Ingersoll-Rand 302 SERIES Operating instructions

Brand: Ingersoll-Rand

Model: 302 SERIES

Type: Operating instructions

INGERSOLL RAND

302 SERIES

VARIABLE FREQUENCY DRIVE

INSTALLATION AND OPERATION MANUAL

More Than Air. Answers.

Online answers: http://www.air.irco.com

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.

C.C.N. : 23046360

REV. C

DATE: DECEMBER 2009

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

SECTION 1 — INTRODUCTION

The purpose of this manual is to provide instructions

needed to install, operate, and maintain the Ingersoll-

Rand 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 cycling, 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 / PRE-

INSTALLATION 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 access 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.

• 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 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.

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 operations 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 pressure within

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 only

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, instructions 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 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 unshielded power

conductors for more than three PWM operated

motors.

• 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

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 failure, serious

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.

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 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.

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.

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

RECOMMENDED INGERSOLL RAND 302 SERIES VFD AND COMPRESSOR SYSTEM INSTALLATION

WITH X-SERIES INTERFACE

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 claims.

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 Rand 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

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

Side by Side Free Air Space

The Ingersoll Rand 302 Series VFD does not require free

air space between drives.

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 analog input terminals 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.

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 Electrical 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 the correct

schematic for the corresponding compressor and refer to

the Wiring Schematics section in this manual. The three

control relays, pressure transducer, and contactor (Sierra

only) should be wired per the proper schematic.

See Compressor Schematics in the VSD

Interconnect Guide

Safety Grounding

Please note that the Ingersoll 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 should 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

Cable and Control Terminal Connection

All terminals for the control cables are located under the

protective cover of the Ingersoll Rand 302 Series VFD.

The protective cover can be removed using care. All

terminals to the control cables are located beneath the

LCP. They are accessed by removing the cover or

opening the door.

Max. 16 AWG (4.0mm2) wire for all Ingersoll Rand

302 Series VFD models.

Transducer Installation

The Ingersoll Rand 302 Series VFD utilizes the signal

from an electronic pressure sensor. The pressure sensor

must be located where it will see the discharge air

pressure of the compressor.

1. Compressor Package Discharge Pressure

Transducer

2. Ingersoll Rand 302 Series VFD Discharge

Pressure Transducer

A pressure transducer (4-20 mA; 0-200 psig / 0-13.8

barg) has been provided as a feedback sensor for the

Ingersoll Rand 302 Series VFD.

It is recommended that the transducer receives its

pressure signal from discharge of the compressor.

The pressure sensor must be connected to the Ingersoll

Rand 302 Series VFD using a shielded (earth screened),

three-conductor (3 core), 20 gauge (0.5mm

CSA

minimum), cable no greater than 330ft (100m) in length.

The transducer has a 0.125-in NPT threaded connection.

A 6-ft long cable has also been provided to wire the

transducer into the drive (see proper wiring schematic).

The transducer can be mounted somewhere near the

drive and plastic tubing can be plumbed into the

compressor’s discharge. Or, the transducer can be

mounted at the discharge of the compressor and

shielded cable can be ran between the transducer and

the drive.

Connect the transducer to the Ingersoll Rand 302

Series VFD per the proper wiring schematic in the VSD

Interconnect Guide

Modbus RS-485 Installation and Set-up

RS-485 is a two-wire bus interface compatible with multi-

drop network topology, i.e. nodes can be connected as a

bus, or via drop cables from a common trunk line. A total

of 32 nodes can be connected to one network segment.

Network segments are divided up by repeaters. Please

note that each repeater functions as a node within the

segment in which it is installed. Each node connected

within a given network must have a unique node address,

across all segments. Terminate each segment at both

ends, using either the termination switch (S801) of the

frequency converters or a biased termination resistor

network. Always use screened twisted pair (STP) cable

for bus cabling, and always follow good common

installation practice. Low-impedance ground connection

of the screen at every node is very important, including at

high frequencies. This can be achieved by connecting a

large surface of the screen to ground, for example by

means of a cable clamp or a conductive cable gland. It

may be necessary to apply potential equalizing cables to

maintain the same ground potential throughout the

network, particularly in installations where there are long

lengths of cable. To prevent impedance mismatch,

always use the same type of cable throughout the entire

network. When connecting a motor to the frequency

converter, always use screened motor cable.

Cable: Screened twisted pair (STP)

Impedance: 120 Ohm

Cable length: Max. 1200 m (including drop lines)

Max. 500 m station-to-station

Connect the frequency converter to the RS-485 network

as follows (see also diagram):

1. Connect signal wires to terminal 68 (P+) and

terminal 69 (N-) on the main control board of the

frequency converter.

2. Connect the cable screen to the cable clamps.

Screened, twisted-pair cables are recommended

in order to reduce noise between conductors.

The following EMC precautions are recommended

in order to achieve interference-free operation of the RS-

485 network.

1. Relevant national and local regulations, for

example regarding protective earth connection,

must be observed. The RS-485 communication

cable must be kept away from motor and brake

resistor cables to avoid coupling of high

frequency noise from one cable to another.

