627204086-Nirvana-15-30kW-20-40Hp-Troubleshooting

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<p>Issue 5 Rev. E Oct 2010</p><p>Nirvana 15 - 30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 2</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Copyright Notice</p><p> 2007 Ingersoll Rand Company</p><p>Proprietary Notices and Disclaimer</p><p>PROPRIETARY NOTICES</p><p>Copyright 2007 INGERSOLL RAND COMPANY</p><p>CONFIDENTIAL AND TRADE SECRET INFORMATION. This manual contains confidential and trade secret</p><p>information owned by Ingersoll-Rand Company (hereinafter referred to as "Proprietary Matter"). In consideration</p><p>of the disclosure of the Proprietary Matter herein to the authorized recipient hereof, the recipient shall treat the</p><p>Proprietary Matter as secret and confidential; shall not disclose or give such Proprietary Matter to third parties</p><p>without the express written authorization of INGERSOLL RAND; shall not use the Proprietary Matter except to</p><p>the extent necessary to use or service the equipment disclosed herein; and shall disclose such Proprietary</p><p>Matter only to those of its employees whose use or knowledge of the Proprietary Matter is necessary. This</p><p>manual shall be returned upon request by Ingersoll Rand Company. The unauthorized use of this manual may</p><p>be punishable by law.</p><p>DISCLAIMERS</p><p>PROVIDED "AS IS". THIS MANUAL AND THE CONTENTS THEREOF ARE PROVIDED "AS IS" AND</p><p>WITHOUT ANY IMPLIED WARRANTIES.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 3</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Environmental concerns.. ............................... 4</p><p>Pre-Installation Checks ................................... 5</p><p>Power Quality Requirements .......................... 5</p><p>Remote Alarm Location .................................. 6</p><p>Fan Logics and Mechanical notes……………..7</p><p>VFD inputs and outputs………………………...8</p><p>Motor wiring information and testing………….9</p><p>Fault Messages ............................................. 10</p><p>Using the LCP ............................................... 16</p><p>Description of LCP Screens .......................... 17</p><p>Trouble Shooting The LCD ........................... 19</p><p>General Trouble Shooting ............................. 21</p><p>Drive Terminal Pin Connections ................... 21</p><p>Static Testing Description…………………….22</p><p>Static Test On HV 20-25 HP (15-18.5kW)</p><p>Drives……………………………………….23-24</p><p>Static Test On 20-25 HP</p><p>(15-18.5kW) (Low Voltage Units)</p><p>and the 30/40 HP (22-30kW) (High and low</p><p>Voltage) Drives….………………………….25-26</p><p>Replacement of Drive Control Board ............ 27</p><p>Drive Replacement Dip Switch Settings ..... ..30</p><p>Turning the RFI Filter Off ............... …..……...31</p><p>Drive / Motor Investigation Site Log………….32</p><p>Software Version History ............................. .33</p><p>Troubleshooting Guide Revision History ...... 34</p><p>Introduction</p><p>This manual has been designed to provide you with</p><p>fundamental knowledge about troubleshooting the</p><p>Nirvana 15-30kW (20-40Hp) . Please note any</p><p>changes to this manual will be noted at the back of</p><p>this manual under Revision History.</p><p>Table of contents</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 4</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Environmental Concerns for the Drive</p><p> Clean and Dry – 5% - 95% Humidity, non-</p><p>condensing</p><p> 24-Hour temperature limit = 45°C (113°F)</p><p> Max temp limit = 50°C (122°F)</p><p> Altitude Limits – 1000m – reduced above</p><p>1000m (3200 Ft)</p><p> Storage Limits = -25° to +65°C (-13° to 149°F)</p><p> Keep the drive clean</p><p> Use dust covers to keep construction dust from</p><p>getting into it</p><p> Remove the dust covers before applying</p><p>power</p><p>CAUTION!!!</p><p>Dangerous Voltage Levels Present!</p><p>Output leads can have voltage to ground</p><p>even when motor is not running!</p><p>Allow Sufficient time for DC Capacitors to</p><p>discharge after power is disconnected or</p><p>performing any testing on drive!</p><p>Warning</p><p>Water will prevent the LCP from</p><p>operating correctly!</p><p>VFD Drive: Max - Min Operating Temperatures</p><p>Note: Maximum Compressor operating temperature is 115F / 46C</p><p>Minimum compressor operating temperature is 36F / 2C</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 5</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Introduction Diagnostics</p><p>Troubleshooting</p><p>Pre-Installation Checks</p><p>VFD Rated Voltage = Line Voltage</p><p> 208–240V</p><p> 380–500V</p><p> 15-18.5kW (20-25Hp)</p><p> 22-30kW (30-40Hp)</p><p> IntelliKey Rated Hp = Motor Hp</p><p>4 Models</p><p> 15-18.5kW (20-25Hp), 208-230V</p><p> 15-18.5kW (20-25Hp), 380-460V</p><p> 22-30kW (30-40Hp), 208-230V</p><p> 22-30kW (30-40Hp), 380-460V</p><p>4 IntelliKey Modules</p><p> 15kW (20Hp)</p><p> 18.5kW (25Hp)</p><p> 22kW (30Hp)</p><p> 30kW (40Hp)</p><p>POWER QUALITY REQUIREMENTS</p><p>The Nirvana 20-40 HP / 15-33 kW compressor re-</p><p>quires a ‘clean’ power source on all three legs of the</p><p>incoming power supply in order to operate efficiently</p><p>and reliably.</p><p>The incoming power supplied to the compressor pack-</p><p>age should meet the following requirements and</p><p>should originate from a clean power supply separate</p><p>from other equipment and processes that could poten-</p><p>tially create power disturbances.</p><p>The power requirements are:</p><p>Voltage</p><p> (HV) 380-480V +/- 6%</p><p> (LV) 208-230V +10% / -6%</p><p>Voltage Unbalance per IEC61800-3</p><p> 2%</p><p>Examples of disruptive equipment and processes</p><p>include but are not limited to:</p><p> Electrical welding machines</p><p> Induction furnaces</p><p> Customers producing their own power</p><p> Power factor compensation devices</p><p> Other variable speed drives (AC or DC)</p><p> Do not use line reactors on the 20-40 HP</p><p>(15-30 kW) units!</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 6</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Remote Alarm Location B2 Frame</p><p>The remote alarm contacts are physically located in</p><p>different areas of the drive depending on the frame</p><p>size. The pictures below show where they are</p><p>located.</p><p>B2 Drive remote alarm relay location on the 20/25</p><p>HP (15-18.5 kW) (High Voltage units) is near the</p><p>bottom of the drive. Relay 2 is the default remote</p><p>alarm</p><p>for P2 Pressure Sensor when a Sensor Calibration is attempted and the zero (0) PSI reading is less than 3.5mA or greater than 5.6mA.This is the transducer after the dryer.</p><p>Check wiring to pressure sensors</p><p>"P1 Pressure Sensor Failure"</p><p>(Manual Reset)</p><p>Alarm when the P1 pressure sensor current readings are below 3mA or above 21 mA.</p><p>Check wiring to pressure sensors</p><p>"P2 Pressure Sensor Failure"</p><p>(Manual Reset)</p><p>Alarm when the P2 pressure sensor current readings are below 3mA or above 21 mA. This is the transducer after the dryer.</p><p>Check wiring to pressure sensors</p><p>(207) "Failed to Set RTC Time"</p><p>(Locked IN)</p><p>If the RTC/Intellikey (Real Time Clock) does not properly program the current date/time when requested an alarm will be generated with the text “Failed to Set RTC Time.”</p><p>(Automatically Resets)</p><p>(Automatically Resets)</p><p>(Automatically Resets)</p><p>(Automatically Resets)</p><p>(Automatically Resets)</p><p>(Automatically Resets)</p><p>(Automatically Resets)</p><p>(Automatically Resets)</p><p>Resets after technician performs the initial startup.</p><p>Using the LCP</p><p>Description of the LCP Screens</p><p>Trouble Shooting the LCP</p><p>Trouble Shooting the LCP</p><p>If Compressor has blown incoming fuse.</p><p>Drive Terminal Pin Connections</p><p>Static Testing description for VFD drives on the 15-30kW (20- 40 HP) Nirvana</p><p>Replacement of Drive Control Board</p><p>Replacement of Drive Control Board continued</p><p>Replacement of Drive Control Board continued</p><p>Important Note When Replacing the Drive</p><p>Dip Switch Settings</p><p>When replacing drive, remove the key from old drive to use in replacement drive. Before inserting the key in the new drive, check the positions of the switches S201 and S202.</p><p>These switches come from the factory in the left position for voltage input. They need to be moved to the right/on position (switches are in the left position as pictured below) for the 4-20 ma inputs of the pressure transducers. Do not change the positions of these switches with the power on. These switches are delicate and it does not take much force to change them.