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INDUSTRIAL AIR

COMPRESSOR
REMOTE
VARIABLE
SPEED DRIVE

INSTALLATION
MANUAL

KEEP FOR
FUTURE
REFERENCE
Part Number
02250152-374
©Sullair Corporation
AIR CARE
SEMINAR TRAINING

Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, mainte-
nance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor
electrical systems are presented at regular intervals throughout the year at a dedicated training facility at
Sullair’s corporate headquarters in Michigan City, Indiana.

Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of
the most common problems, and actual equipment operation. The seminars are recommended for main-
tenance and service personnel.

For detailed course outlines, schedule and cost information contact:

Sullair Corporate Training Department


: 1-888-SULLAIR or
219-879-5451 (ext. 5363)
www.sullair.com

- Or Write -

Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
TABLE OF CONTENTS

OPERATOR IS REQUIRED TO READ


ENTIRE INSTRUCTION MANUAL

Section 1 PAGE
SAFETY 1 1.0 SAFETY
1 1.1 OVERVIEW
1 1.2 HAZARDOUS HIGH VOLTAGE
1 1.3 WARNINGS AND CAUTIONS
1 1.3.1 WARNINGS
2 1.3.2 CAUTIONS
2 1.3.3 MOTOR AND EQUIPMENT SAFETY
2 1.4 LIFTING

Section 2
INSTALLATION 5 2.0 INSTALLATION
5 2.1 DIMENSIONS
5 2.2 MOUNTING
7 2.3 COOLING
9 2.4 ENVIRONMENTAL REQUIREMENTS

Section 3
CONDUCTORS AND CONNECTIONS
11 3.1 POWER UNIT
11 3.2 INCOMING POWER AND MOTOR CONDUCTORS
18 3.3 CONTROL CABLE
18 3.4 INSTALLATION INSTRUCTIONS
18 3.5 CONDUCTOR INSTALLATION
18 3.6 SULLAIR VSD RELAY INSTALLATION
Section 1
SAFETY
1.0 SAFETY understand the procedures before you attempt to
The following special instructions apply to VSD service this VSD.
packages provided with electronic adjustable speed 1.3.1 WARNINGS:
motor drives. These are in addition to other warn-
ings and cautions.
Be sure to ground the unit following the instruc-
tions in this manual. Ungrounded units may
cause electric shock and/or fire.

OPERATOR IS REQUIRED TO BE FAMILIAR


This equipment should be installed, adjusted,
WITH THE CONCEPTS REPRESENTED IN and serviced by qualified electrical maintenance
THIS INSTRUCTION MANUAL personnel familiar with the construction and
operation of this type of equipment and the haz-
1.1 OVERVIEW ards involved. Failure to observe this precaution
could result in death or severe injury.
The Sullair VSD application is custom designed for
operation of air compressors. All necessary control
functions are performed through the Supervisor
keypad. The drive functions as a module on the
Components within the VSD power unit are live
Supervisor communications bus. when the drive is connected to power. Contact
Relevant drive status data and compressor per- with this voltage is extremely dangerous and
may cause death or severe injury.
formance are presented on the Supervisor display.
Its keypad provides simple setup and adjustment of
necessary drive parameters. Drive controls are
coordinated with internal compressor controls, and
with other Supervisor compressors in sequenced Line terminals (L1, L2, L3), motor terminals (U, V,
W) and the DClink/brake resistor terminals (-/+)
systems. The Supervisor monitors drive perform- are live when the drive is connected to power,
ance to provide motor thermal and other protec- even if the motor is not running. Contact with this
tions in an easy-to-use, robust design. voltage is extremely dangerous and may cause
death or severe injury.
1.2 HAZARDOUS HIGH VOLTAGE

Motor control equipment and electronic con- Even though the control I/O-terminals are isolat-
trollers are connected to hazardous line volt- ed from line voltage, the relay outputs and other
ages. When servicing drives and electronic con- I/O-terminals may have dangerous voltage pres-
trollers, there may be exposed components with ent even when the drive is disconnected from
housings or protrusions at or above line poten- power. Contact with this voltage is extremely
tial. Extreme care should be taken to protect dangerous and may cause death or severe injury.
against shock.

