Ingersoll-Rand 302 SERIES Installation And Operation Manual

INGERSOLL RAND
302 SERIES
VARIABLE FREQUENCY DRIVE
INSTALLATION AND OPERATION MANUAL
More Than Air. Answers.
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 D ATA and should be kept with the unit at all times.
C.C.N. : 23046360
REV. C DATE: DECEMBER 2009
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TABLE OF CONTENTS
TABLE OF CONTENTS ................................................... 2
SECTION 1 — INTRODUCTION ..................................... 3
SECTION 2 — SAFETY .................................................. 3
SAFETY PRECAUTIONS ....................................................... 3
SHIPMENT INSPECTION / PRE-INSTALLATION CHECK ............... 3
LIFTING .......................................................................... 3
INSTALLATION ................................................................. 3
MECHANICAL INSTALLATION .............................................. 3
OPERATION .................................................................... 4
MAINTENANCE AND REPAIR .............................................. 4
INGERSOLL RAND 302 SERIES VFD WARNINGS AND
PRECAUTIONS ................................................................. 4
WARNING AGAINST UNINTENDED START ............................. 5
SECTION 3 — CONTROL FEATURES AND FUNCTIONS .. 6
STANDARD FEATURES AND FUNCTIONALITY .......................... 6
SECTION 4 — INSTALLATION ..................................... 10
SECTION 5 — DISPLAY AND MENU OPERATION ........ 18
SECTION 6 — COMMISSIONING ................................ 25
PHYSICAL CHECKS .......................................................... 25
RESISTANCE CHECKS ....................................................... 25
KEYPAD OPERATIONS ..................................................... 25
POWER-UP CHECKS ....................................................... 25
INTELLISYS SETUP ........................................................... 25
SECTION 7 — FAULT CODES ...................................... 31
WARNINGS / ALARM MESSAGES ...................................... 31
SECTION 8 — PART LIST ............................................ 39
SECTION 9 — TECHNICAL DATA ................................. 40
SECTION 10 — WIRING DIAGRAM ............................. 46
Refer to Section Indicated
Note
Important or Caution, Safety
3
SECTION 1 — INTRODUCTION
The purpose of this manual is to provide instructions needed to install, operate, and maintain the Ingersoll­Rand rotary screw air compressor with the Ingersoll Rand 302 Series Variable Frequency Drive (VFD). 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 cyc l ing, lower noise, and monitoring energy parameters are other benefits from an Ingersoll-Rand compressor equipped with Ingersoll Rand 302 Series VFD.
SECTION 2 — SAFETY
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.
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.
SHIPMENT INSPECTION / PRE­INSTALLATION CHECK
The crating should be inspected for shipping damage after the unit has arrived.
Before unpacking the frequency converter it is recommended that it is located as close as possible to the final installation site. Remove the box and handle the frequency converter on the pallet, as long as possible.
LIFTING
Always lift the frequency converter in the dedicated lifting eyes. Use a bar to avoid bending the lifting holes of the frequency converter.
INSTALLATION
Installation work must only be carried out by a competent person under qualified supervision.
A fused isolation switch must be fitted between the main power supply and the Ingersoll Rand 302 Series VFD.
The Ingersoll Rand 302 Series VFD should be mounted in such a location as to allow operational and maintenance acces s without obstruction or hazard and to allow clear visibility of indicators at all times.
If raised platforms are required to provide access to the Ingersoll Rand 302 Series VFD, they must not interfere with normal operation or obstruct access. Platforms and stairs should be of grid or plate construction with safety rails on all open sides.
MECHANICAL INSTALLATION
Preparation of the mechanical installation of the frequency converter must be done carefully to ensure a proper result and to avoid additional work during installation. Start taking a close look at the mechanical drawings at the end of this instruction to become familiar with the space demands.
To perform the mechanical installation the following tools are needed:
o Drill with 10 or 12 mm drill o Tape measure o Wrench with relevant metric sockets (7-17
mm)
o Extensions to wrench o Sheet metal punch for conduits or cable
glands in IP 21/Nema 1 and IP 54 units
o Lifting bar to lift the unit (rod or tube max. Ø
25 mm (1 inch), able to lift minimum 400 kg (880 lbs)).
o Crane or other lifting aid to place the
frequency converter in position
o A Torx T50 tool is needed to install the E1
in IP21 and IP54 enclosure types.
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Space: Ensure proper space above and below the frequency converter to allow airflow and cable access. In addition space in front of the unit must be considered to enable opening of the door of the panel.
Wire access: Ensure that proper cable access is present including necessary bending allowance. As the IP00 enclosure is open to the bottom cables must be fixed to the back panel of the enclosure where the frequency converter is mounted, i.e. by using cable clamps. o All cable lugs/ shoes must mount within the
width of the terminal bus bar
OPERATION
The Ingersoll Rand 302 Series VFD must onl y 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 onl y 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.
