Trane TR150, TR170 Service Manual

TR150 and TR170 Service Manual

February 2017

BAS-SVM04B-EN

Contents TR150 and TR170 Service Manual

Contents

1 Introduction

1.1 Purpose

1.2 Product Overview

1.3 Safety

1.4 Electrostatic Discharge (ESD)

1.5 Tools Required

1.6 Electrical Installation in General

1.6.1 Electrical Installation in General 10

1.7 Exploded Views – H Frame Size

1.8 Exploded Views - I Frame Size

1.9 Ratings

1.9.1 Short Circuit and Overcurrent Trips 17

1.9.2 DC Voltage Levels 17

2 Frequency Converter Control

2.1 Introduction

2.2 Status Messages

2.3 Frequency Converter Inputs and Outputs

2.3.1 Input Signals 18

2.3.2 Output Signals 19

2.4 Service Functions

2.5 Control Terminals

2.6 Control Terminal Functions

2.7 Grounding Shielded Cables

3 Internal Frequency Converter Operation

3.1 General

3.2 Description of Operation

3.2.1 Control Logic Section 23

3.2.2 Logic to Power Interface 24

3.2.3 Power Section 24

3.3 Sequence of Operation

3.3.1 Rectier Section 24

3.3.2 Intermediate Section 24

3.3.3 Inverter Section 25

3.3.4 Fan Speed Control 25

4 Troubleshooting

4.1 Troubleshooting Tips

4.2 Exterior Fault Troubleshooting

Contents

4.3 Fault Symptom Troubleshooting

4.4 Visual Inspection

4.5 Fault Symptoms

4.5.1 No Display

4.5.2 Intermittent Display 30

4.5.3 Display (Line 2) Flashing 30

4.5.4 WRONG or WRONG LCP Shown

4.5.5 Motor Will Not Run 30

4.5.6 Incorrect Motor Operation 31

4.6 Warnings and Alarms

4.6.1 Alarms 32

4.6.2 Warnings 32

4.6.3 Warning And Alarm Messages

4.7 After Repair Tests

5 Frequency Converter and Motor Applications

5.1 Torque Limit, Current Limit, and Unstable Motor Operation

5.1.1 Overvoltage Trips 39

5.1.2 Mains Phase Loss Trips 40

5.1.3 Control Logic Problems 40

5.1.4 Programming Problems 40

5.1.5 Motor/Load Problems 41

5.2 Internal Frequency Converter Problems

5.2.1 Overtemperature Faults 41

5.2.2 Current Sensor Faults 41

5.2.3 Signal and Power Wiring Considerations for Electromagnetic Compatibility 41

5.2.4 Eects of EMI 42

5.2.5 Sources of EMI 42

5.2.6 EMI Propagation 43

5.2.7 Preventive Measures 44

6 Test Procedures

6.1 Non-repairable Units

6.2 Introduction

6.3 Static Test Procedures

6.3.2 Rectier Circuit Test 48

6.3.3 Inverter Section Tests 48

6.3.4 Intermediate Section Tests 49

6.3.5 Location of UDC Terminals 49

6.4 Dynamic Test Procedures

6.4.1 No Display Test (Display is Optional) 52

Contents TR150 and TR170 Service Manual

6.4.2 Input Voltage Test

6.4.3 Basic Control Card Voltage Test 53

6.4.4 Input Imbalance of Supply Voltage Test 53

6.4.5 Input Waveform Test

6.4.6 Output Imbalance of Motor Supply Voltage Test 54

6.4.7 Input Terminal Signal Tests 55

6.5 Initial Start-up Or After Repair Drive Tests

7 H-Frame Size Disassembly and Assembly Instructions

7.1 Electrostatic Discharge (ESD)

7.2 General Disassembly Procedure

7.3 H6 Frame Size Disassembly and Assembly Instructions

7.3.1 Control Card and Control Card Mounting Plate 57

7.3.2 Heat sink Fan Assembly 58

7.3.3 DC Coil 59

7.3.4 DC Link Card 59

7.3.5 RFI Filter 60

7.3.6 Power Card 60

7.4 H7 Frame Size Disassembly and Assembly Instructions

7.4.1 Control Card and Control Card Mounting Plate 61

7.4.2 Power Card 61

7.4.3 Inrush Card 62

7.4.4 RFI Filter 62

7.4.5 Relay Transducer Card 63

7.4.6 Rectier Modules 63

7.4.7 IGBT 63

7.4.8 Heat Sink Fan Assembly 64

7.4.9 DC Coil 65

7.4.10 Capacitor Bank 65

7.5 H8 Frame Size Disassembly and Assembly Instructions

7.5.1 Control Card and Control Card Mounting Plate 66

7.5.2 Power Card 66

7.5.3 Inrush Card 67

7.5.4 Rectier Modules 67

7.5.5 RFI Filter 68

7.5.6 Relay Transducer Card 69

7.5.7 IGBT 69

7.5.8 Heat Sink Fan Assembly 70

7.5.9 DC Coil 71

7.5.10 Capacitor Bank 71

7.6 H10 Frame Size Disassembly and Assembly Instructions

Contents

7.6.1 Control Card and Control Card Mounting Plate

7.6.2 Power Card Cover 72

7.6.3 Power Card 73

7.6.4 Heat Sink and DC Coils

7.6.5 Heat Sink Fan Assembly 74

8 I-Frame Size Disassembly and Assembly Procedures

8.1 General Disassembly Procedure