• Stand on an insulating pad and make it a habit


to use only one hand when checking compo- The VSD has a large capacitive leakage current
nents. during operation, which can cause enclosure
parts to be above ground potential. Proper
• Always work with another person in case an grounding, as described in this manual, is
emergency occurs. required. Failure to observe this precaution
• Disconnect power before checking controllers could result in death or severe injury.
or performing maintenance.
• Be sure equipment is properly grounded.
• Wear safety glasses whenever working on
Before applying power to the VSD, make sure
electronic controllers or rotating machinery. that the front and cable covers are closed and
1.3 WARNINGS AND CAUTIONS fastened to prevent exposure to potential electri-
cal fault conditions. Failure to observe this pre-
Read this manual thoroughly and make sure you
caution could result in death or severe injury.

1
Section 1
SAFETY

An upstream disconnect/protective device must Install the VSD in a well-ventilated room that is
be provided as required by the National Electric not subject to temperature extremes, high
Code (NEC). Failure to follow this precaution humidity, or condensation, and avoid locations
may result in death or severe injury. that are directly exposed to sunlight, or have
high concentrations of dust, corrosive gas,
explosive gas, inflammable gas, grinding fluid
mist, etc. Improper installation may result in a
fire hazard.
Before opening the VSD covers:
• Disconnect all power to the VSD. 1.3.3 MOTOR AND EQUIPMENT SAFETY
• Wait a minimum of 5 (five) minutes after all the
lights on the keypad are off. This allows time
for the DC bus capacitors to discharge.
• A hazard voltage may still remain in the DC bus Before starting the motor, check that the motor
capacitors even if the power has been turned is mounted properly and aligned with the driven
off. Confirm that the capacitors have fully dis- equipment. Ensure that starting the motor will
charged by measuring their voltage using a not cause personal injury or damage equipment
multimeter set to measure DC voltage. Failure connected to the motor.
to follow the above precautions may cause
death or severe injury.

1.3.2 CAUTIONS:
Make sure that no power correction capacitors
are connected to the VSD output or the motor
terminals to prevent VSD malfunction and poten-
tial damage.
Do not perform any meggar or voltage withstand
tests on any part of the VSD or its components.
Improper testing may result in damage.

Make sure that the VSD output terminals (U, V,


W) are not connected to the utility line power as
severe damage to the VSD may occur.
Prior to any tests or measurements of the motor
or the motor conductor, disconnect the motor
conductor at the VSD output terminals (U, V, W) 1.4 LIFTING
to avoid damaging the VSD during motor or con- A. If the VSD is provided with a lifting bail, then lift
ductor testing. by the bail provided. If no bail is provided, then lift
by sling. Lift and/or handle only in full compliance
with OSHA standards 29 CFR 1910 subpart N
and/or any applicable Federal, State, and Local
Do not touch any components on the circuit codes, standards and regulations.
boards. Static voltage discharge may damage B. Inspect points of attachment for cracked welds
the components.
and for cracked, bent, corroded or otherwise
degraded members and for loose bolts or nuts prior
to lifting.
C. Make sure entire lifting, rigging and supporting
Any electrical or mechanical modification to this structure has been inspected, is in good condition
equipment without prior written consent will and has a rated capacity of at least the weight of
void all warranties and may result in a safety
hazard in addition and voiding of the UL listing. the compressor. If you are unsure of the weight,
then weigh compressor before lifting.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and
latched on the bail or slings.
Prevent foreign material such as wire clippings
or metal shavings from entering the drive enclo- E. Use guide ropes or equivalent to prevent twisting
sure, as this may cause arcing damage and fire. or swinging of the compressor once it has been lift-

2
Section 1
SAFETY
ed clear of the ground. K. Make sure forklift truck forks are fully engaged
F. Keep all personnel out from under and away from and tipped back prior to lifting or transporting the
the compressor whenever it is suspended. compressor.
G. Lift compressor no higher than necessary. L. Forklift no higher than necessary to clear obsta-
cles at floor level and transport and corner at mini-
H. Keep lift operator in constant attendance when- mum practical speeds.
ever compressor is suspended.
M. Make sure pallet-mounted units are firmly bolted
I. Set the unit down only on a level surface capable or otherwise secured to the pallet prior to attempt-
of safely supporting at least its weight and its load- ing to forklift or transport them. NEVER attempt to
ing unit. forklift a compressor that is not secured to its pallet,
J. When moving the unit by forklift truck, utilize fork as uneven floors or sudden stops may cause the
pockets if provided. Otherwise, utilize pallet if pro- compressor to tumble off, possibly causing serious
vided. If neither fork pockets or pallet are provided, injury or property damage in the process.
then make sure compressor is secure and well bal-
anced on forks before attempting to raise or trans-
port it any significant distance.

