded. The Intellisys controller logic determines which setup the Ingersoll Rand 302 Series VFD operates. See Intellisys and Ingersoll Rand 302 Series VFD Controllers Interface Logic Diagram As always, the Intellisys controller, set to On / Off Line mode, will load and unload the compressor, depending on the system pressure relative to the pressure band limits. The Ingersoll Rand 302 Series VFD, however, tries to keep the system pressure within the pressure band as long as possible. When the system pressure rises above the target pressure, the drive will slow the compressor s motors so that the compressor supplies less air to the system and allows the pressure to fall. Likewise, when the system pressure falls, the drive increases the compressor s motor speed so that the compressor supplies more air to the system. 5

6 The compressor with the Ingersoll Rand 302 Series VFD will only load and unload at minimum speed, unless the system pressure swings outside the Intellisys pressure band faster than the drive can react. When the system pressure rises above the Off Line pressure setpoint, the blowdown valve opens and the inlet valve closes to unload the compressor. The load relay, 2CR, simultaneously opens to switch the drive to Setup 1 (constant, minimum speed). Conversely, when the system pressure falls below the On Line pressure setpoint, the blowdown valve closes and the inlet valve opens to load the compressor. The load relay, 2CR, simultaneously closes to switch the drive to Setup 2 (pressure regulation). Even with the Ingersoll Rand 302 Series VFD wired to the compressor, the Start button on the Intellisys controller initiates the full-voltage or star-delta starters. When the 1M contactor closes, the start relay, 1CR, closes to start the Ingersoll Rand 302 Series VFD. On air-cooled, SSR units, the contactors have no power flowing through them. However, the 1M contactor does provide power to the constant-speed fan (for a water-cooled unit) and the oil pump (on Sierra units only). After the Start process is completed, the compressor will automatically load and the Ingersoll Rand 302 Series VFD will try to regulate the pressure. On SSR air cooled units, the Ingersoll Rand 302 Series VFD controls the main drive motor and the cooling fan motor. On SSR water cooled units, the Ingersoll Rand 302 Series VFD controls the main drive motor. The small enclosure fan motor gets its power from the compressor starter. On Sierra units, the air cooled and water cooled units are configured the same as the SSR units, except the externally driven oil pump gets its power from the compressor starter. 6

7 INTELLISYS AND 302 Series VFD CONTROLLERS INTERFACE LOGIC DIAGRAM Power at VFD & Compressor VFD Closes 3CR Relay Press START on Compressor The Intellisys Closes 1CR Relay to START the VFD. The Compressor begins to run Unloaded with the VFD in SETUP 1 The Intellisys loads the Compressor and closes 2CR Relay switching to SETUP 2. Variable Speed and Flow operation continues until the Intellisys Unloads the Compressor. The Intellisys Unloads the Compressor, opening 2CR Relay. This switches the VFD to SETUP 1. The Compressor slows down to minimum speed for the duration of the Unload cycle. The Compressor continues to cycle between Load and Unload (2CR Relay closing/opening) until one of the following happens: Has the Intellisys decided the Unload time has been long enough to shut the Compressor off? Has the VFD Faulted for any reason? (I.E.: High Current, Loss of Phase, etc.) The Intellisys shuts down the Compressor and Opens 1CR Relay, stopping the VFD power to the motor. The VFD Drive opens 3CR Relay telling the Intellisys to Stop the Compressor immediately, similar to the Compressor Emergency Stop button being pressed. The Compressor and the VFD are stopped in Stand-by mode awaiting a Start signal. The Compressor and VFD Stop, both flashing alarms. 7