</p><p>The switch S801, on the left, is for communication buss termination.</p><p>Start up procedure error will be given when the drive is replaced.</p><p>The time, pressure set points and maintenance timer will need to be set.</p><p>S202</p><p>S201</p><p>S801</p><p>Turning RFI Filter OFF</p><p>Software Version 1.10</p><p>Software Version 1.20</p><p>Software Version 1.3</p><p>></p><p>/ColorImageDict ></p><p>/JPEG2000ColorACSImageDict ></p><p>/JPEG2000ColorImageDict ></p><p>/AntiAliasGrayImages false</p><p>/CropGrayImages true</p><p>/GrayImageMinResolution 300</p><p>/GrayImageMinResolutionPolicy /OK</p><p>/DownsampleGrayImages true</p><p>/GrayImageDownsampleType /Bicubic</p><p>/GrayImageResolution 300</p><p>/GrayImageDepth -1</p><p>/GrayImageMinDownsampleDepth 2</p><p>/GrayImageDownsampleThreshold 1.50000</p><p>/EncodeGrayImages true</p><p>/GrayImageFilter /DCTEncode</p><p>/AutoFilterGrayImages true</p><p>/GrayImageAutoFilterStrategy /JPEG</p><p>/GrayACSImageDict ></p><p>/GrayImageDict ></p><p>/JPEG2000GrayACSImageDict ></p><p>/JPEG2000GrayImageDict ></p><p>/AntiAliasMonoImages false</p><p>/CropMonoImages true</p><p>/MonoImageMinResolution 1200</p><p>/MonoImageMinResolutionPolicy /OK</p><p>/DownsampleMonoImages true</p><p>/MonoImageDownsampleType /Bicubic</p><p>/MonoImageResolution 1200</p><p>/MonoImageDepth -1</p><p>/MonoImageDownsampleThreshold 1.50000</p><p>/EncodeMonoImages true</p><p>/MonoImageFilter /CCITTFaxEncode</p><p>/MonoImageDict ></p><p>/AllowPSXObjects false</p><p>/CheckCompliance [</p><p>/None</p><p>]</p><p>/PDFX1aCheck false</p><p>/PDFX3Check false</p><p>/PDFXCompliantPDFOnly false</p><p>/PDFXNoTrimBoxError true</p><p>/PDFXTrimBoxToMediaBoxOffset [</p><p>0.00000</p><p>0.00000</p><p>0.00000</p><p>0.00000</p><p>]</p><p>/PDFXSetBleedBoxToMediaBox true</p><p>/PDFXBleedBoxToTrimBoxOffset [</p><p>0.00000</p><p>0.00000</p><p>0.00000</p><p>0.00000</p><p>]</p><p>/PDFXOutputIntentProfile ()</p><p>/PDFXOutputConditionIdentifier ()</p><p>/PDFXOutputCondition ()</p><p>/PDFXRegistryName ()</p><p>/PDFXTrapped /False</p><p>/CreateJDFFile false</p><p>/Description</p><p>/BGR</p><p>/CHS</p><p>/CHT</p><p>/CZE</p><p>/DAN</p><p>/DEU</p><p>/ESP</p><p>/ETI</p><p>/FRA</p><p>/GRE</p><p>/HEB</p><p>/HRV (Za stvaranje Adobe PDF dokumenata najpogodnijih za visokokvalitetni ispis prije tiskanja koristite ove postavke. Stvoreni PDF dokumenti mogu se otvoriti Acrobat i Adobe Reader 5.0 i kasnijim verzijama.)</p><p>/HUN</p><p>/ITA</p><p>/JPN</p><p>/KOR</p><p>/LTH</p><p>/LVI</p><p>/NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken die zijn geoptimaliseerd voor prepress-afdrukken van hoge kwaliteit. De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 5.0 en hoger.)</p><p>/NOR</p><p>/POL</p><p>/PTB</p><p>/RUM</p><p>/RUS</p><p>/SKY</p><p>/SLV</p><p>/SUO</p><p>/SVE</p><p>/TUR</p><p>/UKR</p><p>/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)</p><p>>></p><p>/Namespace [</p><p>(Adobe)</p><p>(Common)</p><p>(1.0)</p><p>]</p><p>/OtherNamespaces [</p><p>></p><p>></p><p>/FormElements false</p><p>/GenerateStructure false</p><p>/IncludeBookmarks false</p><p>/IncludeHyperlinks false</p><p>/IncludeInteractive false</p><p>/IncludeLayers false</p><p>/IncludeProfiles false</p><p>/MultimediaHandling /UseObjectSettings</p><p>/Namespace [</p><p>(Adobe)</p><p>(CreativeSuite)</p><p>(2.0)</p><p>]</p><p>/PDFXOutputIntentProfileSelector /DocumentCMYK</p><p>/PreserveEditing true</p><p>/UntaggedCMYKHandling /LeaveUntagged</p><p>/UntaggedRGBHandling /UseDocumentProfile</p><p>/UseDocumentBleed false</p><p>>></p><p>]</p><p>>> setdistillerparams</p><p>> setpagedevice</p><p>relay and corresponds to the 4,5 and 6</p><p>terminals on the wiring schematic</p><p>Remote Alarm Location C1 and C2 Frame</p><p>C1 and C2 Drives remote alarm relay location on the</p><p>20/25 HP (15-18.5 kW) (Low Voltage Units), 30/40</p><p>HP (22-30kW) (High and low Voltage Units) is near</p><p>the top of the drive. Relay 2 is the default remote</p><p>alarm relay and corresponds to the 4,5 and 6</p><p>terminals on the wiring schematic.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 7</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Fan Logic</p><p>The fan will turn off if it is not needed.</p><p>The three status LEDs are at the left of the lower</p><p>programming key and on the Keypad. The green</p><p>LED is for power on, the yellow LED is a warning,</p><p>and the red LED is for a fault.</p><p>The 15-30kW (20-40Hp) Nirvana Fan is limited to 20</p><p>starts per hour by controlling the off time of the fan.</p><p>If the air compressor runs for 3 minutes or more,</p><p>then the cooling fan cuts off with the compressor. On</p><p>TAS units (dryer equipped units) if the air compres-</p><p>sor runs less than 3 minutes then the cooling fan</p><p>continues to run for an additional 3 minutes.</p><p>Startup Alarms</p><p>When the unit is first powered up and the following</p><p>settings are not set “Time, Maintenance timer, Pres-</p><p>sure Set Points” you will receive the following mes-</p><p>sage: “Procedure start up procedure” To keep mes-</p><p>sage from repeating add values to all these set</p><p>points.</p><p>*Note: Energy savings does not start until one hour</p><p>has passed on the Hour Meter.</p><p>Mechanical Notes:</p><p>If the motor rotor is removed and replaced, Loctite</p><p>242 is to be applied to rotor retaining bolt and the</p><p>bolt is to be torqued to 158 FT LBS.</p><p>Loctite 242 is used on the blower to motor shaft re-</p><p>taining screw. Once motor and fan assembly are in-</p><p>stalled back in unit, fan must be positioned over</p><p>cone. Cooling fan must be positioned over inlet cone.</p><p>A gap between fan and inlet cone is not acceptable.</p><p>The cone must be adjusted for clearance to</p><p>prevent contact between blower and cone during</p><p>operation.</p><p>Tool CCN 22860563 is recommended to remove the</p><p>motor rotor.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 8</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>This diagram provides an overview of the different types of inputs and outputs that you must troubleshoot when</p><p>repairing a unit. There are four digital outputs for turning on a fan, dryer, PORO alarm and Common alarm. The</p><p>six digital inputs are for Emergency stop, Remote Load Enable, Remote Load/Unload, VFD/Fixed (restricted)</p><p>speed, High Air end Temperature Switch (HATS), and Dryer Status Switch (high pressure switch). The VFD will</p><p>regulate the discharge pressure to a target pressure using fixed (restricted) VFD speed or true VFD speed</p><p>closed loop control. The restricted VFD speed option must be field installed using customer supplied switches.</p><p>Use the wiring schematic in the owners manual for the proper drive terminal numbers. Also read logic descrip-</p><p>tion on page 33 for Remote Load Enable, Remote Load/Unload, VFD/Fixed (restricted) speed switch under Soft-</p><p>ware 1.10 version.</p><p>You can also use the LCP (Service Button) then Factory Service parameter 4.4.6 VFD Special Parameters and</p><p>view current drive inputs, outputs and drive conditions (see page 18 of this manual for more information).</p><p>IR VFD Inputs and Outputs</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 9</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>High and low voltage motor wiring</p><p>For 400V (high voltage) drives:</p><p>On the back side of the terminals the Y connection</p><p>is connected, and on the front side U2, V2, and W2 of</p><p>the motor is connected to U’, V’, and W’ (of the termi-</p><p>nal). Then U1, V1, and W1 is as usual connected to</p><p>the motor terminals U, V, W.</p><p>For 200V (low voltage) drives:</p><p>Only the motor terminals U, V, and W are</p><p>necessary. U1+W2 must be connected in terminal</p><p>U; U2+V1 must be connected in terminal V;</p><p>V2+W1 must be connected in terminal W.</p><p>Motor winding insulation testing with 1000 volt Megohm Meter and Milliohm Meter</p><p>When testing the insulation on the motor windings use a 1000 volt megger and be sure you disconnect the wires</p><p>from the drive output or damage to the drive may result. The motor should read >20 Megohms to ground from</p><p>the U,V and W phases of the motor. Megohm meters will find a fault between the motor windings to ground but</p><p>will not find a turn to turn winding fault (a milliohm meter will). If the windings are not balanced (resistive load)</p><p>then the motor current will not be balanced and the drive will fault. When using a milliohm meter disconnect the</p><p>output wires from the VFD and test the motor as it is normally wired ( depends on the motor voltage see below)</p><p>and don't separate the motor leads. Make sure that the connections are tight when performing the test.