3
NOTES

4
Section 2
INSTALLATION
2.0 INSTALLATION FR10 and FR11: See Figure 2-1C and Table 2C for
frame dimensions.
2.2 MOUNTING
The VSD should be installed at a distance such The VSD can be mounted in either vertical or hori-
that the motor conductors do not exceed 30.5 m/ zontal position on the wall. Also confirm that the
100 ft.
mounting plane is relatively even.
2.1 DIMENSIONS
FR6 through FR8: See Figure 2-1A and Table 2A for
frame dimensions.
Power and load electrical conductors are routed
FR9: See Figure 2-1B and Table 2B for frame through the bottom of the drive.
dimensions.

Figure 2-1A FR6, FR7 and FR8 Frame Dimensions

Table 2A: FR6, FR7 and FR8 Frame Dimensions


Type Dimensions
W1 W2 Ø H1 H2 H3 D1 Weight
FR6 [mm] 195 148 9 558 541 519 237 18.6 lb
FR6 [in] 7.7 5.8 0.35 22.0 21.3 20.4 9.3 41 kg
FR7 [mm] 237 190 9 630 614 591 257 34.9 lb
FR7 [in] 9.33 7.5 0.35 24.8 24.2 23.3 10.1 77 kg
FR8 [mm] 285 255 9 755 732 721 312 58.1 lb
FR8 [in] 11.2 10.0 0.35 29.7 28.8 28.4 12.3 128 kg

5
Section 2
INSTALLATION
Figure 2-1B FR9 Frame Dimensions

Table 2B: FR9 Frame Dimensions


Type Dimensions
W1 W2 W3 H1 H2 H3 D1 Weight
FR9 [mm] 480 400 9 1150 1120 16 340 146 kg
FR9 [in] 18.9 5.7 0.35 45.3 44.1 0.63 13.4 322 lb

6
Section 2
INSTALLATION

Figure 2-1C FR10 and FR11 Frame Dimensions

FR10 and FR11 Power and load electrical


conductors are routed through the bottom
of the drive.

Table 2C: FR10 and FR11 Frame Dimensions


Type Dimensions
W1 W2 W3 W4 Ø H1 H2 D1 Weight
FR10 [mm] 604 559 13 483 16 2270 2235 610 422 kg
FR10 [in] 23.81 22 0.5 19 0.63 89.4 88 24 930 lb
FR11 [mm] 813 762 13 676 16 2270 2235 610 590 kg
FR11 [in] 31.5 30 0.5 26.6 0.63 89.4 88 24 1300 lb

2.3 COOLING If several units are mounted above each other the
Enough free space shall be left around the VSD to required free space equals C + B (see Table 2D).
ensure sufficient air circulation and cooling. You will Moreover, the outlet air used for cooling by the
find the required dimensions for free space in Table lower unit must be directed away from the inlet air
2D Ventilation Clearance, and the cooling air to be used by the upper unit.
requirements in Table 2E Required Cooling Air.

7
Section 2
INSTALLATION
Table 2D: Ventilation Clearance for FR6 - FR11 Figure 2-2A Ventilation Clearance for FR6 - FR9
Type Dimensions
A B C
FR6 [mm] 30 160 80
FR6 [in] 1.2 6.3 3.1
FR7 [mm] 80 300 100
FR7 [in] 3.1 11.8 3.9
FR8 [mm] 80 300 200
FR8 [in] 3.1 11.8 7.9
FR9 [mm] 50 400 250
FR9 [in] 2.0 15.7 9.8
FR10 [mm] SEE FIGURE 2-2B
FR10 [i[in]
FR00 SEE FIGURE 2-2B
FR11 [mm] SEE FIGURE 2-2B
FR11 [in] SEE FIGURE 2-2B

A = side clearance around the VSD.