8 RECOMMENDED INGERSOLL RAND 302 SERIES VFD AND COMPRESSOR SYSTEM INSTALLATION 8

9 RECOMMENDED INGERSOLL RAND 302 SERIES VFD AND COMPRESSOR SYSTEM INSTALLATION WITH X-SERIES INTERFACE 9

10 SECTION 5 DISPLAY AND MENU OPERATION Graphical LCP The control panel is divided into four functional groups: 1. Graphical display with Status lines. 2. Menu keys and indicator lights - changing parameters and switching between display functions. 3. Navigation keys and indicator lights (LEDs). 4. Operation keys and indicator lights (LEDs). All data is displayed in a graphical LCP display, which can show up to five items of operating data while displaying [Status]. Display lines: a. Status line: Status messages displaying icons and graphic. b. Line 1-2: Operator data lines displaying data defined or chosen by the user. By pressing the [Status] key, up to one extra line can be added. c. Status line: Status messages displaying text. The LCD-Display The LCD-display has back light and a total of 6 alphanumeric lines. The display lines show the direction of rotation (arrow), the chosen Set-up as well as the programming Set-up. The display is divided into 3 sections: Top section: Displays up to 2 measurements in normal operating status. Middle section: The top line in the displays up to 5 measurements with related unit, regardless of status (except in the case of alarm/warning). Bottom section: This always displays the state of the frequency converter in Status mode. Top Section Middle Section Bottom Section The Active Set-up (selected as the Active Set-up in par. 0-10) is shown. When programming another Setup than the Active Set-up, the number of the programmed Set-up appears to the right. 10

11 Display Contrast Adjustment Press [status] and [ ] for darker display Press [status] and [ ] for brighter display Most FC 300 parameter set-ups can be changed immediately via the control panel, unless a password has been created via par Main Menu Password or via par Quick Menu Password Indicator lights (LEDs): If certain threshold values are exceeded, the alarm and/or warning LED lights up. A status and alarm text appear on the control panel. The ON LED is activated when the frequency converter receives mains voltage or via a DC bus terminal or 24 V external supply. At the same time, the back light is on. [Main Menu] is used for programming all parameters. It is possible to switch directly between Main Menu mode and Quick Menu mode. Parameter shortcut can be carried out by pressing down the [Main Menu] key for 3 seconds. The parameter shortcut allows direct access to any parameter. [Alarm Log] displays an Alarm list of the five latest alarms (numbered A1-A5). To obtain additional details about an alarm, use the arrow keys to maneuver to the alarm number and press [OK]. You will now receive information about the condition of your frequency converter right before entering the alarm mode. [Back] takes you to the previous step or layer in the navigation structure. [Cancel] annuls your last change or command as long as the display has not been changed. Green LED/On: Control section is working Yellow LED/Warn.: Indicates a warning Flashing Red LED/Alarm: Indicates an alarm LCP Keys [Info] supplies information about a command, parameter, or function in any display window. [Info] provides detailed information whenever help is needed. Exit info mode by pressing either [Info], [Back], or [Cancel]. The control keys are divided into functions. The keys below the display and indicator lamps are used for parameter Set-up, including choice of display indication during normal operation. 130BP [Status] indicates the status of the frequency converter and/or the motor. You can choose between 3 different readouts by pressing the [Status] key: 5 line readouts, 4 line readouts or Smart Logic Control. Use [Status] for selecting the mode of display or for changing back to Display mode from either the Quick Menu mode, the Main Menu mode or Alarm mode. Also use the [Status] key to toggle single or double read-out mode. [ Quick Menu] allows quick access to different Quick Menus such as: - My Personal Menu - Quick Set-up - Changes Made - Loggings Use [Quick Menu] for programming the parameters belonging to the Quick Menu. It is possible to switch directly between Quick Menu mode and Main Menu mode. Navigation Keys The four navigation arrows are used to navigate between the different choices available in [Quick Menu], [Main Menu] and [Alarm Log]. Use the keys to move the cursor. [OK] is used for choosing a parameter marked by the cursor and for enabling the change of a parameter. 11