</p><p>Using a precision milliohm meter EXTECH 380460 or equivalent you should get the following readings. (NOTE:</p><p>A precision milliohm meter is not the same as a standard ohm meter). It is recommended that you complete both</p><p>test when confirming a failed motor.</p><p>15-18.5 kW (20-25HP) should read 100 milliohms +/- 4% @ 20 deg C (68 F).</p><p>22-30 kW (30-40 HP) should read 3.65 milliohms +/- 4% @ 20 deg C (68 F).</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 10</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Fault Messages</p><p>There are two types of fault messages in the control-</p><p>ler of a 15-30kW Nirvana. Alarm and Warning mes-</p><p>sages have different effects on the operation of the</p><p>drive. Below is a basic description of the logic.</p><p>Fault Drive Logic</p><p>Once a critical level is reached the drive/controller</p><p>will react in two ways. If the fault causes a Latched</p><p>condition the motor will coast to a stop. The fault</p><p>can only be reset after the fault condition is cor-</p><p>rected. This could include cycling power. If the fault</p><p>causes an Unlatched condition the motor will still run,</p><p>and the fault is automatically reset. See table 1 and 2</p><p>for additional information.</p><p>If the fault causes an Unlatched condition the motor</p><p>will still run, and the fault is automatically reset. Ex-</p><p>amples of this type of Warnings are fault codes 217</p><p>through 223.</p><p>Warnings will occur if:</p><p> Close to a Critical Level</p><p> The Compressor will still be running (In Most</p><p>Cases (See table 1 and 2)</p><p> Warnings are Not stored in Alarm Log</p><p>How Alarms / Warnings are Reset:</p><p>Automatic</p><p> Indicates items that will automatically reset when</p><p>the fault condition is corrected</p><p>Manual</p><p> Indicates items that require a manual reset using</p><p>the “Reset” button on the LCD</p><p>Locked</p><p> Indicates that the drive will be in a locked alarm</p><p>state until power is cycled</p><p> Please Note: Warnings are not stored in the</p><p>alarm log.</p><p>Table 1</p><p>Alarm Fault Codes</p><p>The letters used in the table indicate the following behavior:</p><p>• A – indicates items that will automatically reset when the fault</p><p>condition is corrected</p><p>• L – indicates that the drive will be in a locked alarm state until</p><p>power is cycled</p><p>• M – indicates items that require a manual reset using the “Reset”</p><p>button on the LCP</p><p>CODE Description</p><p>Alarm</p><p>Reset</p><p>Alarm</p><p>Lock</p><p>4 Mains phase loss L</p><p>7 DC Buss over voltage A A</p><p>8 DC Buss under voltage A A</p><p>9 Inverter overloaded A A</p><p>12 Torque limit M</p><p>13 Over Current L</p><p>14 Earth Fault L</p><p>16 Short Circuit L</p><p>29 Drive over temperature L</p><p>30 Motor phase U missing L</p><p>31 Motor phase V missing L</p><p>32</p><p>Motor phase W miss-</p><p>ing L</p><p>33 Inrush fault L</p><p>36 Mains failure M</p><p>38 Internal fault L</p><p>47 24 V supply low L</p><p>48 1.8 V supply low L</p><p>65</p><p>Control Card Over</p><p>Temperature L</p><p>68</p><p>E-Stop (Safe Stop</p><p>Activated) M</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 11</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Alarm Messages</p><p>Note: these faults may be proceeded by a “A”</p><p>* Which designates them as an Alarm.</p><p>Alarm 4 - Main Phase Loss</p><p>(Automatically Resets)</p><p>* Probable cause, Power loss, Unbalanced supply</p><p>voltage (Turn off RFI filter and make sure line</p><p>reactor is not installed). An 36 Alarm may also</p><p>occur along with this Alarm. Also read 20-40</p><p>Nirvana A14 and A4 fault (2008FSB-068) on the IR</p><p>Service Net for more information on this alarm.</p><p> Check Input Voltage & Current for Balance</p><p> Must be Balanced Within 3% @ Full Load</p><p> Check for dirty condenser on TAS units. Due</p><p>to wiring this can cause unbalanced input</p><p>voltage to drive.</p><p>Alarm 7 - DC Buss Over voltage</p><p>(Automatically Resets)</p><p> Check Input Voltage</p><p> Check for High Inertia or Short Ramp Down</p><p> If all checks are good (Please call Customer</p><p>Services)</p><p>Alarm 8 – DC Buss Under voltage</p><p>(Automatically Resets)</p><p> Check Input Voltage</p><p> Check all Input Voltage Wiring for Good</p><p>Connections</p><p> Check Fusible Disconnect</p><p>Alarm 9 – Inverter Overload</p><p>(Automatically Resets)</p><p> Check Bearings/Mechanical Load</p><p>(Compressor)</p><p> Check for Correct IntelliKey</p><p> Check that Motor and Compressor turns freely</p><p> Check Motor Windings</p><p> Check that all Motor connections are</p><p>terminated correctly at the Drive out put</p><p>Alarm 12 – Torque Limit</p><p>(Manual Reset)</p><p>* Probable cause motor bearing bad, air end bad</p><p> Check Mechanical Load (Compressor)</p><p> Check that Motor and Compressor Rotates</p><p>Freely</p><p>Alarm 13 – Over current</p><p>(Locked IN)</p><p>* Probable cause motor bearing bad, air end bad</p><p> Check Motor Windings and Ensure that Motor</p><p>Rotates freely</p><p> Check Mechanical Load / (Compressor), En-</p><p>sure that it Rotates freely</p><p> Check Drive Size by viewing Data Plate Infor-</p><p>mation</p><p> Check Motor Wiring at Drive output Phases</p><p>A failed or dirty check valve can cause a Fault 13</p><p>(over current fault). The failed check valve allows</p><p>oil to flood the air end after the unit sets for a pe-</p><p>riod of time, as shown in the picture below. This</p><p>results in a “locked rotor” condition and results in</p><p>very high current. The first time the drive faults, the</p><p>oil is usually cleared out and the unit usually starts</p><p>up the second time. To check for this problem it is</p><p>necessary to allow the unit to set for a period of</p><p>time and then check for flooding as shown below.</p><p>If one of the six motor leads is loose or discon-</p><p>nected a Fault 13 will occur when it is first started</p><p>up.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 12</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Alarm 33 – Inrush Fault “Soft-charge Fault”</p><p>(Locked IN)</p><p> Possible Faulty Drive</p><p> Too many power-ups have occurred within a</p><p>short time period.</p><p>Alarm 36 - Mains Failure</p><p>(Manual Reset)</p><p> The A4 and the A36 fault are determined by</p><p>the condition of the DC Buss. The new</p><p>software version 1.3 added fixes for the A4</p><p>fault and an additional fault, the A36. The</p><p>drives with the temporary patch did not have</p><p>this fault enabled. The A36 occurs when the</p><p>DC Buss value indicates a voltage level of less</p><p>than 180 VAC on a 208 volt system. The DC</p><p>buss voltage is directly related to the incoming</p><p>line voltage.</p><p> Also read A36 fault on 20-40 HP Nirvanas</p><p>(2009FSB-122) on the IR Service Net for</p><p>information on this alarm.</p><p>Alarm 38 – Internal Fault</p><p>(Locked IN)</p><p> Probable Cause Control board bad / software</p><p>problem</p><p> Defective Drive</p><p> Do Not Attempt to Reset & Restart Drive</p><p>Alarm 47 – 24V Supply Low</p><p>(Locked IN)</p><p> Check Control Wiring for Shorts</p><p> Possible Faulty Drive Power Supply</p><p>Alarm 48 – 1.8V Supply Low</p><p>(Locked IN)</p><p> Faulty Drive Power Supply</p><p> Check Fixed/Variable Speed Selector Wiring</p><p>for Short</p><p>Alarm 14 – Earth Fault</p><p>(Locked IN)</p><p> Check Motor, Motor Wiring for Short to Ground</p><p> Check Motor Wiring at Drive output Phases</p><p>Also read 20-40 Nirvana A14 and A4 fault</p><p>(2008FSB-068) on the IR Service Net for more</p><p>information on this alarm.</p><p>Alarm 16 – Short Circuit</p><p>(Locked IN)</p><p> Check Motor, Motor Wiring for Phase to Phase</p><p>Short</p><p> Check Motor Wiring at Drive out put Phases</p><p>Alarm 29 – Drive Heat sink Over Temperature</p><p>(Locked IN)</p><p> Check Operation of Cooling Fans</p><p> Drive Fans should rotate momentarily when</p><p>Power is applied to the Compressor</p><p> Check for Blockage of Airflow</p><p> Check Main Blower for correct Rotation</p><p>Alarm 30, 31, 32 – Missing Motor Phase</p><p>(Locked IN)</p><p> Alarm 30 is U phase missing.</p><p> Alarm 31 is V phase missing.</p><p> Alarm 32 is W phase missing.</p><p> Check Connections to Motor at the Output of</p><p>the Drive’s U V W Phases</p><p> Check for Open Winding in Motor</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 13</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Table 2</p><p>IR Specific Fault Codes</p><p>This table shows warning codes along with alarms that are</p><p>only in IR Software / drives.