8.2 I6 Frame Size Disassembly and Assembly Instructions

8.2.1 Control Card and Control Card Mounting Plate 75

8.2.2 Cable Mounting Plate 76

8.2.3 Heat Sink Fan Assembly 76

8.2.4 SMPS Card 77

8.2.5 Bus Bar Unit 77

8.2.6 Power Card 78

8.2.7 DC Coil 78

8.2.8 RFI Filter 79

8.3 I7 Frame Size Disassembly and Assembly Instructions

8.3.1 Control Card and Control Card Mounting Plate 79

8.3.2 Power Card 80

8.3.3 Power Card Mounting Plate 80

8.3.4 Inrush Card 81

8.3.5 Bus Bar 81

8.3.6 RFI Filter 82

8.3.7 Relay Transducer Card 82

8.3.8 Fan 83

8.3.9 Terminal Plate 83

8.3.10 DC Bus Bar Assembly 84

8.3.11 Heat Sink Fan Assembly 84

8.3.12 Capacitor Bank 85

8.3.13 DC Coil 85

8.3.14 IGBT 86

8.3.15 Thyristor 86

8.4 I8 Frame Size Disassembly and Assembly Procedure

8.4.1 Control Card and Control Card Mounting Plate 86

8.4.2 Power Card 87

8.4.3 Power Card Mounting Plate 88

8.4.4 Inrush Card 88

8.4.5 Bus Bar 89

8.4.6 RFI Filter 89

8.4.7 Relay Transducer Card 90

Contents TR150 and TR170 Service Manual

8.4.8 Terminal Plate

8.4.9 DC Bus Bar Assembly 91

8.4.10 Heat Sink Fan Assembly 91

8.4.11 Capacitor Bank

8.4.12 DC Coil 92

8.4.13 IGBT 93

8.4.14 Thyristor

9 Block Diagrams

9.1 Block Diagrams, Frame Sizes H and 9

9.1.1 H6 Frame Size 94

9.1.2 I6 Frame Size 95

9.1.3 H7, H8, I7, I8 Frame Size 96

9.1.4 H9 Frame Size 97

9.1.5 H10 Frame Size 98

Index

Introduction

1Introduction

1.1 Purpose

This manual provides the technical information and instructions required, for a qualied technician approved by Trane to identify faults and perform repairs and maintenance on the frequency converter:

Data for the dierent enclosure sizes

•

Description of user interfaces and internal

•

processing

Troubleshooting and test instructions

•

Assembly and disassembly instructions

•

The manual applies to frequency converter models and voltage ranges described in Table 1.2 to Table 1 . 4 .

1.2 Product Overview

TR150 and TR170 frequency converters are designed for the Heating, Ventilation, and Air-Conditioning (HVAC) markets. They operate in variable torque mode, and include features suited for fan and pump applications within the HVAC market.

1.3 Safety

nected (linkage of DC intermediate circuit). There may be high voltage on the DC-link even when the LEDs are turned potentially live parts of the frequency converter, wait at least as stated in Table 1 . 1.

2. Before conducting repair or inspection, disconnect mains.

4. During operation and while programming

5. When operating on a PM motor, disconnect

Volt age [V] Power range [kW ]

on the LCP does not disconnect mains.

[O]

parameters, the motor may start without warning. Press [Stop] when changing data.

motor cable.

3x200 0.25–3.7 4

3x200 5.5–11 15

3x400 0.37–7.5 4

3x400 11–90 15

3x600 2.2–7.5 4

3x600 11–90 15

Before touching any

o.

Minimum waiting

time (minutes)

CAUTION

Frequency converters contain dangerous voltages when connected to mains. Only qualied personnel should carry out the service. See also chapter 2.1 Introduction.

CAUTION

For dynamic test procedures, main input power is required and all devices and power supplies connected to mains are energized at rated voltage. Take extreme caution when conducting tests in a powered frequency converter. Contact with powered components could result in electrical shock and personal injury.

1. DO NOT touch electrical parts of the frequency converter when connected to mains. Also make sure that other voltage inputs have been discon-

Tab le 1.1 Dis c har ge Tim e

1.4 Electrostatic Discharge (ESD)

CAUTION

ELECTROSTATIC DISCHARGE

When performing service, use proper electrostatic discharge (ESD) procedures to prevent damage to sensitive components. Many electronic components within the frequency converter are sensitive to static electricity. The voltage of static electricity can reduce lifetime, sensitive electronic components.

•

performance, or completely destroy

aect

Do not touch components on the circuit boards.

Hold circuit boards by the edges or corners only.