12 Local Control Key Four local control are found at the bottom of the control panel [Hand On] enables control of the frequency converter via the LCP. [Hand on] also starts the motor, and it is now possible to enter the motor speed data by means of the arrow keys. The key can be selected as Enable [1] or Disable [0] via par [Hand on] key on LCP. External stop signals activated by means of control signals or a serial bus will override a start command via the LCP. The following control signals will still be active when [Hand on] is activated: [Hand on] [Off] [Auto on] Reset Coasting stop inverse Reversing Set-up select bit 0- Set-up select bit 1 Stop command from serial communication Quick stop DC brake [Off] stops the connected motor. The key can be selected as Enable [1] or Disable [0] via par [Off] key on LCP. If no external stop function is selected and the [Off] key is inactive the motor can be stopped by disconnecting the voltage. [Auto On] enables the frequency converter to be controlled via the control terminals and/or serial communication. When a start signal is applied on the control terminals and/or the bus, the frequency converter will start. The key can be selected as Enable [1] or Disable [0] via par [Auto on] key on LCP. An active HAND-OFF-AUTO signal via the digital inputs has higher priority than the control keys [Hand on] [Auto on]. [Reset] is used for resetting the frequency converter after an alarm (trip). It can be selected as Enable [1] or Disable [0] via par Reset Keys on LCP. The parameter shortcut can be carried out by holding down the [Main Menu] key for 3 seconds. The parameter shortcut allows direct access to any parameter. Display Mode In normal operation, up to 5 different operating variables can be indicated continuously in the middle section: 1.1, 1.2, and 1.3 as well as 2 and 3. Display Mode - Selection of Read-Outs It is possible to toggle between three status readout screens by pressing the [Status] key. Operating variables with different formatting are shown in each status screen - see below. The table shows the measurements you can link to each of the operating variables. Define the links via par. 0-20, 0-21, 0-22, 0-23, and Each readout parameter selected in par to par has its own scale and digits after a possible decimal point. By larger numeric value of a parameter fewer digits are displayed after the decimal point. Ex.: Current readout 5.25 A; 15.2 A 105 A. Operating Variable: Unit: Par Control Word hex Par Reference [unit] Par Reference % Par Status Word hex Par Main Actual Value % Par Power [kw] Par Power [HP] Par Motor Voltage [V] Par Frequency [Hz] Par Motor Current [A] Par Torque Nm Par Speed [RPM] Par Motor Thermal % Par Motor Angle Par DC Link Voltage V Par Brake Energy / s kw Par Brake Energy / 2 min kw Par Heatsink Temp. C Par Inverter Thermal % Par Inv. Nom. Current A Par Inv. Max. Current A Par SL Control State Par Control Card Temp. C Par Logging Buffer Full Par External Reference Par Pulse Reference Par Feedback [Unit] Par Digi Pot Reference Par Digital Input bin Par Terminal 53 Switch Setting V Par Analog Input 53 Par Terminal 54 Switch Setting V Par Analog Input 54 Par Analog Output 42 [ma] Par Digital Output [bin] Par Freq. Input #29 [Hz] Par Freq. Input #33 [Hz] Par Pulse Output #27 [Hz] Par Pulse Output #29 [Hz] Par Relay Output Par Counter A Par Counter B Par Fieldbus CTW hex Par Fieldbus REF 1 hex Par Comm. Option STW hex Par FC Port CTW 1 hex Par FC Port REF 1 hex Par Alarm Word Par Warning Word Par Ext. Status Word 12

13 Status screen I: This read-out state is standard after start-up or initialization. Use [INFO] to obtain information about the measurement links to the displayed operating variables (1.1, 1.2, 1.3, 2 and 3). See the operating variables shown in the screen in this illustration. Regardless of the mode of programming, you can change a parameter both in the Main Menu mode and in the Quick Menu mode , Status screen II: See the operating variables (1.1, 1.2, 1.3 and 2) shown in the screen in this illustration. In the example, Speed, Motor current, Motor power and Frequency are selected as variables in the first and second , Status screen III: This state displays the event and action of the Smart Logic Control. For further information, see section Smart Logic Control. Parameter Set-Up The Ingersoll Rand 302 Series (VFD) can be used for practically all assignments, which is why the number of parameters is quite large. The series offers a choice between two programming modes - a Main Menu and a Quick Menu mode. The former provides access to all parameters. The latter takes the user through a few parameters making it possible to start operating the frequency converter. 13

14 Quick Menu Key Functions Pressing [Quick Menus] The list indicates the different areas contained in the Quick menu. Select My Personal Menu to display the chosen personal parameters. These parameters are selected in par Personal Menu. Up to 20 different parameters can be added in this menu. Select Quick setup to go through a limited amount of parameters to get the motor running almost optimally. The default setting for the other parameters considers the desired control functions and the configuration of signal inputs/outputs (control terminals). The selection of parameter is effected by means of the arrow keys. The parameters in the following table are accessible. Parameter Designation Setting 0-01 Language 1-20 Motor Power [kw] 1-22 Motor Voltage [V] 1-23 Motor Frequency [Hz] 1-24 Motor Current [A] 1-25 Motor Nominal Speed [rpm] 5-12 Terminal 27 Digital Input [0] No function* 1-29 Automatic Motor Adaptation (AMA) 3-02 Min Reference [rpm] 3-03 Max Reference [sec] 3-41 Ramp 1 Ramp-up Time [sec] 3-42 Ramp 1 Ramp-down Time [sec] 3-13 Reference Site [1] Enable complete AMA * If terminal 27 is set to no function, no connection to +24 V on terminal 27 is necessary. Select Changes made to get information about: the last 10 changes. Use the [ ] [ ] navigation keys to scroll between the last 10 changed parameters. the changes made since default setting. Select Loggings to get information about the display line read-outs. The information is shown as graphs. Only display parameters selected in par and par can be viewed. It is possible to store up to 120 samples in the memory for later reference. 14