</p><p>The letters used in the table indicate the following behavior:</p><p>• A – indicates items that will automatically reset when the fault</p><p>condition is corrected</p><p>• L – indicates that the drive will be in a locked alarm state until</p><p>power is cycled</p><p>• M – indicates items that require a manual reset using the “Reset”</p><p>button on the LCP</p><p>• NA – indicates items that are not applicable to the IR302</p><p>CODE   Description   Warning    Alarm    Alarm Lock</p><p>200   No IntelliKey</p><p>key   NA      L</p><p>201</p><p>Incorrect Intellikey</p><p>key   NA      L</p><p>202   HAT Switch Opened   NA   M</p><p>203   P1 Sensor Cal Error   NA   M</p><p>204   P2 Sensor Cal Error   NA   M</p><p>205   P1 Sensor Failed   NA   M</p><p>206   P2 Sensor Failed   NA   M</p><p>207</p><p>Failed to Set RTC</p><p>(Real Time Clock )</p><p>Time   NA      L</p><p>215</p><p>Immediate Stop</p><p>Pressure Exceeded    A</p><p>217</p><p>Dryer Delta Pressure</p><p>Exceeded    A</p><p>218</p><p>Dryer Stopped High</p><p>Pressure    A</p><p>219</p><p>PORO Countdown</p><p>Active OR Start</p><p>Inhibit Delay Active    A</p><p>220</p><p>Scheduled Start</p><p>Count down Active    A</p><p>221   Service Soon    A</p><p>222   Maintenance Due    A</p><p>223</p><p>Perform Initial</p><p>Startup    A</p><p>Alarm 65 – “Control Card Over Temperature”</p><p>(Locked IN)</p><p>The cut-out temperature of the control card is 80° C /</p><p>176 F.</p><p>Alarm 68 – E-Stop “Safe Stop Activated”</p><p>(Manual Reset)</p><p>Safe Stop has been activated. To resume normal</p><p>operation reset E-stop.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 14</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>(200) “No Intellikey”</p><p>(201) “Incorrect Intellikey”</p><p>(Locked IN)</p><p>If no Intellikey is installed or Intellikey does not</p><p>match the drive frame size, an alarm will occur.</p><p>(202) "HAT Switch Opened"</p><p>(Manual Reset)</p><p>Check that cooling fan overload has not tripped.</p><p>If dryer is installed check that overpressure trip has</p><p>not occurred. If the alarm does not latch in check</p><p>current draw to motor to insure that the motor</p><p>thermal</p><p>is not being made. Also check the main cooling fan,</p><p>if the set screw is lose that attaches the fan to the</p><p>motor the fan can contact the bottom of the fan</p><p>housing causing the fan motor over load to trip. Be</p><p>aware that there are three switches connected to</p><p>this one alarm input.</p><p> Motor Thermal Switch in the Open position.</p><p>It automatically resets when temperature</p><p>lowers to operating range.</p><p>Most likely causes:</p><p> Cooling fan is inoperable (30-40 HP only)</p><p> Failing Air end bearings or Failing Motor</p><p>bearings causing drive to go into</p><p>current limit causing motor to overheat.</p><p> Hat Switch is in the Open position.</p><p> It automatically resets when temperature</p><p>lowers to operating range.</p><p>Most likely causes:</p><p> Low oil level</p><p> Failed thermostat valve</p><p> Fouled Cooler / Fan Rotation</p><p> Fan Starter Overload is in the Open</p><p>position. It has to be manually reset.</p><p>Most likely causes:</p><p> Incorrect incoming three phase power</p><p> Failing Motor bearings</p><p> Make sure that the cooling fan is not touching</p><p>the fan housing.</p><p>(203) "P1 Sensor Calibration Failure"</p><p>(Manual Reset)</p><p>Alarm for P1Pressure Sensor when a Sensor</p><p>Calibration is attempted and the zero (0) PSI reading</p><p>is less than 3.5mA or greater than 5.6mA.</p><p> Check wiring to pressure sensors</p><p>(204) "P2 Sensor Calibration Failure"</p><p>(Manual Reset)</p><p>Alarm for P2 Pressure Sensor when a Sensor</p><p>Calibration is attempted and the zero (0) PSI reading</p><p>is less than 3.5mA or greater than 5.6mA.This is the</p><p>transducer after the dryer.</p><p> Check wiring to pressure sensors</p><p>(205) "P1 Pressure Sensor Failure"</p><p>(Manual Reset)</p><p>Alarm when the P1 pressure sensor current</p><p>readings are below 3mA or above 21 mA.</p><p> Check wiring to pressure sensors</p><p>(206) "P2 Pressure Sensor Failure"</p><p>(Manual Reset)</p><p>Alarm when the P2 pressure sensor current</p><p>readings are below 3mA or above 21 mA. This is the</p><p>transducer after the dryer.</p><p> Check wiring to pressure sensors</p><p>(207) "Failed to Set RTC Time"</p><p>(Locked IN)</p><p>If the RTC/Intellikey (Real Time Clock) does not</p><p>properly program the current date/time when</p><p>requested an alarm will be generated with the text</p><p>“Failed to Set RTC Time.”</p><p>(215)“Immediate Stop Pressure Exceeded”</p><p>(Automatically Resets)</p><p>Warning condition that will stop compressor and</p><p>will automatically reset when monitored pressure</p><p>falls below the Target Pressure</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 15</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>(217)“Dryer Delta Pressure Exceeded”</p><p>(Automatically Resets)</p><p>This is a condition detected when a dryer is installed</p><p>and the difference between the Pressure Before</p><p>Dryer and the Package Discharge Pressure readings</p><p>exceed 20 PSI. The machine continues to run in a</p><p>speed pressure mode, and displays the warning</p><p>message ”High Dryer DP”.</p><p>(218)“Dryer Stopped High Pressure”</p><p>(Automatically Resets)</p><p>This is a condition detected when the Dryer is En-</p><p>abled and the Dryer Status Switch input is open. The</p><p>compressor continues to run and displays the warn-</p><p>ing message ”Dryer Stopped High Pressure” You</p><p>must reset this alarm by removing panels to access</p><p>the high pressure switch inside the dryer.</p><p>(219)“Scheduled Start Countdown / PORO Count-</p><p>down Active”</p><p>(Automatically Resets)</p><p>Appears in the controller display when either of the</p><p>above selection are active</p><p>(220) PORO Or Scheduled Warning −</p><p>(Automatically Resets)</p><p>”Compressor Start in XXX seconds” should be</p><p>displayed for the PORO warning. ”Scheduled Start in</p><p>XXX seconds” should be displayed for the scheduled</p><p>start warning. XXX is the time remaining before the</p><p>actual start.</p><p>(221)“Service Soon”</p><p>(Automatically Resets)</p><p>Appears when the bar graph has 20% or less time</p><p>remaining of services time remaining.</p><p>(222)“Maintenance Due”</p><p>(Automatically Resets)</p><p>Appears when the maintenance timer reaches zero.</p><p>(223)“Perform Initial Startup”</p><p>(Automatically Resets)</p><p>Resets after technician performs the initial startup.</p><p>You must set the time, date and pressure set points</p><p>on initial startup or you will get this alarm.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 16</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Using the LCP</p><p>Note that inactivity for 10 seconds the menu will re-</p><p>turn to Status 1.1</p><p>To change any of the values press OK to enable the</p><p>change. For a Yes or NO feature use the up or down</p><p>button to toggle between Yes and No. For a number</p><p>change use the right or left button to select the posi-</p><p>tion to enter a number and the up or down button to</p><p>change the value at that location.</p><p>The Factory Service screen has 4 sub menus, Ser-</p><p>vice Information, Service Set points, Alarm Log and</p><p>Factory Service.</p><p>Scroll up/down to submenu required and hit OK.</p><p>Note that activating options will insert screens which</p><p>will shift the order of other screens.</p><p>10</p><p>11</p><p>12</p><p>13</p><p>14</p><p>9</p><p>1</p><p>2</p><p>3</p><p>4</p><p>5</p><p>6</p><p>7</p><p>8</p><p>15</p><p>16</p><p>1) Selects Setup Main Screen</p><p>2) Selects Status Main Screen</p><p>3) Return to previous Screen</p><p>4) Left select</p><p>5) Green OK LED</p><p>6) Yellow warning LED</p><p>7) Red Alarm Led</p><p>8) Run Push Button</p><p>9) Selects Menu Main Screen</p><p>10) Selects Main Service Screen</p><p>11) Information about current screen is shown when</p><p>pushed.</p><p>12) UP arrow,</p><p>moves up to next screen or increases</p><p>number when changing data</p><p>13) Right select</p><p>14) OK selects option offered on current screen and</p><p>then accepts data entered.</p><p>15) Down arrow, Moves down to next screen or</p><p>changes number to lower value when changing data.</p><p>16) Stops compressor or resets fault.