Introduction TR150 and TR170 Service Manual

1.4.1 Frame Size Denitions

Model HP @200–240 V AC kW @200–240 V AC Frame Size IP Rating Repairable Yes/No

PK25 0.33 0.25 H1 IP20 No

PK37 0.5 0.37 H1 IP20 No

PK75 1.0 0.75 H1 IP20 No

P1K5 2.0 1.5 TR150: H1

TR170: H2

P2K2 3.0 2.2 H2 IP20 No

P3K7 5.0 3.7 H3 IP20 No

P5K5 7.5 5.5 H4 IP20 No

P7K5 10.0 7.5 H4 IP20 No

P11K 15.0 11.0 H5 IP20 No

P15K 20.0 15.0 H6 IP20 Yes

P18K 25.0 18.5 H6 IP20 Yes

P22K 30.0 22.0 H7 IP20 Yes

P30K 40.0 30.0 H7 IP20 Yes

P37K 50.0 37.0 H8 IP20 Yes

P45K 60.0 45.0 H8 IP20 Yes

Table 1.2 TR150 and TR170 Frequency Converters 200–240 V AC

IP20 No

1 1

Introduction

Model HP @380–480 V AC kW @380–480 V AC Frame Size IP Rating Repairable Yes/No

PK37 0.5 0.37 H1 IP20 No

PK75 1.0 0.75 H1 IP20 No

P1K5 2.0 1.5 TR150:H1

TR170:H2

P2K2 3.0 2.2 H2 IP20 No

P3K0 4.0 3.0 H2 IP20 No

P4K0 5.0 4.0 H2 IP20 No

P5K5 7.5 5.5 H3 IP20 No

P7K5 10.0 7.5 H3 IP20 No

P11K 15.0 11.0 H4 IP20 No

P15K 20.0 15.0 H4 IP20 No

P18K 25.0 18.0 H5 IP20 No

P22K 30.0 22.0 H5 IP20 No

P30K 40.0 30.0 H6 IP20 Yes

P37K 50.0 37.0 H6 IP20 Yes

P45K 60.0 45.0 H6 IP20 Yes

P55K 70.0 55.0 H7 IP20 Yes

P75K 100.0 75.0 H7 IP20 Yes

P90K 125.0 90.0 H8 IP20 Yes

PK75 1.0 0.75 I2 IP54 No

P1K5 2.0 1.5 I2 IP54 No

P2K2 3.0 2.2 I2 IP54 No

P3K3 4.0 3.3 I2 IP54 No

P4K0 5.0 4.0 I2 IP54 No

P5K5 7.5 5.5 I3 IP54 No

P7K5 10.0 7.5 I3 IP54 No

P11K 15.0 11.0 I4 IP54 No

P15K 20.0 15.0 I4 IP54 No

P22K 25.0 18.0 I4 IP54 No

P11K 15.0 11.0 I5 IP54 No

P15K 20.0 15.0 I5 IP54 No

P22K 25.0 18.0 I5 IP54 No

P22K 30.0 22.0 I6 IP54 Yes

P30K 40.0 30.0 I6 IP54 Yes

P37K 50.0 37.0 I6 IP54 Yes

P45K 60.0 45.0 I7 IP54 Yes

P55K 70.0 55.0 I7 IP54 Yes

P75K 100.0 75.0 I8 IP54 Yes

P90K 125.0 90.0 I8 IP54 Yes

IP20 No

Table 1.3 TR150 and TR170 Frequency Converters 380–480 V AC

Introduction TR150 and TR170 Service Manual

Model HP @525–600 V AC kW @525–600 V AC Frame Size IP Rating Repairable Yes/No

P2K2 3.0 2.2 H9 IP20 No

P3K0 4.0 3.0 H9 IP20 No

P5K5 7.5 5.5 H9 IP20 No

P7K5 10.0 7.5 H9 IP20 No

P11K 15.0 11.0 H10 IP20 Yes

P15K 20.0 15.0 H10 IP20 Yes

P22K 30.0 22.0 H6 IP20 Yes

P30K 40.0 30.0 H6 IP20 Yes

P45K 60.0 45.0 H7 IP20 Yes

P55K 70.0 55.0 H7 IP20 Yes

P75K 100.0 75.0 H8 IP20 Yes

P90K 125.0 90.0 H8 IP20 Yes

Table 1.4 Repairable Yes/No Frequency Converters 525–600 V AC

1.5 Tools Required

Quick Guide for TR150 and TR170.

ESD Protection Kit Wrist strap and Mat

Metric socket set 7–19 mm

Torque wrench 0.5 N · m to 19 N · m

Socket extensions 100–150 mm (4 in and 6 in)

Torx driver set T10-T50

Needle nose pliers

Magnetic sockets

Ratchet

Screwdrivers Standard and Philips

1 1

Table 1.5 Required Tools

Additional Tools Recommended for Testing

Digital voltmeter/ohmmeter (must be rated for

•

1000 V DC for 600 V units)

Analog voltmeter

•

Oscilloscope

•

Clamp-on style ammeter

•

Introduction

1.6 Electrical Installation in General

1.6.1 Electrical Installation in General

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper conductors are required. 75 °C (167 °F) is recommended. For TR170 drives operating in ambients over 50 °C (122 °F), copper conductors rated 80 °C (176 °F) or higher are recommended.

Power [kW (hp)] Torque [N · m (in-lb)]

Enclosure

size

TR150

H1 IP20 0.25–1.5

H2 IP20 2.2 (3) 2.2–4.0 (3–5) 0.8 (7) 0.8 (7) 0.8 (7) 0.5 (4) 0.8 (7) 0.5 (4)

H3 IP20 3.7 (5) 5.5–7.5 (7.5–10) 0.8 (7) 0.8 (7) 0.8 (7) 0.5 (4) 0.8 (7) 0.5 (4)

H4 IP20 5.5–7.5 (7.5–10) 11–15 (15–20) 1.2 (11) 1.2 (11) 1.2 (11) 0.5 (4) 0.8 (7) 0.5 (4)

H5 IP20 11 (15) 18.5–22 (25–30) 1.2 (11) 1.2 (11) 1.2 (11) 0.5 (4) 0.8 (7) 0.5 (4)

H6 IP20 15–18.5 (20–25) 30–45 (40–60) 4.5 (40) 4.5 (40) – 0.5 (4) 3 (27) 0.5 (4)

H7 IP20 22–30 (30–40) 55 (70) 10 (89) 10 (89) – 0.5 (4) 3 (27) 0.5 (4)

H7 IP20 – 75 (100) 14 (124) 14 (124) – 0.5 (4) 3 (27) 0.5 (4)

H8 IP20 37–45 (50–60) 90 (125)

TR170

H2 IP20 1.5 (2) 1.5 (2) 0.8 (7) 0.8 (7) 0.8 (7) 0.5 (4) 0.8 (7) 0.5 (4)

IP class 3x200–240 V 3x380–480 V Mains Motor DC

connection

0.37–1.5 (0.5–2) 0.8 (7) 0.8 (7) 0.8 (7) 0.5 (4) 0.8 (7) 0.5 (4)

(0.33–2)

24 (212)

Control

terminals

– 0.5 (4) 3 (27) 0.5 (4)

Ground Relay

Table 1.6 Tightening Torques for Enclosure Sizes H1–H8, 3x200–240 V & 3x380–480 V

Power [kW (hp)] Torque [N · m (in-lb)]

Enclosure

size

TR150

H9 IP20 2.2–7.5 (3–10) 1.8 (16) 1.8 (16) Not

H10 IP20 11–15 (15–20) 1.8 (16) 1.8 (16) Not

H6 IP20 18.5–30 (25–40) 4.5 (40) 4.5 (40) – 0.5 (4) 3 (27) 0.5 (4)

H7 IP20 37–55 (50–70) 10 (89) 10 (89) – 0.5 (4) 3 (27) 0.5 (4)

H8 IP20 75–90 (100–125) 14 (124)/24

Table 1.7 Tightening Torques for Enclosure Sizes H6–H10, 3x525–600 V

1) Cable dimensions >95 mm

2) Cable dimensions ≤95 mm

IP class 3x525–600 V Mains Motor DC

connection

recommended

14 (124)/24

(212)

Control

terminals

0.5 (4) 3 (27) 0.6 (5)

– 0.5 (4) 3 (27) 0.5 (4)

Ground Relay

Introduction TR150 and TR170 Service Manual

1.7 Exploded Views – H Frame Size

NOTICE

Non-repairable units are not shown with exploded views.