MAINTENANCE AND REPAIR
Maintenance, repairs or modifications must only be carried out by competent personnel under qualified supervision.
If replacement parts are required, use only genuine parts from the original equipment manufacturer, or an alternative approved source.
Carry out the following operati ons before opening or removing any access panels or carrying out any work on the Ingersoll Rand 302 Series VFD:
i. Isolate the Ingersoll Rand 302 Series
VFD from the main electrical power supply. Lock the isolator in the “OFF” position and remove the fuses.
ii. Attach labels to the isolator switch and
to the unit stating “WORK IN PROGRESS - DO NOT APPLY VOLTAGE”. Do not switch on electrical power or attempt to start the CX Box if such a warning label is attached.
Make sure that all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good working order.
The accuracy of sensor devices must be checked on a regular basis. They must be calibrated when acceptable tolerances are exceeded. Always ensure any pressur e withi n the compressed air system is safely vented to atmosphere before attempting to remove or install a sensor device.
The Ingersoll Rand 302 Series VFD must onl y be cleaned with a damp cloth, using mild detergents if necessary. Avoid the use of any substances containing corrosive acids or alkalis.
Do not paint the control faceplate or obscure any indicators, controls, instru ctio ns or
warnings
.
INGERSOLL RAND 302 SERIES 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:
o 380 - 500 V 90 - 200 kW 20 minutes
250 - 800 kW 40 minutes
o 525 - 690 V 37 - 315 kW 20 minutes
355 - 1200 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 ove rload 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 unshielded power conductors for more than three PWM operated motors.
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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.
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.
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 other voltage inputs have been disconnected, such as external 24 VDC, load-sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up. Only a competent electrician should carry out the electrical installation. Improper installation of the motor or the Ingersoll Rand 302 Series VFD may cause equipment fail ur e, seri ous injury or death. Follow this manual and National
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.
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SECTION 3 — CONTROL FEATURES AND FUNCTIONS
STANDARD FEATURES AND FUNCTIONALITY
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 Intellisy s contr o ller, 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.
The compressor with the Ingersoll Rand 302 Series VFD will only load and unload at minimu m spee d, unle ss 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 swit ch 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 water­cooled 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.
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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.
INTELLISYS AND Ingersoll Rand 302 Series VFD CONTROLLERS INTERFACE LOGIC DIAGRAM
8
RECOMMENDED INGERSOLL RAND 302 SERIE S VFD AND COMPRESSOR SYSTEM INSTALLATION
9
RECOMMENDED INGERSOLL RAND 302 SERIE S V FD AND COMPRESSOR SYSTEM INSTALLATION
WITH X-SERIES INTERFACE
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SECTION 4 — INSTALLATION
When you receive the Ingersoll Rand 302 Series VFD, inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt, especially if the Ingersoll Rand 302 Series VFD will not be immediately uncrated. Obtaining the delivery person’s signed agreement to any noted damages will facilitate any future insurance c laims.
Uncrating and Handling
It is recommended that installation and commissioning be carried out by an authorized and trained product supplier.”
To lessen the possibility of damage, it is recommended that the crated Ingersoll Ra nd 302 Series VFD be located as close to the final installation site as possible. If the Ingersoll Rand 302 Series VFD is not to be installed immediately, the following storage temperatures need to be observed: –13°F to +150°F (-25°C to +65°C).
Door and ceiling clearances must be considered when moving and installing the drive.
A qualified person with a forklift or other similar lifting device will be needed to remove the drive from the crate.
When unpacking the frequency converter, ensure that the unit is undamaged and complete.
IMPORTANT
READ THIS
LOST OR DAMAGED GOODS
THOROUGHLY INSPECT THIS SHIPMENT
IMMEDIATELY UPON ARRIVAL
OUR RESPONSIBILITY FOR THIS SHIPMENT
CEASED WHEN THE CARRIER SIGNED
If goods are received short or in damaged condition, it is important that you notify the carrier and insist on a notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the transportation company.
If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an inspection and grant a concealed damage notation. If you give the transportation company a clear receipt for goods that have been damaged or lost in transit, you do so at your own risk and expense.
WE, AT INGERSOLL RAND, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR RESPONSIBILITY.
Ingersoll-Rand Company Davidson, North Carolina APDDG-99-79
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To open the crate: Pry up the metal locking tabs that secure the top panel of the crate, this will allow access to the lifting rings on the top of the drive.
See General Arrangement drawings in the VSD Interconnect Guide for dimensions, weight, and installation information.
Environment
The area selected for the location of the Ingersoll Rand 302 Series VFD should be free of dust, chemicals, metal filings, paint fumes and overspray.
Dimensions: NEMA1 & NEMA 12
See General Arrangement drawings in the VSD Interconnect Guide for dimensions, weight, and installation information.
Cooling
The Ingersoll Rand 302 Ingersoll Rand 302 Series VFD is cooled by means of air circulation. For the cooling air to escape from the unit a minimum clearance must be left above and below the unit.