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 17</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Description of the LCP Screens</p><p>Status</p><p>1.1 Displays pressure, Life Savings, etc</p><p>1.2 Displays RPM, Savings, Pressure</p><p>1.3 Displays graph of pressure</p><p>1.4 Displays graph of Percent Load</p><p>1.5 Displays Start time and Stop time, software</p><p>version, service contact number, running hours, date</p><p>Setup</p><p>2.1 Target Pressure</p><p>2.2 Auto Stop Pressure</p><p>2.3 Schedule Start / Stop (On / Off)</p><p>2.4 Schedule Start time set</p><p>2.5 Schedule Stop time set</p><p>2.6 Energy Savings Reset</p><p>Menu</p><p>3.1 Set Date and Time</p><p>3.2 Turn PORO ON/Off</p><p>3.3 PORO Start delay time</p><p>3.4 Remote Control</p><p>3.5 Modbus ON/OFF</p><p>3.6 Modbus Address</p><p>3.7 Modbus Baud Rate</p><p>3.8 Energy Rate</p><p>3.9 Units of Pressure PSI, Bar, kPA</p><p>3.10 Language Select</p><p>Service</p><p>Service Information</p><p>Has an id number of 4.1.X, where X is from 1 to 6</p><p>4.1.1 Rated HP/KW</p><p>4.1.2 VFD Serial Number</p><p>4.1.3 After Cooler Discharge Pressure</p><p>4.1.4 Dryer Discharge Pressure</p><p>4.1.5 Dryer Pressure Drop</p><p>4.1.6 Immediate Stop Pressure</p><p>Service</p><p>Set Points</p><p>To activate select OK then push up or down button,</p><p>to escape push the Service button</p><p>Has an id of 4.2.X, where X is form 1 to 3</p><p>4.2.1 Calibrate P1</p><p>4.2.2 Calibrate P2</p><p>4.2.3 Maintenance Timer reset</p><p>Service</p><p>Alarm Log</p><p>Has an id of 4.3.X, where X is from 1 to 15</p><p>The last alarm is display first. Press OK on the</p><p>selected alarm to obtain more information. You can</p><p>then scroll up/down to inspect conditions</p><p>drive parameters.</p><p>Service Menu Continued on next page:</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 18</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Service</p><p>Factory Service</p><p>Factory Service Code (Password protected)</p><p>For access to this section of the controller, a pass</p><p>code is asked for, that code is 01945. (Under no cir-</p><p>cumstance should this code be given out to custom-</p><p>ers).</p><p>4.4.1 Service Contact Information</p><p>This is where the Technician can input in the local</p><p>service provider name and phone number so it will</p><p>display the information on the LCP under Menu pa-</p><p>rameter 1.5.</p><p>4.4.2 Dryer</p><p>Enable / Disable TAS (Dryer) package in the soft-</p><p>ware.</p><p>4.4.3 PORO (Power Out Restart Option)</p><p>If the PORO option has been field installed, this is</p><p>where it must be turned on before the controller will</p><p>accept commands from other set points throughout</p><p>the controller.</p><p>4.4.4 Hour Meter Adjustment</p><p>Access this function if controller is being replaced</p><p>and the customer wants the new controller to have</p><p>the old controller’s hours on it.</p><p>4.4.5 Adjust Minimum Speed</p><p>This allows the user to adjust the drive to a range of</p><p>25% to 99%. See page 33 for logic description. De-</p><p>fault is 75 % and is not active unless turned on in</p><p>Menu mode parameter 3.4 and digital inputs are</p><p>used per the wiring schematic in the owners manual.</p><p>4.4.6 VFD Special Parameter</p><p>Allows technician to view current drive parameters</p><p>by putting the codes below into the parameter list.</p><p>4.4.7 RFI Filter</p><p>Enable or disable RFI filter. See page 33 for descrip-</p><p>tion.</p><p>4.4.8 DC Link Compensation</p><p>DC Link Compensation can be turned On or Off.</p><p>Default is Off</p><p>See page 31 and page 33 Software version 1.30</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 19</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Perform the following if you are having prob-</p><p>lems with the LCP Readout.</p><p>If the Power LED is NOT lit.</p><p>1) Check Input Fuses</p><p>2) Check Input Power</p><p>- Possible Faulty Drive</p><p>If the Power LED is lit.</p><p>1) Check LCP Contrast</p><p>by holding the Status Button and Pressing the Up</p><p>and Down navigation keys</p><p>2) Check LCP Cable</p><p>Trouble Shooting the LCP</p><p>Does the display have lines in it but no useful infor-</p><p>mation?</p><p>1) Check the cable for lose connections .</p><p>2) If the unit is outside and subject to water replace</p><p>the LCP.</p><p>See flow chart next on the next page for more Trou-</p><p>bleshooting.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 20</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Is LCP cable</p><p>properly</p><p>seated?</p><p>Properly seat</p><p>cable.</p><p>Exchange</p><p>LCP</p><p>Does it</p><p>work?</p><p>Replace LCP.</p><p>Is 24VDC</p><p>present on</p><p>power sup-</p><p>ply</p><p>Contact your</p><p>Regional Tech-</p><p>nical Support</p><p>Team</p><p>Check con-</p><p>trol wires for</p><p>shorts.</p><p>Plug controller di-</p><p>rectly into drive. If it</p><p>works replace the</p><p>cable.</p><p>YES</p><p>NO</p><p>NO</p><p>NO</p><p>NO</p><p>YES</p><p>YES</p><p>YES</p><p>YES</p><p>Is the</p><p>Power</p><p>LED</p><p>green?</p><p>Check LCP</p><p>Contrast</p><p>(Hold Status and or</p><p>the up and down</p><p>navigation keys)</p><p>NO</p><p>Is input</p><p>power pre-</p><p>sent?</p><p>Correct power</p><p>delivery.</p><p>YES</p><p>NO</p><p>Are fuses</p><p>OK?</p><p>Replace</p><p>fuse.</p><p>Continuity</p><p>check.</p><p>Contact your</p><p>Regional Tech-</p><p>nical Support</p><p>Team</p><p>NO</p><p>YES</p><p>YES</p><p>NO</p><p>Contact your</p><p>Regional Techni-</p><p>cal Support</p><p>Trouble Shooting the LCP</p><p>Continuation</p><p>Continue to next column</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 21</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>If Compressor has blown incoming fuse.</p><p> Do Not Attempt to replace fuses.</p><p> Do Not Attempt to Restart the compressor!</p><p>Further Damage May Result</p><p>Perform the Static Tests and IGBT Test to</p><p>determine if drive is faulty (see next page for start</p><p>of procedures).</p><p>If compressor passes Static Test, replace fuses,</p><p>Terminal</p><p>Number</p><p>Function</p><p>18 VFD/Fixed</p><p>19 HAT (24 volts DC)</p><p>27 Dryer Status</p><p>29 Dryer Control (24 volts DC)</p><p>32 Remote Load Enable</p><p>33 Remote Load/Unload</p><p>37 Emergency Stop (24 volts DC)</p><p>42 PORO Alarm (24 volts DC)</p><p>Terminal Block</p><p>01, 02, 03 Fan Control (24 volts DC)</p><p>Terminal Block</p><p>04, 05, 06 Common Alarm Relay</p><p>Terminal Block</p><p>53 Discharge Pressure (24 volts DC)</p><p>54 Dryer Output Pressure (24 volts DC)</p><p>Terminal Block</p><p>Drive Terminal Pin Connections</p><p>The following is a list of the commonly</p><p>accessed terminals pins</p><p>General Troubleshooting</p><p>Terminal 13 is a common terminal and must be con-</p><p>nected to terminal 37 before the VFD will run. The E-</p><p>Stop button is connected between these two termi-</p><p>nals. If this connection is broken you will get</p><p>Alarm 68.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 22</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Static Testing description for VFD drives on the 15-30kW (20- 40 HP) Nirvana</p><p>In the event that blown inputs fuses are found, a simple set of ohmmeter checks can be performed on the drive</p><p>to locate any shorted rectifier diodes or IGBTs. These tests should also be performed before to applying power</p><p>to a drive if its condition is unknown. Lock out and tag out the machine and ensure that all power has been re-</p><p>moved from the drive and that the DC Capacitors have been sufficiently discharged prior to performing these</p><p>tests (measure the DC bus with a meter). Also be sure that the motor leads are disconnected from the output</p><p>terminals of the drive. A Fluke 87 multimeter or equivalent with a diode test should be sued to perform these</p><p>test.</p><p>Be aware that there are 3 different drives frames that we use on the Nirvana B2, C1, C2.</p><p>Technical Overview</p><p>The Drives used on the 15-30kW (20-40HP) Nirvana use three different frame sizes, The Drive’s DC Buss is</p><p>accessible at the top of the drive. There are holes where a voltmeter probes can be inserted.</p><p>Testing procedure for B2 Frame is on pages 23 and 24.</p><p> Drive frame B2 is used on the 20/25 High Voltage units only.</p><p> Drive frame B2 have all diodes on the input.</p><p>Testing procedure for C1 and C2 Frames is on page 25 and 26.</p><p> Drive frame C1 is used on the 20/25 Low Voltage units and the 30/40 High Voltage units.</p><p> Drive frame C2 is used on the 30/40 Low Voltage units.</p><p> The C1 and C2 frame sizes have 3 diode/SCR packs on the input. The diodes feeds the – Buss and the</p><p>SCRs feed the + Buss.</p><p>Caution</p><p>Frame size C1 and C2 have SCRs in the input bridge going to the positive (+). When the drive first starts up a</p><p>control circuit fires the SCRs to get Buss voltage. The control board gets its power directly from the incoming line</p><p>after the input filters.