1 1

1 Blind cover 10 Filter protection cover

2Front cover LCP 11RFI lter

3Cradle 12EMC shield

4 Control card 13 Bus bar unit

5 Control card mounting plate 14 Heat sink fan assembly

6 DC coils 15 Connector

7 Coil mounting plate 16 DC coil cover

8 Coil mounting plate 17 Capacitor bank metal cover

9 DC link card 18 Capacitor vibration support

Illustration 1.1 Exploded View - H6 Frame Size

Introduction

1 Blind cover 13 Relay/transducer card mounting plate

2 LCP 14 DC coil cover plate

3Front cover 15Bus bar

4EMC shield 16Plastic cover

5 Cradle 17 Rectier modules

6 Control card 18 Heat sink fan assembly

7 Control card mounting plate 19 DC coils

8Power card 20Capacitors

9 Power card mounting plate 21 Base plate

10 RFI lter 22 Relay/transducer card

11 EMC shield 23 IGBT

12 Inrush card 24 Cable mounting plate

Illustration 1.2 Exploded View - H7 Frame Size

Introduction TR150 and TR170 Service Manual

1 1

1LCP 12SMPS card

2 Front cover 13 Cable mounting plate

3 Cradle, control card, and mounting plate 14 IGBT

4 EMC shield 15 Relay/transducer card mounting plate

5 Power card 16 Relay/transducer card

6 Power card mounting plate 17 Bus bar

7 Support bracket 18 Rectier modules

8 Plastic cover 19 Heat sink fan assembly

9 RFI lter 20 Capacitors

10 DC coil cover plate 21 Base cover

11 Bus bar unit 22 Connection terminals

Illustration 1.3 Exploded View - H8 Frame Size

Introduction

1.8 Exploded Views - I Frame Size

1 Local Control Panel (LCP) 9 DC coil

2Front cover 10Heat sink

3 Cradle 11 Fan assembly

4 Control card 12 Cable mounting plate

5 Control card mounting plate 13 RFI lter

6 Fan 14 Connectors

7 Bus bar unit 15 EMC shield

8 Power card 16 Cable entry

Illustration 1.4 Exploded View - I6 Frame Size

Introduction TR150 and TR170 Service Manual

1 1

1 Local Control Panel (LCP) 14 DC coil

2 Front door 15 Thyristors

3 Cradle 16 Back plate

4 Control card 17 IGBT

5 Control card mounting plate 18 Capacitor

6 Terminal plates 19 Heat sink fan

7 Support bracket 20 Bus bar unit

8 RFI lter 21 Relay/transducer card

9 Inrush card 22 Relay card mounting plate

10 Terminal connectors 23 Power card

11 Cable mounting plate 24 Power card mounting plate

12 Bus bar 25 Cable entry

13 Bracket

Illustration 1.5 Exploded View - I7 Frame Size

Introduction

1LCP 11DC coil

2 Front cover 12 Rectier modules

3Cradle 13IGBTs

4LCP gasket 14Capacitors

5 Control card 15 Heat sink fan assembly

6 Control card mounting plate 16 Fan

7 Support bracket 17 Cable mounting plate

8 RFI lter 18 Relay/transducer card with mounting plate

9 Power Card 19 Cable entry

10 Power card mounting plate

Illustration 1.6 Exploded View - I8 Frame Size

Introduction TR150 and TR170 Service Manual

1.9 Ratings

1.9.1 Short Circuit and Overcurrent Trips

The frequency converter is protected against short circuits with current measurement in each of the 3 motor phases or in the DC link. A short circuit between 2 output phases causes an overcurrent in the inverter. The inverter turns o the IGBTs individually when the short-circuit current exceeds the permitted value (Alarm 16 Trip Lock).

1.9.2 DC Voltage Levels

200–240 V AC 380–480 V AC 525–600 V AC

H1–H5 H6–H8 H1–H5

I2–I3–I4

Inrush circuit enabled

Inrush circuit disabled 202 184 314 372 532

Undervoltage 202 184 314 372 532

Undervoltage re-enable 202+15 184+16 314+30 372+24 532+20

Overvoltage 410 412 800 800 976

Overvoltage re-enable 410-15 412-16 800-30 800-24 976-20

IT Grid Turn on 410+25 412+25 800+35 800+35 976+35

Table 1.8 DC Voltage Levels

H6–H8

I6–I8

H6–H10

1 1

Frequency Converter Control

2 Frequency Converter Control

2.1 Introduction

This section describes the optional display interfaces available for the frequency converter, the inputs and outputs, and the control terminal functions.

The following optional interfaces are available:

Numerical Local Control Panel (LCP 21).

•

Graphical Local Control Panel (GLCP or LCP 102).

•

Use the selected interface to adapt parameter settings or read status. Commands given to the frequency converter are indicated on the selected interface display. Fault logs are maintained within the frequency converter, for fault history. The frequency converter issues warnings and alarms for fault conditions arising within or external to the frequency converter itself. Usually, the fault condition is found outside of the frequency converter.

2.2 Status Messages

Status messages appear in the bottom of the display. The left part of the status line indicates the active operation model of the frequency converter.

The center part of the status line indicates the references site. The last part of the status line gives the operation status, for example:

Running.

•

Stop.

•

Standby.

•

Other status messages may appear and are related to the software version and frequency converter type.

2.3 Frequency Converter Inputs and Outputs

The frequency converter operates by receiving control input signals. The frequency converter can also output status data or control auxiliary devices.