The Ingersoll Rand 302 Ingersoll Rand 302 Series VFD must be installed vertically.
To avoid overheating the unit, the ambient temperature is not to exceed 115°F (46°C) and the mean temperature is not to exceed 104°F (40°C). If the ambient temperature is in the range of 115°F to 131°F (46°C to 55°C), there is a possibility of a reduction of the service life of the Ingersoll Rand 302 Series VFD .
For proper cooling, mount the Ingersoll Rand 302 Series VFD against a flat surface, such as a wall or a piece of sheet metal.
Top and Bottom Free Space
See General Arrangement drawings in the VSD Interconnect Guide for Air Space requirements.
DUST CHEMICALS
PAINT SPRAY
METAL FILINGS
OVERSPRAY
12
Side by Side Free Air Space
The Ingersoll Rand 302 Series VFD does not require free air space between drives.
13
Terminal and Switch Locations
Control Terminals, Ingersoll Rand 302 Series VFD Drawing reference numbers:
1. 10 pole plug digital I/O.
2. 3 pole plug RS485 Bus.
3. 6 pole analog I/O.
4. USB Connection.
To mount the cable to the terminal:
1. Strip insulation of 9-10 mm
2. Insert a screwdriver1) in the square hole.
3. Insert the cable in the adjacent circular hole.
4. Remove the screw driver. The cable is now mounted to the terminal.
To remove the cable from the terminal:
1. Insert a screwdriver (1) in the square hole.
2. Pull out the cable.
(1)Max. 0.4 x 2.5 mm
.
Switches S201, S202, and S801
Switches S201 (A53) and S202 (A54) are used to select a current (0-20 mA) or a voltage (-10 to 10 V) configuration of the anal og inp ut termin als 53 and 54 respectively.
Switch S801 (BUS TER.) can be used to enable termination on the RS-485 port (terminals 68 and 69).
See Power Wiring Diagram in the VSD
Interconnect Guide for all electrical terminals. Default setting:
S201 (A53) = OFF (voltage input)
S202 (A54) = OFF (voltage input)
S801 (Bus termination) = OFF
When changing the function of S201, S202 or S801 be careful not to use force for the switch over. It is recommended to remove the LCP fixture (cradle) when operating the switches. The switches must not be operated with power on the frequency converter.
14
Ingersoll Rand 302 Series VFD Electrical Installation
The voltage of the Ingersoll Rand 302 Series VFD is dangerous when the unit is connected to the AC line. Incorrect installation of the motor or Ingersoll Rand 302 Ingersoll Rand 302 Series VFD may lead to material damage or serious injury or death. Follow the instructions in this manual and comply to National El ectr ica l Codes (NEC) and local codes and safety guidelines.
DO NOT touch the electrical components of the Ingersoll Rand 302 Series VFD for at least 15 minutes after the AC line has been disconnected.
To avoid potential shock hazard when servicing a motor or variable frequency drives, remove all power to all drives having 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 unshielded power conductors for more than three PWM operated motors.
It is the responsibility of the user or installer to ensure correct grounding, branch circuit and motor protection in accordance with the NEC and local codes
Connection of AC Line
Connect the three AC line phases to L1 (91), L2 (92), and L3 (93) of the terminal block labeled Mains.
See Power Wiring Diagrams in the VSD Interconnect Guide
To minimize electrical noise, install the drive within 100 feet (30 meters) of compressor.
To avoid electrical noise, do not route high-voltage motor wires and low-voltage control wires through the same conduit.
For proper safety, wire compressor and drive to a common ground.
Schematics
The following table lists the electrical schematics that illustrate the proper way to wire the Ingersoll Rand 302 Series VFD to the compressor. Locate t he corr e ct schematic for the corresponding compressor and refer to the Wiring Schematics section in this manual. The three control relays, pressure transd ucer, and con tac t or (Si erra only) should be wired per the proper schematic.
See Compressor Schematics in the VSD Interconnect Guide
Safety Grounding
Please note that the Inger s oll Rand 302 Series VFD has a high leakage current and must be grounded appropriately for safety reasons. Use the ground terminals (refer to the terminal drawings) which enable reinforced grounding.
All national and local safety codes must be
observed.
See Power Wiring Diagrams in the VSD
Interconnect Guide
Motor Connection
The power cables from the Ingersoll Rand 302 Series VFD connect to the motor terminal block located at the bottom of the compressor’s starter box. The compressor and fan motors’ leads are connected to the other side of this block.
The power cables from the compressor/Ingersoll Rand 302 Series VFD system’s main disconnect (DIS1) to the top of the compressor’s starter contactors sho uld be sized for the full amp rating of the machine. This setup allows for the compressor to be quickly converted from variable speed to constant speed control should the Ingersoll Rand 302 Series VFD need servicing.
See Power Wiring Diagrams in the VSD
Interconnect Guide
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