How to wire a Static VFD

[DRRummel]

It has been discussed before and I know this is not the recommended solution. But, here I am again, taking the more difficult path.

I bought a large Ingersoll Rand two stage air compressor as a project. It has a 10hp 3phase motor. To convert my 1 phase 220v shop power to 3phase, I bought a 7.5kw overseas VFD. I know know it is underrated for the job, but I am gong to use it to at least to verify the pump and pressure valves are working. I can usually figure out how to fix and hookup things, but I over estimated my ability on this one. I have had no success with working with the seller and I sent the manufacture an email a few days ago and have not gotten a reply.

Looking through the manual, the input power is supposed to be wired to the R, S, T and ground (PE) terminals. That is four wires. My 220 power only had three wires. Two hot legs and the neutral and ground are tied together. I have rewired the motor to run on 230 instead of 460. I want the pressure switch to signal the VFD to power on and off. To do this I have the pressure switch wired to the COM and X1 terminals on the VFD. The pressure switch is closed when the pressure is low. The switch is open when the pressure is high.

1. So does the neutral on the power source go to the ground or one of the R, S, or T terminals?
2. If neutral goes to ground, that leaves two hot wires and three power terminals on the VFD. Which two terminals of the VFD do the two hot power legs use? (R, S, or T)

Once the wiring is complete, then comes the programing.

1. For the on-off control to come from the pressure switch. I've the COM and X1 wires to the pressure switch. How do I program the controller for remote terminal?
   1. P0-02 Command source selection- 1 Terminal command channel (LED on)
   2. P4-00 X1 terminal function selection -
      1. 1 : Forward running ( FWD ) or 20 : Run command switching terminal 1
2. I've read that I should have a slow ramp up and a coast to decel for stopping. “Soft start” How do I program these?
   1. P0-19 Acceleration and Deceleration Time units - 0 : 1 seconds
   2. P0-17 Acceleration time 1 : 10 (seconds)
3. Do I have to program that the source power is 60 Hz and the output should be 60 Hz?
4. Should I lock out the reverse rotation setting?

 

[DRRummel]

The original pump has a impressive failure. The counter weight failed, high pressure piston came out of its bore, and the crank repeatedly tried to put it back in.

 

[mm08822]

The original pump has a impressive failure. The counter weight failed, high pressure piston came out of its bore, and the crank repeatedly tried to put it back in.

So you don't need the belt for now!

 

[larry_g]

Are we now to assume that you got the VFD. connected and had it set for 600 hz out instead of 60 hz?
I see on the name plate that it will go to 3200 hz.

lg

 

[wyliesdiesels]

Two hot legs and the neutral and ground are tied together.

NEVER tie neutral and ground together.

 

[mm08822]

It has been discussed before and I know this is not the recommended solution. But, here I am again, taking the more difficult path.

I bought a large Ingersoll Rand two stage air compressor as a project. It has a 10hp 3phase motor. To convert my 1 phase 220v shop power to 3phase, I bought a 7.5kw overseas VFD. I know know it is underrated for the job, but I am gong to use it to at least to verify the pump and pressure valves are working. I can usually figure out how to fix and hookup things, but I over estimated my ability on this one. I have had no success with working with the seller and I sent the manufacture an email a few days ago and have not gotten a reply.

Looking through the manual, the input power is supposed to be wired to the R, S, T and ground (PE) terminals. That is four wires. My 220 power only had three wires. Two hot legs and the neutral and ground are tied together. I have rewired the motor to run on 230 instead of 460. I want the pressure switch to signal the VFD to power on and off. To do this I have the pressure switch wired to the COM and X1 terminals on the VFD. The pressure switch is closed when the pressure is low. The switch is open when the pressure is high.

1. So does the neutral on the power source go to the ground or one of the R, S, or T terminals?
2. If neutral goes to ground, that leaves two hot wires and three power terminals on the VFD. Which two terminals of the VFD do the two hot power legs use? (R, S, or T)

Once the wiring is complete, then comes the programing.