15 Main Menu Mode Start the Main Menu mode by pressing the [Main Menu] key. The read-out shown to the right appears on the display. The middle and bottom sections on the display show a list of parameter groups which can be chosen by toggling the up and down buttons. Changing Data The procedure for changing data is the same whether you select a parameter in the Quick menu or the Main menu mode. Press [OK] to change the selected parameter. The procedure for changing data depends on whether the selected parameter represents a numerical data value or a text value. Changing a Text Value If the selected parameter is a text value, change the text value by means of the [ ] [ ] navigation keys. The up key increases the value, and the down key decreases the value. Place the cursor on the value you want to save and press [OK]. Each parameter has a name and number which remain the same regardless of the programming mode. In the Main Menu mode, the parameters are divided into groups. The first digit of the parameter number (from the left) indicates the parameter group number. All parameters can be changed in the Main Menu. However, depending on the choice of configuration (par. 1-00), some parameters can be "missing". E.g. open loop hides all the PID parameters, and other enabled options make more parameter groups visible. Parameter Selection In the Main menu mode, the parameters are divided into groups. You select a parameter group by means of the navigation keys. The following parameter groups are accessible: Group # Parameter group: Group 0 Operation/Display 1 Load/Motor 2 Brakes 3 References/Ramps 4 Limits/Warnings 5 Digital In/Out 6 Analog In/Out 7 Controls 8 Comm. and Options 9 Profibus 10 CAN Fieldbus 11 Reserved Com Reserved Com Smart Logic 14 Special Functions 15 Drive Information 16 Data Readouts 17 Motor Feedb. Option After selecting a parameter group, choose a parameter by means of the navigation keys. The middle section on the display shows the parameter number and name as well as the selected parameter value. Changing a Group of Numeric Data Values If the chosen parameter represents a numeric data value, change the chosen data value by means of the [ ] [ ] navigation keys as well as the [ ] [ ] navigation keys. Use the [ ] [ ] navigation keys to move the cursor horizontally Use the [ ] [ ] navigation keys to change the data value. The up key enlarges the data value, and the down key reduces the data value. Place the cursor on the value you want to save and press [OK]. 15

16 Infinitely Variable Change of Numeric Data Value If the chosen parameter represents a numeric data value, select a digit by means of the [ ] [ ] navigation keys. Change the selected digit infinitely variably by means of the [ ] [ ] navigation keys. The chosen digit is indicated by the cursor. Place the cursor on the digit you want to save and press [OK]. Changing a Data Value, Step-by-Step Certain parameters can be changed step by step or infinitely variably. This applies to Motor Power (par. 1-20), Motor Voltage (par. 1-22) and Motor Frequency (par. 1-23). The parameters are changed both as a group of numeric data values and as numeric data values infinitely variably. Read-out and Programming of Indexed Parameters Parameters are indexed when placed in a rolling stack. Par to contain a fault log which can be read out. Choose a parameter, press [OK], and use the [ ] [ ] navigation keys to scroll through the value log. Use par as another example: Choose the parameter, press [OK], and use the [ ] [ ] navigation keys to scroll through the indexed values. To change the parameter value, select the indexed value and press [OK]. Change the value by using the [ ] [ ] keys. Press [OK] to accept the new setting. Press [CANCEL] to abort. Press [Back] to leave the parameter. 16