Control input is sent to the frequency converter in 3 ways:

Via the optional LCP connected by cable to the

•

frequency converter, operating in [Hand On] mode. These inputs include start, stop, reset, and speed reference.

Via serial communication from a eldbus,

•

connected to the frequency converter through the RS485 serial port, or through a communication option card. The serial communication protocol:

- Supplies commands and references to the frequency converter.

- Programs the frequency converter.

- Reads status data from the frequency

converter.

Via signal wiring connected to the frequency

•

converter control terminals. Improperly connected control wiring can result in the frequency converter failing to start or to respond to a remote input.

2.3.1 Input Signals

The frequency converter can receive 2 types of remote input signals: digital or analog. Digital inputs are wired to terminals 18, 19, 20 (common), 27, 29. Analog or digital inputs are wired to terminals 53 or 54 and 55 (common). A switch placed under the LCP sets the terminal functions. Some options include additional terminals.

Analog signals can be either voltage (0 V to +10 V DC) or current (0–20 mA or 4–20 mA). Analog signals can be varied like dialing a rheostat up and down. The frequency converter can be programmed to increase or decrease output in relation to the amount of current or voltage. For example, a sensor or external controller may supply a variable current or voltage. The frequency converter output, in turn, regulates the speed of the motor connected to the frequency converter in response to the analog signal.

Digital signals are a simple binary 0 or 1 acting as a switch. A 0-24 V DC signal controls the digital signals. A voltage signal lower than 5 V DC is a logic 0. A voltage higher than 10 V DC is a logic 1. 0 is open, 1 is close. Digital inputs to the frequency converter are switched commands such as start, stop, reverse, coast, reset. (Do not confuse these digital inputs with serial communication formats where digital bytes are grouped into communication words and protocols).

The RS485 serial communication connector is wired to terminals (+) 68 and (-) 69. Terminal 61 is a common terminal. It is used for terminating shields only when the control cable is run between frequency converters, and not between frequency converters and other devices.

Parameters for NPN and PNP.

These parameters cannot be changed while the motor is running.

conguring

the input and output using

Frequency Converter Control TR150 and TR170 Service Manual

2.3.2 Output Signals

The frequency converter also produces output signals that are carried either through the RS485 serial bus or terminal

42. Output terminal 42 operates in the same manner as the inputs. The terminal can be programmed for either a variable analog signal in mA or a digital signal (0 or 1) in 24 V DC. In addition, a pulse reference can be provided on terminals 27 and 29. Output analog signals generally indicate the frequency, current, torque, and so on, to an external controller or system. Digital outputs can be control signals used to open or close a damper, or send a start or stop command to auxiliary equipment.

Additional terminals are Form C relay outputs on terminals 01, 02, and 03, and terminals 04, 05, and 06.

Terminals 12 and 13 provide 24 V DC low voltage power, often used to supply power to the digital input terminals (18–33). Those terminals must be supplied with power from either terminal 12 or 13, or from a customer supplied external 24 V DC power source. Improperly connected control wiring is a common service issue for a motor not operating or the frequency converter not responding to a remote input.

Number of digital outputs 2

Ter mina l nu m ber

Voltage level at digital output 17 V

Maximum output current at digital

output

Maximum load at digital output

42, 45

20 mA

1 k

See the Quick Guide for detailed information on accessing and showing parameters, and for descriptions and procedures for service information available in parameter group 6-** Analog In/Out.

2.5 Control Terminals

For proper function of the frequency converter functioning, the input control terminals must be:

Wired properly.

•

Powered.

•

Programmed correctly for the intended function.

•

Ensure that the input terminal is wired correctly:

1. Conrm that the control and power sources are wired to the terminal.

2. Check the signal in either of 2 ways:

Press [Display Mode], then select Digital

•

Input. The LCP shows the digital inputs which are correctly wired.

Use a voltmeter to check for voltage at

•

the control terminal.

Conrm that each control terminal is programmed for the correct function. Each terminal has specic functions and a numbered parameter associated with it. The setting selected in the parameter enables the function of the terminal.

See the Quick Guide for details on changing parameters and the functions available for each control terminal.

Table 2.1 Digital Output

1) Terminals 42 and 45 can also be programmed as analog output.

2.4 Service Functions

Service information for the frequency converter can be shown in display lines 1 and 2. 24 dierent items can be accessed. Included in the data are

Counters that tabulate hours run, and so on.

•

Fault logs that store frequency converter status

•

values present at the ten most recent events that stopped the frequency converter

Frequency converter nameplate data

•

Parameter 14-28 Production Settings and parameter 14-29 Service Code, are the relevant service

parameters.

Parameter settings are shown by pressing [Main Menu].

Press [

], [▼], [►] and [◄] to scroll through parameters.

▲

Frequency Converter Control

2.6 Control Terminal Functions

Tab l e 2.2 describes the functions of the control terminals. Many of these terminals have multiple functions determined by parameter settings. See Illustration 2.1.

Ter m in al

number

01, 02, 03 Form C relay output on control card. Maximum 240

04, 05 Form A relay output on control card. 30 V AC, 42.5

12, 13 Voltage supply to digital inputs and external

16–33 Programmable digital inputs for controlling the

20 Common for digital inputs.

39 Common for analog and digital outputs.

42, 45 Analog and digital outputs for indicating values

50 10 V DC, 17 mA maximum analog supply voltage

53, 54

55 Common for analog inputs. This common is

60 Programmable 0–20 mA or 4–20 mA, analog

61 RS485 common.

68, 69 RS485 interface and serial communication.

Func tion

V AC, 2 A. Minimum 24 V DC, 10 mA, or 24 V AC,

100 mA. Can be used for indicating status and

warnings. Physically located on power card.

V DC. Can be used for indicating status and

warnings.

transducers. For the 24 V DC to be used for digital

inputs, switch 4 on the control card must be closed

(ON position). The maximum output current is 200

mA.

frequency converter. R=2 k

(open). Greater than 10 V=logic 1 (closed).

such as frequency, reference, current, and torque.

The analog signal is 0–20 mA, or 4–20 mA at a

maximum of 500

a minimum of 600

for potentiometer or thermistor.