B = free space above the VSD.
C = free space underneath the VSD.

Table 2E: Required Cooling Air* for FR6-FR11


Figure 2-2B FR10 - FR11 Ventilation Clearance Type Cooling Air Required

FR6 [m3/h] 425


FR6 [CFM] 250

FR7 [m3/h] 425


FR7 [CFM] 250

FR8 [m3/h] 650


FR8 [CFM] 383

FR9 [m3/h] 1300


FR9 [CFM] 765

FR10 [m3/h] 2600


FR10 [CFM] 1530

FR11 [m3/h] 3900


FR11 [CFM] 2295

*All drives are equipped with an integral cooling fan.

8
Section 2
INSTALLATION
2.4 ENVIRONMENTAL REQUIREMENTS
Consult Table 2F.

Table 2F: Environmental Requirements


DESCRIPTION SPECIFICATION
Ambient Operating 14ºF/-10ºC, no frost to 104ºF/40ºC (122ºF/50ºC ratings are available
Temperature upon request).

Relative Humidity 0 to 95% RH, non-condensing, non-corrosive, no dripping water.

Altitude 100% load capacity (no derating) up to 3300 ft/1000m; 1% derating


for each 330 ft/100m above 3300ft/1000m; maximum 10000 ft/3000m.
For altitudes above 10,000ft/3000m application consult factory.

9
NOTES

10
Section 3
CONDUCTORS AND CONNECTIONS
3.1 POWER UNIT Figure 3-1A Principal Wiring Diagram of Power Unit, FR6
The wiring diagrams show the incoming power and
motor connections of the VSD unit.
3.2 INCOMING POWER AND MOTOR CONDUC-
TORS
Figure breakdown for incoming power and motor
conductors are as follows:

Reference Chart for Section 3 Figures


FR Size Wiring Conductor
Diagram Installation

FR6 Figure 3-1A Figure 3-1B

FR7 Figure 3-2A Figure 3-2B

FR8 Figure 3-3A Figure 3-3B

FR9 Figure 3-4A Figure 3-4B

FR10 Figure 3-5A Figure 3-5B

FR11 Figure 3-5A Figure 3-5B

Figure 3-1B Conductor Installation for FR6

11
Section 3
CONDUCTORS AND CONNECTIONS

Figure 3-2A Principal Wiring Diagram of Power Unit,


FR7

Figure 3-2B Conductor Installation for FR7

12
Section 3
CONDUCTORS AND CONNECTIONS
Figure 3-3A Principal Wiring Diagram of Power Unit,
FR8

Figure 3-3B Conductor Installation for FR8 (including


Brake Terminal location above box)

13
Section 3
CONDUCTORS AND CONNECTIONS

Figure 3-4A Principal Wiring Diagram of Power Unit,


FR9

Figure 3-4B Conductor Installation for FR9

14
Section 3
CONDUCTORS AND CONNECTIONS

Figure 3-5A Principal Wiring Diagram of Power Unit, Figure 3-5B Conductor Installation for FR10 and
FR10 and FR11 FR11 for Motor Leads

FOR FR11 ONLY


Incoming power must be paralleled
through both sets of line lugs.

FOR FR11 ONLY


Incoming power must be paralleled
through both sets of line lugs.

15
Section 3
CONDUCTORS AND CONNECTIONS
3.2 INCOMING POWER AND MOTOR CONDUCTORS PUT current which you can find on the rating plate.
(CONTINUED) Dimensioning according to the output current is rec-
The incoming power conductors are connected to ommended because the VSD input current never
terminals L1, L2 and L3 and the motor conductors significantly exceeds the output current.
to terminals marked with U, V and W. See Table 3A: Table 3B: Conductor and Fuse Sizes (380/460V),
Stripping Lengths of Incoming Power and Motor and Table 3C: Conductor and Fuse Sizes (575V)
Conductors. A conductor entry flange should be show the minimum dimensions of the Cu-conduc-
used when installing the motor conductor at both tors.
ends in order to reach the EMC levels.
Use conductors with heat resistance of at least These instructions apply only to cases with one
+60°C. The conductors and the fuses must be motor and one conductor connection from the VSD
dimensioned according to the VSD nominal OUT- to the motor. In any other case, consult the factory
for more information.