17 SECTION 6 COMMISSIONING When commissioning the Ingersoll Rand 302 Series VFD, carry out the following procedures before attempting to start. It is recommended that an authorized and trained IR person carry out commissioning. Basic operation: The Intellisys monitors the pressure and attempts to control the pressure by loading and unloading the compressor. The condition of the unload solenoid is monitored by the drive and it either runs at a fixed speed when the compressor is in the unload mode or the drive runs in a variable speed in the load mode. In the load mode the speed is controlled by the drive s set point compared to the drives pressure transducer. WARNING: The Ingersoll Rand 302 Series VFD contains dangerous voltages when connected to line voltage. After disconnecting from the line wait at least 15 minutes before touching any electrical components. Also make sure that any other voltage inputs have been disconnected. Only a competent electrician should carry out the electrical installation. Improper installation of the Ingersoll Rand 302 VFD to the compressor control logic circuits and motor(s) may cause equipment failure, serious injury or death. Follow this manual along with National and Local Electrical Wiring Codes and all Safety Procedures. PHYSICAL CHECKS Observe correct lockout and safety procedures. 1. Install drive pressure sensor per instructions in this manual. This should be at the discharge of the compressor. Remove display from drive and slide Switches S201 (A53) and S202 (A54) to the ON position to select current (0-20 ma). 2. Install wiring per Conversion Manual that is correct for your drive size and compressor model. Resistance Checks 1. Remove the 110VAC fuse from air compressor control circuit. 2. Measure resistance from RFI side of fuse to all of the 3TB terminals. 3. Terminals 4 and 5 should be the only ones that have continuity. 4. Terminal 5 should read approximately 300 ohms with 3CR plugged in and open with it removed. 5. If the above tests do not pass DO NOT REPLACE THE CONTROL POWER FUSE AND APPLY 110 VAC TO THE COMPRESSOR UNTIL THE WIRING IS CORRECTED. If this test passes, then proceed to step Remove the relay plug from the drive with terminals 1-3 and the control plug to the drive with terminals 12 through Replace the control power fuse, apply power and repeat test from output of fuse to 3TB (with plugs still removed). 8. Measure the voltage to 3TB terminals 1 to With 1CR, 2CR and 3CR plugged in and the air compressor running, loaded or unloaded, there should not be 110 VAC on any terminal except terminal 4 to ground (neutral). If this test fails, do not replace the plugs into the drive until the wiring is corrected. 10. When wiring is correct, then remove power and replace the relay and control plugs in the drive and proceed to the Power-Up Checks. 302 VFD Programming And Setup 1. With Power OFF, Pull relays 1CR, 2CR and 3CR relays from their sockets. 2. Ensure switch S201 is set to ON for current input for pressure transducer signal. 3. Power up unit. Ensure Sierra oil pump has been primed and is ready to run 4. Set drive to factory default first by changing to 2 and then cycle power. 5. After Power up the Ingersoll Rand 302 Series VFD should now be in Setup 1. If not, then change to Setup 1 using parameter Enter the parameters for Setup 1 (see following pages) a. Only non factory default values are listed 7. After entering parameters for Setup 1, copy Setup 1 to Setup 2 using parameter Link Setup 2 to Setup 1 using parameter

18 9. Now change the active setup using 0-11 and enter the parameters that are different in Setup 2. (3-02, 3-10, 3-41, and 3-42) 10. Link Setup 2 to Setup 1 using parameter Power down unit and replace relays removed. 12. Jog compressor to determine correct rotation main drive motor, fan motor and Sierra oil pump motor. 13. Perform Intellisys setup. Intellisys Setup 1. SE, Set to Star Delta 2. SG, a. Go to Operator Setpoints, Select Mode of Operation, Select Online/Offline, b. Go to Options, Select VFD option and set to on 3. S3, a. Go to P01 Select MD (Modulation) to off b. Go to P04 Select Sr (Soft Starter) to on (2) c. Go to P03, Select St, Set Soft Starter time Starting Compressor Ensure Sierra oil pump has been installed, wired, primed and motor rotation verified before proceeding 1. With all components mounted and wired, completion of the resistance checks and correct parameters entered into the series 302 VFD along with correct Intellisys setup, start and run compressor. To start unit the green start button must be pushed one time on the compressor control unit. 2. If during loaded operations, the compressor speed becomes unstable (rapid fluctuation in speed) and is not a smooth operation, adjustments to the PID controller may be required. The first step would be to raise the Itime from 1 second to 5 seconds (parameter 7-34). If system is still unstable, contact Ingersoll Rand Customer Support. 18