1. For the on-off control to come from the pressure switch. I've the COM and X1 wires to the pressure switch. How do I program the controller for remote terminal?
   1. P0-02 Command source selection- 1 Terminal command channel (LED on)
   2. P4-00 X1 terminal function selection -
      1. 1 : Forward running ( FWD ) or 20 : Run command switching terminal 1
2. I've read that I should have a slow ramp up and a coast to decel for stopping. “Soft start” How do I program these?
   1. P0-19 Acceleration and Deceleration Time units - 0 : 1 seconds
   2. P0-17 Acceleration time 1 : 10 (seconds)
3. Do I have to program that the source power is 60 Hz and the output should be 60 Hz?
4. Should I lock out the reverse rotation setting?

Nothing like a user manual that contradicts other labeling. And Chinglish to boot.

Reset the drive back to its default values so there is no surprizes.

Per the cat# in the manual, you have a 3 phase 220vac input unit, not single or dual phase input. (I see the decal showing 1/3.)


Try R & S terminals for the 2 hots. No neutral is needed. Connect earth to PE. See if the drive powers up w/o a fault.

Since the manual only shows a 3 phase input option, it's a guess. If it is 3 phase only, you might get a phase input loss fault on the drive.
A quick scan through the manual didn't show any setting for single vs. 3 phase input.

PS between com and X1 looks correct.

There should be a parameter setting to permit remote inputs vs. keypad input......

1. P0-02 Command source selection = 1
2. P0-03 = 1 (set elsewhere to 60hz and leave alone)
3. P4-00 X1 terminal function selection - 0 ?
   1. 1 : Forward running ( FWD ) or 20 : Run command switching terminal 1
4. P0-08 = 60.0
5. P0-09 = 0 (may have to switch to reverse = 1)
6. p0-10 = 60.0
7. p0=17 = 5 secs
8. p0-18 = 0
9. p0-25 = 0
10. p1's = input motor nameplate
11. p2's - leave at defaults
12. p3-00 = 0
13. p3-01 = 10% (guess)
14. p4-00 =1
15. p4-01,02,03,04,05 = 0
16. p6-00 1 (safer than 0)
17. p6-01 = 0
18. p6-07 = 0
19. p6-10 = 0

(Sorry, I reached my fill of Chinglish for the day.)

 

[matt_i]

I would try bare bones operation. Single phase in, 3 phase out. Use start stop control on the vfd itself. Try to get the motor running with no belt in proper rotation. Assuming success to that level, you may be able to run the compressor with belts hooked up from zero back pressure (zero tank pressure). But you are going to run out of HP, guaranteed. Where the vfd faults for overload (over current) is something you'd have to find by testing.

 

[DRRummel]

Using the instructions from mm08822, the motor starts for about .5 to 1 second before the vfd say "No way". After 30 degrees of rotation, the vfd displays "Err 10". Which translate to the motor pull to much current. Maybe I made a mistake with the P1 values. But after I bought the 10 hp vfd for a 10hp motor I read that for an air compressor I should have at least a 15hp vfd. I am thinking of trying a 20hp vfd. Or a rotary inverter next. I need to find a good deal on a used one.

The belt is still install. The unloader tubing is disconnected and I can move the belt with two fingers.

 

[mm08822]

Was the motor ever confirmed good?
Did you megger the motor or at least ohm it out?
Is it wired correctly for 230v?

Take the belt off and see if it can even spin the unloaded motor.

Disconnect the motor leads from the vfd. Does it ramp up/down/stop w/o faulting?

Did you contact vfd mfr to find out about mismatch of manual's documentation regarding single phase/three phase input? What should the max input amps be with single phase input? What is the max output amps with single phase input? What are the correct input connections? (Label is confusing.) Anything to set set in drive for single phase input?

Did you reset the drive to default values before you programmed it for your application?

You should post the parameter values. See if you can copy/paste the table into excel or word and edit the values in the parameter you changed.