0–10 V DC voltage input, R = 10 k

reference or feedback signals. A thermistor can be

connected here.

isolated from the common of all other power

supplies. If, for example, the frequency converter’s

24 V DC power supply is used to power an

external transducer, which provides an analog

input signal, terminal 55 must be wired to terminal

39.

current input, Resistance=approx. 200

reference or feedback signals.

. The digital signal is 24 V DC at

. Less than 5 V=logic 0

Used for

. Used for

Tab le 2.2 Term ina l Functi ons

Frequency Converter Control TR150 and TR170 Service Manual

Illustration 2.1 Control Terminal Electrical Overview

Control terminals must be programmed. Each terminal has specic functions and a numbered parameter associated with it. The setting selected in the parameter enables the function of the terminal. See the TR150 and TR170 Quick Guide for details.

Frequency Converter Control

2.7 Grounding Shielded Cables

Connect the shielded control cables to the metal cabinet of the frequency converter with cable camps at both ends. Illustration 2.3 shows ground cabling for optimal results.

Correct grounding

To ensure the best possible electrical connection, t control cables and cables for serial communication with cable clamps at both ends.

Illustration 2.2 Correct Grounding

Incorrect grounding

Do not use twisted cable ends (pigtails) since they increase shield impedance at high frequencies.

Ground potential protection

When the ground potential between the frequency converter and the PLC or other interface device is dierent, electrical noise may occur that can disturb the entire system. Resolve the electrical noise by cable next to the control cable. Minimum cable cross-

section is 10 mm

(8 AWG).

tting

an equalizing

Serial communication control cables

Low-frequency noise currents between frequency converters can be eliminated by connecting 1 end of the shielded cable to frequency converter terminal 61. This terminal connects to ground through an internal RC link. To reduce the dierential mode interference between conductors, use twisted-pair cables.

Illustration 2.5 Serial Communication Control Cables

Minimum 10 mm

2 Equalizing cable

Illustration 2.3 Ground Potential Protection

(8 AWG)

50/60 Hz ground loops

When using long control cables, 50/60 Hz ground loops may occur that can disturb the entire system. Resolve the ground loops by connecting 1 end of the shield with a 100 nF capacitor and keeping the lead short.

Illustration 2.4 50/60 Hz Ground Loops

Internal Frequency Converte... TR150 and TR170 Service Manual

3 Internal Frequency Converter Operation

3.1 General

This chapter provides an operational overview of the main assemblies and circuitry in the frequency converter.

3.2 Description of Operation

3.2.1 Control Logic Section

The control card includes most of the logic section (see Illustration 3.2). The primary logic element of the control card is a microprocessor, which supervises and controls all functions of frequency converter operation. In addition, a separate PROM contains the parameters to provide the user with programmable options. These parameters are programmed to enable the frequency converter to meet specic application requirements. This data is stored in an EEPROM providing security during power-down and also allows the exibility to change the operational characteristics of the frequency converter.

undesired program changes. With the addition of a remote mounting kit, the LCP can be mounted in a remote location.

Control terminals, with programmable functions, are provided for input commands such as run, stop, forward, reverse and speed reference. Additional output terminals are provided to supply signals to run peripheral devices or for monitoring and reporting status.

The control card logic

Communicates via serial link with outside devices

•

such as personal computers or Programmable Logic Controllers (PLC).

Provides 2 voltage supplies for use from the

•

control terminals.

24 V DC is used for switching functions such as start, stop, and forward/reverse. The 24 V DC supply also supplies 200 mA of power, which can partly be used to power external encoders or other devices. A 10 V DC supply rated at 17 mA is also available for use with speed reference circuitry.

The analog and digital output signals are powered through an internal supply. The 3 power supplies are isolated from one another to eliminate ground loop conditions in the control input circuitry.

Illustration 3.1 Logic Section

Another part of the logic section is the removable LCP or display mounted on the front of the frequency converter. The LCP provides a user interface to the frequency converter.

All programmable parameter settings can be uploaded into the EEPROM of the LCP. This function helps in maintaining a back-up frequency converter prole and parameter set. Its download function can be used in programming other frequency converters or restoring a program to a repaired unit. The LCP is removable during operation to prevent

2 relays for monitoring the status of the frequency converter are located on the power card. These relays are programmable through parameter group 5-4* Relays. The relays are Form C. These relays have one normally open contact, and one normally closed contact on a single throw. The contacts of the relay are rated for a maximum load of 240 V AC at 2 Amps resistance.

The logic circuitry on the control card allows for adding:

Option modules for synchronizing control

•

Serial communications

•

Additional relays

•

Cascade pump controller

•

Custom operating software

•

Internal Frequency Converte...

3.2.2 Logic to Power Interface

The logic to power interface isolates the high-voltage components of the power section from the low voltage signals of the logic section. The interface consists of two sections.

Power Card

•

Gate Driver

•

The control card handles much of the fault processing for output short circuit and ground fault conditions. The power card provides conditioning of these signals. Scaling of current feedback and voltage feedback is accomplished on the interface sections before processing by the control card.

Illustration 3.2 Typical Power Section

3.3 Sequence of Operation

3.3.1

Rectier

Section

The power card contains a Switch Mode Power Supply (SMPS). The SMPS provides the unit with 24 V DC, 16 V DC, 7 V DC, 6 V DC, and 3.3 V DC operating voltage. SMPS powers the logic and interface circuitry. SMPS is supplied by the DC bus voltage. A secondary SMPS provides power to the logic circuitry with main input disconnected. It can keep units with communication options live on a network when the frequency converter is not powered from the mains.

Circuitry for controlling speed of the cooling fans is also provided on the power card.

3.2.3 Power Section

The DC coil is a single unit 2 two coils wound on a common core. One coil resides in the positive side of the DC bus and the other in the negative. The coil aids in the reduction of mains harmonics.

The DC bus capacitors are arranged into a capacitor bank along with bleeder and balancing circuitry.