19 SECTION SERIES VFD PARAMETER SETTINGS Parameter Parameter Name Setup 1 Setup 2 Number Unloaded Mode Loaded PID 0-01 Language Note A: Select proper language: Same as Setup Motor Speed Unit Hz Hz 0-03 Regional Settings Note B: (US for NA) Note B: US 0-10 Active Set-up Multi Set-up Multi Set-up 0-12 This Set-up Linked to Setup 2 Setup Display Line 1.1 Small Speed RPM Speed RPM 0-23 Display Line 3 Large Frequency Frequency 0-24 Display Line 3 Large Feedback[unit] (1652) Feedback[unit] 0-40 [Hand on] Key on LCP Disabled Disabled 0-41 [Off] Key on LCP Disabled Disabled 1-00 Configuration Mode Process (3) (required only for PSI display) Process 1-04 Overload Mode Normal torque (1) Normal torque 1-21 Motor Power [HP] Note C: Note C: 1-22 Motor Voltage Note C: Note C: 1-23 Motor Frequency Set by 0-03 Set by Motor Current Note C: Note C: 1-25 Motor Nominal Speed Note C: Note C: 3-01 Reference/Feedback Unit PSI (170) PSI 3-03 Maximum Reference Use value from Speed Table This value is the pressure set point 3-02 Minimum Reference Use value from Speed Table Use value from Speed Table 3-10 Preset Reference 2 step operation; select preset 0 then percentage value (normally the percentage is 100) 3-13 Reference Site Remote (1) remote Same as Setup Reference Resource 1 no function (0) no function 3-16 Reference Resource 2 no function (0) no function 3-17 Reference Resource 3 no function (0) no function 3-18 Reference Scaling Reference Resource no function (0) no function 3-41 Ramp 1 Ramp up Time See Table 2 - Parameter 3-41 See Table 2 - Parameter Ramp 1 Ramp Down Time See Table 2 - Parameter 3-42 See Table 2 - Parameter Motor Speed Low Limit [Hz] Use value from Excel speed table Use value from Excel speed table 4-14 Motor Speed High Limit [Hz] Use value from Excel speed table Use value from Excel speed table 4-18 Current Limit (Service Factor) Use service factor value from motor data name plate Same as Setup Terminal 33 Digital Input Setup Select bit 0 (23) Setup Select bit 0 (23) 5-40 Function Relay Select relay 1 then type of output Alarm (9) 6-12 Terminal 53 Ref./Feedback offset 4 ma 4 ma 6-15 Terminal 53 High Ref./Feedback 1 Value Alarm 7-20 Process CL Feedback 1 Resource Analog input 53 Analog input Process PID Proportional Gain Process PID Integral Time Process PID Differentiation Time Caution: Failure to set above parameters correctly can cause compressor and VFD malfunction and may result in a void warranty should equipement damage result 19

20 Note A: Select proper language Note B: Selects 50 or 60 Hz input frequency, also determines basis motor RPM Note C: Determined by total package current, motor voltage, service factor and RPM 3-41 Time it takes to go from zero speed (0 RPM) to Max speed 3-42 Time it takes to go from Max speed to zero speed (0 RPM) 7-33 P = gain (.01-10) higher # is more gain (amount of correction to be made, to large a number can cause instability and speed fluctuations) 7-34 I = integration time ( ) sample time, to small a number can cause instability and speed fluctuations D = differential time ( ), in most cases not used. Leave at factory default (0.01) Table 2 - Minimum Ramp Up Times Minimum Ramp Up and Ramp Down Times (In Seconds) Parameter HP 50 PE SE Single Stage SSR HP Single Stage SSR HP Two Stage Sierra HP Sierra HP SSR HP Setup 1 (Unloaded) Setup 2 (Loaded) Caution: Do not set the ramp up or ramp down times to less than listed above without contacting IR Technical Services 20