</p><p>Under certain conditions the SCRs can be turned off. If this happens there will be some Buss voltage but it will</p><p>be falling. There will be no warning that the control board has shut the SCRs off. After approximately 10 sec-</p><p>onds if everything is normal and the Buss voltage is built up, the drive cooling fan will turn on and the 3 status</p><p>LEDs will be enabled.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 23</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Static Testing</p><p>This Procedure checks the First Set of Input Rectifier Diodes on HV 20-25 HP (15-18.5kW) High</p><p>Voltage Units Only (B2 Frame Size)</p><p>Prerequisites Before Starting These Procedures</p><p>1.Power must be removed from the drive and Lock Out Tag Out procedures in place for this test.</p><p>2.If drive has blown the input fuses or has been repaired, it is always recommended to carry out a static test.</p><p>3.Connect the drive to mains and power it up only after conducting the static test.</p><p>4.Take all the necessary safety precautions for system start up prior to applying power to the drive.</p><p>5. Always use proper Personal Protective Equipment when working with high voltage after the test is complete.</p><p>Step - 01 Select diode test on multimeter and connect the negative terminal of the multimeter lead to the posi-</p><p>tive DC bus.</p><p>Step - 02 Connect the positive terminal of the multimeter lead to the input terminal L1, L2, L3 and check each in</p><p>turn. The multimeter will show a diode voltage of around 0.4 volt on the three terminals in respect to the +DC</p><p>Bus terminal. The exact reading is not important; however you should get approximately the same reading on all</p><p>three test points. If not then the drive must be repaired by a local Danfoss repair center or replaced.</p><p>Step - 03 Reverse the meter leads. Connect the positive terminal of the meter lead to the positive DC bus.</p><p>Step - 04 Connect the negative terminal of the meter lead to the input terminals L1, L2, L3 and check each in</p><p>turn. The multimeter will show charging on all three phases NOTE: only allow the meter stay connected long</p><p>enough to watch the voltage start to climb. If you allow the meter to stay connected long enough the me-</p><p>ter will charge the capacitor fully and the meter will show OL in the display. If the capacitors charge fully</p><p>place the volt meter on DC voltage and discharge the capacitors. If the test does not show charging then</p><p>the drive must be repaired by a local Danfoss repair center or replaced.</p><p>This Procedure checks the Second Set of Input Rectifier Diodes on HV 20-25 HP (15-18.5kW) High</p><p>Voltage Units Only (B2 Frame Size)</p><p>Step - 05 Connect the positive terminal of the multimeter meter lead to the negative DC bus.</p><p>Step - 06 Connect the negative terminal of the multimeter lead to the input terminal L1, L2, L3 and check each in</p><p>turn. The multimeter will show the diode voltage of around 0.4 volt on the three terminals. The exact reading is</p><p>not important however you should get approximately the same reading on all three test points. If not then the</p><p>drive must be repaired by a local Danfoss repair center or replaced.</p><p>Step – 07 Reverse the meter leads. Connect the negative terminal of the meter lead to the negative DC bus.</p><p>Step – 08 Connect the positive terminal of the meter lead to the input terminals L1, L2, L3 in turn. The multimeter</p><p>will show charging on all three phases. NOTE: only allow the meter stay connected long enough to watch</p><p>the voltage start to climb. If you allow the meter to stay connected long enough the meter will charge the</p><p>capacitor fully and the meter will show OL in the display. If the test does not show charging then the drive</p><p>must be repaired by a local Danfoss repair center or replaced.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 24</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>This Procedure checks the First set of IGBT’s in output module on HV 20-25 HP (15-18.5kW) High</p><p>Voltage Units Only (B2 Frame Size)</p><p>Step – 09 Connect the positive terminal of the multimeter meter lead to the positive DC bus.</p><p>Step – 10 Connect the negative terminal of the multimeter lead to the motor terminal U, V, W in turn. NOTE:</p><p>only allow the meter stay connected long enough to watch the voltage start to climb. If you allow the me-</p><p>ter to stay connected long enough the meter will charge</p><p>the capacitor fully and the meter will show OL in</p><p>the display. If the test does not show charging then the drive must be repaired by a local Danfoss repair center</p><p>or replaced.</p><p>Step – 11 Reverse the meter leads. Connect the negative terminal of the meter lead to the positive DC bus and</p><p>connect the positive terminal of the meter lead to motor terminals U, V and W. The multimeter will show the di-</p><p>ode voltage of around 0.4 volt on the three terminals (after allowing time for the reading to stabilize). The exact</p><p>reading is not important however you should get approximately the same reading on all three test points. If not</p><p>then the drive must be repaired by a local Danfoss repair center or replaced.</p><p>Procedure to conduct static test on the Second Set of IGBT’s in output module on HV 20-25 HP (15-</p><p>18.5kW) High Voltage Units Only (B2 Frame Size)</p><p>Step – 12 Connect the negative terminal of the multimeter meter lead to the negative DC bus.</p><p>Step - 13 Connect the positive terminal of the multimeter lead to the motor terminal U, V, W in turn. NOTE: only</p><p>allow the meter stay connected long enough to watch the voltage start to climb. If you allow the meter to</p><p>stay connected long enough the meter will charge the capacitor fully and the meter will show OL in the</p><p>display. If the test does not show charging then the drive must be repaired by a local Danfoss repair center or</p><p>replaced.</p><p>Step – 14 Reverse the meter leads. Connect the positive terminal of the meter lead to the negative DC bus.</p><p>Step – 15 Connect the negative terminal of the meter lead to the motor terminals U, V, W in turn. The multimeter</p><p>should show the diode voltage of around 0.4 volt on the three terminals (after allowing time for the reading to</p><p>stabilize). The exact reading is not important however you should get approximately the same reading on all</p><p>three test points. If not then the drive must be repaired by a local Danfoss repair center or replaced.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 25</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>This Procedure checks the First Set of Input Rectifier IGBT’s on 20-25 HP (15-18.5kW) (Low Volt-</p><p>age Units) and the 30/40 HP (22-30kW) (High and low Voltage Units) C1 and C2 Frame Sizes</p><p>Prerequisites Before Starting These Procedures</p><p>1.Power must be removed from the drive and Lock Out Tag Out procedures in place for this test.</p><p>2.If drive has blown the input fuses or has been repaired, it is always recommended to carry out a static test.</p><p>3.Connect the drive to mains and power it up only after conducting the static test.</p><p>4.Take all the necessary safety precautions for system start up prior to applying power to the drive.</p><p>5. Always use proper Personal Protective Equipment when working with high voltage after the test is complete.</p><p>Step - 01 Select diode test on multimeter and connect the negative terminal of the multimeter lead to the posi-</p><p>tive DC bus.</p><p>Step - 02 Connect the positive terminal of the multimeter lead to the input terminal L1, L2, L3 and check each in</p><p>turn. The multimeter will show OL on the three terminals in respect to the +DC Bus terminal. You should get the</p><p>same reading on all three test points. If not then the drive must be repaired by a local Danfoss repair center or</p><p>replaced.</p><p>Step - 03 Reverse the meter leads. Connect the positive terminal of the meter lead to the positive DC bus.</p><p>Step - 04 Connect the negative terminal of the meter lead to the input terminals L1, L2, L3 and check each in</p><p>turn. The multimeter will show charging on all three phases NOTE: only allow the meter stay connected long</p><p>enough to watch the voltage start to climb. If you allow the meter to stay connected long enough the me-</p><p>ter will charge the capacitor fully and the meter will show OL in the display. If the test does not show</p><p>charging then the drive must be repaired by a local Danfoss repair center or replaced.</p><p>This Procedure checks the Second Set of Input Rectifier Diodes on 20-25 HP (15-18.5kW) (Low</p><p>Voltage Units) and the 30/40 HP (22-30kW) (High and low Voltage Units) C1 and C2 Frame Sizes</p><p>Step - 05 Connect the positive terminal of the multimeter meter lead to the negative DC bus.