2. Normally a distance of 200 mm (8 inches) is

sufficient, but keeping the greatest possible

distance between the cables is generally

recommended, especially where cables run in

parallel over long distances.

3. When crossing is unavoidable, the RS-485

cable must cross motor and brake resistor

cables at an angle of 90 degrees.

See the Dan Foss Design Guide for more detailed

Modbus information

Field Conversion

For field conversions contact your local Ingersoll

Rand distributor or air center to ensure that the motor

and 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 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.

See Compressor Schematics in the VSD

Interconnect Guide

. 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.

Starter to Ingersoll Rand 302 Series VFD

Conversion

If the Ingersoll Rand 302 Series VFD is wired as shown

in the schematics in the Wiring Schematics Section of

this manual, a simple procedure is followed to convert the

compressor from operation with the compressor’s

conventional starter to operation with the Ingersoll Rand

302 Series VFD and vice versa.

Changes required for conversion from a conventional

starter to the Ingersoll Rand 302 Series VFD are

described in the following:

1. Disconnect all power from the Ingersoll Rand

302 Series VFD and compressor.

2. Wait at least 15 minutes for power to dissipate

from the Ingersoll Rand 302 Series VFD’s

capacitors.

3. Move the motor leads from the starter contactor

terminal lugs to the tie-off block mounted in the

bottom of the starter box (where the Ingersoll

Rand 302 Series VFD leads come into the

compressor starter box). For air cooled units,

the fan motor leads must also be moved. The

lugs on the bottom of the 1M, 2M, and 1S

contactors may have to be removed to meet the

terminal clearance requirements of some local

electrical codes.

4. Wire the normally-open contact of the Ingersoll

Rand 302 Series VFD alarm relay (3CR) into the

control power wiring as shown in the Wiring

Schematics Section of this manual. Make sure

relays (1CR and 2CR) are properly wired as

shown on the appropriate wiring schematic.

See Compressor Schematics in the VSD

Interconnect Guide

5. Restore power to the machine and Ingersoll

Rand 302 Series VFD .

Ingersoll Rand 302 Series VFD to Starter

Conversion

For conversion back to the starter from the Ingersoll

Rand 302 Series VFD, reconnect the motor leads to the

motor contactors and remove the Ingersoll Rand 302

Series VFD alarm relay (3CR)

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 alpha-

numeric 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.

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. 0-60 Main Menu Password or via

par. 0-65 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. •

Green LED/On: Control section is working

Yellow LED/Warn.: Indicates a warning

Flashing Red LED/Alarm: Indicates an alarm

LCP Keys

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. 130BP045.10

[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.

[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.

[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].

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.

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. 0-40 [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. 0-41 [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. 0-42 [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. 0-43 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 0-24.

Each readout parameter selected in par. 0-20 to par. 0-

24 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. 16-00

Control Word

hex

Par. 16-01

Reference

[unit]

Par. 16-02

Reference

Par. 16-03

Status Word

hex

Par. 16-05

Main Actual Value

Par. 16-10

Power

[kW]

Par. 16-11

Power

[HP]

Par. 16-12

Motor Voltage

[V]

Par. 16-13

Frequency

[Hz]

Par. 16-14

Motor Current

[A]

Par. 16-16

Torque

Par. 16-17

Speed

[RPM]

Par. 16-18

Motor Thermal

Par. 16-20

Motor Angle

Par. 16-30

DC Link Voltage

Par. 16-32

Brake Energy / s

Par. 16-33 Brake Energy / 2 min kW

Par. 16-34

Heatsink Temp.

Par. 16-35

Inverter Thermal

Par. 16-36

Inv. Nom. Current

Par. 16-37

Inv. Max. Current

Par. 16-38

SL Control State

Par. 16-39 Control Card Temp. C

Par. 16-40

Logging Buffer Full

Par. 16-50

External Reference

Par. 16-51

Pulse Reference

Par. 16-52

Feedback [Unit]

Par. 16-53

Digi Pot Reference

Par. 16-60

Digital Input bin

Par. 16-61

Terminal 53 Switch Setting

Par. 16-62

Analog Input 53

Par. 16-63

Terminal 54 Switch Setting

Par. 16-64

Analog Input 54

Par. 16-65

Analog Output 42

[mA]

Par. 16-66

Digital Output [bin]

Par. 16-67

Freq. Input #29

[Hz]

Par. 16-68 Freq. Input #33 [Hz]

Par. 16-69

Pulse Output #27

[Hz]

Par. 16-70

Pulse Output #29

[Hz]

Par. 16-71 Relay Output

Par. 16-72

Counter A

Par. 16-73

Counter B

Par. 16-80

Fieldbus CTW hex

Par. 16-82

Fieldbus REF 1

hex

Par. 16-84

Comm. Option STW

hex

Par. 16-85

FC Port CTW 1

hex

Par. 16-86

FC Port REF 1

hex

Par. 16-90

Alarm Word

Par. 16-92

Warning Word

Par. 16-94

Ext. Status Word

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Ingersoll-Rand 302 SERIES Operating instructions

Ingersoll-Rand 302 SERIES Operating instructions

Ingersoll-Rand 302 SERIES Operating instructions

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