21 SECTION 8 - SPEED TABLES CONTACT COOLED UNLOADED (Setup 1) LOADED (Setup 2) Parameter Description Min. Max. Min. Max. Min. Max. Min. Max. Speed Speed Speed Speed Speed Speed Speed Speed Compressor Motor (Hz) (Hz) psig psig psig psig (Hz) (Hz) (barg) (barg) (barg) (barg) Contact Cooled kw - 50 Hz, Single Stage All (4.5) (4.5) Target hp - 60 Hz, Single Stage All (4.5) (4.5) Target XFE & EPE 100 hp - All (4.5) (4.5) Target 60 Hz, Two Stage HPE 100 hp - 60 Hz, All (4.5) (4.5) Target Two Stage ML/MM/MH 75 kw - All (4.5) (4.5) Target 50 Hz, Two Stage hp, 60 Hz, Single & Two All (4.5) (4.5) Target Stage MM 90 kw - 50 Hz, Single Stage All (4.5) (4.5) Target MH 90 kw - 50 Hz, Single Stage All (4.5) (4.5) Target kw - 50 Hz, Single Stage (except MM & MH All (4.5) (4.5) Target 90) kw - 50 Hz, All (4.5) (4.5) Target Two Stage 200 hp - 50 Hz, Std. ODP (4.5) (4.5) Target Single & Two Stage All Others (4.5) (4.5) Target 200 hp - 60 Hz, Std. ODP (4.5) (4.5) Target Single & Two Stage All Others (4.5) (4.5) Target 250 hp - 50 Hz, Std. Eff (4.5) (4.5) Target Single Stage Prem. Eff (4.5) (4.5) Target 250 hp - 60 Hz, Std. Eff (4.5) (4.5) Target Single Stage Prem. Eff (4.5) (4.5) Target 250 hp - 50 Hz, Two Stage All (4.5) (4.5) Target 250 hp - 60 Hz, Std. Eff (4.5) (4.5) Target Two Stage Prem. Eff (4.5) (4.5) Target 300 hp - 50 Hz, Std. Eff (4.5) (4.5) Target Single & Two Stage Prem. Eff (4.5) (4.5) Target 300 hp - 60 Hz, Std. Eff (4.5) (4.5) Target Single & Two Stage Prem. Eff (4.5) (4.5) Target 350 hp - 50 Hz, Std. Eff (4.5) (4.5) Target Single & Two Stage Prem. Eff (4.5) (4.5) Target 350 hp - 60 Hz, Std. Eff (4.5) (4.5) Target Single & Two Stage Prem. Eff (4.5) (4.5) Target 400 hp - 50 Hz, Std. Eff (4.5) (4.5) Target Single & Two Stage Prem. Eff (4.5) (4.5) Target 400 hp - 60 Hz, Std. Eff (4.5) (4.5) Target Single & Two Stage Prem. Eff (4.5) (4.5) Target 450 hp - 50 Hz, Std. Eff (4.5) (4.5) Target Single & Two Stage Prem. Eff (4.5) (4.5) Target 450 hp - 60 Hz, Std. Eff (4.5) (4.5) Target Single & Two Stage Prem. Eff (4.5) (4.5) Target CAUTION: SETTING THE MINIMUM SPEED LOWER THAN OR MAXIMUM SPEED HIGHER THAN LISTED ABOVE CAN DAMAGE COMPRESSOR PACKAGE AND VOID THE WARRANTY. 21

22 SPEED TABLES CONTACT COOLED CONTINUED UNLOADED (Setup 1) LOADED (Setup 2) Parameter Description Min. Speed Max. Speed Min. Speed Max. Speed Min. Speed Max. Speed Min. Speed Max. Speed Compressor Motor (Hz) (Hz) psig (barg) psig (barg) (Hz) (Hz) psig (barg) psig (barg) Contact Cooled EP & HP SE 60 Hz XF & EP & HP 50 SE 60 Hz All (4.5) (4.5) Target All (4.5) (4.5) Target UP All (4.5) (4.5) Target UP All (4.5) (4.5) Target UP All (4.5) (4.5) Target UP & 150 All (4.5) (4.5) Target UP & 150 All (4.5) (4.5) Target UP & 125 & 150 HF & EP & HHP 50-PE 60 Hz All (4.5) (4.5) Target All (4.5) (4.5) Target CAUTION: Setting the minimum speed lower than or maximum speed higher than listed above can damage compressor package and void the warranty. 22

23 SECTION 9 - SPEED TABLES OIL FREE UNLOADED (Setup 1) LOADED (Setup 2) Parameter Description Min. Speed Max. Speed Compressor Motor (Hz) (Hz) Min. Speed Max. Speed Min. Speed Max. Speed Min. Speed Max. Speed psig (barg) psig (barg) (Hz) (Hz) psig (barg) psig (barg) OIL FREE H150 (125 psig) All (4.5) (4.5) Target H200 (125 psig) All (4.5) (4.5) Target H250 (125 psig) All (4.5) (4.5) Target H300 (125 psig) All (4.5) (4.5) Target H350 (125 psig) All (4.5) (4.5) Target H400 (115 psig) All (4.5) (4.5) Target H400 (125 psig) All (4.5) (4.5) Target H75 (125 psig) All (4.5) (4.5) Target HH150 (150 psig) All (4.5) (4.5) Target HH350 (150 psig) All (4.5) (4.5) Target HH400 (150 psig) All (4.5) (4.5) Target L100 (100 psig) All (4.5) (4.5) Target L100 (125 psig) All (4.5) (4.5) Target L125 (100 psig) All (4.5) (4.5) Target L150 (100 psig) All (4.5) (4.5) Target L200 (100 psig) All (4.5) (4.5) Target L200 (125 psig) All (4.5) (4.5) Target L250 (100 psig) All (4.5) (4.5) Target L300 (100 Psig) All (4.5) (4.5) Target L350 (100 psig) All (4.5) (4.5) Target L350 (125 psig) All (4.5) (4.5) Target L75 (100 psig) All (4.5) (4.5) Target SH110 (10 barg) All (4.5) (4.5) Target SH150 (10 barg) All (4.5) (4.5) Target SH250 (10 barg) All (4.5) (4.5) Target SH300 (10 barg) All (4.5) (4.5) Target SL110 (7 barg) All (4.5) (4.5) Target SL132 (7 barg) All (4.5) (4.5) Target SL150 (7 barg) All (4.5) (4.5) Target SL150 (8.5 barg) All (4.5) (4.5) Target SL200 (7 barg) All (4.5) (4.5) Target SL250 (7 barg) All (4.5) (4.5) Target SL45 (7 barg) All (4.5) (4.5) Target SL55 (7 barg) All (4.5) (4.5) Target SL75 (7 barg) All (4.5) (4.5) Target SL75 (8.5 barg) All (4.5) (4.5) Target SL90 (7 barg) All (4.5) (4.5) Target SM110 (8.5 barg) All (4.5) (4.5) Target SM132 (8.5 barg) All (4.5) (4.5) Target SM150 (8.5 barg) All (4.5) (4.5) Target SM200 (8.5 barg) All (4.5) (4.5) Target SM250 (8.5 barg) All (4.5) (4.5) Target SM55 (8.5 barg) All (4.5) (4.5) Target SM75 (8.5 barg) All (4.5) (4.5) Target CAUTION: Setting the minimum speed lower than or maximum speed higher than listed above can damage compressor package and void the warranty. 23

24 SECTION 10 FAULT AND WARNING CODES Warnings / Alarm Messages A warning or an alarm is signaled by the relevant LED on the front of the frequency converter and indicated by a code on the display. A warning remains active until its cause is no longer present. Under certain circumstances operation of the motor may still be continued. Warning messages may be critical, but are not necessarily so. In the event of an alarm, the frequency converter will have tripped. Alarms must be reset to restart operation once their cause has been rectified. This may be done in three ways: 1. By using the [RESET] control button on the LCP. 2. Via a digital input with the Reset function. 3. Via serial communication/optional Fieldbus. After a manual reset using the [RESET] button on the LCP, the [AUTO ON] button must be pressed to restart the motor. If an alarm cannot be reset, the reason may be that its cause has not been rectified, or the alarm is trip-locked (see also table on following page). Alarms that are trip-locked offer additional protection, meaning that the mains supply must be switched off before the alarm can be reset. After being switched back on, the frequency converter is no longer blocked and may be reset as described above once the cause has been rectified. Alarms that are not trip-locked can also be reset using the automatic reset function in par Reset Mode (Warning: automatic wake-up is possible!) If a warning and alarm is marked against a code in the table on the following page, this means that either a warning occurs before an alarm, or else that you can specify whether it is a warning or an alarm that is to be displayed for a given fault. This is possible, for instance, in par Motor Thermal Protection. After an alarm or trip, the motor carries on coasting, and the alarm and warning flash. Once the problem has been rectified, only the alarm continues flashing until the frequency converter is reset. No. Description Warning Alarm/Trip Alarm/Trip Lock Parameter 1 10 Volts low X 2 Live zero error (X) (X) Par Live Zero Time-out Function 3 No motor (X) Par Function at Stop 4 Mains phase loss (X) (X) (X) Par Function at Mains Imbalance 5 DC link voltage high X 6 DC link voltage low X 7 DC over-voltage X X 8 DC under voltage X X 9 Inverter overloaded X X 10 Motor ETR over temperature (X) (X) Par Motor Thermal Protection 11 Motor thermistor over temperature (X) (X) Par Motor Thermal Protection 12 Torque limit X X 13 Over Current X X X 14 Earth Fault X X X 15 Hardware mismatch X X 16 Short Circuit X X 17 Control word time-out (X) (X) Par Control Word Timeout Function 22 Hoist Mech. Brake 23 Internal Fan Fault X 24 External Fan Fault X Par Fan Monitor 24