Table 3A: Stripping Lengths of Incoming Power and Motor Conductors

Frame A1 B1 C1 D1 A2 B2 C2 D2
FR6 [mm] 20 90 15 60 20 90 15 60
FR6 [in] 0.8 3.5 0.6 2.4 0.8 3.5 0.6 2.4
FR7 [mm] 25 120 25 120 25 120 25 120
FR7 [in] 1 4.7 1 4.7 1 4.7 1 4.7
FR8 [mm] 25 240 25 240 25 240 25 240
FR8 [in] 1 9.5 1 9.5 1 9.5 1 9.5
FR9 [mm] 28 295 28 295 28 295 28 295
FR9 [in] 1.1 11.6 1.1 11.6 1.1 11.6 1.1 11.6

DISCLAIMER
The wiring sizes listed in Tables 3B and 3C represent the minimum manufacture recom-
mendations. Customers or users must comply with local electric codes and site conditions.

16
Section 3
CONDUCTORS AND CONNECTIONS
Table 3B: Conductor and Fuse Sizes (380/460V)
Frame IL Incoming Power Ground Power In Ground Fuse
Amps & Motor Conductor Conductor Lug Lug Size

FR6 61 4 4 1 2 75
FR7 72 3 4 1 1/0 100
FR7 87 2 4 1 1/0 110
FR7 105 1/0 3 2 1/0 125
FR8 140 2/0 1 3/0 3/0 175
FR8 168 4/0 1/0 350 3/0 200
FR8 205 300 or 2*1/0 3/0 350 3/0 250
FR9 261 400 or 2*3/0 4/0 2*350 3/0 350
FR9 300 500 or 2*3/0 4/0 2*350 3/0 400
FR10 385 2*250 2*3/0 STUD STUD 450
FR10 460 2*350 2*3/0 STUD STUD 600
FR10 520 2*400 2*4/0 STUD STUD 600
FR11 590 2*500 2*4/0 STUD STUD 700
FR11 650 4*4/0 2*4/0 STUD STUD 800
FR11 730 4*4/0 2*4/0 STUD STUD 1000

Table 3C: Conductor and Fuse Sizes (575V)


Frame IL Incoming Power Ground Power In Ground Fuse
Amps & Motor Conductor Conductor Lug Lug Size

FR7 52 6 4 1 1 70
FR8 62 3 4 3/0 3/0 75
FR8 80 1 4 3/0 3/0 100
FR8 100 1/0 4 3/0 3/0 125
FR9 144 4/0 1/0 350 3/0 175
FR9 170 250 1/0 2*350 3/0 200
FR9 208 350 3/0 2*350 3/0 250
FR10 261 2*3/0 2*3/0 STUD STUD 300
FR10 325 2*250 2*3/0 STUD STUD 400
FR10 385 2*300 2*4/0 STUD STUD 450
FR10 415 2*350 2*4/0 STUD STUD 500
FR11 460 2*500 2*4/0 STUD STUD 600
FR11 502 2*500 2*4/0 STUD STUD 600
FR11 590 4*4/0 2*4/0 STUD STUD 700