</p><p>Step - 06 Connect the negative terminal of the multimeter lead to the input terminal L1, L2, L3 and check each in</p><p>turn. The multimeter will show the diode voltage of around 0.4 volt on the three terminals. The exact reading is</p><p>not important however you should get approximately the same reading on all three test points. If not then the</p><p>drive must be repaired by a local Danfoss repair center or replaced.</p><p>Step – 07 Reverse the meter leads. Connect the negative terminal of the meter lead to the negative DC bus.</p><p>Step – 08 Connect the positive terminal of the meter lead to the input terminals L1, L2, L3 in turn. The multimeter</p><p>will show OL on all three phases in respect to the - DC buss. If not then the drive must be repaired by a local</p><p>Danfoss repair center or replaced.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 26</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>This Procedure checks the First Set of IGBT’s in output module on 20-25 HP (15-18.5kW) (Low</p><p>Voltage Units) and the 30/40 HP (22-30kW) (High and low Voltage Units) C1 and C2 Frame Sizes</p><p>Step – 09 Connect the positive terminal of the multimeter meter lead to the positive DC bus.</p><p>Step – 10 Connect the negative terminal of the multimeter lead to the motor terminal U, V, W in turn. NOTE:</p><p>only allow the meter stay connected long enough to watch the voltage start to climb. If you allow the</p><p>meter to stay connected long enough the meter will charge the capacitor fully and the meter will show</p><p>OL in the display. If the test does not show charging then the drive must be repaired by a local Danfoss repair</p><p>center or replaced.</p><p>Step – 11 Reverse the meter leads. Connect the negative terminal of the meter lead to the positive DC bus and</p><p>connect the positive terminal of the meter lead to motor terminals U, V and W. The multimeter will show the</p><p>diode voltage of around 0.4 volt on the three terminals . The exact reading is not important however you should</p><p>get approximately the same reading on all three test points. If not then the drive must be repaired by a local</p><p>Danfoss repair center or replaced.</p><p>This Procedure checks the Second Set of IGBT’s in Output Module on 20-25 HP (15-18.5kW)</p><p>(Low Voltage Units) and the 30/40 HP (22-30kW) (High and low Voltage Units) C1 and C2 Frame Sizes</p><p>Step – 12 Connect the negative terminal of the multimeter meter lead to the negative DC bus.</p><p>Step - 13 Connect the positive terminal of the multimeter lead to the motor terminal U, V, W in turn. NOTE:</p><p>only allow the meter stay connected long enough to watch the voltage start to climb. If you allow the</p><p>meter to stay connected long enough the meter will charge the capacitor fully and the meter will show</p><p>OL in the display. If the test does not show charging then the drive must be repaired by a local Danfoss repair</p><p>center or replaced.</p><p>Step – 14 Reverse the meter leads. Connect the positive terminal of the meter lead to the negative DC bus.</p><p>Step – 15 Connect</p><p>the negative terminal of the meter lead to the motor terminals U, V, W in turn. The multime-</p><p>ter should show the diode voltage of around 0.4 volt on the three terminals. The exact reading is not important</p><p>however you should get approximately the same reading on all three test points. If not then the drive must be</p><p>repaired by a local Danfoss repair center or replaced.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 27</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>2) Remove drive cover by removing 6 thorax screws.</p><p>(Some covers may have 8 screws.)</p><p>Replacement of Drive Control Board</p><p>1) Turn power off and wait 15 minutes and then</p><p>remove drive access panel.</p><p>3) Remove LCD cable and plastic adaptor by</p><p>loosing the two screws holding the cable plug to</p><p>the plastic cover. (Some plugs may be connected</p><p>directly to the board plug as shown at step 5. If so</p><p>then skip to step 6)</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 28</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Replacement of Drive Control Board</p><p>continued</p><p>4) Remove plastic cover by squeezing in at the</p><p>sides of the cover.</p><p>5) Remove Drive IntelliKey key by pulling straight</p><p>out at arrows.</p><p>6) Go ahead and remove top screw for board</p><p>plate then remove screws to remove bottom</p><p>cover.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 29</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Replacement of Drive Control Board con-</p><p>tinued</p><p>7) Push in at sides with straight blade screwdriver,</p><p>then pull straight out.</p><p>9) Remove the metal frame from the control board</p><p>by holding the metal frame and pushing down on the</p><p>control board at the arrows.</p><p>8) After removing the bottom cover remove the last</p><p>screw holding the board to the drive at the arrow.</p><p>Board can now be removed by pulling straight up.</p><p>10) To attach the metal frame to the replacement</p><p>control board insert the metal tabs, of the metal</p><p>frame, into the metal holder of the control board.</p><p>Reverse the removal procedure to complete the</p><p>installation.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 30</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Important Note When Replacing the Drive</p><p>Dip Switch Settings</p><p>When replacing drive, remove the key from old drive</p><p>to use in replacement drive. Before inserting the key</p><p>in the new drive, check the positions of the switches</p><p>S201 and S202.</p><p>These switches come from the factory in the left po-</p><p>sition for voltage input. They need to be moved to</p><p>the right/on position (switches are in the left posi-</p><p>tion as pictured below) for the 4-20 ma inputs of the</p><p>pressure transducers. Do not change the positions</p><p>of these switches with the power on. These switches</p><p>are delicate and it does not take much force to</p><p>change them.</p><p>The switch S801, on the left, is for communication</p><p>buss termination.</p><p>Start up procedure error will be given when the drive</p><p>is replaced.</p><p>The time, pressure set points and maintenance timer</p><p>will need to be set.</p><p>S2</p><p>02</p><p>S2</p><p>01</p><p>S8</p><p>01</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 31</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Turning RFI Filter OFF</p><p>The RFI filter is set to on by default.</p><p>The purpose of a RFI (Radio Frequency Interfer-</p><p>ence) filter is to remove out bound noise from the</p><p>drive.</p><p>If you have balanced incoming line voltage, (such</p><p>as a transformer with a Y output to the drive) the</p><p>filter can be left on. If the filter is on and the voltage</p><p>is not balanced the drive may trip out on DC Over</p><p>volt.</p><p>Note that if the LCD detects inactivity for over 10</p><p>seconds the LCD will return to the default screen,</p><p>which is the Status screen, if this occurs.</p><p>To turn the AC Filter off, push the Service button</p><p>on the LCD and the push the down arrow until you</p><p>reach the Factory Service screen, then press OK</p><p>button to enter this screen.</p><p>Press OK to allow the entering of the password.</p><p>To enter the password of 01945, use the left button</p><p>to position the curser at 00000 and the up arrow to</p><p>change the numbers. Use the right button to enter</p><p>the next number. Continue until you have entered</p><p>the last number on the right, then push the OK but-</p><p>ton to accept.</p><p>Push the down arrow until you reach the RFI</p><p>screen, press the OK button enable the changing</p><p>of the filter. Use the up or down button to turn the</p><p>filter on or off. Use the OK button to accept the</p><p>change. You can either hit the Status button to re-</p><p>turn to the home position or wait for 10 seconds for</p><p>the automatic return to home position.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 32</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 33</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Software Version 1.10</p><p> This revision was made to improve the opera-</p><p>tion when used with a X4i controller.</p><p> One screen was removed and one was added.</p><p> Screen 2.3 “Fixed Speed Enable” was re-</p><p>moved and the screens 2.4 to 2.7 were moved</p><p>up one extension number.</p><p> “Adjust Minimum Speed” screen 4.4.5 was in-</p><p>serted after 4.4.4.</p><p> The original screens after 4.4.4 were renum-</p><p>bered by adding one extension number.</p><p> The PID values were changed to allow for</p><p>faster response to pressure changes.