The inverter section is made up of six IGBTs, commonly referred to as switches. One switch is necessary for each half phase of the 3-phase power, for a total of 6. The 6 IGBTs are contained in 3 dual modules.

A Hall eect type current sensor is located on each phase of the output to measure motor current.

The rectier provides a path for current owing from the line to the DC-link circuitry. As a result, the DC-link capacitors charge.

The rectier section consists of 6 diodes.

Inrush current, which appears when connected to grid, is limited with a PTC. A relay short-circuits the PTC when the DC-link capacitors are fully charged.

As long as power is applied to the frequency converter, voltage is present in the DC link and the inverter circuit. Voltage is also fed to the switch mode power supply (SMPS) on the power card and is used for generating all other low voltage supplies.

3.3.2 Intermediate Section

From the rectier section, voltage passes to the intermediate section. The DC link is an LC lter circuit consisting of the DC-link inductor and the DC-link capacitor bank that smooths the rectied voltage.

The intermediate section consists of the following components:

The DC-link inductor located in the positive side

•

of the DC link provides series impedance to changing current. This impedance aids the ltering process while reducing harmonic distortion to the input AC current waveform normally inherent in rectier circuits.

The DC-link capacitors are arranged into a

•

capacitor bank along with bleeder and balancing circuitry.

High frequency (HF) lter lm capacitors. These

•

capacitors reduce the common mode noise caused by switching into stray capacitors to ground in cable and motor.

Internal Frequency Converte... TR150 and TR170 Service Manual

The voltage on a fully charged DC link is equal to the peak voltage of the input AC line. Theoretically, this voltage can be calculated by multiplying the AC line value by 1.414 (V AC x 1.414). However, since AC ripple voltage is present on the DC link, the actual DC value is closer to (V AC x 1.38) under unloaded conditions. The DC value can drop to (V AC x 1.32) while running under load.

Example

For a frequency converter sitting idle while connected to a nominal 460 V line, the DC-link voltage is approximately 635 V DC (460 x 1.38). As long as power is applied to the frequency converter, this voltage is present in the DC link and the inverter circuit. Voltage is also fed to the switch mode power supply (SMPS) on the power card which is used for generating all other low voltage supplies. The SMPS is activated when the DC-link voltage reaches approximately 250 V DC.

3.3.3 Inverter Section

The inverter section is made up of six IGBTs, commonly referred to as switches. One switch is necessary for each half phase of the 3-phase power, for a total of six. The six IGBTs are contained in one power module shared with the rectier. The inverter section receives gate signals from the MOC.

Once a run command and speed reference are present, the IGBTs begin switching to create the output waveform, as shown in Illustration 3.3. Looking at the phase to phase voltage waveform with an oscilloscope, a train of pulses of dierent widths is shown. The amplitude of the pulses measures the DC-link voltage. To view the fundamental sinusoidal curve, set the oscilloscope to lter out high harmonic content.

When measuring current, the normal view will be a sinusoidal curve. The amplitude of the measured current depends on the loading form.

This waveform, as generated by the frequency converter, provides optimal performance and minimal losses in the motor.

Hall eect current sensors monitor the output current and feed it back to the control. The current signal is used for two purposes:

to compensate for dynamic motor operation.

•

to monitor overcurrent conditions, including

•

ground faults and phase-to-phase shorts.

During normal operation, the power card and control monitor various functions within the frequency converter. The current sensors provide current feedback information. The DC bus voltage and mains voltage are monitored and

the voltage delivered to the motor. A thermal sensor mounted inside the IGBT module provides heat sink temp feedback for the inverter.

Illustration 3.3 Output Voltage and Current Waveforms

3.3.4 Fan Speed Control

IP20

Enclosure H6 H7 H8

Voltage T2T2T2 T2T2T2

Power rating

[kW]

FAN s tar t

temperature

FAN maximum

speed

temperature

FAN s top

temperature

Table 3.1 Fan Speed Control, IP20, H6–H8, T2

IP20

Enclosure H6 H7 H8

Volt age T4 T4 T 4 T4 T4 T4

Power rating

[kW]

FAN s tar t

temperature

FAN maximum

speed

temperature

FAN s top

temperature

Table 3.2 Fan Speed Control, IP20, H6–H8, T4

IP54

Enclosure I6 I7 I8

Voltage T4T4T4T4T4T4T4

Power rating

[kW]

FAN s tar t

temperature

15 18.5 22 30 37 45

45 45 45 45 45 45

60 60 60 60 60 60

36 36 36 36 36 36

30 37 45 55 75 90

45 45 45 40 40 40

60 60 60 55 55 55

41 41 41 30 30 30

22 30 37 45 55 75 90

45 45 45 40 40 40 40

Internal Frequency Converte...

IP54

Enclosure I6 I7 I8

FAN maximum

speed

temperature

FAN s top

temperature

Table 3.3 Fan Speed Control, IP54, I6–I8

IP20

Enclosure H9 H10 H6 H7 H8

Voltage T6T6T6T6T6T6T6T6T6T6T6T6

Power

rating

[kW]

FAN s tar t

tempera-

ture

FA N

maximum

speed

tempera-

ture

FAN s top

tempera-

ture

60 60 60 55 55 55 55

35 35 35 30 30 30 30

2.2 3.0 5.5 7.5 11 15 22 30 45 55 75 90

35 35 35 35 45 45 45 45 40 40 40 40

55 55 55 55 60 60 60 60 55 55 55 55

31 31 31 31 36 41 41 41 30 30 30 30

Table 3.4 Fan Speed Control, IP20, H9–H10, and H6–H8, T6

Troubleshooting TR150 and TR170 Service Manual

4 Troubleshooting

4.1 Troubleshooting Tips

Before repairing a frequency converter, read and understand the following instructions.

1. Note all warnings concerning voltages present in the frequency converter. Always verify the presence of AC input voltage and DC link voltage before working on the unit. Some points in the frequency converter are referenced to the negative DC link. They are at DC link potential even though it sometimes appears on diagrams to be a neutral reference.