17
Section 3
CONDUCTORS AND CONNECTIONS
3.3 CONTROL CABLE
Table 3D: Tightening Torques for Power Terminals

Frame Tightening Torque


To meet the UL (Underwriters Laboratories) reg-
ulations, a UL-approved copper cable with a min- Nm in-lbs
imum heat-resistance of +60/75°C must be used.
FR6 10 86.5
2
The control cables shall be at least 0.5 mm [20
FR7 10 86.5
AWG] shielded multi-conductor cables. The maxi-
mum terminal wire size is 2.5 mm2 [12 AWG] for the FR8 20/9* 173/78
relay terminals and 1.5 mm2 [14 AWG] for other ter-
minals. FR9 40/22* 346/190
3.4 INSTALLATION INSTRUCTIONS
FR10 40** 346
1. Before starting the installation, check that none of
the compressor components or the VSD are FR11 40** 346
live.
* Tightening torque for power terminal/ground termi-
2. Place the motor conductors sufficiently far from nal.
other conductors:
•Avoid placing the motor conductors in long **Apply counter-torque to the nut on the other side
parallel lines with other conductors. of the power terminal when tightening/loosening
•The motor conductors must not exceed the power terminal screw in order to avoid damage
30.5m/ 100 ft. to the power terminal.
•The motor conductors should cross other connect its conductor to the appropriate ter-
conductors at an angle of 90 degrees. minal.
3. If conductor insulation checks are needed, con- • Check the connection of the ground conduc-
sult factory. tor to the motor and the VSD terminals
4. Connect the conductors:
marked with .
• Strip the motor and incoming power conduc-
• If applicable, connect the separate shield of
tors as advised in Table 3A.
the power conductor to the ground terminals
• Remove the screws of the conductor protec- of the VSD, motor and the supply centre.
tion plate.
• Attach the conductor protection plate with
the screws.
• Ensure that the control conductors or the
DO NOT open the cover of the power unit! conductors of the unit are not trapped
between the frame and the protection plate.
• Make holes into and pass the conductors
through the rubber grommets on the bottom 5. Verify the suitability and integrity of the site earth
of the power unit (see grommets shown in ground connection.
Figures 3-1B and 3-2B). 3.5 CONDUCTOR INSTALLATION
• Connect the incoming power, motor and The tightening torques for power terminals are
control conductors into their respective ter- given in Table 3D: Tightening Torques for Power
minals (see Figures 3-1B, 3-2B, 3-3B, 3-4B Terminals.
and 3-5B). 3.6 SULLAIR VSD RELAY INSTALLATION
• For information on the installation of greater If not already installed, follow these instructions.
units, please contact the factory or your Refer to Figures 3-6 and 3-7.
local distributor. 1. With the machine and VSD de-energized remove
• Make sure that the control conductor wires the cover on the front of the VSD. Unlatch the
do not come in contact with the electronic two screws that hold the front cover on the con-
components of the unit. trol module closed. Open the control module
cover and install and wire the relay board in slot
• If an external brake resistor (option) is used,

18
Section 3
CONDUCTORS AND CONNECTIONS
“C” per Figure 3-7. The board is keyed and can Figure 3-7 Controls Wiring Diagram
only be installed in slot “C”.

Disconnect the yellow wire in the starter box. It is


not used for the remote VSD.

2. Energize the drive and package. Press the


Emergency Stop button. The Supervisor should
indicate “VSD Emergency Stop” in addition to
“E-Stop Push Button” faults. If both messages
are not shown on the alternate displays, discon-
nect power and check wiring of the relay board.
3. Release the E-Stop button, and restart the
Supervisor. If the “VSD Emergency Stop” does
not clear, check wiring of the relay board.
Repeat the emergency stop button operation to
ensure that both faults show up on the

Figure 3-6 Connection Points

Supervisor whenever the button is pressed, and


both are cleared properly when the Supervisor is
reset.

If this is not functioning properly, do not operate


the compressor.

19
NOTES

20
NOTES

21
WORLDWIDE SALES AND SERVICE

SULLAIR ASIA, LTD.


SULLAIR EUROPE, S.A.
Sullair Road, No. 1
Zone Des Granges BP 82
Chiwan, Shekou
42602 Montbrison Cedex, France
Shenzhen, Guangdong PRV.
: 33-477968470
PRC POST CODE 518068
Fax: 33-477968499
: 755-6851686
www.sullaireurope.com
Fax: 755-6853473
www.sullair-asia.com

SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
www.sullair.com
: 1-800-SULLAIR (U.S.A. & Canada Only)
or 1-219-879-5451
Fax: (219) 874-1273
PARTS DEPARTMENT
Telephone: 1-888-SULLAIR
Fax: (219) 874-1835
www.sullair.com
SERVICE DEPARTMENT
: 1-888-775-1604 (U.S.A. & Canada Only)
Fax: (219) 874-1205
www.sullaircompressors.com

DISTRIBUTOR LOCATION LIST


www.sullinet.com/sullairdistributorsearch/Distributor_Search.asp

Specifications Subject To
Change Without Prior Notice
E05
DEV

Printed in the U.S.A.

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