</p><p> The control software was changed so that the</p><p>digital input that was designated for switching</p><p>the compressor from fixed to variable speed</p><p>was changed to run in the following modes:</p><p>True Variable Speed: The compressor will be al-</p><p>lowed to track demand based on its own target</p><p>pressure; running from its true minimum speed</p><p>(1500 rpm) to its true maximum speed (6000 rpm,</p><p>or based on the speed table for the target pres-</p><p>sure).</p><p>Restricted Variable Speed: The compressor will</p><p>be allowed to track demand based on its own tar-</p><p>get pressure; running from a speed that is 75% of</p><p>the maximum speed, to its true maximum speed</p><p>6000 rpm, or based on the speed table for the tar-</p><p>get pressure. This is the same as the first version</p><p>of software. This function is used when you have 2</p><p>units running and one unit is at 100% output but</p><p>need to slightly reduce the output from the second</p><p>unit to maintain control. When the restricted vari-</p><p>able speeds contact is closed on the second unit</p><p>this allows both machines to run loaded and not</p><p>have one unit constantly starting and stopping. The</p><p>Restricted VFD minimum speed parameter should</p><p>have a factory default of 75% but be adjustable</p><p>from 25% to 100%, where 100% will effectively be</p><p>a fixed speed mode. This is set in the Factory Ser-</p><p>vice Menu parameter 4.4.5. Adjust this parameter</p><p>as necessary to obtain the desired performance.</p><p>This logic is used primarily for the X4i, X8i, etc.</p><p>.</p><p>The drive has a differential pressure of 10 PSI built</p><p>into the software when using the built in pressure</p><p>transducer. If the customer requires a wider DP</p><p>range you can use a customer supplied remote DP</p><p>switch to load and unload the machine by using the</p><p>digital inputs. First it will be necessary to install a</p><p>customer supplied switch connected to the Remote</p><p>Load Enable contact of the compressor and mount it</p><p>in a convenient location (Remote Load Enable Ter-</p><p>minal 32 - see wiring diagram in owner’s manual).</p><p>When the Remote Load Enable input is made the</p><p>compressor will load and unload using the pressure</p><p>setting on the DP switch. Use the contacts on the DP</p><p>switch to operate the remote load unload contact</p><p>(terminal 33) on the drive.</p><p>To use Remote Load Enable, Remote Load/</p><p>Unload, VFD/Fixed (restricted) digital inputs or</p><p>Modbus you must enable it in the LCP Menu</p><p>mode parameter 3.4. (Digital) or 3.5 (Modbus)</p><p>Software Version 1.20</p><p> Compressor maintenance base time changed</p><p>from 3000 hours to 2000 hours.</p><p>Software Version 1.3</p><p> Disabling of DC-link compensation (Danfoss ref-</p><p>erence CR81625). This change resulted in the</p><p>special DSP software version 4.28.</p><p>The DC-link compensation parameter (14-51)</p><p>defaults to “OFF.”</p><p> Parameter 14-03 (Over modulation) set to “ON”</p><p>by default.</p><p> Parameter 14-10 (Mains Failure) set to “Alarm”</p><p>by default.</p><p> Set the mains failure alarm to a manual reset</p><p>only alarm.</p><p> Set the mains phase loss (DC ripple) alarm to</p><p>trip lock (same as FC-302) to match the function-</p><p>ality provided by the DSP.</p><p>Updated fan and dryer control to remove synchroni-</p><p>zation issues with the timers.</p><p>Nirvana 15-30kW (20-40Hp)</p><p>Troubleshooting Manual</p><p>Nirvana 15 - 30kW (20-40Hp) Troubleshooting Manual Page 34</p><p>Issue 05 Rev E Davidson, Oct 2010. ©Ingersoll Rand Proprietary Information</p><p>Danger</p><p>Please utilize extreme caution when performing work within the compressor cabinet.</p><p>When opening the cabinet: be certain the drive protective cover is in place, wear appropriate PPE</p><p>(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures</p><p>are followed.</p><p>Revision History</p><p>Original manual dated February 2007</p><p>Issue 2 Revision A , dated February 2008</p><p>Contains software changes made by 1.10 operating</p><p>software, Instructions for changing the drive, added</p><p>additional warning and alarm codes, added warning</p><p>about LCD getting wet, added perform startup proce-</p><p>dure warning</p><p>Issue 3 Revision B , dated July 2008</p><p>Manual completely revised. Training material re-</p><p>moved.</p><p>Issue 4 Revision C , dated March 2010</p><p>Revised alarms format and added additional alarms.</p><p>Removed reference to troubleshooting software.</p><p>Added IR VFD Inputs and Outputs on page 7.</p><p>Added motor wiring diagram page 8.</p><p>Added Mechanical Notes page 6.</p><p>Added Static Testing procedures pages 20-27 .</p><p>Added Drive / Motor Investigation Site Log page 38.</p><p>Issue 5 Revision D , dated May 2010</p><p>Corrected fault 65 duplication on page 12.</p><p>Added information to Restricted Variable Speed on</p><p>page 35.</p><p>Corrected and expanded parameter list on page 16</p><p>and extended parameters to page 17.</p><p>Issue 5 Revision E , dated Oct 2010</p><p>Revised static testing procedures on VFD drives</p><p>pages 22 through 26.</p><p>Added information on physical location of alarm relay</p><p>contacts, page 5 and moved pages.</p><p>Corrected Restricted Variable Speed information on</p><p>page 32 for remote start stop using remote pressure</p><p>switch.</p><p>Corrected FSB number on A36 Fault on page 12</p><p>from 2008FSB-122 to 2009FSB-122.</p><p>Changed revision history to reflect issue first then</p><p>revision on this page.</p><p>Added page to give description of static testing.</p><p>Added picture of rotor removal tool.</p><p>Changed the site log to correct the milliohm readings</p><p>for the 20-25 and 30-40 motors and added meter</p><p>requirements</p><p>Issue 5 Revision E , dated Oct 2010 cont.</p><p>Added motor testing information to page 9.</p><p>Environmental Concerns for the Drive</p><p>CAUTION!!!</p><p>Introduction Diagnostics</p><p>Troubleshooting</p><p>Pre-Installation Checks</p><p>POWER QUALITY REQUIREMENTS</p><p>Remote Alarm Location B2 Frame</p><p>Remote Alarm Location C1 and C2 Frame</p><p>IR VFD Inputs and Outputs</p><p>High and low voltage motor wiring</p><p>Motor winding insulation testing with 1000 volt Megohm Meter and Milliohm Meter</p><p>Fault Messages</p><p>Table 1</p><p>Alarm Fault Codes</p><p>Alarm Messages</p><p>Note: these faults may be proceeded by a “A”</p><p>* Which designates them as an Alarm.</p><p>Alarm 4 - Main Phase Loss</p><p>(Automatically Resets)</p><p>Alarm 7 - DC Buss Over voltage</p><p>(Automatically Resets)</p><p>Alarm 8 – DC Buss Under voltage</p><p>(Automatically Resets)</p><p>Alarm 9 – Inverter Overload</p><p>(Automatically Resets)</p><p>Alarm 12 – Torque Limit</p><p>(Manual Reset)</p><p>Alarm 13 – Over current</p><p>(Locked IN)</p><p>Alarm 33 – Inrush Fault “Soft-charge Fault”</p><p>(Locked IN)</p><p>(Manual Reset)</p><p>Alarm 38 – Internal Fault</p><p>(Locked IN)</p><p>Alarm 47 – 24V Supply Low</p><p>(Locked IN)</p><p>Alarm 48 – 1.8V Supply Low</p><p>(Locked IN)</p><p>Alarm 14 – Earth Fault</p><p>(Locked IN)</p><p>Alarm 16 – Short Circuit</p><p>(Locked IN)</p><p>Alarm 29 – Drive Heat sink Over Temperature</p><p>(Locked IN)</p><p>Alarm 30, 31, 32 – Missing Motor Phase</p><p>(Locked IN)</p><p>Table 2</p><p>IR Specific Fault Codes</p><p>This table shows warning codes along with alarms that are</p><p>only in IR Software / drives.</p><p>Alarm 65 – “Control Card Over Temperature”</p><p>(Locked IN)</p><p>The cut-out temperature of the control card is 80° C / 176 F.</p><p>Alarm 68 – E-Stop “Safe Stop Activated”</p><p>(Manual Reset)</p><p>“No Intellikey”</p><p>(201) “Incorrect Intellikey”</p><p>(Locked IN)</p><p>If no Intellikey is installed or Intellikey does not match the drive frame size, an alarm will occur.</p><p>"HAT Switch Opened"</p><p>(Manual Reset)</p><p>Check that cooling fan overload has not tripped.</p><p>If dryer is installed check that overpressure trip has</p><p>not occurred. If the alarm does not latch in check</p><p>current draw to motor to insure that the motor thermal</p><p>is not being made. Also check the main cooling fan,</p><p>if the set screw is lose that attaches the fan to the</p><p>motor the fan can contact the bottom of the fan housing causing the fan motor over load to trip. Be aware that there are three switches connected to this one alarm input.</p><p>"P1 Sensor Calibration Failure"</p><p>(Manual Reset)</p><p>Alarm for P1Pressure Sensor when a Sensor Calibration is attempted and the zero (0) PSI reading is less than 3.5mA or greater than 5.6mA.</p><p>Check wiring to pressure sensors</p><p>"P2 Sensor Calibration Failure"</p><p>(Manual Reset)</p><p>Alarm</p>