CAUTION

Voltage can be present for as long as 20 minutes on frequency converters after removing power from the unit. See the label on the front of the frequency converter door for the specic discharge time.

2. Never apply power to a unit that is suspected of being faulty. Many faulty components within the frequency converter can damage other components when power is applied. Always perform the procedure for testing the unit after repair as described in chapter 4.7 After Repair Tes ts .

3. Never attempt to defeat any fault protection circuitry within the frequency converter, as this results in unnecessary component damage and can cause personal injury.

4. Always use factory approved replacement parts. The frequency converter is designed to operate within certain specications. Incorrect parts can

tolerances and result in further damage to

aect the unit.

5. Read the instruction manual. A thorough understanding of the unit is the best approach. If ever in doubt, consult the factory or authorised repair centre for assistance.

4.2 Exterior Fault Troubleshooting

There may be slight dierences in servicing a frequency converter that has been operational for extended time, compared to a new installation. In either case, use proper troubleshooting procedures.

CAUTION

RISK OF INJURY OR PROPERTY DAMAGE

Never assume that a motor is wired properly after a service of the frequency converter. Check for:

Loose connections.

•

Improper programming.

•

Added equipment.

•

Failure to perform these checks can result in personal injury, property damage, or less than optimal performance.

Take a systematic approach, beginning with a visual inspection of the system. See Tabl e 4.1 for items to examine.

4.3 Fault Symptom Troubleshooting

The troubleshooting procedures are divided into sections based on the

1. See the visual inspection check list in Tab l e 4.1.

2. The most common fault symptoms are described

dierent

Often, incorrect installation or wiring of the frequency converter causes the problem. The check list provides guidance through the items to inspect during servicing of the frequency converter.

in chapter 4.5 Fault Symptoms:

•

The frequency converter processor monitors inputs and outputs as well as internal frequency converter functions. An alarm or warning does not necessarily indicate a problem within the frequency converter itself.

For each incident, further description explains how to troubleshoot that particular symptom. When necessary, further referrals are made to other parts of the manual for more procedures.

When troubleshooting is complete, perform the list of tests provided in chapter 6.5 Initial Start-up Or After Repair Drive Tes ts .

occurring symptom.

Problems with motor operation.

A warning or alarm shown by the frequency converter.

Troubleshooting

4.4 Visual Inspection

Visually inspect the conditions in Table 4 .1 as part of any initial troubleshooting procedure.

Inspect for Description

Auxiliary equipment

Cable routing

Control wiring

Frequency converter cooling Check operational status of all cooling fans:

Frequency converter display The display shows important items, such as:

Frequenc y converter interior

EMC considerations

Environmental conditions

GLCP

Grounding

Look if more auxiliary equipment, switches, disconnects, or input fuses/circuit breakers reside on the

•

input power side of frequency converter or output side to motor.

Examine operation and condition of these items as possible causes for operational faults.

•

Check function and installation of pressure sensors or encoders, and other equipment used for

•

feedback to the frequency converter.

Avoid routing motor wiring, AC line wiring, and signal wiring in parallel. If parallel routing is

•

unavoidable, maintain a separation of 150–200 mm (6–8 inches) between the cables or separate them

with a grounded conductive partition.

Avoid routing cables through free air.

•

Check for broken or damaged wires and connections.

•

Check the voltage source of the signals. Though not always necessary depending on the installation

•

conditions, the use of screened cable or a twisted pair is recommended.

Ensure that the screen is terminated correctly.

•

When voltage is applied to the frequency converter, the fan activates for a few seconds.

•

Check for blockage or constrained air passages.

•

Warn ings.

•

Alarms.

•

Frequency converter status.

•

Fault histor y.

•

Check that the frequency converter interior is free of :

•

- Dirt.

- Metal chips.

- Moisture.

- Corrosion.

Check for burnt or damaged power components, or carbon deposits that are the result of a

•

catastrophic component failure.

Check for cracks or breaks in the housings of power semiconductors, or pieces of broken component

•

housings, which are loose inside the unit.

Check for proper installation regarding electromagnetic capability.

•

Refer to the frequency converter operating instructions and this chapter for further details.

•

Under

•

Humidity levels must be less than 95% non-condensing.

•

Check for harmful airborne contaminates such as sulfur-based compounds.

•

If supplied, check that the GLCP is correctly installed, and that the display is lit when powered on.

•

The frequency converter requires a dedicated ground wire from its enclosure to the building ground.

•

It is also suggested to ground the motor to the frequency converter enclosure.

The use of conduit or mounting of the frequency converter to a metal surface is not considered to

•

be suitable grounding.

Check for good ground connections that are tight and free of oxidation.

•

conditions, these units can be operated within a maximum ambient of 50 °C (122 °F).

specic

Troubleshooting TR150 and TR170 Service Manual

Inspect for Description

Input power wiring Check for:

Loose connections.

•

Proper fusing.

•

Blown fuses.

•

Memory module

Motor

Output to motor wiring Check for:

PROFIBUS option

Programming Ensure that frequency converter parameter settings are correct according to:

Proper clearance The frequency converter requires top and bottom clearance adequate to ensure proper air ow for

Vibration

Check that the memory module is plugged in correctly.

•

Check nameplate ratings of the motor.

•

Ensure that motor ratings coincide with frequency converters.

•

Ensure that the frequency converter motor parameters (parameter 1-20 Motor Power to

•

parameter 1-25 Motor Nominal Speed) are set according to motor ratings.

Loose connections.

•

Switching components in output circuit.

•

Faulty contacts in switch gear.

•

Check that the option is mounted correctly on the control card.

•

Motor.

•

Application.

•

I/O conguration.

•

cooling in accordance with the frequency converter size. When the heat sink is exposed at the rear of

the frequency converter, mount the frequency converter on a

Check for exposure to an unusual amount of vibration.

•

When the frequency converter experiences a high level of vibration, ensure solid mounting or use

•

shock mounts.

solid surface.

at,

Table 4.1 Visual Inspection Check List

+ 73 hidden pages

Trane TR150, TR170 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual