I-R 5000 SERIES

VARIABLE FREQUENCY
DRIVE

INSTALLATION AND OPERATION

MANUAL

More Than Air. Answers.

Online answers: http://www.air.irco.com
PHONE: 1-800-526-3615
C.C.N. : 80440506
REV. : C
DATE : September 2007
 AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material
and workmanship for a period of twelve months (see extended airend warranty) from the date of placing the Equipment
in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, whichever
shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to
the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair
to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed
maintained and operated such Equipment in accordance with good industry practices and has complied with specific
recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others,
shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the
Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs
of labor performed by the Purchaser or others without Company’s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company’s proposal. Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company’s obligation shall be to correct in the manner and for the period of
time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED
OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in
writing of its intention to do so. Any such Equipment will be at Purchaser’s sole risk and liability.

Limitation or Liability
The remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to this
contract or the Equipment and services furnished hereunder, in connection with the performance or breach thereof, or
from the manufacture, sale, delivery, installation, repair or technical direction covered by or furnished under this
contract, whether passed on contract, warranty negligence, indemnity, strict liability or otherwise, shall not exceed the
purchase price of the unit of Equipment upon which such liability is based.
The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any
beneficiary or assignee of this contract for any consequential, incidental, indirect, special or punitive damages arising out
of this contract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder, whether
based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other goods, loss
by reason of shutdown or non-operation, increased expenses of operation, cost of purchase of replacement power or
claims of Purchaser or customers of Purchaser for service interruption whether or not such loss or damage is based on

©INGERSOLL-RAND COMPANY
 TABLE OF CONTENTS

0.0 SAFETY AND WARNINGS

0.1 compressor warnings
0.2 VFD warnings and precautions
0.3 warning against unintended start

1.0 RECEIPT OF EQUIPMENT

1.1 inspection
1.2 un-crating and handling

2.0 INTRODUCTION
2.1 purpose
2.2 general operation
2.3 service contacts

3.0 INSTALLATION
3.1 VFD mechanical installation
3.2 VFD electrical installation
3.3 control signal warning
3.4 conversion
3.5 VFD start-up proceedure

4.0 USER INTERFACE

4.1 VFD local control panel
4.2 display
4.3 LEDs
4.4 control keys
4.5 display modes

5.0 OPERATION
5.1 compressor operation control
5.2 parameter description and adjustment
5.3 VFD operation control
5.4 start-up check list

6.0 AUTOMATIC MOTOR ADAPTION

7.0 MODIFYING COMPRESSOR OUTPUT PRESSURE

8.0 MODIFYING PROCESS PID LOUP

9.0 TROUBLE SHOOTING

9.1 VFD warning and alarms
9.2 compressor warnings and alarms
9.3 troubleshooting faults and remedies

10.0 REFERENCE DRAWINGS

1
0.0 SAFETY
Safety instructions in the this manual are bold-faced for
emphasis. The signal words DANGER, WARNING and
CAUTION are used to indicate the level of hazard
seriousness as follows:
! DANGER
Danger is used to indicate the presence of a
hazard which will cause severe personal injury,
death, or substantial property damage if
ignored.
! WARNING
Warning is used to indicate the presence of a
hazard which can cause personal injury or
substantial property damage if ignored.
! CAUTION
Caution is used to indicate the presence of a
hazard which will or can cause minor personal
injury or property damage if ignored.
NOTICE
A notice is used to emphasize important
installation, operation, or maintenance
information which is not hazard related.
0.1 Compressor Warnings and Precautions
Before installing this air compressor, carefully read all
the instructions contained in this manual.
Electricity and compressed air have the potential to
cause death, severe personal injury or property damage.
Before installing, wiring, starting, operating or making
any adjustments, identify the components of the air
compressor using this manual as a guide.
The operator should use common sense and good
working practices while operating and maintaining this
unit. Follow all codes, understand the starting and
stopping sequence, and pipe adequately. Check the
safety devices by following the procedures contained in
this manual.
Maintenance should be done by qualified personnel
adequately equipped with proper tools. Follow the
maintenance schedules as outlined in the operator's
manual to ensure problem free operation after start up.
2
SAFETY PRECAUTIONS
BEFORE PROCEEDING, READ THE
FOLLOWING CAREFULLY BEFORE
INSTALLING THE COMPRESSOR OR
PERFORMING ANY MAINTENANCE.
WARNING
Compressed air and electricity are dangerous.
Before doing any work on this unit, be sure
the electrical supply has been cut off, locked
and tagged. Ensure the entire compressor
system has been vented of all pressure.
1. Do not remove the covers, loosen or remove any
fittings, connections or devices when this unit is in
operation. Hot liquid and air that are contained
within this unit can cause severe injury or death.
2. The compressor has high and dangerous voltage in
the motor starter and control box. All installations
must be in accordance with recognized electrical
codes. Before working on the electrical system, be
sure to remove voltage from the system by use of a
manual disconnect switch. A circuit breaker or fuse
safety switch must be provided in the electrical
supply line leading to the compressor.
3. Those responsible for installation of this equipment
must provide suitable grounding, maintenance
clearance and lighting arrestors for all electrical
components as stipulated in O.S.H.A.1910.308
through 1910.309.
4. Do not operate the compressor at higher discharge
pressure than those specified on the compressor
namplate or motor overload will occur. This
condition will result in compressor motor shutdown.
5. Install a manual shut off valve (isolation type) in the
discharge line. When a saftey valve is installed
between the isolation valve and the compressor it
must have sufficient capacity to relieve the full
capacity of the compressor(s).
6. Whenever pressure is released through the
pressure relief valve it is due to excessive pressure
in the system. The cause for the excessive
pressure should be investigated immediately.
7. Before doing any mechanical work on the
compressor:
a) Shut the unit down.
b) Electrically isolate the compressor by use of
the manual disconnect switch in the power
line to the unit. Lock and tag the switch so
that it cannot be operated.
c) Vent pressure from the compressor and
isolate the unit from any other source of air.
8. There can be adverse effects if compressor
lubricants are allowed to enter plant air systems. Air
line separators, properly selected and installed, will
minimize any liquid carryover.
The use of plastic bowls on line filters without metal
guards can be hazardous. From a safety
standpoint, metal bowls should be used on any
pressurized system. Review of your plant air lines
system is recommended.
9. When a receiver is installed, it is recommended that
occupational safety and health standards; as
covered in the Federal Register, volume 36, number
105, part 11, paragraph1910.159; be adhered to in
the maintenance of this receiver.
10. Before starting the compressor, its maintenance
instructions should be read thoroughly and
understood.
11. After maintenance functions are completed, covers
and guards must be replaced.
12. Use only safety solvent for cleaning the compressor
and auxiliary equipment.
0.2 Variable Frequency Drive Warnings and
Precautions
Safety Precautions
1. The variable frequency drive (VFD) must be
disconnected from the AC line if repair work is to be
carried out. After the AC supply has been
disconnected WAIT 15 MINUTES before removing
motor and line terminal plugs.
2. The Stop/Reset key on the local control panel of
the VFD DOES NOT disconnect the equipment
from the AC line. DO NOT use the Stop/Reset key
as a safety switch.
3. 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.
4. To avoid potential shock hazard when servicing a
motor or 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.
5. The ground leakage currents are higher at 3.5 mA.
6. 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 128 is set for "TRIP"
and parameter 105 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 128 to
data value ETR trip or data value ETR warning.
Note
ETR function is initialized at 1.16 x rated
motor current.
3
0.3 Warning Against Unintended Start
1. The motor can be brought to a stop by means of
digital commands, bus commands, references or a
local stop, while the VFD is connected to the AC
line.
2. While parameters are being changed, the motor
may start. Consequently, the Stop/Reset button must be
enabled (Parameter 014) after which data can be modified.
When the drive is in local stop the LCP will be flashing.
Parameter 014 will be changed later during the startup
procedure.

These stop functions are NOT sufficient to ensure 3. A motor that has been stopped may start if faults
that no unintended start occurs and should NOT be occur in the electronics of the VFD or if a temporary
used for personal safety considerations. overload or a fault in the AC line supply or the motor
connection clears.

The Variable Frequency Drive 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-shar-
ing
(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 VFD may cause equipment failure, serious injury or death. Follow this manual and National

Electrostatic Discharge (ESD) Precaution. Many electronic components are sensitive to static
electricity. Voltages 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.

It is the responsibility of the user or the person installing the VFD to provide proper grounding, as

! well as motor overload and branch circuit protection according to the National Electrical Code and
local codes.

4
1.0 RECEIPT OF EQUIPMENT 1.2 Uncrating and Handling (5350-5500 Series)

1.1 Inspection To lessen the possibility of damage, it is recommended

When you receive the VFD, inspect it closely. Any
indication of careless handling by the carrier should be
noted on the delivery receipt, especially if the VFD will
not be immediately uncrated. Obtaining the delivery per-
son’s signed agreement to any noted damages will facili-
tate any future insurance claims.
that the crated VFD be located as close to the final
installation site as possible. If the 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. Crate dimensions in
inches and (mm), weight in pounds crated (uncrated):

Dimensions H W D
NEMA 1 91.5 (2324) 53.0 (1346) 30.0 (762)
NEMA 12 91.5 (2324) 53.0 (1346) 30.0 (762)

IMPORTANT Weights 5350 5450 5500

READ THIS NEMA 1 1516 (1386) 1615 (1485) 1670 (1540)
LOST OR DAMAGED GOODS NEMA 12 1538 (1408) 1637 (1507) 1692 (1562)

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 impor-
tant 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.
A qualified person with a forklift or other similar lifting
device will be needed to remove the drive from the crate.
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.

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 con-
cealed damage notation. If you give the transportation company
a clear receipt for goods that have been damaged or lost in tran-
sit, you do so at your own risk and expense.

WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSI-

BLE MANNER TO COLLECT CLAIMS FOR LOSS OR DAM-
AGE, 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

5
A forklift or similar lifting device should be used at this
time to ensure the stability of the VFD while the rest of
the crating is removed. Position the lifting device to the
front side of the crate.
The VFD should be lifted using a spreader bar or other
similar lifting device. Lift the VFD slightly, using all four
lifting rings, distributing the weight as evenly as possible.
DO NOT lift in this manner.
At this point refer to Section 3.0.
NOTE
Observe all warnings and safety precautions as well
as all National Electrical Codes (NEC) and local
codes.
NEMA 1 and NEMA 12
NEMA 1 and NEMA 12 units are secured to the floor
using the four mounting holes in the bottom panel.

Proper lifting method.

Pry up the metal locking tabs and remove the

remaining crate panels.

6
2.0 INTRODUCTION
2.1 Purpose
The purpose of this manual is to provide instructions
needed to install, operate, and maintain the Ingersoll-
Rand rotary screw air compressor with the I-R 5000
Variable Frequency Drive (VFD) control. The
Operators/Instruction Manual supplied with the compres-
sor and this Instruction Manual supplied with the
Variable Frequency Drive should be referenced for more
detailed instructions regarding each of these compo-
nents.
The VFD will maintain a constant pressure in com-
pressed air systems by adjusting the compressor
motor’s speed to match the compressed air usage.
Depending on the application and air demand profile, the
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 VFD.
2.2 General Operation
The I-R 5000 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 VFD’s controller varies
the compressor’s motor speed to regulate constant sys-
tem pressure. The VFD operates in two different setups:
1) In Setup 1, the VFD runs at constant minimum
speed and the compressor is unloaded.
2) In Setup 2, the VFD regulates a constant pressure
and the compressor is loaded.
The Intellisys controller logic determines which setup the
VFD operates. See Intellisys and VFD Controllers
Interface Logic Diagram Figure 2.2-1. 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 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 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 (See Section 5.2 and Section 8.0 to avoid this
occurrence). 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 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 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 VFD will try to regulate the pressure.
On SSR air cooled units, the VFD controls the main
drive motor and the cooling fan motor.
On SSR water cooled units, the 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 com-
pressor starter.
2.3 Service Contacts
Contact your local Ingersoll-Rand distributor or air center
for any service inquiries, maintenance, or any other
additional technical support.
7
 Figure 2.2-1 INTELLISYS AND VFD CONTROLLERS INTERFACE LOGIC DIAGRAM

8
3.0 INSTALLATION I-R 5052, 200-240V, NEMA 1, NEMA 12
A = 10 inches (250mm)
3.1 VFD Mechanical Installation
I-R 5062-5102, 380-500V, NEMA 1, NEMA 12
3.1.1 Environment A = 8 inches (200mm)

The area selected for the location of the VFD should be I-R 5075-5125, 550-600V, NEMA 1, NEMA 12
free of dust, chemicals, metal filings, paint fumes and A = 10 inches (250mm)
overspray.
I-R 5122-5302, 380-500V, NEMA 1, NEMA 12
A = 8.9 inches (225mm)

I-R 5150-5250, 550-600V, NEMA 1

DUST CHEMICALS A = 11.8 inches (300mm)
METAL PAINT
FILINGS SPRAY

OVERSPRAY

3.1.2 Dimensions: NEMA1 & NEMA 12

For VFD dimensional information, including weights,

please refer to Section 10.0 (Figure 10.1).

3.1.3 Cooling

3.1.3.a Cooling (I-R 5052-5302 Series)

The I-R 5000 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 I-R 5000 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 VFD.

NOTE
For proper cooling, mount the VFD against a
flat surface, such as a wall or a piece of sheet
metal.

Top and Bottom Free Space

I-R 5052, 380-500V, NEMA 1, NEMA 12

A = 8 inches (200 mm) Side by Side Free Air Space
The I-R 5000 Series VFD does not require free air space
I-R 5052, 550-600V, NEMA 1 between drives.
A = 8 inches (200 mm)

9
3.1.3.b Cooling (I-R 5350-5500 Series)
The I-R 5300-5500 Series VFD drive does not require
The I-R 5000 VFD is cooled by means of air circulation. free air space between the drives.
For the cooling air to escape from the unit a minimum
clearance of 15.7 inches (400mm) must be left above
the units.

The I-R 5000 VFD must be installed vertically.

To avoid overheating the unit, the ambient temperature

is
not to exceed 115°F (46°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 VFD.

NOTE
For proper cooling, mount VFD against a flat surface
such as a wall or sheet metal.

Top and Bottom Free Air Space

Side by Side Free Air Space

Mounting

NEMA 1 and NEMA 12 units are secured to the floor

using the four mounting holes in the bottom panel.

10
3.1.4 Terminal and Switch Locations In general, a conduit should not contain unshielded
power conductors for more than three PWM operated
For VFD terminal and switch locations, please refer to motors.
the Terminal and Switch Locations drawings in Section
10.0. NOTE
It is the responsibility of the user or installer to
3.2 VFD Electrical Installation ensure correct grounding, branch circuit and motor
protection in accordance with the NEC and local
The voltage of the VFD is dangerous when the unit is codes.
connected to the AC line. Incorrect installation of the
motor or I-R 5000 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 I-R 5000

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 dri-
ves 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.

11
3.2.1 Connection of AC Line 3.2.2 Schematics

Connect the three AC line phases to L1 (91), L2 (92),
and L3 (93) of the terminal block labeled Mains. Refer to
the Terminal and Switch Location Drawings in Section
10.0.
NOTE
To minimize electrical noise, install the drive within
100 feet (30 meters) of compressor.
NOTE
To avoid electrical noise, do not route high-voltage
motor wires and low-voltage control wires through
the same conduit.
Table 3-1 lists the electrical schematics that illustrate the
proper way to wire the VFD to the compressor. Locate
the correct schematic for the corresponding compressor
as shown in Table 3.1 and Section 10.0. The three con-
trol relays, pressure transducer, and contactor (Sierra
only) should be wired per the proper schematic. Also
refer to Figure 10.2, Control Relay Wiring.
NOTE
For proper safety, wire compressor and drive to a
common ground.

TABLE 3.1 WIRING SCHEMATIC DRAWING NUMBERS

Compressor Starter Cooling Schematic

Intellisys 22345490
UP6-20 to UP6-30 Full-Voltage
Non-Intellisys 22430466
Intellisys 22398093
Star-Delta
Non-Intellisys 22563498
Aircooled
Intellisys 22560239
UP6-40 to 50 PE Full-Voltage
Non-Intellisys 22560247
Intellisys 22560262
Star-Delta
Non-Intellisys 22560254

SSR50E-100HP (37-75 kW) Full-Voltage Aircooled 54592076

Star-Delta 54592084
Full-Voltage Watercooled 54615117
Star-Delta 54615141

SSR100-500 HP (75-370 kW) Star-Delta Aircooled 54600333

Watercooled 54622451

Sierra 100 HP (75 kW) Star-Delta Aircooled 54612338

Watercooled 54616032

Sierra 200 HP (150 kW) Star-Delta Aircooled 54629894

Sierra 350 HP (300kW) Watercooled 54630686

12
 FIGURE 3.2-1 RECOMMENDED VFD AND COMPRESSOR SYSTEM DESIGN DATA

13
3.2.3 Pre-fuses 3.2.5 Switches 1-4

External pre-fuses must be installed in the AC line sup- The switch located on the control card is used for serial
ply to the I-R 5000 VFD. communication, terminals 68 and 69 and the 24V supply.
Switch 1 has no function. Switch 2 and 3 are used for
TABLE 3.2 FUSING terminating an RS 485 interface, serial communication.
Switch 4 is used for separating the common potential for
Drive Voltage Fuse Type Max. Amps.
the internal 24 VDC supply from the common potential of
5016 80 an external 24 VDC supply, if used.
5022 KTN-R or JJN 125 3.2.6 RFI Switch (optional)
5027 200-240 125
5032 150 Refer to the Terminal and Switch Location drawings in
5042 FWX Semi-Conductor 200 Section 10.0. In special situations, it may be desirable to
5052 250 cut off the internal RFI filter capacitors between the
5016 63 chassis and the intermediate circuit. Units are shipped
5022 63
from the factory with the switch in the ON position.
5027 63
5032 KTS-R or JJS 80 Disconnect by moving the RFI switch to the OFF posi-
5042 100 tion.
5052 125
5062 150 NOTE:
5072 200 The RFI switch is NOT to be operated with the
5102 380-500 250 AC line connected to the unit. Check that the AC line
5122 300 has been disconnected before removing the motor and
5152 350 line terminal plugs.
5202 FWH Semi-Conductor 400
5252 500
5302 600 The RFI switch disconnects the capacitors galvanically;
5350 700 however, transients higher than approx. 1,000 V will be
5450 800 bypassed by a spark gap. It is necessary that the RFI
5500 800 Switch is opened when installing on Delta configuration
5052 KTS-R 90 AC power systems. Failure to open this switch may
5062 KTS-R 100 result in occasional tripping or possible unit damage.
5075 FWP 125
5100 550-600 FWP 175 For units with RFI Option only;
5125 FWP 200
It is necessary that the two (2) RFI Jumpers are
5150 FWP 250
5200 FWP 350 removed when installing on Delta configured AC power
5250 FWP 400 systems. Failure to open these RFI Jumpers may result
in occasional tripping or possible unit damage. Both RFI
Jumper assemblies are "plug-in" type that do not require
Suitable for use on a circuit capable of delivering not tools to be removed or re-installed.
more than 100 kA rms symmetrical amperes, 500 Volts
maximum when protected by the above fuses. One jumper is located on the RFI Filter itself on the far
left side, midway between the top and bottom of the unit.
On NEMA 1 drives, it is necessary to remove the wiring
NOTE channel for the routing of the logic wiring to the control
Fuse Type: Bussmann FWH Semi-conductor. Use card, (do not remove the control card) to gain access to
proper pre-fuse for corresponding VFD. the jumper. The jumper is a small black plastic tab with
two wire prongs (approx. 0.25 x 0.5 inch). It is inserted
3.2.4 Safety Grounding on the circuit board of the RFI Filter assembly. The
jumper may be removed or re-inserted by hand.
Please note that the I-R 5000 variable frequency drive
has a high leakage current and must be grounded The other jumper is on a circuit board located in the
appropriately for safety reasons. Use the ground termi- lower portion of the unit on the bottom of the capacitor
nals (refer to the terminal drawings) which enable rein- bank assembly. The jumper assembly is a black wire
forced grounding. All national and local safety codes approximately 1.5 inches long with a right-angle fast-on
must be observed. connector on each end.

14
3.2.7 Motor Connection
The power cables from the 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/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 VFD need servicing.
3.3 Control Signal Wiring
3.3.1 Cable and Control Terminal Connection
For models up to I-R 5302, all terminals for the control
cables are located under the protective cover of the I-R
5000 variable frequency drive. The protective cover can
be removed as pictured, using care.
Max. 16 AWG (4.0mm2) wire for all I-R 5000 models.
Screw size M3. Torque to 5 in-lbs (0.6 Nm).
3.3.2 Transducer Installation
A pressure transducer (4-20 mA; 0-200 psig / 0-13.8
barg) has been provided as a feedback sensor for the
I-R 5000 variable frequency drive. In order to maximize
stability, it is recommended that the transducer receives
its pressure signal from the system tank.
The transducer has a 0.125-in NPT threaded connec-
tion. A 6-ft long cable has also been provided to wire the
transducer into the drive (see proper wiring schematic).
The transducer is to be mounted somewhere on the
drive. This will provide a cleaner installation and mini-
mize electrical noise interfering with the transducer’s sig-
nal. With the transducer on the drive, a plastic tube can
be plumbed into the system’s receiver tank.
Connect the transducer to the VFD per the proper wiring
schematic.
3.4 Conversion
3.4.1 Field Conversion
For field conversions contact your local I-R distribu-
tor or air center to ensure that the motor and con-
trols 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 I-R
representative.
The 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, ter-
minals, and three relays required to convert to 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 specified in Table 3.2 and
located in Section 10.0. The electric-driven oil pump and
its components (for Sierra only) must be installed per the
assembly drawing specified.
15
 ! CAUTION
Prime 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.
Note: 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 com-
pressor has sat idle for extended time.
NOTE
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) Move the motor leads from the starter contactor termi-
nal lugs to the tie-off block mounted in the bottom of the
starter box (where the VFD leads come into the com-
pressor 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 VFD alarm
relay (3CR) into the control power wiring as shown in the
wiring schematics. Make sure relays (1CR and 2CR) are
properly wired as shown on the appropriate wiring
schematic (see Section 10.0).
5) Restore power to the machine and VFD.

3.4.2 Starter to VFD Conversion 3.4.3 VFD to Starter Conversion

If the VFD is wired as shown in the schematics in
Section 10.0, a simple procedure is followed to convert
the compressor from operation with the compressor’s
conventional starter to operation with the VFD and vice
versa.
For conversion back to the starter from the VFD, recon-
nect the motor leads to the motor contactors and remove
the VFD alarm relay (3CR).

Changes required for conversion from a conventional

starter to the VFD are described in the following:

1) Disconnect all power from the VFD and compressor.

2) Wait at least 15 minutes for power to dissipate from

the VFD’s capacitors.

TABLE 3.2 ASSEMBLY DRAWINGS

Compressor Cycle [Hz] Starter/VFD Oil Pump

Assembly DWGs Installation DWGs

SSR50E-100HP (37-75 kW) 50/60 54576137 N/A

Sierra 100 HP 60 54576137 54761655
Sierra 75 kW 50 54576152 54761655
SSR100-500HP (75-370 kW) 50/60 54576160 N/A
Sierra 200 HP 60 54576160 54761663
Sierra 150 kW 50 54576178 54761663
Sierra 250-400 HP 60 22083968 22064869
Sierra 200-300 kW 50 22083976 22064869

16
3.5 VFD STARTUP PROCEDURE
1) Locate customer’s compressor power supply discon-
nect box. Lock and Tag-out this power source.
2) Determine which Semi-conductor quick blow fuses
are necessary. Ensure the fusible disconnect is appropri-
ately sized for the necessary fuses.
3) Check or install power cables from the customer’s dis-
connect to the fusible disconnect.
4) Check or install power cables from the customer’s dis-
connect to the compressor starter contactor.
5) Locate the correct wiring schematic based on com-
pressor model, configuration and size of VFD being
used.
6) Check or install power cables between fusible discon-
nect and VFD (if applicable for size of VFD) refer to your
wiring schematic.
7) Refer to recommended compressor VFD system
design diagram Figure 3.2-1.
a) Note location and arrangement for VFD
pressure transducer.
b) Note arrangement for control air piping
from receiver.
8) Locate control relays 1CR, 2CR and 3CR on the
wiring schematic.
9) Check installation of the 1CR, 2CR and 3CR relays in
the compressor starter cabinet.
10) Wire 1CR, 2CR and 3CR relays according to the
proper wiring schematic.
11) Verify a normally closed alarm contact internal to the
drive, located on terminals 01 and 03, using a continuity
meter.
12) Complete interface wiring for all 3 relays from termi-
nal strip 3TB to the VFD terminal strip shown on the
wiring schematic.
13) Add jumper wires as shown on the VFD control wire
terminal strip. (39 to 55) and (12 to 18).
14) Complete wiring for pressure transducer on VFD;
refer to the proper electrical schematic.
15) Check and confirm proper wiring of the oil stop valve
starting from wiring location 3CR N.O. contact (contact
cooled compressor only).
16) Check or complete wiring from VFD ouput to motor
terminal block MTB.
Note: Remember to attach fan motor wiring as
shown on the proper wiring schematic for aircooled
units.
17) Remove lock and tag from disconnect.
18) Turn on incoming power. The drive powers up in
Setup 1. Setup 1 is the setup for the compressor’s
unloaded condition.
19) Depress the “QUICK MENU” button on the drives
Local Control Panel (LCP).
Note: In order to make changes to any parameter
you must first depress the “CHANGE DATA” button
on the LCP. After any changes are made the “OK”
button must be depressed to save them.
20) In the quick menu the first parameter is the 001, it is
your language choice.
Note: To move to your next parameter after changes
are made and saved, depress the UP Arrow on the
LCP.
21) Parameter 102 – Main Motor Power KW.
Note: Main Motor Power KW is determined by taking
Main motor nameplate horsepower and multiplying it
by .75 to get your kW. (HP X .75 = kW).
22) Parameter 103 – Motor Voltage (Motor
Nameplate Voltage)
23) Parameter 104 – Motor Frequency (Motor
Nameplate Frequency (Hz).
24) Parameter 105 – Motor Current (Motor
Nameplate Amps)
Note: Some units may give you a Alarm during AMA
If a motor does not match message you may need to
change Parameter 105 to motor nameplate amps
plus service factor.
25) Parameter 106 – Motor Nominal Speed (Motor
Nameplate RPM)
26) Parameter 107 – AMA (Automatic Motor Adaptation)
Skip at this time.
27) Parameter 204 – Minimum Reference (Parameter
setpoint on Table 5.2 use the setup 1 setpoints)
17
28) Parameter 205 – Maximum Reference (Parameter
setpoint on Table 5.2 use the setup 1 setpoints)
29) Parameter 207 – Ramp Up Time (Parameter setpoint
on Table 5.3)
Note: If Ramp Up Time (Par 207) is set too short, you
may get a overcurrent alarm at startup.
30) Parameter 208 – Ramp Down Time (Parameter set-
point on Table 5.3)
31) Parameter 002 – Local / Remote Control (Parameter
should be set for Local at this time) (The LCP display
should start flashing).
32) Parameter 003 – Local Reference (Should be set at
the factory default of 30Hz) This is the last step on the
Quick Menu.
33) Depress the Menu button on the LCP (Use the left
and right arrows on the LCP to get to the “0” menu.
Then depress the “+” until Parameter 013 is displayed.
34) Parameter 013 – Local Control / Configuration as
Parameter 100 (Set Parameter to LCP CTRL / AS P100
35) Parameter 014 – Local Stop (Set Parameter to
ENABLE)
36) Check your motor rotation (Start and Stop the com-
pressor with the Start and Stop buttons on the LCP).
Note: After disconnecting the AC power, the DC bus
in the drive can stay live for 15 minutes so NO
WORK SHOULD BE DONE IN THE STARTER PANEL
UNTIL 15 MINUTES HAS PASSED AFTER DISCON-
NECTING INCOMING POWER.
37) Shut off incoming power, disconnect fan motor
(record your fan motor lead connections to ensure prop-
er rotation when reinstalled) Turn power back on after
disconnecting fan motor.
38) Depress the menu button.
39) Use the right arrow on the LCP to get to the 100
menu. Depress the “+” key until you get to Parameter
107 – AMA (Set Parameter to ENABLE Rs + Xs)
depress the Start button on the LCP. The LCP display
will stop flashing and display “WORKING” (AMA could
take up to 10 minutes to complete) When the AMA has
completed, the LCP will display “ALARM 21 AUTO
MOTOR ADAPT OK”. Depress the Reset / Stop button.
40) Shut off incoming power. Reconnect fan motor. Turn
power back on after reconnecting the fan motor.
18
Note: After disconnecting the AC power, the DC bus
in the drive can stay live for 15 minutes so NO
WORK SHOULD BE DONE IN THE STARTER PANEL
UNTIL 15 MINUTES HAS PASSED AFTER DISCON-
NECTING INCOMING POWER.
41) Depress the Menu button.
42) Select the “0” menu, depress the “+” button until
Parameter 002 is displayed.
43) Parameter 002 – Local / Remote Control (Parameter
should be set for REMOTE at this time)
44) Parameter 004 – Active Setup (Parameter should be
set for MULTI SETUP)
45) Parameter 005 – Edit Setup (Parameter should be
set for SETUP 1)
46) Parameter 008 – Display Scaling of Motor
Frequency ( Parameter should be set for 0.01)
47) Parameter 009 – Display Line 2 (Parameter should
be set for FREQUENCY [Hz])
48) Parameter 010 – Display Line 1.1 (Parameter should
be set for REFERENCE [unit])
49) Parameter 011 – Display Line 1.2 (Parameter should
be set for FREQUENCY X SCALE)
50) Parameter 012 – Display Line 1.3 (Parameter should
be set for POWER [kW])
51) Parameter 013 – Local Control / Config. ( Parameter
should be set for “LCP+DIG CTRL / AS P100)
52) Parameter 014 – Local Stop ( Parameter should be
set for “DISABLED”)
53) Depress Right Arrow Button until the “1” menu is dis-
played, Depress the “+” button until Parameter 100 is
displayed.
54) Parameter 100 – Configuration ( Parameter should
be set for SPEED OPEN LOOP)
55) Parameter 101 – Torque Characteristics ( Parameter
should be set for N-CONSTANT TORQUE)
56) Review Parameters 102 through 109. Write these
parameters down to ensure they are properly copied to
setup 2.
57) Parameter 120 – Start Delay ( Parameter should be
set for 0.1 sec)
58) Parameter 128 – Motor Thermal Protection
(Parameter should be set for ETR TRIP 1)
59) Depress the right arrow button until the “2” menu is
displayed. Depress the “+” key until Parameter 201 is
displayed. Parameters 201 – 205 need to be set per
Table 5.2.
60) Parameters 207 and 208 need to be set per Table
5.3.
61) Parameter 215 – Preset Reference 1 ( Parameter
should be set for 0.00)
62) Depress the right arrow button until the “3” menu is
displayed. Depress the “+” key until parameter 300 is
displayed.
63) Parameter 300 – Terminal 16, Input (Parameter
should be set for NO OPERATION)
64) Parameter 301 – Terminal 17, Input (Parameter
should be set for NO OPERATION)
65) Parameter 302 – Terminal 18 Start, Input (Parameter
should be set for START)
66) Parameter 303 – Terminal 19, Input (Parameter
should be set for NO OPERATION)
67) Parameter 304 – Terminal 27, Input (Parameter
should be set for COAST INVERSE)
68) Parameter 305 – Terminal 29, Input (Parameter
should be set for NO OPERATION)
69) Parameter 306 – Terminal 32, Input (Parameter
should be set for NO OPERATION)
70) Parameter 307 – Terminal 33, Input (Parameter
should be set for SETUP, lsb/SPEED DOWN)
71) Parameter 308 – Terminal 53, Analog Input Voltage
(Parameter should be set for NO OPERATION)
72) Parameter 314 – Terminal 60, Analog Input Current
(Parameter should be set for NO OPERATION)
73) Parameter 315 – Terminal 60, Min. Scaling
(Parameter should be set for 4.0mA)
74) Parameter 316 – Terminal 60, Max Scaling
(Parameter should be set for 20.0mA)
75) Parameter 323 – Relay 01, Output (Parameter
should be set for ALARM)
76) Depress the right arrow key until menu “4” is dis-
played. Depress the “+” key until Parameter 400 is dis-
played.
77) Parameter 400 – Brake Function (Parameter should
be set per Table 5.1)
78) Parameter 409 - Trip Delay Torque (Parameter
should be set for 10 sec.)
Note: Parameter 414 through 416 should be pro-
grammed in reverse order for proper setup.
79) Parameter 416 – Process Unit ( Parameter should
be set for NO UNIT)
80) Parameter 415 – Maximum Feed Back (Parameter
should be set for 200)
81) Parameter 414 – Minimum Feed Back (Parameter
should be set for 0)
82) Setup 1 is complete, depress the right arrow button
until menu “0” is displayed, depress the “+” key until
Parameter 006 is displayed.
83) Parameter 006 – Copying of Setups (Parameter
should be set for COPY TO SETUP 2) After the “OK”
button is pushed the LCP will display “COPYING”
84) Parameter 005 – Programming Setup (Parameter
should be set for SETUP 2) The small 2 should be flash-
ing on the right hand side of the LCP screen.
85) All the Parameters on Tables 5.1, 5.2 and 5.3 for
setup 2 should be verified. A large portion of these
Parameters are the same as setup 1, the following are
the ones that are different.
86) Parameter 008 – Display Scaling of Motor
Frequency (Parameter should be set for the solution of
the equation in section 5.3.2 “setting VFD display”.
87) Depress the right arrow until “1” menu is displayed.
Depress the “+” key until Parameter 100 is displayed.
88) Parameter 100 – Configuration (Parameter should
be set for Process Closed Loop)
89) Depress the right arrow until “2” menu is displayed.
Note: Parameter 205 should be set before parameter
204.
90) Parameter 205 – Maximum Reference ( Parameter
should be set for max rated pressure of the compressor)
Note: Hundreds must be set before tens in most
cases with parameter 205.
19
91) Parameter 204 – Minimum Reference (Parameter
should be set to Table 5.2 for the correct compressor).
92) Parameter 215 – Preset Reference 1 (Parameter
should be set for the solution of the equation in section
5.3.8 “preset reference data”).
93) Depress the right arrow until “3” menu is displayed.
94) Parameter 314 – Terminal 60, Analog Input Current
(Parameter should be set to FEEDBACK).
95) Depress the right arrow until “4” menu is displayed.
96) Parameter 409 - Trip Delay Torque (Parameter
should be set to OFF).
97) Parameter 440 – Process PID Proportional Gain
(Parameter should be set to 3).
98) Parameter 441 – Process PID Integral Time
(Parameter should be set for 1 sec).
99) Parameter 442 – Process PID Differentiation Time
(Parameter should be set for .01 sec).
100) Parameter 455 – Monitor Frequency Range
(Parameter should be set for Disable).
20
101) Setup 2 is now completed.
102) Depress the left arrow button until “0” menu is dis-
played. Depress the “+” button until Parameter 005 is
displayed.
103) Parameter 005 – Programming setup (Parameter
should be set for ACTIVE DISPLAY).
104) Set SG Controller customer setpoints. Set on-line
and off-line pressures on each side of the target pres-
sure (Parameter 215) selected for the VFD transducer.
Note: Be aware of any pressure drop that may exist
between the drive pressure transducer pick-up loca-
tion and the SG controller pressure transducer pick-
up location.
105) Start the compressor from the Compressor control
panel. Adjust Parameter 215 as required to meet the
customer’s requirements.
Note: The fine-tuning of Parameter 215 should be
done with the customer’s air load at a normal steady
condition.
4.0 USER INTERFACE locked out via parameter 018.

4.1 VFD Local Control Panel

The front of the I-R 5000 Variable Frequency Drive

features a Local Control Panel (LCP) which provides a
complete interface for operation and monitoring of the
VFD Series. 1st line 12345678901234567890

2nd line
The control panel is detachable (except NEMA 12 units) 12345678 SETUP
1
and can, as an alternative, be installed up to 10 feet (3
meters) away from the VFD, e.g., on a control panel
3rd line 12345678901234567890

door 4th line 12345678901234567890

by means of the mounting kit option.

The functions of the LCP can be divided into three

groups:

• display
• keys for changing program parameters
• keys for local operation

All data is indicated by means of a 4-line LCD alpha-

numerical display. In normal operation the display is able
to show 4 system measurements and 3 VFD operating
conditions continuously. During programming, all the
information required for quick, effective parameter setup
of the VFD is displayed. As a supplement to the display,
there are three indicator LEDs for warning, alarm, and
voltage.

All program parameters of the I-R 5000 Series can be

changed immediately from the control panel, unless this
func-
SETUP
tion
has
1
been 4.2 Display

The LCD display is rear lighted and has a total of 4

alpha-numerical lines with the possibility to display vari-
ous control, system and programming messages.

1st line shows up to 3 measurements continuously in

DISPLAY QUICK MENU
normal operating status or a parameter name during
STATUS MENU programming.

CHANGE CANCEL OK 2nd line continuously shows a measurement with rela-

DATA
tion to the unit, regardless of status (except in the
case of alarm/warning).
+
3rd line is normally blank and is used in the menu mode
– to show the selected parameter group, parameter num-
ber and name.
ALARM WARNING ON
4th line is used in operation for showing a status text or,
STOP FWD.
RESET JOG REV. START
in data change mode, the mode or value of the selected
parameter.

21
4.4 Control Keys 4.5 Display Modes

The control keys on the LCP are divided into functions.
The keys between the LCD display and the LEDs are
used for parameter setup, including choice of display
indication during normal operation.
In normal operation, up to 4 different operating variables
can be indicated continuously, 3 on line one (1.1, 1.2 and
1.3) and another on the large display (line 2). Line four
displays the present operating status or any alarms or
warnings that have occurred.

DISPLAY QUICK MENU

STATUS MENU

VAR 1.1 VAR 1.2 VAR 1.3

CHANGE CANCEL OK
DATA
VAR 2 SETUP
1

+
STATUS
–

The list below identifies the variables and units available

Keys for local control are found under the LEDs.
for the first and second line of the display. The BOLD
variables are important for compressor applications.

STOP Operating Variable Unit

FWD.
RESET JOG REV. START Reference [%]
REFERENCE (Target Pressure) [unit]
Feedback [unit]
FREQUENCY [Hz]
NOTE FREQUENCY x SCALING (Capacity) [–]
Motor current [A]
Torque [%]
Since digital operational control is handled remotely POWER [kW]
from Intellisys System, keys for local control are inac- Power [HP]
tive for proper compressor operation. Output energy [kWh]
Motor voltage [V]
DC-link voltage [V]
[DISPLAY / STATUS] is used for selecting the Motor thermal load [%]
DISPLAY
STATUS mode of display or for changing back to Status VLT thermal load [%]
mode. Hours run [hours]
Input status, digital input [binary code]
Input status, analog terminal 53 [V]
QUICK
[QUICK MENU] is not used in compressor appli- Input status, analog terminal 54 [V]
MENU cations. Input status, analog terminal 60 [mA]
Pulse reference [Hz]
MENU
[MENU] provides the access to all parameters for External Reference [%]
programming. Status word [Hex]
Brake effect/2 minutes [kW]
Brake effect/seconds [kW]
CHANGE
[CHANGE DATA] is used for changing the data Heatsink temperature [°C]
DATA value of a parameter when programming. Alarm word [Hex]
Control word [Hex]
[CANCEL] is used to cancel the last programming Warning word 1 [Hex]
CANCEL Warning word 2 [Hex]
command so it is not carried out.
Operating variables 1.1 and 1.2 and 1.3 in the first line,
[OK] is used for confirming that the last program- and operating variable 2 in the second line are selected
OK
ming change is acceptable and should be stored. via parameter 009, 010, 011 and 012.

+ [+] and [–], [<] and [>] provide the user the
– ability to move the cursor around the LCD
display, or sequence through display
values. These keys are active during
operation as well as programming modes.

22
4.5.1 Display Mode Selection

There are three display modes available: I, II and III. The

choice determines the operating variables or description
displayed in the first (top) line of the display. The dis-
plays
selected for line one are summarized below.

Mode: I II III
REF% TORQ% CUR A
Line 1 display: Description 3 operational Description
for operating data values of the 3
value in line 2. in line 1. values in 60.0 HZ SETUP
1 In
line 1.

RUNNING
Mode I
This display type shown is the default after start up or
re-initialization. Line 1 describes the value in line 2 (large
dis- mode II, data for four operating values are shown at
the same time, in the selected unit. In the example
shown, Reference, Torque, Current and Frequency are
FREQUENCY selected as variables in the first and second lines.

60.0 HZ SETUP
1

RUNNING

Mode III

play). FREQUENCY

60.0 HZ SETUP
1

0 . . KEYB & DISPLAY

Mode II provides identification of the units programmed

as the operation variables in the top display line. The
24, 3% 30, 2% 13, 8A display in the large display does not change.

In
60.0 HZ SETUP
1
the

RUNNING

example, Frequency has selected as variable in

the large display via parameter 009. During normal
operation the variable in line 2 can immediately be
changed by using the [+] and [–] keys. Mode III is engaged as long as the [DISPLAY / STATUS]
key is pressed and held in for 1 second or longer. When
Mode II the key is released, the display shifts back to mode II.
To switch between modes I and II, press the [DISPLAY /
STATUS] key. 4.5.2 Menu Mode

23
When the desired parameter group has been selected, a 4.5.3.2 Changing a Number Value
parameter within that group can be chosen with the [+]
and [–] keys: The numerical value of some parameters are selected
from a fixed list of values, such as 0.37 kW, 0.55 kW or
1.00 kW. These cannot be individually modified, as they
are part of the software data base. Other parameters
FREQUENCY provide data values that can be set within a range (i.e.,
0-130 Hz) and fine-tuned by the user.
60.0 HZ SETUP
1
4.5.3.2.1 Selection from a List
001 LANGUAGE

ENGLISH The value of parameters represented by a number of a

fixed data list is changed by scrolling through the list with
the [+] and [–] keys.

The 3rd line of the display shows the parameter number

and name. Line 4 shows the status/value of the chosen
parameter.
FREQUENCY
4.5.3 Changing Data

Pressing the [CHANGE DATA] key gives access to the 60.0 HZ SETUP
1

selected parameter value shown on the 4th line of the 102 MOTOR POWER
display. 0.37 KW

The procedure for changing data depends on whether

the selected parameter represents a numerical data
value or a text value.

4.5.3.1 Changing a Text Value

FREQUENCY
If the selected parameter is a text value, it is changed by
means of the [+] and [–] keys.
60.0 HZ SETUP
1

102 MOTOR POWER

0.55 KW

FREQUENCY

60.0 HZ SETUP
1
The chosen data value is indicated by the digit flashing.
001 LANGUAGE The bottom display line shows the data value that will be
ENGLISH entered (saved) by pressing the [OK] key.

The bottom display line shows the text value that will be
entered (stored) when acknowledgment is given by
pressing the [OK] key. The [CANCEL] key abandons the
selection.

24
4.5.3.2.2 Changing in a Value Range

When a chosen parameter represents a programmable FREQUENCY

numeric value, a blinking cursor appears on a digit. The
cursor can be moved to other digits on the display by 60.0 HZ SETUP
1
means of the [<] and [>] keys.
130 START FREQUENCY

10. 0 Hz

FREQUENCY

60.0 HZ SETUP
1
Selecting a digit to the left allows for faster programming
130 START FREQUENCY when a larger change is desired. Fine-tuning is easier
09 . Hz using digits farther to the left on the data value. The
bottom display line shows the data value that will be
entered (saved) when pressing the [OK] key.

When the cursor is in place, the digit's value is changed

by using the [+] and [–] keys to increase or decrease the
value.

25
5.0 OPERATION I-R 5000 Series LCD display:
5.1 Compressor Operation Control

The Intellisys control system must be set for On Line/Off

Line control. Modulation, if available, must NOT be oper-
ational while the VFD is in control. Refer to the compres- 1st line 12345678901234567890
sor operation manual for the procedure to change opera-
2nd line
tion to On Line/Off Line control. 12345678 SETUP
1

The on and off line pressure setpoints on Intellisys must

3rd line 12345678901234567890

have enough range to allow the VFD as much as 3 to 5 4th line 12345678901234567890
psi of overshoot of the target pressure. In addition to the
overshoot range, the off line setpoint must be set high
enough to allow for the pressure drop between the com-
pressor’s pressure transducer and the VFD’s transducer.
On the right hand side of the display the active setup is
The unloaded inlet vacuum may be lower than expected shown, as well as the setup in which programming is
when the VFD controls the compressor to minimum taking place. A flashing setup number indicates that pro-
speed. Therefore, the stepper motor inlet valve control gramming is taking place.
system on some compressors may create nuisance
alarms or warnings at startup. This is most likely to hap- SETUP
pen if the Intellisys controller is programmed to remain 1
12
unloaded after start-up. To prevent these problems, pro-
gram the controller in accordance with the following: Active Flashing
Operation Programming
1) Perform the Inlet Valve Getting Smart Procedure at Setup Setup
minimum speed. (Contact your service representative To change the programming setup, select the corre-
for details.) sponding setup in parameter 005.

2) If the compressor shuts down on “Check Inlet

Control” alarm, set the compressor to “VFD ON” mode 005 Programming Setup
on SG Intellisys software revision numbers 1.40 and (EDIT SETUP)
above. If you do not have the proper software revision,
Value
contact your service representative.
Factory setup (FACTORY SETUP) [0]
Setup 1 (SETUP 1) [1]
For a temporary solution, the unloaded minimum speed
Setup 2 (SETUP 2) [2]
may be increased by approximately 10% to 15% in para-
Setup 3 (SETUP 3) [3]
meter 204.
Setup 4 (SETUP 4) [4]
★Active setup (ACTIVE SETUP) [5]
5.2 I-R 5000 Parameter Description and
Adjustment
Description
The I-R 5000 series has the ability to operate four Setup 1 corresponds to the Unloaded Mode. Setup 2
independent setups. All parameters can be pro- corresponds to the Loaded PID Mode. Once adjusted,
grammed in the four setups. For the compressor appli- the setup that is being edited will flash on the I-R 5000
cation, two of the four setups are used. Setup 1 corre- display.
sponds to the Unloaded Mode. Setup 2 corresponds
to the Loaded PID Mode. Terminal 33 is used to
switch between the two setups.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

26
5.3 VFD Operation Control
NOTE
Table 5-1 lists all of the important VFD parameters that Both Setup 1 and Setup 2 must be programmed
must be programmed for proper compressor operation. for proper compressor operation. Parameters
(See Chapter 4, VFD User Interface, for instructions on may not have been programmed completely at
programming parameters.) Section 5.1 contains detailed the factory. Before startup, ensure that all
descriptions and instructions for programming the VFD parameters are programmed in accordance with
parameter. values in Table 5.1.

Setup 1 corresponds to the Unloaded Mode. Setup 2

corresponds to the Loaded PID Mode.
TABLE 5.1 VFD PARAMETER SETTINGS

Parameter Parameter Setup 1 Setup 2

Number Name Unloaded Mode Loaded PID

001 Language *** ***

004 Active Setup Multi Setup Multi Setup
008 Display Scaling of Motor Frequency 0.01 ***
009 Display Line 2 Frequency [Hz] Frequency [Hz]
010 Display Line 1.1 Reference [unit] Reference [unit]
011 Display Line 1.2 Frequency * Scale Frequency * Scale
012 Display Line 1.3 Power [kW] Power [kW]
014 Local Stop Disable Disable
100 Configuration Speed Open Loop Process Closed Loop
101 Torque Characteristics Normal-Constant Torque Normal-Constant Torque
102 Motor Power *** ***
103 Motor Voltage *** ***
104 Motor Frequency *** ***
105 Motor Current *** ***
106 Rated Motor Speed *** ***
108 Stator Resistance *** ***
109 Stator Reactance *** ***
119 High Starting Torque *** 0.0 Sec
120 Start Delay 0.1 sec 0.1 sec
128 Motor Thermal Protection ETR Trip 1 ETR Trip 1
201 Minimum Frequency *** ***
202 Maximum Frequency *** ***
204 Minimum Reference *** ***
205 Maximum Reference *** ***
207 Ramp Up Time 1 *** ***
208 Ramp Down Time 1 *** ***
215 Preset Reference 1 0.00% ***
300 Terminal 16, Input No Operation No Operation
301 Terminal 17, Input No Operation No Operation
302 Terminal 18, Input Start Start
303 Terminal 19, Input No Operation No Operation
304 Terminal 27, Input Coast, Inverse Coast, Inverse
305 Terminal 29, Input No Operation No Operation
306 Terminal 32, Input No Operation No Operation
307 Terminal 33, Input Choice of Setup,lsb/Speed Down Choice of Setup,lsb/Speed Down
308 Terminal 53, Analog Input Voltage No Operation No Operation
314 Terminal 60, Analog Input Current No Operation Feedback
315 Terminal 60, Minimum Scaling 4.0 mA 4.0 mA
316 Terminal 60, Maximum Scaling 20.0 mA 20.0 mA
323 Relay 01, Output Alarm Alarm
400 Brake Function Overvoltage Control Overvoltage Control
409 Trip Delay Torque 10 Sec. Off
414 Minimum Feedback *** ***
415 Maximum Feedback *** ***
416 Process Unit *** ***
440 Process PID Proportional Gain N.D.R. 3.00
441 Process PID Intergral Time N.D.R. 1.00 sec
442 Process PID Differentiation Time N.D.R. .01 sec
455 Monitor Frequency Range N.D.R. Disable
*** Value dependent on drive size or customer requirements, please refer to following setup procedures.
N.D.R.- No Data Required

27
5.3.1 Language and Setup

001 Language 006 Copying of Setups

(LANGUAGE) (SETUP COPY)
Value Value
English (ENGLISH) [0] No copying (NO COPY) [0]
German (DEUTSCH) [1] ★Copy to setup 1 from # (COPY TO SETUP 1) [1]
French (FRANCAIS) [2] Copy to setup 2 from # (COPY TO SETUP 2) [2]
Danish (DANSK) [3] Copy to setup 3 from # (COPY TO SETUP 3) [3]
Spanish (ESPANOL) [4] Copy to setup 4 from # (COPY TO SETUP 4) [4]
Italian (ITALIANO) [5] Copy to setup all from # (COPY TO ALL) [5]

# = the setup selected in parameter 005

Description
The drive language can be set for one of six posibile Description
languages depending on customer requirements. A copy is made from the setup selected in parameter
005 to one of the other setups or to all the other setups
simultaneously. The copying starts when the desired
004 Active Setup copying function has been entered and confirmed by
pressing the "OK" key. The display indicates when
(ACTIVE SETUP)
copying is in progress.
Value
Factory setup (FACTORY SETUP) [0]
Setup 1 (SETUP 1) [1]
Setup 2 (SETUP 2) [2]
Setup 3 (SETUP 3) [3]
Setup 4 (SETUP 4) [4]
★Multi setup (MULTI SETUP) [5]

Description
This parameter selects the setup number to control the
functions of the I-R 5000.

For compressor operation the value should be set to

MULTI SETUP. This allows the compressor’s Intellisys
controller to toggle between the parameter setups
controlling the unloaded mode and loaded PID mode.

Terminal 33 is the digital input used to switch between

desired setups.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

28
007 LCP Copy
(LCP COPY)
Value
★No copying (NO COPY) [0]
Upload all parameters (UPLOAD ALL PARAM) [1]
Download all parameters (DOWNLOAD ALL) [2]
Download power-independent parameters
(DOWNLOAD SIZE INDEP.) [3]
Description
Parameter 007 is used for the integrated copying
function of the control panel. This function is used if a
given parameter setup is to be copied from one variable
frequency drive to another by the removable control
panel.
Select Upload all parameters [1] if all parameter values
are to be transmitted from the VFD to the control panel.
Select Download all parameters [2] if all transmitted
parameter values are to be copied to the VFD from the
control panel.
Select Download power-independent par. [3] if only the
power-independent parameters are to be downloaded.
This is used if downloading to a VFD that has a different
rated power than the VFD which originated the parame-
ter setup.
NOTE
Unloading/Downloading can only be carried
out in the Stop mode.
★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port
5.3.2 Setting VFD Display
In normal operation, up to four different operating
variables can be viewed continuously. The last line of
the
display indicates status. Please refer to Chapter 4, User
Interface, for details on display settings.
For a compressor application some of the most impor-
tant operating variables to view are Frequency (Hz),
Input Reference indicating target pressure, Capacity,
and
Motor Power.
In order to show the correct value for capacity the dis-
play scaling of the motor frequency must be set properly
008 Display scaling of motor frequency
(FREQUENCY SCALE)
Value
0.01 - 100.00 ★Depends on
capacity unit of
measure
Description
This parameter scales the display value for the
compressor’s capacity. The value for this parameter
should be found by the following formula:
rated capacity at rated pressure
value =
standard AC power frequency
For example, if the rated capacity is 600 cfm and the
standard AC power is 60 Hz, then value for parameter
008 should be 600/60 = 10.
29
009 Display line 2 011 Display line 1.2
(DISPLAY LINE2) (DISPLAY LINE 1.2)
Value Value
[0] See parameter 009. ★ Frequency Scale
Reference [%] (REFERENCE [%]) [1]
Reference [unit] (REFERENCE [UNIT]) [2] Description
Feedback [unit] (FEEDBACK [UNIT]) [3] Display line 1.2 indicates the second of three data val-
★Frequency [Hz] (FREQUENCY [HZ]) [4] ues to be displayed in line 1, position 2.
Frequency x Scaling [–] (FREQUENCY x SCALE) [5] Setting this parameter to FREQUENCY SCALE will
Motor current [A] (MOTOR CURRENT [A]) [6] display the approximate capacity that the compressor is
Torque [%] (TORQUE [%]) [7] delivering. The scale is set by parameter 008.
Power [kW] (POWER [KW]) [8]
Power [HP] (POWER [HP] [US]) [9]
Output energy [kWh] (OUTPUT ENERGY [KWH]) [10]
Motor voltage [V] (MOTOR VOLTAGE [V]) [11] 012 Display line 1.3
DC link voltage [V] (DC LINK VOLTAGE [V]) [12] (DISPLAY LINE 1.3)
Thermal load, motor [%] (MOTOR THERMAL [%]) [13] Value
Thermal load, VLT [%] (VLT THERMAL [%]) [14] See parameter 009. ★ Power [kW]
Hours run [Hours] (RUNNING HOURS) [15]
Digital input [Binary code] (DIGITAL INPUT [BIN]) [16] Description
Analog input 53 [V] (ANALOG INPUT 53 [V]) [17] Display line 1.3 indicates the third of three data values
Analog input 54 [V] (ANALOG INPUT 54 [V]) [18] to be displayed in line 1, position 3.
Analog input 60 [mA] (ANALOG INPUT 60 [MA]) [19] Setting this parameter to POWER [kW] will display the
Pulse reference [Hz] (PULSE REF. [HZ]) [20] power the compressor is consuming in kilowatts.
External reference [%] (EXTERNAL REF [%]) [21]
Status word [Hex] (STATUS WORD [HEX]) [22]
Brake effect/2 min. [kW] (AVERAGE BRAKE ENERGY) [23]
Brake effect/sec. [kW] (ACTUAL BRAKE ENERGY) [24]
014 Local Stop
Heatsink temp. [°C] (HEATSINK TEMP [°C]) [25]
Alarm word [Hex] (ALARM WORD [HEX]) [26] (LOCAL STOP)
Control word [Hex] (CONTROL WORD [HEX]) [27] Value
Warning word 1 [Hex] (WARNING WORD 1 [HEX]) [28] Not possible (DISABLE) ★ [0]
Warning word 2 [Hex] (WARNING WORD 2 [HEX]) [29] Possible (ENABLE [1]

Description
Display line 2 is the main line of the display. For
compressor operation this parameter should be set to
FREQUENCY [Hz].
Description
Set this parameter to DISABLE so that the drive can
only be stopped from the Intellisys controller.

010 Display line 1.1

(DISPLAY LINE 1.1)
Value
See parameter 009. ★ Reference [unit]

Description
Display line 1.1 indicates the first of three data values to
be displayed in line 1, position 1.

Setting this parameter to REFERENCE [Unit] will dis-

play the target pressure that the VFD will maintain.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

30
5.3.3 Operation and Load Data

100 Configuration 101 Torque Characteristics

(CONFIG. MODE) (TORQUE CHARACT)
Value Value
Speed regulation, open loop High overload torque (160%)
(SPEED OPEN LOOP) ★ Setup 1 [0]
Speed regulation, closed loop High-constant torque
(SPEED CLOSED LOOP) [1] (H-CONSTANT TORQUE) [1]
Process regulation, closed loop High-variable torque low
(PROCESS CLOSED LOOP) ★ Setup 2 [3] (H-VAR. TORQ. : LOW) [2]
Torque regulation, open loop H-variable torque medium
(TORQUE OPEN LOOP) [4] (H-VAR. TORQ.: MEDIUM) [3]
Torque regulation, speed feedback High-variable torque high
(TORQUE CONTROL SPEED) [5] (H-VAR. TRQ.: HIGH) [4]
High-special motor characteristics
Description (H-SPEC.MOTOR. CHAR.ACT) [5]
High-variable torque with low starting torque
This parameter is used for selecting the appropriate (H-VT LOW W. CT-START) [6]
configuration mode for each setup. High-variable torque with medium starting torque
(H-VT MED W. CT-START) [7]
For the compressor application the value should be set High-variable torque with high starting torque
to: (H-VT HIGH W. CT-START) [8]

Setup 1 (Unloaded Mode) = Speed Open Loop Normal overload torque (110%)
Setup 2 (Loaded PID) = Process Closed Loop
★ Norm-constant torque
SPEED REGULATION OPEN LOOP allows for normal (N-CONSTANT TORQUE) [11]
speed control, without process feedback from the Norm-variable torque low
pressure transducer. In this setup, the compressor is (N-VAR. TORQ. : LOW) [12]
unloaded and will run at a constant minimum speed. N-variable torque medium
(N-VAR. TORQ.: MED) [13]
PROCESS REGULATION CLOSED LOOP activates the Norm-variable torque high
internal process regulator. This allows for accurate (N-VAR. TRQ.: HIGH) [14]
regulation of the compressor with respect to the Norm-special motor characteristics
pressure setpoint. The output from the pressure (N-SPEC.MOTOR. CHARACT) [15]
transducer is the feedback signal to the VFD. Normal-variable torque with low constant
starting torque (N-VT LOW W. CT-START) [16]
Normal-variable torque with medium constant
starting torque (N-VT MED W. CT-START) [17]
Normal-variable torque with high constant
starting torque (N-VT HIGH W. CT-START) [18]

Description
Set this parameter to N-CONSTANT TORQUE. The
compressor application is optimized when using the
NORMAL constant torque overload mode. This mode
will provide 100% of rated drive torque on a continuous
basis and 110% of torque intermittently.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

31
5.3.4 Motor Tuning Procedures 5.3.5 Motor Data

Parameters 102 – 109 define the operating parameters

102 Motor Power
of the motor. Set these parameters in numerical order,
since the values entered are related to some automated (MOTOR POWER)
calculation functions. Value
0.18 kW (0.18 KW) [18]
Motor Setup procedures are covered in Section 3.5 VFD 0.25 kW (0.25 KW) [25]
Startup Procedure. 0.37 kW (0.37 KW) [37]
0.55 kW (0.55 KW) [55]
0.75 kW (0.75 KW) [75]
1.1 kW (1.10 KW) [110]
1.5 kW (1.50 KW) [150]
2.2 kW (2.20 KW) [220]
3 kW (3.00 KW) [300]
4 kW (4.00 KW) [400]
5.5 kW (5.50 KW) [550]
7.5 kW (7.50 KW) [750]
11 kW (11.00 KW) [1100]
15 kW (15.00 KW) [1500]
18.5 kW (18.50 KW) [1850]
22 kW (22.00 KW) [2200]
30 kW (30.00 KW) [3000]
37 kW (37.00 KW) [3700]
45 kW (45.00 KW) [4500]
55 kW (55.00 KW) [5500]
75 kW (75.00 KW) [7500]
90 kW (90.00 KW) [9000]
110 kW (110.00 KW) [11000]
132 kW (132.00 KW) [13200]
160 kW (160.00 KW) [16000]
200 kW (200.00 KW) [20000]
250 kW (250.00 KW) [25000]
★ Depends on the unit

Description
This parameter sets the kW value that corresponds to
the compressor. If the compressor’s motor is
horsepower-rated, multiply the horsepower by 0.75 to
convert to kilowatts.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

32
103 Motor Voltage 106 Rated Motor Speed
(MOTOR VOLTAGE) (MOTOR NOM. SPEED)
Value Value
200 V [200] 100 - 60000 RPM [100 - 60000]
208 V [208] ★ Depends on the unit
220 V [220]
230 V [230] Description
240 V [240] This parameter sets the rated motor speed (rpm) value
380 V [380] that corresponds to the compressor.
400 V [400]
415 V [415] NOTE
440 V [440] Parameters 108 and 109 normally are not set if
460 V [460] nameplate data has been entered.
480 V [480]
500 V [500]
550 V [550]
575 V [575] 108 Stator Resistor
★ Depends on the unit
(STATOR RESIST)
Description Value
This parameter sets the voltage (Volt) value that x ohm - y ohm
corresponds to the compressor. ★ Depends on the choice of motor

Description
104 Motor Frequency
This parameter corresponds to the value of stator
(MOTOR FREQUENCY) resistance of the main motor.
Value
50 Hz (50 HZ) [50]
60 Hz (60 HZ) [60]
Max. motor frequency 1000 Hz 109 Stator Resistance
★ Depends on the unit (STATOR REACT.)
Value
Description x ohm - y ohm
This parameter sets the frequency (Hz) value that ★ Depends on the choice of motor
corresponds to the compressor.
Description
This parameter corresponds to the value of stator
105 Motor Current resistance of the main motor.
(MOTOR CURRENT)
Value
0.01 to drive rating Set nameplate data 119 High Starting Torque
★ Depends on the unit (HIGH START TORQU.)
Value
Description 0.0 - 0.5 sec. ★ 0.0 sec
This parameter sets the current (A) value that
corresponds to the compressor. Description
For compressors with normally open inlet valves
(e.g. 50 SE Full Voltage), the drive may need to supply
higher startup torque. In order to secure a high starting
torque, approx. 2 times the maximum normal output cur-
rent for max. 0.5 sec. is allowed. However, the current is
limited by the protection limit of VFD. This should only
be adjusted in Setup 1 if needed.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

33
120 Start Delay 5.3.6 Setting Motor Operation Range
(START DELAY)
Value Parameters 201 and 202 set the minimum and
0.0 - 10.0 sec. ★ 0.1 sec. maximum frequency of operation. This range is based on
Depends on the choice of motor the type of compressor.

Description
For compressor operation this value should be set to
0.1
sec. This enables a delay of the start time.
128 Motor Thermal Protection
(MOT. THERM PROTEC)
Value
No protection (NO PROTECTION)
Thermistor warning (THERMISTOR WARN)
Thermistor trip (THERMISTOR FAULT)
ETR Warning 1 (ETR WARNING 1)
★ETR Trip 1 (ETR TRIP 1)
ETR Warning 1 (ETR WARNING 2)
ETR Trip 2 (ETR TRIP 2)
ETR Warning 1 (ETR WARNING 3)
ETR Trip 3 (ETR TRIP 3)
ETR Warning 1 (ETR WARNING 4)
ETR Trip 4 (ETR TRIP 4)
Description
For compressor operation set this parameter to ETR
TRIP 1. This parameter provides motor thermal
protection based on calculation of thermal load.
CAUTION
Severe damage to compressor or motor can
result if minimum or maximum frequencies
(parameters 201 and 202) are set outside
recommended speed range. Warranty will be
voided if recommended settings are not
followed.
Parameters 204 and 205 set the operation range for both
[0] the Unloaded and Loaded PID modes. For the Unloaded
[1] mode (Setup 1) and the Loaded PID mode (Setup 2), the
[2] values of Parameters 204 and 205 should correspond to
[3] Tables 5.2A and 5.2B.
[4]
[5] Pressure units selected in setting parameters 204 and
[6] 205 in Setup 2 must be consistent with those used in
[7] parameters 414, 415, and 416.
[8]
[9] NOTE
[10] Compressor will not operate properly if parameters
204 and 205 are not set properly for Setup 2. For SSR
compressors, a minimum of 65 psig (4.5 barg) is
required for proper coolant flow through the com-
pressor. For Sierra compressors, 65 psig (4.5 barg) is
required for proper oil pressure to operate inlet
valve. Maximum pressure must be rated pressure of
machine, or less.

201 Minimum Frequency

(MIN OUTPUT FREQ.)
Value
0.0 to parameter 02 ★ See Tables 5.2A
Depends on the choice of motor and 5.2B

Description
In this parameter, the minimum motor frequency limit
can be set. For parameter value, see Tables 5.2A and
5.2B.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

34
202 Maximum Frequency 205 Maximum Reference
(MAX OUTPUT FREQ.) (MAX REFERENCE)
Value Value
Parameter 201 to parameter 200 ★ See Tables 5.2A Min reference to 100,000.000 ★ See Tables 5.2A
and 5.2B and 5.2B

Description Description
In this parameter, the maximum motor frequency limit This parameter sets the value of the maximum refer-
can be set. For parameter value, see Tables 5.2A and ence.
5.2B. For compressor operation the maximum reference
corresponds to different values depending on which
setup parameter is active.
In Setup 1 (Open-loop mode), this parameter controls
204 Minimum Reference the maximum speed that the compressor is allowed to
(MIN. REFERENCE) operate. In Setup 2 (Closed-loop mode), this parameter
Value controls the maximum discharge pressure that the
-100,000.000 to max reference ★ See Tables compressor is allowed.
5.2A and For proper compressor operation, set the value of the
5.2B parameter according to Tables 5.2A and 5.2B.
Depends on parameter 100.

Description
This parameter sets the value of the minimum refer-
ence.
For compressor operation the minimum reference
corresponds to different values depending on which
setup parameter is active.

In Setup 1 (Open-loop mode), this parameter controls

the minimum speed that the compressor is allowed to
operate. In Setup 2 (Closed-loop mode), this parameter
controls the minimum discharge pressure that the
compressor is allowed.

For proper compressor operation, set the value of the

parameter according to Tables 5.2A and 5.2B.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

35
 UNLOADED (Setup 1) LOADED (Setup 2)
Parameter 201 202 204 205 201 202 204 205
Description Min. Speed Max. Speed Min. Speed Max. Speed Min. Speed Max. Speed Min. Speed Max. Speed
Compressor Motor (Hz) (Hz) (Hz) (Hz) (Hz) (Hz) [psig] (barg) [psig] (barg)
SSR (Oil-Flooded)
37-75 kw -50 Hz, 1 Stage All 0 50 25 25 25 50 65 (4.5) rated
50-100 hp - 60 Hz, 1 Stage All 0 60 30 30 30 60 65 (4.5) rated
XFE & EPE 100 -60 Hz, 2 Stage All 0 60 40 40 40 60 65 (4.5) rated
HPE 100 hp - 60 Hz, 2 Stage All 0 60 42 42 42 60 65 (4.5) rated
ML/MM/MH 75-50 Hz, 2 Stage All 0 50 33 33 33 50 65 (4.5) rated
125-150 hp, 60 Hz, 1 & 2 Stage All 0 60 30 30 30 60 65 (4.5) rated
MM 90 -50 Hz, 1 Stage All 0 50 27 27 27 50 65 (4.5) rated
MH 90 -50 Hz, 1 Stage All 0 50 30 30 30 50 65 (4.5) rated
90-160 kw -50 Hz, 1 Stage (except
All 0 50 25 25 25 50 65 (4.5) rated
MM & MH 90)
110-160 kw, -50 Hz, 2 Stage All 0 50 25 25 25 50 65 (4.5) rated
Stnd. ODP 0 28 28 28
200 hp - 50 Hz, 1 & 2 Stage 50 50 65 (4.5) rated
All Others 0 25 25 25
Stnd. ODP 0 34 34 34
200 hp - 60 Hz, 1 & 2 Stage 60 60 65 (4.5) rated
All Others 0 30 30 30
Stnd. Eff. 0 32 32 32
250 hp - 50 Hz, 1 Stage 50 50 65 (4.5) rated
Prem. Eff. 0 25 25 25
Stnd. Eff. 0 38 38 38
250 hp - 60 Hz, 1 Stage 60 60 65 (4.5) rated
Prem. Eff. 0 30 30 30
250 hp - 50 Hz, 2 Stage All 0 50 32 32 32 50 65 (4.5) rated
250 hp - 60 Hz, 2 Stage Stnd. Eff. 0 38 38 38
60 60 65 (4.5) rated
Prem. Eff. 0 34 34 34
Stnd. Eff. 0 32 32 32
300 hp - 50 Hz, 1 & 2 Stage 50 50 65 (4.5) rated
Prem. Eff. 0 25 25 25
Stnd. Eff. 0 38 38 38
300 hp - 60 Hz, 1 & 2 Stage 60 60 65 (4.5) rated
Prem. Eff. 0 30 30 30
Stnd. Eff. 0 35 35 35
350 hp - 50 Hz, 1 & 2 Stage 50 50 65 (4.5) rated
Prem. Eff. 0 25 25 25
Stnd. Eff. 0 42 42 42
350 hp - 60 Hz, 1 & 2 Stage 60 60 65 (4.5) rated
Prem. Eff. 0 30 30 30
Stnd. Eff. 0 38 38 38
400 hp - 50 Hz, 1 & 2 Stage 50 50 65 (4.5) rated
Prem. Eff. 0 25 25 25
Stnd. Eff. 0 45 45 45
400 hp - 60 Hz, 1 & 2 Stage 60 60 65 (4.5) rated
Prem. Eff. 0 30 30 30
Stnd. Eff. 0 38 38 38
450 hp - 50 Hz, 1 & 2 Stage 50 50 65 (4.5) rated
Prem. Eff. 0 25 25 25
Stnd. Eff. 0 45 45 45
450 hp - 60 Hz, 1 & 2 Stage 60 60 65 (4.5) rated
Prem. Eff. 0 30 30 30
EP & HP 30-40 SE 60 Hz All 0 60 30 30 30 60 65 (4.5) rated
XF & EP & HP 50 SE 60 Hz All 0 60 30 30 30 60 65 (4.5) rated
UP6- 15-125 All 0 60 43 43 43 60 65 (4.5) rated
UP6- 20-125 All 0 60 33 33 33 60 65 (4.5) rated
UP6- 20-150 All 0 60 38 38 38 60 65 (4.5) rated
UP6- 25-125 & 150 All 0 60 30 30 30 60 65 (4.5) rated
UP6- 30-125 & 150 All 0 60 30 30 30 60 65 (4.5) rated
UP6- 40-115 & 125 & 150 All 0 60 30 30 30 60 65 (4.5) rated
HF & EP & HHP 50-PE 60 Hz All 0 60 30 30 30 60 65 (4.5) rated

NOTES:
1. Parameters apply only to machines that are pressure related up to 140 psig or 10 barg unless otherwise noted (upg 20-50 is 150 psig.
2. Non-IR supplied motors, and motors manufactured prior to 1996 may not be suitable for VFD use. Contact IR before applying VFD to motors of this type.

TABLE 5.2A SSR SPEED AND PRESSURE RANGES

36
 UNLOADED (Setup 1) LOADED (Setup 2)
Parameter 201 202 204 205 201 202 204 205
Description Min. Speed Max. Speed Min. Speed Max. Speed Min. Speed Max. Speed Min. Speed Max. Speed
Compressor Motor (Hz) (Hz) (Hz) (Hz) (Hz) (Hz) [psig] (barg) [psig] (barg)
Sierra (Oil-Free)
H150 (125 psig) All 0 60 40 40 40 60 65 (4.5) rated
H200 (125 psig) All 0 60 32 32 32 60 65 (4.5) rated
H250 (125 psig) All 0 60 48 48 48 60 65 (4.5) rated
H300 (125 psig) All 0 60 33 33 33 60 65 (4.5) rated
H350 (125 psig) All 0 60 35 35 35 60 65 (4.5) rated
H75 (125 psig) All 0 60 41 41 41 60 65 (4.5) rated
HH150 (150 psig) All 0 60 50 50 50 60 65 (4.5) rated
HH350 (150 psig) All 0 60 38 38 38 60 65 (4.5) rated
HH400 (150 psig) All 0 60 44 44 44 60 65 (4.5) rated
L100 (100 psig) All 0 60 30 30 30 60 65 (4.5) rated
L100 (125 psig) All 0 58 30 30 30 58 65 (4.5) 125 (8.6)
L125 (100 psig) All 0 60 50 50 50 60 65 (4.5) rated
L150 (100 psig) All 0 60 40 40 40 60 65 (4.5) rated
L200 (100 psig) All 0 60 30 30 30 60 65 (4.5) rated
L200 (125 psig) All 0 57 30 30 30 57 65 (4.5) 125 (8.6)
L250 (100 psig) All 0 60 35 35 35 60 65 (4.5) rated
L350 (100 psig) All 0 60 30 30 30 60 65 (4.5) rated
L350 (125 psig) All 0 54 30 30 30 54 65 (4.5) 125 (8.6)
L75 (100 psig) All 0 60 30 30 30 60 65 (4.5) rated
SH110 (10 barg) All 0 50 40 40 40 50 65 (4.5) rated
SH150 (10 barg) All 0 50 36 36 36 50 65 (4.5) rated
SH250 (10 barg) All 0 50 36 36 36 50 65 (4.5) rated
SH300 (10.0 barg) All 0 50 28 28 28 50 65 (4.5) rated
SL110 (7.0 barg) All 0 50 35 35 35 50 65 (4.5) rated
SL132 (7.0 barg) All 0 50 31 31 31 50 65 (4.5) rated
SL150 (7.0 barg) All 0 50 25 25 25 50 65 (4.5) rated
SL150 (8.5 barg) All 0 48 25 25 25 48 65 (4.5) 123 (8.5)
SL200 (7.0 barg) All 0 50 35 35 35 50 65 (4.5) rated
SL250 (7.0 barg) All 0 50 25 25 25 50 65 (4.5) rated
SL45 (7.0 barg) All 0 50 38 38 38 50 65 (4.5) rated
SL55 (7.0 barg) All 0 50 30 30 30 50 65 (4.5) rated
SL75 (7.0 barg) All 0 50 25 25 25 50 65 (4.5) rated
SL75 (8.5 barg) All 0 47 25 25 25 47 65 (4.5) 123 (8.5)
SL90 (7.0 barg) All 0 50 42 42 42 50 65 (4.5) rated
SM110 (8.5 barg) All 0 50 36 36 36 50 65 (4.5) rated
SM132 (8.5 barg) All 0 50 31 31 31 50 65 (4.5) rated
SM150 (8.5 barg) All 0 50 25 25 25 50 65 (4.5) rated
SM200 (8.5 barg) All 0 50 37 37 37 50 65 (4.5) rated
SM250 (8.5 barg) All 0 50 30 30 30 50 65 (4.5) rated
SM55 (8.5 barg) All 0 50 36 36 36 50 65 (4.5) rated
SM75 (8.5 barg) All 0 50 27 27 27 50 65 (4.5) rated

NOTES:
1. Parameters apply only to machines that are pressure rated up to 150 psig or 10 barg.
2. Non-IR supplied motors, and motors manufactured prior to 1996 may not be suitable for VFD use. Contact IR before applying VFD to motors of this type.
3. Some factory configured VFD compressors that are nameplated as “H” or “SM” have “L” or “SL” gear sets. These machines may be operated at 125 psig or 8.5
barg using the “L” or “SL” values listed above.
4. 200HP TEFC motors must be premium efficiency.

TABLE 5.2B SIERRA SPEED AND PRESSURE RANGES

37
5.3.7 Setting Ramp Up and Down Times 5.3.8 Preset Reference Data

Table 5-3 describes the values for parameters 207 and 215 Preset Reference 1
208. If values below these recommended settings are (PRESET REF.1)
used, the drive may trip on high DC-bus voltage or over- Value
current. If values above these recommended settings are –100.00% TO + 100.00% ★ See Formula below
used, the motor may take a longer time than necessary to of maximum frequency external reference
ramp up or down to the correct speed.

207 Ramp-up Time 1 Description

(RAMP UP TIME 1) The value for the preset reference parameter 215 is
Value found by the formula below, where the minimum and
0.05 - 3600 sec. ★ See Table 5.3 maximum pressures are set by parameters 204 and
205, respectively.

Description *desired pressure - min pressure (204)

The ramp-up time is the acceleration time from 0 Hz to value = ––––––––––––––––––––––––––––– x 100%
the rated motor frequency. To ensure proper compres- max pressure (205) - min pressure (204)
sor
operation, set the parameter value to correspond with
* Desired pressure is the VFD transducer pressure at
receiver or customer system pressure.

208 Ramp-down Time The value of this parameter is the target pressure set
(RAMP DOWM TIME 1) point in Loaded PID mode (Setup 2). (See Figure 5.3-1)
Value
For more detail on how to set compressor output
0.05 - 3600 sec. ★ See Table 5.3
pressure, please refer to Section 7.0.

Description
The ramp-down time is the acceleration time from the
rated motor frequency to 0 Hz. To ensure proper
compressor operation set the parameter value to
correspond with Table 5.3.

Transmitter
4 - 20 mA
0 - 200 psi
Parameters
314 Term 60 = Feedback
315 low mA = 4.0 mA
316 high mA = 20 mA

100 = Process closed Loop

4.0 mA Pressure Transmitter Range 20.0 mA

414 Min Fdbk = 0 psi

415 - Max Fdbk = 200 psi
200 psi
0 psi 416 - Process Units = psi (or "No Unit" if not available)
100 psi

204 - Min Ref = 60 psi

205 - Max Ref = 100 psi
Reference
60 psi 100 psi

0% - Reference 100 %

215 - Preset Ref = 50% (80 psi)

SETPOINT

FIGURE 5.3-1 PARAMETER 215 PRESET REFERENCE SETPOINT DIAGRAM

EXAMPLE: (SETUP 2) FOR PRESSURE UNITS OF “PSI”
★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

38
 TABLE 5.3 MINIMUM RAMP TIMES

Minimum Ramp Up and Down Times

(in seconds)

Parameter 15-40 UP SSR 50-200 SSR 100-200 Sierra Sierra SSR

50 PE Single Stage Two Stage 75-200 250-400 250-500
30-40 SE
Single Stage
Setup 1 (Unloaded) 207 8 8 8 8 10 10
208 5 5 5 5 6 6

Setup 2 (Loaded) 207 3 3 6 10 10 10

208 2 2 4 8 8 6

39
5.3.9 Setting Control Inputs and Outputs 300 Terminal 16, Input
(Digital Input 16)
Parameters in the 300 group refer to inputs and out- Value
puts. Parameters 300 – 307 program digital input func- [0] to [13] ★ No Operation [0]
tions. Parameters 308 and 314 correspond to analog
inputs. Parameter 323 programs a Form C relay func-
tion. Description
This parameter sets the operation of terminal 16. For
Digital Inputs compressor application, set this parameter at NO
For the compressor application, three digital inputs are OPERATION.
used:

Terminal 18 (parameter 302) START

Terminal 27 (parameter 304) COAST INVERSE
Terminal 33 (parameter 307) SETUP LSB/SPD DOWN 301 Terminal 17, Input
(Digital Input 17)
Ensure these parameters are set accordingly. All other Value
digital inputs should be set to NO OPERATION. [0] to [23] ★ No Operation [0]
Analog Inputs
In Setup 1: Description
Parameters 308 and 314 NO OPERATION This parameter sets the operation of terminal 17. For
In Setup 2: compressor application, set this parameter at NO
Parameter 308 NO OPERATION OPERATION.
Parameter 314 FEEDBACK.

Relay Outputs
Set Parameter 323 for ALARM. This will warn the
Intellisys controller of a drive fault and shut down the 302 Terminal 18, Start Input
compressor. (Digital Input 18)
Value
[0] to [3] ★ Start [1]

Description
This parameter sets the operation of terminal 18. For
compressor application, set this parameter at START.

303 Terminal 19, Input

(Digital Input 19)
Value
[0] to [3] ★ No Operation [0]

Description
This parameter sets the operation of terminal 19. For
compressor application, set this parameter at NO
OPERATION.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

40
304 Terminal 27, Input 308 Terminal 53, Analog input voltage
(Digital Input 27) (AI [V] 53 FUNCT.)
Value Value
[0] to [4] ★ Coast Inverse [0] ★No operation (NO OPERATION)
Reference (REFERENCE)
Feedback signal (FEEDBACK)
Description Torque limit (TORQUE LIMIT CTRL)
This parameter sets the operation of terminal 27. For Thermistor (THERMISTOR INPUT)
compressor application, set this parameter at COAST Relative reference (RELATIVE REFERENCE)
INVERSE to allow the compressor to send a start signal Max. torque frequency (MAX. TORQUE FREQ.)
to the VFD.
Description
This terminal activates the analog voltage input, terminal
53. For compressor application, this parameter should
305 Terminal 29, Input be set to NO OPERATION.
(Digital Input 29)
Value
[0] to [28] ★ No Operation [0]

314 Terminal 60, Analog Input Current

Description (AI [mA] 60 FUNCT.)
This parameter sets the operation of terminal 29. For Value
compressor application, set this parameter at NO See parameter 308 ★ No Operation (Setup 1)
OPERATION. ★ Feedback (Setup 2)

Description
This terminal activates the analog current input, terminal
60.
306 Terminal 32, Input
(Digital Input 32) For Setup 1, this parameter needs to be set to NO
Value OPERATION.
[0] to [24] ★ No Operation [0]
For setup 2, this parameter needs to be set to
FEEDBACK to enable the 4-20 mA transducer to
Description provide a signal to the VFD.
This parameter sets the operation of terminal 32. For
compressor application, set this parameter at NO
OPERATION.
315 Terminal 60, Min. Scaling
(AI 60 LOW)
Value
307 Terminal 33, Input 4.0 - 20.mA ★ 4.0 mA
(Digital Input 33)
Value
[0] to [25] ★ Setup LSB/Speed Down [11] Description
This parameter sets the value of the reference signal
that is to correspond to the minimum reference value
Description set in parameter 204. The pressure transducer used
This parameter sets the operation of terminal 33. For with the compressor ranges from 4 to 20 mA. This para-
compressor application, set this parameter at SETUP meter
LSB/SPEED DOWN to allow the compressor to switch needs to be set to 4 mA.
the VFD between the unloaded constant speed mode
and the loaded PID constant pressure mode.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

41
316 Terminal 60, Max. Scaling 5.3.10 Setting Feedback
(AI 60 HIGH)
Value 414 Minimum Feedback
4.0 - 20.0 mA ★ 20.0 mA (MIN. FEEDBACK)
Value
-100,000.000 to Feedback High ★ Min. feedback
Description
This parameter sets the value of the reference signal
that is to correspond to the maximum reference value Description
set in parameter 205. This parameter needs to be set to This parameter determines the minimum feedback of
20 mA. the VFD’s pressure transducer. For the pressure trans-
ducer supplied, set this parameter value to 0.

Pressure units selected in setting parameter 414 must

323 Relay 01, Output
be consistent with those used in parameters 204, 205,
(RELAY 1-3 FUNCT.) 415, and 416.
Value
[0] to [33] ★ Fault (ALARM) [9]

Description 415 Maximum Feedback

For compressor application, set parameter value to (MAX. FEEDBACK)
ALARM. Value
Feedback Low to - 100,000.000
★Depends on pressure transducer
409 Trip delay Torque
(TRIP DELAY TORQ.) Description
Value This parameter determines the maximum feedback of
0-60 sec. (OFF) ★ OFF the VFD’s pressure transducer. For example, a
transducer that produces a 4-20 mA signal on a range
of 0-200 psig, the maximum feedback should be set to
Description 200. Likewise, if the transducer range is 0-13.8 barg,
Select how long the VFD is to be able to run at the parameter 415 should be set to 13.8, corresponding
torque limit before cutting out. 60 sec. = OFF means with the top of the range.
that the time is infinite; however the thremal VFD moni-
toring will still be active. Pressure units selected in setting parameter 415 must
be consistent with those used in parameters 204, 205,
414 and 416.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

42
416 Process Unit 440 Process PID Proportional Gain
(PROCESS UNIT) (PROC. PROP. GAIN)
Value Value
★NO UNIT [0] t/min [21] 0.00 - 10.00 ★ 3.00 sec.
% [1] t/h [22]
PPM [2] m [23]
RPM [3] Nm [24] Description
bar [4] m/s [25] For compressor operation, set this parameter value at
CYCLE/min [5] m/min [26] 3.00.
PULSE/s [6] °F [27]
UNITS/s [7] in wg [28]
UNITS/min [8] gal/s [29]
UNITS/h [9] ft 3 /s [30]
°C [10] gal/min [31]
Pa [11] ft 3 /min [32] 441 Process PID Integral Time
l/s [12] gal/h [33] (PROC. INTEGR.T.)
m3/s [13] ft 3 /h [34] Value
l/min [14] lb/s [35] 0.01 - 9999.99 sec. (OFF) ★ 1.0 sec.
m3/min [15] lb/min [36]
l/h [16] lb/h [37]
m3/h [17] lb ft [38] Description
kg/s [18] ft/s [39] For compressor operation, the starting value of this
kg/min [19] ft/min [40] parameter should be set at 1.00 sec. If instability
kg/h [20] occurs, this value may be lowered by decrements of 0.1
sec. or less until system stability is achieved.
Description
This parameter sets the units of measure for the
feedback pressure display. Pressure units selected in 442 Process PID Differentiation Time
setting parameter 416 must be consistent with those
(PROC. DIFF.TIME)
used in parameters 204, 205, 414 and 415. The units of
“psi” may not be available, so parameter 416 should be Value
set to NO UNIT. 0.00 (OFF) - 10.00 sec. ★ 0.01 sec.

5.3.11 Setting Process PID Loop Description

For compressor operation, set this parameter value at
The system’s performance is highly sensitive to 0.01 sec.
parameters 440, 441, and 442. However, if the drive
seems to be taking a long time to settle into the desired
pressure with the recommended settings, the Integral
time (parameter 441) may need to be lowered by 455 Monitor Frequency Range
decrements of 0.1 sec or less. This may be required for (OUT FREQ RNG/ROT LIM)
systems with large receiver tanks. The proportional gain
Value
and differentiation time (parameters 441 and 442)
Enable/Disable ★ Disable
should NOT be adjusted.

The 400 series parameters do not apply to steup 1.

Description
This parameter disables the Warning 35 function. For
For additional information on setting the process PID,
proper compressor operation, set this parameter value
please refer to Section 8.0.
to DISABLE.

★= proper parameter value, ( ) = display text, [ ] = data value for use in communication via serial communication port

43
5.4 Startup Checklist
The following is a list of questions that should be
answered before starting the compressor for the first
time. The section of this manual that gives instructions
for the appropriate procedure is also listed. Table 9.2 in
Section 9, Troubleshooting, lists some faults and
remedies.
Environment:
Are clearances allowed for and installation
suitable for proper ventilation?
(Section 3.1.2)
Has the drive been installed with the back
covered for proper cooling?
(Section 3.1.3)
Drive Connections:
Are fast blow semiconductor fuses installed?
(Section 3.2.4)
Inspect and tighten drive input, output, and
control connections?
(Terminal and Switch Location Drawings in
Section 10.0)
Ensure proper earth ground?
Are the relays wired properly?
(Section 3.2.3)
Are the motor leads connected properly?
(Section 3.2.8)
If fused disconnect option is used, have all
connections been tightened and inspected?
(Section 3.2.3)
44
Drive and Compressor Operation:
Are all the correct parameters loaded into the
drive?
(Section 5.3)
Were the motor and package amp parameters
loaded in the correct sequence?
(Section 5.3.5; Parameters 102-109)
Is the compressor Intellisys in on/off line control?
(Section 5.1)
Have proper minimum and maximum speed
points been set?
(Section 5.3.6; Parameters 201, 202)
Have proper minimum and maximum pressure
set points been set?
(Section 5.3.6; Parameters 204, 205)
Have proper ramp up and ramp down times
been set?
(Section 5.3.7; Parameters 207, 208)
Running Conditions:
Is the nominal voltage within the range of the
specific drive ±10%? (Section 5.3.5)
Are all equipment, personnel, and/or
obstructions clear from the equipment?
(Sections 0.1, 0.2, and 0.3)
Is the rotation of the main motor correct?
(Installation Section of Compressor Operation
Manual)
For Sierra units, is the rotation of the oil pump
motor correct?
(Section 3.4.1)
For Sierra units, has the oil pump been primed?
(Section 3.4.1)
6.0 AUTOMATIC MOTOR 3) Alarms will be shown on the display if a problem is
spotted during auto-tuning.
ADAPTATION (AMA)
4) If automatic motor adaptation is to be discontinued,
In some cases, the efficiency of the motor may be slight- push the [STOP/RESET] key.
ly increased by allowing the VFD to tune itself to the
motor’s characteristics. The fan motor leads on an air-
cooled compressor must be removed from the VFD For Automatic Motor Adaption Procedure refer to Section
power block before this procedure can be performed to 3.5.
ensure that only the main motor’s characteristics are
considered.

Automatic motor adaptation is a test algorithm that mea-

sures the electrical motor parameters at motor standstill.
This means that AMA itself does not supply any torque
to the motor.

AMA is useful when commissioning compressor sys-

tems, where the user wants to optimize the adjustment
of the I-R 5000 variable frequency drive to the main
motor applied. This feature is used in particular where
the factory setting does not adequately cover the motor
in question.

There are two motor characteristics that are of primary

significance in automatic motor adaptation:

1) Stator resistance, Rs
2) Reactance at normal magnetizing level, Xs

For the best adjustment of the I-R 5000 variable

frequency drive, it is recommended to carry out AMA on
a cold motor.

It must be noted that repeated running of the AMA may

lead to motor heating that will result in an increase of the
stator resistance Rs.

Parameter 107 allows a choice of automatic motor

adaptation with determination of both Xs and Rs or with
Rs only.

The following must be noted when using the AMA

function:

1) If correct nameplate data for the main motor con-

nect to the variable frequency drive has not been
entered, AMA will not be able to optimally determine
the motor characteristics.

2) Total automatic motor adaptation may take from a

few minutes up to approximately 15 minutes, depend-
ing on the power rating of the motor.

45
7.0 MODIFYING COMPRESSOR
OUTPUT PRESSURE
The VFD allows a compressor to provide a constant
pressure by varying airend speed. This desired pressure
can be set at any time by following the method below.
Any unit of measure for pressure is possible, provided
that all relevant parameters are consistent. Parameters
315, 316, 414 and 415 determine the scale of the trans-
ducer. For example, a 4-20 mA transducer can have a
range of 0-200 psig or 0-13.8 barg. If parameters 414
and 415 are set up for metric units, parameters 204 and
205 must also reflect those units.

1. Set parameter 010 to show the target pressure set

point (Reference [unit]) on the display line 1.1.
8.0 MODIFYING PROCESS PID
2. In Setup 2, set parameter 204 to the minimum pres-
sure allowed for the compressor, 65 psig (4.5 barg).
LOOP
The VFD maintains constant pressure by a process
3. In Setup 2, set parameter 205 to the maximum pres-
feedback loop that uses the system’s output pressure as
sure allowed for the compressor, which is the compres-
an input. The PID loop consists of three components: a
sor’s rated pressure.
proportional gain, integral time, and differentiation time.
The three components are interdependent and affect the
4. Set parameter 315 to the minimum current that the
speed, stability, and error of the drive's response to the
transducer will produce. For the supplied transducer, this
system. Parameters 440, 441, and 442 set the
is 4 mA.
proportional gain, integral time, and differentiation time,
respectively.
5. Set parameter 316 to the maximum current that the
transducer will produce. For the supplied transducer, this
Parameter 440, Proportional Gain, should be set to 3.00
is 20 mA.
and parameter 442, Differentiation Time, should be set
to 0.01 sec. The value of 1.00 sec is generally the best
6. Set parameter 414 to the minimum pressure that the
choice for parameter 441, Integral Time. However, on
pressure transducer is capable of reading. For the sup-
some systems with large receiver tanks, parameter 441
plied transducer, this is 0 psig / 0 barg.
may need to be slightly decreased (by decrements of 0.1
sec or less) if the compressor excessively speeds up
7. Set parameter 415 to the maximum pressure that the
and down trying to find the target pressure on startup.
pressure transducer is capable of reading. For the sup-
plied transducer, this is 200 psig / 13.8 barg.
If the compressor’s speed seems to be fluctuating even
after parameter 441 has been lowered, the transducer
8. Set parameter 416 to the desired unit of measure for
signal may be affected by electrical noise. If electrical
the pressure transducer. If the desired unit is not avail-
noise is a problem and cannot be removed, parameter
able, NO UNIT should be selected.
444 is available to filter out the noise. A reasonable
value
9. In Setup 2 enter the target pressure setpoint
for parameter 444 is 0.25 sec, but other values may be
into parameter 215 by the following formula:
just as suitable.
*desired pressure - min pressure (204)
value = ————————————————————x 100%
max pressure (205) - min pressure (204)

*Desired pressure is the VFD transducer pressure at

receiver or customer system pressure.

The minimum and maximum pressures are set by para-

meters 204 and 205, respectively, in steps 2 and 3
above.

10. Change the Intellisys on-line / off-line pressure point

so that the target pressure is within the pressure band.
Allow as much as 3 to 5 psi of overshoot in the off-line
pressure point. Additionally, set the off-line pressure
point high enough to allow for the pressure drop in the
system between the Intellisys and the drive transducers.

46
 TABLE 9.1 WARNINGS AND ALARMS

No. Description Warning Alarm Trip locked

1 10 volts low (10 VOLT LOW) X

2 Live zero fault (LIVE ZERO ERROR) X X
3 No motor (NO MOTOR) X
4 Phase fault (MAINS PHASE LOSS) X X X
5 Voltage warning high (DC LINK VOLTAGE HIGH) X
6 Voltage warning low (DC LINK VOLTAGE LOW) X
7 Overvoltage (DC LINK OVERVOLT) X X
8 Undervoltage (DC LINK UNDERVOLT) X X
9 Inverter overloaded (INVERTER TIME) X X
10 Motor overloaded (MOTOR TIME) X X
11 Motor thermistor (MOTOR THERMISTOR) X X
12 Torque limit (TORQUE LIMIT) X X
13 Overcurrent (OVERCURRENT) X X
14 Ground fault (EARTH FAULT) X X
15 Switch mode fault (SWITCH MODE FAULT) X X
16 Short-circuit (CURR.SHORT CIRCUIT) X X
17 Standard bus timeout (STD BUS TIMEOUT) X X
18 HPFB bus timeout (HPFB TIMEOUT) X X
19 Fault in EEPROM on power card (EE ERROR POWER CARD) X
20 Fault in EEPROM on control card (EE ERROR CTRL.CRD) X
21 Auto-optimization OK (AUTO MOTOR ADAPT OK) X
22 Auto-optimization not OK (AUTO MOT ADAPT FAIL) X
23 Brake test failed (BRAKE TEST FAILED) X
25 Brake resistor short-circuited (BRAKE RESISTOR FAULT ) X
26 Brake resistor power 100% (BRAKE POWER 100%) X X
27 Brake transistor short-circuited (BRAKE IGBT FAULT ) X
29 Heat-sink temperature too high (HEAT SINK OVER TEMP.) X X
30 Motor phase U missing (MISSING MOT.PHASE U) X
31 Motor phase V missing (MISSING MOT.PHASE V) X
32 Motor phase W missing (MISSING MOT.PHASE W) X
33 Quick discharge not OK (QUICK DISCHARGE FAIL) X X
34 Profibus communication fault (PROFIBUS COMM. FAULT) X X
35 Out of frequency range (OUT FREQ RNG/ROT LIM) X
36 Mains failure (MAINS FAILURE) X X
37 Inverter fault (INVERTER FAULT) X X
39 Check parameters 104 and 106 (CHECK P.104 & P.106) X
40 Check parameters 103 and 105 (CHECK P.103 & P.105) X
41 Motor too big (MOTOR TOO BIG) X
42 Motor too small (MOTOR TOO SMALL) X
43 Brake fault (BRAKE FAULT) X X
44 Encoder loss (ENCODER FAULT) X X

47
 TABLE 9.1 WARNINGS AND ALARMS

No. Description Warning Alarm Trip locked

1 10 volts low (10 VOLT LOW) X

2 Live zero fault (LIVE ZERO ERROR) X X
3 No motor (NO MOTOR) X
4 Phase fault (MAINS PHASE LOSS) X X X
5 Voltage warning high (DC LINK VOLTAGE HIGH) X
6 Voltage warning low (DC LINK VOLTAGE LOW) X
7 Overvoltage (DC LINK OVERVOLT) X X
8 Undervoltage (DC LINK UNDERVOLT) X X
9 Inverter overloaded (INVERTER TIME) X X
10 Motor overloaded (MOTOR TIME) X X
11 Motor thermistor (MOTOR THERMISTOR) X X
12 Torque limit (TORQUE LIMIT) X X
13 Overcurrent (OVERCURRENT) X X
14 Ground fault (EARTH FAULT) X X
15 Switch mode fault (SWITCH MODE FAULT) X X
16 Short-circuit (CURR.SHORT CIRCUIT) X X
17 Standard bus timeout (STD BUS TIMEOUT) X X
18 HPFB bus timeout (HPFB TIMEOUT) X X
19 Fault in EEPROM on power card (EE ERROR POWER CARD) X
20 Fault in EEPROM on control card (EE ERROR CTRL.CRD) X
21 Auto-optimization OK (AUTO MOTOR ADAPT OK) X
22 Auto-optimization not OK (AUTO MOT ADAPT FAIL) X
23 Brake test failed (BRAKE TEST FAILED) X
25 Brake resistor short-circuited (BRAKE RESISTOR FAULT ) X
26 Brake resistor power 100% (BRAKE POWER 100%) X X
27 Brake transistor short-circuited (BRAKE IGBT FAULT ) X
29 Heat-sink temperature too high (HEAT SINK OVER TEMP.) X X
30 Motor phase U missing (MISSING MOT.PHASE U) X
31 Motor phase V missing (MISSING MOT.PHASE V) X
32 Motor phase W missing (MISSING MOT.PHASE W) X
33 Quick discharge not OK (QUICK DISCHARGE FAIL) X X
34 Profibus communication fault (PROFIBUS COMM. FAULT) X X
35 Out of frequency range (OUT FREQ RNG/ROT LIM) X
36 Mains failure (MAINS FAILURE) X X
37 Inverter fault (INVERTER FAULT) X X
39 Check parameters 104 and 106 (CHECK P.104 & P.106) X
40 Check parameters 103 and 105 (CHECK P.103 & P.105) X
41 Motor too big (MOTOR TOO BIG) X
42 Motor too small (MOTOR TOO SMALL) X
43 Brake fault (BRAKE FAULT) X X
44 Encoder loss (ENCODER FAULT) X X

47
WARNING/ALARM 11
Motor Thermistor (MOTOR THERMISTOR)
The thermistor or the thermistor connection has been
disconnected. Parameter 128, Motor Thermal Protection,
allows a choice of whether the VFD is to give a warning
or an alarm. Check that the thermistor has been correct-
ly connected between terminal 53 or 54 (analog voltage
input) and terminal 50 (+10 V supply).
WARNING/ALARM 12
Torque Limit (TORQUE LIMIT
The torque is higher than the value in parameter 221,
Torque Limit for Motor Mode, in motor operation, or the
torque is higher than the value in parameter 222, Torque
Limit for Generating Operation, in regenerative mode.
WARNING/ALARM 13
Overcurrent (OVER CURRENT)
The inverter peak current limit, approximately 200% of
the rated current, has been exceeded. The warning will
last approximately 1 or 2 seconds, and then the VFD will
trip and signal an alarm. This can be caused if parame-
ter 201 in setup 1 is not set for 0.
Remove power to the VFD and check for free rotation of
the motor shaft and other causes of the overload.
Ensure
that VFD and motor sizes match.
ALARM 14
Ground Fault (EARTH FAULT)
There is current leakage from the output phases to
ground, either in the leads between the VFD and the
motor or in the motor itself.
Remove power to the VFD and correct the ground fault.
ALARM 15
Switch Mode Fault (SWITCH MODE FAULT)
Fault in the switch mode power supply (internal ±15 V
supply). Contact your local I-R distributor or air center.
ALARM 16
Short Circuit (CURR. SHORT CIRCUIT)
There is a short circuit in the output from the VFD or in
the motor.
Remove power to the VFD and correct the short circuit.
WARNING/ALARM 17
Serial Communication Timeout (STD BUS TIMEOUT)
There is no serial communication with the VFD.
This warning will only be enabled if parameter 514, Bus
Time Interval Function, has been set to a value other
than OFF.
If parameter 514 has been set to Stop and Trip [5], the
VFID will first give a warning, ramp down, and finally trip
while giving an alarm. The interval is set in parameter
513, Bus Time Interval.
WARNING/ALARM 18
Serial Bus Timeout (HPFB BUS TIMEOUT)
There is no serial communication with the VFD.
The warning will only be enabled if parameter 804, Bus
Time Interval Function, has been set to a value other
than OFF. If parameter 804 has been set to Stop and
Trip [5], the drive will first give a warning, ramp down,
and finally trip while giving an alarm. The interval is set
in parameter 803, Bus Time Interval. Parameter 803 is
only available when a communication option card is
installed in the drive.
WARNING 19
Fault on the Power Card (EE ERROR POWER)
There is a fault on the power card EEPROM. The VFD
will continue to function, but is likely to fail at the next
power up. Contact your local I-R distributor or air center.
WARNING 20
Fault on the Control Card (EE ERROR CONTROL)
There is a fault in the control card EEPROM. The VFD
will continue to function, but is likely to fail at the next
power up. Contact your local I-R distributor or air center.
ALARM: 21
AMA OK (AUTO MOTOR ADAPT OK)
Automatic Motor Adaptation (AMA) has completed suc-
cessfully and the VFD is ready for operation.
ALARM 22
Automatic Motor Adaptation Failed (AMA FAULT)
A fault has been found during Automatic Motor
Adaptation (AMA). The text shown in the display indi-
cates a fault message. AMA will only function with no
alarms active.
CHECK 103,105
Parameter 103 or 105 has a wrong setting. Correct the
setting and repeat AMA.
LOW P 105
The motor is too small for AMA to be carried out. If AMA
is to be enabled, the rated motor current, parameter 105,
must be higher than 35% of the rated output current of
the VFD.
ASYMMETRICAL IMPEDANCE
AMA has detected an asymmetrical impedance in the
motor connected to the system. The motor could be
defective.
MOTOR TOO BIG
The motor connected to the system is too big for AMA to
be carried out. The setting in parameter 102 does not
match the motor used.
MOTOR TOO SMALL
The motor connected to the system is too small for AMA
to be carried out. The setting in parameter 102 does not
match the motor used.
49
TIME OUT
AMA failed because of noisy measuring signals. Retry
until AMA is successfully completed. Please note that
repeated AMA runs may heat the motor to a level where
the stator resistance is increased.
INTERRUPTED BY USER
AMA has been interrupted by the user.
INTERNAL FAULT
An internal fault has occurred in the VFD. Contact your
local I-R distributor or air center.
LIMIT VALUE FAULT
The parameter values found for the motor are outside
the acceptable range within which the VFD is able to
work.
MOTOR ROTATES
The motor shaft is rotating. Make sure that the load is
not able to make the motor shaft rotate while the AMA is
being performed. Then start AMA over again.
ALARM 29
Heat Sink Temperature Too High (HEAT SINK OVER
TEMP.):
The heat sink temperature is too high. For NEMA 1
VFDs, the limit is 194°F (90°C). For NEMA 12 VFDs, the
limit is 176°F (80°C). The tolerance is ±9°F (±5°C). The
fault cannot be reset until the temperature of the heat
sink has fallen below 140°F (60°C).
The fault could be due to the following:
- Ambient temperature too high
- Air obstructed
- Cooling fan(s) not operating
- Motor leads too long
- Switching frequency too high
ALARM 30
Motor Phase U Missing (MISSING MOT.PHASE U):
Motor phase U, as indicated by the letters on the output
terminal block, is missing or has a high impedance.
Remove power to the VFD and check motor phase U.
ALARM 31 Motor Phase V Missing (MISSING
MOT.PHASE V):
Motor phase V, as indicated by the letters on the output
terminal block, is missing or has a high impedance.
Remove power to the VFD and check motor phase V.
ALARM 32 Motor Phase W Missing (MISSING
MOT.PHASE W):
Motor phase W, as indicated by the letters on the output
terminal block, is missing or has a high impedance.
Remove power to the VFD and check motor phase W.
ALARM: 33 Quick Discharge Error (QUICK DIS-
CHARGE NOT OK):
Check whether 24 Volts external DC supply has been
connected.
50
WARNING:35
Out of Frequency Range (OUT OF FREQ. RANGE):
This warning is active if the output frequency has
reached its low limit (parameter 201) or high limit (para-
meter 202). If the VFD is in closed loop process regula-
tion, the warning will be active in the display. If the VFD
is in a mode other than closed loop process regulation, a
serial bus output (warning word 2) will be active, with no
warning in the display.
WARNINGIALARM: 36
AC Power Failure (MAINS FAILURE):
The supply voltage to the VFD has been lost and
parameter 407, Mains fault, has been set to a value
other than OFF.
If parameter 407 has been set to Contr. ramp-down trip
[2], the VFD will first give a warning and then ramp down
and trip, while giving an alarm. Check the fuses to the
VFD.
ALARM 37
Inverter Fault (GATE DRIVE FAULT):
A VFD output IGBT or the power card is defective.
Contact your local I-R distributor or air center.
WARNING 39
Check Parameters 104 and 106
(CHECK PAR. 104,106)
AMA has stopped. Parameter 104, Motor Frequency, or
106, Rated Motor Speed, has probably been set wrong.
Correct the setting and run AMA again.
WARNING 40
Check Parameters 103 and 105
(CHECK PAR. 103,105)
Parameter 103, Motor Voltage, or 105, Motor Current,
has probably been set wrong. Correct the setting and
run AMA again.
WARNING 41
Motor Too Large (MOTOR TOO BIG)
The motor is probably too large for AMA. The setting in
parameter 102 Motor Power, may not match the motor.
Check the motor size and select ‘Continue’ or press the
STOP key to exit.
WARNING 42
Motor Too Small (MOTOR TOO SMALL)
The motor is probably too small for AMA. The setting in
parameter 102 Motor Power, may not match the motor.
Check the motor and select ‘Continue’ or press the
STOP key to exit.
WARNING/ALARM: 44
Encoder loss (ENCODER FAULT)
The encoder signal is interrupted from terminal 32 or 33.
Check the connections or health of encoder device.
9.2 Compressor Warnings and Alarms 9.3 Troubleshooting Faults and Remedies

If the VFD shuts down on an alarm condition, the com- Table 9.2 lists some faults and remedies.
pressor will shutdown on a “Control Power Loss” alarm
or a “No Control Power” alarm. Please refer to the com-
pressor’s Operation Manual for other warnings and
alarms that the compressor may develop.

Problem Solution Reference

VFD trips on Alarm 13 (Overcurrent) Confirm all motor parameters in Section 5.3.5 and
on Start Group 1 are set correctly. If problem Section 5.3.7
persists, increase ramp up time,
parameter 207, in Setup 1

Compressor oscillates above and Decrease integral time, parameter Appendix C

below target pressure 441

Compressor oscillates above and Increase PID low-pass filter time, Appendix C
below target pressure due to parameter 444
transducer noise

Compressor does not generate proper Contact service representative N/A

sump pressure while unloading and
fails to Low Sump Pressure Alarm

SSR: Compressor fails on Check Inlet Change Intellisys controller settings Section 5.1
Control Alarm on start with SG
Intellisys controller

SSR: VFD trips on Alarm 13 Airend is in hydro-lock. Manually turn N/A

(Overcurrent) on Start after airend. Use Emergency Stop button
Emergency Stop button was pressed ONLY for emergencies

51
10.0 REFERENCE DRAWINGS

FIGURE 10.1. OVERALL DIMENSIONS AND WEIGHTS

 FIGURE 10.2 CONTROL RELAYS WIRING
53
54
22563498
REV A

WIRING SCHEMATIC UP6-20 TO UP6-30

STAR DELTA, NON-INTELLISYS
 22345490
REV A

WIRING SCHEMATIC UP6-20 TO UP6-30

FULL VOLTAGE, INTELLISYS
55
56
22398093
REV A

WIRING SCHEMATIC UP6-20 TO UP6-30

STAR DELTA, INTELLISYS
 22430466
REV A

WIRING SCHEMATIC UP6-20 TO UP6-30

FULL VOLTAGE, NON-INTELLISYS
57
58
22560239
REV A

WIRING SCHEMATIC UP6-40 TO 50-PE

FULL VOLTAGE, INTELLISYS
 22560247
REV A

WIRING SCHEMATIC UP6-40 TO 50-PE

FULL VOLTAGE, NON-INTELLISYS
59
60
22560254
REV A

WIRING SCHEMATIC UP6-40 TO 50-PE

STAR DELTA, NON-INTELLISYS
 22560262
REV A

WIRING SCHEMATIC UP6-40 TO 50-PE

STAR DELTA, INTELLISYS
61
62
54592076
REV D

WIRING SCHEMATIC FOR SSR 50E-100 HP (37-75KW)

FULL VOLTAGE, AIRCOOLED
 54592084
REV D

WIRING SCHEMATIC FOR SSR 50E-100 HP (37-75KW)

STAR DELTA, AIRCOOLED
63
64
54615117
REV D

WIRING SCHEMATIC FOR SSR 50E-100 HP (37-75KW)

FULL VOLTAGE, WATERCOOLED
 54615141
REV D

WIRING SCHEMATIC FOR SSR 50E-100 HP (37-75KW)

STAR DELTA, WATERCOOLED
65
66
54600333
REV C

WIRING SCHEMATIC FOR SSR 100-500 HP (75-450KW)

STAR DELTA, AIRCOOLED (1 OF 2)
 54600333
REV C

WIRING SCHEMATIC FOR SSR 100-500 HP (75-450KW)

STAR DELTA, AIRCOOLED (2 OF 2)
67
68
54622451
REV C

WIRING SCHEMATIC FOR SSR 100-500 HP (75-450KW)

STAR DELTA, WATERCOOLED (1 OF 2)
 54622451
REV C

WIRING SCHEMATIC FOR SSR 100-500 HP (75-450KW)

STAR DELTA, WATERCOOLED (2 OF 2)
69
70
54612338
REV C

WIRING SCHEMATIC FOR SIERRA 100 HP (75KW)

STAR DELTA, AIRCOOLED (1 OF 2)
 54612338
REV C

WIRING SCHEMATIC FOR SIERRA 100 HP (75KW)

STAR DELTA, AIRCOOLED (2 OF 2)
71
72
54616032
REV C

WIRING SCHEMATIC FOR SIERRA 100 HP (75KW)

STAR DELTA, WATERCOOLED (1 OF 2)
 54616032
REV C

WIRING SCHEMATIC FOR SIERRA 100 HP (75KW)

STAR DELTA, WATERCOOLED (2 OF 2)
73
74
54629894
REV D

WIRING SCHEMATIC FOR SIERRA 200 HP (150KW) & 350 HP (300 KW)
STAR DELTA,AIRCOOLED (1 OF 2)
 54629894
REV D

WIRING SCHEMATIC FOR SIERRA 200 HP (150KW) & 350 HP (300 KW)
STAR DELTA,AIRCOOLED (2 OF 2)
75
76
54630686
REV C

WIRING SCHEMATIC FOR SIERRA 200 HP (150KW) & 350 HP (300 KW)
STAR DELTA, WATERCOOLED (1 OF 2)
 54630686
REV C

WIRING SCHEMATIC FOR SIERRA 200 HP (150KW) & 350 HP (300 KW)
STAR DELTA, WATERCOOLED (2 OF 2)
77
78
54576137
REV B

STARTER ASSEMBLY FOR SSR 50SE-100 HP (37-75 KW)

AND SIERRA 100 HP
 54576152
REV A

STARTER ASSEMBLY FOR SIERRA 75 KW

79
80
54576160
REV A

STARTER ASSEMBLY FOR SSR 100-500 HP (75-370 KW)

AND SIERRA 200 HP
 54576178
REV A

STARTER ASSEMBLY FOR SIERRA 150 KW

81
82
22083968
REV A

REF PART
NO NO. QTY. DESCRIPTION

1 39252903 5 BLOCK, TERMINAL-MOUNT

ON DIN RAIL
2 39252929 1 BARRIER, END-MOUNT ON RAIL
3 39252937 1 ANCHOR, END-MOUNT ON DIN RAIL
4 39251236 1 STARTER, MANUAL MOTOR-
MOUNT ON DIN RAIL
5 54579909 3 SOCKET, RELAY-DIN RAIL MOUNTED
6 39403290 3 RELAY, CONTROL
7 39136486 1 BLOCK, POWER TERMINAL-
MOUNT IN BOTTOM OF BOX
7A 35352279 6 SCREW

STARTER ASSEMBLY FOR SIERRA 250-400 HP

 22083976
REV A

REF PART
NO NO. QTY. DESCRIPTION

1 39252903 5 BLOCK, TERMINAL-MOUNT

ON DIN RAIL
2 39252929 1 BARRIER, END-MOUNT ON RAIL
3 39252937 1 ANCHOR, END-MOUNT ON DIN RAIL
4 54579909 3 SOCKET, RELAY-DIN RAIL MOUNTED
5 39403290 3 RELAY, CONTROL
6 39136486 1 BLOCK, POWER TERMINAL-
MOUNT IN BOTTOM OF BOX
6A 35352279 6 SCREW

STARTER ASSEMBLY FOR SIERRA 200-300 KW

83
84
54761655
REV C

OIL PUMP ASSEMBLY FOR SIERRA 100 HP (75 KW)

 54761663
REV D

OIL PUMP ASSEMBLY FOR SIERRA 200 HP (150 KW)

85
86
22064869
REV A

REF
NO PART NO. QTY. DESCRIPTION

1 22064331 1 GASKET, SUMP SUCTION

2 22063580 1 PLATE, SUMP SUCTION
3 54756184 1 CONNECTOR
4 54755665 1 TUBE, SUMP SUCTION
5 95946034 1 ELBOW
6 39573001 1 HOSE, 1.50 X 30.00 LONG
7 39573175 1 HOSE, 1 .00 X 50.00 LONG
8 22056253 1 ASSEMBLY, OIL PUMP 2.0 HP
230/460V 60 HZ
22063283 1 ASSEMBLY, OIL PUMP 2.0 HP
380V 60 HZ
22063291 1 ASSEMBLY, OIL PUMP 2.0 HP
400V 60 HZ
8A 95934626 4 SCREW
8B 95245288 4 NUT
9 22062004 1 SUPPORT, PUMP ASSEMBLY
9A 39178678 5 SCREW
10 22079669 1 COVER, OIL PUMP VFD
11 22080816 1 ORIFICE
12 22080790 1 TEE
13 39572649 1 HOSE, .38 X 46.0 LONG

FIGURE 10.21 OIL PUMP ASSEMBLY FOR SIERRA 250-400 HP (150-300 KW)
 DRIVE ENCLOSURE

DISCONNECT ENCLOSURE

Drive Terminal and Switch Locations

Exterior

FUSE TERMINAL BLOCK

DISCONNECT

L1, L2, L3
LINE INPUT

Fuse Disconnect
FIGURE 10.22
FIGURE 10.22 I-R 5016-5027,200-240V,
I-R 5016-5027, 200-240V
I-R ,5016-5052,
I-R 5016-5052, 380-460V
380-460V
NEMA 1 AND NEMA
NEMA 1 AND NEMA 12 12

87
 DRIVE ENCLOSURE

DISCONNECT ENCLOSURE

Drive Terminal and Switch Locations

Exterior

FUSE TERMINAL BLOCK

DISCONNECT

INPUT
L1 L2 L3

GND
L1, L2, L3
LINE INPUT

FIGURE 10.23 I-R 5032-5052, 200 TO 240V, NEMA 1

FIGURE 10.23 I-R 5032-5052, 200 to 240 V, NEMA 1

88
DRIVE ENCLOSURE

DISCONNECT ENCLOSURE

Exterior
88

Drive Terminal and Switch Locations

L1, L2, L3
LINE INPUT

INPUT
GND
L1 L2 L3

DISCONNECT

FUSE TERMINAL BLOCK

Fuse Disconnect

FIGURE
FIGURE 10.2410.24
I-RI-R 5032, 200 TO
5032-5052, 240V,
200 NEMA
to 240 V, 12
NEMA 12

89
 DRIVE ENCLOSURE

DISCONNECT ENCLOSURE

Drive Terminal and Switch Locations

Exterior

FUSE TERMINAL BLOCK

DISCONNECT

L1, L2, L3
LINE INPUT

Fuse Disconnect
FIGURE FIGURE
10.25 10.25
I-R 5062, 380 380-460V,
I-R 5062, to 460 V,NEMA
NEM A 1 AND
1 AND NEMA
NEMA 12 12

90
 DRIVE ENCLOSURE

DISCONNECT ENCLOSURE

Drive Terminal and Switch Locations

Exterior
FUSE TERMINAL BLOCK

DISCONNECT

L1, L2, L3
LINE INPUT

Fuse Disconnect
FIGURE 10.26I-R I-R
FIGURE 10.26 5072-5102,
5072-5102, 380
380 TO to 460
460V, V, 1NEMA
NEMA 1 AND
AND NEMA 12 NEMA 12

91
 FUSES

DISCONNECT

FIGURE 10.27 I-R 5122-5302, 380 TO 460V, NEMA 1 AND NEMA 12

FIGURE 10.27 I-R 5122-5302, 380 to 460 V, NEMA 1 AND NEM A 12

92
 FIGURE
FIGURE 10.28
10.28 I-RI-R5350-5500,
5350-5500, 380
380TO
to 460V,
460 V,NEMA
NEMA1 AND NEMA
1 AND 12
NEMA 12

93